Lincoln Electric Welding System SVM153 A User Manual
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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, most importantly, think  
before you act and be careful.  
SERVICE MANUAL  
Copyright © 2002 Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating  
products.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
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iii  
iii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
the welding sparks from starting a fire.  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact can  
cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate circuits.  
This can create fire hazards or overheat lifting chains or  
cables until they fail.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
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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  
zones où l’on pique le laitier.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
Sûreté Pour Soudage A L’Arc  
7. Quand on ne soude pas, poser la pince à une endroit isolé  
de la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
8. S’assurer que la masse est connectée le plus prés possible  
de la zone de travail qu’il est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou d’autres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher  
metallique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une  
grande partie du corps peut être en contact avec la  
masse.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
d. Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les  
vapeurs du solvant pour produire du phosgéne (gas forte-  
ment toxique) ou autres produits irritants.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à soud-  
er parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
2. Dans le cas de travail au dessus du niveau du sol, se pro-  
téger contre les chutes dans le cas ou on recoit un choc. Ne  
jamais enrouler le câble-électrode autour de n’importe quelle  
partie du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
1. Relier à la terre le chassis du poste conformement au code  
de l’électricité et aux recommendations du fabricant. Le dis-  
positif de montage ou la piece à souder doit être branché à  
une bonne mise à la terre.  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du  
rayonnement de l’arc et des projections quand on soude  
ou quand on regarde l’arc.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
2. Autant que possible, I’installation et l’entretien du poste  
seront effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflamma-  
bles.  
3. Avant de faires des travaux à l’interieur de poste, la  
debrancher à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection  
libres de l’huile, tels que les gants en cuir, chemise épaisse,  
pantalons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
Mar. ‘93  
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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...............................................................................................................................Section B  
Accessories ..........................................................................................................................Section C  
Maintenance..........................................................................................................................Section D  
Theory of Operation .............................................................................................................Section E  
Troubleshooting and Repair ................................................................................................Section F  
Electrical Diagrams..............................................................................................................Section G  
Parts Manual .................................................................................................................................P386  
COMMANDER 500  
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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/Ventilation .....................................................................................................................A-3  
Storing .................................................................................................................................A-3  
Stacking................................................................................................................................A-3  
Angle of Operation................................................................................................................A-3  
Lifting .................................................................................................................................A-4  
High Altitude Operation.........................................................................................................A-4  
High Temperature Operation ................................................................................................A-4  
Towing .................................................................................................................................A-4  
Pre-Operation Engine Service ....................................................................................................A-5  
Oil ........................................................................................................................................A-5  
Fuel.......................................................................................................................................A-5  
Fuel Cap ...............................................................................................................................A-5  
Engine Cooling System ........................................................................................................A-5  
Battery Connection ...............................................................................................................A-5  
Muffler Outlet Pipe................................................................................................................A-6  
Spark Arrester.......................................................................................................................A-6  
High Frequency Generators for TIG Applications.......................................................................A-6  
Electrial Connections ..................................................................................................................A-6  
Remote Control.....................................................................................................................A-6  
Welding Terminals ................................................................................................................A-6  
Welding Output Cables.........................................................................................................A-7  
Machine Grounding ..............................................................................................................A-7  
Auxiliary Power Receptacles................................................................................................A-7  
Standby Power Connections ................................................................................................A-7  
COMMANDER 500  
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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  
System  
Capacities  
Deutz 3 cylinder 44 HP(33 kw)  
High Idle 1900  
Low Idle 1475  
Full Load 1800  
173 cu. in  
(2.83 L)  
12VDC battery  
& Starter  
Fuel: 25 gal.  
94.6 L  
F3L 912  
@ 1800 RPM  
Diesel Engine  
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%  
60%  
50%  
500 Amps (DC multi-purpose)  
550 Amps (DC multi-purpose)  
575 Amps (DC multi-purpose)  
40 Volts  
36 Volts  
35 Volts  
OUTPUT - WELDER AND GENERATOR  
Welding Range  
Open Circuit Voltage  
Auxiliary Power1  
30 - 575 Amps CC/CV  
80 Max OCV @ 1900 RPM  
120/240 VAC  
12,000 Watts, 60 Hz.  
100% Duty Cycle  
20 - 250 Amps TIG  
PHYSICAL DIMENSIONS  
Height2  
42.0 in.  
Width  
31.5 in.  
Depth  
63.1 in.  
Weight  
1638 labs. (743 kg)  
(Approx.)  
1966.8 mm  
800.1 mm  
1602.7 mm  
1Output rating in watts is equivalent to volt-amperes at unity power factor.  
Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.  
2Top of enclosure. Add 8.9” (226.1mm) for exhaust.  
COMMANDER 500  
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A-3  
A-3  
INSTALLATION  
Read this entire installation section before you  
start installation.  
LOCATION / VENTILATION  
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  
welder so that the engine exhaust fumes are properly  
vented to an outside area.  
SAFETY PRECAUTIONS  
WARNING  
Do not attempt to use this equipment until you have  
thoroughly read all operating and maintenance  
manuals supplied with your machine. They include  
important safety precautions, \detailed engine starting,  
operating and maintenance instructions and parts lists.  
STORING  
1. Store the machine in a cool, dry place when it is not  
in use. Protect it from dust and dirt. Keep it where  
it can’t be accidentally damaged from construction  
activities, moving vehicles, and other hazards.  
2. Drain the engine oil and refill with fresh 10W30 oil.  
Run the engine for about five minutes to circulate oil  
to all the parts. See the MAINTENANCE section of  
this manual for details on changing oil.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts  
such as output terminals or internal  
wiring.  
3. Remove the battery, recharge it, and adjust the  
electrolyte level. Store the battery in a dry, dark  
place.  
• Insulate yourself from the work and  
ground.  
• Always wear dry insulating gloves.  
STACKING  
Commander 500 machines cannot be stacked.  
ENGINE EXHAUST can kill.  
ANGLE OF OPERATION  
To achieve optimum engine performance the  
Commander 500 should be run in a level position. The  
maximum angle of operation for the Deutz engine is 30  
degrees fore and aft, 40 degrees right and 45 degrees  
left. If the engine is to be operated at an angle, provi-  
sions must be made for checking and maintaining the  
oil level at the normal (FULL) oil capacity in the  
crankcase. When operating the welder at an angle, the  
effective fuel capacity will be slightly less than the  
specified 25 gallons (94.6 liters).  
• Use in open, well ventilated areas or  
vent exhaust outside  
• Do not stack anything near the engine.  
MOVING PARTS can injure.  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
• Keep away from moving parts  
Only qualified personnel should install, use or ser-  
vice this equipment  
COMMANDER 500  
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A-4  
A-4  
INSTALLATION  
LIFTING  
TOWING  
The Commander lift bale should be used to lift the  
machine. The Commander is shipped with the lift bale  
retracted. Before attempting to lift the Commander,  
secure the lift bale in a raised position. Secure the lift  
bale as follows:  
The recommended trailer for use with this equipment  
for road, in-plant and yard towing by a vehicle1 is  
Lincoln’s K953-1. If the user adapts a non-Lincoln trail-  
er, he must assume responsibility that the method of  
attachment and usage does not result in a safety haz-  
ard nor damage the welding equipment. Some of the  
factors to be considered are as follows:  
a. Open the engine compartment door.  
b. Locate the two access holes on the upper mid-  
dle region of the compartment wall just below  
the lift bale.  
1. Design capacity of the trailer vs. weight of the  
Lincoln equipment and likely additional attach-  
ments.  
c. Use the lifting strap to raise the lift bale to the  
full upright position. This will align the mount-  
ing holes on the lift bale with the access holes.  
2. Proper support of, and attachment to, the base of  
the welding equipment so that there will be no  
undue stress to the trailer’s framework.  
d. Secure the lift bale with 2 thread forming  
screws. The screws are provided in the loose  
parts bag shipped with the machine.  
3. Proper placement of the equipment on the trailer to  
insure stability side to side and front to back when  
being moved and when standing by itself.  
4. Typical conditions of use, such as travel speed,  
roughness of surface on which the trailer will be  
operated, and environmental conditions.  
WARNING  
5. Proper preventative maintenance of the trailer.  
6. Conformance with federal, state and local laws.1  
FALLING EQUIPMENT can cause  
injury.  
• Do not lift this machine using lift bale if it  
is equipped with a heavy accessory such  
as a trailer or gas cylinder.  
1Consult applicable federal, state and local laws  
regarding specific requirements for use on public high-  
ways.  
• Lift only with equipment of adequate lift-  
ing capacity.  
• Be sure machine is stable when lifting.  
HIGH ALTITUDE OPERATION  
At higher altitudes, output derating may be necessary.  
For maximum rating, derate the welder output 5% for  
every 300 meters (984 ft.) above 1500 meters (4920  
ft.). For output of 500A and below, derate the welder  
output 5% for every 300 meters (984 ft.) above 2100  
meters (6888 ft.)  
Contact a Deutz Service Representative for any engine  
adjustments that may be required.  
HIGH TEMPERATURE OPERATION  
At temperatures above 30°C (86°F), output voltage  
derating is necessary. For maximum output current rat-  
ings, derate the welder voltage rating two volts for  
every 10°C (21°F) above 30°C (86°F).  
COMMANDER 500  
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A-5  
A-5  
INSTALLATION  
PRE-OPERATION ENGINE SERVICE  
READ the engine operating and maintenance instruc-  
tions supplied with this machine.  
NOTE: Before starting the engine, open the fuel shut-  
off valve (pointer to be in line with hose).  
WARNING  
FUEL CAP  
Remove the plastic cap covering from the fuel tank filler  
neck and install the fuel cap.  
• Keep hands away from the engine muf-  
fler or HOT engine parts.  
• Stop engine and allow to cool before  
fueling.  
ENGINE COOLING SYSTEM  
The Deutz engine is air cooled by a belt-driven axial  
blower. The oil cooler and engine cooling fins should  
be blown out with compressed air or steam to maintain  
proper cooling. (See the engine Operator’s Manual for  
procedures and frequency.)  
• Do not smoke when fueling.  
• Fill fuel tank at a moderate rate and do not overfill.  
• Wipe up spilled fuel and allow fumes to clear before  
starting engine.  
• Keep sparks and flame away from tank.  
OIL  
BATTERY CONNECTION  
The Commander is shipped with the engine crankcase  
filled with high quality SAE 10W-30 oil (API class CD  
or better). Check the oil level before starting the  
engine. If it is not up to the full mark on the dip stick,  
add oil as required. Check the oil level every four  
hours of running time during the first 35 running hours.  
Refer to the engine Operator’s Manual for specific oil  
recommendations and break-in information. The oil  
change interval is dependent on the quality of the oil  
and the operating environment. Refer to the engine  
Operator’s Manual for the proper service and mainte-  
nance intervals.  
WARNING  
GASES FROM BATTERY can explode.  
• Keep sparks, flame and cigarettes away  
from battery.  
To prevent EXPLOSION when:  
• INSTALLING A NEW BATTERY — disconnect nega-  
tive cable from old battery first and connect to new  
battery last.  
• CONNECTING A BATTERY CHARGER — remove  
battery from welder by disconnecting negative cable  
first, then positive cable and battery clamp. When  
reinstalling, connect negative cable last. Keep well  
ventilated.  
FUEL  
NOTE: USE DIESEL FUEL ONLY.  
Fill the fuel tank with clean, fresh diesel fuel. The  
capacity of the fuel tank is 25 gallons (94.6 liters). See  
the engine Operator’s Manual for specific fuel recom-  
mendations. The Commander 500 Deluxe is protected  
by a low fuel shutdown to prevent the engine from run-  
ning out of fuel. The machine will indicate a low fuel  
condition by turning on the low fuel light. A time of 30  
minutes will elapse once the low fuel light illuminates  
before the machine will shutdown. A restart of the  
machine will restart the timer to allow the operator to  
override this feature. The amount of reserve fuel  
remaining in the tank after the first shutdown will vary  
from machine to machine. The operator must deter-  
mine the amount of fuel remaining before restarting the  
machine. Running out of fuel may require bleeding the  
fuel injection pump.  
• USING A BOOSTER — connect positive lead to  
battery first then connect negative lead to  
negative battery lead at engine foot.  
BATTERY ACID can burn eyes and skin.  
• Wear gloves and eye protection and be  
careful when working near battery.  
• Follow instructions printed on battery.  
COMMANDER 500  
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A-6  
A-6  
INSTALLATION  
IMPORTANT: To prevent ELECTRICAL DAMAGE  
WHEN:  
HIGH FREQUENCY GENERATORS  
FOR TIG APPLICATIONS  
a) Installing new batteries  
b) Using a booster  
The K799 Hi-Freq Unit and the K930-1 or-2 TIG  
Module are suitable for use with the Commander 500.  
The Commander 500 is equipped with the required  
R.F. bypass circuitry for the connection of high fre-  
quency generating equipment. The high frequency  
bypass network supplied with the K799 Hi-Freq Unit  
does NOT need to be installed into the Commander  
500.  
Use correct polarity — Negative Ground.  
The Commander is shipped with the negative battery  
cable disconnected. Before you operate the machine,  
make sure the Engine Switch is in the OFF position  
and attach the disconnected cable securely to the neg-  
ative (-) battery terminal.  
The Commander 500 and any high frequency generat-  
ing equipment must be properly grounded. See the  
K799 Hi-Freq Unit and the K930-1 or-2 TIG Module  
operating manuals for complete instructions on instal-  
lation, operation, and maintenance.  
Remove the insulating cap from the negative battery  
terminal. Replace and tighten the negative battery  
cable terminal.  
NOTE: This machine is furnished with a wet charged  
battery; if unused for several months, the battery may  
require a booster charge. Be sure to use the correct  
polarity when charging the battery.  
ELECTRICAL CONNECTIONS  
MUFFLER OUTLET PIPE  
REMOTE CONTROL  
Remove the plastic plug covering the muffler outlet  
tube. Using the clamp provided, secure the outlet pipe  
to the outlet tube with the pipe positioned to direct the  
exhaust in the desired direction.  
The Commander 500 is equipped with a 6-pin and a  
14-pin connector. The 6-pin connector is for connecting  
the K857 or K857-1 Remote Control (optional) or, in the  
case of TIG welding applications, with the foot or hand  
Amptrol (K870 or K963-1 respectively).  
SPARK ARRESTER  
The 14-pin connector is used to directly connect a wire  
feeder or TIG Module (K930-1 or-2) control cable.  
Some federal, state or local laws may require that  
gasoline or diesel engines be equipped with exhaust  
spark arresters when they are operated in certain loca-  
tions where unarrested sparks may present a fire haz-  
ard. The standard muffler included with this welder  
does not qualify as a spark arrester. When required by  
local regulations, a suitable spark arrester must be  
installed and properly maintained.  
NOTE: When using the 14-pin connector, if the wire  
feeder has a built-in power source output control, do  
not connect anything to the 6-pin connector.  
WELDING TERMINALS  
The Commander is equipped with a toggle switch for  
selecting "hot" welding terminals when in the "WELD  
TERMINALS ON" position or "cold" welding terminals  
when in the "WELDING TERMINALS REMOTELY  
CONTROLLED" position.  
CAUTION  
An incorrect arrester may lead to damage to the engine  
or adversely affect performance.  
COMMANDER 500  
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A-7  
A-7  
INSTALLATION  
WELDING OUTPUT CABLES  
With the engine off, route the electrode and work  
cables through the strain relief bracket provided on the  
front of the base and connect to the terminals provided.  
These connections should be checked periodically and  
tightened if necessary.  
In general, if the machine is to be grounded, it should  
be connected with a #8 or larger copper wire to a solid  
earth ground such as a metal water pipe going into the  
ground for at least ten feet and having no insulated  
joints, or to the metal framework of a building which has  
been effectively grounded. The U.S. National Electrical  
Code lists a number of alternate means of grounding  
electrical equipment. A machine grounding stud  
Listed in Table A.1 are copper cable sizes recommend-  
ed for the rated current and duty cycle. Lengths stipu-  
lated are the distance from the welder to work and back  
to the welder again. Cable sizes are increased for  
greater lengths primarily for the purpose of minimizing  
cable voltage drop.  
marked with the  
the welder.  
symbol is provided on the front of  
AUXILIARY POWER RECEPTACLES  
TABLE A.1 – COMBINED LENGTH OF  
ELECTRODE AND WORK CABLES  
The auxiliary power capacity of the Commander 500 is  
12,000 watts of 60 Hz, single-phase power. The auxil-  
iary power capacity rating in watts is equivalent to volt-  
amperes at unity power factor. The maximum permis-  
sible current of the 240 VAC output is 50 A. The 240  
VAC output can be split to provide two separate 120  
VAC outputs with a maximum permissible current of  
50 A per output to two separate 120 VAC branch cir-  
cuits. The output voltage is within ± 10% at all loads up  
to rated capacity.  
Total Combined Length of  
Electrode and Work Cables  
Amps  
@ 100%  
Duty Cycle Up to 150 ft. 150-200 ft. 200-250 ft.  
500  
3/0 AWG  
3/0 AWG  
4/0 AWG  
NOTE: The 120/240V receptacle has two 120V outlets  
of different phases and cannot be paralleled.  
MACHINE GROUNDING  
The Commander has two 20A-120VAC (5-20R) duplex  
receptacles and one 50A-120/240 VAC (14-50R)  
receptacle. The 120/240 VAC receptacle can be split  
for single-phase 120 VAC operation. The auxiliary  
power receptacles should only be used with three-wire  
grounded type plugs or approved double insulated  
tools with two-wire plugs. The current rating of any plug  
used with the system must be at least equal to the cur-  
rent capacity of the associated receptacle.  
Because this portable engine driven welder creates its  
own power, it is not necessary to connect its frame to  
an earth ground, unless the machine is connected to  
premises wiring (home, shop, etc.).  
To prevent dangerous electric shock, other equipment  
powered by this engine driven welder must:  
a) be grounded to the frame of the welder using a  
grounded type plug,  
STANDBY POWER CONNECTIONS  
or  
The Commander 500 is suitable for temporary, stand-  
by or emergency power using the engine manufac-  
turer’s recommended maintenance schedule.  
b) be double insulated.  
When this welder is mounted on a truck or trailer, its  
frame must be securely connected to the metal frame  
of the vehicle. When this engine driven welder is con-  
nected to premises wiring such as that in a home or  
shop, its frame must be connected to the system earth  
ground. See further connection instructions in the sec-  
tion entitled Standby Power Connections as well as  
the article on grounding in the latest U.S. National  
Electrical Code and the local code.  
The Commander 500 can be permanently installed as  
a standby power unit for 240 volt, three-wire, 50 amp  
service. Connections must be made by a licensed  
electrician who can determine how the 120/240 VAC  
power can be adapted to the particular installation and  
comply with all applicable electrical codes. The follow-  
ing information can be used as a guide by the electri-  
cian for most applications. Refer to the connection dia-  
gram shown in Figure A.2.  
COMMANDER 500  
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A-8  
A-8  
INSTALLATION  
1. Install the double-pole, double-throw switch  
between the power company meter and the  
premises disconnect.  
able -10% of rated voltage, which may damage  
appliances or other motor-driven equipment and  
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  
protection.  
3. Install a 50 amp 120/240 VAC plug (NEMA Type  
14-50) to the double-pole circuit breaker using No.  
6, four-conductor cable of the desired length. (The  
50 amp, 120/240 VAC plug is available in the  
optional K802R plug kit.)  
2. Take necessary steps to assure load is limited to  
the capacity of the Commander by installing a 50  
amp, 240 VAC double-pole circuit breaker.  
Maximum rated load for each leg of the 240 VAC  
auxiliary is 50 amperes. Loading above the rated  
output will reduce output voltage below the allow-  
4. Plug this cable into the 50 amp 120/240 volt recep-  
tacle on the Commander 500 case front.  
FIGURE A.2 – CONNECTION OF THE COMMANDER 500 TO PREMISES WIRING  
240 VOLT  
GROUNDED CONDUCTOR  
POWER  
COMPANY  
METER  
240 Volt  
60 Hz.  
3-Wire  
Service  
120 VOLT  
120 VOLT  
NEUTRAL  
BUS  
N
LOAD  
DOUBLE POLE DOUBLE THROW  
SWITCH RATING TO BE THE SAME  
AS OR GREATER THAN PREMISES  
SERVICE OVERCURRENT  
PROTECTION.  
PREMISES  
DISCONNECT AND  
SERVICE  
GROUND  
OVERCURRENT  
50AMP  
240 VOLT  
PROTECTION  
DOUBLE  
POLE  
CIRCUIT  
BREAKER  
50 AMP, 120/240  
VOLT PLUG  
NEMA TYPE 14-50  
240 VOLT  
GND  
N
50 AMP, 120/240 VOLT  
RECEPTACLE  
NOTE: No. 6 COPPER CONDUCTOR CABLE. SEE  
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE  
SIZE RECOMMENDATIONS.  
COMMANDER 500  
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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 Description ....................................................................................................................B-2  
Recommended Applications .................................................................................................B-3  
Design Features and Advantages ........................................................................................B-3  
Welding Capability................................................................................................................B-4  
Controls and Settings..................................................................................................................B-4  
Engine Controls ....................................................................................................................B-5  
Welder Controls....................................................................................................................B-6  
Auxiliary Power Controls ......................................................................................................B-7  
Engine Operation ........................................................................................................................B-8  
Starting the Engine...............................................................................................................B-8  
Stopping the Engine .............................................................................................................B-8  
Break-In Period.....................................................................................................................B-8  
Typical Fuel Consumption ....................................................................................................B-8  
Welder Operation........................................................................................................................B-9  
Stick Welding........................................................................................................................B-9  
Pipe Welding.........................................................................................................................B-9  
Constant Current (CC) Welding............................................................................................B-9  
TIG Welding..........................................................................................................................B-9  
Wire Feed (Constant Voltage) Welding ..............................................................................B-11  
Auxiliary Power Operation.........................................................................................................B-11  
Simultaneous Welding and Auxiliary Power Loads ............................................................B-11  
Arc Gouging........................................................................................................................B-11  
Paralleling ...........................................................................................................................B-11  
Extension Cord Recommendations...........................................................................................B-12  
COMMANDER 500  
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B-2  
B-2  
OPERATION  
ENGINE EXHAUST can kill.  
OPERATING INSTRUCTIONS  
• Use in open, well ventilated areas or  
vent exhaust outside  
Read and understand this entire section before operat-  
ing your Commander 500.  
• Do not stack anything near the engine.  
SAFETY INSTRUCTIONS  
WARNING  
MOVING PARTS can injure.  
• Do not operate with doors open or  
guards off.  
Do not attempt to use this equipment until you have  
thoroughly read all operating and maintenance man-  
uals supplied with your machine. They include impor-  
tant safety precautions: detailed engine starting, oper-  
ating, and maintenance instructions and parts lists.  
• Stop engine before servicing.  
• Keep away from moving parts  
Only qualified personnel should operate this  
equipment.  
ELECTRIC SHOCK can kill.  
ADDITIONAL SAFETY PRECAUTIONS  
• Do not touch electrically live parts or  
electrodes with your skin or wet cloth-  
ing.  
Always operate the welder with the hinged door closed  
and the side panels in place, as these provide maxi-  
mum protection from moving parts and insure proper  
cooling air flow.  
• Insulate yourself from the work and  
ground.  
• Always wear dry insulating gloves.  
GENERAL DESCRIPTION  
The Commander 500 is a diesel engine-driven welding  
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  
welding control system uses state of the art Chopper  
Technology.  
FUMES AND GASES CAN BE  
DANGEROUS.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
The generator has a single sealed bearing for mainte-  
nance free service. The rotor is a copper wound design  
with two slip rings and brushes. The stator is wound  
entirely with heavy gauge copper wire and insulated  
with NEMA class F insulation material. The stator is  
then impregnated with three layers of high quality var-  
nish. After the stator is assembled using tie bars, the  
entire assembly is covered with an environmentally  
protective coating. These measures insure trouble-free  
operation in the harshest environments.  
WELDING SPARKS CAN  
CAUSE FIRE OR EXPLOSION.  
• Keep flammable material away.  
• Do not weld on containers that have  
held combustibles.  
The fuel tank is made from high density polyethylene  
and holds 25 gallons (94.6 liters) of diesel fuel. This  
will provide enough fuel to run for more than 12 hours  
at full load.  
ARC RAYS CAN BURN.  
• Wear eye, ear, and body protection.  
The Deutz F3L-912 engine is equipped with a stan-  
dard, heavy duty, combination fuel filter/water separa-  
tor element.  
COMMANDER 500  
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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  
and for standby emergency power.  
The Commander 500 provides excellent constant cur-  
rent DC welding output for stick (SMAW) and TIG weld-  
ing. The Commander 500 also provides excellent con-  
stant voltage DC welding output for MIG (GMAW) and  
Innershield (FCAW) welding.  
• Drive a 5 HP motor (provided it is started under no  
load).  
• Two 20 amp 120 VAC duplex receptacles for up to 40  
amps of 120 VAC power.  
GENERATOR  
• One 50 amp, 120/240 VAC dual voltage receptacle  
for up to 50 amps of 240 VAC, and up to 50 amps per  
side to separate branch circuits (not in parallel) of  
120 VAC single-phase auxiliary power. Allows easy  
connection to premises wiring.  
The Commander 500 provides smooth 120/240 VAC  
output for auxiliary power and emergency standby  
power.  
• Weld and AC auxiliary power at the same time (with-  
in machine total capacity).  
DESIGN FEATURES AND ADVANTAGES  
K1639-2 COMMANDER 500 DELUXE MODEL  
FEATURES  
OTHER FEATURES  
• Deutz 3-cylinder, air/oil cooled diesel engine.  
Designed for long life, easy maintenance, and excel-  
lent fuel economy.  
FOR WELDING  
• Excellent DC multi-purpose welding for stick, MIG,  
TIG, cored wire and arc gouging applications.  
• Engine protection system shuts the engine down for  
low oil pressure, high oil temperature, or a broken  
fan/engine alternator belt.  
• 30 to 500 amps output in five slope-controlled ranges  
for out-of position and pipe electrodes, one constant  
current output range for general purpose welding,  
one constant voltage range for MIG wire and cored  
wire welding and one 20-250 amp range for “Touch  
Start” TIG welding.  
• Gauges for oil pressure, oil temperature, engine  
alternator output, and fuel level.  
• Indicator lights for low oil pressure, high oil tempera-  
ture, engine alternator low output/broken belt, and  
low fuel level (on K1639-2 only).  
• 100% duty cycle at 500 amps output and 50% duty  
cycle at 575 amps output.  
• Automatic low fuel shutdown before running out of  
fuel (K1639-2 only).  
• Dual 3-digit output meters are provided (optional on  
K1639-1) for presetting the weld amperage or volt-  
age and displaying the actual amperage and voltage  
during welding. The meters use superbrite L.E.D.'s  
for improved readability in full sunlight.  
• Engine hour meter standard on all models.  
• Extended range 25 gallon (94.6 l) fuel tank.  
• Automatic idler reduces engine speed when not  
welding or drawing auxiliary power. This feature  
reduces fuel consumption and extends engine life.  
LOOK-BACK FEATURE: After welding has stopped,  
both displays will remain on for 7 seconds with the  
last current and voltage value displayed. During this  
time, the left-most decimal point in each display will  
be FLASHING.  
• Compact size fits crosswise in full size pickup truck.  
• Single-side engine service.  
• Standard remote control capability with 14-pin and  
6-pin connectors for easy connection of Lincoln  
remote control accessories.  
• Copper alternator windings and high temperature  
insulation for dependability and long life.  
• New paint system on case and base for outstanding  
corrosion protection.  
• An internal "Solid State" contactor allows for the  
selection of "hot" or "cold" output terminals with a  
toggle switch on the control panel.  
• “Arc Control”potentiometer in Wire and Stick modes  
for precise adjustment of arc characteristics.  
• Advanced circuitry to prevent pop-outs in the five  
slope modes.  
COMMANDER 500  
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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  
Commander 500 and has all the features of the  
K1639-2 Deluxe version except that there are no  
gauges, low fuel light, nor dual output meters. This  
version does have fully functional engine protection  
for low oil pressure, high oil temperature, and alter-  
nator output with associated lights.  
The Commander 500 is rated at 500 amps, 40 VDC at  
100% duty cycle and 575 amps, 36 VDC at 50% duty  
cycle. The maximum open circuit voltage at 1900 RPM  
is 80 volts. The weld current is variable from 30 to 575  
amps.  
CONTROLS AND SETTINGS  
• A field-installed Dual Output Meter and Gauge Kit  
(K-1768-1) is available for the K1639-1 Commander  
500.The kit includes dual output meters, oil pressure  
gauge, oil temperature gage, and alternator amme-  
ter.  
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  
3
10  
5
7
8
6
2
4
1
9
OIL  
OIL  
TEMP  
FUEL  
AMPS  
PRESS  
9
11  
17 19  
12  
19  
21  
22  
15  
20  
23  
14  
16  
18  
13  
COMMANDER 500  
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B-5  
B-5  
OPERATION  
5. OIL PRESSURE GAUGE (K1639-2 Std.,  
K1639-1 Opt.) AND LIGHT  
ENGINE CONTROLS (Items 1 through 8)  
1.  
RUN/STOP  
SWITCH  
The gauge displays the engine oil pressure when the  
engine is running. The yellow oil pressure light remains  
off with proper oil pressure. If the light turns on, the  
engine protection system will stop the engine. Check  
for proper oil level and add oil if necessary. Check for  
loose or disconnected leads at the oil pressure sender  
located on the engine. The light will go on and stay on  
when the RUN/STOP switch is switched to the RUN  
position with the engine not running.  
When placed in the RUN position, this switch energizes  
the fuel solenoid and other electric accessories. When  
placed in the STOP position, the flow of fuel to the  
injection pump is stopped to shut down the engine.  
NOTE: If the switch is left in the RUN position and the  
engine is not running, the fuel solenoid will be engaged  
for 15 seconds and then shut down. This is to protect  
the battery from discharge. After 15 seconds, the  
RUN/STOP switch must be toggled off then on before  
starting.  
6. ENGINE ALTERNATOR AMMETER  
(K1639-2 Std., K1639-1 Opt.) AND LIGHT  
The yellow engine alternator light is off when the bat-  
tery charging system is functioning normally. If the light  
turns on, the engine protection system will shut down  
the engine. Check the engine cooling blower belt. Also,  
the alternator or the voltage regulator may not be oper-  
ating correctly. The light may also come on due to a  
faulty flashing circuit. The light will remain on when the  
engine has been shut down due to a fault in the alter-  
nator, regulator, or the cooling blower belt.  
2. START PUSHBUTTON  
Energizes the starter motor to crank the engine. With  
the engine RUN/STOP switch in the RUN position,  
push and hold the Start button to crank the engine;  
release as the engine starts. The Start button must be  
depressed for a minimum of two seconds. Do not  
press it while the engine is running, since this can  
cause damage to the ring gear and/or starter motor.  
3. FUEL LEVEL GAUGE AND LIGHT  
7. IDLER SWITCH  
(K1639-2 only) - Displays the level of diesel fuel in the  
25-gallon (94.6 liter) fuel tank. The yellow light turns on  
when the fuel gage reaches the reserve level. Once the  
reserve level is reached, the engine protection system  
will shut down the engine after 30 minutes of operation.  
The machine can be restarted and operated for an  
additional 30 minutes before the protection system will  
shut down the engine. This ability to override the  
engine protection allows the operator to “finish up” if  
necessary. The operator must watch the fuel level  
closely to prevent running out of fuel and having to  
bleed the system.  
Has two positions as follows:  
A) In the HIGH position  
, the engine runs at the  
high idle speed controlled by the governor.  
B) In the AUTO  
ates as follows:  
/
position, the idler oper-  
a. When switched from HIGH to AUTO or after  
starting the engine, the engine will operate at  
full speed for approximately 12 seconds and  
then go to low idle speed.  
b. When the electrode touches the work or power  
is drawn for lights or tools (approximately 100  
Watts minimum) the engine accelerates and  
operates at full speed.  
4. ENGINE TEMPERATURE GAUGE (K1639-2  
Std., K1639-1 Opt.) AND LIGHT  
c. When welding ceases or the AC power load is  
turned off, a fixed time delay of approximately  
12 seconds starts.  
The gauge displays the engine oil temperature. The  
yellow temperature light remains off under normal  
operating temperatures. If the light turns on, the engine  
protection system will shut down the engine. Check for  
restrictions at the engine cooling air inlets and outlets.  
(Consult the engine Operator’s Manual.) Check for  
loose or disconnected leads at the temperature sender  
located on the engine. Check the engine cooling blow-  
er belt. Also, check to be sure that the welder loads are  
within the rating of the welder. The light will remain on  
when the engine has been shut down due to an over-  
temperature condition.  
d. If the welding or AC power load is not restarted  
before the end of the time delay, the idler  
reduces the engine speed to low idle speed.  
e. The engine will automatically return to high idle  
speed when the welding load or AC power load  
is reapplied.  
COMMANDER 500  
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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  
always “Hot.”  
When the WELDING TERMINALS switch is in the  
“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  
Amptrol, Arc Start Switch or some other type of trig-  
gering device through the use of a control cable con-  
nected to the 14-pin amphenol.  
a. When the triggering device (Amptrol, Arc Start  
Switch, etc.) is pressed, the engine will accelerate  
and operate at full speed provided a welding load  
is applied within approximately 15 seconds.  
• If the triggering device remains pressed but no  
welding load is applied within approximately 15  
seconds, the engine will return to low idle speed.  
When the triggering device is pressed, the contactor is  
closed and the welding terminals are “Hot.”  
When the triggering device is released, the contactor is  
opened and the welding terminals are “Cold.”  
• If the triggering device is released or welding  
ceases, the engine will return to low idle speed  
after approximately 15 seconds.  
NOTE: The new Chopper Technology control circuitry  
automatically senses when a remote output control pot  
is plugged into either amphenol. Therefore, there is no  
need for a local / remote switch.  
8. HOUR METER  
The hour meter displays the total time that the engine  
has been running. This meter is a useful indicator for  
scheduling preventive maintenance.  
TABLE B.1 – WELD MODE AND OUTPUT  
CONTROL FUNCTIONS  
WELDER CONTROLS (Items 9 through 13 )  
M
M
9.  
WELD MODE &  
OUTPUT CONTROL  
Application  
Weld Mode1  
Output2  
These two controls allow you to select between various  
welding output slopes and adjust the desired welding  
output. Refer to Table B.1 for a description of how  
these two controls work.  
Sloped Output  
for Pipe  
Welding  
5 Range  
Settings  
90, 150, 200,  
350, 500 (max. Provides a Fine  
current on each  
setting)  
Adjustment of  
Welding Current  
from  
10. DIGITAL OUTPUT METERS  
The digital output meters are located in the center of  
the control panel between the two large control knobs.  
The meters allow the output current level to be set prior  
to welding in stick mode, and voltage level to be set  
prior to welding in the wire modes. During the welding  
process the meters display the actual output current  
and voltage, within ±5% accuracy.  
Touch Start TIG  
Welding  
1 Range Setting Min (1) to Max  
15-200 Amps  
(10) within each  
range  
Constant Current 1 Range Setting  
Output for  
20-250 Amps  
Fabrication and  
General Purpose  
Welding  
The digital meters allow the output voltage (CV-WIRE  
mode) or current (CC-STICK, PIPE and TIG modes) to  
be set prior to welding using the OUTPUT control dial.  
