Lincoln Electric IM544 User Manual

IM544-B

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Commander 400

For use with machines having Code Numbers:

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.

™

June, 1998

9978, 10580 (Stick Model), 9979, 10581 (Stick and Wire Model)

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

• Sales and Service through Subsidiaries and Distributors Worldwide •

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

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. A Free 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.

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

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, coversand 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.

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

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.

___________________________________________________

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.

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.

Mar ‘95

SAFETY

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.

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. Headshield 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.

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

vapors

5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY

iii

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.

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

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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, VA 22202.

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.

Mar ‘95

SAFETY

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.

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

7. Quand on ne soud 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” CSA Standard W 117.2-1974.

e pas, poser la pince à une endroit isolé de

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.

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

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference.This information can be found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

TABLE OF CONTENTS

Page

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

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

Technical Specifications ................................................................................................................A-1

Safety Precautions........................................................................................................................A-2

Location/ Ventilation ......................................................................................................................A-2

Stacking.................................................................................................................................A-2

Angle of Operation ................................................................................................................A-2

Lifting.....................................................................................................................................A-2

High Altitude Operation .........................................................................................................A-3

Towing ...................................................................................................................................A-3

Pre-Operation Engine Service ......................................................................................................A-3

Oil ..........................................................................................................................................A-3

Fuel........................................................................................................................................A-3

Fuel Cap................................................................................................................................A-4

Engine Cooling System.........................................................................................................A-4

Battery Connection................................................................................................................A-4

Muffler Outlet Pipe.................................................................................................................A-4

Spark Arrester .......................................................................................................................A-4

Electrical Output Connections ......................................................................................................A-4

Welding Output Cables..........................................................................................................A-5

Machine Grounding ...............................................................................................................A-5

Auxiliary Power Receptacles.................................................................................................A-5

Standby Power Connections .................................................................................................A-5

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

Safety Instructions.........................................................................................................................B-1

General Description ......................................................................................................................B-1

Recommended Applications..................................................................................................B-1

Design Features and Advantages.........................................................................................B-1

Welding Capability.................................................................................................................B-1

Controls and Settings....................................................................................................................B-3

Engine Controls.....................................................................................................................B-3

Welder Controls.....................................................................................................................B-5

Auxiliary Power Controls .......................................................................................................B-5

Engine Operation ..........................................................................................................................B-6

Starting the Engine................................................................................................................B-6

Stopping the Engine..............................................................................................................B-6

Break-In Period......................................................................................................................B-6

Typical Fuel Consumption .....................................................................................................B-6

Welder Operation..........................................................................................................................B-7

Stick Welding.........................................................................................................................B-7

Pipe Welding .........................................................................................................................B-7

General Welding....................................................................................................................B-7

TIG Welding...........................................................................................................................B-7

Arc Gouging ..........................................................................................................................B-7

Wire Feed (Constant Voltage) Welding .................................................................................B-9

Connection of Stick and Wire model to LN-25, LN-7, LN-8, LN-23P or NA-3 ......................B-9

Auxiliary Power Operation...........................................................................................................B-10

Simultaneous Welding and Auxiliary Power Loads.............................................................B-10

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

Optional Field Installed Accessories.............................................................................................C-1

Recommended Equipment ...........................................................................................................C-1

High Frequency Generators For TIG Applications........................................................................C-1

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

Safety Precautions........................................................................................................................D-1

Routine and Periodic Maintenance...............................................................................................D-1

Engine Maintenance .............................................................................................................

Air Filter.................................................................................................................................D-1

Fuel Filters ............................................................................................................................D-2

Cooling System .....................................................................................................................D-3

Cooling Blower Belt...............................................................................................................D-3

Engine Maintenance Components........................................................................................D-4

Troubleshooting.......................................................................................................................Section E

Diagrams and Dimension Print ..............................................................................................Section F

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

........D-1

vivi

COMMANDER 400

A-1

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

A-1

100%

60%

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

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

OUTPUT - WELDER AND GENERATOR

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

HEIGHT

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

1066.8 mm 800.1 mm 1602.7 mm 1683 lbs.(763 kg)

WIDTH DEPTH WEIGHT

(Stick model)

(Stick & Wire model)

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.

COMMANDER 400

A-2

INSTALLATION

A-2

Read this entire installation section before you start installation.

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.

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.

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MOVING PARTS can injure.

•Do not operate with doors open or guards off.

•Stop engine before servicing.

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.

LIFTING

The Commander lift bale should be used to lift the machine. The Commander is shipped with the lift bale retracted. Before attempting to lift the Commander the lift bale must be secured in a raised position. Secure the lift bale 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 bale.

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

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

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

The screws are provided in the shipped loose parts bag.

•Keep away from moving parts

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Only qualified personnel should install, use or service this equipment

LOCATION/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.

COMMANDER 400

WARNING

FALLING EQUIPMENT can cause injury.

•Do not lift this machine using lift bale if it is equipped with a heavy accessory such as a trailer or gas cylinder.

•Lift only with equipment of adequate lifting capacity.

•Be sure machine is stable when lifting.

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A-3

INSTALLATION

A-3

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary. As a rule of thumb, derate the welder output 5% for every 400 meters (1312 ft.) above 1000 meters (3280 ft.).

Contact a Deutz Service Representative for any engine adjustments that may be required for high altitude operation.

TOWING

The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle 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 be considered are as follows:

1. Design capacity of trailer vs. weight of 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 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, and environmental conditions.

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.

(1)

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instructions supplied with this machine.

WARNING

•Stop engine and allow to cool before fueling.

•Do not smoke when fueling.

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

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

•Keep sparks and flame away from tank.

------------------------------------------------------------------------

OIL

The Commander is shipped with the engine crankcase filled with high quality SAE 10W-30 oil (API class CD or better). Check the oil level before starting the engine. If it is not up to the full mark on the dip stick, add oil as required. Check the oil level every four hours of running time during the first 35 running hours. Refer to the engine Operator’s Manual for specific oil recommendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the engine Operator’s Manual for the proper service and maintenance intervals.

FUEL 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 engine Operator’s Manual for specific fuel recommendations. 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.

TE: Before starting the engine, open the fuel shutoff

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

COMMANDER 400

A-4

INSTALLATION

A-4

FUEL CAP

Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap.

ENGINE 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 Owners Manual for procedures and frequency).

BATTERY CONNECTION

WARNING: Use caution as the electrolyte is a strong

acid that can burn skin and damage eyes.

Remove and discard the insulating cap from the negative battery terminal. Attach and tighten negative battery cable terminal.

NOTE: This machine is furnished with a wet charged battery; if unused for several months, the battery may require a booster charge. Be careful to charge the battery with the correct polarity. Make sure that the battery is level while charging.

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

Some federal, state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder does not qualify as a spark arrester. When required by local regulations, a suitable spark arrester, such as the K899-1 must be installed and properly maintained.

CAUTION

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

------------------------------------------------------------------------

ELECTRICAL OUTPUT CONNECTIONS

See Figure A.1 for the location of the weld output terminals, ground stud, and auxiliary power receptacles

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 -)

FIGURE A.1 - Weld Terminal, Ground Stud and Auxiliary Power Receptacle Locations

COMMANDER 400

A-5

INSTALLATION

A-5

WELDING OUTPUT CABLES

With the engine off, route the electrode and work cables thru the strain relief bracket provided on either side of the base and connect to the terminals provided. These connections should be checked periodically and tightened if necessary.

