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SVM133-B
September, 2002

Commander

TM

400

For use with machine code numbers: 9978, 9979, 10580, 10581

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Safety Depends on You

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Lincoln arc welding and cutting

equipment is designed and built
with safety in mind. However,
your overall safety can be increased by proper installation . . .
and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.

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SERVICE MANUAL

Copyright 2002 Lincoln Global Inc.

World's Leader in Welding and Cutting Products

Sales and Service through Subsidiaries and Distributors Worldwide

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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SAFETY

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines

The engine exhaust from this product contains

chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

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Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of Safety in Welding & Cutting - ANSI Standard Z49.1 from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE
powered equipment.

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
hot.

1.a. Turn 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.

____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers
and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.

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____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.

Mar 95
COMMANDER 400

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ii

SAFETY
ELECTRIC SHOCK can kill.

ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits

are electrically hot when the welder is on.
Do not touch these hot parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Head shield and filter lens
should conform to ANSI Z87. I standards.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from
the arc rays.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
Semiautomatic DC Constant Voltage (Wire) Welder.
DC Manual (Stick) Welder.
AC Welder with Reduced Voltage Control.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically hot.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

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ii

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically hot parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.

FUMES AND GASES

can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturers instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employers safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

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5.e. Also see item 1.b.

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COMMANDER 400

Mar 95

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iii

WELDING SPARKS can

cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to Safety in Welding and Cutting (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

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6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been cleaned. For information, purchase Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

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iii

SAFETY

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.

CYLINDER may explode

if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
Away from areas where they may be struck or subjected to
physical damage.
A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically hot parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
Precautions for Safe Handling of Compressed Gases in
Cylinders, available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturers
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturers recommendations.

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Mar 95

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COMMANDER 400

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iv

iv

SAFETY
PRCAUTIONS DE SRET

Pour votre propre protection lire et observer toutes les instructions

et les prcautions de sret specifiques qui parraissent dans ce
manuel aussi bien que les prcautions de sret gnrales suivantes:
Sret Pour Soudage A LArc
1. Protegez-vous contre la secousse lectrique:
a. Les circuits llectrode et la pice sont sous tension
quand la machine souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vtements mouills. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trs attention de bien sisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couch pour lesquelles une grande
partie du corps peut tre en contact avec la masse.
c. Maintenir le porte-lectrode, la pince de masse, le cble de
soudage et la machine souder en bon et sr tat defonctionnement.
d.Ne jamais plonger le porte-lectrode dans leau pour le
refroidir.
e. Ne jamais toucher simultanment les parties sous tension
des porte-lectrodes connects deux machines souder parce que la tension entre les deux pinces peut tre le
total de la tension vide des deux machines.
f. Si on utilise la machine souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-lectrode sapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le cble-lectrode autour de nimporte quelle partie
du corps.
3. Un coup darc peut tre plus svre quun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant appropri
ainsi quun verre blanc afin de se protger les yeux du rayonnement de larc et des projections quand on soude ou
quand on regarde larc.
b. Porter des vtements convenables afin de protger la
peau de soudeur et des aides contre le rayonnement de
larc.
c. Protger lautre personnel travaillant proximit au
soudage laide dcrans appropris et non-inflammables.
4. Des gouttes de laitier en fusion sont mises de larc de
soudage. Se protger avec des vtements de protection libres
de lhuile, tels que les gants en cuir, chemise paisse, pantalons sans revers, et chaussures montantes.

zones o lon pique le laitier.

6. Eloigner les matriaux inflammables ou les recouvrir afin de
prvenir tout risque dincendie d aux tincelles.
7. Quand on ne soude pas, poser la pince une endroit isol de
la masse. Un court-circuit accidental peut provoquer un
chauffement et un risque dincendie.
8. Sassurer que la masse est connecte le plus prs possible de
la zone de travail quil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dautres endroits
loigns de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
cbles de grue, ou autres circuits. Cela peut provoquer des
risques dincendie ou dechauffement des chaines et des
cbles jusqu ce quils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particulirement important pour le soudage de tles
galvanises plombes, ou cadmies ou tout autre mtal qui
produit des fumes toxiques.
10. Ne pas souder en prsence de vapeurs de chlore provenant
doprations de dgraissage, nettoyage ou pistolage. La
chaleur ou les rayons de larc peuvent ragir avec les vapeurs
du solvant pour produire du phosgne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sret, voir
le code Code for safety in welding and cutting CSA Standard
W 117.2-1974.

PRCAUTIONS DE SRET POUR

LES MACHINES SOUDER
TRANSFORMATEUR ET
REDRESSEUR
1. Relier la terre le chassis du poste conformement au code de
llectricit et aux recommendations du fabricant. Le dispositif
de montage ou la piece souder doit tre branch une
bonne mise la terre.
2. Autant que possible, Iinstallation et lentretien du poste seront
effectus par un lectricien qualifi.
3. Avant de faires des travaux linterieur de poste, la debrancher linterrupteur la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sret leur
place.

5. Toujours porter des lunettes de scurit dans la zone de

soudage. Utiliser des lunettes avec crans lateraux dans les

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COMMANDER 400

Mar. 93

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

RETURN TO MAIN INDEX
Page
Safety .................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Technical Specifications ..............................................................................................................A-2
Safety Precautions ......................................................................................................................A-3
Location and Ventilation ..............................................................................................................A-3
Pre-Operation Engine Service ....................................................................................................A-4
Electrical Output Connections.....................................................................................................A-6
Connection Of Commander 400 To Premisis Wiring ..................................................................A-8
Operation...............................................................................................................................Section B
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-2
Recommended Applications........................................................................................................B-3
Design Features..........................................................................................................................B-3
Welding Capability ......................................................................................................................B-4
Controls and Settings..................................................................................................................B-5
Engine Operation ........................................................................................................................B-8
Welder Operation ......................................................................................................................B-10
Auxiliary Power .........................................................................................................................B-12
Accessories ..........................................................................................................................Section C
Maintenance ..........................................................................................................................Section D

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair ................................................................................................Section F
Electrical Diagrams ..............................................................................................................Section G
Parts Manual......................................................................................................................P267 Series

COMMANDER 400

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Section A-1

TABLE OF CONTENTS
- INSTALLATION SECTION -

Section A-1

Installation
Technical Specifications ..............................................................................................................A-2
Safety Precautions ......................................................................................................................A-3
Location and Ventilation ..............................................................................................................A-3
Storing ..................................................................................................................................A-3
Stacking ................................................................................................................................A-3
Angle of Operation................................................................................................................A-3

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Lifting ....................................................................................................................................A-4
High Altitude Operation.........................................................................................................A-4
Towing...................................................................................................................................A-4
Pre-Operation Engine Service ....................................................................................................A-4
Oil .........................................................................................................................................A-4
Fuel.......................................................................................................................................A-5
Cooling System.....................................................................................................................A-5
Battery Connections .............................................................................................................A-5
Muffler Outlet Pipe ................................................................................................................A-5
Spark Arrester.......................................................................................................................A-5
Electrical Output Connections.....................................................................................................A-6

Machine Grounding ..............................................................................................................A-7

Auxiliary Power Receptacles ................................................................................................A-7
Standby Power Connections ................................................................................................A-7
Connection Of The Commander 400 To Premises Wiring..........................................................A-8

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Welding Cable Connections .................................................................................................A-6

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COMMANDER 400

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A-2

A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - Commander 400

INPUT - DIESEL ENGINE
Make/Model

Description

Speed (RPM)

Displacement

Starting
System

Capacities

Deutz
F3L 912 Diesel
Engine

3 cylinder
44.2 HP(33kw)
@ 1800 RPM

High Idle 1900

Low Idle 1350
Full Load 1800

173 cu. in
(2.827 L)

12VDC battery
& Starter

Fuel: 25 gal.
94.6 L

Bore x Stroke

Oil: 8.5 Qts.

8.04 L

3.94 x 4.72
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(100mm x 120mm)

RATED OUTPUT - WELDER

Duty Cycle

Welding Output

Volts at Rated Amps

100%

400 amps (DC Constant Current)

400 amps (DC Constant Voltage)

40 volts
40 volts

60%

500 amps (DC Constant Current)

500 amps (DC Constant Voltage)

40 volts
40 volts

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OUTPUT - WELDER AND GENERATOR

Welding Range

Open Circuit Voltage

Auxiliary Power1

40 - 575 Amps
in 7 Ranges (Stick model)
or 8 Ranges (Stick & Wire model)

64-74 OCV

120/240 VAC
10,000 Watts, 60 Hz.
100% Duty Cycle

@1915 RPM

PHYSICAL DIMENSIONS
HEIGHT2

WIDTH

DEPTH

42.0 in.

31.5 in.

63.1 in.

1066.8 mm

800.1 mm

1602.7 mm

WEIGHT
1650 lbs.(748 kg)
(Stick model)
1683 lbs.(763 kg)
(Stick & Wire model)

1. Output rating in watts is equivalent to volt-amperes at unity power factor.

Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.
2. Top of Enclosure. Add 6.64 (168.7mm) for exhaust.

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COMMANDER 400

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INSTALLATION

Read this entire installation section before you

start installation.

SAFETY PRECAUTIONS
WARNING

ELECTRIC SHOCK can kill.

Do not touch electrically live
parts such as output terminals or
internal wiring.
Insulate yourself from the work
and ground.
Always
gloves.

wear

dry

insulating

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ENGINE EXHAUST can kill.

LOCATION AND VENTILATION

STORING
1. Store the machine in a cool, dry place when it is not
in use. Protect it from dust and dirt. Keep it where
it cant be accidentally damaged from construction
activities, moving vehicles, and other hazards.
2. Drain the engine oil and refill with fresh 10W30 oil.
Run the engine for about five minutes to circulate oil
to all the parts. See the Maintenance section of
this manual for details on changing oil.
3. Remove the battery, recharge it, and adjust the
electrolyte level. Store the battery in a dry, dark
place.
4. See your engine operation manual for further information on fuel and engine preservation.

STACKING

Use in open, well ventilated

areas or vent exhaust outside.

Commander 400 machines CANNOT be stacked.

Do not stack anything near the

engine.

ANGLE OF OPERATION

MOVING PARTS can injure.

Do not operate with doors open
or guards off.
Stop the engine before servicing.
Keep away from moving parts.

To achieve optimum engine performance the

Commander 400 should be run in a level position. The
maximum angle of operation for the Deutz engine is 20
degrees in a direction to cause the control panel to be
angled up, 30 degrees for side to side tilting and for the
control panel to be angled down. If the engine is to be
operated at an angle, provisions must be made for
checking and maintaining the oil level at the normal
(FULL) oil capacity in the crankcase. When operating
the welder at an angle, the effective fuel capacity will
be slightly less than the specified 25 gallons.

Only qualified personnel should install, use, or service this equipment.

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See additional safety information at the front of this

manual.

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A-3

The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to
avoid restricting the cooling air outlets. Also, locate the
welder so that the engine exhaust fumes are properly
vented to an outside area.

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.

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A-3

COMMANDER 400

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A-4

INSTALLATION

LIFTING
The Commander 400 weights 1650 lb./748 kg (Stick
model); 1683 lb./763 kg. (Stick & Wire model). A lift bail
is provided for lifting with a hoist.

WARNING

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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 stable when lifting.
The Commander is shipped with the lift bail retracted.
Before attempting to lift the Commander, secure the lift
bail in a raised position. Secure the lift bail as follows:

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6. Conformance with federal, state and local laws.1

1

Consult applicable federal, state and local laws regarding

specific requirements for use on public highways.

PRE-OPERATION ENGINE SERVICE

Read and understand the information about the diesel
engine in the Operation and Maintenance sections of
this manual before you operate the Commander 400.

WARNING

b. Locate the 2 access holes on the upper middle

region of compartment wall just below the lift bail.

d. Secure the lift bail with 2 thread forming screws.

The screws are provided in the shipped loose
parts bag.

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5. Proper preventative maintenance of trailer.

a. Open the engine compartment door.

c. Use the lifting strap to raise the lift bail to the full
upright position. This will align the mounting
holes on the lift bail with the access holes.

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3. Proper placement of the equipment on the trailer to

insure stability side to side and front to back when
the trailer is being moved and when standing by
itself.
4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, environmental conditions, and likely
maintenance.

FALLING EQUIPMENT can cause injury.

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A-4

Stop the engine and allow it to cool before fueling.

Do not smoke when fueling.
Fill the fuel tank at a moderate rate and
do not overfill.
Wipe up spilled fuel and allow the fumes
to clear before starting the engine.
Keep sparks and flame away from the tank.

HIGH ALTITUDE OPERATION

OIL

At higher altitudes, output derating may be necessary.

Some engine adjustments may be required. Contact a
Deutz Service Representative.

TOWING
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle(1) is
Lincolns K953-1. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of
attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the
factors to consider are as follows:

The Commander 400 is shipped with the engine filled

with SAE 10W-30 oil (API class CD or better). This
should be fine for most ambient operating temperature
conditions. See the engine operation manual for specific recommendations. CHECK THE OIL LEVEL
BEFORE YOU START THE ENGINE. This is an
added precaution. When full, the oil level should be up
to but not over the FULL mark on the dipstick. If it is
not full, add enough oil to fill it to the full mark. DO NOT
overfill.
Check oil level after every 4 hours of running time during the first 35 hours of operation.

1. Design capacity of trailer vs. the weight of the

Lincoln equipment and likely additional attachments.

NOTE: This machine is equipped with an engine protection package. An internal kill switch will shut down
the engine if the oil pressure drops below a minimum
level or if oil temperature becomes excessive.

2. Proper support of, and attachment to, the base of

the welding equipment so that there will be no
undue stress to the trailers framework.

For more oil fill and service information, see the

Maintenance section of this manual.

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COMMANDER 400

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A-5

A-5

INSTALLATION
BATTERY CONNECTIONS
FUEL

WARNING
BATTERY ACID CAN BURN EYES AND
SKIN.

NOTE: Use diesel fuel only.

Fill the fuel tank with clean, fresh diesel fuel. The
capacity of the fuel tank is 25 gallons (94.6 liters). See
the Operation and Maintenance sections of this manual for more details about fuel.
The Commander 400 is protected by a low fuel
shutdown to prevent the engine from running out of
fuel. The machine will indicate a low fuel condition by
turning on the low fuel light. A time of 30 minutes will
elapse once the low fuel light illuminates before the
machine will shutdown. A restart of the machine will
restart the timer to allow the operator to override this
feature. The amount of reserve fuel remaining in the
tank after the first shutdown will vary from machine to
machine. The operator must determine the amount of
fuel remaining before re-starting the machine.
Running out of fuel may require bleeding the fuel
injection pump.

Wear gloves and eye protection and be careful when working near a battery, follow the
instructions printed on the battery.

+ The Commander 400 is shipped with the

negative battery cable disconnected.

Before you operate the machine, make sure the IGNITION switch is in the OFF position and attach the disconnected cable securely to the battery terminal. If the
battery is discharged and won't start the engine, see
the battery charging instructions in the Maintenance
section.

MUFFLER OUTLET PIPE

NOTE: Before starting the engine, open the fuel shutoff valve (lever to be in line with hose) located on the
side of the fuel pre-filter/water separator housing.

Remove the plastic plug covering the muffler outlet

tube. Using the clamp provided secure the outlet pipe
to the outlet tube with the pipe positioned such that it
will direct the exhaust in the desired direction.

FUEL CAP

SPARK ARRESTER

Remove the plastic cap covering the fuel tank filler

neck and install the fuel cap.

Diesel engine mufflers may emit sparks when the

engine is running. Some federal, state, or local laws
require spark arresters in locations where unarrested
sparks could present a fire hazard.

COOLING SYSTEM
The Deutz engine is air cooled by a belt driven axial
blower. The oil cooler and engine cooling fins should
be blown out with compressed air or steam to maintain
proper cooling (See the engine owners manual for
procedures and frequency).

Standard mufflers (like the one included with the

Commander 400) do not act as spark arresters. When
local laws require it, a spark arrester must be installed
on the machine and properly maintained. An optional
spark arrester kit is available for your Commander 400.
See the Accessories section of this manual for more
information.

CAUTION

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An incorrect arrester may lead to damage to the engine

or adversely affect performance.

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COMMANDER 400

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A-6

A-6

INSTALLATION

ELECTRICAL OUTPUT
CONNECTIONS

CAUTION
Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.

See Figure A.1 for the location of the 120 and 240 volt
receptacles, weld output terminals, and ground stud.

Do not cross the welding cables at the output terminal

connection. Keep the cables isolated and separate
from one another.

WELDING CABLE CONNECTIONS

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CABLE INSTALLATION AND CABLE SIZES

With the engine off, route the electrode and work
cables through the strain relief bracket on the base and
connect to the terminals located on the fuel tank mounting rail. (See size recommendations below.) For positive polarity, connect the electrode cable to the terminal
marked Positive (+). For Negative polarity, connect the
electrode cable to the Negative (-) terminal. These
connections should be checked periodically and tightened if necessary.

When welding at a considerable distance from the

welder, be sure you use ample size welding cables.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
Lincoln Electric offers a welding accessory kit with the
properly specified welding cables.
See the
Accessories section of this manual for more
information.

FIGURE A.1 - COMMANDER 400 OUTPUT CONNECTIONS

OIL

FUEL

TEMP

AMPS

PRESS

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HOURS

1 2 0 VOLT
R E C E P TACL ES

C V WOR K WELD OU TP U T
TER MIN A L

240 VOLT R EC E P TAC LE

GR OU N D S TU D
WEL D OU TP U T TER MIN A LS
( EL ECTR OD E + & C C WOR K -)

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TABLE A.1 - RECOMMENDED COPPER WELDING CABLE SIZE AND LENGTH

TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
Cable sizes for combined length of
electrode plus work cable
Amps

Duty Cycle

Up to 200 ft.

200 to 250 ft.

250

100%

1 AWG

1/0 AWG

400

100%

3/0 AWG

4/0 AWG

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COMMANDER 400

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A-7

INSTALLATION

MACHINE GROUNDING
Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.).
To prevent dangerous electric shock, other equipment
powered by this engine driven welder must:
a) be grounded to the frame of the welder using a
grounded type plug,

A-7

NOTE: The two 120VAC outlets of the 120/240VAC

receptacle cannot be paralleled. They are on two different phases.
The auxiliary power receptacles should be used with
only three-wire, grounded type plugs or approved double-insulated tools with two-wire plugs. The current rating of any plug used with the system must be at least
equal to the current-carrying capacity of the associated
receptacle. An optional power plug kit is available.
See the Accessories section.

or

STANDBY POWER CONNECTIONS

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b) be double insulated.
When this welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
of the vehicle. When connected to premises wiring
such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the section Standby Power
Connections as well as the article on grounding in the
latest U.S. National Electrical Code and the local code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints or to the metal framework of a building that has
been effectively grounded. The U.S National Electrical
Code lists a number of alternate means of grounding
electrical equipment. A machine grounding stud
marked with the
symbol is provided on the front of
the welder.

AUXILIARY POWER RECEPTACLES

The Commander 400 can produce 10,000 watts of 60
Hz, single-phase auxiliary power. (The rating in watts
is equivalent to volt-amperes at unity power factor.)
The output voltage is within 10% at all loads up to the
rated capacity.
The following receptacles are provided:

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Two 15 amp-120VAC duplex GFCI receptacles

(5-15R)
One 50 amp-120/240VAC receptacle (14-50R)
The 50 amp receptacle has a maximum permissible
output of 44 amps. However, it can be split to power
two separate, single-phase 120VAC branch circuits
each capable of 44 amps output.

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The Commander 400 is suitable for temporary,

standby or emergency power using the engine manufacturers recommended maintenance schedule.
The Commander 400 can be permanently installed as
a standby power unit for 240 volt 3-wire, 44 ampere
service. Connections must be made by a licensed
electrician who can determine how the 120/240 VAC
power can be adapted to the particular installation and
comply with all applicable electrical codes. The following information can be used as a guide by the electrician for most applications. Refer to the connection
diagram shown in Figure A.2.
1. Install the double-pole, double-throw switch between
the power company meter and the premises disconnect.
The switch rating must be the same or greater than the
customers premises disconnect and service over
current protection.
2. Take the necessary steps to assure the load is limited to the capacity of the Commander 400 by
installing a 45 amp, 240 VAC double-pole circuit
breaker. Maximum rated load for each leg of the 240
VAC auxiliary is 45 amperes. Loading above the
rated output will reduce output voltage below the
allowable -10% of rated voltage, which may damage
appliances or other motor-driven equipment and
may result in overheating of the Commander 400
engine.
3. Install a 50 amp 120/240 VAC plug (NEMA Type 1450) to the double-pole circuit breaker using No. 6, 4
conductor cable of the desired length. (The 50 amp,
120/240 VAC plug is available in the optional K802R
plug kit.) See the Accessories section.
4. Plug this cable into the 50 ampere 120/240 volt
receptacle on the Commander 400 case front.

