Lincoln Electric SVM153-A User Manual
SVM153-A
September, 2002
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
CONT AINED THROUGHOUT .
And, most importantly, think
before you act and be careful.
SERVICE MANUAL
For use with machines having Code Numbers: 10837 (Standard),
10838 (Deluxe)
Commander 500
TM
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• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © 2002 Lincoln Global Inc.
CALIFORNIA PROPOSITION 65 WARNINGS
i i
SAFETY
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, covers
and 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.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.
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.
WARNING
Mar ‘95
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.
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.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The Above For Gasoline Engines
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ii ii
SAFETY
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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.
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.
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
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
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.
5.e. Also see item 1.b.
Mar ‘95
iii iii
SAFETY
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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.
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.
Mar ‘95
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.
Remember that welding sparks and hot
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
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
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.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
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.
iv iv
SAFETY
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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.
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
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.
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
v v
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
COMMANDER 500
Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Operation...............................................................................................................................Section B
Accessories ..........................................................................................................................Section C
Maintenance..........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual .................................................................................................................................P386
RETURN TO MAIN INDEX
Installation.............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location/Ventilation.....................................................................................................................A-3
Storing .................................................................................................................................A-3
Stacking................................................................................................................................A-3
Angle of Operation................................................................................................................A-3
Lifting .................................................................................................................................A-4
High Altitude Operation.........................................................................................................A-4
High Temperature Operation ................................................................................................A-4
Towing .................................................................................................................................A-4
Pre-Operation Engine Service ....................................................................................................A-5
Oil ........................................................................................................................................A-5
Fuel.......................................................................................................................................A-5
Fuel Cap...............................................................................................................................A-5
Engine Cooling System........................................................................................................A-5
Battery Connection...............................................................................................................A-5
Muffler Outlet Pipe ............................................................................................................ ....A-6
Spark Arrester.......................................................................................................................A-6
High Frequency Generators for TIG Applications.......................................................................A-6
Electrial Connections ..................................................................................................................A-6
Remote Control.....................................................................................................................A-6
Welding Terminals ................................................................................................................A-6
Welding Output Cables.........................................................................................................A-7
Machine Grounding ..............................................................................................................A-7
Auxiliary Power Receptacles................................................................................................A-7
Standby Power Connections................................................................................................A-7
Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
COMMANDER 500
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A-2 A-2
INSTALLATION
COMMANDER 500
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TECHNICAL SPECIFICATIONS - COMMANDER 500 (K1639-1 & -2)
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Deutz 3 cylinder 44 HP(33 kw) High Idle 1900 173 cu. in 12VDC battery Fuel: 25 gal.
F3L 912 @ 1800 RPM Low Idle 1475 (2.83 L) & Starter 94.6 L
Diesel Engine Full Load 1800
Bore x Stroke Oil: 9.5 Qts.
9.0 L
3.94” x 4.72”
(100mm x 120mm)
Duty Cycle Welding Output Volts at Rated Amps
100% 500 Amps (DC multi-purpose) 40 Volts
60% 550 Amps (DC multi-purpose) 36 Volts
50% 575 Amps (DC multi-purpose) 35 Volts
Welding Range Open Circuit Voltage Auxiliary Power
1
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
Height
2
Width Depth Weight
42.0 in. 31.5 in. 63.1 in. 1638 labs. (743 kg)
1966.8 mm 800.1 mm 1602.7 mm (Approx.)
INPUT - DIESEL ENGINE
OUTPUT - WELDER AND GENERATOR
PHYSICAL DIMENSIONS
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.
RATED OUTPUT - WELDER
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
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.
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
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.
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.
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 (94.6 liters).
A-3 A-3
INSTALLATION
COMMANDER 500
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WARNING
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,
secure the lift bale in a raised position. Secure the lift
bale as follows:
a. Open the engine compartment door.
b. Locate the two access holes on the upper mid-
dle region of the 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 loose
parts bag shipped with the machine.
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.
HIGH TEMPERATURE OPERATION
At temperatures above 30°C (86°F), output voltage
derating is necessary . For maximum output current ratings, derate the welder voltage rating two volts for
every 10°C (21°F) above 30°C (86°F).
TOWING
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle
1
is
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 the trailer vs. weight of the
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 the trailer.
6. Conformance with federal, state and local laws.
1
1
Consult applicable federal, state and local laws
regarding specific requirements for use on public highways.
A-4 A-4
INSTALLATION
COMMANDER 500
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WARNING
A-5 A-5
INSTALLATION
COMMANDER 500
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PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instructions 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 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
NOTE: 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
the 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 restarting the
machine. Running out of fuel may require bleeding the
fuel injection pump.
NOTE: Before starting the engine, open the fuel shutoff valve (pointer to be in line with hose).
FUEL CAP
Remove the plastic cap covering from the fuel tank filler
neck and install the fuel cap.
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 Operator’s Manual for
procedures and frequency.)
BATTERY CONNECTION
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes away
from battery.
To prevent EXPLOSION when:
• INSTALLING ANEW BATTER Y — disconnect nega-
tive 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.
BATTERYACID can burn eyes and skin.
• Wear gloves and eye protection and be
careful when working near battery.
• Follow instructions printed on battery.
WARNING
WARNING
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.
Remove the insulating cap from the negative battery
terminal. Replace and tighten the 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.
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 to 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.
An incorrect arrester may lead to damage to the engine
or adversely affect performance.
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 generat-
ing 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.