Listed in Table A.1 are copper cable sizes recommended for the rated current and duty cycle. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop.

Table A.1 Combined Length of Electrode and Work

Cables.

TOTAL COMBINED LENGTH OF ELEC-

TRODE AND WORK CABLES

AMPS

@100%

Duty Cycle

250

400

Up to 150

FT.

1 AWG

3/0 AWG

150-200 FT.

1 AWG

3/0 AWG

200-250 FT.

1/0 AWG

4/0 AWG

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.).

joints, or to the metal framework of a building which 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 auxiliary power capacity of the Commander 400 is 10,000 watts of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to voltamperes at unity power factor. The maximum permissible current of the 240 VAC output is 44 A. The 240 VAC output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 44 A per output to two separate 120 VAC branch circuits. The output voltage is within ± 10% at all loads up to rated capacity.

TE: The 120/240V receptacle has two 120V outlets

of different phases and cannot be paralleled.

The Commander has two 15 Amp-120VAC (5-15R) duplex receptacles with GFCI protection and one 50 Amp-120/240 VAC (14-50R) receptacle. The 120/240 VAC receptacle can be split for single phase 120 VAC operation. The auxiliary power receptacles should only be used with 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 capacity of the associated receptacle.

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 this engine driven welder is 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 entitled “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

COMMANDER 400

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 amp 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.

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

A-6

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. 8 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

INSTALLATION

A-6

2. Take necessary steps to assure load is limited to the capacity of the Commander 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.

Figure A.2 Connection of the Commander 400 to Premises Wiring

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

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

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

COMMANDER 400

B-1

OPERATION

B-1

OPERATING INSTRUCTIONS

Read and understand this entire section before operating your Commander 400.

SAFETY INSTRUCTIONS

WARNING

ELECTRIC SHOCK can kill.

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

•Insulate yourself from the work and ground.

GENERAL DESCRIPTION

The Commander 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.

RECOMMENDED APPLICATIONS

•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 engine before servicing.

•Keep away from moving parts

------------------------------------------------------------------------

Only qualified personnel should operate this equipment.

ADDITIONAL SAFETY PRECAUTIONS

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 Innershield (FCAW) welding.

GENERATOR

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

DESIGN FEATURES AND ADVANTAGES

(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 and 50 to 575 amps constant current output in one general purpose welding range.

Always operate the welder with the hinged door closed and the side panels in place as these provide maximum protection from moving parts and insure proper cooling air flow.

COMMANDER 400

• 3 digit display is provided for presetting the weld

amperage and displaying the actual amperage during welding. The display uses superbrite L.E.D.’s for improved readability in full sunlight.

• Remote control capability standard on all models.

B-2

• Selection of “hot” or “cold” output terminals with a toggle 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.

• 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 VAC, 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.

OPERATION

B-2

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

ADDITIONAL DESIGN FEATURES AND ADVANTAGES (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 Innershield (FCAW) welding.

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

• A built in “Electronic Contactor” for “Cold” electrode when not welding. This feature and DC Constant Voltage output provide an added margin of safety when welding must be performed under electrically hazardous conditions such as: damp locations, while wearing wet clothing or in cramped positions if there is a high risk of unavoidable or accidental contact with the workpiece or ground.

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

• 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.

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.

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

COMMANDER 400

MAY96

B-3

OPERATION

B-3

CONTROLS AND SETTINGS

All welder and engine 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

FUEL

TEMP

OIL

PRESS

AMPS

00000

HOURS

ENGINE CONTROLS (Items 1 through 8)

1. RUN- STOP SWITCH

When placed in the “RUN” position, this switch energizes the fuel solenoid and other electric accessories. When placed in the “STOP” position, the flow of fuel to the injection pump is stopped to shut down the engine. (Note: If the switch is left in the “RUN” position and the engine is not running, the battery will be drained by the fuel solenoid).

2. START PUSHBUTTON

Energizes the starter motor to crank the engine. With the engine RUN-STOP 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 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.

COMMANDER 400

B-4

OPERATION

B-4

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 Operator’s 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 engine not running.

6. ENGINE ALTERNATOR AMMETER

AND LIGHT

The yellow engine alternator light is off when battery charging system is functioning normally. If 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.

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 A.C. 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.

7. IDLER SWITCH

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 oper-

ates 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

COMMANDER 400

B-5

OPERATION

B-5

WELDER CONTROLS (Items 9 through 14 )

9. OUTPUT RANGE SWITCH & OUTPUT CONTROL

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 Output Control

Functions

Range

Switch

Sloped Output for Pipe Welding. (all models)

6 Range

Settings

90, 120, 180,

230, 270, 400

(Max. current on

each setting)

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)

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

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

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

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.

Control

range

With the switch in the “Welding Terminals Always On” position the contactor is closed and the welding terminals are always “Hot”.

With the switch in the “Welding Terminals Remotely Controlled” 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 the operator the option of controlling the output at the welder control panel or at a remote station.

For remote control the toggle switch is set in the “Remote” position.

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

13. 6 - PIN CONNECTOR

The 6-pin connector located 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 this “-” terminal. For negative polarity welding the work cable connects to the “+” terminal and the electrode cable connects to this “-” terminal.

AUXILIARY POWER CONTROLS

(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. This receptacle has a 50 amp rating. Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about this receptacle. Also refer to the AUXILIARY POWER OPERATION section later in this chapter.

16. 50 AMP CIRCUIT BREAKERS

These circuit breaker provide separate overload current protection for each 120V circuit at the 240V receptacle.

COMMANDER 400

B-6

OPERATION

B-6

17. 120VAC RECEPTACLES

These two 120VAC (5-15R) receptacles with GFCI protection provide 120VAC for auxiliary power. These receptacles have a 20 amp total rating. Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about these receptacles. Also refer to the AUXILIARY POWER OPERATION section later in this chapter.

18. 15 AMP CIRCUIT BREAKERS

These circuit breakers provide separate overload current protection for each 120V receptacle.

19. GROUND STUD

Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. Refer to “MACHINE GROUNDING” in the Installation chapter for proper machine grounding information.

WIRE FEEDER MODE CONTROLS

(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 and work cables. For positive polarity welding the electrode cable connects to the “+” terminal and the work cable connects to this “-” terminal. For negative polarity welding the work cable connects to the “+” terminal and the electrode cable connects to this “-” 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 to be in line with the hose).

2. Check for proper oil level on the oil dipstick. Close engine compartment door.

3. Remove all plugs connected to the AC power receptacles.

4. Set 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.

Check that the indicator lights are off. If the LOW FUEL light is

8. on , the engine will shutdown 30 minutes after starting. If any other indicator light is on after starting, the engine will shutdown 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 / RUNNING

With a fully charged battery and the proper weight oil, the engine should start satisfactorily even down to about 0°F. If the engine must be frequently started below 10 ether starter kit (K825-1). Installation and operating instructions are included in the kit. Use ether starting only when required because excessive use shortens engine life. If the engine must be operated in extreme cold environments 0°F to -35°F (-18°C to -37°C) an optional Cold Weather Kit (K1665-1) is available. Installation and operating instructions are included in the kit.

F, it may be desirable to install the optional

STOPPING THE ENGINE

1. Switch the RUN/STOP switch to “STOP”. This turns

off the voltage supplied to the shutdown solenoid. A backup shutdown 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).

