Manuale d’uso / di manutenzione del prodotto 500 del fabbricante Lincoln Electric
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Commander 500 OPERA T OR’S MANUAL IM699 April, 2002 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by proper installation ... and thoughtful operation on your part.
FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
ii SAFETY ii ARC RA YS can burn. 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.
FOR ELECTRICALL Y powered equipment. 8.a. T urn 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.
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ 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: Sûreté Pour Soudage A L ’Arc 1.
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment.
T ABLE OF CONTENTS Page Safety ......................................................................................................................... i-iv Installation ................................................................................
T ABLE OF CONTENTS Accessories .....................................................................................................Section C Optional Field Installed Accessories .....................................................................C-1 Recommended Optional Equipment .
A-1 INST ALLA TION COMMANDER 500 A-1 TECHNICAL SPECIFICA TIONS - Commander 500 (K1639-1 & -2) Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder High Idle 1900 173 cu. in 12VDC battery Fuel: 25 gal. F3L 912 44 HP(33 kw) Low Idle 1475 (2.
A-2 INST ALLA TION COMMANDER 500 A-2 Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine.
A-3 INST ALLA TION COMMANDER 500 A-3 LIFTING 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 the lift bale must be secured in a raised position.
A-4 INST ALLA TION COMMANDER 500 A-4 PRE-OPERA TION ENGINE SER VICE READ the engine operating and maintenance instruc- tions supplied with this machine. •Keep hands away from the engine muffler or HOT engine parts. •Stop engine and allow to cool before fueling.
A-5 INST ALLA TION COMMANDER 500 A-5 MUFFLER OUTLET PIPE 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 such that it will direct the exhaust in the desired direction.
A-6 INST ALLA TION COMMANDER 500 A-6 WELDING OUTPUT CABLES With the engine off, route the electrode and work cables thru the strain relief bracket provided on the front of the base and connect to the terminals provid- ed. These connections should be checked periodical- ly and tightened if necessary .
A-7 INST ALLA TION COMMANDER 500 A-7 2. T ake necessary steps to assure load is limited to the capacity of the Commander by installing a 50 amp, 240 V AC double pole circuit breaker . Maximum rated load for each leg of the 240 V AC auxiliary is 50 amperes.
A-8 INST ALLA TION COMMANDER 500 A-8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Shut off welder before making any electrical connec- tions. ------------------------------------------------------------------------ CONNECTION OF THE LN-25 TO THE COMMANDER 500 The LN-25 with or without an external contactor may be used with the Commander 500.
A-9 INST ALLA TION COMMANDER 500 A-9 CONNECTION OF AN LN-23P WIRE FEEDER TO THE COMMANDER 500 • Shut the welder of f. • Connect the LN-23P per instructions on the appro- priate connection diagram in the DIAGRAMS sec- tion. (NOTE): When connecting an LN-23P to the Commander 500, a K350-1 adapter kit must be used.
B-1 OPERA TION B-1 Read and understand this entire section before operat- ing your Commander 500. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine.
B-2 OPERA TION B-2 FOR AUXILIAR Y POWER • 12,000 watts of 120/240 V AC, 60Hz auxiliary power . • Power for tools, 120/240 V AC lights, electric pumps and for standby emergency power . • Drive a 5 HP motor (provided it is started under no load). • T wo 20 amp 120 V AC duplex receptacles for up to 40 amps of 120 V AC power .
B-3 OPERA TION B-3 ENGINE CONTROLS (Items 1 through 8) 1. RUN STOP SWITCH When placed in the “ RUN ” position, this switch ener- gizes 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.
B-4 OPERA TION B-4 4. ENGINE TEMPERA TURE GAUGE (K1639-2 Std., K1639-1 Opt.) AND LIGHT 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.
WELDER CONTROLS (Items 9 through 13 ) 9. WELD MODE & OUTPUT CONTROL These two controls allow you to select between various welding output slopes and adjust the desired welding output. Refer to T able B.1 for a description of how these two controls work.
B-6 OPERA TION B-6 15. CIRCUIT BREAKERS These circuit breakers provide separate overload cur- rent protection for each 120V circuit at the 240V recep- tacle, each 120V receptacle, the 120V AC in the 14-Pin connector , the 42V AC in the 14-Pin connector and (for codes above 10838 only) battery circuit overload pro- tection.
B-7 OPERA TION B-7 BREAK-IN PERIOD 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.
B-8 OPERA TION B-8 Commander 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the “ 20-250 setting ” (TIG) • . Set the IDLER switch to the “ HIGH “ position. • Set the WELDING TERMINALS switch to the “ Weld T erminals On ” position.
B-9 OPERA TION B-9 WIRE FEED (CONST ANT VOL T AGE) WELD- ING Connect a wire feeder to the Commander 500 and set welder controls according to the instructions listed earlier in this section.
B-10 OPERA TION B-10 COMMANDER 500 Welding Output Range Setting 30-575 500 350 200 150 90 Welding Output 500A/40V 500A/40V 350A/30V 200A/28V 150A/27V 90A/25V Permissible Power - W atts (Unity Power Fa.
