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IM644-A
January, 2001
™
Commander 500
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.
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS For Diesel Engines: Diesel engine exhaust and For Gasoline Engines: The engine exhaust from some of its constituents are known to the State this product contains chemicals known to the of California to cause cancer, birth defects, and State of California to cause cancer, birth defects, other reproductive harm. or other reproductive harm. ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHIL
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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 PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ��� Thank You as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment
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vi vi TABLE OF CONTENTS Page Safety .........................................................................................................................i-iv Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions.............................................................................
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vii vii TABLE OF CONTENTS Accessories.....................................................................................................Section C Optional Field Installed Accessories .....................................................................C-1 Recommended Optional Equipment .....................................................................C-1 High Frequency Generators For TIG Applications ................................................C-1 Maintenance ...........................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Commander 500 (K1639-1 & -2) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder High Idle 1900 173 cu. in 12VDC battery Fuel: 25 gal. F3L 912 44 HP(33 kw) Low Idle 1400 (2.83 L) & Starter 94.6 L Diesel Engine @ 1800 RPM 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 500 Amps (DC multi
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A-2 A-2 INSTALLATION Read this entire installation section before you LOCATION / VENTILATION start installation. The welder should be located to provide an unrestricted SAFETY PRECAUTIONS flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to WARNING an outside area. Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man-
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A-3 A-3 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 the Lincoln’s K953-1. If the user adapts a non-Lincoln trail- lift bale must be secured in a raised position. Secure er, he must assume responsibility that the method of the lift bale as follows: att
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A-4 A-4 INSTALLATION ENGINE COOLING SYSTEM PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc- The Deutz engine is air cooled by a belt driven axial tions supplied with this machine. blower. The oil cooler and engine cooling fins should be blown out with compressed air or steam to maintain WARNING proper cooling (See the engine Owners Manual for pro- cedures and frequency). �Keep hands away from the engine muffler or HOT engine parts. BATTERY CONNECTION �Stop engi
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A-5 A-5 INSTALLATION MUFFLER OUTLET PIPE REMOTE CONTROL Remove the plastic plug covering the muffler outlet OUTPUT tube. Using the clamp provided secure the outlet pipe The Commander 500 is equipped with a 6 pin & 14-pin to the outlet tube with the pipe positioned such that it connector. The 6 pin connector is for connecting the will direct the exhaust in the desired direction. K857 or K857-1 Remote Control (Optional) or in the case of TIG welding applications, with the foot or hand SPARK ARR
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A-6 A-6 INSTALLATION joints, or to the metal framework of a building which WELDING OUTPUT CABLES has been effectively grounded. The U.S. National Electrical Code lists a number of alternate means of With the engine off, route the electrode and work grounding electrical equipment. A machine grounding cables thru the strain relief bracket provided on the stud marked with the symbol is provided on the front of the base and connect to the terminals provid- front of the welder. ed. These c
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A-7 A-7 INSTALLATION 2. Take necessary steps to assure load is limited to the 3. Install a 50 amp 120/240 VAC plug (NEMA Type 14- capacity of the Commander by installing a 50 amp, 50) to the double-pole circuit breaker using No. 6, 4 240 VAC double pole circuit breaker. Maximum conductor cable of the desired length. (The 50 amp, rated load for each leg of the 240 VAC auxiliary is 50 120/240 VAC plug is available in the optional K802R amperes. Loading above the rated output will plug kit.) red
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A-8 A-8 INSTALLATION CONNECTION OF LINCOLN CAUTION ELECTRIC WIRE FEEDERS If you are using an LN-25 without an internal contactor, the electrode will be energized when the Commander WARNING 500 is started. ------------------------------------------------------------------------ Shut off welder before making any electrical connec- h. When the gun trigger is closed, the current sensing tions. circuit will cause the Commander 500 engine to go ------------------------------------------------------
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A-9 A-9 INSTALLATION CONNECTION OF AN LN-23P WIRE CONNECTION OF AN NA-3 AUTOMATIC FEEDER TO THE COMMANDER 500 WELDING SYSTEM TO THE COMMANDER 500 a. Shut the welder off. For connection diagrams and instructions for connect- b. Connect the LN-23P per instructions on the appro- ing an NA-3 Welding System to the Commander 500, priate connection diagram in the DIAGRAMS sec- refer to the NA-3 Welding System instruction manual. tion. (NOTE): When connecting an LN-23P to the The connection diagram f
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B-1 B-1 OPERATION OPERATING INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section before operat- The Commander 500 is a diesel engine-driven welding ing your Commander 500. power source. The machine uses a brush type alter- nating current generator for DC multi-purpose welding and for 120/240 VAC auxiliary standby power. The SAFETY INSTRUCTIONS welding control system uses state of the art Chopper Technology. The Commander 500 is not recom- mended for pipe thawing. WARNING The
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B-2 B-2 OPERATION � 100% duty cycle at 500 amps output and 50% duty � Indicator lights for low oil pressure, high oil tempera- cycle at 575 amps output. ture, engine alternator low output/broken belt and low fuel level (on K1639-2 only). � Dual 3-digit output meters are provided (optional on K1639-1) for presetting the weld amperage or voltage � Automatic low fuel shutdown before running out of and displaying the actual amperage and voltage during fuel (K1639-2 only). welding. The meters use s
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B-3 B-3 OPERATION CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow. Figure B.1 Case Front Panel Controls 10 9 9 1 4 5 6 7 8 3 2 OIL OIL 0 0 0 0 00 HOURS FUEL TEMP PRESS AMPS 24 13 18 15 16 25 21 22 11 12 19 17 23 14 3. FUEL LEVEL GAUGE AND LIGHT ENGINE CONTROLS (Items 1 through 8) (K1639-2 only) - Displays the level of diesel fuel in the 25-gallon fuel tank. The 1. RUN- STOP SWITCH yellow ligh