COMMANDER 400

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A-8

A-8

INSTALLATION
FIGURE A.2 - CONNECTION OF THE COMMANDER 400 TO PREMISES WIRING

240 VOLT
GROUNDED CONDUCTOR
POWER

240 Volt
60 Hz.
3-Wire
Service

120 VOLT

COMPANY
120 VOLT
METER

NEUTRAL
BUS

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DOUBLE POLE DOUBLE THROW

SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.

GROUND

45AMP
240 VOLT

240 VOLT

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50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50

PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION

DOUBLE
POLE
CIRCUIT
BREAKER

GND

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50 AMP, 120/240 VOLT

RECEPTACLE

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LOAD

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NOTE: No. 6 COPPER CONDUCTOR CABLE.

SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE
WIRE SIZE RECOMMENDATIONS.

COMMANDER 400

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Section B-1

Section B-1

TABLE OF CONTENTS
- OPERATION SECTION Operation...............................................................................................................................Section B
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-2
Recommended Applications........................................................................................................B-3
Design Features..........................................................................................................................B-3
Welding Capability ......................................................................................................................B-4
Controls and Settings..................................................................................................................B-5
Engine Controls ....................................................................................................................B-5

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Welder Controls ....................................................................................................................B-7

Auxiliary Power Controls ......................................................................................................B-8
Wire Feeder Mode Controls .................................................................................................B-8
Engine Operation ........................................................................................................................B-8
Starting the Engine ...............................................................................................................B-8
Stopping the Engine .............................................................................................................B-9
Break-In Period.....................................................................................................................B-9
Typical Fuel Consumption ....................................................................................................B-9
Welder Operation ......................................................................................................................B-10
Stick Welding ......................................................................................................................B-10
TIG Welding........................................................................................................................B-10

Wire Feed (Constant Voltage) Welding.....................................................................................B-12

Auxiliary Power .........................................................................................................................B-12
Simultaneous Welding and Auxiliary Power Loads ............................................................B-12

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Commander 400 Settings With K799 Hi-Freq./K930-1 Tig Module....................................B-11

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COMMANDER 400

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B-2

OPERATION
WARNING

OPERATING INSTRUCTIONS
Read and understand this entire section before operating your Commander 400.

ENGINE EXHAUST can kill.

SAFETY INSTRUCTIONS

Use in open, well ventilated areas or

vent exhaust to the outside.

WARNING

Do not stack anything on or near the

engine.

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Do not attempt to use this equipment until you have

thoroughly read all the operating and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating and maintenance instructions and parts lists.

Insulate yourself from the work and

ground.

Stop the engine before servicing it.

Keep away from moving parts.

Only qualified personnel should install, use, or service this equipment.

Always wear dry insulating gloves.

GENERAL DESCRIPTION

Use ventilation or exhaust to remove

fumes from breathing zone.
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Do not operate this equipment with any

of its doors open or guards off.

Do not touch electrically live parts or

electrodes with your skin or wet clothing.

Keep your head out of fumes.

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MOVING PARTS can injure.

ELECTRIC SHOCK can kill.

FUMES AND GASES can be dangerous.

WELDING SPARKS can cause

fire or explosion.
Keep flammable material away.
Do not weld on containers that have held
combustibles.

The Commander 400 is a diesel engine driven welding

power source. The machine uses a brushless asynchronous alternating current generator for DC stick
electrode welding and for 120/240 VAC auxiliary
standby power. As a generator it can supply up to
10,000 watts of 120/240 volt AC power. As a welder it
provides up to 400 amps of DC constant current output
in six slope-controlled ranges. In addition a seventh
general purpose welding range provides up to 575
amps of constant current welding output.
The engine is a 44.2 Hp (33kw), 3-cylinder air/oil
cooled diesel made by Deutz. This naturally aspirated,
4 cycle engine features direct injection, a Bosch in-line
injection pump and a Bosch mechanical governor.
This machine is controlled by a high quality microcontroller. The microcontroller provides high speed control
of the weld process as well as the engine protection
features.

ARC RAYS can burn.

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Wear eye, ear, and body protection.

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B-2

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COMMANDER 400

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B-3

OPERATION

RECOMMENDED APPLICATIONS
WELDER
The Commander 400 (Stick model) provides excellent
constant current DC welding output for stick (SMAW)
welding. The Commander 400 (Stick & Wire model)
also provides excellent constant voltage DC welding
output for MIG (GMAW) and Inner shield (FCAW)
welding.

GENERATOR

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The Commander 400 provides smooth 120/240 VAC

output for auxiliary power and emergency standby
power.

(All Models)

FOR STICK WELDING

Excellent DC constant current output for stick welding applications.
40 to 400 amps output in six slope controlled ranges
for out-of position and pipe electrodes; 50 to 575
amps constant current output in one general purpose
welding range.

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3 digit display is provided for presetting the weld

amperage and displaying the actual amperage during
welding. The display uses super brite LEDs for
improved readability in full sunlight.
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One 50 amp, 120/240 VAC dual voltage receptacle

for up to 44 amps of 240 VAC, and up to 44 amps per
side to separate branch circuits (not in parallel) of 120
VAC single phase auxiliary power. Allows easy connection to premises wiring.
Weld and AC auxiliary power at the same time (within machine total capacity).

OTHER FEATURES
Deutz 3-cylinder, air/oil cooled diesel engine.
Designed for long life, easy maintenance and excellent 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 alternator output and fuel level.

DESIGN FEATURES

Remote control capability standard on all models.

Selection of hot or cold output terminals with a toggle switch on the control panel. This feature can also
be controlled by installing a remote output terminal
control cable designed to open and close the #2 and
#4 leads in the amphenol receptacle.

Indicator lights for low oil pressure, high oil temperature, engine alternator low output/broken belt and low
fuel level.
Automatic low fuel shutdown before running out of
fuel.
Engine hour meter standard on all models.
Extended range 25 gallon (94.6 l) fuel tank.
Fuel pre-filter/water separator with dry change element.
Automatic idler reduces engine speed when not welding or drawing auxiliary power. This feature reduces
fuel consumption and extends engine life.
Single side engine service with over the top access to
the engine.
Copper alternator windings and high temperature
insulation for dependability and long life.

FOR AUXILIARY POWER

10,000 watts of 120/240 VAC, 60Hz auxiliary power.
Will drive a 2 HP motor (provided it is started under
no load).

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Two 15 amp 120 VAC duplex receptacles with GFCI

protection for up to 30 amps of 120 VAC power.

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B-3

COMMANDER 400

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B-4

OPERATION

ADDITIONAL DESIGN FEATURES

(Stick & Wire Model only)

FOR WIRE WELDING

One constant voltage position for all wire welding. A
12 to 45V range across the entire current output
range.

WELDING CAPABILITY
The Commander 400 is rated at 400 amps, 40 volts at
100% duty cycle. The weld current is variable from 40
to 575 amps.

Excellent arc characteristics with MIG (GMAW) and

Inner shield (FCAW) welding.
A Wire Feeder connector for quick connection of the
control cable.

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A built in Electronic Contactor for Cold electrode

when not welding.
The 3 digit display has the additional feature of presetting the open circuit voltage and displaying the
actual voltage during welding.
Designed for use with the following Lincoln wire feeders.
LN-25

LN-23P

LN-7

LN-8

NA-3

Spool Gun &

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B-4

K488 Module

COMMANDER 400

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B-5

B-5

OPERATION

CONTROLS AND SETTINGS

The welder/generator controls are located on the case
front panel. Refer to Figure B.1 and the explanations
that follow.
FIGURE B.1 CASE FRONT PANEL CONTROLS
2

9
OIL

FUEL

TEMP

AMPS

PRESS

HOURS

11

10

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12
23
13

17

22

21

24

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18

15

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16

14

19

ENGINE CONTROLS
(Figure B.1, Items 1 through 8)
See Figure B.1 for the location of the following features:
1. RUN-STOP SWITCH: When placed in the RUN
position, this switch energizes the fuel solenoid and
other electric accessories. When placed in the
STOP position, the flow of fuel to the injection
pump is stopped to shut down the engine.
NOTE: If the switch is left in the RUN position and
the engine is not running, the battery will be drained by
the fuel solenoid.

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20

3. FUEL LEVEL GAUGE AND LIGHT: Displays the

level of diesel fuel in the 25-gallon (94.6 liter) fuel
tank. The yellow light turns on when the fuel gage
reaches the reserve level. Once the reserve level is
reached, the engine protection system will shut
down the engine after 30 minutes of operation. The
machine can be restarted and operated for an additional 30 minutes before the protection system will
shut down the engine. This ability to override the
engine protection is to allow the operator to finish
up if necessary. The operator must watch the fuel
level closely to prevent running out of fuel and having to bleed the system.

2. START PUSHBUTTON: Energizes the starter

motor to crank the engine. With the engine RUNSTOP switch in the RUN position, push and hold
the START button for a minimum of 2 seconds to
crank the engine; release as the engine starts. Do
not press while engine is running since this can
cause damage to the ring gear and/or starter motor.

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COMMANDER 400

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B-6

OPERATION

4. ENGINE TEMPERATURE GAUGE AND LIGHT:

The gauge displays the engine oil temperature. The
yellow temperature light remains off under normal
operating temperatures. If the light turns on, the
engine protection system will shut down the engine.
Check for restrictions at the engine cooling air inlets
and outlets (consult the engine Operation manual).
Check for loose or disconnected leads at the temperature sender located on the engine. Check
engine cooling blower belt. Also, check to be sure
that the welder loads are within the rating of the
welder. The light will remain on when the engine
has been shut down due to an over- temperature
condition.
5. OIL PRESSURE GAUGE AND LIGHT: The gauge
displays the engine oil pressure when the engine is
running. The yellow oil pressure light remains off
with proper oil pressure. If the light turns on, the
engine protection system will stop the engine.
Check for proper oil level and add oil if necessary.
Check for loose or disconnected leads at the oil
pressure sender located on the engine. The light
will go on and stay on when the RUN-STOP switch
is switched to the RUN position with the engine
not running.
6. ENGINE ALTERNATOR AMMETER AND LIGHT:
The yellow engine alternator light is off when the
battery charging system is functioning normally. If
the light turns on, the engine protection system will
shut down the engine. Check the engine cooling
blower belt. Also, the alternator or the voltage regulator may not be operating correctly. The light may
also come on if the alternator did not flash up due to
not holding the start button in long enough (minimum of 2 seconds) or due to a faulty flashing circuit.
The light will remain on when the engine has been
shut down due to a fault in the alternator, regulator,
or the cooling blower belt.

b. When the electrode touches the work or

power is drawn for lights or tools (approximately 100 Watts minimum), the engine
accelerates and operates at full speed.
c. When welding ceases or the AC power load
is turned off, a fixed time delay of approximately 15 seconds starts.
d. If the welding or AC power load is not
restarted before the end of the time delay,
the idler reduces the engine speed to low
idle speed.
e. The engine will automatically return to high
idle speed when the welding load or AC
power load is reapplied.

Idler Operational Exceptions

When the WELDING TERMINALS switch is in the
WELDING TERMINALS REMOTELY CONTROLLED
position, the idler will operate as follows:
a. When the triggering device (Amptrol, Arc Start
Switch, etc.) is pressed, the engine will accelerate
and operate at full speed provided a welding load is
applied within approximately 15 seconds.
If the triggering device remains pressed but no
welding load is applied, within approximately 15
seconds the engine will return to low idle speed.
If the triggering device is released or welding
ceases, the engine will return to low idle speed
after approximately 15 seconds.
8. HOUR METER: The hour meter displays the total
time that the engine has been running. This meter
is a useful indicator for scheduling preventive maintenance.

7. IDLER SWITCH: Adjusts the running speed of the

engine. Has two positions as follows:
A) In the High position, the engine runs at the high
idle speed controlled by the governor.

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B) In the Auto position, the idler operates as

follows:
a. When switched from HIGH to AUTO or
after starting the engine, the engine will
operate at full speed for approximately 15
seconds and then go to low idle speed.

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B-6

COMMANDER 400

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B-7

OPERATION

WELDER CONTROLS (Figure B.1 Items 9

through 14 )
9. OUTPUT RANGE SWITCH AND OUTPUT CONTROL: These two controls allow you to select
between various welding output slopes and adjust
the desired welding output. Refer to Table B.1 for a
description of how these two controls work.

TABLE B.1 OUTPUT RANGE SWITCH AND OUTPUT CONTROL FUNCTIONS

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Range
1
Switch
Sloped Output for
Pipe Welding.
(all models)

Control

1 Range setting
50-575 Amps

Constant Voltage
Output for Wire
Welding (Stick &
Wire model only)

1 Range setting
12 to 40 Volts

With the switch in the WELDING TERMINALS

ALWAYS ON position, the contactor is closed and
the welding terminals are always Hot.
With the switch in the WELDING TERMINALS
REMOTELY CONTROLLED position, the contactor operation is controlled by an Amptrol, Arc Start
Switch or some other type of triggering device
through the use of a control cable connected to
the 6-pin MS connector.
When the triggering device is pressed the contactor is closed and the welding terminals are Hot.
When the triggering device is released the contactor is opened and the welding terminals are
Cold.
12. LOCAL/REMOTE SWITCH: The toggle switch on
the control panel labeled LOCAL/REMOTE gives
you the option of controlling the output at the
welder control panel or at a remote location.

6 Range
Settings
90, 120, 180,
230, 270, 400
(Max. current on
each setting)

Constant Current
Output for
Fabrication and
General Purpose
Welding (This setting also used for
TIG) (all models)

Provides a fine
adjustment of
welding current
or voltage from
Min (1) to Max
(10) within each
range

If the OUTPUT RANGE switch is positioned between settings, the

previous setting is maintained until the switch is properly positioned
on a setting.

The OUTPUT CONTROL also controls O.C.V. while in the 6 sloped

output ranges.

For remote control, set the toggle switch in the

REMOTE position.
For control at the welder control panel, set the
toggle switch in the LOCAL position.
13. 6 - PIN CONNECTOR: The 6-pin connector located on the control panel allows for connection of
Remote Control accessories.
14. WELD OUTPUT TERMINALS + AND - : These
1/2 - 13 studs with flange nuts provide welding
connection points for the electrode and work
cables. For positive polarity welding, the electrode
cable connects to the + terminal and the work
cable connects to the - terminal. For negative
polarity welding, the work cable connects to the
+ terminal and the electrode cable connects to
the - terminal.

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10. DIGITAL OUTPUT METER: The digital output

meter is located in the center of the control panel
between the two large control knobs. The meter
allows the output current level to be set prior to
welding. During the welding process the meter
displays the actual output current.
11. WELDING TERMINALS SWITCH: The toggle
switch on the control panel labeled WELDING
TERMINALS ALWAYS ON and WELDING TERMINALS REMOTELY CONTROLLED, is used to
control the operation of the solid state contactor,
which allows for the selection of Hot or Cold
welding terminals.

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B-7

COMMANDER 400

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B-8

OPERATION

AUXILIARY POWER CONTROLS

ENGINE OPERATION

(Figure B.1 Items 15 - 19 )

STARTING THE ENGINE

15. 120/240VAC RECEPTACLE: This is a 120/240VAC

(14-50R) receptacle that provides 240VAC or can
be split for 120VAC single phase auxiliary power.
The receptacle has a 50 amp rating. Refer to
Auxiliary Power Receptacles in the
Installation section for further information about
this receptacle. Also refer to Auxiliary Power
Operation later in this section.

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16. 50 AMP CIRCUIT BREAKERS: These circuit

breaker provide separate overload current protection for each 120V circuit at the 240V receptacle.
17. 120VAC RECEPTACLES: These two 120VAC (515R) receptacles with GFCI protection provide
120VAC for auxiliary power. The receptacles have
a 20 amp total rating. Refer to Auxiliary Power
Receptacles in the Installation section for further information about these receptacles. Also
refer to Auxiliary Power Operation later in this
section.
18. 15 AMP CIRCUIT BREAKERS: These circuit
breakers provide separate overload current protection for each 120V receptacle.

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19. GROUND STUD: Provides a point for connecting

the machine case to earth ground for the safest
grounding procedure.
Refer to Machine
Grounding in the Installation section for proper
machine grounding information.

WIRE FEEDER MODE CONTROLS

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1. Open the engine compartment door and check that

the fuel shutoff valve located to the left of the fuel filter housing is in the open position (lever in line with
the hose).
2. Check for proper oil level on the oil dipstick. Close
engine compartment door.
3. Remove all plugs connected to the AC power receptacles.
4. Set the IDLER switch to AUTO.
5. Set the RUN/STOP switch to RUN. Observe that
all engine protection lights momentarily turn on.
Some lights may turn off before starting. Check the
fuel gauge to make sure that there is an adequate
fuel level.
6. Press and hold the engine START button for a minimum of 2 seconds.
7. Release the engine START button when the engine
starts.
8. Check that the indicator lights are off. If the LOW
FUEL light is on , the engine will shut down 30 minutes after starting. If any other indicator light is on
after starting, the engine will shut down in a few
seconds. Investigate any indicated problem.
9. Allow the engine to warm up at low idle speed for
several minutes before applying a load and/or
switching to high idle. Allow a longer warm up time
in cold weather.

(Figure B.1 Items 20 - 24 Stick & Wire model only)

20. WELD OUTPUT TERMINAL - WIRE: This 1/2-13
stud with flange nut provides a welding connection
point for the electrode or work cables. For positive
polarity welding, the electrode cable connects to
the + terminal and the work cable connects to the
- terminal. For negative polarity welding, the work
cable connects to the + terminal and the electrode cable connects to the - terminal.
21. 15 AMP CIRCUIT BREAKER: This circuit breaker
provides overload protection for the 14-pin connector.

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B-8

COLD WEATHER STARTING

With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about 0oF.
If the engine must be frequently started below 10oF, it
may be desirable to install the optional Ether Start kit
(K825-1). Installation and operating instructions are
included in the kit. Use ether starting only when
required, because excessive use shortens engine life.

22. VOLTMETER +/- SWITCH: Changes the polarity

display on the wire feeder.
23. VOLTS-AMPS SWITCH:
between volts and amps.

Switches the display

24. 14 - PIN CONNECTOR: For quick connection of

wire feeder control cable.

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COMMANDER 400

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B-9

OPERATION

STOPPING THE ENGINE

TYPICAL FUEL CONSUMPTION

1. Switch the RUN/STOP switch to STOP. This turns

off the voltage supplied to the shut down solenoid. A
backup shut down can be accomplished by shutting
off the fuel valve located on the fuel filter housing.

Refer to Table B.2 for typical fuel consumption of the

Commander 400 engine for various operating scenarios.

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Table B.2 Deutz F3L 912 Engine Fuel Consumption

BREAK-IN PERIOD
The engine used to supply power for your welder is a
heavy duty, industrial engine. It is designed and built
for rugged use. It is very normal for any engine to use
small quantities of oil until the break-in is accomplished. Check the oil level twice a day during the
break-in period (about 200 running hours).

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B-9

CAUTION
During break-in, subject the Commander 400 to heavy
loads. Avoid long periods running at idle. Before stopping the engine, remove all loads and allow the engine
to cool several minutes.

Deutz F3L 912 Running Time for

44.2 Hp
25 gallons
@ 1800 RPM
(Hours)
Low Idle - No
.30 gallons/hour
Load 1350 RPM (1.36 liters/hour)

83.3

High Idle - No
.78 gallons/hour
Load 1900 RPM ( 3.55 liters/hour)

32.1

DC CC Weld
Output 400
Amps @ 40
Volts
Auxiliary Power
10,000 VA

1.84 gallons/hour
( 8.36 liters/hour)

13.6

1.32 gallons/hour
(6.00 liters/hour)

18.9

The heavy loading of the engine during break-in, within the rating of the machine, is recommended to properly seat the piston rings and prevent wetstacking.
Wetstacking is an accumulation of unburned fuel
and/or lubricant in the form of a wet, black, tar-like substance in the exhaust pipe. The rings are seated and
the break-in period is complete when there are no
longer any signs of wetstacking, which should occur
within the first 50 to 100 hours of operation.

