Lincoln Electric IM700-D User Manual

IM700-D

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Commander 300

For use with machines having Code Numbers:

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.

™

July, 2004

10702; 10870; 10899; 10950; 11200 (Standard) 10703; 10871; 10900; 10951; 11201 (Deluxe)

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

For Diesel Engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” 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 Gasoline Engines: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stop the engine and allow it to cool before refueling 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.

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1.d. Keep all equipment safety guards, coversand devices in position 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.

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1.e. In some cases it may be necessary to remove safety

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.

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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

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

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

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.

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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

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 equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. 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.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. 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.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS 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 and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

5.a.Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating products.

5.c. 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.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

vapors

5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY

iii

WELDING SPARKS can 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.

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.

6.b. 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.

6.c. 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.

6.d. 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 been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

6.g. 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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn 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 Electrical Code and the manufacturer’s recommendations.

Mar ‘95

SAFETY

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 suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-é soudage.

lectrode s’applicuent aussi au pistolet de

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code

“Code for safety in welding and cutting” CSAStandard

W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branchéà une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûretéà leur place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number____________________________________________________________________________ Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________ Whenever you request replacement parts or information on this equipment, always supply the information you

have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

TABLE OF CONTENTS

Page

Safety .........................................................................................................................i-iv

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1

Safety Precautions ................................................................................................A-2

Location / Ventilation.............................................................................................A-2

Storing.............................................................................................................A-2

Stacking ..........................................................................................................A-2

Angle of Operation..........................................................................................A-2

Lifting...............................................................................................................A-3

High Altitude Operation...................................................................................A-3

Towing.............................................................................................................A-3

Pre-Operation Engine Service...............................................................................A-4

Oil....................................................................................................................A-4

Fuel.................................................................................................................A-4

Fuel Cap..........................................................................................................A-4

Engine Cooling System...................................................................................A-4

Battery Connection..........................................................................................A-4

Muffler.............................................................................................................A-5

Spark Arrester.................................................................................................A-5

High Frequency Generators for TIG Applications .................................................A-5

Remote Control .....................................................................................................A-5

Welding Terminals .................................................................................................A-5

Welding Output Cables..........................................................................................A-6

Machine Grounding...............................................................................................A-6

Auxiliary Power Receptacles.................................................................................A-6

Standby Power Connections..........................................................................A-6, A-7

Connection of Lincoln Electric Wire Feeders.................................................A-8, A-9

vivi

Operation.........................................................................................................Section B

Safety Precautions ................................................................................................B-1

General Description ...............................................................................................B-1

Recommended Applications............................................................................B-1

Design Features and Advantages...................................................................B-1

Welding Capability ..........................................................................................B-2

Controls and Settings............................................................................................B-3

Engine Controls .......................................................................................B-3, B-4

Welder Controls,Auxiliary Power Controls..............................................B-5, B-6

Engine Operation...................................................................................................B-6

Starting the Engine .........................................................................................B-6

Stopping the Engine........................................................................................B-6

Break-In Period...............................................................................................B-7

Typical Fuel Consumption...............................................................................B-7

Welder Operation ..................................................................................................B-7

Stick Welding ..................................................................................................B-7

TIG Welding................................................................................................... B-8

Typical Current Ranges for Tungsten Electrodes..........................................B-9

Wire Feed (Constant Voltage) Welding.........................................................B-10

Arc Gouging..................................................................................................B-10

Paralleling .....................................................................................................B-10

Auxiliary Power Operation...................................................................................B-11

Simultaneous Welding and Auxiliary Power Loads.......................................B-11

COMMANDER 300

TABLE OF CONTENTS

Accessories.....................................................................................................Section C

Optional Field Installed Accessories.....................................................................C-1

Recommended Optional Equipment .....................................................................C-1

High Frequency Generators For TIG Applications ................................................C-1

Maintenance ....................................................................................................Section D

Safety Precautions................................................................................................D-1

Routine and Periodic Maintenance.......................................................................D-1

Engine Maintenance..............................................................................................D-1

Air Filter...........................................................................................................D-1

Fuel Filters......................................................................................................D-2

Cooling System ...............................................................................................D-2

Cooling Blower Belt ........................................................................................D-2

Battery Handling .............................................................................................D-3

Nameplates / Warning Decals Maintenance.........................................................D-3

Welder / Generator Maintenance..........................................................................D-3

Storage ...........................................................................................................D-3

Cleaning..........................................................................................................D-3

Brush Removal and Replacement..................................................................D-3

Engine Maintenance Components........................................................................D-4

viivii

Troubleshooting..............................................................................................Section E

Diagrams and Dimension Print ......................................................................Section F

Parts List......................................................................................................P388 Series

COMMANDER 300

A-2

INSTALLATION

A-2

Read this entire installation section before you start installation.

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important 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.

•Insulate yourself from the work and ground.

•Always wear dry insulating gloves.

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LOCATION / VENTILATION

The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area.

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SURFACES

Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface should be covered with a steel plate at least .06”(1.6mm) thick, which should extend not less than

5.90”(150mm) beyond the equipment on all sides.

STORING

1. 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.

ENGINE EXHAUST can kill.

•Use in open, well ventilated areas or vent exhaust outside

•Do not stack anything near the engine.

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MOVING PARTS can injure.

•Do not operate with doors open or guards off.

•Stop engine before servicing.

•Keep away from moving parts

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Only qualified personnel should install, use or service this equipment

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 electrolyte level. Store the battery in a dry, dark place.

4. If the engine is not used for a long period of time, every two to three months run the engine for about five minutes to keep it free from rust.

STACKING

Commander 300 machines cannot be stacked.

ANGLE OF OPERATION

To achieve optimum engine performance the Commander 300 should be run in a level position. The maximum angle of operation for the Deutz engine is 20 degrees in a direction to cause the control panel to be angled up, 30 degrees for side to side tilting and for the control panel to be angled down. If the engine is to be operated at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity in the crankcase. When operating the welder at an angle, the effective fuel capacity will be slightly less than the specified 25 gallons.

COMMANDER 300

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.

WARNING

TOWING

The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle Lincoln’s K953-1. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of the welding equipment so that there will be no undue stress to the trailer’s framework.

3. Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself.

4. Typical conditions of use, such as travel speed, roughness of surface on which the trailer will be operated, and environmental conditions.

(1)

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

• Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder.

FALLING • Do not lift machine if lift bale

is damaged.

EQUIPMENT can • Do not operate machine while

cause injury. suspended from lift bale.

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HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary. For maximum rating, derate the welder output 5% for every 300 meters (984 ft.) above 1500 meters (4920 ft.). For output of 300A and below, derate the welder output 5% for every 300 meters (984 ft.) above 2100 meters (6888 ft.)

Contact a Deutz Service Representative for any engine adjustments that may be required.

5. Proper preventative maintenance of trailer.

6. Conformance with federal, state and local laws.

(1)

Consult applicable federal, state and local laws regarding specific requirements for use on public highways.

VEHICLE MOUNTING

(1)

WARNING

Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail.

• Only transport this Equipment on serviceable vehicles which are rated and designed for such loads.

• Distribute, balance and secure loads so vehicle is stable under conditions of use.

• Do not exceed maximum rated loads for components such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of vehicle.

• Follow vehicle manufacture’s instructions.

COMMANDER 300

A-4

INSTALLATION

A-4

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instructions supplied with this machine.

WARNING

•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 over-

fill.

•Wipe up spilled fuel and allow fumes to clear before starting engine.

•Keep sparks and flame away from tank.

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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 Operator’s Manual for specific oil recommendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the engine Operator’s Manual for the proper service and maintenance intervals.

FUEL USE DIESEL FUEL ONLY

Fill the fuel tank with clean, fresh diesel fuel. The capacity of the fuel tank is 25 gallons (94.6 liters). See engine Operator’s 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. Atime of 30 minutes will elapse once the low fuel light illuminates before the machine will shutdown. 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.

ENGINE COOLING SYSTEM

The Deutz engine is air cooled by a belt driven axial blower. The oil cooler and engine cooling fins should be blown out with compressed air or steam to maintain proper cooling (See the engine Owners Manual for procedures and frequency).

BATTERY CONNECTION

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.

● CONNECTING A BATTERY CHARGER —

remove battery 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

battery first then connect negative lead to negative battery lead at engine foot.

BATTERY ACID can burn eyes and skin.

● Wear gloves and eye protection

and be careful when working near battery.

● Follow instructions printed on battery.

------------------------------------------------------------------------

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 negative (-) battery terminal.

NOTE:

valve (pointer to be in line with hose).

Before starting the engine, open the fuel shutoff

FUEL CAP

Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap.

COMMANDER 300

Remove the insulating cap from the negative battery terminal. Replace and tighten negative battery cable terminal. charged battery; if unused for several months, the battery may require a booster charge. Be sure to use the correct polarity when charging the battery.

NOTE: This machine is furnished with a wet

A-5

INSTALLATION

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 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 locations where unarrested sparks may present a fire hazard. 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 S24647 must be installed and properly maintained.

CAUTION

REMOTE CONTROL

OUTPUT

The Commander 300 is equipped with a 6-pin & 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.

NOTE: When using the 14-pin connector, if the wire feeder has a built in power source output control, do not connect anything to the 6-pin connector.

WELDING TERMINALS

The Commander is equipped with a toggle switch for selecting "hot" welding terminals when in the "WELD TERMINALS ON" position or "cold" welding terminals when in the "WELDING TERMINALS REMOTELY CONTROLLED" position.

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 frequency 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 generating 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 installation, operation, and maintenance.

COMMANDER 300

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Commander 300

INPUT - DIESEL ENGINE

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 Below)

Deutz 142 cu. in Full Load 1800 Oil: 6.3 Qts. F3L2011 (2.33L) 3 cylinder 6.0 L (Codes 11200 and above) 3.70” x 4.41” @ 1800 RPM

Duty Cycle Welding Output Volts at Rated Amps

(99mm x 105mm) 94.6 L

High Idle 1900 12 VDC battery Low Idle 1475 & Starter

Bore x Stroke 32 HP(24 kw)

(94mm x 112mm)

RATED OUTPUT - WELDER

A-1

100%

60%

300 amps (DC multi-purpose) 32 volts

375 amps (DC multi-purpose) 34 volts

OUTPUT - WELDER AND GENERATOR

Welding Range Open Circuit Voltage Auxiliary Power

30-300 Amps CC / CV TIG 80 Max OCV 120/240 VAC

10,000 Watts, 60 Hz.

