Lincoln Electric COMMANDER SVM145-B Instrukcja Użytkownika

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SVM145-B
September, 2002
Safety Depends on You
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 INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
SERVICE MANUAL
For use with machines having Code Numbers: 10469 (Standard),
10470 (Deluxe)
Commander 300
TM
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
View Safety Info View Safety Info View Safety Info View Safety Info
RETURN TO MAIN INDEX
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © 2002 Lincoln Global Inc.
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Podsumowanie treści

Strona 1 - Commander 300

SVM145-BSeptember, 2002Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, your overall

Strona 2 - MAGNETIC FIELDS

LIFTINGThe Commander 300 weighs 1325 lb./601 kg. A lift bailis provided for lifting with a hoist.FALLING EQUIPMENT can cause injury.Do not lift this

Strona 3 - FUMES AND GASES

TROUBLESHOOTING & REPAIRF-44 F-44COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 4

TROUBLESHOOTING & REPAIRF-45 F-45COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 5 - REDRESSEUR

TABLE F.1.RF BY-PASS RESISTANCE TABLECHECK POINTS COMPONENT BEING MAXIMUM ALLOWABLECHECKED RESISTANCE1J61 to 5J60 L4 and Board Trace 4.2 OHMS (3.5 Typ

Strona 6

TROUBLESHOOTING & REPAIRF-47 F-47COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 7 - - INSTALLATION SECTION

TROUBLESHOOTING & REPAIRF-48 F-48COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 8

TROUBLESHOOTING & REPAIRF-49 F-49COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 9

NOTESF-50 F-50COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Strona 10 - INSTALLATION

TROUBLESHOOTING & REPAIRF-51 F-51COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 11

TROUBLESHOOTING & REPAIRF-52 F-52COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 12

TROUBLESHOOTING & REPAIRF-53 F-53COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 13

OILThe Commander 300 is shipped with theengine crankcase filled with high qualitySAE 1OW-30 oil (API class CD or better).CHECK THE OIL LEVEL BEFORE YO

Strona 14

TROUBLESHOOTING & REPAIRF-54 F-54COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 15

TROUBLESHOOTING & REPAIRF-55 F-55COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 16 - A-10 A-10

TROUBLESHOOTING & REPAIRF-56 F-56COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 17 - - OPERATION SECTION

TROUBLESHOOTING & REPAIRF-57 F-57COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 18 - OPERATION

TROUBLESHOOTING & REPAIRF-58 F-58COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 19

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Strona 20

TROUBLESHOOTING & REPAIRF-60 F-60COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 21

TROUBLESHOOTING & REPAIRF-61 F-61COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 22

NOTESF-62 F-62COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Strona 23

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Strona 24

HIGH FREQUENCY GENERATORSFOR TIG APPLICATIONSThe K799 Hi-Freq Unit and the K930-1 or –2 TIGModule can be used with the Commander 300. Themachine is e

Strona 25

TROUBLESHOOTING & REPAIRF-64 F-64COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 26

TROUBLESHOOTING & REPAIRF-65 F-65COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 27

TROUBLESHOOTING & REPAIRF-66 F-66COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 28 - B-12 B-12

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Strona 29 - - ACCESSORIES

TROUBLESHOOTING & REPAIRF-68 F-68COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 30 - ACCESSORIES

TROUBLESHOOTING & REPAIRF-69 F-69COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 31

NOTESF-70 F-70COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Strona 32

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Strona 33

TROUBLESHOOTING & REPAIRF-72 F-72COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 34

TROUBLESHOOTING & REPAIRF-73 F-73COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 35

WELDING CABLE CONNECTIONSCABLE INSTALLATION, POLARITY CONTROL,AND CABLE SIZESWith the engine off, route the electrode and workcables through the strai

Strona 36

TROUBLESHOOTING & REPAIRF-74 F-74COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 37

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Strona 38 - C-10 C-10

TROUBLESHOOTING & REPAIRF-76 F-76COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 39 - -MAINTENANCE

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Strona 40 - MAINTENANCE

TROUBLESHOOTING & REPAIRF-78 F-78COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 41

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Strona 42

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Strona 43

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Strona 45

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Strona 46

MACHINE GROUNDINGBecause this portable engine-driven welder creates itsown power, you do not need to connect the machineframe to an earth ground, unle

Strona 47

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Strona 48 - D-10 D-10

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Strona 49 - -THEORY OF OPERATION SECTION

TROUBLESHOOTING & REPAIRF-86 F-86COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 50 - THEORY OF OPERATION

TROUBLESHOOTING & REPAIRF-87 F-87COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 51

