Lincoln Electric COMMANDER SVM145-B User manual

SVM145-B
September, 2002
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be in-
creased 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.
SERVICE MANUAL
For use with machines having Code Numbers: 10469 (Standard),
10470 (Deluxe)
Commander 300
TM
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• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © 2002 Lincoln Global Inc.

SAFETY
i i
COMMANDER 300
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel-
ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers
and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. 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.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle con-
trol rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting -ANSI Standard Z49.1” from theAmerican Welding Society, P.O. Box 351040,
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.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
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SAFETY
ii ii
COMMANDER 300
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
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. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b. Mar ‘95
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COMMANDER 300
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•Asafe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
iii
SAFETY
iii
Mar ‘95
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. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
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SAFETY
iv iv
COMMANDER 300
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. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSAStandard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
v v
COMMANDER 300
Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation..............................................................................................................A-3
Pre-Operation Engine Service ....................................................................................................A-4
Electrical Output Connections.....................................................................................................A-6
Operation...............................................................................................................................Section B
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-3
Recommended Applications........................................................................................................B-3
Design Features..........................................................................................................................B-3
Welding Capability ......................................................................................................................B-4
Controls and Settings..................................................................................................................B-4
Engine Operation........................................................................................................................B-8
Welder Operation........................................................................................................................B-9
Auxiliary Power Operation.........................................................................................................B-11
Accessories ..........................................................................................................................Section C
Maintenance..........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual .................................................................................................................................P334
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TABLE OF CONTENTS
- INSTALLATION SECTION -
Section A-1 Section A-1
COMMANDER 300
Installation .............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Input - Diesel Engine............................................................................................................A-2
Rated Output - Welder..........................................................................................................A-2
Output - Welder and Generator............................................................................................A-2
Physical Dimensions.............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation..............................................................................................................A-3
Storing ..................................................................................................................................A-3
Stacking................................................................................................................................A-3
Angle of Operation................................................................................................................A-3
Lifting....................................................................................................................................A-4
High Altitude Operation.........................................................................................................A-4
Towing...................................................................................................................................A-4
Pre-Operation Engine Service ....................................................................................................A-4
Oil .........................................................................................................................................A-5
Fuel.......................................................................................................................................A-5
Cooling System.....................................................................................................................A-5
Battery Connections .............................................................................................................A-5
Muffler Outlet Pipe................................................................................................................A-5
Spark Arrester.......................................................................................................................A-5
High Frequency Generation for TIG Applications .......................................................................A-6
Remote Control...........................................................................................................................A-6
Welding Terminals.......................................................................................................................A-6
Electrical Output Connections.....................................................................................................A-6
Welding Cable Connections.................................................................................................A-7
Cable Installation, Polarity Control, and Cable Sizes.....................................................A-7
Machine Grounding ..............................................................................................................A-8
Auxiliary Power Receptacles................................................................................................A-8
Standby Power Connections................................................................................................A-8
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INSTALLATION
A-2 A-2
COMMANDER 300
TECHNICAL SPECIFICATIONS - Commander 300
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Deutz 3 cylinder 1800 Full Load 125 cu. in. Electric Fuel: 25 gal.
F3L 1011F Air/cooled 1900 High Idle (2.05 liters) 12 VDC (94.6 liters)
diesel 1400 Low Idle
31 HP Oil: 6.3 qt.
@ 1800 RPM (6.0 liters)
RATED OUTPUT - WELDER
Duty Cycle Welding Output Volts at Rated Amps
100% 300 amps (DC Multi-purpose) 32 volts
60% 375 amps (DC Multi-purpose) 34 volts
OUTPUT - WELDER AND GENERATOR
Welding Range Max. Open Circuit Voltage Auxiliary Power1
30 - 300 Amps DC 87 OCV 120/240 VAC
in 5 Ranges @ 1900 RPM 10,000 Watts, 60 Hz.
100% Duty Cycle
PHYSICAL DIMENSIONS
Height2Width Depth Weight
42.0 in. 31.5 in. 63.1 in. 1325 lbs.
1066.8 mm 800.1 mm 1602.7 mm 1683 lbs.(601 kg)
1Output rating in watts is equivalent to volt-amperes at unity power factor.
Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.
2Top of Enclosure. Add 8.9” (16mm) for exhaust.

Read this entire installation section before you
start installation.