@1900 RPM 100% Duty Cycle

PHYSICAL DIMENSIONS

HEIGHT

40.0 in. 31.5 in. 63.1 in. 1327 lbs.(602 kg)

1016.0 mm 800.1 mm 1602.7 mm

WIDTH DEPTH WEIGHT

1325 lbs.(601 kg) (Codes 11199 and below)

(Code 11200)

1332 lbs.(604 kg) (Code 11201)

1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.

2. Top of Enclosure. Add 8.6” (218.4mm) for exhaust.

COMMANDER 300

A-6

INSTALLATION

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 provided. These connections should be checked periodically and tightened if necessary.

Listed in Table A.1 are copper cable sizes recommended for the rated current and duty cycle. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop.

Table A.1 Combined Length of Electrode and

Work Cables.

TOTAL COMBINED LENGTH OF ELEC-

TRODE AND WORK CABLES

AMPS

@100%

Duty Cycle

300

Up to 150

FT.

(45.7m)

2/0 AWG

150-200 FT.

(45.7-61.0m)

2/0 AWG

200-250 FT.

(45.7-76.2m)

3/0 AWG

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.).

joints, or to the metal framework of a building which has been effectively grounded. The U.S. National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.

AUXILIARY POWER RECEPTACLES

The auxiliary power capacity of the Commander 300 is 10,000 watts of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to voltamperes 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 Aper output 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 current capacity of the associated receptacle.

* 15 Amp receptacles for codes below 10500.

STANDBY POWER CONNECTIONS

To prevent dangerous electric shock, other equipment powered by this engine driven welder must:

• be grounded to the frame of the welder using a grounded type plug,

• 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 connected 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 section 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

COMMANDER 300

The Commander 300 is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule.

The Commander 300 can be permanently installed as a standby power unit for 240 volt-3 wire, 44 amp service. Connections must be made by a licensed electrician who can determine how the 120/240 VAC power can be adapted to the particular installation and comply 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.

• Install the double-pole, double-throw switch between the power company meter and the premises disconnect.

Switch rating must be the same or greater than the customer’s premises disconnect and service over current protection.

A-7

240 Volt

60 Hz. 3-Wire

Service

POWER

COMPANY

METER

240 VOLT

120 VOLT

LOAD

NEUTRAL BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

NOTE: No. 8 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

240 VOLT

GROUNDED CONDUCTOR

45AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES

SERVICE OVERCURRENT

PROTECTION.

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT

RECEPTACLE

INSTALLATION

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 rated load for each leg of the 240 VAC auxiliary is 45 amperes. Loading above the rated output will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motordriven equipment and may result in overheating of the Commander 300 engine.

Figure A.2 Connection of the Commander 300 to Premises Wiring

• Install a 50 amp 120/240 VAC plug (NEMA Type 14-

50) to the double-pole circuit breaker using No. 6, 4 conductor cable of the desired length. (The 50 amp, 120/240 VAC plug is available in the optional K802R plug kit.)

• Plug this cable into the 50 Amp 120/240 Volt receptacle on the Commander 300 case front.

COMMANDER 300

A-8

INSTALLATION

A-8

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

WARNING

ELECTRIC SHOCK can kill.

Shut off welder before making any electrical connections.

------------------------------------------------------------------------

CONNECTION OF THE LN-25 TO THE COMMANDER 300

The LN-25 with or without an external contactor may be used with the Commander 300. See the appropriate connection diagram in the DIAGRAMS section.

NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the Commander 300.

• Shut the welder off.

• For electrode Positive, connect the electrode cable

from the LN-25 to the “+” terminal of the welder and work cable to the “-” terminal of the welder. For electrode Negative, connect the electrode cable from the LN-25 to the “-” terminal of the welder and work cable to the “+” terminal of the welder.

• Attach the single lead from the front of the LN-25 to work using the spring clip at the end of the lead. This is a sense lead to supply current to the wire feeder motor; it does not carry welding current.

• Set the SELECTOR switch to the “CV-WIRE” posi- tion.

• Set the “WELDING TERMINALS” switch to “WELD TERMINALS ON”

CAUTION

ELECTRIC SHOCK can kill.

If you are using an LN-25 without an internal contactor, the electrode will be

energized when the Commander 300 is started.

------------------------------------------------------------------------

h. When the gun trigger is closed, the current sensing

circuit will cause the Commander 300 engine to go to the high idle speed, the wire will begin to feed and the welding process started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

CONNECTION OF LN-7 OR LN-8 TO THE COMMANDER 300

• Shut the welder off.

• Connect the LN-7 or LN-8 per instructions on the

appropriate connection diagram in the DIAGRAMS section.

• Set the “WIRE FEEDER VOLTMETER” switch to either “+” or “-” as required by the electrode being used.

• Set the “SELECTOR” switch to the “CV-WIRE” posi- tion.

• Adjust the “ARC CONTROL” knob to desired Crispness. SOFT for MIG and CRISP for Innershield.

• Set the “WELDING TERMINALS” switch to the “REMOTELY CONTROLLED” position.

• Set the “IDLE” switch to the “HIGH” position. When

not welding, the Commander 300 engine will be at the low idle speed.

• Adjust the “ARC CONTROL” knob to desired crispness. Generally, welding is best if the “ARC CONTROL” is set to SOFT for MIG and CRISP for Innershield. You may however, want to start in the middle and adjust (as needed) from there.

• Set the “IDLE” switch to the “AUTO” position. When not welding, the Commander 300 engine will be at the low idle speed. If you are using an LN-25 with an internal contactor, the electrode is not energized until the gun trigger is closed.

COMMANDER 300

A-9

INSTALLATION

A-9

CONNECTION OF LN-15 TO THE COMMANDER 300

These connections instructions apply to both the LN15 Across-The-Arc and Control Cable models. The LN15 has an internal contactor and the electrode is not energized until the gun trigger is closed. When the gun trigger is closed the wire will begin to feed and the welding process is started.

• Shut the welder off.

• For electrode Positive, connect the electrode cable

to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable "-" terminal of the welder and work cable to the "+" terminal of the welder.

• Across-The-Arc Model:

Attach the single lead from the front of the LN-15 to work using the spring clip at the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current.

Control Cable Model:

Connect Control Cable between Engine Welder and Feeder.

• Set the MODE switch to the "CV-WIRE " position.

• Across-The-Arc Model:

Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"

Control Cable Model:

Set the "WELD TERMINALS" switch to "REMOTELY CONTROLLED"

• Set the "WIRE FEEDER VOLTMETER" switch to either "+" or "-" as required by the electrode polarity being used.

CONNECTION OF AN NA-3 AUTOMATIC WELDING SYSTEM TO THE COMMANDER 300

For connection diagrams and instructions for connecting 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)

Transformer Kit).

• Shut the welder off.

• Connect the LN-742 per instructions on the appro-

priate connection diagram in the DIAGRAMS section.

• Set the “WIRE FEEDER VOLTMETER” switch to either “+” or “-” as required by the electrode being used.

• Set the “SELECTOR” switch to the “CV-WIRE” posi- tion.

• Adjust the “ARC CONTROL” knob to desired Crispness. SOFT for MIG and CRISP for Innershield.

• Set the “WELDING TERMINALS” switch to the “REMOTELY CONTROLLED” position.

• Set the “IDLE” switch to the “AUTO” position. When

not welding, the Commander 300 engine will be at the low idle speed.

(Requires optional K1597-1, 42 VAC

• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

COMMANDER 300

B-1

OPERATION

B-1

SAFETY INSTRUCTIONS

Read and understand this entire section before operating your Commander 300.

WARNING

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such as output terminals or internal wiring.

•Insulate 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

------------------------------------------------------------------------

Diesel Fuel

• Stop engine while fueling.

• Do not smoke when fueling.

• Do not overfill tank, fuel expansion may cause overflow

• Keep sparks and flame away from tank.

• Do not leave unattended while fueling

• Wipe up spilled fuel before starting engine.

DIESEL FUEL ONLY

------------------------------------------------------------------------

Only qualified personnel should operate this equipment.

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door closed and the side panels in place as these provide maximum protection from moving parts and insure proper cooling air flow.

can cause fire.

GENERAL DESCRIPTION

The Commander 300 is a diesel engine-driven welding power source. The machine uses a brush type alternating 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 maintenance free service. The rotor is a copper wound design with two slip rings and brushes. The stator is wound entirely with heavy gauge copper wire and insulated with NEMA class F insulation material. The stator is then impregnated with three layers of high quality varnish. After the stator is assembled using tie bars, the entire assembly covered with an environmentally protective coating. These measures insure trouble-free operation in the harshest environments.

The fuel tank is made from high density polyethylene and holds 25 gallons(94.6Liters) of diesel fuel. This will provide enough fuel to run for 18 hours at full load.

The Deutz F3L-1011F engine is equipped with a standard, heavy duty, combination fuel filter/water separator 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 output 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, one constant voltage range for MIG wire and cored wire welding and on 20-250 amp range for “Touch Start” TIG welding.

COMMANDER 300

B-2

• 100% duty cycle at 300 amps output and 60 % duty cycle at 375 amps output.

• Dual 3-digit output meters are provided (optional on K1585-1) for presetting the weld amperage or voltage and displaying the actual amperage and voltage during welding. The meters use superbrite L.E.D.'s for improved readability in full sunlight.

LOOK-BACK FEATURE: After welding has stopped, both displays will remain on for 7 seconds with the last current and voltage value displayed. During this time, the left-most decimal point in each display will be flashing.

OPERATION

B-2

• Gauges for oil pressure, oil temperature, engine alternator output and fuel level (fuel level gauge on K1585-2 only codes above 10871 have a fuel level gauge on both K1585-1 and K1585-2).

• Indicator lights for low oil pressure, high oil temperature, engine alternator low output/broken belt and low fuel level Low fuel level indicator (on K1585-2 only for codes 10871 and below).

• Automatic low fuel shutdown before running out of fuel (K1585-2 only for codes 10871 and below).

• Standard remote control capability with 14 pin and 6 pin connectors for easy connection of Lincoln remote control accessories.

• An internal "Solid State" contactor allows for the selection 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 Arc-Breaks in the five slope modes.

FOR AUXILIARY POWER

• 10,000 watts of 120/240 VAC, 60Hz auxiliary power.

• Power for tools, 120/240 VAC lights, 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 V AC, and up to 44 amps per side to separate branch circuits (not in parallel) of 120 VAC single phase auxiliary power. Allows easy connection to premises wiring.

• Weld and AC auxiliary power at the same time (with-

in machine total capacity).

• Engine hour meter standard on all models.

