RETURN TO MAIN MENU IM700-D Commander™ 300 For use with machines having Code Numbers: July, 2004 10702; 10870; 10899; 10950; 11200 (Standard) 10703; 10871; 10900; 10951; 11201 (Deluxe) 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.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS For Gasoline Engines: The engine exhaust from For Diesel Engines: Diesel engine exhaust and this product contains chemicals known to the some of its constituents are known to the State State of California to cause cancer, birth defects, of California to cause cancer, birth defects, and or other reproductive harm. other reproductive harm. ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 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. 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. 3.b.
iii iii SAFETY 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.
iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi vi TABLE OF CONTENTS Page Safety .........................................................................................................................i-iv Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions ......................................................................................
vii vii TABLE OF CONTENTS Accessories .....................................................................................................Section C Optional Field Installed Accessories .....................................................................C-1 Recommended Optional Equipment .....................................................................C-1 High Frequency Generators For TIG Applications ................................................C-1 Maintenance ....................................
A-2 A-2 INSTALLATION Read this entire installation section before you start installation. LOCATION / VENTILATION The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area.
A-3 A-3 INSTALLATION LIFTING TOWING The Commander lift bale should be used to lift the machine. The Commander is shipped with the lift bale retracted. Before attempting to lift the Commander the lift bale must be secured in a raised position. Secure the lift bale as follows: The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle(1) is Lincoln’s K953-1.
A-4 A-4 INSTALLATION PRE-OPERATION ENGINE SERVICE ENGINE COOLING SYSTEM READ the engine operating and maintenance instructions supplied with this machine. The Deutz engine is air cooled by a belt driven axial blower. The oil cooler and engine cooling fins should be blown out with compressed air or steam to maintain proper cooling (See the engine Owners Manual for procedures and frequency). WARNING •Keep hands away from the engine muffler or HOT engine parts.
A-5 INSTALLATION MUFFLER REMOTE CONTROL Remove the plastic plug covering the muffler outlet tube. Using the clamp provided secure the extension to the outlet tube. This welder is supplied with an adjustable rain cap for the muffler. Install the rain cap using the clamp provided with the outlet facing away from the direction in which this unit will be transported. This will minimize the amount of water and debris which could enter the muffler during transportation.
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Commander 300 INPUT - DIESEL ENGINE Make/Model Diesel Engine Deutz F3L 1011F (Codes 11199 and Below) Displacement Description 125 cu. in (2.05 L) Bore x Stroke 3.89” x 4.13” 3 cylinder 31 HP(23 kw) @ 1800 RPM Speed (RPM) Starting System Capacities Fuel: 25 gal. 94.6 L (99mm x 105mm) Deutz F3L2011 (Codes 11200 and above) High Idle 1900 Low Idle 1475 Full Load 1800 142 cu. in (2.33L) Bore x Stroke 3.70” x 4.41” 12 VDC battery & Starter Oil: 6.
A-6 INSTALLATION WELDING OUTPUT CABLES With the engine off, route the electrode and work cables thru the strain relief bracket provided on the front of the base and connect to the terminals provided. These connections should be checked periodically and tightened if necessary. A-6 joints, or to the metal framework of a building which has been effectively grounded. The U.S. National Electrical Code lists a number of alternate means of grounding electrical equipment.
A-7 A-7 INSTALLATION • Take necessary steps to assure load is limited to the capacity of the Commander by installing a 45 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 45 amperes. Loading above the rated output will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motordriven equipment and may result in overheating of the Commander 300 engine.
A-8 A-8 INSTALLATION CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS CAUTION ELECTRIC SHOCK can kill. WARNING ELECTRIC SHOCK can kill. Shut off welder before making any electrical connections. ------------------------------------------------------------------------ CONNECTION OF THE LN-25 TO THE COMMANDER 300 The LN-25 with or without an external contactor may be used with the Commander 300. See the appropriate connection diagram in the DIAGRAMS section.
A-9 INSTALLATION CONNECTION OF LN-15 TO THE COMMANDER 300 These connections instructions apply to both the LN15 Across-The-Arc and Control Cable models. The LN15 has an internal contactor and the electrode is not energized until the gun trigger is closed. When the gun trigger is closed the wire will begin to feed and the welding process is started. • Shut the welder off.
