Page 2 - SAFETY; WARNING; Mar; 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 ’ s recommendations. 8.c. Ground the equipment in...
Page 5 - iv
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 ’ A...
Page 6 - Thank You; as much pride as we have in bringing this product to you!; Please Examine Carton and Equipment For Damage Immediately; Quick Links
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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...
Page 7 - TABLE OF CONTENTS; Page
TABLE OF CONTENTS Page Safety .........................................................................................................................i-iv Installation .......................................................................................................Section A Technical Specific...
Page 8 - vii
TABLE OF CONTENTS Accessories .....................................................................................................Section C Optional Field Installed Accessories .....................................................................C-1Recommended Optional Equipment ......................
Page 9 - INSTALLATION; SAFETY PRECAUTIONS; STORING; Store the machine in a cool, dry place when it is not; STACKING; Commander 300 machines cannot be stacked.; ANGLE OF OPERATION
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 manu-als supplied with your machine. They include impor-tant safety precautions, ...
Page 10 - 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 11 - PRE-OPERATION ENGINE SERVICE; OIL; s Manual for specific oil recommendations and; FUEL USE DIESEL FUEL ONLY; s Manual for specific fuel recommendations.; FUEL CAP; Use correct polarity
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 beforefueling. • Do not smoke when fueling. • Fill fuel t...
Page 12 - MUFFLER; REMOTE CONTROL; OUTPUT; 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 13 - TECHNICAL SPECIFICATIONS - Commander 300; cylinder; INPUT - DIESEL ENGINE
A-1 INSTALLATION COMMANDER 300 A-1 TECHNICAL SPECIFICATIONS - Commander 300 Make/Model Displacement Description Speed (RPM) Starting Capacities Diesel Engine System 125 cu. in Deutz (2.05 L) 3 cylinder F3L 1011F Bore x Stroke 31 HP(23 kw) (Codes 11199 3.89 ” x 4.13 ” @ 1800 RPM Fuel: 25 gal. and Bel...
Page 14 - WELDING OUTPUT CABLES; Table A.1 Combined Length of Electrode and; 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 • 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 ratedload for each leg of the 240 VAC auxiliary is 45amperes. Loading above the rated output will reduceoutput volt...
Page 18 - OPERATION; SAFETY INSTRUCTIONS; Diesel Fuel; may cause overflow; ADDITIONAL SAFETY PRECAUTIONS; GENERAL DESCRIPTION; RECOMMENDED APPLICATIONS; DESIGN FEATURES AND ADVANTAGES; cored wire and arc gouging applications.
B-1 OPERATION B-1 SAFETY INSTRUCTIONS Read and understand this entire section before operat-ing your Commander 300. Do not attempt to use this equipment until youhave thoroughly read all operating and mainte-nance manuals supplied with your machine. Theyinclude important safety precautions, detailed...
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 - RUN; CONTROLS AND SETTINGS; Figure B.1 Case Front Panel Controls
B-3 OPERATION B-3 ENGINE CONTROLS (Items 1 through 8) 1. RUN- STOP SWITCHWhen 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...
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 - Table B.1 Weld Mode and Output Control
B-5 OPERATION B-5 COMMANDER 300 WELDER CONTROLS (Items 9 through 14 ) 9. WELD MODE & OUTPUT CONTROLThese 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 Weld ...
Page 23 - ENGINE OPERATION; STARTING THE ENGINE; COLD WEATHER STARTING; STOPPING THE ENGINE
B-6 OPERATION B-6 15. CIRCUIT BREAKERSThese circuit breakers provide separate overload cur-rent protection for each 120V circuit at the 240V recep-tacle, each 120V receptacle, the 120VAC in the 14-Pinconnector, the 42VAC in the 14-Pin connector and (forcodes above 10871 only) battery circuit overloa...
Page 24 - TYPICAL FUEL CONSUMPTION; WELDER OPERATION; STICK WELDING; PIPE WELDING
B-7 OPERATION B-7 BREAK-IN PERIOD Lincoln Electric selects high quality, heavy-duty indus-trial engines for the portable welding machines weoffer. While it is normal to see a small amount ofcrankcase oil consumption during initial operation,excessive oil use, wet stacking (oil or tar like substancea...
Page 25 - TIG WELDING
B-8 OPERATION B-8 • CONSTANT CURRENT (CC) WELDING The CC - STICK position of “ 30 to 375", the "WELD MODE" Switch is designed for horizontal welds with alltypes of electrodes especially low hydrogen. The"OUTPUT" adjusts the full range of 30 to 375 amps.This setting provides a sof...
