Lincoln Electric COMMANDER 500 User Manual
IM699
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Commander 500
For use with machines having Code Numbers:
Safety Depends on You
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
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
™
April, 2002
10837, (Standard),
10838, (Deluxe)
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
Copyright © 2002 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
For
For Diesel Engines: Diesel engine exhaust and
some of its constituents are known to the State
of California to cause cancer, birth defects, and
other reproductive harm.
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
Gasoline Engines: The engine exhaust from
this product contains chemicals known to the
State of California to cause cancer, birth defects,
or other reproductive harm.
i
FOR ENGINE
powered 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.
____________________________________________________
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, coversand devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
SAFETY
ii
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS 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 and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
vapors
to
5.e. Also see item 1.b.
Mar ‘95
iii
SAFETY
iii
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn 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 Code and the manufacturer’s recommendations.
Mar ‘95
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 suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product •••
as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.
vv
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
T
ABLE OF CONTENTS
Safety .........................................................................................................................i-iv
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions ................................................................................................A-2
Location/ Ventilation ..............................................................................................A-2
Storing.............................................................................................................A-2
Stacking ..........................................................................................................A-2
Angle of Operation ..........................................................................................A-2
Lifting...............................................................................................................A-3
High Altitude Operation ...................................................................................A-3
High Temperature Operation...........................................................................A-3
Towing .............................................................................................................A-3
Pre-Operation Engine Service...............................................................................A-4
Oil....................................................................................................................A-4
Fuel .................................................................................................................A-4
Fuel Cap..........................................................................................................A-4
Engine Cooling System...................................................................................A-4
Battery Connection..........................................................................................A-4
Muffler Outlet Pipe ..........................................................................................A-5
Spark Arrester .................................................................................................A-5
High Frequency Generators for TIG Applications .................................................A-5
Remote Control .....................................................................................................A-5
Welding Terminals .................................................................................................A-5
Welding Output Cables ...................................................................................A-6
Machine Grounding ...............................................................................................A-6
Auxiliary Power Receptacles.................................................................................A-6
Standby Power Connections...........................................................................A-6,A-7
Connection of Lincoln Electric Wire Feeders..................................................A-8,A-9
vivi
Page
Operation .........................................................................................................Section B
Safety Instructions .................................................................................................B-1
General Description...............................................................................................B-1
Recommended Applications............................................................................B-1
Design Features and Advantages...................................................................B-1
Welding Capability ..........................................................................................B-2
Controls and Settings ............................................................................................B-3
Engine Controls ........................................................................................B-3,A-4
Welder Controls ..............................................................................................B-5
Auxiliary Power Controls.................................................................................B-5
Engine Operation...................................................................................................B-6
Starting the Engine .........................................................................................B-6
Stopping the Engine........................................................................................B-6
Break-In Period ...............................................................................................B-7
Typical Fuel Consumption...............................................................................B-7
Welder Operation ..................................................................................................B-7
Stick Welding ..................................................................................................B-7
TIG Welding..............................................................................................B-7,B-8
Wire Feed (Constant Voltage) Welding...........................................................B-9
Auxiliary Power Operation.....................................................................................B-9
Simultaneous Welding and Auxiliary Power Loads.........................................B-9
Arc Gouging ....................................................................................................B-9
Paralleling .......................................................................................................B-9
Extension Cord Length Recommendations.........................................................B-10
COMMANDER 500
TABLE OF CONTENTS
Accessories.....................................................................................................Section C
Optional Field Installed Accessories .....................................................................C-1
Recommended Optional Equipment .....................................................................C-1
High Frequency Generators For TIG Applications ................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Maintenance .......................................................................D-1
Engine Maintenance..............................................................................................D-1
Air Filter...........................................................................................................D-1
Fuel Filters ...............................................................................................D-2,D-3
Cooling System...............................................................................................D-3
Cooling Blower Belt ........................................................................................D-3
Battery Handling .............................................................................................D-3
Nameplate / Warning Decal Maintenance.............................................................D-4
Welder / Generator Maintenance ..........................................................................D-4
Engine Maintenance Components ........................................................................D-4
Troubleshooting..............................................................................................Section E
viivii
Wiring,Connection Diagrams and Dimension Print.....................................Section F
Parts Lists .....................................................................................................P386Series
COMMANDER 500
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - Commander 500 (K1639-1 & -2)
INPUT - DIESEL ENGINE
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
Bore x Stroke Oil: 9.5 Qts.
