Lincoln Electric COMMANDER SVM145-B Service Manual
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Lincoln Electric COMMANDER SVM145-B Service Manual

Lincoln Electric COMMANDER SVM145-B Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN INDEX
SVM145-B
September, 2002
TM
Commander
300
For use with machines having Code Numbers: 10469 (Standard),
10470 (Deluxe)
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be in-
creased by proper installation . . .
and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
SERVICE MANUAL
Copyright © 2002 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric COMMANDER SVM145-B

  • Page 1 RETURN TO MAIN INDEX SVM145-B September, 2002 Commander 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 .

  • Page 2: Safety

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    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.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6: Table Of Contents

    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...
  • Page 7 Section A-1 - 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...

  • Page 8: Installation

    F3L 1011F Air/cooled diesel 31 HP @ 1800 RPM Duty Cycle 100% OUTPUT - WELDER AND GENERATOR Welding Range 30 - 300 Amps DC in 5 Ranges Height 42.0 in. 1066.8 mm Output rating in watts is equivalent to volt-amperes at unity power factor.

  • Page 9: Safety Precautions

    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. STORING 1.

  • Page 10: Pre-Operation Engine Service

    For maximum rating, derate the welder output 5% for every 300 meters (984 ft.) above 1500 meters (4920 ft.). For output of 300A and below, derate the welder output 5% for every 300 meters (984 ft.) above 2100 meters (6888 ft.) Contact a Deutz Service Representative for any engine adjustments that may be required.

  • Page 11: Oil

    The Commander 300 is shipped with the engine crankcase filled with high quality SAE 1OW-30 oil (API class CD or better). CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE. If it is not up to the FULL mark on the dip- stick, add oil as required.

  • Page 12: Electrical Output Connections

    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.

  • Page 13: Welding Cable Connections

    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.

  • Page 14: Machine Grounding

    (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, b) be double insulated. When the Commander 300 is mounted to a truck or trailer, its frame must be securely connected to the metal frame of the vehicle.
  • Page 15 FIGURE A.2 - CONNECTION OF THE COMMANDER TO PREMISES WIRING 240 VOLT POWER 240 Volt 60 Hz. COMPANY 3-Wire Service METER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. 50 AMP, 120/240 VOLT PLUG NEMA TYPE 14-50 50 AMP, 120/240 VOLT...
  • Page 16 A-10 A-10 NOTES COMMANDER 300...

  • Page 17: Welding Capability

    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...

  • Page 18: Operation

    Only qualified personnel should install, use, or ser- vice this equipment. ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and the side panels in place. These provide maximum protection from moving parts and insure proper cooling air flow.

  • Page 19: General Description

    The Deutz F3L-1011 F engine is equipped with a stan- dard, heavy duty, combination fuel filter/water separa- tor element. RECOMMENDED APPLICATIONS WELDER The Commander 300 (Stick model) provides excellent constant current DC welding output for stick (SMAW) welding. The Commander 300 (Stick & Wire model)

  • Page 20: Welding Capability

    87 volts. The weld current is variable from 30 to 375 amps. CONTROLS AND SETTINGS The welder/generator controls are located on the case front panel. Diesel engine idler control, start/stop con- trols, welding output terminals and ground stud are also on the case front.

  • Page 21: Engine Controls

    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.

  • Page 22: Welder Controls

    This meter is a useful indicator for scheduling preventative maintenance. WELDER CONTROLS (Items 9 through 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.

  • Page 23: Auxiliary Power Controls

    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.

  • Page 24: Engine Operation

    -30°F. With the above and a battery warmer,* the engine should start satisfactorily down to about -40°F. * Contact your local Lincoln Electric Representative for suggested after-market kits. STOPPING THE ENGINE Switch the RUN/STOP switch to “STOP.” This turns off the voltage supplied to the shutdown solenoid.

