Lincoln Electric IM644-A manual Commander, Safety Depends on You

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IM644-A

Commander™ 500	January, 2001

For use with machines having Code Numbers: 10599 (Standard),

10600 (Deluxe)

10704 (Standard),

10705 (Deluxe)

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.

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OPERATOR’S MANUAL

ISO 9001

ANSI RAB

QMS

Designed and Manufactured Under a

Quality Program Certified by

ABS Quality Evaluations, Inc.

to ISO 9001 Requirements.

CERTIFICATE NUMBER: 30273

Copyright © 2001 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• 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

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Contents Safety Depends on You CommanderCalifornia Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéThank You Table of Contents Section D Section CSection E Section FWelding Range Open Circuit Voltage Auxiliary Power1 InstallationHEIGHT2 Width Depth Weight Bore x StrokeLocation / Ventilation Safety PrecautionsStoring StackingLifting High Temperature OperationHigh Altitude Operation TowingEngine Cooling System Battery Connection PRE-OPERATION Engine ServiceOIL Fuel USE Diesel Fuel onlyHigh Frequency Generators for TIG Applications Remote ControlWelding Terminals Standby Power Connections Auxiliary Power ReceptaclesWelding Output Cables Machine GroundingPower Connection of the LN-25 to the Commander Connection of Lincoln Electric Wire FeedersConnection of LN-7 or LN-8 to the Commander Connection of AN LN-23P Wire Feeder to the Commander Design Features and Advantages Safety InstructionsOperation Operating InstructionsOther Features For Auxiliary PowerK1639-1 Commander 500 Standard Model Welding CapabilityRUN- Stop Switch Controls and SettingsStart Pushbutton Fuel Level Gauge and LightOIL Pressure Gauge K1639-2 Std., K1639-1 Opt. and Light Idler SwitchIdler Operational exceptions Hour MeterAuxiliary Power Controls Starting the Engine Engine OperationStopping the Engine BREAK-IN Period Welder OperationTypical Fuel Consumption Stick WeldingCommander 500 Settings When Using the K930-1 TIG Module Commander 500 Settings When Using the K799 HI-FREQ UnitTable B.3 Typical Current Ranges 1 for Tungsten ELECTRODES2 Wire Feed Constant Voltage WELD- ING Auxiliary Power OperationSimultaneous Welding and AUXIL- Iary Power Loads Table B.4 Commander 500 Simultaneous Welding and Power Loads Optional Field Installed Accessories AccessoriesRecommended Optional Equipment Routine and Periodic Maintenance MaintenanceEngine Maintenance Fuel PRE-FILTER/WATER Separator ASSEM- BLY Fuel FiltersWater Separator Element Cooling System Cooling Blower Belt Battery HandlingWelder / Generator Maintenance Nameplates / Warning Decals MaintenanceCleaning Brush Removal and ReplacementHOW to USE Troubleshooting Guide TroubleshootingPossible Areas SymptomsCourse of Action Function Problems Output Problems Commander 500 Wiring Diagram DiagramsConnection Diagram To Work Electrode Cable To Wire Feed Unit Commander / K867 / K775 / LN-7 Connection DiagramRemote Control Connection DiagramTo Wire Feed Unit Electrode CableCommander to K867 Adapter Connection Diagram Connection DiagramCommander / K867 / LN-8 Connection Diagram Remove the Three Screws Shown and USE PIN Amphenol To LN-8 Input Cable Plug K595 Control Cable Commander / LN-8 Connection DiagramTo Work To Work PIN Commander / K930 TIG Module / Connection Diagram To LN-742 Input Cable Plug K592 Control Cable Commander / LN-742 Connection Diagram24.97 Dimension Print$700.00 Basic CoursePrecaucion Aviso DE