Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii; ELECTRIC SHOCK can kill.
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and...
Page 7 - TABLE OF CONTENTS
TABLE OF CONTENTS Page Safety ................................................................................................................................................ i-iv Installation ..............................................................................................................
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS - Commander 400; Deutz; INPUT - DIESEL ENGINE
A-1 INSTALLATION COMMANDER 400 A-1 TECHNICAL SPECIFICATIONS - Commander 400 Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder High Idle 1900 173 cu. in 12VDC battery Fuel: 25 gal. F3L 912 Diesel 44.2 HP(33kw) Low Idle 1350 (2.827 L) & Starter 94.6 L Engi...
Page 9 - SAFETY PRECAUTIONS; STACKING
A-2 INSTALLATION COMMANDER 400 A-2 Read this entire installation section before youstart installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read all operating and maintenance man-uals supplied with your machine. They include impor-tant safety precautions, ...
Page 10 - HIGH ALTITUDE OPERATION; PRE-OPERATION ENGINE SERVICE; OIL; The; Running out of fuel may require bleeding; Before starting the engine, open the fuel shutoff
A-3 INSTALLATION COMMANDER 400 A-3 HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary.As a rule of thumb, derate the welder output 5% forevery 400 meters (1312 ft.) above 1000 meters (3280ft.). Contact a Deutz Service Representative for any engineadjustments that may be re...
Page 11 - FUEL CAP; Use caution as the electrolyte is a strong; MUFFLER OUTLET PIPE; CAUTION
A-4 INSTALLATION COMMANDER 400 A-4 FUEL CAP Remove the plastic cap covering from the Fuel TankFiller neck and install the Fuel Cap. ENGINE COOLING SYSTEM The Deutz engine is air cooled by a belt driven axialblower. The oil cooler and engine cooling fins shouldbe blown out with compressed air or stea...
Page 12 - WELDING OUTPUT CABLES; Table A.1 Combined Length of Electrode and Work; MACHINE GROUNDING
A-5 INSTALLATION COMMANDER 400 A-5 WELDING OUTPUT CABLES With the engine off, route the electrode and workcables thru the strain relief bracket provided on eitherside of the base and connect to the terminals provided.These connections should be checked periodically andtightened if necessary. Listed ...
Page 13 - Take necessary steps to assure load is limited to the; Figure A.2 Connection of the Commander 400 to Premises Wiring
A-6 INSTALLATION COMMANDER 400 A-6 2. Take necessary steps to assure load is limited to the capacity of the Commander by installing a 45 amp,240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 45amperes. Loading above the rated output will reduce output v...
Page 14 - OPERATION; OPERATING INSTRUCTIONS; ADDITIONAL SAFETY PRECAUTIONS; GENERAL DESCRIPTION; RECOMMENDED APPLICATIONS
B-1 OPERATION B-1 OPERATING INSTRUCTIONS Read and understand this entire section before operat-ing your Commander 400. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you havethoroughly read all operating and maintenance man-uals supplied with your machine. They include impor-tant saf...
Page 15 - FOR AUXILIARY POWER; WELDING CAPABILITY
B-2 OPERATION B-2 FOR AUXILIARY POWER • 10,000 watts of 120/240 VAC, 60Hz auxiliary power. • Drive a 2 HP motor (provided it is started under no load). • Two 15 amp 120 VAC duplex receptacles with GFCI protection for up to 30 amps of 120 VAC power. • One 50 amp, 120/240 VAC dual voltage receptacle f...
Page 16 - ENGINE CONTROLS; RUN- STOP SWITCH; CONTROLS AND SETTINGS; Figure B.1 Case Front Panel Controls
B-3 OPERATION B-3 ENGINE CONTROLS (Items 1 through 8) 1. RUN- STOP SWITCH When placed in the “RUN” position, this switch ener-gizes the fuel solenoid and other electric accessories.When placed in the “STOP” position, the flow of fuel tothe injection pump is stopped to shut down the engine.(Note: If ...
Page 18 - WELDER CONTROLS
B-5 OPERATION B-5 WELDER CONTROLS (Items 9 through 14 ) 9. OUTPUT RANGE SWITCH & OUTPUT CONTROL These two controls allow you to select between variouswelding output slopes and adjust the desired weldingoutput. Refer to Table B.1 for a description of howthese two controls work. Table B.1 Output R...
Page 19 - 5 AMP CIRCUIT BREAKERS; WIRE FEEDER MODE CONTROLS; ENGINE OPERATION; STARTING THE ENGINE; COLD WEATHER STARTING / RUNNING; STOPPING THE ENGINE
B-6 OPERATION B-6 17. 120VAC RECEPTACLES These two 120VAC (5-15R) receptacles with GFCI pro-tection provide 120VAC for auxiliary power. Thesereceptacles have a 20 amp total rating. Refer to theAUXILIARY POWER RECEPTACLES section in theinstallation chapter for further information about thesereceptacl...
