COMMANDER 300 WIRING DIAGRAM FOR (CODES 11200 AND ABOVE)
COMMANDER 300
LEADS 3 & 6A |
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| 6A |
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PASS THROUGH |
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| 3 |
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TOROID TWICE |
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IN OPPOSITE |
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DIRECTIONS |
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| +WELD LEAD TO PASS |
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| D2 |
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| HEATSINK |
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| LEFT | 200 AMP |
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| THRU TOROID ONCE |
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| POS. |
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| MODULE |
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| IGBT |
| B1 |
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| 3 | 2 | 1 | ||
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| 6A |
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| POS. |
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| DRIVER |
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| PCB6 |
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| B7 |
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| 9 | 8 | 7 |
50MV=400AMPS |
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| 260 |
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| W7 |
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+I |
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| 1 | 2 | 3 | 18 | |||
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| 261 |
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| W8 |
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| 250 |
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| CAPACITOR |
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| TS1 |
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| 249 |
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| 204S |
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| NEG. |
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| +WELD |
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| D1 |
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| 206S |
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| NEG. |
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| J50 | 7 | 8 | 9 | 23 | |||
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| 4 | 5 | 6 |
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| 260A |
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| LEAD |
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| 261A |
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| 25 | |
ELECT. |
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| CHOKE |
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| L1 |
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206A | 206B |
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| D4 |
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| HEATSINK |
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| P51 |
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| 200 AMP |
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| BYPASS |
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| RIGHT |
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| MODULE |
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| FILTER |
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| IGBT |
| B1 |
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| ASSEMBLY |
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| DRIVER |
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| 13 |
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| 13A |
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| POS. |
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| PCB7 |
| B3 |
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| B7 |
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| W9 |
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| POS. |
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| W10 |
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| CAPACITOR |
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| WORK |
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| NEG. |
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| NEG. |
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| 15 | ||||||
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| 208B |
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| D3 |
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| J51 | 1 | 2 | 3 | 16 | ||
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| 4 | 5 | 6 | 23A | |||||
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| 208A |
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| 7 | 8 | 9 | ||||
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| 25A | |
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| SWITCH SHOWN IN |
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| POSITIVE POLARITY |
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| POSITION |
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| 41A |
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| POLARITY | 21 |
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| 42A |
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| SWITCH |
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| 206A |
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| 208B | |
115VAC | J | 31 |
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A | 32 |
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| M1 |
| 1 | M1 |
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42VAC | I | 41A |
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| M2 |
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K | 42A |
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| M3 |
| 3 | M3 |
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| VOLTMETER |
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WORK | H | 21 |
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| M4 |
| 4 | M4 |
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| M5 |
| 5 | M5 |
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REMOTE | E | 77B |
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| M6 |
| 6 | M6 |
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F | 76B |
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| 7 |
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CONTROL |
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| G | 75B |
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| M1 | M2 | M3 | M4 | M5 | M6 | M9 | M10 |
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| 8 | M9 |
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| M9 |
| 9 |
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CONTACTOR D | 4B |
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| M10 | 10 | M10 |
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| C | 2B |
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GROUND | B |
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| M1 | M2 | M3 | M4 | M5 | M6 | M9 | M10 |
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| M1 |
| 1 | M1 |
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| AMPHENOL 1 |
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| M2 |
| 2 | M2 |
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| M3 |
| 3 | M3 |
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| M4 |
| 4 | M4 |
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| AMMETER |
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| M5 |
| 5 | M5 |
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| 77A |
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| M6 |
| 6 | M6 |
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| A | 77B |
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| 7 |
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REMOTE | 76A |
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| 8 |
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CONTROL | B | 76B | 75A |
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| M9 |
| 9 | M9 |
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| C | 75B |
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| METER KIT OPTIONAL |
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| M10 | 10 | M10 |
