SVM128-A
March, 1999
TM
SHIELD-ARC SA-250
Diesel Engine Driven DC Arc Welding Power Source
For use with machine code numbers 10073 or 10073CV.
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be in-
creased by proper installation . . .
and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
SERVICE MANUAL
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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ii
ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
SA-250
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iii
iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
SA-250
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iv
iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
SA-250
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v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation..............................................................................................................A-3
Pre-operation Engine Service .....................................................................................................A-4
Electrical Output Connections.....................................................................................................A-6
Operation...............................................................................................................................Section B
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-2
Recommended Applications........................................................................................................B-3
Operational Features and Controls.............................................................................................B-3
Design Features..........................................................................................................................B-3
Welding Capability ......................................................................................................................B-4
Limitations .................................................................................................................................B-4
Controls and Settings..................................................................................................................B-5
Engine Operation ........................................................................................................................B-8
Welding Operation ....................................................................................................................B-10
Auxiliary Power .........................................................................................................................B-12
Accessories ..........................................................................................................................Section C
Maintenance..........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance.............................................................................................D-2
Major Component Locations.....................................................................................................D-13
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual ...............................................................................................................................P-237
SA-250
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Section A-1
Installation
Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Technical Specifications..............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation..............................................................................................................A-3
Storing .................................................................................................................................A-3
Stacking................................................................................................................................A-4
Tilting .................................................................................................................................A-4
Lifting .................................................................................................................................A-4
High Altitude Operation.........................................................................................................A-4
Pre-operation Engine Service .....................................................................................................A-4
Oil ........................................................................................................................................A-4
Fuel.......................................................................................................................................A-4
Battery Connections .............................................................................................................A-4
Cooling System.....................................................................................................................A-5
Muffler .................................................................................................................................A-5
Exhaust Spark Arrester.........................................................................................................A-5
Trailer .................................................................................................................................A-5
Electrical Output Connections.....................................................................................................A-6
Welding Cable Connections .................................................................................................A-6
Cable Installation, Polarity Control, and Cable Sizes..............................................A-6
Machine Grounding ..............................................................................................................A-7
Auxiliary Power Receptacles, Plugs, and Hand-held Equipment.........................................A-7
Circuit Breakers ....................................................................................................................A-7
SA-250
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - SA-250
INPUT - DIESEL ENGINE
Manufacturer Description
Speed
Displacement
Ignition
Capacities
Perkins
D3.152
3 cyl., 4 cycle
Water-cooled
diesel
1725 RPM
Full load
152 cu. in.
(2500 cc)
Electric
Fuel: 15 gal.
(57 liters)
38.2 HP @
1725 RPM
1800 RPM
High idle
Oil: 7.2 qt.
(6.9 liters)
1350 RPM
Low idle
Water/coolant: 10 qt.
(9.5 liters)
RATED OUTPUT - WELDER
Duty Cycle
Amps
Volts at Rated Amperes
100% Duty Cycle
60% Duty Cycle
35% Duty Cycle
200 DC Constant Current
250 DC Constant Current
325 DC Constant Current
40V
40V(1)
33V
OUTPUT - WELDER AND GENERATOR
Welding Ranges Max. Open Circuit Voltage
Auxiliary Power
40-325 Amps DC
98.5
3.0 kVA of 115/230 V, 60Hz Power
26 Amps @ 115 V(2)
13 Amps @ 230 V
PHYSICAL DIMENSIONS
Height
Width
Depth
Weight
43.1 in.
1096 mm
28 in.
711 mm
67 in.
1702 mm
1650 lb.
742.5 kg
1 Lincoln rating. Nema rating at 60% duty cycle is 250 amps @ 30 V.
2 15 amps can be drawn from either half of the receptacle. Total combined load of all receptacles cannot exceed 3.0 kVA.
SA-250
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A-3
A-3
INSTALLATION
Read this entire installation section before you
start installation.
LOCATION AND VENTILATION
Always operate the SA-250 with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating. Always operate the
welder with the case roof on and all machine compo-
nents completely assembled.
SAFETY PRECAUTIONS
WARNING
Whenever you use the SA-250, be sure that clean
cooling air can flow through the machine’s diesel
engine and the generator. Avoid dusty, dirty areas.
Also, keep the machine away from heat sources. Do
not place the back end of the generator anywhere near
hot engine exhaust from another machine. And of
course, make sure that engine exhaust is ventilated to
an open, outside area.
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.
The SA-250 may be used outdoors. Do not set the
machine in water. Such practices pose safety hazards
and cause improper operation and corrosion of parts.
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.
• Insulate yourself from the work
and ground.
STORING
• Always wear dry insulating
gloves.
1. Store the machine in a cool, dry place when it is not
in use. Protect it from dust and dirt. Keep it where
it can’t be accidentally damaged from construction
activities, moving vehicles, and other hazards.
ENGINE EXHAUST can kill.
2. Drain the engine oil and refill with fresh 10W30 oil.
Run the engine for about five minutes to circulate oil
to all the parts. See the Maintenance section of
this manual for details on changing oil.
• Use in open, well ventilated
areas or vent exhaust to the out-
side.
• Do not stack anything on or near
the engine.
3. Remove the battery, recharge it, and adjust the
electrolyte level. Store the battery in a dry, dark
place. See the Maintenance section for informa-
tion about charging the battery.
MOVING PARTS can injure.
4. See your engine operation manual for further infor-
mation on fuel and engine preservation.
• Do not operate this equipment
with any of its doors open or
guards off.
• Stop the engine before servicing
it.
• Keep away from moving parts.
See additional safety information at the front of this
manual.
Only qualified personnel should install, use, or ser-
vice this equipment.
SA-250
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A-4
A-4
INSTALLATION
STACKING
WARNING
SA-250 machines CANNOT be stacked.
Keep hands away from the engine muffler or HOT
engine parts.
• Stop the engine when fueling.
TILTING
• Do not smoke when fueling.
Place the machine on a secure, level surface whenev-
er you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
structurally sound.
• Remove the fuel cap slowly to release pressure.
• Do not overfill the fuel tank.
• Wipe up spilled fuel and allow the fumes to clear
before starting the engine.
The diesel engine is designed to run in a level position
for best performance. If you do operate it at a slight
angle, be sure to check the oil regularly and keep the
oil level at the FULL mark as it would be in its normal
level condition. Also, fuel capacity will be a little less at
an angle.
• Keep sparks and flame away from the fuel tank.
OIL
The SA-250 is shipped with the engine filled
with SAE 10W-30 oil. This should be fine
for most ambient operating temperature
conditions. See the engine operation manual for spe-
cific recommendations. CHECK THE OIL LEVEL
BEFORE YOU START THE ENGINE. This is an
added precaution. When full, the oil level should be up
to but not over the FULL mark on the dipstick. If it is
not full, add enough oil to fill it to the full mark. DO NOT
overfill.
LIFTING
The SA-250 weighs 1650 lb./743 kg. A lift bail is
provided for lifting with a hoist.
WARNING
For more oil fill and service information, see the
Maintenance section of this manual.
FALLING EQUIPMENT can
cause injury.
FUEL
Do not lift this machine using lift bail if
it is equipped with a heavy accessory
such as a trailer.
Fill the fuel tank with clean, diesel fuel only.
The SA-250 has a 15 gallon (57 liter) fuel
tank with a top fill and fuel gauge mounted
on the control panel. See the Operation and
Maintenance sections of this manual for more details
about fuel.
Lift only with equipment of adequate lifting capacity. Be
sure machine is stable when lifting.
HIGH ALTITUDE OPERATION
BATTERY CONNECTIONS
It may be necessary to derate welder output at higher
altitudes. Some engine adjustment may be required.
Contact a Perkins Service Representative.
–
+
The SA-250 is shipped with the negative
battery cable disconnected. Before you
operate
the
machine,
make
sure
the
IGNITION switch is in the OFF position and attach the
disconnected cable securely to the battery terminal. If
the battery is discharged and won't start the engine,
see the battery charging instructions in the
Maintenance section.
PRE-OPERATION ENGINE SERVICE
Read and understand the information about the diesel
engine in the Operation and Maintenance sections of
this manual before you operate the SA-250.
SA-250
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A-5
A-5
INSTALLATION
COOLING SYSTEM
TRAILER
The cooling system has been filled at the factory with a
50-50 mixture of ethylene glycol antifreeze and water.
Check the radiator level and add a 50-50 solution as
needed. (See your engine manual or antifreeze con-
tainer for alternate antifreeze recommendations.)
If you use a non-Lincoln trailer, you must assume
responsibility that the method of attachment and usage
does not result in a safety hazard nor damage the
welding equipment. Some of the factors to be consid-
ered are as follows:
1. Design capacity of the trailer vs. the weight of the
Lincoln equipment and likely additional attach-
ments.
MUFFLER
This welder is supplied with an adjustable rain cap for
the muffler. Install the rain cap using the clamp provid-
ed with the outlet facing away from the direction in
which this unit will be transported. This will minimize
the amount of water and debris that could enter the
muffler during transportation.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back. This
includes when being moved and when standing by
itself for operation or service.
4. Typical conditions of use, such as travel speed,
roughness of the surfaces where the trailer will be
used, environmental conditions, likely maintenance.
EXHAUST SPARK ARRESTER
Some federal, state or local laws may require that
diesel engines be equipped with exhaust spark
arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
The standard mufflers included with these welders do
not qualify as a spark arrester. When required by local
regulations, suitable spark arresters must be installed
and properly maintained.
5. Conformance with federal, state, and local laws.
Consult applicable federal, state, and local laws
about specific requirements for use on public high-
ways.
CAUTION
Use of an incorrect arrester may lead to engine dam-
age or performance loss. Contact the engine manu-
facturer for specific recommendations.
SA-250
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A-6
A-6
INSTALLATION
ELECTRICAL OUTPUT
CONNECTIONS
CAUTION
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
See Figure A.1 for the location of the 115 and 230 volt
receptacles, weld output terminals, and ground stud.
• Do not cross the welding cables at the output terminal
connection. Keep the cables isolated and separate
from one another.
WELDING CABLE CONNECTIONS
CABLE INSTALLATION AND CABLE SIZES
With the engine off, route the electrode and work
cables through the strain relief bracket on the base and
connect to the terminals located on the fuel tank mount-
ing rail. (See size recommendations below.) For posi-
tive polarity, connect the electrode cable to the terminal
marked Positive (+). For Negative polarity, connect the
electrode cable to the Negative (-) terminal. These
connections should be checked periodically and tight-
ened if necessary.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
Lincoln Electric offers a welding accessory kit with the
properly specified welding cables.
See the
Accessories section of this manual for more
information.
FIGURE A.1 - SA-250 OUTPUT CONNECTIONS
4
3
2
1. 230 VAC RECEPTACLE
2. 115 VAC RECEPTACLE
3. OUTPUT TERMINALS
4. GROUND STUD
1
5
5. CABLE STRAIN RELIEF
TABLE A.1 - RECOMMENDED COPPER WELDING CABLE SIZE AND LENGTH
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
Cable sizes for combined length of
electrode plus work cable
Amps
250
Duty Cycle
60%
Up to 200 ft.
200 to 250 ft.
1
1/0
3/0
350
25%
2/0
SA-250
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A-7
A-7
INSTALLATION
For further protection against electric shock, any elec-
trical equipment connected to the generator recepta-
cles must use a three-blade, grounded type plug or an
Underwriter's Laboratories (UL) approved double insu-
lation system with a two-blade plug. Lincoln offers an
accessory plug kit that has the right type of plugs. See
the Accessories section of this manual for details.
MACHINE GROUNDING
According to the United States National Electrical
Code, the frame of this portable generator is not
required to be grounded and is permitted to serve as
the grounding means for cord connected equipment
plugged into its receptacles.
Some state, local or other codes or unusual operating
circumstances may require the machine frame to be
grounded. It is recommended that you determine the
extent to which such requirements may apply to your
If you need ground fault protection for hand-held equip-
ment, refer to the Accessories section of this manual
for the GFCI Receptacle kit.
particular situation and follow them explicitly.
A
machine grounding stud marked with the symbol
is provided on the welding generator frame foot.
(If an older portable welder does not have a grounding
stud, connect the ground wire to an unpainted frame
screw. See Figure A.2.
CIRCUIT BREAKERS
SA-250 welders are equipped with cir-
cuit breakers on the 115 and the 230
volt receptacles for overload protec-
tion. Under high heat a breaker may
tend to trip at lower loads than it would normally.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment.
Operation with high ambient temperatures may cause
the breakers to trip at lower than normal loads.
CAUTION
Never bypass the circuit breakers. Without overload
protection, the SA-250 could overheat and/or cause
damage to the equipment being used.
WARNING
Do not ground the machine to a pipe that carries explo-
sive or combustible material.
FIGURE A.2 - GROUND STUD LOCATION
When the SA-250 is mounted on a truck or a trailer, the
machine generator ground stud MUST be securely
connected to the metal frame of the vehicle. See
Figure A.2. The ground stud is marked with the ground
symbol.
AUXILIARY POWER RECEPTACLES,
PLUGS, AND HAND-HELD EQUIPMENT
The AC auxiliary power, supplied as a standard, has a
rating of 3.0 kVA of 115/230V AC (60 hertz).
With the 3.0 kVA, 115/230V AC auxiliary power, one
115V duplex and one 230V duplex grounding type
receptacle are provided. The circuit is protected with
circuit breakers.
1
The rating of 3.0 kVA permits a maximum continuous
current of 13 amps to be drawn from the 230 volt
duplex receptacle. Or a total of 26 amps can be drawn
from the 115 volt duplex receptacle. The 115 volt
duplex receptacle has a configuration which permits 15
amps to be drawn from either half of the receptacle.
The total combined load of all receptacles is not to
exceed 3.0 kVA.
1. GROUND STUD
SA-250
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A-8
A-8
NOTES
SA-250
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Section B-1
Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-2
Recommended Applications........................................................................................................B-3
Welder .................................................................................................................................B-3
Generator..............................................................................................................................B-3
Operational Features and Controls.............................................................................................B-3
Design Features..........................................................................................................................B-3
Welding Capability ......................................................................................................................B-4
Limitations .................................................................................................................................B-4
Controls and Settings..................................................................................................................B-5
Welder/Generator Controls...................................................................................................B-5
Control of Welding Current...................................................................................................B-6
Diesel Engine Controls:........................................................................................................B-7
Engine Operation ........................................................................................................................B-8
Before Starting the Engine ...................................................................................................B-8
Starting the Engine...............................................................................................................B-8
Stopping the Engine .............................................................................................................B-9
Cold Weather Starting ..........................................................................................................B-9
Break-in Period.....................................................................................................................B-9
Welding Operation ....................................................................................................................B-10
SA-250 DC Constant Current Stick or TIG Welding...........................................................B-10
SA-250 DC Wire Feed Welding (Constant Voltage)...........................................................B-11
Auxiliary Power .........................................................................................................................B-12
SA-250
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B-2
B-2
OPERATION
WARNING
OPERATING INSTRUCTIONS
Read and understand this entire section before operat-
ing your SA-250.
ENGINE EXHAUST can kill.
SAFETY INSTRUCTIONS
WARNING
• Use in open, well ventilated areas or
vent exhaust to the outside.
• Do not stack anything on or near the
engine.
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.
MOVING PARTS can injure.
• Do not operate this equipment with any
of its doors open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet clothing.
Only qualified personnel should install, use, or ser-
vice this equipment.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
GENERAL DESCRIPTION
The SA-250 is a heavy duty engine driven DC arc
welding power source capable of providing constant
current output for stick welding or DC TIG welding.
With the addition of the optional Wire Feed Module, the
SA-250 will provide constant voltage output for running
the LN-7 or LN-25 wire feeders.
FUMES AND GASES can be dan-
gerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
The SA-250 has a current range of 40-325 DC amps
with a 60% duty cycle at 250 amps/40 volts. The units
are also capable of providing 3 kVA of 115/230 volt, 60
Hertz AC auxiliary power.
WELDING SPARKS can cause
fire or explosion.
