Manuel d’utilisation Lincoln Electric COMMANDER 400 SVM133-B

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Summary

Lincoln Electric COMMANDER 400 SVM133-B - page 1

SVM133-B September , 2002 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be in- creased by proper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PREC ...
Lincoln Electric COMMANDER 400 SVM133-B - page 2

SAFETY i i COMMANDER 400 FOR ENGINE powered equipment. 1.a. T urn 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. ______________________ ...
Lincoln Electric COMMANDER 400 SVM133-B - page 3

SAFETY ii ii COMMANDER 400 ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Head shield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to pr ...
Lincoln Electric COMMANDER 400 SVM133-B - page 4

COMMANDER 400 FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with the U.S. Natio ...
Lincoln Electric COMMANDER 400 SVM133-B - page 5

SAFETY iv iv COMMANDER 400 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-vous contre la secousse électrique: a. ...
Lincoln Electric COMMANDER 400 SVM133-B - page 6

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v COMMANDER 400 Page Safety .................................................................................................................................................i-iv Installation .................................................................................................................. ...
Lincoln Electric COMMANDER 400 SVM133-B - page 7

T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 COMMANDER 400 Installation T echnical Specifications ....................................................................................................... .......A-2 Safety Precautions ............................................................................................. ...
Lincoln Electric COMMANDER 400 SVM133-B - page 8

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-2 A-2 COMMANDER 400 INST ALLA TION TECHNICAL SPECIFICA TIONS - Commander 400 Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder High Id ...
Lincoln Electric COMMANDER 400 SVM133-B - page 9

Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating and maintenance instructions and parts lists. ...
Lincoln Electric COMMANDER 400 SVM133-B - page 10

LIFTING The Commander 400 weights 1650 lb./748 kg (Stick model); 1683 lb./763 kg. (Stick & Wire model). A lift bail is provided for lifting with a hoist. F ALLING EQUIPMENT can cause injury . Do not lift this machine using lift bail if it is equipped with a heavy accessory such as a trailer . Lift only with equipment of adequate lifting capacit ...
Lincoln Electric COMMANDER 400 SVM133-B - page 11

FUEL NOTE: Use diesel fuel only . Fill the fuel tank with clean, fresh diesel fuel. The capacity of the fuel tank is 25 gallons (94.6 liters). See the Operation and Maintenance sections of this man- ual for more details about fuel. The Commander 400 is protected by a low fuel shutdown to prevent the engine from running out of fuel. The machine will ...
Lincoln Electric COMMANDER 400 SVM133-B - page 12

ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the 120 and 240 volt receptacles, weld output terminals, and ground stud. WELDING CABLE CONNECTIONS CABLE INST ALLA TION AND CABLE SIZES With the engine off, route the electrode and work cables through the strain relief bracket on the base and connect to the terminals located on the f ...
Lincoln Electric COMMANDER 400 SVM133-B - page 13

MACHINE GROUNDING Because this portable engine driven welder creates its own power , it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.). T o prevent dangerous electric shock, other equipment powered by this engine driven welder must: a) be grounded to the frame of the w ...
Lincoln Electric COMMANDER 400 SVM133-B - page 14

INST ALLA TION A-8 A-8 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERC ...
Lincoln Electric COMMANDER 400 SVM133-B - page 15

Section B-1 Section B-1 COMMANDER 400 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions ...................................................................................................... ...
Lincoln Electric COMMANDER 400 SVM133-B - page 16

OPERA TING INSTRUCTIONS Read and understand this entire section before operat- ing your Commander 400. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all the operating and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating and mainte ...
Lincoln Electric COMMANDER 400 SVM133-B - page 17

RECOMMENDED APPLICA TIONS WELDER The Commander 400 (Stick model) provides excellent constant current DC welding output for stick (SMA W) welding. The Commander 400 (Stick & Wire model) also provides excellent constant voltage DC welding output for MIG (GMA W) and Inner shield (FCA W) welding. GENERA TOR The Commander 400 provides smooth 120/240 ...
Lincoln Electric COMMANDER 400 SVM133-B - page 18

ADDITIONAL DESIGN FEA TURES (Stick & Wire Model only) FOR WIRE WELDING • One constant voltage position for all wire welding. A 12 to 45V range across the entire current output range. • Excellent arc characteristics with MIG (GMAW) and Inner shield (FCA W) welding. • A Wire Feeder connector for quick connection of the control cable. • A ...
Lincoln Electric COMMANDER 400 SVM133-B - page 19

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-5 B-5 COMMANDER 400 FIGURE B.1 – CASE FRONT P ANEL CONTROLS ENGINE CONTROLS (Figure B.1, Items 1 through 8) See Figure B.1 for the location of the following fea- t ...
Lincoln Electric COMMANDER 400 SVM133-B - page 20

OPERA TION B-6 B-6 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 4. ENGINE TEMPERA TURE GAUGE AND LIGHT : The gauge displays the engine oil temperature. The yellow temperature light remains off under normal ope ...
Lincoln Electric COMMANDER 400 SVM133-B - page 21

WELDER CONTROLS ( Figure B.1 Items 9 through 14 ) 9. OUTPUT RANGE SWITCH AND OUTPUT CON- TROL: These two controls allow you to select between various welding output slopes and adjust the desired welding output. Refer to T able B.1 for a description of how these two controls work. T ABLE B.1 OUTPUT RANGE SWITCH AND OUT- PUT CONTROL FUNCTIONS 1 If th ...
Lincoln Electric COMMANDER 400 SVM133-B - page 22

AUXILIAR Y POWER CONTROLS ( Figure B.1 Items 15 - 19 ) 15. 120/240V AC RECEPT ACLE: This is a 120/240V AC (14-50R) receptacle that provides 240V AC or can be split for 120V AC single phase auxiliary power . The receptacle has a 50 amp rating. Refer to “Auxiliary Power Receptacles” in the Installation section for further information about this r ...
Lincoln Electric COMMANDER 400 SVM133-B - page 23

STOPPING THE ENGINE 1. Switch the RUN/STOP switch to “STOP .” This turns off the voltage supplied to the shut down solenoid. A backup shut down can be accomplished by shutting off the fuel valve located on the fuel filter housing. BREAK-IN PERIOD The engine used to supply power for your welder is a heavy duty , industrial engine. It is designed ...
Lincoln Electric COMMANDER 400 SVM133-B - page 24

WELDER OPERA TION STICK WELDING The Commander 400 can be used with a broad range of DC stick electrodes. The OUTPUT RANGE switch provides six overlapping slope controlled current ranges. The OUTPUT CON- TROL adjusts the current from minimum to maximum within each range. Open circuit voltage is also con- trolled by the OUTPUT CONTROL in the slope co ...
Lincoln Electric COMMANDER 400 SVM133-B - page 25

