Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS
FOR ENGINEpowered equipment. 1.a. Turn 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....
Page 3 - ii; ELECTRIC SHOCK can kill.
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
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...
Page 7 - TABLE OF CONTENTS; Page
TABLE OF CONTENTS Page Safety ......................................................................................................................... i-iv Installation .......................................................................................................Section A Technical Specifi...
Page 8 - vii
TABLE OF CONTENTS Accessories .....................................................................................................Section C Optional Field Installed Accessories .....................................................................C-1Recommended Optional Equipment ......................
Page 9 - INSTALLATION; Deutz; INPUT - DIESEL ENGINE; Ranges; PHYSICAL DIMENSIONS
A-1 INSTALLATION COMMANDER 300 A-1 TECHNICAL SPECIFICATIONS - Commander 300 (K1585-1 & -2) Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder High Idle 1900 125 cu. in 12VDC battery Fuel: 25 gal. F3L 1011F 31 HP(23 kw) Low Idle 1400 (2.05 L) & Starter...
Page 10 - SAFETY PRECAUTIONS; DO NOT MOUNT OVER COMBUSTIBLE SURFACES.; STORING
A-2 INSTALLATION COMMANDER 300 A-2 Read this entire installation section before youstart installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read all operating and maintenance man-uals supplied with your machine. They include impor-tant safety precautions, ...
Page 11 - LIFTING
A-3 INSTALLATION COMMANDER 300 A-3 LIFTING The Commander lift bale should be used to lift themachine. The Commander is shipped with the lift baleretracted. Before attempting to lift the Commander thelift bale must be secured in a raised position. Securethe lift bale as follows: a. Open the engine co...
Page 12 - PRE-OPERATION ENGINE SERVICE; OIL; Running out of fuel may require bleeding; FUEL CAP
A-4 INSTALLATION COMMANDER 300 A-4 PRE-OPERATION 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...
Page 13 - MUFFLER; The high frequency; REMOTE CONTROL; OUTPUT; When using the 14 pin connector, if the wire; WELDING TERMINALS
A-5 INSTALLATION COMMANDER 300 A-5 MUFFLER Remove the plastic plug covering the muffler outlettube. Using the clamp provided secure the extension tothe outlet tube. This welder is supplied with anadjustable rain cap for the muffler. Install the rain capusing the clamp provided with the outlet facing...
Page 14 - WELDING OUTPUT CABLES; Table A.1 Combined Length of Electrode and Work; MACHINE GROUNDING
A-6 INSTALLATION COMMANDER 300 A-6 WELDING OUTPUT CABLES With the engine off, route the electrode and workcables thru the strain relief bracket provided on thefront of the base and connect to the terminals provid-ed. These connections should be checked periodicallyand tightened if necessary. Listed ...
Page 15 - Take necessary steps to assure load is limited to the; Figure A.2 Connection of the Commander 300 to Premises Wiring
A-7 INSTALLATION COMMANDER 300 A-7 2. Take necessary steps to assure load is limited to the capacity of the Commander by installing a 45 amp,240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 45amperes. Loading above the rated output will reduce output v...
Page 18 - OPERATION; OPERATING INSTRUCTIONS; ADDITIONAL SAFETY PRECAUTIONS; GENERAL DESCRIPTION; RECOMMENDED APPLICATIONS; DESIGN FEATURES AND ADVANTAGES
B-1 OPERATION B-1 OPERATING INSTRUCTIONS Read and understand this entire section before operat-ing your Commander 300. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you havethoroughly read all operating and maintenance man-uals supplied with your machine. They include impor-tant saf...
Page 19 - FOR AUXILIARY POWER; OTHER FEATURES; WELDING CAPABILITY
B-2 OPERATION B-2 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 o...
Page 20 - ENGINE CONTROLS; RUN- STOP SWITCH; CONTROLS AND SETTINGS; Figure B.1 Case Front Panel Controls
B-3 OPERATION 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 tothe injection pump is stopped to shut down the engine.(Note: If ...
Page 21 - Idler Operational exceptions
B-4 OPERATION B-4 4. ENGINE TEMPERATURE GAUGE (K1585-2 Std., K1585-1 Opt.) AND LIGHT The gauge displays the engine oil temperature. Theyellow temperature light remains off under normaloperating temperatures. If the light turns on, the engineprotection system will shut down the engine. Check forrestr...
Page 22 - WELDER CONTROLS
B-5 OPERATION B-5 WELDER CONTROLS (Items 9 through 14 ) 9. OUTPUT SELECTOR SWITCH & OUTPUT CONTROL These two controls allow you to select between variouswelding output slopes and adjust the desired weldingoutput. Refer to Table B.1 for a description of howthese two controls work. Table B.1 Outpu...
Page 23 - ENGINE OPERATION; STARTING THE ENGINE; COLD WEATHER STARTING; STOPPING THE ENGINE
B-6 OPERATION B-6 17. 120VAC RECEPTACLES These two 120VAC (5-20*R) receptacles provide 120VACfor auxiliary power. These receptacles have a 40* amptotal rating. Refer to the AUXILIARY POWER RECEPTA-CLES section in the installation chapter for further infor-mation about these receptacles. Also refer t...
