IM699 Commander 500 - Lincoln Electric Global Sites ... · PDF fileCommander 500...

Commander 500

OPERATOR’S MANUAL

IM699April, 2002

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thoughtfuloperation on your part. DO NOTINSTALL, OPERATE OR REPAIRTHIS EQUIPMENT WITHOUTREADING THIS MANUAL ANDTHE SAFETY PRECAUTIONSCONTAINED THROUGHOUT. And,most importantly, think before youact and be careful.

For use with machines having Code Numbers: 10837, (Standard),10838, (Deluxe)

™

Date of Purchase:Serial Number:Code Number:Model:Where Purchased:

• 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.

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework 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. Stopthe engine and allow it to cool before refuel-ing to prevent spilled fuel from vaporizing oncontact with hot engine parts and igniting. Donot spill fuel when filling tank. If fuel is spilled,wipe it up and do not start engine until fumeshave been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, coversand devices in posi-

tion and in good repair.Keep hands, hair, clothing and toolsaway from V-belts, gears, fans and all other moving partswhen starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

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 youpurchase 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 theLincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay 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, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem 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 andwork 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 aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

For Diesel Engines: Diesel engine exhaust andsome of its constituents are known to the Stateof California to cause cancer, birth defects, andother reproductive harm.

For Gasoline Engines: The engine exhaust fromthis product contains chemicals known to theState of California to cause cancer, birth defects,or other reproductive harm.

CALIFORNIA PROPOSITION 65 WARNINGS

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves 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 bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air andcause 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 thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contact cancause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate circuits.This can create fire hazards or overheat lifting chains orcables until they fail.

6.h. Also see item 1.c.

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un plancher met-allique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble desoudage et la machine à souder en bon et sûr état defonc-tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à soud-er parce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu 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 appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible dela zone de travail qu’il est pratique de le faire. Si on place lamasse sur la charpente de la construction ou d’autres endroitséloignés de la zone de travail, on augmente le risque de voirpasser le courant de soudage par les chaines de levage,câbles de grue, ou autres circuits. Cela peut provoquer desrisques d’incendie ou d’echauffement des chaines et descâbles 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 tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voirle code “Code for safety in welding and cutting” CSA StandardW 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product •••as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can be foundon 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 youhave recorded above.

vv

TABLE OF CONTENTSPage

Safety .........................................................................................................................i-iv

Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1Safety Precautions ................................................................................................A-2Location/ Ventilation ..............................................................................................A-2

Storing.............................................................................................................A-2Stacking ..........................................................................................................A-2Angle of Operation ..........................................................................................A-2Lifting...............................................................................................................A-3High Altitude Operation ...................................................................................A-3High Temperature Operation...........................................................................A-3Towing .............................................................................................................A-3

Pre-Operation Engine Service...............................................................................A-4Oil ....................................................................................................................A-4Fuel .................................................................................................................A-4Fuel Cap..........................................................................................................A-4Engine Cooling System...................................................................................A-4Battery Connection..........................................................................................A-4Muffler Outlet Pipe ..........................................................................................A-5Spark Arrester .................................................................................................A-5

High Frequency Generators for TIG Applications .................................................A-5Remote Control .....................................................................................................A-5Welding Terminals .................................................................................................A-5

Welding Output Cables ...................................................................................A-6Machine Grounding ...............................................................................................A-6Auxiliary Power Receptacles .................................................................................A-6Standby Power Connections...........................................................................A-6,A-7Connection of Lincoln Electric Wire Feeders..................................................A-8,A-9

Operation .........................................................................................................Section BSafety Instructions .................................................................................................B-1General Description...............................................................................................B-1

Recommended Applications............................................................................B-1Design Features and Advantages...................................................................B-1Welding Capability ..........................................................................................B-2

Controls and Settings ............................................................................................B-3Engine Controls ........................................................................................B-3,A-4Welder Controls ..............................................................................................B-5Auxiliary Power Controls.................................................................................B-5

Engine Operation...................................................................................................B-6Starting the Engine .........................................................................................B-6Stopping the Engine........................................................................................B-6Break-In Period ...............................................................................................B-7Typical Fuel Consumption...............................................................................B-7

Welder Operation ..................................................................................................B-7Stick Welding ..................................................................................................B-7TIG Welding..............................................................................................B-7,B-8Wire Feed (Constant Voltage) Welding...........................................................B-9

Auxiliary Power Operation .....................................................................................B-9Simultaneous Welding and Auxiliary Power Loads.........................................B-9Arc Gouging ....................................................................................................B-9Paralleling .......................................................................................................B-9

Extension Cord Length Recommendations.........................................................B-10

vivi

COMMANDER 500

TABLE OF CONTENTS

Accessories.....................................................................................................Section COptional Field Installed Accessories .....................................................................C-1Recommended Optional Equipment .....................................................................C-1High Frequency Generators For TIG Applications ................................................C-1

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Routine and Periodic Maintenance .......................................................................D-1Engine Maintenance..............................................................................................D-1

Air Filter...........................................................................................................D-1Fuel Filters ...............................................................................................D-2,D-3Cooling System...............................................................................................D-3Cooling Blower Belt ........................................................................................D-3Battery Handling .............................................................................................D-3

Nameplate / Warning Decal Maintenance.............................................................D-4Welder / Generator Maintenance ..........................................................................D-4Engine Maintenance Components ........................................................................D-4

Troubleshooting ..............................................................................................Section E

Wiring,Connection Diagrams and Dimension Print.....................................Section F

Parts Lists .....................................................................................................P386Series

viivii

COMMANDER 500

A-1INSTALLATION

COMMANDER 500

A-1

TECHNICAL SPECIFICATIONS - Commander 500 (K1639-1 & -2)

Make/Model Description Speed (RPM) Displacement Starting CapacitiesSystem

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 LDiesel Engine @ 1800 RPM Full Load 1800

Bore x Stroke Oil: 9.5 Qts.9.0 L

3.94” x 4.72”(100mm x 120mm)

INPUT - DIESEL ENGINE

RATED OUTPUT - WELDER

HEIGHT2 WIDTH DEPTH WEIGHT

42.0 in. 31.5 in. 63.1 in. 1638 lbs.(743 kg)( Approx.)

1066.8 mm 800.1 mm 1602.7 mm

OUTPUT - WELDER AND GENERATOR

Duty Cycle Welding Output Volts at Rated Amps

100% 500 Amps (DC multi-purpose) 40 Volts



Welding Range Open Circuit Voltage Auxiliary Power1

30 - 575 Amps CC/CV 80 Max OCV @1900 RPM 120/240 VAC12,000 Watts, 60 Hz.

20 - 250 Amps TIG 100% Duty Cycle

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.

A-2INSTALLATION

COMMANDER 500

A-2

Read this entire installation section before youstart installation.

SAFETY PRECAUTIONS

Do not attempt to use this equipment until you havethoroughly read all operating and maintenance man-uals supplied with your machine. They include impor-tant safety precautions, detailed engine starting,operating and maintenance instructions and partslists.

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts suchas output terminals or internal wiring.

•Insulate yourself from the work andground.

•Always wear dry insulating gloves.------------------------------------------------------------------------

ENGINE EXHAUST can kill.

•Use in open, well ventilated areas orvent exhaust outside

•Do not stack anything near the engine.------------------------------------------------------------------------

MOVING PARTS can injure.

•Do not operate with doors open orguards off.

•Stop engine before servicing.

•Keep away from moving parts------------------------------------------------------------------------Only qualified personnel should install, use or servicethis equipment

LOCATION / VENTILATION

The welder should be located to provide an unrestrictedflow of clean, cool air to the cooling air inlets and to avoidrestricting the cooling air outlets. Also, locate the welderso that the engine exhaust fumes are properly vented toan outside area.

DO NOT MOUNT OVER COMBUSTIBLE SUFACESWhere there is a combustible surface directly understationary or fixed electrical equipment, that surfaceshould be covered with a steel plate at least.06”(1.6mm) thick, which should extend not less than5.90(150mm) beyond the equipment on all sides.

STORING

1. Store the machine in a cool, dry place when it is notin use. Protect it from dust and dirt. Keep it where itcan’t be accidentally damaged from constructionactivities, 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 oilto all the parts. See the MAINTENANCE section ofthis manual for details on changing oil.

3. Remove the battery, recharge it, and adjust the elec-trolyte level. Store the battery in a dry, dark place.

STACKING

Commander 500 machines cannot be stacked.

ANGLE OF OPERATIONTo achieve optimum engine performance theCommander 500 should be run in a level position. Themaximum angle of operation for the Deutz engine is 30degrees fore and aft, 40 degrees right and 45 degreesleft. If the engine is to be operated at an angle, provi-sions must be made for checking and maintaining theoil level at the normal (FULL) oil capacity in thecrankcase. When operating the welder at an angle, theeffective fuel capacity will be slightly less than thespecified 25 gallons.

WARNING

CAUTION

A-3INSTALLATION

COMMANDER 500

A-3

LIFTING

The Commander lift bale should be used to lift themachine. The Commander is shipped with the lift baleretracted. Before attempting to lift the Commander thelift bale must be secured in a raised position. Securethe lift bale as follows:

a. Open the engine compartment door.

b. Locate the 2 access holes on the upper middleregion of compartment wall just below the liftbale.

c. Use the lifting strap to raise the lift bale to the fullupright position. This will align the mountingholes 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 looseparts bag.

