Lincoln Electric COMMANDER 300 IM700-D manual

Commander 300 OPERA T OR’S MANUAL IM700-D July , 2004 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS [...]

FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _______________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’ s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrica[...]

iv SAFETY iv Mar . ‘ 93 PR É CAUTIONS DE S Û RET É Pour votre propre protection lire et observer toutes les instructions et les pr é cautions de s û ret é specifiques qui parraissent dans ce manuel aussi bien que les pr é cautions de s û ret é g é n é rales suiv- antes: S û ret é Pour Soudage A L ’ Arc 1. Protegez-vous contre la se[...]

v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

T ABLE OF CONTENTS Page Safety ......................................................................................................................... i-iv Installation .......................................................................................................Section A T echnical Specifications ........................................[...]

T ABLE OF CONTENTS Accessories .....................................................................................................Section C Optional Field Installed Accessories .....................................................................C-1 Recommended Optional Equipment ...................................................................[...]

A-2 INST ALLA TION COMMANDER 300 A-2 Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manu- als supplied with your machine. They include impor- tant safety precautions, detailed engine starting, oper- ating and ma[...]

A-3 INST ALLA TION COMMANDER 300 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 hole[...]

A-4 INST ALLA TION COMMANDER 300 A-4 PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep 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 ove[...]

A-5 INST ALLA TION COMMANDER 300 A-5 MUFFLER Remove the plastic plug covering the muffler outlet tube. Using the clamp provided secure the extension to the outlet tube. This welder is supplied with an adjustable rain cap for the muffler . Install the rain cap using the clamp provided with the outlet facing away from the direction in which this unit[...]

A-1 INST ALLA TION COMMANDER 300 A-1 TECHNICAL SPECIFICA TIONS - Commander 300 Make/Model Displacement Description Speed (RPM) Starting Capacities Diesel Engine System 125 cu. in Deutz (2.05 L) 3 cylinder F3L 101 1F Bore x Stroke 31 HP(23 kw) (Codes 1 1 199 3.89 ” x 4.13 ” @ 1800 RPM Fuel: 25 gal. and Below) (99mm x 105mm) 94.6 L High Idle 1900[...]

A-6 INST ALLA TION COMMANDER 300 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 T able A.1 are copper cable sizes recom-[...]

A-7 INST ALLA TION COMMANDER 300 A-7 • T ake necessary steps to assure load is limited to the capacity of the Commander by installing a 45 amp, 240 V AC double pole circuit breaker . Maximum rated load for each leg of the 240 V AC auxiliary is 45 amperes. Loading above the rated output will reduce output voltage below the allowable -10% of rated [...]

A-8 INST ALLA TION COMMANDER 300 A-8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS ELECTRIC SHOCK can kill. S hut off welder before making any electrical connections. ------------------------------------------------------------------------ CONNECTION OF THE LN-25 TO THE COMMANDER 300 The LN-25 with or without an external contactor may be used with th[...]

A-9 INST ALLA TION COMMANDER 300 A-9 CONNECTION OF LN-15 TO THE COM- MANDER 300 These connections instructions apply to both the LN- 15 Across-The-Arc and Control Cable models. The LN- 15 has an internal contactor and the electrode is not energized until the gun trigger is closed. When the gun trigger is closed the wire will begin to feed and the w[...]

B-1 OPERA TION B-1 SAFETY INSTRUCTIONS Read and understand this entire section before operat- ing your Commander 300. Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance i[...]

B-2 OPERA TION B-2 FOR AUXILIAR Y POWER • 10,000 watts of 120/240 V AC, 60Hz auxiliary power . • Power for tools, 120/240 V AC lights, electric pumps and for standby emergency power . • Drive a 5 HP motor (provided it is started under no load). • T wo 20* amp 120 V AC duplex receptacles for up to 40* amps of 120 V AC power . * 15 Amp for ea[...]

B-3 OPERA TION B-3 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 "R[...]

B-4 OPERA TION B-4 4. ENGINE TEMPERA TURE GAUGE (K1585-2 Std., K1585-1 Opt.) AND LIGHT The gauge displays the engine oil temperature. The yellow temperature light remains off under normal operating temperatures. If the light turns on, the engine protection system will shut down the engine. Check for restrictions at the engine cooling air inlets and[...]

B-5 OPERA TION B-5 COMMANDER 300 WELDER CONTROLS (Items 9 through 14 ) 9. WELD MODE & OUTPUT CONTROL These two controls allow you to select between various welding output slopes and adjust the desired welding output. Refer to T able B.1 for a description of how these two controls work. T able B.1 Weld Mode and Output Control Functions 1 If the [...]