  • Page 25: Welder Operation

    CAUTION 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.
  • Page 26 B-10 Table B.3 TYPICAL CURRENT RANGES DCEN (-) Tungsten Electrode 1%, 2% Diameter Thoriated in. (mm) Tungsten 0 .010 (.25) 2-15 0.020 (.50) 5-20 0.040 (1.0) 15-80 1/16 (1.6) 70-150 3/32 (2.4) 150-250 (3.2) 250-400 5/32 (4.0) 400-500 3/16 (4.8) 500-750 (6.4) 750-1000...

  • Page 27: Auxiliary Power 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 Commander 300 in the “WIRE WELDING” posi- tion, permits it to be used with a broad range of flux...
  • Page 28 B-12 B-12 NOTES COMMANDER 300...
  • Page 29 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...

  • Page 30: Accessories

    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...

  • Page 31: Semiautomatic Welding Accessories

    SEMIAUTOMATIC WELDING ACCESSORIES LN-7 OR LN-8 WIRE FEEDERS - Semiautomatic, con- stant speed wire feeders. For CV operation only. LN-23P WIRE FEEDER - This portable wire feeder is capable of CV operation. K350-1 Adapter Kit is required. LN-25 WIRE FEEDER - The LN-25 with or without an external contactor may be used with the Commander 300.

  • Page 32: Connection Of The

    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.

  • Page 33: Connection Of The

    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.
  • Page 34 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.
  • Page 35 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.
  • Page 36 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.
  • Page 37 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. NOTE: Welding cable must be sized for current and duty cycle of application.
  • Page 38 C-10 C-10 NOTES COMMANDER 300...
  • Page 39 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...

  • Page 40: Maintenance

    SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. •...

  • Page 41: Maintenance

    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.

  • Page 42: Fuel Filter

    Consult the engine operation manual. It is important to locate the welder to provide an unrestricted flow of clean, cool air. COMMANDER 300...
  • Page 43 COOLING BLOWER BELT: The following procedure should be followed to replace the cooling blower belt: 1. Allow the machine to cool. 2. Remove the engine case side. 3. Loosen the air filter hose clamp and detach hose. 4. Disconnect the negative battery cable. 5.

  • Page 44: Cooling Blower Belt

    DEUTZ ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before • Fill fuel tank. Starting Engine • Check oil level. • Check air cleaner for dirty, loose, or damaged parts • Check air intake and cooling areas, clean as necessary. First 50 Hours •...

  • Page 45: Battery Maintenance

    • 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.

  • Page 46: Welder/Generator Maintenance

    WELDER/GENERATOR MAINTENANCE STORAGE: Store the Commander 300 in clean, dry, protected areas. 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.

  • Page 47: Major Component Locations

    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 COMMANDER 300...
  • Page 48 D-10 D-10 NOTES COMMANDER 300...
  • Page 49 Section E-1 -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 MECHANICAL...

  • Page 50: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND ENGINE PROTECTION MECHANICAL ENGINE ROTATION STARTER ALTERNATOR ENGINE SENSORS BATTERY ENGINE PROTECTION 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.
  • Page 51 THEORY OF OPERATION FIGURE E.3 – WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK MECHANICAL ENGINE ROTATION STARTER ALTERNATOR ENGINE SENSORS BATTERY ENGINE PROTECTION 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.
  • Page 52 THEORY OF OPERATION FIGURE E.4 – CONTROL TRANSFORMER AND CONTROL BOARD MECHANICAL ENGINE ROTATION STARTER ALTERNATOR ENGINE SENSORS BATTERY ENGINE PROTECTION 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.
  • Page 53 THEORY OF OPERATION SOURCE DRAIN A. PASSIVE 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.

  • Page 54: Pulse Width Modulation

    THEORY OF OPERATION FIGURE E.6 – TYPICAL IGBT OUTPUTS 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.

  • Page 55: Chopper Technology Fundamentals

    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. 3 PHASE DC RECTIFIER ALTERNATOR...
  • Page 56 NOTES COMMANDER 300...
  • Page 57 Section F-1 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...

