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Lincoln Electric SVM145-B manuel d'utilisation

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Table des matières du manuel d’utilisation

  • Page 1

    SVM145-B September , 2002 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PREC[...]

  • Page 2

    SAFETY i i COMMANDER 300 FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ______________________[...]

  • Page 3

    SAFETY ii ii COMMANDER 300 ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to pro[...]

  • Page 4

    COMMANDER 300 FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with the U.S. Natio[...]

  • Page 5

    SAFETY iv iv COMMANDER 300 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a.[...]

  • Page 6

    MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v COMMANDER 300 Page Safety .................................................................................................................................................i-iv Installation ..................................................................................................................[...]

  • Page 7

    T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 COMMANDER 300 Installation ............................................................................................................................. Section A T echnical Specifications ...........................................................................................[...]

  • Page 8

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-2 A-2 COMMANDER 300 TECHNICAL SPECIFICA TIONS - Commander 300 INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System De[...]

  • Page 9

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating and maintenance instructions and parts lists.[...]

  • Page 10

    LIFTING The Commander 300 weighs 1325 lb./601 kg. A lift bail is provided for lifting with a hoist. F ALLING EQUIPMENT can cause injury . Do not lift this machine using lift bail if it is equipped with a heavy accessory such as a trailer . Lift only with equipment of adequate lifting capacity . Be sure machine is sta- ble when lifting. The Commande[...]

  • 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 ST ART 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 [...]

  • Page 12

    HIGH FREQUENCY GENERA TORS FOR TIG APPLICA TIONS 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 [...]

  • Page 13

    WELDING CABLE CONNECTIONS CABLE INST ALLA TION, POLARITY CONTROL, AND CABLE SIZES With the engine off, route the electrode and work cables through the strain relief bracket on the base front and connect them to the terminals. (See size rec- ommendations below .) For positive polarity , connect the electrode cable to the terminal marked Positive (+)[...]

  • Page 14

    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 weld[...]

  • Page 15

    INST ALLA TION A-9 A-9 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A.2 - CONNECTION OF THE COMMANDER TO PREMISES WIRING 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOA[...]

  • Page 16

    NOTES A-10 A-10 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 17

    Section B-1 Section B-1 COMMANDER 300 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Operating Instructions ...................................................................................................[...]

  • Page 18

    OPERA TING INSTRUCTIONS Read and understand this entire section before operat- ing your Commander 300. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all the operating and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating and mainte[...]

  • Page 19

    GENERAL DESCRIPTION The Commander 300 is a diesel engine-driven welding power source. The machine uses a brush type alter- nating current generator for DC multi-purpose welding and for 120/240 V AC auxiliary standby power . The welding control system uses state of the art Chopper Te chnology . The generator has a single sealed bearing for mainte- n[...]

  • Page 20

    ADDITIONAL DESIGN FEA TURES • Deutz 3-cylinder , air/oil cooled diesel engine. Designed for long life, easy maintenance, and excel- lent fuel economy . • Engine protection system shuts the engine down for low oil pressure, high oil temperature, or a broken fan/engine alternator belt. • Gauges for oil pressure, oil temperature, engine alternat[...]

  • Page 21

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-5 B-5 COMMANDER 300 ENGINE CONTROLS (Items 1 through 8) 1. RUN/STOP SWITCH : When placed in the “RUN” position, this switch energizes the fuel solenoid and other[...]

  • Page 22

    OPERA TION B-6 B-6 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 o[...]

  • Page 23

    10. DIGIT AL 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 cu[...]

  • Page 24

    “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. In general, MIG welding performs best in the “SOFT” range and Innershield in the “CRISP” range. EN[...]

  • Page 25

    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 . TYPICAL FUEL CONSUMPTION Refer to T able B.2 for typical fuel consumption[...]

  • Page 26

    COMMANDER 300 SETTINGS WHEN USING THE K799 HL-FREQ UNIT a. Set the SELECTOR switch to the “30-375” setting (STICK/TIG). b. Set the IDLER switch to the “HIGH” position. c. Set the LOCAL/REMOTE switch to the “REMOTE” position. d. Set the WELDING TERMINALS switch to the “WELDING TERMINALS AL W A YS ON” position. This will close the sol[...]

