Page 1: Service Manual
RETURN TO MAIN INDEX SVM153-A September, 2002 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 .
Page 2: Safety
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
Page 3: Electric Shock Can Kill
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. 3.b.
Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent 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.
Page 5 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. Protegez-vous contre la secousse électrique: a.
Page 6: Table Of Contents
- 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...
Page 7 Section A-1 - 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...
Page 8: Installation
TECHNICAL SPECIFICATIONS - COMMANDER 500 (K1639-1 & -2) Make/Model Description Deutz 3 cylinder 44 HP(33 kw) F3L 912 @ 1800 RPM Diesel Engine Duty Cycle 100% OUTPUT - WELDER AND GENERATOR Welding Range 30 - 575 Amps CC/CV 20 - 250 Amps TIG Height 42.0 in.
Page 9: Safety Precautions
Read this entire installation section before you start installation. 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.
Page 10: Lifting
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, secure the lift bale in a raised position. Secure the lift bale as follows: a.
Page 11: Pre-Operation Engine Service
PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. WARNING • Keep hands away from the engine muf- fler or HOT engine parts. • Stop engine and allow to cool before fueling. • Do not smoke when fueling. •...
Page 12: Muffler Outlet Pipe
IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster 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.
Page 13: Welding Output Cables
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. Listed in Table A.1 are copper cable sizes recommend- ed for the rated current and duty cycle.
Page 14 1. Install the double-pole, double-throw switch between the power company meter and the premises disconnect. Switch rating must be the same or greater than the cus- tomer’s premises disconnect and service over current protection. 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.
Page 15: Operation Section
Section B-1 - 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...
Page 16: Operation
OPERATING INSTRUCTIONS Read and understand this entire section before operat- ing your Commander 500. SAFETY INSTRUCTIONS WARNING 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.
Page 17: Recommended Applications
RECOMMENDED APPLICATIONS WELDER 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. GENERATOR The Commander 500 provides smooth 120/240 VAC output for auxiliary power and emergency standby...
Page 18: Welding Capability
K1639-1 COMMANDER 500 STANDARD MODEL • 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.
Page 19: Engine Controls
ENGINE CONTROLS (Items 1 through 8) RUN/STOP SWITCH 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.
Page 20: Welder Controls
Idler Operational Exceptions When the WELDING TERMINALS switch is in the “Welding Terminals Remotely Controlled” position, the idler will operate as follows: 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.
Page 21: Auxiliary Power Controls
12. 6 - PIN CONNECTOR (AMPHENOL) The 6-pin amphenol located on the control panel allows for connection of interfacing equipment. 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 “+”...
Page 22: Engine Operation
ENGINE OPERATION 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.
Page 23: Welder Operation
Table B.2 – DEUTZ F3L 912 ENGINE FUEL CONSUMPTION Deutz F3L 912 44.2 Hp @ 1800 RPM Low Idle - No .47 gallons/hour Load 1475 RPM (1.77 liters/hour) High Idle - No .66 gallons/hour Load 1900 RPM (2.50 liters/hour) DC CC Weld 1.94 gallons/hour Output 500 (7.34 liters/hour)
Page 24 B-10 TABLE B.3 – TYPICAL CURRENT RANGES DCEN (-) Tungsten Electrode 1%, 2% Diameter Thoriated in. (mm) Tungsten 0.010 (.25) 2-15 0.020 (.50) 5-20 0.40 (1.0) 15-80 1/16 (1.6) 70-150 3/32 (2.4) 150-250 (3.2) 250-400 5/32 (4.0) 400-500 3/16 (4.8) 500-750 (6.4) 750-1000...
Page 25: Wire Feed (Constant Voltage) Welding
B-11 WIRE FEED (CONSTANT VOLTAGE) WELDING Connect a wire feeder to the Commander 500 and set welder controls according to the instructions listed ear- lier in this section. 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).