During welding, the meters display the actual output  
voltage (VOLTS) and current (AMPS). A memory fea-  
ture holds the display of both meters on for seven sec-  
onds after the welding is stopped. This allows the oper-  
ator to read the actual current and voltage just prior to  
when welding was ceased. While the display is being  
held the left-most decimal point in each display will be  
flashing. The accuracy of the meters is +/- 3%.  
Constant Voltage 1 Range Setting  
Output for MIG  
WIRE or  
CORED WIRE  
Welding  
Provides Fine  
Voltage  
Adjustment  
14 to 40 Volts  
1
2
If the WELD MODE switch is positioned between settings, the pre-  
vious setting is maintained until the switch is properly positioned on  
a setting.  
11. WELDING TERMINALS SWITCH  
OUTPUT also controls O.C.V. while in the 5 sloped output ranges.  
The toggle switch on the control panel labeled WELD  
TERMINALS ON and REMOTELY CONTROLLED is  
used to control the operation of the “solid state contac-  
tor.” The switch allows for the selection of “Hot” or  
“Cold” welding terminals.  
COMMANDER 500  
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B-7  
B-7  
OPERATION  
12. 6 - PIN CONNECTOR (AMPHENOL)  
18. GROUND STUD  
The 6-pin amphenol located on the control panel  
allows for connection of interfacing equipment.  
Provides a connection point for connecting the  
machine case to earth ground for the safest grounding  
procedure. Refer to MACHINE GROUNDING in the  
Installation section for proper machine grounding infor-  
mation.  
13. WELD OUTPUT TERMINALS + AND -  
These 1/2 - 13 studs with flange nuts provide welding  
connection points for the electrode and work cables.  
For positive polarity welding, the electrode cable con-  
nects to the “+” terminal and the work cable connects  
to this “-” terminal. For negative polarity welding, the  
work cable connects to the “+” terminal and the elec-  
trode cable connects to this “-” terminal.  
19. 20 AMP CIRCUIT BREAKER  
This circuit breaker provides overload protection for the  
120 VAC circuit in the 14-pin amphenol.  
20. VOLTMETER +/- SWITCH  
Changes the polarity display on the wire feeder.  
AUXILIARY POWER CONTROLS  
21. 10 AMP CIRCUIT BREAKER  
(Items 14 through 18 )  
This circuit breaker provides overload protection for the  
42 VAC circuit in the 14-pin amphenol.  
14. 120/240VAC RECEPTACLE  
This is a 120/240VAC (14-50R) receptacle that  
provides 240VAC. Or, it can be split for 120VAC sin-  
gle-phase auxiliary power. This receptacle has a 50  
amp rating. Refer to AUXILIARY POWER RECEP-  
TACLES section in the Installation section for further  
information about this receptacle. Also refer to the  
AUXILIARY POWER OPERATION later in this section.  
22. 14 - PIN CONNECTOR (AMPHENOL)  
For quick connection of interfacing equipment.  
23. ARC CONTROL  
The ARC CONTROL potentiometer is active in two  
modes: CC - STICK and CV - WIRE with different pur-  
poses in each mode.  
15. 50 AMP CIRCUIT BREAKERS  
CC - STICK mode: In this mode, the ARC CONTROL  
knob sets the short circuit current during stick welding.  
Increasing the number from 1 to 10 increases the short  
circuit current. This prevents sticking of the electrode to  
the plate at low welding current settings. This also  
increases spatter. It is recommended that the control  
be set to the minimum number without electrode stick-  
ing.  
These circuit breakers provide separate overload  
current protection for each 120V circuit at the 240V  
receptacle.  
16. 120VAC RECEPTACLES  
These two 120VAC (5-20R) receptacles provide  
120VAC for auxiliary power. Each receptacle has a 20  
amp total rating. Refer to AUXILIARY POWER  
RECEPTACLES in the Installation section for further  
information about these receptacles. Also refer to the  
AUXILIARY POWER OPERATION later in this section.  
CV - WIRE mode: In this mode increasing the number  
from 1 to 10 changes the arc from soft and washed in  
to crisp and narrow. It acts as an inductance control.  
The proper setting depends on the application and  
operator preference.  
17. 20 AMP CIRCUIT BREAKERS  
In general, MIG welding performs best in the “SOFT”  
range and Innershield in the “CRISP” range.  
These circuit breakers provide separate overload cur-  
rent protection for each 120V receptacle.  
COMMANDER 500  
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B-8  
B-8  
OPERATION  
BREAK-IN PERIOD  
ENGINE OPERATION  
The engine used to supply power for your welder is a  
heavy duty, industrial engine. It is designed and built  
for rugged use. It is very normal for any engine to use  
small quantities of oil until the break-in is accom-  
plished. Check the oil level twice a day during the  
break-in period (about 200 running hours).  
STARTING THE ENGINE  
1. Open the engine compartment door and check that  
the fuel shutoff valve located to the left of the fuel fil-  
ter housing is in the open position (lever to be in line  
with the hose).  
2. Check for proper oil level on the oil dipstick. Close  
engine compartment door.  
CAUTION  
During break-in, subject the Commander 500 to heavy  
loads. Avoid long periods running at idle. Before stop-  
ping the engine, remove all loads and allow the engine  
to cool several minutes.  
3. Remove all plugs connected to the AC power recep-  
tacles.  
4. Set IDLER switch to “AUTO”.  
5. Set the RUN/STOP switch to RUN. Observe that  
all engine protection lights momentarily turn on.  
Some lights may turn off before starting. Check the  
fuel gauge (K1639-2 only) to make sure that there  
is an adequate fuel level.  
The heavy loading of the engine during break-in, with-  
in the rating of the machine, is recommended to prop-  
erly seat the piston rings and prevent wetstacking.  
Wetstacking is an accumulation of unburned fuel  
and/or lubricant in the form of a set, black, tar-like sub-  
stance in the exhaust pipe. The rings are seated and  
the break-in period is complete when there are no  
longer any signs of wetstacking, which should occur  
within the first 50 to 100 hours of operation.  
6. Press and hold the engine START button for a min-  
imum of two seconds.  
7. Release the engine START button when the engine  
starts.  
8. Check that the indicator lights are off. If the LOW  
FUEL light is on (K1639-2 only), the engine will shut  
down 30 minutes after starting. If any other indica-  
tor light is on after starting, the engine will shut  
down in a few seconds. Investigate any indicated  
problem.  
CAUTION  
Using your welder at low amperages with long idle run-  
ning periods during the break-in period may result in a  
glaze forming on the engine cylinder walls and the  
rings not seating properly. No amount of loading will  
properly seat the pistons rings after they are glazed  
over.  
9. Allow the engine to warm up at low idle speed for  
several minutes before applying a load and/or  
switching to high idle. Allow a longer warm-up time  
in cold weather.  
COLD WEATHER STARTING  
With a fully charged battery and the proper weight oil,  
the engine should start satisfactorily even down to  
about 0°F. If the engine must be frequently started  
below 10°F, it may be desirable to install the optional  
ether starter kit (K825-1). Installation and operating  
instructions are included in the kit.  
TYPICAL FUEL CONSUMPTION  
Refer to Table B.2 for typical fuel consumption of the  
Commander 500 engine for various operating  
scenarios.  
STOPPING THE ENGINE  
1. Switch the RUN/STOP switch to STOP. This turns  
off the voltage supplied to the shutdown solenoid. A  
backup shutdown can be accomplished by shutting  
off the fuel valve located on the fuel line.  
COMMANDER 500  
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B-9  
B-9  
OPERATION  
Table B.2 – DEUTZ F3L 912  
ENGINE FUEL CONSUMPTION  
CONSTANT CURRENT (CC) WELDING  
In the CC - STICK position of 30 to 575, the WELD  
MODE switch is designed for horizontal welds with all  
types of electrodes, especially low hydrogen. The  
OUTPUT adjusts the full range of 30 to 575 amps. This  
setting provides a soft, constant current arc. If a more  
forceful arc is desired, select the proper range from the  
slope controlled current ranges.  
Deutz F3L 912  
44.2 Hp  
@ 1800 RPM  
Running Time  
for 25 gallons  
(Hours)  
Low Idle - No  
Load 1475 RPM  
.47 gallons/hour  
(1.77 liters/hour)  
53.2  
37.9  
12.9  
In the CC mode, sticking can be prevented by adjust-  
ing the ARC CONTROL. Turning this control clockwise  
increases the short circuit current, thus preventing  
sticking. This is another way of increasing arc force.  
High Idle - No  
Load 1900 RPM  
.66 gallons/hour  
(2.50 liters/hour)  
DC CC Weld  
Output 500  
Amps @ 40 Volts  
1.94 gallons/hour  
(7.34 liters/hour)  
TIG WELDING  
The furthest position clockwise of the WELD MODE  
switch is for TIG welding in the range of 20 amps to 250  
amps, with a “Touch Start” feature. To initiate a weld,  
the OUTPUT is first set to the desired current, and the  
tungsten is touched to the work. During the time the  
tungsten is touching the work, there is very little voltage  
or current and, in general, no tungsten contamination.  
Then, the tungsten is gently lifted off the work in a rock-  
ing motion, which establishes the arc.  
Auxiliary Power  
12,000 VA  
1.31 gallons/hour  
(4.96 liters/hour)  
19.1  
WELDER OPERATION  
STICK WELDING  
The Commander 500 can be used in a wide variety of  
DC Tungsten Inert Gas (TIG) welding applications. In  
general the “Touch Start” feature allows contamination-  
free starting without the use of a Hi-Freq unit. But the  
K930-1 or -2 TIG module or K799 Hi-Freq unit can be  
used with the Commander 500. The settings for these  
follow the tungsten current range table, Table B.3.  
The Commander 500 can be used with a broad range  
of DC stick electrodes.  
The “WELD MODE” switch provides five overlapping  
slope controlled current ranges. The OUTPUT adjusts  
the current from minimum to maximum within each  
range. Voltage is also controlled by the OUTPUT in the  
slope controlled setting. These slope controlled set-  
tings are intended for “out-of-position” welding, includ-  
ing pipe welding, where the operator would like to con-  
trol the current level by changing the arc length.  
PIPE WELDING  
The Commander 500 is equipped with special circuitry  
to minimize pop-outs in the five slope modes at any  
open circuit voltage.  
For a soft arc characteristic, set the WELD MODE  
switch to the lowest setting that still provides the cur-  
rent you need and set the OUTPUT near maximum.  
For example: to obtain 140 amps and a soft arc, set  
the WELD MODE switch to the 150 MAX position and  
then adjust the OUTPUT for 140 amps.  
When a forceful, "digging" arc is required, use a higher  
setting and lower the open circuit voltage. For example:  
to obtain 140 amps and a forceful arc, set the WELD  
MODE to the 250 MAX position and then adjust the  
OUTPUT to get 140 amps.  
COMMANDER 500  
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B-10  
B-10  
OPERATION  
TABLE B.3 – TYPICAL CURRENT RANGES1 FOR TUNGSTEN ELECTRODES2  
Approximate Argon Gas Flow Rate  
DCEN (-)  
DCEP (+)  
C.F.H. (l/min.)  
Tungsten  
Electrode  
Diameter  
in. (mm)  
1%, 2%  
Thoriated  
Tungsten  
1%, 2%  
Thoriated  
Tunsten  
TIG TORCH  
Nozzle  
Aluminum  
3-8 (2-4)  
Stainless Steel  
Size4, 5  
3
3
3
0.010 (.25)  
0.020 (.50)  
2-15  
5-20  
15-80  
3-8  
(2-4)  
(3-5)  
(3-5)  
#4, #5, #6  
5-10  
5-10  
(3-5)  
(3-5)  
5-10  
5-10  
0.40  
(1.0)  
1/16  
(1.6)  
70-150  
10-20  
5-10  
(3-5)  
9-13  
(4-6)  
#5, #6  
3/32  
1/8  
(2.4)  
(3.2)  
150-250  
250-400  
15-30  
25-40  
13-17  
15-23  
(6-8)  
(7-11)  
11-15  
11-15  
(5-7)  
(5-7)  
#6, #7, #8  
5/32  
3/16  
1/4  
(4.0)  
(4.8)  
(6.4)  
400-500  
500-750  
750-1000  
40-55  
55-80  
80-125  
21-25 (10-12) 13-17  
23-27 (11-13) 18-22  
28-32 (13-15) 23-27 (11-13)  
(6-8)  
(8-10)  
#8, #10  
1When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.  
2Tungsten electrodes are classified as follows by the American Welding Society (AWS):  
Pure  
EWP  
1% Thoriated  
2% Thoriated  
EWTh-1  
EWTh-2  
2Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC  
applications.  
3DCEP is not commonly used in these sizes.  
4TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:  
# 4 = 1/4 in.  
# 5 = 5/16 in.  
# 6 = 3/8 in.  
(6 mm)  
(8 mm)  
(10 mm)  
# 7 = 7/16 in.  
# 8 = 1/2 in.  
#10 = 5/8 in.  
(11 mm)  
(12.5 mm)  
(16 mm)  
5TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to break-  
age, but cannot withstand high temperatures and high duty cycles.  
COMMANDER 500 SETTINGS WHEN USING THE  
K799 HI-FREQ UNIT  
COMMANDER 500 SETTINGS WHEN USING THE  
K930-1 TIG MODULE  
• Set the WELD MODE switch to the 20-250 setting  
(TIG).  
• Set the WELD MODE switch to the 20-250 setting  
(TIG).  
• Set the IDLER switch to the HIGH position.  
• Set the IDLER switch to the AUTO position.  
• Set the WELDING TERMINALS switch to the WELD  
TERMINALS ON position. This will close the solid  
state contactor and provide an always “hot” electrode.  
• Set the WELDING TERMINALS switch to the  
REMOTELY CONTROLLED position. This will keep  
the solid state contactor open and provide a “cold”  
electrode until the triggering device (Amptrol or Arc  
Start Switch) is pressed.  
NOTE: This is necessary because the K799 circuitry  
with respect to the #2 and #4 leads does not provide  
the proper signal to open and close the solid state con-  
tactor in the Commander 500.  
COMMANDER 500  
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B-11  
B-11  
OPERATION  
NOTE: The 120/240V receptacle has two 120V out-  
puts of different phases and cannot be paralleled.  
WIRE FEED (CONSTANT VOLTAGE)  
WELDING  
The auxiliary power receptacles should only be used  
with three-wire grounded type plugs or approved dou-  
ble insulated tools with two wire plugs.  
Connect a wire feeder to the Commander 500 and set  
welder controls according to the instructions listed ear-  
lier in this section.  
The current rating of any plug used with the system  
must be at least equal to the current capacity of the  
associated receptacle.  
The Commander 500 in the CV-WIRE position can be  
used with a broad range of flux cored wire (Innershield  
and Outershield) electrodes and solid wires for MIG  
welding (gas metal arc welding). Welding can be finely  
tuned using the ARC CONTROL.  
SIMULTANEOUS WELDING AND  
AUXILIARY POWER LOADS  
Some recommended Innershield electrodes are: NR-  
311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.  
It must be noted that the above auxiliary power ratings  
are with no welding load. Simultaneous welding and  
power loads are specified in Table B.4. The permissi-  
ble currents shown assume that current is being drawn  
from either the 120 VAC or 240 VAC supply (not both  
at the same time).  
Recommended Outershield electrodes are: 0S-70, 0S-  
71M.  
Some recommended solid wires for MIG welding are:  
.035 (0.9 mm), .045 (1.1 mm) and .052 (1.3 mm), L-50  
and L-56, .035 (0.9 mm) and .045 (1.1 mm) Blue Max  
MIG 308 LS.  
ARC GOUGING  
For any electrodes, including the above recommenda-  
tions, the procedures should be kept within the rating of  
the machine. For additional electrode information, see  
Lincoln publications N-675, GS-100 and GS-210.  
For optimal performance when arc gouging, set the  
Commander 500 WELD MODE switch to the CC -  
STICK position, and the ARC CONTROL to 10.  
Set the OUTPUT knob to adjust output current to the  
desired level for the gouging electrode being used  
according to the ratings in the following table:  
AUXILIARY POWER OPERATION  
Start the engine and set the IDLER control switch to  
the desired operating mode. Full power is available  
regardless of the welding control settings, if no welding  
current is being drawn.  
Electrode  
Diameter  
Current Range  
(DC, electrode positive)  
1/8”  
5/32”  
3/16”  
1/4”  
5/16”  
3/8”  
30-60 Amps  
90-150 Amps  
150-200 Amps  
200-400 Amps  
250-400 Amps  
350-575 Amps*  
The auxiliary power of the Commander consists of two  
20 Amp-120VAC (5-20R) duplex receptacles and one  
50 Amp-120/240 VAC (14-50R) receptacle. The  
120/240VAC receptacle can be split for single phase  
120 VAC operation.  
The auxiliary power capacity is 12,000 watts of 60 Hz,  
single phase power. The auxiliary power capacity rating  
in watts is equivalent to volt-amperes at unity power  
factor. The maximum permissible current of the 240  
VAC output is 50 A. The 240 VAC output can be split to  
provide two separate 120 VAC outputs with a maxi-  
mum permissible current of 50 A per output to two sep-  
arate 120 VAC branch circuits. Output voltage is within  
± 10% at all loads up to rated capacity.  
* Maximum current setting is limited to the Commander  
500 maximum of 575 Amps.  
PARALLELING  
When paralleling machines in order to combine their  
outputs, all units must be operated in the CC - STICK  
mode only. To achieve this, turn the WELD MODE  
switch to the CC - STICK position. Operation in other  
modes may produce erratic outputs and large output  
imbalances between the units.  
COMMANDER 500  
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B-12  
B-12  
OPERATION  
TABLE B.4 – COMMANDER 500 SIMULTANEOUS WELDING AND POWER LOADS  
Permissible  
Power - Watts  
(Unity Power  
Factor)  
Permissible Auxiliary  
Current in Amperes  
Welding  
Output Range  
Setting  
Welding Output  
@ 120 V ± 10%*  
@ 240 V ± 10%*  
30-575  
500  
350  
250  
150  
90  
500A/40V  
500A/40V  
350A/30V  
250A/29V  
150A/27V  
90A/25V  
0
0
0
0
80*  
100**  
100**  
100**  
0
0
40  
50  
50  
50  
9500  
12000  
12000  
12000  
* Each duplex receptacle is limited to 20 amps.  
** Not to exceed 50 A per 120 VAC branch circuit when splitting the 240 VAC output.  
EXTENSION CORD  
RECOMMENDATIONS  
An extension cord can be used with the auxiliary power  
outputs as long as it is of ample size. Table B.5 lists  
permissible extension cord lengths based on conduc-  
tor size and auxiliary power output.  
TABLE B.5 – COMMANDER 500 EXTENSION CORD LENGTH RECOMMENDATIONS  
Current Voltage Load  
(Amps) (Volts) (Watts)  
Maximum Allowable Cord Length in ft. (m) for Conductor Size  
12 AWG 10 AWG 8 AWG 6 AWG  
125 175  
14 AWG  
4 AWG  
15  
15  
20  
20  
25  
30  
38  
50  
120  
240  
120  
240  
240  
240  
240  
240  
1800  
3600  
2400  
48010  
6000  
7200  
9000  
12000  
30  
60  
(9)  
40  
(12)  
(23)  
(9)  
75  
(23)  
(46)  
(15)  
(30)  
(27)  
(23)  
(38)  
(69)  
(27)  
(53)  
(46)  
(37)  
(30)  
(53)  
(107)  
(42)  
(84)  
(69)  
(53)  
(46)  
(38)  
300  
600  
225  
450  
250  
300  
250  
200  
(91)  
(183)  
(69)  
(137)  
(76)  
(91)  
(76)  
(61)  
(18)  
75  
30  
60  
150  
50  
100  
90  
225  
88  
175  
150  
120  
100  
350  
138  
275  
225  
175  
150  
125  
(18)  
75  
Conductor size is based on maximum 2.0% voltage drop.  
COMMANDER 500  
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Section C-1  
Section C-1  
TABLE OF CONTENTS  
- ACCESSORIES SECTION -  
Accessories ..........................................................................................................................Section C  
Options/Accessories ...................................................................................................................C-2  
Field Installed Options..........................................................................................................C-2  
Stick Welding Accessories....................................................................................................C-2  
TIG Welding Accessories .....................................................................................................C-2  
Semiautomatic Welding Accessories....................................................................................C-3  
Connection of Lincoln Electric Wire Feeders .......................................................................C-3  
Connection of the LN-7 Using K867 Universal Adapter ................................................C-4  
Connection of the LN-7 Using the K584 or K594 Input Cable Assembly......................C-5  
Connection of the LN-8 Using the K867 Universal Adapter ..........................................C-6  
Connection of the LN-8 Using the K595 Input Cable Assembly....................................C-7  
Connection of the LN-23-P Using K350-1 Adapter........................................................C-8  
Connection of the LN-25 “Across the Arc”.....................................................................C-9  
COMMANDER 500  
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C-2  
C-2  
ACCESSORIES  
K1816-1 FULL KVA ADAPTER KIT - Plugs into the  
120/240V NEMA 14-50R receptacle on the case front  
(which accepts 4-prong plugs) and converts it to a  
NEMA 6-50R receptacle (which accepts 3-prong  
plugs).  
OPTIONS/ACCESSORIES  
The following options/accessories are available for  
your Commander 500 from your local Lincoln  
Distributor.  
K1768-1 DUAL OUTPUT METERS AND GAUGES -  
Dual output meters provide preset ability of voltage for  
wire welding and current for stick welding. Measures  
both current and voltage when welding. Gauges  
include battery ammeter, engine temperature, and  
engine oil pressure. Fuel gauge is not available in kit  
form.  
FIELD INSTALLED OPTIONS  
K802N POWER PLUG KIT - Provides a plug for each  
receptacle.  
K857 25 ft. (8.5 m) or K857-1 100 ft. (30.4 m)  
REMOTE CONTROL - Portable control provides same  
dial range as the output control on the welder from a  
location up to the specified length from the welder. Has  
convenient plug for easy connection to the welder. The  
Commander 500 is equipped with a 6-pin connector for  
connecting the remote control.  
STICK WELDING ACCESSORIES  
K704 Accessory Kit, which includes:  
• Electrode holder and cable.  
• Ground clamp and cable.  
• Headshield.  
K704 ACCESSORY SET - Includes 35 feet (10 m) of  
electrode cable and 30 feet (9 m) of work cable, head-  
shield, work clamp and electrode holder. Cable is rated  
at 500 amps, 60% duty cycle.  
K857 Remote Control Kit is optional for remote cur-  
rent control.  
K953-1 TWO-WHEEL TRAILER - For road, in-plant  
and yard towing. Road towing with optional fender and  
light kit. (For highway use, consult applicable federal,  
state and local laws regarding possible additional  
requirements.)  
TIG WELDING ACCESSORIES  
• Magnum TIG Torch  
• Magnum Parts Kit and Argon gas  
• K930-ALL TIG Module (not required for  
scratch-start DC TIG welding)  
• K936-1 Control Cable  
• K953-1 Trailer  
• K958-1 Ball Hitch  
• K958-2 Lunette Eye Hitch  
• K959-1 Fender and Light Kit  
• K965-1 Cable Storage Rack  
• K870 Foot Amptrol  
K825-1 ETHER START KIT - Provides maximum cold  
weather starting assistance for frequent starting below  
10° F (-12.2° C). Required Ether tank is not provided  
with kit.  
Also available:  
• K963-1/-2 Hand Amptrol  
• K814 Arc Start Switch  
• K937-22 Control Cable Extension  
• K937-45 Control Cable Extension  
• K844-1 Water Valve  
K949-1 OIL DRAIN KIT - Includes ball valve, hose and  
clamp.  
K1690-1 (1 DUPLEX) GFCI KIt - Includes a UL  
approved 115 volt ground fault circuit interrupter recep-  
tacle (duplex type) with cover and installation instruc-  
tions. Each half of the receptacle is rated 15 amps, but  
the maximum total current from the GFCI duplex is lim-  
ited to 20 amps. The GFCI receptacle replaces the fac-  
tory installed 115 volt duplex receptacle. Two kits are  
required.  
K899-1 SPARK ARRESTER KIT - Easily mounts to  
standard muffler.  
COMMANDER 500  
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C-3  
C-3  
ACCESSORIES  
SEMIAUTOMATIC WELDING  
ACCESSORIES  
CONNECTION OF LINCOLN  
ELECTRIC WIRE FEEDERS  
LN-7 OR LN-8 WIRE FEEDERS - Semiautomatic, con-  
stant speed wire feeders. For CV operation only.  
WARNING  
LN-23P WIRE FEEDER - This portable wire feeder is  
capable of CV operation. K350-1 Adapter Kit is  
required.  
ELECTRIC SHOCK can kill.  
• Do not operate with panels open.  
LN-25 WIRE FEEDER - The LN-25 with or without an  
external contactor may be used with the Commander  
300.  
• Disconnect NEGATIVE (-) BATTERY  
LEAD before servicing.  
• Do not touch electrically live parts.  
NOTE: Gas-shielded welding requires a Magnum Gun.  
Gasless welding requires an Innershield Gun.  
MOVING PARTS can injure.  
• Keep guards in place.  
OTHER WIRE FEEDERS FOR THE  
COMMANDER 300  
• Keep away from moving parts.  
• Only qualified personnel should install,  
use or service this equipment.  
• NA-3 Automatic Wire Feeder  
• LN-742 Semiautomatic Wire Feeder  
• Spool gun and K488 Module  
HIGH FREQUENCY GENERATORS FOR  
TIG APPLICATIONS  
The K799 Hi-Freq Unit and the K930-ALL TIG Modules  
are suitable for use with the Commander 500. The  
Commander 500 is equipped with the required RF  
bypass circuitry for the connection of high frequency  
generating equipment. The high frequency bypass net-  
work supplied with the K799 Hi-Freq Unit does NOT  
need to be installed into the Commander 500.  
The Commander 500 and any high frequency-generat-  
ing equipment must be properly grounded. See the  
K799 Hi-Freq Unit and the K930-AII TIG Module oper-  
ating manuals for complete instructions on installation,  
operation, and maintenance.  
COMMANDER 500  
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C-4  
C-4  
ACCESSORIES  
CONNECTION OF THE LN-7 TO THE  
COMMANDER 500 USING K867  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control cir-  
cuits may be damaged. The engine governor setting is  
preset at the factory—do not adjust above RPM speci-  
fications listed in this manual.  
UNIVERSAL ADAPTER (SEE FIGURE C.1.)  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-7 to the  
“+” terminal of the welder. Connect the work cable  
to the “-” terminal of the welder.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
6. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
NOTE: Figure C.1 shows the electrode connected for  
positive polarity. To change polarity, shut the welder off  
and reverse the electrode and work cables at the  
Commander 500 output terminals.  
7. Set the OUTPUT RANGE switch to WIRE WELD-  
ING CV.  
3. Connect the K867 Universal Adapter to the K291 or  
K404 input cable and the 14-pin amphenol of the  
Commander 500 as indicated in Figure C.1. Make  
the proper connections for local or remote control  
according to Figure C.1.  
8. Set the WELDING TERMINALS switch to WELD-  
ING TERMINAL REMOTELY CONTROLLED.  
9. Adjust wire feed speed at the LN-7.  
10. Adjust the ARC CONTROL to the desired level  
(“soft” or “crisp”).  
4. Connect the K291 or K404 input cable to the LN-7.  
5. Place the IDLER switch in the HIGH position.  
FIGURE C.1  
COMMANDER 500/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM  
SPARE  
82  
LN-7  
WIRE  
FEEDER  
81  
42  
41  
31  
32  
2
31  
32  
2
14 PIN  
AMPHENOL  
4
4
+
–
21  
GND  
21  
GND  
K291 OR K404  
INPUT CABLE  
K867 UNIVERSAL  
ADAPTER PLUG  
GREEN  
75  
76  
77  
75  
76  
77  
TO WORK  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
K775 OPTIONAL  
REMOTE CONTROL  
COMMANDER 500  
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C-5  
C-5  
ACCESSORIES  
CONNECTION OF THE LN-7 TO THE  
COMMANDER 500 USING K584 OR  
K594 INPUT CABLE ASSEMBLY  
(SEE FIGURE C.2.)  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control cir-  
cuits may be damaged. The engine governor setting is  
preset at the factory—do not adjust above RPM speci-  
fications listed in this manual.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-7 to the  
“+” terminal of the welder. Connect the work cable  
to the “-” terminal of the welder.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
6. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
NOTE: Figure C.2 shows the electrode connected for  
positive polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Commander 500 output terminals.  
7. Set the OUTPUT RANGE switch toWIRE WELD-  
ING CV.  
7. Set the WELDING TERMINALS switch to WELD-  
ING TERMINALS REMOTELY CONTROLLED.  
3. Connect the K584-XX or K594-XX Input Cable  
Assembly to the LN-7.  
9. Adjust wire feed speed at the LN-7.  
4. Connect the K584-XX or 594-XX input cable  
assembly to the 14-pin amphenol on the  
Commander 500.  
10. Adjust the ARC CONTROL to the desired level  
(“soft” or “crisp”).  
5. Place the IDLER switch in the HIGH position.  
NOTE: For remote control, a K857 or K857-1 remote  
control is required. Connect it to the 6-pin amphenol.  
FIGURE C.2  
COMMANDER 500/LN-7 WITH K584 OR K594 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM  
TO LN-7 INPUT  
CABLE PLUG  
6 PIN  
AMPHENOL  
K584 OR K594 CONTROL CABLE  
OPTIONAL K857  
REMOTE CONTROL  
14 PIN  
AMPHENOL  
+
–
TO WORK  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
COMMANDER 500  
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C-6  
C-6  
ACCESSORIES  
CONNECTION OF THE LN-8 TO THE  
COMMANDER 500 USING K867  
CAUTION  
UNIVERSAL ADAPTER (SEE FIGURE C.3.)  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory—do not adjust above RPM  
specifications listed in this manual.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-8 to the  
“+” terminal of the welder. Connect the work cable  
to the “-” terminal of the welder.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
6. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
NOTE: Figure C.3 shows the electrode connected for  
positive polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Commander 500 output terminals.  
7. Set the OUTPUT RANGE switch to WIRE WELD-  
ING CV.  
3. Connect the K867 Universal Adapter to the K196  
input cable and the 14-pin amphenol of the  
Commander 300 as indicated in Figure C.3. Make  
the proper connections for local or remote control  
according to Figure C.3.  
8
Set the WELDING TERMINALS switch to WELD-  
ING TERMINALS REMOTELY CONTROLLED.  
9. Adjust wire feed speed and voltage at the LN-8.  
10. Adjust the ARC CONTROL to the desired level  
(“soft” or “crisp”).  
4. Connect the K196 input cable to the LN-8.  
5. Place the IDLER switch in the HIGH position.  
FIGURE C.3  
COMMANDER 500/LN-8 WITH K867 ADAPTER CONNECTION DIAGRAM  
SPARE  
82  
LN-8  
WIRE  
81  
FEEDER  
42  
41  
31  
32  
2
31  
32  
2
14 PIN  
AMPHENOL  
4
4
ELECTRODE  
TO WORK  
21  
GND  
21  
GND  
K196  
INPUT CABLE  
K867 UNIVERSAL  
ADAPTER PLUG  
75  
76  
77  
A
TO WORK  
B
C
ELECTRODE CABLE  
TO WIRE FEED UNIT  
COMMANDER 500  
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C-7  
C-7  
ACCESSORIES  
CONNECTION OF THE LN-8 TO THE  
COMMANDER 500 USING K595 INPUT  
CABLE ASSEMBLY (SEE FIGURE C.4.)  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory—do not adjust above RPM  
specifications listed in this manual.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-8 to the  
“+” terminal of the welder. Connect the work  
cable to the “-” terminal of the welder.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
NOTE: Figure C.4 shows the electrode connected for  
positive polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Commander 500 output terminals.  
6. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
7. Set the OUTPUT RANGE switch to WIRE WELD-  
ING CV.  
3. Connect the K595-XX Input Cable Assembly to the  
LN-8.  
8. Set the WELDING TERMINALS switch to WELD-  
ING TERMINALS REMOTELY CONTROLLED.  
4. Connect the K595-XX to the 14-pin amphenol on  
the Commander 500.  
9. Adjust wire feed speed and voltage at the LN-8.  
10. Adjust the ARC CONTROL to the desired level  
(“soft” or “crisp”).  
5. Place the IDLER switch in the HIGH position.  
FIGURE C.4  
COMMANDER 500/LN-8 WITH K595 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM  
TO LN-8 INPUT  
CABLE PLUG  
K595 INPUT CABLE ASSEMBLY  
14 PIN  
AMPHENOL  
+
–
TO WORK  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
COMMANDER 500  
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C-8  
C-8  
ACCESSORIES  
CONNECTION OF THE LN-23P TO THE  
COMMANDER 500 USING K350-1  
ADAPTER (SEE FIGURE C.5.)  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set  
ting is preset at the factory—do not adjust above RPM  
specifications listed in this manual.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-23P to  
the “-” terminal of the welder. Connect the work  
cable to the “+” terminal of the welder.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
NOTE: Figure C.5 shows the electrode connected for  
negative polarity.  
5. Set the VOLTMETER switch to negative.  
6. Set the OUTPUT RANGE switch to WIRE WELD-  
ING CV.  
3. Connect the K350-1 adapter to the amphenol on  
the LN-23P and the 14-pin amphenol of the  
Commander 500 as indicated in Figure C.5.  
7. Set the WELDING TERMINALS switch to WELD-  
ING TERMINALS REMOTELY CONTROLLED.  
4. Place the IDLER switch in the HIGH position.  
8. Adjust wire feed speed and voltage at the LN-23P.  
FIGURE C.5  
COMMANDER 500/LN-23P CONNECTION DIAGRAM  
COMMANDER 500 WITH  
115 VAC AUXILIARY  
14 PIN AMPHENOL  
9 CONDUCTOR ADAPTER CABLE  
K350-1  
TO  
ELECTRODE  
WORK  
LN-23P ADAPTER KIT  
FEEDER "A"  
FEEDER "B"  
LN-23P  
LN-23P  
WORK  
WIRE FEEDER "A"  
WIRE FEEDER "B"  
ELECTRODE  
ELECTRODE  
COMMANDER 500  
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C-9  
C-9  
ACCESSORIES  
CONNECTION OF THE LN-25 TO THE  
COMMANDER 500 “ACROSS THE ARC”  
(SEE FIGURE C.6.)  
CAUTION  
If you are using an LN-25 without an internal contactor,  
the electrode will be HOT when the Commander 300 is  
started.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-25 to the  
“-” terminal of the welder. Connect the work cable  
to the “+” terminal of the welder.  
5. Set the OUTPUT RANGE switch to WIRE WELD-  
ING CV.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
6. Set the WELDING TERMINALS switch to WELD-  
ING TERMINALS ALWAYS ON.  
NOTE: Figure C.6 shows the electrode connected for  
negative polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Commander 500 output terminals. Reverse the LN-25  
polarity switch.  
7. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
8. Adjust wire feed speed at the LN-25.  
9. Adjust the ARC CONTROL to the desired level  
(“soft” or “crisp”).  
3. Attach the single lead from the LN-25 to the work  
using the spring clip on the end of the lead. This is  
only a sense lead – it carries no welding current.  