CAUTION
Using your welder at low amperages with long idle running 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.

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COMMANDER 400

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B-10

OPERATION

WELDER OPERATION

GENERAL WELDING

STICK WELDING

The seventh position of the OUTPUT RANGE switch is

designed for horizontal welds with all types of electrodes, especially low hydrogen. The OUTPUT CONTROL adjusts the full range of 50 to 575 amps. This
setting provides a soft, constant current arc. If a more
forceful arc is desired, then select the proper range
from the slope controlled current ranges.

The Commander 400 can be used with a broad range

of DC stick electrodes.
The OUTPUT RANGE switch provides six overlapping
slope controlled current ranges. The OUTPUT CONTROL adjusts the current from minimum to maximum
within each range. Open circuit voltage is also controlled by the OUTPUT CONTROL in the slope controlled setting. These slope controlled settings are
intended for out-of-position welding, including pipe
welding, where the operator would like to control the
current level by changing the arc length.
PIPE WELDING
When using a sloped range, a high open circuit voltage
setting provides the softest arc with best resistance to
pop-outs. To get this characteristic, set the OUTPUT
RANGE switch to the lowest setting that still provides
the current you need and set the OUTPUT CONTROL
near maximum. For example: to obtain 175 amps and
a soft arc, set the OUTPUT RANGE switch to the 180
MAX position and then adjust the OUTPUT CONTROL for 175 amps.

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When a forceful digging arc is required, use a higher

setting and lower open circuit voltage. For example: to
obtain 175 amps and a forceful arc, set the OUTPUT
RANGE switch to the 230 MAX position and then
adjust the OUTPUT CONTROL to get 175 amps.

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B-10

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TIG WELDING
The Commander 400 can be used in a wide variety of
DC Tungsten Inert Gas (TIG) welding applications for
DC TIG welding up to 400 amps at a 20% duty cycle,
300 amps at a 60% duty cycle and 250 amps at a 80%
duty cycle. Refer to Table B.3 for recommended output setting depending on the tungsten electrode size.
The Commander 400 can be used without a TIG module or Hi-Freq Unit for scratch start DC TIG welding.
Using a K799 Hi-Freq Unit or K930-1 TIG Module
enables DC TIG welding without having to scratch
start. The end of this section also details Commander
400 settings when using either of these units for DC
TIG welding. See Commander 400 Settings When
Using the K799 Hi-Freq Unit and Commander 400
Settings When Using the K930-1 TIG Module. See
the Accessories section for recommended equipment
for TIG welding.

COMMANDER 400

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Table B.3 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES

Tungsten
Electrode
Diameter
in. (mm)

DCEN (-)

DCEP (+)

1%, 2%
Thoriated
Tungsten

1%, 2%
Thoriated
Tungsten

0 .010
0.020
0.040

(.25)
(.50)
(1.0)

2-15
5-20
15-80

1/16

(1.6)

70-150

3/32
1/8

(2.4)
(3.2)

5/32
3/16
1/4

(4.0)
(4.8)
(6.4)

Approximate Argon Gas Flow Rate

C.F.H. (l/min.)
Aluminum

Stainless Steel

TIG TORCH
Nozzle
Size 4,5

3-8
5-10
5-10

(2-4)
(3-5)
(3-5)

3-8
5-10
5-10

(2-4)
(3-5)
(3-5)

#4, #5, #6

10-20

5-10

(3-5)

9-13

(4-6)

#5, #6

150-250
250-400

15-30
25-40

13-17
15-23

(6-8)
(7-11)

11-15
11-15

(5-7)
(5-7)

#6, #7, #8

400-500
500-750
750-1000

40-55
55-80
80-125

21-25
23-27
28-32

(10-12) 13-17
(11-13) 18-22
(13-15) 23-27

3
3

(6-8)
#8, #10
(8-10)
(11-13)

When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.

Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure
EWP
1% Thoriated
EWTh-1
2% Thoriated
EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated
Tungsten in AC and DC applications.

DCEP is not commonly used in these sizes.

TIG torch nozzle sizes are in multiples of 1/16ths of an inch:
# 4 = 1/4 in.
(6 mm)
# 5 = 5/16 in.
(8 mm)
# 6 = 3/8 in.
(10 mm)
# 7 = 7/16 in.
(11 mm)
# 8 = 1/2 in.
(12.5 mm)
#10 = 5/8 in.
(16 mm)

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B-11

OPERATION

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B-11

TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are
less prone to breakage, but cannot withstand high temperatures and high duty cycles.

COMMANDER 400 SETTINGS WHEN USING THE

K799 HI-FREQ UNIT

COMMANDER 400 SETTINGS WHEN USING THE

K930-1 TIG MODULE

1. Set the OUTPUT RANGE switch to the 50-575 setting

(Fabrication and General Purpose).

1. Set the OUTPUT RANGE switch to the 50-575 Setting

(Fabrication and General Purpose).

2. Set the IDLER switch to the HIGH position.

2. Set the IDLER switch to the AUTO position.

3. Set the LOCAL/REMOTE switch to the REMOTE

position.

3. Set the LOCAL/REMOTE switch to the REMOTE

position.

4. Set the WELDING TERMINALS switch to the WELDING TERMINALS ALWAYS ON position. This will
close the solid state contactor and provide an always
hot electrode.

4. Set the WELDING TERMINALS switch to the WELDING TERMINALS REMOTELY CONTROLLED position. This will keep the solid state contactor open and
provide a cold electrode until the triggering device
(Amptrol or Arc Start switch) is pressed.

(Note: This is necessary because the K799 circuitry with

respect to the #2 and #4 leads does not provide the proper signal to open and close the solid state contactor in the
Commander).

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COMMANDER 400

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B-12

The following receptacles are provided:

WIRE FEED (CONSTANT VOLTAGE)

WELDING
Stick and Wire models only. Connect a wire feeder to
the Commander 400 (see the Accessories section)
and set the welder controls according to the instructions in Controls and Settings in this section of the
manual.
The Stick and Wire model of the Commander 400, with
its CV tap, permits it to be used with a broad range of
flux cored wire (inner shield and Outer shield) electrodes and solid wires for MIG (GMAW).
For any electrodes, the procedures should be kept
within the rating of this machine. For additional electrode information, see Lincoln publications N-675, GS100 and GS-210.

AUXILIARY POWER
WARNING
Be sure that any electrical equipment plugged into the
generator AC power receptacles can withstand a 10%
voltage and a 3% frequency variation.

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Two 15 amp-120VAC duplex FGCI receptacles

(5-15R)
One 50 amp-120/240VAC receptacle (14-50R)
The 50 amp receptacle has a maximum permissible
output of 44 amps. However, it can be split to power
two separate, single-phase 120VAC branch circuits
each capable of 44 amps output.
NOTE: The two 120VAC outlets of the 120/240VAC
receptacle cannot be paralleled. They are on two different phases.
The auxiliary power receptacles should be used with
only three-wire, grounded type plugs or approved double-insulated tools with two-wire plugs. The current rating of any plug used with the system must be at least
equal to the current-carrying capacity of the associated
receptacle. An optional power plug kit is available.
See the Accessories section.

SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS

The auxiliary power ratings above are with no welding
load. Simultaneous welding and power loads are specified in Table B.4. The permissible currents shown
assume that current is being drawn from either the 120
VAC or 240 VAC supply (not both at the same time).

TABLE B.4 Commander 400 Simultaneous Welding and Power Loads

Welding
Output Range
Setting

50-575
400
270
230
180
120
90
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The Commander 400 can produce 10,000 watts of 60

Hz, single-phase auxiliary power. (The rating in watts
is equivalent to volt-amperes at unity power factor.)
The output voltage is within 10% at all loads up to the
rated capacity.

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B-12

OPERATION

Welding Output

500A/40V
400A/36V
270A/31V
230A/29V
180A/27V
120A/25V
90A/24V

Permissible
Power - Watts
(Unity Power
Factor)

@120 V 10% *

@ 240 V 10%

None
None
3000
6000
7500
9500
9500

0
0
28
56**
70**
88**
88**

0
0
14
28
35
44
44

Permissible Auxiliary
Current in Amperes

* Each GFCI duplex receptacle is limited to 15 amps.

** Not to exceed 44 A per 120 VAC branch circuit when splitting the 240 VAC output.

COMMANDER 400

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Section C-1

Section C-1

TABLE OF CONTENTS
- ACCESSORIES Accessories...........................................................................................................................Section C
Options/Accessories ...................................................................................................................C-2
Stick Welding ..............................................................................................................................C-2
TIG Welding ................................................................................................................................C-2
Semiautomatic Welding Accessories ..........................................................................................C-2
Connection of Lincoln Electric Wire Feeders..............................................................................C-3
Connection of the LN-7 using K867 Universal Adapter........................................................C-3
Connection of the LN-7 using K584 Input Cable Assembly .................................................C-4

Connection of the LN-8 using K595 Input Cable Assembly .................................................C-6

Connection of the LN-23P using K350-1 Adapter Kit...........................................................C-7
Connection of the LN-25 Across the Arc ...........................................................................C-8
Connection of the K488 SG Control Module and K487 Magnum Spool Gun ......................C-9

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Connection of the LN-8 using K867 Universal Adapter........................................................C-5

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COMMANDER 400

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C-2

ACCESSORIES
TIG WELDING

OPTIONS/ACCESSORIES

K802R Power Plug Kit - Provides a plug for each

receptacle. The kit includes 4-120V plugs rated at 15
Amps each and 1-120V/240V Full-KVA plug rated at 50
Amps.
K857 28 ft. (8.5 m) or K857-1 100 ft. (30.4 m) Remote
Control - Portable control provides same dial range as
the output control on the welder from a location up to
the specified length from the welder. Has convenient
plug for easy connection to the welder.
The
Commander 400 is equipped with a 6 pin connector for
connecting the remote control and a toggle switch for
selecting LOCAL output control or REMOTE output
control.
K704 Accessory Kit - Includes 35 feet (10 m) of electrode cable and 30 feet (9 m) of work cable, head
shield, work clamp and electrode holder. Cable is
rated at 500 amps, 60% duty cycle.
K953-1 Two Wheel Trailer - For road, in-plant and
yard towing. Road towing with optional fender & light
kit. (For highway use, consult applicable federal, state
and local laws regarding possible additional requirements.)
K953-1
K958-1
K958-2
K959-1
K965-1

Trailer
Ball Hitch
Lunette Eye Hitch
Fender & Light Kit
Cable Storage Rack

K825-1 Ether Start Kit - Provides maximum cold

weather starting assistance for frequent starting below
10oF (-12.2oC). Required Ether tank is not provided
with kit.
K899-1 Spark Arrestor Kit - Easily mounts to standard muffler.

STICK WELDING
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Magnum TIG Torch

Magnum Parts Kit and Argon gas
K930-1 TIG Module (not required for scratch
start DC TIG welding)

The following options/accessories are available for

your Commander 400 from your local Lincoln
Distributor.

K949-1 Oil Drain Kit - Includes ball valve, hose and

clamp.

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C-2

K704 Accessory Kit which includes:

Electrode holder and cable.
Ground clamp and cable.
Head shield.

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K936-3 Control Cable

K870 Foot Amptrol
Also available:
K963 Hand Amptrol
K814 Arc Start Switch
K937-22 Control Cable Extension
K937-45 Control Cable Extension
K844-1 Water Valve

HIGH FREQUENCY
APPLICATIONS

GENERATORS

FOR

TIG

The K799 Hi-Freq Unit and the K930-1 TIG Module are
suitable for use with the Commander 400. The
Commander is equipped with the required R.F. bypass
circuitry for the connection of high frequency generating equipment. The high frequency bypass network
supplied with the K799 Hi-Freq Unit does NOT need
to be installed into the Commander 400.
The Commander 400 and any high frequency generating equipment must be properly grounded. See the
K799 Hi-Freq Unit and the K930-1 TIG Module operating manuals for complete instructions on installation,
operation, and maintenance.

SEMIAUTOMATIC WELDING ACCESSORIES

LN-25 Wire Feeder - This portable wire feeder is capable of CC/CV wire feed welding.
LN-7 or LN-8 Wire Feeders - Semiautomatic, constant
speed wire feeder. For CV operation only.
LN-23P Wire Feeder - This portable wire feeder is
capable of CV operation. K350-1 adapter kit is
required.
NOTE: Gas-shielded welding requires a Magnum Gun.
Gasless welding requires an Inner shield Gun.
Magnum Spool Gun (K487-25) - A lightweight, semiautomatic wire feeder for aluminum welding with argon
gas. Has built-in remote wire speed control in the handle. Requires the K488 SG Control Module with appropriate control cable. Includes 25 feet (7.6 meters) of
power cable.

COMMANDER 400

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C-3

ACCESSORIES

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

WARNING
ELECTRIC SHOCK can kill.
Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY
LEAD before servicing.
Do not touch electrically live parts.

MOVING PARTS can injure.

Keep guards in place.
Keep away from moving parts.
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C-3

Only qualified personnel should install,

use or service this equipment.

3. Connect the K867 Universal Adapter to the K291 or

K404 input cable and the 14 pin amphenol of the
Commander 400 as indicated in Figure C.1. Make
the proper connections for local or remote control
according to Figure C.1.
4. Connect the K291 or K404 input cable to the LN-7.
5. Place the IDLER switch in the HIGH position.
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor setting is preset at the factory do not adjust above
RPM specifications listed in this manual.
6. Set the LOCAL/REMOTE switch to REMOTE if a
K775 remote control is used. Set the switch to
LOCAL if no remote control is used.

CONNECTION OF THE LN-7 TO THE

COMMANDER 400 USING K867
UNIVERSAL ADAPTER (SEE FIGURE C.1.)

7. Set the VOLTMETER switch to + or - depending on the polarity chosen.

1. Shut the welder off.

8. Set the RANGE switch to WIRE WELDING CV.

2. Connect the electrode cable from the LN-7 to the

+ terminal of the welder. Connect the work
cable to the CV- Wire terminal of the welder.

9. Set the WELDING TERMINALS switch to WELDING TERMINAL REMOTELY CONTROLLED.

10. Adjust wire feed speed at the LN-7.

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NOTE: Welding cable must be sized for current and

duty cycle of application.
NOTE: Figure C.1 shows the electrode connected for
positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Commander 400 output terminals.
FIGURE C.1
COMMANDER 400/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM
SPARE

82
81
42
41

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CV-

K867 UNIVERSAL
ADAPTER PLUG

31

31

32

32

21

21

GND

GND

LN-7
WIRE
FEEDER

K291 OR K404
INPUT CABLE

GREEN

ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK

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75

75

76

76

77

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14 PIN
AMPHENOL

INSULATE UNUSED
LEADS INDIVIDUALLY

SPLICE LEADS
AND INSULATE

COMMANDER 400

77
K775 OPTIONAL
REMOTE CONTROL

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C-4

ACCESSORIES

CONNECTION OF THE LN-7 TO THE

COMMANDER 400 USING K584 INPUT
CABLE ASSEMBLY (SEE FIGURE C.2.)
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 CV- Wire terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.

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NOTE: Figure C.2 shows the electrode connected for

positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Commander 400 output terminals.

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C-4

3. Connect the K584-XX Input Cable Assembly to the

LN-7.
4. Connect the K584-XX input cable assembly to the
14 pin amphenol on the Commander 400.
5. Place the IDLER switch in the HIGH position.

CAUTION
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor setting is preset at the factory do not adjust above
RPM specifications listed in this manual.
6. Set the LOCAL/REMOTE switch to REMOTE if a
K857 remote control is used. Set the switch to
LOCAL if no remote control is used.
7. Set the VOLTMETER switch to + or - depending on the polarity chosen.
8. Set the RANGE switch to WIRE WELDING CV.
9. Set the WELDING TERMINALS switch to WELDING TERMINALS REMOTELY CONTROLLED.
10. Adjust wire feed speed at the LN-7.
NOTE: For remote control, a K857 control is required.
Connect it to the 6 pin amphenol.

FIGURE C.2
COMMANDER 400/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM

TO LN-7 INPUT
CABLE PLUG
6-PIN

K595 CONTROL CABLE

14 PIN

OPTIONAL
K857 REMOTE
CONTROL

AMPHENOL
+

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CV-

ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK

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COMMANDER 400

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C-5

ACCESSORIES

CONNECTION OF THE LN-8 TO THE

COMMANDER 400 USING K867
UNIVERSAL ADAPTER (SEE FIGURE C.3.)
1. Shut the welder off.
2. Connect the electrode cable from the LN-8 to the
+ terminal of the welder. Connect the work
cable to the CV- Wire terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.

CAUTION
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor setting is preset at the factory do not adjust above
RPM specifications listed in this manual.
6. Set the LOCAL/REMOTE switch to REMOTE.

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NOTE: Figure C.3 shows the electrode connected for

positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Commander 400 output terminals.
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C-5

3. Connect the K867 Universal Adapter to the K196

input cable and the 14 pin amphenol of the
Commander 400 as indicated in Figure C.3. Make
the proper connections for local or remote control
according to Figure C.3.

7. Set the VOLTMETER switch to + or - depending on the polarity chosen.

8. Set the RANGE switch to WIRE WELDING CV.
9. Set the WELDING TERMINALS switch to WELDING TERMINALS REMOTELY CONTROLLED.
10. Adjust wire feed speed and voltage at the LN-8.

4. Connect the K196 input cable to the LN-8.

5. Place the IDLER switch in the HIGH position.

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FIGURE C.3
COMMANDER 400/LN-8 WITH K867 ADAPTER CONNECTION DIAGRAM

SPARE

82
81
42
41

14 PIN
AMPHENOL
CV-

K867 UNIVERSAL
ADAPTER PLUG

ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK

31

31

32

32

21

21

GND

GND

75

76

77

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LN-8
WIRE

INSULATE UNUSED
LEADS INDIVIDUALLY

SPLICE LEADS
AND INSULATE

COMMANDER 400

FEEDER

K196
INPUT CABLE

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C-6

ACCESSORIES

CONNECTION OF THE LN-8 TO THE

COMMANDER 400 USING K595 INPUT
CABLE ASSEMBLY (SEE FIGURE C.4.)

CAUTION

1. Shut the welder off.

2. Connect the electrode cable from the LN-8 to the
+ terminal of the welder. Connect the work cable
to the CV- Wire terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.

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NOTE: Figure C.4 shows the electrode connected for

positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Commander 400 output terminals.

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C-6

3. Connect the K595-XX Input Cable Assembly to the

LN-8.
4. Connect the K595-XX to the 14 pin amphenol on
the Commander 400.

Any increase of the high idle engine RPM by changing

the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor setting is preset at the factory do not adjust above
RPM specifications listed in this manual.
6. Set the LOCAL/REMOTE switch to REMOTE.
7. Set the VOLTMETER switch to + or - depending on the polarity chosen.
8. Set the RANGE switch to WIRE WELDING CV.
9. Set the WELDING TERMINALS switch to WELDING TERMINALS REMOTELY CONTROLLED.
10. Adjust wire feed speed and voltage at the LN-8.

5. Place the IDLER switch in the HIGH position.

FIGURE C.4
COMMANDER 400/LN-8 WITH K595 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM

TO LN-8 INPUT
CABLE PLUG

K595 CONTROL CABLE

14 PIN
AMPHENOL

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CV-

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ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK

COMMANDER 400

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C-7

ACCESSORIES

CONNECTION OF THE LN-23P TO THE

COMMANDER 400 USING K350-1
ADAPTER (SEE FIGURE C.5.)
1. Shut the welder off.
2. Connect the electrode cable from the LN-23P to
the CV- Wire terminal of the welder. Connect the
work cable to the + terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.

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NOTE: Figure C.5 shows the electrode connected for

negative polarity.

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C-7

3. Connect the K350-1 adapter to the 6 pin amphenol

on the LN-23P and the 14 pin amphenol of the
Commander 400 as indicated in Figure C.5.
4. Place the IDLER switch in the AUTO position.

CAUTION
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor setting is preset at the factory do not adjust above
RPM specifications listed in this manual.

5. Set the VOLTMETER switch to negative.

6. Set the RANGE switch to WIRE WELDING CV.
7. Set the WELDING TERMINALS switch to WELDING TERMINALS REMOTELY CONTROLLED.
8. Set the LOCAL/REMOTE switch according to
whether you are controlling the welder at the
machine or remotely.
9. Adjust wire feed speed and voltage at the LN-23P.