ELECTRICAL CONNECTIONS
REMOTE CONTROL
The Commander 500 is equipped with a 6-pin and a
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 "WELDING TERMINALS REMOTELY
CONTROLLED" position.
A-6 A-6
INSTALLATION
COMMANDER 500
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CAUTION
WELDING OUTPUT CABLES
With the engine off, route the electrode and work
cables through 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
Electrode and Work Cables
Amps
@ 100%
Duty Cycle Up to 150 ft. 150-200 ft. 200-250 ft.
500 3/0 AWG 3/0 AWG 4/0 A WG
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.).
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
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: The 120/240V receptacle has two 120V outlets
of different phases and cannot be paralleled.
The Commander has two 20A-120VAC (5-20R) duplex
receptacles and one 50A-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.
STANDBY POWER CONNECTIONS
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, three-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.
A-7 A-7
INSTALLATION
COMMANDER 500
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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 cus-
tomer’s premises disconnect and service over current
protection.
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 allow-
able -10% of rated voltage, which may damage
appliances or other motor-driven equipment and
may result in overheating of the Commander 500
engine.
3. Install a 50 amp 120/240 VAC plug (NEMA Type
14-50) to the double-pole circuit breaker using No.
6, four-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.
A-8 A-8
INSTALLATION
COMMANDER 500
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FIGURE A.2 – CONNECTION OF THE COMMANDER 500 TO PREMISES WIRING
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
Operation...............................................................................................................................Section B
Operating Instructions.................................................................................................................B-2
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-2
Recommended Applications.................................................................................................B-3
Design Features and Advantages........................................................................................B-3
Welding Capability................................................................................................................B-4
Controls and Settings ..................................................................................................................B-4
Engine Controls....................................................................................................................B-5
Welder Controls....................................................................................................................B-6
Auxiliary Power Controls ......................................................................................................B -7
Engine Operation........................................................................................................................B-8
Starting the Engine...............................................................................................................B-8
Stopping the Engine.............................................................................................................B-8
Break-In Period................................................................................................................ .....B-8
Typical Fuel Consumption....................................................................................................B-8
Welder Operation........................................................................................................................B-9
Stick Welding........................................................................................................................B-9
Pipe Welding.........................................................................................................................B-9
Constant Current (CC) Welding............................................................................................B-9
TIG Welding..........................................................................................................................B-9
Wire Feed (Constant Voltage) Welding ..............................................................................B-11
Auxiliary Power Operation .........................................................................................................B-11
Simultaneous Welding and Auxiliary Power Loads ............................................................B-11
Arc Gouging........................................................................................................................B-11
Paralleling ...........................................................................................................................B-11
Extension Cord Recommendations...........................................................................................B-12
Section B-1 Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
COMMANDER 500
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B-2 B-2
OPERATION
COMMANDER 500
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OPERATING INSTRUCTIONS
Read and understand this entire section before operating your Commander 500.
SAFETY INSTRUCTIONS
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 or
electrodes with your skin or wet clothing.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
FUMES AND GASES CAN BE
DANGEROUS.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS CAN
CAUSE FIRE OR EXPLOSION.
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.
ARC RAYS CAN BURN.
• Wear eye, ear, and body protection.
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 operate this
equipment.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged door closed
and the side panels in place, as these provide maximum protection from moving parts and insure proper
cooling air flow.
GENERAL DESCRIPTION
The Commander 500 is a diesel engine-driven welding
power source. The machine uses a brush type alternating current generator for DC multi-purpose welding
and for 120/240 VAC auxiliary standby power. The
welding control system uses state of the art Chopper
Technology.
The generator has a single sealed bearing for maintenance free service. The rotor is a copper wound design
with two slip rings and brushes. The stator is wound
entirely with heavy gauge copper wire and insulated
with NEMA class F insulation material. The stator is
then impregnated with three layers of high quality varnish. After the stator is assembled using tie bars, the
entire assembly is covered with an environmentally
protective coating. These measures insure trouble-free
operation in the harshest environments.
The fuel tank is made from high density polyethylene
and holds 25 gallons (94.6 liters) of diesel fuel. This
will provide enough fuel to run for more than 12 hours
at full load.
The Deutz F3L-912 engine is equipped with a standard, heavy duty, combination fuel filter/water separator element.
WARNING
RECOMMENDED APPLICATIONS
WELDER
The Commander 500 provides excellent constant current DC welding output for stick (SMAW) and TIG welding. The Commander 500 also provides excellent constant voltage DC welding output for MIG (GMAW) and
Innershield (FCAW) welding.
GENERATOR
The Commander 500 provides smooth 120/240 VAC
output for auxiliary power and emergency standby
power.
DESIGN FEATURES AND ADVANTAGES
K1639-2 COMMANDER 500 DELUXE MODEL
FEATURES
FOR WELDING
• Excellent DC multi-purpose welding for stick, MIG,
TIG, cored wire and arc gouging applications.
• 30 to 500 amps output in five slope-controlled ranges
for out-of position and pipe electrodes, one constant
current output range for general purpose welding,
one constant voltage range for MIG wire and cored
wire welding and one 20-250 amp range for “Touch
Start” TIG welding.
• 100% duty cycle at 500 amps output and 50% duty
cycle at 575 amps output.
• Dual 3-digit output meters are provided (optional on
K1639-1) for presetting the weld amperage or voltage and displaying the actual amperage and voltage
during welding. The meters use superbrite L.E.D.'s
for improved readability in full sunlight.
LOOK-BACK FEA TURE:After welding has stopped,
both displays will remain on for 7 seconds with the
last current and voltage value displayed. During this
time, the left-most decimal point in each display will
be FLASHING.
