Lincoln Electric Welder SVM145 B User Manual
RETURN TO MAIN INDEX  
SVM145-B  
September, 2002  
TM  
Commander 300  
For use with machines having Code Numbers: 10469 (Standard),  
10470 (Deluxe)  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be 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  
Copyright © 2002 Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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ii  
ii  
SAFETY  
ARC RAYS can burn.  
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.  
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.  
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.  
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.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
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.  
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.  
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.  
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.  
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.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
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.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
COMMANDER 300  
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iii  
iii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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.  
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.  
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.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
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.  
•A safe 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.  
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).  
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.  
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.  
FOR ELECTRICALLY  
powered equipment.  
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.  
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.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
COMMANDER 300  
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iv  
iv  
SAFETY  
zones où l’on pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
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:  
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.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
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.  
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.  
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.  
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.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
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.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
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.  
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.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
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.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
Mar. ‘93  
COMMANDER 300  
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v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS  
RETURN TO MAIN INDEX  
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  
COMMANDER 300  
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Section A-1  
Section A-1  
TABLE OF CONTENTS  
- INSTALLATION SECTION -  
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  
COMMANDER 300  
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A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS - Commander 300  
INPUT - DIESEL ENGINE  
Make/Model  
Description  
Speed (RPM) Displacement  
Starting  
System  
Capacities  
Deutz  
F3L 1011F  
3 cylinder  
Air/cooled  
diesel  
1800 Full Load  
1900 High Idle  
1400 Low Idle  
125 cu. in.  
(2.05 liters)  
Electric  
12 VDC  
Fuel: 25 gal.  
(94.6 liters)  
31 HP  
@ 1800 RPM  
Oil: 6.3 qt.  
(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  
in 5 Ranges  
87 OCV  
@ 1900 RPM  
120/240 VAC  
10,000 Watts, 60 Hz.  
100% Duty Cycle  
PHYSICAL DIMENSIONS  
Height2  
Width  
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)  
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 8.9” (16mm) for exhaust.  
COMMANDER 300  
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A-3  
A-3  
INSTALLATION  
Read this entire installation section before you  
start installation.  
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.  
SAFETY PRECAUTIONS  
WARNING  
STORING  
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.  
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.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live  
parts such as output terminals or  
internal wiring.  
3. Remove the battery, recharge it, and adjust the  
electrolyte level. Store the battery in a dry, dark  
place.  
• Insulate yourself from the work  
and ground.  
4. See your engine operation manual for further infor-  
mation on fuel and engine preservation.  
• Always wear dry insulating  
gloves.  
STACKING  
ENGINE EXHAUST can kill.  
Commander 300 machines CANNOT be stacked.  
• Use in open, well ventilated  
areas or vent exhaust outside.  
• Do not stack anything near the  
engine.  
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).  
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.  
COMMANDER 300  
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A-4  
A-4  
INSTALLATION  
1. Design capacity of trailer vs. the weight of the  
Lincoln equipment and likely additional attach-  
ments.  
LIFTING  
The Commander 300 weighs 1325 lb./601 kg. A lift bail  
is provided for lifting with a hoist.  
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.  
WARNING  
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.  
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.  
4. Typical conditions of use, such as travel speed,  
roughness of surface on which the trailer will be  
operated, environmental conditions, and likely  
maintenance.  
Lift only with equipment of adequate  
lifting capacity. Be sure machine is sta-  
ble when lifting.  
5. Proper preventative maintenance of trailer.  
6. Conformance with federal, state and local laws.1  
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:  
1
Consult applicable federal, state and local laws regarding specific  
requirements for use on public highways.  
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.  
PRE-OPERATION ENGINE SERVICE  
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.  
Read and understand the information about the diesel  
engine in the Operation and Maintenance sections of  
this manual before you operate the Commander 300.  
d. Secure the lift bail with two thread forming  
screws. The screws are provided in the shipped  
loose parts bag.  
WARNING  
• Keep hands away from the engine muf-  
fler or HOT engine parts.  
HIGH ALTITUDE OPERATION  
• Stop the engine and allow it to cool  
before fueling.  
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.)  
• 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.  
Contact a Deutz Service Representative for any engine  
adjustments that may be required.  
• Wipe up spilled fuel and allow the fumes to clear  
before starting the engine.  
• Keep sparks and flame away from the fuel tank.  
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:  
COMMANDER 300  
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A-5  
A-5  
INSTALLATION  
OIL  
BATTERY CONNECTIONS  
The Commander 300 is shipped with the  
engine crankcase filled with high quality  
SAE 1OW-30 oil (API class CD or better).  
WARNING  
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.  
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.  
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  
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.  
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.  
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.  
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  
CAUTION  
Remove the plastic cap covering from the fuel tank filler  
neck and install the fuel cap.  
An incorrect spark arrester may lead to engine damage  
or may adversely affect performance.  
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.  
COMMANDER 300  
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A-6  
A-6  
INSTALLATION  
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.  
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.  
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.  
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.  
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).  
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).  
ELECTRICAL OUTPUT  
CONNECTIONS  
See Figure A.1 for the location of the 120 and 240 volt  
receptacles, weld output terminals, and ground stud.  
FIGURE A.1 - Commander 300 OUTPUT CONNECTIONS  
OIL  
OIL  
1. 120 VOLT, 20 AMP  
RECEPTACLES (2)  
00000 0  
HOURS  
FUEL  
TEMP  
PRESS  
AMPS  
2. 120/240 VOLT, 50  
AMP RECEPTACLE  
3. WELD OUTPUT  
TERMINALS  
4. GROUND STUD  
2
4
1
3
COMMANDER 300  
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A-7  
A-7  
INSTALLATION  
WELDING CABLE CONNECTIONS  
CAUTION  
CABLE INSTALLATION, POLARITY CONTROL,  
AND CABLE SIZES  
• Loose connections will cause the output terminals to  
overheat. The terminals may eventually melt.  
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.  
• 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.  
TABLE A.1 - RECOMMENDED WELDING CABLE SIZE AND LENGTH  
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES  
Cable sizes for combined length of electrode  
plus work cable  
Amps @ 100%  
Duty Cycle  
Up to 150 ft.  
150 - 200 ft.  
200 - 250 ft.  
300  
2/0 AWG  
2/0 AWG  
3/0 AWG  
COMMANDER 300  
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A-8  
A-8  
INSTALLATION  
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.  
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  
STANDBY POWER CONNECTIONS  
b) be double insulated.  
The Commander 300 is suitable for temporary, stand-  
by or emergency power using the engine manufactur-  
er's recommended maintenance schedule.  
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.  
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.  
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  
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.  
stud marked with the  
of the welder.  
symbol is provided on the front  
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.  
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.  
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.)  
NOTE: The 120/240V receptacle has two 120V outlets  
of different phases and cannot be paralleled.  
4. Plug this cable into the 50 Amp 120/240 Volt recep-  
tacle on the Commander 300 case front.  
COMMANDER 300  
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A-9  
A-9  
INSTALLATION  
FIGURE A.2 - CONNECTION OF THE COMMANDER TO PREMISES WIRING  
240 VOLT  
GROUNDED CONDUCTOR  
POWER  
240 Volt  
120 VOLT  
60 Hz.  
3-Wire  
Service  
COMPANY  
120 VOLT  
METER  
NEUTRAL  
BUS  
N
LOAD  
DOUBLE POLE DOUBLE THROW  
SWITCH RATING TO BE THE SAME  
AS OR GREATER THAN PREMISES  
SERVICE OVERCURRENT  
PROTECTION.  
PREMISES  
DISCONNECT AND  
SERVICE  
OVERCURRENT  
PROTECTION  
GROUND  
45AMP  
240 VOLT  
DOUBLE  
POLE  
CIRCUIT  
50 AMP, 120/240  
VOLT PLUG  
NEMA TYPE 14-50  
240 VOLT  
BREAKER  
GND  
N
50 AMP, 120/240 VOLT  
RECEPTACLE  
NOTE: No. 8 COPPER CONDUCTOR CABLE SEE  
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE  
SIZE RECOMMENDATIONS.  
COMMANDER 300  
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A-10  
A-10  
NOTES  
COMMANDER 300  
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Section B-1  
Section B-1  
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  
COMMANDER 300  
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B-2  
B-2  
OPERATION  
WARNING  
OPERATING INSTRUCTIONS  
Read and understand this entire section before operat-  
ing your Commander 300.  
ENGINE EXHAUST can kill.  
SAFETY INSTRUCTIONS  
WARNING  
• Use in open, well ventilated areas or  
vent exhaust to the outside.  
• Do not stack anything on or near the  
engine.  
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.  
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.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts such  
as output terminals or internal wiring.  
Only qualified personnel should install, use, or ser-  
vice this equipment.  
• Insulate yourself from the work and  
ground.  
• Always wear dry insulating gloves.  
ADDITIONAL SAFETY PRECAUTIONS  
FUMES AND GASES can be dan-  
gerous.  
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.  
• 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.  
COMMANDER 300  
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B-3  
B-3  
OPERATION  
GENERAL DESCRIPTION  
DESIGN FEATURES  
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.  
K1585-2 Commander 300 Deluxe Model Features  
FOR WELDING:  
• Excellent DC multi-purpose welding for stick, MIG,  
TIG, cored wire and arc gouging applications.  
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.  
• 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.  
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.  
• 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.  
RECOMMENDED APPLICATIONS  
WELDER  
• ”Arc Control” potentiometer in Wire and Stick modes  
for precise adjustment of arc characteristics.  
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.  
• Advanced circuitry to prevent pop-outs in the five  
slope modes.  
FOR AUXILIARY POWER  
• 10,000 watts of 120/240 VAC, 60Hz auxiliary power.  
GENERATOR  
• Power for tools, 120/240 VAC lights, electric pumps  
and for standby emergency power.  
The Commander 300 provides smooth 120/240 VAC  
output for auxiliary power and emergency standby  
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).  
COMMANDER 300  
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B-4  
B-4  
OPERATION  
ADDITIONAL DESIGN FEATURES  
K1585-1 COMMANDER 300  
STANDARD MODEL  
• Deutz 3-cylinder, air/oil cooled diesel engine.  
Designed for long life, easy maintenance, and excel-  
lent fuel economy.  
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.  
• 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.  
A field 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.  
• 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).  
WELDING CAPABILITY  
• Engine hour meter standard on all models.  
• Extended range 25 gallon (94.6 I) fuel tank.  
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.  
• 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.  
CONTROLS AND SETTINGS  
• Copper alternator windings and high temperature  
insulation for dependability and long life.  
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.  
• New paint system on case and base for outstanding  
corrosion protection.  
COMMANDER 300  
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B-5  
B-5  
OPERATION  
Figure B.1 Case Front Panel Controls  
9
10  
9
1
4
5
6
7
8
3
2
OIL  
OIL  
00000 0  
HOURS  
FUEL  
TEMP  
PRESS  
AMPS  
23  
13  
18  
17  
20  
22  
11  
12  
15  
21  
19  
16  
24  
14  
reaches the reserve level. Once the reserve level is  
reached, the engine protection system will shut  
down the engine after 30 minutes of operation. The  
machine can be restarted and operated for an addi-  
tional 30 minutes before the protection system will  
shut down the engine. This ability to override the  
engine protection allows the operator to “finish up”  
if necessary. The operator must watch the fuel level  
closely to prevent running out of fuel and having to  
bleed the system.  
ENGINE CONTROLS (Items 1 through 8)  
1. RUN/STOP SWITCH: When placed in the “RUN”  
position, this switch energizes the fuel solenoid and  
other electric accessories. When placed in the  
“STOP” position, the flow of fuel to the injection  
pump is stopped to shut down the engine. (If the  
switch is left in the “RUN” position and the engine is  
not running, the fuel solenoid will be engaged for 15  
seconds and then shut down. This is to protect the  
battery from discharge. After 15 seconds, the  
RUN/STOP switch must be toggled off then on  
before starting.)  
4. ENGINE TEMPERATURE GAUGE AND LIGHT  
(K1585-2 Std., K1585-1 Opt.): The gauge displays  
the engine oil temperature. The yellow temperature  
light remains off under normal operating tempera-  
tures. If the light turns on, the engine protection sys-  
tem will shut down the engine. Check for restrictions  
at the engine cooling air inlets and outlets (consult  
the engine operator's manual). Check for loose or  
disconnected leads at the temperature sender locat-  
ed on the engine. Check engine cooling blower belt.  
Also check to be sure that the welder loads are with-  
in the rating of the welder. The light will remain on  
when the engine has been shut down due to an over  
temperature condition.  
2. START PUSH BUTTON: Energizes the starter  
motor to crank the engine. With the engine “Run /  
Stop” switch in the “RUN” position, push and hold  
the START button to crank the engine; release as  
the engine starts. The START button must be  
depressed for a minimum of two seconds. Do not  
press it while engine is running, since this can cause  
damage to the ring gear and/or starter motor.  
3. FUEL LEVEL GAUGE AND LIGHT (K1585-2 only):  
Displays the level of diesel fuel in the 25-gallon fuel  
tank. The yellow light turns on when the fuel gage  
COMMANDER 300  
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B-6  
B-6  
OPERATION  
5. OIL PRESSURE GAUGE AND LIGHT (K1585-2  
Std., K1585-1 Opt.): The gauge displays the  
engine oil pressure when the engine is running.  
The yellow oil pressure light remains off with proper  
oil pressure. If the light turns on, the engine pro-  
tection system will stop the engine. Check for prop-  
er oil level and add oil if necessary. Check for loose  
or disconnected leads at the oil pressure sender  
located on the engine. The light will go on and stay  
on when the RUN/STOP switch is switched to the  
“RUN” position with engine not running.  
IDLER OPERATIONAL EXCEPTIONS  
When the WELDING TERMINALS switch is in the  
“WELDING TERMINALS REMOTELY CONTROLLED”  
position the idler will operate as follows:  
a. When the triggering device (Amptrol, Arc Start  
Switch, etc.) is pressed, the engine will acceler-  
ate and operate at full speed provided a welding  
load is applied within approximately 12 seconds.  
b. If the triggering device remains pressed but no  
welding load is applied within approximately 12  
seconds, the engine will return to low idle speed.  
6. ENGINE ALTERNATOR AMMETER AND LIGHT  
(K1585-2 Std., K1585-1 Opt.): The yellow engine  
alternator light is off when battery charging system  
is functioning normally. If the light turns on, the  
engine protection system will shut down the engine.  
Check the engine cooling blower belt. Also, the  
alternator or the voltage regulator may not be oper-  
ating correctly. The light may also come on due to  
a faulty flashing circuit. The light will remain on  
when the engine has been shut down due to a fault  
in the alternator, regulator, or the cooling blower  
belt.  
c. If the triggering device is released or welding  
ceases, the engine will return to low idle speed  
after approximately 12 seconds.  
8. HOUR METER: The hour meter displays the total  
time that the engine has been running. This meter  
is a useful indicator for scheduling preventative  
maintenance.  
WELDER CONTROLS (Items 9 through  
14)  
9. OUTPUT RANGE SELECTOR SWITCH & OUT-  
PUT CONTROL: These two controls allow you to  
select between various welding output slopes and  
adjust the desired welding output. Refer to Table  
B.1 for a description of how these two controls work.  
7. IDLER SWITCH: The switch has two positions as  
follows:  
A) In the “HIGH” position, the engine runs at the  
high idle speed controlled by the governor.  
B) In the “AUTO” position, the idler operates as fol-  
lows:  
TABLE B.1 OUTPUT RANGE SWITCH  
AND OUTPUT CONTROL FUNCTIONS  
a. When switched from “HIGH” to “AUTO” or  
after starting the engine, the engine will  
operate at full speed for approximately 12  
seconds and then go to low idle speed.  
OUTPUT  
RANGE  
OUTPUT  
CONTROL2  
SELECTOR  
SWITCH1  
b. When the electrode touches the work or  
power is drawn for lights or tools (approxi-  
mately 100 watts minimum) the engine  
accelerates and operates at full speed.  
Sloped Output for  
Pipe Welding  
5 Range Settings  
60, 90, 150, 230,  
300 (Max. current  
Provides a fine  
adjustment of  
welding current  
on each adjustment from Min (1) to  
c. When welding ceases or the AC power load  
is turned off, a fixed time delay of approxi-  
mately 12 seconds starts.  
of setting  
Max (10) within  
each range  
Constant Current  
1 Range setting  
Fabrication and General 30-375 Amps  
Purpose Welding (This  
d. If the welding or AC power load is not  
restarted before the end of the time delay,  
the idler reduces the engine speed to low  
idle speed.  
setting also used for TIG.)  
Constant Voltage Output 1 Range setting  
for MIG Wire or CORED 12 to 40 Volts  
WIRE Welding  
Provides Fine  
Voltage  
Adjustment  
e. The engine will automatically return to high  
idle speed when the welding load or AC  
power load is reapplied.  
1 If the SELECTOR switch is positioned between settings the previ-  
ous setting is maintained until the switch is properly positioned on a  
setting.  
2 CONTROL also controls O.C.V. while in the 5 sloped output ranges.  
COMMANDER 300  
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B-7  
B-7  
OPERATION  
10. DIGITAL OUTPUT METER: The digital output  
meters are located in the center of the control  
panel between the two large control knobs. The  
meters allow the output current level to be set prior  
to welding in stick mode and voltage level to be set  
prior to welding in the wire modes. During the  
welding process the meters display the actual  
output current and voltage, within +1%, -10%  
accuracy.  
AUXILIARY POWER CONTROLS  
(Items 15 through 19)  
15. 120/240VAC  
RECEPTACLE:  
This  
is  
a
120/240VAC (14-50R) receptacle that provides  
240VAC or can be split for 120VAC single-phase  
auxiliary power. This receptacle has a 50-amp rat-  
ing. Refer to AUXILIARY POWER RECEPTA-  
CLES in the Installation section for further informa-  
tion about this receptacle. Also refer to AUXIL-  
IARY POWER OPERATION later in this section.  
11. WELDING TERMINALS SWITCH: The toggle  
switch on the control panel labeled “WELDING  
TERMINALS ALWAYS ON” and “WELDING TER-  
MINALS REMOTELY CONTROLLED” is used to  
control the operation of the “solid state contactor”  
which allows for the selection of “Hot” or “Cold”  
welding terminals.  
16. 50 AMP CIRCUIT BREAKERS: These circuit  
breakers provide separate overload current protec-  
tion for each 120V circuit at the 240V receptacle.  
17. 120VAC RECEPTACLES: These two 120VAC (5-  
15R) receptacles with GFCI protection provide  
120VAC for auxiliary power. These receptacles  
have a 20 amp total rating. Refer to AUXILIARY  
POWER RECEPTACLES in the Installation section  
for further information about these receptacles.  
Also refer to AUXILIARY POWER OPERATION  
later in this section.  
With the switch in the “WELDING TERMINALS  
ALWAYS ON” position, the contactor is closed and  
the welding terminals are always “Hot.”  
With the switch in the “WELDING TERMINALS  
REMOTELY CONTROLLED” position, the contac-  
tor operation is controlled by an Amptrol, Arc Start  
Switch or some other type of triggering device  
through the use of a control cable connected to  
the 6-pin or 14-pin MS connector.  
18. 15 AMP CIRCUIT BREAKERS: These circuit  
breakers provide separate overload current protec-  
tion for each 120VAC receptacle.  
19. GROUND STUD: Provides a connection point for  
When the triggering device is pressed the contac-  
tor is closed and the welding terminals are “Hot.”  
connecting the machine case to earth ground for  
the safest grounding procedure.  
MACHINE GROUNDING in the Installation section  
for proper machine grounding information.  
Refer to  
When the triggering device is released the con-  
tactor is opened and the welding terminals are  
“Cold.”  
20. 15 AMP CIRCUIT BREAKER: This circuit breaker  
provides overload protection for the 120 VAC cir-  
cuit in the 14-pin connector.  
12. LOCAL/REMOTE SWITCH: The toggle switch on  
the control panel labeled “LOCAL/REMOTE” gives  
the operator the option of controlling the output at  
the welder control panel or at a remote station.  
For remote control, the toggle switch is set in the  
“REMOTE” position. For control at the welder  
control panel, the toggle switch is set in the  
“LOCAL” position.  
21. VOLTMETER +/- SWITCH: Changes the polarity  
display on the wire feeder.  
22. 15 AMP CIRCUIT BREAKER: This circuit breaker  
provides overload protection for the 42 VAC circuit  
in the 14-pin connector.  
13. 6 - PIN CONNECTOR: The 6-pin connector locat-  
ed on the control panel allows for connection of  
interfacing equipment.  
23. 14-PIN CONNECTOR: For quick connection of  
interfacing equipment.  
24. ARC CONTROL: The “ARC CONTROL” poten-  
tiometer is active in two modes: “STICK/TIG” and  
“WIRE WELDING” with different purposes in each  
mode.  
14. WELD OUTPUT TERMINALS + AND – : These  
1/2 - 13 studs with flange nuts provide welding  
connection points for the electrode and work  
cables. For positive polarity welding, the electrode  
cable connects to the “+” terminal and the work  
cable connects to this “-” terminal. For negative  
polarity welding, the work cable connects to the  
“+” terminal and the electrode cable connects to  
this “-” terminal.  
“STICK/TIG” mode: In this mode, the “ARC CON-  
TROL” knob sets the short circuit current during stick  
welding. Increasing the number from 1 to 10 increas-  
es the short circuit current. This prevents sticking of  
the electrode to the plate at low welding current set-  
tings. This also increases spatter. It is recommended  
that the control be set to the minimum number without  
electrode sticking.  
COMMANDER 300  
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B-8  
B-8  
OPERATION  
“WIRE WELDING” mode: In this mode increasing the  
number from 1 to 10 changes the arc from soft and  
washed-in to crisp and narrow. It acts as an induc-  
tance control. The proper setting depends on the appli-  
cation and operator preference.  
9. Allow the engine to warm up at low idle speed for  
several minutes before applying a load and/or  
switching to high idle. Allow a longer warm up time  
in cold weather.  
In general, MIG welding performs best in the “SOFT”  
range and Innershield in the “CRISP” range.  
COLD WEATHER STARTING  
With a fully charged battery and the proper weight oil,  
the engine should start satisfactorily even down to  
about 0°F. With the above and the optional ether  
starter kit (K887-1), the engine should start satisfacto-  
rily down to about -20°F. With the above and an oil pan  
preheating system,* the engine should start satisfacto-  
rily down to about -30°F. With the above and a battery  
warmer,* the engine should start satisfactorily down to  
about -40°F.  
ENGINE OPERATION  
WARNING  
DO NOT RUN THE ENGINE AT EXCESSIVE  
SPEEDS. The maximum allowable high idle speed for  
the Commander 300 is 1900 RPM, no load. Do NOT  
increase the idle speed on the engine. Severe per-  
sonal injury and damage to the machine can result if it  
is operated at speeds above the maximum rated  
speed.  
* Contact your local Lincoln Electric Representative for  
suggested after-market kits.  
STOPPING THE ENGINE  
Read and understand all safety instructions included in  
the Deutz engine instruction manual that is shipped  
with your Commander 300.  
Switch the RUN/STOP switch to “STOP.” This turns off  
the voltage supplied to the shutdown solenoid. A back-  
up shutdown can be accomplished by shutting off the  
fuel valve located in the fuel line.  
STARTING THE ENGINE  
1. Open the engine compartment door and check that  
the fuel shutoff valve located to the left of the fuel fil-  
ter housing is in the open position. (The lever  
should be in line with the hose.)  
BREAK-IN PERIOD  
The engine used to supply power for your welder is a  
heavy duty, industrial engine. It is designed and built  
for rugged use. It is very normal for any engine to use  
small quantities of oil until the break-in is accom-  
plished. Check the oil level twice a day during the  
break-in period (about 200 running hours).  
2. Check for proper oil level on the oil dipstick. Close  
the engine compartment door.  
3. Remove all plugs connected to the AC power recep-  
tacles.  
4. Set IDLER switch to “AUTO.”  
CAUTION  
5. Set the RUN/STOP switch to “RUN.” Observe that  
all engine protection lights momentarily turn on.  
Some lights may turn off before starting. Check the  
fuel gauge (K1585-2 only) to make sure that there  
is an adequate fuel level.  
During break-in, subject the Commander 300 to  
heavy loads. Avoid long periods running at idle.  
Before stopping the engine, remove all loads and  
allow the engine to cool several minutes.  
6. Press and hold the engine START button for a min-  
imum of 2 seconds.  
The heavy loading of the engine during break-in, with-  
in the rating of the machine, is recommended to prop-  
erly seat the piston rings and prevent wetstacking.  
Wetstacking is an accumulation of unburned fuel  
and/or lubricant in the form of a wet, black, tar-like sub-  
stance in the exhaust pipe. The rings are seated and  
the break-in period is complete when there are no  
longer any signs of wetstacking, which should occur  
within the first 50 to 100 hours of operation.  
7. Release the engine START button when the engine  
starts.  
8. Check that the indicator lights are off. If the LOW  
FUEL light is on (K1585 2 only), the engine will shut  
down 30 minutes after starting. If any other indica-  
tor light is on after starting, the engine will shut  
down in a few seconds. Investigate any indicated  
problem.  
COMMANDER 300  
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B-9  
B-9  
OPERATION  
WELDER OPERATION  
CAUTION  
STICK WELDING  
Using your welder at low amperages with long idle run-  
ning periods during the break-in period may result in a  
glaze forming on the engine cylinder walls and the  
rings not seating properly. No amount of loading will  
properly seat the piston rings after they are glazed  
over.  
The Commander 300 can be used with a broad range  
of DC stick electrodes.  
The SELECTOR switch provides five overlapping  
slope controlled current ranges. The CONTROL  
adjusts the current from minimum to maximum within  
each range. Voltage is also controlled by the CON-  
TROL in the slope controlled setting. These slope-con-  
trolled settings are intended for “out-of-position” weld-  
ing, including pipe welding, where the operator would  
like to control the current level by changing the arc  
length.  
TYPICAL FUEL CONSUMPTION  
Refer to Table B.2 for typical fuel consumption of the  
Commander 300 engine for various operating scenar-  
ios.  
PIPE WELDING  
The Commander 300 is equipped with special circuitry  
to minimize pop-outs in the five slope modes at any  
open circuit voltage.  
Table B.2 Deutz F3L 912 Engine Fuel Consumption  
For a soft arc characteristic, set the “SELECTOR”  
Switch to the lowest setting that still provides the cur-  
rent you need and set the “CONTROL” near maximum.  
For example: to obtain 140 amps and a soft arc, set the  
“SELECTOR” Switch to the “150 MAX” position and  
then adjust the “CONTROL” for 140 amps.  
Deutz F3L 1011 Running Time for  
29 HP  
@ 1800 RPM  
25 gallons  
(Hours)  
Low Idle - No  
.27 gallons/hour  
Load 1400 RPM (1.02 liters/hour)  
92.5  
52  
When a forceful “digging” arc is required, use a higher  
setting and lower the open circuit voltage. For example:  
to obtain 140 amps and a forceful arc, set the “SELEC-  
TOR” to the “230 MAX” position and then adjust the  
“CONTROL” to get 140 amps.  
High Idle - No  
.48 gallons/hour  
Load 1900 RPM (1.81 liters/hour)  
DC CC Weld  
Output 300  
Amps @ 32  
Volts  
Auxiliary Power 1.32 gallons/hour  
10,000 VA (5.00 liters/hour)  
1.34 gallons/hour  
(5.07 liters/hour)  
18.6  
CONSTANT CURRENT (CC) WELDING  
The most clockwise position of the “SELECTOR”  
switch is designed for horizontal welds with all types of  
electrodes, but especially low hydrogen. The “CON-  
TROL” adjusts the full range of 30 to 375 amps. This  
setting provides a soft, constant current arc. If a more  
forceful arc is desired, then select the proper range  
from the slope controlled current ranges.  
18.9  
In the CC mode, sticking can be prevented by adjust-  
ing the “ARC CONTROL.” Turning this control clock-  
wise increases the short circuit current, thus preventing  
sticking. This is another way of increasing arc force.  
TIG WELDING  
The Commander 300 can be used in a wide variety of  
DC Tungsten Inert Gas (TIG) welding applications.  
When used with the K930-1 or -2 TIG module or K799  
Hi-Freq Unit, ratings are limited to 375 amps at 20%  
duty cycle, 300 amps at 60% duty cycle, and 250 amps  
at 80% duty cycle.  
COMMANDER 300  
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B-10  
B-10  
OPERATION  
Table B.3 TYPICAL CURRENT RANGES1 FOR TUNGSTEN ELECTRODES2  
DCEN (-)  
DCEP (+)  
Approximate Argon Gas Flow Rate  
C.F.H. (l/min.)  
Tungsten  
Electrode  
Diameter  
in. (mm)  
TIG TORCH  
Nozzle  
1%, 2%  
Thoriated  
Tungsten  
1%, 2%  
Thoriated  
Tungsten  
Aluminum  
Stainless Steel  
4 5  
Size  
3
3
3
0 .010 (.25)  
0.020 (.50)  
0.040 (1.0)  
2-15  
5-20  
15-80  
3-8  
5-10  
5-10  
(2-4)  
(3-5)  
(3-5)  
3-8  
5-10  
5-10  
(2-4)  
(3-5)  
(3-5)  
#4, #5, #6  
1/16  
(1.6)  
70-150  
10-20  
5-10  
(3-5)  
9-13  
(4-6)  
#5, #6  
3/32  
1/8  
(2.4)  
(3.2)  
150-250  
250-400  
15-30  
25-40  
13-17 (6-8)  
15-23 (7-11) 11-15  
11-15  
(5-7)  
(5-7)  
#6, #7, #8  
5/32  
3/16  
1/4  
(4.0)  
(4.8)  
(6.4)  
400-500  
500-750  
750-1000  
40-55  
55-80  
180-125  
21-25 (10-12) 13-17 (6-8)  
23-27 (11-13) 18-22 (8-10)  
28-32 (13-15) 23-27 (11-13)  
#8, #10  
1
When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shield-  
ing gases.  
2 Tungsten electrodes are classified as follows by the American Welding Society (AWS):  
Pure  
EWP  
1% Thoriated  
2% Thoriated  
EWTh-1  
EWTh-2  
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated  
Tungsten in AC and DC applications.  
3
DCEP is not commonly used in these sizes.  
4 TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:  
# 4 = 1/4 in.  
# 5 = 5/16 in.  
# 6 = 3/8 in.  
# 7 = 7/16 in.  
# 8 = 1/2 in.  
#10 = 5/8 in.  
(6 mm)  
(8 mm)  
(10 mm)  
(11 mm)  
(12.5 mm)  
(16 mm)  
5 TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are  
less prone to breakage, but cannot withstand high temperatures and high duty cycles.  
COMMANDER 300 SETTINGS WHEN USING THE  
K799 HL-FREQ UNIT  
COMMANDER 300 SETTINGS WHEN USING THE  
K930-1 TIG MODULE  
a. Set the SELECTOR switch to the “30-375” setting  
(STICK/TIG).  
a. Set the SELECTOR switch to the 30-375 Setting  
(STICK/TiG).  
b. Set the IDLER switch to the “HIGH” position.  
b. Set the IDLER switch to the “AUTO” position.  
c. Set the LOCAL/REMOTE switch to the “REMOTE”  
position.  
c. Set the LOCAL/REMOTE switch to the “REMOTE”  
position.  
d. Set the WELDING TERMINALS switch to the  
“WELDING TERMINALS ALWAYS ON” position.  
This will close the solid state contactor and provide  
an always “hot” electrode.  
d. Set the WELDING TERMINALS switch to the  
“WELDING TERMINALS REMOTELY CON-  
TROLLED” position. This will keep the solid state  
contactor open and provide a “cold” electrode until  
the triggering device (Amptrol or Arc Start Switch) is  
pressed.  
(Note: This is necessary because the K799 circuitry  
with respect to the #2 and #4 leads does not provide  
the proper signal to open and close the solid state con-  
tactor in the Commander 300).  
