Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii; ELECTRIC SHOCK can kill.
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre 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 Pour Soudage A L’Arc 1. Protegez-vous contre la seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and...
Page 7 - TABLE OF CONTENTS; Page
TABLE OF CONTENTS Page Safety ......................................................................................................................... i-iv Installation .......................................................................................................Section A Technical Specifi...
Page 8 - vii
TABLE OF CONTENTS Accessories .....................................................................................................Section C Optional Field Installed Accessories .....................................................................C-1Recommended Optional Equipment ......................
Page 9 - INSTALLATION; Deutz; INPUT - DIESEL ENGINE
A-1 INSTALLATION COMMANDER 500 A-1 TECHNICAL SPECIFICATIONS - Commander 500 (K1639-1 & -2) Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder High Idle 1900 173 cu. in 12VDC battery Fuel: 25 gal. F3L 912 44 HP(33 kw) Low Idle 1400 (2.83 L) & Starter 9...
Page 10 - SAFETY PRECAUTIONS; LOCATION / VENTILATION; STORING
A-2 INSTALLATION COMMANDER 500 A-2 Read this entire installation section before youstart installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read all operating and maintenance man-uals supplied with your machine. They include impor-tant safety precautions, ...
Page 11 - LIFTING
A-3 INSTALLATION COMMANDER 500 A-3 LIFTING The Commander lift bale should be used to lift themachine. The Commander is shipped with the lift baleretracted. Before attempting to lift the Commander thelift bale must be secured in a raised position. Securethe lift bale as follows: a. Open the engine co...
Page 12 - PRE-OPERATION ENGINE SERVICE; OIL; Running out of fuel may require bleeding; Before starting the engine, open the fuel shutoff; FUEL CAP
A-4 INSTALLATION COMMANDER 500 A-4 PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc-tions supplied with this machine. •Keep hands away from the engine muffler or HOT engine parts. •Stop engine and allow to cool before fueling. •Do not smoke when fueling. •Fill fuel tank...
Page 13 - MUFFLER OUTLET PIPE; The high frequency; REMOTE CONTROL; OUTPUT; When using the 14 pin connector, if the wire; WELDING TERMINALS
A-5 INSTALLATION COMMANDER 500 A-5 MUFFLER OUTLET PIPE Remove the plastic plug covering the muffler outlettube. Using the clamp provided secure the outlet pipeto the outlet tube with the pipe positioned such that itwill direct the exhaust in the desired direction. SPARK ARRESTER Some federal, state ...
Page 14 - WELDING OUTPUT CABLES; Table A.1 Combined Length of Electrode and Work; MACHINE GROUNDING
A-6 INSTALLATION COMMANDER 500 A-6 WELDING OUTPUT CABLES With the engine off, route the electrode and workcables thru the strain relief bracket provided on thefront of the base and connect to the terminals provid-ed. These connections should be checked periodicallyand tightened if necessary. Listed ...
Page 15 - Take necessary steps to assure load is limited to the; Figure A.2 Connection of the Commander 500 to Premises Wiring
A-7 INSTALLATION COMMANDER 500 A-7 2. Take necessary steps to assure load is limited to the capacity of the Commander by installing a 50 amp,240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 50amperes. Loading above the rated output will reduce output v...
Page 18 - OPERATION; OPERATING INSTRUCTIONS; Always wear dry insulating gloves.; ENGINE EXHAUST can kill.; Do not stack anything near the engine.; MOVING PARTS can injure.; Stop engine before servicing.; ADDITIONAL SAFETY PRECAUTIONS; GENERAL DESCRIPTION; RECOMMENDED APPLICATIONS; WELDER; DESIGN FEATURES AND ADVANTAGES; cored wire and arc gouging applications.
B-1 OPERATION B-1 OPERATING INSTRUCTIONS Read and understand this entire section before operat-ing your Commander 500. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you havethoroughly read all operating and maintenance man-uals supplied with your machine. They include impor-tant saf...
