COMMANDER 300 WIRING DIAGRAM FOR CODES 10871 AND BELOW
| 6A |
LEADS 3 & 6A | |
PASS THROUGH | |
TOROID TWICE | |
IN OPPOSITE | |
DIRECTIONS | |
| + WELD LEAD TO PASS |
| THRU TOROID ONCE |
| 260 |
50MV=400AMPS | 261 |
+I | |
| 204S |
206S260A
261A
ELECT.
3
6A
3
+WELD LEAD
HEATSINK |
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D2 |
| 200 AMP |
| LEFT | |
POS. | MODULE | |
IGBT | B1 | |
POS. | DRIVER | B2 |
PCB6 | B3 | |
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| B7 |
| W7 |
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| W8 |
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CAPACITOR |
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NEG. |
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NEG. |
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3 
2 
1 
6 
5 
4 
P50
9 
8 
7 
250
TS1
249
17
1
2
3
18
J50 
4
5
6
7
8
9
23
25
6A |
| 6A |
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3 |
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| COMMANDER 300 WIRING DIAGRAM |
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| 5A |
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| 120V AUXILIARY POWER |
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W4 & W5 | W2 & W3 | W1 & W6 |
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| CORRESPONDING SETTINGS FOR TAP NUMBERS |
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| "INSULATED STUD" |
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| 6A | ON BOTTOM LEFT | STATOR | AUXILIARY WINDINGS |
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| OF CONTROL BOX |
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| 200A | 250A |
| AUXILIARY POWER |
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| 150A 11 | 12 |
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| 10 | 1 300A |
| GND. SCREW ON |
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| 5A | 5 |
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| 90A 9 | 2 | STICK | CONTROL PANEL |
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RECTIFIER BRIDGE |
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| 8 | 3 | TIG |
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| 14 TO 32V |
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| OLDER MACHINES MAY BE WIRED |
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| 20A |
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| EMPTY | EMPTY |
| AS SHOWN: |
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| EMPTY | EMPTY |
| SELECTOR SWITCH |
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| 31 |
| CB1 |
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| SELECTOR SWITCH |
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| (VIEWED FROM REAR) |
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W3 | W2 | (VIEWED FROM REAR) |
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| S5 |
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| S5 |
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| 217 | 6 5 |
| 216 |
| 50A | SILVER |
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W3 | W2 |
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| 6A |
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| 217 |
| 12 | 11 | 216 |
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| 218 | 7 | 4 | 215 | AUXILIARY |
| 11 | J12 |
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| A |
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| 115/230V | |||||
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| 10 | 215 |
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| 8 | 3 | 214 |
| CB3 |
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| NEUTRAL STUD | 3 |
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| 9 | 2 | 213 |
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G4357
COMMANDER 300
C1 | 220 | BACK OF CONTROL |
206A 206B
BYPASS
FILTER 
GND-K
ASSEMBLY
208
208B
WORK
208A
SWITCH SHOWN IN
POSITIVE POLARITY
POSITION
+
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| CHOKE |
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| D4 | HEATSINK |
| P51 |
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| RIGHT | 200 AMP |
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| MODULE |
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| IGBT | 3 | 2 | 1 |
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| DRIVER | B2 | 6 | 5 | 4 |
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13 | 13A | POS. | PCB7 | B3 | 9 | 8 | 7 |
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POS. |
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| W10 |
| TS2 |
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| CAPACITOR |
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| 251 |
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NEG. |
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| D3 |
| 1 | 2 | 3 | 16 |
14 | 14A |
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| J51 | 4 | 5 | 6 | 23A |
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25A
| STATOR |
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| 222 |
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| 20A |
| 9 |
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| WELD |
| 220 |
| 3 | 8 |
| 213 |
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| HOT (GOLD) |
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W4 | WINDINGS | W1 |
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W4 |
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| 5E |
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W5 |
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| CB2 |
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W5 |
| W6 |
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| 5E |
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| STATOR 42V WINDING | 10A |
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| 50A |
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| 42 |
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| 42A |
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| 41 |
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| 16 | 1 01A | 18 | 1 16A |
| 18A |
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| 5C |
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| 105A |
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| 1 | J41 | 2 | 15 | 17 |
| 5J | 115A | 41A | 3 |
| 200B |
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| 201 | 200A |
| 200D |
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| BRUSH | BRUSH |
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| 200C |
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| POWER SUPPLY | J42 |
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| 200E | 2 |
| 200A |
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| 300V |
| 6D |
| 200C | 3 |
| 200D |
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| ROTOR |
| 201B | - |
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3 |
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| 201A |
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| 228 |
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6A |
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| POSITIVE BRUSH CONNECTED |
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| 241A | 6 |
| 241 |
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| TO SLIP RING NEAREST |
| 201 | 5P |
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| TO THE LAMINATION |
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| 201B | 7 |
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| 5H | 8 |
| 5P | ENGINE HARNESS |
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| POLARITY | 21 |
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| SWITCH |
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| 41A |
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| 42A |
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206A |
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| 208B | |
115VAC | J | 31 |
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A | 32 |
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| M1 |
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42VAC | I | 41A |
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K | 42A |
