For use with machines having Code Numbers:

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.

9978, 10580 (Stick Model),

9979, 10581 (Stick and Wire Model)

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SAFETY

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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.

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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

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.

Mar ???95

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits are electrically ???hot??? when the welder is on. Do not touch these ???hot??? parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

???Semiautomatic DC Constant Voltage (Wire) Welder.

???DC Manual (Stick) Welder.

???AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically ???hot???.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically ???hot??? parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer???s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer???s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ???95

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SAFETY

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WELDING SPARKS can cause fire or explosion.

6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot

materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to ???Safety in Welding and Cutting??? (ANSI

Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been ???cleaned???. For information, purchase ???Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous

Substances???, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits.

This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

???Away from areas where they may be struck or subjected to physical damage.

???A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically ???hot??? parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,

???Precautions for Safe Handling of Compressed Gases in

Cylinders,??? available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer???s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer???s recommendations.

Mar ???95

PR??CAUTIONS DE S??RET??

Pour votre propre protection lire et observer toutes les instructions et les 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 A L???Arc

1.Protegez-vous contre la 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.

b.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.

c.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.

e.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.

f.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 contre 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.

3.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.

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- talons sans revers, et chaussures montantes.

5.Toujours porter des lunettes de s??curit?? dans la zone de soudage. Utiliser des lunettes avec ??crans lateraux dans les zones o?? 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.

7.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.

8.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 charpente 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.

9.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.

2.Autant que possible, I???installation et l???entretien du poste seront effectu??s par un ??lectricien qualifi??.

3.Avant de faires des travaux ?? l???interieur de poste, la debranch- er ?? l???interrupteur ?? la boite de fusibles.

4.Garder tous les couvercles et dispositifs de s??ret?? ?? leur place.

Mar. ???93

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Thank You

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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 entire installation section before you start installation.

SAFETY PRECAUTIONS

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 SHOCK can kill.

???Do not touch electrically live parts such as output terminals or internal wiring.

???Insulate yourself from the work and ground.

???Always wear dry insulating gloves.

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ENGINE EXHAUST can kill.

???Use in open, well ventilated areas or vent exhaust outside

???Do not stack anything near the engine.

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MOVING PARTS can injure.

???Do not operate with doors open or guards off.

???Stop engine before servicing.

???Keep away from moving parts

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Only qualified personnel should install, use or service this equipment

LOCATION/VENTILATION

The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area.

STACKING

Commander 400 machines cannot be stacked.

ANGLE OF OPERATION

To achieve optimum engine performance the Commander 400 should be run in a level position. The maximum angle of operation for the Deutz engine is 20 degrees in a direction to cause the control panel to be angled up, 30 degrees for side to side tilting and for the control panel to be angled down. If the engine is to be operated at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity in the crankcase. When operating the welder at an angle, the effective fuel capacity will be slightly less than the specified 25 gallons.

LIFTING

The Commander lift bale should be used to lift the machine. The Commander is shipped with the lift bale retracted. Before attempting to lift the Commander the lift bale must be secured in a raised position. Secure the lift bale as follows:

a.Open the engine compartment door.

b.Locate the 2 access holes on the upper middle region of compartment wall just below the lift bale.

c.Use the lifting strap to raise the lift bale to the full upright position. This will align the mounting holes on the lift bale with the access holes.

d.Secure the lift bale with 2 thread forming screws. The screws are provided in the shipped loose parts bag.

WARNING

FALLING EQUIPMENT can cause injury.

???Do not lift this machine using lift bale if it is equipped with a heavy accessory such as a trailer or gas cylinder.

???Lift only with equipment of adequate lifting capacity.

???Be sure machine is stable when lifting.

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HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary. As a rule of thumb, derate the welder output 5% for every 400 meters (1312 ft.) above 1000 meters (3280 ft.).

Contact a Deutz Service Representative for any engine adjustments that may be required for high altitude operation.

TOWING

The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle(1) is Lincoln???s K953-1. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:

1.Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments.

2.Proper support of, and attachment to, the base of the welding equipment so that there will be no undue stress to the trailer???s framework.

3.Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself.

4.Typical conditions of use, such as travel speed, roughness of surface on which the trailer will be operated, and environmental conditions.

5.Proper preventative maintenance of trailer.

6.Conformance with federal, state and local laws.1

1Consult applicable federal, state and local laws regarding specific requirements for use on public high- ways.

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instruc- tions supplied with this machine.

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.

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OIL

The Commander is shipped with the engine crankcase filled with high quality SAE 10W-30 oil (API class CD or better). Check the oil level before starting the engine. If it is not up to the full mark on the dip stick, add oil as required. Check the oil level every four hours of running time during the first 35 running hours. Refer to the engine Operator???s Manual for specific oil recommendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the engine Operator???s Manual for the proper ser- vice and maintenance intervals.

FUEL USE DIESEL FUEL ONLY

Fill the fuel tank with clean, fresh diesel fuel. The capac- ity of the fuel tank is 25 gallons (94.6 liters). See engine Operator???s Manual for specific fuel recommendations. The Commander 400 is protected by a low fuel shutdown to prevent the engine from running out of fuel. The machine will indicate a low fuel condition by turning on the low fuel light. A time of 30 minutes will elapse once the low fuel light illuminates before the machine will shut- down. A restart of the machine will restart the timer to allow the operator to override this feature. The amount of reserve fuel remaining in the tank after the first shutdown will vary from machine to machine. The operator must determine the amount of fuel remaining before re-starting the machine. Running out of fuel may require bleeding the fuel injection pump.

NOTE: Before starting the engine, open the fuel shutoff valve (lever to be in line with hose) located on the side the fuel pre-filter / water separator housing.

FUEL CAP

Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap.

ENGINE COOLING SYSTEM

The Deutz engine is air cooled by a belt driven axial blower. The oil cooler and engine cooling fins should be blown out with compressed air or steam to maintain proper cooling (See the engine Owners Manual for pro- cedures and frequency).

BATTERY CONNECTION

WARNING: Use caution as the electrolyte is a strong acid that can burn skin and damage eyes.

