Lincoln Electric SVM133-B User Manual

SVM133-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 increased 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 machine code numbers: 9978, 9979, 10580, 10581

Commander 400

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• 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 •

SAFETY

i i

COMMANDER 400

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

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1.d. Keep all equipment safety guards, covers

and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

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1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society , P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. AFree copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

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SAFETY

ii ii

COMMANDER 400

ARC RAYS 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 protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASES can be dangerous.

5.a.Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon

vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors

to form phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

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COMMANDER 400

FOR ELECTRICALLY powered equipment.

8.a. Turn 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. National Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA22202.

iii

SAFETY

iii

Mar ‘95

WELDING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even

though

they have been “cleaned”. For information, purchase “Recommended Safe Practices for the

Preparation

for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

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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 suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

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MASTER TABLE OF CONTENTS FOR ALL SECTIONS

v v

COMMANDER 400

Page

Safety.................................................................................................................................................i-iv

Installation.............................................................................................................................Section A

Technical Specifications..............................................................................................................A-2

Safety Precautions......................................................................................................................A-3

Location and Ventilation..............................................................................................................A-3

Pre-Operation Engine Service ....................................................................................................A-4

Electrical Output Connections.....................................................................................................A-6

Connection Of Commander 400 To Premisis Wiring..................................................................A-8

Operation...............................................................................................................................Section B

Safety Instructions.......................................................................................................................B-2

General Description ....................................................................................................................B-2

Recommended Applications........................................................................................................B-3

Design Features ..........................................................................................................................B-3

Welding Capability ......................................................................................................................B-4

Controls and Settings..................................................................................................................B-5

Engine Operation........................................................................................................................B-8

Welder Operation......................................................................................................................B-10

Auxiliary Power .........................................................................................................................B-12

Accessories ..........................................................................................................................Section C

Maintenance..........................................................................................................................Section D

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair................................................................................................Section F

Electrical Diagrams..............................................................................................................Section G

Parts Manual......................................................................................................................P267 Series

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TABLE OF CONTENTS

- INSTALLATION SECTION -

Section A-1 Section A-1

COMMANDER 400

Installation

Technical Specifications..............................................................................................................A-2

Safety Precautions......................................................................................................................A-3

Location and Ventilation..............................................................................................................A-3

Storing ..................................................................................................................................A-3

Stacking................................................................................................................................A-3

Angle of Operation................................................................................................................A-3

Lifting....................................................................................................................................A-4

High Altitude Operation.........................................................................................................A-4

Towing...................................................................................................................................A-4

Pre-Operation Engine Service ....................................................................................................A-4

Oil .........................................................................................................................................A-4

Fuel.......................................................................................................................................A-5

Cooling System.....................................................................................................................A-5

Battery Connections .............................................................................................................A-5

Muffler Outlet Pipe ............................................................................................................ ....A-5

Spark Arrester.......................................................................................................................A-5

Electrical Output Connections.....................................................................................................A-6

Welding Cable Connections.................................................................................................A-6

Machine Grounding ..............................................................................................................A-7

Auxiliary Power Receptacles................................................................................................A-7

Standby Power Connections................................................................................................A-7

Connection Of The Commander 400 To Premises Wiring..........................................................A-8

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A-2 A-2

COMMANDER 400

INSTALLATION

TECHNICAL SPECIFICATIONS - Commander 400

Make/Model Description Speed (RPM) Displacement Starting Capacities

System

Deutz 3 cylinder High Idle 1900 173 cu. in 12VDC battery Fuel: 25 gal. F3L 912 Diesel 44.2 HP(33kw) Low Idle 1350 (2.827 L) & Starter 94.6 L Engine @ 1800 RPM Full Load 1800

Bore x Stroke Oil: 8.5 Qts.

8.04 L

3.94” x 4.72”

(100mm x 120mm)

INPUT - DIESEL ENGINE

RATED OUTPUT - WELDER

HEIGHT

WIDTH DEPTH WEIGHT

42.0 in. 31.5 in. 63.1 in. 1650 lbs.(748 kg) (Stick model)

1066.8 mm 800.1 mm 1602.7 mm 1683 lbs.(763 kg) (Stick & Wire model)

OUTPUT - WELDER AND GENERATOR

Duty Cycle Welding Output Volts at Rated Amps

100%

400 amps (DC Constant Current) 40 volts 400 amps (DC Constant Voltage) 40 volts

60%

500 amps (DC Constant Current) 40 volts 500 amps (DC Constant Voltage) 40 volts

Welding Range Open Circuit Voltage Auxiliary Power

40 - 575 Amps 64-74 OCV 120/240 VAC in 7 Ranges (Stick model) 10,000 Watts, 60 Hz. or 8 Ranges

(Stick & Wire model)

@1915 RPM 100% Duty Cycle

PHYSICAL DIMENSIONS

1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.

2. Top of Enclosure. Add 6.64” (168.7mm) for exhaust.

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.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

• Do not stack anything near the engine.

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop the engine before servicing.

• Keep away from moving parts.

See additional safety information at the front of this manual.

Only qualified personnel should install, use, or service this equipment.

LOCATION AND VENTILATION

The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area.

STORING

1. Store the machine in a cool, dry place when it is not in use. Protect it from dust and dirt. Keep it where it can’t be accidentally damaged from construction activities, moving vehicles, and other hazards.

2. Drain the engine oil and refill with fresh 10W30 oil. Run the engine for about five minutes to circulate oil to all the parts. See the Maintenance section of this manual for details on changing oil.

3. Remove the battery, recharge it, and adjust the electrolyte level. Store the battery in a dry, dark place.

4. See your engine operation manual for further information on fuel and engine preservation.

STACKING

Commander 400 machines CANNOT be stacked.

ANGLE OF OPERATION

To achieve optimum engine performance the Commander 400 should be run in a level position. The maximum angle of operation for the Deutz engine is 20 degrees in a direction to cause the control panel to be angled up, 30 degrees for side to side tilting and for the control panel to be angled down. If the engine is to be operated at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity in the crankcase. When operating the welder at an angle, the effective fuel capacity will be slightly less than the specified 25 gallons.