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14 PIN
AMPHENOL
ADAPTER
KIT
LN-23P
+
TO WORK

CVELECTRODE

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FIGURE C.5
COMMANDER 400/LN-23P CONNECTION DIAGRAM

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K350-1

6 PIN
AMPHENOL

ELECTRODE CABLE

COMMANDER 400

WIRE FEEDER

TO WORK

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C-8

C-8

ACCESSORIES

CONNECTION OF THE LN-25 TO THE

COMMANDER 400 ACROSS THE ARC
(SEE FIGURE C.6.)

CAUTION

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 CV- terminal of the welder.

If you are using an LN-25 without an internal contactor, the electrode will be HOT when the Commander
400 is started.

5. Set the RANGE switch to WIRE WELDING CV.

NOTE: Welding cable must be sized for current and

duty cycle of application.

6. Set the WELDING TERMINALS switch to WELDING TERMINALS ALWAYS ON.

NOTE: Figure C.6 shows the electrode connected for

negative polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Commander 400 output terminals. Reverse the LN-25
polarity switch.

7. Set the VOLT METER switch to + or - depending on the polarity chosen.

3. Attach the single lead from the LN-25 control box

to the work using the spring clip on the end of the
lead. This is only a control lead it carries no
welding current.

8. Adjust wire feed speed at the LN-25.

9. Set the LOCAL/REMOTE switch to REMOTE if a
K444-1 remote control is used.

CAUTION
Electrode is always HOT.

4. Place the IDLER switch in the AUTO position.

FIGURE C.6
COMMANDER 400/LN-25 ACROSS THE ARC CONNECTION DIAGRAM

OPTIONAL K444-1
REMOTE CONTROL

6 PIN
AMPHENOL

AMPHENOL
14 PIN

LN-25
WIRE FEEDER
+

WORK CLIP LEAD

CV-

TO WORK
TO WORK

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ELECTRODE CABLE

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COMMANDER 400

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C-9

ACCESSORIES

CONNECTION OF THE K488 SG CONTROL

MODULE AND K487 MAGNUM SPOOL GUN
TO THE COMMANDER 400 (SEE FIGURE
C.7.)

5. Place the IDLER switch on the Commander 400 in

the HIGH position.

1. Shut the welder off.

Any increase of the high idle engine RPM by changing

the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor setting is preset at the factory do not adjust above
RPM specifications listed in this manual.

2. Connect the electrode cable from the SG Control

Module to the + terminal of the welder. Connect
the work cable to the CV- Wire terminal of the
welder.

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NOTE: Welding cable must be sized for current and

duty cycle of application.

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CAUTION

NOTE: Figure C.7 shows the electrode connected for

positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Commander 400 output terminals.

6. Set the LOCAL/REMOTE switch to REMOTE if a

K857 remote control is used. Set the switch to
LOCAL if no remote control is used.

3. Connect the K691-10 input cable as shown in

Figure C.7.

7. Set the VOLTMETER switch to + or - depending on the polarity chosen.

4. Set the slide switch on the SG Control Module to

the Lincoln position.

8. Set the RANGE switch to WIRE WELDING CV.

CAUTION

9. Set the WELDING TERMINALS switch to WELDING TERMINALS REMOTELY CONTROLLED.

10. Adjust wire feed speed at the SG Control Module.

Be sure this switch is set to the Lincoln (contact closure) position before attempting to operate the SG
Control Module. Incorrect switch position could result
in damage to the SG Control Module and/or the
Commander 400.
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C-9

NOTE: For remote control, a K857 remote control is

required. Connect it to the 6 pin amphenol.

FIGURE C.7
COMMANDER 400/K691/K488/K487 SPOOL GUN CONNECTION DIAGRAM
115V RECEPTACLE

K488 SG
CONTROL MODULE
K487-25
SPOOL GUN

14 PIN WIRE FEEDER

RECEPTACLE

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TO WORK

6 PIN REMOTE
RECEPTACLE

K691-10
INPUT CABLE

ELECTRODE

TO WORK

ELECTRODE CABLE
TO CONTROL MODULE

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COMMANDER 400

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C-10

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NOTES

COMMANDER 400

C-10

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Section D-1

Section D-1

TABLE OF CONTENTS
-MAINTENANCEMaintenance .........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance.............................................................................................D-2
Engine Maintenance.......................................................................................................D-2
Change the Oil ........................................................................................................D-2
Change the Oil Filter ...............................................................................................D-3
Fuel..........................................................................................................................D-3
Fuel Filters...............................................................................................................D-4

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Bleeding the Fuel System .......................................................................................D-6

Air Filter ...................................................................................................................D-6
Cooling System .......................................................................................................D-7
Cooling Blower Belt .................................................................................................D-7
Engine Maintenance Schedule................................................................................D-8
Engine Maintenance Parts ......................................................................................D-9
Battery Maintenance ....................................................................................................D-10
Cleaning the Battery ..............................................................................................D-10
Checking Specific Gravity .....................................................................................D-10
Checking Electrolyte Level ....................................................................................D-10
Charging the Battery .............................................................................................D-10

Storage ..................................................................................................................D-11
Cleaning.................................................................................................................D-11
Name plates...........................................................................................................D-11
Bearings.................................................................................................................D-11
Receptacles ...........................................................................................................D-11
Cable Connections ................................................................................................D-11
Major Component Locations .....................................................................................................D-12

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Welder/Generator Maintenance....................................................................................D-11

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COMMANDER 400

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D-2

MAINTENANCE

SAFETY PRECAUTIONS

ROUTINE AND PERIODIC

MAINTENANCE

WARNING

ENGINE MAINTENANCE

Have qualified personnel do all maintenance and

troubleshooting work.
Turn the engine off before working inside the
machine.
Remove covers or guards only when necessary to
perform maintenance and replace them when the
maintenance requiring their removal is complete.

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If covers or guards are missing from the machine,

get replacements from a Lincoln Distributor.
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D-2

Read the Safety Precautions in the front of this manual and in the instruction manual for the diesel engine
used with your machine before working on the
Commander 400.
Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep your hands, hair,
clothing, and tools away from the fans, and all other
moving parts when starting, operating, or repairing this
machine.

CAUTION
To prevent the engine from accidentally starting, disconnect the negative battery cable before servicing the
engine.

See Table D.1 for a summary of maintenance intervals

for the items listed below. Follow either the hourly or
the calendar intervals, whichever come first. More frequent service may be required, depending on your specific application and operating conditions.
OIL: Check the oil level after every 8 hours of operation or daily. BE SURE TO MAINTAIN THE OIL
LEVEL.
Change the oil the first time between 25 and 50 hours
of operation. Then, under normal operating conditions,
change the oil as specified in Table D.1. If the engine is
operated under heavy load or in high ambient temperatures, change the oil more frequently.

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CHANGE THE OIL: Change the oil, while the engine

is still warm, as follows:
1 . Drain the oil from the drain plug located on the
engine bottom, as shown in Figure D.1. Examine
the washer and replace it if it appears damaged.
2. Replace the plug and washer and tighten firmly.
3. Remove the oil fill cap and add oil until the level
reaches the MAX mark on the dipstick. See
Figure D.1. Use high quality oil viscosity grade
10W40. Consult the engine manual for oil specifications for various ambient temperatures. Always
check the level with the dipstick before adding
more oil.

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4. Reinstall the oil fill cap and the dipstick.

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D-3

MAINTENANCE

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D-3

FIGURE D.1 OIL DRAIN AND REFILL

MAX

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MIN

OIL FILL CAP

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OIL FILTER

DIPSTICK

DRAIN PLUG

CHANGE THE OIL FILTER: Change the oil filter the

first time between 25 and 50 hours of operation. Then,
under normal operating conditions, change the oil filter
after every 250 hours of operation. If the engine is
operated under heavy load or in high ambient temperatures, change the oil filter more frequently. See Table
D.1 for recommended maintenance intervals. See
Table D.2 for replacement oil filters.
Change the oil filter as follows:
1. Remove the oil drain plug. Drain the oil from the
engine and allow the oil filter to drain. See Figure
D.1.

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2. Remove the old filter (spin it off) and discard it (2).

Wipe off the filter mounting surface and adapter.
See Figure D.1.
3. Fill the new filter with fresh engine oil. Apply a thin
coat of new oil to the rubber gasket on the new oil
filter.

5. Refill the engine with the proper amount and type

of oil as described in the Change the Oil section,
above. Start the engine and check for leaks
around the filter element. Correct any leaks (usually by retightening the filter, but only enough to
stop leaks) before placing the Commander 400
back in service.
6. If there are no leaks, stop the engine and recheck
the oil level. If necessary, add oil to bring the level
up to the MAX mark, but do not overfill. See
Figure D.1.
FUEL: At the end of each day's use, refill the fuel tank
to minimize moisture condensation and dirt contamination in the fuel line. Do not overfill; leave room for the
fuel to expand.
Refer to your engine operation manual for recommended grade of fuel.

4. Spin the new filter onto the mounting adapter finger

tight until the gasket is evenly seated. Then turn it
down another 1/2 turn. Do not over tighten the new
filter.

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D-4

D-4

MAINTENANCE

7. Re-insert the large white volume plug into the

upper cavity.

FUEL FILTERS:

WARNING
When working on the fuel system:
Keep unshielded lights away, do not
smoke !
Do not spill fuel !
The Commander 400 is equipped with a Fuel PreFilter/Water Separator Assembly located before the
lift pump and a Secondary Fuel Filter located after the
lift pump and before the fuel injectors. The Fuel PreFilter/Water Separator is mounted to the engine block
just below the lift pump (Figure D.2). The Secondary
Fuel Filter is mounted directly to the engine just above
the oil filter (Figure D.3).
Fuel Pre-Filter/Water Separator Assembly: The prefilter is a 150 micron screen designed to protect against
gross fuel contamination of the water separator element and the Secondary Fuel Filter. If the pre-filter
becomes plugged, it may be removed, inspected,
cleaned and reinstalled. In general this only needs to
be done with each water separator element change
(about every 1,000 hrs). However, if at any time excessive fuel contamination is suspected or a sudden falloff in engine performance is detected the pre-filter
screen should be inspected and cleaned. See Figure
D.2 and follow this procedure:

8. Place the O-ring onto the angled seal surface of

the filter header and re-install the plastic cap. Make
sure its flange rests on the O-ring.
9. Screw on the cap ring and tighten hand tight.
10. Remember to open the fuel shutoff valve (Lever in
line with the hose) before starting the engine.
Water Separator Element: The water separator element is a two-stage filter with a special filtration/water
separating media. An expanded water reservoir provides maximum protection against water in the fuel.
The recommended change interval for the water separator element is 1,000 hours. See Figure D.2 and follow this procedure.
1. Close the fuel shutoff valve located on the side of
the Fuel Pre-Filter/Water Separator Assembly. The
lever should be perpendicular to the hose.
2. Rotate the quick change ring (located just below filter header) clockwise approximately 1/2 turn and
slide it down and off the element.
3. Grasp the element and pull down with a slight rocking motion to remove the element from the grommet
post on the bottom of the filter header.
FIGURE D.2 FUEL PRE-FILTER/WATER
SEPARATOR ASSEMBLY

1. Close the fuel shutoff valve located on the side of

the Fuel Pre-Filter/Water Separator Assembly. The
lever should be perpendicular to the hose
2. Unscrew the cap ring located on the top of the filter
header and remove the plastic center cap and Oring.
3. Remove the large white volume plug located directly under the center cap in the upper cavity of the filter header. Use a small screwdriver (or similar
device) to lift the plug part way out of the cavity to
assist with its removal.
NOTE: Be careful not to damage the pre-filter screen
with the tool used to remove the plug.

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4. Using a pair of pliers, gently tug on the pull tabs of

the pre-filter screen in an alternating pattern to
gradually remove the pre-filter screen.
5. Brush off any debris and rinse in diesel fuel.
6. Re-install the pre-filter screen into the upper cavity of
the filter header making sure the four pull tabs are
pointing up. Putting your fingers on the pull tabs,
push down evenly until the lower body of the pre-filter screen contacts the floor of the upper cavity.

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FUEL
SHUTOFF
VALVE

COMMANDER 400

FILTER
HEADER

QUICK
CHANGE
RING

CAP
RING

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D-5

MAINTENANCE

4. Slide the new element onto the grommet post on

the bottom of the filter header until the element no
longer easily moves up into the filter header. Now
rotate the element (it may take almost 1 full turn)
with a slight upward pressure until the element
begins to further engage the header. With the proper orientation now established, apply additional
pressure to seat the element in the filter header. You
should feel the element pop into place when properly seated.

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NOTE: The element will only go on one way. Never use

excessive force when mounting the element to the
header.

5. Slide the quick change ring up over the element and

rotate counter clockwise until an audible click or
pop is heard. If you do not hear the click, you have
not rotated the ring far enough and the element is
not in the locked position. Another indication that the
ring is in the locked position is that one set (it doesnt matter which one) of arrows located on the outside of the ring should be located directly under the
air vent valve.
6. Open the fuel shutoff valve (lever in line with the
hose).
7. Open the air vent valve on the front of the filter header until fuel emerges free of air bubbles. Then close
the air vent valve.
Secondary Fuel Filter: The Secondary Fuel Filter is a
spin-on cartridge type mounted directly to the engine.
Consult your engine operation manual for complete
information on service intervals and element changing
procedures.

FIGURE D.3 SECONDARY FUEL FILTER

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SECONDARY
FUEL FILTER

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D-5

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OIL
FILTER

COMMANDER 400

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D-6

MAINTENANCE

BLEEDING THE FUEL SYSTEM: In the event the

engine is operated until it runs out of fuel, you will need
to bleed the fuel system in order to start the engine.
Refer to the engine operation manual.
AIR FILTER:

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3. Remove loose dirt from the element with compressed air or a water hose directed from inside out.
Compressed Air: 100 psi maximum with nozzles
at least one inch away from the
element.
Water Hose:

CAUTION
Excessive air filter restriction will
engine life.

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D-6

result in reduced

The air filter element is a dry cartridge type. It can be

cleaned and reused. However, damaged elements
should not be reused. Stop engine after 100 hours of
running time and clean filter element. Replace the filter if necessary. Service the air cleaner regularly
according to your engine operation manual.
1. Locate the air filter canister located behind the
engine door on the top of the engine.
2. Remove the air filter element.

40 psi maximum without nozzle.

4. Soak the element in a mild detergent solution for 15

minutes. Do not soak more than 24 hours. Swish
the element around in the solution to help remove
dirt.
5. Rinse elements from inside out with a gentle stream
of water (less than 40 psi) to remove all suds and
dirt.
6.Dry the element before reuse with warm air at less
than 160oF (71oC). Do not use a light bulb to dry the
element.
7. Inspect for holes and tears by looking through the
element toward a bright light. Check for damaged
gaskets or dented metal parts. Do not reuse damaged elements. Protect the element from dust and
damage during drying and storage.
8. Reinstall the air filter element.

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After six cleanings, replace the air filter. A cleaned

filter will have approximately 70% of the life of a new
filter element. A restricted filter element may not
appear excessively dirty.

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D-7

D-7

MAINTENANCE

COOLING SYSTEM: The cooling system of the Deutz

engine needs to be checked and cleaned periodically.
Consult the engine Operation Manual for the proper
frequency and procedure.
COOLING BLOWER BELT: The following procedure
should be followed to replace the cooling blower belt:
1. Allow the machine to cool.
2. Unfasten and slide the battery holder out from the
welder.

6. Remove the old cooling blower belt and install a new

one.
7. Push outward on the alternator (4) and adjust the
cold belt tension to 63-73 lbs. (10-15 mm maximum
deflection) midway between any two pulleys.
Tighten bolts (1), (2), (3).
8. Reinstall the engine end panel. Reattach the negative battery cable. Slide in and refasten the battery
holder.
9. Check the cooling blower belt tension after 100
hours of operation.

3. Disconnect the negative battery cable.

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4. Remove the engine end panel for access to the

engine.
5. See Figure D.4. Loosen the alternator mounting
bolts (1, 2, 3) and rotate the alternator toward the
engine.

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FIGURE D.4 COOLING BLOWER BELT REPLACEMENT AND ADJUSTING

1
2

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COMMANDER 400

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D-8

MAINTENANCE
TABLE D.1
DEUTZ ENGINE MAINTENANCE SCHEDULE
FREQUENCY

MAINTENANCE REQUIRED

Daily or Before
Starting Engine

Fill fuel tank.

Check oil level.
Check air cleaner for dirty, loose, or damaged parts. Replace if necessary.
Check air intake and cooling areas, clean as necessary.

First 50 Hours
Change engine oil.
and Every 250
Change oil filter.
Hours Thereafter Change fuel filter.
Check fan belt.

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Every 50 Hours

Check fuel lines and clamps.

Every 100 Hours

Check battery electrolyte level and connections.

Clean air filter.

Refer to your Deutz engine operation manual for periodic maintenance at 100 hours and beyond.
125 Hours for severe conditions.

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D-8

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D-9

MAINTENANCE

Table D.2
ENGINE MAINTENANCE PARTS
ITEM

MANUFACTURER

PART NUMBER

Air Cleaner Element

Donaldson
AC

P181052
A302C

Cooling Blower Belt

Lincoln
Gates

T13536-3
7585

Oil Filter Element

Deutz
Purolator
Napa
Fram

1174418
PER2168
1820
PH3776

Fuel Filter Element

Deutz
Purolator
Napa
Fram

1174423
PC42
3358
P4102

Water Separator Element

Lincoln
Stanadyne

M16890-C
31572

Fuel Pre-Filter Screen

Lincoln
Stanadyne

M16890-B
29575
BCI
Group
34

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Battery

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D-9

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D-10

MAINTENANCE

D-10

CHECKING SPECIFIC GRAVITY: Check each battery

cell with a hydrometer. A fully charged battery will have
a specific gravity of 1.260. Charge the battery if the
reading is below 1.215.

BATTERY MAINTENANCE
WARNING
GASES FROM BATTERY can explode.
Keep sparks, flame, and cigarettes away
from battery.

NOTE: Correct the specific gravity reading by adding

four gravity points (0.004) for every five degrees the
electrolyte temperature is above 80 degrees F (27
degrees (C). Subtract four gravity points (.004) for
every five degrees the electrolyte temperature is below
80 degrees F (27 degrees C).

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BATTERY ACID can burn eyes and skin.

Wear gloves and eye protection and be
careful when working near a battery.
Follow the instructions printed on the
battery.

CHECKING ELECTROLYTE LEVEL: If battery cells

are low, fill them to the neck of the filler hole with distilled water and recharge. If one cell is low, check for
leaks.

To prevent EXPLOSION when:

INSTALLING A NEW BATTERY - Disconnect the
negative cable from the old battery first and connect
to the new battery last.
THE CORRECT POLARITY IS NEGATIVE GROUND Damage to the engine alternator and the printed circuit board can result from incorrect connection.
CONNECTING A BATTERY CHARGER Remove the battery from the welder by
disconnecting the negative cable first,
then the positive cable and battery
clamp. When reinstalling, connect the
negative cable last. Keep the area well
ventilated.
USING A BOOSTER - Connect the positive lead to
the battery first, then connect the negative lead to the
engine foot.
To prevent BATTERY BUCKLING, tighten the nuts
on the battery clamp until snug.

CHARGING THE BATTERY: The Commander 400 is

equipped with a wet charged battery. The charging
current is automatically regulated when the battery is
low (after starting the engine) to a trickle current when
the battery is fully charged.
When you charge, jump, replace, or otherwise connect
battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The Commander 400 charging system is NEGATIVE GROUND. The positive (+) battery terminal has
a red terminal cover.
If you need to charge the battery with an external
charger, disconnect the negative cable first, then the
positive cable before you attach the charger leads.
After the battery is charged, reconnect the positive battery cable first and the negative cable last. Failure to
do so can result in damage to the internal charger components.
Follow the instructions of the battery charger manufacturer for proper charger settings and charging time.

CLEANING THE BATTERY: Keep the battery clean

by wiping it with a damp cloth when dirty. If the terminals appear corroded, disconnect the battery cables
and wash the terminals with an ammonia solution or a
solution of 1/4 pound (0.113 kg) of baking soda and 1
quart (0.946 l) of water. Be sure the battery vent plugs
(if equipped) are tight so that none of the solution
enters the cells.
After cleaning, flush the outside of the battery, the battery compartment, and surrounding areas with clear
water. Coat the battery terminals lightly with petroleum
jelly or a non-conductive grease to retard corrosion.
Keep the battery clean and dry. Moisture accumulation
on the battery can lead to more rapid discharge and
early battery failure.