Remove and discard the insulating cap from the nega- tive battery terminal. Attach and tighten negative bat- tery cable terminal.

NOTE: This machine is furnished with a wet charged battery; if unused for several months, the battery may require a booster charge. Be careful to charge the battery with the correct polar- ity. Make sure that the battery is level while charging.

MUFFLER OUTLET PIPE

Remove the plastic plug covering the muffler outlet tube. Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction.

SPARK ARRESTER

Some federal, state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain loca- tions where unarrested sparks may present a fire haz- ard. The standard muffler included with this welder does not qualify as a spark arrester. When required by local regulations, a suitable spark arrester, such as the K899-1 must be installed and properly maintained.

CAUTION

An incorrect arrester may lead to damage to the engine or adversely affect performance.

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C V W O R K -

W E L D O U T P U T

T E R M I N A L

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

MACHINE GROUNDING

Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.).

To prevent dangerous electric shock, other equipment powered by this engine driven welder must:

a)be grounded to the frame of the welder using a grounded type plug,

or

b) be double insulated.

When this welder is mounted on a truck or trailer, its frame must be securely connected to the metal frame of the vehicle. When this engine driven welder is con- nected to premises wiring such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the sec- tion entitled ???Standby Power Connections??? as well as the article on grounding in the latest U.S. National Electrical Code and the local code.

In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated

joints, or to the metal framework of a building which has been effectively grounded. The U.S. National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.

AUXILIARY POWER RECEPTACLES

The auxiliary power capacity of the Commander 400 is 10,000 watts of 60 Hz, single phase power. The auxil- iary power capacity rating in watts is equivalent to volt- amperes at unity power factor. The maximum permis- sible current of the 240 VAC output is 44 A. The 240 VAC output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 44 A per output to two separate 120 VAC branch circuits. The output voltage is within ?? 10% at all loads up to rated capacity.

NOTE: The 120/240V receptacle has two 120V outlets of different phases and cannot be paralleled.

The Commander has two 15 Amp-120VAC (5-15R) duplex receptacles with GFCI protection and one 50 Amp-120/240 VAC (14-50R) receptacle. The 120/240 VAC receptacle can be split for single phase 120 VAC operation. The auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle.

STANDBY POWER CONNECTIONS

The Commander 400 is suitable for temporary, stand- by or emergency power using the engine manufactur- er???s recommended maintenance schedule.

The Commander 400 can be permanently installed as a standby power unit for 240 volt-3 wire, 44 amp ser- vice. Connections must be made by a licensed electri- cian who can determine how the 120/240 VAC power can be adapted to the particular installation and com- ply with all applicable electrical codes. The following information can be used as a guide by the electrician for most applications. Refer to the connection diagram shown in Figure A.2.

1.Install the double-pole, double-throw switch between the power company meter and the premises discon- nect.

Switch rating must be the same or greater than the customer???s premises disconnect and service over cur- rent protection.

2.Take necessary steps to assure load is limited to the capacity of the Commander by installing a 45 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 45 amperes. Loading above the rated output will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motor-driven equipment and may result in overheating of the Commander 400 engine.

3.Install a 50 amp 120/240 VAC plug (NEMA Type 14-

50)to the double-pole circuit breaker using No. 6, 4 conductor cable of the desired length. (The 50 amp, 120/240 VAC plug is available in the optional K802R plug kit.)

4.Plug this cable into the 50 Amp 120/240 Volt recep- tacle on the Commander 400 case front.

OPERATING INSTRUCTIONS

Read and understand this entire section before operat- ing your Commander 400.

SAFETY INSTRUCTIONS

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 SHOCK can kill.

???Do not touch electrically live parts such as output terminals or internal wiring.

???Insulate yourself from the work and ground.

???Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

???Use in open, well ventilated areas or vent exhaust outside

???Do not stack anything near the engine.

------------------------------------------------------------------------

MOVING PARTS can injure.

???Do not operate with doors open or guards off.

GENERAL DESCRIPTION

The Commander is a diesel engine driven welding power source. The machine uses a brushless asyn- chronous alternating current generator for DC stick electrode welding and for 120/240 VAC auxiliary stand- by power. As a generator it can supply up to 10,000 watts of 120/240 volt AC power. As a welder it provides up to 400 amps of DC constant current output in six slope-controlled ranges. In addition a seventh general purpose welding range provides up to 575 amps of constant current welding output.

The engine is a 44.2 Hp (33kw), 3-cylinder air/oil cooled diesel made by Deutz. This naturally aspirated, 4 cycle engine features direct injection, a Bosch in-line injection pump and a Bosch mechanical governor.

This machine is controlled by a high quality microcon- troller. The microcontroller provides high speed control of the weld process as well as the engine protection features.

RECOMMENDED APPLICATIONS

WELDER

The Commander 400 (Stick model) provides excellent con- stant current DC welding output for stick (SMAW) welding. The Commander 400 (Stick & Wire model) also provides excellent constant voltage DC welding output for MIG (GMAW) and Innershield (FCAW) welding.

GENERATOR

The Commander 400 provides smooth 120/240 VAC output for auxiliary power and emergency standby power.

DESIGN FEATURES AND ADVANTAGES

(All Models)

???Stop engine before servicing.

???Keep away from moving parts

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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.

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.

???Selection of ???hot??? or ???cold??? output terminals with a tog- gle switch on the control panel. This feature can also be controlled by installing a remote output terminal control cable designed to open and close the #2 and #4 leads in the amphenol receptacle.

FOR AUXILIARY POWER

???10,000 watts of 120/240 VAC, 60Hz auxiliary power.

???Drive a 2 HP motor (provided it is started under no load).

???Two 15 amp 120 VAC duplex receptacles with GFCI protection for up to 30 amps of 120 VAC power.

???One 50 amp, 120/240 VAC dual voltage receptacle for up to 44 amps of 240 VAC, and up to 44 amps per side to separate branch circuits (not in parallel) of 120 VAC single phase auxiliary power. Allows easy con- nection to premises wiring.

