Lincoln Electric SVM153-A manual

SVM153-A September , 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 in- creased by proper installation . . . and thoughtful operation on your part. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANU AL AND THE SAFETY PR[...]

CALIFORNIA PROPOSITION 65 W ARNINGS i i SAFETY 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 ii SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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. 4.b. U[...]

iii iii SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 manufactu[...]

iv iv SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 [...]

v v - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - COMMANDER 500 Page Safety .................................................................................................................................................i-iv Installation ..............................................................................................................[...]

Installation ................................................................................................................... ..........Section A T echnical Specifications ..............................................................................................................A-2 Safety Precautions ..........................................[...]

A-2 A-2 INST ALLA TION COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TECHNICAL SPECIFICA TIONS - COMMANDER 500 (K1639-1 & -2) Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz[...]

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 manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. EL[...]

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. Open the engine compartment door . b. Locate the two access holes on the upper mid- dle region of the comp[...]

A-5 A-5 INST ALLA TION COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-OPERA TION ENGINE SER VICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep hands away from [...]

IMPORT ANT : T o 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- ati[...]

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 T able A.1 are copper cable sizes recommend- ed for the rated current and du[...]

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. T ake necessary steps to assure load is limited to the capacity of the Commander by installing a 50 amp, 240 V AC [...]

Operation ............................................................................................................................... Section B Operating Instructions ......................................................................................................... ........B-2 Safety Instructions .........................................[...]

B-2 B-2 OPERA TION COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TING INSTRUCTIONS Read and understand this entire section before operat- ing your Commander 500. SAFETY INSTRUCTIONS Do not attempt to use [...]

RECOMMENDED APPLICA TIONS WELDER The Commander 500 provides excellent constant cur- rent DC welding output for stick (SMA W) and TIG weld- ing. The Commander 500 also provides excellent con- stant voltage DC welding output for MIG (GMA W) and Innershield (FCA W) welding. GENERA TOR The Commander 500 provides smooth 120/240 V AC output for auxiliary[...]

K1639-1 COMMANDER 500 ST ANDARD 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 outp[...]

ENGINE CONTROLS (Items 1 through 8) 1. 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, th[...]

Idler Operational Exceptions When the WELDING TERMINALS switch is in the “Welding T erminals 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[...]

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 “+” ter[...]

ENGINE OPERA TION ST ARTING 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 . 3. Remove all plugs connected to the AC powe[...]

T able B.2 – DEUTZ F3L 912 ENGINE FUEL CONSUMPTION Deutz F3L 912 Running Time 44.2 Hp for 25 gallons @ 1800 RPM (Hours) Low Idle - No .47 gallons/hour 53.2 Load 1475 RPM (1.77 liters/hour) High Idle - No .66 gallons/hour 37.9 Load 1900 RPM (2.50 liters/hour) DC CC Weld 1.94 gallons/hour 12.9 Output 500 (7.34 liters/hour) Amps @ 40 V olts Auxiliar[...]

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 TERMINALS ON position. This will close the solid state contactor and provide an always “hot” electrode. NOTE: This is necessary because [...]

WIRE FEED (CONST ANT VOL T AGE) 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 ar[...]

B-12 B-12 OPERA TION COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE B.4 – COMMANDER 500 SIMUL T ANEOUS WELDING AND POWER LOADS Permissible Permissible Auxiliary Welding Power - W atts Current in Amperes[...]

Accessories .................................................................................................................... ......Section C Options/Accessories ...................................................................................................................C-2 Field Installed Options ..........................................[...]

OPTIONS/ACCESSORIES The following options/accessories are available for your Commander 500 from your local Lincoln Distributor . FIELD INST ALLED 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 w[...]

SEMIAUT OMA TIC 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. NOTE:[...]

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. NOTE: Figu[...]

C-5 C-5 ACCESSORIES COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECTION OF THE LN-7 TO THE COMMANDER 500 USING K584 OR K594 INPUT CABLE ASSEMBL Y (SEE FIGURE C.2.) 1. Shut the welder off. 2. Connect the el[...]

C-6 C-6 ACCESSORIES COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 cabl[...]

C-7 C-7 ACCESSORIES COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECTION OF THE LN-8 TO THE COMMANDER 500 USING K595 INPUT CABLE ASSEMBL Y (SEE FIGURE C.4.) 1. Shut the welder off. 2. Connect the electrode [...]

