Lincoln Electric IM601-A manual

Commander 300 OPERA T OR’S MANU AL IM601-A August, 2001 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with saf ety in mind. Howe ver , y our ov erall saf ety can be increased b y proper installation ... and thoughtful operation on y our par t. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT RE[...]

FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Operate engines in open, well-v entilated areas or vent the engine e xhaust fumes outdoors. ____________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b . Use suitab le clothing made from durab le flame-resistant material to protect you[...]

FOR ELECTRICALL Y powered equipment. 8.a. T ur n off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manuf acturer’ s recommendations. 8.c. Ground the equipment in accordance with the U.S . National Elect[...]

iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ P our v otre 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 P our Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Les circu[...]

Thank You f or selecting a QU ALITY product by Lincoln Electric. We want y ou to take pride in operating this Lincoln Electric Company product ••• as much pride as we hav e in br inging this product to you! Read this Operators Man ual completely bef ore attempting to use this equipment. Sa v e this manual and k eep it handy f or quick ref ere[...]

T ABLE OF CONTENTS P age Safety ......................................................................................................................... i-iv Installation .......................................................................................................Section A T echnical Specifications .......................................[...]

T ABLE OF CONTENTS Accessories .....................................................................................................Section C Optional Field Installed Accessories .....................................................................C-1 Recommended Optional Equipment ...................................................................[...]

A-1 INST ALLA TION COMMANDER 300 A-1 TECHNICAL SPECIFICA TIONS - Commander 300 (K1585-1 & -2) Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder High Idle 1900 125 cu. in 12VDC batter y Fuel: 25 gal. F3L 1011F 31 HP(23 kw) Low Idle 1400 (2.05 L) & Star ter 94.6 L Diesel Engine @ 1800 RPM Full Load 18[...]

A-2 INST ALLA TION COMMANDER 300 A-2 Read this entire installation section before y ou start installation. SAFETY PRECA UTIONS Do not attempt to use this equipment until you ha v e thoroughly read all operating and maintenance man- uals supplied with your machine . They include impor- tant saf ety precautions, detailed engine starting, operating an[...]

A-3 INST ALLA TION COMMANDER 300 A-3 LIFTING The Commander lift bale should be used to lift the machine. The Commander is shipped with the lift bale retracted. Bef ore attempting to lift the Commander the lift bale must be secured in a raised position. Secure the lift bale as f ollows: a. Open the engine compar tment door . b . Locate the 2 access [...]

A-4 INST ALLA TION COMMANDER 300 A-4 PRE-OPERA TION ENGINE SER VICE READ the engine operating and maintenance instruc- tions supplied with this machine. •K eep hands awa y from the engine muffler or HO T engine par ts. •Stop engine and allo w to cool bef ore fueling. •Do not smoke when fueling. •Fill fuel tank at a moderate rate and do not [...]

A-5 INST ALLA TION COMMANDER 300 A-5 MUFFLER Remov e the plastic plug co v ering the muffler outlet tube. Using the clamp provided secure the e xtension to the outlet tube. This welder is supplied with an adjustable r ain cap f or the muffler . Install the rain cap using the clamp provided with the outlet f acing a w a y from the direction in which[...]

A-6 INST ALLA TION COMMANDER 300 A-6 WELDING OUTPUT CABLES With the engine off , route the electrode and work cables thru the strain relief brac k et pro vided on the front of the base and connect to the terminals provid- ed. These connections should be check ed periodically and tightened if necessar y . Listed in T able A.1 are copper cab le siz e[...]

A-7 INST ALLA TION COMMANDER 300 A-7 2. T ake necessary steps to assure load is limited to the capacity of the Commander by installing a 45 amp , 240 V AC doub le pole circuit break er . Maximum rated load f or each leg of the 240 V A C auxiliar y is 45 amperes. Loading abov e the rated output will reduce output v oltage below the allo wab le -10% [...]

A-8 INST ALLA TION COMMANDER 300 A-8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Shut off welder bef ore making an y electrical connec- tions. ------------------------------------------------------------------------ CONNECTION OF THE LN-25 T O THE COMMANDER 300 The LN-25 with or without an e xternal contactor may be used with the Commander 300. See[...]

