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Lincoln Electric COMMANDER IM544-B User's Manual

1. 86 04 JO MHIA WOLLOS 69 Car er 5 Cora gt 4 D 16775 66 2 4479 AWHHILLVH 97 9 92 TANA TINA UNIONS TIO HLIM COMMANDER 400 LINCOLN E NOTES COMMANDER 400 LINCOLN P 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 4th class parcel post 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
2. AIMS HAA Sei HAS APSA BHC Aal d aul d AAL Gail Gras L STATEMENT OF LIMITED 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 2 9 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 port
3. E IM544 8 Commander NM 400 EE For use with machines having Code Numbers 9978 10580 Stick Model 9979 10581 Stick and Wire Model This manual covers equipment which is obsolete and no longer in production by The Lincoln Electric Co Specifications and Safety Depends on You availability of optional Lincoln arc welding and cutting features may have equipment is designed and built changed 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 MMANDER 400 5 MANUAL ISO 9002 Pi SS 5 LINCOLN amp World s Leader in Welding and Cutting Products ELECTRIC Premier Manufacturer of Industrial Motors Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 1 For Diesel Engines Diesel engine exhaust and For Gasoline Engines The engine exhaust from some of its constituents are known to the State this product contains chemicals known to the of
4. ri tec ee defe ide e aea td Routine and Periodic ss Engine Maintenance EH Air el ti pet ee cerei t tee teo ceder Motu eee oh Cooling System Cooling Blower Belt Engine Maintenance Components Troubleshooting Diagrams and Dimension Print Section F Parts E EE P267 Series COMMANDER 400 LINCOLN 5 Vi 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS Commander 400 INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities System Deutz 3 cylinder High Idle 1900 173 cu in 12VDC battery Fuel 25 gal F3L 912 Diesel 44 2 HP 33kw Low Idle 1350 2 827 L amp Starter 94 6 L Engine 1800 RPM Full Load 1800 Bore x Stroke Oil 8 5 Qts 8 04 3 94 4 72 100mm x 120mm RATED OUTPUT WELDER 400 amps DC Constant Current 40 volts 400 amps DC Constant Voltage 40 volts 500 amps DC Constant Current 40 volts 500 amps DC Constant Voltage 40 volts OUTPUT WELDER AND GENERATOR 40 575 Amps 64 74 OCV 120 240 VAC in 7 Ranges Stick model 10 000 Watts 60 Hz or 8 Ranges Stick amp Wire modell 21915 RPM 10096 Duty Cycle PHYSICAL DIMENSIONS WEIGHT 1650 Ibs 748 kg Stick model 1066 8 mm 800 1 mm 1602 7 mm 1683 Ibs 763 kg Stick amp Wire model 1
5. COMMANDER 400 DIAGRAMS F 9 F 9 CONNECTION DIAGRAM 916225 HOS TYNNVN NOILONALSNI HOANOS OL 5 Z HSOTD OL AYTAN TAIM NOILVIOSI ASN LNdLNO TWNOIS V NANLAA LWHL FAIM OL ATTIWNGIAIGNI 5 ALISV IOd NGOWLOWTIS 5 104145 OL HOLIMS NWSLHALIOA ASN UIVONVN ONILVHNHdO AHS SNOLLVOI IddV CONV ALVIGHWNI dO WIOAO ALNA ILNWWHOO AHL HOS ALIOVdVO AO LSAON VN UIVONVW WHQTISM NI 041617 SNOILLVOI4IOWdS Wdd OO LSNCAY LON OG ANOLOV4 LV 145 444 ONILLAS ANIONS QS9VWVG SLINOUIO HAIM SLIOA OPT WHAO 5909 SIHL AI HOVITOA ANVITIXDV OW AHL HHL NI 5 NV SAV NO ONILLSS HHL ONIONVHO Ag Wdd AIAI HOIH AHL 40 SSVHHONI ANV NOILQVO MHOM OL IOWLNOO 114100 XOT LINQ Gada HAIM OL 5 JO WHOM OL SIOSNNOO NOILOSNNOD eLNAL IOA WHIM NOILLOSNNOO 404005 NOM OL
6. quvog sod NRLIOXE IHdON 2115 00 COMMANDER 400 LINCOLN DIAGRAMS F 2 WIRING DIAGRAM eip 600TTT sjaued y jo euo UO y episui pejsed si sened ano JO Aq JO ejeJnooe eq jou 3 JO SI SIUL 310 ANTON aa aaran d 1111 ore 11771 er 9 5 6 d oa HSHLONW 123 4 2 3 4 i tne a L oe eje don HAIM HOLLS 00 SHONVININOO COMMANDER 400 LINCOLN E DIAGRAMS F 3 F 3 CONNECTION DIAGRAM H 96 T 2T NOLLISOd uHOIHu NI HOLIMS A
7. O1 Proper preventative maintenance of trailer Conformance with federal state and local laws Consult 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 WARNING Stop engine and allow to cool before fueling Do not smoke when fueling Fill fuel tank at a moderate rate and do not overfill Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank OIL The Commander 15 with the engine filled with high quality SAE 10W 30 oil API class CD 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 Operators 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 Operators Manual for the proper ser vice and maintenance intervals FUEL USE DIESEL FUEL ONLY Fill the fuel tank with clean fresh diesel fuel The ity of the fuel tank is 25 gallons 94 6 liters See engine Operators Manual for specific fuel recommendations The Co