  • Page 58: Troubleshooting & Repair Section

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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.

  • Page 59: Pc Board Troubleshooting Procedures

    - 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.

  • Page 60: Troubleshooting Guide

    The auxiliary output is normal. 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. POSSIBLE AREAS OF...
  • Page 61 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. detailed in the beginning of this manual.
  • Page 62 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. POSSIBLE AREAS OF...
  • Page 63 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. detailed in the beginning of this manual.
  • Page 64 The battery does not stay charged. 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.
  • Page 65 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. detailed in the beginning of this manual.
  • Page 66 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. POSSIBLE AREAS OF...
  • Page 67 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.
  • Page 68 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. detailed in the beginning of this manual.

  • Page 69: Case Cover Removal And Replacement Procedure

    TROUBLESHOOTING & REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE 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.
  • Page 70 F-14 TROUBLESHOOTING & REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) LEFT FRONT PANEL PROCEDURE 1. Turn the engine off. 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.
  • Page 71 F-15 TROUBLESHOOTING & REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.2 – FRONT PANEL/ROOF DETAILS SCREWS FRONT CONTROL PANEL 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.
  • Page 72 F-16 TROUBLESHOOTING & REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.3 – OUTPUT PANEL REMOVAL OUTPUT LEADS (BEHIND PANEL) OUTPUT PANEL REMOVAL 1. Using the 3/4" wrench, remove the internal leads from the positive and negative output terminals. See Figure F.3. 2.
  • Page 73 F-17 TROUBLESHOOTING & REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) REASSEMBLY PROCEDURE 1. Output panel: Set the panel in place. 2. Install the five screws that mount the panel at the top and bottom. 3. Attach the green ground lead. 4.

  • Page 74: Case Front Knobs - Removal And Replacement Procedure

    F-18 TROUBLESHOOTING & REPAIR CASE FRONT KNOBS - REMOVAL AND REPLACEMENT PROCEDURE Side View (Pull) Knob Nameplate (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"...

  • Page 75: Power Module Capacitor Discharge Procedure

    TROUBLESHOOTING & REPAIR POWER MODULE CAPACITOR DISCHARGE PROCEDURE 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.
  • Page 76 F-20 TROUBLESHOOTING & REPAIR POWER MODULE CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.4 – POWER MODULE CAPACITOR TERMINAL DISCHARGE TEST PROCEDURE 1. This procedure must be performed with the engine off. 2. Using the 3/8" wrench, remove the front left and right side panels. 3.

  • Page 77: Idler Solenoid Test

    F-21 TROUBLESHOOTING & REPAIR 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.
  • Page 78 F-22 TROUBLESHOOTING & REPAIR IDLER SOLENOID TEST (continued) FIGURE F.5 – IDLER SOLENOID LEADS TEST PROCEDURE 1. Turn the engine off. 2. Unlatch, lift, and secure the right side engine service access door. 3. Locate and remove the two in-line connec- tors that attach the idler solenoid leads to the wiring harness leads (#226A, #237A).

  • Page 79: Shutdown Solenoid Test

    TROUBLESHOOTING & REPAIR SHUTDOWN SOLENOID TEST 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.
  • Page 80 F-24 TROUBLESHOOTING & REPAIR SHUTDOWN SOLENOID TEST (continued) TEST PROCEDURE 1. Turn the engine off. 2. Unlatch, lift, and secure the right side engine service access door. FIGURE F.6 - PLUG J30 LOCATION 3. Using the 3/8" wrench, remove the right front case side.
  • Page 81 F-25 SHUTDOWN SOLENOID TEST (continued) FIGURE F.7 – PLUG J30 PIN/LEAD ASSIGNMENTS #224(+) 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.
  • Page 82 F-26 F-26 NOTES COMMANDER 300...

