Lincoln Electric SVM128-A manual

SVM128-A March, 1999 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with saf ety in mind. Howe v er , your o verall saf ety can be in- creased by proper installation . . . and thoughtful operation on your part. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANU AL AND THE SAFETY PR[...]

SAFETY i i SA-250 FOR ENGINE powered equipment. 1.a. T urn 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. _____________________________[...]

SAFETY ii ii SA-250 ARC RA YS 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 yo[...]

SA-250 FOR ELECTRICALL Y powered equipment. 8.a. T urn 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 Ele[...]

SAFETY iv iv SA-250 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les cir[...]

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v SA-250 Page Safety .................................................................................................................................................i-iv Installation .........................................................................................................................[...]

T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 SA-250 Installation T echnical Specifications ..............................................................................................................A-2 Safety Precautions .....................................................................................................[...]

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 INST ALLA TION A-2 A-2 SA-250 TECHNICAL SPECIFICA TIONS - SA-250 INPUT - DIESEL ENGINE Manufacturer Description Speed Displacement Ignition Capacities Perkins 3 cyl., 4 cycle 172[...]

Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions; and parts list[...]

ST ACKING SA-250 machines CANNOT be stacked. TIL TING Place the machine on a secure, level surface whenev- er you use it or store it. Any surfaces you place it on other than the ground must be firm, non-skid, and structurally sound. The diesel engine is designed to run in a level position for best performance. If you do operate it at a slight angle[...]

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 your engine manual or antifreeze con- tainer for alternate antifreeze recommendations.) MUFFLER This welder is supplied with an adjustable rain cap for the [...]

ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the 1 15 and 230 volt receptacles, weld output terminals, and ground stud. WELDING CABLE CONNECTIONS CABLE INST ALLA TION AND CABLE SIZES With the engine off, route the electrode and work cables through the strain relief bracket on the base and connect to the terminals located on the [...]

MACHINE GROUNDING According to the United States National Electrical Code, the frame of this portable generator is not required to be grounded and is permitted to serve as the grounding means for cord connected equipment plugged into its receptacles. Some state, local or other codes or unusual operating circumstances may require the machine frame t[...]

NOTES A-8 A-8 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[...]

Section B-1 Section B-1 SA-250 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions .............................................................................................................[...]

OPERA TING INSTRUCTIONS Read and understand this entire section before operat- ing your SA-250. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance [...]

RECOMMENDED APPLICA TIONS WELDER The SA-250 provides excellent constant current DC welding output for stick (SMA W) welding and for DC TIG welding. It also offers constant voltage output for DC semiautomatic wire feed welding. For more details on using the machine as a welder , see Welding Operation in the Operation section of this manual. GENERA T[...]

WELDING CAP ABILITY The SA-250 is rated 250 amps, 40 volts constant cur- rent DC at 60% duty cycle based on a ten minute time period. Longer duty cycles at lower output currents are possible. The current is continuously variable from 40 to 325 amps DC. LIMIT A TIONS • The SA-250 is not recommended for any processes besides those that are normally[...]

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 OPERA TION B-5 B-5 SA-250 FIGURE B.1 – OUTPUT CONTROLS 1. CURRENT RANGE SELECTOR 2. FINE CURRENT ADJUSTMENT 3. 230 VOL T DUPLEX RECEPT ACLE 4. 1 15 VOL T DUPLEX RECEPT ACLE 5. [...]

CONTROL OF WELDING CURRENT • DO NOT turn the CURRENT RANGE SELECTOR while welding because the current may arc between the contacts and damage the switch. • DO NOT attempt to set the CURRENT RANGE SELECTOR between the five points designated on the nameplate. See Figure B.2. The CURRENT RANGE SELECTOR provides five overlapping current ranges. The[...]

DIESEL ENGINE CONTROLS See Figure B.3 for the location of the following fea- tures: 1. IDLER CONTROL TOGGLE SWITCH: Adjusts the running speed of the engine. The switch has two positions, "HIGH" and "AUTO." In "HIGH," the engine runs continuously at high idle. In "AUTO," the idler control works as follows: Wel[...]

