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

ACCESSORIES

C-5 C-5

COMMANDER 400

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CONNECTION OF THE LN-8 TO THE COMMANDER 400 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.3.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-8 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.3 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 K196

input cable and the 14 pin amphenol of the Commander 400 as indicated in Figure C.3. Make the proper connections for local or remote control according to Figure C.3.

4. Connect the K196 input cable to the LN-8.

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

6. Set the LOCAL/REMOTE switch to “REMOTE.”

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 and voltage at the LN-8.

CAUTION

FIGURE C.3

COMMANDER 400/LN-8 WITH K867 ADAPTER CONNECTION DIAGRAM

14 PIN AMPHENOL

CV-

TO WORK

SPARE

K867 UNIVERSAL

ADAPTER PLUG

ELECTRODE CABLE TO WIRE FEED UNIT

GND

81 42 41

31 32

2 4

75 76 77

SPLICE LEADS AND INSULATE

INSULATE UNUSED LEADS INDIVIDUALLY

}

31 32

GND

2 4

K196 INPUT CABLE

LN-8 WIRE FEEDER

ACCESSORIES

C-6 C-6

COMMANDER 400

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CONNECTION OF THE LN-8 TO THE COMMANDER 400 USING K595 INPUT CABLE ASSEMBLY (SEE FIGURE C.4.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-8 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.4 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 K595-XX Input Cable Assembly to the LN-8.

4. Connect the K595-XX 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.”

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 and voltage at the LN-8.

CAUTION

FIGURE C.4

COMMANDER 400/LN-8 WITH K595 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM

14 PIN AMPHENOL

CV-

TO WORK

TO LN-8 INPUT CABLE PLUG

K595 CONTROL CABLE

ELECTRODE CABLE TO WIRE FEED UNIT

CONNECTION OF THE LN-23P TO THE COMMANDER 400 USING K350-1 ADAPTER (SEE FIGURE C.5.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-23P to the “CV- Wire” terminal of the welder. Connect the work cable to the “+” terminal of the welder.

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

NOTE: Figure C.5 shows the electrode connected for negative polarity.

3. Connect the K350-1 adapter to the 6 pin amphenol on the LN-23P and the 14 pin amphenol of the Commander 400 as indicated in Figure C.5.

4. Place the IDLER switch in the “AUTO” position.

5. Set the VOLTMETER switch to negative.

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

7. Set the WELDING TERMINALS switch to ‘WELDING TERMINALS REMOTELY CONTROLLED.”

8. Set the LOCAL/REMOTE switch according to whether you are controlling the welder at the machine or remotely.

9. Adjust wire feed speed and voltage at the LN-23P.

ACCESSORIES

C-7 C-7

COMMANDER 400

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CAUTION

FIGURE C.5

COMMANDER 400/LN-23P CONNECTION DIAGRAM

LN-23P

KIT

ADAPTER

K350-1

6 PIN

ELECTRODE CABLE

AMPHENOL

TO WORK

WIRE FEEDER

14 PIN

ELECTRODE

TO WORK

CV-

CONNECTION OF THE LN-25 TO THE COMMANDER 400 “ACROSS THE ARC” (SEE FIGURE C.6.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-25 to the “-” terminal of the welder. Connect the work cable to the “CV-” terminal of the welder.

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

NOTE: Figure C.6 shows the electrode connected for negative polarity. To change polarity, shut the welder off and reverse the electrode and work cables at the Commander 400 output terminals. Reverse the LN-25 polarity switch.

3. Attach the single lead from the LN-25 control box to the work using the spring clip on the end of the lead. This is only a control lead — it carries no welding current.

4. Place the IDLER switch in the “AUTO” position.

If you are using an LN-25 without an internal contactor, the electrode will be “HOT” when the Commander 400 is started.

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

6. Set the WELDING TERMINALS switch to ‘WELDING TERMINALS ALWAYS ON.”

7. Set the VOLT METER switch to “+” or “-” depend-

ing on the polarity chosen.

8. Adjust wire feed speed at the LN-25.

9. Set the LOCAL/REMOTE switch to “REMOTE” if a K444-1 remote control is used.

Electrode is always “HOT.”

ACCESSORIES

C-8 C-8

COMMANDER 400

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FIGURE C.6

COMMANDER 400/LN-25 ACROSS THE ARC CONNECTION DIAGRAM

CV-

ELECTRODE CABLE

6 PIN

TO WORK

AMPHENOL

AMPHENOL 14 PIN

LN-25

WIRE FEEDER

TO WORK

WORK CLIP LEAD

OPTIONAL K444-1

REMOTE CONTROL

CAUTION

CONNECTION OF THE K488 SG CONTROL MODULE AND K487 MAGNUM SPOOL GUN TO THE COMMANDER 400 (SEE FIGURE C.7.)

1. Shut the welder off.

2. Connect the electrode cable from the SG Control Module 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.7 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 K691-10 input cable as shown in Figure C.7.

4. Set the slide switch on the SG Control Module to the “Lincoln” position.

Be sure this switch is set to the “Lincoln” (contact closure) position before attempting to operate the SG Control Module. Incorrect switch position could result in damage to the SG Control Module and/or the Commander 400.

5. Place the IDLER switch on the Commander 400 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 SG Control Module. NOTE: For remote control, a K857 remote control is

required. Connect it to the 6 pin amphenol.

ACCESSORIES

C-9 C-9

COMMANDER 400

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CAUTION

FIGURE C.7

COMMANDER 400/K691/K488/K487 SPOOL GUN CONNECTION DIAGRAM

K487-25 SPOOL GUN

K691-10 INPUT CABLE

K488 SG

TO WORK

RECEPTACLE

CONTROL MODULE

ELECTRODE CABLE TO CONTROL MODULE

RECEPTACLE

TO WORK

14 PIN WIRE FEEDER

115V RECEPTACLE

ELECTRODE

6 PIN REMOTE

NOTES

C-10 C-10

COMMANDER 400

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Section D-1 Section D-1

COMMANDER 400

TABLE OF CONTENTS

-MAINTENANCE-

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

Safety Precautions ......................................................................................................................D-2

Routine and Periodic Maintenance .............................................................................................D-2

Engine Maintenance.......................................................................................................D-2

Change the Oil ........................................................................................................D-2

Change the Oil Filter ...............................................................................................D-3

Fuel..........................................................................................................................D-3

Fuel Filters ...............................................................................................................D-4

Bleeding the Fuel System .......................................................................................D-6

Air Filter...................................................................................................................D-6

Cooling System .......................................................................................................D-7

Cooling Blower Belt.................................................................................................D-7

Engine Maintenance Schedule................................................................................D-8

Engine Maintenance Parts ......................................................................................D-9

Battery Maintenance ....................................................................................................D-10

Cleaning the Battery..............................................................................................D-10

Checking Specific Gravity .....................................................................................D-10

Checking Electrolyte Level....................................................................................D-10

Charging the Battery .............................................................................................D-10

Welder/Generator Maintenance....................................................................................D-11

Storage ..................................................................................................................D-11

Cleaning.................................................................................................................D-11

Name plates...........................................................................................................D-11

Bearings.................................................................................................................D-11

Receptacles...........................................................................................................D-11

Cable Connections ................................................................................................D-11

Major Component Locations.....................................................................................................D-12

SAFETY PRECAUTIONS

• Have qualified personnel do all maintenance and troubleshooting work.

• Turn 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 machine, get replacements from a Lincoln Distributor.

Read the Safety Precautions in the front of this manual and in the instruction manual for the diesel engine used with your machine before working on the Commander 400.

Keep all equipment safety guards, covers, and devices in position and in good repair. Keep your hands, hair, clothing, and tools away from the fans, and all other moving parts when starting, operating, or repairing this machine.

ROUTINE AND PERIODIC MAINTENANCE

ENGINE MAINTENANCE

To prevent the engine from accidentally starting, disconnect the negative battery cable before servicing the engine.

See Table D.1 for a summary of maintenance intervals for the items listed below. Follow either the hourly or the calendar intervals, whichever come first. More frequent service may be required, depending on your specific application and operating conditions.

OIL: Check the oil level after every 8 hours of operation or daily. BE SURE TO MAINTAIN THE OIL LEVEL.

Change the oil the first time between 25 and 50 hours of operation. Then, under normal operating conditions, change the oil as specified in Table D.1. If the engine is operated under heavy load or in high ambient temperatures, change the oil more frequently.

CHANGE THE OIL: Change the oil, while the engine is still warm, as follows:

1 . Drain the oil from the drain plug located on the

engine bottom, as shown in Figure D.1. Examine the washer and replace it if it appears damaged.

2. Replace the plug and washer and tighten firmly.

3. Remove the oil fill cap and add oil until the level reaches the “MAX” mark on the dipstick. See Figure D.1. Use high quality oil viscosity grade 10W40. Consult the engine manual for oil specifications for various ambient temperatures. Always check the level with the dipstick before adding more oil.

4. Reinstall the oil fill cap and the dipstick.

MAINTENANCE

D-2 D-2

COMMANDER 400

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WARNING

CAUTION

CHANGE THE OIL FILTER: 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 temperatures, change the oil filter more frequently. See Table D.1 for recommended maintenance intervals. See Table D.2 for replacement oil filters.

Change the oil filter as follows:

1. Remove the oil drain plug. Drain the oil from the engine and allow the oil filter to drain. See Figure D.1.

2. Remove the old filter (spin it off) and discard it (2). Wipe off the filter mounting surface and adapter. See Figure D.1.

3. Fill the new filter with fresh engine oil. Apply a thin coat of new oil to the rubber gasket on the new oil filter.

4. Spin the new filter onto the mounting adapter finger tight until the gasket is evenly seated. Then turn it down another 1/2 turn. Do not over tighten the new filter.

5. Refill the engine with the proper amount and type of oil as described in the Change the Oil section, above. Start the engine and check for leaks around the filter element. Correct any leaks (usually by retightening the filter, but only enough to stop leaks) before placing the Commander 400 back in service.

6. If there are no leaks, stop the engine and recheck the oil level. If necessary, add oil to bring the level up to the “MAX” mark, but do not overfill. See Figure D.1.

FUEL: At the end of each day's use, refill the fuel tank to minimize moisture condensation and dirt contamination in the fuel line. Do not overfill; leave room for the fuel to expand.

Refer to your engine operation manual for recommended grade of fuel.

MAINTENANCE

D-3 D-3

COMMANDER 400

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OIL FILL CAP

DRAIN PLUG

DIPSTICK

OIL FILTER

FIGURE D.1 – OIL DRAIN AND REFILL

MAX MIN

FUEL FILTERS:

When working on the fuel system:

• Keep unshielded lights away, do not smoke !

• Do not spill fuel !