COMMANDER 400 SETTINGS WHEN USING THE K799 HI-FREQ UNIT 1. Set the OUTPUT RANGE switch to the 50-575 setting (Fabrication and General Purpose). 2. Set the IDLER switch to the “HIGH “ position. 3. Set the LOCAL/REMOTE switch to the “REMOTE” position. 4. Set the WELDING TERMINALS switch to the “WELD- ING TERMINALS AL W A YS ON” position. ...
Lincoln Electric COMMANDER 400 SVM133-B - page 26

WIRE FEED (CONST ANT VOL T AGE) WELDING Stick and Wire models only . Connect a wire feeder to the Commander 400 (see the Accessories section) and set the welder controls according to the instruc- tions in “Controls and Settings” in this section of the manual. The Stick and Wire model of the Commander 400, with its CV tap, permits it to be used ...
Lincoln Electric COMMANDER 400 SVM133-B - page 27

T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories ...................................................................................................................C-2 Stick Welding ................ ...
Lincoln Electric COMMANDER 400 SVM133-B - page 28

OPTIONS/ACCESSORIES The following options/accessories are available for your Commander 400 from your local Lincoln Distributor . K802R Power Plug Kit - Provides a plug for each receptacle. The kit includes 4-120V plugs rated at 15 Amps each and 1-120V/240V Full-KV A plug rated at 50 Amps. K857 28 ft. (8.5 m) or K857-1 100 ft. (30.4 m) Remote Contro ...
Lincoln Electric COMMANDER 400 SVM133-B - page 29

ELECTRIC SHOCK can kill. • Do not operate with panels open. • Disconnect NEGA TIVE (-) BA TTER Y LEAD before servicing. • Do not touch electrically live parts. MOVING P AR TS can injure. • Keep guards in place. • Keep away from moving parts. • Only qualified personnel should install, use or service this equipment. CONNECTION OF THE LN-7 ...
Lincoln Electric COMMANDER 400 SVM133-B - page 30

CONNECTION OF THE LN-7 TO THE COMMANDER 400 USING K584 INPUT CABLE ASSEMBL Y (SEE FIGURE C.2.) 1. Shut the welder off. 2. Connect the electrode cable fr om the LN-7 to the “+” terminal of the welder . Connect the work cable to the “CV - Wire” terminal of the welder . NOTE: W elding cable must be sized for current and duty cycle of applicati ...
Lincoln Electric COMMANDER 400 SVM133-B - page 31

ACCESSORIES C-5 C-5 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECTION OF THE LN-8 TO THE COMMANDER 400 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.3.) 1. Shut the welder off. 2. Connect the electrode cabl ...
Lincoln Electric COMMANDER 400 SVM133-B - page 32

ACCESSORIES C-6 C-6 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECTION OF THE LN-8 TO THE COMMANDER 400 USING K595 INPUT CABLE ASSEMBL Y (SEE FIGURE C.4.) 1. Shut the welder off. 2. Connect the electr ode ...
Lincoln Electric COMMANDER 400 SVM133-B - page 33

CONNECTION OF THE LN-23P TO THE COMMANDER 400 USING K350-1 ADAPTER (SEE FIGURE C.5.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-23P to the “CV - Wire” terminal of the welder . Connect the work cable to the “+” terminal of the welder . NOTE: W elding cable must be sized for current and duty cycle of application. NOTE: ...
Lincoln Electric COMMANDER 400 SVM133-B - page 34

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 fr om the LN-25 to the “-” terminal of the welder . Connect the work cable to the “CV -” terminal of the welder . NOTE: W elding cable must be sized for current and duty cycle of application. NOTE: Fig ...
Lincoln Electric COMMANDER 400 SVM133-B - page 35

CONNECTION OF THE K488 SG CONTROL MODULE AND K487 MAGNUM SPOOL GUN TO THE COMMANDER 400 (SEE FIGURE C.7.) 1. Shut the welder off. 2. Connect the electrode cable from the SG Contr ol Module to the “+” terminal of the welder . Connect the work cable to the “CV - Wire” terminal of the welder . NOTE: W elding cable must be sized for current and ...
Lincoln Electric COMMANDER 400 SVM133-B - page 36

NOTES C-10 C-10 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...
Lincoln Electric COMMANDER 400 SVM133-B - page 37

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 COMMANDER 400 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions ................................ ...
Lincoln Electric COMMANDER 400 SVM133-B - page 38

SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. • If covers or guards are missing from the machin ...
Lincoln Electric COMMANDER 400 SVM133-B - page 39

CHANGE THE OIL FIL TER: Change the oil filter the first time between 25 and 50 hours of operation. Then, under normal operating conditions, change the oil filter after every 250 hours of operation. If the engine is operated under heavy load or in high ambient temper- atures, change the oil filter more frequently . See T able D.1 for recommended mai ...
Lincoln Electric COMMANDER 400 SVM133-B - page 40

FUEL FIL TERS: When working on the fuel system: • Keep unshielded lights away , do not smoke ! • Do not spill fuel ! The Commander 400 is equipped with a Fuel Pre- Filter/W ater Separator Assembly located before the lift pump and a Secondary Fuel Filter located after the lift pump and before the fuel injectors. The Fuel Pre- Filter/W ater Separ ...
Lincoln Electric COMMANDER 400 SVM133-B - page 41

4. Slide the new element onto the grommet post on the bottom of the filter header until the element no longer easily moves up into the filter header . Now rotate the element (it may take almost 1 full turn) with a slight upward pressure until the element begins to further engage the header . With the prop- er orientation now established, apply addi ...
Lincoln Electric COMMANDER 400 SVM133-B - page 42

BLEEDING THE FUEL SYSTEM: In the event the engine is operated until it runs out of fuel, you will need to bleed the fuel system in order to start the engine. Refer to the engine operation manual. AIR FIL TER: Excessive air filter restriction will result in reduced engine life. The air filter element is a dry cartridge type. It can be cleaned and re ...
Lincoln Electric COMMANDER 400 SVM133-B - page 43

COOLING SYSTEM: The cooling system of the Deutz engine needs to be checked and cleaned periodically . Consult the engine Operation Manual for the proper frequency and procedure. COOLING BLOWER BEL T: The following procedure should be followed to replace the cooling blower belt: 1. Allow the machine to cool. 2. Unfasten and slide the battery holder ...
Lincoln Electric COMMANDER 400 SVM133-B - page 44

MAINTENANCE D-8 D-8 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE D.1 DEUTZ ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Starting Engine • Fill fuel tank. • Check oil le ...
Lincoln Electric COMMANDER 400 SVM133-B - page 45

MAINTENANCE D-9 D-9 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T able D.2 ENGINE MAINTENANCE P ARTS ITEM Air Cleaner Element Cooling Blower Belt Oil Filter Element Fuel Filter Element W ater Separator Elemen ...
Lincoln Electric COMMANDER 400 SVM133-B - page 46

BA TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTER Y ACID can burn eyes and skin. • W ear gloves and eye protection and be careful when working near a battery . Follow the instructions printed on the battery . T o prevent EXPLOSION when: • INST ALLING A NEW BA TTER Y - Disc ...
Lincoln Electric COMMANDER 400 SVM133-B - page 47