IMPOR IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNIT SHOULD BE SUBJECTED TO HEAVY LOADS, WITHIN THE RATING OF THE MACHINE. AVOID LONG IDLE RUNNING PERIODS.

TANT

COMMANDER 400

B-7

OPERATION

B-7

TYPICAL FUEL CONSUMPTION

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

Table B.2 Deutz F3L 912 Engine Fuel Consumption

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

Deutz F3L 912

44.2 Hp

@ 1800 RPM

.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)

Running Time for

25 gallons

(Hours)

83.3

32.1

13.6

18.9

WELDER OPERATION

STICK WELDING

The Commander 400 can be used with a broad range of DC stick electrodes.

The OUTPUT RANGE switch provides six o 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 where the operator would like to control the current level by changing the arc length.

verlapping

setting and lower open circuit voltage. For example: to obtain 175 amps and a forceful arc, set the 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 hor trodes 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.

izontal welds with all types of elec-

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 400A at a 20% duty cycle, 300A at a 60% duty cycle and 250A at a 80% duty cycle. Refer to Table B.3 for recommended output setting depending on the tungsten electrode size. The Commander can be used without a TIG module or HiFreq 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. Also refer to the Accessories chapter for recommended equipment for TIG welding.

ARC GOUGING

Set the output range switch to the General purpose position (50-575). For current setting, refer to The Procedure Handbook of Arc Welding, section on arc gouging (13.5) or the consumable manufacturer’s recommended current rating.

PIPE WELDING

When using a sloped range, 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 MAX” position and then adjust the OUTPUT CONTROL for 175 amps.

When a forceful “digging” arc is required, use a higher

, set the OUTPUT RANGE switch to the “180

COMMANDER 400

B-8

OPERATION

B-8

Table B.3 TYPICAL CURRENT RANGES

DCEN (-) DCEP (+)

Tungsten Electrode Diameter

in. (mm)

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

shielding gases.

(2) 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.

1%, 2% Thoriated Tungsten

2-15 5-20

15-80

70-150

150-250 250-400

400-500 500-750

750-1000

1%, 2%

Thoriated

Tungsten

(3) (3) (3)

10-20

15-30 25-40

40-55 55-80

80-125

(1)

FOR TUNGSTEN ELECTRODES

Approximate Argon Gas Flow Rate

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

Aluminum Stainless Steel

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)

(2)

TIG TORCH

Nozzle

Size (4), (5)

#4, #5, #6

#5, #6

#6, #7, #8

#8, #10

(3) DCEP is not commonly used in these sizes. (4) 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)

(5) 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.

COMMANDER 400 SETTINGS WHEN USING THE K799 HI-FREQ UNIT

a. Set the OUTPUT RANGE switch to the “50-575 set-

ting” (Fabrication and General Purpose)

b. Set the IDLER switch to the “High “ position.

c. Set the LOCAL/REMOTE switch to the “Remote” posi-

tion.

d. 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

a. Set the OUTPUT RANGE switch to the 50-575 Setting

(Fabrication and General Purpose)

b. Set the IDLER switch to the “Auto “ position.

c. Set the LOCAL/REMOTE switch to the “Remote” posi-

tion.

d. 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.

COMMANDER 400

B-9

OPERATION

B-9

WIRE FEED (CONSTANT VOLTAGE) WELDING

(Stick and Wire models only) Connect a wire feeder to the Commander 400 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 (Innershield and Outershield) 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, GS-100 and GS-

210.

STICK AND WIRE MODEL CONNECTION TO LN-25

The LN-25 with or without an external contactor may be used with the Commander 400 Stick and Wire model. See the appropriate connection diagram in “DIAGRAMS” section. NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the Commander 400 S&W.

a. Shut the welder off. b. For electrode Positive, connect the electrode cable

from the LN-25 to the “+” terminal of the welder and work cable to the “- WIRE” terminal of the welder. For electrode Negative, connect the electrode cable from the LN-25 to the “ WIRE” terminal of the welder and work cable to the “+”terminal of the welder.

c. Attach the single lead from the front of the LN-25 to

work using the spring clip on the end of the lead. This is a control lead to supply current to the wire

feeder motor; it does not carry welding current. d. Set the range switch to “WIRE WELDING CV” e. Set the “OUTPUT CONTROL” switch to “WELDING

TERMINALS ALWAYS ON” f. Set the “VOLTS\AMPS” switch to “VOLTS” g. Set the “IDLE” switch to the “AUTO” position. When

not welding , the Commander 400 S&W engine will

be at the low idle speed. CAUTION: ( if you are

using an LN-25 without an internal contactor, the

electrode will be energized when the Commander

400 Stick and Wire model is started.) If you are

using an LN-25 with an internal contactor, the elec-

trode is not energized until the gun trigger is closed.

In either of the LN-25 wire feeders, when the gun

trigger is closed, the current sensing circuit will

cause the Commander 400 Stick and Wire model

engine to go to the high idle speed, the wire will

begin to feed and the welding process started.

When welding is stopped, the engine will revert to

low idle speed after approximately 15 seconds

unless welding is resumed.

STICK AND WIRE MODEL CONNECTION TO LN-7 or LN-8

a. Shut the welder off. b. Connect the LN-7 or LN-8 per instructions on the

appropriate connection diagram in “DIAGRAMS” section. Set the “LOCAL REMOTE” switch to “REMOTE” for the LN-7 and LN-8 with a K857 remote voltage control cable attached; “LOCAL” for LN-7 with no remote voltage control.

c. Set the “VOLTMETER” switch to either “+” or “-” as

required by the electrode being used.

d. Set the “RANGE” switch to the “WIRE WELDING

CV” position.

e. Set the “OUTPUT CONTROL” switch to the “OUT-

PUT REMOTELLY CONTROLLED” position.

f. Set the “IDLE” switch to the “HIGH” position.

CAUTION

When the gun trigger is closed, the electrode is energised and the wire will begin to feed.

------------------------------------------------------------------------

STICK AND WIRE MODEL CONNECTION TO LN-23P

a. Shut the welder off. b.

Connect the LN-23P as per instructions on the appropriate connection diagram in “DIAGRAMS” section. NOTE: When connecting an LN-23P to the Commander Stick & Wire, a K350-1 adapter kit must be used. Set the “VOLTMETER” switch to either “+”

or “-” as required by the electrode being used. d. Set the “RANGE” switch to “WIRE WELDING CV” e. Set the “OUTPUT CONTROL” switch to “WELDING

TERMINALS ALWAYS ON” Set the “VOLTS/AMPS”

switch to “VOLTS” g. Set the “LOCAL REMOTE” switch to the desired

setting depending upon where the power sources

output is being controlled from. h. Set the “IDLE” switch to the “AUTO” position. When

not welding , the Commander 400 Stick and Wire

model engine will be at the low idle speed. If you are

using an LN-23P with the K350-1 adapter kit, the

electrode is not energized until the gun trigger is

closed. When the gun trigger is closed, the current

sensing circuit will cause the Commander 400 Stick

and Wire model engine to go to the high idle speed,

the wire will begin to feed and the welding process

can be started. When welding is stopped, the

engine will revert to low idle speed after approxi-

mately 15 seconds unless welding is resumed.

STICK AND WIRE MODEL CONNECTION TO NA-3

For connection diagrams and instructions for connecting an NA-3 Welding System to the Commander Stick & Wire, refer to the NA-3 Welding System instruction manual.