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COMMANDER 400

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D-11

MAINTENANCE

D-11

STORAGE: Store the Commander 400 in clean, dry,

protected areas.

When greasing the bearings, keep all dirt out of the

area. Wipe the fittings completely clean and use clean
equipment. More bearing failures are caused by dirt
introduced during greasing than from insufficient
grease.

CLEANING: Blow out the generator and controls periodically with low pressure air. Do this at least once a
week in particularly dirty areas.

RECEPTACLES: Keep the electrical receptacles in

good condition. Remove any dirt, oil, or other debris
from their surfaces and holes.

NAME PLATES: Whenever routine maintenance is

performed on this machine - or at least yearly - inspect
all name plates and labels for legibility. Replace those
which are no longer clear. Refer to the parts list for the
replacement item number.

CABLE CONNECTIONS: Check the welding cable

connections at the weld output terminals often. Be
sure that the connections are always tight.

WELDER/GENERATOR
MAINTENANCE

BEARINGS: The Commander 400 is equipped with

double-shielded ball bearings having sufficient grease
to last indefinitely under normal service. Where the
welder is used constantly or in excessively dirty locations, it may be necessary to add one half ounce of
grease per year. A pad of grease one inch wide, one
inch long, and one inch high weighs approximately one
half ounce. Over-greasing is far worse than insufficient
greasing.

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COMMANDER 400

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D-12

1.
2.
3.
4.
5.
6.
7.
8.
9.

CASE DOOR ASSEMBLY

ENGINE
SHUTDOWN SOLENOID
IDLER SOLENOID
REAR PANEL ASSEMBLY
BASE
FRONT PANEL ASSEMBLY
CONTROL PANEL
SCR/DIODE RECTIFIER
BRIDGE ASSEMBLY
FUEL TANK
CAPACITOR BANK
ROTOR/STATOR
CASE TOP AND SIDES

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MAINTENANCE
FIGURE D.5 - MAJOR COMPONENT LOCATIONS

10.
11.
12.
13.

13

12

11

10

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D-12

5
5

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COMMANDER 400

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Section E-1

Section E-1

TABLE OF CONTENTS
-THEORY OF OPERATION SECTIONTheory of Operation .............................................................................................................Section E
General Description ...............................................................................................................E-2
Battery, Starter, Engine, Rotor and Stator .............................................................................E-2
Exciter Feedback, Control Board, Local and Remote Control ..............................................E-3
Weld Winding, Output Bridge, Output Choke and CV Capacitors ........................................E-4
SCR Operation ......................................................................................................................E-5

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Induction Generators .............................................................................................................E-6

SCR/DIODE
OUTPUT
BRIDGE

OUTPUT
CHOKE

PA CV
CI
TO
R

NEGATIVE
TERMINAL

CA

CV
TERMINAL

GS

SHUNT

ALTERNATOR

ENGINE

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IN
ND

LD

MECHANICAL
ROTATION

WI

WE

STARTER

FEEDBACK

ROTOR

POSITIVE
TERMINAL
F
E
E
D
B
A
C
K

SCR GATE SIGNALS

SHUTDOWN
SOLENOID

EXCITER
WINDINGS
CV
BOARD

IDLER
SOLENOID

BATTERY

42VAC
METER

115VAC

EXCITER
CAPACITORS

14 PIN
AMPHENOL

115/230VAC
RECEPTACLE
6 PIN
AMPHENOL

MAIN
CONTROL
BOARD

REMOTE
SWITCH
BY-PASS
PC
BOARD

FINE
OUTPUT
CONTROL

ENGINE
SENSORS

ENGINE
PROTECTION
BOARD

EXCITER VOLTAGE
FEEDBACK
BOARD

CURRENT/ MODE
SELECTOR
SWITCH

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12VDC

FIGURE E.1 COMMANDER 400 BLOCK LOGIC DIAGRAM

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COMMANDER 400

E-2

THEORY OF OPERATION

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FIGURE E.2 BATTERY, STARTER, ENGINE, ROTOR AND STATOR

SCR/DIODE
OUTPUT
BRIDGE

OUTPUT
CHOKE

CA
PA CV
CI
TO
RS

NEGATIVE
TERMINAL
CV
TERMINAL
SHUNT

GS

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E-2

ALTERNATOR

ENGINE

MECHANICAL
ROTATION

IN
WI

ND

WE
LD

STARTER

FEEDBACK

ROTOR

POSITIVE
TERMINAL
F
E
E
D
B
A
C
K

SCR GATE SIGNALS

SHUTDOWN
SOLENOID

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EXCITER
WINDINGS
CV
BOARD

IDLER
SOLENOID

BATTERY

42VAC
METER

115VAC

EXCITER
CAPACITORS

14 PIN
AMPHENOL

115/230VAC
RECEPTACLE
6 PIN
AMPHENOL

MAIN
CONTROL
BOARD

REMOTE
SWITCH
BY-PASS
PC
BOARD

FINE
OUTPUT
CONTROL

ENGINE
SENSORS

ENGINE
PROTECTION
BOARD

EXCITER VOLTAGE
FEEDBACK
BOARD

CURRENT/ MODE
SELECTOR
SWITCH
12VDC

control board for the idler solenoid, which is mechanically coupled to the engine's throttle linkage.

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GENERAL DESCRIPTION
The Commander 400 is a diesel engine driven welding
power source. The machine uses a brushless asynchronous alternating current generator for DC stick
electrode welding and for 120/240 VAC auxiliary standby power. As a generator it can supply up to 10,000
watts of 120/240 volt AC power. As a welder it provides
up to 400 amps of DC constant current output in six
slope-controlled ranges. In addition a seventh general
purpose welding range provides up to 575 amps of
constant current welding output.

BATTERY, STARTER, ENGINE,

ROTOR AND STATOR
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The stick and wire model has a CV terminal for constant voltage wire welding.

The 12VDC battery powers the engine starter motor

and supplies power to the main control board for the
engine protection circuitry. The engine's alternator
supplies "charging" current for the battery circuit. The
battery circuit also provides power through the main

The diesel engine is coupled to a brushless asynchronous three-phase alternating current induction generator. See Induction Generators. The excitation or
"flashing" voltage is developed in the exciter windings
and capacitor configuration. The rotor, which is manufactured by casting aluminum through steel lamination,
is mechanically coupled to the engine. Through excitation of this rotating magnet, voltages are produced in
the stationary windings of the stator. There are three
separate and isolated sets of windings incorporated in
the stator lamination. Each set has a different number
of turns producing different magnitudes of AC output
voltages. These three windings are the three-phase
weld winding, the three-phase exciter winding; which is
tapped for single phase auxiliary standby power; and
the 42VAC single-phase winding, which supplies power
to the main control board.
The engine protection circuit shuts the engine off in the
event of low oil pressure, engine over temperature,
malfunction in the engine's alternator system, or a low
fuel condition.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

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COMMANDER 400

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E-3

THEORY OF OPERATION
FIGURE E.3 EXCITER FEEDBACK, CONTROL BOARD, LOCAL AND REMOTE CONTROL

SCR/DIODE
OUTPUT
BRIDGE

OUTPUT
CHOKE

CA
PA CV
CI
TO
R

NEGATIVE
TERMINAL
CV
TERMINAL
SHUNT

GS

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E-3

ALTERNATOR

ENGINE

MECHANICAL
ROTATION

IN

FEEDBACK

WI

ND

WE
LD

STARTER

ROTOR

POSITIVE
TERMINAL
F
E
E
D
B
A
C
K

SCR GATE SIGNALS

EXCITER
WINDINGS

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SHUTDOWN
SOLENOID

CV
BOARD

IDLER
SOLENOID

BATTERY

42VAC
METER

115VAC

EXCITER
CAPACITORS

14 PIN
AMPHENOL

115/230VAC
RECEPTACLE
6 PIN
AMPHENOL

MAIN
CONTROL
BOARD

REMOTE
SWITCH
BY-PASS
PC
BOARD

FINE
OUTPUT
CONTROL

ENGINE
SENSORS

ENGINE
PROTECTION
BOARD

EXCITER VOLTAGE
FEEDBACK
BOARD

CURRENT/ MODE
SELECTOR
SWITCH

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12VDC

EXCITER FEEDBACK, CONTROL

BOARD, LOCAL AND REMOTE
CONTROL

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The exciter voltage is monitored and fed back through

the exciter voltage feedback board to the control board.
In the event the exciter voltage increases or decreases
to an unacceptable level, the engine protection circuit
shuts off the engine.

The Commander 400 is controlled by a high quality

microcontroller, which is the main circuit element of the
control board.
The control board also supplies operating voltages and
control signals to the CV board, the meter board, and
the engine protection board.
The remote control and contactor signals are fed to the
control board through the amphenols and the by-pass
board.

The control board compares the commands of the current/mode selector and the fine output control (or
remote control) with the output voltage and current
feedback and sends the appropriate SCR gate firing
signals to the SCR/Diode bridge.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

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COMMANDER 400

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E-4

THEORY OF OPERATION
FIGURE E.4 WELD WINDING, OUTPUT BRIDGE, OUTPUT CHOKE AND CV CAPACITORS

SCR/DIODE
OUTPUT
BRIDGE

OUTPUT
CHOKE

CA
PA CV
CI
TO
R

NEGATIVE
TERMINAL
CV
TERMINAL
SHUNT

GS

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E-4

ALTERNATOR

ENGINE

MECHANICAL
ROTATION

IN

FEEDBACK

WI

ND

WE
LD

STARTER

ROTOR

POSITIVE
TERMINAL
F
E
E
D
B
A
C
K

SCR GATE SIGNALS

SHUTDOWN
SOLENOID

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EXCITER
WINDINGS
CV
BOARD

IDLER
SOLENOID

BATTERY

42VAC
METER

115VAC

EXCITER
CAPACITORS

14 PIN
AMPHENOL

115/230VAC
RECEPTACLE
6 PIN
AMPHENOL

MAIN
CONTROL
BOARD

REMOTE
SWITCH
BY-PASS
PC
BOARD

FINE
OUTPUT
CONTROL

ENGINE
SENSORS

ENGINE
PROTECTION
BOARD

EXCITER VOLTAGE
FEEDBACK
BOARD

CURRENT/ MODE
SELECTOR
SWITCH

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12VDC

WELD WINDING, OUTPUT BRIDGE,

OUTPUT CHOKE AND CV CAPACITORS

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The three-phase AC output that is created in the stator

weld winding is connected to the SCR/Diode output
bridge where it is rectified and controlled. See SCR
Operation.
A choke is connected between the negative side of the
bridge and the negative output terminal. This large
inductor stores energy and provides filtering for the
welding output of the Commander 400.

In the constant voltage (CV) mode, the CV capacitors

are brought into the welding circuit via an SCR that is
activated by the CV board. These capacitors add voltage filtering and help maintain a constant arc voltage at
the output terminals.1
The shunt, which is in series with the positive output
terminal, provides current feedback to the control
board.

CV Board and CV Capacitors are present on stick and wire

model only.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

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COMMANDER 400

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E-5

THEORY OF OPERATION

E-5

FIGURE E.6 SCR OPERATION

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SCR OPERATION
A silicon controlled rectifier (SCR) is a three terminal
device used to control rather large currents to a load.
An SCR acts very much like a switch. When a gate signal is applied to the SCR, it is turned ON and there is
current flow from anode to cathode. In the ON state the
SCR acts like a closed switch. When the SCR is turned
OFF, there is no current flow from anode to cathode
and the device acts like an open switch. As the name
suggests, the SCR is a rectifier, so it passes current
only during positive half cycles of the AC supply. The
positive half cycle is the portion of the sine wave in
which the anode of the SCR is more positive than the
cathode.

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When an AC supply voltage is applied to the SCR, the

device spends a certain portion of the AC cycle time in
the ON state and the remainder of the time in the OFF
state. The amount of time spent in the ON state is controlled by the Gate.

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An SCR is fired by a short burst of current into the gate.

This gate pulse must be more positive than the cathode
voltage. Since there is a standard PN junction between
gate and cathode, the voltage between these terminals
must be slightly greater than 0.6V. Once the SCR has
fired it is not necessary to continue the flow of gate current. As long as current continues to flow from anode
to cathode, the SCR will remain on. When the anode
to cathode current drops below a minimum value,
called holding current, the SCR will shut off. This normally occurs as the AC supply voltage passes through
zero into the negative portion of the sine wave. If the
SCR is turned on early in the positive half cycle, the
conduction time is longer, resulting in greater SCR output. If the gate firing occurs later in the cycle, the conduction time is less, resulting in lower SCR output.

Commander 400

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E-6

THEORY OF OPERATION

E-6

INDUCTION GENERATORS
The Commander 400 utilizes a brushless
Asynchronous Induction Generator to convert mechanical energy into electrical energy. The following is a
brief description of an induction generator.
The induction generator is an induction motor driven
above the synchronous speed. The rotor conductors
pass through the magnetic field of the stator in a direction that converts mechanical energy into electrical
energy. Typical alternators (synchronous generators)
are not self-excited. An induction generator must be
connected in parallel with an electrical system that provides out-of-phase current or reactive power for excitation. The capacitors used in the Commander 400 provide the same reactive power that an induction motor
would use for power factor correction. In fact, the
amount of reactive power used by an induction generator is equal to that used by an induction motor of the
same size.

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To summarize, the stand-alone induction generator

used in the Commander 400 converts mechanical
energy into electrical energy. The electrical energy
supplied by the capacitors is transferred magnetically
to the rotor. Mechanical energy is supplied to the magnetized rotor in the form of torque and rotational speed.
The majority of this energy is magnetically delivered to
the stator weld coils.

COMMANDER 400

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Section F-1

Section F-1

TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION
Troubleshooting & Repair Section ................................................................................Section F
How to Use Troubleshooting Guide .......................................................................................F-2
PC Board Troubleshooting Procedures .................................................................................F-3
Troubleshooting Guide ................................................................................................F-4 - F-15

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Initialization Sequence and Commander 400 Error Code Explanations .............................F-16

Error Codes with G2713-I Control Board ......................................................................F-17
Error Codes with G2713-2 or -3 Control Boards...........................................................F-21
Test Procedures ...................................................................................................................F-27
Case Cover Removal and Replacement Procedure .....................................................F-27
Case Front Knobs - Removal and Replacement Procedure.........................................F-32
Idler Solenoid Test .........................................................................................................F-33
Shutdown Solenoid Test ................................................................................................F-35
Engine Throttle Adjustment Test....................................................................................F-37
Static SCR/Diode Rectifier Bridge Test .........................................................................F-41
Active SCR Test.............................................................................................................F-45
Charging Circuit Test .....................................................................................................F-49
Stator Voltage Test ........................................................................................................F-51
Fine Control Potentiometer Test....................................................................................F-55
Range Switch Test.........................................................................................................F-57
Shunt Calibration Test ...................................................................................................F-61
Exciter Voltage Feedback Test ......................................................................................F-63
Exciter Capacitor Bank Test ..........................................................................................F-65
Control Board Power Supply Test .................................................................................F-67
Stator Resistance Test ..................................................................................................F-69
Oscilloscope Waveforms......................................................................................................F-72
Normal Open Circuit Voltage Waveform (115 VAC Supply)..........................................F-72
Normal Open Circuit Voltage Waveform (Stick) Max Tap .............................................F-73
Normal Weld Voltage Waveform (Stick CC) Machine Loaded
to 400 Amps at 40 Volts ..............................................................................................F-74
Normal Weld Voltage Waveform (Wire CV) Machine Loaded
to 400 Amps at 40 Volts ..............................................................................................F-75
Normal Open Circuit Voltage Waveform (Wire CV Tap)................................................F-76
Normal Solenoid Pull & Hold Coil Waveforms ..............................................................F-77
Abnormal Solenoid Pull & Hold Coil Waveforms...........................................................F-78
Typical Exciter Voltage Feedback Waveforms ..............................................................F-79
Abnormal Exciter Voltage Feedback Waveforms ..........................................................F-80

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Replacement Procedures ....................................................................................................F-81

Control PC Board Removal, Replacement, and Calibration .........................................F-81
Shutdown Solenoid Removal and Replacement...........................................................F-85
SCR/Diode Rectifier Bridge Removal and Replacement ..............................................F-89
SCR Removal and Replacement ..................................................................................F-95
Mounting Stud Type Diodes to Aluminum Heat Sinks.................................................F-103
Engine, Stator/Rotor Removal and Replacement .......................................................F-105
Retest After Repair.............................................................................................................F-117

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COMMANDER 400

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F-2

TROUBLESHOOTING & REPAIR

HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.

This Troubleshooting Guide is provided to help

you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM). Look

under the column labeled PROBLEM (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into four main categories: Output Problems,
Engine Problems Function Problems, and
Welding Problems.

Step 2. PERFORM EXTERNAL TESTS. The

second column, labeled POSSIBLE AREAS OF
MISADJUSTMENT(S), lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be conducted without removing the case cover.

Step 3. PERFORM COMPONENT TESTS. The

last column, labeled Recommended Course of
Action lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the subject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.

All of the referenced test procedures referred to in

the Troubleshooting Guide are described in detail
at the end of this section.
Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.

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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 1-800-833-9353.

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Commander 400

F-2

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F-3

TROUBLESHOOTING & REPAIR

F-3

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING
ELECTRIC SHOCK can kill.
Have an electrician install and service
this equipment. Turn the machine OFF
before working on equipment. Do not
touch electrically hot parts.

Remove the PC Board from the static-shielding bag

and place it directly into the equipment. Dont set the
PC Board on or near paper, plastic or cloth which
could have a static charge. If the PC Board cant be
installed immediately, put it back in the static-shielding
bag.

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If the PC Board uses protective shorting jumpers,

dont remove them until installation is complete.
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:

1. Determine to the best of your technical ability that

the PC board is the most likely component causing
the failure symptom.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.

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3. If the problem persists, replace the suspect PC

board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the
following procedures:

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4. Test the machine to determine if the failure symptom has been corrected by the replacement PC
board.
NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.
5. Remove the replacement PC board and substitute
it with the original PC board to recreate the original
problem.
a. If the original problem does not reappear
by substituting the original board, then the
PC board was not the problem. Continue
to look for bad connections in the control
wiring harness, junction blocks, and terminal strips.

PC Board can be damaged by

static electricity.

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

Reusable
Container
Do Not Destroy

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If you return a PC Board to The Lincoln Electric

Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow proper failure analysis.

Remove your bodys static charge

before opening the static-shielding bag. Wear an anti-static wrist
strap. For safety, use a 1 Meg
ohm resistive cord connected to a
grounded part of the equipment
frame.
If you dont have a wrist strap,
touch an unpainted, grounded,
part of the equipment frame.
Keep touching the frame to prevent static build-up. Be sure not
to touch any electrically live parts
at the same time.

b. If the original problem is recreated by

substitution of the original board, then
PC board was the problem. Reinstall
replacement PC board and test
machine.

6. Always indicate that this procedure was followed

when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the
warranty report, INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM, will help avoid
denial of legitimate PC board warranty claims.

Tools which come in contact with the PC Board must

be either conductive, anti-static or static-dissipative.

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the
the
the
the

Commander 400

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TROUBLESHOOTING & REPAIR

PROBLEMS
(SYMPTOMS)

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F-4

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Major physical or electrical damage
is evident.

1. Contact your local Lincoln

Authorized Field Service Facility.

No welding output in either CV or

Stick modes. Auxiliary power is normal and engine operates normally.

1. Place the Welding Terminals

switch in the ALWAYS ONposition. If the problem is solved, the
fault may be in the external control cable (if used), Leads #2 and
#4. See the Wiring Diagram.

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F-4

2. Check the welding cables,

clamps, and electrode holder for
loose or faulty connections.
3. With the engine at high idle
(1900 RPM), and the machine in
the general fab tap, Check for
the presence of 70VDC at the
output
terminals
of
the
Commander 400.

1. Contact the Lincoln Electric

Service Department. 1-800-8339353 (WELD).
1. Check for loose or faulty connections on the heavy current
carrying leads between the output bridge and the output terminals. Also check for broken
leads at the weld choke. See
the Wiring Diagram.
2. Check the welding terminal
switch (S6) and leads 2 &4 back
to J8 pins 2 & 3 of the control
board.
3. Check for poor connections at
J6 pins 1,2 & 3 molex plug at the
control PC board. Also check
leads G1,G2 & G3 to each SCR.
These are SCR gate drive outputs.
4. Check leads W1 thru W6 for
loose or faulty connections. See
the wiring diagram.
5. Perform the Stator Voltage Test.
6. Perform the SCR/Diode Bridge
Test.
7. Perform the Control
Power Supply Test.