SAFETY PRECAUTIONS
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating and maintenance instructions and parts lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts such as output terminals or
internal wiring.
• Insulate yourself from the work
and ground.
• Always wear dry insulating
gloves.
ENGINE EXHAUST can kill.
• Use in open, well ventilated
areas or vent exhaust outside.
• Do not stack anything near the
engine.
MOVING PARTS can injure.
• Do not operate with doors open
or guards off.
• Stop the engine before servicing.
• Keep away from moving parts.
See additional safety information at the front of this
manual.
Only qualified personnel should install, use, or ser-
vice this equipment.
LOCATION AND VENTILATION
The welder should be located to provide an unrestrict-
ed flow of clean, cool air. Also, locate the welder so
that the engine exhaust fumes are properly vented to
an outside area.
STORING
1. Store the machine in a cool, dry place when it is not
in use. Protect it from dust and dirt. Keep it where
it can’t be accidentally damaged from construction
activities, moving vehicles, and other hazards.
2. Drain the engine oil and refill with fresh 10W30 oil.
Run the engine for about five minutes to circulate oil
to all the parts. See the Maintenance section of
this manual for details on changing oil.
3. Remove the battery, recharge it, and adjust the
electrolyte level. Store the battery in a dry, dark
place.
4. See your engine operation manual for further infor-
mation on fuel and engine preservation.
STACKING
Commander 300 machines CANNOT be stacked.
ANGLE OF OPERATION
To achieve optimum engine performance the
Commander 300 should be run in a level position. The
maximum angle of operation for the Deutz engine is 20
degrees in a direction to cause the control panel to be
angled up, 30 degrees for side to side tilting and for the
control panel to be angled down. If the engine is to be
operated at an angle, provisions must be made for
checking and maintaining the oil level at the normal
(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 (94.6
liters).
INSTALLATION
A-3 A-3
COMMANDER 300
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WARNING

LIFTING
The Commander 300 weighs 1325 lb./601 kg. A lift bail
is provided for lifting with a hoist.
FALLING EQUIPMENT can cause injury.
Do not lift this machine using lift bail if it
is equipped with a heavy accessory
such as a trailer.
Lift only with equipment of adequate
lifting capacity. Be sure machine is sta-
ble when lifting.
The Commander is shipped with the lift bail retracted.
Before attempting to lift the Commander, secure the lift
bail in a raised position. Secure the lift bail as follows:
a. Open the engine compartment door.
b. Locate the two access holes on the upper middle
region of compartment wall just below the lift bail.
c. Use the lifting strap to raise the lift bail to the full
upright position. This will align the mounting
holes on the lift bail with the access holes.
d. Secure the lift bail with two thread forming
screws. The screws are provided in the shipped
loose parts bag.
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary.
For maximum rating, derate the welder output 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.
TOWING
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle is
Lincoln’s K953-1. If the user adapts a non-Lincoln trail-
er, he must assume responsibility that the method of
attachment and usage does not result in a safety haz-
ard nor damage the welding equipment. Some of the
factors to consider are as follows:
1. Design capacity of trailer vs. the weight of the
Lincoln equipment and likely additional attach-
ments.
2. Proper support of, and attachment to, the base of
the welding equipment so that there will be no
undue stress to the trailer’s framework.
3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when
the trailer is being moved and when standing by
itself.
4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, environmental conditions, and likely
maintenance.
5. Proper preventative maintenance of trailer.
6. Conformance with federal, state and local laws.1
1Consult applicable federal, state and local laws regarding specific
requirements for use on public highways.
PRE-OPERATION ENGINE SERVICE
Read and understand the information about the diesel
engine in the Operation and Maintenance sections of
this manual before you operate the Commander 300.
• Keep hands away from the engine muf-
fler or HOT engine parts.
• Stop the engine and allow it to cool
before fueling.
• Do not smoke when fueling.
• Remove the fuel cap slowly to release pressure.
• Fill the fuel tank at a moderate rate and do not over-
fill.
• Wipe up spilled fuel and allow the fumes to clear
before starting the engine.
• Keep sparks and flame away from the fuel tank.
INSTALLATION
A-4 A-4
COMMANDER 300
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WARNING
WARNING

OIL
The Commander 300 is shipped with the
engine crankcase filled with high quality
SAE 1OW-30 oil (API class CD or better).
