RETURN TO MAIN INDEX
IM544-B
Commanderâ„? 400 June, 1998
9978, 10580 (Stick Model),
For use with machines having Code Numbers:
9979, 10581 (Stick and Wire Model)
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.
OPERATOR’S MANUAL
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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
For Gasoline Engines: The engine exhaust from
For Diesel Engines: Diesel engine exhaust and
this product contains chemicals known to the
some of its constituents are known to the State
State of California to cause cancer, birth defects,
of California to cause cancer, birth defects, and
or other reproductive harm.
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 pur-
chase 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 ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
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 refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, coversand devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler 2.d.3. Do not place your body between the electrode and
by pushing on the throttle control rods while work cables. If the electrode cable is on your right
the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot� when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot� parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
3.b. Insulate yourself from work and ground using dry insulation.
material to protect your skin and that of your helpers from
Make certain the insulation is large enough to cover your full
the arc rays.
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if welding
screening and/or warn them not to watch the arc nor expose
must be performed under electrically hazardous
themselves to the arc rays or to hot spatter or metal.
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,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
can be dangerous.
the following equipment:
5.a. Welding may produce fumes and gases
� Semiautomatic DC Constant Voltage (Wire) Welder.
hazardous to health. Avoid breathing these
� DC Manual (Stick) Welder.
fumes and gases.When welding, keep
� AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
fumes and gases away from the breathing zone. When
electrode reel, welding head, nozzle or semiautomatic
welding with electrodes which require special
welding gun are also electrically “hot�.
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
3.d. Always be sure the work cable makes a good electrical
cadmium plated steel and other metals or coatings
connection with the metal being welded. The connection
which produce highly toxic fumes, keep exposure as
should be as close as possible to the area being welded.
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
3.e. Ground the work or metal to be welded to a good electrical
confined spaces or in some circumstances, outdoors, a
(earth) ground.
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating
products.
3.h. Never simultaneously touch electrically “hot� parts of
electrode holders connected to two welders because voltage
5.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
5.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.j. Also see Items 6.c. and 8.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact can
any other source of heat, sparks, or flame.
cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés possible de
1. Protegez-vous contre la secousse électrique:
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
a. Les circuits à l’électrode et à la piéce sont sous tension
éloignés de la zone de travail, on augmente le risque de voir
quand la machine à souder est en marche. Eviter toujours
passer le courant de soudage par les chaines de levage,
tout contact entre les parties sous tension et la peau nue
câbles de grue, ou autres circuits. Cela peut provoquer des
ou les vétements mouillés. Porter des gants secs et sans
risques d’incendie ou d’echauffement des chaines et des
trous pour isoler les mains.
câbles jusqu’� ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans
Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande
galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse.
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
10. Ne pas souder en présence de vapeurs de chlore provenant
tionnement.
d’opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l’eau pour le
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
refroidir.
du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension
ou autres produits irritants.
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
total de la tension à vide des deux machines.
le code “Code for safety in welding and cutting� CSA Standard
f. Si on utilise la machine à souder comme une source de
W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
PRÉCAUTIONS DE SÛRETÉ POUR
contre les chutes dans le cas ou on recoit un choc. Ne jamais
LES MACHINES À SOUDER À
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
TRANSFORMATEUR ET À
REDRESSEUR
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 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
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.
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product •â?¢â??
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.
vi vi
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 .....................................................................................................................D-1
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
COMMANDER 400
A-1 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
400 amps (DC Constant Current) 40 volts
100%
400 amps (DC Constant Voltage) 40 volts
500 amps (DC Constant Current) 40 volts
60%
500 amps (DC Constant Voltage) 40 volts
OUTPUT - WELDER AND GENERATOR
Welding Range Open Circuit Voltage Auxiliary Power1
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
HEIGHT2 WIDTH DEPTH WEIGHT
42.0 in. 31.5 in. 63.1 in. 1650 lbs.(748 kg)
(Stick model)
1066.8 mm 800.1 mm 1602.7 mm 1683 lbs.(763 kg)
(Stick & Wire model)
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 A-2
INSTALLATION
Read this entire installation section before you STACKING
start installation.
Commander 400 machines cannot be stacked.
SAFETY PRECAUTIONS
ANGLE OF OPERATION
WARNING
To achieve optimum engine performance the
Commander 400 should be run in a level position. The
Do not attempt to use this equipment until you have
maximum angle of operation for the Deutz engine is 20
thoroughly read all operating and maintenance man-
degrees in a direction to cause the control panel to be
uals supplied with your machine. They include impor-
angled up, 30 degrees for side to side tilting and for the
tant safety precautions, detailed engine starting,
control panel to be angled down. If the engine is to be
operating and maintenance instructions and parts
operated at an angle, provisions must be made for
lists.
checking and maintaining the oil level at the normal
(FULL) oil capacity in the crankcase. When operating
ELECTRIC SHOCK can kill.
the welder at an angle, the effective fuel capacity will
be slightly less than the specified 25 gallons.
•Do not touch electrically live parts such
as output terminals or internal wiring.
LIFTING
•Insulate yourself from the work and
ground. The Commander lift bale should be used to lift the
machine. The Commander is shipped with the lift bale
•Always wear dry insulating gloves. retracted. Before attempting to lift the Commander the
------------------------------------------------------------------------ lift bale must be secured in a raised position. Secure
the lift bale as follows:
ENGINE EXHAUST can kill.
a. Open the engine compartment door.
•Use in open, well ventilated areas or
vent exhaust outside b. Locate the 2 access holes on the upper middle
region of compartment wall just below the lift
•Do not stack anything near the engine. bale.
------------------------------------------------------------------------
c. Use the lifting strap to raise the lift bale to the full
MOVING PARTS can injure. upright position. This will align the mounting
holes on the lift bale with the access holes.
•Do not operate with doors open or
guards off. d. Secure the lift bale with 2 thread forming screws.
The screws are provided in the shipped loose
•Stop engine before servicing. parts bag.
•Keep away from moving parts
------------------------------------------------------------------------
Only qualified personnel should install, use or service
WARNING
this equipment
FALLING EQUIPMENT can cause
LOCATION/VENTILATION injury.
•Do not lift this machine using lift bale if
The welder should be located to provide an unrestricted
it is equipped with a heavy accessory
flow of clean, cool air to the cooling air inlets and to avoid
such as a trailer or gas cylinder.
restricting the cooling air outlets. Also, locate the welder
so that the engine exhaust fumes are properly vented to
•Lift only with equipment of adequate
an outside area.
lifting capacity.
•Be sure machine is stable when lifting.
------------------------------------------------------------------------
COMMANDER 400
A-3 A-3
INSTALLATION
HIGH ALTITUDE OPERATION PRE-OPERATION ENGINE SERVICE
At higher altitudes, output derating may be necessary. READ the engine operating and maintenance instruc-
As a rule of thumb, derate the welder output 5% for tions supplied with this machine.
every 400 meters (1312 ft.) above 1000 meters (3280
ft.).
WARNING
Contact a Deutz Service Representative for any engine
adjustments that may be required for high altitude •Stop engine and allow to cool before
operation. fueling.
•Do not smoke when fueling.
TOWING
•Fill fuel tank at a moderate rate and do
not overfill.
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle(1) is
•Wipe up spilled fuel and allow fumes to
Lincoln’s K953-1. If the user adapts a non-Lincoln
clear before starting engine.
trailer, he must assume responsibility that the method
of attachment and usage does not result in a safety
•Keep sparks and flame away from
hazard nor damage the welding equipment. Some of
tank.
the factors to be considered are as follows:
------------------------------------------------------------------------
OIL
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
The Commander is shipped with the engine crankcase
2. Proper support of, and attachment to, the base of filled with high quality SAE 10W-30 oil (API class CD or
the welding equipment so that there will be no better). Check the oil level before starting the engine. If it
undue stress to the trailer’s framework. 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
3. Proper placement of the equipment on the trailer to
Operator’s Manual for specific oil recommendations and
insure stability side to side and front to back when
break-in information. The oil change interval is dependent
being moved and when standing by itself.
on the quality of the oil and the operating environment.
Refer to the engine Operator’s Manual for the proper ser-
4. Typical conditions of use, such as travel speed,
vice and maintenance intervals.
roughness of surface on which the trailer will be
operated, and environmental conditions.
FUEL USE DIESEL FUEL ONLY
5. Proper preventative maintenance of trailer.
Fill the fuel tank with clean, fresh diesel fuel. The capac-
ity of the fuel tank is 25 gallons (94.6 liters). See engine
6. Conformance with federal, state and local laws. 1
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
1
Consult applicable federal, state and local laws
machine will indicate a low fuel condition by turning on the
regarding specific requirements for use on public high-
low fuel light. A time of 30 minutes will elapse once the
ways.
low fuel light illuminates before the machine will shut-
down. A restart of the machine will restart the timer to
allow the operator to override this feature. The amount of
reserve fuel remaining in the tank after the first shutdown
will vary from machine to machine. The operator must
determine the amount of fuel remaining before re-starting
the machine. Running out of fuel may require bleeding
the fuel injection pump.
NOTE: Before starting the engine, open the fuel shutoff
valve (lever to be in line with hose) located on the side the
fuel pre-filter / water separator housing.
COMMANDER 400
A-4 A-4
INSTALLATION
FUEL CAP MUFFLER OUTLET PIPE
Remove the plastic cap covering from the Fuel Tank
Remove the plastic plug covering the muffler outlet
Filler neck and install the Fuel Cap.
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.
ENGINE COOLING SYSTEM
SPARK ARRESTER
The Deutz engine is air cooled by a belt driven axial
blower. The oil cooler and engine cooling fins should
Some federal, state or local laws may require that
be blown out with compressed air or steam to maintain
gasoline or diesel engines be equipped with exhaust
proper cooling (See the engine Owners Manual for pro-
spark arresters when they are operated in certain loca-
cedures and frequency).
tions where unarrested sparks may present a fire haz-
ard. The standard muffler included with this welder
BATTERY CONNECTION
does not qualify as a spark arrester. When required by
WARNING: Use caution as the electrolyte is a strong local regulations, a suitable spark arrester, such as the
acid that can burn skin and damage eyes. K899-1 must be installed and properly maintained.
Remove and discard the insulating cap from the nega-
tive battery terminal. Attach and tighten negative bat-
CAUTION
tery cable terminal.
