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Lincoln Electric Shield-Arc SA-200 Service Manual
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Lincoln Electric Shield-Arc SA-200 Service Manual

Lincoln Electric Shield-Arc SA-200 Service Manual

With lincoln model l-200 engine type: s-6090
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SA-200
®
For use with machines having Code Numbers: 7276; 7302; 7307; 7693; 7699; 7789; 8017;8023; 8244; 8245; 8348; 8583; 8638;
8676;8677; 8790; 8791; 8915; 8916; 9052; 9053;9324; 9325; 9442; 9443; 9527; 95303417; 3418; 3554; 3555; 4113;
4149;4150; 4744; 4745; 4815; 4816; 4843;4998; 4999; 5065; 5107; 5108; 5141;5336; 5337; 5376; 5495; 5496; 5500;5537;
5568; 5604; 5642; 5660; 5696;5840; 5841; 5957; 6072; 6073; 6132;6339; 6340; 6345; 6552; 6632; 6633; 6634; 6779; 6791;
6792; 6934; 7044;7074; 7078; 7167; 7168; 7213; 7214; 7242, K-6090 215; 244; 317; 370; 371;445; 459; 527; 671; 681;960;
974; 1122; 1123;1223; 1228; 1421; 1422;1678; 1679; 1827; 1828;1846; 1847; 1903; 1904;2163; 2164; 2292; 2293;2364; 2365;
2866; 2867;2954; 2955; 3311; 3312
SERVICE MANUAL
SVM224-A
| Issue D ate 12-Oct
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

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Summary of Contents for Lincoln Electric Shield-Arc SA-200

  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. SA-200 ® For use with machines having Code Numbers: 7276; 7302; 7307; 7693; 7699; 7789; 8017;8023; 8244; 8245; 8348; 8583; 8638; 8676;8677;...
  • Page 2 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 SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 6.a. Remove fire hazards from the welding area.If this is not possi- 7.a Use only compressed gas cylinders containing the correct ble, cover them to prevent the welding sparks from starting a shielding gas for the process used and properly operating fire.
  • Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 SAFETY 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 •...
  • Page 7 SAFETY Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or • • • WARNING Use ventilation or exhaust to guards off. • remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- •...
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-vi Instruction Manuals .
  • Page 9 Type S-6090 or S6090-SM Codes Below 3400 ..........A-11 IM-208-A Shield-Arc SA-200 Welder with Continental F162 or F163 Engine, Type S-6090, Codes 3400 to 7275 .
  • Page 10 SAFETY FIRST... This manual covers equipment which is obsolete and no longer in production by The Lincoln Electric Company. Specifications and the availability of optional features may have changed. Replacement parts for your machine are available through your local Lincoln Field Service Shop.
  • Page 11 TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Arc Welding Safety Precautions .
  • Page 12 INSTALLATION ARC WELDING SAFETY PRECAUTIONS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. READ AND UNDER- STAND BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING MANUAL FOR THE WELDER AND/OR OTHER EQUIPMENT TO BE USED AS WELL AS THE FOLLOWING GENERAL INFORMATION. 1.
  • Page 13 INSTALLATION They can cause an explosion even though they f. Valve protection caps should always be in place have been “cleaned.” For information purchase and handtight except when the cylinder is in use “Recommended Safe Practices or connected for use. Preparation for Welding and Cutting of g.
  • Page 14 INSTALLATION PROPER GROUNDING DURING INSTAL- OPERATION OF ENGINE WELDERS LATION WARNING: Operate internal combustion engines in open, well ventilated areas or vent engine exhaust The 1984 National Electric Code does not require this fumes outdoors. machine to be grounded under normal operating cir- cumstances.
  • Page 15 INSTALLATION MAINTENANCE and OPERATING INSTRUCTIONS UNCRATING THE WELDER CONTROL OF WELDING CURRENT When the equipment arrives, it should be carefully This welder is provided with Dual Control of the weld- uncrated and all parts checked. The use of pinch bars ing current.
  • Page 16 INSTALLATION CONTROL OF WELDING CURRENT POWER PLUG CONT. A 115 volt D.C. power plug outlet is located on the con- trol panel of welders with rheostat control. The current It is generally best to set the Current control at as low available is 8.7 amperes.
  • Page 17 INSTALLATION COMMUTATOR AND BRUSHES Lincoln Approved Grease is available in a convenient 8 ounce tube. The commutator and brushes are inspected by remov- ing the commutator cover. Do not remove or replace GENERAL INSTRUCTIONS the cover while the welder is running. 1.
  • Page 18 TROUBLESHOOTING AND REPAIR A-10 A-10 LINCOLN ARC WELDING SET “TROUBLE-SHOOTING” CHART TROUBLE CAUSES WHAT TO DO Machine fails to hold the “heat” Rough or dirty commutator. Commutator should be trued or cleaned. constantly. Brushes may be worn down to limit of life. Replace brushes.
  • Page 19 RETURN TO MAIN INDEX IM-142-F Shield-Arc SA-200 Welder With CONTINENTAL 4-CYLINDER GASOLINE ENGINE (Codes below 3400) For K-6090 and K-6090-SM See IM-208 TYPE S-6090 AND S-6090-SM: This manual covers equipment which is obsolete and no longer in production by the Lincoln Electric Co.
  • Page 20 Electrical System ..............A-30 Lincoln Electric Kits for Easy Conversion Anti-Frost .
  • Page 21 GUARANTEE The foregoing guarantees and remedies are exclusive The Lincoln Electric Company the seller warrants all and there are no other guarantees or warranties either new equipment except engines and accessories there- expressed or implied.
  • Page 22 INSTALLATION A-14 A-14 RADIATOR, HOSES, BASE AND CANOPY FIGURE 5141-A Code Note Note Note 3311 3312 Item Description Qty. 1122 1123 Part No. 2954 2955 Radiator Ass’y • • • S-7904 Radiator Ass’y • • • • • • • S-9810 Radiator Ass’y incl.
  • Page 23 INSTALLATION A-15 A-15 WELDING GENERATOR FIGURE 5141-B-1 FIGURE 5141-C-1 CONVERSION KIT TO OVERSIZE (FDW) EXCITER 1. Codes 215 thru 371, Part No. M-6879, (Note 1). 2. Codes 445, 671, 960 and 1122, Part No. M-6878, (Note 2). 3. Codes above 1122 all have the Oversize Exciter. Note 1: M-6879 includes: Engine Regulator, Rheostat, Power Outlet Receptacle, Oversize Exciter, End Bracket, Exciter Pole Pieces and Field Coils, plus misc.
  • Page 24 INSTALLATION A-16 A-16 WELDING GENERATOR (Cont’d) FIGURES 5141-B & 5141-C Code Part Ref. Item Description Qty. Number Pict. T-8845 Lord Bushing (in Flywheel) Pilot Bearing M-4587-A Coupling & Blower Ass’y, incl: L-2427 Coupling Ass’y, incl: S-9311-5 Coupling S-9311-9 Locking Pin S-7247 Drive Pin M-6140...
  • Page 25 INSTALLATION A-17 A-17 WELDING GENERATOR (Cont’d) FIGURES 5141-B & 5141-C-1 Code Part Ref. Item Description Qty. Number Pict. Outer Dust Cap S-4387 1/4-20 x 2 3/4 Screw, Hex Hd. Cap. Dust Cap Grease Pipe • • • T-7599-9 Grease Pipe Cap •...
  • Page 26 INSTALLATION A-18 A-18 CONTROL PANEL FIGURE 5141-K Code Note 3311 3312 Item Description Qty. 1122 2954 2955 Part No..Control Panel Ass’y Incl: • • • • • • • • • • L-2479-A ..Control Panel Ass’y Incl: •...
  • Page 27 INSTALLATION A-19 A-19 GENERATOR BRUSH HOLDERS FIGURE 5111-A FIGURE 5111-B Item Description Qty. Part No. Item Description Qty. Part No. Brush Holder & Stud Ass’y S-5382 Brush Holder Ass’y M-6964-2A incl. incl. Brush Holder Ass’y, incl. S-3939 Spring & Clip Ass’y T-8495 Finger T-574...
  • Page 28 INSTALLATION A-20 A-20 CRANKCASE FIGURE 5141-F1 (See Page A-22) Unless specified to the contrary, the same part numbers apply to all of the various welder code numbers. Item Description Qty. Part No. Item Description Qty. Part No. Stud S-9250-147 Cyl., Water Outlet Elbow S-9311-10 Lockwasher E-106-A-3...
  • Page 29 INSTALLATION A-21 A-21 CRANKCASE, GEAR COVER & ASSOCIATED PARTS FIGURE 5141-F-1 SA-200...
  • Page 30 INSTALLATION A-22 A-22 CRANKCASE (Cont’d) FIGURE 5141-F-1 Item Description Qty. Part No. Item Description Qty. Part No. Exhaust Pipe S-7348 Lockwasher S-9250-168 Exhaust Pipe Cover S-10271 Screw, Ft. Filler Block S-9250-156 S-9250-162 Cork, Filler Block S-9250-142 Lockwasher S-9250-169 Oil Pan Assembly S-9250-70 Stud, Hole Cover S-9250-17...
  • Page 31 INSTALLATION A-23 A-23 PISTONS, CRANKSHAFT, FLYWHEEL FIGURE 5141-G OVERSIZE AND UNDERSIZE DESIGNATIONS To specify either an oversize or undersize Piston, Ring or Bearing add the desired over or undersize dimension to the part number as a suffix; for example: The standard Connecting Rod Bearing (#2 & 4 Cylinders) is S-9250-65, if a 0.020” undersize is desired order S-9250-65-020.
