Im544 COMMANDER B

User Manual: COMMANDER IM544-B

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Commander 400
OPERATOR’S MANUAL
IM544-B
June, 1998
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.
For use with machines having Code Numbers: 9978, 10580 (Stick Model),
9979, 10581 (Stick and Wire Model)
™
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
FOR ENGINE
powered equipment.
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.
____________________________________________________
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-
ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, coversand devices in posi-
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler
by pushing on the throttle control rods while
the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
i
SAFETY
i
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.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
For Diesel Engines: Diesel engine exhaust and
some of its constituents are known to the State
of California to cause cancer, birth defects, and
other reproductive harm.
For Gasoline Engines: The engine exhaust from
this product contains chemicals known to the
State of California to cause cancer, birth defects,
or other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNINGS
ii
SAFETY
ii
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b. Mar ‘95
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
iii
SAFETY
iii
Mar ‘95
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
Thank You for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product •••
as much pride as we have in bringing this product to you!
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.
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
CAUTION
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.
vv
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
vivi
COMMANDER 400
A-1
INSTALLATION
COMMANDER 400
A-1
TECHNICAL SPECIFICATIONS - Commander 400
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Deutz 3 cylinder High Idle 1900 173 cu. in 12VDC battery Fuel: 25 gal.
F3L 912 Diesel 44.2 HP(33kw) Low Idle 1350 (2.827 L) & Starter 94.6 L
Engine @ 1800 RPM Full Load 1800
Bore x Stroke Oil: 8.5 Qts.
8.04 L
3.94” x 4.72”
(100mm x 120mm)
INPUT - DIESEL ENGINE
RATED OUTPUT - WELDER
HEIGHT2WIDTH DEPTH WEIGHT
42.0 in. 31.5 in. 63.1 in. 1650 lbs.(748 kg)
(Stick model)
1066.8 mm 800.1 mm 1602.7 mm 1683 lbs.(763 kg)
(Stick & Wire model)
OUTPUT - WELDER AND GENERATOR
Duty Cycle Welding Output Volts at Rated Amps
100% 400 amps (DC Constant Current) 40 volts
400 amps (DC Constant Voltage) 40 volts
60% 500 amps (DC Constant Current) 40 volts
500 amps (DC Constant Voltage) 40 volts
Welding Range Open Circuit Voltage Auxiliary 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
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.
A-2
INSTALLATION
COMMANDER 400
A-2
Read this entire installation section before you
start installation.
SAFETY PRECAUTIONS
Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance man-
uals supplied with your machine. They include impor-
tant safety precautions, detailed engine starting,
operating and maintenance instructions and parts
lists.
ELECTRIC SHOCK can kill.
•Do not touch electrically live parts such
as output terminals or internal wiring.
•Insulate yourself from the work and
ground.
•Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
•Use in open, well ventilated areas or
vent exhaust outside
•Do not stack anything near the engine.
------------------------------------------------------------------------
MOVING PARTS can injure.
•Do not operate with doors open or
guards off.
•Stop engine before servicing.
•Keep away from moving parts
------------------------------------------------------------------------
Only qualified personnel should install, use or service
this equipment
LOCATION/VENTILATION
The welder should be located to provide an unrestricted
flow of clean, cool air to the cooling air inlets and to avoid
restricting the cooling air outlets. Also, locate the welder
so that the engine exhaust fumes are properly vented to
an outside area.
STACKING
Commander 400 machines cannot be stacked.
ANGLE OF OPERATION
To achieve optimum engine performance the
Commander 400 should be run in a level position. The
maximum angle of operation for the Deutz engine is 20
degrees in a direction to cause the control panel to be
angled up, 30 degrees for side to side tilting and for the
control panel to be angled down. If the engine is to be
operated at an angle, provisions must be made for
checking and maintaining the oil level at the normal
(FULL) oil capacity in the crankcase. When operating
the welder at an angle, the effective fuel capacity will
be slightly less than the specified 25 gallons.
LIFTING
The Commander lift bale should be used to lift the
machine. The Commander is shipped with the lift bale
retracted. Before attempting to lift the Commander the
lift bale must be secured in a raised position. Secure
the lift bale as follows:
a. Open the engine compartment door.
b. Locate the 2 access holes on the upper middle
region of compartment wall just below the lift
bale.
c. Use the lifting strap to raise the lift bale to the full
upright position. This will align the mounting
holes on the lift bale with the access holes.
d. Secure the lift bale with 2 thread forming screws.
The screws are provided in the shipped loose
parts bag.
FALLING EQUIPMENT can cause
injury.
•Do not lift this machine using lift bale if
it is equipped with a heavy accessory
such as a trailer or gas cylinder.
•Lift only with equipment of adequate
lifting capacity.
•Be sure machine is stable when lifting.
------------------------------------------------------------------------
WARNING
WARNING
A-3
INSTALLATION
COMMANDER 400
A-3
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary.
As a rule of thumb, derate the welder output 5% for
every 400 meters (1312 ft.) above 1000 meters (3280
ft.).
Contact a Deutz Service Representative for any engine
adjustments that may be required for high altitude
operation.
TOWING
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle(1) is
Lincoln’s K953-1. If the user adapts a non-Lincoln
trailer, he must assume responsibility that the method
of attachment and usage does not result in a safety
hazard nor damage the welding equipment. Some of
the factors to be considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so that there will be no
undue stress to the trailer’s framework.
3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when
being moved and when standing by itself.
4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, and environmental conditions.
5. Proper preventative maintenance of trailer.
6. Conformance with federal, state and local laws.1
1Consult applicable federal, state and local laws
regarding specific requirements for use on public high-
ways.
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instruc-
tions supplied with this machine.
•Stop engine and allow to cool before
fueling.
•Do not smoke when fueling.
•Fill fuel tank at a moderate rate and do
not overfill.
•Wipe up spilled fuel and allow fumes to
clear before starting engine.
•Keep sparks and flame away from
tank.
------------------------------------------------------------------------
OIL
The Commander is shipped with the engine crankcase
filled with high quality SAE 10W-30 oil (API class CD or
better). Check the oil level before starting the engine. If it
is not up to the full mark on the dip stick, add oil as
required. Check the oil level every four hours of running
time during the first 35 running hours. Refer to the engine
Operator’s Manual for specific oil recommendations and
break-in information. The oil change interval is dependent
on the quality of the oil and the operating environment.
Refer to the engine Operator’s Manual for the proper ser-
vice and maintenance intervals.
FUEL USE DIESEL FUEL ONLY
Fill the fuel tank with clean, fresh diesel fuel. The capac-
ity of the fuel tank is 25 gallons (94.6 liters). See engine
Operator’s Manual for specific fuel recommendations.
The Commander 400 is protected by a low fuel shutdown
to prevent the engine from running out of fuel. The
machine will indicate a low fuel condition by turning on the
low fuel light. A time of 30 minutes will elapse once the
low fuel light illuminates before the machine will 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.
WARNING
A-4
INSTALLATION
COMMANDER 400
A-4
FUEL CAP
Remove the plastic cap covering from the Fuel Tank
Filler neck and install the Fuel Cap.
ENGINE COOLING SYSTEM
The Deutz engine is air cooled by a belt driven axial
blower. The oil cooler and engine cooling fins should
be blown out with compressed air or steam to maintain
proper cooling (See the engine Owners Manual for pro-
cedures and frequency).
BATTERY CONNECTION
WARNING: Use caution as the electrolyte is a strong
acid that can burn skin and damage eyes.
Remove and discard the insulating cap from the nega-
tive battery terminal. Attach and tighten negative bat-
tery cable terminal.
NOTE: This machine is furnished with a wet charged battery; if
unused for several months, the battery may require a booster
charge. Be careful to charge the battery with the correct polar-
ity. Make sure that the battery is level while charging.
MUFFLER OUTLET PIPE
Remove the plastic plug covering the muffler outlet
tube. Using the clamp provided secure the outlet pipe
to the outlet tube with the pipe positioned such that it
will direct the exhaust in the desired direction.
SPARK ARRESTER
Some federal, state or local laws may require that
gasoline or diesel engines be equipped with exhaust
spark arresters when they are operated in certain loca-
tions where unarrested sparks may present a fire haz-
ard. The standard muffler included with this welder
does not qualify as a spark arrester. When required by
local regulations, a suitable spark arrester, such as the
K899-1 must be installed and properly maintained.
An incorrect arrester may lead to damage to the engine
or adversely affect performance.
------------------------------------------------------------------------
CAUTION
ELECTRICAL OUTPUT CONNECTIONS
See Figure A.1 for the location of the weld output terminals, ground stud, and auxiliary power receptacles
FIGURE A.1 - Weld Terminal, Ground Stud and Auxiliary Power Receptacle Locations
0
OIL
00000
FUEL TEMP AMPS
PRESS
HOURS
+-
-
120 VOLT
RECEPTACLES
GROUND STUD
240 VOLT RECEPTACLE
WELD OUTPUT TERMINALS
CV WORK -
WELD OUTPUT
TERMINAL
(ELECTRODE + & CC WORK -)
A-5
INSTALLATION
COMMANDER 400
A-5
WELDING OUTPUT CABLES
With the engine off, route the electrode and work
cables thru the strain relief bracket provided on either
side of the base and connect to the terminals provided.
These connections should be checked periodically and
tightened if necessary.
Listed in Table A.1 are copper cable sizes recom-
mended for the rated current and duty cycle. Lengths
stipulated are the distance from the welder to work and
back to the welder again. Cable sizes are increased for
greater lengths primarily for the purpose of minimizing
cable voltage drop.
Table A.1 Combined Length of Electrode and Work
Cables.
MACHINE GROUNDING
Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.).
To prevent dangerous electric shock, other equipment
powered by this engine driven welder must:
a) be grounded to the frame of the welder using a
grounded type plug,
or
b) be double insulated.
When this welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
of the vehicle. When this engine driven welder is con-
nected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
ground. See further connection instructions in the sec-
tion entitled “Standby Power Connections” as well as
the article on grounding in the latest U.S. National
Electrical Code and the local code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding
stud marked with the symbol is provided on the
front of the welder.
AUXILIARY POWER RECEPTACLES
The auxiliary power capacity of the Commander 400 is
10,000 watts of 60 Hz, single phase power. The auxil-
iary power capacity rating in watts is equivalent to volt-
amperes at unity power factor. The maximum permis-
sible current of the 240 VAC output is 44 A. The 240
VAC output can be split to provide two separate 120
VAC outputs with a maximum permissible current of 44
A per output to two separate 120 VAC branch circuits.
The output voltage is within ± 10% at all loads up to
rated capacity.
NOTE: The 120/240V receptacle has two 120V outlets
of different phases and cannot be paralleled.
The Commander has two 15 Amp-120VAC (5-15R)
duplex receptacles with GFCI protection and one 50
Amp-120/240 VAC (14-50R) receptacle. The 120/240
VAC receptacle can be split for single phase 120 VAC
operation. The auxiliary power receptacles should only
be used with three wire grounded type plugs or
approved double insulated tools with two wire plugs.
The current rating of any plug used with the system
must be at least equal to the current capacity of the
associated receptacle.
STANDBY POWER CONNECTIONS
The Commander 400 is suitable for temporary, stand-
by or emergency power using the engine manufactur-
er’s recommended maintenance schedule.