8. SIT uu A 5404005 00 NO GASNA LON 5 4983 ONIGTSM AAHLA OL LOSNNOO 9000000 0 5404005 W4MOd 00v 0 NO 5 LON IONSHdWV PI 3queudrnbe 5143 3 Aeme e QVHI AHHLLVH HALLVOHN e ur des e uedo KC ONIAOW ERE ONINAVM Y NOILOZNNOO 983 OL HAIM 40115 007 AXANVWNOD COMMANDER 400 DIAGRAMS F 10 F 10 CONNECTION DIAGRAM 116225 96 ET CT queudtnbs NOILISOd NI HOLIMS XLOWSN TWOOT JAIM OL HOLIMS HONVA AHL NOILISOd ALINVIOd WGOWLOSTIdH GSHISHG 10 1 5 OL HOLIMS MNHLNALIOA ASN IVONVW OSNIILVNHdO AHS SNOILVOI ddV CONV ALVIGHWNI 40 3 IOAO LNAXANO ALIOVdVO 40 LSAN 541 0 V N UIVAONVW ONILVNHHdO AHL GHLSIT SNOILVOIAIOHAS 4A
9. li incon Welding School Titles Price Code Quantity Cost 0 80 New Lessons in Arc Welding 5500 L Vot mation Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings H if 22 Incentive Management IM SEET New Approach to Industrial Economics 5500 NA Educational Video Information 0 93 Lames F Lincoln Arc Welding Foundation Book Information JFLF 515 Welding Preheat Calculator m WC8 Pipe Welding Charts 450 SUB TOTAL Additional Shipping Costs COST lt lt 4 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e elec
10. 90 120 180 230 270 400 Max current on each setting Provides a fine adjustment of welding current or voltage from Min 1 to Max 10 within each range Constant Current Output for Fabrication and General Purpose Welding This set ting also used for TIG all models 1 Range setting 50 575 Amps 1 Range setting 12 to 40 Volts Constant Voltage Output for Wire Welding Stick amp Wire model only 1 If the OUTPUT RANGE switch is positioned between settings the previous setting is maintained until the switch is properly positioned on a setting OUTPUT CONTROL also controls O C V while in the 6 sloped 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 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 OPERATION B 5 With the switch in the Welding Terminals Always On position the contactor is closed and the welding termi nals are always With the switch in the Welding Terminals Remotely Controlled position t
11. Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 1096 at all loads up to rated capacity When welding available auxiliary power will be reduced 2 Top of Enclosure Add 6 64 168 7mm for exhaust COMMANDER 400 LINCOLN amp 2 INSTALLATION 2 Read this entire installation section before you start installation SAFETY PRECAUTIONS A WARNING 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 can kill 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 D 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 engin
12. 1 fuel tank Fuel pre filter water separator with dry change ele ment Automatic idler reduces engine speed when not weld ing or drawing auxiliary power This feature reduces fuel consumption and extends engine life Single side engine service with over the top access to the engine COMMANDER 400 Copper alternator windings and high temperature insulation for dependability and long life ADDITIONAL DESIGN FEATURES AND ADVANTAGES Stick amp 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 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 amp K488 Module WELDING CAPABI
13. 10 one location 4 lorders 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 IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value to 549 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 North America invoiced orders over 50 00 A credit card orders if UPS is requested it will be invoiced charged to you at cost Outside U S A Mainland order must be prepaid U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders CHECK ONE Address Please only if order is over 550 00 Check or Money Order Enclosed U S Funds only Credit Card gt Telephone Signature as it appears on Charge Card E LILI exe ate USE THIS FORM TO ORDER Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 looks OR INFORMATIVE CATALOGS Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901
14. 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 the triggering device remains pressed but no weld ing load is applied within approximately 15 seconds the engine will return to low idle speed f 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 LINCOLN 5 WELDER CONTROLS Items 9 through 14 9 OUTPUT RANGE SWITCH amp 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 Pipe Welding all models Settings
15. B 2 Selection of hot or cold output terminals with tog gle switch on the control panel This feature can also be controlled by installing a remote output terminal control cable designed to open and close the 2 and 4 leads in the amphenol receptacle FOR AUXILIARY POWER 10 000 watts 120 240 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
