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Lincoln Electric IM601-A User's Manual

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1. CIDOSVATS 1VNOILdO c 5 1vNOI140 NO M3U2S QN9 vs INVH9VIG 00 H3aQNVIWIWOO COMMANDER 300 LINCOLN E DIAGRAMS F 2 2 WIRING DIAGRAM 189011 86 71 8 3NION3 35 elp oyioeds eu ds 10u1NOO 30 HOVE 3915 LH9I NO anis 2018 3NIDN NO 1108 1004 INI NI NO anis 104100 NO TAT 1904 waluvis Q visa sjaued y JO euo uo y episui pejsed s sened 14 Aq JO ejeJnooe eq jou 3 AJUO 10 SI SIUL 310 82d NOILDILOYd 3NION3 um m 1041802 40 LHOIU WoLLOS SS3NWUVH 3NI9N3 SONIGNIM AWVIIXnv 301915 sos m N HOLIMS 32unos 1ON1NO2 9NIQ13M anis
2. srz 10u1NO2 SSINUVH 1081 2 NOILISOd 1V201 NI NMOHS HOLIMS a 1 aaivinswi SSANYVH 1081 2 Lig 950 E 291 ov SS3NWUVH 1081 2 T 22 indino e Sat 824 SSVdA9 910304 dIOUOL dle 4 annoys Oe 63 suus eco L nonna mmm mm I how no gt 310w3u awom ovinos VINHOISNVUL Id 341 1331 JOYLNOD 30 32v8 anis 2 XO8 TOULNOD 10 1431 WOLLOS NO Q31V 10S NI YIMOd AYYITXNY 2VACT T3NVd 1081N02 NO M3WU2S 9s SdWVOOb AWOS 1 8 390148 33111533 LA ANIS 1931 um u3MOd 1 528 56 4 8 mm luo OLVOT ONIYIM TAGOW 1XN130 00 YAGNVWWOD COMMANDER 300 LINCOLN E F 3 289011 86 71 8 TOWLNOD 30 2 8 3015 LHOIY NO GNLS 3NI9N3 35 awed
3. WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese it is BIR LEIA E COMPREENDA AS INSTRUC ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR 2 018 7 44 RA ETIEMLT FEU ET ABL BE A Rr de OE D EL FE B SR RRR ST EZ BUR BS 0 gt nie HA ZARE AS gt SAIT BEHE Saal cual 5 alayla aul Gud al ply Gail agil g LINCOLN amp World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
4. i iv Lt Section A Technical Specifications sssssssssssseseee eene tenentes A 1 Safety Precautions a a n Y ec et e cv Ya Panne dt A 2 Location ss A 2 Re ep E A 2 cid AE A 2 Angle of Operation redire eene e rr LT er ed ae eodd A 2 i o de sta uerum err DERE UT e EH A 3 High Altitude Operation us A 3 TOWING eec Rae AT 3 Pre Operation Engine Service A 4 cec euet acto a oN A 4 FUG wii nti tied iii on eh ng ie a aes A 4 UCI efe te Eee 4 Engine Cooling System 4 Battery Connection iii A 4 urge A 5 Spark Arrester iio ad eerte tede tuae abere A 5 High Frequency Generators for TIG Applications A 5 Remote Control eene A 5 Welding Terminals peere een rci e De i dee t enn A 5 Welding Output Cables iii A 6 Machine Gro ndihg A 6 Auxiliary Power Receptacles eene eene A 6 Standby Power Connections si A 6 Connection of Lincoln Electric Wire Feeders see A 8 m S Section B Safety Instructions d r
5. Section D Safety Precautions iii D 1 Routine and Periodic Maintenance D 1 Engine Maintenance ss D 1 Air c EU D 1 FUG LUE SP CT EC 2 Cooling Syst r o a i aan ee ae 2 Cooling Blower Belt su D 2 Battery Handling cicada D 3 Nameplates Warning Decals Maintenance D 3 Welder Generator Maintenance nennen nnns D 3 Sohle EE D 3 orte teri a anne a wai M D 3 Brush Removal and Replacement esse D 3 Engine Maintenance Components ener D 4 Troubleshooting 2 44 2 2 4 524 2 4 41242 1 4 241124 414411412 Section E Diagrams and Dimension Print ns Section F Parts 27 1 P334 Series COMMANDER 300 LINCOLN vii A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS Commander 300 K1585 1 amp 2 Make Model Deutz F3L 1011F Diesel Engine 5 Ranges Description 3 cylinder 31 HP 23 kw 1800 RPM INPUT DIESEL ENGINE Speed RPM High Idle 1900 Low Idle 1400 Full Load 1800 Displacement 125 cu in 2 05 L Bore x Stroke 3 89 x 4 13 99mm x 105mm RATED OUTPUT WELDER 300 amps DC multi purpose 375 amps DC multi purpose S
6. Nid vb 2697 OQ OfYrid INdNI 272 1 jueuudinbe 14 sois 10 sued 10 og e pjnoys jeuuosied Ajuo e syed Aeme e av11 SALLVDAN 12euuoosiq e goed ul e uedo sjeued um jou og e einiul 44 4 ONIAOW 42 gt 951412313 ONINUVMW WVH9VIQ NOLLO3NNOO H3O0NVWINOO COMMANDER 300 LINCOLN E DIAGRAMS F 16 F 16 DIMENSION PRINT 3SV8 3 13 40 WOLLOS cC9681l1WN Mu g8 SNOILV2O1 310H ONILNNOW YATIVEL IWAOWAY AuUudllv8 404 66 84 gt lt OT E9 1304 11014 3NISN3 NI 110 dO Wu3lN3O COMMANDER 300 LINCOLN E NOTES COMMANDER 300 LINCOLN NOTES COMMANDER 300 LINCOLN Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding infor
7. jou OG e esn jejsur pjnous Ajuo e syed Aeme des e SALLVDAN 12euuoosiq e sed ul e uedo sjoued jou e einiul UD 14 ONIAOW IDH uoo lere DNO ONINUVM W INVH9VIG NOLLO3NNOO Z N1 00 H3aNVWINOO TONAHdNV Nid tL TON3HdAV Nid 9 COMMANDER 300 LINCOLN E DIAGRAMS F 7 F 7 CONNECTION DIAGRAM 886625 LNAYYND WNNIXVN TWANVW NOILONEHLSNI 56 H3MOd OL 42434 uaqaad e 8 SQVAT1 35010 OL AV134 OL Teg ATIVNGIAIGNI QV31 GASNNN HOVA ALVINSNI ALIWV10d AGOYLOATA Q3HIS3G LOATAS OL HOLIMS HALAWLIOA ASN IWANVW ONILVYAdO 33 SNOILVOMddV 89 ALVIGAWWI 40 ALNG ANY LNSYYND AHL ALIOVdVO 40 LSNW 318VO ONIGTAM 9NILVH3dO H3Q 13M ANION JHL NI 041511 SNOILVOISIOSdS 3AO8V LSNPAV LON OG LV 135 3 SI 9NILI3S HONH3AO9 JHL d39VIAVG 38 AV SLINOHI9 103109 430334 5110 091 8309 SDVLIOA SIHL 3I 39 VL 10A IHL JHL NI NV ASNVO TIIM JILLOYHL 9NIGIHH3AO HO ONILLAS HONH3AO9 JHL Wd 3NION3 4101 JHL 40 3SV3HONI NOILV10SI ASN 404100 9NIQT3M
8. sued uono jou og e esn ejsur pinoys jeuuosJed e Bullies e40Jeq sued Aeme deey e av11 3ALLVO3N 1290009514 e eoe d ui des e uedo sjeued jou e einiul ONIAOW US 010 EMO TIENE ONINUVM INVHOVIG NOILOJNNOO 3AINGOW 511 0 65 00 YHAGNVWWOD COMMANDER 300 LINCOLN E DIAGRAMS F 15 F 15 CONNECTION DIAGRAM 609755 LDA H3INHOJSNVHLL 1 2691 IVNOLLdO SAYINDAY 504 3 LOWY NI HOLIMS 3 LOW3H 1V90139V ld SNIGTAM OL HOLIMS HOLO313S AHL NOILISOd ALIHV IOd 3404191313 Q3HIS3Q LOATAS OL HOLIMS YALAWLIOA ISN AN IWANVIN 9NILVH3dO 335 SNOILVOl1ddV aYNLNA ALVIGAWWI 40 319A9 ALNG LN3HHfIO AHL ALIOVdVO H3dOHd 40 LSNW S3 18VO V N IWANVW ONILVH3dO 3NION3 NI 31911 SNOILVOIJIO3dS 3408Y 15 LON OG AHOLOVA IHL LY 13S 3Hd SI ONLLLAS HONH3AOO 3NION3 IHL AVIN SLINOHIO S L10A 309 SIHL 4 39 V L10A OV JHL IHL NI 3SV3HONI NV ASNVO 31LLOHH L ONIGIHH3AO HO 9NILI3S HONH3AOO 3NION3 HOIH HO 3SV3HONI LINN Q33d 3HIM OL 3 18VO 24041913 MYOM OL 3HOM OL
9. ayeundoe jou juo 10 SI 54 3 LON 82d NOIL2310WUd 3NI9N3 82d 10Y 1LNOD ef s 28180 ml 19 J t1 AMFLLVE AZT 2 1 Qe 13Nvd 104100 NO anis wes leds divano az asi 9420 ove a hounos aonan v 13004 auvanvis 7565 oe ren FOX a aiouoi ed Sever over Pa selo a ot udes DE ve xuom a9 se a Aq TH uz als LL 224 ssvsaa a deca os 1 aa ee 194v E 104100 1 TI Noo SS 2 9NIQ13M ii 3 Sot o E x Xm 108 dove 553 TOYLNOD gt 553 1081 2 SS3NuvH procis 7 l 22 HIWHOASNVUL TOYLNOD we ei Tib LOREMS L ot fat e a9 st et et 21
10. Aeme e qva 3ALLVO3N 19euuoosiq e eoe d ui e uedo sjoued jou oq e ub 14 4 ONIAOW PT 91419313 ONINUVM WVYSVIC NOILOANNODO Z N1 SZZM 2987 006 HIONVWWOIY COMMANDER 300 LINCOLN E DIAGRAMS F 6 F 6 CONNECTION DIAGRAM L86EZS NOLLISOd 1 NI HOLIMS 31O0W3H 39V1d aasn SI TOHLNOO 104100 3L0W3H IWANVW 9NILVH3dO 33S SNOILVOlIlddV A4N1N1 ANY ALVIGAWWI 40 319A9 ALNA LN3HHD JHL ALIOVdVO 40 LSNW S318VO AO SNIGTAM OL HOLIMS HOLOATAS NOILISOd ALIlHV IOd 390419313 Q3HIS3G 193135 OL HOLIMS H3I3IALTOA ASN IVANY 9NILVH3dO 3NION3 NI QG31ST1 5301191519345 Wd 3AOG8V LSNFAV LON OG AHOLOVH JHL LV 135 SI DNILLAS HONH3AOO 3NION3 JHL AVIN SLINOHI9 TOHLNOO 430334 3HIM SLIOA 091 H3AO S309 39V TOA SIHL 41 39 VL 10A OV JHL IHL NI 3SV3HONI NV TIIM 39VMNIT3TLLOWHL 9NIGIHH3AO HO ONILLIS HONH3AOO9 JHL 3NION3 HOIH JHL 30 3SV3HONI LINN OL 318VO 390419373 3HOM OL OL 9 1 ALOWSY 2987 1VNOILdO 37870 1OHLNOO 7697 HO 89M 318VO LAdNI Z N1 OL ueuudinbe 14 10 sued