Page 19 - FOR AUXILIARY POWER; WELDING CAPABILITY
B-2 OPERATION B-2 FOR AUXILIARY POWER • 12,000 watts of 120/240 VAC, 60Hz auxiliary power. • Power for tools, 120/240 VAC lights, electric pumps and for standby emergency power. • Drive a 5 HP motor (provided it is started under no load). • Two 20 amp 120 VAC duplex receptacles for up to 40 amps of ...
Page 20 - RUN- STOP SWITCH; CONTROLS AND SETTINGS; Figure B.1 Case Front Panel Controls
B-3 OPERATION B-3 ENGINE CONTROLS (Items 1 through 8) 1. RUN- STOP SWITCH When placed in the “ RUN ” position, this switch ener- gizes the fuel solenoid and other electric accessories.When placed in the “ STOP ” position, the flow of fuel to the injection pump is stopped to shut down the engine.(Not...
Page 21 - Idler Operational exceptions
B-4 OPERATION B-4 4. ENGINE TEMPERATURE GAUGE (K1639-2 Std., K1639-1 Opt.) AND LIGHT The gauge displays the engine oil temperature. Theyellow temperature light remains off under normaloperating temperatures. If the light turns on, the engineprotection system will shut down the engine. Check forrestr...
Page 23 - ENGINE OPERATION; STARTING THE ENGINE; COLD WEATHER STARTING; STOPPING THE ENGINE
B-6 OPERATION B-6 17. 120VAC RECEPTACLES These two 120VAC (5-20R) receptacles provide120VAC for auxiliary power. Each receptacle has a 20amp total rating. Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter forfurther information about these receptacles. Also referto the AUX...
Page 24 - IMPORTANT; TYPICAL FUEL CONSUMPTION; Table B.2 Deutz F3L 912 Engine Fuel Consumption; WELDER OPERATION; STICK WELDING; PIPE WELDING; TIG WELDING
B-7 OPERATION B-7 BREAK-IN PERIOD The engine used to supply power for your welder is aheavy duty, industrial engine. It is designed and builtfor rugged use. It is very normal for any engine to usesmall quantities of oil until the break-in is accom-plished. Check the oil level twice a day during theb...
Page 25 - Table B.3 TYPICAL CURRENT RANGES
B-8 OPERATION B-8 Commander 500 SETTINGS WHEN USING THEK799 HI-FREQ UNIT a. Set the SELECTOR switch to the “ 15-200 setting ” (TIG) b. Set the IDLER switch to the “ HIGH “ position. c. Set the LOCAL/REMOTE switch to the “ REMOTE ” posi- tion. d. Set the WELDING TERMINALS switch to the “ Welding Term...
Page 26 - The Commander 500 in the; AUXILIARY POWER OPERATION
B-9 OPERATION B-9 WIRE FEED (CONSTANT VOLTAGE) WELD-ING Connect a wire feeder to the Commander 500 and setwelder controls according to the instructions listed earlierin this section. The Commander 500 in the ” WIRE WELDING ” position, permits it to be used with a broad range of flux cored wire(Inner...
Page 27 - TABLE B.4 Commander 500 Simultaneous Welding and Power
B-10 OPERATION B-10 COMMANDER 500 Welding Output Range Setting 30-575 500350250150 90 Welding Output 500A/40V500A/40V350A/30V250A/29V150A/27V 90A/25V Permissible Power - Watts (Unity Power Factor) 00 9500 120001200012000 Permissible Current in @120 V ±10% * 00 80* 100**100**100** AuxiliaryAmperes @ ...
Page 28 - ACCESSORIES; RECOMMENDED OPTIONAL EQUIPMENT; STICK; does
C-1 ACCESSORIES C-1 OPTIONAL FIELD INSTALLEDACCESSORIES K802N POWER PLUG KIT - Provides a plug for each recep-tacle. K857 28 ft. (8.5 m) or K857-1 100 ft. (30.4 m) REMOTECONTROL - Portable control provides same dial range asthe output control on the welder from a location up to thespecified length f...