COMMANDER 300  
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B-11  
B-11  
OPERATION  
The auxiliary power of the Commander 300 consists of  
two 15 Amp-120 VAC (5-15R) duplex receptacles and  
one 50 Amp-120/240 VAC (14-50R) receptacle. The  
120/240VAC receptacle can be split for single-phase  
120 VAC operation.  
WIRE FEED (CONSTANT VOLTAGE)  
WELDING  
Connect a wire feeder to the Commander 300 and set  
welder controls according to the instructions listed ear-  
lier in this section.  
The auxiliary power capacity is 10,000 watts of 60 Hz,  
single-phase power. The auxiliary power capacity rat-  
ing in watts is equivalent to volt-amperes at unity power  
factor. The maximum permissible 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 maxi-  
mum permissible current of 44 A per output to two sep-  
arate 120 VAC branch circuits. Output voltage is with-  
in + 10% at all loads up to rated capacity.  
The Commander 300 in the “WIRE WELDING” posi-  
tion, permits it to be used with a broad range of flux  
cored wire (Innershield and Outershield) electrodes  
and solid wires for MIG welding (gas metal arc weld-  
ing). Welding can be finely tuned using the “ARC CON-  
TROL.”  
Some recommended Innershield electrodes are NR-  
311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.  
NOTE: The 120/240V receptacle has two 120V outputs  
of different phases and cannot be paralleled.  
Recommended Outershield electrodes are 0S-70,  
0S71M.  
The auxiliary power receptacles should only be used  
with three-wire, grounded type plugs or approved dou-  
ble-insulated tools with two-wire plugs.  
Some recommended solid wires for MIG welding  
are.035 (0.9 mm), .045 (1.1 mm) and .052 (1.3 mm), L-  
50 and L56, .035 (0.9 mm) and .045 (1.1 mm) Blue  
Max MIG 308 LS.  
The current rating of any plug used with the system  
must be at least equal to the current capacity of the  
associated receptacle.  
For any electrodes, including the above recommenda-  
tions, the procedures should be kept within the rating of  
the machine. For additional electrode information, see  
Lincoln publications N-675, GS-100 and GS-210.  
SIMULTANEOUS WELDING AND  
AUXILIARY POWER LOADS  
AUXILIARY POWER OPERATION  
It must be noted that the above auxiliary power ratings  
are with no welding load. Simultaneous welding and  
power loads are specified in table B.4. The permissi-  
ble currents shown assume that current is being drawn  
from either the 120 VAC or 240 VAC supply (not both  
at the same time).  
Start the engine and set the IDLER control switch to  
the desired operating mode. Full power is available  
regardless of the welding control settings, if no welding  
current is being drawn.  
TABLE B.4 Commander 300 Simultaneous Welding and Power Loads  
Permissible Auxiliary  
Current in Amperes  
Permissible  
Welding  
Output Range  
Setting  
Welding Output  
Power - Watts  
(Unity Power  
Factor)  
@120 V ±10% * @ 240 V ±10%  
3.3  
3.3  
26*  
47**  
63**  
70**  
1.6  
1.6  
13  
23.5  
31.5  
35  
300A/32V  
300A/32V  
230A/30V  
150A/29V  
90A27V  
400  
400  
3100  
5650  
7600  
8500  
30-375  
300  
230  
150  
90  
60A/25V  
60  
* Each duplex receptacle is limited to 15 amps.  
** Not to exceed 44 amps per 120VAC branch circuit when splitting the 240VAC output.  
COMMANDER 300  
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B-12  
B-12  
NOTES  
COMMANDER 300  
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Section C-1  
Section C-1  
TABLE OF CONTENTS  
- ACCESSORIES -  
Accessories...........................................................................................................................Section C  
Options/Accessories ...................................................................................................................C-2  
Field Installed Options .........................................................................................................C-2  
Stick Welding Accessories....................................................................................................C-2  
TIG Welding Accessories .....................................................................................................C-2  
Semiautomatic Welding Accessories....................................................................................C-3  
Connection of Lincoln Electric Wire Feeders .......................................................................C-3  
Connection of the LN-7 ..................................................................................................C-4  
Connection of the LN-7 Using the K584 or K594 Input Cable Assembly ......................C-5  
Connection of the LN-8 Using the K867 Universal Adapter ..........................................C-6  
Connection of the LN-8 Using the K595 Input Cable Assembly ...................................C-7  
Connection of the LN-23-P ............................................................................................C-8  
Connection of the LN-25 ................................................................................................C-9  
COMMANDER 300  
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C-2  
C-2  
ACCESSORIES  
K1596-1 DUAL OUTPUT METERS AND GAUGES -  
Dual output meters provide preset ability of voltage for  
wire welding and current for stick welding. Measures  
both current and voltage when welding. Gauges  
include battery ammeter, engine temperature, and  
engine oil pressure. Fuel gauge is not available in kit  
form.  
OPTIONS/ACCESSORIES  
The following options/accessories are available for  
your Commander 300 from your local Lincoln  
Distributor.  
FIELD INSTALLED OPTIONS  
K802R POWER PLUG KIT - Provides a plug for each  
receptacle.  
K1597-1 42 VAC TRANSFORMER KIT - For products  
requiring 42 VAC power source.  
K857 25 ft. (8.5 m) or K857-1 100 ft. (30.4 m)  
REMOTE CONTROL - Portable control provides same  
dial range as the output control on the welder from a  
location up to the specified length from the welder. Has  
convenient plug for easy connection to the welder. The  
Commander 300 is equipped with a 6-pin connector for  
connecting the remote control and a toggle switch for  
selecting “LOCAL” output control or “REMOTE” output  
control.  
STICK WELDING ACCESSORIES  
K704 Accessory Kit, which includes:  
• Electrode holder and cable.  
• Ground clamp and cable.  
• Headshield.  
K704 ACCESSORY SET - Includes 35 feet (10 m) of  
electrode cable and 30 feet (9 m) of work cable, head-  
shield, work clamp and electrode holder. Cable is rated  
at 500 amps, 60% duty cycle.  
TIG WELDING ACCESSORIES  
• Magnum TIG Torch  
• Magnum Parts Kit and Argon gas  
• K930-ALL TIG Module (not required for  
scratch-start DC TIG welding)  
• K936-1 Control Cable  
K953-1 TWO-WHEEL TRAILER - For road, in-plant  
and yard towing. Road towing with optional fender and  
light kit. (For highway use, consult applicable federal,  
state and local laws regarding possible additional  
requirements.)  
• K870 Foot Amptrol  
• K953-1 Trailer  
• K958-1 Ball Hitch  
Also available:  
• K963-1/-2 Hand Amptrol  
• K814 Arc Start Switch  
• K937-22 Control Cable Extension  
• K937-45 Control Cable Extension  
• K844-1 Water Valve  
• K958-2 Lunette Eye Hitch  
• K959-1 Fender & Light Kit  
• K965-1 Cable Storage Rack  
K887-1 ETHER START KIT - Provides maximum cold  
weather starting assistance for frequent starting below  
10( F (-12.2( C). Required Ether tank is not provided  
with kit.  
K1604-1 OIL DRAIN KIT - Includes ball valve, hose  
and clamp.  
K1690-1 (2 DUPLEXES) GFCI KIt - Includes a UL  
approved 115 volt ground fault circuit interrupter recep-  
tacle (duplex type) with covers and installation instruc-  
tions. Each half of the receptacle is rated 15 amps, but  
the maximum total current from the GFCI duplex is lim-  
ited to 20 amps. The GFCI receptacle replaces the  
factory installed 115 volt duplex receptacle.  
S24647 SPARK ARRESTER  
COMMANDER 300  
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C-3  
C-3  
ACCESSORIES  
SEMIAUTOMATIC WELDING  
ACCESSORIES  
CONNECTION OF LINCOLN  
ELECTRIC WIRE FEEDERS  
LN-7 OR LN-8 WIRE FEEDERS - Semiautomatic, con-  
stant speed wire feeders. For CV operation only.  
WARNING  
LN-23P WIRE FEEDER - This portable wire feeder is  
capable of CV operation. K350-1 Adapter Kit is  
required.  
ELECTRIC SHOCK can kill.  
• Do not operate with panels open.  
LN-25 WIRE FEEDER - The LN-25 with or without an  
external contactor may be used with the Commander  
300.  
• Disconnect NEGATIVE (-) BATTERY  
LEAD before servicing.  
• Do not touch electrically live parts.  
NOTE: Gas-shielded welding requires a Magnum Gun.  
Gasless welding requires an Innershield Gun.  
MOVING PARTS can injure.  
• Keep guards in place.  
• Keep away from moving parts.  
OTHER WIRE FEEDERS FOR THE  
COMMANDER 300  
• Only qualified personnel should  
install, use or service this equip-  
ment.  
• NA-3 Automatic Wire Feeder  
• LN-142 Semiautomatic Wire Feeder(requires  
optional K1597-1 42VAC Transformer Kit).  
HIGH FREQUENCY GENERATORS FOR  
TIG APPLICATIONS  
The K799 Hi-Freq Unit and the K930-ALL TIG Modules  
are suitable for use with the Commander 300. The  
Commander 300 is equipped with the required RF  
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-generat-  
ing equipment must be properly grounded. See the  
K799 Hi-Freq Unit and the K930-AII TIG Module oper-  
ating manuals for complete instructions on installation,  
operation, and maintenance.  
COMMANDER 300  
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C-4  
C-4  
ACCESSORIES  
CONNECTION OF THE LN-7 TO THE  
COMMANDER 300 USING K867  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control cir-  
cuits may be damaged. The engine governor setting is  
preset at the factory—do not adjust above RPM speci-  
fications listed in this manual.  
UNIVERSAL ADAPTER (SEE FIGURE C.1.)  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-7 to the  
“+” terminal of the welder. Connect the work cable  
to the “-” terminal of the welder.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
6. Set the LOCAL/REMOTE switch to “REMOTE” if  
a K775 remote control is used. Set the switch to  
“LOCAL” if no remote control is used.  
NOTE: Figure C.1 shows the electrode connected for  
positive polarity. To change polarity, shut the welder off  
and reverse the electrode and work cables at the  
Commander 300 output terminals.  
7. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
3. Connect the K867 Universal Adapter to the K291  
or K404 input cable and the 14-pin amphenol of the  
Commander 300 as indicated in Figure C.1. Make  
the proper connections for local or remote control  
according to Figure C.1.  
8. Set the OUTPUT RANGE switch to “WIRE  
WELDING CV.”  
9. Set the WELDING TERMINALS switch to  
“WELDING TERMINAL REMOTELY CON-  
TROLLED.”  
4. Connect the K291 or K404 input cable to the LN-7.  
5. Place the IDLER switch in the “HIGH” position.  
10. Adjust wire feed speed at the LN-7.  
11. Adjust the ARC CONTROL to the desired level  
(“soft” or “crisp”).  
FIGURE C.1  
COMMANDER 300/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM  
SPARE  
82  
LN-7  
WIRE  
FEEDER  
81  
42  
41  
31  
32  
2
31  
32  
2
14 PIN  
AMPHENOL  
4
4
+
–
21  
GND  
21  
GND  
K291 OR K404  
INPUT CABLE  
K867 UNIVERSAL  
ADAPTER PLUG  
GREEN  
75  
76  
77  
75  
76  
77  
TO WORK  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
K775 OPTIONAL  
REMOTE CONTROL  
COMMANDER 300  
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C-5  
C-5  
ACCESSORIES  
CONNECTION OF THE LN-7 TO THE  
COMMANDER 300 USING K584 OR  
K594 INPUT CABLE ASSEMBLY  
(SEE FIGURE C.2.)  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control cir-  
cuits may be damaged. The engine governor setting is  
preset at the factory—do not adjust above RPM speci-  
fications listed in this manual.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-7 to the  
“+” terminal of the welder. Connect the work cable  
to the “-” terminal of the welder.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
7. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
NOTE: Figure C.2 shows the electrode connected for  
positive polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Commander 300 output terminals.  
8. Set the OUTPUT RANGE switch to “WIRE  
WELDING CV.”  
9. Set the WELDING TERMINALS switch to  
“WELDING TERMINALS REMOTELY CON-  
TROLLED.”  
3. Connect the K584-XX or K594-XX Input Cable  
Assembly to the LN-7.  
4. Connect the K584-XX or 594-XX input cable  
assembly to the 14-pin amphenol on the  
Commander 300.  
10. Adjust wire feed speed at the LN-7.  
11. Adjust the ARC CONTROL to the desired level  
(“soft” or “crisp”).  
5. Place the IDLER switch in the “HIGH” position.  
NOTE: For remote control, a K857 or K857-1 remote  
control is required. Connect it to the 6-pin amphenol.  
6. Set the LOCAL/REMOTE switch to “REMOTE” if a  
K857 or K857-1 remote control is used. Set the  
switch to “LOCAL” if no remote control is used.  
FIGURE C.2  
COMMANDER 300/LN-7 WITH K584 OR K594 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM  
TO LN-7 INPUT  
CABLE PLUG  
6 PIN  
AMPHENOL  
K584 OR K594 CONTROL CABLE  
OPTIONAL K857  
REMOTE CONTROL  
14 PIN  
AMPHENOL  
+
–
TO WORK  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
COMMANDER 300  
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C-6  
C-6  
ACCESSORIES  
CONNECTION OF THE LN-8 TO THE  
COMMANDER 300 USING K867  
CAUTION  
UNIVERSAL ADAPTER (SEE FIGURE C.3.)  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory—do not adjust above RPM  
specifications listed in this manual.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-8 to the  
“+” terminal of the welder. Connect the work cable  
to the “CV- Wire” terminal of the welder.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
6. Set the LOCAL/REMOTE switch to “REMOTE.”  
NOTE: Figure C.3 shows the electrode connected for  
positive polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Commander 300 output terminals.  
7. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
8. Set the OUTPUT RANGE switch to “WIRE  
WELDING CV.”  
3. Connect the K867 Universal Adapter to the K196  
input cable and the 14-pin amphenol of the  
Commander 300 as indicated in Figure C.3. Make  
the proper connections for local or remote control  
according to Figure C.3.  
9. Set the WELDING TERMINALS switch to  
“WELDING TERMINALS REMOTELY CON-  
TROLLED.”  
10. Adjust wire feed speed and voltage at the LN-8.  
4. Connect the K196 input cable to the LN-8.  
5. Place the IDLER switch in the “HIGH” position.  
11. Adjust the ARC CONTROL to the desired level  
(“soft” or “crisp”).  
FIGURE C.3  
COMMANDER 300/LN-8 WITH K867 ADAPTER CONNECTION DIAGRAM  
SPARE  
82  
LN-8  
WIRE  
81  
FEEDER  
42  
41  
31  
32  
2
31  
32  
2
14 PIN  
AMPHENOL  
4
4
ELECTRODE  
TO WORK  
21  
GND  
21  
GND  
K196  
INPUT CABLE  
K867 UNIVERSAL  
ADAPTER PLUG  
75  
76  
77  
A
TO WORK  
B
C
ELECTRODE CABLE  
TO WIRE FEED UNIT  
COMMANDER 300  
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C-7  
C-7  
ACCESSORIES  
CONNECTION OF THE LN-8 TO THE  
COMMANDER 300 USING K595 INPUT  
CABLE ASSEMBLY (SEE FIGURE C.4.)  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set  
ting is preset at the factory—do not adjust above RPM  
specifications listed in this manual.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-8 to the  
“+” terminal of the welder. Connect the work  
cable to the “-” terminal of the welder.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
NOTE: Figure C.4 shows the electrode connected for  
positive polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Commander 300 output terminals.  
6. Set the LOCAL/REMOTE switch to “REMOTE.”  
7. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
8. Set the OUTPUT RANGE switch to “WIRE  
WELDING CV.”  
3. Connect the K595-XX Input Cable Assembly to the  
LN-8.  
9. Set the WELDING TERMINALS switch to  
“WELDING TERMINALS REMOTELY CON-  
TROLLED.”  
4. Connect the K595-XX to the 14-pin amphenol on  
the Commander 300.  
5. Place the IDLER switch in the “HIGH” position.  
10. Adjust wire feed speed and voltage at the LN-8.  
11. Adjust the ARC CONTROL to the desired level  
(“soft” or “crisp”).  
FIGURE C.4  
COMMANDER 300/LN-8 WITH K595 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM  
TO LN-8 INPUT  
CABLE PLUG  
K595 INPUT CABLE ASSEMBLY  
14 PIN  
AMPHENOL  
+
–
TO WORK  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
COMMANDER 300  
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C-8  
C-8  
ACCESSORIES  
CONNECTION OF THE LN-23P TO THE  
COMMANDER 300 USING K350-1  
ADAPTER (SEE FIGURE C.5.)  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set  
ting is preset at the factory—do not adjust above RPM  
specifications listed in this manual.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-23P to  
the “-” terminal of the welder. Connect the work  
cable to the “+” terminal of the welder.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
NOTE: Figure C.5 shows the electrode connected for  
negative polarity.  
5. Set the VOLTMETER switch to negative.  
6. Set the OUTPUT RANGE switch to “WIRE WELD-  
ING CV.”  
3. Connect the K350-1 adapter to the amphenol on  
the LN-23P and the 14-pin amphenol of the  
Commander 300 as indicated in Figure C.5.  
7. Set the WELDING TERMINALS switch to “WELD-  
ING TERMINALS REMOTELY CONTROLLED.”  
4. Place the IDLER switch in the “HIGH” position.  
8. Set the LOCAL/REMOTE switch according to  
whether you are controlling the welder at the  
machine or remotely.  
9. Adjust wire feed speed and voltage at the LN-23P.  
FIGURE C.5  
COMMANDER 300/LN-23P CONNECTION DIAGRAM  
ENGINE WELDER WITH  
115 VAC AUXILIARY  
14 PIN AMPHENOL  
9 CONDUCTOR ADAPTER CABLE  
21  
+
N.D.  
K350-1  
CV-  
LN-23P ADAPTER KIT  
FEEDER "A"  
N.C.  
FEEDER "B"  
N.A.  
N.B.  
WORK  
LN-23P  
LN-23P  
WIRE FEEDER "A"  
WIRE FEEDER "B"  
ELECTRODE  
ELECTRODE  
COMMANDER 300  
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C-9  
C-9  
ACCESSORIES  
CONNECTION OF THE LN-25 TO THE  
COMMANDER 300 “ACROSS THE ARC”  
(SEE FIGURE C.6.)  
CAUTION  
If you are using an LN-25 without an internal contactor,  
the electrode will be “HOT” when the Commander 300  
is started.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-25 to the  
“-” terminal of the welder. Connect the work cable  
to the “+” terminal of the welder.  
5. Set the OUTPUT RANGE switch to “WIRE  
WELDING CV.”  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
6. Set the WELDING TERMINALS switch to 'WELD-  
ING TERMINALS ALWAYS ON.”  
NOTE: Figure C.6 shows the electrode connected for  
negative polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Commander 300 output terminals. Reverse the LN-25  
polarity switch.  
7. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
8. Adjust wire feed speed at the LN-25.  
9. Set the LOCAL/REMOTE switch to “REMOTE” if  
a K444-1 remote control is used.  
3. Attach the single lead from the LN-25 to the work  
using the spring clip on the end of the lead. This is  
only a sense lead – it carries no welding current.  
10. Adjust the ARC CONTROL to the desired level  
(“soft” or “crisp”).  
4. Place the IDLER switch in the “AUTO” position.  
FIGURE C.6  
COMMANDER 300/LN-25 ACROSS THE ARC CONNECTION DIAGRAM  
14 PIN  
AMPHENOL  
6 PIN  
AMPHENOL  
OPTIONAL K444-1  
REMOTE CONTROL  
LN-25  
WIRE FEEDER  
WORK CLIP LEAD  
TO WORK  
ELECTRODE  
TO WORK  
TO WORK  
COMMANDER 300  
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C-10  
C-10  
NOTES  
COMMANDER 300  
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Section D-1  
Section D-1  
TABLE OF CONTENTS  
-MAINTENANCE-  
Maintenance .........................................................................................................................Section D  
Safety Precautions......................................................................................................................D-2  
Routine and Periodic Maintenance.............................................................................................D-2  
Engine Maintenance.............................................................................................................D-2  
Oil ..................................................................................................................................D-2  
Change the Oil ...............................................................................................................D-2  
Change the Oil Filter ......................................................................................................D-3  
Fuel.................................................................................................................................D-3  
Fuel Filter .......................................................................................................................D-4  
Bleeding the Fuel System ..............................................................................................D-4  
Air Filter..........................................................................................................................D-4  
Cooling System ..............................................................................................................D-4  
Cooling Blower Belt .......................................................................................................D-5  
Spark Arrester Screen....................................................................................................D-5  
Engine Maintenance Schedule.......................................................................................D-6  
Engine Maintenance Parts .............................................................................................D-6  
Battery Maintenance.............................................................................................................D-7  
Cleaning the Battery.......................................................................................................D-7  
Checking Specific Gravity ..............................................................................................D-7  
Checking Electrolyte Level.............................................................................................D-7  
Charging the Battery ......................................................................................................D-7  
Welder/Generator Maintenance ...........................................................................................D-8  
Storage...........................................................................................................................D-8  
Cleaning .........................................................................................................................D-8  
Name plates ...................................................................................................................D-8  
Receptacles....................................................................................................................D-8  
Cable Connections.........................................................................................................D-8  
Major Component Locations ................................................................................................D-9  
COMMANDER 300  
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D-2  
D-2  
MAINTENANCE  
SAFETY PRECAUTIONS  
WARNING  
ROUTINE AND PERIODIC  
MAINTENANCE  
Refer to Figure D.2 for the location of maintenance  
components.  
• Have qualified personnel do all maintenance and  
troubleshooting work.  
• Turn the engine off before working inside the  
machine.  
ENGINE MAINTENANCE  
• Remove covers or guards only when necessary to  
perform maintenance and replace them when the  
maintenance requiring their removal is complete.  
CAUTION  
To prevent the engine from accidentally starting, dis-  
connect the negative battery cable before servicing the  
engine.  
• If covers or guards are missing from the machine,  
get replacements from a Lincoln Distributor.  
See Table D.1 for a summary of maintenance intervals  
for the items listed below. Follow either the hourly or  
the calendar intervals, whichever come first. More fre-  
quent service may be required, depending on your spe-  
cific application and operating conditions.  
Read the Safety Precautions in the front of this manu-  
al and in the instruction manual for the diesel engine  
used with your machine before working on the  
Commander 300.  
Keep all equipment safety guards, covers, and devices  
in position and in good repair. Keep your hands, hair,  
clothing, and tools away from the fans, and all other  
moving parts when starting, operating, or repairing this  
machine.  
OIL: Check the oil level after every 8 hours of opera-  
tion or daily. BE SURE TO MAINTAIN THE OIL  
LEVEL.  
Change the oil the first time between 25 and 50 hours  
of operation. Then, under normal operating conditions,  
change the oil as specified in Table D.1. If the engine  
is operated under heavy load or in high ambient tem-  
peratures, change the oil more frequently.  
CHANGE THE OIL: Change the oil, while the engine  
is still warm, as follows:  
1 . Drain the oil from the drain plug located on the  
engine bottom, as shown in Figure D.1.  
2. Replace the plug and tighten it securely.  
3. Remove the oil fill cap and add oil until the level  
reaches the “MAX” mark on the dipstick. Use high  
quality detergent oil of API service class CD or bet-  
ter, oil viscosity grade 10W30. Consult the engine  
manual for oil specifications for various ambient  
temperatures. Always check the level with the dip-  
stick before adding more oil.  
4. Reinstall the oil fill cap and the dipstick.  
COMMANDER 300  
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D-3  
D-3  
MAINTENANCE  
FIGURE D.1 – OIL DRAIN AND REFILL  
MAX  
MIN  
CHANGE THE OIL FILTER: Change the oil filter the  
first time between 25 and 50 hours of operation. Then,  
under normal operating conditions, change the oil filter  
after every 250 hours of operation. If the engine is  
operated under heavy load or in high ambient temper-  
atures, change the oil filter more frequently. See Table  
D.1 for recommended maintenance intervals. See  
Table D.2 for replacement oil filters.  
5. Refill the engine with the proper amount and type  
of oil as described in the Change the Oil section.  
Start the engine and check for leaks around the fil-  
ter element. Correct any leaks (usually by retight-  
ening the filter, but only enough to stop leaks)  
before placing the Commander 300 back in ser-  
vice.  
6. If there are no leaks, stop the engine and recheck  
the oil level. If necessary, add oil to bring the level  
up to the “MAX” mark, but do not overfill.  
Change the oil filter as follows (See Figure D.1.):  
1. Drain the oil from the engine and allow the oil filter  
to drain.  
FUEL: At the end of each day's use, refill the fuel tank  
to minimize moisture condensation and dirt contamina-  
tion in the fuel line. Do not overfill; leave room for the  
fuel to expand.  
2. Remove the old filter (spin it off) and discard it.  
Wipe off the filter mounting surface and adapter.  
3. Apply a thin coat of new oil to the rubber gasket on  
the new oil filter  
Refer to your engine operation manual for recom-  
mended grade of fuel.  
4. Spin the new filter onto the mounting adapter finger  
tight until the gasket is evenly seated. Then turn it  
down another 1/2 turn. Do not over tighten the new  
filter.  
COMMANDER 300  
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D-4  
D-4  
MAINTENANCE  
FUEL FILTER:  
The air filter element is a dry cartridge type. It can be  
cleaned and reused; however, damaged elements  
should not be reused. Remove loose dirt from the ele-  
ment with compressed air or a water hose directed  
from inside out. Compressed Air: 100 psi maximum  
with nozzles at least one inch away from element.  
Water Hose: 40 psi maximum without nozzle.  
WARNING  
When working on the fuel system:  
• Keep naked lights away.  
• Do not smoke !  
• Do not spill fuel !  
Soak the element in a mild detergent solution for 15  
minutes. Do not soak more than 24 hours. Swish the  
element around in the solution to help remove dirt.  
Rinse the element from inside out with a gentle stream  
of water (less than 40 psi) to remove all suds and dirt.  
Dry the element before reuse with warm air at less than  
160° F (71° C). Do not use a light bulb to dry the ele-  
ment.  
Inspect the fuel filter daily. Replace the fuel filter car-  
tridge every 1000 hours of operation. Dust and dirt in  
the fuel system can cause the injection pump and  
injection nozzle to wear quickly. Replace the fuel filter  
as follows (See Figure D.1.):  
1. Close the fuel stopcock.  
Inspect for holes and tears by looking through the ele-  
ment toward a bright light. Check for damaged gaskets  
or dented metal parts. Do not reuse a damaged ele-  
ment. Protect the element from dust and damage dur-  
ing drying and storage.  
2. Loosen the fuel filter cartridge with a removal tool  
and spin the cartridge off. Catch any escaping fuel  
in an appropriate container.  
3. Clean the sealing surface of the filter carrier. Apply  
a light film of oil or diesel fuel to the rubber gasket  
of the new fuel filter cartridge.  
Replace the air filter after six cleanings. A cleaned fil-  
ter will have approximately 70% of the life of a new fil-  
ter element. A restricted filter element may not appear  
excessively dirty.  
4. Screw the new cartridge into position finger tight  
until the gasket is evenly seated. Then turn it down  
another 1/2 turn. Do not over tighten the new filter.  
COOLING SYSTEM: The Deutz diesel engine is air  
cooled. Clean the engine cooling system periodically  
to prevent clogging the air passages on the cylinder  
heads and oil cooler, which would overheat the engine.  
Consult the engine operation manual. It is important to  
locate the welder to provide an unrestricted flow of  
clean, cool air.  
5. Open the fuel stopcock. Check the assembly for  
leaks.  
BLEEDING THE FUEL SYSTEM: If the engine is oper-  
ated until it runs out of fuel, you will need to bleed air  
from the fuel system in order to start the engine. See  
the engine operation manual for the recommended  
procedure.  
AIR FILTER  
CAUTION  
Excessive air filter restriction will result in reduced  
engine life.  
1. Service air cleaner regularly according to engine  
operation manual.  
2. Stop engine after 100 hours of running time and  
clean filter element, replace the filter if necessary.  
The air filter canister is located behind the engine door  
on top of the air intake box.  
COMMANDER 300  
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D-5  
D-5  
MAINTENANCE  
COOLING BLOWER BELT: The following procedure  
should be followed to replace the cooling blower belt:  
8. Remove the old V-belt and install a new one.  
Refer to the engine operation manual for proper  
tensioning of the belt.  
1. Allow the machine to cool.  
9. Reinstall the rubber strap on the fan cowling, the  
pulley belt guard, the engine case back, the air fil-  
ter hose, and the engine case side.  
2. Remove the engine case side.  
3. Loosen the air filter hose clamp and detach hose.  
4. Disconnect the negative battery cable.  
10. Reconnect the negative battery terminal.  
5. Remove the engine case back panel for access to  
the engine.  
SPARK ARRESTER SCREEN: If the muffler has the  
optional spark arrester, remove it every 50 hours or  
once a year, whichever comes first, and inspect it.  
Clean the arrester. Replace it if you find any damage.  
6. Remove the pulley belt guard (5 screws).  
7. Remove the rubber strap on the lower half of the  
engine fan cowling. Loosen the tensioning pulley  
(2 bolts).  
COMMANDER 300  
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D-6  
D-6  
MAINTENANCE  
TABLE D.1  
DEUTZ ENGINE MAINTENANCE SCHEDULE  
FREQUENCY  
MAINTENANCE REQUIRED  
Daily or Before  
Starting Engine  
• Fill fuel tank.  
• Check oil level.  
• Check air cleaner for dirty, loose, or damaged parts  
• Check air intake and cooling areas, clean as necessary.  
First 50 Hours  
and Every 2501  
• Change engine oil.  
• Change oil filter.  
Hours Thereafter • Change fuel filter2.  
• Check fan belt.  
Every 50 Hours  
• Check fuel lines and clamps.  
Every 100 Hours • Check battery electrolyte level and connections.  
• Clean air filter.  
Refer to your Deutz engine operation manual for periodic maintenance at 100 hours and beyond.  
1125 Hours for severe conditions.  
2After the first 50 hours, change the fuel filter every 1000 hours. See the Deutz engine operation manual for specifics.  
TABLE D.2  
DEUTZ ENGINE MAINTENANCE PARTS  
ITEM  
MAKE  
PART NUMBER  
Air Cleaner Element  
Donaldson  
Frame  
AC  
P181050  
CAK-256  
A297C  
Nelson  
70206N  
Cooling Blower Belt  
Oil Filter Element  
Fuel Filter  
Deutz  
Deutz  
Deutz  
117-9565  
117-4416  
117-4482  
Battery  
BCI  
Group 34  
COMMANDER 300  
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D-7  
D-7  
MAINTENANCE  
CHECKING SPECIFIC GRAVITY: Check each battery  
cell with a hydrometer. A fully charged battery will have  
a specific gravity of 1.260. Charge the battery if the  
reading is below 1.215.  
BATTERY MAINTENANCE  
WARNING  
NOTE: Correct the specific gravity reading by adding four  
gravity points (0.004) for every five degrees the electrolyte  
temperature is above 80° F (27° C). Subtract four gravity  
points (9.004) for every five degrees the electrolyte tem-  
perature is below 80° F (27° C).  
GASES FROM BATTERY can explode.  
• Keep sparks, flame, and cigarettes  
away from battery.  
BATTERY ACID can burn eyes and skin.  
CHECKING ELECTROLYTE LEVEL: If battery cells  
are low, fill them to the neck of the filler hole with dis-  
tilled water and recharge. If one cell is low, check for  
leaks.  
• Wear gloves and eye protection and be  
careful when working near a battery.  
Follow the instructions printed on the  
battery.  
CHARGING THE BATTERY: The Commander 300 is  
equipped with a wet charged battery. The charging  
current is automatically regulated when the battery is  
low (after starting the engine) to a trickle current when  
the battery is fully charged.  
To prevent EXPLOSION when:  
• INSTALLING A NEW BATTERY - Disconnect the  
negative cable from the old battery first and connect  
to the new battery last.  
