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TROUBLESHOOTING

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SA-250

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.

CAUTION

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled

“

PROBLEM (SYMP-

TOMS)

”

. This column describes possible symptoms

that the machine may exhibit. Find the listing that best
describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled

“

POSSIBLE CAUSE

”

lists

the obvious external possibilities that may contribute to
the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

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.

__________________________________________________________________________

WARNING

ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.

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

MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.

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

See additional warning information at the

front of this operator’s manual.

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

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Содержание SA-250

Страница 1: ...TY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful R 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 World s Leader in Welding and Cutting Products Date of Purchase Serial Number Code Number Model Where Purchased Copyright 2003 Lincoln Globa...

Страница 2: ...R 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 availa...

Страница 3: ...rical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders ...

Страница 4: ...event 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 Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Weldin...

Страница 5: ...s et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloign...

Страница 6: ...he information must be followed to avoid minor personal injury or damage to this equipment CAUTION 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 receive...

Страница 7: ...wer B 4 ________________________________________________________________________ Accessories Section C Optional Features Field Installed C 1 ________________________________________________________________________ Maintenance Section D Safety Precautions D 1 General Instructions D 1 Cooling System D 1 Bearings D 1 Commutator and Brushes D 1 D 2 Idler Maintenance D 2 Nameplates D 2 Purging Air from...

Страница 8: ...f Solenoid Mechanical Fuel Pump AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION Low noise Muffler Shutdown on low oil Single Element Automatic Idler Made from long life pressure and engine aluminized steel temperature RATED OUTPUT 104 F 40C GENERATOR Auxiliary Power 1 3 000 Watts Continuous 60 Hz AC 26 Amps 115V 13 Amps 230V PHYSICAL DIMENSIONS ENGINE COMPONENTS Perkins 104 22 4 Cylinder 4 Stro...

Страница 9: ... a metal water pipe going into the ground for at least ten feet and having no insulat ed joints or to the metal framework of a building which has been effectively grounded The U S National Code lists a number of alternate means of grounding electrical equipment DO NOT MOUNT OVER COMBUSTIBLE SUFACES Where there is a combustible surface directly under stationary or fixed electrical equipment the sur...

Страница 10: ...STALLATION SA 250 A 3 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework Proper placement of the equipment on the trailer to ensure stability side to side and front to back when being moved and when standing by itself while being operated ...

Страница 11: ...ear battery To prevent EXPLOSION when Installing a new battery disconnect the negative cable from the old battery first and connect the negative cable to the new battery last Connecting a battery charger remove the battery from the welder by disconnecting the negative cable first then the positive cable and battery clamp When reinstalling connect the negative cable last Using a booster connect the...

Страница 12: ...rting The control panel also contains an engine tempera ture gauge a battery charging ammeter an oil pres sure gauge two three prong grounding type recepta cles and four circuit breakers for auxiliary power ENGINE IDLER The SA 250 is equipped with an electronic automatic engine idler It automatically increases and decreases engine speed when start ing and stopping welding or using auxiliary power ...

Страница 13: ...even down to about 15 F 26 C If the engine must be frequently started at or below 15 F 26 C it may be desirable to install cold starting aides Note Extreme cold weather starting may require longer glow plug operation Under NO conditions should ether or other starting fluids be used SA 250 WARNING STOPPING the ENGINE 1 Turn the IGNITION switch to OFF At the end of each day s welding check the crank...

Страница 14: ...y may be experienced with EXX10 electrodes when trying to operate with long arc tech niques at settings at the lower end of the open circuit voltage range DO NOT attempt to set the Current Range Selector between the five points designated on the nameplate These switches have a spring loaded cam which almost eliminates the possibility of setting this switch between the designated points IDLER OPERA...

Страница 15: ... breakers The rating of 3 0 kVA permits a maximum continuous current of 13 amps to be drawn from the 230 volt duplex receptacle Or a total of 26 amps can be drawn from the 115 volt duplex receptacle The 115 volt duplex receptacle has a configuration which permits 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 ...

Страница 16: ...958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender Light Kit Pipe Thawing with an arc welder can cause fire explosion damage to electric wiring or to the arc welder if done improperly The use of an arc welder for pipe thawing is not approved by the CSA nor is it recommended or supported by Lincoln Electric Wire Feed Module K623 1 Provides constant voltage CV output with improved arc stability...