Board

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1800-833-9353 (WELD).

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Commander 400

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F-5

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

Return to Master TOC

Observe Safety Guidelines

detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
--- or CRS stuck on display when
machine is powered up. No welding
output in both stick and CV modes.
Engine operates normally and auxiliary power is normal.

1. Contact your local Lincoln

Authorized Field Service shop.

1. Check for loose or faulty connections or wires at the T1, T2, or T3

capacitor connection block and
back to the capacitor bank. On
machines
equipped
with
L10953-1 Exciter feedback
Module Assembly check leads
T1, T2 & T3 for faulty connections.
2. Check for loose or faulty connections at leads 268,269, & 270
from the exciter PC board to J4
pins 1,2, & 3 on the control
board.
3. Check the exciter waveforms as
illustrated in the Oscilloscope
Waveforms Section.

The welding output is low with little

or no control of output. The auxiliary power is OK. The engine is
operating normal.
Return to Section TOC

F-5

1. If the remote control unit is not

connected to the machine, make
sure the Local/Remote switch
(S1) is in the Local position.
2. If a remote control unit is connected, and the machine operates normally when the switch is
in the Local position, the
remote control cable or unit may
be faulty. Check or replace.

The machine has low welding output and low auxiliary output.

1. The engine speed may be low.

Normal high idle (no load) is
1900 RPM.

1. Perform the Fine

Potentiometer Test.

Control

2. Perform the Stator Voltage Test.

3. Perform the SCR/Diode Bridge
Test.

1. If the speed is low, perform the

Engine Throttle Adjustment
Test.
2. Perform the Stator Voltage Test.
3. Perform the Exciter Capacitor
Bank Test.

Return to Master TOC

Return to Section TOC

4. The engine may have lost horsepower and may need major
repairs.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1800-833-9353 (WELD).

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COMMANDER 400

Return to Master TOC

TROUBLESHOOTING & REPAIR

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Low or no constant voltage (CV)
welding output. Constant current
(CC) and the auxiliary power are
operating normally.

1. Make sure the wire feeder, control cable and welding cables are
connected correctly.
2. Make sure the range switch is in
the correct position.
3. Check the heavy current carrying cables associated with the
CV output terminal. See the
Wiring Diagram.

1. Perform the Range Switch

Test.
2. Check for poor connections at
J21 pins 1 & 4 at the CV daughter board. This is CVSCR gate
drive output. Will not affect
welding in the general fab or
pipe taps.
3. Check for poor connections
along lead #208 at the negative
CV output stud and at the J21
pin 6 molex plug at the CV
daughter board. This is CV voltage feedback input. Will not
affect welding in the general fab
or pipe taps.
4. Perform the Control Board
Power Supply Test.

1. Contact your local Lincoln

Authorized Field Service Shop.

1. Check to make sure that the

machine has an L10953-1
Exciter Feedback Module Asbly.
2. Check for loose or faulty connections or wires at the T1, T2 or
T3 capacitor connection block
and back to the capacitor bank.
On machines equipped with
L10953-1 Exciter Feedback
Module Asbly check leads T1,
T2 and T3 for fault connections.

Return to Master TOC

The machine powers down within

seconds of power up and all lamp
indicators on the front panel are lit.
ECL, ECH, or CSS appears on
display as machine is shutting
down.
Return to Section TOC

F-6

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

detailed in the beginning of this manual.

Return to Master TOC

Return to Section TOC

Return to Section TOC

F-6

3. Check for loose or faulty connections at leads 268, 269, &

270 from the exciter PC Board to
J4 pins 1, 2 & 3 on the control
board.
4. If possible check exciter waveforms as illustrated in the
Oscilloscope
Waveforms
Section.

Return to Master TOC

Return to Section TOC

5. If possible perform the Exciter

Voltage Feedback Test.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1800-833-9353 (WELD).

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Commander 400

Return to Section TOC

Return to Master TOC

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Return to Master TOC

F-7

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)

F-7

Observe Safety Guidelines

detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
No welding output in either CV or
stick modes. Also no auxiliary
power. Engine operates normally.

1. Contact your local Lincoln

Authorized Field Service Shop.

1. Check for loose or faulty connections or wires at the T1, T2 or

T3 capacitor connection block
and back to the capacitor bank.
On machines equipped with
L10953-1 Exciter feedback module asbly check leads T1, T2 and
T3 for faulty connections. See
the Wiring Diagram.
2. Perform the Exciter Capacitor
Bank Test.
3. Check for a short across the
weld bridge plates.
4. Disconnect leads 3, 5 & 6 from
the terminal block located inside
the right hand side of the control
box. Check for a short across
each 115v and 115V/230V
receptacle.

Return to Master TOC

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5. Check fro shorts or opens in the

stator by performing the Stator
Resistance Test.
6. Perform the Control Board
Power Supply Test.
No auxiliary power at receptacles.
The engine operates normally and
the welding output is normal.

1. Check the circuit breakers CB1

thru CB4. Reset if tripped.
2. Check the GFCI receptacles.
Reset if tripped.
3. Check for loose or faulty plugs at
the power receptacles.

1. Check the GFCI receptacles and

associated wires for loose or
faulty connections. See the
Wiring Diagram.
2. Check the continuity of leads #3,
#5, #5A and #6 from the exciter
windings to their respective tie
points. See the Wiring Diagram.

Return to Master TOC

Return to Section TOC

3. Perform the Stator Voltage Test.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1800-833-9353 (WELD).

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COMMANDER 400

Return to Master TOC

Return to Section TOC

F-8

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines

detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

RECOMMENDED
COURSE OF ACTION

1. Make sure the Idler switch (S4)

is in the AUTO position.
2. Make sure there is not an external load on either the weld terminals or the auxiliary receptacles.
3. Check for mechanical restriction
in the solenoid linkage.

Return to Master TOC

Return to Master TOC
Return to Master TOC

Return to Section TOC

Return to Section TOC

POSSIBLE AREAS OF
MISADJUSTMENT(S)
ENGINE PROBLEMS

Engine will not idle down to low

speed. Machine has normal weld
and auxiliary power.

Return to Section TOC

F-8

1. Perform the Idler Solenoid Test.

2. Make sure the control board
mounting/grounding screws are
tight.
3. Check leads #226, #227, #237 &
#254 for loose or faulty connections. See the Wiring Diagram.
4. Check solenoid waveforms as
illustrated in the Oscilloscope
Waveforms Section.
5. Check to make sure that leads
#227 & #232 at the B1 & B3 terminals on the control board are
not swapped. See the Wiring
Diagram.

Engine will not go to high idle when

attempting to weld or use auxiliary
power. Output is normal when Idler
switch is in the HIGH position.
Automatic idle function works properly when the auxiliary power is
loaded.

1. Make sure the welding cables

and connections are tight.
NOTE: The automatic idler may
not function if the auxiliary
power is loaded to less
than 150 watts.

1. Check the current sensing toroid

for loose or faulty connections.
CV models only. See the Wiring
Diagram.
2. Make sure the toroid and lead
assembly are assembled correctly. CV models only. See the
Wiring Diagram.
3. Check the shunt and associated
leads for loose or faulty connections. Stick models only.
4. The control board may be faulty.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1800-833-9353 (WELD).

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COMMANDER 400

Return to Master TOC

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

F-9

Observe Safety Guidelines

detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

ENGINE PROBLEMS
The machine goes to low idle but
does not stay at low idle.

1. Make sure there is NOT an

external load (auxiliary or weld)
connected to the Commander
400.

1. The idler solenoid linkage may

be misadjusted or damaged.
2. The idler solenoid hold-in circuitry may be faulty. Check leads
#237 and #226 for loose or faulty
connections. See the Wiring
Diagram.
3. Perform the Idler Solenoid Test.

Return to Master TOC

Return to Section TOC

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F-9

4. Make sure the control board

mounting/grounding screws are
tight.
5. Check solenoid waveforms as
illustrated in the Oscilloscope
Waveforms Section.
6. The control board may be faulty.
Replace.

Return to Section TOC

Return to Master TOC

Return to Section TOC

Return to Master TOC

The engine will not crank or cranks

very slowly.

1. Check for loose, faulty, or corroded battery cable connections.

2. Check the leads and connections at the starter solenoid and
the start push button.
3. The battery may be faulty.

1. The starter motor, solenoid or

push button may be faulty.
Check or replace.
2. The engine may be hard to
crank due to a mechanical failure in the engine.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1800-833-9353 (WELD).

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Commander 400

Return to Master TOC

Return to Section TOC

F-10

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines

detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

RECOMMENDED
COURSE OF ACTION

POSSIBLE AREAS OF
MISADJUSTMENT(S)
ENGINE PROBLEMS

The engine cranks but will not start.

1. Check for adequate fuel supply.

2. Make sure the fuel shut off valve
is in the open position (lever is in
line with the hose).
3. The battery voltage may be too
low. If it is less than 11VDC,
charge or replace the battery.
Check the charging system.

Return to Master TOC

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F-10

4. If the engine temperature light is

lit, check the engine cooling system.

1. Check leads #274 & #240A at

J50 (exciter voltage plug) for
loose or faulty connections.
See the Wiring Diagram.
2. Perform
the
Solenoid Test.

Shutdown

3. Check leads #224, #225, #240

and #262 for loose or faulty connections.
See the Wiring
Diagram.
4. Make sure the control board
mounting/grounding screws are
tight.
5. Check solenoid waveforms as
illustrated in the Oscilloscope
Waveforms Section.

Return to Section TOC

Return to Master TOC

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6. Check to make sure that J4 &

J23 are not swapped at the control board. See the Wiring
Diagram.
The engine shuts down shortly after
start. Initialize sequence is normal
(see Initialization Sequence section).

1. Check for adequate fuel supply.

2. If any indicator light is lit when
the engine shuts down, that
particular system has faulted.
Check system.
3. Check for loose, faulty, or corroded battery cable connections.

1. Perform
the
Solenoid Test.

Shutdown

2. If possible check solenoid waveforms as illustrated in the

Oscilloscope Waveforms section.
3. The control board may be faulty.

4. Check the Run/Stop switch and

associated leads for loose or
faulty connections.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1800-833-9353 (WELD).

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COMMANDER 400

Return to Master TOC

Return to Section TOC

F-11

F-11

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

Observe Safety Guidelines

detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

FUNCTION PROBLEMS
The battery does not stay charged.

1. Check for loose, faulty or corroded battery cable connections.

1. Perform the Charging Circuit

Test.

Return to Master TOC

Return to Section TOC

2. The battery may be faulty.

Check or replace.
The Fine Control on the
Commander 400 does not work
properly.

1. Make sure the Remote/Local

switch (S1) is in the LOCAL
position.

1. Perform the Fine

Potentiometer Test.

Remote output control not functioning correctly.

1. Make sure the Remote/Local

switch (S1) is in the REMOTE
position.

1. Perform the Fine

Potentiometer Test.

2. The remote control unit or cable

may be faulty.
Repair or
replace.

Control

3. The control board may be faulty.

Control

2. Check the Remote/Local switch

(S1) and associated leads. See
the Wiring Diagram.
3. The RF Bypass PC Board (CV
models) may be faulty. See the
Wiring Diagram.

Return to Master TOC

Return to Section TOC

The Remote Protection PC

Board (Stick models) may be
faulty. See the Wiring Diagram.
4. Check amphenols and associated leads. See the Wiring
Diagram.
The wire feeder does not work
when connected to the machines
14 pin amphenol.

1. Check the circuit breaker CB5.

Reset if tripped.
2. The wire feeder control cable
may be faulty.
Check or
replace.
3. The wire feeder may be faulty.
Check or replace.

1. With the engine at high idle

speed: Check for the presence
of 115VAC at leads #31 pin J
and #32 pin A at the 14 pin
amphenol. If the voltage is
missing or low, Check for loose
or broken connections. See the
Wiring Diagram. Also check
CB5 for proper operation.
2. The RF bypass board (CV modules only) may be faulty. See
the Wiring Diagram.

Return to Master TOC

Return to Section TOC

3. Perform the Stator Voltage Test.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1800-833-9353 (WELD).

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COMMANDER 400

Return to Master TOC

Return to Section TOC

F-12

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS

RECOMMENDED
COURSE OF ACTION

The welding arc is cold. The

engine runs normally. The auxiliary
power is normal.

1. Check for loose or faulty connections at the weld output terminals and welding cable connections.

1. Using a voltmeter, check for the

correct OCV at the weld terminals. If the correct voltage is
present, then check for loose
connections on the heavy current carrying leads inside the
machine.
See the Wiring
Diagram.

Return to Master TOC

3. Check to make sure that the

machine settings match the
weld application.
4. If a remote control unit is not
connected to the machine, make
sure the Local/Remote switch
(S1) is in the LOCAL position.
5. If the remote control unit is connected, and the machine operates normally when the switch is
in the LOCAL position, the
remote control cable or unit may
be faulty. Check or replace.

2. If the OCV is low, perform the

Engine Throttle Adjustment
Test.
3. Perform the SCR/Diode Bridge
Test.
4. Perform the Stator Voltage Test.
5. Perform the Range Switch Test.
6. Perform the Fine
Potentiometer Test.

Control

7. Check fro poor connections at

the J1 molex plug at the control
board and at the shunt. Also,
perform the Shunt Calibration
Test.
8. Check for poor connections
along lead #204A at the diode
bridge and at J6 pin 4 molex at
the control pc board. This is
control board common.

Return to Master TOC

Return to Section TOC

2. The welding cables may be too

long or coiled, causing an
excessive voltage drop.

Return to Section TOC

F-12

9. Check for poor connections at

J6 pins 1, 2 & 3 molex plug at
the control board. Also check
leads G1, G2 & G3 to each
SCR. These are SCR gate drive
outputs.

Return to Master TOC

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10. Check for poor connections

along lead #207 at the negative
CC output stud, and at the J6
pin 10 molex plug at the control
board. This is CC arc voltage
feedback input. Will not affect
welding in the CV tap.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1800-833-9353 (WELD).

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COMMANDER 400

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F-13

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

Observe Safety Guidelines

detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

WELDING PROBLEMS
The welding arc is cold. The
engine runs normally. The auxiliary
power is normal. (Continued)

11. Check for poor connection at

J21 pins 1 & 4 at the CV daughter board. This is CVSCR gate
drive output. Will not affect
welding in the general fab or
pipe taps.
12. Check for poor connection
along lead #208 at the negative
CV output stud and at J21 pin 6
molex plug at the CV daughter
board. This is CV voltage feedback input. Will not affect welding in the general fab or pipe
taps.

Return to Master TOC

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F-13

13. Check the weld & CV chokes (if

so equipped) for turn to turn
shorts.
14. Check all waveforms as illustrated in the Oscilloscope
Waveforms Section.

Return to Section TOC

Return to Master TOC

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Return to Master TOC

15. Perform the Control Board

Power Supply Test.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1800-833-9353 (WELD).

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COMMANDER 400

TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)

F-14

Observe Safety Guidelines

detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

WELDING PROBLEMS
The welding arc is hot, spattery,
cannonballs or flares up. The
engine runs normally. The auxiliary power is normal.

1. Check to make sure that the

machine settings match the
weld application.
2. If the remote control unit is not
connected to the machine,
make sure the Local/Remote
switch (S1) is in the Local
position.
3. If a remote control unit is connected, and the machine operates normally when the switch
is in the Local position, the
remote control cable or unit
may be faulty.
Check or
replace.

Return to Master TOC

Return to Master TOC

TROUBLESHOOTING & REPAIR

1. Perform the Range Switch

Test.
2. Perform the Fine Control
Potentiometer Test.
3. Check for poor connections at
the J1 molex plug at the control
board. Also, perform the Shunt
Calibration Test.
4. Check for poor connections at
J4 pins 1, 2, 3, 6, & 7 at the control board. Also, perform the
Exciter Voltage Feedback
Test.
5. Check for poor connections
along lead #207 at the negative
CC output stud, and at J6 pin
10 molex plug at the control
board. This is CC arc voltage
feedback input. Will not effect
welding in the CV tap.
6. Check for poor connections
along lead #204A at the diode
bridge and at J6 pin 4 molex
plug at the control board. This
is control board common.

Return to Master TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

F-14

7. Check for poor connection

along lead #208 at the negative
CV output stud and at J21 pin 6
molex plug at the CV daughter
board. This is CV voltage feedback input. Will not affect welding in the general fab or pipe
taps.

Return to Master TOC

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8. Check for poor connection at

J21 pins 1 & 4 at the CV daughter board. This is CVSCR gate
drive output. Will not affect
welding in the general fab or
pipe taps.
9. Check the weld & CV chokes (if
so equipped) for turn to turn
shorts.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1800-833-9353 (WELD).
COMMANDER 400

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Return to Master TOC

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Return to Section TOC

Return to Section TOC

F-15

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

Observe Safety Guidelines

detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

WELDING PROBLEMS
The welding arc is hot, spattery,
cannonballs or flares up. The
engine runs normally. The auxiliary power is normal. (Continued)

Machine shuts down while arc

gouging and all lamp indicators on
front panel are lit. ECL, ECH,
or CCS appears on display as
machine is shutting down.

10. Check all waveforms as illustrated in the Oscilloscope

Wave forms Section.
11. Perform the Control Board
Power Supply Test.
1. Check to make sure that the
machine settings match the
weld application.
2. Check to make sure the propper carbon arc rod is being
used. The maximum carbon
arc rod for the Commander 400
is 5/16.
3. Attempt to arc gouge at a lesser current, if the application will
permit.

Return to Master TOC

4. If the machine shuts down

while arc gouging in the general fab tap, use the CV tap
instead. This is also an acceptable process.
Return to Section TOC

F-15

1. Check for poor connections at

J4 pins 1, 2, 3, 6 & 7 at the control pc board. Also, perform the
Exciter Voltage Feedback
Test.
2. Check for loose or faulty connections or wires at the T1, T2,
or T3 capacitor connection
block and back to the capacitor
bank. On machines equipped
with
L10953-1
Exciter
Feedback module asbly, check
leads T1, T2, & T3 for faulty
connections.
3. Check for loose or faulty connections at leads 268, 269 &
270 from the exciter pc board
to J4 pins 1, 2 & 3 on the control board.
4. Perform the Exciter Capacitor
Bank Test.
5. Check for poor connections at
the J1 molex plug at the control
pc board. Also, perform the
Shunt Calibration Test.
6. Perform the Engine Throttle
Adjustment Test.

Return to Master TOC

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7. Check exciter waveforms as

illustrated in the Oscilloscope
Waveforms Section.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1800-833-9353 (WELD).

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COMMANDER 400

Return to Master TOC

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Return to Section TOC

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F-16

TROUBLESHOOTING & REPAIR

COMMANDER 400 INITIALIZATION SEQUENCE
AND ERROR CODE EXPLANATIONS
When the Commander 400 is started, the display flashes several messages during initialization. They usually go by so fast you cannot see them. Each message correlates to an initialization test that the microcontroller program runs. No message should be present for more
than a few seconds before the next message appears. If any of these initialization messages
remain on the display, there is a problem. The microcontrollers program will not advance past
that test.
The initialization period is over immediately after the --- disappears from the display. Once
past the initialization, under normal circumstances, the unit displays a welding current preset
determined by the position of the front panel control knobs and switches. If a later control
board (G2713-2 or -3 is in place, the message cdr 400 rEAdy scrolls across the display.
Initialization is over after this message finishes scrolling. In the Stick & Wire model a preset
voltage or actual voltage, as well as current, may be displayed after initialization.
If the microcontroller detects an error, the error code will show on the display first and then the
unit may shut down. Use the Error Code Explanations on the following pages to aid in troubleshooting diagnosis.
If the unit begins to shut down first and then the error code appears, this is not a microcontroller initiated shutdown. In this case the unit has shut down due to lack of fuel, engine failure, etc.

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COMMANDER 400

F-16

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F-17

TROUBLESHOOTING & REPAIR

COMMANDER 400 WITH G2713-1 CONTROL BOARD

ERROR CODES DURING

INITIALIZATION SEQUENCE
300

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DEFINITION / SYMPTOM

CORRECTIVE ACTION

Program is stuck in ROM/RAM

check.

Replace control board.

