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Lincoln Electric IM700-D User's Manual

1. KEN 2915109 TERT 2007 01 KS ev Si IS a E S
2. A 5 Remote EE 5 Ee Huet UE A 5 Welding 5 6 Machine Grounding 000 6 Auxiliary Power Receptacles EE eias a Eu i 6 Standby Power Connections A 6 A 7 Connection of Lincoln Electric Wire A 8 A 9 mE Section B Safety Precautions ss 1 General lee DEEL 1 Recommended Applications ss B 1 Design Features and Advantages B 1 Welding Capability AA B 2 Controls and 3 Engine 5 B 3 BA Welder Controls Auxiliary Power Controls B 5 B 6 Engine 6 Starting 6 Stopping the Engine su 6 Break lit Perlod 2 un 7 Typical Fuel Consumption ss 7 Welder Operation 7 Slick Welding 7 EE 8 Typical Current Ranges for Tungsten Electrodes n nsssnnnsseserneeenenneneenee B 9 Wire Feed Constant Voltage Welding B 10 10 e
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10. jou e QNINYVM_ M AN ONA COMMANDER 300 LINCOLN E DIAGRAMS F 13 13 CONNECTION DIAGRAM 866825 NOILdO Levy 430334 SCHT ALVINSNI SQV31 321145 3 N ATIVACIAIGNI SQV31 GASNNN H VA ALVINSNI ON ESPA SNOILONYLSNI H3Q713M OL ELHA LNNOW HOLIMS ALINW10d 52 1 HOLIMS 19HN0OS LY 65318 2 300419773 3SH3A3H 1440 NYNL ALIYW10d OL 3ALLSOd SMOHS ON IVANY 9NILVH3dO 33 5 SYNLNA 31via3WiWi dO 1949 ALNA LNAYYND ALIOVdVO HO 38 LSNW SNIQT3A V N 300419413 MYOM OL H31dvav 2983 390845373 14 e21AJes 10 esn jeisui pjnous jauuosiad e sped Aeme e eoejd ui des e up S1LYVd ONIAOW sued Aje2ujoeje jou e 5 a10jaq ava SALLVDAN 12euuo sig e uedo sjeued eje1edo jou ub 5OHS OI31241i13 ONINHVM Wf INVHOVIG NOILOANNOO NOILdO 1 2E pH 8 52 1 006 H30NVIAINOO 300 DIAGRAMS F 14 F 14 CONNECTION DIAGRAM 678
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12. OL HOLIMS YSLAWLIOA Y30334 JHL LAS AN NMOHS NVHL 143333514 ATLHONMS 38 SANIHOVW SOS NO ADOTONINYSL 031412445 330 933 sv noL Levd JHL GaddiINda 1VH L S3NIHOVIN SSOHL OL AINO A lddV SALON SNIMOTIOS JHL 1 ANY QV3 AYOM QV319NISN3S dVHM 72 8 1 GSLOSANNOOSIC 30 Q3S0dX3 3dYL dIYLS TWNINYSL OL QV319NISN3S LOANNOO ANY 131 TVNIWH3LL AHL WO 414V9 14 0 40 LOANNOOSIC 4 27875 YAldvav 404 38189 NIVELS QV319NISN3S 31008 X314 42342109 434414 YAONVT ONISN OL ATLO3SIG YAWOLSNO A8 Q3ON3 LLX3 38 OL QV319NISN3S SLOWSY H31dVQV NI 9115 TWNIWYAL A 330333 OL 193NNOO 381 SI d CN13NO ATNO dl 753715 41d0d 303 WNNVW ONILVYAdO 2 1 335 SNOILVO M VON ANY 30 31949 ON LNAYYND JHL ALIO VdVO 934034 30 38 LSNW SATEVO 9NITT3M SNOILONYLSNI 9NILVi3dO 9390319513 390519513 V 330333 38IM 8 830334 38IM 8 830334 V 434333 431dvQv LOCH LOANNOOSIG Ba 3189 ION3HdlAV Nid OWA SLL IN SNIDNA sued jou oq pee
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16. 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running CS 2 4 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side AY 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 2 d 5 Do not work next to welding power source Mar 95 LINCOLN B SAFETY i 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 Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a h
17. Mount equipment base to metal bed or frame of vehi cle Follow vehicle manufacture s instructions COMMANDER 300 LINCOLN 4 PRE OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc tions supplied with this machine A WARNING Keep hands away from the engine muffler or HOT engine parts eStop engine and allow to cool before fueling not smoke when fueling Fill fuel tank at a moderate rate and do not over fill Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank OIL Commander is shipped with the engine crankcase filled with high quality SAE 10W 30 oil API class CD or better Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Check the oil level every four hours of running time during the first 35 running hours Refer to the engine Operator s Manual for specific oil recommendations and break in information The oil change interval is dependent on the quality of the oil and the operating environment Refer to the engine Operator s Manual for the proper ser vice and maintenance intervals FUEL USE DIESEL FUEL ONLY Fill the fuel tank with clean fresh diesel fuel The ty of the fuel tank is 25 gallons 94 6 liters See engine Operator s Manual for specific fuel recommendations The Commander 300 Deluxe i
18. RETURN MAIN MENU IM700 D Commander WM 300 Li For use with machines having Code Numbers 10702 10870 10899 10950 11200 Standard 10703 10871 10900 10951 11201 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 increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful N SS Cs RSS ONE GE NEN S e EEN NN im SSS OPERATOR S MANUAL ISO 9001 e Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 LI NCOLN Se O 2004LincolnGlobal Inc e World s Leader in Welding and Cutting Products e 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 SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel Engines Diesel engine exhaust For Gasoline Engines The engine exhaust from some of its constituents are known to the State this product contains chemicals known to the of California to cause cancer birth def
19. 1 81 5 1 34 gallons hour 186 Output 300 Amps 5 07 liters hour 32 Volts 1 32 gallons hour STICK WELDING The Commander 300 can be used with a broad range of DC stick electrodes 33 gallons hour 1 23 liters hour 52 gallons hour 1 98 liters hour 75 8 48 1 25 3 2 7 ZE Ld 6 2 79 99 gallons hour 3 74 liters hour 1 10 gallons hour 2 4 16 liters hour Auxiliary Power The WELD switch provides five overlapping slope controlled current ranges The OUTPUT adjusts the current from minimum to maximum within each range Voltage is also controlled by the OUTPUT in the slope controlled setting These slope controlled set tings are intended for out of position welding includ ing pipe welding where the operator would like to con trol the current level by changing the arc length PIPE WELDING The Commander 300 is equipped with special circuitry to minimize pop outs in the five slope modes at any open circuit voltage For a soft arc characteristic set the WELD MODE Switch to the lowest setting that still provides the cur rent you need and set the OUTPUT near maximum For example to obtain 140 amps and a soft arc set the WELD MODE Switch to the 150 MAX position and then adjust the OUTPUT for 140 amps When a forceful digging arc is required use a higher setting and lower
20. enrouler le c ble lectrode autour de n importe quelle partie du corps LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray Ji onnement de et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 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 talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de f
21. 0002 11 SALON H 9 4 3 d 2 Y ON JY UN 678 0 9 8785 goe Bz 968 Ti 98 Ger 82 29681 aan os oS va 9 8 2 991 968 UR HSVd ATH MAO MHA WOLLOd PE K i 8704 67 CZ 6 Jequunu epoo 1ueuudinbe y jueueoe dai 104 eui elqiBelll si eu sjeued einsoj oue y jo euo uo y episul si 104 oyloeds siy eq jou Aew y 10 SI SIUL 310 5 DNINDONWWHIVHL DIAGRAMS DIMENSION PRINT IVIQVH NYIOGO ANVIL T ANIANANNI TIO HLIM ALIAVHO JO HNINSOS H N TANVONSHNIONA NI TIO HLIM ALIAVHO WSLNHSOV V N dd SALON 2 ST F 17 gNUNWVOXON COMMANDER 300 LINCOLN E 5 COMMANDER 300 LINCOLN 5 COMMANDER 300 LINCOLN WARNING zzSpanish AVISO DE PRECAUCION French ATTE
22. 02 NIOONIT IHL NI SI HOLIMS IAOW SINGOW TOYLNOD 1 SYNS 38 OL 93189 1 9199193934 01 169 310 Nid 9 E 4 10085 SC 19V JINON TOMINOO J10V1d393M OS 887 Y30334 34IM Nid FL 3199193933 Juawdinba siy 2 195 JO Sed e AI 9119918 yono jou esn esu pjnous jeuuo sad p 9 0194 syed deeye pee Aaye g 3ALLVO3N Youu osiq eoejd deeye uedo sjaued um ejejedo jou ONIN dv M 7 WVYSVIC NOLL23NNOO 100646 2977 88v 01 1697 SHAG 13M 3NISN3 COMMANDER 300 LINCOLN E DIAGRAMS F 6 F 6 CONNECTION DIAGRAM 886625 1 391145 3 N GASNNN HOV3 31VINSNI ON JOHLNOO SLOWAY OL GAHOLIMS ATIVOIIVNOLNY SI SI TOHLNOO LNdLNO SLOWAY 1VNOLLdO 4 O N NOLLISOd 3 18VO 430334 SHIM OL HOLIMS 430334 SHIM 39V ld ONIQTAM OL HOLIMS HOLO3T13S AHL NOILISOd ALIHV TOd 3200419113 Q3HIS3G 123135 OL HOLIMS HALAWLIOA ASN ON AAS 5 1 ANY ALVIGAWWI 40 319A9 ALNA ANY LN3HHDO JHL ALIOVdVO 30 38 LSNW 3 18VO ONIIV8340 H3Q 13M ANIONS 3H NI 93151 SNOI1V914193dS 3AO8V LSNPAV LON OG AHOLOVJ JHL 13S 3 d SI ONILLAS HONH3AO9 3NION3 3
23. BIR Chinese Qai dul A os Qui al J ale cuts UI ai Jadi y e Aale Viel Al all LEIA COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO AS PARTES DE USO SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA 4 CL TRHORERME 85 ET REL BE SUCR Rr de OE D AMENER 0 SAAD FAIS zeit ele EFSA BEHE VT veel d illai aul ui AAL SOA Ai ag ls Ca L LINCOLN amp e World s Leader in Welding and Cutting Products e 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
24. Crispness SOFT for MIG and CRISP for Innershield Set the WELDING TERMINALS switch to the REMOTELY CONTROLLED position Set the IDLE switch to the HIGH position When not welding the Commander 300 engine will be at the low idle speed COMMANDER 300 LINCOLN 9 INSTALLATION A 9 CONNECTION OF LN 15 TO THE COM MANDER 300 These connections instructions apply to both the LN 15 Across The Arc and Control Cable models The LN 15 has an internal contactor and the electrode is not energized until the gun trigger is closed When the gun trigger is closed the wire will begin to feed and the welding process is started Shut the welder off For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder Across The Arc Model Attach the single lead from the front of the LN 15 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current Control Cable Model Connect Control Cable between Engine Welder and Feeder Set the MODE switch to the CV WIRE position Across The Arc Model Set the WELD TERMINALS switch to WELD TERMINALS ON Control Cable Model Set the WELD TERMINALS REMOTELY CONTRO
