RETURN TO MAIN INDEX
IM568
SAM400 & 650 PERKINS DIESEL ENGINE DRIVEN April, 1997
MULTI-PROCESS DC ARC WELDING POWER SOURCES
For use with SAM400 machines having Code Numbers: 10140 & 10141
For use with SAM650 machines having Code Number: 10333
Supersedes IM247-D
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built with
safety in mind. However, your overall
safety can be increased by proper
installation ... and thoughtful opera-
tion on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think before
you act and be careful.
OPERATOR’S MANUAL
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-
chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and before welding.
devices in position and in good repair.Keep
hands, hair, clothing and tools away from V- 2.c. Exposure to EMF fields in welding may have other health
belts, gears, fans and all other moving parts effects which are now not known.
when starting, operating or repairing equip-
ment. 2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
____________________________________________________
2.d.1. Route the electrode and work cables together - Secure
1.e. In some cases it may be necessary to remove safety
them with tape when possible.
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.2. Never coil the electrode lead around your body.
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
2.d.3. Do not place your body between the electrode and
parts.
work cables. If the electrode cable is on your right
___________________________________________________
side, the work cable should also be on your right side.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle con-
trol rods while the engine is running. 2.d.4. Connect the work cable to the workpiece as close as
___________________________________________________ possible to the area being welded.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance 2.d.5. Do not work next to welding power source.
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Mar �95
SAM400 & 650
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. Use suitable clothing made from durable flame-resistant
3.b. Insulate yourself from work and ground using dry insulation.
material to protect your skin and that of your helpers from
Make certain the insulation is large enough to cover your full
the arc rays.
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if welding
screening and/or warn them not to watch the arc nor expose
must be performed under electrically hazardous
themselves to the arc rays or to hot spatter or metal.
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
can be dangerous.
the following equipment:
5.a. Welding may produce fumes and gases
� Semiautomatic DC Constant Voltage (Wire) Welder.
hazardous to health. Avoid breathing these
� DC Manual (Stick) Welder.
fumes and gases.When welding, keep
� AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
fumes and gases away from the breathing zone. When
electrode reel, welding head, nozzle or semiautomatic
welding with electrodes which require special
welding gun are also electrically “hot�.
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
3.d. Always be sure the work cable makes a good electrical
cadmium plated steel and other metals or coatings
connection with the metal being welded. The connection
which produce highly toxic fumes, keep exposure as
should be as close as possible to the area being welded.
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
3.e. Ground the work or metal to be welded to a good electrical
confined spaces or in some circumstances, outdoors, a
(earth) ground.
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating
products.
3.h. Never simultaneously touch electrically “hot� parts of
electrode holders connected to two welders because voltage
5.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
5.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.j. Also see Items 6.c. and 8.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar �95
SAM400 & 650
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 hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact can
any other source of heat, sparks, or flame.
cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
SAM400 & 650
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés possible de
1. Protegez-vous contre la secousse électrique:
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
a. Les circuits à l’électrode et à la piéce sont sous tension
éloignés de la zone de travail, on augmente le risque de voir
quand la machine à souder est en marche. Eviter toujours
passer le courant de soudage par les chaines de levage,
tout contact entre les parties sous tension et la peau nue
câbles de grue, ou autres circuits. Cela peut provoquer des
ou les vétements mouillés. Porter des gants secs et sans
risques d’incendie ou d’echauffement des chaines et des
trous pour isoler les mains.
câbles jusqu’� ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans
Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande
galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse.
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
10. Ne pas souder en présence de vapeurs de chlore provenant
tionnement.
d’opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l’eau pour le
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
refroidir.
du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension
ou autres produits irritants.
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
total de la tension à vide des deux machines.
le code “Code for safety in welding and cutting� CSA Standard
f. Si on utilise la machine à souder comme une source de
W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
PRÉCAUTIONS DE SÛRETÉ POUR
contre les chutes dans le cas ou on recoit un choc. Ne jamais
LES MACHINES À SOUDER À
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
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.
Mar. �93
SAM400 & 650
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product •â?¢â??
as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
SAM400 & 650
vi vi
TABLE OF CONTENTS
Page
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Pre-Operation Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Welder Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Pipe Thawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Engine Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Welder Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Starting Welders with Dead Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Diode Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
SCR Bridge PC Board Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
Control PC Board Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
Ground Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
Wiring Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix
SAM400 & 650
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - SAM400
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Perkins 4 cylinder High Idle 1790 236 cu. in 12VDC batteries Fuel: 22.5 gal.
4.236 Diesel 63 HP @ Low Idle 1100 (3.87 L) (2) & Starter 85.1 L
Engine 1725 RPM Full Load 1725
Bore x Stroke Oil: 8.5 Qts.
8.04 L
3.875� x 5.00�
(98.4 mm x 127.0mm) Coolant: 3.2 gal.
12.11 L
RATED OUTPUT - WELDER
Duty Cycle Welding Output Volts at Rated Amps
60% (NEMA) 400 amps 36 volts
60% (Lincoln Plus) 400 amps 40 volts
OUTPUT - WELDER AND GENERATOR
Welding Range Open Circuit Voltage Auxiliary Power
60 - 500 Amps 17 - 45 OCV 120/240 VAC
(excluding hot start voltage)
CV Current Range 2kVA, 60 Hz.
80 - 500 60 - 95 OCV 100% Duty Cycle
VV Current Range
PHYSICAL DIMENSIONS
HEIGHT1 WIDTH DEPTH WEIGHT
50.13 in. 27.12 in. 83.00 in. 2163 lbs.
1273.3 mm 688.9 mm 2108.2 mm 981.1 kg
1. Add 15.4� (391.2 mm) for optional muffler.
SAM400 & 650
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - SAM650
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Perkins 6 cylinder High Idle 1790 365 cu. in 12VDC batteries Fuel: 22.5 gal.
1006-6 Diesel 93 HP @ Low Idle 1200 (5.98 L) (2) & Starter 85.1 L
Engine 1730 RPM Full Load 1750
Bore x Stroke Oil: 14.0 Qts.
13.24 L
3.937� x 5.00�
(100mm x 127mm) Coolant: 5.5 gal.
20.8 L
RATED OUTPUT - WELDER
Duty Cycle Welding Output Volts at Rated Amps
80% (NEMA) 650 Amps 44 volts
60%(NEMA) 725 Amps 44 volts
80%(Lincoln Plus) 650 Amps 50 volts
60%(Lincoln Plus) 725 Amps 50 volts
OUTPUT - WELDER AND GENERATOR
Welding Range Open Circuit Voltage Auxiliary Power
80 - 815 Amps 18 - 50 OCV 120/240 VAC
(excluding hot start voltage)
CV Current Range 2kVA, 60 Hz.
80 - 815 45 - 90 OCV 100% Duty Cycle
VV Current Range
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
56.7 in. 27.12 in. 88.75 in. 2800 lbs.
1440.2 mm 688.9 mm 2254.2 mm 1270.1 kg
SAM400 & 650
A-3 A-3
INSTALLATION
PRODUCT DESCRIPTION earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
The SAM engine welders are multi-purpose welding
has been effectively grounded. The National Electrical
machines. They are designed to be used on all open
Code lists a number of alternate means of grounding
arc or submerged arc processes within the rating of the
electrical equipment.
unit.
The machine is designed to be used with the following
automatic equipment: LN-7, LN-8, LN-9, LN-22, LN-
WARNING
23P (with Adapter Kit), LN-25, NA-3, LT-7, or LT-56. It
can be used with most other equipment whose power
ADDITIONAL SAFETY PRECAUTIONS
requirements do not exceed the rating of the machine.
FALLING EQUIPMENT can cause
injury.
The SAM machines have two types of output charac-
teristics; a variable voltage output characteristic for q Do not lift this machine using lift
stick and submerged arc welding and also constant bale if it is equipped with a heavy
voltage characteristics for Innershield® plus both dip- accessory such as trailer or gas
transfer and spray-transfer processes. cylinder.
Lift only with equipment of adequate lifting
q
capacity.