ENGINE OPERA TION DO NOT RUN THE ENGINE A T EXCESSIVE SPEEDS. The maximum allowable high idle speed for the SA-250 is 1800 RPM, no load. Do NOT increase the idle speed on the engine. Severe personal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed. Read and understand all safety instructions incl[...]

STOPPING THE ENGINE 1. Remove all welding and generator power loads and let the engine cool by running it for several minutes at low idle. 2. Place the IGNITION switch in the OFF position. When an engine is started for the first time, some of the oil will be needed to fill the passages of the lubricating system. Therefore, on initial starting, run [...]

WELDING OPERA TION TO USE THE SA-250 FOR DC CONST ANT CURRENT STICK OR TIG WELDING: 1. Remove the flange nuts from the weld output ter- minals and place the work and electrode welding cables over the terminals. See Figure B.4. Replace and tighten the flange nuts securely . Be sure the connections are tight. 2. Select the appropriate electrode. 3. A[...]

TO USE THE SA-250 FOR DC WIRE FEED WELDING (CONST ANT VOL T AGE WITH WIRE FEED MODULE): 1. Connect the LN-25 or LN-7 Wire Feeder . Follow the installation instructions provided with the wire feeder . 2. Set the machine for CV operation. 3. Start the diesel engine. See Engine Operation in this section of the manual. 4. Set the Idler Switch to "[...]

AUXILIAR Y POWER Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand a ± 10% voltage and a ± 3% frequency variation. The AC auxiliary power , supplied as a standard, has a rating of 3.0 kV A of 1 15/230V AC power (60 hertz). One 1 15V duplex and one 230V duplex grounding type receptacle are provided[...]

T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories ...................................................................................................................C-2 TIG Welding Accessories ......[...]

OPTIONS/ACCESSORIES The following options/accessories are available for your SA-250 from your local Lincoln Distributor . T railer (K913) - T wo-wheeled trailer for in-plant and yard towing. V arious hitches and accessories are available. For highway use, consult applicable federal, state, and local laws. Power Plug Kit (K802-C) - Provides a plug f[...]

TIG WELDING ACCESSORIES TIG Module (K930-1) - The TIG Module is an acces- sory that provides high frequency and shielding gas control for DC GT AW (TIG) welding applications. The K930-1 TIG Module is supplied without acces- sories. Arc Start switches, Amptrols, cables, torches and mounting brackets must be purchased separately . Control Cable (K936[...]

CONNECTION OF THE LN-7 T O THE SA-250 WITH K623-1 WIRE FEED MODULE USING K867 UNIVERSAL AD APTER (SEE FIGURE C.1.) 1. Shut the welder off. 2. Connect the electrode cable fr om the LN-7 to the “+” terminal of the welder . Connect the work cable to the “CV–” terminal of the welder . NOTE: W elding cable must be sized for current and duty cy[...]

CONNECTION OF THE LN-7 T O THE SA-250 WITH K623-1 WIRE FEED MODULE USING K584 INPUT CABLE ASSEMBL Y (SEE FIGURE C.2.) 1. Shut the welder off. 2. Connect the electr ode cable from the LN-7 to the “+” terminal of the welder . Connect the work cable to the “CV -” terminal of the welder . NOTE: W elding cable must be sized for current and duty [...]

CONNECTION OF THE LN-25 T O THE SA-250 WITH K623-1 WIRE FEED MODULE USING K867 UNIVERSAL AD APTER (SEE FIGURE C.3.) 1. Shut the welder off. 2. Connect the electr ode cable from the LN-25 to the “+” terminal of the welder . Connect the work cable to the “CV -” terminal of the welder . NOTE: W elding cable must be sized for current and duty c[...]

