SVM153-ASeptember, 2002Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, your overall
LIFTINGThe Commander lift bale should be used to lift themachine. The Commander is shipped with the lift baleretracted. Before attempting to lift the
TROUBLESHOOTING & REPAIRF-47 F-47COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-48 F-48COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-49 F-49COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-50 F-50COMMANDER 500CHARGING CIRCUIT TESTWARNINGService and repair should be performed by only Lincoln Electric factory
TROUBLESHOOTING & REPAIRF-51 F-51COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
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A-5 A-5INSTALLATIONCOMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to
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TROUBLESHOOTING & REPAIRF-58 F-58COMMANDER 500SHUTDOWN SOLENOID REMOVAL AND REPLACEMENTWARNINGService and repair should be performed by only Linco
TROUBLESHOOTING & REPAIRF-59 F-59COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-60 F-60COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-61 F-61COMMANDER 500POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLYREMOVAL AND REPLACEMENTWARNINGService and repair should
TROUBLESHOOTING & REPAIRF-62 F-62COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-63 F-63COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-64 F-64COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-65 F-65COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-66 F-66COMMANDER 500POWER MODULE (CHOPPER) PC BOARD/DIODEMODULE REMOVAL AND REPLACEMENTWARNINGService and repair should
IMPORTANT: To prevent ELECTRICAL DAMAGEWHEN:a) Installing new batteriesb) Using a boosterUse correct polarity — Negative Ground.The Commander is ship
TROUBLESHOOTING & REPAIRF-67 F-67COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-68 F-68COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-69 F-69COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-70 F-70COMMANDER 500OUTPUT RECTIFIER BRIDGE DIODE REMOVAL AND REPLACEMENTWARNINGService and repair should be performed b
TROUBLESHOOTING & REPAIRF-71 F-71COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-72 F-72COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-73 F-73COMMANDER 500STATOR/ROTOR REMOVAL AND REPLACEMENTWARNINGService and repair should be performed by only Lincoln El
TROUBLESHOOTING & REPAIRF-74 F-74COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-75 F-75COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-76 F-76COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
WELDING OUTPUT CABLESWith the engine off, route the electrode and workcables through the strain relief bracket provided on thefront of the base and co
TROUBLESHOOTING & REPAIRF-77 F-77COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-78 F-78COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-79 F-79COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-80 F-80COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-81 F-81COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-82 F-82COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-83 F-83COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
G-1ELECTRICAL DIAGRAMSG-1TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION-Electrical Diagrams ...
ELECTRICAL DIAGRAMSG-2COMMANDER 500WIRING DIAGRAM - COMMANDER 500GND-H6D3GND-F5AAUXILIARY POWERGND-D121110EMPTYCB610AEMPTYEMPTY42A4231GND-E42A5JOUTPUT
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1. Install the double-pole, double-throw switchbetween the power company meter and thepremises disconnect.Switch rating must be the same or greater th
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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa
ELECTRICAL DIAGRAMSG-10COMMANDER 500SCHEMATIC - POWER SUPPLY (ANALOG) PC BOARDG-10NOTE: This diagram is for reference only. It may not be accurate for
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa
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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa
Operation...Section BOpera
ELECTRICAL DIAGRAMSG-14COMMANDER 500SCHEMATIC - WELD CONTROL PC BOARD - SHEET 1G-14NOTE: This diagram is for reference only. It may not be accurate fo
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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa
SVM ERROR REPORTING FORMWe need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that wo
B-2 B-2OPERATIONCOMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas
RECOMMENDED APPLICATIONSWELDERThe Commander 500 provides excellent constant cur-rent DC welding output for stick (SMAW) and TIG weld-ing. The Commande
K1639-1 COMMANDER 500 STANDARD MODEL• The K1639-1 is the standard version of theCommander 500 and has all the features of theK1639-2 Deluxe version e
ENGINE CONTROLS (Items 1 through 8)1. RUN/STOP SWITCHWhen placed in the RUN position, this switch energizesthe fuel solenoid and other electr
CALIFORNIA PROPOSITION 65 WARNINGSi iSAFETYFOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the
