SVM145-B
September, 2002
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.
SERVICE MANUAL
For use with machines having Code Numbers: 10469 (Standard),
10470 (Deluxe)
Commander 300
TM
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• 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
• World's Leader in Welding and Cutting Products •
Copyright © 2002 Lincoln Global Inc.
SAFETY
i i
COMMANDER 300
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
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.
____________________________________________________
1.d. 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 equipment.
____________________________________________________
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.
___________________________________________________
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.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.
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.
WARNING
Mar ‘95
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.
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.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The Above For Gasoline Engines
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SAFETY
ii ii
COMMANDER 300
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.
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.
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
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating
products.
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.
5.e. Also see item 1.b.
Mar ‘95
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COMMANDER 300
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.
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.
iii
SAFETY
iii
Mar ‘95
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.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
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
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
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.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
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.
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SAFETY
iv iv
COMMANDER 300
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-électrode s’applicuent aussi au pistolet de
soudage.
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
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.
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 branché à 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 sûreté à leur
place.
Mar. ‘93
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
v v
COMMANDER 300
Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation..............................................................................................................A-3
Pre-Operation Engine Service ....................................................................................................A-4
Electrical Output Connections.....................................................................................................A-6
Operation...............................................................................................................................Section B
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-3
Recommended Applications........................................................................................................B-3
Design Features ..........................................................................................................................B-3
Welding Capability ......................................................................................................................B-4
Controls and Settings..................................................................................................................B-4
Engine Operation........................................................................................................................B-8
Welder Operation........................................................................................................................B-9
Auxiliary Power Operation .........................................................................................................B-11
Accessories ..........................................................................................................................Section C
Maintenance..........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair ................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual .................................................................................................................................P334
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TABLE OF CONTENTS
- INSTALLATION SECTION -
Section A-1 Section A-1
COMMANDER 300
Installation .............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Input - Diesel Engine............................................................................................................A-2
Rated Output - Welder..........................................................................................................A-2
Output - Welder and Generator ............................................................................................A-2
Physical Dimensions.............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation..............................................................................................................A-3
Storing ..................................................................................................................................A-3
Stacking................................................................................................................................A-3
Angle of Operation................................................................................................................A-3
Lifting....................................................................................................................................A-4
High Altitude Operation.........................................................................................................A-4
Towing...................................................................................................................................A-4
Pre-Operation Engine Service ....................................................................................................A-4
Oil .........................................................................................................................................A-5
Fuel.......................................................................................................................................A-5
Cooling System.....................................................................................................................A-5
Battery Connections .............................................................................................................A-5
Muffler Outlet Pipe ............................................................................................................ ....A-5
Spark Arrester.......................................................................................................................A-5
High Frequency Generation for TIG Applications .......................................................................A-6
Remote Control...........................................................................................................................A-6
Welding Terminals.......................................................................................................................A-6
Electrical Output Connections.....................................................................................................A-6
Welding Cable Connections.................................................................................................A-7
Cable Installation, Polarity Control, and Cable Sizes.....................................................A-7
Machine Grounding ..............................................................................................................A-8
Auxiliary Power Receptacles................................................................................................A-8
Standby Power Connections................................................................................................A-8
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INSTALLATION
A-2 A-2
COMMANDER 300
TECHNICAL SPECIFICATIONS - Commander 300
INPUT - DIESEL ENGINE
Make/Model Description
Speed (RPM)
Displacement Starting Capacities
System
Deutz 3 cylinder 1800 Full Load 125 cu. in. Electric Fuel: 25 gal.
F3L 1011F Air/cooled 1900 High Idle (2.05 liters) 12 VDC (94.6 liters)
diesel 1400 Low Idle
31 HP Oil: 6.3 qt.
@ 1800 RPM (6.0 liters)
RATED OUTPUT - WELDER
Duty Cycle Welding Output Volts at Rated Amps
100% 300 amps (DC Multi-purpose) 32 volts
60% 375 amps (DC Multi-purpose) 34 volts
OUTPUT - WELDER AND GENERATOR
Welding Range Max. Open Circuit Voltage Auxiliary Power
1
30 - 300 Amps DC 87 OCV 120/240 VAC
in 5 Ranges @ 1900 RPM 10,000 Watts, 60 Hz.
100% Duty Cycle
PHYSICAL DIMENSIONS
Height
2
Width Depth Weight
42.0 in. 31.5 in. 63.1 in. 1325 lbs.
1066.8 mm 800.1 mm 1602.7 mm 1683 lbs.(601 kg)
1
Output rating in watts is equivalent to volt-amperes at unity power factor.
Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.
2
Top of Enclosure. Add 8.9” (16mm) for exhaust.
Read this entire installation section before you
start installation.
SAFETY PRECAUTIONS
Do not attempt to use this equipment until you have
thoroughly read all the operation 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.
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 the engine before servicing.
• Keep away from moving parts.
See additional safety information at the front of this
manual.
Only qualified personnel should install, use, or service this equipment.
LOCATION AND VENTILATION
The welder should be located to provide an unrestricted flow of clean, cool air. Also, locate the welder so
that the engine exhaust fumes are properly vented to
an outside area.
STORING
1. Store the machine in a cool, dry place when it is not
in use. Protect it from dust and dirt. Keep it where
it can’t be accidentally damaged from construction
activities, moving vehicles, and other hazards.
2. Drain the engine oil and refill with fresh 10W30 oil.
Run the engine for about five minutes to circulate oil
to all the parts. See the Maintenance section of
this manual for details on changing oil.
3. Remove the battery, recharge it, and adjust the
electrolyte level. Store the battery in a dry, dark
place.
4. See your engine operation manual for further information on fuel and engine preservation.
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 (94.6
liters).
INSTALLATION
A-3 A-3
COMMANDER 300
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WARNING
LIFTING
The Commander 300 weighs 1325 lb./601 kg. Alift bail
is provided for lifting with a hoist.
FALLING EQUIPMENT can cause injury.
Do not lift this machine using lift bail if it
is equipped with a heavy accessory
such as a trailer.
Lift only with equipment of adequate
lifting capacity . Be sure machine is stable when lifting.
The Commander is shipped with the lift bail retracted.
Before attempting to lift the Commander, secure the lift
bail in a raised position. Secure the lift bail as follows:
a. Open the engine compartment door.
b. Locate the two access holes on the upper middle
region of compartment wall just below the lift bail.
c. Use the lifting strap to raise the lift bail to the full
upright position. This will align the mounting
holes on the lift bail with the access holes.
d. Secure the lift bail with two thread forming
screws. The screws are provided in the shipped
loose parts bag.
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.
TOWING
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle is
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 consider are as follows:
1. Design capacity of trailer vs. the weight of the
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
the trailer is 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, environmental conditions, and likely
maintenance.
5. Proper preventative maintenance of trailer.
6. Conformance with federal, state and local laws.
1
1
Consult applicable federal, state and local laws regarding specific
requirements for use on public highways.
PRE-OPERATION ENGINE SERVICE
Read and understand the information about the diesel
engine in the Operation and Maintenance sections of
this manual before you operate the Commander 300.
• Keep hands away from the engine muffler or HOT engine parts.
• Stop the engine and allow it to cool
before fueling.
• Do not smoke when fueling.
• Remove the fuel cap slowly to release pressure.
• Fill the fuel tank at a moderate rate and do not overfill.
• Wipe up spilled fuel and allow the fumes to clear
before starting the engine.
• Keep sparks and flame away from the fuel tank.
INSTALLATION
A-4 A-4
COMMANDER 300
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WARNING
WARNING
OIL
The Commander 300 is shipped with the
engine crankcase filled with high quality
SAE 1OW-30 oil (API class CD or better).
CHECK THE OIL LEVEL BEFORE YOU START THE
ENGINE. If it is not up to the FULL mark on the dip-
stick, add oil as required. Check the oil every four
hours of running time during the first 35 running hours.
Refer to the engine operatorís 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
operatorís manual for the proper service and maintenance intervals.
For more oil fill and service information, see the
Maintenance section of this manual.
FUEL
Use Diesel fuel only.
Fill the fuel tank with clean, fresh diesel fuel.
The Commander 300 has 25 gallon (94.6
liter) fuel tank. See the engine operatorís 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. Once the light comes on, the machine will have
thirty minutes before it shuts down. The operator can
override this feature by restarting the engine, which
restarts the timer. 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 restarting the
machine. Running out of fuel may require bleeding
the fuel injection pump.
NOTE: Before starting the engine, open the fuel shut-
off valve. The pointer on the valve should be in line
with the hose.
FUEL CAP
Remove the plastic cap covering from the fuel tank filler
neck and install the fuel cap.
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 operator’s manual for
procedures and frequency.
BATTERY CONNECTIONS
BATTERY ACID CAN BURN EYES AND
SKIN.
•
Wear gloves and eye protection and be careful when working near a battery. Follow the
instructions printed on the battery.
The Commander 300 is shipped with the
negative battery cable disconnected.
Before you operate the machine, make sure
the IGNITION switch is in the OFF position and remove
and discard the insulating cap from the negative battery terminal. Attach the disconnected cable securely
to the battery terminal. If the battery is discharged and
won't start the engine, see the battery charging instructions in the Maintenance section.
MUFFLER OUTLET PIPE
Remove the plastic plug covering the muffler outlet
tube. Using the clamp provided, secure the outlet pipe
to the outlet tube with the pipe positioned so that it will
direct exhaust in the desired direction.
SPARK ARRESTER
Diesel engine mufflers may emit sparks when the
engine is running. Some federal, state, or local laws
require spark arresters in locations where unarrested
sparks could present a fire hazard.
Standard mufflers (like the one included with the
Commander 300) do not act as spark arresters. When
local laws require it, a spark arrester must be installed
on the machine and properly maintained. An optional
spark arrester kit (K903-1) is available for your
Commander 300. See the Accessories section of this
manual for more information.
An incorrect spark arrester may lead to engine damage
or may adversely affect performance.
INSTALLATION
A-5 A-5
COMMANDER 300
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CAUTION
WARNING
–+
HIGH FREQUENCY GENERATORS
FOR TIG APPLICATIONS
The K799 Hi-Freq Unit and the K930-1 or –2 TIG
Module can be used with the Commander 300. The
machine is equipped with the required RF 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.
REMOTE CONTROL
The Commander 300 is equipped with a 6-pin and a
14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control (optional) or
the K870 hand Amptrol or K812 foot Amptrol (TIG
applications).
The 14-pin connector is used to connect a wire feeder
or K930-1 or –2 TIG Module control cable. When
remote output control is used, the output control toggle switch must be set at REMOTE.
NOTE: When using the 14-pin connector , do NOTconnect anything to the 6-pin connector if the wire feeder
has a built-in power source output control.
Also see the Accessories section of this manual for
more information on wire feeder connections.
WELDING TERMINALS
The Commander 300 has a toggle switch for selecting
“hot” welding terminals (WELDING TERMINALS
ALWAYS ON position) or “cold” welding terminals
(WELDING TERMINALS REMOTELY CONTROLLED
position).
ELECTRICAL OUTPUT
CONNECTIONS
See Figure A.1 for the location of the 120 and 240 volt
receptacles, weld output terminals, and ground stud.
INSTALLATION
A-6 A-6
COMMANDER 300
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FIGURE A.1 - Commander 300 OUTPUT CONNECTIONS
3
1
OIL
0
HOURS
FUEL
OIL
TEMP PRESS
2
4
00000
AMPS
1. 120 VOLT, 20 AMP
RECEPTACLES (2)
2. 120/240 VOLT, 50
AMP RECEPTACLE
3. WELD OUTPUT
TERMINALS
4. GROUND STUD
WELDING CABLE CONNECTIONS
CABLE INSTALLATION, POLARITY CONTROL,
AND CABLE SIZES
With the engine off, route the electrode and work
cables through the strain relief bracket on the base
front and connect them to the terminals. (See size recommendations below.) For positive polarity, connect
the electrode cable to the terminal marked Positive (+).
For Negative polarity, connect the electrode cable to
the Negative (-) terminal. These connections should be
checked periodically and tightened if necessary.
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
• Do not cross the welding cables at the output terminal
connection. Keep the cables isolated and separate
from one another.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
Lincoln Electric offers a welding accessory kit with properly specified welding cables. See the Accessories
section of this manual for more information.
INSTALLATION
A-7 A-7
COMMANDER 300
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CAUTION
TABLE A.1 - RECOMMENDED WELDING CABLE SIZE AND LENGTH
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
Amps @ 100%
Cable sizes for combined length of electrode
Duty Cycle
plus work cable
Up to 150 ft. 150 - 200 ft. 200 - 250 ft.
300 2/0 AWG 2/0 AWG 3/0 AWG
MACHINE GROUNDING
Because this portable engine-driven welder creates its
own power, you do not need to connect the machine
frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.).
To prevent dangerous electric shock, other equipment
powered by the Commander 300 must:
a) be grounded to the frame of the welder using a
grounded type plug,
or
b) be double insulated.
When the Commander 300 is mounted to a truck or
trailer, its frame must be securely connected to the
metal frame of the vehicle. When connected to premises wiring such as a home or shop, its frame must be
connected to the system earth ground. See further
connection instructions in the section titled Standby
Power Connections as well as the article on grounding
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 AWG 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 joints, or to the metal framework of a building that
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
44A per 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 300 has two 15 Amp-120VAC (515R) duplex receptacles with GFCI protection 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.
STANDBY POWER CONNECTIONS
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, three-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.
1. Install the double-pole, double-throw switch between
the power company meter and the premises disconnect.
Switch rating must be the same as or greater than the
customer's premises disconnect and service over current protection.
2. Take necessary steps to assure the load is limited to
the capacity of the Commander 300 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 motor-driven equipment and
may result in overheating of the Commander 300
engine.
3. Install a 50 amp 120/240 VAC plug (NEMAType 14-
50) to the double-pole circuit breaker using No. 6, 4conductor cable of the desired length. (The 50 amp,
120/240 V AC plug is available in the optional K802R
plug kit.)