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| VOLTMETER |
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WORK | H | 21 |
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REMOTE | E | 77B |
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| 6 | M6 |
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F | 76B |
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CONTROL |
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| G | 75B |
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CONTACTOR |
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| M1 | M2 | M3 | M4 | M5 | M 6 | M9 |
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D | 4B |
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| C | 2B |
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GROUND | B |
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AMPHENOL 1 |
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| 3 | M3 |
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| M4 |
| 4 | M4 |
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| AMMETER |
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| 5 | M5 |
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| 77A |
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| M6 |
| 6 | M6 |
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| A | 77B |
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REMOTE | 76A |
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CONTROL | B | 76B |
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| M9 |
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| C | 75B | 75A |
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| METER KIT OPTIONAL |
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| M10 |
| 10 | M10 |
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CONTACTOR | 2A |
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D | 2B |
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| ON STANDARD MODEL |
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| E | 4B | 4A |
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GROUND | F |
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AMPHENOL 2 |
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| 3 TURNS |
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| 3 TURNS | ||
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| THRU |
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| THRU | |
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| TOROID |
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| TOROID | |
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| 204S | M1 |
| M3 | M9 | M10 |
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| 712 | 218 220 | 2 | M6 |
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| M9 | M10 |
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| 4 |
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| 206S |
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| 2 |
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| 2 |
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| 2 |
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| 1 | M6 | M2 | M4 | M5 |
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| 251 | 252 | 250 | 253 | 213 | 214 215 | 612 | M1 | M2 | M3 | M4 | M5 |
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| 77A 76A 75A |
| ||
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| SELECT |
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| 1 |
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| 5 |
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| 1 |
| 3 | 1 |
| 4 | 1 |
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| 1 |
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| 3 | 6 | J6 |
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| MACHINE |
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| J3 | SHUNT | 6 |
| J4 |
| 10 |
| 4 | J11 | 6 | J2 | 6 |
| J5 |
| 10 |
| 4 |
| J10 |
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| AM METER |
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| THERMAL |
| MODE |
| VOLT METER |
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| AMPHENOL |
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| 8 | 16 |
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| WELD BOARD |
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| 3 | 1 | 75 | |||
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| 77 | ||||
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| PROGRAMMING |
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| PCB3 |
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| 782 | 279 | 727 |
| 572 208B 562 262 | 2W23 | 40423A | 261A 23260A | 25 | A116 | 05A1 | 5G | 01A1 | A181 | 15A1 4 | J7 | ||
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| 76 | |||||||||||||||||
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| J1 |
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| A |
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| 25 |
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| CONTROLPOT | ||
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| 3 | 16 |
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| 9 | 8 |
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| 1 | 9 |
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| 2 | J8 | 1 |
| 2 | J9 | 1 |
| 8 | J12 |
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| 1 | 4 |
| J13 |
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| 1 |
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| HOT START | PINCH |
| MISC CONTROL |
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| POWER |
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| 31 |
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| 232T | 9 |
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| 232S |
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| 32 |
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| 226 | 10 |
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| 226A |
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| 200 | 11 |
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| 200B |
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| 41A |
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| 232T | 224A | 12 |
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| 224 |
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| 42A |
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| 234A | 13 |
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| 234 |
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| 5J |
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| 233A | 14 |
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| 233 |
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| 281A | 15 |
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| 281 |
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| WELDING TERMINALS |
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| 239A | 16 |
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| 239 |
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| OUTPUT |
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| 232W | 232D |
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| CONTROL | SWITCH |
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| IDLER |
| P52 | J52 |
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| CONTROL |
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| VIEWED |
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| SHOWN IN |
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| HOUR |
| CONTROL |
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| CCW |
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| FROM |
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| "ALWAYS ON" POSITION |
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| METER |
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| R1 |
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| BACK |
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| 4 |
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| 257 |
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| PINCH POT |
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| - |
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| VIEWED |