Idler Operational ExceptionsWhen the WELDING TERMINALS switch is in the“Welding Terminals Remotely Controlled” position, theidler will operate as foll
12. 6 - PIN CONNECTOR (AMPHENOL)The 6-pin amphenol located on the control panelallows for connection of interfacing equipment.13. WELD OUTPUT TERMIN
ENGINE OPERATIONSTARTING THE ENGINE1. Open the engine compartment door and check thatthe fuel shutoff valve located to the left of the fuel fil-ter h
Table B.2 – DEUTZ F3L 912ENGINE FUEL CONSUMPTIONDeutz F3L 912 Running Time44.2 Hp for 25 gallons@ 1800 RPM (Hours)Low Idle - No .47 gallons/hour 53.2L
COMMANDER 500 SETTINGS WHEN USING THEK799 HI-FREQ UNIT• Set the WELD MODE switch to the 20-250 setting(TIG).• Set the IDLER switch to the HIGH posit
WIRE FEED (CONSTANT VOLTAGE)WELDINGConnect a wire feeder to the Commander 500 and setwelder controls according to the instructions listed ear-lier in
B-12 B-12OPERATIONCOMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M
Accessories ...Section COptions
OPTIONS/ACCESSORIESThe following options/accessories are available foryour Commander 500 from your local LincolnDistributor.FIELD INSTALLED OPTIONSK80
SEMIAUTOMATIC WELDING ACCESSORIESLN-7 OR LN-8 WIRE FEEDERS - Semiautomatic, con-stant speed wire feeders. For CV operation only.LN-23P WIRE FEEDER -
ii iiSAFETYReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCARC RAYS can burn.4.a. Use a shield with the proper filt
CONNECTION OF THE LN-7 TO THE COMMANDER 500 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1.)1. Shut the welder off. 2. Connect the electrode cable from
C-5 C-5ACCESSORIESCOMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M
C-6 C-6ACCESSORIESCOMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M
C-7 C-7ACCESSORIESCOMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M
C-8 C-8ACCESSORIESCOMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M
C-9 C-9ACCESSORIESCOMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M
Maintenance...Section DSafety P
SAFETY PRECAUTIONS• Have qualified personnel do all maintenance andtroubleshooting work.• Turn the engine off before working inside themachine.• Re
CHANGE THE OIL FILTER: Change the oil filter thefirst time between 25 and 50 hours of operation. Then,under normal operating conditions, change the
FUEL FILTERS: When working on the fuel system:• Keep naked lights away, do not smoke !• Do not spill fuel ! The Commander 500 is equipped with a
iii iiiSAFETYReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFOR ELECTRICALLYpowered equipment.8.a. Turn off input
4. Slide the new element onto the grommet post onthe bottom of the filter header until the element nolonger easily moves up into the filter header.
BLEEDING THE FUEL SYSTEM: In the event theengine is operated until it runs out of fuel, you will needto bleed the fuel system in order to start the en
COOLING SYSTEM: The cooling system of the Deutzengine needs to be checked and cleaned periodically.Consult the engine Operation Manual for the properf
D-8 D-8MAINTENANCECOMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M
BATTERY MAINTENANCEGASES FROM BATTERY can explode.• Keep sparks, flame, and cigarettesaway from battery.BATTERY ACID can burn eyes and skin.• Wear g
WELDER/GENERATOR MAINTENANCESTORAGE: Store the Commander 500 in clean, dry,protected areas.CLEANING: Blow out the generator and controls peri-odically
D-11 D-11MAINTENANCECOMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to
General Description ...E-2Battery
GENERAL DESCRIPTIONThe Commander 500 is a diesel engine-driven weldingpower source capable of producing 500 amps at40VDC at a 100% duty cycle. The en
WELD WINDINGS, RECTIFIER,POWER MODULES ANDFEEDBACKThe three-phase stator weld windings are connected toa three-phase rectifier bridge. The resultant
iv ivSAFETYReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire e
ANALOG CONTROL POWER SUPPLY BOARD AND WELD CONTROL BOARDThe Analog Power Supply PC board, which is poweredby 80 VDC derived from the filter capacitors
INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATIONAn IGBT is a type of transistor. IGBTs are semicon-ductors well suited for high frequency switching
PULSE WIDTH MODULATIONThe term PULSE WIDTH MODULATION is used todescribe how much time is devoted to conduction in thecycle. Changing the pulse width
CHOPPER TECHNOLOGYFUNDAMENTALS The new era of welding machines such as theCommander 500, employ a technology whereby a DCsource is turned on and off
Troubleshooting & Repair Section...Section FHow to Use Troubles
This Troubleshooting Guide is provided to helpyou locate and repair possible machine malfunc-tions. Simply follow the three-step procedurelisted belo
ELECTRIC SHOCK can kill.Have an electrician install and servicethis equipment. Turn the machine OFFbefore working on equipment. Do nottouch electric
Observe Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced
TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced
Observe Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced
v v- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -COMMANDER 500PageSafety...
TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced
Observe Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced
TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced
Observe Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced
TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced
Observe Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced
TROUBLESHOOTING & REPAIRF-13COMMANDER 500ENGINE STARTING DIAGNOSTIC CHARTF-13Return to Section TOC Return to Section TOC Return to Section TOC Ret
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TROUBLESHOOTING & REPAIRF-15 F-15COMMANDER 500CASE COVER REMOVAL AND REPLACEMENT PROCEDUREWARNINGService and repair should be performed by only Li
TROUBLESHOOTING & REPAIRF-16 F-16COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
Installation...Section ATech
TROUBLESHOOTING & REPAIRF-17 F-17COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-18 F-18COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-19 F-19COMMANDER 500POWER MODULE CAPACITOR DISCHARGE PROCEDUREWARNINGService and repair should be performed by only Linc
TROUBLESHOOTING & REPAIRF-20 F-20COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-21 F-21COMMANDER 500IDLER SOLENOID TESTWARNINGService and repair should be performed by only Lincoln Electric factory tr
TROUBLESHOOTING & REPAIRF-22 F-22COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-23 F-23COMMANDER 500SHUTDOWN SOLENOID TESTWARNINGService and repair should be performed by only Lincoln Electric factory
TROUBLESHOOTING & REPAIRF-24 F-24COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-25 F-25COMMANDER 500ENGINE THROTTLE ADJUSTMENT TESTWARNINGService and repair should be performed by only Lincoln Electri
TROUBLESHOOTING & REPAIRF-26 F-26COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
A-2 A-2INSTALLATIONCOMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to
TROUBLESHOOTING & REPAIRF-27 F-27COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-28 F-28COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-29 F-29COMMANDER 500ROTOR RESISTANCE TESTWARNINGService and repair should be performed by only Lincoln Electric factory
TROUBLESHOOTING & REPAIRF-30 F-30COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-31 F-31COMMANDER 500FLASHING AND ROTOR VOLTAGE TESTWARNINGService and repair should be performed by only Lincoln Electri
TROUBLESHOOTING & REPAIRF-32 F-32COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-33 F-33COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-34 F-34COMMANDER 500STATOR VOLTAGE TESTWARNINGService and repair should be performed by only Lincoln Electric factory tr
TROUBLESHOOTING & REPAIRF-35 F-35COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-36 F-36COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
Read this entire installation section before youstart installation.SAFETY PRECAUTIONSDo not attempt to use this equipment until you havethoroughly rea
TROUBLESHOOTING & REPAIRF-37 F-37COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-38 F-38COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-39 F-39COMMANDER 500ANALOG POWER SUPPLY PC BOARD VOLTAGE TESTWARNINGService and repair should be performed by only Linco
TROUBLESHOOTING & REPAIRF-40 F-40COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-41 F-41COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-42 F-42COMMANDER 500OUTPUT RECTIFIER BRIDGE TESTWARNINGService and repair should be performed by only Lincoln Electric f
TROUBLESHOOTING & REPAIRF-43 F-43COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-44 F-44COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-45 F-45COMMANDER 500Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-46 F-46COMMANDER 500POWER MODULE TESTWARNINGService and repair should be performed by only Lincoln Electric factory trai
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