Lincoln Electric SA-250 User Manual

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Diesel Engine Driven DC Arc Welding Power Source

For use with machines having Code Number 10073 or 10073CV: 10074

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought­ful operation on your part.

NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.

importantly, think before you act
and be careful.

And, most

DO

IM518-A

October, 2000

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

OPERATOR’S MANUAL

Copyright © 2000 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel 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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

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.

____________________________________________________

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii

SAFETY

ii

ELECTRIC SHOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

5.b.

Do not weld in locations near chlorinated hydrocarbon

coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.

5.c. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

vapors

to

iii

SAFETY

iii

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instruc­tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosg
ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

éne (gas forte-

2. Dans le cas de travail au dessus du niveau du sol, se pro­téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflamma-
bles.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis­positif de montage ou la piece à souder doit être branchéà
une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûretéà leur
place.

Mar. ‘93

Thank You

vv

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediatel

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

y

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.

TABLE OF CONTENTS

Page

GENERAL DESCRIPTION ..................................................................................................7

DESIGN SUMMARY............................................................................................................7

OPTIONAL FEATURES.......................................................................................................8

SPECIFICATIONS ...............................................................................................................9

PRE-OPERATION INSTALLATION .................................................................................10-11

Safety Precautions .......................................................................................................10

Exhaust Spark Arrester ................................................................................................10

Location/Ventilation ......................................................................................................10

Machine Grounding ......................................................................................................10

Lift Bail..........................................................................................................................10

Trailers .......................................................................................................................10-11

Polarity Control and Cable Sizes..................................................................................11

PRE-OPERATION SERVICE .............................................................................................12

Oil ...............................................................................................................................12

Fuel...............................................................................................................................12

Cooling System ............................................................................................................12

Battery Charging...........................................................................................................12

ENGINE OPERATION ........................................................................................................13

Starting the Perkins D3.152 Engine .............................................................................13

Stopping the Perkins D3.152 Engine............................................................................13

WELDER OPERATION....................................................................................................14-15

Duty Cycle ....................................................................................................................14

Control of Welding Current ...........................................................................................14

Idler Operation..............................................................................................................14

Auxiliary Power.............................................................................................................15

MAINTENANCE ...............................................................................................................15-17

General Instructions for Diesel Engine Welders...........................................................15

Cooling System ............................................................................................................16

Bearings .......................................................................................................................16

Commutator and Brushes.............................................................................................16

Idler Maintenance .........................................................................................................17

Nameplate ....................................................................................................................17

TROUBLESHOOTING .....................................................................................................17-20

Welder Troubleshooting.............................................................................................17-19

Flashing the Fields .......................................................................................................19

Electronic Idler Troubleshooting ...................................................................................20

WIRING DIAGRAM - SA-250..............................................................................................21

DIMENSION PRINT............................................................................................................22

PARTS LISTS.................................................................................P237 Series, P78-D and P25-L

– 6 –

GENERAL DESCRIPTION

Auxiliary Power

The SA-250 is a heavy duty engine-driven DC arc
welding power source capable of providing constant
current output for stick welding or DC TIG welding.
With the addition of the optional Wire Feed Module for
K1283-4, the SA-250 will provide constant voltage
output for running the LN-25, LN-23P or LN-7 wire
feeders. The Wire Feed Module is factory-installed on
the K1283-5 SA-250.

The SA-250 has a current range of 40-325 DC amps
with a 60% duty cycle at 250 amps/40 volts. The units
are also capable of providing 3 kVA of 115/230 volt,
60 Hertz AC auxiliary power.

DESIGN SUMMARY

Control Panel

Both the engine and the welder controls are located
on one recessed panel at the auxiliary power alterna­tor end of the machine. The welder controls consist of
a five step “Current Range Selector” switch and a
“Fine Current Adjustment” rheostat. Each welder is
equipped with a “Start” button and an “Idler Control”
switch. The Perkins diesel uses a “Thermostart” but­ton, and has a “Stop” control.

3.0 kVA of nominal 115/230V, 60 Hz, AC1. (See
Optional Features for Power Plug Kits).

(1)

Output voltage is within ± 10% at all loads up to
rated capacity.

Welder Enclosures

The complete welder is rubber mounted on a rugged
steel base.

The output terminals are placed at the side of the
machine so that they are protected by the door. The
output terminals are labeled (+) and (-).

Remote Control

K924-1 (for K1283-4, -5) (Field Installed). Provides a
receptacle switch and remote control box with 100 ft
cord for fine current and OCV adjustment at the weld­ing site.

