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Lincoln Electric IM544-B - page 1
Commander 400 OPERA T OR’S MANU AL IM544-B June, 1998 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with saf ety in mind. Howe ver , y our ov erall saf ety can be increased b y proper installation ... and thoughtful operation on y our par t. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ ...
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Lincoln Electric IM544-B - page 2
FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Operate engines in open, well-v entilated areas or vent the engine e xhaust fumes outdoors. ____________________________________________ ...
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Lincoln Electric IM544-B - page 3
ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b . Use suitab le clothing made from durab le flame-resistant material to protect you ...
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Lincoln Electric IM544-B - page 4
FOR ELECTRICALL Y powered equipment. 8.a. T ur n off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manuf acturer’ s recommendations. 8.c. Ground the equipment in accordance with the U.S . National Elect ...
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Lincoln Electric IM544-B - page 5
iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ P our v otre 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 P our Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Les circu ...
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Lincoln Electric IM544-B - page 6
Thank You f or selecting a QU ALITY product by Lincoln Electric. We want y ou to take pride in operating this Lincoln Electric Company product ••• as much pride as we hav e in br inging this product to you! Read this Operators Manual completel y bef ore attempting to use this equipment. Sa v e this manual and k eep it handy f or quick ref ere ...
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Lincoln Electric IM544-B - page 7
T ABLE OF CONTENTS P age Safety ................................................................................................................................................ i-iv Installation ................................................................................................................... .............Section A T echnical Speci ...
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Lincoln Electric IM544-B - page 8
A-1 INST ALLA TION COMMANDER 400 A-1 TECHNICAL SPECIFICA TIONS - Commander 400 Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder High Idle 1900 173 cu. in 12VDC batter y Fuel: 25 gal. F3L 912 Diesel 44.2 HP(33kw) Lo w Idle 1350 (2.827 L) & Star ter 94.6 L Engine @ 1800 RPM Full Load 1800 Bore x Stroke O ...
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Lincoln Electric IM544-B - page 9
A-2 INST ALLA TION COMMANDER 400 A-2 Read this entire installation section before y ou start installation. SAFETY PRECA UTIONS Do not attempt to use this equipment until you ha v e thoroughly read all operating and maintenance man- uals supplied with your machine . They include impor- tant saf ety precautions, detailed engine starting, operating an ...
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Lincoln Electric IM544-B - page 10
A-3 INST ALLA TION COMMANDER 400 A-3 HIGH AL TITUDE OPERA TION At higher altitudes, output derating ma y be necessar y . As a rule of thumb, der ate the welder output 5% f or e v er y 400 meters (1312 ft.) abov e 1000 meters (3280 ft.). Contact a Deutz Ser vice Representativ e f or any engine adjustments that ma y be required f or high altitude ope ...
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Lincoln Electric IM544-B - page 11
A-4 INST ALLA TION COMMANDER 400 A-4 FUEL CAP Remov e the plastic cap co v ering from the Fuel T ank Filler neck and install the Fuel Cap . ENGINE COOLING SYSTEM The Deutz engine is air cooled by a belt driv en axial blo wer . The oil cooler and engine cooling fins should be blo wn out with compressed air or steam to maintain proper cooling (See th ...
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Lincoln Electric IM544-B - page 12
A-5 INST ALLA TION COMMANDER 400 A-5 WELDING OUTPUT CABLES With the engine off , route the electrode and work cables thru the strain relief brac k et provided on either side of the base and connect to the ter minals pro vided. These connections should be check ed periodically and tightened if necessar y . Listed in T able A.1 are copper cab le siz ...
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Lincoln Electric IM544-B - page 13
A-6 INST ALLA TION COMMANDER 400 A-6 2. T ake necessary steps to assure load is limited to the capacity of the Commander by installing a 45 amp , 240 V AC doub le pole circuit break er . Maximum rated load f or each leg of the 240 V A C auxiliar y is 45 amperes. Loading abov e the rated output will reduce output voltage belo w the allo wab le -10% ...
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Lincoln Electric IM544-B - page 14
B-1 OPERA TION B-1 OPERA TING INSTRUCTIONS Read and understand this entire section bef ore operat- ing your Commander 400. SAFETY INSTR UCTIONS Do not attempt to use this equipment until you ha v e thoroughly read all operating and maintenance man- uals supplied with your machine . They include impor- tant saf ety precautions, detailed engine start ...
