Lincoln Electric IM544-B manual

Contents

Main Commander 400 OPERATORS MANUAL IM544-B 9979, 10581 (Stick and Wire Model) Safety Depends on You FOR ENGINE powered equipment. i CALIFORNIA PROPOSITION 65 WARNINGS i ELECTRIC AND MAGNETIC FIELDS may be dangerous ARC RAYS can burn. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. iii WELDING SPARKS can cause fire or explosion. iv PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Thank You vv Please Examine Carton and Equipment For Damage Immediately TABLE OF CONTENTS Page vivi A-1 OUTPUT - WELDER AND GENERATOR TECHNICAL SPECIFICATIONS - Commander 400 INPUT - DIESEL ENGINE RATED OUTPUT - WELDER PHYSICAL DIMENSIONS A-2 SAFETY PRECAUTIONS LOCATION/VENTILATION STACKING ANGLE OF OPERATION LIFTING PRE-OPERATION ENGINE SERVICE OIL FUEL USE DIESEL FUEL ONLY A-4 +- A-4 FUEL CAP - ENGINE COOLING SYSTEM BATTERY CONNECTION A-5 A-5 WELDING OUTPUT CABLES MACHINE GROUNDING AUXILIARY POWER RECEPTACLES STANDBY POWER CONNECTIONS A-6 Figure A.2 Connection of the Commander 400 to Premises Wiring B-1 OPERATING INSTRUCTIONS SAFETY INSTRUCTIONS ADDITIONAL SAFETY PRECAUTIONS GENERAL DESCRIPTION RECOMMENDED APPLICATIONS B-2 ADDITIONAL DESIGN FEATURES AND ADVANT AGES WELDING CAPABILITY B-3 +- B-3 - ENGINE CONTROLS (Items 1 through 8) CONTROLS AND SETTINGS B-4 B-5 B-5 WELDER CONTROLS (Items 9 through 14 ) AUXILIARY POWER CONTROLS (Items 15 - 19 ) B-6 WIRE FEEDER MODE CONTROLS (Items 20 - 24 Stick & Wire model only) ENGINE OPERATION STARTING THE ENGINE STOPPING THE ENGINE BREAK-IN PERIOD B-7 WELDER OPERATION STICK WELDING TIG WELDING ARC GOUGING B-8 COMMANDER 400 SETTINGS WHEN USING THE K799 HI-FREQ UNIT COMMANDER 400 SETTINGS WHEN USING THE K930-1 TIG MODULE Table B.3 TYPICAL CURRENT RANGES (1)FOR TUNGSTEN ELECTRODES(2) B-9 B-9 WIRE FEED (CONSTANT VOLTAGE) WELD- ING LN-25 LN-7 or LN-8 LN-23P AUXILIARY POWER OPERATION SIMULTANEOUS WELDING AND AUXIL- IARY POWER LOADS C-1 ACCESSORIES C-1 OPTIONAL FIELD INSTALLED ACCESSORIES RECOMMENDED EQUIPMENT STICK SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE DAILY WEEKLY ENGINE MAINTENANCE D-2 FUEL FILTERS Be careful not to damage the pre-filter screen with the tool used to remove the plug. D-3 SECONDARY FUEL FILTER COOLING SYSTEM COOLING BLOWER BELT BATTERY HANDLING D-4 E-1 Step 1. LOCATE PROBLEM(SYMPTOM). Step 2. PERFORM EXTERNAL TESTS. Step 3. RECOMMENDED COURSE OF ACTION HOW TO USE TROUBLESHOOTING GUIDE E-2 ENGINE PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION Page E-4 OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION F-1 5-15-98A COMMANDER 400-STICK MODEL WIRING DIAGRAM TEMP. PC BOARD F-2 5-15-98A ENGINE PROT. BOARD 32A WARNING 6 PIN REMOTE F-4 WARNING F-4 TERMINALS REMOTELY CONTROLLED" POSITION. N.D. ON COMMANDER 400 STICK & WIRE, THE OUTPUT CONTROL SWITCH MUST BE IN THE "WELDING N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE F-5 AND FUTURE APPLICATIONS. SEE OPERATING MANUAL. N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE TERMINALS ALWAYS ON" POSITION . N.D. ON COMMANDER 400 STICK & WIRE, THE OUTPUT CONTROL SWITCH MUST BE IN THE "WELDING WARNING THE ENGINE WELDER OPERATING MANUAL. F-6 Do not operate with panels open. before servicing. F-7 COMMANDER 400 STICK & WIRE / LN-7 CONNECTION DIAGRAM ELECTRODE CABLE TO WIRE FEED UNIT F-8 } } F-9 COMMANDER 400 STICK & WIRE TO K867 ADAPTER CONNECTION DIAGRAM ELECTRODE CABLE WARNING F-10 WARNING F-10 ELECTRODE CABLE K595 CONTROL CABLE TO LN-8 INPUT F-11 * F-11 DIMENSION PRINT Page Now Available...12th Edition The Procedure Handbook of Arc Welding How To Read Shop Drawings New Lessons in Arc Welding Need Welding Training? Lincoln Welding School AVISO DE PRECAUCION ATTENTION WARNUNG ATENO AVISO DE PRECAUCION ATTENTION WARNUNG ATENO STATEMENT OF LIMITED WARRANTY Dec, 97 WARRANTY PERIOD CONDITIONS OF WARRANTY LIMITED WARRANTY