A-9 INST ALLA TION COMMANDER 300 A-9 CONNECTION OF AN LN-23P WIRE FEEDER T O THE COMMANDER 300 a. Shut the welder off . b . Connect the LN-23P as per instructions on the appropriate connection diagram in Section 4. (NO TE): When connecting an LN-23P to the Commander 300, a K350-1 adapter kit must be used. c. Set the “V OL TMETER” s witch to “[...]

B-1 OPERA TION B-1 OPERA TING INSTRUCTIONS Read and understand this entire section bef ore operat- ing your Commander 300. SAFETY INSTR UCTIONS Do not attempt to use this equipment until you ha v e thoroughly read all operating and maintenance man- uals supplied with your machine . They include impor- tant saf ety precautions, detailed engine start[...]

B-2 OPERA TION B-2 FOR A UXILIAR Y PO WER • 10,000 watts of 120/240 V A C , 60Hz auxiliary power . • P o wer f or tools, 120/240 V AC lights , electric pumps and f or standby emergency po wer . • Drive a 5 HP motor (provided it is started under no load). • T wo 20* amp 120 V A C duple x receptacles f or up to 40* amps of 120 V AC po wer . *[...]

B-3 OPERA TION B-3 ENGINE CONTROLS (Items 1 through 8) 1. RUN- ST OP SWITCH When placed in the “R UN” position, this switch ener- gizes the fuel solenoid and other electric accessories. When placed in the “ST OP” position, the flow of fuel to the injection pump is stopped to shut down the engine . (Note: If the switch is left in the "R[...]

B-4 OPERA TION B-4 4. ENGINE TEMPERA TURE GA UGE (K1585-2 Std., K1585-1 Opt.) AND LIGHT The gauge displa ys the engine oil temperature . The yello w temperature light remains off under normal operating temperatures . If the light tur ns on, the engine protection system will shut down the engine . Check f or restrictions at the engine cooling air in[...]

B-5 OPERA TION B-5 WELDER CONTROLS (Items 9 through 14 ) 9. OUTPUT SELECT OR SWITCH & OUTPUT CONTROL These two controls allo w you to select betw een v arious welding output slopes and adjust the desired welding output. Refer to T able B .1 f or a description of how these two controls work. T able B.1 Output Range Switch and Output Control Func[...]

B-6 OPERA TION B-6 17. 120V A C RECEPT A CLES These two 120V AC (5-20*R) receptacles pro vide 120V AC f or auxiliar y pow er . These receptacles hav e a 40* amp total rating. Refer to the A UXILIAR Y PO WER RECEPT A- CLES section in the installation chapter f or fur ther inf or- mation about these receptacles. Also ref er to the A UXIL- IAR Y POWER[...]

B-7 OPERA TION B-7 BREAK-IN PERIOD The engine used to supply pow er f or your w elder is a heavy duty , industr ial engine . It is designed and built f or rugged use. It is ver y normal for an y engine to use small quantities of oil until the break-in is accom- plished. Check the oil le v el twice a da y during the break-in period (about 200 r unni[...]

B-8 OPERA TION B-8 Commander 300 SETTINGS WHEN USING THE K799 HI-FREQ UNIT a. Set the SELECT OR s witch to the “30-375 setting” (STICK / TIG) b . Set the IDLER s witch to the “HIGH “ position. c. Set the LOCAL/REMO TE s witch to the “REMO TE” posi- tion. d. Set the WELDING TERMINALS switch to the “W elding T er minals Alwa ys On” po[...]

B-9 OPERA TION B-9 WIRE FEED (CONST ANT V OL T A GE) WELD- ING Connect a wire f eeder 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 an[...]

B-10 OPERA TION B-10 A UXILIAR Y PO WER OPERA TION Star t the engine and set the IDLER control s witch to the desired operating mode . Full pow er is av ailab le regardless of the welding control settings, if no w elding current is being dra wn. The auxiliar y pow er of the Commander consists of two 20 Δ Amp-120V AC (5-20 Δ R) duple x receptacles[...]