  • Page 27

    WIRE FEED (CONST ANT VOL T AGE) 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 cored wire (Innershield and Outershield) electrodes and solid wires for MI[...]

  • Page 28

    NOTES B-12 B-12 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 29

    T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories ...................................................................................................................C-2 Field Installed Options ......[...]

  • Page 30

    OPTIONS/ACCESSORIES The following options/accessories are available for your Commander 300 from your local Lincoln Distributor . FIELD INST ALLED OPTIONS K802R POWER PLUG KIT - Provides a plug for each receptacle. 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 w[...]

  • Page 31

    SEMIAUT OMA TIC 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. NOTE:[...]

  • Page 32

    CONNECTION OF THE LN-7 TO THE COMMANDER 300 USING K867 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: W elding cable must be sized for current and duty cycle of application. NOTE: Fig[...]

  • Page 33

    ACCESSORIES C-5 C-5 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECTION OF THE LN-7 TO THE COMMANDER 300 USING K584 OR K594 INPUT CABLE ASSEMBL Y (SEE FIGURE C.2.) 1. Shut the welder off. 2. Connect the el[...]

  • Page 34

    ACCESSORIES C-6 C-6 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECTION OF THE LN-8 TO THE COMMANDER 300 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.3.) 1. Shut the welder off. 2. Connect the electrode cabl[...]

  • Page 35

    CONNECTION OF THE LN-8 TO THE COMMANDER 300 USING K595 INPUT CABLE ASSEMBL Y (SEE FIGURE C.4.) 1. Shut the welder off. 2. Connect the electrode cable fr om the LN-8 to the “+” terminal of the welder . Connect the work cable to the “-” terminal of the welder . NOTE: W elding cable must be sized for current and duty cycle of application. NOTE[...]

  • Page 36

    CONNECTION OF THE LN-23P TO THE COMMANDER 300 USING K350-1 ADAPTER (SEE FIGURE C.5.) 1. Shut the welder off. 2. Connect the electrode cable fr om the LN-23P to the “-” terminal of the welder . Connect the work cable to the “+” terminal of the welder . NOTE: W elding cable must be sized for curr ent and duty cycle of application. NOTE: Figur[...]

  • Page 37

    CONNECTION OF THE LN-25 TO THE COMMANDER 300 “ACROSS THE ARC” (SEE FIGURE C.6.) 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: W elding cable must be sized for current and duty cycle of application. NOTE: Figure C.[...]

  • Page 38

    NOTES C-10 C-10 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 39

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 COMMANDER 300 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions ................................[...]

  • Page 40

    SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine of f 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. • If covers or guards are missing from the machi[...]

  • Page 41

    CHANGE THE OIL FIL TER: 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 T able D.1 for recommended mai[...]

  • Page 42

    FUEL FIL TER: When working on the fuel system: • Keep naked lights away . • Do not smoke ! • Do not spill fuel ! 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 foll[...]

  • Page 43

    COOLING BLOWER BEL T : 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. Remove the engine case back panel for access to the engine. 6. Remove the pulley belt gu[...]

  • Page 44

    T ABLE D.1 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 • Change engine oil. and Every 250 1 • Change oil filter . Hour[...]

  • Page 45

    BA TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTER Y ACID can burn eyes and skin. • W ear gloves and eye protection and be careful when working near a battery . Follow the instructions printed on the battery . To prevent EXPLOSION when: • INST ALLING A NEW BA TTER Y - Disco[...]

  • Page 46

    WELDER/GENERA TOR 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 PLA TES: Whenever routine maintenance is performed on this machine - or at least yearly - inspect all name[...]

  • Page 47

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-9 D-9 COMMANDER 300 FIGURE D.2 - MAJOR COMPONENT LOCA TIONS 1 2 4 3 9 5 7 6 8 10 1. CONTROL P ANEL 2. FRONT P ANEL ASSEMBL Y 3. POWER MODULE/DIODE RECTIFIER BRIDGE [...]