Page 26: Extension Cord Recommendations
B-12 TABLE B.4 – COMMANDER 500 SIMULTANEOUS WELDING AND POWER LOADS Welding Output Range Setting Welding Output 30-575 500A/40V 500A/40V 350A/30V 250A/29V 150A/27V 90A/25V * 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...
Page 27 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...
Page 28: Accessories
OPTIONS/ACCESSORIES The following options/accessories are available for your Commander 500 from your local Lincoln Distributor. 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.
Page 29: Connection Of Lincoln Electric Wire Feeders
SEMIAUTOMATIC WELDING ACCESSORIES LN-7 OR LN-8 WIRE FEEDERS - Semiautomatic, con- stant speed wire feeders. For CV operation only. LN-23P WIRE FEEDER - This portable wire feeder is capable of CV operation. K350-1 Adapter Kit is required. LN-25 WIRE FEEDER - The LN-25 with or without an external contactor may be used with the Commander 300.
Page 30 CONNECTION OF THE LN-7 TO THE COMMANDER 500 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1.) 1. Shut the welder off. 2. Connect the electrode cable from 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.
Page 31 CONNECTION OF THE LN-7 TO THE COMMANDER 500 USING K584 OR K594 INPUT CABLE ASSEMBLY (SEE FIGURE C.2.) 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 “-”...
Page 32 CONNECTION OF THE LN-8 TO THE COMMANDER 500 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.3.) 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.
Page 33 CONNECTION OF THE LN-8 TO THE COMMANDER 500 USING K595 INPUT CABLE ASSEMBLY (SEE FIGURE C.4.) 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.
Page 34 CONNECTION OF THE LN-23P TO THE COMMANDER 500 USING K350-1 ADAPTER (SEE FIGURE C.5.) 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.
Page 35 CONNECTION OF THE LN-25 TO THE COMMANDER 500 “ACROSS THE ARC” (SEE FIGURE C.6.) 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. NOTE: Welding cable must be sized for current and duty cycle of application.
Page 36: Maintenance Section
Section D-1 - 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...
Page 37: Maintenance
SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. •...
Page 38: Change The Oil Filter
FIGURE D.1 – OIL DRAIN AND REFILL OIL FILTER DIPSTICK 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.
Page 39: Fuel Filters
FUEL FILTERS: WARNING When working on the fuel system: • Keep naked lights away, do not smoke ! • Do not spill fuel ! 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.
Page 40 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.
Page 41: Bleeding The Fuel System
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. AIR FILTER: CAUTION Excessive air filter restriction will result in reduced engine life.
Page 42: Cooling System
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. COOLING BLOWER BELT: The following procedure should be followed to replace the cooling blower belt: 1.
Page 43: Cooling Blower Belt
DEUTZ ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before • Fill fuel tank. Starting Engine • Check oil level. • Check air cleaner for dirty, loose, or damaged parts. Replace if necessary. • Check air intake and cooling areas, clean as necessary. First 50 Hours •...
Page 44: Cleaning The Battery
BATTERY MAINTENANCE WARNING 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.
Page 45: Welder/Generator Maintenance
D-10 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.
Page 46 D-11 FIGURE D.5 – MAJOR COMPONENT LOCATIONS 1. CASE DOOR ASSEMBLY 2. ENGINE 3. SHUT DOWN SOLENOID 4. IDLER SOLENOID 5. REAR PANEL ASSEMBLY 6. BASE MAINTENANCE 7. FRONT PANEL ASSEMBLY WITH OUTPUT PANEL 8. CONTROL PANEL 9. OUTPUT RECTIFIER BRIDGE ASSEMBLY 10.
Page 47 Section E-1 - 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...
Page 48 THEORY OF OPERATION FIGURE E.2 - BATTERY, ENGINE, ROTOR, STATOR, PULL COIL BOARD AND PERIPHERAL BOARD – ENGINE PROTECTION COMMANDER 500 MECHANICAL ENGINE ROTATION STARTER ALTERNATOR RUN/STOP ENGINE SWITCH SENSORS BATTERY BOARD BATTERY BATTERY PULL COIL TO WELD BOARD CONTROL BOARD PERIPHERAL BOARD...