9.0 L
3.94” x 4.72”
(100mm x 120mm)
RATED OUTPUT - WELDER
Duty Cycle Welding Output Volts at Rated Amps
A-1
100%
60%
50%
500 Amps (DC multi-purpose) 40 Volts
550 Amps (DC multi-purpose) 36 Volts
575 Amps (DC multi-purpose) 35 Volts
OUTPUT - WELDER AND GENERATOR
Welding Range Open Circuit Voltage Auxiliary Power
30 - 575 Amps CC/CV 80 Max OCV @1900 RPM 120/240 VAC
12,000 Watts, 60 Hz.
20 - 250 Amps TIG 100% Duty Cycle
1
PHYSICAL DIMENSIONS
HEIGHT
42.0 in. 31.5 in. 63.1 in. 1638 lbs.(743 kg)
1066.8 mm 800.1 mm 1602.7 mm
2
WIDTH DEPTH WEIGHT
( Approx.)
1. Output rating in watts is equivalent to volt-amperes at unity power factor.
Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.
2. Top of Enclosure. Add 8.9” (226.1mm) for exhaust.
COMMANDER 500
A-2
INSTALLATION
A-2
Read this entire installation section before you
start installation.
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting,
operating and maintenance instructions and parts
lists.
ELECTRIC SHOCK can kill.
•Do not touch electrically live parts such
as output terminals or internal wiring.
•Insulate yourself from the work and
ground.
•Always wear dry insulating gloves.
------------------------------------------------------------------------
LOCATION / VENTILATION
The welder should be located to provide an unrestricted
flow of clean, cool air to the cooling air inlets and to avoid
restricting the cooling air outlets. Also, locate the welder
so that the engine exhaust fumes are properly vented to
an outside area.
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SUFACES
Where there is a combustible surface directly under
stationary or fixed electrical equipment, that surface
should be covered with a steel plate at least
.06”(1.6mm) thick, which should extend not less than
5.90(150mm) beyond the equipment on all sides.
STORING
1. Store the machine in a cool, dry place when it is not
in use. Protect it from dust and dirt. Keep it where it
can’t be accidentally damaged from construction
activities, moving vehicles, and other hazards.
ENGINE EXHAUST can kill.
•Use in open, well ventilated areas or
vent exhaust outside
•Do not stack anything near the engine.
------------------------------------------------------------------------
MOVING PARTS can injure.
•Do not operate with doors open or
guards off.
•Stop engine before servicing.
•Keep away from moving parts
------------------------------------------------------------------------
Only qualified personnel should install, use or service
this equipment
2. Drain the engine oil and refill with fresh 10W30 oil.
Run the engine for about five minutes to circulate oil
to all the parts. See the MAINTENANCE section of
this manual for details on changing oil.
3. Remove the battery, recharge it, and adjust the electrolyte level. Store the battery in a dry, dark place.
STACKING
Commander 500 machines cannot be stacked.
ANGLE OF OPERATION
To achieve optimum engine performance the
Commander 500 should be run in a level position. The
maximum angle of operation for the Deutz engine is 30
degrees fore and aft, 40 degrees right and 45 degrees
left. If the engine is to be operated at an angle, provisions must be made for checking and maintaining the
oil level at the normal (FULL) oil capacity in the
crankcase. When operating the welder at an angle, the
effective fuel capacity will be slightly less than the
specified 25 gallons.
COMMANDER 500
A-3
INSTALLATION
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 holes on the upper middle
region of compartment wall just below the lift
bale.
c. Use the lifting strap to raise the lift bale to the full
upright position. This will align the mounting
holes on the lift bale with the access holes.
d. Secure the lift bale with 2 thread forming screws.
The screws are provided in the shipped loose
parts bag.
WARNING
TOWING
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle
Lincoln’s K953-1. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of
attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the
factors to be considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so that there will be no
undue stress to the trailer’s framework.
3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when
being moved and when standing by itself.
4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, and environmental conditions.
5. Proper preventative maintenance of trailer.
(1)
is
FALLING EQUIPMENT can cause
injury.
•Do not lift this machine using lift bale if
it is equipped with a heavy accessory
such as a trailer or gas cylinder.
•Lift only with equipment of adequate
lifting capacity.
•Be sure machine is stable when lifting.
------------------------------------------------------------------------
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary.
For maximum rating, derate the welder output 5% for
every 300 meters (984 ft.) above 1500 meters (4920
ft.). For output of 500A and below, derate the welder
output 5% for every 300 meters (984 ft.) above 2100
meters (6888 ft.).