  • Page 48

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES D-10 D-10 COMMANDER 300[...]

  • Page 49

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 COMMANDER 300 Theory of Operation ............................................................................................................. Section E General Description ....................................................................[...]

  • Page 50

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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[...]

  • Page 51

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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[...]

  • Page 52

    THEOR Y OF OPERA TION E-4 E-4 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL TRANSFORMER AND CONTROL BOARD The control transformer primary winding is powered by the 1 15V AC auxiliary coil in the stator [...]

  • Page 53

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-5 E-5 COMMANDER 300 FIGURE E.5 – IGBT OPERA TION DRAIN SOURCE GATE INJECTING LAYER BUFFER LAYER DRAIN DRIFT REGION BODY REGION p + n + n - p n + n + DRA[...]

  • Page 54

    COMMANDER 300 PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION is used to describe how much time is devoted to conduction in the cycle. Changing the pulse width is known as MODU- LA TION. 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. MINIMUM OUTPUT By co[...]

  • Page 55

    CHOPPER TECHNOLOGY FUNDAMENT ALS 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,[...]

  • Page 56

    NOTES E-8 E-8 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 57

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 COMMANDER 300 T roubleshooting & Repair Section ................................................................................ Section F How to Use T roubleshooting Guide .................................................................[...]

  • Page 58

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW T O USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may[...]

  • Page 59

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-3 F-3 COMMANDER 300 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical co[...]

  • Page 60

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 COMMANDER 300 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 61

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 COMMANDER 300 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 62

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 COMMANDER 300 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 63

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 COMMANDER 300 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 64

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-8 F-8 COMMANDER 300 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 65

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 COMMANDER 300 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 66

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 COMMANDER 300 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do n[...]

  • Page 67

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-11 F-11 COMMANDER 300 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do n[...]

  • Page 68

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-12 F-12 COMMANDER 300 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do n[...]

  • Page 69

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-13 F-13 COMMANDER 300 CASE COVER REMOV AL AND REPLACEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric facto[...]

  • Page 70

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 COMMANDER 300 PROP ROD LEFT FRONT P ANEL RIGHT FRONT P ANEL DOOR ASSEMBL Y ROUND HEAD SCREW LOCA TION FIGURE F .1 – DOOR REMOV AL CASE C[...]

  • Page 71

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-15 F-15 COMMANDER 300 FRONT CONTROL P ANEL SCREWS SCREW FIGURE F .2 – FRONT P ANEL/ROOF DET AILS CASE COVER REMOV AL AND REPLACEMENT PROCEDURE ([...]

  • Page 72

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-16 F-16 COMMANDER 300 OUTPUT LEADS (BEHIND PANEL) GREEN GROUND LEAD SCREWS FIGURE F .3 – OUTPUT P ANEL REMOV AL CASE COVER REMOV AL AND REPLACEM[...]

  • Page 73

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-17 F-17 COMMANDER 300 REASSEMBL Y PROCEDURE 1. Output panel: Set the panel in place. 2. Install the five screws that mount the panel at the top an[...]

  • Page 74

    TROUBLESHOOTING & REP AIR F-18 F-18 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CASE FRONT KNOBS - REMOV AL AND REPLACEMENT PROCEDURE Replacement Removal Flat Rounded Replacement: 1. If the white nylon ca[...]

  • Page 75

    TROUBLESHOOTING & REP AIR F-19 F-19 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W ARNING POWER MODULE CAP ACITOR DISCHARGE PROCEDURE Service and repair should be performed by only Lincoln Electric factory[...]

  • Page 76

    TROUBLESHOOTING & REP AIR F-20 F-20 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE CAP ACITOR DISCHARGE PROCEDURE (continued) FIGURE F .4 – POWER MODULE CAP ACITOR TERMINAL DISCHARGE POWER MOD[...]

  • Page 77

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-21 F-21 COMMANDER 300 W ARNING IDLER SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unau[...]