The Commander 400 can be permanently installed as
a standby power unit for 240 volt-3 wire, 44 amp ser-
vice. Connections must be made by a licensed electri-
cian who can determine how the 120/240 VAC power
can be adapted to the particular installation and com-
ply with all applicable electrical codes. The following
information can be used as a guide by the electrician
for most applications. Refer to the connection diagram
shown in Figure A.2.
1. Install the double-pole, double-throw switch between
the power company meter and the premises discon-
nect.
Switch rating must be the same or greater than the
customer’s premises disconnect and service over cur-
rent protection.
Up to 150
FT.
1 AWG
3/0 AWG
150-200 FT.
1 AWG
3/0 AWG
200-250 FT.
1/0 AWG
4/0 AWG
AMPS
@100%
Duty Cycle
250
400
TOTAL COMBINED LENGTH OF ELEC-
TRODE AND WORK CABLES
A-6
INSTALLATION
COMMANDER 400
A-6
2. Take necessary steps to assure load is limited to the
capacity of the Commander by installing a 45 amp,
240 VAC double pole circuit breaker. Maximum
rated load for each leg of the 240 VAC auxiliary is 45
amperes. Loading above the rated output will
reduce output voltage below the allowable -10% of
rated voltage which may damage appliances or
other motor-driven equipment and may result in
overheating of the Commander 400 engine.
3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-
50) to the double-pole circuit breaker using No. 6, 4
conductor cable of the desired length. (The 50 amp,
120/240 VAC plug is available in the optional K802R
plug kit.)
4. Plug this cable into the 50 Amp 120/240 Volt recep-
tacle on the Commander 400 case front.
Figure A.2 Connection of the Commander 400 to Premises Wiring
240 Volt
60 Hz.
3-Wire
Service
POWER
COMPANY
METER
240 VOLT
120 VOLT
120 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GND
N
NOTE: No. 8 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
240 VOLT
GROUNDED CONDUCTOR
45AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE
B-1
OPERATION
B-1
OPERATING INSTRUCTIONS
Read and understand this entire section before operat-
ing your Commander 400.
SAFETY INSTRUCTIONS
Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance man-
uals supplied with your machine. They include impor-
tant safety precautions, detailed engine starting,
operating and maintenance instructions and parts
lists.
ELECTRIC SHOCK can kill.
•Do not touch electrically live parts such
as output terminals or internal wiring.
•Insulate yourself from the work and
ground.
•Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
•Use in open, well ventilated areas or
vent exhaust outside
•Do not stack anything near the engine.
------------------------------------------------------------------------
MOVING PARTS can injure.
•Do not operate with doors open or
guards off.
•Stop engine before servicing.
•Keep away from moving parts
------------------------------------------------------------------------
Only qualified personnel should operate this equip-
ment.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged door closed
and the side panels in place as these provide maxi-
mum protection from moving parts and insure proper
cooling air flow.
GENERAL DESCRIPTION
The Commander is a diesel engine driven welding
power source. The machine uses a brushless asyn-
chronous alternating current generator for DC stick
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
slope-controlled ranges. In addition a seventh general
purpose welding range provides up to 575 amps of
constant current welding output.
The engine is a 44.2 Hp (33kw), 3-cylinder air/oil
cooled diesel made by Deutz. This naturally aspirated,
4 cycle engine features direct injection, a Bosch in-line
injection pump and a Bosch mechanical governor.
This machine is controlled by a high quality microcon-
troller. The microcontroller provides high speed control
of the weld process as well as the engine protection
features.
RECOMMENDED APPLICATIONS
WELDER
The Commander 400 (Stick model) provides excellent con-
stant current DC welding output for stick (SMAW) welding.
The Commander 400 (Stick & Wire model) also provides
excellent constant voltage DC welding output for MIG
(GMAW) and Innershield (FCAW) welding.
GENERATOR
The Commander 400 provides smooth 120/240 VAC
output for auxiliary power and emergency standby
power.
DESIGN FEATURES AND ADVANTAGES
(All Models)
FOR STICK WELDING
• Excellent DC constant current output for stick weld-
ing applications.
• 40 to 400 amps output in six slope controlled ranges
for out-of position and pipe electrodes and 50 to 575
amps constant current output in one general purpose
welding range.
• 3 digit display is provided for presetting the weld
amperage and displaying the actual amperage during
welding. The display uses superbrite L.E.D.’s for
improved readability in full sunlight.
• Remote control capability standard on all models.
COMMANDER 400
WARNING
B-2
OPERATION
B-2
FOR AUXILIARY POWER
• 10,000 watts of 120/240 VAC, 60Hz auxiliary power.
• Drive a 2 HP motor (provided it is started under no
load).
• Two 15 amp 120 VAC duplex receptacles with GFCI
protection for up to 30 amps of 120 VAC power.
• One 50 amp, 120/240 VAC dual voltage receptacle for
up to 44 amps of 240 VAC, and up to 44 amps per
side to separate branch circuits (not in parallel) of 120
VAC single phase auxiliary power. Allows easy con-
nection to premises wiring.
• Weld and AC auxiliary power at the same time (with-
in machine total capacity).
OTHER FEATURES
• Deutz 3-cylinder, air/oil cooled diesel engine.
Designed for long life, easy maintenance and excel-
lent fuel economy.
• Engine protection system shuts the engine down for
low oil pressure, high oil temperature or a broken
fan/engine alternator belt.
• Gauges for oil pressure, oil temperature, engine alter-
nator output and fuel level.
• Indicator lights for low oil pressure, high oil tempera-
ture, engine alternator low output/broken belt and low
fuel level.
• Automatic low fuel shutdown before running out of
fuel.
• Engine hour meter standard on all models.
• Extended range 25 gallon (94.6 l) fuel tank.
• Fuel pre-filter/water separator with “dry” change 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.
• Copper alternator windings and high temperature
insulation for dependability and long life.
ADDITIONAL DESIGN FEATURES AND
ADVANTAGES (Stick & Wire Model only)
FOR WIRE WELDING
• One constant voltage position for all wire welding. A
12 to 45V range across the entire current output
range.
• Excellent arc characteristics with MIG (GMAW) and
Innershield (FCAW) welding.
• A Wire Feeder connector for quick connection of the
control cable.
• A built in “Electronic Contactor” for “Cold” electrode
when not welding. This feature and DC Constant
Voltage output provide an added margin of safety
when welding must be performed under electrically
hazardous conditions such as: damp locations, while
wearing wet clothing or in cramped positions if there
is a high risk of unavoidable or accidental contact with
the workpiece or ground.
• The 3 digit display has the additional feature of pre-
setting the open circuit voltage and displaying the
actual voltage during welding.
•
Designed for use with the following Lincoln wire feeders.
•LN-25 •LN-23P •LN-7
•LN-8 •NA-3 •Spool Gun &
K488 Module
WELDING CAPABILITY
The Commander 400 is rated at 400 amps, 40 volts at
100% duty cycle. The weld current is variable from 40
to 575 amps.
COMMANDER 400
• Selection of “hot” or “cold” output terminals with a tog-
gle switch on the control panel. This feature can also
be controlled by installing a remote output terminal
control cable designed to open and close the #2 and
#4 leads in the amphenol receptacle.
MAY96
B-3
OPERATION
B-3
ENGINE CONTROLS (Items 1 through 8)
1. RUN- STOP SWITCH
When placed in the “RUN” position, this switch ener-
gizes the fuel solenoid and other electric accessories.
When placed in the “STOP” position, the flow of fuel to
the injection pump is stopped to shut down the engine.
(Note: If the switch is left in the “RUN” position and the
engine is not running, the battery will be drained by the
fuel solenoid).
2. START PUSHBUTTON
Energizes the starter motor to crank the engine. With
the engine RUN-STOP switch in the “Run” position,
push and hold the START button for a minimum of 2
seconds to crank the engine; release as the engine
starts. Do not press while engine is running since this
can cause damage to the ring gear and/or starter
motor.
3. FUEL LEVEL GAUGE AND LIGHT
Displays the level of diesel fuel in the 25-gallon fuel
tank. The yellow light turns on when the fuel gage
reaches the reserve level. Once the reserve level is
reached, the engine protection system will shut down
the engine after 30 minutes of operation. The machine
can be restarted and operated for an additional 30 min-
utes before the protection system will shut down the
engine. This ability to override the engine protection is
to allow the operator to “finish up” if necessary. The
operator must watch the fuel level closely to prevent
running out of fuel and having to bleed the system.
COMMANDER 400
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
0
OIL
2
9
17
23
00000
8
7
16
15
18
FUEL TEMP
4
AMPS
56
PRESS
9
HOURS
13
22
21
24
20
3
1
10
11
12
19
14
+-
-
B-4
OPERATION
B-4
4. ENGINE TEMPERATURE GAUGE AND
LIGHT
The gauge displays the engine oil temperature. The
yellow temperature light remains off under normal
operating temperatures. If the light turns on, the
engine protection system will shut down the engine.
Check for restrictions at the engine cooling air inlets
and outlets (consult the engine Operator’s Manual).
Check for loose or disconnected leads at the tempera-
ture sender located on the engine. Check engine cool-
ing blower belt. Also, check to be sure that the welder
loads are within the rating of the welder. The light will
remain on when the engine has been shut down due to
an over- temperature condition.
5. OIL PRESSURE GAUGE AND LIGHT
The gauge displays the engine oil pressure when the
engine is running. The yellow oil pressure light
remains off with proper oil pressure. If the light turns
on, the engine protection system will stop the engine.
Check for proper oil level and add oil if necessary.
Check for loose or disconnected leads at the oil pres-
sure sender located on the engine. The light will go on
and stay on when the RUN-STOP switch is switched to
the “Run” position with engine not running.
6. ENGINE ALTERNATOR AMMETER
AND LIGHT
The yellow engine alternator light is off when battery
charging system is functioning normally. If light turns
on, the engine protection system will shut down the
engine. Check the engine cooling blower belt. Also,
the alternator or the voltage regulator may not be oper-
ating correctly. The light may also come on if the alter-
nator did not flash up due to not holding the start but-
ton in long enough (minimum of 2 seconds) or due to a
faulty flashing circuit. The light will remain on when the
engine has been shut down due to a fault in the 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
at full speed.
c. When welding ceases or the AC power load is
turned off, a fixed time delay of approximately 15
seconds starts.
d. If the welding or AC power load is not restarted
before the end of the time delay, the idler reduces
the engine speed to low idle speed.
e. The engine will automatically return to high idle
speed when the welding load or A.C. power load
is reapplied.
Idler Operational exceptions
When the WELDING TERMINALS switch is in the
“Welding Terminals Remotely Controlled” position the
idler will operate as follows:
a. When the triggering device (Amptrol, Arc Start
Switch, etc.) is pressed the engine will accelerate
and operate at full speed provided a welding load is
applied within approximately 15 seconds.
• If the triggering device remains pressed but no weld-
ing load is applied within approximately 15 seconds
the engine will return to low idle speed.
• If the triggering device is released or welding ceases
the engine will return to low idle speed after approxi-
mately 15 seconds.
8. HOUR METER
The hour meter displays the total time that the engine
has been running. This meter is a useful indicator for
scheduling preventive maintenance.