Page 24 - IMPORTANT; TYPICAL FUEL CONSUMPTION; Table B.2 Deutz F3L 912 Engine Fuel Consumption; WELDER OPERATION; STICK WELDING; The CONTROL; PIPE WELDING; TIG WELDING; Running Time for
B-7 OPERATION B-7 BREAK-IN PERIOD The engine used to supply power for your welder is aheavy duty, industrial engine. It is designed and builtfor rugged use. It is very normal for any engine to usesmall quantities of oil until the break-in is accom-plished. Check the oil level twice a day during theb...
Page 25 - Table B.3 TYPICAL CURRENT RANGES
B-8 OPERATION B-8 Commander 300 SETTINGS WHEN USING THEK799 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 WELDING TERMINALS switch to the “Welding Te...
Page 27 - AUXILIARY POWER OPERATION; TABLE B.4 Commander 300 Simultaneous Welding and Power
B-10 OPERATION B-10 AUXILIARY POWER OPERATION Start the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregardless of the welding control settings, if no weldingcurrent is being drawn. The auxiliary power of the Commander consists of two20 Δ Amp-120VAC (5...
Page 28 - ACCESSORIES; STICK; does NOT
C-1 ACCESSORIES C-1 OPTIONAL FIELD INSTALLEDACCESSORIES 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 d...
Page 29 - MAINTENANCE; DAILY; ENGINE MAINTENANCE; AIR FILTER
D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS • Have a qualified technician do the maintenanceand troubleshooting work. • Turn the engine off before working inside themachine. • Remove guards only when necessary and replacethem when the maintenance requiring theirremoval is complete. • Always use the great...
Page 30 - FUEL FILTERS; When working on the fuel system; COOLING SYSTEM
D-2 MAINTENANCE D-2 FUEL FILTERS 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 FilterAssembly attached vertically to the engine block in...
Page 31 - BATTERY HANDLING; PREVENTING ELECTRICAL DAMAGE; PREVENTING BATTERY DISCHARGE; CHARGING THE BATTERY; STORAGE; Store the Commander in clean, dry protected areas.; CLEANING
D-3 MAINTENANCE D-3 BATTERY HANDLING 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 newbattery last. • CONNECTING A BATTERY CHARGER - Re...
Page 32 - Table D.1 Engine Maintenance Components
D-4 MAINTENANCE D-4 COMMANDER 300 Table D.1 Engine Maintenance Components ITEM Air Cleaner Element Cooling Blower Belt Oil Filter Element Fuel Filter / Water Separator Battery MAKE Donaldson Fram AC Nelson Deutz Deutz Deutz PART NUMBER P181050 CAK-256 A297C 70206N 117-9565 117-4416 117-4482 BCI Grou...
Page 33 - TROUBLESHOOTING; Local; for technical troubleshooting assistance before you proceed.; CAUTION; Perform; HOW TO USE TROUBLESHOOTING GUIDE
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 Troubleshooting ...
Page 34 - ENGINE PROBLEMS; Local Lincoln Authorized
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 troubleshootin...
Page 35 - FUNCTION PROBLEMS; High
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 troubleshootin...
Page 36 - OUTPUT PROBLEMS
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 troubleshootin...
Page 37 - DIAGRAMS
F-1 DIAGRAMS F-1 COMMANDER 300 NO TE: This diag ram is f or ref erence only . It ma y not be accur ate f or all machines co v ered b y this man ual. The specific dia- g ram f or y our par ticular machine is pasted inside the machine on one of the enclosure panels . WIRING DIAGRAM: 5M 1 2 237A 3 4 5 ...
Page 48 - ARN
F-12 DIAGRAMS F-12 COMMANDER 300 CONNECTION DIAGRAM: o r s e rvice t his e q u ip m e n t. O n ly qualified pe rs onne l s hou ld ins tall, u s e Keep aw ay from m ovi ng pa rt s . Keep gua rd s in p lac e. MO VING PART S ca n injure W ARN ING Do not touch e lectricall y liv e pa rt s . be fo re s e...
Page 50 - COMMANDER 300 / K930 TIG MODULE / CONNECTION DIAGRAM
F-14 DIAGRAMS F-14 COMMANDER 300 CONNECTION DIAGRAM: )'" " " ! " " S24062 A %% & ++,-./01234,5/6+ ++,/?/@A07<<7834-,/092 WARNING 45@;./53A3+1,+02744+52:7.513429/55(.2+ 702+0836+9:32+;.3,<+49 74797,+0/9+?39:,/4+527,+4 326744+69%" & COMMANDER 300 / K930 TIG MOD...
Page 52 - DIMENSION PRINT
F-16 DIAGRAMS F-16 COMMANDER 300 DIMENSION PRINT TRAILER MOUNTING HOLE LOCATIONS. * 45.67 * 42.00 * * 6.55 22.25 8.69 6.53 24.97 6.56 BOTTOM VIEW OF WELDER BASE. 30.25 32.08 38.58 50.85 GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK. CENTER OF FOR BATTERY REMOVAL. 31.50 14.63 * 37.30 45.38 19.63 28.9...
Page 53 - NOTES
Page 55 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
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Page 56 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TOBE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...