  • Page 83: Engine Throttle Adjustment Test

    TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST 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.
  • Page 84 F-28 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.8 – STROBE MARK LOCATION TEST PROCEDURE 1. Conduct this procedure with the engine OFF. 2. Unlatch, lift, and secure the right side service access door. With the 3/8" wrench, remove the right front side cover.
  • Page 85 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...
  • Page 86 F-30 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) 6. 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.

  • Page 87: Rotor Resistance Test

    F-31 TROUBLESHOOTING & REPAIR 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.
  • Page 88 F-32 TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST (continued) SLIP RINGS LEADS REMOVED TEST PROCEDURE Conduct this test with the engine off. 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.

  • Page 89: Flashing And Rotor Voltage Test

    TROUBLESHOOTING & REPAIR FLASHING AND ROTOR VOLTAGE TEST 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.
  • Page 90 F-34 TROUBLESHOOTING & REPAIR FLASHING AND ROTOR VOLTAGE TEST (continued) TEST PROCEDURE 1. Using the 3/8" wrench, remove the sheet metal screws from the left front case side. 2. Carefully remove the left case side. 3. Set the volt/ohmmeter to the DC volts posi- tion.
  • Page 91 F-35 TROUBLESHOOTING & REPAIR FLASHING AND ROTOR VOLTAGE TEST (continued) FIGURE F.13 - FIELD DIODE RECTIFIER BRIDGE AND FILTER CAPACITOR FILTER CAPACITOR 7. If the voltage reading is low or not present, the generator field is not functioning proper- Perform the Rotor Resistance Test. Also check the field diode rectifier bridge, fil- ter capacitor, and associated leads and con- nections.
  • Page 92 F-36 F-36 NOTES COMMANDER 300...

  • Page 93: Stator Voltage Test

    F-37 TROUBLESHOOTING & REPAIR 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.
  • Page 94 F-38 TROUBLESHOOTING & REPAIR STATOR VOLTAGE TEST (continued) FIGURE F.14 – FRONT CONTROL PANEL REMOVAL SCREWS FRONT CONTROL PANEL 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.
  • Page 95 F-39 TROUBLESHOOTING & REPAIR STATOR VOLTAGE TEST (continued) FIGURE F.15 – OUTPUT PANEL REMOVAL 6. Using the 3/8” wrench, remove the five screws holding the lower front panel (output panel) to the case front assembly. Figure F.15. Carefully move the lower front panel to the right side.
  • Page 96 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.
  • Page 97 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. 5. Check for approximately 68VAC from W1 to W2.
  • Page 98 F-42 F-42 NOTES COMMANDER 300...

  • Page 99: Rf By-Pass Board Resistance Test

    TROUBLESHOOTING & REPAIR RF BY-PASS BOARD RESISTANCE TEST 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.
  • Page 100 F-44 TROUBLESHOOTING & REPAIR RF BY-PASS BOARD RESISTANCE TEST (continued) FIGURE F.18 – FRONT CONTROL PANEL REMOVAL SCREWS FRONT CONTROL PANEL 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.
  • Page 101 F-45 TROUBLESHOOTING & REPAIR RF BY-PASS BOARD RESISTANCE TEST (continued) 4. Locate, label, and remove the three plugs from the RF By-Pass board. See Figure 19. 5. Using the phillips head screwdriver, remove the three mounting screws from the board. NOTE: Take note of the screw and washer place- ment for reassembly.
  • Page 102 F-46 TROUBLESHOOTING & REPAIR CHECK POINTS 1J61 to 5J60 1J61 to 5J62 2J61 to 4J60 2J61 to 4J62 3J61 to 1J60 3J61 to 1J62 4J61 to 2J60 4J61 to 2J62 5J61 to 6J60 5J61 to 6J62 8J61 to 3J60 8J61 to 3J62 NOTE: The pins should not have continuity to the PC board ground plane.