This unit uses the Perkins D3.152 three-cylinder,
industrial water-cooled diesel engine.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
SA-250
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B-3
B-3
OPERATION
RECOMMENDED APPLICATIONS
DESIGN FEATURES
• Constant current DC Stick welding (SMAW) process
capability with output range from 40 - 325 DC amps.
WELDER
The SA-250 provides excellent constant current DC
welding output for stick (SMAW) welding and for DC
TIG welding. It also offers constant voltage output for
DC semiautomatic wire feed welding. For more details
on using the machine as a welder, see Welding
Operation in the Operation section of this manual.
• Constant current DC TIG Welding with output across
the entire range of settings.
• Work and Electrode welding cable mounting termi-
nals.
• Separate ground stud for safe connection of case to
earth ground.
GENERATOR
The SA-250 is also capable of providing 3.0 kVA of
115/230 volts of 60 Hertz AC auxiliary power.
• Duplex, 230 volt auxiliary power receptacle.
• Duplex, 115 volt auxiliary power receptacles.
• Integrated generator output overload protection
through four 15 amp circuit breakers.
OPERATIONAL FEATURES AND
CONTROLS
• Electric starting.
• Battery Charging Ammeter.
• Engine Oil Pressure Gauge.
The SA-250 was designed for simplicity. Therefore, it
has very few operating controls. Two switches are
used for welding operations:
• Engine Hour Meter for determining periodic mainte-
nance.
• A five-position CURRENT RANGE SELECTOR
switch selects current output ranges for constant cur-
rent stick or TIG applications and constant voltage
wire feed applications (with optional Wire Feed
Module - see the Accessories section)
• Top-of-the-line 38.2 HP Perkins diesel engine.
• Top-mounted 15 gallon (57.0 litter) fuel tank with
convenient top fill.
• Automatic engine shutdown protection for low oil
pressure.
• A FINE CURRENT ADJUSTMENT switch for fine
adjustment of current from minimum to maximum
within each range
• Automatic engine idler goes to low idle approximate-
ly 15 seconds after welding for greater fuel economy;
includes high idle switch.
Controls for the diesel engine control include a two-
position IGNITION ON/OFF toggle switch, a START
pushbutton, and a two-position IDLER switch that
selects engine speed for welding or auxiliary power
applications. See Engine Operation in the Operation
section of this manual for details about starting, run-
ning, stopping, and breaking in the diesel engine.
SA-250
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B-4
B-4
OPERATION
WELDING CAPABILITY
LIMITATIONS
The SA-250 is rated 250 amps, 40 volts constant cur-
rent DC at 60% duty cycle based on a ten minute time
period. Longer duty cycles at lower output currents are
possible.
• The SA-250 is not recommended for any processes
besides those that are normally performed using DC
stick welding (SMAW) and DC TIG welding. Specific
limitations on using the SA-250 for these processes
are described in the Welding Operation section of
this manual. Constant voltage welding is available
with the optional Wire Feed Module.
The current is continuously variable from 40 to 325
amps DC.
SA-250
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B-5
B-5
OPERATION
CONTROLS AND SETTINGS
the case front. Welding output terminals and ground
stud are located on the machine left side, under the
door. See Figure B.1, B.2 and B.3 and the explana-
tions that follow.
The welder/generator controls are located on the
Output Control Panel of the machine case front. Diesel
engine idler control and start/stop controls are also on
FIGURE B.1 – OUTPUT CONTROLS
2
1
3
4
6
5
7
1. CURRENT RANGE SELECTOR
2. FINE CURRENT ADJUSTMENT
3. 230 VOLT DUPLEX RECEPTACLE
4. 115 VOLT DUPLEX RECEPTACLE
5. WELD OUTPUT TERMINAL (–)
6. WELD OUTPUT TEMRINAL (+)
7. GROUND STUD
WELDER/GENERATOR CONTROLS
See Figure B.1 for the location of the following fea-
tures:
4. 115 VOLT DUPLEX RECEPTACLE: Connection
point for supplying 115 volt power to operate one or
two electrical devices.
1. CURRENT RANGE SELECTOR: Selects ranges
of continuous current output for constant current
stick or TIG applications and constant voltage wire
feed applications (with optional Wire Feed Module).
See Control of Welding Current for more informa-
tion.
5. WELD OUTPUT TERMINAL (–) WITH FLANGE
NUT: Provides the connection point for either the
electrode holder or the work cable.
2. FINE CURRENT ADJUSTMENT: Allows fine
adjustment of current within the selected output
range. See Control of Welding Current for more
information.
6. WELD OUTPUT TERMINAL (+) WITH FLANGE
NUT: Provides the connection point for either the
electrode holder or the work cable.
7. GROUND STUD: Provides a connection point for
connecting the machine case to earth ground for
the safest grounding procedure.
3. 230 VOLT DUPLEX RECEPTACLE: Connection
point for supplying 230 volt power to operate one or
two electrical devices.
SA-250
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B-6
B-6
OPERATION
A high open circuit voltage setting provides the soft
"buttering" arc with best resistance to pop-outs pre-
ferred for most welding. To get this characteristic, set
the CURRENT RANGE SELECTOR to the lowest set-
ting that still provides the current you need and set the
FINE CURRENT ADJUSTMENT near maximum. For
example: to obtain 175 amps and a soft arc, set the
CURRENT RANGE SELECTOR to the 190 -120 posi-
tion and then adjust the FINE CURRENT ADJUST-
MENT for 175 amps.
CONTROL OF WELDING CURRENT
CAUTION
• DO NOT turn the CURRENT RANGE SELECTOR
while welding because the current may arc between
the contacts and damage the switch.
• DO NOT attempt to set the CURRENT RANGE
SELECTOR between the five points designated on
the nameplate.
When a forceful "digging" arc is required, usually for
vertical and overhead welding, use a higher CURRENT
RANGE SELECTOR setting and lower open circuit
voltage. For example: to obtain 175 amps and a force-
ful arc, set the CURRENT RANGE SELECTOR to 240-
160 position and the FINE CURRENT ADJUSTMENT
setting to get 175 amps.
See Figure B.2. The CURRENT RANGE SELECTOR
provides five overlapping current ranges. The FINE
CURRENT ADJUSTMENT adjusts the current from
minimum to maximum within each range. Open circuit
voltage is also controlled by the FINE CURRENT
ADJUSTMENT, permitting control of the arc character-
istics.
Some arc instability may be experienced with EXX10
electrodes when trying to operate with long arc tech-
niques at settings at the lower end of the open circuit
voltage range.
FIGURE B.2 – CURRENT CONTROLS
CURRENT RANGE
SELECTION
FINE CURRENT
ADJUSTMENT
190-120
240-160
50
60
130-80
70
80
90
40
30
20
220
MAX
90
MIN
CURRENT
RANGE
SELECTOR
FINE
CURRENT
ADJUSTMENT
10
100
ENGINE
PROTECTION
IDLER IGNITION
START
REMOTE
CONTROL
230 VOLTAC
115 VOLTAC
SA-250
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B-7
B-7
OPERATION
FIGURE B.3 – DIESEL ENGINE CONTROLS
CURRENT RANGE
SELECTION
FINE CURRENT
ADJUSTMENT
190-120
5
4
50
60
240-160
130-80
8
7
6
70
80
90
40
30
20
220
MAX
90
MIN
10
100
ENGINE
PROTECTION
IDLER IGNITION
START
REMOTE
CONTROL
230 VOLT AC
115 VOLTAC
1. IDLER CONTROL TOGGLE
SWITCH
2. IGNITION TOGGLE SWITCH
3. RESET BUTTON
4. START PUSHBUTTONS
5. ENGINE HOUR METER
6. OIL PRESSURE GAUGE
7. AMMETER
8. WATER TEMPERATURE GAUGE
1
2
3
DIESEL ENGINE CONTROLS
See Figure B.3 for the location of the following fea-
tures:
4. START AND THERMOSTART PUSHBUTTONS:
Press the START button to start the diesel engine.
The IGNITION switch must be in the ON position.
The THERMOSTART button should be used for
starting when air temperature ranges between
10°F (-12°C) and freezing.
1. IDLER CONTROL TOGGLE SWITCH: Adjusts the
running speed of the engine. The switch has two
positions, "HIGH" and "AUTO." In "HIGH," the
engine runs continuously at high idle. In "AUTO,"
the idler control works as follows:
NOTE: If you press either START pushbutton when
the engine is running, you may damage the engine
flywheel gear or starter motor.
Welding: The engine accelerates to high speed
when the electrode touches the work and strikes a
welding arc. The engine returns to low idle approx-
imately 15 seconds after welding stops, as long as
no auxiliary power is being drawn.
5. ENGINE HOUR METER: Records engine running
time. Use the meter to determine when to
perform required maintenance.
Auxiliary Power: The engine accelerates to high
speed when power is drawn at the receptacles for
lights or tools. The engine returns to low idle
approximately 15 seconds after demand for
auxiliary power stops.
6. OIL PRESSURE GAUGE: Indicates engine oil
pressure. If no oil pressure shows on the gauge
within 30 seconds after startup, the engine should
be stopped by placing the IGNITION switch in the
OFF position.
2. IGNITION CONTROL TOGGLE SWITCH: Has
two positions, ON and OFF. When the switch is in
the ON position, the diesel engine can be started
by pressing the START pushbutton. When the
switch is placed in the OFF position, the engine
stops.
7. AMMETER: Shows whether the charging circuit
is performing its job of charging the battery when
the engine is running. The meter will register
discharge during starting, but then the needle
should return to a position slightly toward positive
during running. The needle will hold position in the
center when the engine stops.
3. RESET BUTTON: Resets engine protection circuit.
Press this button before starting the diesel engine.
8. WATER TEMPERATURE GAUGE: Indicates tem-
perature of engine coolant.
SA-250
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B-8
B-8
OPERATION
Check and fill the engine fuel tank:
ENGINE OPERATION
WARNING
WARNING
Do not add fuel near an open flame,
welding arc or when the engine is run-
ning. Stop the engine and allow it to
cool before refueling to prevent spilled
fuel from vaporizing on contact with
hot engine parts and igniting. Do not
spill fuel when filling tank. If fuel is spilled, wipe it up
and do not start engine until fumes have been elimi-
nated.
DO NOT RUN THE ENGINE AT EXCESSIVE
SPEEDS. The maximum allowable high idle speed for
the SA-250 is 1800 RPM, no load. Do NOT increase
the idle speed on the engine. Severe personal injury
and damage to the machine can result if it is operated
at speeds above the maximum rated speed.
Read and understand all safety instructions included in
the Perkins engine instruction manual that is shipped
with your SA-250.
1. Remove the fuel tank cap.
2. Fill the tank to allow approximately 1/4 inch (5 mm)
of tank space for fuel expansion. DO NOT FILL
THE TANK TO THE POINT OF OVERFLOW.
BEFORE STARTING THE ENGINE
Check and fill the engine oil level:
3. Replace the fuel tank cap and tighten securely.
1. Be sure the machine is on a level
surface.
NOTE: USE DIESEL FUEL ONLY. Purchase diesel
fuel in quantities that will be used within 30 days, to
assure freshness.
2. Remove the engine oil dipstick and wipe it with a
clean cloth. Reinsert the dipstick and check the
level on the dipstick.
See Figure D.1 in the
Maintenance section of this manual.
3. Add oil (if necessary) to bring the level up to the full
mark. Do not overfill.
STARTING THE ENGINE
NOTE: Remove all loads connected to the AC power
receptacles before starting the diesel engine.
4. Replace the dipstick.
1. Place the IDLER switch in the "HIGH" position and
the IGNITION switch in the ON position. Press the
RESET button, then press the START button.
NOTE: If the engine fails to start in 60 seconds, wait 30
seconds then repeat step 1.
2. When the engine starts running, observe the oil
pressure. If no pressure shows within 30 seconds,
stop the engine and consult the engine operating
manual.
3. Allow the engine to run at high idle for several min-
utes to warm the engine prior to welding.
SA-250
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B-9
B-9
OPERATION
STOPPING THE ENGINE
COLD WEATHER STARTING
1. Remove all welding and generator power loads
and let the engine cool by running it for several
minutes at low idle.
When temperatures are between 10oF (-12oC) and
freezing, use the standard Thermostart feature. Follow
the instructions on the nameplate and in the engine
manual shipped with the welder. With a fully charged
battery and the proper weight oil, the engine should
start satisfactorily even when the air temperature is
down to about 0oF (-18°C).
2. Place the IGNITION switch in the OFF position.
When an engine is started for the first time, some of the
oil will be needed to fill the passages of the lubricating
system. Therefore, on initial starting, run the engine for
about five minutes and then stop the engine and
recheck the oil. If the level is down, fill to the full mark
again.
If the engine is frequently started below 10oF (-12°C),
you may want to remove the “Thermostart” and install
the optional ether starter kit. Installation and operating
instructions are included in the kit. Use ether starting
only when required because excessive use shortens
engine life.
The engine controls were properly set at the factory
and should require no adjusting when received.
It is important to follow the engine manufacturer’s rec-
ommendations for oil and fuel to obtain satisfactory
cold weather performance. Consult the engine manu-
al and the Maintenance section of this manual.
At the end of each day’s welding, drain accumulated
dirt and water from the sediment bowl under the fuel
tank and from the fuel filter per instructions in the
engine manufacturer’s operating manual. Refill the
fuel tank to minimize moisture condensation in the
tank. Also, running out of fuel tends to draw dirt into the
fuel system. Check the crankcase oil level.
BREAK-IN PERIOD
Any engine will use a small amount of oil during its
break-in period. For the diesel engine on the SA-250,
break-in is about 200 running hours.
In diesel engines, if the fuel supply is cut off or runs out
while the fuel pump is operating, air may be entrapped
in the fuel distribution system. See “How to Eliminate
Air From the Fuel System” in the Maintenance section.
Check the oil twice a day during break-in. Change the
oil and oil filter cartridge after the first 25 hours of oper-
ation. Also change the fuel filter cartridge. For more
details, see the Maintenance section of this manual.
CAUTION
During break-in, subject the SA-250 to only moderate
loads. Avoid long periods running at idle. Before stop-
ping the engine, remove all loads and allow the engine
to cool several minutes.
SA-250
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B-10
B-10
OPERATION
WELDING OPERATION
TO USE THE SA-250 FOR DC CONSTANT
CURRENT STICK OR TIG WELDING:
After you finish welding:
1. Remove the flange nuts from the weld output ter-
minals and place the work and electrode welding
cables over the terminals. See Figure B.4.
Replace and tighten the flange nuts securely. Be
sure the connections are tight.
1. Stop the engine. See Engine Operation in this
section of the manual.
2. Allow the electrode and work to cool completely.
3. Remove the work clamp from the work.
2. Select the appropriate electrode.
4. Remove any remaining piece of electrode from the
electrode holder.
3. Attach the work clamp securely to the work you are
welding.
4. Insert the electrode into the electrode holder.
5. Start the diesel engine. See Engine Operation in
this section of the manual.
6. Set the Idler Switch to “AUTO.”
7. Set the CURRENT RANGE SELECTOR to a set-
ting equal to or slightly higher than the desired
welding current.
8. Set the FINE CURRENT ADJUSTMENT to the set-
ting that gives the best arc characteristics for the
range selected. See Control of Welding Current
in this section of the manual.
9. Strike an arc and begin welding.
FIGURE B.4 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING
1. FLANGE NUT
2. ELECTRODE CABLE
3. ELECTRODE HOLDER
4. ELECTRODE
5. WORK
6. WORK CLAMP
7. WORK CABLE
1
7
6
5
4
3
2
SA-250
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B-11
B-11
OPERATION
TO USE THE SA-250 FOR DC WIRE FEED
WELDING (CONSTANT VOLTAGE WITH
WIRE FEED MODULE):
1. Connect the LN-25 or LN-7 Wire Feeder. Follow
the installation instructions provided with the wire
feeder.
2. Set the machine for CV operation.
3. Start the diesel engine. See Engine Operation in
this section of the manual.
4. Set the Idler Switch to "AUTO."
5. Set the CURRENT RANGE SELECTOR to a set-
ting appropriate for your wire size and wire feed
speed. See Table B.1 for recommended settings.
6. Set the VOLTAGE ADJUSTMENT to the setting
that gives the best arc characteristics for the range
selected.
