Manual de Servicio Sa 250 Lincoln

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SVM128-A
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March, 1999
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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

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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.
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SERVICE MANUAL
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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
i i
Return to Master TOC SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers before welding.
and devices in position and in good
repair.Keep hands, hair, clothing and tools 2.c. Exposure to EMF fields in welding may have other health
away from V-belts, gears, fans and all other effects which are now not known.
moving parts when starting, operating or
repairing equipment. 2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d.1. Route the electrode and work cables together - Secure
guards to perform required maintenance. Remove them with tape when possible.
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.2. Never coil the electrode lead around your body.
Always use the greatest care when working near moving
parts. 2.d.3. Do not place your body between the electrode and
___________________________________________________ work cables. If the electrode cable is on your right
1.f. Do not put your hands near the engine fan. Do not attempt to side, the work cable should also be on your right side.
override the governor or idler by pushing on the throttle con-
trol rods while the engine is running. 2.d.4. Connect the work cable to the workpiece as close as
___________________________________________________ possible to the area being welded.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance 2.d.5. Do not work next to welding power source.
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Mar ‘95
SA-250
ii ii
ELECTRIC SHOCK can kill. ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot” when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot” parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
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 FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
• Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
3.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating

products.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
5.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
5.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.j. Also see Items 6.c. and 8.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.

Mar ‘95
SA-250
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. 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
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • 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 • A safe distance from arc welding or cutting operations and
cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building

switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
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
iv iv
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matériaux inflammables ou les recouvrir afin de
et les précautions de sûreté specifiques qui parraissent dans ce prévenir tout risque d’incendie dû aux étincelles.
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
Sûreté Pour Soudage A L’Arc échauffement et un risque d’incendie.
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible de
a. Les circuits à l’électrode et à la piéce sont sous tension la zone de travail qu’il est pratique de le faire. Si on place la
quand la machine à souder est en marche. Eviter toujours masse sur la charpente de la construction ou d’autres endroits
tout contact entre les parties sous tension et la peau nue éloignés de la zone de travail, on augmente le risque de voir
ou les vétements mouillés. Porter des gants secs et sans passer le courant de soudage par les chaines de levage,
trous pour isoler les mains. câbles de grue, ou autres circuits. Cela peut provoquer des
b. Faire trés attention de bien s’isoler de la masse quand on risques d’incendie ou d’echauffement des chaines et des
soude dans des endroits humides, ou sur un plancher met- câbles jusqu’à ce qu’ils se rompent.
allique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut être en contact avec la masse. Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble de galvanisées plombées, ou cadmiées ou tout autre métal qui
soudage et la machine à souder en bon et sûr état defonc- produit des fumeés toxiques.
tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le 10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir. d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
des porte-électrodes connectés à deux machines à soud- du solvant pour produire du phosgéne (gas fortement toxique)
er parce que la tension entre les deux pinces peut être le ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
courant pour soudage semi-automatique, ces precautions le code “Code for safety in welding and cutting” CSA Standard
pour le porte-électrode s’applicuent aussi au pistolet de W 117.2-1974.
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
PRÉCAUTIONS DE SÛRETÉ POUR
du corps. LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc: REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. 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
v v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
RETURN TO MAIN INDEX

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
Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation
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
A-2 A-2
INSTALLATION
Return to Section TOC
TECHNICAL SPECIFICATIONS - SA-250
INPUT - DIESEL ENGINE
Manufacturer Description Speed Displacement Ignition Capacities

Perkins 3 cyl., 4 cycle 1725 RPM 152 cu. in. Electric Fuel: 15 gal.
D3.152 Water-cooled Full load (2500 cc) (57 liters)
diesel
38.2 HP @ 1800 RPM Oil: 7.2 qt.
1725 RPM High idle (6.9 liters)
1350 RPM Water/coolant: 10 qt.

Low idle (9.5 liters)
RATED OUTPUT - WELDER

Duty Cycle Amps Volts at Rated Amperes
100% Duty Cycle 200 DC Constant Current 40V
60% Duty Cycle 250 DC Constant Current 40V(1)
35% Duty Cycle 325 DC Constant Current 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. 28 in. 67 in. 1650 lb.
1096 mm 711 mm 1702 mm 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
A-3 A-3
INSTALLATION
Read this entire installation section before you LOCATION AND VENTILATION
start installation.
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
SAFETY PRECAUTIONS welder with the case roof on and all machine compo-
nents completely assembled.
WARNING
Whenever you use the SA-250, be sure that clean
Do not attempt to use this equipment until you have cooling air can flow through the machine’s diesel
thoroughly read all the operation and maintenance engine and the generator. Avoid dusty, dirty areas.
manuals supplied with your machine. They include Also, keep the machine away from heat sources. Do
important safety precautions; detailed engine starting, not place the back end of the generator anywhere near
operating, and maintenance instructions; and parts hot engine exhaust from another machine. And of
lists. course, make sure that engine exhaust is ventilated to
an open, outside area.
The SA-250 may be used outdoors. Do not set the

ELECTRIC SHOCK can kill.

machine in water. Such practices pose safety hazards
• Do not touch electrically live and cause improper operation and corrosion of parts.
parts or electrodes with your
skin or wet clothing.
• Insulate yourself from the work
and ground. STORING
• Always wear dry insulating 1. Store the machine in a cool, dry place when it is not
gloves. 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.
• Use in open, well ventilated Run the engine for about five minutes to circulate oil
areas or vent exhaust to the out- to all the parts. See the Maintenance section of
side. this manual for details on changing oil.
• Do not stack anything on or near 3. Remove the battery, recharge it, and adjust the
the engine. 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-
• Do not operate this equipment mation on fuel and engine preservation.
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
A-4 A-4
INSTALLATION
STACKING WARNING
SA-250 machines CANNOT be stacked.
Keep hands away from the engine muffler or HOT
engine parts.
TILTING • Stop the engine when fueling.
Place the machine on a secure, level surface whenev- • Do not smoke when fueling.
er you use it or store it. Any surfaces you place it on • Remove the fuel cap slowly to release pressure.
other than the ground must be firm, non-skid, and
structurally sound. • Do not overfill the fuel tank.
The diesel engine is designed to run in a level position • Wipe up spilled fuel and allow the fumes to clear
for best performance. If you do operate it at a slight before starting the engine.
angle, be sure to check the oil regularly and keep the • Keep sparks and flame away from the fuel tank.
oil level at the FULL mark as it would be in its normal
level condition. Also, fuel capacity will be a little less at
OIL
an angle.
The SA-250 is shipped with the engine filled

with SAE 10W-30 oil. This should be fine
for most ambient operating temperature
LIFTING conditions. See the engine operation manual for spe-
cific recommendations. CHECK THE OIL LEVEL
The SA-250 weighs 1650 lb./743 kg. A lift bail is
BEFORE YOU START THE ENGINE. This is an
provided for lifting with a hoist.
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.
WARNING
For more oil fill and service information, see the
FALLING EQUIPMENT can Maintenance section of this manual.
cause injury.
Do not lift this machine using lift bail if FUEL
it is equipped with a heavy accessory

Fill the fuel tank with clean, diesel fuel only.
such as a trailer.
The SA-250 has a 15 gallon (57 liter) fuel
Lift only with equipment of adequate lifting capacity. Be tank with a top fill and fuel gauge mounted
sure machine is stable when lifting. on the control panel. See the Operation and
Maintenance sections of this manual for more details
about fuel.
HIGH ALTITUDE OPERATION
It may be necessary to derate welder output at higher BATTERY CONNECTIONS
altitudes. Some engine adjustment may be required. – + The SA-250 is shipped with the negative
Contact a Perkins Service Representative. battery cable disconnected. Before you
operate the machine, make sure the
IGNITION switch is in the OFF position and attach the
PRE-OPERATION ENGINE SERVICE disconnected cable securely to the battery terminal. If
the battery is discharged and won't start the engine,
Read and understand the information about the diesel see the battery charging instructions in the
engine in the Operation and Maintenance sections of Maintenance section.

this manual before you operate the SA-250.
SA-250
A-5 A-5
INSTALLATION
COOLING SYSTEM TRAILER

The cooling system has been filled at the factory with a If you use a non-Lincoln trailer, you must assume
50-50 mixture of ethylene glycol antifreeze and water. responsibility that the method of attachment and usage
Check the radiator level and add a 50-50 solution as does not result in a safety hazard nor damage the
needed. (See your engine manual or antifreeze con- welding equipment. Some of the factors to be consid-
tainer for alternate antifreeze recommendations.) ered are as follows:
1. Design capacity of the trailer vs. the weight of the
Lincoln equipment and likely additional attach-
MUFFLER ments.
This welder is supplied with an adjustable rain cap for 2. Proper support of, and attachment to, the base of
the muffler. Install the rain cap using the clamp provid- the welding equipment so there will be no undue
ed with the outlet facing away from the direction in stress to the framework.
which this unit will be transported. This will minimize
the amount of water and debris that could enter the 3. Proper placement of the equipment on the trailer to
muffler during transportation. ensure stability side to side and front to back. This
includes when being moved and when standing by

itself for operation or service.
EXHAUST SPARK ARRESTER 4. Typical conditions of use, such as travel speed,

roughness of the surfaces where the trailer will be
Some federal, state or local laws may require that used, environmental conditions, likely maintenance.
diesel engines be equipped with exhaust spark
arresters when they are operated in certain locations 5. Conformance with federal, state, and local laws.
where unarrested sparks may present a fire hazard. Consult applicable federal, state, and local laws
The standard mufflers included with these welders do about specific requirements for use on public high-
not qualify as a spark arrester. When required by local ways.
regulations, suitable spark arresters must be installed
and properly maintained.
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
A-6 A-6
INSTALLATION
ELECTRICAL OUTPUT
CAUTION
CONNECTIONS
• Loose connections will cause the output terminals to
See Figure A.1 for the location of the 115 and 230 volt overheat. The terminals may eventually melt.
receptacles, weld output terminals, and ground stud.
• Do not cross the welding cables at the output terminal
connection. Keep the cables isolated and separate
WELDING CABLE CONNECTIONS from one another.
CABLE INSTALLATION AND CABLE SIZES

With the engine off, route the electrode and work
When welding at a considerable distance from the
cables through the strain relief bracket on the base and
welder, be sure you use ample size welding cables.
connect to the terminals located on the fuel tank mount-
Table A.1 lists recommended cable sizes and lengths
ing rail. (See size recommendations below.) For posi-
for rated current and duty cycle. Length refers to the
tive polarity, connect the electrode cable to the terminal
distance from the welder to the work and back to the
marked Positive (+). For Negative polarity, connect the
welder. Cable diameters are increased for long cable

electrode cable to the Negative (-) terminal. These
lengths to reduce voltage drops.
connections should be checked periodically and tight-
ened if necessary. 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

1 2. 115 VAC RECEPTACLE
3. OUTPUT TERMINALS
4. GROUND STUD
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 Duty Cycle Up to 200 ft. 200 to 250 ft.

