Lincoln Electric SVM133-B Manual do Utilizador

SVM133-BSeptember, 2002Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, your overall

LIFTINGThe Commander 400 weights 1650 lb./748 kg (Stickmodel); 1683 lb./763 kg. (Stick & Wire model). A lift bailis provided for lifting with a h

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TROUBLESHOOTING & REPAIRF-53 F-53COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-54 F-54COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

FINE CONTROL POTENTIOMETER TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performe

FUELNOTE: Use diesel fuel only.Fill the fuel tank with clean, fresh diesel fuel. Thecapacity of the fuel tank is 25 gallons (94.6 liters). Seethe O

TROUBLESHOOTING AND REPAIRFINE CONTROL POTENTIOMETER TEST (continued)F-56 F-56Return to Section TOC Return to Section TOC Return to Section TOC Return

RANGE SWITCH TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equi

TROUBLESHOOTING AND REPAIRRANGE SWITCH TEST (continued)Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t

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SHUNT CALIBRATION TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this

TROUBLESHOOTING AND REPAIRSHUNT CALIBRATION TEST (continued)Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCRet

EXCITER VOLTAGE FEEDBACK TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed

TROUBLESHOOTING AND REPAIREXCITER VOLTAGE FEEDBACK TEST (continued)Return to Section TOC Return to Section TOC Return to Section TOC Return to Section

EXCITER CAPACITOR BANK TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on

ELECTRICAL OUTPUT CONNECTIONSSee Figure A.1 for the location of the 120 and 240 voltreceptacles, weld output terminals, and ground stud.WELDING CABLE

TROUBLESHOOTING AND REPAIREXCITER CAPACITOR BANK TEST (continued)Return to Section TOC Return to Section TOC Return to Section TOC Return to Section T

CONTROL BOARD POWER SUPPLY TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performe

TROUBLESHOOTING AND REPAIRCONTROL BOARD POWER SUPPLY TEST (continued)Return to Section TOC Return to Section TOC Return to Section TOC Return to Secti

STATOR RESISTANCE TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this

TROUBLESHOOTING AND REPAIRSTATOR RESISTANCE TEST (continued)Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCRet

TROUBLESHOOTING AND REPAIRSTATOR RESISTANCE TEST (continued)Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCRet

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MACHINE GROUNDINGBecause this portable engine driven welder creates itsown power, it is not necessary to connect its frame toan earth ground, unless t

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TROUBLESHOOTING & REPAIRF-77 F-77COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-78 F-78COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-79 F-79COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-80 F-80COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

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TROUBLESHOOTING & REPAIRF-82 F-82COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-83 F-83COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-84 F-84COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

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INSTALLATIONA-8 A-8COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to

TROUBLESHOOTING & REPAIRF-86 F-86COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-87 F-87COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

NOTESF-88 F-88COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

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TROUBLESHOOTING & REPAIRF-90 F-90COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-91 F-91COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-92 F-92COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-93 F-93COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

NOTESF-94 F-94COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

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Section B-1 Section B-1COMMANDER 400TABLE OF CONTENTS- OPERATION SECTION -Operation...

TROUBLESHOOTING & REPAIRF-96 F-96COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-97 F-97COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-98 F-98COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-99 F-99COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-100 F-100COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-101 F-101COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

NOTESF-102 F-102COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

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TROUBLESHOOTING & REPAIRF-104 F-104COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

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OPERATING INSTRUCTIONSRead and understand this entire section before operat-ing your Commander 400. SAFETY INSTRUCTIONSDo not attempt to use this equi

TROUBLESHOOTING & REPAIRF-106 F-106COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-107 F-107COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-108 F-108COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-109 F-109COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-110 F-110COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-111 F-111COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-112 F-112COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-113 F-113COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-114 F-114COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-115 F-115COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

RECOMMENDED APPLICATIONSWELDERThe Commander 400 (Stick model) provides excellentconstant current DC welding output for stick (SMAW)welding. The Comman

TROUBLESHOOTING & REPAIRF-116 F-116COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

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NOTESF-118 F-118COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

ELECTRICAL DIAGRAMSG-1 G-1COMMANDER 400Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectrical Diagrams Section