FALLING EQUIPMENT can causeinjury.

•Do not lift this machine using lift bale ifit is equipped with a heavy accessorysuch as a trailer or gas cylinder.

•Lift only with equipment of adequatelifting 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% forevery 300 meters (984 ft.) above 1500 meters (4920ft.). For output of 500A and below, derate the welderoutput 5% for every 300 meters (984 ft.) above 2100meters (6888 ft.).

Contact a Deutz Service Representative for anyengine adjustments that may be required.

HIGH TEMPERATURE OPERATION

At temperatures above 30°C (86°F), output voltagederating is necessary. For maximum output current rat-ings, derate welder voltage rating 2 volts for every10°C (21°F) above 30°C (86°F).

TOWING

The recommended trailer for use with this equipmentfor road, in-plant and yard towing by a vehicle(1) isLincoln’s K953-1. If the user adapts a non-Lincoln trail-er, he must assume responsibility that the method ofattachment and usage does not result in a safety haz-ard nor damage the welding equipment. Some of thefactors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincolnequipment and likely additional attachments.

2. Proper support of, and attachment to, the base ofthe welding equipment so that there will be noundue stress to the trailer’s framework.

3. Proper placement of the equipment on the trailer toinsure stability side to side and front to back whenbeing moved and when standing by itself.

4. Typical conditions of use, such as travel speed,roughness of surface on which the trailer will beoperated, and environmental conditions.

5. Proper preventative maintenance of trailer.

6. Conformance with federal, state and local laws.1

1Consult applicable federal, state and local lawsregarding specific requirements for use on public high-ways.

WARNING

A-4INSTALLATION

COMMANDER 500

A-4

PRE-OPERATION ENGINE SERVICEREAD the engine operating and maintenance instruc-tions supplied with this machine.

•Keep hands away from the engine muffler or HOT engine parts.

•Stop engine and allow to cool beforefueling.

•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 beforestarting engine.

•Keep sparks and flame away from tank.------------------------------------------------------------------------OIL

The Commander is shipped with the engine crankcasefilled with high quality SAE 10W-30 oil (API class CD orbetter). Check the oil level before starting the engine. Ifit is not up to the full mark on the dip stick, add oil asrequired. Check the oil level every four hours of runningtime during the first 35 running hours. Refer to the engineOperator’s Manual for specific oil recommendations andbreak-in information. The oil change interval is depen-dent on the quality of the oil and the operating environ-ment. Refer to the engine Operator’s Manual for theproper service and maintenance intervals.

FUEL USE DIESEL FUEL ONLY

Fill the fuel tank with clean, fresh diesel fuel. The capac-ity of the fuel tank is 25 gallons (94.6 liters). See engineOperator’s Manual for specific fuel recommendations.The Commander 500 Deluxe is protected by a low fuelshutdown to prevent the engine from running out of fuel.The machine will indicate a low fuel condition by turningon the low fuel light. A time of 30 minutes will elapse oncethe low fuel light illuminates before the machine will shut-down. A restart of the machine will restart the timer toallow the operator to override this feature. The amount ofreserve fuel remaining in the tank after the first shutdownwill vary from machine to machine. The operator mustdetermine the amount of fuel remaining before re-startingthe machine. Running out of fuel may require bleed-ing the fuel injection pump.

NOTE: Before starting the engine, open the fuel shutoffvalve (pointer to be in line with hose).

FUEL CAP

Remove the plastic cap covering from the Fuel TankFiller neck and install the Fuel Cap.

ENGINE COOLING SYSTEM

The Deutz engine is air cooled by a belt driven axialblower. The oil cooler and engine cooling fins shouldbe blown out with compressed air or steam to maintainproper cooling (See the engine Owners Manual forprocedures and frequency).

BATTERY CONNECTION

GASES FROM BATTERY can explode.

● Keep sparks, flame and cigarettesaway from battery.

To prevent EXPLOSION when:

● INSTALLING A NEW BATTERY — disconnectnegative cable from old battery first and connectto new battery last.

● CONNECTING A BATTERY CHARGER —remove battery from welder by disconnecting neg-ative cable first, then positive cable and batteryclamp. When reinstalling, connectnegative cable last. Keep well ventilated.

● USING A BOOSTER — connect positive lead tobattery first then connect negative lead to negativebattery lead at engine foot.

BATTERY ACID can burn eyes andskin.

● Wear gloves and eye protection andbe careful when working near battery.

● Follow instructions printed on battery.

------------------------------------------------------------------------

IMPORTANT: To prevent ELECTRICAL DAMAGEWHEN:

a) Installing new batteries.

b) Using a booster.

Use correct polarity — Negative Ground.

The Commander is shipped with the negative batterycable disconnected. Before you operate the machine,make sure the Engine Switch is in the OFF positionand attach the disconnected cable securely to the neg-ative (-) battery terminal.

Remove the insulating cap from the negative batteryterminal. Replace and tighten negative battery cableterminal. NOTE: This machine is furnished with a wetcharged battery; if unused for several months, the bat-tery may require a booster charge. Be sure to use thecorrect polarity when charging the battery.

WARNING

WARNING

A-5INSTALLATION

COMMANDER 500

A-5

MUFFLER OUTLET PIPE

Remove the plastic plug covering the muffler outlettube. Using the clamp provided secure the outlet pipeto the outlet tube with the pipe positioned such that itwill direct the exhaust in the desired direction.

SPARK ARRESTER

Some federal, state or local laws may require thatgasoline or diesel engines be equipped with exhaustspark arresters when they are operated in certain loca-tions where unarrested sparks may present a fire haz-ard. The standard muffler included with this welderdoes not qualify as a spark arrester. When required bylocal regulations, a suitable spark arrester, must beinstalled and properly maintained.

An incorrect arrester may lead to damage to the engineor adversely affect performance.------------------------------------------------------------------------

HIGH FREQUENCY GENERATORSFOR TIG APPLICATIONS

The K799 Hi-Freq Unit and the K930-1 or -2 TIGModule are suitable for use with the Commander 500.The Commander 500 is equipped with the requiredR.F. bypass circuitry for the connection of high fre-quency generating equipment. The high frequencybypass network supplied with the K799 Hi-Freq Unitdoes NOT need to be installed into the Commander500.

The Commander 500 and any high frequency generat-ing equipment must be properly grounded. See theK799 Hi-Freq Unit and the K930-1 or-2 TIG Moduleoperating manuals for complete instructions on instal-lation, operation, and maintenance.

REMOTE CONTROL

OUTPUTThe Commander 500 is equipped with a 6-pin & 14-pinconnector. The 6-pin connector is for connecting theK857 or K857-1 Remote Control (Optional) or in thecase of TIG welding applications, with the foot or handAmptrol (K870 or K963-1 respectively).

The 14-pin connector is used to directly connect a wirefeeder or TIG Module (K930-1 or -2) control cable.

NOTE: When using the 14-pin connector, if the wirefeeder has a built in power source output control, donot connect anything to the 6-pin connector.

WELDING TERMINALS

The Commander is equipped with a toggle switch forselecting "hot" welding terminals when in the "WELDTERMINALS ON" position or "cold" welding terminalswhen in the "REMOTELY CONTROLLED" position.

CAUTION

A-6INSTALLATION

COMMANDER 500

A-6

WELDING OUTPUT CABLES

With the engine off, route the electrode and workcables thru the strain relief bracket provided on thefront of the base and connect to the terminals provid-ed. These connections should be checked periodical-ly and tightened if necessary.

Listed in Table A.1 are copper cable sizes recom-mended for the rated current and duty cycle. Lengthsstipulated are the distance from the welder to work andback to the welder again. Cable sizes are increasedfor greater lengths primarily for the purpose of mini-mizing cable voltage drop.

Table A.1 Combined Length of Electrode andWork Cables.

MACHINE GROUNDING

Because this portable engine driven welder creates itsown power, it is not necessary to connect its frame toan earth ground, unless the machine is connected topremises wiring (home, shop, etc.).

To prevent dangerous electric shock, other equipmentpowered by this engine driven welder must:

a) be grounded to the frame of the welder using agrounded type plug,

orb) be double insulated.

When this welder is mounted on a truck or trailer, itsframe must be securely connected to the metal frameof the vehicle. When this engine driven welder is con-nected to premises wiring such as that in a home orshop, its frame must be connected to the system earthground. See further connection instructions in the sec-tion entitled “Standby Power Connections” as well asthe article on grounding in the latest U.S. NationalElectrical Code and the local code.

In general, if the machine is to be grounded, it shouldbe connected with a #8 or larger copper wire to a solidearth ground such as a metal water pipe going into theground for at least ten feet and having no insulated

joints, or to the metal framework of a building whichhas been effectively grounded. The U.S. NationalElectrical Code lists a number of alternate means ofgrounding electrical equipment. A machine groundingstud marked with the symbol is provided on thefront of the welder.

AUXILIARY POWER RECEPTACLES

The auxiliary power capacity of the Commander 500 is12,000 watts of 60 Hz, single phase power. The auxil-iary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The maximum permis-sible current of the 240 VAC output is 50 A. The 240VAC output can be split to provide two separate 120VAC outputs with a maximum permissible current of 50A per output to two separate 120 VAC branch circuits.The output voltage is within ± 10% at all loads up torated capacity.

