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IM747
January, 2003
SA-250
For Machines with Code Numbers 10890
Safety Depends on You
Lincoln arc welding equipment
is designed and built with safety
in mind. However, your overall
safety can be increased 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.
R
NTRL/C
OPERATOR’S MANUAL
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Copyright © 2003 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• 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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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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.
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.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.
fumes and gases.When welding, keep
your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control.
ventilation and/or exhaust at the arc to keep
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.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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.
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.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
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.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.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.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
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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 cir-
cuits. 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
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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 lev-
age, 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
metallique 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
defonctionnement.
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 souder
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.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
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.
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
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for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Thank You
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
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TABLE OF CONTENTS
Page
________________________________________________________________________
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Pre-Operation Installation ...............................................................................A-2
Safety Precautions..........................................................................................A-2
Exhaust Spark Arrester...................................................................................A-2
Location/Ventilation.........................................................................................A-2
Machine Grounding.........................................................................................A-2
Lift Bail ............................................................................................................A-2
Trailers......................................................................................................A-2,A-3
Polarity Control and Cable Sizes ....................................................................A-3
Pre-Operation Service ...........................................................................................A-3
Oil....................................................................................................................A-3
Fuel .................................................................................................................A-3
Cooling System...............................................................................................A-3
Battery Charging .............................................................................................A-4
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions.................................................................................................B-1
General Description...............................................................................................B-1
Engine Operation...................................................................................................B-2
Starting The Perkins 104-22 Engine ...............................................................B-2
Stopping the Engine........................................................................................B-2
Typical Fuel Consumption...............................................................................B-2
Welder Operation...................................................................................................B-3
Duty Cycle.......................................................................................................B-3
Control of Welding Current..............................................................................B-3
Idler Operation ................................................................................................B-3
Auxiliary Power ...............................................................................................B-4
________________________________________________________________________
Accessories ......................................................................................................Section C
Optional Features (Field Installed ) .......................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Instructions..............................................................................................D-1
Cooling System.....................................................................................................D-1
Bearings................................................................................................................D-1
Commutator and Brushes ..............................................................................D-1,D-2
Idler Maintenance..................................................................................................D-2
Nameplates...........................................................................................................D-2
Purging Air from Fuel System................................................................................D-2
Engine Service Chart ............................................................................................D-3
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
Welder Troubleshooting ........................................................................................E-2
Engine Troubleshooting Guide .......................................................................E-3,E-4
Electronic Idler Troubleshooting Guide .........................................................E-5, E-6
________________________________________________________________________
Diagrams ..........................................................................................................Section F
Wiring Diagram ( SA - 250 )...................................................................................F-1
Dimension Print......................................................................................................F-2
________________________________________________________________________
Parts List ..........................................................................................P433, P25-L Series
________________________________________________________________________
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - SA-250 ( K1283-8)
INPUT - DIESEL ENGINE
Make/Model Description Horsepower Operating Displacement cu. in.(ltrs) Starting
Capacities
@ 1800RPM
SPEED
System
12VDC Battery
and starter
4 Cylinder
Fuel: 15gal.(57L)
Oil: 8.7 qts.
(8.2L)
High
4 Stroke
1800RPM
Naturally
Aspirated
Water
Cooled
Engine
Perkins
104-22
32.7 HP
Push Button
Starter
Full Load
1725RPM
135.6 (2.2)
Radiator Coolant
9.5 qts.
(650 Cold
crank amps)
Low Idle
1400RPM
(9.0L)
RATED OUTPUT @ 104°F(40C°) - WELDER
DUTY CYCLE
RATED DC OUTPUT*
DESCRIPTION
DC CURRENT RANGE
Fine Adjustment in each Range
40-350 AMPS
220-Max.
VOLTS @ RATED AMPS
100%
60%
30V @ 250A
32V @ 300A
98V DC Max. OCV @ 1800RPM
300 Amp DC Welder
All Copper Windings
Pure DC Power Generator
160-240
120-190
80-130
Min.-90
RATED OUTPUT @ 104°F(40C°) - GENERATOR
1
Auxiliary Power
3,000 Watts Continuous, 60 Hz AC
26 Amps @115V
13 Amps @ 230V
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
WEIGHT
43.13** in.
1096.0 mm
28.00 in.
711.2 mm
67.00 in.
1702.0mm
1470 lbs. (667kg.)