ROM/RAM is corrupt.

Replace control board.

400

Program is stuck in power supply

stabilization.

Perform the Control Board

Power Supply Test.

600

Program is stuck in register

initialization and Interrupt
enables.

Replace control board.

700

Program is stuck in calibration

constant loading.

Replace control board.

500
or
---

The processor is not getting good

initial zero crosses.
The program waits for 32 clean
crosses and then waits for
frequency to get between 55
and 65 HZ.
or
Program is stuck waiting for
program stabilization and loading
of exciter voltage register table.

Check exciter voltage waveforms

as illustrated in the Oscilloscope
Waveforms Section.

bAd uP

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F-17

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Perform the Stator Voltage

Exciter Winding Test.
Perform the Engine Throttle
Adjustment Test.
Perform the Exciter Capacitor
Bank Test.
Check leads #268, #269, & #270
from J50 to J4 at the control
board for loose or faulty connections. Also check the T1, T2, &
T3 lead connections from the
exciter module to the stator and
capacitor bank leads.

COMMANDER 400

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F-18

TROUBLESHOOTING & REPAIR

COMMANDER 400 WITH G2713-1 CONTROL BOARD

ERROR CODES DURING

INITIALIZATION SEQUENCE
CSS

or

DEFINITION / SYMPTOM

CORRECTIVE ACTION

The processor is not receiving

zero cross signals properly or the
engine RPM is out of range.

Check exciter voltage waveforms

as illustrated in the Oscilloscope
Waveforms Section.

or

Perform the Stator Voltage

Exciter Winding Test.

The exciter voltage is out of

range (greater than 550 or less
than 140VAC).

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Perform the Engine Throttle

Adjustment Test.
Perform the Exciter Capacitor
Bank Test.

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ECL

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F-18

Check leads #268, #269, & #270

from J50 to J4 at the control
board for loose or faulty connections. Also check the T1, T2, &
T3 lead connections from the
Exciter Module to the stator and
capacitor bank leads.

COMMANDER 400

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F-19

TROUBLESHOOTING & REPAIR

COMMANDER 400 WITH G2713-1 CONTROL BOARD

ERROR CODES DURING

INITIALIZATION SEQUENCE
LCH

DEFINITION / SYMPTOM
The output current is too high
(greater than 750 amps for more
than 1 second).

CORRECTIVE ACTION
The machine may be over
loaded. Remove any external
loads. If the problem persists
with no external load, check the
shunt leads and associated connections to the control board.
See the Wiring Diagram. Perform
the SCR/Diode Rectifier Bridge
Test.
If the above procedures
do not reveal the problem, the
control board may be faulty.

Err

XIRQ error (illegal external

interrupt request).

If a High Frequency unit is being

used, make sure it is connected
properly. There may be high
frequency intrusion from another
source in the immediate area.
Remove all possible forms of RF
intrusion.

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If the problem persists, the

control board may be faulty.

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F-19

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COMMANDER 400

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F-20

TROUBLESHOOTING & REPAIR

F-20

COMMANDER 400 WITH G2713-1 CONTROL BOARD

ERROR CODES DURING
INITIALIZATION SEQUENCE

DEFINITION / SYMPTOM

Ert

RTI error (illegal return from

interrupt).

Esi

SWI error (illegal software

interrupt request).

EIO

IOT error (illegal op code trap).

ECP

COP time-out error.

ECE

CME error (slow or stopped

processor clock).

EO5

OC5 unintended execution.

IC3

IC3 unintended execution.

SS?

Invalid range control switch

position.

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COMMANDER 400

CORRECTIVE ACTION

If a High Frequency unit is being

used, make sure it is connected
properly. There may be high frequency intrusion from another
source in the immediate area.
Remove all possible forms of RF
intrusion.
If the problem persists, the
control board may be faulty.

Check for proper selector

switch/handle alignment.
Check the selector switch and
associated wiring. See the Wiring
Diagram. If the problem persists,
the control board may be faulty.

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F-21

TROUBLESHOOTING & REPAIR

COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD

ERROR CODES DURING

INITIALIZATION SEQUENCE
uP

CORRECTIVE ACTION
Replace control board.

ROM/RAM is corrupt.

Replace control board.

CAL

Program is stuck in calibration

constant loading.

Replace control board.

CrS

The processor is not getting good

initial zero crosses. Program
waits for 32 clean crosses and
then waits for frequency to get
between 55 and 65 HZ.

Check exciter voltage waveforms

as illustrated in the Oscilloscope
Waveforms Section.

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DEFINITION / SYMPTOM
Program is stuck in ROM/RAM
check.

bAd uP

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F-21

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Program is stuck waiting for

program stabilization and loading
of exciter voltage register table.

Perform the Stator Voltage

Exciter Winding Test.
Perform the Engine Throttle
Adjustment Test.
Perform the Exciter Capacitor
Bank Test.
Check leads #268, #269, & #270
from J50 to J4 at the control
board for loose or faulty connections. Also check the T1, T2, &
T3 lead connections from the
Exciter Module to the stator and
capacitor bank leads.

COMMANDER 400

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F-22

TROUBLESHOOTING & REPAIR

F-22

COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD

ERROR CODES DURING
INITIALIZATION SEQUENCE
SSr

DEFINITION / SYMPTOM
Processor is not reading a valid
range control switch position.

CORRECTIVE ACTION
Check for proper selector
switch/handle alignment.
Perform the Range Switch Test.

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EHC

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Check the exciter voltage waveforms as illustrated in the

Oscilloscope Waveforms Section.
Perform the Stator Voltage Exciter
Winding Test.

ECL

CSS

Return to Section TOC

The exciter voltage level is too

high (greater than 550VAC).

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The exciter voltage level is too

low (less than 140VAC).

The processor is not receiving

zero cross signals properly or the
engine RPM is too high.

COMMANDER 400

Perform the Engine Throttle

Adjustment Test.
Perform the Exciter Capacitor
Bank Test.
Check leads #268, #269 & #270
from J50 to J4 at the control
board for loose or faulty connections. Also check the T1, T2, &
T3 lead connections from the
exciter module to the stator and
capacitor bank leads.

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Return to Section TOC

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F-23

TROUBLESHOOTING & REPAIR

F-23

COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD

ERROR CODES
WHILE RUNNING
LCH

Err

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DEFINITION / SYMPTOM

CORRECTIVE ACTION

The output current is too high

(greater than 750 amps for more
than 1 second).

The machine may be over

loaded. Remove any external
loads. If the problem persists
with no external load, check the
shunt leads and associated
connects to the control board.
See the Wiring Diagram. Perform
the SCR/Diode Rectifier Bridge
Test. If the above procedures
do not reveal the problem, the
control board may be faulty.

XIRQ error (illegal external

interrupt request).

If a High Frequency unit is being

used, make sure it is connected
properly. There may be high
frequency intrusion from another
source in the immediate area.
Remove all possible forms of RF
intrusion. If the problem persists,
the control board may be faulty.

COMMANDER 400

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F-24

TROUBLESHOOTING & REPAIR

F-24

COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD

ERROR CODES
WHILE RUNNING

DEFINITION / SYMPTOM

CORRECTIVE ACTION

LFL

Unit has shut down because of

low fuel.

Add more fuel. If there is less

than half a tank of fuel,check for
proper operation of the fuel float.
If the float is at the top of the
tank, the resistance across its
terminals should be less than
100 ohms. If the float is on the
bottom of the tank, the resistance
across its terminals should be
greater than 175 ohms. If the
float is OK, check the leads and
connections between the float,
the fuel gauge and the engine
protection board. See the Wiring
Diagram. If the above checks do
not reveal the problem, the
engine protection board may be
faulty.

SS?

Invalid range control switch

position.

Check for proper selector

switch/handle alignment.
Check the selector switch and
associated wiring. See the Wiring
Diagram. If the problem persists,
the control board may be faulty.

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COMMANDER 400

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F-25

TROUBLESHOOTING & REPAIR

F-25

COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD

ERROR CODES
WHILE RUNNING

DEFINITION / SYMPTOM

Ert

RTI error (illegal return from

interrupt).

Esi

SWI error (illegal software

interrupt request).

EIO

IOT error (illegal op code trap).

ECP

COP time-out error.

ECE

CME error (slow or stopped

processor clock).

EO5

OC5 unintended execution.

IC3

IC3 unintended execution.

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COMMANDER 400

CORRECTIVE ACTION

If a High Frequency unit is being

used, make sure it is connected
properly. There may be high
frequency intrusion from another
source in the immediate area.
Remove all possible forms of
RF intrusion.
If the problem persists, the
control board may be faulty.

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Return to Section TOC

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F-26

TROUBLESHOOTING & REPAIR

F-26

COMMANDER 400 WITH G2713-2 OR -3 CONTROL BOARD

ERROR CODES WHILE
RUNNING

DEFINITION / SYMPTOM

CORRECTIVE ACTION

ECH

The exciter voltage is too high

(greater than 550 VAC).

Check exciter voltage waveforms

as illustrated in the Oscilloscope
Waveforms Sections.

ECL

The exciter voltage is too low (less

than 140 VAC).

CSS

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The processor is not receiving

zero cross signals properly or the
engine RPM is too high.

COMMANDER 400

Perform the Stator

Exciter Winding Test.

Voltage

Perform the Engine Throttle

Adjustment Test.
Perform the Exciter Capacitor
Bank Test.
Check leads #268, #269, & #270
from J50 to J4 at the control board
for loose or faulty connections.
Also check the T1, T2, & T3 lead
connections from the Exciter
Module to the stator and capacitor
bank leads.

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F-27

TROUBLESHOOTING & REPAIR

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION
This procedure will aid the technician in the removal and replacement of the case sheet
metal covers.

MATERIALS NEEDED

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3/8" Nut driver or Socket Wrench

7/16" Wrench
5/16" Nut Driver

This procedure takes approximately 35 minutes to perform.

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COMMANDER 400

F-27

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F-28

TROUBLESHOOTING & REPAIR

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.1 DOOR CHAIN REMOVAL

DOOR
ASSEMBLY

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CHAIN

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F-28

PROCEDURE
1. Turn the engine off.
2. Unlatch and open engine service access
door.
3. Using the 7/16" wrench, remove the chain
from the door assembly. See Figure F.1

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COMMANDER 400

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F-29

TROUBLESHOOTING & REPAIR

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)

4. Using the 3/8" wrench, remove the three
screws holding the door assembly to the left
side panel. See Figure F.2.
FIGURE F.2 DOOR ASSEMBLY/LEFT SIDE PANEL SCREW LOCATIONS

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THREE SCREWS

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LEFT SIDE PANEL

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F-29

5. Using the 3/8" wrench, remove the two

screws under the hinge. While supporting
the door assembly, remove the two screws

at the ends of the hinge. See Figure F.3

When these screws are removed, the door
assembly will be free to fall.

FIGURE F.3 DOOR HINGE SCREW LOCATIONS

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2 SCREWS
OUTSIDE

2 SCREWS
UNDER

COMMANDER 400

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F-30

TROUBLESHOOTING & REPAIR

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)

6. Carefully lift the door assembly from the
machine.

7. Using the 3/8" wrench, loosen the two bottom end screws from the left side engine
cover panel. See Figure F.4. Remove the
center screw. Remove the panel.

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FIGURE F.4 LEFT SIDE ENGINE COVER REMOVAL

LEFT SIDE
ENGINE COVER PANEL

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REMOVE CENTER SCREW

8. Using the 3/8" wrench, remove the screws

from the front roof assembly.
9. Remove the fuel cap and rubber seal.
Carefully lift and remove the front roof
assembly. Replace the fuel cap.

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LOOSEN
TWO END SCREWS

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F-30

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10. Remove the screws from the lower front left

and right side panels. The bottom end
screws need only to be loosened.
11. Remove the panels.

Commander 400

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F-31

TROUBLESHOOTING & REPAIR

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)

FRONT SHROUD REMOVAL
PROCEDURE
1. Using the 5/16" nut driver, remove the
screws from the front control panel assembly. Do NOT remove the phillips head
screws. Lower the panel. See Figure F.5.

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FRONT CONTROL
PANEL LOWERED
ARROWS INDICATE
SCREW LOCATIONS

2. Using the 5/16" nut driver, remove the four

screws from the left and right sides of the
shroud assembly. See Figure F.6.
FIGURE F.6 SHROUD ASSEMBLY SCREW REMOVAL - SIDES

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FIGURE F.5 FRONT CONTROL PANEL REMOVAL

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F-31

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SHROUD ASSEMBLY

REMOVE 2 SCREWS,
EACH SIDE

COMMANDER 400

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F-32

TROUBLESHOOTING & REPAIR

CASE FRONT KNOBS - REMOVAL AND REPLACEMENT PROCEDURE

Removal
Side View
(Pull)

(Pull)

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Knob

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F-32

Nameplate

(Push)
(Push)

Removal:

1. Rotate the handle portion of the knob to an approximate vertical orientation (switch detent may position
handle a few degrees off vertical). This orientation should be noted and repeated at replacement for proper
"D" shaft orientation.
2. With one hand, grasp the very bottom of vertical handle and push towards the machine nameplate and
pull down. At the same time and with the other hand, grasp the very top of the handle and pull the top edge
of the knob away from the machine nameplate. The knob should "peel" away from the nameplate and the
white nylon holding fingers of the knob base, from top to bottom.

Replacement
Rounded

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Flat

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Replacement:
1. If the white nylon cam of the detent mechanism is removed from it's spring loaded base by the above
procedure or intentionally, it should be returned before the knob replacement is attempted. Press the cam
into it's spring loaded holder so it sets flat and flush (Selector Switch Only).
2. Orientate the knob handle to the vertical as noted above and position the knob over the base, centered
and parallel.
3. Press the knob onto the "D" shaft and white nylon holding fingers, maintaining the parallel position.
The knob should "click" into place and should not pull off with normal operation.

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COMMANDER 400

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F-33

TROUBLESHOOTING & REPAIR

IDLER SOLENOID TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

Return to Master TOC

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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

TEST DESCRIPTION
This test will determine if the idler solenoid is capable of functioning when it is energized with
12VDC.

MATERIALS NEEDED

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External 12VDC supply ( 30 amps required)

Wiring Diagram
Volt/Ohmmeter

This procedure takes approximately 40 minutes to perform.

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COMMANDER 400

F-33

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F-34

F-34

TROUBLESHOOTING & REPAIR

IDLER SOLENOID TEST (continued)
FIGURE F.8 IDLER SOLENOID LEAD TERMINALS
PULL-IN COIL
(LARGER TERMINALS
TOP AND BOTTOM
#227 AND #254)

SHUTDOWN
SOLENOID

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HOLD-IN COIL
(SMALLER
TERMINALS
TOP AND BOTTOM
#226 AND #237)
IDLER
SOLENOID

TEST PROCEDURE

CAUTION

1. Turn the engine off.

2. Unlatch, lift and secure the right side engine
service access door. Using a 5/16, open
the control panel and tilt out. Remove the
control board cover.

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3. Check the pull-in coil resistance by disconnecting lead #227 from the B1 terminal at
the control board and measuring the resistance from lead #227 to the ground screw at
the control board. Normal coil resistance is
approximately 0.4 ohms. Reconnect lead
#227 to the B1 terminal at the control board.
Check the hold-in coil resistance by disconnecting J3 from the control board and measuring across pins 3 & 4. Normal coil resistance is approximately 20 ohms.
Reconnect J3 at the control board.
If either coil resistance is incorrect, the
wiring may be faulty. Inspect the solenoid
leads for faulty or loose connections.

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If the lead connections are OK, recheck the

coil resistance directly across the solenoid.
If the coil resistances are incorrect, the
solenoid may be faulty. Replace.
4. Using the external 12VDC voltage supply,
apply 12VDC to the larger idler solenoid terminals (#227+ to #254-). The solenoid
should activate.

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When the solenoid activates, remove the voltage

supply immediately. Do not leave the external
supply connected to terminals #227 and #254 for
longer than three seconds. Component damage
could result.
The solenoid should deactivate when the
12VDC supply is removed.
5. If the solenoid does not operate properly,
check for a mechanical restriction in the
linkage.
6. Using the external 12VDC voltage supply,
apply 12VDC to the smaller idler solenoid
terminals for the hold-in coil (#226+ to #237-).
Push in the solenoid plunger. With 12VDC
applied to the hold-in coil, the plunger
should stay in until the 12VDC is removed.
7. If the linkage is intact and the solenoid does
not operate correctly when 12VDC is applied,
the solenoid may be faulty. Replace.
8. Replace the harness leads to the correct
terminals. See Figure F. 8 and the Wiring
Diagram. Replace any previously removed
wire wraps.
8a. Using the control PC board layout, locate
Q21 on the control board. Scrape the environmental coating from all three legs of the
device, and check the resistance between
all three legs. If there is continuity between
any of the legs, Q21 is bad. Replace the
control PC board.
9. Close and secure the right side engine service access door. Replace the control board
and close the control panel.

COMMANDER 400

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F-35

TROUBLESHOOTING & REPAIR

SHUTDOWN SOLENOID TEST

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

Return to Master TOC

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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

TEST DESCRIPTION
This test will determine if the shutdown solenoid is capable of functioning when it is energized
with 12VDC.

MATERIALS NEEDED

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External 12VDC supply ( 30 amps required)

Wiring Diagram
Volt/Ohmmeter

This procedure takes approximately 40 minutes to perform.

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COMMANDER 400

F-35

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F-36

TROUBLESHOOTING & REPAIR

SHUTDOWN SOLENOID TEST (continued)
FIGURE F.9 - SHUTDOWN SOLENOID LEAD TERMINALS
PULL-IN COIL
(LARGER TERMINALS
EACH SIDE
#225 AND #262)
SHUTDOWN
SOLENOID

IDLER
SOLENOID

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HOLD-IN COIL
(SMALLER TERMINALS
EACH SIDE
#224 AND #240)

TEST PROCEDURE

CAUTION

1. Turn the engine off.

2. Unlatch, lift and secure the right side engine
service access door. Using a 5/16 nut driver, open up the control panel and tilt out.
Remove the control board cover
3. Check the pull-in coil resistance by disconnecting lead #262 from the B2 terminal at
the control board and measuring the resistance from lead #262 to the ground screw at
the control board. Normal coil resistance is
approximately 0.4 ohms. Reconnect lead
#262 to the B2 terminal at the control board.
Check the hold-in coil resistance by disconnecting J3 & J4 from the control board and
measuring across J3 pin 2 to J4 pin 5.
Normal coil resistance is approximately 20
ohms. Reconnect J3 at the control board.
If either coil resistance is incorrect, the
wiring may be faulty. Inspect the solenoid
leads for faulty or loose connections.
If the lead connections are OK, recheck the
coil resistances directly across the solenoid.
If the coil resistances are incorrect, the solenoid may be faulty. Replace.

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F-36

4. Using the external 12VDC voltage supply,

apply 12VDC to the larger shutdown solenoid terminals (#262+ to #225-). The solenoid should activate.

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When the solenoid activates, remove the voltage

supply immediately. Do not leave the external
supply connected to terminals #262 and #225 for
longer than three seconds. Component damage
could result.
The solenoid should deactivate when the
12VDC supply is removed.
5. If the solenoid does not operate properly, check
for a mechanical restriction in the linkage.
6. Using the external 12VDC voltage supply,
apply 12VDC to the smaller solenoid terminals
for the hold-in coil, (#240+ to #224-). Push in
the solenoid plunger. With 12VDC applied to
the hold-in coil, the plunger should stay in until
the 12VDC is removed.
7. If the linkage is intact and the solenoid does
not operate correctly when 12VDC is applied,
the solenoid may be faulty. Replace.
8. Replace the harness leads to the correct terminals. See Figure F.9 and the Wiring
Diagram. Replace any previously removed
wire wraps.
8a. Using the control PC board layout, locate
the Q25 on the control board. Scrape the
environmental coating from all three legs of
the device, and check the resistance
between all three legs. If there is continuity
between any of the legs, Q23 is bad.
Replace the control PC board.
9. Close and secure the right side engine service access door. Replace the control board
cover and close the control panel.

COMMANDER 400

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F-37

TROUBLESHOOTING & REPAIR

ENGINE THROTTLE ADJUSTMENT TEST

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

Return to Master TOC

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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

TEST DESCRIPTION
If the machine output is low or high, this test will determine whether the engine is operating at
the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for adjusting
the throttle to the correct RPM are given.

MATERIALS NEEDED

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This procedure takes approximately 25 minutes to perform.