250 60% 1 1/0
350 25% 2/0 3/0
SA-250
A-7 A-7
INSTALLATION
MACHINE GROUNDING For further protection against electric shock, any elec-
trical equipment connected to the generator recepta-
According to the United States National Electrical cles must use a three-blade, grounded type plug or an
Code, the frame of this portable generator is not Underwriter's Laboratories (UL) approved double insu-
required to be grounded and is permitted to serve as lation system with a two-blade plug. Lincoln offers an
the grounding means for cord connected equipment accessory plug kit that has the right type of plugs. See
plugged into its receptacles. the Accessories section of this manual for details.
Some state, local or other codes or unusual operating If you need ground fault protection for hand-held equip-
circumstances may require the machine frame to be ment, refer to the Accessories section of this manual
grounded. It is recommended that you determine the for the GFCI Receptacle kit.
extent to which such requirements may apply to your
particular situation and follow them explicitly. A
machine grounding stud marked with the symbol
CIRCUIT BREAKERS
is provided on the welding generator frame foot.
(If an older portable welder does not have a grounding SA-250 welders are equipped with cir-
stud, connect the ground wire to an unpainted frame cuit breakers on the 115 and the 230
screw. See Figure A.2. volt receptacles for overload protec-

tion. Under high heat a breaker may
In general, if the machine is to be grounded, it should
tend to trip at lower loads than it would normally.
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the Operation with high ambient temperatures may cause
ground for at least ten feet and having no insulated the breakers to trip at lower than normal loads.
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 CAUTION
grounding electrical equipment.
Never bypass the circuit breakers. Without overload
protection, the SA-250 could overheat and/or cause
WARNING damage to the equipment being used.
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 1
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 1. GROUND STUD

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.
SA-250
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
A-8
SA-250
NOTES
A-8
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
B-2 B-2
OPERATION
OPERATING INSTRUCTIONS WARNING

Read and understand this entire section before operat-
ing your SA-250.
ENGINE EXHAUST can kill.
SAFETY INSTRUCTIONS • Use in open, well ventilated areas or
vent exhaust to the outside.
WARNING • 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
MOVING PARTS can injure.
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts • Do not operate this equipment with any
lists. of its doors open or guards off.
• Stop the engine before servicing it.
ELECTRIC SHOCK can kill. • Keep away from moving parts.
• Do not touch electrically live parts or

electrodes with your skin or wet clothing. Only qualified personnel should install, use, or ser-
• Insulate yourself from the work and vice this equipment.
ground.
• Always wear dry insulating gloves.
GENERAL DESCRIPTION
The SA-250 is a heavy duty engine driven DC arc
FUMES AND GASES can be dan- welding power source capable of providing constant
gerous. current output for stick welding or DC TIG welding.
With the addition of the optional Wire Feed Module, the
• Keep your head out of fumes.
SA-250 will provide constant voltage output for running
• Use ventilation or exhaust to remove the LN-7 or LN-25 wire feeders.
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
WELDING SPARKS can cause Hertz AC auxiliary power.
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
B-3 B-3
OPERATION
RECOMMENDED APPLICATIONS DESIGN FEATURES
WELDER • Constant current DC Stick welding (SMAW) process

capability with output range from 40 - 325 DC amps.
The SA-250 provides excellent constant current DC
welding output for stick (SMAW) welding and for DC • Constant current DC TIG Welding with output across
TIG welding. It also offers constant voltage output for the entire range of settings.
DC semiautomatic wire feed welding. For more details • Work and Electrode welding cable mounting termi-
on using the machine as a welder, see Welding nals.
Operation in the Operation section of this manual.
• Separate ground stud for safe connection of case to
GENERATOR earth ground.
The SA-250 is also capable of providing 3.0 kVA of • Duplex, 230 volt auxiliary power receptacle.
115/230 volts of 60 Hertz AC auxiliary power.
• Duplex, 115 volt auxiliary power receptacles.
• Integrated generator output overload protection
through four 15 amp circuit breakers.
OPERATIONAL FEATURES AND
• Electric starting.
CONTROLS
• Battery Charging Ammeter.
The SA-250 was designed for simplicity. Therefore, it
has very few operating controls. Two switches are • Engine Oil Pressure Gauge.
used for welding operations: • Engine Hour Meter for determining periodic mainte-
• A five-position CURRENT RANGE SELECTOR nance.
switch selects current output ranges for constant cur- • Top-of-the-line 38.2 HP Perkins diesel engine.
rent stick or TIG applications and constant voltage
wire feed applications (with optional Wire Feed • Top-mounted 15 gallon (57.0 litter) fuel tank with
Module - see the Accessories section) convenient top fill.
• A FINE CURRENT ADJUSTMENT switch for fine • Automatic engine shutdown protection for low oil
adjustment of current from minimum to maximum pressure.
within each range • Automatic engine idler goes to low idle approximate-
Controls for the diesel engine control include a two- ly 15 seconds after welding for greater fuel economy;
position IGNITION ON/OFF toggle switch, a START includes high idle switch.
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
B-4 B-4
OPERATION
WELDING CAPABILITY LIMITATIONS

The SA-250 is rated 250 amps, 40 volts constant cur- • The SA-250 is not recommended for any processes
rent DC at 60% duty cycle based on a ten minute time besides those that are normally performed using DC
period. Longer duty cycles at lower output currents are stick welding (SMAW) and DC TIG welding. Specific
possible. limitations on using the SA-250 for these processes
are described in the Welding Operation section of
The current is continuously variable from 40 to 325
this manual. Constant voltage welding is available
amps DC.
with the optional Wire Feed Module.
SA-250
B-5 B-5
OPERATION
CONTROLS AND SETTINGS

The welder/generator controls are located on the the case front. Welding output terminals and ground
Output Control Panel of the machine case front. Diesel stud are located on the machine left side, under the
engine idler control and start/stop controls are also on door. See Figure B.1, B.2 and B.3 and the explana-
tions that follow.
FIGURE B.1 – OUTPUT CONTROLS
1 2
3
6
4
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:
1. CURRENT RANGE SELECTOR: Selects ranges 4. 115 VOLT DUPLEX RECEPTACLE: Connection
of continuous current output for constant current point for supplying 115 volt power to operate one or
stick or TIG applications and constant voltage wire two electrical devices.
feed applications (with optional Wire Feed Module).
5. WELD OUTPUT TERMINAL (–) WITH FLANGE
See Control of Welding Current for more informa-
NUT: Provides the connection point for either the
tion.
electrode holder or the work cable.
2. FINE CURRENT ADJUSTMENT: Allows fine
6. WELD OUTPUT TERMINAL (+) WITH FLANGE
adjustment of current within the selected output
NUT: Provides the connection point for either the
range. See Control of Welding Current for more
electrode holder or the work cable.
information.
7. GROUND STUD: Provides a connection point for
3. 230 VOLT DUPLEX RECEPTACLE: Connection
connecting the machine case to earth ground for
point for supplying 230 volt power to operate one or

the safest grounding procedure.
two electrical devices.
SA-250
B-6 B-6
OPERATION
CONTROL OF WELDING CURRENT 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
CAUTION the CURRENT RANGE SELECTOR to the lowest set-
ting that still provides the current you need and set the
• DO NOT turn the CURRENT RANGE SELECTOR FINE CURRENT ADJUSTMENT near maximum. For
while welding because the current may arc between example: to obtain 175 amps and a soft arc, set the
the contacts and damage the switch. CURRENT RANGE SELECTOR to the 190 -120 posi-
tion and then adjust the FINE CURRENT ADJUST-
• DO NOT attempt to set the CURRENT RANGE MENT for 175 amps.
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
See Figure B.2. The CURRENT RANGE SELECTOR voltage. For example: to obtain 175 amps and a force-
provides five overlapping current ranges. The FINE ful arc, set the CURRENT RANGE SELECTOR to 240-
CURRENT ADJUSTMENT adjusts the current from 160 position and the FINE CURRENT ADJUSTMENT
minimum to maximum within each range. Open circuit setting to get 175 amps.
voltage is also controlled by the FINE CURRENT Some arc instability may be experienced with EXX10
ADJUSTMENT, permitting control of the arc character- electrodes when trying to operate with long arc tech-
istics. niques at settings at the lower end of the open circuit
voltage range.
FIGURE B.2 – CURRENT CONTROLS
CURRENT RANGE FINE CURRENT

190-120 SELECTION ADJUSTMENT
60 50
240-160 130-80
70 40
220 90 80 30
CURRENT MAX MIN

90 20 FINE
RANGE 100 10
CURRENT
SELECTOR ADJUSTMENT
ENGINE
IDLER IGNITION PROTECTION START
230 VOLT AC 115 VOLT AC REMOTE

CONTROL
SA-250
B-7 B-7
OPERATION
FIGURE B.3 – DIESEL ENGINE CONTROLS
8 240-160
190-120
CURRENT RANGE
SELECTION
130-80
FINE CURRENT
ADJUSTMENT
60 50 5
70 40
220 90 80 30
7
MAX MIN
90
10
20 4
100
6 IDLER IGNITION
ENGINE
PROTECTION START
1. IDLER CONTROL TOGGLE 230 VOLT AC 115 VOLT AC REMOTE

CONTROL
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:
1. IDLER CONTROL TOGGLE SWITCH: Adjusts the Press the START button to start the diesel engine.
running speed of the engine. The switch has two The IGNITION switch must be in the ON position.
positions, "HIGH" and "AUTO." In "HIGH," the The THERMOSTART button should be used for
engine runs continuously at high idle. In "AUTO," starting when air temperature ranges between
the idler control works as follows: 10°F (-12°C) and freezing.
Welding: The engine accelerates to high speed NOTE: If you press either START pushbutton when
when the electrode touches the work and strikes a the engine is running, you may damage the engine
welding arc. The engine returns to low idle approx- flywheel gear or starter motor.
imately 15 seconds after welding stops, as long as 5. ENGINE HOUR METER: Records engine running
no auxiliary power is being drawn. time. Use the meter to determine when to
Auxiliary Power: The engine accelerates to high perform required maintenance.
speed when power is drawn at the receptacles for 6. OIL PRESSURE GAUGE: Indicates engine oil
lights or tools. The engine returns to low idle pressure. If no oil pressure shows on the gauge
approximately 15 seconds after demand for within 30 seconds after startup, the engine should
auxiliary power stops. be stopped by placing the IGNITION switch in the
2. IGNITION CONTROL TOGGLE SWITCH: Has OFF position.
two positions, ON and OFF. When the switch is in 7. AMMETER: Shows whether the charging circuit
the ON position, the diesel engine can be started is performing its job of charging the battery when
by pressing the START pushbutton. When the the engine is running. The meter will register
switch is placed in the OFF position, the engine discharge during starting, but then the needle
stops. should return to a position slightly toward positive
3. RESET BUTTON: Resets engine protection circuit. during running. The needle will hold position in the
Press this button before starting the diesel engine. center when the engine stops.
8. WATER TEMPERATURE GAUGE: Indicates tem-
perature of engine coolant.
SA-250
B-8 B-8
OPERATION
ENGINE OPERATION Check and fill the engine fuel tank:
WARNING WARNING
DO NOT RUN THE ENGINE AT EXCESSIVE Do not add fuel near an open flame,
SPEEDS. The maximum allowable high idle speed for welding arc or when the engine is run-
the SA-250 is 1800 RPM, no load. Do NOT increase ning. Stop the engine and allow it to
the idle speed on the engine. Severe personal injury cool before refueling to prevent spilled
and damage to the machine can result if it is operated fuel from vaporizing on contact with
at speeds above the maximum rated speed. 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-
Read and understand all safety instructions included in nated.
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)

BEFORE STARTING THE ENGINE of tank space for fuel expansion. DO NOT FILL
THE TANK TO THE POINT OF OVERFLOW.
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.
2. Remove the engine oil dipstick and wipe it with a NOTE: USE DIESEL FUEL ONLY. Purchase diesel
clean cloth. Reinsert the dipstick and check the fuel in quantities that will be used within 30 days, to
level on the dipstick. See Figure D.1 in the assure freshness.
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
4. Replace the dipstick. NOTE: Remove all loads connected to the AC power
receptacles before starting the diesel engine.
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
B-9 B-9
OPERATION
STOPPING THE ENGINE COLD WEATHER STARTING

1. Remove all welding and generator power loads When temperatures are between 10oF (-12oC) and
and let the engine cool by running it for several freezing, use the standard Thermostart feature. Follow
minutes at low idle. the instructions on the nameplate and in the engine
manual shipped with the welder. With a fully charged
2. Place the IGNITION switch in the OFF position.
battery and the proper weight oil, the engine should
start satisfactorily even when the air temperature is
down to about 0oF (-18°C).
When an engine is started for the first time, some of the
oil will be needed to fill the passages of the lubricating If the engine is frequently started below 10oF (-12°C),
system. Therefore, on initial starting, run the engine for you may want to remove the “Thermostart” and install
about five minutes and then stop the engine and the optional ether starter kit. Installation and operating
recheck the oil. If the level is down, fill to the full mark instructions are included in the kit. Use ether starting
again. 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