Page 49 THEORY OF OPERATION FIGURE E.3 - WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK COMMANDER 500 MECHANICAL ENGINE ROTATION STARTER ALTERNATOR RUN/STOP ENGINE SWITCH SENSORS BATTERY BOARD BATTERY BATTERY PULL COIL TO WELD BOARD CONTROL BOARD PERIPHERAL BOARD WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK The three-phase stator weld windings are connected to...
Page 50: Control Board
THEORY OF OPERATION FIGURE E-4 – ANALOG CONTROL POWER SUPPLY BOARD AND WELD CONTROL BOARD COMMANDER 500 MECHANICAL ENGINE ROTATION STARTER ALTERNATOR RUN/STOP ENGINE SWITCH SENSORS BATTERY BOARD BATTERY BATTERY PULL COIL TO WELD BOARD CONTROL BOARD PERIPHERAL BOARD ANALOG CONTROL POWER SUPPLY BOARD AND WELD CONTROL BOARD The Analog Power Supply PC board, which is powered...
Page 51 THEORY OF OPERATION SOURCE DRAIN 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 A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow.
Page 52: Theory Of Operation
THEORY OF OPERATION FIGURE E.6 – TYPICAL IGBT OUTPUTS 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.
Page 53: Chopper Technology Fundamentals
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. EXTERNAL DC SOURCE In this system, the engine drives a three-phase alter-...
Page 54 Section F-1 - 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...
Page 55: How To Use Troubleshooting Guide
TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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.
Page 56: Pc Board Troubleshooting Procedures
• If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete. • 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.
Page 57: Troubleshooting Guide
The auxiliary output is normal. 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. POSSIBLE AREAS OF...
Page 58 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. detailed in the beginning of this manual.
Page 59 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. POSSIBLE AREAS OF...
Page 60 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. detailed in the beginning of this manual.
Page 61 The battery does not stay charged. 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.
Page 62 The engine cranks but will not start. 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.
Page 63 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. POSSIBLE AREAS OF...
Page 64 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.
Page 65 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. POSSIBLE AREAS OF...
Page 66: Troubleshooting And Repair
F-13 ENGINE STARTING DIAGNOSTIC CHART 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.
Page 67: Start-Up And Ocv Diagnostic Chart
F-14 START-UP AND OCV DIAGNOSTIC CHART 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 Go to the Control (10K)Pot.
Page 68: Case Cover Removal And Replacement Procedure
TROUBLESHOOTING & REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE 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.
Page 69 F-16 TROUBLESHOOTING & REPAIR AND REPLACEMENT PROCEDURE (CONTINUED) LEFT FRONT PANEL PROCEDURE 1. Turn the engine off. 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.
Page 70 F-17 TROUBLESHOOTING & REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.2 – FRONT PANEL/ROOF DETAILS SCREWS FRONT CONTROL PANEL 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.
Page 71: Case Front Knobs - Removal And Replacement Procedure
F-18 TROUBLESHOOTING & REPAIR CASE FRONT KNOBS - REMOVAL AND REPLACEMENT PROCEDURE Side View (Pull) Knob Nameplate (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"...
Page 72: Power Module Capacitor Discharge Procedure
TROUBLESHOOTING & REPAIR POWER MODULE CAPACITOR DISCHARGE PROCEDURE 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.
Page 73 F-20 TROUBLESHOOTING & REPAIR POWER MODULE CAPACITOR DISCHARGE PROCEDURE (CONTINUED) FIGURE F.4 – POWER MODULE CAPACITOR TERMINAL DISCHARGE PROCEDURE 1. This procedure must be performed with the engine off. 2. Using the 3/8" wrench, remove the front left and right side panels. 3.
Page 74: Idler Solenoid Test
F-21 TROUBLESHOOTING & REPAIR 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.
Page 75 F-22 TROUBLESHOOTING & REPAIR IDLER SOLENOID TEST (CONTINUED) TEST PROCEDURE 1. Turn the engine off. 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).
