A-4
INSTALLATION
A-4
PRE-OPERATION SERVICE
Oil: This unit is supplied from the factory with the
engine crankcase filled with a high quality 10W30 oil.
This oil should be acceptable for most typical ambient
temperatures. Consult the Engine Operation Manual
for specific recommendations. Upon receipt of the
welder, check the dipstick to be sure the oil is at the
"full" mark. DO NOT OVERFILL.
Fuel: Fill the fuel tank with the grade of diesel fuel rec-
ommended in the engine Instruction Manual. Open the
fuel feed valve on the sediment bowl by turning the
handle counterclockwise.
Cooling System:The cooling system has been filled at
the factory with a 50-50 mixture of ethylene glycol
antifreeze and water. Check the radiator level and add
a 50-50 solution as needed. (See Engine Manual or
antifreeze container for alternate antifreeze recom-
mendation.)
Battery: Remove the insulating cap from the negative
battery terminal. Replace and tighten negative battery
cable terminal. NOTE: This machine is furnished with
wet charged batteries; if unused for several months,
the batteries may require a booster charge. Be sure to
use the correct polarity when charging the batteries.
GASES FROM BATTERY can explode.
●
Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOSION when:
●
INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and
connect to new battery last.
●
CONNECTING A BATTERY CHARGER —
remove battery from welder by disconnecting
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
●
USING A BOOSTER — connect positive lead to
battery first then connect negative lead to neg-
ative battery lead at engine foot.
BATTERY ACID can burn eyes and
skin.
●
Wear gloves and eye protection
and be careful when working near
battery.
●
Follow instructions printed on battery.
IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:
a) Installing new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.
To prevent BATTERY BUCKLING, tighten nuts on bat-
teries only until snug. DO NOT OVERTIGHTEN.
Muffler: On SAM650 units: Screw the muffler into the
exhaust flange and tighten.
On SAM400 units with the optional noise
control muffler: Attach the muffler with the
supplied hardware.
The engine and welder controls were properly set at
the factory and should require no adjusting when
received.
OUTPUT CABLES
With the engine off, connect the electrode and work
cables to the studs provided. These connections
should be checked periodically and tightened if neces-
sary. When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Listed below are copper cable sizes recommended for
the rated current and duty cycle. Lengths stipulated are
the distance from the welder to work and back to the
welder again. Cable sizes are increased for greater
lengths primarily for the purpose of minimizing cable
voltage drop.
WELDER LOCATION
The welder should be located to provide an unrestrict-
ed flow of clean, cool air to the cooling air inlets (lou-
vered panel and below side doors) and to avoid heat-
ed air coming out the radiator of the welder recirculat-
ing back to the cooling air inlets. Also, locate the welder
so that engine fumes are properly exhausted.
SAM400 & 650
WARNING
%
Cable Sizes For Combined Lengths
Duty
Of Electrode And Work Cables
Amps
Cycle
0-100 ft.
100-200 ft.
200-250 ft.
650
60
3/0
2-2/0
2-3/0
650
80
2-1/0
2-2/0
2-3/0
400
60
2/0
3/0
4/0