COMMANDER 400
B-5
OPERATION
B-5
WELDER CONTROLS (Items 9 through 14 )
9. OUTPUT RANGE SWITCH & OUTPUT
CONTROL
These two controls allow you to select between various
welding output slopes and adjust the desired welding
output. Refer to Table B.1 for a description of how
these two controls work.
Table B.1 Output Range Switch and Output Control
Functions
1If the OUTPUT RANGE switch is positioned between settings the
previous setting is maintained until the switch is properly positioned
on a setting.
2OUTPUT CONTROL also controls O.C.V. while in the 6 sloped out-
put ranges.
10. DIGITAL OUTPUT METER
The digital output meter is located in the center of the
control panel between the two large control knobs. The
meter allows the output current level to be set prior to
welding. During the welding process the meter dis-
plays the actual output current.
11. WELDING TERMINALS SWITCH
The toggle switch on the control panel labeled
“Welding Terminals Always On” and “Welding
Terminals Remotely Controlled”: is used to control the
operation of the “solid state contactor” which allows for
the selection of “Hot” or “Cold” welding terminals.
With the switch in the “Welding Terminals Always On”
position the contactor is closed and the welding termi-
nals are always “Hot”.
With the switch in the “Welding Terminals Remotely
Controlled” position the contactor operation is con-
trolled by an Amptrol, Arc Start Switch or some other
type of triggering device through the use of a control
cable connected to the 6-pin MS connector.
When the triggering device is pressed the contactor is
closed and the welding terminals are “Hot”.
When the triggering device is released the contactor is
opened and the welding terminals are “Cold”.
12. LOCAL /REMOTE SWITCH
The toggle switch on the control panel labeled
“Local/Remote” gives the operator the option of con-
trolling the output at the welder control panel or at a
remote station.
For remote control the toggle switch is set in the
“Remote” position.
For control at the welder control panel, the toggle
switch is set in the “Local” position.
13. 6 - PIN CONNECTOR
The 6-pin connector located on the control panel
allows for connection of Remote Control accessories.
14. WELD OUTPUT TERMINALS + AND -
These 1/2 - 13 studs with flange nuts provide welding
connection points for the electrode and work cables.
For positive polarity welding the electrode cable con-
nects to the “+” terminal and the work cable connects
to this “-” terminal. For negative polarity welding the
work cable connects to the “+” terminal and the elec-
trode cable connects to this “-” terminal.
AUXILIARY POWER CONTROLS
(Items 15 - 19 )
15. 120/240VAC RECEPTACLE
This is a 120/240VAC (14-50R) receptacle that pro-
vides 240VAC or can be split for 120VAC single phase
auxiliary power. This receptacle has a 50 amp rating.
Refer to the AUXILIARY POWER RECEPTACLES sec-
tion in the installation chapter for further information
about this receptacle. Also refer to the AUXILIARY
POWER OPERATION section later in this chapter.
16. 50 AMP CIRCUIT BREAKERS
These circuit breaker provide separate overload cur-
rent protection for each 120V circuit at the 240V recep-
tacle.
COMMANDER 400
Sloped Output for
Pipe Welding.
(all models)
Constant Current
Output for
Fabrication and
General Purpose
Welding (This set-
ting also used for
TIG) (all models)
Constant Voltage
Output for Wire
Welding (Stick &
Wire model only)
6 Range
Settings
90, 120, 180,
230, 270, 400
(Max. current on
each setting)
1 Range setting
50-575 Amps
1 Range setting
12 to 40 Volts
Provides a fine
adjustment of
welding current
or voltage from
Min (1) to Max
(10) within each
range
Range
Switch1Control2
B-6
OPERATION
B-6
17. 120VAC RECEPTACLES
These two 120VAC (5-15R) receptacles with GFCI pro-
tection provide 120VAC for auxiliary power. These
receptacles have a 20 amp total rating. Refer to the
AUXILIARY POWER RECEPTACLES section in the
installation chapter for further information about these
receptacles. Also refer to the AUXILIARY POWER
OPERATION section later in this chapter.
18. 15 AMP CIRCUIT BREAKERS
These circuit breakers provide separate overload cur-
rent protection for each 120V receptacle.
19. GROUND STUD
Provides a connection point for connecting the
machine case to earth ground for the safest grounding
procedure. Refer to “MACHINE GROUNDING” in the
Installation chapter for proper machine grounding infor-
mation.
WIRE FEEDER MODE CONTROLS
(Items 20 - 24 Stick & Wire model only)
20. WELD OUTPUT TERMINAL - WIRE
This 1/2-13 stud with flange nut provides a welding
connection point for the electrode and work cables. For
positive polarity welding the electrode cable connects
to the “+” terminal and the work cable connects to this
“-” terminal. For negative polarity welding the work
cable connects to the “+” terminal and the electrode
cable connects to this “-” terminal.
21. 15 AMP CIRCUIT BREAKER
This circuit breaker provides overload protection for the
14-pin connector.
22. VOLTMETER +/- SWITCH
Changes the polarity display on the wire feeder.
23. VOLTS-AMPS SWITCH
Switches the display between volts and amps.
24. 14 - PIN CONNECTOR
For quick connection of wire feeder control cable.
ENGINE OPERATION
STARTING THE ENGINE
1. Open the engine compartment door and check that
the fuel shutoff valve located to the left of the fuel fil-
ter housing is in the open position (lever to be in line
with the hose).
2. Check for proper oil level on the oil dipstick. Close
engine compartment door.
3. Remove all plugs connected to the AC power receptacles.
4. Set IDLER switch to “AUTO”.
5. Set the RUN/STOP switch to “RUN”. Observe that all
engine protection lights momentarily turn on, some lights
may turn off before starting. Check the fuel gauge to
make sure that there is an adequate fuel level.
6. Press and hold the engine START button for a minimum
of 2 seconds.
7. Release the engine START button when the engine starts.
8.
Check that the indicator lights are off. If the LOW FUEL light is
on , the engine will shutdown 30 minutes after starting. If any
other indicator light is on after starting, the engine will shut-
down in a few seconds. Investigate any indicated problem.
9. Allow the engine to warm up at low idle speed for several
minutes before applying a load and/or switching to high
idle. Allow a longer warm up time in cold weather.
COLD WEATHER STARTING / RUNNING
With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about 0°F. If the engine must be frequently started
below 10oF, it may be desirable to install the optional
ether starter kit (K825-1). Installation and operating
instructions are included in the kit. Use ether starting
only when required because excessive use shortens
engine life. If the engine must be operated in extreme
cold environments 0°F to -35°F (-18°C to -37°C) an
optional Cold Weather Kit (K1665-1) is available.
Installation and operating instructions are included in
the kit.
STOPPING THE ENGINE
1. Switch the RUN/STOP switch to “STOP”. This turns
off the voltage supplied to the shutdown solenoid. A
backup shutdown can be accomplished by shutting
off the fuel valve located on the fuel filter housing.
BREAK-IN PERIOD
The engine used to supply power for your welder is a
heavy duty, industrial engine. It is designed and built
for rugged use. It is very normal for any engine to use
small quantities of oil until the break-in is accom-
plished. Check the oil level twice a day during the
break-in period (about 200 running hours).
IMPORTANT
IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE
UNIT SHOULD BE SUBJECTED TO HEAVY LOADS,
WITHIN THE RATING OF THE MACHINE. AVOID
LONG IDLE RUNNING PERIODS.
COMMANDER 400
B-7
OPERATION
B-7
TYPICAL FUEL CONSUMPTION
Refer to Table B.2 for typical fuel consumption of the
Commander 400’s Engine for various operating sce-
narios.
Table B.2 Deutz F3L 912 Engine Fuel Consumption
WELDER OPERATION
STICK WELDING
The Commander 400 can be used with a broad range
of DC stick electrodes.
The OUTPUT RANGE switch provides six overlapping
slope controlled current ranges. The OUTPUT CON-
TROL adjusts the current from minimum to maximum
within each range. Open circuit voltage is also con-
trolled by the OUTPUT CONTROL in the slope con-
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
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-
TROL to get 175 amps.
GENERAL WELDING
The seventh position of the OUTPUT RANGE switch is
designed for horizontal welds with all types of elec-
trodes especially low hydrogen. The OUTPUT CON-
TROL adjusts the full range of 50 to 575 amps. This
setting provides a soft, constant current arc. If a more
forceful arc is desired, then select the proper range
from the slope controlled current ranges.
TIG WELDING
The Commander 400 can be used in a wide variety of
DC Tungsten Inert Gas (TIG) welding applications for
DC TIG welding up to 400A at a 20% duty cycle, 300A
at a 60% duty cycle and 250A at a 80% duty cycle.
Refer to Table B.3 for recommended output setting
depending on the tungsten electrode size. The
Commander can be used without a TIG module or Hi-
Freq Unit for scratch start DC TIG welding. Using a
K799 Hi-Freq Unit or K930-1 TIG Module enables DC
TIG welding without having to scratch start. The end of
this section also details Commander 400 settings
when using either of these units for DC TIG welding.
Also refer to the Accessories chapter for recommend-
ed equipment for TIG welding.
ARC GOUGING
Set the output range switch to the General purpose
position (50-575). For current setting, refer to The
Procedure Handbook of Arc Welding, section on arc
gouging (13.5) or the consumable manufacturer’s rec-
ommended current rating.
COMMANDER 400
Low Idle - No
Load 1350 RPM
High Idle - No
Load 1900 RPM
DC CC Weld
Output 400
Amps @ 40 Volts
Auxiliary Power
10,000 VA
.30 gallons/hour
(1.36 liters/hour)
.78 gallons/hour
( 3.55 liters/hour)
1.84 gallons/hour
( 8.36 liters/hour)
1.32 gallons/hour
(6.00 liters/hour)
83.3
32.1
13.6
18.9
Deutz F3L 912
44.2 Hp
@ 1800 RPM
Running Time for
25 gallons
(Hours)
B-8
OPERATION
B-8
COMMANDER 400 SETTINGS WHEN USING THE
K799 HI-FREQ UNIT
a. Set the OUTPUT RANGE switch to the “50-575 set-
ting” (Fabrication and General Purpose)
b. Set the IDLER switch to the “High “ position.
c. Set the LOCAL/REMOTE switch to the “Remote” posi-
tion.
d. Set the WELDING TERMINALS switch to the “Welding
Terminals Always On” position. This will close the solid
state contactor and provide an always “hot” electrode.
(Note: This is necessary because the K799 circuitry with
respect to the #2 and #4 leads does not provide the prop-
er signal to open and close the solid state contactor in the
Commander).
COMMANDER 400 SETTINGS WHEN USING THE
K930-1 TIG MODULE
a. Set the OUTPUT RANGE switch to the 50-575 Setting
(Fabrication and General Purpose)
b. Set the IDLER switch to the “Auto “ position.
c. Set the LOCAL/REMOTE switch to the “Remote” posi-
tion.
d. Set the WELDING TERMINALS switch to the “Welding
Terminals Remotely Controlled” position. This will
keep the solid state contactor open and provide a
“cold” electrode until the triggering device (Amptrol or
Arc Start Switch) is pressed.