TROUBLESHOOTING & REPAIRF-88 F-88COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

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TROUBLESHOOTING & REPAIRF-89 F-89COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 53

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

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Strona 55

TROUBLESHOOTING & REPAIRF-92 F-92COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 56

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Strona 57

INSTALLATIONA-9 A-9COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to

Strona 58

TROUBLESHOOTING & REPAIRF-94 F-94COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 59

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Strona 60

TROUBLESHOOTING & REPAIRF-96 F-96COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 61

TROUBLESHOOTING & REPAIRF-97 F-97COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 62

TROUBLESHOOTING & REPAIRF-98 F-98COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 63

TROUBLESHOOTING & REPAIRF-99 F-99COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 64

TROUBLESHOOTING & REPAIRF-100 F-100COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

Strona 65

TROUBLESHOOTING & REPAIRF-101 F-101COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

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TROUBLESHOOTING & REPAIRF-102 F-102COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

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TROUBLESHOOTING & REPAIRF-103 F-103COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

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NOTESA-10 A-10COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Strona 69

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Strona 70

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Strona 71

COMMANDER 300G-1ELECTRICAL DIAGRAMSG-1TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION-ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . .

Strona 72

G-2ELECTRICAL DIAGRAMSCOMMANDER 300WIRING DIAGRAM - COMMANDER 300 DELUXE MODELMOTORSTART BUTTONSTARTERSOLENOIDALTERNATORSTARTINGÍÍ214215216217218219

Strona 73

G-3ELECTRICAL DIAGRAMSCOMMANDER 300WIRING DIAGRAM - COMMANDER 300 STANDARD MODELG-3Return to Section TOC Return to Section TOC Return to Section TOC R

Strona 74

G-4ELECTRICAL DIAGRAMSCOMMANDER 300G-4Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

Strona 75

G-5ELECTRICAL DIAGRAMSCOMMANDER 300PC BOARD ASSEMBLY - CONTROL BOARD G-5Return to Section TOC Return to Section TOC Return to Section TOC Retu

Strona 76

COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return t

Strona 77

COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return t

Strona 78

COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return t

Strona 79

Section B-1 Section B-1COMMANDER 300TABLE OF CONTENTS- OPERATION SECTION -Operation...

Strona 80 - Do not operate with

COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return t

Strona 81

COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return t

Strona 82 - F-26 F-26

COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return t

Strona 83

COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return t

Strona 84

COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return t

Strona 85

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

Strona 86

OPERATING INSTRUCTIONSRead and understand this entire section before operat-ing your Commander 300. SAFETY INSTRUCTIONSDo not attempt to use this equi

Strona 87

GENERAL DESCRIPTIONThe Commander 300 is a diesel engine-driven weldingpower source. The machine uses a brush type alter-nating current generator for

Strona 88

SAFETYi iCOMMANDER 300FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requ

Strona 89

ADDITIONAL DESIGN FEATURES• Deutz 3-cylinder, air/oil cooled diesel engine.Designed for long life, easy maintenance, and excel-lent fuel economy. •

Strona 90

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Strona 91

OPERATIONB-6 B-6COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

Strona 92 - F-36 F-36

10. DIGITAL OUTPUT METER: The digital outputmeters are located in the center of the controlpanel between the two large control knobs. Themeters allo

Strona 93

“WIRE WELDING” mode: In this mode increasing thenumber from 1 to 10 changes the arc from soft andwashed-in to crisp and narrow. It acts as an induc-t

Strona 94

Using your welder at low amperages with long idle run-ning periods during the break-in period may result in aglaze forming on the engine cylinder wall

Strona 95

COMMANDER 300 SETTINGS WHEN USING THEK799 HL-FREQ UNITa. Set the SELECTOR switch to the “30-375” setting(STICK/TIG). b. Set the IDLER switch to the “

Strona 96

WIRE FEED (CONSTANT VOLTAGE)WELDINGConnect a wire feeder to the Commander 300 and setwelder controls according to the instructions listed ear-lier in

Strona 97

NOTESB-12 B-12COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Strona 98 - F-42 F-42

TABLE OF CONTENTS- ACCESSORIES -Accessories...