• Standard remote control capability with 14-pin and
6-pin connectors for easy connection of Lincoln
remote control accessories.
• An internal "Solid State" contactor allows for the
selection of "hot" or "cold" output terminals with a
toggle switch on the control panel.
• “Arc Control”potentiometer in Wire and Stick modes
for precise adjustment of arc characteristics.
• Advanced circuitry to prevent pop-outs in the five
slope modes.
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).
• T wo 20 amp 120 VAC duplex receptacles for up to 40
amps of 120 VAC power.
• One 50 amp, 120/240 VAC dual voltage receptacle
for up to 50 amps of 240 V AC, and up to 50 amps per
side to separate branch circuits (not in parallel) of
120 VAC single-phase auxiliary power. Allows easy
connection to premises wiring.
• Weld and AC auxiliary power at the same time (within machine total capacity).
OTHER FEATURES
• Deutz 3-cylinder, air/oil cooled diesel engine.
Designed for long life, easy maintenance, and excellent fuel economy.
• Engine protection system shuts the engine down for
low oil pressure, high oil temperature, or a broken
fan/engine alternator belt.
• Gauges for oil pressure, oil temperature, engine
alternator output, and fuel level.
• Indicator lights for low oil pressure, high oil temperature, engine alternator low output/broken belt, and
low fuel level (on K1639-2 only).
• Automatic low fuel shutdown before running out of
fuel (K1639-2 only).
• Engine hour meter standard on all models.
• Extended range 25 gallon (94.6 l) fuel tank.
• Automatic idler reduces engine speed when not
welding or drawing auxiliary power. This feature
reduces fuel consumption and extends engine life.
• Compact size fits crosswise in full size pickup truck.
• Single-side engine service.
• Copper alternator windings and high temperature
insulation for dependability and long life.
• New paint system on case and base for outstanding
corrosion protection.
B-3 B-3
OPERATION
COMMANDER 500
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K1639-1 COMMANDER 500 STANDARD MODEL
• The K1639-1 is the standard version of the
Commander 500 and has all the features of the
K1639-2 Deluxe version except that there are no
gauges, low fuel light, nor dual output meters. This
version does have fully functional engine protection
for low oil pressure, high oil temperature, and alternator output with associated lights.
• A field-installed Dual Output Meter and Gauge Kit
(K-1768-1) is available for the K1639-1 Commander
500.The kit includes dual output meters, oil pressure
gauge, oil temperature gage, and alternator ammeter.
WELDING CAPABILITY
The Commander 500 is rated at 500 amps, 40 VDC at
100% duty cycle and 575 amps, 36 VDC at 50% duty
cycle. The maximum open circuit voltage at 1900 RPM
is 80 volts. The weld current is variable from 30 to 575
amps.
CONTROLS AND SETTINGS
All welder and engine controls are located on the case
front panel. Refer to Figure B.1 and the explanations
that follow.
B-4 B-4
OPERATION
COMMANDER 500
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FIGURE B.1 – CASE FRONT PANEL CONTROLS
3
2
1
4
10
5
6
7 8
OIL
9
1917
FUEL
TEMP
OIL
PRESS
AMPS
9
11
21
19
15
14
16
23
13
20
12
22
18
ENGINE CONTROLS (Items 1 through 8)
1. RUN/STOP SWITCH
When placed in the RUN position, this switch energizes
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 RUN position and the
engine is not running, the fuel solenoid will be engaged
for 15 seconds and then shut down. This is to protect
the battery from discharge. After 15 seconds, the
RUN/STOP switch must be toggled off then on before
starting.
2. START PUSHBUTTON
Energizes the starter motor to crank the engine. With
the engine RUN/STOP switch in the RUN position,
push and hold the Start button to crank the engine;
release as the engine starts. The Start button must be
depressed for a minimum of two seconds. Do not
press it while the engine is running, since this can
cause damage to the ring gear and/or starter motor.
3. FUEL LEVEL GAUGE AND LIGHT
(K1639-2 only) - Displays the level of diesel fuel in the
25-gallon (94.6 liter) fuel tank. The yellow light turns on
when the fuel gage reaches the reserve level. Once the
reserve level is reached, the engine protection system
will shut down the engine after 30 minutes of operation.
The machine can be restarted and operated for an
additional 30 minutes before the protection system will
shut down the engine. This ability to override the
engine protection allows the operator to “finish up” if
necessary. The operator must watch the fuel level
closely to prevent running out of fuel and having to
bleed the system.
4. ENGINE TEMPERATURE 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 outlets.
(Consult the engine Operator’s Manual.) Check for
loose or disconnected leads at the temperature sender
located on the engine. Check the engine cooling blower belt. Also, check to be sure that the welder loads are
within the rating of the welder. The light will remain on
when the engine has been shut down due to an overtemperature condition.
5. OIL PRESSURE GAUGE (K1639-2 Std.,
K1639-1 Opt.) AND LIGHT
The gauge displays the engine oil pressure when the
engine is running. The yellow oil pressure light remains
off with proper oil pressure. If the light turns on, the
engine protection system will stop the engine. Check
for proper oil level and add oil if necessary. Check for
loose or disconnected leads at the oil pressure sender
located on the engine. The light will go on and stay on
when the RUN/STOP switch is switched to the RUN
position with the engine not running.
