
SVM145-BSeptember, 2002Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, your overall
LIFTINGThe Commander 300 weighs 1325 lb./601 kg. A lift bailis provided for lifting with a hoist.FALLING EQUIPMENT can cause injury.Do not lift this
TROUBLESHOOTING & REPAIRF-44 F-44COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-45 F-45COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TABLE F.1.RF BY-PASS RESISTANCE TABLECHECK POINTS COMPONENT BEING MAXIMUM ALLOWABLECHECKED RESISTANCE1J61 to 5J60 L4 and Board Trace 4.2 OHMS (3.5 Typ
TROUBLESHOOTING & REPAIRF-47 F-47COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-48 F-48COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-49 F-49COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
NOTESF-50 F-50COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste
TROUBLESHOOTING & REPAIRF-51 F-51COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-52 F-52COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-53 F-53COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
OILThe Commander 300 is shipped with theengine crankcase filled with high qualitySAE 1OW-30 oil (API class CD or better).CHECK THE OIL LEVEL BEFORE YO
TROUBLESHOOTING & REPAIRF-54 F-54COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-55 F-55COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-56 F-56COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-57 F-57COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-58 F-58COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
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TROUBLESHOOTING & REPAIRF-60 F-60COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-61 F-61COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
NOTESF-62 F-62COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste
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HIGH FREQUENCY GENERATORSFOR TIG APPLICATIONSThe K799 Hi-Freq Unit and the K930-1 or –2 TIGModule can be used with the Commander 300. Themachine is e
TROUBLESHOOTING & REPAIRF-64 F-64COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-65 F-65COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-66 F-66COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
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TROUBLESHOOTING & REPAIRF-68 F-68COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-69 F-69COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
NOTESF-70 F-70COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste
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TROUBLESHOOTING & REPAIRF-72 F-72COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-73 F-73COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
WELDING CABLE CONNECTIONSCABLE INSTALLATION, POLARITY CONTROL,AND CABLE SIZESWith the engine off, route the electrode and workcables through the strai
TROUBLESHOOTING & REPAIRF-74 F-74COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
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TROUBLESHOOTING & REPAIRF-76 F-76COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
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TROUBLESHOOTING & REPAIRF-78 F-78COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
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MACHINE GROUNDINGBecause this portable engine-driven welder creates itsown power, you do not need to connect the machineframe to an earth ground, unle
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TROUBLESHOOTING & REPAIRF-86 F-86COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-87 F-87COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-88 F-88COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-89 F-89COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
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TROUBLESHOOTING & REPAIRF-92 F-92COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
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INSTALLATIONA-9 A-9COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to
TROUBLESHOOTING & REPAIRF-94 F-94COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
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TROUBLESHOOTING & REPAIRF-96 F-96COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-97 F-97COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-98 F-98COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-99 F-99COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-100 F-100COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M
TROUBLESHOOTING & REPAIRF-101 F-101COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M
TROUBLESHOOTING & REPAIRF-102 F-102COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M
TROUBLESHOOTING & REPAIRF-103 F-103COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M
NOTESA-10 A-10COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste
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COMMANDER 300G-1ELECTRICAL DIAGRAMSG-1TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION-ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . .
G-2ELECTRICAL DIAGRAMSCOMMANDER 300WIRING DIAGRAM - COMMANDER 300 DELUXE MODELMOTORSTART BUTTONSTARTERSOLENOIDALTERNATORSTARTINGÍÍ214215216217218219
G-3ELECTRICAL DIAGRAMSCOMMANDER 300WIRING DIAGRAM - COMMANDER 300 STANDARD MODELG-3Return to Section TOC Return to Section TOC Return to Section TOC R
G-4ELECTRICAL DIAGRAMSCOMMANDER 300G-4Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu
G-5ELECTRICAL DIAGRAMSCOMMANDER 300PC BOARD ASSEMBLY - CONTROL BOARD G-5Return to Section TOC Return to Section TOC Return to Section TOC Retu
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Section B-1 Section B-1COMMANDER 300TABLE OF CONTENTS- OPERATION SECTION -Operation...
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SVM ERROR REPORTING FORMWe need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that wo
OPERATING INSTRUCTIONSRead and understand this entire section before operat-ing your Commander 300. SAFETY INSTRUCTIONSDo not attempt to use this equi
GENERAL DESCRIPTIONThe Commander 300 is a diesel engine-driven weldingpower source. The machine uses a brush type alter-nating current generator for
SAFETYi iCOMMANDER 300FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requ
ADDITIONAL DESIGN FEATURES• Deutz 3-cylinder, air/oil cooled diesel engine.Designed for long life, easy maintenance, and excel-lent fuel economy. •
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OPERATIONB-6 B-6COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas
10. DIGITAL OUTPUT METER: The digital outputmeters are located in the center of the controlpanel between the two large control knobs. Themeters allo
“WIRE WELDING” mode: In this mode increasing thenumber from 1 to 10 changes the arc from soft andwashed-in to crisp and narrow. It acts as an induc-t
Using your welder at low amperages with long idle run-ning periods during the break-in period may result in aglaze forming on the engine cylinder wall
COMMANDER 300 SETTINGS WHEN USING THEK799 HL-FREQ UNITa. Set the SELECTOR switch to the “30-375” setting(STICK/TIG). b. Set the IDLER switch to the “
WIRE FEED (CONSTANT VOLTAGE)WELDINGConnect a wire feeder to the Commander 300 and setwelder controls according to the instructions listed ear-lier in
NOTESB-12 B-12COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste
TABLE OF CONTENTS- ACCESSORIES -Accessories...