NOTE: This machine is furnished with a wet charged battery; if An incorrect arrester may lead to damage to the engine
unused for several months, the battery may require a booster or adversely affect performance.
charge. Be careful to charge the battery with the correct polar- ------------------------------------------------------------------------
ity. Make sure that the battery is level while charging.
ELECTRICAL OUTPUT CONNECTIONS
See Figure A.1 for the location of the weld output terminals, ground stud, and auxiliary power receptacles
OIL
FUEL TEMP PRESS AMPS 0
00000
HOURS
120 VOLT
RECEPTACLES
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 A-5
INSTALLATION
WELDING OUTPUT CABLES 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
With the engine off, route the electrode and work
grounding electrical equipment. A machine grounding
cables thru the strain relief bracket provided on either
stud marked with the symbol is provided on the
side of the base and connect to the terminals provided.
front of the welder.
These connections should be checked periodically and
tightened if necessary.
AUXILIARY POWER RECEPTACLES
Listed in Table A.1 are copper cable sizes recom-
mended for the rated current and duty cycle. Lengths The auxiliary power capacity of the Commander 400 is
stipulated are the distance from the welder to work and 10,000 watts of 60 Hz, single phase power. The auxil-
back to the welder again. Cable sizes are increased for iary power capacity rating in watts is equivalent to volt-
greater lengths primarily for the purpose of minimizing amperes at unity power factor. The maximum permis-
cable voltage drop. sible current of the 240 VAC output is 44 A. The 240
VAC output can be split to provide two separate 120
Table A.1 Combined Length of Electrode and Work VAC outputs with a maximum permissible current of 44
Cables. A per output to two separate 120 VAC branch circuits.
The output voltage is within ± 10% at all loads up to
TOTAL COMBINED LENGTH OF ELEC-
rated capacity.
TRODE AND WORK CABLES
AMPS Up to 150 150-200 FT. 200-250 FT. NOTE: The 120/240V receptacle has two 120V outlets
@100% FT. of different phases and cannot be paralleled.
Duty Cycle
The Commander has two 15 Amp-120VAC (5-15R)
250 1 AWG 1 AWG 1/0 AWG duplex receptacles with GFCI protection and one 50
Amp-120/240 VAC (14-50R) receptacle. The 120/240
400 3/0 AWG 3/0 AWG 4/0 AWG VAC receptacle can be split for single phase 120 VAC
operation. The auxiliary power receptacles should only
MACHINE GROUNDING
be used with three wire grounded type plugs or
approved double insulated tools with two wire plugs.
Because this portable engine driven welder creates its
The current rating of any plug used with the system
own power, it is not necessary to connect its frame to
must be at least equal to the current capacity of the
an earth ground, unless the machine is connected to
associated receptacle.
premises wiring (home, shop, etc.).
STANDBY POWER CONNECTIONS
To prevent dangerous electric shock, other equipment
powered by this engine driven welder must:
The Commander 400 is suitable for temporary, stand-
by or emergency power using the engine manufactur-
a) be grounded to the frame of the welder using a er’s recommended maintenance schedule.
grounded type plug,
or The Commander 400 can be permanently installed as
b) be double insulated. a standby power unit for 240 volt-3 wire, 44 amp ser-
vice. Connections must be made by a licensed electri-
When this welder is mounted on a truck or trailer, its cian who can determine how the 120/240 VAC power
frame must be securely connected to the metal frame can be adapted to the particular installation and com-
of the vehicle. When this engine driven welder is con- ply with all applicable electrical codes. The following
nected to premises wiring such as that in a home or information can be used as a guide by the electrician
shop, its frame must be connected to the system earth for most applications. Refer to the connection diagram
ground. See further connection instructions in the sec- shown in Figure A.2.
tion entitled “Standby Power Connections� as well as
the article on grounding in the latest U.S. National 1. Install the double-pole, double-throw switch between
Electrical Code and the local code. the power company meter and the premises discon-
nect.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid Switch rating must be the same or greater than the
earth ground such as a metal water pipe going into the customer’s premises disconnect and service over cur-
ground for at least ten feet and having no insulated rent protection.
COMMANDER 400
A-6 A-6
INSTALLATION
2. Take necessary steps to assure load is limited to the 3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-
capacity of the Commander by installing a 45 amp, 50) to the double-pole circuit breaker using No. 6, 4
240 VAC double pole circuit breaker. Maximum conductor cable of the desired length. (The 50 amp,
rated load for each leg of the 240 VAC auxiliary is 45 120/240 VAC plug is available in the optional K802R
amperes. Loading above the rated output will plug kit.)
reduce output voltage below the allowable -10% of
rated voltage which may damage appliances or 4. Plug this cable into the 50 Amp 120/240 Volt recep-
other motor-driven equipment and may result in tacle on the Commander 400 case front.
overheating of the Commander 400 engine.
Figure A.2 Connection of the Commander 400 to Premises Wiring
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt 120 VOLT
60 Hz.
COMPANY
3-Wire
120 VOLT
Service
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
45AMP
PROTECTION
240 VOLT
DOUBLE
POLE
50 AMP, 120/240 CIRCUIT
VOLT PLUG 240 VOLT BREAKER
NEMA TYPE 14-50
GND
N
50 AMP, 120/240 VOLT
NOTE: No. 8 COPPER CONDUCTOR CABLE SEE
RECEPTACLE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
COMMANDER 400
B-1 B-1
OPERATION
OPERATING INSTRUCTIONS GENERAL DESCRIPTION
Read and understand this entire section before operat- The Commander is a diesel engine driven welding
ing your Commander 400. power source. The machine uses a brushless asyn-
chronous alternating current generator for DC stick
SAFETY INSTRUCTIONS electrode welding and for 120/240 VAC auxiliary stand-
by 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
WARNING
slope-controlled ranges. In addition a seventh general
purpose welding range provides up to 575 amps of
Do not attempt to use this equipment until you have
constant current welding output.
thoroughly read all operating and maintenance man-
uals supplied with your machine. They include impor-
The engine is a 44.2 Hp (33kw), 3-cylinder air/oil
tant safety precautions, detailed engine starting,
cooled diesel made by Deutz. This naturally aspirated,
operating and maintenance instructions and parts
4 cycle engine features direct injection, a Bosch in-line
lists.
injection pump and a Bosch mechanical governor.
ELECTRIC SHOCK can kill.
This machine is controlled by a high quality microcon-
troller. The microcontroller provides high speed control
•Do not touch electrically live parts such
of the weld process as well as the engine protection
as output terminals or internal wiring.
features.
•Insulate yourself from the work and
RECOMMENDED APPLICATIONS
ground.
WELDER
•Always wear dry insulating gloves.
------------------------------------------------------------------------
The Commander 400 (Stick model) provides excellent con-
stant current DC welding output for stick (SMAW) welding.
ENGINE EXHAUST can kill.
The Commander 400 (Stick & Wire model) also provides
excellent constant voltage DC welding output for MIG
•Use in open, well ventilated areas or
(GMAW) and Innershield (FCAW) welding.
vent exhaust outside
GENERATOR
•Do not stack anything near the engine.
------------------------------------------------------------------------
The Commander 400 provides smooth 120/240 VAC
output for auxiliary power and emergency standby
MOVING PARTS can injure.
power.
•Do not operate with doors open or
DESIGN FEATURES AND ADVANTAGES
guards off.
(All Models)
•Stop engine before servicing.
FOR STICK WELDING
� Excellent DC constant current output for stick weld-
•Keep away from moving parts
ing applications.
------------------------------------------------------------------------
Only qualified personnel should operate this equip-
� 40 to 400 amps output in six slope controlled ranges
ment.
for out-of position and pipe electrodes and 50 to 575
amps constant current output in one general purpose
welding range.
ADDITIONAL SAFETY PRECAUTIONS
� 3 digit display is provided for presetting the weld
Always operate the welder with the hinged door closed
amperage and displaying the actual amperage during
and the side panels in place as these provide maxi-
welding. The display uses superbrite L.E.D.’s for
mum protection from moving parts and insure proper
improved readability in full sunlight.
cooling air flow.
� Remote control capability standard on all models.
COMMANDER 400
B-2 B-2
OPERATION
� Copper alternator windings and high temperature
� Selection of “hot� or “cold� output terminals with a tog- insulation for dependability and long life.
gle switch on the control panel. This feature can also
be controlled by installing a remote output terminal ADDITIONAL DESIGN FEATURES AND
control cable designed to open and close the #2 and ADVANTAGES (Stick & Wire Model only)
#4 leads in the amphenol receptacle.
FOR WIRE WELDING
FOR AUXILIARY POWER � One constant voltage position for all wire welding. A
� 10,000 watts of 120/240 VAC, 60Hz auxiliary power. 12 to 45V range across the entire current output
range.
� Drive a 2 HP motor (provided it is started under no
load). � Excellent arc characteristics with MIG (GMAW) and
Innershield (FCAW) welding.
� Two 15 amp 120 VAC duplex receptacles with GFCI
protection for up to 30 amps of 120 VAC power. � A Wire Feeder connector for quick connection of the
control cable.
� One 50 amp, 120/240 VAC dual voltage receptacle for
up to 44 amps of 240 VAC, and up to 44 amps per � A built in “Electronic Contactor� for “Cold� electrode
side to separate branch circuits (not in parallel) of 120 when not welding. This feature and DC Constant
VAC single phase auxiliary power. Allows easy con- Voltage output provide an added margin of safety
nection to premises wiring. when welding must be performed under electrically
hazardous conditions such as: damp locations, while
� Weld and AC auxiliary power at the same time (with- wearing wet clothing or in cramped positions if there
in machine total capacity). is a high risk of unavoidable or accidental contact with
the workpiece or ground.
OTHER FEATURES
� Deutz 3-cylinder, air/oil cooled diesel engine. � The 3 digit display has the additional feature of pre-
Designed for long life, easy maintenance and excel- setting the open circuit voltage and displaying the
lent fuel economy. actual voltage during welding.
� Engine protection system shuts the engine down for
� Designed for use with the following Lincoln wire feeders.
low oil pressure, high oil temperature or a broken
•LN-25 •LN-23P •LN-7
fan/engine alternator belt.
•LN-8 •NA-3 •Spool Gun &
K488 Module
� Gauges for oil pressure, oil temperature, engine alter-
nator output and fuel level.