At the end of each day’s welding, drain accumulated
cold weather performance. Consult the engine manu-
dirt and water from the sediment bowl under the fuel
al and the Maintenance section of this manual.
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 BREAK-IN PERIOD
fuel system. Check the crankcase oil level. Any engine will use a small amount of oil during its
In diesel engines, if the fuel supply is cut off or runs out break-in period. For the diesel engine on the SA-250,
while the fuel pump is operating, air may be entrapped break-in is about 200 running hours.
in the fuel distribution system. See “How to Eliminate Check the oil twice a day during break-in. Change the
Air From the Fuel System” in the Maintenance section. 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
B-10 B-10
OPERATION
WELDING OPERATION
TO USE THE SA-250 FOR DC CONSTANT

CURRENT STICK OR TIG WELDING:
1. Remove the flange nuts from the weld output ter- After you finish welding:
minals and place the work and electrode welding 1. Stop the engine. See Engine Operation in this
cables over the terminals. See Figure B.4. section of the manual.
Replace and tighten the flange nuts securely. Be
2. Allow the electrode and work to cool completely.
sure the connections are tight.
3. Remove the work clamp from the work.
2. Select the appropriate electrode.
4. Remove any remaining piece of electrode from the
3. Attach the work clamp securely to the work you are
electrode holder.
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
6
5 4 3
2
SA-250
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
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 Appropriate Current Range

(inches/minute)
.035 80-110 75 to 120 Amps
.045 70-130 120 to 170 Amps

.068 40-90 125 to 210 Amps
SA-250
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 1. Start the diesel engine. See Engine Operation in
generator AC power receptacles can withstand a ±10% this section of the manual.
voltage and a ±3% frequency variation.
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
The AC auxiliary power, supplied as a standard, has a volt power receptacle.
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
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
C-2 C-2
ACCESSORIES
OPTIONS/ACCESSORIES Wire Feed Module - (K623-1) - Provides constant

voltage output for semiautomatic welding. Includes
The following options/accessories are available for remote for CV mode and internal “Cold Tip Contactor.”
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 • Electrode cable
available. For highway use, consult applicable federal, • Work cable
state, and local laws.
• Headshield
Power Plug Kit (K802-C) - Provides a plug for each • Work clamp
auxiliary receptacle. • Insulated electrode holder
Ether Start Kit (K793-1) - Automatic ether start kit pro- Remote Control - (K924-1) - Includes a receptacle
vides cold weather starting assistance in temperatures switch and control box with 100 ft. (7.5 meters) of 4-
below 10oF (-12.2oC). Requires an ether tank that must conductor cable. Allows fine current and OCV to be
be purchased locally. “Thermostart” system must be

controlled remotely.
removed.
GFCI Receptacle Kit (K896-2) - Includes a UL
NOTE: Ether starting can contribute to shortened approved 115 volt ground fault circuit interrupter recep-
engine life. Avoid unnecessary or indiscriminate use. tacle (duplex type) with covers and installation instruc-
tions. Each half of the receptacle is rated 15 amps, but
Linc Thaw™ Control Unit (L2964-5) - Includes meter the maximum total current from the GFCI duplex is lim-
and fuses to protect the welder when thawing frozen ited to 20 amps. The GFCI receptacle replaces the
water pipes. factory installed 115 volt duplex receptacle.
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
C-3 C-3
ACCESSORIES
TIG WELDING ACCESSORIES SEMIAUTOMATIC WELDING ACCESSORIES

TIG Module (K930-1) - The TIG Module is an acces- LN-25 Wire Feeder - This portable wire feeder is capa-
sory that provides high frequency and shielding gas ble of CC/CV wire feed welding.
control for DC GTAW (TIG) welding applications.
LN-7 Wire Feeder - Semiautomatic, constant speed
The K930-1 TIG Module is supplied without acces- wire feeder. For CV operation only.
sories. Arc Start switches, Amptrols, cables, torches
NOTE: Gas-shielded welding requires a Magnum Gun.
and mounting brackets must be purchased separately.
Gasless welding requires an Innershield Gun.
Control Cable (K936-4) - Control cable for connecting
Magnum Spool Gun (K487-25) - A lightweight, semi-
the K930-1 TIG Module to an SA-250.
automatic wire feeder for aluminum welding with argon
Arc Start Switch (K814) - Remote start switch for TIG gas. Has built-in remote wire speed control in the han-
module (K930-1). dle. Requires the K488 SG Control Module with appro-
priate control cable. Includes 25 feet (7.6 meters) of
NOTE: TIG welding requires a Magnum™ TIG Gun,
power cable.
appropriate Magnum Parts Kit and argon gas.
SA-250
C-4 C-4
ACCESSORIES
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

CONNECTION OF THE LN-7 TO THE 4. Connect the K291 or K404 input cable to the LN-7.
SA-250 WITH K623-1 WIRE FEED MODULE USING 5. Place the IDLER switch in the “HIGH” position.
K867 UNIVERSAL ADAPTER (SEE FIGURE C.1.)
1. Shut the welder off. CAUTION
2. Connect the electrode cable from the LN-7 to the Any increase of the high idle engine RPM by changing
“+” terminal of the welder. Connect the work the governor setting or overriding the throttle linkage
cable to the “CV–” terminal of the welder. will cause an increase in the AC auxiliary voltage. If
NOTE: Welding cable must be sized for current and this voltage goes over 140 volts, wire feeder control
duty cycle of application. circuits may be damaged. The engine governor set-
ting is preset at the factory — do not adjust above
NOTE: Figure C.1 shows the electrode connected for RPM specifications listed in this manual.
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 NOTE: For remote control, a K775 remote control is
K404 input cable and the 14 pin amphenol of the required. See Figure C.1.
SA-250 as indicated in Figure C.1. Make the prop-
er connections for local or remote control accord-
ing to 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
14 PIN 82 Insulate Each LN-7
AMPHENOL 81 Unused Lead CONTROL
42 Individually BOX
41
31 31
+ 32 32
2 2
CV- 4 4
21 21 K291 OR K404
GND GND INPUT CABLE
TO GREEN
K867 UNIVERSAL
WORK 75 75
ADAPTER PLUG
76 76
ELECTRODE CABLE 77 77
TO LN-7 K775 OPTIONAL
Splice Leads REMOTE CONTROL
and Insulate
SA-250
C-5 C-5
ACCESSORIES
CONNECTION OF THE LN-7 TO THE

SA-250 WITH K623-1 WIRE FEED MODULE USING CAUTION
K584 INPUT CABLE ASSEMBLY (SEE FIGURE C.2.) Any increase of the high idle engine RPM by changing
1. Shut the welder off. the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
2. Connect the electrode cable from the LN-7 to the this voltage goes over 140 volts, wire feeder control
“+” terminal of the welder. Connect the work cable circuits may be damaged. The engine governor set-
to the “CV-” terminal of the welder. ting is preset at the factory — do not adjust above
NOTE: Welding cable must be sized for current and RPM specifications listed in this manual.
duty cycle of application.
NOTE: Figure C.2 shows the electrode connected for 6. Adjust wire feed speed at the LN-7.
off and reverse the electrode and work cables at the NOTE: For remote control, a K857 control is required.
SA-250 output terminals. 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 CAUTION
K864 adapter and the input cable plug on the LN-
7. 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
14 PIN CONTROL
AMPHENOL BOX
14 PIN
AMPHENOL
K584-"L" INPUT CABLE
+
CV- 6 PIN
K864 AMPHENOL
ADAPTER
TO K857
WORK REMOTE CONTROL
ELECTRODE CABLE
TO LN-7
SA-250
C-6 C-6
ACCESSORIES
CONNECTION OF THE LN-25 TO THE 4. Connect the K432-L cable to the LN-25 equipped
SA-250 WITH K623-1 WIRE FEED MODULE USING with the K431-1 remote output control kit.
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 CAUTION
to the “CV-” terminal of the welder.
Any increase of the high idle engine RPM by changing
NOTE: Welding cable must be sized for current and the governor setting or overriding the throttle linkage
duty cycle of application. will cause an increase in the AC auxiliary voltage. If
NOTE: Figure C.3 shows the electrode connected for this voltage goes over 140 volts, wire feeder control
positive polarity. To change polarity, shut the welder circuits may be damaged. The engine governor set-
off and reverse the electrode and work cables at the ting is preset at the factory — do not adjust above
SA-250 output terminals. Reverse the LN-25 polarity RPM specifications listed in this manual.
switch.
3. Connect the K867 Universal adapter to the K433 6. Adjust wire feed speed and voltage at the LN-25.
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.
FIGURE C.3
SA-250/LN-25 CONNECTION DIAGRAM
SPARE
14 PIN 82 Insulate Each
AMPHENOL 81
42
Unused Lead
41 Individually K433
21
+ 31 31
32 32 K432-"L" CABLE
CV- 2 2
4 4
GND GND
K867 UNIVERSAL
ADAPTER PLUG 75 75
76 76
TO LN-25 WIRE FEEDER
WORK 77 77
WITH K431 OPTION
Splice Leads and Insulate
ELECTRODE CABLE
SA-250
C-7 C-7
ACCESSORIES
CONNECTION OF THE LN-25 TO THE 3. Connect the K444-2 remote control cable to the 14
SA-250 “ACROSS THE ARC” pin amphenol on the wire feed module.
(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
1. Shut the welder off. lead. This is only a control lead — it carries no
2. Connect the electrode cable from the LN-25 to the welding current.
“+” terminal of the welder. Connect the work cable 5. Place the IDLER switch in the “HIGH” position.
to the “CV–” terminal of the welder.
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
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
CV- VOLTAGECONTROL OPTION
ELECTRODE CABLE
TO WORK CLIP
WORK LEAD TO WORK
SA-250
C-8 C-8
ACCESSORIES
CONNECTION OF THE K488 SG CONTROL 6. Place the IDLER switch on the SA-250 in the
MODULE AND K487 MAGNUM SPOOL GUN “HIGH” position.
TO THE SA-250 (SEE FIGURE C.5.)
CAUTION
1. Shut the welder off.
2. Connect the electrode cable from the SG Control Any increase of the high idle engine RPM by changing
Module to the “+” terminal of the welder. Connect the governor setting or overriding the throttle linkage
the work cable to the “CV–” terminal of the welder. will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
NOTE: Welding cable must be sized for current circuits may be damaged. The engine governor set-
and duty cycle of application. ting is preset at the factory — do not adjust above
NOTE: Figure C.5 shows the electrode connected RPM specifications listed in this manual.
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.
3. Connect the K867 Universal adapter to the K492 NOTE: For remote control, a K775 remote control is
input cable as shown in Figure C.5. Connect the required.
other end of the adapter to the 14 pin amphenol on
the SA-250.
4. Connect the K492 Input Cable to the SG Control CAUTION
Module.
5. Set the slide switch on the SG Control Module to When the welder is in local control, the electrode is
the “Lincoln” position. always “HOT.”
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
14 PIN 82 Insulate Each
81 K488 SG
AMPHENOL Unused Lead CONTROL
42 K487-25
Individually MODULE SPOOL
41
21 GUN
+ 31 31
32 32
CV- 2 2 K492
4 4 INPUT CABLE
GND GND
TO GREEN
K867 UNIVERSAL
WORK 75 75
ADAPTER PLUG
76 76
ELECTRODE CABLE TO 77 77
K438 SG CONTROL CABLE K775 OPTIONAL
Splice Leads REMOTE CONTROL
and Insulate
SA-250
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
D-2 D-2
MAINTENANCE
SAFETY PRECAUTIONS ROUTINE AND PERIODIC