11. AHL AVIN SLINOHI9 TOHLINOO 414114 3HIM S LIOA 071 S309 ADVLIOA SIHL Al 39V L10A OV JHL AHL NI 3SV3HONI NV ASNVO TIM AILLOHHL AHL 9NIGIHH3AO HO 35 HONH3AOO JHL ONIONVHO INdH 31d JHL AO 3SV3HONI ADYNOS FINGOW T1OHLINOO OL NI LINSAY NOILISOd HOLIMS LO3HHOONI JINGOW 1 1 3494340 OL SNILdW3LLV 3401434 NOILISOd JYNSOTO 19 1 9 1 IHL NI SI HOLIMS IAOW 31000W 1OHINOO 1VH L 3805 38 q18VO AGOYLOATA FINGOW 1OHLNOO OL MYOM OL AYOM OL 3904153713 LAdNI 315v1d323u 01 1694 330334 Nid pT 312v1d323u 3LOW3Y Nid 9 100dS S6 8VM 1OH1INOO 95 887 1 ASIT jueuudinbe 10 sous 10 sued ont jou og e esn jejsui pjnous AIUO e Buls e10Jeq sued Bui vou Aeme des e AYALLVG 3ALLVO3N 19euuoosiq e goed ui e uedo sjeued jou e ejnlu ub 44 ONIAOW IIR D ONINUVM Y INVHOVIG NOILO3NNOO Nf19 1OOdS 2877 8877 OL L69M 006 H3aNVININOO COMMANDER 300 LINCOLN E DIAGRAMS F 5 F 5 CONNECTION DIAGRAM 886825 ALVINSNI ATIVNIAIGNI QV31 GASNNN HOYA ALV
12. WIRE WELDING mode In this mode increasing the number from 1 to 10 changes the arc from soft and washed in to crisp and narrow It acts as an inductance control The proper setting depends on the application and operator preference In general Mig welding performs best in the SOFT range and Innershield in the CRISP range 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 fil ter housing is in the open position lever to be in line with the hose 2 Check for proper oil level on the oil dipstick Close engine compartment door 3 Remove all plugs connected to the AC 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 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 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 indi cated problem 9 Allow the engine to warm up at low idle speed for several minutes before applying a
13. ANNOYS 1004 3NI9N3 9115 AUSLLVE T3Nvd 104100 NO anis SS3NWUVH 3NI9N3 85 Tree DIAGRAMS elp oyioeds eu eez SS veez 922 aoc nme age Se SE vzoz sjaued y jo euo UO y episui pejsed si sened ano 35 aionanos 82d NOIL231O0WUd 3NION3 ud a mmm 1031802 40 1H9Iu WOLLOS NO anis ano NO savmav HOLIMS 323105 10u1NO2 ONIGTAM SSANYVH 1081 2 SSINUVH 1081 2 mmm j NOILISOd 1 201 NI NMOHS HOLIMS aaivinsNi soz 1v501 ee 310W3wu 104 dove _ 14 Aq JO ejeJnooe eq jou 3 AJUO 10 SI 414 310 82d 1031405 ef ez ore tt si zz ferz 9 os 3 oke lt 3 wdLovLNOD a gea PER ouged 2 au v 824 SSVdA8 du m 1 nouo 310w3u som ovinoo 1 ovastt ee
14. No toque las partes los electrodos bajo carga con la piel ropa moja da Aislese del trabajo y 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 Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra ORBPORBARA OHLMPT APYORAPHRBS NTWSHRELTFSU An Xe snp e AXE ole Lei do ill M xl QuAL ye 1 ASI asi AI Qu ule tn e Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos CORRE THEN EA e i 9 E Vi ML IF AT AIX uie 082231 ALD 351 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
15. 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine 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 c ble de soudage et la machine souder en 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 Si on utilise la machine souder comme une source de 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 enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v
16. HINHOISNVUL mort as ws 3815 1337 JOYLNOD 30 anis SONIGNIM AYVITIXNY 301915 WIRING DIAGRAM F 3 10H AUYIIXAY yo 1VNOILdO 2VACT TOULNOD NO u3MOd AUVITIXNY 14 ce M 31NGOW 7 ANIS 1v3H ee 11 330H2 f f wk ANIS 1v3H vos im I p 824 ssvdAgil COMMANDER 300 LINCOLN E luo 69VOT NVHOVIG 13HON 165 006 YAGNVWWOD DIAGRAMS F 4 F 4 CONNECTION DIAGRAM 116810 NI HOLIMS NOILISOd 3 LOWY NI HOLIMS 310W3H 1V201 39V1d J19YLd303Y Nid 9 OL GALOANNOO SI TOHLNOO LNdLNO SLOWAY 2987 IWNOILdO dl NOILISOd Q3TIOHINOO ATA3LOW3H OL HOLIMS S IVNIINH3I 39V Id S9NIGQT3JM OL HOLIMS HOLO3T13S AHL NOILISOd 1004191413 Q3HIS3Q LO313S OL HOLIMS H313IALL1OA ASN AN WANVW 9NILVH3dO 33 SNOILVO dd A4N1N1 ALVIGAWWI 30 41949 LN3HHWfO ALIOVdVO H3dOud AO LSNW 18YO ONIGTAM WANVW SNILVH3dO H3Q T3M JHL NI GALSIT SNOILVOISIDAdS INdH LsNrdv LON Od AHOLOV4 AHL LV 13S738d SI ONILLAS HONH3AOO9
17. Stop engine before servicing Keep away from moving parts Only qualified personnel should install use or 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 MOUNT OVER COMBUSTIBLE SURFACES Where their is a combustible surface directly under sta tionary or fixed electrical equipment that surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides STORING 1 Store 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 f 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 A
18. e Burores syed Aeme doay e JALLVO3N 1 euuoosiq e eoel d ui desye uedo sjeued jou e ONINSHVM WV NVYSVId NOLLO3NNOO 3 INGOW TOULNOI 104110 31034 110 L vC99l SC N T S83Q TSM 3NISN3 COMMANDER 300 LINCOLN E F 13 966825 NOILISOd SAYMIY S IVNIINH3 IL AHL NI 38 LSNW HOLIMS 104110 AHL NOILISOd 10 NI HOLIMS 3 L0W3H 1V901 30V 1d dasn SI TOHLNOO LNdLNO 31L0IN3H 41 ALIHV TOd 1404191413 GAYISAG LOATAS OL HOLIMS HALAINLTIOA ASN DIAGRAMS F 13 CONNECTION DIAGRAM IWANVW S9NILVH3dO 335 SNOILVOMddV AYNLNA 31VIQ3IAWI 40 41949 ALNG ANY LN3HH IO JHL ALIOVdVO YAdOdd 30 LSNW 1 ONIGTAM MYOM OL MYOM OL qd18vo 1040419113 QV31 4119 MHOM Sc N1 OL 3G00ul10313 TOYLNOS ALOWAY 1 IWNOILdO jueuudinbe 141 sous 10 esn je1sui pjnous AIUO e sued des e ui des e ejnlur up 14 ONIAOW TONAHdNV TONAHdNV 9 tL sued Ajeoujoeje og e 3ALLVO3N 19euuoosiq e uedo sjoued 4 jou e 115 uo ele Se Ter RE ONINUVM P TOULNOO ALOWSAY 1 IWNOILdO
19. or K857 1 remote voltage control cable attached LOCAL for LN 7 with no remote voltage control d Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode being used e Set the SELECTOR switch to the WIRE WELD ING position f Adjust the ARC CONTROL knob to desired Crispness SOFT for MIG CRISP for Innershield g Set the WELDING TERMINALS switch to the WELDING TERMINALS REMOTELY CON TROLLED position h 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 A 9 INSTALLATION A 9 CONNECTION OF AN LN 23P WIRE FEEDER TO THE COMMANDER 300 a Shut the welder off b Connect the LN 23P as per instructions on the appropriate connection diagram in Section 4 NOTE When connecting an LN 23P to the Commander 300 a K350 1 adapter kit must be used c Set the VOLTMETER switch to d Set the SELECTOR switch to WIRE WELDING position e Set the WELDING TERMINALS switch to WELD ING TERMINALS ALWAYS ON f Set the ARC CONTROL to desired crispness SOFT for MIG crisp for Innershield g Set the LOCAL REMOTE switch to the desired setting depending upon where the power sources output is being controlled from h Set the IDLE switch to the HIGH position If you are using an LN 23P with the K350 1 adapter kit the electrode i
20. re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c 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 zones ou l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d 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 incendie 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 c bl
21. 1VNOIS V LVHL S430334 HOS OL 7 8 LINN 9393 3HIM OL 114100 3LOWSY 0 91 379 2404193713 H u3MOd 40 IVNINHAL OL SLO3NNOO HHOM OL NOLLO3NNOO 1 Y30334 SHIM o 12 NOLLO3NNOO 08 O 05 YOM OL 3004193713 OVAS uL lt 0 16 0 OVAG LNdLNO 9NIQT3M e H3ldVav H3H13901 1L93NNOO TWSUYAAINN 2989 O uvds S3ounos YAMOd H3QNVWINOO NO 045010 28 A 0 18 TONSHdNV vl jueuudinbe 14 4 10 sued Aje2u199Jo OG e pjnous jeuuosiod AIUO e BUIDIAIOS sued Aeme des e qva AYALLVG 3ALLVO3N 19euuoosiq e sed ui doay e uedo sjoued jou og e einlul 14 ONIAOW l ub 32OHS 21419313 ONINUVM W INVHS VIG NOLLO3NNOO H3 LdVQV 2987 OL 006 H3Q0NVIWINOO COMMANDER 300 LINCOLN E DIAGRAMS F 8 F 8 CONNECTION DIAGRAM 686825 ALVINSNI SQV3139lr1dS ATIWNGIAIGNI GASNNN H VA ALVINSNI NOILISOd NI HOLIMS SLOWAY 1V90 1 39V Id S9NIGT3M OL HOLIMS HOLO3 T13S NOILISOd ALIHV TlOd 3040419413 Q3HIS3G LOATAS OL HOLIMS HALAWLIOA ASN 4 N IWANVW 9NILVH3dO 335 SNOILVOIddV 890 ALVIGAWWI 40 3