Contact a Deutz Service Representative for any
engine adjustments that may be required.
6. Conformance with federal, state and local laws.
1
Consult applicable federal, state and local laws
regarding specific requirements for use on public highways.
1
HIGH TEMPERATURE OPERATION
At temperatures above 30°C (86°F), output voltage
derating is necessary. For maximum output current ratings, derate welder voltage rating 2 volts for every
10°C (21°F) above 30°C (86°F).
COMMANDER 500
A-4
INSTALLATION
A-4
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instructions supplied with this machine.
WARNING
•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 overfill.
•Wipe up spilled fuel and allow fumes to clear before
starting engine.
•Keep sparks and flame away from tank.
------------------------------------------------------------------------
OIL
The Commander is shipped with the engine crankcase
filled with high quality SAE 10W-30 oil (API class CD or
better). Check the oil level before starting the engine. If
it is not up to the full mark on the dip stick, add oil as
required. Check the oil level every four hours of running
time during the first 35 running hours. Refer to the engine
Operator’s Manual for specific oil recommendations and
break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the engine Operator’s Manual for the
proper service and maintenance intervals.
FUEL USE DIESEL FUEL ONLY
Fill the fuel tank with clean, fresh diesel fuel. The capacity of the fuel tank is 25 gallons (94.6 liters). See engine
Operator’s Manual for specific fuel recommendations.
The Commander 500 Deluxe is protected by a low fuel
shutdown to prevent the engine from running out of fuel.
The machine will indicate a low fuel condition by turning
on the low fuel light. A time of 30 minutes will elapse once
the low fuel light illuminates before the machine will shutdown. A restart of the machine will restart the timer to
allow the operator to override this feature. The amount of
reserve fuel remaining in the tank after the first shutdown
will vary from machine to machine. The operator must
determine the amount of fuel remaining before re-starting
the machine. Running out of fuel may require bleed-
ing the fuel injection pump.
ENGINE COOLING SYSTEM
The Deutz engine is air cooled by a belt driven axial
blower. The oil cooler and engine cooling fins should
be blown out with compressed air or steam to maintain
proper cooling (See the engine Owners Manual for
procedures and frequency).
BATTERY CONNECTION
WARNING
GASES FROM BATTERY can explode.
● Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOSION when:
● INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and connect
to new battery last.
● CONNECTING A BATTERY CHARGER —
remove battery from welder by disconnecting negative cable first, then positive cable and battery
clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
● USING A BOOSTER — connect positive lead to
battery first then connect negative lead to negative
battery lead at engine foot.
BATTERY ACID can burn eyes and
skin.
● Wear gloves and eye protection and
be careful when working near battery.
● Follow instructions printed on battery.
------------------------------------------------------------------------
IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:
a) Installing new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.
The Commander is shipped with the negative battery
cable disconnected. Before you operate the machine,
make sure the Engine Switch is in the OFF position
and attach the disconnected cable securely to the negative (-) battery terminal.
NOTE:
valve (pointer to be in line with hose).
Before starting the engine, open the fuel shutoff
FUEL CAP
Remove the plastic cap covering from the Fuel Tank
Filler neck and install the Fuel Cap.
COMMANDER 500
Remove the insulating cap from the negative battery
terminal. Replace and tighten negative battery cable
terminal. NOTE: This machine is furnished with a wet
charged battery; if unused for several months, the battery may require a booster charge. Be sure to use the
correct polarity when charging the battery.
A-5
INSTALLATION
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.
SPARK ARRESTER
Some federal, state or local laws may require that
gasoline or diesel engines be equipped with exhaust
spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder
does not qualify as a spark arrester. When required by
local regulations, a suitable spark arrester, must be
installed and properly maintained.
CAUTION
An incorrect arrester may lead to damage to the engine
or adversely affect performance.
------------------------------------------------------------------------
REMOTE CONTROL
OUTPUT
The Commander 500 is equipped with a 6-pin & 14-pin
connector. The 6-pin connector is for connecting the
K857 or K857-1 Remote Control (Optional) or in the
case of TIG welding applications, with the foot or hand
Amptrol (K870 or K963-1 respectively).
The 14-pin connector is used to directly connect a wire
feeder or TIG Module (K930-1 or -2) control cable.
NOTE: When using the 14-pin connector, if the wire
feeder has a built in power source output control, do
not connect anything to the 6-pin connector.
