IM518-A

SA-250 PERKINS October, 2000

Diesel Engine Driven DC Arc Welding Power Source

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

RETURN TO MAIN MENU

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 thought-
ful 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:
R

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: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________

1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ‘95
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.

3.f. Maintain the electrode holder, work clamp, welding cable and 5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
3.g. Never dip the electrode in water for cooling. products.

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

5.e. Also see item 1.b.

Mar ‘95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.

6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.

6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95
iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instruc- zones où l’on pique le laitier.
tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté 6. Eloigner les matériaux inflammables ou les recouvrir afin de
générales suivantes: prévenir tout risque d’incendie dû aux étincelles.

Sûreté Pour Soudage A L’Arc 7. Quand on ne soude pas, poser la pince à une endroit isolé de
1. Protegez-vous contre la secousse électrique: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours 8. S’assurer que la masse est connectée le plus prés possible
tout contact entre les parties sous tension et la peau nue de la zone de travail qu’il est pratique de le faire. Si on place
ou les vétements mouillés. Porter des gants secs et sans la masse sur la charpente de la construction ou d’autres
trous pour isoler les mains. endroits éloignés de la zone de travail, on augmente le risque
b. Faire trés attention de bien s’isoler de la masse quand on de voir passer le courant de soudage par les chaines de lev-
soude dans des endroits humides, ou sur un plancher age, câbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques d’incendie ou d’echauffement des chaines et des
les positions assis ou couché pour lesquelles une câbles jusqu’à ce qu’ils se rompent.
grande partie du corps peut être en contact avec la
masse. 9. Assurer une ventilation suffisante dans la zone de soudage.
c. Maintenir le porte-électrode, la pince de masse, le câble Ceci est particuliérement important pour le soudage de tôles
de soudage et la machine à souder en bon et sûr état galvanisées plombées, ou cadmiées ou tout autre métal qui
defonctionnement. produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir. 10. Ne pas souder en présence de vapeurs de chlore provenant
e. Ne jamais toucher simultanément les parties sous tension d’opérations de dégraissage, nettoyage ou pistolage. La
des porte-électrodes connectés à deux machines à soud- chaleur ou les rayons de l’arc peuvent réagir avec les
er parce que la tension entre les deux pinces peut être le vapeurs du solvant pour produire du phosgéne (gas forte-
total de la tension à vide des deux machines. ment toxique) ou autres produits irritants.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions 11. Pour obtenir de plus amples renseignements sur la sûreté,
pour le porte-électrode s’applicuent aussi au pistolet de voir le code “Code for safety in welding and cutting” CSA
soudage. Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se pro-

téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
TRANSFORMATEUR ET À
REDRESSEUR
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 1. Relier à la terre le chassis du poste conformement au code
ou quand on regarde l’arc. de l’électricité et aux recommendations du fabricant. Le dis-
b. Porter des vêtements convenables afin de protéger la positif de montage ou la piece à souder doit être branché à
peau de soudeur et des aides contre le rayonnement de une bonne mise à la terre.
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au 2. Autant que possible, I’installation et l’entretien du poste
soudage à l’aide d’écrans appropriés et non-inflamma- seront effectués par un électricien qualifié.
bles.
3. Avant de faires des travaux à l’interieur de poste, la
4. Des gouttes de laitier en fusion sont émises de l’arc de debrancher à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur
pantalons sans revers, et chaussures montantes. place.

Mar. ‘93
v v

for selecting a QUALITY product by Lincoln Electric. We want you

Thank 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 Immediately

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

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

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

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

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

CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
 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 3.0 kVA of nominal 115/230V, 60 Hz, AC1. (See
welding power source capable of providing constant Optional Features for Power Plug Kits).
current output for stick welding or DC TIG welding.
(1) Output voltage is within ± 10% at all loads up to
With the addition of the optional Wire Feed Module for
K1283-4, the SA-250 will provide constant voltage rated capacity.
output for running the LN-25, LN-23P or LN-7 wire
feeders. The Wire Feed Module is factory-installed on Welder Enclosures
the K1283-5 SA-250.
The complete welder is rubber mounted on a rugged
The SA-250 has a current range of 40-325 DC amps
steel base.
with a 60% duty cycle at 250 amps/40 volts. The units
are also capable of providing 3 kVA of 115/230 volt,
The output terminals are placed at the side of the
60 Hertz AC auxiliary power.
machine so that they are protected by the door. The
output terminals are labeled (+) and (-).

DESIGN SUMMARY Remote Control

Control Panel K924-1 (for K1283-4, -5) (Field Installed). Provides a

receptacle switch and remote control box with 100 ft
Both the engine and the welder controls are located cord for fine current and OCV adjustment at the weld-
on one recessed panel at the auxiliary power alterna- ing site.
tor 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 Cranking System
equipped with a “Start” button and an “Idler Control”
switch. The Perkins diesel uses a “Thermostart” but-
ton, and has a “Stop” control. A 12 volt electric starter is standard.