6. ENGINE ALTERNATOR AMMETER
(K1639-2 Std., K1639-1 Opt.) AND LIGHT
The yellow engine alternator light is off when the battery charging system is functioning normally. If the light
turns on, the engine protection system will shut down
the engine. Check the engine cooling blower belt. Also,
the alternator or the voltage regulator may not be operating correctly. The light may also come on due to a
faulty flashing circuit. The light will remain on when the
engine has been shut down due to a fault in the alternator, regulator, or the cooling blower belt.
7. IDLER SWITCH
Has two positions as follows:
A) In the HIGH position , the engine runs at the
high idle speed controlled by the governor.
B) In the AUTO / position, the idler oper-
ates as follows:
a. When switched from HIGH to AUTO or after
starting the engine, the engine will operate at
full speed for approximately 12 seconds and
then go to low idle speed.
b. When the electrode touches the work or power
is drawn for lights or tools (approximately 100
Watts minimum) the engine accelerates and
operates at full speed.
c. When welding ceases or the AC power load is
turned off, a fixed time delay of approximately
12 seconds starts.
d. If the welding or AC power load is not restarted
before the end of the time delay, the idler
reduces the engine speed to low idle speed.
e. The engine will automatically return to high idle
speed when the welding load or AC power load
is reapplied.
B-5 B-5
OPERATION
COMMANDER 500
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Idler Operational Exceptions
When the WELDING TERMINALS switch is in the
“Welding Terminals Remotely Controlled” position, the
idler will operate as follows:
a. When the triggering device (Amptrol, Arc Start
Switch, etc.) is pressed, the engine will accelerate
and operate at full speed provided a welding load
is applied within approximately 15 seconds.
• If the triggering device remains pressed but no
welding load is applied within approximately 15
seconds, the engine will return to low idle speed.
• If the triggering device is released or welding
ceases, the engine will return to low idle speed
after approximately 15 seconds.
8. HOUR METER
The hour meter displays the total time that the engine
has been running. This meter is a useful indicator for
scheduling preventive maintenance.
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 Table B.1 for a description of how
these two controls work.
10. DIGITAL OUTPUT METERS
The digital output meters are located in the center of
the control panel between the two large control knobs.
The meters allow the output current level to be set prior
to welding in stick mode, and voltage level to be set
prior to welding in the wire modes. During the welding
process the meters display the actual output current
and voltage, within ±5% accuracy.
The digital meters allow the output voltage (CV-WIRE
mode) or current (CC-STICK, PIPE and TIG modes) to
be set prior to welding using the OUTPUT control dial.
During welding, the meters display the actual output
voltage (VOLTS) and current (AMPS). A memory feature holds the display of both meters on for seven seconds after the welding is stopped. This allows the operator to read the actual current and voltage just prior to
when welding was ceased. While the display is being
held the left-most decimal point in each display will be
flashing. The accuracy of the meters is +/- 3%.
11. WELDING TERMINALS SWITCH
The toggle switch on the control panel labeled WELD
TERMINALS ON and REMOTELY CONTROLLED is
used to control the operation of the “solid state contactor.” The switch allows for the selection of “Hot” or
“Cold” welding terminals.
With the switch in the WELD TERMINALS ON position,
the contactor is closed and the welding terminals are
always “Hot.”
With the switch in the REMOTELY CONTROLLED
position, the contactor operation is controlled by an
Amptrol, Arc Start Switch or some other type of triggering device through the use of a control cable connected to the 14-pin amphenol.
When the triggering device is pressed, the contactor is
closed and the welding terminals are “Hot.”
When the triggering device is released, the contactor is
opened and the welding terminals are “Cold.”
NOTE: The new Chopper Technology control circuitry
automatically senses when a remote output control pot
is plugged into either amphenol. Therefore, there is no
need for a local / remote switch.
TABLE B.1 – WELD MODE AND OUTPUT
CONTROL FUNCTIONS
Application Weld Mode
1
Output
2
Sloped Output 5 Range
for Pipe Settings
Welding 90, 150, 200,
350, 500 (max. Provides a Fine
current on each Adjustment of
setting) Welding Current
from
Touch Start TIG 1 Range Setting Min (1) to Max
Welding 15-200 Amps (10) within each
range
Constant Current 1 Range Setting
Output for 20-250 Amps
Fabrication and
General Purpose
Welding
Constant Voltage 1 Range Setting Provides Fine
Output for MIG 14 to 40 Volts Voltage
WIRE or Adjustment
CORED WIRE
Welding
1
If the WELD MODE switch is positioned between settings, the previous setting is maintained until the switch is properly positioned on
a setting.
2
OUTPUT also controls O.C.V. while in the 5 sloped output ranges.
B-6 B-6
OPERATION
COMMANDER 500
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M
M
12. 6 - PIN CONNECTOR (AMPHENOL)
The 6-pin amphenol located on the control panel
allows for connection of interfacing equipment.
13. WELD OUTPUT TERMINALS + AND -
These 1/2 - 13 studs with flange nuts provide welding
connection points for the electrode and work cables.
For positive polarity welding, the electrode cable connects to the “+” terminal and the work cable connects
to this “-” terminal. For negative polarity welding, the
work cable connects to the “+” terminal and the electrode cable connects to this “-” terminal.
AUXILIARY POWER CONTROLS
(Items 14 through 18 )
14. 120/240VAC RECEPTACLE
This is a 120/240VAC (14-50R) receptacle that
provides 240VAC. Or, it can be split for 120VAC single-phase auxiliary power. This receptacle has a 50
amp rating. Refer to AUXILIARY POWER RECEP-
TACLES section in the Installation section for further
information about this receptacle. Also refer to the
AUXILIARY POWER OPERA TION later in this section.