25. TM 10 Auxiliary Power Operation 11 Simultaneous Welding and Auxiliary Power B 11 COMMANDER 300 LINCOLN vii TABLE OF CONTENTS TE Section Optional Installed Accessories niiina C 1 Recommended Optional Equipment C 1 High Frequency Generators For TIG C 1 Maintenance Section D Safety D 1 Routine and Periodic Maintenance D 1 Engine Maintenance see D 1 Ait LE PAR A D 1 FUG EE D 2 Systems Re ee i Pens esa D 2 Cooling Blower Belt D 2 Battery aa e a ii D 3 Nameplates Warning Decals Maintenance D 3 Welder Generator Maintenance aE Aa D 3 ele D 3 ue BE D 3 Brush Removal and D 3 Engine Maintenance Components D 4 Troubleshooting Taser anne Section E Diagrams and Dimension Print ss Section F Parts LSE P388 Series COMMANDER 300 LINCOLN vii 2 INSTALLATION 2 Read this entire installation section before you start installation SAFETY PRECAUTIONS A
26. The following information can be used as a guide by the electrician for most applications Refer to the connection diagram shown in Figure A 2 Install the double pole double throw switch between the power company meter and the premises discon nect Switch rating must be the same or greater than the customer s premises disconnect and service over cur rent protection COMMANDER 300 LINCOLN amp 7 INSTALLATION A 7 Take necessary steps to assure load is limited to the Install a 50 amp 120 240 VAC plug NEMA 14 capacity of the Commander by installing a 45 amp 50 to the double pole circuit breaker using No 6 4 240 VAC double pole circuit breaker Maximum rated conductor cable of the desired length The 50 amp load for each leg of the 240 VAC auxiliary is 45 120 240 VAC plug is available in the optional K802R amperes Loading above the rated output will reduce plug kit output voltage below the allowable 10 of rated volt age which may damage appliances or other motor Plug this cable into the 50 Amp 120 240 Volt recepta driven equipment and may result in overheating of cle on the Commander 300 case front the Commander 300 engine Figure A 2 Connection of the Commander 300 to Premises Wiring 240 VOLT GROUNDED CONDUCTOR 60 Hz 3 Wire COMPANY Service METER LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PRO
27. Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo A HAUSHERMRELTTF HRSESOREME ez 119 59 de 4 aun y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einat
28. before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards coversand devices in posi tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety aid ae minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body
29. confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Mar LINCOLN 95 SAFETY WELDING SPARKS gt 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 Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard 7491 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they ha
30. standby power The welding control system uses state of the art Chopper Technology 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 94 6Liters of diesel fuel This will provide enough fuel to run for 18 hours at full load The Deutz F3L 1011F engine is equipped with a stan dard heavy duty combination fuel filter water separa tor element RECOMMENDED APPLICATIONS WELDER The Commander 300 provides excellent constant current DC welding output for stick SMAW welding The Commander 300 also provides excellent constant voltage DC welding out put for MIG GMAW and Innershield FCAW welding GENERATOR The Commander 300 provides smooth 120 240 VAC output for auxiliary power and emergency standby power DESIGN FEATURES AND ADVANTAGES K1585 2 Commander 300 Deluxe Model Features For Welding Excellent DC multi purpose welding for stick MIG TIG cored wire and arc gouging applicat
31. 1 0 SLOWSY 2987 TWNOILdO NOLL23NNOO SHL 5504 5 62 1 544014 3NION3 lON3HdlAV COMMANDER 300 LINCOLN E DIAGRAMS F 12 F 12 CONNECTION DIAGRAM 9 78 05 000c vi v NOILISOd HOIH NI HOLIMS XOV Id AN H ISVO AHL AO ALIAV IOd AHL HOLVW 5 AALANL IOA 44444 ANIM AHIL NOILISOd ALIAV IOd 5 404 SGAQLS LAdLNO OL 5 LOHNNOO UIVANVW ONIJLVHMddO 445 SNOILVOI IddV HanLNA ANY ALVIGHNWNI dO ALNA GNV INAANO AHL 404 ALIOVdVO JO 44 LS W SHTAVO ONIG IJM VN UIVANVW ONILVAHdO ANI NA HHL NI AALSIT SNOILVOIdIOHdS HAO4Y LON Od AMOLOV4A HHL LV N LLAS ANIONA AHL LIQONIO IOWLNOD FHL HOVNVA NVO HOIHM HOVI IOA HAIM OV AHL NI ASVAUONI NV 4 NIT AHL HO ONILLAS ONIONVHO AH ANIONA AICI HOIH ANW TOILNWO LINA CHA AISVO MHOMOL AISVO IOWLNOCh6 SH 418vo LOSNS N OL TIONS Hd WV IN juewudinbe 14 JO syed jou esn jejsur pjnoys jeuuosjed peyrjenb Ajuo e sued Aeme desye 12euuoosiq ui uado sjeued
32. 2 5 10 syed Ajeoujoeje jou e esn ejsui pjnous jauuosied peyijenb e BUIDIAIaS eJojeq syed e Qv31 Ad3 LIV8 3ALIVO3N 19euuoosiq e eoe d ui e uado sjeued jou e e1nlur up EK ONIAOW D 51445313 ONINHVM INVHOVIG NOILOANNOD 8 1 2987 HIONVWWNOI COMMANDER 300 DIAGRAMS F 10 F 10 CONNECTION DIAGRAM d c 4VN 0002 22 01 HO OM ANIONS H3QT3M 3HL OLNO ATAWASSY 3 LdvOv AHL N31SV4 OL W3H 3SN ANY NMOHS 5 4825 SSYHL UN 2 1 V SVH LVHL L330V88 Haldvav A THW3SSV NO L3X0 V8 ONILSIX 30V 1d38 006 00 AHL 3403 SNOILONUYLSNI NOILVTIVLSNI 119345 NOUWDOO SNIHOVW OL LON SV NOILY907 LN3IN3ANOO V NI H21dvOv LNNOW TN TAN HO STHIM S1N3NOdWOO 149119313 OL LON 118 6 HONS 3NIHOVIA OL LON SV NAYVL 39 OL SI 1 10446 YSCTAM OL 319 ONILNNOW N3HM NOLL SNOILONALSNI NOILVTIVLSNI LIM 8 14 0 OL HOLIMS STVNINYAL ONIQTAM LIS HN 1 OL HOLIMS SLOWSY 1V907 JHL 195 ISN SI IOHLNO9 LAdLNO SLOWSY 41 ON FAIMA OL HOLIMS YOLOATAS JHL 135
33. 30 SV NOILISOd 7101 HOI OLAV NIHOLIMS 414101 39 TN NOILISOd GSTIONLNOD ATSLOWSY OL HOLIMS STVNINYSL YSCTAM 39V1ld ON NOILISOd NI HOLIMS SGOW 39V1d 741872 300819313 JHL 40 SHL HOLVN OL HOLIMS YALAWLIOA Y30334 38IM SHL NOILISOd AU Od 6341540 50715 LNdLNO OL SATEVO ONIGTAM LOANNOO ON WANVI 0 33 SNOILVONMddV 39179 ANY SLVIGAWWI 40 371949 ALNG LN33800 JHL YAdOUd 30 38 LSNW S318VO ONIGTAM 830713M ANIONS JHL NI 0316511 SNOLLVOISIOSdS 3AO8V LSNPAV LON OG 7 AHOLOVA 3HL LV 13S 3Md SI ONILLAS HONH3AO9 3NION3 2 TOHLNOO JHL HOIHM S9VLIOA 830333 JAIM OV IHL NI 3SV3HONI NV ASNVO TIM FTLLOYHL AHL 9NIGIHSH3AO HO ONILLAS HONS3AO9 JHL A8 3NISN3 710 AHL 30 3SV3HONI 99333 38IM OL NOUT 3189 300412414 OL 18 2 TOULNOD 691 9N1d 31875 JON3HdlAV CYZ NTOL Nid tl jueuudinbe siy 10 sued Ajeouioeje jou oq e esn j eysur pjnous jeuuosjed e e10Joq sued Bui oui deeye pee JALLVO3N 10901028 goed ui deeye uedo sjeued ejejedo jou ONINHVM WV NVYSVId NOLLD3NNOO CtZ N 1 SH3Q13M COMMANDER 300 LINCOLN E 17
34. 7705 0002 22 01 AXISA SV NOILISOd 4101 OLAY NI HOLIMS 44101 39VId FN NOILISOd STIVNINYSL OD NI HOLIMS S IVNIINSH3 L 9NIQT3M SHL ADV Id ON NOILISOd SHL NI HOLIMS SHL ADV Id ON 318Vv9 300819313 AHL 40 ALIS V 10d AHL HOLVN OL HOLIMS YSLAWLIOA 430334 38IM NOILISOd ALIYV10d 931 34 SCALS LAdLAO OL 318V9 LOANNOO ON IVANY 9NILVel3dO 395 SNOILVONddV 991113 ANY 31VIQ3AWNI 40 41949 ALNG ANY ALIOVaVO 40 38 LSNW 318V9 ONIGTAM 931899 390819513 OL OL 4781 3033 38IM OW LNOO 31034 WNOILdO TON3HdlAV Nid 9 JON3HdAV jueuudinbo 14 2 5 Jo sued A jeouoeje jou esn ejsui pnoys Ajuo e sued Aeme desye pee JALLVO3N 129 1028 e eoejd ui sjaued jou oq e ONINHVM WV 10 1 09 SLOWSY L H TYNOILdO NOLLO3NNOO JHL 5504 SC N T1 SH3Q 13M 3NISN3 COMMANDER 300 LINCOLN E DIAGRAMS F 15 15 CONNECTION DIAGRAM 6 8 705 0002 22 01 0341530 SV NOILISOd HOI 1 NI HOLIMS 414101 39V1d TN NOILISOd SLOWS NI HOLIMS 1041 09 LAdLNO 32 1 ON
35. E posi tion Set the WELDING TERMINALS switch to WELD TERMINALS ON Adjust the ARC CONTROL knob to desired crisp ness Generally welding is best if the ARC CON TROL is set to SOFT for MIG 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 300 engine will be at the low idle speed If you are using an LN 25 with an internal contactor the electrode is not energized until the gun trigger is closed CAUTION ELECTRIC SHOCK can kill If you are using an LN 25 without an internal contactor the electrode will be energized when the Commander 300 is started h When the gun trigger is closed the current sensing circuit will cause the Commander 300 engine to go to the high idle speed the wire will begin to feed and the welding process started When welding is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed CONNECTION OF LN 7 OR LN 8 TO THE COMMANDER 300 Shut the welder off Connect the LN 7 or LN 8 per instructions on the appropriate connection diagram in the DIAGRAMS section Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode being used Set the SELECTOR switch to the CV WIRE posi tion Adjust the ARC CONTROL knob to desired
36. GENERATOR 30 300 Amps CC CV TIG 80 Max OCV 120 240 VAC 10 000 Watts 60 Hz 1900 RPM 100 Duty Cycle PHYSICAL DIMENSIONS WEIGHT 1325 lbs 601 kg Codes 11199 and below 1327 lbs 602 kg Code 11200 1332 Ibs 604 kg Code 11201 1 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced 2 Top of Enclosure Add 8 6 218 4mm for exhaust COMMANDER 300 LINCOLN 6 WELDING OUTPUT CABLES With the engine off route the electrode and work cables thru the strain relief bracket provided on the front of the base and connect to the terminals provid ed These connections should be checked periodically and tightened if necessary Listed in Table A 1 are copper cable sizes recom mended for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop Table A 1 Combined Length of Electrode and Work Cables TOTAL COMBINED LENGTH OF ELEC TRODE AND WORK CABLES AMPS Up to 150 150 200 FT 200 250 FT 100 FT 45 7 61 0m 45 7 76 2m Duty Cycle 45 7 2 0 AWG 2 0 AWG 3 0 AWG MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not n
37. HL 38 AN SLINOHI9 TOH1NOO 430334 SHIM SETOA OFF 309 SIHL 31 SOVIIOA OV IHL IHL NI 3SV389NI NV 3S0 v9 FTLLOYHL JHL 9NIGIHH3AO ONILLAS HONYSAOD JHL Ad ANIONS 4101 HEH SHL 40 3SV389NI IOHLNOO 310WN3H NOILNVO 84 3 LINN 0334 OL 119v9 2004193173 DE o OL 318V9 LAdNI 0 HO 1629 WSUYAAINN 2983 HOM OL 3004193713 30334 O jueuudinbe 14 2 5 10 asn je su pinoys jsuuosied e syed eme deey e ui e up 5174 4 ODNIAOW syed jou e Buas C 3ALIVO3N 1 euuoosiq e sjeued jou 5 91419113 ONINHVM W INVHOVIG NOILO3NNOO Z N1 8224 2984 5 COMMANDER 300 LINCOLN E DIAGRAMS F 7 F 7 CONNECTION DIAGRAM v 181v7S 0002 22 01 NOILISOd HOI NI HOLIMS 41101 39 1 ON NOLLISOd A4IM A9 JHL NI HOLIMS SGOW 39V1d 7218 2 300819313 JHL 30 JHL HOLVN OL HOLIMS YSLAWLIOA 420333 38IM SHL NOILISOd AV 10d 40441530 50115 114100 OL 531979 ONIGTAM LO3NNOO ONILVYSdO 33 SNOLLVO
