CommanderTM
California Proposition 65 Warnings
Safety
Electric Shock can kill
Iii
Welding Sparks can cause fire or explosion
Sûreté Pour Soudage a L’Arc
Précautions DE Sûreté
Master Table of Contents for ALL Sections
Table of Contents Installation Section
Technical Specifications Commander 500 K1639-1
Installation
Stacking
Safety Precautions
Location / Ventilation
Storing
High Altitude Operation
High Temperature Operation
Lifting
Towing
PRE-OPERATION Engine Service
Spark Arrester
Muffler Outlet Pipe
Machine Grounding
Auxiliary Power Receptacles
Standby Power Connections
Welding Output Cables
Company
Table of Contents Operation Section
General Description
Safety Instructions
Operation
Operating Instructions
Recommended Applications
Design Features and Advantages
K1639-1 Commander 500 Standard Model
Controls and Settings
Welding Capability
Fuel Level Gauge and Light
RUN/STOP Switch
Idler Switch
Start Pushbutton
Hour Meter
Weld Mode Output Control
Welding Terminals Switch
Table B.1 Weld Mode and Output Control Functions
Auxiliary Power Controls
Typical Fuel Consumption
Engine Operation
Starting the Engine
BREAK-IN Period
TIG Welding
Welder Operation
Stick Welding
Constant Current CC Welding
TIG Torch
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 RANGES1 for Tungsten ELECTRODES2
ARC Gouging
Auxiliary Power Operation
Wire Feed Constant Voltage Welding
Simultaneous Welding and Auxiliary Power Loads
Permissible Permissible Auxiliary
Extension Cord Recommendations
Table of Contents Accessories Section
Stick Welding Accessories
Accessories
OPTIONS/ACCESSORIES
Field Installed Options
High Frequency Generators for TIG Applications
Semiautomatic Welding Accessories
Connection of Lincoln Electric Wire Feeders
Other Wire Feeders for the Commander
To Work Electrode Cable To Wire Feed Unit
ING CV
ING CV
ING CV
Figure C.5 Commander 500/LN-23P Connection Diagram
ING Terminals Always on
Table of Contents Maintenance Section
Daily
Maintenance
Routine and Periodic Maintenance
Engine Maintenance
Figure D.1 OIL Drain and Refill
Fuel Filters
Figure D.2 Fuel PRE-FILTER/WATER Separator Assembly
Figure D.3 Secondary Fuel Filter
AIR Filter
Maintenance
Table D.2 Engine Maintenance Parts Manufacturer Part Number
Frequency Maintenance Required
Connecting a Battery Charger
Battery Maintenance
WELDER/GENERATOR Maintenance
Figure D.5 Major Component Locations
Table of Contents Theory of Operation Section
Commander
Theory of Operation
Commander
Weld WINDINGS, RECTIFIER, Power Modules and Feedback
Analog Control Power Supply Board and Weld Control Board
Insulated Gate Bipolar Transistor Igbt Operation
Maximum Output
Pulse Width Modulation
6E-6
Minimum Output
Chopper Technology Fundamentals
External DC Solid State Inductor ARC Source Switch Diode
70-80VDC
Troubleshooting & Repair Section
Table of Contents
Section F-1
HOW to USE Troubleshooting Guide
Troubleshooting & Repair
PC Board can be damaged by static electricity
PC Board Troubleshooting Procedures
Observe Safety Guidelines
Troubleshooting Guide
Detailed in the beginning of this manual
Perform the Rotor Resistance
Justment Test
Function Problems
Charging Circuit Test
Engine Problems
Shutdown
Perform the Idler Solenoid
Symptoms Misadjustments Course of Action
Problems Possible Areas
Engine Starting Diagnostic Chart
Return
START-UP and OCV Diagnostic Chart
Description
Case Cover Removal and Replacement Procedure
Materials Needed
Procedure
Case Cover Removal Replacement Procedure
Figure F.1
Removal
Case Front Knobs Removal and Replacement Procedure
Power Module Capacitor Discharge Procedure
Procedure
Test Description
Idler Solenoid Test
Figure F.5 Idler Solenoid Leads
Test Procedure
Shutdown Solenoid Test