ENGINE COMPONENTS
FUEL SYSTEM
LUBRICATION
GOVERNOR
Full Pressure with Full Flow Filter
Indirect Fuel Injector
Electrical Shutoff Solenoid
Mechanical Fuel Pump
MUFFLER
Low noise Muffler:
Made from long life,
aluminized steel.
Mechanical Governor
AIR CLEANER
ENGINE IDLER
Automatic Idler
ENGINE PROTECTION
Shutdown on low oil
pressure and engine
temperature.
Single Element
1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within 10% at all loads up to
rated capacity. When welding, available auxiliary power will be reduced.
* Based on a 10 min. period.
** Includes Top of Lift Bale.
SA-250
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A-2
A-2
INSTALLATION
MACHINE GROUNDING
PRE-OPERATION INSTALLATION
WARNING
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 receptacle.
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
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
particular situation and follow them explicitly. A
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
machine grounding stud marked with the symbol
is
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
provided on the welding generator frame foot. In gen-
eral, 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 insulat-
ed joints, or to the metal framework of a building
which has been effectively grounded. The U.S.
National Code lists a number of alternate means of
grounding electrical equipment.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
CAUTION
------------------------------------------------------------------------
See additional warning information at the
DO NOT MOUNT OVER COMBUSTIBLE SUFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, the surface
shall be covered with a steel plate at least
.06”(1.6mm) thick, which shall extend not more than
5.90”(150mm) beyond the equipment on all sides.
------------------------------------------------------------------------
front of this operator’s manual.
-----------------------------------------------------------
EXHAUST SPARK ARRESTER
Some federal, state or local laws may require that
engines be equipped with exhaust spark arresters
when they are operated in certain locations where
unarrested sparks may present a fire hazard. The
standard muffler included with this welder does not
qualify as a spark arrester. When required by local
regulations, a suitable spark arrester must be installed
and properly maintained.
LIFT BAIL
A lift bail is provided for lifting with a hoist.
WARNING
FALLING EQUIPMENT can cause
injury.
CAUTION
Use of an incorrect arrester may lead to engine damage
or performance loss. Contact the engine manufacturer
for specific recommendations.
------------------------------------------------------------------------
LOCATION / VENTILATION
• Do not lift this machine using lift bale if
it is equipped with a heavy accessory
such as a trailer or gas cylinder.
• Lift only with equipment of adequate lifting capacity.
• Be sure machine is stable when lifting.
----------------------------------------------------------------------
TRAILER (See Optional Features)
Always operate the welder with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating.
If the user adapts a non-Lincoln trailer, he must
assume responsibility that the method of attachment
and usage does not result in a safety hazard nor dam-
age the welding equipment. Some of the factors to be
considered are as follows:
The welder should be located to provide an unrestrict-
ed flow of clean, cool air. Also, locate the welder so
that engine exhaust fumes are properly vented to an
outside area.
SA-250
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A-3
A-3
INSTALLATION
• Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
PRE-OPERATION SERVICE
CAUTION
• Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
READ the engine operating and maintenance instruc-
tions supplied with this machine.
• Proper placement of the equipment on the trailer to
ensure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.
WARNING
can cause fire or explosion.
Fuel
-
• Stop engine while fueling.
• Do not smoke when fueling.
• Do not overfill tank.
• Typical conditions of use, i.e., travel speed, rough-
ness of surface on which the trailer will be operat-
ed; environmental conditions, likely maintenance.
• Keep sparks and flame away from tank.
• Wipe up spilled fuel and allow fumes to clear
before starting engine.
------------------------------------------------------------------------
(1)
• Conformance with federal, state and local laws.
(1)
Consult applicable federal, state and local laws regarding specific
requirements for use on public highways.
POLARITY CONTROL and CABLE SIZES
OIL
With the engine off, connect the electrode and work
cables to the studs located on the fuel tank mounting
rail. (See size recommendations below.) For positive
polarity, connect the electrode cable to the terminal
marked “+”. For Negative polarity, connect the elec-
trode cable to the “-” stud. These connections should
be checked periodically and tightened if necessary.
This unit is supplied from the factory with the engine
crankcase filled with a high quality SAE 10W/30 oil.
This oil should be acceptable for most typical ambient
temperatures. Consult the engine operation manual
for specific engine manufacturer’s recommendations.
Upon receipt of the welder, check the engine dipstick
to be sure the oil is at the “full” mark. DO NOT overfill.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
FUEL
Fill the fuel tank with the grade of fuel recommended
in the Engine Operator’s manual. Make sure the fuel
valves on the sediment bowl and the water separator
are in the open positions.