4. Place the IDLER switch in the AUTO position.  
FIGURE C.6  
COMMANDER 500/LN-25 ACROSS THE ARC CONNECTION DIAGRAM  
14 PIN  
AMPHENOL  
6 PIN  
AMPHENOL  
OPTIONAL K444-1  
REMOTE CONTROL  
LN-25  
WIRE FEEDER  
WORK CLIP LEAD  
TO WORK  
ELECTRODE CABLE  
TO WORK  
COMMANDER 500  
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Section D-1  
Section D-1  
TABLE OF CONTENTS  
- MAINTENANCE SECTION -  
Maintenance..........................................................................................................................Section D  
Safety Precautions......................................................................................................................D-2  
Routine and Periodic Maintenance.............................................................................................D-2  
Daily......................................................................................................................................D-2  
Weekly..................................................................................................................................D-2  
Engine Maintenance.............................................................................................................D-2  
Change the Oil...............................................................................................................D-2  
Change the Oil Filter......................................................................................................D-3  
Fuel ................................................................................................................................D-3  
Fuel Filters .....................................................................................................................D-4  
Bleeding the Fuel System..............................................................................................D-6  
Air Filter..........................................................................................................................D-6  
Cooling System..............................................................................................................D-7  
Cooling Blower Belt........................................................................................................D-7  
Engine Maintenance Schedule ......................................................................................D-8  
Engine Maintenance Parts.............................................................................................D-8  
Battery Maintenancce...........................................................................................................D-9  
Cleaning the Battery ......................................................................................................D-9  
Checking Specific Gravity..............................................................................................D-9  
Checking Electrolyte Level.............................................................................................D-9  
Charging the Battery......................................................................................................D-9  
Welder/Generator Maintenance .........................................................................................D-10  
Storage.........................................................................................................................D-10  
Cleaning.......................................................................................................................D-10  
Nameplates..................................................................................................................D-10  
Brush Removal and Replacement...............................................................................D-10  
Bearings.......................................................................................................................D-10  
Receptacles .................................................................................................................D-10  
Cable Connections.......................................................................................................D-10  
Major Component Locations .....................................................................................................D-11  
COMMANDER 500  
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D-2  
D-2  
MAINTENANCE  
SAFETY PRECAUTIONS  
WARNING  
CAUTION  
To prevent the engine from accidentally starting, dis-  
connect the negative battery cable before servicing the  
engine.  
• Have qualified personnel do all maintenance and  
troubleshooting work.  
• Turn the engine off before working inside the  
machine.  
See Table D.1 for a summary of maintenance intervals  
for the items listed below. Follow either the hourly or  
the calendar intervals, whichever come first. More fre-  
quent service may be required, depending on your spe-  
cific application and operating conditions.  
• Remove covers or guards only when necessary to  
perform maintenance and replace them when the  
maintenance requiring their removal is complete.  
• If covers or guards are missing from the machine, get  
replacements from a Lincoln Distributor.  
OIL: Check the oil level after every 8 hours of operation  
or daily. BE SURE TO MAINTAIN THE OIL LEVEL.  
Change the oil the first time between 25 and 50 hours  
of operation. Then, under normal operating conditions,  
change the oil as specified in Table D.1. If the engine  
is operated under heavy load or in high ambient tem-  
peratures, change the oil more frequently.  
Read the Safety Precautions in the front of this manu-  
al and in the instruction manual for the diesel engine  
used with your machine before working on the  
Commander 500.  
Keep all equipment safety guards, covers, and devices  
in position and in good repair. Keep your hands, hair,  
clothing, and tools away from the fans, and all other  
moving parts when starting, operating, or repairing this  
machine.  
CHANGE THE OIL: Change the oil, while the engine  
is still warm, as follows:  
1 . Drain the oil from the drain plug located on the  
engine bottom, as shown in Figure D.1. Examine  
the washer and replace it if it appears damaged.  
ROUTINE AND PERIODIC  
MAINTENANCE  
2. Replace the plug and washer and tighten firmly.  
3. Remove the oil fill cap and add oil until the level  
reaches the “MAX” mark on the dipstick. See  
Figure D.1. Use high quality oil viscosity grade  
10W40. Consult the engine manual for oil specifi-  
cations for various ambient temperatures. Always  
check the level with the dipstick before adding  
more oil.  
ENGINE MAINTENANCE  
DAILY  
a. Check the crankcase oil level.  
b. Refill the fuel tank to minimize moisture condensa-  
tion in the tank.  
4. Reinstall the oil fill cap and the dipstick.  
c. Open the water drain valve located on the bottom  
of the water separator element one or two turns  
and allow to drain into a container suitable for  
diesel fuel for two to three seconds. Repeat the  
above drainage procedure until diesel fuel is  
detected in the container.  
WEEKLY  
Blow out the machine with low pressure air periodical-  
ly. In particularly dirty locations, this may be required  
once a week.  
COMMANDER 500  
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D-3  
D-3  
MAINTENANCE  
FIGURE D.1 – OIL DRAIN AND REFILL  
MAX  
MIN  
OIL FILL CAP  
OIL FILTER  
DIPSTICK  
DRAIN PLUG  
CHANGE THE OIL FILTER: Change the oil filter the  
first time between 25 and 50 hours of operation. Then,  
under normal operating conditions, change the oil filter  
after every 250 hours of operation. If the engine is  
operated under heavy load or in high ambient tem-  
peratures, change the oil filter more frequently. See  
Table D.1 for recommended maintenance intervals.  
See Table D.2 for replacement oil filters.  
5. Refill the engine with the proper amount and type  
of oil as described in the Change the Oil section,  
above. Start the engine and check for leaks  
around the filter element. Correct any leaks (usu-  
ally by retightening the filter, but only enough to  
stop leaks) before placing the Commander 500  
back in service.  
6. If there are no leaks, stop the engine and recheck  
the oil level. If necessary, add oil to bring the level  
up to the “MAX” mark, but do not overfill. See  
Figure D.1.  
Change the oil filter as follows:  
1. Remove the oil drain plug. Drain the oil from the  
engine and allow the oil filter to drain. See Figure  
D.1.  
FUEL: At the end of each day's use, refill the fuel tank  
to minimize moisture condensation and dirt contamina-  
tion in the fuel line. Do not overfill; leave room for the  
fuel to expand.  
2. Remove the old filter (spin it off) and discard it.  
Wipe off the filter mounting surface and adapter.  
See Figure D.1.  
Refer to your engine operation manual for recom-  
mended grade of fuel.  
3. Fill the new filter with fresh engine oil. Apply a thin  
coat of new oil to the rubber gasket on the new oil  
filter.  
4. Spin the new filter onto the mounting adapter finger  
tight until the gasket is evenly seated. Then turn it  
down another 1/2 turn. Do not overtighten the new  
filter.  
COMMANDER 500  
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D-4  
D-4  
MAINTENANCE  
FUEL FILTERS:  
7. Re-insert the large white volume plug into the  
upper cavity.  
WARNING  
8. Place the O-ring onto the angled seal surface of  
the filter header and re-install the plastic cap. Make  
sure its flange rests on the O-ring.  
When working on the fuel system:  
• Keep naked lights away, do not smoke !  
• Do not spill fuel !  
9. Screw on the cap ring and tighten hand tight.  
10. Remember to open the fuel shutoff valve (Lever in  
line with the hose) before starting the engine.  
The Commander 500 is equipped with a Fuel Pre-  
Filter/Water Separator Assembly located before the  
lift pump and a Secondary Fuel Filter located after the  
lift pump and before the fuel injectors. The Fuel Pre-  
Filter/Water Separator is mounted to the engine block  
just below the lift pump (Figure D.2). The Secondary  
Fuel Filter is mounted directly to the engine just above  
the oil filter (Figure D.3).  
Water Separator Element: The water separator ele-  
ment is a two-stage filter with a special filtration/water  
separating media. An expanded water reservoir pro-  
vides maximum protection against water in the fuel.  
The recommended change interval for the water sepa-  
rator element is 1,000 hours. See Figure D.2 and follow  
this procedure.  
1. Close the fuel shutoff valve located on the side of  
the Fuel Pre-Filter/Water Separator Assembly. The  
lever should be perpendicular to the hose.  
Fuel Pre-Filter/Water Separator Assembly: The pre-  
filter is a 150 micron screen designed to protect against  
gross fuel contamination of the water separator ele-  
ment and the Secondary Fuel Filter. If the pre-filter  
becomes plugged, it may be removed, inspected,  
cleaned and reinstalled. In general this only needs to  
be done with each water separator element change  
(about every 1,000 hrs). However, if at any time exces-  
sive fuel contamination is suspected or a sudden fall-  
off in engine performance is detected the pre-filter  
screen should be inspected and cleaned. See Figure  
D.2 and follow this procedure:  
2. Rotate the quick change ring (located just below fil-  
ter header) clockwise approximately 1/2 turn and  
slide it down and off the element.  
3. Grasp the element and pull down with a slight rock-  
ing motion to remove the element from the grommet  
post on the bottom of the filter header.  
FIGURE D.2 – FUEL PRE-FILTER/WATER  
SEPARATOR ASSEMBLY  
1. Close the fuel shutoff valve located on the side of  
the Fuel Pre-Filter/Water Separator Assembly. The  
lever should be perpendicular to the hose  
2. Unscrew the cap ring located on the top of the filter  
header and remove the plastic center cap and O-  
ring.  
3. Remove the large white volume plug located direct-  
ly under the center cap in the upper cavity of the fil-  
ter header. Use a small screwdriver (or similar  
device) to lift the plug part way out of the cavity to  
assist with its removal.  
NOTE: Be careful not to damage the pre-filter screen  
with the tool used to remove the plug.  
4. Using a pair of pliers, gently tug on the pull tabs of  
the pre-filter screen in an alternating pattern to  
gradually remove the pre-filter screen.  
5. Brush off any debris and rinse in diesel fuel.  
6. Re-install the pre-filter screen into the upper cavity of  
the filter header making sure the four pull tabs are  
pointing up. Putting your fingers on the pull tabs,  
push down evenly until the lower body of the pre-fil-  
ter screen contacts the floor of the upper cavity.  
FUEL  
SHUTOFF  
VALVE  
FILTER  
HEADER  
QUICK  
CHANGE  
RING  
CAP  
RING  
COMMANDER 500  
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D-5  
D-5  
MAINTENANCE  
4. Slide the new element onto the grommet post on  
the bottom of the filter header until the element no  
longer easily moves up into the filter header. Now  
rotate the element (it may take almost 1 full turn)  
with a slight upward pressure until the element  
begins to further engage the header. With the prop-  
er orientation now established, apply additional  
pressure to seat the element in the filter header.  
You should feel the element “pop” into place when  
properly seated.  
5. Slide the quick change ring up over the element and  
rotate counter clockwise until an audible click or  
pop is heard. If you do not hear the click, you have  
not rotated the ring far enough and the element is  
not in the locked position. Another indication that  
the ring is in the locked position is that one set (it  
doesn’t matter which one) of arrows located on the  
outside of the ring should be located directly under  
the air vent valve.  
6 . Open the fuel shutoff valve (lever in line with the  
hose).  
NOTE: The element will only go on one way. Never use  
excessive force when mounting the element to the  
header.  
7 . Open the air vent valve on the front of the filter  
header until fuel emerges free of air bubbles. Then  
close the air vent valve.  
Secondary Fuel Filter: The Secondary Fuel Filter is a  
spin-on cartridge type mounted directly to the engine.  
Consult your engine Operator’s Manual for complete  
information on service intervals and element changing  
procedures.  
FIGURE D.3 – SECONDARY FUEL FILTER  
SECONDARY  
FUEL FILTER  
OIL  
FILTER  
COMMANDER 500  
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D-6  
D-6  
MAINTENANCE  
BLEEDING THE FUEL SYSTEM: In the event the  
engine is operated until it runs out of fuel, you will need  
to bleed the fuel system in order to start the engine.  
Refer to the engine operation manual.  
3. Remove loose dirt from the element with com-  
pressed air or a water hose directed from inside out.  
Compressed Air:  
100 psi maximum with nozzles  
at least one inch away from  
the element.  
AIR FILTER:  
Water Hose: 40 psi maximum without nozzle.  
4. Soak the element in a mild detergent solution for 15  
minutes. Do not soak more than 24 hours. Swish  
the element around in the solution to help remove  
dirt.  
CAUTION  
Excessive air filter restriction will result in reduced  
engine life.  
5. Rinse elements from inside out with a gentle stream  
of water (less than 40 psi) to remove all suds and  
dirt.  
The air filter element is a dry cartridge type. It can be  
cleaned and reused. However, damaged elements  
should not be reused. Stop engine after 100 hours of  
running time and clean filter element. Replace the fil-  
ter if necessary. Service the air cleaner regularly  
according to your engine operation manual.  
6. Dry the element before reuse with warm air at less  
than 160°F (71°C). Do not use a light bulb to dry  
the element.  
7. Inspect for holes and tears by looking through the  
element toward a bright light. Check for damaged  
gaskets or dented metal parts. Do not reuse dam-  
aged elements. Protect the element from dust and  
damage during drying and storage.  
1. Locate the air filter canister located behind the  
engine door on the top of the engine.  
2. Remove the air filter element.  
8. Reinstall the air filter element.  
After six cleanings, replace the air filter. A cleaned  
filter will have approximately 70% of the life of a  
new filter element. A restricted filter element may  
not appear excessively dirty.  
COMMANDER 500  
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D-7  
D-7  
MAINTENANCE  
COOLING SYSTEM: The cooling system of the Deutz  
engine needs to be checked and cleaned periodically.  
Consult the engine Operation Manual for the proper  
frequency and procedure.  
8. Remove the old cooling blower belt and install a  
new one.  
9. Push outward on the alternator (4) and adjust the  
cold belt tension to 63-73 lbs. (10-15 mm maxi-  
mum deflection) midway between any two pulleys.  
Tighten bolts (1), (2), (3).  
COOLING BLOWER BELT: The following procedure  
should be followed to replace the cooling blower belt:  
1. Allow the machine to cool.  
10. Reinstall the air cleaner hose, engine case side,  
and engine end panel. Reattach the negative bat-  
tery cable. Slide in and refasten the battery holder.  
2. Unfasten and slide the battery holder out from the  
welder.  
11. Check the cooling blower belt tension after 100  
hours of operation. (Follow seps 1-6; 9 and 10.)  
3. Disconnect the negative battery cable.  
4. Remove the engine case side.  
5. Loosen the air cleaner hose clamp and detach the  
hose.  
6. Remove the engine end panel with air box and air  
cleaner attached for access to the engine.  
7. See Figure D.4. Loosen the alternator mounting  
bolts (1, 2, 3) and rotate the alternator toward the  
engine.  
FIGURE D.4 – COOLING BLOWER BELT REPLACEMENT AND ADJUSTING  
1
2
4
3
COMMANDER 500  
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D-8  
D-8  
MAINTENANCE  
TABLE D.1  
DEUTZ ENGINE MAINTENANCE SCHEDULE  
FREQUENCY  
MAINTENANCE REQUIRED  
Daily or Before  
Starting Engine  
• Fill fuel tank.  
• Check oil level.  
• Check air cleaner for dirty, loose, or damaged parts. Replace if necessary.  
• Check air intake and cooling areas, clean as necessary.  
1First 50 Hours  
and Every 250  
• Change engine oil.  
• Change oil filter.  
Hours Thereafter • Change fuel filter.  
• Check fan belt.  
Every 50 Hours  
• Check fuel lines and clamps.  
Every 100 Hours • Check battery electrolyte level and connections.  
• Clean air filter.  
Refer to your Deutz engine operation manual for periodic maintenance at 100 hours and beyond.  
1125 Hours for severe conditions.  
TABLE D.2  
ENGINE MAINTENANCE PARTS  
ITEM  
MANUFACTURER  
PART NUMBER  
Air Cleaner Element  
Donaldson  
AC  
P181052  
A302C  
Cooling Blower Belt  
Oil Filter Element  
Lincoln  
Gates  
T13536-3  
7585  
Deutz  
Purolator  
Napa  
1174418  
PER2168  
1820  
Fram  
PH3776  
Fuel Filter Element  
Deutz  
Purolator  
Napa  
1174423  
PC42  
3358  
Fram  
P4102  
Water Separator Element  
Fuel Pre-Filter Screen  
Battery  
Lincoln  
Stanadyne  
M16890-C  
31572  
Lincoln  
Stanadyne  
M16890-B  
29575  
BCI  
Group  
34  
COMMANDER 500  
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D-9  
D-9  
MAINTENANCE  
CHECKING SPECIFIC GRAVITY: Check each battery  
cell with a hydrometer. A fully charged battery will have  
a specific gravity of 1.260. Charge the battery if the  
reading is below 1.215.  
BATTERY MAINTENANCE  
WARNING  
NOTE: Correct the specific gravity reading by adding  
four gravity points (0.004) for every five degrees the  
electrolyte temperature is above 80 degrees F (27  
degrees (C). Subtract four gravity points (.004) for  
every five degrees the electrolyte temperature is below  
80 degrees F (27 degrees C).  
GASES FROM BATTERY can explode.  
• Keep sparks, flame, and cigarettes  
away from battery.  
BATTERY ACID can burn eyes and skin.  
• Wear gloves and eye protection and be  
careful when working near a battery.  
Follow the instructions printed on the  
battery.  
CHECKING ELECTROLYTE LEVEL: If battery cells  
are low, fill them to the neck of the filler hole with dis-  
tilled water and recharge. If one cell is low, check for  
leaks.  
To prevent EXPLOSION when:  
• INSTALLING A NEW BATTERY - Disconnect the  
negative cable from the old battery first and connect  
to the new battery last.  
CHARGING THE BATTERY: The Commander 500 is  
equipped with a wet charged battery. The charging  
current is automatically regulated when the battery is  
low (after starting the engine) to a trickle current when  
the battery is fully charged.  
• THE CORRECT POLARITY IS NEGATIVE  
GROUND - Damage to the engine alternator and the  
printed circuit board can result from incorrect con-  
nection.  
When you charge, jump, replace, or otherwise connect  
battery cables to the battery, be sure the polarity is cor-  
rect. Improper polarity can damage the charging cir-  
cuit. The Commander 500 charging system is NEG-  
ATIVE GROUND. The positive (+) battery terminal has  
a red terminal cover.  
• CONNECTING A BATTERY CHARGER  
- Remove the battery from the welder by  
disconnecting the negative cable first,  
then the positive cable and battery  
clamp. When reinstalling, connect the  
negative cable last. Keep the area well  
ventilated.  
If you need to charge the battery with an external  
charger, disconnect the negative cable first, then the  
positive cable before you attach the charger leads.  
After the battery is charged, reconnect the positive bat-  
tery cable first and the negative cable last. Failure to  
do so can result in damage to the internal charger com-  
ponents.  
• USING A BOOSTER - Connect the positive lead to  
the battery first, then connect the negative lead to the  
engine foot.  
• To prevent BATTERY BUCKLING, tighten the nuts  
on the battery clamp until snug.  
Follow the instructions of the battery charger manufac-  
turer for proper charger settings and charging time.  
CLEANING THE BATTERY: Keep the battery clean  
by wiping it with a damp cloth when dirty. If the termi-  
nals appear corroded, disconnect the battery cables  
and wash the terminals with an ammonia solution or a  
solution of 1/4 pound (0.113 kg) of baking soda and 1  
quart (0.946 l) of water. Be sure the battery vent plugs  
(if equipped) are tight so that none of the solution  
enters the cells.  
After cleaning, flush the outside of the battery, the bat-  
tery compartment, and surrounding areas with clear  
water. Coat the battery terminals lightly with petroleum  
jelly or a non-conductive grease to retard corrosion.  
Keep the battery clean and dry. Moisture accumulation  
on the battery can lead to more rapid discharge and  
early battery failure.  
COMMANDER 500  
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D-10  
D-10  
MAINTENANCE  
BEARINGS: The Commander 500 is equipped with  
double-shielded ball bearings having sufficient grease  
to last indefinitely under normal service. Where the  
welder is used constantly or in excessively dirty loca-  
tions, it may be necessary to add one half ounce of  
grease per year. A pad of grease one inch wide, one  
inch long, and one inch high weighs approximately one  
half ounce. Over-greasing is far worse than insufficient  
greasing.  
WELDER/GENERATOR  
MAINTENANCE  
STORAGE: Store the Commander 500 in clean, dry,  
protected areas.  
CLEANING: Blow out the generator and controls peri-  
odically with low pressure air. Do this at least once a  
week in particularly dirty areas.  
NAMEPLATES: Whenever routine maintenance is  
performed on this machine - or at least yearly - inspect  
all nameplates and labels for legibility. Replace those  
which are no longer clear. Refer to the parts list for the  
replacement item number.  
When greasing the bearings, keep all dirt out of the  
area. Wipe the fittings completely clean and use clean  
equipment. More bearing failures are caused by dirt  
introduced during greasing than from insufficient  
grease.  
BRUSH REMOVAL AND REPLACEMENT: It is normal  
for the brushes and slip rings to wear and darken slight-  
ly. Inspect the brushes when a generator overhaul is  
necessary.  
RECEPTACLES: Keep the electrical receptacles in  
good condition. Remove any dirt, oil, or other debris  
from their surfaces and holes.  
CABLE CONNECTIONS: Check the welding cable  
connections at the weld output terminals often. Be  
sure that the connections are always tight.  
WARNING  
Do not attempt to polish slip rings while the engine is  
running.  
COMMANDER 500  
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D-11  
D-11  
MAINTENANCE  
FIGURE D.5 – MAJOR COMPONENT LOCATIONS  
12  
1
2
3
11  
10  
4
5
9
7
8
6
1. CASE DOOR ASSEMBLY  
2. ENGINE  
7. FRONT PANEL ASSEMBLY WITH OUTPUT PANEL  
8. CONTROL PANEL  
3. SHUT DOWN SOLENOID  
4. IDLER SOLENOID  
5. REAR PANEL ASSEMBLY  
6. BASE  
9. OUTPUT RECTIFIER BRIDGE ASSEMBLY  
10. FUEL TANK  
11. ROTOR/STATOR  
12. CASE TOP AND SIDES  
COMMANDER 500  
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Section E-1  
Section E-1  
TABLE OF CONTENTS  
- THEORY OF OPERATION SECTION -  
General Description .......................................................................................................................E-2  
Battery, Starter, Engine, Rotor, Stator, Pull Coil Board and Peripheral  
Board – Engine Protection .....................................................................................................E-2  
Weld Windings, Rectifier, Power Modules and Feedback ..........................................................E-3  
Analog Power Supply Board and Weld Control Board ...............................................................E-4  
Insulated Gate Bipolar Transistor (IGBT) Operation...................................................................E-5  
Pulse Width Modulation ..............................................................................................................E-6  
Chopper Technology Fundamentals ...........................................................................................E-7  
FIGURE E.1 – MULTI-WELD 500 BLOCK LOGIC DIAGRAM  
WORK  
THREE-PHASE  
RECTIFIER  
TERMINAL  
__  
COMMANDER 500  
TO WELD  
CONTROL  
BOARD  
POWER MODULES  
(2)  
(2)  
(2)  
ELECTRODE  
TERMINAL  
+
IGBT  
80 VDC  
CHOKE  
+
SHUNT  
F
E
E
D
B
A
W
I
D
N
D
L
(2)  
20 VDC  
PWM  
SIGNALS (2)  
E
W
I
ANALOG  
POWER SUPPLY  
BOARD  
N
G
C
K
WELD  
CONTROL  
BOARD  
TO  
MECHANICAL  
ROTATION  
IDLE  
HOLD  
COIL  
ENGINE  
ROTOR  
VOLTMETER  
AMMETER  
STARTER  
SLIP  
RINGS  
ALTERNATOR  
ARC  
OUTPUT  
PROCESS/RANGE  
THERMAL  
LIGHT  
CONTROL SELECTOR  
CONTROL  
RUN/STOP  
SWITCH  
STATOR  
ENGINE  
SENSORS  
42 VAC TO 14 PIN AMPHENOL  
FOR WIRE FEEDER  
S
BATTERY  
BOARD  
H
U
AUXILIARY  
WINDINGS  
I
D
L
E
R
1/2  
BATTERY  
BD  
T
D
O
W
N
120  
VDC  
10  
VDC  
1
2
0
240VAC  
RECEPTACLE  
BATTERY  
V
A
C
SOL  
PULL  
COIL  
BOARD  
TO WELD  
CONTROL  
BOARD  
SOL  
10  
VDC  
120VAC  
RECEPTACLES (2)  
PERIPHERAL  
BOARD  
COMMANDER 500  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2 - BATTERY, ENGINE, ROTOR, STATOR, PULL COIL BOARD  
AND PERIPHERAL BOARD – ENGINE PROTECTION  
WORK  
THREE-PHASE  
RECTIFIER  
TERMINAL  
__  
COMMANDER 500  
TO WELD  
CONTROL  
BOARD  
POWER MODULES  
(2)  
(2)  
(2)  
ELECTRODE  
TERMINAL  
+
IGBT  
80 VDC  
CHOKE  
+
SHUNT  
F
W
I
E
E
D
B
A
C
K
D
N
D
L
(2)  
20 VDC  
PWM  
SIGNALS (2)  
E
W
I
ANALOG  
POWER SUPPLY  
BOARD  
N
G
WELD  
CONTROL  
BOARD  
TO  
MECHANICAL  
ROTATION  
IDLE  
HOLD  
COIL  
ENGINE  
ROTOR  
VOLTMETER  
AMMETER  
STARTER  
SLIP  
RINGS  
ALTERNATOR  
ARC  
OUTPUT  
PROCESS/RANGE  
THERMAL  
LIGHT  
CONTROL SELECTOR  
CONTROL  
RUN/STOP  
SWITCH  
STATOR  
ENGINE  
SENSORS  
42 VAC TO 14 PIN AMPHENOL  
FOR WIRE FEEDER  
S
BATTERY  
BOARD  
H
U
AUXILIARY  
WINDINGS  
I
D
L
E
R
1/2  
BATTERY  
BD  
T
D
O
W
N
120  
VDC  
10  
VDC  
1
2
0
240VAC  
RECEPTACLE  
BATTERY  
V
A
C
SOL  
PULL  
COIL  
BOARD  
TO WELD  
CONTROL  
BOARD  
SOL  
10  
VDC  
120VAC  
RECEPTACLES (2)  
PERIPHERAL  
BOARD  
GENERAL DESCRIPTION  
The Commander 500 is a diesel engine-driven welding  
power source capable of producing 500 amps at  
40VDC at a 100% duty cycle. The engine is coupled to  
a brush-type alternating current generator. This AC  
output is rectified and controlled by Chopper  
Technology to produce DC current for multi-purpose  
welding applications. The Commander 500 is also  
capable of producing 12,000 watts of AC auxiliary  
power at 100% duty cycle.  
battery voltage is fed through the Battery PC board to  
the rotor field coil via a brush and slip ring configura-  
tion. This excitation or "flashing" voltage magnetizes  
the rotor lamination. This rotating magnet induces a  
voltage in the stationary windings of the main alterna-  
tor stator. The stator houses a three-phase weld wind-  
ing, a 120/240VAC single-phase auxiliary winding, and  
a 42VAC wire feeder power winding.  
The engine alternator supplies charging current for the  
battery circuit. The Peripheral board monitors the  
engine sensors and will shut the engine off in the event  
of low oil pressure, engine over temperature, malfunc-  
tion of the engine’s alternator system or a low fuel con-  
dition. The idler solenoid is mechanically connected to  
the engine’s throttle linkage. If no welding or auxiliary  
current is being drawn from the Commander 500, the  
Pull Coil board activates the idler solenoid, which then  
brings the engine to a low idle state. When output cur-  
rent is sensed, either weld or auxiliary, the Weld  
Control PC board deactivates the idler solenoid, and  
the engine returns to high RPM.  
BATTERY, ENGINE, ROTOR,  
STATOR, PULL COIL BOARD AND  
PERIPHERAL BOARD – ENGINE  
PROTECTION  
The 12VDC battery powers the engine starter motor  
and also supplies power to the Battery PC board, Pull  
Coil PC board, Peripheral PC board and associated  
circuitry. When the engine, which is mechanically cou-  
pled to the rotor, is started and running, the 12 VDC  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
COMMANDER 500  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.3 - WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK  
WORK  
THREE-PHASE  
RECTIFIER  
TERMINAL  
__  
COMMANDER 500  
TO WELD  
CONTROL  
BOARD  
POWER MODULES  
(2)  
(2)  
(2)  
ELECTRODE  
TERMINAL  
+
IGBT  
80 VDC  
CHOKE  
+
SHUNT  
F
W
I
E
E
D
B
A
C
K
D
N
D
L
(2)  
20 VDC  
PWM  
SIGNALS (2)  
E
W
I
ANALOG  
POWER SUPPLY  
BOARD  
N
G
WELD  
CONTROL  
BOARD  
TO  
MECHANICAL  
ROTATION  
IDLE  
HOLD  
COIL  
ENGINE  
ROTOR  
VOLTMETER  
AMMETER  
STARTER  
SLIP  
RINGS  
ALTERNATOR  
ARC  
OUTPUT  
PROCESS/RANGE  
THERMAL  
LIGHT  
CONTROL SELECTOR  
CONTROL  
RUN/STOP  
SWITCH  
STATOR  
ENGINE  
SENSORS  
42 VAC TO 14 PIN AMPHENOL  
FOR WIRE FEEDER  
S
BATTERY  
BOARD  
H
U
AUXILIARY  
WINDINGS  
I
D
L
E
R
1/2  
BATTERY  
BD  
T
D
O
W
N
120  
VDC  
10  
VDC  
1
2
0
240VAC  
RECEPTACLE  
BATTERY  
V
A
C
SOL  
PULL  
COIL  
BOARD  
TO WELD  
CONTROL  
BOARD  
SOL  
10  
VDC  
120VAC  
RECEPTACLES (2)  
PERIPHERAL  
BOARD  
WELD WINDINGS, RECTIFIER,  
POWER MODULES AND  
FEEDBACK  
"chopped" DC output is applied through choke coils  
The three-phase stator weld windings are connected to  
a three-phase rectifier bridge. The resultant DC volt-  
age is applied to four paralleled capacitors incorporat-  
ed within each of the two power modules. There are  
two capacitors in each module. These capacitors func-  
tion as filters and also as power supplies for the IGBTs.  
See IGBT Operation in this section. The IGBTs act as  
high-speed switches operating at 20KHZ. These  
devices are switched on and off by the Weld Control  
PC board through pulse width modulation circuitry.  
See Pulse Width Modulation in this section. This  
and a shunt to the welding output terminals. The choke  
functions as a current filter, and it helps to balance the  
outputs of the two power modules. Free-wheeling  
diodes are incorporated in the power modules to pro-  
vide a current path for the stored energy in the choke  
when the IGBTs are turned off. See Chopper  
Technology in this section.  
Output voltage and current feedback information is fed  
to the Weld Control PC board. This information is  
sensed from the output terminal circuits and the shunt.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
COMMANDER 500  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E-4 – ANALOG CONTROL POWER SUPPLY BOARD AND WELD CONTROL BOARD  
WORK  
THREE-PHASE  
RECTIFIER  
TERMINAL  
__  
COMMANDER 500  
TO WELD  
CONTROL  
BOARD  
POWER MODULES  
(2)  
(2)  
(2)  
ELECTRODE  
TERMINAL  
+
IGBT  
80 VDC  
CHOKE  
+
SHUNT  
F
W
I
E
E
D
B
A
C
K
D
N
D
L
(2)  
20 VDC  
PWM  
SIGNALS (2)  
E
W
I
ANALOG  
POWER SUPPLY  
BOARD  
N
G
WELD  
CONTROL  
BOARD  
TO  
MECHANICAL  
ROTATION  
IDLE  
HOLD  
COIL  
ENGINE  
ROTOR  
VOLTMETER  
AMMETER  
STARTER  
SLIP  
RINGS  
ALTERNATOR  
ARC  
OUTPUT  
PROCESS/RANGE  
THERMAL  
LIGHT  
CONTROL SELECTOR  
CONTROL  
RUN/STOP  
SWITCH  
STATOR  
ENGINE  
SENSORS  
42 VAC TO 14 PIN AMPHENOL  
FOR WIRE FEEDER  
S
BATTERY  
BOARD  
H
U
AUXILIARY  
WINDINGS  
I
D
L
E
R
1/2  
BATTERY  
BD  
T
D
O
W
N
120  
VDC  
10  
VDC  
1
2
0
240VAC  
RECEPTACLE  
BATTERY  
V
A
C
SOL  
PULL  
COIL  
BOARD  
TO WELD  
CONTROL  
BOARD  
SOL  
10  
VDC  
120VAC  
RECEPTACLES (2)  
PERIPHERAL  
BOARD  
ANALOG CONTROL POWER  
SUPPLY BOARD AND WELD  
CONTROL BOARD  
and output terminal circuits. The circuitry on the Weld  
Control PC board determines how the output should be  
controlled to optimize welding results, and it sends the  
correct PWM signals to the IGBT driver circuits. The  
Weld Control PC board also commands the thermal  
light and the voltmeter and ammeter (some items may  
be optional).  
The Analog Power Supply PC board, which is powered  
by 80 VDC derived from the filter capacitors on the  
Power Modules, supplies various regulated DC volt-  
ages to operate the Weld Control PC board circuitry. It  
also supplies two regulated DC voltages to operate the  
IGBT driver circuitry on the two Power Modules.  
The Weld Control PC board monitors the operator con-  
trols (arc control, output, and process/range selector).  
It compares these commands to the current and volt-  
age feedback information it receives from the shunt  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
COMMANDER 500  
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E-5  
E-5  
THEORY OF OPERATION  
FIGURE E.5 – IGBT OPERATION  
POSITIVE  
VOLTAGE  
APPLIED  
GATE  
GATE  
SOURCE  
SOURCE  
n +  
n +  
n +  
n +  
p
BODY REGION  
p
BODY REGION  
DRAIN DRIFT REGION  
DRAIN DRIFT REGION  
n -  
n -  
n +  
p +  
BUFFER LAYER  
n +  
p +  
BUFFER LAYER  
INJECTING LAYER  
INJECTING LAYER  
DRAIN  
DRAIN  
B. ACTIVE  
A. PASSIVE  
INSULATED GATE BIPOLAR  
TRANSISTOR (IGBT) OPERATION  
An IGBT is a type of transistor. IGBTs are semicon-  
ductors well suited for high frequency switching and  
high current applications.  
Drawing B shows the IGBT in an active mode. When  
the gate signal, a positive DC voltage relative to the  
source, is applied to the gate terminal of the IGBT, it is  
capable of conducting current. A voltage supply con-  
nected to the drain terminal will allow the IGBT to con-  
duct and supply current to circuit components coupled  
to the source. Current will flow through the conducting  
IGBT to downstream components as long as the posi-  
tive gate signal is present. This is similar to turning ON  
a light switch.  
Drawing A shows an IGBT in a passive mode. There is  
no gate signal, zero volts relative to the source, and  
therefore, no current flow. The drain terminal of the  
IGBT may be connected to a voltage supply; but since  
there is no conduction the circuit will not supply current  
to components connected to the source. The circuit is  
turned off like a light switch in the OFF position.  
COMMANDER 500  
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E-6  
E-6  
THEORY OF OPERATION  
FIGURE E.6 – TYPICAL IGBT OUTPUTS  
MINIMUM OUTPUT  
(Dwell or Off Time)  
sec  
sec  
sec  
48  
50  
2
MAXIMUM OUTPUT  
(Dwell or Off Time)  
sec  
sec  
48  
50  
PULSE WIDTH MODULATION  
The term PULSE WIDTH MODULATION is used to  
describe how much time is devoted to conduction in the  
cycle. Changing the pulse width is known as MODU-  
LATION. Pulse Width Modulation (PWM) is the varying  
of the pulse width over the allowed range of a cycle to  
affect the output of the machine.  