B-6 OPERA TION B-6 15. CIRCUIT BREAKERS These circuit breakers provide separate overload cur- rent protection for each 120V circuit at the 240V recep- tacle, each 120V receptacle, the 120V AC in the 14-Pin connector , the 42V AC in the 14-Pin connector and (for codes above 10871 only) battery circuit overload pro- tection. 16. 120V AC RECEPT ACLES [...]

B-7 OPERA TION B-7 BREAK-IN PERIOD Lincoln Electric selects high quality , heavy-duty indus- trial engines for the portable welding machines we offer . While it is normal to see a small amount of crankcase oil consumption during initial operation, excessive oil use, wet stacking (oil or tar like substance at the exhaust port), or excessive smoke is[...]

B-8 OPERA TION B-8 • CONST ANT CURRENT (CC) WELDING The CC - STICK position of “ 30 to 375", the "WELD MODE" Switch is designed for horizontal welds with all types of electrodes especially low hydrogen. The "OUTPUT" adjusts the full range of 30 to 375 amps. This setting provides a soft, constant current arc. If a more f[...]

B-9 OPERA TION B-9 Commander 300 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the “ 20-250 setting ” (TIG) • . Set the IDLER switch to the “ HIGH “ position. • Set the WELDING TERMINALS switch to the “ W eld T erminals On ” position. This will close the solid state contactor and provide an always “ hot[...]

B-10 OPERA TION B-10 WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the Commander 300 and set welder controls according to the instructions listed earlier in this section. The Commander 300 in the ” WIRE WELDING ” position, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and[...]

B-1 1 OPERA TION B-1 1 AUXILIAR Y POWER OPERA TION 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 Δ Amp-120V AC (5-20 Δ R) duplex receptacles and one 50[...]

K1604-1 OIL DRAIN KIT - Includes ball valve, hose and clamp. K1690-1 (1 Duplex) GFCI Kit - Includes one UL approved 1 15V ground fault circuit interrupter duplex type receptacle with cover and installation instruc- tions.Replaces the factory installed 1 15V duplex recep- tacle.The receptacle of the GFCI duplex is rated at 20 amps,the maximum total [...]

C-2 ACCESSORIES C-2 PLASMA CUTTING Pro-Cut 55 AC TIG WELDING Square wave TIG 175, Invertec V205T AC/DC COMMANDER 300 RECOMMENDED OPTIONAL EQUIPMENT 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 T or[...]

D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS 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 sta[...]

D-2 MAINTENANCE D-2 FUEL FIL TERS When working on the fuel system • Keep unguarded 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 o[...]

D-3 MAINTENANCE D-3 BA TTER Y HANDLING GASES FROM BA TTERY can explode. • Keep sparks, flame and cigarettes away from bat- tery . T o prevent EXPLOSION when: • INST ALLING A NEW BA TTER Y - disconnect nega- tive cable from old battery first and connect to new battery last. • CONNECTING A BA TTER Y CHARGER - Remove bat- tery from welder by dis[...]

D-4 MAINTENANCE D-4 COMMANDER 300 T able D.1 Engine Maintenance Components ITEM Air Cleaner Element Cooling Blower Belt Oil Filter Element Fuel Filter / W ater Separator Battery MAKE Donaldson Fram AC Nelson Deutz Deutz Deutz P ART NUMBER P181050 CAK-256 A297C 70206N 1 17-9565 1 17-4416 1 17-4482 BCI Group 34[...]

E-1 TROUBLESHOOTING E-1 COMMANDER 300 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. CAUTION This T roubleshooting Guide is provided to help you locate and repair [...]

E-2 TROUBLESHOOTING E-2 COMMANDER 300 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION ENGINE P[...]

E-3 TROUBLESHOOTING E-3 COMMANDER 300 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION FUNCTION[...]

E-4 TROUBLESHOOTING E-4 COMMANDER 300 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION OUTPUT P[...]

F-1 DIAGRAMS F-1 COMMANDER 300 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific dia- gram for your particular machine is pasted inside the machine on one of the enclosure panels. GND-H 6D 3 GND-F 12 GND-F 5A AUXILIARY POWER GND-D 12 11 10 EMPTY EMPTY EMPTY 31 GND-E 42A 5J OUTPUT[...]

F-2 DIAGRAMS F-2 COMMANDER 300 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific dia- gram for your particular machine is pasted inside the machine on one of the enclosure panels. GND-H 6D 3 GND-F 12 GND-F 5A GND-D 12 11 10 EMPTY EMPTY EMPTY 31 GND-E 42A OUTPUT 31 CONTROL CCW 236[...]