COMMANDER 400

B-10

OPERATION

B-10

AUXILIARY POWER OPERATION

Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings, if no welding current is being drawn..

The auxiliary power of the Commander consists of two120VAC (5-15R) duplex receptacles with GFCI protection and one 120/240 VAC (14-50R) receptacle. The 120/240VAC receptacle can be split for single phase 120 VAC operation.

The auxiliary power capacity is 10,000 watts of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The maximum permissible current of the 240 VAC output is 44 A. The 240 VAC output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 44 A per output to two separate 120 VAC branch circuits. Output voltage is within ± 10% at all loads up to rated capacity.

TE: The 240V receptacle has two 120V outlets of

different phases and cannot be paralleled.

The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle.

SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS

It must be noted that the above auxiliary power ratings 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).

The auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs.

TABLE B.4 Commander 400 Simultaneous Welding and Power

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)

Loads

None None

3000 6000 7500 9500 9500

Permissible

Current in

@120 V ±10% *

0 0

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

Auxiliary Amperes

@ 240 V ±10%

0 14 28 35 44 44

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

VAC output.

COMMANDER 400

C-1

ACCESSORIES

C-1

OPTIONAL FIELD INSTALLED ACCESSORIES

K802R POWER PLUG KIT - Provides a plug for each

receptacle.

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 SET - Includes 35 feet (10 m) of electrode cable and 30 feet (9 m) of work cable, headshield, 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

RECOMMENDED EQUIPMENT

STICK

K704 Accessory Kit which includes:

• Electrode holder and cable.

• Ground clamp and cable.

• Headshield.

K857 Remote Control Kit is optional for remote current control.

TIG

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:

K812 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

K825-1 ETHER START KIT - Provides maximum cold

weather starting assistance for frequent starting below 10 F (-12.2

with kit.

K899-1 SPARK ARRESTOR KIT - Easily mounts to standard muffler.

K949-1 OIL DRAIN KIT - Includes ball valve, hose and clamp.

C). Required Ether tank is not provided

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.

The Commander 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.

COMMANDER 400

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

•Have a qualified technician do the maintenance and troubleshooting work.

•Turn the engine off before working inside the machine.

•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.

------------------------------------------------------------------------

Read the Safety Precautions in front of this manual and the engine instruction manual before working on this machine.

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 the equipment.

ROUTINE AND PERIODIC MAINTENANCE

DAILY

a. Check the crankcase oil level .

b. Refill the fuel tank to minimize moisture condensa-

tion in the tank.

c. Open the water drain valve located on the bottom of

the water separator element 1 or 2 turns and allow to drain into a container suitable for diesel fuel for 2 to 3 seconds. Repeat the above drainage procedure until diesel fuel is detected in the container.

WEEKLY

Blow out the machine with low pressure air periodically. In particularly dirty locations, this may be required once a week.

ENGINE MAINTENANCE

Refer to the “Periodic Checks” section of the Engine Operator’s Manual for the recommended maintenance schedule of the following:

a) Engine Oil and Filter b) Air Cleaner c) Fuel Filter - and Delivery System d) Cooling Blower Belt e) Battery f) Cooling System

Refer to Table D.1 at the end of this section for various engine maintenance components.

AIR FILTER

CAUTION

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 air cleaner regularly according to Engine Operator’s Manual.

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

2. Remove air filter element.

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

Compressed Air: 100 psi maximum with nozzles at

least one inch away from element.

Water Hose: 40 psi maximum without nozzle.

4. Soak element in a mild detergent solution for 15 minutes. Do not soak more than 24 hours. Swish 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 element before reuse with warm air at less than

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

160 ment.

COMMANDER 400

D-2

MAINTENANCE

D-2

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 element from dust and damage during drying and storage.

8. Reinstall air filter element.

After six cleanings replace 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.

FUEL FILTERS

WARNING

When working on the fuel system

• Keep naked 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. The Secondary Fuel Filter is mounted directly to the engine just above the oil filter.

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.

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.

6. 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 cavity.

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

FUEL PRE-FILTER/WATER SEPARATOR ASSEMBLY

The pre-filter 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. Follow the following procedure:

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

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

COMMANDER 400

The water separator element is a two stage filter with a special filtration/water separating media, and an expanded water reservoir providing maximum protection against water in the fuel. The recommended change interval for the water separator element is 1,000 hours. The procedure for changing the element is as follows:

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

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

D-3

MAINTENANCE

D-3

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 (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 and then close the air vent valve.

Note : Consult your engine operation manual for information on air -bleeding the entire fuel system.

SECONDARY FUEL FILTER

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

COOLING SYSTEM

The cooling system of the Deutz engine needs to be checked and cleaned periodically. Consult the engine owners manual for the proper frequency and procedure.

COOLING BLOWER BELT

The following procedure should be followed to replace the cooling blower belt:

1. Allow 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. Loosen the alternator mounting bolts and rotate the alternator towards the engine.

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

7. Adjust the cold belt tension to 63-73 lbs. midway between any two pulleys.

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. (Follow steps 1,2,3,4,7 & 8)

BATTERY HANDLING

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away from battery.

To prevent EXPLOSION when:

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

• CONNECTING A BATTERY CHARGER - Remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.

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

BATTERY ACID CAN BURN EYES AND SKIN.

• Wear gloves and eye protection and be careful when working near battery. Follow instructions printed on battery.

-------------------------------------------------------

-----------------

PREVENTING ELECTRICAL DAMAGE

1. When replacing, jumping, or otherwise connecting the battery to the battery cables, the proper polarity must be observed. Failure to observe the proper polarity could result in damage to the charging circuit. The positive (+) battery cable has a red terminal cover.

2. If the battery requires charging from an external charger, disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads. Failure to do so can result in damage to the internal charger components. When reconnecting the cables, connect the positive cable first and the negative cable last.

PREVENTING BATTERY DISCHARGE

If you have an ignition switch, turn it off when engine is not running.

PREVENTING BATTERY BUCKLING

Tighten nuts on battery clamp until snug.

COMMANDER 400

D-4

MAINTENANCE

Table D.1 Engine Maintenance Components

D-4

ITEM

Air Cleaner Element

Cooling Blower Belt

Oil Filter Element

Fuel Filter Element

Water Separator Element

Fuel Pre-Filter Screen

Battery

MAKE

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

COMMANDER 400

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by 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.

__________________________________________________________________________

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

E-1

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 the following categories: engine problems, function problems and output 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 wrap-around cover.

Step 3. RECOMMENDED COURSE OF ACTION

If you have exhausted all of the items in step

2. Contact your Local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

COMMANDER 400

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-2

PROBLEMS

(SYMPTOMS)

Major Physical or Electrical Damage is Evident.

Engine will not “crank”.

Engine will “crank” but not start.

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

ENGINE PROBLEMS

1. Contact your Local Lincoln Authorized Field Service Facility.

1. Battery is low. Charge Battery.

2. Loose battery cable connections. Inspect, clean and tighten.

1. Out of fuel. Fill prime tank.

2. Fuel shut off valve is in off

position.

3. High oil temperature (Indicator light lit. Check engine cooling system. (Consult engine service dealer.

RECOMMENDED

COURSE OF ACTION

Engine shuts down shortly after starting.

Battery does not stay charged.