On this panel is also mounted an engine temperature

gauge, a battery charging ammeter, an oil pressure Air Cleaner
gauge, and the three prong grounded type auxiliary
power receptacle. Heavy duty two stage dry type.

Copper Shunt Windings Muffler

For long life and dependable operation. A muffler to reduce engine noise is standard on the
diesel engine units.

Engine Idler Engine Hour Meter

The SA-250 is equipped with an electronic automatic A meter to record the hours of operation.
engine idler. It automatically increases and decreases
engine speed when starting and stopping welder or
using auxiliary power. A built-in time delay permits Diesel Engine Protection
changing electrodes before the engine slows to its low
idle speed. The “Idler Control Switch” on the panel The system shuts the engine down in the event of
locks the idler in full speed position when desired. sudden low oil pressure or high coolant temperature.

–7–
OPTIONAL FEATURES Power Plug Kit (K802C)

• A power plug kit for the auxiliary power receptacles

is available. (Provides a plug for each receptacle).
Accessory Set (K703)

Includes electrode and work cables, headshield, work Trailer (K913)

clamp, and electrode holder.
Two-wheeled highway trailer with steel, torsion-bar
axle, 54” (137cm) wheel track. Low sway, low center-
Ether Start Kit (K793-1) for Perkins Engine of-gravity. Sturdy tread plate platform. Choice of 3
hitches. Add on fender & light package. For highway
When frequent starting is expected below 10°F use, consult applicable local laws regarding possible
(-12°C), remove the “thermostart” system and install additional requirements.
the optional ether start kit to provide maximum cold
weather starting assistance. Note: The required ether Order: K913-1 Base Trailer
tank is not provided with the kit and must be pur- K913-2 Ball Hitch
chased locally. Ether starting should only be used as K913-3 Lunette Eye Hitch
required since indiscriminate application will contribute K913-4 Clevis Pin Hitch
to shortened engine life. (Available for field installation K913-5 Fender & Light Kit
only).

Hi-Freq™ (K799)
Wire Feed Module (K623-1)
Provides high frequency plus gas valve for DC TIG
welding. (Request Publication E385). The Wire Feed Module is field-installed on the K1283-4,
and factory-installed on the K1283-5 to provide CV
Optional field installed water valve kit available. Order (constant voltage) output for semiautomatic welding.
K844. Output rated at 250 Amps at 35 Volts with a 60% Duty
Cycle and 310 Amps at 32 Volts with a 35% Duty
Cycle.
Linc-Thaw™ (L2964-5) Control Unit

Includes meter and fuses to protect welder when DIMENSIONS

thawing frozen water pipes. See dimension Print M8869-24 at the rear of this man-
ual.

WARNING
Pipe Thawing IS NOT a CSA approved procedure.
If not done properly, it can result in fire, explosion,
damage to wiring which may make it unsafe, dam-
age to pipes, burning up the welder, or other haz-
ards.
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.

–8–
 SPECIFICATIONS

Machine
Product Ordering (1) Description Rated DC Output (2) Current Range Auxiliary Dimensions & Weight
(Fine Adjustments
Name Information Amps / Volts / Duty Cycle Power HxWxL
in each Range)

250 Amp DC
SA-250 K1283-4 Lincoln Rating 40 - 325 Amps 3 kVA 43.1 x 28 x 67 in
Arc Welder
Perkins (WFM 250A / 40V (1096 x 711 x 1702 mm)
Field- 220 - Max.
60% Duty Cycle 115/230V,
Installed) Stick / DC TIG 160 - 240
120 - 190 60 Hz 1650 lbs
Welding
K1283-5 NEMA Rating 80 - 130 (742.5 kg)
(WFM 250A / 30V Min. - 90
Factory- Pure DC Power
60% Duty Cycle
Installed) Generator

(1) WFM = Wire Feed Module.

(2) Based on a 10 Minute Period.

Engine
Product Description Horsepower Operating Displacement Capacities
Name Speeds

Perkins D3.152 3 Cylinder, Full Load: Full Load: 152 Cu. in. Fuel:
4 Cycle, 38.2 HP 1725 RPM (2.5 ltrs) 15 gals (57 ltrs)
Water-Cooled @ 1725 RPM
Diesel Engine with High Idle: Oil:
Thermostart Glow Plug 1800 RPM 7.2 qts (6.9 ltrs)
and Engine Protection
Low Idle: Water:
1350 RPM 10 qts (9.5 ltrs)