Cranking System

A 12 volt electric starter is standard.

On this panel is also mounted an engine temperature
gauge, a battery charging ammeter, an oil pressure
gauge, and the three prong grounded type auxiliary
power receptacle.

Copper Shunt Windings

For long life and dependable operation.

Engine Idler

The SA-250 is equipped with an electronic automatic
engine idler. It automatically increases and decreases
engine speed when starting and stopping welder or
using auxiliary power. A built-in time delay permits
changing electrodes before the engine slows to its low
idle speed. The “Idler Control Switch” on the panel
locks the idler in full speed position when desired.

Air Cleaner

Heavy duty two stage dry type.

Muffler

A muffler to reduce engine noise is standard on the
diesel engine units.

Engine Hour Meter

A meter to record the hours of operation.

Diesel Engine Protection

The system shuts the engine down in the event of
sudden low oil pressure or high coolant temperature.

– 7 –

OPTIONAL FEATURES

Accessory Set (K703)

Power Plug Kit (K802C)

• A power plug kit for the auxiliary power receptacles
is available. (Provides a plug for each receptacle).

Includes electrode and work cables, headshield, work
clamp, and electrode holder.

Ether Start Kit (K793-1) for Perkins Engine

When frequent starting is expected below 10°F
(-12°C), remove the “thermostart” system and install
the optional ether start kit to provide maximum cold
weather starting assistance. Note: The required ether
tank is not provided with the kit and must be pur-
chased locally. Ether starting should only be used as
required since indiscriminate application will contribute
to shortened engine life. (Available for field installation

only).

Hi-Freq™ (K799)

Provides high frequency plus gas valve for DC TIG
welding. (Request Publication E385).

Optional field installed water valve kit available. Order

K844.

Linc-Thaw™ (L2964-5) Control Unit

Trailer (K913)

Two-wheeled highway trailer with steel, torsion-bar
axle, 54” (137cm) wheel track. Low sway, low center­of-gravity. Sturdy tread plate platform. Choice of 3
hitches. Add on fender & light package. For highway
use, consult applicable local laws regarding possible
additional requirements.

Order: K913-1 Base Trailer

K913-2 Ball Hitch
K913-3 Lunette Eye Hitch
K913-4 Clevis Pin Hitch

K913-5 Fender & Light Kit

Wire Feed Module (K623-1)

The Wire Feed Module is field-installed on the K1283­and factory-installed on the K1283-5 to provide CV
(constant voltage) output for semiautomatic welding.
Output rated at 250 Amps at 35 Volts with a 60% Duty
Cycle and 310 Amps at 32 Volts with a 35% Duty
Cycle.

4,

Includes meter and fuses to protect welder when
thawing frozen water pipes.

WARNING

Pipe Thawing IS
If not done properly, it can result in fire, explosion,
damage to wiring which may make it unsafe, dam­age to pipes, burning up the welder, or other haz­ards.

Do not use a welder to thaw pipe before reviewing
Lincoln Bulletin E695.1 (dated October 1987 or later.)

------------------------------------------------------------------------

Mufflers

Mufflers are standard on the SA-250 Perkins.

NOT a CSA approved procedure.

DIMENSIONS

See dimension Print M8869-24 at the rear of this man­ual.

– 8 –

SPECIFICATIONS

Machine

Product

Name

SA-250
Perkins

(1) WFM = Wire Feed Module.
(2) Based on a 10 Minute Period.

Ordering
Information

Installed)

Installed)

(1)

K1283-4

(WFM
Field-

K1283-5

(WFM

Factory-

Description

250 Amp DC

Arc Welder

Stick / DC TIG

Welding

Pure DC Power

Generator

Rated DC Output

Amps / Volts / Duty Cycle

Lincoln Rating

250A / 40V

60% Duty Cycle

NEMA Rating

250A / 30V

60% Duty Cycle

(2)

Current Range

(Fine Adjustments

in each Range)

40 - 325 Amps

220 - Max.
160 - 240
120 - 190

80 - 130

Min. - 90

Auxiliary

Power

3 kVA

115/230V,

60 Hz

Dimensions & Weight

H x W x L

43.1 x 28 x 67 in

(1096 x 711 x 1702 mm)

1650 lbs

(742.5 kg)

Engine

Product

Name

Perkins D3.152 3 Cylinder,

Water-Cooled

Diesel Engine with

Thermostart Glow Plug

and Engine Protection

Description Horsepower Operating

Full Load:

4 Cycle,

38.2 HP

@ 1725 RPM

Speeds

Full Load:

1725 RPM

High Idle:

1800 RPM

Low Idle:

1350 RPM

Displacement Capacities

152 Cu. in.

(2.5 ltrs)

Fuel:

15 gals (57 ltrs)

Oil:

7.2 qts (6.9 ltrs)

Water:

10 qts (9.5 ltrs)

– 9 –

PRE-OPERATION INSTALLATION

Machine Grounding

Safety Precautions

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or
guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

According to the United States National Electrical
Code, the frame of this portable generator is not
required to be grounded and is permitted to serve as
the grounding means for cord connected equipment
plugged into its receptacle.