MAINTENANCE
WARNING 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
• Remove covers or guards only when necessary to engine.
perform maintenance and replace them when the
maintenance requiring their removal is complete.
• If covers or guards are missing from the machine, See Table D.1 for a summary of maintenance intervals
get replacements from a Lincoln Distributor. 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-

Read the Safety Precautions in the front of this manu- cific application and operating conditions.
al and in the instruction manual for the diesel engine OIL: Check the oil level after every 8
used with your machine before working on the SA-250. hours of operation or daily. BE SURE
Keep all equipment safety guards, covers, and devices TO MAINTAIN THE OIL LEVEL.
in position and in good repair. Keep your hands, hair, Change the oil the first time between 25 and 50 hours
clothing, and tools away from the recoil housing, fans, of operation. Then, under normal operating conditions,
and all other moving parts when starting, operating, or change the oil as specified in Table D.1. If the engine is
repairing this machine. 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
D-3 D-3
MAINTENANCE
FIGURE D.1 – OIL DRAIN AND REFILL
1
CHANGE THE OIL FILTER: Change the oil filter the 5. Refill the engine with the proper amount and type
first time between 25 and 50 hours of operation. Then, of oil as described in the Change the Oil section,
under normal operating conditions, change the oil filter above. Start the engine and check for leaks
after every 200 to 250 hours of operation. If the engine around the filter element. Correct any leaks (usu-
is operated under heavy load or in high ambient tem- ally by retightening the filter, but only enough to
peratures, change the oil filter more frequently. See stop leaks) before placing the SA-250 back in ser-
Table D.1 for recommended maintenance intervals. vice.
Order Perkins oil filter #2654408 from your local
6. See Figure D.1. If there are no leaks, stop the
Perkins service center.
engine and recheck the oil level. If necessary, add
Change the oil filter as follows: oil to bring the level up to the “MAX” mark, but do
not overfill.
1 . See Figure D.1. Remove the oil drain plug (1).
Drain the oil from the engine and allow the oil filter FUEL: At the end of each day's use, refill
to drain. the fuel tank to minimize moisture conden-
sation and dirt contamination in the fuel
2. See Figure D.1. Remove the old filter (spin it off)
line. Do not overfill; leave room for the fuel
and discard it (2). Wipe off the filter mounting sur-
to expand.
face and adapter.
Refer to your engine operation manual for recom-
3. Fill the new filter with fresh engine oil. Apply a thin
mended grade of fuel.
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
D-4 D-4
MAINTENANCE
FUEL FILTER: Inspect the fuel filter daily. Drain any AIR CLEANER: The Perkins diesel engine is equipped
accumulated water from the engine fuel filter/water with a dry type air filter. Inspect the air cleaner daily -
separator daily. Change the fuel filter every 400 hours more often in dusty conditions. Never apply oil to the
of operation. Dust and dirt in the fuel system can air cleaner. Service the air cleaner as follows:
cause the injection pump and injection nozzle to wear
1. Remove the dust cup from the bottom of the air
quickly. Change the fuel filter as follows:
cleaner housing. Clean out any accumulated dust.
1. See Figure D.2. Clean the outside surfaces of the
2. Loosen the wing nut and remove the filter element.
fuel filter assembly. If a drain tap (1) is fitted to the
filter bowl, drain the fuel from the filter. 3. If dust is sticking to the dust collector element, blow
compressed air through it from the inside out.
2. See Figure D.2. Hold the bottom cover of the filter
Turn the element as you apply air. Air pressure
element and release the setscrew (2) which is fitted
should be under 686 kPa (7 kgf/cm2, 99 psi).
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
3. See Figure D.2. Lower the bottom cover (3) of the
appears damaged. Order Donaldson element part
filter.
number P10-1275.
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
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 1. See Figure D.3. Loosen the banjo connection bolt
system according to the type of pump fitted: which is fitted on the top of the filter (1).
See Figure D.3. The standard method is used where 2. See Figure D.3. Operate the priming lever on the
the fuel injection pump has vent screws 4 and 5. fuel lift pump (2) until fuel, free from air, comes from
the filter vent point. Tighten the banjo connection
The self-vent method is used where the fuel injection
bolt. If the drive cam of the fuel lift pump is at the
pump has a self-vent feature. Vent screws are not fit-
point of maximum cam lift, it will not be possible to
ted to these pumps. No connections or plugs need to
operate the priming lever. In this situation, the
be released to eliminate air from the fuel system.
crankshaft must be turned one revolution.
If air enters the fuel system, it must be eliminated
3. See Figure D.3. Where the fuel filter is fitted lower
before the engine can be started.
than the fuel injection pump, loosen the inlet con-
Air can enter the system if: nection at the fuel injection pump (3) and operate
the lift pump to remove any air. Tighten the inlet
• The fuel tank is drained during normal operation.
connection.
• The low-pressure fuel pipes are disconnected.

4. Ensure that the manual stop control is in the “run”
• A part of the low-pressure fuel system leaks during position. If an electrical stop control is used, turn
engine operation. the start key to the “R” position.
In order to eliminate air from the fuel system, proceed 5. See Figure D.3. Loosen the vent screw in the lock
as follows: 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

3
5
4
2
SA-250
D-6 D-6
MAINTENANCE
7. See Figure D.4. Loosen the union nut (1) at the 1. If a manual stop control is fitted, ensure that it is in
fuelled starting aid (if one is fitted) and operate the the “run” position.
lift pump until fuel, free from air, comes from the
2. Operate the starter motor until the engine starts.
connection. Tighten the union nut at the starting
aid. 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 1. Turn the start key to the “R” position. If a manual
the starter motor until fuel, free from air, comes from stop control is fitted, ensure that it is in the “run”
the pipe connections. Tighten the high-pressure position.
pipe connections.
2. Operate the lever of the fuel lift pump slowly for
9. The engine is now ready to start. If the engine runs approximately two minutes. If the drive cam of the
correctly for a short time and then stops or runs fuel lift pump is at the point of maximum cam lift, it
roughly, check for air in the fuel system. If there is will not be possible to operate the priming lever. In
air in the fuel system, there is probably a leakage in this situation, the crankshaft must be turned one
the low pressure system. revolution.
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 the engine has been stopped by air in the fuel sys-
If there is air in the fuel system, there is probably a
tem:
leakage in the low pressure system.
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
D-7 D-7
MAINTENANCE
COOLING SYSTEM: The Perkins diesel engine is 2. Remove the radiator filler cap.
water cooled. Check the coolant level at the radiator
3. Remove the drain plug from the side of the cylinder
filler daily. Add a 50-50 mixture of water and antifreeze
block in order to drain the engine. Ensure that the
as needed. To drain and refill the system, do the fol-
drain hole is not restricted. See Figure D.5.
lowing:
4. Open the radiator drain cock at the bottom of the
1. Ensure that the machine is on level ground.
radiator in order to drain the radiator.
5. If necessary, flush the system with clean water.
WARNING
6. Fit the engine drain plug and the radiator drain cock.
To avoid personal injury, never remove the radiator
7. Fill the cooling system at the radiator filler with a 50-
pressure cap nor the reserve tank cap while the engine
50 mixture of water and antifreeze.
is running or immediately after it has stopped. Hot
water may gush out, which can scald people nearby.
FIGURE D.5 – ENGINE COOLANT DRAIN PLUG

SA-250
D-8 D-8
MAINTENANCE
TIGHTENING THE FAN BELT: Fan belts tend to 2. Change the position of the alternator to give the cor-
loosen after the first 50 hours of operation. If the fan rect tension. Tighten the pivot fasteners of the alter-
belts are loose, the engine can overheat and the bat- nator and the adjustment link fasteners.
tery can lose its charge. Check belt tightness by press-
3. Check the belt tension again to ensure that it is still
ing on the belt midway between the pulleys. The belt
correct.
should deflect no more than 10 mm (0.375 in.). See
Figure D.6. 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
2
SA-250
D-9 D-9
MAINTENANCE
TABLE D.1
PERKINS ENGINE MAINTENANCE SCHEDULE
FREQUENCY MAINTENANCE REQUIRED
Daily or Before • Fill fuel tank.

Starting Engine • 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 • Check drive belts.

Hours • 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
D-10 D-10
MAINTENANCE
BATTERY MAINTENANCE CHECKING SPECIFIC GRAVITY

Check each battery cell with a hydrometer. A fully
charged battery will have a specific gravity of 1.260.
WARNING Charge the battery if the reading is below 1.215.
NOTE: Correct the specific gravity reading by adding
GASES FROM BATTERY can explode. four gravity points (0.004) for every five degrees the
• Keep sparks, flame, and cigarettes away electrolyte temperature is above 80 degrees F (27
from battery. degrees (C). Subtract four gravity points (.004) for
every five degrees the electrolyte temperature is below
80 degrees F (27 degrees C).
BATTERY ACID can burn eyes and skin.
• Wear gloves and eye protection and be CHECKING ELECTROLYTE LEVEL
careful when working near a battery.
Follow the instructions printed on the If battery cells are low, fill them to the neck of the filler
battery. 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 CHARGING THE BATTERY
to the new battery last. The SA-250 is equipped with a wet charged battery.
• THE CORRECT POLARITY IS NEGATIVE The charging current is automatically regulated when
GROUND - Damage to the engine alternator and the battery is low (after starting the engine) to a trickle
the printed circuit board can result from incorrect current when the battery is fully charged.
connection. When you charge, jump, replace, or otherwise connect
• CONNECTING A BATTERY CHARGER - battery cables to the battery, be sure the polarity is cor-
Remove the battery from the welder by rect. Improper polarity can damage the charging cir-
disconnecting the negative cable first, cuit. The SA-250 charging system is NEGATIVE
then the positive cable and battery GROUND. The positive (+) battery terminal has a red
clamp. When reinstalling, connect the terminal cover.
negative cable last. Keep the area well If you need to charge the battery with an external
ventilated.
charger, disconnect the negative cable first, then the

• USING A BOOSTER - Connect the positive lead to positive cable before you attach the charger leads.
the battery first, then connect the negative lead to the After the battery is charged, reconnect the positive bat-
engine foot. tery cable first and the negative cable last. Failure to
• To prevent BATTERY BUCKLING, tighten the nuts do so can result in damage to the internal charger com-
on the battery clamp until snug. ponents.
Follow the instructions of the battery charger manufac-
CLEANING THE BATTERY turer for proper charger settings and charging time.
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
D-11 D-11
MAINTENANCE
WELDER/GENERATOR Replace brushes when they wear within 1/4" of the pig-
tail. A complete set of replacement brushes should be
MAINTENANCE kept on hand. Lincoln brushes have a curved face to
STORAGE: Store the SA-250 in clean, dry, protected fit the commutator. Have experienced maintenance
areas. personnel seat these brushes by lightly stoning the
commutator as the armature rotates at full speed until
CLEANING: Blow out the generator and controls peri- contact is made across the full face of the brushes.
odically with low pressure air. Do this at least once a After stoning, blow out the dust with low pressure air.
week in particularly dirty areas.
NAMEPLATES: Whenever routine maintenance is WARNING
performed on this machine - or at least yearly - inspect
all nameplates and labels for legibility. Replace those Uncovered rotating equipment can be dangerous. Use
which are no longer clear. Refer to the parts list for the care so your hands, hair, clothing or tools do not catch
replacement item number. in the rotating parts. Protect yourself from particles
ALTERNATOR BRUSH REMOVAL AND REPLACE- that may be thrown out by the rotating armature when
MENT: It's normal for the brushes and slip rings to stoning the commutator.
wear and darken slightly. Inspect the brushes when a