7. Pull the gun trigger and begin welding.
TABLE B.1
RANGE SETTINGS FOR WIRE SIZE/SPEED
Diameter (inches)
Wire Speed Range
(inches/minute)
Appropriate Current Range
.035
.045
.068
80-110
70-130
40-90
75 to 120 Amps
120 to 170 Amps
125 to 210 Amps
SA-250
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B-12
B-12
OPERATION
AUXILIARY POWER
WARNING
To use the generator as an auxiliary power supply:
Be sure that any electrical equipment plugged into the
generator AC power receptacles can withstand a ±10%
voltage and a ±3% frequency variation.
1. Start the diesel engine. See Engine Operation in
this section of the manual.
2. Set the IDLER switch to AUTO. Set the CURRENT
RANGE SELECTOR to “MAX.” See Figure B.1.
3. Plug the load(s) into the appropriate 115 volt or 230
volt power receptacle.
The AC auxiliary power, supplied as a standard, has a
rating of 3.0 kVA of 115/230V AC power (60 hertz).
One 115V duplex and one 230V duplex grounding type
receptacle are provided. The circuit is protected with
circuit breakers.
The rating of 3.0 kVA permits a maximum continuous
current of 13 amps to be drawn from the 230 volt
duplex receptacle. Or a total of 26 amps can be drawn
from the 115 volt duplex receptacle. The 115 volt
duplex receptacle permits 15 amps to be drawn from
either half. The total combined load of all receptacles
must not exceed 3.0 kVA.
An optional power plug kit is available. When this kit is
specified, the customer is supplied with a plug for each
receptacle. See the Accessories section of this man-
ual.
An optional GFCI 115 volt receptacle kit is also avail-
able. Note that the use of this GFCI kit reduces avail-
able current to a total of 20 Amps of available 115 volt
power. See the Accessories section of this manual.
SA-250
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Section C-1
Section C-1
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Options/Accessories ...................................................................................................................C-2
TIG Welding Accessories............................................................................................................C-3
Semiautomatic FCAW and MIG Welding Accessories ...............................................................C-3
Connection of Lincoln Electric Wire Feeders..............................................................................C-4
Connection of the LN-7 using K867 Universal Adapter........................................................C-4
Connection of the LN-7 using K584 Input Cable Assembly.................................................C-5
Connection of the LN-25 using K867 Universal Adapter......................................................C-6
Connection of the LN-25 “Across the Arc” ...........................................................................C-7
Connection of the K488 SG Control Module and K487 Magnum Spool Gun......................C-8
SA-250
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C-2
C-2
ACCESSORIES
Wire Feed Module - (K623-1) - Provides constant
voltage output for semiautomatic welding. Includes
remote for CV mode and internal “Cold Tip Contactor.”
OPTIONS/ACCESSORIES
The following options/accessories are available for
your SA-250 from your local Lincoln Distributor.
Accessory Kit (K703) - Includes the following:
Trailer (K913) - Two-wheeled trailer for in-plant and
yard towing. Various hitches and accessories are
available. For highway use, consult applicable federal,
state, and local laws.
• Electrode cable
• Work cable
• Headshield
• Work clamp
Power Plug Kit (K802-C) - Provides a plug for each
auxiliary receptacle.
• Insulated electrode holder
Ether Start Kit (K793-1) - Automatic ether start kit pro-
vides cold weather starting assistance in temperatures
below 10oF (-12.2oC). Requires an ether tank that must
be purchased locally. “Thermostart” system must be
removed.
Remote Control - (K924-1) - Includes a receptacle
switch and control box with 100 ft. (7.5 meters) of 4-
conductor cable. Allows fine current and OCV to be
controlled remotely.
GFCI Receptacle Kit (K896-2) - Includes a UL
approved 115 volt ground fault circuit interrupter recep-
tacle (duplex type) with covers and installation instruc-
tions. Each half of the receptacle is rated 15 amps, but
the maximum total current from the GFCI duplex is lim-
ited to 20 amps. The GFCI receptacle replaces the
factory installed 115 volt duplex receptacle.
NOTE: Ether starting can contribute to shortened
engine life. Avoid unnecessary or indiscriminate use.
Linc Thaw™ Control Unit (L2964-5) - Includes meter
and fuses to protect the welder when thawing frozen
water pipes.
WARNING
PIPE THAWING can result in fire, explosion, damage
to pipes, wiring, and the welder as well as other unsafe
or hazardous conditions. Do not use a welder to thaw
pipes before reviewing Lincoln Bulletin E695.1 (dated
October 1987 or later).
SA-250
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C-3
C-3
ACCESSORIES
TIG WELDING ACCESSORIES
SEMIAUTOMATIC WELDING ACCESSORIES
TIG Module (K930-1) - The TIG Module is an acces-
sory that provides high frequency and shielding gas
control for DC GTAW (TIG) welding applications.
LN-25 Wire Feeder - This portable wire feeder is capa-
ble of CC/CV wire feed welding.
LN-7 Wire Feeder - Semiautomatic, constant speed
The K930-1 TIG Module is supplied without acces-
sories. Arc Start switches, Amptrols, cables, torches
and mounting brackets must be purchased separately.
wire feeder. For CV operation only.
NOTE: Gas-shielded welding requires a Magnum Gun.
Gasless welding requires an Innershield Gun.
Control Cable (K936-4) - Control cable for connecting
the K930-1 TIG Module to an SA-250.
Magnum Spool Gun (K487-25) - A lightweight, semi-
automatic wire feeder for aluminum welding with argon
gas. Has built-in remote wire speed control in the han-
dle. Requires the K488 SG Control Module with appro-
priate control cable. Includes 25 feet (7.6 meters) of
power cable.
Arc Start Switch (K814) - Remote start switch for TIG
module (K930-1).
NOTE: TIG welding requires a Magnum™ TIG Gun,
appropriate Magnum Parts Kit and argon gas.
SA-250
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C-4
C-4
ACCESSORIES
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS
4. Connect the K291 or K404 input cable to the LN-7.
5. Place the IDLER switch in the “HIGH” position.
CONNECTION OF THE LN-7 TO THE
SA-250 WITH K623-1 WIRE FEED MODULE USING
K867 UNIVERSAL ADAPTER (SEE FIGURE C.1.)
CAUTION
1. Shut the welder off.
2. Connect the electrode cable from the LN-7 to the
“+” terminal of the welder. Connect the work
cable to the “CV–” terminal of the welder.
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor set-
ting is preset at the factory — do not adjust above
RPM specifications listed in this manual.
NOTE: Welding cable must be sized for current and
duty cycle of application.
NOTE: Figure C.1 shows the electrode connected for
positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
SA-250 output terminals.
6. Adjust wire feed speed at the LN-7.
3. Connect the K867 Universal Adapter to the K291 or
K404 input cable and the 14 pin amphenol of the
SA-250 as indicated in Figure C.1. Make the prop-
er connections for local or remote control accord-
ing to Figure C.1.
NOTE: For remote control, a K775 remote control is
required. See Figure C.1.
CAUTION
When the welder is in local control, the electrode is
always “HOT.”
FIGURE C.1
SA-250/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM
SPARE
Insulate Each
Unused Lead
Individually
82
81
42
41
LN-7
CONTROL
BOX
14 PIN
AMPHENOL
31
32
2
4
21
GND
31
32
2
4
21
+
CV-
K291 OR K404
INPUT CABLE
GND
GREEN
75
76
77
TO
WORK
K867 UNIVERSAL
ADAPTER PLUG
75
76
77
ELECTRODE CABLE
TO LN-7
K775 OPTIONAL
REMOTE CONTROL
Splice Leads
and Insulate
SA-250
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C-5
C-5
ACCESSORIES
CONNECTION OF THE LN-7 TO THE
SA-250 WITH K623-1 WIRE FEED MODULE USING
K584 INPUT CABLE ASSEMBLY (SEE FIGURE C.2.)
CAUTION
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor set-
ting is preset at the factory — do not adjust above
RPM specifications listed in this manual.
1. Shut the welder off.
2. Connect the electrode cable from the LN-7 to the
“+” terminal of the welder. Connect the work cable
to the “CV-” terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.
NOTE: Figure C.2 shows the electrode connected for
positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
SA-250 output terminals.
6. Adjust wire feed speed at the LN-7.
NOTE: For remote control, a K857 control is required.
Connect it to the K864 adapter.
3. Connect the input cable from the K584-XX Input
Cable Assembly to the 14 pin amphenol on the
K864 adapter and the input cable plug on the LN-
7.
CAUTION
When the welder is in local control, the electrode is
always “HOT.”
4. Connect the K864 adapter to the 14 pin amphenol
on the SA-250.
5. Place the IDLER switch in the “HIGH” position.
FIGURE C.2
SA-250/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM
LN-7
CONTROL
BOX
14 PIN
AMPHENOL
14 PIN
AMPHENOL
K584-"L" INPUT CABLE
+
CV-
6 PIN
AMPHENOL
K864
ADAPTER
TO
WORK
K857
REMOTE CONTROL
ELECTRODE CABLE
TO LN-7
SA-250
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C-6
C-6
ACCESSORIES
4. Connect the K432-L cable to the LN-25 equipped
with the K431-1 remote output control kit.
CONNECTION OF THE LN-25 TO THE
SA-250 WITH K623-1 WIRE FEED MODULE USING
K867 UNIVERSAL ADAPTER (SEE FIGURE C.3.)
5. Place the IDLER switch in the “HIGH” position.
1. Shut the welder off.
2. Connect the electrode cable from the LN-25 to the
“+” terminal of the welder. Connect the work cable
to the “CV-” terminal of the welder.
CAUTION
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor set-
ting is preset at the factory — do not adjust above
RPM specifications listed in this manual.
NOTE: Welding cable must be sized for current and
duty cycle of application.
NOTE: Figure C.3 shows the electrode connected for
positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
SA-250 output terminals. Reverse the LN-25 polarity
switch.
3. Connect the K867 Universal adapter to the K433
cable and the 14 pin amphenol of the SA-250 as
indicated in Figure C.3. Mount the K433 to the
welder according to instructions included with the
K433 kit.
6. Adjust wire feed speed and voltage at the LN-25.
FIGURE C.3
SA-250/LN-25 CONNECTION DIAGRAM
SPARE
82
81
42
41
Insulate Each
14 PIN
AMPHENOL
Unused Lead
Individually
K433
21
+
31
32
2
31
32
2
K432-"L" CABLE
CV-
4
4
GND
GND
K867 UNIVERSAL
ADAPTER PLUG
75
76
77
75
76
77
TO
WORK
LN-25 WIRE FEEDER
WITH K431 OPTION
Splice Leads and Insulate
ELECTRODE CABLE
SA-250
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C-7
C-7
ACCESSORIES
3. Connect the K444-2 remote control cable to the 14
pin amphenol on the wire feed module.
CONNECTION OF THE LN-25 TO THE
SA-250 “ACROSS THE ARC”
(SEE FIGURE C.4.)
4. Attach the single lead from the LN-25 control box
to the work using the spring clip on the end of the
lead. This is only a control lead — it carries no
welding current.
1. Shut the welder off.
2. Connect the electrode cable from the LN-25 to the
“+” terminal of the welder. Connect the work cable
to the “CV–” terminal of the welder.
5. Place the IDLER switch in the “HIGH” position.
6. Adjust wire feed speed and voltage at the LN-25.
NOTE: Welding cable must be sized for current and
duty cycle of application.
NOTE: Figure C.4 shows the electrode connected for
positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
SA-250 output terminals. Reverse the LN-25 polarity
switch.
FIGURE C.4
SA-250/LN-25 ACROSS THE ARC CONNECTION DIAGRAM
14 PIN
AMPHENOL
+
LN-25 WIRE FEEDER
WITH K444-2 REMOTE
VOLTAGECONTROL OPTION
CV-
ELECTRODE CABLE
TO
WORK
WORK CLIP
LEAD TO WORK
SA-250
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C-8
C-8
ACCESSORIES
6. Place the IDLER switch on the SA-250 in the
“HIGH” position.
CONNECTION OF THE K488 SG CONTROL
MODULE AND K487 MAGNUM SPOOL GUN
TO THE SA-250 (SEE FIGURE C.5.)
CAUTION
1. Shut the welder off.
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor set-
ting is preset at the factory — do not adjust above
RPM specifications listed in this manual.
2. Connect the electrode cable from the SG Control
Module to the “+” terminal of the welder. Connect
the work cable to the “CV–” terminal of the welder.
NOTE: Welding cable must be sized for current
and duty cycle of application.
NOTE: Figure C.5 shows the electrode connected
for positive polarity. To change polarity, shut the
welder off and reverse the electrode and work cables
at the SA-250 output terminals.
7. Adjust wire feed speed at the SG Control Module.
NOTE: For remote control, a K775 remote control is
required.
3. Connect the K867 Universal adapter to the K492
input cable as shown in Figure C.5. Connect the
other end of the adapter to the 14 pin amphenol on
the SA-250.
CAUTION
4. Connect the K492 Input Cable to the SG Control
Module.
When the welder is in local control, the electrode is
always “HOT.”
5. Set the slide switch on the SG Control Module to
the “Lincoln” position.
CAUTION
Be sure this switch is set to the “Lincoln” (contact clo-
sure) position before attempting to operate the SG
Control Module. Incorrect switch position could result
in damage to the SG Control Module and/or the SA-
250.
FIGURE C.5
SA-250/K492/K488/K487 SPOOL GUN CONNECTION DIAGRAM
SPARE
82
Insulate Each
14 PIN
K488 SG
81
AMPHENOL
Unused Lead
CONTROL
K487-25
SPOOL
GUN
42
41
21
MODULE
Individually
+
31
32
2
31
32
2
CV-
K492
4
4
INPUT CABLE
GND
GND
GREEN
75
76
77
TO
WORK
K867 UNIVERSAL
ADAPTER PLUG
75
76
77
ELECTRODE CABLE TO
K438 SG CONTROL CABLE
K775 OPTIONAL
REMOTE CONTROL
Splice Leads
and Insulate
SA-250
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Section D-1
Section D-1
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance .........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance.............................................................................................D-2
Engine Maintenance.......................................................................................................D-2
Change the Oil ........................................................................................................D-2
Change the Oil Filter ...............................................................................................D-3
Fuel..........................................................................................................................D-3
Fuel Filter.................................................................................................................D-4
Air Cleaner...............................................................................................................D-4
How to Eliminate Air From the Fuel System ...........................................................D-5
Cooling System .......................................................................................................D-7
Tightening the Fan Belt ...........................................................................................D-8
Engine Maintenance Schedule................................................................................D-9
Battery Maintenance ....................................................................................................D-10
Cleaning the Battery..............................................................................................D-10
Checking Specific Gravity .....................................................................................D-10
Checking Electrolyte Level....................................................................................D-10
Charging the Battery .............................................................................................D-10
Welder/Generator Maintenance....................................................................................D-11
Storage ..................................................................................................................D-11
Cleaning.................................................................................................................D-11
Nameplates............................................................................................................D-11
Brush Removal and Replacement.........................................................................D-11
Commutator and Brushes......................................................................................D-11
Bearings.................................................................................................................D-11
Current Range Selector Contacts..........................................................................D-11
Receptacles ...........................................................................................................D-11
Cable Connections ................................................................................................D-11
Idler Maintenance.........................................................................................................D-12
Major Component Locations.....................................................................................................D-13
SA-250
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D-2
D-2
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ROUTINE AND PERIODIC
MAINTENANCE
ENGINE MAINTENANCE
• Have qualified personnel do all maintenance and
troubleshooting work.
CAUTION
• Turn the engine off before working inside the
machine.
To prevent the engine from accidentally starting, dis-
connect the negative battery cable before servicing the
engine.
• Remove covers or guards only when necessary to
perform maintenance and replace them when the
maintenance requiring their removal is complete.
See Table D.1 for a summary of maintenance intervals
for the items listed below. Follow either the hourly or
the calendar intervals, whichever come first. More fre-
quent service may be required, depending on your spe-
cific application and operating conditions.
• If covers or guards are missing from the machine,
get replacements from a Lincoln Distributor.
