Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
i SAFETY i SAM400 & 650 FOR ENGINEpowered equipment. 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 en...
Page 3 - ii; ELECTRIC SHOCK can kill.
ii SAFETY ii SAM400 & 650 ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing ...
Page 4 - iii
iii SAFETY iii SAM400 & 650 FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations....
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv SAM400 & 650 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vo...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
SAM400 & 650 Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product •••as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save...
Page 7 - TABLE OF CONTENTS
vi TABLE OF CONTENTS SAM400 & 650 vi Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1Product...
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS - SAM400; INPUT - DIESEL ENGINE
A-1 INSTALLATION SAM400 & 650 A-1 TECHNICAL SPECIFICATIONS - SAM400 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 ...
Page 9 - TECHNICAL SPECIFICATIONS - SAM650
A-2 INSTALLATION SAM400 & 650 A-2 TECHNICAL SPECIFICATIONS - SAM650 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...
Page 10 - PRODUCT DESCRIPTION; INSTALLATION PRECAUTIONS
A-3 INSTALLATION SAM400 & 650 A-3 PRODUCT DESCRIPTION The SAM engine welders are multi-purpose weldingmachines. They are designed to be used on all openarc or submerged arc processes within the rating of theunit. The machine is designed to be used with the followingautomatic equipment: LN-7, LN-...
Page 11 - PRE-OPERATION SERVICE; OUTPUT CABLES
A-4 INSTALLATION A-4 PRE-OPERATION SERVICE Oil: This unit is supplied from the factory with theengine crankcase filled with a high quality 10W30 oil.This oil should be acceptable for most typical ambienttemperatures. Consult the Engine Operation Manualfor specific recommendations. Upon receipt of th...
Page 12 - OPERATION; OPERATING PRECAUTIONS
B-1 OPERATION B-1 OPERATING PRECAUTIONS Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists. PIPE THAWING...
Page 13 - OUTPUT STUDS
B-2 OPERATION B-2 WELDER CONTROLS:FUNCTION/OPERATION PORTABLE FIELD CONTROL CONNECTION A “Portable Field Control” complete with 25’ leads isshipped with each SAM welder. A “Portable Field Control” is not required for proper operation of the SAM welder when connected to anLN-8, LN-9, NA-3, NA-5, LT-7...
Page 14 - TOGGLE SWITCH; CAUTION
B-3 OPERATION B-3 c. Be sure the wire feeder is properly set for constant or variable voltage as appropri-ate. 2. ML-2, ML-3, MN-1, LN-4, LN-5 and LN-6 Wire Feeders This power source can be used with these obsolete wire feeders. Write to the factoryfor specific connections. 3. Other Wire Feeders Thi...
Page 20 - STARTING WELDERS WITH DEAD BATTERIES; DUTY CYCLE
B-9 OPERATION B-9 STARTING WELDERS WITH DEAD BATTERIES DO NOT attempt to start a SAM engine driven welderby driving the welding generator as a starter motorusing the output of another welder. In addition to thepossibility of damaging the machines, starting a SAMengine welder without using its starti...
Page 21 - ACCESSORIES
C-1 ACCESSORIES C-1 K799 Hi-Freq™ - Provides high frequency plus a gasvalve for TIG welding. A water valve is available as anoption. Requires 115 volt AC input. Cannot be usedwith optional meters connected, or in constant voltagemode. (Limited to 250A - 60% Duty Cycle). K802-D Power Plug Kit - For S...
Page 22 - MAINTENANCE; ROUTINE MAINTENANCE
D-1 MAINTENANCE D-1 ELECTRIC SHOCK can kill. ● Do not touch electrically live partssuch as output terminals or inter-nal wiring ENGINE EXHAUST can kill. ● Use in open, well ventilated areasor vent exhaust outside MOVING PARTS can injure. ● Do not operate with doors open orguards off ● Stop engine be...
Page 24 - TROUBLESHOOTING
E-1 TROUBLESHOOTING E-1 SAM400 & 650 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshootin...
Page 25 - FUNCTION PROBLEMS
E-2 TROUBLESHOOTING E-2 SAM400 & 650 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshoot...
Page 29 - DIODE TEST PROCEDURE
E-6 TROUBLESHOOTING E-6 DIODE TEST PROCEDURE Figure E.1 1. Isolate the diode in question from the remainder of the circuit and determine its polarity from the wiringdiagram and Figure E.1. 2. Establish the polarity of the ohmmeter leads. 3. Connect the ohmmeter across the diode in question as illust...
Page 30 - CONTROL PC BOARD CALIBRATION
E-7 TROUBLESHOOTING E-7 CONTROL PC BOARD CALIBRATION THE SCR BRIDGE SHOULD BE CHECKEDBEFORE INSTALLING A NEW CONTROL BOARD.COMPONENTS ON THE NEW CONTROL BOARDCOULD BE DAMAGED BY A DEFECTIVE SCRBRIDGE. NOTE: Before the PC Boards can be calibrated themachine must be "hot". That is, it should b...
Page 31 - GROUND TESTS
E-8 TROUBLESHOOTING E-8 GROUND TESTS This machine is equipped with solid-state electroniccomponents which can be damaged if subjected to aground test or a megger test without observing specialprecautions as outlined here: A. Prior to the ground test always turn the engine off and remove the two Prin...
Page 32 - WIRING DIAGRAMS; CHINE
F-1 WIRING DIAGRAMS SAM400 & 650 F-1 4-22-94 L9603 R20 AM VM + - 7CR 232 234 D14 D13 SEE BATTERY CIRCUIT DIAGRAM F1 2CR 7CR 8CR 9CR 10CR C9 C10 D5 D6 D7 D9 D10 D11 D12 D13 D14 R19 R20 R21 R22 R24 PILOT RELAY HOT START RELAY S-78 CONTACTOR REED SWITCH 1.0 MFD 6.0 MFD .022 MFD 16 A. 16 A. 100 A. 1...
Page 34 - WIRING DIA
SAM400 & 650 F-3 WIRING DIAGRAMS F-3 DAILY CHECKS: - Electrode and work connections are tight. - All equipment in serviceable condition. AS REQUIRED: See the Operating Manual for instructions. MOVING PARTS CAN INJURE WARNING: Y B + EXC TO FLASHING DIODE + - IGNITER + - S MOTOR + + - - START AMME...
Page 36 - DIMENSION PRINT; DIMENSION PRINT - SAM400 AND SAM650 PERKINS ENGINE
SAM400 & 650 F-5 DIMENSION PRINT F-5 .88 3.00 8.12 5.75 (SAM650 Only) 8.90 83.00 81.25 F 69.75 44.50 * 6.00 39.69 50.13 63.06 38.50 25.95 19.80 Additional Muffler for SAM400 P er kins Only . 28.00 27.12 24.50 22.14 * E A A B B C C D D 11.00 Height of SAM650 Muffler Installed ** ** * .59 x 1.10 S...
Page 37 - Lincoln Welding School
Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. This printing will go fast so don’t delay. Place your order now using the ...
Page 40 - LIMITED WARRANTY; IN; WARRANTY; WARRANTY SUPERSEDED
• Sales and Service through Subsidiaries and Distributors Worldwide • 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. 216-481-8100 World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors STATEMENT OF WARRANTY: The Lincoln Electric Company (Lincoln) warran...