WELDER/GENERA TOR MAINTENANCE STORAGE: Store the Commander 400 in clean, dry , protected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas. NAME PLA TES: Whenever routine maintenance is performed on this machine - or at least yearly - inspect all name ...
Lincoln Electric COMMANDER 400 SVM133-B - page 48

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-12 D-12 COMMANDER 400 FIGURE D.5 - MAJOR COMPONENT LOCA TIONS 1. CASE DOOR ASSEMBL Y 2. ENGINE 3. SHUTDOWN SOLENOID 4. IDLER SOLENOID 5. REAR P ANEL ASSEMBL Y 6. BA ...
Lincoln Electric COMMANDER 400 SVM133-B - page 49

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 COMMANDER 400 Theory of Operation ............................................................................................................. Section E General Description .................................................................... ...
Lincoln Electric COMMANDER 400 SVM133-B - page 50

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GENERAL DESCRIPTION The Commander 400 is a diesel engine driven welding power source. The machine uses a brushless asyn- chronous alternating current generator for DC stick elect ...
Lincoln Electric COMMANDER 400 SVM133-B - page 51

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC EXCITER FEEDBACK, CONTROL BOARD, LOCAL AND REMOTE CONTROL The exciter voltage is monitored and fed back through the exciter voltage feedback board to the control board. In the ev ...
Lincoln Electric COMMANDER 400 SVM133-B - page 52

THEOR Y OF OPERA TION E-4 E-4 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WELD WINDING, OUTPUT BRIDGE, OUTPUT CHOKE AND CV CAP ACI- T ORS The three-phase AC output that is created in the stator weld winding i ...
Lincoln Electric COMMANDER 400 SVM133-B - page 53

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-5 E-5 Commander 400 FIGURE E.6 – SCR OPERA TION SCR OPERA TION A silicon controlled rectifier (SCR) is a three terminal device used to control rather la ...
Lincoln Electric COMMANDER 400 SVM133-B - page 54

INDUCTION GENERA TORS The Commander 400 utilizes a brushless Asynchronous Induction Generator to convert mechan- ical energy into electrical energy . The following is a brief description of an induction generator . The induction generator is an induction motor driven above the synchronous speed. The rotor conductors pass through the magnetic field ...
Lincoln Electric COMMANDER 400 SVM133-B - page 55

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 COMMANDER 400 T roubleshooting & Repair Section ................................................................................ Section F How to Use T roubleshooting Guide ................................................................. ...
Lincoln Electric COMMANDER 400 SVM133-B - page 56

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW T O USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may ...
Lincoln Electric COMMANDER 400 SVM133-B - page 57

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T urn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes ...
Lincoln Electric COMMANDER 400 SVM133-B - page 58

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 Commander 400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not ...
Lincoln Electric COMMANDER 400 SVM133-B - page 59

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 COMMANDER 400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not ...
Lincoln Electric COMMANDER 400 SVM133-B - page 60

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 Commander 400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not ...
Lincoln Electric COMMANDER 400 SVM133-B - page 61

No welding output in either CV or stick modes. Also no auxiliary power . Engine operates normally . No auxiliary power at receptacles. The engine operates normally and the welding output is normal. 1. Contact your local Lincoln Authorized Field Service Shop. 1. Check the circuit breakers CB1 thru CB4. Reset if tripped. 2. Check the GFCI receptacles ...
Lincoln Electric COMMANDER 400 SVM133-B - page 62

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-8 F-8 COMMANDER 400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not ...
Lincoln Electric COMMANDER 400 SVM133-B - page 63

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 Commander 400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not ...
Lincoln Electric COMMANDER 400 SVM133-B - page 64

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 COMMANDER 400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do n ...
Lincoln Electric COMMANDER 400 SVM133-B - page 65

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-11 F-11 COMMANDER 400 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do n ...
Lincoln Electric COMMANDER 400 SVM133-B - page 66

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-12 F-12 COMMANDER 400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do n ...
Lincoln Electric COMMANDER 400 SVM133-B - page 67

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-13 F-13 COMMANDER 400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do n ...
Lincoln Electric COMMANDER 400 SVM133-B - page 68

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 The welding arc is “hot”, “spattery”, “cannonballs” or “flares up”. The engine runs normally . The auxil- iary power is no ...
Lincoln Electric COMMANDER 400 SVM133-B - page 69

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-15 F-15 The welding arc is “hot”, “spattery”, “cannonballs” or “flares up”. The engine runs normally . The auxil- iary power is no ...
Lincoln Electric COMMANDER 400 SVM133-B - page 70

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-16 F-16 COMMANDER 400 COMMANDER 400 INITIALIZA TION SEQUENCE AND ERROR CODE EXPLANA TIONS When the Commander 400 is started, the display flashes s ...
Lincoln Electric COMMANDER 400 SVM133-B - page 71

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-17 F-17 COMMANDER 400 WITH G2713-1 CONTROL BOARD ERROR CODES DURING INITIALIZA TION SEQUENCE DEFINITION / SYMPTOM CORRECTIVE ACTION 300 bAd uP 400 ...
Lincoln Electric COMMANDER 400 SVM133-B - page 72

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-18 F-18 COMMANDER 400 WITH G2713-1 CONTROL BOARD ERROR CODES DURING INITIALIZA TION SEQUENCE DEFINITION / SYMPTOM CORRECTIVE ACTION CSS or ECL The ...
Lincoln Electric COMMANDER 400 SVM133-B - page 73

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 COMMANDER 400 WITH G2713-1 CONTROL BOARD ERROR CODES DURING INITIALIZA TION SEQUENCE DEFINITION / SYMPTOM CORRECTIVE ACTION LCH Err The ou ...
Lincoln Electric COMMANDER 400 SVM133-B - page 74

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-20 F-20 COMMANDER 400 WITH G2713-1 CONTROL BOARD ERROR CODES DURING INITIALIZA TION SEQUENCE DEFINITION / SYMPTOM CORRECTIVE ACTION Ert Esi EIO EC ...
Lincoln Electric COMMANDER 400 SVM133-B - page 75

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-21 F-21 COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD ERROR CODES DURING INITIALIZA TION SEQUENCE DEFINITION / SYMPTOM CORRECTIVE ACTION uP bAd u ...
Lincoln Electric COMMANDER 400 SVM133-B - page 76

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-22 F-22 COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD ERROR CODES DURING INITIALIZA TION SEQUENCE DEFINITION / SYMPTOM CORRECTIVE ACTION SSr EHC ...
Lincoln Electric COMMANDER 400 SVM133-B - page 77

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-23 F-23 COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD ERROR CODES WHILE RUNNING DEFINITION / SYMPTOM CORRECTIVE ACTION LCH Err The output current ...
Lincoln Electric COMMANDER 400 SVM133-B - page 78