WELDING CAPABILITY
� Indicator lights for low oil pressure, high oil tempera-
The Commander 400 is rated at 400 amps, 40 volts at
ture, engine alternator low output/broken belt and low
100% duty cycle. The weld current is variable from 40
fuel level.
to 575 amps.
� 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 ele-
ment.
� Automatic idler reduces engine speed when not weld-
ing or drawing auxiliary power. This feature reduces
fuel consumption and extends engine life.
� Single side engine service with over the top access to
the engine.
COMMANDER 400 MAY96
B-3 B-3
OPERATION
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
3 4
2 6
5 7
1 8
9
9
OIL
11
FUEL TEMP PRESS AMPS 0
00000
HOURS
10
12
23
13
17
22
21
24
- 20
+ -
15 16
18
19
14
ENGINE CONTROLS (Items 1 through 8)
3. FUEL LEVEL GAUGE AND LIGHT
1. RUN- STOP SWITCH
Displays the level of diesel fuel in the 25-gallon fuel
When placed in the “RUN� position, this switch ener-
tank. The yellow light turns on when the fuel gage
gizes the fuel solenoid and other electric accessories.
reaches the reserve level. Once the reserve level is
When placed in the “STOP� position, the flow of fuel to
reached, the engine protection system will shut down
the injection pump is stopped to shut down the engine.
the engine after 30 minutes of operation. The machine
(Note: If the switch is left in the “RUN� position and the
can be restarted and operated for an additional 30 min-
engine is not running, the battery will be drained by the
utes before the protection system will shut down the
fuel solenoid).
engine. This ability to override the engine protection is
to allow the operator to “finish up� if necessary. The
2. START PUSHBUTTON
operator must watch the fuel level closely to prevent
Energizes the starter motor to crank the engine. With
running out of fuel and having to bleed the system.
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.
COMMANDER 400
B-4 B-4
OPERATION
4. ENGINE TEMPERATURE GAUGE AND at full speed.
LIGHT
The gauge displays the engine oil temperature. The c. When welding ceases or the AC power load is
yellow temperature light remains off under normal turned off, a fixed time delay of approximately 15
operating temperatures. If the light turns on, the seconds starts.
engine protection system will shut down the engine.
Check for restrictions at the engine cooling air inlets d. If the welding or AC power load is not restarted
and outlets (consult the engine Operator’s Manual). before the end of the time delay, the idler reduces
Check for loose or disconnected leads at the tempera- the engine speed to low idle speed.
ture sender located on the engine. Check engine cool-
ing blower belt. Also, check to be sure that the welder e. The engine will automatically return to high idle
loads are within the rating of the welder. The light will speed when the welding load or A.C. power load
remain on when the engine has been shut down due to is reapplied.
an over- temperature condition.
Idler Operational exceptions
5. OIL PRESSURE GAUGE AND LIGHT
The gauge displays the engine oil pressure when the When the WELDING TERMINALS switch is in the
engine is running. The yellow oil pressure light “Welding Terminals Remotely Controlled� position the
remains off with proper oil pressure. If the light turns idler will operate as follows:
on, the engine protection system will stop the engine.
Check for proper oil level and add oil if necessary. a. When the triggering device (Amptrol, Arc Start
Check for loose or disconnected leads at the oil pres- Switch, etc.) is pressed the engine will accelerate
sure sender located on the engine. The light will go on and operate at full speed provided a welding load is
and stay on when the RUN-STOP switch is switched to applied within approximately 15 seconds.
the “Run� position with engine not running.
� If the triggering device remains pressed but no weld-
6. ENGINE ALTERNATOR AMMETER ing load is applied within approximately 15 seconds
AND LIGHT the engine will return to low idle speed.
The yellow engine alternator light is off when battery
charging system is functioning normally. If light turns � If the triggering device is released or welding ceases
on, the engine protection system will shut down the the engine will return to low idle speed after approxi-
engine. Check the engine cooling blower belt. Also, mately 15 seconds.
the alternator or the voltage regulator may not be oper-
ating correctly. The light may also come on if the alter- 8. HOUR METER
nator did not flash up due to not holding the start but- The hour meter displays the total time that the engine
ton in long enough (minimum of 2 seconds) or due to a has been running. This meter is a useful indicator for
faulty flashing circuit. The light will remain on when the scheduling preventive maintenance.
engine has been shut down due to a fault in the alter-
nator, regulator, or the cooling blower belt.
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 B-5
OPERATION
WELDER CONTROLS (Items 9 through 14 ) With the switch in the “Welding Terminals Always On�
position the contactor is closed and the welding termi-
nals are always “Hot�.
9. OUTPUT RANGE SWITCH & OUTPUT
CONTROL
With the switch in the “Welding Terminals Remotely
These two controls allow you to select between various
Controlled� position the contactor operation is con-
welding output slopes and adjust the desired welding
trolled by an Amptrol, Arc Start Switch or some other
output. Refer to Table B.1 for a description of how
type of triggering device through the use of a control
these two controls work.
cable connected to the 6-pin MS connector.
Table B.1 Output Range Switch and Output Control
When the triggering device is pressed the contactor is
Functions
closed and the welding terminals are “Hot�.
When the triggering device is released the contactor is
2
Range Control
opened and the welding terminals are “Cold�.
1
Switch
12. LOCAL /REMOTE SWITCH
Sloped Output for 6 Range
The toggle switch on the control panel labeled
Pipe Welding. Settings
“Local/Remote� gives the operator the option of con-
(all models) 90, 120, 180,
trolling the output at the welder control panel or at a
230, 270, 400
remote station.
(Max. current on
each setting)
For remote control the toggle switch is set in the
Provides a fine
Constant Current “Remote� position.
1 Range setting adjustment of
Output for
50-575 Amps welding current
Fabrication and For control at the welder control panel, the toggle
or voltage from
General Purpose switch is set in the “Local� position.
Min (1) to Max
Welding (This set-
(10) within each
ting also used for 13. 6 - PIN CONNECTOR
range
TIG) (all models) The 6-pin connector located on the control panel
allows for connection of Remote Control accessories.
1 Range setting
Constant Voltage
12 to 40 Volts
Output for Wire
14. WELD OUTPUT TERMINALS + AND -
Welding (Stick &
These 1/2 - 13 studs with flange nuts provide welding
Wire model only)
connection points for the electrode and work cables.
For positive polarity welding the electrode cable con-
nects to the �+� terminal and the work cable connects
to this �-� terminal. For negative polarity welding the
If the OUTPUT RANGE switch is positioned between settings the
1
work cable connects to the �+� terminal and the elec-
previous setting is maintained until the switch is properly positioned
on a setting. trode cable connects to this �-� terminal.
OUTPUT CONTROL also controls O.C.V. while in the 6 sloped out-
2
AUXILIARY POWER CONTROLS
put ranges.
(Items 15 - 19 )
10. DIGITAL OUTPUT METER
The digital output meter is located in the center of the
15. 120/240VAC RECEPTACLE
control panel between the two large control knobs. The
This is a 120/240VAC (14-50R) receptacle that pro-
meter allows the output current level to be set prior to
vides 240VAC or can be split for 120VAC single phase
welding. During the welding process the meter dis-
auxiliary power. This receptacle has a 50 amp rating.
plays the actual output current.
Refer to the AUXILIARY POWER RECEPTACLES sec-
tion in the installation chapter for further information
about this receptacle. Also refer to the AUXILIARY
11. WELDING TERMINALS SWITCH
POWER OPERATION section later in this chapter.
The toggle switch on the control panel labeled
“Welding Terminals Always On� and “Welding
16. 50 AMP CIRCUIT BREAKERS
Terminals Remotely Controlled�: is used to control the
These circuit breaker provide separate overload cur-
operation of the “solid state contactor� which allows for
rent protection for each 120V circuit at the 240V recep-
the selection of “Hot� or “Cold� welding terminals.
tacle.
COMMANDER 400
B-6 B-6
OPERATION
17. 120VAC RECEPTACLES 3. Remove all plugs connected to the AC power receptacles.
These two 120VAC (5-15R) receptacles with GFCI pro-
tection provide 120VAC for auxiliary power. These 4. Set IDLER switch to “AUTO�.
receptacles have a 20 amp total rating. Refer to the
AUXILIARY POWER RECEPTACLES section in the 5. Set the RUN/STOP switch to “RUN�. Observe that all
installation chapter for further information about these engine protection lights momentarily turn on, some lights
receptacles. Also refer to the AUXILIARY POWER may turn off before starting. Check the fuel gauge to
OPERATION section later in this chapter. make sure that there is an adequate fuel level.
18. 15 AMP CIRCUIT BREAKERS 6. Press and hold the engine START button for a minimum
These circuit breakers provide separate overload cur- of 2 seconds.
rent protection for each 120V receptacle.
7. Release the engine START button when the engine starts.
19. GROUND STUD
Provides a connection point for connecting the 8. Check that the indicator lights are off. If the LOW FUEL light is
machine case to earth ground for the safest grounding on , the engine will shutdown 30 minutes after starting. If any
procedure. Refer to “MACHINE GROUNDING� in the other indicator light is on after starting, the engine will shut-
Installation chapter for proper machine grounding infor- down in a few seconds. Investigate any indicated problem.
mation.
9. Allow the engine to warm up at low idle speed for several
WIRE FEEDER MODE CONTROLS minutes before applying a load and/or switching to high
idle. Allow a longer warm up time in cold weather.
(Items 20 - 24 Stick & Wire model only)
COLD WEATHER STARTING / RUNNING
20. WELD OUTPUT TERMINAL - WIRE
This 1/2-13 stud with flange nut provides a welding With a fully charged battery and the proper weight oil,
connection point for the electrode and work cables. For the engine should start satisfactorily even down to
positive polarity welding the electrode cable connects about 0°F. If the engine must be frequently started
to the �+� terminal and the work cable connects to this below 10o F, it may be desirable to install the optional
�-� terminal. For negative polarity welding the work ether starter kit (K825-1). Installation and operating
cable connects to the �+� terminal and the electrode instructions are included in the kit. Use ether starting
cable connects to this �-� terminal. only when required because excessive use shortens
engine life. If the engine must be operated in extreme
21. 15 AMP CIRCUIT BREAKER cold environments 0°F to -35°F (-18°C to -37°C) an
This circuit breaker provides overload protection for the optional Cold Weather Kit (K1665-1) is available.