WELDING TERMINALS
The Commander is equipped with a toggle switch for
selecting "hot" welding terminals when in the "WELD
TERMINALS ON" position or "cold" welding terminals
when in the "REMOTELY CONTROLLED" position.
HIGH FREQUENCY GENERATORS
FOR TIG APPLICATIONS
The K799 Hi-Freq Unit and the K930-1 or -2 TIG
Module are suitable for use with the Commander 500.
The Commander 500 is equipped with the required
R.F. bypass circuitry for the connection of high frequency generating equipment. The high frequency
bypass network supplied with the K799 Hi-Freq Unit
does NOT need to be installed into the Commander
500.
The Commander 500 and any high frequency generating equipment must be properly grounded. See the
K799 Hi-Freq Unit and the K930-1 or-2 TIG Module
operating manuals for complete instructions on installation, operation, and maintenance.
COMMANDER 500
A-6
INSTALLATION
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 provided. These connections should be checked periodically and tightened if necessary.
Listed in Table A.1 are copper cable sizes recommended for the rated current and duty cycle. Lengths
stipulated are the distance from the welder to work and
back to the welder again. Cable sizes are increased
for greater lengths primarily for the purpose of minimizing cable voltage drop.
Table A.1 Combined Length of Electrode and
Work Cables.
TOTAL COMBINED LENGTH OF ELEC-
TRODE AND WORK CABLES
AMPS
@100%
Duty Cycle
500
Up to 150
FT.
3/0 AWG
150-200 FT.
3/0 AWG
200-250 FT.
4/0 AWG
MACHINE GROUNDING
Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.).
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding
stud marked with the symbol is provided on the
front of the welder.
AUXILIARY POWER RECEPTACLES
The auxiliary power capacity of the Commander 500 is
12,000 watts of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to voltamperes at unity power factor. The maximum permissible current of the 240 VAC output is 50 A. The 240
VAC output can be split to provide two separate 120
VAC outputs with a maximum permissible current of 50
A per output to two separate 120 VAC branch circuits.
The output voltage is within ± 10% at all loads up to
rated capacity.
NOTE:
of different phases and cannot be paralleled.
The Commander has two 20 Amp-120VAC (5-20R)
duplex receptacles and one 50 Amp-120/240 VAC
(14-50R) receptacle. The 120/240 VAC receptacle can
be split for single phase 120 VAC operation. The auxiliary power receptacles should only be used with three
wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any
plug used with the system must be at least equal to the
current capacity of the associated receptacle.
The 120/240V receptacle has two 120V outlets
STANDBY POWER CONNECTIONS
To prevent dangerous electric shock, other equipment
powered by this engine driven welder must:
a) be grounded to the frame of the welder using a
grounded type plug,
or
b) be double insulated.
When this welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
of the vehicle. When this engine driven welder is connected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
ground. See further connection instructions in the section entitled “Standby Power Connections” as well as
the article on grounding in the latest U.S. National
Electrical Code and the local code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
COMMANDER 500
The Commander 500 is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule.
The Commander 500 can be permanently installed as
a standby power unit for 240 volt-3 wire, 50 amp service. Connections must be made by a licensed electrician who can determine how the 120/240 VAC power
can be adapted to the particular installation and comply with all applicable electrical codes. The following
information can be used as a guide by the electrician
for most applications. Refer to the connection diagram
shown in Figure A.2.
1. Install the double-pole, double-throw switch
between the power company meter and the premises disconnect.
Switch rating must be the same or greater than the
customer’s premises disconnect and service over current protection.
A-7
240 Volt
60 Hz.
3-Wire
Service
POWER
COMPANY
METER
240 VOLT
120 VOLT
120 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GND
N
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
240 VOLT
GROUNDED CONDUCTOR
50AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE
INSTALLATION
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 50
amperes. Loading above the rated output will
reduce output voltage below the allowable -10% of
rated voltage which may damage appliances or
other motor-driven equipment and may result in
overheating of the Commander 500 engine.
Figure A.2 Connection of the Commander 500 to Premises Wiring
3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-
50) to the double-pole circuit breaker using No. 6, 4
conductor cable of the desired length. (The 50 amp,
120/240 VAC plug is available in the optional K802R
plug kit.)
4. Plug this cable into the 50 Amp 120/240 Volt receptacle on the Commander 500 case front.
COMMANDER 500
A-8
INSTALLATION
A-8
CONNECTION OF LINCOLN
ELECTRIC WIRE FEEDERS
WARNING
Shut off welder before making any electrical connections.