The positive portion of the signal represents one IGBT  
group conducting for 2 microsecond. The dwell time (off  
time) is 48 microseconds. Since only 2 microseconds of  
the 50-microsecond time period is devoted to conduct-  
ing, the output power is minimized.  
MAXIMUM OUTPUT  
MINIMUM OUTPUT  
By holding the gate signals on for 48 microseconds and  
allowing only 2 microseconds of dwell time (off time)  
during the 50-microsecond cycle, the output is maxi-  
mized. The darkened area under the top curve can be  
compared to the area under the bottom curve. The  
more darkened area under the curve, the more power  
is present.  
By controlling the duration of the gate signal, the IGBT  
is turned on and off for different durations during a  
cycle. The top drawing shows the minimum output sig-  
nal possible over a 50-microsecond time period.  
COMMANDER 500  
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E-7  
E-7  
THEORY OF OPERATION  
CHOPPER TECHNOLOGY  
FUNDAMENTALS  
The new era of welding machines such as the  
Commander 500, employ a technology whereby a DC  
source is turned on and off (chopped up) at high speed,  
then smoothed through an inductor to control an arc.  
Hence the name “Chopper.” The biggest advantage of  
chopper technology is the high-speed control of the  
arc, similar to the inverter machines. A block diagram  
for this is as follows:  
EXTERNAL DC  
SOURCE  
SOLID STATE  
SWITCH  
INDUCTOR  
ARC  
AND DIODE  
ARC  
CONTROL  
In this system, the engine drives a three-phase alter-  
nator, which generates power that is rectified and  
filtered to produce about 85VDC[?]. The current is  
applied through a solid state switch to an inductor. By  
turning the switch on and off, current in the inductor  
and the arc can be controlled. The following diagram  
depicts the current flow in the system when the switch  
is open and closed.s  
INDUCTOR  
SWITCH  
DIODE  
ARC  
70-80VDC  
CURRENT WITH SWITCH OPEN  
CURRENT WITH SWITCH CLOSED  
When the switch is closed, current is applied through  
the inductor to the arc. When the switch opens, current  
stored in the inductor sustains flow in the arc and  
through the diode. The repetition rate of switch closure  
is 20Khz, which allows ultra-fast control of the arc. By  
varying the ratio of on time versus off time of the switch  
(Duty Cycle), the current applied to the arc is con-  
trolled. This is the basis for Chopper Technology:  
Controlling the switch in such a way as to produce  
superior welding.  
COMMANDER 500  
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Section F-1  
Section F-1  
TABLE OF CONTENTS  
- TROUBLESHOOTING & REPAIR SECTION -  
Troubleshooting & Repair Section......................................................................................Section F  
How to Use Troubleshooting Guide ...........................................................................................F-2  
PC Board Troubleshooting Procedures ......................................................................................F-3  
Troubleshooting Guide ...............................................................................................................F-4  
Engine Starting Diagnostic Chart..............................................................................................F-13  
Start-Up and OCV Diagnostic Chart .........................................................................................F-14  
Test Procedures .......................................................................................................................F-15  
Case Cover Removal and Replacement Procedure...........................................................F-15  
Case Front Knobs - Removal and Replacement Procedure ..............................................F-18  
Power Module Capacitor Discharge Procedure .................................................................F-19  
Idler Solenoid Test ..............................................................................................................F-21  
Shutdown Solenoid Test .....................................................................................................F-23  
Engine Throttle Adj ustment Test.........................................................................................F-25  
Rotor Resistance Test.........................................................................................................F-29  
Flashing and Rotor Voltage Test.........................................................................................F-31  
Stator Voltage Test..............................................................................................................F-34  
Analog Power Supply PC Board Voltage Test....................................................................F-39  
Output Rectifier Bridge Test................................................................................................F-42  
Power Module Test .............................................................................................................F-46  
Charging Circuit Test...........................................................................................................F-50  
Oscilloscope Waveforms ..........................................................................................................F-52  
Normal Open Circuit Voltage Waveform (Stick) .................................................................F-53  
Normal Weld Voltage Waveform (Stick CC) .......................................................................F-54  
Normal Weld Voltage Waveform (Wire CV)........................................................................F-55  
Normal TIG Mode Voltage Waveform.................................................................................F-56  
Normal Open Circuit Voltage Waveform (Wire CV Tap).....................................................F-57  
Replacement Procedures .........................................................................................................F-58  
Shutdown Solenoid Removal and Replacement ................................................................F-58  
Power Module/ Output Rectifier Bridge Assembly Removal and Replacement ..................F-61  
Power Module (Chopper) PC Board/ Diode Module Removal and Replacement...............F-66  
Output Rectifier Bridge Diode Removal and Replacement ................................................F-70  
Stator/ Rotor Removal and Replacement............................................................................F-73  
Retest After Repair ...................................................................................................................F-82  
COMMANDER 500  
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F-2  
F-2  
TROUBLESHOOTING & REPAIR  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and machine  
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please  
observe all safety notes and precautions detailed throughout this manual.  
This Troubleshooting Guide is provided to help  
you locate and repair possible machine malfunc-  
tions. Simply follow the three-step procedure  
listed below.  
Step 3. PERFORM COMPONENT TESTS. The  
last column, labeled “Recommended Course of  
Action” lists the most likely components that may  
have failed in your machine. It also specifies the  
appropriate test procedure to verify that the sub-  
ject component is either good or bad. If there are  
a number of possible components, check the  
components in the order listed to eliminate one  
possibility at a time until you locate the cause of  
your problem.  
Step 1. LOCATE PROBLEM (SYMPTOM). Look  
under the column labeled “PROBLEM” (SYMP-  
TOMS). This column describes possible symp-  
toms that the machine may exhibit. Find the list-  
ing that best describes the symptom that the  
machine is exhibiting. Symptoms are grouped  
into four main categories: Output Problems,  
Function Problems, Engine Problems and  
Welding Problems.  
All of the referenced test procedures referred to in  
the Troubleshooting Guide are described in detail  
at the end of this section.  
Refer to the  
Troubleshooting and Repair Table of Contents to  
locate each specific Test Procedure. All of the  
referred to test points, components, terminal  
strips, etc., can be found on the referenced elec-  
trical wiring diagrams and schematics. Refer to  
the Electrical Diagrams Section Table of Contents  
to locate the appropriate diagram.  
Step 2. PERFORM EXTERNAL TESTS. The  
second column, labeled “POSSIBLE AREAS OF  
MISADJUSTMENT(S)”, lists the obvious external  
possibilities that may contribute to the machine  
symptom. Perform these tests/checks in the  
order listed. In general, these tests can be con-  
ducted without removing the case cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs  
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before  
you proceed. Call 1-800-833-9353.  
COMMANDER 500  
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F-3  
F-3  
TROUBLESHOOTING & REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
WARNING  
• Remove the PC Board from the static-shielding bag  
and place it directly into the equipment. Don’t set the  
PC Board on or near paper, plastic or cloth which  
could have a static charge. If the PC Board can’t be  
installed immediately, put it back in the static-  
shielding bag.  
ELECTRIC SHOCK can kill.  
Have an electrician install and service  
this equipment. Turn the machine OFF  
before working on equipment. Do not  
touch electrically hot parts.  
• If the PC Board uses protective shorting jumpers,  
don’t remove them until installation is complete.  
Sometimes machine failures appear to be due to PC  
board failures. These problems can sometimes be  
traced to poor electrical connections. To avoid prob-  
lems when troubleshooting and replacing PC boards,  
please use the following procedure:  
• If you return a PC Board to The Lincoln Electric  
Company for credit, it must be in the static-shielding  
bag. This will prevent further damage and allow prop-  
er failure analysis.  
4. Test the machine to determine if the failure symp-  
tom has been corrected by the replacement PC  
board.  
1. Determine to the best of your technical ability that  
the PC board is the most likely component causing  
the failure symptom.  
NOTE: Allow the machine to heat up so that all electri-  
cal components can reach their operating temperature.  
2. Check for loose connections at the PC board to  
assure that the PC board is properly connected.  
5. Remove the replacement PC board and substitute  
it with the original PC board to recreate the original  
problem.  
3. If the problem persists, replace the suspect PC  
board using standard practices to avoid static elec-  
trical damage and electrical shock. Read the warn-  
ing inside the static resistant bag and perform the  
following procedures:  
a. If the original problem does not reappear  
by substituting the original board, then the  
PC board was not the problem. Continue  
to look for bad connections in the control  
wiring harness, junction blocks, and termi-  
nal strips.  
PC Board can be damaged by  
static electricity.  
b. If the original problem is recreated by the  
substitution of the original board, then the  
PC board was the problem. Reinstall the  
replacement PC board and test the  
machine.  
• Remove your body’s static charge  
before opening the static-shielding  
bag. Wear an anti-static wrist  
strap. For safety, use a 1 Meg  
ohm resistive cord connected to a  
grounded part of the equipment  
frame.  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
6. Always indicate that this procedure was followed  
when warranty reports are to be submitted.  
• If you don’t have a wrist strap,  
touch an unpainted, grounded,  
part of the equipment frame. Keep  
touching the frame to prevent sta-  
tic build-up. Be sure not to touch  
any electrically live parts at the  
same time.  
NOTE: Following this procedure and writing on the  
warranty report, “INSTALLED AND SWITCHED PC  
BOARDS TO VERIFY PROBLEM,” will help avoid  
denial of legitimate PC board warranty claims.  
Workstations  
Reusable  
Container  
Do Not Destroy  
• Tools which come in contact with the PC Board must  
be either conductive, anti-static or static-dissipative.  
COMMANDER 500  
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F-4  
F-4  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical damage 1. Contact your local Lincoln 1. Contact the Lincoln Electric  
is evident.  
Authorized  
Facility.  
Field  
Service  
Service Department at 1-800-  
833-9353 (WELD)  
No welding output in neither Stick 1. Place the Welding Terminals 1. Check for loose or faulty con-  
or CV modes. The engine operates  
normally. The auxiliary output is  
normal.  
Switch in the "ALWAYS ON"  
position. If the problem is  
solved, the fault may be in the  
external control cable (if used),  
leads #2 and #4. See the  
Wiring Diagram.  
nections on the heavy current  
carrying leads between the out-  
put bridge, the power modules,  
the choke and the output termi-  
nals.  
2. Check the Welding Terminals  
Switch and associated leads.  
See the Wiring Diagram.  
2. With the engine at high idle  
(1900RPM), the machine in the  
Stick mode and the OUTPUT  
CONTROL at maximum, check  
for the presence of approxi-  
mately 87VDC (open circuit volt-  
age) at the output terminals.  
3. Check gate leads #23, #23A,  
#25 and #25A for loose or faulty  
connections. See the Wiring  
Diagram.  
4. Perform the Stator Voltage  
3. If the correct OCV is present at  
the welding output terminals  
Test.  
check the welding cables, 5. Perform the Output Rectifier  
clamps and electrode holder for  
loose or faulty connections.  
Bridge Test.  
6. Perform the Power Module  
Test.  
7. Perform the Analog Power  
Supply PC Board Test.  
8. The Weld Control PC Board  
may be faulty.  
9. See the Start-Up and OCV  
Diagnostic Chart.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 500  
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F-5  
F-5  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No welding output in neither Stick 1. Check the brushes for wear and 1. Perform the Rotor Resistance  
or CV modes. Also no auxiliary  
power. The engine operates nor-  
mally.  
proper contact to the rotor slip  
rings.  
Test.  
2. Perform the Flashing and  
Rotor Voltage Test. If the  
"flashing" voltage is not present  
the Battery PC board or leads  
#201 or #200 may be faulty.  
See the Wiring Diagram. Also  
make sure that lead #5P has  
continuity (zero ohms) to  
ground.  
2. Make sure the engine is operat-  
ing at the correct high idle  
speed (1900RPM).  
3. Check for loose or faulty con-  
nections or leads on the auxil-  
iary power studs in the control  
box. See the Wiring Diagram.  
3. Check the field diode bridge and  
capacitor. Replace if necessary.  
4. Perform the Stator Voltage  
Test.  
5. See the Start-Up and OCV  
Diagnostic Chart.  
No auxiliary power at the recepta- 1. The circuit breakers may be 1. Check the wiring between the  
cles. The welding output is normal  
and the engine operates normally.  
tripped. Reset if necessary.  
auxiliary receptacles, the con-  
nection studs in the control box,  
and the main stator. See the  
Wiring Diagram.  
2. Check for loose or faulty con-  
nections at the auxiliary recep-  
tacles.  
2. Perform the Stator Voltage  
Test.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 500  
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F-6  
F-6  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The machine has welding output 1. If a remote control unit is con- 1. Check the OUTPUT control  
but no control of output. The auxil-  
iary power is normal.  
nected to the machine, check  
the remote control and related  
cable.  
potentiometer and related  
leads. See the Wiring Diagram.  
2. Check the shunt and associated  
feedback leads. See the Wiring  
Diagram.  
2. Check the welding and work  
cables for loose or faulty con-  
nections.  
3. Check the voltage feedback  
leads for loose or faulty connec-  
tions. See the Wiring Diagram.  
4. Perform the Power Module  
Test.  
5. The Weld Control PC board  
may be faulty.  
5. See the Start-Up and OCV  
Diagnostic Chart.  
The machine has low welding out- 1. Check the brushes for wear and 1. If the engine high idle speed is  
put and low auxiliary output.  
proper contact to the slip rings.  
low, perform the Throttle Ad-  
justment Test.  
2. The engine RPM may be low.  
2. Perform the Rotor Resistance  
Test.  
3. Perform the Flashing and  
Rotor Voltage Test. If the rotor  
voltage is low, the field capacitor  
or field bridge may be faulty.  
Test and replace if necessary.  
See the Wiring Diagram.  
4. If the engine high idle RPM is  
OK, then the engine may have  
lost horsepower and be in need  
of major repair.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 500  
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F-7  
F-7  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The machine control is still active 1. This is normal in TIG mode.  
1. Check Plug J10 on the Weld  
Control PC board for loose or  
faulty connections.  
when the remote control unit is  
2. The remote control unit may be  
attached.  
defective.  
2. The Weld Control PC board  
may be faulty.  
3. Check the Amphenol connec-  
tions and associated wiring.  
The machine seems locked into the 1. Check the position of the MODE 1. Check the MODE SELECTOR  
CC mode of operation (Stick  
mode).  
SELECTOR switch. It must be  
in the correct position for the  
process being used.  
switch and associated leads.  
See the Wiring Diagram.  
2. The Weld Control PC board  
may be faulty.  
2. Check that the jumper plug J3 is  
properly installed in the Weld  
Control PC board. (J3 has a  
jumper wire from pin 1 to pin 5.)  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 500  
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F-8  
F-8  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The wire feeder does not work 1. Check the appropriate circuit 1. Check for the presence of  
when connected to the welder  
amphenol.  
breaker (CB1 or CB6). Reset if  
tripped.  
appropriate source voltage at  
the 14-pin amphenol.  
2. The wire feeder control cable 2. If the appropriate voltage (42  
may be faulty.  
VAC or 115 VAC) is NOT pre-  
sent at the 14-pin amphenol,  
check for loose or faulty con-  
3. The wire feeder may be faulty.  
nections.  
Diagram.  
See the Wiring  
3. Perform the Stator Voltage  
Test.  
The battery does not stay charged. 1. Check for loose or faulty con- 1. The battery charging circuit may  
nections at the battery and  
engine charging system.  
be faulty.  
Charging Circuit Test.  
Perform the  
2. The battery may be faulty.  
Check or replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 500  
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F-9  
F-9  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine will not crank when the 1. Check for loose or faulty battery 1. The starter motor or starter  
start button is pushed. cable connections. solenoid may be faulty.  
2. The battery may be low or faulty. 2. The engine may be hard to  
crank due to a mechanical fail-  
3. The START button may be  
ure in the engine.  
faulty.  
3. See the Engine Starting Diag-  
nostic Chart.  
The engine cranks but will not start. 1. Check for adequate fuel supply. 1. The shutdown solenoid may be  
faulty. Perform the Shutdown  
2. Make sure the fuel shut off valve  
Solenoid Test.  
is in the open position.  
2. The Peripheral PC board may  
3. The engine oil temperature may  
be faulty. With the RUN/STOP  
be too high. Check cooling sys-  
switch in the "RUN" position, the  
tem.  
Peripheral PC board should nor-  
4. The battery voltage may be too  
low.  
mally supply 10VDC to the shut-  
down solenoid via leads #224  
and #262. See the Wiring  
Diagram.  
3. The Pull Coil PC board may be  
faulty.  
4. The engine may be in need of  
mechanical repair.  
5. See the Engine Starting Diag-  
snostic Chart.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 500  
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F-10  
F-10  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine shuts down shortly 1. Check for adequate fuel supply. 1. Check the RUN/STOP switch  
after starting.  
and associated leads for loose  
or faulty connections.  
2. If any indicator light is lit when  
the engine shuts down, that par-  
ticular system has faulted. 2. Perform  
the  
Shutdown  
Check system. Solenoid Test.  
3. Check the battery cables for 3. The Peripheral PC board may  
loose or faulty connections.  
be faulty. With the RUN/STOP  
switch in the "RUN" position, the  
Peripheral PC board should nor-  
mally supply 10VDC to the shut-  
down solenoid via leads #224  
and #262. See the Wiring  
Diagram.  
4. See the Engine Starting Diag-  
nostic Chart.  
The engine will not idle down to low 1. Make sure the IDLER switch is 1. Perform the Idler Solenoid  
speed. The machine has normal  
weld output and auxiliary power.  
in the "AUTO" position.  
Test.  
2. Make sure there is NOT an 2. Check leads #227, #232L,  
external load on the weld termi-  
nals nor the auxiliary power  
receptacles.  
#232M and #226A for loose or  
faulty connections. See the  
Wiring Diagram.  
3. Check for mechanical restric- 3. The Pull Coil PC board may be  
tions in the solenoid linkage.  
faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 500  
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F-11  
F-11  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine will not go to high idle 1. Make sure the auxiliary power 1. Check the current sensing  
when using the auxiliary power.  
Auxiliary power is normal when the  
IDLER switch is in the "HIGH" posi-  
tion. Automatic idle function works  
properly when the welding termi-  
nals are loaded.  
leads are tight.  
toroid for loose or faulty connec-  
tions. See the Wiring Diagram.  
2. The automatic idler may not  
function if the auxiliary power is 2. Make sure leads #3 and #6A  
loaded to less than 150 watts.  
pass through the toroid twice in  
opposite directions.  
3. The current sensing toroid may  
be faulty.  
4. The Weld Control PC board  
may be faulty.  
The engine will not go to high idle 1. Make sure the welding cables 1. The Weld Control PC board  
when attempting to weld or when  
the auxiliary power is loaded.  
Welding output and auxiliary power  
outputs are normal when IDLER  
switch is in the " HIGH" position.  
and auxiliary power lead con-  
nections are tight.  
may be faulty.  
2. The current sensing toroid may  
be faulty.  
The machine goes to low idle but 1. Make sure there is NOT an 1. The idler solenoid linkage may  
does not stay at low idle.  
external load (auxiliary or weld)  
connected to the Commander  
500.  
be misadjusted or damaged.  
2. The idler solenoid lead connec-  
tions may be loose or damaged.  
See the Wiring Diagram.  
3. Perform the Idler Solenoid  
Test.  
4. The Weld Control PC board  
may be faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 500  
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F-12  
F-12  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
WELDING PROBLEMS  
The welding arc is "cold." The 1. Check for loose or faulty con- 1. Check for the correct OCV at  
engine runs normally. The auxiliary  
power is normal.  
nections at the weld output ter-  
minals and welding cable con-  
nections.  
the welding output terminals. If  
the correct voltage is present at  
the output terminals, check for  
loose connection on the heavy  
current carrying leads inside the  
2. The welding cables may be too  
long or coiled, causing an  
excessive voltage drop.  
Commander 500.  
Wiring Diagram.  
See the  
3. Make sure the electrode (wire,  
gas, voltage, current etc.) is cor-  
rect for the process being used.  
2. If the OCV is low at the welder  
output terminals, perform the  
Engine Throttle Adjustment  
Test.  
3. Perform the Output Rectifier  
Bridge Test.  
4. Perform the Stator Voltage  
Test.  
5. Perform the Power Module  
Test.  
6. The Weld Control PC board  
may be faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 500  
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F-13  
F-13  
TROUBLESHOOTING & REPAIR  
ENGINE STARTING DIAGNOSTIC CHART  
Starting  
ENGINE  
Upon placing the RUN/STOP switch in the “RUN” position, you should hear a  
“click” near the engine. This is the FUEL SOLENOID engaging. It should stay  
engaged. You should also see all 5 ENGINE WARNING LIGHTS come on for  
about 5 seconds and then go off. Then, operate the START button. ENGINE  
WARNING LIGHTS WILL COME BACK on then off again. All gauges should be  
in the NORMAL operating ranges. About 30 seconds after starting the engine,  
the “inihibit” circuit which prevents ENGINE SHUTDOWN will turn-off. Engine  
should remain running.  
Is the BATTERY  
charged ENOUGH to  
start the ENGINE?  
N
Is there FUEL?  
Did engine START?  
N
N
Y
CORRECT  
that problem.  
Are the BATTERY  
CABLES properly  
connected?  
Did you hear the  
FUEL SOLENOID  
engage?  
Does the PULL COIL  
read .3 ohms?  
Is the SOLENOID  
LINKAGE bound-up?  
Is the BATTERY  
charged?  
Y
Y
Y
N
MAY HAVE ENGINE  
PROBLEMS.  
N
N
N
N
Y
CORRECT  
that problem.  
Did engine  
REMAIN running after  
the 30 second  
MAY HAVE WEAK FUEL  
SOLENOID OR BAD  
PERIPHERAL PCB.  
N
Did 1 of the WARNING  
lights come on?  
N
Look at wires 224,  
262, 405, 270, 5T,  
402, 232, 236a, &  
236. Also, 403,  
232M or 265.  
INBHIT timer?  
Y
Did the  
Look at wires 224,  
262  
PERIPHERAL PCB  
MAY BE BAD.  
FUEL SOLENOID  
engage and REMAIN  
engaged?  
Does the HOLD COIL  
read 21 ohms?  
OK  
Y
OK  
N
CORRECT  
that problem.  
PERIPHERAL PCB or  
BATTERY PCB MAY BE  
BAD. ALSO, THE PULL  
COIL PCB.  
CORRECT  
that problem.  
Y
Look at wires 243,  
247, 248, 245,  
232f, 232g, 232e,  
232p, 252 & 253.  
Check the WARNING  
LIGHTS.  
PERIPHERAL PCB  
MAY BE BAD.  
Did all 5 ENGINE  
WARNING LIGHTS  
come on?  
OK  
OK  
N
Y
CORRECT  
that problem.  
PERIPHERAL PCB  
MAY BE BAD.  
Did all 5 ENGINE  
WARNING LIGHTS  
go OFF?  
N
Y
COMMANDER 500  
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F-14  
F-14  
TROUBLESHOOTING & REPAIR  
START-UP AND OCV DIAGNOSTIC CHART  
Start  
Upon starting the engine, there should be only ONE display illuminated (depending on which mode the machine is  
in). The numbers in the display should increase/decrease smoothly and in a “linear” fashion with the rotation of  
the Control (10K)Pot. Place the WELDING TERMINALS SW. In the “REMOTELY CONTROLLED” position and  
place the IDLER SW. in the “AUTO” position. After about 12 seconds, the engine should go to LOW IDLE. Then  
place the WELDING TERMINALS SW. in the “WELD TERMINALS ON” position. Engine should go back to HIGH  
IDLE for 12 seconds and back to LOW IDLE and remain there. With the machine in CV Mode, you should have  
an OCV range 23.7-25.2V at Min. and 75.0-78.0V at Max. In CC Mode, you should have an OCV range of 77-80V.  
This WILL NOT change with the rotation of the Control Pot. In TIG Mode, you should have an OCV range of 11.0-  
15.0V at Min. and 13.0-17.0V at Max. There is no need to check the PIPE OCV.  
Go to  
Engine  
Starting  
Diagnostic  
Chart  
CORRECT  
that problem.  
CONTROL PCB MAY  
BE BAD.  
Check for short on  
any STATOR  
winding. Check  
WELD BRIDGE for  
shorts.  
TWO displays  
illuminated?  
Then NO displays  
are illuminated.  
Is only ONE display  
N
N
Check the Amphenols.  
illuminated?  
Insure nothing is  
plugged into them. Also  
check for excessive  
tracking or corrosion of  
the Amphenol.  
Check the CONTROL  
POT continuity and  
continuity of wires 75,  
76 & 77.  
Y
Y
The numbers DO  
NOT change.  
CORRECT  
that problem.  
Y
Does  
The numbers  
“jump” as you turn  
the Control Pot.  
The Pot may be  
bad.  
Are J4 & 5  
plugged  
in properly?  
the display inc./  
Is WELD current  
flowing?  
Did the  
ROTOR flash?  
CORRECT  
that problem.  
Do you have AUX.  
voltage?  
N
dec. smoothly with the  
Control Pot rotation?  
Does it change?  
N
N
N
CORRECT  
that problem.  
N
Y
Y
Y
N
Check BRUSHES,  
BATTERY PCB  
and wires 200,  
200B, 200C, 200A,  
200E, 201, 201A,  
201B and 5L.  
Check wires 13 & 14. OK  
CORRECT  
that problem.  
CORRECT  
that problem.  
OCV is between 9-20V  
in all modes. If so,  
place a LIGHT load  
(about 1/4 amp) across  
the WELD TERM. If  
the voltage goes away,  
Chopper has some  
slight leakage.  
OCV is higher, 70V or  
more. Check  
With the  
WELD. TER. SW in  
No LOW IDLE. Is  
AUX current flowing?  
CHOPPER for a short  
by unplugging J50 &  
J51. This turns the  
CHOPPER off. If OCV  
still exists, then  
“REM. CONT.” and IDLER SW.  
N
N
N
in “AUTO”, do you have 0-8V OCV  
in all modes and go  
to LOW IDLE?  
CONTROL PCB MAY  
Y
No LOW IDLE. Check Idle  
Solenoid (.3 ohms for PULL  
COIL and 21 ohms for  
HOLD COIL) and wires 232L  
& 227; 232S & 226A. Also  
check mechanical linkage  
going to Idle Solenoid.  
Y
BE BAD.  
CHOPPER must be  
shorted or wired wrong.  
Continue.  
CORRECT  
that problem.  
CORRECT  
that problem.  
OK  
ANALOG POWER  
SUPPLY MY BE BAD.  
CORRECT  
that problem.  
With the  
No HIGH IDLE.  
Check the WELD.  
TERM. SW. Check  
wires 2 & 4.  
(NOTE: Under some circumstances, the CONTROL PCB can become defective in  
such a way that it causes the ANALOG POWER SUPPLY (APS) to stop working and  
visa versa. If you replace the APS, it may be suggested to replace the Control PCB  
too. Inspect BOTH boards. If you notice any signs of over-heated or burnt compo-  
nents on either board, replace BOTH boards together. IF YOU CHANGE ANY CIR-  
CUIT BOARDS, START FROM THE BEGINNING OF THIS TEST.  
WELDING TER. SW.  
in“WELD TERM. ON” did unit go  
to HI IDLE/back to LO and is there  
OCV present at WELD  
TERMINALS?  
N
CORRECT  
N
OK  
that problem.  
Y
CORRECT  
that problem.  
No OCV. Check  
CORRECT  
that problem.  
CONTROL PCB MAY  
BE BAD.  
CHOPPER and wires  
OK  
15, 16, 17, 18, 23, 25,  
23A and 25A.  
Is the A meter or  
V meter illuminated?  
In CV Mode, do you  
have proper OCV?  
In TIG Mode, do you  
have proper OCV?  
N
OCV too high.  
V meter  
N
Check VOLTAGE  
FEEDBACK wire 208B.  
ANALOG POWER  
SUPPLY MAY BE  
BAD.  
Y
A meter  
Y
CORRECT  
that problem.  
OK  
Check the MODE  
OK  
SELECT rotary switch  
and wires 214, 218, 220  
& 222.  
In CC Mode, do you  
have proper OCV?  
CONTROL PCB MAY  
BE BAD.  
N
COMMANDER 500  
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F-15  
F-15  
TROUBLESHOOTING & REPAIR  
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This procedure will aid the technician in the removal and replacement of the case sheet  
metal covers.  
MATERIALS NEEDED  
3/8" wrench  
7/16" wrench  
1/2" wrench  
3/4" wrench  
This procedure should take approximately 30 minutes to perform.  
COMMANDER 500  
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F-16  
F-16  
TROUBLESHOOTING & REPAIR  
CASE COVER REMOVAL  
AND REPLACEMENT PROCEDURE (CONTINUED)  
FIGURE F.1 – COVER REMOVAL  
ROUND  
HEAD SCREW  
LOCATION  
DOOR  
ASSEMBLY  
LEFT  
FRONT  
PANEL  
PROP ROD  
RIGHT  
FRONT  
PANEL  
PROCEDURE  
1. Turn the engine off.  
4. Support the door assembly. Using the 3/8"  
wrench, remove the #10-24 round head  
screw, lock washer, flat washer, and nut from  
the top corner of the door hinge assembly  
where it attaches to the roof. Remove the  
support rod.  
2. Using the 3/8" wrench, remove the battery  
cover. Slide the battery out and disconnect  
the negative battery cable.  
3. Unlatch and open the engine service access  
door. See Figure F.1.  
COMMANDER 500  
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F-17  
F-17  
TROUBLESHOOTING & REPAIR  
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)  
FIGURE F.2 – FRONT PANEL/ROOF DETAILS  
SCREWS  
FRONT  
CONTROL  
PANEL  
SCREW  
5. Using the 3/8" wrench, remove the four  
screws from the top front of the roof assem-  
bly and the two screws from the sides of the  
control box. Carefully lower the front con-  
trol panel. See Figure F.2.  
7. Remove the fuel tank cap, gasket, and the  
lift bail cover seal.  
8. With the help of an assistant, carefully  
remove the roof. The door assembly  
remains attached to the roof. Replace the  
fuel cap.  
6. sWith the 9/16" wrench, remove the  
exhaust pipe rain cap.  
9. With 3/8" wrench, remove the left rear panel  
and the right and left front panels. See  
Figure F.1.  
COMMANDER 500  
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F-18  
F-18  
TROUBLESHOOTING & REPAIR  
CASE FRONT KNOBS - REMOVAL AND REPLACEMENT PROCEDURE  
Removal  
Side View  
(Pull)  
(Pull)  
Knob  
Nameplate  
(Push)  
(Push)  
Removal:  
1. Rotate the handle portion of the knob to an approximate vertical orientation (switch detent may position  
handle a few degrees off vertical). This orientation should be noted and repeated at replacement for proper  
" D" shaft orientation.  
2. With one hand, grasp the very bottom of vertical handle and push towards the machine nameplate and  
pull down. At the same time and with the other hand, grasp the very top of the handle and pull the top edge  
of the knob away from the machine nameplate. The knob should " peel" away from the nameplate and the  
white nylon holding fingers of the knob base, from top to bottom.  
Replacement  
Rounded  
Flat  
Replacement:  
1. If the white nylon cam of the detent mechanism is removed from it's spring loaded base by the above  
procedure or intentionally, it should be returned before the knob replacement is attempted. Press the cam  
into it's spring loaded holder so it sets flat and flush (Selector Switch Only).  
2. Orientate the knob handle to the vertical as noted above and position the knob over the base, centered  
and parallel.  
3. Press the knob onto the " D" shaft and white nylon holding fingers, maintaining the parallel position.  
The knob should " click" into place and should not pull off with normal operation.  
COMMANDER 500  
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F-19  
F-19  
TROUBLESHOOTING & REPAIR  
POWER MODULE CAPACITOR DISCHARGE PROCEDURE  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This procedure will insure that the large capacitors in the power modules have been dis-  
charged. This procedure should be performed whenever work is to be attempted on or  
near the power modules.  
MATERIALS NEEDED  
3/8" Wrench  
Volt/Ohmmeter  
Resistor (25-1000 ohms and 25 watts minimum)  
Jumper leads  
This procedure should take approximately 15 minutes to perform.  
COMMANDER 500  
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F-20  
F-20  
TROUBLESHOOTING & REPAIR  
POWER MODULE CAPACITOR DISCHARGE PROCEDURE (CONTINUED)  
FIGURE F.4 – POWER MODULE CAPACITOR TERMINAL DISCHARGE  
POWER  
MODULE  
CAPACITOR  
TERMINALS  
PROCEDURE  
1. This procedure must be performed with the  
engine off.  
4. Using the resistor and jumper leads, CARE-  
FULLY discharge the capacitor terminals.  
NEVER USE A SHORTING STRAP FOR  
THIS PURPOSE. DO NOT TOUCH THE  
TERMINALS WITH YOUR BARE HANDS.  
Repeat procedure on the other side.  
2. Using the 3/8" wrench, remove the front left  
and right side panels.  
3. Locate the four capacitors (two on each  
side). See Figure F.4.  
5. Check the voltage across the capacitor ter-  
minals. It should be zero volts.  
COMMANDER 500  
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F-21  
F-21  
TROUBLESHOOTING & REPAIR  
IDLER SOLENOID TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the idler solenoid is capable of functioning when it is energized  
with 12VDC.  
MATERIALS NEEDED  
External 12VDC supply ( 30 amps required)  
Wiring Diagram  
Volt/Ohmmeter  
This procedure should take approximately 30 minutes to perform.  
COMMANDER 500  
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F-22  
F-22  
TROUBLESHOOTING & REPAIR  
IDLER SOLENOID TEST (CONTINUED)  
FIGURE F.5 – IDLER SOLENOID LEADS  
PULL-IN COIL  
(LARGER TERMINALS  
TOP AND BOTTOM  
#227 AND #232L)  
SHUTDOWN  
SOLENOID  
HOLD-IN COIL  
(SMALLER  
TERMINALS  
TOP AND BOTTOM  
#226A AND #232S)  
IDLER  
SOLENOID  
TEST PROCEDURE  
CAUTION  
1. Turn the engine off.  
When the solenoid activates, remove the voltage  
supply immediately. Do not leave the external  
supply connected to terminals #227 and #232L for  
longer than three seconds. Component damage  
could result.  
2. Unlatch, lift, and secure the right side engine  
service access door.  
3. Locate and remove the four spade connec-  
tors that attach the idler solenoid leads to the  
wiring harness leads (#226A, #232S, #227  
and #232L). See Figure F.5 and the Wiring  
Diagram. Remove and necessary wire  
wraps.  
The solenoid should deactivate when the  
12VDC is removed.  
6. If the solenoid does not operate properly,  
check for a mechanical restriction in the link-  
age.  
4. Check the pull-in coil resistance (larger ter-  
minals #227 to #232L). The normal resis-  
tance is approximately 0.4 ohms.  
7. Using the external 12VDC supply, apply  
12VDC to the smaller idler solenoid terminals  
for the hold-in coil (#226A to #232S +). Push  
in the solenoid plunger. With 12 VDC applied  
to the hold-in coil, the plunger should stay in  
until the 12 VDC is removed.  
Check the hold-in coil resistance (smaller  
terminals #226A to #232S). Normal coil  
resistance is approximately 20 ohms.  