COMMANDER 400
Tungsten
Electrode
Diameter
in. (mm)
2-15
5-20
15-80
70-150
150-250
250-400
400-500
500-750
750-1000
(3)
(3)
(3)
10-20
15-30
25-40
40-55
55-80
80-125
3-8 (2-4)
5-10 (3-5)
5-10 (3-5)
5-10 (3-5)
13-17 (6-8)
15-23 (7-11)
21-25 (10-12)
23-27 (11-13)
28-32 (13-15)
3-8 (2-4)
5-10 (3-5)
5-10 (3-5)
9-13 (4-6)
11-15 (5-7)
11-15 (5-7)
13-17 (6-8)
18-22 (8-10)
23-27 (11-13)
TIG TORCH
Nozzle
Size (4), (5)
Approximate Argon Gas Flow Rate
C.F.H. (l/min.)
DCEN (-) DCEP (+)
#4, #5, #6
#5, #6
#6, #7, #8
#8, #10
0 .010 (.25)
0.020 (.50)
0.040 (1.0)
1/16 (1.6)
3/32 (2.4)
1/8 (3.2)
5/32 (4.0)
3/16 (4.8)
1/4 (6.4)
1%, 2%
Thoriated
Tungsten
1%, 2%
Thoriated
Tungsten
Aluminum Stainless Steel
Table B.3 TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES(2)
(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.
B-9
OPERATION
B-9
WIRE FEED (CONSTANT VOLTAGE) WELD-
ING
(Stick and Wire models only)
Connect a wire feeder to the Commander 400 and set the
welder controls according to the instructions in “Controls
and Settings” in this section of the manual.
The Stick and Wire model of the Commander 400 with its
CV tap, permits it to be used with a broad range of flux
cored wire (Innershield and Outershield) electrodes and
solid wires for MIG (GMAW).
For any electrodes, the procedures should be kept within
the rating of this machine. For additional electrode infor-
mation, see Lincoln publications N-675, GS-100 and GS-
210.
STICK AND WIRE MODEL CONNECTION TO
LN-25
The LN-25 with or without an external contactor may be
used with the Commander 400 Stick and Wire model. See
the appropriate connection diagram in “DIAGRAMS” sec-
tion. NOTE: The LN-25 (K431) Remote Control Module
and (K432) Remote Cable are not recommended for use
with the Commander 400 S&W.
a. Shut the welder off.
b. For electrode Positive, connect the electrode cable
from the LN-25 to the “+” terminal of the welder and
work cable to the “- WIRE” terminal of the welder.
For electrode Negative, connect the electrode cable
from the LN-25 to the “ WIRE” terminal of the welder
and work cable to the “+”terminal of the welder.
c. Attach the single lead from the front of the LN-25 to
work using the spring clip on the end of the lead.
This is a control lead to supply current to the wire
feeder motor; it does not carry welding current.
d. Set the range switch to “WIRE WELDING CV”
e. Set the “OUTPUT CONTROL” switch to “WELDING
TERMINALS ALWAYS ON”
f. Set the “VOLTS\AMPS” switch to “VOLTS”
g. Set the “IDLE” switch to the “AUTO” position. When
not welding , the Commander 400 S&W engine will
be at the low idle speed. CAUTION: ( if you are
using an LN-25 without an internal contactor, the
electrode will be energized when the Commander
400 Stick and Wire model is started.) If you are
using an LN-25 with an internal contactor, the elec-
trode is not energized until the gun trigger is closed.
In either of the LN-25 wire feeders, when the gun
trigger is closed, the current sensing circuit will
cause the Commander 400 Stick and Wire model
engine to go to the high idle speed, the wire will
begin to feed and the welding process started.
When welding is stopped, the engine will revert to
low idle speed after approximately 15 seconds
unless welding is resumed.
STICK AND WIRE MODEL CONNECTION TO
LN-7 or LN-8
a. Shut the welder off.
b. Connect the LN-7 or LN-8 per instructions on the
appropriate connection diagram in “DIAGRAMS”
section. Set the “LOCAL REMOTE” switch to
“REMOTE” for the LN-7 and LN-8 with a K857
remote voltage control cable attached; “LOCAL” for
LN-7 with no remote voltage control.
c. Set the “VOLTMETER” switch to either “+” or “-” as
required by the electrode being used.
d. Set the “RANGE” switch to the “WIRE WELDING
CV” position.
e. Set the “OUTPUT CONTROL” switch to the “OUT-
PUT REMOTELLY CONTROLLED” position.
f. Set the “IDLE” switch to the “HIGH” position.
When the gun trigger is closed, the electrode is energised
and the wire will begin to feed.
------------------------------------------------------------------------
STICK AND WIRE MODEL CONNECTION TO
LN-23P
a. Shut the welder off.
b.
Connect the LN-23P as per instructions on the
appropriate connection diagram in “DIAGRAMS”
section. NOTE: When connecting an LN-23P to the
Commander Stick & Wire, a K350-1 adapter kit must
be used. Set the “VOLTMETER” switch to either “+”
or “-” as required by the electrode being used.
d. Set the “RANGE” switch to “WIRE WELDING CV”
e. Set the “OUTPUT CONTROL” switch to “WELDING
TERMINALS ALWAYS ON” Set the “VOLTS/AMPS”
switch to “VOLTS”
g. Set the “LOCAL REMOTE” switch to the desired
setting depending upon where the power sources
output is being controlled from.
h. Set the “IDLE” switch to the “AUTO” position. When
not welding , the Commander 400 Stick and Wire
model engine will be at the low idle speed. If you are
using an LN-23P with the K350-1 adapter kit, the
electrode is not energized until the gun trigger is
closed. When the gun trigger is closed, the current
sensing circuit will cause the Commander 400 Stick
and Wire model engine to go to the high idle speed,
the wire will begin to feed and the welding process
can be started. When welding is stopped, the
engine will revert to low idle speed after approxi-
mately 15 seconds unless welding is resumed.
STICK AND WIRE MODEL CONNECTION TO
NA-3
For connection diagrams and instructions for connecting
an NA-3 Welding System to the Commander Stick & Wire,
refer to the NA-3 Welding System instruction manual.
COMMANDER 400
CAUTION
B-10
OPERATION
B-10
AUXILIARY POWER OPERATION
Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings, if no welding
current is being drawn..
The auxiliary power of the Commander consists of two-
120VAC (5-15R) duplex receptacles with GFCI protec-
tion and one 120/240 VAC (14-50R) receptacle. The
120/240VAC receptacle can be split for single phase
120 VAC operation.
The auxiliary power capacity is 10,000 watts of 60 Hz,
single phase power. The auxiliary power capacity 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.
The current rating of any plug used with the system
must be at least equal to the current capacity of the
associated receptacle.
SIMULTANEOUS WELDING AND AUXIL-
IARY POWER LOADS
It must be noted that the above auxiliary power ratings
are with no welding load. Simultaneous welding and
power loads are specified in table B.4. The permissible
currents shown assume that current is being drawn
from either the 120 VAC or 240 VAC supply (not both at
the same time).
COMMANDER 400
Welding
Output Range
Setting
50-575
400
270
230
180
120
90
Welding Output
500A/40V
400A/36V
270A/31V
230A/29V
180A/27V
120A/25V
90A/24V
Permissible
Power - Watts
(Unity Power
Factor)
None
None
3000
6000
7500
9500
9500
Permissible
Current in
@120 V ±10% *
0
0
28
56**
70**
88**
88**
Auxiliary
Amperes
@ 240 V ±10%
0
0
14
28
35
44
44
* Each GFCI duplex receptacle is limited to 15 amps.
** Not to exceed 44 A per 120 VAC branch circuit when splitting the 240
VAC output.
TABLE B.4 Commander 400 Simultaneous Welding and Power
Loads
C-1
ACCESSORIES
C-1
OPTIONAL FIELD INSTALLED
ACCESSORIES
K802R POWER PLUG KIT - Provides a plug for each
receptacle.
K857 28 ft. (8.5 m) or K857-1 100 ft. (30.4 m)
REMOTE CONTROL - Portable control provides same
dial range as the output control on the welder from a
location up to the specified length from the welder. Has
convenient plug for easy connection to the welder. The
Commander 400 is equipped with a 6 pin connector
for connecting the remote control and a toggle switch
for selecting “LOCAL” output control or “REMOTE” out-
put control.
K704 ACCESSORY SET - Includes 35 feet (10 m) of
electrode cable and 30 feet (9 m) of work cable, head-
shield, work clamp and electrode holder. Cable is
rated at 500 amps, 60% duty cycle.
K953-1 TWO WHEEL TRAILER - For road, in-plant
and yard towing. Road towing with optional fender &
light kit. (For highway use, consult applicable federal,
state and local laws regarding possible additional
requirements)
K953-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit
K965-1 Cable Storage Rack
K825-1 ETHER START KIT - Provides maximum cold
weather starting assistance for frequent starting below
10 F (-12.2oC). Required Ether tank is not provided
with kit.
K899-1 SPARK ARRESTOR KIT - Easily mounts to
standard muffler.
K949-1 OIL DRAIN KIT - Includes ball valve, hose and
clamp.
RECOMMENDED EQUIPMENT
STICK
K704 Accessory Kit which includes:
• Electrode holder and cable.
• Ground clamp and cable.
• Headshield.
K857 Remote Control Kit is optional for remote cur-
rent control.
TIG
Magnum TIG Torch
Magnum Parts Kit and Argon gas
K930-1 TIG Module (not required for scratch start
DC TIG welding)
K936-3 Control Cable
K870 Foot Amptrol
Also available:
K812 Hand Amptrol
K814 Arc Start Switch
K937-22 Control Cable Extension
K937-45 Control Cable Extension
K844-1 Water Valve
HIGH FREQUENCY GENERATORS FOR
TIG APPLICATIONS
The K799 Hi-Freq Unit and the K930-1 TIG Module are
suitable for use with the Commander 400. The
Commander is equipped with the required R.F. bypass
circuitry for the connection of high frequency generat-
ing equipment. The high frequency bypass network
supplied with the K799 Hi-Freq Unit does NOT need
to be installed into the Commander.
The Commander and any high frequency generating
equipment must be properly grounded. See the K799
Hi-Freq Unit and the K930-1 TIG Module operating
manuals for complete instructions on installation, oper-
ation, and maintenance.
COMMANDER 400
D-1
MAINTENANCE
D-1
SAFETY PRECAUTIONS
•Have a qualified technician do the maintenance
and troubleshooting work.
•Turn the engine off before working inside the
machine.
•Remove guards only when necessary and replace
them when the maintenance requiring their
removal is complete.
•Always use the greatest care when working near
moving parts.
------------------------------------------------------------------------
Read the Safety Precautions in front of this manual and
the engine instruction manual before working on this
machine.
Keep all equipment safety guards, covers and devices
in position and in good repair. Keep hands, hair, cloth-
ing and tools away from V-belts, gears, fans and all
other moving parts when starting, operating or repair-
ing the equipment.
ROUTINE AND PERIODIC
MAINTENANCE
DAILY
a. Check the crankcase oil level .
b. Refill the fuel tank to minimize moisture condensa-
tion in the tank.
c. Open the water drain valve located on the bottom of
the water separator element 1 or 2 turns and allow to
drain into a container suitable for diesel fuel for 2 to
3 seconds. Repeat the above drainage procedure
until diesel fuel is detected in the container.
WEEKLY
Blow out the machine with low pressure air periodical-
ly. In particularly dirty locations, this may be required
once a week.