RECOMMENDED COPPER CABLE SIZES
Cables Sizes for Combined Length
of Electrode Plus Work Cable
Amps
250
Duty Cycle
100%
Up to 200 ft.
200 to 250 ft.
1
1/0
2/0
COOLING SYSTEM
300
60%
1/0
The radiator 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 engine manual or antifreeze container for
alternate antifreeze recommendations).
SA-250
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A-4
A-4
INSTALLATION
Battery Charging
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away.
BATTERY ACID can burn eyes and
skin.
• Wear gloves and eye protection and
be careful when boosting, charging or
working near battery.
To prevent EXPLOSION when:
•
Installing a new battery - disconnect the
negative cable from the old battery first and
connect the negative cable to the new battery
last.
•
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.
•
Using a booster - connect the positive lead to
the battery first, then connect the negative lead to
the ground lead on the base.
To prevent ELECTRICAL DAMAGE when:
•
•
Installing a new battery.
Using a booster.
Use correct polarity - Negative Ground.
• To prevent BATTERY DISCHARGE, if you have an
ignition switch, turn it off when engine is not
running.
• To prevent BATTERY BUCKLING, tighten nuts on
battery clamp until snug.
------------------------------------------------------------------------
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.
When replacing, jumping or otherwise connecting the
battery to the battery cables, the proper polarity must
be observed. This system is NEGATIVE GROUND.
SA-250
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B-1
B-1
OPERATION
The SA-250 has a current range of 40-350 DC amps
with output ratings as follows:
SAFETY PRECAUTIONS
RATED OUTPUT
DUTY CYCLE
WARNING
250A @ 30V
300A @ 32V
100%
60%
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
These units are also capable of providing 3 kVA of
115/230 volts of 60 cycle AC auxiliary power.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
The SA-250 uses the Perkins 104-22 industrial water-
cooled diesel engine.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
CONTROL PANEL
Both the engine and the welder controls are located
on one recessed panel at the exciter end of the
machine. The welder controls consist of a five step
“Current Range Selector” switch and a “Fine Current
Adjustment” rheostat. The welder is equipped with a
“Start” button, an “Ignition” switch, an “Idler” control
switch, and a “Glow Plug” button for easier cold
weather starting.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
The control panel also contains an engine tempera-
ture gauge, a battery charging ammeter, an oil pres-
sure gauge, two three prong grounding type recepta-
cles and four circuit breakers for auxiliary power.
------------------------------------------------------------------------
See additional warning information at the
front of this operator’s manual.
-----------------------------------------------------------
ENGINE IDLER - The SA-250 is equipped with an
electronic automatic engine idler. It automatically
increases and decreases engine speed when start-
ing and stopping welding or using auxiliary
power. A built-in time delay permits changing elec-
trodes before the engine slows to its low idle speed.
The “Idler” control switch on the panel locks the idler
in high idle position when desired.
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.
This welder is wound with all copper coils, rated at
300 amps/32 Volts. With the addition of the optional
Wire Feed Module, the SA - 250 will provide constant
voltage output for running the LN-7, LN-23P, or LN-25
wire feeders.
AUXILIARY POWER- 3.0 kVA of nominal
115/230V, 60Hz, AC. Output voltage is maintained
within 10% at all loads up to rated capacity. (See
Optional Features for Power Plug Kit.)
The optional Remote Control Kit provides a remote
control rheostat for remote fine current and open cir-
cuit voltage adjustment.
The SA-250 has Diesel Engine Protection. In the
event of sudden low oil pressure or high coolant tem-
perature, the engine immediately shuts down.
SA-250
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B-2
B-2
OPERATION
ENGINE OPERATION
STOPPING the ENGINE
1. Turn the “IGNITION” switch to “OFF”
Operate the welder with the doors closed. Leaving the
doors open changes the designed air flow and can
cause overheating.
At the end of each day’s welding, check the crankcase
oil level, drain accumulated dirt and water from the
sediment bowl under the fuel tank and refill the fuel
tank to minimize moisture condensation in the tank.
Also, running out of fuel tends to draw dirt into the fuel
system.
STARTING the SA-250 PERKINS 104-22
DIESEL ENGINE
1. Turn the “IDLER” switch to “HIGH”.
2. Turn the “IGNITION” switch to “ON”.
When hauling the welder between job sites, close the
fuel feed valve beneath the fuel tank.
3. Press the Glow Plug button for 20 to 30 seconds.
(maximum 60 seconds).
