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Lincoln Electric Commander 500 Cummins Operator's Manual

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Commander
For use with machines having Code Numbers:
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful
operation on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS
EQUIPMENT
READING THIS MANUAL AND
THE
SAFETY
PRECAUTIONS
CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
™
10839, 10903 (Standard),
10840, 10904 (Deluxe)
WITHOUT
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
500 Cummins
Copyright © 2001 Lincoln Global Inc.
IM707-A
December, 2001

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Summary of Contents for Lincoln Electric Commander 500 Cummins

  • Page 1 10839, 10903 (Standard), For use with machines having Code Numbers: 10840, 10904 (Deluxe) This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci cations and availability of optional features may have changed. Safety Depends on You...

  • Page 2: California Proposition 65 Warnings

    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

    SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.

  • Page 5: Safety

    SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
  • Page 6 QUALITY product by Lincoln Electric. We want you Thank You to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.

  • Page 7: Table Of Contents

    Remote Control .....................A-5 Welding Terminals ....................A-5 Welding Output Cables ...................A-6 Machine Grounding ....................A-6 Auxiliary Power Receptacles .................A-6 Standby Power Connections................A-6,A-7 Connection of Lincoln Electric Wire Feeders..........A-8,A-9 Operation ......................Section B Safety Instructions ....................B-1 General Description....................B-1 Recommended Applications ................B-1 Design Features and Advantages..............B-1 Welding Capability ..................B-2...
  • Page 8 Air Filter......................D-1 Fuel Filters ......................D-2 Cooling System....................D-2 Battery Handling ..................D-2, D-3 Nameplate / Warning Decal Maintenance.............D-3 Welder / Generator Maintenance ................D-3 Engine Maintenance Components ................D-3 Troubleshooting ....................Section E Wiring,Connection Diagrams and Dimension Print........Section F Parts Lists ......................P391Series COMMANDER 500 CUMMINS...

  • Page 9: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - COMMANDER 500 CUMMINS (K1846-1 & -2) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Cummins 4 cylinder High Idle 1900 199 cu. in 12VDC battery Fuel: 25 gal. B3.3 56 HP(42kw) Low Idle 1475 (3.3 L)

  • Page 10: Safety Precautions

    Store the battery in a dry, dark place. •Do not stack anything near the engine. ------------------------------------------------------------------------ STACKING MOVING PARTS can injure. COMMANDER 500 CUMMINS machines cannot be stacked. •Do not operate with doors open or guards off. ANGLE OF OPERATION •Stop engine before servicing.

  • Page 11: Lifting

    300 meters (984 ft.) above 1500 meters (4920 ft.). For output of 500A and below, derate the welder output 4% for every 300 meters (984 ft.) above 2100 meters (6888 ft.). Contact a Cummins Service Representative for any engine adjustments that may be required. COMMANDER 500 CUMMINS...

  • Page 12: Pre-Operation Engine Service

    BATTERY ACID can burn eyes and Operator’s Manual for specific fuel recommendations. skin. The COMMANDER 500 CUMMINS Deluxe is protected • Wear gloves and eye protection and by a low fuel shutdown to prevent the engine from running be careful when working near bat- out of fuel.

  • Page 13: Muffler Outlet Pipe

    Be sure to use the the COMMANDER 500 CUMMINS. correct polarity when charging the battery. The COMMANDER 500 CUMMINS and any high fre- MUFFLER OUTLET PIPE quency generating equipment must be properly grounded. See the K799 Hi-Freq Unit and the K930-1...

  • Page 14: Welding Output Cables

    STANDBY POWER CONNECTIONS premises wiring (home, shop, etc.). To prevent dangerous electric shock, other equipment The COMMANDER 500 CUMMINS is suitable for tem- porary, standby or emergency power using the engine powered by this engine driven welder must: manufacturer’s recommended maintenance schedule.
  • Page 15 COMMANDER 500 CUMMINS case ing of the COMMANDER 500 CUMMINS engine. front. Figure A.2 Connection of the COMMANDER 500 CUMMINS to Premises Wiring 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz.

  • Page 16: Connection Of Lincoln Electric Wire Feeders

    12 seconds The LN-25 with or without an external contactor may unless welding is resumed. be used with the COMMANDER 500 CUMMINS. See the appropriate connection diagram in the DIAGRAMS CONNECTION OF LN-7 OR LN-8 TO THE section.
  • Page 17 The connection diagram for the LN-8 can tion. (NOTE): When connecting an LN-23P to the be used for connecting the NA-3. COMMANDER 500 CUMMINS, a K350-1 adapter kit must be used. CONNECTION OF AN LN-742 TO THE COMMANDER 500 CUMMINS •...

  • Page 18: Operation

    OPERATION SAFETY INSTRUCTIONS GENERAL DESCRIPTION The COMMANDER 500 CUMMINS is a diesel engine- Read and understand this entire section before operat- driven welding power source. The machine uses a ing your COMMANDER 500 CUMMINS. brush type alternating current generator for DC multi- purpose welding and for 120/240 VAC auxiliary stand- by power.

  • Page 19: Welding Capability

    • Engine protection system shuts the engine down for The COMMANDER 500 CUMMINS is rated at 500 low oil pressure, high water temperature or a broken amps, 40 VDC at 100% duty cycle and 575 amps, 36 fan/engine alternator belt.