ENGINE MAINTENANCE
Refer to the “Periodic Checks” section of the Engine
Operator’s Manual for the recommended maintenance
schedule of the following:
a) Engine Oil and Filter
b) Air Cleaner
c) Fuel Filter - and Delivery System
d) Cooling Blower Belt
e) Battery
f) Cooling System
Refer to Table D.1 at the end of this section for various
engine maintenance components.
AIR FILTER
EXCESSIVE AIR FILTER RESTRICTION WILL
RESULT IN REDUCED ENGINE LIFE.
------------------------------------------------------------------------
The air filter element is a dry cartridge type. It can be
cleaned and reused; however, damaged elements
should not be reused. Stop engine after 100 hours of
running time and clean filter element , replace the fil-
ter if necessary. Service air cleaner regularly accord-
ing to Engine Operator’s Manual.
1. Locate the air filter canister located behind the
engine door on the top of the engine.
2. Remove air filter element.
3. Remove loose dirt from element with compressed
air or water hose directed from inside out.
Compressed Air: 100 psi maximum with nozzles at
least one inch away from element.
Water Hose: 40 psi maximum without nozzle.
4. Soak element in a mild detergent solution for 15 min-
utes. Do not soak more than 24 hours. Swish ele-
ment around in the solution to help remove dirt.
5. Rinse elements from inside out with a gentle stream
of water (less than 40 psi) to remove all suds and
dirt.
6.Dry element before reuse with warm air at less than
160oF (71oC). Do not use a light bulb to dry the ele-
ment.
COMMANDER 400
WARNING
CAUTION
D-2
MAINTENANCE
D-2
7. Inspect for holes and tears by looking through the
element toward a bright light. Check for damaged gas-
kets or dented metal parts. Do not reuse damaged ele-
ments. Protect element from dust and damage during
drying and storage.
8. Reinstall air filter element.
After six cleanings replace air filter. A cleaned filter will
have approximately 70% of the life of a new filter ele-
ment. A restricted filter element may not appear exces-
sively dirty.
FUEL FILTERS
When working on the fuel system
• Keep naked lights away, do not smoke !
• Do not spill fuel !
------------------------------------------------------------------------
The Commander 400 is equipped with a Fuel Pre-
Filter/Water Separator Assembly located before the
lift pump and a Secondary Fuel Filter located after the
lift pump and before the fuel injectors. The Fuel Pre-
Filter/Water Separator is mounted to the engine block
just below the lift pump. The Secondary Fuel Filter is
mounted directly to the engine just above the oil filter.
FUEL PRE-FILTER/WATER SEPARATOR ASSEM-
BLY
The pre-filter is a 150 micron screen designed to pro-
tect against gross fuel contamination of the water sep-
arator element and the Secondary Fuel Filter. If the
pre-filter becomes plugged it may be removed, inspect-
ed, cleaned and reinstalled. In general this only needs
to be done with each water separator element change
(about every 1,000 hrs.) However if at any time exces-
sive fuel contamination is suspected or a sudden fall-
off in engine performance is detected the pre-filter
screen should be inspected and cleaned. Follow the
following procedure:
1. Close the fuel shutoff valve (Lever should be per-
pendicular to the hose) located on the side of the
Fuel Pre-Filter/Water Separator Assembly.
2. Unscrew the cap ring located on the top of the filter
header and remove the plastic center cap and O-
ring.
3. Remove the large white volume plug located direct-
ly under the center cap in the upper cavity of the fil-
ter header. Use a small screwdriver (or similar
device) to lift the plug part way out of the cavity to
assist with its removal.
Be careful not to damage the pre-filter screen with
the tool used to remove the plug.
4. Using a pair of pliers, gently tug on the pull tabs of
the pre-filter screen in an alternating pattern to
gradually remove the pre-filter screen.
5. Brush off any debris and rinse in diesel fuel.
6. Re-install the pre-filter screen into the upper cavity
of the filter header making sure the four pull tabs
are pointing up. Putting your fingers on the pull tabs,
push down evenly until the lower body of the pre-fil-
ter screen contacts the floor of the upper cavity.
7. Re-insert the large white volume plug into the upper
cavity.
8. Place the O-ring onto the angled seal surface of the
filter header and re-install the plastic cap. Make sure
its flange rests on the O-ring.
9. Screw on the cap ring and tighten hand tight.
10. Remember to open the fuel shutoff valve (Lever in
line with the hose) before starting the engine.
WATER SEPARATOR ELEMENT
The water separator element is a two stage filter with a
special filtration/water separating media, and an
expanded water reservoir providing maximum protec-
tion against water in the fuel. The recommended
change interval for the water separator element is
1,000 hours. The procedure for changing the element
is as follows:
1. Close the fuel shutoff valve (Lever should be per-
pendicular to the hose) located on the side of the
Fuel Pre-Filter/Water Separator Assembly.
2. Rotate the quick change ring (located just below fil-
ter header) clockwise approximately 1/2 turn and
slide it down and off of the element.
3. Grasp the element and pull down with a slight rock-
ing motion to remove the element from the grommet
post on the bottom of the filter header.
COMMANDER 400
WARNING
D-3
MAINTENANCE
D-3
4. Slide the new element onto the grommet post on the
bottom of the filter header until the element no longer
easily moves up into the filter header. Now rotate the
element (may take almost 1 full turn) with a slight
upward pressure until the element begins to further
engage the header. With the proper orientation now
established apply additional pressure to seat the ele-
ment in the filter header. You should feel the element
“pop” into place when properly seated.
Note: The element will only go on one way. Never use
excessive force when mounting the element to the
header.
5. Slide the quick change ring up over the element and
rotate counter clockwise until an audible click or pop
is heard. If you do not hear the click you have not rotat-
ed the ring far enough and the element is not in the
locked position. Another indication that the ring is in
the locked position is that one set (it doesn’t matter
which one) of arrows located on the outside of the ring
should be located directly under the air vent valve.
6. Open the fuel shutoff valve (lever in line with the hose).
7. Open the air vent valve on the front of the filter header
until fuel emerges free of air bubbles and then close
the air vent valve.
Note : Consult your engine operation manual for informa-
tion on air -bleeding the entire fuel system.
SECONDARY FUEL FILTER
The Secondary Fuel Filter is a spin on cartridge type
mount directly to the engine. Consult your engine opera-
tion manual for complete information on service intervals
and element changing procedures.
COOLING SYSTEM
The cooling system of the Deutz engine needs to be
checked and cleaned periodically. Consult the engine
owners manual for the proper frequency and procedure.
COOLING BLOWER BELT
The following procedure should be followed to replace the
cooling blower belt:
1. Allow machine to cool.
2. Unfasten and slide the battery holder out from the
welder.
3. Disconnect the negative battery cable.
4. Remove the engine end panel for access to the
engine.
5. Loosen the alternator mounting bolts and rotate the
alternator towards the engine.
6. Remove the old cooling blower belt and install a new
one.
7. Adjust the cold belt tension to 63-73 lbs. midway
between any two pulleys.
8. Reinstall the engine end panel. Reattach the negative
battery cable. Slide in and refasten the battery holder.
9. Check the cooling blower belt tension after 100 hours
of operation. (Follow steps 1,2,3,4,7 & 8)
BATTERY HANDLING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes away from bat-
tery.
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY - disconnect nega-
tive cable from old battery first and connect to new
battery last.
• CONNECTING A BATTERY CHARGER - Remove bat-
tery from welder by disconnecting negative cable
first, then positive cable and battery clamp. When
reinstalling, connect negative cable last. Keep well
ventilated.
• USING A BOOSTER - connect positive lead to bat-
tery first then connect negative lead to engine foot.
BATTERY ACID CAN BURN EYES AND SKIN.
• Wear gloves and eye protection and be careful when
working near battery. Follow instructions printed on
battery.
-------------------------------------------------------
-----------------
PREVENTING ELECTRICAL DAMAGE
1. When replacing, jumping, or otherwise connecting the
battery to the battery cables, the proper polarity must be
observed. Failure to observe the proper polarity could
result in damage to the charging circuit. The positive (+)
battery cable has a red terminal cover.
2. If the battery requires charging from an external charg-
er, disconnect the negative battery cable first and then the
positive battery cable before attaching the charger leads.
Failure to do so can result in damage to the internal
charger components. When reconnecting the cables,
connect the positive cable first and the negative cable
last.
PREVENTING BATTERY DISCHARGE
If you have an ignition switch, turn it off when engine is
not running.
PREVENTING BATTERY BUCKLING
Tighten nuts on battery clamp until snug.
COMMANDER 400
WARNING
D-4
MAINTENANCE
D-4
COMMANDER 400
Table D.1 Engine Maintenance Components
ITEM
Air Cleaner Element
Cooling Blower Belt
Oil Filter Element
Fuel Filter Element
Water Separator Element
Fuel Pre-Filter Screen
Battery
MAKE
Donaldson
AC
Lincoln
Gates
Deutz
Purolator
Napa
Fram
Deutz
Purolator
Napa
Fram
Lincoln
Stanadyne
Lincoln
Stanadyne
PART NUMBER
P181052
A302C
T13536-3
7585
1174418
PER2168
1820
PH3776
1174423
PC42
3358
P4102
M16890-C
31572
M16890-B
29575
BCI
Group
34
E-1
TROUBLESHOOTING
E-1
COMMANDER 400
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.
CAUTION
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos-
sible symptoms that the machine may exhib-
it. Find the listing that best describes the
symptom that the machine is exhibiting.
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.
Step 3. RECOMMENDED COURSE OF
ACTION
If you have exhausted all of the items in step
2. Contact your Local Lincoln Authorized
Field Service Facility.
HOW TO USE TROUBLESHOOTING GUIDE
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.
__________________________________________________________________________
WARNING
E-2
TROUBLESHOOTING
E-2
COMMANDER 400
Observe all Safety Guidelines detailed throughout this manual
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.
CAUTION
ENGINE PROBLEMS
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
Major Physical or Electrical Damage
is Evident.
Engine will not “crank”.
Engine will “crank” but not start.
Engine shuts down shortly after
starting.
Battery does not stay charged.
1. Contact your Local Lincoln
Authorized Field Service Facility.
1. Battery is low. Charge Battery.
2. Loose battery cable connections.
Inspect, clean and tighten.
1. Out of fuel. Fill prime tank.
2. Fuel shut off valve is in off
position.
3. High oil temperature (Indicator
light lit. Check engine cooling
system. (Consult engine service
dealer.
4. Low battery voltage.
1. Low fuel. (Indicator light lit) Add
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.
1. Faulty battery. Replace
Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
E-3
TROUBLESHOOTING
E-3
COMMANDER 400
Observe all Safety Guidelines detailed throughout this manual
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.
CAUTION
FUNCTION PROBLEMS
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
Engine will not idle down to low
speed.
Engine will not go to high idle when
attempting to weld.
Engine will not go to high idle when
using auxiliary power.
1. Idler switch in High idle position.
Set switch to Auto.
2. External load on welder or auxil-
iary power. Remove all external
loads.
1. Poor work lead connection to
work. Make sure work clamp is
tightly connected to clean base
metal.
2. ”Welding Terminals” switch is in
wrong position. Set to “Always
On” when welding without a weld-
ing terminal control cable. Refer
to Operations chapter for proper
use of this switch.
1. Auxiliary power load is less than
100 watts. Idler may not respond
with less than a 100 watt load.