  • Page 32 INSTALLATION A-24 A-24 PISTONS, CRANKSHAFT, FLYWHEEL, FIGURE 5141-G Item Description Qty. Part No. Crankshaft - Code 1223 & higher S-9250-204 Crankshaft, incl: - Code 215 thru 1123 S-9311-1 Bushing - Code 215 thru 1123 S-9311-2 Thrust Washer S-9250-35 Pin, Thrust Washer S-9250-46 Shim, .002”...
  • Page 33 INSTALLATION A-25 A-25 OIL PUMP, VALVES & CAMSHAFT FIGURE 5141-H SA-200...
  • Page 34 INSTALLATION A-26 A-26 OIL PUMP, VALVES AND CAMSHAFT, FIGURE 5141-H Item Description Qty. Part No. Camshaft S-9250-41 Stud, Camshaft, Thrust Plate S-9250-18 Lockwasher 3/8” S-9250-170 Nut 3/8-16 S-9250-163 Thrust Plate S-9250-131 Plate, Oiler, Timing Gear S-9250-134 Lockwasher S-9250-171 Screw 7/16”-14 x 1-1/4” S-9250-160 Gear, Camshaft S-9250-130...
  • Page 35 INSTALLATION A-27 A-27 WATER PUMP FIGURE 5141-I PREFACE: Three different Water Pumps have been used on the original installations: S-9311-24 Codes 215 thru 681 (Note 1) Order S-9311-64 S-9311-4 Codes 960 thru 1904 (Note 1) Order S-9311-64 S-9250-74 Codes 2163 & higher (Note 1) Order S-9311-64 Item Description Qty.
  • Page 36 INSTALLATION A-28 A-28 WATER PUMP (Cont’d) FIGURE 5141-I Item Description Qty. S-9311-24 S-9311-4 S-9250-74 Seal Assembly S-9311-32 S-9311-32 S-9250-78 Support Assembly, including S-9311-33 S-9311-33 Bushing S-9311-34 S-9311-34 Water Shedder S-9250-80 Gasket S-9311-35 S-9311-35 S-9311-39 S-9311-39 Set Screw, Bearing S-9311-40 S-9311-40 Retainer S-9311-41 S-9311-41...
  • Page 37 INSTALLATION A-29 A-29 FUEL SYSTEM FIGURE 5141-J-I Item Description Part No. Item Description Part No. Fuel Tank Assy. (6) L-2581-A Control Rod T-8583 Fuel Tank Assy. Incl: L-3167-A (Codes 215 thru 1422) Fuel Tank, (6) L-2581 Control Rod S-6192-5 Fuel Tank L-3167 (Codes 1678 &...
  • Page 38 INSTALLATION A-30 A-30 ENGINE ELECTRICAL SYSTEM Item Description Part No. Item Description Part No. Screw, Hex Hd. Cap 7/16-14x1-1/2 Magneto (5) (7) L-2677 ..Magneto L-3228 Lockwasher E-106A-8 Starter Spacer S-8073 Magneto Gasket S-9234 Generator Pulley M-7204 Screw, Hex Hd. Cap. 3/8-16x3-1/4 Generator Pulley Fan Delco 1866400...
  • Page 39 INSTALLATION A-31 A-31 MARVEL - SCHEBLER CARBURETOR PARTS Carburetor Part Number S-9239 Item Part Name And Description Part No. Req’d. Body Assembly 10-3180 Lever, Throttle, Loose 12-A38 Shaft, Stop & Lever Ass’y. Throttle 13-930* Valve, Throttle (20º) 14-227 Screw, Throttle Stop (8-32 x 3/4) 15-42 Screw, Choke Swivel (8-32 x 5/16) 15-285...
  • Page 40 Type: K-6090 Models: SA-200-F162, SA-200-F163 Codes 3400 to 7275. For machines above code 7275 request IM-276. This manual covers equipment which is obsolete and no longer in production by the Lincoln Electric Co. Specifications and availability of optional features may have changed. Safety Depends on You Lincoln arc welding equipment is designed and built with safety in mind.
  • Page 41 TABLE OF CONTENTS - INSTALLATION SECTION A-33 A-33 Installation ................A-1 Damage Claims .
  • Page 42 INSTALLATION A-34 A-34 PROPER GROUNDING DURING INSTAL- OPERATION OF ENGINE WELDERS LATION WARNING: Operate internal combustion engines in open, well ventilated areas or vent engine exhaust The 1985 National Electrical Code does not require fumes outdoors. this machine to be grounded under normal operating circumstances.
  • Page 43 A-35 A-35 Need Welding Training? The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland, Ohio. Over 60,000 students have graduated. Tuition is low and training is “hands on”.
  • Page 44 INSTALLATION A-36 A-36 DAMAGE CLAIMS Always operate the welder with the doors closed. Leaving the doors open changes the designed air flow When Lincoln equipment is shipped, title passes to the and can cause overheating. purchaser upon receipt by carrier. Consequently, Before starting the engine everyday, check the fuel claims for material damaged in shipment must be supply (running out of fuel may draw dirt into the fuel...
  • Page 45 Periodically inspect the commutators and brushes by N E G A T I V E N E G A T I V E THE LINCOLN ELECTRIC COMPANY THE LINCOLN ELECTRIC COMPANY P O S I T I V E P O S I T I V E...
  • Page 46 INSTALLATION A-38 A-38 Seat these brushes by lightly stoning the commutator 2. Current control contacts should not be greased. To as the armature rotates at full speed until contact is keep the contacts clean, rotate the current control made across the full face of the brushes. After stoning, through its entire range frequently.
  • Page 47 INSTALLATION A-39 A-39 TROUBLE SHOOTING Have a qualified electrician do the maintenance and trouble shooting work. Turn the engine off before working inside the machine. TROUBLE CAUSES WHAT TO DO Machine fails to hold the “heat” Rough or dirty commutator. Commutator should be trued or cleaned.
  • Page 48 INSTALLATION A-40 A-40 TROUBLE SHOOTING (Continued) TROUBLE CAUSES WHAT TO DO Low oil pressure. Oil too light. Drain, refill with heavier grade. Oil too low. Fill to “full” mark on bayonet gage. Do not overfill. Defective oil gage. Replace. Lack of power. Carbon deposits, causing pre-ignition.
  • Page 49 INSTALLATION A-41 A-41 REMANUFACTURING After your welder has provided many years of service, it can be returned to the factory for a remanufacturing service called Lincolnditioning™. It will be com- pletely disassembled and all electrical and mechanical parts will be refurbished or replaced as needed.
  • Page 50 INSTALLATION A-42 A-42 CONTROL PANEL WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-23-D Item Part Name And Description Item Part Name And Description Req’d. Req’d. Control Panel Selector Switch Rheostat Selector Switch Handle Instruction Decal Output Stud Assembly, (Code 4113 and above), Receptacle...
  • Page 51 INSTALLATION A-43 A-43 FUEL SYSTEM WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-23-F Item Part Name And Description Item Part Name And Description Req’d. Req’d. Fuel Tank Hose Clamp Filler Neck Gasket Hose - Heater Tube to Air Filter Filler Cap Heater Tube...
  • Page 52 INSTALLATION A-44 A-44 COOLING SYSTEM Parts List P-23-E WHEN ORDERING GIVE: Item No., Part Name, Item Part Name And Description Req’d. Parts List No., and Welder Code. Radiator Cap Radiator Hex Nut Washer Lockwasher Radiator Hose - Upper Cylinder Water Outlet Elbow Nut - Cylinder Water Outlet Elbow to Head Lockwasher - Cylinder Water Outlet Elbow to Head...
  • Page 53 INSTALLATION A-45 A-45 Parts List P-23-G Continued Item Part Name And Description Item Part Name And Description Req’d. Req’d. *Packing, Throttle Shaft Plug, Bowl Drain Venturi (25/32” Dia.) Clevis Assembly Nozzle, Main Throttle Body and Shaft Assembly *Jet, Economizer *Valve and Seat Assembly, Float *Jet, Power Repair Kit *Jet, Idle...
  • Page 54 INSTALLATION A-46 A-46 ENGINE EXTERIOR PARTS WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-23-J Item Part Name And Description Req’d. Pipe Plug - Temperature Gauge Hole in Cylinder Head Cylinder Head Cylinder Head Gasket Cylinder Head Nut Washer - Cylinder Head Nut Stud - Cylinder Head to Block...
  • Page 55 INSTALLATION A-47 A-47 CRANKSHAFT AND PISTON ASSEMBLY WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-23-K Item Part Name And Description Item Part Name And Description Req’d. Req’d. Crankshaft Assembly - Includes: Piston Ring - Oil Control (Bottom) Crankshaft Piston Pin Crankshaft Thrust Shim (.002)
  • Page 56 INSTALLATION A-48 A-48 CAMSHAFT AND VALVE ASSEMBLY WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-23-L Item Part Name And Description Req’d. Camshaft Camshaft Thrust Plate Stud - Camshaft Thrust Plate to Block Lockwasher - Camshaft Thrust Plate to Block Hex Nut - Camshaft Thrust Plate to Block Timing Gear Oiler Plate...
  • Page 57 INSTALLATION A-49 A-49 WELDING GENERATOR WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-23-M Item Part Name And Description Item Part Name And Description Req’d. Req’d. Welder Frame Screw, Mounts End Cover Main Pole Lamination Bracket Cover Shunt Field Coil Round Head Screw, Mounts Bracket Cover...