4. Low battery voltage.

1. Low fuel. (Indicator light lit) Add fuel.

2. Low output of battery charging alternator. (Indicator light lit) Check if neccessary.

3. High oil temperature (Indicator light lit). Check engine cooling system. (Consult engine service dealer.

1. Faulty battery. Replace

cooling blower belt. Replace

Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance.

CAUTION

COMMANDER 400

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

PROBLEMS

(SYMPTOMS)

Engine will not idle down to low speed.

Engine will not go to high idle when attempting to weld.

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

FUNCTION PROBLEMS

1. Idler switch in High idle position. Set switch to Auto.

2. External load on welder or auxiliary power. Remove all external loads.

1. Poor work lead connection to work. Make sure work clamp is tightly connected to clean base metal.

2. ”Welding Terminals” switch is in wrong position. Set to “Always On” when welding without a welding terminal control cable. Refer to Operations chapter for proper use of this switch.

RECOMMENDED

COURSE OF ACTION

Contact your Local Lincoln Authorized Field Service Facility for technical

troubleshooting assistance.

Engine will not go to high idle when using auxiliary power.

1. Auxiliary power load is less than 100 watts. Idler may not respond with less than a 100 watt load. Set Idler to “High”

CAUTION

COMMANDER 400

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS

(SYMPTOMS)

No welding power output.

Welder has output and no control.

No auxiliary power.

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

OUTPUT PROBLEMS

1. Welding terminals switch in wrong position. Place switch in “Always On” position when welding without welding terminal control cable. Refer to Operation chapter for proper switch function.

1. Local/Remote switch is in wrong position. Place switch in Local position to control output at welder. Place switch in Remote position to control output remotely. Refer to Operation chapter for proper switch function.

2. Poor remote kit connection. Check connections.

3. Faulty remote kit. Replace if neccessary.

1. Open circuit breakers. Reset breakers. If breakers keep tripping check connections to auxiliary receptacles. Also make sure load does not exceed receptacles current rating. Refer to Auxiliary Connections in the Installation and Operation chapters.

RECOMMENDED

COURSE OF ACTION

Contact your Local Lincoln Authorized Field Service Facility for technical

troubleshooting assistance.

2. Faulty connections to auxiliary receptacles. Check connections.

3. GFCI tripped. Clear any ground fault and reset GFCI circuit by pressing “Reset” button on the 120 V receptacle.

CAUTION

COMMANDER 400

F-1

WIRING DIAGRAM:

DIAGRAMS

F-1

287

223

NEXT AVLB.

CONNECTOR CAVITY NUMBERING SEQUENCE

(VIEWED FROM COMPONENT SIDE OF BOARD)

POS.

STAND-OFF

STAINLESS STEEL

207

206S

SHUNT

600 AMP

204S

204B

RECTIFIER

ASSEMBLY

204A

SCR C

SCR B

SCR A

COMMANDER 400-STICK MODEL WIRING DIAGRAM

240A

OLTAG

ITER V

273

268

270

FEEDBACK BOARD

EXC

272

J50

274

269

VIA BOLTED

CAPACITORS MADE

CONNECTIONS TO

204

261

260

ELECTRICAL SYMBOLS PER E1537

BYPASS PC

BOARD

FRAME GROUND

CHOKE

OUTPUT

50 Ohm

100 W

209

STATOR

CONNECTIONS

NEG.

204

223

261

260

217

SNUBBER PC BOARD

J30

216

213

215

214

222

221

220

219

218

SWITCH

POT

FINE CONTROL

SELECTOR

(VIEWED FROM BACK)

(SEE SELECT SWITCH CHART)

76C

77C

REMOTE/

AUXILIARY BYPASS PCB

STAND-OFF

STAINLESS STEEL

LOCAL

206

206S

273

274

268

270

77B

BACK

VIEWED FROM

76B

SWITCH

FRAME GROUND

EXCITER

WINDINGS

207

204A

204S

280

272

279

269

255

256

75B

CONTROL HARNESS

ALWAYS ON

OUTPUT

CONTROL

CONTROL HARNESS

1008

1006

1004

1002

CAPACITOR

1015

1013

1011

1009

240 uF

1016

1014

1012

1010

1023

1021

1019

1017

240 uF

1024

1022

1020

1018

1007

1005

1003

1001

240 uF

251

252

250

ENGINE

PROT.

BOARD

(VIEWED AS INSTALLED)

CONNECTIONS ON CONTROL BOARD

MOTHER

CONTROL

213

214

215

217

216

OUTPUT REMOTELY

CONTROLLED

CONTROL HARNESS

SOURCE

1008

1006

1004

1002

253

SCI

SPI

J23

J5 J8 J7 J1

PC BOARD

219

218

220

REMOTE

CONTROL

76D

77D

75D

J40

STAINLESS STEEL

J23

ENGINE PROT.

BOARD

221

222

GROUND

TRIGGER

75D

242I

76D2D77D

J60

J61

77C

75B

METER

PCB

(optional)

STAND-OFF

COMMON BATT.

AMPHENOL 2

STAND-OFF

STAINLESS STEEL

REMOTE PROTECTION PCB

76C

NEUTRAL T2 STUD

IN CONTROL BOX

AUX. POWER

FRAME GROUND

246

243

229B

233

247

245

239A

232

262

227

234

237

226

224

285

FRAME GROUND

242I

ON CONTROL PANEL

GROUND SCREW

GND-C

GND-D

240A

1 NO FUNCTION

2 NO FUNCTION

3 90 MAX

4 120 MAX

SELECTOR SWITCH (S8)

POSITION NAMEPLATE SETTING

240

START BUTTON

240

233

RUN

STOP

232

232H

232A

HIGH

256

IDLER

SWITCH

237

SOLENOID

COIL

PULL

HOLD

IDLE

ENGINE TO PCB HARNESS

226

240

SOLENOID

COIL

PULL

HOLD

SHUTDOWN

224

AUX. CURRENT

SENSE TOROID

279

280

GND-F

GND-A

WELDED STUD

ON OUTPUT PANEL

GND-E

HOT

J12

LOAD

WHITE

LOAD

HOT

LINE

WHITE

LINE

120 V

GFCI

GREEN

GND-E

5 180 MAX

6 230 MAX

7 270 MAX

8 400 MAX

9 50-575

236B

231A

236A

233A

236A

267

AUTO

255

254

COIL

227

262

STUD ON ENGINE

SOLENOID GROUND

COIL

METER

225

HOUR

BLACK

HOT

J11

LOAD

HOT

LINE

120 V

GREEN

GND-D

231A

SOLENOID

STARTER

236C

BOLT ONTO

SENDER BRK’T

286

PANEL TO PANEL WIRES

PANEL TO PCB HARNESS

242G

239A

239B

LOAD

WHITE

LINE

WHITE

GFCI

MOUNT CHANNEL

STUD ON ENGINE

12 VOLT

BATTERY

(-)

(+)

ALTERNATOR

EXC

NEG

POS

MOTOR

SENSE

STARTING

& SENSOR

OIL PRESSURE SWITCH

245

229B

232C

246

232A

232B

247

232F

INSULATED STUD

234

SENSOR

228

P16

J16

15A

239

285

LARGE

TAB

233A

SWITCH

SENSOR

FUEL LVL.

SENSOR

OIL TEMP. SENSOR & SWITCH

241

229

242E

241A

228A

242D

SILVER

TAB

LOW

FUEL

232E

FUEL

229A

TEMP.