INSTALLATION

A-3 A-3

COMMANDER 400

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WARNING

LIFTING

The Commander 400 weights 1650 lb./748 kg (Stick model); 1683 lb./763 kg. (Stick & Wire model). Alift bail is provided for lifting with a hoist.

FALLING 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 capacity . Be sure machine is stable when lifting.

The Commander is shipped with the lift bail retracted. Before attempting to lift the Commander, secure the lift bail in a raised position. Secure the lift bail as follows:

a. Open the engine compartment door. b. Locate the 2 access holes on the upper middle

region of compartment wall just below the lift bail.

c. Use the lifting strap to raise the lift bail to the full

upright position. This will align the mounting holes on the lift bail with the access holes.

d. Secure the lift bail with 2 thread forming screws.

The screws are provided in the shipped loose parts bag.

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary. Some engine adjustments may be required. Contact a Deutz Service Representative.

TOWING

The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle

(1)

is Lincoln’s K953-1. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to consider are as follows:

1. Design capacity of trailer vs. the weight of the Lincoln equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of the welding equipment so that there will be no undue stress to the trailer’s framework.

3. Proper placement of the equipment on the trailer to insure stability side to side and front to back when the trailer is being moved and when standing by itself.

4. Typical conditions of use, such as travel speed, roughness of surface on which the trailer will be operated, environmental conditions, and likely maintenance.

5. Proper preventative maintenance of trailer.

6. Conformance with federal, state and local laws.

Consult applicable federal, state and local laws regarding specific requirements for use on public highways.

PRE-OPERATION ENGINE SERVICE

Read and understand the information about the diesel engine in the Operation and Maintenance sections of this manual before you operate the Commander 400.

• Stop the engine and allow it to cool before fueling.

• Do not smoke when fueling.

• Fill the fuel tank at a moderate rate and do not overfill.

• Wipe up spilled fuel and allow the fumes to clear before starting the engine.

• Keep sparks and flame away from the tank.

OIL

The Commander 400 is shipped with the engine filled with SAE 10W-30 oil (API class CD or better). This should be fine for most ambient operating temperature conditions. See the engine operation manual for specific recommendations. CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE. This is an added precaution. When full, the oil level should be up to but not over the FULL mark on the dipstick. If it is not full, add enough oil to fill it to the full mark. DO NOT overfill.

Check oil level after every 4 hours of running time during the first 35 hours of operation.

NOTE: This machine is equipped with an engine protection package. An internal kill switch will shut down the engine if the oil pressure drops below a minimum level or if oil temperature becomes excessive.

For more oil fill and service information, see the Maintenance section of this manual.

INSTALLATION

A-4 A-4

COMMANDER 400

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WARNING

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 manual 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 indicate a low fuel condition by turning on the low fuel light. A time of 30 minutes will elapse once the low fuel light illuminates before the machine will shutdown. A restart of the machine will restart the timer to allow the operator to override this feature. The amount of reserve fuel remaining in the tank after the first shutdown will vary from machine to machine. The operator must determine the amount of fuel remaining before re-starting the machine.

Running out of fuel may require bleeding the fuel injection pump.

NOTE: Before starting the engine, open the fuel shut-

off valve (lever to be in line with hose) located on the side of the fuel pre-filter/water separator housing.

FUEL CAP

Remove the plastic cap covering the fuel tank filler neck and install the fuel cap.

COOLING SYSTEM

The Deutz engine is air cooled by a belt driven axial blower. The oil cooler and engine cooling fins should be blown out with compressed air or steam to maintain proper cooling (See the engine owner’s manual for procedures and frequency).

BATTERY CONNECTIONS

BATTERY 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.

The Commander 400 is shipped with the

negative battery cable disconnected. Before you operate the machine, make sure the IGNITION switch is in the OFF position and attach the disconnected cable securely to the battery terminal. If the battery is discharged and won't start the engine, see the battery charging instructions in the Maintenance section.

MUFFLER OUTLET PIPE

Remove the plastic plug covering the muffler outlet tube. Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction.

SPARK ARRESTER

Diesel engine mufflers may emit sparks when the engine is running. Some federal, state, or local laws require spark arresters in locations where unarrested sparks could present a fire hazard.

Standard mufflers (like the one included with the Commander 400) do not act as spark arresters. When local laws require it, a spark arrester must be installed on the machine and properly maintained. An optional spark arrester kit is available for your Commander 400. See the Accessories section of this manual for more information.

An incorrect arrester may lead to damage to the engine or adversely affect performance.

INSTALLATION

A-5 A-5

COMMANDER 400

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CAUTION

WARNING

–+

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 INSTALLATION 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 fuel tank mounting rail. (See size recommendations below.) For positive polarity , connect the electrode cable to the terminal marked Positive (+). For Negative polarity , connect the electrode cable to the Negative (-) terminal. These connections should be checked periodically and tightened if necessary.

• Loose connections will cause the output terminals to

overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output terminal

connection. Keep the cables isolated and separate from one another.

When welding at a considerable distance from the welder, be sure you use ample size welding cables. Table A.1 lists recommended cable sizes and lengths for rated current and duty cycle. Length refers to the distance from the welder to the work and back to the welder. Cable diameters are increased for long cable lengths to reduce voltage drops.

Lincoln Electric offers a welding accessory kit with the properly specified welding cables. See the Accessories section of this manual for more information.

INSTALLATION

A-6 A-6

COMMANDER 400

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CAUTION

FIGURE A.1 - COMMANDER 400 OUTPUT CONNECTIONS

TABLE A.1 - RECOMMENDED COPPER WELDING CABLE SIZE AND LENGTH

TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES

Cable sizes for combined length of

electrode plus work cable

Amps Duty Cycle Up to 200 ft. 200 to 250 ft.

