Filter
Top Products
B-1
OPERATION
B-1
Read and understand this entire section before operat-
ing your Commander 500.
SAFETY INSTRUCTIONS
Do not attempt to use this equipment until you
have thoroughly read all operating and mainte-
nance manuals supplied with your machine. They
include important safety precautions, detailed
engine starting, operating and maintenance
instructions and parts lists.
ELECTRIC SHOCK can kill.
•Do not touch electrically live parts
such as output terminals or internal
wiring.
•Insulate yourself from the work and
ground.
•Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
•Use in open, well ventilated areas or
vent exhaust outside
•Do not stack anything near the
engine.
------------------------------------------------------------------------
MOVING PARTS can injure.
•Do not operate with doors open or
guards off.
•Stop engine before servicing.
•Keep away from moving parts
------------------------------------------------------------------------
Only qualified personnel should operate this
equipment.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged door
closed and the side panels in place as these pro-
vide maximum protection from moving parts and
insure proper cooling air flow.
GENERAL DESCRIPTION
The Commander 500 is a diesel engine-driven welding
power source. The machine uses a brush type alter-
nating current generator for DC multi-purpose welding
and for 120/240 VAC auxiliary standby power. The
welding control system uses state of the art Chopper
Technology. The Commander 500 is not recom-
mended for pipe thawing.
The generator has a single sealed bearing for mainte-
nance free service. The rotor is a copper wound design
with two slip rings and brushes. The stator is wound
entirely with heavy gauge copper wire and insulated
with NEMA class F insulation material. The stator is
then impregnated with three layers of high quality var-
nish. After the stator is assembled using tie bars, the
entire assembly covered with an environmentally pro-
tective coating. These measures insure trouble-free
operation in the harshest environments.
The fuel tank is made from high density polyethylene
and holds 25 gallons of diesel fuel. This will provide
enough fuel to run for more than 12 hours at full load.
The Deutz F3L-912 engine is equipped with a stan-
dard, heavy duty, combination fuel filter/water separa-
tor element.
RECOMMENDED APPLICATIONS
WELDER
The Commander 500 provides excellent constant current DC
welding output for stick (SMAW) and TIG welding. The
Commander 500 also provides excellent constant 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
power.
DESIGN FEATURES AND ADVANTAGES
K1639-2 Commander 500 Deluxe Model Features
For Welding:
• Excellent DC multi-purpose welding for stick, MIG, TIG,
cored wire and arc gouging applications.
• 30 to 500 amps output in five slope controlled ranges
for out-of position and pipe electrodes, one constant
current output range for general purpose welding, one
constant voltage range for MIG wire and cored wire
welding and one 20-250 amp range for “Touch Start”
TIG welding.
• 100% duty cycle at 500 amps output and 50% duty
cycle at 575 amps output.
COMMANDER 500
WARNING