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-24 F-24 COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD ERROR CODES WHILE RUNNING DEFINITION / SYMPTOM CORRECTIVE ACTION LFL SS? Unit has shut down ...
Lincoln Electric COMMANDER 400 SVM133-B - page 79

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-25 F-25 COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD ERROR CODES WHILE RUNNING DEFINITION / SYMPTOM CORRECTIVE ACTION Ert Esi EIO ECP ECE EO5 IC ...
Lincoln Electric COMMANDER 400 SVM133-B - page 80

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-26 F-26 COMMANDER 400 WITH G2713-2 OR -3 CONTROL BOARD ERROR CODES WHILE RUNNING DEFINITION / SYMPTOM CORRECTIVE ACTION ECH ECL CSS The exciter vo ...
Lincoln Electric COMMANDER 400 SVM133-B - page 81

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-27 F-27 COMMANDER 400 CASE COVER REMOV AL AND REPLACEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric facto ...
Lincoln Electric COMMANDER 400 SVM133-B - page 82

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-28 F-28 COMMANDER 400 CHAIN DOOR ASSEMBL Y FIGURE F .1 – DOOR CHAIN REMOV AL CASE COVER REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE ...
Lincoln Electric COMMANDER 400 SVM133-B - page 83

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-29 F-29 COMMANDER 400 THREE SCREWS LEFT SIDE P ANEL FIGURE F .2 – DOOR ASSEMBL Y/LEFT SIDE P ANEL SCREW LOCA TIONS 4. Using the 3/8" wrench ...
Lincoln Electric COMMANDER 400 SVM133-B - page 84

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-30 F-30 Commander 400 LEFT SIDE ENGINE COVER P ANEL LOOSEN TWO END SCREWS REMOVE CENTER SCREW FIGURE F .4 – LEFT SIDE ENGINE COVER REMOV AL 6. C ...
Lincoln Electric COMMANDER 400 SVM133-B - page 85

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-31 F-31 COMMANDER 400 FRONT CONTROL P ANEL LOWERED ARROWS INDICA TE SCREW LOCA TIONS FIGURE F .5 – FRONT CONTROL P ANEL REMOV AL FRONT SHROUD RE ...
Lincoln Electric COMMANDER 400 SVM133-B - page 86

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-32 F-32 COMMANDER 400 TROUBLESHOOTING & REP AIR CASE FRONT KNOBS - REMOV AL AND REPLACEMENT PROCEDURE Replacement Removal Flat Rounded Replacement:  1. If the white n ...
Lincoln Electric COMMANDER 400 SVM133-B - page 87

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-33 F-33 COMMANDER 400 W ARNING IDLER SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unau ...
Lincoln Electric COMMANDER 400 SVM133-B - page 88

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-34 F-34 COMMANDER 400 IDLER SOLENOID TEST (continued) FIGURE F .8 – IDLER SOLENOID LEAD TERMINALS PULL-IN COIL (LARGER TERMINALS TOP AND BOTTOM ...
Lincoln Electric COMMANDER 400 SVM133-B - page 89

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-35 F-35 COMMANDER 400 W ARNING SHUTDOWN SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. U ...
Lincoln Electric COMMANDER 400 SVM133-B - page 90

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-36 F-36 COMMANDER 400 SHUTDOWN SOLENOID TEST (continued) FIGURE F .9 - SHUTDOWN SOLENOID LEAD TERMINALS PULL-IN COIL (LARGER TERMINALS EACH SIDE # ...
Lincoln Electric COMMANDER 400 SVM133-B - page 91

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-37 F-37 COMMANDER 400 W ARNING ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained per ...
Lincoln Electric COMMANDER 400 SVM133-B - page 92

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-38 F-38 COMMANDER 400 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .10 - BLOWER P ADDLE MARKED FOR STROBE-T ACH METHOD MARK BLOWER P ADDLE ...
Lincoln Electric COMMANDER 400 SVM133-B - page 93

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-39 F-39 COMMANDER 400 ENGINE THROTTLE ADJUSTMENT TEST (continued) 6. If either of the readings is incorrect, adjust the throttle as follows: Adjus ...
Lincoln Electric COMMANDER 400 SVM133-B - page 94

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-40 F-40 COMMANDER 400 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .11 - HIGH IDLE ADJUSTMENT BOSCH 5 7 0 0 8 1 6 903 PES 3A 80D 410/3R 0 ...
Lincoln Electric COMMANDER 400 SVM133-B - page 95

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-41 F-41 COMMANDER 400 W ARNING ST A TIC SCR/DIODE RECTIFIER BRIDGE TEST Service and repair should be performed by only Lincoln Electric factory tr ...
Lincoln Electric COMMANDER 400 SVM133-B - page 96

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-42 F-42 COMMANDER 400 ST A TIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F .13 – CONTROL BOARD PLUG J6 LOCA TION PLUG J6 P e l 9 9 6 TE ...
Lincoln Electric COMMANDER 400 SVM133-B - page 97

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-43 F-43 COMMANDER 400 ST A TIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F .15 – RESISTOR R1 LOCA TION RESISTOR R1 LEAD #204B 6. Using ...
Lincoln Electric COMMANDER 400 SVM133-B - page 98

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-44 F-44 COMMANDER 400 ST A TIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F .16 – HEA T SINK AND SCR TEST POINTS ANODE CA THODE DIODE DD ...
Lincoln Electric COMMANDER 400 SVM133-B - page 99

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-45 F-45 COMMANDER 400 W ARNING ACTIVE SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthor ...
Lincoln Electric COMMANDER 400 SVM133-B - page 100

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-46 F-46 COMMANDER 400 ACTIVE SCR TEST (continued) FIGURE F .17 – CONTROL BOARD PLUG J6 LOCA TION PLUG J6 P e l 9 9 6 TEST PROCEDURE 1. T urn OFF ...
Lincoln Electric COMMANDER 400 SVM133-B - page 101

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-47 F-47 COMMANDER 400 FIGURE F .19 - RESISTOR R1 LOCA TION RESISTOR R1 LEAD #204B ACTIVE SCR TEST (continued) 8. Locate and remove lead #204B from ...
Lincoln Electric COMMANDER 400 SVM133-B - page 102

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-48 F-48 COMMANDER 400 ACTIVE SCR TEST (continued) FIGURE F .21 - SCR TESTER CIRCUIT AND SCR CONNECTIONS T o test SCRs construct the circuit outlin ...
Lincoln Electric COMMANDER 400 SVM133-B - page 103

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-49 F-49 COMMANDER 400 W ARNING CHARGING CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Un ...
Lincoln Electric COMMANDER 400 SVM133-B - page 104

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-50 F-50 COMMANDER 400 CHARGING CIRCUIT TEST (continued) FIGURE F .22 – ENGINE AL TERNA TOR LOCA TION #239 #238 #285(#281) TEST PROCEDURE 1. T ur ...
Lincoln Electric COMMANDER 400 SVM133-B - page 105