250 100% 1 AWG 1/0 AWG 400 100% 3/0 AWG 4/0 AWG

OIL

120 VOLT

RECEPTACLES

FUEL

TEMP

PRESS

AMPS

00000

HOURS

CV WORK WELD OUTPUT TERMINAL

240 VOLT RECEPTACLE

GROUND STUD

WELD OUTPUT TERMINALS

(ELECTRODE + & CC WORK -)

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.).

To prevent dangerous electric shock, other equipment powered by this engine driven welder must:

a) be grounded to the frame of the welder using a

grounded type plug,

b) be double insulated.

When this welder is mounted on a truck or trailer, its frame must be securely connected to the metal frame of the vehicle. When connected to premises wiring such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the section “Standby Power Connections” as well as the article on grounding in the latest U.S. National Electrical Code and the local code.

In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints or to the metal framework of a building that has been effectively grounded. The U.S National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.

AUXILIARY POWER RECEPTACLES

The Commander 400 can produce 10,000 watts of 60 Hz, single-phase auxiliary power. (The rating in watts is equivalent to volt-amperes at unity power factor.) The output voltage is within ±10% at all loads up to the rated capacity.

The following receptacles are provided:

• Two 15 amp-120VAC duplex GFCI receptacles (5-15R)

• One 50 amp-120/240VAC receptacle (14-50R)

The 50 amp receptacle has a maximum permissible output of 44 amps. However, it can be split to power two separate, single-phase 120VAC branch circuits each capable of 44 amps output.

NOTE: The two 120VAC outlets of the 120/240VAC receptacle cannot be paralleled. They are on two different phases.

The auxiliary power receptacles should be used with only three-wire, grounded type plugs or approved double-insulated tools with two-wire plugs. The current rating of any plug used with the system must be at least equal to the current-carrying capacity of the associated receptacle. An optional power plug kit is available. See the Accessories section.

STANDBY POWER CONNECTIONS

The Commander 400 is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule.

The Commander 400 can be permanently installed as a standby power unit for 240 volt 3-wire, 44 ampere service. Connections must be made by a licensed electrician who can determine how the 120/240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes. The following information can be used as a guide by the electrician for most applications. Refer to the connection diagram shown in Figure A.2.

1. Install the double-pole, double-throw switch between the power company meter and the premises disconnect.

The switch rating must be the same or greater than the customer’s premises disconnect and service over current protection.

2. Take the necessary steps to assure the load is limited to the capacity of the Commander 400 by installing a 45 amp, 240 VAC double-pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 45 amperes. Loading above the rated output will reduce output voltage below the allowable -10% of rated voltage, which may damage appliances or other motor-driven equipment and may result in overheating of the Commander 400 engine.

3. Install a 50 amp 120/240 VAC plug (NEMAType 14-

50) to the double-pole circuit breaker using No. 6, 4 conductor cable of the desired length. (The 50 amp, 120/240 V AC plug is available in the optional K802R plug kit.) See the Accessories section.

4. Plug this cable into the 50 ampere 120/240 volt receptacle on the Commander 400 case front.

INSTALLATION

A-7 A-7

COMMANDER 400

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INSTALLATION

A-8 A-8

COMMANDER 400

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240 Volt

60 Hz. 3-Wire

Service

POWER

COMPANY

METER

240 VOLT

120 VOLT

LOAD

NEUTRAL BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

NOTE: No. 6 COPPER CONDUCTOR CABLE.

SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE

WIRE SIZE RECOMMENDATIONS.

240 VOLT

GROUNDED CONDUCTOR

45AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT

RECEPTACLE

FIGURE A.2 - CONNECTION OF THE COMMANDER 400 TO PREMISES WIRING

Section B-1 Section B-1

COMMANDER 400

TABLE OF CONTENTS

- OPERATION SECTION -

Operation...............................................................................................................................Section B

Safety Instructions.......................................................................................................................B-2

General Description ....................................................................................................................B-2

Recommended Applications........................................................................................................B-3

Design Features ..........................................................................................................................B-3

Welding Capability ......................................................................................................................B-4

Controls and Settings..................................................................................................................B-5

Engine Controls....................................................................................................................B-5

Welder Controls....................................................................................................................B-7

Auxiliary Power Controls ......................................................................................................B-8

Wire Feeder Mode Controls .................................................................................................B-8

Engine Operation........................................................................................................................B-8

Starting the Engine...............................................................................................................B-8

Stopping the Engine.............................................................................................................B-9

Break-In Period................................................................................................................ .....B-9

Typical Fuel Consumption....................................................................................................B-9

Welder Operation......................................................................................................................B-10

Stick Welding......................................................................................................................B-10

TIG Welding.................................................................................................................... ....B-10

Commander 400 Settings With K799 Hi-Freq./K930-1 Tig Module....................................B-11

Wire Feed (Constant Voltage) Welding.....................................................................................B-12

Auxiliary Power .........................................................................................................................B-12

Simultaneous Welding and Auxiliary Power Loads ............................................................B-12

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OPERATING INSTRUCTIONS

Read and understand this entire section before operating 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 maintenance instructions and parts lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrodes with your skin or wet clothing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust to the outside.

• Do not stack anything on or near the engine.

MOVING PARTS can injure.

• Do not operate this equipment with any of its doors open or guards off.

• Stop the engine before servicing it.

• Keep away from moving parts.

Only qualified personnel should install, use, or service this equipment.

GENERAL DESCRIPTION

The Commander 400 is a diesel engine driven welding power source. The machine uses a brushless asynchronous alternating current generator for DC stick electrode welding and for 120/240 VAC auxiliary standby power. As a generator it can supply up to 10,000 watts of 120/240 volt AC power. As a welder it provides up to 400 amps of DC constant current output in six slope-controlled ranges. In addition a seventh general purpose welding range provides up to 575 amps of constant current welding output.