ELECTRICAL DIAGRAMSG-2G-2Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

ELECTRICAL DIAGRAMSG-3COMMANDER 400WIRING DIAGRAM - STICK & WIRE MODEL (CODE 9979) 6 230 MAX. 9 50-575 8 400

ELECTRICAL DIAGRAMSG-4COMMANDER 400WIRING DIAGRAM - STICK MODEL (CODE 10580)240 uF240 uF240 uFSTATOR ASSEMBLYRECTIFIERSHUNT600 AMPCHOKEOUTPUTSCR ASCR

ELECTRICAL DIAGRAMSG-5COMMANDER 400WIRING DIAGRAM - STICK & WIRE MODEL (CODE 10581) 6 230 MAX. 9 50-575 8 4

ELECTRICAL DIAGRAMSG-6COMMANDER 400SCHEMATIC - AMPHENOL BYPASS PC BOARDWITH PUBLISHED STANDARDSJ61280J150VTP480J150VTP280J150VTP3J618J611J613J614J6158

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

ADDITIONAL DESIGN FEATURES (Stick & Wire Model only)FOR WIRE WELDING• One constant voltage position for all wire welding. A12 to 45V range across

ELECTRICAL DIAGRAMSG-8COMMANDER 400SCHEMATIC - AUXILIARY PROTECTION PC BOARDXA12-15-95G-8Return to Section TOC Return to Section TOC Return to Section

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

ELECTRICAL DIAGRAMSG-10COMMANDER 400SCHEMATIC - BYPASS PC BOARDXA12-15-95G-10Return to Section TOC Return to Section TOC Return to Section TOC Return

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

ELECTRICAL DIAGRAMSG-12COMMANDER 400SCHEMATIC - CONTROL PC BOARD PART 1A4853-27-97BG-12Return to Section TOC Return to Section TOC Return to Section T

ELECTRICAL DIAGRAMSG-13COMMANDER 400SCHEMATIC - CONTROL PC BOARD PART 2G-13Return to Section TOC Return to Section TOC Return to Section TOC Return to

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

ELECTRICAL DIAGRAMSG-15COMMANDER 400SCHEMATIC - CV CONTROL PC BOARD+10v6.81KR176.19KR1650V0.1C31.00KR11J21550V0.1C2J212100R1210.0KR1526.7KR1828.0KR19X

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

ELECTRICAL DIAGRAMSG-17COMMANDER 400SCHEMATIC - ENGINE PROTECTION PC BOARDCONTROLLAMP DRIVER+12V BATT.PCBTHIS SHEET CONTAINS PROPRIETARY INFORMATION O

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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

ELECTRICAL DIAGRAMSG-19COMMANDER 400SCHEMATIC - METER PC BOARD714/Q1CLOCK 1SET 1RESET 1Q154HC74RESET 2N.C.DATA 1DATA 2GNDQ2CLOCK 2VCCSET 2X41011142369

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

ELECTRICAL DIAGRAMSG-21COMMANDER 400SCHEMATIC - REMOTE PROTECTION PC BOARD53000V.0047C1J604J601J606J603J605J602J613J6143000V.0047C33000V.0047C4J611J61

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

ELECTRICAL DIAGRAMSG-23COMMANDER 400SCHEMATIC - SNUBBER PC BOARD1-16-98EG-23Return to Section TOC Return to Section TOC Return to Section TOC Return t

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

SVM ERROR REPORTING FORMWe need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that wo

SAFETYi iCOMMANDER 400FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requ

OPERATIONB-6 B-6COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

WELDER CONTROLS (Figure B.1 Items 9through 14 )9. OUTPUT RANGE SWITCH AND OUTPUT CON-TROL: These two controls allow you to selectbetween various weld

AUXILIARY POWER CONTROLS (Figure B.1 Items 15 - 19 )15.120/240VAC RECEPTACLE: This is a 120/240VAC(14-50R) receptacle that provides 240VAC or canbe sp

STOPPING THE ENGINE1. Switch the RUN/STOP switch to “STOP.” This turnsoff the voltage supplied to the shut down solenoid. Abackup shut down can be a

WELDER OPERATIONSTICK WELDINGThe Commander 400 can be used with a broad rangeof DC stick electrodes. The OUTPUT RANGE switch provides six overlappin

COMMANDER 400 SETTINGS WHEN USING THEK799 HI-FREQ UNIT1. Set the OUTPUT RANGE switch to the 50-575 setting(Fabrication and General Purpose).2. Set th

WIRE FEED (CONSTANT VOLTAGE)WELDINGStick and Wire models only. Connect a wire feeder tothe Commander 400 (see the Accessories section)and set the wel

TABLE OF CONTENTS- ACCESSORIES -Accessories...