• Extended range 25 gallon (94.6 l) 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 there is no oil pressure gauge, oil temperature gauge, engine alternator gauge, nor dual output meters (codes 10871 and below do not have a fuel level gauge nor low fuel light). This version does have fully functional engine protection for low oil pressure, high oil temperature, and alternator output with associated lights.

• A field installed Dual Output Meter and Gauge Kit (K-1768-1) is available for the K1585-1 Commander

300.The kit includes dual output meters, oil pressure gauge, oil temperature gage, and alternator ammeter.

OTHER FEATURES

• Deutz 3-cylinder, air/oil cooled diesel engine. Designed for long life, easy maintenance and excellent fuel economy.

• Engine protection system shuts the engine down for low oil pressure, high oil temperature or a broken fan/engine alternator belt.

COMMANDER 300

WELDING CAPABILITY

The Commander 300 is rated at 300 amps, 32 VDC at 100% duty cycle and 375 amps, 34 VDC at 60% duty cycle. The maximum open circuit voltage at 1900 RPM is 80 volts. The weld current is variable from 30 to 375 amps.

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

FUEL

WATER

TEMP

OIL

PRESS

AMPS

7 8

ENGINE CONTROLS (Items 1 through 8)

1. RUN- STOP SWITCH

When placed in the “RUN” position, this switch energizes 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 starting.)

2. START PUSH BUTTON

Energizes the starter motor to crank the engine. With the engine "Run / Stop" switch in the "Run" position, push and hold the Start button to crank the engine; release as the engine starts. Start button must be depressed for a minimum of two seconds. Do not press while engine is running since this can cause damage to the ring gear and/or starter motor.

3. FUEL LEVEL GAUGE AND LIGHT

(K1585-2 only on codes 10871 and below) Displays the level of diesel fuel in the 25-gallon(94.6 liters) fuel tank. The yellow light turns on when the fuel gage reaches the reserve level. For Codes 10950 and 10951 yellow light is not required. 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

B-4

OPERATION

B-4

4. ENGINE TEMPERATURE GAUGE (K1585-2

Std., K1585-1 Opt.) AND LIGHT

The gauge displays the engine oil temperature. The yellow temperature light remains off under normal operating temperatures. If the light turns on, the engine protection system will shut down the engine. Check for restrictions at the engine cooling air inlets and outlets (consult the engine Operator’s Manual). Check for loose or disconnected leads at the temperature sender located on the engine. Check engine cooling blower belt. Also, check to be sure that the welder loads are within the rating of the welder. The light will remain on when the engine has been shut down due to an overtemperature condition.

5. OIL PRESSURE GAUGE (K1585-2 Std.,

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.

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 speed provided a welding load is applied within approximately 15 seconds.

• If the triggering device remains pressed but no welding load is applied within approximately 15 seconds the engine will return to low idle speed.

ENGINE ALTERNATOR AMMETER (K15852 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 operating 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 alternator, 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” / 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.

• If the triggering device is released or welding ceases the engine will return to low idle speed after approximately 12 seconds.

8. HOUR METER

The hour meter displays the total time that the engine has been running. This meter is a useful indicator for scheduling preventive maintenance.

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.

COMMANDER 300

B-5

OPERATION

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 Table B.1 for a description of how these two controls work.

Table B.1 Weld Mode and Output Control

B-5

11. WELDING TERMINALS SWITCH

The toggle switch on the control panel labeled “Weld Terminals On” and “Remotely Controlled”: is used to control the operation of the “solid state contactor” which allows for the selection of “Hot” or “Cold” welding terminals.

With the switch in the “Weld Terminals On” position the contactor is closed and the welding terminals are always “Hot”.

Application

Sloped Output for Pipe Welding.

Weld Mode

5 Range

Settings

Output

90, 150, 200,

250, 300 (Max.

current on each

setting)

Touch Start TIG Welding

Constant Current Output for Fabrication and General Purpose Welding

Constant Voltage Output for MIG Wire or CORED WIRE Welding

Functions

If the WELD MODE switch is positioned between settings the previous setting is maintained until the switch is properly positioned on a setting.

OUTPUT also controls O.C.V. while in the 5 sloped output ranges.

1 Range setting

20-200 Amps

1 Range setting

30-575 Amps

1 Range setting

14 to 32 Volts

Provides a fine

adjustment of

welding current

from

Min (1) to Max

(10) within each

range

Provides Fine

Voltage

Adjustment

10. DIGITAL OUTPUT METERS

The digital output meters are located in the center of the control panel between the two large control knobs. The digital meters allow the output voltage (CV-WIRE mode) or current (CC-STICK, PIPE and TIG modes) to be set prior to welding using the OUTPUT control dial. During welding, the meter display the actual output voltage (VOLTS) and current (AMPS). A memory feature holds the display of both meters on the seven seconds after welding is stopped. This allows the operator to read the actual current and voltage just prior to when welding was ceased. While the display is being held the left-most decimal point in each display will be flashing. The accuracy of the meters is + or - 3%.

With the switch in the “Remotely Controlled” position the con-

tactor operation is controlled by an Amptrol, Arc Start Switch or some other type of triggering device through the use of a control cable connected to the 14-pin MS connector.

When the triggering device is pressed the contactor is closed and the welding terminals are “Hot”.

When the triggering device is released the contactor is opened and the welding terminals are “Cold”.

NOTE: The new Chopper Technology control circuitry automatically senses when a remote output control pot is plugged into either amphenol. Therefore, there is no need for a local / remote switch.

12. 6 - PIN CONNECTOR

For attaching optional remote control equipment. When in the CC-STICK, PIPE, and CV-WIRE modes and when a remote control is connected to the Amphenol, the auto-sensing circuit automatically switches the OUTPUT control from control at the welder to remote control . When using the TOUCH START TIG mode with a TIG Module connected, the OUTPUT control is used to set the maximum current range of the CURRENT CONTROL on the TIG Module.

13. 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 connects to the “+” terminal and the work cable connects to this “-” terminal. For negative polarity welding the work cable connects to the “+” terminal and the electrode cable connects to this “-” terminal.

AUXILIARY POWER CONTROLS

(Items 14 - 17 )

14. 120/240VAC RECEPTACLE

This is a 120/240VAC (14-50R) receptacle that provides 240VAC or can be split for 120VAC single phase auxiliary power. This receptacle has a 50 amp rating. Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about this receptacle. Also refer to the AUXILIARY POWER OPERATION section later in this chapter.

COMMANDER 300

B-6

OPERATION

B-6

15. CIRCUIT BREAKERS

These circuit breakers provide separate overload current protection for each 120V circuit at the 240V receptacle, each 120V receptacle, the 120VAC in the 14-Pin connector, the 42VAC in the 14-Pin connector and (for codes above 10871 only) battery circuit overload protection.

16. 120VAC RECEPTACLES

These two 120V AC (5-20*R) receptacles provide 120VAC for auxiliary power. These receptacles have a 40* amp total rating. Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about these receptacles. Also refer to the AUXILIARY POWER OPERATION section later in this chapter.

* 15 Amps per receptacle up to 30 Amps total for codes below 10500 only.

17. GROUND STUD

Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. Refer to “MACHINE GROUNDING” in the Installation chapter for proper machine grounding information.

18. VOLTMETER +/- SWITCH

Changes the polarity display on the wire feeder.

ENGINE OPERATION

STARTING THE ENGINE

1. Open the engine compartment door and check that the

fuel shutoff valve located to the left of the fuel filter 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 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.

for codes 10871 and below

) to make

19. 14 - PIN CONNECTOR

For attaching wire feeder control cables. Includes contactor closure circuit, auto-sensing remote control circuit, and 120V and 42V power. The remote control circuit operates the same as the 6 Pin Amphenol.

20. ARC CONTROL

The ARC CONTROL WIRE/STICK dial is active in the WIRE and STICK modes, and has different functions in these modes. This control is not active in the TIG and PIPE modes.

CC-STICK mode: In this mode, the ARC CONTROL knob sets the short circuit current during stick welding (arc-force). Increasing the number from -10 to +10 increases the short circuit current and prevents sticking of the electrode to the plate while welding. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with a setting at 0.

CV-WIRE mode: In this mode, turning the ARC CONTROL clockwise from –10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp and narrow. It acts as an inductance control. The proper setting depends on the procedure and operator preference. Start with a setting at 0.

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 indicated problem.

9. Allow the engine to warm up at low idle speed for several

minutes before applying a load and/or switching to high idle. Allow a longer warm up time in cold weather.

COLD WEATHER 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 satisfactorily down to about -20°F. With the above and an oil pan preheating system* the engine should start satisfactorily down to about -30°F. With the above and a battery warmer*, the engine should start satisfactorily down to about-40°F.

* Contact your local Lincoln Electric Representative for sug-

gested after-market kits.

for codes 10871 and below

STOPPING THE ENGINE

1. Switch the RUN/STOP switch to “STOP”. This turns off

the voltage supplied to the shutdown solenoid. A backup shutdown can be accomplished by shutting off the fuel

COMMANDER 300

B-7

OPERATION

B-7

BREAK-IN PERIOD

Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil consumption during initial operation, excessive oil use, wet stacking (oil or tar like substance at the exhaust port), or excessive smoke is not normal.

Larger machines with a capacity of 350 amperes and higher, which are operated at low or no-load conditions for extended periods of time are especially susceptible to the conditions described above. To accomplish successful engine break-in, most diesel-powered equipment needs only to be run at a reasonably heavy load within the rating of the welder for some period of time during the engine’s early life. However, if the welder is subjected to extensive light loading, occasional moderate to heavy loading of the engine may sometimes be necessary. Caution must be observed in correctly loading a diesel/generator unit.

1. Connect the welder output studs to a suitable resistive load bank. Note that any attempt to short the output studs by connecting the welding leads together, direct shorting of the output studs, or connecting the output leads to a length of steel will result in catastrophic damage to the generator and voids the warranty.

2. Set the welder controls for an output current and voltage within the welder rating and duty cycle. Note that any attempt to exceed the welder rating or duty cycle for any period of time will result in catastrophic damage to the generator and voids the warranty.

3. Periodically shut off the engine and check the

crankcase oil level.

TYPICAL FUEL CONSUMPTION

Refer to Table B.2 for typical fuel consumption of the Commander 300’s Engine for various operating scenarios.