CONNECTION OF THE LN-25 TO THE SA-250 “ACROSS THE ARC” (SEE FIGURE C.4.) 1. Shut the welder off. 2. Connect the electrode cable fr om the LN-25 to the “+” terminal of the welder . Connect the work cable to the “CV–” terminal of the welder . NOTE: W elding cable must be sized for current and duty cycle of application. NOTE: Figur e C.4[...]

CONNECTION OF THE K488 SG CONTROL MODULE AND K487 MAGNUM SPOOL GUN TO THE SA-250 (SEE FIGURE C.5.) 1. Shut the welder off. 2. Connect the electrode cable fr om the SG Control Module to the “+” terminal of the welder . Connect the work cable to the “CV–” terminal of the welder . NOTE: W elding cable must be sized for current and duty cycle[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 SA-250 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions .......................................[...]

SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. • If covers or guards are missing from the machin[...]

CHANGE THE OIL FIL TER: Change the oil filter the first time between 25 and 50 hours of operation. Then, under normal operating conditions, change the oil filter after every 200 to 250 hours of operation. If the engine is operated under heavy load or in high ambient tem- peratures, change the oil filter more frequently . See T able D.1 for recommen[...]

FUEL FIL TER: Inspect the fuel filter daily . Drain any accumulated water from the engine fuel filter/water separator daily . Change the fuel filter every 400 hours of operation. Dust and dirt in the fuel system can cause the injection pump and injection nozzle to wear quickly . Change the fuel filter as follows: 1. See Figure D.2. Clean the outsid[...]

HOW TO ELIMINA TE AIR FROM THE FUEL SYSTEM There are two methods to eliminate air from the fuel system according to the type of pump fitted: See Figure D.3. The standard method is used where the fuel injection pump has vent screws 4 and 5. The self-vent method is used where the fuel injection pump has a self-vent feature. V ent screws are not fit- [...]

7. See Figure D.4. Loosen the union nut (1) at the fuelled starting aid (if one is fitted) and operate the lift pump until fuel, free from air , comes from the connection. T ighten the union nut at the starting aid. 8. See Figure D.4. Loosen the union nuts of the high- pressure pipes (2) at two of the atomisers. Operate the starter motor until fuel[...]

COOLING SYSTEM: The Perkins diesel engine is water cooled. Check the coolant level at the radiator filler daily . Add a 50-50 mixture of water and antifreeze as needed. T o drain and refill the system, do the fol- lowing: 1. Ensure that the machine is on level ground. T o avoid personal injury , never remove the radiator pressure cap nor the reserv[...]

TIGHTENING THE F AN BEL T : Fan belts tend to loosen after the first 50 hours of operation. If the fan belts are loose, the engine can overheat and the bat- tery can lose its charge. Check belt tightness by press- ing on the belt midway between the pulleys. The belt should deflect no more than 10 mm (0.375 in.). See Figure D.6. T o adjust the fan b[...]

MAINTENANCE D-9 D-9 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 T ABLE D.1 PERKINS ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Starting Engine • Fill fuel tank. • Check oil level. [...]

BA TTER Y MAINTENANCE GASES FROM BA TTERY can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • W ear gloves and eye protection and be careful when working near a battery . Follow the instructions printed on the battery . T o prevent EXPLOSION when: • INST ALLING A NEW BA TTERY - Disconn[...]

WELDER/GENERA TOR MAINTENANCE STORAGE: Store the SA-250 in clean, dry , protected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas. NAMEPLA TES: Whenever routine maintenance is performed on this machine - or at least yearly - inspect all nameplates a[...]

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 [...]

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 MAINTENANCE D-13 D-13 SA-250 FIGURE D.5 - MAJOR COMPONENT LOCA TIONS SA250-1 1 1. RIGHT CASE SIDE (DOOR) 2. BASE (WITH BA TTERY) 3. AL TERNA TOR BRUSHES 4. AL TERNA TOR 5. GENERA[...]

NOTES D-14 D-14 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[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 SA-250 Theory of Operation ............................................................................................................. Section E General Description ...........................................................................[...]