–9–
PRE-OPERATION INSTALLATION Machine Grounding

Safety Precautions According to the United States National Electrical

Code, the frame of this portable generator is not
WARNING required to be grounded and is permitted to serve as
Do not attempt to use this equipment until you the grounding means for cord connected equipment
have thoroughly read the engine manufacturer’s plugged into its receptacle.
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions, Some state, local or other codes or unusual operating
and parts lists. circumstances may require the machine frame to be
------------------------------------------------------------------------ grounded. It is recommended that you determine the
ELECTRIC SHOCK can kill. extent to which such requirements may apply to your
• Do not touch electrically live parts or particular situation and follow them explicitly. A
electrode with skin or wet clothing. machine grounding stud marked with the symbol
• Insulate yourself from work and
is provided on the welding generator frame foot. (If an
ground
• Always wear dry insulating gloves. older portable welder does not have a grounding stud,
------------------------------------------------------------------------ connect the ground wire to an unpainted frame screw
ENGINE EXHAUST can kill. or bolt.
• Use in open, well ventilated areas or
vent exhaust outside. 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
------------------------------------------------------------------------
MOVING PARTS can injure. ground for at least ten feet and having no insulated
• Do not operate with doors open or joints, or to the metal framework of a building which
guards off. has been effectively grounded. The U.S. National
• Stop engine before servicing. Electrical Code lists a number of alternate means of
• Keep away from moving parts. grounding electrical equipment.
------------------------------------------------------------------------
Lift Bail
See additional warning information at
front of this operator’s manual. A lift bail is provided for lifting with a hoist.
-----------------------------------------------------------
WARNING
Exhaust Spark Arrester
FALLING EQUIPMENT can cause
Some federal, state or local laws may require that injury.
diesel engines be equipped with exhaust spark • Do not lift this machine using lift bail if
arresters when they are operated in certain locations it is equipped with a heavy accessory
where unarrested sparks may present a fire hazard. such as a trailer or gas cylinder.
The standard mufflers included with these welders do • Lift only with equipment of adequate lifting capacity.
not qualify as a spark arrester. When required by • Be sure machine is stable when lifting.
local regulations, suitable spark arresters must be ----------------------------------------------------------------------
installed and properly maintained.

CAUTION Trailers (See Optional Features)

Use of an incorrect arrester may lead to engine damage
or performance loss. Contact the engine manufacturer If the user adapts a non-Lincoln trailer, he must
for specific recommendations. 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
Location / Ventilation
considered are as follows:

Always operate the welder with the doors closed. 1. Design capacity of trailer vs. weight of Lincoln
Leaving the doors open changes the designed air flow equipment and likely additional attachments.
and may cause overheating.
2. Proper support of, and attachment to, the base of
The welder should be located to provide an unrestrict- the welding equipment so there will be no undue
ed flow of clean, cool air. Also, locate the welder so stress to the framework.
that the engine exhaust fumes are properly vented to
an outside area.
– 10 –
3. Proper placement of the equipment on the under-
carriage 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, rough-

ness of surface on which the trailer will be operat-
ed, environmental conditions & likely maintenance.

5. Conformance with federal, state and local laws. (1)

(1) Consult applicable federal, state and local laws regarding specific
requirements for use on public highways.

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 350 Amps
@ 60% Duty Cycle @ 25% Duty Cycle
Up to 200 ft 1 2/0
200-250 ft 1/0 3/0

– 11 –
PRE-OPERATION SERVICE Battery Charging

WARNING
CAUTION
GASES FROM BATTERY can explode.
READ the engine operating and maintenance instruc- • Keep sparks, flame and cigarettes
tions supplied with this machine. away.
------------------------------------------------------------

WARNING BATTERY ACID can burn eyes and

skin.
Fuel can cause fire or explosion. • Wear gloves and eye protection and
- be careful when boosting, charging or
• Stop engine while fueling. working near battery.
• Do not smoke when fueling.
• Do not overfill tank.
To prevent EXPLOSION when:
a) Installing a new battery - disconnect the
• Keep sparks and flame away from tank.
negative cable from the old battery first and
• Wipe up spilled fuel and allow fumes to clear connect the negative cable to the new battery
before starting engine. last.
------------------------------------------------------------------------ b) Connecting a battery charger - remove the
battery from the welder by disconnecting the
negative cable first, then the positive cable and
Oil battery clamp. When reinstalling, connect the
negative cable last.
This unit is supplied from the factory with the engine c) Using a booster - connect the positive lead to
crankcase filled with a high quality 10W30 oil. This oil the battery first, then connect the negative lead to
should be acceptable for most typical ambient temper- the ground lead on the base.
atures. Consult the engine operation manual for spe-
cific engine manufacturer’s recommendations. Upon To prevent ELECTRICAL DAMAGE when:
receipt of the welder, check the engine dipstick to be a) Installing a new battery.
sure the oil is at the “full” mark. DO NOT OVERFILL. b) Using a booster.

Use correct polarity - Negative Ground.