38. HOVN X30710 NMOHS SY 04102 40 SONIONIM 50118 145101108 NO AMVI IXIV GALVINSNIe EE 1051409 NO ONS YIMOd ei NOHA GIMANA gy AL HO1 SONLLLSS ONIGNOdSaYOD 006 az Liz 10 55 HOLIMS 30128188 Lie sM ccc EM WAAR lt een MG 4 saat SALLISOd NINMOHS HOLMS OMY HOLIOVAVO 3180440 La 39IM1 GIOHOL e HONO HL 55 4 V9 SOVAT yo MO 138 14801 59803 401 INVH9VIG ONIHIM 00 H3aQNVIWINOO COMMANDER 300 LINCOLN E DIAGRAMS F 2 2 y euo UO pajsed si je noraed noA 10 Bip 5994 eu 141 jou 1 JO S siu 3 0
39. L 43333 SIM TN 01 o g l ATIWNGIAIGNI 50 31 GASNNN 31V1nSNI ON NOILISOd IHL NI HOLIMS IQON 3HL3OYld O N J18v2 300912313 IHL 30 ALIHV1Od JHL HOLVIN OL HOLIMS HSLAWLIOA Y30334 IHL NOLLISOd ALIM TOd 93163 0115 114100 OL 5318 2 ONIGTAM 103 SN JO 31240 ALNG ONY LNSYYND HO 03215 38 LSNN 531872 ONIGTAM NRINVIN 0 Y3013M JHL NI QALS SNOILVOISIOAdS 3AO8V 15 LON OQ 7 AHOLOV4 FHL LV 13S 34d SI ONILLAS YONYSAOD 3NION3 SHL TONLNOD 1 NYO HOIHM Y30334 SHIM OV JHL NI 3SV3SONI NV 39 VMNIT FTLLOYHL SHL ONIGIMYSAO ONILLAS JHL ONIONVHI A8 3NISN3 J101 HOIH SHL 30 ASVAYONI NIN SL 1OHLNO9 LNdLNO SLOWSY 94 3240065 HAMOd 40 IVNINHAL OL SLO3NNOO LINN 9333 SHIM OL 318 2 30041933 NOUT OL NOLLOSNNOO Y30333 E NOLLOSNNOO 308105 To OWA SLL JN e zen 19 i NN INdLNO n 390 LO3NNOO 1o Z mu 5 ON 1d H3ldVOv JON3HdlAV S3OMfIOS 3NION3 NO 0381 LON 4 8 1 5 298 Nid vl jueuudinboe siy 10 sued uonoi 100 ode esn ejsui
40. LLED switch to Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode polarity being used Set the ARC CONTROL knob to 0 initially and adjust to suit CONNECTION OF AN NA 3 AUTOMATIC WELDING SYSTEM TO THE COMMANDER 300 For connection diagrams and instructions for connect ing an NA 3 Welding System to the Commander 300 refer to the NA 3 Welding System instruction manual The connection diagram for the LN 8 can be used for connecting the 3 CONNECTION OF AN LN 742 TO THE COMMANDER 300 FOR CODES ABOVE 10500 ONLY Requires optional K1597 1 42 VAC Transformer Kit Shut the welder off Connect the LN 742 per instructions on the appro priate connection diagram in the DIAGRAMS sec tion Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode being used Set the SELECTOR switch to the CV WIRE posi tion Adjust the ARC CONTROL knob to desired Crispness SOFT for MIG and CRISP for Innershield Set the WELDING TERMINALS switch to the REMOTELY CONTROLLED position Set the IDLE switch to the AUTO position When not welding the Commander 300 engine will be at the low idle speed COMMANDER 300 LINCOLN 8 B 1 OPERATION B 1 SAFETY INSTRUCTIONS Read and understand this entire section before operat ing your Commander 300 WARNING Do not attempt to use this equipment until you have t
41. NOILISOd 911 FHL NI HOLIMS 3HL 39Vld Q38I 30 SONLS LNdLAO OL 318V9 ONIGTAM LOANNOO ON WANVW ONILVYAdO 33 SNOILVOrTdav ANY 30 41949 ALNG ANY 1 844409 JHL ALIOVdVO JO 38 16 51895 ONIGTAM WANVA 0 GALSIT SNOILVOISIOSdS Wd 3409Y LSNPAV LON OG 7 AHOLOVA 3H L LV 13 4 SI ONILLAS 9 3NION3 JHL LINDYID TOHLNOO SHL NYO HOIHM 83033 SHIM OV IHL NI 3SV3SONI NV ASNVS 7 UIO AHL ONIGIHSSAO ONILLAS HONH3AO9 SHL 9NIDNVHO Ad 3NION3 40 3SV389NI NOILNVO OL HOLIMS LYVLS 7 87 HO Old QNVH 2964 mc 300410313 HO 318V9 1 1 1003 0287 L 986 ONILLIA LNdNI 570 OL 579 e JON3HdIV HILINMOT4 HOLVIN934 jueuudinbe 14 98 Jo sued jou asn jeysul pjnous jeuuosied AIUO e Buas eJoJeq sued Aeme deey e peg JALLVO3N 12euuoosiq e ui e uedo sjeued 9jejedo jou oq e ONINHVM 77 WVYOVIG NOLLO3NNOO 9IL 0569 COMMANDER 300 LINCOLN E 16 DIAGRAMS CONNECTION DIAGRAM F 16 5 8 705 0002 22 01 04415
42. NTION German WARNUNG it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 0 los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra 7 het EE FSU UD TERRE RR E SPR C EUNT PETER ONTA SUSS Xe e anc AXE endi AN A h l ei Vile ne Keep flammable materials away Mantenga el material combustible fuera del de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e naedoe6 0o08 CIE REA Pam SEL IF eis Jo ALD al gll pis Ac AI
43. ONTROL on the TIG Module 13 WELD OUTPUT TERMINALS AND These 1 2 13 studs with flange nuts provide welding con nection points for the electrode and work cables For posi tive polarity welding the electrode cable connects to the terminal and the work cable connects to this terminal For negative polarity welding the work cable connects to the terminal and the electrode cable connects to this terminal AUXILIARY POWER CONTROLS Items 14 17 14 120 240VAC RECEPTACLE This is 120 240 14 50R receptacle that provides 240VAC or can be split for 120VAC single phase auxiliary power This receptacle has a 50 amp rating Refer to the AUXILIARY POWER RECEPTACLES section in the installa tion chapter for further information about this receptacle Also refer to the AUXILIARY POWER OPERATION section later in this chapter COMMANDER 300 LINCOLN B 6 OPERATION B 6 m 15 CIRCUIT BREAKERS These circuit breakers provide separate overload rent protection for each 120V circuit at the 240V recep tacle each 120V receptacle the 120VAC in the 14 Pin connector the 42VAC in the 14 Pin connector and for codes above 10871 only battery circuit overload pro tection 16 120VAC RECEPTACLES These two 120VAC 5 20 receptacles provide 120VAC for auxiliary power These receptacles have a 40 amp total rat ing Refer to the AUXILIARY POWER RECEPTACLES sec tion in the installat
44. RE FEED WELDING LN 25 LN 7 LN 8 NA 3 LN 15 LN 742 Magnum Spool Gun amp K488 Module HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi Freq Unit and the K930 ALL TIG Modules are suitable for use with the Commander 300 The Commander is equipped with the required R F bypass circuitry for the connection of high frequency generat ing equipment The high frequency bypass network supplied with the K799 Hi Freq Unit does 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 300 LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when neces sary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill R Do not touch electrically live parts or electrod
45. RTING With a fully charged battery and the proper weight oil the engine should start satisfactorily even down to about O F With the above and the optional ether starter kit K887 1 the engine should start satisfactorily down to about 20 F With the above and an oil pan preheating system the engine should start satisfactorily down to about 30 F With the above and a battery warmer the engine should start satis factorily down to about 40 F Contact your local Lincoln Electric Representative for sug gested after market kits STOPPING THE ENGINE 1 Switch the RUN STOP switch to STOP This turns off the voltage supplied to the shutdown solenoid A backup shutdown can be accomplished by shutting off the fuel COMMANDER 300 LINCOLN B 7 OPERATION B 7 BREAK IN PERIOD Lincoln Electric selects high quality heavy duty indus trial engines for the portable welding machines we offer While it is normal to see a small amount of crankcase oil Consumption during initial operation excessive oil use wet stacking oil or tar like substance at the exhaust port or excessive smoke is not normal Larger machines with a capacity of 350 amperes and higher which are operated at low or no load conditions for extended periods of time are especially susceptible to the conditions described above To accomplish suc cessful engine break in most diesel powered equip ment needs only to be run at a reasonably heavy load within the ra
46. T dy SYNLNA ANY 30 41949 ALNG ANY JHL ALIOVdVO 0 38 LSNN S318V9 9NIQTJM WANVW 9NILVe3dO YACTAM 3NISN3 3H L NI 9531 SNOILVOISIOAdS Wd LSNPAV LON OG 7 019 SHL LV 13S 3Md SI ONILL3S HONS3AO9 1081 00 JHL NYO HOIHM Y30334 3SIM OV JHL NI SSVSYONI NV ASNVS 39 VMNTT JTLLOSH L JHL ONILLAS JHL 9NISNVHO 3NION3 4101 HOIH 30 3SV38ONI Q333 38IM OL NOILNVO 931899 300819313 OL GIN 7 Nid 9 UNO 318 2 10HLNO9 785 3780 LNdNI Z N1OL 14 2 5 10 sued 110 pjnous jeuuosied Ajuo e sued deey e peaj JALLVON 129910281 e eoejd ui e uedo jou oq e fep ONINHVM WV NOLLO3NNOO 1 SH3Q0 13M ANISNA COMMANDER 300 LINCOLN E DIAGRAMS F 8 F 8 CONNECTION DIAGRAM 7181768 0002 22 01 LNSYYNO WAWIXVW NOLLONYLSNI 308008 HAMOd OL DIEN TN X30334 11 130 339 9 2 931 38012 OL AVTSY WM 1983 NOILV10SI ISN 114110 04 V NYNLIY LVH
47. TECTION PREMISES DISCONNECT AND SERVICE GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE CIRCUIT 240 VOLT BREAKER 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 1 A 50 AMP 120 240 VOLT se fe RECEPTACLE NOTE No 8 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS COMMANDER 300 LINCOLN 8 INSTALLATION A 8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS A WARNING ELECTRIC SHOCK can kill 0 Shut off welder before making any electrical connections CONNECTION OF THE LN 25 TO THE COMMANDER 300 The LN 25 with or without an external contactor may be used with the Commander 300 See the appropriate connection diagram in the DIAGRAMS section NOTE The LN 25 K431 Remote Control Module and K432 Remote Cable are not recommended for use with the Commander 300 Shut the welder off For electrode Positive connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder For elec trode Negative connect the electrode cable from the LN 25 to the terminal of the welder and work oon cable to the terminal of the welder Attach the single lead from the front of the LN 25 to work using the spring clip at the end of the lead This is a sense lead to supply current to the wire feeder motor it does not carry welding current Set the SELECTOR switch to the CV WIR
48. Touch Start feature allows contamination free starting without the use of a Hi Freq unit But the K930 1 or 2 TIG module or K799 Hi Freq unit can be used with the Commander 300 The settings for these follow the tungsten current range table COMMANDER 300 LINCOLN 9 OPERATION Table TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES DCEN DCEP Approximate Argon Gas Flow Rate C F H I min 1 2 1 2 Aluminu Stainless Steel 3 8 Thoriated Thoriated m Tungsten Tungsten 2 15 3 2 4 3 8 5 20 5 10 15 80 5 10 B 9 Tungsten Electrode Diameter TIG TORCH Nozzle Size 4 5 2 4 70 150 5 10 150 250 250 400 13 17 15 23 400 500 500 750 750 1000 21 25 23 27 28 32 1 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shielding gases 2 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 1 Thoriated EWTh 1 2 Thoriated EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications 3 DCEP is not commonly used in these sizes 4 TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 6 mm 5 5 16 in 8 mm 6 3 8 in 10 mm 7 7 16 11 mm 8 1 2 in 12 5 mm 10 5 8 in 16 mm 5 TIG torch nozzles are typical
49. WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manu als supplied with your machine They include impor tant safety precautions detailed engine starting oper ating and maintenance instructions and parts lists ELECTRIC SHOCK can kill h not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground eAlways wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas vent exhaust outside Do not stack anything near the engine MOVING PARTS can injure 26 not operate with doors open or AW guards off Stop engine before servicing Keep away from moving parts Only qualified personnel should install use service this equipment LOCATION VENTILATION The welder should be located to provide an unrestricted flow of clean cool air to the cooling air inlets and to avoid restricting the cooling air outlets Also locate the welder so that the engine exhaust fumes are properly vented to an outside area CAUTION DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment that surface should be covered with a steel plate at least 06 1 6mm thick which should extend not less than 5 90 150mm beyond the equipment on all sides STORING 1 S
50. WELDING AND AUXIL IARY POWER LOADS It must be noted that the above auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in table B 4 The permissi ble currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply not both at the same time TABLE B 4 Commander 300 Simultaneous Welding and Power Loads Welding Output Range Welding Output Setting 300A 32V 300A 32V 230A 30V 150A 29V 90A 27V 60A 25V Permissible Permissible Auxiliary Unity Power Factor 0120 V 10 240 V 10 Each duplex receptacle is limited to 20 amps Not to exceed 44 A per 120 VAC branch circuit when splitting the 240 VAC output COMMANDER 300 LINCOLN C 1 ACCESSORIES C1 OPTIONAL FIELD INSTALLED ACCESSORIES K802N POWER PLUG KIT Provides four 120V plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240V 50 amps 120V plug may not be compatible with NEMA common household receptacles K802R POWER PLUG KIT Provides four 120V plugs rated 15amps each and one dual voltage full KVA plug rated at 120 240V 50 amps 120V plug is compatible with NEMA common household receptacles K857 25 ft 7 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 Has convenient plug for ea
51. WITCH The toggle switch on the control panel labeled Weld 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 With the switch in the Weld Terminals On position the con tactor is closed and the welding terminals are always Hot With the switch in the Remotely Controlled position the con tactor operation is controlled by an Amptrol Arc Start Switch or some other type of triggering device through the use of a control cable connected to the 14 pin MS connector When the triggering device is pressed the contactor is closed 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 auto matically senses when a remote output control pot is plugged into either amphenol Therefore there is no need for a local remote switch 12 6 PINCONNECTOR For attaching optional remote control equipment When in the CC STICK PIPE and CV WIRE modes and when a remote control is connected to the Amphenol the auto sens ing circuit automatically switches the OUTPUT control from control at the welder to remote control When using the TOUCH START TIG mode with a TIG Module connected the OUTPUT control is used to set the maximum current range of the CURRENT C
52. bles ou les recouvrir afin de et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et la pi ce sont sous tension quand la machine a souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le cable de soudage et la machine souder bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d in
53. by a vehicle 1 is Lincoln s K953 1 If the user adapts a non Lincoln trail er he must assume responsibility that the method of attachment and usage does not result in a safety haz ard nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so that there will be no undue stress to the trailer s framework 3 Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself 4 Typical conditions of use such as travel speed roughness of surface on which the trailer will be operated and environmental conditions 5 Proper preventative maintenance of trailer 6 Conformance with federal state and local laws Consult applicable federal state and local laws regarding specific requirements for use on public high ways VEHICLE MOUNTING WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehi cles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for compo nents such as suspension axles and tires
54. c idler reduces engine speed when not weld ing or drawing auxiliary power This feature reduces fuel consumption and extends engine life Compact size fits crosswise in full size pick up truck Single side engine service Copper alternator windings and high temperature insulation for dependability and long life New paint system on case and base for outstanding corrosion protection K1585 1 Commander 300 Standard Model K1585 1 is the standard version of the Commander 300 and has all the features of the K1585 2 Deluxe version except there is no oil pres sure gauge oil temperature gauge engine alternator gauge nor dual output meters codes 10871 and below do not have a fuel level gauge nor low fuel light This version does have fully functional engine protection for low oil pressure high oil temperature and alternator output with associated lights A field installed Dual Output Meter and Gauge Kit K 1768 1 is available for the K1585 1 Commander 300 The kit includes dual output meters oil pressure gauge oil temperature gage and alternator amme ter WELDING CAPABILITY The Commander 300 is rated at 300 amps 32 VDC at 100 duty cycle and 375 amps 34 VDC at 60 duty cycle The maximum open circuit voltage at 1900 RPM is 80 volts The weld current is variable from 30 to 375 amps COMMANDER 300 LINCOLN B 3 OPERATION B 3 CONTROLS AND SETTINGS All welder and engine controls are locate
55. can result in damage to the internal charger com ponents Follow the instructions of the battery charger manufac turer for proper charger settings and charging time WELDER GENERATOR MAINTENANCE STORAGE Store the Commander in clean dry protected areas CLEANING Blow out the alternator and controls periodically with low pressure air do this at least once a week in par ticularly dirty areas BRUSH REMOVAL AND REPLACEMENT It is normal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator overhaul is necessary WARNING Do not attempt to polish slip rings while the engine is running COMMANDER 300 LINCOLN 4 Table D 1 Engine Maintenance Components P181050 CAK 256 A297C 70206N 117 9565 117 4416 117 4482 Group 34 COMMANDER 300 LINCOLN TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or internal wiring ENGINE EXHAUST can kill e Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts D Remove guards only when necessary and replace when work requiring removal is complete e Only qualified personnel should ins
56. cendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage cables de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des cables jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Si on utilise la machine souder comme une source de 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POU R
57. city rating in watts is equivalent to volt amperes at unity power factor The maximum permissible current of the 240 VAC output is 44 A 240 VAC out put can be split to provide two separate 120 VAC outputs with a maximum permissible current of 44 A per output to two separate 120 VAC branch circuits The output volt age is within 10 at all loads up to rated capacity NOTE The 120 240V receptacle has two 120V outlets of different phases and cannot be paralleled The Commander has two 20 Amp 120VAC 5 20 R duplex receptacles and one 50 Amp 120 240 VAC 14 50R receptacle The 120 240 VAC receptacle can be split for single phase 120 VAC operation The aux iliary power receptacles should only be used with three wire grounded type plugs or approved double insulat ed tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle 15 Amp receptacles for codes below 10500 STANDBY POWER CONNECTIONS The Commander 300 is suitable for temporary stand by or emergency power using the engine manufactur er s recommended maintenance schedule The Commander 300 can be permanently installed as a standby power unit for 240 volt 3 wire 44 amp ser vice Connections must be made by a licensed electri cian who can determine how the 120 240 VAC power can be adapted to the particular installation and com ply with all applicable electrical codes
58. d K1768 1 Dual Output Meters and Gauges Dual out put meters provide preset ability of voltage for wire welding and current for stick welding Measures both current and voltage when welding Gauges includes battery ammeter engine temperature and engine oil pressure Fuel gauge is not available in kit form K1816 1 Full KVA Adapter Kit Plugs into 120 240 NEMA 14 50R receptacle on case front which accepts 4 prong plugs and converts it to a NEMA 6 50R receptacle which accepts 3 prong plugs A WARNING Pipe Thawing with an arc welder can cause fire explosion damage to electric wiring or to the arc welder if done improperly The use of an arc welder for pipe thawing is not approved by the CSA nor is it recommended or supported by Lincoln Electric COMMANDER 300 LINCOLN C 2 ACCESSORIES RECOMMENDED OPTIONAL PLASMA CUTTING EQUIPMENT Pro Cut 55 STICK AC TIG WELDING Square wave TIG 175 Invertec V205T AC DC K704 Accessory Kit which includes e Electrode holder and cable Ground clamp and cable Headshield K857 Remote Control Kit is optional for remote cur rent control TIG Magnum TIG Torch Magnum Parts Kit and Argon gas K930 ALL Module not required for scratch start DC TIG welding K936 1 Control Cable K870 Foot Amptrol Also available K963 1 2 Hand Amptrol K814 Arc Start Switch K937 22 Control Cable Extension K937 45 Control Cable Extension K844 1 Water Valve WI