  • Page 20: Controls And Settings

    Start button to crank the engine; release as the engine starts. Start button must be depressed for a minimum of two seconds. Do not press while engine is running since this can cause damage to the ring gear and/or starter motor. COMMANDER 500 CUMMINS...
  • Page 21 12 seconds and then go to low idle speed. b. When the electrode touches the work or power is drawn for lights or tools (approximately 100 Watts COMMANDER 500 CUMMINS...

  • Page 22: Welder Controls

    The toggle switch on the control panel labeled “Weld POWER OPERATION section later in this chapter. Terminals On” and “Remotely Controlled”: is used to control the operation of the “solid state contactor” which allows for the selection of “Hot” or “Cold” welding terminals. COMMANDER 500 CUMMINS...

  • Page 23: Engine Operation

    The proper setting off the fuel valve located on the fuel line. depends on the procedure and operator preference. Start with a setting at 0. COMMANDER 500 CUMMINS...

  • Page 24: Break-In Period

    Then, the tungsten is gently lifted off the work in a rock- STICK WELDING ing motion, which establishes the arc. The COMMANDER 500 CUMMINS can be used in a The COMMANDER 500 CUMMINS can be used with a wide variety of DC Tungsten Inert Gas (TIG) welding broad range of DC stick electrodes.
  • Page 25 (5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures and high duty cycles. COMMANDER 500 CUMMINS SETTINGS WHEN COMMANDER 500 CUMMINS SETTINGS WHEN...

  • Page 26: Wire Feed (Constant Voltage) Welding

    The COMMANDER 500 CUMMINS in the ”CV-WIRE” The current rating of any plug used with the system position, permits it to be used with a broad range of flux...
  • Page 27 90A/25V 12000 * Each duplex receptacle is limited to 20 amps. ** Not to exceed 50 A per 120 VAC branch circuit when splitting the 240 VAC output. TABLE B.5 COMMANDER 500 CUMMINS Extension Cord Length Recommendations Current Voltage Load Maximum Allowable Cord Length in ft.

  • Page 28: Accessories

    Has convenient plug for easy connection to the (which accepts 4-prong plugs) and converts it to a welder. The COMMANDER 500 CUMMINS is equipped with a 6 NEMA 6-50R receptacle, (which accepts 3-prong pin connector for connecting the remote control.

  • Page 29: Recommended Optional Equipment

    NOT need to be installed into the Commander. The Commander and any high frequency generating equipment must be properly grounded. See the K799 Hi-Freq Unit and the K930-All TIG Module operating manuals for complete instructions on installation, oper- ation, and maintenance. COMMANDER 500 CUMMINS...

  • Page 30: Maintenance

    In particularly dirty locations, this may be required once a week. 6. Dry element before reuse with warm air at less than F (71 C). Do not use a light bulb to dry the ele- ment. COMMANDER 500 CUMMINS...

  • Page 31: Fuel Filters

    • USING A BOOSTER - connect posi- tive lead to battery first then connect ------------------------------------------------------------------------ negative lead to engine foot. The COMMANDER 500 CUMMINS is equipped with a BATTERY ACID CAN BURN EYES AND Fuel Filter located after the lift pump and before fuel SKIN.

  • Page 32: Nameplate / Warning Decal Maintenance

    Replace every 500 hours or 6 months, Water Separator FS19594 Fleetguard whichever is less. Battery BCI GROUP 34 -–––––– Inspect every 500 hours. Engine Oil Change ––––––––– See Manual Change every 750 hours or 3 months, whichever is less. Check daily. COMMANDER 500 CUMMINS...

  • Page 33: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by 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 34: Troubleshooting

    Battery does not stay charged. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. COMMANDER 500 CUMMINS...
  • Page 35 Authorized Field Service Facility. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. COMMANDER 500 CUMMINS...
  • Page 36 3. Faulty auxiliary circuit wiring. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. COMMANDER 500 CUMMINS...
  • Page 37 DIAGRAMS COMMANDER 500 CUMMINS...
  • Page 38 DIAGRAMS COMMANDER 500 CUMMINS...
  • Page 39 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 500 CUMMINS...
  • Page 40 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 500 CUMMINS...
  • Page 41 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 500 CUMMINS...
  • Page 42 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 500 CUMMINS...
  • Page 43 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 500 CUMMINS...
  • Page 44 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 500 CUMMINS...
  • Page 45 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 500 CUMMINS...
  • Page 46 F-10 F-10 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 500 CUMMINS...
  • Page 47 F-11 F-11 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 500 CUMMINS...
  • Page 48 F-12 F-12 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 500 CUMMINS...
  • Page 49 F-13 F-13 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 500 CUMMINS...
  • Page 50 F-14 F-14 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 500 CUMMINS...
  • Page 51 F-15 F-15 DIAGRAMS DIMENSION PRINT COMMANDER 500 CUMMINS...
  • Page 52 NOTES COMMANDER 500 CUMMINS...
  • Page 53 NOTES COMMANDER 500 CUMMINS...
  • Page 54 ● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el ●...
  • Page 55 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● ● ● WARNING ● Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- ●...
  • Page 56 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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