Read the Safety Precautions in the front of this manu-
al and in the instruction manual for the diesel engine
used with your machine before working on the SA-250.
OIL: Check the oil level after every 8
hours of operation or daily. BE SURE
TO MAINTAIN THE OIL LEVEL.
Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep your hands, hair,
clothing, and tools away from the recoil housing, fans,
and all other moving parts when starting, operating, or
repairing this machine.
Change the oil the first time between 25 and 50 hours
of operation. Then, under normal operating conditions,
change the oil as specified in Table D.1. If the engine is
operated under heavy load or in high ambient temper-
atures, change the oil more frequently.
CHANGE THE OIL: Change the oil, while the engine
is still warm, as follows:
1 . Drain the oil from the drain plug located on the
engine bottom, as shown in Figure D.1. Examine
the washer and replace it if it appears damaged.
2. Replace the plug and washer and tighten to 25 ft.-
lb. (34 Nm).
3. Remove the oil fill cap and add oil until the level
reaches the “MAX” mark on the dipstick. See
Figure D.1. Use high quality oil viscosity grade
10W30. Consult the engine manual for oil specifi-
cations. Always check the level with the dipstick
before adding more oil.
4. Reinstall the oil fill cap and the dipstick.
SA-250
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D-3
D-3
MAINTENANCE
FIGURE D.1 – OIL DRAIN AND REFILL
2
1
CHANGE THE OIL FILTER: Change the oil filter the
first time between 25 and 50 hours of operation. Then,
under normal operating conditions, change the oil filter
after every 200 to 250 hours of operation. If the engine
is operated under heavy load or in high ambient tem-
peratures, change the oil filter more frequently. See
Table D.1 for recommended maintenance intervals.
Order Perkins oil filter #2654408 from your local
Perkins service center.
5. Refill the engine with the proper amount and type
of oil as described in the Change the Oil section,
above. Start the engine and check for leaks
around the filter element. Correct any leaks (usu-
ally by retightening the filter, but only enough to
stop leaks) before placing the SA-250 back in ser-
vice.
6. See Figure D.1. If there are no leaks, stop the
engine and recheck the oil level. If necessary, add
oil to bring the level up to the “MAX” mark, but do
not overfill.
Change the oil filter as follows:
1 . See Figure D.1. Remove the oil drain plug (1).
Drain the oil from the engine and allow the oil filter
to drain.
FUEL: At the end of each day's use, refill
the fuel tank to minimize moisture conden-
sation and dirt contamination in the fuel
line. Do not overfill; leave room for the fuel
to expand.
2. See Figure D.1. Remove the old filter (spin it off)
and discard it (2). Wipe off the filter mounting sur-
face and adapter.
Refer to your engine operation manual for recom-
mended grade of fuel.
3. Fill the new filter with fresh engine oil. Apply a thin
coat of new oil to the rubber gasket on the new oil
filter.
4. Spin the new filter onto the mounting adapter finger
tight until the gasket is evenly seated. Then turn it
down another 1/2 turn. Do not overtighten the new
filter.
SA-250
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D-4
D-4
MAINTENANCE
FUEL FILTER: Inspect the fuel filter daily. Drain any
accumulated water from the engine fuel filter/water
separator daily. Change the fuel filter every 400 hours
of operation. Dust and dirt in the fuel system can
cause the injection pump and injection nozzle to wear
quickly. Change the fuel filter as follows:
AIR CLEANER: The Perkins diesel engine is equipped
with a dry type air filter. Inspect the air cleaner daily -
more often in dusty conditions. Never apply oil to the
air cleaner. Service the air cleaner as follows:
1. Remove the dust cup from the bottom of the air
cleaner housing. Clean out any accumulated dust.
1. See Figure D.2. Clean the outside surfaces of the
fuel filter assembly. If a drain tap (1) is fitted to the
filter bowl, drain the fuel from the filter.
2. Loosen the wing nut and remove the filter element.
3. If dust is sticking to the dust collector element, blow
compressed air through it from the inside out.
Turn the element as you apply air. Air pressure
should be under 686 kPa (7 kgf/cm2, 99 psi).
2. See Figure D.2. Hold the bottom cover of the filter
element and release the setscrew (2) which is fitted
through the filter head above the center of the ele-
ment.
4. Check the element for damage before reassem-
bling the air cleaner. Replace the element if it
appears damaged. Order Donaldson element part
number P10-1275.
3. See Figure D.2. Lower the bottom cover (3) of the
filter.
4. Remove the element and discard it.
5. Clean the inside surfaces of the filter head and of
the cover.
6. Renew the seals and lightly lubricate them with
clean fuel.
7. Put the bottom cover under the new element and
hold the element squarely to the filter head. Ensure
that the element is fitted in the center against the
joint in the filter head. With the assembly in this
position, engage and tighten the setscrew.
8. Bleed the air from the fuel system. See How to
Eliminate Air from the Fuel System.
Order Perkins fuel filter #26560017 or #26561117 from
your local Perkins Service Center.
FIGURE D.2 – FUEL FILTER REPLACEMENT
2
1
3
SA-250
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D-5
D-5
MAINTENANCE
HOW TO ELIMINATE AIR FROM THE FUEL SYSTEM
Standard method
There are two methods to eliminate air from the fuel
system according to the type of pump fitted:
1. See Figure D.3. Loosen the banjo connection bolt
which is fitted on the top of the filter (1).
See Figure D.3. The standard method is used where
the fuel injection pump has vent screws 4 and 5.
2. See Figure D.3. Operate the priming lever on the
fuel lift pump (2) until fuel, free from air, comes from
the filter vent point. Tighten the banjo connection
bolt. If the drive cam of the fuel lift pump is at the
point of maximum cam lift, it will not be possible to
operate the priming lever. In this situation, the
crankshaft must be turned one revolution.
The self-vent method is used where the fuel injection
pump has a self-vent feature. Vent screws are not fit-
ted to these pumps. No connections or plugs need to
be released to eliminate air from the fuel system.
If air enters the fuel system, it must be eliminated
before the engine can be started.
3. See Figure D.3. Where the fuel filter is fitted lower
than the fuel injection pump, loosen the inlet con-
nection at the fuel injection pump (3) and operate
the lift pump to remove any air. Tighten the inlet
connection.
Air can enter the system if:
• The fuel tank is drained during normal operation.
• The low-pressure fuel pipes are disconnected.
4. Ensure that the manual stop control is in the “run”
position. If an electrical stop control is used, turn
the start key to the “R” position.
• A part of the low-pressure fuel system leaks during
engine operation.
In order to eliminate air from the fuel system, proceed
as follows:
5. See Figure D.3. Loosen the vent screw in the lock
screw of the hydraulic head (4) and the vent screw
on the governor cover of the fuel injection pump (5).
6. Operate the priming lever of the fuel lift pump until
fuel, free from air, comes from the vent screw(s).
Tighten the vent screw(s).
FIGURE D.3 – ELIMINATING AIR FROM THE FUEL SYSTEM
1
3
5
4
2
SA-250
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D-6
D-6
MAINTENANCE
7. See Figure D.4. Loosen the union nut (1) at the
fuelled starting aid (if one is fitted) and operate the
lift pump until fuel, free from air, comes from the
connection. Tighten the union nut at the starting
aid.
1. If a manual stop control is fitted, ensure that it is in
the “run” position.
2. Operate the starter motor until the engine starts.
If the system or a component in the system has been
drained:
8. See Figure D.4. Loosen the union nuts of the high-
pressure pipes (2) at two of the atomisers. Operate
the starter motor until fuel, free from air, comes from
the pipe connections. Tighten the high-pressure
pipe connections.
1. Turn the start key to the “R” position. If a manual
stop control is fitted, ensure that it is in the “run”
position.
2. Operate the lever of the fuel lift pump slowly for
approximately two minutes. If the drive cam of the
fuel lift pump is at the point of maximum cam lift, it
will not be possible to operate the priming lever. In
this situation, the crankshaft must be turned one
revolution.
9. The engine is now ready to start. If the engine runs
correctly for a short time and then stops or runs
roughly, check for air in the fuel system. If there is
air in the fuel system, there is probably a leakage in
the low pressure system.
3. Operate the starter motor until the engine starts.
Self-vent method
If the engine runs correctly for a short time and then
stops or runs roughly, check for air in the fuel system.
If there is air in the fuel system, there is probably a
leakage in the low pressure system.
If the engine has been stopped by air in the fuel sys-
tem:
Ensure that fuel has been added to the tank or that the
leakage has been corrected.
FIGURE D.4 – ELIMINATING AIR FROM THE FUEL SYSTEM (continued)
1
2
SA-250
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D-7
D-7
MAINTENANCE
COOLING SYSTEM: The Perkins diesel engine is
water cooled. Check the coolant level at the radiator
filler daily. Add a 50-50 mixture of water and antifreeze
as needed. To drain and refill the system, do the fol-
lowing:
2. Remove the radiator filler cap.
3. Remove the drain plug from the side of the cylinder
block in order to drain the engine. Ensure that the
drain hole is not restricted. See Figure D.5.
4. Open the radiator drain cock at the bottom of the
radiator in order to drain the radiator.
1. Ensure that the machine is on level ground.
5. If necessary, flush the system with clean water.
6. Fit the engine drain plug and the radiator drain cock.
WARNING
To avoid personal injury, never remove the radiator
pressure cap nor the reserve tank cap while the engine
is running or immediately after it has stopped. Hot
water may gush out, which can scald people nearby.
7. Fill the cooling system at the radiator filler with a 50-
50 mixture of water and antifreeze.
FIGURE D.5 – ENGINE COOLANT DRAIN PLUG
SA-250
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D-8
D-8
MAINTENANCE
TIGHTENING THE FAN BELT: Fan belts tend to
loosen after the first 50 hours of operation. If the fan
belts are loose, the engine can overheat and the bat-
tery can lose its charge. Check belt tightness by press-
ing on the belt midway between the pulleys. The belt
should deflect no more than 10 mm (0.375 in.). See
Figure D.6.
2. Change the position of the alternator to give the cor-
rect tension. Tighten the pivot fasteners of the alter-
nator and the adjustment link fasteners.
3. Check the belt tension again to ensure that it is still
correct.
If a new belt is fitted, the belt tension must be checked
again after the first 25 hours of operation.
To adjust the fan belt, do the following:
1. See Figure D.6. Loosen the pivot fasteners of the
alternator (1) and the adjustment link fasteners (2).
FIGURE D.6 – TIGHTENING THE FAN BELT
1
2
SA-250
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D-9
D-9
MAINTENANCE
TABLE D.1
PERKINS ENGINE MAINTENANCE SCHEDULE
FREQUENCY
MAINTENANCE REQUIRED
Daily or Before
Starting Engine
• Fill fuel tank.
• Check oil level.
• Check air cleaner for dirty, loose, or damaged parts.
• Check air intake and cooling areas, clean as necessary.
• Inspect fuel filter. Drain any accumulated water from water separator.
First 25-50 Hours
• Change engine oil.
• Change oil filter.
• Check fan belt.
• Check coolant.
Every 200-250
Hours
• Check drive belts.
• Check fuel lines and clamps.
• Check coolant.
• Check air filter.
• Change oil.
• Change oil filter.
• Check battery electrolyte level and connections.
Every 400 Hours
• Change fuel filter.
Refer to your Perkins engine Owner's Manual for periodic maintenance beyond 400 hours.
SA-250
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D-10
D-10
MAINTENANCE
CHECKING SPECIFIC GRAVITY
BATTERY MAINTENANCE
WARNING
Check each battery cell with a hydrometer. A fully
charged battery will have a specific gravity of 1.260.
Charge the battery if the reading is below 1.215.
NOTE: Correct the specific gravity reading by adding
four gravity points (0.004) for every five degrees the
electrolyte temperature is above 80 degrees F (27
degrees (C). Subtract four gravity points (.004) for
every five degrees the electrolyte temperature is below
80 degrees F (27 degrees C).
GASES FROM BATTERY can explode.
• Keep sparks, flame, and cigarettes away
from battery.
BATTERY ACID can burn eyes and skin.
• Wear gloves and eye protection and be
careful when working near a battery.
Follow the instructions printed on the
battery.
CHECKING ELECTROLYTE LEVEL
If battery cells are low, fill them to the neck of the filler
hole with distilled water and recharge. If one cell is low,
check for leaks.
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY - Disconnect the
negative cable from the old battery first and connect
to the new battery last.
CHARGING THE BATTERY
The SA-250 is equipped with a wet charged battery.
The charging current is automatically regulated when
the battery is low (after starting the engine) to a trickle
current when the battery is fully charged.
• THE CORRECT POLARITY IS NEGATIVE
GROUND - Damage to the engine alternator and
the printed circuit board can result from incorrect
connection.
When you charge, jump, replace, or otherwise connect
battery cables to the battery, be sure the polarity is cor-
rect. Improper polarity can damage the charging cir-
cuit. The SA-250 charging system is NEGATIVE
GROUND. The positive (+) battery terminal has a red
terminal cover.
• CONNECTING A BATTERY CHARGER -
Remove the battery from the welder by
disconnecting the negative cable first,
then the positive cable and battery
clamp. When reinstalling, connect the
negative cable last. Keep the area well
ventilated.
If you need to charge the battery with an external
charger, disconnect the negative cable first, then the
positive cable before you attach the charger leads.
After the battery is charged, reconnect the positive bat-
tery cable first and the negative cable last. Failure to
do so can result in damage to the internal charger com-
ponents.
• USING A BOOSTER - Connect the positive lead to
the battery first, then connect the negative lead to the
engine foot.
• To prevent BATTERY BUCKLING, tighten the nuts
on the battery clamp until snug.
Follow the instructions of the battery charger manufac-
turer for proper charger settings and charging time.
CLEANING THE BATTERY
Keep the battery clean by wiping it with a damp cloth
when dirty. If the terminals appear corroded, discon-
nect the battery cables and wash the terminals with an
ammonia solution or a solution of 1/4 pound (0.113 kg)
of baking soda and 1 quart (0.946 l) of water. Be sure
the battery vent plugs (if equipped) are tight so that
none of the solution enters the cells.
After cleaning, flush the outside of the battery, the bat-
tery compartment, and surrounding areas with clear
water. Coat the battery terminals lightly with petroleum
jelly or a non-conductive grease to retard corrosion.
Keep the battery clean and dry. Moisture accumulation
on the battery can lead to more rapid discharge and
early battery failure.
SA-250
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D-11
D-11
MAINTENANCE
Replace brushes when they wear within 1/4" of the pig-
tail. A complete set of replacement brushes should be
kept on hand. Lincoln brushes have a curved face to
fit the commutator. Have experienced maintenance
personnel seat these brushes by lightly stoning the
commutator as the armature rotates at full speed until
contact is made across the full face of the brushes.
After stoning, blow out the dust with low pressure air.
WELDER/GENERATOR
MAINTENANCE
STORAGE: Store the SA-250 in clean, dry, protected
areas.
CLEANING: Blow out the generator and controls peri-
odically with low pressure air. Do this at least once a
week in particularly dirty areas.
NAMEPLATES: Whenever routine maintenance is
performed on this machine - or at least yearly - inspect
all nameplates and labels for legibility. Replace those
which are no longer clear. Refer to the parts list for the
replacement item number.
WARNING
Uncovered rotating equipment can be dangerous. Use
care so your hands, hair, clothing or tools do not catch
in the rotating parts. Protect yourself from particles
that may be thrown out by the rotating armature when
stoning the commutator.
ALTERNATOR BRUSH REMOVAL AND REPLACE-
MENT: It's normal for the brushes and slip rings to
wear and darken slightly. Inspect the brushes when a
generator overhaul is necessary. Remove the brushes
and clean the slip rings with fine emery paper. To seat
new slip ring brushes, position the brushes in place.
Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres-
sure on top of the brushes, pull the sandpaper around
the circumference of the rings - in the direction of rota-
tion only - until brushes seat property. Brushes must
be seated 100%.
Arcing or excessive exciter brush wear indicates a pos-
sible misaligned shaft. Have an authorized Lincoln
Electric Field Service facility check and realign the
shaft.
BEARINGS: The SA-250 is equipped with double-
shielded ball bearings having sufficient grease to last
indefinitely under normal service. Where the welder is
used constantly or in excessively dirty locations, it may
be necessary to add one half ounce of grease per year.