Some state, local or other codes or unusual operating
circumstances may require the machine frame to be
grounded. It is recommended that you determine the
extent to which such requirements may apply to your
particular situation and follow them explicitly. A
machine grounding stud marked with the symbol
is provided on the welding generator frame foot. (If an
older portable welder does not have a grounding stud,
connect the ground wire to an unpainted frame screw
or bolt.

In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment.

See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

Exhaust Spark Arrester

Some federal, state or local laws may require that
diesel engines be equipped with exhaust spark
arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
The standard mufflers included with these welders do
not qualify as a spark arrester. When required by
local regulations, suitable spark arresters must be
installed and properly maintained.

CAUTION

Use of an incorrect arrester may lead to engine damage
or performance loss. Contact the engine manufacturer
for specific recommendations.

-----------------------------------------------------------------------

Location / Ventilation

Lift Bail

A lift bail is provided for lifting with a hoist.

WARNING

FALLING EQUIPMENT can cause

injury.

• Do not lift this machine using lift bail if
it is equipped with a heavy accessory
such as a trailer or gas cylinder.

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

----------------------------------------------------------------------

Trailers (See Optional Features)

If the user adapts a non-Lincoln trailer, he must
assume responsibility that the method of attachment
and usage does not result in a safety hazard nor dam­age the welding equipment. Some of the factors to be
considered are as follows:

Always operate the welder with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating.

The welder should be located to provide an unrestrict­ed flow of clean, cool air. Also, locate the welder so
that the engine exhaust fumes are properly vented to
an outside area.

1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.

– 10 –

3. Proper placement of the equipment on the under­carriage to ensure stability side to side and front to
back when being moved and when standing by
itself while being operated or serviced.

4. Typical conditions of use, i.e. travel speed, rough­ness of surface on which the trailer will be operat­ed, environmental conditions & likely maintenance.

5. Conformance with federal, state and local laws.

(1)

Consult applicable federal, state and local laws regarding specific

requirements for use on public highways.

(1)

Polarity Control & Cable Sizes

With the engine off, connect the electrode and work
cables of the appropriate size (see the following table)
to the studs located on the fuel tank mounting rail.
For Positive polarity, connect the electrode cable to
the terminal marked “Positive”. For Negative polari-
ty, connect the electrode cable to the “Negative” stud.
These connections should be checked periodically
and tightened if necessary.

When welding at a considerable distance from the
welder, be sure you use ample size welding cables.

Recommended Copper Cable Sizes

250 Amps

@ 60% Duty Cycle

350 Amps

@ 25% Duty Cycle

Up to 200 ft

200-250 ft

1

1/0

2/0

3/0

– 11 –

PRE-OPERATION SERVICE

Battery Charging

CAUTION

READ the engine operating and maintenance instruc-

tions supplied with this machine.

------------------------------------------------------------

WARNING

can cause fire or explosion.

Fuel

-

• Stop engine while fueling.

• Do not smoke when fueling.

• Do not overfill tank.

• Keep sparks and flame away from tank.

• Wipe up spilled fuel and allow fumes to clear

before starting engine.

------------------------------------------------------------------------

Oil

This unit is supplied from the factory with the engine
crankcase filled with a high quality 10W30 oil. This oil
should be acceptable for most typical ambient temper­atures. Consult the engine operation manual for spe­cific engine manufacturer’s recommendations. Upon
receipt of the welder, check the engine dipstick to be
sure the oil is at the “full” mark. DO NOT OVERFILL.

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes
away.

BATTERY ACID can burn eyes and
skin.

• Wear gloves and eye protection and
be careful when boosting, charging or
working near battery.

To prevent EXPLOSION when:

a) Installing a new battery - disconnect the

negative cable from the old battery first and
connect the negative cable to the new battery
last.

b) Connecting a battery charger - remove the

battery from the welder by disconnecting the
negative cable first, then the positive cable and
battery clamp. When reinstalling, connect the
negative cable last.

c) Using a booster - connect the positive lead to

the battery first, then connect the negative lead to
the ground lead on the base.