The engine is a 44.2 Hp (33kw), 3-cylinder air/oil cooled diesel made by Deutz. This naturally aspirated, 4 cycle engine features direct injection, a Bosch in-line injection pump and a Bosch mechanical governor.

This machine is controlled by a high quality microcontroller. The microcontroller provides high speed control of the weld process as well as the engine protection features.

OPERATION

B-2 B-2

COMMANDER 400

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WARNING

RECOMMENDED APPLICATIONS

WELDER

The Commander 400 (Stick model) provides excellent constant current DC welding output for stick (SMAW) welding. The Commander 400 (Stick & Wire model) also provides excellent constant voltage DC welding output for MIG (GMAW) and Inner shield (FCAW) welding.

GENERATOR

The Commander 400 provides smooth 120/240 VAC output for auxiliary power and emergency standby power.

DESIGN FEATURES

(All Models)

FOR STICK WELDING

• Excellent DC constant current output for stick welding applications.

• 40 to 400 amps output in six slope controlled ranges

for out-of position and pipe electrodes; 50 to 575 amps constant current output in one general purpose welding range.

• 3 digit display is provided for presetting the weld

amperage and displaying the actual amperage during welding. The display uses super brite LEDs for improved readability in full sunlight.

• Remote control capability standard on all models.

• Selection of “hot” or “cold” output terminals with a tog-

gle switch on the control panel. This feature can also be controlled by installing a remote output terminal control cable designed to open and close the #2 and #4 leads in the amphenol receptacle.

FOR AUXILIARY POWER

• 10,000 watts of 120/240 VAC, 60Hz auxiliary power.

• Will drive a 2 HP motor (provided it is started under

no load).

• Two 15 amp 120 VAC duplex receptacles with GFCI

protection for up to 30 amps of 120 VAC power.

• One 50 amp, 120/240 VAC dual voltage receptacle for up to 44 amps of 240 V AC, and up to 44 amps per side to separate branch circuits (not in parallel) of 120 VAC single phase auxiliary power. Allows easy connection to premises wiring.

• Weld and AC auxiliary power at the same time (within machine total capacity).

OTHER FEATURES

• Deutz 3-cylinder, air/oil cooled diesel engine. Designed for long life, easy maintenance and excellent fuel economy.

• Engine protection system shuts the engine down for low oil pressure, high oil temperature or a broken fan/engine alternator belt.

• Gauges for oil pressure, oil temperature, engine alternator output and fuel level.

• Indicator lights for low oil pressure, high oil temperature, engine alternator low output/broken belt and low fuel level.

• Automatic low fuel shutdown before running out of fuel.

• Engine hour meter standard on all models.

• Extended range 25 gallon (94.6 l) fuel tank.

• Fuel pre-filter/water separator with “dry” change element.

• Automatic idler reduces engine speed when not welding or drawing auxiliary power. This feature reduces fuel consumption and extends engine life.

• Single side engine service with over the top access to the engine.

• Copper alternator windings and high temperature insulation for dependability and long life.

OPERATION

B-3 B-3

COMMANDER 400

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ADDITIONAL DESIGN FEATURES

(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 (FCAW) welding.

• A Wire Feeder connector for quick connection of the control cable.

• A built in “Electronic Contactor” for “Cold” electrode when not welding.

• The 3 digit display has the additional feature of presetting the open circuit voltage and displaying the actual voltage during welding.

•

Designed for use with the following Lincoln wire feeders.

•LN-25 •LN-23P •LN-7

•LN-8 •NA-3 •Spool Gun & K488 Module

WELDING CAPABILITY

The Commander 400 is rated at 400 amps, 40 volts at 100% duty cycle. The weld current is variable from 40 to 575 amps.

OPERATION

B-4 B-4

COMMANDER 400

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OPERATION

B-5 B-5

COMMANDER 400

FIGURE B.1 – CASE FRONT PANEL CONTROLS

ENGINE CONTROLS

(Figure B.1, Items 1 through 8) See Figure B.1 for the location of the following fea-

tures:

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, the battery will be drained by the fuel solenoid.

2. START PUSHBUTTON: Energizes the starter motor to crank the engine. With the engine RUNSTOP switch in the “RUN” position, push and hold the START button for a minimum of 2 seconds to crank the engine; release as the engine starts. Do not press while engine is running since this can cause damage to the ring gear and/or starter motor.

3. FUEL LEVEL GAUGE AND LIGHT: Displays the level of diesel fuel in the 25-gallon (94.6 liter) fuel tank. The yellow light turns on when the fuel gage reaches the reserve level. Once the reserve level is reached, the engine protection system will shut down the engine after 30 minutes of operation. The machine can be restarted and operated for an additional 30 minutes before the protection system will shut down the engine. This ability to override the engine protection is to allow the operator to “finish up” if necessary. The operator must watch the fuel level closely to prevent running out of fuel and having to bleed the system.

CONTROLS AND SETTINGS

The welder/generator controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow.

OIL

00000

FUEL

TEMP

AMPS

PRESS

HOURS

OPERATION

B-6 B-6

COMMANDER 400

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4. ENGINE TEMPERATURE GAUGE AND LIGHT: The gauge displays the engine oil temperature. The yellow temperature light remains off under normal operating temperatures. If the light turns on, the engine protection system will shut down the engine. Check for restrictions at the engine cooling air inlets and outlets (consult the engine Operation manual). Check for loose or disconnected leads at the temperature sender located on the engine. Check engine cooling blower belt. Also, check to be sure that the welder loads are within the rating of the welder. The light will remain on when the engine has been shut down due to an over- temperature condition.

5. OIL PRESSURE GAUGE AND LIGHT: The gauge displays the engine oil pressure when the engine is running. The yellow oil pressure light remains off with proper oil pressure. If the light turns on, the engine protection system will stop the engine. Check for proper oil level and add oil if necessary. Check for loose or disconnected leads at the oil pressure sender located on the engine. The light will go on and stay on when the RUN-STOP switch is switched to the “RUN” position with the engine not running.