15. 50 AMP CIRCUIT BREAKERS
These circuit breakers provide separate overload
current protection for each 120V circuit at the 240V
receptacle.
16. 120VAC RECEPTACLES
These two 120VAC (5-20R) receptacles provide
120VAC for auxiliary power. Each receptacle has a 20
amp total rating. Refer to AUXILIARY POWER
RECEPTACLES in the Installation section for further
information about these receptacles. Also refer to the
AUXILIARY POWER OPERA TION later in this section.
17. 20 AMP CIRCUIT BREAKERS
These circuit breakers provide separate overload current protection for each 120V receptacle.
18. GROUND STUD
Provides a connection point for connecting the
machine case to earth ground for the safest grounding
procedure. Refer to MACHINE GROUNDING in the
Installation section for proper machine grounding information.
19. 20 AMP CIRCUIT BREAKER
This circuit breaker provides overload protection for the
120 VAC circuit in the 14-pin amphenol.
20. VOLTMETER +/- SWITCH
Changes the polarity display on the wire feeder.
21. 10 AMP CIRCUIT BREAKER
This circuit breaker provides overload protection for the
42 VAC circuit in the 14-pin amphenol.
22. 14 - PIN CONNECTOR (AMPHENOL)
For quick connection of interfacing equipment.
23. ARC CONTROL
The ARC CONTROL potentiometer is active in two
modes: CC - STICK and CV - WIRE with different purposes in each mode.
CC - STICK mode: In this mode, the ARC CONTROL
knob sets the short circuit current during stick welding.
Increasing the number from 1 to 10 increases the short
circuit current. This prevents sticking of the electrode to
the plate at low welding current settings. This also
increases spatter. It is recommended that the control
be set to the minimum number without electrode sticking.
CV - WIRE mode: In this mode increasing the number
from 1 to 10 changes the arc from soft and washed in
to crisp and narrow. It acts as an inductance control.
The proper setting depends on the application and
operator preference.
In general, MIG welding performs best in the “SOFT”
range and Innershield in the “CRISP” range.
B-7 B-7
OPERATION
COMMANDER 500
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ENGINE OPERATION
STARTING THE ENGINE
1. Open the engine compartment door and check that
the fuel shutoff valve located to the left of the fuel filter housing is in the open position (lever to be in line
with the hose).
2. Check for proper oil level on the oil dipstick. Close
engine compartment door.
3. Remove all plugs connected to the AC power receptacles.
4. Set IDLER switch to “AUTO”.
5. Set the RUN/STOP switch to RUN. Observe that
all engine protection lights momentarily turn on.
Some lights may turn off before starting. Check the
fuel gauge (K1639-2 only) to make sure that there
is an adequate fuel level.
6. Press and hold the engine START button for a minimum of two seconds.
7. Release the engine STARTbutton when the engine
starts.
8. Check that the indicator lights are off. If the LOW
FUEL light is on (K1639-2 only), the engine will shut
down 30 minutes after starting. If any other indicator light is on after starting, the engine will shut
down in a few seconds. Investigate any indicated
problem.
9. Allow the engine to warm up at low idle speed for
several minutes before applying a load and/or
switching to high idle. Allow a longer warm-up time
in cold weather.
COLD WEATHER STARTING
With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about 0°F. If the engine must be frequently started
below 10°F, it may be desirable to install the optional
ether starter kit (K825-1). Installation and operating
instructions are included in the kit.
STOPPING THE ENGINE
1. Switch the RUN/STOP switch to STOP. This turns
off the voltage supplied to the shutdown solenoid. A
backup shutdown can be accomplished by shutting
off the fuel valve located on the fuel line.
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 accomplished. Check the oil level twice a day during the
break-in period (about 200 running hours).
During break-in, subject the Commander 500 to heavy
loads. Avoid long periods running at idle. Before stopping the engine, remove all loads and allow the engine
to cool several minutes.
The heavy loading of the engine during break-in, within the rating of the machine, is recommended to properly seat the piston rings and prevent wetstacking.
Wetstacking is an accumulation of unburned fuel
and/or lubricant in the form of a set, black, tar-like substance in the exhaust pipe. The rings are seated and
the break-in period is complete when there are no
longer any signs of wetstacking, which should occur
within the first 50 to 100 hours of operation.
Using your welder at low amperages with long idle running periods during the break-in period may result in a
glaze forming on the engine cylinder walls and the
rings not seating properly. No amount of loading will
properly seat the pistons rings after they are glazed
over.
TYPICAL FUEL CONSUMPTION
Refer to Table B.2 for typical fuel consumption of the
Commander 500 engine for various operating
scenarios.
B-8 B-8
OPERATION
COMMANDER 500
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CAUTION
CAUTION
Table B.2 – DEUTZ F3L 912
ENGINE FUEL CONSUMPTION
Deutz F3L 912 Running Time
44.2 Hp for 25 gallons
@ 1800 RPM (Hours)
Low Idle - No .47 gallons/hour 53.2
Load 1475 RPM (1.77 liters/hour)
High Idle - No .66 gallons/hour 37.9
Load 1900 RPM (2.50 liters/hour)
DC CC Weld 1.94 gallons/hour 12.9
Output 500 (7.34 liters/hour)
Amps @ 40 Volts
Auxiliary Power 1.31 gallons/hour 19.1
12,000 VA (4.96 liters/hour)
WELDER OPERATION
STICK WELDING
The Commander 500 can be used with a broad range
of DC stick electrodes.