Page 76: Shutdown Solenoid Test
TROUBLESHOOTING & REPAIR SHUTDOWN SOLENOID TEST 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.
Page 77 F-24 TROUBLESHOOTING & REPAIR SHUTDOWN SOLENOID TEST (CONTINUED) FIGURE F.6 – SHUTDOWN SOLENOID LEAD TERMINALS TEST PROCEDURE 1. Turn the engine off. 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).
Page 78: Engine Throttle Adjustment Test
TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST 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.
Page 79 F-26 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) TEST PROCEDURE Strobe-tach Method 1. Conduct this procedure with the engine OFF. 2. Unlatch, lift and secure the right side engine service access door. Cover Removal Procedure through Step 9. (For Strobe- Tach method only.) 3.
Page 80 F-27 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) FIGURE F.8 – HIGH IDLE ADJUSTMENT FIGURE F.9 – LOW IDLE ADJUSTMENT ADJUSTING COLLAR LOCKING NUT B O S C H 90 3 5 7 0 0 8 PE S 3A 0 40 0 46 3 COMMANDER 500 F-27...
Page 81 F-28 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) 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.
Page 82: Rotor Resistance Test
TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST 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.
Page 83 F-30 TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST (CONTINUED) TEST PROCEDURE 1. Conduct this test with the engine off. 2. Using the 3/8" wrench, remove the right front case side. 3. Using the 3/8" wrench, remove the brush holder access panel. See Figure F.10. 4.
Page 84: Flashing And Rotor Voltage Test
TROUBLESHOOTING & REPAIR FLASHING AND ROTOR VOLTAGE TEST 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.
Page 85 F-32 TROUBLESHOOTING & REPAIR FLASHING AND ROTOR VOLTAGE TEST(CONTINUED) LEAD # 200A TEST PROCEDURE 1. Using the 3/8" wrench, remove the sheet metal screws from the right front case side. 2. Carefully remove the right case side. 3. Set the volt/ohmmeter to the DC volts position.
Page 86 F-33 TROUBLESHOOTING & REPAIR FLASHING AND ROTOR VOLTAGE TEST(CONTINUED) FIGURE F.12 - FIELD DIODE RECTIFIER BRIDGE AND FILTER CAPACITOR 7. If the voltage reading is low or not present, the generator field is not functioning proper- Perform the Rotor Resistance Test. Also check the field diode rectifier bridge, fil- ter capacitor, and associated leads and con- nections.
Page 87: Stator Voltage Test
F-34 TROUBLESHOOTING & REPAIR 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.
Page 88 F-35 TROUBLESHOOTING & REPAIR STATOR VOLTAGE TEST (CONTINUED) FIGURE F.13 – FRONT CONTROL PANEL REMOVAL SCREWS FRONT CONTROL PANEL TEST PROCEDURE 1. Turn the engine off. 2. Using the 3/8" wrench, remove the four screws holding the front control panel to the case top and sides.
Page 89 F-36 TROUBLESHOOTING & REPAIR STATOR VOLTAGE TEST (CONTINUED) FIGURE F.14 – OUTPUT PANEL REMOVAL OUTPUT LEADS (BEHIND PANEL) OUTPUT PANEL 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.
Page 90 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).
Page 91 F-38 TROUBLESHOOTING & REPAIR STATOR VOLTAGE TEST (CONTINUED) FIGURE F.16 – OUTPUT RECTIFIER DIODE BRIDGE WELD WINDING LEAD CONNECTIONS 4. Locate the weld winding leads connected to the three-phase output rectifier diode bridge. See Figure F.16. 5. Check for approximately 68VAC from W1 to W2.
Page 92: Analog Power Supply Pc Board Voltage Test
TROUBLESHOOTING & REPAIR ANALOG POWER SUPPLY PC BOARD VOLTAGE TEST 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.