4. Plug this cable into the 50 Amp 120/240 Volt receptacle on the Commander 300 case front.
INSTALLATION
A-8 A-8
COMMANDER 300
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INSTALLATION
A-9 A-9
COMMANDER 300
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FIGURE A.2 - CONNECTION OF THE COMMANDER TO PREMISES WIRING
240 Volt
60 Hz.
3-Wire
Service
POWER
COMPANY
METER
240 VOLT
120 VOLT
120 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GND
N
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
NOTES
A-10 A-10
COMMANDER 300
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Section B-1 Section B-1
COMMANDER 300
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Operating Instructions.................................................................................................................B-2
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-3
Recommended Applications........................................................................................................B-3
Welder ..................................................................................................................................B-3
Generator..............................................................................................................................B-3
Design Features ..........................................................................................................................B-3
Welding Capability ......................................................................................................................B-4
Controls and Settings..................................................................................................................B-4
Engine Controls....................................................................................................................B-5
Welder Controls....................................................................................................................B-6
Auxiliary Power Controls ......................................................................................................B -7
Engine Operation........................................................................................................................B-8
Starting the Engine...............................................................................................................B-8
Cold Weather Starting..........................................................................................................B-8
Stopping the Engine.............................................................................................................B-8
Break-in Period.....................................................................................................................B-8
Typical Fuel Consumption....................................................................................................B-9
Welder Operation........................................................................................................................B-9
Stick Welding........................................................................................................................B-9
Pipe Welding ...................................................................................................................B-9
Constant Current (CC) Welding ......................................................................................B-9
TIG Welding.................................................................................................................... ......B-9
Wire Feed (Constant Voltage) Welding ..............................................................................B-11
Auxiliary Power Operation .........................................................................................................B-11
Simultaneous Welding and Auxiliary Power Loads ............................................................B-11
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OPERATING INSTRUCTIONS
Read and understand this entire section before operating your Commander 300.
SAFETY INSTRUCTIONS
Do not attempt to use this equipment until you have
thoroughly read all the 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.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust to the outside.
• Do not stack anything on or near the
engine.
MOVING PARTS can injure.
• Do not operate this equipment with any
of its doors open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
Only qualified personnel should install, use, or service this equipment.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged door
closed and the side panels in place. These provide
maximum protection from moving parts and insure
proper cooling air flow.
OPERATION
B-2 B-2
COMMANDER 300
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WARNING
WARNING
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 is covered with an environmentally protective coating. These measures insure troublefree operation in the harshest environments.
The fuel tank is made from high density polyethylene
and holds 25 gallons (94.6 liters) of diesel fuel. This
will provide enough fuel to run for 18 hours at full load.
The Deutz F3L-1011 F engine is equipped with a standard, heavy duty, combination fuel filter/water separator element.
RECOMMENDED APPLICATIONS
WELDER
The Commander 300 (Stick model) provides excellent
constant current DC welding output for stick (SMAW)
welding. The Commander 300 (Stick & Wire model)
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
K1585-2 Commander 300 Deluxe Model Features
FOR WELDING:
• Excellent DC multi-purpose welding for stick, MIG,
TIG, cored wire and arc gouging applications.
• 30 to 300 amps output in five slope controlled ranges
for out-of position and pipe electrodes, one constant
current output range for general purpose welding,
and one constant voltage range for MIG wire and
cored wire welding.
• 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 LEDs for
improved readability in full sunlight.
• Standard remote control capability with 14-pin and 6pin 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 pop-outs in the five
slope modes.
FOR AUXILIARY POWER
• 10,000 watts of 120/240 VAC, 60Hz auxiliary power.
• Power for tools, 120/240 VAC lights, electric pumps
and for standby emergency power.
• Power to drive a 2 HP motor (provided it is started
under no load).
• Two 15 amp 120 VAC duplex receptacles with GFCI
protection for up to 30 amps of 120 VAC power.
• 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 provide AC auxiliary power at the same
time (within machine total capacity).
OPERATION
B-3 B-3
COMMANDER 300
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ADDITIONAL DESIGN 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.
• Gauges for oil pressure, oil temperature, engine
alternator output and fuel level.
• Indicator lights for low oil pressure, high oil temperature, engine alternator low output/broken belt and
low fuel level (on K1585-2 only).
• Automatic low fuel shutdown before running out of
fuel (K1585-2 only).
• Engine hour meter standard on all models.
• Extended range 25 gallon (94.6 I) fuel tank.
• Automatic idler reduces engine speed when not
welding or drawing auxiliary power. This feature
reduces fuel consumption and extends engine life.
• Compact size fits crosswise in full size pick-up truck.
Single side engine service.
• Copper alternator windings and high temperature
insulation for dependability and long life.
• New paint system on case and base for outstanding
corrosion protection.
K1585-1 COMMANDER 300
STANDARD MODEL
The K1585-1 is the standard version of the
Commander 300, and has all the features of the
K1585-2 Deluxe version except that there are no
gauges, low fuel light nor dual output meters. This version does have fully functional engine protection for low
oil pressure, high oil temperature, and alternator output
with associated lights.
A field installed Dual Output Meter and Gauge Kit
(K1596-1) is available for the K1585-1 Commander
300. The kit includes dual output meters, oil pressure
gauge, oil temperature gage, and alternator ammeter.
WELDING CAPABILITY
The Commander 300 is rated 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 87 volts. The weld current is variable from 30 to 375
amps.
CONTROLS AND SETTINGS
The welder/generator controls are located on the case
front panel. Diesel engine idler control, start/stop controls, welding output terminals and ground stud are
also on the case front. See Figure B.1 and the explanations that follow.
OPERATION
B-4 B-4
COMMANDER 300
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OPERATION
B-5 B-5
COMMANDER 300
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. (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. The START button must be
depressed for a minimum of two seconds. Do not
press it 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):
Displays the level of diesel fuel in the 25-gallon fuel
tank. The yellow light turns on when the fuel gage
reaches the reserve level. Once the reserve level is
reached, the engine protection system will shut
down the engine after 30 minutes of operation. The
machine can be restarted and operated for an additional 30 minutes before the protection system will
shut down the engine. This ability to override the
engine protection allows 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.
4. ENGINE TEMPERATURE GAUGE AND LIGHT
(K1585-2 Std., K1585-1 Opt.): 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 over
temperature condition.
Figure B.1 Case Front Panel Controls
12
7
9
00000
HOURS
0
23
13
19
9
1
18
17
2
3
FUEL
10
4
OIL
TEMP PRESS
15
16
OIL
24
5
20
22
6 8
AMPS
11
21
14
OPERATION
B-6 B-6
COMMANDER 300
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5. OIL PRESSURE GAUGE AND LIGHT (K1585-2
Std., K1585-1 Opt.): The gauge displays the
engine oil pressure when the engine is running.
The yellow oil pressure light remains off with proper
oil pressure. If the light turns on, the engine protection system will stop the engine. Check for proper oil level and add oil if necessary . Check for loose
or disconnected leads at the oil pressure sender
located on the engine. The light will go on and stay
on when the RUN/STOP switch is switched to the
“RUN” position with engine not running.
6. ENGINE ALTERNATOR AMMETER AND LIGHT
(K1585-2 Std., K1585-1 Opt.): The yellow engine
alternator light is off when battery charging system
is functioning normally. If the 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: The 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 operates as fol-
lows:
a. When switched from “HIGH” to “AUTO” or
after starting the engine, the engine will
operate at full speed for approximately 12
seconds and then go to low idle speed.
b. When the electrode touches the work or
power is drawn for lights or tools (approximately 100 watts minimum) the engine
accelerates and operates at full speed.
c. When welding ceases or the AC power load
is turned off, a fixed time delay of approximately 12 seconds starts.
d. If the welding or AC power load is not
restarted before the end of the time delay,
the idler reduces the engine speed to low
idle speed.
e. The engine will automatically return to high
idle speed when the welding load or AC
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 12 seconds.
b. If the triggering device remains pressed but no
welding load is applied within approximately 12
seconds, the engine will return to low idle speed.
c. 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 preventative
maintenance.
WELDER CONTROLS (Items 9 through
14)
9. OUTPUT RANGE SELECTOR SWITCH & OUTPUT CONTROL: These two controls allow you to
select between various welding output slopes and
adjust the desired welding output. Refer to Table
B.1 for a description of how these two controls work.
TABLE B.1 OUTPUT RANGE SWITCH
AND OUTPUT CONTROL FUNCTIONS
OUTPUT OUTPUT
RANGE CONTROL
2
SELECTOR
SWITCH
1
Sloped Output for 5 Range Settings Provides a fine
Pipe Welding 60, 90, 150, 230, adjustment of
300 (Max. current welding current
on each adjustment from Min (1) to
of setting Max (10) within
each range
Constant Current 1 Range setting
Fabrication and General 30-375 Amps
Purpose Welding (This
setting also used for TIG.)
Constant Voltage Output 1 Range setting Provides Fine
for MIG Wire or CORED 12 to 40 Volts Voltage
WIRE Welding Adjustment
1
If the SELECTOR switch is positioned between settings the previous setting is maintained until the switch is properly positioned on a
setting.
2
CONTROL also controls O.C.V. while in the 5 sloped output ranges.
10. DIGITAL OUTPUT METER: The digital output
meters are located in the center of the control
panel between the two large control knobs. The
meters allow the output current level to be set prior
to welding in stick mode and voltage level to be set
prior to welding in the wire modes. During the
welding process the meters display the actual
output current and voltage, within +1%, -10%
accuracy.
11. WELDING TERMINALS SWITCH: The toggle
switch on the control panel labeled “WELDING
TERMINALS ALWAYS ON” and “WELDING TERMINALS REMOTELY CONTROLLED” is used to
control the operation of the “solid state contactor”
which allows for the selection of “Hot” or “Cold”
welding terminals.
With the switch in the “WELDING TERMINALS
AL W AYS ON” position, the contactor is closed and
the welding terminals are always “Hot.”
With the switch in the “WELDING TERMINALS
REMOTEL YCONTROLLED” position, the contactor 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 6-pin or 14-pin MS connector.
When the triggering device is pressed the contactor is closed and the welding terminals are “Hot.”
When the triggering device is released the contactor is opened and the welding terminals are
“Cold.”
12. LOCAL/REMOTE SWITCH: The toggle switch on
the control panel labeled “LOCAL/REMOTE” gives
the operator the option of controlling the output at
the welder control panel or at a remote station.
For remote control, the toggle switch is set in the
“REMOTE” position. For control at the welder
control panel, the toggle switch is set in the
“LOCAL” position.
13. 6 - PIN CONNECTOR: The 6-pin connector locat-
ed on the control panel allows for connection of
interfacing equipment.
14. WELD OUTPUT TERMINALS + AND – : These
1/2 - 13 studs with flange nuts provide welding
connection points for the electrode and work
cables. For positive polarity welding, the electrode
cable 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 15 through 19)
15. 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 AUXILIARY POWER RECEPTA-
CLES in the Installation section for further information about this receptacle. Also refer to AUXIL-
IARY POWER OPERATION later in this section.
16. 50 AMP CIRCUIT BREAKERS: These circuit
breakers provide separate overload current protection for each 120V circuit at the 240V receptacle.
17. 120VAC RECEPTACLES: These two 120VAC (5-
15R) receptacles with GFCI protection provide
120VAC for auxiliary power. These receptacles
have a 20 amp total rating. Refer to AUXILIARY
POWER RECEPT ACLES in the Installation section
for further information about these receptacles.
Also refer to AUXILIARY POWER OPERATION
later in this section.
18. 15 AMP CIRCUIT BREAKERS: These circuit
breakers provide separate overload current protection for each 120VAC receptacle.
19. GROUND STUD: Provides a connection point for
connecting the machine case to earth ground for
the safest grounding procedure. Refer to
MACHINE GROUNDING in the Installation section
for proper machine grounding information.
20. 15 AMP CIRCUIT BREAKER: This circuit breaker
provides overload protection for the 120 VAC circuit in the 14-pin connector.
21. VOLTMETER +/- SWITCH: Changes the polarity
display on the wire feeder.
22. 15 AMP CIRCUIT BREAKER: This circuit breaker
provides overload protection for the 42 VAC circuit
in the 14-pin connector.
23. 14-PIN CONNECTOR: For quick connection of
interfacing equipment.
24. ARC CONTROL: The “ARC CONTROL” poten-
tiometer is active in two modes: “STICK/TIG” and
“WIRE WELDING” with different purposes in each
mode.
“STICK/TIG” mode: In this mode, the “ARC CONTROL” knob sets the short circuit current during stick
welding. Increasing the number from 1 to 10 increases the short circuit current. This prevents sticking of
the electrode to the plate at low welding current settings. This also increases spatter. It is recommended
that the control be set to the minimum number without
electrode sticking.
OPERATION
B-7 B-7
COMMANDER 300
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“WIRE WELDING” mode: In this mode increasing the
number from 1 to 10 changes the arc from soft and
washed-in to crisp and narrow. It acts as an inductance control. The proper setting depends on the application and operator preference.
In general, MIG welding performs best in the “SOFT”
range and Innershield in the “CRISP” range.
ENGINE OPERATION
DO NOT RUN THE ENGINE AT EXCESSIVE
SPEEDS. The maximum allowable high idle speed for
the Commander 300 is 1900 RPM, no load. Do NOT
increase the idle speed on the engine. Severe personal injury and damage to the machine can result if it
is operated at speeds above the maximum rated
speed.
Read and understand all safety instructions included in
the Deutz engine instruction manual that is shipped
with your Commander 300.
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. (The lever
should be in line with the hose.)
2. Check for proper oil level on the oil dipstick. Close
the engine compartment door.
3. Remove all plugs connected to the AC power recep-
tacles.
4. Set IDLER switch to “AUTO.”
5. Set the RUN/STOP switch to “RUN.” Observe that
all engine protection lights momentarily turn on.
Some lights may turn off before starting. Check the
fuel gauge (K1585-2 only) to make sure that there
is an adequate fuel level.
6. Press and hold the engine START button for a minimum of 2 seconds.
7. Release the engine START button when the engine
starts.