A pad of grease one inch wide, one inch long, and one
inch high weighs approximately one half ounce. Over-
greasing is far worse than insufficient greasing.
COMMUTATOR AND BRUSHES: The generator
brushes are properly adjusted when the welder is
shipped. They require no particular attention.
When greasing the bearings, keep all dirt out of the
area. Wipe the fittings completely clean and use clean
equipment. More bearing failures are caused by dirt
introduced during greasing than from insufficient
grease.
CAUTION
DO NOT SHIFT THE BRUSHES or adjust the rocker
setting.
CURRENT RANGE SELECTOR CONTACTS: The
contacts should not be greased. To keep the contacts
clean, rotate the current control handle through its
entire range frequently. Good practice is to turn the
handle from maximum to minimum setting twice each
morning before starting to weld. Never rotate the han-
dle while machine is under load.
Shifting of the brushes may result in:
• Change in machine output
• Commutator damage
• Excessive brush wear
Put a drop of oil on the CURRENT RANGE SELEC-
TOR shaft at least once every month.
Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove
these covers while the machine is running.
RECEPTACLES: Keep the electrical receptacles in
good condition. Remove any dirt, oil, or other debris
from their surfaces and holes.
Commutators and brushes require little attention.
However, if they are black or appear uneven, have
them cleaned by experienced maintenance personnel
using a commutator stone. Never use emery cloth or
paper for this purpose.
CABLE CONNECTIONS: Check the welding cable
connections at the weld output terminals often. Be
sure that the connections are always tight.
SA-250
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D-12
D-12
MAINTENANCE
IDLER MAINTENANCE
1. The solenoid plunger must work freely because
binding can cause engine surging. If surging
occurs, be sure the plunger is properly lined up
with the throttle lever. Dust the plunger about once
a year with graphite powder.
2. When any service is done, reassemble the rubber
bellows on the solenoid plunger with the vent hole
on the lower side.
3. Proper operation of the idler requires good ground-
ing of the printed circuit board (through its mount-
ing), reed switch and battery.
4. If desired, the welder can be used without auto-
matic idling by setting the “Idler Control” switch to
the “High Idle” position.
SA-250
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D-13
D-13
MAINTENANCE
FIGURE D.5 - MAJOR COMPONENT LOCATIONS
1. RIGHT CASE SIDE (DOOR)
2. BASE (WITH BATTERY)
3. ALTERNATOR BRUSHES
4. ALTERNATOR
5. GENERATOR
6. GENERATOR BRUSHES
7. OUTPUT TERMINALS
8. FUEL TANK
9. CASE FRONT WITH CONTROL PANEL
10. LEFT CASE SIDE
11. CASE TOP
12
11
12. CASE BACK WITH RADIATOR
13. COOLING FAN
14. AIR CLEANER
15. IDLER CONTROL
9
10
15
8
13
14
7
5
6
4
3
2
1
SA-250
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D-14
D-14
NOTES
SA-250
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Section E-1
Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation .............................................................................................................Section E
General Description...............................................................................................................E-2
Battery, Starter, Engine Alternator, and Protection Circuits ..................................................E-2
Engine, Generator Armature and Frame, Alternator Stator and Rotor..................................E-3
Excitation (Flashing)........................................................................................................E-3
Auxiliary and Field Feedback Coils.................................................................................E-3
Interpole and Series Coils...............................................................................................E-4
Current Range Selector ..................................................................................................E-4
Fine Current Adjustment .................................................................................................E-4
Engine Idler Circuit..........................................................................................................E-4
DC Generator Machines........................................................................................................E-5
PROTECTION
RELAY
SELECTOR
SWITCH
REED
RELAY
CR2
IDLER
BOARD
NEGATIVE
OUTPUT
TERMINAL
115 & 230VAC
RECEPTACLES
IDLER
SOLENOID
OIL
PRESSURE
SWITCH
GENERATOR
FRAME
TEMPERATURE
GAUGE
CURRENT
TRANSFORMER
FUEL
INJECTION
PUMP
SERIES
COILS
ALTERNATOR STATOR
ROTOR
GENERATOR
MECHANICAL
COUPLING
ENGINE
ARMATURE
SHAFT
IGNITION
SWITCH
ARMATURE
ENGINE
ALTERNATOR
SLIP
RINGS
INTERPOLE
COILS
RESIDUAL
MAGNETISM
FLASHING
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
BATTERY
RECTIFIER
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
FIGURE E.1 – SA-250 BLOCK LOGIC DIAGRAM
SA-250
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 – BATTERY, STARTER, ENGINE ALTERNATOR, AND PROTECTION CIRCUITS
PROTECTION
RELAY
SELECTOR
SWITCH
REED
RELAY
CR2
IDLER
BOARD
NEGATIVE
OUTPUT
TERMINAL
115 & 230VAC
RECEPTACLES
IDLER
SOLENOID
OIL
PRESSURE
SWITCH
GENERATOR
FRAME
TEMPERATURE
GAUGE
CURRENT
TRANSFORMER
FUEL
INJECTION
PUMP
SERIES
COILS
ALTERNATOR STATOR
ROTOR
GENERATOR
MECHANICAL
COUPLING
ENGINE
ARMATURE
SHAFT
IGNITION
SWITCH
ARMATURE
ENGINE
ALTERNATOR
SLIP
RINGS
INTERPOLE
COILS
RESIDUAL
MAGNETISM
FLASHING
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
BATTERY
RECTIFIER
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
GENERAL DESCRIPTION
BATTERY, STARTER, ENGINE
ALTERNATOR, AND PROTECTION
CIRCUITS
The SA-250 is a heavy duty, engine driven DC arc
welding power source capable of providing constant
current output for stick welding or DC TIG welding.
Also, a total of 3000 watts of auxiliary power is available
at the 115 or 230VAC receptacles.
The 12VDC battery powers the starter motor and,
through the ignition switch, the engine protection cir-
cuitry. In the event of a low oil pressure or a high
coolant temperature condition, the engine protection
system shuts the engine off. The protection relay mon-
itors the oil pressure switch and the coolant tempera-
ture sensor. If either sensor “faults,” the protection relay
deactivates the fuel injection pump, and the engine
shuts down. The engine alternator supplies “charging”
current for the battery circuit.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
SA-250
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 – ENGINE GENERATOR ARMATURE AND FRAME, ALTERNATOR STATOR AND ROTOR
PROTECTION
RELAY
SELECTOR
SWITCH
REED
RELAY
CR2
IDLER
BOARD
NEGATIVE
OUTPUT
TERMINAL
115 & 230VAC
RECEPTACLES
IDLER
SOLENOID
OIL
PRESSURE
SWITCH
GENERATOR
FRAME
TEMPERATURE
GAUGE
CURRENT
TRANSFORMER
FUEL
INJECTION
PUMP
SERIES
COILS
ALTERNATOR STATOR
ROTOR
GENERATOR
MECHANICAL
COUPLING
ENGINE
ARMATURE
SHAFT
IGNITION
SWITCH
ARMATURE
ENGINE
ALTERNATOR
SLIP
RINGS
INTERPOLE
COILS
RESIDUAL
MAGNETISM
FLASHING
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
BATTERY
RECTIFIER
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
ENGINE, GENERATOR ARMATURE
AND FRAME, ALTERNATOR
STATOR AND ROTOR
AUXILIARY AND FIELD FEEDBACK COILS
There are two isolated windings incorporated in the sta-
tor lamination assembly. One of these windings is
tapped and provides 115VAC and 230VAC of auxiliary
power to the appropriate receptacles. The other
115VAC isolated winding is rectified to a DC voltage
and is used to supply field feedback voltage to the rotor.
It also, through the generator field rheostat control, sup-
plies voltage to the field shunt windings in the main
generator frame.
EXCITATION (FLASHING)
When the engine is started and running, the residual
magnetism voltage is applied to the alternator rotor via
a brush and slip ring configuration. This excitation
(“flashing”) voltage magnetizes the rotor lamination.
The alternator rotor is connected to the armature shaft,
which is mechanically coupled to the engine. This
rotating magnet (rotor) induces a voltage in the station-
ary windings of the alternator stator.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
SA-250
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E-4
E-4
THEORY OF OPERATION
INTERPOLE AND SERIES COILS
FINE CURRENT ADJUSTMENT
The generator armature rotates within the magnetic
field created by the field shunt windings. A DC voltage
is induced in the armature and is transferred, through
the armature commutator and brushes, to the series
and interpole coils. The interpole coils, which are con-
nected in series with the positive output terminal, are
located so as to counteract any magnetic influences
that could cause mechanical distortion in the rotating
armature. The series coils are designed to oppose or
“buck” the DC voltage that is generated in the arma-
ture.
The field rheostat control functions as a fine output cur-
rent adjustment by controlling the current through the
shunt windings. In this way it controls the amount of
magnetism created in the field shunt windings. Open
circuit weld voltage can also be controlled by the field
rheostat control.
ENGINE IDLER CIRCUIT
The idler solenoid is mechanically connected to the
engine governor linkage. When welding current is
being drawn, the reed switch CR2 is closed. This sig-
nals the idler PC board to release (deactivate) the idler
solenoid, which then lets the machine go to a high
speed condition. Also, when auxiliary power is being
used, the current is passed through the current trans-
former, which signals the idler PC board to release the
idler solenoid.
CURRENT RANGE SELECTOR
The selector switch acts as a coarse current adjust-
ment by allowing for varying amounts of series wind-
ings to be included in the welding current path. The
series coils and selector switch are connected in series
with the negative output terminal.
When welding ceases or the auxiliary load is removed,
a preset time delay of about 15 seconds starts. After
approximately 15 seconds, the idler PC board activates
the idler solenoid, and the machine will return to a low
idle speed condition.
SA-250
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E-5
E-5
THEORY OF OPERATION
FIGURE E.4 – DC GENERATOR MACHINES
C
U
F
R
I
R
E
E
L
N
D
T
SHUNT FIELD WINDINGS
DC CURRENT
MAGNETIC FIELD
BRUSH
GENERATOR
ARMATURE
SHAFT
MECHANICAL
COUPLING
ARMATURE
BRUSH
MAGNETIC FIELD
DC CURRENT
WINDINGS
SHUNT FIELD
C
U
R
R
E
N
T
F
I
E
L
D
winding induces a coil voltage in the armature winding.
The voltage induced in an individual armature coil is an
alternating (AC) voltage, which must be rectified. In a
conventional DC Generator, rectification is provided
mechanically by means of a commutator. A commuta-
tor is a cylinder formed of copper segments insulated
from each other and mounted on, but insulated from,
the rotating shaft. Stationary carbon brushes held
against the commutator surface connect the armature
windings to external terminals. The commutator pro-
vides full-wave rectification, transforming the voltage
waveform between brushes and making available a DC
voltage to the external circuit.
DC GENERATOR MACHINES
The armature winding of a DC generator is located on
the rotating member. Current is conducted from it by
means of carbon brushes. The field winding is located
in the stator, which is stationary, and is excited by direct
current.
The armature coil sides are placed at opposite points
on the rotating shaft with the conductors parallel to the
shaft. The armature assembly is normally turned at a
constant speed by a source of mechanical power con-
nected to the shaft. Rotation of the armature through
the magnetic field produced by the stationary field
SA-250
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E-6
E-6
NOTES
SA-250
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Section F-1
Section F-1
TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION
Troubleshooting & Repair Section ................................................................................Section F
How to Use Troubleshooting Guide.......................................................................................F-2
PC Board Troubleshooting Procedures .................................................................................F-3
Troubleshooting Guide................................................................................................F-4 - F-12
Test Procedures...................................................................................................................F-13
Alternator Rotor Test......................................................................................................F-13
Field Shunt Winding Test...............................................................................................F-17
Idler Solenoid Test.........................................................................................................F-20
Engine Throttle Adjustment Test....................................................................................F-22
Flashing the Fields ........................................................................................................F-26
Oscilloscope Waveforms......................................................................................................F-28
Normal Open Circuit Voltage Waveform (115VAC Supply)...........................................F-28
Normal Open Circuit DC Weld Voltage Waveform........................................................F-29
Typical DC Weld Output Voltage Waveform..................................................................F-30
Replacement Procedures ....................................................................................................F-31
Alternator Rotor Removal and Replacement ................................................................F-31
Alternator Stator Removal and Replacement................................................................F-36
Generator Frame Removal and Replacement ..............................................................F-41
Generator Armature Removal and Replacement..........................................................F-47
Retest After Repair...............................................................................................................F-49
SA-250
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F-2
F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunc-
tions. Simply follow the three-step procedure list-
ed below.
Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the sub-
ject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.
Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM” (SYMP-
TOMS). This column describes possible symp-
toms that the machine may exhibit. Find the list-
ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into four main categories: Output Problems,
Function Problems, Engine Problems and
Welding Problems.
All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this chapter.
Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced elec-
trical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be con-
ducted without removing the case wrap-around
cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 216-383-2531 or 1-800-833-9353.
SA-250
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
• Remove the PC Board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC Board on or near paper, plastic or cloth which
could have a static charge. If the PC Board can’t be
installed immediately, put it back in the static-shielding
bag.
ELECTRIC SHOCK can kill.
Have an electrician install and service
this equipment. Turn the machine OFF
before working on equipment. Do not
touch electrically hot parts.
• If the PC Board uses protective shorting jumpers,
don’t remove them until installation is complete.
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
• If you return a PC Board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop-
er failure analysis.
4. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
board.
1. Determine to the best of your technical ability that
the PC board is the most likely component causing
the failure symptom.
NOTE: Allow the machine to heat up so that all electri-
cal components can reach their operating temperature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
5. Remove the replacement PC board and substitute
it with the original PC board to recreate the original
problem.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static elec-
trical damage and electrical shock. Read the warn-
ing inside the static resistant bag and perform the
following procedures:
a. If the original problem does not reappear
by substituting the original board, then the
PC board was not the problem. Continue
to look for bad connections in the control
wiring harness, junction blocks, and termi-
nal strips.
PC Board can be damaged by
static electricity.
b. If the original problem is recreated by the
substitution of the original board, then the
PC board was the problem. Reinstall the
replacement PC board and test the
machine.
• Remove your body’s static charge
before opening the static-shield-
ing bag. Wear an anti-static wrist
strap. For safety, use a 1 Meg
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
ohm resistive cord connected to a
grounded part of the equipment
frame.
6. Always indicate that this procedure was followed
when warranty reports are to be submitted.
• If you don’t have a wrist strap,
touch an unpainted, grounded,
part of the equipment frame.
Keep touching the frame to pre-
vent static build-up. Be sure not
to touch any electrically live parts
at the same time.
Workstations
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
Reusable
Container
Do Not Destroy
• Tools which come in contact with the PC Board must
be either conductive, anti-static or static-dissipative.
SA-250
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F-4
F-4
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
OUTPUT PROBLEMS
The engine starts and runs at cor- 1. Check the 15 amp fuse located 1. Check the “flashing” diode and
rect speed, but there is no, or very
low, welder output voltage. There
is no AC auxiliary output voltage.
on the inside of the front control
panel.
associated leads connected
between the generator brushes
and the exciter alternator brush-
es.
2. If the welder output is zero volts,
the fields may need to be
flashed. See Flashing the 2. Check the field diode bridge and
Fields in this section.
associated leads and connec-
tions. See the Wiring Diagram.
3. Check for loose or missing
brushes in the exciter alternator 3. Perform the Alternator Rotor
and welding generator.
Test.
4. Check for “opens” or shorted
turns in the alternator stator
windings. The coils must NOT
be grounded to the stator lami-
nation.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
SA-250
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F-5
F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The engine starts and runs at cor- 1. Check for loose or missing 1. Check the Fine Current
rect speed, but there is no, or very
low, welder output voltage. The AC
auxiliary output voltage is normal.
brushes in the welding genera-
tor.
Adjustment rheostat for resis-
tance and proper operation.
Normal resistance is 64 ohms.
Check associated wires for
loose or faulty connections.
See the Wiring Diagram.
2. Check the welding cables for
loose or faulty connection.
2. Perform the Shunt Field
Winding Test.