NOTE: The 120/240V receptacle has two 120V outletsof 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 canbe split for single phase 120 VAC operation. The aux-iliary power receptacles should only be used with threewire grounded type plugs or approved double insulat-ed tools with two wire plugs. The current rating of anyplug used with the system must be at least equal to thecurrent capacity of the associated receptacle.

STANDBY POWER CONNECTIONS

The Commander 500 is suitable for temporary, stand-by or emergency power using the engine manufactur-er’s recommended maintenance schedule.

The Commander 500 can be permanently installed asa standby power unit for 240 volt-3 wire, 50 amp ser-vice. Connections must be made by a licensed electri-cian who can determine how the 120/240 VAC powercan be adapted to the particular installation and com-ply with all applicable electrical codes. The followinginformation can be used as a guide by the electricianfor most applications. Refer to the connection diagramshown in Figure A.2.

1. Install the double-pole, double-throw switchbetween the power company meter and the premis-es disconnect.

Switch rating must be the same or greater than thecustomer’s premises disconnect and service over cur-rent protection.

Up to 150FT.

3/0 AWG

150-200 FT.

3/0 AWG

200-250 FT.

4/0 AWG

AMPS@100%

Duty Cycle

500

TOTAL COMBINED LENGTH OF ELEC-TRODE AND WORK CABLES

A-7INSTALLATION

COMMANDER 500

A-7

2. Take necessary steps to assure load is limited to thecapacity of the Commander by installing a 50 amp,240 VAC double pole circuit breaker. Maximumrated load for each leg of the 240 VAC auxiliary is 50amperes. Loading above the rated output willreduce output voltage below the allowable -10% ofrated voltage which may damage appliances orother motor-driven equipment and may result inoverheating 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, 4conductor cable of the desired length. (The 50 amp,120/240 VAC plug is available in the optional K802Rplug kit.)

4. Plug this cable into the 50 Amp 120/240 Volt recep-tacle on the Commander 500 case front.

Figure A.2 Connection of the Commander 500 to Premises Wiring

240 Volt60 Hz.3-WireService

POWER

COMPANY

METER

240 VOLT

120 VOLT

120 VOLT

LOADN

NEUTRALBUS

GROUND

PREMISESDISCONNECT AND

SERVICEOVERCURRENT

PROTECTION

GND

N

NOTE: No. 6 COPPER CONDUCTOR CABLE SEENATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

240 VOLT

GROUNDED CONDUCTOR

50AMP240 VOLT

DOUBLEPOLE

CIRCUITBREAKER

DOUBLE POLE DOUBLE THROWSWITCH RATING TO BE THE SAMEAS OR GREATER THAN PREMISESSERVICE OVERCURRENTPROTECTION.

50 AMP, 120/240VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLTRECEPTACLE

A-8INSTALLATION

COMMANDER 500

A-8

CONNECTION OF LINCOLNELECTRIC WIRE FEEDERS

Shut off welder before making any electrical connec-tions.------------------------------------------------------------------------

CONNECTION OF THE LN-25 TO THECOMMANDER 500

The LN-25 with or without an external contactor maybe used with the Commander 500. See the appropri-ate connection diagram in the DIAGRAMS section.

NOTE: The LN-25 (K431) Remote Control Module and(K432) Remote Cable are not recommended for usewith the Commander 500.

• Shut the welder off.

• For electrode Positive, connect the electrode cablefrom the LN-25 to the “+” terminal of the welder andwork cable to the “-” terminal of the welder. For elec-trode Negative, connect the electrode cable from theLN-25 to the “-” terminal of the welder and workcable to the “+” terminal of the welder.

• Attach the single lead from the front of the LN-25 towork using the spring clip at the end of the lead. Thisis a sense lead to supply current to the wire feedermotor; it does not carry welding current.

• Set the SELECTOR switch to the “CV-WIRE” posi-tion.

• Set the “WELDING TERMINALS” switch to “WELDTERMINALS ON”

• Adjust the “ARC CONTROL” knob to desired crisp-ness. Generally, welding is best if the “ARC CON-TROL” is set to SOFT for MIG and CRISP forInnershield. You may however, want to start in themiddle and adjust (as needed) from there.

• Set the “IDLE” switch to the “AUTO” position. Whennot welding, the Commander 500 engine will be atthe low idle speed. If you are using an LN-25 with aninternal contactor, the electrode is not energized untilthe gun trigger is closed.

If you are using an LN-25 without an internal contactor,the electrode will be energized when the Commander500 is started.------------------------------------------------------------------------h. When the gun trigger is closed, the current sensing

circuit will cause the Commander 500 engine to goto the high idle speed, the wire will begin to feedand the welding process started. When welding isstopped, the engine will revert to low idle speedafter approximately 12 seconds unless welding isresumed.

CONNECTION OF LN-7 OR LN-8 TO THECOMMANDER 500


• Connect the LN-7 or LN-8 per instructions on theappropriate connection diagram in the DIAGRAMSsection.

• Set the “WIRE FEEDER VOLTMETER” switch toeither “+” or “-” as required by the electrode beingused.

• Set the “SELECTOR” switch to the “CV-WIRE” posi-tion.

• Adjust the “ARC CONTROL” knob to desiredCrispness. SOFT for MIG and CRISP for Innershield.

• Set the “WELDING TERMINALS” switch to the“REMOTELY CONTROLLED” position.

• Set the “IDLE” switch to the “HIGH” position. Whennot welding, the Commander 500 engine will be atthe low idle speed.

WARNING

CAUTION

A-9INSTALLATION

COMMANDER 500

A-9

CONNECTION OF AN LN-23P WIREFEEDER TO THE COMMANDER 500


• Connect the LN-23P per instructions on the appro-priate connection diagram in the DIAGRAMS sec-tion. (NOTE): When connecting an LN-23P to theCommander 500, a K350-1 adapter kit must beused.

• 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. SOFTfor MIG - CRISP for Innershield.

• Set the “IDLE” switch to the “HIGH” position. If youare using an LN-23P with the K350-1 adapter kit, theelectrode is not energized until the gun trigger isclosed.

CONNECTION OF AN NA-3 AUTOMATICWELDING SYSTEM TO THE COMMANDER500

For connection diagrams and instructions for connect-ing 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 forconnecting the NA-3.

CONNECTION OF AN LN-742 TO THECOMMANDER 500


• Connect the LN-742 per instructions on the appro-priate connection diagram in the DIAGRAMS sec-tion.

• Set the “WIRE FEEDER VOLTMETER” switch toeither “+” or “-” as required by the electrode beingused.

• Set the “SELECTOR” switch to the “CV-WIRE” posi-tion.

• Adjust the “ARC CONTROL” knob to desiredCrispness. 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. Whennot welding, the Commander 500 engine will be atthe low idle speed.

B-1OPERATIONB-1

Read and understand this entire section before operat-ing your Commander 500.

SAFETY INSTRUCTIONS

Do not attempt to use this equipment until youhave thoroughly read all operating and mainte-

nance manuals supplied with your machine. Theyinclude important safety precautions, detailedengine starting, operating and maintenanceinstructions and parts lists.

ELECTRIC SHOCK can kill.

•Do not touch electrically live partssuch as output terminals or internalwiring.

•Insulate yourself from the work andground.

•Always wear dry insulating gloves.------------------------------------------------------------------------

ENGINE EXHAUST can kill.

•Use in open, well ventilated areas orvent exhaust outside

•Do not stack anything near theengine.

------------------------------------------------------------------------

MOVING PARTS can injure.

•Do not operate with doors open orguards off.

•Stop engine before servicing.

•Keep away from moving parts------------------------------------------------------------------------Only qualified personnel should operate thisequipment.

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged doorclosed and the side panels in place as these pro-vide maximum protection from moving parts andinsure proper cooling air flow.

GENERAL DESCRIPTIONThe Commander 500 is a diesel engine-driven weldingpower source. The machine uses a brush type alter-nating current generator for DC multi-purpose weldingand for 120/240 VAC auxiliary standby power. Thewelding control system uses state of the art ChopperTechnology. The Commander 500 is not recom-mended for pipe thawing.

The generator has a single sealed bearing for mainte-nance free service. The rotor is a copper wound designwith two slip rings and brushes. The stator is woundentirely with heavy gauge copper wire and insulatedwith NEMA class F insulation material. The stator isthen impregnated with three layers of high quality var-nish. After the stator is assembled using tie bars, theentire assembly covered with an environmentally pro-tective coating. These measures insure trouble-freeoperation in the harshest environments.

The fuel tank is made from high density polyethyleneand holds 25 gallons of diesel fuel. This will provideenough fuel to run for more than 12 hours at full load.

The Deutz F3L-912 engine is equipped with a stan-dard, heavy duty, combination fuel filter/water separa-tor element.

RECOMMENDED APPLICATIONSWELDER

The Commander 500 provides excellent constant current DCwelding output for stick (SMAW) and TIG welding. TheCommander 500 also provides excellent constant voltageDC welding output for MIG (GMAW) and Innershield (FCAW)welding.

GENERATOR

The Commander 500 provides smooth 120/240 VACoutput for auxiliary power and emergency standbypower.

DESIGN FEATURES AND ADVANTAGESK1639-2 Commander 500 Deluxe Model FeaturesFor 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 rangesfor out-of position and pipe electrodes, one constantcurrent output range for general purpose welding, oneconstant voltage range for MIG wire and cored wirewelding and one 20-250 amp range for “Touch Start”TIG welding.