16. Power Connections ii lt ee Safety INStructions er qae emet de Yr ee IG Wade dos General Description Recommended Applications Design Features and 1 Welding Capability Controls arid Settings ce es ee e ee a A RUE e eei Engine Controls Welder Controls Auxiliary Power Control ceto Pie co T d e B 5 Engine Operation aise ete tae c egets e egt bere bie idees duet eae Starting the Engine Stopping the Engine aie eene tune iade cit ttim d eet coe nimes Cede de n Typical Fuel Consumption Welder Operatiori nece edad o Tert elle EA te EEN Pipe Welding General Welding TIG Welding Arc Gouging Wire Feed Constant Voltage Welding Connection of Stick and Wire model to LN 25 LN 7 LN 8 LN 23P or 3 B 9 Auxiliary Power Operation Simultaneous Welding and Auxiliary Power Loads B 10 ACCeSSOLFIGS eege cec ero Optional Field Installed Accessories Recommended Equipment iii High Frequency Generators For TIG 1 RE Safety Precautions
17. 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 Also see item 1 c LINCOLN amp CYLINDER may explode if damaged 7 a Use only compressed 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 Always keep cyl
18. 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 amp 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 amp Light Kit K965 1 Cable Storage Rack K825 1 ETHER START KIT Provides maximum cold weather starting assistance for frequent starting below 10 F 122 C 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 Ext
19. 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 LINCOLN 8 8 8 Table TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES DCEN DCEP Tungsten Electrode Diameter 1 2 Thoriated Tungsten 1 2 Thoriated Tungsten 2 15 5 20 15 80 70 150 150 250 250 400 400 500 500 750 750 1000 Approximate Argon Gas Flow Rate I min TIG TORCH Nozzle Size 4 5 Aluminum Stainless Steel 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
20. 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 GF
21. 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 general these tests can be conducted with out removing the case wrap around cover CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed COMMANDER 400 LINCOLN 8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION Major Physical or Electrical Damage 1 is Evident Engine will not crank Engine will crank but not start Engine shuts down shortly after starting Battery does not stay charged ENGINE PROBLEMS Contact your Local Lincoln Authorized Field Service Facility Battery is low Charge Battery Loose battery cable connections Inspect clean and tighten Out of fuel Fill prime tank Fuel shut off valve is in off position High oil temperature Indicator light lit Check engine cooling system Consult engine service dealer Low battery voltage Low fuel Indicator light lit Add fuel Low output of battery charging alternator Indicator light lit Check cooling blowe
22. pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage L Arc 1 Protegez vous contre secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger co
23. to Auxiliary Connections in the Installation and Operation chapters Faulty connections to auxiliary receptacles Check connections GFCI tripped Clear any ground fault and reset GFCI circuit by pressing Reset button on the 120 V receptacle CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed COMMANDER 400 LINCOLN 8 DIAGRAMS F 1 F 1 WIRING DIAGRAM 86 51 5 eip Sjoued eunsoj oue y euo uo pejsed si 1 10 Aq ejeunooe jou 3 89U819 91 s SIUL 310 mr TITTIS Stel es m gt t Em CET nues is ie TONINOO ATHLON gt B 424224224271
24. trodos com a pele ou roupa molha da 1501 da e terra RABE ELE KEE 945 MAIER e Xe nisle e AXE HZA ole Je do gi el ai QuAL el ai ay d o ell Aal aal All E die e Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos CORRE e i 9 E ML IF LS AS Aal uie dall pis Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und perschutz Use prote o para a vista ouvido e corpo HRUBS ISUCRSREUCT ez 119 59 s ESSA due lan Al e 4 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUM ABLES 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 SI
25. 081611 Wdd 3AOQV 5 LON OG ANOLOVA LV 145 SI ONILLHS ANIONS HH 81100412 IONLNOO WEQSH4 FAIM SLIOA OFT 0 5909 SIHL 4I HHL NI 9 NV TIIM HHL NO ONILLZS HHL ONIONVHO Ad 101 HOIH dO 5 ANN TOULNOD SLOWHMN IVNOILdO 5112 MHOM OL LINN dd 5 1987 SISVO L dNI HO 6 t Y XJ dads HAIM L N I queudtnbs 5743 3 30 jou esn T easur ATU e e AWX LLLVH e ur deo e s eued jou od e SLAYd ONIAOW 5 01410313 ONINHVM Wy NOLLOHNNOO L NI GLLM 1987 HAIM 5 MOILS OOF
26. 5 OL HOLIMS AALANL IOA ASN UIVANVW ONILVAHAdO 445 SNOILVOIddV SHOLOS ALVIGHWNI AO W IDAO ALNA LNSNHOO AHL 404 ALIOVdVO AO LSAN WIHVO ONIG ISM FHL GHLSIT SNOILVOISIOddS LSACACY LON OG ASNOLOVS HHL 185 444 SI ONILLYS YONYHAOD S3NIONS 51 MACHA HAIM SLIOA OFT 0 5409 SIHL AI HOWL IOA ANVITIXDV OV HHL SSVSWONI NV ASOVO HOVANIT S LLLOWHL AHL YO 145 WONWSAOD ONIONVHO Wad HOIH SHL AO ASVHYONI AN 1 NOLLNWO OL LINN OL ONId IVSHHAINQ 1987 LOdNI 96TA HUOM OL PT HAIM 8 NT sty ode prnous e 91070q e AWSLLVH e ur