  • Page 58 INSTALLATION A-50 A-50 GENERATOR BRUSH HOLDER WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-25-L Item Part Name And Description Req’d. Brush Holder Assembly Includes: Spring and Clip Assembly Round Head Cap Screw Plate and Retainer Assembly Round Head Cap Screw Hex Head Cap Screw...
  • Page 59 Type: K-6090-SB Model: SA-200-F163 (Code 8023 and up) Type: K-6090-SM (Codes 7276 to 8017) (For Codes below 7276 see IM-208-A) This manual covers equipment which is obsolete and no longer in production by the Lincoln Electric Co. Specifications and availability of optional features may have changed. DAMAGE CLAIMS...
  • Page 60 TABLE OF CONTENTS - INSTALLATION SECTION A-52 A-52 Installation ................A-1 Engine Operation .
  • Page 61 INSTALLATION A-53 A-53 OPERATION OF ENGINE WELDERS INSTALLATION, CONNECTION, AND MAINTENANCE OF BATTERY WARNING: Operate internal combustion engines in open, well ventilated areas or vent engine exhaust To prevent EXPLOSION when: fumes outdoors. a) Installing a new battery – disconnect the nega- tive cable from the old battery first and connect OPERATION OF ALL WELDERS the negative cable to the new battery last.
  • Page 62 INSTALLATION A-54 A-54 PROPER GROUNDING DURING INSTAL- In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid LATION earth ground such as a metal pipe going into the The 1985 National Electrical Code does not require ground for at least ten feet and having no insulated this machine to be grounded under normal operating...
  • Page 63 DC WELDER Positive polarity, connect the electrode cable to the ter- IDLER CONTROL OIL PRESSURE minal marked “Positive”. For Negative polarity, connect THE LINCOLN ELECTRIC COMPANY THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO CLEVELAND, OHIO MADE IN U.S.A. MADE IN U.S.A.
  • Page 64 INSTALLATION A-56 A-56 PIPE THAWING Lincoln bulletin E-695.1 (dated December ’76 or later). WARNING: Pipe thawing, if not done properly, can For protection of the welder from overloads when result in fire, explosion, damage to wiring which thawing pipe, use of a device called the “Linc-Thaw” is may make it unsafe, damage to pipes, burning up recommended.
  • Page 65 INSTALLATION A-57 A-57 TROUBLE CAUSES WHAT TO DO Machine fails to hold the “heat” Rough or dirty commutator. Commutator should be trued or cleaned. constantly. Brushes may be worn down to limit. Replace brushes. Brush springs may be broken. Replace brush springs. Field circuit may have variable resistance con- Check field current with ammeter to discover vary- nection or intermittent open-circuit, due to...
  • Page 66 INSTALLATION A-58 A-58 TROUBLE SHOOTING (Continued) TROUBLE CAUSES WHAT TO DO Overheating. No water in radiator or clogged cooling sys- Check throughout for dirty or broken hoses, tem. clogged radiator or defective water pump. Late timing. Time ignition* INTAKE EXHAUST Improper valve clearance.
  • Page 67 INSTALLATION A-59 A-59 REMANUFACTURING After your welder has provided many years of service, it can be returned to the factory for a remanufacturing service called Lincolnditioning™. It will be completely disassembled and all electri- cal and mechanical parts will be refurbished or replaced as needed. The machine will be returned to you in “new Welder”...
  • Page 68 INSTALLATION A-60 A-60 CONTROL PANEL AND OUTPUT STUDS WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-111-D Item Part Name And Description Item Part Name And Description Req’d. Req’d. Control Panel (Without Volt Ammeter) Control Panel (With Volt Ammeter) Old Style Output Stud Assembly, Includes Items Selector Switch...
  • Page 69 INSTALLATION A-61 A-61 ENGINE FUEL SYSTEM AND OIL FILTER WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-111-F Item Part Name And Description Item Part Name And Description Req’d. Req’d. Mounting Spacer Oil Filter Roll Pin Filter Adapter Base Mounting Bracket...
  • Page 70 INSTALLATION A-62 A-62 COOLING SYSTEM WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-23-E Item Part Name And Description Item Part Name And Description Req’d. Req’d. Radiator Cap Water Pump Assembly Radiator Water Pump Repair Kit Hex Nut Gasket Washer...
  • Page 71 INSTALLATION A-63 A-63 ENGINE ELECTRICAL SYSTEM WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-111-H Item Part Name And Description Item Part Name And Description Req’d. Req’d. Distributor Starting Motor Drive Shaft Assembly Hex Head Screw (Starter Mounting) Stud Battery...
  • Page 72 INSTALLATION A-64 A-64 ENGINE EXTERIOR PARTS WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-23-J Item Part Name And Description Req’d. Pipe Plug - Temprature Gauge Hole in Cylinder Head Cylinder Head Cylinder Head Gasket Cylinder Head Nut Washer - Cylinder Head Nut Stud - Cylinder Head to Block...
  • Page 73 INSTALLATION A-65 A-65 CRANKSHAFT AND PISTON ASSEMBLY For fastest service, order engine parts from an area WHEN ORDERING GIVE: Item No., Part Name, Parts Continental parts distributor using these parts descrip- List No., and Welder Code. tions and the engine nameplate data. Parts List P-23-K Item Part Name And Description...
  • Page 74 INSTALLATION A-66 A-66 CAMSHAFT AND VALVE ASSEMBLY Parts List P-23-L ITEM PART NAME AND DESCRIPTION REQ’D. Camshaft Camshaft Thrust Plate Stud - Camshaft Thrust Plate to Block Lockwasher - Camshaft Thrust Plate to Block Hex Nut - Camshaft Thrust Plate to Block Timing Gear Oiler Plate Lockwasher - Oiler Plate to Thrust Plate Block...
  • Page 75 INSTALLATION A-67 A-67 WELDING GENERATOR WHEN ORDERING GIVE: Item No., Part Name, Parts List No., and Welder Code. Parts List P-23-M Item Part Name And Description Item Part Name And Description Req’d. Req’d. Welder Frame Screw, Rocker to Hub Main Pole Lamination Ball Bearing Shunt Field Coil Exciter End Cover...
  • Page 76 INSTALLATION A-68 A-68 GENERATOR BRUSH HOLDER Parts List P-25-L Item Part Name And Description Req’d. Brush Holder Assembly Includes: Spring and Clip Assembly Round Head Cap Screw Plate and Retainer Assembly Round Head Cap Screw Hex Head Cap Screw Stud Clamping Washer Insulating Washer Insulating Tube...
  • Page 77 A-69 A-69 Need Welding Training? The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland, Ohio. Over 60,000 students have graduated. Tuition is low and training is “hands on”.
  • Page 78 The Lincoln Electric Company, the Seller, warrants all The Seller shall not be liable for any consequential new equipment except engines and accessories there-...
  • Page 79 ZENITH CARBURETOR TYPES: S-7538, S-8110, M-7033 This manual covers equipment which is obsolete and no longer in production by the Lincoln Electric Co. Specifications and availability of optional features may have changed. SEE REVERSE SIDE FOR PART NUMBERS Copyright © Lincoln Global Inc.
  • Page 80 C141-4-1 C141-4-1 Gasket Kit (Includes 1) C181-74 C181-74 C181-74 Gasket Kit (Includes *) K10150 K10647 K10779 Shaft and Levers Assembly (Includes #) C29-1095 C29-1096 C29-1095 These parts are available from the Lincoln Electric Company and its Field Service Shops. SA-200...
  • Page 81 (used with Continental F-162 Engine) Type: S-9790 This manual covers equipment which is obsolete and no longer in production by the Lincoln Electric Co. Specifications and availability of optional features may have changed. Copyright © Lincoln Global Inc. • World's Leader in Welding and Cutting Products •...
  • Page 82 INSTALLATION A-74 A-74 MARVEL-SCHEBLER CARBURETOR PARTS Part Number Item Qty. Part Name Carburetor Assembly Complete 10-3594 Body Assembly 10-3912 Lever, Throttle, Loose 12-A38 Lever Assembly, Governor 12-952 *Throttle Shaft & Stop Assembly 13-955 *Throttle Shaft & Levers Assembly 13-1199 Valve, Throttle (20º) 14-227 Screw, Throttle Stop (8/32x3/4) 15-42...
  • Page 83 ZENITH CARBURETOR TYPES: S-8318, S-8082 This manual covers equipment which is obsolete and no longer in production by the Lincoln Electric Co. Specifications and availability of optional features may have changed. Copyright © Lincoln Global Inc. • World's Leader in Welding and Cutting Products •...
  • Page 84 KIT GASKET (includes items marked #) C181-74 C181-73 KIT, SERVICE PARTS (includes items marked *) K10906 K10989 Note 1 - Pin, Throttle Shaft (not shown) order C121-12 These parts are available from The Lincoln Electric Company and its Field Service Shops. SA-200...
  • Page 85 TIMING, CARBURETOR, GOVERNOR & IDLER FIGURE 1 – Fuel Control System This manual covers equipment which is obsolete and no longer in production by the Lincoln Electric Co. Specifications and availability of optional features may have changed. GENERAL INSTRUCTIONS This manual is designed to help a qualified...
  • Page 86 TABLE OF CONTENTS - INSTALLATION SECTION A-78 A-78 Installation ................A-1 Timing .