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 GENERAL DESCRIPTION The SA-250 is a heavy duty , engine driven DC arc welding pow er source capable of providing constant current output f or stick welding or DC TIG welding. Als[...]

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 ENGINE, GENERA T OR ARMA TURE AND FRAME, AL TERNA T OR ST A T OR AND RO T OR EXCIT A TION (FLASHING) When the engine is star ted and r unning, the residual magnetism v oltage is [...]

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 INTERPOLE AND SERIES COILS The generator armature rotates within the magnetic field created by the field shunt windings. A DC voltage is induced in the armature and is transferre[...]

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 THEOR Y OF OPERA TION E-5 E-5 SA-250 FIGURE E.4 – DC GENERA TOR MACHINES ARMATURE SHAFT GENERATOR ARMATURE SHUNT WINDINGS FIELD MECHANICAL COUPLING SHUNT WINDINGS FIELD B RUSH [...]

NOTES E-6 E-6 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[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 SA-250 T roubleshooting & Repair Section ................................................................................ Section F How to Use T roubleshooting Guide ........................................................................[...]

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 HOW T O USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may [...]

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 ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T urn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes[...]

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 TROUBLESHOOTING & REP AIR F-4 F-4 SA-250 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not unders[...]

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 TROUBLESHOOTING & REP AIR F-5 F-5 SA-250 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not unders[...]

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 TROUBLESHOOTING & REP AIR F-6 F-6 SA-250 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not unders[...]

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 TROUBLESHOOTING & REP AIR F-7 F-7 SA-250 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not unders[...]

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 TROUBLESHOOTING & REP AIR F-8 F-8 SA-250 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not unders[...]

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 TROUBLESHOOTING & REP AIR F-9 F-9 SA-250 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not unders[...]

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 TROUBLESHOOTING & REP AIR F-10 F-10 SA-250 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not unde[...]

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 TROUBLESHOOTING & REP AIR F-11 F-11 SA-250 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not unde[...]

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 F-12 F-12 SA-250 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not unde[...]

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 TROUBLESHOOTING & REP AIR F-13 F-13 SA-250 AL TERNA TOR ROT OR TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauth[...]

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 TROUBLESHOOTING & REP AIR F-14 F-14 SA-250 LOOSEN 5 SCREWS ALTERNATOR COVER SLIP RINGS BRUSHES FIGURE F .1 – AL TERNA TOR COVER REMOV AL AL TERNA TOR ROT OR TEST (continued[...]

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 TROUBLESHOOTING & REP AIR F-15 F-15 SA-250 FIGURE F .2 – MEASURING ROTOR RESIST ANCE 8. Working from the left side of the machine, measure the resistance across the rotor s[...]

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 TROUBLESHOOTING & REP AIR F-16 F-16 SA-250 FIGURE F .3 – MEASURING ROTOR RESIST ANCE TO GROUND 9. Measure the rotor resistance to ground. A. Set the ohmmeter on the high sc[...]

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 TROUBLESHOOTING & REP AIR F-17 F-17 SA-250 W ARNING FIELD SHUNT WINDING TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauth[...]

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 TROUBLESHOOTING & REP AIR F-18 F-18 SA-250 FIELD SHUNT WINDING TEST (continued) FIGURE F .4 – PLUG P10 LOCA TIONS PLUG P10 TEST PROCEDURE 1. T urn engine off. 2. Unlatch, l[...]

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 TROUBLESHOOTING & REP AIR F-19 F-19 SA-250 FIELD SHUNT WINDING TEST (continued) 6. Using the volt/ohmmeter set on the low scale (X1), measure the resistance between the blue [...]

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 TROUBLESHOOTING & REP AIR F-20 F-20 SA-250 W ARNING IDLER SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorize[...]

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 TROUBLESHOOTING & REP AIR F-21 F-21 SA-250 IDLER SOLENOID TEST (continued) FIGURE F .6 - SOLENOID LEAD CONNECTIONS LEADS 56 & 57 SOLENOID TEST PROCEDURE 1. T urn engine o[...]