To prevent ELECTRICAL DAMAGE when:

a) Installing a new battery.
b) Using a booster.

Fuel

Fill the fuel tank with the grade of fuel recommended
in the Engine Operator’s Manual. Make sure the fuel
valve on the sediment bowl is in the open position.

Cooling System

The cooling system has been filled at the factory with
a 50-50 mixture of ethylene glycol antifreeze and
water. Check the radiator level and add a 50-50 solu­tion as needed. (See engine manual or antifreeze
container from alternate antifreeze recommendation.)

Use correct polarity - Negative Ground.

To prevent BATTERY DISCHARGE, if you have an

ignition switch, turn it off when engine is not
running.

• To prevent BATTERY BUCKLING, tighten nuts on
battery clamp until snug.

------------------------------------------------------------------------

The SA-250 is equipped with a wet charged battery.
The charging current is automatically regulated when
the battery is low (after starting the engine) to a trickle
current when the battery is fully charged.

When replacing, jumping or otherwise connecting the
battery to the battery cables, the proper polarity must
be observed. The system is

NEGATIVE GROUND.

– 12 –

ENGINE OPERATION

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or
guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

Operate the welder with the doors closed. Leaving
the doors open changes the designed air flow and can
cause overheating.

Cold Weather Starting -- When overnight tempera­tures are between 10°F (-12°C) and freezing, use the
standard “Thermostart” starting system installed on all
engines. Follow the instructions on the nameplate
and in the engine manual shipped with the welder.
With fully charged batteries and the proper weight oil,
the “Thermostart” system operates satisfactorily even
down to about 0°F (-18°C).

If the engine must be frequently started below 10°F (-12°C)
it may be desirable to remove the “Thermostart” and
install the optional ether starter kit. Installation and
operating instructions are included in the kit. Use
ether starting only when required because excessive
use shortens engine life.

Stopping the Perkins D3.152 Engine

a) Turn the ignition control to “OFF”.

At the end of each day’s welding, refill the fuel tank to
minimize moisture condensation in the tank. Also,
running out of fuel tends to draw dirt into the fuel sys­tem.

Check the crankcase oil and radiator water level.

,

Starting the Perkins D3.152 Engine

a) Turn the idler control to “HIGH”.

b) Turn the ignition control to “ON”.

c) Push in the “RESET” button.

d) Press the “START” button. Release button when

engine starts.

e) If the engine fails to start in 60 seconds, wait 30

seconds before repeating the above procedure.

f) Allow the engine to run at high idle speed for sever-

al minutes to warm up. Cold engines tend to run at
a speed too slow to supply the voltage required for
proper idler operation.

– 13 –

WELDER OPERATION

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and ground.

When a forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Current
Range Selector” setting and lower open circuit volt­age. For example: to obtain 175 amps and a forceful
arc, set the “Current Range Selector” to the 240-160
position and the “Fine Current Adjustment” setting to
get 175 amps.

FUMES & GASES can be dangerous.

• Keep your head out of the fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause fire or
explosion.

• Keep flammable material away.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Duty Cycle

The NEMA output rating of the SA-250 is 250
amperes at 30
cycle is based on a ten minute period; thus, the
welder can be loaded at rated output for six minutes
out of every ten minute period.

(1)

The Lincoln “plus output” rating at 60% duty cycle
is 250 amperes at 40 volts.

(1)

arc volts on a 60% duty cycle. Duty

Control of Welding Current

CAUTION

CAUTION

DO NOT attempt to set the “Current Range Selector”
between the five points designated on the nameplate.

------------------------------------------------------------------------

These switches have a spring loaded cam which
almost eliminates the possibility of setting this switch
between the designated points.

Idler Operation

Start the engine with the “Idler Control” switch in
“High Idle” position. Allow it to run at high idle speed

for several minutes to warm the engine. The operat­ing speeds are as follows:

ORDERING

INFO.

K1283-

ALL

The idler is controlled by an “Idler Control” toggle
switch on the welder control panel. The switch has
two positions as follows:

1. In the “High” position, the idler is off, and the
engine runs at the high speed controlled by the
governor.

ENGINE FULL

Perkins

LOAD

1725 1800 1350

Diesel

HIGH

IDLE

LOW
IDLE

DO NOT TURN THE “CURRENT RANGE SELEC­TOR” WHILE WELDING because the current may
arc between the contacts and damage the switch.