8. Check that the indicator lights are off. If the LOW
FUEL light is on (K1585 2 only), the engine will shut
down 30 minutes after starting. If any other indicator light is on after starting, the engine will shut
down 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
suggested after-market kits.
STOPPING THE ENGINE
Switch the RUN/STOP switch to “STOP.” This turns off
the voltage supplied to the shutdown solenoid. Abackup shutdown can be accomplished by shutting off the
fuel valve located in the fuel line.
BREAK-IN PERIOD
The engine used to supply power for your welder is a
heavy duty, industrial engine. It is designed and built
for rugged use. It is very normal for any engine to use
small quantities of oil until the break-in is accomplished. Check the oil level twice a day during the
break-in period (about 200 running hours).
During break-in, subject the Commander 300 to
heavy loads. Avoid long periods running at idle.
Before stopping the engine, remove all loads and
allow the engine to cool several minutes.
The heavy loading of the engine during break-in, within the rating of the machine, is recommended to properly seat the piston rings and prevent wetstacking.
Wetstacking is an accumulation of unburned fuel
and/or lubricant in the form of a wet, black, tar-like substance in the exhaust pipe. The rings are seated and
the break-in period is complete when there are no
longer any signs of wetstacking, which should occur
within the first 50 to 100 hours of operation.
OPERATION
B-8 B-8
COMMANDER 300
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WARNING
CAUTION
Using your welder at low amperages with long idle running periods during the break-in period may result in a
glaze forming on the engine cylinder walls and the
rings not seating properly. No amount of loading will
properly seat the piston rings after they are glazed
over.
TYPICAL FUEL CONSUMPTION
Refer to Table B.2 for typical fuel consumption of the
Commander 300 engine for various operating scenarios.
Table B.2 Deutz F3L 912 Engine Fuel Consumption
WELDER OPERATION
STICK WELDING
The Commander 300 can be used with a broad range
of DC stick electrodes.
The SELECTOR switch provides five overlapping
slope controlled current ranges. The CONTROL
adjusts the current from minimum to maximum within
each range. Voltage is also controlled by the CONTROL in 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 “SELECTOR”
Switch to the lowest setting that still provides the current you need and set the “CONTROL” near maximum.
For example: to obtain 140 amps and a soft arc, set the
“SELECTOR” Switch to the “150 MAX” position and
then adjust the “CONTROL” for 140 amps.
When a forceful “digging” arc is required, use a higher
setting and lower the open circuit voltage. For example:
to obtain 140 amps and a forceful arc, set the “SELECTOR” to the “230 MAX” position and then adjust the
“CONTROL” to get 140 amps.
CONSTANT CURRENT (CC) WELDING
The most clockwise position of the “SELECTOR”
switch is designed for horizontal welds with all types of
electrodes, but especially low hydrogen. The “CONTROL” adjusts the full range of 30 to 375 amps. This
setting provides a soft, constant current arc. If a more
forceful arc is desired, then select the proper range
from the slope controlled current ranges.
In the CC mode, sticking can be prevented by adjusting the “ARC CONTROL.” Turning this control clockwise increases the short circuit current, thus preventing
sticking. This is another way of increasing arc force.
TIG WELDING
The Commander 300 can be used in a wide variety of
DC Tungsten Inert Gas (TIG) welding applications.
When used with the K930-1 or -2 TIG module or K799
Hi-Freq Unit, ratings are limited to 375 amps at 20%
duty cycle, 300 amps at 60% duty cycle, and 250 amps
at 80% duty cycle.
OPERATION
B-9 B-9
COMMANDER 300
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Low Idle - No
Load 1400 RPM
High Idle - No
Load 1900 RPM
DC CC Weld
Output 300
Amps @ 32
Volts
Auxiliary Power
10,000 VA
.27 gallons/hour
(1.02 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)
92.5
52
18.6
18.9
Deutz F3L 1011
29 HP
@ 1800 RPM
Running Time for
25 gallons
(Hours)
CAUTION
COMMANDER 300 SETTINGS WHEN USING THE
K799 HL-FREQ UNIT
a. Set the SELECTOR switch to the “30-375” setting
(STICK/TIG).
b. Set the IDLER switch to the “HIGH” position.
c. Set the LOCAL/REMOTE switch to the “REMOTE”
position.
d. Set the WELDING TERMINALS switch to the
“WELDING TERMINALS ALWAYS ON” position.
This will close the solid state contactor and provide
an always “hot” electrode.
(Note: This is necessary because the K799 circuitry
with respect to the #2 and #4 leads does not provide
the proper signal to open and close the solid state contactor in the Commander 300).
COMMANDER 300 SETTINGS WHEN USING THE
K930-1 TIG MODULE
a. Set the SELECTOR switch to the 30-375 Setting
(STICK/TiG).
b. Set the IDLER switch to the “AUTO” position.
c. Set the LOCAL/REMOTE switch to the “REMOTE”
position.
d. Set the WELDING TERMINALS switch to the
“WELDING TERMINALS REMOTELY CON-
TROLLED” 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.
OPERATION
B-10 B-10
COMMANDER 300
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Tungsten
Electrode
Diameter
in. (mm)
2-15
5-20
15-80
70-150
150-250
250-400
400-500
500-750
750-1000
3
3
3
10-20
15-30
25-40
40-55
55-80
180-125
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)
TIG TORCH
Nozzle
Size
4 5
Approximate Argon Gas Flow Rate
C.F.H. (l/min.)
DCEN (-) DCEP (+)
#4, #5, #6
#5, #6
#6, #7, #8
#8, #10
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%, 2%
Thoriated
Tungsten
1%, 2%
Thoriated
Tungsten
Aluminum Stainless Steel
Table B.3 TYPICAL CURRENT RANGES1FOR TUNGSTEN ELECTRODES
2
1
When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
2
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure EWP
1% Thoriated EWTh-1
2% Thoriated EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated
Tungsten in AC and DC applications.
3
DCEP is not commonly used in these sizes.
4
TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:
# 4 = 1/4 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.
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.”
Some recommended Innershield electrodes are NR311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.
Recommended Outershield electrodes are 0S-70,
0S71M.
Some recommended solid wires for MIG welding
are.035 (0.9 mm), .045 (1.1 mm) and .052 (1.3 mm), L50 and L56, .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.
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 300 consists of
two 15 Amp-120 VAC (5-15R) duplex receptacles and
one 50 Amp-120/240 VAC (14-50R) receptacle. The
120/240VAC receptacle can be split for single-phase
120 VAC operation.
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.
NOTE: The 120/240V receptacle has two 120V outputs
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 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).
OPERATION
B-11 B-11
COMMANDER 300
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Welding
Output Range
Setting
30-375
300
230
150
90
60
Welding Output
300A/32V
300A/32V
230A/30V
150A/29V
90A27V
60A/25V
Permissible
Power - Watts
(Unity Power
Factor)
400
400
3100
5650
7600
8500
Permissible
Current in
@120 V ±10% *
3.3
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 15 amps.
** Not to exceed 44 amps per 120VAC branch circuit when splitting the 240VAC output.
TABLE B.4 Commander 300 Simultaneous Welding and Power Loads
NOTES
B-12 B-12
COMMANDER 300
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TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Options/Accessories ...................................................................................................................C-2
Field Installed Options ....................................................................................................... ..C-2
Stick Welding Accessories....................................................................................................C-2
TIG Welding Accessories .....................................................................................................C-2
Semiautomatic Welding Accessories....................................................................................C-3
Connection of Lincoln Electric Wire Feeders.......................................................................C-3
Connection of the LN-7..................................................................................................C-4
Connection of the LN-7 Using the K584 or K594 Input Cable Assembly......................C-5
Connection of the LN-8 Using the K867 Universal Adapter ..........................................C-6
Connection of the LN-8 Using the K595 Input Cable Assembly ...................................C-7
Connection of the LN-23-P ............................................................................................C-8
Connection of the LN-25................................................................................................C-9
Section C-1 Section C-1
COMMANDER 300
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OPTIONS/ACCESSORIES
The following options/accessories are available for
your Commander 300 from your local Lincoln
Distributor.
FIELD INSTALLED OPTIONS
K802R POWER PLUG KIT - Provides a plug for each
receptacle.
K857 25 ft. (8.5 m) or K857-1 100 ft. (30.4 m)
REMOTE CONTROL - Portable control provides same
dial range as the output control on the welder from a
location up to the specified length from the welder. Has
convenient plug for easy connection to the welder. The
Commander 300 is equipped with a 6-pin connector for
connecting the remote control and a toggle switch for
selecting “LOCAL” output control or “REMOTE” output
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.
K953-1 TWO-WHEEL TRAILER - For road, in-plant
and yard towing. Road towing with optional fender and
light kit. (For highway use, consult applicable federal,
state and local laws regarding possible additional
requirements.)
• K953-1 Trailer
• K958-1 Ball Hitch
• K958-2 Lunette Eye Hitch
• K959-1 Fender & Light Kit
• K965-1 Cable Storage Rack
K887-1 ETHER START KIT - Provides maximum cold
weather starting assistance for frequent starting below
10( F (-12.2( C). Required Ether tank is not provided
with kit.
K1604-1 OIL DRAIN KIT - Includes ball valve, hose
and clamp.
K1690-1 (2 DUPLEXES) GFCI KIt - Includes a UL
approved 1 15 volt ground fault circuit interrupter receptacle (duplex type) with covers and installation instructions. Each half of the receptacle is rated 15 amps, but
the maximum total current from the GFCI duplex is limited to 20 amps. The GFCI receptacle replaces the
factory installed 115 volt duplex receptacle.
S24647 SPARK ARRESTER
K1596-1 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
include battery ammeter, engine temperature, and
engine oil pressure. Fuel gauge is not available in kit
form.
K1597-1 42 VAC TRANSFORMER KIT - For products
requiring 42 VAC power source.
STICK WELDING ACCESSORIES
K704 Accessory Kit, which includes:
• Electrode holder and cable.
• Ground clamp and cable.
• Headshield.
TIG WELDING ACCESSORIES
• Magnum TIG Torch
• Magnum Parts Kit and Argon gas
• K930-ALL TIG Module (not required for
scratch-start DC TIG welding)
• K936-1 Control Cable
• K870 Foot Amptrol
Also available:
• K963-1/-2 Hand Amptrol
• K814 Arc Start Switch
• K937-22 Control Cable Extension
• K937-45 Control Cable Extension
• K844-1 Water Valve
ACCESSORIES
C-2 C-2
COMMANDER 300
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SEMIAUTOMATIC WELDING
ACCESSORIES
LN-7 OR LN-8 WIRE FEEDERS - Semiautomatic, con-
stant speed wire feeders. For CV operation only.
LN-23P WIRE FEEDER - This portable wire feeder is
capable of CV operation. K350-1 Adapter Kit is
required.
LN-25 WIRE FEEDER - The LN-25 with or without an
external contactor may be used with the Commander
300.
NOTE: Gas-shielded welding requires a Magnum Gun.
Gasless welding requires an Innershield Gun.
OTHER WIRE FEEDERS FOR THE
COMMANDER 300
• NA-3 Automatic Wire Feeder
• LN-142 Semiautomatic Wire Feeder(requires
optional K1597-1 42VAC Transformer Kit).
HIGH FREQUENCY GENERATORS FOR
TIG APPLICATIONS
The K799 Hi-Freq Unit and the K930-ALL TIG Modules
are suitable for use with the Commander 300. The
Commander 300 is equipped with the required RF
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-AII TIG Module operating manuals for complete instructions on installation,
operation, and maintenance.
CONNECTION OF LINCOLN
ELECTRIC WIRE FEEDERS
ELECTRIC SHOCK can kill.
• Do not operate with panels open.
• Disconnect NEGATIVE (-) BATTERY
LEAD before servicing.
• Do not touch electrically live parts.
MOVING PARTS can injure.
• Keep guards in place.
• Keep away from moving parts.
• Only qualified personnel should
install, use or service this equipment.
ACCESSORIES
C-3 C-3
COMMANDER 300
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WARNING
CONNECTION OF THE LN-7 TO THE
COMMANDER 300 USING K867
UNIVERSAL ADAPTER (SEE FIGURE C.1.)
1. Shut the welder off.
2. Connect the electrode cable from the LN-7 to the
“+” terminal of the welder. Connect the work cable
to the “-” terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.
NOTE: Figure C.1 shows the electrode connected for
positive polarity . To change polarity, shut the welder off
and reverse the electrode and work cables at the
Commander 300 output terminals.
3. Connect the K867 Universal Adapter to the K291
or K404 input cable and the 14-pin amphenol of the
Commander 300 as indicated in Figure C.1. Make
the proper connections for local or remote control
according to Figure C.1.
4. Connect the K291 or K404 input cable to the LN-7.
5. Place the IDLER switch in the “HIGH” position.
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control circuits may be damaged. The engine governor setting is
preset at the factory—do not adjust above RPM specifications listed in this manual.
6. Set the LOCAL/REMOTE switch to “REMOTE” if
a K775 remote control is used. Set the switch to
“LOCAL” if no remote control is used.
7. Set the VOLTMETER switch to “+” or “-” depending on the polarity chosen.
8. Set the OUTPUT RANGE switch to “WIRE
WELDING CV.”
9. Set the WELDING TERMINALS switch to
“WELDING TERMINAL REMOTELY CONTROLLED.”
10. Adjust wire feed speed at the LN-7.
11. Adjust the ARC CONTROL to the desired level
(“soft” or “crisp”).
ACCESSORIES
C-4 C-4
COMMANDER 300
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CAUTION
FIGURE C.1
COMMANDER 300/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM
GND
75
76
77
GREEN
K291 OR K404
75
INPUT CABLE
76
77
K775 OPTIONAL
REMOTE CONTROL
81
42
41
31
31
32
32
2
2
4
4
21
21
GND
82
LN-7
WIRE
FEEDER
SPARE
+
ELECTRODE CABLE
TO WIRE FEED UNIT
K867 UNIVERSAL
ADAPTER PLUG
14 PIN
AMPHENOL
–
TO WORK
ACCESSORIES
C-5 C-5
COMMANDER 300
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CONNECTION OF THE LN-7 TO THE
COMMANDER 300 USING K584 OR
K594 INPUT CABLE ASSEMBLY
(SEE FIGURE C.2.)