• 100% duty cycle at 500 amps output and 50% dutycycle at 575 amps output.

COMMANDER 500

WARNING

B-2OPERATIONB-2

FOR AUXILIARY POWER• 12,000 watts of 120/240 VAC, 60Hz auxiliary power.

• Power for tools, 120/240 VAC lights, electric pumpsand for standby emergency power.

• Drive a 5 HP motor (provided it is started under noload).

• Two 20 amp 120 VAC duplex receptacles for up to 40amps of 120 VAC power.

• One 50 amp, 120/240 VAC dual voltage receptaclefor up to 50 amps of 240 VAC, and up to 50 amps perside to separate branch circuits (not in parallel) of 120VAC single phase auxiliary power. Allows easy con-nection to premises wiring.

• Weld and AC auxiliary power at the same time (with-in machine total capacity).

OTHER FEATURES• Deutz 3-cylinder, air/oil cooled diesel engine.

Designed for long life, easy maintenance and excel-lent fuel economy.

• Engine protection system shuts the engine down forlow oil pressure, high oil temperature or a brokenfan/engine alternator belt.

• Gauges for oil pressure, oil temperature, engine alter-nator output and fuel level (on K1639-2 only codesabove 10838 have a fuel level gauge on both K1639-1 and K1639-2).

• Indicator lights for low oil pressure, high oil tempera-ture, engine alternator low output/broken belt and lowfuel level (on K1639-2 only for codes 10838 andbelow).

• Automatic low fuel shutdown before running out offuel (K1639-2 only for codes 10838 and below).

• Engine hour meter standard on all models.

• Extended range 25 gallon (94.6 l) fuel tank.

• Automatic idler reduces engine speed when not weld-ing or drawing auxiliary power. This feature reducesfuel consumption and extends engine life.

• Compact size fits crosswise in full size pick-up truck.

• Single side engine service.

• Copper alternator windings and high temperatureinsulation for dependability and long life.

• New paint system on case and base for outstandingcorrosion protection.

K1639-1 Commander 500 Standard Model

• The K1639-1 is the standard version of theCommander 500, and has all the features of theK1639-2 Deluxe version except there is no oil pres-sure gauge, oil temperature gauge, engine alternatorgauge, nor dual output meters (codes 10838 andbelow do not have a fuel level gauge nor low fuellight). This version does have fully functional engineprotection for low oil pressure, high oil temperature,and alternator output with associated lights.

• A field installed Dual Output Meter and Gauge Kit (K1768-1) is available for the K1639-1 Commander500.The kit includes dual output meters, oil pressuregauge, oil temperature gage, and alternator ammeter.

WELDING CAPABILITY

The Commander 500 is rated at 500 amps, 40 VDC at100% duty cycle and 575 amps, 36 VDC at 50% dutycycle. The maximum open circuit voltage at 1900 RPMis 80 volts. The weld current is variable from 30 to 575amps.

COMMANDER 500

• Dual 3-digit output meters are provided (optional onK1639-1) for presetting the weld amperage or voltageand displaying the actual amperage and voltage duringwelding. The meters use superbrite L.E.D.'s forimproved readability in full sunlight.

LOOK-BACK FEATURE: After welding has stopped,both displays will remain on for 7 seconds with the lastcurrent and voltage value displayed. During this time,the left-most decimal point in each display will beFLASHING.

• Standard remote control capability with 14 pin and 6 pinconnectors for easy connection of Lincoln remote con-trol accessories.

• An internal "Solid State" contactor allows for the selec-tion of "hot" or "cold" output terminals with a toggleswitch on the control panel.

• “Arc Control”potentiometer in Wire and Stick modes forprecise adjustment of arc characteristics.

• Advanced circuitry to prevent pop-outs in the five slopemodes.

B-3OPERATIONB-3

ENGINE CONTROLS (Items 1 through 8)

1. RUN STOP SWITCHWhen placed in the “RUN” position, this switch ener-gizes the fuel solenoid and other electric accessories.When placed in the “STOP” position, the flow of fuel tothe injection pump is stopped to shut down the engine.(Note: If the switch is left in the "RUN" position and theengine is not running, the fuel solenoid will be engagedfor 15 seconds and then shut down. This is to protectthe battery from discharge. After 15 seconds, the Run/ Stop switch must be toggled off then on before start-ing.)

2. START PUSHBUTTON Energizes the starter motor to crank the engine. With theengine "Run / Stop" switch in the "Run" position, push andhold the Start button to crank the engine; release as theengine starts. Start button must be depressed for a minimumof two seconds. Do not press while engine is running sincethis can cause damage to the ring gear and/or starter motor.

3. FUEL LEVEL GAUGE AND LIGHT(K1639-2 only on codes 10838 andbelow) - Displays the level of diesel fuelin the 25-gallon fuel tank. The yellow light turns onwhen the fuel gage reaches the reserve level. Oncethe reserve level is reached, the engine protection sys-tem will shut down the engine after 30 minutes of oper-ation. The machine can be restarted and operated foran additional 30 minutes before the protection systemwill shut down the engine. This ability to override theengine protection is to allow the operator to “finish up”if necessary. The operator must watch the fuel levelclosely to prevent running out of fuel and having tobleed the system.

COMMANDER 500

CONTROLS AND SETTINGSAll welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations thatfollow.

Figure B.1 Case Front Panel Controls

1 23

4 5 6 7 8

9

1912

171814 16 20

9 FUEL TEMP

WATER

PRESS

OIL

AMPS

10

11

15

13

B-4OPERATIONB-4

4. ENGINE TEMPERATURE GAUGE (K1639-2Std., K1639-1 Opt.) AND LIGHT

The gauge displays the engine oil temperature. Theyellow temperature light remains off under normaloperating temperatures. If the light turns on, the engineprotection system will shut down the engine. Check forrestrictions at the engine cooling air inlets and outlets(consult the engine Operator’s Manual). Check forloose or disconnected leads at the temperature senderlocated on the engine. Check engine cooling blowerbelt. Also, check to be sure that the welder loads arewithin the rating of the welder. The light will remain onwhen the engine has been shut down due to an over-temperature condition.

5. OIL PRESSURE GAUGE (K1639-2 Std.,K1639-1 Opt.) AND LIGHTThe gauge displays the engine oil pressure when theengine is running. The yellow oil pressure light remainsoff with proper oil pressure. If the light turns on, theengine protection system will stop the engine. Checkfor proper oil level and add oil if necessary. Check forloose or disconnected leads at the oil pressure senderlocated on the engine. The light will go on and stay onwhen the RUN-STOP switch is switched to the “Run”position with engine not running. NOTE: Ammeter lightmay also be lit in an oil pressure fault condition.

6. ENGINE ALTERNATOR AMMETER (K1639-2 Std., K1639-1 Opt.) AND LIGHT

The yellow engine alternator light is off when batterycharging system is functioning normally. If light turnson, the engine protection system will shut down theengine. Check the engine cooling blower belt. Also, thealternator or the voltage regulator may not be operat-ing correctly. The light may also come on due to afaulty flashing circuit. The light will remain on when theengine has been shut down due to a fault in the alter-nator, regulator, or the cooling blower belt.

7. IDLER SWITCH Has two positions as follows:

A) In the “High” position , the engine runs atthe 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 afterstarting the engine, the engine will operate at fullspeed for approximately 12 seconds and then goto low idle speed.

b. When the electrode touches the work or power isdrawn for lights or tools (approximately 100Watts minimum) the engine accelerates andoperates at full speed.

c. When welding ceases or the AC power load isturned off, a fixed time delay of approximately 12seconds starts.

d. If the welding or AC power load is not restartedbefore the end of the time delay, the idlerreduces the engine speed to low idle speed.

e. The engine will automatically return to high idlespeed when the welding load or A.C. power loadis reapplied.

Idler Operational exceptions

When the WELDING TERMINALS switch is in the“Remotely Controlled” position the idler will operate asfollows:

a. When the triggering device (Amptrol, Arc StartSwitch, etc.) is pressed the engine will accelerateand operate at full speed provided a welding load isapplied within approximately 15 seconds.

• If the triggering device remains pressed but no weld-ing load is applied within approximately 15 secondsthe engine will return to low idle speed.

• If the triggering device is released or welding ceasesthe engine will return to low idle speed after approxi-mately 15 seconds.

8. HOUR METERThe hour meter displays the total time that the enginehas been running. This meter is a useful indicator forscheduling preventive maintenance.

COMMANDER 500

WELDER CONTROLS (Items 9 through 13 )

9. WELD MODE & OUTPUT CONTROLThese two controls allow you to select between variouswelding output slopes and adjust the desired weldingoutput. Refer to Table B.1 for a description of howthese two controls work.

Table B.1 Weld Mode and Output Control

Functions1 If the WELD MODE switch is positioned between settings the pre-

vious setting is maintained until the switch is properly positioned ona setting.