  • Page 103: Control Transformer Test

    TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER TEST 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.
  • Page 104 F-48 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER TEST (continued) FIGURE F.20 – FRONT CONTROL PANEL REMOVAL SCREWS FRONT CONTROL PANEL 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.
  • Page 105 F-49 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER TEST (continued) CONTROL TRANSFORMER 4. Locate and disconnect plug J16 from P16. See the Wiring Diagram and Figure 21. 5. Using the isolated supply, carefully apply 115VAC to the black (primary) leads at plug J16 pins 7 and 8.
  • Page 106 F-50 F-50 NOTES COMMANDER 300...

  • Page 107: Output Rectifier Bridge Test

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST 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.
  • Page 108 F-52 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.22 – FRONT CONTROL PANEL REMOVAL SCREWS FRONT CONTROL PANEL TEST PROCEDURE 1. Turn the engine off. 2. Using the 3/8" wrench remove the screws holding the front control panel to the case top and sides.
  • Page 109 F-53 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.23 – OUTPUT PANEL REMOVAL OUTPUT LEADS (BEHIND PANEL) 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.
  • Page 110 F-54 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.24 – DIODE LEAD REMOVAL STATOR AND DIODE PIGTAIL LEAD CONNECTIONS 9. Electrically isolate the six diode pigtail leads by carefully bending them out into “free air.” 10. With an ohmmeter or diode tester, check each of the six diodes from their pigtails to their respective heat sinks.

  • Page 111: Power Module Test

    F-55 TROUBLESHOOTING & REPAIR 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.
  • Page 112 F-56 TROUBLESHOOTING & REPAIR POWER MODULE TEST (continued) FIGURE F.25 – POWER MODULE CAPACITOR LEADS TEST PROCEDURE 1. This procedure must be performed with the engine off. 2. Remove the left and right case sides. 3. Perform the Power Module Capacitor Discharge Procedure.
  • Page 113 F-57 TROUBLESHOOTING & REPAIR POWER MODULE TEST (continued) 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.
  • Page 114 F-58 TROUBLESHOOTING & REPAIR POWER MODULE TEST (continued) 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).

  • Page 115: Current Balance Test

    F-59 TROUBLESHOOTING & REPAIR 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.
  • Page 116 F-60 TROUBLESHOOTING & REPAIR CURRENT BALANCE TEST (continued) TEST PROCEDURE 1. Turn the engine off. 2. Perform the Case Cover Removal 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.
  • Page 117 F-61 TROUBLESHOOTING & REPAIR CURRENT BALANCE TEST (continued) CONTROL BOARD FIGURE F.29 – PLUG LOCATIONS ENGINE PROTECTION COMMANDER 300 CONTROL G3002-1 COMMANDER 300 F-61 BOARD C300 ENGINE PROTECTION G3004-1...
  • Page 118 F-62 F-62 NOTES COMMANDER 300...

  • Page 119: Control Input Test

    F-63 TROUBLESHOOTING & REPAIR 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.
  • Page 120 F-64 TROUBLESHOOTING & REPAIR CONTROL INPUT TEST (continued) TEST PROCEDURE 1. Turn the engine off. 2. Perform the Case Cover Removal and Replacement Procedure. 3. Tilt the control panel out. 4. Locate the J2 connector on the control board. See Figure F.30. 5.
  • Page 121 F-65 TROUBLESHOOTING & REPAIR CONTROL INPUT TEST (continued) CONTROL DIAL POSITION 14. Using an ohmmeter, measure continuity at J4 in the following switch positions. See Table F.3 below. RANGE SEL. SWITCH POSITION 150A 230A 300A 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.
  • Page 122 F-66 TROUBLESHOOTING & REPAIR CONTROL INPUT TEST (continued) 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.