  • Page 87 INSTALLATION A-79 A-79 PROPER GROUNDING DURING INSTAL- OPERATION OF ENGINE WELDERS LATION WARNING: Operate internal combustion engines in open, well ventilated areas or vent engine exhaust The 1985 National Electrical Code does not require fumes outdoors. this machine to be grounded under normal operating circumstances.
  • Page 88 INSTALLATION A-80 A-80 TIMING WARNING WARNING • Only qualified personnel should do mainte- nance and troubleshooting work. If possible, turn the engine off and disconnect the bat- tery before working inside the machine. • Run engine in open, well ventilated areas or vent exhaust outside.
  • Page 89 INSTALLATION A-81 A-81 THROTTLE CONTROL LEVER (Figures 4 and 5) The control lever screw holds the throttle control lever (C) onto the throttle shaft (D). Check the lever and screw for tightness. If they are tight, leave them alone. If they are loose or if you suspect the lever has slipped in its position on the shaft, loosen the control lever screw and reset the lever so angle A equals angle B in Figure 4.
  • Page 90 INSTALLATION A-82 A-82 CONTROL ROD If this adjustment was changed, reset the control rod (Figures 2, 3, 5, 6 and 7) length as follows: Remove the toggle (L) at the gover- The carburetor to governor control rod (J) is set at the nor end of the rod.
  • Page 91 INSTALLATION A-83 A-83 SENSITIVITY ADJUSTMENT attached to the lower half of the throttle lever (S) by a spring link (T), which oscillates on a pin (U). The pin The governor sensitivity adjustment has two purposes: has serrated teeth (V), which engage a tooth rack (W) (1) to control speed fluctuations (surge) at idle and load in the throttle lever slot.
  • Page 92 INSTALLATION A-84 A-84 Recommended Engine RPM WARNING Model Low Idle Full Load High Idle • If possible, Turn the engine off and discon- 1000 1450 1550 SA-200-F162 & F-163 nect the battery before working inside the machine. 1100 1500 1590 SAF-300-F163 •...
  • Page 93 INSTALLATION A-85 A-85 TIME ADJUSTMENTS Remove solenoid assembly (3), which is fastened to the case (1) with two sheet metal screws. Valve (6) and A time delay feature prevents the idler from slowing the valve spring (7) may then be removed. Care should be engine speed when the arc is momentarily broken.
  • Page 94 A-86 A-86 HOW TO ORDER IDLER PARTS Order parts from The Lincoln Electric Co., its branch offices, or the nearest Authorized Field Service Shop. Give the Item No., Part Name and No. Req’d from P- (The “Lincoln Service Directory” listing of these shops 71-G.
  • Page 95 INSTALLATION A-87 A-87 TROUBLESHOOTING WARNING • Have qualified personnel do maintenance and troubleshooting work. • If possible, turn the engine off and disconnect the battery before working inside the machine. • Remove guards only when necessary to perform maintenance, and replace them when the main- tenance requiring their removal is complete.
  • Page 96 ??? not cov- ered by this warranty. TO OBTAIN WARRANTY COVERAGE: You are required to notify Lincoln Electric, your Lincoln Distributor, Lincoln Service ??? Field Service ??? of any defect within the warranty period. Written notifica- tion is recommended.
  • Page 97 SEC. AA This manual covers equipment which is SMALL END OF SPRING AGAINST obsolete and no longer SHOULDER F FLOAT VALVE in production by the Lincoln Electric Co. Specifications and availability of optional features may have changed. Parts List P-71-G Item Part Name And Description Req’d.
  • Page 98 INSTALLATION A-90 A-90 2. The diaphragm assembly is operated by the engine cleaning or replacement of felt will improve idler intake manifold vacuum. The diaphragm vacuum is operation.) controlled by a spring loaded valve (6). 2. Turning the petcock counter-clockwise shortens the 3.
  • Page 99 Order parts from The Lincoln Electric Co., its branch offices, or the nearest Authorized Field Service Shop. (The “Lincoln Service Directory” listing these shops geographically is available on request.) All authorized...
  • Page 100 L-2299, L-2299-D TYPES: This manual covers equipment which is obsolete and no longer in production by the Lincoln Electric Co. Specifications and availability of optional features may have changed. Copyright © Lincoln Global Inc. • World's Leader in Welding and Cutting Products •...
  • Page 101 TABLE OF CONTENTS - INSTALLATION SECTION A-93 A-93 Installation ................A-1 Installation on “Build Your Own”...
  • Page 102 INSTALLATION A-94 A-94 SCREW IN THE VALVE BODY UNTIL THE MAGNET ARMATURE WHEN RESTING ON THE VALVE STEM IS IN THE POSITION SHOWN. SENT OUT WITH REPLACEMENT ORDERS WRAP IN PLACE WITH H LAYERS ASSEMBLY L-2299 - AS PICTURED ABOVE - USED ON HERCULES JXD & QXCS CONTINENTAL M-330 & F-162 WITH RHEO CONTROL L-2299 SPECIAL APPLICATIONS REPLACEMENT PARTS...
  • Page 103 INSTALLATION A-95 A-95 INSTRUCTIONS FOR USE OF LINCOLN ENGINE IDLER Do not confuse this idling device with the engine governor which is also required. The governor keeps the engine operating at approximately the same speed regardless of load. The idling device causes the engine to decrease to idling speed when no welding is being done.
  • Page 104 “Prevention and Control of Distortion in Arc Welding” by Walt Disney Productions. An education color-sound film, which As a service to its users, the Lincoln Electric Company pub- explains through the cartoon figure, Mr. Shrink, the causes lishes the following books. Order directly from the Lincoln and cures of distortion in arc welding.
  • Page 105 This manual covers equipment which is FIGURE 1 – Fuel Control Systems. (Unit shown with Magneto Ignition) obsolete and no longer in production by the Lincoln Electric Co. Specifications and availability of optional features may have changed. IMPORTANT: This manual is designed to help a b.
  • Page 106 TABLE OF CONTENTS - INSTALLATION SECTION A-98 A-98 Installation ................A-1 Engine Adjustments For Smooth Operation .
  • Page 107 INSTALLATION A-99 A-99 WARNING WARNING • Only qualified personnel should do mainte- nance and troubleshooting work. If possible, turn the engine off and disconnect the bat- tery before working inside the machine. • Run engine in open, well ventilated areas or vent exhaust outside.
  • Page 108 INSTALLATION A-100 A-100 Be sure the lead connected to the stud on the outside IDLE JET ADJUSTING SCREW (See of the magneto isn’t grounded against the magneto Figure 3 ) housing. If it is, the engine will not run. On the F-163 engine, a carburetor from any one of three manufacturers may be used.
  • Page 109 INSTALLATION A-101 A-101 FIGURE 3 – Carburetor Adjustments (Unit shown with Magneto Ignition). 5. Idle speed should be 1000 to 1050 RPM. Readjust HIGH IDLE SPEED (See Figure 4) if necessary. Adjust the high idle speed with the governor speed control screw (N) per the following instructions: 1.
  • Page 110 INSTALLATION A-102 A-102 GOVERNOR ADJUSTMENTS WARNING SENSITIVITY ADJUSTMENT • Do not attempt to override the governor or The governor sensitivity adjustment has two purposes: idler by pushing on the throttle control rods while that engine is running. (1) to control speed fluctuations (surge) at idle and load speeds, and (2) to control speed drop from high idle to •...
  • Page 111 Do NOT exceed the 15 amp rating of the auxiliary power IDLER CONTROL OIL PRESSURE receptacle. THE LINCOLN THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO CLEVELAND, OHIO FIGURE 5 – Idler Control Switch. SA-200...
  • Page 112 INSTALLATION A-104 A-104 TROUBLESHOOTING WARNING • Have qualified personnel do maintenance and troubleshooting work. • If possible, turn the engine off and discon- nect the battery before working inside the machine. MOVING PARTS can • Remove guards only when necessary to perform maintenance, and replace them injure.
  • Page 113 INSTALLATION A-105 A-105 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 OK, replace Check continuity of...
  • Page 114 ??? not cov- ered by this warranty. TO OBTAIN WARRANTY COVERAGE: You are required to notify Lincoln Electric, your Lincoln Distributor, Lincoln Service ??? Field Service ??? of ERFORMANCE any defect within the warranty period. Written notifica- ROTECTION tion is recommended.
  • Page 115 INSTALLATION A-107 A-107 LINCOLN ARC WELDING SET “TROUBLE-SHOOTING” CHART TROUBLE CAUSES WHAT TO DO Low oil pressure. Oil too light. Drain, refill with heavier grade. (See OPERA- TOR’S MANUAL) Oil too low. Fill to “full” mark on bayonet gauge. Defective oil gauge. Replace.
  • Page 116 When ??? expense will be paid by The Lincoln Electric Company. individual ??? ?? diode assembly is replaced the ??? After 12 months any labor expense will be the owner’s diode or diode assembly must be returned to responsibility.
  • Page 117 This manual covers equipment which is obsolete and no longer in production by the Lincoln Electric Co. Specifications and availability of optional features may have changed. Copyright © Lincoln Global Inc.
  • Page 118 TABLE OF CONTENTS - INSTALLATION SECTION A-110 A-110 Installation ................A-1 INDEX I.
  • Page 119 INSTALLATION A-111 A-111 INSTRUCTION MANUAL IM-127-B ADJUSTMENT OF LINCOLN MODEL L-200 (CONTINENTAL F-162) ENGINE Continental F-162’s are 4 cycle, 4 cylinder in line gasoline engines with a bore of 3-7/16”, a stroke of 4-3/8”, a displacement of 162 cu. in., and 27 H.