OPTIONS/ACCESSORIESThe following options/accessories are available foryour Commander 400 from your local LincolnDistributor.K802R Power Plug Kit - Pro

ELECTRIC SHOCK can kill.• Do not operate with panels open.• Disconnect NEGATIVE (-) BATTERYLEAD before servicing.• Do not touch electrically live part

SAFETYii iiCOMMANDER 400ARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the

CONNECTION OF THE LN-7 TO THE COMMANDER 400 USING K584 INPUTCABLE ASSEMBLY (SEE FIGURE C.2.)1. Shut the welder off.2. Connect the electrode cable fr

ACCESSORIESC-5 C-5COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

ACCESSORIESC-6 C-6COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

CONNECTION OF THE LN-23P TO THE COMMANDER 400 USING K350-1ADAPTER (SEE FIGURE C.5.)1. Shut the welder off.2. Connect the electrode cable from the LN

CONNECTION OF THE LN-25 TO THE COMMANDER 400 “ACROSS THE ARC”(SEE FIGURE C.6.)1. Shut the welder off.2. Connect the electrode cable from the LN-25 t

CONNECTION OF THE K488 SG CONTROLMODULE AND K487 MAGNUM SPOOL GUNTO THE COMMANDER 400 (SEE FIGUREC.7.)1. Shut the welder off.2. Connect the electrod

NOTESC-10 C-10COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection D-1 Section D-1COMMANDER 400TABLE OF CONTENTS-MAINTENANCE-M

SAFETY PRECAUTIONS• Have qualified personnel do all maintenance andtroubleshooting work.• Turn the engine off before working inside themachine.• Re

CHANGE THE OIL FILTER: Change the oil filter thefirst time between 25 and 50 hours of operation. Then,under normal operating conditions, change the

COMMANDER 400FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b

FUEL FILTERS: When working on the fuel system:• Keep unshielded lights away, do notsmoke !• Do not spill fuel ! The Commander 400 is equipped wi

4. Slide the new element onto the grommet post onthe bottom of the filter header until the element nolonger easily moves up into the filter header.

BLEEDING THE FUEL SYSTEM: In the event theengine is operated until it runs out of fuel, you will needto bleed the fuel system in order to start the en

COOLING SYSTEM: The cooling system of the Deutzengine needs to be checked and cleaned periodically.Consult the engine Operation Manual for the properf

MAINTENANCED-8 D-8COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

MAINTENANCED-9 D-9COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

BATTERY MAINTENANCEGASES FROM BATTERY can explode.• Keep sparks, flame, and cigarettes awayfrom battery.BATTERY ACID can burn eyes and skin.• Wear g

WELDER/GENERATOR MAINTENANCESTORAGE: Store the Commander 400 in clean, dry,protected areas.CLEANING: Blow out the generator and controls peri-odicall

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection E-1 Section E-1COMMANDER 400Theory of Operation ...

SAFETYiv ivCOMMANDER 400PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifi

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THEORY OF OPERATIONE-4 E-4COMMANDER 400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Ret

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INDUCTION GENERATORSThe Commander 400 utilizes a brushlessAsynchronous Induction Generator to convert mechan-ical energy into electrical energy. The

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection F-1 Section F-1COMMANDER 400Troubleshooting & Repair Se

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MASTER TABLE OF CONTENTS FOR ALL SECTIONSv vCOMMANDER 400PageSafety...

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No welding output in either CV orstick modes. Also no auxiliarypower. Engine operates normally.No auxiliary power at receptacles.The engine operates

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TABLE OF CONTENTS- INSTALLATION SECTION -Section A-1 Section A-1COMMANDER 400InstallationTechnical Specifications...

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Read this entire installation section before youstart installation.SAFETY PRECAUTIONSDo not attempt to use this equipment until you havethoroughly rea

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