generator overhaul is necessary. Remove the brushes Arcing or excessive exciter brush wear indicates a pos-
and clean the slip rings with fine emery paper. To seat sible misaligned shaft. Have an authorized Lincoln
new slip ring brushes, position the brushes in place. Electric Field Service facility check and realign the
Then slide one end of a piece of fine sandpaper shaft.
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres- BEARINGS: The SA-250 is equipped with double-
sure on top of the brushes, pull the sandpaper around shielded ball bearings having sufficient grease to last
the circumference of the rings - in the direction of rota- indefinitely under normal service. Where the welder is
tion only - until brushes seat property. Brushes must used constantly or in excessively dirty locations, it may
be seated 100%. be necessary to add one half ounce of grease per year.
A pad of grease one inch wide, one inch long, and one
COMMUTATOR AND BRUSHES: The generator inch high weighs approximately one half ounce. Over-
brushes are properly adjusted when the welder is greasing is far worse than insufficient greasing.
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
CAUTION equipment. More bearing failures are caused by dirt

introduced during greasing than from insufficient
DO NOT SHIFT THE BRUSHES or adjust the rocker grease.
setting.
CURRENT RANGE SELECTOR CONTACTS: The
Shifting of the brushes may result in: contacts should not be greased. To keep the contacts
• Change in machine output clean, rotate the current control handle through its
• Commutator damage entire range frequently. Good practice is to turn the
• Excessive brush wear handle from maximum to minimum setting twice each
morning before starting to weld. Never rotate the han-
dle while machine is under load.
Put a drop of oil on the CURRENT RANGE SELEC-
Periodically inspect the commutator, slip rings, and
TOR shaft at least once every month.
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
Commutators and brushes require little attention.
from their surfaces and holes.
However, if they are black or appear uneven, have

them cleaned by experienced maintenance personnel CABLE CONNECTIONS: Check the welding cable
using a commutator stone. Never use emery cloth or connections at the weld output terminals often. Be
paper for this purpose. sure that the connections are always tight.
SA-250
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
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 12
11. CASE TOP 11
12. CASE BACK WITH RADIATOR
13. COOLING FAN
14. AIR CLEANER
15. IDLER CONTROL
10 15
13
14
7
5
6
3
2
1
SA250-11
SA-250
D-14
SA-250
NOTES
D-14
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
IDLER RELAY
BOARD CR2 NEGATIVE
OUTPUT
TERMINAL
115 & 230VAC

RECEPTACLES
IDLER
SOLENOID
OIL GENERATOR
TEMPERATURE PRESSURE
GAUGE SWITCH FRAME
FUEL SERIES CURRENT
INJECTION
PUMP COILS TRANSFORMER
ALTERNATOR STATOR
COMMUTATOR
BRUSHES
ENGINE MECHANICAL
GENERATOR ARMATURE ROTOR
&
COUPLING SHAFT
IGNITION ARMATURE
SWITCH ENGINE
ALTERNATOR SLIP
RINGS
INTERPOLE
COILS RESIDUAL
STARTER
MAGNETISM FLASHING
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
BATTERY RECTIFIER
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
FIGURE E.1 – SA-250 BLOCK LOGIC DIAGRAM
SA-250
E-2 E-2
THEORY OF OPERATION
FIGURE E.2 – BATTERY, STARTER, ENGINE ALTERNATOR, AND PROTECTION CIRCUITS
PROTECTION
RELAY SELECTOR
SWITCH
REED
IDLER RELAY
BOARD CR2 NEGATIVE
OUTPUT
TERMINAL
115 & 230VAC

RECEPTACLES
IDLER
SOLENOID
OIL
PRESSURE
GENERATOR
TEMPERATURE
GAUGE SWITCH FRAME

FUEL SERIES CURRENT
INJECTION
ALTERNATOR STATOR
COMMUTATOR
BRUSHES
ENGINE MECHANICAL
&
COUPLING SHAFT
IGNITION ARMATURE
SWITCH ENGINE
ALTERNATOR SLIP
RINGS
INTERPOLE
COILS RESIDUAL
STARTER
MAGNETISM FLASHING
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
BATTERY RECTIFIER
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
GENERAL DESCRIPTION BATTERY, STARTER, ENGINE

The SA-250 is a heavy duty, engine driven DC arc ALTERNATOR, AND PROTECTION
welding power source capable of providing constant CIRCUITS
current output for stick welding or DC TIG welding.
Also, a total of 3000 watts of auxiliary power is available The 12VDC battery powers the starter motor and,
at the 115 or 230VAC receptacles. 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
E-3 E-3
THEORY OF OPERATION
FIGURE E.3 – ENGINE GENERATOR ARMATURE AND FRAME, ALTERNATOR STATOR AND ROTOR
PROTECTION
RELAY SELECTOR
SWITCH
REED
IDLER RELAY
BOARD CR2 NEGATIVE
OUTPUT
TERMINAL
115 & 230VAC

RECEPTACLES
IDLER
SOLENOID
OIL
PRESSURE
GENERATOR
TEMPERATURE
GAUGE SWITCH FRAME

FUEL SERIES CURRENT
INJECTION
ALTERNATOR STATOR
COMMUTATOR
BRUSHES
ENGINE MECHANICAL
&
COUPLING SHAFT
IGNITION ARMATURE
SWITCH ENGINE
ALTERNATOR SLIP
RINGS
INTERPOLE
COILS RESIDUAL
STARTER
MAGNETISM FLASHING
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
BATTERY RECTIFIER
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
ENGINE, GENERATOR ARMATURE AUXILIARY AND FIELD FEEDBACK COILS

AND FRAME, ALTERNATOR There are two isolated windings incorporated in the sta-
STATOR AND ROTOR tor lamination assembly. One of these windings is
tapped and provides 115VAC and 230VAC of auxiliary
EXCITATION (FLASHING) power to the appropriate receptacles. The other
115VAC isolated winding is rectified to a DC voltage
When the engine is started and running, the residual and is used to supply field feedback voltage to the rotor.
magnetism voltage is applied to the alternator rotor via It also, through the generator field rheostat control, sup-
a brush and slip ring configuration. This excitation plies voltage to the field shunt windings in the main
(“flashing”) voltage magnetizes the rotor lamination. generator frame.
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
E-4 E-4
THEORY OF OPERATION
INTERPOLE AND SERIES COILS FINE CURRENT ADJUSTMENT

The generator armature rotates within the magnetic The field rheostat control functions as a fine output cur-
field created by the field shunt windings. A DC voltage rent adjustment by controlling the current through the
is induced in the armature and is transferred, through shunt windings. In this way it controls the amount of
the armature commutator and brushes, to the series magnetism created in the field shunt windings. Open
and interpole coils. The interpole coils, which are con- circuit weld voltage can also be controlled by the field
nected in series with the positive output terminal, are rheostat control.
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 ENGINE IDLER CIRCUIT
“buck” the DC voltage that is generated in the arma-
ture. 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-
CURRENT RANGE SELECTOR nals the idler PC board to release (deactivate) the idler
solenoid, which then lets the machine go to a high
The selector switch acts as a coarse current adjust- speed condition. Also, when auxiliary power is being
ment by allowing for varying amounts of series wind- used, the current is passed through the current trans-
ings to be included in the welding current path. The former, which signals the idler PC board to release the
series coils and selector switch are connected in series idler solenoid.
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
E-5 E-5
THEORY OF OPERATION
FIGURE E.4 – DC GENERATOR MACHINES
C
F U
I R
E R
L E
D N
T
SHUNT FIELD WINDINGS
DC CURRENT
MAGNETIC FIELD
GENERATOR BRUSH
ARMATURE
MECHANICAL
COUPLING SHAFT
ARMATURE BRUSH
MAGNETIC FIELD DC CURRENT
SHUNT FIELD WINDINGS
C
F U
I R
E R
L E
D N
T
DC GENERATOR MACHINES winding induces a coil voltage in the armature winding.

The voltage induced in an individual armature coil is an
The armature winding of a DC generator is located on alternating (AC) voltage, which must be rectified. In a
the rotating member. Current is conducted from it by conventional DC Generator, rectification is provided
means of carbon brushes. The field winding is located mechanically by means of a commutator. A commuta-
in the stator, which is stationary, and is excited by direct tor is a cylinder formed of copper segments insulated
current. from each other and mounted on, but insulated from,
The armature coil sides are placed at opposite points the rotating shaft. Stationary carbon brushes held
on the rotating shaft with the conductors parallel to the against the commutator surface connect the armature
shaft. The armature assembly is normally turned at a windings to external terminals. The commutator pro-
constant speed by a source of mechanical power con- vides full-wave rectification, transforming the voltage
nected to the shaft. Rotation of the armature through waveform between brushes and making available a DC
the magnetic field produced by the stationary field voltage to the external circuit.
SA-250
E-6
SA-250
NOTES
E-6
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
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 Step 3. PERFORM COMPONENT TESTS. The
you locate and repair possible machine malfunc- last column, labeled “Recommended Course of
tions. Simply follow the three-step procedure list- Action” lists the most likely components that may
ed below. 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
Step 1. LOCATE PROBLEM (SYMPTOM). Look a number of possible components, check the
under the column labeled “PROBLEM” (SYMP- components in the order listed to eliminate one
TOMS). This column describes possible symp- possibility at a time until you locate the cause of
toms that the machine may exhibit. Find the list- your problem.
ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into four main categories: Output Problems, All of the referenced test procedures referred to in
Function Problems, Engine Problems and the Troubleshooting Guide are described in detail
Welding Problems. at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
Step 2. PERFORM EXTERNAL TESTS. The referred to test points, components, terminal
second column, labeled “POSSIBLE AREAS OF strips, etc., can be found on the referenced elec-
MISADJUSTMENT(S)”, lists the obvious external trical wiring diagrams and schematics. Refer to
possibilities that may contribute to the machine the Electrical Diagrams Section Table of Contents
symptom. Perform these tests/checks in the to locate the appropriate diagram.
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
F-3 F-3
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
• Remove the PC Board from the static-shielding bag
ELECTRIC SHOCK can kill. and place it directly into the equipment. Don’t set the
PC Board on or near paper, plastic or cloth which
Have an electrician install and service could have a static charge. If the PC Board can’t be
this equipment. Turn the machine OFF installed immediately, put it back in the static-shielding
before working on equipment. Do not bag.
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 • If you return a PC Board to The Lincoln Electric
board failures. These problems can sometimes be Company for credit, it must be in the static-shielding
traced to poor electrical connections. To avoid prob- bag. This will prevent further damage and allow prop-
lems when troubleshooting and replacing PC boards,
er failure analysis.
please use the following procedure:
4. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
1. Determine to the best of your technical ability that board.
the PC board is the most likely component causing NOTE: Allow the machine to heat up so that all electri-
the failure symptom. cal components can reach their operating temperature.
2. Check for loose connections at the PC board to 5. Remove the replacement PC board and substitute
assure that the PC board is properly connected. it with the original PC board to recreate the original
3. If the problem persists, replace the suspect PC problem.
board using standard practices to avoid static elec- a. If the original problem does not reappear
trical damage and electrical shock. Read the warn- by substituting the original board, then the
ing inside the static resistant bag and perform the PC board was not the problem. Continue
following procedures: to look for bad connections in the control
PC Board can be damaged by wiring harness, junction blocks, and termi-
static electricity. nal strips.
• Remove your body’s static charge b. If the original problem is recreated by the
before opening the static-shield- substitution of the original board, then the
ing bag. Wear an anti-static wrist PC board was the problem. Reinstall the
strap. For safety, use a 1 Meg replacement PC board and test the
ATTENTION
Static-Sensitive ohm resistive cord connected to a machine.
Devices grounded part of the equipment 6. Always indicate that this procedure was followed
Handle only at frame. when warranty reports are to be submitted.
Static-Safe
Workstations • If you don’t have a wrist strap, NOTE: Following this procedure and writing on the
touch an unpainted, grounded, warranty report, “INSTALLED AND SWITCHED PC
part of the equipment frame. BOARDS TO VERIFY PROBLEM,” will help avoid
Reusable Keep touching the frame to pre- denial of legitimate PC board warranty claims.
Container vent static build-up. Be sure not
Do Not Destroy to touch any electrically live parts
at the same time.
• Tools which come in contact with the PC Board must
be either conductive, anti-static or static-dissipative.
SA-250
F-4 F-4
Observe Safety Guidelines TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.
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 on the inside of the front control associated leads connected
low, welder output voltage. There panel. between the generator brushes
is no AC auxiliary output voltage. and the exciter alternator brush-
2. If the welder output is zero volts,
es.
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
F-5 F-5
TROUBLESHOOTING GUIDE Observe Safety Guidelines