14-pin connector. Installation and operating instructions are included in
the kit.
22. VOLTMETER +/- SWITCH
Changes the polarity display on the wire feeder.
STOPPING THE ENGINE
1. Switch the RUN/STOP switch to “STOP�. This turns
23. VOLTS-AMPS SWITCH
off the voltage supplied to the shutdown solenoid. A
Switches the display between volts and amps.
backup shutdown can be accomplished by shutting
off the fuel valve located on the fuel filter housing.
24. 14 - PIN CONNECTOR
For quick connection of wire feeder control cable.
BREAK-IN PERIOD
The engine used to supply power for your welder is a
ENGINE OPERATION heavy duty, industrial engine. It is designed and built
for rugged use. It is very normal for any engine to use
STARTING THE ENGINE small quantities of oil until the break-in is accom-
plished. Check the oil level twice a day during the
1. Open the engine compartment door and check that break-in period (about 200 running hours).
the fuel shutoff valve located to the left of the fuel fil-
ter housing is in the open position (lever to be in line IMPORTANT
with the hose). IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE
UNIT SHOULD BE SUBJECTED TO HEAVY LOADS,
2. Check for proper oil level on the oil dipstick. Close WITHIN THE RATING OF THE MACHINE. AVOID
engine compartment door. LONG IDLE RUNNING PERIODS.
COMMANDER 400
B-7 B-7
OPERATION
TYPICAL FUEL CONSUMPTION 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 CON-
Refer to Table B.2 for typical fuel consumption of the
TROL to get 175 amps.
Commander 400’s Engine for various operating sce-
narios.
GENERAL WELDING
Table B.2 Deutz F3L 912 Engine Fuel Consumption
The seventh position of the OUTPUT RANGE switch is
designed for horizontal welds with all types of elec-
Deutz F3L 912 Running Time for trodes especially low hydrogen. The OUTPUT CON-
44.2 Hp 25 gallons TROL adjusts the full range of 50 to 575 amps. This
@ 1800 RPM (Hours) 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.
Low Idle - No .30 gallons/hour 83.3
Load 1350 RPM (1.36 liters/hour)
TIG WELDING
High Idle - No .78 gallons/hour 32.1
Load 1900 RPM ( 3.55 liters/hour)
The Commander 400 can be used in a wide variety of
DC Tungsten Inert Gas (TIG) welding applications for
DC CC Weld 1.84 gallons/hour 13.6
DC TIG welding up to 400A at a 20% duty cycle, 300A
Output 400 ( 8.36 liters/hour)
at a 60% duty cycle and 250A at a 80% duty cycle.
Amps @ 40 Volts
Refer to Table B.3 for recommended output setting
Auxiliary Power
depending on the tungsten electrode size. The
10,000 VA 1.32 gallons/hour 18.9
Commander can be used without a TIG module or Hi-
(6.00 liters/hour)
Freq Unit for scratch start DC TIG welding. Using a
K799 Hi-Freq Unit or K930-1 TIG Module enables DC
WELDER OPERATION 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.
STICK WELDING
Also refer to the Accessories chapter for recommend-
ed equipment for TIG welding.
The Commander 400 can be used with a broad range
of DC stick electrodes.
ARC GOUGING
The OUTPUT RANGE switch provides six overlapping
Set the output range switch to the General purpose
slope controlled current ranges. The OUTPUT CON-
position (50-575). For current setting, refer to The
TROL adjusts the current from minimum to maximum
Procedure Handbook of Arc Welding, section on arc
within each range. Open circuit voltage is also con-
gouging (13.5) or the consumable manufacturer’s rec-
trolled by the OUTPUT CONTROL in the slope con-
ommended current rating.
trolled 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.
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, set the OUTPUT RANGE switch to the �180
MAX� position and then adjust the OUTPUT CON-
TROL for 175 amps.
When a forceful “digging� arc is required, use a higher
COMMANDER 400
B-8 B-8
OPERATION
(1) (2)
Table B.3 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES
DCEN (-) DCEP (+) Approximate Argon Gas Flow Rate
C.F.H. (l/min.)
Tungsten
Electrode TIG TORCH
1%, 2% 1%, 2%
Diameter Nozzle
Thoriated Thoriated Aluminum Stainless Steel
in. (mm) Size (4), (5)
Tungsten Tungsten
0 .010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6
0.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)
0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)
(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.
(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 COMMANDER 400 SETTINGS WHEN USING THE
K799 HI-FREQ UNIT K930-1 TIG MODULE
a. Set the OUTPUT RANGE switch to the �50-575 set- a. Set the OUTPUT RANGE switch to the 50-575 Setting
ting� (Fabrication and General Purpose) (Fabrication and General Purpose)
b. Set the IDLER switch to the “High � position. b. Set the IDLER switch to the “Auto � position.
c. Set the LOCAL/REMOTE switch to the “Remote� posi- c. Set the LOCAL/REMOTE switch to the “Remote� posi-
tion. tion.
d. Set the WELDING TERMINALS switch to the “Welding d. Set the WELDING TERMINALS switch to the “Welding
Terminals Always On� position. This will close the solid Terminals Remotely Controlled� position. This will
state contactor and provide an always “hot� electrode. keep the solid state contactor open and provide a
“cold� electrode until the triggering device (Amptrol or
(Note: This is necessary because the K799 circuitry with Arc Start Switch) is pressed.
respect to the #2 and #4 leads does not provide the prop-
er signal to open and close the solid state contactor in the
Commander).
COMMANDER 400
B-9 B-9
OPERATION
WIRE FEED (CONSTANT VOLTAGE) WELD- STICK AND WIRE MODEL CONNECTION TO
ING LN-7 or LN-8
(Stick and Wire models only) a. Shut the welder off.
Connect a wire feeder to the Commander 400 and set the b. Connect the LN-7 or LN-8 per instructions on the
welder controls according to the instructions in “Controls appropriate connection diagram in “DIAGRAMS�
and Settings� in this section of the manual. section. Set the “LOCAL REMOTE� switch to
“REMOTE� for the LN-7 and LN-8 with a K857
The Stick and Wire model of the Commander 400 with its remote voltage control cable attached; “LOCAL� for
CV tap, permits it to be used with a broad range of flux LN-7 with no remote voltage control.
cored wire (Innershield and Outershield) electrodes and c. Set the “VOLTMETER� switch to either �+� or �-� as
solid wires for MIG (GMAW). required by the electrode being used.
d. Set the “RANGE� switch to the “WIRE WELDING
For any electrodes, the procedures should be kept within CV� position.
the rating of this machine. For additional electrode infor- e. Set the “OUTPUT CONTROL� switch to the “OUT-
mation, see Lincoln publications N-675, GS-100 and GS- PUT REMOTELLY CONTROLLED� position.
210. f. Set the “IDLE� switch to the “HIGH� position.
STICK AND WIRE MODEL CONNECTION TO CAUTION
LN-25
When the gun trigger is closed, the electrode is energised
The LN-25 with or without an external contactor may be
and the wire will begin to feed.
used with the Commander 400 Stick and Wire model. See
------------------------------------------------------------------------
the appropriate connection diagram in “DIAGRAMS� sec-
STICK AND WIRE MODEL CONNECTION TO
tion. NOTE: The LN-25 (K431) Remote Control Module
LN-23P
and (K432) Remote Cable are not recommended for use
with the Commander 400 S&W. a. Shut the welder off.
a. Shut the welder off. b. Connect the LN-23P as per instructions on the
b. For electrode Positive, connect the electrode cable appropriate connection diagram in “DIAGRAMS�
from the LN-25 to the �+� terminal of the welder and section. NOTE: When connecting an LN-23P to the
work cable to the �- WIRE� terminal of the welder. Commander Stick & Wire, a K350-1 adapter kit must
For electrode Negative, connect the electrode cable be used. Set the “VOLTMETER� switch to either �+�
from the LN-25 to the � WIRE� terminal of the welder or �-� as required by the electrode being used.
and work cable to the â€?+â€terminal of the welder. d. Set the “RANGEâ€? switch to “WIRE WELDING CVâ€?
c. Attach the single lead from the front of the LN-25 to e. Set the “OUTPUT CONTROL� switch to “WELDING
work using the spring clip on the end of the lead. TERMINALS ALWAYS ON� Set the “VOLTS/AMPS�
This is a control lead to supply current to the wire switch to “VOLTS�
feeder motor; it does not carry welding current. g. Set the “LOCAL REMOTE� switch to the desired
d. Set the range switch to “WIRE WELDING CV� setting depending upon where the power sources
e. Set the “OUTPUT CONTROL� switch to “WELDING output is being controlled from.
TERMINALS ALWAYS ON� h. Set the “IDLE� switch to the “AUTO� position. When
f. Set the “VOLTS\AMPS� switch to “VOLTS� not welding , the Commander 400 Stick and Wire
g. Set the “IDLE� switch to the “AUTO� position. When model engine will be at the low idle speed. If you are
not welding , the Commander 400 S&W engine will using an LN-23P with the K350-1 adapter kit, the
be at the low idle speed. CAUTION: ( if you are electrode is not energized until the gun trigger is
using an LN-25 without an internal contactor, the closed. When the gun trigger is closed, the current
electrode will be energized when the Commander sensing circuit will cause the Commander 400 Stick
400 Stick and Wire model is started.) If you are and Wire model engine to go to the high idle speed,
using an LN-25 with an internal contactor, the elec- the wire will begin to feed and the welding process
trode is not energized until the gun trigger is closed. can be started. When welding is stopped, the
In either of the LN-25 wire feeders, when the gun engine will revert to low idle speed after approxi-
trigger is closed, the current sensing circuit will mately 15 seconds unless welding is resumed.
cause the Commander 400 Stick and Wire model
engine to go to the high idle speed, the wire will STICK AND WIRE MODEL CONNECTION TO
begin to feed and the welding process started. NA-3
When welding is stopped, the engine will revert to For connection diagrams and instructions for connecting
low idle speed after approximately 15 seconds an NA-3 Welding System to the Commander Stick & Wire,
unless welding is resumed. refer to the NA-3 Welding System instruction manual.
COMMANDER 400
B-10 B-10
OPERATION
AUXILIARY POWER OPERATION The current rating of any plug used with the system
must be at least equal to the current capacity of the
associated receptacle.