If either coil resistance is not correct, the  
solenoid may be faulty. Replace.  
8. If the linkage is intact and the solenoid does  
not operate correctly when the 12VDC is  
applied, the solenoid may be faulty. Replace.  
5. Using the external 12VDC supply, apply  
12VDC to the larger idler solenoid terminals  
(#227 to #232L +). The solenoid should acti-  
vate.  
9. Replace harness leads to the correct termi-  
nals. See Figure F.5 and the Wiring Diagram.  
Replace any previously removed wire wraps.  
10. Close and secure the right side engine ser-  
vice access door.  
COMMANDER 500  
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F-23  
F-23  
TROUBLESHOOTING & REPAIR  
SHUTDOWN SOLENOID TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the shutdown solenoid is capable of functioning when it is ener-  
gized with 12VDC.  
MATERIALS NEEDED  
External 12VDC supply ( 30 amps required)  
Wiring Diagram  
Volt/Ohmmeter  
This procedure should take approximately 30 minutes to perform.  
COMMANDER 500  
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F-24  
F-24  
TROUBLESHOOTING & REPAIR  
SHUTDOWN SOLENOID TEST (CONTINUED)  
FIGURE F.6 – SHUTDOWN SOLENOID LEAD TERMINALS  
PULL-IN COIL  
(LARGER TERMINALS  
EACH SIDE  
#232M AND #265)  
SHUTDOWN  
SOLENOID  
HAND-IN COIL  
(SMALLER TERMINALS  
EACH SIDE  
#224 AND #262)  
IDLER  
SOLENOID  
TEST PROCEDURE  
CAUTION  
1. Turn the engine off.  
When the solenoid activates, remove the voltage  
supply immediately. Do not leave the external  
supply connected to terminals #232M and #265  
for longer than three seconds. Component dam-  
age could result.  
2. Unlatch, lift, and secure the right side engine  
service access door.  
3. Locate and remove the four spade connec-  
tors that attach the shutdown solenoid leads  
to the wiring harness leads (#224, #262,  
#232M and #265). See Figure F.6 and the  
Wiring Diagram. Remove any necessary  
wire wraps.  
The solenoid should deactivate when the  
12VDC is removed.  
6. If the solenoid does not operate properly,  
check for a mechanical restriction in the link-  
age.  
4. Check the pull-in coil resistance (larger ter-  
minals #232M to #265). The normal resis-  
tance is approximately 0.4 ohms.  
7. Using the external 12VDC supply, apply  
12VDC to the smaller idler solenoid terminals  
for the hold-in coil (#262- to #224+). Push in  
the solenoid plunger. With 12 VDC applied to  
the hold-in coil, the plunger should stay in  
until the 12 VDC is removed.  
Check the hold-in coil resistance (smaller  
terminals #224 to #262). Normal coil resis-  
tance is approximately 20 ohms.  
If either coil resistance is not correct, the  
solenoid may be faulty. Replace.  
8. If the linkage is intact and the solenoid does  
not operate correctly when the 12VDC is  
applied, the solenoid may be faulty. Replace.  
5. Using the external 12VDC supply, apply  
12VDC to the larger shutdown solenoid ter-  
minals (#232M+ to #265-). The solenoid  
should activate.  
9. Replace harness leads to the correct termi-  
nals. See Figure F.6 and the Wiring Diagram.  
Replace any previously removed wire wraps.  
10. Close and secure the right side engine ser-  
vice access door.  
COMMANDER 500  
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F-25  
F-25  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
If the machine output is low or high, this test will determine whether the engine is operat-  
ing at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for  
adjusting the throttle to the correct RPM are given.  
MATERIALS NEEDED  
Slot head screw driver  
10mm Wrench  
White or red marking pencil  
Strobe-tach, frequency counter, or oscilloscope  
This procedure should take approximately 35 minutes to perform.  
COMMANDER 500  
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F-26  
F-26  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)  
FIGURE F.7 – STROBE MARK LOCATION  
MARK BLOWER  
PADDLE HERE  
TEST PROCEDURE  
5. Start the engine and direct the strobe-tach  
light on the bolt head. Synchronize it to the  
rotating mark.  
Strobe-tach Method  
1. Conduct this procedure with the engine  
OFF.  
With the machine at HIGH IDLE the tach  
should read between 1890 and 1910 RPM.  
2. Unlatch, lift and secure the right side engine  
service access door. Perform the Case  
Cover Removal and Replacement  
Procedure through Step 9. (For Strobe-  
Tach method only.)  
With the machine at LOW IDLE the tach  
should read between 1450 and 1500 RPM.  
3. With a white or red marking pencil, place a  
mark on one of the blower paddles. See  
Figure F.7 for location.  
4. Connect the strobe-tach according to the  
manufacturer's instructions.  
COMMANDER 500  
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F-27  
F-27  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)  
FIGURE F.8 – HIGH IDLE ADJUSTMENT  
BOSCH  
903  
5 7 0 0 8 1 6  
80D 410/3R  
PES 3A  
0 400 463 12  
LOCKING  
NUT  
ADJUSTING  
SCREW  
FIGURE F.9 – LOW IDLE ADJUSTMENT  
BOSCH  
903  
5 7 0 0 8 1 6  
80D 410/3R  
PES 3A  
0 400 463 12  
ADJUSTING  
COLLAR  
LOCKING NUT  
COMMANDER 500  
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F-28  
F-28  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)  
6. If either of the readings is incorrect, adjust  
the throttle as follows:  
Adjust LOW IDLE: First make sure there is  
no load on the machine. Set the IDLE  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 10mm  
wrench to loosen the solenoid lever arm  
locking nut. See Figure F.9. Adjust the col-  
lar, to change the amount of throw in the  
lever arm, until the frequency reads 49 Hz.  
Retighten the locking nut.  
Adjust HIGH IDLE: Use the 10mm wrench  
to loosen the locking nut. See Figure F.8  
for location of the adjusting screw and lock-  
ing nut. Turn the threaded screw counter-  
clockwise to increase the HIGH IDLE  
speed. Adjust the speed until the tach  
reads between 1890 and 1910 RPM.  
Retighten the locking nut.  
Oscilloscope Method  
Adjust LOW IDLE: First make sure there is  
no load on the machine. Set the IDLE  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 10mm  
wrench to loosen the solenoid lever arm  
locking nut. See Figure F.9. Adjust the col-  
lar, to change the amount of throw in the  
lever arm, until the tach reads between  
1450 and 1500 RPM. Retighten the locking  
nut.  
1. Connect the oscilloscope to the 115 VAC  
receptacle, according to the manufacturer’s  
instructions. At HIGH IDLE (1900 RPM),  
the waveform should exhibit a period of  
15.8 milliseconds. At LOW IDLE (1475  
RPM), the waveform should exhibit a period  
of 20.3 milliseconds. Refer to the NORMAL  
OPEN CIRCUIT VOLTAGE WAVEFORM  
(115 VAC SUPPLY) HIGH IDLE - NO LOAD  
in this section of the manual.  
Frequency Counter Method  
2. If either of these waveform periods is incor-  
rect, adjust the throttle as follows:  
1. Plug the frequency counter into one of the  
115 VAC auxiliary receptacles.  
Adjust HIGH IDLE: Use the 10mm wrench  
to loosen the locking nut. See Figure F.8  
for location of the adjusting screw and lock-  
ing nut. Turn the threaded screw counter-  
clockwise to increase the HIGH IDLE  
speed. Adjust the speed until the period is  
15.8 milliseconds. Retighten the locking  
nut.  
2. Start the engine and check the frequency  
counter. At HIGH IDLE (1900 RPM), the  
counter should read 63 Hz. At LOW IDLE  
(1475 RPM), the counter should read 49  
Hz. Note that these are median measure-  
ments; hertz readings may vary slightly  
above or below.  
Adjust LOW IDLE: First make sure there is  
no load on the machine. Set the IDLE  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 10mm  
wrench to loosen the solenoid lever arm  
locking nut. See Figure F.9 Adjust the col-  
lar, to change the amount of throw in the  
lever arm, until the period is 20.3 millisec-  
onds. Retighten the locking nut.  
3. If either of the readings is incorrect, adjust  
the throttle as follows:  
Adjust HIGH IDLE: Use the 10mm wrench  
to loosen the locking nut. See Figure F.8  
for location of the adjusting screw and lock-  
ing nut. Turn the threaded screw counter-  
clockwise to increase the HIGH IDLE  
speed. Adjust the speed until the frequen-  
cy reads 63 Hz. Retighten the locking nut.  
COMMANDER 500  
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F-29  
F-29  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if there is a shorted winding in the rotor or if the rotor is grounded.  
MATERIALS NEEDED  
Ohmmeter  
3/8" Wrench or socket wrench  
This procedure should take approximately 15 minutes to perform.  
COMMANDER 500  
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F-30  
F-30  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST (CONTINUED)  
FIGURE F.10 – ROTOR BRUSH LEADS  
SLIP  
RINGS  
BRUSH  
HOLDER  
ASSEMBLY  
ACCESS PANEL  
TEST PROCEDURE  
1. Conduct this test with the engine off.  
7. If the test does not meet the resistance  
specifications, then the rotor may be faulty.  
Replace.  
2. Using the 3/8" wrench, remove the right front  
case side.  
8. Position the brush holder assembly and  
attach it with two screws previously  
removed. Make certain the brushes are  
centered and seated properly on the slip  
rings. Adjust if necessary.  
3. Using the 3/8" wrench, remove the brush  
holder access panel. See Figure F.10.  
4. Using the 3/8" wrench, remove the brush  
holder assembly. See Figure F.10.  
5. Using the ohmmeter, check the rotor winding  
resistance across the slip rings. Normal  
resistance is approximately 27.0 ohms.  
9. Replace the brush holder access panel.  
10. Replace the right front case cover.  
6. Measure the resistance to ground. Place  
one meter probe on either of the slip rings.  
Place the other probe on any good unpaint-  
ed ground. The resistance should be very  
high, at least 500,000 ohms.  
COMMANDER 500  
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F-31  
F-31  
TROUBLESHOOTING & REPAIR  
FLASHING AND ROTOR VOLTAGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the correct DC voltage is being applied to the rotor at the maxi-  
mum engine speed (1900 RPM). This information will aid the technician in determining if  
the generator field is operating properly.  
MATERIALS NEEDED  
Volt/Ohmmeter  
3/8" Wrench  
Wiring Diagram  
This procedure should take approximately 35 minutes to perform.  
COMMANDER 500  
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F-32  
F-32  
TROUBLESHOOTING & REPAIR  
FLASHING AND ROTOR VOLTAGE TEST(CONTINUED)  
FIGURE F.11 – PLUG P/J52 LOCATION  
PLUG P/J52  
FILTER  
CAPACITOR  
FIELD DIODE  
RECTIFIER BRIDGE  
PLUG P/J52  
9
1
12 13  
10 11  
2 3  
14 15 16  
8
4
5 6  
7
LEAD # 201A  
LEAD # 200A  
TEST PROCEDURE  
1. Using the 3/8" wrench, remove the sheet  
metal screws from the right front case side.  
5. Connect the positive meter probe to lead  
#200A and the negative meter probe to lead  
#201A.  
2. Carefully remove the right case side.  
6. Start the engine and run it at high idle speed  
(1900 RPM). Check the voltage reading on  
the meter. It should read approximately  
16 VDC.  
3. Set the volt/ohmmeter to the DC volts  
position.  
4. Locate Plug P/J52 and leads #200A and  
#201A. See Figure F.11.  
NOTE: Cut any cable ties necessary to perform  
the test. DO NOT UNPLUG PLUG P/J52.  
COMMANDER 500  
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F-33  
F-33  
TROUBLESHOOTING & REPAIR  
FLASHING AND ROTOR VOLTAGE TEST(CONTINUED)  
FIGURE F.12 - FIELD DIODE RECTIFIER BRIDGE AND FILTER CAPACITOR  
FIELD  
DIODE  
RECTIFIER  
BRIDGE  
FILTER  
CAPACITOR  
7. If the voltage reading is low or not present,  
the generator field is not functioning proper-  
ly. Perform the Rotor Resistance Test.  
Also check the field diode rectifier bridge, fil-  
ter capacitor, and associated leads and con-  
nections. See Figure F.12 for location. See  
the Wiring Diagram.  
8. If the rotor voltage readings are normal, the  
field circuit is functioning properly. Replace  
any cable ties cut during the test. Install the  
right case side.  
NOTE: The normal flashing voltage is approxi-  
mately 9VDC. This is battery voltage, which is  
processed through the Battery board. This volt-  
age must be present during start-up to "flash"  
the rotor field.  
COMMANDER 500  
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F-34  
F-34  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the correct AC voltages are being generated from the stator  
windings.  
MATERIALS NEEDED  
Volt/Ohmmeter  
3/8" wrench  
3/4" Wrench  
This procedure should take approximately 40 minutes to perform.  
COMMANDER 500  
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F-35  
F-35  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST (CONTINUED)  
FIGURE F.13 – FRONT CONTROL PANEL REMOVAL  
SCREWS  
FRONT  
CONTROL  
PANEL  
SCREW  
TEST PROCEDURE  
1. Turn the engine off.  
4. Using the 3/8" wrench, remove the front left  
and right side panels.  
2. Using the 3/8" wrench, remove the four  
screws holding the front control panel to the  
case top and sides. See Figure F.13.  
(There are two screws on the top and one  
screw on each side.)  
5. Using the 3/4" wrench, remove the internal  
leads from the output terminals. Insulate the  
leads.  
3. Carefully lower the front control panel.  
COMMANDER 500  
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F-36  
F-36  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST (CONTINUED)  
FIGURE F.14 – OUTPUT PANEL REMOVAL  
OUTPUT LEADS  
(BEHIND PANEL)  
OUTPUT PANEL  
GREEN  
GROUND  
LEAD  
SCREWS  
6. Using the 3/8" wrench, remove the three  
screws holding the lower front panel (output  
panel) to the case front assembly. Then  
remove the front two screws holding the top  
of the panel. These are accessed in the  
control box, on the bottom at each side of  
the box. See Figure F.14. Carefully move  
the lower front panel to the right side. Note  
the green ground lead will still be attached.  
COMMANDER 500  
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F-37  
F-37  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST (CONTINUED)  
FIGURE F.15 – AUXILIARY LEAD TEST LOCATION  
AUXILIARY  
LEADS #5B, #5E,  
#8, #9, #11, #12  
(BEHIND PANEL)  
AUXILIARY POWER AND WELD  
WINDINGS TEST  
1. Start the engine and run at high idle (1900  
RPM). Do not load welding or auxiliary  
power.  
3. Check for 230 to 264VAC at leads #11 to  
#12. See Figure F.15 and the Wiring  
Diagram.  
2. Check for 115-132VAC at leads #9 to #5B.  
Also check for 115-132VAC from leads #8 to  
#5E. See Figure F.15 and the Wiring  
Diagram.  
COMMANDER 500  
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F-38  
F-38  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST (CONTINUED)  
FIGURE F.16 – OUTPUT RECTIFIER DIODE BRIDGE  
W6  
W2  
W4  
W1  
W3  
W5  
WELD WINDING  
LEAD CONNECTIONS  
4. Locate the weld winding leads connected to  
the three-phase output rectifier diode bridge.  
See Figure F.16.  
8. If the tests in Steps 6 and 7 are OK and the  
stator voltages are low or missing, the stator  
may be faulty.  
5. Check for approximately 68VAC from W1 to  
W2. Also check from W3 to W4 and from  
W5 to W6.  
9. Replace the lower front panel and output  
leads.  
10. Replace the upper control panel and  
secure.  
6. If any of these voltages are low or missing  
perform the Flashing and Rotor Voltage  
Test and also the Rotor Resistance Test.  
11. Replace the front left and right case sides.  
7. Also check leads #6F and #5P for loose or  
faulty connections to the field bridge. See  
the Wiring Diagram.  
COMMANDER 500  
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F-39  
F-39  
TROUBLESHOOTING & REPAIR  
ANALOG POWER SUPPLY PC BOARD VOLTAGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the Analog Power Supply PC board is receiving and passing the  
proper signal voltages.  
MATERIALS NEEDED  
Analog Volt/Ohmmeter  
Wiring Diagram  
This procedure should take approximately 30 minutes to perform.  
COMMANDER 500  
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F-40  
F-40  
TROUBLESHOOTING & REPAIR  
ANALOG POWER SUPPLY PC BOARD VOLTAGE TEST (CONTINUED)  
FIGURE F.17 – ANALOG POWER SUPPLY PC BOARD  
3 1  
PCB2  
CONTROL  
CIRCUIT  
INPUT  
2
ANALOG  
POWER  
4
13 1J41 to POS TERMINAL ON C2 - 85V SUPPLY  
14 2J41 to NEG TERMINAL ON C2 - 85V SUPPLY  
J41  
PC BOARD  
J41  
POWER  
6
7
8
9
10  
1
2
3
4
5
J42  
J42  
TEST PROCEDURE  
1. Turn the engine off.  
If the reading is not correct, the stator out-  
put may be incorrect, the rectifier output  
may be incorrect, the power capacitors may  
be faulty, or the Power Module PC board  
may be faulty. Perform the Stator Voltage  
Test, the Output Rectifier Bridge Test,  
and the Power Module PC Board Test.  
The capacitors C1, C2, C3 or C4 may be  
faulty. Test and replace if necessary.  
2. Perform the Case Cover Removal proce-  
dure.  
3. Locate plugs J41 and J42 from the Analog  
Power Supply PC board. See Figure F.17.  
4. Start the engine and run it at high idle (1900  
RPM) with no load.  
5. Check for the correct input voltage:  
6. Check for the correct output voltage read-  
ings per Table F.1. If any of the readings  
are not correct, the Analog Power Supply  
PC board may be faulty.  
a. Set the volt/ohmmeter to the Volts DC  
position.  
b. Place the negative probe on J41 pin 2  
and the positive probe on J41 pin 1.  
7. When finished testing, perform the Case  
Cover Replacement procedure.  
c. The reading should be between 75 and  
85 VDC.  
COMMANDER 500  
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F-41  
F-41  
TROUBLESHOOTING & REPAIR  
ANALOG CONTROL POWER SUPPLY PC BOARD TEST (CONTINUED)  
TABLE F.1  
ANALOG CONTROL POWER SUPPLY PC BOARD VOLTAGE TABLE  
Test Points  
Component Tested  
Voltage Reading  
1J42 to 6J42  
3J42 to 8J42  
2J42 to 7J42  
5J42 to 7J42  
9J42 to 7J42  
10J42 to 4J42  
Chopper Power Supply  
+20 VDC  
+20 VDC  
+5 VDC  
Chopper Power Supply  
Weld Control PC Board Power Supply  
Weld Control PC Board Power Supply  
Weld Control PC Board Power Supply  
Weld Control PC Board Power Supply  
+15 VDC  
-15 VDC  
+15 VDC  
COMMANDER 500  
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F-42  
F-42  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if there are faulty diodes in the output rectifier bridge.  
MATERIALS NEEDED  
Volt/Ohmmeter (Diode Tester)  
3/8" Wrench  
7/16" Wrench  
3/4" Wrench  
Wiring Diagram  
This procedure should take approximately 40 minutes to perform.  
COMMANDER 500  
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F-43  
F-43  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST(CONTINUED)  
FIGURE F.18 – FRONT CONTROL PANEL REMOVAL  
SCREWS  
FRONT  
CONTROL  
PANEL  
SCREW  
TEST PROCEDURE  
1. Turn the engine off.  
5. Perform the Power Module Capacitor  
Discharge Procedure.  
2. Using the 3/8" wrench remove the screws  
holding the front control panel to the case  
top and sides. See Figure F.18. (There are  
two screws on the top and one screw on  
each side.)  
6. Using the 3/4" wrench, remove the internal  
leads from the output terminals. Insulate the  
leads.  
3. Carefully lower the front control panel.  
4. Using the 3/8" wrench, remove the front left  
and right side panels.  
COMMANDER 500  
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F-44  
F-44  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST(CONTINUED)  
FIGURE F.19 – OUTPUT PANEL REMOVAL  
OUTPUT LEADS  
(BEHIND PANEL)  
OUTPUT PANEL  
GREEN  
GROUND  
LEAD  
SCREWS  
7. Using the 3/8" wrench, remove the three  
screws holding the lower front panel (output  
panel) to the case front assembly. Then  
remove the front two screws holding the top  
of the panel. These are accessed in the  
control box, on the bottom at each side of  
the box. Using the 7/16" wrench, discon-  
nect the green ground lead. See Figure  
F.19. Carefully move the lower front panel  
to the right side.  
8. Disconnect Bypass PC board leads #206B  
and #208 from their in-line connectors.  
COMMANDER 500  
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F-45  
F-45  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST(CONTINUED)  
FIGURE F.20 – DIODE LEAD REMOVAL  
W6  
W2  
W4  
W1  
W3  
W5  
WELD WINDING  
LEAD CONNECTIONS  
9. Using the 7/16" wrench, remove the stator  
leads and diode pigtail leads from the three  
studs. Label the leads for reassembly.  
Note leads and pigtail placement for  
reassembly. See Figure F.20.  
13. Replace any "shorted" or "open" diode as  
the tests indicate. See the Diode Removal  
and Replacement Procedure.  
14. Replace the pigtails and stator leads onto  
the correct studs. Assemble the washers  
and nuts.  
10. Electrically isolate the six diode pigtail  
leads by carefully bending them out into  
"free air."  
15. Replace the lower front panel and output  
leads.  
11. With an ohmmeter or diode tester, check  
each of the six diodes from their pigtails to  
their respective heat sinks.  
16. Replace the upper control panel and  
secure.  
17. Replace the front left and right case sides.  
12. Reverse the tester leads and check the  
diodes again. Diodes should have a low  
resistance in one polarity and a very high  
resistance in the opposite polarity.  
COMMANDER 500  
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F-46  
F-46  
TROUBLESHOOTING & REPAIR  
POWER MODULE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will help determine if the power modules are shorted. This is a resistance test,  
not a voltage test. This test will only help diagnose a problem in the "power" section of  
the module. Other PC board components could be faulty.  
MATERIALS NEEDED  
Volt/Ohmmeter (Analog)  
3/8" Wrench  
7/16" Wrench  
3/4" Wrench  
This procedure should take approximately 45 minutes to perform.  
COMMANDER 500  
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F-47  
F-47  
TROUBLESHOOTING & REPAIR  
POWER MODULE TEST (CONTINUED)  
FIGURE F.21 – POWER MODULE CAPACITOR LEADS (LEFT SIDE)  
TEMPERATURE  
SWITCH  
POSITIVE (+)  
STRAP  
W9  
W10  
POWER  
MODULE  
PC BOARD  
DIODE  
LEAD D4  
POSITIVE (+)  
STRAP  
TEST PROCEDURE  
1. Turn the engine off.  
5. Using the 7/16" wrench, remove the flex  
leads W9 and W10 (left side) or W7 and W8  
(right side) from the Power Module PC board  
terminals.  
2. Perform the Case Cover Removal proce-  
dure.  
3. Perform the Power Module Capacitor  
6. Using the 7/16" wrench, remove the nega-  
tive jumper strap attaching the power capac-  
itors to the Power Module PC board.  
Discharge procedure.  
4. Using the 7/16" wrench, loosen the nuts on  
the positive terminals of the power capaci-  
tors. Then remove the nuts, lock washers,  
and flat washers from the terminals where  
the positive straps connect to the power  
module PC board. Flip the straps out of the  
way. Also remove diode lead D3 (if working  
on right side power module) or D4 (if work-  
ing on left side power module). See Figure  
F.21.  
NOTE: Make sure the bolts do not fall back  
against the heat sink.  
COMMANDER 500  
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F-48  
F-48  
TROUBLESHOOTING & REPAIR  
POWER MODULE TEST (CONTINUED)  
FIGURE F.22 – IGBT TEST  
HEAT SINK  
POSITIVE (+)  
CAPACITOR  
TERMINAL  
CONNECTIONS  
Check IGBT For "Shorts"  
7. Using the analog ohmmeter, connect the  
positive meter probe to the heat sink and the  
negative meter probe to the positive capaci-  
tor terminal on the Power Module PC board.  
See Figure F.22. The resistance reading  
should be high (over 20,000 ohms).  
8. Reverse the meter probe leads. The resis-  
tance should be very high (over 50,000  
ohms). It the resistance is low in either Step  
7 or 8, the IGBT may be shorted or leaky.  
COMMANDER 500  
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F-49  
F-49  
TROUBLESHOOTING & REPAIR  
POWER MODULE TEST (CONTINUED)  
FIGURE F.23 – DIODE MODULE TEST  
HEAT SINK  
DIODE  
MODULE  
TERMINALS  
Check Diode Module  
When all tests are complete:  
11. Reconnect all leads previously removed.  
9. Using the analog ohmmeter, connect the  
negative meter probe to the terminal on the  
diode module. See Figure F.23. Connect  
the positive meter probe to the heat sink.  
The resistance should be very high (over  
50,000 ohms).  
12. Torque the capacitor nuts to 50-60 inch-  
pounds.  
13. If finished testing, perform the Case Cover  
Replacement procedure.  
10. Using the analog ohmmeter, connect the  
positive meter probe to the terminal on the  
diode module. Connect the negative meter  
probe to the heat sink. The resistance  
should be low (approximately 300 ohms).  
Also check diode D3 (right side) or D4 (left  
side) for an open or shorted condition. See  
the Wiring Diagram.  
COMMANDER 500  
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F-50  
F-50  
TROUBLESHOOTING & REPAIR  
CHARGING CIRCUIT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the engine alternator and associated circuitry are functioning  
properly.  
MATERIALS NEEDED  
3/8" Wrench  
Volt/Ohmmeter  
Wiring Diagram  
This procedure should take approximately 30 minutes to perform.  
COMMANDER 500  
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F-51  
F-51  
TROUBLESHOOTING & REPAIR  
CHARGING CIRCUIT TEST (CONTINUED)  
FIGURE F.24 – ENGINE ALTERNATOR LOCATION  
#239  
#281  
#238  
TEST PROCEDURE  
1. Turn engine off.  
7. Set the voltmeter for DC volts and measure  
the DC volts at lead #281 to engine  
ground. See the Wiring Diagram. Normal  
is 13.2 to 14.5 VDC.  
2. Using the 3/8" wrench, remove the left rear  
case cover.  
3. Locate the engine alternator. See Figure  
F.24.  
NOTE: Lead #281 carries the flashing voltage  
for the engine alternator. Battery voltage should  
be present whenever the engine is running.  
See the Wiring Diagram.  
4. Start the engine and run it at high idle (1900  
RPM).  
5. Set the voltmeter for DC volts and measure  
the DC volts at lead #239 to engine ground.  
See the Wiring Diagram. Normal is 13.2 to  
14.5VDC.  
8. If the correct flashing voltage is present  
and the charging output voltage is low or  
missing, the engine alternator may be  
faulty.  
6. Set the voltmeter for DC volts and measure  
the DC volts at lead #238 to engine ground.  
See the Wiring Diagram. Normal is 13.2 to  
14.5VDC.  
9. Stop the engine and check the alternator V-  
belt for proper tension. See the engine  
operation manual.  
10. Replace the left rear case cover.  
COMMANDER 500  
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F-52  
F-52  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)  
HIGH IDLE – NO LOAD  
15.8 ms  
0 volts  
5ms  
50V  
This is the typical auxiliary output  
voltage generated from a properly  
operating machine. Note that each  
vertical division represents 50 volts  
and that each horizontal division rep-  
resents 5 milliseconds in time.  
Note: Scope probes connected at  
machine 115VAC receptacle.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 500  
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F-53  
F-53  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (STICK)  
MAX TAP – MAX CONTROL POT – HIGH IDLE – NO LOAD  
0 volts  
5ms  
50V  
This is the typical DC open circuit out-  
put voltage generated from a properly  
operating machine. Note that each  
vertical division represents 50 volts  
and that each horizontal division rep-  
resents 5 milliseconds in time.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 500  
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F-54  
F-54  
TROUBLESHOOTING & REPAIR  
NORMAL WELD VOLTAGE WAVEFORM (STICK CC)  
MACHINE LOADED TO 500 AMPS AT 40 VOLTS  
0 volts  
20V  
0.1ms  
This is the typical DC output voltage  
generated from a properly operating  
machine. Note that each vertical  
division represents 20 volts and that  
each horizontal division represents  
0.1 milliseconds in time.  
The machine was loaded with a  
resistance grid bank to 500 amps at  
40 volts.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep..0.1 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 500  
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F-55  
F-55  
TROUBLESHOOTING & REPAIR  
NORMAL WELD VOLTAGE WAVEFORM (WIRE CV)  
MACHINE LOADED TO 500 AMPS AT 40 VOLTS  
0 volts  
0.1ms  
20V  
This is the typical DC output voltage  
generated from a properly operating  
machine. Note that each vertical  
division represents 20 volts and that  
each horizontal division represents 5  
milliseconds in time.  
The machine was loaded with a  
resistance grid bank to 500 amps at  
40 volts.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep..0.1 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 500  
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F-56  
F-56  
TROUBLESHOOTING & REPAIR  
NORMAL TIG MODE VOLTAGE WAVEFORM  
LOADED TO 200A 16 VOLTS  
0 volts  
50ms  
10V  
This is the typical TIG MODE output  
voltage generated from a properly  
operating machine. Note that each  
vertical division represents 10 volts  
and that each horizontal division rep-  
resents 50 microseconds in time.  
The machine was loaded with a resis-  
tance grid bank to 200 amps at 16  
VDC.  
SCOPE SETTINGS  
Volts/Div.....................10V/Div.  
Horizontal Sweep...50 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 500  
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F-57  
F-57  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV TAP)  
MAX CONTROL POT – HIGH IDLE – NO LOAD  
0 volts  
5MS  
50V  
This is the typical DC open circuit  
output voltage generated from a  
properly operating machine. Note  
that each vertical division represents  
50 volts and that each horizontal  
division represents 5 milliseconds in  
time.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 500  
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F-58  
F-58  
TROUBLESHOOTING & REPAIR  
SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This procedure will aid the technician in the removal and replacement of the shutdown  
solenoid.  
MATERIALS NEEDED  
7/16" Wrench  
Long slot head screwdriver  
Needle nose pliers  
This procedure should take approximately 30 minutes to perform.  
COMMANDER 500  
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F-59  
F-59  
TROUBLESHOOTING & REPAIR  
SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F. 25 – SHUTDOWN SOLENOID LEAD CONNECTIONS  
PULL-IN COIL  
(LARGER TERMINALS  
EACH SIDE  
#232M AND #265)  
SHUTDOWN  
SOLENOID  
HOLD-IN COIL  
(SMALLER TERMINALS  
IDLER  
SOLENOID  
EACH SIDE  
#224 AND #262)  
PROCEDURE  
1. Turn engine off.  
2. Unlatch, lift and secure the engine access  
door.  
3. Locate and remove the four spade connec-  
tors that attach the shutdown solenoid termi-  
nals to the wiring harness leads (#224,  
#232M, #265 and #262). See Figure F.25.  
Cut the cable tie.  
COMMANDER 500  
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F-60  
F-60  
TROUBLESHOOTING & REPAIR  
SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F. 26 – SHUTDOWN SOLENOID LINKAGE ARM ASSEMBLY  
MOUNTING  
FASTENERS  
PIVOT PIN  
SPACER  
WASHER  
PLAIN  
WASHER  
RETAINING  
RING  
4. Using the 7/16" wrench, remove the three  
REASSEMBLY  
nuts, two bolts and three lock washers  
1. Using the long screw driver and needle nose  
mounting the shutdown solenoid assembly  
pliers, carefully assemble the retaining ring,  
to the engine. See Figure F.26.  
plain washer, spacer washer, and pivot pin  
5. Using the long screwdriver and needle nose  
pliers carefully remove the retaining ring,  
plain washer, spacer washer and pivot pin  
from the linkage arm assembly. See Figure  
F.26.  
to the to the linkage arm assembly. See  
Figure F. 26.  
2. Using the 7/16" wrench, mount the shut-  
down solenoid assembly to the engine with  
three nuts, two bolts, and three lock wash-  
ers.  
6. Carefully remove the solenoid assembly.  
7. Replace any faulty parts and reassemble the  
solenoid assembly.  
3. Attach the four spade connectors from the  
wiring harness leads (#224, #232M, #265,  
and #262) to the shutdown solenoid termi-  
nals. See Figure F.25. Replace the cable  
tie.  
4. Close the engine access door.  
COMMANDER 500  
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F-61  
F-61  
TROUBLESHOOTING & REPAIR  
POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY  
REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This procedure will aid the technician in the removal and replacement of the power mod-  
ule/output rectifier bridge assembly. Once the assembly is removed, the power module  
PC boards and output rectifier bridge diodes can be accessed for removal and replace-  
ment.  
MATERIALS NEEDED  
3/8" Wrench  
7/16" Wrench or socket wrench  
1/2” Wrench  
Phillips head screw driver  
This procedure should take approximately 80 minutes to perform.  
COMMANDER 500  
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F-62  
F-62  
TROUBLESHOOTING & REPAIR  
POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY  
REMOVAL AND REPLACEMENT (CONTINUED)  
F.27 – CONTROL PANEL REMOVAL  
SCREWS  
FRONT  
CONTROL  
PANEL  
SCREW  
GREEN  
GROUND  
LEAD  
PROCEDURE  
1. Turn the engine off.  
5. Perform the Output Panel Removal section  
of the Case Cover Removal procedure.  
2. Using the 3/8" wrench, remove the screws  
holding the front control panel to the case  
top and sides. See Figure F.27. (There are  
two screws on the top and one screw on  
each side.)  
6. Perform the Power Module Capacitor  
Discharge Procedure.  
7. Optional: With the 7/16" wrench, remove the  
ground wire from the output panel assembly.  
If the ground wire is not in the way, it can  
remain attached.  
3. Carefully lower the front control panel.  
4. Using the 3/8" wrench, remove the front left  
and right side panels.  
COMMANDER 500  
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F-63  
F-63  
TROUBLESHOOTING & REPAIR  
POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY  
REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F. 28 – POWER MODULE CAPACITOR LEAD REMOVAL  
POWER  
MODULE  
REMOVE LEADS  
Refer to Figure F.28 for Steps 8-12.  
10. Disconnect the thermostat leads. Separate  
lead #249 on the right side. Cut any nec-  
essary cable ties.  
8. Using the 7/16" wrench, loosen the nuts on  
the positive terminals of the power capaci-  
tors. Then remove the nuts, lock washers,  
and flat washers from the terminals where  
the positive straps connect to the power  
module PC board. Flip the straps out of  
the way. Also disconnect diode lead D3  
(right side power module) and D4 (left side  
power module).  
11. Disconnect leads #14A and 13A at their in-  
line connectors (left side only).  
12. With the 1/2" wrench, disconnect the bolt,  
lock washer and flat washer from the shunt  
at choke lead W11. Cut the cable tie and  
pull lead W11 through the toroid.  
9. With the phillips screw driver, remove plug  
and lead assembly for P/J 50 (right side) or  
P/J51 (left side). Cut any necessary cable  
ties.  
