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Commander 400

OPERATOR’S MANUAL

IM544-B

June, 1998

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful
operation on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.

For use with machines having Code Numbers:

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

™

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

World's Leader in Welding and Cutting Products

Premier Manufacturer of Industrial Motors

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Summary of Contents for Commander 400

Page 1: ...IS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 9978 10580 S...

Page 2: ...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...

Page 3: ...ical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for co...

Page 4: ...vent 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...

Page 5: ...pri s et non inflammables 4 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...

Page 6: ...e information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes...

Page 7: ...Controls B 5 Auxiliary Power Controls B 5 Engine Operation B 6 Starting the Engine B 6 Stopping the Engine B 6 Break In Period B 6 Typical Fuel Consumption B 6 Welder Operation B 7 Stick Welding B 7...

Page 8: ...mm 1683 lbs 763 kg Stick Wire model OUTPUT WELDER AND GENERATOR Duty Cycle Welding Output Volts at Rated Amps 100 400 amps DC Constant Current 40 volts 400 amps DC Constant Voltage 40 volts 60 500 am...

Page 9: ...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 f...

Page 10: ...moke when fueling Fill fuel tank at a moderate rate and do not overfill Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank OIL The Commander is s...

Page 11: ...g 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 ma...

Page 12: ...h 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 capac...

Page 13: ...able of the desired length The 50 amp 120 240 VAC plug is available in the optional K802R plug kit 4 Plug this cable into the 50 Amp 120 240 Volt recep tacle on the Commander 400 case front Figure A 2...

Page 14: ...f 120 240 volt AC power As a welder it provides up to 400 amps of DC constant current output in six slope controlled ranges In addition a seventh general purpose welding range provides up to 575 amps...

Page 15: ...nds engine life Single side engine service with over the top access to the engine Copper alternator windings and high temperature insulation for dependability and long life ADDITIONAL DESIGN FEATURES...

Page 16: ...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...

Page 17: ...e 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 fo...

Page 18: ...2 LOCAL REMOTE SWITCH The toggle switch on the control panel labeled Local Remote gives the operator the option of con trolling the output at the welder control panel or at a remote station For remote...

Page 19: ...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...

Page 20: ...venth 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 setti...

Page 21: ...500 500 750 750 1000 3 3 3 10 20 15 30 25 40 40 55 55 80 80 125 3 8 2 4 5 10 3 5 5 10 3 5 5 10 3 5 13 17 6 8 15 23 7 11 21 25 10 12 23 27 11 13 28 32 13 15 3 8 2 4 5 10 3 5 5 10 3 5 9 13 4 6 11 15 5 7...

Page 22: ...re 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...

Page 23: ...different phases and cannot be paralleled The auxiliary power receptacles should only be used with three wire grounded type plugs or approved dou ble insulated tools with two wire plugs The current r...

Page 24: ...frequent starting below 10 F 12 2 o 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 R...

Page 25: ...o the Periodic Checks section of the Engine Operator s Manual for the recommended maintenance schedule of the following a Engine Oil and Filter b Air Cleaner c Fuel Filter and Delivery System d Coolin...

Page 26: ...astic 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...

Page 27: ...e 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 tow...

Page 28: ...ent Fuel Filter Element Water Separator Element Fuel Pre Filter Screen Battery MAKE Donaldson AC Lincoln Gates Deutz Purolator Napa Fram Deutz Purolator Napa Fram Lincoln Stanadyne Lincoln Stanadyne P...

Page 29: ...put problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform thes...

Page 30: ...starting Battery does not stay charged 1 Contact your Local Lincoln Authorized Field Service Facility 1 Battery is low Charge Battery 2 Loose battery cable connections Inspect clean and tighten 1 Out...

Page 31: ...e when attempting to weld Engine will not go to high idle when using auxiliary power 1 Idler switch in High idle position Set switch to Auto 2 External load on welder or auxil iary power Remove all ex...

Page 32: ...chapter for proper switch function 1 Local Remote switch is in wrong position Place switch in Local position to control output at welder Place switch in Remote position to control output remotely Ref...

Page 33: ...9B 242I 204B 209 9 237 J16 P16 254 COIL COIL PULL HOLD SOLENOID SHUTDOWN 256 232 224 242D 76C 228 STARTING 206 6 8 15 16 SPI SCI OUTPUT SOURCE CONTROL ALWAYS ON OUTPUT REMOTELY CONTROLLED CW VIEWED FR...

Page 34: ...246 232A FUEL 232F LOW FUEL S TEMP OIL TEMP 243 232E S PRESS 229A 242 5K CONTROL 8A REMOTE B CONTROL C 75D D AUXILIARY BYPASS PCB J 9A 5K 5J 8A A GROUND 242I 242H AMPHENOL 2 75E 7 CB5 15AMP REMOTE 2E...

Page 35: ...ONTROL MODULE Keep away from moving parts ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE Only qualified personnel should instal...

Page 36: ...DER N A WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL 14 PIN S22911 N D ON COMMANDER 400 STICK WIRE THE OUTPUT CONTR...

Page 37: ...REMOTE OUTPUT CONTROL IS USED PLACE LOCAL REMOTE SWITCH IN REMOTE POSITION COMMANDER 400 STICK WIRE LN 25 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL K857 REMOTE CONTROL S22912 12 13 96 N A WELDI...

Page 38: ...O NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN SPARE 82 Only qualified personnel should install use 81 before servicing or service this equipment Keep away from moving parts N C Keep guards in place...

Page 39: ...OPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE N C IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE LOCAL REMOTE SWITCH IN REMOTE POSITION COMMANDER 400 STICK WIRE LN 7 CONNECTION...

Page 40: ...EADS AND INSULATE ELECTRODE K867 UNIVERSAL ADAPTER PLUG CAUTION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN T...

Page 41: ...AMPHENOL POWER SOURCE FRAME CONNECTION Do not operate with panels open WIRE FEEDER VOLTMETER CONNECTION REMOTE OUTPUT CONTROL CONNECTS TO WORK TERMINAL OF POWER SOURCE TO WIRE FEEDER CAUTION THE ENGI...

Page 42: ...use or service this equipment TO LN 8 INPUT K595 CONTROL CABLE S22917 CABLE PLUG N B USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY POSITION THE RANGE SWITCH TO WIRE WELDING CV ELECTRODE C...

Page 43: ...19 63 23 69 28 99 50 38 54 44 1 26 6 21 96 45 67 CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK 6 56 63 10 6 55 15 75 14 63 42 00 37 30 45 38 6 53 24 97 BOTTOM VIEW OF WELDER BASE 48 64 10 22...

Page 44: ...F 12 NOTES F 12 COMMANDER 400...

Page 45: ...letin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for s...

Page 46: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 47: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 48: ...y 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 th...

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