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
SIMULTANEOUS WELDING AND AUXIL-
current is being drawn..
IARY POWER LOADS
The auxiliary power of the Commander consists of two-
120VAC (5-15R) duplex receptacles with GFCI protec- It must be noted that the above auxiliary power ratings
tion and one 120/240 VAC (14-50R) receptacle. The are with no welding load. Simultaneous welding and
120/240VAC receptacle can be split for single phase power loads are specified in table B.4. The permissible
120 VAC operation. currents shown assume that current is being drawn
from either the 120 VAC or 240 VAC supply (not both at
The auxiliary power capacity is 10,000 watts of 60 Hz, the same time).
single phase power. The auxiliary power capacity rat-
ing 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.
NOTE: The 240V receptacle has two 120V outlets of
different phases and cannot be paralleled.
The auxiliary power receptacles should only be used
with three wire grounded type plugs or approved dou-
ble insulated tools with two wire plugs.
TABLE B.4 Commander 400 Simultaneous Welding and Power
Loads
Permissible Auxiliary
Permissible
Welding
Current in Amperes
Welding Output Power - Watts
Output Range
(Unity Power
Setting
@120 V ±10% * @ 240 V ±10%
Factor)
0 0
500A/40V None
50-575
0 0
400A/36V None
400
28 14
270A/31V 3000
270
56** 28
230A/29V 6000
230
70** 35
180A/27V 7500
180
88** 44
120A/25V 9500
120
88** 44
90A/24V 9500
90
* 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 C-1
ACCESSORIES
OPTIONAL FIELD INSTALLED RECOMMENDED EQUIPMENT
ACCESSORIES
STICK
K802R POWER PLUG KIT - Provides a plug for each
K704 Accessory Kit which includes:
receptacle.
� Electrode holder and cable.
� Ground clamp and cable.
K857 28 ft. (8.5 m) or K857-1 100 ft. (30.4 m)
� Headshield.
REMOTE CONTROL - Portable control provides same
dial range as the output control on the welder from a
K857 Remote Control Kit is optional for remote cur-
location up to the specified length from the welder. Has
rent control.
convenient plug for easy connection to the welder. The
Commander 400 is equipped with a 6 pin connector
TIG
for connecting the remote control and a toggle switch
for selecting “LOCAL� output control or “REMOTE� out-
Magnum TIG Torch
put control.
Magnum Parts Kit and Argon gas
K930-1 TIG Module (not required for scratch start
K704 ACCESSORY SET - Includes 35 feet (10 m) of
DC TIG welding)
electrode cable and 30 feet (9 m) of work cable, head-
shield, work clamp and electrode holder. Cable is
K936-3 Control Cable
rated at 500 amps, 60% duty cycle.
K870 Foot Amptrol
K953-1 TWO WHEEL TRAILER - For road, in-plant
Also available:
and yard towing. Road towing with optional fender &
light kit. (For highway use, consult applicable federal,
K812 Hand Amptrol
state and local laws regarding possible additional
K814 Arc Start Switch
requirements)
K937-22 Control Cable Extension
K937-45 Control Cable Extension
K953-1 Trailer
K844-1 Water Valve
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
HIGH FREQUENCY GENERATORS FOR
K959-1 Fender & Light Kit
K965-1 Cable Storage Rack TIG APPLICATIONS
The K799 Hi-Freq Unit and the K930-1 TIG Module are
K825-1 ETHER START KIT - Provides maximum cold suitable for use with the Commander 400. The
weather starting assistance for frequent starting below Commander is equipped with the required R.F. bypass
o
10 F (-12.2 C). Required Ether tank is not provided circuitry for the connection of high frequency generat-
with kit. ing equipment. The high frequency bypass network
supplied with the K799 Hi-Freq Unit does NOT need
K899-1 SPARK ARRESTOR KIT - Easily mounts to to be installed into the Commander.
standard muffler.
The Commander and any high frequency generating
K949-1 OIL DRAIN KIT - Includes ball valve, hose and equipment must be properly grounded. See the K799
clamp. Hi-Freq Unit and the K930-1 TIG Module operating
manuals for complete instructions on installation, oper-
ation, and maintenance.
COMMANDER 400
D-1 D-1
MAINTENANCE
SAFETY PRECAUTIONS ENGINE MAINTENANCE
WARNING Refer to the “Periodic Checks� section of the Engine
Operator’s Manual for the recommended maintenance
•Have a qualified technician do the maintenance schedule of the following:
and troubleshooting work.
a) Engine Oil and Filter
•Turn the engine off before working inside the b) Air Cleaner
machine. c) Fuel Filter - and Delivery System
d) Cooling Blower Belt
•Remove guards only when necessary and replace e) Battery
them when the maintenance requiring their f) Cooling System
removal is complete.
Refer to Table D.1 at the end of this section for various
•Always use the greatest care when working near engine maintenance components.
moving parts.
------------------------------------------------------------------------ AIR FILTER
Read the Safety Precautions in front of this manual and CAUTION
the engine instruction manual before working on this
machine. EXCESSIVE AIR FILTER RESTRICTION WILL
RESULT IN REDUCED ENGINE LIFE.
Keep all equipment safety guards, covers and devices ------------------------------------------------------------------------
in position and in good repair. Keep hands, hair, cloth- The air filter element is a dry cartridge type. It can be
ing and tools away from V-belts, gears, fans and all cleaned and reused; however, damaged elements
other moving parts when starting, operating or repair- should not be reused. Stop engine after 100 hours of
ing the equipment. running time and clean filter element , replace the fil-
ter if necessary. Service air cleaner regularly accord-
ROUTINE AND PERIODIC ing to Engine Operator’s Manual.
MAINTENANCE 1. Locate the air filter canister located behind the
engine door on the top of the engine.
DAILY
2. Remove air filter element.
a. Check the crankcase oil level .
3. Remove loose dirt from element with compressed
b. Refill the fuel tank to minimize moisture condensa- air or water hose directed from inside out.
tion in the tank.
Compressed Air: 100 psi maximum with nozzles at
c. Open the water drain valve located on the bottom of least one inch away from element.
the water separator element 1 or 2 turns and allow to
drain into a container suitable for diesel fuel for 2 to Water Hose: 40 psi maximum without nozzle.
3 seconds. Repeat the above drainage procedure
until diesel fuel is detected in the container. 4. Soak element in a mild detergent solution for 15 min-
utes. Do not soak more than 24 hours. Swish ele-
ment around in the solution to help remove dirt.
WEEKLY
5. Rinse elements from inside out with a gentle stream
Blow out the machine with low pressure air periodical- of water (less than 40 psi) to remove all suds and
ly. In particularly dirty locations, this may be required dirt.
once a week.
6.Dry element before reuse with warm air at less than
o o
160 F (71 C). Do not use a light bulb to dry the ele-
ment.
COMMANDER 400
D-2 D-2
MAINTENANCE
7. Inspect for holes and tears by looking through the 3. Remove the large white volume plug located direct-
element toward a bright light. Check for damaged gas- ly under the center cap in the upper cavity of the fil-
kets or dented metal parts. Do not reuse damaged ele- ter header. Use a small screwdriver (or similar
ments. Protect element from dust and damage during device) to lift the plug part way out of the cavity to
drying and storage. assist with its removal.
Be careful not to damage the pre-filter screen with
8. Reinstall air filter element.
the tool used to remove the plug.
After six cleanings replace air filter. A cleaned filter will
have approximately 70% of the life of a new filter ele- 4. Using a pair of pliers, gently tug on the pull tabs of
ment. A restricted filter element may not appear exces- the pre-filter screen in an alternating pattern to
sively dirty. gradually remove the pre-filter screen.
5. Brush off any debris and rinse in diesel fuel.
FUEL FILTERS
6. Re-install the pre-filter screen into the upper cavity
of the filter header making sure the four pull tabs
WARNING
are pointing up. Putting your fingers on the pull tabs,
push down evenly until the lower body of the pre-fil-
When working on the fuel system
ter screen contacts the floor of the upper cavity.
� Keep naked lights away, do not smoke !
7. Re-insert the large white volume plug into the upper
cavity.
� Do not spill fuel !
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.
The Commander 400 is equipped with a Fuel Pre-
Filter/Water Separator Assembly located before the
9. Screw on the cap ring and tighten hand tight.
lift pump and a Secondary Fuel Filter located after the
lift pump and before the fuel injectors. The Fuel Pre-
10. Remember to open the fuel shutoff valve (Lever in
Filter/Water Separator is mounted to the engine block
line with the hose) before starting the engine.
just below the lift pump. The Secondary Fuel Filter is
mounted directly to the engine just above the oil filter.
WATER SEPARATOR ELEMENT
The water separator element is a two stage filter with a
FUEL PRE-FILTER/WATER SEPARATOR ASSEM-
special filtration/water separating media, and an
BLY
expanded water reservoir providing maximum protec-
tion against water in the fuel. The recommended
The pre-filter is a 150 micron screen designed to pro-
change interval for the water separator element is
tect against gross fuel contamination of the water sep-
1,000 hours. The procedure for changing the element
arator element and the Secondary Fuel Filter. If the
is as follows:
pre-filter becomes plugged it may be removed, inspect-
ed, cleaned and reinstalled. In general this only needs
1. Close the fuel shutoff valve (Lever should be per-
to be done with each water separator element change
pendicular to the hose) located on the side of the
(about every 1,000 hrs.) However if at any time exces-
Fuel Pre-Filter/Water Separator Assembly.
sive fuel contamination is suspected or a sudden fall-
off in engine performance is detected the pre-filter
2. Rotate the quick change ring (located just below fil-
screen should be inspected and cleaned. Follow the
ter header) clockwise approximately 1/2 turn and
following procedure:
slide it down and off of the element.
1. Close the fuel shutoff valve (Lever should be per-
3. Grasp the element and pull down with a slight rock-
pendicular to the hose) located on the side of the
ing motion to remove the element from the grommet
Fuel Pre-Filter/Water Separator Assembly.
post on the bottom of the filter header.
2. Unscrew the cap ring located on the top of the filter
header and remove the plastic center cap and O-
ring.
COMMANDER 400
D-3 D-3
MAINTENANCE
4. Slide the new element onto the grommet post on the 6. Remove the old cooling blower belt and install a new
bottom of the filter header until the element no longer one.
easily moves up into the filter header. Now rotate the
element (may take almost 1 full turn) with a slight 7. Adjust the cold belt tension to 63-73 lbs. midway
upward pressure until the element begins to further between any two pulleys.
engage the header. With the proper orientation now
established apply additional pressure to seat the ele- 8. Reinstall the engine end panel. Reattach the negative
ment in the filter header. You should feel the element battery cable. Slide in and refasten the battery holder.
“pop� into place when properly seated.
9. Check the cooling blower belt tension after 100 hours
Note: The element will only go on one way. Never use of operation. (Follow steps 1,2,3,4,7 & 8)
excessive force when mounting the element to the
header.
5. Slide the quick change ring up over the element and
BATTERY HANDLING
rotate counter clockwise until an audible click or pop
is heard. If you do not hear the click you have not rotat-
ed the ring far enough and the element is not in the WARNING
locked position. Another indication that the ring is in
GASES FROM BATTERY can explode.
the locked position is that one set (it doesn’t matter
� Keep sparks, flame and cigarettes away from bat-
which one) of arrows located on the outside of the ring tery.
should be located directly under the air vent valve.
To prevent EXPLOSION when:
� INSTALLING A NEW BATTERY - disconnect nega-
6. Open the fuel shutoff valve (lever in line with the hose).
tive cable from old battery first and connect to new
battery last.
7. Open the air vent valve on the front of the filter header
until fuel emerges free of air bubbles and then close � CONNECTING A BATTERY CHARGER - Remove bat-
tery from welder by disconnecting negative cable
the air vent valve.
first, then positive cable and battery clamp. When
reinstalling, connect negative cable last. Keep well
Note : Consult your engine operation manual for informa- ventilated.
tion on air -bleeding the entire fuel system.
� USING A BOOSTER - connect positive lead to bat-
tery first then connect negative lead to engine foot.
SECONDARY FUEL FILTER BATTERY ACID CAN BURN EYES AND SKIN.
� Wear gloves and eye protection and be careful when
The Secondary Fuel Filter is a spin on cartridge type working near battery. Follow instructions printed on
mount directly to the engine. Consult your engine opera- battery.
-------------------------------------------------------
tion manual for complete information on service intervals
-----------------
and element changing procedures.
PREVENTING ELECTRICAL DAMAGE
COOLING SYSTEM 1. When replacing, jumping, or otherwise connecting the
battery to the battery cables, the proper polarity must be
The cooling system of the Deutz engine needs to be
observed. Failure to observe the proper polarity could
checked and cleaned periodically. Consult the engine
result in damage to the charging circuit. The positive (+)
owners manual for the proper frequency and procedure.
battery cable has a red terminal cover.
COOLING BLOWER BELT
2. If the battery requires charging from an external charg-
The following procedure should be followed to replace the er, disconnect the negative battery cable first and then the
cooling blower belt: positive battery cable before attaching the charger leads.
Failure to do so can result in damage to the internal
1. Allow machine to cool. charger components. When reconnecting the cables,
connect the positive cable first and the negative cable
2. Unfasten and slide the battery holder out from the last.
welder.
PREVENTING BATTERY DISCHARGE
3. Disconnect the negative battery cable.
If you have an ignition switch, turn it off when engine is
not running.
4. Remove the engine end panel for access to the
engine.
PREVENTING BATTERY BUCKLING
5. Loosen the alternator mounting bolts and rotate the
alternator towards the engine.
Tighten nuts on battery clamp until snug.
COMMANDER 400
D-4 D-4
MAINTENANCE
Table D.1 Engine Maintenance Components
ITEM MAKE PART NUMBER
Air Cleaner Element Donaldson P181052
AC A302C
Cooling Blower Belt Lincoln T13536-3
Gates 7585
Oil Filter Element Deutz 1174418
Purolator PER2168
Napa 1820
Fram PH3776
Fuel Filter Element Deutz 1174423
Purolator PC42
Napa 3358
Fram P4102
Water Separator Element Lincoln M16890-C
Stanadyne 31572
Fuel Pre-Filter Screen Lincoln M16890-B
Stanadyne 29575
Battery BCI
Group
34
COMMANDER 400
E-1 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.
Step 1. LOCATE PROBLEM (SYMPTOM). Step 3. RECOMMENDED COURSE OF
Look under the column labeled “PROBLEM ACTION
(SYMPTOMS)�. This column describes pos-
sible symptoms that the machine may exhib- If you have exhausted all of the items in step
it. Find the listing that best describes the 2. Contact your Local Lincoln Authorized
symptom that the machine is exhibiting. Field Service Facility.
Symptoms are grouped into the following
categories: engine problems, function prob-
lems and output problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)� lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
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 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
ENGINE PROBLEMS
Major Physical or Electrical Damage 1. Contact your Local Lincoln
is Evident. Authorized Field Service Facility.
Engine will not “crank�. 1. Battery is low. Charge Battery.
2. Loose battery cable connections.
Inspect, clean and tighten.
Engine will “crank� but not start. 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.
Contact your Local Lincoln Authorized
4. Low battery voltage.
Field Service Facility for technical
troubleshooting assistance.
Engine shuts down shortly after 1. Low fuel. (Indicator light lit) Add
starting. fuel.
2. Low output of battery charging
alternator. (Indicator light lit)
Check cooling blower belt. Replace
if neccessary.
3. High oil temperature (Indicator
light lit). Check engine cooling
system. (Consult engine service
dealer.
Battery does not stay charged. 1. Faulty battery. Replace
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-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
FUNCTION PROBLEMS
Engine will not idle down to low 1. Idler switch in High idle position.
speed. Set switch to Auto.
2. External load on welder or auxil-
iary power. Remove all external
loads.
Engine will not go to high idle when 1. Poor work lead connection to
attempting to weld. work. Make sure work clamp is
tightly connected to clean base
metal.
2. â€Welding Terminalsâ€? switch is in
wrong position. Set to “Always
On� when welding without a weld-
ing terminal control cable. Refer
to Operations chapter for proper Contact your Local Lincoln Authorized
Field Service Facility for technical
use of this switch.
troubleshooting assistance.
Engine will not go to high idle when 1. Auxiliary power load is less than
using auxiliary power. 100 watts. Idler may not respond
with less than a 100 watt load.
Set Idler to “High�
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-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
OUTPUT PROBLEMS
No welding power output. 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.
Welder has output and no control. 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 nec-
cessary.
Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
No auxiliary power. 1. Open circuit breakers. Reset
breakers. If breakers keep trip-
ping check connections to auxil-
iary receptacles. Also make sure
load does not exceed receptacles
current rating. Refer to Auxiliary
Connections in the Installation
and Operation chapters.
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
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
COMMANDER 400-STICK MODEL WIRING DIAGRAM
F-1
3D
5D CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
1008
1002 1006
1004 287
NEXT AVLB.
5D 273 240A
268
270
272 3D
274
269
CAPACITOR G2
G1 G3 204A
T1
RECTIFIER
5
3
1 2 4 8 9 10
7
6 204S 206S 207
ASSEMBLY
1009 1013
J50 EXCITER VOLTAGE
1015
1011
FEEDBACK BOARD
POS.
W2
CONNECTIONS TO
STAINLESS STEEL
204B 600 AMP
CAPACITORS MADE W5 STAND-OFF
SHUNT
VIA BOLTED SCR C
240 uF SCR B
SCR A
CONNECTIONS
BYPASS PC
W4
DD BOARD ELECTRICAL SYMBOLS PER E1537
W6
1010 STATOR FRAME GROUND
1014 50 Ohm
W3
100 W
1012 1016
OUTPUT
CHOKE
209
W6 W3 DB DC
DA
W1
T2
261
204
260
223
CC NEG.
WIRING DIAGRAM:
W4
W5 223
260 261 204
1021
1017
217 1
S8
SELECTOR SWITCH 4
1019 1023 2 3
T3
3D (VIEWED FROM BACK)
W1
W2 218 5 216
(SEE SELECT SWITCH CHART)
6
W6 4
J30
219
240 uF 215
76C
77C 7 3
FINE CONTROL A SNUBBER PC BOARD
220
STAINLESS STEEL
5D 214
8
POT 2
STAND-OFF AUXILIARY BYPASS PCB 222
1018 1022 REMOTE/ 213
221
1
9
CW
LOCAL
1024
1020
SWITCH
B6
B5 B7
B4
VIEWED FROM
75
FRAME GROUND S1
EXCITER 76B 77B
BACK
G3
G1
206S 206
270 273
274
268
T3 WINDINGS
280
279 207
272
269 204A
G2
204S
2 75B
76 76
77 256
CONTROL HARNESS 4 77
75 255
1001 1005
1003 1007 9A
T1 T2 2
2B
5K
6
5 8
2 3 1
9 2 9
10 2 4 5 6
11 12
1 12 1 8
4
3
8
4 7 4 7
3 7 3 6 10
5J
3
CONTROL HARNESS
6
OUTPUT
8A
5A
240 uF ALWAYS ON
CONTROL
5
SOURCE
OUTPUT REMOTELY
S6 CONTROLLED
213 1 J1
1002 1006 J4 J6
J8
4
1004 1008 4B 214 2 CONNECTIONS ON CONTROL BOARD
(VIEWED AS INSTALLED) 1 250
215 3
CONTROL HARNESS ENGINE
216 2 251
4 MOTHER PROT.
217 252
BOARD 3
5 CONTROL
218 253
4
6
1
PC BOARD SPI
J5
A
1 2D 77D J23 6
219 B1 B2 B3
5J 7
REMOTE SCI
2
4B 2 75D B J7
76D
E1
E2
3 8A 8
J2 J6 J5 J8 J7 J1 J4 J3
220 8
CONTROL
2B
3
3 C
76D 75D
5K
15
221 9
5
5A
J60
75B
4
4 4 3 2 1
4D 4D D
9A 222 16
TRIGGER 10 ENGINE PROT.
J3
77C 5 E
2D
J61
6 11 STAINLESS STEEL
J23
65
5D BOARD J40
77D
6 F GROUND
242I
3 STAND-OFF
12
5E STAINLESS STEEL
B1 B3
B2
5C COMMON BATT.
