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Lincoln Electric Commander 500 Cummins, Operator'S Manual

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Lincoln Electric Commander 500 Cummins Operator'S Manual Download Page 8

TABLE OF CONTENTS

Accessories .....................................................................................................Section C

Optional Field Installed Accessories .....................................................................C-1
Recommended Optional Equipment .....................................................................C-1
High Frequency Generators For TIG Applications ................................................C-1

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1
Routine and Periodic Maintenance .......................................................................D-1
Engine Maintenance..............................................................................................D-1

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

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COMMANDER 500 CUMMINS

Summary of Contents for Commander 500 Cummins

Page 1: ...ost importantly think before you act and be careful For use with machines having Code Numbers 10839 10903 Standard 10840 10904 Deluxe Date of Purchase Serial Number Code Number Model Where Purchased S...

Page 2: ...PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase...

Page 3: ...ical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for co...

Page 4: ...vent 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 Avoid welding near hydraulic...

Page 5: ...pri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan...

Page 6: ...e information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes...

Page 7: ...ine 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...

Page 8: ...Precautions D 1 Routine and Periodic Maintenance D 1 Engine Maintenance D 1 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...

Page 9: ...42 0 in 31 5 in 63 1 in 1625 lbs 737 kg Approx 1066 8 mm 800 1 mm 1602 7 mm OUTPUT WELDER AND GENERATOR Duty Cycle Welding Output Volts at Rated Amps 100 500 Amps DC multi purpose 40 Volts 60 550 Amps...

Page 10: ...DO NOT MOUNT OVER COMBUSTIBLE SUFACES Where there is a combustible surface directly under sta tionary or fixed electrical equipment that surface should be covered with a steel plate at least 06 1 6mm...

Page 11: ...ers 6888 ft Contact a Cummins Service Representative for any engine adjustments that may be required HIGH TEMPERATURE OPERATION At temperatures above 40 C 104 F output voltage derating may be necessar...

Page 12: ...fore the machine will shutdown A restart of the machine will restart the timer to allow the operator to override this fea ture The amount of reserve fuel remaining in the tank after the first shutdown...

Page 13: ...ich are taped to the radiator cap cover AIR CLEANER INLET HOOD Remove the plastic plug covering the air cleaner inlet Install the air cleaner inlet hood to the air cleaner HIGH FREQUENCY GENERATORS FO...

Page 14: ...stud marked with the symbol is provided on the front of the welder AUXILIARY POWER RECEPTACLES The auxiliary power capacity of the COMMANDER 500 CUMMINS is 12 000 watts of 60 Hz single phase power Th...

Page 15: ...ble of the desired length The 50 amp 120 240 VAC plug is available in the optional K802R plug kit 4 Plug this cable into the 50 Amp 120 240 Volt recep tacle on the COMMANDER 500 CUMMINS case front Fig...

Page 16: ...and CRISP for INNERSHIELD You may however want to start in the middle and adjust as needed from there Set the IDLE switch to the AUTO position When not welding the COMMANDER 500 CUMMINS engine will b...

Page 17: ...ONNECTION OF AN NA 3 AUTOMATIC WELDING SYSTEM TO THE COMMANDER 500 CUMMINS For connection diagrams and instructions for connect ing an NA 3 Welding System to the COMMANDER 500 CUMMINS refer to the NA...

Page 18: ...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...

Page 19: ...w paint system on case and base for outstanding corrosion protection K1846 1 COMMANDER 500 CUMMINS Standard Model The K1846 1 is the standard version of the Commander 500 and has all the features of t...

Page 20: ...while engine is running since this can cause damage to the ring gear and or starter motor 3 FUEL LEVEL GAUGE AND LIGHT K1846 2 only on codes 10840 and below Displays the level of diesel fuel in the 25...

Page 21: ...aulty flashing circuit The light will remain on when the engine has been shut down due to a fault in the alter nator regulator or the alternator belt 7 IDLER SWITCH Has two positions as follows A In t...

Page 22: ...sed and the welding terminals are Hot When the triggering device is released the contactor is opened and the welding terminals are Cold NOTE The new Chopper Technology control circuitry automatically...

Page 23: ...TROL clockwise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance control The proper setting depends on the procedure and operator preference...

Page 24: ...ltage For example to obtain 140 amps and a forceful arc set the WELD MODE to the 250 MAX position and then adjust the OUTPUT to get 140 amps CONSTANT CURRENT CC WELDING The CC STICK position of 30 to...

Page 25: ...3 5 5 10 3 5 13 17 6 8 15 23 7 11 21 25 10 12 23 27 11 13 28 32 13 15 3 8 2 4 5 10 3 5 5 10 3 5 9 13 4 6 11 15 5 7 11 15 5 7 13 17 6 8 18 22 8 10 23 27 11 13 TIG TORCH Nozzle Size 4 5 Approximate Argo...