22. 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 8 1 MAINTENANCE 1 SAFETY PRECAUTIONS A WARNING eHave a qualified technician do the maintenance and troubleshooting work eTurn the engine off before working inside the machine eRemove guards only when necessary and replace them when the maintenance requiring their removal is complete eAlways use the greatest care when working near moving parts 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 a Check the crankcase oil level b Refill the fuel tank to minimize moisture condensa tion in the tank c 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
23. Manual for specific fuel recommendations The Commander 300 Deluxe is 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 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 pro cedures 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 connect to new battery last e CONNECTING A BATTE
24. and then adjust the CONTROL for 140 amps When a forceful digging arc is required use a higher setting and lower the open circuit voltage For example to obtain 140 amps and a forceful arc set the SELEC TOR to the 230 MAX position and then adjust the CONTROL to get 140 amps CONSTANT CURRENT CC WELDING The most clockwise position of 30 to 375 the SELECTOR Switch is designed for horizontal welds with all types of electrodes especially low hydrogen The CONTROL 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 Commander 300 can be used in a wide variety of DC Tungsten Inert Gas TIG welding applications When used with the K930 1 or 2 TIG module or K799 Hi freq unit ratings are limited to 375A at a 20 duty cycle 300A at a 60 duty cycle and 250A at a 80 duty cycle COMMANDER 300 LINCOLN 8 B 8 OPERATION B 8 Table B 3 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES Tungsten Electrode 1 2 Diameter Thoriated Tungsten 1 2 Thoriated Tungsten 2 15 5 20 15 80 70 150 150 250 2
25. 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 maintenance schedule of the following Engine Oil and Filter Air Cleaner Fuel Filter and Delivery System Cooling Blower Belt Battery Cooling System 0e 0 5 2 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 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 4
26. 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 capacity rating in watts is equivalent to volt amperes at unity power factor The maximum permissi ble current of the 240 VAC output is 44 A The 240 VAC output can be split to provide two separate 120 VAC out puts with a maximum permissible current of 44 A per out put to two separate 120 VAC branch circuits The output voltage 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 auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the cur rent 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
27. for typical fuel consumption of the Commander 300 s Engine for various operating sce narios Table B 2 Deutz F3L 912 Engine Fuel Consumption 29 Hp 1800 RPM 25 gallons Hours Low Idle No Load 1400 RPM 27 gallons hour 1 02 liters hour 48 gallons hour 52 1 81 liters hour 1 34 gallons hour 5 07 liters hour High Idle No Load 1900 RPM DC CC Weld Output 300 Amps 32 Volts Auxiliary Power 10 000 VA WELDER OPERATION 1 32 gallons hour 5 00 liters hour STICK WELDING The Commander 300 can be used with a broad range of DC stick electrodes The SELECTOR switch provides five overlapping slope controlled current ranges The CONTROL adjusts the current from minimum to maximum within each range Voltage is also controlled by the CON TROL in the slope controlled setting These slope con OPERATION B 7 trolled settings are intended for out of position weld ing including pipe welding where the operator would like to control 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 a soft arc characteristic set the SELECTOR Switch to the lowest setting that still provides the cur rent you need and set the CONTROL near maximum For example to obtain 140 amps and a soft arc set the SELECTOR Switch to the 150 MAX position
28. 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 d Set the SELECTOR switch to the WIRE WELD ING position e Set the WELDING TERMINALS switch to WELD ING TERMINALS ALWAYS ON f 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 g 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 A CAUTION 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 a Shut the welder off b Connect the LN 7 or LN 8 per instructions on the appropriate connection diagram in Section 4 c Set the LOCAL switch to REMOTE for the LN 8 or LN 7 with a K857
29. 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 SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Step 3 RECOMMENDED COURSE OF ACTION If you have exhausted all of the items in step 2 Contact your Local Lincoln Authorized Field Service Facility Symptoms are grouped into the following categories engine problems function prob lems and output problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover 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 8 E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMME
30. perschutz Use para a vista ouvido e corpo e BH HRUBS ISUCRSREUCT ez 12 59 s ESSA due gulag cl ysl e dang 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 STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventilac o e exh
31. that the engine has been running This meter is a useful indicator for scheduling preventive maintenance COMMANDER 300 LINCOLN 8 B 5 OPERATION WELDER CONTROLS Items 9 through 14 9 OUTPUT SELECTOR SWITCH 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 Output Range Switch and Output Control Functions Switch Sloped Output for Pipe Welding 5 Range Settings 60 90 150 230 300 Max current on each setting Provides a fine adjustment of welding current from 1 Range setting Min 1 to Max 30 375 Amps 10 within each range Constant Current Output for Fabrication and General Purpose Welding This set ting also used for TIG Provides Fine Voltage Adjustment 1 Range setting 12 to 40 Volts Constant Voltage Output for MIG Wire or CORED WIRE Welding 1 If the SELECTOR switch is positioned between settings the previ ous setting is maintained until the switch is properly positioned on a setting CONTROL 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 meters allow the output current level to be set prior to welding in stick mode and volt
32. up to the specified length from the welder Has convenient plug for easy connection to the welder The Commander 300 is equipped with a 6 pin connector for connecting the remote control and a toggle switch for selecting LOCAL output con trol or REMOTE output 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 TWO WHEEL TRAILER For road in plant and yard towing Road towing with optional fender amp light kit For highway use consult applicable federal state and local laws regarding possible additional requirements K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender amp Light Kit K965 1 Cable Storage Rack K887 1 ETHER START KIT Provides maximum cold weather starting assistance for frequent starting below 10 F 12 2 C Required Ether tank is not provided with kit 524647 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 instructions Replaces the factory installed 115V duplex receptacle The receptacle of the GFCI duplex is rated at 20 amps the maximum total current from the GFCI duplex is