The Commander 400 is equipped with a Fuel Pre- Filter/Water Separator Assembly located before the lift pump and a Secondary Fuel Filter located after the lift pump and before the fuel injectors. The Fuel PreFilter/Water Separator is mounted to the engine block just below the lift pump (Figure D.2). The Secondary Fuel Filter is mounted directly to the engine just above the oil filter (Figure D.3).

Fuel Pre-Filter/Water Separator Assembly: The prefilter is a 150 micron screen designed to protect against gross fuel contamination of the water separator element and the Secondary Fuel Filter. If the pre-filter becomes plugged, it may be removed, inspected, cleaned and reinstalled. In general this only needs to be done with each water separator element change (about every 1,000 hrs). However, if at any time excessive fuel contamination is suspected or a sudden falloff in engine performance is detected the pre-filter screen should be inspected and cleaned. See Figure D.2 and follow this procedure:

1. Close the fuel shutoff valve located on the side of the Fuel Pre-Filter/Water Separator Assembly. The lever should be perpendicular to the hose

2. Unscrew the cap ring located on the top of the filter header and remove the plastic center cap and Oring.

3. Remove the large white volume plug located directly under the center cap in the upper cavity of the filter header. Use a small screwdriver (or similar device) to lift the plug part way out of the cavity to assist with its removal.

NOTE: Be careful not to damage the pre-filter screen with the tool used to remove the plug.

4. Using a pair of pliers, gently tug on the pull tabs of the pre-filter screen in an alternating pattern to gradually remove the pre-filter screen.

5. Brush off any debris and rinse in diesel fuel.

Re-install the pre-filter screen into the upper cavity of the filter header making sure the four pull tabs are pointing up. Putting your fingers on the pull tabs, push down evenly until the lower body of the pre-filter screen contacts the floor of the upper cav

ity.

7. Re-insert the large white volume plug into the upper cavity.

8. Place the O-ring onto the angled seal surface of the filter header and re-install the plastic cap. Make sure its flange rests on the O-ring.

9. Screw on the cap ring and tighten hand tight.

10. Remember to open the fuel shutoff valve (Lever in line with the hose) before starting the engine.

Water Separator Element: The water separator element is a two-stage filter with a special filtration/water separating media. An expanded water reservoir provides maximum protection against water in the fuel. The recommended change interval for the water separator element is 1,000 hours. See Figure D.2 and follow this procedure.

1. Close the fuel shutoff valve located on the side of the Fuel Pre-Filter/Water Separator Assembly. The lever should be perpendicular to the hose.

2. Rotate the quick change ring (located just below filter header) clockwise approximately 1/2 turn and slide it down and off the element.

3. Grasp the element and pull down with a slight rocking motion to remove the element from the grommet post on the bottom of the filter header.

MAINTENANCE

D-4 D-4

COMMANDER 400

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WARNING

FIGURE D.2 – FUEL PRE-FILTER/WATER

SEP ARATOR ASSEMBLY

FUEL SHUTOFF VALVE

FILTER HEADER

QUICK CHANGE RING

CAP RING

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 proper orientation now established, apply additional pressure to seat the element in the filter header. You should feel the element “pop” into place when properly seated.

NOTE: The element will only go on one way. Never use excessive force when mounting the element to the header.

5. Slide the quick change ring up over the element and rotate counter clockwise until an audible click or pop is heard. If you do not hear the click, you have not rotated the ring far enough and the element is not in the locked position. Another indication that the ring is in the locked position is that one set (it doesn’t matter which one) of arrows located on the outside of the ring should be located directly under the air vent valve.

6. Open the fuel shutoff valve (lever in line with the hose).

7. Open the air vent valve on the front of the filter header until fuel emerges free of air bubbles. Then close the air vent valve.

Secondary Fuel Filter: The Secondary Fuel Filter is a spin-on cartridge type mounted directly to the engine. Consult your engine operation manual for complete information on service intervals and element changing procedures.

MAINTENANCE

D-5 D-5

COMMANDER 400

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FIGURE D.3 – SECONDARY FUEL FILTER

SECONDARY FUEL FILTER

OIL FILTER

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 FILTER:

Excessive air filter restriction will result in reduced engine life.

The air filter element is a dry cartridge type. It can be cleaned and reused. However, damaged elements should not be reused. Stop engine after 100 hours of running time and clean filter element. Replace the filter if necessary. Service the air cleaner regularly according to your engine operation manual.

1. Locate the air filter canister located behind the engine door on the top of the engine.

2. Remove the air filter element.

3. Remove loose dirt from the element with compressed air or a water hose directed from inside out.

Compressed Air: 100 psi maximum with nozzles

at least one inch away from the element.

Water Hose: 40 psi maximum without nozzle.

4. Soak the element in a mild detergent solution for 15 minutes. Do not soak more than 24 hours. Swish the element around in the solution to help remove dirt.

5. Rinse elements from inside out with a gentle stream of water (less than 40 psi) to remove all suds and dirt.

6.Dry the element before reuse with warm air at less

than 160

F (71oC). Do not use a light bulb to dry the

element.

7. Inspect for holes and tears by looking through the element toward a bright light. Check for damaged gaskets or dented metal parts. Do not reuse damaged elements. Protect the element from dust and damage during drying and storage.

8. Reinstall the air filter element. After six cleanings, replace the air filter. A cleaned

filter will have approximately 70% of the life of a new filter element. A restricted filter element may not appear excessively dirty.

MAINTENANCE

D-6 D-6

COMMANDER 400

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CAUTION

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 BELT: 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 out from the welder.

3. Disconnect the negative battery cable.

4. Remove the engine end panel for access to the engine.

5. See Figure D.4. Loosen the alternator mounting bolts (1, 2, 3) and rotate the alternator toward the engine.

6. Remove the old cooling blower belt and install a new one.

7. Push outward on the alternator (4) and adjust the cold belt tension to 63-73 lbs. (10-15 mm maximum deflection) midway between any two pulleys. Tighten bolts (1), (2), (3).

8. Reinstall the engine end panel. Reattach the negative battery cable. Slide in and refasten the battery holder.

9. Check the cooling blower belt tension after 100 hours of operation.

MAINTENANCE

D-7 D-7

COMMANDER 400

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FIGURE D.4 – COOLING BLOWER BELT REPLACEMENT AND ADJUSTING

MAINTENANCE

D-8 D-8

COMMANDER 400

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TABLE D.1

DEUTZ ENGINE MAINTENANCE SCHEDULE

FREQUENCY MAINTENANCE REQUIRED

Daily or Before Starting Engine

• Fill fuel tank.

• Check oil level.

• Check air cleaner for dirty, loose, or damaged parts. Replace if necessary.

• Check air intake and cooling areas, clean as necessary.

First 50 Hours • Change engine oil. and Every 250 • Change oil filter. Hours Thereafter • Change fuel filter.

• Check fan belt.

Every 50 Hours • Check fuel lines and clamps. Every 100 Hours • Check battery electrolyte level and connections.

• Clean air filter.

Refer to your Deutz engine operation manual for periodic maintenance at 100 hours and beyond.

125 Hours for severe conditions.

MAINTENANCE

D-9 D-9

COMMANDER 400

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Table D.2

ENGINE MAINTENANCE PARTS

ITEM

Air Cleaner Element

Cooling Blower Belt

Oil Filter Element

Fuel Filter Element

Water Separator Element

Fuel Pre-Filter Screen

Battery

MANUFACTURER

Donaldson

Lincoln

Gates

Deutz

Purolator

Napa

Fram

Deutz

Purolator

Napa

Fram

Lincoln

Stanadyne

Lincoln

Stanadyne

PART NUMBER

P181052

A302C

T13536-3

7585

1174418

PER2168

1820

PH3776

1174423

PC42

3358

P4102

M16890-C

31572

M16890-B

29575

BCI

Group

BATTERY MAINTENANCE

GASES FROM BATTERY can explode.

• Keep sparks, flame, and cigarettes away from battery.

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.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY - Disconnect the negative cable from the old battery first and connect to the new battery last.

•

THE CORRECT POLARITY IS NEGATIVE GROUND

Damage to the engine alternator and the printed circuit board can result from incorrect connection.

• CONNECTING ABATTERYCHARGER Remove the battery from the welder by disconnecting the negative cable first, then the positive cable and battery clamp. When reinstalling, connect the negative cable last. Keep the area well ventilated.

• USING A BOOSTER - Connect the positive lead to the battery first, then connect the negative lead to the engine foot.

• To prevent BATTERY BUCKLING, tighten the nuts on the battery clamp until snug.

CLEANING THE BATTERY: Keep the battery clean by wiping it with a damp cloth when dirty. If the terminals appear corroded, disconnect the battery cables and wash the terminals with an ammonia solution or a solution of 1/4 pound (0.113 kg) of baking soda and 1 quart (0.946 l) of water. Be sure the battery vent plugs (if equipped) are tight so that none of the solution enters the cells.

After cleaning, flush the outside of the battery, the battery compartment, and surrounding areas with clear water. Coat the battery terminals lightly with petroleum jelly or a non-conductive grease to retard corrosion.

Keep the battery clean and dry . Moisture accumulation on the battery can lead to more rapid discharge and early battery failure.

CHECKING SPECIFIC GRA VITY: Check each battery cell with a hydrometer. Afully charged battery will have a specific gravity of 1.260. Charge the battery if the reading is below 1.215.

NOTE: Correct the specific gravity reading by adding four gravity points (0.004) for every five degrees the electrolyte temperature is above 80 degrees F (27 degrees (C). Subtract four gravity points (.004) for every five degrees the electrolyte temperature is below 80 degrees F (27 degrees C).

CHECKING ELECTROLYTE LEVEL: If battery cells are low, fill them to the neck of the filler hole with distilled water and recharge. If one cell is low, check for leaks.

CHARGING THE BATTERY: The Commander 400 is equipped with a wet charged battery. The charging current is automatically regulated when the battery is low (after starting the engine) to a trickle current when the battery is fully charged.

When you charge, jump, replace, or otherwise connect battery cables to the battery , be sure the polarity is correct. Improper polarity can damage the charging circuit. The Commander 400 charging system is NEG- A TIVE GROUND. The positive (+) battery terminal has a red terminal cover.

If you need to charge the battery with an external charger, disconnect the negative cable first, then the positive cable before you attach the charger leads. After the battery is charged, reconnect the positive battery cable first and the negative cable last. Failure to do so can result in damage to the internal charger components.

Follow the instructions of the battery charger manufacturer for proper charger settings and charging time.

MAINTENANCE

D-10 D-10

COMMANDER 400

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WARNING

WELDER/GENERATOR MAINTENANCE

STORAGE: Store the Commander 400 in clean, dry,

protected areas. CLEANING: Blow out the generator and controls peri-

odically with low pressure air. Do this at least once a week in particularly dirty areas.

NAME PLATES: Whenever routine maintenance is performed on this machine - or at least yearly - inspect all name plates and labels for legibility. Replace those which are no longer clear. Refer to the parts list for the replacement item number.