Page 93 F-40 TROUBLESHOOTING & REPAIR ANALOG POWER SUPPLY PC BOARD VOLTAGE TEST (CONTINUED) FIGURE F.17 – ANALOG POWER SUPPLY PC BOARD CONTROL 13 1J41 to POS TERMINAL ON C2 - 85V SUPPLY CIRCUIT 14 2J41 to NEG TERMINAL ON C2 - 85V SUPPLY INPUT POWER TEST PROCEDURE...
Page 94 F-41 TROUBLESHOOTING & REPAIR ANALOG CONTROL POWER SUPPLY PC BOARD TEST (CONTINUED) ANALOG CONTROL POWER SUPPLY PC BOARD VOLTAGE TABLE Test Points 1J42 to 6J42 3J42 to 8J42 2J42 to 7J42 Weld Control PC Board Power Supply 5J42 to 7J42 Weld Control PC Board Power Supply 9J42 to 7J42 Weld Control PC Board Power Supply...
Page 95: Output Rectifier Bridge Test
TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST 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.
Page 96 F-43 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST(CONTINUED) FIGURE F.18 – FRONT CONTROL PANEL REMOVAL SCREWS FRONT CONTROL PANEL TEST PROCEDURE 1. Turn the engine off. 2. Using the 3/8" wrench remove the screws holding the front control panel to the case top and sides.
Page 97 F-44 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST(CONTINUED) FIGURE F.19 – OUTPUT PANEL REMOVAL OUTPUT LEADS (BEHIND PANEL) OUTPUT PANEL 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.
Page 98 F-45 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST(CONTINUED) 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.
Page 99: Power Module Test
F-46 TROUBLESHOOTING & REPAIR 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.
Page 100 F-47 TROUBLESHOOTING & REPAIR POWER MODULE TEST (CONTINUED) FIGURE F.21 – POWER MODULE CAPACITOR LEADS (LEFT SIDE) TEMPERATURE SWITCH POWER MODULE PC BOARD DIODE LEAD D4 POSITIVE (+) STRAP TEST PROCEDURE 1. Turn the engine off. 2. Perform the Case Cover Removal proce- dure.
Page 101 F-48 TROUBLESHOOTING & REPAIR POWER MODULE TEST (CONTINUED) 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.
Page 102 F-49 TROUBLESHOOTING & REPAIR POWER MODULE TEST (CONTINUED) DIODE MODULE TERMINALS Check Diode Module 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).
Page 103: Charging Circuit Test
F-50 TROUBLESHOOTING & REPAIR 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.
Page 104 F-51 TROUBLESHOOTING & REPAIR CHARGING CIRCUIT TEST (CONTINUED) FIGURE F.24 – ENGINE ALTERNATOR LOCATION #239 #238 TEST PROCEDURE 1. Turn engine off. 2. Using the 3/8" wrench, remove the left rear case cover. 3. Locate the engine alternator. See Figure F.24.
Page 105 F-52 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) HIGH IDLE – NO LOAD 15.8 ms 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.
Page 106: Normal Open Circuit Voltage Waveform (Stick
F-53 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (STICK) MAX TAP – MAX CONTROL POT – HIGH IDLE – NO LOAD 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.
Page 107: Normal Weld Voltage Waveform (Stick Cc
F-54 TROUBLESHOOTING & REPAIR NORMAL WELD VOLTAGE WAVEFORM (STICK CC) MACHINE LOADED TO 500 AMPS AT 40 VOLTS 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.
Page 108: Normal Weld Voltage Waveform (Wire Cv
F-55 TROUBLESHOOTING & REPAIR NORMAL WELD VOLTAGE WAVEFORM (WIRE CV) MACHINE LOADED TO 500 AMPS AT 40 VOLTS 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 5 milliseconds in time.
Page 109: Normal Tig Mode Voltage Waveform
F-56 TROUBLESHOOTING & REPAIR NORMAL TIG MODE VOLTAGE WAVEFORM LOADED TO 200A 16 VOLTS 50ms 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.