C-8 C-8 ACCESSORIES COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 fr o[...]

C-9 C-9 ACCESSORIES COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 fro[...]

Maintenance .................................................................................................................... ......Section D Safety Precautions ............................................................................................................. .........D-2 Routine and Periodic Maintenance ..............................[...]

SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn 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. • If covers or guards are missing from the machin[...]

CHANGE THE OIL FIL TER: 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 T able D.1 for recommended mai[...]

FUEL FIL TERS: 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/W ater 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/W ater Separator [...]

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 addi[...]

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 FIL TER: Excessive air filter restriction will result in reduced engine life. The air filter element is a dry cartridge type. It can be cleaned and re[...]

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 BEL T : The following procedure should be followed to replace the cooling blower belt: 1. Allow the machine to cool. 2. Unfasten and slide the battery holder[...]

D-8 D-8 MAINTENANCE COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE D.1 DEUTZ ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Starting Engine • Fill fuel tank. • Check oil le[...]

BA TTER Y MAINTENANCE GASES FROM BA TTERY can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY 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 . T o prevent EXPLOSION when: • INST ALLING A NEW BA TTERY - Disconne[...]

WELDER/GENERA TOR 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. NAMEPLA TES: Whenever routine maintenance is performed on this machine - or at least yearly - inspect all namep[...]

D-11 D-11 MAINTENANCE COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 12 10 8 7 9 6 5 4 3 2 1 11 FIGURE D.5 – MAJOR COMPONENT LOCA TIONS 1. CASE DOOR ASSEMBL Y 2. ENGINE 3. SHUT DOWN SOLENOID 4. IDLER SOLENOID [...]

General Description .......................................................................................................................E-2 Battery , Starter , Engine, Rotor , Stator , Pull Coil Board and Peripheral Board – Engine Protection .....................................................................................................E-[...]

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 T echnology to produce DC current for multi-purpose welding applications. The Co[...]

WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK 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 a[...]

ANALOG CONTROL POWER SUPPL Y BOARD AND WELD CONTROL BOARD 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 t[...]

INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT s 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 . The drain terminal of the[...]

PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION is used to describe how much time is devoted to conduction in the cycle. Changing the pulse width is known as MODU- LA TION. 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. MINIMUM OUTPUT By controlling the [...]

CHOPPER TECHNOLOGY FUNDAMENT ALS 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, s[...]

Tr oubleshooting & Repair Section ......................................................................................Section F How to Use T roubleshooting Guide ...........................................................................................F-2 PC Board T roubleshooting Procedures ..................................................[...]

This T roubleshooting Guide is provided to help you locate and repair possible machine malfunc- tions. Simply follow the three-step procedure listed below . Step 1. LOCA TE 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 be[...]

ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T urn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting an[...]

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. 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. PROBLEMS ([...]

TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. 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. PROBLEMS ([...]

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. 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. PROBLEMS ([...]

TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. 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. PROBLEMS ([...]

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. 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. PROBLEMS ([...]

TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. 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. PROBLEMS ([...]

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. 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. PROBLEMS ([...]

TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. 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. PROBLEMS ([...]

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. 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. PROBLEMS ([...]

TROUBLESHOOTING & REP AIR F-13 COMMANDER 500 ENGINE ST ARTING DIAGNOSTIC CHART F-13 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Does the PULL COIL read .3 ohms? Is there FUEL? Did 1 of the W ARNING lights come on? Is t[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 COMMANDER 500 ST ART -UP AND OCV DIAGNOSTIC CHART F-14 No LOW IDLE. Is AUX current flowing? TWO displays illuminated? Is WELD current flowing? [...]

TROUBLESHOOTING & REP AIR F-15 F-15 COMMANDER 500 CASE COVER REMOV AL AND REPLACEMENT PROCEDURE W ARNING 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 [...]

TROUBLESHOOTING & REP AIR F-16 F-16 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROP R OD LEFT FRONT P ANEL RIGHT FRONT P ANEL DOOR ASSEMBL Y ROUND HEAD SCREW LOCA TION FIGURE F .1 – COVER REMOV AL CASE[...]

TROUBLESHOOTING & REP AIR F-17 F-17 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FRONT CONTROL P ANEL SCREWS SCREW FIGURE F .2 – FRONT P ANEL/ROOF DET AILS CASE COVER REMOV AL AND REPLACEMENT PROCEDURE ([...]