Fuel To prevent BATTERY DISCHARGE, if you have an
ignition switch, turn it off when engine is not
Fill the fuel tank with the grade of fuel recommended running.
in the Engine Operator’s Manual. Make sure the fuel
valve on the sediment bowl is in the open position. • To prevent BATTERY BUCKLING, tighten nuts on
battery clamp until snug.
------------------------------------------------------------------------
Cooling System

The cooling system has been filled at the factory with

The SA-250 is equipped with a wet charged battery.
a 50-50 mixture of ethylene glycol antifreeze and
The charging current is automatically regulated when
water. Check the radiator level and add a 50-50 solu-
the battery is low (after starting the engine) to a trickle
tion as needed. (See engine manual or antifreeze
current when the battery is fully charged.
container from alternate antifreeze recommendation.)
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 Cold Weather Starting -- When overnight tempera-
tures are between 10°F (-12°C) and freezing, use the
WARNING standard “Thermostart” starting system installed on all
engines. Follow the instructions on the nameplate
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s and in the engine manual shipped with the welder.
manual supplied with your welder. It includes With fully charged batteries and the proper weight oil,
important safety precautions, detailed engine the “Thermostart” system operates satisfactorily even
starting, operating and maintenance instructions, down to about 0°F (-18°C).
and parts lists.
------------------------------------------------------------------------ If the engine must be frequently started below 10°F (-12°C),
ELECTRIC SHOCK can kill. it may be desirable to remove the “Thermostart” and
• Do not touch electrically live parts or
electrode with skin or wet clothing. install the optional ether starter kit. Installation and
• Insulate yourself from work and operating instructions are included in the kit. Use
ground ether starting only when required because excessive
• Always wear dry insulating gloves. use shortens engine life.
------------------------------------------------------------------------
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. Stopping the Perkins D3.152 Engine
------------------------------------------------------------------------
a) Turn the ignition control to “OFF”.
See additional warning information at
front of this operator’s manual. 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 sys-
Operate the welder with the doors closed. Leaving tem.
the doors open changes the designed air flow and can
cause overheating. 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 When a forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Current
WARNING Range Selector” setting and lower open circuit volt-
age. For example: to obtain 175 amps and a forceful
ELECTRIC SHOCK can kill. arc, set the “Current Range Selector” to the 240-160
• Do not touch electrically live parts or position and the “Fine Current Adjustment” setting to
electrode with skin or wet clothing. get 175 amps.
• Insulate yourself from work and ground.

FUMES & GASES can be dangerous. CAUTION

• Keep your head out of the fumes. DO NOT attempt to set the “Current Range Selector”
• Use ventilation or exhaust to remove between the five points designated on the nameplate.
fumes from breathing zone. ------------------------------------------------------------------------
These switches have a spring loaded cam which
WELDING SPARKS can cause fire or almost eliminates the possibility of setting this switch
explosion. between the designated points.
• Keep flammable material away.

Idler Operation
ARC RAYS can burn.
• Wear eye, ear, and body protection.
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 operat-
Duty Cycle ing speeds are as follows:

The NEMA output rating of the SA-250 is 250 ORDERING ENGINE FULL HIGH LOW
INFO. LOAD IDLE IDLE
amperes at 30(1) arc volts on a 60% duty cycle. Duty
cycle is based on a ten minute period; thus, the K1283- Perkins 1725 1800 1350
welder can be loaded at rated output for six minutes ALL Diesel
out of every ten minute period.