Page 110: Normal Open Circuit Voltage Waveform (Wire Cv Tap
F-57 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV TAP) MAX CONTROL POT – HIGH IDLE – NO LOAD 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.
Page 111: Shutdown Solenoid Removal And Replacement
TROUBLESHOOTING & REPAIR SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT 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.
Page 112 F-59 TROUBLESHOOTING & REPAIR SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F. 25 – SHUTDOWN SOLENOID LEAD CONNECTIONS 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).
Page 113 F-60 TROUBLESHOOTING & REPAIR SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F. 26 – SHUTDOWN SOLENOID LINKAGE ARM ASSEMBLY PIVOT PIN SPACER WASHER PLAIN WASHER RETAINING RING 4. Using the 7/16" wrench, remove the three nuts, two bolts and three lock washers mounting the shutdown solenoid assembly to the engine.
Page 114: Power Module/Output Rectifier Bridge Assembly Removal And Replacement
POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT 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.
Page 115 F-62 TROUBLESHOOTING & REPAIR POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT (CONTINUED) SCREWS FRONT CONTROL PANEL PROCEDURE 1. Turn the engine off. 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.) 3.
Page 116 F-63 TROUBLESHOOTING & REPAIR POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F. 28 – POWER MODULE CAPACITOR LEAD REMOVAL Refer to Figure F.28 for Steps 8-12. 8. Using the 7/16" wrench, loosen the nuts on the positive terminals of the power capaci- tors.
Page 117 F-64 TROUBLESHOOTING & REPAIR POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.29 – POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY DETAILS BRACKET POWER MODULE PC BOARD (CHOPPER PC BOARD) BOTTOM BRACKET CAPACITOR POWER MODULE HEATSINK DIODE HEATSINK DIODE LEADS CONTROL TRANSFORMER COMMANDER 500...
Page 118 F-65 TROUBLESHOOTING & REPAIR POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT (CONTINUED) Refer to Figure F.29 for Steps 13-15. 13. Using the 7/16" wrench, remove the stator "W" leads from the three terminals on the plastic insulator bracket of the rectifier bridge.
Page 119: Power Module (Chopper) Pc Board/Diode Module Removal And Replacement
POWER MODULE (CHOPPER) PC BOARD/DIODE MODULE REMOVAL AND REPLACEMENT 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.
Page 120 F-67 TROUBLESHOOTING & REPAIR POWER MODULE (CHOPPER) PC BOARD/DIODE MODULE REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.30 – POWER MODULE PC BOARD TEMPERATURE SWITCH COPPER SPACERS ALLEN HEAD SCREWS (4) PLUG J50 POWER MODULE PC BOARD REMOVAL Refer to Figure F.30. 1.
Page 121 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. 2.
Page 122 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 SPRING WASHER PLAIN WASHER FINGER TIGHT 5.0-10 IN-LBS. DIODE MODULE REMOVAL Refer to Figure F.31.
Page 123: Output Rectifier Bridge Diode Removal And Replacement
TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE DIODE REMOVAL AND REPLACEMENT 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.
Page 124 F-71 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE DIODE REMOVAL AND REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.32 – POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY DETAILS PROCEDURE Refer to Figure F.32. 1. Turn the engine off. 2. Perform the Output Panel Removal as described in the Case Cover Removal pro- cedure.
Page 125 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. 9.
Page 126: Stator/Rotor Removal And Replacement
TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT 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.
Page 127 F-74 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.33 – FUEL TANK REMOVAL DETAILS LEADS #229 AND #242D PREPARATION AND LEAD REMOVAL PROCEDURE Refer to Figure F.33. 1. Turn the engine off. 2. Perform the Case Cover Removal proce- dure, including removing the output panel.
Page 128 F-75 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.34 – PLUG J52/FILTER CAPACITOR/FIELD RECTIFIER BRIDGE DISCONNECTION PLUG P/J52 FILTER CAPACITOR Refer to Figure F.34 for Steps 10-12. 10. Disconnect plug J52 at the right front side. See Figure F.34. 11.