  • Page 78

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-22 F-22 COMMANDER 300 IDLER SOLENOID TEST (continued) FIGURE F .5 – IDLER SOLENOID LEADS IDLER SOLENOID IN-LINE CONNECTORS TEST PROCEDURE 1. T u[...]

  • Page 79

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-23 F-23 COMMANDER 300 W ARNING SHUTDOWN SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. U[...]

  • Page 80

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-24 F-24 COMMANDER 300 SHUTDOWN SOLENOID TEST (continued) MOVING PARTS Do not operate with doors open or guar ds of f. J30 TEST PROCEDURE 1. T urn [...]

  • Page 81

    INST ALLA TION F-25 F-25 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SHUTDOWN SOLENOID TEST (continued) 8 7 65 4 32 1 91 0 11 1 2 13 14 15 16 #224(+) #262(-) J30 5. Check the shutdown solenoid coil resistance[...]

  • Page 82

    NOTES F-26 F-26 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 83

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-27 F-27 COMMANDER 300 W ARNING ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained per[...]

  • Page 84

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-28 F-28 COMMANDER 300 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .8 – STROBE MARK LOCA TION MARK BLOWER P ADDLE HERE TEST PROCEDURE 1.[...]

  • Page 85

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-29 F-29 COMMANDER 300 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .9 - HIGH IDLE ADJUSTMENT ADJUSTING SCREW LOCKING NUT FIGURE F .10 - LO[...]

  • Page 86

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-30 F-30 COMMANDER 300 ENGINE THROTTLE ADJUSTMENT TEST (continued) 6. If either of the readings is incorrect, adjust the throttle as follows: Adjus[...]

  • Page 87

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-31 F-31 COMMANDER 300 W ARNING ROT OR RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. [...]

  • Page 88

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-32 F-32 COMMANDER 300 ROT OR RESIST ANCE TEST (continued) FIGURE F .1 1 – ROTOR BRUSH LEADS LEADS REMOVED SLIP RINGS TEST PROCEDURE 1 Conduct th[...]

  • Page 89

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-33 F-33 COMMANDER 300 W ARNING FLASHING AND ROTOR VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained p[...]

  • Page 90

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-34 F-34 COMMANDER 300 FLASHING AND ROTOR VOL T AGE TEST (continued) FIGURE F .12 – ROTOR BRUSH LEADS #200A #200B #201 TEST PROCEDURE 1. Using th[...]

  • Page 91

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-35 F-35 COMMANDER 300 FIGURE F .13 - FIELD DIODE RECTIFIER BRIDGE AND FIL TER CAP ACITOR FIL TER CAP ACIT OR FIELD DIODE RECTIFIER BRIDGE FLASHING[...]

  • Page 92

    NOTES F-36 F-36 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 93

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-37 F-37 COMMANDER 300 W ARNING ST A TOR VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. [...]

  • Page 94

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-38 F-38 COMMANDER 300 ST A TOR VOL T AGE TEST (continued) FIGURE F .14 – FRONT CONTROL P ANEL REMOV AL FRONT CONTROL P ANEL SCREWS SCREW TEST PR[...]

  • Page 95

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-39 F-39 COMMANDER 300 ST A TOR VOL T AGE TEST (continued) FIGURE F .15 – OUTPUT P ANEL REMOV AL GREEN GROUND LEAD SCREW S 6. Using the 3/8” wr[...]

  • Page 96

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-40 F-40 COMMANDER 300 ST A TOR VOL T AGE TEST (continued) FIGURE F .16 – AUXILIARY LEAD TEST LOCA TION A UXILIAR Y LEADS #3, #5, #6 (BEHIND P AN[...]

  • Page 97

    TROUBLESHOOTING & REP AIR F-41 F-41 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TOR VOL T AGE TEST (continued) FIGURE F .17 – OUTPUT RECTIFIER DIODE BRIDGE WELD WINDING LEAD CONNE C TIONS 4. Locate[...]

  • Page 98

    NOTES F-42 F-42 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 99

    TROUBLESHOOTING & REP AIR F-43 F-43 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W ARNING RF BY -P ASS BOARD RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained[...]