2 OUTPUT also controls O.C.V. while in the 5 sloped output ranges.

10. DIGITAL OUTPUT METERSThe digital output meters are located in the center ofthe control panel between the two large control knobs.The digital meters allow the output voltage (CV-WIREmode) or current (CC-STICK, PIPE and TIG modes) tobe set prior to welding using the OUTPUT control dial.During welding, the meter display the actual outputvoltage (VOLTS) and current (AMPS). A memory fea-ture holds the display of both meters on the seven sec-onds after welding is stopped. This allows the operatorto read the actual current and voltage just prior to whenwelding was ceased. While the display is being heldthe left-most decimal point in each display will be flash-ing. The accuracy of the meters is + or - 3%.

11. WELDING TERMINALS SWITCHThe toggle switch on the control panel labeled “WeldTerminals On” and “Remotely Controlled”: is used tocontrol the operation of the “solid state contactor”which allows for the selection of “Hot” or “Cold” weld-

B-5OPERATIONB-5

ing terminals.With the switch in the “Weld Terminals On” position thecontactor is closed and the welding terminals arealways “Hot”.

With the switch in the “Remotely Controlled” positionthe contactor operation is controlled by an Amptrol, ArcStart Switch or some other type of triggering devicethrough the use of a control cable connected to the 14-pin MS connector.

When the triggering device is pressed the contactor isclosed and the welding terminals are “Hot”.

When the triggering device is released the contactor isopened and the welding terminals are “Cold”.

NOTE: The new Chopper Technology control circuitryautomatically senses when a remote output control potis plugged into either amphenol. Therefore, there is noneed for a local / remote switch.

12. 6 - PIN CONNECTOR For attaching optional remote control equipment.When in the CC-STICK, PIPE, and CV-WIRE modesand when a remote control is connected to theAmphenol, the auto-sensing circuit automaticallyswitches the OUTPUT control from control at thewelder to remote control .When using the TOUCH START TIG mode with a TIGModule connected, the OUTPUT control is used to setthe maximum current range of the CURRENT CON-TROL on the TIG Module.

13. WELD OUTPUT TERMINALS + AND -These 1/2 - 13 studs with flange nuts provide weldingconnection points for the electrode and work cables.For positive polarity welding the electrode cable con-nects to the “+” terminal and the work cable connectsto this “-” terminal. For negative polarity welding thework cable connects to the “+” terminal and the elec-trode cable connects to this “-” terminal.

AUXILIARY POWER CONTROLS (Items 14 - 17)

14. 120/240VAC RECEPTACLEThis is a 120/240VAC (14-50R) receptacle that pro-vides 240VAC or can be split for 120VAC single phaseauxiliary power. This receptacle has a 50 amp rating.Refer to the AUXILIARY POWER RECEPTACLESsection in the installation chapter for further informationabout this receptacle. Also refer to the AUXILIARYPOWER OPERATION section later in this chapter.

COMMANDER 500

M

Sloped Output forPipe Welding.

Touch Start TIGWelding

Constant CurrentOutput forFabrication andGeneral PurposeWelding

Constant VoltageOutput for MIGWire or COREDWIRE Welding

5 RangeSettings

90, 150, 200,350, 500 (Max.current on each

setting)

1 Range setting20-250 Amps

1 Range setting30-575 Amps

1 Range setting14 to 40 Volts

Provides a fineadjustment of

welding currentfrom

Min (1) to Max(10) within each

range

Provides FineVoltage

Adjustment

Weld Mode1

ApplicationOutput

2M

B-6OPERATIONB-6

15. CIRCUIT BREAKERSThese circuit breakers provide separate overload cur-rent protection for each 120V circuit at the 240V recep-tacle, each 120V receptacle, the 120VAC in the 14-Pinconnector, the 42VAC in the 14-Pin connector and (forcodes above 10838 only) battery circuit overload pro-tection.

16. 120VAC RECEPTACLESThese two 120VAC (5-20R) receptacles provide120VAC for auxiliary power. Each receptacle has a 20amp total rating. Refer to the AUXILIARY POWERRECEPTACLES section in the installation chapter forfurther information about these receptacles. Also referto the AUXILIARY POWER OPERATION section laterin this chapter.

17. GROUND STUDProvides a connection point for connecting themachine case to earth ground for the safest groundingprocedure. Refer to “MACHINE GROUNDING” in theInstallation chapter for proper machine grounding infor-mation.

18. VOLTMETER +/- SWITCHChanges the polarity display on the wire feeder.

19. 14 - PIN CONNECTORFor attaching wire feeder control cable. Includes con-tactor closure circuit, auto-sensing remote control cir-cuit, and 120V and 42V power. The remote control cir-cuit operates the same as the 6 Pin Amphenol.

20. ARC CONTROLThe ARC CONTROL WIRE/STICK dial is active in theWIRE and STICK modes, and has different functions inthese modes. This control is not active in the TIG andPIPE modes.

CC-STICK mode: In this mode, the ARC CONTROLknob sets the short circuit current during stick welding(arc-force). Increasing the number from -10 to +10increases the short circuit current and prevents stick-ing of the electrode to the plate while welding. This canalso increase spatter. It is recommended that the ARCCONTROL be set to the minimum number withoutelectrode sticking. Start with a setting at 0.

CV-WIRE mode: In this mode, turning the ARC CON-TROL clockwise from –10 (soft) to +10 (crisp) changesthe arc from soft and washed-in to crisp and narrow. Itacts as an inductance control. The proper settingdepends on the procedure and operator preference.Start with a setting at 0.

ENGINE OPERATION

STARTING THE ENGINE

1. Open the engine compartment door and check thatthe fuel shutoff valve located to the left of the fuel fil-ter housing is in the open position (lever to be in linewith the hose).

2. Check for proper oil level on the oil dipstick. Closeengine 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 allengine protection lights momentarily turn on, some lightsmay turn off before starting. Check the fuel gauge(K1639-2 only for codes 10838 and below) to makesure that there is an adequate fuel level.

6. Press and hold the engine START button for a minimumof 2 seconds.

7. Release the engine START button when the enginestarts.

8. Check that the indicator lights are off. If the LOW FUEL lightis on (K1639-2 only for codes 10838 and below), theengine will shutdown 30 minutes after starting. If any otherindicator light is on after starting, the engine will shutdown in afew seconds. Investigate any indicated problem.

9. Allow the engine to warm up at low idle speed for severalminutes before applying a load and/or switching to highidle. 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 toabout 0°F. If the engine must be frequently startedbelow 10°F, it may be desirable to install the optionalether starter kit (K825-1). Installation and operatinginstructions are included in the kit.

STOPPING THE ENGINE

1. Switch the RUN/STOP switch to “STOP”. This turnsoff the voltage supplied to the shutdown solenoid.A backup shutdown can be accomplished by shut-ting off the fuel valve located on the fuel line.

COMMANDER 500

B-7OPERATIONB-7

BREAK-IN PERIOD

The engine used to supply power for your welder is aheavy duty, industrial engine. It is designed and builtfor rugged use. It is very normal for any engine to usesmall quantities of oil until the break-in is accom-plished. Check the oil level twice a day during thebreak-in period (about 200 running hours).

IMPORTANT

IN ORDER TO ACCOMPLISH THIS BREAK-IN, THEUNIT SHOULD BE SUBJECTED TO HEAVY LOADS,WITHIN THE RATING OF THE MACHINE. AVOIDLONG IDLE RUNNING PERIODS.

TYPICAL FUEL CONSUMPTION

Refer to Table B.2 for typical fuel consumption of theCommander 500’s Engine for various operating sce-narios.

Table B.2 Deutz F3L 912 Engine Fuel Consumption

WELDER OPERATIONSTICK WELDING

The Commander 500 can be used with a broad rangeof DC stick electrodes.

The “WELD MODE” switch provides five overlappingslope controlled current ranges. The OUTPUT adjuststhe current from minimum to maximum within eachrange. Voltage is also controlled by the OUTPUT in theslope controlled setting. These slope controlled set-tings are intended for “out-of-position” welding, includ-ing pipe welding, where the operator would like to con-trol the current level by changing the arc length.

PIPE WELDING

The Commander 500 is equipped with special circuitryto minimize pop-outs in the five slope modes at anyopen circuit voltage.

For a soft arc characteristic, set the "WELD MODE"Switch to the lowest setting that still provides the cur-rent you need and set the "OUTPUT" near maximum.For example: to obtain 140 amps and a soft arc, setthe " WELD MODE" Switch to the "150 MAX" positionand then adjust the "OUTPUT" for 140 amps.

When a forceful "digging" arc is required, use a highersetting and lower the open circuit voltage. For exam-ple: to obtain 140 amps and a forceful arc, set the “WELD MODE” to the "250 MAX" position and thenadjust the "OUTPUT" to get 140 amps.

CONSTANT CURRENT (CC) WELDING

The CC - STICK position of “30 to 575", the "WELDMODE" Switch is designed for horizontal welds with alltypes 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 amore forceful arc is desired, then select the properrange from the slope controlled current ranges.

In the CC mode, sticking can be prevented by adjust-ing the “ARC CONTROL”. Turning this control clock-wise, increases the short circuit current, thus prevent-ing sticking. This is another way of increasing arcforce.

TIG WELDING

The most clockwise position of the WELD MODEswitch is for TIG welding in the range of 20 amps to250 amps, with a “Touch Start” feature. To initiate aweld, the OUTPUT is first set to the desired currentand the tungsten is touched to the work. During thetime the tungsten is touching the work there isvery little voltage or current and, in general, no tung-sten contamination. Then, the tungsten is gently liftedoff the work in a rocking motion, which establishes thearc.

