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Lincoln Electric SVM153-A manual

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Table of contents for the manual

  • Page 1

    SVM153-A 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 NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANU AL AND THE SAFETY PR[...]

  • Page 2

    CALIFORNIA PROPOSITION 65 W ARNINGS i i SAFETY 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. [...]

  • Page 3

    ii ii SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. U[...]

  • Page 4

    iii iii SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 manufactu[...]

  • Page 5

    iv iv SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 [...]

  • Page 6

    v v - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - COMMANDER 500 Page Safety .................................................................................................................................................i-iv Installation ..............................................................................................................[...]

  • Page 7

    Installation ................................................................................................................... ..........Section A T echnical Specifications ..............................................................................................................A-2 Safety Precautions ..........................................[...]

  • Page 8

    A-2 A-2 INST ALLA TION COMMANDER 500 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 TECHNICAL SPECIFICA TIONS - COMMANDER 500 (K1639-1 & -2) Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz[...]

  • 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 operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. EL[...]

  • Page 10

    LIFTING The Commander lift bale should be used to lift the machine. The Commander is shipped with the lift bale retracted. Before attempting to lift the Commander , secure the lift bale in a raised position. Secure the lift bale as follows: a. Open the engine compartment door . b. Locate the two access holes on the upper mid- dle region of the comp[...]

  • Page 11

    A-5 A-5 INST ALLA TION COMMANDER 500 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 PRE-OPERA TION ENGINE SER VICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep hands away from [...]

  • Page 12

    IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster Use correct polarity — Negative Ground. The Commander is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the neg- ati[...]

  • Page 13

    WELDING OUTPUT CABLES With the engine off, route the electrode and work cables through the strain relief bracket provided on the front of the base and connect to the terminals provided. These connections should be checked periodically and tightened if necessary . Listed in T able A.1 are copper cable sizes recommend- ed for the rated current and du[...]

  • Page 14

    1. Install the double-pole, double-throw switch between the power company meter and the premises disconnect. Switch rating must be the same or greater than the cus- tomer ’s premises disconnect and service over current protection. 2. T ake necessary steps to assure load is limited to the capacity of the Commander by installing a 50 amp, 240 V AC [...]

  • Page 15

    Operation ............................................................................................................................... Section B Operating Instructions ......................................................................................................... ........B-2 Safety Instructions .........................................[...]

  • Page 16

    B-2 B-2 OPERA TION COMMANDER 500 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 TING INSTRUCTIONS Read and understand this entire section before operat- ing your Commander 500. SAFETY INSTRUCTIONS Do not attempt to use [...]

  • Page 17

    RECOMMENDED APPLICA TIONS WELDER The Commander 500 provides excellent constant cur- rent DC welding output for stick (SMA W) and TIG weld- ing. The Commander 500 also provides excellent con- stant voltage DC welding output for MIG (GMA W) and Innershield (FCA W) welding. GENERA TOR The Commander 500 provides smooth 120/240 V AC output for auxiliary[...]

  • Page 18

    K1639-1 COMMANDER 500 ST ANDARD MODEL • The K1639-1 is the standard version of the Commander 500 and has all the features of the K1639-2 Deluxe version except that there are no gauges, low fuel light, nor dual output meters. This version does have fully functional engine protection for low oil pressure, high oil temperature, and alter- nator outp[...]

  • Page 19

    ENGINE CONTROLS (Items 1 through 8) 1. RUN/STOP SWITCH When placed in the RUN position, this switch energizes the fuel solenoid and other electric accessories. When placed in the STOP position, the flow of fuel to the injection pump is stopped to shut down the engine. NOTE: If the switch is left in the RUN position and the engine is not running, th[...]

  • Page 20

    Idler Operational Exceptions When the WELDING TERMINALS switch is in the “Welding T erminals Remotely Controlled” position, the idler will operate as follows: a. When the triggering device (Amptrol, Arc Start Switch, etc.) is pressed, the engine will accelerate and operate at full speed provided a welding load is applied within approximately 15[...]

  • Page 21

    12. 6 - PIN CONNECTOR (AMPHENOL) The 6-pin amphenol located on the control panel allows for connection of interfacing equipment. 13. WELD OUTPUT TERMINALS + AND - These 1/2 - 13 studs with flange nuts provide welding connection points for the electrode and work cables. For positive polarity welding, the electrode cable con- nects to the “+” ter[...]