???Weld and AC auxiliary power at the same time (with- in machine total capacity).

OTHER FEATURES

???Deutz 3-cylinder, air/oil cooled diesel engine. Designed for long life, easy maintenance and excel- lent fuel economy.

???Engine protection system shuts the engine down for low oil pressure, high oil temperature or a broken fan/engine alternator belt.

???Gauges for oil pressure, oil temperature, engine alter- nator output and fuel level.

???Indicator lights for low oil pressure, high oil tempera- ture, engine alternator low output/broken belt and low fuel level.

???Automatic low fuel shutdown before running out of fuel.

???Engine hour meter standard on all models.

???Extended range 25 gallon (94.6 l) fuel tank.

???Fuel pre-filter/water separator with ???dry??? change ele- ment.

???Automatic idler reduces engine speed when not weld- ing or drawing auxiliary power. This feature reduces fuel consumption and extends engine life.

???Single side engine service with over the top access to the engine.

???Copper alternator windings and high temperature insulation for dependability and long life.

ADDITIONAL DESIGN FEATURES AND

ADVANTAGES (Stick & Wire Model only)

FOR WIRE WELDING

???One constant voltage position for all wire welding. A 12 to 45V range across the entire current output range.

???Excellent arc characteristics with MIG (GMAW) and Innershield (FCAW) welding.

???A Wire Feeder connector for quick connection of the control cable.

???A built in ???Electronic Contactor??? for ???Cold??? electrode when not welding. This feature and DC Constant Voltage output provide an added margin of safety when welding must be performed under electrically hazardous conditions such as: damp locations, while wearing wet clothing or in cramped positions if there is a high risk of unavoidable or accidental contact with the workpiece or ground.

???The 3 digit display has the additional feature of pre- setting the open circuit voltage and displaying the actual voltage during welding.

???Designed for use with the following Lincoln wire feeders.

WELDING CAPABILITY

The Commander 400 is rated at 400 amps, 40 volts at 100% duty cycle. The weld current is variable from 40 to 575 amps.

9

1 0

2 3

1 7

-

9

11

12

1 3

2 2

2 1

2 4

2 0

ENGINE CONTROLS (Items 1 through 8)

1. RUN- STOP SWITCH

When placed in the ???RUN??? position, this switch ener- gizes the fuel solenoid and other electric accessories. When placed in the ???STOP??? position, the flow of fuel to the injection pump is stopped to shut down the engine. (Note: If the switch is left in the ???RUN??? position and the engine is not running, the battery will be drained by the fuel solenoid).

2. START PUSHBUTTON

Energizes the starter motor to crank the engine. With the engine RUN-STOP switch in the ???Run??? position, push and hold the START button for a minimum of 2 seconds to crank the engine; release as the engine starts. Do not press while engine is running since this can cause damage to the ring gear and/or starter motor.

3. FUEL LEVEL GAUGE AND LIGHT

Displays the level of diesel fuel in the 25-gallon fuel tank. The yellow light turns on when the fuel gage reaches the reserve level. Once the reserve level is reached, the engine protection system will shut down the engine after 30 minutes of operation. The machine can be restarted and operated for an additional 30 min- utes before the protection system will shut down the engine. This ability to override the engine protection is to allow the operator to ???finish up??? if necessary. The operator must watch the fuel level closely to prevent running out of fuel and having to bleed the system.

4.ENGINE TEMPERATURE GAUGE AND

LIGHT

The gauge displays the engine oil temperature. The yellow temperature light remains off under normal operating temperatures. If the light turns on, the engine protection system will shut down the engine. Check for restrictions at the engine cooling air inlets and outlets (consult the engine Operator???s Manual). Check for loose or disconnected leads at the tempera- ture sender located on the engine. Check engine cool- ing blower belt. Also, check to be sure that the welder loads are within the rating of the welder. The light will remain on when the engine has been shut down due to an over- temperature condition.

5. OIL PRESSURE GAUGE AND LIGHT

The gauge displays the engine oil pressure when the engine is running. The yellow oil pressure light remains off with proper oil pressure. If the light turns on, the engine protection system will stop the engine. Check for proper oil level and add oil if necessary. Check for loose or disconnected leads at the oil pres- sure sender located on the engine. The light will go on and stay on when the RUN-STOP switch is switched to the ???Run??? position with engine not running.

6.ENGINE ALTERNATOR AMMETER

AND LIGHT

The yellow engine alternator light is off when battery charging system is functioning normally. If light turns on, the engine protection system will shut down the engine. Check the engine cooling blower belt. Also, the alternator or the voltage regulator may not be oper- ating correctly. The light may also come on if the alter- nator did not flash up due to not holding the start but- ton in long enough (minimum of 2 seconds) or due to a faulty flashing circuit. The light will remain on when the engine has been shut down due to a fault in the alter- nator, regulator, or the cooling blower belt.

7. IDLER SWITCH

Has two positions as follows:

A) In the ???High??? position , the engine runs at the high idle speed controlled by the governor.

B)In the ???Auto??? / position, the idler oper- ates as follows:

a.When switched from ???High??? to ???Auto??? or after starting the engine, the engine will operate at full speed for approximately 15 seconds and then go to low idle speed.

b.When the electrode touches the work or power is drawn for lights or tools (approximately 100 Watts minimum) the engine accelerates and operates

at full speed.

c.When welding ceases or the AC power load is turned off, a fixed time delay of approximately 15 seconds starts.

d.If the welding or AC power load is not restarted before the end of the time delay, the idler reduces the engine speed to low idle speed.

e.The engine will automatically return to high idle speed when the welding load or A.C. power load is reapplied.

Idler Operational exceptions

When the WELDING TERMINALS switch is in the ???Welding Terminals Remotely Controlled??? position the idler will operate as follows:

a.When the triggering device (Amptrol, Arc Start Switch, etc.) is pressed the engine will accelerate and operate at full speed provided a welding load is applied within approximately 15 seconds.

???If the triggering device remains pressed but no weld- ing load is applied within approximately 15 seconds the engine will return to low idle speed.

