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RETURN TO MAIN INDEX
SVM133-B
September, 2002
TM
Commander 400
For use with machine code numbers: 9978, 9979, 10580, 10581
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be in-
creased by proper installation . . .
and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importan
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Head shield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 4.b. U
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety.................................................................................................................................................i-iv Installation.............................................................................................................................Section A Technical Specifications.....................................................................................................
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Section A-1 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Installation Technical Specifications..............................................................................................................A-2 Safety Precautions......................................................................................................................A-3 Location and Ventilation..............................................................................................................A-3 Stor
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - Commander 400 INPUT - DIESEL ENGINE 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) RATED OUTPUT - WELDER Duty Cycle Welding Output Volts at Rated Amps 400 amps (DC Constant Current) 4
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A-3 A-3 INSTALLATION Read this entire installation section before you LOCATION AND VENTILATION start installation. The welder should be located to provide an unrestrict- ed flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the SAFETY PRECAUTIONS welder so that the engine exhaust fumes are properly vented to an outside area. WARNING Do not attempt to use this equipment until you have STORING thoroughly read all the operation and main
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A-4 A-4 INSTALLATION 3. Proper placement of the equipment on the trailer to LIFTING insure stability side to side and front to back when The Commander 400 weights 1650 lb./748 kg (Stick the trailer is being moved and when standing by model); 1683 lb./763 kg. (Stick & Wire model). A lift bail itself. is provided for lifting with a hoist. 4. Typical conditions of use, such as travel speed, roughness of surface on which the trailer will be operated, environmental conditions, and likely WARNING m
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A-5 A-5 INSTALLATION BATTERY CONNECTIONS FUEL WARNING BATTERY ACID CAN BURN EYES AND NOTE: Use diesel fuel only. SKIN. Fill the fuel tank with clean, fresh diesel fuel. The • Wear gloves and eye protection and be care- capacity of the fuel tank is 25 gallons (94.6 liters). See ful when working near a battery, follow the the Operation and Maintenance sections of this man- instructions printed on the battery. ual for more details about fuel. The Commander 400 is protected by a low fuel The
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A-6 A-6 INSTALLATION ELECTRICAL OUTPUT CAUTION CONNECTIONS • Loose connections will cause the output terminals to See Figure A.1 for the location of the 120 and 240 volt overheat. The terminals may eventually melt. receptacles, weld output terminals, and ground stud. • Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another. WELDING CABLE CONNECTIONS CABLE INSTALLATION AND CABLE SIZES With the engine off, route the electrode a
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A-7 A-7 INSTALLATION NOTE: The two 120VAC outlets of the 120/240VAC MACHINE GROUNDING receptacle cannot be paralleled. They are on two dif- Because this portable engine driven welder creates its ferent phases. own power, it is not necessary to connect its frame to The auxiliary power receptacles should be used with an earth ground, unless the machine is connected to only three-wire, grounded type plugs or approved dou- premises wiring (home, shop, etc.). ble-insulated tools with two-wire plugs.
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A-8 A-8 INSTALLATION FIGURE A.2 - CONNECTION OF THE COMMANDER 400 TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz. COMPANY 3-Wire 120 VOLT Service METER NEUTRAL BUS N LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. PREMISES DISCONNECT AND SERVICE GROUND OVERCURRENT 45AMP PROTECTION 240 VOLT DOUBLE POLE 50 AMP, 120/240 CIRCUIT VOLT PLUG 240 VOLT BREAKER NEMA TYPE 14-50 GND N 50 AMP, 120/240 VOLT NO
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Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Operation...............................................................................................................................Section B Safety Instructions.......................................................................................................................B-2 General Description ....................................................................................................................B-2 Recommen
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B-2 B-2 OPERATION WARNING OPERATING INSTRUCTIONS Read and understand this entire section before operat- ing your Commander 400. ENGINE EXHAUST can kill. SAFETY INSTRUCTIONS • Use in open, well ventilated areas or vent exhaust to the outside. WARNING • Do not stack anything on or near the engine. Do not attempt to use this equipment until you have thoroughly read all the operating and maintenance manuals supplied with your machine. They include MOVING PARTS can injure. important safety precauti
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B-3 B-3 OPERATION • One 50 amp, 120/240 VAC dual voltage receptacle RECOMMENDED APPLICATIONS for up to 44 amps of 240 VAC, and up to 44 amps per WELDER side to separate branch circuits (not in parallel) of 120 VAC single phase auxiliary power. Allows easy con- The Commander 400 (Stick model) provides excellent nection to premises wiring. constant current DC welding output for stick (SMAW) • Weld and AC auxiliary power at the same time (with- welding. The Commander 400 (Stick & Wire model) in mac
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B-4 B-4 OPERATION ADDITIONAL DESIGN FEATURES WELDING CAPABILITY (Stick & Wire Model only) The Commander 400 is rated at 400 amps, 40 volts at FOR WIRE WELDING 100% duty cycle. The weld current is variable from 40 to 575 amps. • 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 i
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B-5 B-5 OPERATION CONTROLS AND SETTINGS The welder/generator controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow. FIGURE B.1 – CASE FRONT PANEL CONTROLS 3 2 4 5 6 7 1 8 9 9 OIL FUEL TEMP PRESS AMPS 00000 0 11 HOURS 10 12 23 13 17 22 21 24 - 20 +- 15 16 18 19 14 ENGINE CONTROLS (Figure B.1, Items 1 through 8) 3. FUEL LEVEL GAUGE AND LIGHT: Displays the level of diesel fuel in the 25-gallon (94.6 liter) fuel See Figure B.1 for the location of the f
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B-6 B-6 OPERATION 4. ENGINE TEMPERATURE GAUGE AND LIGHT: b. When the electrode touches the work or The gauge displays the engine oil temperature. The power is drawn for lights or tools (approxi- yellow temperature light remains off under normal mately 100 Watts minimum), the engine operating temperatures. If the light turns on, the accelerates and operates at full speed. engine protection system will shut down the engine. c. When welding ceases or the AC power load Check for restrictions at t