27. 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 amp 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 LINCOLN B 2 OPERATION
28. CI protection and one 50 120 240 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 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 A2 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 COMMANDER 400 LINCOLN 6 INSTALLATION 6 2 Take necessary steps to assure load is limited to the 3 Install a 50 amp 120 240 VAC plug NEMA Type 14 capacity of the Command
29. COLN amp 5 INSTALLATION 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 TOTAL COMBINED LENGTH OF ELEC TRODE AND WORK CABLES AMPS Up to 150 150 200 FT 200 250 FT 810096 FT Duty Cycle 250 1 AWG 1 AWG 400 3 0 ANG 3 0 AWG MACHINE GROUNDING 1 0 AWG 4 0 AWG 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
30. California to cause cancer birth defects and State of California to cause cancer birth defects other reproductive harm or other reproductive harm ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety Welding amp Cutting ANSI Standard 249 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 Free copy of Arc Welding Safety booklet 205 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 ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 X 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS 3 may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fie
31. GA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS 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 UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP5o5SUtRcXo5cuc 9 fsPBHEILTABESUCFEU c EUR Bit MaRS SH7IAE S XACE E AAS AH FAAA H4 Qai dul jaa jl axial os Qui BAL al ue Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualqui
32. ICI NOLLISOd HOLIMS IWOOT NId 9 OL SI IOWLNOO LAdLNO 2581 TYNOILAO NOLLISOd 4QGWTIOWLNOO OL HOLIMS S IVNINAAL OL HOLIMS AHL NOILISOd ALIAVIO4d SHGOWLOWIS GSHISHG 104145 OL HOLIMS NWiLHALIOA ASN IVONWW 445 SNOILVOI IddV WHOIS dO ALNA AHL 404 ALIOVAVO 40 LSOW ONIGISM UIVONVWN ONILVHHdO AHL NI GHLSTT 5 5 15 LON OG ANOLOVS AHL LV 5 SI ONILLAS AHL GCHOVIAVG SLIQONIO 5 OPI SHOD SIHL HHL NI HSVHSHONI NV HSQVO TITIM W LLLOWHIL ONIGINNHSAO 145 AHL Ad AICI HOIH 5 HO GNV SINGOW IOXLNOO AHL OL NI L INSHH NOILISOd HOLIMS OL DNILANALLY NOILLISOd 050 LOWLNOD 4NIOONIT NI SI HOLIMS 5 AGOW L
33. LITY The Commander 400 is rated at 400 amps 40 volts at 10096 duty cycle The weld current is variable from 40 to 575 amps MAY96 LINCOLN 3 B 3 CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel Refer to Figure 1 and the explanations that follow Figure B 1 Case Front Panel Controls 20200 00000072 aaa y 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 C 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
34. O IOWLNOOT6S8M 7843 BN MU WISVO VI L dNI Z N T OL queudrnbe styq 3 e e107eq d y e SALLVOHN e ur s eued jou od e SLAYd ONIAOW 01410313 ONINHVM Wy WVNOVIG NOILOSNNOO L NT HAIM 5 MOILLS 00 MWHONVWWOO COMMANDER 400 DIAGRAMS F 8 F 8 CONNECTION DIAGRAM 516228 96 ALV INSNI ONV SAWAT 21145 QVA T GHSNNN ALV INSNI NOILISOd uALOWAUu NI HOLIMS HOV Id SI LNdINO ALOWHY 40 NOLLISOd IOWLNOO HLIM JAIM OL HOLIMS HAIM HOV Id ONIGISM SHIMa OL HOLIMS NOILISOd ALIHVIOd 104145 OL HOLIMS AALANLIOA ASN ONILVHHdO AHS SNOLLVOI IIddV CONV ALVIGHWWI 41929 ALNA LNSWNHOO AHL ALIOVdVO AO LSOAW WN UIVONVW ONIIVEHdO ANIONS
35. OHV LSACAV LON Od JHL LV 1 5 SI 5 SNIONS AHL OC SLINOUIO IOWLNOO SLIOA OFT SHOD HOVLIOA SIHL HOVL IOA ANVITIXQV AHL AHL NI ASVAUONI NV ASANVO HOVANIT W LLLOWHIL ONILLAS HHL ONIONVHO ATAI HOIH AHL 5 ANW OL LINA OL S IHVO GOHILOSTS MXuoM OL NOIL QVO TONSHdWV ST 47870 IOWLNOO 4643 LAGNI 8 NT OL yono e 91079q desx e ANALLYA HAILVOHN e e jou oq Spivd ONIAOW 1 uo 35OHS DLO ONINSHVM WVWOVIG NOILOHNNOO 8 1 HAIM HOLLS 005 COMMANDER 400 DIAGRAMS F 11 F 11 DIMENSION PRINT S89LTN SNOILVOOT ATOH ONILNNOW TAM
36. RANGE switch to the WIRE WELDING CV position e Set the OUTPUT CONTROL switch to the OUT PUT REMOTELLY CONTROLLED position Set the IDLE switch to the HIGH position CAUTION When the gun trigger is closed the electrode is energised and the wire will begin to feed STICK AND WIRE MODEL CONNECTION TO LN 23P a Shut the welder off b Connect the LN 23P as per instructions on the appropriate connection diagram in DIAGRAMS section NOTE When connecting an LN 23P to the Commander Stick amp Wire 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 ONT Set the VOLTS AMPS switch to VOLTS 9 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
37. RE 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 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 amp 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 moto