59. d on the case front panel Refer to Figure B 1 and the explanations that follow Figure B 1 Case Front Panel Controls 24 ENGINE CONTROLS Items 1 through 8 1 RUN 3 STOP SWITCH When placed in the RUN position this switch ener gizes 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 This is to protect the battery from discharge After 15 seconds the Run Stop switch must be toggled off then on before start ing 2 START PUSH BUTTON Energizes the starter motor to crank the engine With the engine Run Stop switch in the Run position push and hold the 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 29 3 FUEL LEVEL GAUGE AND LIGHT K1585 2 only on codes 10871 and below Displays the level of diesel fuel in the 25 gal lon 94 6 liters fuel tank The yellow light turns on when the fuel gage reaches the reserve level For Codes 10950 and 10951 yellow light is not required Onc
60. dercarriage or fixed support Cylinders should be located Away from areas where they be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY iv PRECAUTIONS DE SURETE zones pique le laitier Pour votre propre protection lire et observer toutes les instructions 6 Eloigner les materiaux inflamma
61. e the reserve level is reached the engine protection system will shut down the engine after 30 minutes of operation The machine can be restarted and operated for an additional 30 minutes before the protection system will shut down the engine This ability to override the engine protection is to allow the operator to finish up if necessary The operator must watch the fuel level closely to prevent running out of fuel and having to bleed the system COMMANDER 300 LINCOLN B 4 OPERATION B 4 4 ENGINE TEMPERATURE GAUGE K1585 2 Std K1585 1 Opt AND LIGHT The gauge displays the engine oil temperature The yellow temperature light remains off under normal operating temperatures If the light turns on the engine protection system will shut down the engine Check for restrictions at the engine cooling air inlets and outlets consult the engine Operators Manual Check for loose or disconnected leads at the temperature sender located on the engine Check engine cooling blower belt Also check to be sure that the welder loads are within the rating of the welder The light will remain on when the engine has been shut down due to an over temperature condition 5 OIL PRESSURE GAUGE K1585 2 Std G17 K1585 1 Opt AND LIGHT The gauge displays the engine oil pressure when the engine is running The yellow oil pressure light remains off with proper oil pressure If the light turns on the engine protection system will stop the en
62. e with skin or wet clothing nsulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off A Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual Read the Safety Precautions in front of this manual and the engine instruction manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair cloth ing and tools away from V belts gears fans and all other moving parts when starting operating or repair ing the equipment ROUTINE AND PERIODIC MAINTENANCE DAILY Check the crankcase oil level Refill the fuel tank to minimize moisture condensation in the tank Open the water drain valve located on the bottom of the water separator element 1 or 2 turns and allow to drain into a container suitable for diesel fuel for 2 to 3 seconds Repeat the above drainage procedure until diesel fuel is detected in the container WEEKLY Blow out the machine with low pressure air periodical ly In particularly dirty locations this may be required once a week ENGINE MAINTENANCE Refer to the Periodic Checks section of the Engine Operator s Manual for the recommended mai
63. ecessary to connect its frame to an earth ground unless the machine is connected to premises wiring home shop etc To prevent dangerous electric shock other equipment powered by this engine driven welder must grounded to the frame of the welder using grounded type plug or be double insulated When this welder is mounted on a truck or trailer its frame must be securely connected to the metal frame of the vehicle When this engine driven welder is con nected to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See further connection instructions in the sec tion entitled Standby Power Connections as well as the article on grounding in the latest U S National Electrical Code and the local code In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated INSTALLATION A 6 joints or to the metal framework of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is provided on the front of the welder AUXILIARY POWER RECEPTACLES The auxiliary power capacity of the Commander 300 is 10 000 watts of 60 Hz single phase power The auxiliary power capa
64. echnical troubleshooting assistance before you proceed COMMANDER 300 LINCOLN 4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS No welding power output Welding terminals switch in wrong position Place switch in WELD TERMINALS position when weld ing without welding terminal con trol cable Refer to Operation chapter for proper switch function Welder has output and no control Poor remote kit connection Check connections Faulty remote kit Replace if nec essary No auxiliary power Open circuit breakers Reset breakers breakers keep trip ping check connections to auxil iary receptacles Also make sure load does not exceed receptacles current rating Refer to Auxiliary Connections in the Installation and Operation chapters Faulty connections to auxiliary receptacles Check connections Faulty auxiliary circuit wiring If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln 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 300 LINCOLN
65. ecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery first then connect negative lead to neg ative battery lead at engine foot BATTERY ACID can burn eyes and skin PS Wear gloves and eye protection and be careful when working near battery e Follow instructions printed on battery 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 Remove the insulating cap from the negative battery terminal Replace and tighten negative battery cable terminal NOTE This machine is furnished with a wet charged battery if unused for several months the bat tery may require a booster charge Be sure to use the correct polarity when charging the battery COMMANDER 300 LINCOLN amp 5 INSTALLATION 5 MUFFLER Remove the plastic plug covering the muffler outlet tube Using the clamp provided secure the extension to the outlet tube This welder is supplied with an adjustable rain cap for the muffler Install the rain cap using the clamp provided with the outlet facing a
66. ects and State of California to cause cancer birth defects other reproductive harm or other reproductive harm ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY 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 purchase copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 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 FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 X 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 RS MAGNETIC FIELDS be dangerous 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool
67. electric pumps and for standby emergency power Drive a 5 HP motor provided it is started under no load Two 20 amp 120 VAC duplex receptacles for up to 40 amps of 120 VAC power 15 Amp for each receptacle up to 30 Amp for codes below 10500 only One 50 amp 120 240 VAC dual voltage receptacle for up to 44 amps of 240 VAC and up to 44 amps per side to separate branch circuits not in parallel of 120 VAC single phase auxiliary power Allows easy con nection to premises wiring Weld and AC auxiliary power at the same time with in machine total capacity OTHER FEATURES Deutz 3 cylinder air oil cooled diesel engine Designed for long life easy maintenance and excel lent fuel economy Engine protection system shuts the engine down for low oil pressure high oil temperature or a broken fan engine alternator belt Gauges for oil pressure oil temperature engine alter nator output and fuel level fuel level gauge on K1585 2 only codes above 10871 have a fuel level gauge on both 1585 1 K1585 2 Indicator lights for low oil pressure high oil tempera ture engine alternator low output broken belt and low fuel level Low fuel level indicator on K1585 2 only for codes 10871 and below Automatic low fuel shutdown before running out of fuel K1585 2 only for codes 10871 and below Engine hour meter standard on all models Extended range 25 gallon 94 6 fuel tank Automati
68. engine Remove the pulley belt guard 5 screws e Remove rubber strap on lower half of engine fan cowl ing Loosen tensioning pulley 2 bolts e Remove the old V belt and install a new one Refer to operation manual for proper tensioning of belt Per manual tighten tensioning pulley Reinstall the rubber strap fan cowling the pulley belt guard the engine case back the Air filter hose and the engine case side Reconnect the negative battery terminal COMMANDER 300 LINCOLN D 3 MAINTENANCE D 3 BATTERY HANDLING A WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from bat tery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect nega tive cable from old battery first and connect to new battery last CONNECTING A BATTERY CHARGER Remove bat tery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to bat tery first then connect negative lead to engine foot BATTERY ACID CAN BURN EYES AND SKIN Wear gloves and eye protection and be careful when working near battery Follow instructions printed on battery PREVENTING ELECTRICAL DAMAGE 1 When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed Failure to observe the pr