33. 0 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 ment toward a bright light Check for damaged gaskets 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 A cleaned filter will have approximately 70 of the life of a new filter element A restricted filter element may not appear excessively dirty COMMANDER 300 LINCOLN 8 D 2 MAINTENANCE D 2 FUEL FILTERS A WARNING When working on the fuel system Keep naked lights away do 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
34. 19A9 ALNG LN3HHD JHL ALIOVdVO H3dOHd 40 LSNN 3 18VO ONIGTAM IVONVIN ONILV43d0 H3Q 13M 3NION3 NI Q31ST1SNOILVOI3IO3dS 3AO8V 15 LON Od AHOLOVJ JHL LY 135 384 SI ONILLAS HONH3AOO ANIONA JHL O39 VIVO 38 AYN SLIN9419 1081405 Y30334 3HIM SLIOA 09 H3AO 309 39VLTOA SIHL dl 39VL 10A AYYNIXNY OV AHL NI 3SV389NI NV 3Sn v9 TIM 39 VMNIT31LLOSHL 9NIGIHH3AO ONILLAS HONH3AO9 JHL 9NIDBNVHO 3NION3 4101 H9IH SHL 40 ASVAYONI NOILNVD O _ Q334 3HIM OL g gi AGOYLOATA HOM OL LAdNI TWSYSAINN 2987 96 EM AYOM OL 3aoui031 1 Y30334 8 2 jueuudinbe 14 10 syed 9 jou OG e asn je sul pjnous e syed Aeme e ava 3ALLVO3N 12euuoosiq e goed ui e uedo sjoued ejeJedo jou e einiul UD 14 ONIAOW IP uo ONINUYM W INVHSVIG NOILOANNOO 8 N 2987 006 H3ONVINIWOO COMMANDER 300 LINCOLN E F 9 998LTW Y30334 390415373 Y30334 390415373 SANWL 13014 YO S3UIM SLNANOdWOD 71V2Iu12313 OL GALIWIT LON 1 9 5 HONS SLN3NOdWOO 3NIHOVW 39VWVG
35. 1M Some recommended solid wires for MIG welding are 035 0 9 mm 045 1 1 mm and 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 recommendations 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 COMMANDER 300 LINCOLN 8 B 10 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 20 120 5 20 R 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 15 Amps for codes below 10500 only The auxiliary power capacity is 10 000 watts of 60 Hz single phase power The auxiliary power capacity rating 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 parall
36. 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 Indicator lights for low oil pressure high oil tempera ture engine alternator low output broken belt and low fuel level on K1585 2 only Automatic low fuel shutdown before running out of fuel K1585 2 only Engine hour meter standard on all models Extended range 25 gallon 94 6 1 fuel tank Automatic 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 The K1585 1 is the standard version of the Commander 300 and has all the features of the K1585 2 Deluxe version except that there are no gauges low fuel light nor dual output meters This version does have fully functional engine protection for low oil pressure high oil temperature and alter nator output with associated lights A field installed Dual Out
37. 50 400 400 500 500 750 750 1000 Approximate Argon Gas Flow Rate I min Stainless Steel 8 2 4 3 5 3 5 TIG TORCH Nozzle Size 4 5 3 3 8 2 4 3 5 3 5 3 5 4 6 6 8 7 11 5 7 10 12 11 13 13 15 6 8 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 5 5 16 6 3 8 7 7 16 8 1 2 10 5 8 6 8 10 11 12 5 16 5 TIG torch nozzles are typically made from alumina ceramic Special applications may require lava nozzles which less prone to breakage but cannot withstand high temperatures and high duty cycles Commander 300 SETTINGS WHEN USING THE K799 HI FREQ UNIT a Set the SELECTOR switch to the 30 375 setting STICK TIG b Set the IDLER switch to the HIGH position c Set the LOCAL REMOTE switch to the REMOTE posi tion d Set the WELDIN
38. 6 pin connector located on the control panel allows for connection of interfacing equipment 14 WELD OUTPUT TERMINALS AND These 1 2 13 studs with flange nuts provide welding connection points for the electrode and work cables For positive polarity welding the electrode cable con nects to the terminal and the work cable connects to this terminal For negative polarity welding the work cable connects to the terminal and the elec trode cable connects to this terminal AUXILIARY POWER CONTROLS Items 15 19 15 120 240VAC RECEPTACLE This is a 120 240 14 50R receptacle that pro vides 240VAC or can be split for 120VAC single phase auxiliary power This receptacle has a 50 amp rating Refer to the AUXILIARY POWER RECEPTACLES sec tion in the installation chapter for further information about this receptacle Also refer to the AUXILIARY POWER OPERATION section later in this chapter 16 50 AMP CIRCUIT BREAKERS These circuit breakers provide separate overload rent protection for each 120V circuit at the 240V recep tacle COMMANDER 300 LINCOLN 8 B 6 OPERATION B 6 17 120VAC RECEPTACLES These two 120VAC 5 20 R receptacles provide 120VAC for auxiliary power These receptacles have a 40 amp total rating Refer to the AUXILIARY POWER RECEPTA CLES section in the installation chapter for further infor mation about these receptacles Also refer to the AUXIL IARY POW
39. 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 Gr 7 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 engine 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
40. Commander 300 to Premises Wiring 240 VOLT GROUNDED CONDUCTOR 60 Hz d Service METER LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION 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 N 50 AMP 120 240 VOLT n RE RECEPTACLE NOTE No 8 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS COMMANDER 300 LINCOLN A 8 INSTALLATION A 8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS A WARNING Shut off welder before making any electrical connec tions 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 appropri ate connection diagram in the ACCESSORIES section NOTE The LN 25 K431 Remote Control Module and K432 Remote Cable are not recommended for use with the Commander 300 a Shut the welder off b 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 electrode Negative connect the electrode cable from the LN 25 to the terminal of the welder and amp work cable to the terminal of the welder c Attach the single lead
41. ER OPERATION section later in this chapter 15 Amps per receptacle up to 30 Amps total for codes below 10500 only 18 20 AMP CIRCUIT BREAKERS These circuit breakers provide separate overload cur rent protection for each 120V receptacle 15 Amps for codes below 10500 only 19 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 21 15 AMP CIRCUIT BREAKER This circuit breaker provides overload protection for the 120 VAC in the 14 pin connector 22 VOLTMETER SWITCH Changes the polarity display on the wire feeder 23 15 AMP CIRCUIT BREAKER This circuit breaker provides overload protection for the 42 VAC in the 14 pin connector 24 14 PIN CONNECTOR For quick connection of interfacing equipment 25 ARC CONTROL The ARC CONTROL potentiometer is active in two modes STICK TIG and WIRE WELDING with dif ferent purposes in each mode STICK TIG mode In this mode the ARC CON TROL knob sets the short circuit current during stick welding Increasing the number from 1 to 10 increases the short circuit current This prevents sticking of the electrode to the plate at low welding current settings This also increases spatter It is recommended that the control be set to the minimum number without elec trode sticking
