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RETURN TO MAIN INDEX
SVM153-A
September, 2002
TM
Commander 500
For use with machines having Code Numbers: 10837 (Standard),
10838 (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 in-
creased 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,
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 3.b. In
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les Pour votre propre protection lire et observer toutes les instructions zones où l’on pique le laitier. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 6. Eloigner les matériaux inflammables ou les recouvrir afin de antes: prévenir tout risque d’incendie dû aux éti
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v v - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN INDEX Page Safety.................................................................................................................................................i-iv Installation.............................................................................................................................Section A Operation................................................................................................................
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Section A-1 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Installation.............................................................................................................................Section A Technical Specifications..............................................................................................................A-2 Safety Precautions......................................................................................................................A-3 Location
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - COMMANDER 500 (K1639-1 & -2) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder 44 HP(33 kw) High Idle 1900 173 cu. in 12VDC battery Fuel: 25 gal. F3L 912 @ 1800 RPM Low Idle 1475 (2.83 L) & Starter 94.6 L Diesel Engine Full Load 1800 Bore x Stroke Oil: 9.5 Qts. 9.0 L 3.94” x 4.72” (100mm x 120mm) RATED OUTPUT - WELDER Duty Cycle Welding Output Volts at Rated Amps 100% 500 Amps (DC mult
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A-3 A-3 INSTALLATION Read this entire installation section before you LOCATION / VENTILATION start installation. The welder should be located to provide an unrestrict- ed flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the SAFETY PRECAUTIONS welder so that the engine exhaust fumes are properly vented to an outside area. WARNING Do not attempt to use this equipment until you have STORING thoroughly read all operating and maintenanc
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A-4 A-4 INSTALLATION LIFTING TOWING The Commander lift bale should be used to lift the The recommended trailer for use with this equipment 1 machine. The Commander is shipped with the lift bale for road, in-plant and yard towing by a vehicle is retracted. Before attempting to lift the Commander, Lincoln’s K953-1. If the user adapts a non-Lincoln trail- secure the lift bale in a raised position. Secure the lift er, he must assume responsibility that the method of bale as follows: attachment an
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A-5 A-5 INSTALLATION PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc- NOTE: Before starting the engine, open the fuel shut- tions supplied with this machine. off valve (pointer to be in line with hose). WARNING FUEL CAP Remove the plastic cap covering from the fuel tank filler • Keep hands away from the engine muf- neck and install the fuel cap. fler or HOT engine parts. • Stop engine and allow to cool before ENGINE COOLING SYSTEM fueling. The Deutz engine is air c
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A-6 A-6 INSTALLATION IMPORTANT: To prevent ELECTRICAL DAMAGE HIGH FREQUENCY GENERATORS WHEN: FOR TIG APPLICATIONS a) Installing new batteries The K799 Hi-Freq Unit and the K930-1 or-2 TIG b) Using a booster Module are suitable for use with the Commander 500. The Commander 500 is equipped with the required Use correct polarity — Negative Ground. R.F. bypass circuitry for the connection of high fre- The Commander is shipped with the negative battery quency generating equipment. The high frequenc
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A-7 A-7 INSTALLATION WELDING OUTPUT CABLES With the engine off, route the electrode and work In general, if the machine is to be grounded, it should cables through the strain relief bracket provided on the be connected with a #8 or larger copper wire to a solid front of the base and connect to the terminals provided. earth ground such as a metal water pipe going into the These connections should be checked periodically and ground for at least ten feet and having no insulated tightened if necessa
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A-8 A-8 INSTALLATION 1. Install the double-pole, double-throw switch able -10% of rated voltage, which may damage between the power company meter and the appliances or other motor-driven equipment and premises disconnect. may result in overheating of the Commander 500 engine. Switch rating must be the same or greater than the cus- tomer’s premises disconnect and service over current 3. Install a 50 amp 120/240 VAC plug (NEMA Type protection. 14-50) to the double-pole circuit breaker using No. 6,
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Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Operation...............................................................................................................................Section B Operating Instructions.................................................................................................................B-2 Safety Instructions.......................................................................................................................B-2 General D
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B-2 B-2 OPERATION ENGINE EXHAUST can kill. OPERATING INSTRUCTIONS • Use in open, well ventilated areas or Read and understand this entire section before operat- vent exhaust outside ing your Commander 500. • Do not stack anything near the engine. SAFETY INSTRUCTIONS MOVING PARTS can injure. WARNING • Do not operate with doors open or guards off. Do not attempt to use this equipment until you have • Stop engine before servicing. thoroughly read all operating and maintenance man- uals supplied w
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B-3 B-3 OPERATION FOR AUXILIARY POWER RECOMMENDED APPLICATIONS • 12,000 watts of 120/240 VAC, 60Hz auxiliary power. WELDER • Power for tools, 120/240 VAC lights, electric pumps The Commander 500 provides excellent constant cur- and for standby emergency power. rent DC welding output for stick (SMAW) and TIG weld- • Drive a 5 HP motor (provided it is started under no ing. The Commander 500 also provides excellent con- load). stant voltage DC welding output for MIG (GMAW) and Innershield (FCAW
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B-4 B-4 OPERATION K1639-1 COMMANDER 500 STANDARD MODEL WELDING CAPABILITY • The K1639-1 is the standard version of the The Commander 500 is rated at 500 amps, 40 VDC at Commander 500 and has all the features of the 100% duty cycle and 575 amps, 36 VDC at 50% duty K1639-2 Deluxe version except that there are no cycle. The maximum open circuit voltage at 1900 RPM gauges, low fuel light, nor dual output meters. This is 80 volts. The weld current is variable from 30 to 575 version does have fully
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B-5 B-5 OPERATION 5. OIL PRESSURE GAUGE (K1639-2 Std., ENGINE CONTROLS (Items 1 through 8) K1639-1 Opt.) AND LIGHT 1. RUN/STOP SWITCH The gauge displays the engine oil pressure when the engine is running. The yellow oil pressure light remains When placed in the RUN position, this switch energizes off with proper oil pressure. If the light turns on, the the fuel solenoid and other electric accessories. When engine protection system will stop the engine. Check placed in the STOP position
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B-6 B-6 OPERATION Idler Operational Exceptions With the switch in the WELD TERMINALS ON position, the contactor is closed and the welding terminals are When the WELDING TERMINALS switch is in the always “Hot.” “Welding Terminals Remotely Controlled” position, the idler will operate as follows: With the switch in the REMOTELY CONTROLLED position, the contactor operation is controlled by an a. When the triggering device (Amptrol, Arc Start Amptrol, Arc Start Switch or some other type of trig- Swit
