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IM700-D
July, 2004
™
Commander 300
For use with machines having Code Numbers: 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. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAI
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS For Diesel Engines: Diesel engine exhaust and For Gasoline Engines: The engine exhaust from some of its constituents are known to the State this product contains chemicals known to the of California to cause cancer, birth defects, and State of California to cause cancer, birth defects, other reproductive harm. or other reproductive harm. ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHIL
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ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 3.b. In
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ��� Thank You as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment
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vi vi TABLE OF CONTENTS Page Safety .........................................................................................................................i-iv Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions ...........................................................................
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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 ..........................
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A-2 A-2 INSTALLATION Read this entire installation section before you LOCATION / VENTILATION start installation. The welder should be located to provide an unrestricted SAFETY PRECAUTIONS 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 WARNING an outside area. Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manu-
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A-3 A-3 INSTALLATION LIFTING TOWING The Commander lift bale should be used to lift the The recommended trailer for use with this equipment (1) machine. The Commander is shipped with the lift bale for road, in-plant and yard towing by a vehicle is retracted. Before attempting to lift the Commander the Lincoln’s K953-1. If the user adapts a non-Lincoln trail- lift bale must be secured in a raised position. Secure er, he must assume responsibility that the method of the lift bale as follows: att
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A-4 A-4 INSTALLATION ENGINE COOLING SYSTEM PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc- The Deutz engine is air cooled by a belt driven axial tions supplied with this machine. blower. The oil cooler and engine cooling fins should be blown out with compressed air or steam to maintain WARNING proper cooling (See the engine Owners Manual for procedures and frequency). �Keep hands away from the engine muffler or HOT engine parts. BATTERY CONNECTION �Stop engin
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A-5 A-5 INSTALLATION MUFFLER REMOTE CONTROL Remove the plastic plug covering the muffler outlet OUTPUT tube. Using the clamp provided secure the extension to The Commander 300 is equipped with a 6-pin & 14-pin the outlet tube. This welder is supplied with an connector. The 6-pin connector is for connecting the adjustable rain cap for the muffler. Install the rain cap K857 or K857-1 Remote Control (Optional) or in the using the clamp provided with the outlet facing away case of TIG welding app
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Commander 300 INPUT - DIESEL ENGINE Make/Model Displacement Description Speed (RPM) Starting Capacities Diesel Engine System 125 cu. in Deutz (2.05 L) 3 cylinder F3L 1011F Bore x Stroke 31 HP(23 kw) (Codes 11199 3.89” x 4.13” @ 1800 RPM Fuel: 25 gal. and Below) (99mm x 105mm) 94.6 L High Idle 1900 12 VDC battery Low Idle 1475 & Starter Deutz 142 cu. in Full Load 1800 Oil: 6.3 Qts. F3L2011 (2.33L) 3 cylinder 6.0 L (Codes 11200 Bore x Stroke 32
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A-6 A-6 INSTALLATION joints, or to the metal framework of a building which WELDING OUTPUT CABLES has been effectively grounded. The U.S. National Electrical Code lists a number of alternate means of With the engine off, route the electrode and work grounding electrical equipment. A machine grounding cables thru the strain relief bracket provided on the stud marked with the symbol is provided on the front of the base and connect to the terminals provid- front of the welder. ed. These c
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A-7 A-7 INSTALLATION � Take necessary steps to assure load is limited to the � Install a 50 amp 120/240 VAC plug (NEMA Type 14- capacity of the Commander by installing a 45 amp, 50) to the double-pole circuit breaker using No. 6, 4 240 VAC double pole circuit breaker. Maximum rated conductor cable of the desired length. (The 50 amp, load for each leg of the 240 VAC auxiliary is 45 120/240 VAC plug is available in the optional K802R amperes. Loading above the rated output will reduce plug kit.
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A-8 A-8 INSTALLATION CONNECTION OF LINCOLN CAUTION ELECTRIC WIRE FEEDERS ELECTRIC SHOCK can kill. WARNING ELECTRIC SHOCK can kill. If you are using an LN-25 without an internal contactor, the electrode will be energized when the Commander 300 is started. Shut off welder before making any ------------------------------------------------------------------------ electrical connections. h. When the gun trigger is closed, the current sensing -------------------------------------------------------
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A-9 A-9 INSTALLATION CONNECTION OF LN-15 TO THE COM- CONNECTION OF AN NA-3 AUTOMATIC MANDER 300 WELDING SYSTEM TO THE COMMANDER 300 These connections instructions apply to both the LN- 15 Across-The-Arc and Control Cable models. The LN- For connection diagrams and instructions for connect- 15 has an internal contactor and the electrode is not ing an NA-3 Welding System to the Commander 300, energized until the gun trigger is closed. When the gun refer to the NA-3 Welding System instruction ma
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B-1 B-1 OPERATION SAFETY INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section before operat- The Commander 300 is a diesel engine-driven welding ing your Commander 300. power source. The machine uses a brush type alter- WARNING nating 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 Do not attempt to use this equipment until you Technology. have thoroughly read all operating an
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B-2 B-2 OPERATION � Gauges for oil pressure, oil temperature, engine alter- � 100% duty cycle at 300 amps output and 60 % duty nator output and fuel level (fuel level gauge on cycle at 375 amps output. K1585-2 only codes above 10871 have a fuel level gauge on both K1585-1 and K1585-2). � 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 � Indicator lights for low oil pressure, high oi
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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 10 1 2 4 5 6 7 8 9 WATER OIL FUEL TEMP PRESS AMPS 9 11 15 12 19 14 20 18 16 17 13 3. FUEL LEVEL GAUGE AND LIGHT ENGINE CONTROLS (Items 1 through 8) (K1585-2 only on codes 10871 and below) - Displays the level of diesel fuel in the 25-gal- 1. RUN- STOP SWITCH lon(94.6 liters) fu