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| 2A |
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CONTACTOR | 2B |
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| ON STANDARD MODEL |
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| |||||||||
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| D |
| 4A |
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| E | 4B |
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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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| 127 | 218 | 220 |
| 2 | M6 |
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| M9 | M10 |
| 4 |
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| 206S |
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| 2 |
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| 2 |
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| SELECT |
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| 1252 |
| 3253 |
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| 2 |
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| |
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| 3 | 6 |
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| M6 | 1 | M2 | M4 | M5 | 5 |
| 251 | 250 |
| 1 | 213 | 214 | 215 | 4 | 1 |
| M2 | M3 M4 | M5 | 5 | 1 |
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| 3 |
| ||||||
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| MACHINE |
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| 1 |
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| 612 |
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| M1 |
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| 77A 76A 75A |
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| |||
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| 1 | 4 | SHUNT |
| 6 |
| J4 |
| 10 |
| 4 | J11 | 6 |
| 5 |
| J2 |
| 8 |
| 6 |
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| J5 |
| 10 | 4 | J10 |
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| J3 | 2 | 2 |
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| J6 |
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| 8 | 16 |
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| AM METER |
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| THERMAL |
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| MODE |
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| VOLT METER |
| AMPHENOL |
| |||||||||||
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| 3 |
| 1 | 75 |
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| PROGRAMMING |
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| 4 |
| 3 |
| 4 | 279 | 3 | 257 | 208B | 256 | 226 | 232W |
| 404 | 23A | 261A | 23 | 260A | 25 | 116A | 105A 5G | 101A | 118A | 115A | 4 |
|
| 77 |
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| WELD BOARD |
|
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| 278 |
| 277 |
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| 25A |
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| J7 | ||||||
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| 2 | 76 | |||||||||
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| J1 |
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| PCB3 |
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| CONTROL POT | |||||
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| 16 |
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| 9 | 8 |
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| 5 |
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| 1 | 9 |
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| 2 | J8 | 1 |
| 2 | J9 | 1 |
| 8 |
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| J12 |
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| 1 | 4 | J13 |
| 1 |
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| |
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| HOT START | PINCH |
|
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| MISC CONTROL |
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| POWER |
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| ||||||||||||
| 6A |
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| 6A |
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| 3 |
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| COMMANDER 300 WIRING DIAGRAM |
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| 3 |
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| 120V AUXILIARY POWER |
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| ||||||||||||||||||||
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| W2 & W3 |
| W1 & W6 |
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| AUXILIARY POWER |
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| "INSULATED STUD" |
|
| STATOR | AUXILIARY WINDINGS |
| |||||||||||
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| W4 & W5 |
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| CORRESPONDING SETTINGS FOR TAP NUMBERS |
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| 6A ON BOTTOM LEFT |
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| ||||||||||||||||||||||||||||
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| GND. SCREW ON |
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| OF CONTROL BOX |
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| (AS VIEWED FROM THE FRONT) |
| CONTROL PANEL |
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| 6D | 6 |
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| 3 |
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| 200A |
| 250A |
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| 5A |
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| 5A |
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| 5 |
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| 150A | 11 |
| 12 | 300A |
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| 10 |
| 1 |
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| |||
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| 90A | 9 |
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| 2 | STICK |
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| 14 TO 32V |
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| WIRE | 8 |
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| 3 | TIG |
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| 20A |
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| 9 |
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| EMPTY |
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| EMPTY |
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| 31 |
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| CB1 |
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| EMPTY | EMPTY |
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| 3A |
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| W3 | W2 | RECTIFIER |
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| AUXILIARY |
|
| 50A | 11 |
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| NEUTRAL STUD |
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| SILVER |
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| |||||||||||
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| W3 | W2 | BRIDGE |
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| S5 |
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| 5B |
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| |||||||||
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| 217 |
| 216 |
|
|
| STATOR 42V WINDING |
| 10A | BACK OF CONTROL |
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| |||||||||||||||||
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| 12 | 11 |
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| BOX "LEFT SIDE" |
|
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| CB3 |
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| J12 |
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| 115/230V | 11 |
| ||||||||||||
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| 218 | 1 | 10 | 215 |
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| 3 |
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| 42 |
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| |||||||||||
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| 2 | C1 | 9 | 214 |
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| CB6 |
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| STATOR |
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| 9 |
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| W4 |
| WELD | W1 |