7 AMPHENOL 2 METER
13
STAND-OFF
NEUTRAL T2 STUD 6 7
5
1 6 5
2 4 8
3 1 3 4
76C 8 PCB
14
IN CONTROL BOX
REMOTE PROTECTION PCB (optional)
E2 1
DIAGRAMS
J2
COMMANDER 400
AUX. POWER E1 4 227 232
GROUND SCREW 229B 246
247
224 237 239A
5G 262
ON CONTROL PANEL
233
234
285 226 243
FRAME GROUND 245
GND-C FRAME GROUND
GND-D 242I
GND-E 240A
240 240
ENGINE TO PCB HARNESS
8
GND-A
8A
GREEN
SELECTOR SWITCH (S8)
START BUTTON
S2
HOT HOT
LINE LOAD 280 279
GND-E POSITION NAMEPLATE SETTING
232A 232
256 233
120 V HOLD HOLD
GND-F 1 NO FUNCTION
J12 224
5K 240 226 237
COIL
AUX. CURRENT COIL 232H 2 NO FUNCTION
WELDED STUD SENSE TOROID HIGH
IDLER
9A SHUTDOWN SOLENOID 3 90 MAX
IDLE
ON OUTPUT PANEL SOLENOID RUN
WHITE
GFCI LOAD
5H SWITCH S3
5J 4 120 MAX
LINE WHITE PULL PULL STOP
AUTO
GND-D S4
225 262 227 254 5 180 MAX
COIL
8 COIL 236B
231A
8A
6 230 MAX
5J
5G
267 233A 7 270 MAX
255 236A
8 400 MAX
BLACK
9A
9
9 50-575
GREEN
SOLENOID GROUND
+
HOT HOT
LOAD
LINE HOUR
5C 236A
METER STUD ON ENGINE
-
120 V J11 8A 239B PANEL TO PANEL WIRES 236C 231A
242G
5J
STARTER
GFCI LOAD 239A
LINE BOLT ONTO
9A PANEL TO PCB HARNESS
WHITE
WHITE SENDER BRK’T SOLENOID
5K
286
WHITE
232C
5K
5E (+)
232B OIL PRESSURE SWITCH STARTING
T3 & SENSOR
232F MOTOR
229B 245
232A 246
INSULATED STUD
GREEN
12 VOLT
247
9 15A SENSOR
228
6
3 P16 234
J16
OIL SWITCH
243
CB4 IN CONTROL BOX BATTERY
G WK
FUEL
AMMETER
GND-C TEMP.
PRESS. 1 285
3B
J10
BLACK
BLACK
OIL TEMP. SENSOR & SWITCH
2
SILVER
LOW
120/240V
+
(-)
S
+
S S
+
ALTERNATOR
PRESS. STUD ON ENGINE
LOW TAB
ALT. TEMP. EXC
228A LARGE SENSE
3
FUEL
15A
WHITE
233A
SENSOR
- MOUNT CHANNEL
-
+
- 241
3D - TAB
POS
241A 4 NEG
CB3 3A SWITCH
241A
232G 229A
228A
238 236C 232D 232E 242E
5
242D FUEL LVL.
12
11 242A
242C
SENSOR 239 STUD ON
229
242G 229A 6 SMALL
ENGINE
50A
50A 6B GND-H
TAB
242B
SILVER 7
CB1 CB2 242D 238
T1 INSULATED STUD TAB 242
239
239B 8
BLACK
ENGINE HARNESS TO PANEL WIRES
IN CONTROL BOX
BLACK
WHITE CONTROL PANEL
GND-F
GROUND SCREW
TERM. ENGINE HARNESS
SILVER 9
6A
5H
5C
12 TAB
ENGINE GROUND
242
5C
STUD ON GENERATOR
MOUNT CHANNEL
11
3D 5-15-98A
L11008
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-
F-1
gram for your particular machine is pasted inside the machine on one of the enclosure panels.
COMMANDER 400-STICK & WIRE MODEL WIRING DIAGRAM
CONNECTOR CAVITY NUMBERING SEQUENCE
F-2
(VIEWED FROM COMPONENT SIDE OF BOARD)
6
3D 6 NEXT AVAILABLE 287
5D
3
1008 3
1002 1006
1004
240A
273
5D
268
270
NOTE:
274 272 3D
269
279
T1 NO CONNECTION
6 6 206
ON NEWER MODELS
280
G2
G1 G4
277
G3 204A 3
3
5
3
1 2 4 8 9 10
7
6 RECTIFIER
204S 206S 208
ASSEMBLY 207
1009 1013
POS.
J50 EXCITER VOLTAGE
1015
1011
204C SCR 1
W5
FEEDBACK BOARD
CONNECTIONS TO 206A ELECTRICAL SYMBOLS PER E1537
600 AMP
204B CURRENT
W2
CAPACITORS MADE
SHUNT SENSE TOROID
DE
SCR C
VIA BOLTED SCR B
SCR A
240 uF
206A
CONNECTIONS 285 285A BYPASS PC
W1
30,000 uF
DD
W4 BOARD
R1-50
NEG.
ELECTRODE
100 W
1010 STATOR
1014
POLARITY
1012 1016 OUTPUT SWITCH
L1
R2-12
R3-12
300W
FRAME
CHOKE
C1-C4
209 S5
GROUND POS. 21
DB DC
DA
T2 CC
208A
WIRING DIAGRAM:
223 NEG.
260
W3 261 204 209A 284B
284A 284
W4
W1 CV CHOKE CV
1021
1017 W6 L2 208A
1019 1023 T3
3D
W2 W3
261
204
260
223
(VIEWED
SELECTOR
217
240 uF
FROM BACK)
SWITCH S8
76C
77C FINE CONTROL
W5 W6 SEE CHART
218
21
5D 5 216
POT 6 1 4
2 3
4
1018 1022 219
REMOTE/ 215
7 3
CW
LOCAL
2
2B
1024
1020 A
V 220 J30
214
8
SWITCH 2
VOLT/AMP 282
VIEWED FROM 222
OUTPUT 75
S1
SWITCH
EXCITER 77B
76B
3 3
6 BACK
ALWAYS ON 221
6 213
283
CONTROL 1
9
S9
T3 SOURCE
WINDINGS OUTPUT REMOTELY
S6 CONTROLLED A 76
77
4B 4
1001 1005 206
G3
G1
206S
2 75B 76 256 268
270 273
274
1003 1007 4 77
75 255
T2
T1 280
279 207
272
269 204A
G2
204S
3
6
5A
240 uF
5 6
5 8
2 3 1
9 2 9
10 2 4 5 6
11 12
1 12 1 8
4
3
8
4 7 4 7
3 7 3 6 10
RF BYPASS
21
1002 1006 PC BOARD
J20
1004 1008
J 31 213
1
1 1 J1
115AC
J4
6
A J6
32A
2
214 2 J8
7 CONNECTIONS ON CONTROL BOARD
J21
5
77C
D 4E 4 253
215 (VIEWED AS INSTALLED)
3
3
J61
4
75B
5
1
CONTACTOR G4
5A MOTHER CV
216
C 252
2E ENGINE
4
8 3
76C
4
E1
E2 BOARD PROT.
2
CONTROL
3
2B 282 BOARD 2
217
WORK 251
H 21 5
5
5D 4B 2
3
PC BOARD
218 1 250
6
E
32A 77E
5E
6
3 6 J5
4
5C 77E 6 277 5
REMOTE 219 J21
7 J23
F 76E
7
SPI
4
4E
NEUTRAL T2 STUD J7
CONTROL
5
283 B1 B2 B3 6
31 220
76E 3
IN CONTROL BOX 8
75E
G
8
J62 J2 J6 J5 J8 J7 J1 J4 J3
2
6
75E
208 221 7
9 SCI
I 2E 1 1 4
5H 2 3
222
5 8
10
AUX. POWER ENGINE PROT.
K J3
GROUND SCREW 9 10
11 STAINLESS STEEL
5G J23
IN CONTROL BOX BOARD
B 242H J40
CV DAUGHTER BOARD STAND-OFF
GROUND 12
GND-C
8A B1 B3
B2 COMMON BATT. METER
CB5 15AMP 13
GND-D AMPHENOL 1
5 6 7
5
1 6 5
2 4 8
3 1 3 4
242I
GND-E PCB
14
2
75D
A 77D
8 242H
6
77D
REMOTE
GND-A J60 E2
GREEN
1
1
B 76D 2D
CONTROL J2
DIAGRAMS
COMMANDER 400
3
76D
HOT HOT
LOAD
LINE
GND-E E1 4
C 75D 4
4D 262 229B 246
247
224 237 239A
115 V GND-F
J12 4D
D 227 232 233
234
226 243
285 245
CONTACTOR
WELDED STUD FRAME GROUND
E 2D
ON OUTPUT PANEL
GFCI LOAD
LINE 240 240A
GROUND F 242I
WHITE WHITE
GND-D
8 240
AMPHENOL 2
5G SELECTOR SWITCH (S8)
242I
FRAME GROUND
5J 242H
POSITION NAMEPLATE SETTING
9A 9
ENGINE TO PCB HARNESS 1 NO FUNCTION
HOT HOT
LOAD
LINE
GREEN
5C 2 WIRE WELDING CV
232A 232 233
115 V HOLD
J11 START BUTTON
HOLD 3 90 MAX.
224 240 226 237
COIL COIL S2 4 120 MAX.
256 232H
5H SHUTDOWN SOLENOID 5 180 MAX.
IDLE SOLENOID
9
GFCI RUN
LINE LOAD
S3
WHITE WHITE 6 230 MAX.
PULL PULL HIGH
IDLER
225 STOP
262 227 254
BLACK
COIL 7 270 MAX.
COIL SWITCH
WHITE
SOLENOID GROUND 8 400 MAX.
AUTO
S4
5E 267 233A
32 STUD ON ENGINE 236A
5K 9 50-575
T3 236B
231A
INSULATED STUD
15A 255
6
3
GREEN
CB4 IN CONTROL BOX
+
HOUR METER - 236A
GND-C
3B
J10 239B BOLT ON
BLACK
BLACK
PANEL TO PANEL WIRES
236C 231A
115/230V SENDER
242G
BRACKET
15A
WHITE
239A STARTER
3D PANEL TO PCB HARNESS
CB3 3A SOLENOID
286
11
12 232C
232B (+)
285
OIL PRESSURE SWITCH & SENSOR STARTING
50A 232F
50A 6B 229B 245 MOTOR
232A 246
247
CB1 CB2 12 VOLT
SENSOR
228
OIL P16 234
T1 INSULATED STUD J16
243 SWITCH
BLACK
BATTERY
G
FUEL WK
IN CONTROL BOX
BLACK
AMMETER
WHITE TEMP.