Set Idler to “High”
Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
E-4
TROUBLESHOOTING
E-4
COMMANDER 400
Observe all Safety Guidelines detailed throughout this manual
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.
CAUTION
OUTPUT PROBLEMS
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
No welding power output.
Welder has output and no control.
No auxiliary power.
1. Welding terminals switch in wrong
position. Place switch in “Always
On” position when welding without
welding terminal control cable.
Refer to Operation chapter for
proper switch function.
1. Local/Remote switch is in wrong
position. Place switch in Local
position to control output at
welder. Place switch in Remote
position to control output remotely.
Refer to Operation chapter for
proper switch function.
2. Poor remote kit connection.
Check connections.
3. Faulty remote kit. Replace if nec-
cessary.
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.
Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
F-1
DIAGRAMS
F-1
COMMANDER 400
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-
gram for your particular machine is pasted inside the machine on one of the enclosure panels.
WIRING DIAGRAM:
240 uF
240 uF
240 uF
STATOR
ASSEMBLY
RECTIFIER
SHUNT
600 AMP
CHOKE
OUTPUT
SCR A SCR B SCR C
G1 G2 G3
G1
G2
G3
12368
23
123
204S
206S
204S 206S 207
SNUBBER PC BOARD
123
221
220
219
218
217
216
215
214
213
222
1
2
3
4
5
6
7
8
9
10
213
214
215
216
217
218
219
220
221
222
261 223 204
50 Ohm
100 W
120 V
WHITE
120/240V
15A
CB4
15A
CB3
CB1 CB2
11
12
9
6A
50A 50A
9
11 12
TERM.
3A
GREEN GREEN GREEN
WHITE
BLACK
BLACK
BLACK
8
8
GND-C
GND-D
E1
E2
3
IDLER
SWITCH
AUTO
S4
SWITCH
FINE CONTROL
POT
SELECTOR
S1
4
276
75
75 77
77
76B 77B
76
12 VOLT
BATTERY
(+)
(-)
COIL
COIL
PULL
HOLD
SOLENOID
IDLE
ENGINE GROUND
1
J2
134
B1
E2
E1
MOTOR
+
-
232
231A
231A
236C
240
234
233A
255
GROUND SCREW
3
GND-E
5C
5A 5
5C
5C
236B
236A
METER
HOUR
SENSOR
SENSOR
FUEL LVL.
S2
232A
239A
229
241
J10
6
WHITE
5E
5G
5G
5E
5H
5H
5C
GROUND SCREW
IN CONTROL BOX
GND-D
GND-C
GND-E
IN CONTROL BOX
6B
3B
S3
START BUTTON
HIGH
3
BLACK
6
BLACK
IN CONTROL BOX
T1
1002 1004 1006 1008
1011
1013
1015
1009
1010
1012
1014
1016
1017
1019
1021
1023
1018
1020
1022
1024
1001
1003
1005
1007
1002
1004
1006
1008
CAPACITOR
T2
T3
S8
W5
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
ELECTRICAL SYMBOLS PER E1537
NEG.
POS.
RUN
STOP
242E
239A 229B
245 243
5678
242D
247
227
239
EXC
NEG
POS
SENSE
226
225
224
STARTER
SOLENOID
ALTERNATOR
242
242
NEXT AVLB.
S6
A
C
B
D
E
F
AMPHENOL 2
77D
76D
75D
2D
4D
REMOTE
CONTROL
GROUND
TRIGGER
77C
GFCI
LINE
LOAD
LOAD
LINE HOT
WHITE
WHITE
HOT
227
75B
J12
METER
PCB
1
2
3
4
1
2
3
4
250
251
252
253
9
8
7
65
4
3
2
1
A
226 234
246
242G
123456
SENSOR
SWITCH
SWITCH
228A
241A
229A
239
239B
1
2
3
4
5
6
7
8
ENGINE TO PCB HARNESS
PANEL TO PANEL WIRES
PANEL TO PCB HARNESS
120 V
GFCI
LINE LOAD
LOAD
LINE HOT
WHITE
WHITE
HOT
J11
239B
242I
204B
209
9
237
J16 P16
254
COIL
COIL
PULL
HOLD
SOLENOID
SHUTDOWN
256
232
224
242D
76C
228
STARTING
206
6
8
15
16
SPI
SCI
OUTPUT
SOURCE
CONTROL
ALWAYS ON
OUTPUT REMOTELY
CONTROLLED
CW
VIEWED FROM
BACK
11
12
13
14
23 5689
4
267
238
262
262
261
204
223
CC
BYPASS PC
BOARD
260
12345678910
270
269
268
272
273
270
269
268
272
273
REMOTE/
LOCAL
SWITCH
GND-F
GND-F
8
7
65
204A
2
4
WELDED STUD
ON OUTPUT PANEL
GND-A
DC
DB
DA
DD
AUX. POWER
B3
B2
4
J30
260
ENGINE PROT.
BOARD
J23
J8
J4 J1 J6
J7
J3
237
274
280
10
207
233
280 279
10 11
256
255
STAINLESS STEEL
STAND-OFF
FRAME GROUND
147 12 1447 9
204A
T3
T2
T1
6
5
5A
3
EXCITER
WINDINGS
W1
W5
W2
W6
W3
W3
W6
W1
W4
W2
240
287
SOLENOID GROUND
STUD ON ENGINE
4
279
236A
233A
233
240 240A
MOTHER
CONTROL
PC BOARD
J5
J40
J50
STUD ON ENGINE
MOUNT CHANNEL
STUD ON
ENGINE
CONNECTIONS TO
CAPACITORS MADE
EXCITER VOLTAGE
FEEDBACK BOARD
5D
3D
3D
3D
5D
3D 5D
3D
NEUTRAL T2 STUD
T1 INSULATED STUD
T3
INSULATED STUD
(optional)
232H
CONNECTIONS
WK
G
OIL TEMP. SENSOR & SWITCH
+
-
AMMETER
229A
+
-
+
-
+
-
FUEL
S
SS
228A 241A
232B
TEMP.
232C
232A
242B
242A
242C
LOW
FUEL
LOW
PRESS.
245
OIL
PRESS.
TEMP.
ALT.
243
236C
229B
247 246
238
242G
232E
232G
232F
232D
L11008
COMMANDER 400-STICK MODEL WIRING DIAGRAM
1
23
45
J60
2
4D
75D
76D
2D
77D
3
4
5
6
1
7
8
6
77C
75B
76C
4B
2B
4B
2B
FRAME GROUND
J61
(VIEWED FROM BACK)
REMOTE PROTECTION PCB
AUXILIARY BYPASS PCB
5J
9A
5K
8A
5J
9A
5K
8A
AUX. CURRENT
SENSE TOROID
8A
5J
9A
5K
8A
5J
9A
5K
B4 B5 B6 B7
9A
5K
5J
8A
5D
274
240A
CONTROL HARNESS
CONTROL HARNESS
CONTROL HARNESS
ENGINE HARNESS TO PANEL WIRES
ENGINE HARNESS
CONTROL PANEL
GND-H
ON CONTROL PANEL
SMALL
TAB
LARGE
TAB
SILVER
TAB
SILVER
TAB
SILVER
TAB
STUD ON GENERATOR
MOUNT CHANNEL
STAINLESS STEEL
STAND-OFF
FRAME GROUND
STAINLESS STEEL
STAND-OFF
FRAME GROUND
W4
W6
242I
CONNECTIONS ON CONTROL BOARD
(VIEWED AS INSTALLED)
J2 J6 J5 J8 J7 J1 J4 J3
B1 B2 B3
J23
ENGINE
PROT.
BOARD
POSITION NAMEPLATE SETTING
SELECTOR SWITCH (S8)
1 NO FUNCTION
2 NO FUNCTION
3 90 MAX
4 120 MAX
5 180 MAX
6 230 MAX
7 270 MAX
8 400 MAX
9 50-575
(SEE SELECT SWITCH CHART)
STAINLESS STEEL
STAND-OFF
COMMON BATT.
285
285
OIL PRESSURE SWITCH
& SENSOR
286
BOLT ONTO
SENDER BRK’T
VIA BOLTED
5-15-98A
F-2
DIAGRAMS
F-2
COMMANDER 400
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-
gram for your particular machine is pasted inside the machine on one of the enclosure panels.
WIRING DIAGRAM:
COMMANDER 400-STICK & WIRE MODEL WIRING DIAGRAM
6 230 MAX.
9 50-575
8 400 MAX.
7 270 MAX.
2 WIRE WELDING CV
5 180 MAX.
4 120 MAX.
3 90 MAX.
1 NO FUNCTION
POSITION NAMEPLATE SETTING
FROM BACK)
(VIEWED
S8
216
5
FINE CONTROL
2
4
6
215
208A
POT
3
219
214
A
NEG.
220
CW
CC
77
77B
CV 284B
222
BOARD
284
1
CHOKE 284A
L2
CV
3
216
217
218
4
219
4
220
5
221
222
5
67
E2
E1
237
9
6
226 227
234
2
1345
9
8
7
6
5
4
32
112
6
77D
2
4B
2D
6
2B
76D
76C
J62
208
282
3
2
21
1
206S
208A
S5
SWITCH
POLARITY
ELECTRODE
4
285A285
SHUNT
4D
31
32A
21
77E
76E
H
E
F
242H
WORK
G
I
K
B
242I
F
AMPHENOL 1
GROUND
223
204
EXCITER VOLTAGE
FEEDBACK BOARD
ENGINE
J50
OIL PRESSURE SWITCH & SENSOR
OIL TEMP. SENSOR & SWITCH
STUD ON ENGINE
MOUNT CHANNEL
MOUNT CHANNEL
STUD ON
STUD ON GENERATOR
11
12
STAINLESS STEEL
T3
1005
1024
1003
T2
1023
1016
1021
T1
1015
5D
1008
3D
1002
1013
1014
240 uF
1012
1010
1017
1019
1006
1011
240 uF
1004
1009
3D
WHITE
5H
TERM.
WHITE
GND-C
GREEN
GFCI
J11
HOT
LOAD
HOT
115 V
LINE
9
GREEN
WELDED STUD
WHITE
5G
LOAD
WHITE
9
12
B6
11
B5B4
FRAME
GROUND
STAND-OFF
B7
10
207
9
8
4
3
2
1
2
1
204S
7
6
J6
253
252
251
250
J1
COMMON BATT.
206
SELECTOR SWITCH (S8)
LINE
GFCI
GND-A
8
LOAD
WHITE
BLACK
3D
15A
3A
CB3
WHITE
AMMETER
6B
T1 INSULATED STUD
50A
IN CONTROL BOX
+
50A
CB2
CB1
238
6A
BLACK
J12
3D
115 V
5G
LINE HOT LOAD HOT
11
10
J6 J5
262
J2
POS
J8
SENSE
1
MOTHER
CONTROL
2
PC BOARD
213
3
214
239
215
234
SENDER
BRACKET
286
BOLT ON
10
3D
9
240A
8
7
273
6
272
5
5D
3
T3
T2
EXCITER
WINDINGS
6
4
3
6
5A
5
ON OUTPUT PANEL
GND-E
GND-D
GND-C
IN CONTROL BOX
GROUND SCREW
AUX. POWER
5C
E1
274
268
STATOR
2
269
CONNECTIONS
CAPACITORS MADE
1
CONNECTIONS TO
270
VIA BOLTED
247
LOW
PRESS.