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70. ges 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 Start with a setting at O 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 filter hous ing 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 power receptacles 4 Set IDLER switch to AUTO 5 Set the RUN STOP switch to RUN Observe that all engine protection lights momentarily turn on some lights may turn off before starting Check the fuel gauge K1585 2 only for codes 10871 and below to make sure that there is an adequate fuel level 6 Press and hold the engine START button for a minimum of 2 seconds 7 Release the engine START button when the engine starts 8 Check that the indicator lights are off If the LOW FUEL light is on K1585 2 only for codes 10871 and below the engine will shutdown 30 minutes after starting If any other indicator light is on after starting the engine will shutdown in a few seconds Investigate any indicated problem 9 Allow the engine to warm up at low idle speed for several minutes before applying a load and or switching to high idle Allow a longer warm up time in cold weather COLD WEATHER STA
71. gine Check for proper oil level and add oil if necessary Check for loose or disconnected leads at the oil pressure sender located on the engine The light will go on and stay on when the RUN STOP switch is switched to the Run position with engine not running 6 ENGINE ALTERNATOR AMMETER K1585 2 Std K1585 1 Opt AND LIGHT The yellow engine alternator light is off when battery charging system is functioning normally If light turns on the engine protection system will shut down the engine Check the engine cooling blower belt Also the alternator or the voltage regulator may not be operat ing correctly The light may also come on due to a faulty 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 cooling blower belt 7 IDLER SWITCH Has two positions as follows A In the High position the engine runs at the high idle speed controlled by the governor B In the Auto gt position the idler oper ates as follows a When switched from High to Auto or after starting the engine the engine will operate at full speed for approximately 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 minimum the engine accelerates and operates at full speed c When welding ceases or the AC power load is turned off a fixed t
72. horized Field Service Facility for technical troubleshooting assistance before you proceed COMMANDER 300 LINCOLN 5 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION ENGINE PROBLEMS Major Physical or Electrical Damage 1 Contact your Local Lincoln is Evident Authorized Field Service Facility Engine will not crank Battery is low Charge Battery Loose battery cable connections Inspect clean and tighten Engine will crank but not start Out of fuel Fill fuel tank Fuel shut off valve is in off position High oil temperature Indicator light lit Check engine cooling system Consult engine service dealer If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Engine shuts down shortly after Low fuel Indicator light lit K1585 starting 2 only Add fuel Low battery voltage Low output of battery charging alternator Indicator light lit Check cooling blower belt Replace if necessary High oil temperature Indicator light lit Check engine cooling system Consult engine service dealer Battery does not stay charged Faulty battery Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform
73. horoughly 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 TX e ELECTRIC SHOCK kill Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground eAlways wear dry insulating gloves ENGINE EXHAUST can kill 23 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 Diesel Fuel can cause fire Stop engine while fueling Do not smoke when fueling e Do not overfill tank fuel expansion may cause overflow Keep sparks and flame away from tank Do not leave unattended while fueling Wipe up spilled fuel before starting engine DIESEL FUEL ONLY Only qualified personnel should operate this equip ment ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and the side panels in place as these provide maxi mum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION The Commander 300 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
74. igh risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L 4 0 ARC RAYS 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 287 standards Use suitable clothing made fro
75. ime delay of approximately 12 seconds starts d If the welding or AC power load is not restarted before the end of the time delay the idler reduces the engine speed to low idle speed e The engine will automatically return to high idle speed when the welding load or A C power load is reapplied 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 e f the triggering device remains pressed but no weld ing load is applied within approximately 15 seconds the engine will return to low idle speed f the triggering device is released or welding ceases the engine will return to low idle speed after approxi mately 12 seconds 8 HOUR METER The hour meter displays the total time that the engine has been running This meter is a useful indicator for scheduling preventive maintenance COMMANDER 300 LINCOLN 5 OPERATION B 5 WELDER CONTROLS Items 9 through 14 9 WELD MODE amp OUTPUT CONTROL These two controls allow you to select between various welding output slopes and adjust the desired welding output Refer to Table B 1 for a description of how these two controls work Table B 1 Weld Mode and Ou
76. ion chapter for further information about these receptacles Also refer to the AUXILIARY POWER OPERATION section later in this chapter 15 Amps per receptacle up to 30 Amps total for codes below 10500 only 17 GROUND STUD Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure Refer to MACHINE GROUNDING in the Installation chapter for proper machine grounding information 18 VOLTMETER SWITCH Changes the polarity display on the wire feeder 19 14 PIN CONNECTOR For attaching wire feeder control cables Includes con tactor closure circuit auto sensing remote control cir cuit and 120V and 42V power The remote control cir cuit operates the same as the 6 Pin Amphenol 20 ARC CONTROL The ARC CONTROL WIRE STICK dial is active in the WIRE and STICK modes and has different functions in these modes This control is not active in the TIG and PIPE modes CC STICK mode In this mode the ARC CONTROL knob sets the short circuit current during stick welding arc force Increasing the number from 10 to 10 increases the short circuit current and prevents stick ing of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with a setting at 0 CV WIRE mode In this mode turning the ARC CON TROL clockwise from 10 soft to 10 crisp chan
77. ions 30 to 300 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 on 20 250 amp range for Touch Start TIG welding COMMANDER 300 LINCOLN B 2 OPERATION B 2 100 duty cycle at 300 amps output and 60 duty cycle at 375 amps output Dual 3 digit output meters are provided optional on K1585 1 for presetting the weld amperage or voltage and displaying the actual amperage and voltage during welding The meters use superbrite L E D s for improved readability in full sunlight LOOK BACK FEATURE After welding has stopped both displays will remain on for 7 seconds with the last current and voltage value displayed During this time the left most decimal point in each display will be flash ing Standard remote control capability with 14 pin and 6 connectors for easy connection of Lincoln remote con trol accessories An internal Solid State contactor allows for the selec tion of hot or cold output terminals with a toggle switch on the control panel e Arc Control potentiometer in Wire and Stick modes for precise adjustment of arc characteristics Advanced circuitry to prevent Arc Breaks in the five slope modes FOR AUXILIARY POWER 10 000 watts of 120 240 VAC 60Hz auxiliary power Power for tools 120 240 VAC lights
78. lectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE CONTENTS Page Safety i iv matalat mE Section A UE alle Ee ee 1 Safety Or re 2 Location 2 2 LACKING MEET 2 Angle of 2 RAR ES A A T E E A A 3 High Altitude Operation 3 MOWING EE 3 Pre Operation Engine Service 4 o m A 4 4 FUG 4 Engine Cooling 4 Battery t ed e E E 4 Ou 5 SpatlCAITeSter 5 High Frequency Generators for TIG Applications
79. ly 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 300 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 the K799 circuitry with respect to the 2 and 4 leads does not provide the prop er signal to open and close the solid state contactor in the Commander 300 Commander 300 SETTINGS WHEN USING THE K930 1 or 2 TIG MODULE Set the WELD MODE switch to the 20 250 Setting TIG Set the IDLER switch to the AUTO position Set the WELDING TERMINALS switch to the Remotely Controlled position This will keep the solid state con tactor open and provide a cold electrode until the trig gering device Amptrol or Arc Start Switch is pressed COMMANDER 300 LINCOLN 10 WIRE FEED CONSTANT VOLTAGE WELDING Connect a wire feeder to the Commander 300 and set welder controls according to the instructions listed earlier in this section The Commander 300 in the WIRE WELDING position permits it to be used with a broad range of flux cored wire Innershield and Ou
80. m durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in
81. men von Schweibrauch Sorgen Sie fiir gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o exhaust o para remover fumo da zona respirat ria eti ADP5oUtRc5cuc 9 gt KEE za 24752 else SUAS MAS sis PARAH 7 Turn power off before servicing Desconectar el cable de ali mentaci n de poder de maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servi o N o toque as partes el tricas nuas 9 PRE BRAY FE e HMDS RK AGS XA Do not operate with panel open guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas NRIVOAN ERUALEEE CHkBEELZVCNEUS CRRRIARRARS Ro 20 Sel dos Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O it ie