  • Page 120 INSTALLATION A-112 A-112 MAGNETO Figure 2 I. (F-162) IGNITION SYSTEM “DC” mark) just beneath the inspection hole pointer, (See Figs. 1 and 2) which is on the right side of the hole and on the inside Magneto Ignition or back of the flywheel housing plate. SPARK PLUG POINT GAP --- 0.025”.
  • Page 121 INSTALLATION A-113 A-113 “IGN” mark on the flywheel. At the time of the flash, the IDLE SPEED SCREW --- CONTROL LEVER SCREW “IGN” mark should be just beneath the inspection hole --- and YOKE STOP SCREW AND NUT. pointer. If the “IGN” mark doesn’t fall just beneath the THE IDLE SPEED SCREW --- The purpose of the pointer, or if it is desired to advance or retard the spark IDLE SPEED SCREW is to set the low idle speed of...
  • Page 122 INSTALLATION A-114 A-114 CHECKING AND ADJUSTING VALVE CLEARANCES Figure 4 The recommended low idle speed is 750 - 950 R.P.M. A. Smoothness and Economy (STANDARD EXCITER MODELS) or 950 - 1050 THE IDLE JET ADJUSTING SCREW --- The purpose R.P.M. (OVERSIZE EXCITER MODELS.) of the idle jet is to give smoothness in engine perfor- THE CONTROL LEVER SCREW --- The control lever mance at low idle speed.
  • Page 123 INSTALLATION A-115 A-115 It is also advisable to check the position of the float tight; that the nuts which hold the toggles onto the assembly for correct measurement to obtain the prop- GOVERNOR CONTROL LEVER and the CARBURE- er fuel level. The float setting is measured from the TOR THROTTLE CONTROL LEVER are tight;...
  • Page 124 INSTALLATION A-116 A-116 However, if the screw was already in or up nearly all Toggle and noting the amount of surge still in the the way, it may be necessary to reverse the above pro- engine. Never lengthen the rod more than just enough cedure and lower the head of the screw.
  • Page 125 INSTALLATION A-117 A-117 GOVERNOR (Oversize Exciter Models with Rheostat Control) Figure 6 The speed drop is usually increased too much when B. OVERSIZE EXCITER MODEL this screw is adjusted too far in eliminating speed fluc- 1. Setting the High Idle Speed tuations (surge).
  • Page 126 INSTALLATION A-118 A-118 V. (F-162) THE ENGINE REGULATOR The throttle opening spring on the carburetor throttle shaft should pull the throttle wide open quickly when (Idling Device) (See Figs. 7 and Figs. 8) the arc is struck. The link between the control lever (tri- angular plate) underneath the metal bellows and the The purpose of the engine regulator is to cause the regulator link lever should be adjusted in length so that...
  • Page 127 INSTALLATION A-119 A-119 ENGINE REGULATOR CONNECTIONS AT CARBURETOR END OF LINK Figure 8 The mercury tilting switch terminals should be con- This is usually because the mercury switch does not nected across the voltage rheostat terminals, i.e,. one return quickly to open position (bellows fully extended). lead to each side of the rheostat.
  • Page 128 “Prevention and Control of Distortion in Arc Welding” by Walt Disney Productions. An education color-sound film, which As a service to its users, the Lincoln Electric Company pub- explains through the cartoon figure, Mr. Shrink, the causes lishes the following books. Order directly from the Lincoln and cures of distortion in arc welding.
  • Page 129 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .
  • Page 130 THEORY OF OPERATION FIGURE E.2 - BATTERY, STARTER, ENGINE ALTERNATOR AND OIL SWITCH CIRCUIT SELECTOR SWITCH REED RELAY NEGATIVE IDLER BOARD OUTPUT TERMINAL ENGINE PRESSURE HOUR LIGHT METER IDLER SOLENOID GENERATOR PRESSURE FRAME SWITCH SERIES RESIDUAL COILS MAGNETISM SHUNT FIELD ENGINE GENERATOR MECHANICAL...
  • Page 131 THEORY OF OPERATION FIGURE E.3 - ENGINE, MAIN GENERATOR ARMATURE AND FRAME AND DC EXCITER SELECTOR SWITCH REED RELAY NEGATIVE IDLER BOARD OUTPUT TERMINAL ENGINE PRESSURE HOUR LIGHT METER IDLER SOLENOID GENERATOR PRESSURE FRAME SWITCH SERIES RESIDUAL COILS MAGNETISM SHUNT FIELD ENGINE GENERATOR...
  • Page 132 THEORY OF OPERATION ENGINE, MAIN GENERATOR ENGINE IDLER CIRCUIT ARMATURE AND FRAME AND DC The idler solenoid is mechanically connected to the engine governor linkage. When welding current is EXCITER (CONTINUED) being drawn, the reed switch CR2 is closed. This CURRENT RANGE SELECTOR signals the idler PC board to release (deactivate) the idler solenoid, which then lets the machine go to a high The selector switch acts as a course current adjust-...
  • Page 133 THEORY OF OPERATION DC GENERATOR MACHINES The armature winding of a DC generator is located on the rotating member. Current is conducted from it by means of carbon brushes. The field winding is located in the stator, which is stationary and excited by direct current.
  • Page 134 NOTES SA-200...
  • Page 135 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .
  • Page 136 HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 137 Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
  • Page 138 Perform Rack Adjustment Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SA-200...
  • Page 139 See Wiring Diagram. all machines) CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SA-200...
  • Page 140 5. Test Series coils for a short. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SA-200...
  • Page 141 (Above code 7275 only) 3877. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SA-200...
  • Page 142 3. Engine throttle may need adjustment. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SA-200...
  • Page 143 4. Series coils may be shorted. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SA-200...
  • Page 144 = IM-179 3754 - 7275 See IM-129. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SA-200...
  • Page 145 Lincoln Electric Service Dept. 1-888-935-3877. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SA-200...
  • Page 146 NOTES F-12 F-12 SA-200...
  • Page 147 DC EXCITER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 148 TROUBLESHOOTING AND REPAIR F-14 F-14 DC EXCITER TEST (continued) FIGURE F.1 – 120VDC RECEPTACLE SERIES COIL CONNECTION POINT (NEGATIVE) POSITIVE PROCEDURE 1. Turn off the engine and remove all external 2. Start the engine and put the idler switch in the loads to the welder terminals and auxiliary HIGH idle position.
  • Page 149 TROUBLESHOOTING AND REPAIR F-15 F-15 DC EXCITER TEST (continued) FIGURE F.2 – EXCITER COVER REMOVAL WARRANTY CHECK VOLTAGE EXCITER AT BRUSH COVER HOLDERS HERE (RIGHT SIDE IS +) 4. Turn off the engine. Using the 3/8” nutdriver, remove the exciter cover. See Figure F.2. 5.
  • Page 150 TROUBLESHOOTING AND REPAIR F-16 F-16 DC EXCITER TEST (continued) FIGURE F.3 – BRUSH HOLDER LEADS WARRANTY RED LEAD - EXCITER ARMATURE WHITE 120 VOLTS FLEX EXCITER SERIES FIELD LEAD SMALL FLEX EXCITER SHUNT FIELD LEAD SOLID LEAD SHUNT COIL AND SERIES COIL RESISTANCE TESTS 7.
  • Page 151 TROUBLESHOOTING AND REPAIR F-17 F-17 DC EXCITER TEST (continued) FIGURE F.4 – STANDARD (SERIES) 1KW EXCITER EXCITER ARMATURE 120 VDC STANDARD (SERIES) 1KW EXCITER TEST - Code 445, 671, 960, 1122 & above 1. There are two exciter coils, in series, in the FBS exciter.
  • Page 152 NOTES F-18 F-18 SA-200...
  • Page 153 IDLER SOLENOID TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 154 TROUBLESHOOTING AND REPAIR F-20 F-20 IDLER SOLENOID TEST (continued) FIGURE F.5 – IDLER SOLENOID CONNECTIONS QUICK CONNECT LEADS PROCEDURE 1. Turn the engine OFF. 7. If the solenoid does not operate properly, check for a mechanical restriction in the linkage or for 2.
  • Page 155 TROUBLESHOOTING AND REPAIR F-21 F-21 IDLER SOLENOID TEST (continued) FIGURE F.6 – IDLER SOLENOID FLOWCHART CODE: 7276 & ABOVE 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...
  • Page 156 TROUBLESHOOTING AND REPAIR F-22 F-22 IDLER SOLENOID TEST (continued) FIGURE F.7 – MANUAL SPEED CONTROL CODES 215-1122 STD. FBS EXCITER ONLY GREASE ALL RUBBING SURFACES WITH 10% GRAPHITE GREASE PER E-708 ASSEMBLY S-7291 (WITHOUT HANDLE S-8158) CHAIN MUST BE PLACED WITH ASSEMBLY No.
  • Page 157 TROUBLESHOOTING AND REPAIR F-23 F-23 IDLER SOLENOID TEST (continued) FIGURE F.8 – R51 BELLOWS IDLER CODE 445-3312 FBS OVERSIZE EXCITER ONLY NEGATIVE MIN. MAX. IDLER COIL GENERATOR ARMATURE SERIES FIELDS INTERPOLES POSITIVE RHEOSTAT POWER OUTLET WHITE GENERATOR REGULATOR SHUNT FIELDS LEAD BLOCK BLUE BROWN...