• CONNECTING A BATTERY CHARGER  
- Remove the battery from the welder by  
disconnecting the negative cable first,  
then the positive cable and battery clamp.  
When reinstalling, connect the negative  
cable last. Keep the area well ventilated.  
When you charge, jump, replace, or otherwise connect  
battery cables to the battery, be sure the polarity is cor-  
rect. Improper polarity can damage the charging cir-  
cuit. The Commander 300 charging system is NEG-  
ATIVE GROUND. The positive (+) battery terminal has  
a red terminal cover.  
• USING A BOOSTER - Connect the positive lead to  
the battery first, then connect the negative lead to the  
engine foot.  
If you need to charge the battery with an external  
charger, disconnect the negative cable first, then the  
positive cable before you attach the charger leads.  
After the battery is charged, reconnect the positive bat-  
tery cable first and the negative cable last. Failure to  
do so can result in damage to the internal charger com-  
ponents.  
• To prevent BATTERY BUCKLING, tighten the nuts  
on the battery clamp until snug.  
CLEANING THE BATTERY: Keep the battery clean by  
wiping it with a damp cloth when dirty. If the terminals  
appear corroded, disconnect the battery cables and  
wash the terminals with an ammonia solution or a solu-  
tion of 1/4 pound (0.113 kg) of baking soda and 1 quart  
(0.946 1) of water. Be sure the battery vent plugs (if  
equipped) are tight so that none of the solution enters  
the cells.  
Follow the instructions of the battery charger manufac-  
turer for proper charger settings and charging time.  
After cleaning, flush the outside of the battery, the bat-  
tery compartment, and surrounding areas with clear  
water. Coat the battery terminals lightly with petroleum  
jelly or a non-conductive grease to retard corrosion.  
Keep the battery clean and dry. Moisture accumulation  
on the battery can lead to more rapid discharge and  
early battery failure.  
COMMANDER 300  
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D-8  
D-8  
MAINTENANCE  
RECEPTACLES: Keep the electrical receptacles in  
good condition. Remove any dirt, oil, or other debris  
from their surfaces and holes.  
WELDER/GENERATOR  
MAINTENANCE  
STORAGE: Store the Commander 300 in clean, dry,  
protected areas.  
CABLE CONNECTIONS: Check the welding cable  
connections at the weld output terminals often. Be  
sure that the connections are always tight.  
CLEANING: Blow out the generator and controls peri-  
odically with low pressure air. Do this at least once a  
week in particularly dirty areas.  
NAME PLATES: Whenever routine maintenance is  
performed on this machine - or at least yearly - inspect  
all name plates and labels for legibility. Replace name  
plates that are no longer clear. Refer to the parts list  
for the replacement item number.  
COMMANDER 300  
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D-9  
D-9  
MAINTENANCE  
FIGURE D.2 - MAJOR COMPONENT LOCATIONS  
1. CONTROL PANEL  
2. FRONT PANEL ASSEMBLY  
3. POWER MODULE/DIODE  
RECTIFIER BRIDGE ASSEMBLY  
4. BASE  
5. FUEL TANK  
6. ENGINE  
7. ROTOR/STATOR  
8. IDLER SOLENOID  
9. REAR PANEL ASSEMBLY  
10. CASE TOP AND SIDES  
10  
6
8
7
5
9
2
1
3
4
COMMANDER 300  
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D-10  
D-10  
NOTES  
COMMANDER 300  
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Section E-1  
Section E-1  
TABLE OF CONTENTS  
-THEORY OF OPERATION SECTION-  
Theory of Operation .............................................................................................................Section E  
General Description ..............................................................................................................E-2  
Battery, Engine, Rotor, Stator and Engine Protection ...........................................................E-2  
Weld Windings, Rectifier, Power Modules and Feedback.....................................................E-3  
Control Transformer and Control Board ...............................................................................E-4  
Insulated Gate Bipolar Transistor (IGBT) Operation .............................................................E-5  
Pulse Width Modulation.........................................................................................................E-6  
Chopper Technology Fundamentals......................................................................................E-7  
TO  
CONTROL  
BOARD  
WORK  
TERMINAL  
__  
THREE-PHASE  
RECTIFIER  
SHUNT  
TO  
CONTROL  
BOARD  
POWER MODULES  
(TWO)  
ELECTRODE  
TERMINAL  
IGBT  
CHOKE  
+
IGBT  
W
I
D
N
L
D
E
W
I
N
G
CONTROL  
BOARD  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
STARTER  
SLIP  
RINGS  
ARC  
OUTPUT  
MODE  
CONTROL CONTROL SELECTOR  
STATOR  
ALTERNATOR  
ENGINE  
SENSORS  
AUXILIARY  
WINDINGS  
SOL  
1
1
5
V
A
C
I
D
L
E
R
SOL  
BATTERY  
S
H
U
T
230VAC  
RECEPTACLE  
D
O
W
N
115VAC  
RECEPTACLE  
42VAC  
ENGINE  
PROTECTION  
30VAC  
30VAC  
CONTROL  
TRANSFORMER  
FIGURE E.1 – Commander 300 BLOCK LOGIC DIAGRAM  
COMMANDER 300  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND ENGINE PROTECTION  
TO  
WORK  
CONTROL  
BOARD  
TERMINAL  
__  
THREE-PHASE  
RECTIFIER  
SHUNT  
TO  
CONTROL  
BOARD  
POWER MODULES  
(TWO)  
ELECTRODE  
TERMINAL  
IGBT  
CHOKE  
+
IGBT  
W
I
D
N
L
D
E
W
I
N
G
CONTROL  
BOARD  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
STARTER  
SLIP  
RINGS  
ARC  
OUTPUT  
MODE  
CONTROL CONTROL SELECTOR  
STATOR  
ALTERNATOR  
ENGINE  
SENSORS  
AUXILIARY  
WINDINGS  
SOL  
1
1
5
V
A
C
I
D
L
E
R
SOL  
BATTERY  
S
H
U
T
230VAC  
RECEPTACLE  
D
O
W
N
115VAC  
RECEPTACLE  
42VAC  
ENGINE  
PROTECTION  
30VAC  
30VAC  
CONTROL  
TRANSFORMER  
voltage magnetizes the rotor lamination. The rotor is  
mechanically coupled to the engine. This rotating mag-  
net induces a voltage in the stationary windings of the  
main alternator stator. The stator houses a three-  
phase weld winding and also a 115/230VAC single-  
phase auxiliary winding. The 115VAC portion of the  
auxiliary winding is also rectified and serves as a feed-  
back supply for the rotor field winding.  
GENERAL DESCRIPTION  
The Commander 300 is a diesel engine-driven welding  
power source capable of producing 300 amps at  
32VDC at a 100% duty cycle. The engine is coupled to  
a brush-type alternating current generator. This AC  
output is rectified and controlled by Chopper  
Technology to produced DC current for multi-purpose  
welding applications. The Commander 300 is also  
capable of producing 10,000 watts of AC auxiliary  
power.  
The engine alternator supplies charging current for the  
battery circuit. The engine protection board monitors  
the sensors and will shut the engine off in the event of  
low oil pressure, engine over temperature, malfunction  
in the engines alternator system or a low fuel condition.  
The idler solenoid is mechanically connected to the  
engines throttle linkage. If no welding or auxiliary cur-  
rent is being drawn from the Commander 300, the pro-  
tection board activates the idler solenoid, which then  
brings the engine to a low idle state. When output cur-  
rent is sensed, either weld or auxiliary, the protection  
board deactivates the idler solenoid and the engine  
returns to high RPM.  
BATTERY, ENGINE, ROTOR, STA-  
TOR AND ENGINE PROTECTION  
The 12VDC battery powers the engine starter motor  
and also supplies power to the engine alternator and  
engine protection board. When the engine is started  
and running, the battery circuit voltage is fed through  
the protection board to the rotor field coil via a brush  
and slip ring configuration. This excitation or “flashing”  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
COMMANDER 300  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.3 – WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK  
TO  
CONTROL  
BOARD  
WORK  
TERMINAL  
__  
THREE-PHASE  
RECTIFIER  
SHUNT  
TO  
CONTROL  
BOARD  
POWER MODULES  
(TWO)  
ELECTRODE  
TERMINAL  
IGBT  
CHOKE  
+
IGBT  
W
I
D
N
L
D
E
W
I
N
G
CONTROL  
BOARD  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
STARTER  
SLIP  
RINGS  
ARC  
OUTPUT  
MODE  
CONTROL CONTROL SELECTOR  
STATOR  
ALTERNATOR  
ENGINE  
SENSORS  
AUXILIARY  
WINDINGS  
SOL  
1
1
5
V
A
C
I
D
L
E
R
SOL  
BATTERY  
S
H
U
T
230VAC  
RECEPTACLE  
D
O
W
N
115VAC  
RECEPTACLE  
42VAC  
ENGINE  
PROTECTION  
30VAC  
30VAC  
CONTROL  
TRANSFORMER  
output is applied through choke coils to the welding out-  
put terminals. The chokes function as current filters  
and also help to balance the outputs of the two power  
modules. Free-wheeling diodes are incorporated in the  
power modules to provide a current path for the stored  
energy in the chokes when the IGBTs are turned off.  
See Chopper Technology in this section.  
WELD WINDINGS, RECTIFIER,  
POWER MODULES AND FEED-  
BACK  
The three-phase stator weld windings are connected to  
a three-phase rectifier bridge. The resultant DC volt-  
age is applied to parallel capacitors incorporated with-  
in the two power modules. These capacitors function  
as filters and also as power supplies for the IGBTs.  
See IGBT Operation in this section. The IGBTs act as  
high-speed switches operating at 20KHZ. These  
devices are switched on and off by the control board  
through pulse width modulation circuitry. See Pulse  
Width Modulation in this section. This “chopped” DC  
Output voltage and current feedback information is fed  
to the control board. This information is sensed at the  
output terminals and the shunt.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
COMMANDER 300  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.4 – CONTROL TRANSFORMER AND CONTROL BOARD  
TO  
CONTROL  
BOARD  
WORK  
TERMINAL  
__  
THREE-PHASE  
RECTIFIER  
SHUNT  
TO  
CONTROL  
BOARD  
POWER MODULES  
(TWO)  
ELECTRODE  
TERMINAL  
IGBT  
CHOKE  
+
IGBT  
W
I
D
N
L
D
E
W
I
N
G
CONTROL  
BOARD  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
STARTER  
SLIP  
RINGS  
ARC  
OUTPUT  
MODE  
CONTROL CONTROL SELECTOR  
STATOR  
ALTERNATOR  
ENGINE  
SENSORS  
AUXILIARY  
WINDINGS  
SOL  
1
1
5
V
A
C
I
D
L
E
R
SOL  
BATTERY  
S
H
U
T
230VAC  
RECEPTACLE  
D
O
W
N
115VAC  
RECEPTACLE  
42VAC  
ENGINE  
PROTECTION  
30VAC  
30VAC  
CONTROL  
TRANSFORMER  
The control board monitors the operator controls (out-  
put, mode selector and arc control). It compares these  
commands to the current and voltage feedback infor-  
mation it receives from the shunt and output terminals.  
The circuitry on the control board determines how the  
output should be controlled to optimize welding results  
and sends the correct PWM signals to the IGBT driver  
circuits.  
CONTROL TRANSFORMER AND  
CONTROL BOARD  
The control transformer primary winding is powered by  
the 115VAC auxiliary coil in the stator. Three sec-  
ondary voltages are developed by the control trans-  
former. The 42VAC is applied to the control board  
where it is rectified and used to operate the control  
board circuitry. The two isolated 30VAC windings sup-  
ply power to the IGBT driver circuits.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
COMMANDER 300  
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E-5  
E-5  
THEORY OF OPERATION  
FIGURE E.5 – IGBT OPERATION  
POSITIVE  
VOLTAGE  
APPLIED  
GATE  
GATE  
SOURCE  
SOURCE  
n +  
n +  
n +  
n +  
p
BODY REGION  
p
BODY REGION  
DRAIN DRIFT REGION  
DRAIN DRIFT REGION  
n -  
n -  
n +  
p +  
BUFFER LAYER  
n +  
p +  
BUFFER LAYER  
INJECTING LAYER  
INJECTING LAYER  
DRAIN  
DRAIN  
B. ACTIVE  
A. PASSIVE  
Drawing B shows the IGBT in an active mode. When  
the gate signal, a positive DC voltage relative to the  
source, is applied to the gate terminal of the IGBT, it is  
capable of conducting current. A voltage supply con-  
nected to the drain terminal will allow the IGBT to con-  
duct and supply current to circuit components coupled  
to the source. Current will flow through the conducting  
IGBT to downstream components as long as the posi-  
tive gate signal is present. This is similar to turning ON  
a light switch.  
INSULATED GATE BIPOLAR  
TRANSISTOR (IGBT) OPERATION  
An IGBT is a type of transistor. IGBTs are semiconduc-  
tors well suited for high frequency switching and high  
current applications.  
Drawing A shows an IGBT in a passive mode. There is  
no gate signal, zero volts relative to the source, and  
therefore, no current flow. The drain terminal of the  
IGBT may be connected to a voltage supply; but since  
there is no conduction the circuit will not supply current  
to components connected to the source. The circuit is  
turned off like a light switch in the OFF position.  
COMMANDER 300  
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E-6  
E-6  
THEORY OF OPERATION  
FIGURE E.6 – TYPICAL IGBT OUTPUTS  
MINIMUM OUTPUT  
(Dwell or Off Time)  
sec  
sec  
sec  
48  
50  
2
MAXIMUM OUTPUT  
(Dwell or Off Time)  
sec  
sec  
48  
50  
PULSE WIDTH MODULATION  
The term PULSE WIDTH MODULATION is used to  
describe how much time is devoted to conduction in the  
cycle. Changing the pulse width is known as MODU-  
LATION. Pulse Width Modulation (PWM) is the varying  
of the pulse width over the allowed range of a cycle to  
affect the output of the machine.  
The positive portion of the signal represents one IGBT  
group conducting for 2 microsecond. The dwell time (off  
time) is 48 microseconds. Since only 2 microseconds of  
the 50-microsecond time period is devoted to conduct-  
ing, the output power is minimized.  
MAXIMUM OUTPUT  
MINIMUM OUTPUT  
By holding the gate signals on for 48 microseconds and  
allowing only 2 microseconds of dwell time (off time)  
during the 50-microsecond cycle, the output is maxi-  
mized. The darkened area under the top curve can be  
compared to the area under the bottom curve. The  
more darkened area under the curve, the more power  
is present.  
By controlling the duration of the gate signal, the IGBT  
is turned on and off for different durations during a  
cycle. The top drawing shows the minimum output sig-  
nal possible over a 50-microsecond time period.  
COMMANDER 300  
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E-7  
E-7  
THEORY OF OPERATION  
CHOPPER TECHNOLOGY  
FUNDAMENTALS  
The new era of welding machines such as the  
Commander 300, employ a technology whereby a DC  
source is turned on and off (chopped up) at high speed,  
then smoothed through an inductor to control an arc.  
Hence the name “Chopper.” The biggest advantage of  
the chopper technology is the high-speed control of the  
arc, similar to the inverter machines. A block diagram  
for this is as follows:  
3 PHASE  
ALTERNATOR  
DC RECTIFIER  
AND FILTER  
SOLID STATE  
INDUCTOR  
AND DIODE  
ARC  
SWITCH  
ARC  
CONTROL  
In this system, the engine drives a three-phase alter-  
nator, which generates power that is rectified and fil-  
tered to produce about 85VDC. The current is  
applied through a solid state switch to an inductor. By  
turning  
the switch on and off, current in the inductor and the  
arc can be controlled. The following diagram depicts  
the current flow in the system when the switch is open  
and closed:  
INDUCTOR  
SWITCH  
DIODE  
ARC  
85VDC  
CURRENT WITH SWITCH OPEN  
CURRENT WITH SWITCH CLOSED  
When the switch is closed, current is applied through  
the inductor to the arc. When the switch opens, current  
stored in the inductor sustains flow in the arc and  
through the diode. The repetition rate of switch closure  
is 20Khz, which allows ultra-fast control of the arc. By  
varying the ratio of on time versus off time of the switch  
(Duty Cycle), the current applied to the arc is con-  
trolled. This is the basis for Chopper Technology:  
Controlling the switch in such a way as to produce  
superior welding.  
COMMANDER 300  
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E-8  
E-8  
NOTES  
COMMANDER 300  
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Section F-1  
Section F-1  
TABLE OF CONTENTS  
TROUBLESHOOTING & REPAIR SECTION  
Troubleshooting & Repair Section ................................................................................Section F  
How to Use Troubleshooting Guide.......................................................................................F-2  
PC Board Troubleshooting Procedures .................................................................................F-3  
Troubleshooting Guide................................................................................................F-4 - F-12  
Test Procedures...................................................................................................................F-13  
Case Cover Removal and Replacement Procedure ....................................................F-13  
Case Front Knobs - Removal and Replacement Procedure.........................................F-18  
Power Module Capacitor Discharge Procedure ...........................................................F-19  
Idler Solenoid Test ........................................................................................................F-21  
Shutdown Solenoid Test ...............................................................................................F-23  
Engine Throttle Adjustment Test ...................................................................................F-27  
Rotor Resistance Test ..................................................................................................F-31  
Flashing and Rotor Voltage Test ..................................................................................F-33  
Stator Voltage Test .......................................................................................................F-37  
RF By-Pass Board Resistance Test .............................................................................F-43  
Control Transformer Test ..............................................................................................F-47  
Output Rectifier Bridge Test .........................................................................................F-51  
Power Module Test........................................................................................................F-55  
Current Balance Test.....................................................................................................F-59  
Control Input Test ..........................................................................................................F-63  
Feedback Input Test......................................................................................................F-67  
PWM Output Test ..........................................................................................................F-71  
Power Supply Test.........................................................................................................F-75  
Display Board Calibration Test ......................................................................................F-77  
Oscilloscope Waveforms......................................................................................................F-79  
Normal Open Circuit Voltage Waveform (115 VAC Supply)..........................................F-79  
Normal Open Circuit Voltage Waveform (Stick)............................................................F-80  
Normal Weld Voltage Waveform (Stick CC)..................................................................F-81  
Normal Weld Voltage Waveform (Wire CV) ..................................................................F-82  
Normal Open Circuit Voltage Waveform (Wire CV Tap)................................................F-83  
Replacement Procedures ....................................................................................................F-85  
Power Module/Output Rectifier Bridge Assembly Removal  
and Replacement .......................................................................................................F-85  
Power Module (Chopper) PC Board Removal and Replacement ................................F-91  
Diode Removal and Replacement ...............................................................................F-93  
Stator/Rotor Removal and Replacement .....................................................................F-95  
Retest After Repair.............................................................................................................F-104  
COMMANDER 300  
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F-2  
F-2  
TROUBLESHOOTING & REPAIR  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and machine  
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please  
observe all safety notes and precautions detailed throughout this manual.  
This Troubleshooting Guide is provided to help  
you locate and repair possible machine malfunc-  
tions. Simply follow the three-step procedure list-  
ed below.  
Step 3. PERFORM COMPONENT TESTS. The  
last column, labeled “Recommended Course of  
Action” lists the most likely components that may  
have failed in your machine. It also specifies the  
appropriate test procedure to verify that the sub-  
ject component is either good or bad. If there are  
a number of possible components, check the  
components in the order listed to eliminate one  
possibility at a time until you locate the cause of  
your problem.  
Step 1. LOCATE PROBLEM (SYMPTOM). Look  
under the column labeled “PROBLEM” (SYMP-  
TOMS). This column describes possible symp-  
toms that the machine may exhibit. Find the list-  
ing that best describes the symptom that the  
machine is exhibiting. Symptoms are grouped  
into four main categories: Output Problems,  
Function Problems, Engine Problems, and  
Welding Problems.  
All of the referenced test procedures referred to in  
the Troubleshooting Guide are described in detail  
at the end of this section.  
Refer to the  
Troubleshooting and Repair Table of Contents to  
locate each specific Test Procedure. All of the  
referred to test points, components, terminal  
strips, etc., can be found on the referenced elec-  
trical wiring diagrams and schematics. Refer to  
the Electrical Diagrams Section Table of Contents  
to locate the appropriate diagram.  
Step 2. PERFORM EXTERNAL TESTS. The  
second column, labeled “POSSIBLE AREAS OF  
MISADJUSTMENT(S)”, lists the obvious external  
possibilities that may contribute to the machine  
symptom. Perform these tests/checks in the  
order listed. In general, these tests can be con-  
ducted without removing the case cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs  
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before  
you proceed. Call 1-800-833-9353.  
COMMANDER 300  
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F-3  
F-3  
TROUBLESHOOTING & REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
- Remove the PC board from the static-shielding bag  
and place it directly into the equipment. Don’t set the  
PC board on or near paper, plastic or cloth which  
could have a static charge. If the PC board can’t be  
installed immediately, put it back in the static-shield-  
ing bag.  
WARNING  
ELECTRIC SHOCK  
can kill.  
•
Have an electrician install and  
service this equipment. Turn the  
input power OFF at the fuse box  
before working on equipment. Do  
not touch electrically hot parts.  
- If the PC board uses protective shorting jumpers,  
don’t remove them until installation is complete.  
- If you return a PC board to The Lincoln Electric  
Company for credit, it must be in the static-shielding  
bag. This will prevent further damage and allow prop-  
er failure analysis.  
CAUTION  
Sometimes machine failures appear to be due to PC  
board failures. These problems can sometimes be  
traced to poor electrical connections. To avoid prob-  
lems when troubleshooting and replacing PC boards,  
please use the following procedure:  
4. Test the machine to determine if the failure  
symptom has been corrected by the  
replacement PC board.  
NOTE: It is desirable to have a spare (known good)  
PC board available for PC board troubleshooting.  
1. Determine to the best of your technical ability  
that the PC board is the most likely component  
causing the failure symptom.  
NOTE: Allow the machine to heat up so that all  
electrical components can reach their operating  
temperature.  
2. Check for loose connections at the PC board  
to assure that the PC board is properly  
connected.  
5. Remove the replacement PC board and  
substitute it with the original PC board to  
recreate the original problem.  
3. If the problem persists, replace the suspect PC  
board using standard practices to avoid static  
electrical damage and electrical shock. Read  
the warning inside the static resistant bag and  
perform the following procedures:  
a. If the original problem does not reappear by  
substituting the original board, then the PC  
board was not the problem. Continue to look  
for bad connections in the control wiring  
harness, junction blocks, and terminal  
strips.  
PC board can be damaged by static electricity.  
b. If the original problem is recreated by the  
substitution of the original board, then the  
PC board was the problem. Reinstall the  
replacement PC board and test the machine.  
- Remove your body’s static  
charge before opening the static-  
shielding bag. Wear an anti-static  
wrist strap. For safety, use a 1  
Meg ohm resistive cord connected  
6. Always indicate that this procedure was  
followed when warranty reports are to be  
submitted.  
to  
a
grounded part of the  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
equipment frame.  
- If you don’t have a wrist strap,  
touch an un-painted, grounded,  
part of the equipment frame. Keep  
touching the frame to prevent  
static build-up. Be sure not to  
touch any electrically live parts at  
the same time.  
NOTE: Following this procedure and writing on the  
warranty report, “INSTALLED AND SWITCHED PC  
BOARDS TO VERIFY PROBLEM,” will help avoid  
denial of legitimate PC board warranty claims.  
Workstations  
- Tools which come in contact with the PC board must  
be either conductive, anti-static or static-dissipative.  
COMMANDER 300  
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F-4  
F-4  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical damage 1. Contact your local Lincoln 1. Contact the Lincoln Electric  
is evident.  
Authorized Field Service Facility.  
Service Department at 1-800-  
833-9353 (WELD).  
1. Check for loose or faulty connec-  
tions on the heavy current carry-  
ing leads between the output,  
the power modules, the choke  
and the output terminals.  
No welding output in neither Stick 1. Place the Welding Terminals  
or CV modes. The engine operates  
normally. The auxiliary output is  
normal.  
Switch in the “ALWAYS ON”  
position. If the problem is  
solved, the fault may be in the  
external control cable (if used),  
leads #2 and #4. See the Wiring  
Diagram.  
2. Check the Welding Terminals  
Switch and associated leads.  
See the Wiring Diagram.  
2. With the engine at high idle  
(1900 RPM), the machine in the  
Stick mode and the OUTPUT  
CONTROL at maximum, check  
for the presence of approximate-  
ly 87VDC (open circuit voltage at  
the output terminals.  
3. If the correct OCV is present  
when the Welding Terminals  
Switch is in the “ALWAYS ON”  
position, perform the RF Bypass  
Board Resistance Test. Also  
check associated wiring. See  
the Wiring Diagram.  
3. If the correct OCV is present at  
the welding output terminals,  
check the welding cables,  
clamps and electrode holder for  
loose or faulty connections.  
4. Check the Remote/Local switch  
and associated wiring. See the  
Wiring Diagram. (leads #75, #76  
and #77)  
4. Make  
sure  
that  
the  
5. Perform the Stator Voltage  
LOCAL/REMOTE switch is in the  
correct position.  
Test.  
6. Perform the Output Rectifier  
Bridge Test.  
7. Perform the Power Module  
Test.  
8. Perform the Control Trans-  
former Test.  
9. Perform the Power Supply  
Test.  
10. Perform the Control Input Test.  
11. Perform the Feedback Input  
Test.  
12. Perform the PWM Output Test.  
13. Perform the Current Balance  
Test (codes 10469 & 10470).  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 300  
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F-5  
F-5  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No welding output in neither Stick 1. Check the brushes for wear and 1. Perform the Rotor Resistance  
or CV modes. Also, no auxiliary  
power. The engine operates nor-  
mally.  
proper contact to the rotor slip  
rings.  
Test.  
2. Perform the Flashing and  
Rotor Voltage Test. If the  
“flashing” voltage is not present,  
the protection board or leads  
#201 or #200 may be faulty.  
See the Wiring Diagram. Also,  
make sure that lead #5P has  
continuity (zero ohms) to  
ground.  
2. Make sure the engine is operat-  
ing at the correct high idle  
speed (1900 RPM).  
3. Check for loose or faulty con-  
nections or leads on the auxil-  
iary power studs in the control  
box. See the Wiring Diagram.  
3. Check the field diode and  
capacitor. Replace if necessary.  
4. Perform the Stator Voltage  
Test.  
No auxiliary power at the recepta- 1. The circuit breakers may be 1. Check the wiring between the  
cles. The welding output is normal  
and the engine operates normally.  
tripped. Reset if necessary.  
auxiliary receptacles, the con-  
nection studs in the control box,  
and the main stator. See the  
Wiring Diagram.  
2. Check for loose or faulty con-  
nections at the auxiliary recep-  
tacles.  
2. Perform the Stator Voltage  
Test.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 300  
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F-6  
F-6  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The machine has welding output 1. If a remote control unit is NOT 1. If the machine operates normal-  
but no control of output. The auxil-  
iary power is normal.  
connected to the machine,  
make sure the LOCAL/  
REMOTE switch is in the  
“LOCAL” position.  
ly in the “LOCAL” position but  
not in the “remote” position, per-  
form the RF Bypass Board  
Resistance Test.  
2. If a remote control unit IS con- 2. Check the Remote/Local switch  
nected and the machine oper-  
ates normally when the switch is  
in the “Local” position, the  
remote control cable or unit may  
be faulty. Check or replace.  
and associated wiring. See the  
Wiring Diagram. (leads #75,  
#76 and #77)  
3. Perform the Power Module  
Test.  
4. Perform the Control Input Test.  
5. Perform the Feedback Input  
Test.  
6. Perform the PWM Output Test.  
7. The Control Board may be faulty.  
The machine has low welding out- 1. Check the brushes for wear and 1. If the engine high idle speed is  
put and low auxiliary output.  
proper contact to the slip rings.  
low, perform the Throttle Ad-  
justment Test.  
2. The engine RPM may be low.  
2. Perform the Rotor Resistance  
Test.  
3. Perform the Rotor Voltage  
Test. If the rotor voltage is low,  
the field capacitor or field bridge  
may be faulty. Test and replace  
if necessary. See the Wiring  
Diagram.  
4. If the engine high idle RPM is  
OK, then the engine may have  
lost horsepower and be in need  
of major repair.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 300  
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F-7  
F-7  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The output control on the 1. Make sure the Remote/Local 1. Check the Remote/Local switch  
Commander 300 does not work  
properly.  
switch is in the “Local” position.  
and associated wiring. See the  
Wiring Diagram. (leads #75,  
#76 and #77)  
2. The output control (R1) may be  
defective.  
2. Perform the Power Supply  
Test.  
3. Perform the Control Input  
Test.  
4. Perform the Feedback Input  
Test.  
5. Perform the PWM Output Test.  
6. Perform the Power Module  
Test.  
The remote output control does not 1. Make sure the Remote/Local 1. Check the Remote/Local switch  
function properly.  
switch is in the “Remote” posi-  
tion.  
and associated leads. See the  
Wiring Diagram.  
2. The remote control unit may be 2. Check the amphenols and  
faulty. Repair or replace.  
associated leads.  
Wiring Diagram.  
See the  
3. Perform the RF Bypass Board  
Resistance Test.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 300  
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F-8  
F-8  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The wire feeder does not work 1. Check the circuit breaker (CB5). 1. Check for the presence of  
when connected to the welder  
amphenol.  
Reset if tripped.  
115VAC at leads #31(J) and  
#32(A) at the 14-pin amphenol.  
2. The wire feeder control cable  
may be faulty.  
2. If the 115VAC is NOT present at  
the 14-pin amphenol, check  
leads #31 and #32 for loose or  
faulty connections. See the  
Wiring Diagram.  
3. The wire feeder may be faulty.  
3. Perform the Stator Voltage  
Test.  
The battery does not stay charged. 1. Check for loose or faulty con- 1. The battery charging circuit may  
nections at the battery and  
engine charging system.  
be faulty.  
Diagram.  
See the Wiring  
2. The battery may be faulty.  
Check or replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 300  
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F-9  
F-9  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine will not crank when the 1. Check for loose or faulty battery 1. If the battery is replaced or tests  
start button is pushed.  
cable connections.  
good, then the charging circuit  
may be faulty. See the Wiring  
Diagram.  
2. The battery may be low or faulty.  
2. The starter motor or starter sole-  
noid may be faulty.  
3. The engine may be hard to  
crank due to a mechanical fail-  
ure in the engine.  
The engine cranks, but will not 1. Check for adequate fuel supply. 1. The shutdown solenoid may be  
start.  
faulty. Perform the Fuel Shut-  
down Solenoid Test.  
2. Make sure the fuel shut off valve  
is in the open position.  
2. The engine protection board  
3. The engine oil temperature may  
be too high. Check cooling sys-  
tem.  
may be faulty.  
With the  
Run/Stop switch in the “Run”  
position, the protection board  
should normally supply 10VDC  
to the shutdown solenoid via  
leads #224 and #262. See the  
Wiring Diagram.  
4. The battery voltage may be too  
low.  
3. The engine may be in need of  
mechanical repair.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 300  
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F-10  
F-10  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine shuts down shortly after 1. Check for adequate fuel supply. 1. Check the Run/Stop switch and  
starting.  
associated leads for loose or  
faulty connections.  
2. If any indicator light is lit when  
the engine shuts down, that par-  
ticular system has faulted. 2. Perform the Fuel Shutdown  
Check system. Solenoid Test.  
3. Check the battery cables for 3. The engine protection board  
loose or faulty connections.  
may be faulty. With the Run/  
Stop switch in the “Run” posi-  
tion, the protection board should  
normally supply 10VDC to the  
shutdown solenoid via leads  
#224 and #262. See the Wiring  
Diagram.  
The engine will not idle down to low 1. Make sure the idler switch is in 1. Perform the Idler Solenoid  
speed. The machine has normal  
weld output and auxiliary power.  
the “Auto” position.  
Test.  
2. Make sure there is NOT an 2. The engine protection board  
external load on the weld termi-  
nals nor the auxiliary power  
receptacles.  
may be faulty.  