82. n connector is for connecting the K857 or K857 1 Remote Control Optional or in the case of TIG welding applications with the foot or hand Amptrol K870 or K812 respectively The 14 pin connector is used to directly connect a wire feeder or TIG Module K930 1 or 2 control cable NOTE When using the 14 pin connector if the wire feeder has a built in power source output control do not connect anything to the 6 pin connector WELDING TERMINALS The Commander is equipped with a toggle switch for selecting hot welding terminals when in the WELD TERMINALS ON position or cold welding terminals when in the WELDING TERMINALS REMOTELY CONTROLLED position COMMANDER 300 LINCOLN 1 Make Model Diesel Engine Deutz F3L 1011 Codes 11199 and Below Codes 11200 and above Displacement 125 cu in 2 05 L Bore x Stroke 3 89 x 4 13 99mm x 105mm 142 cu in 2 33L Bore x Stroke 3 70 x 4 41 INSTALLATION TECHNICAL SPECIFICATIONS Commander 300 INPUT DIESEL ENGINE Description 3 cylinder 31 HP 23 kw 1800 RPM 3 cylinder 32 HP 24 kw 1800 RPM Speed RPM High Idle 1900 Low Idle 1475 Full Load 1800 Starting System 12 VDC battery amp Starter Capacities Fuel 25 gal 94 6 Oil 6 3 Qts 6 0 L 94mm x 112mm RATED OUTPUT WELDER 300 amps DC multi purpose 32 volts 34 volts 375 amps DC multi purpose OUTPUT WELDER AND
83. nt toward a bright light Check for damaged gas kets or dented metal parts Do not reuse damaged ele ments Protect element from dust and damage during drying and storage Replace air filter after six cleanings cleaned filter will have approximately 70 of the life of a new filter ele ment A restricted filter element may not appear exces sively dirty FUEL FILTERS A WARNING When working on the fuel system unguarded lights away not smoke Do not spill fuel The Commander 300 is equipped with a Fuel Filter Assembly attached vertically to the engine block in the lower center of the engine left of the fuel pump The recommended change interval for the fuel filter ele ment is 1 000 hours Consult your engine operation manual for replacement procedure and for information on air bleeding the entire fuel system Note The fuel shut off valve before the fuel pump must be closed before changing the fuel filter COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically Consult the engine owners manual for the proper frequency and procedure COOLING BLOWER BELT The following procedure should be followed to replace the cooling blower belt Allow machine to cool Remove the engine case side Loosen air filter hose clamp and detach hose Disconnect the negative battery cable Remove the engine case back panel for access to the
84. ntenance schedule of the following Engine Oil and Filter Air Cleaner Fuel Filter and Delivery System Cooling Blower Belt Battery Cooling System Refer to Table D 1 at the end of this section for various engine maintenance components AIR FILTER CAUTION EXCESSIVE AIR FILTER RESTRICTION WILL RESULT IN REDUCED ENGINE LIFE 1 Service air cleaner regularly according to Engine Operator s Manual 2 Stop engine after 100 hours of running time and clean filter element replace the filter if necessary The air filter canister is located behind the engine door on top of the air intake box The air filter element is a dry cartridge type It can be cleaned and reused however damaged elements should not be reused Remove loose dirt from element with compressed air or water hose directed from inside out Compressed Air 100 psi maximum with nozzles at least one inch away from element Water Hose 40 psi maximum without nozzle COMMANDER 300 LINCOLN D 2 MAINTENANCE D 2 Soak element in a mild detergent solution for 15 min utes Do not soak more than 24 hours Swish element around in the solution to help remove dirt Rinse ele ments from inside out with a gentle stream of water less than 40 psi to remove all suds and dirt Dry ele ment before reuse with warm air at less than 1600F 710C Do not use a light bulb to dry the element Inspect for holes and tears by looking through the ele me
85. oper polarity could result in damage to the charging circuit The positive battery cable has a red terminal cover 2 If the battery requires charging from an external charg er disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads Failure to do so can result in damage to the internal charger components When reconnecting the cables connect the positive cable first and the negative cable last PREVENTING BATTERY DISCHARGE If you have an ignition switch turn it off when engine is not running PREVENTING BATTERY BUCKLING Tighten nuts on battery clamp until snug NAMEPLATES WARNING DECALS MAINTENANCE Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are longer clear Refer to the parts list for the replacement item number CHARGING THE BATTERY When you charge jump replace or otherwise connect battery cables to the battery be sure the polarity is cor rect Improper polarity can damage the charging cir 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 attach the charger leads after the battery is charged reconnect the positive bat tery cable first and the negative cable last Failure to do co
86. produce erratic outputs and large output imbalances between the units COMMANDER 300 LINCOLN B 11 AUXILIARY POWER OPERATION Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings if no welding current is being drawn The auxiliary power of the Commander consists of two 20 Amp 120VAC 5 204R duplex receptacles and one 50 Amp 120 240 VAC 14 50R receptacle The 120 240VAC receptacle can be split for single phase 120 VAC operation 445 Amps for codes below 10500 The auxiliary power capacity is 10 000 watts of 60 Hz single phase power The auxiliary power capacity rat ing in watts is equivalent to volt amperes at unity power factor The maximum permissible current of the 240 VAC output is 44 A The 240 VAC output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 44 A per output to two separate 120 VAC branch circuits Output voltage is within 10 at all loads up to rated capacity NOTE The 120 240V receptacle has two 120V out puts of different phases and cannot be paralleled The auxiliary power receptacles should only be used with three wire grounded type plugs or approved dou ble insulated tools with two wire plugs OPERATION B 11 The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle SIMULTANEOUS
87. s ANNOYS 9 1 Ze es 1 OND vom 8404 Op TINA reng gogo IOMLNOD OSIN 15418 LOH Lee e Leaz oe oe oe 4 ATAM on ggz 9962 i 60000000 Sol jo 2 1262 vee WOSN3S AT 1304 1 r aN9 xoa Tounoa Hom woog ONUS ezz NO WNOLLdO THGON GUVGNVIS aonvo 9 aN9 NOLLOS AVIS us pzez Ae rs ozz wel 1 aw vez v veez BEZ SAVE STOW GHVONYLS NO anis G3lv insni ws DOAZ SS3NUVH OLNI S 13QOW NO SWALI S31LON3G OL TN 81108 38 01387 en gt on Ean lt s Serre meen Emo
88. s protected by a low fuel shutdown to prevent the engine from running out of fuel The machine will indicate a low fuel condition by turning on the low fuel light A time of 30 minutes will elapse once the low fuel light illuminates before the machine will shut down A restart of the machine will restart the timer to allow the operator to override this feature The amount of reserve fuel remaining in the tank after the first shutdown will vary from machine to machine The operator must determine the amount of fuel remaining before re starting the machine Running out of fuel may require bleeding the fuel injection pump NOTE Before starting the engine open the fuel shutoff valve pointer to be in line with hose FUEL CAP Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap INSTALLATION A 4 ENGINE COOLING SYSTEM The Deutz engine is air cooled by a belt driven axial blower The oil cooler and engine cooling fins should be blown out with compressed air or steam to maintain proper cooling See the engine Owners Manual for procedures and frequency BATTERY CONNECTION A WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and con nect to new battery last CONNECTING A BATTERY CHARGER remove battery from welder by disconn
89. s shipped with the lift bale retracted Before attempting to lift the Commander the lift bale must be secured in a raised position Secure the lift bale as follows a Open the engine compartment door b Locate the 2 access holes on the upper middle region of compartment wall just below the lift bale c Use the lifting strap to raise the lift bale to the full upright position This will align the mounting holes on the lift bale with the access holes Secure the lift bale with 2 thread forming screws The screws are provided in the shipped loose parts bag A WARNING e Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trail er or gas cylinder Do not lift machine if lift bale is damaged EQUIPMENT can Do not operate machine while cause injury suspended from lift bale FALLING HIGH ALTITUDE OPERATION At higher altitudes output derating may be necessary For maximum rating derate the welder output 5 for every 300 meters 984 ft above 1500 meters 4920 ft For output of 300A and below derate the welder output 5 for every 300 meters 984 ft above 2100 meters 6888 ft Contact a Deutz Service Representative for any engine adjustments that may be required TOWING The recommended trailer for use with this equipment for road in plant and yard towing
90. sy connection to the welder The Commander 300 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 of work cable head shield work clamp and electrode holder Cable is rated at 500 amps 60 duty cycle K953 1 TRAILER Two wheeled trailer with optional fender and light package For highway use consult applicable federal state and local laws regarding pos sible additional requirements There is a choice of 2 hitches a fender amp a light package Order K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender amp Light Kit K965 1 Cable Rack K767 2 TRAILER Four wheeled steerable yard trailer for in plant and yard towing K887 1 ETHER START KIT Provides maximum cold weather starting assistance for frequent starting below 10 oF 12 2 oC Required Ether tank is not provided with kit K1898 1 SPARK ARRESTOR KIT Easily mounts to standard muffler Approved by U S D A Forest Service K1604 1 OIL DRAIN KIT Includes ball valve hose and clamp K1690 1 1 Duplex GFCI Kit Includes one UL approved 115V ground fault circuit interrupter duplex type receptacle with cover and installation instruc tions Replaces the factory installed 115V duplex recep tacle The receptacle of the GFCI duplex is rated at 20 amps the maximum total current from the GFCI duplex is limited to 20 amps Two kits are require