------------------------------------------------------------------------

The “Current Range Selector” provides five overlap­ping current ranges. The “Fine Current Adjustment”
adjusts the current from minimum to maximum within
each range. Open circuit voltage is also controlled by
the “Fine Current Adjustment” permitting control of the
arc characteristics.

A high open circuit voltage setting provides the soft
“buttering” arc with best resistance to pop-outs pre­ferred for most welding. To get this characteristic, set
the “Current Range Selector” to the lowest setting that
still provides the current you need and set the “

Fine
Current Adjustment” near maximum. For example: to
obtain 175 amps and a soft arc, set the “Current Range
Selector” to the 190-120 position and then adjust the
“Fine Current Adjustment” for 175

amps.

– 14 –

2. In the “Automatic” / position, the
idler operates as follows:

a. When welding or drawing power for lights or

tools (approximately 100-150 watts minimum)
from the receptacles, the engine operates at full
speed.

b. When welding ceases or the power load is

turned off, a preset time delay of about 15 sec­onds starts. This time delay cannot be adjust­ed.

c. If the welding or power load is not re-started

before the end of the time delay, the idler
reduces the engine to low idle speed.

Auxiliary Power

MAINTENANCE

The AC auxiliary power, supplied as a standard, has a
rating of 3.0 kVA of 115/230V AC (60 Hz).

With the 3.0 kVA, 115/230V AC auxiliary power, one
duplex 115V grounding type receptacle (NEMA con­figuration 5-15R) is provided. For the 230V AC
power, one grounding type duplex receptacle is pro­vided (NEMA configuration 6-15R). The circuit is pro­tected with circuit breakers.

The rating of 3.0 kVA permits a maximum continuous
current of 13 amps to be drawn from the 230 volt
duplex receptacle. Or a total of 26 amps can be
drawn from the 115 volt duplex receptacle. The 115
volt duplex receptacle has a configuration which per­mits 15 amps to be drawn from either half. Therefore,
on this machine, up to 15 amps continuous can be
drawn from one half and the balance of 11 amps from
the other half. The total combined load of all recepta­cles is not to exceed 3.0 kVA.

An optional power plug kit is available. When this kit
is specified, the customer is supplied with a plug for
each receptacle. In this case, he will receive two 15
amp, 115 volt plugs (NEMA configuration 5-15P) and
two 15 amp, 230 volt plugs (NEMA configuration
6-15P).

WARNING

Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be neces­sary to remove safety guards to perform
required maintenance. Remove guards only
when necessary and replace them when the
maintenance requiring their removal is com­plete. Always use the greatest care when work­ing near moving parts.

Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or
guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

General Instructions for Diesel Engine
Welders

1. Blow out the welder and controls with an air hose
at least once every two months. In particularly
dirty locations, this cleaning may be necessary
once a week. Use low pressure air to avoid driving
dirt into the insulation.

2. “Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the
current control through its entire range frequently.
Good practice is to turn the handle from maximum
to minimum setting twice each morning before
starting to weld.

– 15 –

3. Change the crankcase oil at regular intervals using
the proper grade of oil as recommended in the
engine operating manual.

clean equipment. More bearing failures are caused
by dirt introduced during greasing than from insuffi­cient grease.

4. Change the oil filter in accordance with the instruc­tions in the engine operator’s manual. When the
filter is changed, add a quart of oil to the crankcase
to replace the oil held in the filter during operation.

5. Inspect the air filter daily - more often in dusty con­ditions. When necessary, clean or replace. The
filter should never be removed while the engine is
running.

6. Change the diesel fuel filters every 500 hours of
operation.

7. Fan belts tend to loosen after the first 30 or 40
hours of operation. Check and tighten if neces-

DO NOT OVERTIGHTEN.

sary.

8. Put a drop of oil on the “Current Range Selector”
shaft at least once every month.

9. See the engine manufacturer’s Operating Manual
for detailed engine maintenance and troubleshoot­ing instructions.

Cooling System

The SA-250 is equipped with a pressure radiator.
Keep the radiator cap tight to prevent loss of coolant.
Clean and flush the cooling system periodically to pre­vent clogging the passage and overheating the
engine. When antifreeze is needed, always use the
permanent type.

ORDERING INFORMA-

TION

K1283-ALL 10 Quarts

COOLING SYSTEM

CAPACITY

Commutator & Brushes

WARNING

Uncovered rotating equipment can be dangerous.
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself
from particles that may be thrown out by the rotat­ing armature when stoning the commutator.