COMMANDER 500  
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F-64  
F-64  
TROUBLESHOOTING & REPAIR  
POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY  
REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F.29 – POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY DETAILS  
TOP  
BRACKET  
}
}
POWER  
MODULE  
PC BOARD  
(CHOPPER  
PC BOARD)  
POWER  
MODULE  
HEATSINK  
DIODE &  
“W” LEAD  
TERMINAL  
(3)  
DIODE  
HEATSINK  
GLASTIC  
INSULATOR  
BRACKET  
DIODE  
LEADS  
CONTROL  
TRANSFORMER  
BOTTOM  
BRACKET  
CAPACITOR  
COMMANDER 500  
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F-65  
F-65  
TROUBLESHOOTING & REPAIR  
POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY  
REMOVAL AND REPLACEMENT (CONTINUED)  
Refer to Figure F.29 for Steps 13-15.  
4. Feed the stator "W" leads through the top  
bracket and attach them to the terminals on  
the glastic insulator bracket.  
13. Using the 7/16" wrench, remove the stator  
"W" leads from the three terminals on the  
plastic insulator bracket of the rectifier  
bridge. Label the leads for reassembly.  
Pull the leads out through the power mod-  
ule top bracket.  
5. Pass choke lead W11 through the toroid  
and connect it to the shunt.  
6. Connect plug assemblies P/J50 and P/J51  
to the power module PC board (both  
sides).  
14. Using the 1/2" wrench, remove the flat  
strap to the negative output terminal. Pull  
the strap through the power module top  
bracket.  
7. Connect the power module capacitor  
leads. Torque the capacitor nuts to 50-60  
inch-pounds.  
15. With the 7/16" socket wrench, remove the  
four nuts, lock washers, flat washers, and  
carriage bolts that hold the power module  
bottom bracket to the machine base.  
8. Replace any cable ties cut during removal.  
9. Install the output panel.  
10. Connect the ground wire to the output  
panel assembly, if removed.  
The power module/output rectifier bridge  
assembly can now be removed and set to the  
side.  
11. Attach the front left and right side panels  
and the front control panel.  
REPLACEMENT PROCEDURE  
1. Place the assembly back into the machine.  
2. Install the four carriage bolts, flat washers,  
lock washers, and nuts that hold the bottom  
bracket to the machine base.  
3. Pull the flat negative output strap through  
the top bracket and attach it.  
COMMANDER 500  
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F-66  
F-66  
TROUBLESHOOTING & REPAIR  
POWER MODULE (CHOPPER) PC BOARD/DIODE  
MODULE REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This procedure will aid the technician in the removal and replacement of the Power  
Module (chopper) PC board and the board diode module.  
MATERIALS NEEDED  
7/16" Wrench  
3/8" Allen head wrench  
9/64" Allen head socket  
Phillips head screw driver  
Penetrox A13 thermal joint compound (T12837-1) -2 gm tube  
This procedure should take approximately 60 minutes to perform.  
COMMANDER 500  
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F-67  
F-67  
TROUBLESHOOTING & REPAIR  
POWER MODULE (CHOPPER) PC BOARD/DIODE  
MODULE REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F.30 – POWER MODULE PC BOARD  
TEMPERATURE  
SWITCH  
HEAT SINK  
COPPER  
SPACERS  
DIODE MODULE  
ALLEN HEAD  
SCREWS (4)  
POWER  
MODULE  
PC BOARD  
PLUG J50  
POWER MODULE PC BOARD  
REMOVAL  
to the Power Module PC board. (Right  
side: W7, W8, and D3. Left side: W9, W10  
and D4.) See the Wiring Diagram.  
Refer to Figure F.30.  
1. Turn the engine off.  
2. Remove the front right or left case side,  
depending on which Power Module PC  
board you are removing.  
7. With the 7/16" wrench, remove the nuts, lock  
washers, and flat washers holding the posi-  
tive capacitor straps to the Power Module  
PC board. Loosen the nuts at the capacitor  
terminals and swing the straps out of the  
way.  
3. Perform the Output Panel Removal proce-  
dure section of the Case Cover Removal  
procedure.  
4. Perform the Power Module Capacitor  
8. With the 3/8" allen wrench, remove the top  
and bottom cap screws from the Power  
Module PC board.  
Discharge procedure.  
5. With the phillips screw driver, remove plug  
and lead assembly for P/J 50 (right side) or  
P/J51 (left side). Cut any necessary cable  
ties.  
NOTE: Each top cap screw has a copper stand-  
off on the opposite side of the board. Be sure  
to place this standoff between the heat sink and  
the PC board at reassembly.  
6. With the 7/16" wrench, remove the nuts,  
lock washers, and flat washers holding the  
two heavy leads and the small diode leads  
9. Remove the power module board.  
COMMANDER 500  
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F-68  
F-68  
TROUBLESHOOTING & REPAIR  
POWER MODULE (CHOPPER) PC BOARD/DIODE  
MODULE REMOVAL AND REPLACEMENT (CONTINUED)  
POWER MODULE PC BOARD  
REPLACEMENT  
1. Apply Penetrox A-13 joint compound  
(T12837-1) to the surface of the heat sink  
where the Power Module PC board mounts.  
4. Install the small diode leads and the heavy  
leads, flat washers, lock washers, and nuts  
to the Power Module PC board. Torque the  
nuts to 50-60 inch-pounds.  
2. Install the top and bottom allen head cap  
screws. Insert the bolts into the board  
before mounting it. Torque the screws to 50-  
60 inch-pounds.  
5. Install plug and lead assembly P/J50 (right  
side) or P/J51 (left side).  
6. Replace any cable ties cut at disassembly.  
IMPORTANT: Each top cap screw has a copper  
standoff on the opposite side of the board. Be  
sure to place this standoff between the heat  
sink and the PC board.  
See the procedures below for removal and  
replacement of the Power Module PC board  
diode module. When procedures are complete,  
perform the Output Panel Replacement and  
the Case Cover Replacement Procedures.  
3. Install the positive capacitor straps, flat  
washers, lock washers, and nuts. Torque  
the nuts to 50-60 inch-pounds at the Power  
Module PC board and at the capacitor termi-  
nals.  
COMMANDER 500  
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F-69  
F-69  
TROUBLESHOOTING & REPAIR  
POWER MODULE (CHOPPER) PC BOARD/DIODE  
MODULE REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F.31 – DIODE MODULE MOUNTING DETAILS AND TIGHTENING SEQUENCE  
2 TO 3  
TURNS EACH  
12-18 IN.LBS.  
SPRING WASHER  
PLAIN WASHER  
5.0-10 IN-LBS.  
30-40 IN.LBS.  
FINGER TIGHT  
5.0-10 IN-LBS.  
1. Be sure the heat sink mounting surface is  
clean, dry, and free of grease.  
DIODE MODULE REMOVAL  
Refer to Figure F.31.  
2. Apply a thin, even coat (.1 to .25mm or .004  
to .010 in) of Penetrox A13 thermal joint  
compound (T12837-1) to the diode module  
base plate only, under the plastic body of the  
module. Do not apply compound to the area  
under the mounting holes.  
1. Remove the Power Module PC board as  
described above.  
2. Using the 7/16" wrench, remove the two  
outer screws, spring washers, and large flat  
washers from the diode module.  
3. Press the module firmly against the heat  
sink, aligning the mounting holes.  
3. Using the 9/64" allen wrench, remove the  
set screw from the center of the diode  
module.  
4. Place a spring washer then a flat washer  
over each outer mounting screw and insert  
them into the holes. Insert the allen head  
screw into the center hole. Tighten all three  
screws 2 – 3 turns each, finger-tight only (1).  
4. Remove the diode module from the heat  
sink.  
DIODE MODULE REPLACEMENT  
5. Using the torque wrench and 7/16" socket,  
tighten each outer screw between 5.0 and  
10 in-lbs (2).  
Refer to Figure F.31.  
6. Using the torque wrench and 9/64" allen  
head socket, tighten the center screw  
between 12 and 18 in-lbs (3).  
CAUTION  
The proper tightening sequence is required to  
mount the diode module to the heat sink in  
order to avoid warping the base plate. Apply  
the proper torque to all fasteners.  
7. Now tighten the two outer screws between  
30 and 40 in-lbs (4).  
8. Replace the Power Module PC board as  
described above.  
COMMANDER 500  
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F-70  
F-70  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE DIODE REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing and replacing stud type diodes  
to the aluminum heat sinks on the Commander 500.  
MATERIALS NEEDED  
7/16" Wrench  
1/2” Wrench  
1" Open end wrench  
Penetrox A13 joint compound (T12837-1) -2 gm. tube  
Loctite 271  
"Slip" type torque wrench  
E2827-2 abrasive disc or fine steel wool  
This procedure should take approximately 25 minutes to perform.  
COMMANDER 500  
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F-71  
F-71  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE DIODE REMOVAL AND  
REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F.32 – POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY DETAILS  
HEATSINKS  
DIODE  
DIODE  
PIGTAIL  
LEADS  
PROCEDURE  
Refer to Figure F.32.  
Label the leads for reassembly if more than one  
is removed.  
1. Turn the engine off.  
5. Using the 1" wrench, loosen the appropriate  
diode and remove the diode that is to be  
replaced.  
2. Perform the Output Panel Removal as  
described in the Case Cover Removal pro-  
cedure.  
6. Clean the area on the heat sink around the  
diode mounting surface using a putty knife  
or similar tool. DO NOT SCRATCH THE  
DIODE MOUNTING SURFACE.  
3. Perform the Power Module Capacitor  
Discharge procedure.  
4. Using the 7/16" wrench, remove the appro-  
priate stator leads and diode pigtail lead  
from the stud on the output rectifier bridge  
glastic insulator bracket. The bottom diodes  
require a 1/2" wrench to remove the double  
heavy leads.  
7. Polish the heat sink's mounting surface  
using an abrasive disc, E2827-2 or fine steel  
wool to provide a bright, clean surface where  
the diode seats on the heat sink. Wipe the  
surface clean with a lint-free cloth or paper  
towel.  
COMMANDER 500  
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F-72  
F-72  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE DIODE REMOVAL AND  
REMOVAL AND REPLACEMENT (CONTINUED)  
8. Inspect the mounting surfaces of each new  
diode. Remove all burrs and wipe clean.  
Do not use steel wool or any abrasive  
cleanser on the diode mounting surface.  
NOTE: The diode threads must be clean and  
free of defects so that it can be finger tightened  
before applying torque. A "slip" type torque  
wrench must be used to tighten the diode.  
9. Apply a thin (0.003" to 0.007") uniform  
layer of Penetrox A13 joint compound  
(T12837-1) to the heat sink mounting sur-  
face.  
10. Tighten the diode to the specifications in  
the following table.  
11. Connect the stator leads and diode pigtail  
leads as labeled at disassembly.  
a. Do not apply compound to the diode  
stud or mounting threads.  
12. Replace the output panel.  
b. Apply two drops of Loctite 271 to the  
diode stud threads before tightening.  
DIODE STUD SIZE  
3/4 - 16  
FOOT POUNDS  
25-27  
INCH POUNDS  
300-324  
3/8 - 24  
10 ± 0.5  
125 +0/-5  
COMMANDER 500  
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F-73  
F-73  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing and replacing the Commander  
500 stator and rotor.  
MATERIALS NEEDED  
5/16" Wrench  
3/8" Wrench  
7/16" Wrench  
1/2" Wrench  
Slot head screw driver  
Phillips head screw driver  
Gear puller (small)  
3/4" Wrench  
Hoist  
1" Open end wrench  
1 1/8" Wrench  
Feeler gauge (for air gap check)  
9/16" Deep socket wrench  
17mm Wrench  
This procedure should take approximately 5-1/2 hours to perform.  
COMMANDER 500  
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F-74  
F-74  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F.33 – FUEL TANK REMOVAL DETAILS  
LEADS #229  
AND #242D  
PLUG  
FUEL  
LINES  
U-BOLTS (2)  
{
PREPARATION AND LEAD  
REMOVAL PROCEDURE  
Refer to Figure F.33.  
6. Turn the fuel off at the shutoff valve.  
Remove and plug the fuel return line.  
1. Turn the engine off.  
7. Remove and plug the lower fuel line. Pull it  
through the firewall.  
2. Perform the Case Cover Removal proce-  
dure, including removing the output panel.  
8. Using the 9/16" deep socket wrench,  
remove the four lock nuts, washers, and rub-  
ber washers from the fuel tank mounting U-  
bolts.  
3. Perform the Power Module/Output  
Rectifier Bridge Assembly Removal  
Procedure.  
4. Perform the Power Module Capacitor  
9. Carefully remove the U-bolts and lift the fuel  
tank from the machine.  
Discharge Procedure.  
5. Using the 3/8" wrench, remove leads #229  
(white) and #242D from the fuel level sensor.  
Label the leads for reassembly.  
COMMANDER 500  
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F-75  
F-75  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F.34 – PLUG J52/FILTER CAPACITOR/FIELD RECTIFIER BRIDGE DISCONNECTION  
PLUG P/J52  
#200D  
#5P  
6F  
#201  
#201A  
FILTER  
CAPACITOR  
FIELD DIODE  
RECTIFIER BRIDGE  
Refer to Figure F.34 for Steps 10-12.  
12. Label and remove leads #5P, #201 and  
#201A, #200D, and #6F from the field  
diode rectifier bridge.  
10. Disconnect plug J52 at the right front side.  
See Figure F.34.  
11. Using the slot head screw driver, discon-  
nect leads #200C, #200E(+) and #201D(-)  
from the filter capacitor.  
COMMANDER 500  
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F-76  
F-76  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F.35 – BRUSH HOLDER AND LEAD REMOVAL  
Refer to Figure F.35 for Steps 13-15.  
13. Using the 3/8" wrench, remove the brush holder  
access panel.  
#200A  
#200B  
14. Using the 3/8" wrench, remove the brush holder  
assembly.  
15. Cut the cable tie and then label and remove brush  
leads #201(-) and piggy-backed leads #200A(+)  
and #200B(+) from the brush holder assembly.  
(The piggy-backed leads connect closest to the  
stator laminations.)  
#201  
FIGURE F.36 – CONTROL BOX CONNECTIONS  
PULL COIL PC BOARD  
(LEADS #265 AND #227)  
CONTROL BOX  
12 VDC STUD  
LEADS #232L  
AND #232M  
16. See Figure F.36. Disconnect leads #265 and #227  
from the Pull Coil PC board. With the 7/16"  
wrench, remove the nut, lock washer, and flat  
washer from the 12 VDC insulated stud. Remove  
leads 232L and #232M from the stud. Cut any  
necessary cable ties. Pull all leads freed in this  
step through the control box panel.  
17. With the 3/8" wrench, remove the two screws from  
the bottom of the control box. Swing the control  
box aside and lay it down.  
COMMANDER 500  
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F-77  
F-77  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F.37 – ALTERNATOR SHROUD REMOVAL  
6 SCREWS  
SHROUD  
ACOUSTICAL  
FOAM  
18. With the 5/16" wrench, remove the six  
screws that hold the top and bottom of the  
alternator shroud together.  
19. With the 7/16" wrench, remove the two  
nuts, lock washers and flat washers that  
hold the bottom of the shroud to the  
machine base. Remove the shroud.  
COMMANDER 500  
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F-78  
F-78  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F.38 – LIFT FRAME AND ASSOCIATED COMPONENT REMOVAL  
LIFT FRAME  
WELDMENT  
CENTER PANEL  
FUEL TANK  
SUPPORTS  
FAN BAFFLE  
BASE  
In steps 20 – 24, the lift frame weldment, fuel  
tank supports, and fan baffle are removed as a  
unit. See Figure F.38.  
22. With the 3/8" wrench, remove the nuts, lock  
washers, and flat washers from the two  
studs that hold the fan baffle to the  
machine base.  
20. Using the 3/8" wrench, remove the two  
bolts (at top) that hold the center panel to  
the lift frame weldment.  
23. Using the 3/4" wrench, remove the four  
bolts, lock washers, and nuts from the bot-  
tom of the lift frame weldment.  
21. Using the 1/2" wrench, remove the two  
bolts (at bottom) that hold the center panel  
to the lift frame weldment.  
24. Carefully remove the lift frame weldment,  
fuel tank supports, and attached fan baffle.  
You will need to lift the fan baffle off the two  
studs on the machine base, then cock it  
slightly to remove it.  
COMMANDER 500  
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F-79  
F-79  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F.39 – STATOR REMOVAL  
STATOR / ENGINE  
MOUNTING BOLTS &  
LOCK WASHERS  
BEARING  
FAN HUB  
FLYWHEEL  
SPLASH  
PLATE  
BOLTS  
(4)  
FAN  
NUT  
MOUNTING  
FOOT  
STATOR REMOVAL PROCEDURE  
5. Using two 3/4" wrenches, remove the nut,  
lock washer, and carriage bolt holding the  
alternator mounting foot to the machine  
base. Do this on each side.  
First, cut any necessary cable ties in order to  
free the stator leads from the bundle of leads  
running to the control box. Refer to Figure F.39  
for stator removal.  
6. Using the 3/8" wrench, remove the three  
bolts from the flywheel splash plate.  
Remove the plate.  
1. Using the 1/2” wrench, remove the four fan  
blade mounting bolts and lock washers.  
2. Using the 1 1/8" wrench, remove the fan nut.  
Remove the fan, noting its direction for  
reassembly.  
7. Support the stator with the hoist. Place  
wooden blocks under the engine to support  
it when the stator is removed.  
3. Using the gear puller, remove the fan hub.  
8. Using the 17mm" wrench, remove the bolts  
and lock washers holding the stator to the  
engine.  
4. Using the 3/8" wrench, remove the two bolts  
and flat washers holding the bearing in  
place.  
9. Remove the stator from the engine. It may  
be necessary to pry and slide it free.  
COMMANDER 500  
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F-80  
F-80  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED)  
FIGURE F.40 – ROTOR REMOVAL  
FLEX PLATE  
ROTOR  
BLOWER  
SEGMENT (4)  
ROTOR REMOVAL PROCEDURE  
Refer to Figure F.40 for rotor removal.  
1. Support the rotor with the hoist.  
INSTALL ROTOR: Support the rotor with the  
hoist. Install the blower segments and flex plate  
to the engine flywheel.  
2. Using the 5/8" wrench, remove the flex plate  
bolts, lock washers, and four blower seg-  
ments.  
INSTALL STATOR: Be sure the engine is  
blocked securely and the stator is supported  
with the hoist. Install the stator to the engine  
with the bolts and lock washers. Install the fan  
blade, making sure that it faces the proper  
direction, with the fan nut and four cap screws.  
WARNING  
The rotor will be free to fall when the bolts are  
removed.  
Check the air gap for .010" minimum.  
Install the brush holder assembly. Be sure the  
brushes are centered and properly seated on  
the slip rings.  
3. Using the hoist, carefully remove the rotor  
and flex plate assembly.  
Install the flywheel splash plate.  
REASSEMBLY NOTES  
Reassemble the rotor and stator to the  
Commander 500 by carefully retracing the dis-  
assembly procedure steps in reverse order.  
Keep the following special points in mind as you  
proceed. Lead Reconnection Checklists are  
provided here as an aid to reassembly.  
COMMANDER 500  
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F-81  
F-81  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED)  
LEAD RECONNECTION CHECKLIST  
ENGINE  
OUTPUT PANEL AND CONTROL BOX  
I Leads #242D and #229 to fuel level sensor  
I Leads #265 and #227 to Pull Coil PC board  
I Plug J52  
I Leads #232L and #232M to 12 VDC insu-  
lated stud  
I Brush leads #201(-) and #200A(+) and  
I Leads #200C, #200E(+), and #200B(-) to  
#200B(+)  
the field capacitor  
I Leads #5P, #201 and #201A, #200D, and  
#6F to the field bridge rectifier  
COMMANDER 500  
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F-82  
F-82  
TROUBLESHOOTING & REPAIR  
RETEST AFTER REPAIR  
Retest a machine:  
• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the  
machine’s electrical characteristics. OR  
• If you repair or replace any electrical components.  
ENGINE RPM  
Mode  
No Load RPM  
1400 - 1450  
1890 - 1910  
Load RPM  
NA  
Low Idle  
High Idle  
1750 - 1890  
WELDER DC (STICK) OUTPUT  
Mode Selector  
Open Circuit  
Switch  
Fine Control  
Maximum  
Voltage  
Load Volts  
39.5 - 42.0  
Load Amps  
575 - 585  
30-575 Setting  
75 - 80  
PIPE MODES SHORT CIRCUIT CURRENT  
(FINE CONTROL AT MAXIMUM)  
Selector Position  
Short Circuit Current (Amps)  
90  
127 - 140  
215 - 230  
310 - 330  
545 - 575  
640 - 660  
150  
200  
350  
500  
WELDER CV (WIRE) OUTPUT  
Mode Selector  
Switch  
Open Circuit  
Fine Control  
Voltage  
75 - 78  
NA  
Load Volts  
39 - 42  
Load Amps  
520 - 535  
20  
CV - Wire  
CV - Wire  
CV - Wire  
Maximum  
Maximum  
Minimum  
48 - 49  
13 - 14  
23 - 25  
20  
COMMANDER 500  
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F-83  
F-83  
TROUBLESHOOTING & REPAIR  
RETEST AFTER REPAIR (CONTINUED)  
TOUCH START TIG MODE OUTPUT  
Open Circuit  
Mode Selector  
Switch  
Short Circuit  
Current  
Fine Control  
Voltage  
TIG 20 - 250 A  
TIG 20 - 250 A  
Maximum  
14.0 - 15.8  
12.0 - 13.8  
25 - 27  
21 - 24  
Minimum  
AUXILIARY POWER OUTPUT  
230 Volt Receptacle  
115 Volt Receptacles  
Open Circuit  
Voltage  
Open Circuit  
Voltage  
Load Volts  
Load Amps  
Load Volts  
Load Amps  
15  
245 - 254  
225 - 240  
50  
118 - 132  
112 - 128  
COMMANDER 500  
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G-1  
G-1  
ELECTRICAL DIAGRAMS  
TABLE OF CONTENTS  
-ELECTRICAL DIAGRAMS SECTION-  
Electrical Diagrams ........................................................................................................................G-1  
Wiring Diagram...........................................................................................................................G-2  
Schematic – Complete Machine.................................................................................................G-3  
Schematic – Battery PC Board...................................................................................................G-4  
PC Board Assembly – Battery PC Board ...................................................................................G-5  
Schematic – Chopper PC Board ................................................................................................G-6  
PC Board Assembly – Chopper PC Board.................................................................................G-7  
Schematic – Peripheral PC Board..............................................................................................G-8  
PC Board Assembly – Peripheral PC Board ..............................................................................G-9  
Schematic – Power Supply (Analog) PC Board .......................................................................G-10  
PC Board Assembly – Power Supply (Analog) PC Board........................................................G-11  
Schematic – Pull-Coil PC Board...............................................................................................G-12  
PC Board Assembly – Pull-Coil PC Board ...............................................................................G-13  
Schematic – Weld Control PC Board – Sheet 1.......................................................................G-14  
Schematic – Weld Control PC Board – Sheet 2.......................................................................G-15  
Schematic – Weld Control PC Board – Sheet 3.......................................................................G-16  
Schematic – Weld Control PC Board – Sheet 4.......................................................................G-17  
Schematic – Weld Control PC Board – Sheet 5.......................................................................G-18  
PC Board Assembly – Weld Control PC Board........................................................................G-19  
COMMANDER 500  
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G-2  
G-2  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - COMMANDER 500  
6A  
6A  
6A  
3
3
3
LEADS 3 & 6A  
PASS THROUGH  
TOROID TWICE  
IN OPPOSITE  
DIRECTIONS  
3
GND-F  
5A  
COMMANDER 500 WIRING DIAGRAM  
120V AUXILIARY POWER  
"INSULATED STUD"  
CORRESPONDING SETTINGS  
FOR TAP NUMBERS  
(AS VIEWED FROM THE FRONT)  
W2 & W3  
W1 & W6  
W4 & W5  
STATOR AUXILIARY WINDINGS  
6A  
ON BOTTOM LEFT  
OF CONTROL BOX  
WELD LEAD TO PASS  
+
THRU TOROID ONCE  
350A  
12  
200A  
11  
P50  
6D  
3
HEATSINK  
B1  
6
D3  
AUXILIARY POWER  
GND. SCREW ON  
CONTROL PANEL  
150A  
500A  
6A  
10  
1
5A  
5
POS.  
+
3
6
9
2
5
8
1
4
7
POS  
STICK  
GND-C  
B2  
B3  
B7  
90A  
C1  
C2  
C3  
C4  
9
8
2
3
30-575A  
W7  
260  
261  
3
GND-D  
RECTIFIER BRIDGE  
WIRE  
14 TO 40V  
TIG  
GND-E  
PC BOARD TO  
NEG.  
20-250A  
250  
HEAT SINK CONN.  
OLDER MACHINES MAYBE  
WIRED AS SHOWN:  
20A  
9
TS1  
249  
D1 DIODE  
MODULE  
EMPTY  
EMPTY  
NEG.  
31  
EMPTY  
SELECTOR SWITCH  
(VIEWED FROM REAR)  
S5  
204S  
EMPTY  
CB1  
17  
18  
PC BOARD TO  
SELECTOR SWITCH  
(VIEWED FROM REAR)  
NEG.  
3A  
3
HEAT SINK CONN.  
GND-E  
5B  
1
4
7
2
5
8
3
6
9
31  
W3  
W3  
W2  
W2  
217  
6
5
216  
WELD  
LEAD  
+
J50  
SILVER  
50A  
S5  
206S  
GND-C  
260A  
261A  
LEFTSIDE  
300 AMP  
MODULE  
3
W8  
218  
7
4
215  
23  
25  
11  
217  
218  
12  
216  
11  
J12  
6A  
A
PCB 6  
11  
8
3
214  
213  
115/230V  
POS.  
1
+
10 215  
L1 CHOKE  
AUXILIARY  
CB3  
20A  
J10  
2
220  
9
ELECT.  
NEUTRAL STUD  
BACK OF CONTROL  
BOX "LEFT SIDE"  
GND-D  
C1  
2
214  
213  
9
STATOR  
WELD  
WINDINGS  
222  
9
8
HOT (GOLD)  
SILVER  
8
220  
3
W4  
W4  
W1  
W1  
P51  
GND-G  
D4  
HEATSINK  
8
5E  
222  
12  
CB2  
50A  
POS.  
206A  
206B  
+
J11  
B1  
B2  
3
6
9
2
5
8
1
4
7
STATOR 42V WINDING  
GND-F  
W5  
W5  
W6  
W6  
10A  
CB6  
POS  
6B  
5
W9  
B3  
B7  
GND-H  
42  
5C  
6D  
6A  
BYPASS  
FILTER  
ASSEMBLY  
PC BOARD TO  
NEG.  
5E  
HOT (GOLD)  
249  
GND-K  
CB4  
HEAT SINK CONN.  
42A  
5B  
41  
5C  
TS2  
251  
D2 DIODE  
MODULE  
NEG.  
5
14A  
14  
12  
15  
16  
PC BOARD TO  
NEG.  
HEAT SINK CONN.  
208  
1
4
7
2
5
8
3
6
9
41A  
J41  
RIGHT SIDE  
300 AMP  
MODULE  
23A  
25A  
W10  
1
2
J51  
6A  
200B  
PCB 2  
1
GND-G  
5
13  
14  
POS.  
+
208B  
3
201  
200A  
200D  
WORK  
BRUSH  
13  
13A  
3
4
BRUSH  
POWER MODULE  
200E  
200C  
3200MFD  
208A  
+
-
10  
6
1
2
6F  
6D  
200E  
200C  
POWER SUPPLY  
PCB2  
J42  
200A  
200D  
262  
300V  
NOTE: ON SOME MACHINES, LEADS  
6D & 6F, 5H & 5P MAY BE CONNECT-  
ED OUTSIDE THE J52/P52 IN-LINE  
CONNECTOR.  
5J  
6D  
3
201B  
ROTOR  
SWITCH SHOWN IN  
POSITIVE POLARITY  
POSITION  
262A  
228A  
241A  
201B  
5H  
4
3
201A  
228  
5
POSITIVE BRUSH CONNECTED  
TO SLIP RING NEAREST  
TO THE LAMINATION  
241  
201A  
5P  
6
6A  
5P  
201  
7
6F  
8
+
ENGINE HARNESS  
232S  
226A  
200B  
232T  
226  
9
POLARITY  
SWITCH  
21  
10  
11  
12  
13  
14  
200  
31  
32  
31  
-
232T  
224A  
234A  
233A  
281A  
239A  
224  
234  
233  
281  
239  
32  
41A  
42A  
5J  
41A  
MULTI-LEAD  
15  
16  
42A  
206A  
208B  
232W  
232D  
256  
WELDING  
CONTROL  
TERMINALS  
SWITCH  
IDLER  
CONTROL  
OUTPUT  
CONTROL  
CCW  
J52  
P52  
SHOWN IN  
"ALWAYS ON" POSITION  
VIEWED  
FROM  
BACK  
HOUR  
METER  
NOTE: IDLER SWITCH MAY NOT  
APPEAR ON SOME MACHINES.  
LEAD 256 & 257 WILL BE  
31  
J
115VAC  
4
32  
R1  
A
I
-
M1  
M2  
1
2
3
4
M1  
M2  
M3  
M4  
M5  
M6  
CONNECTED TOGETHER, AND  
AUTO IDLE WILL BE DISABLED ON  
THESE MACHINES.  
4A  
HIGH  
VIEWED  
FROM  
BACK  
76  
PINCH POT  
10K  
226A  
41A  
42A  
42VAC  
WORK  
M3  
M4  
K
H
E
HOLD  
COIL  
232S  
232L  
+
2
2A  
77  
75  
AUTO  
21  
VOLTMETER  
NOTE: 238A, 236A, CB5  
MAY APPEAR ON SOME  
MACHINES IN PLACE OF  
OLD 236A.  
M5  
M6  
5
6
PULL  
227  
+
IDLE  
77B  
76B  
COIL  
REMOTE  
CONTROL  
232R  
7
SOL.  
262A  
262B  
SHOWN IN  
"HIGH" POSITION  
F
8
257  
279  
75B  
4B  
278  
277  
G
D
C
B
M9  
M9  
9
CONTACTOR  
M10  
M10  
10  
32  
PULL  
COIL  
265  
+
232M  
2B  
SHUTDOWN SOL.  
GROUND  
GND-A  
M1  
M2  
1
2
3
4
M1  
M2  
M3  
M4  
M5  
M6  
START BUTTON  
20A  
CB5  
GND-H  
HOLD  
COIL  
+
AMPHENOL 1  
M3  
M4  
ON STANDARD MODELS,  
238A  
LEADS 238 & 236C ARE TO BE  
BOLTED TOGETHER AND  
TAPED. LEADS 228A, 241A,  
242B, 232K AND 229A ARE TO  
BE TAPED INDIVIDUALY AND  
TIED INTO HARNESS.  
262  
224  
228  
DENOTES ITEMS  
INCLUDED ON DELUXE  
MODELS ONLY  
M5  
M6  
5
6
236A  
236A  
232B  
232C  
236  
238 238A  
AMMETER  
236B  
236C  
OIL PRESSURE SWITCH  
&
SENSOR  
77A  
7
77B  
76B  
75B  
2B  
A
BATT.  
CHRG.  
OIL  
8
OIL  
TEMP  
5H  
GND-G  
REMOTE  
CONTROL  
5J  
76A  
75A  
2A  
FUEL  
SENSOR  
PRESS.  
234  
231  
RUN/STOP  
SWITCH  
M9  
SWITCH  
M9  
9
B
C
D
E
F
RUN  
232R  
M10  
M10  
10  
12VDC  
INSULATED  
STUD  
METER KIT OPTIONAL  
ON STANDARD MODEL  
G
WK  
S
I
S
I
S
I
SHOWN IN  
"RUN" POS.  
STOP  
243  
245  
247  
246  
CONTACTOR  
5G  
242D  
OIL TEMP. SENSOR  
&
SWITCH  
GND. STUD ON  
BOTTOM RIGHT OF  
CONTROL BOX  
GOLD  
GOLD  
GOLD  
GOLD  
232A  
4A  
GOLD  
252  
5L  
5T  
232L  
232H  
4B  
232J  
233  
SENSOR  
241  
ON STANDARD  
242A  
LOW  
PRESS.  
LOW  
GND-J  
GROUND  
GND-B  
232D  
265  
242C  
TEMP.  
228A  
SWITCH  
MODELS, LEADS  
242D & 229 ARE  
TO BE TAPED  
WELDER  
TEMP.  
ALT.  
FUEL  
232  
GND-J  
238  
232M  
229A  
242B  
GAUGES  
OPTIONAL ON  
STANDARD MODEL  
229  
AMPHENOL 2  
232K  
FUEL LVL.  
SENSOR  
SILVER  
SILVER  
SILVER  
SILVER  
SILVER  
3 TURNS  
THRU  
TOROID  
3 TURNS  
THRU  
TOROID  
253  
241A 232K  
242D  
NOTE: MAY NOT APPEAR ON  
SOME DELUXE MACHINES.  
232F 232G 232E  
232P  
232N  
227  
232A  
238  
236  
32  
2
4
206S  
204S  
GROUND STUD ON  
OUTPUT PANEL  
236C  
231  
76A 75A  
77A  
1
NOTE: LEADS 229 AND 229A MAY  
BE SPLICED TOGETHER ON SOME  
MACHINES. LOW FUEL SHUTDOWN  
WILL BE DISABLED ON THESE  
MACHINES.  
5R  
GND-K  
5
5
1
1
3
1
1
4
1
3
265  
227  
STARTER  
SOLENOID  
2
232N  
J6  
5S  
J3  
8
5
SHUNT  
4
4
6
10  
10  
J11  
J10  
AMPHENOL  
STARTING  
J4  
J5  
VOLT METER  
6
J2  
6
PERIPHERAL BD.  
BATTERY  
BOARD  
PCB4  
MOTOR  
(+)  
12V BATTERY  
THERMAL  
AM METER  
MODE  
B1  
B3 B2  
PROGRAMMING  
B4  
PCB1  
STUD ON ENGINE  
MOUNTING FOOT  
LEFT SIDE  
3
1
SENSE  
EXC  
281  
STUD ON ENGINE  
MOUNTING FOOT  
RIGHT SIDE  
239  
75  
77  
76  
(-)  
POS  
NEG  
WELD BOARD  
PCB3  
-
+
J7  
ALTERNATOR  
6
4
32  
3
6
J30  
1
5N  
7
1
12  
9
1
J1  
CONTROL POT  
238  
16  
8
GROUNDING BOLT  
ON ENGINE BLOCK  
PULL COIL BD.  
PCB8  
239  
5S  
4
9
16  
FRAME  
J65  
1
4
6
4
3
3
8
J31  
J32  
5R  
9
8
4
5
1
16  
GND STUD ON RIGHT SIDE  
BACK OF CONTROL BOX  
J43  
242B  
GND-H ENGINE GROUND  
GND-A  
1
2
1
1
GND-B  
GND-K  
2
J9  
PINCH  
J13  
POWER  
J8  
HOT START  
8
J12  
MISC CONTROL  
B
G3777  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
COMMANDER 500  
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G-3  
G-3  
ELECTRICAL DIAGRAMS  
SCHEMATIC - COMPLETE MACHINE - COMMANDER 500  
G4357  
D3  
IGBT  
G3834  
IGBT MODULE - EMMITTER  
IS COMMON TO HEATSINK  
E
C
NOTE: COMMANDER 500  
GATE SIGNAL  
2400uf  
2400uf  
100vdc  
USES (2) 300 AMP  
CHOPPER MODULES &  
COMMANDER 300 USES  
(2) 200 AMP CHOPPER  
MODULES.  