6. ENGINE ALTERNATOR AMMETER AND LIGHT: The yellow engine alternator light is off when the battery charging system is functioning normally. If the light turns on, the engine protection system will shut down the engine. Check the engine cooling blower belt. Also, the alternator or the voltage regulator may not be operating correctly. The light may also come on if the alternator did not flash up due to not holding the start button in long enough (minimum of 2 seconds) or due to a faulty flashing circuit. The light will remain on when the engine has been shut down due to a fault in the alternator, regulator, or the cooling blower belt.

7. IDLER SWITCH: Adjusts the running speed of the engine. Has two positions as follows:

A) In the “High” position, the engine runs at the high

idle speed controlled by the governor.

B) In the “Auto” position, the idler operates as

follows:

a. When switched from “HIGH” to “AUTO” or

after starting the engine, the engine will operate at full speed for approximately 15 seconds and then go to low idle speed.

b. When the electrode touches the work or

power is drawn for lights or tools (approximately 100 Watts minimum), the engine accelerates and operates at full speed.

c. When welding ceases or the AC power load

is turned off, a fixed time delay of approximately 15 seconds starts.

d. If the welding or AC power load is not

restarted before the end of the time delay, the idler reduces the engine speed to low idle speed.

e. The engine will automatically return to high

idle speed when the welding load or AC power load is reapplied.

Idler Operational Exceptions

When the WELDING TERMINALS switch is in the “WELDING TERMINALS 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 seconds.

• If the triggering device remains pressed but no welding load is applied, within approximately 15 seconds the engine will return to low idle speed.

• If the triggering device is released or welding ceases, the engine will return to low idle speed after approximately 15 seconds.

8. HOUR METER: The hour meter displays the total time that the engine has been running. This meter is a useful indicator for scheduling preventive maintenance.

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 Table B.1 for a description of how these two controls work.

TABLE B.1 OUTPUT RANGE SWITCH AND OUT-

PUT CONTROL FUNCTIONS

If the OUTPUT RANGE switch is positioned between settings, the previous setting is maintained until the switch is properly positioned on a setting.

The OUTPUT CONTROL also controls O.C.V. while in the 6 sloped output ranges.

10. DIGITAL OUTPUT METER: The digital output

meter is located in the center of the control panel between the two large control knobs. The meter allows the output current level to be set prior to welding. During the welding process the meter displays the actual output current.

11. WELDING TERMINALS SWITCH: The toggle

switch on the control panel labeled “WELDING TERMINALS ALWAYS ON” and “WELDING TERMINALS REMOTELY CONTROLLED,” is used to control the operation of the “solid state contactor,” which allows for the selection of “Hot” or “Cold” welding terminals.

With the switch in the “WELDING TERMINALS AL W AYS ON” position, the contactor is closed and the welding terminals are always “Hot.”

With the switch in the “WELDING TERMINALS REMOTEL YCONTROLLED” position, the contactor operation is controlled by an Amptrol, Arc Start Switch or some other type of triggering device through the use of a control cable connected to the 6-pin MS connector.

When the triggering device is pressed the contactor is closed and the welding terminals are “Hot.”

When the triggering device is released the contactor is opened and the welding terminals are “Cold.”

12. LOCAL/REMOTE SWITCH: The toggle switch on the control panel labeled “LOCAL/REMOTE” gives you the option of controlling the output at the welder control panel or at a remote location.

For remote control, set the toggle switch in the “REMOTE” position.

For control at the welder control panel, set the toggle switch in the “LOCAL” position.

13. 6 - PIN CONNECTOR: The 6-pin connector locat- ed on the control panel allows for connection of Remote Control accessories.

14. 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 connects to the “+” terminal and the work cable connects to the “-” terminal. For negative polarity welding, the work cable connects to the “+” terminal and the electrode cable connects to the “-” terminal.

OPERATION

B-7 B-7

COMMANDER 400

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Sloped Output for Pipe Welding. (all models)

Constant Current Output for Fabrication and General Purpose Welding (This setting also used for TIG) (all models)

Constant Voltage Output for Wire Welding (Stick & Wire model only)

6 Range

Settings

90, 120, 180,

230, 270, 400

(Max. current on

each setting)

1 Range setting

50-575 Amps

1 Range setting

12 to 40 Volts

Provides a fine

adjustment of welding current or voltage from

Min (1) to Max

(10) within each

range

Range

Switch

Control

AUXILIARY POWER CONTROLS

(Figure B.1 Items 15 - 19 )

15.

120/240VAC RECEPTACLE: This is a 120/240VAC (14-50R) receptacle that provides 240VAC or can be split for 120VAC 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 receptacle. Also refer to “Auxiliary Power Operation” later in this section.

16. 50 AMP CIRCUIT BREAKERS: These circuit breaker provide separate overload current protection for each 120V circuit at the 240V receptacle.

17. 120VAC RECEPTACLES: These two 120VAC (5- 15R) receptacles with GFCI protection provide 120VAC for auxiliary power. The receptacles have a 20 amp total rating. Refer to “Auxiliary Power Receptacles” in the Installation section for further information about these receptacles. Also refer to “Auxiliary Power Operation” later in this section.

18. 15 AMP CIRCUIT BREAKERS: These circuit breakers provide separate overload current protection for each 120V receptacle.

19. GROUND STUD: Provides a point for connecting the machine case to earth ground for the safest grounding procedure. Refer to “Machine Grounding” in the Installation section for proper machine grounding information.

WIRE FEEDER MODE CONTROLS

(Figure B.1 Items 20 - 24 Stick & Wire model only)

20. WELD OUTPUT TERMINAL - WIRE: This 1/2-13 stud with flange nut provides a welding connection point for the electrode or work cables. For positive polarity welding, the electrode cable connects to the “+” terminal and the work cable connects to the “-” terminal. For negative polarity welding, the work cable connects to the “+” terminal and the electrode cable connects to the “-” terminal.