  • Page 123: Feedback Input Test

    F-67 TROUBLESHOOTING & REPAIR 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.
  • Page 124 F-68 TROUBLESHOOTING & REPAIR FEEDBACK INPUT TEST (continued) TEST PROCEDURE 1. Turn the engine off. 2. Using 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 terminals or internal wiring.
  • Page 125 F-69 TROUBLESHOOTING & REPAIR FEEDBACK INPUT TEST (continued) Pin 1 Pin 2 Plug J2 Pin 5 6. If the continuity is not present, check the 67 lead for poor connection. Diagram. Look closely for broken molex pins. 7. Plug J3 back into the control PC board. 8.
  • Page 126 F-70 F-70 NOTES COMMANDER 300...

  • Page 127: Pwm Output Test

    F-71 TROUBLESHOOTING & REPAIR 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.
  • Page 128 F-72 TROUBLESHOOTING & REPAIR PWM OUTPUT TEST (continued) Right Chopper Board Plug J13 TEST PROCEDURE 1. Turn the engine off. 2. Using Case Cover Replacement Procedure and tilt the control panel out. WARNING ELECTRIC SHOCK CAN KILL. • Do not touch electrically live parts such as output terminals or internal wiring.
  • Page 129 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.
  • Page 130 F-74 TROUBLESHOOTING & REPAIR PWM OUTPUT TEST (continued) FIGURE F.38 – Engine Protection Board (Plug Locations) CONTROL BOARD 9. Using Case Cover Replacement Procedure, install the control panel and side panels of the machine. ENGINE PROTECTION COMMANDER 300 CONTROL G3002-1 Removal COMMANDER 300 F-74...

  • Page 131: Power Supply Test

    F-75 TROUBLESHOOTING & REPAIR 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.
  • Page 132 F-76 TROUBLESHOOTING & REPAIR POWER SUPPLY TEST (continued) TEST PROCEDURE 1. Turn the engine off. 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.

  • Page 133: Display Board Calibration Test

    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.
  • Page 134 F-78 TROUBLESHOOTING & REPAIR DISPLAY BOARD CALIBRATION TEST (continued) TEST PROCEDURE 1. Start the engine. 2. Turn the range selector switch to the CC posi- tion, and control dial to the min. position. 3. With no load applied, slowly turn the control dial clockwise from min to max in each range selector switch position.

  • Page 135: Normal Open Circuit Voltage Waveform (115 Vac Supply

    F-79 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) 15.8 ms HIGH IDLE – NO LOAD 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.

  • Page 136: Normal Open Circuit Voltage Waveform (Stick

    F-80 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (STICK) MAX TAP – MAX CONTROL POT – HIGH IDLE – NO LOAD 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.

  • Page 137: Normal Weld Voltage Waveform (Stick Cc

    F-81 TROUBLESHOOTING & REPAIR NORMAL WELD VOLTAGE WAVEFORM (STICK CC) MACHINE LOADED TO 300 AMPS AT 32 VOLTS 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.

  • Page 138: Normal Weld Voltage Waveform (Wire Cv

    F-82 TROUBLESHOOTING & REPAIR NORMAL WELD VOLTAGE WAVEFORM (WIRE CV) MACHINE LOADED TO 300 AMPS AT 32 VOLTS 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.

  • Page 139: Normal Open Circuit Voltage Waveform (Wire Cv Tap

    F-83 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV TAP) MAX CONTROL POT – HIGH IDLE – NO LOAD 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.
  • Page 140 F-84 F-84 NOTES COMMANDER 300...

  • Page 141: Power Module/Output Rectifier Bridge Assembly Removal And Replacement

    POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT 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.
  • Page 142 F-86 TROUBLESHOOTING & REPAIR POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT (continued) FIGURE F.39 – CONTROL PANEL REMOVAL SCREWS FRONT CONTROL PANEL TEST PROCEDURE 1. Turn the engine off. 2. Using the 3/8" wrench, remove the screws holding the front control panel to the case top and sides.
  • Page 143 F-87 TROUBLESHOOTING & REPAIR POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT (continued) FIGURE F. 40 – POWER MODULE CAPACITOR LEAD REMOVAL 8. Label the power module capacitor leads. Using the 7/16" wrench, disconnect the leads by removing the nut, lock washer, and flat washer.
  • Page 144 F-88 TROUBLESHOOTING & REPAIR POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT (continued) FIGURE F.41 – POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY DETAILS BRACKET DIODE HEATSINK DIODE LEADS CONTROL TRANSFORMER BOTTOM BRACKET 13. Free the positive output lead. Cut any nec- essary cable ties and slip the lead through the current sensing toroid assembly.
  • Page 145 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). 2. Place the assembly back into the machine. 3. Connect the positive output lead. Feed it through the toroid assembly.
  • Page 146 F-90 F-90 NOTES COMMANDER 300...

  • Page 147: Power Module (Chopper) Pc Board Removal And Replacement

    POWER MODULE (CHOPPER) PC BOARD REMOVAL AND REPLACEMENT 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.
  • Page 148 F-92 TROUBLESHOOTING & REPAIR POWER MODULE (CHOPPER) PC BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.42 – POWER MODULE PC BOARD CAPACITOR TERMINALS TEST PROCEDURE 1. Turn the engine off. 2. Remove the front right or left case side, depending on which power module PC board you are removing.

  • Page 149: Diode Removal And Replacement

    TROUBLESHOOTING & REPAIR DIODE REMOVAL AND REPLACEMENT 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.
  • Page 150 F-94 TROUBLESHOOTING & REPAIR DIODE REMOVAL AND REPLACEMENT (continued) FIGURE F.43 – POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY DETAILS DIODE DIODE PIGTAIL LEADS TEST PROCEDURE 1. Turn the engine off. 2. Perform Output Procedure. 3. Perform Capacitor Procedure. 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.

  • Page 151: Stator/Rotor Removal And Replacement

    TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT 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.
  • Page 152 F-96 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.44 – FUEL TANK REMOVAL DETAILS LEADS #229 AND #242D PREPARATION AND LEAD REMOVAL PROCEDURE 1. Turn the engine off. 2. Perform the Case Cover Removal Pro- cedure, including removing the output panel. 3.
  • Page 153 F-97 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.45 – LEAD REMOVAL DETAILS PLUG J30 FILTER CAPACITOR Disconnect plug J30 at the right front side. See Figure F.45. Using the slot head screw driver, discon- nect leads #200C, #200E(+) and #201B(-) from the filter capacitor.
  • Page 154 F-98 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.46 – BRUSH LEAD REMOVAL 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.
  • Page 155 F-99 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.47 – LEADS #68A/#69A BOLTED CONNECTIONS POWER STUD & LEADS #5A, #6 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.
  • Page 156 F-100 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.49 – LIFT FRAME AND ASSOCIATED COMPONENT REMOVAL LIFT FRAME WELDMENT FUEL TANK SUPPORTS In steps 21 – 25, the lift frame weldment, fuel tank supports, and fan baffle are removed as a unit. See Figure F.49.
  • Page 157 F-101 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) BOLTS (4) FAN NUT STATOR REMOVAL PROCEDURE 1. Using the 1/2" wrench, remove the four fan blade mounting bolts and lock washers. See Figure F.50. 2. Using the 1 1/8" wrench, remove the fan nut. Remove the fan, noting its direction for reassembly.
  • Page 158 F-102 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FLEX PLATE BLOWER SEGMENT (4) ROTOR ROTOR REMOVAL PROCEDURE 1. Support the rotor with the hoist. 2. Using the 5/8" wrench, remove the flex plate bolts, lock washers, and four blower seg- ments.
  • Page 159 F-103 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) LEAD RECONNECTION CHECKLIST Engine Leads #242D and #229 to fuel level sensor Plug J30 Brush leads #201(-) and #200A(+) and #200B(+) Leads #5P, #201 and #201A, #200D, and #6H to the field bridge rectifier Power Module Supply Bolted leads #68A and #69A Stator leads W1-W6...