Table B.2 Deutz F3L 912 Engine Fuel Consumption

Low Idle - No Load 1475 RPM

High Idle - No Load 1900 RPM

DC CC Weld Output 300 Amps @ 32 Volts

Auxiliary Power 10,000 VA

(Codes 11199 and below)

Deutz F3L 1011

31 Hp @

1800 RPM

.35 gallons/hour (1.32 liters/hour)

.48 gallons/hour

( 1.81 liters/hour)

1.34 gallons/hour ( 5.07 liters/hour)

1.32 gallons/hour (5.00 liters/hour)

(Codes 11200 and above)

Running

Deutz F3L 2011

Time

for 25 gallons (Hours)

71.4

18.6

18.9

32 Hp

@ 1800 RPM

.33 gallons/hour (1.23 liters/hour)

.52 gallons/hour

(1.98 liters/hour)

.99 gallons/hour

(3.74 liters/hour)

1.10 gallons/hour (4.16 liters/hour)

Running

Time

for 25 gallons (Hours)

75.8

48.1

25.3

22.7

WELDER OPERATION

STICK WELDING

The Commander 300 can be used with a broad range of DC stick electrodes.

The “WELD MODE” switch provides five overlapping slope controlled current ranges. The OUTPUT adjusts the current from minimum to maximum within each range. Voltage is also controlled by the OUTPUTin the slope controlled setting. These slope controlled settings are intended for “out-of-position” welding, 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.

For a soft arc characteristic, set the "WELD MODE" Switch to the lowest setting that still provides the current you need and set the "OUTPUT" near maximum. For example: to obtain 140 amps and a soft arc, set the " WELD MODE" Switch to the "150 MAX" position and then adjust the "OUTPUT" for 140 amps.

When a forceful "digging" arc is required, use a higher setting and lower the open circuit voltage. For example: to obtain 140 amps and a forceful arc, set the “WELD MODE” to the "250 MAX" position and then adjust the "OUTPUT" to get 140 amps.

COMMANDER 300

B-8

• CONSTANT CURRENT (CC) WELDING

The CC - STICK position of “30 to 375", the "WELD MODE" Switch is designed for horizontal welds with all types of electrodes especially low hydrogen. The "OUTPUT" adjusts the full range of 30 to 375 amps. This setting provides a soft, constant current arc. If a more forceful arc is desired, then select the proper range from the slope controlled current ranges.

In the CC mode, sticking can be prevented by adjusting the “ARC CONTROL”. Turning this control clockwise, increases the short circuit current, thus preventing sticking. This is another way of increasing arc force.

OPERATION

TIG WELDING

The most clockwise position of the WELD MODE switch is for TIG welding in the range of 20 amps to 250 amps, with a “Touch Start” feature. To initiate a weld, the OUTPUT is first set to the desired current and the tungsten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and, in general, no tungsten contamination. Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.

B-8

The Commander 300 can be used in a wide variety of DC Tungsten Inert Gas (TIG) welding applications. In general the “Touch Start” feature allows contamination free starting without the use of a Hi-Freq unit. But the K930-1 or -2 TIG module or K799 Hi-Freq unit, can be used with the Commander 300. The settings for these follow the tungsten current range table.

COMMANDER 300

B-9

OPERATION

B-9

Table B.3 TYPICAL CURRENT RANGES

DCEN (-) DCEP (+)

Tungsten Electrode Diameter

in. (mm)

0 .010 (.25)

0.020 (.50)

0.040 (1.0) 1/16 (1.6) 3/32 (2.4)

1/8 (3.2) 5/32 (4.0)

3/16 (4.8) 1/4 (6.4)

(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.

1%, 2%

Thoriated

Tungsten

2-15 5-20

15-80

70-150

150-250 250-400

400-500 500-750

750-1000

1%, 2%

Thoriated

Tungsten

(3) (3)

(3) 10-20 15-30

25-40 40-55

55-80

80-125

(1)

FOR TUNGSTEN ELECTRODES

Approximate Argon Gas Flow Rate

C.F.H. (l/min.)

Aluminum Stainless Steel

3-8 (2-4) 5-10 (3-5) 5-10 (3-5)

5-10 (3-5) 13-17 (6-8)

15-23 (7-11) 21-25 (10-12)

23-27 (11-13) 28-32 (13-15)

3-8 (2-4) 5-10 (3-5) 5-10 (3-5)

9-13 (4-6) 11-15 (5-7)

11-15 (5-7) 13-17 (6-8)

18-22 (8-10) 23-27 (11-13)

(2)

TIG TORCH

Nozzle

Size (4), (5)

#4, #5, #6

#5, #6 #6, #7, #8

#8, #10

(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 in. (6 mm) # 5 = 5/16 in. (8 mm) # 6 = 3/8 in. (10 mm) # 7 = 7/16 in. (11 mm) # 8 = 1/2 in. (12.5 mm) #10 = 5/8 in. (16 mm)

(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are

less prone to breakage, but cannot withstand high temperatures and high duty cycles.

Commander 300 SETTINGS WHEN USING THE K799 HI-FREQ UNIT

• Set the WELD MODE switch to the “20-250 setting” (TIG)

•. Set the IDLER switch to the “HIGH “ position.

• Set the WELDING TERMINALS switch to the “Weld

Terminals On” position. This will close the solid state contactor and provide an always “hot” electrode.

(Note: This is necessary because the K799 circuitry with respect to the #2 and #4 leads does not provide the proper signal to open and close the solid state contactor in the Commander 300).

Commander 300 SETTINGS WHEN USING THE K930-1 or -2 TIG MODULE

• Set the WELD MODE switch to the 20-250 Setting (TIG).

• Set the IDLER switch to the “AUTO “ position.

• Set the WELDING TERMINALS switch to the “Remotely

Controlled” position. This will keep the solid state contactor open and provide a “cold” electrode until the triggering device (Amptrol or Arc Start Switch) is pressed.

COMMANDER 300

B-10

OPERATION

B-10

WIRE FEED (CONSTANT VOLTAGE) WELDING

Connect a wire feeder to the Commander 300 and set welder controls according to the instructions listed earlier in this section.

The Commander 300 in the ”WIRE WELDING” position, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding). Welding can be finely tuned using the “ARC CONTROL”.

Electrodes suitable for use are: NR-311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.

Electrodes suitable for use are: 0S-70, 0S-71M. Electrodes suitable for 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.

PARALLELING

When paralleling machines in order to combine their outputs, all units must be operated in th CC - STICK mode only. To achieve this turn the WELD MODE switch to the CC - STICK position. Operation in other modes may produce erratic outputs, and large output imbalances between the units.

ARC GOUGING

For optimal performance when arc gouging, set the Commander 300’s “WELD MODE” switch to the “CC STICK” position, and the “ARC CONTROL” to 10.

Set the “OUTPUT” knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table:

* Maximum current setting is limited to the Commander

ELECTRODE CURRENT RANGE

DIAMETER (DC,electrode positive)

1/8” 60-90 Amps 5/32” 90-150 Amps 3/16” 200-250 Amps 1/4 300-375 Amps*

300’s maximum of 375 Amps.

COMMANDER 300

B-11

OPERATION

B-11

AUXILIARY POWER OPERATION

Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings, if no welding current is being drawn.

The auxiliary power of the Commander consists of two

Amp-120V AC (5-20ΔR) duplex receptacles and one

20 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.

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 Aper output to two separate 120 VAC branch circuits. Output voltage is within ± 10% at all loads up to rated capacity.

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 AUXILIARY 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).

NOTE:

puts of different phases and cannot be paralleled. The auxiliary power receptacles should only be used

with three wire grounded type plugs or approved double insulated tools with two wire plugs.

The 120/240V receptacle has two 120V out-

TABLE B.4 Commander 300 Simultaneous Welding and Power

Welding

Output Range

Setting

30-375

300 230 150

90 60

Welding Output

300A/32V 300A/32V 230A/30V 150A/29V

90A/27V 60A/25V

Permissible

Power - Watts

(Unity Power

Factor)

Loads

400

400 3100 5650 7600 8500

Permissible

Current in

@120 V ±10% *

3.3

26* 47** 63** 70**

Auxiliary Amperes

@ 240 V ±10%

1.6

1.6 13

23.5

31.5 35

* Each duplex receptacle is limited to 20Δamps. ** Not to exceed 44 Aper 120 VAC branch circuit when splitting the 240

VAC output.

COMMANDER 300

C-1

ACCESSORIES

C-1

OPTIONAL FIELD INSTALLED ACCESSORIES

K802N POWER PLUG KIT - Provides four 120V

plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240V, 50 amps. 120V plug may not be compatible with NEMA common household receptacles.

K802R POWER PLUG KIT - Provides four 120V plugs rated 15amps each and one dual voltage, full KV Aplug rated at 120/240V, 50 amps. 120V plug is compatible with NEMA common household receptacles.

K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CONTROL - Portable control provides same

dial range as the output control on the welder from a location up to the specified length from the welder. Has convenient plug for easy connection to the welder. The Commander 300 is equipped with a 6 pin connector for connecting the remote control.

K704 ACCESSORY SET - Includes 35 feet (10 m) of electrode cable and 30 feet (9 m) of work cable, headshield, work clamp and electrode holder. Cable is rated at 500 amps, 60% duty cycle.

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 1 15V duplex receptacle.The receptacle of the GFCI duplex is rated at 20 amps,the maximum total current from the GFCI duplex is limited to 20 amps. Two kits are required.

K1768-1 Dual Output Meters and Gauges - Dual output meters provide preset ability of voltage for wire welding and current for stick welding. Measures both current and voltage when welding. Gauges includes: battery ammeter, engine temperature, and engine oil pressure. Fuel gauge is not available in kit form.

K1816-1 Full KVA Adapter Kit - Plugs into the120/240v NEMA 14-50R receptacle on case front (which accepts 4-prong plugs) and converts it to a NEMA 6-50R receptacle, (which accepts 3-prong plugs.

WARNING

(K953-1) TRAILER - Two-wheeled trailer with optional

fender and light package. For highway use, consult applicable federal, state, and local laws regarding possible additional requirements. There is a choice of 2 hitches, a fender & a light package. Order: K953-1 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hitch K959-1 Fender & Light Kit K965-1 Cable Rack

(K767-2) TRAILER - Four-wheeled steerable yard trailer for in plant and yard towing:

K887-1 ETHER START KIT - Provides maximum cold weather starting assistance for frequent starting below 10 oF (-12.2 oC). Required Ether tank is not provided with kit.

K1898-1 SPARK ARRESTOR KIT - Easily mounts to standard muffler. Approved by U.S.D.A. Forest Service.

Pipe Thawing with an arc welder can cause fire, explosion, damage to electric wiring or to the arc welder if done improperly . The use of an arc welder for pipe thawing is not approved by the CSA, nor is it recommended or supported by Lincoln Electric.