42. ETHOD OF PAYMENT Sorry No C O D Orders CHECK ONE Address Please Invoice only if order is over 50 00 Check or Money Order Enclosed U S Funds only 1 Credit Card Telephone Signature as it appears on Charge Card er No III ee ate LI Ly i USE THIS FORM TO ORDER Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 looks OR FREE INFORMATIVE CATALOGS Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 li incon Welding School Titles Price Code Quantity Cost 80 New Lessons in Arc Welding 5 00 L Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings H Lec ees Incentive Management IM New Approach to Industrial Economics 5 00 NA Educational Video Information ED 93 lames F Lincoln Arc Welding Foundation Book Information JFLF 515 Welding Preheat Calculator 5500 WC8 Pipe Welding Chats 3450 SUB TOTAL Acton Shipping Costs Ce ee ee ee ee l WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground
43. G TERMINALS switch to the Welding Terminals Always 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 TIG MODULE a Set the SELECTOR switch to the 30 375 Setting STICK TIG b Set the IDLER switch to the AUTO position c Set the LOCAL REMOTE switch to the REMOTE posi tion d Set the WELDING TERMINALS switch to the Welding Terminals Remotely Controlled position This will keep the solid state contactor open and provide a cold electrode until the triggering device Amptrol or Arc Start Switch is pressed COMMANDER 300 LINCOLN 8 B 9 OPERATION WIRE FEED CONSTANT VOLTAGE WELD ING 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 Outershield electrodes and solid wires for MIG welding gas metal arc welding Welding can be finely tuned using the ARC CONTROL Some recommended Innershield electrodes are NR 311 NS 3M NR 207 NR 203 Ni 1 NR 204 H Recommended Outershield electrodes are 05 70 05 7
44. ILOANNOO IVA SIT 83Q13M ANION ddd 13M 01 MIGWASSV LIX YAldvdv N31SVJ OL WAHL 350 NMOHS SM3UDS 33UHl1 FHL 2 LI NI 310H d1VH V SVH 1 udldVQOV JHL AI WSSV ddldVOV NO L3592VW8 ONILSIXA 39V1d34 T SNOILONYLSNI NOILVTIVISNI COMMANDER 300 F 10 166625 NOILISOd SAVM TV SIVYNIWY3L AHL NI 38 LSNW HOLIMS 10411100 AHL NOILISOd NI HOLIMS 3 L0W3H 1V901 30V ld 35 SI TOHLNOO 10 100 31088 41 ALIHV TOd AGOYLOATA Q3HIS3G LOATAS OL HOLIMS H33IALL 1OA ASN DIAGRAMS F 10 CONNECTION DIAGRAM IWANVW S9NILVH3dO 335 SNOILVOMddV AYNLNA ALVIGAWWI 30 41949 ALNG ANY LN3HHfIO AHL ALIOVdVO HO LSNW ATEVO ONIGTAM MYOM OL MYOM OL QV31 do MHOM Sc N1 TOYLNOS J LOWY 29872 1VNOILdO u wdinb 14 10 esn j ejsur pjnous e sued des e ooejd ui des e e1nlur up SIYWd ONIAOW qd18vo 1040419113 OL 3004193173 TONSAHdNV Nid vb TONAHdNV Nid 9 sued Ajeouoo o jou og e AH3LLVa 3ALLVO3N 12euuoosiq e uedo sjoued jou e IIR u09 ONINUVYM P JOuH LNOO AL
45. INSNI 5804 3 L0IN3H NI HOLIMS 3 LOW3 17901 aasn SI TOHLNOO 104100 310Wa3H TWNOILdO 4 NOILISOd 3 18VO 71031405 H3Q334 OL HOLIMS H3Q334 3HIM 39V Id SNIGQ T3M 3HIA OL HOLIMS HOLO3T3S AHL NOILISOd ALIHV 10d 3004191413 Q3HIS3G LOATAS OL HOLIMS YALAWLIOA ASN HN TWANVIN 9NILVH3dO 33 SNOILVONMIddV ALVIGAWWI 40 310A9 ALNA 1 AHL 303 ALIOVdVO 40 38 LSNW ATAVO ONIGTAM VN TWANVIN 9NILVH3dO H3QTT3M ANIONS JHL NI 031511 SNOILVOISIOAdS 3409Y 15 LON 00 AHOLOV4 LV 13S 3ud 35 YONYSAOD 3H1 39 VIAVG 38 AVN SLINDYID 3343334 SHIM 5110 091 309 39V L10 SIHL 41 SDVLIOA OW NI 3SV3HONI NV ASNVO JILLOYHL JHL 9NIGIHH3AO ONILLAS HONH3AO9 JHL 9NISNVHO 3NI9N3 4101 40 3SV3HONI ANY SLOWSY HN TWNOILdO 9277 2 LINN 38IM OL 41 2004191313 94 _O 91 GL O MYOM OL N33H5 3 18VO LNdNI aNd Hadldvav HO 1627 IVSH3AIN 2983 O 33003912313 v O 10N3HdWV Nid ce O 334333 jueuudinbeo si 2 10 syed A jeoujoosje jou e esn jejsui pjnous jeuuosied e e10Jeq sued
46. INVH9VIG NOILO3NNOO AHL 55 Sc N1 006 HIONVWWOI COMMANDER 300 LINCOLN E DIAGRAMS F 14 F 14 CONNECTION DIAGRAM 290925 SV ATI wHDIHs NIHOLIMS 44101 NOILISOd 1 IOHLNO9 3 LONW3H NI HOLIMS T1OHLNOO 111100 39V 1d NOILISOd Q3TIOHINOO ATALOWSY OL HOLIMS S IVNIAH3 L H3Q13M 39V ld ALIH V TlOd 3040419313 Q3HIS3G 193 13S OL YACTAM 30 SGNLS 3ALLVO3N 3ALLISOd AHL OL 3 InGOMW 9IL dO SQV315IHOM 3904195753 HOVLLV SN IWANVW SNILVH3dO 335 SNOILVOl1ddV 1 ALVIGAWWI 40 319A9 ALNA ANY LN3HHO JHL ALIOVdVO 40 LSNW S3 18VO ONIGTAM IWANVI SNILVH3dO JHL NI 43 5301191519345 3409Y 15 LON OG AHOLOVJ JHL LV 135 9 SI DNILLAS HONH3AOO 3NION3 JHL Q39VINVG AVW SLINOHIO 1031409 Y30334 3HIM SLIOA 091 H3AO S309 ADVLIOA SIHL 41 39V L1OA OV AHL NI 3SV3HONI NV 3SnvO 39VHNIT A1LLOHHL 9NIGIHH3AO HO ONILLAS JHL AG 3NION3 JAI HOIH JHL 30 3SV3HONI NOILOVO HOLIMS 1 15 71872 OL 2404191313 JOULdNV GNVH L 96H TONAHdWIV Nid vt HO J18VO 1 1 TOULdINV 1004 0783 L 9 63 ONILLIS LANI 00 YIGNVWWOD SV9 NO9uV H313INMO 14 d01V1N934 jueuudinbe 14
47. NDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION ENGINE PROBLEMS Major Physical or Electrical Damage 11 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 Low battery voltage Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance Engine shuts down shortly after Low fuel Indicator light lit K1585 starting 2 only Add fuel Low output of battery charging alternator Indicator light lit Check cooling blower belt Replace if neccessary High oil temperature Indicator light lit Check engine cooling system Consult engine service dealer Battery does not stay charged Faulty battery Replace A 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 8 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED S
48. NGLE 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 is 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 d Secure the lift bale with 2 thread forming screws The screws are provided in the shipped loose parts bag A WARNING FALLING EQUIPMENT can cause injury Do not lift this machine using lift bale if it is equipped with a heavy accessory such as a t
49. OL LON SV 3801 SI duvO 1VI2ddS u3d13M OL ONILNNOW NAHM NOILN VI NOILISOd 034110 2 STIVNIIWU3I 13 NI 38 LSNAW HOLIMS 1 INdINO AHL AN DIAGRAMS F 9 CONNECTION DIAGRAM NOILISOd wS LOWS NI HOLIMS 310W34 1V907139vV1d ddsn SI 1OYLNOD 104100 ALOWSY 417 OL HILIMS YOLIAIAS JHL NOILISO d ALIYV1Od 10019313 034154 123135 OL HILIMS YALAWLIOA ISA ddldvav NI 41515 Y30334 OL LOANNOD G4SN SI d Z N1 INO AINO dl 53215 TWANVW ONILVYAdO 33S SNOILVOITddv 3unind ANY ALVIGAWWI 40 31949 ALNG ANY LN3YYND FHL 4 30 38 LSNW S318VO ONIGTAM SNOILINLYSNI ONILVYAdO 4 8 430334 334333 d Z N1 318 YOLINAGNOD 6 300912313 TlON3HdNWV Nid U3Q13M jueuudinbe 14 eorues 10 esn jre1sur pjnous Ajuo e sued e goed e e1nluj ub Spivd ONIAOW ibd sued jou e Burorues Qva1 3ALLVO3N 12euuoosig e uedo sjeued eje1edo jou og e NDOHS 1419113 ONINUVM Y LIM Hd3LdVQV d c N1 OL 00 H33aNVININOO 1 130 NOILVTIVLSNI 8 INVg89VIG NO
50. OWAY 21987 IWNOILdO HLIM INVH9VIG NOILOANNOO AHL SSOUOV 90 1 006 H30NVIWINOO COMMANDER 300 LINCOLN E DIAGRAMS F 11 F 11 CONNECTION DIAGRAM 266625 NI HOLIMS SLOWSY 1V9071 39V Id SNIGTAM OL HOLIMS HOLOATAS AHL NOILISOd ALIHV lOd 1404191311 6 LOATAS OL HOLIMS YSALAWLIOA ISN IWANVW 9NILVH3dO 335 3uninad ANY ALVIGAWWI 40 41949 ALNG LN3HHfIO ALIOVdVO YAdOUd AO LSNW ST T8VO SNIQT3JM IWANVIN 9NILVH3dO 3NION3 AHL NI 31511 SNOILVOISIOAdS Wd 3AOG amp YV LSNFGV LON OG AHOLOVH AHL LV 135 39 SI 9NILL3S HONH3AOO ANIONS AHL AVIA SLINOHI9 TOHLNOO H3Q33H SHIM SLIOA 071 S309 ADVLIOA SIHL 41 ADVLIOA OV JHL FHL NI 3SV3HONI NV ASNVO ATLLOYHL AHL 9NIGIHH3AO HO 35 HONH3AOO JHL Ad 3NION3 JHL 30 3SV3HONI LINN 3HIM OL 24041913 MYOM OL 3HOM OL 3004191313 TONSHdNV Nid vb 371970 lOH LNOO S69 2 INdNI 8 N1 OL jueuudinbe siy eoriues 10 sued Ajeouoeje oq e pjnous Ajuo e syed Aeme qva AYALLVd 3ALLVO3N 12euuoosig e ui doay e uedo sjeued ejeJ
