Lincoln-electric IM544 Commander 400 Manuel d'utilisateur

Commander 400OPERATOR’S MANUALIM544-BJune, 1998Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in

A-3INSTALLATION COMMANDER 400A-3HIGH ALTITUDE OPERATIONAt higher altitudes, output derating may be necessary.As a rule of thumb, derate the welder o

A-4INSTALLATION COMMANDER 400A-4FUEL CAPRemove the plastic cap covering from the Fuel TankFiller neck and install the Fuel Cap.ENGINE COOLING SYSTEM

A-5INSTALLATION COMMANDER 400A-5WELDING OUTPUT CABLESWith the engine off, route the electrode and workcables thru the strain relief bracket provided

A-6INSTALLATION COMMANDER 400A-62. Take necessary steps to assure load is limited to thecapacity of the Commander by installing a 45 amp,240 VAC dou

B-1OPERATIONB-1OPERATING INSTRUCTIONSRead and understand this entire section before operat-ing your Commander 400.SAFETY INSTRUCTIONSDo not attempt to

B-2OPERATIONB-2FOR AUXILIARY POWER• 10,000 watts of 120/240 VAC, 60Hz auxiliary power.• Drive a 2 HP motor (provided it is started under noload).• Tw

B-3OPERATIONB-3ENGINE CONTROLS (Items 1 through 8)1. RUN- STOP SWITCHWhen placed in the “RUN” position, this switch ener-gizes the fuel sole

B-4OPERATIONB-44. ENGINE TEMPERATURE GAUGE ANDLIGHTThe gauge displays the engine oil temperature. Theyellow temperature light remains off under normal

B-5OPERATIONB-5WELDER CONTROLS (Items 9 through 14 )9. OUTPUT RANGE SWITCH & OUTPUT CONTROLThese two controls allow you to select betwe

B-6OPERATIONB-617. 120VAC RECEPTACLESThese two 120VAC (5-15R) receptacles with GFCI pro-tection provide 120VAC for auxiliary power. Thesereceptacles h

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

B-7OPERATIONB-7TYPICAL FUEL CONSUMPTIONRefer to Table B.2 for typical fuel consumption of theCommander 400’s Engine for various operating sce-narios.T

B-8OPERATIONB-8COMMANDER 400 SETTINGS WHEN USING THEK799 HI-FREQ UNITa. Set the OUTPUT RANGE switch to the “50-575 set-ting” (Fabrication and General

B-9OPERATIONB-9WIRE FEED (CONSTANT VOLTAGE) WELD-ING(Stick and Wire models only)Connect a wire feeder to the Commander 400 and set thewelder controls

B-10OPERATIONB-10AUXILIARY POWER OPERATIONStart the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregar

C-1ACCESSORIESC-1OPTIONAL FIELD INSTALLEDACCESSORIESK802R POWER PLUG KIT - Provides a plug for eachreceptacle.K857 28 ft. (8.5 m) or K857-1 100 ft. (3

D-1MAINTENANCED-1SAFETY PRECAUTIONS•Have a qualified technician do the maintenanceand troubleshooting work.•Turn the engine off before working inside

D-2MAINTENANCED-27. Inspect for holes and tears by looking through theelement toward a bright light. Check for damaged gas-kets or dented metal parts.

D-3MAINTENANCED-34. Slide the new element onto the grommet post on thebottom of the filter header until the element no longereasily moves up into th

D-4MAINTENANCED-4COMMANDER 400Table D.1 Engine Maintenance ComponentsITEMAir Cleaner ElementCooling Blower BeltOil Filter ElementFuel Filter ElementWa

E-1TROUBLESHOOTINGE-1COMMANDER 400If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, conta

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

E-2TROUBLESHOOTINGE-2COMMANDER 400Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proced

E-3TROUBLESHOOTINGE-3COMMANDER 400Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proced

E-4TROUBLESHOOTINGE-4COMMANDER 400Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proced

F-1DIAGRAMSF-1COMMANDER 400NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-

F-2DIAGRAMSF-2COMMANDER 400NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-

F-3DIAGRAMSF-3COMMANDER 400CONNECTION DIAGRAM:CONTROL MODULE. INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND/OR POWER SOUR

F-4DIAGRAMSF-4COMMANDER 400CONNECTION DIAGRAM:LN-23PKITADAPTERK350-16 PINELECTRODE CABLEAMPHENOLAMPHENOLN.B. USE VOLTMETER SWITCH TO SELECT DESIRED E

F-5DIAGRAMSF-5COMMANDER 400CONNECTION DIAGRAM:ELECTRODETO WORKN.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY.ELECTRODE CABLE6 PINTO W

F-6DIAGRAMSF-6COMMANDER 400CONNECTION DIAGRAM:CAUTION :ELECTRODE14 PINAMPHENOLTO WORKTO WORKWIRECOMMANDER 400 STICK & WIRE / K867 / LN-8 CONNECTIO

F-7DIAGRAMSF-7COMMANDER 400CONNECTION DIAGRAM:ELECTRODETO WORK S22914 12-13-96CAUTION :AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTA

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

F-8DIAGRAMSF-8COMMANDER 400CONNECTION DIAGRAM:GND757677GREENK291 OR K40475INPUT CABLE76N.E.77TO WORKK775 OPTIONALREMOTE CONTROLDAMAGED. THE ENGINE GOV

F-9DIAGRAMSF-9COMMANDER 400CONNECTION DIAGRAM:Keep guards in place.Keep away from moving parts.Only qualified personnel should install,useor service t

F-10DIAGRAMSF-10COMMANDER 400CONNECTION DIAGRAM:Disconnect NEGATIVE (-) BATTERY LEADDo not touch electrically live parts.14 PINAMPHENOLTO WORKELECTROD

F-11DIAGRAMSF-11COMMANDER 400DIMENSION PRINTFOR BATTERYREMOVAL.19.6323.6928.9950.3854.441.26 6-21-9645.67CENTER OF GRAVITYWITH OIL IN ENGINEAND FULL F

F-12NOTESF-12COMMANDER 400

Now Available...12th EditionThe Procedure Handbook of Arc WeldingWith over 500,000 copies of previous editions publishedsince 1933, the Procedure Hand

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ivSAFETYivPRÉCAUTIONS DE SÛRETÉPourvotre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parrai

Thank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product •••as much p

TABLE OF CONTENTSPageSafety ...

A-1INSTALLATION COMMANDER 400A-1TECHNICAL SPECIFICATIONS - Commander 400Make/Model Description Speed (RPM) Displacement Starting CapacitiesSystemDeu

A-2INSTALLATION COMMANDER 400A-2Read this entire installation section before youstart installation.SAFETY PRECAUTIONSDo not attempt to use this equi