3. Check the continuity of the inter-
pole coils. They should show
continuity from the positive
brush holders to the positive
output terminal and should NOT
be grounded to the generator
frame.
4. Check the continuity of the
series coils. They should show
continuity from the negative
brush holders, through the
Current Range Selector switch,
to the negative output terminal
and should NOT be grounded.
Also check the Selector switch
for proper operation.
5. The main armature may be
faulty.
Check for grounds
and/or shorts.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-
383-2531 or 1-800-833-9353.
SA-250
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F-6
F-6
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
OUTPUT PROBLEMS
The welding output varies abnor- 1. May be a normal condition. The 1. Check the Fine Current
mally. The auxiliary output remains
constant. The engine is operating
correctly.
machine will normally lose
some output as the components
get heated.
Adjustment rheostat for resis-
tance and proper operation.
Normal resistance is 64 ohms.
Check associated wires for
loose or faulty connections.
See the Wiring Diagram.
2. Check for loose, worn, dirty, or
poorly seated DC generator
brushes.
2. Perform the Field Shunt
3. The armature commutator may
need cleaned.
Winding Test.
3. Check the Current Range
Selector switch and contacts for
proper operation.
4. Check for loose or faulty weld-
ing cables.
4. While the machine is loaded,
check the interpole and series
coils for signs of “arcing” This
condition would point to shorted
turns in the “arcing” coil.
5. The main armature may be
faulty. Check for grounds.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
SA-250
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F-7
F-7
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The engine starts and runs at the 1. Check the AC auxiliary output 1. Check for loose or faulty con-
correct speed, but there is no AC
auxiliary output voltage. The DC
welding generator is functioning
correctly.
circuit breakers. Reset is nec-
essary.
nections between the recepta-
cles, the circuit breakers, the
current transformer and the
exciter alternator stator. See
the Wiring Diagram.
2. Check the 115VAC and 230VAC
receptacles and plugs for loose
or faulty connections.
2. Check the 115VAC and
230VAC windings in the alterna-
tor stator for shorted turns or
grounds. Check the continuity
of the windings. See the Wiring
Diagram.
The engine starts and runs normal- 1. Contact your local Authorized 1. Check the “flashing” diode
ly. The machine takes a long time
to “build-up” and produce output
voltage. The AC auxiliary voltage
varies when the Fine Current
Control rheostat is adjusted.
Field Service Facility.
located on the DC generator
brush holder. The diode may
be “shorted” or installed incor-
rectly.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-
383-2531 or 1-800-833-9353.
SA-250
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F-8
F-8
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
FUNCTION PROBLEMS
The engine will not return to low 1. Make sure the Idler Control 1. Check the Idler Control switch
idle when the welding and auxiliary
loads are removed.
switch is set to the “Auto” posi-
tion.
and associated leads for loose
or faulty connections. See the
Wiring Diagram.
2. Make sure both welding and
auxiliary loads are removed.
2. Check the reed switch CR2. It
may be stuck closed. Replace if
necessary.
3. Check for mechanical restric-
tions in the idle and throttle link-
age.
3. Perform the Idler Solenoid
Test.
4. Check for loose or faulty con-
nections at the idler PC board.
5. Make sure lead #60D is ground-
ed correctly.
6. The idler PC board may be
faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
SA-250
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F-9
F-9
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The engine will NOT go to high 1. Check welding cables for loose 1. Check the reed switch (CR2) for
speed when a load is applied to the
welding output terminals. The
engine does go to high speed when
a load is applied to the AC auxiliary
power receptacles.
or faulty connections.
proper operation. The reed
switch should close when there
is current flow in the welding cir-
cuit.
2. Locate the red lead connected
to the idler PC board. While
leaving the red lead connected,
jumper the red lead to frame
ground. If the engine goes to
high speed, the fault is in the
reed switch or associated leads.
3. If the engine does NOT go to
high speed (in step 2), the idler
PC board may be faulty.
The engine will NOT go to high 1. Check the auxiliary power plug 1. Check the leads associated with
speed when a load is applied to the
AC auxiliary receptacles. The
engine does go to high speed when
a load is applied to the welding out-
put terminals.
and associated leads for loose
or faulty connections.
the current transformer for loose
or faulty connections. See the
Wiring Diagram.
2. The load may be too small. The
load must be above 150 watts.
2. Check the current transformer
for “opens” in the windings.
3. The idler PC board may be
faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
SA-250
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F-10
F-10
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
FUNCTION PROBLEMS
The engine will NOT go to high 1. Check the welding cables and 1. The idler PC board may be
speed when either a welding load
or an auxiliary load is connected to
the SA-250.
auxiliary load leads for loose or
faulty connections.
faulty. Replace.
2. Check for mechanical restric-
tions or missing parts in the idler
and throttle linkage (springs,
etc.).
The machine has normal output
and engine speed when the Idler
Control switch is in the “High” posi-
tion.
The engine will not shut down.
1. Make sure the ignition switch 1. Check the fuel injection pump
is turned off and operating cor-
rectly.
for proper operation. When
12VDC is applied to the pump at
leads #59C (+) to #60(-), the
fuel pump should be working.
When the 12VDC is removed,
the pump should stop pumping
fuel to the engine.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
SA-250
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F-11
F-11
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
ENGINE PROBLEMS
The engine “cranks” but will not 1. Check for adequate fuel supply. 1. Check the ignition switch for
start.
proper operation. Check the
associated leads for loose or
faulty connections. See the
Wiring Diagram.
2. Press the engine protection
“Reset” button.
3. Check the fuse in the engine
protection relay.
2. Check the fuel injection pump.
Make sure it is operating when
12VDC is applied to leads
#59C(+) to #60(-).
3. The engine protection relay may
be faulty. Replace.
4. The engine fuel injectors may
need service.
The engine starts but shuts down 1. Check for adequate fuel supply. 1. The oil pressure switch or
after a short period of time.
coolant temperature sensor
may be causing the engine pro-
tection relay to shut off the fuel
injection pump. Make sure oil
pressure and coolant tempera-
ture are correct before replacing
sensors.
2. Check engine oil level.
3. Air may be entrapped in fuel
system. Refer to Maintenance
section to bleed fuel system.
2. The protection relay may be
faulty.
3. The engine fuel injectors may
need service.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
SA-250
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F-12
F-12
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The welding arc is loud and spat- 1. The current setting may be too 1. Check the engine speed. High
ters excessively.
high for the electrode and
process.
idle speed should be 1800
RPM.
2. The polarity may be wrong for 2. Check the DC generator brush-
the electrode and process.
es for good commutation and
alignment. Contact the Lincoln
Electric Service Dept. 1-216-
383-2531 or 1-800-833-9353
(WELD).
3. Check for shorted series coils.
The welding arc frequently “pops 1. The Fine Current Control rheo- 1. Check the engine speed. High
out.”
stat may be set too low for the
process and electrode.
idle speed should be 1800
RPM.
2. Check the welding cables for 2. The Current Range Selector
loose or faulty connections.
switch may be faulty. Check for
proper operation.
3. Check the DC generator brush-
es for good commutation and
alignment. Contact the Lincoln
Electric Service Dept. 1-216-
383-2531 or 1-800-833-9353
(WELD).
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
SA-250
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F-13
F-13
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353
(WELD).
TEST DESCRIPTION
This test will help determine if there is a shorted, open or grounded winding in the alter-
nator rotor.
MATERIALS NEEDED
Volt/Ohmmeter
3/8" Nut driver or socket wrench
Wiring Diagram
SA-250
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F-14
F-14
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR TEST (continued)
FIGURE F.1 – ALTERNATOR COVER REMOVAL
LOOSEN 5
SCREWS
ALTERNATOR
COVER
SLIP
RINGS
BRUSHES
TEST PROCEDURE
4. With the 3/8" socket wrench, remove the
screw and lock washer from the top center
of the alternator cover. See Figure F.1.
1. Turn engine off.
2. Unlatch, lift and secure the right and left
side doors. Note that there are latches at
both ends of the door.
5. With the 3/8" socket wrench, loosen the
two screws on the right side of the alterna-
tor cover.
3. With the 3/8" nut driver or socket wrench,
loosen the two screws on the left side of
the alternator cover. See Figure F.1.
6. Remove the alternator top cover. Be care-
ful to clear the leads.
7. Locate and lift the brushes off of the rotor
slip rings. See Figure F.1.
SA-250
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F-15
F-15
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR TEST (continued)
8. Working from the left side of the machine,
measure the resistance across the rotor
slip rings.
A. Set the ohmmeter on the low scale (X1).
B. Place one meter probe on one of the
rotor slip rings. Place the other probe on
the other slip ring. See Figure F.2.
C. Check the resistance across the slip
rings. It should read approximately 41
ohms.
FIGURE F.2 – MEASURING ROTOR RESISTANCE
SA-250
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F-16
F-16
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR TEST (continued)
9. Measure the rotor resistance to ground.
10. Replace the brushes on the slip rings.
Make sure they are seated correctly.
A. Set the ohmmeter on the high scale
(X100,000).
11. Reinstall the alternator cover.
B. Place one probe on either of the rotor
slip rings. Place the other probe on any
good, unpainted ground. See Figure
F.3.
12. Close and latch the right and left side cover
doors.
C. Check the resistance. It should read
very high, at least 0.5 megohm (500,000
ohms).
If the test does not meet the resistance
specifications, then the rotor may be
faulty. Replace the rotor.
FIGURE F.3 – MEASURING ROTOR RESISTANCE TO GROUND
SA-250
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F-17
F-17
TROUBLESHOOTING & REPAIR
FIELD SHUNT WINDING TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will help determine if the field shunt coils are shorted, open or grounded.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram
SA-250
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F-18
F-18
TROUBLESHOOTING & REPAIR
FIELD SHUNT WINDING TEST (continued)
FIGURE F.4 – PLUG P10 LOCATIONS
PLUG P10
TEST PROCEDURE
4. Remove plug P10. See Figure F.4.
1. Turn engine off.
5. Locate the blue lead (U, pin 3) and the
brown lead (N, pin 5) in the harness plug.
See Figure F.5.
2. Unlatch, lift and secure the right side door.
Note that there are latches at both ends of
the door.
3. Locate plug P10. See Figure F.4.
SA-250
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F-19
F-19
TROUBLESHOOTING & REPAIR
FIELD SHUNT WINDING TEST (continued)
FIGURE F.5 – SHUNT LEAD RESISTANCE CHECK
PIN 3
PIN 5
TAB
6. Using the volt/ohmmeter set on the low
scale (X1), measure the resistance
between the blue and the brown leads.
See Figure F.5. Normal resistance is
approximately 50 ohms.
9. If the plug and associated leads are okay,
then the shunt field coils may be faulty.
Replace.
10. If the test does meet the resistance specifi-
cations, then the shunt coils are okay.
7. Also measure the resistance from either
lead (blue or brown) to ground. Set the
volt/ohmmeter on the high scale (X100,000).
This resistance should be at least 500,000
ohms.
11. Replace plug P10, making sure the leads
and plug are secure.
12. Close and latch the right side door.
8. If the test does not meet the resistance
specifications, then check the harness plug
and inline connectors for loose connec-
tions or shorted leads.
SA-250
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F-20
F-20
TROUBLESHOOTING & REPAIR
IDLER SOLENOID TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the idler solenoid is capable of functioning when it is energized with
12VDC.
MATERIALS NEEDED
External 12VDC supply
Wiring Diagram
5/16" Nut Driver
5/16" Wrench
SA-250
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F-21
F-21
TROUBLESHOOTING & REPAIR
IDLER SOLENOID TEST (continued)
FIGURE F.6 - SOLENOID LEAD CONNECTIONS
SOLENOID
LEADS
56 & 57
TEST PROCEDURE
1. Turn engine off.
6. The solenoid should deactivate when the
12VDC is removed.
2. Unlatch, lift and secure the left side door.
Note that there are latches at both ends of
the door.
7. If the solenoid does not operate properly,
check for a mechanical restriction in the
linkage or a missing spring.
3. Using the 5/16" nut driver, remove the three
screws holding the fan guard. Remove the
fan guard.
8. If the linkage is intact and the solenoid
does not operate correctly when 12VDC is
applied, the solenoid may be faulty.
Replace. Normal solenoid coil resistance
is approximately 9 ohms.
4. Locate leads #56 and #57 on the idler sole-
noid. See Figure F.6 and the Wiring
Diagram. Using the 5/16" wrench, remove
the leads from the solenoid.
9. When the test is complete and the problem
repaired, be sure to reconnect leads #56
and #57 to the idler solenoid.
5. Using the external voltage supply, apply
12VDC to the idler solenoid terminals.
Attach positive (+) to the terminal where lead
#56 was connected. The solenoid should
activate.
10. Close and latch the left side door.
SA-250
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F-22
F-22
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
TEST DESCRIPTION
If the machine output is low, or high, this test will determine whether the engine is operating
at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for adjust-
ing the throttle to the correct RPM are given.
MATERIALS NEEDED
Slot head screw driver
7/16" wrench
8mm wrench
White or red marking pencil, strobe-tach, or frequency counter, or oscilloscope
SA-250
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F-23
F-23
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.7 - STROBE MARK LOCATION
STROBE
MARK
TEST PROCEDURE
5. Start the engine and direct the strobe-tach
light on the blower paddle. Synchronize it to
the rotating mark.
Strobe Tach Method
1. Turn the engine welder OFF.
2. Unlatch, lift and secure the left side door.
Note that there are latches at both ends of
the door.
With the machine at HIGH IDLE the tach
should read between 1780 and 1810 RPM.
With the machine at LOW IDLE the tach
should read between 1350 and 1400 RPM.
3. With a white or red marking pencil, place a
mark on one of the blower paddles. See
Figure F.7 for location.
4. Connect the strobe-tach according to the
manufacturer's instructions.
SA-250
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F-24
F-24
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
6. If either of the readings is incorrect, adjust
the throttle as follows:
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
change to low idle speed. Use the 7/16"
wrench to loosen the solenoid lever arm
locking nut. See Figure F.9. Adjust the
threaded solenoid lever arm shaft, to
change the amount of throw in the lever
arm, until the frequency reads 47 Hz.
Retighten the locking nut.
Adjust HIGH IDLE: Use the 8mm wrench to
loosen the locking nut. See Figure F.8 for
location of the adjusting screw and locking
nut. Avoid breaking the seal. There should
be enough play to allow adjustment without
disturbing the seal. Turn the threaded screw
counter-clockwise to increase the HIGH
IDLE speed. Adjust the speed until the tach
reads between 1780 and 1810 RPM.
Retighten the locking nut.
Oscilloscope Method
1. Connect the oscilloscope to the 115 VAC
receptacle, according to the manufacturer’s
instructions. At HIGH IDLE (1800 RPM), the
waveform should exhibit a period of 16.6
milliseconds. At LOW IDLE (1400 RPM),
the waveform should exhibit a period of 21.4
milliseconds. Refer to the NORMAL OPEN
CIRCUIT VOLTAGE WAVEFORM (115
VAC SUPPLY) HIGH IDLE - NO LOAD in
this section of the manual.
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
change to low idle speed.
Use the 7/16" wrench to loosen the solenoid
lever arm locking nut. See Figure F.9.
Adjust the threaded solenoid lever arm
shaft, to change the amount of throw in the
lever arm, until the tach reads between 1350
and 1400 RPM. Retighten the locking nut.
2. If either of these periods is incorrect, adjust
the throttle as follows:
Frequency Counter Method
Adjust HIGH IDLE: Use the 8mm wrench to
loosen the locking nut. See Figure F.8 for
location of the adjusting screw and locking
nut. Avoid breaking the seal. There should
be enough play to allow adjustment without
disturbing the seal. Turn the threaded screw
counter-clockwise to increase the HIGH
IDLE speed. Adjust the speed until the peri-
od is 16.6 milliseconds. Retighten the lock-
ing nut.
1. Plug the frequency counter into one of the
115 VAC auxiliary receptacles.
2. Start the engine and check the frequency
counter. At HIGH IDLE (1800 RPM), the
counter should read 60 Hz. At LOW IDLE
(1400 RPM), the counter should read 47 Hz.