51. RETURN TO MAIN MENU RENT IM601 A Commander 300 For use with machines having Code Numbers 10469 10642 Standard 10470 10643 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 Date of Purchase Serial Number Code Number Model Where Purchased OPERATOR S MANUAL e C ISO 9001 nme Gun Designed and Manufactured Under a i by Quality Program LINCOLN Copyright 2001 Lincoln Global 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 A For Diesel Engines Diesel engine exhaust and 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 defects and State of California to cause cancer birth defects other reproductive harm or o
52. RY CHARGER remove battery from welder by disconnecting neg ative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated e USING A BOOSTER connect positive lead to battery first then connect negative lead to negative battery lead at engine foot gt BATTERY ACID can burn eyes and skin e Wear gloves and eye protection and be careful when working near battery 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 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 ca
53. 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 E FUEL LEVEL GAUGE AND LIGHT K1585 2 only Displays the level of diesel fuel in the 25 gallon fuel tank The yellow light turns on when the fuel gage reaches the reserve level Once 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 8 B 4 OPERATION B 4 4 ENGINE TEMPERATURE GAUGE 1585 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
54. YMPTOMS MISADJUSTMENTS S COURSE OF ACTION FUNCTION PROBLEMS Engine will not idle down to low Idler switch in High idle position speed Set switch to Auto External load on welder or auxil iary power Remove all external loads Engine will not go to high idle when 1 Poor work lead connection to attempting to weld work Make sure work clamp is tightly connected to clean base metal Welding Terminals switch is in wrong position Set to Always On when welding without a weld ing terminal control cable Refer to Operations chapter for proper Contact your Local Lincoln Authorized use of this switch Field Service Facility for technical troubleshooting assistance Engine will not go to high idle when 1 Auxiliary power load is less than using auxiliary power 100 watts Idler may not respond with less than a 100 watt load Set Idler to High A 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 8 E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION OUTPUT PROBLEMS No welding power output Welding terminals switch in wrong position Place switch in Always On positio
55. 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 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 1 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 A 7 INSTALLATION A 7 2 Take necessary steps to assure load is limited to the 3 Install a 50 amp 120 240 VAC plug NEMA Type 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 conductor cable of the desired length The 50 amp rated 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 plug kit reduce output voltage below the allowable 10 of rated voltage which may damage appliances or 4 Plug this cable into the 50 Amp 120 240 Volt recep other motor driven equipment and may result in tacle on the Commander 300 case front overheating of the Commander 300 engine Figure A 2 Connection of the
56. age level to be set prior to welding in the wire modes During the welding process the meters display the actual output current and voltage within 1 10 accuracy 11 WELDING TERMINALS SWITCH The toggle switch on the control panel labeled Welding Terminals Always On and Welding Terminals Remotely Controlled is used to control the operation of the solid state contactor which allows for the selection of Hot or Cold welding terminals B 5 With the switch in the Welding Terminals Always On position the contactor is closed and the welding termi nals are always Hot With the switch in the Welding Terminals Remotely Controlled position the contactor operation is con trolled 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 12 LOCAL remote SWITCH The toggle switch on the control panel labeled Local Remote gives the operator the option of con trolling the output at the welder control panel or at a remote station For remote control the toggle switch is set in the Remote position For control at the welder control panel the toggle switch is set in the Local position 13 6 PIN CONNECTOR The
57. ance 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 COMMANDER 300 LINCOLN A 4 INSTALLATION PRE OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc tions supplied with this machine A WARNING hands away from the engine muffler or HOT engine parts Stop engine and allow to cool before fueling Do not smoke when fueling Fill fuel tank at a moderate rate and do not overfill Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank OIL The 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 Operators 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 Operators Manual for the proper ser vice and maintenance intervals FUEL USE DIESEL FUEL ONLY Fill the fuel tank with clean fresh diesel fuel The capac ity of the fuel tank is 25 gallons 94 6 liters See engine Operators
58. aust o para remover fumo da zona respirat ria 6 9 fsPBHEILTABSSUCFEU c EUR e SH7IAE 5 25 MASH AH 7145 714 7 iua duly axial oe ial uc Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio 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 servico toque as partes el tricas nuas e LFF YA H ERIRUD PSB ETRRAT FE e HERES BEER e AIR pil gS ghil e Do not operate with panel open or guards off No operar con panel abierto guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e EX CRMBIFELEWTE EU CRRRIARRARS Ro egado wel AREY Gals 13 lla Gada ve
59. 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 proper 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 no 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 exte
60. ctrode and Work Cables TOTAL COMBINED LENGTH OF ELEC TRODE AND WORK CABLES AMPS Up to 150 150 200 FT 200 250 FT 100 FT Duty Cycle MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary 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 a be grounded to the frame of the welder using a grounded type plug or b 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
61. edo jou og e einiul up 14 ONIAOW ub 3 5OHS 91319313 ONINUVM Y WVH9VIQ NOILO3NNOO 8 N1 006 COMMANDER 300 LINCOLN E DIAGRAMS F 12 F 12 CONNECTION DIAGRAM L8Z02S 0002 22 01 144540 Sv NOILISOd HOIH NI HOLIMS 414101 39 1 WANVA 9NILV8H3dO 33 SNOILVOMTddV 38h ANY SLVIGANWI 40 31949 ANY LN33802 ALIOVdVO H3dO8d 40 38 LSNW 53185 ONIGTAM 314v9 300819373 40 JHL OL HOLIMS YSLAWLIOA 830333 38IM AHL NOILISOd 04416540 303 58715 LAdLNO OL 318v9 ONIGTAM LOANNOO NOILISOd 4411081 9 OL HOLIMS S IVNIIASI3LL Y3013M SOV 1d 804 JHL NI HOLIMS 3HL 39V1ld JHL NI 041511 SNOILVOISIDAdS 3AO8V LSNPAV LON OG AHOLOVA AHL LV 13S 3Md SI ONILL3S HONS3AO9 JHL TONLNOD JHL NYO HOIHM SOVLIOA 830334 OV FHL NI 3SV3SONI NV ASNVO TIM 39 VMNTET31LLOSH ONIGINYSAO ONILLAS HONH3AO9 Ad 3101 AHL 40 ASVAYONI OL NOILOVO 0344 OL 9199 3008319313 AT8N3SSV 318V9 LAdNI 9297 414V9 LAdNI OL lON3HdMAV jueuudinbe 14 10 syed A jeoujoeje uonoj jou esn ejsui jeuuosJed peyrjenb
