Table of Contents
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Safety Depends on You
Lincoln arc welding equipment
is designed and built with safety
in mind. However, your overall
safety can be increased by
proper installation ... and
thoughtful operation on your
part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT
WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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SA-250
For Machines with Code Numbers 10890
NTRL/C
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
R
Copyright © 2003 Lincoln Global Inc.
IM747
January, 2003
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric SA-250
Summary of Contents for Lincoln Electric SA-250
- Page 1 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com RETURN TO MAIN MENU SA-250 For Machines with Code Numbers 10890 NTRL/C Copyright © 2003 Lincoln Global Inc.
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Page 2: California Proposition 65 Warnings
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. -
Page 3: Electric Shock Can Kill
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. - Page 4 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. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 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.
- Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...
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Page 7: Table Of Contents
________________________________________________________________________ Installation ...Section A Technical Specifications ...A-1 Pre-Operation Installation ...A-2 Safety Precautions ...A-2 Exhaust Spark Arrester ...A-2 Location/Ventilation...A-2 Machine Grounding...A-2 Lift Bail ...A-2 Trailers...A-2,A-3 Polarity Control and Cable Sizes ...A-3 Pre-Operation Service ...A-3 Oil...A-3 Fuel ...A-3 Cooling System ...A-3 Battery Charging ...A-4 ________________________________________________________________________ Operation ...Section B Safety Precautions...B-1... -
Page 8: Installation
TECHNICAL SPECIFICATIONS - SA-250 ( K1283-8) Make/Model Description Horsepower Operating Displacement cu. in.(ltrs) @ 1800RPM 4 Cylinder 4 Stroke Naturally Perkins 32.7 HP Aspirated 104-22 Water Cooled Engine RATED OUTPUT @ 104°F(40C°) - WELDER DESCRIPTION RATED DC OUTPUT* VOLTS @ RATED AMPS... -
Page 9: Safety Precautions
If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor dam- age the welding equipment. Some of the factors to be considered are as follows: SA-250 CAUTION WARNING can cause... -
Page 10: Polarity Control And Cable Sizes
The radiator has been filled at the factory with a 50-50 mixture of ethylene glycol antifreeze and water. Check the radiator level and add a 50-50 solution as needed (see engine manual or antifreeze container for alternate antifreeze recommendations). SA-250 CAUTION WARNING can cause fire or explosion. -
Page 11: Battery Charging
• 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. -
Page 12: Operation
----------------------------------------------------------- GENERAL DESCRIPTION The SA-250 is a heavy duty, engine driven, DC arc welding power source, capable of providing constant current output for stick welding or DC TIG welding. This welder is wound with all copper coils, rated at 300 amps/32 Volts. -
Page 13: Engine Operation
Use qualified person- nel to do this per the instructions in the MAINTE- NANCE section of this manual. SA-250 WITH PERKINS 104-22 DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATA Low idle (1375 RPM ) No Load @ 45 Volts High idle ( 1800 Rpm ) No load @ 96.6 Volts... -
Page 14: Welder Operation
ARC RAYS can burn. • Wear eye, ear, and body protection. DUTY CYCLE The NEMA output rating of the SA-250 is 300 amperes at 32 arc volts on a 60% duty cycle (consult Specifications in this manual for alternate ratings). -
Page 15: Auxiliary Power
20 amps to be drawn from either half. The total com- bined load of all receptacles is not to exceed 3.0 kVA. An optional power plug kit is available. When this kit is specified, the customer is supplied with a plug for each receptacle. SA-250... -
Page 16: Accessories
The use of an arc welder for pipe thawing is not approved by the CSA, nor is it recommended or supported by Lincoln Electric. ------------------------------------------------------------------------ ACCESSORIES Wire Feed Module (K623-1) - Provides constant voltage (CV) output with improved arc stability for Innershield welding. -
Page 17: Maintenance
COOLING SYSTEMS The SA-250 is equipped with a pressure radiator. Keep the radiator cap tight to prevent loss of coolant. Clean and flush the cooling system periodically to pre- vent clogging the passage and overheating the engine. -
Page 18: Idler Maintenance
Operate the electric fuel pump by turning the “Ignition” switch “ON” until fuel, free of air, flows from the vent point. Tighten the vent screw. 3. Contact your Perkins Engine repair facility if prob- lems persist. SA-250 WARNING Vent Screw FIGURE D.1... -
Page 19: Engine Service Chart
If necessary use shorter periods. MAINTENANCE ENGINE SERVICE 50/50 Water/Ethylene Glycol 9.5qrts, (9.0L) 8.7qrts, (8.2L) (including filter) Perkins #140517000 Perkins #1300366020 Perkins # 080109080 Donaldson #P181050 or Nelson #70206N Intake .008", exhaust .008" Contact Perkins R = Replace SA-250 TYPE OR QUANTITY 12/99 S20919-2... -
Page 20: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. -
Page 21: Welder Troubleshooting
WELDER TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Machine fails to hold the heat consistently. Welder starts but fails to generate current. Welding arc is loud and spatters excessively. Welding current too great or too small compared to indication on the dial. -
Page 22: Engine Troubleshooting Guide
ENGINE TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine does not start or operates Irregularly Engine stops during operation and the Engine Protection light does not turn on Engine stops during operation and the Engine Protection light does turn on If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. - Page 23 1. Broken Light Bulb 2. Faulty light wiring (to GND or P.C. Board ) 3. Faulty Idler/Engine Protection P.C. Board CAUTION SA-250 RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.
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Page 24: Electronic Idler Troubleshooting Guide
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TROUBLESHOOTING Set Idler Control Switch to the Auto Position Check for Continuity through Idler Control Switch 0 VDC Check for Jamming of the Idler Solenoid Return Spring Closed Replace Reed Switch CAUTION SA-250 Closed Replace Idler Control Switch... - Page 25 2. Check for Jamming of the Idler Solenoid Mechanism. Speed 3. Check for Continuity of Current Transformer (Toroid). Replace as Required. 4. Check Idler Circuit Wiring and Repair as Required. 5. Replace Idler P.C. Board. CAUTION SA-250 Power Load Too Small Try Load Above 150 Watts...
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Page 26: Wiring Diagrams
DIAGRAMS SA-250... -
Page 27: Dimension Print
DIMENSION PRINT SA-250... - Page 28 NOTES SA-250...
- Page 29 NOTES SA-250...
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Page 30: Basic Course
Address: Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Titles: Price New Lessons in Arc Welding $5.00... - Page 31 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 32 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 33 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...
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Do you have a question about the SA-250 and is the answer not in the manual?
Questions and answers
I’m trying to rewire my SA250 with Diesel engine
To rewire a Lincoln Electric SA-250 with a diesel engine:
1. Disconnect the battery to ensure safety.
2. Remove all damaged or rigged wiring.
3. Use a wiring diagram specific to the SA-250 to identify correct wire routing and connections.
4. Replace wires using proper gauge and type for each circuit.
5. Ensure all connections are clean, secure, and insulated.
6. Label wires for easier troubleshooting in the future.
7. Reconnect the battery and test all functions, including starting, welding, and auxiliary power.
Note: Total rewiring may be needed if previous wiring was heavily modified or spliced.
This answer is automatically generated