  • Page 22

    ENGINE OPERA TION ST ARTING THE ENGINE 1. Open the engine compartment door and check that the fuel shutoff valve located to the left of the fuel fil- ter housing is in the open position (lever to be in line with the hose). 2. Check for proper oil level on the oil dipstick. Close engine compartment door . 3. Remove all plugs connected to the AC powe[...]

  • Page 23

    T able B.2 – DEUTZ F3L 912 ENGINE FUEL CONSUMPTION Deutz F3L 912 Running Time 44.2 Hp for 25 gallons @ 1800 RPM (Hours) Low Idle - No .47 gallons/hour 53.2 Load 1475 RPM (1.77 liters/hour) High Idle - No .66 gallons/hour 37.9 Load 1900 RPM (2.50 liters/hour) DC CC Weld 1.94 gallons/hour 12.9 Output 500 (7.34 liters/hour) Amps @ 40 V olts Auxiliar[...]

  • Page 24

    COMMANDER 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the 20-250 setting (TIG). • Set the IDLER switch to the HIGH position. • Set the WELDING TERMINALS switch to the WELD TERMINALS ON position. This will close the solid state contactor and provide an always “hot” electrode. NOTE: This is necessary because [...]

  • Page 25

    WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the Commander 500 and set welder controls according to the instructions listed ear- lier in this section. The Commander 500 in the CV -WIRE position can be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal ar[...]

  • Page 26

    B-12 B-12 OPERA TION COMMANDER 500 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 B.4 – COMMANDER 500 SIMUL T ANEOUS WELDING AND POWER LOADS Permissible Permissible Auxiliary Welding Power - W atts Current in Amperes[...]

  • Page 27

    Accessories .................................................................................................................... ......Section C Options/Accessories ...................................................................................................................C-2 Field Installed Options ..........................................[...]

  • Page 28

    OPTIONS/ACCESSORIES The following options/accessories are available for your Commander 500 from your local Lincoln Distributor . FIELD INST ALLED OPTIONS K802N POWER PLUG KIT - Provides a plug for each receptacle. K857 25 ft. (8.5 m) or K857-1 100 ft. (30.4 m) REMOTE CONTROL - Portable control provides same dial range as the output control on the w[...]

  • Page 29

    SEMIAUT OMA TIC WELDING ACCESSORIES LN-7 OR LN-8 WIRE FEEDERS - Semiautomatic, con- stant speed wire feeders. For CV operation only . LN-23P WIRE FEEDER - This portable wire feeder is capable of CV operation. K350-1 Adapter Kit is required. LN-25 WIRE FEEDER - The LN-25 with or without an external contactor may be used with the Commander 300. NOTE:[...]

  • Page 30

    CONNECTION OF THE LN-7 TO THE COMMANDER 500 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-7 to the “+” terminal of the welder . Connect the work cable to the “-” terminal of the welder . NOTE: Welding cable must be sized for current and duty cycle of application. NOTE: Figu[...]

  • Page 31

    C-5 C-5 ACCESSORIES COMMANDER 500 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-7 TO THE COMMANDER 500 USING K584 OR K594 INPUT CABLE ASSEMBL Y (SEE FIGURE C.2.) 1. Shut the welder off. 2. Connect the el[...]

  • Page 32

    C-6 C-6 ACCESSORIES COMMANDER 500 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 500 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.3.) 1. Shut the welder off. 2. Connect the electrode cabl[...]

  • Page 33

    C-7 C-7 ACCESSORIES COMMANDER 500 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 500 USING K595 INPUT CABLE ASSEMBL Y (SEE FIGURE C.4.) 1. Shut the welder off. 2. Connect the electrode [...]

  • Page 34

    C-8 C-8 ACCESSORIES COMMANDER 500 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-23P TO THE COMMANDER 500 USING K350-1 ADAPTER (SEE FIGURE C.5.) 1. Shut the welder off. 2. Connect the electrode cable fr o[...]

  • Page 35

    C-9 C-9 ACCESSORIES COMMANDER 500 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-25 TO THE COMMANDER 500 “ ACROSS THE ARC ” (SEE FIGURE C.6.) 1. Shut the welder off. 2. Connect the electrode cable fro[...]