The Commander 500 can be used in a wide variety ofDC Tungsten Inert Gas (TIG) welding applications. Ingeneral the “Touch Start” feature allows contaminationfree starting without the use of a Hi-Freq unit. But theK930-1 or -2 TIG module or K799 Hi-Freq unit, can beused with the Commander 500. The settings for thesefollow the tungsten current range table.

COMMANDER 500

Low Idle - NoLoad 1475 RPM

High Idle - NoLoad 1900 RPM

DC CC WeldOutput 500Amps @ 40Volts

Auxiliary Power

.47 gallons/hour(1.77 liters/hour)

.66 gallons/hour( 2.50 liters/hour)

1.94 gallons/hour( 7.34 liters/hour)

1.31 gallons/hour(4.96 liters/hour)

53.2

37.9

12.9

19.1

Deutz F3L 91244.2 Hp

@ 1800 RPM

Running Time for25 gallons

(Hours)

B-8OPERATIONB-8

Commander 500 SETTINGS WHEN USING THEK799 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 “WeldTerminals On” position. This will close the solid statecontactor and provide an always “hot” electrode.

(Note: This is necessary because the K799 circuitry withrespect to the #2 and #4 leads does not provide the prop-er signal to open and close the solid state contactor in theCommander 500).

Commander 500 SETTINGS WHEN USING THEK930-1 or -2 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 “RemotelyControlled” position. This will keep the solid state con-tactor open and provide a “cold” electrode until the trig-gering device (Amptrol or Arc Start Switch) is pressed.

COMMANDER 500

TungstenElectrodeDiameterin. (mm)

2-155-2015-80

70-150

150-250250-400

400-500500-750750-1000

(3)(3)(3)

10-20

15-3025-40

40-5555-8080-125

3-8 (2-4)5-10 (3-5)5-10 (3-5)

5-10 (3-5)

13-17 (6-8)15-23 (7-11)

21-25 (10-12)23-27 (11-13)28-32 (13-15)

3-8 (2-4)5-10 (3-5)5-10 (3-5)

9-13 (4-6)

11-15 (5-7)11-15 (5-7)

13-17 (6-8)18-22 (8-10)23-27 (11-13)

TIG TORCHNozzle

Size (4), (5)

Approximate Argon Gas Flow Rate C.F.H. (l/min.)

DCEN (-) DCEP (+)

#4, #5, #6

#5, #6

#6, #7, #8

#8, #10

0 .010 (.25)0.020 (.50)0.040 (1.0)

1/16 (1.6)

3/32 (2.4)1/8 (3.2)

5/32 (4.0)3/16 (4.8)1/4 (6.4)

1%, 2%ThoriatedTungsten

1%, 2%ThoriatedTungsten

Aluminum Stainless Steel

Table B.3 TYPICAL CURRENT RANGES (1)

FOR TUNGSTEN ELECTRODES(2)

(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure heliumshielding gases.

(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):Pure EWP1% Thoriated EWTh-12% Thoriated EWTh-2

Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% ThoriatedTungsten 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)# 5 = 5/16 in. (8 mm)# 6 = 3/8 in. (10 mm)# 7 = 7/16 in. (11 mm)# 8 = 1/2 in. (12.5 mm)#10 = 5/8 in. (16 mm)

(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which areless prone to breakage, but cannot withstand high temperatures and high duty cycles.

B-9OPERATIONB-9

WIRE FEED (CONSTANT VOLTAGE) WELD-ING

Connect a wire feeder to the Commander 500 and setwelder controls according to the instructions listed earlierin this section.

The Commander 500 in the ”CV-WIRE” position, permits itto be used with a broad range of flux cored wire(Innershield and Outershield) electrodes and solid wiresfor MIG welding (gas metal arc welding). Welding can befinely tuned using the “ARC CONTROL”.

Some recommended Innershield electrodes are: NR-311,NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.

Recommended Outershield electrodes are: 0S-70, 0S-71M.

Some recommended solid wires for MIG welding are: .035 (0.9 mm), .045 (1.1 mm) and .052 (1.3 mm), L-50and L-56, .035 (0.9 mm) and .045 (1.1 mm) Blue Max MIG308 LS.

For any electrodes, including the above recommenda-tions, the procedures should be kept within the rating ofthe machine. For additional electrode information, seeLincoln publications N-675, GS-100 and GS-210.

AUXILIARY POWER OPERATION

Start the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregardless of the welding control settings, if no weldingcurrent is being drawn.

The auxiliary power of the Commander consists of two20 Amp-120VAC (5-20R) duplex receptacles and one50 Amp-120/240 VAC (14-50R) receptacle. The120/240VAC receptacle can be split for single phase120 VAC operation.

The auxiliary power capacity is 12,000 watts of 60 Hz,single phase power. The auxiliary power capacity rat-ing in watts is equivalent to volt-amperes at unitypower factor. The maximum permissible current of the240 VAC output is 50 A. The 240 VAC output can besplit to provide two separate 120 VAC outputs with amaximum permissible current of 50 A per output to twoseparate 120 VAC branch circuits. Output voltage iswithin ± 10% at all loads up to rated capacity.

NOTE: The 120/240V receptacle has two 120V out-puts of different phases and cannot be paralleled.

The auxiliary power receptacles should only be usedwith three wire grounded type plugs or approved dou-ble insulated tools with two wire plugs.

The current rating of any plug used with the systemmust be at least equal to the current capacity of theassociated receptacle.

SIMULTANEOUS WELDING AND AUXIL-IARY POWER LOADS

It must be noted that the above auxiliary power ratingsare with no welding load. Simultaneous welding andpower loads are specified in table B.4. The permissi-ble currents shown assume that current is being drawnfrom either the 120 VAC or 240 VAC supply (not bothat the same time).

ARC GOUGING

For optimal performance when arc gouging, set theCommander 500’s “WELD MODE” switch to the “CC -STICK” position, and the “ARC CONTROL” to 10.

Set the “OUTPUT” knob to adjust output current to thedesired level for the gouging electrode being usedaccording to the ratings in the following table:

* Maximum current setting is limited to the Commander500’s maximum of 575 Amps.

PARALLELING

When paralleling machines in order to combine theiroutputs, all units must be operated in th CC - STICKmode only. To achieve this turn the WELD MODEswitch to the CC - STICK position. Operation in othermodes may produce erratic outputs, and large outputimbalances between the units.

COMMANDER 500

ELECTRODE CURRENT RANGE DIAMETER (DC,electrode positive)

1/8” 60-90 Amps5/32” 90-150 Amps3/16” 200-250 Amps1/4 300 Amps5/16” 350-450 Amps3/8” 450 Amps*

B-10OPERATIONB-10

COMMANDER 500

WeldingOutput Range

Setting

30-57550035020015090

Welding Output

500A/40V500A/40V350A/30V200A/28V150A/27V90A/25V

PermissiblePower - Watts (Unity Power

Factor)

00

9500120001200012000

PermissibleCurrent in

@120 V ±10% *

00

80*100**100**100**

AuxiliaryAmperes

@ 240 V ±10%

0040505050

* Each duplex receptacle is limited to 20 amps.** Not to exceed 50 A per 120 VAC branch circuit when splitting the 240

VAC output.

TABLE B.4 Commander 500 Simultaneous Welding and PowerLoads

TABLE B.5 Commander 500 Extension Cord LengthRecommendations

Current(Amps)

1515202025303850

Voltage(Volts)

120240120240240240240240

Load(Watts)180036002400480060007200900012000

3060

(9)(18)

40753060

(12)(23)(9)

(18)

7515050

1009075

(23)(46)(15)(30)(27)(23)

12522588

175150120100

(38)(69)(27)(53)(46)(37)(30)

175350138275225175150125

(53)(107)(42)(84)(69)(53)(46)(38)

300600225450250300250200

(91)(183)(69)

(137)(76)(91)(76)(61)

Maximum Allowable Cord Length in ft. (m) for Conductor Size

Conductor size is based on manimum 2.0% voltage drop.

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

K1690-1 (1 Duplex) GFCI Kit - Includes one ULapproved 115V ground fault circuit interrupter duplextype receptacle with cover and installation instructions.Replaces the factory installed 115V duplex receptacle.The receptacle of the GFCI duplex is rated at 20 amps,the maximum total current from the GFCI duplex is lim-ited to 20 amps. Two kits are required.

K1768-1 Dual Output Meters and Gauges - Dual out-put meters provide preset ability of voltage for wirewelding and current for stick welding. Measures bothcurrent and voltage when welding. Gauges include:battery ammeter, engine temperature, and engine oilpressure. Fuel gauge is not available in kit form.

K1816-1 Full KVA Adapter Kit - Plugs into the120/240v NEMA 14-50R receptacle on case front(which accepts 4-prong plugs) and converts it to aNEMA 6-50R receptacle, (which accepts 3-prongplugs.

Pipe Thawing with an arc welder can cause fire,explosion, damage to electric wiring or to the arcwelder if done improperly. The use of an arcwelder for pipe thawing is not approved by theCSA, nor is it recommended or supported byLincoln Electric.------------------------------------------------------------------------

C-1ACCESSORIESC-1

OPTIONAL FIELD INSTALLEDACCESSORIES

K802N POWER PLUG KIT - Provides foue 120V plugs rated at 20amps each and one dual voltage, full KVA plug rated at 120/240V,50 amps. 120V plug may not be compatible with NEMA commonhousehold receptacles.