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. If this happens, bleeding of the
fuel system may be necessary. Use qualified person-
nel to do this per the instructions in the MAINTE-
NANCE section of this manual.
4. Press the Start button. When the engine starts run-
ning, release both buttons. If the engine fails to start
in 20 seconds, wait 30 seconds and repeat the
above procedure.
5. Observe the oil pressure. If no pressure shows with-
in 30 seconds, stop the engine and consult the
engine operating manual. To stop the engine, turn
the “IGNITION” switch to “OFF”.
SA-250 WITH PERKINS 104-22 DIESEL ENGINE
TYPICAL FUEL CONSUMPTION DATA
Low idle (1375 RPM )
No Load @ 45 Volts
0.28 gal/hr ( 1.06 ltrs/hr )
6. If the engine protection warning light comes on dur-
ing cranking or after start up, the “IGNITION” switch
must be turned “OFF” to reset the engine protection
system.
High idle ( 1800 Rpm ) 0.45 gal/hr ( 1.70 ltrs/hr )
No load @ 96.6 Volts
50 Amps @ 22 Volts
100 Amps @ 24 Volts
150 Amps @ 26 Volts
200 Amps @ 28 Volts
250 Amps @ 30 Volts
300 Amps @ 32 Volts
350 Amps @ 34 Volts
0.51 gal/hr (1.93 ltrs/hr )
0.58 gal/hr ( 2.19 ltrs/hr )
0.70 gal/hr ( 2.65 ltrs/hr )
0.85 gal/hr ( 3.21 ltrs/hr )
1.05 gal/hr ( 3.97 ltrs/hr )
1.31 gal/hr ( 4.95 ltrs/hr )
1.68 gal/hr ( 6.35 ltrs/hr )
7. Allow the engine to run at high idle speed for sever-
al minutes to warm the engine. Stop the engine and
recheck the oil level after allowing sufficient time for
the oil drain into the pan. If the level is down, fill it to
the full mark again. The engine controls were prop-
erly set at the factory and should require no adjust-
ing when received.
COLD WEATHER STARTING
With a fully charged battery and a proper weight oil,
the engine should start satisfactorily even down to
about -15°F -(26°C). If the engine must be frequently
started at or below -15°F -(26°C), it may be desirable
to install cold-starting aides.
Note: Extreme cold weather starting may require
longer glow plug operation
WARNING
Under NO conditions should ether or other starting
fluids be used!
------------------------------------------------------------------------
SA-250
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B-3
B-3
OPERATION
Range Selector” to the 190-120 position and then
adjust the “Fine Current Adjustment” for 175 amps.
WELDER OPERATION
WARNING
When a forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Current
Range Selector” setting and lower open circuit volt-
age. For example: to obtain 175 amps and a forceful
arc, set the “Current Range Selector” to the 240-160
position and the “Fine Current Adjustment” setting to
get 175 amps.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground.
FUMES & GASES can be dangerous.
• Keep your head out of the fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
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.
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
CAUTION
DO NOT attempt to set the “Current Range Selector”
between the five points designated on the nameplate.
------------------------------------------------------------------------
ARC RAYS can burn.
• Wear eye, ear, and body protection.
These switches have a spring loaded cam which
almost eliminates the possibility of setting this switch
between the designated points.
DUTY CYCLE
The NEMA output rating of the SA-250 is 300
amperes at 32 arc volts on a 60% duty cycle (consult
Specifications in this manual for alternate ratings).
Duty cycle is based on a ten minute period; thus, the
welder can be loaded at rated output for six minutes
out of every ten minute period.
IDLER OPERATION
Start the engine with the “Idler” switch in the “High”
position. Allow it to run at high idle speed for several
minutes to warm the engine. See Specifications for
operating speeds.
CONTROL OF WELDING CURRENT
The idler is controlled by the “Idler” toggle switch on
the welder control panel. The switch has two posi-
tions as follows:
CAUTION
DO NOT TURN THE “CURRENT RANGE SELEC-
TOR” WHILE WELDING because the current may
arc between the contacts and damage the switch.
------------------------------------------------------------------------
1. In the “High”
vates, and the engine goes to high idle speed. The
speed is controlled by the governor.
position, the idler solenoid acti-
2. In the “Auto”
ates as follows:
/
position, the idler oper-
The “Current Range Selector” provides five overlap-
ping 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 characteristics.
•
When welding or drawing power for lights or tools
(approximately 100-150 watts minimum) from the
receptacles, the idler solenoid activates and the
engine operates at high idle speed.