1. Shut the welder off.
2. Connect the electrode cable from the LN-7 to the
“+” terminal of the welder. Connect the work cable
to the “-” terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.
NOTE: Figure C.2 shows the electrode connected for
positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Commander 300 output terminals.
3. Connect the K584-XX or K594-XX Input Cable
Assembly to the LN-7.
4. Connect the K584-XX or 594-XX input cable
assembly to the 14-pin amphenol on the
Commander 300.
5. Place the IDLER switch in the “HIGH” position.
6. Set the LOCAL/REMOTE switch to “REMOTE” if a
K857 or K857-1 remote control is used. Set the
switch to “LOCAL” if no remote control is used.
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control circuits may be damaged. The engine governor setting is
preset at the factory—do not adjust above RPM specifications listed in this manual.
7. Set the VOLTMETER switch to “+” or “-” depending on the polarity chosen.
8. Set the OUTPUT RANGE switch to “WIRE
WELDING CV.”
9. Set the WELDING TERMINALS switch to
“WELDING TERMINALS REMOTELY CONTROLLED.”
10. Adjust wire feed speed at the LN-7.
11. Adjust the ARC CONTROL to the desired level
(“soft” or “crisp”).
NOTE: For remote control, a K857 or K857-1 remote
control is required. Connect it to the 6-pin amphenol.
CAUTION
FIGURE C.2
COMMANDER 300/LN-7 WITH K584 OR K594 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM
–
TO LN-7 INPUT
CABLE PLUG
AMPHENOL
OPTIONAL K857
REMOTE CONTROL
6 PIN
AMPHENOL
ELECTRODE CABLE
TO WORK
14 PIN
K584 OR K594 CONTROL CABLE
TO WIRE FEED UNIT
+
ACCESSORIES
C-6 C-6
COMMANDER 300
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CONNECTION OF THE LN-8 TO THE
COMMANDER 300 USING K867
UNIVERSAL ADAPTER (SEE FIGURE C.3.)
1. Shut the welder off.
2. Connect the electrode cable from the LN-8 to the
“+” terminal of the welder. Connect the work cable
to the “CV- Wire” terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.
NOTE: Figure C.3 shows the electrode connected for
positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Commander 300 output terminals.
3. Connect the K867 Universal Adapter to the K196
input cable and the 14-pin amphenol of the
Commander 300 as indicated in Figure C.3. Make
the proper connections for local or remote control
according to Figure C.3.
4. Connect the K196 input cable to the LN-8.
5. Place the IDLER switch in the “HIGH” position.
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor setting is preset at the factory—do not adjust above RPM
specifications listed in this manual.
6. Set the LOCAL/REMOTE switch to “REMOTE.”
7. Set the VOLTMETER switch to “+” or “-” depending on the polarity chosen.
8. Set the OUTPUT RANGE switch to “WIRE
WELDING CV.”
9. Set the WELDING TERMINALS switch to
“WELDING TERMINALS REMOTELY CONTROLLED.”
10. Adjust wire feed speed and voltage at the LN-8.
11. Adjust the ARC CONTROL to the desired level
(“soft” or “crisp”).
CAUTION
FIGURE C.3
COMMANDER 300/LN-8 WITH K867 ADAPTER CONNECTION DIAGRAM
75
32
31
41
42
GND
31
4
21
B
C
A
14 PIN
AMPHENOL
TO WORK
TO WORK
ELECTRODE
TO WIRE FEED UNIT
ELECTRODE CABLE
WIRE
FEEDER
K196
K867 UNIVERSAL
ADAPTER PLUG
INPUT CABLE
2
4
76
77
SPARE
82
81
21
GND
32
2
LN-8
CONNECTION OF THE LN-8 TO THE
COMMANDER 300 USING K595 INPUT
CABLE ASSEMBLY (SEE FIGURE C.4.)
1. Shut the welder off.
2. Connect the electrode cable from the LN-8 to the
“+” terminal of the welder. Connect the work
cable to the “-” terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.
NOTE: Figure C.4 shows the electrode connected for
positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Commander 300 output terminals.
3. Connect the K595-XX Input Cable Assembly to the
LN-8.
4. Connect the K595-XX to the 14-pin amphenol on
the Commander 300.
5. Place the IDLER switch in the “HIGH” position.
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor set
ting is preset at the factory—do not adjust above RPM
specifications listed in this manual.
6. Set the LOCAL/REMOTE switch to “REMOTE.”
7. Set the VOLTMETER switch to “+” or “-” depending on the polarity chosen.
8. Set the OUTPUT RANGE switch to “WIRE
WELDING CV.”
9. Set the WELDING TERMINALS switch to
“WELDING TERMINALS REMOTELY CONTROLLED.”
10. Adjust wire feed speed and voltage at the LN-8.
11. Adjust the ARC CONTROL to the desired level
(“soft” or “crisp”).
ACCESSORIES
C-7 C-7
COMMANDER 300
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CAUTION
FIGURE C.4
COMMANDER 300/LN-8 WITH K595 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM
–
TO LN-8 INPUT
CABLE PLUG
AMPHENOL
ELECTRODE CABLE
TO WORK
14 PIN
K595 INPUT CABLE ASSEMBLY
TO WIRE FEED UNIT
+
CONNECTION OF THE LN-23P TO THE
COMMANDER 300 USING K350-1
ADAPTER (SEE FIGURE C.5.)
1. Shut the welder off.
2. Connect the electrode cable from the LN-23P to
the “-” terminal of the welder. Connect the work
cable to the “+” terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.
NOTE: Figure C.5 shows the electrode connected for
negative polarity.
3. Connect the K350-1 adapter to the amphenol on
the LN-23P and the 14-pin amphenol of the
Commander 300 as indicated in Figure C.5.
4. Place the IDLER switch in the “HIGH” position.
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor set
ting is preset at the factory—do not adjust above RPM
specifications listed in this manual.
5. Set the VOLTMETER switch to negative.
6. Set the OUTPUT RANGE switch to “WIRE WELDING CV.”
7. Set the WELDING TERMINALS switch to “WELDING TERMINALS REMOTELY CONTROLLED.”
8. Set the LOCAL/REMOTE switch according to
whether you are controlling the welder at the
machine or remotely.
9. Adjust wire feed speed and voltage at the LN-23P.
ACCESSORIES
C-8 C-8
COMMANDER 300
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CAUTION
FIGURE C.5
COMMANDER 300/LN-23P CONNECTION DIAGRAM
LN-23P
LN-23P
602
604
521
757677
602
604
521
757677
14 PIN AMPHENOL
WORK
ELECTRODE
WIRE FEEDER "A" WIRE FEEDER "B"
ELECTRODE
21
9 CONDUCTOR ADAPTER CABLE
N.D.
N.C.
N.A.
N.B.
K350-1
LN-23P ADAPTER KIT
FEEDER "A" FEEDER "B"
CV-
+
ENGINE WELDER WITH
115 VAC AUXILIARY
CONNECTION OF THE LN-25 TO THE
COMMANDER 300 “ACROSS THE ARC”
(SEE FIGURE C.6.)
1. Shut the welder off.
2. Connect the electrode cable from the LN-25 to the
“-” terminal of the welder. Connect the work cable
to the “+” terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.
NOTE: Figure C.6 shows the electrode connected for
negative polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Commander 300 output terminals. Reverse the LN-25
polarity switch.
3. Attach the single lead from the LN-25 to the work
using the spring clip on the end of the lead. This is
only a sense lead – it carries no welding current.
4. Place the IDLER switch in the “AUTO” position.
If you are using an LN-25 without an internal contactor,
the electrode will be “HOT” when the Commander 300
is started.
5. Set the OUTPUT RANGE switch to “WIRE
WELDING CV.”
6. Set the WELDING TERMINALS switch to 'WELDING TERMINALS ALWAYS ON.”
7. Set the VOLTMETER switch to “+” or “-” depending on the polarity chosen.
8. Adjust wire feed speed at the LN-25.
9. Set the LOCAL/REMOTE switch to “REMOTE” if
a K444-1 remote control is used.
10. Adjust the ARC CONTROL to the desired level
(“soft” or “crisp”).
ACCESSORIES
C-9 C-9
COMMANDER 300
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CAUTION
FIGURE C.6
COMMANDER 300/LN-25 ACROSS THE ARC CONNECTION DIAGRAM
AMPHENOL
TO WORK
WORK CLIP LEAD
LN-25
WIRE FEEDER
OPTIONAL K444-1
REMOTE CONTROL
TO WORK
ELECTRODE
AMPHENOL
6 PIN
14 PIN
TO WORK
NOTES
C-10 C-10
COMMANDER 300
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Section D-1 Section D-1
COMMANDER 300
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance .........................................................................................................................Section D
Safety Precautions ......................................................................................................................D-2
Routine and Periodic Maintenance .............................................................................................D-2
Engine Maintenance............................................................................................................. D-2
Oil ..................................................................................................................................D-2
Change the Oil ...............................................................................................................D-2
Change the Oil Filter......................................................................................................D-3
Fuel.................................................................................................................................D-3
Fuel Filter .......................................................................................................................D-4
Bleeding the Fuel System..............................................................................................D-4
Air Filter..........................................................................................................................D-4
Cooling System..............................................................................................................D-4
Cooling Blower Belt .......................................................................................................D-5
Spark Arrester Screen....................................................................................................D-5
Engine Maintenance Schedule.......................................................................................D-6
Engine Maintenance Parts.............................................................................................D-6
Battery Maintenance.............................................................................................................D-7
Cleaning the Battery.......................................................................................................D-7
Checking Specific Gravity ..............................................................................................D-7
Checking Electrolyte Level.............................................................................................D-7
Charging the Battery ......................................................................................................D-7
Welder/Generator Maintenance ...........................................................................................D-8
Storage...........................................................................................................................D-8
Cleaning .........................................................................................................................D-8
Name plates...................................................................................................................D-8
Receptacles....................................................................................................................D-8
Cable Connections.........................................................................................................D-8
Major Component Locations ................................................................................................D-9
SAFETY PRECAUTIONS
• Have qualified personnel do all maintenance and
troubleshooting work.
• Turn the engine off before working inside the
machine.
• Remove covers or guards only when necessary to
perform maintenance and replace them when the
maintenance requiring their removal is complete.
• If covers or guards are missing from the machine,
get replacements from a Lincoln Distributor.
Read the Safety Precautions in the front of this manual and in the instruction manual for the diesel engine
used with your machine before working on the
Commander 300.
Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep your hands, hair,
clothing, and tools away from the fans, and all other
moving parts when starting, operating, or repairing this
machine.
ROUTINE AND PERIODIC
MAINTENANCE
Refer to Figure D.2 for the location of maintenance
components.
ENGINE MAINTENANCE
To prevent the engine from accidentally starting, disconnect the negative battery cable before servicing the
engine.
See Table D.1 for a summary of maintenance intervals
for the items listed below. Follow either the hourly or
the calendar intervals, whichever come first. More frequent service may be required, depending on your specific application and operating conditions.
OIL: Check the oil level after every 8 hours of operation or daily. BE SURE TO MAINTAIN THE OIL
LEVEL.
Change the oil the first time between 25 and 50 hours
of operation. Then, under normal operating conditions,
change the oil as specified in Table D.1. If the engine
is operated under heavy load or in high ambient temperatures, change the oil more frequently.
CHANGE THE OIL: Change the oil, while the engine
is still warm, as follows:
1 . Drain the oil from the drain plug located on the
engine bottom, as shown in Figure D.1.
2. Replace the plug and tighten it securely.
3. Remove the oil fill cap and add oil until the level
reaches the “MAX” mark on the dipstick. Use high
quality detergent oil of API service class CD or better, oil viscosity grade 10W30. Consult the engine
manual for oil specifications for various ambient
temperatures. Always check the level with the dipstick before adding more oil.
4. Reinstall the oil fill cap and the dipstick.
MAINTENANCE
D-2 D-2
COMMANDER 300
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WARNING
CAUTION
CHANGE THE OIL FILTER: Change the oil filter the
first time between 25 and 50 hours of operation. Then,
under normal operating conditions, change the oil filter
after every 250 hours of operation. If the engine is
operated under heavy load or in high ambient temperatures, change the oil filter more frequently . See Table
D.1 for recommended maintenance intervals. See
Table D.2 for replacement oil filters.
Change the oil filter as follows (See Figure D.1.):
1. Drain the oil from the engine and allow the oil filter
to drain.
2. Remove the old filter (spin it off) and discard it.
Wipe off the filter mounting surface and adapter.
3. Apply a thin coat of new oil to the rubber gasket on
the new oil filter
4. Spin the new filter onto the mounting adapter finger
tight until the gasket is evenly seated. Then turn it
down another 1/2 turn. Do not over tighten the new
filter.
5. Refill the engine with the proper amount and type
of oil as described in the Change the Oil section.
Start the engine and check for leaks around the filter element. Correct any leaks (usually by retightening the filter, but only enough to stop leaks)
before placing the Commander 300 back in service.
6. If there are no leaks, stop the engine and recheck
the oil level. If necessary, add oil to bring the level
up to the “MAX” mark, but do not overfill.
FUEL: At the end of each day's use, refill the fuel tank
to minimize moisture condensation and dirt contamination in the fuel line. Do not overfill; leave room for the
fuel to expand.
Refer to your engine operation manual for recommended grade of fuel.
MAINTENANCE
D-3 D-3
COMMANDER 300
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FIGURE D.1 – OIL DRAIN AND REFILL
MAX
MIN
FUEL FILTER:
When working on the fuel system:
• Keep naked lights away.
• Do not smoke !
• Do not spill fuel !
Inspect the fuel filter daily. Replace the fuel filter cartridge every 1000 hours of operation. Dust and dirt in
the fuel system can cause the injection pump and
injection nozzle to wear quickly. Replace the fuel filter
as follows (See Figure D.1.):
1. Close the fuel stopcock.
2. Loosen the fuel filter cartridge with a removal tool
and spin the cartridge off. Catch any escaping fuel
in an appropriate container.