  • Page 36

    Maintenance .................................................................................................................... ......Section D Safety Precautions ............................................................................................................. .........D-2 Routine and Periodic Maintenance ..............................[...]

  • Page 37

    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[...]

  • Page 38

    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 tem- peratures, change the oil filter more frequently . See T able D.1 for recommended mai[...]

  • Page 39

    FUEL FIL TERS: When working on the fuel system: • Keep naked lights away , do not smoke ! • Do not spill fuel ! The Commander 500 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 Separator [...]

  • Page 40

    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[...]

  • Page 41

    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[...]

  • Page 42

    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[...]

  • Page 43

    D-8 D-8 MAINTENANCE COMMANDER 500 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[...]

  • Page 44

    BA TTER Y MAINTENANCE GASES FROM BA TTERY can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • Wear 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 TTERY - Disconne[...]

  • Page 45

    WELDER/GENERA TOR MAINTENANCE STORAGE: Store the Commander 500 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. NAMEPLA TES: Whenever routine maintenance is performed on this machine - or at least yearly - inspect all namep[...]

  • Page 46

    D-11 D-11 MAINTENANCE COMMANDER 500 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 12 10 8 7 9 6 5 4 3 2 1 11 FIGURE D.5 – MAJOR COMPONENT LOCA TIONS 1. CASE DOOR ASSEMBL Y 2. ENGINE 3. SHUT DOWN SOLENOID 4. IDLER SOLENOID [...]

  • Page 47

    General Description .......................................................................................................................E-2 Battery , Starter , Engine, Rotor , Stator , Pull Coil Board and Peripheral Board – Engine Protection .....................................................................................................E-[...]

  • Page 48

    GENERAL DESCRIPTION The Commander 500 is a diesel engine-driven welding power source capable of producing 500 amps at 40VDC at a 100% duty cycle. The engine is coupled to a brush-type alternating current generator . This AC output is rectified and controlled by Chopper T echnology to produce DC current for multi-purpose welding applications. The Co[...]

  • Page 49

    WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK The three-phase stator weld windings are connected to a three-phase rectifier bridge. The resultant DC volt- age is applied to four paralleled capacitors incorporat- ed within each of the two power modules. There are two capacitors in each module. These capacitors func- tion as filters and also a[...]

  • Page 50

    ANALOG CONTROL POWER SUPPL Y BOARD AND WELD CONTROL BOARD The Analog Power Supply PC board, which is powered by 80 VDC derived from the filter capacitors on the Power Modules, supplies various regulated DC volt- ages to operate the Weld Control PC board circuitry . It also supplies two regulated DC voltages to operate the IGBT driver circuitry on t[...]

  • Page 51

    INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT s are semicon- ductors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow . The drain terminal of the[...]

  • Page 52

    PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION is used to describe how much time is devoted to conduction in the cycle. Changing the pulse width is known as MODU- LA TION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine. MINIMUM OUTPUT By controlling the [...]

  • Page 53

    CHOPPER TECHNOLOGY FUNDAMENT ALS The new era of welding machines such as the Commander 500, employ a technology whereby a DC source is turned on and off (chopped up) at high speed, then smoothed through an inductor to control an arc. Hence the name “ Chopper . ” The biggest advantage of chopper technology is the high-speed control of the arc, s[...]

  • Page 54

    Tr oubleshooting & Repair Section ......................................................................................Section F How to Use T roubleshooting Guide ...........................................................................................F-2 PC Board T roubleshooting Procedures ..................................................[...]

  • Page 55

    This T roubleshooting Guide is provided to help you locate and repair possible machine malfunc- tions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “ PROBLEM ” (SYMP- TOMS). This column describes possible symp- toms that the machine may exhibit. Find the list- ing that be[...]

  • Page 56

    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 machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting an[...]

  • Page 57

    Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 58

    TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 59

    Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 60

    TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 61

    Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 62

    TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 63

    Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 64

    TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 65

    Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 66

    TROUBLESHOOTING & REP AIR F-13 COMMANDER 500 ENGINE ST ARTING DIAGNOSTIC CHART F-13 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 Does the PULL COIL read .3 ohms? Is there FUEL? Did 1 of the W ARNING lights come on? Is t[...]