TROUBLESHOOTING & REP AIR F-18 F-18 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CASE FRONT KNOBS - REMOV AL AND REPLACEMENT PROCEDURE Replacement Removal Flat Rounded Replacement:  1. If the white n[...]

TROUBLESHOOTING & REP AIR F-19 F-19 COMMANDER 500 POWER MODULE CAP ACITOR DISCHARGE PROCEDURE W ARNING 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 . [...]

TROUBLESHOOTING & REP AIR F-20 F-20 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE CAP ACITOR TERMINALS FIGURE F .4 – POWER MODULE CAP ACITOR TERMINAL DISCHARGE POWER MODULE CAP ACITOR DISCHAR[...]

TROUBLESHOOTING & REP AIR F-21 F-21 COMMANDER 500 IDLER SOLENOID TEST W ARNING 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 a[...]

TROUBLESHOOTING & REP AIR F-22 F-22 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PULL-IN COIL (LARGER TERMINALS TOP AND BOTTOM #227 AND #232L) HOLD-IN COIL (SMALLER TERMINALS TOP AND BOTTOM #226A AND #232S[...]

TROUBLESHOOTING & REP AIR F-23 F-23 COMMANDER 500 SHUTDOWN SOLENOID TEST W ARNING 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 t[...]

TROUBLESHOOTING & REP AIR F-24 F-24 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PULL-IN COIL (LARGER TERMINALS EACH SIDE #232M AND #265) HAND-IN COIL (SMALLER TERMINALS EACH SIDE #224 AND #262) SHUTDOWN S[...]

TROUBLESHOOTING & REP AIR F-25 F-25 COMMANDER 500 ENGINE THROTTLE ADJUSTMENT TEST W ARNING 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 saf[...]

TROUBLESHOOTING & REP AIR F-26 F-26 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MARK BLOWER P ADDLE HERE FIGURE F .7 – STROBE MARK LOCA TION ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) TEST PROCEDURE St[...]

TROUBLESHOOTING & REP AIR F-27 F-27 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) FIGURE F .8 – HIGH IDLE ADJUSTMENT BOSCH 5 7 0 0 8 1 6 903 PES 3A 80D 410/3R 0[...]

TROUBLESHOOTING & REP AIR F-28 F-28 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) 6. If either of the readings is incorrect, adjust the throttle as follows: Adjus[...]

TROUBLESHOOTING & REP AIR F-29 F-29 COMMANDER 500 ROT OR RESIST ANCE TEST W ARNING 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 [...]

TROUBLESHOOTING & REP AIR F-30 F-30 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SLIP RINGS BRUSH HOLDER ASSEMBL Y ACCESS P ANEL FIGURE F .10 – ROTOR BRUSH LEADS ROT OR RESIST ANCE TEST (CONTINUED) TEST [...]

TROUBLESHOOTING & REP AIR F-31 F-31 COMMANDER 500 FLASHING AND ROTOR VOL T AGE TEST W ARNING 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 s[...]

TROUBLESHOOTING & REP AIR F-32 F-32 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PLUG P/J52 LEAD # 200A LEAD # 201A PLUG P/J52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 FIL TER CAP ACITOR FIELD DIODE RECTIFIE[...]

TROUBLESHOOTING & REP AIR F-33 F-33 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIL TER CAP ACITOR FIELD DIODE RECTIFIER BRIDGE FIGURE F .12 - FIELD DIODE RECTIFIER BRIDGE AND FIL TER CAP ACITOR FLASHING [...]

TROUBLESHOOTING & REP AIR F-34 F-34 COMMANDER 500 ST A TOR VOL T AGE TEST W ARNING 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 [...]

TROUBLESHOOTING & REP AIR F-35 F-35 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FRONT CONTROL P ANEL SCREWS SCREW FIGURE F .13 – FRONT CONTROL P ANEL REMOV AL ST A TOR VOL T AGE TEST (CONTINUED) TEST PR[...]

TROUBLESHOOTING & REP AIR F-36 F-36 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GREEN GROUND LEAD OUTPUT P ANEL SCREWS OUTPUT LEADS (BEHIND P ANEL) FIGURE F .14 – OUTPUT P ANEL REMOV AL ST A TOR VOL T A[...]

TROUBLESHOOTING & REP AIR F-37 F-37 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC AUXILIAR Y LEADS #5B, #5E, #8, #9, #1 1, #12 (BEHIND P ANEL) FIGURE F .15 – AUXILIAR Y LEAD TEST LOCA TION ST A TOR VOL T [...]