3. Clean the sealing surface of the filter carrier. Apply
a light film of oil or diesel fuel to the rubber gasket
of the new fuel filter cartridge.
4. Screw the new cartridge into position finger tight
until the gasket is evenly seated. Then turn it down
another 1/2 turn. Do not over tighten the new filter.
5. Open the fuel stopcock. Check the assembly for
leaks.
BLEEDING THE FUEL SYSTEM: If the engine is operated until it runs out of fuel, you will need to bleed air
from the fuel system in order to start the engine. See
the engine operation manual for the recommended
procedure.
AIR FILTER
Excessive air filter restriction will result in reduced
engine life.
1. Service air cleaner regularly according to engine
operation 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 the element with compressed air or a water hose directed
from inside out. Compressed Air: 100 psi maximum
with nozzles at least one inch away from element.
Water Hose: 40 psi maximum without nozzle.
Soak the element in a mild detergent solution for 15
minutes. Do not soak more than 24 hours. Swish the
element around in the solution to help remove dirt.
Rinse the element from inside out with a gentle stream
of water (less than 40 psi) to remove all suds and dirt.
Dry the element before reuse with warm air at less than
160° F (71° C). 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 a damaged element. Protect the element from dust and damage during drying and storage.
Replace the air filter after six cleanings. A cleaned filter will have approximately 70% of the life of a new filter element. Arestricted filter element may not appear
excessively dirty.
COOLING SYSTEM: The Deutz diesel engine is air
cooled. Clean the engine cooling system periodically
to prevent clogging the air passages on the cylinder
heads and oil cooler, which would overheat the engine.
Consult the engine operation manual. It is important to
locate the welder to provide an unrestricted flow of
clean, cool air.
MAINTENANCE
D-4 D-4
COMMANDER 300
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WARNING
CAUTION
COOLING BLOWER BELT: The following procedure
should be followed to replace the cooling blower belt:
1. Allow the machine to cool.
2. Remove the engine case side.
3. Loosen the air filter hose clamp and detach hose.
4. Disconnect the negative battery cable.
5. Remove the engine case back panel for access to
the engine.
6. Remove the pulley belt guard (5 screws).
7. Remove the rubber strap on the lower half of the
engine fan cowling. Loosen the tensioning pulley
(2 bolts).
8. Remove the old V-belt and install a new one.
Refer to the engine operation manual for proper
tensioning of the belt.
9. Reinstall the rubber strap on the fan cowling, the
pulley belt guard, the engine case back, the air filter hose, and the engine case side.
10. Reconnect the negative battery terminal.
SPARK ARRESTER SCREEN: If the muffler has the
optional spark arrester, remove it every 50 hours or
once a year, whichever comes first, and inspect it.
Clean the arrester. Replace it if you find any damage.
MAINTENANCE
D-5 D-5
COMMANDER 300
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TABLE D.1
DEUTZ ENGINE MAINTENANCE SCHEDULE
FREQUENCY MAINTENANCE REQUIRED
Daily or Before • Fill fuel tank.
Starting Engine • Check oil level.
• Check air cleaner for dirty, loose, or damaged parts
• Check air intake and cooling areas, clean as necessary.
First 50 Hours • Change engine oil.
and Every 250
1
• Change oil filter.
Hours Thereafter • Change fuel filter2.
• Check fan belt.
Every 50 Hours • Check fuel lines and clamps.
Every 100 Hours • Check battery electrolyte level and connections.
• Clean air filter.
Refer to your Deutz engine operation manual for periodic maintenance at 100 hours and beyond.
1
125 Hours for severe conditions.
2
After the first 50 hours, change the fuel filter every 1000 hours. See the Deutz engine operation manual for specifics.
TABLE D.2
DEUTZ ENGINE MAINTENANCE PARTS
ITEM MAKE PART NUMBER
Air Cleaner Element Donaldson P181050
Frame CAK-256
AC A297C
Nelson 70206N
Cooling Blower Belt Deutz 117-9565
Oil Filter Element Deutz 117-4416
Fuel Filter Deutz 117-4482
Battery BCI
Group 34
MAINTENANCE
D-6 D-6
COMMANDER 300
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BATTERY MAINTENANCE
GASES FROM BATTERY can explode.
• Keep sparks, flame, and cigarettes
away from battery.
BATTERY ACID can burn eyes and skin.
• Wear gloves and eye protection and be
careful when working near a battery.
Follow the instructions printed on the
battery.
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY - Disconnect the
negative cable from the old battery first and connect
to the new battery last.
• CONNECTING ABATTERYCHARGER
- Remove the battery from the welder by
disconnecting the negative cable first,
then the positive cable and battery clamp.
When reinstalling, connect the negative
cable last. Keep the area well ventilated.
• USING A BOOSTER - Connect the positive lead to
the battery first, then connect the negative lead to the
engine foot.
• To prevent BATTERY BUCKLING, tighten the nuts
on the battery clamp until snug.
CLEANING THE BA TTERY: Keep the battery clean by
wiping it with a damp cloth when dirty. If the terminals
appear corroded, disconnect the battery cables and
wash the terminals with an ammonia solution or a solution of 1/4 pound (0.1 13 kg) of baking soda and 1 quart
(0.946 1) of water. Be sure the battery vent plugs (if
equipped) are tight so that none of the solution enters
the cells.
After cleaning, flush the outside of the battery, the battery compartment, and surrounding areas with clear
water. Coat the battery terminals lightly with petroleum
jelly or a non-conductive grease to retard corrosion.
Keep the battery clean and dry . Moisture accumulation
on the battery can lead to more rapid discharge and
early battery failure.
CHECKING SPECIFIC GRAVITY: Check each battery
cell with a hydrometer. Afully charged battery will have
a specific gravity of 1.260. Charge the battery if the
reading is below 1.215.
NOTE: Correct the specific gravity reading by adding four
gravity points (0.004) for every five degrees the electrolyte
temperature is above 80° F (27° C). Subtract four gravity
points (9.004) for every five degrees the electrolyte temperature is below 80° F (27° C).
CHECKING ELECTROLYTE LEVEL: If battery cells
are low, fill them to the neck of the filler hole with distilled water and recharge. If one cell is low, check for
leaks.
CHARGING THE BATTERY: The Commander 300 is
equipped with a wet charged battery. The charging
current is automatically regulated when the battery is
low (after starting the engine) to a trickle current when
the battery is fully charged.
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 300 charging system is NEG-
ATIVE GROUND. The 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 so can result in damage to the internal charger components.
Follow the instructions of the battery charger manufacturer for proper charger settings and charging time.
MAINTENANCE
D-7 D-7
COMMANDER 300
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WARNING
WELDER/GENERATOR
MAINTENANCE
STORAGE: Store the Commander 300 in clean, dry,
protected areas.
CLEANING: Blow out the generator and controls peri-
odically with low pressure air. Do this at least once a
week in particularly dirty areas.
NAME PLATES: Whenever routine maintenance is
performed on this machine - or at least yearly - inspect
all name plates and labels for legibility. Replace name
plates that are no longer clear. Refer to the parts list
for the replacement item number.
RECEPTACLES: Keep the electrical receptacles in
good condition. Remove any dirt, oil, or other debris
from their surfaces and holes.
CABLE CONNECTIONS: Check the welding cable
connections at the weld output terminals often. Be
sure that the connections are always tight.
MAINTENANCE
D-8 D-8
COMMANDER 300
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MAINTENANCE
D-9 D-9
COMMANDER 300
FIGURE D.2 - MAJOR COMPONENT LOCATIONS
1
2
4
3
9
5
7
6
8
10
1. CONTROL PANEL
2. FRONT PANELASSEMBLY
3. POWER MODULE/DIODE
RECTIFIER BRIDGE ASSEMBLY
4. BASE
5. FUEL TANK
6. ENGINE
7. ROTOR/STATOR
8. IDLER SOLENOID
9. REAR PANELASSEMBLY
10. CASE TOPAND SIDES
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NOTES
D-10 D-10
COMMANDER 300
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Section E-1 Section E-1
COMMANDER 300
Theory of Operation .............................................................................................................Section E
General Description ..............................................................................................................E-2
Battery, Engine, Rotor, Stator and Engine Protection ...........................................................E-2
Weld Windings, Rectifier, Power Modules and Feedback.....................................................E-3
Control Transformer and Control Board ...............................................................................E-4
Insulated Gate Bipolar Transistor (IGBT) Operation.............................................................E-5
Pulse Width Modulation.........................................................................................................E-6
Chopper Technology Fundamentals......................................................................................E-7
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
ENGINE
CONTROL
BOARD
ROTOR
CONTROL
TRANSFORMER
STATOR
AUXILIARY WINDINGS
ENGINE
PROTECTION
BATTERY
W
E
L
D
W
I
N
D
I
N
G
CHOKE
IGBT
IGBT
SHUNT
TO
CONTROL
BOARD
MECHANICAL
ROTATION
STARTER
ALTERNATOR
ENGINE
SENSORS
SOL
SOL
S
H
U
T
D
O
W
N
I
D
L
E
R
ARC
CONTROL
OUTPUT
CONTROL
MODE
SELECTOR
POWER MODULES
THREE-PHASE
RECTIFIER
WORK
TERMINAL
ELECTRODE
TERMINAL
__
+
42VAC
30VAC
30VAC
1
1
5
V
A
C
115VAC
RECEPTACLE
230VAC
RECEPTACLE
SLIP
RINGS
(TWO)
TO
CONTROL
BOARD
FIGURE E.1 – Commander 300 BLOCK LOGIC DIAGRAM
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GENERAL DESCRIPTION
The Commander 300 is a diesel engine-driven welding
power source capable of producing 300 amps at
32VDC at a 100% duty cycle. The engine is coupled to
a brush-type alternating current generator. This AC
output is rectified and controlled by Chopper
Technology to produced DC current for multi-purpose
welding applications. The Commander 300 is also
capable of producing 10,000 watts of AC auxiliary
power.
BATTERY, ENGINE, ROTOR, STATOR AND ENGINE PROTECTION
The 12VDC battery powers the engine starter motor
and also supplies power to the engine alternator and
engine protection board. When the engine is started
and running, the battery circuit voltage is fed through
the protection board to the rotor field coil via a brush
and slip ring configuration. This excitation or “flashing”
voltage magnetizes the rotor lamination. The rotor is
mechanically coupled to the engine. This rotating magnet induces a voltage in the stationary windings of the
main alternator stator. The stator houses a threephase weld winding and also a 115/230VAC singlephase auxiliary winding. The 115VAC portion of the
auxiliary winding is also rectified and serves as a feedback supply for the rotor field winding.
The engine alternator supplies charging current for the
battery circuit. The engine protection board monitors
the sensors and will shut the engine off in the event of
low oil pressure, engine over temperature, malfunction
in the engines alternator system or a low fuel condition.
The idler solenoid is mechanically connected to the
engines throttle linkage. If no welding or auxiliary current is being drawn from the Commander 300, the protection board activates the idler solenoid, which then
brings the engine to a low idle state. When output current is sensed, either weld or auxiliary, the protection
board deactivates the idler solenoid and the engine
returns to high RPM.
THEORY OF OPERATION
E-2 E-2
COMMANDER 300
FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND ENGINE PROTECTION
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
BATTERY
STARTER
ALTERNATOR
ENGINE
ENGINE
SENSORS
SOL
S
H
U
T
D
O
W
N
ENGINE
PROTECTION
SOL
I
D
L
E
R
MECHANICAL
ROTATION
D
L
E
W
SLIP
RINGS
STATOR
AUXILIARY WINDINGS
1
1
5
V
A
C
CONTROL
TRANSFORMER
W
I
N
D
I
N
G
ROTOR
115VAC
RECEPTACLE
THREE-PHASE
RECTIFIER
230VAC
RECEPTACLE
42VAC
30VAC
30VAC
TO
CONTROL
BOARD
IGBT
IGBT
CONTROL
BOARD
OUTPUT
ARC
CONTROL
CONTROL
SHUNT
CONTROL
BOARD
POWER MODULES
(TWO)
CHOKE
MODE
SELECTOR
WORK
TERMINAL
__
TO
ELECTRODE
TERMINAL
+
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WELD WINDINGS, RECTIFIER,
POWER MODULES AND FEEDBACK
The three-phase stator weld windings are connected to
a three-phase rectifier bridge. The resultant DC voltage is applied to parallel capacitors incorporated within the two power modules. These capacitors function
as filters and also as power supplies for the IGBTs.
See IGBT Operation in this section. The IGBTs act as
high-speed switches operating at 20KHZ. These
devices are switched on and off by the control board
through pulse width modulation circuitry. See Pulse
Width Modulation in this section. This “chopped” DC
output is applied through choke coils to the welding output terminals. The chokes function as current filters
and also help to balance the outputs of the two power
modules. Free-wheeling diodes are incorporated in the
power modules to provide a current path for the stored
energy in the chokes when the IGBTs are turned off.
See Chopper Technology in this section.
Output voltage and current feedback information is fed
to the control board. This information is sensed at the
output terminals and the shunt.
THEORY OF OPERATION
E-3 E-3
COMMANDER 300
FIGURE E.3 – WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
ENGINE
CONTROL
BOARD
ROTOR
CONTROL
TRANSFORMER
STATOR
AUXILIARY WINDINGS
ENGINE
PROTECTION
BATTERY
W
E
L
D
W
I
N
D
I
N
G
CHOKE
IGBT
IGBT
SHUNT
TO
CONTROL
BOARD
MECHANICAL
ROTATION
STARTER
ALTERNATOR
ENGINE
SENSORS
SOL
SOL
S
H
U
T
D
O
W
N
I
D
L
E
R
ARC
CONTROL
OUTPUT
CONTROL
MODE
SELECTOR
POWER MODULES
THREE-PHASE
RECTIFIER
WORK
TERMINAL
ELECTRODE
TERMINAL
__
+
42VAC
30VAC
30VAC
1
1
5
V
A
C
115VAC
RECEPTACLE
230VAC
RECEPTACLE
SLIP
RINGS
(TWO)
TO
CONTROL
BOARD
THEORY OF OPERATION
E-4 E-4
COMMANDER 300
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CONTROL TRANSFORMER AND
CONTROL BOARD
The control transformer primary winding is powered by
the 115VAC auxiliary coil in the stator. Three secondary voltages are developed by the control transformer. The 42VAC is applied to the control board
where it is rectified and used to operate the control
board circuitry. The two isolated 30VAC windings supply power to the IGBT driver circuits.