  • 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-14 COMMANDER 500 ST ART -UP AND OCV DIAGNOSTIC CHART F-14 No LOW IDLE. Is AUX current flowing? TWO displays illuminated? Is WELD current flowing? [...]

  • Page 68

    TROUBLESHOOTING & REP AIR F-15 F-15 COMMANDER 500 CASE COVER REMOV AL AND REPLACEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty [...]

  • Page 69

    TROUBLESHOOTING & REP AIR F-16 F-16 COMMANDER 500 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 PROP R OD LEFT FRONT P ANEL RIGHT FRONT P ANEL DOOR ASSEMBL Y ROUND HEAD SCREW LOCA TION FIGURE F .1 – COVER REMOV AL CASE[...]

  • Page 70

    TROUBLESHOOTING & REP AIR F-17 F-17 COMMANDER 500 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 FRONT CONTROL P ANEL SCREWS SCREW FIGURE F .2 – FRONT P ANEL/ROOF DET AILS CASE COVER REMOV AL AND REPLACEMENT PROCEDURE ([...]

  • Page 71

    TROUBLESHOOTING & REP AIR F-18 F-18 COMMANDER 500 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 CASE FRONT KNOBS - REMOV AL AND REPLACEMENT PROCEDURE Replacement Removal Flat Rounded Replacement:  1. If the white n[...]

  • Page 72

    TROUBLESHOOTING & REP AIR F-19 F-19 COMMANDER 500 POWER MODULE CAP ACITOR DISCHARGE PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . [...]

  • Page 73

    TROUBLESHOOTING & REP AIR F-20 F-20 COMMANDER 500 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 POWER MODULE CAP ACITOR TERMINALS FIGURE F .4 – POWER MODULE CAP ACITOR TERMINAL DISCHARGE POWER MODULE CAP ACITOR DISCHAR[...]

  • Page 74

    TROUBLESHOOTING & REP AIR F-21 F-21 COMMANDER 500 IDLER SOLENOID TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to a[...]

  • Page 75

    TROUBLESHOOTING & REP AIR F-22 F-22 COMMANDER 500 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 PULL-IN COIL (LARGER TERMINALS TOP AND BOTTOM #227 AND #232L) HOLD-IN COIL (SMALLER TERMINALS TOP AND BOTTOM #226A AND #232S[...]

  • Page 76

    TROUBLESHOOTING & REP AIR F-23 F-23 COMMANDER 500 SHUTDOWN SOLENOID TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and t[...]

  • Page 77

    TROUBLESHOOTING & REP AIR F-24 F-24 COMMANDER 500 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 PULL-IN COIL (LARGER TERMINALS EACH SIDE #232M AND #265) HAND-IN COIL (SMALLER TERMINALS EACH SIDE #224 AND #262) SHUTDOWN S[...]

  • Page 78

    TROUBLESHOOTING & REP AIR F-25 F-25 COMMANDER 500 ENGINE THROTTLE ADJUSTMENT TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your saf[...]

  • Page 79

    TROUBLESHOOTING & REP AIR F-26 F-26 COMMANDER 500 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 MARK BLOWER P ADDLE HERE FIGURE F .7 – STROBE MARK LOCA TION ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) TEST PROCEDURE St[...]

  • Page 80

    TROUBLESHOOTING & REP AIR F-27 F-27 COMMANDER 500 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 THROTTLE ADJUSTMENT TEST (CONTINUED) FIGURE F .8 – HIGH IDLE ADJUSTMENT BOSCH 5 7 0 0 8 1 6 903 PES 3A 80D 410/3R 0[...]

  • Page 81

    TROUBLESHOOTING & REP AIR F-28 F-28 COMMANDER 500 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 THROTTLE ADJUSTMENT TEST (CONTINUED) 6. If either of the readings is incorrect, adjust the throttle as follows: Adjus[...]

  • Page 82

    TROUBLESHOOTING & REP AIR F-29 F-29 COMMANDER 500 ROT OR RESIST ANCE TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and [...]

  • Page 83

    TROUBLESHOOTING & REP AIR F-30 F-30 COMMANDER 500 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 SLIP RINGS BRUSH HOLDER ASSEMBL Y ACCESS P ANEL FIGURE F .10 – ROTOR BRUSH LEADS ROT OR RESIST ANCE TEST (CONTINUED) TEST [...]