------------------------------------------------------------------------

COMMANDER 300

C-2

ACCESSORIES

C-2

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 current 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:

PLASMA CUTTING

Pro-Cut 55

AC TIG WELDING

Square wave TIG 175, Invertec V205T AC/DC

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 • LN-7

• LN-8

• NA-3 • LN-15

• LN-742 • Magnum Spool Gun & K488 Module

HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS

The K799 Hi-Freq Unit and the K930-ALLTIG 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 generating equipment. The high frequency bypass network supplied with the K799 Hi-Freq Unit does NOT need to be installed into the Commander.

The Commander and any high frequency generating equipment must be properly grounded. See the K799 Hi-Freq Unit and the K930-All TIG Module operating manuals for complete instructions on installation, operation, and maintenance.

COMMANDER 300

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

Do not put your hands near the engine cooling blower fan. If a problem cannot be corrected by following the instructions, take the machine to the nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

Read the Safety Precautions in front of this manual and the engine instruction manual before working on this machine.

Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing the equipment.

ROUTINE AND PERIODIC MAINTENANCE

DAILY

• Refill the fuel tank to minimize moisture condensation in the tank.

• Open the water drain valve located on the bottom of the water separator element 1 or 2 turns and allow to drain into a container suitable for diesel fuel for 2 to 3 seconds. Repeat the above drainage procedure until diesel fuel is detected in the container.

WEEKLY

Blow out the machine with low pressure air periodically. 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

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.

• Check the crankcase oil level .

COMMANDER 300

D-2

MAINTENANCE

D-2

Soak element in a mild detergent solution for 15 minutes. Do not soak more than 24 hours. Swish element around in the solution to help remove dirt. Rinse elements from inside out with a gentle stream of water (less than 40 psi) to remove all suds and dirt. Dry element 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 element toward a bright light. Check for damaged gaskets or dented metal parts. Do not reuse damaged elements. Protect element from dust and damage during drying and storage.

Replace air filter after six cleanings. Acleaned filter will have approximately 70% of the life of a new filter element. Arestricted filter element may not appear excessively dirty.

FUEL FILTERS

WARNING

When working on the fuel system

COOLING SYSTEM

The cooling system of the Deutz engine needs to be checked and cleaned periodically. Consult the engine owners manual for the proper frequency and procedure.

COOLING BLOWER BELT

The following procedure should be followed to replace the cooling blower belt:

• Allow machine to cool.

• Remove the engine case side.

• Loosen air filter hose clamp, and detach hose.

• Disconnect the negative battery cable.

• Remove the engine case back panel for access to the

engine.

• Remove the pulley belt guard (5 screws).

• Remove rubber strap on lower half of engine fan cowl-

ing. Loosen tensioning pulley (2 bolts).

• 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 of the fuel pump. The recommended change interval for the fuel filter element 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.

• Remove the old V- belt and install a new one. Refer to operation manual for proper tensioning of belt. Per manual tighten tensioning pulley.

• Reinstall: the rubber strap on fan cowling; the pulley

belt guard; the engine case back; the Air filter hose; and the engine case side.

• Reconnect the negative battery terminal.

COMMANDER 300

D-3

MAINTENANCE

D-3

BATTERY HANDLING

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away from battery.

To prevent EXPLOSION when:

• INSTALLINGA NEW BATTERY - disconnect negative cable from old battery first and connect to new battery last.

• CONNECTING A BATTERY CHARGER - Remove battery 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 battery first then connect negative lead to engine foot.

BATTERY ACID CAN BURN EYES AND SKIN.

• Wear gloves and eye protection and be careful when working near battery. Follow instructions printed on battery.

-------------------------------------------------------

-----------------

PREVENTING ELECTRICAL DAMAGE

1. When replacing, jumping, or otherwise connecting the battery to the battery cables, the proper polarity must be observed. Failure to observe the proper polarity could result in damage to the charging circuit. The positive (+) battery cable has a red terminal cover.

CHARGING THE BATTERY

When you charge, jump, replace, or otherwise connect battery cables to the battery , be sure the polarity is correct. Improper polarity can damage the charging circuit. The Commander positive (+) battery terminal has a red terminal cover.

If you need to charge the battery with an external charger, disconnect the negative cable first, then the positive cable before you attach the charger leads. after the battery is charged, reconnect the positive battery 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 manufacturer for proper charger settings and charging time.

WELDER / GENERATOR MAINTENANCE

STORAGE

Store the Commander in clean, dry protected areas.

2. If the battery requires charging from an external charger, 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.

CLEANING

Blow out the alternator and controls periodically with low pressure air. do this at least once a week in particularly dirty areas.

BRUSH REMOVAL AND REPLACEMENT

It is normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary.

WARNING

Do not attempt to polish slip rings while the engine is running.

------------------------------------------------------------------------

COMMANDER 300

D-4

MAINTENANCE

Table D.1 Engine Maintenance Components

D-4

ITEM

Air Cleaner Element

Cooling Blower Belt

Oil Filter Element

Fuel Filter / Water Separator

Battery

MAKE

Donaldson

Fram

Nelson

Deutz

PART NUMBER

P181050 CAK-256

A297C

70206N

117-9565

117-4416

117-4482

BCI

Group

COMMANDER 300

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

• Remove guards only when necessary and replace when work

requiring removal is complete.

• Only qualified personnel should install, use or service this equipment.

E-1

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty . For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

COMMANDER 300

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-2

PROBLEMS

(SYMPTOMS)

Major Physical or Electrical Damage is Evident.

Engine will not “crank”.

Engine will “crank” but not start.

Engine shuts down shortly after starting.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

ENGINE PROBLEMS

1. Contact your Local Lincoln Authorized Field Service Facility.

1. Battery is low. Charge Battery.

2. Loose battery cable connections. Inspect, clean and tighten.

1. Out of fuel. Fill fuel tank.

2. Fuel shut off valve is in off position.

3. High oil temperature (Indicator light lit. Check engine cooling system. (Consult engine service dealer.

4. Low battery voltage.

1. Low fuel. (Indicator light lit K15852 only) Add fuel.

RECOMMENDED

COURSE OF ACTION

f all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

2. Low output of battery charging alternator. (Indicator light lit)

cooling blower belt.

Battery does not stay charged.

Check Replace if necessary.

3. High oil temperature (Indicator light lit). Check engine cooling system. (Consult engine service dealer.

1. Faulty battery. Replace

CAUTION

COMMANDER 300

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

PROBLEMS

(SYMPTOMS)

Engine will not idle down to low speed.

Engine will not go to high idle when attempting to weld.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Idler switch in High idle position. Set switch to Auto.

2. External load on welder or auxiliary power. Remove all external loads.

1. Poor work lead connection to work. Make sure work clamp is tightly connected to clean base metal.

2. ”Welding Terminals” switch is in wrong position. Set to “WELD TERMINALS” when welding without a welding terminal control cable. Refer to Operations chapter for proper use of this switch.

RECOMMENDED

COURSE OF ACTION

f all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

Engine will not go to high idle when using auxiliary power.

1. Auxiliary power load is less than 100 watts. Idler may not respond with less than a 100 watt load. Set Idler to “High”

CAUTION

COMMANDER 300

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS

(SYMPTOMS)

No welding power output.

Welder has output and no control.

No auxiliary power.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Welding terminals switch in wrong position. Place switch in “WELD TERMINALS” position when welding without welding terminal control cable. Refer to Operation chapter for proper switch function.

1. Poor remote kit connection. Check connections.

2. Faulty remote kit. Replace if necessary.

1. Open circuit breakers. Reset breakers. If breakers keep tripping check connections to auxiliary receptacles. Also make sure load does not exceed receptacles current rating. Refer to Auxiliary Connections in the Installation and Operation chapters.

RECOMMENDED

COURSE OF ACTION

f all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

2. Faulty connections to auxiliary receptacles. Check connections.

3. Faulty auxiliary circuit wiring.

CAUTION

COMMANDER 300

F-1

G4357

G3834

DIAGRAMS

F-1

GND-H

ON STANDARD

MODELS, LEADS

242D & 229 ARE

TO BE TAPED

CB3

NEUTRAL STUD

BACK OF CONTROL

214

213

220

215

218

ELECT.

233

SOL.

SHUTDOWN

START BUTTON

GND-A

GROUND

ON STANDARD MODELS,

M3M4M5

23456

M3M4M5

AMPHENOL 1

234

SWITCH

262

SENSOR

OIL PRESSURE SWITCH & SENSOR

228

224

231

236

236A

RUN

236B

SWITCH

SHOWN IN

RUN/STOP

"RUN" POS.

GND-G

FUEL

232C

OIL

TEMP

232B

OIL

PRESS.

238

CHRG.

BATT.

236C

LEADS 238 & 236C ARE TO BE

BOLTED TOGETHER AND

TAPED. LEADS 228A, 241A,

242B, 232K AND 229A ARE TO

BE TAPED INDIVIDUALY AND

TIED INTO HARNESS.

232R

DENOTES ITEMS

INCLUDED ON DELUXE

MODELS ONLY

M10

AMMETER

METER KIT OPTIONAL

75A

77A

76A

76B

77B

ABCDE

REMOTE

CONTROL

SWITCH

SENSOR

OIL TEMP. SENSOR & SWITCH

241

232J

STOP

232H

232A

232D

242D

GND. STUD ON

CONTROL BOX

BOTTOM RIGHT OF

GND-J

242A

II I

242C

228A

STUD

12VDC

INSULATED

GOLD

LOW

245

GOLD

TEMP.

GOLD

LOW

PRESS.

247 246

GOLD

ALT.

243

GOLD

WELDER

252

ON STANDARD MODEL

GND-B

75B

CONTACTOR

GROUND

FUEL LVL.

229

232

GND-J

238

229A

232K

242B

241A

GAUGE KIT

OPTIONAL ON

232K

SILVER

FUEL

SILVER

TEMP.