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| 4A |
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| HIGH |
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| FROM |
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| 77 | BACK |
| 75 |
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| 10K |
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| 2A |
| 2 |
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| 232S | + | HOLD |
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| 76 |
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| AUTO |
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| COIL |
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| 232L | + | PULL | 227 |
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| 232R |
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| COIL |
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| 262A |
| SHOWN IN |
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| IDLE | SOL. |
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| 256 |
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| 277 |
| 278 | 279 |
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| 262B | "HIGH" POSITION |
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| 32 |
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| START BUTTON |
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| SHUTDOWN SOL. |
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| + |
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| ON STANDARD MODELS, |
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| DENOTES ITEMS |
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| LEADS 238 & 236C ARE TO BE |
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| 224 | 262 |
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| BOLTED TOGETHER AND |
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| 236A |
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| INCLUDED ON DELUXE | TAPED. LEADS 228A, 241A, | 236C 238 |
| 232B |
| 232C |
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| 236 |
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| 242B, 232K AND 229A ARE TO |
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| 236B |
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| OIL PRESSURE SWITCH & SENSOR |
| ||||||||||
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| MODELS ONLY |
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| BE TAPED INDIVIDUALY AND |
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| TIED INTO HARNESS. | BATT. | OIL | OIL |
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| 5J |
| 5H |
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| RUN/STOP |
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| CHRG. | PRESS. | TEMP |
| FUEL |
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| SWITCH | RUN |
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| 231 | 228 | SENSOR | SWITCH 234 |
| |
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| 232R |
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| SHOWN IN |
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| 12VDC |
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| WK |
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| 243 | 247 | 246 | 245 |
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| S I | S | I | S | I |
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| "RUN" POS. | STOP |
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| G |
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| INSULATED |
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| 5G |
| GND. STUD ON | 242D |
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| OIL TEMP. SENSOR & SWITCH |
| |||||||||||||
252 | GOLD | GOLD |
| GOLD |
| GOLD | GOLD | STUD |
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| 5L |
| BOTTOM RIGHT OF |
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| 232A | 232H |
| 232J |
| 241 |
| 233 |
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| 242A |
| 5T |
| CONTROL BOX |
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| SENSOR | ON STANDARD | |||||
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| LOW |
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| 228A 242C |
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| 232D |
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| WELDER | ALT. | TEMP. | LOW |
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| SWITCH | |||||||||
| PRESS. | FUEL |
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| 238 |
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| 232 |
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| MODELS, LEADS | ||||||||||
| TEMP. |
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| 232K GAUGE KIT |
| 242B | 229A |
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| 229 |
| 242D & 229 ARE | |||
253 | SILVER | SILVER |
| SILVER |
| SILVER | SILVER |
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| 241A | 232K |
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| FUEL LVL. | TO BE TAPED | ||||
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| 232F | 232G | 232E |
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| OPTIONAL ON |
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| 242D | SENSOR |
| ||||||
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| 232N |
| STANDARD MODEL |
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| 232L |
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| 231 |
| OUTPUT PANEL | |
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| SOLENOID |
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| PERIPHERAL BD. |
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| BATTERY |
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| STARTING | (+) | 12V BATTERY | |||||||
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| BOARD |
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| B4 | B3 B2 B1 |
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| STUD ON ENGINE | ||||
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| 200 281A |
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| MOUNTING FOOT | |
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| 27 1 40 1 270 | 40 2 |
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| LEFT SIDE | ||||
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| 12 234A 233A | 5 | 9 |
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| 232 |
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| 401 404 40 2 405 |
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| 239 W | D- | STUD ON ENGINE | ||||||
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| 24 | 22 |
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| MOUNTING FOOT |
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| 270 | 262B 224A | 232P 232J | 4 05 403 | 5T |
| 243 2 29A | 239A 462 271 | 247 |
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| RIGHT SIDE |
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| 9 | 7 |
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| 238 | 281 |
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| PULL COIL BD. |
| 32 |
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| GROUNDING BOLT | |||
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| PCB8 |
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| ON ENGINE BLOCK | ||||
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| 9 |
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| 4 |
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| 1 | 6 |
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| 16 |
| J65 | 242B |
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| FRAME |
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| 8 | J31 |
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| J32 |
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| J43 |
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| GND STUD ON RIGHT SIDE |
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| BACK OF CONTROL BOX | |||||||
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G3776
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia- gram for your particular machine is pasted inside the machine on one of the enclosure panels.
DIAGRAMS
G3834