Figure F.6 Shutdown Solenoid Lead Terminals
Engine Throttle Adjustment Test
Strobe-tach Method
Figure F.7 Strobe Mark Location Mark Blower Paddle Here
Locking NUT
Frequency Counter Method
28F-28
Oscilloscope Method
Rotor Resistance Test
Test Procedure
Flashing and Rotor Voltage Test
Lead # 201A
10 11 12 13 14 15
Troubleshooting & Repair
Stator Voltage Test
Figure F.13 Front Control Panel Removal Screws
Troubleshooting & Repair
Auxiliary Leads #5B, #5E, #8, #9, #11, #12
Auxiliary Power and Weld Windings Test
Behind Panel
Weld Winding Lead Connections
W6W1
Analog Power Supply PC Board Voltage Test
40F-40
Control Circuit Input Power
J41
Test Points Component Tested Voltage Reading
Analog Control Power Supply PC Board Test
Output Rectifier Bridge Test
Perform the Power Module Capacitor Discharge Procedure
Troubleshooting & Repair
Figure F.20 Diode Lead Removal
Power Module Test
Power Module PC Board Diode Lead D4 Positive + Strap
Temperature Switch
W10
Check Igbt For Shorts
Check Diode Module
When all tests are complete
Charging Circuit Test
#239 #281 #238
Figure F.24 Engine Alternator Location
15.8 ms Volts 50V5ms
Scope Settings
Normal Open Circuit Voltage Waveform 115VAC Supply
High Idle no Load
MAX TAP MAX Control POT High Idle no Load
Normal Open Circuit Voltage Waveform Stick
Volts 50V5ms
Machine Loaded to 500 Amps AT 40 Volts
Normal Weld Voltage Waveform Stick CC
Volts 20V0.1ms
Normal Weld Voltage Waveform Wire CV
Loaded to 200A 16 Volts
Normal TIG Mode Voltage Waveform
Volts 10V50ms
MAX Control POT High Idle no Load
Normal Open Circuit Voltage Waveform Wire CV TAP
Shutdown Solenoid Removal and Replacement
Figure F Shutdown Solenoid Lead Connections
Figure F Shutdown Solenoid Linkage ARM Assembly
Reassembly
Description
Control Panel Removal Screws Front Green Ground Lead
Figure F Power Module Capacitor Lead Removal
Troubleshooting & Repair
Replacement Procedure
Description
Figure F.30 Power Module PC Board
Power Module PC Board Removal
Power Module PC Board Replacement
Diode Module Removal
Diode Module Replacement
Output Rectifier Bridge Diode Removal and Replacement
Refer to Figure F.32 Turn the engine off
Diode Stud Size Foot Pounds Inch Pounds
Return Section TOC
STATOR/ROTOR Removal and Replacement
Leads #229 #242D
Preparation and Lead Removal Procedure
Plug Fuel Lines Bolts
Filter Field Diode Capacitor
#200D #5P #201 #201A
#232M
Figure F.35 Brush Holder and Lead Removal
Figure F.37 Alternator Shroud Removal Screws Acoustical Foam
Figure F.38 Lift Frame and Associated Component Removal
Figure F.39 Stator Removal
Stator Removal Procedure
Reassembly Notes
Rotor Removal Procedure
Engine
Lead Reconnection Checklist
Output Panel and Control BOX
Welder DC Stick Output
Welder CV Wire Output
Retest After Repair
Engine RPM
Auxiliary Power Output
Touch Start TIG Mode Output
Table of Contents Electrical Diagrams Section
Electrical Diagrams
Electrical Diagrams
G3834
Schematic Complete Machine Commander
Schematic Battery PC Board
Return to Section
PC Board Assembly Battery PC Board
PWM Input
Schematic Chopper PC Board
Return to Section Return to Section TOC
PC Board Assembly Chopper PC Board
Schematic Peripheral PC Board
Return to Section
PC Board Assembly Peripheral PC Board
Schematic Power Supply Analog PC Board
PC Board Reference QTY Designators Description
PC Board Assembly Power Supply Analog PC Board
Schematic PULL-COIL PC Board
MOSFET/HEATSINK ASBLY,T12704-82&S1810
PC Board Assembly PULL-COIL PC Board
Schematic Weld Control PC Board Sheet
Electrical Diagrams
Electrical Diagrams
Electrical Diagrams
Electrical Diagrams
RESISTOR,SMD,METAL FILM,1/10W,150OHMS
PC Board Assembly Weld Control PC Board
SVM Error Reporting Form