  • Page 84

    TROUBLESHOOTING & REP AIR F-31 F-31 COMMANDER 500 FLASHING AND ROTOR VOL T AGE TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your s[...]

  • Page 85

    TROUBLESHOOTING & REP AIR F-32 F-32 COMMANDER 500 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 PLUG P/J52 LEAD # 200A LEAD # 201A PLUG P/J52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 FIL TER CAP ACITOR FIELD DIODE RECTIFIE[...]

  • Page 86

    TROUBLESHOOTING & REP AIR F-33 F-33 COMMANDER 500 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 FIL TER CAP ACITOR FIELD DIODE RECTIFIER BRIDGE FIGURE F .12 - FIELD DIODE RECTIFIER BRIDGE AND FIL TER CAP ACITOR FLASHING [...]

  • Page 87

    TROUBLESHOOTING & REP AIR F-34 F-34 COMMANDER 500 ST A TOR VOL T AGE TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and [...]

  • Page 88

    TROUBLESHOOTING & REP AIR F-35 F-35 COMMANDER 500 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 FRONT CONTROL P ANEL SCREWS SCREW FIGURE F .13 – FRONT CONTROL P ANEL REMOV AL ST A TOR VOL T AGE TEST (CONTINUED) TEST PR[...]

  • Page 89

    TROUBLESHOOTING & REP AIR F-36 F-36 COMMANDER 500 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 GREEN GROUND LEAD OUTPUT P ANEL SCREWS OUTPUT LEADS (BEHIND P ANEL) FIGURE F .14 – OUTPUT P ANEL REMOV AL ST A TOR VOL T A[...]

  • Page 90

    TROUBLESHOOTING & REP AIR F-37 F-37 COMMANDER 500 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 AUXILIAR Y LEADS #5B, #5E, #8, #9, #1 1, #12 (BEHIND P ANEL) FIGURE F .15 – AUXILIAR Y LEAD TEST LOCA TION ST A TOR VOL T [...]

  • Page 91

    TROUBLESHOOTING & REP AIR F-38 F-38 COMMANDER 500 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 LEAD CONNECTIONS W6 W2 W4 W1 W3 W5 FIGURE F .16 – OUTPUT RECTIFIER DIODE BRIDGE ST A TOR VOL T AGE TEST (CONT[...]

  • Page 92

    TROUBLESHOOTING & REP AIR F-39 F-39 COMMANDER 500 ANALOG POWER SUPPL Y PC BOARD VOL T AGE TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .[...]

  • Page 93

    TROUBLESHOOTING & REP AIR F-40 F-40 COMMANDER 500 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 CIRCUIT INPUT POWER 13 1J41 to POS TERMINAL ON C2 - 85V SUPPL Y J41 J42 14 2J41 to NEG TERMINAL ON C2 - 85V SUPPL Y [...]

  • Page 94

    TROUBLESHOOTING & REP AIR F-41 F-41 COMMANDER 500 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 F .1 ANALOG CONTROL POWER SUPPL Y PC BOARD VOL T AGE T ABLE T est Points Component T ested V oltage Reading 1J42 to 6[...]

  • Page 95

    TROUBLESHOOTING & REP AIR F-42 F-42 COMMANDER 500 OUTPUT RECTIFIER BRIDGE TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety[...]

  • Page 96

    TROUBLESHOOTING & REP AIR F-43 F-43 COMMANDER 500 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 FRONT CONTROL P ANEL SCREW SCREWS FIGURE F .18 – FRONT CONTROL P ANEL REMOV AL OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) TE[...]

  • Page 97

    TROUBLESHOOTING & REP AIR F-44 F-44 COMMANDER 500 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 GREEN GROUND LEAD OUTPUT P ANEL SCREWS OUTPUT LEADS (BEHIND P ANEL) FIGURE F .19 – OUTPUT P ANEL REMOV AL OUTPUT RECTIFIER[...]

  • Page 98

    TROUBLESHOOTING & REP AIR F-45 F-45 COMMANDER 500 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 LEAD CONNECTIONS W6 W2 W4 W1 W3 W5 FIGURE F .20 – DIODE LEAD REMOV AL OUTPUT RECTIFIER BRIDGE TEST (CONTINUED[...]

  • Page 99

    TROUBLESHOOTING & REP AIR F-46 F-46 COMMANDER 500 POWER MODULE TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avo[...]