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-51 F-51 COMMANDER 400 W ARNING ST A TOR VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. ...
Lincoln Electric COMMANDER 400 SVM133-B - page 106

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-52 F-52 COMMANDER 400 ST A TOR VOL T AGE TEST (continued) FIGURE F .23 – CONTROL BOX STUD TERMINALS T1 STUD #6 LEADS T2 STUD #5 LEADS T3 STUD #3 ...
Lincoln Electric COMMANDER 400 SVM133-B - page 107

TROUBLESHOOTING & REP AIR F-53 F-53 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TOR VOL T AGE TEST (continued) FIGURE F .24 – SCR/DIODE RECTIFIER BRIDGE LEADS COMMANDER 400 STICK an d W IRE STICK a ...
Lincoln Electric COMMANDER 400 SVM133-B - page 108

TROUBLESHOOTING & REP AIR F-54 F-54 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TOR VOL T AGE TEST (continued) FIGURE F .26 – EXCITER LEADS T1, T2, T3 W ARNING T1 T2 T3 TEST PROCEDURE – Exciter W ...
Lincoln Electric COMMANDER 400 SVM133-B - page 109

FINE CONTROL POTENTIOMETER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety n ...
Lincoln Electric COMMANDER 400 SVM133-B - page 110

TROUBLESHOOTING AND REP AIR FINE CONTROL POTENTIOMETER TEST (continued) F-56 F-56 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TEST PROCEDURE NOTE: In this test procedur e, the positive output stud is used for common. 1. ...
Lincoln Electric COMMANDER 400 SVM133-B - page 111

RANGE SWITCH TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and preca ...
Lincoln Electric COMMANDER 400 SVM133-B - page 112

TROUBLESHOOTING AND REP AIR RANGE SWITCH TEST (continued) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST PROCEDURE NOTE: In this test procedur e, the positive output stud is used for common. 1. Using the 5/16” nut driv ...
Lincoln Electric COMMANDER 400 SVM133-B - page 113

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-59 F-59 RANGE SWITCH TEST (continued) COMMANDER 400 J2 J6 J5 J8 J7 J1 J4 J22 J20 C112 Plug J7 Pin #7 Pin #10 Pin #1 Figure F .28 Control Board Plu ...
Lincoln Electric COMMANDER 400 SVM133-B - page 114

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-60 F-60 COMMANDER 400 ...
Lincoln Electric COMMANDER 400 SVM133-B - page 115

SHUNT CALIBRA TION TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and ...
Lincoln Electric COMMANDER 400 SVM133-B - page 116

TROUBLESHOOTING AND REP AIR SHUNT CALIBRA TION TEST (continued) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST PROCEDURE NOTE: In this test procedur e, the positive output stud is used for common. 1. Using the 5/16” nu ...
Lincoln Electric COMMANDER 400 SVM133-B - page 117

EXCITER VOL T AGE FEEDBACK TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety n ...
Lincoln Electric COMMANDER 400 SVM133-B - page 118

TROUBLESHOOTING AND REP AIR EXCITER VOL T AGE FEEDBACK TEST (continued) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST PROCEDURE 1. Set the machine to the following settings, then start the machine: Control dial to 1 (mi ...
Lincoln Electric COMMANDER 400 SVM133-B - page 119

EXCITER CAP ACITOR BANK TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety note ...
Lincoln Electric COMMANDER 400 SVM133-B - page 120

TROUBLESHOOTING AND REP AIR EXCITER CAP ACITOR BANK TEST (continued) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Check for voltage across capacitors. V oltages could be high and danger- ous. Discharge capacitors with a hig ...
Lincoln Electric COMMANDER 400 SVM133-B - page 121

CONTROL BOARD POWER SUPPL Y TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety ...
Lincoln Electric COMMANDER 400 SVM133-B - page 122

TROUBLESHOOTING AND REP AIR CONTROL BOARD POWER SUPPL Y TEST (continued) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST PROCEDURE NOTE 1: In this test procedure, the positive output stud is used for common. NOTE 2: This ...
Lincoln Electric COMMANDER 400 SVM133-B - page 123

ST A TOR RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes a ...
Lincoln Electric COMMANDER 400 SVM133-B - page 124

TROUBLESHOOTING AND REP AIR ST A TOR RESIST ANCE TEST (continued) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST PROCEDURE 1. With the engine off, disconnect the negative bat- tery cable. Make sure that ther e is nothing ...
Lincoln Electric COMMANDER 400 SVM133-B - page 125

TROUBLESHOOTING AND REP AIR ST A TOR RESIST ANCE TEST (continued) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST PROCEDURE 14. Connect the test leads J50 and J51 to the stator winding under test. Close S1 and read the vo ...
Lincoln Electric COMMANDER 400 SVM133-B - page 126

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-72 F-72 COMMANDER 400 This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division r ...
Lincoln Electric COMMANDER 400 SVM133-B - page 127

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-73 F-73 COMMANDER 400 This is the typical DC open circuit out- put voltage generated from a properly operating machine. Note that each vertical di ...
Lincoln Electric COMMANDER 400 SVM133-B - page 128

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-74 F-74 COMMANDER 400 This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represen ...
Lincoln Electric COMMANDER 400 SVM133-B - page 129

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-75 F-75 COMMANDER 400 This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represen ...
Lincoln Electric COMMANDER 400 SVM133-B - page 130

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-76 F-76 COMMANDER 400 This is the typical DC open circuit output voltage generated from a properly operating machine. Note that each vertical divi ...
Lincoln Electric COMMANDER 400 SVM133-B - page 131

TROUBLESHOOTING & REP AIR F-77 F-77 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NORMAL SOLENOID PULL & HOLD COIL W A VEFORMS The scope pictures above are typical waveforms seen directly across the pul ...
Lincoln Electric COMMANDER 400 SVM133-B - page 132

TROUBLESHOOTING & REP AIR F-78 F-78 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ABNORMAL SOLENOID PULL & HOLD COIL W A VEFORMS 1V 20 ms 20 ms 200 MV 5 ms The scope pictures above are exam- ples of a s ...
Lincoln Electric COMMANDER 400 SVM133-B - page 133

TROUBLESHOOTING & REP AIR F-79 F-79 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TYPICAL EXCITER VOL T AGE FEEDBACK W A VEFORMS 1 V 2 ms This is the typical waveform output from each of the three phases fr ...
Lincoln Electric COMMANDER 400 SVM133-B - page 134

TROUBLESHOOTING & REP AIR F-80 F-80 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ABNORMAL EXCITER VOL T AGE FEEDBACK W A VEFORMS 1 V 2 ms This is an example of a bad wave- form at one of the Exciter Module ...
Lincoln Electric COMMANDER 400 SVM133-B - page 135

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-81 F-81 COMMANDER 400 W ARNING CONTROL PC BOARD REMOV AL, REPLACEMENT , AND CALIBRA TION Service and repair should be performed by only Lincoln El ...
Lincoln Electric COMMANDER 400 SVM133-B - page 136