  • Page 160: Retest After Repair

    230 - 264 216-250 RETEST AFTER REPAIR ENGINE OUTPUT No Load RPM 1350 - 1400 1880 - 1919 WELDER DC (STICK) OUTPUT Open Circuit Volts 82-89 (FINE CONTROL AT MAXIMUM) Short Circuit Current (Amps) WELDER CV (WIRE) OUTPUT Open Circuit...
  • Page 161 F-105 F-105 NOTES COMMANDER 300...
  • Page 162 ELECTRICAL DIAGRAMS TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS ............SECTION G WIRING DIAGRAM (COMMANDER 300 DELUXE) .

  • Page 163: Electrical Diagrams

    WIRING DIAGRAM - COMMANDER 300 DELUXE MODEL CAP. IGBT DRIVER PCB1 LEADC 203 TO PASS THRU TOROID LEFT ONE TIME HEAT SINK CHOKE RIGHT HEAT SINK LEADS 3 & 6A PASS THROUGH ELECT. TOROID TWICE IN OPPOSITE CAP. IGBT DIRECTIONS DRIVER PCB2 BYPASS PCB...
  • Page 164 WIRING DIAGRAM - COMMANDER 300 STANDARD MODEL CAP. IGBT DRIVER PCB1 LEAD 203 TO PASS THRU TOROID ONE TIME LEFT HEAT SINK CHOKE RIGHT HEAT SINK LEADS 3 & 6A PASS THROUGH ELECT. TOROID TWICE IN OPPOSITE CAP. IGBT DIRECTIONS DRIVER PCB2 BYPASS PCB...
  • Page 165 SCHEMATIC - CONTROL PC BOARD +12V 90.9K 43.2K +12V CURRENT SET POINT CIRCUITRY PIPE TP-A TP-C 681K 8.2V TO CONTROL POT 12.1K TP-B R165 100K PIPE +12V R166 221K ABSOLUTE CURRENT 3.32K LIMIT 550A 68.1K TP-M 1N4936 56.2K 100K .0047 TP-D R102 R103...
  • Page 166 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.
  • Page 167 SCHEMATIC - ENGINE PROTECTION PC BOARD R132 1.0A R100 2.21K R102 R101 AUX CURRENT SENSING 2N4401 1.00K R103 R104 R106 2.21K R107 R108 1.0A CTL +12V CTL +12V 2.43K OCI1 CNY17-3 CTL COM 2N4401 681K CURRENT SENSE 10.0K FROM CONTROL BD 1.00K +10V .0047...
  • Page 168 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.
  • Page 169 SCHEMATIC - CHOPPER PC BOARD Vin + Vc 5.1V 8.2V INV IN N.I. IN 10.0K 1.00K INPUT OCI1 1N4936 22 to 32 Vac ELECTRICAL DIAGRAMS 10.0 /40V 10.0 10.0 10.0 4.75K /40V 10.0 10.0 2.21K 150V 4.75K 4.75K 4.75K 4.75K NOTES : N.A.
  • Page 170 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.
  • Page 171 G-10 SCHEMATIC - METER PC BOARD A/D CTL LINE CS TEST 7 10.0K OCI1 TEST 8 CTL COM 10.0K R120 2N4403 TEST 9 CTL COM 10.0K R126 CTL COM CURRENT TEST 10 100K R146 CTL COM VOLTAGE TEST 11 100K R147 MC145051 10.0K...
  • Page 172 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.
  • Page 173 G-12 SCHEMATIC - BYPASS PC BOARD TO "OUTPUT CONTROL SOURCE" SWITCH TO MOTHER CONTROL PCB TO "REMOTELOCAL" SWITCH ELECTRICAL DIAGRAMS .39mH .0047 3000V .39mH .0047 150V 3000V .39mH .0047 3000V .39mH .0047 150V 3000V .39mH .0047 3000V 150V 150V .39mH .0047 3000V NOTES :...
  • Page 174 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.
  • Page 175 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99 Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...

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Commander 300

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