------------------------------------------------------------------------

The generator brushes are properly adjusted when
the welder is shipped. They require no particular
attention. DO NOT SHIFT THE BRUSHES or adjust
the rocker setting. Shifting of the brushes may result
in:

• change in machine output

• commutator damage

• excessive brush wear

Periodically inspect the commutator, slip rings and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.

Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.

NOTE: If the welder is used in dirty or dusty locations,
or if the welder is not used for prolonged periods of
time, it may be necessary to clean the commutator
and slip rings more often.

Replace brushes when they wear within 1/4” of the
pigtail. A complete set of replacement brushes should
be kept on hand. Lincoln brushes have a curved face
to fit the commutator. Have an experienced mainte­nance man seat these brushes by lightly stoning the
commutator as the armature rotates at full speed until
contact is made across the full face of the brushes.
After stoning, blow out the dust with low pressure air.

Bearings

This welder is equipped with a double-shielded ball
bearing having sufficient grease to last indefinitely
under normal service. Where the welder is used con­stantly or in excessively dirty locations, it may be nec­essary to add one-half ounce of grease per year. A
pad of grease one inch wide, one inch long, and one
inch high weighs approximately one-half ounce.
Over-greasing is far worse than insufficient greasing.

When greasing the bearings, keep all dirt out of the
area. Wipe the fittings completely clean and use

To seat the slip ring brushes, position the brushes in
place. Then slide one end of a piece of fine sandpa­per between slip rings and brushes with the coarse
side against the brushes. With slight additional finger
pressure on top of the brushes, pull the sandpaper
around the circumference of the rings, in direction of
rotation only - until brushes seat properly. In addition,
stone slip ring with a fine stone. Brushes must be
seated 100%.

Arcing or excessive exciter brush wear indicates a
possible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.

– 16 –

Idler Maintenance

TROUBLESHOOTING

CAUTION

Before doing electrical work on the idler printed
circuit board, disconnect the battery.

------------------------------------------------------------------------

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 ground­ing of the printed circuit board (through its mount­ing), reed switch and battery.

4. If desired, the welder can be used without automat­ic idling by setting the “Idler Control” switch to the
“High Idle” position.

5. When installing a new battery or using a jumper
battery to start the engine, be sure the battery
polarity is connected properly. The correct polarity
is negative ground. Damage to the engine alterna­tor and the printed circuit board can result from
incorrect connection.

WARNING

Have qualified personnel do the troubleshooting
work. Turn the engine off before working inside
the machine. In some cases, it may be neces­sary to remove safety guards to perform
required maintenance. Remove guards only
when necessary and replace them when the
maintenance requiring their removal is com­plete. Always use the greatest care when work­ing near moving parts.

Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.

-----------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or
guards off.

• Stop engine before servicing.

• Keep away from moving parts.

Nameplates

Whenever routine maintenance is performed on this
machine, or at least yearly, inspect all nameplates and
labels for legibility. Replace those which are no
longer clear. Refer to the parts list for the replace­ment item number.

------------------------------------------------------------------------

See additional warning information at

front of this operator’s manual

------------------------------------------------------------

– 17 –

TROUBLESHOOTING

TROUBLE

A. Machine fails to hold the “heat”

consistently.

B. Welder starts but fails to gener-

ate current.

CAUSE

1. Rough or dirty commutator.

2. Brushes may be worn down to
limit.

3. Field circuit may have variable
resistance connection or inter­mittent open circuit due to loose
connection or broken wire.

4. Electrode lead or work lead con­nection may be poor.

5. Wrong grade of brushes may
have been installed on genera­tor.

6. Field rheostat may be making
poor contact and overheating.

1. Generator or exciter brushes
may be loose or missing.

WHATTODO

1. Commutator should be turned
or cleaned.

2. Replace brushes.

3. Check field current with ammeter

to discover varying current. This
applies to both the main genera­tor & the exciter.

4. Tighten all connections.

5. Use Lincoln brushes.

6. Inspect & clean the rheostat.

1. Be sure that all brushes bear on

the commutator and have proper
spring tension.

2. Exciter may not be operating.

3. Field circuit of generator or
exciter may be open.

4. Exciter may have lost excitation.

5. Series field and armature circuit
may be open-circuited.

C. Welding arc is loud and spat-

ters excessively.

(1)

See FLASHING THE FIELDS on following page.

1. Current setting may be too high.

2. Polarity may be wrong.

2. Check exciter output voltage
with voltmeter or lamp.

3. Check for open circuits in rheo­stat, field leads and field coils.
Check rectifier bridge.

4. Flash fields.

5. Check circuit with ringer or volt­meter.

1. Check setting and current output
with ammeter.

2. Check polarity. Try reversing
polarity or try an electrode of the
opposite polarity.

(1)

– 18 –

TROUBLESHOOTING

(Continued)

TROUBLE

D. Welding current too great or

too small compared to indica­tion on the dial.