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 brushes in the welding genera- Adjustment rheostat for resis-
low, welder output voltage. The AC tor. tance and proper operation.
auxiliary output voltage is normal. Normal resistance is 64 ohms.
2. Check the welding cables for
Check associated wires for
loose or faulty connection.
loose or faulty connections.
See the Wiring Diagram.
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
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-
383-2531 or 1-800-833-9353.
SA-250
F-6 F-6

OUTPUT PROBLEMS
The welding output varies abnor- 1. May be a normal condition. The 1. Check the Fine Current
mally. The auxiliary output remains machine will normally lose Adjustment rheostat for resis-
constant. The engine is operating some output as the components tance and proper operation.
correctly. get heated. Normal resistance is 64 ohms.
Check associated wires for
2. Check for loose, worn, dirty, or
loose or faulty connections.
poorly seated DC generator
See the Wiring Diagram.
brushes.
2. Perform the Field Shunt
3. The armature commutator may

Winding Test.
need cleaned.
3. Check the Current Range
4. Check for loose or faulty weld-
Selector switch and contacts for
ing cables.
proper operation.
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
216-383-2531 or 1-800-833-9353.
SA-250
F-7 F-7

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 circuit breakers. Reset is nec- nections between the recepta-
auxiliary output voltage. The DC essary. cles, the circuit breakers, the
welding generator is functioning current transformer and the
2. Check the 115VAC and 230VAC
correctly. exciter alternator stator. See
receptacles and plugs for loose
the Wiring Diagram.
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 Field Service Facility. located on the DC generator
to “build-up” and produce output brush holder. The diode may
voltage. The AC auxiliary voltage be “shorted” or installed incor-
varies when the Fine Current rectly.
Control rheostat is adjusted.
CAUTION
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-
383-2531 or 1-800-833-9353.
SA-250
F-8 F-8


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 switch is set to the “Auto” posi- and associated leads for loose
loads are removed. tion. 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
3. Check for mechanical restric-
necessary.
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
216-383-2531 or 1-800-833-9353.
SA-250
F-9 F-9

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 or faulty connections. proper operation. The reed
welding output terminals. The switch should close when there
engine does go to high speed when is current flow in the welding cir-
a load is applied to the AC auxiliary cuit.
power receptacles.
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 and associated leads for loose the current transformer for loose
AC auxiliary receptacles. The or faulty connections. or faulty connections. See the
engine does go to high speed when Wiring Diagram.
2. The load may be too small. The
a load is applied to the welding out-
load must be above 150 watts. 2. Check the current transformer
put terminals.
for “opens” in the windings.

3. The idler PC board may be
faulty. Replace.
CAUTION
216-383-2531 or 1-800-833-9353.
SA-250
F-10 F-10


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 auxiliary load leads for loose or faulty. Replace.
or an auxiliary load is connected to faulty connections.
the SA-250.
2. Check for mechanical restric-
The machine has normal output tions or missing parts in the idler
and engine speed when the Idler and throttle linkage (springs,
Control switch is in the “High” posi- etc.).

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- for proper operation. When
rectly. 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
216-383-2531 or 1-800-833-9353.
SA-250
F-11 F-11


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
2. Press the engine protection
associated leads for loose or
“Reset” button.
faulty connections. See the
3. Check the fuse in the engine Wiring Diagram.
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
2. Check engine oil level.
may be causing the engine pro-
3. Air may be entrapped in fuel tection relay to shut off the fuel
system. Refer to Maintenance injection pump. Make sure oil
section to bleed fuel system. pressure and coolant tempera-
ture are correct before replacing
sensors.
2. The protection relay may be

faulty.
3. The engine fuel injectors may
need service.
CAUTION
216-383-2531 or 1-800-833-9353.
SA-250
F-12 F-12


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 idle speed should be 1800
process. 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 idle speed should be 1800
process and electrode. 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
216-383-2531 or 1-800-833-9353.
SA-250
F-13 F-13
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
F-14 F-14
ALTERNATOR ROTOR TEST (continued)
FIGURE F.1 – ALTERNATOR COVER REMOVAL
LOOSEN 5
SCREWS
ALTERNATOR
COVER
SLIP
RINGS
BRUSHES
TEST PROCEDURE
1. Turn engine off. 4. With the 3/8" socket wrench, remove the
screw and lock washer from the top center
2. Unlatch, lift and secure the right and left of the alternator cover. See Figure F.1.
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-
3. With the 3/8" nut driver or socket wrench, tor cover.
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
F-15 F-15
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
F-16 F-16
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 12. Close and latch the right and left side cover
slip rings. Place the other probe on any doors.
good, unpainted ground. See Figure
F.3.
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
F-17 F-17
FIELD SHUNT WINDING TEST
WARNING
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.
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
F-18 F-18
FIELD SHUNT WINDING TEST (continued)
FIGURE F.4 – PLUG P10 LOCATIONS
PLUG P10
TEST PROCEDURE
1. Turn engine off. 4. Remove plug P10. See Figure F.4.
2. Unlatch, lift and secure the right side door. 5. Locate the blue lead (U, pin 3) and the
Note that there are latches at both ends of brown lead (N, pin 5) in the harness plug.
the door. See Figure F.5.
3. Locate plug P10. See Figure F.4.

SA-250
F-19 F-19
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 9. If the plug and associated leads are okay,
scale (X1), measure the resistance then the shunt field coils may be faulty.
between the blue and the brown leads. Replace.
See Figure F.5. Normal resistance is
10. If the test does meet the resistance specifi-
approximately 50 ohms.
cations, then the shunt coils are okay.
7. Also measure the resistance from either
11. Replace plug P10, making sure the leads
lead (blue or brown) to ground. Set the
and plug are secure.
volt/ohmmeter on the high scale (X100,000).
This resistance should be at least 500,000 12. Close and latch the right side door.
ohms.
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
F-20 F-20
IDLER SOLENOID TEST
WARNING
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
F-21 F-21
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 7. If the solenoid does not operate properly,
the door. 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 8. If the linkage is intact and the solenoid
fan guard. does not operate correctly when 12VDC is
applied, the solenoid may be faulty.
4. Locate leads #56 and #57 on the idler sole-
Replace. Normal solenoid coil resistance
noid. See Figure F.6 and the Wiring
is approximately 9 ohms.
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
5. Using the external voltage supply, apply
and #57 to the idler solenoid.
12VDC to the idler solenoid terminals.
Attach positive (+) to the terminal where lead 10. Close and latch the left side door.
#56 was connected. The solenoid should
activate.
SA-250
F-22 F-22
ENGINE THROTTLE ADJUSTMENT TEST
WARNING
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
F-23 F-23
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.7 - STROBE MARK LOCATION

STROBE
MARK
TEST PROCEDURE
Strobe Tach Method 5. Start the engine and direct the strobe-tach
light on the blower paddle. Synchronize it to
1. Turn the engine welder OFF. the rotating mark.
2. Unlatch, lift and secure the left side door. With the machine at HIGH IDLE the tach
Note that there are latches at both ends of should read between 1780 and 1810 RPM.
the door.
With the machine at LOW IDLE the tach
3. With a white or red marking pencil, place a should read between 1350 and 1400 RPM.
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
F-24 F-24
6. If either of the readings is incorrect, adjust Adjust LOW IDLE: First make sure there is
the throttle as follows: no load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
Adjust HIGH IDLE: Use the 8mm wrench to
change to low idle speed. Use the 7/16"
loosen the locking nut. See Figure F.8 for
wrench to loosen the solenoid lever arm
location of the adjusting screw and locking
locking nut. See Figure F.9. Adjust the
nut. Avoid breaking the seal. There should
threaded solenoid lever arm shaft, to
be enough play to allow adjustment without
change the amount of throw in the lever
disturbing the seal. Turn the threaded screw
arm, until the frequency reads 47 Hz.
counter-clockwise to increase the HIGH
Retighten the locking nut.
IDLE speed. Adjust the speed until the tach
reads between 1780 and 1810 RPM. Oscilloscope Method

1. Connect the oscilloscope to the 115 VAC
Adjust LOW IDLE: First make sure there is receptacle, according to the manufacturer’s
no load on the machine. Set the IDLE instructions. At HIGH IDLE (1800 RPM), the
switch to AUTO and wait for the engine to waveform should exhibit a period of 16.6
change to low idle speed. milliseconds. At LOW IDLE (1400 RPM),
the waveform should exhibit a period of 21.4
Use the 7/16" wrench to loosen the solenoid
milliseconds. Refer to the NORMAL OPEN
lever arm locking nut. See Figure F.9.
CIRCUIT VOLTAGE WAVEFORM (115
Adjust the threaded solenoid lever arm
VAC SUPPLY) HIGH IDLE - NO LOAD in
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
1. Plug the frequency counter into one of the
115 VAC auxiliary receptacles.

2. Start the engine and check the frequency nut. Avoid breaking the seal. There should
counter. At HIGH IDLE (1800 RPM), the be enough play to allow adjustment without
counter should read 60 Hz. At LOW IDLE disturbing the seal. Turn the threaded screw
(1400 RPM), the counter should read 47 Hz. counter-clockwise to increase the HIGH
Note that these are median measurements; IDLE speed. Adjust the speed until the peri-
hertz readings may vary slightly above or od is 16.6 milliseconds. Retighten the lock-
below. ing nut.
3. If either of the readings is incorrect, adjust Adjust LOW IDLE: First make sure there is
the throttle as follows: 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
nut. Avoid breaking the seal. There should
threaded solenoid lever arm shaft, to
be enough play to allow adjustment without
change the amount of throw in the lever
disturbing the seal. Turn the threaded screw
arm, until the period is 21.4 milliseconds.

counter-clockwise to increase the HIGH
IDLE speed. Adjust the speed until the fre-
quency reads 60 Hz. Retighten the locking
nut.
SA-250
F-25 F-25
FIGURE F.8 - HIGH IDLE ADJUSTMENT
ADJUSTING
SCREW
LOCKING
NUT
FIGURE F.9 - LOW IDLE ADJUSTMENT

THREADED SOLENOID
LEVER ARM
LOCKING NUT
SA-250
F-26 F-26
FLASHING THE FIELDS

WARNING
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
F-27 F-27
FLASHING THE FIELDS (continued)
FIGURE F.10 - FLASHING THE FIELDS

NEGATIVE (-)
BRUSH HOLDER
_
+
POSITIVE (+)
BRUSH HOLDER
12 VOLT
BATTERY
PROCEDURE
1. Turn engine welder OFF. 6. With the engine OFF, use the other lead with
alligator clips and touch the positive battery
2. Unlatch, lift and secure the right and left side terminal to the positive brushholder. Then
doors. Note that there are latches at both disconnect the leads to remove the battery
ends of the door. from the circuit.
3. Remove the cover from the exciter. See 7. Replace the exciter cover.
Figure F.10.
8. Start the welder. The generator voltage
4. Turn the FINE CURRENT ADJUSTMENT should build up.
control (rheostat) to “100.”
If voltage does not build up, there are a num-
5. Using one of the leads with alligator clips, ber of possible causes, such as loose or
connect the negative terminal of the 12-volt missing brushes, open leads or poor con-
automotive battery to the negative brush- nections at the field diode bridge or between
holder. This is the brushholder nearest the the exciter alternator brushes and the gener-
rotor lamination. See Figure F.10 and the ator brushes. See OUTPUT PROBLEMS in
Wiring Diagram. the Troubleshooting Guide located in this
DO NOT remove brush holder. section of the manual for recommended

action.
SA-250
F-28 F-28
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)

HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM
16.6 ms
CH1
0 volts
50 volts 5 ms
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
F-29 F-29
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM

HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR
SWITCH AT MAXIMUM
CH1
0 volts
50 volts 5 ms
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.
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Coupling.............................DC
SA-250
F-30 F-30
TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM

MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM POSITION
CH1
0 volts
20 volts 5 ms
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.

machine output terminals.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Coupling.............................DC
SA-250
F-31 F-31
ALTERNATOR ROTOR REMOVAL

AND REPLACEMENT
WARNING
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
F-32 F-32

AND REPLACEMENT (continued)
PROCEDURE 3. With the 1/2" wrench, disconnect the negative

battery cable.
1. Turn the engine off.
4. With the 1/2" wrench, remove the four bolts
2. Unlatch, lift and secure the left and right side and washers from the panel located below the
doors. There are latches on both sides of the control panel. Remove the panel. See Figure
doors. F.11.
FIGURE F.11 – FRONT PANEL REMOVAL

REMOVE BATTERY RETAINER

FASTENERS FASTENERS
TERMINAL
CABLES
SA-250
F-33 F-33

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
SA-250
F-34 F-34

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 NOTE: The sleeve collar will have to be
holder assembly to the stator frame. removed with a gear puller. Be careful not to
damage the rotor slip ring assembly. Remove
10. Bend the flat washer away from the rotor
the rotor by pulling it free of the generator shaft.
locking nut.
FIGURE F.13 – ROTOR REMOVAL

"BENT"
WASHER
STATOR
FRAME
SLEEVE BRUSH
NUT COLLAR HOLDER
ASSEMBLY
SA-250
F-35 F-35
INSTALLATION

Replacement d. The exciter brush spring must lie flat on
the corner of the brush and not touch
12. Carefully mount the rotor onto the generator
either side of the retainer.
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
NOTE: Be careful not to damage or deform
sandpaper between the slip rings and
the new sleeve collar. Carefully tap the new
brushes (abrasive against brushes). With
sleeve collar into position. The rotor locking
slight additional finger pressure on top of
nut should be torqued to 175 ft.-lbs.
brushes, pull the paper around the cir-
After the rotor locking nut is properly cumference of the rings in the direction of
torqued, bend the washer down over the rotation only. Repeat this procedure until
locking nut. the entire face of the brush is contoured
to the radius of the slip ring.

Check rotor air gap. .017" minimum is
allowed. f. Check the brushes to be certain that there
is spring tension holding them firmly
13. Mount the brush holder assembly to the sta-
against the slip rings.
tor frame using two bolts, washers, and nuts.
14. Install the alternator cover with the screw
Installing and Seating Exciter Slip Ring Brushes
and washer at top and the screws at the two
a. Make sure the slip rings are clean and sides.
free from oil and grease.
15. Install the panel below the control panel on
b. Spacing between the brush holder and the case front.
slip rings must be .050" to .090". Adjust
16. Connect the negative battery cable.
as required.
17. Close and latch left and right side case
c. Before placing the exciter brushes in their
doors.
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.
SA-250
F-36 F-36
ALTERNATOR STATOR REMOVAL AND REPLACEMENT
WARNING
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
SA-250
F-37 F-37
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-
2. Perform the Alternator Rotor Removal
nect the black auxiliary power lead from
procedure.
the current transformer. Cut any neces-
3. With the 1/2" wrench, remove the four nuts sary cable ties. See the Wiring Diagram
and bolts holding the case top and doors and Figure F.15.
assembly to the welder frame. Carefully lift

11. Remove the red auxiliary power lead from
up and remove the top and doors assembly.
the CB4 circuit breaker. See the Wiring
4. With the 3/8" nut driver, remove the two Diagram.
leads from the alternator brush holder
12. Remove the white auxiliary power lead
assembly. Note lead placement. Set brush
from the 115VAC receptacle. Cut any nec-
holder aside.
essary cable ties.
5. With the 1/2" wrench, remove the battery.
NOTE: The CB1 circuit breaker may have to
6. With the 3/8" wrench, remove the bottom be removed to access the terminal for the white
alternator cover. lead.
7. With the slot head screwdriver, remove the 13. Remove the red lead from the negative ter-
commutator wrap-around. See Figure F.14. 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 14. Remove the black lead from the positive
and Figure F.15. 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.
SA-250
F-38 F-38
ALTERNATOR STATOR REMOVAL

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
F-39 F-39

15. Clear the leads in preparation for remov- 16. Lift the eight brushes from the commuta-
ing the stator/end bracket. 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
F-40 F-40

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 24. Connect the four heavy cables from the
bolts mounting the stator/end bracket generator frame coils to the generator
assembly to the generator frame. Note brush holders.
the "drill spot" for reassembly. See Figure
25. Install the eight commutator brushes
F.18.
according to how you marked their posi-
19. With the 7/16" wrench, loosen (do not tions at disassembly.
remove) the generator brush holder
26. Attach the black lead to the positive termi-

clamping bolt. Note the drill spot for
nal of the field rectifier bridge. Attach the
reassembly. See Figure F.18.
red lead to the negative terminal.
20. Carefully pry the stator/end bracket
27. Attach the white auxiliary power lead to
assembly away from the generator frame.
the 115 VAC receptacle. Attach the red
NOTE: The generator brush holder assembly auxiliary power lead to the CB4 circuit
will also be removed. breaker. Attach the black auxiliary power
lead to the current transformer. Tape the
Replacement
bolted connection.
21. Mount the stator/end bracket assembly to
28. Connect the two yellow leads to the field
the generator frame. Line up the mating
bridge and to the field fuse holder.
parts at the stator end bracket drill spot.
Connect the white and yellow wires at the
Tighten the four mounting bolts with the
in-line connectors.
5/8" wrench.
29. Install the commutator wrap-around, the
22. Check armature air gap. Minimum gap is
bottom alternator cover, the battery, and
.035." Loosen the four mounting bolts;
the alternator brush holder assembly.

adjust and re-tighten if necessary.
30. Install the alternator rotor according to the
23. Tighten the generator brush holder
reassembly directions in the Alternator
assembly with the 7/16" wrench. Note
Rotor Removal and Replacement pro-
brush holder drill spot.
cedure. Before installing the case top and
sides, replace any cable ties cut for disas-
sembly.
SA-250
F-41 F-41
GENERATOR FRAME
REMOVAL AND REPLACEMENT
WARNING
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
SA-250
F-42 F-42
GENERATOR FRAME REMOVAL

FIGURE F.19 – FUEL TANK / OUTPUT CABLE REMOVAL
FUEL TANK
RETURN LINE
POSITIVE CABLE
COPPER FUEL TANK

STRAP 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
2. Perform the Alternator Rotor Removal
driver to pry the retainer from the rail.
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
4. Turn off the fuel at the fuel bowl and remove
strap/reed switch assembly from the nega-
the fuel line. Plug the line to prevent spillage.
tive output terminal. Clear the strap.
5. Remove the fuel return line from the top of the
10. With the 3/4" wrench, remove the cable from
fuel tank.
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.
SA-250
F-43 F-43

FIGURE F.20 – WIRE AND SELECTOR SWITCH CONNECTIONS
CIRCUIT BREAKER CB2

WITH BLACK CURRENT
TRANSFORMER LEAD SELECTOR
IDLER SWITCH
PC BOARD
BLUE CURRENT
TRANSFORMER
LEADS
IN-LINE CONNECTOR
BLUE/BROWN LEADS
See Figure F.20 for steps 11 - 16. NOTE: Some terminals have more than one cable
connected. Tape any pairs together before removing
11. Cut all necessary cable ties.
them.
12. Disconnect the blue and the brown wires at the in-
14. With the 1/2" wrench, remove the cables connect-
line connectors. See Figure F.20 and the Wiring
ed to the selector switch.
Diagram.
15. Disconnect the current transformer black lead from
13. Label the cables that are connected to the selector
circuit breaker CB2.
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
F-44 F-44

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
F-45 F-45

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
20. With the 3/4" wrench, remove the frame
steel block under the engine adapter plate.
mounting bolts, nuts and spacers from the
With the 9/16" wrench, install the bolts that
feet of the generator frame.
attach the generator frame to the engine.

21. With the rope sling around the generator Attach the two starting motor bolts and nuts.
frame, carefully lift the frame and engine
25. With the 3/4" wrench, install the frame
assembly a small distance. Slide the wood
mounting bolts, nuts, and spacers to the feet
or steel block under the engine adapter
of the generator frame. See Figure F.22.
plate.
26. Install the case front to the welder frame.
22. With the 9/16" wrench, remove the bolts
See steps 17 - 19.
mounting the engine to the generator frame.
Only two of the starting motor mounting bolts 27. Connect the cables to the selector switch
and nuts will have to be removed. according to how you labeled them during
disassembly. See the Wiring Diagram if nec-
23. Using the rope sling and pry bars, carefully
essary.
lift and “wiggle” the generator frame away
from the engine and armature assembly. Be 28. Connect the blue and black current trans-
careful to support the generator frame as former leads to the idler PC board and CB2
you remove it. circuit breaker, respectively.
29. Reconnect the blue and brown leads at the

in-line connectors.
Replacement
30. Install the copper strap/reed switch assem-
24. Support the generator frame with the rope
bly to the negative output terminal.
sling. Mount the generator frame to the
engine and armature assembly. Before
SA-250
F-46 F-46

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
F-47 F-47
GENERATOR ARMATURE
REMOVAL AND REPLACEMENT
WARNING
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
F-48 F-48
GENERATOR ARMATURE REMOVAL

FIGURE F.23 – BLOWER PADDLE REMOVAL
ROPE SLING
BLOWER PADDLE
BLOWER
PADDLE/ARMATURE
MOUNTING BOLTS (8)
PROCEDURE
CAUTION
1. Turn the engine OFF.
2. Perform the Alternator Rotor Removal pro- The armature is now free to be removed from the
cedure. engine.
3. Perform the Alternator Stator Removal pro-

cedure. Replacement
4. Perform the Generator Frame Removal pro- 9. Support the armature with the rope sling.
cedure. Mount the armature to the engine, rotating it
5. Using the rope sling, support the armature. 1/8 of a turn in either direction to achieve
proper attachment. Before removing the
6. Make sure the engine is supported with the rope sling, be careful to support the arma-
wood or steel blocks. ture with the wood or steel blocks under the
7. With the 5/8" wrench, remove the eight bolts engine. With the 5/8" wrench, install the
and lock washers holding the blower paddles eight bolts and lock washers that attach the
and the armature to the engine flywheel. See blower paddles and the armature to the
Figure F.23. engine flywheel.
8. With the armature supported and “balanced” 10. Perform the replacement procedures accord-
in the rope sling, carefully rotate the armature ing to each of the following:
1/8 turn in either direction to release. Generator Frame Removal and Replacement
Alternator Stator Removal and Replacement

Alternator Rotor Removal and Replacement
SA-250
F-49 F-49
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 No Load RPM Load RPM
Low Idle 1350 - 1400 NA
High Idle 1780 - 1810 1700 - 1795
WELDER DC OUTPUT
Current Control Current Selector Open Circuit Load Volts Load Amps
Rheostat Switch Voltage

Maximum Maximum 91 - 98.5 40 - 47 300
AC AUXILIARY POWER RECEPTACLE OUTPUT

230 Volt Receptacle 115 Volt Receptacle
Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps
Voltage Voltage
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 Alt. Rotor Amps RPM
123 - 133 2.25 - 2.6 2.2 - 2.6 1780 - 1810

SA-250
F-50
SA-250
NOTES
F-50
G-1 G-1
Return to Master TOC 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
SA-250
NOTES
G-2 ELECTRICAL DIAGRAMS G-2
Wiring Diagram
SA-250 & 350-SA WIRING DIAGRAM