  • Page 100

    TROUBLESHOOTING & REP AIR F-44 F-44 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RF BY -P ASS BOARD RESIST ANCE TEST (continued) FIGURE F .18 – FRONT CONTROL P ANEL REMOV AL FRONT CONTROL P ANEL SCREWS S[...]

  • Page 101

    TROUBLESHOOTING & REP AIR F-45 F-45 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RF BY -P ASS BOARD RESIST ANCE TEST (continued) FIGURE F .19 – RF BY -P ASS BOARD J61 J62 J60 ARA 4. Locate, label, and re[...]

  • Page 102

    T ABLE F .1. RF BY -P ASS RESIST ANCE T ABLE CHECK POINTS COMPONENT BEING MAXIMUM ALLOWABLE CHECKED RESIST ANCE 1J61 to 5J60 L4 and Board T race 4.2 OHMS (3.5 T ypical) 1J61 to 5J62 L4 and Board T race 4.2 OHMS (3.5 T ypical) 2J61 to 4J60 L5 and Board T race 4.2 OHMS (3.5 T ypical) 2J61 to 4J62 L5 and Board T race 4.2 OHMS (3.5 T ypical) 3J61 to 1J[...]

  • Page 103

    TROUBLESHOOTING & REP AIR F-47 F-47 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W ARNING CONTROL TRANSFORMER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.[...]

  • Page 104

    TROUBLESHOOTING & REP AIR F-48 F-48 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL TRANSFORMER TEST (continued) FIGURE F .20 – FRONT CONTROL P ANEL REMOV AL FRONT CONTROL P ANEL SCREWS SCREW TEST P[...]

  • Page 105

    TROUBLESHOOTING & REP AIR F-49 F-49 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL TRANSFORMER TEST (continued) FIGURE F .21 – PLUG J16 DET AILS J16 43 2 1 5 6 7 8 J16 CONTROL TRANSFORMER 4. Locate[...]

  • Page 106

    NOTES F-50 F-50 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 107

    TROUBLESHOOTING & REP AIR F-51 F-51 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W ARNING OUTPUT RECTIFIER BRIDGE TEST Service and repair should be performed by only Lincoln Electric factory trained person[...]

  • Page 108

    TROUBLESHOOTING & REP AIR F-52 F-52 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F .22 – FRONT CONTROL P ANEL REMOV AL FRONT CONTROL P ANEL SCREWS SCREW TE[...]

  • Page 109

    TROUBLESHOOTING & REP AIR F-53 F-53 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F .23 – OUTPUT P ANEL REMOV AL OUTPUT LEADS (BEHIND PANEL) GREEN GROUND LE[...]

  • Page 110

    TROUBLESHOOTING & REP AIR F-54 F-54 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F .24 – DIODE LEAD REMOV AL ST AT OR AND DIODE PIG TAIL LEAD CONNEC TIONS [...]

  • Page 111

    TROUBLESHOOTING & REP AIR F-55 F-55 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W ARNING POWER MODULE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauth[...]

  • Page 112

    TROUBLESHOOTING & REP AIR F-56 F-56 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE TEST (continued) FIGURE F .25 – POWER MODULE CAP ACITOR LEADS REMOVE LEADS POWER MODULE (CHOPPER PC BOARD) TE[...]

  • Page 113

    TROUBLESHOOTING & REP AIR F-57 F-57 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE TEST (continued) FIGURE F .26 – IGBT TEST REMOVE LEADS POWER MODULE (CHOPPER PC BOARD) HEAT SINK CHECK IGBT F[...]

  • Page 114

    TROUBLESHOOTING & REP AIR F-58 F-58 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE TEST (continued) FIGURE F .27 – DIODE MODULE TEST DIODE MODULES AND HEAT SINKS CHECK DIODE MODULE 8. Using th[...]

  • Page 115

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-59 F-59 COMMANDER 300 W ARNING CURRENT BALANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Una[...]

  • Page 116

    TROUBLESHOOTING & REP AIR F-60 F-60 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CURRENT BALANCE TEST (continued) TEST PROCEDURE 1. T urn the engine off. 2. Perform the Case Cover Removal Procedure and til[...]