CHECK THE OIL LEVEL BEFORE YOU START THE
ENGINE. If it is not up to the FULL mark on the dip-
stick, add oil as required. Check the oil every four
hours of running time during the first 35 running hours.
Refer to the engine operatorís manual for specific oil
recommendations and break-in information. The oil
change interval is dependent on the quality of the oil
and the operating environment. Refer to the engine
operatorís manual for the proper service and mainte-
nance intervals.
For more oil fill and service information, see the
Maintenance section of this manual.
FUEL
Use Diesel fuel only.
Fill the fuel tank with clean, fresh diesel fuel.
The Commander 300 has 25 gallon (94.6
liter) fuel tank. See the engine operatorís manual for
specific fuel recommendations. The Commander 300
Deluxe is protected by a low fuel shutdown to prevent
the engine from running out of fuel. The machine will
indicate a low fuel condition by turning on the low fuel
light. Once the light comes on, the machine will have
thirty minutes before it shuts down. The operator can
override this feature by restarting the engine, which
restarts the timer. The amount of reserve fuel remain-
ing in the tank after the first shutdown will vary from
machine to machine. The operator must determine the
amount of fuel remaining before restarting the
machine. Running out of fuel may require bleeding
the fuel injection pump.
NOTE: Before starting the engine, open the fuel shut-
off valve. The pointer on the valve should be in line
with the hose.
FUEL CAP
Remove the plastic cap covering from the fuel tank filler
neck and install the fuel cap.
COOLING SYSTEM
The Deutz engine is air cooled by a belt-driven axial
blower. The oil cooler and engine cooling fins should
be blown out with compressed air or steam to maintain
proper cooling. See the engine operator’s manual for
procedures and frequency.
BATTERY CONNECTIONS
BATTERY ACID CAN BURN EYES AND
SKIN.
•
Wear gloves and eye protection and be care-
ful when working near a battery. Follow the
instructions printed on the battery.
The Commander 300 is shipped with the
negative battery cable disconnected.
Before you operate the machine, make sure
the IGNITION switch is in the OFF position and remove
and discard the insulating cap from the negative bat-
tery terminal. Attach the disconnected cable securely
to the battery terminal. If the battery is discharged and
won't start the engine, see the battery charging instruc-
tions in the Maintenance section.
MUFFLER OUTLET PIPE
Remove the plastic plug covering the muffler outlet
tube. Using the clamp provided, secure the outlet pipe
to the outlet tube with the pipe positioned so that it will
direct exhaust in the desired direction.
SPARK ARRESTER
Diesel engine mufflers may emit sparks when the
engine is running. Some federal, state, or local laws
require spark arresters in locations where unarrested
sparks could present a fire hazard.
Standard mufflers (like the one included with the
Commander 300) do not act as spark arresters. When
local laws require it, a spark arrester must be installed
on the machine and properly maintained. An optional
spark arrester kit (K903-1) is available for your
Commander 300. See the Accessories section of this
manual for more information.
An incorrect spark arrester may lead to engine damage
or may adversely affect performance.
INSTALLATION
A-5 A-5
COMMANDER 300
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CAUTION
–+
WARNING

HIGH FREQUENCY GENERATORS
FOR TIG APPLICATIONS
The K799 Hi-Freq Unit and the K930-1 or –2 TIG
Module can be used with the Commander 300. The
machine is equipped with the required RF bypass cir-
cuitry for the connection of high frequency generating
equipment. The high frequency bypass network sup-
plied with the K799 Hi-Freq Unit does NOT need to be
installed into the Commander 300.
The Commander 300 and any high frequency generat-
ing equipment must be properly grounded. See the
K799 Hi-Freq Unit and the K930-1 or –2 TIG Module
operating manuals for complete instructions on instal-
lation, operation, and maintenance.
REMOTE CONTROL
The Commander 300 is equipped with a 6-pin and a
14-pin connector. The 6-pin connector is for connect-
ing the K857 or K857-1 Remote Control (optional) or
the K870 hand Amptrol or K812 foot Amptrol (TIG
applications).
The 14-pin connector is used to connect a wire feeder
or K930-1 or –2 TIG Module control cable. When
remote output control is used, the output control tog-
gle switch must be set at REMOTE.
NOTE: When using the 14-pin connector, do NOT con-
nect anything to the 6-pin connector if the wire feeder
has a built-in power source output control.