38. S SNOLLVOI IddV HANLANA WHGOHLOH IH WWI HIOAO ALNG LNHNWHOO AHL HOS ALIOVdVO LSAN MHOM OL NL HAIM 5 2 aval IO LLNOO ALONSA LS883 eru esn reasur e S34aed e e NId St jou ode AUALIVA HSAILVONN 0 e jou 5 0110313 DNINAVM LS8X IVNOILdO HLIM NOILOSNNOO DEV HHL 550404 SC NT HAIM 5 XOILS 007 COMMANDER 400 LINCOLN E DIAGRAMS F 6 F 6 CONNECTION DIAGRAM 6208 96 ALWINSNI SAWAT HOI IdS VAT GHSONN ALVINSNI NOILISOd ALOWA HOLIMS TWOOT uhh ONIG IHM JAIM OL HOLIMS AHL SNGO LOW IH 10 1
39. VHL 4405 MHOM OL HINGOW IOWLNOO OL HGOOWLOS IM C VY i SGONIOSTS TIVO LAANT OI I69X ALONAU NId 9 3TOVLdSOSN ANIM 10045 SC L8YVM OWINOO DS 887A A e SIOVIldSOSH ASIT 3queudrnbe 3 yonoq ode euuoszed ATu e Aeme desx e AWHLLVH HALLVOHN e ur 4 uodo s eued SRE ZEN l ub 32OHS 2l312313 ONINHVM Wy WVHOVIG NOILOSNNOO 70045 2877 887 0 694 HAIM HOILS 005 COMMANDER 400 116 5 NOILISOd 4 QW TIIORLNOO S TVNIWAAL DIAGRAMS F 4 CONNECTION DIAGRAM HHL NI LSAW HOLIMS LOdLNO HHL 9 MOILS 00v NO NOILISOd HOLIMS HLONHU IVOOT ASN SI OWLNOO 104100 HLONHU 4I ALTAV IOd 104145 OL HOLIMS AALANL IOA ONILVHdHdO 445 SNOILVOI I
40. able 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 s ei er peri ed perde pere per per el pe per pel per el per er el per perl pe e per pel el e pel er pe el er er er e LIMITED WARRANTY 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
41. air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 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 Mar 95 SAFETY WELDING SPARKS gt 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 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 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 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
42. auxiliary power 100 watts Idler may not respond with less than a 100 watt load Set Idler to High CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed COMMANDER 400 LINCOLN 8 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION OUTPUT PROBLEMS No welding power output Welding terminals switch in wrong position Place switch in Always On position when welding without welding terminal control cable Refer to Operation chapter for proper switch function Welder has output and no control 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 Poor remote kit connection Check connections Faulty remote kit Replace if nec cessary Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance No auxiliary power 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
43. bale if itis 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 COMMANDER 400 LINCOLN amp 3 INSTALLATION HIGH ALTITUDE OPERATION At higher altitudes output derating may be necessary As a rule of thumb derate the welder output 596 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 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
44. 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 amp Wire refer to the NA 3 Welding System instruction manual COMMANDER 400 LINCOLN 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 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 th
45. 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 Equipment manufactured for the Lincoln Electric Company is subject to the warranty period of the original manufacturer All engines and engine accessories are warranted by the engine or engine accessory manufacturer and are not covered by this war
46. 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 Engine Oil and Filter Air Cleaner Fuel Filter and Delivery System Cooling Blower Belt Battery Cooling System D OD OO D Refer to Table D 1 at the end of this section for various engine maintenance components AIR FILTER CAUTION EXCESSIVE AIR FILTER RESTRICTION WILL RESULT IN REDUCED ENGINE LIFE The air filter element is a dry cartridge type It can be cleaned and reused however damaged elements should not be reused Stop engine after 100 hours of running time and clean filter element replace the fil ter if necessary Service air cleaner regularly accord ing to Engine Operators Manual 1 Locate the air filler canister located behind the engine door on the top of the engine 2 Remove air filter element 3 Remove loose dirt from element with compresse
47. d y uodo s eued e ub 614 4 ONIAOW 1 ub 35OHS OLAS ONINSHVM WVHOVIG NOILOSNNOO 8 NT 4987 5 0115 007 COMMANDER 400 DIAGRAMS F 7 F 7 CONNECTION DIAGRAM 976228 96 5 4 NI HOLIMS SLOWEY TWOOT HOV Id AHSA SI IOMLNOD INALNO IVNOILdO AI UIVANVW ONILVHHdO AAS SNOILVOI IddV SHOLOS ALVIGHWNI AO HTOAD ALNA LNSWHOO AHL 404 ALIOVdVO AO LSAW SATAY uhh SAIM OL HOLIMS AHL NOLLISOd ALINVIOd sGOLLOsS IHS 104145 OL HOLIMS NHLHALIOA ASNA V N TWONVW ONILVHHdO AHL NI G amp LSIT 5 LSNCAY LON OG AHL LV 145 4 SI ONIJLLSS HONWHAOD SNIONS AHL SLIDQONIO JAIM SLIOA 5400 SIHL 0 OV AHL AHL NV ASAVO TIIM NILLAS ONIONVHO Ad STAI HOIH HHL AO 5 ANW NOILAWO MHOM OL LINO Gadd OL Aavo HGOOLOH IH TONSHANW HOM OL _ NId 9 ALOWA LS8X TWNOILd