  • Page 158 TROUBLESHOOTING AND REPAIR F-24 F-24 IDLER SOLENOID TEST (continued) R57 Vacuum Code 3417 - 7242 R-51 Bellows Code 445-3312 @ FDW oversize exciter only. TROUBLE SHOOTING AND MAINTENANCE – R51 AND R57 IDLERS The idler has been carefully set and calibrated at Sources of leaks are as follows: the factory and should require a minimum of main- a.
  • Page 159 TROUBLESHOOTING AND REPAIR F-25 F-25 IDLER SOLENOID TEST (continued) TROUBLE SHOOTING AND MAINTENANCE – R51 AND R57 IDLERS (2) If there is voltage on the coil but it is still not pulling in, then the coil may either be burned out or the air gap between the core and cap assembly and the valve stem may be exces- sive.
  • Page 160 NOTES F-26 F-26 SA-200...
  • Page 161 MAIN GENERATOR SHUNT FIELD WINDING TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 162 TROUBLESHOOTING AND REPAIR F-28 F-28 MAIN GENERATOR SHUNT FIELD WINDING TEST (continued) PROCEDURE 1. Locate the blue and brown leads emerging from Lift the rheostat wiper and place an insulator the welder lead block at the top of the main gen- between the brush and the winding Ohm between erating housing (On SA200 Short hood code the BLUE and BROWN leads.
  • Page 163 TROUBLESHOOTING AND REPAIR F-29 F-29 MAIN GENERATOR SHUNT FIELD WINDING TEST (continued) FIGURE F.10 – BATTERY IGNITION WIRING DIAGRAM OIL PRESSURE LIGHT BATTERY AMMETER IGNITION SWITCH START BUTTON IDLER IDLER CONTROL CONTROL SWITCH P.C. BOARD IDLER SOLENOID IGNITION DISTRIBUTOR COIL ALTERNATOR VOLT-AMMETER (OPTIONAL)
  • Page 164 TROUBLESHOOTING AND REPAIR F-30 F-30 MAIN GENERATOR SHUNT FIELD WINDING TEST (continued) FIGURE F.11 – ENGINE DRIVEN - TYPE 6090 CODE 445 - 3312 POS. NEG. POWER PLUG SELECTOR SWITCH RHEO BLACK LEAD BLOCK COMPOUND EXCITER CHECK SERIES EXCITER FACING COMMUTATOR END GOVERNOR CONTROL When governor control is used, leads “E”...
  • Page 165 TROUBLESHOOTING AND REPAIR F-31 F-31 MAIN GENERATOR SHUNT FIELD WINDING TEST (continued) FIGURE F.12 – L-200 FJW, FDW WELDER CHECK POWER RECEPTACLE (GROUNDING) SELECTOR TERMINAL NOT PROVIDED ON SWITCH EARLY MACHINES RHEOSTAT POS. NEG. WELDER LEAD BLOCK YELLOW ENGINE IDLER LIMIT OF ±...
  • Page 166 NOTES F-32 F-32 SA-200...
  • Page 167 FLASHING THE FIELDS WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 168 TROUBLESHOOTING AND REPAIR F-34 F-34 FLASHING THE FIELDS (continued) FIGURE F.13 – EXCITER COVER REMOVAL EXCITER COVER PROCEDURE 1. Turn the engine OFF. 2. Using a 3/8” Nutdriver, remove the exciter cover. See Figure F.13. SA-200...
  • Page 169 TROUBLESHOOTING AND REPAIR F-35 F-35 FLASHING THE FIELDS (continued) FIGURE F.14 – BRUSH HOLDER / BATTERY JUMPER CONNECTIONS WARRANTY RAISE EXCITER BRUSH OFF COMMUTATOR TO POSITIVE BATTERY TO NEGATIVE TERMINAL BATTERY TERMINAL 3. Raise one exciter brush off the armature com- 6.
  • Page 170 NOTES F-36 F-36 SA-200...
  • Page 171 RACK ADJUSTMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 172 TROUBLESHOOTING AND REPAIR F-38 F-38 RACK ADJUSTMENT PROCEDURE (continued) PROCEDURE 1. Connect the SA 200 to a load bank, make sure the engine is adjusted to specifications and the machine is hot. 2. Set the machine for MAXIMUM TAP, Maximum Rheostat.
  • Page 173 TROUBLESHOOTING AND REPAIR F-39 F-39 RACK ADJUSTMENT PROCEDURE (continued) FIGURE F.15 – RACK INSTRUCTIONS FOR ROTATING THE ROCKER (“RACK”) 6. Re-tighten the rocker clamp screw to 70-75 inch lbs. FOR: CLASSIC 300 D&G, CLASSIC II, SA-250, & SA 200 (Before adjusting the rocker, the NOTE: Rocker must be fully seated against the machine must be set to factory spec.
  • Page 174 TROUBLESHOOTING AND REPAIR F-40 F-40 RACK ADJUSTMENT PROCEDURE (continued) FIGURE F.16 – TEST AND INSPECTION MAX. MAX. IDLE MIN. IDLE 200 AMPS MIN. SHORT EXCITER 300 AMPS AMPS AMPS ENGINE WELDER IDLE FIELD D.C. EXC. FIELD D.C. EXC. FIELD VOLTS RPM VOLTS RPM VOLTS VOLTS VOLTS AMPS AMPS VOLTS AMPS VOLTS...
  • Page 175 NOTES F-41 F-41 SA-200...
  • Page 176 TROUBLESHOOTING AND REPAIR F-42 F-42 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VDC SUPPLY) HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM 0 volts 50 Volts 2 ms This is the typical auxiliary output voltage generated from a properly operating machine.
  • Page 177 TROUBLESHOOTING AND REPAIR F-43 F-43 NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR SWITCH AT MAXIMUM 0 volts 50 Volts 5 ms This is the typical DC welding output voltage generated from a properly operating machine.
  • Page 178 TROUBLESHOOTING AND REPAIR F-44 F-44 TYPICAL DC WELD VOLTAGE WAVEFORM MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM 0 volts 20 Volts MACHINE LOADED TO 200 AMPS AT 40VDC This is the typical DC welding output voltage generated from a properly operating machine.
  • Page 179 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 180 TROUBLESHOOTING AND REPAIR F-46 F-46 DC EXCITER ARMATURE AND FIELD COILS REMOVAL AND REPLACEMENT (continued) FIGURE F.17 – EXCITER COVER REMOVAL POLE PIECE BOLTS (4) EXCITER FRAME BRUSH HOLDER ASSEMBLY (2) ARMATURE SLEEVE COLLAR FLAT WASHER ARMATURE LOCKING NUT EXCITER COVER PROCEDURE DC Exciter Armature Removal Procedure Reassembly:...
  • Page 181 TROUBLESHOOTING AND REPAIR F-47 F-47 DC EXCITER ARMATURE AND FIELD COILS REMOVAL AND REPLACEMENT (continued) Field Coils Removal Procedure Reassembly: 1. Perform the DC Exciter Armature Removal 7. Assemble the new coils to their respective pole Procedure. pieces. 2. Using the 3/8” wrench, remove the leads from 8.
  • Page 182 NOTES F-48 F-48 SA-200...
  • Page 183 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 184 TROUBLESHOOTING AND REPAIR F-50 F-50 MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.18 – BATTERY PANEL REMOVAL NEGATIVE BATTERY CABLE PROCEDURE 1. Turn the engine OFF. 2. Using the 7/16” wrench, remove the two bolts and washers and partially slide out the battery mounting panel.
  • Page 185 TROUBLESHOOTING AND REPAIR F-51 F-51 MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.19 – TOP AND DOORS ASSEMBLY DETAILS BOLT / NUT (4) ‘L’ DOOR HOOKS (4) 4. Using the 1/2” wrench, remove the four nuts and bolts holding the case top and doors assembly to the welder frame.
  • Page 186 TROUBLESHOOTING AND REPAIR F-52 F-52 MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.20 – FUEL TANK MOUNTING DETAILS BOLTS / NUTS / WASHERS (4) FUEL LINE FUEL TANK FUEL BOWL RAILS 5. Perform the DC Exciter Armature Removal 7. Using the 9/16” wrench, remove the four nuts, Procedure.
  • Page 187 TROUBLESHOOTING AND REPAIR F-53 F-53 MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.21 – SELECTOR SWITCH LEAD REMOVAL SELECTOR SWITCH TERMINAL LEAD (5) 9. Using the 1/2” wrench, remove the five heavy flex leads from the selector switch terminals. Label the leads for reassembly.
  • Page 188 TROUBLESHOOTING AND REPAIR F-54 F-54 MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – CHOKE CONTROL CABLE REMOVAL LOOSEN HERE CHOKE CABLE 12. Using the slot head screw driver, remove the choke control cable from the engine carbure- tor assembly. Mark cable replacement for reassembly.
  • Page 189 TROUBLESHOOTING AND REPAIR F-55 F-55 MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.24 – FRONT PANEL WIRING CONNECTIONS 14. BLACK LEAD TO IDLER PC BOARD 18. WHITE LEAD 22. BROWN LEAD TO IDLER SWITCH 21. YELLOW LEAD TO IDLER SWITCH 17.
  • Page 190 TROUBLESHOOTING AND REPAIR F-56 F-56 MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.25 – FRONT PANEL FASTENER REMOVAL BOLTS / NUTS / WASHERS (2) MIDDLE SCREW (1) BASE MOUNTING BOLTS (4) 23. Using the 1/2” wrench, remove the two bolts, 25.