TROUBLESHOOTING & REP AIR F-82 F-82 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL PC BOARD REMOV AL AND REPLACEMENT (continued) FIGURE F .33 – MOLEX PLUG REMOV AL CV BOARD MOLEX PLUG CONTROL BOARD ...
Lincoln Electric COMMANDER 400 SVM133-B - page 137

TROUBLESHOOTING & REP AIR F-83 F-83 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL PC BOARD REMOV AL AND REPLACEMENT (continued) FIGURE F .34 – CONTROL BOARD LEADS P e l 9 9 6 B1/227 B2/262 B3/232 ...
Lincoln Electric COMMANDER 400 SVM133-B - page 138

TROUBLESHOOTING & REP AIR F-84 F-84 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL PC BOARD REMOV AL AND REPLACEMENT (continued) CALIBRA TION PROCEDURE (Stick and Wire Model Only) 1. Set the front co ...
Lincoln Electric COMMANDER 400 SVM133-B - page 139

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-85 F-85 COMMANDER 400 W ARNING SHUTDOWN SOLENOID REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory ...
Lincoln Electric COMMANDER 400 SVM133-B - page 140

TROUBLESHOOTING & REP AIR F-86 F-86 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SHUTDOWN SOLENOID REMOV AL AND REPLACEMENT (continued) FIGURE F .35 – SHUTDOWN SOLENOID LEAD CONNECTIONS PULL-IN COIL (LAR ...
Lincoln Electric COMMANDER 400 SVM133-B - page 141

TROUBLESHOOTING & REP AIR F-87 F-87 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SHUTDOWN SOLENOID REMOV AL AND REPLACEMENT (continued) FIGURE F .36 – SHUTDOWN SOLENOID LINKAGE ARM ASSEMBL Y PIVOT PIN SP ...
Lincoln Electric COMMANDER 400 SVM133-B - page 142

NOTES F-88 F-88 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...
Lincoln Electric COMMANDER 400 SVM133-B - page 143

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-89 F-89 COMMANDER 400 W ARNING SCR/DIODE RECTIFIER BRIDGE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric ...
Lincoln Electric COMMANDER 400 SVM133-B - page 144

TROUBLESHOOTING & REP AIR F-90 F-90 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR/DIODE RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .37 – SCR/DIODE RECTIFIER BRIDGE DET AILS #209 (s ...
Lincoln Electric COMMANDER 400 SVM133-B - page 145

TROUBLESHOOTING & REP AIR F-91 F-91 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR/DIODE RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .38 – NEGA TIVE “STICK” OUTPUT TERMINAL #207 ...
Lincoln Electric COMMANDER 400 SVM133-B - page 146

TROUBLESHOOTING & REP AIR F-92 F-92 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR/DIODE RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .40 – RESISTOR R1 LOCA TION RESISTOR R1 LEAD #204 ...
Lincoln Electric COMMANDER 400 SVM133-B - page 147

TROUBLESHOOTING & REP AIR F-93 F-93 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR/DIODE RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .42 – SCR/DIODE RECTIFIER BRIDGE ASSEMBL Y REMOV ...
Lincoln Electric COMMANDER 400 SVM133-B - page 148

NOTES F-94 F-94 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...
Lincoln Electric COMMANDER 400 SVM133-B - page 149

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-95 F-95 COMMANDER 400 W ARNING SCR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained person ...
Lincoln Electric COMMANDER 400 SVM133-B - page 150

TROUBLESHOOTING & REP AIR F-96 F-96 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR REMOV AL AND REPLACEMENT (continued) FIGURE F .43 – SCR DET AILS SPECIAL INSTRUCTIONS NOTE: Before disassembling the e ...
Lincoln Electric COMMANDER 400 SVM133-B - page 151

TROUBLESHOOTING & REP AIR F-97 F-97 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR REMOV AL AND REPLACEMENT (continued) FIGURE F .44 – RECTIFIER BRIDGE ASSEMBL Y BRACKET DET AILS GROMMET BRACKET SCREWS ...
Lincoln Electric COMMANDER 400 SVM133-B - page 152

TROUBLESHOOTING & REP AIR F-98 F-98 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR REMOV AL AND REPLACEMENT (continued) FIGURE F .45 – 1/2” WIDE LEAF SPRING 1 1. Go to the procedure below that matche ...
Lincoln Electric COMMANDER 400 SVM133-B - page 153

TROUBLESHOOTING & REP AIR F-99 F-99 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR REMOV AL AND REPLACEMENT (continued) CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE: This procedure can only be used with ...
Lincoln Electric COMMANDER 400 SVM133-B - page 154

TROUBLESHOOTING & REP AIR F-100 F-100 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR REMOV AL AND REPLACEMENT (continued) FIGURE F .47 – HOUSING AND PRESSURE P AD FOR 5/8” WIDE LEAF SPRING PROCEDURE ...
Lincoln Electric COMMANDER 400 SVM133-B - page 155

TROUBLESHOOTING & REP AIR F-101 F-101 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR REMOV AL AND REPLACEMENT (continued) CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE: This procedure can only be used wi ...
Lincoln Electric COMMANDER 400 SVM133-B - page 156

NOTES F-102 F-102 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...
Lincoln Electric COMMANDER 400 SVM133-B - page 157

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-103 F-103 COMMANDER 400 W ARNING MOUNTING OF STUD TYPE DIODES T O ALUMINUM HEA T SINKS Service and repair should be performed by only Lincoln Elec ...
Lincoln Electric COMMANDER 400 SVM133-B - page 158

TROUBLESHOOTING & REP AIR F-104 F-104 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MOUNTING OF STUD TYPE DIODES T O ALUMINUM HEA T SINKS (continued) PROCEDURE 1. T urn the engine off. 2. Perform the SCR/Di ...
Lincoln Electric COMMANDER 400 SVM133-B - page 159

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-105 F-105 COMMANDER 400 W ARNING ENGINE, ST A TOR/ROT OR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric ...
Lincoln Electric COMMANDER 400 SVM133-B - page 160

TROUBLESHOOTING & REP AIR F-106 F-106 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE, ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .49 – FUEL T ANK REMOV AL DET AILS FUEL LEVEL SENS ...
Lincoln Electric COMMANDER 400 SVM133-B - page 161

TROUBLESHOOTING & REP AIR F-107 F-107 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE, ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .50 – REAR P ANEL ASSEMBL Y REMOV AL DET AILS BASE ...
Lincoln Electric COMMANDER 400 SVM133-B - page 162

TROUBLESHOOTING & REP AIR F-108 F-108 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE, ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .52 – SHUTDOWN SOLENOID LEAD REMOV AL PULL-IN COIL ...
Lincoln Electric COMMANDER 400 SVM133-B - page 163

TROUBLESHOOTING & REP AIR F-109 F-109 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE, ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .54 – OIL PRESSURE SENSOR LEAD REMOV AL OIL PRESSU ...
Lincoln Electric COMMANDER 400 SVM133-B - page 164