BEARINGS: The Commander 400 is equipped with double-shielded ball bearings having sufficient grease to last indefinitely under normal service. Where the welder is used constantly or in excessively dirty locations, it may be necessary to add one half ounce of grease per year. A pad of grease one inch wide, one inch long, and one inch high weighs approximately one half ounce. Over-greasing is far worse than insufficient greasing.

When greasing the bearings, keep all dirt out of the area. Wipe the fittings completely clean and use clean equipment. More bearing failures are caused by dirt introduced during greasing than from insufficient grease.

RECEPTACLES: Keep the electrical receptacles in good condition. Remove any dirt, oil, or other debris from their surfaces and holes.

CABLE CONNECTIONS: Check the welding cable connections at the weld output terminals often. Be sure that the connections are always tight.

MAINTENANCE

D-11 D-11

COMMANDER 400

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MAINTENANCE

D-12 D-12

COMMANDER 400

FIGURE D.5 - MAJOR COMPONENT LOCATIONS

1. CASE DOOR ASSEMBLY

2. ENGINE

3. SHUTDOWN SOLENOID

4. IDLER SOLENOID

5. REAR PANELASSEMBLY

6. BASE

7. FRONT PANEL ASSEMBLY

8. CONTROL PANEL

9. SCR/DIODE RECTIFIER

BRIDGE ASSEMBLY

10. FUEL TANK

11. CAPACITOR BANK

12. ROTOR/STATOR

13. CASE TOPAND SIDES

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Section E-1 Section E-1

COMMANDER 400

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

General Description...............................................................................................................E-2

Battery, Starter, Engine, Rotor and Stator.............................................................................E-2

Exciter Feedback, Control Board, Local and Remote Control ..............................................E-3

Weld Winding, Output Bridge, Output Choke and CV Capacitors ........................................E-4

SCR Operation ......................................................................................................................E-5

Induction Generators.............................................................................................................E-6

TABLE OF CONTENTS

-THEORY OF OPERATION SECTION-

ENGINE ROTOR

MECHANICAL

ROTATION

EXCITER

WINDINGS

WELD

WINDING

SCR/DIODE

OUTPUT

BRIDGE

OUTPUT

CHOKE

CAPACITO

SHUNT

POSITIVE

TERMINAL CV

TERMINAL

NEGATIVE

EXCITER

CAPACITORS

115/230VAC

RECEPTACLE

14 PIN

AMPHENOL

6 PIN

AMPHENOL

EXCITER VOLTAGE

FEEDBACK

BOARD

ENGINE

PROTECTION

BOARD

CURRENT/ MODE

SELECTOR

SWITCH

BATTERY

STARTER

ALTERNATOR

SHUTDOWN

SOLENOID

IDLER SOLENOID

SENSORS

ENGINE

FINE OUTPUT CONTROL

BY-PASS

BOARD

METER

BOARD

MAIN

CONTROL

BOARD

REMOTE SWITCH

42VAC

12VDC

SCR GATE SIGNALS

115VAC

FEEDBACK

F E E D B A C K

FIGURE E.1 – COMMANDER 400 BLOCK LOGIC DIAGRAM

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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 V AC 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 stick and wire model has a CV terminal for constant voltage wire welding.

BATTERY, STARTER, ENGINE, ROTOR AND ST ATOR

The 12VDC battery powers the engine starter motor and supplies power to the main control board for the engine protection circuitry. The engine's alternator supplies "charging" current for the battery circuit. The battery circuit also provides power through the main

control board for the idler solenoid, which is mechanically coupled to the engine's throttle linkage.

The diesel engine is coupled to a brushless asynchronous three-phase alternating current induction generator. See Induction Generators. The excitation or "flashing" voltage is developed in the exciter windings and capacitor configuration. The rotor, which is manufactured by casting aluminum through steel lamination, is mechanically coupled to the engine. Through excitation of this rotating magnet, voltages are produced in the stationary windings of the stator. There are three separate and isolated sets of windings incorporated in the stator lamination. Each set has a different number of turns producing different magnitudes of AC output voltages. These three windings are the three-phase weld winding, the three-phase exciter winding; which is tapped for single phase auxiliary standby power; and the 42V AC single-phase winding, which supplies power to the main control board.

The engine protection circuit shuts the engine off in the event of low oil pressure, engine over temperature, malfunction in the engine's alternator system, or a low fuel condition.

THEORY OF OPERATION

E-2 E-2

COMMANDER 400

FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR AND STATOR

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

BATTERY

STARTER

ALTERNATOR

SHUTDOWN

SOLENOID

WELD

ENGINE ROTOR

ENGINE

SENSORS

MECHANICAL

ROTATION

IDLER SOLENOID

EXCITER

CAPACITORS

115/230VAC

RECEPTACLE

EXCITER

WINDINGS

EXCITER VOLTAGE

FEEDBACK

BOARD

WINDING

115VAC

14 PIN

AMPHENOL

6 PIN

AMPHENOL

SCR/DIODE

OUTPUT

BRIDGE

CAPACITO

SCR GATE SIGNALS

42VAC

REMOTE

BY-PASS

BOARD

12VDC

SWITCH

FINE OUTPUT CONTROL

OUTPUT

CHOKE

ENGINE

PROTECTION

BOARD

SHUNT

CONTROL

FEEDBACK

BOARD

MAIN

BOARD

NEGATIVE TERMINAL

CV TERMINAL

POSITIVE TERMINAL

F E E D B A C K

CURRENT/ MODE

SELECTOR

SWITCH

METER

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EXCITER FEEDBACK, CONTROL BOARD, LOCAL AND REMOTE CONTROL

The exciter voltage is monitored and fed back through the exciter voltage feedback board to the control board. In the event the exciter voltage increases or decreases to an unacceptable level, the engine protection circuit shuts off the engine.

The control board compares the commands of the current/mode selector and the fine output control (or remote control) with the output voltage and current feedback and sends the appropriate SCR gate firing signals to the SCR/Diode bridge.

The Commander 400 is controlled by a high quality microcontroller, which is the main circuit element of the control board.

The control board also supplies operating voltages and control signals to the CV board, the meter board, and the engine protection board.

The remote control and contactor signals are fed to the control board through the amphenols and the by-pass board.

THEORY OF OPERATION

E-3 E-3

COMMANDER 400

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

FIGURE E.3 – EXCITER FEEDBACK, CONTROL BOARD, LOCAL AND REMOTE CONTROL

BATTERY

STARTER

ALTERNATOR

SHUTDOWN

SOLENOID

WELD

ENGINE ROTOR

ENGINE

SENSORS

MECHANICAL

ROTATION

IDLER SOLENOID

EXCITER

CAPACITORS

115/230VAC

RECEPTACLE

EXCITER

WINDINGS

EXCITER VOLTAGE

FEEDBACK

BOARD

WINDINGS

115VAC

14 PIN

AMPHENOL

6 PIN

AMPHENOL

BY-PASS

BOARD

12VDC

SCR/DIODE

OUTPUT

BRIDGE

CAPAC

42VAC

ITORS

SCR GATE SIGNALS

REMOTE SWITCH

FINE OUTPUT CONTROL

OUTPUT

CHOKE

ENGINE

PROTECTION

BOARD

SHUNT

FEEDBACK

BOARD

MAIN

CONTROL

BOARD

NEGATIVE TERMINAL

CV TERMINAL

POSITIVE TERMINAL

F E E D B A C K

CURRENT/ MODE

SELECTOR

SWITCH

METER

THEORY OF OPERATION

E-4 E-4

COMMANDER 400

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WELD WINDING, OUTPUT BRIDGE, OUTPUT CHOKE AND CV CAPACITORS

The three-phase AC output that is created in the stator weld winding is connected to the SCR/Diode output bridge where it is rectified and controlled. See SCR

Operation.

A choke is connected between the negative side of the bridge and the negative output terminal. This large inductor stores energy and provides filtering for the welding output of the Commander 400.

In the constant voltage (CV) mode, the CV capacitors are brought into the welding circuit via an SCR that is activated by the CV board. These capacitors add voltage filtering and help maintain a constant arc voltage at the output terminals.

The shunt, which is in series with the positive output terminal, provides current feedback to the control board.

CV Board and CV Capacitors are present on stick and wire model only.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

FIGURE E.4 – WELD WINDING, OUTPUT BRIDGE, OUTPUT CHOKE AND CV CAPACITORS

BATTERY

STARTER

ALTERNATOR

SHUTDOWN

SOLENOID

WELD

ENGINE ROTOR

ENGINE

SENSORS

MECHANICAL

ROTATION

IDLER SOLENOID

EXCITER

CAPACITORS

115/230VAC

RECEPTACLE

EXCITER

WINDINGS

EXCITER VOLTAGE

FEEDBACK

BOARD

WINDINGS

115VAC

14 PIN

AMPHENOL

6 PIN

AMPHENOL

BY-PASS

BOARD

12VDC

SCR/DIODE

OUTPUT

BRIDGE

CAPAC

42VAC

ITORS

SCR GATE SIGNALS

REMOTE SWITCH

FINE OUTPUT CONTROL

OUTPUT

CHOKE

ENGINE

PROTECTION

BOARD

SHUNT

FEEDBACK

BOARD

MAIN

CONTROL

BOARD

NEGATIVE TERMINAL

CV TERMINAL

POSITIVE TERMINAL

F E E D B A C K

CURRENT/ MODE

SELECTOR

SWITCH

METER

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THEORY OF OPERATION

E-5 E-5

Commander 400

FIGURE E.6 – SCR OPERATION

SCR OPERATION

A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load. An SCR acts very much like a switch. When a gate signal is applied to the SCR, it is turned ON and there is current flow from anode to cathode. In the ON state the SCR acts like a closed switch. When the SCR is turned OFF, there is no current flow from anode to cathode and the device acts like an open switch. As the name suggests, the SCR is a rectifier, so it passes current only during positive half cycles of the AC supply. The positive half cycle is the portion of the sine wave in which the anode of the SCR is more positive than the cathode.

When an AC supply voltage is applied to the SCR, the device spends a certain portion of the AC cycle time in the ON state and the remainder of the time in the OFF state. The amount of time spent in the ON state is controlled by the Gate.

An SCR is fired by a short burst of current into the gate. This gate pulse must be more positive than the cathode voltage. Since there is a standard PN junction between gate and cathode, the voltage between these terminals must be slightly greater than 0.6V. Once the SCR has fired it is not necessary to continue the flow of gate current. As long as current continues to flow from anode to cathode, the SCR will remain on. When the anode to cathode current drops below a minimum value, called holding current, the SCR will shut off. This normally occurs as the AC supply voltage passes through zero into the negative portion of the sine wave. If the SCR is turned on early in the positive half cycle, the conduction time is longer, resulting in greater SCR output. If the gate firing occurs later in the cycle, the conduction time is less, resulting in lower SCR output.

