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Lincoln Electric POWER WAVE 455 User Manual

Lincoln Electric POWER WAVE 455
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SERVICE MANUAL
SVM135-B | Issue D ate 01, Jul
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
Power Wave 455: 10372, 10521, 10522, 10552, 10553, 10554, 10555
Power Feed 10: 10435, 10436, 10437, 10438, 10493, 10494, 10760,
10767, 10768, 10779, 10780, 10781, 10782, 10783
POWER WAVE 455/POWER FEED 10
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com
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NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

Table of Contents

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Lincoln Electric POWER WAVE 455 Specifications

General IconGeneral
Protection ClassIP23
Input Phase3
Output Voltage Range10 - 38V
Rated Output455 A at 40 V
Duty Cycle100%
ProcessesMIG, Pulsed MIG, TIG, Stick
Wire Feed Speed Range50-1000 ipm
Weight136 kg (300 lbs)

Summary

Safety Precautions

California Proposition 65 Warnings

Warnings about chemicals known to cause cancer, birth defects, or reproductive harm from engine exhaust.

Electric and Magnetic Fields (EMF)

Information regarding the potential dangers of EMF fields from welding equipment and pacemakers.

Electric Shock Hazards

Precautions against electric shock from hot parts, wet clothing, and proper insulation.

Fumes and Gases Hazards

Guidance on avoiding hazardous fumes and gases from welding operations, emphasizing ventilation.

Welding Sparks and Fire Hazards

Instructions on preventing fires and explosions caused by welding sparks and hot materials.

Cylinder Safety

Precautions to prevent cylinder explosions due to damage or improper handling.

Electrical Equipment Safety

Safety measures for electrically powered equipment, including grounding and input power handling.

Installation Procedures

Electrical Connections

Instructions for making safe and correct electrical connections to the equipment.

Operation Guide

Operating Instructions

General instructions to read and understand before operating the welding machine.

Safety Instructions

Key safety highlights for operating welding equipment, covering shock, fumes, sparks, and rays.

Maintenance and Repair

Safety Precautions

General safety guidelines to follow during maintenance and repair procedures.

Troubleshooting and Repair

How to Use Troubleshooting Guide

Instructions on how to effectively use the troubleshooting guide for machine malfunctions.

PC Board Troubleshooting Procedures

Guidelines for troubleshooting and replacing PC boards, including static precautions.

Power Wave Troubleshooting

Troubleshooting guide for issues related to the Power Wave power source.

Power Feed Troubleshooting

Troubleshooting guide for issues related to the Power Feed 10 wire feeder unit.

Input Filter Capacitor Discharge Procedure

Safety procedure to discharge capacitors before internal maintenance or repair.

Switch Board Test

Procedure to test the power section of the switch boards for correct functionality.

Power Source Error Interpretation Guide

Guide to interpreting error codes and identifying potential causes for power source issues.

Functional Troubleshooting Guide

Flowchart for troubleshooting functional issues with the welding system components.

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