62. eete B 1 General Description is B 1 Recommended Applications essen een B 1 Design Features and Advantages B 1 Welding Capability ret Lee ie eR Pee eee B 2 Controls and Settings si B 3 Engine Controls ee Fee Tre aaa B 3 Welder Controls iii B 5 Auxiliary Power Controls esses eene nene B 5 Engine Operation iii B 6 Starting the Engine re ener ren een nt ea d X e o deas B 6 Stopping the Engine sus B 6 Break In Period endet nieder de i dtd a due eti aerea B 7 Typical Fuel Consumption sss eene eene nene B 7 Welder Operation 4 urne e I ge e ne eai A ERR eua pa B 7 Stick etre terre B 7 TIG Welding n core is etre Bai SEU A B 7 Wire Feed Constant Voltage Welding sse B 9 Auxiliary Power Operation ui B 10 Simultaneous Welding and Auxiliary Power B 10 COMMANDER 300 LINCOLN vii TABLE OF CONTENTS ACCOSSOMIOS neers Section C Optional Field Installed Accessories C 1 Recommended Optional Equipment nennen 1 High Frequency Generators For TIG Applications C 1
63. eled 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 10 The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle SIMULTANEOUS 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 permissible 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 120 V 10 240 V 1096 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 8 C4 ACCESSORIES 1 OPTIONAL FIELD INSTALLED ACCESSORIES K802R POWER PLUG KIT Provides a plug for each receptacle Use K802N for code numbers above 10500 K802N POWER PLUG KIT Provides four 120V plugs K857 28 ft 8 5 m or K857 1 100 ft 30 4 m REMOTE CONTROL Portable control provides same dial range as the output control on the welder from a location
64. er by pushing on the throttle control rods while the engine is running we 2 d 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 At IN 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 Do not work next to welding power source Mar 95 LINCOLN 8 SAFETY 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 high risk of unavoidable or accidental contact with the workpiece or ground use the following eq
65. erstand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employers safety practices MSDS forms are available from your welding distributor or from the manufacturer Mar 95 SAFETY WELDING SPARKS can 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 Z49 1 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 have been cleaned For information purchase Recommended Safe Practices for the Preparation for Weldin
66. es de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles 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 10 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 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 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 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 fusibles Garder tous les couvercles et dispositifs de s ret leur place LINCOLN for selecting a QUALITY product by Li
67. g 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 za CYLINDER may explode 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 undercarriage or fixed support Cylinders should be located Away from areas where the
68. h NEMA class F insulation material The stator is then impregnated with three layers of high quality var nish After the stator is assembled using tie bars the entire assembly covered with an environmentally pro tective coating These measures insure trouble free operation in the harshest environments The fuel tank is made from high density polyethylene and holds 25 gallons of diesel fuel This will provide enough fuel to run for 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 applications 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 and one constant voltage range for MIG wire and cored wire welding COMMANDER 300 LINCOLN 8 B 2 OPERATION B 2 100 duty cycle at 300 amps o
69. hly read all operating and maintenance man uals supplied with your machine They include impor tant safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring elnsulate yourself from the work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside Do not stack anything near the engine MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts Only qualified personnel should operate this 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 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 wit
70. ining The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 students have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location 4 lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only IPrices include shipment 4 th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment M
71. lim ited to 20 amps Two kits are required K1596 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 include battery ammeter engine temperature and engine oil pressure Fuel gauge is not available in kit form K1597 1 42vac Transformer Kit For products requir ing 42 VAC power source RECOMMENDED OPTIONAL EQUIP MENT STICK K704 Accessory Kit which includes 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 TIG 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 WIRE FEED WELDING LN 25 e LN 7 LN 23P LN 8 NA 3 Spool Gun amp K488 Module LN 742 requires optional K1597 1 42vac trans former kit 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
72. load and or switching to high idle Allow a longer warm up time in cold weather COLD WEATHER STARTING With a fully charged battery and the proper weight oil the engine should start satisfactorily even down to about 0 F With the above and the optional ether starter kit K887 1 the engine should start satisfacto rily down to about 20 F With the above and an oil pan preheating system the engine should start satisfacto rily down to about 30 F With the above and a battery warmer the engine should start satisfactorily down to about 40 F Contact your local Lincoln Electric Representative for suggested 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 valve located on the fuel line COMMANDER 300 LINCOLN 8 B 7 BREAK IN PERIOD The engine used to supply power for your welder is a heavy duty industrial engine It is designed and built for rugged use It is very normal for any engine to use small quantities of oil until the break in is accom plished Check the oil level twice a day during the break in period about 200 running hours IMPORTANT IN ORDER TO ACCOMPLISH THIS BREAK IN THE UNIT SHOULD BE SUBJECTED TO HEAVY LOADS WITHIN THE RATING OF THE MACHINE AVOID LONG IDLE RUNNING PERIODS TYPICAL FUEL CONSUMPTION Refer to Table B 2
73. mation techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quan tity discount prices which include shipping 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and drafts men use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Tra
74. n flame weld ing arc or when the engine is running Stop the engine and allow it to cool 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 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 1 6 In some cases it may be necessary to remove safety k M 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 4 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idl