Page 26: ...The 240 VAC output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 50 A per output to two separate 120 VAC branch circuits Output voltage is within 10 at al...

Page 27: ...ABLE B 4 COMMANDER 500 CUMMINS Simultaneous Welding and Power Loads TABLE B 5 COMMANDER 500 CUMMINS Extension Cord Length Recommendations Current Amps 15 15 20 20 25 30 38 50 Voltage Volts 120 240 120...

Page 28: ...asy connection to the welder The COMMANDER 500 CUMMINS is equipped with a 6 pin connector for connecting the remote control K704 ACCESSORY SET Includes 35 feet 10 m of electrode cable and 30 feet 9 m...

Page 29: ...844 1 Water Valve WIRE FEED WELDING OPTIONS LN 25 LN 7 LN 23P LN 8 NA 3 Spool Gun K488 Module LN 742 HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi Freq Unit and the K930 ALL TIG Modules a...

Page 30: ...week ENGINE MAINTENANCE Refer to the Periodic Checks section of the Engine Operator s Manual for the recommended maintenance schedule of the following a Engine Oil and Filter b Air Cleaner c Fuel Fil...

Page 31: ...it off when engine is not running PREVENTING BATTERY BUCKLING Tighten nuts on battery clamp until snug WARNING D 2 MAINTENANCE D 2 COMMANDER 500 CUMMINS 7 Inspect for holes and tears by looking throug...

Page 32: ...cuit The Commander positive battery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable before you...

Page 33: ...SSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause gene...

Page 34: ...arting Battery does not stay charged 1 Battery is low Charge Battery 2 Loose battery cable connections Inspect clean and tighten 1 Out of fuel Fill fuel tank 2 Fuel shut off valve is in off position 3...

Page 35: ...Engine will not go to high idle when using auxiliary power 1 Idler switch in High idle position Set switch to Auto 2 External load on welder or auxil iary power Remove all external loads 1 Poor work l...

Page 36: ...rong position Place switch in WELD TERMINAL ON position when welding without welding terminal control cable Refer to Operation chapter for proper switch function 1 Poor remote kit connection Check con...

Page 37: ...232W 270 5L 5T 232S 232J 262B 224A 405 271 270 281A 200 401 213 214 232T 232R 262A 262B 281A 241A 233A 228A 234A 262A 224A 239 281 241 233 228 234 262 224 226A 200B 6F 5P 200D 201A 200A 239A 226 200 6...

Page 38: ...260A 226 232W 270 5L 5T 232S 232J 262B 224A 405 271 270 281A 200 401 213 214 232T 232R 262A 262B 281A 241A 233A 228A 234A 262A 224A 239 281 241 233 228 234 262 224 226A 200B 6F 5P 200D 201A 200A 239A...

Page 39: ...F 3 DIAGRAMS F 3 COMMANDER 500 CUMMINS CONNECTION DIAGRAM...

Page 40: ...AUTION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140...

Page 41: ...F 5 DIAGRAMS F 5 COMMANDER 500 CUMMINS CONNECTION DIAGRAM...

Page 42: ...F 6 DIAGRAMS F 6 COMMANDER 500 CUMMINS CONNECTION DIAGRAM...

Page 43: ...Y INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WI...

Page 44: ...F 8 DIAGRAMS F 8 COMMANDER 500 CUMMINS CONNECTION DIAGRAM...

Page 45: ...F 9 DIAGRAMS F 9 COMMANDER 500 CUMMINS CONNECTION DIAGRAM...

Page 46: ...NIT CAUTION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE AC WIRE FEEDER VOLTAGE WHICH CAN DAMAGE THE CONTR...

Page 47: ...E RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE AC WIRE FEEDER VOLTAGE WHICH CAN DAMAGE THE CONTROL CIRCUIT THE ENGINE GOVERNOR SETTING IS PRE S...

Page 48: ...F 12 DIAGRAMS F 12 COMMANDER 500 CUMMINS CONNECTION DIAGRAM...

Page 49: ...F 13 DIAGRAMS F 13 COMMANDER 500 CUMMINS CONNECTION DIAGRAM...

Page 50: ...F 14 DIAGRAMS F 14 COMMANDER 500 CUMMINS CONNECTION DIAGRAM...

Page 51: ...46 35 BOTTOM VIEW OF WELDER BASE NOTES PER TABLE N A B CENTER OF GRAVITY WITH OIL IN ENGINE EMPTY FUEL TANK AND COOLANT IN RADIATOR N A B NOTE This diagram is for reference only It may not be accurate...

Page 52: ...NOTES COMMANDER 500 CUMMINS...

Page 53: ...NOTES COMMANDER 500 CUMMINS...

Page 54: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 55: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 56: ...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 World s Leader in Welding and Cutting Pr...

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