INDUCTION GENERATORS

The Commander 400 utilizes a brushless Asynchronous Induction Generator to convert mechanical energy into electrical energy. The following is a brief description of an induction generator.

The induction generator is an induction motor driven above the synchronous speed. The rotor conductors pass through the magnetic field of the stator in a direction that converts mechanical energy into electrical energy. Typical alternators (synchronous generators) are not self-excited. An induction generator must be connected in parallel with an electrical system that provides out-of-phase current or reactive power for excitation. The capacitors used in the Commander 400 provide the same reactive power that an induction motor would use for power factor correction. In fact, the amount of reactive power used by an induction generator is equal to that used by an induction motor of the same size.

To summarize, the stand-alone induction generator used in the Commander 400 converts mechanical energy into electrical energy. The electrical energy supplied by the capacitors is transferred magnetically to the rotor. Mechanical energy is supplied to the magnetized rotor in the form of torque and rotational speed. The majority of this energy is magnetically delivered to the stator weld coils.

THEORY OF OPERATION

E-6 E-6

COMMANDER 400

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Section F-1 Section F-1

COMMANDER 400

Troubleshooting & Repair Section................................................................................Section F

How to Use Troubleshooting Guide.......................................................................................F-2

PC Board Troubleshooting Procedures.................................................................................F-3

Troubleshooting Guide ................................................................................................F-4 - F-15

Initialization Sequence and Commander 400 Error Code Explanations .............................F-16

Error Codes with G2713-I Control Board......................................................................F-17

Error Codes with G2713-2 or -3 Control Boards ...........................................................F-21

Test Procedures...................................................................................................................F-27

Case Cover Removal and Replacement Procedure.....................................................F-27

Case Front Knobs - Removal and Replacement Procedure.........................................F-32

Idler Solenoid Test .........................................................................................................F-33

Shutdown Solenoid Test ................................................................................................F-35

Engine Throttle Adjustment Test....................................................................................F-37

Static SCR/Diode Rectifier Bridge Test.........................................................................F-41

Active SCR Test.............................................................................................................F-45

Charging Circuit Test.....................................................................................................F-49

Stator Voltage Test ........................................................................................................F-51

Fine Control Potentiometer Test....................................................................................F-55

Range Switch Test.........................................................................................................F-57

Shunt Calibration Test...................................................................................................F-61

Exciter Voltage Feedback Test......................................................................................F-63

Exciter Capacitor Bank Test..........................................................................................F-65

Control Board Power Supply Test.................................................................................F-67

Stator Resistance Test ..................................................................................................F-69

Oscilloscope Waveforms......................................................................................................F-72

Normal Open Circuit Voltage Waveform (115 VAC Supply) ..........................................F-72

Normal Open Circuit Voltage Waveform (Stick) Max Tap .............................................F-73

Normal Weld Voltage Waveform (Stick CC) Machine Loaded

to 400 Amps at 40 Volts..............................................................................................F-74

Normal Weld Voltage Waveform (Wire CV) Machine Loaded

to 400 Amps at 40 Volts..............................................................................................F-75

Normal Open Circuit Voltage Waveform (Wire CV Tap)................................................F-76

Normal Solenoid Pull & Hold Coil Waveforms..............................................................F-77

Abnormal Solenoid Pull & Hold Coil Waveforms...........................................................F-78

Typical Exciter Voltage Feedback Waveforms..............................................................F-79

Abnormal Exciter Voltage Feedback Waveforms..........................................................F-80

Replacement Procedures ....................................................................................................F-81

Control PC Board Removal, Replacement, and Calibration .........................................F-81

Shutdown Solenoid Removal and Replacement ...........................................................F-85

SCR/Diode Rectifier Bridge Removal and Replacement..............................................F-89

SCR Removal and Replacement ..................................................................................F-95

Mounting Stud Type Diodes to Aluminum Heat Sinks.................................................F-103

Engine, Stator/Rotor Removal and Replacement.......................................................F-105

Retest After Repair.............................................................................................................F-117

TABLE OF CONTENTS

TROUBLESHOOTING & REPAIR SECTION

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HOW TO USE TROUBLESHOOTING GUIDE

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 and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

TROUBLESHOOTING & REPAIR

F-2 F-2

Commander 400

CAUTION

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM” (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into four main categories: Output Problems, Engine Problems Function Problems, and Welding Problems.

Step 2. PERFORM EXTERNAL TESTS. The second column, labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)”, lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case cover.

Step 3. PERFORM COMPONENT TESTS. The last column, labeled “Recommended Course of Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.

All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this section. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the referred to test points, components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.

WARNING

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.

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ELECTRIC SHOCK can kill.

Have an electrician install and service this equipment. Turn 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. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:

1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2. Check for loose connections at the PC board to assure that the PC board is properly connected.

3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

PC Board can be damaged by static electricity.

• Remove your body’s static charge before opening the static-shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.

• If you don’t have a wrist strap, touch an unpainted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.

• Tools which come in contact with the PC Board must be either conductive, anti-static or static-dissipative.

• Remove the PC Board from the static-shielding bag and place it directly into the equipment. Don’t set the PC Board on or near paper, plastic or cloth which could have a static charge. If the PC Board can’t be installed immediately , put it back in the static-shielding bag.

• If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete.

• If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.

4. Test the machine to determine if the failure symp-

tom has been corrected by the replacement PC board.

NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

5. Remove the replacement PC board and substitute

it with the original PC board to recreate the original problem.

a. If the original problem does not reappear

by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.

6. Always indicate that this procedure was followed

when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

TROUBLESHOOTING & REPAIR

F-3 F-3

Commander 400

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations

Reusable Container Do Not Destroy

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TROUBLESHOOTING & REPAIR

F-4 F-4

Commander 400

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

Major physical or electrical damage is evident.

No welding output in either CV or Stick modes. Auxiliary power is normal and engine operates normally.

1. Contact your local Lincoln Authorized Field Service Facility .

1. Place the Welding Terminals switch in the “ALWAYS ON”position. If the problem is solved, the fault may be in the external control cable (if used), Leads #2 and #4. See the Wiring Diagram.

2. Check the welding cables, clamps, and electrode holder for loose or faulty connections.

3. With the engine at high idle (1900 RPM), and the machine in the general fab tap, Check for the presence of 70VDC at the output terminals of the Commander 400.

1. Contact the Lincoln Electric Service Department. 1-800-8339353 (WELD).

1. Check for loose or faulty connections on the heavy current carrying leads between the output bridge and the output terminals. Also check for broken leads at the weld choke. See the Wiring Diagram.

2. Check the welding terminal switch (S6) and leads 2 &4 back to J8 pins 2 & 3 of the control board.

3. Check for poor connections at J6 pins 1,2 & 3 molex plug at the control PC board. Also check leads G1,G2 & G3 to each SCR. These are SCR gate drive outputs.

4. Check leads W1 thru W6 for loose or faulty connections. See the wiring diagram.

5. Perform the Stator Voltage Test.

6. Perform the SCR/Diode Bridge

T est.

7. Perform the Control Board

Power Supply Test.

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TROUBLESHOOTING & REPAIR

F-5 F-5

COMMANDER 400

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

The welding output is low with little or no control of output. The auxiliary power is OK. The engine is operating normal.

The machine has low welding output and low auxiliary output.

1. If the remote control unit is not connected to the machine, make sure the Local/Remote switch (S1) is in the “Local” position.

2. If a remote control unit is connected, and the machine operates normally when the switch is in the “Local” position, the remote control cable or unit may be faulty. Check or replace.

1. The engine speed may be low. Normal high idle (no load) is 1900 RPM.

1. Perform the Fine Control

Potentiometer Test.

2. Perform the Stator Voltage Test.

3. Perform the SCR/Diode Bridge

Test.

1. If the speed is low, perform the

Engine Throttle Adjustment Test.

2. Perform the Stator Voltage Test.

3. Perform the Exciter Capacitor

Bank Test.

4. The engine may have lost horsepower and may need major repairs.

“---” or “CRS” stuck on display when machine is powered up. No welding output in both stick and CV modes. Engine operates normally and auxiliary power is normal.

1. Contact your local Lincoln Authorized Field Service shop.

1. Check for loose or faulty connections or wires at the T1, T2, or T3 capacitor connection block and back to the capacitor bank. On machines equipped with L10953-1 Exciter feedback Module Assembly check leads T1, T2 & T3 for faulty connections.

2. Check for loose or faulty connections at leads 268,269, & 270 from the exciter PC board to J4 pins 1,2, & 3 on the control board.

3. Check the exciter waveforms as illustrated in the Oscilloscope

Waveforms Section.

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TROUBLESHOOTING & REPAIR

F-6 F-6

Commander 400

Observe Safety Guidelines

TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

The machine powers down within seconds of power up and all lamp indicators on the front panel are lit. “ECL”, “ECH”, or “CSS” appears on display as machine is shutting down.

1. Contact your local Lincoln Authorized Field Service Shop.

1. Check to make sure that the machine has an L10953-1 Exciter Feedback Module Asbly.

2. Check for loose or faulty connections or wires at the T1, T2 or T3 capacitor connection block and back to the capacitor bank. On machines equipped with L10953-1 Exciter Feedback Module Asbly check leads T1, T2 and T3 for fault connections.

3. Check for loose or faulty connections at leads 268, 269, & 270 from the exciter PC Board to J4 pins 1, 2 & 3 on the control board.

4. If possible check exciter waveforms as illustrated in the

Oscilloscope Waveforms Section.

5. If possible perform the Exciter Voltage Feedback Test.

Low or no constant voltage (CV) welding output. Constant current (CC) and the auxiliary power are operating normally.

1. Make sure the wire feeder, control cable and welding cables are connected correctly.

2. Make sure the range switch is in the correct position.

3. Check the heavy current carrying cables associated with the CV output terminal. See the Wiring Diagram.

1. Perform the Range Switch

Test.

2. Check for poor connections at J21 pins 1 & 4 at the CV daughter board. This is CVSCR gate drive output. Will not affect welding in the general fab or pipe taps.

3. Check for poor connections along lead #208 at the negative CV output stud and at the J21 pin 6 molex plug at the CV daughter board. This is CV voltage feedback input. Will not affect welding in the general fab or pipe taps.

4. Perform the Control Board

Power Supply Test.

No welding output in either CV or stick modes. Also no auxiliary power. Engine operates normally.

No auxiliary power at receptacles. The engine operates normally and the welding output is normal.

1. Contact your local Lincoln Authorized Field Service Shop.

1. Check the circuit breakers CB1 thru CB4. Reset if tripped.

2. Check the GFCI receptacles. Reset if tripped.

3. Check for loose or faulty plugs at the power receptacles.

1. Check for loose or faulty connections or wires at the T1, T2 or T3 capacitor connection block and back to the capacitor bank. On machines equipped with L10953-1 Exciter feedback module asbly check leads T1, T2 and T3 for faulty connections. See the Wiring Diagram.