Page 26 - Table B.3 TYPICAL CURRENT RANGES
B-9 OPERATION B-9 Commander 300 SETTINGS WHEN USING THEK799 HI-FREQ UNIT • Set the WELD MODE switch to the “ 20-250 setting ” (TIG) • . Set the IDLER switch to the “ HIGH “ position. • Set the WELDING TERMINALS switch to the “ Weld Terminals On ” position. This will close the solid state contactor a...
Page 27 - ARC GOUGING
B-10 OPERATION B-10 WIRE FEED (CONSTANT VOLTAGE) WELDING Connect a wire feeder to the Commander 300 and setwelder controls according to the instructions listed earlierin this section. The Commander 300 in the ” WIRE WELDING ” position, permits it to be used with a broad range of flux cored wire(Inne...
Page 28 - AUXILIARY POWER OPERATION; TABLE B.4 Commander 300 Simultaneous Welding and Power
B-11 OPERATION B-11 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 29 - ACCESSORIES
K1604-1 OIL DRAIN KIT - Includes ball valve, hoseand clamp. K1690-1 (1 Duplex) GFCI Kit - Includes one ULapproved 115V ground fault circuit interrupter duplextype receptacle with cover and installation instruc-tions.Replaces the factory installed 115V duplex recep-tacle.The receptacle of the GFCI du...
Page 30 - PLASMA CUTTING; Square wave TIG 175, Invertec V205T AC/DC; STICK; K704 Accessory Kit which includes:; TIG; Magnum Spool Gun & K488 Module
C-2 ACCESSORIES C-2 PLASMA CUTTING Pro-Cut 55 AC TIG WELDING Square wave TIG 175, Invertec V205T AC/DC COMMANDER 300 RECOMMENDED OPTIONALEQUIPMENT STICK K704 Accessory Kit which includes: • Electrode holder and cable. • Ground clamp and cable. • Headshield. K857 Remote Control Kit is optional for re...
Page 31 - MAINTENANCE; DAILY; ENGINE MAINTENANCE; AIR FILTER; CAUTION; See additional warning information at
D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS Read the Safety Precautions in front of this manualand the engine instruction manual before working onthis machine. Keep all equipment safety guards, covers and devicesin position and in good repair. Keep hands, hair, cloth-ing and tools away from V-belts, gear...
Page 32 - FUEL FILTERS; When working on the fuel system; COOLING SYSTEM
D-2 MAINTENANCE D-2 FUEL FILTERS 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 FilterAssembly attached vertically to the engine bloc...
Page 33 - BATTERY HANDLING; PREVENTING ELECTRICAL DAMAGE; Tighten nuts on battery clamp until snug.; 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 34 - 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 35 - TROUBLESHOOTING; Look under the column labeled; 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 LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting G...
Page 36 - ENGINE PROBLEMS; cooling blower
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 LocalLincoln Authorized Field Service Facility for technical troubleshooting...
Page 37 - FUNCTION PROBLEMS
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 LocalLincoln Authorized Field Service Facility for technical troubleshooting...
Page 38 - 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 LocalLincoln Authorized Field Service Facility for technical troubleshooting...
Page 39 - DIAGRAMS; This diagram is for reference only; COMMANDER 300 WIRING DIAGRAM FOR CODES 10871 AND BELOW
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 AU XILIARY PO W E R...
Page 40 - COMMANDER 300 WIRING DIAGRAM FOR CODES 10871 AND ABOVE
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 EM PT ...
Page 42 - COMMANDER 300 WIRING DIAGRAM FOR (CODES 11200 AND ABOVE)
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 ...
Page 44 - GRAM; ARNING
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 REMO TE CONTR OL D AMA GED . THE ENGINE GO VERNOR SETTING IS PRE-SET A T THE F A CT OR Y - DO NO T ADJUST ABO VE RPM SPECIFICA TIONS LISTED IN 81 42 41 31 31 32 32 2 2 4 4 21 21...
Page 50 - ARN; CAUTIO
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 51 - CONNECTION DIA
F-13 DIAGRAMS F-13 COMMANDER 300 CONNECTION DIAGRAM: or ser vice this equipment. K432-"L" CABLE ELECTR ODE CABLE 14 PIN LN-25 WIRE FEEDER WITH K431 OPTION K eep a w a y fr om mo ving par ts. N.B. DIA GRAM SHO WS ELECTR ODE POSTIVE. T O CHANGE POLARITY , TURN PO WER "OFF". N.C. MOUNT ...
Page 55 - DIMENSION PRINT
F-17 DIAGRAMS F-17 COMMANDER 300 TR A I LER M O UNT ING HO L E L OC A T ION S . * M 1 89 62 M 1 89 62 -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...
Page 56 - NOTES
Page 58 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O zzSpanish 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...
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