PRESS. 1
TERM. 6A
5H
OIL TEMP. SENSOR & SWITCH
11 LOW 2
+
STUD ON ENGINE
S
+
S S
+
(-)
PRESS. LOW ALTERNATOR
ALT. TEMP. MOUNT CHANNEL
FUEL 228A EXC
SENSE
3
12 - 233A
-
+
- SENSOR
- 241
POS
241A
3D 4 NEG
241A SWITCH
232G
STAINLESS STEEL 229A
228A
238 236C 232D 232E
STAND-OFF 242E
5
242D FUEL LVL.
242A
242C STUD ON GENERATOR
SENSOR 239
242G STUD ON
MOUNT CHANNEL
229
229A
AUXILIARY BYPASS PCB 6
ENGINE
242
242B
7
242D ENGINE TO PANEL HARNESS 238
B4 B5 B6 B7
239
ENGINE TO PANEL HARNESS 239B 8
INSTRUMENT PANEL
GROUND SCREW GND-F
FRAME 5C
9
IN CONTROL BOX
GROUND
ENGINE GROUND
5C
242
8A
5J
9A 5K GND-H
5-15-98A
L11009
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-
F-2
gram for your particular machine is pasted inside the machine on one of the enclosure panels.
COMMANDER 400 STICK & WIRE / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM
F-3
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
CONNECTION DIAGRAM:
115V RECEPTACLE
K488 SG
CONTROL MODULE
K487-25
SPOOL GUN
14 PIN WIRE FEEDER
6 PIN REMOTE
RECEPTACLE K691-10
RECEPTACLE INPUT CABLE
ELECTRODE
TO WORK
DIAGRAMS
COMMANDER 400
ELECTRODE CABLE
TO CONTROL MODULE
TO WORK
BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE "LINCOLN" (CONTACT CLOSURE) POSITION BEFORE ATTEMPTING TO OPERATE
CAUTION :
CONTROL MODULE. INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND/OR POWER SOURCE.
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.
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".
PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.C. IF OPTIONAL K857 REMOTE OUTPUT CONTROL IS CONNECTED TO 6 PIN RECEPTACLE,PLACE LOCAL REMOTE SWITCH IN
"REMOTE" POSITION.
N.D. PLACE IDLE SWITCH IN "HIGH" IDLE POSITION.
12-13-96
M18284
F-3
F-4
COMMANDER 400 STICK & WIRE / LN-23P CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
CONNECTION DIAGRAM:
14 PIN
AMPHENOL
ADAPTER
KIT
LN-23P
6 PIN
K350-1 WIRE FEEDER
AMPHENOL
ELECTRODE
TO WORK
DIAGRAMS
COMMANDER 400
ELECTRODE CABLE
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.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.
12-13-96
S22911
F-4
COMMANDER 400 STICK & WIRE / LN-25 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL K857 REMOTE CONTROL
F-5
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
CONNECTION DIAGRAM:
OPTIONAL K857
6 PIN
REMOTE CONTROL
AMPHENOL AMPHENOL
14 PIN
LN-25
WIRE FEEDER
WORK CLIP LEAD
ELECTRODE
TO WORK
TO WORK
DIAGRAMS
COMMANDER 400
TO WORK
ELECTRODE CABLE
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE
AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
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 ALWAYS ON" POSITION .
12-13-96
S22912
F-5
COMMANDER 400 STICK & WIRE / K867 / LN-8 CONNECTION DIAGRAM
F-6
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
SPARE
CONNECTION DIAGRAM:
82 LN-8
WIRE
81 N.C.
FEEDER
42
41
31 31
32 32
2
14 PIN 2
AMPHENOL
4 4
ELECTRODE
TO WORK 21 21 K196
K867 UNIVERSAL
GND INPUT CABLE
GND
ADAPTER PLUG
DIAGRAMS
COMMANDER 400
75 A
ELECTRODE CABLE
76 B
TO WIRE FEED UNIT
TO WORK 77 C
CAUTION : N.D.
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.
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPICATIONS. SEE OPERATING MANUAL.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".
PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.D. SPLICE LEADS AND INSULATE.
12-13-96
S22913
F-6
COMMANDER 400 STICK & WIRE / LN-7 CONNECTION DIAGRAM
F-7
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
CONNECTION DIAGRAM:
TO LN-7 INPUT
CABLE PLUG
14 PIN
AMPHENOL
K584 OR K594CONTROL CABLE
OPTIONAL K857
REMOTE CONTROL
6 PIN
ELECTRODE
TO WORK
AMPHENOL
DIAGRAMS
COMMANDER 400
ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK
CAUTION :
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.
N.A. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL REMOTE SWITCH IN "REMOTE" POSITION.
12-13-96
S22914
F-7
COMMANDER 400 STICK & WIRE / K867 / K775 / LN-7 CONNECTION DIAGRAM
F-8
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
SPARE
CONNECTION DIAGRAM:
82
LN-7
81 N.D.
WIRE
42 FEEDER
41
}
31 31
32 32
2
14 PIN 2
AMPHENOL
4 4
ELECTRODE
TO WORK 21 21
K291 OR K404
K867 UNIVERSAL
GND INPUT CABLE
GND
ADAPTER PLUG
DIAGRAMS
COMMANDER 400
GREEN
75 75
ELECTRODE CABLE
76
TO WIRE FEED UNIT 76
TO WORK 77 77
}
K775 OPTIONAL
N.E. REMOTE CONTROL
CAUTION :
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.
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPILICATIONS. SEE OPERATING MANUAL.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE "RANGE" SWITCH TO "WIRE WELDING CV".
PLACE WIRE FEEDER SWITCH TO "WIRE FEEDER WITH CONTROL CABLE POSITION.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION.
N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.E. SPLICE LEADS AND INSULATE.
13-13-96
S22915
F-8
COMMANDER 400 STICK & WIRE TO K867 ADAPTER CONNECTION DIAGRAM
F-9
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
14 PIN
N.C.
AMPHENOL
CONNECTION DIAGRAM:
81
NOT USED ON COMMANDER 400 POWER SOURCES
82
SPARE N.D.
2
K867 UNIVERSAL
CONNECT TOGETHER FOR WELDING OUTPUT N.C.
4
ADAPTER PLUG
41
NOT USED ON COMMANDER 400 POWER SOURCES
42
N.E.
31
115 VAC
32
ELECTRODE
TO WORK
GND POWER SOURCE FRAME CONNECTION
21 WIRE FEEDER VOLTMETER CONNECTION
ELECTRODE CABLE CONNECTS TO (WORK TERMINAL) OF POWER SOURCE
DIAGRAMS
COMMANDER 400
77
TO WIRE FEED UNIT 10K
76 REMOTE OUTPUT CONTROL
MIN.
TO WORK 75
CAUTION :
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.
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY.
2 TO
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
TO
WIRE
N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION
K867
RELAY TO CLOSE LEADS 2 & 4. FEEDER
4
N.E. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW.
6-12-98
S22916
F-9
COMMANDER 400 STICK & WIRE / LN-8 CONNECTION DIAGRAM
F-10
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
CONNECTION DIAGRAM:
TO LN-8 INPUT
CABLE PLUG
K595 CONTROL CABLE
14 PIN
AMPHENOL
ELECTRODE
TO WORK
DIAGRAMS
COMMANDER 400
ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK
CAUTION :
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.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".
PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION.
12-13-96
S22917
F-10
48.30
F-11
10.22
32.06
29.50
DIMENSION PRINT
CENTER OF GRAVITY
WITH OIL IN ENGINE
AND FULL FUEL TANK.
48.64
45.67
42.00
15.75
63.10 6.56
31.50
*
45.38
37.30
DIAGRAMS
COMMANDER 400
FOR BATTERY
14.63
REMOVAL.
*
6.55
MOUNTING HOLE LOCATIONS.
* TRAILER
28.99
24.97 *
6-21-96
M17685
*
6.53
19.63
23.69
1.26 BOTTOM VIEW OF
50.38 WELDER BASE.
54.44
F-11
F-12 F-12
NOTES
COMMANDER 400
Now Available...12th Edition New Lessons in Arc Welding
The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects, such
since 1933, the Procedure Handbook is considered by many to as distortion; and supplemental information on arc welding
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This printing will go fast so don’t delay. Place your
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A must for all welders, supervisors, engineers and
designers. Many welding instructors will want to use the book as
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tity discount prices which include shipping by
4th class parcel post.
$15.00 postage paid U.S.A. Mainland
Need Welding Training?
The Lincoln Electric Company operates the oldest and
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How To Read Shop Drawings
corporate headquarters in Cleveland, Ohio. Over 100,000 students
have graduated. Tuition is low and the training is
The book contains the latest information and application
“hands on�
data on the American Welding Society Standard Welding
For details write: Lincoln Welding School
Symbols. Detailed discussion tells how engineers and drafts-
22801 St. Clair Ave.
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assembly and welding information to shop personnel. Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability and ask for bulletin ED-80 or call 216-383-2259 and ask for the
to visualize mechanically drawn objects as they will appear in Welding School Registrar.
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187 pages with more than 100 illustrations. Size 8-1/2� x 11� Lincoln Welding School
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BOOKS OR FREE INFORMATIVE CATALOGS
Lincoln Welding School Titles: Price Code Quantity Cost
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q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.
German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
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 HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or
WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
ED
Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
q Mantenga la cabeza fuera de los
1 SED
antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
q Débranchez le courant avant l’entre- q N’opérez pas avec les panneaux
q Gardez la tête à l’écart des fumées.
W ER
tien. ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira-
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
IM P
E SU
S
German
q Strom vor Wartungsarbeiten q Anlage nie ohne Schutzgehäuse
q Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
nen; Maschine anhalten!) Betrieb setzen!
q Sorgen Sie für gute Be- und
SE Y
Entlüftung des Arbeitsplatzes!
NT
Portuguese
q Não opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
RA
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENÇÃO
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratória.
q Não toque as partes elétricas nuas. ou guardas removidas.
AR
Japanese
W
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
|