253

3 TURNS

THRU

AMPHENOL 2

SENSOR

THRU

242D

232E

232G

STANDARD MODEL

232N

232F

TOROID

OUTPUT PANEL

GROUND STUD ON

231

236

236C

238

232A

232L

232P

4 3

220

204S

206S

75A

76A

77A

M M

1 1

2 2

SILVER

HOT (GOLD)

20A

J11

HOT (GOLD)

50A

CB2

CB4

GND-G

GND-F

GND-G

BOX "LEFT SIDE"

GND-H

200D

200B

42A

222

10A

42V WINDING

STATOR

214

213

222

220

WELD

STATOR

WINDINGS

200A

CB6

BRUSH

201

41A

J41

ENGINE HARNESS

232S

241

200A

262

228

200D

201A

789

123

456

228A

241A

262A

200C

201B

200E

201

201B

300V

200C

200E

3200MFD

201A

ROTOR

TO THE LAMINATION

TO SLIP RING NEAREST

POSITIVE BRUSH CONNECTED

J42

PCB2

POWER SUPPLY

239

233

226A

281

234

224

200B

121314

200

226

239A

233A

234A

281A

224A

232T

232D

232T

232W

MULTI-LEAD

SWITCH

TERMINALS

WELDING

CONTROL

41A

42A

J52

P52

IDLER

CONTROL

HOUR

METER

SHOWN IN

"ALWAYS ON" POSITION

FROM

VIEWED

CCW

OUTPUT

CONTROL

257

BACK

226A

HIGH

PINCH POT

FROM

VIEWED

227

SOL.

COIL

PULL

COIL

HOLD

IDLE

232S

232L

256

AUTO

SHOWN IN

"HIGH" POSITION

262A

262B

232R

279

278

10K

277

BACK

23A

25A

987

654

789

456

251

249

P51

321

MODULE

200 AMP

IGBT

RIGHT

HEATSINK

CHOKE

GND-K

206B

BYPASS

FILTER

123

TS2

J51

B7 B3

W10

PCB7

DRIVER

POS.

NEG.

CAPACITOR

14A

13A

POS.

NEG.

WORK

POSITION

POSITIVE POLARITY

208

ASSEMBLY

SWITCH SHOWN IN

208A

208B

206A

208B

M10

45678

42A

41A

M10

4 3

VOLTMETER

41A

42A

75B

76B

POLARITY

SWITCH

206A

77B

DCH

EFG

42VAC

115VAC

WORK

REMOTE

CONTACTOR

CONTROL

AUXILIARY WINDINGS

STATOR

OF CONTROL BOX

120V AUXILIARY POWER

ON BOTTOM LEFT

"INSULATED STUD"

GND-C

GND-F

GND-D

CONTROL PANEL

GND. SCREW ON

AUXILIARY POWER

STICK

30-375A

300A

250A

200A

150A

90A

WIRE

GND-E

TIG

GND-C

115/230V

GND-D

GND-E

J12

SILVER

50A

20A

CB1

AUXILIARY

215

216

SELECTOR SWITCH

(VIEWED FROM REAR)

217

218

OLDER MACHINES MAY BE WIRED

AS SHOWN:

20-250A

EMPTY

14 TO 32V

(AS VIEWED FROM THE FRONT)

CORRESPONDING SETTINGS FOR TAP NUMBERS

COMMANDER 300 WIRING DIAGRAM

W1 & W6

W2 & W3

216

SELECTOR SWITCH

(VIEWED FROM REAR)

217

RECTIFIER BRIDGE

W4 & W5

P50

789

456

250

321

MODULE

200 AMP

PCB6

IGBT

LEFT

DRIVER

HEATSINK

POS.

COMMANDER 300 WIRING DIAGRAM FOR CODES 10871 AND BELOW

WELD LEAD TO PASS

THRU TOROID ONCE

DIRECTIONS

LEADS 3 & 6A

IN OPPOSITE

PASS THROUGH

TOROID TWICE

987

654

249

123

TS1

J50

NEG.

CAPACITOR

LEAD

WELD

261

260

261A

260A

204S

206S

50MV=400AMPS

LEFT SIDE

MOUNTING FOOT

STUD ON ENGINE

RIGHT SIDE

MOUNTING FOOT

STUD ON ENGINE

12V BATTERY

GND-K

(-)

(+)

D-

D+

B+

MOTOR

STARTING

STARTER

SOLENOID

239

ALTERNATOR

227

B2B3

232N

PCB4

BATTERY

BOARD

J30

4 1

PROGRAMMING

PCB1

PERIPHERAL BD.

777675

J10

AMPHENOL

VOLT METER

MODE

J11

THERMAL

AM METER

PCB3

WELD BOARD

SHUNT

GROUNDING BOLT

ON ENGINE BLOCK

FRAME

281

239

238

GND-J

242B

PCB8

PULL COIL BD.

J65

J32

8 J31

CONTROL POT

PROGRAMMING MACHINE SELECT

ENGINE GROUND

GND-H

BACK OF CONTROL BOX

GND STUD ON RIGHT SIDE

GND-B

GND-A

J43

J13

854 9

J12

9-01-

G3776

GND-K

POWER

MISC CONTROL

HOT START PINCH

gram for your particular machine is pasted inside the machine on one of the enclosure panels.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-

COMMANDER 300

F-2

DIAGRAMS

F-2

GND-H

10-2001

FRAME

PCB8

J65

242B

J32

J31

ENGINE GROUND

GND-H

BACK OF CONTROL BOX

GND STUD ON RIGHT SIDE

GND-B

GND-A

J43

G4167

GND-K

J13

POWER

J12

MISC CONTROL

HOT START PINCH

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.

AUXILIARY WINDINGS

STATOR

OF CONTROL BOX

ON BOTTOM LEFT

120V AUXILIARY POWER

"INSULATED STUD"

GND-C

GND-F

GND-D

AUXILIARY POWER

GND. SCREW ON

CONTROL PANEL

TIG

STICK

30-375A

300A

250A

200A

150A

90A

WIRE

(AS VIEWED FROM THE FRONT)

CORRESPONDING SETTINGS FOR TAP NUMBERS

OMMANDER 300 WIRING DIAGRAM C

W1 & W6

W2 & W3

RECTIFIER BRIDGE

W4 & W5

P50

789

456

250

321

TS1

MODULE

200 AMP

PCB6

IGBT

LEFT

DRIVER

HEATSINK

POS.

COMMANDER 300 WIRING DIAGRAM FOR CODES 10871 AND ABOVE

LEADS 3 & 6A

PASS THROUGH

261

260

WELD LEAD TO PASS

THRU TOROID ONCE

DIRECTIONS

IN OPPOSITE

TOROID TWICE

GND-E

14 TO 32V

249

CAPACITOR

115/230V

CB3

AUXILIARY

215

218

NEUTRAL STUD

HOT (GOLD)

20A

BOX "LEFT SIDE"

BACK OF CONTROL

CB6

214

213

220

WELD

STATOR

SILVER

GND-F

42A

222

WINDINGS

J11

HOT (GOLD)

50A

CB2

CB4

GND-G

GND-H

200D

200B

200A

BRUSH

201

41A

116

J41

1 2

ENGINE HARNESS

262

241

232S

200A

228

200D

123

456

228A

262A

200C

200E

201B

300V

200C

200E

3200MFD

201A

ROTOR

J42

PCB2

POWER SUPPLY

233

239

226A

201A

234

224

281

200B

789

241A

201B

121314

200

226

239A

233A

234A

281A

224A

232T

232D

232T

IDLER

232W

MULTI-LEAD

201

SWITCH

TO THE LAMINATION

TO SLIP RING NEAREST

POSITIVE BRUSH CONNECTED

TERMINALS

WELDING

CONTROL

41A

42A

OUTPUT

CONTROL

GND-C

GND-D

GND-E

J12

SILVER

50A

20A

CB1

10A

20-250A

EMPTY

42V WINDING

EMPTY

STATOR

EMPTY

216

SELECTOR SWITCH

(VIEWED FROM REAR)

217

J52

P52

CONTROL

SHOWN IN

"ALWAYS ON" POSITION

FROM

VIEWED

CCW

HOUR

BACK

227

226A

SOL.

COIL

PULL

COIL

HOLD

IDLE

SHUTDOWN

232L

232S

START BUTTON

257

256

HIGH

AUTO

SHOWN IN

"HIGH" POSITION

236A

262A

262B

METER

20A

232R

238A

279

ON STANDARD MODELS,

LEADS 238, 238A & 236C

278

10K

PINCH POT

277

BACK

FROM

VIEWED

987

654

123

J50

CHOKE

NEG.

789

456

P51

321

B7 B3

MODULE

200 AMP

IGBT

PCB7

DRIVER

RIGHT

HEATSINK

POS.

13A

LEAD

WELD

261A

260A

204S

206S

50MV=400AMPS

ELECT.

GND-K

206B

BYPASS

FILTER

ASSEMBLY

206A

23A

25A

987

654

251

249

123

TS2

J51

W10

NEG.

CAPACITOR

14A

POS.

NEG.

208B

456

M3M4M5

M10

42A

41A

VOLTMETER

41A

42A

WORK

208

208A

208B

POLARITY

SWITCH

POSITION

POSITIVE POLARITY

SWITCH SHOWN IN

206A

115VAC

75B

76B

77B

GND-A

DCH

EFG

42VAC

WORK

AMPHENOL 1

REMOTE

GROUND

CONTACTOR

CONTROL

262

OIL PRESSURE SWITCH & SENSOR

224

231

236

236B

236A

CB5

232C

OIL

232B

OIL

238

238A

BATT.

236C

ARE TO BE BOLTED

TOGETHER AND TAPED.

LEADS 228A & 241A

ARE TO BE TAPED

INDIVIDUALLY AND TIED

INTO HARNESS.

DENOTES ITEMS

INCLUDED ON DELUXE

MODELS ONLY

456

AMMETER

77A

76A

77B

ABCDE

REMOTE

234

SENSOR

228

FUEL

TEMP

PRESS.

CHRG.

SWITCH

RUN

RUN/STOP

GND-G

232R

75A

76B

CONTROL

OIL TEMP. SENSOR & SWITCH

STOP

SWITCH

SHOWN IN

"RUN" POS.

242D

GND. STUD ON

II I

12VDC

INSULATED

245

247 246

243

M10

METER KIT OPTIONAL

ON STANDARD MODEL

75B

CONTACTOR

233

SENSOR

232J

232H

232A

CONTROL BOX

BOTTOM RIGHT OF

STUD

GOLD

252

OUTPUT PANEL

GROUND STUD ON

SWITCH

SENSOR

FUEL LVL.

229

242D

241

231

236

236C

238

232

GND-J

232D

GND-J

238

232K

242B

242A

229A

241A

242C

228A

GAUGE KIT

OPTIONAL ON

STANDARD MODEL

232A

232L

232K

232N

SILVER

LOW

FUEL

232E

SILVER

TEMP.

232G

SILVER

LOW

PRESS.

232F

SILVER

ALT.

232P

SILVER

TEMP.