E. Arc continuously pops out.

(1)

FLASHING THE FIELDS

CAUSE

1. Exciter output low causing low
output compared to dial indica­tion.

2. Operating speed too low or high.

1. “Current Range Selector” switch
may be set at an intermediate
position.

AC Auxiliary Power:

1. Stop the engine welder and remove the cover from the exciter.

WHATTODO

1. Check exciter field circuit.

2. Adjust speed screw on governor
for 1800 RPM operating speed.

1. Set the switch at the center of
the current range desired.

2. Turn the “Fine Adjustment Control” (rheostat) to “100” on the dial.

3. Using a 12 volt automotive battery, connect its negative terminal to the negative brushholder. The negative
brushholder is the one nearest to the rotor lamination. See the wiring diagram. With the engine NOT running,
touch the positive battery terminal to the positive brushholder. Remove the battery from the circuit.

4. Replace the exciter cover. Start the welder and the generator voltage should build up.

– 19 –

ELECTRONIC IDLER TROUBLESHOOTING GUIDE

Engine Will Not Return to Idle

in Approximately 15 Seconds

Set Idler Control Switch

to the Auto Position

Check to see Whether Oil Pressure

Light is On and Alternator is Charging

Light OFF

If Oil Light is O.K., Replace Check Continuity of Idler

Oil Pressure Switch Control Switch

Continuity Good Open

1. Reed Switch in Weld Replace Switch

Circuit may be Stuck Closed

2. Check Continuity of Idler
Solenoid Coil (25 ohms)

3. Replace P.C. Board

Engine Will Not Pick Up Speed When:

Light ON

The Arc is Struck

Reed Switch in Weld Circuit

Defective. Will Not Close Power Load Too Small

To Check; Short the Red Lead
on P.C. Board to Welder Frame Engine Does Not Pick Up Speed

Engine Picks Up Engine Does Not

Speed When Arc Pick Up Speed

is Struck

Replace P.C. Board

Replace Reed Switch

in Weld Circuit

The Auxiliary Power

Load is Turned On

Try Load Above 150 Watts

Replace P.C. Board

– 20 –

CONTROL PANEL COMPONENTS

LEAD COLOR CODE

B-BLACK

G-GREEN

N-BROWN

B

R

+

-

+

-

Y

R

W

B

B

U

U

SLIP RINGS

TO IRON

R

N

A

54

3

2

1

ALTERNATOR

AUXILIARY

POWER

WINDINGS

CURRENT

TRANSFORMER

CB3

CB1

115 VOLT

RECEPTACLE

230 VOLT

RECEPTACLE

Y

NEGATIVE

SELECTOR

SWITCH

WELDER

LEAD BLOCK

AC

AC

CR2 REED

RELAY

42

602A

G

U

CB2

CB4

FUSE

15A.

1

2

3

456

7

89

10

11

12

1

2

3

4

5

6

600A

41

GENERATOR

N

-W

+Y

G

G

W

B

B

600B

610

610

602B

IDLER

P.C.

BOARD

U

U

R

W

Y

IGNITION

SWITCH

START

STARTING

MOTOR

ENGINE

+

52

FUSE

(SFE-14)

IDLER

SWITCH

+

A

GNONC S B

IDLER

SOLENOID

ENGINE

PROTECTION

RELAY

ALTERNATOR

ROTOR

SLIP RING

NEAREST

-

HOUR

METER

J5

P9

J8

POSITIVE

ELECTRICAL SYMBOLS

PER E1537

P10

+Y

-W

N

U

W

B

-

50A

51

60

60A

56A

57

56

60D

RHEOSTAT

EXC

ALTERNATOR

+

OIL PRESSURE

SWITCH(N.C.)

TEMPERATURE

GAUGE

58

59A

59C

50

51A

54

53

(CC-)

(CC+) & (CV+ WITH W.F.M.)

B

S

B

Y

B

SEE

BELOW

*

W

G

PLUG FOR

REMOTE CONTROL

POTENTIOMETER

B

*

P8

1

2

3

4

5

6

X

41

600

42

602

R

W

R

BELOW

SEE

*

REMOTE CONTROL RECEPTACLE & SWITCH

X

Y

#2 HEAVY LEAD

WIRE FEED MODULE (OPTIONAL)

WIRE

FEED

MODULE

NEG.