91. tall use or service this equipment 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE 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 generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand are unable to perform the Recommended Course of Action safely contact your local Lincoln 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 Aut
92. tershield electrodes and solid wires for MIG welding gas metal arc welding Welding can be finely tuned using the ARC CONTROL Electrodes suitable for use are NR 311 NS 3M NR 207 NR 203 Ni 1 NR 204 H Electrodes suitable for use are 05 70 05 71 Electrodes suitable for wires for MIG welding are 035 0 9 mm 045 1 1 mm 052 1 3 mm L 50 and L 56 035 0 9 mm and 045 1 1 mm Blue Max MIG 308 LS For any electrodes including the above recommenda tions the procedures should be kept within the rating of the machine For additional electrode information see Lincoln publications N 675 GS 100 and GS 210 ARC GOUGING For optimal performance when arc gouging set the Commander 3005 WELD switch to the CC STICK position and the ARC CONTROL to 10 Set the OUTPUT knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table Maximum current setting is limited to the Commander ELECTRODE CURRENT RANGE DIAMETER DC electrode positive 1 8 60 90 Amps 5 32 90 150 Amps 200 250 Amps 3 16 1 4 300 375 Amps 300 s maximum of 375 Amps OPERATION B 10 PARALLELING When paralleling machines in order to combine their outputs all units must be operated in th CC STICK mode only To achieve this turn the WELD MODE switch to the CC STICK position Operation in other modes may
93. the open circuit voltage For exam ple 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 COMMANDER 300 LINCOLN B 8 OPERATION CONSTANT CURRENT CC WELDING The CC STICK position of 30 to 375 the WELD MODE Switch is designed for horizontal welds with all types of electrodes especially low hydrogen The OUTPUT adjusts the full range of 30 to 375 amps This setting provides a soft constant current arc If a more forceful arc is desired then select the proper range from the slope controlled current ranges In the CC mode sticking can be prevented by adjust ing the ARC CONTROL Turning this control clock wise increases the short circuit current thus prevent ing sticking This is another way of increasing arc force TIG WELDING The most clockwise position of the WELD MODE switch is for TIG welding in the range of 20 amps to 250 amps with a Touch Start feature To initiate a weld the OUTPUT is first set to the desired current and the tungsten is touched to the work During the time the tungsten is touching the work there is very lit tle voltage or current and in general no tungsten con tamination Then the tungsten is gently lifted off the work in a rocking motion which establishes the arc The Commander 300 can be used in a wide variety of DC Tungsten Inert Gas TIG welding applications In general the
94. the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed COMMANDER 300 LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Engine will not idle down to low speed Engine will not go to high idle when attempting to weld Engine will not go to high idle when using auxiliary power FUNCTION PROBLEMS Idler switch in High idle position Set switch to Auto External load on welder or auxil iary power Remove all external loads Poor work lead connection to work Make sure work clamp is tightly connected to clean base metal Welding Terminals switch is in wrong position Set to WELD TERMINALS when welding with out a welding terminal control cable Refer to Operations chap ter for proper use of this switch Auxiliary power load is less than 100 watts Idler may not respond with less than a 100 load Set Idler to High If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln 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 t
95. ting of the welder for some period of time during the engine s early life However if the welder is subjected to extensive light loading occasional moder ate to heavy loading of the engine may sometimes be necessary Caution must be observed in correctly loading a diesel generator unit 1 Connect the welder output studs to a suitable resis tive load bank Note that any attempt to short the output studs by connecting the welding leads together direct shorting of the output studs or con necting the output leads to a length of steel will result in catastrophic damage to the generator and voids the warranty 2 Set the welder controls for an output current and voltage within the welder rating and duty cycle Note that any attempt to exceed the welder rating or duty cycle for any period of time will result in cata strophic damage to the generator and voids the warranty 3 Periodically shut off the engine and check the crankcase oil level TYPICAL FUEL CONSUMPTION Refer to Table B 2 for typical fuel consumption of the Commander 300 s Engine for various operating sce narios Table B 2 Deutz F3L 912 Engine Fuel Consumption Codes 11199 and below Codes 11200 and above Deutz F3L 1011 Running Deutz F3L 2011 Running 31 Hp 9 Time 32 Hp Time 1800 RPM for25 1800 RPM 19725 gallons gallons Hours Hours Low Idle No Load 35 gallons hour 714 1 32 liters hour 48 gallons hour 2 Load 1900 RPM
96. tore the machine in a cool dry place when it is not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from construction activities moving vehicles and other hazards 2 Drain the engine oil and refill with fresh 10W30 oil Run the engine for about five minutes to circulate oil to all the parts See the MAINTENANCE section of this manual for details on changing oil 3 Remove the battery recharge it and adjust the elec trolyte level Store the battery in a dry dark place 4 If the engine is not used for a long period of time every two to three months run the engine for about five minutes to keep it free from rust STACKING Commander 300 machines cannot be stacked ANGLE OF OPERATION To achieve optimum engine performance the Commander 300 should be run in a level position The maximum angle of operation for the Deutz engine is 20 degrees in a direction to cause the control panel to be angled up 30 degrees for side to side tilting and for the control panel to be angled down If the engine is to be operated at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the specified 25 gallons COMMANDER 300 LINCOLN A 3 INSTALLATION A 3 LIFTING The Commander lift bale should be used to lift the machine The Commander i
97. tput Conirol Application M Weld Mode Output Sloped Output for 5 Range Pipe Welding Settings 90 150 200 250 300 Max current on each setting Provides a fine adjustment of welding current from Ver Start TIG 1 Range setting Min 1 to SES 20 200 10 within each Constant Current range Output for Fabrication and General Purpose 1 Range setting 30 575 Amps Provides Fine Voltage Adjustment 1 Range setting 14 to 32 Volts Functions 1 f the WELD MODE switch is positioned between settings the pre vious setting is maintained until the switch is properly positioned on a setting 2 OUTPUT also controls O C V while in the 5 sloped output ranges 10 DIGITAL OUTPUT METERS The digital output meters are located in the center of the control panel between the two large control knobs The digital meters allow the output voltage CV WIRE mode or current CC STICK PIPE and TIG modes to be set prior to welding using the OUTPUT control dial During welding the meter display the actual output voltage VOLTS and current AMPS A memory fea ture holds the display of both meters on the seven sec onds after welding is stopped This allows the operator to read the actual current and voltage just prior to when welding was ceased While the display is being held the left most decimal point in each display will be flash ing The accuracy of the meters is or 3 11 WELDING TERMINALS S
98. usibles Garder tous les couvercles et dispositifs de s ret leur place V V J for selecting a QUALITY product by Lincoln Electric We want you ank 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 Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolne
99. ve been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN amp 224 if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an un
100. way from the direction in which this unit will be transported This will minimize the amount of water and debris which could enter the muffler during transportation SPARK ARRESTER Some federal state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain loca tions where unarrested sparks may present a fire haz ard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations a suitable spark arrester such as the 524647 must be installed and properly maintained CAUTION An incorrect arrester may lead to damage to the engine or adversely affect performance HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi Freq Unit and the K930 1 or 2 TIG Module are suitable for use with the Commander 300 The Commander 300 is equipped with the required R F bypass circuitry for the connection of high fre quency generating equipment The high frequency bypass network supplied with the K799 Hi Freq Unit does NOT need to be installed into the Commander 300 The Commander 300 and any high frequency generat ing equipment must be properly grounded See the K799 Hi Freq Unit and the K930 1 or 2 TIG Module operating manuals for complete instructions on instal lation operation and maintenance REMOTE CONTROL OUTPUT The Commander 300 is equipped with a 6 pin amp 14 pin connector The 6 pi

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