75. n when welding without welding terminal control cable Refer to Operation chapter for proper switch function Welder has output and no control Local Remote switch is in wrong position Place switch in Local position to control output at welder Place switch in Remote position to control output remotely Refer to Operation chapter for proper switch function Poor remote kit connection Check connections Faulty remote kit Replace if nec cessary Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance No auxiliary power Open circuit breakers Reset breakers If 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 A 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 8 1 DIAGRAMS WIRING DIAGRAM F 1 sjeued ainsojoUa eui JO euo UO eui paysed si 10 eip oyioeds eu 141 Aq sauluoeui
76. ncoln Electric We want you hank 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 Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above 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 A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page
77. 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 23 FUMES AND GASES can be dangerous 5 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 confined areas to insure breathing air is safe Read and und
78. p using the clamp provided with the outlet facing away 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 equip
79. ped with a 6 pin amp 14 pin connector The 6 pin 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 When remote output control is used the output control toggle switch is to be set at Remote 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 ING TERMINALS ALWAYS ON position cold welding terminals when in the WELDING TERMI NALS REMOTELY CONTROLLED position COMMANDER 300 LINCOLN A 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 Ele
80. 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 time 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 soeed provided a welding load is applied within approximately 12 seconds f the triggering device remains pressed but no weld ing load is applied within approximately 12 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
81. put Meter and Gauge Kit K 1596 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 10096 duty cycle and 375 amps 34 VDC at 6096 duty cycle The maximum open circuit voltage at 1900 RPM is 87 volts The weld current is variable from 30 to 375 amps COMMANDER 300 LINCOLN 8 B 3 OPERATION B 3 CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel Refer to Figure B 1 and the explanations that follow Figure B 1 Case Front Panel Controls ENGINE CONTROLS Items 1 through 8 1 RUN 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 PUSHBUTTON Energizes the starter motor to crank the engine With the engine Run Stop switch in the
82. railer or gas cylinder Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting 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 596 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 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 trailers 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 mainten
83. rnal 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 can result in damage to the internal charger components 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 generator 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 A WARNING Do not attempt to polish slip rings while the engine is running COMMANDER 300 LINCOLN 8 D 4 MAINTENANCE D 4 Table D 1 Engine Maintenance Components P181050 CAK 256 A297C 70206N 117 9565 117 4416 117 4482 BCI Group 34 COMMANDER 300 LINCOLN 8 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please
84. s not energized until the gun trigger is closed 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 NA 3 CONNECTION OF AN LN 742 TO THE COMMANDER 300 FOR CODES ABOVE 10500 ONLY Requires optional K1597 1 42 VAC Transformer Kit for codes below 10642 a Shut the welder off b Connect the LN 742 per instructions on the appro priate connection diagram in the DIAGRAMS sec tion c Set the LOCAL REMOTE switch to REMOTE d Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode being used e Set the SELECTOR switch to the WIRE WELD ING CV position f Adjust the ARC CONTROL knob to desired Crispness SOFT for MIG and CRISP for Innershield g Set the WELDING TERMINALS switch to the WELDING TERMINALS REMOTELY CON TROLLED position h 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 B 1 OPERATION B 1 OPERATING INSTRUCTIONS Read and understand this entire section before operat ing your Commander 300 SAFETY INSTRUCTIONS A WARNING Do not attempt to use this equipment until you have thoroug
85. tarting System Capacities 12VDC battery amp Starter Fuel 25 gal 94 6 L Oil 6 3 Qts 6 0L 32 volts 34 volts OUTPUT WELDER AND GENERATOR 30 300 Amps 87 Max OCV 1900 RPM 120 240 VAC 10 000 Watts 60 Hz 100 Duty Cycle PHYSICAL DIMENSIONS WEIGHT 1066 8 mm 800 1 mm 1602 7 mm 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 9 226 1mm for exhaust COMMANDER 300 LINCOLN 1325 lbs 601 kg A 2 INSTALLATION A 2 Read this entire installation section before you start installation SAFETY PRECAUTIONS A WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man uals supplied with your machine They include impor tant safety precautions detailed engine starting operating and maintenance instructions and parts lists _ ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring elnsulate yourself from the work and ground eAlways wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside Do not stack anything near the engine MOVING PARTS can injure Do not operate with doors open or N guards off
86. the cooling blower belt 1 Allow machine to cool 2 Remove the engine case side 3 Loosen air filter hose clamp and detach hose 4 Disconnect the negative battery cable 5 Remove the engine case back panel for access to the engine 6 Remove the pulley belt guard 5 screws 7 Remove rubber strap on lower half of engine fan cowl ing Loosen tensioning pulley 2 bolts 8 Remove the old V belt and install a new one Refer to operation manual for proper tensioning of belt Per manual tighten tensioning pulley 9 Reinstall the rubber strap on fan cowling the pulley belt guard the engine case back the Air filter hose and the engine case side 10 Reconnect the negative battery terminal COMMANDER 300 LINCOLN 8 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
87. ther 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 pur chase a 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 hy h 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 MAGNETIC FIELDS _ may be dangerous 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 1 c Do not add the fuel near an ope
88. uipment 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 LINCOLN Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 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 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that
89. utput 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 Standard remote control capability with 14 pin and 6 pin 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 Arc Control potentiometer in Wire and Stick modes for precise adjustment of arc characteristics Advanced circuitry to prevent pop outs 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 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
90. y may 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 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 iv SAFETY iv PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc

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