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| 220 | 3 |
| 8 | 213 |
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| WINDINGS |
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| 42A |
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| SILVER |
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| W4 |
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| 222 |
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| 41 |
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| 5E |
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| 12 |
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| W5 |
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| W6 |
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| SELECTOR SWITCH |
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| 8 |
| J11 |
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| CB2 |
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| W5 |
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| W6 |
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| (VIEWED FROM REAR) |
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| 6B |
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| 5E |
| 50A |
| 8 |
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| 5 | ||
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| 41A |
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| 6A |
| 12 |
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| 5C |
| CB4 |
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| 16 | 101A | 18 | 16A | 118A |
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| 5C |
| 5 |
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| A | 17 | 5J 115A |
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| 1 | J41 | 2 | 15 105 |
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| 13 |
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| 6A |
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| 14 |
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| 201 |
| 200B |
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| 4 |
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| 200A | 200D |
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| 6 |
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| 10 |
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| ENGINE HARNESS |
| ||||||||||
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| J42 |
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| BRUSH | BRUSH |
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| ||||||||||||
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| POWER SUPPLY |
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| 200E | + |
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| 1 |
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| 5J |
| PCB2 |
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| 200C |
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| 200E |
| 2 |
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| 200A |
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| 3200MFD |
| 5H |
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| 200C |
| 3 |
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| 200D |
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| 3 |
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| 300V | - |
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| 262A |
| 4 |
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| 262 |
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| ROTOR |
| 201B |
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| 6A |
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| 201A |
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| 228A |
| 5 |
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| 228 |
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| POSITIVE BRUSH CONNECTED |
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| 241A |
| 6 |
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| 241 |
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| TO SLIP RING NEAREST |
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| ||||
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| 41A |
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| TO THE LAMINATION |
| 201 | 6D |
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| 201B |
| 7 |
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| 201A |
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| 42A |
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| 8 |
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| 232T |
| 9 |
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| |
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| 31 |
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| 232T |
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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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| 224A |
| 12 |
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| 224 |
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| 234A |
| 13 |
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| 234 |
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| 233A |
| 14 |
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| 233 |
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| OUTPUT |
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| WELDING TERMINALS |
|
|
|
| 232W | 232D |
| 281A |
| 15 |
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| 281 |
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| ||||||
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| CONTROL |
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| CONTROL | SWITCH |
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| 239A |
| 16 |
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| 239 |
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| |||||||
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| VIEWED |
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| SHOWN IN |
|
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| IDLER |
|
| P52 |
| J52 |
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| |||||||||
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| CCW |
|
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| FROM |
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| "ALWAYS ON" POSITION |
|
| HOUR | CONTROL |
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| IDLER |
| ||||||||||||||
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| R1 |
|
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| BACK |
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| 4A |
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| 4 |
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| 257 |
|
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| SHUTDOWN |
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| |||||||||||
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| VIEWED |
|
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| PINCH POT |
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| METER |
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| SOLENOID | SOLENOID |
| ||||||||||||||
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| + | - |
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| |||||||||||||||
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| FROM |
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| 10K |
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| HIGH |
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| ||||
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| 77 | BACK | 76 | 75 |
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| 2A |
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| 2 |
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| COIL |
|
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| HOLD | PULL |
| ||||||
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| AUTO |
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| BLK |
|
| RED |
| COIL | COIL |
| |||
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| RED | WHT |
| |||||
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| 232R |
|
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| |||
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|
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| 277 |
| 278 |
| 279 |
|
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| 262A | SHOWN IN |
|
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| BLK |
| |||