TROUBLESHOOTING & REP AIR F-38 F-38 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WELD WINDING LEAD CONNECTIONS W6 W2 W4 W1 W3 W5 FIGURE F .16 – OUTPUT RECTIFIER DIODE BRIDGE ST A TOR VOL T AGE TEST (CONT[...]

TROUBLESHOOTING & REP AIR F-39 F-39 COMMANDER 500 ANALOG POWER SUPPL Y PC BOARD VOL T AGE TEST W ARNING 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 .[...]

TROUBLESHOOTING & REP AIR F-40 F-40 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL CIRCUIT INPUT POWER 13 1J41 to POS TERMINAL ON C2 - 85V SUPPL Y J41 J42 14 2J41 to NEG TERMINAL ON C2 - 85V SUPPL Y [...]

TROUBLESHOOTING & REP AIR F-41 F-41 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE F .1 ANALOG CONTROL POWER SUPPL Y PC BOARD VOL T AGE T ABLE T est Points Component T ested V oltage Reading 1J42 to 6[...]

TROUBLESHOOTING & REP AIR F-42 F-42 COMMANDER 500 OUTPUT RECTIFIER BRIDGE TEST W ARNING 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[...]

TROUBLESHOOTING & REP AIR F-43 F-43 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FRONT CONTROL P ANEL SCREW SCREWS FIGURE F .18 – FRONT CONTROL P ANEL REMOV AL OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) TE[...]

TROUBLESHOOTING & REP AIR F-44 F-44 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GREEN GROUND LEAD OUTPUT P ANEL SCREWS OUTPUT LEADS (BEHIND P ANEL) FIGURE F .19 – OUTPUT P ANEL REMOV AL OUTPUT RECTIFIER[...]

TROUBLESHOOTING & REP AIR F-45 F-45 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WELD WINDING LEAD CONNECTIONS W6 W2 W4 W1 W3 W5 FIGURE F .20 – DIODE LEAD REMOV AL OUTPUT RECTIFIER BRIDGE TEST (CONTINUED[...]

TROUBLESHOOTING & REP AIR F-46 F-46 COMMANDER 500 POWER MODULE TEST W ARNING 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 avo[...]

TROUBLESHOOTING & REP AIR F-47 F-47 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W10 W9 DIODE LEAD D4 TEMPERA TURE SWITCH POWER MODULE PC BOARD POSITIVE (+) STRAP POSITIVE (+) STRAP FIGURE F .21 – POWER [...]

TROUBLESHOOTING & REP AIR F-48 F-48 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HEA T SINK POSITIVE (+) CAP ACITOR TERMINAL CONNECTIONS FIGURE F .22 – IGBT TEST POWER MODULE TEST (CONTINUED) Check IGBT [...]

TROUBLESHOOTING & REP AIR F-49 F-49 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DIODE MODULE TERMINALS HEA T SINK FIGURE F .23 – DIODE MODULE TEST POWER MODULE TEST (CONTINUED) Check Diode Module 9. Usi[...]

TROUBLESHOOTING & REP AIR F-50 F-50 COMMANDER 500 CHARGING CIRCUIT TEST W ARNING 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[...]

TROUBLESHOOTING & REP AIR F-51 F-51 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC #239 #281 #238 FIGURE F .24 – ENGINE AL TERNA TOR LOCA TION CHARGING CIRCUIT TEST (CONTINUED) TEST PROCEDURE 1. T urn engi[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-52 F-52 COMMANDER 500 This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division r[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-53 F-53 COMMANDER 500 This is the typical DC open circuit out- put voltage generated from a properly operating machine. Note that each vertical di[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-54 F-54 COMMANDER 500 This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represen[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-55 F-55 COMMANDER 500 NORMAL WELD VOL T AGE W A VEFORM (WIRE CV) MACHINE LOADED TO 500 AMPS A T 40 VOL TS This is the typical DC output voltage ge[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-56 F-56 COMMANDER 500 This is the typical TIG MODE output voltage generated from a properly operating machine. Note that each vertical division re[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-57 F-57 COMMANDER 500 This is the typical DC open circuit output voltage generated from a properly operating machine. Note that each vertical divi[...]

TROUBLESHOOTING & REP AIR F-58 F-58 COMMANDER 500 SHUTDOWN SOLENOID REMOV AL AND REPLACEMENT W ARNING 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 . F[...]