(1) The Lincoln “plus output” rating at 60% duty cycle The idler is controlled by an “Idler Control” toggle
is 250 amperes at 40 volts. switch on the welder control panel. The switch has
two positions as follows:
Control of Welding Current
1. In the “High” position, the idler is off, and the
CAUTION engine runs at the high speed controlled by the
governor.
DO NOT TURN THE “CURRENT RANGE SELEC-
2. In the “Automatic” / position, the
TOR” WHILE WELDING because the current may
idler operates as follows:
arc between the contacts and damage the switch.
------------------------------------------------------------------------
a. When welding or drawing power for lights or
The “Current Range Selector” provides five overlap-
tools (approximately 100-150 watts minimum)
ping current ranges. The “Fine Current Adjustment”
from the receptacles, the engine operates at full
adjusts the current from minimum to maximum within
speed.
each range. Open circuit voltage is also controlled by
the “Fine Current Adjustment” permitting control of the
b. When welding ceases or the power load is
arc characteristics.
turned off, a preset time delay of about 15 sec-
onds starts. This time delay cannot be adjust-
A high open circuit voltage setting provides the soft
ed.
“buttering” arc with best resistance to pop-outs pre-
ferred for most welding. To get this characteristic, set
c. If the welding or power load is not re-started
the “Current Range Selector” to the lowest setting that
before the end of the time delay, the idler
still provides the current you need and set the “Fine
reduces the engine to low idle speed.
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 –
Auxiliary Power MAINTENANCE
The AC auxiliary power, supplied as a standard, has a WARNING
rating of 3.0 kVA of 115/230V AC (60 Hz). Have qualified personnel do the maintenance
work. Turn the engine off before working inside
With the 3.0 kVA, 115/230V AC auxiliary power, one the machine. In some cases, it may be neces-
duplex 115V grounding type receptacle (NEMA con- sary to remove safety guards to perform
figuration 5-15R) is provided. For the 230V AC required maintenance. Remove guards only
power, one grounding type duplex receptacle is pro- when necessary and replace them when the
vided (NEMA configuration 6-15R). The circuit is pro- maintenance requiring their removal is com-
tected with circuit breakers. plete. Always use the greatest care when work-
ing near moving parts.
The rating of 3.0 kVA permits a maximum continuous
current of 13 amps to be drawn from the 230 volt Do not put your hands near the engine cooling
duplex receptacle. Or a total of 26 amps can be blower fan. If a problem cannot be corrected by
drawn from the 115 volt duplex receptacle. The 115 following the instructions, take the machine to
volt duplex receptacle has a configuration which per- the nearest Lincoln Field Service Shop.
mits 15 amps to be drawn from either half. Therefore, -----------------------------------------------------------------------
on this machine, up to 15 amps continuous can be ELECTRIC SHOCK can kill.
drawn from one half and the balance of 11 amps from • Do not touch electrically live parts or
the other half. The total combined load of all recepta- electrode with skin or wet clothing.
cles is not to exceed 3.0 kVA. • Insulate yourself from work and
ground
• Always wear dry insulating gloves.
An optional power plug kit is available. When this kit ------------------------------------------------------------------------
is specified, the customer is supplied with a plug for ENGINE EXHAUST can kill.
each receptacle. In this case, he will receive two 15 • Use in open, well ventilated areas or
amp, 115 volt plugs (NEMA configuration 5-15P) and vent exhaust outside.
two 15 amp, 230 volt plugs (NEMA configuration
6-15P).
------------------------------------------------------------------------
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 clean equipment. More bearing failures are caused
the proper grade of oil as recommended in the by dirt introduced during greasing than from insuffi-
engine operating manual. cient grease.

4. Change the oil filter in accordance with the instruc- Commutator & Brushes
tions in the engine operator’s manual. When the
filter is changed, add a quart of oil to the crankcase WARNING
to replace the oil held in the filter during operation.
Uncovered rotating equipment can be dangerous.
5. Inspect the air filter daily - more often in dusty con- Use care so your hands, hair, clothing or tools do
ditions. When necessary, clean or replace. The not catch in the rotating parts. Protect yourself
filter should never be removed while the engine is from particles that may be thrown out by the rotat-
running. ing armature when stoning the commutator.
------------------------------------------------------------------------
6. Change the diesel fuel filters every 500 hours of The generator brushes are properly adjusted when
operation. the welder is shipped. They require no particular
attention. DO NOT SHIFT THE BRUSHES or adjust
7. Fan belts tend to loosen after the first 30 or 40 the rocker setting. Shifting of the brushes may result
hours of operation. Check and tighten if neces- in:
sary. DO NOT OVERTIGHTEN. • change in machine output
• commutator damage
8. Put a drop of oil on the “Current Range Selector” • excessive brush wear
shaft at least once every month.
Periodically inspect the commutator, slip rings and
9. See the engine manufacturer’s Operating Manual brushes by removing the covers. DO NOT remove or
for detailed engine maintenance and troubleshoot- replace these covers while the machine is running.
ing instructions.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
Cooling System using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
The SA-250 is equipped with a pressure radiator.
Keep the radiator cap tight to prevent loss of coolant. NOTE: If the welder is used in dirty or dusty locations,
Clean and flush the cooling system periodically to pre- or if the welder is not used for prolonged periods of
vent clogging the passage and overheating the time, it may be necessary to clean the commutator
engine. When antifreeze is needed, always use the and slip rings more often.
permanent type.
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
ORDERING INFORMA- COOLING SYSTEM
to fit the commutator. Have an experienced mainte-
TION CAPACITY
nance man seat these brushes by lightly stoning the
K1283-ALL 10 Quarts 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.

