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SVM128-A
March, 1999
TM
SHIELD-ARC SA-250
Diesel Engine Driven DC Arc Welding Power Source
For use with machine code numbers 10073 or 10073CV.
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be in-
creased by proper installation . . .
and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CON
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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
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 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” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety.................................................................................................................................................i-iv Installation.............................................................................................................................Section A Technical Specifications.....................................................................................................
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Section A-1 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Installation Technical Specifications..............................................................................................................A-2 Safety Precautions......................................................................................................................A-3 Location and Ventilation..............................................................................................................A-3 Stor
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - SA-250 INPUT - DIESEL ENGINE Manufacturer Description Speed Displacement Ignition Capacities Perkins 3 cyl., 4 cycle 1725 RPM 152 cu. in. Electric Fuel: 15 gal. D3.152 Water-cooled Full load (2500 cc) (57 liters) diesel 38.2 HP @ 1800 RPM Oil: 7.2 qt. 1725 RPM High idle (6.9 liters) 1350 RPM Water/coolant: 10 qt. Low idle (9.5 liters) RATED OUTPUT - WELDER Duty Cycle Amps Volts at Rated Amperes 100% Duty Cycle 200 DC Constant Current 40V (1) 60% D
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A-3 A-3 INSTALLATION Read this entire installation section before you LOCATION AND VENTILATION start installation. Always operate the SA-250 with the doors closed. Leaving the doors open changes the designed air flow and may cause overheating. Always operate the SAFETY PRECAUTIONS welder with the case roof on and all machine compo- nents completely assembled. WARNING Whenever you use the SA-250, be sure that clean Do not attempt to use this equipment until you have cooling air can flow through
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A-4 A-4 INSTALLATION STACKING WARNING SA-250 machines CANNOT be stacked. Keep hands away from the engine muffler or HOT engine parts. • Stop the engine when fueling. TILTING • Do not smoke when fueling. Place the machine on a secure, level surface whenev- er you use it or store it. Any surfaces you place it on • Remove the fuel cap slowly to release pressure. other than the ground must be firm, non-skid, and • Do not overfill the fuel tank. structurally sound. • Wipe up spilled fuel and
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A-5 A-5 INSTALLATION COOLING SYSTEM TRAILER The cooling system has been filled at the factory with a If you use a non-Lincoln trailer, you must assume 50-50 mixture of ethylene glycol antifreeze and water. responsibility that the method of attachment and usage Check the radiator level and add a 50-50 solution as does not result in a safety hazard nor damage the needed. (See your engine manual or antifreeze con- welding equipment. Some of the factors to be consid- tainer for alternate antifreez
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A-6 A-6 INSTALLATION ELECTRICAL OUTPUT CAUTION CONNECTIONS • Loose connections will cause the output terminals to See Figure A.1 for the location of the 115 and 230 volt overheat. The terminals may eventually melt. receptacles, weld output terminals, and ground stud. • Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another. WELDING CABLE CONNECTIONS CABLE INSTALLATION AND CABLE SIZES With the engine off, route the electrode a
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A-7 A-7 INSTALLATION For further protection against electric shock, any elec- MACHINE GROUNDING trical equipment connected to the generator recepta- According to the United States National Electrical cles must use a three-blade, grounded type plug or an Code, the frame of this portable generator is not Underwriter's Laboratories (UL) approved double insu- required to be grounded and is permitted to serve as lation system with a two-blade plug. Lincoln offers an the grounding means for cord conn
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A-8 A-8 NOTES SA-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Operation...............................................................................................................................Section B Safety Instructions.......................................................................................................................B-2 General Description ....................................................................................................................B-2 Recommen
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B-2 B-2 OPERATION WARNING OPERATING INSTRUCTIONS Read and understand this entire section before operat- ing your SA-250. ENGINE EXHAUST can kill. SAFETY INSTRUCTIONS • Use in open, well ventilated areas or vent exhaust to the outside. WARNING • Do not stack anything on or near the engine. Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include MOVING PARTS can injure. important safety precautions; de
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B-3 B-3 OPERATION RECOMMENDED APPLICATIONS DESIGN FEATURES • Constant current DC Stick welding (SMAW) process WELDER capability with output range from 40 - 325 DC amps. The SA-250 provides excellent constant current DC • Constant current DC TIG Welding with output across welding output for stick (SMAW) welding and for DC the entire range of settings. TIG welding. It also offers constant voltage output for DC semiautomatic wire feed welding. For more details • Work and Electrode welding cab
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B-4 B-4 OPERATION WELDING CAPABILITY LIMITATIONS The SA-250 is rated 250 amps, 40 volts constant cur- • The SA-250 is not recommended for any processes rent DC at 60% duty cycle based on a ten minute time besides those that are normally performed using DC period. Longer duty cycles at lower output currents are stick welding (SMAW) and DC TIG welding. Specific possible. limitations on using the SA-250 for these processes are described in the Welding Operation section of The current is con
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B-5 B-5 OPERATION CONTROLS AND SETTINGS the case front. Welding output terminals and ground The welder/generator controls are located on the stud are located on the machine left side, under the Output Control Panel of the machine case front. Diesel door. See Figure B.1, B.2 and B.3 and the explana- engine idler control and start/stop controls are also on tions that follow. FIGURE B.1 – OUTPUT CONTROLS 1 2 3 6 4 5 7 1. CURRENT RANGE SELECTOR 2. FINE CURRENT ADJUSTMENT 3. 230 VOLT DUPLEX RE
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B-6 B-6 OPERATION A high open circuit voltage setting provides the soft CONTROL OF WELDING CURRENT "buttering" arc with best resistance to pop-outs pre- ferred for most welding. To get this characteristic, set CAUTION the CURRENT RANGE SELECTOR to the lowest set- ting that still provides the current you need and set the FINE CURRENT ADJUSTMENT near maximum. For • DO NOT turn the CURRENT RANGE SELECTOR example: to obtain 175 amps and a soft arc, set the while welding because the current may ar