3. Check for mechanical restric-  
tions in the solenoid linkage.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 300  
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F-11  
F-11  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine will not go to high idle 1. Make sure the auxiliary power 1. Check the current sensing  
when using the auxiliary power.  
Auxiliary power is normal when the  
idler switch is in the “high” position.  
Automatic idle function works prop-  
erly when the welding terminals are  
loaded.  
leads are tight.  
toroid for loose or faulty connec-  
tions. See the Wiring Diagram.  
2. The automatic idler may not  
function if the auxiliary power is 2. Make sure leads #3 and #6A  
loaded to less than 150 watts.  
pass through the toroid twice in  
opposite directions.  
3. The current sensing toroid may  
be faulty.  
4. The engine protection board  
may be faulty.  
The engine will not go to high idle 1. Make sure the welding cables 1. The engine protection board  
when attempting to weld or when  
the auxiliary power is loaded.  
Welding output and auxiliary power  
outputs are normal when idler  
switch is in the “High” position.  
and auxiliary power lead con-  
nections are tight.  
may be faulty.  
The machine goes to low idle but 1. Make sure there is NOT an 1. The idler solenoid linkage may  
does not stay at low idle.  
external load (auxiliary or weld)  
connected to the Commander  
300.  
be misadjusted or damaged.  
2. The idler solenoid lead connec-  
tions (#226A and #237A) may  
be loose or damaged.  
3. Perform the Idler Solenoid  
Test.  
4. The engine protection board  
may be faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 300  
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F-12  
F-12  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
WELDING PROBLEMS  
The welding arc is “cold.” The 1. Check for loose or faulty connec- 1. Check for the correct OCV at the  
engine runs normally. The auxiliary  
power is normal.  
tions at the weld output terminals  
and welding cable connections.  
welding output terminals. If the  
correct voltage is present at the  
output terminals, check for loose  
connection on the heavy current  
carrying leads inside the  
2. Make sure the work clamp has a  
clean connection to the work  
piece.  
Commander 300.  
Wiring Diagram.  
See the  
3. The welding cables may be too  
long or coiled, causing an  
excessive voltage drop.  
2. If the OCV is low at the welder  
output terminals, perform the  
Engine Throttle Adjustment  
Test.  
4. Make sure the electrode (wire,  
gas, voltage, current, etc.) is  
correct for the process being  
used.  
3. Perform the Output Rectifier  
Bridge Test.  
5. Make sure the machine settings  
match the weld application.  
4. Perform the Stator Voltage  
Test.  
5. Perform the Power Module  
Test.  
6. Perform the Control Input Test.  
7. Perform the Feedback Input  
Test.  
8. Perform the PWM Output Test.  
9. If so equipped, perform the  
Display Board Calibration  
Test.  
1. Make sure the electrode (wire, 1. Perform the Power Module  
The welding arc is “hot”. The  
engine runs normally. The auxiliary  
power is normal.  
gas, voltage, current, ect.) is  
correct for the process being  
used.  
Test.  
2. Perform the Control Input Test.  
3. Perform the Feedback Input  
2. Make sure the machine settings  
match the weld application.  
Test.  
4. Perform the PWM Output Test.  
5. If so equipped, perform the  
Display Board Calibration  
Test.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
COMMANDER 300  
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F-13  
F-13  
TROUBLESHOOTING & REPAIR  
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This procedure will aid the technician in the removal and replacement of the case sheet  
metal covers.  
MATERIALS NEEDED  
3/8" wrench  
7/16" wrench  
1/2" wrench  
3/4" wrench  
This procedure should take approximately 30 minutes to perform.  
COMMANDER 300  
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F-14  
F-14  
TROUBLESHOOTING & REPAIR  
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)  
FIGURE F.1 – DOOR REMOVAL  
ROUND  
HEAD SCREW  
LOCATION  
DOOR  
ASSEMBLY  
LEFT  
FRONT  
PANEL  
PROP ROD  
RIGHT  
FRONT  
PANEL  
PROCEDURE  
1. Turn the engine off.  
4. Support the door assembly. Using the 3/8"  
wrench, remove the #10-24 round head  
screw, lock washer, flat washer, and nut from  
the top corner of the door hinge assembly,  
where it attaches to the roof. Remove the  
support rod.  
2. Using the 3/8" wrench, remove the battery  
cover. Slide the battery out and disconnect  
the negative battery cable.  
3. Unlatch and open the engine service access  
door. See Figure F.1.  
COMMANDER 300  
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F-15  
F-15  
TROUBLESHOOTING & REPAIR  
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)  
FIGURE F.2 – FRONT PANEL/ROOF DETAILS  
SCREWS  
FRONT  
CONTROL  
PANEL  
SCREW  
5. Using the 3/8" wrench, remove the two  
screws from the top front of the roof assem-  
bly and the two screws from the sides of the  
control box. Carefully lower the front control  
panel. See Figure F.2.  
7. With the 1/2" wrench, remove the exhaust  
pipe rain cap.  
8. Remove the fuel tank cap, gasket, and the  
lift bail cover seal.  
9. With the help of an assistant, carefully  
remove the roof. The door assembly  
remains attached to the roof. Replace the  
fuel cap.  
6. With 3/8" wrench, remove the right rear  
panel and the right and left front panels.  
See Figure F.1.  
COMMANDER 300  
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F-16  
F-16  
TROUBLESHOOTING & REPAIR  
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)  
FIGURE F.3 – OUTPUT PANEL REMOVAL  
OUTPUT LEADS  
(BEHIND PANEL)  
GREEN  
GROUND  
LEAD  
SCREWS  
OUTPUT PANEL REMOVAL  
1. Using the 3/4" wrench, remove the internal  
leads from the positive and negative output  
terminals. See Figure F.3.  
3. Using the 3/8" wrench, remove the green  
ground lead from the panel.  
4. The output panel can now be removed and  
set aside.  
2. Using the 3/8" wrench, remove the three  
screws along the bottom of the output panel.  
Then remove the two screws holding the top  
of the panel. These are accessed in the con-  
trol box, on the bottom at each side of the  
box. See Figure F.3.  
COMMANDER 300  
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F-17  
F-17  
TROUBLESHOOTING & REPAIR  
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)  
REASSEMBLY PROCEDURE  
6. Install the right rear panel and the right and  
left front panels. Raise the control panel  
front and install the two screws at the roof  
and the two at the sides.  
1. Output panel: Set the panel in place.  
2. Install the five screws that mount the panel  
at the top and bottom.  
7. Install the support rod and the #10-24 round  
head screw, washer, and nut.  
3. Attach the green ground lead.  
4. Install the internal leads to the output termi-  
nals.  
5. Side panels, roof and door assembly:  
Remove the fuel cap. With the help of an  
assistant, carefully set the roof/door assem-  
bly in place. Replace the fuel tank gasket  
and the lift bail cover seal. Replace the fuel  
cap. Install the exhaust pipe rain cap.  
COMMANDER 300  
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F-18  
F-18  
TROUBLESHOOTING & REPAIR  
CASE FRONT KNOBS - REMOVAL AND REPLACEMENT PROCEDURE  
Removal  
Side View  
(Pull)  
(Pull)  
Knob  
Nameplate  
(Push)  
(Push)  
Removal:  
1. Rotate the handle portion of the knob to an approximate vertical orientation (switch detent may position  
handle a few degrees off vertical). This orientation should be noted and repeated at replacement for proper  
"D" shaft orientation.  
2. With one hand, grasp the very bottom of vertical handle and push towards the machine nameplate and  
pull down. At the same time and with the other hand, grasp the very top of the handle and pull the top edge  
of the knob away from the machine nameplate. The knob should "peel" away from the nameplate and the  
white nylon holding fingers of the knob base, from top to bottom.  
Replacement  
Rounded  
Flat  
Replacement:  
1. If the white nylon cam of the detent mechanism is removed from it's spring loaded base by the above  
procedure or intentionally, it should be returned before the knob replacement is attempted. Press the cam  
into it's spring loaded holder so it sets flat and flush (Selector Switch Only).  
2. Orientate the knob handle to the vertical as noted above and position the knob over the base, centered  
and parallel.  
3. Press the knob onto the "D" shaft and white nylon holding fingers, maintaining the parallel position.  
The knob should "click" into place and should not pull off with normal operation.  
COMMANDER 300  
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F-19  
F-19  
TROUBLESHOOTING & REPAIR  
POWER MODULE CAPACITOR DISCHARGE PROCEDURE  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This procedure will insure that the large capacitors in the power modules have been dis-  
charged. This procedure should be performed whenever work is to be attempted on or  
near the power modules.  
MATERIALS NEEDED  
3/8" Wrench  
Volt/Ohmmeter  
Resistor (25-1000 ohms and 25 watts minimum)  
Jumper leads  
This procedure should take approximately 15 minutes to perform.  
COMMANDER 300  
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F-20  
F-20  
TROUBLESHOOTING & REPAIR  
POWER MODULE CAPACITOR DISCHARGE PROCEDURE (continued)  
FIGURE F.4 – POWER MODULE CAPACITOR TERMINAL DISCHARGE  
POWER  
MODULE  
CAPACITOR  
TERMINALS  
TEST PROCEDURE  
1. This procedure must be performed with the  
engine off.  
4. Using the resistor and jumper leads, CARE-  
FULLY discharge the capacitor terminals.  
NEVER USE A SHORTING STRAP FOR  
THIS PURPOSE. DO NOT TOUCH THE  
TERMINALS WITH YOUR BARE HANDS.  
Repeat procedure on the other side.  
2. Using the 3/8" wrench, remove the front left  
and right side panels.  
3. Locate the two power modules (one on  
each side). See Figure F.4.  
5. Check the voltage across the capacitor ter-  
minals. It should be zero volts.  
COMMANDER 300  
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F-21  
F-21  
TROUBLESHOOTING & REPAIR  
IDLER SOLENOID TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the idler solenoid is capable of functioning when it is energized  
with 12VDC.  
MATERIALS NEEDED  
External 12VDC supply ( 30 amps)  
Wiring Diagram  
Volt/Ohmmeter  
This procedure should take approximately 25 minutes to perform.  
COMMANDER 300  
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F-22  
F-22  
TROUBLESHOOTING & REPAIR  
IDLER SOLENOID TEST (continued)  
FIGURE F.5 – IDLER SOLENOID LEADS  
IN-LINE  
CONNECTORS  
IDLER  
SOLENOID  
TEST PROCEDURE  
1. Turn the engine off.  
6. If the solenoid does not operate properly,  
check for a mechanical restriction in the  
linkage.  
2. Unlatch, lift, and secure the right side  
engine service access door.  
7. If the linkage is intact and the solenoid does  
not operate correctly when the 12VDC is  
applied, the solenoid may be faulty.  
Replace.  
3. Locate and remove the two in-line connec-  
tors that attach the idler solenoid leads to  
the wiring harness leads (#226A, #237A).  
See Figure F.5 and the Wiring Diagram.  
8. Replace leads #226A and #237A to the cor-  
rect in-line connectors. See Figure F.5 and  
the wiring diagram. Replace any previously  
removed wire wraps.  
4. Check the coil resistance. The normal  
resistance is approximately 4.5 ohms. If the  
coil resistance is not correct, the solenoid  
may be faulty. Replace.  
9. Close and secure the right side engine ser-  
vice access door.  
5. Using the external 12VDC supply, apply  
12VDC to the solenoid leads. The solenoid  
should activate. The solenoid should deac-  
tivate when the 12VDC is removed.  
COMMANDER 300  
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F-23  
F-23  
TROUBLESHOOTING & REPAIR  
SHUTDOWN SOLENOID TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the shutdown solenoid is capable of functioning when it is ener-  
gized with 12VDC.  
MATERIALS NEEDED  
External 12VDC supply (10 amps minimum)  
Wiring Diagram  
Volt/Ohmmeter  
3/8" Socket wrench  
This procedure should take approximately 30 minutes to perform.  
COMMANDER 300  
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F-24  
F-24  
TROUBLESHOOTING & REPAIR  
SHUTDOWN SOLENOID TEST (continued)  
FIGURE F.6 - PLUG J30 LOCATION  
MOVING P  
ARTS  
Do not operate with  
doors open or guar  
ds of  
f.  
J30  
3. Using the 3/8" wrench, remove the right front  
case side.  
TEST PROCEDURE  
1. Turn the engine off.  
4. Locate and unplug J30 from P30. See  
Figure F.6 and the Wiring Diagram.  
2. Unlatch, lift, and secure the right side engine  
service access door.  
COMMANDER 300  
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F-25  
F-25  
INSTALLATION  
SHUTDOWN SOLENOID TEST (continued)  
FIGURE F.7 – PLUG J30 PIN/LEAD ASSIGNMENTS  
#224(+)  
#262(-)  
8
9
6
5
4
1
7
3
2
11 12 13 14  
10  
15 16  
J30  
5. Check the shutdown solenoid coil resistance  
from lead #224 (8J30) to lead #262 (7J30).  
The normal resistance is approximately 3  
ohms. If the resistance is not correct, the  
coil or the diode that is in parallel with the  
coil may be faulty. See the Wiring Diagram.  
See Figure F.7.  
7. The solenoid should deactivate when the  
12VDC is removed.  
8. If the solenoid does not activate when the  
12VDC is applied the solenoid or internal  
diode may be faulty. Replace.  
9. Reconnect plug J30 and P30. Replace any  
cable ties previously removed.  
6. Using the external 12VDC supply apply  
12VDC to leads #224(+) and #262(-). See  
Figure F.7. CORRECT POLARITY MUST  
BE OBSERVED OR DAMAGE TO THE  
INTERNAL DIODE MAY RESULT. See the  
Wiring Diagram. The shutdown solenoid  
should activate when the 12VDC is applied.  
This can be detected by a “clicking” sound.  
10. Reassemble the right front case side and  
close the engine service access door.  
COMMANDER 300  
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F-26  
F-26  
NOTES  
COMMANDER 300  
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F-27  
F-27  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
If the machine output is low or high, this test will determine whether the engine is operat-  
ing at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for  
adjusting the throttle to the correct RPM are given.  
MATERIALS NEEDED  
Slot head screw driver  
3/8" wrench  
7/16" wrench  
10mm wrench  
White or red marking pencil  
Strobe-tach, frequency counter, or oscilloscope  
This procedure should take approximately 35 minutes to perform.  
COMMANDER 300  
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F-28  
F-28  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.8 – STROBE MARK LOCATION  
MARK BLOWER  
PADDLE HERE  
TEST PROCEDURE  
1. Conduct this procedure with the engine OFF.  
4. Connect the strobe-tach according to the  
manufacturer's instructions.  
2. Unlatch, lift, and secure the right side service  
access door. With the 3/8" wrench, remove  
the right front side cover.  
5. Start the engine and direct the strobe-tach  
light on the blower paddle. Synchronize it to  
the rotating mark.  
3. With a white or red marking pencil, place a  
mark on one of the blower paddles or on the  
side of the flywheel. See Figure F.8 for loca-  
tion.  
With the machine at HIGH IDLE the tach  
should read between 1880 and 1910 RPM.  
With the machine at LOW IDLE the tach  
should read between 1350 and 1400 RPM.  
COMMANDER 300  
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F-29  
F-29  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.9 - HIGH IDLE ADJUSTMENT  
LOCKING NUT  
ADJUSTING SCREW  
FIGURE F.10 - LOW IDLE ADJUSTMENT  
ADJUSTING COLLAR  
LOCKING NUT  
COMMANDER 300  
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F-30  
F-30  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
6. If either of the readings is incorrect, adjust  
the throttle as follows:  
Adjust LOW IDLE: First make sure there is  
no load on the machine. Set the IDLE  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 7/16"  
wrench to loosen the solenoid lever arm  
locking nut. See Figure F.10. Adjust the  
collar, to change the amount of throw in the  
lever arm, until the frequency reads 47 Hz.  
Retighten the locking nut.  
Adjust HIGH IDLE: Use the 10mm wrench  
to loosen the locking nut. See Figure F.9 for  
location of the adjusting screw and locking  
nut. Turn the threaded screw counter-clock-  
wise to increase the HIGH IDLE speed.  
Adjust the speed until the tach reads  
between 1880 and 1910 RPM. Retighten  
the locking nut.  
Oscilloscope Method  
Adjust LOW IDLE: First make sure there is  
no load on the machine. Set the IDLE  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 7/16"  
wrench to loosen the solenoid lever arm  
locking nut. See Figure F.10. Adjust the  
collar, to change the amount of throw in the  
lever arm, until the tach reads between 1350  
and 1400 RPM. Retighten the locking nut.  
1. Connect the oscilloscope to the 115 VAC  
receptacle, according to the manufacturer’s  
instructions. At HIGH IDLE (1900 RPM), the  
waveform should exhibit a period of 15.8  
milliseconds. At LOW IDLE (1400 RPM),  
the waveform should exhibit a period of 21.4  
milliseconds. Refer to the NORMAL OPEN  
CIRCUIT VOLTAGE WAVEFORM (115  
VAC AUXILIARY) HIGH IDLE - NO LOAD  
in this section of the manual.  
Frequency Counter Method  
2. If either waveform periods is incorrect,  
adjust the throttle as follows:  
1. Plug the frequency counter into one of the  
115 VAC auxiliary receptacles.  
Adjust HIGH IDLE: Use the 10mm wrench  
to loosen the locking nut. See Figure F.9 for  
location of the adjusting screw and locking  
nut. Turn the threaded screw counter-clock-  
wise to increase the HIGH IDLE speed.  
Adjust the speed until the period is 15.8 mil-  
liseconds. Retighten the locking nut.  
2. Start the engine and check the frequency  
counter. At HIGH IDLE (1900 RPM), the  
counter should read 63 Hz. At LOW IDLE  
(1400 RPM), the counter should read 47 Hz.  
Note that these are median measurements;  
hertz readings may vary slightly above or  
below.  
Adjust LOW IDLE: First make sure there is  
no load on the machine. Set the IDLE  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 7/16"  
wrench to loosen the solenoid lever arm  
locking nut. See Figure F.10. Adjust the  
collar, to change the amount of throw in the  
lever arm, until the period is 21.4 millisec-  
onds. Retighten the locking nut.  
3. If either of the readings is incorrect, adjust  
the throttle as follows:  
Adjust HIGH IDLE: Use the 10mm wrench  
to loosen the locking nut. See Figure F.9 for  
location of the adjusting screw and locking  
nut. Turn the threaded screw counter-clock-  
wise to increase the HIGH IDLE speed.  
Adjust the speed until the frequency reads  
63 Hz. Retighten the locking nut.  
COMMANDER 300  
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F-31  
F-31  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if there is a shorted winding in the rotor or if the rotor is grounded.  
MATERIALS NEEDED  
Ohmmeter  
3/8" wrench  
Needle nose pliers  
This procedure should take approximately 15 minutes to perform.  
COMMANDER 300  
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F-32  
F-32  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST (continued)  
FIGURE F.11 – ROTOR BRUSH LEADS  
SLIP RINGS  
LEADS REMOVED  
TEST PROCEDURE  
1
Conduct this test with the engine off.  
5. Measure the resistance to ground. Place  
one meter probe on either of the slip rings.  
Place the other probe on any good unpaint-  
ed ground. The resistance should be very  
high, at least 500,000 ohms.  
2. Using the 3/8" wrench, remove the left front  
case side.  
3. Locate, label and remove the three leads  
from the rotor brush holder assembly. See  
Figure 11. This will electrically isolate the  
rotor windings.  
6. If the test does not meet the resistance spec-  
ifications, then the rotor may be faulty.  
Replace.  
4. Using the ohmmeter, check the rotor winding  
resistance across the slip rings. Normal  
resistance is approximately 23.5 ohms.  
7. Connect the leads previously removed from  
the brush assembly. Make sure the leads  
are connected to the proper brushes.  
8. Replace the left front case cover previously  
removed.  
COMMANDER 300  
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F-33  
F-33  
TROUBLESHOOTING & REPAIR  
FLASHING AND ROTOR VOLTAGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the correct DC voltage is being applied to the rotor at the maxi-  
mum engine speed (1900 RPM). This information will aid the technician in determining if  
the generator field is operating properly.  
MATERIALS NEEDED  
Volt/Ohmmeter  
3/8" Wrench  
Wiring Diagram  
This procedure should take approximately 20 minutes to perform.  
COMMANDER 300  
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F-34  
F-34  
TROUBLESHOOTING & REPAIR  
FLASHING AND ROTOR VOLTAGE TEST (continued)  
FIGURE F.12 – ROTOR BRUSH LEADS  
#200A  
#200B  
#201  
5. Connect the negative meter probe to the  
TEST PROCEDURE  
other brush (lead #201).  
1. Using the 3/8" wrench, remove the sheet  
metal screws from the left front case side.  
6. Start the engine and run it at high idle  
speed (1900 RPM). Check the voltage  
reading on the meter. It should read  
approximately 160VDC.  
2. Carefully remove the left case side.  
3. Set the volt/ohmmeter to the DC volts posi-  
tion.  
4. Connect the positive meter probe to the  
brush nearest the rotor lamination (leads  
#200A and #200B). See Figure F.12.for  
location.  
COMMANDER 300  
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F-35  
F-35  
TROUBLESHOOTING & REPAIR  
FLASHING AND ROTOR VOLTAGE TEST (continued)  
FIGURE F.13 - FIELD DIODE RECTIFIER BRIDGE AND FILTER CAPACITOR  
FILTER  
CAPACITOR  
FIELD DIODE  
RECTIFIER BRIDGE  
7. If the voltage reading is low or not present,  
the generator field is not functioning proper-  
ly. Perform the Rotor Resistance Test.  
Also check the field diode rectifier bridge, fil-  
ter capacitor, and associated leads and con-  
nections. See Figure F.13 for location. See  
the Wiring Diagram.  
8. If the rotor voltage readings are normal, the  
field circuit is functioning properly. Install  
the left case side with the sheet metal  
screws previously removed.  
NOTE: The normal flashing voltage is approx-  
imately 9VDC. This is battery voltage, which is  
processed and controlled through the engine  
protection board. This voltage must be present  
during start-up to “flash” the rotor field.  
COMMANDER 300  
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F-36  
F-36  
NOTES  
COMMANDER 300  
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F-37  
F-37  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the correct AC voltages are being generated from the stator  
windings.  
MATERIALS NEEDED  
Volt/Ohmmeter  
3/8" wrench  
3/4" wrench  
This procedure should take approximately 40 minutes to perform.  
COMMANDER 300  
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F-38  
F-38  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST (continued)  
FIGURE F.14 – FRONT CONTROL PANEL REMOVAL  
SCREWS  
FRONT  
CONTROL  
PANEL  
SCREW  
TEST PROCEDURE  
1. Turn the engine off.  
3. Carefully lower the front control panel.  
2. Using the 3/8" wrench, remove the four  
screws holding the front control panel to the  
case top and sides. See Figure F.14. (There  
are two screws on the top and one screw on  
each side.)  
4. Using the 3/8" wrench, remove the front left  
and right side panels.  
5. Using the 3/4" wrench, remove the internal  
leads from the output terminals. Insulate the  
leads.  
COMMANDER 300  
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F-39  
F-39  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST (continued)  
FIGURE F.15 – OUTPUT PANEL REMOVAL  
GREEN  
GROUND  
LEAD  
SCREWS  
6. Using the 3/8” wrench, remove the five  
screws holding the lower front panel (output  
panel) to the case front assembly. See  
Figure F.15. Carefully move the lower front  
panel to the right side. Note the green  
ground lead will still be attached.  
COMMANDER 300  
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F-40  
F-40  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST (continued)  
FIGURE F.16 – AUXILIARY LEAD TEST LOCATION  
AUXILIARY  
LEADS #3, #5, #6  
(BEHIND PANEL)  
AUXILIARY POWER AND WELD  
WINDINGS TEST  
1. Start the engine and run at high idle (1900  
RPM). Do not load welding or auxiliary  
power.  
2. Check for 115-132VAC at leads #3 to #5.  
Also check for 115-132VAC from leads #6 to  
#5. See the Wiring Diagram.  
3. Check for 230 to 264VAC at leads #3 to #6.  
See the Wiring Diagram.  
COMMANDER 300  
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F-41  
F-41  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST (continued)  
FIGURE F.17 – OUTPUT RECTIFIER DIODE BRIDGE  
WELD WINDING  
LEAD CONNECTIONS  
4. Locate the weld winding leads connected to  
the three-phase output rectifier diode bridge.  
See Figure F.17.  
8. If the tests in Steps 6 and 7 are OK and the  
stator voltages are low or missing, the sta-  
tor may be faulty.  
5. Check for approximately 68VAC from W1 to  
W2. Also check from W2 to W3 and from W1  
to W3.  
9. Replace the lower front panel and output  
leads.  
10. Replace the upper control panel and  
secure.  
6. If any of these voltages are low or missing  
perform the Rotor Flashing and Voltage  
Test and also the Rotor Resistance Test.  
11. Replace the front left and right case sides.  
7. Also check leads #6H and #5P for loose or  
faulty connections to the field bridge. See the  
Wiring Diagram.  
COMMANDER 300  
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F-42  
F-42  
NOTES  
COMMANDER 300  
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F-43  
F-43  
TROUBLESHOOTING & REPAIR  
RF BY-PASS BOARD RESISTANCE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the inductor filters on the RF By-Pass Board are intact and capa-  
ble of passing signal information.  
MATERIALS NEEDED  
Volt/Ohmmeter  
3/8" Nut driver  
Phillips head screwdriver  
This procedure should take approximately 25 minutes to perform.  
COMMANDER 300  
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F-44  
F-44  
TROUBLESHOOTING & REPAIR  
RF BY-PASS BOARD RESISTANCE TEST (continued)  
FIGURE F.18 – FRONT CONTROL PANEL REMOVAL  
SCREWS  
FRONT  
CONTROL  
PANEL  
SCREW  
TEST PROCEDURE  
1. Turn the engine off.  
2. Using the 3/8" wrench, remove the four  
screws holding the front control panel to the  
case top and sides. See Figure F.18. (There  
are two screws on the top and one screw on  
each side.)  
3. Carefully lower the front control panel.  
COMMANDER 300  
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F-45  
F-45  
TROUBLESHOOTING & REPAIR  
RF BY-PASS BOARD RESISTANCE TEST (continued)  
FIGURE F.19 – RF BY-PASS BOARD  
J61  
J62  
J60  
A R A  
4. Locate, label, and remove the three plugs  
from the RF By-Pass board. See Figure 19.  
7. Replace the board making sure the mounting  
screws and washers are in place and tight.  
5. Using the phillips head screwdriver, remove  
the three mounting screws from the board.  
8. Install the three plugs into the board.  
9. Replace the front control panel.  
NOTE: Take note of the screw and washer place-  
ment for reassembly.  
6. Using the ohmmeter, check for the correct  
resistance readings per Table F.1. If any of  
the checks are not correct, the RF By-Pass  
Board may be faulty.  
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F-46  
F-46  
TROUBLESHOOTING & REPAIR  
TABLE F.1.  
RF BY-PASS RESISTANCE TABLE  
CHECK POINTS  
COMPONENT BEING  
CHECKED  
MAXIMUM ALLOWABLE  
RESISTANCE  
1J61 to 5J60  
1J61 to 5J62  
L4 and Board Trace  
L4 and Board Trace  
4.2 OHMS (3.5 Typical)  
4.2 OHMS (3.5 Typical)  
2J61 to 4J60  
2J61 to 4J62  
L5 and Board Trace  
L5 and Board Trace  
4.2 OHMS (3.5 Typical)  
4.2 OHMS (3.5 Typical)  
3J61 to 1J60  
3J61 to 1J62  
L1 and Board Trace  
L1 and Board Trace  
4.2 OHMS (3.5 Typical)  
4.2 OHMS (3.5 Typical)  
4J61 to 2J60  
4J61 to 2J62  
L2 and Board Trace  
L2 and Board Trace  
4.2 OHMS (3.5 Typical)  
4.2 OHMS (3.5 Typical)  
5J61 to 6J60  
5J61 to 6J62  
L6 and Board Trace  
L6 and Board Trace  
4.2 OHMS (3.5 Typical)  
4.2 OHMS (3.5 Typical)  
8J61 to 3J60  
8J61 to 3J62  
L3 and Board Trace  
L3 and Board Trace  
4.2 OHMS (3.5 Typical)  
4.2 OHMS (3.5 Typical)  
NOTE: The pins should not have continuity to the PC board ground plane. See M18948 schematic.  
COMMANDER 300  
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F-47  
F-47  
TROUBLESHOOTING & REPAIR  
CONTROL TRANSFORMER TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine that if the correct voltage (115VAC) is applied to the primary of the  
control transformer, the correct voltages are induced on the secondary windings of the  
transformer.  
MATERIALS NEEDED  
Volt/Ohmmeter  
Wiring diagram  
Isolated 115VAC supply  
3/8" wrench  
This procedure should take approximately 20 minutes to perform.  
COMMANDER 300  
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F-48  
F-48  
TROUBLESHOOTING & REPAIR  
CONTROL TRANSFORMER TEST (continued)  
FIGURE F.20 – FRONT CONTROL PANEL REMOVAL  
SCREWS  
FRONT  
CONTROL  
PANEL  
SCREW  
TEST PROCEDURE  
1. This test should be performed with the  
engine off.  
2. Using the 3/8" wrench, remove the four  
screws holding the front control panel to the  
case top and sides. See Figure F.20. (There  
are two screws on the top and one on each  
side.)  
3. Carefully lower the front control panel.  
COMMANDER 300  
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F-49  
F-49  
TROUBLESHOOTING & REPAIR  
CONTROL TRANSFORMER TEST (continued)  
FIGURE F.21 – PLUG J16 DETAILS  
J16  
4
8
3
7
2
6
1
5
J16  
CONTROL TRANSFORMER  
4. Locate and disconnect plug J16 from P16.  
See the Wiring Diagram and Figure 21.  
8. Carefully check for approximately 30VAC at  
the brown (secondary) leads plug J16 pins 5  
and 6.  
5. Using the isolated supply, carefully apply  
115VAC to the black (primary) leads at plug  
J16 pins 7 and 8.  
9. If any of the secondary voltages are missing  
or low the control transformer may be faulty.  
Also check the leads at the plug for loose or  
faulty connections.  
6. Carefully check for approximately 42VAC at  
the red (secondary) leads at plug J16 pins 3  
and 4.  
10. Reconnect plugs J16 to P16.  
7. Carefully check for approximately 30VAC at  
the yellow (secondary) leads plug J16 pins 1  
and 2.  
11. Replace the front control panel and secure  
with the screws previously removed.  
COMMANDER 300  
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F-50  
F-50  
NOTES  
COMMANDER 300  
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F-51  
F-51  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if there are faulty diodes in the output rectifier bridge.  
MATERIALS NEEDED  
Volt/Ohmmeter (diode tester)  
1/2" wrench  
3/8" wrench  
Wiring diagram  
This procedure should take approximately 40 minutes to perform.  
COMMANDER 300  
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F-52  
F-52  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST (continued)  
FIGURE F.22 – FRONT CONTROL PANEL REMOVAL  
SCREWS  
FRONT  
CONTROL  
PANEL  
SCREW  
TEST PROCEDURE  
1. Turn the engine off.  
4. Using the 3/8" wrench, remove the front left  
and right side panels.  
2. Using the 3/8" wrench remove the screws  
holding the front control panel to the case top  
and sides. See Figure F.22. (There are two  
screws on the top and one screw on each  
side.)  
5. Perform the Power Module Capacitor  
Discharge Procedure.  
6. Using the 3/4" wrench, remove the internal  
leads from the output terminals. Insulate the  
leads.  
3. Carefully lower the front control panel.  
COMMANDER 300  
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F-53  
F-53  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST (continued)  
FIGURE F.23 – OUTPUT PANEL REMOVAL  
OUTPUT LEADS  
(BEHIND PANEL)  
GREEN  
GROUND  
LEAD  
SCREWS  
7. Using the 3/8" wrench, remove the five  
screws holding the lower front panel to the  
case front assembly. See Figure F.23.  
Carefully move the lower front panel to the  
right side. Note that he green ground lead  
will still be attached.  