???If the triggering device is released or welding ceases the engine will return to low idle speed after approxi- mately 15 seconds.

8. HOUR METER

The hour meter displays the total time that the engine has been running. This meter is a useful indicator for scheduling preventive maintenance.

WELDER CONTROLS (Items 9 through 14 )

9.OUTPUT RANGE SWITCH & OUTPUT

CONTROL

These two controls allow you to select between various welding output slopes and adjust the desired welding output. Refer to Table B.1 for a description of how these two controls work.

Table B.1 Output Range Switch and Output Control

Functions

1If the OUTPUT RANGE switch is positioned between settings the previous setting is maintained until the switch is properly positioned on a setting.

2OUTPUT CONTROL also controls O.C.V. while in the 6 sloped out- put ranges.

10. DIGITAL OUTPUT METER

The digital output meter is located in the center of the control panel between the two large control knobs. The meter allows the output current level to be set prior to welding. During the welding process the meter dis- plays the actual output current.

11. WELDING TERMINALS SWITCH

The toggle switch on the control panel labeled ???Welding Terminals Always On??? and ???Welding Terminals Remotely Controlled???: is used to control the operation of the ???solid state contactor??? which allows for the selection of ???Hot??? or ???Cold??? welding terminals.

With the switch in the ???Welding Terminals Always On??? position the contactor is closed and the welding termi- nals are always ???Hot???.

With the switch in the ???Welding Terminals Remotely Controlled??? position the contactor operation is con- trolled by an Amptrol, Arc Start Switch or some other type of triggering device through the use of a control cable connected to the 6-pin MS connector.

When the triggering device is pressed the contactor is closed and the welding terminals are ???Hot???.

When the triggering device is released the contactor is opened and the welding terminals are ???Cold???.

12. LOCAL /REMOTE SWITCH

The toggle switch on the control panel labeled ???Local/Remote??? gives the operator the option of con- trolling the output at the welder control panel or at a remote station.

For remote control the toggle switch is set in the ???Remote??? position.

For control at the welder control panel, the toggle switch is set in the ???Local??? position.

13. 6 - PIN CONNECTOR

The 6-pin connector located on the control panel allows for connection of Remote Control accessories.

14. WELD OUTPUT TERMINALS + AND -

These 1/2 - 13 studs with flange nuts provide welding connection points for the electrode and work cables. For positive polarity welding the electrode cable con- nects to the ???+??? terminal and the work cable connects to this ???-??? terminal. For negative polarity welding the work cable connects to the ???+??? terminal and the elec- trode cable connects to this ???-??? terminal.

AUXILIARY POWER CONTROLS

(Items 15 - 19 )

15. 120/240VAC RECEPTACLE

This is a 120/240VAC (14-50R) receptacle that pro- vides 240VAC or can be split for 120VAC single phase auxiliary power. This receptacle has a 50 amp rating. Refer to the AUXILIARY POWER RECEPTACLES sec- tion in the installation chapter for further information about this receptacle. Also refer to the AUXILIARY POWER OPERATION section later in this chapter.

16. 50 AMP CIRCUIT BREAKERS

These circuit breaker provide separate overload cur- rent protection for each 120V circuit at the 240V recep- tacle.

17. 120VAC RECEPTACLES

These two 120VAC (5-15R) receptacles with GFCI pro- tection provide 120VAC for auxiliary power. These receptacles have a 20 amp total rating. Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about these receptacles. Also refer to the AUXILIARY POWER OPERATION section later in this chapter.

18. 15 AMP CIRCUIT BREAKERS

These circuit breakers provide separate overload cur- rent protection for each 120V receptacle.

19. GROUND STUD

Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. Refer to ???MACHINE GROUNDING??? in the Installation chapter for proper machine grounding infor- mation.

WIRE FEEDER MODE CONTROLS

(Items 20 - 24 Stick & Wire model only)

20. WELD OUTPUT TERMINAL - WIRE

This 1/2-13 stud with flange nut provides a welding connection point for the electrode and work cables. For positive polarity welding the electrode cable connects to the ???+??? terminal and the work cable connects to this ???-??? terminal. For negative polarity welding the work cable connects to the ???+??? terminal and the electrode cable connects to this ???-??? terminal.

21. 15 AMP CIRCUIT BREAKER

This circuit breaker provides overload protection for the 14-pin connector.

22. VOLTMETER +/- SWITCH

Changes the polarity display on the wire feeder.

23. VOLTS-AMPS SWITCH

Switches the display between volts and amps.

24. 14 - PIN CONNECTOR

For quick connection of wire feeder control cable.

ENGINE OPERATION

STARTING THE ENGINE

1.Open the engine compartment door and check that the fuel shutoff valve located to the left of the fuel fil- ter housing is in the open position (lever to be in line with the hose).

2.Check for proper oil level on the oil dipstick. Close engine compartment door.

3.Remove all plugs connected to the AC power receptacles.

4.Set IDLER switch to ???AUTO???.

5.Set the RUN/STOP switch to ???RUN???. Observe that all engine protection lights momentarily turn on, some lights may turn off before starting. Check the fuel gauge to make sure that there is an adequate fuel level.

6.Press and hold the engine START button for a minimum of 2 seconds.

7.Release the engine START button when the engine starts.

8.Check that the indicator lights are off. If the LOW FUEL light is on , the engine will shutdown 30 minutes after starting. If any other indicator light is on after starting, the engine will shut- down in a few seconds. Investigate any indicated problem.

9.Allow the engine to warm up at low idle speed for several minutes before applying a load and/or switching to high idle. Allow a longer warm up time in cold weather.

COLD WEATHER STARTING / RUNNING

With a fully charged battery and the proper weight oil, the engine should start satisfactorily even down to about 0??F. If the engine must be frequently started below 10o 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) an optional Cold Weather Kit (K1665-1) is available. Installation and operating instructions are included in the kit.

STOPPING THE ENGINE

1.Switch the RUN/STOP switch to ???STOP???. This turns off the voltage supplied to the shutdown solenoid. A backup shutdown can be accomplished by shutting off the fuel valve located on the fuel filter housing.