------------------------------------------------------------------------
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 appropriate connection diagram in the DIAGRAMS section.
NOTE: The LN-25 (K431) Remote Control Module and
(K432) Remote Cable are not recommended for use
with the Commander 500.
• Shut the welder off.
• For electrode Positive, connect the electrode cable
from the LN-25 to the “+” terminal of the welder and
work cable to the “-” terminal of the welder. For electrode Negative, connect the electrode cable from the
LN-25 to the “-” terminal of the welder and work
cable to the “+” terminal of the welder.
• Attach the single lead from the front of the LN-25 to
work using the spring clip at the end of the lead. This
is a sense lead to supply current to the wire feeder
motor; it does not carry welding current.
• Set the SELECTOR switch to the “CV-WIRE” posi-
tion.
CAUTION
If you are using an LN-25 without an internal contactor,
the electrode will be energized when the Commander
500 is started.
------------------------------------------------------------------------
h. When the gun trigger is closed, the current sensing
circuit will cause the Commander 500 engine to go
to the high idle speed, the wire will begin to feed
and the welding process started. When welding is
stopped, the engine will revert to low idle speed
after approximately 12 seconds unless welding is
resumed.
CONNECTION OF LN-7 OR LN-8 TO THE
COMMANDER 500
• Shut the welder off.
• Connect the LN-7 or LN-8 per instructions on the
appropriate connection diagram in the DIAGRAMS
section.
• Set the “WIRE FEEDER VOLTMETER” switch to
either “+” or “-” as required by the electrode being
used.
• Set the “SELECTOR” switch to the “CV-WIRE” posi-
tion.
• Adjust the “ARC CONTROL” knob to desired
Crispness. SOFT for MIG and CRISP for Innershield.
• Set the “WELDING TERMINALS” switch to the
“REMOTELY CONTROLLED” position.
• Set the “WELDING TERMINALS” switch to “WELD
TERMINALS ON”
• Adjust the “ARC CONTROL” knob to desired crisp-
ness. Generally, welding is best if the “ARC CONTROL” is set to SOFT for MIG and CRISP for
Innershield. You may however, want to start in the
middle and adjust (as needed) from there.
• Set the “IDLE” switch to the “AUTO” position. When
not welding, the Commander 500 engine will be at
the low idle speed. If you are using an LN-25 with an
internal contactor, the electrode is not energized until
the gun trigger is closed.
COMMANDER 500
• Set the “IDLE” switch to the “HIGH” position. When
not welding, the Commander 500 engine will be at
the low idle speed.
A-9
INSTALLATION
A-9
CONNECTION OF AN LN-23P WIRE
FEEDER TO THE COMMANDER 500
• Shut the welder off.
• Connect the LN-23P per instructions on the appro-
priate connection diagram in the DIAGRAMS section. (NOTE): When connecting an LN-23P to the
Commander 500, a K350-1 adapter kit must be
used.
• Set the “WIRE FEEDER VOLTMETER” switch to “-”.
• Set the “SELECTOR” switch to “CV-WIRE” position.
• Set the “WELDING TERMINALS” switch to
“REMOTELY CONTROLLED”.
• Set the ARC CONTROL to desired crispness. SOFT
for MIG - CRISP for Innershield.
• Set the “IDLE” switch to the “HIGH” position. If you
are using an LN-23P with the K350-1 adapter kit, the
electrode is not energized until the gun trigger is
closed.
CONNECTION OF AN NA-3 AUTOMATIC
WELDING SYSTEM TO THE COMMANDER
500
For connection diagrams and instructions for connecting an NA-3 Welding System to the Commander 500,
refer to the NA-3 Welding System instruction manual.
The connection diagram for the LN-8 can be used for
connecting the NA-3.
CONNECTION OF AN LN-742 TO THE
COMMANDER 500
• Shut the welder off.
• Connect the LN-742 per instructions on the appro-
priate connection diagram in the DIAGRAMS section.
• Set the “WIRE FEEDER VOLTMETER” switch to
either “+” or “-” as required by the electrode being
used.
• Set the “SELECTOR” switch to the “CV-WIRE” posi-
tion.
• Adjust the “ARC CONTROL” knob to desired
Crispness. SOFT for MIG and CRISP for Innershield.
• Set the “WELDING TERMINALS” switch to the
“REMOTELY CONTROLLED” position.
• Set the “IDLE” switch to the “AUTO” position. When
not welding, the Commander 500 engine will be at
the low idle speed.
COMMANDER 500
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