8. Using the 7/16" wrench, remove the stator  
leads and diode pigtail leads from the three  
studs. Label the leads for reassembly. Note  
leads and pigtail placement for reassembly.  
See Figure F.24.  
COMMANDER 300  
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F-54  
F-54  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST (continued)  
FIGURE F.24 – DIODE LEAD REMOVAL  
DIODE  
HEATSINKS  
STATOR AND DIODE  
PIGTAILLEAD  
CONNECTIONS  
9. Electrically isolate the six diode pigtail leads  
13. Replace the pigtails and stator leads onto  
by carefully bending them out into “free air.”  
the correct studs. Assemble the washers  
and nuts.  
10. With an ohmmeter or diode tester, check  
each of the six diodes from their pigtails to  
their respective heat sinks.  
14. Replace the lower front panel and output  
leads.  
11. Reverse the tester leads and check the  
diodes again. Diodes should have a low  
resistance in one polarity and a very high  
resistance in the opposite polarity  
15. Replace the upper control panel and  
secure.  
16. Replace the front left and right case sides.  
12. Replace any “shorted” or “open” diode as  
the tests indicate. See the Diode Removal  
and Replacement Procedure.  
COMMANDER 300  
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F-55  
F-55  
TROUBLESHOOTING & REPAIR  
POWER MODULE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will help determine if the power modules are shorted. This is a resistance test,  
not a voltage test. This test will only help diagnose a problem in the “power” section of  
the module. Other PC board components could be faulty.  
MATERIALS NEEDED  
Volt/Ohmmeter (analog)  
3/8" wrench  
7/16" wrench  
This procedure should take approximately 45 minutes to perform.  
COMMANDER 300  
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F-56  
F-56  
TROUBLESHOOTING & REPAIR  
POWER MODULE TEST (continued)  
FIGURE F.25 – POWER MODULE CAPACITOR LEADS  
POWER MODULE  
(CHOPPER PC BOARD)  
REMOVE LEADS  
TEST PROCEDURE  
1. This procedure must be performed with the  
engine off.  
NOTE: The left side module will also have the  
bleeder resistor leads attached. Label and  
remove them also.  
2. Remove the left and right case sides.  
3. Perform the Power Module Capacitor  
Discharge Procedure.  
4. Using the 7/16" wrench, remove the positive  
and negative strap leads from the power  
module capacitor terminals. See Figure F.25.  
Remove the leads from both the left and right  
side modules.  
COMMANDER 300  
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F-57  
F-57  
TROUBLESHOOTING & REPAIR  
POWER MODULE TEST (continued)  
FIGURE F.26 – IGBT TEST  
POWER MODULE  
(CHOPPER PC BOARD)  
REMOVE LEADS  
HEAT SINK  
CHECK IGBT FOR “SHORTS”  
5. Using the analog ohmmeter, connect the pos-  
itive meter probe to the heat sink and the neg-  
ative meter probe to the positive capacitor ter-  
minal on the chopper PC board. See Figure  
F.26. The resistance reading should be very  
high (over 20,000 ohms).  
6. Reverse the meter probe leads. The resis-  
tance should be very high (over 20,000  
ohms). It the resistance is low in either Step  
5 or 6, the IGBT may be shorted or leaky.  
7. Repeat Steps 4 and 5 for the other module.  
COMMANDER 300  
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F-58  
F-58  
TROUBLESHOOTING & REPAIR  
POWER MODULE TEST (continued)  
FIGURE F.27 – DIODE MODULE TEST  
DIODE MODULES  
AND HEAT SINKS  
CHECK DIODE MODULE  
8. Using the analog ohmmeter, connect the  
negative meter probe to the terminal on the  
diode module. See Figure F.27. Connect the  
positive meter probe to the heat sink. The  
resistance should be very high (over 20,000  
ohms).  
10. Reconnect all leads and sheet metal previ-  
ously removed.  
11. Torque the capacitor nuts to 50-60 inch-  
pounds.  
9. Using the analog ohmmeter, connect the  
positive meter probe to the terminal on the  
diode module. See Figure F.27. Connect the  
negative meter probe to the heat sink. The  
resistance should be low (approximately  
1000 ohms).  
COMMANDER 300  
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F-59  
F-59  
TROUBLESHOOTING & REPAIR  
CURRENT BALANCE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-  
ing assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will determine if there is a balance current between the IGBT modules and can also  
eliminate intermittent lack of output problems. This test to be performed on machine codes  
10469 and 10470 only.  
MATERIALS NEEDED  
3/8" Wrench  
5/16” Nut Driver  
Wire Cutters  
This procedure should take approximately 30 minutes to perform.  
COMMANDER 300  
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F-60  
F-60  
TROUBLESHOOTING & REPAIR  
CURRENT BALANCE TEST (continued)  
tive weld stud. Each voltage measurement  
should be .75-1.3 VDC and both measure-  
ments must be within .1VDC of each other.  
TEST PROCEDURE  
1. Turn the engine off.  
2. Perform the Case Cover Removal  
8. A voltage out of spec indicates a possible  
blown IGBT chopper module and the chopper  
boards must be replaced. Replace both chop-  
per boards using the POWER MODULE  
(CHOPPER) PC BOARD REMOVAL AND  
REPLACEMENT PROCEDURE.  
Procedure and tilt the control panel out.  
3. Locate plug J3 at the control board and P15  
in the main harness. See Figure F.29.  
4. Disconnect P15.  
9. A voltage within spec indicates that the chop-  
per modules are sharing weld current relative-  
ly equal and the chopper boards are ok.  
WARNING  
ELECTRIC SHOCK CAN KILL.  
10. Remove the load and turn off the engine.  
• Do not touch electrically  
live parts such as output  
terminals or internal wiring.  
11. Disconnect J3 at the control board. See  
Figure F.29.  
12. Using a pair of wire cutters, cut leads 68 and  
69 from the #3 and #4 cavities of plug J3.  
Butt tape and insulate loose ends. See  
Figure F.28.  
• Insulate yourself from the  
work and ground.  
• Always wear dry insulating  
gloves.  
NOTE: Cutting and removing these leads will  
help to eliminate intermittent lack of out-  
put problems.  
5. Start the machine.  
13. Plug J3 back into the control board.  
6. In CC mode, load the machine on a load grid  
to 375 amps at 34 VDC.  
14. Using the CASE COVER REMOVAL AND  
REPLACEMENT PROCEDURE, install the  
control panel and side panels on the  
machine.  
7. Immediately after applying the load, use a  
voltmeter to measure (one at a time) the volt-  
age from each chopper heat sink to the posi-  
FIGURE - F.28 PLUG J3  
69  
68  
Plug J3  
COMMANDER 300  
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F-61  
F-61  
TROUBLESHOOTING & REPAIR  
CURRENT BALANCE TEST (continued)  
FIGURE F.29 – PLUG LOCATIONS  
ENGINE PROTECTION  
CONTROL BOARD  
BOARD  
C300 ENGINE PROTECTION  
G3004-1  
C14  
COMMANDER 300  
CONTROL  
G3002-1  
Q9  
R89  
R93  
R12  
R98  
D3  
J5  
J6  
J7  
J4  
J2  
J1  
J3  
P15  
J3  
COMMANDER 300  
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F-62  
F-62  
NOTES  
COMMANDER 300  
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F-63  
F-63  
TROUBLESHOOTING & REPAIR  
CONTROL INPUT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-  
ing assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will determine if the Range Selector Switch, Control dial, Arc Force dial, and circuits  
on the control board that interface with these weld control components are functioning prop-  
erly.  
MATERIALS NEEDED  
3/8" Wrench  
5/16” Nut Driver  
Multi-meter  
This procedure should take approximately 60 minutes to perform.  
COMMANDER 300  
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F-64  
F-64  
TROUBLESHOOTING & REPAIR  
CONTROL INPUT TEST (continued)  
FIGURE F.30 – PLUG J2  
COMMANDER 300  
Pin 2 (-)  
CONTROL  
G3002-1  
Plug J2  
J4  
J3  
J2  
J1  
Pin 6 (+)  
Pin 7 (+)  
7. Set the Arc Force dial in the min. position, the  
Range Selector switch to the CC position, and  
the Control dial to min.  
TEST PROCEDURE  
1. Turn the engine off.  
2. Perform the Case Cover Removal and  
8. Short the output studs.  
Replacement Procedure.  
9. Using a voltmeter, measure 4.378 - 4.648  
VDC from J2 pin 7 (pos. lead) to J2 pin 2 (neg.  
lead). Set the Arc Force dial in the max. posi-  
tion. Measure 8.352 - 8.868 VDC from J2 pin  
7 (pos. lead) to J2 pin 2 (neg. lead). The short  
circuit output current should increase as the  
Arc Force dial is turned from min to max. See  
Figure F.30.  
3. Tilt the control panel out.  
4. Locate the J2 connector on the control  
board. See Figure F.30.  
5. Start the machine.  
6. With a voltmeter, measure the following volt-  
ages from J2 pin 6 (pos. lead) to J2 pin 2  
(neg. lead) at the control board. See Table  
F.2.  
10. Remove the short and turn the engine off.  
11. If any of the voltage checks fail, proceed to  
the continuity check section.  
WARNING  
ELECTRIC SHOCK CAN KILL.  
12. Locate and disconnect J4 at the control  
board. See Figure F.30.  
• Do not touch electrically  
live parts such as output  
terminals or internal wiring.  
13. Set the range selector switch in the CV posi-  
tion.  
• Insulate yourself from the  
work and ground.  
• Always wear dry insulating  
gloves.  
COMMANDER 300  
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F-65  
F-65  
TROUBLESHOOTING & REPAIR  
CONTROL INPUT TEST (continued)  
Table F.2.  
CONTROL DIAL POSITION  
RANGE SEL. SWITCH POS.  
VOLTAGE  
MIN  
MIN  
MIN  
MIN  
MIN  
MIN  
MIN  
MAX  
MAX  
MAX  
MAX  
MAX  
MAX  
MAX  
CV  
60A  
90A  
150A  
230A  
300A  
CC  
1.223-1.299 VDC  
.553-.587 VDC  
.844-.896 VDC  
1.162-1.234 VDC  
1.524-1.618 VDC  
1.868-1.984 VDC  
.319-.339 VDC  
CV  
4.799-5.095 VDC  
1.085-1.153 VDC  
1.660-1.762 VDC  
2.285-2.427 VDC  
2.998-3.184 VDC  
3.669-3.895 VDC  
3.870-4.110 VDC  
60A  
90A  
150A  
230A  
300A  
CC  
14. Using an ohmmeter, measure continuity at J4  
in the following switch positions. See Table  
F.3 below.  
Table F.3.  
RANGE SEL. SWITCH POSITION  
CONTINUITY FROM  
CV  
60A  
J4 pin 1 to 9  
J4 pin 1 to 6  
J4 pin 1 to 2  
J4 pin 1 to 5  
J4 pin 1 to 7  
J4 pin 1 to 8  
J4 pin 1 to 10  
90A  
150A  
230A  
300A  
CC  
15. If continuity fails or is intermittent in any of the  
above switch positions, check for continuity  
and poor connections on all leads from the  
switch back to the control board. Check for  
loose or faulty connections in molex connec-  
tors.  
20. Using an ohmmeter, measure the resistance  
from J3 pin 7 to J3 pin 16. See Figure F.31.  
The resistance on the ohmmeter should  
increase from 0 ohms to 10K uniformly as the  
control dial is turned clockwise from minimum  
to maximum.  
16. Plug J4 back into the control PC board.  
21. If the resistance check in step 19 & 20 fails,  
check for continuity and poor connections on  
all 75, 76, and 77 leads from the potentiome-  
ter back to the control board. See the Wiring  
Diagram. Look closely for broken molex pins.  
17. Locate and disconnect J3 at the control PC  
board. See Figure F.30.  
18. Set the control dial to the minimum position,  
set the Arc Force dial to the minimum posi-  
tion, and set the Local/Remote switch in the  
“Local” position.  
22. Check the Local/Remote switch for continuity.  
23. If all the leads and the Local/Remote switch  
check ok, the control potentiometer is bad.  
Replace.  
19. Using an ohmmeter, measure 10K from J3  
pin 7 to J3 pin 8.  
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F-66  
F-66  
TROUBLESHOOTING & REPAIR  
CONTROL INPUT TEST (continued)  
FIGURE F.31 – Plug J3  
Pin 7  
Pin 5  
Pin 8  
Plug J3  
Pin 16  
Pin 14  
24. Using a remote control hooked up to the  
machine amphenol, set the Local/Remote  
switch in the “Remote” position, and the  
remote control dial to the minimum position.  
Repeat steps 19-21. Remember to include  
the RF bypass PC board in the continuity  
check.  
28. If all leads check ok, the Arc Force poten-  
tiometer is bad. Replace.  
29. Plug J3 back into the control PC board.  
30. If all continuity checks in this section are ok  
but the voltage checks from the previous sec-  
tion are off, replace the control board.  
25. Disconnect the remote control.  
31. Using the Case Cover Removal and  
Replacement Procedure, install the control  
panel and side panels on the machine.  
26. Using an ohmmeter, measure the resistance  
from J3 pin 5 to J3 pin 14. See Figure F.31.  
The resistance should decrease from 50K to  
0 ohms uniformly as the arc force dial is  
turned clockwise from minimum to maximum.  
27. If the resistance check in step 26 fails, check  
for continuity and poor connections on leads  
277, 278, and 278A from the potentiometer  
back to the control board. See the Wiring  
Diagram. Look closely for broken molex pins.  
COMMANDER 300  
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F-67  
F-67  
TROUBLESHOOTING & REPAIR  
FEEDBACK INPUT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-  
ing assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will determine if the weld current and voltage feedback circuits, and the circuits on  
the control board that interface with the feedback circuits are functioning properly.  
MATERIALS NEEDED  
3/8" Wrench  
5/16” Nut Driver  
Multi-meter  
Ammeter (for weld current)  
Voltmeter (for weld voltage)  
This procedure should take approximately 45 minutes to perform.  
COMMANDER 300  
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F-68  
F-68  
TROUBLESHOOTING & REPAIR  
FEEDBACK INPUT TEST (continued)  
FIGURE F.32 - CONTROL BOARD  
COMMANDER 300  
CONTROL  
G3002-1  
J4  
J3  
J2  
J1  
8. Using a voltmeter, measure the voltage from  
J2 pin 1 (pos. lead) to J2 pin 2 (neg. lead).  
See Figure F.33. The voltage should read  
1.788 - 2.185 VDC.  
TEST PROCEDURE  
1. Turn the engine off.  
2. Using the Case Cover Removal and  
Replacement Procedure and tilt the control  
panel out.  
9. In the CC mode, load the machine to 200  
amps at 30 VDC using an external ammeter  
and voltmeter.  
WARNING  
10. Using a voltmeter, measure the voltage from  
J2 pin 5 (pos. lead) to J2 pin 2 (neg.lead).  
See Figure F.33. The voltage should read  
3.521 - 3.739 VDC.  
ELECTRIC SHOCK CAN KILL.  
• Do not touch electrically  
live parts such as output  
terminals or internal wiring.  
11. Remove the load and turn the engine off.  
• Insulate yourself from the  
work and ground.  
12. If any of the voltage checks fail, proceed to  
the continuity check section.  
• Always wear dry insulating  
gloves.  
CONTINUITY CHECKS SECTION:  
1. Locate and disconnect J3 at the control PC  
board.  
3. Start the machine.  
2. Using an ohmmeter, check for continuity from  
J3 pin 15 to J3 pin 6. See Figure F.33. Also  
check for continuity from J3 pin 6 to the nega-  
tive stud.  
4. In CC mode and with the weld terminal switch  
in the “always on” position, load the machine  
on a load grid to 200 amps at 25 VDC using  
an external ammeter and voltmeter to mea-  
sure weld amps and volts.  
3. If either continuity test does not measure 0  
ohms, check for continuity and poor connec-  
tions on leads 21 and 22 from the shunt back  
to the control board. See the wiring diagram.  
Look closely for broken molex pins.  
5. With a voltmeter, measure the voltage from J3  
pin 15 (pos. lead) to J3 pin 6 (neg. lead). See  
Figure F.33. The voltage should be approxi-  
mately 25 mvdc.  
4. If all leads check ok, the shunt is bad.  
Replace.  
6. If the voltage is off by more than 2.5 mvdc, the  
shunt and lead assembly is bad. Replace.  
5. Using an ohmmeter, check for continuity from  
J3 pin 2 to the positive stud.  
7. Locate the J2 connector on the control PC  
board. Keep the machine running and same  
grid load applied.  
COMMANDER 300  
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F-69  
F-69  
TROUBLESHOOTING & REPAIR  
FEEDBACK INPUT TEST (continued)  
FIGURE F.33. – Plug J2 & J3  
Pin 1  
Pin 2  
Pin 6  
Pin 2  
Plug J3  
Plug J2  
Pin 15  
Pin 5  
6. If the continuity is not present, check the 67  
lead for poor connection. See the Wiring  
Diagram. Look closely for broken molex pins.  
7. Plug J3 back into the control PC board.  
8. If all continuity checks in this section are ok but  
the voltage checks from the previous section  
are off, replace the control board.  
9. Using the Case Cover Removal and  
Replacement Procedure, install the control  
panel and side panels on the machine.  
COMMANDER 300  
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F-70  
F-70  
NOTES  
COMMANDER 300  
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F-71  
F-71  
TROUBLESHOOTING & REPAIR  
PWM OUTPUT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-  
ing assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will determine if the weld terminal switch and PWM output circuit on the control board  
are responding properly to input changes from the feedback and control input circuits. This  
test assumes that the CONTROL INPUT TEST and FEEDBACK INPUT TEST have already  
been performed.  
MATERIALS NEEDED  
3/8” Wrench  
5/16" Nut Driver  
Multi-meter  
Oscilloscope  
This procedure should take approximately 60 minutes to perform.  
COMMANDER 300  
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F-72  
F-72  
TROUBLESHOOTING & REPAIR  
PWM OUTPUT TEST (continued)  
FIGURE F.34 – Plug J13 w/pins 4 & 5  
Plug J13  
Right Chopper Board  
+
Plug J13  
Pin 4  
Pin 5  
5. Using an oscilloscope, measure the PWM wave-  
form from J13 pin 5 (probe) to J13 pin 4 (gnd) at the  
right chopper board. See Figure F.34.  
TEST PROCEDURE  
1. Turn the engine off.  
2. Using the Case Cover Removal and  
Replacement Procedure and tilt the control panel  
out.  
6. Turn the weld terminals switch to the “Remotely  
Controlled” position. The PWM waveform on the  
scope should go to zero and the machine output  
should go to zero.  
WARNING  
ELECTRIC SHOCK CAN KILL.  
7. Connect a remote control to the machine amphe-  
nol. Turn the remote 2-4 switch to the “on” position.  
The PWM waveform should reappear and the  
machine output should be re-established.  
• Do not touch electrically live  
parts such as output terminals  
or internal wiring.  
8. Disconnect the remote control.  
• Insulate yourself from the work  
and ground.  
9. If the PWM waveform does not change, use a volt-  
meter to check for 10.0 VDC from J1 pin 6 to frame  
ground with the weld terminal switch in the remote-  
ly controlled position. See Figure F.35.  
• Always wear dry insulating  
gloves.  
10. Turn the weld terminals switch to the “always on”  
position and the control dial to the max position.  
3. Start the machine.  
4. In the CC mode, load the machine on a load grid to  
375 amps at 34 VDC.  
FIGURE F.35 – Plug J1 pin 6  
Plug J1  
Pin 6  
COMMANDER 300  
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F-73  
F-73  
TROUBLESHOOTING & REPAIR  
PWM OUTPUT TEST (continued)  
11. Using an oscilloscope, measure the PWM wave-  
form from J13 pin 5 (probe) to J13 pin 4 (gnd).  
See Figure F.34. The PWM waveform should uni-  
formly decrease as the control dial is turned coun-  
terclockwise to the min position. See below for  
min and max potentiometer waveforms.  
FIGURE F.36 – Min./Max. Potentiometer Waveforms  
Minimum Potentiometer  
Maximum Potentiometer  
0 Volts  
0 Volts  
5V/Div  
10µS/Div  
5V/Div  
10µS/Div  
12. Repeat step 11 to check the PWM waveform at J12  
pins 4 & 5 at the left chopper board. See Figure  
F.37.  
3. Plug J3 back into the control board, J12 and J13  
back into their chopper boards.  
4. Locate and disconnect J1 at the control board. Also  
locate and disconnect J5 & J7 at the engine protec-  
tion board. See Figure F.38.  
13. Remove the load and turn the engine off.  
14. If the measured min and max PWM waveforms do  
not match the waveforms shown, proceed to the  
continuity check section.  
5. Check leads 90, 91, 248, and 242 for continuity.  
See the Wiring Diagram. Check for broken molex  
pins.  
CONTINUITY CHECK SECTION:  
6. Check the weld terminal switch for continuity.  
1. Locate and disconnect J12 and J13 at each of the  
chopper boards and J3 at the control board.  
7. Plug J1 back into the control board, J5 & J7 back  
into the engine protection board.  
2. Check leads 23, 23A, 25, & 25A for continuity from  
J12 and J13 at the chopper boardS to J3 at the con-  
trol board. See the Wiring Diagram. Look closely  
for broken molex pins.  
8. If all continuity checks in this section are ok but the  
voltage checks from the previous section are off,  
replace the control board.  
FIGURE F.37 – Plug J12 Pins 4 & 5  
Plug J12  
Pin 4  
Pin 5  
COMMANDER 300  
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F-74  
F-74  
TROUBLESHOOTING & REPAIR  
PWM OUTPUT TEST (continued)  
FIGURE F.38 – Engine Protection Board (Plug Locations)  
ENGINE PROTECTION  
CONTROL BOARD  
BOARD  
C300 ENGINE PROTECTION  
G3004-1  
C14  
COMMANDER 300  
CONTROL  
G3002-1  
Q9  
R89  
R93  
R12  
R98  
D3  
J5  
J6  
J7  
J4  
J2  
J1  
J3  
9. Using the Case Cover Removal and  
Replacement Procedure, install the control panel  
and side panels of the machine.  
COMMANDER 300  
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F-75  
F-75  
TROUBLESHOOTING & REPAIR  
POWER SUPPLY TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-  
ing assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will determine if all the power supplies needed to control weld, display, and idler out-  
put are ok. This test assumes that the CONTROL TRANSFORMER TEST has already been  
performed.  
MATERIALS NEEDED  
3/8" Wrench  
5/16” Nut Driver  
Multi-meter  
This procedure should take approximately 30 minutes to perform.  
COMMANDER 300  
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F-76  
F-76  
TROUBLESHOOTING & REPAIR  
POWER SUPPLY TEST (continued)  
5. Turn the engine off.  
TEST PROCEDURE  
6. Using the Case Cover Removal and  
1. Turn the engine off.  
Replacement Procedure, install the control  
panel and side panels on the machine.  
2. Perform the Case Cover Removal and  
Replacement Procedure and tilt the control  
panel out.  
WARNING  
ELECTRIC SHOCK CAN KILL.  
• Do not touch electrically live  
parts such as output termi-  
nals or internal wiring.  
• Insulate yourself from the  
work and ground.  
• Always wear dry insulating  
gloves.  
3. Start the machine.  
4. Using a voltmeter, measure the following sup-  
ply voltages at the designated points. See  
Table F.4.  
Table F.4  
SUPPLY VOLTAGE  
MEASURED AT:  
FUNCTION AFFECTED  
CHECK/REPLACE  
Weld output/display output  
Idler control  
+12VDC control  
+12VDC control  
+12VDC control  
30VAC control  
30VAC control  
42VAC control  
+12VDC control  
+12VDC Battery  
J2 pin 3 to 2 @ control bd  
J1 pin 4 to 1 @ control bd  
J5 pin 4 to 1 @ engine prot. bd  
J12 pin 1 to 2 @ LT chopper bd  
J13 pin 1 to 2 @ RT chopper bd  
J3 pin 1 to 9 @ control bd  
J9 pin 4 to 5 @ display bd  
Control board  
Control board  
Idler control  
leads 108, 109/cont. bd  
leads 15, 16  
Weld output  
Weld output  
leads 13, 14  
Weld output  
leads 17, 18  
Display output (if so equipped)  
Display output (if so equipped)  
leads 106, 107/cont. bd  
J9 pin 1 to 2 @ display bd  
(run/stop on)  
leads 232, 232J, 5L, 5N,  
5M/Battery  
Note: When checking leads for continuity or poor connection, remember to look closely for  
broken molex pins.  
COMMANDER 300  
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F-77  
F-77  
TROUBLESHOOTING & REPAIR  
DISPLAY BOARD CALIBRATION TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-  
ing assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will determine if the display board (if so equipped) is properly calibrated.  
MATERIALS NEEDED  
None  
This procedure should take approximately 45 minutes to perform.  
COMMANDER 300  
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F-78  
F-78  
TROUBLESHOOTING & REPAIR  
DISPLAY BOARD CALIBRATION TEST (continued)  
“Crd”, switch the range selector switch to the  
TEST PROCEDURE  
CV position and back to the 60A position a  
minimum of 5 times. Must end up in the 60A  
position.  
1. Start the engine.  
2. Turn the range selector switch to the CC posi-  
tion, and control dial to the min. position.  
9. The top display should read “001” for about 5  
seconds, then read “CAL” for about 5 sec-  
onds. The top display will then read “30”.  
The bottom display will read “---”. This com-  
pletes the calibration process.  
3. With no load applied, slowly turn the control  
dial clockwise from min to max in each range  
selector switch position. The display should  
read the same as the Table F.5 shown below.  
10. Repeat steps 2 & 3.  
4. If the display reading is off in any mode, the  
display board must be re-calibrated.  
11. If the display is still off, turn the engine off.  
12. Perform the Case Cover Removal and  
Replacement Procedure and tilt the control  
panel out.  
RE-CALIBRATION PROCEDURE  
5. Turn the engine off.  
13. Check all leads at J8 & J9 at the display  
board for continuity and poor connection.  
See the Wiring Diagram. Check for broken  
molex pins.  
6. Set the control panel switches as follows:  
Welding Terminals switch to “Remotely  
Controlled”.  
14. If all the leads are ok, perform steps 5 & 6 of  
the Control Input Test. Measure the volt-  
ages in step 6 at J8 pin 3 (pos. lead) to J9  
pin 5 (neg. lead) instead of measuring at the  
J2 connector on the control board.  
Local/Remote switch to “Remote”.  
Range Selector switch to “60A”.  
Control Dial to “Min”.  
Idler Switch to “High”.  
15. Turn the engine off.  
Arc Control Wire/Stick dial to “Min”.  
7. Start the engine.  
16. If any of the voltages were wrong, replace  
the control board. If the voltages were ok,  
replace the display board.  
8. Within 5 seconds after the top display reads  
Table F.5.  
RANGE SELECTOR SW. POSITION  
FROM MIN.  
30 amps  
TO MAX.  
375 amps  
300 amps  
230 amps  
150 amps  
90 amps  
CC  
300A  
230A  
150A  
90A  
140 amps  
100 amps  
70 amps  
50 amps  
60A  
30 amps  
60 amps  
CV  
10.5 volts  
49-50 volts  
COMMANDER 300  
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F-79  
F-79  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)  
HIGH IDLE – NO LOAD  
15.8 ms  
0 volts  
50V  
5ms  
This is the typical auxiliary output  
voltage generated from a properly  
operating machine. Note that each  
vertical division represents 50 volts  
and that each horizontal division rep-  
resents 5 milliseconds in time.  
Note: Scope probes connected at  
machine 115VAC receptacle.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 300  
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F-80  
F-80  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (STICK)  
MAX TAP – MAX CONTROL POT – HIGH IDLE – NO LOAD  
0 volts  
50V  
5ms  
This is the typical DC open circuit out-  
put voltage generated from a properly  
operating machine. Note that each  
vertical division represents 50 volts  
and that each horizontal division rep-  
resents 5 milliseconds in time.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 300  
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F-81  
F-81  
TROUBLESHOOTING & REPAIR  
NORMAL WELD VOLTAGE WAVEFORM (STICK CC)  
MACHINE LOADED TO 300 AMPS AT 32 VOLTS  
0 volts  
20V  
5ms  
This is the typical DC output voltage  
generated from a properly operating  
machine. Note that each vertical  
division represents 20 volts and that  
each horizontal division represents 5  
milliseconds in time.  
The machine was loaded with a  
resistance grid bank to 300 amps at  
32 volts.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 300  
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F-82  
F-82  
TROUBLESHOOTING & REPAIR  
NORMAL WELD VOLTAGE WAVEFORM (WIRE CV)  
MACHINE LOADED TO 300 AMPS AT 32 VOLTS  
0 volts  
20V  
5ms  
This is the typical DC output voltage  
generated from a properly operating  
machine. Note that each vertical  
division represents 20 volts and that  
each horizontal division represents 5  
milliseconds in time.  
The machine was loaded with a  
resistance grid bank to 300 amps at  
32 volts.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 300  
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F-83  
F-83  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV TAP)  
MAX CONTROL POT – HIGH IDLE – NO LOAD  
0 volts  
50V  
5ms  
This is the typical DC open circuit  
output voltage generated from a  
properly operating machine. Note  
that each vertical division represents  
50 volts and that each horizontal  
division represents 5 milliseconds in  
time.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 300  
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F-84  
F-84  
NOTES  
COMMANDER 300  
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F-85  
F-85  
TROUBLESHOOTING & REPAIR  
POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY  
REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This procedure will aid the technician in the removal and replacement of the power mod-  
ule/output rectifier bridge assembly. Once the assembly is removed, the power module  
PC boards and output rectifier bridge diodes can be accessed for removal and replace-  
ment.  
MATERIALS NEEDED  
3/8" Wrench  
7/16" Wrench  
1/2" Wrench  
This procedure should take approximately 80 minutes to perform.  
COMMANDER 300  
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F-86  
F-86  
TROUBLESHOOTING & REPAIR  
POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY  
REMOVAL AND REPLACEMENT (continued)  
FIGURE F.39 – CONTROL PANEL REMOVAL  
SCREWS  
FRONT  
CONTROL  
PANEL  
SCREW  
TEST PROCEDURE  
1. Turn the engine off.  
5. Perform the Output Panel Removal  
Procedure.  
2. Using the 3/8" wrench, remove the screws  
holding the front control panel to the case top  
and sides. See Figure F.39. (There are two  
screws on the top and one screw on each  
side.)  
6. Perform the Power Module Capacitor  
Discharge Procedure.  
7. Optional: With the 7/16" wrench, remove the  
ground wire from the output panel assembly.  
If the ground wire is not in the way, it can  
remain attached.  
3. Carefully lower the front control panel.  
4. Using the 3/8" wrench, remove the front left  
and right side panels.  
COMMANDER 300  
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F-87  
F-87  
TROUBLESHOOTING & REPAIR  
POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY  
REMOVAL AND REPLACEMENT (continued)  
FIGURE F. 40 – POWER MODULE CAPACITOR LEAD REMOVAL  
REMOVE LEADS  
8. Label the power module capacitor leads.  
Using the 7/16" wrench, disconnect the  
leads by removing the nut, lock washer, and  
flat washer. See Figure F.40.  
11. Using the 1/2" wrench, remove the flat strap  
to the negative output terminal. Pull the  
strap through the power module top brack-  
et. See Figure F.41.  
9. Disconnect plug J12 and plug J13 from  
each power module PC board. See the  
Wiring Diagram.  
12. With the 7/16" socket wrench, remove the  
four nuts, lock washers, flat washers, and  
carriage bolts that hold the power module  
bottom bracket to the machine base. See  
Figure F.41.  
10. Using the 7/16" wrench, remove the stator  
“W” leads from the three terminals on the  
plastic insulator bracket of the rectifier  
bridge. Label the leads for reassembly.  
Pull the leads out through the power module  
top bracket. See Figure F.41.  