INSTALLATION PRECAUTIONS Be sure machine is stable when lifting.
q
SPARK ARRESTER
The recommended undercarriage for use with this
Some federal, state or local laws may require that
equipment for in-plant and yard towing by a vehicle is
diesel engines be equipped with exhaust spark
Lincoln’s K767-1. If the user adapts a non-Lincoln
arresters when they are operated in certain locations
undercarriage, he must assume responsibility that the
where unarrested sparks may present a fire hazard.
method of attachment and usage does not result in a
The standard mufflers included with these welders do
safety hazard nor damage the welding equipment.
not qualify as spark arresters. When required by local
Some of the factors to be considered are as follows:
regulations suitable spark arresters must be installed
and properly maintained.
1. Design capacity of undercarriage vs. weight of
Lincoln equipment and likely additional attach-
CAUTION ments.
An incorrect arrester may lead to damage of the
2. Proper support of, and attachment to, the base of
engine or its performance. Contact the engine
the welding equipment so there will be no undue
manufacturer for specific recommendations.
stress to the framework.
3. Proper placement of the equipment on the under-
carriage to insure stability side to side and front to
MACHINE GROUNDING
back when being moved and when standing by itself
while being operated or serviced.
The 1984 National Electrical Code does not require
this machine to be grounded under normal operating
4. Typical conditions of use, i.e., travel speed; rough-
circumstances.
ness of surface on which the undercarriage will be
operated; environmental conditions; likely mainte-
Some state, local or other codes or unusual operating
nance.
circumstances may require the machine frame to be
grounded. It is recommended that you determine the
5. Conformance with federal, state and local laws.(1)
extent to which such requirements may apply to your
particular situation and follow them explicitly. A
machine grounding stud marked with the symbol is
provided on the welding generator frame foot.
(1) Consult applicable federal, state and local laws regarding
In general, if the machine is to be grounded it should specific requirements for use on public highways.
be connected with a #8 or larger copper wire to a solid
SAM400 & 650
A-4 A-4
INSTALLATION
PRE-OPERATION SERVICE IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:
Oil: This unit is supplied from the factory with the a) Installing new batteries.
engine crankcase filled with a high quality 10W30 oil.
b) Using a booster.
This oil should be acceptable for most typical ambient
Use correct polarity � Negative Ground.
temperatures. Consult the Engine Operation Manual
for specific recommendations. Upon receipt of the
To prevent BATTERY BUCKLING, tighten nuts on bat-
welder, check the dipstick to be sure the oil is at the
teries only until snug. DO NOT OVERTIGHTEN.
"full" mark. DO NOT OVERFILL.
Fuel: Fill the fuel tank with the grade of diesel fuel rec-
Muffler: On SAM650 units: Screw the muffler into the
ommended in the engine Instruction Manual. Open the
exhaust flange and tighten.
fuel feed valve on the sediment bowl by turning the
On SAM400 units with the optional noise
handle counterclockwise.
control muffler: Attach the muffler with the
supplied hardware.
Cooling System:The cooling system has been filled at
the factory with a 50-50 mixture of ethylene glycol
The engine and welder controls were properly set at
antifreeze and water. Check the radiator level and add
the factory and should require no adjusting when
a 50-50 solution as needed. (See Engine Manual or
received.
antifreeze container for alternate antifreeze recom-
mendation.)
OUTPUT CABLES
Battery: Remove the insulating cap from the negative
battery terminal. Replace and tighten negative battery
With the engine off, connect the electrode and work
cable terminal. NOTE: This machine is furnished with
cables to the studs provided. These connections
wet charged batteries; if unused for several months,
should be checked periodically and tightened if neces-
the batteries may require a booster charge. Be sure to
sary. When welding at a considerable distance from the
use the correct polarity when charging the batteries.
welder, be sure you use ample size welding cables.
Listed below are copper cable sizes recommended for
WARNING
the rated current and duty cycle. Lengths stipulated are
the distance from the welder to work and back to the
GASES FROM BATTERY can explode.
welder again. Cable sizes are increased for greater
q Keep sparks, flame and cigarettes
lengths primarily for the purpose of minimizing cable
away from battery.
voltage drop.
Cable Sizes For Combined Lengths
%
To prevent EXPLOSION when: Of Electrode And Work Cables
Duty
q INSTALLING A NEW BATTERY � disconnect Amps Cycle 0-100 ft. 100-200 ft. 200-250 ft.
negative cable from old battery first and 650 60 3/0 2-2/0 2-3/0
650 80 2-1/0 2-2/0 2-3/0
connect to new battery last.
400 60 2/0 3/0 4/0
q CONNECTING A BATTERY CHARGER �
remove battery from welder by disconnecting
negative cable first, then positive cable and WELDER LOCATION
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated. The welder should be located to provide an unrestrict-
ed flow of clean, cool air to the cooling air inlets (lou-
USING A BOOSTER � connect positive lead to
q
vered panel and below side doors) and to avoid heat-
battery first then connect negative lead to neg-
ed air coming out the radiator of the welder recirculat-
ative battery lead at engine foot.
ing back to the cooling air inlets. Also, locate the welder
so that engine fumes are properly exhausted.
BATTERY ACID can burn eyes and
skin.
q Wear gloves and eye protection
and be careful when working near
battery.
Follow instructions printed on battery.
q
SAM400 & 650
B-1 B-1
OPERATION
OPERATING PRECAUTIONS SPEED CONTROL LEVER
Manually allows the engine to run at its high idle speed
WARNING
controlled by the governor or at the factory set low idle
speed. When welding or using auxiliary power the
Do not attempt to use this equipment until you
speed control lever must be in the “RUN� position. To
have thoroughly read the engine manufacturer’s
reduce the engine to low idle speed when not welding
manual supplied with your welder. It includes
or not using auxiliary power place the speed control
important safety precautions, detailed engine
lever in the “IDLE� position notch.
starting, operating and maintenance instructions,
and parts lists.
ENGINE TEMPERATURE GAUGE
PIPE THAWING
Displays the coolant temperature in the engine block.
WARNING
OIL PRESSURE GAUGE
PIPE THAWING can result in fire or
Displays the oil pressure to the engine. When the
explosion.
engine starts running, watch for the oil pressure to
Only connect welder across
q
build up. If no pressure shows within 30 seconds, stop
FROZEN section of CONTINUOUS
the engine and consult the engine instruction manual.
METAL PIPE.
While thawing, remove any ground leads con-
q
nected to Frozen pipe. BATTERY CHARGING AMMETER
Turn welder on AFTER cables are connected to
q
Displays the current going from the charging alternator
pipe. Turn off when done.
into the batteries. It is normal for charging current to be
high (above 15 amps) after starting or when the batter-
ies are ‘low� on charge.
IMPORTANT: DO NOT USE A WELDER TO THAW A
PIPE BEFORE REVIEWING LINCOLN BULLETIN
E695.1 (dated May 1987 or later). This bulletin may be
ENGINE HOUR METER (Factory Installed Optional
obtained from your local Lincoln distributor or by writ-
Feature)
ing directly to Lincoln Electric at the address on the
back of this manual.
The optional engine hour meter records the total run-
ADDITIONAL SAFETY PRECAUTIONS ning time on the engine in hours. It can be used to keep
a record of maintenance on the engine and or welder.
Always operate the welder with the hinged doors
closed as these provide maximum protection from
ENGINE PROTECTION SYSTEM
moving parts and insure proper cooling air flow.
The engine protection system shuts down the engine
Read carefully the Safety Precautions page in the
under high coolant temperature or low oil pressure
Instruction Manual before operating this machine.
conditions by allowing the fuel solenoid valve to close.
Always follow these and any other safety procedures
included in this manual and in the engine instruction
manual.
ENGINE CONTROLS:
FUNCTION/OPERATION
IGNITION SWITCH
When placed in the “ON� position, this switch energizes
the fuel solenoid. When placed in the “OFF� position,
the flow of fuel to the injection pump is stopped to shut
down the engine.
SAM400 & 650
B-2 B-2
OPERATION
WELDER CONTROLS: place.
FUNCTION/OPERATION
3. Remove the two screws on the top end of the wire
feeder nameplate.