48. d 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 160 F 71 Do not use a light bulb to dry the ele ment COMMANDER 400 LINCOLN 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 ju
49. ddV ALVIOHNNI HO ALNA INAAAND AHL AOA ALIOVdVO LSOW WIHVO ONIC IAM HAOM OL HGO LLOW IH 9 queudrnbe styq e Aeme dooye ur desye up ONIAOW ode AWHLLVH HAILVOHN e jou u6 345OHS 21419413 ONINSHVM NOILLOHNNOO dr NI HAIM 9 MOLLS 007 NId COMMANDER 400 LINCOLN E DIAGRAMS F 5 F 5 CONNECTION DIAGRAM 216225 96 ET 2T ONIQ IAMu 4 NI NOILISOd ISAW HOLIMS IOMLNOD AHL HAIM NOILISOd nu ALONA SAVM IV S IVNINANHL MOILS 007 HZIGNVWIANOO NO HOLIMS XLONWHN IVOOTI GHSN SI TIOMLNOD LNdINO X4GOWLOS IH QAAAISHA 104145 OL HOLIMS AALANL IOA ASNA UIVONVW AA
50. drafts men use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability 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 Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding 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 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 5 weeks of fundamentals 700 00 There is a 10 discount on all orders of 50 00 or more for shipment at one time
51. e electrode lead around your body 14 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 es 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 AN Connect the work cable to workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits 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 sittin
52. e 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 Usethe 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 WARNING FALLING EQUIPMENT can cause injury Do not lift this machine using lift
53. e light will go on and stay on when the RUN STOP switch is switched to the 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 the high idle speed controlled by the governor In the Auto lt gt 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
54. elding the electrode cable connects to terminal and the work cable connects to this terminal For negative polarity welding the work cable connects to 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 T 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
55. ension 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 LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING Have a qualified technician do the maintenance and troubleshooting work Turn the engine off before working inside the machine Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Read the Safety Precautions in front of this manual and the engine instruction manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair 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
56. er by installing a 45 amp 50 to the double pole circuit breaker using No 6 4 240 VAC double pole circuit breaker Maximum conductor cable of the desired length The 50 amp rated load for each leg of the 240 VAC auxiliary is 45 120 240 VAC plug is available in the optional K802R amperes Loading above the rated output will plug kit reduce output voltage below the allowable 10 of rated voltage which may damage appliances or 4 Plug this cable into the 50 Amp 120 240 Volt recep other motor driven equipment and may result in tacle on the Commander 400 case front overheating of the Commander 400 engine Figure A 2 Connection of the Commander 400 to Premises Wiring 240 VOLT GROUNDED CONDUCTOR om Diesel si 60 Hz 3 Wire COMPANY d Service METER LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES DISCONNECT AND SERVICE GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE CIRCUIT 240 VOLT BREAKER 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 1 N M 50 AMP 120 240 VOLT NE ERI EN RECEPTACLE NOTE No 8 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS COMMANDER 400 LINCOLN amp B 1 OPERATION B 1 OPERATING INSTRUCTIONS Read and understand this entire section before operat ing your Commander 400 SAFETY INSTRUCTIONS WARNING Do not attempt to use this equi
57. er header COMMANDER 400 LINCOLN 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 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 car
58. er servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig Oft nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e X7TTL 2A 9 UAVCBRUD PRE gt e HERES BEER e Meg xp ett Als Jl ale Do not operate with panel open guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas EX BUS e 40 del AS L t Cols Vil lu Qai ye Al ll Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it is BIR LEIA E COMPREENDA AS INSTRUC ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR moi s THHORERME CF eU Rr de FH B SR