  • Page 100

    TROUBLESHOOTING & REP AIR F-47 F-47 COMMANDER 500 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 W10 W9 DIODE LEAD D4 TEMPERA TURE SWITCH POWER MODULE PC BOARD POSITIVE (+) STRAP POSITIVE (+) STRAP FIGURE F .21 – POWER [...]

  • Page 101

    TROUBLESHOOTING & REP AIR F-48 F-48 COMMANDER 500 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 HEA T SINK POSITIVE (+) CAP ACITOR TERMINAL CONNECTIONS FIGURE F .22 – IGBT TEST POWER MODULE TEST (CONTINUED) Check IGBT [...]

  • Page 102

    TROUBLESHOOTING & REP AIR F-49 F-49 COMMANDER 500 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 DIODE MODULE TERMINALS HEA T SINK FIGURE F .23 – DIODE MODULE TEST POWER MODULE TEST (CONTINUED) Check Diode Module 9. Usi[...]

  • Page 103

    TROUBLESHOOTING & REP AIR F-50 F-50 COMMANDER 500 CHARGING CIRCUIT TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to[...]

  • Page 104

    TROUBLESHOOTING & REP AIR F-51 F-51 COMMANDER 500 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 #239 #281 #238 FIGURE F .24 – ENGINE AL TERNA TOR LOCA TION CHARGING CIRCUIT TEST (CONTINUED) TEST PROCEDURE 1. T urn engi[...]

  • 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-52 F-52 COMMANDER 500 This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division r[...]

  • 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-53 F-53 COMMANDER 500 This is the typical DC open circuit out- put voltage generated from a properly operating machine. Note that each vertical di[...]

  • Page 107

    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-54 F-54 COMMANDER 500 This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represen[...]

  • Page 108

    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-55 F-55 COMMANDER 500 NORMAL WELD VOL T AGE W A VEFORM (WIRE CV) MACHINE LOADED TO 500 AMPS A T 40 VOL TS This is the typical DC output voltage ge[...]

  • Page 109

    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-56 F-56 COMMANDER 500 This is the typical TIG MODE output voltage generated from a properly operating machine. Note that each vertical division re[...]

  • Page 110

    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-57 F-57 COMMANDER 500 This is the typical DC open circuit output voltage generated from a properly operating machine. Note that each vertical divi[...]

  • Page 111

    TROUBLESHOOTING & REP AIR F-58 F-58 COMMANDER 500 SHUTDOWN SOLENOID REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . F[...]

  • Page 112

    TROUBLESHOOTING & REP AIR F-59 F-59 COMMANDER 500 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 PULL-IN COIL (LARGER TERMINALS EACH SIDE #232M AND #265) HOLD-IN COIL (SMALLER TERMINALS EACH SIDE #224 AND #262) SHUTDOWN S[...]

  • Page 113

    TROUBLESHOOTING & REP AIR F-60 F-60 COMMANDER 500 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 PIVOT PIN SP ACER W ASHER PLAIN W ASHER RET AINING RING MOUNTING F ASTENERS FIGURE F . 26 – SHUTDOWN SOLENOID LINKAGE ARM [...]

  • Page 114

    TROUBLESHOOTING & REP AIR F-61 F-61 COMMANDER 500 POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalid[...]

  • Page 115

    TROUBLESHOOTING & REP AIR F-62 F-62 COMMANDER 500 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 FRONT CONTROL P ANEL SCREWS SCREW GREEN GROUND LEAD F .27 – CONTROL P ANEL REMOV AL POWER MODULE/OUTPUT RECTIFIER BRIDGE A[...]

  • Page 116

    TROUBLESHOOTING & REP AIR F-63 F-63 COMMANDER 500 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 REMOVE LEADS POWER MODULE FIGURE F . 28 – POWER MODULE CAP ACITOR LEAD REMOV AL POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEM[...]

  • Page 117

    TROUBLESHOOTING & REP AIR F-64 F-64 COMMANDER 500 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 } } } } } } } } } } } } TOP BRACKET DIODE HEA TSINK DIODE LEADS CONTROL TRANSFORMER BOTTOM BRACKET DIODE & “ W ” LEA[...]

  • Page 118

    TROUBLESHOOTING & REP AIR F-65 F-65 COMMANDER 500 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 POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT (CONTINUED) Refer to Figure F .29 for Steps 13-15. 1[...]