PORTABLE FIELD CONTROL CONNECTION
4. Position the “Portable Field Control� mounting slots
A “Portable Field Control� complete with 25� leads is
over these holes and replace the screws.
shipped with each SAM welder.
5. Route the leads with the LN-5 or LN-6 control cable
A “Portable Field Control� is not required for proper
back to the power source.
operation of the SAM welder when connected to an
LN-8, LN-9, NA-3, NA-5, LT-7, or LT-56 wire feeder.
MOUNTING ON LN-7
With other wire feeders and when stick electrode weld-
ing, the “Portable Field Control� must be installed or
1. Remove the top screws on the side of the LN-7 con-
the SAM cannot produce its full open circuit voltage.
trol box cover. (This is the left side when facing the
nameplate).
When installed the “Portable Field Control� is a fine
voltage adjustment when using the SAM as a constant
2. Position the “Portable Field Control� on the side of
voltage power source. It is a fine current adjustment
the control box with the mounting slots over these
when using the SAM as a variable voltage power
holes and replace the screws.
source.
3. Route the leads with the LN-7 control cable back to
The “Portable Field Control� can be mounted on the
the power source.
SAM or wherever convenient for the welding operation.
When using an LN-4, LN-5, LN-6 or LN-7 wire feeder,
the control should normally be mounted on the wire
feeder. Specific mounting instructions are given below.
OUTPUT STUDS
After mounting, connect the “Portable Field Control�
With the Engine OFF connect the work cable to the “To
leads to #75 and #76 on the SAM terminal strip locat-
Work� stud.
ed behind the lower cover panel directly below the con-
trol panel on the SAM400 or behind the right front
A. For Stick Electrode Welding
hinged door on the SAM650. Connect the green lead
1. Connect the electrode cable to the “Stick� stud
of the “Portable Field Control� to the grounding stud
and the work cable to the “To Work� stud.
marked with the symbol located near the terminal
Connect the “TAP� lead in the SAM650 to the
strips.
appropriate stud to adjust current and the arc
characteristics as described under “Current
and Voltage Controls.�
MOUNTING ON LN-4 (Discontinued)
2. Install the “Portable Field Control�.
1. Place the “Portable Field Control� on the vertical
front panel of the LN-4 on the wire reel side (next to
B. Automatic or Semiautomatic Welding
the rheostat panel) and mark the location of the
For all automatic welding processes, connect the
mounting slots.
welding power cable from the wire feeder to the
“Connect to Auto. Equipment� stud. Connect the
2. Drill two holes in the panel and mount the control
“TAP� lead in the SAM650 to the appropriate stud to
using #10 sheet metal screws.
adjust current and the arc characteristics as
described under “Current and Voltage Controls.�
3. Route the leads with the LN-4 control cable back to
1. LN-7, LN-8, LN-9, NA-3, NA-5, LT-7 and LT-
the power source.
56 Wire Feeders.
MOUNTING ON LN-5 OR LN-6 (Discontinued)
a. Make the connections exactly as speci-
fied on the connection wiring diagram
1. Remove the knob from the upper rheostat on the
included in the wire feeder Instruction
wire feeder control panel.
Manual.
b. Install the “Portable Field Control� when
2. Be sure the appropriate wire feeder nameplate -
using an LN-7.
“Constant Voltage� or � Variable Voltage � - is in
SAM400 & 650
B-3 B-3
OPERATION
c. Be sure the wire feeder is properly set for CURRENT AND VOLTAGE CONTROLS
constant or variable voltage as appropri-
ate. Constant Voltage Welding
2. ML-2, ML-3, MN-1, LN-4, LN-5 and LN-6 The SAM-400 “Current Control� is NOT in the circuit
Wire Feeders when the ‘Electrode Polarity� switch is set for constant
voltage welding.
This power source can be used with these
obsolete wire feeders. Write to the factory Set the open circuit voltage (OCV) needed for the par-
for specific connections. ticular application with the “Constant Voltage Control�
located to the left of the nameplate. Adjust the final
3. Other Wire Feeders welding voltage with either the wire feeder voltage con-
trol or the “Portable Field Control�. Set the welding cur-
This power source can be used with wire rent with “Amps� or “Wire Feed Speed� control on the
feeders manufactured by other companies. wire feeder.
The connection must be determined by the
customer for the specific equipment being Low Range Feature (SAM400 K1279-1 only) --
used. Extends the output voltage range of the SAM400
welder down to 12 volts for constant voltage welding.
Auxiliary power available for wire feeder The maximum output current is not to exceed the rat-
operation is described under “Auxiliary ing of the machine. The Low Range Feature provides
Power� in this section of the manual. To a two-position manual switch which allows the operator
operate the SAM contactor, connect the to set his machine for normal welding or for low voltage
appropriate wire feeder control circuit to welding. Factory installed only.
close the circuit from #2 to #4 on the SAM
terminal strip. On the SAM650 connect the “Tap� lead inside the
machine to the appropriate “Innershieldâ€? stud forâ€Min.
TOGGLE SWITCH (Flat) Slope.� “Med. Slope� or “Max. Slope�. Low voltage
(below 20 volts) low current welding often requires
This switch is located on the front of the control panel “Max. Slope� to adjust the weld metal droplet size for
at the top of the nameplate. Set the switch to “Variable minimum spatter and to control puddle fluidity and
Voltage� or “Constant Voltage� as appropriate for the bead shape. Innershield and other spray transfer type
welding process to be used. See Control Panel operat- processes generally operate with “Med. Slope�.
ing illustrations in this section of the manual.
A Hot Start circuit on all models operates automatical-
CONTACTOR ly whenever the toggle switch is set on “Constant
Voltage.� It increases the open circuit voltage by sev-
The output contactor is automatically in the welding cir- eral volts until the arc is established -- then the voltage
cuit when the machine is properly connected to a automatically drops to normal welding voltage. When
Lincoln® wire feeder through the “Connect to Auto. the wire feeder is started before the arc is started, the
Equipment� stud. It closes only when the wire feeder is voltmeter indicates a voltage several volts higher than
welding. The contactor is not in the welding circuit welding voltage. To read actual welding voltage, the
when using the ‘Stick� stud. arc must be established.
ELECTRODE POLARITY SWITCH Constant Voltage Welding With Variable Inductance
Control: SAM-400 Only.
Select electrode negative (straight) or electrode posi-
tive (reverse) polarity as needed. On the SAM-400, Variable inductance or slope control is usually desir-
this switch must also be set for either constant or vari- able for low voltage (below 20 volts) applications and is
able voltage welding as appropriate. sometimes useful in other constant voltage jobs.
To introduce this control into the circuit, set the
CAUTION “Electrode Polarity� switch to “Variable Voltage� and the
toggle switch to “Constant Voltage�. Then the “Current
DO NOT SWITCH WHILE WELDING. Control� acts as the variable inductance control.
Normally this control must be kept within the 8 to 1
o’clock range.
SAM400 & 650
B-4 B-4
OPERATION
To Set The Controls -- Stick Welding
Set the welding current and voltage as described under
“Constant Voltage Welding� above. a. Make the coarse setting of welding heat with the
SAM400 “Current Control� or the SAM650
Variable Voltage Welding “Tap’â?lead.
The SAM400 “Current Control� provides the major b. Adjust for the desired arc characteristics with the
adjustment of current. It has two calibrated scales; the “Variable Voltage Control�. For a soft arc desired
one gives maximum and the other minimum current for most welding keep this control between 7 and
available at any given setting. High. For a more digging arc, set it lower.
c. If remote control is NOT desired leave the
CAUTION
“Portable Field Control� on “High�. For remote con-
DO NOT ADJUST THE “CURRENT CONTROL� trol, leave the “Variable Voltage Control� near
WHEN WELDING. “High� and make the adjustments described in
paragraph “b� above with the “Portable Field
The SAM650 “Tap� lead inside the machine and the Control�. Remember, increasing either the
series of five “Sub Arc & Stick� studs provide the major “Variable Voltage Control� or “Portable Field
adjustment of welding current. Generally connect the Control� setting also increases the current.