100vdc  
DIODE  
MODULE  
(J50-3) 18  
(J50-1) 17  
CHOPPER  
PC BOARD  
+20V  
(J50-7) 25 23 (J50-9)  
+12 INS. STUD  
+12V  
IGBT MODULE - EMMITTER  
IS COMMON TO HEATSINK  
232K  
13  
D4  
IGBT  
14  
L1 CHOKE  
SHUNT  
232C  
232B  
POSITIVE  
OUTPUT  
TERMINAL  
50MV=400 AMPS  
E
C
W1  
W1  
W6  
W6  
OIL  
PRESS.  
FUEL  
TEMP.  
CURRENT LEVEL  
FEED BACK SIGNAL  
204S  
206S  
GATE SIGNAL  
(J51-3) 16  
S
S
S
206A  
206B  
2400uf  
100vdc  
2400uf  
100vdc  
DIODE  
MODULE  
CHOPPER  
PC BOARD  
W2  
+20V  
STATOR  
WELD  
WINDINGS  
BY-PASS  
PC BOARD  
W2  
(J51-1) 15  
THREE PHASE  
RECTIFIER  
WIREFEEDER  
VOLTMETER  
POLARITY  
SWITCH  
FOUR POLE 1800 RPM ALTERNATOR  
242A  
242C  
W3  
21  
228A  
(J51-7) 25A  
23A (J51-9)  
W3  
208  
241A  
208A  
+12V  
229A  
NEGATIVE  
OUTPUT  
TERMINAL  
W4  
W5  
W5  
W4  
T
W
I
T
W
I
T
W
I
S
T
E
D
S
T
E
D
S
T
E
D
41  
208B  
42 VOLT AC  
WIRE FEEDER  
POWER  
ROTOR FIELD  
P
A
I
P
A
I
P
A
I
SLIP RINGS  
200B  
232J (J31-4)  
5T (J31-9)  
17 (J42-3)  
18 (J42-8)  
15 (J42-1)  
16 (J42-6)  
105A (J42-2)  
R
R
ANALOG  
POWER PC  
BOARD  
(J32-10) 229A  
(J32-6) 234A  
R
160 VDC  
OIL PRESSURE  
42  
3
200A  
25A 23A  
(J12-3) (J12-4)  
25 23  
(J12-2)  
+
PERIPHERAL  
PC BOARD  
(J12-1)  
206S (J6-2)  
5V  
3200uf  
300vdc  
SENSOR  
TEMPERATURE  
SWITCH  
(J13-3) 105A  
(J13-1) 115A  
204S (J6-1)  
ARC VOLTAGE FEEDBACK  
OUTPUT  
R1  
CONTROL 10K  
15V  
208B (J12-16)  
115A (J42-5)  
101A (J42-7)  
COM  
120 V AC  
120 V AC  
(J13-2) 101A  
(J13-4) 116A  
(J13-5) 118A  
AC AUX.  
POWER  
(J32-5) 233A  
(J32-9) 229  
201  
15V  
15V TO GND.  
10 V  
116A (J42-9)  
118A (J42-10)  
WELD CONTROL  
PC BOARD  
77 (J7-1)  
76 (J7-2)  
SENSOR  
SWITCH  
ROTOR RESISTANCE= 25- 27 OHMS  
240 V AC  
0-10 V  
5
6
0 V  
239A (J32-8)  
405 (J31-11)  
(J12-8) 257  
(J12-7) 256  
FUEL LVL.  
SENSOR  
IDLER SWITCH  
5A  
0 V  
10 V  
5J (J42-4)  
75 (J7-3)  
13 (J41-1)  
14 (J41-2)  
15 V  
15 V  
2A  
(TO AMPHENOL)  
+
77A (J10-1)  
76A (J10-2)  
SHUT DOWN HOLD COIL  
271 (J32-7)  
270 (J31-8)  
(J10-5) 2  
(J10-4) 4  
REMOTE  
CONTROL 10K  
WELD TERMINALS SWITCH  
-15 V (W/O POT.)  
21Ω  
(J31-5) 224A  
(J31-6) 262B  
(TO AMPHENOL)  
262  
0 V  
120 VOLT AC  
POWER FOR  
ROTOR FIELD CIRCUIT  
(TO AMPHENOL)  
4A  
0 V  
75A (J10-3)  
279 (J9-3)  
278 (J9-2)  
403 (J31-3)  
CV  
(J2-1) 213  
(J32-12)  
232P  
(J32-1)  
247  
(J32-3)  
245  
(J32-2)  
246  
(J32-4)  
243  
6F  
262A  
90A PIPE  
(J2-2) 214  
(J2-3) 215  
(J2-4) 216  
(J2-5) 217  
(J2-6) 218  
ARC  
CONTROL 10K  
5P  
_
150A PIPE  
R2  
OUTPUT  
SELECTOR  
+
250A PIPE  
80V DC INPUT POWER  
LOW  
PRESS.  
HOUR METER  
LOW  
FUEL  
277 (J9-1)  
HIGH  
TEMP.  
350A PIPE SWITCH  
500A PIPE  
ALT.  
TOROID-  
232R  
SENSES AC POWER &  
"TRIGGER" CURRENT  
FROM LN25 TO  
260A (J12-9)  
261A (J12-10)  
CC  
+12 VOLTS FROM THE BATTERY VIA  
THE RUN / STOP SWITCH.  
(J2-7) 220  
(J2-8) 222  
TIG  
ACTIVATE IDLER  
232F  
232G  
232P  
232E  
ROTOR  
FLASHING  
(J43-11) 200  
232A  
(232D, 232T & 232W  
MULTI LEAD)  
281A (J43-3)  
(J43-14) 271  
232 (J43-5)  
(J43-8) 270  
403 (J65-3)  
PULL COIL  
PC BOARD  
(232D,  
232T &  
232W  
MULTI  
LEAD)  
232T  
232W (J12-14)  
226 (J12-15)  
5G (J13-7)  
(J11-5) 250  
THERMOSTATS ON  
CHOPPER MODULES  
NORMALLY CLOSED  
+12 INS. STUD  
IDLE SOL.  
PULL COIL  
249  
232S  
232  
+12  
INSULATED  
STUD  
0 - .1V WHEN ON  
405 (J65-5)  
401 (J65-1)  
402 (J65-2)  
21Ω  
IDLER HOLD COIL  
232J  
(J11-4) 251  
(J11-1) 252  
.3 Ω  
232L  
227 (B1)  
(J43-15)401  
BATTERY  
PC BOARD  
THERMAL  
SHUTDOWN  
RUN-STOP SWITCH  
SHOWN IN RUN POS.  
J43-16) 402  
(J43-9) 5L  
SHUT DOWN  
PULL COIL  
(J4-1 THRU 10) (J5-1 THRU 10)  
M1 THRU M10 M1 THRU M10  
(J11-6) 253  
(J12-12) 404  
START  
BUTTON  
SWITCH  
236B  
5S (B4)  
232M  
.3 Ω  
EXC.  
NEG  
265 (B3)  
SENSE  
+12 INS. STUD  
232N (B2)  
404 (J65-4)  
POS  
+
236A  
ENGINE  
ALTERNATOR  
232D  
236  
232A  
231  
232H  
236C  
A
M
P
S
D
I
-
+
238  
S
P
L
A
Y
S
BATT  
CHRG.  
METER  
+
ENGINE  
STARTER  
SOLENOID  
12 VOLT  
BATTERY  
V
O
L
T
ENGINE  
STARTER  
FRAME  
GROUND  
31  
J
115VAC  
404  
32  
A
INPUT TO  
AMPHENOL  
41A  
I
42VAC  
WORK  
K
H
E
42A  
21  
A
B
C
D
E
F
77B  
76B  
75B  
2B  
REMOTE  
CONTROL  
77A  
76A  
75A  
4A  
REMOTE  
CONTROL  
77B  
76B  
75B  
F
G
D
C
B
CONTACTOR  
4B  
4B  
2B  
2A  
GROUND  
GND-B  
GROUND  
GND-A  
AMPHENOL  
AMPHENOL  
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
"X" INFO.  
5000762  
XA  
Chg. Sheet No.  
DESIGN INFORMATION  
DRAWN BY: DP  
ENGINEER: DP  
APPROVED:  
REFERENCE:  
MANUFACTURING TOLERANCE PER E2056  
ON 2 PLACE DECIMALS IS .02  
EQUIPMENT TYPE:  
COM. CONTROL COMMANDER 300 & 500  
MACHINE SCHEMATIC  
ON  
ON ALL ANGLES IS .5 OF  
MATERIAL TOLERANCE ("  
3
PLACE DECIMALS IS .002  
DEGREE  
") TO AGREE  
A
SUBJECT:  
SUPERSEDING:  
t
XB-UF  
XC-UF  
WITH PUBLISHED STANDARDS.  
11-22-99  
DRAWING No.:  
SCALE:  
NONE  
DATE:  
G 3834  
DO NOT SCALE THIS DRAWING  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 500  
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G-4  
G-4  
ELECTRICAL DIAGRAMS  
SCHEMATIC - BATTERY PC BOARD  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 500  
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G-5  
G-5  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - BATTERY PC BOARD  
PC BOARD REFERENCE  
DESIGNATORS  
ITEM  
PART NO.  
L11325-C  
QTY  
DESCRIPTION  
V
1
BATTERY PC BOARD BLANK  
POTTING TRAY  
1
2
3
4
5
M19436-3  
S8025-80  
E2527  
1
2
SELF TAPPING SCREW  
112 g  
AS REQ'D  
EPOXY ENCAPSULATION RESIN  
ELECTRICAL INSULATING COMPOUND  
1
2
E3539  
3
FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS  
N.E.  
T11577-26  
2
1
1
1
1
6
3
9
4
1
1
6
1
1
1
1
2
2
1
4
6
1
2
2
1
2
1
1
1
3
2
1
1
6
2
1
C1, C2  
CAPACITOR; PEF; 0.1/100V; 10%  
6
S16668-8  
C3  
CAPACITOR; CEMO; 330pf / 100V; 5%  
CAPACITOR; ALEL; 1000/35V +30% / -20%  
CAPACITOR; ALEL; 100/16V +75% / -10%  
CAPACITOR; CD; 0.0047/3000V; 20%  
CAPACITOR; CEMO;.1 / 50V; 10%  
7
S13490-121  
S13490-15  
T11577-58  
C4  
8
C5  
2
D
9
9
D
3 4  
J
C6  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
4
D
S16668-11  
T12705-37  
C7 THRU C12  
D1, D2, D3  
0 1  
0 3  
7 1  
D
DIODE; AXLDS; 3A; 40V; SCHOTTKY  
R
D
T12199-1  
D4, D5, D6, D7, D8, D13, D14, D15, D16 DIODE; AXLDS; 1A; 400V; 1N4004  
7 3  
3 1  
R
D
T12705-29  
D9, D10, D12, D17  
DIODE; AXLDS; 3A; 600V; 1N5406  
7 1  
6 1  
4 1  
3 1  
R
4
Q
7
D
R
R
R
S24020-16  
T13640-26  
J43  
CONNECTOR; MOLEX; MINI; PCB; 16 PIN; TIN  
MOV; 14VRMS; 100J; 20MM  
1
0 2  
9 1  
R
7
C
4 3  
2 1  
R
R
3 3  
6 1  
R
MOV1  
R
0 1  
9 2  
R
R
3
Q
D
D
R
9
C
3
R
T12704-68  
Q1 THRU Q6  
TRANSISTOR; NPN;TO226; 0.5A; 40V; 2N4401  
TRANSISTOR; PNP;TO226; 0.5A; 40V; 2N4403  
TRANSISTOR; P; T220; 8A; 150V; MJE15031  
TRANSISTOR; N; T220; 8A; 150V; MJE15030  
RESISTOR; MF; 1/4W; 475 OHM; 1%  
RESISTOR; MF; 1/4W; 1K OHM; 1%  
RESISTOR; MF; 1/4W; 2.21K OHM; 1%  
RESISTOR; MF; 1/4W; 4.75K OHM; 1%  
RESISTOR; MF; 1/4W; 10K OHM; 1%  
RESISTOR; MF; 1/4W; 1.21K OHM; 1%  
RESISTOR; MF; 1/4W; 68.1K OHM; 1%  
RESISTOR; MF; 1/4W; 3.32K OHM; 1%  
RESISTOR; MF; 1/4W; 8.25K OHM; 1%  
RESISTOR; MF; 1/4W; 9.09K OHM; 1%  
RESISTOR; MF; 1/4W; 33.2K OHM; 1%  
RESISTOR; MF; 1/4W; 511 OHM; 1%  
RESISTOR; MF; 1/4W; 100K OHM; 1%  
THERMISTOR; PTC; .08-0.19 OHMS; 1.85A  
RESISTOR; MF; 1/4W; 3.92K OHM; 1%  
RESISTOR; WW; 10W; 4.7 OHM; 5% SQ.  
RESISTOR; MF; 1/4W; 47.5 OHM; 1%  
RESISTOR; MF; 1/4W; 24.9 OHM; 1%  
RESISTOR; MF; 1/4W; 100 OHM; 1%  
RESISTOR; WW; 5W; 50 OHM; 5% SQ.  
IC; COMPARATOR; QUAD; 2901N  
2
Q
5
3
R
5
C
5 2  
5 1  
2 3  
R
Q 1  
Q
0 1  
6 2  
1 1  
C
C
R
5 1  
6
R
1 2  
4
R
T12704-69  
Q7  
R
R
R
R
5
R
9
8 2  
7 2  
R
R
T12704-49  
Q8  
5 3  
R
5
2 1  
D
6
D
T12704-41  
Q9  
C
8
C
8
R
S19400-4750  
S19400-1001  
S19400-2211  
S19400-4751  
S19400-1002  
S19400-1211  
S19400-6812  
S19400-3321  
S19400-8251  
S19400-9091  
S19400-3322  
S19400-5110  
S19400-1003  
S18380-3  
R1  
R2, R4  
R3, R25  
R6  
N.D.  
R7, R8, R9, R10  
R11, R12, R13, R14 & R16, R17  
R15  
R18, R19  
R20, R21  
R26  
R5, R27  
R28  
R29  
R30  
S19400-3921  
T14649-1  
R32, R33, R34  
R35, R36  
S19400-47R5  
S19400-24R9  
S19400-1000  
T14648-22  
R37  
R38  
R39, R40, & R46, R47, R48, R49  
R44, R45  
X1  
S15128-11  
UNLESS OTHERWISE SPECIFIED:  
CAPACITORS = MFD/VOLTS  
RESISTORS = 1/4W/OHMS  
INDUCTANCE = HENRYS  
BUY PER E3867  
TEST PER E3868-1  
SCHEMATIC REFERENCE - L11309  
BUY AS  
L11325-1C1  
NOTES:  
N.A.  
CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY  
IDENTIFICATION CODE  
STATIC ELECTRICITY. LINCOLN ELECTRIC TO SEE E2454  
BEFORE HANDLING.  
N.C.  
N.D.  
N.E.  
SECURE PC BOARD ASSEMBLY IN PLACE WITH ITEM (3).  
(2 PLACES)  
IDENTIFY COMPLETE ASSEMBLY WITH A PRINTED LABEL OR  
OTHER PERMANENT MARKING IN AREA SHOWN.  
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
Chg. Sheet No.  
3-31-2000  
"X" INFO.  
5000736  
XF-UF  
DESIGN INFORMATION  
REFERENCE:  
MANUFACTURING TOLERANCE PER E2056  
ON 2 PLACE DECIMALS IS .02  
ON 3 PLACE DECIMALS IS .002  
ON ALL ANGLES IS .5 OF A DEGREE  
EQUIPMENT TYPE:  
MISC.  
NO COMPONENTS ON BOTTOM SIDE OF PC BOARD.  
DRAWN BY: MAP  
ENGINEER:  
SUBJECT:  
BATTERY PC BD. ASSEMBLY  
5-26-99  
MATERIAL TOLERANCE (" ") TO AGREE  
SUPERSEDING:  
t
WITH PUBLISHED STANDARDS.  
APPROVED:  
SCALE:  
1:1  
DATE:  
DRAWING No.:  
L 11325-1  
DO NOT SCALE THIS DRAWING  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
COMMANDER 500  
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G-6  
G-6  
ELECTRICAL DIAGRAMS  
SCHEMATIC - CHOPPER PC BOARD  
M 1 9 4 6 2  
+15  
R3  
R10  
10.0  
562  
D6  
1.0A  
30V  
to + cap  
R11  
1
8
VS  
VS  
10.0  
2
5
8
11  
14  
X1  
2
7
IN  
C1 C2 C3 C4 C5  
OUT  
3
R4  
R19  
475  
R13  
10.0  
G1  
G2  
G3  
G4  
G5  
3
6
NC  
GND  
OUT  
1.00K  
6
4
5
A1  
C3  
0.1  
50V  
GND  
DZ1  
5.1V  
1W  
9
R15  
10.0  
MIC4451BN  
D7  
DZ3  
16V  
1W  
12  
M16100-39  
1.0A  
4.75K  
30V  
15  
+15  
R17  
10.0  
E2  
E4  
E1  
1
E3  
E5  
4
7
10  
13  
com  
to heatsink  
to + cap  
B7  
1
8
VS  
VS  
R5  
C4  
1.0  
63V  
C6  
0.1  
50V  
C7  
0.1  
50V  
com  
X1  
MIC4451BN  
10.0  
R6  
1.21K  
GND  
GND  
10.0  
2
5
8
11  
14  
PWM  
INPUT  
4
5
C1 C2 C3 C4 C5  
3
R7  
G1  
G2  
G3  
G4  
G5  
OCI1  
7
10.0  
6
8
6
5
2
3
A2  
9
R8  
M16100-39  
12  
10.0  
4.75K  
15  
com  
NC  
NC  
R9  
E2  
E4  
E1  
1
E3  
E5  
1
4
4
10.0  
7
10  
13  
B3  
com  
to heatsink  
+15  
com  
D5  
150V  
8A  
Q1  
R14  
D1  
D2  
15 to 32 Vac  
4.75K  
R1  
R16  
4.75K  
+
B1  
t
C5  
500  
50V  
C2  
C1  
.24  
R18  
50  
0.1  
DZ2  
16V  
1W  
25V  
50V  
4.75K  
R20  
B2  
4.75K  
D4  
D3  
GENERAL INFORMATION  
LAST NO. USED  
R- 22  
X-  
1
ELECTRICAL SYMBOLS PER E1537  
com  
C-  
D-  
7
7
OCI-  
DZ-  
1
CAPACITORS =  
RESISTORS Ohms  
DIODES  
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
3
LABELS  
=
(
NOTES :  
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
SUPPLY  
VOLTAGE NET  
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
A
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE  
NUMBER.  
FRAME CONNECTION  
FILENAME: M19462_1BA  
EARTH GROUND CONNECTION  
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY  
THE LINCOLN ELECTRIC CO.  
AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF  
THE LINCOLN ELECTRIC CO.  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
ON HOLES SIZES PER E-2056  
Ch’ge.Sht.No.  
XC-RW  
EQUIP.  
TYPE  
CHOPPER, 300 AMP  
THE LINCOLN ELECTRIC CO.  
CLEVELAND, OHIO U.S.A.  
ON  
ON  
2
3
PLACE DECIMALS IS  
PLACE DECIMALS IS  
+
+
.O2  
.OO2  
4-14-2000  
SCHEMATIC  
SUBJECT  
ON ALL ANGLES IS  
+
.5 OF  
A
DEGREE  
NONE  
SCALE  
MATERIAL TOLERANCE ("t") TO AGREE  
WITH PUBLISHED STANDARDS  
SHT.  
LC  
3/26/99  
CHK.  
SUP’S’D’G.  
M
19462  
DR.  
DATE  
NO.  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 500  
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G-7  
G-7  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - CHOPPER PC BOARD  
ITEM  
REQ’D  
PART NO.  
IDENTIFICATION  
OPPOSITE COMPONENT SIDE CIRCUITRY  
OPPOSITE COMPONENT SIDE CIRCUITRY  
COMPONENT SIDE CIRCUITRY  
C
R1  
L11315-1  
300 CHOPPER  
BRA  
B1  
B2  
B7  
B3  
B
RA  
X1  
A1  
A2  
Q1  
C2  
C5  
N.A.  
FOR PARTS ORDERS:  
INCLUDE (1) L11167 PRINT  
AND (1) T12837-1  
CAPACITORS = MFD/VOLTS  
RESISTORS = OHMS  
0
0
0
0
MAKE FROM S19399  
(MAKES 6 BOARDS)  
ITEM  
IDENTIFICATION  
PART NO.  
REQ’D  
1
2
1
P.C. BOARD BLANK  
L11315-B  
1
2
3
4
5
6
NOTE: FOR BLANK SHEARING TOLERANCE SEE P.C. BOARD ASSEMBLY.  
N.A., N.H.  
M16100-39  
T9147-15  
ELECTRONIC MODULE  
EYELETS (MALE)  
EYELETS (FEMALE)  
SEALANT  
BLANK PART NO. L11315-B  
4
4
T9147-11  
E2861  
2.0 OZ.  
S20590-1  
2
1
HEAT SINK  
N.C.  
7
6
7
S18250-542  
PLUG & LEAD ASSEMBLY  
.490~.005  
~.04  
5.75  
(RESTRAINED)  
N.E., N.F.  
NOTES :  
3C060  
L11315-1  
ˇ
300 CHOPPER  
N.J.  
4
1
3
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC  
ELECTRICITY. SEE E2454 BEFORE HANDLING.  
N.G.  
.275  
.285  
N.C. THESE AREAS TO BE COVERED ON BOTH SIDES OF BOARD WITH  
SEALANT PRIOR TO ENCAPSULATION.  
R .045  
.105  
4.55  
MAX.  
N.D. INJECT SEALANT ITEM  
(10 HOLES) TO SEAL MODULE LEADS. CAVITY BETWEEN BOARD  
AND MODULE TO BE COMPLETELY FILLED WITH ITEM SEALANT  
5
THROUGH THE PC BOARD HOLES  
N.J.  
N.D.  
1.75  
CRIMP HEIGHT  
2
N.K.  
OPPOSITE  
SIDE  
N.C.  
2.80  
5
MATERIAL AS PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS.  
COVER ALL MODULE LEADS THAT PROTRUDE FROM THE NON-MODULE  
EYELET DETAIL  
SIDE OF THE BOARD WITH ITEM  
5
SEALANT.  
N.E. FEMALE EYELET TO BE AGAINST THE OPPOSITE COMPONENT SIDE AS  
SHOWN. EYELET MUST NOT SPIN AFTER CLINCHING.  
N.C.  
N.F. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND ALL  
AROUND EYELET ON OPPOSITE COMPONENT SIDE ONLY. NO ICICLES OR  
SOLDER BLOBS PERMITTED.  
MANUFACTURED AS:  
N.G. DO NOT COVER OVER COMPONENT C5 WITH SEALANT.  
PLACE SEALANT ALONG SIDE AND UNDER COMPONENTS.  
L11315-1B0  
N.H. ELECTRONIC MODULES ON A COMMON P.C. BOARD ASSEMBLY TO HAVE  
.475  
0
VGE(TH) WITHIN 5 SORT CODES (0.5VSPAN) FOR THE SAME VCE(SAT) CODE  
IDENTIFICATION CODE  
AND MANUFACTURING CODE.  
N.J. THIS DIMENSION APPLIES TO TWO OF THE FOUR EYELETS  
N.K. ELECTRONIC MODULES TO BE ASSEMBLED AND ENCAPSULATD PER E3875.  
1.425  
e.g. M16100-39 X XX XX ........  
.075  
~.04  
0
6.00  
VENDOR CODE  
1.012  
1.575  
3.60  
VCE(SAT)  
VGE(TH)  
~.02  
MAKE PER E1911  
3.78  
ENCAPSULATE WITH E1844 (1 COAT)  
TEST PER E3846-CH  
2.21  
C A D  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
COMMANDER 500  
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G-8  
G-8  
ELECTRICAL DIAGRAMS  
SCHEMATIC - PERIPHERAL PC BOARD  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 500  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-9  
G-9  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - PERIPHERAL PC BOARD  
PC BOARD REFERENCE  
DESIGNATORS  
ITEM  
PART NO.  
G3662-B  
QTY  
DESCRIPTION  
N.C.  
1
2
3
4
5
6
7
1
PCB BLANK  
V
4
S24671  
M19436-4  
S8025-80  
E2527  
1
PLUG,KEYING PLUG  
1
POTTING TRAY  
3
N.F.  
2
65g  
SELF TAPPING SCREW  
EPOXY ENCAPSULATING RESIN  
ELECTRICAL INSULATING COMPOUND  
SOFTWARE  
E3539  
AS REQ.  
1
S24764-3  
X5  
N.H.  
FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT  
SPECIFICATIONS  
8
9
S25020-3SMT  
15  
C15,C17,C19,C20,C21,C22,  
C28,C29,C30,C31,C32,C37,  
C40,C41,C42  
SCAP,0.1uF,0805,50V,X7R,10%,TR,NP  
S25020-2SMT  
7
1
C2,C3,C36,C43,C44,C45,C46 SCAP,0.022uF,CER,0805,50V,X7R,10%,TR  
10 T11577-58  
C23  
CAP,0.0047,3000V,20%,CERAMIC DISC  
SCAP,4.7uF,TANT,7343,35V,10%,TR,NP  
SCAP,100uF,TAN,7343,20V,20%,TR,NP  
SCAP,47uF,TAN,7343,20V,10%  
Br  
11 S25024-5SMT  
12 S25024-9SMT  
13 S25024-7SMT  
14 S25024-8SMT  
15 S25040-3SMT  
16 S25040-2SMT  
2
C24,C27  
1
C34  
2
C35, C38  
(2.09)  
1
C39  
SCAP,22uF,TAN,7343,25V,10%,POLAR,TR  
SDIO,MURD620CT,6A,200V,ULTRA-FAST,TR,NP  
SDIO,1A,400V,DO-214BA,GLS,NP  
1
D1  
11  
D6,D7,D10,D11,D12,D15,  
D17,D18,D19,D20,D22  
17 S25044-4SMT  
18 S25044-6SMT  
19 S25044-7SMT  
20 S25044-8SMT  
21 S18248-6  
2
1
1
1
1
1
1
1
3
1
6
DZ2,DZ3  
SDIO,1SMB5929BT3,3W,15V,5%  
SDIO,1SMB5935BT3,3W,27V,5%,TR,NP  
SDIO,1SMB5943BT3,3W,56V,5%  
SDIO,1SMB5932BT3,3W,20V,5%  
CON,MOLEX,39-28-1063,PCB,6 PIN,TIN  
CON,MOLEX,15-97-7162,MINI,PCB,16 PIN,TIN  
CON,MOLEX,15-97-7122,MINI,PCB,12 PIN,TIN  
STRA,IRF640S,200V,D2 PAK  
DZ4  
DZ5  
DZ6  
J30  
22 S24020-16  
J31  
23 S24020-12  
J32  
24 S25051-2SMT  
25 S25050-1SMT  
26 S25050-2SMT  
27 S25000-5110SMT  
Q1  
Q2,Q3,Q4  
STRA,2N4401,SOT-23,NPN,TR,  
Q5  
STRA,2N4403L,PNP,SOT-23,NP  
R102,R156,R157,R158,  
SRES,511,TKF,0805,1%,1/10W,TR  
R159,R160  
28 S25000-47R5SMT  
29 S25000-4750SMT  
30 S25000-1211SMT  
31 S25000-1501SMT  
32 S25001-47R5SMT  
33 S25010-4SMT  
1
1
3
5
2
1
2
1
2
1
1
1
1
1
2
20  
R103  
SRES,47.5,0805,1%,1/10W  
(6.59)  
R127  
SRES,475,TKF,0805,1%.1/10W,TR  
SRES,1.21K,0805,1%,1/10W,TR,NP  
SRES,1.5K,TKF,0805,1%,1/10W,TR  
SRES,47.5,TKF,1206,1%,1/4W  
SRES,4.32K,2512,1%,1W  
R129,R130,R144  
R131,R132,R141,R142,R173  
R133,R150  
2
R134  
34 S25010-5SMT  
R135, R143  
SRES,3.92K,2512,1%,1W  
N.B.  
35 S25000-7500SMT  
36 S25000-2210SMT  
37 S25000-2000SMT  
38 S25000-5111SMT  
39 S25000-2002SMT  
40 S25056-3SMT  
R136  
SRES,750,TKF,0805,1%,1/10W  
SRES,221,TKF,0805,1%,1/10W,TR  
SRES,200,TKF,0805,1%,1/10W  
SRES,5.11K,TKF,0805,1%,1/10W  
SRES,20K,TKF,0805,1%,1/10W  
SRES,50K,5 TURN POT,1/4W,10%  
SRES,15K,TKF,0805,1%,1/10W  
SRES,6.81K,TKF,0805,1%,1/10W  
SRES,4.75K,0805,1%,TR,NP  
N.G.  
R145,R146  
R162  
R163  
R168  
R169  
41 S25000-1502SMT  
42 S25000-6811SMT  
43 S25000-4751SMT  
R170  
R171, R172  
R20,R21,R23,R25,R27,R30,  
R32,R33,R34,R109,  
R113,R114,R115,R116,R138,  
R151,R152,R153,R154,R166  
R35,R111  
44 S25000-6812SMT  
45 S25000-3321SMT  
2
6
SRES,68.1K,0805,1%,1/10W,NP  
R37,R118,R119,R139, R140, SRES,3.32K,0805,1%,1/10W,NP(B80Q42M71)  
R155  
46 S25000-1001SMT  
47 S25056-4SMT  
3
1
1
4
8
R40,R46,R167  
SRES,1K,0805,1%,1/10W,TR,NP  
SRES,5K,5 TURN POT,1/4W,10%  
SRES,22.1K,TKF,0805,1%,1/10W  
SRES,100,TKF,0805,1%,1/10W  
SRES,267,1206,1%,1/4W,TR,NP  
R47  
48 S25000-2212SMT  
49 S25000-1000SMT  
50 S25001-2670SMT  
R51  
R55,R124,R125,R126  
R57,R58,R59,R60,R62,R63,  
R64,R65  
51 S25000-1002SMT  
52 S15128-11SMT  
53 M15102-4SMT  
54 S25068-1SMT  
55 S25070-3SMT  
56 S17900-8SMT  
4
2
1
1
1
1
R7,R110,R164,R165  
SRES,10K,0805,1%,1/10W,TR,NP  
SICS,2901,NP  
X1,X2  
X3  
SICS,MC1413BD,ARRAY DRIVER,SO16  
SICS,5V REG,0.5A,2%,DPAK  
SICS,XC9536,44-PIN,VQ44  
SICS,74HC14A  
X4  
X5  
N.H.  
X6  
UNLESS OTHERWISE SPECIFIED:  
RESISTANCE = OHMS  
SCHEMATIC REFERENCE - G3663  
NOTES:  
N.A.  
CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY  
STATIC ELECTRICITY. LINCOLN ELECTRIC TO SEE E2454  
BEFORE HANDLING.  
N.B.  
N.C.  
PLACE CONNECTOR KEYING PLUG, OVER HEADER PIN, IN  
LOCATION SHOWN. PLUG SHOULD BE INSERTED BELOW  
CONNECTOR TOP SURFACE.  
SECURE PC BOARD ASSEMBLY IN PLACE WITH ITEM (4).  
(2 PLACES)  
N.F.  
N.G.  
N.H.  
IDENTIFY COMPLETE ASSEMBLY WITH A PRINTED LABEL OR  
OTHER PERMANENT MARKING IN AREA SHOWN.  
BUY AS  
NO COMPONENTS ON BOTTOM SIDE OF PC BOARD.  
PROGRAM ITEM 55 WITH ITEM 7 .  
BUY PER E3867  
TEST PER E3869-P  
G3662-1B1  
PART NO.  
IDENTIFICATION CODE  
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
Chg. Sheet No.  
"X" INFO.  
DESIGN INFORMATION  
DRAWN BY: ILD  
ENGINEER: APM  
APPROVED:  
REFERENCE:  
MANUFACTURING TOLERANCE PER E2056  
ON 2 PLACE DECIMALS IS .02  
EQUIPMENT TYPE:  
COMMON ANALOG CONTROL  
9-17-99A  
3-24-2000J  
8-4-2000L  
G3360-2  
ON  
ON ALL ANGLES IS .5 OF A DEGREE  
MATERIAL TOLERANCE (" ") TO AGREE  
3
PLACE DECIMALS IS .002  
SUBJECT:  
PERIPHERAL CONTROL PCB ASSEMBLY  
2/10/99  
SUPERSEDING:  
t
WITH PUBLISHED STANDARDS.  
1.5X  
SCALE:  
DRAWING No.:  
DATE:  
G 3662-1  
DO NOT SCALE THIS DRAWING  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
COMMANDER 500  
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G-10  
G-10  
ELECTRICAL DIAGRAMS  
SCHEMATIC - POWER SUPPLY (ANALOG) PC BOARD  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 500  
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G-11  
G-11  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - POWER SUPPLY (ANALOG) PC BOARD  
PC BOARD REFERENCE  
DESIGNATORS  
N. C.  
ITEM  
PART NO.  
G3679-B  
QTY  
DESCRIPTION  
3
4
v
1
2
3
4
5
6
1
PCB BLANK  
N. E.  
S24671  
M19436-3  
S8025-80  
E2527  
1
PLUG,KEYING PLUG  
1
2
POTTING TRAY  
SELF TAPPING SCREW  
112 g  
AS REQD  
EPOXY ENCAPSULATING RESIN  
ELECTRICAL INSULATING COMPOUND  
E3539  
FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT  
SPECIFICATIONS  
7
8
9
S13490-66  
S13490-25  
S16668-11  
5
1
7
1
2
2
1
3
1
1
1
2
6
1
2
1
1
1
1
4
1
1
1
3
3
1
1
3
2
1
1
1
2
1
1
1
1
1
1
C1,C3,C4,C5,C6  
C2  
CAPACITOR,TAEL,47,35V 10%  
CAPACITOR,TAEL,4.7,35V 10%  
C7,C8,C9,C10,C11,C12,C13 CAPACITOR,CEMO,0.1, 50V,10%  
10 T11577-62  
11 S16668-4  
C14  
CAPACITOR,PEMF,1.0,200V,10%  
CAPACITOR,CEMO,2700PF,50V,5%  
CAPACITOR,CEMO,100PF,100V,5%  
CAPACITOR,PPMF,.0015,2000V  
CAPACITOR,TAEL,100,20V 10%  
CAPACITOR,CEMO,150P,100V,5%  
DIODE,AXLDS,4A,200V,UFR  
C15,C20  
12 S16668-3  
C16,C21  
(3.64)  
2
13 S20500-5  
C17  
14 S13490-97  
15 S16668-9  
C18,C19,C23  
C22  
16 T12705-47  
17 T12705-59  
18 T12705-23  
19 T12705-44  
20 T12702-45  
21 T12702-25  
22 S24020-4  
D1  
D2  
DIODE,AXLDS,3A,600V,UFR  
D3,D11  
DIODE,AXLDS,1A,30V,SCHOTTKY  
DIODE,AXLDS,1A,1000V,FR  
D4,D5,D7,D8,D9,D10  
DZ1  
ZENER DIODE,1W,18V,5%  
DZ2,DZ3  
ZENER DIODE,5W,20V,5%  
J41  
CONNECTOR,MOLEX,MINI,PCB,4-PIN  
CONNECTOR,MOLEX,MINI,PCB,10-PIN  
OPTOCOUPLER,PHOTO-Q,70V  
TRANSISTOR,NMF,T247,38A,250V(SS)  
RESISTOR,MF,1/4W,39.2K,1%  
RESISTOR,MF,1/4W,10.0K,1%  
RESISTOR,MF,1/4W,15.0K,1%  
RESISTOR,MF,1/4W,56.2K,1%  
RESISTOR,MF,1/4W,44.2K,1%  
RESISTOR,MF,1/4W,47.5,1%  
RESISTOR,WW,3W,0.05,1%  
23 S24020-10  
24 S15000-10  
25 T12704-89  
26 S19400-3922  
27 S19400-1002  
28 S19400-1502  
29 S19400-5622  
30 S19400-4422  
31 S19400-47R5  
32 T12300-86  
33 S19400-1500  
34 S19400-1211  
35 S19400-2211  
36 S19400-33R2  
37 S19400-1821  
38 S19400-2213  
39 S19400-1003  
40 S19400-15R0  
41 S19400-2490  
42 S20375-7  
J42  
OCI 1  
N.D.  