SAFETYii iiCOMMANDER 300ARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the
OPTIONS/ACCESSORIESThe following options/accessories are available foryour Commander 300 from your local LincolnDistributor.FIELD INSTALLED OPTIONSK80
SEMIAUTOMATIC WELDING ACCESSORIESLN-7 OR LN-8 WIRE FEEDERS - Semiautomatic, con-stant speed wire feeders. For CV operation only.LN-23P WIRE FEEDER -
CONNECTION OF THE LN-7 TO THE COMMANDER 300 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1.)1. Shut the welder off. 2. Connect the electrode cable from
ACCESSORIESC-5 C-5COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M
ACCESSORIESC-6 C-6COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M
CONNECTION OF THE LN-8 TO THE COMMANDER 300 USING K595 INPUTCABLE ASSEMBLY (SEE FIGURE C.4.) 1. Shut the welder off.2. Connect the electrode cable fr
CONNECTION OF THE LN-23P TO THECOMMANDER 300 USING K350-1ADAPTER (SEE FIGURE C.5.)1. Shut the welder off.2. Connect the electrode cable from the LN-23
CONNECTION OF THE LN-25 TO THE COMMANDER 300 “ACROSS THE ARC”(SEE FIGURE C.6.) 1. Shut the welder off.2. Connect the electrode cable from the LN-25 t
NOTESC-10 C-10COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection D-1 Section D-1COMMANDER 300TABLE OF CONTENTS-MAINTENANCE-M
COMMANDER 300FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b
SAFETY PRECAUTIONS• Have qualified personnel do all maintenance andtroubleshooting work.• Turn the engine off before working inside themachine.• Re
CHANGE THE OIL FILTER: Change the oil filter thefirst time between 25 and 50 hours of operation. Then,under normal operating conditions, change the o
FUEL FILTER: When working on the fuel system:• Keep naked lights away.• Do not smoke !• Do not spill fuel !Inspect the fuel filter daily. Replace the
COOLING BLOWER BELT: The following procedureshould be followed to replace the cooling blower belt: 1. Allow the machine to cool. 2. Remove the engin
TABLE D.1DEUTZ ENGINE MAINTENANCE SCHEDULEFREQUENCY MAINTENANCE REQUIREDDaily or Before • Fill fuel tank.Starting Engine • Check oil level.• Check
BATTERY MAINTENANCEGASES FROM BATTERY can explode.• Keep sparks, flame, and cigarettesaway from battery.BATTERY ACID can burn eyes and skin.• Wear g
WELDER/GENERATOR MAINTENANCESTORAGE: Store the Commander 300 in clean, dry,protected areas.CLEANING: Blow out the generator and controls peri-odicall
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection E-1 Section E-1COMMANDER 300Theory of Operation ...
SAFETYiv ivCOMMANDER 300PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifi
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THEORY OF OPERATIONE-4 E-4COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Ret
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COMMANDER 300PULSE WIDTH MODULATIONThe term PULSE WIDTH MODULATION is used todescribe how much time is devoted to conduction in thecycle. Changing th
CHOPPER TECHNOLOGYFUNDAMENTALSThe new era of welding machines such as theCommander 300, employ a technology whereby a DCsource is turned on and off (c
NOTESE-8 E-8COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection F-1 Section F-1COMMANDER 300Troubleshooting & Repair Se
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MASTER TABLE OF CONTENTS FOR ALL SECTIONSv vCOMMANDER 300PageSafety...
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TABLE OF CONTENTS- INSTALLATION SECTION -Section A-1 Section A-1COMMANDER 300Installation ...
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TROUBLESHOOTING & REPAIRF-18 F-18COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-19 F-19COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
TROUBLESHOOTING & REPAIRF-20 F-20COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
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INSTALLATIONF-25 F-25COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t
NOTESF-26 F-26COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste
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Read this entire installation section before youstart installation.SAFETY PRECAUTIONSDo not attempt to use this equipment until you havethoroughly rea
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NOTESF-36 F-36COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste
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TROUBLESHOOTING & REPAIRF-41 F-41COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
NOTESF-42 F-42COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste
TROUBLESHOOTING & REPAIRF-43 F-43COMMANDER 300Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas
Komentarze do niniejszej Instrukcji