59. g 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 plates to protect your eyes from the rays of the arc when welding or observing open arc welding Headshield and filter lens sho
60. gle 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 rent protection for each 120V circuit at the 240V recep tacle COMMANDER 400 LINCOLN 6 B 6 17 120VAC RECEPTACLES These two 120VAC 5 15 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 120 receptacle 19 GROUND STUD Provides 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 amp 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 w
61. harpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l in
62. he 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 remore 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 sin
63. inders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 iv SAFETY iv PR CAUTIONS DE Pour votre propre protection lire et observer toutes les instructions et les
64. lds EMF Welding current creates EMF fields around welding cables and welding machines 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 spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety do ger minimize exposure to fields from welding circuit 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 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil th
65. le 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 ELECTRICAL OUTPUT CONNECTIONS 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 CAUTION An incorrect arrester may lead to damage to the engine or adversely affect performance See Figure 1 for the location of the weld output terminals ground stud and auxiliary power receptacles 120 VOLT RECEPTACLES CV WORK WELD OUTPUT TERMINAL 240 VOLT RECEPTACLE GROUND STUD WELD OUTPUT TERMINALS ELECTRODE CC WORK FIGURE A 1 Weld Terminal Ground Stud and Auxiliary Power Receptacle Locations COMMANDER 400 LIN
66. 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 LINCOLN B4 OPERATION B 4 4 ENGINE TEMPERATURE GAUGE AND 4 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 E 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 Th
67. mm 7 7 16 in 11 mm 8 1 2in 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 less prone to breakage but cannot withstand high temperatures and high duty cycles COMMANDER 400 SETTINGS WHEN USING THE K799 HI FREQ UNIT a Set the OUTPUT RANGE switch to the 50 575 set ting Fabrication and General Purpose b Set the IDLER switch to the High position COMMANDER 400 SETTINGS WHEN USING THE K930 1 TIG MODULE m Set the OUTPUT RANGE switch to the 50 575 Setting Fabrication and General Purpose IDLER switch to the Auto position c Set the LOCAL REMOTE switch to the Remote posi c Set the LOCAL REMOTE switch to the Remote posi tion tion d Set the WELDING TERMINALS switch to the Welding d Set the WELDING TERMINALS switch to the Welding Terminals Always On position This will close the solid 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 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 LINCOLN B 9 OPERATION B 9 WI
68. mmander 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 COMMANDER 400 LINCOLN amp 4 INSTALLATION 4 FUEL 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 cab
69. ntre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la c
70. 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 O F If the engine must be frequently started below 10 F 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 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 pe
71. pment 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 can kill 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
72. r 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 IDLE switch to the AUTO position When not welding the Commander 400 S amp 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 Set the VOLTMETER switch to either or as required by the electrode being used d Set the
73. r belt Replace if neccessary High oil temperature Indicator light lit Check engine cooling system Consult engine service dealer Faulty battery Replace Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed COMMANDER 400 LINCOLN 8 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION FUNCTION PROBLEMS Engine will not idle down to low ldler switch in High idle position speed Set switch to Auto External load on welder or auxil iary power Remove all external loads Engine will not go to high idle when 1 Poor work lead connection to attempting to weld work Make sure work clamp is tightly connected to clean base metal 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 Contact your Local Lincoln Authorized use of this switch Field Service Facility for technical troubleshooting assistance Engine will not go to high idle when 1 Auxiliary power load is less than using