POS.

OUTPUT TERMINALS

CONNECT TO POS. & NEG.

CONNECT TO NEG.

BRUSH HOLDER

608

609

#2 HEAVY LEAD

#8 LEAD

MACHINE MUST NOT BE RUNNING

WHEN MAKING THESE CONNECTIONS.

*

ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".

CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.

250 AMP

THERMOSTAT

ASSEMBLY

+

GROUND

B

B

B

SHOWN AS VIEWED FROM REAR.

CONNECT

TO CASE

THERMOSTART

IGNITER

THERMO

START

TO BASE

59B

FUEL

INJECTION

PUMP

51B

60B

SA-250 & 350-SA WIRING DIAGRAM

59

G

Y

B

B

’

NEUTRAL BONDED TO FRAME

NEUTRE RACCORDE AU BATI

-

(LEADS APPEAR ON

EARLIER UNITS ONLY)

WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON

MACHINE FROM CONNECTOR "J8". THEN CONNECT

PLUG "P8" ON REMOTE CONTROL TO

CONNECTOR "J8" ON MACHINE.

THE RED AND BLACK LEADS ARE USED ON CLASSIC I MACHINES ONLY AND ARE NOT

CONNECTED ON THIS MACHINE. DAMAGE TO THE REMOTE CONTROL AND/OR MACHINE

WILL RESULT IF THE RED AND BLACK LEADS ARE CONNECTED IN THE SA-250

AND 350-SA.

K924-1 REMOTE CONTROL (OPTIONAL)

REMOTE CONTROL

POTENTIOMETER BOX

SWITCH FOR LOCAL OR

REMOTE CONTROL SHOWN

IN LOCAL POSITION.

INLINE

CONNECTORS

W.F.M.

CONTROL

PANEL

NEGATIVE CV

OUTPUT TERMINAL

PANEL

PLUG

(P5)

Y

B

SEE

BELOW

*

W

G

B

*

P8

1

2

3

4

5

6

X

41

600

42

602

W

R

BELOW

SEE

*

REMOTE CONTROL RECEPTACLE & SWITCH

X

Y

CONNECT

TO CASE

K924-4 REMOTE CONTROL (OPTIONAL)

REMOTE CONTROL

POTENTIOMETER BOX

SWITCH FOR LOCAL OR

REMOTE CONTROL SHOWN

IN LOCAL POSITION.

RESISTORS

1

2

3

4

5

6

7

8

9

10

11

12

P11

SEE

BELOW

*

*

*

*

L9150

PLUG FOR REMOTE

CONTROL POTENTIOMETER

WITH MACHINE OFF, REMOVE PLUG "P9" ON MACHINE FROM CONNECTOR "J8". THEN CONNECT PLUG "P8"

ON REMOTE CONTROL KIT TO CONNECTOR "J8" ON MACHINE.

IF A WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISPOSE OF THE UNCONNECTED

PLUG "P10" (IF ONE IS ON THE MACHINE). FASTEN THE NEW PLUG "P11" NEARBY, LEAVING IT

UNCONNECTED.

IF NO WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISCONNECT PLUG "P10" ON THE

MACHINE FROM CONNECTOR "J5". CONNECT PLUG "P11" FROM THE REMOTE CONTROL KIT TO CONNECTOR

"J5" ON THE MACHINE.

THE RED AND BLACK LEADS ARE USED ON CLASSIC I MACHINES ONLY AND ARE NOT CONNECTED ON THIS

MACHINE. DAMAGE TO THE REMOTE CONTROL AND/OR MACHINE WILL RESULT IF THE RED AND BLACK

LEADS ARE CONNECTED IN THE SA-250 AND 350-SA.

CAUTION:

PLUG INSTALLED OR A WIRE FEED MODULE INSTALLED.

DAMAGE CAN OCCUR TO THE REMOTE CONTROL SWITCH IF IT IS USED WITHOUT THE "P11"

10-31-97L

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

– 21 –

28.00

DIMENSION PRINT

20.91

45.07

43.13

32.82

52.94

31.75

35.10

22.00

22.14

24.50

27.12

*

= .81 DIA HOLES

*

= .69 DIA HOLES

CENTER OF GRAVITY

WITH OIL AND

WATER IN ENGINE,

BUT NO FUEL.

6.00

61.00

65.25

67.00

48.50

53.75

*

*

M8869-24
7-28-95E

16.53

8.12

3.00

.88

– 22 –

NOTES

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How To Read Shop Drawings

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Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH

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James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
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(JFLF-515)

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WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

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Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com