The “WELD MODE” switch provides five overlapping
slope controlled current ranges. The OUTPUT adjusts
the current from minimum to maximum within each
range. Voltage is also controlled by the OUTPUTin the
slope controlled setting. These slope controlled settings are intended for “out-of-position” welding, including pipe welding, where the operator would like to control the current level by changing the arc length.
PIPE WELDING
The Commander 500 is equipped with special circuitry
to minimize pop-outs in the five slope modes at any
open circuit voltage.
For a soft arc characteristic, set the WELD MODE
switch to the lowest setting that still provides the current you need and set the OUTPUT near maximum.
For example: to obtain 140 amps and a soft arc, set
the WELD MODE switch to the 150 MAX position and
then adjust the OUTPUT for 140 amps.
When a forceful, "digging" arc is required, use a higher
setting and lower the open circuit voltage. For example:
to obtain 140 amps and a forceful arc, set the WELD
MODE to the 250 MAX position and then adjust the
OUTPUT to get 140 amps.
CONSTANT CURRENT (CC) WELDING
In the CC - STICK position of 30 to 575, the WELD
MODE switch is designed for horizontal welds with all
types of electrodes, especially low hydrogen. The
OUTPUT adjusts the full range of 30 to 575 amps. This
setting provides a soft, constant current arc. If a more
forceful arc is desired, select the proper range from the
slope controlled current ranges.
In the CC mode, sticking can be prevented by adjusting the ARC CONTROL. Turning this control clockwise
increases the short circuit current, thus preventing
sticking. This is another way of increasing arc force.
TIG WELDING
The furthest position clockwise of the WELD MODE
switch is for TIG welding in the range of 20 amps to 250
amps, with a “Touch Start” feature. To initiate a weld,
the OUTPUT is first set to the desired current, and the
tungsten is touched to the work. During the time the
tungsten is touching the work, there is very little voltage
or current and, in general, no tungsten contamination.
Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.
The Commander 500 can be used in a wide variety of
DC Tungsten Inert Gas (TIG) welding applications. In
general the “Touch Start” feature allows contaminationfree starting without the use of a Hi-Freq unit. But the
K930-1 or -2 TIG module or K799 Hi-Freq unit can be
used with the Commander 500. The settings for these
follow the tungsten current range table, Table B.3.
B-9 B-9
OPERATION
COMMANDER 500
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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
TERMINALS ON position. This will close the solid
state contactor and provide an always “hot” electrode.
NOTE: This is necessary because the K799 circuitry
with respect to the #2 and #4 leads does not provide
the proper signal to open and close the solid state contactor in the Commander 500.
COMMANDER 500 SETTINGS WHEN USING THE
K930-1 TIG MODULE
• Set the WELD MODE switch to the 20-250 setting
(TIG).
• Set the IDLER switch to the AUTO position.
• Set the WELDING TERMINALS switch to the
REMOTELY CONTROLLED position. This will keep
the solid state contactor open and provide a “cold”
electrode until the triggering device (Amptrol or Arc
Start Switch) is pressed.
B-10 B-10
OPERATION
COMMANDER 500
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TABLE B.3 – TYPICAL CURRENT RANGES1FOR TUNGSTEN ELECTRODES
2
Approximate Argon Gas Flow Rate
DCEN (-) DCEP (+) C.F.H. (l/min.)
Tungsten
Electrode 1%, 2% 1%, 2% TIG TORCH
Diameter Thoriated Thoriated Nozzle
in. (mm) Tungsten Tunsten Aluminum Stainless Steel Size
4, 5
0.010 (.25) 2-15
3
3-8 (2-4) 3-8 (2-4) #4, #5, #6
0.020 (.50) 5-20
3
5-10 (3-5) 5-10 (3-5)
0.40 (1.0) 15-80
3
5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)
1
When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
2
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure EWP
1% Thoriated EWTh-1
2% Thoriated EWTh-2
2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC
applications.
3
DCEP is not commonly used in these sizes.
4
TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:
# 4 = 1/4 in. (6 mm) # 7 = 7/16 in. (11 mm)
# 5 = 5/16 in. (8 mm) # 8 = 1/2 in. (12.5 mm)
# 6 = 3/8 in. (10 mm) #10 = 5/8 in. (16 mm)
5
TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures and high duty cycles.
WIRE FEED (CONSTANT VOLTAGE)
WELDING
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 can be
used with a broad range of flux cored wire (Innershield
and Outershield) electrodes and solid wires for MIG
welding (gas metal arc welding). Welding can be finely
tuned using the ARC CONTROL.
Some recommended Innershield electrodes are: NR311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.
Recommended Outershield electrodes are: 0S-70, 0S71M.
Some recommended solid wires for MIG welding are:
.035 (0.9 mm), .045 (1.1 mm) and .052 (1.3 mm), L-50
and L-56, .035 (0.9 mm) and .045 (1.1 mm) Blue Max
MIG 308 LS.
For any electrodes, including the above recommendations, the procedures should be kept within the rating of
the machine. For additional electrode information, see
Lincoln publications N-675, GS-100 and GS-210.
AUXILIARY POWER OPERATION
Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings, if no welding
current is being drawn.
The auxiliary power of the Commander consists of two
20 Amp-120VAC (5-20R) duplex receptacles and one
50 Amp-120/240 VAC (14-50R) receptacle. The
120/240VAC receptacle can be split for single phase
120 VAC operation.
The auxiliary power capacity is 12,000 watts of 60 Hz,
single phase power. The auxiliary power capacity rating
in watts is equivalent to volt-amperes at unity power
factor. The maximum permissible current of the 240
V AC 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 Aper output to two separate 120 VAC branch circuits. Output voltage is within
± 10% at all loads up to rated capacity.