74. ranty 9 SAE400 WELD N AIR compressor is warranted by the compressor manu facturer and not covered by this warranty prr eee pr rr EEE LINCOLN amp World s Leader in Welding and Cutting Products ELECTRIC 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 Premier Manufacturer of Industrial Motors s ale ee Dec 97
75. ree wire grounded type plugs or approved dou ble insulated tools with two wire plugs OPERATION B 10 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 TABLE B 4 Commander 400 Simultaneous Welding and Power Loads Welding Output Range Setting Welding Output 500A 40V 400A 36V 270A 31V 230A 29V 180A 27V 120A 25V 90 24 Permissible Permissible Auxiliary Unity Power Factor 120 V 10 240 V 10 Each GFCI duplex receptacle is limited to 15 amps Not to exceed 44 per 120 branch circuit when splitting the 240 VAC output COMMANDER 400 LINCOLN 1 ACCESSORIES 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 6 pin
76. riod 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 LINCOLN 8 7 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 44 2 Hp 1800 RPM 25 gallons Hours Low Idle No Load 1350 RPM 30 gallons hour 1 36 liters hour High Idle No 78 gallons hour Load 1900 RPM IW 3 55 liters hour DC CC Weld 1 84 gallons hour 8 36 liters hour 10 000 VA 1 32 gallons hour 6 00 liters hour 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 characte
77. ristic 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 60 duty cycle and 250A at 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
78. rush 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 filt
79. sitive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING 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 be careful when working near battery Follow instructions printed 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 LINCOLN 0 4 MAINTENANCE Table D 1 Engine Maintenance Components ITEM MAKE PART NUMBER Air Cleaner Element Donaldson 181052 A302C Cooling Blower Belt Lincoln T13536 3 Gates 7585 Oil Filter Element Deu
80. st 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 an alternating pattern to gradually remove the pre filter screen 5 B
81. tement appears where the information must be followed to avoid minor personal injury or damage to this equipment 5 rii RC i iv Installation m Technical Specifications 1 Safety Pr cautions endi t cete eire eese A 2 Eocation oco eer eret Ee n ete retirar ee o te eed EL A 2 Stacking DEER 2 Angle of Operation i EE A 2 IB reped a en 2 High toe fors A 3 TOWING A 3 Pre Operation Engine Service iii A 3 EIB 3 iil PEE A 3 Fuel Cap DEE A 4 Engine Cooling 518 n ct iet nage RO ace eee ee ees A 4 Battery Connection sise A 4 Muffler Outlet tentera Venere ane A 4 Spark Arrestert Aug ne Rent a A 4 Electrical Output Connections A 4 Welding Output Cable Sisene eeren e eee 5 Machine Grounding Ad 5 Auxiliary Power Receptacles 5 Standby
82. terrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place LINCOLN for selecting QUALITY product by Lincoln Electric We want you kont You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This sta
83. tridge 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 amp 8 BATTERY HANDLING A WARNING 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 po
84. tz 1174418 Purolator PER2168 Napa 1820 Fram PH3776 Fuel Filter Element Deutz 1174423 Purolator PC42 Napa 3358 Fram P4102 Water Separator Element Lincoln M16890 C Stanadyne 31572 Fuel Pre Filter Screen Lincoln M16890 B Stanadyne 29575 Battery Group 34 COMMANDER 400 LINCOLN 8 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Step 3 RECOMMENDED COURSE OF Look under the column labeled PROBLEM ACTION SYMPTOMS This column describes pos sible symptoms that the machine may exhib f you have exhausted all of the items in step it Find the listing that best describes the 2 Contact your Local Lincoln Authorized symptom that the machine is exhibiting Field Service Facility Symptoms are grouped into the following categories engine problems function prob lems and output problems Step 2 PERFORM EXTERNAL TESTS The second column
85. uld conform to ANSI 287 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 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 23 FUMES AND GASES 4 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 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 Shielding gases used for arc welding can displace

Lincoln Electric COMMANDER IM544-B User's Manual

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