21. 15 AMP CIRCUIT BREAKER: This circuit breaker provides overload protection for the 14-pin connector.

22. VOLTMETER +/- SWITCH: Changes the polarity display on the wire feeder.

23. VOLTS-AMPS SWITCH: Switches the display between volts and amps.

24. 14 - PIN CONNECTOR: For quick connection of wire feeder control cable.

ENGINE OPERATION

STARTING THE ENGINE

1. Open the engine compartment door and check that the fuel shutoff valve located to the left of the fuel filter housing is in the open position (lever 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 power receptacles.

4. Set the IDLER switch to “AUTO.”

5. Set the RUN/STOP switch to “RUN.” Observe that all engine protection lights momentarily turn on. Some lights may turn off before starting. Check the fuel gauge to make sure that there is an adequate fuel level.

6. Press and hold the engine START button for a minimum of 2 seconds.

7. Release the engine START button when the engine starts.

8. Check that the indicator lights are off. If the LOW FUEL light is on , the engine will shut down 30 minutes after starting. If any other indicator light is on after starting, the engine will shut down in a few seconds. Investigate any indicated problem.

9. Allow the engine to warm up at low idle speed for several minutes before applying a load and/or switching to high idle. Allow a longer warm up time in cold weather.

COLD WEATHER STARTING

With a fully charged battery and the proper weight oil, the engine should start satisfactorily even down to about 0

If the engine must be frequently started below 10

F, i t may be desirable to install the optional Ether Start kit (K825-1). Installation and operating instructions are included in the kit. Use ether starting only when required, because excessive use shortens engine life.

OPERATION

B-8 B-8

COMMANDER 400

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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 and built for rugged use. It is very normal for any engine to use small quantities of oil until the break-in is accomplished. Check the oil level twice a day during the break-in period (about 200 running hours).

During break-in, subject the Commander 400 to heavy loads. Avoid long periods running at idle. Before stopping the engine, remove all loads and allow the engine to cool several minutes.

The heavy loading of the engine during break-in, within the rating of the machine, is recommended to properly seat the piston rings and prevent wetstacking. Wetstacking is an accumulation of unburned fuel and/or lubricant in the form of a wet, black, tar-like substance in the exhaust pipe. The rings are seated and the break-in period is complete when there are no longer any signs of wetstacking, which should occur within the first 50 to 100 hours of operation.

Using your welder at low amperages with long idle running periods during the break-in period may result in a glaze forming on the engine cylinder walls and the rings not seating properly. No amount of loading will properly seat the piston rings after they are glazed over.

TYPICAL FUEL CONSUMPTION

Refer to Table B.2 for typical fuel consumption of the Commander 400 engine for various operating scenarios.

Table B.2 Deutz F3L 912 Engine Fuel Consumption

OPERATION

B-9 B-9

COMMANDER 400

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CAUTION

Low Idle - No Load 1350 RPM

High Idle - No Load 1900 RPM

DC CC Weld Output 400 Amps @ 40 Volts Auxiliary Power 10,000 VA

.30 gallons/hour (1.36 liters/hour)

.78 gallons/hour

( 3.55 liters/hour)

1.84 gallons/hour ( 8.36 liters/hour)

1.32 gallons/hour (6.00 liters/hour)

83.3

32.1

13.6

18.9

Deutz F3L 912

44.2 Hp

@ 1800 RPM

Running Time for

25 gallons

(Hours)

CAUTION

WELDER OPERATION

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 CONTROL adjusts the current from minimum to maximum within each range. Open circuit voltage is also controlled by the OUTPUT CONTROL in the slope controlled setting. These slope controlled settings are intended for “out-of-position” welding, including pipe welding, where the operator would like to control the current level by changing the arc length.

PIPE WELDING

When using a sloped range, a high open circuit voltage setting provides the softest arc with best resistance to pop-outs. To get this characteristic, set the OUTPUT RANGE switch to the lowest setting that still provides the current you need and set the OUTPUT CONTROL near maximum. For example: to obtain 175 amps and a soft arc

, set the OUTPUT RANGE switch to the “180 MAX” position and then adjust the OUTPUT CONTROL for 175 amps.

When a forceful “digging” arc is required, use a higher setting and lower open circuit voltage. For example: to obtain 175 amps and a forceful arc,

set the OUTPUT RANGE switch to the “230 MAX” position and then adjust the OUTPUT CONTROL to get 175 amps.

GENERAL WELDING

The seventh position of the OUTPUT RANGE switch is designed for horizontal welds

with all types of electrodes, especially low hydrogen. The OUTPUT CONTROL adjusts the full range of 50 to 575 amps. This setting provides a soft, constant current arc. If a more forceful arc is desired, then select the proper range from the slope controlled current ranges.

TIG WELDING

The Commander 400 can be used in a wide variety of DC Tungsten Inert Gas (TIG) welding applications for DC TIG welding up to 400 amps at a 20% duty cycle, 300 amps at a 60% duty cycle and 250 amps at a 80% duty cycle. Refer to Table B.3 for recommended output setting depending on the tungsten electrode size. The Commander 400 can be used without a TIG module or Hi-Freq Unit for scratch start DC TIG welding. Using a K799 Hi-Freq Unit or K930-1 TIG Module enables DC TIG welding without having to scratch start. The end of this section also details Commander 400 settings when using either of these units for DC TIG welding. See “Commander 400 Settings When

Using the K799 Hi-Freq Unit” and “Commander 400 Settings When Using the K930-1 TIG Module.” See

the Accessories section for recommended equipment for TIG welding.

OPERATION

B-10 B-10

COMMANDER 400

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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 “WELDING TERMINALS ALWAYS ON” position. This will close the solid state contactor and provide an always “hot” electrode.

(Note: This is necessary because the K799 circuitry with respect to the #2 and #4 leads does not provide the proper signal to open and close the solid state contactor in the Commander).