WELDER

253

3 TURNS

THRU

TOROID

75A

76A

77A

M M

220

204S

206S

3 TURNS

THRU

TOROID

GND-B

AMPHENOL 2

GROUND

LEFT SIDE

GROUNDING BOLT

ON ENGINE BLOCK

MOUNTING FOOT

STUD ON ENGINE

RIGHT SIDE

MOUNTING FOOT

STUD ON ENGINE

12V BATTERY

GND-K

(-)

(+)

281

D-

D+

B+

MOTOR

STARTING

STARTER

SOLENOID

227

232N

BATTERY

PERIPHERAL BD.

J10

AMPHENOL

4 1

VOLT METER

214

MODE

J11

THERMAL

AM METER

SHUNT

239

238

ALTERNATOR

GND-J

B2B3

PULL COIL BD.

PCB4

BOARD

J30

4 1

PROGRAMMING

243

9161

PCB1

62B

270

777675

CONTROL POT

PCB3

WELD BOARD

PROGRAMMING MACHINE SELECT

COMMANDER 300

F-3

DIAGRAMS

F-3

GND-H

AUXILIARY WINDINGS

STATOR

OF CONTROL BOX

ON BOTTOM LEFT

120V AUXILIARY POWER

"INSULATED STUD"

GND-E

GND-C

GND-F

GND-D

AUXILIARY POWER

GND. SCREW ON

CONTROL PANEL

TIG

STICK

30-375A

300A

250A

200A

150A

90A

WIRE

(AS VIEWED FROM THE FRONT)

CORRESPONDING SETTINGS FOR TAP NUMBERS

OMMANDER 300 WIRING DIAGRAM C

W1 & W6

W2 & W3

RECT IFIER BRIDGE

W4 & W5

P50

789

456

250

321

TS1

MODULE

200 AMP

COMMANDER 300 WIRING DIAGRAM FOR CODES 10950 AND 10951

LEADS 3 & 6A

PASS THROUGH

TOROID TWICE

PCB6

IGBT

LEFT

DRIVER

HEATSINK

POS.

CAPACITOR

261

260

WELD LEAD TO PASS

THRU TOROID ONCE

DIRECTIONS

IN OPPOSITE

GND-C

GND-D

GND-E

J12

SILVER

20A

50A

CB1

115/230V

J11

SILVER

HOT (GOLD)

20A

CB2

CB3

GND-F

ENGINE HARNESS

HOT (GOLD)

50A

CB4

GND-G

GND-H

123

241

262

200A

232S

239

228

200D

456

228A

262A

200C

200E

233

226A

201A

281

234

224

200B

789

241A

201B

121314

200

226

239A

233A

234A

281A

224A

232T

232D

232T

232W

MULTI-LEAD

200D

AUXILIARY

BOX "LEFT SIDE"

NEUTRAL STUD

BACK OF CONTROL

42A

10A

CB6

20-250A

EMPTY

42V WINDING

EMPTY

STATOR

EMPTY

14 TO 32V

SELECTOR SWITCH

41A

214

215

213

216

222

(VIEWED FROM REAR)

217

218

220

WELD

STATOR

WINDINGS

200B

200A

201

J41

1 2

201

201B

300V

200C

200E

3200MFD

201A

BRUSH

ROTOR

BRUSH

TO THE LAMINATION

TO SLIP RING NEAREST

POSITIVE BRUSH CONNECTED

J42

PCB2

POWER SUPPLY

SWITCH

TERMINALS

SHOWN IN

WELDING

CONTROL

VIEWED

41A

42A

OUTPUT

CONTROL

J52

P52

IDLER

"ALWAYS ON" POSITION

CCW

CONTROL

FROM

HOUR

BACK

226A

COIL

HOLD

232S

257

HIGH

METER

10K

PINCH POT

BACK

FROM

VIEWED

227

SOL.

COIL

PULL

IDLE

SHUTDOW N

232L

START BUTTON

256

AUTO

SHOW N IN

"HIGH" POSITION

236A

262A

262B

20A

232R

238A

279

ON STANDARD MODELS,

LEADS 238, 238A & 236C

278

277

987

654

249

123

J50

NEG.

LEAD

WELD

261A

260A

204S

206S

50MV=400AMPS

CHOKE

ELECT.

P51

321

MODULE

200 AMP

IGBT

DRIVER

RIGHT

HEATSINK

GND-K

206B

BYPASS

FILTER

206A

23A

25A

987

654

789

456

251

249

123

TS2

PCB7

POS.

J51

W10

NEG.

CAPACITOR

13A

14A

POS.

NEG.

208B

3456789

M10

45678

M10

42A

41A

VOLTMETER

42A

41A

WORK

208

ASSEMBLY

208A

208B

POLARITY

SWITCH

POSITION

POSITIVE POLARITY

SWITCH SHOWN IN

206A

115VAC

75B

76B

77B

GND-A

DCH

EFG

42VAC

WORK

AMPHENOL 1

REMOTE

GROUND

CONTACTOR

CONTROL

234

SWITCH

262

SENSOR

OIL PRESSURE SWITCH & SENSOR

228

224

231

236

RUN

236B

236A

RUN/STOP

SWITCH

GND-G

CB5

FUEL

232C

OIL

TEMP

232B

OIL

PRESS.

238

238A

CHRG.

BATT.

236C

ARE TO BE BOLTED

TOGETHER AND TAPED.

LEADS 228A & 241A

ARE TO BE TAPED

INDIVIDUALLY AND TIED

INTO HARNESS.

232R

DENOTES ITEMS

INCLUDED ON DELUXE

MODELS ONLY

M10

AMMETER

METER KIT OPTIONAL

75A

76A

77A

76B

77B

ABCDE

REMOTE

CONTROL

233

SWITCH

SENSOR

OIL TEMP. SENSOR & SWITCH

241

232J

232

232H

STOP

232A

SHOWN IN

"RUN" POS.

232D

242D

GND. STUD ON

CONTROL BOX

BOTTOM RIGHT OF

GND-J

232K

242A

II I

242C

228A

STUD

12VDC

INSULATED

GOLD

TEMP.

GOLD

LOW

PRESS.

247 246

GOLD

ALT.

243

GOLD

TEMP.

WELDER

252

ON STANDARD MODEL

GND-B

75B

CONTACTOR

GROUND

SENSOR

FUEL LVL.

229

242D

238

242B

229

241A

GAUGE KIT

OPTIONAL ON

STANDARD MODEL

232K

SILVER

253

3 TURNS

THRU

TOROID

3 TURNS

THRU

TOROID

AMPHENOL 2

232N

GROUND STUD ON

231

236

236C

238

232A

232L

232P

220

204S

206S

OUTPUT PANEL

75A

76A

77A

LEFT SIDE

GROUNDING BOLT

ON ENGINE BLOCK

GND-A

J65

GND-H

FRAME

GND-K

GND-B

J43

J32

J31

J13

POWER

J12

PINCH

GND STUD ON RIGHT SIDE BACK OF CONTROL BOX

MISC CONTROL

HOT START

G4287

gram for your particular machine is pasted inside the machine on one of the enclosure panels.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-

MOUNTING FOOT

STUD ON ENGINE

ENGINE GROUND

RIGHT SIDE

MOUNTING FOOT

STUD ON ENGINE

12V BATTERY

GND-K

(-)

(+)

281

D-

D+

B+

MOTOR

STARTING

STARTER

SOLENOID

238

239

ALTERNATOR

GND-J

242B

227

B2B3

232N

BATTERY

PERIPHERAL BD.

J10

AMPHENOL

VOLT METER

J11

THERMAL

SHUNT

BOARD

MODE

AM METER

PCB8

PULL COIL BD.

PCB4

4 1

PROGRAMMING

PCB1

777675

PCB3

W ELD BOAR D

J30

9161

CONTROL POT

PROGRAMMING MACHINE SELECT

8 9

COMMANDER 300

F-4

DIAGRAMS

F-4

GROUNDING BOLT

ON ENGINE BLOCK

GND-H

ENGINE GROUND

RIGHT SIDE

MOUNTING FOOT

(-)

FRAME

281

D+

B+

238

GND-J

32 239

242B

GND-A

GND-B

PCB8

PULL COIL BD.

J65

4 1

J43

J30

J32

9161

J31

G4891

GND-K

GND STUD ON RIGHT SIDE BACK OF CONTROL BOX

GND-H

AUXILIARY WINDINGS

STATOR

OF CONTROL BOX

ON BOTTOM LEFT

120V AUXILIARY POWER

"INSULATED STUD"

GND-E

GND-C

GND-D

AUXILIARY POWER

GND. SCREW ON

CONTROL PANEL

STICK

30-375A

300A

250A

200A

150A

90A

(AS VIEWED FROM THE FRONT)

CORRESPONDING SETTINGS FOR TAP NUMBERS

COMMANDER 300 WIRING DIAGRAM

W1 & W6

W2 & W3

W4 & W5

GND-C

GND-D

GND-E

J12

SILVER

20A

50A

CB1

AUXILIARY

NEUTRAL STUD

BOX "LEFT SIDE"

BACK OF CONTROL

GND-F

10A

42V WINDING

TIG

20-250A

EMPTY

STATOR

EMPTY

WIRE

14 TO 32V

216

217

BRIDGE

RECTIFIER

115/230V

J11

SILVER

HOT (GOLD)

20A

CB2

CB3

GND-F

ENGINE HARNESS

HOT (GOLD)

50A

CB4

GND-G

GND-H

123

241

262

200A

228

226A

200D

201A

789

456

226

228A

241A

232T

262A

200C

201B

200E

42A

CB6

200D

200B

200A

201

201B

300V

200C

200E

3200MFD

201A

BRUSH

ROTOR

BRUSH

TO THE LAMINATION

TO SLIP RING NEAREST

POSITIVE BRUSH CONNECTED

41A

214

215

213

222

218

220

WELD

STATOR

WINDINGS

J42

SELECTOR SWITCH

(VIEWED FROM REAR)

J41

1 2

PCB2

41A

POWER SUPPLY

42A

IDLER

239

233

281

234

224

200B

J52

SHUTDOWN

121314

P52

200

239A

233A

234A

281A

224A

257

232D

232T

IDLER

232W

CONTROL

MULTI-LEAD

HOUR

METER

SWITCH

TERMINALS

SHOWN IN

WELDING

CONTROL

"ALWAYS ON" POSITION

BACK

FROM

VIEWED

CCW

OUTPUT

CONTROL

COIL

PULL

COIL

HOLD

SOLENOID

COIL

SOLENOID

BLK RED

HIGH

AUTO

10K

PINCH POT

BACK

FROM

VIEWED

227

WHT

BLK

232L

226A

RED

P55

J55

224

262

J54

P54

START BUTTON

256

SHOWN IN

"HIGH" POSITION

236A

262A

262B

20A

232R

238A

279

ON STANDARD MODELS,

LEADS 238, 238A & 236C

ARE TO BE BOLTED

278

277

234

SWITCH

SENSOR

OIL PRESSURE SWITCH & SENSOR

228

231

236

RUN

STOP

236B

236A

RUN/STOP

SWITCH

SHOWN IN

GND-G

CB5

FUEL

232C

OIL

TEMP

232B

II I

OIL

PRESS.