“Tap� lead to the stud with the lowest current range that
still provides the desired current. To Set The Controls -- Submerged Arc
The “Variable Voltage Control� to the left of the name- a. The open circuit voltage (OCV) is generally not
plate on all models is both the open circuit voltage con- critical in submerged arc welding. Therefore, the
trol and a fine adjustment. The wire feeder current con- “Variable Voltage Control� can usually be left
trol and the “Portable Field Control� provide the same between 7 and “High� -- no future adjustments are
function as the “Variable Voltage Control.� needed.
b. Set SAM400 “Current Control� so the calibration
on the higher scale is a little above the current
desired. Set the SAM650 “Tap� lead to the stud
with the lowest current range that still provides the
desired current.
c. Make the final current adjustment with either the
wire feeder current control or the “Portable Field
Control�. Set the arc voltage with the wire feeder
control.
Consult the following illustrations for examples of how
to set the machine.
SAM400 & 650
B-5 B-5
OPERATION
SAM400 Controls
SAM400 & 650
B-6 B-6
OPERATION
SAM400 Controls
SAM400 & 650
B-7 B-7
OPERATION
SAM650 Controls
SAM400 & 650
B-8 B-8
OPERATION
SAM650 Controls
SAM400 & 650
B-9 B-9
OPERATION
STARTING WELDERS WITH DEAD BATTERIES about five minutes and then stop the engine and
recheck the oil. If the level is down, fill to the full mark
again. The engine controls were properly set at the fac-
DO NOT attempt to start a SAM engine driven welder
tory and should require no adjusting when received.
by driving the welding generator as a starter motor
using the output of another welder. In addition to the
For added safety always operate the welder with the
possibility of damaging the machines, starting a SAM
doors closed. Further, leaving the doors open changes
engine welder without using its starting circuit elimi-
the designed air flow and may cause overheating.
nates the operation of the flashing circuit. This can
cause the generator to fail to produce any output.
Cold Weather Starting
AUXILIARY POWER
WARNING
An alternator generates 2 KVA of 120/240 volt 60 Hertz
Never use any other starting aids, such as ether, when
AC power. It is available either from #31 and #32 on
using the “Thermostart� system.
the terminal strip or from the receptacles on the
Control Panel. Be careful not to overload this circuit.
When overnight temperatures are between 10°F (-
12°C) and freezing, use the standard “Thermostart�
The auxiliary power receptacle should only be used
starting system installed on all engines. Follow the
with three wire grounded type plugs or approved dou-
instructions on the start panel nameplate and in the
ble insulated tools with two wire plugs.
engine manual shipped with the welder. With fully
charged batteries and the proper weight oil, the
The alternator is protected by thermostats and fuses.
“Thermostart� system operates satisfactorily even
down to about 0°F (-18°C).
DUTY CYCLE
If the engine must be frequently started below 10°F
Duty cycle is based on a ten minute period and opera- (-12°C), it may be desirable to remove the
tion in an ambient temperature of 104°F(40°C). “Thermostart� and install the optional ether starter kit.
Installation and operating instructions are included in
The SAM400 is NEMA rated at 60% duty cycle. The the kit. Use ether starting only when required because
SAM650 is NEMA rated at 80% duty cycle. Duty cycle excessive use shortens engine life.
is based on a ten minute period. Therefore, a 60% duty
cycle welder can be operated at nameplate rated out-
BREAK-IN PERIOD
put for 6 minutes (8 minutes for 80% duty cycle) out of
every 10 minute period without overheating.
The engine used to supply power for your welder is a
heavy duty, industrial engine. It is designed and built
The auxiliary power can be used continuously (100%
for rugged use. It is very normal for any engine to use
duty cycle) within its rated current capacities.
small quantities of oil until the break-in is accom-
plished. Check the oil level twice a day during the
STARTING INSTRUCTIONS break-in period (about 200 running hours).
Be sure all Pre-Operation Maintenance has been per- IMPORTANT: IN ORDER TO ACCOMPLISH THIS
formed. (See Installation Section of this manual.) BREAK-IN, THE UNIT SHOULD BE SUBJECTED TO
HEAVY LOADS, WITHIN THE RATING OF THE
To start the engine, set the speed control lever in the MACHINE. AVOID LONG IDLE RUNNING PERIODS.
“RUN� position. Place ignition toggle switch in the “ON�
position. Push in the engine protection system reset
button (if so equipped). Engage the starter button.
When the engine starts running, observe the oil pres-
sure. If no pressure shows within 30 seconds, stop the
engine and consult the engine operating manual. To
stop the engine, place the ignition toggle switch in the
“OFF� position.
When an engine is started for the first time, some of the
oil will be needed to fill the passages of the lubricating
system. Therefore, on initial starting, run the engine for
SAM400 & 650
C-1 C-1
ACCESSORIES
K799 Hi-Freqâ„? - Provides high frequency plus a gas
valve for TIG welding. A water valve is available as an
option. Requires 115 volt AC input. Cannot be used
with optional meters connected, or in constant voltage
mode. (Limited to 250A - 60% Duty Cycle).
K802-D Power Plug Kit - For SAM welders with stan-
dard 2KVA of AC auxiliary power. Kit includes male
plugs for each auxiliary receptacle.
K805-1 Ether Start Kit - Injects ether for starting aid.
Recommended only when engines are frequently
started at temperatures under 10°F (-12°C). Ether
cylinder is not included.
K767-1 Undercarriage - A 4-wheel steerable under-
carriage for in-plant and yard towing1 with E78-14 load
range (B) tubeless tires. Mounts directly to welder
base.
1For highway use, consult applicable federal, state and local laws regarding
possible requirements for brakes, lights, fenders, etc.
Linc-Thawâ„? - Includes meter and fuse to protect the
welder when thawing frozen water pipes. (L2964-[ ]
Specify SAM400 or SAM650)
K704(SAM400 only) Standard Accessory Kit -
Includes electrode and work cables, headshield, work
clamp and electrode holder.
K865(SAM400 only) Engine Hour Meter Kit -
(Standard on K1279-1). Keeps track of how long
engine has been operated. Useful for following recom-
mended maintenance schedules on machine.
SAM400 & 650
D-1 D-1
MAINTENANCE
SAM400 only:
WARNING
Inspect the oil bath air filter daily - more often in dusty
ELECTRIC SHOCK can kill. conditions. When necessary clean and fill the oil bath.
The filter should never be removed while the engine is
Do not touch electrically live parts
q
running.
such as output terminals or inter-
nal wiring
PERIODIC MAINTENANCE
ENGINE EXHAUST can kill.
1. Blow out the welder and controls with an air hose at
Use in open, well ventilated areas
q
least once every two months. In particularly dirty
or vent exhaust outside
locations, this cleaning may be necessary once a
week. Use low pressure air to avoid driving dirt into
the insulation.
MOVING PARTS can injure.
Do not operate with doors open or 2. The SAM400 current control reactor brushes are
q
guards off self-lubricating and should not be greased. Keep the
contacts clean. This control should be moved from
Stop engine before servicing
q
maximum to minimum daily to prevent the controls
Keep away from moving parts
q
from sticking.
Remove guards only when necessary and
q
3. See the engine Instruction Manual for periodic
replace when work requiring removal is com-
engine maintenance information. Change the
plete.
crankcase oil at regular intervals using the proper
Only qualified personnel should install, use, or
q grade of oil as recommended in the engine operat-
service this equipment. ing manual. Change the oil filter in accordance with
the instructions in the engine operating manual.
When the filter is changed add one quart of oil to
the crankcase to replace the oil held in the filter dur-
ROUTINE MAINTENANCE ing operation.
At the end of each day’s welding, refill the fuel tank to 4. Belts tend to loosen after the first 30 or 40 hours of
minimize moisture condensation in the tank. Also, run- operation. Check the cooling fan belt and tighten if
ning out of fuel tends to draw dirt into the fuel system. necessary. DO NOT OVER TIGHTEN.
Check the crankcase oil level.
If the fuel supply runs out while the fuel pump is oper- BEARING MAINTENANCE
ating, air may be entrapped in the fuel distribution sys-
tem. If this happens, bleeding of the fuel system may This welder is equipped with a double-shielded ball
be necessary. See the engine instruction manual. bearing having sufficient grease to last indefinitely
under normal service. Where the welder is used con-
stantly or in excessively dirty locations, it may be nec-
AIR FILTER essary to add one-half ounce of grease per year. A pad
of grease one inch wide, one inch long and one inch
SAM650 only: high weighs approximately one-half ounce. Over
greasing is far worse than insufficient greasing.
The air filter element is a dry cartridge type. It can be
cleaned and re-used; however, damaged elements When greasing the bearings, keep all dirt out of the
should not be washed or re-used. Remove loose dirt area. Wipe the fittings completely clean and use clean
from element with compressed air or water hose direct- equipment. More bearing failures are caused by dirt
ed from inside out. Compressed Air: 100 psi maximum. introduced during greasing than from insufficient
The filter should never be removed while the engine is grease.
running.
SAM400 & 650
D-2 D-2
MAINTENANCE
COMMUTATOR AND BRUSH MAINTENANCE Arcing or excessive exciter brush wear indicates a pos-
sible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
WARNING
Uncovered rotating equipment can be dangerous.
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself COOLING SYSTEM
from particles that may be thrown out by the rotat-
ing armature when stoning the commutator. The SAM welders are equipped with a pressure radia-
tor. Keep the radiator cap tight to prevent loss of
coolant. Clean and flush the cooling system periodi-
The generator brushes are properly adjusted when the cally to prevent clogging the passage and overheating
welder is shipped. They require no particular attention. the engine. When antifreeze is needed, always use the
DO NOT SHIFT THE BRUSHES or adjust the rocker permanent type.
setting.
Shifting of the brushes may result in: CONTACTOR MAINTENANCE
- Change in machine output
- Commutator Damage Where the output contactor is operated frequently
- Excessive brush wear when tacking or making short welds, turn the engine off
and inspect the contactor every three months:
Periodically inspect the commutator, slip rings and
brushes by removing the covers. DO NOT remove or 1. be sure the mating surfaces of silver contacts are
replace these covers while the machine is running. not worn and all make contact at approximately
the same time.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have 2. Make sure the springs and holders are not broken
them cleaned by an experienced maintenance man or out of adjustment. Approximate spring com-
using fine sandpaper or a commutator stone. Never pression after making contact is 1/8�. Less than
use emery cloth or paper for this purpose. 1/16� compression indicates worn contacts that
should be replaced.
NOTE: If the welder is used in dirty or dusty locations,
or if the welder is not used for prolonged periods of 3. Make sure the moving contact or other moving
time, it may be necessary to clean the commutator and parts are not binding.
slip rings more often.
4. Check interlock contacts and springs. Be sure
Replace brushes when they wear within 1/4" of the pig- mounting screws are tight.
tail. A complete set of replacement brushes should be
kept on hand. Lincoln brushes have a curved face to fit
the commutator. Have an experienced maintenance
man seat these brushes by lightly stoning the commu-
tator as the armature rotates at full speed until contact
is made across the full face of the brushes. After ston-
ing, blow out the dust with low pressure air.
To seat the 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 direction of rotation
only - until brushes seat properly. In addition, stone
slip ring with a fine stone. Brushes must be seated
100%.
SAM400 & 650 APR97
E-1 E-1
TROUBLESHOOTING
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 3. RECOMMENDED COURSE OF
Step 1. LOCATE PROBLEM (SYMPTOM).
ACTION
Look under the column labeled “PROBLEM
This column provides a course of action for
(SYMPTOMS)�. This column describes pos-
the Possible Cause.
sible symptoms that the machine may exhib-
it. Find the listing that best describes the
If you do not understand or are unable to
symptom that the machine is exhibiting.
perform the Recommended Course of
Action safely, contact you local Lincoln
Step 2. POSSIBLE CAUSE.
Authorized Field Service Facility.
The second column labeled “POSSIBLE
CAUSE� lists the obvious external possibili-
ties that may contribute to the machine
symptom.
WARNING
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts such as output
terminals or internal wiring.
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.
� Remove guards only when necessary and replace when work
requiring removal is complete.
� Only qualified personnel should install, use or service this
equipment.
CAUTION
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.
SAM400 & 650
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS RECOMMENDED
POSSIBLE CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
LOSS OF OUTPUT IN ONE MODE 1. Test for shorted diode on Three 1. Check diodes D7, D8, D9, D10,
ONLY Phase Bridge. D11. (See Diode Test Procedure)
(Constant or Variable Voltage
Positions) (For loss in both modes 2. Test for failure of Control Board 2. a) Turn machine off.
see the following pages) #2. b) Put toggle switch in mode in
question.
These items functioning properly: c) Remove Control Board #2.
1. Alternator d) Turn voltage control and
2. Silicon Controlled Rectifier (SCR) portable field control to mini-
Assembly mum.
3. Control Board #1 e) Start the machine.
4. Generator f) If generator builds up, install
new Control Board #2 (Note
A); if it does not build up,
proceed to Step 3.
3. Test for Defective Toggle Switch, 3. a) Turn machine off.
Rheostat or Open Circuit b) Remove Control Board #1
c) Put toggle switch in the
mode in question.
d) Turn voltage control to maxi-
mum.
e) Check continuity of the tog-
gle switch and voltage con-
trol. (Note B).
1)Variable Voltage Position
Check continuity from Pin
#76 to Pin #204 on Control
Board #1 connector. Meter
should read a short circuit.
2)Constant Voltage Position
Check continuity from Pin
#76 to Pin #207 on
Control Board #1 connec-
tor. Meter should read a
short circuit.
NOTE A: If at any time either of the Control (PC) boards is replaced, follow the calibration procedure outlined later in this sec-
tion under “Control P.C. Board Calibration Procedure�. The open circuit voltage will be out of range if trimmers are
not properly set. If both trimmers are set at minimum, the machine might lose excitation.
NOTE B: When making continuity checks, use the 1K (X1000) or next higher range.
NOTE C: Do not replace PC boards without following outlined procedure for indicated trouble -- damage may result due to
other defective parts.
CAUTION
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.
SAM400 & 650
E-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS RECOMMENDED
POSSIBLE CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
LOSS OF OUTPUT IN BOTH Test Alternator Rotor Voltage (80- 1. If rotor voltage present go to Step 9. If
MODES OF OPERATION 90 Volts DC) Lead #222 to #1 no rotor voltage go to Step 2.
2. Lightly sand slip rings and reseat brush-
(Constant and Variable Voltage es.
Positions) 3. Flash rotor fields.
a) Turn machine off.
b) Use a 12 to 24 volt battery.
c) Apply voltage for 15 seconds, negative
lead to #1, positive lead to #222 at alter-
nator terminal strip.
CAUTION: Wrong polarity may dam-
age diodes.
4. Jumper leads #75 to #222 -- replace
alternator thermostats if this produces
output.
5. Continuity check - (Note B Pg. E-2).
a) Remove rotor brushes.
b) Disconnect #212 and #214 from alterna-
tor terminal strip.
c) Remove all leads from #1 and #2 on con-
trol box terminal strip.
d) Remove both Control Boards.
e) Check continuity from #214 to #1 and #212
to #1 with the positive lead on #214 and
#212. This should read about 27,000 ohms.
If shorted, check C-7 for a short. If all right,
check D5 and D6. See Procedure
6. SCR Bridge Check.-See Procedure
7. Three phase bridge rectifier check.
a) Remove leads from three phase bridge
rectifier assembly and check diodes (D7 -
D8 - D9 - D10 - D11 - D12) See
Procedure
8. Alternator continuity check - (Note B Pg. E-2).
a) Disconnect lead #212 and #214 and
check winding for continuity.
b) Remove one rotor brush, check continuity
of rotor field.
NOTE: Checking resistance of rotor field
may cancel residual magnetism
in the rotor iron. Repeat Step 3,
"Flash Rotor Fields".
9. If Rotor Voltage is present check voltage
between lead #75 and Pin #227 at the
rear of Control Board #2 connector.
(Approximately 15 to 22 volts DC.)
CAUTION
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.