NOTE: The 120/240V receptacle has two 120V outputs of different phases and cannot be paralleled.
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.
SIMULTANEOUS WELDING AND
AUXILIARY POWER LOADS
It must be noted that the above auxiliary power ratings
are with no welding load. Simultaneous welding and
power loads are specified in Table B.4. The permissible currents shown assume that current is being drawn
from either the 120 VAC or 240 VAC supply (not both
at the same time).
ARC GOUGING
For optimal performance when arc gouging, set the
Commander 500 WELD MODE switch to the CC STICK position, and the ARC CONTROL to 10.
Set the OUTPUT knob to adjust output current to the
desired level for the gouging electrode being used
according to the ratings in the following table:
Electrode Current Range
Diameter (DC, electrode positive)
1/8” 30-60 Amps
5/32” 90-150 Amps
3/16” 150-200 Amps
1/4” 200-400 Amps
5/16” 250-400 Amps
3/8” 350-575 Amps*
* Maximum current setting is limited to the Commander
500 maximum of 575 Amps.
PARALLELING
When paralleling machines in order to combine their
outputs, all units must be operated in the CC - STICK
mode only. To achieve this, turn the WELD MODE
switch to the CC - STICK position. Operation in other
modes may produce erratic outputs and large output
imbalances between the units.
B-11 B-11
OPERATION
COMMANDER 500
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B-12 B-12
OPERATION
COMMANDER 500
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TABLE B.4 – COMMANDER 500 SIMULTANEOUS WELDING AND POWER LOADS
Permissible Permissible Auxiliary
Welding Power - Watts Current in Amperes
Output Range (Unity Power
Setting Welding Output Factor) @ 120 V ± 10%* @ 240 V ± 10%*
30-575 500A/40V 0 0 0
500 500A/40V 0 0 0
350 350A/30V 9500 80* 40
250 250A/29V 12000 100** 50
150 150A/27V 12000 100** 50
90 90A/25V 12000 100** 50
* Each duplex receptacle is limited to 20 amps.
** Not to exceed 50 Aper 120 VAC branch circuit when splitting the 240 VAC output.
TABLE B.5 – COMMANDER 500 EXTENSION CORD LENGTH RECOMMENDATIONS
Current
(Amps)
15
15
20
20
25
30
38
50
Voltage
(Volts)
120
240
120
240
240
240
240
240
Load
(Watts)
1800
3600
2400
48010
6000
7200
9000
12000
30
60
(9)
(18)
40
75
30
60
(12)
(23)
(9)
(18)
75
150
50
100
90
75
(23)
(46)
(15)
(30)
(27)
(23)
125
225
88
175
150
120
100
(38)
(69)
(27)
(53)
(46)
(37)
(30)
175
350
138
275
225
175
150
125
(53)
(107)
(42)
(84)
(69)
(53)
(46)
(38)
300
600
225
450
250
300
250
200
(91)
(183)
(69)
(137)
(76)
(91)
(76)
(61)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
Conductor size is based on maximum 2.0% voltage drop.
14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
EXTENSION CORD
RECOMMENDATIONS
An extension cord can be used with the auxiliary power
outputs as long as it is of ample size. Table B.5 lists
permissible extension cord lengths based on conductor size and auxiliary power output.
Accessories ..........................................................................................................................Section C
Options/Accessories ...................................................................................................................C-2
Field Installed Options ........................................................................................................ ..C-2
Stick Welding Accessories....................................................................................................C-2
TIG Welding Accessories .....................................................................................................C-2
Semiautomatic Welding Accessories....................................................................................C-3
Connection of Lincoln Electric Wire Feeders.......................................................................C-3
Connection of the LN-7 Using K867 Universal Adapter................................................C-4
Connection of the LN-7 Using the K584 or K594 Input Cable Assembly......................C-5
Connection of the LN-8 Using the K867 Universal Adapter..........................................C-6
Connection of the LN-8 Using the K595 Input Cable Assembly....................................C-7
Connection of the LN-23-P Using K350-1 Adapter........................................................C-8
Connection of the LN-25 “Across the Arc” .....................................................................C-9
Section C-1 Section C-1
TABLE OF CONTENTS
- ACCESSORIES SECTION -
COMMANDER 500
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OPTIONS/ACCESSORIES
The following options/accessories are available for
your Commander 500 from your local Lincoln
Distributor.
FIELD INSTALLED OPTIONS
K802N POWER PLUG KIT - Provides a plug for each
receptacle.
K857 25 ft. (8.5 m) or K857-1 100 ft. (30.4 m)
REMOTE CONTROL - Portable control provides same
dial range as the output control on the welder from a
location up to the specified length from the welder. Has
convenient plug for easy connection to the welder. The
Commander 500 is equipped with a 6-pin connector for
connecting the remote control.
K704 ACCESSORY SET - Includes 35 feet (10 m) of
electrode cable and 30 feet (9 m) of work cable, headshield, work clamp and electrode holder. Cable is rated
at 500 amps, 60% duty cycle.
K953-1 TWO-WHEEL TRAILER - For road, in-plant
and yard towing. Road towing with optional fender and
light kit. (For highway use, consult applicable federal,
state and local laws regarding possible additional
requirements.)
