Instruction/ maintenance manual of the product IM544-B Lincoln Electric
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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.
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.
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.
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.
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.
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.
T ABLE OF CONTENTS P age Safety ................................................................................................................................................ i-iv Installation ........................................................
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.
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 .
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.
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 .
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 .
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.
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 .
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 .
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 .
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 .
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.
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.
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 .
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.
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.
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.
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 .
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.
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 .
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 .
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
F-12 NO TES F-12 COMMANDER 400.
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 .
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.
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.
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An important point after buying a device Lincoln Electric IM544-B (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric IM544-B yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric IM544-B - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric IM544-B you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric IM544-B will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric IM544-B, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric IM544-B.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric IM544-B. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric IM544-B along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