SAM400 & 650
E-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS RECOMMENDED
POSSIBLE CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
10. Voltage higher than 22 volts DC.
a) If between 22 and 100 volts, replace both
Control Boards. (Note A Pg. E-2).
b) If voltage is greater than 100 volts:
1)Check diode D-4 for a short. See Procedure
2)Replace both Control Boards but only if
voltage between Pin #75 and #227 is
less than 100 volts DC.
11. Voltage less than 15 volts DC, replace
Control Board #1. (Note A Pg. E-2).
12. Voltage within limits.
a) Check SCR Bridge. See Procedure
b) Check generator field coil resistance.
1)Disconnect blue and brown field coil
leads. Resistance should be about 10
ohms.
c) Replace Control Board #1. (Note A Pg. E-2).
d) Check Control Board #2 by following Step
2, Pg E-2.
Output without control - one mode only SCR Bridge Test (See Procedure) If bridge tests good proceed to next step.
(Constant or Variable Voltage)
Output without control - both modes Continuity test. (Note B Pg. E-2). 1. Turn machine off.
(Constant and Variable Voltage) 2. Remove both Control Boards.
3. Place electrode polarity switch in con-
stant voltage positive position.
4. Toggle switch to mode in question.
5. Check continuity of the following (Note
B Pg. E-2):
a) Constant Voltage
1)Work to Pin #217 of the connector for
Control Board #2.
2)Pin #203 of the connector for Control
Board #2 to Pin #216 of the connector
for Control Board #1.
3)Between corresponding numbers of the
connectors for both Control Boards,
Pin #75, 216 and 227.
b) Variable Voltage
1)Blue field lead to Pin #201 of the con-
nector for Control Board #2.
2)Pin #202 of the connector for Control
Board #2 to Pin #216 of the connector
for Control Board #1.
3)Between corresponding pins of the
connectors of both Control Boards, Pin
#75, 216 and 227.
CAUTION
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.
SAM400 & 650
E-5 E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS RECOMMENDED
POSSIBLE CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
Output without control - Continuity test. (Note B Pg. E-2). 1.Make continuity test outlined in Step 3,
one mode on page E-2 except turn voltage con-
trol from maximum (0 ohms) to mini-
mum (10,000 ohms).
2.Replace Control Board #2. (Note A Pg. E-2).
Output without control - l. Replace Control Board #2
both modes 2.Replace Control Board #1. (Note A Pg. E-2).
Output low in both modes - Test rotor voltage (80-90 volts DC) 1.Rotor Voltage less than 80-90 volts DC
open circuit voltage low (CV and VV a)Check Diodes D1 - D2 - D5 -D6. See
positions) Procedure.
b)Check SCR Bridge. See Procedure.
c)Check resistance of rotor fields.
Normal value about 14 ohms.
2.Rotor Voltage Within Limits
a)Check SCR Bridge. See Procedure.
b)Check generator field coil resis-
tance.
1)Disconnect blue and brown
field coil leads. Normal value
about 10 ohms. One field coil
open - 20 ohms. Both field
coils open - infinite resistance.
Arc difficult to start in CV position Test alternator outputs (22-24 1.Set polarity switch in electrode positive
using low current and voltage volts DC) position.
(Characterized by large droplets, low 2.Check voltage between work stud and
frequency transfer) positive alternator lead connected to
input side of line contactor.
a)Within Limits
Check contactor contacts.
b)Less than 22-24 volts DC
Check three phase bridge recti-
fier diodes D7 - D8 -D9 -D10 -
D11 -D12. See Procedure.
CAUTION
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.
SAM400 & 650
E-6 E-6
TROUBLESHOOTING
DIODE TEST PROCEDURE SCR BRIDGE PC BOARD TEST PROCEDURE
CAUTION
Standard Polarity Reverse Polarity
Anode Cathode
THE SCR BRIDGE SHOULD BE CHECKED BEFORE
INSTALLING NEW CONTROL BOARD. COMPONENTS
ON THE NEW CONTROL BOARD COULD BE DAMAGED
Cathode Anode
BY A DEFECTIVE SCR BRIDGE.
Conventional Symbol Symbol Conventional
Current Flow Current Flow
1. Visually inspect the board for obvious failures.
Figure E.1 2. Remove all leads from the terminal strip of the SCR
Bridge PC Board.
1. Isolate the diode in question from the remainder of
the circuit and determine its polarity from the wiring 3. Check C5 and C6 for a short. Read the resistance
diagram and Figure E.1. between terminals 210 and 214 for C5, and between ter-
minals 212 and 213 for C6.
2. Establish the polarity of the ohmmeter leads.
4. Check SCR1 and SCR2. For SCR1, attach the (-) ohm-
3. Connect the ohmmeter across the diode in question meter lead to the "Brn" Terminal. Place the (+) lead first
as illustrated in Figures E.2 and E.3 below. Note on Terminal 210 and then on Terminal 214 and record the
polarity of ohmmeter in reference to diode. resistance of each. To check SCR2, keep the (-) lead on
the Brn terminal and with the (+) lead on Terminal 212 and
A SHORTED DIODE will indicate equally low then on Terminal 214 record the resistances read.
resistance in both directions. Reverse the leads and repeat the above tests. The sec-
ond resistance values should all be higher than those
AN OPEN DIODE will have infinite or high recorded first. The ohmmeter should be set in its highest
resistance in both directions. range or in "Auto Range".
A GOOD DIODE will have a reverse resistance 5. Check D1 and D2. Place the (-) lead on Terminal 75, and
much higher than forward resistance. place the (+) lead on Terminal 214 for D1. Keeping the (-
) lead on Terminal 75, attach the (+) lead to Terminal 212
to test D2. This tests the diodes in the "forward" direction.
OHMMETER
Reverse the leads and repeat the previous test. This tests
the diodes in the "reverse" direction. The resistance val-
-
+ i ues in the reverse direction should all be higher than
those in the forward direction.
Cathode
Anode
6. Test D3 and R28. Connect the (+) lead to the Brn
Terminal and the (-) lead to the 75 Terminal and record the
resistance. Reverse the meter leads to test the diode in
Forward Resistance Low
the reverse direction. The resistance in the reverse direc-
Figure E.2 tion should be higher than it is in the forward direction.
a) If your ohmmeter has a "Diode Test Range"
( ), use that range for this test. Otherwise
OHMMETER
use "Auto Range" or the lowest range that pro-
duces a meter reading.
- +
i
b) If D3 is open (or you are using too high a range
Cathode
Anode
on the ohmmeter) you will read only the value of
R28 (about 1200 ohms) in both directions. If D3
is shorted, you will read zero ohms or a very low
resistance in both directions.
Reverse Resistance Low
Figure E.3 7. If the board fails any of the tests, replace it.
SAM400 & 650
E-7 E-7
TROUBLESHOOTING
CONTROL PC BOARD CALIBRATION DC on SAM400 machines or 45±1 volts for
SAM650 machines. Recheck to make sure
readings fall within limits. Trimmer #4 set-
CAUTION ting is dependent on Trimmer #3.
THE SCR BRIDGE SHOULD BE CHECKED
B. Constant Voltage
BEFORE INSTALLING A NEW CONTROL BOARD.
COMPONENTS ON THE NEW CONTROL BOARD
1. Place toggle switch in constant voltage
COULD BE DAMAGED BY A DEFECTIVE SCR
position.
BRIDGE.
2. Turn constant voltage rheostat and portable
field control to high.
NOTE: Before the PC Boards can be calibrated the
3. Set Trimmer #1 so that OCV is 60±1 volts
machine must be "hot". That is, it should be run
DC on SAM400 machines or 68±1 volts for
approximately one hour at maximum O.C.V. with all
SAM650 machines.
covers on the generator.
4. Turn constant voltage rheostat and portable
field control to low.
Factory replacement Control PC Boards are preset
5. Set Trimmer #2 so that OCV is 21± 0.5 volts
and should require only minor adjustment if any.