The control board monitors the operator controls (output, mode selector and arc control). It compares these
commands to the current and voltage feedback information it receives from the shunt and output terminals.
The circuitry on the control board determines how the
output should be controlled to optimize welding results
and sends the correct PWM signals to the IGBT driver
circuits.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
FIGURE E.4 – CONTROL TRANSFORMER AND CONTROL BOARD
BATTERY
STARTER
ALTERNATOR
ENGINE
ENGINE
SENSORS
SOL
S
H
U
T
D
O
W
N
ENGINE
PROTECTION
SOL
I
D
L
E
R
MECHANICAL
ROTATION
D
L
E
W
SLIP
RINGS
STATOR
AUXILIARY WINDINGS
1
1
5
V
A
C
CONTROL
TRANSFORMER
W
I
N
D
I
N
G
ROTOR
115VAC
RECEPTACLE
THREE-PHASE
RECTIFIER
230VAC
RECEPTACLE
42VAC
30VAC
30VAC
TO
CONTROL
BOARD
IGBT
IGBT
CONTROL
BOARD
OUTPUT
ARC
CONTROL
CONTROL
SHUNT
TO
CONTROL
BOARD
POWER MODULES
(TWO)
CHOKE
MODE
SELECTOR
WORK
TERMINAL
__
ELECTRODE
TERMINAL
+
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THEORY OF OPERATION
E-5 E-5
COMMANDER 300
FIGURE E.5 – IGBT OPERATION
DRAIN
SOURCE
GATE
INJECTING LAYER
BUFFER LAYER
DRAIN DRIFT REGION
BODY REGION
p +
n +
n -
p
n + n +
DRAIN
SOURCE
GATE
INJECTING LAYER
BUFFER LAYER
DRAIN DRIFT REGION
BODY REGION
p +
n +
n -
p
n + n +
POSITIVE
VOLTAGE
APPLIED
B. ACTIVE
A. PASSIVE
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semiconductors well suited for high frequency switching and high
current applications.
Drawing Ashows an IGBT in a passive mode. There is
no gate signal, zero volts relative to the source, and
therefore, no current flow. The drain terminal of the
IGBT may be connected to a voltage supply; but since
there is no conduction the circuit will not supply current
to components connected to the source. The circuit is
turned off like a light switch in the OFF position.
Drawing B shows the IGBT in an active mode. When
the gate signal, a positive DC voltage relative to the
source, is applied to the gate terminal of the IGBT, it is
capable of conducting current. A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to circuit components coupled
to the source. Current will flow through the conducting
IGBT to downstream components as long as the positive gate signal is present. This is similar to turning ON
a light switch.
COMMANDER 300
PULSE WIDTH MODULA TION
The term PULSE WIDTH MODULATION is used to
describe how much time is devoted to conduction in the
cycle. Changing the pulse width is known as MODULA TION. Pulse Width Modulation (PWM) is the varying
of the pulse width over the allowed range of a cycle to
affect the output of the machine.
MINIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT
is turned on and off for different durations during a
cycle. The top drawing shows the minimum output signal possible over a 50-microsecond time period.
The positive portion of the signal represents one IGBT
group conducting for 2 microsecond. The dwell time (off
time) is 48 microseconds. Since only 2 microseconds of
the 50-microsecond time period is devoted to conducting, the output power is minimized.
MAXIMUM OUTPUT
By holding the gate signals on for 48 microseconds and
allowing only 2 microseconds of dwell time (off time)
during the 50-microsecond cycle, the output is maximized. The darkened area under the top curve can be
compared to the area under the bottom curve. The
more darkened area under the curve, the more power
is present.
E-6 E-6
THEORY OF OPERATION
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FIGURE E.6 – TYPICAL IGBT OUTPUTS
MINIMUM OUTPUT
(Dwell or Off Time)
sec
2
MAXIMUM OUTPUT
48
50
sec
sec
(Dwell or Off Time)
sec
48
sec
50
CHOPPER TECHNOLOGY
FUNDAMENTALS
The new era of welding machines such as the
Commander 300, employ a technology whereby a DC
source is turned on and off (chopped up) at high speed,
then smoothed through an inductor to control an arc.
Hence the name “Chopper.” The biggest advantage of
the chopper technology is the high-speed control of the
arc, similar to the inverter machines. A block diagram
for this is as follows:
In this system, the engine drives a three-phase alternator, which generates power that is rectified and filtered to produce about 85VDC. The current is
applied through a solid state switch to an inductor. By
turning
the switch on and off, current in the inductor and the
arc can be controlled. The following diagram depicts
the current flow in the system when the switch is open
and closed:
When the switch is closed, current is applied through
the inductor to the arc. When the switch opens, current
stored in the inductor sustains flow in the arc and
through the diode. The repetition rate of switch closure
is 20Khz, which allows ultra-fast control of the arc. By
varying the ratio of on time versus off time of the switch
(Duty Cycle), the current applied to the arc is controlled. This is the basis for Chopper Technology:
Controlling the switch in such a way as to produce
superior welding.
THEORY OF OPERATION
E-7 E-7
COMMANDER 300
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3 PHASE
ALTERNATOR
DC RECTIFIER
AND FILTER
INDUCTOR
AND DIODE
ARC
ARC
CONTROL
SOLID STATE
SWITCH
INDUCTOR
SWITCH
DIODE
ARC
CURRENT WITH SWITCH OPEN
CURRENT WITH SWITCH CLOSED
85VDC
NOTES
E-8 E-8
COMMANDER 300
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Section F-1 Section F-1
COMMANDER 300
Troubleshooting & Repair Section................................................................................Section F
How to Use Troubleshooting Guide.......................................................................................F-2
PC Board Troubleshooting Procedures.................................................................................F-3
Troubleshooting Guide ................................................................................................F-4 - F-12
Test Procedures...................................................................................................................F-13
Case Cover Removal and Replacement Procedure ....................................................F-13
Case Front Knobs - Removal and Replacement Procedure.........................................F-18
Power Module Capacitor Discharge Procedure ...........................................................F-19
Idler Solenoid Test ........................................................................................................F-2 1
Shutdown Solenoid Test ...............................................................................................F-23
Engine Throttle Adjustment Test ...................................................................................F-27
Rotor Resistance Test ..................................................................................................F-31
Flashing and Rotor Voltage Test ..................................................................................F-33
Stator Voltage Test .......................................................................................................F-37
RF By-Pass Board Resistance Test .............................................................................F-43
Control Transformer Test ..............................................................................................F-47
Output Rectifier Bridge Test .........................................................................................F-51
Power Module Test ........................................................................................................F-55
Current Balance Test .....................................................................................................F-59
Control Input Test..........................................................................................................F-63
Feedback Input Test......................................................................................................F-67
PWM Output Test..........................................................................................................F-71
Power Supply Test.........................................................................................................F-75
Display Board Calibration Test......................................................................................F-77
Oscilloscope Waveforms......................................................................................................F-79
Normal Open Circuit Voltage Waveform (115 VAC Supply) ..........................................F-79
Normal Open Circuit Voltage Waveform (Stick)............................................................F-80
Normal Weld Voltage Waveform (Stick CC) ..................................................................F-81
Normal Weld Voltage Waveform (Wire CV) ..................................................................F-82
Normal Open Circuit Voltage Waveform (Wire CV Tap)................................................F-83
Replacement Procedures ....................................................................................................F-85
Power Module/Output Rectifier Bridge Assembly Removal
and Replacement .......................................................................................................F-85
Power Module (Chopper) PC Board Removal and Replacement ................................F-91
Diode Removal and Replacement ...............................................................................F-93
Stator/Rotor Removal and Replacement .....................................................................F-95
Retest After Repair.............................................................................................................F-104
TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION
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HOW TO USE TROUBLESHOOTING GUIDE
Service and repair should be performed by only 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.
TROUBLESHOOTING & REPAIR
F-2 F-2
COMMANDER 300
CAUTION
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. Symptoms are grouped
into four main categories: Output Problems,
Function Problems, Engine Problems, and
Welding Problems.
Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be conducted without removing the case cover.
Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the subject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.
All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this section. Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.
WARNING
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 1-800-833-9353.
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TROUBLESHOOTING & REPAIR
F-3 F-3
COMMANDER 300
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
2. Check for loose connections at the PC board
to assure that the PC board is properly
connected.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:
PC board can be damaged by static electricity.
- Remove your body’s static
charge before opening the staticshielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
to a grounded part of the
equipment frame.
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
ELECTRIC SHOCK
can kill.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow proper failure analysis.
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal
strips.
b. If the original problem is recreated by the
substitution of the original board, then the
PC board was the problem. Reinstall the
replacement PC board and test the machine.
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
PC BOARD TROUBLESHOOTING PROCEDURES
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
WARNING
CAUTION
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TROUBLESHOOTING & REPAIR
F-4 F-4
COMMANDER 300
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage is evident.
No welding output in neither Stick or CV modes. The engine operates normally. The auxiliary output is normal.
1. Contact your local Lincoln
Authorized Field Service Facility.
1. Place the Welding Terminals
Switch in the “ALWAYS ON”
position. If the problem is
solved, the fault may be in the
external control cable (if used),
leads #2 and #4. See the Wiring
Diagram.
2. With the engine at high idle
(1900 RPM), the machine in the
Stick mode and the OUTPUT
CONTROL at maximum, check
for the presence of approximately 87VDC (open circuit voltage at
the output terminals.
3. If the correct OCV is present at
the welding output terminals,
check the welding cables,
clamps and electrode holder for
loose or faulty connections.
4. Make sure that the
LOCAL/REMOTE switch is in the
correct position.
1. Contact the Lincoln Electric
Service Department at 1-800833-9353 (WELD).
1. Check for loose or faulty connections on the heavy current carrying leads between the output,
the power modules, the choke
and the output terminals.
2. Check the Welding Terminals
Switch and associated leads.
See the Wiring Diagram.
3. If the correct OCV is present
when the Welding Terminals
Switch is in the “ALWAYS ON”
position, perform the RF Bypass
Board Resistance Test. Also
check associated wiring. See
the Wiring Diagram.
4. Check the Remote/Local switch
and associated wiring. See the
Wiring Diagram. (leads #75, #76
and #77)
5. Perform the Stator Voltage
Test.
6. Perform the Output Rectifier
Bridge Test.
7. Perform the Power Module
Test.
8. Perform the Control Transformer Test.
9. Perform the Power Supply
Test.
10. Perform the Control Input Test.
11. Perform the Feedback Input
Test.
12. Perform the PWM Output Test.
13. Perform the Current Balance
Test (codes 10469 & 10470).
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TROUBLESHOOTING & REPAIR
F-5 F-5
COMMANDER 300
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
No welding output in neither Stick
or CV modes. Also, no auxiliary
power. The engine operates normally.
1. Check the brushes for wear and
proper contact to the rotor slip
rings.
2. Make sure the engine is operating at the correct high idle
speed (1900 RPM).
3. Check for loose or faulty connections or leads on the auxiliary power studs in the control
box. See the Wiring Diagram.
1. Perform the Rotor Resistance
Test.
2. Perform the Flashing and
Rotor Voltage Test. If the
“flashing” voltage is not present,
the protection board or leads
#201 or #200 may be faulty.
See the Wiring Diagram. Also,
make sure that lead #5P has
continuity (zero ohms) to
ground.
3. Check the field diode and
capacitor. Replace if necessary.
4. Perform the Stator Voltage
Test.
No auxiliary power at the receptacles. The welding output is normal
and the engine operates normally.
1. The circuit breakers may be
tripped. Reset if necessary.
2. Check for loose or faulty connections at the auxiliary receptacles.
1. Check the wiring between the
auxiliary receptacles, the connection studs in the control box,
and the main stator. See the
Wiring Diagram.
2. Perform the Stator Voltage
Test.
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TROUBLESHOOTING & REPAIR
F-6 F-6
COMMANDER 300
Observe Safety Guidelines
TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The machine has welding output
but no control of output. The auxiliary power is normal.
1. If a remote control unit is NOT
connected to the machine,
make sure the LOCAL/
REMOTE switch is in the
“LOCAL” position.
2. If a remote control unit IS connected and the machine operates normally when the switch is
in the “Local” position, the
remote control cable or unit may
be faulty. Check or replace.
1. If the machine operates normally in the “LOCAL” position but
not in the “remote” position, perform the RF Bypass Board
Resistance Test.
2. Check the Remote/Local switch
and associated wiring. See the
Wiring Diagram. (leads #75,
#76 and #77)
3. Perform the Power Module
Test.
4. Perform the Control Input Test.
5. Perform the Feedback Input
Test.
6. Perform the PWM Output Test.
7. TheControl Board may be faulty.
The machine has low welding output and low auxiliary output.
1. Check the brushes for wear and
proper contact to the slip rings.
2. The engine RPM may be low.
1. If the engine high idle speed is
low, perform the Throttle Ad-
justment Test.
2. Perform the Rotor Resistance
Test.
3. Perform the Rotor Voltage
Test. If the rotor voltage is low,
the field capacitor or field bridge
may be faulty. Test and replace
if necessary. See the Wiring
Diagram.
4. If the engine high idle RPM is
OK, then the engine may have
lost horsepower and be in need
of major repair.
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TROUBLESHOOTING & REPAIR
F-7 F-7
COMMANDER 300
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The output control on the Commander 300 does not work properly.
1. Make sure the Remote/Local
switch is in the “Local” position.
2. The output control (R1) may be
defective.
1. Check the Remote/Local switch
and associated wiring. See the
Wiring Diagram. (leads #75,
#76 and #77)
2. Perform the Power Supply
Test.
3. Perform the Control Input
Test.
4. Perform the Feedback Input
Test.
5. Perform the PWM Output Test.
6. Perform the Power Module
Test.