J40
5
77D
1
76D
4D
2
2D
76E
3
4
5
75D
3
SWITCH
SENSOR
FUEL LVL.
ENGINE TO PANEL HARNESS
SENSOR
228
241
242E
229
239
P16
J16
8
9
228A
241A
242D
229A
239B
233A
WK
SWITCH
285
PANEL TO PANEL WIRES
5
4
6
7
3
G
2
SENSOR
1
(-)
232C
245
229B
232B
246
232A
FUEL
232F
LOW
+
FUEL
S
TEMP.
OIL
-
TEMP.
243
+
232E
S
PRESS.
229A
-
242
5K
CONTROL
8A
REMOTE B
CONTROL
C75D
D
AUXILIARY BYPASS PCB
J
9A 5K 5J 8A
A
GROUND
242I
242H
AMPHENOL 2
75E
7
CB5 15AMP
REMOTE
2E
4E
C
D
CONTACTOR
115AC
RF BYPASS
PC BOARD
1
W2
W5
75E
242H
242I
77E
32A
A
CONTACTOR
E
1
3
J60
CONTROLLED
4
J21
4
ALWAYS ON
OUTPUT REMOTELY
FRAME GROUND
5J
9A
8
75B
4
77C
277
J61
7
267
8
9
10
11
14
1
4
1
J2
232
3
J3
456
233
233A
232H
S3
RUN
STOP
232A
236A
285
6
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
NEXT AVAILABLE 287
76
12345
8
G4
10
283
21
CV DAUGHTER BOARD
77
3
2
J20
12
6
5
4E
2E
ELECTRICAL SYMBOLS PER E1537
255
S4
AUTO
HIGH
PULL
SOLENOID GROUND
-
+
239B
METER
HOUR
PANEL TO PCB HARNESS
COIL
PULL
227
COIL
262
SOLENOID
IDLE
225
COIL
HOLD
SOLENOID
226
240
COIL
ENGINE TO PCB HARNESS
HOLD
224
SHUTDOWN
239A
242G
STUD ON ENGINE
237
236A
IDLER
SWITCH
256 S2
254
231A
236C
206A
SCR C
204B
204C
268
270 273
280 G2
POS.
207
204S
277 G4
280
206
NOTE:
NO CONNECTION
C1-C4
SWITCH
SEE CHART
206A
213
POS.
283
DE
FRAME
GROUND
NEG.
BYPASS PC
ON NEWER MODELS
E2
1022
1020
1007
1018
1008
5H
5D
1001
1006
1004
1002
240 uF
5
5A
GREEN
GND-E
GND-D
5D
5E
3
W6
3
W3
2
W4
W1
6
W3
W5
W4
W6
W1
6
2B
OUTPUT
4B
S6
CONTROL
SOURCE
6
3
6
3
6
32
GND-F
W2
240
245
232
239A
236B
224
BOARD
247
5
START BUTTON
2
240
13
ENGINE PROT.
233
6
12
229B
J7
4
3
1
B3
B2
B1
246
8
243
7
J23
J21
J4
ENGINE
PROT.
BOARD
B2
B1
J1
J23
J3
J8 J7
CONNECTIONS ON CONTROL BOARD
(VIEWED AS INSTALLED)
CV
BOARD
B3
6
3
208
3
279
6
OUTPUT
CHOKE
L1
221
BACK
76B 75
VIEWED FROM
7
9
75
217
8
218
76C
231A
STARTER
+
242G
S
232D
-
241A
242A
ALT.
232G
ENGINE TO PANEL HARNESS
-
228A
242C
242B
242D
236C
5C
INSTRUMENT PANEL
GROUND SCREW
IN CONTROL BOX
ALTERNATOR
238
MOTOR
EXC
NEG
STARTING
SOLENOID
PCB
3
2
1
5
6
7
SPI
8
J5
SCI
STAND-OFF
240A
STAINLESS STEEL
FRAME GROUND
METER
SELECTOR
261
260
261 204
223
300W
R3-12
R2-12
282
21
DB
SCR 1
ASSEMBLY
600 AMP
CURRENT
SENSE TOROID
SCR B
30,000 uF
DD
R1-50
100 W
209
DC
209A
77C
REMOTE/
LOCAL
SWITCH
S1
S9
260
V
A
VOLT/AMP
J30
4
275B
SWITCH
76 256
255 269
206S G1 G3
204A
G2
G1 G3 204A
RECTIFIER
SCR A
DA
BLACK
3
IN CONTROL BOX
INSULATED STUD
T3
3B
15A
CB4
5C
BLACK
J10
115/230V
5H
BLACK
8
5E
WHITE
LINE
31
T1
IN CONTROL BOX
NEUTRAL T2 STUD
5-15-98A
L11009
7
272
274
68
279
1234
4
4
3
5C
12 VOLT
(+)
GND-F
GND-H
ENGINE GROUND
J4
BATTERY
242
F-3
DIAGRAMS
F-3
COMMANDER 400
CONNECTION DIAGRAM:
CONTROL MODULE. INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND/OR POWER SOURCE.
K487-25
SPOOL GUN
BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE "LINCOLN" (CONTACT CLOSURE) POSITION BEFORE ATTEMPTING TO OPERATE
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".
K691-10
INPUT CABLE
K488 SG
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
Keep guards in place.
or service this equipment.
TO WORK
RECEPTACLE
CAUTION :
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
CONTROL MODULE
Keep away from moving parts.
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
Only qualified personnel should install,use
Do not touch electrically live parts.
before servicing.
Disconnect NEGATIVE (-) BATTERY LEAD
Do not operate with panels open.
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
ELECTRODE CABLE
TO CONTROL MODULE
COMMANDER 400 STICK & WIRE / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM
M18284
WARNING
RECEPTACLE
TO WORK
14 PIN WIRE FEEDER
115V RECEPTACLE
ELECTRODE
6 PIN REMOTE
N.D. PLACE IDLE SWITCH IN "HIGH" IDLE POSITION.
"REMOTE" POSITION.
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
THE ENGINE WELDER OPERATING MANUAL.
12-13-96
F-4
DIAGRAMS
F-4
COMMANDER 400
CONNECTION DIAGRAM:
LN-23P
KIT
ADAPTER
K350-1
6 PIN
ELECTRODE CABLE
AMPHENOL
AMPHENOL
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY.
TO WORK
12-13-96
COMMANDER 400 STICK & WIRE / LN-23P CONNECTION DIAGRAM
N.C. IF REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL/REMOTE SWITCH IN "REMOTE" POSITION.
WIRE FEEDER
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE
AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
14 PIN
S22911
N.D. ON COMMANDER 400 STICK & WIRE, THE OUTPUT CONTROL SWITCH MUST BE IN THE "WELDING
TERMINALS REMOTELY CONTROLLED" POSITION.
ELECTRODE
TO WORK
Keep guards in place.
or service this equipment.
Keep away from moving parts.
Only qualified personnel should install,use
Do not touch electrically live parts.
before servicing.
Disconnect NEGATIVE (-) BATTERY LEAD
Do not operate with panels open.
WARNING
F-5
DIAGRAMS
F-5
COMMANDER 400
CONNECTION DIAGRAM:
ELECTRODE
TO WORK
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY.
ELECTRODE CABLE
6 PIN
TO WORK
AMPHENOL
AMPHENOL
14 PIN
LN-25
WIRE FEEDER
TO WORK
WORK CLIP LEAD
OPTIONAL K857
REMOTE CONTROL
N.D. ON COMMANDER 400 STICK & WIRE, THE OUTPUT CONTROL SWITCH MUST BE IN THE "WELDING
TERMINALS ALWAYS ON" POSITION .
N.C. IF REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL/REMOTE SWITCH IN "REMOTE" POSITION.
COMMANDER 400 STICK & WIRE / LN-25 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL K857 REMOTE CONTROL
S22912
12-13-96
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE
AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
Keep guards in place.
or service this equipment.
Keep away from moving parts.
Only qualified personnel should install,use
Do not touch electrically live parts.
before servicing.
Disconnect NEGATIVE (-) BATTERY LEAD
Do not operate with panels open.
WARNING
F-6
DIAGRAMS
F-6
COMMANDER 400
CONNECTION DIAGRAM:
CAUTION :
ELECTRODE
14 PIN
AMPHENOL
TO WORK
TO WORK
WIRE
COMMANDER 400 STICK & WIRE / K867 / LN-8 CONNECTION DIAGRAM
FEEDER
K196
K867 UNIVERSAL
ADAPTER PLUG INPUT CABLE
ELECTRODE CABLE
TO WIRE FEED UNIT
12-13-96
2
4
76
77
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
SPARE
82
Only qualified personnel should install,use
81
before servicing.
or service this equipment.
Keep away from moving parts.
N.C.
Keep guards in place.
Disconnect NEGATIVE (-) BATTERY LEAD
Do not touch electrically live parts.
21
Do not operate with panels open.
GND
N.D.
32
2
WARNING
LN-8
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPICATIONS. SEE OPERATING MANUAL.
75
32
31
41
42
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".
N.D. SPLICE LEADS AND INSULATE.
THE ENGINE WELDER OPERATING MANUAL.
PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION.
GND
31
4
21
B
C
A
S22913
F-7
DIAGRAMS
F-7
COMMANDER 400
CONNECTION DIAGRAM:
ELECTRODE
TO WORK
S22914
12-13-96
CAUTION :
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".
APPLICATIONS. SEE OPERATING MANUAL.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL REMOTE SWITCH IN "REMOTE" POSITION.
COMMANDER 400 STICK & WIRE / LN-7 CONNECTION DIAGRAM
TO LN-7 INPUT
CABLE PLUG
14 PIN
K584 OR K594CONTROL CABLE
AMPHENOL
OPTIONAL K857
REMOTE CONTROL
6 PIN
AMPHENOL
ELECTRODE CABLE
TO WORK
TO WIRE FEED UNIT
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
Keep guards in place.
or service this equipment.
Keep away from moving parts.
Only qualified personnel should install,use
Do not touch electrically live parts.
before servicing.
Disconnect NEGATIVE (-) BATTERY LEAD
Do not operate with panels open.
WARNING
F-8
DIAGRAMS
F-8
COMMANDER 400
CONNECTION DIAGRAM:
GND
75
76
77
GREEN
K291 OR K404
75
INPUT CABLE
76
N.E.
77
TO WORK
K775 OPTIONAL
REMOTE CONTROL
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
14 PIN
81
42
41
31
31
32
32
2
2
4
4
21
21
GND
82
N.D.
ELECTRODE CABLE
TO WIRE FEED UNIT
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPILICATIONS. SEE OPERATING MANUAL.
LN-7
WIRE
FEEDER
COMMANDER 400 STICK & WIRE / K867 / K775 / LN-7 CONNECTION DIAGRAM
SPARE
13-13-96
S22915
}
}
AMPHENOL
TO WORK
N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.E. SPLICE LEADS AND INSULATE.
ELECTRODE
K867 UNIVERSAL
ADAPTER PLUG
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
THE ENGINE WELDER OPERATING MANUAL.
PLACE WIRE FEEDER SWITCH TO "WIRE FEEDER WITH CONTROL CABLE POSITION.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE "RANGE" SWITCH TO "WIRE WELDING CV".