DC on SAM400 machines or 22±0.5 volts
for SAM650 machines. Recheck to make
1. Before any calibrations are made, the engine speed
sure readings fall within limits. Trimmer #2
must be correct. Check the engine speed as fol-
setting is dependent on Trimmer #1.
lows:
a) Set toggle switch to variable voltage.
b) Set variable voltage control and portable
field control to high.
c) Allow engine to warm up for approximately
15 minutes.
d) Using an accurate tachometer, check high
idle engine speed. It must be within limits
given on the nameplate. Adjust governor
only if absolutely necessary. To obtain an
accurate speed setting, the unit must be
generating its maximum open circuit voltage
(Step A.3 below). If no voltage is being gen-
erated, this trouble must be first corrected
before final speed setting is obtained.
MAX MIN Constant
-1- -2- Voltage Trimmers
MAX MIN Variable
-3- -4- Voltage Trimmers
A. Variable Voltage
1. Place toggle switch in variable voltage posi-
tion.
2. Turn variable voltage control and portable
field control to high.
3. Set Trimmer #3 so that OCV is 95±1 volts
DC on SAM400 machines or 89±1 volts for
SAM650 machines.
4. Turn variable voltage rheostat and portable
field control to low.
5. Set Trimmer #4 so that OCV is 65±1 volts
SAM400 & 650
E-8 E-8
TROUBLESHOOTING
GROUND TESTS
CAUTION
This machine is equipped with solid-state electronic
components which can be damaged if subjected to a
ground test or a megger test without observing special
precautions as outlined here:
A. Prior to the ground test always turn the engine off
and remove the two Printed Circuit boards mounted
on the rear of the welder control panel. For access
remove the welder roof and the metal enclosures
over the PC boards. Remove one screw from the
smaller board and two screws from the larger board
and pull each board straight out from the connector
block. There are no wires to disconnect.
B. Connect the following jumpers:
1. Welding generator frame to base.
2. Across D13 (#232 to #1)
3. Across D14 (#234 to #75).
C. Place jumpers across the following points, see
wiring diagram.
1. Across the voltmeter terminals if the unit is
so equipped.
2. Positive side of SCR bridge (#75) to #214
on the SCR bridge located on the rear
panel of the control box.
3. Positive side of SCR bridge (#75) to #212
on the SCR bridge.
4. Across C5 on the SCR bridge.
5. Negative side of the SCR bridge (brown
generator field lead) to #214 on the SCR
bridge.
6. Negative side of the SCR bridge to #212 on
the SCR bridge.
7. Across C6 on the SCR bridge.
8. #1 on the two diode aluminum finned heat
sink to #212 on the SCR bridge.
9. #1 on the two diode aluminum finned heat
sink to #213 on the SCR bridge.
10. #2 on the base of D4, single diode mount-
ed on copper heat sink to #75 on SCR
bridge.
11. Across each of the three-phase bridge
diodes, jumper from the heat sink across
the diode on all six diodes.
NOTE: All jumpers must be as short as possible
SAM400 & 650
SAM400 MACHINE WIRING DIAGRAM
F-1
LOW VOLTAGE OPTION
GROUND SCREW
OPEN BOLTED CONNECTION AT 7, 8 AND 9 AT ALTERNATOR.
CONNECT LEADS BELOW TO RESPECTIVE STATOR LEADS.
INSULATE EACH CONNECTION SEPARATELY.
230
THE VOLTAGE RANGE
AM VM 12 9
10 8
7
11
229
+- +-
230V POWER G SWITCH S3, IS SHOWN
115V POWER
WORK G
G
RECEPTACLE RECEPTACLE IN THE "NORMAL" RANGE
U
STICK POSITON AND AS VIEWED
N.A.
S3
FROM THE REAR OF THE
208
AUTOMATIC F1
SWITCH.
207 R21
75
219
75
21 204
212
220
77 2
214
217
N.O.
OMIT JUMPERS
76
CIRCUIT
201
FROM 2B
TO P.C.
U N.A. 218 TO 219
213 D6
D5 LS1
BOARD #1
2A TO 2B
75
F2
2
214 2B TO 2
1 N.O. CIRCUIT
214
214
210 2A
ON TERMINAL
31 212 218
B
WHITE N.C. CIRCUIT
VARIABLE 210 STRIP AND 219
P.
227 R
TERMINAL 1
216 VOLTAGE CONNECT THESE
214 C.
I LS2
R30
218
BROWN
R19 LEADS TO
32 CONTROL D
1
219
B
G
75
75 TERMINAL STRIPS.
33
D.
10CR 216 204 E LS1 - LIMIT SWITCH (NORMAL VOLTAGE)
10CR 220
227 213
LS2 - LIMIT SWITCH (LOW VOLTAGE)
75
+ + 1
32 S3 - VOLTAGE RANGE SWITCH
202
1 212
212
2 CONSTANT
201 R30- 1000 OHMS (2W)
- 213
R20
VOLTAGE 75
203
A 210
75 207
- TO P.C. 217 212
CONTROL
31
219
BOARD #2
223 LEAD BLOCK 75
N
N
223
207 208
C4
219
32
2CR 8CR
+ 202 216
219 217
220
218 216
R29
203
4
76
3
75 S1 1 4
5 FRONT
2 1
2 75
5
218
6
3 1 C9
C10
9CR
S2 75 R24
3
SAM400 & 650
4 31
1
2 BACK - 75
C8
15
R22
D13
76
232
222 7CR
67
224
222 234
D14
WIRING DIAGRAMS
235 +
SEE BATTERY
224 -
233 CIRCUIT DIAGRAM
75
SEE
31
76 NOTE C
32 12
2B
2A
77 #4
218
219
9
33 NOTES 4. FOR NORMAL VOLTAGE WELDING, CONNECT
C4 7
10
214 D7 D10
8 LEADS 7, 8 AND 9 TOGETHER AND
32 1. CONNECT PORTABLE FIELD CONTROL
+
212 -
11
31
INSULATE CONNECTION. INSULATE LEADS
TO TERMINALS #75 AND #76.
1 D11
2 D8
ROTATING 10, 11 AND 12 SEPARATELY. FOR UNITS
75 2. WHEN NOT USING PORTABLE FIELD
FIELD
B WITH LOW VOLTAGE OPTION SEE INSERT
D12
222 D9
67 CONTROL, CONNECT A JUMPER ACROSS
ABOVE. (THESE CONNECTIONS ARE MADE
- +
21
TERMINALS #75 AND *77.
NEG. SLIP
INTERNALLY ON LATEST MACHINES
RING IS A 3. WHEN NOT USING LINCOLN EQUIPMENT,
LEGEND WITHOUT LOW VOLTAGE OPTION.)
NEAREST ALTERNATOR CONNECT GUN TRIGGER TO #C-4 AND
SPECIFIC VALUES OF LAMINATION
#2 TO OPERATE CONTACTOR.
NUMBERED COMPONENTS LEAD COLOR CODING
100 A. U - BLUE
C8 1.0 MFD D9 F2 20 AMP S1 TOGGLE SWITCH
100 A.
C9 D10 R19 10K POT.
6.0 MFD S2 POLARITY SWITCH N - BROWN GROUNDING
100 A.
C10 D11 R20 10K POT.
.022 MFD 2CR PILOT RELAY W - WHITE TERMINAL
0.5
D5 16 A. D12 100 A. R21 7CR ENERGIZING RELAY
16 A. 100
D6 D13 R22
1 A. HOT START RELAY
8CR N.A. CENTER TERMINAL OF FUSE HOLDER.
500
D7 100 A. D14 R24
1 A. S-78 CONTACTOR
9CR
ELECTRICAL SYMBOLS PER E1537
D8 F1 10 AMP
100 A. R29 100 REED SWITCH
10CR 4-22-94
L9603
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
F-1
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
SAM650 MACHINE WIRING DIAGRAM
F-2
GROUND SCREW
GGG
229
230
AM VM
+- +-
230V POWER
WORK 115V POWER
RECEPTACLE RECEPTACLE
U
N.A.
AUTOMATIC 217
10CR F1
R21
208 75
STICK
207
CONNECT TAP 75
75
31 219
LEAD TO DESIRED 212
204
OUTPUT TERMINAL
214
220
77 201
F2
76
TO P.C.
213 D6
D5
BOARD #1
33 75
N.A.