232D

242A

TEMP.

241A

LOW

PRESS.

232G

242C

228A

OIL

PRESS.

ALT.

243

236C

AMMETER

238

BLACK

IN CONTROL BOX

15A

CB4

CB3

J10

120/240V

GREEN

GND-C

WHITE

ENGINE

GND-F

242

GND-H

238

SMALL

TAB

ENGINE HARNESS

239

239B

229A

242G

ENGINE HARNESS TO PANEL WIRES

SILVER

242D

242B

GROUND SCREW

CONTROL PANEL

SILVER

TAB

IN CONTROL BOX

T1 INSULATED STUD

50A

CB2

50A

CB1

BLACK

WHITE

TERM.

BLACK

5-15-98A

ENGINE GROUND

MOUNT CHANNEL

STUD ON GENERATOR

TAB

242

L11008

gram for your particular machine is pasted inside the machine on one of the enclosure panels.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-

COMMANDER 400

F-2

DIAGRAMS

WIRING DIAGRAM:

207

206

223

204

261

J30

260

SEE CHART

(VIEWED

FROM BACK)

208A

216

213

214

215

SWITCH

SELECTOR

222

218

221

219

217

220

77B

POT

BACK

VIEWED FROM

FINE CONTROL

76B

76C

77C

1023

1021

1019

1017

REMOTE/

1022

1018

LOCAL

1024

1020

SWITCH

282

SWITCH

VOLT/AMP

OUTPUT

EXCITER

ALWAYS ON

283

OUTPUT REMOTELY

CONTROLLED

SOURCE

CONTROL

WINDINGS

240 uF

NEG.

206A

ELECTRODE

BOARD

BYPASS PC

POLARITY

SWITCH

FRAME

POS.

GROUND

208A

NEG.

NEXT AVAILABLE 287

CONNECTOR CAVITY NUMBERING SEQUENCE

(VIEWED FROM COMPONENT SIDE OF BOARD)

POS.

ON NEWER MODELS

NOTE:

NO CONNECTION

ELECTRICAL SYMBOLS PER E1537

206A

206

207

279

280

CURRENT

SENSE TOROID

208

206S

204S

277

RECTIFIER

ASSEMBLY

204A

SCR 1

204C

SHUNT

600 AMP

204B

SCR C

SCR B

SCR A

285A285

30,000 uF

R1-50

100 W

OUTPUT

R2-12

300W

R3-12

CHOKE

C1-C4

284B

284

284A

CHOKE

209

209A

223

261 204

260

COMMANDER 400-STICK & WIRE MODEL WIRING DIAGRAM

240A

ER VOLTA

273

268

1008

1006

1004

1002

FEEDBACK BOARD

EXCIT

272

J50

274

269

270

1013

1009

CAPACITORS MADE

CONNECTIONS TO

1015

1011

VIA BOLTED

CONNECTIONS

STATOR

1016

1014

1012

1010

240 uF

J20

PC BOARD

RF BYPASS

2133214

115AC

32A

204A

204S

206S

280

273

272

274

279

268

269

270

255

256

75B

1007

1005

1003

1001

1008

1006

1004

1002

240 uF

251

252

253

250

SPI

SCI

J23

ENGINE

PROT.

BOARD

ENGINE PROT.

J21

BOARD

J8 J7

(VIEWED AS INSTALLED)

CONNECTIONS ON CONTROL BOARD

MOTHER

PC BOARD

CONTROL

101114

219

217

218

2205221

215

J21

77C

216

J61

75B

76C

CONTACTOR

222

282

283

277

208

J62

76E

77E

75E

76E

77E

WORK

REMOTE

CONTROL

32A

AUX. POWER

GROUND SCREW

NEUTRAL T2 STUD

IN CONTROL BOX

J40

PCB

METER

STAND-OFF

COMMON BATT.

STAINLESS STEEL

J23

BOARD

CV DAUGHTER BOARD

77D

75D

77D

242H

AMPHENOL 1

GROUND

CB5 15AMP

242H

242I

IN CONTROL BOX

GND-E

GND-C

GND-D

J60

REMOTE

GND-A

76D

GREEN

76D

CONTROL

HOT

LOAD

HOT

LINE

GND-E

246

229B

247

239A

262

237

224

75D

GND-F

J12

115 V

FRAME GROUND

243

233

245

232

227

234

226

285

CONTACTOR

WELDED STUD

ON OUTPUT PANEL

LOAD

LINE

GFCI

240A

240

SELECTOR SWITCH (S8)

3 90 MAX.

2 WIRE WELDING CV

1 NO FUNCTION

POSITION NAMEPLATE SETTING

240

START BUTTON

233

232

232A

237

FRAME GROUND

HOLD

ENGINE TO PCB HARNESS

226

240

242H

242I

COIL

HOLD

AMPHENOL 2

GROUND

224

242I

HOT

J11

WHITE

LOAD

HOT

WHITE

LINE

115 V

GREEN

GND-D

6 230 MAX.

9 50-575

8 400 MAX.

7 270 MAX.

5 180 MAX.

4 120 MAX.

236B

231A

233A

RUN

STOP

236A

232H

267

HIGH

AUTO

256

255

IDLER

SWITCH

254

SOLENOID

COIL

PULL

IDLE

227

STUD ON ENGINE

262

SOLENOID GROUND

SOLENOID

COIL

PULL

SHUTDOWN

225

INSULATED STUD

15A

BLACK

LOAD

WHITE

LINE

WHITE

GFCI

WHITE

231A

236A

236C

SENDER

BRACKET

BOLT ON

PANEL TO PANEL WIRES

242G

239B

METER

HOUR

BLACK

IN CONTROL BOX

15A

CB4

J10

115/230V

GREEN

GND-C

(+)

SOLENOID

STARTER

STARTING

285

286

OIL PRESSURE SWITCH & SENSOR

232C

PANEL TO PCB HARNESS

232B

239A

CB3

WHITE

12 VOLT

BATTERY

MOTOR

234

SWITCH

SENSOR

228

P16

J16

245

FUEL

229B

246

232A

TEMP.

247

232F

OIL

PRESS.

243

AMMETER

IN CONTROL BOX

T1 INSULATED STUD

50A

CB2

50A

CB1

BLACK

WHITE

TERM.

BLACK

MOUNT CHANNEL

STUD ON ENGINE

(-)

ALTERNATOR

NEG

EXC

POS

SENSE

233A

SWITCH

SENSOR

OIL TEMP. SENSOR & SWITCH

241

242E

241A

228A

242D

LOW

FUEL

232E

229A

TEMP.

232D

241A

LOW

PRESS.

232G

228A

ALT.

236C

238

STAND-OFF

STAINLESS STEEL

UD ON

ENGINE

ENGINE GROUND

L E

HANN

NT C OU

STUD ON GENERATOR

242

GND-F

GND-H

238

239

SENSOR

ENGINE TO PANEL HARNESS

FUEL LVL.

239

229

239B

229A

242G

ENGINE TO PANEL HARNESS

242

242A

242D

242B

GROUND SCREW

IN CONTROL BOX

INSTRUMENT PANEL

242C

B5B4

AUXILIARY BYPASS PCB

9A 5K

FRAME

GROUND

F-2

L11009

5-15-98A

gram for your particular machine is pasted inside the machine on one of the enclosure panels.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-

COMMANDER 400

F-3

CONNECTION DIAGRAM:

DIAGRAMS

K487-25

SPOOL GUN

K488 SG

CONTROL MODULE

K691-10

INPUT CABLE

F-3

12-13-96

M18284

or service this equipment.