  • Page 119

    TROUBLESHOOTING & REP AIR F-66 F-66 COMMANDER 500 POWER MODULE (CHOPPER) PC BOARD/DIODE MODULE REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidat[...]

  • Page 120

    TROUBLESHOOTING & REP AIR F-67 F-67 COMMANDER 500 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 PLUG J50 ALLEN HEAD SCREWS (4) COPPER SP ACERS TEMPERA TURE SWITCH HEA T SINK POWER MODULE PC BOARD DIODE MODULE FIGURE F .3[...]

  • Page 121

    TROUBLESHOOTING & REP AIR F-68 F-68 COMMANDER 500 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 POWER MODULE (CHOPPER) PC BOARD/DIODE MODULE REMOV AL AND REPLACEMENT (CONTINUED) POWER MODULE PC BOARD REPLACEMENT 1. Apply[...]

  • Page 122

    TROUBLESHOOTING & REP AIR F-69 F-69 COMMANDER 500 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 SPRING WASHER PLAIN WASHER 2 TO 3 TURNS EACH 12-18 IN.LBS. 30-40 IN.LBS. FINGER TIGHT 5.0-10 IN-LBS. 5.0-10 IN-LBS. FIGURE F[...]

  • Page 123

    TROUBLESHOOTING & REP AIR F-70 F-70 COMMANDER 500 OUTPUT RECTIFIER BRIDGE DIODE REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory [...]

  • Page 124

    TROUBLESHOOTING & REP AIR F-71 F-71 COMMANDER 500 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 HEA TSINKS DIODE DIODE PIGT AIL LEADS FIGURE F .32 – POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y DET AILS OUTPUT RECTIF[...]

  • Page 125

    TROUBLESHOOTING & REP AIR F-72 F-72 COMMANDER 500 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 OUTPUT RECTIFIER BRIDGE DIODE REMOV AL AND REMOV AL AND REPLACEMENT (CONTINUED) 8. Inspect the mounting surfaces of each new[...]

  • Page 126

    TROUBLESHOOTING & REP AIR F-73 F-73 COMMANDER 500 ST A TOR/ROT OR REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For[...]

  • Page 127

    TROUBLESHOOTING & REP AIR F-74 F-74 COMMANDER 500 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 PLUG FUEL LINES U-BOL TS (2) LEADS #229 AND #242D { FIGURE F .33 – FUEL T ANK REMOV AL DET AILS ST A TOR/ROT OR REMOV AL A[...]

  • Page 128

    TROUBLESHOOTING & REP AIR F-75 F-75 COMMANDER 500 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 PLUG P/J52 #201 #201A 6F #200D #5P FIL TER CAP ACITOR FIELD DIODE RECTIFIER BRIDGE FIGURE F .34 – PLUG J52/FIL TER CAP ACI[...]

  • Page 129

    TROUBLESHOOTING & REP AIR F-76 F-76 COMMANDER 500 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 #200A #200B #201 12 VDC STUD LEADS #232L AND #232M PULL COIL PC BOARD (LEADS #265 AND #227) CONTROL BOX FIGURE F .35 – BRU[...]

  • Page 130

    TROUBLESHOOTING & REP AIR F-77 F-77 COMMANDER 500 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 6 SCREWS SHROUD ACOUSTICAL FOAM FIGURE F .37 – AL TERNA TOR SHROUD REMOV AL ST A TOR/ROT OR REMOV AL AND REPLACEMENT (CONT[...]

  • Page 131

    TROUBLESHOOTING & REP AIR F-78 F-78 COMMANDER 500 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 CENTER P ANEL LIFT FRAME WELDMENT BASE FUEL T ANK SUPPORTS F AN BAFFLE FIGURE F .38 – LIFT FRAME AND ASSOCIA TED COMPONENT[...]

  • Page 132

    TROUBLESHOOTING & REP AIR F-79 F-79 COMMANDER 500 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 BOL TS (4) F AN HUB MOUNTING FOOT FL YWHEEL SPLASH PLA TE FA N NUT ST A TOR / ENGINE MOUNTING BOL TS & LOCK W ASHERS BEA[...]