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Lincoln Electric IM544-B - page 15
B-2 OPERA TION B-2 FOR A UXILIAR Y PO WER • 10,000 watts of 120/240 V AC , 60Hz auxiliary power . • Drive a 2 HP motor (provided it is started under no load). • T wo 15 amp 120 V A C duple x receptacles with GFCI protection f or up to 30 amps of 120 V AC po wer . • One 50 amp, 120/240 V A C dual voltage receptacle f or up to 44 amps of 240 ...
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Lincoln Electric IM544-B - page 16
B-3 OPERA TION B-3 ENGINE CONTROLS (Items 1 through 8) 1. RUN- ST OP SWITCH When placed in the “R UN” position, this switch ener- gizes the fuel solenoid and other electric accessories. When placed in the “ST OP” position, the flow of fuel to the injection pump is stopped to shut down the engine . (Note: If the s witch is left in the “R U ...
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Lincoln Electric IM544-B - page 17
B-4 OPERA TION B-4 4. ENGINE TEMPERA TURE GA UGE AND LIGHT The gauge displa ys the engine oil temperature . The yello w temperature light remains off under normal operating temperatures . If the light turns on, the engine protection system will shut down the engine . Check f or restr ictions at the engine cooling air inlets and outlets (consult the ...
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Lincoln Electric IM544-B - page 18
B-5 OPERA TION B-5 WELDER CONTROLS (Items 9 through 14 ) 9. OUTPUT RANGE SWITCH & OUTPUT CONTROL These two controls allow y ou to select betw een v arious welding output slopes and adjust the desired welding output. Refer to T able B .1 f or a description of how these two controls work. T able B.1 Output Range Switch and Output Control Function ...
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Lincoln Electric IM544-B - page 19
B-6 OPERA TION B-6 17. 120V A C RECEPT A CLES These two 120V AC (5-15R) receptacles with GFCI pro- tection provide 120V AC f or auxiliar y power . These receptacles hav e a 20 amp total r ating. Refer to the A UXILIAR Y PO WER RECEPT ACLES section in the installation chapter f or fur ther inf ormation about these receptacles. Also ref er to the A U ...
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Lincoln Electric IM544-B - page 20
B-7 OPERA TION B-7 TYPICAL FUEL CONSUMPTION Ref er to T able B .2 f or typical fuel consumption of the Commander 400’ s Engine for v arious operating sce- narios. T able B.2 Deutz F3L 912 Engine Fuel Consumption WELDER OPERA TION STICK WELDING The Commander 400 can be used with a broad range of DC stick electrodes . The OUTPUT RANGE s witch provi ...
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Lincoln Electric IM544-B - page 21
B-8 OPERA TION B-8 COMMANDER 400 SETTINGS WHEN USING THE K799 HI-FREQ UNIT a. Set the OUTPUT RANGE s witch to the “50-575 set- ting” (F abrication and General Purpose) b . Set the IDLER s witch to the “High “ position. c. Set the LOCAL/REMO TE switch to the “Remote” posi- tion. d. Set the WELDING TERMINALS s witch to the “W elding T e ...
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Lincoln Electric IM544-B - page 22
B-9 OPERA TION B-9 WIRE FEED (CONST ANT V OL T A GE) WELD- ING (Stick and Wire models only) Connect a wire f eeder 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 b ...
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Lincoln Electric IM544-B - page 23
B-10 OPERA TION B-10 A UXILIAR Y PO WER OPERA TION Star t the engine and set the IDLER control s witch to the desired operating mode. Full pow er is av ailab le regardless of the welding control settings, if no w elding current is being dra wn.. The auxiliar y pow er of the Commander consists of two- 120V AC (5-15R) duple x receptacles with GFCI pr ...
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Lincoln Electric IM544-B - page 24
C-1 A CCESSORIES C-1 OPTIONAL FIELD INST ALLED A CCESSORIES K802R PO WER PLUG KIT - Provides a plug for each receptacle. K857 28 ft. (8.5 m) or K857-1 100 ft. (30.4 m) REMO TE CONTR OL - P or table control provides same dial range as the output control on the welder from a location up to the specified length from the welder . Has conv enient plug f ...
