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When reinstalling, connect negative cable last. Keep well ventilated. . USING A BOOSTER — connect positive lead to battery first then connect negative lead to negative battery lead at engine foot. BATTERY ACID can burn eyes and skin. . Wear gloves and eye protection and be careful when working near battery. . Follow instructions printed on battery. IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries. b) Using a booster. Use correct polarity — Negative Ground. The Commander is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative (-) battery terminal. Remove the insulating cap from the negative battery terminal. Replace and tighten negative battery cable terminal. NOTE: This machine is furnished with a wet charged battery; if unused for several months, the battery may require a booster charge. Be sure to use the correct polarity when charging the battery. COMMANDER 300 A-5 A-5 INSTALLATION MUFFLER REMOTE CONTROL Remove the plastic plug covering the muffler outlet tube. Using the clamp provided secure the extension to the outlet tube. This welder is supplied with an adjustable rain cap for the muffler. Install the rain cap using the clamp provided with the outlet facing away from the direction in which this unit will be transported. This will minimize the amount of water and debris which could enter the muffler during transportation. SPARK ARRESTER Some federal, state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder does not qualify as a spark arrester. When required by local regulations, a suitable spark arrester, such as the S24647 must be installed and properly maintained. CAUTION An incorrect arrester may lead to damage to the engine or adversely affect performance. HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi-Freq Unit and the K930-1 or -2 TIG Module are suitable for use with the Commander 300. The Commander 300 is equipped with the required R.F. bypass circuitry for the connection of high frequency generating equipment. The high frequency bypass network supplied with the K799 Hi-Freq Unit does NOT need to be installed into the Commander 300. The Commander 300 and any high frequency generating 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 installation, operation, and maintenance. OUTPUT The Commander 300 is equipped with a 6-pin & 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control (Optional) or in the case of TIG welding applications, with the foot or hand Amptrol. (K870 or K812 respectively). The 14-pin connector is used to directly connect a wire feeder or TIG Module (K930-1 or -2) control cable. NOTE: When using the 14-pin connector, if the wire feeder has a built in power source output control, do not connect anything to the 6-pin connector. WELDING TERMINALS The Commander is equipped with a toggle switch for selecting "hot" welding terminals when in the "WELD TERMINALS ON" position or "cold" welding terminals when in the "WELDING TERMINALS REMOTELY CONTROLLED" position. COMMANDER 300 A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Commander 300 Make/Model Diesel Engine Displacement Description INPUT - DIESEL Speed (RPM) ENGINE Starting System Capacities Deutz F3L 1011F (Codes 11199 and Below) 125 cu. in (2.05 L) Bore x Stroke 3.89” x 4.13” (99mm x 105mm) 3 cylinder 31 HP(23 kw) @ 1800 RPM High Idle 1900 Low Idle 1475 Full Load 1800 12 VDC battery & Starter Fuel: 25 gal. 94.6 L Oil: 6.3 Qts. 6.0 L Deutz F3L2011 (Codes 11200 and above) 142 cu. in (2.33L) Bore x Stroke 3.70” x 4.41” (94mm x 112mm) 3 cylinder 32 HP(24 kw) @ 1800 RPM RATED OUTPUT - WELDER Duty Cycle Welding Output Volts at Rated Amps 100% 60% 300 amps (DC multi-purpose) 375 amps (DC multi-purpose) 32 volts 34 volts OUTPUT - WELDER AND GENERATOR Welding Range Open Circuit Voltage Auxiliary Power1 30-300 Amps CC / CV TIG 80 Max OCV @1900 RPM 120/240 VAC 10,000 Watts, 60 Hz. 100% Duty Cycle PHYSICAL DIMENSIONS HEIGHT2 WIDTH DEPTH WEIGHT 40.0 in. 1016.0 mm 31.5 in. 800.1 mm 63.1 in. 1602.7 mm 1325 lbs.(601 kg) (Codes 11199 and below) 1327 lbs.(602 kg) (Code 11200) 1332 lbs.(604 kg) (Code 11201) 1. Output 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. 2. Top of Enclosure. Add 8.6” (218.4mm) for exhaust. COMMANDER 300 A-6 A-6 INSTALLATION WELDING OUTPUT CABLES With the engine off, route the electrode and work cables thru the strain relief bracket provided on the front of the base and connect to the termi...