TROUBLESHOOTING & REP AIR F-59 F-59 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PULL-IN COIL (LARGER TERMINALS EACH SIDE #232M AND #265) HOLD-IN COIL (SMALLER TERMINALS EACH SIDE #224 AND #262) SHUTDOWN S[...]

TROUBLESHOOTING & REP AIR F-60 F-60 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PIVOT PIN SP ACER W ASHER PLAIN W ASHER RET AINING RING MOUNTING F ASTENERS FIGURE F . 26 – SHUTDOWN SOLENOID LINKAGE ARM [...]

TROUBLESHOOTING & REP AIR F-61 F-61 COMMANDER 500 POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT W ARNING 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 invalid[...]

TROUBLESHOOTING & REP AIR F-62 F-62 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FRONT CONTROL P ANEL SCREWS SCREW GREEN GROUND LEAD F .27 – CONTROL P ANEL REMOV AL POWER MODULE/OUTPUT RECTIFIER BRIDGE A[...]

TROUBLESHOOTING & REP AIR F-63 F-63 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC REMOVE LEADS POWER MODULE FIGURE F . 28 – POWER MODULE CAP ACITOR LEAD REMOV AL POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEM[...]

TROUBLESHOOTING & REP AIR F-64 F-64 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC } } } } } } } } } } } } TOP BRACKET DIODE HEA TSINK DIODE LEADS CONTROL TRANSFORMER BOTTOM BRACKET DIODE & “ W ” LEA[...]

TROUBLESHOOTING & REP AIR F-65 F-65 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT (CONTINUED) Refer to Figure F .29 for Steps 13-15. 1[...]

TROUBLESHOOTING & REP AIR F-66 F-66 COMMANDER 500 POWER MODULE (CHOPPER) PC BOARD/DIODE MODULE REMOV AL AND REPLACEMENT W ARNING 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 invalidat[...]

TROUBLESHOOTING & REP AIR F-67 F-67 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PLUG J50 ALLEN HEAD SCREWS (4) COPPER SP ACERS TEMPERA TURE SWITCH HEA T SINK POWER MODULE PC BOARD DIODE MODULE FIGURE F .3[...]

TROUBLESHOOTING & REP AIR F-68 F-68 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE (CHOPPER) PC BOARD/DIODE MODULE REMOV AL AND REPLACEMENT (CONTINUED) POWER MODULE PC BOARD REPLACEMENT 1. Apply[...]

TROUBLESHOOTING & REP AIR F-69 F-69 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SPRING WASHER PLAIN WASHER 2 TO 3 TURNS EACH 12-18 IN.LBS. 30-40 IN.LBS. FINGER TIGHT 5.0-10 IN-LBS. 5.0-10 IN-LBS. FIGURE F[...]

TROUBLESHOOTING & REP AIR F-70 F-70 COMMANDER 500 OUTPUT RECTIFIER BRIDGE DIODE REMOV AL AND REPLACEMENT W ARNING 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 [...]

TROUBLESHOOTING & REP AIR F-71 F-71 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HEA TSINKS DIODE DIODE PIGT AIL LEADS FIGURE F .32 – POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y DET AILS OUTPUT RECTIF[...]

TROUBLESHOOTING & REP AIR F-72 F-72 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFIER BRIDGE DIODE REMOV AL AND REMOV AL AND REPLACEMENT (CONTINUED) 8. Inspect the mounting surfaces of each new[...]

TROUBLESHOOTING & REP AIR F-73 F-73 COMMANDER 500 ST A TOR/ROT OR REMOV AL AND REPLACEMENT W ARNING 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[...]

TROUBLESHOOTING & REP AIR F-74 F-74 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PLUG FUEL LINES U-BOL TS (2) LEADS #229 AND #242D { FIGURE F .33 – FUEL T ANK REMOV AL DET AILS ST A TOR/ROT OR REMOV AL A[...]

TROUBLESHOOTING & REP AIR F-75 F-75 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PLUG P/J52 #201 #201A 6F #200D #5P FIL TER CAP ACITOR FIELD DIODE RECTIFIER BRIDGE FIGURE F .34 – PLUG J52/FIL TER CAP ACI[...]

TROUBLESHOOTING & REP AIR F-76 F-76 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC #200A #200B #201 12 VDC STUD LEADS #232L AND #232M PULL COIL PC BOARD (LEADS #265 AND #227) CONTROL BOX FIGURE F .35 – BRU[...]