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 TROUBLESHOOTING & REP AIR F-22 F-22 SA-250 W ARNING ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.[...]

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 TROUBLESHOOTING & REP AIR F-23 F-23 SA-250 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .7 - STROBE MARK LOCA TION STROBE MARK TEST PROCEDURE Strobe T ach Method 1. T[...]

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 TROUBLESHOOTING & REP AIR F-24 F-24 SA-250 ENGINE THROTTLE ADJUSTMENT TEST (continued) 6. If either of the readings is incorrect, adjust the throttle as follows: Adjust HIGH [...]

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 TROUBLESHOOTING & REP AIR F-25 F-25 SA-250 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .8 - HIGH IDLE ADJUSTMENT LOCKING NUT ADJUSTING SCREW FIGURE F .9 - LOW IDLE A[...]

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 TROUBLESHOOTING & REP AIR F-26 F-26 SA-250 W ARNING FLASHING THE FIELDS Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorize[...]

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 TROUBLESHOOTING & REP AIR F-27 F-27 SA-250 FLASHING THE FIELDS (continued) FIGURE F .10 - FLASHING THE FIELDS NEGATIVE (-) BRUSH HOLDER POSITIVE (+) BRUSH HOLDER 12 VOLT BATT[...]

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 TROUBLESHOOTING & REP AIR F-28 F-28 SA-250 This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division represen[...]

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 TROUBLESHOOTING & REP AIR F-29 F-29 SA-250 This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 50[...]

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 TROUBLESHOOTING & REP AIR F-30 F-30 SA-250 This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20[...]

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 TROUBLESHOOTING & REP AIR F-31 F-31 SA-250 W ARNING AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory train[...]

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 TROUBLESHOOTING & REP AIR F-32 F-32 SA-250 AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .1 1 – FRONT P ANEL REMOV AL REMOVE FASTENERS BATTERY RETAINER [...]

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 TROUBLESHOOTING & REP AIR F-33 F-33 SA-250 AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .12 – AL TERNA TOR COVER REMOV AL LOOSEN 5 SCREWS ALTERNATOR CO[...]

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 TROUBLESHOOTING & REP AIR F-34 F-34 SA-250 AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .13 – ROTOR REMOV AL STATOR FRAME NUT SLEEVE COLLAR "BENT&[...]

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 INST ALLA TION F-35 F-35 SA-250 AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT (continued) Replacement 12. Carefully mount the rotor onto the generator shaft. Install a new sleeve [...]

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 TROUBLESHOOTING & REP AIR F-36 F-36 SA-250 W ARNING AL TERNA TOR ST A TOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory tra[...]

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 TROUBLESHOOTING & REP AIR F-37 F-37 SA-250 AL TERNA TOR ST A TOR REMOV AL AND REPLACEMENT (continued) FIGURE F .14 – COMMUT A TOR WRAP-AROUND REMOV AL COMMUTATOR WRAP-AROUN[...]

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 TROUBLESHOOTING & REP AIR F-38 F-38 SA-250 FIGURE F .15 - LEAD DISCONNECTION POINTS YELLOW AND WHITE WIRE IN-LINE CONNECTORS; YELLOW LEADS; BLACK CURRENT TRANSFORMER LEAD ALL[...]

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 15. Clear the leads in preparation for remov- ing the stator/end bracket. 16. Lift the eight brushes from the commuta- tor . Note the position of the brushes for reassembly . TRO[...]

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 TROUBLESHOOTING & REP AIR F-40 F-40 SA-250 FIGURE F .18 - DRILL SPOT LOCA TIONS BRUSH HOLDER DRILL SPOT LOCATION STATOR/END BRACKET MOUNTING BOLT STATOR END BRACKET DRILL SPO[...]

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 TROUBLESHOOTING & REP AIR F-41 F-41 SA-250 W ARNING GENERA TOR FRAME REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained [...]