BREAK-IN PERIOD

The engine used to supply power for your welder is a heavy duty, industrial engine. It is designed and built for rugged use. It is very normal for any engine to use small quantities of oil until the break-in is accom- plished. Check the oil level twice a day during the break-in period (about 200 running hours).

IMPORTANT

IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE

UNIT SHOULD BE SUBJECTED TO HEAVY LOADS,

WITHIN THE RATING OF THE MACHINE. AVOID

LONG IDLE RUNNING PERIODS.

TYPICAL FUEL CONSUMPTION

Refer to Table B.2 for typical fuel consumption of the Commander 400???s Engine for various operating sce- narios.

Table B.2 Deutz F3L 912 Engine Fuel Consumption

WELDER OPERATION

STICK WELDING

The Commander 400 can be used with a broad range of DC stick electrodes.

The OUTPUT RANGE switch provides six overlapping slope controlled current ranges. The OUTPUT CON- TROL adjusts the current from minimum to maximum within each range. Open circuit voltage is also con- trolled by the OUTPUT CONTROL in the slope con- trolled setting. These slope controlled settings are intended for ???out-of-position??? welding, including pipe where the operator would like to control the current level by changing the arc length.

setting and lower open circuit voltage. For example: to obtain 175 amps and a forceful arc, set the to the ???230 MAX??? position and then adjust the OUTPUT CON- TROL to get 175 amps.

GENERAL WELDING

The seventh position of the OUTPUT RANGE switch is designed for horizontal welds with all types of elec- trodes especially low hydrogen. The OUTPUT CON- TROL adjusts the full range of 50 to 575 amps. This setting provides a soft, constant current arc. If a more forceful arc is desired, then select the proper range from the slope controlled current ranges.

TIG WELDING

The Commander 400 can be used in a wide variety of DC Tungsten Inert Gas (TIG) welding applications for DC TIG welding up to 400A at a 20% duty cycle, 300A at a 60% duty cycle and 250A at a 80% duty cycle. Refer to Table B.3 for recommended output setting depending on the tungsten electrode size. The Commander can be used without a TIG module or Hi- Freq Unit for scratch start DC TIG welding. Using a K799 Hi-Freq Unit or K930-1 TIG Module enables DC TIG welding without having to scratch start. The end of this section also details Commander 400 settings when using either of these units for DC TIG welding. Also refer to the Accessories chapter for recommend- ed equipment for TIG welding.

ARC GOUGING

Set the output range switch to the General purpose position (50-575). For current setting, refer to The Procedure Handbook of Arc Welding, section on arc gouging (13.5) or the consumable manufacturer???s rec- ommended current rating.

COMMANDER 400 SETTINGS WHEN USING THE K799 HI-FREQ UNIT

a.Set the OUTPUT RANGE switch to the ???50-575 set- ting??? (Fabrication and General Purpose)

b.Set the IDLER switch to the ???High ??? position.

c.Set the LOCAL/REMOTE switch to the ???Remote??? posi- tion.

d.Set the WELDING TERMINALS switch to the ???Welding Terminals Always On??? position. This will close the solid state contactor and provide an always ???hot??? electrode.

(Note: This is necessary because the K799 circuitry with respect to the #2 and #4 leads does not provide the prop- er signal to open and close the solid state contactor in the Commander).

COMMANDER 400 SETTINGS WHEN USING THE K930-1 TIG MODULE

a.Set the OUTPUT RANGE switch to the 50-575 Setting (Fabrication and General Purpose)

b.Set the IDLER switch to the ???Auto ??? position.

c.Set the LOCAL/REMOTE switch to the ???Remote??? posi- tion.

d.Set the WELDING TERMINALS switch to the ???Welding Terminals Remotely Controlled??? position. This will keep the solid state contactor open and provide a ???cold??? electrode until the triggering device (Amptrol or Arc Start Switch) is pressed.

WIRE FEED (CONSTANT VOLTAGE) WELD-

ING

(Stick and Wire models only)

Connect a wire feeder to the Commander 400 and set the welder controls according to the instructions in ???Controls and Settings??? in this section of the manual.

The Stick and Wire model of the Commander 400 with its CV tap, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG (GMAW).

For any electrodes, the procedures should be kept within the rating of this machine. For additional electrode infor- mation, see Lincoln publications N-675, GS-100 and GS- 210.

STICK AND WIRE MODEL CONNECTION TO LN-25

The LN-25 with or without an external contactor may be used with the Commander 400 Stick and Wire model. See the appropriate connection diagram in ???DIAGRAMS??? sec- tion. NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the Commander 400 S&W.

a.Shut the welder off.

b.For electrode Positive, connect the electrode cable from the LN-25 to the ???+??? terminal of the welder and work cable to the ???- WIRE??? terminal of the welder. For electrode Negative, connect the electrode cable from the LN-25 to the ??? WIRE??? terminal of the welder and work cable to the ???+???terminal of the welder.

c.Attach the single lead from the front of the LN-25 to work using the spring clip on the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current.

d.Set the range switch to ???WIRE WELDING CV???

e.Set the ???OUTPUT CONTROL??? switch to ???WELDING

TERMINALS ALWAYS ON???

f.Set the ???VOLTS\AMPS??? switch to ???VOLTS???

g.Set the ???IDLE??? switch to the ???AUTO??? position. When not welding , the Commander 400 S&W engine will be at the low idle speed. CAUTION: ( if you are using an LN-25 without an internal contactor, the electrode will be energized when the Commander 400 Stick and Wire model is started.) If you are using an LN-25 with an internal contactor, the elec- trode is not energized until the gun trigger is closed. In either of the LN-25 wire feeders, when the gun trigger is closed, the current sensing circuit will cause the Commander 400 Stick and Wire model engine to go to the high idle speed, the wire will begin to feed and the welding process started. When welding is stopped, the engine will revert to low idle speed after approximately 15 seconds unless welding is resumed.