The remote output control does not function properly.
1. Make sure the Remote/Local
switch is in the “Remote” position.
2. The remote control unit may be
faulty. Repair or replace.
1. Check the Remote/Local switch
and associated leads. See the
Wiring Diagram.
2. Check the amphenols and
associated leads. See the
Wiring Diagram.
3. Perform the RF Bypass Board
Resistance Test.
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TROUBLESHOOTING & REPAIR
F-8 F-8
COMMANDER 300
Observe Safety Guidelines
TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The wire feeder does not work when connected to the welder amphenol.
1. Check the circuit breaker (CB5).
Reset if tripped.
2. The wire feeder control cable
may be faulty.
3. The wire feeder may be faulty.
1. Check for the presence of
115VAC at leads #31(J) and
#32(A) at the 14-pin amphenol.
2. If the 115VAC is NOT present at
the 14-pin amphenol, check
leads #31 and #32 for loose or
faulty connections. See the
Wiring Diagram.
3. Perform the Stator Voltage
Test.
The battery does not stay charged. 1. Check for loose or faulty con-
nections at the battery and
engine charging system.
2. The battery may be faulty.
Check or replace.
1. The battery charging circuit may
be faulty. See the Wiring
Diagram.
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TROUBLESHOOTING & REPAIR
F-9 F-9
COMMANDER 300
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
ENGINE PROBLEMS
The engine will not crank when the start button is pushed.
1. Check for loose or faulty battery
cable connections.
2. The battery may be low or faulty.
1. If the battery is replaced or tests
good, then the charging circuit
may be faulty. See the Wiring
Diagram.
2. The starter motor or starter solenoid may be faulty.
3. The engine may be hard to
crank due to a mechanical failure in the engine.
The engine cranks, but will not start.
1. Check for adequate fuel supply.
2. Make sure the fuel shut off valve
is in the open position.
3. The engine oil temperature may
be too high. Check cooling system.
4. The battery voltage may be too
low.
1. The shutdown solenoid may be
faulty. Perform the Fuel Shut-
down Solenoid Test.
2. The engine protection board
may be faulty. With the
Run/Stop switch in the “Run”
position, the protection board
should normally supply 10VDC
to the shutdown solenoid via
leads #224 and #262. See the
Wiring Diagram.
3. The engine may be in need of
mechanical repair.
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TROUBLESHOOTING & REPAIR
F-10 F-10
COMMANDER 300
Observe Safety Guidelines
TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
ENGINE PROBLEMS
The engine shuts down shortly after starting.
1. Check for adequate fuel supply.
2. If any indicator light is lit when
the engine shuts down, that particular system has faulted.
Check system.
3. Check the battery cables for
loose or faulty connections.
1. Check the Run/Stop switch and
associated leads for loose or
faulty connections.
2. Perform the Fuel Shutdown
Solenoid Test.
3. The engine protection board
may be faulty. With the Run/
Stop switch in the “Run” position, the protection board should
normally supply 10VDC to the
shutdown solenoid via leads
#224 and #262. See the Wiring
Diagram.
The engine will not idle down to low speed. The machine has normal weld output and auxiliary power.
1. Make sure the idler switch is in
the “Auto” position.
2. Make sure there is NOT an
external load on the weld terminals nor the auxiliary power
receptacles.
3. Check for mechanical restrictions in the solenoid linkage.
1. Perform the Idler Solenoid
Test.
2. The engine protection board
may be faulty.
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TROUBLESHOOTING & REPAIR
F-11 F-11
COMMANDER 300
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
ENGINE PROBLEMS
The engine will not go to high idle
when using the auxiliary power.
Auxiliary power is normal when the
idler switch is in the “high” position.
Automatic idle function works properly when the welding terminals are
loaded.
1. Make sure the auxiliary power
leads are tight.
2. The automatic idler may not
function if the auxiliary power is
loaded to less than 150 watts.
1. Check the current sensing
toroid for loose or faulty connections. See the Wiring Diagram.
2. Make sure leads #3 and #6A
pass through the toroid twice in
opposite directions.
3. The current sensing toroid may
be faulty.
4. The engine protection board
may be faulty.
The engine will not go to high idle when attempting to weld or when the auxiliary power is loaded. Welding output and auxiliary power outputs are normal when idler switch is in the “High” position.
1. Make sure the welding cables
and auxiliary power lead connections are tight.
1. The engine protection board
may be faulty.
The machine goes to low idle but does not stay at low idle.
1. Make sure there is NOT an
external load (auxiliary or weld)
connected to the Commander
300.
1. The idler solenoid linkage may
be misadjusted or damaged.
2. The idler solenoid lead connections (#226A and #237A) may
be loose or damaged.
3. Perform the Idler Solenoid
Test.
4. The engine protection board
may be faulty.
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F-12 F-12
COMMANDER 300
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The welding arc is “cold.” The engine runs normally. The auxiliary power is normal.
The welding arc is “hot”. The engine runs normally. The auxiliary power is normal.
1. Check for loose or faulty connections at the weld output terminals
and welding cable connections.
2. Make sure the work clamp has a
clean connection to the work
piece.
3. The welding cables may be too
long or coiled, causing an
excessive voltage drop.
4. Make sure the electrode (wire,
gas, voltage, current, etc.) is
correct for the process being
used.
5. Make sure the machine settings
match the weld application.
1. Make sure the electrode (wire,
gas, voltage, current, ect.) is
correct for the process being
used.
2. Make sure the machine settings
match the weld application.
1. Check for the correct OCV at the
welding output terminals. If the
correct voltage is present at the
output terminals, check for loose
connection on the heavy current
carrying leads inside the
Commander 300. See the
Wiring Diagram.
2. If the OCV is low at the welder
output terminals, perform the
Engine Throttle Adjustment
Test.
3. Perform the Output Rectifier
Bridge Test.
4. Perform the Stator Voltage
Test.
5. Perform the Power Module
Test.
6. Perform the Control Input Test.
7. Perform the Feedback Input
Test.
8. Perform the PWM Output Test.
9. If so equipped, perform the
Display Board Calibration
Test.
1. Perform the Power Module
Test.
2. Perform the Control Input Test.
3. Perform the Feedback Input
Test.
4. Perform the PWM Output Test.
5. If so equipped, perform the
Display Board Calibration
Test.
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TROUBLESHOOTING & REPAIR
F-13 F-13
COMMANDER 300
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the case sheet
metal covers.
MATERIALS NEEDED
3/8" wrench
7/16" wrench
1/2" wrench
3/4" wrench
This procedure should take approximately 30 minutes to perform.
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TROUBLESHOOTING & REPAIR
F-14 F-14
COMMANDER 300
FIGURE F.1 – DOOR REMOVAL
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)
PROCEDURE
1. Turn the engine off.
2. Using the 3/8" wrench, remove the battery
cover. Slide the battery out and disconnect
the negative battery cable.
3. Unlatch and open the engine service access
door. See Figure F.1.
4. Support the door assembly. Using the 3/8"
wrench, remove the #10-24 round head
screw, lock washer, flat washer, and nut from
the top corner of the door hinge assembly,
where it attaches to the roof. Remove the
support rod.
ROUND
HEAD SCREW
LOCATION
DOOR
ASSEMBLY
LEFT
FRONT
PANEL
PROP ROD
RIGHT
FRONT
PANEL
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TROUBLESHOOTING & REPAIR
F-15 F-15
COMMANDER 300
FIGURE F.2 – FRONT PANEL/ROOF DETAILS
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)
5. Using the 3/8" wrench, remove the two
screws from the top front of the roof assembly and the two screws from the sides of the
control box. Carefully lower the front control
panel. See Figure F.2.
6. With 3/8" wrench, remove the right rear
panel and the right and left front panels.
See Figure F.1.
7. With the 1/2" wrench, remove the exhaust
pipe rain cap.
8. Remove the fuel tank cap, gasket, and the
lift bail cover seal.
9. With the help of an assistant, carefully
remove the roof. The door assembly
remains attached to the roof. Replace the
fuel cap.
SCREWS
FRONT
CONTROL
PANEL
SCREW
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TROUBLESHOOTING & REPAIR
F-16 F-16
COMMANDER 300
FIGURE F.3 – OUTPUT PANEL REMOVAL
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)
OUTPUT PANEL REMOVAL
1. Using the 3/4" wrench, remove the internal
leads from the positive and negative output
terminals. See Figure F.3.
2. Using the 3/8" wrench, remove the three
screws along the bottom of the output panel.
Then remove the two screws holding the top
of the panel. These are accessed in the control box, on the bottom at each side of the
box. See Figure F.3.
3. Using the 3/8" wrench, remove the green
ground lead from the panel.
4. The output panel can now be removed and
set aside.
OUTPUT LEADS
(BEHIND PANEL)
SCREWS
GREEN
GROUND
LEAD
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TROUBLESHOOTING & REPAIR
F-17 F-17
COMMANDER 300
REASSEMBLY PROCEDURE
1. Output panel: Set the panel in place.
2. Install the five screws that mount the panel
at the top and bottom.
3. Attach the green ground lead.
4. Install the internal leads to the output terminals.
5. Side panels, roof and door assembly:
Remove the fuel cap. With the help of an
assistant, carefully set the roof/door assembly in place. Replace the fuel tank gasket
and the lift bail cover seal. Replace the fuel
cap. Install the exhaust pipe rain cap.
6. Install the right rear panel and the right and
left front panels. Raise the control panel
front and install the two screws at the roof
and the two at the sides.
7. Install the support rod and the #10-24 round
head screw, washer, and nut.
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)
TROUBLESHOOTING & REPAIR
F-18 F-18
COMMANDER 300
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CASE FRONT KNOBS - REMOVAL AND REPLACEMENT PROCEDURE
Removal
Side View
(Pull)
NameplateKnob
(Push)
Removal:
(Pull)
(Push)
1. Rotate the handle portion of the knob to an approximate vertical orientation (switch detent may position
handle a few degrees off vertical). This orientation should be noted and repeated at replacement for proper
"D" shaft orientation.
2. With one hand, grasp the very bottom of vertical handle and push towards the machine nameplate and
pull down. At the same time and with the other hand, grasp the very top of the handle and pull the top edge
of the knob away from the machine nameplate. The knob should "peel" away from the nameplate and the
white nylon holding fingers of the knob base, from top to bottom.
Replacement
Rounded
Replacement:
1. If the white nylon cam of the detent mechanism is removed from it's spring loaded base by the above
procedure or intentionally, it should be returned before the knob replacement is attempted. Press the cam
into it's spring loaded holder so it sets flat and flush (Selector Switch Only).
2. Orientate the knob handle to the vertical as noted above and position the knob over the base, centered
and parallel.
3. Press the knob onto the "D" shaft and white nylon holding fingers, maintaining the parallel position.
The knob should "click" into place and should not pull off with normal operation.
Flat
TROUBLESHOOTING & REPAIR
F-19 F-19
COMMANDER 300
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WARNING
POWER MODULE CAPACITOR DISCHARGE PROCEDURE
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This procedure will insure that the large capacitors in the power modules have been discharged. This procedure should be performed whenever work is to be attempted on or
near the power modules.
MATERIALS NEEDED
3/8" Wrench
Volt/Ohmmeter
Resistor (25-1000 ohms and 25 watts minimum)
Jumper leads
This procedure should take approximately 15 minutes to perform.
TROUBLESHOOTING & REPAIR
F-20 F-20
COMMANDER 300
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POWER MODULE CAPACITOR DISCHARGE PROCEDURE (continued)
FIGURE F.4 – POWER MODULE CAPACITOR TERMINAL DISCHARGE
POWER
MODULE
CAPACITOR
TERMINALS
TEST PROCEDURE
1. This procedure must be performed with the
engine off.
2. Using the 3/8" wrench, remove the front left
and right side panels.
3. Locate the two power modules (one on
each side). See Figure F.4.
4. Using the resistor and jumper leads, CAREFULLY discharge the capacitor terminals.
NEVER USE A SHORTING STRAP FOR
THIS PURPOSE. DO NOT TOUCH THE
TERMINALS WITH YOUR BARE HANDS.
Repeat procedure on the other side.
5. Check the voltage across the capacitor terminals. It should be zero volts.
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TROUBLESHOOTING & REPAIR
F-21 F-21
COMMANDER 300
WARNING
IDLER SOLENOID TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the idler solenoid is capable of functioning when it is energized
with 12VDC.
MATERIALS NEEDED
External 12VDC supply ( 30 amps)
Wiring Diagram
Volt/Ohmmeter
This procedure should take approximately 25 minutes to perform.
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TROUBLESHOOTING & REPAIR
F-22 F-22
COMMANDER 300
IDLER SOLENOID TEST (continued)
FIGURE F.5 – IDLER SOLENOID LEADS
IDLER
SOLENOID
IN-LINE
CONNECTORS
TEST PROCEDURE
1. Turn the engine off.
2. Unlatch, lift, and secure the right side
engine service access door.
3. Locate and remove the two in-line connectors that attach the idler solenoid leads to
the wiring harness leads (#226A, #237A).
See Figure F.5 and the Wiring Diagram.
4. Check the coil resistance. The normal
resistance is approximately 4.5 ohms. If the
coil resistance is not correct, the solenoid
may be faulty. Replace.
5. Using the external 12VDC supply, apply
12VDC to the solenoid leads. The solenoid
should activate. The solenoid should deactivate when the 12VDC is removed.
6. If the solenoid does not operate properly,
check for a mechanical restriction in the
linkage.
7. If the linkage is intact and the solenoid does
not operate correctly when the 12VDC is
applied, the solenoid may be faulty.
Replace.
8. Replace leads #226A and #237A to the correct in-line connectors. See Figure F.5 and
the wiring diagram. Replace any previously
removed wire wraps.
9. Close and secure the right side engine service access door.
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TROUBLESHOOTING & REPAIR
F-23 F-23
COMMANDER 300
WARNING
SHUTDOWN SOLENOID TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the shutdown solenoid is capable of functioning when it is energized with 12VDC.
MATERIALS NEEDED
External 12VDC supply (10 amps minimum)
Wiring Diagram
Volt/Ohmmeter
3/8" Socket wrench
This procedure should take approximately 30 minutes to perform.