B-1 OPERATION SAFETY INSTRUCTIONS B-1 GENERAL DESCRIPTION Read and understand this entire section before operating your Commander 300. WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. ELECTRIC SHOCK can kill.
B-2 OPERATION • 100% duty cycle at 300 amps output and 60 % duty cycle at 375 amps output. • Dual 3-digit output meters are provided (optional on K1585-1) for presetting the weld amperage or voltage and displaying the actual amperage and voltage during welding. The meters use superbrite L.E.D.'s for improved readability in full sunlight. LOOK-BACK FEATURE: After welding has stopped, both displays will remain on for 7 seconds with the last current and voltage value displayed.
B-3 B-3 OPERATION CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow. Figure B.1 Case Front Panel Controls 3 1 2 10 4 5 6 7 8 9 9 WATER OIL TEMP PRESS FUEL AMPS 11 15 14 20 16 13 ENGINE CONTROLS (Items 1 through 8) 1. RUNSTOP SWITCH When placed in the “RUN” position, this switch energizes the fuel solenoid and other electric accessories.
B-4 OPERATION 4. ENGINE TEMPERATURE GAUGE (K1585-2 Std., K1585-1 Opt.) AND LIGHT The gauge displays the engine oil temperature. The yellow temperature light remains off under normal operating temperatures. If the light turns on, the engine protection system will shut down the engine. Check for restrictions at the engine cooling air inlets and outlets (consult the engine Operator’s Manual). Check for loose or disconnected leads at the temperature sender located on the engine.
B-5 OPERATION B-5 WELDER CONTROLS (Items 9 through 14 ) 9. M WELD MODE & OUTPUT CONTROL These two controls allow you to select between various welding output slopes and adjust the desired welding output. Refer to Table B.1 for a description of how these two controls work. Table B.1 Weld Mode and Output Control Application M Weld Mode1 Sloped Output for Pipe Welding. 5 Range Settings 90, 150, 200, 250, 300 (Max.
B-6 OPERATION 15. CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 120V circuit at the 240V receptacle, each 120V receptacle, the 120VAC in the 14-Pin connector, the 42VAC in the 14-Pin connector and (for codes above 10871 only) battery circuit overload protection. 16. 120VAC RECEPTACLES These two 120VAC (5-20*R) receptacles provide 120VAC for auxiliary power. These receptacles have a 40* amp total rating.
B-7 B-7 OPERATION BREAK-IN PERIOD TYPICAL FUEL CONSUMPTION Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil consumption during initial operation, excessive oil use, wet stacking (oil or tar like substance at the exhaust port), or excessive smoke is not normal. Refer to Table B.2 for typical fuel consumption of the Commander 300’s Engine for various operating scenarios. Table B.
B-8 OPERATION • CONSTANT CURRENT (CC) WELDING The CC - STICK position of “30 to 375", the "WELD MODE" Switch is designed for horizontal welds with all types of electrodes especially low hydrogen. The "OUTPUT" adjusts the full range of 30 to 375 amps. This setting provides a soft, constant current arc. If a more forceful arc is desired, then select the proper range from the slope controlled current ranges. In the CC mode, sticking can be prevented by adjusting the “ARC CONTROL”.
B-9 B-9 OPERATION Table B.3 TYPICAL CURRENT RANGES Tungsten Electrode Diameter in. (mm) DCEN (-) DCEP (+) 1%, 2% Thoriated Tungsten 1%, 2% Thoriated Tungsten (1) (2) FOR TUNGSTEN ELECTRODES Approximate Argon Gas Flow Rate C.F.H. (l/min.) Aluminum Stainless Steel TIG TORCH Nozzle Size (4), (5) 0 .010 0.020 0.040 (.25) (.50) (1.0) 2-15 5-20 15-80 (3) (3) (3) 3-8 5-10 5-10 (2-4) (3-5) (3-5) 3-8 5-10 5-10 (2-4) (3-5) (3-5) #4, #5, #6 1/16 (1.
B-10 OPERATION 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”.
B-11 B-11 OPERATION AUXILIARY POWER OPERATION Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings, if no welding current is being drawn. The auxiliary power of the Commander consists of two 20Δ Amp-120VAC (5-20ΔR) 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. Δ 15 Amps for codes below 10500.