COMMANDER 300  
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F-88  
F-88  
TROUBLESHOOTING & REPAIR  
POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY  
REMOVAL AND REPLACEMENT (continued)  
FIGURE F.41 – POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY DETAILS  
TOP  
BRACKET  
DIODE &  
"W" LEAD  
TERMINAL (3)  
GLASTIC  
INSULATOR  
BRACKET  
POWER MODULE  
HEAT SINK  
DIODE  
HEATSINK  
POWER  
MODULE  
PC BOARD  
(CHOPPER  
PC BOARD)  
DIODE  
LEADS  
CONTROL  
TRANSFORMER  
CAPACITOR  
BOTTOM  
BRACKET  
BASE BOLT (4)  
13. Free the positive output lead. Cut any nec-  
essary cable ties and slip the lead through  
the current sensing toroid assembly.  
NOTE: Leads #68A and #69A will remain  
attached between the machine and the assembly.  
To completely remove the assembly, label and  
disconnect leads #68A and #69A at their bolted  
connections beneath the bottom bracket.  
14. The power module/output rectifier bridge  
assembly can now be removed and set to  
the side.  
COMMANDER 300  
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F-89  
F-89  
TROUBLESHOOTING & REPAIR  
POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY  
REMOVAL AND REPLACEMENT (continued)  
REPLACEMENT PROCEDURE  
1. Connect leads #68A and #69A at their bolted  
connections beneath the bottom bracket (if  
removed).  
7. Connect plugs J12 and J13 to the power  
module PC board (both sides).  
8. Connect the power module capacitor leads.  
Torque the capacitor nuts to 50-60 inch-  
pounds.  
2. Place the assembly back into the machine.  
3. Connect the positive output lead. Feed it  
through the toroid assembly.  
9. Replace any cable ties cut during removal.  
10. Install the output panel.  
4. Install the four carriage bolts, flat washers,  
lock washers, and nuts that hold the bottom  
bracket to the machine base.  
11. Connect the ground wire to the output panel  
assembly, if removed.  
5. Pull the flat negative output strap through the  
top bracket and attach it.  
12. Attach the front left and right side panels  
and the front control panel.  
6. Feed the stator “W” leads through the top  
bracket and attach them to the terminals on  
the plastic insulator bracket.  
COMMANDER 300  
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F-90  
F-90  
NOTES  
COMMANDER 300  
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F-91  
F-91  
TROUBLESHOOTING & REPAIR  
POWER MODULE (CHOPPER) PC BOARD  
REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This procedure will aid the technician in the removal and replacement of the power mod-  
ule (chopper) PC board.  
MATERIALS NEEDED  
7/16" Wrench  
3/8" Allen head wrench  
This procedure should take approximately 35 minutes to perform.  
COMMANDER 300  
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F-92  
F-92  
TROUBLESHOOTING & REPAIR  
POWER MODULE (CHOPPER) PC BOARD  
REMOVAL AND REPLACEMENT (continued)  
FIGURE F.42 – POWER MODULE PC BOARD  
COPPER STANDOFF  
POWER MODULE  
PC BOARD  
CAPACITOR  
TERMINALS  
TEST PROCEDURE  
REPLACEMENT PROCEDURE  
1. Turn the engine off.  
1. Apply Penetrox A-13 joint compound to the  
surface of the heat sink where the power  
module PC board mounts.  
2. Remove the front right or left case side,  
depending on which power module PC board  
you are removing.  
2. Install the three bolts, lock washers, and flat  
washers to mount the power module PC  
board to the heat sink.  
3. Perform  
Procedure.  
the  
Capacitor  
Discharge  
IMPORTANT: The top, long, bolt has a copper  
standoff on the opposite side of the board. Be  
sure to place this standoff between the heat sink  
and the PC board.  
4. Perform the Output Panel Removal  
Procedure.  
5. With the 3/8" allen wrench, remove the top  
and bottom cap screws from the power mod-  
ule PC board. See Figure F.42.  
3. Install the top and bottom allen head cap  
screws. Torque the screws to 50-60 inch-  
pounds.  
6. With the 7/16" wrench, remove the three  
bolts, lock washers, and flat washers from  
the power module PC board.  
4. Install the leads, flat washers, and nuts to the  
capacitor. Torque the nuts to 50-60 inch-  
pounds.  
NOTE: The top, long, bolt has a copper standoff  
on the opposite side of the board. Be sure to  
place this standoff between the heat sink and the  
PC board at reassembly.  
5. Perform the Output Panel Replacement  
Procedure.  
6. Install the case side(s).  
7. Remove the nuts and flat washers from the  
capacitor terminals and remove the flat  
leads.  
8. Remove the power module board.  
COMMANDER 300  
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F-93  
F-93  
TROUBLESHOOTING & REPAIR  
DIODE REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
The following procedure will aid the technician in removing and replacing stud type diodes  
to the aluminum heat sinks on the Commander 300.  
MATERIALS NEEDED  
7/16" Wrench  
1" Open end wrench  
Penetrox A13  
Loctite 271  
“Slip” type torque wrench  
E2827-2 abrasive disc  
This procedure should take approximately 25 minutes to perform.  
COMMANDER 300  
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F-94  
F-94  
TROUBLESHOOTING & REPAIR  
DIODE REMOVAL AND REPLACEMENT (continued)  
FIGURE F.43 – POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY DETAILS  
HEATSINKS  
DIODE  
DIODE  
PIGTAIL  
LEADS  
TEST PROCEDURE  
1. Turn the engine off.  
9. Apply a thin (0.003" to 0.007") uniform layer  
of Penetrox A13 joint compound to the heat  
sink mounting surface.  
2. Perform the Output Panel Removal  
Procedure.  
10. Do not apply compound to the diode stud or  
mounting threads.  
3. Perform  
Procedure.  
the  
Capacitor  
Discharge  
11. Apply two drops of Loctite 271to the diode  
stud threads before tightening.  
4. Using the 7/16" wrench, remove the appro-  
priate stator leads and diode pigtail lead from  
the stud on the output rectifier bridge plastic  
insulator bracket. Label leads for reassembly  
if more than one is removed. See Figure  
F.43.  
NOTE: The diode threads must be clean and free  
of defects so that it can be finger tightened before  
applying torque. A “slip” type torque wrench must  
be used to tighten the diode.  
5. Using the 1" wrench, loosen the appropriate  
diode and remove the diode that is to be  
replaced.  
12. Tighten the diode to the specifications in the  
following table.  
6. Clean the area on the heat sink around the  
diode mounting surface using a putty knife or  
similar tool. DO NOT SCRATCH THE  
DIODE MOUNTING SURFACE.  
DIODE  
FOOT-POUNDS INCH-POUNDS  
SIZE  
3/4 - 16  
3/8 - 24  
25-27  
10±.5  
300-324  
125+0/-5  
7. Polish the heat sink's mounting surface using  
an abrasive disc, E2827-2 to provide a bright,  
clean surface where the diode seats on the  
heat sink. Wipe the surface clean with a lint-  
free cloth or paper towel.  
13. Connect the stator leads and diode pigtail  
leads as labeled at disassembly.  
8. Inspect the mounting surfaces of each new  
diode. Remove all burrs and wipe clean. Do  
not use steel wool or any abrasive cleanser  
on the diode mounting surface.  
14. Replace the output panel.  
COMMANDER 300  
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F-95  
F-95  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
The following procedure will aid the technician in removing and replacing the Commander  
300 stator and rotor.  
MATERIALS NEEDED  
3/8" Wrench  
7/16" Wrench  
1/2" Wrench  
Slot head screw driver  
Phillips head screw driver  
Gear puller (small)  
3/4" Wrench  
Hoist  
1" Open end wrench  
1-1/8" Wrench  
Feeler gauge (for air gap check)  
This procedure should take approximately 51⁄  
hours to perform.  
2
COMMANDER 300  
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F-96  
F-96  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.44 – FUEL TANK REMOVAL DETAILS  
LEADS #229  
AND #242D  
PLUG  
FUEL  
LINES  
U-BOLTS (2)  
{
PREPARATION AND LEAD REMOVAL  
PROCEDURE  
1. Turn the engine off.  
5. Turn the fuel off at the shutoff valve. Remove  
and plug the fuel return line. See Figure  
F.44.  
2. Perform the Case Cover Removal Pro-  
cedure, including removing the output panel.  
6. Remove and plug the lower fuel line. Pull it  
through the firewall. See Figure F.44.  
3. Perform the Power Module/Output  
Rectifier Bridge Assembly Removal  
Procedure.  
7. Using the 9/16" socket wrench, remove the  
four lock nuts, washers, and rubber washers  
from from the fuel tank mounting U-bolts.  
See Figure F.44.  
4. Using the 3/8" wrench, remove leads #229  
(white) and #242D from the fuel level sensor.  
See Figure F.44. Label the leads for  
reassembly.  
8. Carefully remove the U-bolts and lift the fuel  
tank from the machine.  
COMMANDER 300  
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F-97  
F-97  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.45 – LEAD REMOVAL DETAILS  
+
#200D  
PLUG J30  
5P  
#201  
#201A  
#64  
FILTER  
CAPACITOR  
FIELD BRIDGE  
RECTIFIER  
9. Disconnect plug J30 at the right front side.  
See Figure F.45.  
11. Label and remove leads #5P, #201 and  
#201A, #200D, and #6H from the field  
bridge rectifier. See Figure F.45.  
10. Using the slot head screw driver, discon-  
nect leads #200C, #200E(+) and #201B(-)  
from the filter capacitor. Label the leads.  
COMMANDER 300  
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F-98  
F-98  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.46 – BRUSH LEAD REMOVAL  
#200A  
#200B  
#201  
12. Label and remove brush leads #201(-) and  
#200A(+) and #200B(+) from the brush hold-  
er assembly. (The piggy-backed leads con-  
nect closest to the stator laminations.) See  
Figure F.46.  
14. Using the 3/8" wrench, remove the brush  
holder assembly.  
15. Using the 1/2" wrench, disconnect leads  
#68A and #69A at their bolted connections  
beneath the power module assembly. Label  
the leads for reassembly. Cut any neces-  
sary cable ties. See Figure F.47.  
13. Pull the harness containing plug J30, the  
brush leads, and the field bridge rectifier  
through the bushing in the firewall. See  
Figure F.45.  
COMMANDER 300  
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F-99  
F-99  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.47 – LEADS #68A/#69A BOLTED CONNECTIONS  
POWER  
MODULE  
ASSEMBLY  
BOLTED  
CONNECTION-  
LEADS 68A / 69A  
FIGURE F.48 – CONTROL BOX LEADS  
POWER STUD &  
LEADS #5A, #6  
GROUND STUD  
& LEAD #5  
TOP 50A  
CIRCUIT BREAKER  
(LEAD #3 ON BACK)  
16. Using the 7/16" wrench, disconnect stator  
lead #6 from the auxiliary power stud on the  
left side of the control box. See Figure F.48.  
NOTE: This lead must be wound two turns clock-  
wise through the toroid (opposite in direction from  
lead #6A).  
17. With the 3/8" wrench, disconnect lead #5  
from the center ground stud (nearest the  
control transformer). See Figure F.48.  
19. Disconnect lead #5A from the auxiliary  
power ground stud (left side of the control  
box, next to the 120V circuit breaker). See  
Figure F.48.  
18. Using the phillips screw driver, remove lead  
#3 from the top 50A circuit breaker for the  
120/240V receptacle. See Figure F.48.  
20. Using the 3/8 wrench, remove the two  
screws holding the control box to the top of  
the fan baffle.  
COMMANDER 300  
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F-100  
F-100  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.49 – LIFT FRAME AND ASSOCIATED COMPONENT REMOVAL  
LIFT FRAME  
WELDMENT  
FIREWALL  
FUEL TANK  
SUPPORTS  
FAN BAFFLE  
BASE  
In steps 21 – 25, the lift frame weldment, fuel tank  
supports, and fan baffle are removed as a unit.  
See Figure F.49.  
23. With the 3/8" wrench, remove the nuts, lock  
washers, and flat washers from the two  
studs that hold the fan baffle to the machine  
base.  
21. Using the 3/8" wrench, remove the two bolts  
(at top) that hold the firewall to the lift frame  
weldment.  
24. Using the 3/4" wrench, remove the four  
bolts, lock washers, and nuts from the bot-  
tom of the lift frame weldment.  
22. Using the 1/2" wrench, remove the two bolts  
(at bottom) that hold the firewall to the lift  
frame weldment.  
25. Carefully remove the lift frame weldment,  
fuel tank supports, and attached fan baffle.  
You will need to lift the fan baffle off the two  
studs on the machine base, then cock it  
slightly to remove it.  
COMMANDER 300  
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F-101  
F-101  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.50 – STATOR REMOVAL  
STATOR / ENGINE  
MOUNTING BOLTS &  
LOCK WASHERS (8)  
BEARING  
BOLTS (4)  
FAN HUB  
FAN NUT  
{
MOUNTING  
PLATE  
STATOR REMOVAL PROCEDURE  
1. Using the 1/2" wrench, remove the four fan  
blade mounting bolts and lock washers. See  
Figure F.50.  
5. Using the 1/2" wrench, remove the two nuts,  
lock washers, and carriage bolts holding the  
generator mounting plate to the machine  
base.  
2. Using the 1 1/8" wrench, remove the fan nut.  
Remove the fan, noting its direction for  
reassembly.  
6. Support the stator with the hoist. Place  
wooden blocks under the engine to support it  
when the stator is removed.  
3. Using the gear puller, remove the fan hub.  
7. Using the 9/16" wrench, remove the eight  
bolts and lock washers holding the stator to  
the engine.  
4. Using the 3/8" wrench, remove the two bolts  
and flat washers holding the bearing in place.  
8. Remove the stator from the engine. It may  
be necessary to pry and slide it free.  
COMMANDER 300  
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F-102  
F-102  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.51 – ROTOR REMOVAL  
FLEX PLATE  
BLOWER  
SEGMENT (4)  
ROTOR  
ROTOR REMOVAL PROCEDURE  
REASSEMBLY NOTES  
1. Support the rotor with the hoist.  
Reassemble the rotor and stator to the  
Commander 300 by carefully retracing the disas-  
sembly procedure steps in reverse order. Keep  
the following special points in mind as you pro-  
ceed. Lead Reconnection Checklists are provid-  
ed here as an aid to reassembly.  
2. Using the 5/8" wrench, remove the flex plate  
bolts, lock washers, and four blower seg-  
ments. See Figure F.51.  
WARNING  
1. INSTALL ROTOR: Support the rotor with the  
hoist. Install the blower segments and flex  
plate to the engine flywheel.  
The rotor will be free to fall when the bolts are  
removed.  
2. INSTALL STATOR: Be sure the engine is  
blocked securely and the stator is supported  
with the hoist. Install the stator to the engine  
with the eight bolts and lock washers. Install  
the fan blade, making sure that it faces the  
proper direction, with the fan nut and four cap  
screws.  
3. Using the hoist, carefully remove the rotor  
and flex plate assembly.  
3. Check the air gap for .012" minimum.  
COMMANDER 300  
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F-103  
F-103  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
LEAD RECONNECTION CHECKLIST  
Engine  
Output Panel and Control Box  
❒ Lead #5 to ground stud (center)  
❒ Leads #242D and #229 to fuel level sensor  
❒ Plug J30  
❒ Lead #5A to auxiliary power ground stud  
❒ Brush leads #201(-) and #200A(+) and  
❒ Lead #6 to auxiliary power stud (left) and  
toroid assembly (note number of turns and  
direction)  
#200B(+)  
❒ Leads #5P, #201 and #201A, #200D, and  
❒ Lead #3 to top 50A circuit breaker  
#6H to the field bridge rectifier  
❒
Leads #200C, #200E(+), and #200B(-) to the  
field capacitor  
Power Module Supply  
❒ Bolted leads #68A and #69A  
❒ Stator leads W1-W6  
❒ Diode pigtails  
COMMANDER 300  
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F-104  
F-104  
TROUBLESHOOTING & REPAIR  
RETEST AFTER REPAIR  
Retest a machine:  
• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the  
machine’s electrical characteristics. OR  
• If you repair or replace any electrical components.  
ENGINE OUTPUT  
Mode  
Low Idle  
High Idle  
No Load RPM  
1350 - 1400  
1880 - 1919  
Load RPM  
NA  
1780 - 1820  
WELDER DC (STICK) OUTPUT  
Mode Selector  
Switch  
30-375 Setting  
Fine Control  
Open Circuit  
Volts  
Load Volts  
Load Amps  
375-380  
Maximum  
82-89  
34-38  
PIPE MODES SHORT CIRCUIT CURRENT  
(FINE CONTROL AT MAXIMUM)  
Selector Position  
Short Circuit Current (Amps)  
60  
90  
150  
230  
300  
80-120  
180-210  
280-320  
380-410  
380-410  
WELDER CV (WIRE) OUTPUT  
Mode Selector  
Switch  
CV Mig/Mag  
CV Mig/Mag  
CV Mig/Mag  
Fine Control  
Open Circuit  
Voltage  
61-64  
Load Volts  
Load Amps  
Maximum  
Maximum  
Minimum  
40-46  
48-52  
11-14  
370-380  
20  
61-64  
28-32  
20  
AUXILIARY POWER OUTPUT  
230 Volt Receptacle  
Load Volts  
115 Volt Receptacles  
Load Volts  
Open Circuit  
Voltage  
Load Amps  
Open Circuit  
Voltage  
Load Amps  
230 - 264  
216-250  
44  
115 - 132  
108 - 132  
15  
COMMANDER 300  
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F-105  
F-105  
NOTES  
COMMANDER 300  
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G-1  
G-1  
ELECTRICAL DIAGRAMS  
TABLE OF CONTENTS  
-ELECTRICAL DIAGRAMS SECTION-  
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G  
WIRING DIAGRAM (COMMANDER 300 DELUXE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2  
WIRING DIAGRAM (COMMANDER 300 STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3  
CONTROL PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4  
CONTROL PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5  
ENGINE PROTECTION PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6  
ENGINE PROTECTION PC BOARD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7  
CHOPPER PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8  
CHOPPER PC BOARD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9  
METER PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10  
METER PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11  
BYPASS PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12  
BYPASS PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-13  
COMMANDER 300  
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G-2  
G-2  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - COMMANDER 300 DELUXE MODEL  
6A  
6A  
3
3
3
CORRESPONDING SETTINGS FOR TAP NUMBERS  
(AS VIEWED FROM THE FRONT)  
67  
STATOR AUXILIARY WINDINGS  
6A  
W2  
GND-E  
AUXILIARY POWER  
"INSULATED STUD"  
W2  
W3  
W3  
6E  
3
150A  
AUXILIARY POWER  
6D  
6
6
90A  
230A  
5A  
5
7
ON BOTTOM LEFT  
OF CONTROL BOX  
J12  
GND. SCREW ON  
CONTROL PANEL  
SELECTOR SWITCH  
6C  
60A  
4
5
6
1
2
3
300A  
15  
16  
4
3
8
(VIEWED FROM REAR)  
S5  
5A  
23A  
25A  
CAP.  
STATOR  
W2  
IGBT  
W3  
GND-D  
5
CV MIG/MAG  
30A-375A  
LOW HYDROGEN  
WELD  
3
DRIVER  
9
217  
6
5
216  
30A-375A  
GND-B  
WINDINGS  
PCB1  
W4  
W4  
W5  
W1  
W1  
218  
7
4
215  
6A  
CB1  
EMPTY  
EMPTY  
15A  
LEADC 203 TO  
PASS THRU TOROID  
ONE TIME  
A
CB5  
219  
220  
8
3
214  
213  
3B  
3
W6  
W6  
W3  
W2  
42VAC KIT  
15A  
261  
68A  
W5  
EMPTY  
EMPTY  
LEFT  
HEAT SINK  
9
8
2
260  
EMPTY  
OPTIONAL  
31  
QUICK CONNECT  
TERMINAL  
222  
RED  
3A  
3
CB3  
204  
42B  
6
+
50A  
HOT (GOLD)  
J11  
115  
WHITE  
GND-C  
CHOKE  
42  
VAC  
GND-B  
R2  
W6  
W6  
6A  
3C  
VAC  
6C  
AUXILIARY  
L1  
3C  
115/230V  
GND-D  
CB6  
10A  
W1  
6E  
NEUTRAL STUD  
3
205  
W1  
42  
BACK OF CONTROL  
BOX "LEFT SIDE"  
WHITE  
41A  
CB2  
SILVER  
-
RIGHT  
203  
GND-C  
6A  
3
4
1
15A  
RED  
41B  
RECTIFIER BRIDGE  
HEAT SINK  
6A  
5M  
GND-E  
HOT (GOLD)  
J12  
BLACK  
BLACK  
BLACK  
BLACK  
9
69A  
5E  
67  
LEADS  
3
&
6A  
41  
6G  
J13  
PASS THROUGH  
TOROID TWICE  
IN OPPOSITE  
DIRECTIONS  
67A  
5G  
SHUNT  
CB4  
ELECT.  
6B  
4
5
6
1
2
3
13  
14  
5B  
50A  
13  
12  
15  
6
23  
25  
50MV=400AMPS  
6E  
3
CAP.  
IGBT  
DRIVER  
PCB2  
11  
5C  
5
14  
16  
5
5E  
SILVER  
6D  
5
5D  
5D  
6A  
P16  
J16  
6G  
- +  
6A  
5C  
5B  
5E  
1
Y
2
Y
7
8
3
R
4
R
P14  
J14  
BYPASS PCB  
21B  
22A  
22  
21  
1
BR BR BK BK  
5C  
CONTROL  
TRANSFORMER  
21A  
4
2
3
TWISTED  
PAIR  
TWISTED  
PAIR  
POWER MODULE  
6A  
WORK  
RED  
200B  
BROWN  
YELLOW  
5M  
11 42VAC  
POWER  
30VAC  
CONTROL  
3
201  
200A  
BRUSH  
15  
200D  
12 13 30VAC 14  
CONTROL  
16  
PCB  
6G  
BRUSH  
200E  
200C  
+
-
21B  
200A  
200E  
16  
201B  
200C  
201A  
15  
14  
13  
12  
120VAC  
PRIMARY  
HOT(BLACK)  
(BLACK)  
6D  
200D  
201B  
NEUTRAL  
ROTOR  
5H  
6D  
5P  
3
201A  
6H  
POSITIVE BRUSH CONNECTED  
TO SLIP RING NEAREST  
TO THE LAMINATION  
200  
11  
10  
9
200B  
226A  
237A  
224  
262  
234  
228  
6A  
5P  
226  
201  
6H  
237  
67A  
CONTROL HARNESS  
224A  
8
SWITCH SHOWN IN  
POSITIVE POLARITY  
POSITION  
31  
31  
42  
262A  
234A  
228A  
7
6
5
32  
32  
+
42  
POLARITY  
SWITCH  
4
233A  
241A  
233  
241  
281  
239  
21C  
5G  
41  
41  
3
2
281A  
239A  
-
1
2C  
2B  
4B  
IDLER  
WELDING CONTROL  
P30  
J30  
CONTROL  
SOURCE SWITCH  
HOUR  
METER  
4C  
SHOWN IN  
SHOWN IN  
31  
32  
4E  
J
"HIGH" POSITION  
"ALWAYS ON" POSITION  
115VAC  
VIEWED  
75B  
75A  
A
D
C
H
E
F
G
I
K
B
OUTPUT  
FROM  
BACK  
77C  
248  
76C  
256  
HIGH  
CONTROL  
CCW  
RF BYPASS PCB  
CONTACTOR  
WORK  
PINCH POT  
REMOTE  
77  
ALWAYS ON  
2E  
-
R1  
226A  
237A  
76C  
21C  
50K  
S6  
REMOTELY  
AUTO  
75B  
CONTROLLED  
HOLD  
COIL  
77E  
76E  
75E  
41  
VIEWED  
FROM  
BACK  
77B  
76  
2C  
REMOTE  
CONTROL  
LOCAL  
SOL.  
75  
263  
264  
IDLE  
278A  
76B  
J61  
255  
5K  
4C  
277  
278  
77C  
77B  
SWITCH SHOWN IN  
"LOCAL" POSITION  
OPTIONAL  
42VAC  
32  
76B  
HOLD  
COIL  
SHUT  
DOWN  
WITH  
42  
SOL.  
K1597-1 KIT  
TOROID  
START BUTTON  
242H  
+
GROUND  
-
76E  
75E  
CONTROL HARNESS  
224  
262  
AMPHENOL  
1
77E  
2E  
236C  
J62  
J60  
232B  
232C  
229B  
238  
236A  
236B  
267  
OIL PRESSURE SWITCH  
&
SENSOR  
5G  
BATT.  
OIL  
OIL  
TEMP  
5H  
242D  
5J  
5K  
5N  
4E  
RUN/STOP  
228  
241  
CHRG.  
234  
PRESS.  
231A  
SENSOR  
FUEL  
RUN  
SWITCH  
SWITCH  
12VDC  
INSULATED  
STUD  
242B  
SHOWN IN  
"RUN" POS.  
G
WK  
TOROID  
228A 229A  
S
I
S
I
S
I
STOP  
243  
245  
LOW  
77D  
76D  
75D  
2D  
247  
246  
GOLD  
A
B
C
D
E
F
5L  
REMOTE  
241A  
229  
OIL TEMP. SENSOR  
&
SWITCH  
5
GOLD  
GOLD  
GOLD  
232A  
CONTROL  
76D  
75D  
232H  
P18  
J18  
232D  
232J  
233  
77D  
2D  
SENSOR  
242A  
LOW  
PRESS.  
1
2
3
4
242C  
TEMP.  
SWITCH  
ALT.  
FUEL  
5N  
242B  
229C  
CONTACTOR  
GROUND  
4D  
GND. STUD ON  
229  
232K  
FUEL LVL.  
SENSOR  
232D  
4D  
SILVER  
232E  
SILVER  
232F  
SILVER  
232G  
SILVER  
232I  
232G  
232F  
232E  
BOTTOM RIGHT OF  
CONTROL BOX  
228B  
241B  
232K  
229B  
232A  
228B  
241B  
229B  
242D  
242I  
242I  
229C  
242H  
AMPHENOL  
2
236B  
TWISTED  
PAIR  
32  
232  
WELD STUD ON  
OUTPUT PANEL  
236C  
236C  
J15  
P15  
238  
229  
68A  
69A  
231A  
4
3
232  
5R  
TOROID  
STARTER  
238  
SOLENOID  
69  
TOROID  
68  
12  
STARTING  
MOTOR  
(+)  
(-)  
TWISTED  
PAIR  
12V BATTERY  
5N  
90  
3
103A  
101A 104A  
105A  
102A  
69  
107A  
232  
W
D-  
D+  
277  
75  
217  
22  
222  
77  
67  
68  
STUD ON ENGINE  
MOUNTING FOOT  
239  
216  
215  
213  
219  
90  
91  
106A  
5L  
91  
220  
23A  
11  
25  
21  
B+  
1
6
218  
1
4
23  
214  
25A  
278  
76  
8
1
GROUNDING BOLT  
ON ENGINE BLOCK  
ALTERNATOR  
1
5
1
3
8
1
5
1
4
8
281  
238  
239  
32  
242I  
242H  
5M  
5
5
1
1
FRAME  
J8  
J9  
7
12  
6
9
16  
J5  
J6  
4
6
DISPLAY PCB  
5F ENGINE GROUND  
8-14-98A  
9
6
J7  
5R  
16  
10  
GND STUD ON RIGHT SIDE  
BACK OF CONTROL BOX  
J3  
J2  
J1  
J4  
ENGINE PROTECTION PCB  
CONTROL PCB  
5F  
L10681  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
COMMANDER 300  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-3  
G-3  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - COMMANDER 300 STANDARD MODEL  
6A  
6A  
3
3
3
CORRESPONDING SETTINGS FOR TAP NUMBERS  
(AS VIEWED FROM THE FRONT)  
67  
STATOR AUXILIARY WINDINGS  
6A  
W2  
GND-E  
AUXILIARY HOT  
W2  
W3  
W3  
6E  
IN CONTROL BOX  
3
150A  
AUXILIARY POWER  
6D  
6
6
90A  
230A  
5A  
5
7
J12  
"INSULATED STUD"  
GND. SCREW ON  
CONTROL PANEL  
SELECTOR SWITCH  
6C  
67  
60A  
4
5
6
1
2
3
300A  
15  
16  
4
3
8
(VIEWED FROM REAR)  
S5  
5A  
23A  
25A  
CAP.  
STATOR  
W2  
IGBT  
W3  
GND-D  
5
CV MIG/MAG  
30A-375A  
LOW HYDROGEN  
WELD  
3
DRIVER  
9
217  
6
5
216  
30A-375A  
GND-B  
WINDINGS  
PCB1  
W4  
W4  
W5  
W1  
W1  
218  
7
4
215  
6A  
LEAD 203 TO  
PASS THRU TOROID  
ONE TIME  
CB1  
EMPTY  
EMPTY  
15A  
A
CB5  
219  
220  
8
3
214  
213  
3B  
3
W6  
W6  
W3  
W2  
42VAC KIT  
15A  
68A  
261  
W5  
EMPTY  
LEFT  
EMPTY  
2
8
9
260  
EMPTY  
OPTIONAL  
HEAT SINK  
31  
QUICK CONNECT  
TERMINAL  
222  
RED  
3A  
3
CB3  
204  
42B  
6
+
50A  
HOT (GOLD)  
J11  
115  
WHITE  
GND-C  
CHOKE  
42  
VAC  
GND-B  
R2  
W6  
W6  
6A  
3C  
VAC  
AUXILIARY  
L1  
3C  
115/230V  
GND-D  
6C  
CB6  
10A  
W1  
6E  
NEUTRAL STUD  
3
205  
W1  
42  
BACK OF CONTROL  
BOX "LEFT SIDE"  
WHITE  
41A  
CB2  
SILVER  
RIGHT  
203  
GND-C  
6A  
3
4
1
15A  
RED  
RECTIFIER BRIDGE  
SHUNT  
HEAT SINK  
69A  
6A  
5M  
GND-E  
HOT (GOLD)  
J12  
BLACK  
BLACK  
BLACK  
BLACK  
67  
9
5E  
LEADS  
3
&
6A  
41  
6G  
J13  
PASS THROUGH  
TOROID TWICE  
IN OPPOSITE  
DIRECTIONS  
67A  
5G  
CB4  
ELECT.  
6B  
4
5
6
1
2
3
13  
14  
5B  
50A  
13  
12  
15  
6
23  
25  
50MV=400AMPS  
6E  
3
5D  
5E  
CAP.  
IGBT  
DRIVER  
PCB2  
11  
5C  
5
14  
16  
5
SILVER  
6D  
5
5D  
6A  
P16  
J16  
6G  
21B  
- +  
6A  
5C  
5B  
5E  
1
Y
2
Y
7
8
3
R
4
R
J14  
P14  
BYPASS PCB  
22A  
21A  
22  
21  
1
BR BR BK BK  
5C  
CONTROL  
TRANSFORMER  
4
2
3
TWISTED  
PAIR  
TWISTED  
PAIR  
POWER MODULE  
6A  
WORK  
RED  
200B  
BROWN  
YELLOW  
5M  
11 42VAC  
POWER  
30VAC  
CONTROL  
3
201  
200A  
BRUSH  
15  
200D  
+
12 13 30VAC 14  
CONTROL  
16  
PCB  
6G  
BRUSH  
200E  
200C  
21B  
200A  
200E  
201B  
200C  
16  
201A  
15  
14  
13  
12  
120VAC  
PRIMARY  
HOT(BLACK)  
(BLACK)  
6D  
200D  
201B  
NEUTRAL  
ROTOR  
-
5H  
6D  
5P  
3
201A  
6H  
POSITIVE BRUSH CONNECTED  
TO SLIP RING NEAREST  
TO THE LAMINATION  
200  
11  
10  
9
200B  
226A  
237A  
224  
262  
234  
228  
6A  
5P  
226  
201  
6H  
237  
67A  
CONTROL HARNESS  
224A  
8
31  
31  
42  
SWITCH SHOWN IN  
262A  
234A  
228A  
7
6
5
32  
POSITIVE POLARITY  
32  
+
POSITION  
42  
POLARITY  
SWITCH  
4
233A  
241A  
233  
241  
281  
239  
21C  
5G  
41  
41  
3
2
281A  
239A  
-
1
2C  
2B  
4B  
IDLER  
WELDING CONTROL  
J30  
P30  
CONTROL  
SOURCE SWITCH  
HOUR  
METER  
4C  
SHOWN IN  
SHOWN IN  
31  
32  
4E  
J
"HIGH" POSITION  
"ALWAYS ON" POSITION  
115VAC  
VIEWED  
75B  
A
D
C
H
E
OUTPUT  
FROM  
BACK  
77C  
248  
76C  
256  
HIGH  
CONTROL  
CCW  
RF BYPASS PCB  
CONTACTOR  
WORK  
PINCH POT  
ALWAYS ON  
2E  
REMOTE  
-
R1  
226A  
237A  
SOL.  