STICK AND WIRE MODEL CONNECTION TO LN-7 or LN-8

a.Shut the welder off.

b.Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in ???DIAGRAMS??? section. Set the ???LOCAL REMOTE??? switch to ???REMOTE??? for the LN-7 and LN-8 with a K857 remote voltage control cable attached; ???LOCAL??? for LN-7 with no remote voltage control.

c.Set the ???VOLTMETER??? switch to either ???+??? or ???-??? as required by the electrode being used.

d.Set the ???RANGE??? switch to the ???WIRE WELDING CV??? position.

e.Set the ???OUTPUT CONTROL??? switch to the ???OUT- PUT REMOTELLY CONTROLLED??? position.

f.Set the ???IDLE??? switch to the ???HIGH??? position.

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 & Wire, a K350-1 adapter kit must be used. Set the ???VOLTMETER??? switch to either ???+??? or ???-??? as required by the electrode being used.

d.Set the ???RANGE??? switch to ???WIRE WELDING CV???

e.Set the ???OUTPUT CONTROL??? switch to ???WELDING TERMINALS ALWAYS ON??? Set the ???VOLTS/AMPS??? switch to ???VOLTS???

g.Set the ???LOCAL REMOTE??? switch to the desired setting depending upon where the power sources output is being controlled from.

h.Set the ???IDLE??? switch to the ???AUTO??? position. When not welding , the Commander 400 Stick and Wire model engine will be at the low idle speed. If you are using an LN-23P with the K350-1 adapter kit, the electrode is not energized until the gun trigger is closed. When the gun trigger is closed, the current sensing circuit will cause the Commander 400 Stick and Wire model engine to go to the high idle speed, the wire will begin to feed and the welding process can be started. When welding is stopped, the engine will revert to low idle speed after approxi- mately 15 seconds unless welding is resumed.

STICK AND WIRE MODEL CONNECTION TO NA-3

For connection diagrams and instructions for connecting an NA-3 Welding System to the Commander Stick & Wire, refer to the NA-3 Welding System instruction manual.

AUXILIARY POWER OPERATION

Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings, if no welding current is being drawn..

The auxiliary power of the Commander consists of two- 120VAC (5-15R) duplex receptacles with GFCI protec- tion and one 120/240 VAC (14-50R) receptacle. The 120/240VAC receptacle can be split for single phase 120 VAC operation.

The auxiliary power capacity is 10,000 watts of 60 Hz, single phase power. The auxiliary power capacity rat- ing in watts is equivalent to volt-amperes at unity power factor. The maximum permissible current of the 240 VAC output is 44 A. The 240 VAC output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 44 A per output to two separate 120 VAC branch circuits. Output voltage is within ?? 10% at all loads up to rated capacity.

NOTE: The 240V receptacle has two 120V outlets of different phases and cannot be paralleled.

The auxiliary power receptacles should only be used with three wire grounded type plugs or approved dou- ble insulated tools with two wire plugs.

The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle.

SIMULTANEOUS WELDING AND AUXIL-

IARY POWER LOADS

It must be noted that the above auxiliary power ratings are with no welding load. Simultaneous welding and power loads are specified in table B.4. The permissible currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply (not both at the same time).

OPTIONAL FIELD INSTALLED

ACCESSORIES

K802R POWER PLUG KIT - Provides a plug for each receptacle.

K857 28 ft. (8.5 m) or K857-1 100 ft. (30.4 m) REMOTE CONTROL - Portable control provides same dial range as the output control on the welder from a location up to the specified length from the welder. Has convenient plug for easy connection to the welder. The Commander 400 is equipped with a 6 pin connector for connecting the remote control and a toggle switch for selecting ???LOCAL??? output control or ???REMOTE??? out- put control.

K704 ACCESSORY SET - Includes 35 feet (10 m) of electrode cable and 30 feet (9 m) of work cable, head- shield, work clamp and electrode holder. Cable is rated at 500 amps, 60% duty cycle.

K953-1 TWO WHEEL TRAILER - For road, in-plant and yard towing. Road towing with optional fender & light kit. (For highway use, consult applicable federal, state and local laws regarding possible additional requirements)

K953-1 Trailer

K958-1 Ball Hitch

K958-2 Lunette Eye Hitch

K959-1 Fender & Light Kit

K965-1 Cable Storage Rack

K825-1 ETHER START KIT - Provides maximum cold weather starting assistance for frequent starting below

10 F (-12.2o 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 Extension

K844-1 Water Valve

HIGH FREQUENCY GENERATORS FOR

TIG APPLICATIONS

The K799 Hi-Freq Unit and the K930-1 TIG Module are suitable for use with the Commander 400. The Commander is equipped with the required R.F. bypass circuitry for the connection of high frequency generat- ing equipment. The high frequency bypass network supplied with the K799 Hi-Freq Unit does NOT need to be installed into the Commander.

The Commander and any high frequency generating equipment must be properly grounded. See the K799 Hi-Freq Unit and the K930-1 TIG Module operating manuals for complete instructions on installation, oper- ation, and maintenance.

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 crankcase oil level .

b.Refill the fuel tank to minimize moisture condensa- tion in the tank.

c.Open the water drain valve located on the bottom of the water separator element 1 or 2 turns and allow to drain into a container suitable for diesel fuel for 2 to 3 seconds. Repeat the above drainage procedure until diesel fuel is detected in the container.

WEEKLY

Blow out the machine with low pressure air periodical- ly. In particularly dirty locations, this may be required once a week.

ENGINE MAINTENANCE

Refer to the ???Periodic Checks??? section of the Engine Operator???s Manual for the recommended maintenance schedule of the following:

a)Engine Oil and Filter

b)Air Cleaner

c)Fuel Filter - and Delivery System

d)Cooling Blower Belt

e)Battery

f)Cooling System

Refer to Table D.1 at the end of this section for various engine maintenance components.

AIR FILTER

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 Operator???s Manual.

1.Locate the air filter canister located behind the engine door on the top of the engine.

2.Remove air filter element.

3.Remove loose dirt from element with compressed air or water hose directed from inside out.

Compressed Air: 100 psi maximum with nozzles at least one inch away from element.

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

160o F (71o C). Do not use a light bulb to dry the ele- ment.