Page 129 F-76 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.35 – BRUSH HOLDER AND LEAD REMOVAL #201 FIGURE F.36 – CONTROL BOX CONNECTIONS 16. See Figure F.36. Disconnect leads #265 and #227 from the Pull Coil PC board. wrench, remove the nut, lock washer, and flat washer from the 12 VDC insulated stud.
Page 130 F-77 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.37 – ALTERNATOR SHROUD REMOVAL 18. With the 5/16" wrench, remove the six screws that hold the top and bottom of the alternator shroud together. ACOUSTICAL FOAM 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.
Page 131 F-78 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.38 – LIFT FRAME AND ASSOCIATED COMPONENT REMOVAL LIFT FRAME WELDMENT FUEL TANK SUPPORTS In steps 20 – 24, the lift frame weldment, fuel tank supports, and fan baffle are removed as a unit.
Page 132 F-79 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED) BEARING FAN HUB BOLTS STATOR REMOVAL PROCEDURE 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.
Page 133 F-80 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED) FLEX PLATE ROTOR ROTOR REMOVAL PROCEDURE Refer to Figure F.40 for rotor removal. 1. Support the rotor with the hoist. 2. Using the 5/8" wrench, remove the flex plate bolts, lock washers, and four blower seg- ments.
Page 134 F-81 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED) LEAD RECONNECTION CHECKLIST ENGINE Leads #242D and #229 to fuel level sensor Plug J52 Brush leads #201(-) and #200A(+) and #200B(+) Leads #5P, #201 and #201A, #200D, and #6F to the field bridge rectifier OUTPUT PANEL AND CONTROL BOX Leads #265 and #227 to Pull Coil PC board Leads #232L and #232M to 12 VDC insu-...
Page 135: Retest After Repair
F-82 TROUBLESHOOTING & 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. • If you repair or replace any electrical components. Mode Low Idle High Idle...
Page 136 F-83 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR (CONTINUED) TOUCH START TIG MODE OUTPUT Mode Selector Switch TIG 20 - 250 A TIG 20 - 250 A 230 Volt Receptacle Open Circuit Voltage Load Volts 245 - 254 225 - 240 Open Circuit Fine Control Voltage...
Page 137 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 –...
Page 138 WIRING DIAGRAM - COMMANDER 500 LEADS 3 & 6A PASS THROUGH TOROID TWICE IN OPPOSITE DIRECTIONS WELD LEAD TO PASS THRU TOROID ONCE POS. NEG. NEG. 204S NEG. WELD 206S 260A LEAD 261A PCB 6 L1 CHOKE POS. ELECT. 206A POS.
Page 139: Electrical Diagrams
ENGINE STARTER 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.
Page 140: Schematic - Battery Pc Board
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...
Page 141: Pc Board Assembly - Battery Pc Board
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.
Page 142: Schematic - Chopper Pc Board
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. THE LINCOLN ELECTRIC CO. THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO.
Page 143: Pc Board Assembly - Chopper Pc Board
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.
Page 144: Schematic - Peripheral Pc Board
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...
Page 145: Pc Board Assembly - Peripheral Pc Board
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.
Page 146: Schematic - Power Supply (Analog) Pc Board
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...
Page 147: Pc Board Assembly - Power Supply (Analog) Pc Board
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.
Page 148: Schematic - Pull-Coil Pc Board
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...
Page 149: Pc Board Assembly - Pull-Coil Pc Board
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.
Page 150: Schematic - Weld Control Pc Board - Sheet 1
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...
Page 151: Schematic - Weld Control Pc Board - Sheet 2
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...
Page 152: Schematic - Weld Control Pc Board - Sheet 3
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...
Page 153: Schematic - Weld Control Pc Board - Sheet 4
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...
Page 154: Schematic - Weld Control Pc Board - Sheet 5
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...
Page 155: Pc Board Assembly - Weld Control Pc Board
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.
Page 156 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99 Thank You, Technical Services Group Lincoln Electric Co. 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...

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