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FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.

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1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes 
outdoors.

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1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel-
ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

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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.

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1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance.

Remove

guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

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1.f. Do not put your hands near the engine fan. Do

not attempt to override the governor or idler
by pushing on the throttle control rods while
the engine is running.

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1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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SAFETY

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ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-
chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND 
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes 

localized Electric and Magnetic Fields (EMF). Welding 
current creates EMF fields around welding cables and 
welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right 
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
hot.

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

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

CALIFORNIA PROPOSITION 65 WARNINGS

Содержание Commander 400

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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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