To seat the slip ring brushes, position the brushes in

Bearings place. Then slide one end of a piece of fine sandpa-
per between slip rings and brushes with the coarse
This welder is equipped with a double-shielded ball side against the brushes. With slight additional finger
bearing having sufficient grease to last indefinitely pressure on top of the brushes, pull the sandpaper
under normal service. Where the welder is used con- around the circumference of the rings, in direction of
stantly or in excessively dirty locations, it may be nec- rotation only - until brushes seat properly. In addition,
essary to add one-half ounce of grease per year. A stone slip ring with a fine stone. Brushes must be
pad of grease one inch wide, one inch long, and one seated 100%.
inch high weighs approximately one-half ounce.
Over-greasing is far worse than insufficient greasing. Arcing or excessive exciter brush wear indicates a
possible misaligned shaft. Have an authorized Field
When greasing the bearings, keep all dirt out of the Service Shop check and realign the shaft.
area. Wipe the fittings completely clean and use
– 16 –
Idler Maintenance TROUBLESHOOTING
CAUTION WARNING
Before doing electrical work on the idler printed Have qualified personnel do the troubleshooting
circuit board, disconnect the battery. work. Turn the engine off before working inside
------------------------------------------------------------------------ the machine. In some cases, it may be neces-
1. The solenoid plunger must work freely because sary to remove safety guards to perform
binding can cause engine surging. If surging required maintenance. Remove guards only
occurs, be sure the plunger is properly lined up when necessary and replace them when the
with the throttle lever. Dust the plunger about once maintenance requiring their removal is com-
a year with graphite powder. plete. Always use the greatest care when work-
ing near moving parts.
2. When any service is done, reassemble the rubber
bellows on the solenoid plunger with the vent hole Do not put your hands near the engine cooling
on the lower side. blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
3. Proper operation of the idler requires good ground- the nearest Lincoln Field Service Shop.
ing of the printed circuit board (through its mount- -----------------------------------------------------------
ing), reed switch and battery. ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
4. If desired, the welder can be used without automat- electrode with skin or wet clothing.
ic idling by setting the “Idler Control” switch to the • Insulate yourself from work and
ground
“High Idle” position. • Always wear dry insulating gloves.
------------------------------------------------------------------------
5. When installing a new battery or using a jumper ENGINE EXHAUST can kill.
battery to start the engine, be sure the battery • Use in open, well ventilated areas or
polarity is connected properly. The correct polarity vent exhaust outside.
is negative ground. Damage to the engine alterna-
tor and the printed circuit board can result from
------------------------------------------------------------------------
incorrect connection. 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
------------------------------------------------------------

Nameplates

Whenever routine maintenance is performed on this

machine, or at least yearly, inspect all nameplates and
labels for legibility. Replace those which are no
longer clear. Refer to the parts list for the replace-
ment item number.

– 17 –
 TROUBLESHOOTING

TROUBLE CAUSE WHAT TO DO

A. Machine fails to hold the “heat” 1. Rough or dirty commutator. 1. Commutator should be turned
consistently. or cleaned.

2. Brushes may be worn down to 2. Replace brushes.

limit.

3. Field circuit may have variable 3. Check field current with ammeter
resistance connection or inter- to discover varying current. This
mittent open circuit due to loose applies to both the main genera-
connection or broken wire. tor & the exciter.

4. Electrode lead or work lead con- 4. Tighten all connections.

nection may be poor.

5. Wrong grade of brushes may 5. Use Lincoln brushes.

have been installed on genera-
tor.

6. Field rheostat may be making 6. Inspect & clean the rheostat.

poor contact and overheating.

B. Welder starts but fails to gener- 1. Generator or exciter brushes 1. Be sure that all brushes bear on
ate current. may be loose or missing. the commutator and have proper
spring tension.

2. Exciter may not be operating. 2. Check exciter output voltage

with voltmeter or lamp.

3. Field circuit of generator or 3. Check for open circuits in rheo-

exciter may be open. stat, field leads and field coils.
Check rectifier bridge.

4. Exciter may have lost excitation. 4. Flash fields. (1)

5. Series field and armature circuit 5. Check circuit with ringer or volt-
may be open-circuited. meter.

C. Welding arc is loud and spat- 1. Current setting may be too high. 1. Check setting and current output
ters excessively. with ammeter.

2. Polarity may be wrong. 2. Check polarity. Try reversing

polarity or try an electrode of the
opposite polarity.

(1) See FLASHING THE FIELDS on following page.

– 18 –
 TROUBLESHOOTING (Continued)

TROUBLE CAUSE WHAT TO DO

D. Welding current too great or 1. Exciter output low causing low 1. Check exciter field circuit.
too small compared to indica- output compared to dial indica-
tion on the dial. tion.

2. Operating speed too low or high. 2. Adjust speed screw on governor

for 1800 RPM operating speed.

E. Arc continuously pops out. 1. “Current Range Selector” switch 1. Set the switch at the center of
may be set at an intermediate the current range desired.
position.