Page 29 - MAINTENANCE; DAILY; ENGINE MAINTENANCE; AIR FILTER
D-1 MAINTENANCE D-1 COMMANDER 500 SAFETY PRECAUTIONS • Have a qualified technician do the maintenanceand troubleshooting work. • Turn the engine off before working inside themachine. • Remove guards only when necessary and replacethem when the maintenance requiring theirremoval is complete. • Always...
Page 30 - FUEL FILTERS; Secondary Fuel Filter located after the
D-2 MAINTENANCE D-2 COMMANDER 500 7. Inspect for holes and tears by looking through theelement toward a bright light. Check for damaged gas-kets or dented metal parts. Do not reuse damaged ele-ments. Protect element from dust and damage duringdrying and storage. 8. Reinstall air filter element. Afte...
Page 31 - SECONDARY FUEL FILTER; COOLING SYSTEM; PREVENTING ELECTRICAL DAMAGE
D-3 MAINTENANCE D-3 COMMANDER 500 4. Slide the new element onto the grommet post on the bottom of the filter header until the element no longereasily moves up into the filter header. Now rotate theelement (may take almost 1 full turn) with a slightupward pressure until the element begins to furthere...
Page 32 - Table D.1 Engine Maintenance Components; STORAGE
D-4 MAINTENANCE D-4 COMMANDER 500 Table D.1 Engine Maintenance Components ITEM Air Cleaner Element Cooling Blower Belt Oil Filter Element Fuel Filter Element Water Separator Element Fuel Pre-Filter Screen Battery MAKE Donaldson AC Lincoln Gates Deutz Purolator Napa Fram Deutz Purolator Napa Fram Lin...
Page 33 - TROUBLESHOOTING; Local; CAUTION
E-1 TROUBLESHOOTING E-1 COMMANDER 500 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting ...
Page 34 - ENGINE PROBLEMS; cooling blower; Local Lincoln Authorized
E-2 TROUBLESHOOTING E-2 COMMANDER 500 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshootin...
Page 35 - FUNCTION PROBLEMS
E-3 TROUBLESHOOTING E-3 COMMANDER 500 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshootin...
Page 36 - OUTPUT PROBLEMS
E-4 TROUBLESHOOTING E-4 COMMANDER 500 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshootin...
Page 37 - DIAGRAMS; COMMANDER 500 WIRING DIAGRAM; ENHANCED DIAGRAM
F-1 DIAGRAMS F-1 COMMANDER 500 NO TE: This diag ram is f or ref erence only . It ma y not be accur ate f or all machines co v ered b y this man ual. The specific dia- g ram f or y our par ticular machine is pasted inside the machine on one of the enclosure panels . WIRING DIAGRAM: 5M 6D 6C 9 GND-E 2...
Page 40 - COMMANDER / LN-7 CONNECTION DIAGRAM
F-4 DIAGRAMS F-4 COMMANDER 500 CONNECTION DIAGRAM: WARNING Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts. S23987 7-21-98 CAUTION : AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEE...
Page 41 - COMMANDER TO K867 ADAPTER CONNECTION DIAGRAM
F-5 DIAGRAMS F-5 COMMANDER 500 CONNECTION DIAGRAM: N.C. NOT USED ON COMMANDER POWER SOURCES } 41 2 N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. SEE OPERATING MANUAL. N.D. CONNECT TOGETHER FOR WELDING OUTPUT } 42 VAC OPTIONAL } 4 4...
Page 43 - COMMANDER TO LN-23P WITH ADAPTER KIT; CONNECTION DIAGRAM & INSTALLATION DETAIL
F-7 DIAGRAMS F-7 COMMANDER 500 CONNECTION DIAGRAM: WIRE FEEDER "B" N.B. 60 2 FEEDER "A" 60 4 75 76 77 14 PIN AMPHENOL M17866 N.D. IF REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL/REMOTE SWITCH IN "REMOTE" N.E THE OUTPUT CONTROL SWITCH MUST BE IN THE "WELDING TERMINALS REMOTE...
Page 44 - WITH OPTIONAL K857 REMOTE CONTROL
F-8 DIAGRAMS F-8 COMMANDER 500 CONNECTION DIAGRAM: ELECTRODE CABLE N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. AMPHENOL TO WORK 14 PIN AMPHENOL LN-25 TO WORK ELECTRODE 6 PIN Do not operate with panels open. before servicing. Disconnect NEGATIVE (-) BATTERY LEAD Do not touch elect...
Page 45 - CABLE PLUG; COMMANDER / LN-8 CONNECTION DIAGRAM
F-9 DIAGRAMS F-9 COMMANDER 500 CONNECTION DIAGRAM: Disconnect NEGATIVE (-) BATTERY LEAD AMPHENOL Do not touch electrically live parts. ELECTRODE CABLE TO WIRE FEED UNIT 14 PIN TO WORK before servicing. Do not operate with panels open. ELECTRODE TO WORK CAUTION : THE ENGINE WELDER OPERATING MANUAL. A...
Page 46 - CONNECTION DIAGRAM
F-10 DIAGRAMS F-10 COMMANDER 500 CONNECTION DIAGRAM: or service this equipment. K432-"L" CABLE ELECTRODE CABLE 14 PIN LN-25 WIRE FEEDER WITH K431 OPTION Keep away from moving parts. N.B. DIAGRAM SHOWS ELECTRODE POSTIVE. TO CHANGE POLARITY, TURN POWER "OFF". N.C. MOUNT K433 TO ENGINE ...
Page 47 - WITH OPTIONAL K444-1 REMOTE CONTROL
F-11 DIAGRAMS F-11 COMMANDER 500 CONNECTION DIAGRAM: N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. TO WORK ELECTRODE CABLE AMPHENOL TO WORK WORK CLIP LEAD LN-25 WIRE FEEDER OPTIONAL K444-1 REMOTE CONTROL TO WORK ELECTRODE AMPHENOL WITH OPTIONAL K444-1 REMOTE CONTROL COMMANDER/ LN-2...
Page 48 - COMMANDER / K930 TIG MODULE / CONNECTION DIAGRAM
F-12 DIAGRAMS F-12 COMMANDER 500 CONNECTION DIAGRAM: TO WORK K963-1 HAND AMPTROL -OR- K814 ARC START SWITCH K870 FOOT AMPTROL -OR- 14 PIN AMPHENOL S24062 7-18-98 N.B. ATTACH ELECTRODE AND WORK LEADS OF TIG MODULE TO THE POSITIVE AND NEGATIVE STUDS OF WELDER TO SELECT DESIRED ELECTRODE P OLARITY. Kee...
Page 49 - COMMANDER / LN-742 CONNECTION DIAGRAM
F-13 DIAGRAMS F-13 COMMANDER 500 CONNECTION DIAGRAM: Do not operate with panels open. before servicing. Disconnect NEGATIVE (-) BATTERY LEAD Do not touch electrically live parts. PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION. APPLICATIONS. SEE OPERATING MANUAL. CAUTION : THE ENGINE WELDER...
Page 50 - DIMENSION PRINT
F-14 DIAGRAMS F-14 COMMANDER 500 DIMENSION PRINT TRAILER MOUNTING HOLE LOCATIONS. * 45.67 * 42.00 * * 6.55 * 6.53 24.97 6.56 45.38 "D" FOR BATTERY REMOVAL. "A" M18962-1 23.38 "A" "B" "C" 31.13 31.50 19.63 28.99 23.69 50.38 1.26 54.44 63.10 "E" 14.63 37...
Page 51 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th Edition The Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. This printing will go fast so don ’ t delay. Place your order now using...
Page 52 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TOBE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...