Q1  
R1,R2,R27,R28  
(6.14)  
R3  
R4  
R5  
R6,R11,R12  
R7,R8,R26  
R9  
UNLESS OTHERWISE SPECIFIED:  
CAPACITORS = MFD/VOLTS  
RESISTORS = 1/4W/OHMS  
INDUCTANCE = HENRYS  
NOTES:  
R10  
RESISTOR,MF,1/4W,150,1%  
R13,R14,R15  
R16,R17  
R18  
RESISTOR,MF,1/4W,1.21K,1%  
RESISTOR,MF,1/4W,2.21K,1%  
RESISTOR,MF,1/4W,33.2,1%  
RESISTOR,MF,1/4W,1.82K,1%  
RESISTOR,MF,1/4W,221K,1%  
RESISTOR,MF,1/4W,100K,1%  
RESISTOR,MF,1/4W,15.0,1%  
RESISTOR,MF,1/4W,249,1%  
N.A.  
CAUTION:  
THIS DEVICE IS SUBJECT TO DAMAGE BY  
BUY AS  
STATIC ELECTRICITY. LINCOLN ELECTRIC TO SEE E2454  
BEFORE HANDLING.  
R19  
R20  
N.B.  
PLACE CONNECTOR KEYING PLUG, OVER HEADER PIN, IN  
LOCATION SHOWN. PLUG SHOULD BE INSERTED BELOW  
CONNECTOR TOP SURFACE.  
M19423-1B0  
IDENTIFICATION CODE  
R21,R22  
R23  
PART NO.  
R24  
N.C.  
N.D.  
N.E.  
SECURE PC BOARD ASSEMBLY IN PLACE WITH ITEM (4).  
(2 PLACES)  
T1  
TRANSFORMER,PCB,PWM,FLYBACK  
MOV,75VRMS,22J,14MM  
43 T13640-9  
TP 1  
BUY PER E3867  
TEST PER E3861  
44 M15458-4  
X1  
IC,PWM-CONTROLLER,IMODE,2842A  
VOLTAGE REF,ADJ, PECISION,431I  
IDENTIFY COMPLETE ASSEMBLY WITH A PRINTED LABEL OR  
OTHER PERMANENT MARKING IN AREA SHOWN.  
45 S15128-10  
X2  
NO COMPONENTS ON BOTTOM SIDE OF PC BOARD.  
SCHEMATIC REFERENCE M19422  
THI S SH EET C ONT AINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THEEXPRESSWRITTEN PERMISSION OF THELINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
MANUFACTURINGTOLERANCE PER E2056  
ON 2PLACE DECIMALS IS .02  
Chg. Sheet No.  
9-17-99  
"X"INFO.  
XM5644  
XM5627  
XC-UF  
DESIGNINFORMATION  
REFERENCE:  
SUPERSEDING:  
EQUIPMENT TYPE:  
SUBJECT:  
COMMON ANALOG CONTROL  
DRAWNBY:  
ENGINEER:  
ILD  
TK  
ON3 PLACE DECIMALS IS .002  
ONALLANGLES IS .5 OF A DEGREE  
MATERIAL TOLERANCE (" t ") TO AGREE  
WITH PUBLISHEDSTANDARDS.  
ANALOG POWER SUPPLY PCB ASSEMBLY  
2/23/99  
APPROVED:  
SCALE:  
1:1  
DATE:  
DRAWING No.:  
M 19423-1  
DO NOT SCALE THIS DRAWING  
XD-UF  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
COMMANDER 500  
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G-12  
G-12  
ELECTRICAL DIAGRAMS  
SCHEMATIC - PULL-COIL PC BOARD  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 500  
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G-13  
G-13  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - PULL-COIL PC BOARD  
PC BOARD REFERENCE  
DESIGNATORS  
ITEM  
PART NO.  
L11384-B  
QTY  
DESCRIPTION  
NOTES:  
1
2
3
4
5
1
PCB BLANK  
M19436-3  
S8025-80  
E2527  
1
2
POTTING TRAY  
v
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY.  
LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING.  
N.B. SECURE P.C. BOARD ASSEMBLY IN PLACE WITH ITEM (4), 2 PLACES.  
N.C. IDENTIFY COMPLETE ASSEMBLY AND SERIAL CODE WITH PRINTED LABELS PER E3876.  
N.D. NO COMPONENTS ON BOTTOM SIDE OF P.C. BOARD.  
SELF TAPPING SCREW  
112 g  
AS REQ'D  
EPOXY ENCAPSULATING RESIN  
ELECTRICAL INSULATING COMPOUND  
E3539  
FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT  
SPECIFICATIONS  
6
7
8
9
T13157-14  
S13490-69  
S16668-11  
S16668-5  
4
2
3
1
4
2
1
2
1
2
2
2
4
2
2
1
2
5
2
1
1
B1,B2,B3,B4  
C1,C2  
CONNECTOR,TAB,QC,VERTICAL,1/4,REEL  
CAPACITOR,TAEL,3.9,35V 10%  
CAPACITOR,CEMO,0.1, 50V,10%  
CAPACITOR,CEMO,.022, 50V,20%  
DIODE,AXLDS,1A,400V,FR,1N4936  
DIODE,AXLDS,3A,200V,1N5402  
C3,C4,C6  
C5  
10 T12705-34  
11 T12705-14  
12 T12705-52  
13 T12702-29  
14 S24020-6  
D1,D2,D6,D7  
D3,D4  
D5  
DIODE,T218,60A,400V,SR  
DZ1,DZ2  
J65  
ZENER DIODE, 1W,15V,5% 1N4744A  
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN  
MOSFET/HEATSINK ASBLY,T12704-82&S1810  
TRANSISTOR,NPN,TO226,0.5A,40V,2N4401  
TRANSISTOR,PNP,TO226,0.5A, 40V,2N4403  
RESISTOR,MF,1/4W,22.1K,1%  
15 S18395-16  
16 T12704-68  
17 T12704-69  
18 S19400-2212  
19 S19400-1000  
21 S19400-4751  
22 S19400-1212  
23 S19400-1003  
24 S19400-1001  
25 S19400-8252  
26 S15128-11  
27 S15128-10  
Q1,Q2  
N.A.  
Q3,Q4  
Q5,Q6  
R1,R4,R17,R18  
R10,R11  
R12,R15  
R16  
RESISTOR,MF,1/4W,100,1%  
RESISTOR,MF,1/4W,4.75K,1%  
RESISTOR,MF,1/4W,12.1K,1%  
R19,R20  
R5,R6,R7,R13,R14  
R8,R9  
RESISTOR,MF,1/4W,100K,1%  
N.B.  
RESISTOR,MF,1/4W,1.00K,1%  
RESISTOR,MF,1/4W,82.5K,1%  
X1  
IC,COMPARATOR,QUAD,2901N  
VOLTAGE REF,ADJ, PECISION,431I  
3
2
X2  
N.D.  
R11  
Q6  
UNLESS OTHERWISE SPECIFIED:  
CAPACITORS = MFD/VOLTS  
RESISTORS = 1/4W/OHMS  
INDUCTANCE = HENRYS  
Q4  
R16  
C3  
D1  
R15  
R10  
R9  
R18  
R20  
R19  
R17  
C2  
Q5  
Q3  
D6  
D7  
R5  
(3.64)  
R14  
C1  
C6  
D2  
C4  
R8  
C5  
BUY AS  
PULL COIL  
L11384-1  
L11384-1B0  
IDENTIFICATION CODE  
PART NO.  
BUY PER E3867  
TEST PER E3883  
N.C.  
(6.14)  
SCHEMATIC REFERENCE L11383  
EXPERIMENTAL DRAWING  
NOT TO BE USED FOR PRODUCTION  
SEE TITLE BLOCK FOR REVISION LEVEL  
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
Chg. Sheet No.  
"X" INFO.  
5000762  
5000751  
XC  
DESIGN INFORMATION  
REFERENCE:  
MANUFACTURING TOLERANCE PER E2056  
ON 2 PLACE DECIMALS IS .02  
ON 3 PLACE DECIMALS IS .002  
ON ALL ANGLES IS .5 OF A DEGREE  
EQUIPMENT TYPE:  
ENGINE WELDERS  
DRAWN BY: MAP/  
ENGINEER:  
M19423-1  
SUBJECT:  
PULL COIL P.C. BOARD ASSEMBLY  
8-26-99  
MATERIAL TOLERANCE (" ") TO AGREE  
SUPERSEDING:  
t
WITH PUBLISHED STANDARDS.  
APPROVED:  
SCALE:  
NONE  
DATE:  
DRAWING No.:  
L 11384-1  
DO NOT SCALE THIS DRAWING  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
COMMANDER 500  
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G-14  
G-14  
ELECTRICAL DIAGRAMS  
SCHEMATIC - WELD CONTROL PC BOARD - SHEET 1  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 500  
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G-15  
G-15  
ELECTRICAL DIAGRAMS  
SCHEMATIC - WELD CONTROL PC BOARD - SHEET 2  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 500  
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G-16  
G-16  
ELECTRICAL DIAGRAMS  
SCHEMATIC - WELD CONTROL PC BOARD - SHEET 3  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 500  
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G-17  
G-17  
ELECTRICAL DIAGRAMS  
SCHEMATIC - WELD CONTROL PC BOARD - SHEET 4  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 500  
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G-18  
G-18  
ELECTRICAL DIAGRAMS  
SCHEMATIC - WELD CONTROL PC BOARD - SHEET 5  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 500  
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G-19  
G-19  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - WELD CONTROL PC BOARD  
R155,R156,R157,R158,R159  
ITEM  
PART NO.  
G3660-C  
QTY  
PC BOARD REFERENCE DESIGNATORS  
DESCRIPTION  
WELD CONTROL PCB BLANK  
61  
62  
S25000-28R7SMT  
S25001-1000SMT  
6
6
RESISTOR,SMD,METAL FILM,1/10W,28.7OHM  
RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR  
R160  
1
2
3
4
5
6
7
8
1
R161,R162,R163,R164,R165  
S24671  
7
PLUG,KEYING PLUG  
POTTING TRAY  
R166  
4
N.B.  
M19436-2  
S8025-80  
E2527  
1
63  
64  
65  
66  
67  
68  
69  
S25001-1213SMT  
S25000-2211SMT  
S25001-7500SMT  
S25001-2002SMT  
S25000-3321SMT  
S25004-2430SMT  
S25000-2002SMT  
3
5
1
3
5
4
1
R167,R168,R169  
RESISTOR,SMD,121K,1/4W,1206,1%,TR  
RESISTOR,SMD,METAL FILM,1/10W,2.21K,1  
RESISTOR,SMD,750OHMS,1/4W,1206,1%,TR  
RESISTOR,SMD,20K,1/4W,1206,1%,TR  
RESISTOR,SMD,METAL FILM,1/10W,3.32K,1  
RESISTOR,SMD,1W,243OHMS,1%  
V
2
170 g  
AS REQ.  
1
SELF TAPPING SCREW  
EPOXY ENCAPSULATING RESIN  
ELECTRICAL INSULATING COMPOUND  
SOFTWARE  
R170,R171,R172,R173,R174  
3
N.C.  
2
R175  
2
E3539  
R176,R177,R178  
N.G.  
N.H.  
S24762-5  
S24763-8  
X30  
X33  
R179,R180,R181,R182,R183  
1
SOFTWARE  
R184,R185,R186,R187  
R188  
RESISTOR,SMD,METAL FILM,1/10W,20.0K,1  
FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS  
R190,R191,R192,R193,R194  
70  
S25000-1500SMT  
7
RESISTOR,SMD,METAL FILM,1/10W,150OHMS  
RESISTOR,SMD,METAL FILM,1/10W,3.01K,1  
C1,C2,C3,C4,C7,C8,C9  
R195,R372  
C10,C11,C12,C13,C14,C15  
C16,C17,C18,C19,C20,C21,C22,  
C23,C24,C25,C26,C28,C29  
C30,C31,C32,C33,C34,C35  
C36,C37,C38,C39,C40,C41  
C42,C43,C44,C45,C46,C47  
C48,C49,C50,C51,C52,C53  
R196,R197,R198,R199,R200  
71  
S25000-3011SMT  
12  
R201,R202,R203,R204,R205  
R206,R207  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
S25000-1822SMT  
S25000-2670SMT  
S25000-3322SMT  
S25000-2213SMT  
S25000-1503SMT  
S25000-3922SMT  
S25000-3323SMT  
S25000-6813SMT  
S25000-6812SMT  
S25001-7681SMT  
2
1
2
5
1
5
2
1
2
3
R208,R209  
RESISTOR,SMD,METAL FILM,1/10W,18.2K,1  
RESISTOR,SMD,METAL FILM,1/10W,267OHMS  
RESISTOR,SMD,METAL FILM,1/10W,33.2K,1  
RESISTOR,SMD,METAL FILM,1/10W,221K,1%  
RESISTOR,SMD,METAL FILM,1/10W,150K,1%  
RESISTOR,SMD,METAL FILM,1/10W,39.2K,1  
RESISTOR,SMD,METAL FILM,1/10W,332K,1%  
RESISTOR,SMD,METAL FILM,1/10W,681K,1%  
RESISTOR,SMD,METAL FILM,1/10W,68.1K,1  
RESISTOR,SMD,7.68K,1/4W,1206,1%,TR  
R211  
N.J.  
R213,R214  
R215,R216,R217,R218,R369  
9
S25020-3SMT  
102  
CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X  
C54,C55,C56,C57,C58,C59  
C60,C61,C62,C63,C64,C65  
C66,C67,C68,C69,C70,C71  
C72,C73,C74,C75,C76,C77  
C78,C79,C80,C81,C82,C83  
C84,C85,C86,C87,C88,C89  
C90,C91,C92,C93,C94,C95  
C96,C97,C98,C99,C100,C101  
C133,C141,C142  
C108,C109,C110,C111,  
C112,C113,C114,C115  
C116  
R219  
R220,R221,R222,R223,R371  
R224,R225  
R226  
R227,R228  
R229,R230,R231  
R232,R233,R234,R235,R236  
82  
S25000-5110SMT  
7
RESISTOR,SMD,METAL FILM,1/10W,511OHMS  
R237,R379  
83  
84  
85  
S25000-2212SMT  
S25000-4322SMT  
S25003-47R5SMT  
4
4
5
R238,R239,R240,R242  
RESISTOR,SMD,METAL FILM,1/10W,22.1K,1  
RESISTOR,SMD,METAL FILM,1/10W,43.2K,1  
RESISTOR,SMD,1W,47.5OHMS,1%  
R241,R320,R321,R322  
10  
11  
S25020-2SMT  
S25020-5SMT  
9
6
CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%  
CAPACITOR,SMD,CERAMIC,2700pF,50V,5%,X  
R245,R246,R247,R248,R249  
R250,R251,R252,R253,R254  
86  
S25004-2430SMT  
10  
RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.1%  
C102,C103,C104,C105,C106  
C107  
R255,R256,R257,R258,R259  
87  
88  
89  
90  
S25008-4321SMT  
S25010-3SMT  
2
3
1
2
R260,R261  
RESISTOR,SMD,PREC,MF,1/10W,4.32K,0.5%  
RESISTOR,SMD,MF,1W,20.0K,1%,SURGE  
RESISTOR,SMD,1.21K,1/4W,1206,1%,TR  
RESISTOR,SMD,METAL FILM,1/10W,6.19K,1  
12  
13  
S25024-6SMT  
S25020-4SMT  
2
1
C117,C118  
CAPACITOR,SMD,TANTALUM,22MF,16V,10%,S  
CAPACITOR,SMD,CERAMIC,820pF,50V,5%,CO  
R262,R263,R264  
C119  
S25001-1211SMT  
S25000-6191SMT  
R265  
C120,C121,C122,C123,C124  
C125  
R266,R267  
14  
S25024-2SMT  
6
CAPACITOR,SMD,TANTALUM,1.0MF,35V,10%,  
R269,R270,R271,R272,R273  
(4.84)  
15  
16  
17  
18  
19  
20  
21  
22  
23  
S25020-8SMT  
S25020-16SMT  
S25024-1SMT  
S25024-5SMT  
S25024-3SMT  
S25020-10SMT  
S25020-1SMT  
S25024-7SMT  
S25020-17SMT  
2
1
1
3
1
2
1
2
1
C126,C127  
CAPACITOR,SMD,CERAMIC,0.056MF,50V,10%  
CAPACITOR,SMD,CERAMIC,0.018MF,50V,1%,  
CAPACITOR,SMD,TANTALUM,0.47MF,50V,10%  
CAPACITOR,SMD,TANTALUM,4.7MF,35V,10%,  
CAPACITOR,SMD,TANTALUM,2.2MF,20V,10%,  
CAPACITOR,SMD,CERAMIC,4700pF,50V,10%,  
CAPACITOR,SMD,CERAMIC,0.022MF,50V,1%,  
CAPACITOR,SMD,TANTALUM,47MF,20V,10%,S  
CAPACITOR,SMD,CERAMIC,0.27MF,50V,10%,  
R274,R275,R276,R277,R278  
91  
S25008-1002SMT  
16  
RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.5%  
2
C128  
R279,R280,R281,R282,R283  
C129  
R284  
C130,C131,C132  
C134  
92  
93  
S25000-4R70SMT  
S25000-5621SMT  
S25008-9091SMT  
S18380-14  
3
1
3
4
1
1
1
1
1
1
1
2
3
2
2
2
1
2
R285,R286,R287  
RESISTOR,SMD,METAL FILM,1/10W,4.70OHM  
RESISTOR,SMD,METAL FILM,1/10W,5.62K,1  
RESISTOR,SMD,PREC,MF,1/10W,9.09K,0.5%  
THERMISTOR,PTC,500OHMS,28mA  
R288  
C135,C136  
94  
R289,R290,R291  
C137  
95  
R292,R293,R294,R295  
C138,C139  
96  
S25008-4751SMT  
S25007-2150SMT  
S25007-6040SMT  
S25001-4751SMT  
S25000-2001SMT  
S25000-2001SMT  
S25000-2801SMT  
S25000-2210SMT  
S25001-1501SMT  
S25000-1503SMT  
S25000-1003SMT  
S25001-1001SMT  
S25000-39R2SMT  
S25000-4753SMT  
R296  
RESISTOR,SMD,PREC,MF,1/10W,4.75K,0.5%  
RESISTOR,SMD,PREC,MF,1/10W,215OHMS,0.  
RESISTOR,SMD,PREC,MF,1/10W,604OHMS,0.  
RESISTOR,SMD,4.75K,1/4W,1206,1%,TR  
RESISTOR,SMD,METAL FILM,1/10W,2.00K,1  
RESISTOR,SMD,METAL FILM,1/10W,2.00K,1  
RESISTOR,SMD,METAL FILM,1/10W,2.80K,1  
RESISTOR,SMD,METAL FILM,1/10W,221OHMS  
RESISTOR,SMD,1.5K,1/4W,1206,1%,TR  
C140  
97  
R297  
D1,D2,D3,D4,D5,D6,D7,D8,D9  
D10,D11,D12  
98  
R298  
24  
S25040-6SMT  
12  
DIODE,SMD,DUAL,0.200A,70V,UDR,CC,SOT-  
99  
R299  
D13,D14,D15,D16,D17,D18  
D19,D20,D21,D22,D23,D24  
D25,D26,D27,D28,D29,D30  
D31,D32  
100  
100  
101  
102  
103  
104  
105  
106  
107  
108  
R300  
R300  
25  
S25040-2SMT  
20  
DIODE,SMD,1A,400V,DO-214BA/AC  
R305  
R306,R307  
D33,D34,D35,D36,D37,D38  
D39,D40,D41,D42,D43,D44  
D45,D46,D47,D48  
D49,D50,D51,D52,D54,D55  
D61,D63,D64  
R308,R309,R310  
26  
27  
S25040-5SMT  
S25049-1SMT  
16  
9
DIODE,SMD,DUAL,0.200A,70V,UFR  
R316,R317  
RESISTOR,SMD,METAL FILM,1/10W,1.82K,1  
RESISTOR,SMD,METAL FILM,1/10W,100K,1%  
RESISTOR,SMD,1K,1/4W,1206,1%,TR  
R318,R319  
R323,R324  
DIODE,SMD,0.5A,30V,SOD-123,SCHOTTKY  
R325  
RESISTOR,SMD,METAL FILM,1/10W,39.2OHM  
RESISTOR,SMD,METAL FILM,1/10W,475K,1%  
28  
29  
30  
31  
32  
S25040-4SMT  
S25049-2SMT  
S25040-3SMT  
S25044-5SMT  
S25044-3SMT  
3
2
1
2
3
D56,D57,D62  
DIODE,SMD,DUAL,0.200A,70V,UFR  
R326,R370  
D58,D59  
DIODE,SMD,1A,30V,SMA,SCHOTTKY  
DIODE,SMD,DUAL,6A,200V,DPAK,CC,ULTRA-  
ZENER DIODE,SMD,3W,18V,5%, SMB  
ZENER DIODE,SMD,3W,12V,5%, SMB  
R327,R328,R329,R330,R331  
109  
S25002-2000SMT  
8
RESISTOR,SMD,200OHMS,1/3W,MF,1%,S1210  
D60  
R332,R333,R334  
DZ1,DZ2  
110  
111  
112  
113  
114  
115  
116  
117  
118  
119  
120  
121  
122  
123  
124  
125  
126  
127  
128  
S25000-10R0SMT  
S25007-2431SMT  
S25007-1301SMT  
S25007-1023SMT  
S25000-5111SMT  
S25001-2370SMT  
S25008-6812SMT  
S25008-1503SMT  
S25008-1212SMT  
S25000-9091SMT  
S25007-6812SMT  
S25007-9091SMT  
S25000-1330SMT  
S25008-1502SMT  
S25007-9092SMT  
S25000-22R1SMT  
S25010-1SMT  
4
1
1
1
1
2
1
1
1
1
2
1
1
1
2
1
1
1
1
R335,R336,R337,R338  
RESISTOR,SMD,METAL FILM,1/10W,10.0OHM  
RESISTOR,SMD,PREC,MF,1/10W,2.43K,0.1%  
RESISTOR,SMD,PREC,MF,1/10W,1.30K,0.1%  
RESISTOR,SMD,PREC,MF,1/10W,102K,0.1%,  
RESISTOR,SMD,METAL FILM,1/10W,5.11K,1  
RESISTOR,SMD,237OHMS,1/4W,1206,1%,TR  
RESISTOR,SMD,PREC,MF,1/10W,68.1K,0.5%  
RESISTOR,SMD,PREC,MF,1/10W,150K,0.5%,  
RESISTOR,SMD,PREC,MF,1/10W,12.1K,0.5%  
RESISTOR,SMD,METAL FILM,1/10W,9.09K,1  
RESISTOR,SMD,PREC,MF,1/10W,68.1K,0.1%  
RESISTOR,SMD,PREC,MF,1/10W,9.09K,0.1%  
RESISTOR,SMD,METAL FILM,1/10W,133OHMS  
RESISTOR,SMD,PREC,MF,1/10W,15.0K,0.5%  
RESISTOR,SMD,PREC,MF,1/10W,90.9K,0.1%  
RESISTOR,SMD,METAL FILM,1/10W,22.1OHM  
RESISTOR,SMD,MF,2.21K,1/4W,1%,SURGE  
RESISTOR,SMD,METAL FILM,1/10W,332OHMS  
RESISTOR,SMD,1W,0.15OHMS,1%  
DZ3,DZ4,DZ14  
R339  
DZ5,DZ6,DZ7,DZ8,DZ9,DZ10  
DZ11  
R340  
33  
S25045-1SMT  
7
ZENER_DIODE,SMD,225mW,12V,5%,SOT-23  
R341  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
S25044-4SMT  
S25044-1SMT  
S18248-12  
S24020-8  
2
1
1
2
3
2
1
3
1
1
DZ12,DZ13  
ZENER DIODE,SMD,3W,15V,5%, SMB  
ZENER DIODE,SMD,3W,5.1V,5%, SMB  
CONNECTOR,MOLEX,MINI,PCB,12-PIN  
CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN  
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN  
CONNECTOR,MOLEX,MINI,PCB,10-PIN,TIN  
CONNECTOR,MOLEX,MINI,PCB,2-PIN,GOLD  
CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN  
CONNECTOR,MOLEX,MINI,PCB,16-PIN,TIN  
OPTOCOUPLER,SMD,PHOTO-TRANSISTOR,70V,  
R342  
DZ15  
R343,R344  
2
2
J1  
N.F.  
R345  
N.F.  
J2,J13  
2
R346  
S24020-6  
J3,J10,J11  
R347  
S24020-10  
S24020-2G  
S24020-4  
J4,J5  
R348  
J6  
(7.84)  
R349,R350  
J7,J8,J9  
R351  
S24020-16  
S15000-22SMT  
J12  
R352  
OCI1  
R353  
Q1,Q2,Q3,Q4,Q5,Q6,Q7,Q8,Q9  
Q10,Q11,Q12,Q14  
Q15,Q16,Q17,Q18,Q19,Q20  
Q21,Q22  
R354,R355  
44  
45  
S25050-1SMT  
S25050-2SMT  
13  
8
TRANSISTOR,SMD,NPN,0.5A,40V,SOT-23,MM  
TRANSISTOR,SMS,PNP,SOT23,0.5A, 40V,MM  
R356  
R357  
S25000-3320SMT  
S25003-0R15SMT  
R358  
46  
47  
S25051-1SMT  
S25051-2SMT  
1
1
Q23  
TRANSISTOR,SMD,NMF,SOT-223,1.5A,100V,  
TRANSISTOR,SMD,NMF,D2PAK,18A,200V,IRF  
R359  
Q24  
R360,R361,R362,R363,R364  
129  
S25001-2001SMT  
9
RESISTOR,SMD,2K,1/4W,1206,1%,TR  
R1,R24,R25,R26,R27,R28,R29  
R30,R31,R32,R34,R35,R36  
R37,R38,R39,R41,R42,R43  
R44,R45,R46,R47,R48,R49  
R382  
R365,R366,R367,R383  
130  
131  
132  
S25007-3321SMT  
S25056-2SMT  
1
4
1
R368  
RESISTOR,SMD,PREC,MF,1/10W,3.32K,0.1%  
TRIMMER,SMD,MT,1/4W,2K,10%,LINEAR  
IC,OP-AMP,SINGLE,PRECISION,LT1097S8  
48  
S25000-4751SMT  
26  
RESISTOR,SMD,METAL FILM,1/10W,4.75K,1  
R380,R561,R619,R766  
S15128-27SMT  
X1  
X2,X3,X39,X40,X41,X42,X51  
133  
S15128-4SMT  
8
OP-AMP,SMD,QUAD, GEN-PURPOSE,224D  
R2,R3,R4,R5,R6,R7,R8,R9  
R10,R11,R12,R13,R14,R17  
R63  
X55  
49  
50  
S25000-1501SMT  
S25000-4750SMT  
15  
6
RESISTOR,SMD,METAL FILM,1/10W,1.50K,1  
RESISTOR,SMD,METAL FILM,1/10W,475OHMS  
X4,X5,X6,X7,X16,X22,X46  
134  
135  
136  
S15128-18SMT  
M15458-6SMT  
S15018-6SMT  
10  
1
IC,OP-AMP,SMT,QUAD,HIGH-PERF,33074D  
IC,SMD,PWM-CONTROL  
X47,X52,X56  
R18,R19,R20,R21,R22,R23  
R50,R51,R52,R53,R54,R55  
R56,R57,R58,R59,R60,R61  
R64,R65,R66,R67,R68,R69  
R70,R71,R72,R73  
R62,R243,R244,R268,R381  
R74,R75,R76,R77  
R78,R79,R80,R81,R82,R83  
R84,R85,R86,R87,R88,R89  
R90,R91  
X8  
X9,X10,X11,X14,X17,X24,X34  
9
IC,SMD,CMOS,SWITCH,ANALOG,QUAD, 4066B  
51  
S25000-1000SMT  
22  
RESISTOR,SMD,METAL FILM,1/10W,100OHMS  
X35,X36  
X15,X43  
X20  
137  
138  
139  
140  
141  
142  
143  
144  
145  
146  
147  
148  
S15128-11SMT  
S25065-1SMT  
S25057-3SMT  
S25069-2SMT  
S25070-5SMT  
S25069-5SMT  
S15128-10SMT  
S25067-1SMT  
S15018-11SMT  
S25057-2SMT  
S25001-1821SMT  
S25001-1502SMT  
2
1
3
1
1
1
1
1
1
1
1
1
IC,SMT,COMPARATOR,QUAD,2901D  
IC,SMD,MULTIPLEXER,2 TO 1 LINE DATA,H  
POT,DIGITAL,SMD,10K,QUAD,TSSOP-24  
IC,SMD,CMOS,EEPROM,SERIAL,SPI,64Kx8,S  
IC,SMD,FPGA,XCS20,TQFP,144PIN  
52  
53  
S25000-8251SMT  
S25001-1301SMT  
5
4
RESISTOR,SMD,METAL FILM,1/10W,8.25K,1  
RESISTOR,SMD,1.3K,1/4W,1206,1%,TR  
X27,X53,X57  
X30  
X31  
54  
S25001-4750SMT  
14  
RESISTOR,SMD,475OHMS,1/4W,1206,1%,TR  
X33  
IC,SMD,EEPROM,CMOS,CONFIGURATION,256K  
IC,SMD,VOLTAGE REF,ADJ, PECISION,431I  
IC,BIPOLAR,TIMER,SOIC-14  
X44  
55  
56  
57  
S25000-2000SMT  
S25000-6811SMT  
S25000-1212SMT  
4
10  
2
R92,R93,R94,R210  
R95,R96,R97,R98,R99,R100  
R101,R102,R103,R212  
R105,R106  
RESISTOR,SMD,METAL FILM,1/10W,200OHMS  
RESISTOR,SMD,METAL FILM,1/10W,6.81K,1  
RESISTOR,SMD,METAL FILM,1/10W,12.1K,1  
X45  
X50  
IC,SMD,CMOS,SWITCH,ANALOG,QUAD,201(SS  
POT,SMD,DIGITAL,10K,1-CHNL,SOIC-8  
RESISTOR, SMD, 1.82K, 1/4W,1206,1%,TR  
RESISTOR, SMD, 15K, 1/4W,1206,1%,TR  
X54  
R311  
R312  
R107,R108,R109,R110,R111  
R112,R113,R114,R115,R116  
R117,R118,R119,R120,R121  
R122,R123,R124,R125,R126  
R127,R128,R129,R130,R131  
R132,R133,R134,R135,R136  
R137,R138  
58  
S25000-1001SMT  
38  
RESISTOR,SMD,METAL FILM,1/10W,10.0K,1  
UNLESS OTHERWISE SPECIFIED:  
RESISTANCE = OHMS  
R378  
R139,R140,R141,R142,R143  
R144,R145,R146,R148,R149  
R150,R151,R152,R153,R154  
R147,R301,R302,R303,R304  
59  
60  
S25000-1001SMT  
S25000-4752SMT  
15  
5
RESISTOR,SMD,METAL FILM,1/10W,1.00K,1  
RESISTOR,SMD,METAL FILM,1/10W,47.5K,1  
SCHEMATIC REFERENCE -G3661_2C3  
NOTES:  
N.A.  
CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC  
ELECTRICITY. LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING.  
NOTE: G3990-2 MUST BE REVIEWED WHEN  
MODIFYING THIS BOARD.  
BUY PER E3867  
TEST PER E3869-C  
N.B.  
PLACE CONNECTOR KEYING PLUG, OVER HEADER PIN, IN  
LOCATION SHOWN. PLUG SHOULD BE INSERTED BELOW  
CONNECTOR TOP SURFACE (6 PLACES).  
BUY AS  
N.C.  
N.F.  
SECURE P.C. BOARD ASSEMBLY IN PLACE WITH ITEM (4).  
(2 PLACES, 5.3 +/- .5 IN. LBS).  
FOR PARTS ORDERS SEND:  
G3660-2C4  
PLACE BARCODED ASSEMBLY NUMBER IDENTIFICATION AND  
BARCODED SERIAL NUMBER IDENTIFICATION IN AREA SHOWN.  
PART NO.  
IDENTIFICATION CODE  
(1) G3660-2 WELD CONTROL PC BOARD ASSEMBLY  
(1) S18250-743 PLUG & LEAD ADAPTER  
(1) S25110PRINT PARTS ORDER INSTRUCTION SHEET  
N.G.  
N.H.  
N.J.  
PROGRAM ITEM (140) WITH ITEM (7).  
PROGRAM ITEM (142) WITH ITEM (8).  
PARTS SHOWN MUST BE COMPLETELY COVERED  
WITH ENCAPSULATION.  
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
Chg. Sheet No.  
7-7-2000  
"X" INFO.  
DESIGN INFORMATION  
DRAWN BY: MAP  
ENGINEER: ILD  
REFERENCE:  
MANUFACTURING TOLERANCE PER E2056  
ON 2 PLACE DECIMALS IS .02  
EQUIPMENT TYPE:  
COMMON ANALOG CONTROL  
G3660-1  
ON  
ON ALL ANGLES IS .5 OF A DEGREE  
MATERIAL TOLERANCE (" ") TO AGREE  
3
PLACE DECIMALS IS .002  
8-4-2000P  
SUBJECT:  
WELD CONTROL PCB ASSEMBLY  
1-27-2000  
DRAWING No.:  
SUPERSEDING:  
t
WITH PUBLISHED STANDARDS.  
1:5X  
APPROVED:  
SCALE:  
DATE:  
APM  
G 3660-2  
DO NOT SCALE THIS DRAWING  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
COMMANDER 500  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SVM ERROR REPORTING FORM  
We need to know if there are errors in our manuals. We also value any suggestions as to  
additional tests or procedures that would make this SVM a better tool for you.  
If you discover new or different “Problems or Symptoms” that are not covered in the three col-  
umn troubleshooting chart, please share this information with us. Please include the  
machine’s code number and how the problem was resolved.  
Thank You,  
Technical Services Group  
Lincoln Electric Co.  
22801 St. Clair Ave.  
Cleveland, Ohio 44117-1199  
FAX 216-481-2309  
SVM Number ___________________________  
Page Number if necessary__________________  
Your Company__________________________  
Your Name_____________________________  
Please give detailed description below:  
___________________________________________________________________________  
___________________________________________________________________________  
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SD287 01/99  
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