K802-R POWERPLUG KIT - Provides four 120V plugs rated 15amps each and one dual voltage, full KVA plug rated at 120/240V,50 amps, 120V plug is compatible with NEMA common householdreceptacles.

K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CON-TROL - Portable control provides same dial range as the outputcontrol on the welder from a location up to the specified lengthfrom the welder. Has convenient plug for easy connection to thewelder. The Commander 500 is equipped with a 6 pin connec-tor for connecting the remote control.

K704 ACCESSORY SET - Includes 35 feet (10 m) ofelectrode cable and 30 feet (9 m) of work cable, head-shield, work clamp and electrode holder. Cable israted at 500 amps, 60% duty cycle.

(K953-1) TRAILER - Two-wheeled trailer withoptional fender and light package. For highway use,consult applicable federal, state, and local laws regard-ing possible additional requirements. There is a choiceof 2 hitches, a fender & a light package. Order:K953-1 TrailerK958-1 Ball HitchK958-2 Lunette Eye HitchK959-1 Fender & Light KitK965-1 Cable Storage Rack

(K957-1) TRAILER - Two-wheeled trailer for in-plant and yard towing at speeds under 20 mphonly.Order:K957-1 TrailerK958-1 Ball HitchK958-2 Lunette Eye Hitch K959-2 Fender & Light KitK965-1 Cable Rack

K825-1 ETHER START KIT - Provides maximum coldweather starting assistance for frequent starting below10 oF (-12.2 oC). Required Ether tank is not providedwith kit.K899-1 SPARK ARRESTOR KIT - Easily mounts tostandard muffler.

K949-1 OIL DRAIN KIT - Includes ball valve, hose and clamp.

COMMANDER 500

WARNING

C-2ACCESSORIESC-2

COMMANDER 500

RECOMMENDED OPTIONALEQUIPMENT

STICK

K704 Accessory Kit which includes:• Electrode holder and cable.• Ground clamp and cable.• Headshield.

K857 Remote Control Kit is optional for remote cur-rent control.

TIG

Magnum TIG TorchMagnum Parts Kit and Argon gasK930-ALL TIG Module (not required for scratch startDC TIG welding)

K936-1 Control CableK870 Foot Amptrol

Also available:

K963-1/-2 Hand AmptrolK814 Arc Start SwitchK937-45 Control Cable ExtensionK844-1 Water Valve

WIRE FEED WELDING OPTIONS

• LN-25 • LN-7• LN-23P • LN-8• NA-3 • Spool Gun & K488 Module• LN-742

HIGH FREQUENCY GENERATORS FORTIG APPLICATIONS

The K799 Hi-Freq Unit and the K930-ALL TIG Modulesare suitable for use with the Commander 500. TheCommander is equipped with the required R.F. bypasscircuitry for the connection of high frequency generat-ing equipment. The high frequency bypass networksupplied with the K799 Hi-Freq Unit does NOT needto be installed into the Commander.

The Commander and any high frequency generatingequipment must be properly grounded. See the K799Hi-Freq Unit and the K930-All TIG Module operatingmanuals for complete instructions on installation, oper-ation, and maintenance.

D-1MAINTENANCED-1

COMMANDER 500

SAFETY PRECAUTIONS

•Have a qualified technician do the maintenanceand troubleshooting work.

•Turn the engine off before working inside themachine.

•Remove guards only when necessary and replacethem when the maintenance requiring theirremoval is complete.

•Always use the greatest care when working nearmoving parts.

------------------------------------------------------------------------

Read the Safety Precautions in front of this manualand the engine instruction manual before working onthis machine.

Keep all equipment safety guards, covers and devicesin position and in good repair. Keep hands, hair, cloth-ing and tools away from V-belts, gears, fans and allother moving parts when starting, operating or repair-ing the equipment.

ROUTINE AND PERIODIC MAINTENANCE

DAILY

a. Check the crankcase oil level .

b. Refill the fuel tank to minimize moisture condensa-tion in the tank.

c. Open the water drain valve located on the bottom ofthe water separator element 1 or 2 turns and allowto drain into a container suitable for diesel fuel for 2to 3 seconds. Repeat the above drainage procedureuntil diesel fuel is detected in the container.

WEEKLY

Blow out the machine with low pressure air periodical-ly. In particularly dirty locations, this may be requiredonce a week.

ENGINE MAINTENANCE

Refer to the “Periodic Checks” section of the EngineOperator’s Manual for the recommended maintenanceschedule of the following:

a) Engine Oil and Filterb) Air Cleanerc) Fuel Filter - and Delivery Systemd) Cooling Blower Belte) Batteryf) Cooling System

Refer to Table D.1 at the end of this section for variousengine maintenance components.

AIR FILTER

EXCESSIVE AIR FILTER RESTRICTION WILLRESULT IN REDUCED ENGINE LIFE. ------------------------------------------------------------------------The air filter element is a dry cartridge type. It can becleaned and reused; however, damaged elementsshould not be reused. Stop engine after 100 hours ofrunning time and clean filter element , replace the fil-ter if necessary. Service air cleaner regularly accord-ing to Engine Operator’s Manual.

1. Locate the air filter canister located behind theengine door on the top of the engine.

2. Remove air filter element.

3. Remove loose dirt from element with compressedair or water hose directed from inside out.

Compressed Air: 100 psi maximum with nozzles atleast one inch away from element.

Water Hose: 40 psi maximum without nozzle.

4. Soak element in a mild detergent solution for 15minutes. Do not soak more than 24 hours. Swishelement around in the solution to help remove dirt.

5. Rinse elements from inside out with a gentle streamof water (less than 40 psi) to remove all suds anddirt.

6. Dry element before reuse with warm air at less than

160oF (71

oC). Do not use a light bulb to dry the ele-

ment.

WARNING

CAUTION

D-2MAINTENANCED-2

COMMANDER 500

7. Inspect for holes and tears by looking through theelement toward a bright light. Check for damaged gas-kets or dented metal parts. Do not reuse damaged ele-ments. Protect element from dust and damage duringdrying and storage.

8. Reinstall air filter element.

After six cleanings replace air filter. A cleaned filter willhave approximately 70% of the life of a new filter ele-ment. A restricted filter element may not appear exces-sively dirty.

FUEL FILTERS

When working on the fuel system

• Keep naked lights away, do not smoke !

• Do not spill fuel !

------------------------------------------------------------------------

The Commander 500 is equipped with a Fuel Pre-Filter/Water Separator Assembly located before thelift pump and a Secondary Fuel Filter located after thelift pump and before the fuel injectors. The Fuel Pre-Filter/Water Separator is mounted to the engine blockjust below the lift pump. The Secondary Fuel Filter ismounted directly to the engine just above the oil filter.

FUEL PRE-FILTER/WATER SEPARATOR ASSEM-BLY

The pre-filter is a 150 micron screen designed to pro-tect against gross fuel contamination of the water sep-arator element and the Secondary Fuel Filter. If thepre-filter becomes plugged it may be removed, inspect-ed, cleaned and reinstalled. In general this only needsto be done with each water separator element change(about every 1,000 hrs.) However if at any time exces-sive fuel contamination is suspected or a sudden fall-off in engine performance is detected the pre-filterscreen should be inspected and cleaned. Follow thefollowing procedure:

1. Close the fuel shutoff valve (Lever should be per-pendicular to the hose) located on the side of theFuel Pre-Filter/Water Separator Assembly.

2. Unscrew the cap ring located on the top of the filterheader and remove the plastic center cap and O-ring.

3. Remove the large white volume plug located direct-ly under the center cap in the upper cavity of the fil-ter header. Use a small screwdriver (or similardevice) to lift the plug part way out of the cavity toassist with its removal.

Be careful not to damage the pre-filter screen withthe tool used to remove the plug.

4. Using a pair of pliers, gently tug on the pull tabs ofthe pre-filter screen in an alternating pattern togradually remove the pre-filter screen.

5. Brush off any debris and rinse in diesel fuel.

6. Re-install the pre-filter screen into the upper cavityof the filter header making sure the four pull tabsare pointing up. Putting your fingers on the pulltabs, push down evenly until the lower body of thepre-filter screen contacts the floor of the upper cav-ity.

7. Re-insert the large white volume plug into the uppercavity.

8. Place the O-ring onto the angled seal surface of thefilter header and re-install the plastic cap. Makesure its flange rests on the O-ring.

9. Screw on the cap ring and tighten hand tight.

10. Remember to open the fuel shutoff valve (Lever inline with the hose) before starting the engine.

WATER SEPARATOR ELEMENT

The water separator element is a two stage filter with aspecial filtration/water separating media, and anexpanded water reservoir providing maximum protec-tion against water in the fuel. The recommendedchange interval for the water separator element is1,000 hours. The procedure for changing the elementis as follows:

1. Close the fuel shutoff valve (Lever should be per-pendicular to the hose) located on the side of theFuel Pre-Filter/Water Separator Assembly.

2. Rotate the quick change ring (located just below fil-ter header) clockwise approximately 1/2 turn andslide it down and off of the element.

3. Grasp the element and pull down with a slight rock-ing motion to remove the element from the grom-met post on the bottom of the filter header.