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 TROUBLESHOOTING & REP AIR F-42 F-42 SA-250 GENERA TOR FRAME REMOV AL AND REPLACEMENT (continued) FIGURE F .19 – FUEL T ANK / OUTPUT CABLE REMOV AL FUEL BOWL REED SWITCH ASS[...]

See Figure F .20 for steps 1 1 - 16. 1 1. Cut all necessary cable ties. 12. Disconnect the blue and the brown wires at the in- line connectors. See Figure F .20 and the Wiring Diagram. 13. Label the cables that are connected to the selector switch. Otherwise, you will need to see the Wiring Diagram during reassembly . NOTE: Some terminals have more[...]

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[...]

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 TROUBLESHOOTING & REP AIR F-45 F-45 SA-250 GENERA TOR FRAME REMOV AL AND REPLACEMENT (continued) FIGURE F .22 – FRAME MOUNTING DET AILS ENGINE/GENERATOR MOUNTING HOLES ROPE[...]

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 repl[...]

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 TROUBLESHOOTING & REP AIR F-47 F-47 SA-250 W ARNING GENERA TOR ARMA TURE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trai[...]

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 TROUBLESHOOTING & REP AIR F-48 F-48 SA-250 GENERA TOR ARMA TURE REMOV AL AND REPLACEMENT (continued) FIGURE F .23 – BLOWER P ADDLE REMOV AL BLOWER PADDLE/ARMATURE MOUNTING [...]

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 TROUBLESHOOTING & REP AIR F-49 F-49 SA-250 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical p[...]

NOTES F-50 F-50 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[...]

ELECTRICAL DIAGRAMS G-1 G-1 SA-250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams Section ................................................................................................ Section G Wiring Diagram .................................................................................[...]

NOTES 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[...]

G-2 ELECTRICAL DIAGRAMS SA-250 Wiring Diagram 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[...]

G-3 ELECTRICAL DIAGRAMS SA-250 Wiring Diagram (Wire Feed Module) CLEVELAND, OHIO U.S.A. 3-18-94 L9259 R AMPHENOL 1 A D F 510 602 610A 503A 609 501 CONTACTOR CONTACTOR ++ + 622 666 633 75A 76 77 75 R501 630 631 CV CONTROL 4 667 634 J2 J3 501 631 600 608 610A 509 503A 630 503 J4 2 1 GND 31 32 609 610A 510 501 503A 602 75 76 77 2 4 J1 E G J 32 31 4A G[...]

G-4 ELECTRICAL DIAGRAMS SA-250 Idler PC Board (M13708) Schematic -A X1 6 1 7 B209 T13157-14 1 D7 13.7K R18 5.11K R21 C3 X1 13 10 11 511 R16 5W 10V DZ1 LM2901 X1 3 12 22.1K R3 X1 8 14 9 4536B X2 16 8 C1 10K R2 133K R6 D1 47.5K R7 10K R1 + t 56 R8 13.7K R13 D G S 15A 60V Q1 B212 1 D2 33.2K R20 100V .047 C10 B213 1 15.0 R9 15.0 R15 26.7K R12 D8 10K R1[...]

G-5 ELECTRICAL DIAGRAMS SA-250 Idler PC Board (M13708) Components CAPACITORS = MFD/VOLTS RESISTORS = OHMS IDLER ENGINE WELDER R20 R17 R15 R9 R13 R1 R21 R16 R12 R2 R7 R4 R10 R3 R14 R18 R6 R19 R5 C9 C1 C8 C7 C5 C3 C2 C10 C6 D5 DZ3 D8 D7 D3 D2 D1 DZ2 X1 X2 R11 Q1 Q2 DZ1 C4 B210 B212 B211 B209 B213 R8 M13708 G-5 Return to Section TOC Return to Section [...]

SVM ERR OR REPORTING FORM W e need to know if there are errors in our manuals . W e also value an y suggestions as to additional tests or procedures that would mak e this SVM a better tool for y ou. If you disco ver ne w or different “Prob lems or Symptoms” that are not cov ered in the three col- umn troubleshooting chart, please share this inf[...]