COMMANDER 400 SETTINGS WHEN USING THE K930-1 TIG MODULE

1. Set the OUTPUT RANGE switch to the 50-575 Setting (Fabrication and General Purpose).

2. Set the IDLER switch to the “AUTO “ position.

3. Set the LOCAL/REMOTE switch to the “REMOTE” position.

4. Set the WELDING TERMINALS switch to the “WELDING TERMINALS REMOTELY CONTROLLED” position. This will keep the solid state contactor open and provide a “cold” electrode until the triggering device (Amptrol or Arc Start switch) is pressed.

OPERATION

B-11 B-11

COMMANDER 400

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Tungsten

Electrode Diameter

in. (mm)

2-15 5-20

15-80

70-150

150-250 250-400

400-500 500-750

750-1000

3 3 3

10-20 15-30

25-40 40-55

55-80

80-125

3-8 (2-4) 5-10 (3-5) 5-10 (3-5)

5-10 (3-5) 13-17 (6-8)

15-23 (7-11) 21-25 (10-12)

23-27 (11-13) 28-32 (13-15)

3-8 (2-4) 5-10 (3-5) 5-10 (3-5)

9-13 (4-6) 11-15 (5-7)

11-15 (5-7) 13-17 (6-8)

18-22 (8-10) 23-27 (11-13)

TIG TORCH

Nozzle Size

4,5

Approximate Argon Gas Flow Rate

C.F.H. (l/min.)

DCEN (-) DCEP (+)

#4, #5, #6

#5, #6 #6, #7, #8

#8, #10

0 .010 (.25)

0.020 (.50)

0.040 (1.0) 1/16 (1.6) 3/32 (2.4)

1/8 (3.2) 5/32 (4.0)

3/16 (4.8) 1/4 (6.4)

1%, 2%

Thoriated

Tungsten

1%, 2%

Thoriated

Tungsten

Aluminum Stainless Steel

Table B.3 TYPICAL CURRENT RANGES1FOR TUNGSTEN ELECTRODES

When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.

Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure EWP 1% Thoriated EWTh-1

2% Thoriated EWTh-2 Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.

DCEP is not commonly used in these sizes.

TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:

# 4 = 1/4 in. (6 mm) # 5 = 5/16 in. (8 mm) # 6 = 3/8 in. (10 mm) # 7 = 7/16 in. (11 mm) # 8 = 1/2 in. (12.5 mm) #10 = 5/8 in. (16 mm)

TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are

less prone to breakage, but cannot withstand high temperatures and high duty cycles.

WIRE FEED (CONSTANT VOLTAGE) 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 instructions 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 with a broad range of flux cored wire (inner shield and Outer shield) electrodes and solid wires for MIG (GMAW).

For any electrodes, the procedures should be kept within the rating of this machine. For additional electrode information, see Lincoln publications N-675, GS100 and GS-210.

AUXILIARY POWER

Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand a ±10% voltage and a ±3% frequency variation.

The following receptacles are provided:

• Two 15 amp-120VAC duplex FGCI receptacles (5-15R)

• One 50 amp-120/240VAC receptacle (14-50R)

The 50 amp receptacle has a maximum permissible output of 44 amps. However, it can be split to power two separate, single-phase 120VAC branch circuits each capable of 44 amps output.

NOTE: The two 120VAC outlets of the 120/240VAC receptacle cannot be paralleled. They are on two different phases.

SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS

The auxiliary power ratings above are with no welding load. Simultaneous welding and power loads are specified in Table B.4. The permissible currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply (not both at the same time).

OPERATION

B-12 B-12

COMMANDER 400

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WARNING

Welding

Output Range

Setting

50-575

400 270 230 180 120

Welding Output

500A/40V 400A/36V 270A/31V 230A/29V 180A/27V 120A/25V

90A/24V

Permissible

Power - Watts

(Unity Power

Factor)

None None

3000 6000 7500 9500 9500

@120 V ±10% *

0 0

28 56** 70** 88** 88**

@ 240 V ±10%

0 14 28 35 44 44

* Each GFCI duplex receptacle is limited to 15 amps. ** Not to exceed 44 Aper 120 VAC branch circuit when splitting the 240 VAC output.

TABLE B.4 Commander 400 Simultaneous Welding and Power Loads

Permissible Auxiliary

Current in Amperes

TABLE OF CONTENTS

- ACCESSORIES -

Accessories...........................................................................................................................Section C

Options/Accessories ...................................................................................................................C-2

Stick Welding..............................................................................................................................C-2

TIG Welding................................................................................................................................C-2

Semiautomatic Welding Accessories..........................................................................................C-2

Connection of Lincoln Electric Wire Feeders..............................................................................C-3

Connection of the LN-7 using K867 Universal Adapter........................................................C-3

Connection of the LN-7 using K584 Input Cable Assembly .................................................C-4

Connection of the LN-8 using K867 Universal Adapter........................................................C-5

Connection of the LN-8 using K595 Input Cable Assembly .................................................C-6

Connection of the LN-23P using K350-1 Adapter Kit...........................................................C-7

Connection of the LN-25 “Across the Arc”...........................................................................C-8

Connection of the K488 SG Control Module and K487 Magnum Spool Gun......................C-9

Section C-1 Section C-1

COMMANDER 400

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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 Aplug rated at 50 Amps.

K857 28 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 welder from a location up to the specified length from the welder. Has convenient plug for easy connection to the welder. The Commander 400 is equipped with a 6 pin connector for connecting the remote control and a toggle switch for selecting “LOCAL” output control or “REMOTE” output control.

K704 Accessory Kit - Includes 35 feet (10 m) of electrode cable and 30 feet (9 m) of work cable, head shield, work clamp and electrode holder. Cable is rated at 500 amps, 60% duty cycle.

K953-1 Two Wheel Trailer - For road, in-plant and yard towing. Road towing with optional fender & light kit. (For highway use, consult applicable federal, state and local laws regarding possible additional requirements.)

