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B-1
OPERATION
B-1
OPERATING INSTRUCTIONS
Read and understand this entire section before operat-
ing your Commander 400.
SAFETY INSTRUCTIONS
Do not attempt to use this equipment until you 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.
•Stop engine before servicing.
•Keep away from moving parts
------------------------------------------------------------------------
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.
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)
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.
COMMANDER 400
WARNING