Main
Commander 500
OPERATORS MANUAL
IM644-A
FOR ENGINE powered equipment.
i
CALIFORNIA PROPOSITION 65 WARNINGS
i
ELECTRIC AND MAGNETIC FIELDS may be dangerous
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
FUMES AND GASES can be dangerous.
FOR ELECTRICALLY powered equipment.
CYLINDER may explode if damaged.
iii
WELDING SPARKS can cause fire or explosion.
iv
PRCAUTIONS DE SRET
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR
Thank You
vv
Please Examine Carton and Equipment For Damage Immediately
TABLE OF CONTENTS
vivi
TABLE OF CONTENTS
viivii
A-1
OUTPUT - WELDER AND GENERATOR
TECHNICAL SPECIFICATIONS - Commander 500 (K1639-1 & -2)
INPUT - DIESEL ENGINE
RATED OUTPUT - WELDER
PHYSICAL DIMENSIONS
A-2
SAFETY PRECAUTIONS
LOCATION / VENTILATION
STORING
STACKING
ANGLE OF OPERATION
A-3
A-3 LIFTING
HIGH ALTITUDE OPERATION
HIGH TEMPERATURE OPERATION
TOWING
PRE-OPERATION ENGINE SERVICE
OIL
FUEL USE DIESEL FUEL ONLY
FUEL CAP
ENGINE COOLING SYSTEM
HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS
REMOTE CONTROL
OUTPUT
WELDING TERMINALS
A-6
A-6 WELDING OUTPUT CABLES
MACHINE GROUNDING
AUXILIARY POWER RECEPTACLES
STANDBY POWER CONNECTIONS
A-7
Figure A.2 Connection of the Commander 500 to Premises Wiring
A-8
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS
CONNECTION OF THE LN-25 TO THE COMMANDER 500
CONNECTION OF LN-7 OR LN-8 TO THE COMMANDER 500
A-9
A-9 CONNECTION OF AN LN-23P WIRE FEEDER TO THE COMMANDER 500
CONNECTION OF AN NA-3 AUTOMATIC WELDING SYSTEM TO THE COMMANDER 500
CONNECTION OF AN LN-742 TO THE COMMANDER 500
B-1
OPERATING INSTRUCTIONS
SAFETY INSTRUCTIONS
ADDITIONAL SAFETY PRECAUTIONS
GENERAL DESCRIPTION
RECOMMENDED APPLICATIONS
WELDING CAPABILITY
B-3
ENGINE CONTROLS (Items 1 through 8)
CONTROLS AND SETTINGS
B-4
WELDER CONTROLS (Items 9 through 14 )
B-5
AUXILIARY POWER CONTROLS (Items 15 - 19 )
B-6
ENGINE OPERATION
STARTING THE ENGINE
STOPPING THE ENGINE
B-7
B-7 BREAK-IN PERIOD
WELDER OPERATION
STICK WELDING
TIG WELDING
B-8
Commander 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT
Commander 500 SETTINGS WHEN USING THE K930-1 TIG MODULE
Table B.3 TYPICAL CURRENT RANGES (1)FOR TUNGSTEN ELECTRODES(2)
B-9
AUXILIARY POWER OPERATION
SIMULTANEOUS WELDING AND AUXIL- IARY POWER LOADS
B-10
C-1
ACCESSORIES
C-1
OPTIONAL FIELD INSTALLED ACCESSORIES
RECOMMENDED OPTIONAL EQUIPMENT
STICK
SAFETY PRECAUTIONS
ROUTINE AND PERIODIC
DAILY
WEEKLY
ENGINE MAINTENANCE
D-2
FUEL FILTERS
D-3
SECONDARY FUEL FILTER
COOLING SYSTEM
COOLING BLOWER BELT
BATTERY HANDLING
NAMEPLATES / WARNING DECALS
WELDER / GENERATOR
STORAGE
CLEANING
BRUSH REMOVAL AND REPLACEMENT
HOW TO USE TROUBLESHOOTING GUIDE
E-2
ENGINE PROBLEMS
E-3
FUNCTION PROBLEMS
E-4
OUTPUT PROBLEMS
F-1
ENHANCED DIAGRAM
232
TRANSFORMER
CONTROL
WARNING
INPUT CABLE K488 SG
or service this equipment.
CONTROL MODULE
Keep away from moving parts.
}
before servicing. Do not touch electrically live parts.
}
F-4
TO WIRE FEED UNIT
WARNING
F-5
TO WIRE FEED UNIT
COMMANDER TO K867 ADAPTER CONNECTION DIAGRAM
}
{
TO WORK ELECTRODE CABLE
WARNING
F-6
}
}
WARNING
Disconnect NEGATIVE (-) BATTERY LEAD Do not touch electrically live parts.
F-7
WARNING
F-8
COMMANDER / LN-25 ACROSS THE ARC CONNECTION DIAGRAM
WITH OPTIONAL K857 REMOTE CONTROL
AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE
F-9
TO LN-8 INPUT
TO WIRE FEED UNIT
ELECTRODE CABLE
TO WORK
}
Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing.
Do not touch electrically live parts.
F-11
AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE
N.C. IF REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL REMOTE SWITCH IN "REMOTE" POSITION.
N.D. THE OUTPUT CONTROL SWITCH MUST BE IN THE "WELDING TERMINALS ALWAYS ON" POSITION .
WARNING
F-12
COMMANDER / K930 TIG MODULE / CONNECTION DIAGRAM
F-13
TO WIRE FEED UNIT
ELECTRODE CABLE
K592 CONTROL CABLE
COMMANDER / LN-742 CONNECTION DIAGRAM
F-14
COMMANDER 500
DIMENSION PRINT
M18962 A
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AVISO DE PRECAUCION ATTENTION WARNUNG ATENO
AVISO DE PRECAUCION ATTENTION WARNUNG ATENO