Only qualified personnel should install,use

Keep guards in place.

Keep away from moving parts.

WARNING

Do not operate with panels open.

before servicing.

Disconnect NEGATIVE (-) BATTERY LEAD

Do not touch electrically live parts.

RECEPTACLE

6 PIN REMOTE

ELECTRODE CABLE

TO CONTROL MODULE

ELECTRODE

TO WORK

BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE "LINCOLN" (CONTACT CLOSURE) POSITION BEFORE ATTEMPTING TO OPERATE

115V RECEPTACLE

RECEPTACLE

14 PIN WIRE FEEDER

TO WORK

CONTROL MODULE. INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND/OR POWER SOURCE.

CAUTION :

COMMANDER 400 STICK & WIRE / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM

THE ENGINE WELDER OPERATING MANUAL.

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.

"REMOTE" POSITION.

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".

N.C. IF OPTIONAL K857 REMOTE OUTPUT CONTROL IS CONNECTED TO 6 PIN RECEPTACLE,PLACE LOCAL REMOTE SWITCH IN

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.

N.D. PLACE IDLE SWITCH IN "HIGH" IDLE POSITION.

COMMANDER 400

F-4

CONNECTION DIAGRAM:

DIAGRAMS

LN-23P

WIRE FEEDER

TO WORK

F-4

12-13-96

S22911

Only qualified personnel should install,use

Keep guards in place.

or service this equipment.

Keep away from moving parts.

WARNING

Do not operate with panels open.

before servicing.

Disconnect NEGATIVE (-) BATTERY LEAD

Do not touch electrically live parts.

KIT

ADAPTER

6 PIN

AMPHENOL

K350-1

ELECTRODE

ELECTRODE CABLE

TO WORK

COMMANDER 400 STICK & WIRE / LN-23P CONNECTION DIAGRAM

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE

AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.

AMPHENOL

14 PIN

COMMANDER 400

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY.

N.C. IF REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL/REMOTE SWITCH IN "REMOTE" POSITION.

N.D. ON COMMANDER 400 STICK & WIRE, THE OUTPUT CONTROL SWITCH MUST BE IN THE "WELDING

TERMINALS REMOTELY CONTROLLED" POSITION.

F-5

CONNECTION DIAGRAM:

DIAGRAMS

REMOTE CONTROL

OPTIONAL K857

WORK CLIP LEAD

LN-25

WIRE FEEDER

TO WORK

F-5

12-13-96

S22912

Only qualified personnel should install,use

Keep guards in place.

or service this equipment.

Keep away from moving parts.

WARNING

Do not operate with panels open.

Disconnect NEGATIVE (-) BATTERY LEAD

before servicing.

Do not touch electrically live parts.

6 PIN

AMPHENOL

ELECTRODE CABLE

TO WORK

ELECTRODE

TO WORK

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE

AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.

N.C. IF REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL/REMOTE SWITCH IN "REMOTE" POSITION.

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY.

N.D. ON COMMANDER 400 STICK & WIRE, THE OUTPUT CONTROL SWITCH MUST BE IN THE "WELDING

AMPHENOL

COMMANDER 400 STICK & WIRE / LN-25 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL K857 REMOTE CONTROL

14 PIN

TERMINALS ALWAYS ON" POSITION .

COMMANDER 400

F-6

CONNECTION DIAGRAM:

Only qualified personnel should install,use

or service this equipment.

Keep away from moving parts.

Keep guards in place.

LN-8

WIRE

N.C.

FEEDER

DIAGRAMS

K196

INPUT CABLE

GND

F-6

12-13-96

S22913

SPARE

WARNING

Do not operate with panels open.

before servicing.

Disconnect NEGATIVE (-) BATTERY LEAD

Do not touch electrically live parts.

N.D.

GND

K867 UNIVERSAL

ADAPTER PLUG

ELECTRODE CABLE

TO WIRE FEED UNIT

COMMANDER 400 STICK & WIRE / K867 / LN-8 CONNECTION DIAGRAM

ELECTRODE

TO WORK

14 PIN

AMPHENOL

TO WORK

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

CAUTION :

THE ENGINE WELDER OPERATING MANUAL.

COMMANDER 400

PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION.

APPICATIONS. SEE OPERATING MANUAL.

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.D. SPLICE LEADS AND INSULATE.

F-7

CONNECTION DIAGRAM:

DIAGRAMS

OPTIONAL K857

REMOTE CONTROL

TO WIRE FEED UNIT

ELECTRODE CABLE

F-7

12-13-96

S22914

or service this equipment.

Only qualified personnel should install,use

Keep guards in place.

Keep away from moving parts.

WARNING

Do not operate with panels open.

before servicing.

Disconnect NEGATIVE (-) BATTERY LEAD

Do not touch electrically live parts.

TO LN-7 INPUT

CABLE PLUG

K584 OR K594CONTROL CABLE

TO WORK

ELECTRODE

TO WORK

COMMANDER 400 STICK & WIRE / LN-7 CONNECTION DIAGRAM

N.A. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

THE ENGINE WELDER OPERATING MANUAL.

14 PIN

AMPHENOL

6 PIN

AMPHENOL

COMMANDER 400

CAUTION :

APPLICATIONS. SEE OPERATING MANUAL.

N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL REMOTE SWITCH IN "REMOTE" POSITION.

F-8

CONNECTION DIAGRAM:

LN-7

WIRE

FEEDER

DIAGRAMS

K291 OR K404

INPUT CABLE

K775 OPTIONAL

REMOTE CONTROL

F-8

13-13-96

S22915

or service this equipment.

Only qualified personnel should install,use

Keep guards in place.

Keep away from moving parts.

SPARE

WARNING

Do not operate with panels open.

before servicing.

Disconnect NEGATIVE (-) BATTERY LEAD

Do not touch electrically live parts.

N.D.

}

81424131313232

224

GND

K867 UNIVERSAL

GREEN

757677

ADAPTER PLUG

}

N.E.

ELECTRODE CABLE

TO WIRE FEED UNIT

ELECTRODE

COMMANDER 400 STICK & WIRE / K867 / K775 / LN-7 CONNECTION DIAGRAM

14 PIN

AMPHENOL

TO WORK

CAUTION :

PLACE WIRE FEEDER SWITCH TO "WIRE FEEDER WITH CONTROL CABLE POSITION.

N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE "RANGE" SWITCH TO "WIRE WELDING CV".

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPILICATIONS. SEE OPERATING MANUAL.

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

THE ENGINE WELDER OPERATING MANUAL.

N.E. SPLICE LEADS AND INSULATE.

N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION.

COMMANDER 400

F-9

CONNECTION DIAGRAM:

DIAGRAMS

F-9

6-12-98

S22916

N.C.

Only qualified personnel should install,use

Keep guards in place.

or service this equipment.

Keep away from moving parts.

NOT USED ON COMMANDER 400 POWER SOURCES

N.C.

N.D.

CONNECT TOGETHER FOR WELDING OUTPUT

NOT USED ON COMMANDER 400 POWER SOURCES

SPARE

N.E.

REMOTE OUTPUT CONTROL

10K

MIN.