K1690-1 (1 Duplex) GFCI Kit - Includes one UL approved 1 15V ground fault circuit interrupter duplex type receptacle with cover and installation instructions. Replaces the factory installed 1 15V duplex receptacle. The receptacle of the GFCI duplex is rated at 20 amps, the maximum total current from the GFCI duplex is lim- ited to 20 amps.
C-2 ACCESSORIES C-2 COMMANDER 500 RECOMMENDED OPTIONAL EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode holder and cable. • Ground clamp and cable.
D-1 MAINTENANCE D-1 COMMANDER 500 SAFETY PRECAUTIONS • Have a qualified technician do the maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove guards only when necessary and replace them when the maintenance requiring their removal is complete.
D-2 MAINTENANCE D-2 COMMANDER 500 7. Inspect for holes and tears by looking through the element toward a bright light. Check for damaged gas- kets or dented metal parts. Do not reuse damaged ele- ments. Protect element from dust and damage during drying and storage.
D-3 MAINTENANCE D-3 COMMANDER 500 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 (may take almost 1 full turn) with a slight upward pressure until the element begins to further engage the header .
D-4 MAINTENANCE D-4 COMMANDER 500 T able D.1 Engine Maintenance Components ITEM Air Cleaner Element Cooling Blower Belt Oil Filter Element Fuel Filter Element W ater Separator Element Fuel Pre-Filter .
E-1 TROUBLESHOOTING E-1 COMMANDER 500 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-2 TROUBLESHOOTING E-2 COMMANDER 500 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-3 TROUBLESHOOTING E-3 COMMANDER 500 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-4 TROUBLESHOOTING E-4 COMMANDER 500 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
F-1 DIAGRAMS F-1 COMMANDER 500 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific dia- gram for your particular machine is pasted inside the machine on one of the enclosure panels.
F-2 DIAGRAMS F-2 COMMANDER 500 CONNECTION DIAGRAM:.
F-3 DIAGRAMS F-3 COMMANDER 500 CONNECTION DIAGRAM: GND 75 76 77 GREEN K291 OR K404 75 INPUT CABLE 76 N.E. 77 K775 OPTIONAL REMOTE CONTR OL D AMAGED . THE ENGINE GOVERNOR SETTING IS PRE-SET A T THE F ACT ORY - DO NO T ADJUST ABO VE RPM SPECIFICA TIONS LISTED IN 81 42 41 31 31 32 32 2 2 4 4 21 21 GND 82 N.
F-4 DIAGRAMS F-4 COMMANDER 500 CONNECTION DIAGRAM:.
F-5 DIAGRAMS F-5 COMMANDER 500 CONNECTION DIAGRAM:.
F-6 DIAGRAMS F-6 COMMANDER 500 CONNECTION DIAGRAM: CA UTION : N.A. WELDING CABLE MUST BE OF PROPER CAP ACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIA TE AND FUTURE APPICA TIONS. SEE OPERA TING MANUAL. 75 32 31 41 42 N.C. INSULA TE EACH UNUSED LEAD INDIVIDU ALL Y .
F-7 DIAGRAMS F-7 COMMANDER 500 CONNECTION DIAGRAM:.
F-8 DIAGRAMS F-8 COMMANDER 500 CONNECTION DIAGRAM:.
F-9 DIAGRAMS F-9 COMMANDER 500 CONNECTION DIAGRAM: o r se rvi ce t his eq ui pm e nt . Only q ua lifie d personne l should install, use Ke ep aw ay f rom mo v ing pa rt s. Ke ep gu ar d s in p lac e. MOVIN G PAR TS ca n in jure WA R N I N G Do no t to uc h e l ec tri cal ly liv e p art s .
F-10 DIAGRAMS F-10 COMMANDER 500 CONNECTION DIAGRAM: or service this equ ipm ent. On ly qualified personnel should install,use Keep away from movi ng parts. Keep guards in place. MOVING PART S can injure WA R N I N G Do not touch electrically live pa rts.
F-1 1 DIAGRAMS F-1 1 COMMANDER 500 CONNECTION DIAGRAM:.
F-12 DIAGRAMS F-12 COMMANDER 500 CONNECTION DIAGRAM:.
F-13 DIAGRAMS F-13 COMMANDER 500 CONNECTION DIAGRAM:.
F-14 DIAGRAMS F-14 COMMANDER 500 DIMENSION PRINT TRAILER MOUNT ING HOLE LOCATIONS. * 22.25 30.2 5 8.69 46.00 38.58 M18962 11-2000 REV 28.99 1.26 19.63 6.53 24.9 7 6.55 23.69 50.38 54.4 4 14.6 3 37.3 0 45.38 63.1 0 6.56 42.00 32.0 8 31.5 0 45.6 7 * * * * BOTT OM VIEW OF WELDER BASE .
NOTES COMMANDER 500.
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W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Lincoln Electric 500 è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Lincoln Electric 500 - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Lincoln Electric 500 imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Lincoln Electric 500 ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Lincoln Electric 500, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Lincoln Electric 500.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Lincoln Electric 500. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Lincoln Electric 500 insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