TROUBLESHOOTING & REP AIR F-110 F-110 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE, ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .56 – ENGINE GROUNDING LEAD ENGINE GROUNDING LEAD ...
Lincoln Electric COMMANDER 400 SVM133-B - page 165

TROUBLESHOOTING & REP AIR F-111 F-111 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE, ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .57 – EXCITER BOARD COVER REMOV AL EXCITER BOARD C ...
Lincoln Electric COMMANDER 400 SVM133-B - page 166

TROUBLESHOOTING & REP AIR F-112 F-112 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE, ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .58 – CONTROL BOARD PLUG J2 LOCA TION PLUG J2 P e ...
Lincoln Electric COMMANDER 400 SVM133-B - page 167

TROUBLESHOOTING & REP AIR F-113 F-113 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE, ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .60 – VERTICAL BAFFLE /ENGINE MOUNT REMOV AL CV CA ...
Lincoln Electric COMMANDER 400 SVM133-B - page 168

TROUBLESHOOTING & REP AIR F-114 F-114 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE, ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .61 – ST A TOR REMOV AL Fan Nut Cap Screws (4) Fan ...
Lincoln Electric COMMANDER 400 SVM133-B - page 169

TROUBLESHOOTING & REP AIR F-115 F-115 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE, ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .62 – BLOWER P ADDLE/FLEX PLA TE REMOV AL ROTOR FL ...
Lincoln Electric COMMANDER 400 SVM133-B - page 170

TROUBLESHOOTING & REP AIR F-116 F-116 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE, ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) LEAD RECONNECTION CHECKLIST Engine ❒ Engine grounding strap ...
Lincoln Electric COMMANDER 400 SVM133-B - page 171

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-117 F-117 COMMANDER 400 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mec ...
Lincoln Electric COMMANDER 400 SVM133-B - page 172

NOTES F-118 F-118 COMMANDER 400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...
Lincoln Electric COMMANDER 400 SVM133-B - page 173

ELECTRICAL DIAGRAMS G-1 G-1 COMMANDER 400 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams Section .......................................................................................... Section G Wiring Diagram - Stick Model (Code 9978) ...................................................... ...
Lincoln Electric COMMANDER 400 SVM133-B - page 174

ELECTRICAL DIAGRAMS G-2 G-2 Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-2 COMMANDER 400 WIRING DIAGRAM - STICK MODEL (CODE 9978) 240 uF 240 uF 240 uF S TATO R ASSEMBL Y RECTIFIER SHUNT 600 AMP CHOKE ...
Lincoln Electric COMMANDER 400 SVM133-B - page 175

ELECTRICAL DIAGRAMS G-3 COMMANDER 400 WIRING DIAGRAM - STICK & WIRE MODEL (CODE 9979) 6 230 MAX. 9 50-575 8 400 MAX. 7 270 MAX. 2 WIRE WELDING CV 5 180 MAX. 4 120 MAX. 3 90 MAX. 1 NO FUNCTION L8910 POSITION NAMEPLATE SETTING FROM BACK) (VIEWED S8 216 5 FINE CONTROL 2 4 6 215 208A POT 3 219 214 A NEG. 220 CW CC 77 77B CV 284B 222 BOARD 284 1 CHO ...
Lincoln Electric COMMANDER 400 SVM133-B - page 176

ELECTRICAL DIAGRAMS G-4 COMMANDER 400 WIRING DIAGRAM - STICK MODEL (CODE 10580) 240 uF 240 uF 240 uF STATOR ASSEMBLY RECTIFIER SHUNT 600 AMP CHOKE OUTPUT SCR A SCR B SCR C G1 G2 G3 G1 G2 G3 1 2 3 6 8 2 3 1 2 3 204S 206S 204S 206S 207 SNUBBER PC BOARD 1 2 3 221 220 219 218 217 216 215 214 213 222 1 2 3 4 5 6 7 8 9 10 213 214 215 216 217 218 219 220 ...
Lincoln Electric COMMANDER 400 SVM133-B - page 177

ELECTRICAL DIAGRAMS G-5 COMMANDER 400 WIRING DIAGRAM - STICK & WIRE MODEL (CODE 10581) 6 230 MAX. 9 50-575 8 400 MAX. 7 270 MAX. 2 WIRE WELDING CV 5 180 MAX. 4 120 MAX. 3 90 MAX. 1 NO FUNCTION POSITION NAMEPLATE SETTING FROM BACK) (VIEWED S8 216 5 FINE CONTROL 2 4 6 215 208A POT 3 219 214 A NEG. 220 CW CC 77 77B CV 284B 222 BOARD 284 1 CHOKE 28 ...
Lincoln Electric COMMANDER 400 SVM133-B - page 178

ELECTRICAL DIAGRAMS G-6 COMMANDER 400 SCHEMA TIC - AMPHENOL BYP ASS PC BOARD WITH PUBLISHED STANDARDS J61 2 80J 150V TP4 80J 150V TP2 80J 150V TP3 J61 8 J61 1 J61 3 J61 4 J61 5 80J 150V TP1 J61 7 3000V .0047 C1 ON 3 PLACE DECIMALS IS + .OO2 TO MOTHER CONTROL PCB .39mH L3 .39mH L2 TO "OUTPUT CONTROL SOURCE" SWITCH 76C 3000V .0047 C4 3000V ...
Lincoln Electric COMMANDER 400 SVM133-B - page 179

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub ...
Lincoln Electric COMMANDER 400 SVM133-B - page 180

ELECTRICAL DIAGRAMS G-8 COMMANDER 400 SCHEMA TIC - AUXILIARY PROTECTION PC BOARD XA 12-15-95 G-8 Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: This diagram is for reference only . It may not be accurate for all machi ...
Lincoln Electric COMMANDER 400 SVM133-B - page 181

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub ...
Lincoln Electric COMMANDER 400 SVM133-B - page 182

ELECTRICAL DIAGRAMS G-10 COMMANDER 400 SCHEMA TIC - BYPASS PC BOARD XA 12-15-95 G-10 Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: This diagram is for reference only . It may not be accurate for all machines covered ...
Lincoln Electric COMMANDER 400 SVM133-B - page 183

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub ...
Lincoln Electric COMMANDER 400 SVM133-B - page 184

ELECTRICAL DIAGRAMS G-12 COMMANDER 400 SCHEMA TIC - CONTROL PC BOARD P ART 1 A485 3-27-97B G-12 Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: This diagram is for reference only . It may not be accurate for all machin ...
Lincoln Electric COMMANDER 400 SVM133-B - page 185

ELECTRICAL DIAGRAMS G-13 COMMANDER 400 SCHEMA TIC - CONTROL PC BOARD P ART 2 G-13 Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: This diagram is for reference only . It may not be accurate for all machines covered by ...
Lincoln Electric COMMANDER 400 SVM133-B - page 186

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub ...
Lincoln Electric COMMANDER 400 SVM133-B - page 187