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

WARNING

When working on the fuel system

??? Keep naked lights away, do not smoke !

??? Do not spill fuel !

------------------------------------------------------------------------

The Commander 400 is equipped with a Fuel Pre- Filter/Water Separator Assembly located before the lift pump and a Secondary Fuel Filter located after the lift pump and before the fuel injectors. The Fuel Pre- Filter/Water Separator is mounted to the engine block just below the lift pump. The Secondary Fuel Filter is mounted directly to the engine just above the oil filter.

FUEL PRE-FILTER/WATER SEPARATOR ASSEM-

BLY

The pre-filter is a 150 micron screen designed to pro- tect against gross fuel contamination of the water sep- arator element and the Secondary Fuel Filter. If the pre-filter becomes plugged it may be removed, inspect- ed, cleaned and reinstalled. In general this only needs to be done with each water separator element change (about every 1,000 hrs.) However if at any time exces- sive fuel contamination is suspected or a sudden fall- off in engine performance is detected the pre-filter screen should be inspected and cleaned. Follow the following procedure:

1.Close the fuel shutoff valve (Lever should be per- pendicular to the hose) located on the side of the Fuel Pre-Filter/Water Separator Assembly.

2.Unscrew the cap ring located on the top of the filter header and remove the plastic center cap and O- ring.

3.Remove the large white volume plug located direct- ly under the center cap in the upper cavity of the fil- ter header. Use a small screwdriver (or similar device) to lift the plug part way out of the cavity to assist with its removal.

Be careful not to damage the pre-filter screen with the tool used to remove the plug.

4. Using a pair of pliers, gently tug on the pull tabs of the pre-filter screen in an alternating pattern to gradually remove the pre-filter screen.

5.Brush off any debris and rinse in diesel fuel.

6.Re-install the pre-filter screen into the upper cavity of the filter header making sure the four pull tabs are pointing up. Putting your fingers on the pull tabs, push down evenly until the lower body of the pre-fil- ter screen contacts the floor of the upper cavity.

7.Re-insert the large white volume plug into the upper cavity.

8.Place the O-ring onto the angled seal surface of the filter header and re-install the plastic cap. Make sure its flange rests on the O-ring.

9.Screw on the cap ring and tighten hand tight.

10.Remember to open the fuel shutoff valve (Lever in line with the hose) before starting the engine.

WATER SEPARATOR ELEMENT

The water separator element is a two stage filter with a special filtration/water separating media, and an expanded water reservoir providing maximum protec- tion against water in the fuel. The recommended change interval for the water separator element is 1,000 hours. The procedure for changing the element is as follows:

1.Close the fuel shutoff valve (Lever should be per- pendicular to the hose) located on the side of the Fuel Pre-Filter/Water Separator Assembly.

2.Rotate the quick change ring (located just below fil- ter header) clockwise approximately 1/2 turn and slide it down and off of the element.

3.Grasp the element and pull down with a slight rock- ing motion to remove the element from the grommet post on the bottom of the filter header.

4.Slide the new element onto the grommet post on the bottom of the filter header until the element no longer easily moves up into the filter header. Now rotate the element (may take almost 1 full turn) with a slight upward pressure until the element begins to further engage the header. With the proper orientation now established apply additional pressure to seat the ele- ment in the filter header. You should feel the element ???pop??? into place when properly seated.

Note: The element will only go on one way. Never use excessive force when mounting the element to the header.

5.Slide the quick change ring up over the element and rotate counter clockwise until an audible click or pop is heard. If you do not hear the click you have not rotat- ed the ring far enough and the element is not in the locked position. Another indication that the ring is in the locked position is that one set (it doesn???t matter which one) of arrows located on the outside of the ring should be located directly under the air vent valve.

6.Open the fuel shutoff valve (lever in line with the hose).

7.Open the air vent valve on the front of the filter header until fuel emerges free of air bubbles and then close the air vent valve.

Note : Consult your engine operation manual for informa- tion on air -bleeding the entire fuel system.

SECONDARY FUEL FILTER

The Secondary Fuel Filter is a spin on cartridge type mount directly to the engine. Consult your engine opera- tion manual for complete information on service intervals and element changing procedures.

COOLING SYSTEM

The cooling system of the Deutz engine needs to be checked and cleaned periodically. Consult the engine owners manual for the proper frequency and procedure.

COOLING BLOWER BELT

The following procedure should be followed to replace the cooling blower belt:

1.Allow machine to cool.

2.Unfasten and slide the battery holder out from the welder.

3.Disconnect the negative battery cable.

4.Remove the engine end panel for access to the engine.

5.Loosen the alternator mounting bolts and rotate the alternator towards the engine.

6.Remove the old cooling blower belt and install a new one.

7.Adjust the cold belt tension to 63-73 lbs. midway between any two pulleys.

8.Reinstall the engine end panel. Reattach the negative battery cable. Slide in and refasten the battery holder.

9.Check the cooling blower belt tension after 100 hours of operation. (Follow steps 1,2,3,4,7 & 8)

BATTERY HANDLING

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 positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.

???USING A BOOSTER - connect positive lead to bat- tery first then connect negative lead to engine foot.

BATTERY ACID CAN BURN EYES AND SKIN.

??? Wear gloves and eye protection and be careful when working near battery. Follow instructions printed on battery.

-------------------------------------------------------

-----------------

PREVENTING ELECTRICAL DAMAGE

1.When replacing, jumping, or otherwise connecting the battery to the battery cables, the proper polarity must be observed. Failure to observe the proper polarity could result in damage to the charging circuit. The positive (+) battery cable has a red terminal cover.

2.If the battery requires charging from an external charg- er, disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads. Failure to do so can result in damage to the internal charger components. When reconnecting the cables, connect the positive cable first and the negative cable last.

PREVENTING BATTERY DISCHARGE

If you have an ignition switch, turn it off when engine is not running.

PREVENTING BATTERY BUCKLING

Tighten nuts on battery clamp until snug.