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION.
Keep guards in place.
or service this equipment.
Keep away from moving parts.
Only qualified personnel should install,use
Do not touch electrically live parts.
before servicing.
Disconnect NEGATIVE (-) BATTERY LEAD
Do not operate with panels open.
WARNING
F-9
DIAGRAMS
F-9
COMMANDER 400
CONNECTION DIAGRAM:
Keep guards in place.
Keep away from moving parts.
Only qualified personnel should install,use
or service this equipment.
4
41
2
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
TO WORK
TO WIRE FEED UNIT
ELECTRODE CABLE
ADAPTER PLUG
K867 UNIVERSAL
COMMANDER 400 STICK & WIRE TO K867 ADAPTER CONNECTION DIAGRAM
75
115 VAC
76
77
21
GND
32
31
ELECTRODE
TO WORK
TO
K867
MIN.
10K
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
RELAY TO CLOSE LEADS 2 & 4.
N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY.
14 PIN
AMPHENOL
POWER SOURCE FRAME CONNECTION
Do not operate with panels open.
WIRE FEEDER VOLTMETER CONNECTION
REMOTE OUTPUT CONTROL
CONNECTS TO (WORK TERMINAL) OF POWER SOURCE
TO
WIRE
FEEDER
CAUTION :
THE ENGINE WELDER OPERATING MANUAL.
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
N.E. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW.
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
4
2
S22916
42
WARNING
Do not touch electrically live parts.
before servicing.
Disconnect NEGATIVE (-) BATTERY LEAD
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
82
SPARE
81
N.D.
CONNECT TOGETHER FOR WELDING OUTPUT
NOT USED ON COMMANDER 400 POWER SOURCES
NOT USED ON COMMANDER 400 POWER SOURCES
N.C.
N.E.
N.C.
6-12-98
F-10
DIAGRAMS
F-10
COMMANDER 400
CONNECTION DIAGRAM:
Disconnect NEGATIVE (-) BATTERY LEAD
Do not touch electrically live parts.
14 PIN
AMPHENOL
TO WORK ELECTRODE
before servicing.
Do not operate with panels open.
TO WORK
CAUTION :
THE ENGINE WELDER OPERATING MANUAL.
APPLICATIONS. SEE OPERATING MANUAL.
PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION.
Keep guards in place.
COMMANDER 400 STICK & WIRE / LN-8 CONNECTION DIAGRAM
Keep away from moving parts.
WARNING
Only qualified personnel should install,use
or service this equipment.
TO LN-8 INPUT
K595 CONTROL CABLE
S22917
CABLE PLUG
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".
ELECTRODE CABLE
TO WIRE FEED UNIT
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
12-13-96
F-11
DIAGRAMS
F-11
COMMANDER 400
DIMENSION PRINT
FOR BATTERY
REMOVAL.
19.63
23.69
28.99
50.38
54.44
1.26
6-21-96
45.67
CENTER OF GRAVITY
WITH OIL IN ENGINE
AND FULL FUEL TANK.
6.56
*
63.10
*
6.55
15.75
14.63
*
42.00
37.30
45.38
*
6.53
24.97
BOTTOM VIEW OF
WELDER BASE.
48.64
10.22
29.50
29.50
32.06
48.30
*TRAILER MOUNTING HOLE LOCATIONS.
31.50
M17685
F-12
NOTES
F-12
COMMANDER 400
Now Available...12th Edition
The Procedure Handbook of Arc Welding
With over 500,000 copies of previous editions published
since 1933, the Procedure Handbook is considered by many to
be the “Bible” of the arc welding industry.
This printing will go fast so don’t delay. Place your
order now using the coupon below.
The hardbound book contains over 750 pages of welding infor-
mation, techniques and procedures. Much of this material
has never been included in any other book.
A must for all welders, supervisors, engineers and
designers. Many welding instructors will want to use the book as
a reference for all students by taking advantage of the low quan-
tity discount prices which include shipping by
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$15.00 postage paid U.S.A. Mainland
How To Read Shop Drawings
The book contains the latest information and application
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and drafts-
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assembly and welding information to shop personnel.
Practical exercises and examples develop the reader’s
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to visualize mechanically drawn objects as they will appear in
their assembled form.
187 pages with more than 100 illustrations. Size 8-1/2” x
11”
Durable, cloth-covered board binding.
$4.50 postage paid U.S.A.
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New Lessons in Arc Welding
Lessons, simply written, cover manipulatory techniques;
machine and electrode characteristics; related subjects, such
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applications, speeds and costs. Practice materials, exercises,
questions and answers are suggested for each
lesson.
528 pages, well illustrated, 6” x 9” size, bound in simulated,
gold embossed leather.
$5.00 postage paid U.S.A.
Mainland
Need Welding Training?
The Lincoln Electric Company operates the oldest and
most respected Arc Welding School in the United States at its
corporate
headquarters in Cleveland, Ohio. Over 100,000 students
have graduated. Tuition is low and the training is
“hands on”
For details write: Lincoln Welding School
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199.
and ask for bulletin ED-80 or call 216-383-2259 and ask
for the
Welding School Registrar.
Lincoln Welding School
BASIC COURSE $700.00
5 weeks of fundamentals
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only.Please allow up to 4 weeks for delivery.
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METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)
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USE THIS FORM TO ORDER:
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BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
Lincoln Welding School Titles: Price Code Quantity Cost
(ED-80) New Lessons in Arc Welding $5.00 L
Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH
(ED-45) How to Read Shop Drawings $4.50 H
Educational Video Information Incentive Management $5.00 IM
(ED-93) A New Approach to Industrial Economics $5.00 NA
James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Foundation Book Information Welding Preheat Calculator $3.00 WC-8
(JFLF-515) Pipe Welding Charts $4.50 ED-89
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WARNING
AVISO DE
PRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
●Do not touch electrically live parts or
electrode with skin or wet clothing.
●Insulate yourself from work and
ground.
●No toque las partes o los electrodos
bajo carga con la piel o ropa moja-
da.
●Aislese del trabajo y de la tierra.
●Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
●Isolez-vous du travail et de la terre.
●Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
●Isolieren Sie sich von den
Elektroden und dem Erdboden!
●Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
●Isole-se da peça e terra.
●Keep flammable materials away.
●Mantenga el material combustible
fuera del área de trabajo.
●Gardez à l’écart de tout matériel
inflammable.
●Entfernen Sie brennbarres Material!
●Mantenha inflamáveis bem guarda-
dos.
●Wear eye, ear and body protection.
●Protéjase los ojos, los oídos y el
cuerpo.
●Protégez vos yeux, vos oreilles et
votre corps.
●Tragen Sie Augen-, Ohren- und Kör-
perschutz!
●Use proteção para a vista, ouvido e
corpo.
WARNING
AVISO DE
PRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
●Keep your head out of fumes.
●Use ventilation or exhaust to
remove fumes from breathing zone.
●Los humos fuera de la zona de res-
piración.
●Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
●Gardez la tête à l’écart des fumées.
●Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
●Vermeiden Sie das Einatmen von
Schweibrauch!
●Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
●Mantenha seu rosto da fumaça.
●Use ventilação e exhaustão para
remover fumo da zona respiratória.
●Turn power off before servicing.
●Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
●Débranchez le courant avant l’entre-
tien.
●Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
●Não opere com as tampas removidas.
●Desligue a corrente antes de fazer
serviço.
●Não toque as partes elétricas nuas.
●Do not operate with panel open or
guards off.
●No operar con panel abierto o
guardas quitadas.
●N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
●Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
●Mantenha-se afastado das partes
moventes.
●Não opere com os paineis abertos
ou guardas removidas.
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
STATEMENT OF LIMITED WARRANTY
The Lincoln Electric Company (Lincoln) warrants to the end
user (purchaser) of all new welding and cutting equipment,
electrode and flux (collectively called the “Goods”) that it will
be free of defects in workmanship and material.
This warranty is void if Lincoln or its Authorized Service
Facility finds that the equipment has been subjected to
improper installation, improper care or abnormal opera-
tions.
WARRANTY PERIOD (1) (2) (3)
Lincoln will assume both the parts and labor expense of
correcting defects during the full warranty period. All war-
ranty periods date from the date of purchase to the original
end user and are as follows:
7 Years
• Main power rectifiers on all non-inverter low frequency (50
and 60 Hz) type welders.
3 Years
• All Lincoln welding machines, wirefeeders and plasma
cutting machines unless listed below.
2 Years
• Power Arc 5000
Ranger 10, Ranger 10-LX
Weldanpower 125, Weldanpower 150
1 Year
• AC-100
Invertec V100-S, Invertec V130-S, Invertec V200-T
Power Arc 4000
Pro-Cut 20
• All water coolers (internal or external models)
• All stick electrode, welding wire and flux.
• Arc welding and cutting robots and robotic controllers
• All Environmental Systems equipment, including portable
units, central units, gun and cable assemblies and acces-
sories. (Does not include consumable items listed under
30 day warranty.)
• All welding and cutting accessories including gun and
cable assemblies, TIG and plasma torches, spool guns,
wire feed modules, undercarriages, field installed options
that are sold separately, unattached options, welding sup-
plies, standard accessory sets, replacement parts, and
Magnum products. (Does not include expendable parts
listed under 30 day warranty)
30 Days
• All consumable items that may be used with the environ-
mental systems described above. This includes hoses, fil-
ters, belts and hose adapters.
• Expendable Parts - Lincoln is not responsible for the
replacement of any expendable part that is required due
to normal wear.
CONDITIONS OF WARRANTY
TO OBTAIN WARRANTY COVERAGE:
The purchaser must contact Lincoln or Lincoln’s Authorized
Service Facility about any defect claimed under Lincoln’s
warranty.
Determination of warranty on welding and cutting equipment
will be made by Lincoln or Lincoln’s Authorized Service
Facility.
WARRANTY REPAIR:
If Lincoln or Lincoln’s Authorized Service Facility confirms
the existence of a defect covered by this warranty, the defect
will be corrected by repair or replacement at Lincoln’s
option.
At Lincoln’s request, the purchaser must return, to Lincoln or
its Authorized Service Facility, any “Goods” claimed defec-
tive under Lincoln’s warranty.
FREIGHT COSTS:
The purchaser is responsible for shipment to and from the
Lincoln Authorized Service Facility.
WARRANTY LIMITATIONS
Lincoln will not accept responsibility or liability for repairs
made outside of a Lincoln Authorized Service Facility.
Lincoln’s liability under this warranty shall not exceed the
cost of correcting the defect of the Lincoln product.
Lincoln will not be liable for incidental or consequential dam-
ages (such as loss of business, etc.) caused by the defect
or the time involved to correct the defect.
This written warranty is the only express warranty provided
by Lincoln with respect to its products. Warranties implied
by law such as the warranty of merchantability are limited to
the duration of this limited warranty for the equipment
involved.
This warranty gives the purchaser specific legal rights. The
purchaser may also have other rights which vary from state
to state.
(1) Equipment manufactured for the Lincoln Electric Company is subject to the
warranty period of the original manufacturer.
(2) All engines and engine accessories are warranted by the engine or engine
accessory manufacturer and are not covered by this warranty.
(3) SAE400 WELD N’ AIR compressor is warranted by the compressor manu-
facturer and not covered by this warranty.
LIMITED WARRANTY
Dec, ‘97

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