K953-1 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hitch K959-1 Fender & Light Kit K965-1 Cable Storage Rack

K825-1 Ether Start Kit - Provides maximum cold weather starting assistance for frequent starting below 10

F (-12.2oC). Required Ether tank is not provided

with kit. K899-1 Spark Arrestor Kit - Easily mounts to stan-

dard muffler. K949-1 Oil Drain Kit - Includes ball valve, hose and

clamp.

STICK WELDING

K704 Accessory Kit which includes:

• Electrode holder and cable.

• Ground clamp and cable.

• Head shield.

TIG WELDING

Magnum TIG Torch Magnum Parts Kit and Argon gas K930-1 TIG Module (not required for scratch start DC TIG welding)

K936-3 Control Cable K870 Foot Amptrol

Also available:

K963 Hand Amptrol K814 Arc Start Switch K937-22 Control Cable Extension K937-45 Control Cable Extension K844-1 Water Valve

HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS

The K799 Hi-Freq Unit and the K930-1 TIG Module are suitable for use with the Commander 400. The Commander is equipped with the required R.F. bypass circuitry for the connection of high frequency generating equipment. The high frequency bypass network supplied with the K799 Hi-Freq Unit does NOT need to be installed into the Commander 400.

The Commander 400 and any high frequency generating equipment must be properly grounded. See the K799 Hi-Freq Unit and the K930-1 TIG Module operating manuals for complete instructions on installation, operation, and maintenance.

SEMIAUTOMATIC WELDING ACCESSORIES

LN-25 Wire Feeder - This portable wire feeder is capa-

ble of CC/CV wire feed welding. LN-7 or LN-8 Wire Feeders - Semiautomatic, constant

speed wire feeder. For CV operation only. LN-23P Wire Feeder - This portable wire feeder is

capable of CV operation. K350-1 adapter kit is required.

NOTE: Gas-shielded welding requires a Magnum Gun. Gasless welding requires an Inner shield Gun.

Magnum Spool Gun (K487-25) - A lightweight, semiautomatic wire feeder for aluminum welding with argon gas. Has built-in remote wire speed control in the handle. Requires the K488 SG Control Module with appropriate control cable. Includes 25 feet (7.6 meters) of power cable.

ACCESSORIES

C-2 C-2

COMMANDER 400

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ELECTRIC SHOCK can kill.

• Do not operate with panels open.

• Disconnect NEGATIVE (-) BATTERY LEAD before servicing.

• Do not touch electrically live parts.

MOVING PARTS 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 TO THE COMMANDER 400 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 “CV- Wire” terminal of the welder.

NOTE: Welding cable must be sized for current and duty cycle of application.

NOTE: Figure C.1 shows the electrode connected for positive polarity. To change polarity, shut the welder off and reverse the electrode and work cables at the Commander 400 output terminals.

3. Connect the K867 Universal Adapter to the K291 or K404 input cable and the 14 pin amphenol of the Commander 400 as indicated in Figure C.1. Make the proper connections for local or remote control according to Figure C.1.

4. Connect the K291 or K404 input cable to the LN-7.

5. Place the IDLER switch in the “HIGH” position.

Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage. If this voltage goes over 140 volts, wire feeder control circuits may be damaged. The engine governor setting is preset at the factory — do not adjust above RPM specifications listed in this manual.

6. Set the LOCAL/REMOTE switch to “REMOTE” if a K775 remote control is used. Set the switch to “LOCAL” if no remote control is used.

7. Set the VOLTMETER switch to “+” or “-” depending on the polarity chosen.

8. Set the RANGE switch to “WIRE WELDING CV.”

9. Set the WELDING TERMINALS switch to “WELDING TERMINAL REMOTELY CONTROLLED.”

10. Adjust wire feed speed at the LN-7.

ACCESSORIES

C-3 C-3

COMMANDER 400

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CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

FIGURE C.1

COMMANDER 400/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM

WARNING

14 PIN AMPHENOL

CV-

TO WORK

K867 UNIVERSAL

ADAPTER PLUG

ELECTRODE CABLE TO WIRE FEED UNIT

SPARE

82 81 42 41

31 32

GND

75 76 77

2 4

}

SPLICE LEADS AND INSULATE

INSULATE UNUSED LEADS INDIVIDUALLY

31 32

2 4

GND

GREEN 75 76 77

K291 OR K404 INPUT CABLE

LN-7 WIRE FEEDER

K775 OPTIONAL REMOTE CONTROL

CONNECTION OF THE LN-7 TO THE COMMANDER 400 USING K584 INPUT CABLE ASSEMBLY (SEE FIGURE C.2.)

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 “CV- Wire” terminal of the welder.

NOTE: Welding cable must be sized for current and duty cycle of application.

NOTE: Figure C.2 shows the electrode connected for positive polarity. To change polarity, shut the welder off and reverse the electrode and work cables at the Commander 400 output terminals.

3. Connect the K584-XX Input Cable Assembly to the LN-7.

4. Connect the K584-XX input cable assembly to the 14 pin amphenol on the Commander 400.

5. Place the IDLER switch in the “HIGH” position.

6. Set the LOCAL/REMOTE switch to “REMOTE” if a K857 remote control is used. Set the switch to “LOCAL” if no remote control is used.

7. Set the VOLTMETER switch to “+” or “-” depending on the polarity chosen.

8. Set the RANGE switch to “WIRE WELDING CV.”

9. Set the WELDING TERMINALS switch to “WELDING TERMINALS REMOTELY CONTROLLED.”

10. Adjust wire feed speed at the LN-7. NOTE: For remote control, a K857 control is requir ed.

Connect it to the 6 pin amphenol.

ACCESSORIES

C-4 C-4

COMMANDER 400

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CAUTION

FIGURE C.2

COMMANDER 400/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM

14 PIN AMPHENOL

CV-

TO WORK

TO LN-7 INPUT CABLE PLUG

K595 CONTROL CABLE

ELECTRODE CABLE TO WIRE FEED UNIT

6-PIN

OPTIONAL K857 REMOTE CONTROL

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