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|
| 262B | "HIGH" POSITION | 256 |
|
|
| J54 | 2 | 1 |
| J55 | 1 | 2 | 3 | 4 |
| |||
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| P54 |
| P55 |
| |||||||
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| 224 |
|
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| 232L |
| |
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| ON STANDARD MODELS, |
|
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| 20A |
|
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|
|
| START BUTTON | 262 |
|
|
| 226A | 227 |
| |||||||||
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| |||||||||
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| LEADS 238, 238A & 236C |
|
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|
| 238A | 236A |
|
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| ||||
|
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| DENOTES ITEMS |
| ARE TO BE BOLTED |
|
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| |||||||||
|
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| TOGETHER AND TAPED. |
|
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| CB5 |
|
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|
| |||||||||||
|
|
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|
|
| INCLUDED ON DELUXE | LEADS 228A & 241A |
| 236C 238A |
| 232B |
| 232C |
|
|
|
|
|
| 236A | 236B |
|
| 236 |
|
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| ||||||||||||
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| ARE TO BE TAPED |
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| OIL PRESSURE SWITCH & SENSOR |
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| MODELS ONLY |
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| INDIVIDUALLY AND TIED | BATT. | 238 OIL |
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| OIL |
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| 5J |
| 5H |
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| 231 |
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| INTO HARNESS. |
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| CHRG. | PRESS. | TEMP |
| FUEL |
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| RUN/STOP | RUN |
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| 228 |
| SENSOR |
| SWITCH | 234 |
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| 12VDC | 232R |
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| 5G |
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| G |
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| WK |
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| 243 | 247 | 246 |
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| S |
| I |
| S | I | S I |
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| SWITCH | STOP |
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| SHOWN IN |
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252 |
| INSULATED |
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| 5L | GND. STUD ON | 242D |
| "RUN" POS. |
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| OIL TEMP. SENSOR & SWITCH |
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GOLD |
| GOLD |
| GOLD |
| GOLD |
| STUD |
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| 5T | BOTTOM RIGHT OF |
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| 232A | 232H | 232J |
| 241 |
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| 233 |
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| 242A 232K |
| CONTROL BOX |
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| 232 |
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| SENSOR |
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| WELDER | ALT. | LOW | TEMP. |
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| 228A |
| 242C |
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| 232D |
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| TEMP. |
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| PRESS. |
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| 242B | 238 |
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253 | SILVER |
| SILVER |
| SILVER |
| SILVER |
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| 232K | GAUGE KIT |
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| 229 |
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| 229 |
| FUEL LVL. |
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| OPTIONAL ON |
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| 241A |
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| 242D | SENSOR |
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| 232N |
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| STANDARD MODEL |
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| 232A |
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| 232P |
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| 232L |
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| 32 |
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| 236C | 236 |
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| GROUND STUD ON | |||
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| 231 |
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| OUTPUT PANEL | ||
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| 227 |
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| 5R |
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| STARTER |
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| 5S | 232N |
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| PERIPHERAL BD. |
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| SOLENOID |
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| 12V BATTERY | |||||||||
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| BATTERY |
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| ALTERNATOR | MOTOR |
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| STARTING |
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| ||
| 270 | 262B | 24A2 | 232P | 232J 405 340 | 5T |
| 234A | 3A2 243 | 39A2 462 271 724 | PROGRAMMING |
|
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| 5L | 200 | 281A | 232 | 271 401 270 402 | BOARD | 1 401 404402 405 | 403 3 | B4 B3 B2 B1 |
| 32 |
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| 239 | B+ | D+ |
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| STUD ON ENGINE | ||||||||
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| PCB1 |
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| 1 |
| 3 |
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| PCB4 |
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| MOUNTING FOOT | |||
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| STUD ON ENGINE LEFT SIDE | |||||||
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| PULL COIL BD. | 5S |
| W |
| D- |
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| MOUNTING FOOT | |||||||||
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| PCB8 |
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| RIGHT SIDE |
| ||
| 16 |
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| 9 | 12 |
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| 7 | 4 | J30 | 6 |
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| 1 |
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| 8 |
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| ENGINE GROUND | ||||
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| 242B |
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| 238 |
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| 281 |
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| 9 |
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| 16 |
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| 4 | 6 |
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| GROUNDING BOLT | |||
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| ||||||
| 8 |
| J31 |
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| 1 | 6 |
| J32 |
| 1 |
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| J65 |
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| FRAME |
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| ON ENGINE BLOCK | |||
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| J43 |
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| 5R |
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| GND STUD ON RIGHT SIDE BACK OF CONTROL BOX |
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| A | |||||||||
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| ||||||||||
G4891
DIAGRAMS
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.