ELECTRICAL DIAGRAMS G-15 COMMANDER 400 SCHEMA TIC - CV CONTROL PC BOARD +10v 6.81K R17 6.19K R16 50V 0.1 C3 1.00K R11 J21 5 50V 0.1 C2 J21 2 100 R12 10.0K R15 26.7K R18 28.0K R19 X1 7 6 5 .33mH L1 1W 10V DZ2 10K R13 100 R10 D3 J21 6 X1 14 13 12 15.0K R14 J20 6 J20 7 com com com J20 10 EQUIP. 17741 FILE: M17741_1AE NOT SHOW THE EXACT COMPONENTS OR C ...
Lincoln Electric COMMANDER 400 SVM133-B - page 188

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub ...
Lincoln Electric COMMANDER 400 SVM133-B - page 189

ELECTRICAL DIAGRAMS G-17 COMMANDER 400 SCHEMA TIC - ENGINE PROTECTION PC BOARD CONTROL LAMP DRIVER +12V BATT. PCB THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY Ch’ge.Sht.No. TO FUEL TO OIL LVL LED LED TO OIL TEMP LED PRESS LED 10 05-12-95 DR. CAPACITORS = EQUIP. TYPE THE LINCOLN ELECTRIC CO. THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. ...
Lincoln Electric COMMANDER 400 SVM133-B - page 190

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub ...
Lincoln Electric COMMANDER 400 SVM133-B - page 191

ELECTRICAL DIAGRAMS G-19 COMMANDER 400 SCHEMA TIC - METER PC BOARD 7 14 /Q1 CLOCK 1 SET 1 RESET 1 Q1 54HC74 RESET 2 N.C. DATA 1 DATA 2 GND Q2 CLOCK 2 VCC SET 2 X4 10 1 11 4 2 3 6 9 13 12 5 8 X5 13 12 H Q A C Q Q CLK Q Q Q B Q A1 A2 E F G Q R D 74HC164 X1 6 4 2 12 13 1 10 11 8 5 3 9 H Q A C Q Q CLK Q Q Q B Q A1 A2 E F G Q R D 74HC164 X2 6 4 2 12 13 ...
Lincoln Electric COMMANDER 400 SVM133-B - page 192

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub ...
Lincoln Electric COMMANDER 400 SVM133-B - page 193

ELECTRICAL DIAGRAMS G-21 COMMANDER 400 SCHEMA TIC - REMOTE PROTECTION PC BOARD 5 3000V .0047 C1 J60 4 J60 1 J60 6 J60 3 J60 5 J60 2 J61 3 J61 4 3000V .0047 C3 3000V .0047 C4 J61 1 J61 2 J61 6 J61 7 .39mH L4 .39mH L3 .39mH L5 80J 150V TP2 80J 150V TP3 80J 150V TP1 80J 150V TP4 J61 8 J61 5 3000V .0047 C5 .39mH L1 .39mH L2 FRAME FRAME FRAME FRAME FRAM ...
Lincoln Electric COMMANDER 400 SVM133-B - page 194

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub ...
Lincoln Electric COMMANDER 400 SVM133-B - page 195

ELECTRICAL DIAGRAMS G-23 COMMANDER 400 SCHEMA TIC - SNUBBER PC BOARD 1-16-98E G-23 Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: This diagram is for reference only . It may not be accurate for all machines covered by ...
Lincoln Electric COMMANDER 400 SVM133-B - page 196

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub ...
Lincoln Electric COMMANDER 400 SVM133-B - page 197

SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information w ...

Fabricant Lincoln Electric Catégorie Welder

Les documents que nous recevons du fabricant de l'appareilLincoln Electric COMMANDER 400 SVM133-B peuvent être divisés en plusieurs groupes. Ceux-ci sont, entre autres:
- dessins techniques Lincoln Electric
- manuels d’utilisations COMMANDER 400 SVM133-B
- fiches produit Lincoln Electric
- dépliants
- ou étiquettes-énergie Lincoln Electric COMMANDER 400 SVM133-B
Tous sont importants, mais les informations les plus importantes du point de vue de l'utilisation de l'appareil se trouvent dans le manuel d’utilisation Lincoln Electric COMMANDER 400 SVM133-B.

Un groupe de documents appelé manuels d’utilisation est également divisé en types plus spécifiques, tels que: Manuels d’installation Lincoln Electric COMMANDER 400 SVM133-B, manuels d’entretien, brefs manuels ou manuels de l’utilisateur Lincoln Electric COMMANDER 400 SVM133-B. Selon vos besoins, vous devriez chercher le document dont vous avez besoin. Sur notre site, vous pouvez voir le manuel le plus populaire d’utilisation du produit Lincoln Electric COMMANDER 400 SVM133-B.

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Manuel d’utilisation complet de l’appareil Lincoln Electric COMMANDER 400 SVM133-B, quelle devrait-elle être?
Le manuel d’utilisation, également appelé le mode d’emploi, ou tout simplement le manuel, est un document technique destiné à aider à utiliser Lincoln Electric COMMANDER 400 SVM133-B par les utilisateurs. Des manuels sont généralement écrits par un rédacteur technique, mais dans un langage accessible à tous les utilisateurs Lincoln Electric COMMANDER 400 SVM133-B.

Le manuel d’utilisation complet Lincoln Electric, devrait inclure plusieurs éléments de base. Certains d'entre eux sont moins importants, tels que: la couverture / page de titre ou pages d'auteur. Cependant, la partie restante, devrait nous fournir des informations importantes du point de vue de l'utilisateur.

1. Introduction et des conseils sur la façon d'utiliser le manuel Lincoln Electric COMMANDER 400 SVM133-B - Au début de chaque manuel, nous devrions trouver des indices sur la façon d'utiliser le document. Il doit contenir des informations sur l'emplacement de la table des matières Lincoln Electric COMMANDER 400 SVM133-B, FAQ ou des problèmes les plus fréquents - les points qui sont les plus souvent recherchés par les utilisateurs de chaque manuel
2. Table des matières - index de tous les conseils pour lLincoln Electric COMMANDER 400 SVM133-B qui peuvent être trouvés dans le document courant
3. Conseils sur la façon d'utiliser les fonctions de base de l’appareil Lincoln Electric COMMANDER 400 SVM133-B - qui devraient nous aider dans les premières étapes lors de l'utilisation Lincoln Electric COMMANDER 400 SVM133-B
4. Troubleshooting - séquence systématique des activités qui nous aideront à diagnostiquer et ensuite résoudre les principaux problèmes de Lincoln Electric COMMANDER 400 SVM133-B
5. FAQ - questions fréquemment posées
6. Détails du contact Informations sur l'endroit où chercher le contact avec le fabricant / service Lincoln Electric COMMANDER 400 SVM133-B dans un pays donné, si le problème ne peut être résolu par nous-mêmes.

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Manuel d’utilisation Lincoln Electric COMMANDER 400 SVM133-B

Summary

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