C-1 C-1 ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES K1604-1 OIL DRAIN KIT - Includes ball valve, hose and clamp. K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240V, 50 amps. 120V plug may not be compatible with NEMA common household receptacles. K1690-1 (1 Duplex) GFCI Kit - Includes one UL approved 115V ground fault circuit interrupter duplex type receptacle with cover and installation instructions.
C-2 ACCESSORIES RECOMMENDED OPTIONAL EQUIPMENT PLASMA CUTTING STICK AC TIG WELDING Pro-Cut 55 Square wave TIG 175, Invertec V205T AC/DC K704 Accessory Kit which includes: • Electrode holder and cable. • Ground clamp and cable. • Headshield. K857 Remote Control Kit is optional for remote current control.
D-1 D-1 MAINTENANCE • Refill the fuel tank to minimize moisture condensation in the tank. SAFETY PRECAUTIONS WARNING Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
D-2 MAINTENANCE Soak element in a mild detergent solution for 15 minutes. Do not soak more than 24 hours. Swish element around in the solution to help remove dirt. Rinse elements from inside out with a gentle stream of water (less than 40 psi) to remove all suds and dirt. Dry element before reuse with warm air at less than 1600F (710C). Do not use a light bulb to dry the element. Inspect for holes and tears by looking through the element toward a bright light.
D-3 D-3 MAINTENANCE CHARGING THE BATTERY BATTERY HANDLING WARNING GASES FROM BATTERY can explode. • Keep sparks, flame and cigarettes away from battery. To prevent EXPLOSION when: • INSTALLING A NEW BATTERY - disconnect negative cable from old battery first and connect to new battery last. • CONNECTING A BATTERY CHARGER - Remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.
D-4 D-4 MAINTENANCE Table D.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. ENGINE EXHAUST can kill. • Use in open, well ventilated areas or vent exhaust outside. MOVING PARTS can injure. • Do not operate with doors open or guards off. • Stop engine before servicing. • Keep away from moving parts. • Remove guards only when necessary and replace when work requiring removal is complete.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS Major Physical or Electrical Damage 1. Contact your Local Lincoln is Evident. Authorized Field Service Facility. Engine will not “crank”. 1. Battery is low. Charge Battery. 2. Loose battery cable connections. Inspect, clean and tighten. Engine will “crank” but not start. 1. Out of fuel. Fill fuel tank. 2.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Engine will not idle down to low speed. 1. Idler switch in High idle position. Set switch to Auto. 2. External load on welder or auxiliary power. Remove all external loads. Engine will not go to high idle when 1. Poor work lead connection to attempting to weld. work.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS No welding power output. 1. Welding terminals switch in wrong position. Place switch in “WELD TERMINALS” position when welding without welding terminal control cable. Refer to Operation chapter for proper switch function. Welder has output and no control. 1. Poor remote kit connection. Check connections. 2.
I + 206A 42VAC J A I K H E F G D C B - A B C D E F AMPHENOL 2 GROUND CONTACTOR REMOTE CONTROL J1 J3 3 TURNS THRU TOROID 21 2 6 1 14A AMMETER 2 J8 1 3 HOT START 4 10 5 2 4 J11 J9 1 3 16 6 3 THERMAL PINCH 4 1 31 5 1 CAPACITOR METER KIT OPTIONAL ON STANDARD MODEL AM METER J4 WELD BOARD PCB3 SHUNT J6 1 204S 206S NEG. POS. 13A VOLTMETER 14 13 NEG. 32 8 41A NEG. D4 NEG.
+ 50MV=400AMPS - A B C CONTACTOR D E GROUND F AMPHENOL 2 REMOTE CONTROL 4A 2A 75A 76A GND-B 4B 2B 75B 76B 77B 77A GND-A 2B 75B 4B 76B 77B 21 42A 41A 32 31 POLARITY SWITCH + AMPHENOL 1 115VAC WORK J1 2 1 6 1 14A AMMETER 2 J8 1 3 HOT START 4 10 5 2 4 J11 J9 1 3 16 6 3 THERMAL PINCH 4 1 42A 5 1 41A CAPACITOR METER KIT OPTIONAL ON STANDARD MODEL AM METER J4 WELD BOARD PCB3 SHUNT J6 206S 204S NEG. POS. 13A VOLTMETER 14 13 NEG.
+ 42VAC A B C D E F AMPHENOL 2 GROUND CONTACTOR REMOTE CONTROL AMPHENOL 1 GROUND CONTACTOR REMOTE CONTROL WORK 4A 75A 2A GND-B 4B 2B 75B 76B 77B 77A 76A GND-A 2B 75B 4B 76B 77B 21 42A 41A 32 31 J1 J3 3 TURNS THRU TOROID 1 6 1 14A AMMETER J8 1 3 2 3 J9 1 PINC H 4 J11 16 6 3 THERMAL 1 4 5 8 31 NEG. D4 NEG.
+ A B C D E F AMPHENOL 2 GROUND CONTACTOR REMOTE CONTROL AMPHENOL 1 GROUND CONTACTOR REMOTE CONTROL WORK 42VAC J A I K H E F G D C B 4A 75A 2A 77A 76A GND-B 4B 2B 75B 76B 77B GND-A 2B 75B 4B 76B 77B 21 42A 41A 32 31 J1 J3 3 TURNS THRU TOROID 1 6 1 AMMETER J8 1 3 2 J11 J9 1 3 16 6 3 THERMAL PINC H 4 4 1 5 8 31 NEG. D4 NEG. 8 D1 32 POS.
F-5 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300 F-5
COMMANDER 300 TO WORK ADAPTER PLUG K867 UNIVERSAL 77 76 75 GND 21 4 2 32 31 41 42 81 82 SPARE } N.E. 21 4 2 32 31 77 76 75 GND N.D. N.E. SPLICE LEADS AND INSULATE. N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED,CONTROL IS AUTOMATICALLY SWITCHED TO REMOTE CONTROL. PLACE WIRE FEEDER SWITCH TO "WIRE FEEDER WITH CONTROL CABLE POSITION. N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY.
F-7 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300 F-7
F-8 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300 F-8
COMMANDER 300 TO WORK ADAPTER PLUG K867 UNIVERSAL 77 76 75 GND 21 4 2 32 31 41 42 81 82 SPARE } N.D. N.C. C B A GND 21 4 2 32 31 or service this equipment. Only qualified personnel should install,use Keep away from moving parts. Keep guards in place. N.D. SPLICE LEADS AND INSULATE. N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPICATIONS. SEE OPERATING MANUAL. N.B.
F-10 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300 F-10
F-11 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300 F-11
COMMANDER 300 + _ ELECTRODE CABLE TO WIRE F EED UNIT K595CONTROL CABLE TO N L-8NPUT I CABLE PLUG TO W ORK Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. Do not operate with panels open. Disconnect NEGATIVE (-) Battery lead before servicing. Do not touch electrically live parts. S24787-6 DIAGRAMS 4-14-2000 WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
COMMANDER 300 ELECTRODE CABLE ADAPTER PLUG K867 UNIVERSAL 77 76 75 GND 4 2 32 31 21 41 42 81 N.E. SPLICE LEADS AND INSULATE. N.D. INSULATE EACH UNUSED LEADS INDIVIDUALLY. N.C. MOUNT K433 TO ENGINE WELDER PER INSTRUCTIONS PACKAGED WITH K433. REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE, SWITCH LN-25 POLARITY SWITCH. N.B. DIAGRAM SHOWS ELECTRODE POSTIVE. TO CHANGE POLARITY, TURN POWER "OFF". N.A.
F-14 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300 F-14
F-15 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300 F-15
F-16 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300 F-16
COMMANDER 300 50.3 8 54.4 4 63.1 0 BOTTOM VIEW OF W ELDER BASE. 19.6 3 23.6 9 F * 37.30 45.3 8 14.6 3 6.5 5 24.9 7 * 6.5 3 * 6.5 6 * 31.5 0 A 22.2 5 16.5 0 B 30.2 5 31.1 3 32.8 8 C 38.5 8 49.0 5 42.3 5 D 46.0 0 48.6 4 47.5 6 E 8.6 9 10.2 2 -2. 24 * TRAILER MOUNTING HOLE LOCATIONS. M18962 PART NO. 45.6 7 F 50.1 5 G 46.3 5 H NOTES N.A.A. N.A.A. N.B.B. M18962 11-2000 5.8 6 NOTES PER TABLE: N.A.A.CENTER OF GRAVITY WITH OIL IN ENGINE L FUE AND L TANK. FUL N.B.B.
NOTES COMMANDER 300
NOTES COMMANDER 300
WARNING zzSpanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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