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WELDER/GENERATOR
MAINTENANCE
STORAGE: Store the SA-250 in clean, dry, protected
areas.
CLEANING: Blow out the generator and controls peri-
odically with low pressure air. Do this at least once a
week in particularly dirty areas.
NAMEPLATES: Whenever routine maintenance is
performed on this machine - or at least yearly - inspect
all nameplates and labels for legibility. Replace those
which are no longer clear. Refer to the parts list for the
replacement item number.
ALTERNATOR BRUSH REMOVAL AND REPLACE-
MENT: It's normal for the brushes and slip rings to
wear and darken slightly. Inspect the brushes when a
generator overhaul is necessary. Remove the brushes
and clean the slip rings with fine emery paper. To seat
new slip ring brushes, position the brushes in place.
Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres-
sure on top of the brushes, pull the sandpaper around
the circumference of the rings - in the direction of rota-
tion only - until brushes seat property. Brushes must
be seated 100%.
COMMUTATOR AND BRUSHES: The generator
brushes are properly adjusted when the welder is
shipped. They require no particular attention.
DO NOT SHIFT THE BRUSHES or adjust the rocker
setting.
Shifting of the brushes may result in:
• Change in machine output
• Commutator damage
• Excessive brush wear
Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove
these covers while the machine is running.
Commutators and brushes require little attention.
However, if they are black or appear uneven, have
them cleaned by experienced maintenance personnel
using a commutator stone. Never use emery cloth or
paper for this purpose.
Replace brushes when they wear within 1/4" of the pig-
tail. A complete set of replacement brushes should be
kept on hand. Lincoln brushes have a curved face to
fit the commutator. Have experienced maintenance
personnel seat these brushes by lightly stoning the
commutator as the armature rotates at full speed until
contact is made across the full face of the brushes.
After stoning, blow out the dust with low pressure air.
Uncovered rotating equipment can be dangerous. Use
care so your hands, hair, clothing or tools do not catch
in the rotating parts. Protect yourself from particles
that may be thrown out by the rotating armature when
stoning the commutator.
Arcing or excessive exciter brush wear indicates a pos-
sible misaligned shaft. Have an authorized Lincoln
Electric Field Service facility check and realign the
shaft.
BEARINGS: The SA-250 is equipped with double-
shielded ball bearings having sufficient grease to last
indefinitely under normal service. Where the welder is
used constantly or in excessively dirty locations, it may
be necessary to add one half ounce of grease per year.
A pad of grease one inch wide, one inch long, and one
inch high weighs approximately one half ounce. Over-
greasing is far worse than insufficient greasing.
When greasing the bearings, keep all dirt out of the
area. Wipe the fittings completely clean and use clean
equipment. More bearing failures are caused by dirt
introduced during greasing than from insufficient
grease.
CURRENT RANGE SELECTOR CONTACTS: The
contacts should not be greased. To keep the contacts
clean, rotate the current control handle through its
entire range frequently. Good practice is to turn the
handle from maximum to minimum setting twice each
morning before starting to weld. Never rotate the han-
dle while machine is under load.
Put a drop of oil on the CURRENT RANGE SELEC-
TOR shaft at least once every month.
RECEPTACLES: Keep the electrical receptacles in
good condition. Remove any dirt, oil, or other debris
from their surfaces and holes.
CABLE CONNECTIONS: Check the welding cable
connections at the weld output terminals often. Be
sure that the connections are always tight.
MAINTENANCE
D-11 D-11
SA-250
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WARNING
CAUTION