TROUBLESHOOTING & REP AIR F-77 F-77 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 6 SCREWS SHROUD ACOUSTICAL FOAM FIGURE F .37 – AL TERNA TOR SHROUD REMOV AL ST A TOR/ROT OR REMOV AL AND REPLACEMENT (CONT[...]

TROUBLESHOOTING & REP AIR F-78 F-78 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CENTER P ANEL LIFT FRAME WELDMENT BASE FUEL T ANK SUPPORTS F AN BAFFLE FIGURE F .38 – LIFT FRAME AND ASSOCIA TED COMPONENT[...]

TROUBLESHOOTING & REP AIR F-79 F-79 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC BOL TS (4) F AN HUB MOUNTING FOOT FL YWHEEL SPLASH PLA TE FA N NUT ST A TOR / ENGINE MOUNTING BOL TS & LOCK W ASHERS BEA[...]

TROUBLESHOOTING & REP AIR F-80 F-80 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FLEX PLA TE BLOWER SEGMENT (4) ROTOR FIGURE F .40 – ROTOR REMOV AL ST A TOR/ROT OR REMOV AL AND REPLACEMENT (CONTINUED) RO[...]

TROUBLESHOOTING & REP AIR F-81 F-81 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TOR/ROT OR REMOV AL AND REPLACEMENT (CONTINUED) LEAD RECONNECTION CHECKLIST ENGINE ■ ■ Leads #242D and #229 to fuel[...]

TROUBLESHOOTING & REP AIR F-82 F-82 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mecha[...]

TROUBLESHOOTING & REP AIR F-83 F-83 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RETEST AFTER REP AIR (CONTINUED) TOUCH ST ART TIG MODE OUTPUT Mode Selector Open Circuit Short Circuit Switch Fine Control V[...]

G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- Electrical Diagrams ........................................................................................................................G-1 Wiring Diagram ..................................................................................................................[...]

ELECTRICAL DIAGRAMS G-2 COMMANDER 500 WIRING DIAGRAM - COMMANDER 500 GND-H 6D 3 GND-F 5A AUX I LI AR Y P OWE R GND-D 12 11 10 EMPT Y CB6 10A EMPTY EMPTY 42A 42 31 GND-E 42A 5J OUTPUT 31 CONTROL 32 CCW 236C 8 POLARITY SWITCH 1 31 32 RECT IFI ER BR IDGE 50A TO THE LAMIN ATION TO SLIP RING NEAREST POSITIVE BRUSH CONNECTED CO NTROL IDLER 5B 6D 5E 5C 5 [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-3 COMMANDER 500 SCHEMA TIC - COMPLETE MACHINE - COMMANDER 500 EN-170 SOLID EDG E MA NUFACTURING TOLERANC E PER E 2056 UNL ESS OTHERW ISE SPEC IFIED TOLER AN[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-4 COMMANDER 500 SCHEMA TIC - BA TTER Y PC BOARD G-4 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manua[...]

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 troub[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-6 COMMANDER 500 SCHEMA TIC - CHOPPER PC BOARD FILENAME: M19462_1BA 10.0 R5 10.0 R9 (UNLESS OTHER WISE SPECIFIED) UNLESS OTHER WISE SPECIFIED) .022/50V 10.0 [...]

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 troub[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-8 COMMANDER 500 SCHEMA TIC - PERIPHERAL PC BOARD G-8 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manu[...]

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 troub[...]

ELECTRICAL DIAGRAMS G-10 COMMANDER 500 SCHEMA TIC - POWER SUPPL Y (ANALOG) PC BOARD G-10 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Ret[...]

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 troub[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-12 COMMANDER 500 SCHEMA TIC - PULL-COIL PC BOARD G-12 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this man[...]

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 troub[...]

ELECTRICAL DIAGRAMS G-14 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 1 G-14 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Ret[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-15 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 2 G-15 NOTE: This diagram is for reference only . It may not be accurate for all machines covere[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-16 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 3 G-16 NOTE: This diagram is for reference only . It may not be accurate for all machines covere[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-17 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 4 G-17 NOTE: This diagram is for reference only . It may not be accurate for all machines covere[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-18 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 5 G-18 NOTE: This diagram is for reference only . It may not be accurate for all machines covere[...]

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 troub[...]

SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e 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 w[...]