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TROUBLESHOOTING & REPAIR
F-24 F-24
COMMANDER 300
SHUTDOWN SOLENOID TEST (continued)
TEST PROCEDURE
1. Turn the engine off.
2. Unlatch, lift, and secure the right side engine
service access door.
3. Using the 3/8" wrench, remove the right front
case side.
4. Locate and unplug J30 from P30. See
Figure F.6 and the Wiring Diagram.
FIGURE F.6 - PLUG J30 LOCATION
MOVING PARTS
Do not operate with
doors open or guar
ds of
f.
J30
INSTALLATION
F-25 F-25
COMMANDER 300
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SHUTDOWN SOLENOID TEST (continued)
5. Check the shutdown solenoid coil resistance
from lead #224 (8J30) to lead #262 (7J30).
The normal resistance is approximately 3
ohms. If the resistance is not correct, the
coil or the diode that is in parallel with the
coil may be faulty. See the Wiring Diagram.
See Figure F.7.
6. Using the external 12VDC supply apply
12VDC to leads #224(+) and #262(-). See
Figure F.7. CORRECT POLARITY MUST
BE OBSERVED OR DAMAGE TO THE
INTERNAL DIODE MAY RESULT. See the
Wiring Diagram. The shutdown solenoid
should activate when the 12VDC is applied.
This can be detected by a “clicking” sound.
7. The solenoid should deactivate when the
12VDC is removed.
8. If the solenoid does not activate when the
12VDC is applied the solenoid or internal
diode may be faulty. Replace.
9. Reconnect plug J30 and P30. Replace any
cable ties previously removed.
10. Reassemble the right front case side and
close the engine service access door.
FIGURE F.7 – PLUG J30 PIN/LEAD ASSIGNMENTS
#224(+) #262(-)
8
910
654
7
11 12 13 14
32
1
15 16
J30
NOTES
F-26 F-26
COMMANDER 300
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TROUBLESHOOTING & REPAIR
F-27 F-27
COMMANDER 300
WARNING
ENGINE THROTTLE ADJUSTMENT TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
If the machine output is low or high, this test will determine whether the engine is operating at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for
adjusting the throttle to the correct RPM are given.
MATERIALS NEEDED
Slot head screw driver
3/8" wrench
7/16" wrench
10mm wrench
White or red marking pencil
Strobe-tach, frequency counter, or oscilloscope
This procedure should take approximately 35 minutes to perform.
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TROUBLESHOOTING & REPAIR
F-28 F-28
COMMANDER 300
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.8 – STROBE MARK LOCATION
MARK BLOWER
PADDLE HERE
TEST PROCEDURE
1. Conduct this procedure with the engine OFF.
2. Unlatch, lift, and secure the right side service
access door. With the 3/8" wrench, remove
the right front side cover.
3. With a white or red marking pencil, place a
mark on one of the blower paddles or on the
side of the flywheel. See Figure F.8 for location.
4. Connect the strobe-tach according to the
manufacturer's instructions.
5. Start the engine and direct the strobe-tach
light on the blower paddle. Synchronize it to
the rotating mark.
With the machine at HIGH IDLE the tach
should read between 1880 and 1910 RPM.
With the machine at LOW IDLE the tach
should read between 1350 and 1400 RPM.
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TROUBLESHOOTING & REPAIR
F-29 F-29
COMMANDER 300
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.9 - HIGH IDLE ADJUSTMENT
ADJUSTING SCREW
LOCKING NUT
FIGURE F.10 - LOW IDLE ADJUSTMENT
ADJUSTING COLLAR
LOCKING NUT
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TROUBLESHOOTING & REPAIR
F-30 F-30
COMMANDER 300
ENGINE THROTTLE ADJUSTMENT TEST (continued)
6. If either of the readings is incorrect, adjust
the throttle as follows:
Adjust HIGH IDLE: Use the 10mm wrench
to loosen the locking nut. See Figure F.9 for
location of the adjusting screw and locking
nut. Turn the threaded screw counter-clockwise to increase the HIGH IDLE speed.
Adjust the speed until the tach reads
between 1880 and 1910 RPM. Retighten
the locking nut.
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
change to low idle speed. Use the 7/16"
wrench to loosen the solenoid lever arm
locking nut. See Figure F.10. Adjust the
collar, to change the amount of throw in the
lever arm, until the tach reads between 1350
and 1400 RPM. Retighten the locking nut.
Frequency Counter Method
1. Plug the frequency counter into one of the
115 VAC auxiliary receptacles.
2. Start the engine and check the frequency
counter. At HIGH IDLE (1900 RPM), the
counter should read 63 Hz. At LOW IDLE
(1400 RPM), the counter should read 47 Hz.
Note that these are median measurements;
hertz readings may vary slightly above or
below.
3. If either of the readings is incorrect, adjust
the throttle as follows:
Adjust HIGH IDLE: Use the 10mm wrench
to loosen the locking nut. See Figure F.9 for
location of the adjusting screw and locking
nut. Turn the threaded screw counter-clockwise to increase the HIGH IDLE speed.
Adjust the speed until the frequency reads
63 Hz. Retighten the locking nut.
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
change to low idle speed. Use the 7/16"
wrench to loosen the solenoid lever arm
locking nut. See Figure F.10. Adjust the
collar, to change the amount of throw in the
lever arm, until the frequency reads 47 Hz.
Retighten the locking nut.
Oscilloscope Method
1. Connect the oscilloscope to the 115 VAC
receptacle, according to the manufacturer’s
instructions. At HIGH IDLE (1900 RPM), the
waveform should exhibit a period of 15.8
milliseconds. At LOW IDLE (1400 RPM),
the waveform should exhibit a period of 21.4
milliseconds. Refer to the NORMAL OPEN
CIRCUIT VOLTAGE WAVEFORM (115
VAC AUXILIARY) HIGH IDLE - NO LOAD
in this section of the manual.
2. If either waveform periods is incorrect,
adjust the throttle as follows:
Adjust HIGH IDLE: Use the 10mm wrench
to loosen the locking nut. See Figure F.9 for
location of the adjusting screw and locking
nut. Turn the threaded screw counter-clockwise to increase the HIGH IDLE speed.
Adjust the speed until the period is 15.8 milliseconds. Retighten the locking nut.
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
change to low idle speed. Use the 7/16"
wrench to loosen the solenoid lever arm
locking nut. See Figure F.10. Adjust the
collar, to change the amount of throw in the
lever arm, until the period is 21.4 milliseconds. Retighten the locking nut.
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TROUBLESHOOTING & REPAIR
F-31 F-31
COMMANDER 300
WARNING
ROTOR RESISTANCE TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there is a shorted winding in the rotor or if the rotor is grounded.
MATERIALS NEEDED
Ohmmeter
3/8" wrench
Needle nose pliers
This procedure should take approximately 15 minutes to perform.
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TROUBLESHOOTING & REPAIR
F-32 F-32
COMMANDER 300
ROTOR RESISTANCE TEST (continued)
FIGURE F.11 – ROTOR BRUSH LEADS
LEADS REMOVED
SLIP RINGS
TEST PROCEDURE
1 Conduct this test with the engine off.
2. Using the 3/8" wrench, remove the left front
case side.
3. Locate, label and remove the three leads
from the rotor brush holder assembly. See
Figure 11. This will electrically isolate the
rotor windings.
4. Using the ohmmeter, check the rotor winding
resistance across the slip rings. Normal
resistance is approximately 23.5 ohms.
5. Measure the resistance to ground. Place
one meter probe on either of the slip rings.
Place the other probe on any good unpainted ground. The resistance should be very
high, at least 500,000 ohms.
6. If the test does not meet the resistance specifications, then the rotor may be faulty.
Replace.
7. Connect the leads previously removed from
the brush assembly. Make sure the leads
are connected to the proper brushes.
8. Replace the left front case cover previously
removed.
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TROUBLESHOOTING & REPAIR
F-33 F-33
COMMANDER 300
WARNING
FLASHING AND ROTOR VOLTAGE TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct DC voltage is being applied to the rotor at the maximum engine speed (1900 RPM). This information will aid the technician in determining if
the generator field is operating properly.
MATERIALS NEEDED
Volt/Ohmmeter
3/8" Wrench
Wiring Diagram
This procedure should take approximately 20 minutes to perform.
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TROUBLESHOOTING & REPAIR
F-34 F-34
COMMANDER 300
FLASHING AND ROTOR VOLTAGE TEST (continued)
FIGURE F.12 – ROTOR BRUSH LEADS
#200A
#200B
#201
TEST PROCEDURE
1. Using the 3/8" wrench, remove the sheet
metal screws from the left front case side.
2. Carefully remove the left case side.
3. Set the volt/ohmmeter to the DC volts position.
4. Connect the positive meter probe to the
brush nearest the rotor lamination (leads
#200A and #200B). See Figure F.12.for
location.
5. Connect the negative meter probe to the
other brush (lead #201).
6. Start the engine and run it at high idle
speed (1900 RPM). Check the voltage
reading on the meter. It should read
approximately 160VDC.
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TROUBLESHOOTING & REPAIR
F-35 F-35
COMMANDER 300
FIGURE F.13 - FIELD DIODE RECTIFIER BRIDGE AND FILTER CAPACITOR
FILTER
CAPACITOR
FIELD DIODE
RECTIFIER BRIDGE
FLASHING AND ROTOR VOLTAGE TEST (continued)
7. If the voltage reading is low or not present,
the generator field is not functioning properly. Perform the Rotor Resistance Test.
Also check the field diode rectifier bridge, filter capacitor, and associated leads and connections. See Figure F.13 for location. See
the Wiring Diagram.
NOTE: The normal flashing voltage is approximately 9VDC. This is battery voltage, which is
processed and controlled through the engine
protection board. This voltage must be present
during start-up to “flash” the rotor field.
8. If the rotor voltage readings are normal, the
field circuit is functioning properly. Install
the left case side with the sheet metal
screws previously removed.
NOTES
F-36 F-36
COMMANDER 300
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TROUBLESHOOTING & REPAIR
F-37 F-37
COMMANDER 300
WARNING
STATOR VOLTAGE TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct AC voltages are being generated from the stator
windings.
MATERIALS NEEDED
Volt/Ohmmeter
3/8" wrench
3/4" wrench
This procedure should take approximately 40 minutes to perform.
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TROUBLESHOOTING & REPAIR
F-38 F-38
COMMANDER 300
STATOR VOLTAGE TEST (continued)
FIGURE F.14 – FRONT CONTROL PANEL REMOVAL
FRONT
CONTROL
PANEL
SCREWS
SCREW
TEST PROCEDURE
1. Turn the engine off.
2. Using the 3/8" wrench, remove the four
screws holding the front control panel to the
case top and sides. See Figure F.14. (There
are two screws on the top and one screw on
each side.)
3. Carefully lower the front control panel.
4. Using the 3/8" wrench, remove the front left
and right side panels.
5. Using the 3/4" wrench, remove the internal
leads from the output terminals. Insulate the
leads.
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TROUBLESHOOTING & REPAIR
F-39 F-39
COMMANDER 300
STATOR VOLTAGE TEST (continued)
FIGURE F.15 – OUTPUT PANEL REMOVAL
6. Using the 3/8” wrench, remove the five
screws holding the lower front panel (output
panel) to the case front assembly. See
Figure F.15. Carefully move the lower front
panel to the right side. Note the green
ground lead will still be attached.
SCREWS
GREEN
GROUND
LEAD
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TROUBLESHOOTING & REPAIR
F-40 F-40
COMMANDER 300
STATOR VOLTAGE TEST (continued)
FIGURE F.16 – AUXILIARY LEAD TEST LOCATION
AUXILIARY POWER AND WELD
WINDINGS TEST
1. Start the engine and run at high idle (1900
RPM). Do not load welding or auxiliary
power.
2. Check for 115-132VAC at leads #3 to #5.
Also check for 115-132VAC from leads #6 to
#5. See the Wiring Diagram.
3. Check for 230 to 264VAC at leads #3 to #6.
See the Wiring Diagram.
AUXILIARY
LEADS #3, #5, #6
(BEHIND PANEL)
TROUBLESHOOTING & REPAIR
F-41 F-41
COMMANDER 300
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STATOR VOLTAGE TEST (continued)
FIGURE F.17 – OUTPUT RECTIFIER DIODE BRIDGE
4. Locate the weld winding leads connected to
the three-phase output rectifier diode bridge.
See Figure F.17.
5. Check for approximately 68VAC from W1 to
W2. Also check from W2 to W3 and from W1
to W3.
6. If any of these voltages are low or missing
perform the Rotor Flashing and Voltage
Test and also the Rotor Resistance Test.
7. Also check leads #6H and #5P for loose or
faulty connections to the field bridge. See the
Wiring Diagram.
8. If the tests in Steps 6 and 7 are OK and the
stator voltages are low or missing, the stator may be faulty.
9. Replace the lower front panel and output
leads.
10. Replace the upper control panel and
secure.
11. Replace the front left and right case sides.
WELD WINDING
LEAD CONNECTIONS
NOTES
F-42 F-42
COMMANDER 300
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TROUBLESHOOTING & REPAIR
F-43 F-43
COMMANDER 300
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WARNING
RF BY-PASS BOARD RESISTANCE TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the inductor filters on the RF By-Pass Board are intact and capable of passing signal information.
MATERIALS NEEDED
Volt/Ohmmeter
3/8" Nut driver
Phillips head screwdriver
This procedure should take approximately 25 minutes to perform.
TROUBLESHOOTING & REPAIR
F-44 F-44
COMMANDER 300
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RF BY-PASS BOARD RESISTANCE TEST (continued)
FIGURE F.18 – FRONT CONTROL PANEL REMOVAL
FRONT
CONTROL
PANEL
SCREWS
SCREW
TEST PROCEDURE
1. Turn the engine off.
2. Using the 3/8" wrench, remove the four
screws holding the front control panel to the
case top and sides. See Figure F.18. (There
are two screws on the top and one screw on
each side.)
3. Carefully lower the front control panel.
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