(1) FLASHING THE FIELDS

AC Auxiliary Power:

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

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 Light ON

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:

The Arc is Struck The Auxiliary Power

Load is Turned On
Reed Switch in Weld Circuit
Defective. Will Not Close Power Load Too Small
Try Load Above 150 Watts
To Check; Short the Red Lead
on P.C. Board to Welder Frame Engine Does Not Pick Up Speed
Replace P.C. Board

Engine Picks Up Engine Does Not

Speed When Arc Pick Up Speed
is Struck
Replace P.C. Board
Replace Reed Switch
in Weld Circuit

– 20 –
 SA-250 & 350-SA WIRING DIAGRAM
CONTROL PANEL COMPONENTS
ELECTRICAL SYMBOLS
PER E1537 SHOWN AS VIEWED FROM REAR.
P10
NEUTRAL BONDED TO FRAME
LEAD COLOR CODE ’
NEUTRE RACCORDE AU BATI 12 11 10 9 8 7 6 5 4 3 2 1
B-BLACK J5
THERMOSTART U G-GREEN W
IDLER B +Y
IGNITER U N-BROWN N -W
P.C. R ALTERNATOR ROTOR U
ENGINE
W (LEADS APPEAR ON SLIP RINGS
PROTECTION BOARD
Y EARLIER UNITS ONLY) -
RELAY + B 610
56A SLIP RING +
53 ENGINE NEAREST 610
IDLER 57 W B
HOUR IGNITION R 602B
SWITCH TO IRON AC AC 600B
METER SWITCH
THERMO IDLER
FUSE (SFE-14) 41 1
START START SOLENOID
+ - 56
115 VOLT 230 VOLT - 600A 2
G NO NC S B Y
58 59B RECEPTACLE RECEPTACLE 42 3
OIL PRESSURE
B 15A.
51B G 4
59 SWITCH(N.C.) Y
60 54 FUSE 602A
52 5
51A RHEOSTAT
6
Y J8 P9
59C B
60A
SELECTOR
50A B
R SWITCH
FUEL
INJECTION G
B PUMP ALTERNATOR
CB2 B B CB3 W
CB1 CB4 AUXILIARY
TEMPERATURE POWER
GAUGE
G
WINDINGS
GENERATOR
50 B
B G
S A
+ - 59A B
A
ALTERNATOR
B 5 4 3 2 1

+
STARTING CURRENT
EXC
CR2 REED WELDER
+ - U TRANSFORMER
MOTOR 51 RELAY LEAD BLOCK
U N
R U

– 21 –
-W
60B +Y
60D
GROUND N
TO BASE NEGATIVE POSITIVE
(CC-) (CC+) & (CV+ WITH W.F.M.)

K924-4 REMOTE CONTROL (OPTIONAL) P11

K924-1 REMOTE CONTROL (OPTIONAL) WIRE FEED MODULE (OPTIONAL)
PLUG FOR REMOTE ** SEE
REMOTE CONTROL RECEPTACLE & SWITCH
CONTROL POTENTIOMETER BELOW
PLUG FOR ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
REMOTE CONTROL RECEPTACLE & SWITCH
REMOTE CONTROL CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE. 1
B X RESISTORS G Y X
POTENTIOMETER * SEE 2
BELOW R
B X 3
* SEE
BELOW R Y X INLINE
1 41 4
CONNECTORS PLUG
2 600 W Y 5
(P5) W
1 41 W.F.M. B
* SEE 3 42 6
2 600 CONTROL BELOW
Y
SEE 4 602 7
PANEL
* 3 42 W
BELOW R G B 5 8
4 602 WIRE
#8 LEAD 6 9
5 CONNECT
W CONNECT TO POS. & NEG. POS. P8 10
TO CASE
6 FEED
OUTPUT TERMINALS 11
NEG. CONNECT
P8 SWITCH FOR LOCAL OR
MODULE TO CASE 12
NEGATIVE CV REMOTE CONTROL SHOWN
SWITCH FOR LOCAL OR REMOTE CONTROL
OUTPUT TERMINAL #2 HEAVY LEAD IN LOCAL POSITION.
REMOTE CONTROL SHOWN POTENTIOMETER BOX
PANEL
IN LOCAL POSITION. 608
* WITH MACHINE OFF, REMOVE PLUG "P9" ON MACHINE FROM CONNECTOR "J8". THEN CONNECT PLUG "P8"
609
CONNECT TO NEG. ON REMOTE CONTROL KIT TO CONNECTOR "J8" ON MACHINE.
* WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON
REMOTE CONTROL BRUSH HOLDER ** IF A WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISPOSE OF THE UNCONNECTED
MACHINE FROM CONNECTOR "J8". THEN CONNECT POTENTIOMETER BOX PLUG "P10" (IF ONE IS ON THE MACHINE). FASTEN THE NEW PLUG "P11" NEARBY, LEAVING IT
PLUG "P8" ON REMOTE CONTROL TO #2 HEAVY LEAD UNCONNECTED.
CONNECTOR "J8" ON MACHINE. 250 AMP IF NO WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISCONNECT PLUG "P10" ON THE
* MACHINE MUST NOT BE RUNNING MACHINE FROM CONNECTOR "J5". CONNECT PLUG "P11" FROM THE REMOTE CONTROL KIT TO CONNECTOR
THERMOSTAT
ASSEMBLY "J5" ON THE MACHINE.
THE RED AND BLACK LEADS ARE USED ON CLASSIC I MACHINES ONLY AND ARE NOT
WHEN MAKING THESE CONNECTIONS.
CAUTION: DAMAGE CAN OCCUR TO THE REMOTE CONTROL SWITCH IF IT IS USED WITHOUT THE "P11"
CONNECTED ON THIS MACHINE. DAMAGE TO THE REMOTE CONTROL AND/OR MACHINE PLUG INSTALLED OR A WIRE FEED MODULE INSTALLED.
WILL RESULT IF THE RED AND BLACK LEADS ARE CONNECTED IN THE SA-250 THE RED AND BLACK LEADS ARE USED ON CLASSIC I MACHINES ONLY AND ARE NOT CONNECTED ON THIS
AND 350-SA. 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.
10-31-97L

L9150

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..
 DIMENSION PRINT

52.94

28.00 31.75

20.91

45.07

43.13 32.82 35.10

16.53

6.00

22.00
*
48.50

22.14
* CENTER OF GRAVITY
*
53.75 8.12

24.50 61.00 3.00

WITH OIL AND
WATER IN ENGINE,
27.12 BUT NO FUEL. 65.25 .88

67.00

* = .81 DIA HOLES

= .69 DIA HOLES

M8869-24
7-28-95E

– 22 –
NOTES
Now Available...12th Edition New Lessons in Arc Welding
The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
since 1933, the Procedure Handbook is considered by many to such as distortion; and supplemental information on arc
be the “Bible” of the arc welding industry. welding applications, speeds and costs. Practice materials,
This printing will go fast so don’t delay. Place your exercises, questions and answers are suggested for each
order now using the coupon below. lesson.

The hardbound book contains over 750 pages of welding 528 pages, well illustrated, 6” x 9” size, bound in simulated,
information, techniques and procedures. Much of this material gold embossed leather.
has never been included in any other book. $5.00 postage paid U.S.A. Mainland

A must for all welders, supervisors, engineers and

designers. Many welding instructors will want to use the book
as a reference for all students by taking advantage of the low
quantity discount prices which include shipping by
4th class parcel post.
$15.00 postage paid U.S.A. Mainland
Need Welding Training?
The Lincoln Electric Company operates the oldest and
How To Read Shop Drawings most respected Arc Welding School in the United States at its
corporate headquarters in Cleveland, Ohio. Over 100,000 stu-
dents have graduated. Tuition is low and the training is
The book contains the latest information and application
“hands on”
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and For details write: Lincoln Welding School
draftsmen use the “short-cut” language of symbols to pass 22801 St. Clair Ave.
on assembly and welding information to shop personnel. Cleveland, Ohio 44117-1199.

Practical exercises and examples develop the reader’s ability and ask for bulletin ED-80 or call 216-383-2259 and ask for the
to visualize mechanically drawn objects as they will appear Welding School Registrar.
in their assembled form.
187 pages with more than 100 illustrations. Size 8-1/2” x 11” Lincoln Welding School
Durable, cloth-covered board binding. BASIC COURSE $700.00
$4.50 postage paid U.S.A. Mainland 5 weeks of fundamentals
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
$5.00 For order value up to $49.99
$10.00 For order value between $50.00 & $99.99
$15.00 For order value between $100.00 & $149.00

For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders) Name: _______________________________________________
CHECK ONE:
Address: _______________________________________________
Please Invoice (only if order is over $50.00)
Check or Money Order Enclosed, U.S. Funds only _______________________________________________
Credit Card - VISA MasterCard
®
Telephone: _______________________________________________
®

Signature as it appears on Charge Card:

Account No. |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|
MasterCard
AMERICAN EXPRESS
Exp Date |_|_|
Month
|_|_|
Year ______________________
AMERICAN EXPRESS

USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.

Lincoln Welding School Titles: Price Code Quantity Cost

(ED-80) New Lessons in Arc Welding $5.00 L
Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH
(ED-45) How to Read Shop Drawings $4.50 H
Educational Video Information Incentive Management $5.00 IM
(ED-93) A New Approach to Industrial Economics $5.00 NA
James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Foundation Book Information Welding Preheat Calculator $3.00 WC-8
(JFLF-515) Pipe Welding Charts $4.50 ED-89
SUB TOTAL
Additional Shipping Costs if any
TOTAL COST
 ● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.

WARNING electrode with skin or wet clothing.

● Insulate yourself from work and
ground.
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.

PRECAUCION ● Aislese del trabajo y de la tierra.

French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.

German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
● Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

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

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

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

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos ATENÇÃO
● Não toque as partes elétricas nuas. ou guardas removidas.

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.
 • 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