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 setting 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
• When welding ceases or the power load is turned off,
a preset time delay of about 15 seconds starts. This
time delay cannot be adjusted.
• If the welding or power load is not re-started before
the end of the time delay, the idler solenoid deacti-
vates and reduces the engine to low idle speed.
SA-250
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B-4
B-4
OPERATION
AUXILIARY POWER
The AC auxiliary power, supplied as a standard, has a
rating of 3.0 kVA of 115/230 VAC (60 hertz).
With the 3.0 kVA, 115/230 VAC auxiliary power, 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 has a configuration which permits
20 amps to be drawn from either half. The total com-
bined load of all receptacles is not to 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.
SA-250
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C-1
C-1
ACCESSORIES
Wire Feed Module (K623-1) - Provides constant
voltage (CV) output with improved arc stability for
Innershield welding. Excellent for MIG welding.
Recommended wire feeders are the LN-7, LN-23P
and LN-25. (Factory installed on the K1643-2).
OPTIONAL FEATURES (Field Installed)
Accessory Set (K704) - Includes electrode and work
cables, headshield, work clamp and electrode holder.
TIG Module (K930-2) - Portable, high frequency unit
with gas valve for TIG welding. Rated at 300 amps /
60% duty cycle. (Request Publication E3.205).
GFCI Receptacle Kit (K1690-1) - Includes one UL
approved 115V ground fault circuit interrupter duplex
type receptacle with cover and installation instruc-
tions. Replaces the factory installed 115V duplex
receptacle. Each receptacle of the GFCI duplex is
rated at 20 amps. Maximum total current from the
GFCI duplex is limited to 20 amps.
Power Plug Kit (K802D) - A power plug kit for the
auxiliary power receptacles is available. (Provides a
plug for each receptacle.)
Remote Control Kit (K924-4) - Contains a remote
control rheostat, and 100 ft (30.5m) cable for adjusting
the OCV at the welding site.
Spark Arrestor Kit (K903-1) - Includes a heavy gage
steel, approved spark arrestor, clamp and adapter for
mounting to the muffler exhaust pipe.
Trailer (K957-1) - Two-wheeled trailer for in-plant and
yard towing at speeds under 20 mph only.
Oil Drain Kit (K1586-1) - Includes ball valve, hose
and clamp.
Trailer (K953-1) - Two-wheeled trailer with optional
fender and light package. For highway use, consult
applicable federal, state, and local laws regarding
possible additional requirements. Choice of 2 hitches
and add on fender & light package. Order: K953-1
Trailer, K958-1 Ball Hitch, K958-2 Lunette Eye
Hitch, K959-1 Fender & Light Kit.
Water Valve Kit (K844-1)
WARNING
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc
welder for pipe thawing is not approved by the
CSA, nor is it recommended or supported by
Lincoln Electric.
------------------------------------------------------------------------
SA-250
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D-1
D-1
MAINTENANCE
• When necessary, remove the sediment bowl, if so
equipped, from beneath the fuel tank and clean out
any accumulated dirt and water.
MAINTENANCE
WARNING
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be neces-
sary to remove safety guards to perform
required maintenance. Remove guards only
when necessary and replace them when the
maintenance requiring their removal is com-
plete. Always use the greatest care when work-
ing near moving parts.
• Follow the engine service schedule in this manual
and the detailed maintenance and troubleshooting in
the engine manufacturer’s manual.
COOLING SYSTEMS
The SA-250 is equipped with a pressure radiator.
Keep the radiator cap tight to prevent loss of coolant.
Clean and flush the cooling system periodically to pre-
vent clogging the passage and overheating the
engine. When antifreeze is needed, always use the
permanent type. Capacity = 9.5 qts (9.0 Ltrs.).
Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
BEARINGS
This welder is equipped with a double-shielded ball
bearing having sufficient grease to last indefinitely
under normal service. Where the welder is used con-
stantly or in excessively dirty locations, it may be nec-
essary 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.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
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.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
COMMUTATOR AND BRUSHES
• Stop engine before servicing.
• Keep away from moving parts.
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 rotat-
See additional warning information at
front of this operator’s manual.
-----------------------------------------------------------
ing armature when stoning the commutator.
------------------------------------------------------------------------
Shifting of the commutator brushes may result in:
- Change in machine output
GENERAL INSTRUCTIONS
- Commutator damage
- Excessive brush wear
• Blow out the welder and controls with an air hose at
least once every two months. In particularly dirty
locations, this cleaning may be necessary once a
week. Use low pressure air to avoid driving dirt into
the insulation.
Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
• “Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the cur-
rent control through its entire range frequently.
Good practice is to turn the handle from maximum
to minimum setting twice each morning before
starting to weld.
Replace brushes when they wear within 1/4” of the
pigtail. A complete set of replacement brushes should
be kept on hand.
• Put a drop of oil on the “Current Range Selector”
shaft at least once every month.
SA-250
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D-2
D-2
MAINTENANCE
Lincoln brushes have a curved face to fit the commu-
tator. Have an experienced maintenance man 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.
PURGING AIR from FUEL SYSTEM
(Perkins 104-22 Engine)
WARNING
Keep fuel clear of open flames or arcs, allow
engine to cool before working on the fuel system.
Wipe up any spilled fuel and do not start engine
until fumes clear.
------------------------------------------------------------------------
If the engine is running rough and you suspect air has
been trapped in the fuel system, (EG. the engine was
allowed to run out of fuel) perform the following steps
using qualified personnel:
To seat slip ring brushes, position the brushes in
place. Then slide one end of a piece of fine sandpa-
per between slip rings and brushes with the coarse
side against the brushes. Pull the sandpaper around
the circumference of the rings - in direction of rotation
only - until brushes seat properly. In addition, stone
slip ring with a fine stone. Brushes must be seated
100%.
Arcing or excessive exciter brush wear indicates a
possible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
1. Loosen by two or three turns, the vent screw
(Figure D.1) on the fuel inlet connection.
IDLER MAINTENANCE
CAUTION
Vent Screw
Before doing electrical work on the idler printed
circuit board, disconnect the battery.
------------------------------------------------------------------------
When installing a new battery or using a jumper bat-
tery to start the engine, be sure the battery polarity is
connected properly. The correct polarity is negative
ground. Damage to the engine alternator and the
printed circuit board can result from incorrect connec-
tion.
Priming
Lever
FIGURE D.1
2. For Engines Equipped with a mechanical fuel pump:
Operate the priming lever on the fuel lift pump until
fuel, free of air, flows from the vent point. Tighten
the vent screw. If the pump is at the point of maxi-
mum lift, it will not be possible to operate the prim-
ing lever. If this occurs, turn the crankshaft one
revolution.
1. The solenoid plunger must work freely and not
bind. Dust the plunger about once a year with
graphite powder.
2. Proper operation of the idler requires good ground-
ing of the printed circuit board, reed switch, and
battery.
For Engines Equipped with an electric fuel pump:
Operate the electric fuel pump by turning the
“Ignition” switch “ON” until fuel, free of air, flows
from the vent point. Tighten the vent screw.
3. Idler solenoid is activated for high idle.
4. If desired, the welder can be used without automat-
ic idling by setting the “Idler” switch to the “High”
position.
3. Contact your Perkins Engine repair facility if prob-
lems persist.
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 replace-
ment item number.
SA-250
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D-3
D-3
MAINTENANCE
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE-(20 / 50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 200 HOURS OR 6 MONTHS
EVERY 400 HOURS OR 12 MONTHS
EVERY 600 HOURS OR 18 MONTHS
ENGINE SERVICE (NOTE 2)
MAINTENANCE ITEM
Coolant level
TYPE OR QUANTITY
I
I
I
Concentration of antifreeze
Coolant (NOTE 3)
50/50 Water/Ethylene Glycol
R
9.5qrts, (9.0L)
Engine oil level (NOTE 1)
Engine oil (NOTE 1 & 3)
Engine oil filter
R
R
C
R
R
C
8.7qrts, (8.2L) (including filter)
Perkins #140517000
Drain water separator & fuel strainer
Fuel filter canister
R
Perkins #1300366020
I
Tension of alternator drive belt
Alternator drive belt wear
Alternator drive belt
I
R
Perkins # 080109080
C
C
I
Air filter (earlier check may be req'd.)
Air filter element
R
Donaldson #P181050 or Nelson #70206N
Check and adjust idle speed
Tighten cylinder head
Valve clearances
I
I
I
I
Intake .008", exhaust .008"
Contact Perkins
Electrical systems
All nuts and bolts for tightness
Injector performance
Leaks or engine damage
Battery
I
I
I
I = Inspect
NOTES:
(1) Consult Engine Operators Manual for oil recommendations.
C = Clean
R = Replace
(2) Consult Engine Operators Manual for additional maintenance schedule information.
(3) Fill slowly! Ensure correct quantity is used.
Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.
These preventive maintenance periods apply to average conditions of operation.
If necessary use shorter periods.
12/99
S20919-2
SA-250
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E-1
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by 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 malfunctions.
Simply follow the three-step procedure listed below.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-
TOMS)”. This column describes possible symptoms If you do not understand or are unable to perform the
that the machine may exhibit. Find the listing that best Recommended Course of Action safely, contact your
describes the symptom that the machine is exhibiting.
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute to
the machine symptom.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at the
front of this operator’s manual.
-----------------------------------------------------------
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SA-250
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E-2
E-2
WELDER TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
Machine fails to hold the heat
consistently.
1. Rough or dirty commutator.
2. Brushes may be worn down
to limit.
3. Field circuit may have variable
resistance connection or intermit-
tent open circuit due to loose
connection or broken wire.
4. Electrode lead or work lead con-
nection may be poor.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
5. Wrong grade of brushes may
have been installed on generator.
6. Field rheostat may be making
poor contact and overheating.
Welder starts but fails to generate 1. Generator or exciter brushes
current.
may be loose or missing.
2. Exciter may not be operating.
3. Field circuit of generator or
exciter may be open.
4. Exciter may have lost excitation.
5. Series field and armature circuit
may be open-circuited.
Welding arc is loud and spatters
excessively.
1. Current setting may be to high.
2. Polarity may be wrong.
Welding current too great or too
small compared to indication on
the dial.
1. Exciter output low causing low
output compared to dial indication.
2. Operating speed too low or to
high.
Arc continuously pops out.
1. “Current Range Selector” switch
may be set at an intermediate
position.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SA 250
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E-3
E-3
ENGINE TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
Engine does not start or operates
Irregularly
1. Faulty Ignition switch and or
Injector pump solenoid
2. Insufficient charging or complete
discharge of the battery
3. Lack of fuel
4. Air mixed in the fuel system.
5. Clogged fuel filter
6. Irregular and faulty fuel supply
( Injector pump trouble)
7. Glow plug not heated
8. Improper viscosity of the lubricat-
ing oil
9. Clogged air cleaner
10. No compression
11. Engine protection light is on
12. Defective governor
13. Engine defective
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
Engine stops during operation and
1. Lack of fuel
the Engine Protection light does not 2. Clogged fuel filter
turn on
3. Air mixed in the fuel system
4. Faulty function of the engine
Engine stops during operation and
the Engine Protection light does
turn on
1. Overheating of the engine
• Lack of coolant
• Loose or damaged fan belt
• Clogged radiator
• Dust or scale clogged in the cool-
ing water passages
• Faulty thermostat
• Lack of oil
• Overloading
• Faulty Idler/Engine Protection
P.C. Board
2. Loss of engine oil pressure
• Lack of engine oil
• Faulty oil pressure switch
• Oil leakage from the lubricating
system
• Clogged oil filter
• To low viscosity of the engine oil
• Faulty Idler/Engine Protection
P.C. Board
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SA 250
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E-4
E-4
ENGINE TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
( White or Blue ) Smoke
1. Excess engine oil
2. Too low viscosity of the engine oil
3. Faulty injection timing
Dark Grey Smoke
1. Unsuitable fuel
2. Excess injection
3. Faulty function of the engine
4. Overloading
5. Clogged air cleaner
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
Faulty Charging
1. Loose fan belt
2. Faulty wiring
3. Faulty battery
4. Worn out alternator brush
Starter Motor does not run
1. Loose or damaged wiring
2. Dropped voltage of the battery
3. Damaged starter motor
( including solenoid )
Engine Protection Light not coming 1. Broken Light Bulb
on ( after the ignition switch has
been in the on position for more
than 60 seconds with the engine
not started)
2. Faulty light wiring
(to GND or P.C. Board )
3. Faulty Idler/Engine Protection
P.C. Board
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SA-250
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E-5
E-5
TROUBLESHOOTING
ELECTRONIC IDLER TROUBLESHOOTING GUIDE
With Idler Control Switch in the Auto Position,
Engine Will Not Return to Low Idle in Approximately 15 Seconds
After Welding and Auxiliary Loads are Removed
Set Idler Control Switch
to the Auto Position
Check for Continuity through Idler
Control Switch
Open
Closed
Measure DC Voltage on
Idler Solenoid Coil
Replace Idler
Control Switch
12 VDC
0 VDC
Check Continuity of
Reed Switch in Weld Circuit
Check for Jamming
of the Idler Solenoid
Mechanism or a broken
Return Spring
Open
Closed
1. Check Wiring in
Idler Solenoid
Circuit
Replace Reed
Switch
2. Replace Idler
P.C. Board
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SA-250
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E-6
E-6
TROUBLESHOOTING
ELECTRONIC IDLER TROUBLESHOOTING GUIDE
With Idler Control Switch in the AUTO Position,
Engine Will Not Pick Up Speed When:
The Arc is Struck
The Auxiliary Power Load is Turned ON
Reed Switch in Weld Circuit
Defective -- Will Not Close
Power Load Too Small
Try Load Above 150 Watts
To Check: Short the Red Lead
on P.C. Board to Welder Frame.