  • Page 117

    TROUBLESHOOTING & REP AIR F-61 F-61 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CURRENT BALANCE TEST (continued) FIGURE F .29 – PLUG LOCA TIONS G3002-1 COMMANDER 300 CONTROL Q1 C1 C54 C2 C25 X4 X8 X2 X1[...]

  • Page 118

    NOTES F-62 F-62 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 119

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-63 F-63 COMMANDER 300 W ARNING CONTROL INPUT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unaut[...]

  • Page 120

    TROUBLESHOOTING & REP AIR F-64 F-64 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL INPUT TEST (continued) FIGURE F .30 – PLUG J2 G3002-1 COMMANDER 300 CONTROL Q1 C1 C54 C2 C25 X4 X8 X2 X10 X12 X13 [...]

  • Page 121

    TROUBLESHOOTING & REP AIR F-65 F-65 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL INPUT TEST (continued) 14. Using an ohmmeter , measure continuity at J4 in the following switch positions. See T abl[...]

  • Page 122

    TROUBLESHOOTING & REP AIR F-66 F-66 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL INPUT TEST (continued) FIGURE F .31 – Plug J3 Pin 7 Plug J3 Pin 8 Pin 16 Pin 14 Pin 5 24. Using a remote control h[...]

  • Page 123

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-67 F-67 COMMANDER 300 W ARNING FEEDBACK INPUT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unau[...]

  • Page 124

    TROUBLESHOOTING & REP AIR F-68 F-68 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FEEDBACK INPUT TEST (continued) FIGURE F .32 - CONTROL BOARD G3002-1 COMMANDER 300 CONTROL Q1 C1 C54 C2 C25 X4 X8 X2 X10 X12[...]

  • Page 125

    TROUBLESHOOTING & REP AIR F-69 F-69 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FEEDBACK INPUT TEST (continued) FIGURE F .33. – Plug J2 & J3 Plug J2 Pin 5 Pin 2 Pin 1 6. If the continuity is not pre[...]

  • Page 126

    NOTES F-70 F-70 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 127

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-71 F-71 COMMANDER 300 W ARNING PWM OUTPUT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthor[...]

  • Page 128

    TROUBLESHOOTING & REP AIR F-72 F-72 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PWM OUTPUT TEST (continued) FIGURE F .34 – Plug J13 w/pins 4 & 5 FIGURE F .35 – Plug J1 pin 6 + Plug J13 J13 Right C[...]

  • Page 129

    TROUBLESHOOTING & REP AIR F-73 F-73 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PWM OUTPUT TEST (continued) FIGURE F .36 – Min./Max. Potentiometer Waveforms FIGURE F .37 – Plug J12 Pins 4 & 5 Mini[...]

  • Page 130

    TROUBLESHOOTING & REP AIR F-74 F-74 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PWM OUTPUT TEST (continued) FIGURE F .38 – Engine Protection Board (Plug Locations) G3002-1 COMMANDER 300 CONTROL Q1 C1 C5[...]

  • Page 131

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-75 F-75 COMMANDER 300 W ARNING POWER SUPPL Y TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unaut[...]

  • Page 132

    TROUBLESHOOTING & REP AIR F-76 F-76 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER SUPPL Y TEST (continued) TEST PROCEDURE 1. T urn the engine off. 2. Perform the Case Cover Removal and Replacement Pro[...]

  • Page 133

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-77 F-77 COMMANDER 300 W ARNING DISPLA Y BOARD CALIBRA TION TEST Service and repair should be performed by only Lincoln Electric factory trained pe[...]

  • Page 134

    TROUBLESHOOTING & REP AIR F-78 F-78 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DISPLA Y BOARD CALIBRA TION TEST (continued) TEST PROCEDURE 1. Start the engine. 2. T urn the range selector switch to the C[...]

  • Page 135

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-79 F-79 COMMANDER 300 This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division r[...]

  • Page 136

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-80 F-80 COMMANDER 300 This is the typical DC open circuit out- put voltage generated from a properly operating machine. Note that each vertical di[...]

