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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.
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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.
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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.
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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.
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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.
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E-8
E-8
NOTES
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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
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
COMMANDER 300
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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.
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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
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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
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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.
COMMANDER 300
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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
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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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
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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
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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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