Lincoln Electric 500 manual

Commander 500 OPERA T OR’S MANUAL IM699 April, 2002 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MA[...]

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-ventilated areas or vent the engine exhaust fumes outdoors. _______________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical[...]

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 secousse électrique: a. Les circuits [...]

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 keep it handy for quick reference. Pay par[...]

T ABLE OF CONTENTS Page Safety ......................................................................................................................... i-iv Installation .......................................................................................................Section A T echnical Specifications ........................................[...]

T ABLE OF CONTENTS Accessories .....................................................................................................Section C Optional Field Installed Accessories .....................................................................C-1 Recommended Optional Equipment ...................................................................[...]

A-1 INST ALLA TION COMMANDER 500 A-1 TECHNICAL SPECIFICA TIONS - 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 1475 (2.83 L) & Starter 94.6 L Diesel Engine @ 1800 RPM Full Load 1800 B[...]

A-2 INST ALLA TION COMMANDER 500 A-2 Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine. They include impor- tant safety precautions, detailed engine starting, operating and main[...]

A-3 INST ALLA TION COMMANDER 500 A-3 LIFTING The Commander lift bale should be used to lift the machine. The Commander is shipped with the lift bale retracted. Before attempting to lift the Commander the lift bale must be secured in a raised position. Secure the lift bale as follows: a. Open the engine compartment door . b. Locate the 2 access hole[...]

A-4 INST ALLA TION COMMANDER 500 A-4 PRE-OPERA TION ENGINE SER VICE 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 at a moderate rate and do not overfi[...]

A-5 INST ALLA TION COMMANDER 500 A-5 MUFFLER OUTLET PIPE Remove the plastic plug covering the muffler outlet tube. Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction. SP ARK ARRESTER Some federal, state or local laws may require that gasoline or d[...]

A-6 INST ALLA TION COMMANDER 500 A-6 WELDING OUTPUT CABLES With the engine off, route the electrode and work cables thru the strain relief bracket provided on the front of the base and connect to the terminals provid- ed. These connections should be checked periodical- ly and tightened if necessary . Listed in T able A.1 are copper cable sizes reco[...]

A-7 INST ALLA TION COMMANDER 500 A-7 2. T ake necessary steps to assure load is limited to the capacity of the Commander by installing a 50 amp, 240 V AC double pole circuit breaker . Maximum rated load for each leg of the 240 V AC auxiliary is 50 amperes. Loading above the rated output will reduce output voltage below the allowable -10% of rated v[...]

A-8 INST ALLA TION COMMANDER 500 A-8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Shut off welder before making any electrical connec- tions. ------------------------------------------------------------------------ CONNECTION OF THE LN-25 TO THE COMMANDER 500 The LN-25 with or without an external contactor may be used with the Commander 500. See the[...]

A-9 INST ALLA TION COMMANDER 500 A-9 CONNECTION OF AN LN-23P WIRE FEEDER TO THE COMMANDER 500 • Shut the welder of f. • Connect the LN-23P per instructions on the appro- priate connection diagram in the DIAGRAMS sec- tion. (NOTE): When connecting an LN-23P to the Commander 500, a K350-1 adapter kit must be used. • Set the “ WIRE FEEDER VOL [...]

B-1 OPERA TION B-1 Read and understand this entire section before operat- ing your Commander 500. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance i[...]

B-2 OPERA TION B-2 FOR AUXILIAR Y POWER • 12,000 watts of 120/240 V AC, 60Hz auxiliary power . • Power for tools, 120/240 V AC lights, electric pumps and for standby emergency power . • Drive a 5 HP motor (provided it is started under no load). • T wo 20 amp 120 V AC duplex receptacles for up to 40 amps of 120 V AC power . • One 50 amp, 1[...]

B-3 OPERA TION 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. (Note: If the switch is left in the "RU[...]

B-4 OPERA TION B-4 4. ENGINE TEMPERA TURE GAUGE (K1639-2 Std., K1639-1 Opt.) AND LIGHT The gauge displays the engine oil temperature. The yellow temperature light remains off under normal operating temperatures. If the light turns on, the engine protection system will shut down the engine. Check for restrictions at the engine cooling air inlets and[...]

WELDER CONTROLS (Items 9 through 13 ) 9. WELD MODE & OUTPUT CONTROL These two controls allow you to select between various welding output slopes and adjust the desired welding output. Refer to T able B.1 for a description of how these two controls work. T able B.1 Weld Mode and Output Control Functions 1 If the WELD MODE switch is positioned be[...]

B-6 OPERA TION B-6 15. CIRCUIT BREAKERS These circuit breakers provide separate overload cur- rent protection for each 120V circuit at the 240V recep- tacle, each 120V receptacle, the 120V AC in the 14-Pin connector , the 42V AC in the 14-Pin connector and (for codes above 10838 only) battery circuit overload pro- tection. 16. 120V AC RECEPT ACLES [...]

B-7 OPERA TION B-7 BREAK-IN PERIOD The engine used to supply power for your welder is a heavy duty , industrial engine. It is designed and built for rugged use. It is very normal for any engine to use small quantities of oil until the break-in is accom- plished. Check the oil level twice a day during the break-in period (about 200 running hours). I[...]

B-8 OPERA TION B-8 Commander 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the “ 20-250 setting ” (TIG) • . Set the IDLER switch to the “ HIGH “ position. • Set the WELDING TERMINALS switch to the “ Weld T erminals On ” position. This will close the solid state contactor and provide an always “ hot [...]

B-9 OPERA TION B-9 WIRE FEED (CONST ANT VOL T AGE) WELD- ING Connect a wire feeder to the Commander 500 and set welder controls according to the instructions listed earlier in this section. The Commander 500 in the ” CV -WIRE ” position, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and sol[...]

B-10 OPERA TION B-10 COMMANDER 500 Welding Output Range Setting 30-575 500 350 200 150 90 Welding Output 500A/40V 500A/40V 350A/30V 200A/28V 150A/27V 90A/25V Permissible Power - W atts (Unity Power Factor) 0 0 9500 12000 12000 12000 Permissible Current in @120 V ± 10% * 0 0 80* 100** 100** 100** Auxiliary Amperes @ 240 V ± 10% 0 0 40 50 50 50 * E[...]

K1690-1 (1 Duplex) GFCI Kit - Includes one UL approved 1 15V ground fault circuit interrupter duplex type receptacle with cover and installation instructions. Replaces the factory installed 1 15V duplex receptacle. The receptacle of the GFCI duplex is rated at 20 amps, the maximum total current from the GFCI duplex is lim- ited to 20 amps. T wo kit[...]

C-2 ACCESSORIES C-2 COMMANDER 500 RECOMMENDED OPTIONAL EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode holder and cable. • Ground clamp and cable. • Headshield. K857 Remote Control Kit is optional for remote cur- rent control. TIG Magnum TIG T orch Magnum Parts Kit and Argon gas K930-ALL TIG Module (not required for scratch sta[...]

D-1 MAINTENANCE D-1 COMMANDER 500 SAFETY PRECAUTIONS • Have a qualified technician do the maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. • Always use the greatest care when working n[...]

D-2 MAINTENANCE D-2 COMMANDER 500 7. Inspect for holes and tears by looking through the element 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 during drying and storage. 8. Reinstall air filter element. After six cleanings replace air filter . A cleaned[...]

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 longer easily moves up into the filter header . Now rotate the element (may take almost 1 full turn) with a slight upward pressure until the element begins to further engage the header . With the proper orientatio[...]

D-4 MAINTENANCE D-4 COMMANDER 500 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 Screen Battery MAKE Donaldson AC Lincoln Gates Deutz Purolator Napa Fram Deutz Purolator Napa Fram Lincoln Stanadyne Lincoln Stanadyne P ART NUMBER P1[...]

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 T roubleshooting Guide is provided to help you locate and repair [...]

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 troubleshooting assistance before you proceed. CAUTION ENGINE P[...]

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 troubleshooting assistance before you proceed. CAUTION FUNCTION[...]

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 troubleshooting assistance before you proceed. CAUTION OUTPUT P[...]

F-1 DIAGRAMS F-1 COMMANDER 500 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific dia- gram for your particular machine is pasted inside the machine on one of the enclosure panels. GND-H 6D 3 GND-F 5A AUXILI ARY POW ER GND-D 12 11 10 EMPTY CB6 10A EMPTY EMPTY 42A 42 31 GND-E 42A 5[...]

F-2 DIAGRAMS F-2 COMMANDER 500 CONNECTION DIAGRAM:[...]

F-3 DIAGRAMS F-3 COMMANDER 500 CONNECTION DIAGRAM: GND 75 76 77 GREEN K291 OR K404 75 INPUT CABLE 76 N.E. 77 K775 OPTIONAL REMOTE CONTR OL D AMAGED . THE ENGINE GOVERNOR SETTING IS PRE-SET A T THE F ACT ORY - DO NO T ADJUST ABO VE RPM SPECIFICA TIONS LISTED IN 81 42 41 31 31 32 32 2 2 4 4 21 21 GND 82 N.D . LN-7 WIRE FEEDER K eep guards in place. C[...]

F-4 DIAGRAMS F-4 COMMANDER 500 CONNECTION DIAGRAM:[...]

F-5 DIAGRAMS F-5 COMMANDER 500 CONNECTION DIAGRAM:[...]

F-6 DIAGRAMS F-6 COMMANDER 500 CONNECTION DIAGRAM: CA UTION : N.A. WELDING CABLE MUST BE OF PROPER CAP ACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIA TE AND FUTURE APPICA TIONS. SEE OPERA TING MANUAL. 75 32 31 41 42 N.C. INSULA TE EACH UNUSED LEAD INDIVIDU ALL Y . N.D . SPLICE LEADS AND INSULA TE. THE ENGINE WELDER OPERA TING MANU AL. GND 31 4 21 [...]

F-7 DIAGRAMS F-7 COMMANDER 500 CONNECTION DIAGRAM:[...]

F-8 DIAGRAMS F-8 COMMANDER 500 CONNECTION DIAGRAM:[...]

F-9 DIAGRAMS F-9 COMMANDER 500 CONNECTION DIAGRAM: o r se rvi ce t his eq ui pm e nt . Only q ua lifie d personne l should install, use Ke ep aw ay f rom mo v ing pa rt s. Ke ep gu ar d s in p lac e. MOVIN G PAR TS ca n in jure WA R N I N G Do no t to uc h e l ec tri cal ly liv e p art s . bef or e s e rv i c i ng . D is co nn ect NE GAT IV E (- ) [...]

F-10 DIAGRAMS F-10 COMMANDER 500 CONNECTION DIAGRAM: or service this equ ipm ent. On ly qualified personnel should install,use Keep away from movi ng parts. Keep guards in place. MOVING PART S can injure WA R N I N G Do not touch electrically live pa rts. before servicing. Disconnect NEGATI VE (-) Battery lead Do not operate with panels open. ELECT[...]

F-1 1 DIAGRAMS F-1 1 COMMANDER 500 CONNECTION DIAGRAM:[...]

F-12 DIAGRAMS F-12 COMMANDER 500 CONNECTION DIAGRAM:[...]

F-13 DIAGRAMS F-13 COMMANDER 500 CONNECTION DIAGRAM:[...]

F-14 DIAGRAMS F-14 COMMANDER 500 DIMENSION PRINT TRAILER MOUNT ING HOLE LOCATIONS. * 22.25 30.2 5 8.69 46.00 38.58 M18962 11-2000 REV 28.99 1.26 19.63 6.53 24.9 7 6.55 23.69 50.38 54.4 4 14.6 3 37.3 0 45.38 63.1 0 6.56 42.00 32.0 8 31.5 0 45.6 7 * * * * BOTT OM VIEW OF WELDER BASE . NOTES PER TABLE: N.A.A. CENTER OF GRAVITY WITH OIL IN ENGINE AND F[...]

NOTES COMMANDER 500[...]

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W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese 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. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA E[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese 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. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com • World's Leader in W elding and Cutting Products •[...]