  • Page 137

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-81 F-81 COMMANDER 300 This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represen[...]

  • Page 138

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-82 F-82 COMMANDER 300 This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represen[...]

  • Page 139

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-83 F-83 COMMANDER 300 This is the typical DC open circuit output voltage generated from a properly operating machine. Note that each vertical divi[...]

  • Page 140

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-84 F-84 COMMANDER 300[...]

  • Page 141

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-85 F-85 COMMANDER 300 W ARNING POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT Service and repair should be performed by o[...]

  • Page 142

    TROUBLESHOOTING & REP AIR F-86 F-86 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .39 – CONTROL P ANEL REMOV AL[...]

  • Page 143

    TROUBLESHOOTING & REP AIR F-87 F-87 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F . 40 – POWER MODULE CAP ACITO[...]

  • Page 144

    TROUBLESHOOTING & REP AIR F-88 F-88 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .41 – POWER MODULE/OUTPUT REC[...]

  • Page 145

    TROUBLESHOOTING & REP AIR F-89 F-89 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. Connect leads #[...]

  • Page 146

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-90 F-90 COMMANDER 300[...]

  • Page 147

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-91 F-91 COMMANDER 300 W ARNING POWER MODULE (CHOPPER) PC BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Ele[...]

  • Page 148

    TROUBLESHOOTING & REP AIR F-92 F-92 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE (CHOPPER) PC BOARD REMOV AL AND REPLACEMENT (continued) FIGURE F .42 – POWER MODULE PC BOARD COPPER ST ANDOFF[...]

  • Page 149

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-93 F-93 COMMANDER 300 W ARNING DIODE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained pers[...]

  • Page 150

    TROUBLESHOOTING & REP AIR F-94 F-94 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DIODE REMOV AL AND REPLACEMENT (continued) TEST PROCEDURE 1. T urn the engine off. 2. Perform the Output Panel Removal Proce[...]

  • Page 151

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-95 F-95 COMMANDER 300 W ARNING ST A TOR/ROT OR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory tr[...]

  • Page 152

    TROUBLESHOOTING & REP AIR F-96 F-96 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .44 – FUEL T ANK REMOV AL DET AILS PLUG FUEL LINES U-BOL TS [...]

  • Page 153

    TROUBLESHOOTING & REP AIR F-97 F-97 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .45 – LEAD REMOV AL DET AILS FIL TER CA P A CIT OR FIELD BRI[...]

  • Page 154

    TROUBLESHOOTING & REP AIR F-98 F-98 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .46 – BRUSH LEAD REMOV AL 12. Label and remove brush leads #[...]

  • Page 155

    TROUBLESHOOTING & REP AIR F-99 F-99 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) 16. Using the 7/16" wrench, disconnect stator lead #6 from the aux[...]

  • Page 156

    TROUBLESHOOTING & REP AIR F-100 F-100 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .49 – LIFT FRAME AND ASSOCIA TED COMPONENT REMOV AL LIFT F[...]

  • Page 157

    TROUBLESHOOTING & REP AIR F-101 F-101 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) ST A TOR REMOV AL PROCEDURE 1. Using the 1/2" wrench, remove the[...]

  • Page 158

    TROUBLESHOOTING & REP AIR F-102 F-102 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) ROTOR REMOV AL PROCEDURE 1. Support the rotor with the hoist. 2. Usin[...]

  • Page 159

    TROUBLESHOOTING & REP AIR F-103 F-103 COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) LEAD RECONNECTION CHECKLIST Engine ❒ Leads #242D and #229 to fuel l[...]

  • Page 160

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-104 F-104 COMMANDER 300 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mec[...]

  • Page 161

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-105 F-105 COMMANDER 300[...]

  • Page 162

    COMMANDER 300 G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM (COMMANDER 300 DELUXE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 WIRING DIAG[...]