  • Page 191 TROUBLESHOOTING AND REPAIR F-57 F-57 MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.26 – BRUSH BRACKET WRAP-AROUND COVER BRUSH BRACKET REMOVE (2) NUTS, WASHERS, AND SCREWS WRAP-AROUND COVER 27. Using the slot head screw driver, remove the two screws and nuts from the brush bracket wrap-around cover.
  • Page 192 TROUBLESHOOTING AND REPAIR F-58 F-58 MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.28 – MAIN GENERATOR FEET MOUNTING MAIN GENERATOR FEET (2) REMOVE MOUNTING NUTS, WASHERS, AND BOLTS 30. Using the 3/4” wrench, remove the frame mounting bolts, nuts, and washers from the feet of the main generator.
  • Page 193 TROUBLESHOOTING AND REPAIR F-59 F-59 MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) 33. Using the rope sling and pry bars, carefully lift 8. Connect the white wire to the idler PC board. and “wiggle” the generator frame away from Connect the two red wires to the ignition the engine and armature assembly.
  • Page 194 NOTES F-60 F-60 SA-200...
  • Page 195 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 196 TROUBLESHOOTING AND REPAIR F-62 F-62 MAIN GENERATOR ARMATURE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.30 – MAIN GENERATOR ARMATURE MOUNTING SLING BLOWER PADDLE MOUNTING BOLTS / LOCK WASHERS (8) PROCEDURE Replacement: Refer to Figure F.30. 1. Turn the engine OFF. 1.
  • Page 197 TROUBLESHOOTING AND REPAIR F-63 F-63 RETEST AFTER REPAIR MAX. MAX. IDLE MIN. IDLE 200 AMPS MIN. SHORT EXCITER 300 AMPS AMPS AMPS ENGINE WELDER IDLE FIELD D.C. EXC. FIELD D.C. EXC. FIELD VOLTS RPM VOLTS RPM VOLTS VOLTS VOLTS AMPS AMPS VOLTS AMPS VOLTS...
  • Page 198 NOTES F-64 F-64 SA-200...
  • Page 199 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Code 215-3312 - Diagrams (Short Hood, Std.
  • Page 200 DIAGRAMS CODES 215 - 3312 (Short Hood, Std. Exciter, Oversize Opt.) SA-200...
  • Page 201 DIAGRAMS E-725 STANDARD SPECIFICATIONS MANUFACTURING EXCITER WIRING DIAGRAMS COUNTER CLOCKWISE ROTATION FACING EXCITER COMMUTATOR BLACK TO REVERSING SWITCH GREEN SEE CONTROL BOX WIRING DIAGRAM CLOCKWISE ROTATION FACING EXCITER COMMUTATOR BLACK TO REVERSING SWITCH GREEN SEE CONTROL BOX WIRING DIAGRAM SA-200...
  • Page 202 DIAGRAMS M-6478 “X” “X” TO RIGHT HAND EXCITER BRUSH HOLDER TO EXCITER SERIES FIELD OUTPUT LEAD NOTE: ON WELDERS HAVING CROSS CONNECTORS (SHOWN DOTTED) BETWEEN BRUSH HOLDER STUDS OF LIKE POLARITY, LEADS “X” WERE OMITTED. COUNTER-CLOCKWISE ROTATION SA-200...
  • Page 203 DIAGRAMS M-6996 11 18 13 14 15 16 17 STARTER GEN. BUTTON BAT. GEN. AMMETER START – BATT. WIRING DIAGRAM ENGINE ASSEMBLY MATERIAL REQ’D TO CHANGE OVER STD. MAGNETO HAND CRANK UNIT TO BATTERY SELF START UNIT WITH GENERATOR ETC. ITEM DESCRIPTION PART NO.
  • Page 204 DIAGRAMS C-882 SA-200 ENGINE DRIVEN - TYPE 6090 GOVERNOR CONTROL When governor control is used, leads “E” and “F” are brought out of generator through lead block and spliced together as shown by dotted lines. RHEOSTAT CONTROL When rheostat control is used, compound exciter and rheostat are wired as shown by solid lines.
  • Page 205 COMMUTATORS MAY BE CLEANED WITH FINE SANDPAPER WHILE THE MACHINE IS RUNNING TO REMOVE ANY GREASE OR DIRT THAT HAS ACCUMULATED. DO NOT USE EMERY CLOTH KEEP GROUND AND ELECTRODE CONNECTIONS TIGHT. THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO ~ U.S.A. S-7300 DIA. HOLES (2) NOTE: View shown double size.
  • Page 206 DIAGRAMS CODES 3417 - 5841 (Red Face, Long Hood, Oversize Exciter Opt.) SA-200...
  • Page 207 DIAGRAMS T-12505 STARTER PUSH BUTTON AMMETER – CUTOUT GENERATOR STARTING – MOTOR BATTERY GROUND NOTE: Limit of ± 1/2º on all angles unless otherwise specified. Limit of ± 1/64 on all fractional dimensions unless otherwise specified. Limit of ± .002 on all decimal dimensions unless otherwise specified. SA-200...
  • Page 208 DIAGRAMS G-10 G-10 E276-C COMPOUND EXCITER CONNECTIONS FOR COUNTER CLOCKWISE ROTATION FACING THE EXCITER COMMUTATOR EXCITER ARMATURE 115 VOLTS EXCITER SERIES FIELD EXCITER SHUNT FIELD Series Field * T1 Connect to T11. T2 Connect to the left hand exciter brush holder. T12 Bring out a lead through the lower or left hand lead block hole “E”...
  • Page 209 DO NOT USE EMERY CLOTH Keep ground and electrode connections tight. THE LINCOLN ELECTRIC CO. L-200 FJW, FDW WELDER WITH “R” IDLER & METER S-11319 CLEVELAND, OHIO U.S.A.
  • Page 210 DIAGRAMS G-12 G-12 T-13076 + – MAG. PLUGS ALT. START “B” “A” BUTTON VOLTAGE REGULATOR IGNITION SWITCH SHOWN IN OFF POSITION STARTING MOTOR COLOR CODE B = BLACK R = RED W = WHITE – A.S.A. ELECTRICAL SYMBOLS PER E-1537 SA-200...
  • Page 211 DIAGRAMS G-13 G-13 M-8791 YELLOW BROWN BLACK BLUE 34 23 – N.A. – 23 34 COUNTER CLOCKWISE ROTATION NOTE: LEAD USED ONLY ON UNITS WITH VACUUM IDLER. N.A. When optional CV adapter is installed, the thermostat is connected to this brush holder. SA-200...
  • Page 212 DO NOT USE EMERY CLOTH KEEP GROUND AND ELECTRODE CONNECTIONS TIGHT. WELDER LEAD BLOCK YELLOW ENGINE IDLER THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO MADE IN U.S.A. S-11663 PRINT ABOVE TO 4 1/2 TO 10 1/2 SIZE NOTE: LIMIT OF ± 1/2º ON ALL ANGLES UNLESS OTHERWISE SPECIFIED.
  • Page 213 DIAGRAMS G-15 G-15 S-10763 NOTE: View Shown 125 V. DC SELECTOR SW. RHEOSTAT RECEPTACLE Double Size Color per federal std. #595 BROWN BLACK Lithograph YELLOW All letters, figures, border & dia- POS. NEG. WELDER ENGINE IDLER LEAD BLOCK grams to be polished finish on a MAINTENANCE INSTRUCTIONS color #17038 background.
  • Page 214 DIAGRAMS G-16 G-16 M-12078 NOTES 15 13 Item 4 - Attaches batt. to plate. Item 6 - for attaching starter motor. ON FAR Item 10 - mounts amm. panel & atl. mtg. brkt. to engine block. Item 12 - mts. alt. to brkt. ON FAR SIDE Item 14 - for alt.
  • Page 215 DIAGRAMS G-17 G-17 T-9088 STARTER PUSH BUTTON – AMMETER CUTOUT STARTER GENERATOR MOTOR – BATTERY GROUND NOTE: Limit of ± 1/64 on all dimensions. SA-200...
  • Page 216 DIAGRAMS G-18 G-18 CODES 5957 - 7242 (Black Face, Vacuum Idler, P-23 Parts) SA-200...
  • Page 217 DIAGRAMS G-19 G-19 T-13076 + – MAG. PLUGS ALT. START “B” “A” BUTTON VOLTAGE REGULATOR IGNITION SWITCH SHOWN IN OFF POSITION STARTING MOTOR COLOR CODE B = BLACK R = RED W = WHITE – A.S.A. ELECTRICAL SYMBOLS PER E-1537 SA-200...
  • Page 218 DIAGRAMS G-20 G-20 M-8791 YELLOW BROWN BLACK BLUE 34 23 – N.A. – 23 34 COUNTER CLOCKWISE ROTATION NOTE: LEAD USED ONLY ON UNITS WITH VACUUM IDLER. N.A. When optional CV adapter is installed, the thermostat is connected to this brush holder. SA-200...
  • Page 219 DO NOT USE EMERY CLOTH KEEP GROUND AND ELECTRODE CONNECTIONS TIGHT. WELDER LEAD BLOCK YELLOW ENGINE IDLER THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO MADE IN U.S.A. S-11663 PRINT ABOVE TO 4 1/2 X 10 1/2 SIZE NOTE: LIMIT OF ± 1/2º ON ALL ANGLES UNLESS OTHERWISE SPECIFIED.
  • Page 220 DIAGRAMS G-22 G-22 M-12103 NOTES Item 6 mounts alt. to brkt. ON FAR END Item 8 for alt. adj. strap to alternator. Item 10 mts. adj. strap to engine. ON FAR SIDE Item 11 mtg. of alt. fan guard to adj. strap. Item 15 mounts volt regulator.