2. Perform the Exciter Capacitor

Bank Test.

3. Check for a short across the weld bridge plates.

4. Disconnect leads 3, 5 & 6 from the terminal block located inside the right hand side of the control box. Check for a short across each 115v and 115V/230V receptacle.

5. Check fro shorts or opens in the stator by performing the Stator

Resistance Test.

6. Perform the Control Board

Power Supply Test.

1. Check the GFCI receptacles and associated wires for loose or faulty connections. See the Wiring Diagram.

2. Check the continuity of leads #3, #5, #5A and #6 from the exciter windings to their respective tie points. See the Wiring Diagram.

3. Perform the Stator Voltage Test.

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TROUBLESHOOTING & REPAIR

F-7 F-7

COMMANDER 400

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

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TROUBLESHOOTING & REPAIR

F-8 F-8

COMMANDER 400

Observe Safety Guidelines

TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

ENGINE PROBLEMS

Engine will not idle down to low speed. Machine has normal weld and auxiliary power.

1. Make sure the Idler switch (S4) is in the “AUTO” position.

2. Make sure there is not an external load on either the weld terminals or the auxiliary receptacles.

3. Check for mechanical restriction in the solenoid linkage.

1. Perform the Idler Solenoid Test.

2. Make sure the control board mounting/grounding screws are tight.

3. Check leads #226, #227, #237 & #254 for loose or faulty connections. See the Wiring Diagram.

4. Check solenoid waveforms as illustrated in the Oscilloscope

Waveforms Section.

5. Check to make sure that leads #227 & #232 at the B1 & B3 terminals on the control board are not swapped. See the Wiring Diagram.

Engine will not go to high idle when attempting to weld or use auxiliary power. Output is normal when Idler switch is in the “HIGH” position. Automatic idle function works properly when the auxiliary power is loaded.

1. Make sure the welding cables and connections are tight.

NOTE: The automatic idler may

not function if the auxiliary power is loaded to less than 150 watts.

1. Check the current sensing toroid for loose or faulty connections. CV models only. See the Wiring Diagram.

2. Make sure the toroid and lead assembly are assembled correctly . CV models only

. See the

Wiring Diagram.

3. Check the shunt and associated leads for loose or faulty connections. Stick models only

4. The control board may be faulty.

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TROUBLESHOOTING & REPAIR

F-9 F-9

Commander 400

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

ENGINE PROBLEMS

The machine goes to low idle but does not stay at low idle.

1. Make sure there is NOT an external load (auxiliary or weld) connected to the Commander

400.

1. The idler solenoid linkage may be misadjusted or damaged.

2. The idler solenoid hold-in circuitry may be faulty. Check leads #237 and #226 for loose or faulty connections. See the Wiring Diagram.

3. Perform the Idler Solenoid Test.

4. Make sure the control board mounting/grounding screws are tight.

5. Check solenoid waveforms as illustrated in the Oscilloscope

Waveforms Section.

6. The control board may be faulty. Replace.

The engine will not crank or cranks very slowly.

1. Check for loose, faulty, or corroded battery cable connections.

2. Check the leads and connections at the starter solenoid and the start push button.

3. The battery may be faulty.

1. The starter motor, solenoid or push button may be faulty. Check or replace.

2. The engine may be hard to crank due to a mechanical failure in the engine.

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TROUBLESHOOTING & REPAIR

F-10 F-10

COMMANDER 400

Observe Safety Guidelines

TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

ENGINE PROBLEMS

The engine cranks but will not start. 1. Check for adequate fuel supply.

2. Make sure the fuel shut off valve is in the open position (lever is in line with the hose).

3. The battery voltage may be too low. If it is less than 11VDC, charge or replace the battery. Check the charging system.

4. If the engine temperature light is lit, check the engine cooling system.

1. Check leads #274 & #240A at J50 (exciter voltage plug) for loose or faulty connections. See the Wiring Diagram.

2. Perform the Shutdown

Solenoid Test.

3. Check leads #224, #225, #240 and #262 for loose or faulty connections. See the Wiring Diagram.

4. Make sure the control board mounting/grounding screws are tight.

5. Check solenoid waveforms as illustrated in the Oscilloscope

Waveforms Section.

6. Check to make sure that J4 & J23 are not swapped at the control board. See the Wiring Diagram.

The engine shuts down shortly after start. Initialize sequence is normal (see Initialization Sequence sec- tion).

1. Check for adequate fuel supply.

2. If any indicator light is lit when the engine shuts down, that particular system has faulted. Check system.

3. Check for loose, faulty, or corroded battery cable connections.

4. Check the Run/Stop switch and associated leads for loose or faulty connections.

1. Perform the Shutdown

Solenoid Test.

2. If possible check solenoid waveforms as illustrated in the

Oscilloscope Waveforms section.

3. The control board may be faulty.

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F-11 F-11

COMMANDER 400

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

FUNCTION PROBLEMS

The battery does not stay charged. 1. Check for loose, faulty or cor-

roded battery cable connections.

2. The battery may be faulty. Check or replace.

1. Perform the Charging Circuit

Test.

The Fine Control on the Commander 400 does not work properly.

1. Make sure the Remote/Local switch (S1) is in the “LOCAL” position.

1. Perform the Fine Control

Potentiometer Test.

3. The control board may be faulty.

The wire feeder does not work when connected to the machine’s 14 pin amphenol.

1. Check the circuit breaker CB5. Reset if tripped.

2. The wire feeder control cable may be faulty. Check or replace.

3. The wire feeder may be faulty. Check or replace.

1. With the engine at high idle speed: Check for the presence of 115VAC at leads #31 pin “J” and #32 pin “A” at the 14 pin amphenol. If the voltage is missing or low, Check for loose or broken connections. See the Wiring Diagram. Also check CB5 for proper operation.

2. The RF bypass board (CV modules only) may be faulty. See the Wiring Diagram.

3. Perform the Stator Voltage Test.

Remote output control not functioning correctly.

1. Make sure the Remote/Local switch (S1) is in the “REMOTE” position.

2. The remote control unit or cable may be faulty. Repair or replace.

1. Perform the Fine Control

Potentiometer Test.

2. Check the Remote/Local switch (S1) and associated leads. See the Wiring Diagram.

3. The RF Bypass PC Board (CV models) may be faulty. See the Wiring Diagram.

The Remote Protection PC Board (Stick models) may be faulty. See the Wiring Diagram.

4. Check amphenols and associated leads. See the Wiring Diagram.

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TROUBLESHOOTING & REPAIR

F-12 F-12

COMMANDER 400

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

FUNCTION PROBLEMS

The welding arc is “cold.” The engine runs normally. The auxiliary power is normal.

1. Check for loose or faulty connections at the weld output terminals and welding cable connections.

2. The welding cables may be too long or coiled, causing an excessive voltage drop.

3. Check to make sure that the machine settings match the weld application.

4. If a remote control unit is not connected to the machine, make sure the Local/Remote switch (S1) is in the “LOCAL” position.

5. If the remote control unit is connected, and the machine operates normally when the switch is in the “LOCAL” position, the remote control cable or unit may be faulty. Check or replace.

1. Using a voltmeter, check for the correct OCV at the weld terminals. If the correct voltage is present, then check for loose connections on the heavy current carrying leads inside the machine. See the Wiring Diagram.

2. If the OCV is low, perform the

Engine Throttle Adjustment Test.

3. Perform the SCR/Diode Bridge

Test.

4. Perform the Stator Voltage T est.

5. Perform the Range Switch Test.

6. Perform the Fine Control

Potentiometer Test.

7. Check fro poor connections at the J1 molex plug at the control board and at the shunt. Also, perform the Shunt Calibration

Test.

8. Check for poor connections along lead #204A at the diode bridge and at J6 pin 4 molex at the control pc board. This is control board common.

9. Check for poor connections at J6 pins 1, 2 & 3 molex plug at the control board. Also check leads G1, G2 & G3 to each SCR. These are SCR gate drive outputs.

10. Check for poor connections

along lead #207 at the negative CC output stud, and at the J6 pin 10 molex plug at the control board. This is CC arc voltage feedback input. Will not affect welding in the CV tap.

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TROUBLESHOOTING & REPAIR

F-13 F-13

COMMANDER 400

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

WELDING PROBLEMS

The welding arc is “cold.” The engine runs normally. The auxiliary power is normal. (Continued)

11. Check for poor connection at J21 pins 1 & 4 at the CV daughter board. This is CVSCR gate drive output. Will not affect welding in the general fab or pipe taps.

12. Check for poor connection

along lead #208 at the negative CV output stud and at J21 pin 6 molex plug at the CV daughter board. This is CV voltage feedback input. Will not affect welding in the general fab or pipe taps.

13. Check the weld & CV chokes (if

so equipped) for turn to turn shorts.

14. Check all waveforms as illus-

trated in the Oscilloscope

Waveforms Section.

15. Perform the Control Board

Power Supply Test.

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TROUBLESHOOTING & REPAIR

F-14 F-14

The welding arc is “hot”, “spattery”, “cannonballs” or “flares up”. The engine runs normally. The auxiliary power is normal.

1. Check to make sure that the machine settings match the weld application.

2. If the remote control unit is not connected to the machine, make sure the Local/Remote switch (S1) is in the “Local” position.

3. If a remote control unit is connected, and the machine operates normally when the switch is in the “Local” position, the remote control cable or unit may be faulty. Check or replace.

1. Perform the Range Switch

Test.

2. Perform the Fine Control

Potentiometer Test.

3. Check for poor connections at the J1 molex plug at the control board. Also, perform the Shunt

Calibration Test.

4. Check for poor connections at J4 pins 1, 2, 3, 6, & 7 at the control board. Also, perform the

Exciter Voltage Feedback Test.

5. Check for poor connections along lead #207 at the negative CC output stud, and at J6 pin 10 molex plug at the control board. This is CC arc voltage feedback input. Will not effect welding in the CV tap.

6. Check for poor connections along lead #204A at the diode bridge and at J6 pin 4 molex plug at the control board. This is control board common.

7. Check for poor connection along lead #208 at the negative CV output stud and at J21 pin 6 molex plug at the CV daughter board. This is CV voltage feedback input. Will not affect welding in the general fab or pipe taps.

8. Check for poor connection at J21 pins 1 & 4 at the CV daughter board. This is CVSCR gate drive output. Will not affect welding in the general fab or pipe taps.

9. Check the weld & CV chokes (if so equipped) for turn to turn shorts.

COMMANDER 400

WELDING PROBLEMS

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

CAUTION

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TROUBLESHOOTING & REPAIR

F-15 F-15

The welding arc is “hot”, “spattery”, “cannonballs” or “flares up”. The engine runs normally. The auxiliary power is normal. (Continued)

10. Check all waveforms as illustrated in the Oscilloscope

Wave forms Section.