Страница 17: ...irt introduced during greasing than from insufficient grease COMMUTATOR AND BRUSHES Uncovered rotating equipment can be dangerous Use care so your hands hair clothing or tools do not catch in the rotating parts Protect yourself from particles that may be thrown out by the rotat ing armature when stoning the commutator Shifting of the commutator brushes may result in Change in machine output Commut...

Страница 18: ... ing of the printed circuit board reed switch and battery 3 Idler solenoid is activated for high idle 4 If desired the welder can be used without automat ic idling by setting the Idler switch to the High position 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 t...

Страница 19: ...ne Operators Manual for oil recommendations NOTES Alternator drive belt Perkins 080109080 Alternator drive belt wear R Tension of alternator drive belt I Drain water separator fuel strainer Engine oil NOTE 1 3 R Engine oil level NOTE 1 Coolant NOTE 3 MAINTENANCE ITEM Concentration of antifreeze 50 50 Water Ethylene Glycol C I R Coolant level R C R R I R ENGINE SERVICE I EVERY 600 HOURS OR 18 MONTH...

Страница 20: ...cal Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility 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 tec...

Страница 21: ...3 Field circuit may have variable resistance connection or intermit tent open circuit due to loose connection or broken wire 4 Electrode lead or work lead con nection may be poor 5 Wrong grade of brushes may have been installed on generator 6 Field rheostat may be making poor contact and overheating 1 Generator or exciter brushes may be loose or missing 2 Exciter may not be operating 3 Field circu...

Страница 22: ... the fuel system 5 Clogged fuel filter 6 Irregular and faulty fuel supply Injector pump trouble 7 Glow plug not heated 8 Improper viscosity of the lubricat ing oil 9 Clogged air cleaner 10 No compression 11 Engine protection light is on 12 Defective governor 13 Engine defective 1 Lack of fuel 2 Clogged fuel filter 3 Air mixed in the fuel system 4 Faulty function of the engine 1 Overheating of the ...

Страница 23: ...n after the ignition switch has been in the on position for more than 60 seconds with the engine not started 1 Excess engine oil 2 Too low viscosity of the engine oil 3 Faulty injection timing 1 Unsuitable fuel 2 Excess injection 3 Faulty function of the engine 4 Overloading 5 Clogged air cleaner 1 Loose fan belt 2 Faulty wiring 3 Faulty battery 4 Worn out alternator brush 1 Loose or damaged wirin...

Страница 24: ...re DC Voltage on Replace Idler Idler Solenoid Coil Control Switch 12 VDC 0 VDC Check Continuity of Check for Jamming Reed Switch in Weld Circuit of the Idler Solenoid Mechanism or a broken Return Spring Open Closed 1 Check Wiring in Replace Reed Idler Solenoid Switch Circuit 2 Replace Idler P C Board If for any reason you do not understand the test procedures or are unable to perform the tests rep...

Страница 25: ... 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 Engine Picks Up Speed 1 Check for Break in Red Lead and Repair 2 Replace Reed Switch in Weld Circuit Engine Does Not Pick Up Speed 1 Check Continuity of Idler Solenoid Coil 8 5 9 0 ohms and Replace as Required 2 Check for Jamming of the Idler Solenoi...

Страница 26: ...GLOW PLUG CONNECT PLUG P5 ON W F M TO CONNECTOR J5 ON MACHINE ON MACHINE REMOVE PLUG P10 FROM CONNECTOR J5 CONNECTORS INLINE CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR NEUTRAL BONDED TO FRAME NEUTRE RACCORDE AU BATI MACHINE MUST NOT BE RUNNING WHEN MAKING THESE CONNECTIONS TO BASE GROUND GROUND TO ENGINE 53 GLOW PLUGS IDLER SWITCH CURRENT TRANSFORMER CR2 REED RELAY WINDINGS POWER AUXILIARY...

Страница 27: ... 00 22 00 22 14 24 50 27 12 25 00 31 75 51 50 6 00 32 82 42 63 43 13 48 50 53 75 61 00 65 25 67 00 8 12 3 00 88 16 30 33 75 N B N A N A N A N B N C NOTES N A 81 HOLES N B 69 HOLES N C CENTER OF GRAVITY WITH OIL AND COOLANT IN ENGINE BUT NOT FUEL ...

Страница 28: ...NOTES SA 250 ...

Страница 29: ...NOTES SA 250 ...

Страница 30: ...16 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 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 4thClass Book Rate ...

Страница 31: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Страница 32: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Страница 33: ...s 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 World s Leader in Welding and Cutting Products ...

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