CONTROL PANEL COMPONENTS
ELECTRICAL SYMBOLS
PER E1537 SHOWN AS VIEWED FROM REAR.
P10
NEUTRAL BONDED TO FRAME
NEUTRE RACCORDE 'AU BATI
LEAD COLOR CODE
12 11 10 9 8 7 6 5 4 3 2 1
B-BLACK J5
THERMOSTART U G-GREEN W
IDLER B +Y
IGNITER U N-BROWN N -W
P.C. R ALTERNATOR ROTOR U
ENGINE
W
-
(LEADS APPEAR ON SLIP RINGS
PROTECTION BOARD
Y EARLIER UNITS ONLY)
RELAY + B 610
53 ENGINE
56A SLIP RING
NEAREST
+ 610
IDLER 57 W B
HOUR IGNITION R 602B
SWITCH TO IRON AC AC 600B
METER SWITCH
THERMO IDLER
FUSE (SFE-14) 41 1
START START SOLENOID
+ -
G NO NC S B
56
115 VOLT 230 VOLT
Y
- 600A 2
58 59B RECEPTACLE RECEPTACLE 42 3
B
15A.
OIL PRESSURE
51B G 4
59 60
SWITCH(N.C.)
FUSE Y
54 602A 5
52
51A RHEOSTAT
6
Y J8 P9
59C B
60A
SELECTOR
50A B
R SWITCH
FUEL
INJECTION G
B PUMP ALTERNATOR
CB2 B B CB3
.
CB4 W AUXILIARY
CB1
TEMPERATURE POWER
GAUGE
G
WINDINGS
GENERATOR
50 B
B G
S A
+ - 59A B
A
ALTERNATOR
B 5 4 3 2 1
+
STARTING CURRENT
EXC
CR2 REED WELDER
MOTOR
+ - U TRANSFORMER RELAY LEAD BLOCK
51
U N
R U
-W
60B +Y
60D
GROUND N
TO BASE NEGATIVE POSITIVE
(CC-) (CC+) & (CV+ WITH W.F.M.)
REMOTE CONTROL (OPTIONAL) WIRE FEED MODULE (OPTIONAL)

PLUG FOR
REMOTE CONTROL RECEPTACLE & SWITCH
REMOTE CONTROL ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
POTENTIOMETER
CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
* SEE
BELOW
B
R
X
Y X INLINE PLUG
CONNECTORS (P5)
1 41 W.F.M.
. . .
CONTROL
2 600 Y PANEL
* SEE
BELOW
3 42
R B W
G #8 LEAD
4 602
5 CONNECT
CONNECT
TO CASE
CONNECT TO POS. & NEG. POS. WIRE FEED
W OUTPUT TERMINALS NEG.
TO CASE
6
P8 NEGATIVE CV MODULE
OUTPUT TERMINAL #2 HEAVY LEAD
SWITCH FOR LOCAL OR REMOTE CONTROL PANEL
608
SHOWN IN LOCAL POSITION.
609
,
CONNECT TO NEG.
* WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON
BRUSH HOLDER
MACHINE FROM CONNECTOR "J8". THEN CONNECT
PLUG "P8" ON REMOTE CONTROL TO REMOTE CONTROL #2 HEAVY LEAD
CONNECTOR "J8" ON MACHINE. POTENTIOMETER BOX
* MACHINE
THE RED AND BLACK LEADS ARE USED ON CLASSIC I MACHINES ONLY AND ARE NOT 250 AMP
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
THERMOSTAT MUST NOT BE RUNNING
AND 350-SA. ASSEMBLY WHEN MAKING THESE CONNECTIONS. 7-19-96J
R
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
Wiring Diagram (Wire Feed Module)
WIRE FEED MODULE - WIRING DIAGRAM

ELECTRICAL SYMBOLS PER E1537
1 Y CONTROL BOARD
FLASHING
LEADS
MOLEX CONNECTORS 2 W
218 1
J1 J2 J3 J4
3 503 219 2
SHUNT P1 J1
CONNECTOR CAVITY NUMBERING TO 4 602
FIELD
RHEOSTAT
SEQUENCE VIEWED FROM 509
5 634 1
COMPONENT SIDE OF BOARD.
CONNECTS TO
+ 6 610
667 2
ENGINE WELDER 115V
N.A. LEADS 31, 32 AND 602 DO NOT GO INSIDE WIRE FEED MODULE BOX. 7
RECEPTACLE J5 DC 2 3
N.B. COMPONENTS VIEWED FROM REAR
- 8 600
4 4
9 621 5
1 2 3 4
10 GND
633 6
5 6 7 8
11 31
12
115V 75A 7
9 10 11
AC
12 32
76 8
P5 P5
N.A. 77 9
CONNECTOR CAVITY NUMBERING
SEQUENCE VIEWED FROM GND 1 GND 75 10
LEAD SIDE OF CONNECTOR P2 J2
CC/CV SWITCH S1 31 2 31
510 602
SHOWN IN CV MODE
32 3 32 501 1
CV CONTROL
609 4 609 509 2
77A R501 75 610A
610A 5 610A 503A 3
10K 503A
510 6 510 631 4
76A
501 7 501 630 5
503A 8 503A 503 6

609 501
P4 J4
602 9 602
REMOTE CONNECTOR J6 P6
W 1
J 31
115 VAC 610A 2
75 1 75
A 32
Y 3
GROUND B GND 76 2 76
C 2A 600 4
77 3 77
CONTACTOR
D 4A 608 5
2 4 2
E 77B 610 6
4 5 4
REMOTE F 76B
7
75A 6 75A
G 75A
P7 J7 510 8
AMPHENOL 1
77 P3 J3
4A 2
76B
2A 4
77B
218 219
76
LOCAL/REMOTE SWITCH S2
- +
621
SHOWN IN LOCAL MODE 300 AMP 667
SHUNT
77A 76A
633
608 609
NEG
POS
CR4
666
634 + + +
250
R502
CC + CC - TO NEG
CV - 25W
BRUSH HOLDER
CONTACTOR C501 C502 C503 CR3
630 631
622
CONTACTOR
30000 MFD
EACH
75 VOLT
R 3-18-94
L9259
CLEVELAND, OHIO U.S.A.
SA-250
Idler PC Board (M13708) Schematic
M 16989
NOT USED
9
X1 -C R8 D2
14 YEL B213
R9 R15
1
8 +t TO BATTERY
15.0 15.0
56
D1
GND TO SOLENOID
1
WHITE B212
3 16
C3 DZ1 C4
10V 50 C1
X1 5W X2
15V
LM2901
4536B
GND 10K
R1
12
8
TO REED SW. GND

RED GND
T13157-14
1
B209 R13
13.7K
C10
511
R16
D7 .047
47.5K
100V
R7
10K
R2
22.1K
R3
R20 D
5.11K 13.7K 33.2K R6 C8

R18
R21
10K Q1
133K 15A
R5 60V
G
S
16
5 1 SET V DD DZ3 15V DZ2
7
X1 -A 27V
11 2 2 RESET MONO IN 15 1W
R17 X1 -B X2 1
5W
13 4 3 IN 1 OSC INH 14
1.00K X1 -D 6
D8 10 4 13
OUT 1 DECODE
R12
5 OUT 2 D 12
26.7K
C9
C7 6 8 BY-PASS C 11
R19
7 CLOCK INH B 10
10K D5
8 9
V SS A 1N4936
3.32K
4536B
R10
Q2
B210 C2
R14 600mA C6
1 22.1K
TO 40V 18 .5
R11
15.0K
R4
CURRENT 15V 5W
XFMR. C5 D3
R
B211
1
BLUE P.C.BOARD IS CONNECTED DIRECTLY GND
TO FRAME GND THRU MOUNTING SCREW
M16989_2DE
GENERAL INFORMATION LAST NO. USED
R- 21
ELECTRICAL SYMBOLS PER E1537
C- 10
CAPACITORS = M F D ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- 8
DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)

SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT

NOTES :
COMMON CONNECTION
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY FRAME CONNECTION
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
EARTH GROUND CONNECTION
NUMBER.
UNLESS OTHERWISE SPECIFIED TOLERANCE Ch'ge.Sht.No.

EQUIP.
ON HOLES SIZES PER E-2056
THE LINCOLN ELECTRIC CO. ENGINE WELDERS
10-29-93J TYPE
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2
CLEVELAND, OHIO U.S.A. SUBJECT IDLER PCB SCHEMATIC
ON ALL ANGLES IS + .5 OF A DEGREE
MATERIAL TOLERANCE ("t") TO AGREE SCALE NONE
SHT.
AUSTRALIA CANADA FRANCE WITH PUBLISHED STANDARDS
DR. I.E.B. DATE 2/10/93 CHK. SUP'S'D'G.
S16477
NO. M 16989
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
SA-250
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Idler PC Board (M13708) Components
B211 B209 B213 B210 B212
ENGINE WELDER IDLER

R15
D1
D2
R9
R11
R16
C8
DZ3
DZ2
Q1
M13708
R21
R10
D8
D7
C9
R7
R6
R13
R20
R8
DZ1
R1
C6
R17
R12
D5
C4
C10
R14
R18
D3
R19
C2
C7
C5
C3
C1
R4
R3
R2
R5
X1 X2
Q2
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
SA-250
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
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

Manual de Servicio Sa 250 Lincoln

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RETURN TO MAIN INDEX

Safety Depends on You

Lincoln arc welding and cutting

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE 1.h. To avoid scalding, do not remove the

ELECTRIC SHOCK can kill. ARC RAYS can burn.

form phosgene, a highly toxic gas, and other irritating

5.e. Also see item 1.b.

cause fire or explosion. if damaged.

area as practical. Work cables connected to the building

allique ou des grilles metalliques, principalement dans

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

5. Toujours porter des lunettes de sécurité dans la zone de

RETURN TO MAIN INDEX

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair ................................................................................................Section F

Electrical Diagrams ..............................................................................................................Section G

Parts Manual ...............................................................................................................................P-237

Technical Specifications ..............................................................................................................A-2

Pre-operation Engine Service .....................................................................................................A-4

Machine Grounding ..............................................................................................................A-7

TECHNICAL SPECIFICATIONS - SA-250

INPUT - DIESEL ENGINE

Manufacturer Description Speed Displacement Ignition Capacities

1350 RPM Water/coolant: 10 qt.

RATED OUTPUT - WELDER

OUTPUT - WELDER AND GENERATOR

Welding Ranges Max. Open Circuit Voltage Auxiliary Power

Height Width Depth Weight

The SA-250 may be used outdoors. Do not set the

ELECTRIC SHOCK can kill.

See additional safety information at the front of this

Only qualified personnel should install, use, or ser-

The SA-250 is shipped with the engine filled

it is equipped with a heavy accessory

engine in the Operation and Maintenance sections of Maintenance section.

COOLING SYSTEM TRAILER

includes when being moved and when standing by

EXHAUST SPARK ARRESTER 4. Typical conditions of use, such as travel speed,

CABLE INSTALLATION AND CABLE SIZES

welder. Cable diameters are increased for long cable

FIGURE A.1 - SA-250 OUTPUT CONNECTIONS

2 1. 230 VAC RECEPTACLE

TABLE A.1 - RECOMMENDED COPPER WELDING CABLE SIZE AND LENGTH

Cable sizes for combined length of

electrode plus work cable

Amps Duty Cycle Up to 200 ft. 200 to 250 ft.

screw. See Figure A.2. volt receptacles for overload protec-

When the SA-250 is mounted on a truck or a trailer, the

current of 13 amps to be drawn from the 230 volt 1. GROUND STUD

Controls and Settings..................................................................................................................B-5

SA-250 DC Constant Current Stick or TIG Welding...........................................................B-10

OPERATING INSTRUCTIONS WARNING

ELECTRIC SHOCK can kill. • Keep away from moving parts.

• Do not touch electrically live parts or

fumes from breathing zone.