11. Perform the Control Board Power Supply Test.

Machine shuts down while arc gouging and all lamp indicators on front panel are lit. “ECL”, “ECH”, or “CCS” appears on display as machine is shutting down.

1. Check to make sure that the machine settings match the weld application.

2. Check to make sure the propper carbon arc rod is being used. The maximum carbon arc rod for the Commander 400 is 5/16”.

3. Attempt to arc gouge at a lesser current, if the application will permit.

4. If the machine shuts down while arc gouging in the general fab tap, use the CV tap instead. This is also an acceptable process.

1. Check for poor connections at J4 pins 1, 2, 3, 6 & 7 at the control pc board. Also, perform the

Exciter Voltage Feedback Test.

2. Check for loose or faulty connections or wires at the T1, T2, or T3 capacitor connection block and back to the capacitor bank. On machines equipped with L10953-1 Exciter Feedback module asbly, check leads T1, T2, & T3 for faulty connections.

3. Check for loose or faulty connections at leads 268, 269 & 270 from the exciter pc board to J4 pins 1, 2 & 3 on the control board.

4. Perform the Exciter Capacitor

Bank Test.

5. Check for poor connections at the J1 molex plug at the control pc board. Also, perform the

Shunt Calibration Test.

6. Perform the Engine Throttle Adjustment Test.

7. Check exciter waveforms as illustrated in the Oscilloscope

Waveforms Section.

COMMANDER 400

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

WELDING PROBLEMS

CAUTION

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TROUBLESHOOTING & REPAIR

F-16 F-16

COMMANDER 400

COMMANDER 400 INITIALIZATION SEQUENCE

AND ERROR CODE EXPLANATIONS

When the Commander 400 is started, the display flashes several messages during initialization. They usually go by so fast you cannot see them. Each message correlates to an initialization test that the microcontroller program runs. No message should be present for more than a few seconds before the next message appears. If any of these initialization messages remain on the display , there is a problem. The microcontroller’s program will not advance past that test.

The initialization period is over immediately after the “---” disappears from the display. Once past the initialization, under normal circumstances, the unit displays a welding current preset determined by the position of the front panel control knobs and switches. If a later control board (G2713-2 or -3 is in place, the message “cdr 400 rEAdy” scrolls across the display. Initialization is over after this message finishes scrolling. In the “Stick & Wire” model a preset voltage or actual voltage, as well as current, may be displayed after initialization.

If the microcontroller detects an error, the error code will show on the display first and then the unit may shut down. Use the “Error Code Explanations” on the following pages to aid in troubleshooting diagnosis.

If the unit begins to shut down first and then the error code appears, this is not

a microcontroller initiated shutdown. In this case the unit has shut down due to lack of fuel, engine failure, etc.

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TROUBLESHOOTING & REPAIR

F-17 F-17

COMMANDER 400 WITH G2713-1 CONTROL BOARD

ERROR CODES DURING

INITIALIZATION SEQUENCE

DEFINITION / SYMPTOM CORRECTIVE ACTION

300

bAd uP

400

600

700

500

---

Program is stuck in ROM/RAM check.

ROM/RAM is corrupt. Program is stuck in power supply

stabilization.

Program is stuck in register initialization and Interrupt enables.

Program is stuck in calibration constant loading.

The processor is not getting good initial zero crosses. The program waits for 32 clean crosses and then waits for frequency to get between 55 and 65 HZ. or Program is stuck waiting for program stabilization and loading of exciter voltage register table.

Replace control board.

Replace control board. Perform the Control Board

Power Supply Test.

Replace control board.

Check exciter voltage waveforms as illustrated in the Oscilloscope

Waveforms Section. Perform the Stator Voltage

Exciter Winding Test. Perform the Engine Throttle

Adjustment Test. Perform the Exciter Capacitor

Bank Test.

Check leads #268, #269, & #270 from J50 to J4 at the control board for loose or faulty connections. Also check the T1, T2, & T3 lead connections from the exciter module to the stator and capacitor bank leads.

COMMANDER 400

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TROUBLESHOOTING & REPAIR

F-18 F-18

COMMANDER 400 WITH G2713-1 CONTROL BOARD

ERROR CODES DURING

INITIALIZATION SEQUENCE

DEFINITION / SYMPTOM CORRECTIVE ACTION

CSS

ECL

The processor is not receiving zero cross signals properly or the engine RPM is out of range.

or The exciter voltage is out of

range (greater than 550 or less than 140VAC).

Check exciter voltage waveforms as illustrated in the Oscilloscope

Waveforms Section. Perform the Stator Voltage

Exciter Winding Test. Perform the Engine Throttle

Adjustment Test. Perform the Exciter Capacitor

Bank Test.

Check leads #268, #269, & #270 from J50 to J4 at the control board for loose or faulty connections. Also check the T1, T2, & T3 lead connections from the Exciter Module to the stator and capacitor bank leads.

COMMANDER 400

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TROUBLESHOOTING & REPAIR

F-19 F-19

COMMANDER 400 WITH G2713-1 CONTROL BOARD

ERROR CODES DURING

INITIALIZATION SEQUENCE

DEFINITION / SYMPTOM CORRECTIVE ACTION

LCH

Err

The output current is too high (greater than 750 amps for more than 1 second).

XIRQ error (illegal external interrupt request).

The machine may be “over loaded.” Remove any external loads. If the problem persists with no external load, check the shunt leads and associated connections to the control board. See the Wiring Diagram. Perform the SCR/Diode Rectifier Bridge

Test.

If the above procedures do not reveal the problem, the control board may be faulty.

If a High Frequency unit is being used, make sure it is connected properly. There may be high frequency intrusion from another source in the immediate area. Remove all possible forms of RF intrusion.

If the problem persists, the control board may be faulty.

COMMANDER 400

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TROUBLESHOOTING & REPAIR

F-20 F-20

COMMANDER 400 WITH G2713-1 CONTROL BOARD

ERROR CODES DURING

INITIALIZATION SEQUENCE

DEFINITION / SYMPTOM CORRECTIVE ACTION

Ert

Esi

EIO ECP ECE

EO5

IC3

SS?

RTI error (illegal return from interrupt).

SWI error (illegal software interrupt request).

IOT error (illegal op code trap). COP time-out error. CME error (slow or stopped

processor clock). OC5 unintended execution. IC3 unintended execution.

Invalid range control switch position.

If a High Frequency unit is being used, make sure it is connected properly. There may be high frequency intrusion from another source in the immediate area. Remove all possible forms of RF intrusion.

If the problem persists, the control board may be faulty.

Check for proper selector switch/handle alignment. Check the selector switch and associated wiring. See the Wiring Diagram. If the problem persists, the control board may be faulty.

COMMANDER 400

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TROUBLESHOOTING & REPAIR

F-21 F-21

COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD

ERROR CODES DURING

INITIALIZATION SEQUENCE

DEFINITION / SYMPTOM CORRECTIVE ACTION

bAd uP

CAL

CrS

Program is stuck in ROM/RAM check.

ROM/RAM is corrupt. Program is stuck in calibration

constant loading. The processor is not getting good

initial zero crosses. Program waits for 32 clean crosses and then waits for frequency to get between 55 and 65 HZ.

Program is stuck waiting for program stabilization and loading of exciter voltage register table.

Replace control board.

Replace control board. Replace control board.

Check exciter voltage waveforms as illustrated in the Oscilloscope

Waveforms Section. Perform the Stator Voltage

Exciter Winding Test. Perform the Engine Throttle

Adjustment Test. Perform the Exciter Capacitor

Bank Test.

COMMANDER 400

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TROUBLESHOOTING & REPAIR

F-22 F-22

COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD

ERROR CODES DURING

INITIALIZATION SEQUENCE

DEFINITION / SYMPTOM CORRECTIVE ACTION

SSr

EHC

ECL

CSS

Processor is not reading a valid range control switch position.

The exciter voltage level is too high (greater than 550VAC).

The exciter voltage level is too low (less than 140VAC).

The processor is not receiving zero cross signals properly or the engine RPM is too high.

Check for proper selector switch/handle alignment.

Perform the Range Switch Test.

Check the exciter voltage waveforms as illustrated in the Oscilloscope Waveforms Section.

Perform the Stator Voltage Exciter Winding Test.

Perform the Engine Throttle Adjustment Test.

Perform the Exciter Capacitor Bank Test.

Check leads #268, #269 & #270 from J50 to J4 at the control board for loose or faulty connections. Also check the T1, T2, & T3 lead connections from the exciter module to the stator and capacitor bank leads.

COMMANDER 400

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TROUBLESHOOTING & REPAIR

F-23 F-23

COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD

ERROR CODES

WHILE RUNNING

DEFINITION / SYMPTOM CORRECTIVE ACTION

LCH

Err

The output current is too high (greater than 750 amps for more than 1 second).

XIRQ error (illegal external interrupt request).

The machine may be “over loaded.” Remove any external loads. If the problem persists with no external load, check the shunt leads and associated connects to the control board. See the Wiring Diagram. Perform the SCR/Diode Rectifier Bridge Test. If the above procedures do not reveal the problem, the control board may be faulty.

If a High Frequency unit is being used, make sure it is connected properly. There may be high frequency intrusion from another source in the immediate area. Remove all possible forms of RF intrusion. If the problem persists, the control board may be faulty.

COMMANDER 400

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TROUBLESHOOTING & REPAIR

F-24 F-24

COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD

ERROR CODES

WHILE RUNNING

DEFINITION / SYMPTOM CORRECTIVE ACTION

LFL

SS?

Unit has shut down because of low fuel.

Invalid range control switch position.

Add more fuel. If there is less than half a tank of fuel,check for proper operation of the fuel float. If the float is at the top of the tank, the resistance across its terminals should be less than 100 ohms. If the float is on the bottom of the tank, the resistance across its terminals should be greater than 175 ohms. If the float is OK, check the leads and connections between the float, the fuel gauge and the engine protection board. See the Wiring Diagram. If the above checks do not reveal the problem, the engine protection board may be faulty.

Check for proper selector switch/handle alignment. Check the selector switch and associated wiring. See the Wiring Diagram. If the problem persists, the control board may be faulty.

COMMANDER 400

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TROUBLESHOOTING & REPAIR

F-25 F-25

COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD

ERROR CODES

WHILE RUNNING

DEFINITION / SYMPTOM CORRECTIVE ACTION

Ert

Esi

EIO ECP ECE

EO5

IC3

RTI error (illegal return from interrupt).

SWI error (illegal software interrupt request).

IOT error (illegal op code trap). COP time-out error. CME error (slow or stopped

processor clock). OC5 unintended execution. IC3 unintended execution.

If a High Frequency unit is being used, make sure it is connected properly. There may be high frequency intrusion from another source in the immediate area. Remove all possible forms of RF intrusion.

If the problem persists, the control board may be faulty.