76C  
21C  
75A  
50K  
77  
S6  
REMOTELY  
AUTO  
75B  
CONTROLLED  
HOLD  
COIL  
77E  
76E  
75E  
41  
VIEWED  
FROM  
BACK  
77B  
76  
2C  
REMOTE  
CONTROL  
LOCAL  
75  
263  
264  
IDLE  
278A  
76B  
J61  
F
G
I
K
B
255  
5K  
4C  
277  
278  
77C  
77B  
SWITCH SHOWN IN  
"LOCAL" POSITION  
OPTIONAL  
32  
76B  
HOLD  
COIL  
42VAC  
SHUT  
DOWN  
262  
WITH  
42  
SOL.  
K1597-1 KIT  
TOROID  
START BUTTON  
242H  
+
GROUND  
-
76E  
75E  
CONTROL HARNESS  
224  
AMPHENOL  
1
77E  
2E  
236C  
J62  
J60  
232B  
OIL  
238  
236A  
236B  
267  
LEADS 238  
&
236C TO  
OIL PRESSURE SWITCH  
&
SENSOR  
BE BOLTED TOGETHER AND  
TAPED WHEN K1596-1  
NOT INSTALLED  
5G  
BATT.  
OIL  
PRESS.  
5H  
5K  
5N  
4E  
RUN/STOP  
OPTIONAL  
GAUGE  
PACK  
228  
241  
CHRG.  
234  
231A  
SENSOR  
TEMP  
RUN  
SWITCH  
SWITCH  
242B  
SHOWN IN  
"RUN" POS.  
G
WK  
TOROID  
228A  
241A  
S
I
S
I
STOP  
243  
245  
77D  
76D  
75D  
2D  
247  
246  
GOLD  
A
B
C
D
E
F
5L  
5J  
REMOTE  
OIL TEMP. SENSOR  
&
SWITCH  
NOT  
5
GOLD  
GOLD  
232A  
CONTROL  
76D  
75D  
USED  
232H  
P18  
J18  
12VDC  
INSULATED  
STUD  
232D  
232J  
233  
77D  
2D  
SENSOR  
LOW  
PRESS.  
1
2
3
4
242C  
TEMP.  
SWITCH  
ALT.  
5N  
GND. STUD ON  
BOTTOM RIGHT OF  
CONTROL BOX  
242B  
CONTACTOR  
GROUND  
4D  
232K  
232D  
4D  
SILVER  
232E  
SILVER  
232F  
SILVER  
232G  
232G  
228B  
241B  
232K  
232A  
228B  
241B  
242I  
242H  
242I  
232F  
232E  
AMPHENOL  
2
236B  
TWISTED  
PAIR  
32  
232  
J15  
P15  
236C  
236C  
238  
WELD STUD ON  
OUTPUT PANEL  
68A  
69A  
231A  
4
3
232  
TOROID  
5R  
STARTER  
69  
238  
SOLENOID  
TOROID  
68  
STARTING  
MOTOR  
TWISTED  
PAIR  
(+)  
(-)  
5N  
12V BATTERY  
90  
3
103A  
101A 104A  
105A  
102A  
D-  
D+  
12  
69  
107A  
232  
W
277  
75  
217  
22  
222  
77  
67  
68  
STUD ON ENGINE  
MOUNTING FOOT  
239  
216  
215  
213  
219  
90  
3
91  
106A  
5L  
91  
220  
23A  
11  
25  
21  
B+  
1
6
218  
1
4
23  
214  
25A  
278  
76  
8
1
9
GROUNDING BOLT  
ON ENGINE BLOCK  
ALTERNATOR  
1
5
1
4
8
1
5
1
4
8
281  
238  
239  
32  
242I  
242H  
5M  
5
5
1
1
FRAME  
J8  
J9  
7
12  
6
16  
J5  
J6  
6
OPTIONAL DISPLAY PCB  
5F ENGINE GROUND  
8-14-98A  
9
6
J7  
16  
5R  
10  
GND STUD ON RIGHT SIDE  
J3  
J2  
J1  
J4  
BACK OF CONTROL BOX  
5F  
ENGINE PROTECTION PCB  
CONTROL PCB  
L10682  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
COMMANDER 300  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-4  
G-4  
ELECTRICAL DIAGRAMS  
SCHEMATIC - CONTROL PC BOARD  
+12V  
+12V  
+12V  
P5  
-D  
P4  
-A  
11  
1
P3  
-B  
P2  
-C  
P1  
-D  
CURRENT TAIL OUT  
10  
4
3
8
9
11  
A
90.9K  
43.2K  
8
X13  
X13  
-C  
-B  
X2 -C  
16.5K  
14  
14  
14  
14  
14  
4
14  
15  
4
4
14  
C26  
0.1  
50V  
CC  
9
12  
13  
9
5
6
12  
8
4
12  
13  
4
4
22.1K  
10  
2
X19  
X1  
14  
10  
6
5
X9  
X2  
X5  
X18  
X14  
X13  
X12  
X10  
X8  
X5  
R21  
475K  
C31  
C33  
2700p  
50V  
X11  
X4  
4093B  
7
54HC4066  
7
54HC4066  
54HC4066  
54HC4066  
54HC4066  
7
54HC4066  
7
MC33023  
10  
56.2K  
33074A  
11  
33074A  
11  
33074A  
11  
+12V  
90.9K  
CV  
3
LT1014  
11  
28.0K  
10.0K  
26.7K  
6.19K  
GND  
33074A  
11  
20.0K  
7
7
7
GND  
C74  
0.1  
50V  
C79  
0.1  
50V  
C78  
0.1  
50V  
C70  
C77  
0.1  
50V  
C59  
0.1  
50V  
C52  
C27  
0.1  
C28  
C29  
C96  
0.1  
0.1  
C81  
50V  
0.1  
0.1  
0.1  
C62  
CURRENT SET POINT CIRCUITRY  
R1  
50V  
50V  
0.1  
C82  
50V  
50V  
50V  
0.1  
5
R17  
D12  
100  
50V  
0.1  
100  
50V  
J3  
R75  
56  
50V  
7
22.1K  
77  
76  
8
R8  
R5  
-B  
X13  
-A  
C10  
C16  
X2  
PIPE  
DZ6  
10V  
1W  
6
+
0.1  
t
TP-A  
2
1
100  
475  
C45  
2.7  
C
GND  
50V  
C8  
0.1  
GND  
13  
R6  
50V  
50V  
D13  
475  
GND  
GND  
10  
9
GND  
10K  
10K  
10K  
R79  
10.0K  
SET PT. BUFFER  
8
J3  
8
10  
9
setpoint  
ERROR AMP  
16  
12  
13  
R2  
R3  
R225  
X5  
5
6
14  
C7  
1.8  
TP-C  
X9 -C  
Vref  
-Vss  
DZ8  
8.2V  
1W  
R7  
R9  
C41  
0.1  
56.2K  
C100  
1.0  
X9 -D  
POW_+12  
4
681K  
TP-H  
X19 -A  
PWM  
10K  
C9  
20V  
10K  
50V  
35V  
TP-I  
0.1  
13  
10  
13  
R235  
200  
25A  
25  
D14  
267  
X12  
-C  
R13  
50V  
GND  
CC  
J3  
1
16  
INV  
Vref  
Vcc  
X1  
TO CONTROL POT  
J3  
C11  
2
1
R88  
GND  
-D  
GND  
9
8
221K  
R198  
15  
2
3
4
5
6
7
NON INV  
COMP  
CLOCK  
Rt  
GND  
GND  
4.75K  
R74  
100  
X10  
R15  
-A  
-D  
R18  
X18  
6
+12V  
MIN CURRENT  
12  
14  
13  
12  
OUT  
PWR Vcc  
PWR Gnd  
Ilim ref  
22.1K  
22.1K  
R106  
R109  
R72  
200  
R78  
56  
11  
10  
11  
10.0K  
R110  
J3  
14  
75  
7
C54  
22.1K  
3.01K  
.47  
1
R76  
100  
R11  
100  
X10  
X2  
-C  
C15  
X12  
R108  
221K  
12  
50V  
13  
+
0.1  
12.1K  
1.0  
t
TO DRIVER BOARD  
DZ3  
10V  
5W  
R105  
R19  
4.75K  
1
2
2
R143  
221K  
50V  
C50  
35V  
AVE. CURRENT BUFFER  
10.0K  
11  
Ct  
Q2  
1A  
100V  
23  
12  
10.0K  
R221  
8.25K  
12  
C46  
4.75K  
22.1K  
R73  
200  
2
3
X12  
CV  
3
-B  
13  
J3  
10  
5
6
R12  
475  
GND  
2.7  
C39  
820p  
50V  
RAMP  
-A  
X9  
4
1
50V  
10  
0.1  
GND  
7
2
1
8
9
Ilim  
C12  
.018  
50V  
SOFT START  
MC33023  
TP-B  
GND  
R137  
C95  
50V  
C73  
X9 -B  
3
11  
5
GND  
X19 -B  
R233  
J3  
23A  
DZ4  
18  
200  
15V  
GND  
15V  
1W  
0.1  
STARTING  
ENHANCEMENT  
C14  
R165  
100K  
1.00K  
B
50V  
1.0  
GND  
GND  
C48  
C13  
35V  
GND  
-A  
X12  
GND  
PIPE  
267K  
R132  
GND  
GND  
GND  
GND  
2
1
+12V  
X10  
X18  
-B  
13  
P5  
-B  
+12V  
R87  
475  
4
3
4
3
R166  
221K  
R220  
221K  
+12V  
0.1  
POW_gnd  
POW_gnd  
1.50K  
4.75K  
5
5
50V  
DZ13  
10V  
1W  
C104  
3.32K  
+12V  
R140  
C76  
0.1  
ABSOLUTE CURRENT  
LIMIT 550A  
R177  
GND  
68.1K  
221K  
GND  
R130  
R176  
50V  
3.92K  
X10  
R174  
R173  
52.3K  
P4  
-A  
-D  
4.75K  
GND  
IMBALANCE DETECTOR  
8
9
3
20.0K  
C98  
GND  
TP-M  
GND  
1N4936  
61.9K  
3
2
69  
1
2
10  
9
3
R256  
4.75K  
R167  
100K  
2.00K  
C84  
6
-A  
1.00K  
X2  
GND  
J3  
24.3K  
SCR1  
1
R131  
C51  
2
0.1  
8
D38  
X11 -A  
800mA  
200V  
56.2K  
0.1  
50V  
GND  
GND  
+12V  
X11 -C  
221K  
P3  
X8  
50V  
D69  
6
5
3
1
R128  
-B  
GND  
68  
X11  
11  
10  
3
4
R257  
4.75K  
R168  
100K  
D
7
R95  
2N4403  
Q3  
J3  
39.2K  
12  
TP-P  
100K  
C99  
.0047  
50V  
R129  
4.75K  
D59  
1N4936  
1.00K  
GND  
DZ11  
10V  
1W  
221K  
GND  
12  
R175  
10.0K  
R243  
R172  
100K  
C93  
0.1  
TP-D  
R102  
R103  
X8  
-C  
TAIL OUT MAGNITUDE  
100K  
P2  
8
DZ9  
12V  
1W  
14  
10.0K  
33.2K  
20.0K  
7.68K  
R258  
15.0K  
-D  
R126  
4.75K  
20.0K  
X11  
50V  
9
13  
R259  
10.0K  
4.75K  
26.7K  
R250  
1.00K  
2.43K  
Q5  
R144  
6
DZ10  
10V  
1W  
2N4401  
C55  
1.8  
20V  
20.0K  
R127  
221K  
D60  
1N4936  
28.0K  
100K  
Q4  
GND  
C103  
OUTPUT VOLTAGE  
FEEDBACK  
2N4401  
X8  
VOLTAGE FEEDBACK BUFFER  
GND  
-B  
0.1  
P1  
9
8
11  
GND  
R141  
GND  
50V  
4
1
3
2
J3  
67  
6
2
20.0K  
R29  
100K  
+12V  
8
12  
+12V  
5
-D  
GND  
X19  
-C  
D62  
1N4007  
X19  
61.9K  
10  
11  
R125  
221K  
12  
1N4936  
D9  
9
13  
GND  
X8  
D48  
-A  
GND  
90  
6
R187  
10  
R26  
2.43K  
J1  
475  
47.5K  
AVE. CURRENT LIMIT  
CV  
GND  
68.1K  
13  
D49  
400A  
OCI1  
CNY17-3  
5
1
C102  
2.7  
50V  
5
6
3
R181  
Q6  
R180  
100K  
7
1
277  
5
J3  
47.5K  
1.00K  
100K  
X5  
X5  
D50  
TP-E  
2
4
6
2
50K  
C4  
1.8  
20V  
PINCH/ARC FORCE POT  
C105  
0.1  
100K  
2N4401  
D51  
GND  
J3  
R184  
3
R185  
33.2K  
R196  
475  
100K  
91  
14  
J1  
50V  
D57  
278  
1.00K  
267K  
R69  
GND  
10.0K  
D52  
C30  
0.1  
GND  
R94  
GND  
31.6K  
GND  
1.00K  
R227  
50V  
2
3
CURRENT  
J2  
1
101  
GND  
GND  
CC  
10K  
X4  
-A  
GND  
1
R40  
1.00K  
D56  
C44  
820p  
50V  
10  
6
R139  
475  
CURRENT AMP  
5
220  
215  
J4  
GND  
J3  
15  
21  
D70  
R36  
PIPE  
5
PIPE  
5
R142  
475  
10.0  
10.0  
10.0  
10.0  
1.30K  
+
TP-F  
J4  
J4  
7
C2  
0.27  
50V  
X4  
SHUNT INPUT  
50mv=400AMPS  
-B  
PIPE4  
PIPE4  
6
2
R118  
10K  
R68  
475  
Vref  
TP-G  
216  
10  
9
D46  
D41  
-
J3  
8
TP-N  
6
R37  
R38  
R39  
R41  
X4  
R179  
22  
-C  
PIPE3  
PIPE2  
PIPE3  
PIPE2  
13  
12  
5
7
8
R67  
475  
1N4936  
D61  
1.30K  
102K  
221K  
1.00K  
2.43K  
X4  
-D  
217  
218  
219  
J4  
J4  
J4  
14  
C32  
2700p  
50V  
D66  
GND  
C36  
1.0  
35V  
+12V  
R66  
475  
D67  
R47  
475  
SENSE CURRENT  
GND  
PIPE  
1
PIPE  
1
R42  
R44  
R65  
475  
GND  
GND  
20.0K  
22.1K  
A
B
C
D
CV MIG  
C37  
9
4
R64  
475  
162  
214  
213  
J4  
D54  
D55  
20.0K  
CV INN  
R63  
475  
1.00K  
GND  
CC  
J4  
C67  
0.1  
50V  
C63  
0.1  
50V  
C65  
0.1  
50V  
C72  
0.1  
50V  
1.00K  
+15V  
GND  
1
+12V  
C66  
0.1  
50V  
C68  
0.1  
50V  
222  
J4  
1.00K  
C64  
0.1  
50V  
C80  
1.00K  
0.1  
50V  
77  
J2  
J2  
102  
7
8
1.00K  
D39  
75  
103  
110  
GND  
2
R241  
1.00K  
J1  
C53  
0.1  
D68  
76  
J2  
J2  
104  
105  
Vin  
R200  
56  
6
5
50V  
D30  
+12V  
POW_+12  
+
t
t
GND  
VOLTAGE  
R77  
56  
Q1  
+12V  
TP-K  
1
3
LAST NO. USED  
GENERAL INFORMATION  
4.75K  
+
R205  
R206  
R207  
R208  
R- 260  
C- 105  
D- 70  
Q-  
6
SCR-  
1
D1  
D2  
D4  
ELECTRICAL SYMBOLS PER E1537  
109  
J2  
J2  
4.75K  
4.75K  
4.75K  
X- 19  
OCI-  
1
C1  
150  
15V  
106  
107  
2
CAPACITORS  
RESISTORS  
DIODES  
=
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
3
2
4
DZ- 13  
J1  
J3  
LABELS  
SUPPLY  
=
Ohms  
(
1
12  
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
C42  
VOLTAGE NET  
0.1  
10K  
108  
+
1
C25  
1200  
100V  
J2=8 PINS  
J3=16 PINS  
J4=10 PINS  
J3  
1
50V  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
9
11  
J1  
X7  
8
REF  
TL431  
D3  
DZ1  
15V  
5W  
FRAME CONNECTION  
6
-
FILENAME: G3001_1B1  
EARTH GROUND CONNECTION  
R20  
TP-L  
GND  
2.61K  
+12V SUPPLY  
TP-J  
NOTES  
:
GND  
-Vss  
DZ12  
FOR CONTROL CIRCUIT  
5.1V  
1W  
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
8-14-98A  
POW_gnd  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY  
A
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING  
NUMBER.  
A
COMMON CODE  
G 3001  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 300  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-5  
G-5  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - CONTROL BOARD  
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not  
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may  
result in danger to the Machine Operator or Technician. Improper PC Board repairs could result in damage to the machine.  
COMMANDER 300  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-6  
G-6  
ELECTRICAL DIAGRAMS  
SCHEMATIC - ENGINE PROTECTION PC BOARD  
+12V  
+
HOUR METER  
263  
3
J6  
224A  
262A  
4
J6  
D57  
D20  
R132  
1N5402  
SHUT  
DOWN  
SOLENOID  
200  
1.0A  
30V  
D30  
D33  
D31  
D35  
11  
9
C38  
0.1  
R100  
200  
J6  
J6  
D32  
D29  
D55  
D56  
2.21K  
+10V CRANK  
50V  
+10V  
264  
HOUR METER  
Q11  
R102  
200  
R101  
AUX CURRENT SENSING  
J7  
2N4401  
-
SHUTDOWN  
1.00K  
SOLENOID DRIVE  
9
260  
R103  
200  
C40  
100  
1.0  
J7  
35V  
10  
261  
R104  
200  
COM  
10.0K  
Q5  
C39  
0.1  
50V  
+10V  
R106  
200  
2N4401  
2.21K  
D
Q10  
+10V  
100  
R56  
COM  
15A  
60V  
G
R107  
200  
S
D58  
WITH HEATSINK  
R108  
200  
DZ5  
15V  
1W  
1.0A  
30V  
R123  
133K  
10.0K  
47.5K  
Q6  
2N4403  
CTL +12V  
7
6
CTL +12V  
D24  
4
5
1
COM  
X1  
X1  
-B  
-A  
2
J6  
J5  
R62  
10.0  
5
LM2901  
D22  
LM2901  
+5V  
109  
108  
4
C28  
18  
15V  
10.0K  
7.68K  
5W  
.5  
C42  
50  
C26  
0.1  
50V  
C30  
22.1K  
2.43K  
10.0K  
COM  
50V  
J5  
J6  
1
1
5
OCI1  
CNY17-3  
1N4007  
D12  
COM  
Q12  
6
2N4401  
2
6
4
CTL COM  
J5  
2N4401  
Q1  
110  
+10V  
+10V  
2
R27  
681K  
CURRENT SENSE  
+10V  
+12V  
10.0K  
R28  
FROM CONTROL BD  
+10V  
1.00K  
C37  
D14  
7.68K  
R127  
IDLE  
+10V  
.0047  
226  
10  
SOLENOID  
D11  
1N4007  
1400V  
C25  
10.0K  
10.0K  
J6  
IDLE  
SOLENOID DRIVE  
0.1  
COM  
7.68K  
R129  
1N4007  
D53  
50V  
D17  
20.0K  
6
7
100  
X10  
1N4007  
D13  
43.2K  
R128  
CTL COM  
7.68K  
R130  
D41  
1
J7  
239A  
12  
7
D46  
J6  
237  
COM  
TO ENGINE ALT  
TACH SIGNAL POST  
+10V  
2.00K  
D
S
Q13  
2
3
C48  
256  
J7  
C47  
C43  
C46  
2N4401  
DZ6  
15V  
1W  
Q8  
15  
.0047  
IDLER SWITCH  
+10V  
100  
4.7  
35V  
100K  
1400V  
15A  
60V  
D36  
1N4007  
+10V  
1
R95  
15.0K  
G
20.0K  
D52  
1N4007  
C54  
J6  
R149  
DZ8  
15V  
1W  
.0047  
1400V  
D9  
R31  
10.0K  
8
2B  
4B  
COM  
1
R151  
+10V  
1N4007  
47.5K  
Q14  
133K  
+
t
+10V  
270  
5W  
TO CONTROL BOARD  
2N4403  
56  
+10V  
11  
2-4 OPTO INTERFACE  
90  
357  
R25  
D16  
6
13  
COM  
X1  
X1  
-C  
-D  
COM  
2N4401  
Q18  
J5  
14  
10  
J6  
D47  
R150  
R92  
10.0  
D54  
9
D10  
2
R152  
R159  
2.00K  
10.0K  
20.0K  
D27  
R29  
LM2901  
+
t
D38  
D43  
D44  
D45  
270  
5W  
LM2901  
OIL PRESSURE  
OIL TEMP.  
FUEL  
1
R30  
100  
1N4007  
56  
DZ12  
5.1V  
C27  
18  
15V  
DZ11  
10V  
5W  
C53  
0.1  
50V  
C49  
5W  
.5  
3
+
1N4007  
D15  
6.19K  
22.1K  
t
X11  
X11  
X11  
91  
2
10.0K  
56  
1W  
3
C22  
D7  
1N4007  
J5  
0.1  
F
8
9
50V  
COM  
6
5
X12  
14  
4
+5V  
+10V  
COM  
COM  
+10V  
COM  
+12V  
C51  
COM  
IDLER  
12 SEC. TIMER  
+10V  
D34  
J7  
9
8
.047  
100V  
6
248  
16  
10  
11  
1
SET  
Vdd  
MONO IN  
1N4007  
4.75K  
10.0K  
2
3
4
5
6
7
15  
14  
13  
12  
11  
TO WELDING TERMINAL  
CONTROL SWITCH  
RESET  
4.75K  
R69  
33.2K  
R145  
+10V  
J7  
+10V  
IN  
1
OSC INH  
+10V  
14  
R74  
X9  
229A  
ALT. VOLTS  
4
5
13  
12  
4.7  
35V  
4.75K  
4.75K  
OUT  
OUT  
1
2
C33  
DECODE  
D26  
1.00K  
X10  
2
X11  
200  
R47  
D
R144  
Q9  
TO SENDER INPUT  
POST ON FUEL  
GAUGE  
10.0K  
4
1
8A  
C31  
.0047  
1400V  
8
BY-PASS  
C
B
4093B  
13.7K  
10.0K  
C35  
150V  
10.0K  
233A  
J7  
TO OIL TEMP.  
10  
R76  
10.0K  
D8  
CLOCK INH  
Vss  
5K  
Q2  
500mA  
300V  
8
1N5406  
68.1K  
9
C34  
A
200  
12  
13  
R22  
X12  
4.75K  
8
9
2
R98  
SWITCH  
4536B  
CW  
J6  
1.00K  
X10  
D25  
14  
5
2.7  
5W  
R68  
C23  
COM  
S15018-13  
COM  
TO ROTOR  
COM  
3.32K  
0.1  
50V  
C36  
C41  
.0047  
1400V  
COM  
10.0K  
C24  
D28  
281A  
J7  
7
R93  
10.0K  
COM  
50  
5W  
COM  
COM  
ENGINE ALT FLASHING  
+10V  
COM  
12.1K  
R89  
12.1K  
12.1K  
22.1K  
LAMP FAULT LATCH  
50  
5W  
COM  
+10V  
+10V  
2
3
4
5
6
7
8
9
19  
18  
17  
16  
15  
14  
13  
12  
1
D0  
D1  
Q0  
Q1  
+12V  
+10V  
74HC573  
X4  
3
X7  
X7  
X7  
X7  
33.2K  
R75  
R139  
10.0K  
LAMP DRIVER  
X6  
2
68.1K  
D2  
D3  
Q2  
Q3  
Q4  
Q5  
Q6  
Q7  
1
16  
15  
14  
13  
12  
11  
47.5K  
I0  
I1  
O0  
4
5
10.0K  
10.0K  
6
8
11  
2
3
4
5
6
7
8
267  
267  
267  
267  
267  
267  
267  
267  
10.0K  
O1  
O2  
3
1
R143  
R44  
R91  
OIL PRES LAMP  
OIL TEMP LAMP  
FUEL LVL LAMP  
ALT VOLTS LAMP  
247  
D4  
D5  
D6  
D7  
C32  
10.0K  
10  
D2  
234A  
TO OIL PRESS.  
SWITCH  
+10V  
LOW FUEL 30 MIN. TIMER  
J7  
J7  
J7  
J7  
I2  
I3  
I4  
I5  
I6  
J7  
10  
11  
10.0K  
R42  
R43  
R41  
R96  
R88  
R90  
11  
R5  
X12  
16  
O3  
20.0K  
13  
1
9
15 SEC. TIMER  
SET  
SET  
Vdd  
246  
+10V  
1.00K  
X10  
C15  
O4  
13  
2
3
4
5
6
7
15  
14  
13  
12  
11  
R140  
10.0K  
C12  
RESET  
MONO IN  
10  
0.1  
10.0K  
10.0K  
16  
33.2K  
R17  
1
.0047  
1400V  
COM  
10.0K  
O5  
11  
Vdd  
MONO IN  
50V  
IN  
1
OSC INH  
DECODE  
DZ1  
6.2V  
DZ2  
20V  
1W  
X8  
2
3
4
5
6
15  
14  
13  
12  
11  
10  
2
4
245  
RESET  
O6  
12  
13  
221K  
OUT  
OUT  
1
2
18.2K  
11  
1
LE  
COM  
9
C20  
IN  
1
OSC INH  
GND  
CLAMP  
1W  
DZ4  
20V  
1W  
C21  
X5  
R78  
D
OE  
R70  
0.1  
MC1413BP  
10.0K  
OUT  
OUT  
1
2
DECODE  
A
10.0K  
C16  
50V  
243  
8
BY-PASS  
C
B
1
s17900-24  
74HC132  
D
10  
9
CLOCK INH  
Vss  
DZ7  
20V  
DZ3  
20V  
1W  
8
BY-PASS  
C
B
8
C52  
10.0K  
A
COM  
+10V  
1W  
7
8
10  
10.0K  
CLOCK INH  
Vss  
4536B  
COM  
R16  
COM  
+10V  
9
+10V CRANK  
B
A
COM  
10.0K  
10.0K  
COM  
S15018-13  
4536B  
COM  
D5  
S15018-13  
COM  
COM  
R12  
10  
100K  
10.0K  
1
COM  
D1  
S15128-11  
C18  
500  
50V  
5W  
12.1K  
6
COM  
X12  
+5V  
1
+5V  
+10V  
7
+12V  
D4  
COM  
C7  
GENERAL INFORMATION  
LAST NO. USED  
+10V  
E
5
SEC. TIMER FOR LAMP TEST  
C4  
31.6K  
R- 162  
C- 54  
D- 58  
Q-  
18  
RUN STOP SWITCH  
STOP  
3
20  
14  
R10  
68.1  
ELECTRICAL SYMBOLS PER E1537  
16  
16  
16  
14  
3
3
X-  
12  
C13  
C2  
C1  
C10  
C9  
C8  
C11  
C6  
0.1  
50V  
C3  
39  
20V  
CAPACITORS  
RESISTORS  
DIODES  
=
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
DZ- 12  
D3  
C
R13  
LABELS  
SUPPLY  
=
Ohms  
(
X7  
OCI-  
1
232D  
D
J6  
X11  
X3  
X1  
X4  
+12V BATT  
8
R11  
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
X5  
X8  
X9  
X10  
X12  
VOLTAGE NET  
IN  
OUT  
RUN  
74HC132  
+
t
56  
15A  
600V  
D6  
1N4007  
68.1  
LM2901  
12  
74HC573  
4093B  
7
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
LM2901  
LM2901  
12  
COM  
10.0K  
C14  
100  
15V  
4536B  
8
4536B  
8
4536B  
8
GND  
R147  
68.1  
1
10  
7
12  
C17  
100  
15V  
FRAME CONNECTION  
8
X2  
C19  
TP1  
18V  
100J  
HARRIS #V24ZA50  
REF  
EARTH GROUND CONNECTION  
TL431  
6
FILENAME: G3003_1CA  
.0047  
COM  
COM  
3000V  
COM  
COM  
J7  
NOTES  
:
R4  
3.32K  
5
5J  
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
COMPLETE BOARD, THIS DIAGRAM MAY  
1-29-99H  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF  
A
COM  
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING  
NUMBER.  
A
COMMON CODE  
G 3003  
COM  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 300  
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G-7  
G-7  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - ENGINE PROTECTION BOARD  
ITEM  
REQ'D  
21  
PART NO.  