  • Page 163

    G-2 ELECTRICAL DIAGRAMS COMMANDER 300 WIRING DIAGRAM - COMMANDER 300 DELUXE MODEL MOTOR START BUTTON STARTER SOLENOID ALTERNATOR STARTING Í Í 214 215 216 217 218 219 220 222 4 5 6 7 8 9 SELECTOR SWITCH (VIEWED FROM REAR) S5 250 ohms 25 watts 231A 281 J13 3 2 1 4 5 6 CHOKE L1 J12 3 2 1 4 5 6 HEAT SINK HEAT SINK PCB2 CAP. CAP. 15 16 23A 25A 1[...]

  • Page 164

    G-3 ELECTRICAL DIAGRAMS COMMANDER 300 WIRING DIAGRAM - COMMANDER 300 ST ANDARD MODEL G-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MOTOR START BUTTON STARTER SOLENOID ALTERNATOR STARTING Í Í 214 215 216 217 218 2[...]

  • Page 165

    G-4 ELECTRICAL DIAGRAMS COMMANDER 300 G-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCHEMA TIC - CONTROL PC BOARD J1 6 1.00K R99 50V 0.1 C62 25A GND GND +12V -Vss POW_+12 POW_gnd POW_gnd 200 R233 GND 200 R72 200 R73 200 [...]

  • Page 166

    G-5 ELECTRICAL DIAGRAMS COMMANDER 300 PC BOARD ASSEMBL Y - CONTROL BOARD G-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troublesh[...]

  • Page 167

    COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-6 ELECTRICAL DIAGRAMS G-6 SCHEMA TIC - ENGINE PROTECTION PC BOARD S15018-13 IDLER 12 SEC. TIMER F +10V +10V 16 4536B 8 D C DECODE B A Vss OSC INH SET RESET IN 1 O[...]

  • Page 168

    COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-7 ELECTRICAL DIAGRAMS PC BOARD ASSEMBL Y - ENGINE PROTECTION BOARD 0 .22 0 .22 6.00 5.78 4.00 7.78 8.00 ±.04 ±.04 .25 X6 R44 R42 R43 R41 R88 R90 R91 R96 R139 R1[...]

  • Page 169

    COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-8 ELECTRICAL DIAGRAMS G-8 SCHEMA TIC - CHOPPER PC BOARD 1N4936 D8 D5 com com com com +15 com 20 19 DIODES = D3 J1 2 J1 3 D4 J1 1 + t .24 R1 D1 J1 6 50 25V C2 4.75[...]

  • Page 170

    COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-9 ELECTRICAL DIAGRAMS PC BOARD ASSEMBL Y - CHOPPER BOARD 3135-1 3135-1 2-19-99F G G CAPACITORS = MFD/VOLTS RESISTORS = OHMS ITEM REQ'D PART NO IDENTIFICATION[...]

  • Page 171

    COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-10 ELECTRICAL DIAGRAMS G-10 SCHEMA TIC - METER PC BOARD 1.0 35V C9 COM LED3_LE CTL COM D4 MTR1_OE LED2_LE MTR2_OE LED5_LE D4 D5 D6 D5 D7 D6 D7 +5V MTR 1 COM LED B[...]

  • Page 172

    COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-11 ELECTRICAL DIAGRAMS PC BOARD ASSEMBL Y - METER BOARD 2-5-99A G ITEM REQ'D PART NO. DESCRIPTION C2,C4,C7,C10,C11,C12,C13 28 S16668-11 .1/50 C14,C15,C16,C21[...]

  • Page 173

    COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-12 ELECTRICAL DIAGRAMS G-12 SCHEMA TIC - BYP ASS PC BOARD 18948 2E J61 7 J61 1 J61 2 J61 3 J61 8 J61 5 J61 4 J60 6 J62 4 J60 5 J62 3 J62 1 J62 2 J60 4 4D J60 1 J6[...]

  • Page 174

    COMMANDER 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-13 ELECTRICAL DIAGRAMS PC BOARD ASSEMBL Y - BYP ASS BOARD 10-11-96B L 9573-1 IDENTIFICATION PART NO. REQ'D ITEM CAPACITORS = MFD/VOLTS INDUCTANCE = HENRYS ~.[...]

  • Page 175

    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 wi[...]