WARNING

D-3MAINTENANCED-3

COMMANDER 500

4. Slide the new element onto the grommet post on thebottom of the filter header until the element no longereasily moves up into the filter header. Now rotate theelement (may take almost 1 full turn) with a slightupward pressure until the element begins to furtherengage the header. With the proper orientation nowestablished apply additional pressure to seat the ele-ment in the filter header. You should feel the element“pop” into place when properly seated.

Note: The element will only go on one way. Never useexcessive force when mounting the element to theheader.

5. Slide the quick change ring up over the element androtate counter clockwise until an audible click or popis heard. If you do not hear the click you have not rotat-ed the ring far enough and the element is not in thelocked position. Another indication that the ring is inthe locked position is that one set (it doesn’t matterwhich one) of arrows located on the outside of the ringshould be located directly under the air vent valve.

6. Open the fuel shutoff valve (lever in line with the hose).

7. Open the air vent valve on the front of the filter head-er until fuel emerges free of air bubbles and then closethe air vent valve.

Note : Consult your engine operation manual for infor-mation on air bleeding the entire fuel system.

SECONDARY FUEL FILTER

The Secondary Fuel Filter is a spin on cartridge typemount directly to the engine. Consult your engine opera-tion manual for complete information on service intervalsand element changing procedures.

COOLING SYSTEMThe cooling system of the Deutz engine needs to bechecked and cleaned periodically. Consult the engineowners manual for the proper frequency and procedure.

COOLING BLOWER BELTThe following procedure should be followed to replace thecooling blower belt:

1. Allow the machine to cool.

2. Unfasten and slide the battery holder out from the welder.

3. Disconnect the negative battery cable.

4. Remove engine case side.

5. Loosen air cleaner hose clamp and detach hose.

6. Remove the engine end panel with air box and air clean-er attached for access to the engine.

7. Loosen the alternator mounting bolts and rotate thealternator towards the engine.

8. Remove the old cooling blower belt and install a new one.

9. Adjust the cold belt tension to 63-73 lbs. midwaybetween any two pulleys.

10. Reinstall the air cleaner hose, engine case side andend panel. Reattach the negative battery cable. Slidein and refasten the battery holder.

11. Check the cooling blower belt tension after 100 hoursof operation. (Follow steps 1,2,3,4,5,6,9 & 10)

BATTERY HANDLING

GASES FROM BATTERY can explode.• Keep sparks, flame and cigarettes away from bat-

tery.

To prevent EXPLOSION when:• INSTALLING A NEW BATTERY - disconnect nega-

tive cable from old battery first and connect to newbattery last.

• CONNECTING A BATTERY CHARGER - Remove bat-tery from welder by disconnecting negative cablefirst, then positive cable and battery clamp. Whenreinstalling, connect negative cable last. Keep wellventilated.

• USING A BOOSTER - connect positive lead to bat-tery first then connect negative lead to engine foot.

BATTERY ACID CAN BURN EYES AND SKIN.• Wear gloves and eye protection and be careful

when working near battery. Follow instructionsprinted on battery.

------------------------------------------------------------------------PREVENTING ELECTRICAL DAMAGE

1. When replacing, jumping, or otherwise connecting thebattery to the battery cables, the proper polarity must beobserved. Failure to observe the proper polarity couldresult in damage to the charging circuit. The positive (+)battery cable has a red terminal cover.

2. If the battery requires charging from an external charg-er, disconnect the negative battery cable first and then thepositive battery cable before attaching the charger leads.Failure to do so can result in damage to the internalcharger components. When reconnecting the cables,connect the positive cable first and the negative cablelast.

PREVENTING BATTERY DISCHARGE

If you have an ignition switch, turn it off when engine isnot running.

PREVENTING BATTERY BUCKLING

Tighten nuts on battery clamp until snug.

WARNING

D-4MAINTENANCED-4

COMMANDER 500

Table D.1 Engine Maintenance Components

ITEM

Air Cleaner Element

Cooling Blower Belt

Oil Filter Element

Fuel Filter Element

Water Separator Element

Fuel Pre-Filter Screen

Battery

MAKE

DonaldsonAC

LincolnGates

DeutzPurolator

NapaFram

DeutzPurolator

NapaFram

LincolnStanadyne

LincolnStanadyne

PART NUMBER

P181052A302C

T13536-37585

1174418PER2168

1820PH3776

1174423PC423358

P4102

M16890-C31572

M16890-B29575

BCIGroup

34

CHARGING THE BATTERY

When you charge, jump, replace, or otherwise connectbattery cables to the battery, be sure the polarity is cor-rect. Improper polarity can damage the charging cir-cuit. The Commander positive (+) battery terminal hasa red terminal cover.

If you need to charge the battery with an externalcharger, disconnect the negative cable first, then thepositive cable before you attach the charger leads.after the battery is charged, reconnect the positive bat-tery cable first and the negative cable last. Failure todo co can result in damage to the internal charger com-ponents.

Follow the instructions of the battery charger manufac-turer for proper charger settings and charging time.

NAMEPLATES / WARNING DECALS MAINTENANCEWhenever routine maintenance is performed on thismachine - or at least yearly - inspect all nameplatesand labels for legibility. Replace those which are nolonger clear. Refer to the parts list for the replacementitem number.

WELDER / GENERATOR MAINTENANCE

STORAGE

Store the Commander in clean, dry protected areas.

CLEANING

Blow out the generator and controls periodically withlow pressure air. do this at least once a week in par-ticularly dirty areas.

BRUSH REMOVAL AND REPLACEMENT

It is normal for the brushes and slip rings to wear anddarken slightly. Inspect the brushes when a generatoroverhaul is necessary.

Do not attempt to polish slip rings while the engine isrunning.------------------------------------------------------------------------

WARNING

E-1TROUBLESHOOTINGE-1

COMMANDER 500

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions. Simply follow the three-stepprocedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM(SYMPTOMS)”. This column describes pos-sible symptoms that the machine may exhib-it. Find the listing that best describes thesymptom that the machine is exhibiting.Symptoms are grouped into the followingcategories: engine problems, function prob-lems and output problems.

Step 2. PERFORM EXTERNAL TESTS.The second column labeled “POSSIBLEAREAS OF MISADJUSTMENT(S)” lists theobvious external possibilities that may con-tribute to the machine symptom. Performthese tests/checks in the order listed. Ingeneral, these tests can be conducted with-out removing the case wrap-around cover.

Step 3. RECOMMENDED COURSE OFACTION

If you have exhausted all of the items in step2. Contact your Local Lincoln AuthorizedField Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianand machine operator and will invalidate your factory warranty. For your safety and to avoidElectrical Shock, please observe all safety notes and precautions detailed throughout this manual.__________________________________________________________________________

WARNING


COMMANDER 500

Observe all Safety Guidelines detailed throughout this manual


CAUTION

ENGINE PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENTS(S)

RECOMMENDEDCOURSE OF ACTION

Major Physical or Electrical Damageis Evident.

Engine will not “crank”.

Engine will “crank” but not start.

Engine shuts down shortly afterstarting.

Battery does not stay charged.

1. Contact your Local LincolnAuthorized Field Service Facility.

1. Battery is low. Charge Battery.

2. Loose battery cable connections.Inspect, clean and tighten.

1. Out of fuel. Fill fuel tank.

2. Fuel shut off valve is in offposition.

3. High oil temperature (Indicatorlight lit. Check engine coolingsystem. (Consult engine servicedealer.

4. Low battery voltage.

1. Low fuel. (Indicator light lit K1585-2 only) Add fuel.

2. Low output of battery chargingalternator. (Indicator light lit)Check cooling blower belt.Replace if neccessary.

3. High oil temperature (Indicatorlight lit). Check engine coolingsystem. (Consult engine servicedealer.

1. Faulty battery. Replace

Contact your Local Lincoln AuthorizedField Service Facility for technicaltroubleshooting assistance.


COMMANDER 500



CAUTION

FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)



Engine will not idle down to lowspeed.

Engine will not go to high idle whenattempting to weld.

Engine will not go to high idle whenusing auxiliary power.

1. Idler switch in High idle position.Set switch to Auto.

2. External load on welder or auxil-iary power. Remove all externalloads.

1. Poor work lead connection towork. Make sure work clamp istightly connected to clean basemetal.

2. ”Welding Terminals” switch is inwrong position. Set to “WELDTERMINAL ON” when weldingwithout a welding terminal controlcable. Refer to Operations chap-ter for proper use of this switch.

1. Auxiliary power load is less than100 watts. Idler may not respondwith less than a 100 watt load.Set Idler to “High”



COMMANDER 500



CAUTION

OUTPUT PROBLEMS

PROBLEMS(SYMPTOMS)



No welding power output.

Welder has output and no control.

No auxiliary power.

1. Welding terminals switch in wrongposition. Place switch in “WELDTERMINAL ON” position whenwelding without welding terminalcontrol cable. Refer to Operationchapter for proper switch function.

1. Poor remote kit connection.Check connections.

2. Faulty remote kit. Replace if nec-cessary.

1. Open circuit breakers. Resetbreakers. If breakers keep trip-ping check connections to auxil-iary receptacles. Also make sureload does not exceed receptaclescurrent rating. Refer to AuxiliaryConnections in the Installationand Operation chapters.

2. Faulty connections to auxiliaryreceptacles. Check connections.

3. Faulty auxiliary circuit wiring.


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NOTES

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SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

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French

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Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• 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 •

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