COMMANDER 400

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TROUBLESHOOTING & REPAIR

F-26 F-26

COMMANDER 400 WITH G2713-2 OR -3 CONTROL BOARD

ERROR CODES WHILE

RUNNING

DEFINITION / SYMPTOM CORRECTIVE ACTION

ECH

ECL

CSS

The exciter voltage is too high (greater than 550 VAC).

The exciter voltage is too low (less than 140 VAC).

The processor is not receiving zero cross signals properly or the engine RPM is too high.

Check exciter voltage waveforms as illustrated in the Oscilloscope

Waveforms Sections. Perform the Stator Voltage

Exciter Winding Test. Perform the Engine Throttle

Adjustment Test. Perform the Exciter Capacitor

Bank Test.

COMMANDER 400

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TROUBLESHOOTING & REPAIR

F-27 F-27

COMMANDER 400

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE

WARNING

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 avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

DESCRIPTION

This procedure will aid the technician in the removal and replacement of the case sheet metal covers.

MATERIALS NEEDED

3/8" Nut driver or Socket Wrench 7/16" Wrench 5/16" Nut Driver

This procedure takes approximately 35 minutes to perform.

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TROUBLESHOOTING & REPAIR

F-28 F-28

COMMANDER 400

FIGURE F.1 – DOOR CHAIN REMOVAL

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)

PROCEDURE

1. Turn the engine off.

2. Unlatch and open engine service access door.

3. Using the 7/16" wrench, remove the chain from the door assembly. See Figure F.1

DOOR ASSEMBLY

CHAIN

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TROUBLESHOOTING & REPAIR

F-29 F-29

COMMANDER 400

FIGURE F.2 – DOOR ASSEMBLY/LEFT SIDE PANEL SCREW LOCATIONS

4. Using the 3/8" wrench, remove the three screws holding the door assembly to the left side panel. See Figure F.2.

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.3 – DOOR HINGE SCREW LOCATIONS

5. Using the 3/8" wrench, remove the two

screws under the hinge. While supporting the door assembly, remove the two screws

at the ends of the hinge. See Figure F.3 When these screws are removed, the door assembly will be free to fall.

LEFT SIDE PANEL

THREE SCREWS

2 SCREWS UNDER

2 SCREWS OUTSIDE

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TROUBLESHOOTING & REPAIR

F-30 F-30

Commander 400

FIGURE F.4 – LEFT SIDE ENGINE COVER REMOVAL

6. Carefully lift the door assembly from the machine.

7. Using the 3/8" wrench, loosen the two bottom end screws from the left side engine cover panel. See Figure F.4. Remove the center screw. Remove the panel.

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)

8. Using the 3/8" wrench, remove the screws from the front roof assembly.

9. Remove the fuel cap and rubber seal. Carefully lift and remove the front roof assembly. Replace the fuel cap.

10. Remove the screws from the lower front left and right side panels. The bottom end screws need only to be loosened.

11. Remove the panels.

LEFT SIDE ENGINE COVER PANEL

LOOSEN TWO END SCREWS

REMOVE CENTER SCREW

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TROUBLESHOOTING & REPAIR

F-31 F-31

COMMANDER 400

FIGURE F.5 – FRONT CONTROL PANEL REMOVAL

FRONT SHROUD REMOVAL PROCEDURE

1. Using the 5/16" nut driver, remove the screws from the front control panel assembly. Do NOT remove the phillips head screws. Lower the panel. See Figure F.5.

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.6 – SHROUD ASSEMBLY SCREW REMOVAL - SIDES

2. Using the 5/16" nut driver, remove the four screws from the left and right sides of the shroud assembly. See Figure F.6.

FRONT CONTROL PANEL LOWERED

ARROWS INDICATE SCREW LOCATIONS

SHROUD ASSEMBL Y

REMOVE 2 SCREWS, EACH SIDE

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F-32 F-32

COMMANDER 400

TROUBLESHOOTING & REPAIR

CASE FRONT KNOBS - REMOVAL AND REPLACEMENT PROCEDURE



Removal

Side View

(Pull)

NameplateKnob

(Push)

Removal:

(Pull)

(Push)



1. Rotate the handle portion of the knob to an approximate vertical orientation (switch detent may position handle a few degrees off vertical). This orientation should be noted and repeated at replacement for proper "D" shaft orientation.

2. With one hand, grasp the very bottom of vertical handle and push towards the machine nameplate and pull down. At the same time and with the other hand, grasp the very top of the handle and pull the top edge of the knob away from the machine nameplate. The knob should "peel" away from the nameplate and the white nylon holding fingers of the knob base, from top to bottom.

Replacement

Rounded

Replacement: 

1. If the white nylon cam of the detent mechanism is removed from it's spring loaded base by the above  procedure or intentionally, it should be returned before the knob replacement is attempted. Press the cam into it's spring loaded holder so it sets flat and flush (Selector Switch Only).

2. Orientate the knob handle to the vertical as noted above and position the knob over the base, centered  and parallel.

3. Press the knob onto the "D" shaft and white nylon holding fingers, maintaining the parallel position.  The knob should "click" into place and should not pull off with normal operation.

Flat

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TROUBLESHOOTING & REPAIR

F-33 F-33

COMMANDER 400

WARNING

IDLER SOLENOID TEST

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 avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

TEST DESCRIPTION

This test will determine if the idler solenoid is capable of functioning when it is energized with 12VDC.

MATERIALS NEEDED

External 12VDC supply ( 30 amps required) Wiring Diagram Volt/Ohmmeter

This procedure takes approximately 40 minutes to perform.

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TROUBLESHOOTING & REPAIR

F-34 F-34

COMMANDER 400

IDLER SOLENOID TEST (continued)

FIGURE F.8 – IDLER SOLENOID LEAD TERMINALS

PULL-IN COIL (LARGER TERMINALS TOP AND BOTTOM #227 AND #254)

HOLD-IN COIL (SMALLER TERMINALS TOP AND BOTTOM #226 AND #237)

IDLER SOLENOID

SHUTDOWN SOLENOID

TEST PROCEDURE

1. Turn the engine off.

2. Unlatch, lift and secure the right side engine service access door. Using a 5/16”, open the control panel and tilt out. Remove the control board cover.

3. Check the pull-in coil resistance by disconnecting lead #227 from the B1 terminal at the control board and measuring the resistance from lead #227 to the ground screw at the control board. Normal coil resistance is approximately 0.4 ohms. Reconnect lead #227 to the B1 terminal at the control board.

Check the hold-in coil resistance by disconnecting J3 from the control board and measuring across pins 3 & 4. Normal coil resistance is approximately 20 ohms. Reconnect J3 at the control board.

If either coil resistance is incorrect, the wiring may be faulty. Inspect the solenoid leads for faulty or loose connections.

If the lead connections are OK, recheck the coil resistance directly across the solenoid. If the coil resistances are incorrect, the solenoid may be faulty. Replace.

4. Using the external 12VDC voltage supply, apply 12VDC to the larger idler solenoid terminals (#227+ to #254-). The solenoid should activate.

When the solenoid activates, remove the voltage supply immediately. Do not leave the external supply connected to terminals #227 and #254 for longer than three seconds. Component damage could result.

The solenoid should deactivate when the 12VDC supply is removed.

5. If the solenoid does not operate properly, check for a mechanical restriction in the linkage.

6. Using the external 12VDC voltage supply, apply 12VDC to the smaller idler solenoid terminals for the hold-in coil

(#226+ to #237-). Push in the solenoid plunger. With 12VDC applied to the hold-in coil, the plunger should stay in until the 12VDC is removed.

If the linkage is intact and the solenoid does not operate correctly when 12VDC is applied, the solenoid may be faulty. Replace.

8. Replace the harness leads to the correct terminals. See Figure F. 8 and the Wiring Diagram. Replace any previously removed wire wraps.

8a.

Using the control PC board layout, locate Q21 on the control board. Scrape the environmental coating from all three legs of the device, and check the resistance between all three legs. If there is continuity between any of the legs, Q21 is bad. Replace the control PC board.

9. Close and secure the right side engine ser-

vice access door. Replace the control board and close the control panel.

CAUTION

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TROUBLESHOOTING & REPAIR

F-35 F-35

COMMANDER 400

WARNING

SHUTDOWN SOLENOID TEST

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 avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

TEST DESCRIPTION

This test will determine if the shutdown solenoid is capable of functioning when it is energized with 12VDC.

MATERIALS NEEDED

External 12VDC supply ( 30 amps required) Wiring Diagram Volt/Ohmmeter

This procedure takes approximately 40 minutes to perform.

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TROUBLESHOOTING & REPAIR

F-36 F-36

COMMANDER 400

SHUTDOWN SOLENOID TEST (continued)

FIGURE F.9 - SHUTDOWN SOLENOID LEAD TERMINALS

TEST PROCEDURE

1. Turn the engine off.

2. Unlatch, lift and secure the right side engine service access door. Using a 5/16” nut driver, open up the control panel and tilt out. Remove the control board cover

3. Check the pull-in coil resistance by disconnecting lead #262 from the B2 terminal at the control board and measuring the resistance from lead #262 to the ground screw at the control board. Normal coil resistance is approximately 0.4 ohms. Reconnect lead #262 to the B2 terminal at the control board.

Check the hold-in coil resistance by disconnecting J3 & J4 from the control board and measuring across J3 pin 2 to J4 pin 5. Normal coil resistance is approximately 20 ohms. Reconnect J3 at the control board.

If either coil resistance is incorrect, the wiring may be faulty. Inspect the solenoid leads for faulty or loose connections.

If the lead connections are OK, recheck the coil resistances directly across the solenoid. If the coil resistances are incorrect, the solenoid may be faulty. Replace.

4. Using the external 12VDC voltage supply, apply 12VDC to the larger shutdown solenoid terminals (#262+ to #225-). The solenoid should activate.

When the solenoid activates, remove the voltage supply immediately. Do not leave the external supply connected to terminals #262 and #225 for longer than three seconds. Component damage could result.

The solenoid should deactivate when the 12VDC supply is removed.

If the solenoid does not operate properly, check for a mechanical restriction in the linkage.

Using the external 12VDC voltage supply, apply 12VDC to the smaller solenoid terminals for the hold-in coil, (#240+ to #224-). Push in the solenoid plunger. With 12VDC applied to the hold-in coil, the plunger should stay in until the 12VDC is removed.

If the linkage is intact and the solenoid does not operate correctly when 12VDC is applied, the solenoid may be faulty. Replace.

8. Replace the harness leads to the correct terminals. See Figure F.9 and the Wiring Diagram. Replace any previously removed wire wraps.

8a. Using the control PC board layout, locate

the Q25 on the control board. Scrape the environmental coating from all three legs of the device, and check the resistance between all three legs. If there is continuity between any of the legs, Q23 is bad. Replace the control PC board.

9. Close and secure the right side engine ser-

vice access door. Replace the control board cover and close the control panel.