C-1 A CCESSORIES C-1 OPTIONAL FIELD INST ALLED A CCESSORIES K802R PO WER PLUG KIT - Provides a plug for each receptacle. Use K802N f or code numbers abo v e 10500. K802N PO WER PLUG KIT - Provides f our 120V plugs. K857 28 ft. (8.5 m) or K857-1 100 ft. (30.4 m) REMO TE CONTR OL - P or table control pro vides same dial range as the output control on[...]

D-1 MAINTENANCE D-1 SAFETY PRECA UTIONS • Ha ve a qualified technician do the maintenance and troub leshooting work. • T urn the engine off before w orking inside the machine. • Remo ve guar ds only when necessary and replace them when the maintenance requiring their remov al is complete. • Al ways use the greatest care when w orking near m[...]

D-2 MAINTENANCE D-2 FUEL FIL TERS When working on the fuel system • K eep nak ed lights a wa y , do not smoke ! • Do not spill fuel ! ------------------------------------------------------------------------ The Commander 300 is equipped with a Fuel Filter Assembly attached v ertically to the engine block in the lower center of the engine , left[...]

D-3 MAINTENANCE D-3 B A TTER Y HANDLING GASES FROM BA TTER Y can explode. • Keep sparks, flame and cigarettes away from bat- tery . T o prevent EXPLOSION when: • INST ALLING A NEW B A TTER Y - disconnect nega- tive cable from old battery first and connect to ne w battery last. • CONNECTING A B A TTER Y CHARGER - Remo ve bat- tery from welder [...]

D-4 MAINTENANCE D-4 COMMANDER 300 T able D.1 Engine Maintenance Components ITEM Air Cleaner Element Cooling Blower Belt Oil Filter Element Fuel Filter / W ater Separator Batter y MAKE Donaldson Fr a m AC Nelson Deutz Deutz Deutz P ART NUMBER P181050 CAK-256 A297C 70206N 117-9565 117-4416 117-4482 BCI Group 34[...]

E-1 TR OUBLESHOO TING E-1 COMMANDER 300 If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs safely , contact your Local Lincoln A uthorized Field Service Facility f or technical troubleshooting assistance bef ore you proceed. CA UTION This T roubleshooting Guide is pro vided to help you locate [...]

E-2 TR OUBLESHOO TING E-2 COMMANDER 300 Obser v e all Saf ety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs safely , contact your Local Lincoln A uthorized Field Service Facility f or technical troubleshooting assistance bef ore you proceed. CA U[...]

E-3 TR OUBLESHOO TING E-3 COMMANDER 300 Obser v e all Saf ety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs safely , contact your Local Lincoln A uthorized Field Service Facility f or technical troubleshooting assistance bef ore you proceed. CA U[...]

E-4 TR OUBLESHOO TING E-4 COMMANDER 300 Obser v e all Saf ety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs safely , contact your Local Lincoln A uthorized Field Service Facility f or technical troubleshooting assistance bef ore you proceed. CA U[...]

F-1 DIA GRAMS F-1 COMMANDER 300 NO TE: This diagram is f or ref erence only . It may not be accurate f or all machines covered b y this manual. The specific dia- gram f or your par ticular machine is pasted inside the machine on one of the enclosure panels. WIRING DIA GRAM: 5M 1 2 237A 3 4 5 6 7 8 9 11 10 12 5C 13 14 15 16 5E 200B 6E GND-C BRUSH 20[...]

F-2 DIA GRAMS F-2 COMMANDER 300 NO TE: This diagram is f or ref erence only . It may not be accurate f or all machines covered b y this manual. The specific dia- gram f or your par ticular machine is pasted inside the machine on one of the enclosure panels. WIRING DIA GRAM: MOTOR START BUTTON STARTER SOLENOID ALTERNATOR STARTING     214[...]