Note that these are median measurements;
hertz readings may vary slightly above or
below.
3. If either of the readings is incorrect, adjust
the throttle as follows:
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
change to low idle speed. Use the 7/16"
wrench to loosen the solenoid lever arm
locking nut. See Figure F.9. Adjust the
threaded solenoid lever arm shaft, to
change the amount of throw in the lever
arm, until the period is 21.4 milliseconds.
Retighten the locking nut.
Adjust HIGH IDLE: Use the 8mm wrench to
loosen the locking nut. See Figure F.8 for
location of the adjusting screw and locking
nut. Avoid breaking the seal. There should
be enough play to allow adjustment without
disturbing the seal. Turn the threaded screw
counter-clockwise to increase the HIGH
IDLE speed. Adjust the speed until the fre-
quency reads 60 Hz. Retighten the locking
nut.
SA-250
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F-25
F-25
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.8 - HIGH IDLE ADJUSTMENT
ADJUSTING
SCREW
LOCKING
NUT
FIGURE F.9 - LOW IDLE ADJUSTMENT
THREADED SOLENOID
LEVER ARM
LOCKING NUT
SA-250
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F-26
F-26
TROUBLESHOOTING & REPAIR
FLASHING THE FIELDS
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will "flash
the fields of an exciter that has lost excitation.
MATERIALS NEEDED
12-volt automotive battery
Two jumper wires with alligator clip on each end
Wiring Diagram
SA-250
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F-27
F-27
TROUBLESHOOTING & REPAIR
FLASHING THE FIELDS (continued)
FIGURE F.10 - FLASHING THE FIELDS
NEGATIVE(-)
BRUSH HOLDER
_
+
POSITIVE (+)
BRUSH HOLDER
12 VOLT
BATTERY
PROCEDURE
6. With the engine OFF, use the other lead with
alligator clips and touch the positive battery
terminal to the positive brushholder. Then
disconnect the leads to remove the battery
from the circuit.
1. Turn engine welder OFF.
2. Unlatch, lift and secure the right and left side
doors. Note that there are latches at both
ends of the door.
3. Remove the cover from the exciter. See
Figure F.10.
7. Replace the exciter cover.
8. Start the welder. The generator voltage
should build up.
4. Turn the FINE CURRENT ADJUSTMENT
control (rheostat) to “100.”
If voltage does not build up, there are a num-
ber of possible causes, such as loose or
missing brushes, open leads or poor con-
nections at the field diode bridge or between
the exciter alternator brushes and the gener-
ator brushes. See OUTPUT PROBLEMS in
the Troubleshooting Guide located in this
section of the manual for recommended
action.
5. Using one of the leads with alligator clips,
connect the negative terminal of the 12-volt
automotive battery to the negative brush-
holder. This is the brushholder nearest the
rotor lamination. See Figure F.10 and the
Wiring Diagram.
DO NOT remove brush holder.
SA-250
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F-28
F-28
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)
HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM
16.6 ms
CH1
0 volts
5 ms
50 volts
This is the typical auxiliary output
voltage generated from a properly
operating machine. Note that each
vertical division represents 50 volts
and that each horizontal division rep-
resents 5 milliseconds in time.
Note: Scope probes connected at
machine 115VAC receptacle.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
SA-250
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F-29
F-29
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR
SWITCH AT MAXIMUM
CH1
0 volts
5 ms
50 volts
This is the typical DC output voltage
generated from a properly operating
machine. Note that each vertical divi-
sion represents 50 volts and that
each horizontal division represents 5
milliseconds in time.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-30
F-30
TROUBLESHOOTING & REPAIR
TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM
MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM POSITION
CH1
0 volts
5 ms
20 volts
MACHINE LOADED TO 250 AMPS AT 40 VDC
This is the typical DC output voltage
generated from a properly operating
machine. Note that each vertical divi-
sion represents 20 volts and that
each horizontal division represents 5
milliseconds in time. The machine
was loaded with a resistance grid
bank.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-31
F-31
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the alternator rotor.
MATERIALS NEEDED
3/8" wrench
1/2" wrench
1-5/8" wrench
Large slot head screwdriver
Small gear puller
SA-250
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F-32
F-32
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT (continued)
3. With the 1/2" wrench, disconnect the negative
battery cable.
PROCEDURE
1. Turn the engine off.
4. With the 1/2" wrench, remove the four bolts
and washers from the panel located below the
control panel. Remove the panel. See Figure
F.11.
2. Unlatch, lift and secure the left and right side
doors. There are latches on both sides of the
doors.
FIGURE F.11 – FRONT PANEL REMOVAL
BATTERYRETAINER
FASTENERS
REMOVE
FASTENERS
TERMINAL
CABLES
SA-250
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F-33
F-33
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT (continued)
See Figure F.12 for steps 5 - 8.
7. With the 3/8" wrench, loosen the two screws
on the right side of the alternator cover.
5. With the 3/8" wrench, loosen the two screws
on the left side of the alternator cover.
8. Remove the alternator top cover.
6. With the 3/8" wrench, remove the screw and
lock washer from the top center of the alter-
nator cover.
FIGURE F.12 – ALTERNATOR COVER REMOVAL
LOOSEN 5
SCREWS
ALTERNATOR
COVER
SLIP
RINGS
BRUSHES
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F-34
F-34
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT (continued)
See Figure F.13 for steps 9 - 11.
11. With the 1-5/8" socket wrench, remove the
rotor locking nut, washer and sleeve collar.
9. With the 7/16" wrench, remove the two
bolts, nuts and washers mounting the brush
holder assembly to the stator frame.
NOTE: The sleeve collar will have to be
removed with a gear puller. Be careful not to
damage the rotor slip ring assembly. Remove
the rotor by pulling it free of the generator shaft.
10. Bend the flat washer away from the rotor
locking nut.
FIGURE F.13 – ROTOR REMOVAL
"BENT"
WASHER
STATOR
FRAME
SLEEVE
COLLAR
BRUSH
HOLDER
ASSEMBLY
NUT
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F-35
F-35
INSTALLATION
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT (continued)
Replacement
d. The exciter brush spring must lie flat on
the corner of the brush and not touch
either side of the retainer.
12. Carefully mount the rotor onto the generator
shaft. Install a new sleeve collar (part num-
ber T14337), washer, and rotor locking nut.
e. With the brushes in place, insert one end
of a minimum 24" long piece of 180 grit
sandpaper between the slip rings and
brushes (abrasive against brushes). With
slight additional finger pressure on top of
brushes, pull the paper around the cir-
cumference of the rings in the direction of
rotation only. Repeat this procedure until
the entire face of the brush is contoured
to the radius of the slip ring.
NOTE: Be careful not to damage or deform
the new sleeve collar. Carefully tap the new
sleeve collar into position. The rotor locking
nut should be torqued to 175 ft.-lbs.
After the rotor locking nut is properly
torqued, bend the washer down over the
locking nut.
Check rotor air gap. .017" minimum is
allowed.
f. Check the brushes to be certain that there
is spring tension holding them firmly
against the slip rings.
13. Mount the brush holder assembly to the sta-
tor frame using two bolts, washers, and nuts.
14. Install the alternator cover with the screw
and washer at top and the screws at the two
sides.
Installing and Seating Exciter Slip Ring Brushes
a. Make sure the slip rings are clean and
free from oil and grease.
15. Install the panel below the control panel on
the case front.
b. Spacing between the brush holder and
slip rings must be .050" to .090". Adjust
as required.
16. Connect the negative battery cable.
17. Close and latch left and right side case
doors.
c. Before placing the exciter brushes in their
holders, twist the brush pigtail at its
entrance to the brush until the strands are
tightly packed and no part of the pigtail
protrudes beyond the brush surface in the
pigtail slot. When the brush is placed in
the holder, clear the pigtail from the side
of the holder to allow free radial move-
ment of the brush.
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F-36
F-36
TROUBLESHOOTING & REPAIR
ALTERNATOR STATOR REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the alternator stator.
MATERIALS NEEDED
3/8" nut driver
3/8" wrench
1/2" wrench
Slot head screwdriver
Pry bar
5/8" wrench
7/16" wrench
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F-37
F-37
TROUBLESHOOTING & REPAIR
ALTERNATOR STATOR REMOVAL AND
REPLACEMENT (continued)
FIGURE F.14 – COMMUTATOR WRAP-AROUND REMOVAL
COMMUTATOR
WRAP-AROUND
ALTERNATOR
BRUSH HOLDER
ASSEMBLY
(REMOVED)
PROCEDURE
1. Turn the engine OFF.
10. Remove the tape and using the 3/8"
wrench and slot head screw driver, discon-
nect the black auxiliary power lead from
the current transformer. Cut any neces-
sary cable ties. See the Wiring Diagram
and Figure F.15.
2. Perform the Alternator Rotor Removal
procedure.
3. With the 1/2" wrench, remove the four nuts
and bolts holding the case top and doors
assembly to the welder frame. Carefully lift
up and remove the top and doors assembly.
11. Remove the red auxiliary power lead from
the CB4 circuit breaker. See the Wiring
Diagram.
4. With the 3/8" nut driver, remove the two
leads from the alternator brush holder
assembly. Note lead placement. Set brush
holder aside.
12. Remove the white auxiliary power lead
from the 115VAC receptacle. Cut any nec-
essary cable ties.
5. With the 1/2" wrench, remove the battery.
NOTE: The CB1 circuit breaker may have to
be removed to access the terminal for the white
lead.
6. With the 3/8" wrench, remove the bottom
alternator cover.
7. With the slot head screwdriver, remove the
commutator wrap-around. See Figure F.14.
13. Remove the red lead from the negative ter-
minal of the field rectifier bridge. See
Figure F.16.
8. Disconnect the yellow and white wires at the
in-line connectors. See the Wiring Diagram
and Figure F.15.
14. Remove the black lead from the positive
terminal of the field rectifier bridge. See
Figure F.16.
9. Disconnect the two yellow leads. One is
located at the field bridge and the other at
the field fuse holder. Cut any necessary
cable ties. See Figure F.15.
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F-38
F-38
TROUBLESHOOTING & REPAIR
ALTERNATOR STATOR REMOVAL
AND REPLACEMENT (continued)
FIGURE F.15 - LEAD DISCONNECTION POINTS
YELLOW AND WHITE WIRE
IN-LINE CONNECTORS;
YELLOW LEADS; BLACK
CURRENT TRANSFORMER LEAD
ALL LOCATED BEHIND CASE FRONT
FIGURE F.16 - LEAD DISCONNECTION – CIRCUIT BREAKER, RECEPTACLES, FIELD BRIDGE RECTIFIER
FIELD BRIDGE RECTIFIER
230 VAC RECEPTACLE
115 VAC RECEPTACLE
CIRCUIT BREAKER
SA-250
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F-39
F-39
TROUBLESHOOTING & REPAIR
ALTERNATOR STATOR REMOVAL
AND REPLACEMENT (continued)
15. Clear the leads in preparation for remov-
ing the stator/end bracket.
16. Lift the eight brushes from the commuta-
tor. Note the position of the brushes for
reassembly.
FIGURE F.17 - GENERATOR BRUSH HOLDER CABLE REMOVAL
GENERNATOR
BRUSH HOLDER/COIL
CABLES (4)
17. With the 1/2" wrench, disconnect and
clear the four heavy cables from the gen-
erator brush holders to the coils in the
generator frame. It is not necessary to
remove the brush holder jumper cables.
See Figure F.17. Label leads and posi-
tions for re-assembly.
SA-250
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F-40
F-40
TROUBLESHOOTING & REPAIR
ALTERNATOR STATOR REMOVAL
AND REPLACEMENT (continued)
FIGURE F.18 - DRILL SPOT LOCATIONS
BRUSH HOLDER
DRILL SPOT
LOCATION
STATOR END BRACKET
DRILL SPOT
STATOR/END BRACKET
MOUNTING BOLT
18. With the 5/8" wrench, remove the four
bolts mounting the stator/end bracket
assembly to the generator frame. Note
the "drill spot" for reassembly. See Figure
F.18.
24. Connect the four heavy cables from the
generator frame coils to the generator
brush holders.
25. Install the eight commutator brushes
according to how you marked their posi-
tions at disassembly.
19. With the 7/16" wrench, loosen (do not
remove) the generator brush holder
clamping bolt. Note the drill spot for
reassembly. See Figure F.18.
26. Attach the black lead to the positive termi-
nal of the field rectifier bridge. Attach the
red lead to the negative terminal.
20. Carefully pry the stator/end bracket
assembly away from the generator frame.
27. Attach the white auxiliary power lead to
the 115 VAC receptacle. Attach the red
auxiliary power lead to the CB4 circuit
breaker. Attach the black auxiliary power
lead to the current transformer. Tape the
bolted connection.
NOTE: The generator brush holder assembly
will also be removed.
Replacement
21. Mount the stator/end bracket assembly to
the generator frame. Line up the mating
parts at the stator end bracket drill spot.
Tighten the four mounting bolts with the
5/8" wrench.
28. Connect the two yellow leads to the field
bridge and to the field fuse holder.
Connect the white and yellow wires at the
in-line connectors.
29. Install the commutator wrap-around, the
bottom alternator cover, the battery, and
the alternator brush holder assembly.
22. Check armature air gap. Minimum gap is
.035." Loosen the four mounting bolts;
adjust and re-tighten if necessary.
30. Install the alternator rotor according to the
reassembly directions in the Alternator
Rotor Removal and Replacement pro-
cedure. Before installing the case top and
sides, replace any cable ties cut for disas-
sembly.
23. Tighten the generator brush holder
assembly with the 7/16" wrench. Note
brush holder drill spot.
SA-250
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F-41
F-41
TROUBLESHOOTING & REPAIR
GENERATOR FRAME
REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the DC generator
frame.
MATERIALS NEEDED
Rope sling
3/4" wrench
1/2" wrench
9/16" wrench
Wood or steel blocks
Pry bars
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F-42
F-42
TROUBLESHOOTING & REPAIR
GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.19 – FUEL TANK / OUTPUT CABLE REMOVAL
FUEL TANK
RETURN LINE
POSITIVE CABLE
COPPER
STRAP
FUEL TANK
MOUNTING
HARDWARE
REED SWITCH
ASSEMBLY
CABLE
RETAINER
FUEL LINE
FUEL
BOWL
PROCEDURE
1. Turn the engine OFF.
7. Slightly lift the fuel tank and remove the
cable retainer. You will need a large screw
driver to pry the retainer from the rail.
2. Perform the Alternator Rotor Removal
procedure.
8. Carefully remove the fuel tank.
3. Perform the Alternator Stator Removal
procedure.
NOTE: At reassembly, the fuel line may have to
be purged. See the Maintenance section.
See Figure F.19 for steps 4 - 10.
9. With the 3/4" wrench, remove the copper
strap/reed switch assembly from the nega-
tive output terminal. Clear the strap.
4. Turn off the fuel at the fuel bowl and remove
the fuel line. Plug the line to prevent spillage.
5. Remove the fuel return line from the top of the
fuel tank.
10. With the 3/4" wrench, remove the cable from
the positive output terminal.
6. With the 9/16" wrench, remove the four nuts,
bolts, and washers that mount the fuel tank to
the rails.
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F-43
F-43
TROUBLESHOOTING & REPAIR
GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.20 – WIRE AND SELECTOR SWITCH CONNECTIONS
CIRCUIT BREAKER CB2
WITH BLACK CURRENT
TRANSFORMER LEAD
SELECTOR
SWITCH
IDLER
PC BOARD
BLUE CURRENT
TRANSFORMER
LEADS
IN-LINE CONNECTOR
BLUE/BROWN LEADS
See Figure F.20 for steps 11 - 16.
11. Cut all necessary cable ties.
NOTE: Some terminals have more than one cable
connected. Tape any pairs together before removing
them.
12. Disconnect the blue and the brown wires at the in-
line connectors. See Figure F.20 and the Wiring
Diagram.
14. With the 1/2" wrench, remove the cables connect-
ed to the selector switch.
15. Disconnect the current transformer black lead from
circuit breaker CB2.
13. Label the cables that are connected to the selector
switch. Otherwise, you will need to see the Wiring
Diagram during reassembly.