Page 20 - TYPICAL FUEL CONSUMPTION; Table B.2 Deutz F3L 912 Engine Fuel Consumption; WELDER OPERATION; STICK WELDING; These slope controlled settings are; PIPE WELDING; When a forceful “digging” arc is required, use a higher; GENERAL WELDING; TIG WELDING; ARC GOUGING; Running Time for
B-7 OPERATION B-7 TYPICAL FUEL CONSUMPTION Refer to Table B.2 for typical fuel consumption of theCommander 400’s Engine for various operating sce-narios. Table B.2 Deutz F3L 912 Engine Fuel Consumption WELDER OPERATION STICK WELDING The Commander 400 can be used with a broad rangeof DC stick electro...
Page 21 - Table B.3 TYPICAL CURRENT RANGES
B-8 OPERATION B-8 COMMANDER 400 SETTINGS WHEN USING THEK799 HI-FREQ UNIT a. Set the OUTPUT RANGE switch to the “50-575 set- ting” (Fabrication and General Purpose) b. Set the IDLER switch to the “High “ position. c. Set the LOCAL/REMOTE switch to the “Remote” posi- tion. d. Set the WELDING TERMINALS...
Page 23 - AUXILIARY POWER OPERATION; TABLE B.4 Commander 400 Simultaneous Welding and Power
B-10 OPERATION B-10 AUXILIARY POWER OPERATION Start the engine and set the IDLER control switch tothe desired operating mode. Full power is available regardless of the welding control settings, if no weldingcurrent is being drawn.. The auxiliary power of the Commander consists of two-120VAC (5-15R) ...
Page 24 - ACCESSORIES; RECOMMENDED EQUIPMENT; STICK; does NOT
C-1 ACCESSORIES C-1 OPTIONAL FIELD INSTALLEDACCESSORIES 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 alocation up to the specified length f...
Page 25 - MAINTENANCE; •Have a qualified technician do the maintenance; DAILY; ENGINE MAINTENANCE; AIR FILTER
D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS •Have a qualified technician do the maintenance and troubleshooting work. •Turn the engine off before working inside the machine. •Remove guards only when necessary and replace them when the maintenance requiring theirremoval is complete. •Always use the greate...
Page 26 - FUEL FILTERS; Filter/Water Separator Assembly
D-2 MAINTENANCE D-2 7. Inspect for holes and tears by looking through theelement 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 duringdrying and storage. 8. Reinstall air filter element. After six cleaning...
Page 27 - SECONDARY FUEL FILTER; COOLING SYSTEM; PREVENTING ELECTRICAL DAMAGE
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 longereasily moves up into the filter header. Now rotate theelement (may take almost 1 full turn) with a slightupward pressure until the element begins to furtherengage the head...
Page 28 - Table D.1 Engine Maintenance Components
D-4 MAINTENANCE D-4 COMMANDER 400 Table D.1 Engine Maintenance Components ITEM Air Cleaner Element Cooling Blower Belt Oil Filter Element Fuel Filter Element Water Separator Element Fuel Pre-Filter Screen Battery MAKE Donaldson AC Lincoln Gates Deutz Purolator Napa Fram Deutz Purolator Napa Fram Lin...
Page 29 - TROUBLESHOOTING; Local; for technical troubleshooting assistance before you proceed.; Perform; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 COMMANDER 400 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting ...
Page 30 - ENGINE PROBLEMS; cooling blower; Local Lincoln Authorized
E-2 TROUBLESHOOTING E-2 COMMANDER 400 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshootin...
Page 31 - FUNCTION PROBLEMS; High
E-3 TROUBLESHOOTING E-3 COMMANDER 400 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshootin...
Page 32 - OUTPUT PROBLEMS
E-4 TROUBLESHOOTING E-4 COMMANDER 400 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshootin...
Page 33 - DIAGRAMS
F-1 DIAGRAMS F-1 COMMANDER 400 NO TE: This diag ram is f or ref erence only . It ma y not be accur ate f or all machines co v ered b y this man ual. The specific dia- g ram f or y our par ticular machine is pasted inside the machine on one of the enclosure panels . WIRING DIAGRAM: 240 uF 240 uF 240 ...
Page 39 - CABLE PLUG; TO WIRE FEED UNIT
F-7 DIAGRAMS F-7 COMMANDER 400 CONNECTION DIAGRAM: ELECTRODE TO WORK S22914 12-13-96 CAUTION : AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RP...
Page 41 - COMMANDER 400 STICK & WIRE TO K867 ADAPTER CONNECTION DIAGRAM
F-9 DIAGRAMS F-9 COMMANDER 400 CONNECTION DIAGRAM: Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. 4 41 2 N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. SEE O...
Page 43 - DIMENSION PRINT
F-11 DIAGRAMS F-11 COMMANDER 400 DIMENSION PRINT FOR BATTERY REMOVAL. 19.63 23.69 28.99 50.38 54.44 1.26 6-21-96 45.67 CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK. 6.56 * 63.10 * 6.55 15.75 14.63 * 42.00 37.30 45.38 * 6.53 24.97 BOTTOM VIEW OF WELDER BASE. 48.64 10.22 29.5029.50 32.06 48...
Page 44 - NOTES
Page 45 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th EditionThe 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 ...
Page 48 - Years; CONDITIONS OF WARRANTY; TO OBTAIN WARRANTY COVERAGE:; WARRANTY LIMITATIONS; LIMITED WARRANTY
• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors STATEMENT OF LIMITED WARRANTY The Lin...