Manuale d’uso / di manutenzione del prodotto IM544-B del fabbricante 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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Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Lincoln Electric IM544-B è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Lincoln Electric IM544-B - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Lincoln Electric IM544-B imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Lincoln Electric IM544-B ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Lincoln Electric IM544-B, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Lincoln Electric IM544-B.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Lincoln Electric IM544-B. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Lincoln Electric IM544-B insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