Engine Does Not Pick Up Speed
1. Check Continuity of Idler Solenoid Coil
(8.5-9.0 ohms) and Replace as
Required.
2. Check for Jamming of the Idler
Solenoid Mechanism.
Engine Picks Up Speed
Engine Does Not Pick Up
Speed
3. Check for Continuity of Current
Transformer (Toroid). Replace as
Required.
1. Check for Break in
Red Lead and Repair
1. Check Continuity of Idler
Solenoid Coil (8.5-9.0
ohms) and Replace as
Required.
2. Replace Reed Switch
in Weld Circuit.
4. Check Idler Circuit Wiring and Repair
as Required.
2. Check for Jamming of
the Idler Solenoid
Mechanism.
5. Replace Idler P.C. Board.
3. Check Idler Circuit
Wiring and Repair as
Required.
4. Replace Idler P.C.
Board.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SA-250
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F-1
F-1
DIAGRAMS
+
SA-250
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F-2
F-2
DIMENSION PRINT
SA-250
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NOTES
SA-250
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NOTES
SA-250
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Now Available...12th Edition
New Lessons in Arc Welding
The Procedure Handbook of Arc Welding
Lessons, simply written, cover manipulatory techniques;
machine and electrode characteristics; related subjects,
such as distortion; and supplemental information on arc
welding applications, speeds and costs. Practice materials,
exercises, questions and answers are suggested for each
lesson.
With over 500,000 copies of previous editions published
since 1933, the Procedure Handbook is considered by many to
be the “Bible” of the arc welding industry.
This printing will go fast so don’t delay. Place your
order now using the coupon below.
528 pages, well illustrated, 6” x 9” size, bound in simulated,
gold embossed leather.
The hardbound book contains over 750 pages of welding
information, techniques and procedures. Much of this material
has never been included in any other book.
$5.00 postage paid U.S.A. Mainland
A must for all welders, supervisors, engineers and
designers. Many welding instructors will want to use the book
as a reference for all students by taking advantage of the low
quantity discount prices which include shipping by
4th class parcel post.
$15.00 postage paid U.S.A. Mainland
Need Welding Training?
The Lincoln Electric Company operates the oldest and
most respected Arc Welding School in the United States at its
corporate headquarters in Cleveland, Ohio. Over 100,000 stu-
dents have graduated. Tuition is low and the training is
“hands on”
How To Read Shop Drawings
The book contains the latest information and application
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and
draftsmen use the “short-cut” language of symbols to pass
on assembly and welding information to shop personnel.
For details write:
Lincoln Welding School
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability
to visualize mechanically drawn objects as they will appear
in their assembled form.
and ask for bulletin ED-80 or call 216-383-2259 and ask for the
Welding School Registrar.
187 pages with more than 100 illustrations. Size 8-1/2” x 11”
Durable, cloth-covered board binding.
Lincoln Welding School
BASIC COURSE
5 weeks of fundamentals
$700.00
$4.50 postage paid U.S.A. Mainland
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
Prices include shipment by 4thClass Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
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For order value between $100.00 & $149.00
For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
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USE THIS FORM TO ORDER:
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Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
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Titles:
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New Lessons in Arc Welding
Procedure Handbook “Twelfth Edition”
How to Read Shop Drawings
Incentive Management
A New Approach to Industrial Economics $5.00
The American Century of John C. Lincoln $5.00
Seminar Information
(ED-45)
Educational Video Information
(ED-93)
NA
AC
James F. Lincoln Arc Welding
Foundation Book Information
Welding Preheat Calculator
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$3.00
$4.50
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(JFLF-515)
SUB TOTAL
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● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● Keep flammable materials away.
● Wear eye, ear and body protection.
WARNING
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
Spanish
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux
tien.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
● Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• World's Leader in Welding and Cutting Products •
• 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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