F-3 DIAGRAMS F-3 COMMANDER 300 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific dia- gram for your particular machine is pasted inside the machine on one of the enclosure panels. GND-H 6D 3 GND-F GND-F 5A GND-D 12 11 10 EMPTY EMPTY EMPTY GND-E 42A OUTPUT 31 CONTROL CC W 236C 8 P[...]

F-4 DIAGRAMS F-4 COMMANDER 300 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific dia- gram for your particular machine is pasted inside the machine on one of the enclosure panels. GND-H 6D GND-F GND-F 5A GND-D GND-E 42A OUTPUT 31 CONTROL CCW 236C 8 POLARITY SWI TCH 1 31 32 RECT I[...]

F-5 DIAGRAMS F-5 COMMANDER 300 CONNECTION DIAGRAM:[...]

F-6 DIAGRAMS F-6 COMMANDER 300 CONNECTION DIAGRAM: GND 75 76 77 GREEN K291 OR K404 75 INPUT CABLE 76 N.E. 77 K775 OPTIONAL REMOTE CONTR OL D AMAGED . THE ENGINE GOVERNOR SETTING IS PRE-SET A T THE F ACT ORY - DO NO T ADJUST ABO VE RPM SPECIFICA TIONS LISTED IN 81 42 41 31 31 32 32 2 2 4 4 21 21 GND 82 N.D . LN-7 WIRE FEEDER K eep guards in place. C[...]

F-7 DIAGRAMS F-7 COMMANDER 300 CONNECTION DIAGRAM:[...]

F-8 DIAGRAMS F-8 COMMANDER 300 CONNECTION DIAGRAM:[...]

F-9 DIAGRAMS F-9 COMMANDER 300 CONNECTION DIAGRAM: CA UTION : N.A. WELDING CABLE MUST BE OF PROPER CAP ACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIA TE AND FUTURE APPICA TIONS. SEE OPERA TING MANUAL. 75 32 31 41 42 N.C. INSULA TE EACH UNUSED LEAD INDIVIDU ALL Y . N.D . SPLICE LEADS AND INSULA TE. THE ENGINE WELDER OPERA TING MANU AL. GND 31 4 21 [...]

F-10 DIAGRAMS F-10 COMMANDER 300 CONNECTION DIAGRAM:[...]

F-1 1 DIAGRAMS F-1 1 COMMANDER 300 CONNECTION DIAGRAM:[...]

F-12 DIAGRAMS F-12 COMMANDER 300 CONNECTION DIAGRAM: or ser vice t his e quip m ent. On ly qualified personnel should install,use Keep away from movi ng parts. Keep guards in place. MOVING PARTS can injure W ARNING Do not touch electrically live parts . before servicing. Disconnect NEGATIVE (-) Bat tery lead Do not operate with panels open. ELECTRI[...]

F-13 DIAGRAMS F-13 COMMANDER 300 CONNECTION DIAGRAM: or service this equipment. K432-"L" CABLE ELECTRODE CABLE 14 PIN LN-25 WIRE FEEDER WITH K431 OPTION Keep awa y from moving parts. N.B. DIA GRAM SHOWS ELECTRODE POSTIVE. TO CHANGE POLARITY , TURN POWER "OFF". N.C. MOUNT K433 TO ENGINE WELDER PER INSTRUCTIONS P ACKA GED WITH K43[...]

F-14 DIAGRAMS F-14 COMMANDER 300 CONNECTION DIAGRAM:[...]

F-15 DIAGRAMS F-15 COMMANDER 300 CONNECTION DIAGRAM:[...]

F-16 DIAGRAMS F-16 COMMANDER 300 CONNECTION DIAGRAM:[...]

F-17 DIAGRAMS F-17 COMMANDER 300 TR A I L ER M O UNTI NG HO L E L OCA TI ON S . * M 1 8962 M 1 8962 - 1 2 3.3 8 2 2.2 5 A B C 3 1.1 3 3 0.2 5 E 8.6 9 1 0.2 2 D 4 8.6 4 4 6.0 0 3 8.5 8 4 9.0 5 PART NO. M18962 11-2000 2 8.9 9 1.2 6 1 9.6 3 6.5 3 2 4.9 7 6.5 5 2 3.6 9 5 0.3 8 5 4.4 4 1 4.6 3 3 7.3 0 4 5.3 8 6 3.1 0 6.5 6 4 2.0 0 D A B 3 2.0 8 C 3 1.5 [...]

NOTES COMMANDER 300[...]

NOTES COMMANDER 300[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O zzSpanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

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