  • Page 221 DIAGRAMS G-23 G-23 T-9088 STARTER PUSH BUTTON – AMMETER CUTOUT STARTER GENERATOR MOTOR – BATTERY GROUND NOTE: Limit of ± 1/64 on all dimensions. SA-200...
  • Page 222 DIAGRAMS G-24 G-24 E276-C COMPOUND EXCITER CONNECTIONS FOR COUNTER CLOCKWISE ROTATION FACING THE EXCITER COMMUTATOR EXCITER ARMATURE 115 VOLTS EXCITER SERIES FIELD EXCITER SHUNT FIELD Series Field * T1 Connect to T11. T2 Connect to the left hand exciter brush holder. T12 Bring out a lead through the lower or left hand lead block hole “E”...
  • Page 223 DIAGRAMS G-25 G-25 CODES 7276 - 9530 (Electronic Idler, P-111 Parts) SA-200...
  • Page 224 DIAGRAMS G-26 G-26 M-15733 BROWN BLACK BLUE SERIES – N.A. – SERIES COUNTER CLOCKWISE ROTATION N.A. When optional CV adapter is installed, the thermostat is connected to this brush holder. N.B. Flex lead connections to interpoles may be bolted or soldered depending on type of interpoles. SA-200...
  • Page 225 DIAGRAMS G-27 G-27 S-17701 START BUTTON IDLER BATTERY CONTROL CR2 REED RELAY IDLER AMMETER P.C. BOARD SOLENOID IGNITION SWITCH – – ALTERNATOR ON DISTRIBUTOR EARLIER MODELS TO EXCITER OUTPUT AUX POWER RECEPTACLE IGNITION IDLER CONTROL COIL SWITCH 5 4 3 2 1 VOLT - AMMETER (OPTIONAL) PRESSURE...
  • Page 226 DIAGRAMS G-28 G-28 E276-C COMPOUND EXCITER CONNECTIONS FOR COUNTER CLOCKWISE ROTATION FACING THE EXCITER COMMUTATOR EXCITER ARMATURE 115 VOLTS EXCITER SERIES FIELD EXCITER SHUNT FIELD Series Field * T1 Connect to T11. T2 Connect to the left hand exciter brush holder. T12 Bring out a lead through the lower or left hand lead block hole “E”...
  • Page 227 DIAGRAMS G-29 G-29 S-14919 OIL PRESSURE LIGHT START IGNITION SWITCH BUTTON – AUX. POWER WELDER PLUGS CONTROL IDLER IDLER TO 2CR DIAGRAM CONTROL CONTROL REED CIRCUIT SWITCH RELAY P.C. BOARD ALTERNATOR OIL PRESSURE SWITCH IDLER SOLENOID VOLTAGE REGULATOR – STARTING A.N.S.I.
  • Page 228 DIAGRAMS G-30 G-30 S-17298 OIL PRESSURE LIGHT BATTERY AMMETER IGNITION SWITCH START BUTTON – IDLER CONTROL P.C. BOARD + – IDLER SOLENOID IGNITION DISTRIBUTOR COIL ALTERNATOR IDLER CONTROL SWITCH VOLT-AMMETER OIL PRESSURE (OPTIONAL) – – SWITCH SELECTOR RHEOSTAT SWITCH 2CR REED –...
  • Page 229 DO NOT USE EMERY CLOTH KEEP GROUND AND ELECTRODE CONNECTIONS TIGHT. WELDER LEAD BLOCK YELLOW ENGINE IDLER THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO MADE IN U.S.A. S-11663 PRINT ABOVE TO 4 1/2 X 10 1/2 SIZE NOTE: LIMIT OF ± 1/2º ON ALL ANGLES UNLESS OTHERWISE SPECIFIED.
  • Page 230 DIAGRAMS G-32 G-32 S-16483 OIL PRESSURE LIGHT BATTERY AMMETER IGNITION SWITCH START BUTTON – IDLER CONTROL P.C. BOARD + – IDLER SOLENOID IGNITION DISTRIBUTOR COIL ALTERNATOR IDLER CONTROL SWITCH VOLT-AMMETER OIL PRESSURE (OPTIONAL) VOLTAGE – – SWITCH REGULATOR SELECTOR RHEOSTAT SWITCH 2CR REED –...
  • Page 231 DIAGRAMS G-33 G-33 S-17297 OIL PRESSURE LIGHT BATTERY AMMETER IGNITION SWITCH START BUTTON – IDLER CONTROL MAG. TO PLUGS P.C. BOARD IDLER SOLENOID ALTERNATOR IDLER CONTROL SWITCH VOLT-AMMETER OIL PRESSURE (OPTIONAL) – – SWITCH SELECTOR RHEOSTAT SWITCH 2CR REED – ENGINE HOUR RELAY METER (OPTIONAL)
  • Page 232 DIAGRAMS G-34 G-34 S-16129 TO POSITIVE SUPPLY TO REED RELAY TO IDLER SOLENOID AUX. POWER LEAD COLOR CODE B = BLACK Y = YELLOW R = RED W = WHITE NEGATIVE GROUND ELECTRICAL SYMBOLS PER E-1537 LEGEND 200MFD .22 MFD 47 Ω...
  • Page 233 DIAGRAMS G-35 G-35 S-14931 TO POSITIVE SUPPLY TO REED RELAY TO IDLER SOLENOID AUX. POWER LEAD COLOR CODE B = BLACK Y = YELLOW R = RED W = WHITE NEGATIVE GROUND ELECTRICAL SYMBOLS PER E-1537 LEGEND 200MFD REED RELAY 47 Ω...
  • Page 234 DIAGRAMS G-36 G-36 S-17382 BATTERY OIL PRESSURE LIGHT AMMETER START BUTTON IGNITION SWITCH – IDLER CONTROL ALTERNATOR ON MAG. TO PLUGS P.C. BOARD IDLER EARLIER MODELS SOLENOID IDLER CONTROL SWITCH OIL PRESSURE OPTIONAL ALTERNATORS + – – SWITCH VOLT-AMMETER SELECTOR RHEOSTAT (OPTIONAL) SWITCH...
  • Page 235 DIAGRAMS G-37 G-37 S-17383 OIL PRESSURE LIGHT BATTERY AMMETER START BUTTON IGNITION SWITCH – IDLER CONTROL ALTERNATOR ON P.C. BOARD IDLER + – EARLIER MODELS SOLENOID IGNITION DISTRIBUTOR COIL IDLER CONTROL SWITCH OIL PRESSURE OPTIONAL ALTERNATORS + – – SWITCH VOLT-AMMETER SELECTOR RHEOSTAT...
  • Page 236 DIAGRAMS G-38 G-38 S-18866 START BUTTON BATTERY IGNITION AMMETER SWITCH IDLER CR2 REED RELAY CONTROL IDLER – P.C. BOARD SOLENOID – TO EXCITER MAG. PLUGS OUTPUT AUX. POWER IDLER CONTROL RECEPTACLE SWITCH OPTIONAL ALTERNATORS OIL PRESSURE PRESSURE LIGHT SWITCH ENGINE HOUR VOLT - AMMETER METER –...
  • Page 237 DIAGRAMS G-39 G-39 S-14930 VOLT-AMMETER (OPTIONAL) – SEE ENGINE 2CR REED CONTROL DIAGRAM RELAY TO MACHINE SELECTOR GROUND RHEOSTAT SWITCH AUX. POWER RECEPTACLE METER SHUNT (OPTIONAL) LEAD COLOR CODE – B - BLACK N - BROWN EXCITER U - BLUE OUTPUT R - RED Y - YELLOW...
  • Page 238 Y YELLOW NEGATIVE GROUND R RED W WHITE THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO. AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LIN- COLN ELECTRIC CO. NOTES: LABELS N.A.
  • Page 239 DIAGRAMS G-41 G-41 S-15197 OIL PRESSURE LIGHT BATTERY AMMETER IGNITION SWITCH START BUTTON – IDLER CONTROL MAG. TO PLUGS P.C. BOARD IDLER SOLENOID ALTERNATOR IDLER CONTROL SWITCH VOLT-AMMETER OIL PRESSURE (OPTIONAL) VOLTAGE – – SWITCH REGULATOR SELECTOR RHEOSTAT SWITCH 2CR REED –...
  • Page 240 DIAGRAMS G-42 G-42 M-15733 BROWN BLACK BLUE SERIES – N.A. – SERIES COUNTER CLOCKWISE ROTATION N.A. When optional CV adapter is installed, the thermostat is connected to this brush holder. N.B. Flex lead connections to interpoles may be bolted or soldered depending on type of interpoles. SA-200...
  • Page 241 DIAGRAMS G-43 G-43 L-6099 3.41 E-106A-4 (6 REQ’D) 3/8-16x1.00 M-14343-1 HEX HD SCREW WELDER FRAME (6 REQ’D) T-9695-4 (3 REQ’D) M-14361 ENGINE (4 REQ’D) T-8838-1 (3 REQ’D) T-8833-44 (8 REQ’D) N.D. E-106A-8 M-6730 (8 REQ’D) N.E. S-8042 (2 REQ’D) CRANKSHAFT DEPTH OF REAM ARMATURE SHAFT...
  • Page 242 DIAGRAMS G-44 G-44 M-8791 YELLOW BROWN BLACK BLUE 34 23 – N.A. – 23 34 COUNTER CLOCKWISE ROTATION NOTE: LEAD USED ONLY ON UNITS WITH VACUUM IDLER. SA-200...