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Lincoln Electric IM544-B - page 25
D-1 MAINTENANCE D-1 SAFETY PRECA UTIONS •Ha ve a qualified technician do the maintenance and troub leshooting work. •T urn the engine off before w orking inside the machine. •Remo ve guar ds only when necessary and replace them when the maintenance requiring their remov al is complete. •Al ways use the greatest care when w orking near movin ...
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Lincoln Electric IM544-B - page 26
D-2 MAINTENANCE D-2 7. Inspect for holes and tears b y looking through the element tow ard a bright light. Check f or damaged gas- kets or dented metal parts. Do not reuse damaged ele- ments. Protect element from dust and damage dur ing dr ying and storage . 8. Reinstall air filter element. After six cleanings replace air filter . A cleaned filter ...
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Lincoln Electric IM544-B - page 27
D-3 MAINTENANCE D-3 4. Slide the new element onto the grommet post on the bottom of the filter header until the element no longer easily mov es up into the filter header . Now rotate the element (ma y take almost 1 full turn) with a slight upward pressure until the element begins to further engage the header . With the proper orientation now establ ...
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Lincoln Electric IM544-B - page 28
D-4 MAINTENANCE D-4 COMMANDER 400 T able D.1 Engine Maintenance Components ITEM Air Cleaner Element Cooling Blower Belt Oil Filter Element Fuel Filter Element W ater Separator Element Fuel Pre-Filter Screen Batter y MAKE Donaldson AC Lincoln Gates Deutz Purolator Napa Fr a m Deutz Purolator Napa Fr a m Lincoln Stanadyne Lincoln Stanadyne P ART NUMB ...
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Lincoln Electric IM544-B - page 29
E-1 TR OUBLESHOO TING E-1 COMMANDER 400 If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs safely , contact your Local Lincoln A uthorized Field Service Facility f or technical troubleshooting assistance bef ore you proceed. CA UTION This T roubleshooting Guide is pro vided to help you locate ...
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Lincoln Electric IM544-B - page 30
E-2 TR OUBLESHOO TING E-2 COMMANDER 400 Obser v e all Saf ety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs safely , contact your Local Lincoln A uthorized Field Service Facility f or technical troubleshooting assistance bef ore you proceed. CA U ...
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Lincoln Electric IM544-B - page 31
E-3 TR OUBLESHOO TING E-3 COMMANDER 400 Obser v e all Saf ety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs safely , contact your Local Lincoln A uthorized Field Service Facility f or technical troubleshooting assistance bef ore you proceed. CA U ...
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Lincoln Electric IM544-B - page 32
E-4 TR OUBLESHOO TING E-4 COMMANDER 400 Obser v e all Saf ety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs safely , contact your Local Lincoln A uthorized Field Service Facility f or technical troubleshooting assistance bef ore you proceed. CA U ...
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Lincoln Electric IM544-B - page 33
F-1 DIA GRAMS F-1 COMMANDER 400 NO TE: This diagram is f or ref erence only . It may not be accurate f or all machines covered b y this manual. The specific dia- gram f or your par ticular machine is pasted inside the machine on one of the enclosure panels. WIRING DIA GRAM: 240 uF 240 uF 240 uF STATOR ASSEMBLY RECTIFIER SHUNT 600 AMP CHOKE OUTPUT S ...
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Lincoln Electric IM544-B - page 34
F-2 DIA GRAMS F-2 COMMANDER 400 NO TE: This diagram is f or ref erence only . It may not be accurate f or all machines covered b y this manual. The specific dia- gram f or your par ticular machine is pasted inside the machine on one of the enclosure panels. WIRING DIA GRAM: COMMANDER 400-STICK & WIRE MODEL WIRING DIAGRAM 6 230 MAX. 9 50-575 8 4 ...
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Lincoln Electric IM544-B - page 35
F-3 DIA GRAMS F-3 COMMANDER 400 CONNECTION DIA GRAM: CONTROL MODULE. INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND/OR POWER SOURCE. K487-25 SPOOL GUN BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE "LINCOLN" (CONTACT CLOSURE) POSITION BEFORE ATTEMPTING TO OPERATE N.B. USE VOLTMETER SWITCH TO SELECT DES ...