Also see the Accessories section of this manual for
more information on wire feeder connections.
WELDING TERMINALS
The Commander 300 has a toggle switch for selecting
“hot” welding terminals (WELDING TERMINALS
ALWAYS ON position) or “cold” welding terminals
(WELDING TERMINALS REMOTELY CONTROLLED
position).
ELECTRICAL OUTPUT
CONNECTIONS
See Figure A.1 for the location of the 120 and 240 volt
receptacles, weld output terminals, and ground stud.
INSTALLATION
A-6 A-6
COMMANDER 300
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FIGURE A.1 - Commander 300 OUTPUT CONNECTIONS
3
1
OIL
0
HOURS
FUEL
OIL
TEMP PRESS
24
00000
AMPS
1. 120 VOLT, 20 AMP
RECEPTACLES (2)
2. 120/240 VOLT, 50
AMP RECEPTACLE
3. WELD OUTPUT
TERMINALS
4. GROUND STUD

WELDING CABLE CONNECTIONS
CABLE INSTALLATION, POLARITY CONTROL,
AND CABLE SIZES
With the engine off, route the electrode and work
cables through the strain relief bracket on the base
front and connect them to the terminals. (See size rec-
ommendations below.) For positive polarity, connect
the electrode cable to the terminal marked Positive (+).
For Negative polarity, connect the electrode cable to
the Negative (-) terminal. These connections should be
checked periodically and tightened if necessary.
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
• Do not cross the welding cables at the output terminal
connection. Keep the cables isolated and separate
from one another.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
Lincoln Electric offers a welding accessory kit with prop-
erly specified welding cables. See the Accessories
section of this manual for more information.
INSTALLATION
A-7 A-7
COMMANDER 300
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CAUTION
TABLE A.1 - RECOMMENDED WELDING CABLE SIZE AND LENGTH
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
Amps @ 100%
Cable sizes for combined length of electrode
Duty Cycle plus work cable
Up to 150 ft. 150 - 200 ft. 200 - 250 ft.
300 2/0 AWG 2/0 AWG 3/0 AWG

MACHINE GROUNDING
Because this portable engine-driven welder creates its
own power, you do not need to connect the machine
frame to an earth ground, unless the machine is con-
nected to premises wiring (home, shop, etc.).
To prevent dangerous electric shock, other equipment
powered by the Commander 300 must:
a) be grounded to the frame of the welder using a
grounded type plug,
or
b) be double insulated.
When the Commander 300 is mounted to a truck or
trailer, its frame must be securely connected to the
metal frame of the vehicle. When connected to premis-
es wiring such as a home or shop, its frame must be
connected to the system earth ground. See further
connection instructions in the section titled Standby
Power Connections as well as the article on grounding
the latest U.S. National Electrical Code and the local
code.
In general, if the machine is to be grounded, it should
be connected with a #8 AWG or larger copper wire to a
solid earth ground such as a metal water pipe going
into the ground for at least ten feet and having no insu-
lated joints, or to the metal framework of a building that
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding
stud marked with the symbol is provided on the front
of the welder.
AUXILIARY POWER RECEPTACLES
The auxiliary power capacity of the Commander 300 is
10,000 watts of 60 Hz, single phase power. The auxil-
iary power capacity rating in watts is equivalent to volt-
amperes at unity power factor. The maximum permis-
sible current of the 240 VAC output is 44 A. The 240
VAC output can be split to provide two separate 120
VAC outputs with a maximum permissible current of
44A per output to two separate 120 VAC branch cir-
cuits. The output voltage is within ±10% at all loads up
to rated capacity.
NOTE: The 120/240V receptacle has two 120V outlets
of different phases and cannot be paralleled.
The Commander 300 has two 15 Amp-120VAC (5-
15R) duplex receptacles with GFCI protection and one
50 Amp-120/240 VAC (14-50R) receptacle. The
120/240 VAC receptacle can be split for single-phase
120 VAC operation. The auxiliary power receptacles
should only be used with three-wire, grounded type
plugs or approved double-insulated tools with two-wire
plugs. The current rating of any plug used with the sys-
tem must be at least equal to the current capacity of the
associated receptacle.
STANDBY POWER CONNECTIONS
The Commander 300 is suitable for temporary, stand-
by or emergency power using the engine manufactur-
er's recommended maintenance schedule.
The Commander 300 can be permanently installed as
a standby power unit for 240 volt, three-wire, 44 amp
service. Connections must be made by a licensed
electrician who can determine how the 120/240 VAC
power can be adapted to the particular installation and
comply with all applicable electrical codes. The follow-
ing information can be used as a guide by the electri-
cian for most applications. Refer to the connection dia-
gram shown in Figure A.2.
1. Install the double-pole, double-throw switch between
the power company meter and the premises discon-
nect.
Switch rating must be the same as or greater than the
customer's premises disconnect and service over cur-
rent protection.
2. Take necessary steps to assure the load is limited to
the capacity of the Commander 300 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 allow-
able ±10% of rated voltage, which may damage
appliances or other motor-driven equipment and
may result in overheating of the Commander 300
engine.
3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-
50) to the double-pole circuit breaker using No. 6, 4-
conductor cable of the desired length. (The 50 amp,
120/240 VAC plug is available in the optional K802R
plug kit.)
4. Plug this cable into the 50 Amp 120/240 Volt recep-
tacle on the Commander 300 case front.
INSTALLATION
A-8 A-8
COMMANDER 300
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INSTALLATION
A-9 A-9
COMMANDER 300
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FIGURE A.2 - CONNECTION OF THE COMMANDER TO PREMISES WIRING
240 Volt
60 Hz.
3-Wire
Service
POWER
COMPANY
METER
240 VOLT
120 VOLT
120 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GND
N
NOTE: No. 8 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
240 VOLT
GROUNDED CONDUCTOR
45AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE

NOTES
A-10 A-10
COMMANDER 300
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Section B-1 Section B-1
COMMANDER 300
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Operating Instructions.................................................................................................................B-2
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-3
Recommended Applications........................................................................................................B-3
Welder ..................................................................................................................................B-3
Generator..............................................................................................................................B-3
Design Features..........................................................................................................................B-3
Welding Capability ......................................................................................................................B-4
Controls and Settings..................................................................................................................B-4
Engine Controls....................................................................................................................B-5
Welder Controls....................................................................................................................B-6
Auxiliary Power Controls ......................................................................................................B-7
Engine Operation........................................................................................................................B-8
Starting the Engine...............................................................................................................B-8
Cold Weather Starting..........................................................................................................B-8
Stopping the Engine.............................................................................................................B-8
Break-in Period.....................................................................................................................B-8
Typical Fuel Consumption ....................................................................................................B-9
Welder Operation........................................................................................................................B-9
Stick Welding........................................................................................................................B-9
Pipe Welding...................................................................................................................B-9
Constant Current (CC) Welding......................................................................................B-9
TIG Welding..........................................................................................................................B-9
Wire Feed (Constant Voltage) Welding ..............................................................................B-11
Auxiliary Power Operation.........................................................................................................B-11
Simultaneous Welding and Auxiliary Power Loads ............................................................B-11
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OPERATING INSTRUCTIONS
Read and understand this entire section before operat-
ing your Commander 300.
SAFETY INSTRUCTIONS
Do not attempt to use this equipment until you have
thoroughly read all the operating and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating and maintenance instructions and parts lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be dan-
gerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust to the outside.
• Do not stack anything on or near the
engine.
MOVING PARTS can injure.
• Do not operate this equipment with any
of its doors open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
Only qualified personnel should install, use, or ser-
vice this equipment.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged door
closed and the side panels in place. These provide
maximum protection from moving parts and insure
proper cooling air flow.
OPERATION
B-2 B-2
COMMANDER 300
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WARNING
WARNING

GENERAL DESCRIPTION
The Commander 300 is a diesel engine-driven welding
power source. The machine uses a brush type alter-
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
Technology.
The generator has a single sealed bearing for mainte-
nance-free service. The rotor is a copper wound
design with two slip rings and brushes. The stator is
wound entirely with heavy gauge copper wire and insu-
lated with NEMA class F insulation material. The sta-
tor is then impregnated with three layers of high quali-
ty varnish. After the stator is assembled using tie bars,
the entire assembly is covered with an environmental-
ly protective coating. These measures insure trouble-
free operation in the harshest environments.
The fuel tank is made from high density polyethylene
and holds 25 gallons (94.6 liters) of diesel fuel. This
will provide enough fuel to run for 18 hours at full load.
The Deutz F3L-1011 F engine is equipped with a stan-
dard, heavy duty, combination fuel filter/water separa-
tor element.