S16668-5  
IDENTIFICATION  
C1,C2,C3,C7,C8,C9,C10,C11  
C13,C16,C21,C24,C30,C32  
.022/50  
CAPACITORS = MFD/VOLTS  
RESISTORS = OHMS  
C34,C35,C36,C43,C48,C49  
C52  
C4  
1
S13490-104  
S16668-11  
39uF/20V  
.1/50  
C6,C15,C20,C22,C23,C25,C26  
C38,C39,C53  
10  
C12,C31,C37,C41,C47,C54  
6
2
T11577-52  
S13490-15  
.0047 or .005/1400  
C14,C17  
100 /16  
500 /50  
.0047/3000V  
18 /15  
C18  
1
1
2
2
1
1
1
T11577-49  
T11577-58  
S13490-39  
S13490-25  
S13490-42  
S13490-72  
S13490-102  
C19  
.25  
C27,C28  
C33,C46  
C40  
4.7/35  
1.0/35  
50 /50  
C42  
C51  
.047/100  
D1,D2,D4,D5,D8,D10,D16,D17  
D22,D24,D26,D27,D28,D29  
D30,D31,D32,D33,D35,D38  
D41,D43,D44,D45,D46,D54  
D55,D56,D59  
29  
T12199-1  
1N4004  
.04  
6.00  
D3  
1
T12705-32  
T12199-2  
15A/600V  
1N4007  
5.78  
D6,D7,D9,D11,D12,D13,D15  
D34,D36,D47,D52,D53  
12  
R109  
R26  
D12  
B
X3  
E
D20  
1
1
2
1
4
3
T12705-14  
T12705-29  
T12705-23  
T12702-40  
T12702-4  
DIODE  
DIODE  
1N5818  
1N4735  
1N4747  
1N4744A  
D25  
D57,D58  
DZ1  
C18  
D25  
DZ5  
C17  
R97  
DZ2,DZ3,DZ4,DZ7  
DZ5,DZ6,DZ8  
D
T12702-29  
R50  
D5  
DZ11  
DZ12  
J5  
1
1
1
1
1
T12702-33  
T12702-52  
S24016-6  
S24016-12  
S24016-16  
1N5347B  
1N4733A  
HEADER,RT-ANGLE  
HEADER,RT-ANGLE  
HEADER,RT-ANGLE  
J6  
J7  
Q10  
D22  
R40  
OCI1  
1
6
S15000-10  
T12704-68  
T12704-35  
T12704-69  
T12704-54  
T12704-49  
S18395-30  
S19400-1003  
S19400-3162  
S19400-1002  
OPTO ISOLATOR  
2N4401  
R56  
Q1,Q5,Q11,Q12,Q13,Q18  
Q2  
1
NPN TRANSISTOR  
2N4403  
Q6,Q14  
2
X2  
Q8  
1
N-CHANNEL FET (SS)  
8A. 150V. PNP TRANSISTOR  
H.S. ASBLY (SS)  
100K 1/4W  
Q9  
1
C
Q10  
1
D17  
X1  
R1,R126,R165  
3
R35  
R92  
R2  
1
31.6K 1/4W  
R3,R6,R7,R8,R9,R16,R18,R20  
35  
10K 1/4W  
C27  
R31  
R21,R23,R24,R27,R36,R37  
R48,R54,R63,R64,R72,R78  
Q8  
R95  
D1  
R1  
R79,R81,R82,R84,R86,R118  
R124,R125,R134,R137,R139  
R140,R141,R143,R146  
R4,R68  
R152  
C53  
2
5
3
1
4
3
1
3
2
1
1
5
2
4
5
1
4
8
S19400-3321  
S19400-1001  
S19400-68R1  
T14648-25  
3.32K 1/4W  
1K 1/4W  
C4  
R5,R22,R28,R74,R101  
R10,R11,R147  
R12  
R150  
D15  
R149  
D47  
R29  
DZ11  
C25  
R165  
R79  
68.1 1/4W  
C22  
10 5W  
X12  
X9  
X5  
DZ12  
R163  
D7  
R13,R29,R149,R150  
R14,R38,R122  
R15  
S18380-1  
THERMISTOR,PTC,56 OHMS  
47.5K 1/4W  
221K 1/4W  
33.2K 1/4W  
68.1K 1/4W  
357 1/4W  
R159  
D11  
D34  
D28  
S19400-4752  
S19400-2213  
S19400-3322  
S19400-6812  
S19400-3570  
S19400-6813  
S19400-1000  
S19400-1333  
S19400-2002  
S19400-4751  
S19400-6191  
S19400-7681  
S19400-2670  
R28  
R126  
C48  
R30  
D9  
D54  
R17,R75,R145  
R19,R76  
F
D13  
D36  
A
Q18  
R25  
C31  
C41  
C47  
C12  
X8  
X11  
C33  
C46  
R26  
681K 1/4W  
100 1/4W  
X10  
R30,R50,R56,R95,R115  
R31,R123  
133K 1/4W  
20K 1/4W  
R68  
R32,R83,R114,R136  
R33,R35,R69,R73,R77  
R39  
C23  
4.75K  
R71  
R80  
R81  
R22  
DZ3  
6.19K 1/4W  
7.68K 1/4W  
267 1/4W  
R40,R127,R129,R130  
R41,R42,R43,R44,R88,R90  
R91,R96  
R45,R46,R85,R163,R164  
R47,R100,R102,R103,R104  
R139  
R41  
R90  
R162  
D2  
5
9
S19400-2212  
S19400-2000  
22.1K 1/4W  
200 1/4W  
X6  
X7  
X4  
R104  
R106,R107,R108,R132  
R91  
R96  
R88  
R62,R92  
R70  
2
1
S19400-10R0  
S19400-1822  
10 1/4W  
18.2K 1/4W  
R44  
R82  
DZ7  
R78  
R71  
1
4
2
2
1
1
1
1
1
T10812-36  
S19400-1212  
T14648-22  
5K 1/2W TRIMMER  
12.1K 1/4W  
D58  
D57  
R43  
R42  
R80,R87,R138,R142  
R89,R93  
R94,R97  
R98  
50 5W  
.22  
T12300-81  
5 WATT 0.5+/-1% OHM RESISTOR  
2.7 5W  
T14648-21  
R109  
S19400-2431  
S19400-4322  
S19400-1502  
S19400-1372  
2.43K 1/4W  
0
R128  
R131  
R144  
43.2K 1/4W  
15K 1/4W  
13.7K 1/4W  
R151,R152  
R159,R160  
R161,R162  
TP1  
2
2
2
1
3
1
1
1
T14648-17  
S19400-2001  
S19400-2211  
T13640-26  
S15128-11  
S15128-10  
S15128-5  
270 5W  
2.0K 1/4W  
2.21K 1/4W  
18V/100J MOV  
.22  
X1,X10,X12  
X2  
14 PIN QUAD COMPARATOR  
IC,431,VOLTAGE REF.  
+5V REG.  
7.78  
4.00  
0
X3  
.04  
X4  
S17900-25  
IC,74HC573A,CMOS,LATCH,3-STATE (SS)  
X5,X8,X9  
X6  
3
1
1
1
S15018-13  
M15102-4  
S17900-24  
S15018-15  
16 PIN I.C. (SS)  
8.00  
IC,MC1413,ARRAY,DRIVER,PERIPHERAL(SS)  
IC,74HC132,CMOS,GATE,NAND,2-IN,ST(SS)  
14 PIN I.C. (SS)  
X7  
X11  
DESIGN INFORMATION  
REFERENCE:  
Chg. Sheet No.  
5-18-2001A  
11-16-2001L  
EQUIPMENT TYPE:  
SUBJECT:  
COMMANDER 300  
ENGINE PROTECTION P.C. BOARD ASSEMBLY  
DRAWN BY:  
SWB  
ENGINEER:  
SUPERSEDING:  
4-17-2001  
FULL  
11-1-2001  
DRAWING No.:  
APPROVED:  
SCALE:  
DATE:  
G3004-2  
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not  
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may  
result in danger to the Machine Operator or Technician. Improper PC Board repairs could result in damage to the machine.  
COMMANDER 300  
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G-8  
G-8  
ELECTRICAL DIAGRAMS  
SCHEMATIC - CHOPPER PC BOARD  
+15  
19  
562  
R3  
R10  
10.0  
C10  
0.1  
50V  
C4  
4.7  
D6  
3A /40V  
35V  
19  
16  
13  
10  
7
4
R11  
19  
com  
com  
C1 C2 C3 C4 C5 C6  
Vin  
+
Vc  
10.0  
18  
15  
12  
9
G1  
DZ1  
C3  
OUT  
GND  
R13  
10.0  
DZ4  
8.2V  
1W  
G2  
G3  
G4  
G5  
G6  
A1  
5.1V  
1W  
0.1  
FILTER  
X2  
50V  
INV IN  
N.I. IN  
R15  
10.0  
CAPACITOR  
DZ3  
16V  
1W  
M16100-24  
D7  
6
3
80VDC  
(NOMINAL)  
4.75K  
com  
R17  
10.0  
3A /40V  
E2  
E1  
E3  
E4  
E5 E6  
8 5  
20  
17  
14  
11  
R19  
10.0  
20  
20  
C7  
0.1  
50V  
10.0K  
to heatsink  
com  
2.21K  
com  
J1  
5
825  
R4  
1.00K  
to rectifier  
+15  
8
7
6
2
3
to rectifier  
and  
PWM  
INPUT  
OCI1  
D8  
to negative output  
NC  
NC  
J1  
1
4
5
4
D5  
1N4936  
com  
150V  
8A  
Q1  
R14  
D1  
D2  
4.75K  
R1  
J1  
R16  
1
4.75K  
+
t
C5  
500  
50V  
C2  
50  
25V  
C1  
22 to 32 Vac  
.24  
R18  
0.1  
DZ5  
16V  
1W  
J1  
50V  
4.75K  
2
R20  
4.75K  
D4  
D3  
J1  
J1  
3
GENERAL INFORMATION  
LAST NO. USED  
R- 22  
C- 10  
X-  
2
ELECTRICAL SYMBOLS PER E1537  
OCI-  
DZ-  
1
6
CAPACITORS =  
RESISTORS Ohms  
DIODES  
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
com  
D-  
8
5
LABELS  
=
(
NOTES :  
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
SUPPLY  
VOLTAGE NET  
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY  
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE  
NUMBER.  
FRAME CONNECTION  
FILENAME: M18709_2FA  
EARTH GROUND CONNECTION  
12-4-98C  
M
18709  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 300  
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G-9  
G-9  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - CHOPPER BOARD  
3 1 3 5 - 1  
G
REQ'D  
PART NO  
IDENTIFICATION  
ITEM  
C1,C3,C4,C7  
C2  
C5  
C7  
D1,D2,D3,D4,D5  
D6,D7  
DZ1  
4
1
1
1
5
2
1
S16668-11  
S13490-8  
T11577-49  
S16668-3  
T12199-1  
T12705-23  
T12702-52  
.1/50  
50/25  
500 50  
100pf/100V  
1N4004  
/
1N5818  
1N4733A  
DZ2,DZ3,DZ5  
3
T12702-29  
1N4744A  
DZ4  
J1  
OCI1  
Q1  
R1  
R2  
R3  
1
1
1
1
1
1
1
5
6
1
1
T12702-55  
S24020-6  
S15000-28  
T12704-41  
IN4738A  
HEADER,VERTICAL  
OPTOCOUPLER,TTL-OUT  
S18380-5  
PTC THERMISTOR  
332 1/4W  
1K 1/4W  
4.75K  
10 1/4W  
S19400-3320  
S19400-1001  
S19400-4751  
S19400-10R0  
S19400-4752  
S19400-1002  
R4,R14,R16,R18,R20  
R10,R11,R13,R15,R17,R19  
R12  
R21  
47.5K 1/4W  
10K 1/4W  
X2  
1
S15018-19  
IC,T0220T,FETDRIVER  
.500~.005  
CAPACITORS  
RESISTORS  
=
=
MFD/VOLTS  
OHMS  
~.04  
4.00  
200 AMP  
G3135-1  
CHOPPER  
DZ1  
B5  
XXXXXXXXXXXXXXXX  
R3  
R4  
X
X
X
DZ2  
DZ3  
X2  
B4  
X
X
OCI1  
R2  
C5  
X
X
C7  
DZ4  
D5  
X
X
XXXXXXXXXXXXXXXX  
C2  
B1  
B2  
B3  
D4  
D3  
D2  
D1  
0
~.04  
9.00  
0
2-19-99F  
3135-1  
G
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not  
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may  
result in danger to the Machine Operator or Technician. Improper PC Board repairs could result in damage to the machine.  
COMMANDER 300  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-10  
G-10  
ELECTRICAL DIAGRAMS  
SCHEMATIC - METER PC BOARD  
SPARE COMPONENTS  
A/D CTL LINE CS  
+5V  
CTL+5V  
A/D CTL LINE DIN  
+5V  
CTL+5V  
+5V  
CTL+5V  
+5V  
TEST  
7
A/D CTL LINE SCK  
CTL+5V  
+5V  
CTL+5V  
J9  
10.0K  
R98  
A/D LINE DATA OUT  
+5V  
J8  
1
3
102  
C13  
0.1  
C22  
0.1  
77  
A/D LINE EDC  
+5V  
C26  
0.1  
C31  
0.1  
50V  
C24  
0.1  
50V  
50V  
50V  
50V  
OCI2  
8
7
6
5
OCI1  
2
8
7
6
5
2
OCI3  
OCI4  
8
7
6
5
6
5
7
8
2
2
3
OCI5  
TEST  
8
CTL COM  
6
5
7
8
2
3
10.0K  
J8  
2
104  
R120  
76  
Q6  
NC  
NC  
Q7  
NC  
NC  
4
Q3  
2N4403  
3
1
4
NC  
NC  
4
NC  
NC  
C34  
0.1  
50V  
2N4403  
Q5  
2N4403  
Q4  
3
1
NC  
NC  
C23  
C29  
0.1  
2N4403  
3
1
4
1
C36  
0.1  
4
1
0.1  
2N4403  
CTL COM  
50V  
50V  
COM  
50V  
CTL COM  
COM  
CTL COM  
CTL COM  
COM  
COM  
CTL COM  
COM  
TEST  
9
CTL COM  
10.0K  
J8  
3
103  
R126  
75  
C37  
C30  
0.1  
50V  
0.1  
+5V MTR  
3
2
50V  
+5V MTR  
8
1
LED BUS  
162  
162  
CTL COM  
20  
3
8
1
19  
18  
17  
16  
15  
14  
13  
12  
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
19  
18  
17  
16  
15  
14  
13  
12  
D0  
D1  
D0  
D1  
CURRENT  
101  
TEST 10  
AN0  
AN1  
Vdd  
EOC  
Sclk  
Din  
Q0  
Q1  
D0  
D1  
D0  
Q0  
100K  
R84  
R85  
R86  
R83  
R77  
R76  
R67  
R87  
R134  
R135  
R136  
R128  
R125  
R124  
R119  
R137  
J8  
4
1
2
4
6
7
9
74HC573  
74HC573  
X12  
1
2
3
4
5
6
7
8
9
19  
18  
17  
16  
15  
14  
13  
12  
11  
D1  
D2  
D3  
X10  
Q1  
2
4
6
7
R146  
9
9
1
7
7
D2  
D3  
D4  
D5  
D6  
D7  
D2  
D3  
D4  
D5  
D6  
D7  
AN2  
AN3  
AN4  
AN5  
AN6  
AN7  
AN8  
Vss  
Q2 X8  
Q3  
D2  
D3  
Q2  
Q3  
Q4  
Q5  
Q6  
Q7  
CTL+5V  
6
10  
10  
C38  
0.1  
C27  
1.0  
35V  
6
1
9
Dout  
/CS  
Q4  
D4  
D5  
D6  
D7  
D4  
D5  
D6  
D7  
50V  
LED1  
LED4  
4
2
10  
5
10  
5
4
Q5  
1.00K  
R69  
CTL COM  
Vref  
5
2
Q6  
2
5
VOLTAGE  
105  
TEST 11  
100K  
R147  
hundreds meter  
shown as mirror image  
of led4  
1
J8  
5
Q7  
OE  
VAG  
AN10  
AN9  
hundreds meter  
OE  
LE  
LE  
C14  
0.1  
A/D CONVERSION  
+5V  
C15  
0.1  
4.75K  
10  
1
11  
11  
1
MC145051  
LED1_LE  
MTR1_OE  
LED4_LE  
C44  
0.1  
50V  
C25  
1.0  
35V  
+5V MTR  
3
1
50V  
50V  
+5V MTR  
3
2
MTR2_OE  
10.0K  
162  
162  
8
8
19  
18  
17  
16  
15  
14  
13  
12  
2
2
3
4
5
6
7
8
9
19  
18  
17  
16  
15  
14  
13  
12  
D0  
D1  
D0  
D1  
Q0  
Q1  
D0  
D1  
D0  
Q0  
Q1  
CTL COM  
R88  
R89  
R90  
R60  
R59  
R51  
R50  
R91  
R138  
R139  
R140  
R114  
R113  
R110  
R109  
R141  
1
2
74HC573  
74HC573  
X11  
1
3
4
5
6
7
8
9
10.0K  
D1  
D2  
D3  
2
4
6
7
CTL COM  
+5V  
9
9
1
7
7
4
6
7
9
D2  
D3  
D4  
D5  
D6  
D7  
D2  
D3  
D4  
D5  
D6  
D7  
CTL +12V  
Q2 X7  
Q3  
D2  
D3  
Q2  
Q3  
Q4  
Q5  
Q6  
Q7  
+5V  
6
10  
10  
6
4
10.0K  
1
9
Q4  
D4  
D5  
D6  
D7  
D4  
D5  
D6  
D7  
R106  
LED2  
LED5  
4
10  
5
10  
5
4.75K  
R48  
R47  
R46  
Q5  
1
8
100K  
C2  
0.1  
A0  
A1  
Vcc  
4.75K  
R45  
EEPROM SCL  
X3  
5
2
Q6  
2
5
2
3
4
7
C32  
4.75K  
WP  
SCL  
SDA  
tens meter  
1
50V  
Q7  
OE  
tens meter  
+5V MTR  
2
0.1  
Vdd  
shown as mirror image  
of led5  
OE  
6
5
LE  
LE  
A2  
1.00K  
R58  
50V  
X2  
RES  
GND  
1
11  
11  
1
EEPROM SDA  
LED2_LE  
MTR1_OE  
LED5_LE  
24C01A  
S-8054HN  
10.0K  
+5V MTR  
1
2
C11  
0.1  
50V  
COM  
MTR2_OE  
Vss  
m15104-13  
SERIAL EEPROM  
CTL COM  
+5V  
+5V  
162  
162  
4.75K  
8
3
3
8
19  
18  
17  
16  
15  
14  
13  
12  
2
2
3
4
5
6
7
8
9
19  
D0  
D0  
D1  
Q0  
Q1  
D0  
D1  
D0  
Q0  
Q1  
1.00M  
COM  
R92  
R93  
R94  
R53  
R79  
R78  
R52  
R95  
R142  
R143  
R144  
R116  
R130  
R129  
R115  
R145  
1
2
74HC573  
74HC573  
X14  
1
4.75K  
4.75K  
LED BUS  
3
4
5
6
7
8
9
18  
17  
16  
15  
14  
13  
12  
D1  
D2  
D3  
D4  
D5  
D6  
D7  
D1  
D2  
D3  
R75  
2
4
6
9
9
7
7
4
6
7
9
D2  
D3  
D4  
D5  
D6  
D7  
Q2 X9  
Q3  
D2  
D3  
Q2  
Q3  
Q4  
Q5  
Q6  
Q7  
3
4
5
6
D0  
D1  
QA  
QB  
QC  
QD  
QE  
QF  
QG  
6
10  
10  
Y1  
X13  
6
4
7
9
C20  
1
1
C19  
22p  
100V  
28  
Q4  
D4  
D5  
D6  
D7  
D4  
D5  
D6  
D7  
4.0MHz  
130  
2
1
2
8
9
D2  
D3  
D4  
22p  
LED3  
LED6  
/IRQ  
Vdd  
A!  
4
10  
5
10  
5
100V  
Q5  
15  
1
11  
VRH/PC4  
/RESET  
OSC1  
PB5/SDO  
PB7/SCK  
PB6/SDI  
PA2  
A2  
CLK  
R
5
2
Q6  
2
5
2
13  
12  
8
10  
11  
ones meter  
shown as mirror image  
of led6  
1
ones meter  
Q7  
OE  
COM  
LED BUS  
27  
26  
22  
21  
20  
19  
18  
17  
16  
D5  
D6  
OE  
LE  
LE  
13  
12  
OSC2  
X1  
QH  
A/D LINE DATA OUT  
1
11  
11  
1
74HC164  
9
LED1_LE  
LED2_LE  
LED3_LE  
LED4_LE  
LED5_LE  
LED6_LE  
LED3_LE  
MTR1_OE  
LED6_LE  
PC0  
PA1  
D7  
10  
3
MTR2_OE  
PC1  
PA0  
PC2  
PA7  
MTR2_OE  
MTR1_OE  
LED1_LE  
LED2_LE  
LED3_LE  
LED4_LE  
LED5_LE  
LED6_LE  
MTR1_OE  
MTR2_OE  
EEPROM SCL  
EEPROM SDA  
4
AN3/PC3  
AN2/PC4  
AN1/PC5  
AN0/PC6  
PD5  
PA6  
5
PA5  
A/D CTL LINE SCK  
A/D CTL LINE DIN  
A/D CTL LINE CS  
6
PA4  
R33  
15.0  
LED BUS  
7
PA3  
D2  
X6  
23  
14  
24  
25  
TCMP  
PD7/TCAP  
+5V MTR  
2
20.0  
20.0  
R34  
15.0  
Q2  
Vss  
3A  
A/D LINE EDC  
CTL +12V  
MC68HC705  
R55  
R74  
R73  
R56  
R82  
R41  
R38  
R42  
R40  
R39  
LED BUS  
100V  
R36  
15.0  
10.0K  
10.0K  
10.0K  
10.0K  
10.0K  
IN  
OUT  
TEST  
C8  
4
CTL+5V  
C7  
R37  
15.0  
R150  
301  
GND  
0.1  
C9  
4.7  
35V  
1.0  
50V  
COM  
CTL+5V  
35V  
R35  
15.0  
TEST  
5
DZ5  
10V  
1W  
R151  
COM  
COM  
301  
MICROCONTROLLER & SUPPORT  
1.00K  
COM  
R152  
301  
10.0K  
10.0K  
CTL +12V  
20  
C39  
COM  
C40  
1
D1  
0.1  
4.7  
8
X15  
50V  
35V  
+5V MTR  
1
C18  
J9  
4
R19  
15.0  
REF  
X10  
TL431  
6
106  
C42  
C41  
0.1  
50V  
TEST  
3
MC145051  
X5  
R21  
15.0  
39  
POWER SUPPLIES  
IN  
OUT  
TEST  
6
J9  
5
RUN STOP SWITCH  
STOP  
20V  
10  
150  
C4  
C5  
107  
R18  
15.0  
GND  
0.1  
4.7  
C6  
20.0  
20.0  
Q1  
J9  
1
1.0  
50V  
35V  
232  
+5V  
CTL COM  
CTL COM  
3A  
+12V BATT  
35V  
R7  
R9  
R8  
R2  
R4  
R1  
+5V  
DZ1  
100V  
CTL COM  
D3  
RUN  
R20  
15.0  
D4  
1N5402  
10V  
5W  
ISO +12V FROM CONTROL PCB  
COM  
R22  
15.0  
R10  
R6  
R5  
R3  
C45  
.15  
200V  
DZ2  
10V  
5W  
X4  
28  
14  
20  
20  
20  
20  
20  
20  
1.00K  
IN  
OUT  
0.1  
TP1  
R11  
18V  
C16  
C33  
C43  
C12  
C21  
0.1  
50V  
C28  
C35  
0.1  
50V  
TEST  
2
C17  
1.0  
GND  
100J  
X1  
X13  
X7  
X8  
X9  
X11  
X12  
X14  
R12  
R15  
R13  
R17  
R14  
R16  
DZ4  
10V  
1W  
C10  
0.1  
50V  
.022  
50V  
0.1  
50V  
0.1  
50V  
C1  
C3  
MC68HC705  
14  
74HC164  
74HC573  
74HC573  
74HC573  
74HC573  
10  
74HC573  
74HC573  
DZ3  
10V  
5W  
1.0  
4.7  
35V  
35V  
50V  
35V  
7
10  
10  
10  
10  
10  
TEST  
1
J9  
2
5L  
COM  
COM  
COM  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 300  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-11  
G-11  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - METER BOARD  
ITEM  
PART NO.  
DESCRIPTION  
REQ'D  
C1,C6,C9,C17,C25,C27  
6
28  
S13490-42  
S16668-11  
1.0/35  
.1/50  
C2,C4,C7,C10,C11,C12,C13  
C14,C15,C16,C21,C22,C23  
C24,C26,C28,C29,C30,C31  
C32,C34,C35,C36,C37,C38  
C39,C41,C44  
C3,C5,C8,C40  
C18,C33,C43  
C19,C20  
C42  
C45  
D1,D2,D3  
D4  
DZ1,DZ2,DZ3  
DZ4,DZ5  
J8,J9  
4
3
2
1
1
3
1
3
2
2
6
S13490-25  
S16668-5  
S16668-1  
S13490-104  
S13490-96  
T12199-1  
T12705-14  
T12702-33  
T12702-27  
S22025-5  
S17395-5  
4.7/35  
.022/50  
22pF/100  
39uF/20V  
.15/200  
1N4004  
DIODE  
1N5347B  
1N4740  
CONNECTOR,MOLEX,MINI,RT-L  
LED DISPLAY  
LED1,LED2,LED3,LED4,LED5  
LED6  
OCI1,OCI2,OCI3,OCI4,OCI5  
5
S15000-28  
OPTOCOUPLER,TTL-OUT  
Q1,Q2  
Q3,Q4,Q5,Q6,Q7  
2
5
T12704-62  
T12704-69  
TRANSISTOR  
2N4403  
R1,R2,R3,R4,R5,R6,R7,R8,R9  
R10,R38,R39,R40,R41,R42  
20  
S19400-20R0  
20 1/4W  
R55,R56,R73,R74,R82  
R11,R12,R13,R14,R15,R16  
R17,R54,R58,R61,R63,R64  
R65,R66,R69,R71,R72,R80  
R81,R153,R160  
~.04  
9.00  
21  
S19400-1001  
1K 1/4W  
4.25  
.25  
7.75  
~.04  
5.00  
R18,R19,R20,R21,R22,R33  
R34,R35,R36,R37  
10  
10  
S19400-15R0  
S19400-1500  
15 1/4W  
R23,R24,R25,R26,R27,R28  
R29,R30,R31,R32  
150 1/4W  
DZ1  
DZ2  
DZ3  
R43,R44,R96,R97,R98,R104  
R106,R107,R108,R111,R112  
R117,R120,R121,R122,R123  
R126,R132,R133,R148,R149  
R155,R157,R159  
24  
S19400-1002  
10K 1/4W  
G3178-2  
COMMANDER  
METER  
4.75  
X4  
R45,R46,R47,R48,R57,R70  
R118,R127,R131  
9
S19400-4751  
4.75K  
R49,R146,R147  
3
S19400-1003  
S19400-1620  
100K 1/4W  
162 1/4W  
R50,R51,R52,R53,R59,R60  
R67,R76,R77,R78,R79,R83  
48  
D3  
C10  
R84,R85,R86,R87,R88,R89  
R90,R91,R92,R93,R94,R95  
R109,R110,R113,R114,R115  
R116,R119,R124,R125,R128  
R129,R130,R134,R135,R136  
R137,R138,R139,R140,R141  
R142,R143,R144,R145  
X3  
C11  
R50  
51  
R59  
R60  
R54  
R65  
R66  
R71  
R72  
R80  
R81  
R55  
R56  
C13  
R61  
C14  
R49  
R58  
R
Y1  
X7  
C15  
R69  
C16  
C17  
R62,R68,R154,R156,R158  
R75  
5
1
4
S19400-4750  
S19400-1004  
S19400-6811  
475 1/4W  
1M 1/4W  
R68  
C22  
R73  
R74  
R82  
R67  
R76  
R77  
R83  
LED1  
LED2  
LED3  
X8  
R75  
C19  
R99,R100,R101,R105  
6.81K 1/4W  
C23  
C24  
C25  
C26  
C27  
C30  
R102,R103  
R150,R151,R152  
TP1  
X1  
X2  
2
3
S19400-6812  
S19400-3010  
68.1K 1/4W  
301 1/4W  
C20  
X10  
1
1
1
1
1
T13640-26  
S24214-2  
M15102-3  
M15104-13  
S15128-5  
18V/100J MOV  
ROM ASSEMBLY(SS)  
X9  
IC,S8054HN,UNDERVOLT. SENSING CIR. (SS)  
IC,24C01A,CMOS,EEPROM (SS)  
+5V REG.  
R96  
R97  
X3  
X4  
TP1  
R109  
R110  
R113  
R114  
R107  
R108  
R111  
R112  
R117  
X5,X6  
X7,X8,X9,X11,X12,X14  
X10  
X13  
X15  
Y1  
2
6
1
1
1
1
S15128-5  
S17900-25  
M15105-7  
S17900-9  
S15128-10  
S16665-2  
+5  
V
REG.  
X11  
X12  
X14  
IC,74HC573A,CMOS,LATCH,3-STATE (SS)  
IC,CMOS,MPU,A/D,10-BIT(SS)  
14 PIN I.C. (SS)  
IC,431,VOLTAGE REF.  
4.0 MHz  
C31  
R120  
C34  
R121  
R122  
R119  
R124  
R125  
R128  
R118  
C35  
R126  
C37  
LED4  
LED5  
LED6  
R123  
R127  
R131  
R133  
R132  
R148  
R149  
X15  
C38  
R146  
R147  
C44  
X13  
C45  
R150  
R152  
C43  
Q5  
Q6  
Q7  
D4  
J8  
J9  
.25  
0
5.50  
8.75  
1.25  
0
2-5-99A  
3178-2  
G
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not  
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may  
result in danger to the Machine Operator or Technician. Improper PC Board repairs could result in damage to the machine.  
COMMANDER 300  
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G-12  
G-12  
ELECTRICAL DIAGRAMS  
SCHEMATIC - BYPASS PC BOARD  
J62  
5
L4  
J61  
J61  
J61  
J61  
J61  
J60  
1
5
.39mH  
C4  
.0047  
3000V  
J62  
4
4E  
2E  
L5  
J60  
J60  
J60  
J60  
J60  
2
3
4
5
4
4B  
2B  
4D  
.39mH  
C5  
.0047  
3000V  
TP1  
150V  
80J  
J62  
J62  
1
TO "OUTPUT CONTROL SOURCE" SWITCH  
L1  
1
2D  
.39mH  
C1  
.0047  
3000V  
2
6
3
75E  
77E  
76E  
L2  
2
6
3
TO MOTHER CONTROL PCB  
75B  
77C  
76C  
75D  
.39mH  
C2  
.0047  
3000V  
TP2  
150V  
80J  
J62  
L6  
77D  
.39mH  
C6  
.0047  
3000V  
TP4  
150V  
80J  
TP3  
150V  
80J  
J62  
TO "REMOTELOCAL" SWITCH  
L3  
J61  
J61  
8
7
76D  
.39mH  
C3  
.0047  
3000V  
GENERAL INFORMATION  
ELECTRICAL SYMBOLS PER E1537  
LAST NO. USED  
R-  
C-  
L-  
_
6
6
CAPACITORS =  
RESISTORS Ohms  
DIODES  
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
LABELS  
=
(
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
SUPPLY  
VOLTAGE NET  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
NOTES :  
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY  
FRAME CONNECTION  
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE  
NUMBER.  
EARTH GROUND CONNECTION  
FILENAME: M18948_1AA  
8-14-98  
M18948  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 300  
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G-13  
G-13  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - BYPASS BOARD  
ITEM  
REQ'D  
IDENTIFICATION  
.22/400V  
PART NO.  
C1,C2,C3  
3
S20500-3  
C4,C5,C6,C7,C8,C9,C10,C11  
C12,C13,C14,C15,C16,C17,C18  
TP1,TP2,TP3,TP4,TP5  
15  
T11577-52  
.0047 or .005/1400  
~.04  
4.50  
5
T13640-16  
80J  
CAPACITORS = MFD/VOLTS  
INDUCTANCE = HENRYS  
2.98  
4.15  
~.04  
3.80  
B2  
B3  
3.50  
3.28  
x
x
C13  
C12  
C11  
x
x
x
x
x
x
x
x
x x x x x x x x x  
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
TP4  
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x x  
x
x
C3  
x x  
x
x
x x  
x x  
x
x
x
x
x
x
x
x
x x  
C2  
x
x
x
x
x
x
x
x
x x  
x x x x  
x
x
x
x
x
x
x
x
x
x
x
x
x
x
TP2  
x
x
TP3  
C10  
x
x
x
xxx  
xx  
x
x x  
x
x
x x x x x x x x x x  
x
x x  
x x  
x
x
x
x
x
x
x
x x  
C1  
x
x
x
x
xxxxxxx  
x C8  
x
x
x
x
x
x
x
xxCx9xx  
x
x
x
x
x
x
x
x
x C7  
x
B1  
x
x
x
x
x
x
x C6  
x
.82  
.60  
x
x
x
x
x
x
L9573-1  
C5  
x
x
x
x
x
x
x
x
C4  
BYPASS  
x
x
x
x
x x  
x x x  
0
1.48  
.30  
0
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not  
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may  
result in danger to the Machine Operator or Technician. Improper PC Board repairs could result in damage to the machine.  
COMMANDER 300  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SVM ERROR REPORTING FORM  
We need to know if there are errors in our manuals. We also value any suggestions as to  
additional tests or procedures that would make this SVM a better tool for you.  
If you discover new or different “Problems or Symptoms” that are not covered in the three col-  
umn troubleshooting chart, please share this information with us. Please include the  
machine’s code number and how the problem was resolved.  
Thank You,  
Technical Services Group  
Lincoln Electric Co.  
22801 ST. Clair Ave.  
Cleveland, Ohio 44117-1199  
FAX 216-481-2309  
SVM Number ___________________________  
Page Number if necessary__________________  
Your Company__________________________  
Your Name_____________________________  
Please give detailed description below:  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
SD287 01/99  
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