• K953-1 Trailer
• K958-1 Ball Hitch
• K958-2 Lunette Eye Hitch
• K959-1 Fender and Light Kit
• K965-1 Cable Storage Rack
K825-1 ETHER START KIT - Provides maximum cold
weather starting assistance for frequent starting below
10° F (-12.2° C). Required Ether tank is not provided
with kit.
K949-1 OIL DRAIN KIT - Includes ball valve, hose and
clamp.
K1690-1 (1 DUPLEX) GFCI KIt - Includes a UL
approved 1 15 volt ground fault circuit interrupter receptacle (duplex type) with cover and installation instructions. Each half of the receptacle is rated 15 amps, but
the maximum total current from the GFCI duplex is limited to 20 amps. The GFCI receptacle replaces the factory installed 115 volt duplex receptacle. Two kits are
required.
K899-1 SPARK ARRESTER KIT - Easily mounts to
standard muffler.
K1816-1 FULL KVA ADAPTER KIT - Plugs into the
120/240V NEMA 14-50R receptacle on the case front
(which accepts 4-prong plugs) and converts it to a
NEMA 6-50R receptacle (which accepts 3-prong
plugs).
K1768-1 DUAL OUTPUT METERS AND GAUGES -
Dual output meters provide preset ability of voltage for
wire welding and current for stick welding. Measures
both current and voltage when welding. Gauges
include battery ammeter, engine temperature, and
engine oil pressure. Fuel gauge is not available in kit
form.
STICK WELDING ACCESSORIES
K704 Accessory Kit, which includes:
• Electrode holder and cable.
• Ground clamp and cable.
• Headshield.
K857 Remote Control Kit is optional for remote current control.
TIG WELDING ACCESSORIES
• Magnum TIG Torch
• Magnum Parts Kit and Argon gas
• K930-ALL TIG Module (not required for
scratch-start DC TIG welding)
• K936-1 Control Cable
• K870 Foot Amptrol
Also available:
• K963-1/-2 Hand Amptrol
• K814 Arc Start Switch
• K937-22 Control Cable Extension
• K937-45 Control Cable Extension
• K844-1 Water Valve
C-2 C-2
ACCESSORIES
COMMANDER 500
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SEMIAUTOMATIC WELDING
ACCESSORIES
LN-7 OR LN-8 WIRE FEEDERS - Semiautomatic, con-
stant speed wire feeders. For CV operation only.
LN-23P WIRE FEEDER - This portable wire feeder is
capable of CV operation. K350-1 Adapter Kit is
required.
LN-25 WIRE FEEDER - The LN-25 with or without an
external contactor may be used with the Commander
300.
NOTE: Gas-shielded welding requires a Magnum Gun.
Gasless welding requires an Innershield Gun.
OTHER WIRE FEEDERS FOR THE
COMMANDER 300
• NA-3 Automatic Wire Feeder
• LN-742 Semiautomatic Wire Feeder
• Spool gun and K488 Module
HIGH FREQUENCY GENERATORS FOR
TIG APPLICATIONS
The K799 Hi-Freq Unit and the K930-ALL TIG Modules
are suitable for use with the Commander 500. The
Commander 500 is equipped with the required RF
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-AII TIG Module operating manuals for complete instructions on installation,
operation, and maintenance.
CONNECTION OF LINCOLN
ELECTRIC WIRE FEEDERS
ELECTRIC SHOCK can kill.
• Do not operate with panels open.
• Disconnect NEGATIVE (-) BATTERY
LEAD before servicing.
• Do not touch electrically live parts.
MOVING PARTS can injure.
• Keep guards in place.
• Keep away from moving parts.
• Only qualified personnel should install,
use or service this equipment.
C-3 C-3
ACCESSORIES
COMMANDER 500
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WARNING
CONNECTION OF THE LN-7 TO THE
COMMANDER 500 USING K867
UNIVERSAL ADAPTER (SEE FIGURE C.1.)
1. Shut the welder off.
2. Connect the electrode cable from the LN-7 to the
“+” terminal of the welder. Connect the work cable
to the “-” terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.
NOTE: Figure C.1 shows the electrode connected for
positive polarity . To change polarity , shut the welder of f
and reverse the electrode and work cables at the
Commander 500 output terminals.
3. Connect the K867 Universal Adapter to the K291 or
K404 input cable and the 14-pin amphenol of the
Commander 500 as indicated in Figure C.1. Make
the proper connections for local or remote control
according to Figure C.1.
4. Connect the K291 or K404 input cable to the LN-7.
5. Place the IDLER switch in the HIGH position.
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control circuits may be damaged. The engine governor setting is
preset at the factory—do not adjust above RPM specifications listed in this manual.
6. Set the VOLTMETER switch to “+” or “-” depending on the polarity chosen.
7. Set the OUTPUT RANGE switch to WIRE WELDING CV.
8. Set the WELDING TERMINALS switch to WELDING TERMINAL REMOTELY CONTROLLED.
9. Adjust wire feed speed at the LN-7.
10. Adjust the ARC CONTROL to the desired level
(“soft” or “crisp”).
C-4 C-4
ACCESSORIES
COMMANDER 500
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CAUTION
FIGURE C.1
COMMANDER 500/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM
GND
75
76
77
GREEN
K291 OR K404
75
INPUT CABLE
76
77
K775 OPTIONAL
REMOTE CONTROL
81
42
41
31
31
32
32
2
2
4
4
21
21
GND
82
LN-7
WIRE
FEEDER
SPARE
+
ELECTRODE CABLE
TO WIRE FEED UNIT
K867 UNIVERSAL
ADAPTER PLUG
14 PIN
AMPHENOL
–
TO WORK
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