F-3 DIA GRAMS F-3 COMMANDER 300 NO TE: This diagram is f or ref erence only . It may not be accurate f or all machines covered b y this manual. The specific dia- gram f or your par ticular machine is pasted inside the machine on one of the enclosure panels. WIRING DIA GRAM: MOTOR START BUTTON STARTER SOLENOID ALTERNATOR STARTING     214[...]

F-4 DIA GRAMS F-4 COMMANDER 300 CONNECTION DIA GRAM: [...]

F-5 DIA GRAMS F-5 COMMANDER 300 CONNECTION DIA GRAM:  !$ !' !!  #)   !$  !'  !! !!$  %?[...]

F-6 DIA GRAMS F-6 COMMANDER 300 CONNECTION DIA GRAM: WARNING 74797,+0/9+?39:,/4+527,+4 326744+69%"& B+A70+2+083634- 747997.6:+5+69036/55@538+,/092 S23987 A = [...]

F-7 DIA GRAMS F-7 COMMANDER 300 CONNECTION DIA GRAM:   }   # &?[...]

F-8 DIA GRAMS F-8 COMMANDER 300 CONNECTION DIA GRAM: =  &&&[...]

F-9 DIA GRAMS F-9 COMMANDER 300 CONNECTION DIA GRAM: WIRE FEEDER "B" N.B. 602 FEEDER "A" 604 75 76 77 14 PIN AMPHENOL M17866 N.D. IF REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL/REMOTE SWITCH IN "REMOTE" N.E THE OUTPUT CONTROL SWITCH MUST BE IN THE "WELDING TERMINALS REMOTELY ELECTRODE WELDER, SPECIAL CARE IS TO BE [...]

F-10 DIA GRAMS F-10 COMMANDER 300 CONNECTION DIA GRAM:   %&    ?[...]

F-11 DIA GRAMS F-11 COMMANDER 300 CONNECTION DIA GRAM: 326744+69%"&  747997.6:+5+69036/55@538+,/092     [...]

F-12 DIA GRAMS F-12 COMMANDER 300 CONNECTION DIA GRAM: or ser vice t his equi pm ent. On ly qualified personnel should install,use Keep away from movi ng parts. Keep guards in place. MOVING PART S can injure W ARNING Do not touch electrically live parts. before servicing. Disconnect NEGATIVE (-) Bat te ry lead Do not operate with panels open. ELECT[...]

F-13 DIA GRAMS F-13 COMMANDER 300 CONNECTION DIA GRAM: %&      ?[...]

F-14 DIA GRAMS F-14 COMMANDER 300 CONNECTION DIA GRAM:  )'"   ""     ! ""    S24062 A [...]

F-15 DIA GRAMS F-15 COMMANDER 300 CONNECTION DIA GRAM: 74797,+0/9+?39:,/4+527,+4 B+A70+2+083634- 326744+69%"& 747997.6:+5+69036/55@538+,/092 ?[...]

F-16 DIA GRAMS F-16 COMMANDER 300 DIMENSION PRINT TRAILER MOUNTING HOLE LOCATIONS. * 45.67 * 42.00 * * 6.55 22.25 8.69 6.53 24.97 6.56 BOTTOM VIEW OF WELDER BASE. 30.25 32.08 38.58 50.85 GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK. CENTER OF FOR BATTERY REMOVAL. 31.50 14.63 * 37.30 45.38 19.63 28.99 23.69 50.38 1.26 54.44 63.10 M18962 B-RW[...]

NO TES COMMANDER 300[...]

NO TES COMMANDER 300[...]

Now A vailab le...12th Edition The Procedure Handbook of Ar c W elding With ov er 500,000 copies of pre vious editions pub lished since 1933, the Procedure Handbook is considered by man y to be the “ Bible ” of the arc w elding industr y . This printing will go fast so don ’ t dela y . Place your order now using the coupon belo w . The hardbo[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German P ortuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German P ortuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

• Sales and Ser vice through Subsidiaries and Distributors W orldwide • Cle v eland, Ohio 44117-1199 U .S .A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectr ic.com • W orld's Leader in W elding and Cutting Products •[...]