16. Remove the two blue current transformer leads
from the idler PC board. Note lead location.
SA-250
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F-44
F-44
TROUBLESHOOTING & REPAIR
GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.21 – CASE FRONT REMOVAL
STEP #19
STEP #18
STEP #17
See Figure F.21 for steps 17 - 19.
17. With the 9/16" wrench, remove the four bolts and
lock washers holding the case front to the welder
frame. There are two bolts on each side.
18. With the 1/2" wrench, remove the two bolts and
nuts and washers from the gas tank rails - one on
each side.
19. Carefully clear all remaining leads and lift up and
set the front panel assembly to the left side of the
machine. Make sure all leads are clear.
SA-250
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F-45
F-45
TROUBLESHOOTING & REPAIR
GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.22 – FRAME MOUNTING DETAILS
ROPE SLING
ENGINE/GENERATOR
MOUNTING HOLES
See Figure F.22 for steps 20 - 23.
removing the rope sling, be careful to sup-
port the generator frame with the wood or
steel block under the engine adapter plate.
With the 9/16" wrench, install the bolts that
attach the generator frame to the engine.
Attach the two starting motor bolts and nuts.
20. With the 3/4" wrench, remove the frame
mounting bolts, nuts and spacers from the
feet of the generator frame.
21. With the rope sling around the generator
frame, carefully lift the frame and engine
assembly a small distance. Slide the wood
or steel block under the engine adapter
plate.
25. With the 3/4" wrench, install the frame
mounting bolts, nuts, and spacers to the feet
of the generator frame. See Figure F.22.
26. Install the case front to the welder frame.
See steps 17 - 19.
22. With the 9/16" wrench, remove the bolts
mounting the engine to the generator frame.
Only two of the starting motor mounting bolts
and nuts will have to be removed.
27. Connect the cables to the selector switch
according to how you labeled them during
disassembly. See the Wiring Diagram if nec-
essary.
23. Using the rope sling and pry bars, carefully
lift and “wiggle” the generator frame away
from the engine and armature assembly. Be
careful to support the generator frame as
you remove it.
28. Connect the blue and black current trans-
former leads to the idler PC board and CB2
circuit breaker, respectively.
29. Reconnect the blue and brown leads at the
in-line connectors.
Replacement
30. Install the copper strap/reed switch assem-
bly to the negative output terminal.
24. Support the generator frame with the rope
sling. Mount the generator frame to the
engine and armature assembly. Before
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F-46
F-46
TROUBLESHOOTING & REPAIR
GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
31. Re-attach the positive output terminal cable.
32. Attach the cable retainer to the fuel tank rail. Set
the fuel tank into position on the rails and secure it
with the four bolts, washers, and nuts.
33. Attach the fuel return line at the top of the fuel
tank. Remove the plug from the fuel line and
attach it to the fuel bowl.
34. Perform the replacement procedures according to
each of the following:
Alternator Stator Removal and Replacement
Alternator Rotor Removal and Replacement
Before installing the machine case top and sides,
be sure to replace any cable ties cut during disas-
sembly.
SA-250
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F-47
F-47
TROUBLESHOOTING & REPAIR
GENERATOR ARMATURE
REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the main armature.
MATERIALS NEEDED
Rope sling
5/8" wrench
Wood or steel blocks
SA-250
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F-48
F-48
TROUBLESHOOTING & REPAIR
GENERATOR ARMATURE REMOVAL
AND REPLACEMENT (continued)
FIGURE F.23 – BLOWER PADDLE REMOVAL
ROPE SLING
BLOWER PADDLE
BLOWER
PADDLE/ARMATURE
MOUNTING BOLTS(8)
PROCEDURE
CAUTION
1. Turn the engine OFF.
The armature is now free to be removed from the
engine.
2. Perform the Alternator Rotor Removal pro-
cedure.
3. Perform the Alternator Stator Removal pro-
cedure.
Replacement
4. Perform the Generator Frame Removal pro-
9. Support the armature with the rope sling.
Mount the armature to the engine, rotating it
1/8 of a turn in either direction to achieve
proper attachment. Before removing the
rope sling, be careful to support the arma-
ture with the wood or steel blocks under the
engine. With the 5/8" wrench, install the
eight bolts and lock washers that attach the
blower paddles and the armature to the
engine flywheel.
cedure.
5. Using the rope sling, support the armature.
6. Make sure the engine is supported with the
wood or steel blocks.
7. With the 5/8" wrench, remove the eight bolts
and lock washers holding the blower paddles
and the armature to the engine flywheel. See
Figure F.23.
10. Perform the replacement procedures accord-
ing to each of the following:
8. With the armature supported and “balanced”
in the rope sling, carefully rotate the armature
1/8 turn in either direction to release.
Generator Frame Removal and Replacement
Alternator Stator Removal and Replacement
Alternator Rotor Removal and Replacement
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F-49
F-49
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
Retest a machine:
• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the
machine’s electrical characteristics. OR
• If you repair or replace any electrical components.
ENGINE OUTPUT
Mode
Low Idle
High Idle
No Load RPM
1350 - 1400
1780 - 1810
Load RPM
NA
1700 - 1795
WELDER DC OUTPUT
Current Control
Rheostat
Current Selector
Open Circuit
Voltage
Load Volts
Load Amps
Switch
Maximum
Maximum
91 - 98.5
40 - 47
300
AC AUXILIARY POWER RECEPTACLE OUTPUT
230 Volt Receptacle
115 Volt Receptacle
Open Circuit
Voltage
Load Volts
Load Amps
Open Circuit
Voltage
Load Volts
Load Amps
240 - 254
210 - 225
13.8
118 -128
103 - 112
26.0
FIELD AMPS AND VOLTS
(Current Rheostat at Maximum)
Exciter DC Volts
Shunt Field Amps
2.25 - 2.6
Alt. Rotor Amps
RPM
1780 - 1810
123 - 133
2.2 - 2.6
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F-50
F-50
NOTES
SA-250
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G-1
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
Electrical Diagrams Section................................................................................................Section G
Wiring Diagram......................................................................................................................G-2
Wiring Diagram (Wire Feed Module).....................................................................................G-3
Idler PC Board (M13708) Schematic ....................................................................................G-4
Idler PC Board (M13708) Components.................................................................................G-5
SA-250
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NOTES
SA-250
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G-2
G-2
ELECTRICAL DIAGRAMS
Wiring Diagram
SA-250 & 350-SA WIRING DIAGRAM
CONTROL PANEL COMPONENTS
ELECTRICAL SYMBOLS
PER E1537
SHOWN AS VIEWED FROM REAR.
NEUTRAL BONDED TO FRAME
P10
J5
LEAD COLOR CODE
'
NEUTRE RACCORDE AU BATI
9
8
2
1
11
6
5
4
12
7
3
10
B-BLACK
G-GREEN
N-BROWN
U
U
R
THERMOSTART
IGNITER
W
B
IDLER
P.C.
+Y
N
-W
ROTOR
ALTERNATOR
U
ENGINE
PROTECTION
RELAY
W
(LEADS APPEAR ON
EARLIER UNITS ONLY)
SLIP RINGS
BOARD
-
Y
+
B
610
610
SLIP RING
NEAREST
TO IRON
56A
57
+
53
ENGINE
HOUR
IDLER
SWITCH
W
B
602B
IGNITION
SWITCH
R
AC
AC
Y
600B
METER
THERMO
IDLER
FUSE
(SFE-14)
41
1
2
3
START
START
52
SOLENOID
-
+
56
115 VOLT
RECEPTACLE
600A
42
230 VOLT
RECEPTACLE
-
15A.
G NONC S
B
Y
58
59B
B
OIL PRESSURE
SWITCH(N.C.)
51B
4
5
G
59
FUSE
60
54
602A
RHEOSTAT
51A
6
P9
J8
Y
59C
B
60A
SELECTOR
SWITCH
B
50A
R
FUEL
INJECTION
PUMP
G
B
ALTERNATOR
AUXILIARY
POWER
B
B
CB2
CB3
W
CB4
CB1
TEMPERATURE
GAUGE
G
WINDINGS
GENERATOR
B
50
B
S
G
U
A
59A
-
+
B
A
ALTERNATOR
5
4
3
2
1
B
CURRENT
TRANSFORMER
STARTING
MOTOR
CR2 REED
RELAY
WELDER
EXC
+
-
LEAD BLOCK
51
U
N
R
U
-W
60B
+Y
60D
N
GROUND
TO BASE
POSITIVE
(CC+) & (CV+ WITH W.F.M.)
NEGATIVE
(CC-)
REMOTE CONTROL (OPTIONAL)
WIRE FEED MODULE (OPTIONAL)
PLUG FOR
REMOTE CONTROL RECEPTACLE & SWITCH
REMOTE CONTROL
POTENTIOMETER
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
B
R
X
SEE
*
X
Y
INLINE
PLUG
(P5)
BELOW
CONNECTORS
W.F.M.
1
2
3
41
600
42
CONTROL
PANEL
Y
SEE
BELOW
*
W
R
B
G
#8 LEAD
4
5
602
CONNECT
TO CASE
POS.
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
WIRE FEED
CONNECT
TO CASE
W
NEG.
6
MODULE
NEGATIVE CV
OUTPUT TERMINAL
PANEL
P8
#2 HEAVY LEAD
SWITCH FOR LOCAL OR REMOTE CONTROL
SHOWN IN LOCAL POSITION.
608
609
CONNECT TO NEG.
BRUSH HOLDER
WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON
MACHINE FROM CONNECTOR "J8". THEN CONNECT
PLUG "P8" ON REMOTE CONTROL TO
*
REMOTE CONTROL
#2 HEAVY LEAD
CONNECTOR "J8" ON MACHINE.
POTENTIOMETER BOX
THE RED AND BLACK LEADS ARE USED ON CLASSIC
I
MACHINES ONLY AND ARE NOT
250 AMP
THERMOSTAT
ASSEMBLY
R
CONNECTED ON THIS MACHINE. DAMAGE TO THE REMOTE CONTROL AND/OR MACHINE
WILL RESULT IF THE RED AND BLACK LEADS ARE CONNECTED IN THE SA-250
AND 350-SA.
MACHINE MUST NOT BE RUNNING
*
WHEN MAKING THESE CONNECTIONS.
7-19-96J
L9150
CLEVELAND, OHIO U.S.A.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
SA-250
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G-3
G-3
ELECTRICAL DIAGRAMS
Wiring Diagram (Wire Feed Module)
WIRE FEED MODULE - WIRING DIAGRAM
ELECTRICAL SYMBOLS PER E1537
CONTROL BOARD
Y
1
2
FLASHING
LEADS
MOLEX CONNECTORS
W
218
219
1
2
J3
J1
J2
J4
503
602
509
610
3
J1
P1
SHUNT
TO
4
CONNECTOR CAVITY NUMBERING
SEQUENCE VIEWED FROM
FIELD
RHEOSTAT
5
634
667
2
1
2
COMPONENT SIDE OF BOARD.
6
+
CONNECTS TO
ENGINE WELDER
RECEPTACLE J5
115V
DC
N.A. LEADS 31, 32 AND 602 DO NOT GO INSIDE WIRE FEED MODULE BOX.
N.B. COMPONENTS VIEWED FROM REAR
7
3
600
8
-
4
4
9
621
633
75A
76
5
1
5
9
3
4
8
2
6
GND
31
10
11
12
6
7
7
115V
AC
12
10
11
32
8
P5
P5
N.A.
77
9
CONNECTOR CAVITY NUMBERING
SEQUENCE VIEWED FROM
LEAD SIDE OF CONNECTOR
GND
31
75
10
GND
31
1
2
3
4
5
6
7
8
9
J2
P2
CC/CV SWITCH S1
SHOWN IN CV MODE
510 602
32
501
1
2
3
4
5
6
32
CV CONTROL
609
610A
510
501
503A
602
609
610A
510
501
503A
509
77A
R501
75
610A
503A
503A
10K
631
630
503
76A
501
609
J4
P4
602
J6
REMOTE CONNECTOR
P6
W
610A
Y
1
2
3
4
5
6
7
8
31
J
115 VAC
75
76
77
2
75
76
77
2
1
2
3
4
5
6
A
B
C
D
E
32
GND
2A
GROUND
600
608
610
CONTACTOR
4A
77B
76B
75A
4
4
REMOTE
F
75A
75A
P7
G
J7
510
AMPHENOL 1
J3
P3
77
4A
2
76B
2A
4
77B
219
+
218
-
76
LOCAL/REMOTE SWITCH S2
SHOWN IN LOCAL MODE
621
667
300 AMP
SHUNT
76A
77A
633
608
609
CR4
666
634
+
+
+
250
TO NEG
BRUSH HOLDER
CC
-
CC
+
CV
-
25W
CR3
C501
C502
C503
CONTACTOR
631
630
622
CONTACTOR
30000 MFD
75 VOLT
EACH
R
3-18-94
L9259
CLEVELAND, OHIO U.S.A.
SA-250
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G-4
G-4
ELECTRICAL DIAGRAMS
Idler PC Board (M13708) Schematic
M
1 6 9 8 9
NOT USED
9
X1 -C
D2
R8
YEL
B213
1
14
R9
R15
15.0
8
+
56
t
TO BATTERY
15.0
D1
GND
TO SOLENOID
1
WHITE
B212
3
16
DZ1
10V
5W
C3
C4
50
15V
C1
X2
X1
LM2901
12
4536B
8
10K
GND
TO REED SW.
GND
RED
GND
T13157-14
1
R13
B209
13.7K
C10
511
.047
D7
47.5K
100V
10K
22.1K
R20
D
S
13.7K
33.2K
5.11K
R6
C8
Q1
10K
R5
133K
15A
60V
G
16
5
4
1
DZ3
SET
V
DD
15V
1W
DZ2
27V
5W
7
6
X1 -A
11
2
2
3
4
5
6
7
15
14
13
12
11
RESET
MONO IN
OSC INH
1
R17
X1
-B
X2
13
IN
1
1.00K
X1
-D
D8
10
OUT
OUT
1
DECODE
R12
2
D
C
B
26.7K
C9
C7
8
BY-PASS
10
CLOCK INH
VSS
D5
1N4936
10K
8
9
A
3.32K
4536B
Q2
600mA
40V
C2
B210
TO
CURRENT
XFMR.
R14
C6
18
15V
1
22.1K
.5
5W
15.0K
R
C5
D3
B211
1
BLUE
P.C.BOARD IS CONNECTED DIRECTLY
TO FRAME GND THRU MOUNTING SCREW
GND
M16989_2DE
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
R- 21
C- 10
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
D-
8
LABELS
=
Ohms
(
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
SUPPLY
VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
COMPLETE BOARD, THIS DIAGRAM MAY
WITHOUT AFFECTING THE INTERCHANGEABILITY OF
A
FRAME CONNECTION
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
EARTH GROUND CONNECTION
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
Ch'ge.Sht.No.
EQUIP.
TYPE
ENGINE WELDERS
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
10-29-93J
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
IDLER PCB SCHEMATIC
SUBJECT
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
NONE
SCALE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
SHT.
AUSTRALIA
CANADA
FRANCE
S16477
I.E.B.
2/10/93
CHK.
SUP'S'D'G.
M
16989
DR.
DATE
NO.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
in danger to the Machine Operator or Technician. Improper PC board repairDsocwonuloladd rfreosmuWltwinw.Sdoammanaugaels.ctoomt.hAell MmaancuahlisnSee.arch And Download.
SA-250
G-5
G-5
ELECTRICAL DIAGRAMS
Idler PC Board (M13708) Components
B210
Q1
B212
B211
B209
B213
R11
C4
C10
X1
X2
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
in danger to the Machine Operator or Technician. Improper PC board repairDsocwonuloladd rfreosmuWltwinw.Sdoammanaugaels.ctoomt.hAell MmaancuahlisnSee.arch And Download.
SA-250
SVM ERROR REPORTING FORM
We need to know if there are errors in our manuals. We also value any suggestions as to
additional tests or procedures that would make this SVM a better tool for you.
If you discover new or different “Problems or Symptoms” that are not covered in the three col-
umn troubleshooting chart, please share this information with us. Please include the
machine’s code number and how the problem was resolved.
Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 01/99
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