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For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful
operation on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS
EQUIPMENT
WITHOUT
READING THIS MANUAL AND
THE
SAFETY
PRECAUTIONS
CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
• 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
RETURN TO MAIN MENU
Commander
10702; 10870; 10899; 10950; 11200 (Standard)
10703; 10871; 10900; 10951; 11201 (Deluxe)
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
™
300
Copyright © 2004 Lincoln Global Inc.
IM700-D
July, 2004
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Related Manuals for Lincoln Electric COMMANDER 300 IM700-D
Summary of Contents for Lincoln Electric COMMANDER 300 IM700-D
- Page 1 Commander For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT...
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Page 2: California Proposition 65 Warnings
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. -
Page 3: Electric Shock Can Kill
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. - Page 4 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.
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Page 5: 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. - Page 6 The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
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Page 7: Table Of Contents
Remote Control ...A-5 Welding Terminals ...A-5 Welding Output Cables...A-6 Machine Grounding ...A-6 Auxiliary Power Receptacles ...A-6 Standby Power Connections...A-6, A-7 Connection of Lincoln Electric Wire Feeders...A-8, A-9 Operation ...Section B Safety Precautions ...B-1 General Description...B-1 Recommended Applications...B-1 Design Features and Advantages...B-1 Welding Capability ...B-2... - Page 8 Air Filter...D-1 Fuel Filters ...D-2 Cooling System...D-2 Cooling Blower Belt ...D-2 Battery Handling ...D-3 Nameplates / Warning Decals Maintenance ...D-3 Welder / Generator Maintenance ...D-3 Storage ...D-3 Cleaning...D-3 Brush Removal and Replacement ...D-3 Engine Maintenance Components ...D-4 Troubleshooting ...Section E Diagrams and Dimension Print...Section F...
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Page 9: Installation
(FULL) oil capacity in the crankcase. When operating the welder at an angle, the effective fuel capacity will be slightly less than the specified 25 gallons. COMMANDER 300... -
Page 10: Lifting
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. -
Page 11: Pre-Operation Engine Service
● 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. -
Page 12: Muffler
Remove the plastic plug covering the muffler outlet tube. Using the clamp provided secure the extension to the outlet tube. This welder is supplied with an adjustable rain cap for the muffler. Install the rain cap using the clamp provided with the outlet facing away from the direction in which this unit will be transported. - Page 13 (2.33L) (Codes 11200 Bore x Stroke and above) 3.70” x 4.41” (94mm x 112mm) Duty Cycle 100% OUTPUT - WELDER AND GENERATOR Welding Range 30-300 Amps CC / CV TIG HEIGHT WIDTH 40.0 in. 31.5 in. 1016.0 mm 800.1 mm 1.
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Page 14: Welding Output Cables
(home, shop, etc.). To prevent dangerous electric shock, other equipment powered by this engine driven welder must: • be grounded to the frame of the welder using a grounded type plug, • be double insulated. When this welder is mounted on a truck or trailer, its frame must be securely connected to the metal frame of the vehicle. - Page 15 • 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 volt- age which may damage appliances or other motor- driven equipment and may result in overheating of...
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Page 16: Connection Of Lincoln Electric Wire Feeders
• Shut the welder off. • For electrode Positive, connect the electrode cable from the LN-25 to the “+” terminal of the welder and work cable to the “-” terminal of the welder. For elec- trode Negative, connect the electrode cable from the LN-25 to the “-”... - Page 17 • Shut the welder off. • For electrode Positive, connect the electrode cable to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable "-" terminal of the welder and work cable to the "+"...
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Page 18: Operation
Only qualified personnel should operate this equip- ment. ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and the side panels in place as these provide maxi- mum protection from moving parts and insure proper cooling air flow. -
Page 19: Welding Capability
• 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. -
Page 20: Controls And Settings
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. ENGINE CONTROLS (Items 1 through 8) RUN- STOP SWITCH When placed in the “RUN” position, this switch ener- gizes the fuel solenoid and other electric accessories. - Page 21 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.
- Page 22 Voltage ing circuit automatically switches the OUTPUT control from Adjustment control at the welder to remote control . When using the TOUCH START TIG mode with a TIG Module connected, the OUTPUT control is used to set the maximum current range of the CURRENT CONTROL on the TIG Module.
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Page 23: Engine Operation
-30°F. With the above and a battery warmer*, the engine should start satis- factorily down to about-40°F. * Contact your local Lincoln Electric Representative for sug- gested after-market kits. STOPPING THE ENGINE 1. Switch the RUN/STOP switch to “STOP”. This turns off the voltage supplied to the shutdown solenoid. -
Page 24: Break-In Period
BREAK-IN PERIOD Lincoln Electric selects high quality, heavy-duty indus- trial 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. -
Page 25: Tig Welding
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. - Page 26 Table B.3 TYPICAL CURRENT RANGES DCEN (-) Tungsten Electrode 1%, 2% Diameter Thoriated in. (mm) Tungsten 0 .010 (.25) 2-15 0.020 (.50) 5-20 0.040 (1.0) 15-80 1/16 (1.6) 70-150 3/32 (2.4) 150-250 (3.2) 250-400 5/32 (4.0) 400-500 3/16 (4.8) 500-750 (6.4) 750-1000 (1) When used with argon gas.
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Page 27: Wire Feed (Constant Voltage) Welding
B-10 WIRE FEED (CONSTANT VOLTAGE) WELDING Connect a wire feeder to the Commander 300 and set welder controls according to the instructions listed earlier in this section. The Commander 300 in the ”WIRE WELDING” position, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding). -
Page 28: Auxiliary Power Operation
B-11 AUXILIARY POWER OPERATION Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings, if no welding current is being drawn. The auxiliary power of the Commander consists of two Δ... -
Page 29: Accessories
The use of an arc welder for pipe thawing is not approved by the CSA, nor is it recommended or supported by Lincoln Electric. ------------------------------------------------------------------------ COMMANDER 300... -
Page 30: Recommended Optional Equipment
RECOMMENDED OPTIONAL EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode holder and cable. • Ground clamp and cable. • Headshield. K857 Remote Control Kit is optional for remote cur- rent control. 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... -
Page 31: Maintenance
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 neces- sary and replace them when the maintenance requiring their removal is complete. -
Page 32: Fuel Filters
Soak element in a mild detergent solution for 15 min- utes. Do not soak more than 24 hours. Swish element around in the solution to help remove dirt. Rinse ele- ments from inside out with a gentle stream of water (less than 40 psi) to remove all suds and dirt. -
Page 33: Battery Handling
• CONNECTING A BATTERY CHARGER - Remove bat- tery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated. -
Page 34: Engine Maintenance Components
Table D.1 Engine Maintenance Components ITEM Air Cleaner Element Cooling Blower Belt Oil Filter Element Fuel Filter / Water Separator Battery MAINTENANCE MAKE Donaldson Fram Nelson Deutz Deutz Deutz COMMANDER 300 PART NUMBER P181050 CAK-256 A297C 70206N 117-9565 117-4416 117-4482 Group... -
Page 35: Troubleshooting
• Only qualified personnel should install, use or service this equipment. Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. - Page 36 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. Engine will not “crank”. Engine will “crank” but not start. Engine shuts down shortly after starting. Battery does not stay charged. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 37 POSSIBLE AREAS OF MISADJUSTMENT(S) FUNCTION PROBLEMS 1. Idler switch in High idle position. Set switch to Auto. 2. External load on welder or auxil- iary power. Remove all external loads. 1. Poor work lead connection to work. Make sure work clamp is tightly connected to clean base metal.
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Page 38: Commander
PROBLEMS (SYMPTOMS) No welding power output. Welder has output and no control. No auxiliary power. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. - Page 39 G4357 50MV=400AMPS DIAGRAMS COMMANDER 300 G3834 GND-J SELECT MACHINE PROGRAMMING...
- Page 40 50MV=400AMPS DIAGRAMS COMMANDER 300 GND-J SELECT MACHINE PROGRAMMING...
- Page 41 50MV=400AMPS DIAGRAMS COMMANDER 300 MACHI PROGRAMMI...
- Page 42 50MV=400AMPS DIAGRAMS COMMANDER 300 MACHI PROGRAMMI...
- Page 43 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300...
- Page 44 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300...
- Page 45 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300...
- Page 46 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300...
- Page 47 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300...
- Page 48 F-10 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300 F-10...
- Page 49 F-11 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300 F-11...
- Page 50 F-12 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300 F-12...
- Page 51 F-13 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300 F-13...
- Page 52 F-14 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300 F-14...
- Page 53 F-15 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300 F-15...
- Page 54 F-16 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300 F-16...
- Page 55 F-17 F-17 DIAGRAMS DIMENSION PRINT COMMANDER 300...
- Page 56 NOTES COMMANDER 300...
- Page 57 NOTES COMMANDER 300...
- Page 58 ● WARNING ● zzSpanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● German ● WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 59 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 60 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...