Strona 99

SAFETYii iiCOMMANDER 300ARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the

Strona 100 - TROUBLESHOOTING & REPAIR

OPTIONS/ACCESSORIESThe following options/accessories are available foryour Commander 300 from your local LincolnDistributor.FIELD INSTALLED OPTIONSK80

Strona 101

SEMIAUTOMATIC WELDING ACCESSORIESLN-7 OR LN-8 WIRE FEEDERS - Semiautomatic, con-stant speed wire feeders. For CV operation only.LN-23P WIRE FEEDER -

Strona 102

CONNECTION OF THE LN-7 TO THE COMMANDER 300 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1.)1. Shut the welder off. 2. Connect the electrode cable from

Strona 103

ACCESSORIESC-5 C-5COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Strona 104

ACCESSORIESC-6 C-6COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Strona 105

CONNECTION OF THE LN-8 TO THE COMMANDER 300 USING K595 INPUTCABLE ASSEMBLY (SEE FIGURE C.4.) 1. Shut the welder off.2. Connect the electrode cable fr

Strona 106 - COMMANDER 300

CONNECTION OF THE LN-23P TO THECOMMANDER 300 USING K350-1ADAPTER (SEE FIGURE C.5.)1. Shut the welder off.2. Connect the electrode cable from the LN-23

Strona 107

CONNECTION OF THE LN-25 TO THE COMMANDER 300 “ACROSS THE ARC”(SEE FIGURE C.6.) 1. Shut the welder off.2. Connect the electrode cable from the LN-25 t

Strona 108

NOTESC-10 C-10COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Strona 109

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection D-1 Section D-1COMMANDER 300TABLE OF CONTENTS-MAINTENANCE-M

Strona 110

COMMANDER 300FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b

Strona 111

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

Strona 112

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

Strona 113

FUEL FILTER: When working on the fuel system:• Keep naked lights away.• Do not smoke !• Do not spill fuel !Inspect the fuel filter daily. Replace the

Strona 114

COOLING BLOWER BELT: The following procedureshould be followed to replace the cooling blower belt: 1. Allow the machine to cool. 2. Remove the engin

Strona 115

TABLE D.1DEUTZ ENGINE MAINTENANCE SCHEDULEFREQUENCY MAINTENANCE REQUIREDDaily or Before • Fill fuel tank.Starting Engine • Check oil level.• Check

Strona 116

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

Strona 117

WELDER/GENERATOR MAINTENANCESTORAGE: Store the Commander 300 in clean, dry,protected areas.CLEANING: Blow out the generator and controls peri-odicall

Strona 118 - F-62 F-62

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Strona 119

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Strona 120 - Pin 7 (+)

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection E-1 Section E-1COMMANDER 300Theory of Operation ...

Strona 121

SAFETYiv ivCOMMANDER 300PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifi

Strona 122

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Strona 123

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Strona 124

THEORY OF OPERATIONE-4 E-4COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Ret

Strona 125

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Strona 126 - F-70 F-70

COMMANDER 300PULSE WIDTH MODULATIONThe term PULSE WIDTH MODULATION is used todescribe how much time is devoted to conduction in thecycle. Changing th

Strona 127

CHOPPER TECHNOLOGYFUNDAMENTALSThe new era of welding machines such as theCommander 300, employ a technology whereby a DCsource is turned on and off (c

Strona 128 - Plug J13

NOTESE-8 E-8COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

Strona 129

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection F-1 Section F-1COMMANDER 300Troubleshooting & Repair Se

Strona 130 - PWM OUTPUT TEST (continued)

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Strona 131

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Strona 132

MASTER TABLE OF CONTENTS FOR ALL SECTIONSv vCOMMANDER 300PageSafety...

Strona 133

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Strona 134

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Strona 135

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Strona 136

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Strona 137

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Strona 138

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Strona 139

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Strona 140 - F-84 F-84

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Strona 141

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Strona 142

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Strona 143

TABLE OF CONTENTS- INSTALLATION SECTION -Section A-1 Section A-1COMMANDER 300Installation ...

Strona 144

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Strona 145

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Strona 146 - F-90 F-90

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Strona 147

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Strona 148

TROUBLESHOOTING & REPAIRF-18 F-18COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 149

TROUBLESHOOTING & REPAIRF-19 F-19COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 150

TROUBLESHOOTING & REPAIRF-20 F-20COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 151

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Strona 152

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Strona 153 - PLUG J30

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Strona 154

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Strona 155

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Strona 156

INSTALLATIONF-25 F-25COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

Strona 157

NOTESF-26 F-26COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Strona 158

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Strona 159

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Strona 160

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Strona 161 - F-105 F-105

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Strona 162 - ELECTRICAL DIAGRAMS

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Strona 163

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Strona 164

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Strona 165

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

Strona 166

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Strona 167

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Strona 168

NOTESF-36 F-36COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Strona 169

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Strona 170

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Strona 171

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Strona 172

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Strona 173

TROUBLESHOOTING & REPAIRF-41 F-41COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

Strona 174

NOTESF-42 F-42COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Strona 175 - SVM ERROR REPORTING FORM

TROUBLESHOOTING & REPAIRF-43 F-43COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

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