238

238A

CHRG.

BATT.

236C

TOGETHER AND TAPED.

LEADS 228A & 241A

ARE TO BE TAPED

INDIVIDUALLY AND TIED

INTO HARNESS.

232R

12VDC

DENOTES ITEMS

INCLUDED ON DELUXE

MODELS ONLY

233

SWITCH

SENSOR

OIL TEMP. SENSOR & SWITCH

241

232J

232

232H

232A

"RUN" POS.

232D

242D

GND. STUD ON

CONTROL BOX

BOTTOM RIGHT OF

GND-J

238

232K

242B

242A

242C

228A

STUD

INSULATED

GOLD

TEMP.

GOLD

LOW

PRESS.

247 246

GOLD

ALT.

243

GOLD

TEMP.

WELDER

252

229

GAUGE KIT

232K

SILVER

FUEL LVL.

241A

OPTIONAL ON

SILVER

253

OUTPUT PANEL

GROUND STUD ON

SENSOR

242D

231

236

236C

STANDARD MODEL

232A

232L

232N

232P

LEFT SIDE

MOUNTING FOOT

STUD ON ENGINE

12V BATTERY

GND-K

(+)

D-

MOTOR

STARTING

STARTER

SOLENOID

ALTERNATOR

227

B2B3

232N

PCB4

BOARD

BATTERY

PROGRAMMING

PCB1

PERIPHERAL BD.

P50

789

456

321

MODULE

200 AMP

PCB6

IGBT

LEFT

DRIVER

HEATSINK

POS.

COMMANDER 300 WIRING DIAGRAM FOR (CODES 11200 AND ABOVE)

POS.

THRU TOROID ONCE

WELD LEAD TO PASS

DIRECTIONS

LEADS 3 & 6A

IN OPPOSITE

PASS THROUGH

TOROID TWICE

987

654

249

250

123

TS1

J50

CHOKE

NEG.

CAPACITOR

LEAD

WELD

261

260

261A

260A

204S

206S

50MV=400AMPS

ELECT.

456

P51

321

MODULE

200 AMP

IGBT

DRIVER

RIGHT

HEATSINK

GND-K

206B

BYPASS

FILTER

206A

23A

25A

987

654

789

251

249

123

TS2

J51

W10

PCB7

POS.

NEG.

CAPACITOR

14A

13A

POS.

NEG.

208B

WORK

208

ASSEMBLY

POSITIVE POLARITY

POSITION

SWITCH SHOWN IN

208A

208B

3456789

M10

45678

M10

3 TURNS

THRU

M10

42A

41A

VOLTMETER

42A

41A

POLARITY

SWITCH

206A

42VAC

115VAC

WORK

77B

EFG

REMOTE

AMMETER

75B

76B

DCH

GROUND

CONTACTOR

CONTROL

GND-A

AMPHENOL 1

METER KIT OPTIONAL

75A

76A

77A

76B

75B

77B

ABCDE

REMOTE

CONTROL

ON STANDARD MODEL

3 TURNS

THRU

GND-B

AMPHENOL 2

CONTACTOR

GROUND

TOROID

75A

76A

77A

220

204S

206S

TOROID

777675

CONTROL POT

J10

AMPHENOL

4 1

J11

SHUNT

VOLT METER

MODE

THERMAL

AM METER

J13

POWER

J12

MISC CONTROL

PINCH

HOT START

PCB3

WELD BOARD

PROGRAMMING MACHINE SELECT

COMMANDER 300

gram for your particular machine is pasted inside the machine on one of the enclosure panels.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-

F-5 CONNECTION DIAGRAM:

DIAGRAMS

F-5

COMMANDER 300

F-6 CONNECTION DIAGRAM:

LN-7

WIRE

DIAGRAMS

FEEDER

K291 OR K404

INPUT CABLE

K775 OPTIONAL

REMOTE CONTROL

F-6

7-2000

S23983

Only qualified personnel should install,use

Keep guards in place.

or service this equipment.

Keep away from moving parts.

WARNING

Do not operate with panels open.

Disconnect NEGATIVE (-) BATTERY LEAD

before servicing.

Do not touch electrically live parts.

N.D.

81424131313232

SPARE

}

224

K867 UNIVERSAL

GREEN

GND

ADAPTER PLUG

757677

TO WORK

}

N.E.

COMMANDER / K867 / K775 / LN-7 CONNECTION DIAGRAM

14 PIN

AMPHENOL

TO WORK

ELECTRODE

COMMANDER 300

TO WIRE FEED UNIT

ELECTRODE CABLE

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

CAUTION :

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPILICATIONS. SEE OPERATING MANUAL.

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

THE ENGINE WELDER OPERATING MANUAL.

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

PLACE WIRE FEEDER SWITCH TO "WIRE FEEDER WITH CONTROL CABLE POSITION.

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE "SELECTOR" SWITCH TO "WIRE WELDING CV".

N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED,CONTROL IS AUTOMATICALLY SWITCHED TO REMOTE CONTROL.

N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.E. SPLICE LEADS AND INSULATE.

F-7 CONNECTION DIAGRAM:

DIAGRAMS

F-7

COMMANDER 300

F-8 CONNECTION DIAGRAM:

DIAGRAMS

F-8

COMMANDER 300

F-9 CONNECTION DIAGRAM:

or service this equipment.

Only qualified personnel should install,use

Keep away from moving parts.

Keep guards in place.

LN-8

WIRE

N.C.

FEEDER

}

DIAGRAMS

K196

INPUT CABLE

GND

F-9

7-2000

S23989

N.D.

}

COMMANDER / K867 / LN-8 CONNECTION DIAGRAM

WARNING

Do not operate with panels open.

before servicing.

Disconnect NEGATIVE (-) BATTERY LEAD

Do not touch electrically live parts.

SPARE

14 PIN

AMPHENOL

K867 UNIVERSAL

TO WORK

GND

ADAPTER PLUG

TO WORK

ELECTRODE CABLE

TO WIRE FEED UNIT

ELECTRODE

COMMANDER 300

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

CAUTION :

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

THE ENGINE WELDER OPERATING MANUAL.

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

APPICATIONS. SEE OPERATING MANUAL.

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE SELECTOR SWITCH TO "WIRE WELDING CV".

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.D. SPLICE LEADS AND INSULATE.

F-10 CONNECTION DIAGRAM:

DIAGRAMS

F-10

COMMANDER 300

F-11 CONNECTION DIAGRAM:

DIAGRAMS

F-11

COMMANDER 300

F-12 CONNECTION DIAGRAM:

DIAGRAMS

TO W ORK

F-12

4-14-2000

S24787-6

ENGINE W ELDERS /LN-8CONNECTION DIAGRAM

Keep away from moving parts.

Keep guards in place.

MOVING PARTS can injure

WARNING

Do not operate with panels open.

Disconnect NEGATIVE (-) Battery lead

ELECTRIC SHOCK can kill

Only qualified personnel should install,use

before servicing.

or service this equipment.

CABLE PLUG

TO LN-8 INPUT

K595CONTROL CABLE

ELECTRODE CABLE

TO WIRE FEED UNIT

Do not touch electrically live parts.

APPLICATIONS. SEE OPERATING MANUAL.

14 PIN

AMPHENOL

COMMANDER 300

CAUTIONANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE

AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING

AT THE FACTORY — DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITC

MATCH THE POLARITY OF THE ELECTRODE CABLE.

N.C. PLACE IDLER SWITCH IN HIGH POSITION.

F-13 CONNECTION DIAGRAM:

or service this equipment.

Only qualified personnel should install,use

Keep away from moving parts.

Keep guards in place.

DIAGRAMS

WITH K431

OPTION

LN-25

WIRE FEEDER

K432-"L" CABLE

K433

N.D.

GND

F-13

S23993

WARNING

Do not operate with panels open.

before servicing.

Disconnect NEGATIVE (-) BATTERY LEAD

Do not touch electrically live parts.

SPARE

N.E.

}

2314

14 PIN

AMPHENOL

GND

K867 UNIVERSAL

ADAPTER PLUG

ELECTRODE CABLE

CONNECTION DIAGRAM

COMMANDER 300/ LN-25 WITH L431, K433 & K432-"L" OPTION

WORK

ELECTRODE

COMMANDER 300

TO WORK

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE, SWITCH LN-25 POLARITY SWITCH.

N.B. DIAGRAM SHOWS ELECTRODE POSTIVE. TO CHANGE POLARITY, TURN POWER "OFF".

N.C. MOUNT K433 TO ENGINE WELDER PER INSTRUCTIONS PACKAGED WITH K433.

N.D. INSULATE EACH UNUSED LEADS INDIVIDUALLY.

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.

N.E. SPLICE LEADS AND INSULATE.

F-14 CONNECTION DIAGRAM:

DIAGRAMS

F-14

COMMANDER 300

F-15 CONNECTION DIAGRAM:

DIAGRAMS

F-15

COMMANDER 300

F-16 CONNECTION DIAGRAM:

DIAGRAMS

F-16

COMMANDER 300

F-17

DIAGRAMS

DIMENSION PRINT

N.A.A.

N.B.B.

5.86

N.A.A.

NOTES

F-17

M18962

11-2000

10.22

48.64

49.05

31.13

23.38

M18962-1

8.69

46.00

38.58

30.25

22.25

M18962

PART NO.

46.3550.15

31.50

45.67

-2.24

47.5642.35

32.88

TRAILER MOUNTING HOLE LOCATIONS.

N.B.B. CENTER OF GRAVITY WITH OIL IN ENGINE, EMPTY FUEL TANK AND COOLANT IN RADIAT

N.A.A. CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK.

NOTES PER TABLE:

42.00

24.97

16.50

M189 62-2

6.53

6.55

14.63

37.30

45.38

63.10 6.56

54.44

32.08

50.38

23.69

BOTT OM VIEW OF WELDER BASE.

28.99

1.26 19.63

N.A.A., N.A.B.

COMMANDER 300

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

NOTES

COMMANDER 300

NOTES

COMMANDER 300

WARNING

zzSpanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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 HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• 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

Lincoln Electric IM700-D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual