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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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• 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
10469, 10642 (Standard),
10470, 10643 (Deluxe)
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
™
300
Copyright © 2001 Lincoln Global Inc.
IM601-A
August, 2001
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric COMMANDER 300 IM601-A
Summary of Contents for Lincoln Electric COMMANDER 300 IM601-A
- 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. 3.b. - 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 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...
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Page 7: Table Of Contents
Welding Terminals ...A-5 Welding Output Cables ...A-6 Machine Grounding ...A-6 Auxiliary Power Receptacles ...A-6 Standby Power Connections ...A-6 Connection of Lincoln Electric Wire Feeders ...A-8 Operation ...Section B Safety Instructions ...B-1 General Description...B-1 Recommended Applications ...B-1 Design Features and Advantages...B-1 Welding Capability ...B-2... - Page 8 Accessories ...Section C Optional Field Installed Accessories ...C-1 Recommended Optional Equipment ...C-1 High Frequency Generators For TIG Applications ...C-1 Maintenance ...Section D Safety Precautions ...D-1 Routine and Periodic Maintenance ...D-1 Engine Maintenance...D-1 Air Filter...D-1 Fuel Filters ...D-2 Cooling System...D-2 Cooling Blower Belt...D-2 Battery Handling ...D-3 Nameplates/Warning Decals Maintenance ...D-3 Welder/Generator Maintenance ...D-3...
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Page 9: Installation
TECHNICAL SPECIFICATIONS - Commander 300 (K1585-1 & -2) Make/Model Description Deutz 3 cylinder F3L 1011F 31 HP(23 kw) Diesel Engine @ 1800 RPM Duty Cycle Welding Output 300 amps (DC multi-purpose) 100% 375 amps (DC multi-purpose) OUTPUT - WELDER AND GENERATOR Welding Range 30 - 300 Amps 5 Ranges... -
Page 10: Safety Precautions
Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine. They include impor- tant safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. -
Page 11: Lifting
LIFTING The Commander lift bale should be used to lift the machine. The Commander is shipped with the lift bale retracted. Before attempting to lift the Commander the lift bale must be secured in a raised position. Secure the lift bale as follows: a. -
Page 12: Pre-Operation Engine Service
PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. WARNING •Keep hands away from the engine muffler or HOT engine parts. •Stop engine and allow to cool before fueling. •Do not smoke when fueling. •Fill fuel tank at a moderate rate and do not overfill. -
Page 13: Muffler
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 14: Welding Output Cables
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 provid- ed. These connections should be checked periodically and tightened if necessary. Listed in Table A.1 are copper cable sizes recom- mended for the rated current and duty cycle. - Page 15 2. 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. 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...
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Page 16: Connection Of Lincoln Electric Wire Feeders
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical connec- tions. ------------------------------------------------------------------------ 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 appropri- ate connection diagram in the ACCESSORIES section. - Page 17 CONNECTION OF AN NA-3 AUTOMATIC WELDING SYSTEM TO THE COMMANDER For connection diagrams and instructions for connect- ing an NA-3 Welding System to the Commander 300, refer to the NA-3 Welding System instruction manual. The connection diagram for the LN-8 can be used for connecting the NA-3.
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Page 18: Operation
OPERATING INSTRUCTIONS Read and understand this entire section before operat- ing your Commander 300. SAFETY INSTRUCTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine. They include impor- tant safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. -
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 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).
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Page 22: Welder Controls
WELDER CONTROLS (Items 9 through 14 ) 9. OUTPUT 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. -
Page 23: Engine Operation
-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 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 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 accom- plished. - Page 25 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 26: Wire Feed (Constant Voltage) Welding
OPERATION WIRE FEED (CONSTANT VOLTAGE) WELD- 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 27: Auxiliary Power Operation
B-10 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 28: Accessories
OPTIONAL FIELD INSTALLED ACCESSORIES K802R POWER PLUG KIT - Provides a plug for each receptacle. Use K802N for code numbers above 10500. K802N POWER PLUG KIT - Provides four 120V plugs. K857 28 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. -
Page 29: Maintenance
SAFETY PRECAUTIONS WARNING •Have a qualified technician do the maintenance and troubleshooting work. •Turn the engine off before working inside the machine. •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. -
Page 30: Fuel Filters
FUEL FILTERS WARNING When working on the fuel system • Keep naked lights away, do not smoke ! • Do not spill fuel ! ------------------------------------------------------------------------ The Commander 300 is equipped with a Fuel Filter Assembly attached vertically to the engine block in the lower center of the engine, left of the fuel pump. -
Page 31: Battery Handling
BATTERY HANDLING WARNING GASES FROM BATTERY can explode. • Keep sparks, flame and cigarettes away from bat- tery. To prevent EXPLOSION when: • INSTALLING A NEW BATTERY - disconnect nega- tive cable from old battery first and connect to new battery last. -
Page 32: 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 33: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE 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 34: Troubleshooting
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 35 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine will not idle down to low speed. Engine will not go to high idle when attempting to weld. Engine will not go to high idle when using 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 36 Observe all Safety Guidelines detailed throughout this manual 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 37 WIRING DIAGRAM: watts ohms DIAGRAMS HARNESS ENGINE HARNESS CONTROL COMMANDER 300 281A 229A 233A 239A 234A 224A 262A 232D 110A 109A 108A 110A 109A 108A 103A 102A 106A 104A 107A 105A 101A...
- Page 38 WIRING DIAGRAM: watts ohms DIAGRAMS HARNESS ENGINE HARNESS CONTROL COMMANDER 300 281A 229A 233A 239A 234A 262A 224A 232D 110A 109A 108A 110A 109A 108A 103A 102A 106A 104A 107A 105A 101A...
- Page 39 WIRING DIAGRAM: watts ohms DIAGRAMS HARNESS ENGINE HARNESS CONTROL COMMANDER 300 281A 233A 239A 234A 262A 224A 232D 110A 109A 108A 110A 109A 108A 103A 102A 106A 104A 107A 105A 101A...
- Page 40 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300...
- Page 41 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300...
- Page 42 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300...
- Page 43 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300...
- Page 44 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300...
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Page 45: Connection Diagram
CONNECTION DIAGRAM: DIAGRAMS COMMANDER 300... - Page 46 F-10 F-10 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300...
- Page 47 F-11 F-11 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300...
- Page 48 F-12 F-12 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300...
- Page 49 F-13 F-13 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300...
- Page 50 F-14 F-14 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300...
- Page 51 F-15 F-15 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 300...
- Page 52 F-16 F-16 DIAGRAMS DIMENSION PRINT COMMANDER 300...
- Page 53 NOTES COMMANDER 300...
- Page 54 NOTES COMMANDER 300...
- Page 55 |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Account No. AMERICAN EXPRESS MasterCard AMERICAN EXPRESS USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 BOOKS OR FREE INFORMATIVE CATALOGS Lincoln Welding School (ED-80) Seminar Information (ED-45)
- Page 56 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
- Page 57 ● ● Keep your head out of fumes. Turn power off before servicing. ● Use ventilation or exhaust to remove fumes from breathing zone. ● Los humos fuera de la zona de res- ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...
- Page 58 • 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...