115 VAC

WIRE FEEDER VOLTMETER CONNECTION

CONNECTS TO (WORK TERMINAL) OF POWER SOURCE

POWER SOURCE FRAME CONNECTION

GND

WIRE

FEEDER

K867

WARNING

ADAPTER PLUG

Do not operate with panels open.

before servicing.

Disconnect NEGATIVE (-) BATTERY LEAD

Do not touch electrically live parts.

COMMANDER 400 STICK & WIRE TO K867 ADAPTER CONNECTION DIAGRAM

AMPHENOL

14 PIN

K867 UNIVERSAL

ELECTRODE

TO WORK

TO WIRE FEED UNIT

ELECTRODE CABLE

TO WORK

CAUTION :

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

THE ENGINE WELDER OPERATING MANUAL.

RELAY TO CLOSE LEADS 2 & 4.

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

APPLICATIONS. SEE OPERATING MANUAL.

N.E. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW.

N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION

COMMANDER 400

F-10

CONNECTION DIAGRAM:

DIAGRAMS

F-10

12-13-96

S22917

Only qualified personnel should install,use

Keep guards in place.

or service this equipment.

Keep away from moving parts.

WARNING

Do not operate with panels open.

Disconnect NEGATIVE (-) BATTERY LEAD

before servicing.

Do not touch electrically live parts.

TO LN-8 INPUT

CABLE PLUG

K595 CONTROL CABLE

14 PIN

AMPHENOL

ELECTRODE

TO WORK

ELECTRODE CABLE

TO WIRE FEED UNIT

TO WORK

COMMANDER 400 STICK & WIRE / LN-8 CONNECTION DIAGRAM

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

CAUTION :

COMMANDER 400

APPLICATIONS. SEE OPERATING MANUAL.

PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION.

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".

N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

THE ENGINE WELDER OPERATING MANUAL.

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

F-11

DIMENSION PRINT

10.22

45.67

DIAGRAMS

31.50

F-11

6-21-96

M17685

TRAILER MOUNTING HOLE LOCATIONS.

48.30

32.06

29.50

48.64

42.00

6.56

63.10

FOR BATTERY

REMOVAL.

14.63

37.30

45.38

6.55

24.97

6.53

BOTTOM VIEW OF

WELDER BASE.

50.38

54.44

23.69

19.63

CENTER OF GRAVITY

WITH OIL IN ENGINE

AND FULL FUEL TANK.

15.75

COMMANDER 400

28.99

1.26

F-12

NOTES

F-12

COMMANDER 400

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5 weeks of fundamentals

There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location. Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only. Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery. UPS Shipping f

or North America Only. All prepaid orders that request UPS shipment please add:

$5.00 For order value up to $49.99 $10.00 For order value between $50.00 & $99.99 $15.00 For order value between $100.00 & $149.00

For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost. Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment. METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)

CHECK ONE:

Please Invoice (only if order is over $50.00) Check or Money Order Enclosed, U.S. Funds only Credit Card - Telephone: _______________________________________________

Account No.

USE THIS FORM TO ORDER:

BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.

|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Exp Date |_|_| |_|_|

Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199

Name: _______________________________________________

Address: _______________________________________________

_______________________________________________

Signature as it appears on Charge Card:

Month Year

______________________

Lincoln Welding School Titles: Price Code Quantity Cost

(ED-80)

Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH

(ED-45)

Educational Video Information Incentive Management $5.00 IM

(ED-93)

James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC Foundation Book Information Welding Preheat Calculator $3.00 WC-8

(JFLF-515)

New Lessons in Arc Welding $5.00 L

How to Read Shop Drawings $4.50 H

A New Approach to Industrial Economics $5.00 NA

Pipe Welding Charts $4.50 ED-89

SUB TOTAL

Additional Shipping Costs if any

TOTAL COST

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

LIMITED WARRANTY

STATEMENT OF LIMITED WARRANTY

The Lincoln Electric Company (Lincoln) warrants to the end user (purchaser) of all new welding and cutting equipment, electrode and flux (collectively called the “Goods”) that it will be free of defects in workmanship and material.

This warranty is void if Lincoln or its Authorized Service Facility finds that the equipment has been subjected to improper installation, improper care or abnormal operations.

WARRANTY PERIOD

Lincoln will assume both the parts and labor expense of correcting defects during the full warranty period. All warranty periods date from the date of purchase to the original end user and are as follows:

7 Years

• Main power rectifiers on all non-inverter low frequency (50 and 60 Hz) type welders.

3 Years

• All Lincoln welding machines, wirefeeders and plasma cutting machines unless listed below.

2 Years

• Power Arc 5000 Ranger 10, Ranger 10-LX

Weldanpower 125, Weldanpower 150

1 Year

• AC-100 Invertec V100-S, Invertec V130-S, Invertec V200-T Power Arc 4000 Pro-Cut 20

• All water coolers (internal or external models)

(1) (2) (3)

CONDITIONS OF WARRANTY

TO OBTAIN WARRANTY COVERAGE:

The purchaser must contact Lincoln or Lincoln’s Authorized Service Facility about any defect claimed under Lincoln’s warranty.

Determination of warranty on welding and cutting equipment will be made by Lincoln or Lincoln’s Authorized Service Facility.

WARRANTY REPAIR:

If Lincoln or Lincoln’s Authorized Service Facility confirms the existence of a defect covered by this warranty, the defect will be corrected by repair or replacement at Lincoln’s option.

At Lincoln’s request, the purchaser must return, to Lincoln or its Authorized Service Facility, any “Goods” claimed defective under Lincoln’s warranty.

FREIGHT COSTS:

The purchaser is responsible for shipment to and from the Lincoln Authorized Service Facility.

WARRANTY LIMITATIONS

Lincoln will not accept responsibility or liability for repairs made outside of a Lincoln Authorized Service Facility.

Lincoln’s liability under this warranty shall not exceed the cost of correcting the defect of the Lincoln product.

• All stick electrode, welding wire and flux.

• Arc welding and cutting robots and robotic controllers

• All Environmental Systems equipment, including portable units, central units, gun and cable assemblies and accessories. (Does not include consumable items listed under 30 day warranty.)

• All welding and cutting accessories including gun and cable assemblies, TIG and plasma torches, spool guns, wire feed modules, undercarriages, field installed options that are sold separately, unattached options, welding supplies, standard accessory sets, replacement parts, and Magnum products. (Does not include expendable parts listed under 30 day warranty)

30 Days

• All consumable items that may be used with the environmental systems described above. This includes hoses, filters, belts and hose adapters.

• Expendable Parts - Lincoln is not responsible for the replacement of any expendable part that is required due to normal wear.

Lincoln will not be liable for incidental or consequential damages (such as loss of business, etc.) caused by the defect or the time involved to correct the defect.

This written warranty is the only express warranty provided by Lincoln with respect to its products. Warranties implied by law such as the warranty of merchantability are limited to the duration of this limited warranty for the equipment involved.

This warranty gives the purchaser specific legal rights. The purchaser may also have other rights which vary from state to state.

(1)

Equipment manufactured for the Lincoln Electric Company is subject to the warranty period of the original manufacturer.

(2)

All engines and engine accessories are warranted by the engine or engine accessory manufacturer and are not covered by this warranty.

(3)

SAE400 WELD N’ AIR compressor is warranted by the compressor manu-

facturer and not covered by this warranty.

Dec, ‘97

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

• 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

Lincoln Electric IM544 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual