Lincoln Electric COMMANDER 500 IM644-A manual

Commander 500 OPERA T OR’S MANU AL IM644-A January , 2001 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. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT [...]

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 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. 4.b . Use suitab le clothing made from durab le flame-resistant material to protect you[...]

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. 8.c. Ground the equipment in accordance with the U.S . National Elect[...]

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. Protegez-vous contre la secousse électrique: a. Les circu[...]

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 Man ual completely bef ore attempting to use this equipment. Sa v e this manual and k eep it handy f or quick ref ere[...]

T ABLE OF CONTENTS P age 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 batter y Fuel: 25 gal. F3L 912 44 HP(33 kw) Low Idle 1400 (2.83 L) & Star ter 94.6 L Diesel Engine @ 1800 RPM Full Load 1800[...]

A-2 INST ALLA TION COMMANDER 500 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 . They include impor- tant saf ety precautions, detailed engine starting, operating an[...]

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. Bef ore attempting to lift the Commander the lift bale must be secured in a raised position. Secure the lift bale as f ollows: a. Open the engine compar tment door . b . Locate the 2 access [...]

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. •K eep hands awa y from the engine muffler or HO T engine par ts. •Stop engine and allo w to cool bef ore fueling. •Do not smoke when fueling. •Fill fuel tank at a moderate rate and do not [...]

A-5 INST ALLA TION COMMANDER 500 A-5 MUFFLER OUTLET PIPE Remov e the plastic plug co v ering 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 e xhaust in the desired direction. SP ARK ARRESTER Some f ederal, state or local la ws ma y require that gasoli[...]

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 brac k et pro vided on the front of the base and connect to the terminals provid- ed. These connections should be check ed periodically and tightened if necessar y . Listed in T able A.1 are copper cab le siz e[...]

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 doub le pole circuit break er . Maximum rated load f or each leg of the 240 V A C auxiliar y is 50 amperes. Loading abov e the rated output will reduce output v oltage below the allo wab le -10% [...]

A-8 INST ALLA TION COMMANDER 500 A-8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Shut off welder bef ore making an y electrical connec- tions. ------------------------------------------------------------------------ CONNECTION OF THE LN-25 T O THE COMMANDER 500 The LN-25 with or without an e xternal contactor may be used with the Commander 500. See[...]

A-9 INST ALLA TION COMMANDER 500 A-9 CONNECTION OF AN LN-23P WIRE FEEDER T O THE COMMANDER 500 a. Shut the welder off . b . Connect the LN-23P per instructions on the appro- priate connection diagram in the DIA GRAMS sec- tion. (NO TE): When connecting an LN-23P to the Commander 500, a K350-1 adapter kit must be used. c. Set the “ V OL TMETER ”[...]

B-1 OPERA TION B-1 OPERA TING INSTRUCTIONS Read and understand this entire section bef ore oper at- ing your Commander 500. 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 . They include impor- tant saf ety precautions, detailed engine star[...]

B-2 OPERA TION B-2 FOR A UXILIAR Y PO WER • 12,000 watts of 120/240 V A C , 60Hz auxiliary power . • P o wer f or tools, 120/240 V AC lights , electric pumps and f or standby emergency po wer . • Drive a 5 HP motor (provided it is started under no load). • T wo 20 amp 120 V AC duple x receptacles for up to 40 amps of 120 V AC po wer . • O[...]

B-3 OPERA TION B-3 ENGINE CONTROLS (Items 1 through 8) 1. RUN- ST OP SWITCH When placed in the “ RU N ” position, this switch ener- gizes the fuel solenoid and other electric accessories. When placed in the “ ST OP ” position, the flo w of fuel to the injection pump is stopped to shut down the engine . (Note: If the switch is left in the &q[...]

B-4 OPERA TION B-4 4. ENGINE TEMPERA TURE GA UGE (K1639-2 Std., K1639-1 Opt.) AND LIGHT The gauge displa ys the engine oil temperature . The yello w temperature light remains off under normal operating temperatures . If the light tur ns on, the engine protection system will shut down the engine . Check f or restrictions at the engine cooling air in[...]

WELDER CONTROLS (Items 9 through 14 ) 9. OUTPUT SELECT OR SWITCH & OUTPUT CONTROL These two controls allo w you to select betw een various 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. T able B.1 Output Range Switch and Output Control Functions 1 If the SELEC[...]

B-6 OPERA TION B-6 17. 120V A C RECEPT A CLES These two 120V AC (5-20R) receptacles pro vide 120V AC f or auxiliary power . Each receptacle has a 20 amp total rating. Refer to the A UXILIAR Y PO WER RECEPT ACLES section in the installation chapter f or fur ther inf or mation about these receptacles. Also refer to the A UXILIAR Y PO WER OPERA TION s[...]

B-7 OPERA TION B-7 BREAK-IN PERIOD The engine used to supply pow er f or your w elder is a heavy duty , industrial engine. It is designed and built f or rugged use. It is ver y normal for an y engine to use small quantities of oil until the break-in is accom- plished. Check the oil le v el twice a da y during the break-in period (about 200 r unning[...]

B-8 OPERA TION B-8 Commander 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT a. Set the SELECT OR s witch to the “ 15-200 setting ” (TIG) b . Set the IDLER s witch to the “ HIGH “ position. c. Set the LOCAL/REMO TE s witch to the “ REMO TE ” posi- tion. d. Set the WELDING TERMINALS switch to the “ W elding T er minals Alwa ys On ” pos[...]

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

B-10 OPERA TION B-10 COMMANDER 500 W elding Output Range Setting 30-575 500 350 250 150 90 W elding Output 500A/40V 500A/40V 350A/30V 250A/29V 150A/27V 90A/25V P er missible P ower - W atts (Unity P ower F actor) 0 0 9500 12000 12000 12000 P er missible Current in @120 V ±10% * 0 0 80* 100** 100** 100** A uxiliar y Amperes @ 240 V ±10% 0 0 40 50 [...]

C-1 A CCESSORIES C-1 OPTIONAL FIELD INST ALLED A CCESSORIES K802N PO WER PLUG KIT - Provides a plug for each recep- tacle. K857 28 ft. (8.5 m) or K857-1 100 ft. (30.4 m) REMO TE CONTROL - P or table control pro vides same dial range as the output control on the welder from a location up to the specified length from the welder . Has conv enient plug[...]

D-1 MAINTENANCE D-1 COMMANDER 500 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 onl y when necessary and replace them when the maintenance requiring their remov al is complete. • Al ways use the greatest care when [...]

D-2 MAINTENANCE D-2 COMMANDER 500 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. 8. Reinstall air filter element. After six cleanings replace air filter . A cl[...]

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 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 . With the proper orientat[...]

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 Batter y MAKE Donaldson AC Lincoln Gates Deutz Purolator Napa Fr a m Deutz Purolator Napa Fr a m Lincoln Stanadyne Lincoln Stanadyne P ART NUMB[...]

E-1 TR OUBLESHOO TING E-1 COMMANDER 500 If f or any reason y ou do not understand the test procedures or are unab le to perf or m the tests/repairs safely , contact your Local Lincoln A uthorized Field Service Facility f or technical troubleshooting assistance bef ore you proceed. CA UTION This T roubleshooting Guide is pro vided to help you locate[...]

E-2 TR OUBLESHOO TING E-2 COMMANDER 500 Obser ve 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 or m the tests/repairs safely , contact your Local Lincoln A uthorized Field Service Facility f or technical troubleshooting assistance bef ore you proceed. CA U[...]

E-3 TR OUBLESHOO TING E-3 COMMANDER 500 Obser ve 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 or m the tests/repairs safely , contact your Local Lincoln A uthorized Field Service Facility f or technical troubleshooting assistance bef ore you proceed. CA U[...]

E-4 TR OUBLESHOO TING E-4 COMMANDER 500 Obser ve 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 or m the tests/repairs safely , contact your Local Lincoln A uthorized Field Service Facility f or technical troubleshooting assistance bef ore you proceed. CA U[...]

F-1 DIA GRAMS F-1 COMMANDER 500 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. WIRING DIA GRAM: 5M 6D 6C 9 GND-E 201B 200E 5H 6D 200C 200 226 237 224A 12 262A 234A 228A 23[...]

F-2 DIA GRAMS F-2 COMMANDER 500 CONNECTION DIA GRAM: BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE "LINCOLN" (CONTACT CLOSURE) POSITION BEFORE ATTEMPTING TO OPERATE SPOOL GUN CONTROL MODULE. INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND/OR POWER SOURCE. K487-25 WARNING N.B. USE VOLTMETER SWITCH TO SE[...]

F-3 DIA GRAMS F-3 COMMANDER 500 CONNECTION DIA GRAM: GND 75 76 77 GREEN K291 OR K404 75 INPUT CABLE 76 N.E. 77 K775 OPTIONAL REMOTE CONTROL DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN 81 42 41 31 31 32 32 2 2 4 4 21 21 GND 82 N.D. LN-7 WIRE FEEDER Keep guards in place. COMMANDER [...]

F-4 DIA GRAMS F-4 COMMANDER 500 CONNECTION DIA GRAM: 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 FEEDER CONTROL CIRCUITS MAY BE ANY INCREASE OF THE [...]

F-5 DIA GRAMS F-5 COMMANDER 500 CONNECTION DIA GRAM: 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 42 } 4 N.E. 2 31 SPARE COMMANDER TO K867 ADAPTER [...]

F-6 DIA GRAMS F-6 COMMANDER 500 CONNECTION DIA GRAM: CAUTION : N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPICATIONS. SEE OPERATING MANUAL. 75 32 31 41 42 N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.D. SPLICE LEADS AND INSULATE. THE ENGINE WELDER OPERATING MANUAL. PLACE LOCAL / REMOTE SW[...]

F-7 DIA GRAMS F-7 COMMANDER 500 CONNECTION DIA GRAM: WIRE FEEDER "B" N.B. 602 FEEDER "A" 604 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 REMOTELY ELECTRODE WELDER, SPECIAL CARE IS TO BE [...]

F-8 DIA GRAMS F-8 COMMANDER 500 CONNECTION DIA GRAM: 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 electrically live parts. WIRE FEEDER TO WORK WORK CLI[...]

F-9 DIA GRAMS F-9 COMMANDER 500 CONNECTION DIA GRAM: 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. APPLICATIONS. SEE OPERATING MANUAL. PLACE LOCAL /[...]

F-10 DIA GRAMS F-10 COMMANDER 500 CONNECTION DIA GRAM: 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 WELDER PER INSTRUCTIONS PACKAGED WITH K433. [...]

F-11 DIA GRAMS F-11 COMMANDER 500 CONNECTION DIA GRAM: 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-25 ACROSS THE ARC CONNECTION DIAGRAM 6 PIN 14 PIN[...]

F-12 DIA GRAMS F-12 COMMANDER 500 CONNECTION DIA GRAM: 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 POLARITY. Keep guards in place. Keep away from moving parts. W[...]

F-13 DIA GRAMS F-13 COMMANDER 500 CONNECTION DIA GRAM: 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 OPERATING MANUAL. N.C. REQUIRES OPTIONAL K159[...]

F-14 DIA GRAMS 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 37.30 "D" "E" 48.64[...]

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 w elding industr y . This printing will go fast so don ’ t dela y . Place your order now using the coupon belo w . The hardbo[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O 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. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O 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. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

• Sales and Ser vice through Subsidiaries and Distr ibutors Worldwide • Cle v eland, Ohio 44117-1199 U .S .A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectr ic.com • W orld's Leader in W elding and Cutting Products •[...]