  • Page 133

    TROUBLESHOOTING & REP AIR F-80 F-80 COMMANDER 500 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 FLEX PLA TE BLOWER SEGMENT (4) ROTOR FIGURE F .40 – ROTOR REMOV AL ST A TOR/ROT OR REMOV AL AND REPLACEMENT (CONTINUED) RO[...]

  • Page 134

    TROUBLESHOOTING & REP AIR F-81 F-81 COMMANDER 500 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/ROT OR REMOV AL AND REPLACEMENT (CONTINUED) LEAD RECONNECTION CHECKLIST ENGINE ■ ■ Leads #242D and #229 to fuel[...]

  • Page 135

    TROUBLESHOOTING & REP AIR F-82 F-82 COMMANDER 500 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 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mecha[...]

  • Page 136

    TROUBLESHOOTING & REP AIR F-83 F-83 COMMANDER 500 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 RETEST AFTER REP AIR (CONTINUED) TOUCH ST ART TIG MODE OUTPUT Mode Selector Open Circuit Short Circuit Switch Fine Control V[...]

  • Page 137

    G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- Electrical Diagrams ........................................................................................................................G-1 Wiring Diagram ..................................................................................................................[...]

  • Page 138

    ELECTRICAL DIAGRAMS G-2 COMMANDER 500 WIRING DIAGRAM - COMMANDER 500 GND-H 6D 3 GND-F 5A AUX I LI AR Y P OWE R GND-D 12 11 10 EMPT Y CB6 10A EMPTY EMPTY 42A 42 31 GND-E 42A 5J OUTPUT 31 CONTROL 32 CCW 236C 8 POLARITY SWITCH 1 31 32 RECT IFI ER BR IDGE 50A TO THE LAMIN ATION TO SLIP RING NEAREST POSITIVE BRUSH CONNECTED CO NTROL IDLER 5B 6D 5E 5C 5 [...]

  • 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 ELECTRICAL DIAGRAMS G-3 COMMANDER 500 SCHEMA TIC - COMPLETE MACHINE - COMMANDER 500 EN-170 SOLID EDG E MA NUFACTURING TOLERANC E PER E 2056 UNL ESS OTHERW ISE SPEC IFIED TOLER AN[...]

  • Page 140

    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 ELECTRICAL DIAGRAMS G-4 COMMANDER 500 SCHEMA TIC - BA TTER Y PC BOARD G-4 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manua[...]

  • Page 141

    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[...]

  • Page 142

    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 ELECTRICAL DIAGRAMS G-6 COMMANDER 500 SCHEMA TIC - CHOPPER PC BOARD FILENAME: M19462_1BA 10.0 R5 10.0 R9 (UNLESS OTHER WISE SPECIFIED) UNLESS OTHER WISE SPECIFIED) .022/50V 10.0 [...]

  • Page 143

    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[...]

  • Page 144

    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 ELECTRICAL DIAGRAMS G-8 COMMANDER 500 SCHEMA TIC - PERIPHERAL PC BOARD G-8 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manu[...]

  • Page 145

    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[...]

  • Page 146

    ELECTRICAL DIAGRAMS G-10 COMMANDER 500 SCHEMA TIC - POWER SUPPL Y (ANALOG) PC BOARD G-10 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. 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 Ret[...]

  • Page 147

    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[...]

  • Page 148

    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 ELECTRICAL DIAGRAMS G-12 COMMANDER 500 SCHEMA TIC - PULL-COIL PC BOARD G-12 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this man[...]

  • Page 149

    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[...]

  • Page 150

    ELECTRICAL DIAGRAMS G-14 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 1 G-14 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. 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 Ret[...]

  • Page 151

    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 ELECTRICAL DIAGRAMS G-15 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 2 G-15 NOTE: This diagram is for reference only . It may not be accurate for all machines covere[...]

  • Page 152

    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 ELECTRICAL DIAGRAMS G-16 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 3 G-16 NOTE: This diagram is for reference only . It may not be accurate for all machines covere[...]

  • Page 153

    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 ELECTRICAL DIAGRAMS G-17 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 4 G-17 NOTE: This diagram is for reference only . It may not be accurate for all machines covere[...]

  • Page 154

    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 ELECTRICAL DIAGRAMS G-18 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 5 G-18 NOTE: This diagram is for reference only . It may not be accurate for all machines covere[...]

  • Page 155

    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[...]

  • Page 156

    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[...]