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled ???PROBLEM (SYMPTOMS)???. This column describes pos- sible symptoms that the machine may exhib- it. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into the following categories: engine problems, function prob- lems and output problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled ???POSSIBLE AREAS OF MISADJUSTMENT(S)??? lists the obvious external possibilities that may con- tribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted with- out removing the case wrap-around cover.

Step 3. RECOMMENDED COURSE OF

ACTION

If you have exhausted all of the items in step 2. Contact your Local Lincoln Authorized Field Service Facility.

Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance.

Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance.

Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance.

12-13-96

M18284

3-F

400 COMMANDER

CAUTION :

N.D.

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPICATIONS. SEE OPERATING MANUAL.

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".

PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.D. SPLICE LEADS AND INSULATE.

LN-8

WIRE

FEEDER

K196

INPUT CABLE

DIAGRAMS

12-13-96

S22913

6-F

400 COMMANDER

COMMANDER 400 STICK & WIRE TO K867 ADAPTER CONNECTION DIAGRAM

WARNING

14 PIN

CAUTION :

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

DIAGRAMS

6-12-98

S22916

9-F

400 COMMANDER

COMMANDER 400 STICK & WIRE / LN-8 CONNECTION DIAGRAM

WARNING

TO LN-8 INPUT

CABLE PLUG

K595 CONTROL CABLE

14 PIN

AMPHENOL

ELECTRODE CABLE

TO WIRE FEED UNIT

TO WORK

CAUTION :

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO "WIRE WELDING CV".

PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION.

12-13-96

S22917

DIAGRAMS

10-F

400 COMMANDER

CENTER OF GRAVITY

WITH OIL IN ENGINE

AND FULL FUEL TANK.

DIAGRAMS

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The book contains the latest information and application data on the American Welding Society Standard Welding Symbols. Detailed discussion tells how engineers and drafts- men use the ???short-cut??? language of symbols to pass on assembly and welding information to shop personnel.

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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

and ask for bulletin ED-80 or call 216-383-2259 and ask for the Welding School Registrar.

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5 weeks of fundamentals

CHECK ONE:

Please Invoice (only if order is over $50.00) Check or Money Order Enclosed, U.S. Funds only

Credit Card -

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Address: _______________________________________________

_______________________________________________

Telephone: _______________________________________________

BOOKS OR FREE INFORMATIVE CATALOGS

Lincoln Welding School

(ED-80)

Seminar Information

(ED-45)

Educational Video Information

(ED-93)

James F. Lincoln Arc Welding

Foundation Book Information

(JFLF-515)

Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.

STATEMENT OF LIMITED WARRANTY

The Lincoln Electric Company (Lincoln) warrants to the end user (purchaser) of all new welding and cutting equipment, electrode and flux (collectively called the ???Goods???) that it will be free of defects in workmanship and material.

This warranty is void if Lincoln or its Authorized Service Facility finds that the equipment has been subjected to improper installation, improper care or abnormal opera- tions.

WARRANTY PERIOD (1) (2) (3)

Lincoln will assume both the parts and labor expense of correcting defects during the full warranty period. All war- ranty periods date from the date of purchase to the original end user and are as follows:

7 Years

???Main power rectifiers on all non-inverter low frequency (50 and 60 Hz) type welders.

3 Years

???All Lincoln welding machines, wirefeeders and plasma cutting machines unless listed below.

2 Years

???Power Arc 5000

Ranger 10, Ranger 10-LX Weldanpower 125, Weldanpower 150

1 Year

???AC-100

Invertec V100-S, Invertec V130-S, Invertec V200-T Power Arc 4000

Pro-Cut 20

???All water coolers (internal or external models)

???All stick electrode, welding wire and flux.

???Arc welding and cutting robots and robotic controllers

???All Environmental Systems equipment, including portable units, central units, gun and cable assemblies and acces- sories. (Does not include consumable items listed under 30 day warranty.)

???All welding and cutting accessories including gun and cable assemblies, TIG and plasma torches, spool guns, wire feed modules, undercarriages, field installed options that are sold separately, unattached options, welding sup- plies, standard accessory sets, replacement parts, and Magnum products. (Does not include expendable parts listed under 30 day warranty)

30 Days

???All consumable items that may be used with the environ- mental systems described above. This includes hoses, fil- ters, belts and hose adapters.

???Expendable Parts - Lincoln is not responsible for the replacement of any expendable part that is required due to normal wear.

CONDITIONS OF WARRANTY

TO OBTAIN WARRANTY COVERAGE:

The purchaser must contact Lincoln or Lincoln???s Authorized Service Facility about any defect claimed under Lincoln???s warranty.

Determination of warranty on welding and cutting equipment will be made by Lincoln or Lincoln???s Authorized Service Facility.

WARRANTY REPAIR:

If Lincoln or Lincoln???s Authorized Service Facility confirms the existence of a defect covered by this warranty, the defect will be corrected by repair or replacement at Lincoln???s option.

At Lincoln???s request, the purchaser must return, to Lincoln or its Authorized Service Facility, any ???Goods??? claimed defec- tive under Lincoln???s warranty.

FREIGHT COSTS:

The purchaser is responsible for shipment to and from the Lincoln Authorized Service Facility.

WARRANTY LIMITATIONS

Lincoln will not accept responsibility or liability for repairs made outside of a Lincoln Authorized Service Facility.

Lincoln???s liability under this warranty shall not exceed the cost of correcting the defect of the Lincoln product.

Lincoln will not be liable for incidental or consequential dam- ages (such as loss of business, etc.) caused by the defect or the time involved to correct the defect.

This written warranty is the only express warranty provided by Lincoln with respect to its products. Warranties implied by law such as the warranty of merchantability are limited to the duration of this limited warranty for the equipment involved.

This warranty gives the purchaser specific legal rights. The purchaser may also have other rights which vary from state to state.

(1)Equipment manufactured for the Lincoln Electric Company is subject to the warranty period of the original manufacturer.

(2)All engines and engine accessories are warranted by the engine or engine accessory manufacturer and are not covered by this warranty.

(3)SAE400 WELD N??? AIR compressor is warranted by the compressor manu- facturer and not covered by this warranty.