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Lincoln Electric IM544-B - page 36
F-4 DIA GRAMS F-4 COMMANDER 400 CONNECTION DIA GRAM: LN-23P KIT ADAPTER K350-1 6 PIN ELECTRODE CABLE AMPHENOL AMPHENOL N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. TO WORK 12-13-96 COMMANDER 400 STICK & WIRE / LN-23P CONNECTION DIAGRAM N.C. IF REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL/REMOTE SWITCH IN "REMOTE" POSI ...
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Lincoln Electric IM544-B - page 37
F-5 DIA GRAMS F-5 COMMANDER 400 CONNECTION DIA GRAM: ELECTRODE TO WORK N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. ELECTRODE CABLE 6 PIN TO WORK AMPHENOL AMPHENOL 14 PIN LN-25 WIRE FEEDER TO WORK WORK CLIP LEAD OPTIONAL K857 REMOTE CONTROL N.D. ON COMMANDER 400 STICK & WIRE, THE OUTPUT CONTROL SWITCH MUST BE IN THE "WEL ...
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Lincoln Electric IM544-B - page 38
F-6 DIA GRAMS F-6 COMMANDER 400 CONNECTION DIA GRAM: CAUTION : ELECTRODE 14 PIN AMPHENOL TO WORK TO WORK WIRE COMMANDER 400 STICK & WIRE / K867 / LN-8 CONNECTION DIAGRAM FEEDER K196 K867 UNIVERSAL ADAPTER PLUG INPUT CABLE ELECTRODE CABLE TO WIRE FEED UNIT 12-13-96 2 4 76 77 ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTI ...
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Lincoln Electric IM544-B - page 39
F-7 DIA GRAMS F-7 COMMANDER 400 CONNECTION DIA GRAM: 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 RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPE ...
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Lincoln Electric IM544-B - page 40
F-8 DIA GRAMS F-8 COMMANDER 400 CONNECTION DIA GRAM: GND 75 76 77 GREEN K291 OR K404 75 INPUT CABLE 76 N.E. 77 TO WORK K775 OPTIONAL REMOTE CONTROL DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN 14 PIN 81 42 41 31 31 32 32 2 2 4 4 21 21 GND 82 N.D. ELECTRODE CABLE TO WIRE FEED UNIT ...
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Lincoln Electric IM544-B - page 41
F-9 DIA GRAMS F-9 COMMANDER 400 CONNECTION DIA GRAM: 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 OPERATING MANUAL. TO WORK TO WIRE FEED UNIT ELECT ...
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Lincoln Electric IM544-B - page 42
F-10 DIA GRAMS F-10 COMMANDER 400 CONNECTION DIA GRAM: Disconnect NEGATIVE (-) BATTERY LEAD Do not touch electrically live parts. 14 PIN AMPHENOL TO WORK ELECTRODE before servicing. Do not operate with panels open. TO WORK CAUTION : THE ENGINE WELDER OPERATING MANUAL. APPLICATIONS. SEE OPERATING MANUAL. PLACE LOCAL / REMOTE SWITCH IN "REMOTE&q ...
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Lincoln Electric IM544-B - page 43
F-11 DIA GRAMS 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 29.50 29.50 32.06 48.30 * TRAILER MOUNTING HOLE LOCATIONS. 31.50 M17 ...
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Lincoln Electric IM544-B - page 44
F-12 NO TES F-12 COMMANDER 400 ...
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Lincoln Electric IM544-B - page 45
Now A vailab le...12th Edition The Procedure Handbook of Ar c W elding With ov er 500,000 copies of pre vious editions pub lished since 1933, the Procedure Handbook is considered by man y to be the “Bible” of the arc welding industry . This printing will go fast so don’t dela y . Place your order now using the coupon belo w . The hardbound bo ...
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Lincoln Electric IM544-B - page 46
W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German P ortuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA E ...
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Lincoln Electric IM544-B - page 47
W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German P ortuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f ...
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Lincoln Electric IM544-B - page 48
• Sales and Ser vice through Subsidiaries and Distributors W orldwide • Cle v eland, Ohio 44117-1199 U .S .A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectr ic.com W orld's Leader in W elding and Cutting Products Premier Manuf acturer of Industrial Motors ST A TEMENT OF LIMITED W ARRANTY The Lincoln Electric Company (Lin ...
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