214
1 214
214
210
WHITE
31 212
TERMINAL B
32 210 P.
227 STICK R
1
216 214 C.
I
CONTROL
BROWN
1 R19 D
31 B
10CR G
75
75
D.
216 204 E
220
32 227 213
TO P.C. 75
223 1
MIN. SLOPE, INNERSHIELD
202 212
212
BOARD #2
201
75
213
R20 75
203
CONTROL 207
217 207 212
INNERSHIELD
210
N N
U
N
224 224 223
32
C4
207 208
216 75
MIN TO 140, STICK
(-)
5 4 3 2 1 I (+)
2CR 8CR
202
220
A-
217 216
219
FRONT 203
GENERATOR
R29
77 76
LEAD BLOCK
219
210 TO 330, SUBMERGED ARC, OR STICK
75
1 1
4
D15 1 C9
217
130 TO 225, SUBMERGED ARC, OR STICK
75
SAM400 & 650
2 75
5
450 TO MAX., SUBMERGED ARC, MED. SLOPE, INNERSHIELD
BACK 231
C10 R24
3
1
21 6
9CR S2 S1
300 TO 575, SUBMERGED ARC, MAX. SLOPE, INNERSHIELD
75
R22
D13
C8
75
222
232
7CR
222
WIRING DIAGRAMS
31 234
D14
235 +
SEE BATTERY
-
233 CIRCUIT DIAGRAM
31
32
2 31 32 C4 77 76 75
21 67
NOTES
33 D7 D10
C
+
214 - 1. CONNECT PORTABLE FIELD CONTROL
212
TO TERMINALS #75 AND #76.
B D11
D8
1
ROTATING
LEGEND - SPECIFIC VALUES OF NUMBERED COMPONENTS 2. WHEN NOT USING PORTABLE FIELD
75 LEAD COLOR CODING
FIELD
D12
A
HOT START RELAY
8CR
C8 1.0 MFD D15 1 AMP 222 CONTROL, CONNECT A JUMPER ACROSS
D9 U - BLUE
S-78 CONTACTOR
9CR
C9 F1 10 AMP
6.0 MFD
TERMINALS #75 AND *77.
N - BROWN
C10 F2
.022 MFD 20 AMP
W - WHITE
10CR REED SWITCH 3. WHEN NOT USING LINCOLN EQUIPMENT,
D5 16 A. R19 10K POT.
(2 REQ'D)
16 A.
D6 R20 10K POT. ALTERNATOR CONNECT GUN TRIGGER TO #C4 AND
0.5
D7 100 A. R21 NEG. SLIP
#2 TO OPERATE CONTACTOR.
100
R22
D8 100 A. RING IS
500
100 A.
D9 R24 NEAREST
100 A.
D10 R29 100 LAMINATION
100 A.
D11 S1 TOGGLE SWITCH
D12 100 A. S2 POLARITY SWITCH
N.A. CENTER TERMINAL OF FUSE HOLDER.
D13 2CR
1 A. PILOT RELAY
D14 7CR
1 A. ENERGIZING RELAY ELECTRICAL SYMBOLS PER E1537 4-22-94
L9606
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
F-2
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
F-3 F-3
WIRING DIAGRAMS
GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE DRIVEN ARC WELDING POWER SOURCES
WARNING: Have only qualified personnel perform
maintenance work.
Turn the engine or input power OFF before
maintenance work unless the maintenance work
requires it to be running.
Keep hands, hair, clothing and tools away
MOVING from moving parts, and insure all guards or
PARTS
covers are replaced after servicing.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
CAN INJURE
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
MAINTENANCE INSTRUCTIONS
DAILY CHECKS:
- Electrode and work connections are tight.
- Rotate the current control twice to clean contacts.
- All equipment in serviceable condition.
- Engine oil, coolant, air cleaner and fuel strainer are at
proper operating level and clean.
AS REQUIRED:
SAM400 ENGINE WIRING DIAGRAM
- Blow dust from the machine using clean low pressure air.
- Clean commutators or slip rings with fine sandpaper-
NOT EMERY CLOTH. See the Operating Manual for instructions.
- Replace brushes before the pigtail is within 1/ 4" of the commutator.
See the Operating Manual for instructions.
- Grease may be added to bearings no more than once a year. See
the Operating Manual for instructions.
TO FLASHING DIODE
THERMOSTART
(SAE UNITS ONLY)
AMMETER
EXC
START
THERMOSTART
-
+
IGNITER
+
COLD
TERMINAL
B
}
TO CR7
ALTERNATOR
(SAM UNITS
Y ONLY)
-
+
IGNITION
- -
ENGINE HOUR SWITCH
METER
(OPTIONAL)
+
+
FUEL SHUT
OFF VALVE
S
FUEL INJECTION
STARTING
PUMP
MOTOR
M16879
4-3-92A
SAM400 & 650
SAM650 ENGINE WIRING DIAGRAM
F-4
ENGINE HOUR METER
GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE
AND MOTOR DRIVEN ARC WELDING POWER SOURCES
+
IND -
Y Y THERMOSTART
IGNITER
WARNING: - Have only qualified personnel perform
THERMOSTART
maintenance work.
+
Y
- Turn the engine or input power OFF before
maintenance work unless the maintenance work
requires it to be running.
B
START
- Keep hands, hair, clothing and tools away
ALTERNATOR
+
MOVING
- from moving parts, and insure all guards or
PARTS
covers are replaced after servicing.
COLD CAN INJURE
G TERMINAL
AMMETER
TO CR7
} MAINTENANCE INSTRUCTIONS
DAILY CHECKS:
- -
- Welding cable connections are tight.
IGNITION
SWITCH - All equipment in serviceable condition.
- Engine oil, coolant, air cleaner and fuel
+
+
ENGINE
strainer are at proper operating level and
PROTECTION
clean.
RELAY
SAM400 & 650
AS REQUIRED:
FUSE
(SFE 14) - Blow dust from the machine using clean low
S
pressure air.
WIRING DIAGRAMS
OIL PRESSURE S B
G NO NC - Clean commutators or slip rings with fine
SWITCH (N.C.) sandpaper- NOT EMERY CLOTH. See the
STARTING
Operating Manual for instructions.
MOTOR
- Replace brushes before the pigtail is within
1/4" of the commutator. See the Operating
Manual for instructions.
G
ENGINE GROUND
FUEL SHUT
OFF VALVE
TEMPERATURE GAGE
FUEL INJECTION PUMP
XB-RW
S22668
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
F-4
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
F-5
DIMENSION PRINT - SAM400 AND SAM650 PERKINS ENGINE WELDERS
Height of SAM650 A
Muffler Installed B
28.00
C
Additional Muffler
for SAM400 Perkins
19.80
Only.
11.00
5.75
39.69
(SAM650 Only)
50.13
SAM400 & 650
E 6.00
DIMENSION PRINT
44.50* 8.90
22.14* 8.12
69.75 **
F
24.50 3.00
** .59 x 1.10 Slots
27.12 .88
D
* .81 Dia. Holes
.69 Dia. Holes
83.00
M8869-23,-25
77.00
22.00
SAM400 63.06 38.50 25.95 81.25 7-28-95E
SAM650 56.38 41.00 23.88
F
E
A B C D
F-5
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With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects, such
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q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.
German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
SAM400 & 650
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or
WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
q Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
q N’opérez pas avec les panneaux
q Gardez la tête à l’écart des fumées. q Débranchez le courant avant l’entre-
ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira- tien.
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
ED
German
q Anlage nie ohne Schutzgehäuse
q Vermeiden Sie das Einatmen von q Strom vor Wartungsarbeiten
oder Innenschutzverkleidung in
Schweibrauch! abschalten! (Netzstrom völlig öff-
WARNUNG
1 SED
Betrieb setzen!
q Sorgen Sie für gute Be- und nen; Maschine anhalten!)
Entlüftung des Arbeitsplatzes!
Portuguese
W ER
q Não opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENÇÃO
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratória.
IM P
q Não toque as partes elétricas nuas. ou guardas removidas.
E SU
S
Japanese
SE Y
NT
Chinese
RA
AR
Korean
W
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
SAM400 & 650
|