RECOMMENDED APPLICATIONS
WELDER
The Commander 300 (Stick model) provides excellent
constant current DC welding output for stick (SMAW)
welding. The Commander 300 (Stick & Wire model)
also provides excellent constant voltage DC welding
output for MIG (GMAW) and Innershield (FCAW)
welding.
GENERATOR
The Commander 300 provides smooth 120/240 VAC
output for auxiliary power and emergency standby
power.
DESIGN FEATURES
K1585-2 Commander 300 Deluxe Model Features
FOR WELDING:
• Excellent DC multi-purpose welding for stick, MIG,
TIG, cored wire and arc gouging applications.
• 30 to 300 amps output in five slope controlled ranges
for out-of position and pipe electrodes, one constant
current output range for general purpose welding,
and one constant voltage range for MIG wire and
cored wire welding.
• 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 volt-
age and displaying the actual amperage and voltage
during welding. The meters use superbrite LEDs for
improved readability in full sunlight.
• Standard remote control capability with 14-pin and 6-
pin connectors for easy connection of Lincoln remote
control accessories.
• An internal “Solid State” contactor allows for the
selection of “hot” or “cold” output terminals with a
toggle switch on the control panel.
• ”Arc Control” potentiometer in Wire and Stick modes
for precise adjustment of arc characteristics.
• Advanced circuitry to prevent pop-outs in the five
slope modes.
FOR AUXILIARY POWER
• 10,000 watts of 120/240 VAC, 60Hz auxiliary power.
• Power for tools, 120/240 VAC lights, electric pumps
and for standby emergency power.
• Power to drive a 2 HP motor (provided it is started
under no load).
• Two 15 amp 120 VAC duplex receptacles with GFCI
protection for up to 30 amps of 120 VAC power.
• One 50 amp, 120/240 VAC dual voltage receptacle
for up to 44 amps of 240 VAC and up to 44 amps per
side to separate branch circuits (not in parallel) of
120 VAC single phase auxiliary power. Allows easy
connection to premises wiring.
• Weld and provide AC auxiliary power at the same
time (within machine total capacity).
OPERATION
B-3 B-3
COMMANDER 300
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ADDITIONAL DESIGN FEATURES
• Deutz 3-cylinder, air/oil cooled diesel engine.
Designed for long life, easy maintenance, and excel-
lent fuel economy.
• Engine protection system shuts the engine down for
low oil pressure, high oil temperature, or a broken
fan/engine alternator belt.
• Gauges for oil pressure, oil temperature, engine
alternator output and fuel level.
• Indicator lights for low oil pressure, high oil tempera-
ture, engine alternator low output/broken belt and
low fuel level (on K1585-2 only).
• Automatic low fuel shutdown before running out of
fuel (K1585-2 only).
• Engine hour meter standard on all models.
• Extended range 25 gallon (94.6 I) fuel tank.
• Automatic idler reduces engine speed when not
welding or drawing auxiliary power. This feature
reduces fuel consumption and extends engine life.
• Compact size fits crosswise in full size pick-up truck.
Single side engine service.
• Copper alternator windings and high temperature
insulation for dependability and long life.
• New paint system on case and base for outstanding
corrosion protection.
K1585-1 COMMANDER 300
STANDARD MODEL
The K1585-1 is the standard version of the
Commander 300, and has all the features of the
K1585-2 Deluxe version except that there are no
gauges, low fuel light nor dual output meters. This ver-
sion does have fully functional engine protection for low
oil pressure, high oil temperature, and alternator output
with associated lights.
Afield installed Dual Output Meter and Gauge Kit
(K1596-1) is available for the K1585-1 Commander
300. The kit includes dual output meters, oil pressure
gauge, oil temperature gage, and alternator ammeter.
WELDING CAPABILITY
The Commander 300 is rated 300 amps, 32 VDC at
100% duty cycle and 375 amps, 34 VDC at 60% duty
cycle. The maximum open circuit voltage at 1900 RPM
is 87 volts. The weld current is variable from 30 to 375
amps.
CONTROLS AND SETTINGS
The welder/generator controls are located on the case
front panel. Diesel engine idler control, start/stop con-
trols, welding output terminals and ground stud are
also on the case front. See Figure B.1 and the expla-
nations that follow.
OPERATION
B-4 B-4
COMMANDER 300
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