CAUTION

PULL-IN COIL (LARGER TERMINALS EACH SIDE #225 AND #262)

SHUTDOWN SOLENOID

HOLD-IN COIL (SMALLER TERMINALS EACH SIDE #224 AND #240)

IDLER SOLENOID

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TROUBLESHOOTING & REPAIR

F-37 F-37

COMMANDER 400

WARNING

ENGINE THROTTLE ADJUSTMENT TEST

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 avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

TEST DESCRIPTION

If the machine output is low or high, this test will determine whether the engine is operating at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for adjusting the throttle to the correct RPM are given.

MATERIALS NEEDED

Slot head screw driver 7/16" wrench 10mm wrench White or red marking pencil Strobe-tach, frequency counter, or oscilloscope 3/8” wrench

This procedure takes approximately 25 minutes to perform.

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TROUBLESHOOTING & REPAIR

F-38 F-38

COMMANDER 400

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.10 - BLOWER PADDLE MARKED FOR STROBE-TACH METHOD

MARK BLOWER PADDLE HERE

TEST PROCEDURE

Strobe T

ach Method

1. Conduct this procedure with the engine OFF.

2. Unlatch, lift and secure the right side engine service access door. Perform Case Cover

Removal and Replacement Procedure

through Step 11. (For Strobe-Tach method only.)

3. With a white or red marking pencil, place a mark on one of the blower paddles. See Figure F.10 for location.

4. Connect the strobe-tach according to the manufacturer's instructions.

5. Start the engine and direct the strobe-tach light on the blower paddle. Synchronize it to the rotating mark.

With the machine at HIGH IDLE the tach should read between 1890 and 1915 RPM.

With the machine at LOW IDLE the tach should read between 1325 and 1400 RPM.

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TROUBLESHOOTING & REPAIR

F-39 F-39

COMMANDER 400

ENGINE THROTTLE ADJUSTMENT TEST (continued)

6. If either of the readings is incorrect, adjust the throttle as follows:

Adjust HIGH IDLE: Use the 10mm wrench to loosen the locking nut. See Figure F.11 for location of the adjusting screw and locking nut. Turn the threaded screw counter-clockwise to increase the HIGH IDLE speed. Adjust the speed until the tach reads between 1890 and 1915 RPM. Retighten the locking nut.

Adjust LOW IDLE: First make sure there is no load on the machine. Set the IDLE switch to AUTO and wait for the engine to change to low idle speed. Use the 7/16" wrench to loosen the solenoid lever arm locking nut. See Figure F.12. Adjust the collar, to change the amount of throw in the lever arm, until the tach reads between 1325 and 1400 RPM. Retighten the locking nut.

Frequency Counter Method

1. Plug the frequency counter into one of the 115 VAC auxiliary receptacles.

2. Start the engine and check the frequency counter. At HIGH IDLE (1900 RPM), the counter should read 63 Hz. At LOW IDLE (1400 RPM), the counter should read 47 Hz. Note that these are median measurements; hertz readings may vary slightly above or below.

3. If either of the readings is incorrect, adjust the throttle as follows:

Adjust HIGH IDLE: Use the 10mm wrench to loosen the locking nut. See Figure F.11 for location of the adjusting screw and locking nut. Turn the threaded screw counterclockwise to increase the HIGH IDLE speed. Adjust the speed until the frequency reads 63 Hz. Retighten the locking nut.

Oscilloscope Method

1. Connect the oscilloscope to the 115 VAC receptacle, according to the manufacturer’s instructions. At HIGH IDLE (1900 RPM), the waveform should exhibit a period of 15.8 milliseconds. At 1400 RPM, the waveform should exhibit a period of 21.4 milliseconds. Refer to the NORMAL OPEN CIRCUIT

VOLTAGE WAVEFORM (115 VAC AUXILIARY) HIGH IDLE - NO LOAD in this sec-

tion of the manual.

2. If either waveform periods is incorrect, adjust the throttle as follows:

Adjust LOW IDLE: First make sure there is no load on the machine. Set the IDLE switch to AUTO and wait for the engine to change to low idle speed. Use the 7/16" wrench to loosen the solenoid lever arm locking nut. See Figure F.12. Adjust the collar, to change the amount of throw in the lever arm, until the period is 21.4 milliseconds. Retighten the locking nut.

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TROUBLESHOOTING & REPAIR

F-40 F-40

COMMANDER 400

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.11 - HIGH IDLE ADJUSTMENT

BOSCH

5 7 0 0 8 1 6

903

PES 3A 80D 410/3R

0 400 463 12

ADJUSTING SCREW

LOCKING NUT

FIGURE F.12 - LOW IDLE ADJUSTMENT

ADJUSTING COLLAR

LOCKING NUT

BOSCH

5 7 0 0 8 1 6

903

PES 3A 80D 410/3R

0 400 463 12

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TROUBLESHOOTING & REPAIR

F-41 F-41

COMMANDER 400

WARNING

STATIC SCR/DIODE RECTIFIER BRIDGE TEST

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 avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

TEST DESCRIPTION

This test will help determine if an SCR or diode is shorted or “leaky.” See the Oscilloscope Waveforms in this section for normal output waveforms.

MATERIALS NEEDED

Analog Volt/Ohmmeter (Multimeter) 5/16” Nut driver 3/8” Nut driver Commander 400 Wiring Diagrams (See the Electrical Diagrams section of this manual.)

This procedure takes approximately 65 minutes to perform.

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TROUBLESHOOTING & REPAIR

F-42 F-42

COMMANDER 400

STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued)

FIGURE F.13 – CONTROL BOARD PLUG J6 LOCATION

PLUG J6

P e l 9 9 6

TEST PROCEDURE

1. Turn off the engine.

2. Disconnect the welding cables from the welding output terminals.

3. Perform the Case Removal Procedure (including front shroud removal).

4. Using the 5/16” nut driver, remove the control board cover. See Figure F.13.

5. Locate and remove molex plug J6 from the control board. See Figure F.13.

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TROUBLESHOOTING & REPAIR

F-43 F-43

COMMANDER 400

STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued)

FIGURE F.15 – RESISTOR R1 LOCATION

RESISTOR R1 LEAD #204B

6. Using the 3/8” nut driver, locate and remove the snubber board cover. See Figure F.14.

7. Locate and remove molex plug J30 from the snubber board. See Figure F.14.

8. Locate and remove lead #204B from resistor R1 (50 ohms, 100 Watts). See Figure F.15.

FIGURE F.14 – SNUBBER BOARD PLUG J30 LOCATION

PLUG J30

COMMANDER SNUBBER

C2 C7

WARNING

SNUBBER BOARD LOCATION (LEFT SIDE, BELOW FUEL TANK)

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TROUBLESHOOTING & REPAIR

F-44 F-44

COMMANDER 400

STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued)

FIGURE F.16 – HEAT SINK AND SCR TEST POINTS

ANODE

CATHODE

DIODE DD

REMOVE INSULATING PAINT

DIODES DA, DB, DC

9. Remove the red insulating paint from the heat sink test points. See Figure F.16.

NOTE: Do not disassemble the heat sink.

10. Measure the resistance from the anode to the cathode of SCR A, using an analog volt/ohmmeter (multimeter) set at R x 1000 scale. See Figure F.16.

a. Reverse the meter leads and measure the

resistance from the cathode to the anode of SCR A. See Figure F.16.

b. If a low resistance is measured in either

meter polarity, SCR A is faulty. Replace SCR A.

11. Test the resistance of SCR B and SCR C using the same procedure described in Step

10.

12. Measure the resistance of diode DD from anode (+probe) to cathode (-probe) using an analog ohmmeter set at R x 1000 scale. The resistance should be low. See Figure F.16.

a. Reverse the meter leads and measure the

resistance from cathode (+probe) to anode (-probe) of diode DD. The resistance should be high. See Figure F.16.

b. If a low resistance is measured in both

meter polarities, diode DD is shorted. Replace diode DD.

c. If a high resistance is measured in both

meter polarities, diode DD is open. Replace diode DD.

13. Test diodes DA, DB and DC for proper operation using the same procedure described in Step 12.

14. Reconnect all leads and molex plugs.

15. If this test did not identify the problem or to further test the SCRs, go to the Active SCR

Test.

If the test is complete, connect plug J6 to the control board and plug J30 to the snubber board and reconnect lead #204B to resistor R1. Replace the covers to the two boards. Replace all case covers. (See the Case Cover Removal and Replacement procedure.)

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TROUBLESHOOTING & REPAIR

F-45 F-45

COMMANDER 400

WARNING

ACTIVE SCR TEST

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 avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

TEST DESCRIPTION

This test will help determine if the device can be gated ON and conduct current from anode to cathode.

MATERIALS NEEDED

An SCR tester as specified in this procedure. 5/16” nut driver 3/8” nut driver Commander 400 Wiring Diagrams (See the Electrical Diagrams section of this manual.)

This procedure takes approximately 60 minutes to perform.

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TROUBLESHOOTING & REPAIR

F-46 F-46

COMMANDER 400

ACTIVE SCR TEST (continued)

FIGURE F.17 – CONTROL BOARD PLUG J6 LOCATION

PLUG J6

P e l 9 9 6

TEST PROCEDURE

1. Turn OFF the engine.

2. Perform the Case Removal procedure (including front shroud removal).

3. Disconnect the welding cables from the welding output terminals.

4. Using the 5/16” nut driver, remove the control board cover. See Figure F.17.

5. Locate and remove molex plug J6 from the control board. See Figure F.17.

6. Using the 3/8” nut driver, locate and remove the snubber board cover. See Figure 18.

7. Locate and remove molex plug J30 from the snubber board. See Figure F.18.

FIGURE F.18 – SNUBBER BOARD PLUG J30 LOCATION

PLUG J30

COMMANDER SNUBBER

C2 C7

WARNING

SNUBBER BOARD LOCATION (LEFT SIDE, BELOW FUEL TANK)

Lincoln Electric SVM133-B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY

Major physical or electrical damage is evident.

Low or no constant voltage (CV) welding output. Constant current (CC) and the auxiliary power are operating normally.

No welding output in either CV or stick modes. Also no auxiliary power. Engine operates normally.

No auxiliary power at receptacles. The engine operates normally and the welding output is normal.

Engine will not idle down to low speed. Machine has normal weld and auxiliary power.

The machine goes to low idle but does not stay at low idle.

The engine will not crank or cranks very slowly.

The engine cranks but will not start. 1. Check for adequate fuel supply.

The battery does not stay charged. 1. Check for loose, faulty or cor-

The Fine Control on the Commander 400 does not work properly.

The wire feeder does not work when connected to the machine’s 14 pin amphenol.

The welding arc is “cold.” The engine runs normally. The auxiliary power is normal.

The welding arc is “cold.” The engine runs normally. The auxiliary power is normal. (Continued)

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