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Slot head screw driver

7/16" wrench
10mm wrench
White or red marking pencil
Strobe-tach, frequency counter, or oscilloscope
3/8 wrench

COMMANDER 400

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F-37

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F-38

TROUBLESHOOTING & REPAIR

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.10 - BLOWER PADDLE MARKED FOR STROBE-TACH METHOD

MARK BLOWER
PADDLE HERE

TEST PROCEDURE
Strobe Tach Method
1. Conduct this procedure with the engine OFF.
2. Unlatch, lift and secure the right side engine
service access door. Perform Case Cover
Removal and Replacement Procedure
through Step 11. (For Strobe-Tach method
only.)

5. Start the engine and direct the strobe-tach

light on the blower paddle. Synchronize it to
the rotating mark.
With the machine at HIGH IDLE the tach
should read between 1890 and 1915 RPM.
With the machine at LOW IDLE the tach
should read between 1325 and 1400 RPM.

3. With a white or red marking pencil, place a

mark on one of the blower paddles. See
Figure F.10 for location.

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4. Connect the strobe-tach according to the

manufacturer's instructions.

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COMMANDER 400

F-38

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F-39

TROUBLESHOOTING & REPAIR

ENGINE THROTTLE ADJUSTMENT TEST (continued)

6. If either of the readings is incorrect, adjust

the throttle as follows:
Adjust HIGH IDLE: Use the 10mm wrench to
loosen the locking nut. See Figure F.11 for
location of the adjusting screw and locking nut.
Turn the threaded screw counter-clockwise to
increase the HIGH IDLE speed. Adjust the
speed until the tach reads between 1890 and
1915 RPM. Retighten the locking nut.
Adjust LOW IDLE: First make sure there is no
load on the machine. Set the IDLE switch to
AUTO and wait for the engine to change to low
idle speed. Use the 7/16" wrench to loosen the
solenoid lever arm locking nut. See Figure
F.12. Adjust the collar, to change the amount
of throw in the lever arm, until the tach reads
between 1325 and 1400 RPM. Retighten the
locking nut.
Frequency Counter Method

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1. Plug the frequency counter into one of the

115 VAC auxiliary receptacles.
2. Start the engine and check the frequency
counter. At HIGH IDLE (1900 RPM), the
counter should read 63 Hz. At LOW IDLE
(1400 RPM), the counter should read 47 Hz.
Note that these are median measurements;
hertz readings may vary slightly above or
below.
3. If either of the readings is incorrect, adjust
the throttle as follows:
Adjust HIGH IDLE: Use the 10mm wrench
to loosen the locking nut. See Figure F.11
for location of the adjusting screw and locking nut. Turn the threaded screw counterclockwise to increase the HIGH IDLE speed.
Adjust the speed until the frequency reads
63 Hz. Retighten the locking nut.

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Adjust LOW IDLE: First make sure there is

no load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
change to low idle speed. Use the 7/16"
wrench to loosen the solenoid lever arm
locking nut. See Figure F.12. Adjust the
collar, to change the amount of throw in the
lever arm, until the frequency reads 47 Hz.
Retighten the locking nut.
Oscilloscope Method
1. Connect the oscilloscope to the 115 VAC
receptacle, according to the manufacturers
instructions. At HIGH IDLE (1900 RPM), the
waveform should exhibit a period of 15.8
milliseconds. At 1400 RPM, the waveform
should exhibit a period of 21.4 milliseconds.
Refer to the NORMAL OPEN CIRCUIT
VOLTAGE WAVEFORM (115 VAC AUXILIARY) HIGH IDLE - NO LOAD in this section of the manual.
2. If either waveform periods is incorrect,
adjust the throttle as follows:
Adjust HIGH IDLE: Use the 10mm wrench
to loosen the locking nut. See Figure F.11
for location of the adjusting screw and locking nut. Turn the threaded screw counterclockwise to increase the HIGH IDLE speed.
Adjust the speed until the period is 15.8 milliseconds. Retighten the locking nut.
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
change to low idle speed. Use the 7/16"
wrench to loosen the solenoid lever arm
locking nut. See Figure F.12. Adjust the
collar, to change the amount of throw in the
lever arm, until the period is 21.4 milliseconds. Retighten the locking nut.

COMMANDER 400

F-39

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F-40

F-40

TROUBLESHOOTING & REPAIR

ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.11 - HIGH IDLE ADJUSTMENT

903

BOSCH6

57008

80D 410/3R
PES 3A
12
0 400 463

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LOCKING
NUT

ADJUSTING
SCREW

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FIGURE F.12 - LOW IDLE ADJUSTMENT

903

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ADJUSTING
COLLAR

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BOSCH6

57008

80D 410/3R
PES 3A 400 463 12
0

LOCKING NUT

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COMMANDER 400

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F-41

TROUBLESHOOTING & REPAIR

STATIC SCR/DIODE RECTIFIER BRIDGE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

TEST DESCRIPTION
This test will help determine if an SCR or diode is shorted or leaky. See the Oscilloscope
Waveforms in this section for normal output waveforms.

MATERIALS NEEDED
Analog Volt/Ohmmeter (Multimeter)
5/16 Nut driver
3/8 Nut driver
Commander 400 Wiring Diagrams (See the Electrical Diagrams section of this manual.)

This procedure takes approximately 65 minutes to perform.

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COMMANDER 400

F-41

TROUBLESHOOTING & REPAIR

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F-42

STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued)

FIGURE F.13 CONTROL BOARD PLUG J6 LOCATION

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Pel996

PLUG J6

4. Using the 5/16 nut driver, remove the control

board cover. See Figure F.13.

TEST PROCEDURE
1. Turn off the engine.

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2. Disconnect the welding cables from the

welding output terminals.

5. Locate and remove molex plug J6 from the

control board. See Figure F.13.

3. Perform the Case Removal Procedure

(including front shroud removal).

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COMMANDER 400

F-42

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F-43

F-43

TROUBLESHOOTING & REPAIR

STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued)
FIGURE F.14 SNUBBER BOARD PLUG J30 LOCATION
PLUG J30

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WARNING

SNUBBER
BOARD
LOCATION
(LEFT SIDE,
BELOW
FUEL TANK)

C3

C1

C2

C7

COMMANDER SNUBBER

6. Using the 3/8 nut driver, locate and remove

the snubber board cover. See Figure F.14.

8. Locate and remove lead #204B from resistor

R1 (50 ohms, 100 Watts). See Figure F.15.

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7. Locate and remove molex plug J30 from the

snubber board. See Figure F.14.

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FIGURE F.15 RESISTOR R1 LOCATION

RESISTOR R1
LEAD #204B

COMMANDER 400

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F-44

F-44

TROUBLESHOOTING & REPAIR

STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued)
FIGURE F.16 HEAT SINK AND SCR TEST POINTS

DIODE DD

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DIODES DA, DB, DC

ANODE

REMOVE
INSULATING PAINT

CATHODE

9. Remove the red insulating paint from the

heat sink test points. See Figure F.16.

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NOTE: Do not disassemble the heat sink.

10. Measure the resistance from the anode to
the cathode of SCR A, using an analog
volt/ohmmeter (multimeter) set at R x 1000
scale. See Figure F.16.
a. Reverse the meter leads and measure the
resistance from the cathode to the anode
of SCR A. See Figure F.16.

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c. If a high resistance is measured in both

meter polarities, diode DD is open.
Replace diode DD.
13. Test diodes DA, DB and DC for proper operation using the same procedure described in
Step 12.
14. Reconnect all leads and molex plugs.

b. If a low resistance is measured in either

meter polarity, SCR A is faulty. Replace
SCR A.

15. If this test did not identify the problem or to

further test the SCRs, go to the Active SCR
Test.

11. Test the resistance of SCR B and SCR C

using the same procedure described in Step
10.

If the test is complete, connect plug J6 to the

control board and plug J30 to the snubber
board and reconnect lead #204B to resistor
R1. Replace the covers to the two boards.
Replace all case covers. (See the Case
Cover Removal and Replacement procedure.)

12. Measure the resistance of diode DD from

anode (+probe) to cathode (-probe) using an
analog ohmmeter set at R x 1000 scale. The
resistance should be low. See Figure F.16.
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b. If a low resistance is measured in both

meter polarities, diode DD is shorted.
Replace diode DD.

a. Reverse the meter leads and measure the

resistance from cathode (+probe) to
anode (-probe) of diode DD. The resistance should be high. See Figure F.16.

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COMMANDER 400

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F-45

TROUBLESHOOTING & REPAIR

ACTIVE SCR TEST

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

TEST DESCRIPTION
This test will help determine if the device can be gated ON and conduct current from anode
to cathode.

MATERIALS NEEDED
An SCR tester as specified in this procedure.
5/16 nut driver
3/8 nut driver
Commander 400 Wiring Diagrams (See the Electrical Diagrams section of this manual.)

This procedure takes approximately 60 minutes to perform.

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COMMANDER 400

F-45

F-46

TROUBLESHOOTING & REPAIR

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F-46

ACTIVE SCR TEST (continued)

FIGURE F.17 CONTROL BOARD PLUG J6 LOCATION

PLUG J6

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Pel996

TEST PROCEDURE
5. Locate and remove molex plug J6 from the
control board. See Figure F.17.

1. Turn OFF the engine.

2. Perform the Case Removal procedure
(including front shroud removal).

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3. Disconnect the welding cables from the

welding output terminals.

6. Using the 3/8 nut driver, locate and remove

the snubber board cover. See Figure 18.
7. Locate and remove molex plug J30 from the
snubber board. See Figure F.18.

4. Using the 5/16 nut driver, remove the control board cover. See Figure F.17.

FIGURE F.18 SNUBBER BOARD PLUG J30 LOCATION

PLUG J30

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WARNING

SNUBBER
BOARD
LOCATION
(LEFT SIDE,
BELOW
FUEL TANK)

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C3

C1

C2

COMMANDER SNUBBER

COMMANDER 400

C7

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F-47

F-47

TROUBLESHOOTING & REPAIR

ACTIVE SCR TEST (continued)
FIGURE F.19 - RESISTOR R1 LOCATION

RESISTOR R1
LEAD #204B

8. Locate and remove lead #204B from

resistor R1 (50 ohms, 100 Watts). See
Figure F.19.

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FIGURE F.20 - HEAT SINK TEST POINTS

ANODE

REMOVE
INSULATING PAINT

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CATHODE

9. Remove the red insulating paint from the

heat sink test points. See Figure F.20.

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NOTE: Do not disassemble the heat sinks.

COMMANDER 400

ACTIVE SCR TEST (continued)

FIGURE F.21 - SCR TESTER CIRCUIT AND SCR CONNECTIONS

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6 VOLT
LANTERN
BATTERY

REMOVE
INSULATING
PAINT

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SW2

A
SCR
UNDER
TEST

R1 = 4 ohms/10 watts
R2 = 3 ohms/10 watts

ANODE

10. Construct the circuit shown in Figure F.21.

One 6-volt lantern battery can be used.
Set voltmeter scale low, at approximately
0-5 volts or 0-10 volts.

NOTE: Be sure the battery is functioning properly. A low battery can affect the results of the
test. Repeat Battery Test Procedure in Step 11
if needed.

11. Test the voltage level of the battery. Short

leads (A) and (C). Close switch SW-1.
Battery voltage should be 4.5 volts or higher. If lower, replace the battery.

17. Open switch SW-1.

a. Connect tester lead (A) to the anode.

18. Reconnect the tester leads. See Figure

F.21.
a. Connect tester lead (A) to the cathode.
b. Connect tester lead (C) to the anode.
c.

Disconnect test lead (G) from the gate.

b. Connect tester lead (C) to the cathode.

19. Close switch SW-1.

c. Connect tester lead (G) to the gate.

20. Read meter for zero voltage.

13. Close switch SW-1.

a. If the voltage is zero, the SCR is functioning.

NOTE: Switch SW-2 should be open.

b. If the voltage is higher than zero, the

SCR is shorted.

14. Read meter for zero voltage.

a. If the voltage reading is higher than
zero, the SCR is shorted.
15. Close or keep closed switch SW-1.
16. Close switch SW-2 for 2 seconds. Release
and read meter.

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R1

To test SCRs construct the circuit outlined above. Resistor values are plus or
minus ten percent. The voltmeter scale should be low, approximately 0-5 or
0-10 volts DC.

CATHODE

12. Connect the tester to the SCR A as shown

in Figure F.21.
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R2

SW1

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F-48

TROUBLESHOOTING & REPAIR

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F-48

a. If the voltage is 3-6 volts while the

switch is closed and after the switch is
open, the SCR is functioning.
b. If the voltage is 3-6 volts only when the
switch is closed or if there is no voltage
when the switch is closed, the SCR is
defective.

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21. Perform the Active Test Procedure outlined

in Steps 12-20 for SCRs B and C.
22. Replace all SCR assemblies that do not
pass the above tests.
23. Replace all molex plugs onto the control
board and snubber board. Reconnect lead
#204B resistor R1.
24. Replace the snubber board cover and control board cover.
25. Replace all case covers. (See the Case
Cover Removal and Replacement procedure.)

COMMANDER 400

TROUBLESHOOTING & REPAIR

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F-49

CHARGING CIRCUIT TEST

WARNING

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Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

TEST DESCRIPTION
This test will determine if the engine alternator and associated circuitry are functioning
properly.

MATERIALS NEEDED

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Volt/Ohmmeter
5/16" Nut driver
3/8" Nut driver
Wiring Diagram

This procedure takes approximately 25 minutes to perform.

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COMMANDER 400

F-49

CHARGING CIRCUIT TEST (continued)

FIGURE F.22 ENGINE ALTERNATOR LOCATION

#239

#285(#281)

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F-50

TROUBLESHOOTING & REPAIR

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F-50

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#238

TEST PROCEDURE
1. Turn the engine off.
2. Perform the Case Cover
Procedure up to Step 7.

Removal

3. Locate the engine alternator. See Figure F.22.

4. Start the engine and run it at high idle (1900
RPM).

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5. Set the voltmeter for DC volts and measure

the DC volts at lead #239 to engine ground.
See the Wiring Diagram. Normal is 12.5 to
14.5VDC.
6. Set the voltmeter for DC volts and measure
the DC volts at lead #238 to engine ground.
See the Wiring Diagram. Normal is 12.5 to
14.5VDC.

NOTE: Some earlier machines may have a lead

#281 instead of #285. Lead #285 carries the
flashing voltage for the engine alternator. Battery
voltage should be present whenever the engine is
running. See the Wiring Diagram. On the earlier
machines, lead #281 carries the flashing voltage
for the engine alternator. Battery voltage should
be present whenever the start button (S2) is
pushed. See the Wiring Diagram.
8. If the correct flashing voltage is present and
the charging output voltage is low or missing,
the engine alternator may be faulty.
9. Stop the engine and check alternator V-belt
for proper tension. See the engine operation
manual.
10. Replace all case covers that were removed.
(See the Case Cover Removal Procedure.)

7. Set the voltmeter for DC volts and measure

the DC volts at lead #285 to engine ground.
See the Wiring Diagram. Normal is 12.5 to
14.5 VDC.

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COMMANDER 400

TROUBLESHOOTING & REPAIR

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F-51

STATOR VOLTAGE TEST

WARNING

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
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Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

TEST DESCRIPTION
This test will determine if the correct AC voltages are being generated from the stator
windings.

MATERIALS NEEDED

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This procedure takes approximately 55 minutes to perform.

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Volt/Ohmmeter
3/8" Nut driver
Wiring Diagram
7/16" Wrench

COMMANDER 400

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F-51

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F-52

TROUBLESHOOTING & REPAIR

STATOR VOLTAGE TEST (continued)
FIGURE F.23 CONTROL BOX STUD TERMINALS

T1 STUD
#6 LEADS
T2 STUD
#5 LEADS

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T3 STUD
#3 LEADS

TEST PROCEDURE Auxiliary Power

Windings Test

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1. Turn off the engine.

2. Perform the Case Cover Removal
Procedure, including front shroud removal.
For this test the control box cover will be open.

5. Check for 230 - 250VAC at leads 6A to 3A at

the stud terminals inside the control box. See
the Wiring Diagram and Figure F.23.

3. Start the engine and run at high idle (1900

RPM). Do NOT load welding or auxiliary
power.
4. Check for 115 - 132VAC at leads 5A to 3B
located at the stud terminals inside the control
box. See the Wiring Diagram and Figure F.23.

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If any of the above voltage checks are low or

missing, check the associated leads for loose or
faulty connections. See the Wiring Diagram.
Then proceed to the Exciter Winding Voltage
Test.

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COMMANDER 400

F-52

F-53

TROUBLESHOOTING & REPAIR

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F-53

STATOR VOLTAGE TEST (continued)

FIGURE F.24 SCR/DIODE RECTIFIER BRIDGE LEADS

COMMANDER 4
WIRE

00

STICK and WIRE

STI

W2/W5
W1/W4

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W3/W6

TEST PROCEDURE Weld and PC

Board Windings Test
7. Check for 48-55VAC at leads W1/W4 to leads
W2/W5 located at the SCR/Diode Bridge. See
Figure F.24 and the Wiring Diagram.

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8. Check for 48 - 55VAC at leads W2/W5 to leads

W3/W6 located at the SCR/Diode Bridge. See
Figure F.24 and the Wiring Diagram.

10. Check for approximately 42VAC at leads E1

to E2 located at plug J2 on the control board.
See Figure F.25. Do not remove the plug from
the control board.
If any of the above voltage checks are low or
missing, check the associated leads for loose or
faulty connections. See the Wiring Diagram.
Then proceed to the Exciter Winding Voltage
Test

9. Check for 48 - 55VAC at leads W3/W6 to leads

W1/W4 located at the SCR/Diode Bridge. See
Figure F.24 and the Wiring Diagram.
FIGURE F.25 CONTROL BOARD PLUG J2 LOCATION

Pel996

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PLUG J2

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COMMANDER 400

TROUBLESHOOTING & REPAIR

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F-54

STATOR VOLTAGE TEST (continued)

FIGURE F.26 EXCITER LEADS T1, T2, T3

WARNING

T1

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T2
T3

TEST PROCEDURE Exciter Winding

Voltage Test

15. Using the voltmeter carefully check for 460

- 550VAC from T1 to T2.

11. Turn the engine off.

16. Using the voltmeter carefully check for 460

- 550VAC from T2 to T3.

12. Locate the exciter leads T1, T2 and T3. See

Figure F.26.

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13. Carefully pierce the insulation on leads T1,

T2 and T3 for voltage measurements.

CAUTION

17. Using the voltmeter carefully check for 460

- 550VAC from T3 to T1.
If the Exciter Winding Voltage Test is OK and any
of the other voltage checks are low or missing,
the stator may be faulty. Check for "shorted" or
"grounded" windings in the stator.

Make the smallest possible puncture away from

any sheet metal parts. Reinsulate these punctures at the end of this test.

If the exciter voltages are low or missing, the

capacitors or associated leads may be faulty.
Check for grounded or shorted windings. See the
Wiring Diagram.

14. Start the engine and run it at high idle (1900

RPM).

18. Replace the front shroud and all case covers

that were removed. (See the Case Cover
Removal Procedure.)

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COMMANDER 400

F-54

TROUBLESHOOTING & REPAIR

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F-55

FINE CONTROL POTENTIOMETER TEST

WARNING

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Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION
This test will determine whether the fine control potentiometer and PC board are defective.
Failure or intermediate failure of the control potentiometer circuit can result in erratic weld
output or loss of weld output.

MATERIALS NEEDED

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5/16 Nut Driver

Multi-Meter
Commander 400 Wiring Diagram (See the electrical diagrams section of this manual)
Control PC Board Layout (See the electrical diagrams section of this manual)

This procedure takes approximately 25 minutes to perform.

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COMMANDER 400

F-55

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F-56

FINE CONTROL POTENTIOMETER TEST (continued)

TEST PROCEDURE
NOTE: In this test procedure, the positive output
stud is used for common.
1. Using the 5/16 nut driver, open the control panel
and tilt out. Remove the control board cover.
Put the LOCAL/REMOTE switch in the LOCAL
position. Set the range switch to the general fabrication tap. Start the machine.

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WARNING
There are high voltages present
inside the control box while the
machine is running. THE VOLTAGES
ARE HIGH ENOUGH TO KILL. Use
extreme caution to avoid the backside of the receptacles, breakers, and
terminal strip while checking voltages inside the
control box.

2. With the control potentiometer in the minimum

position, check the voltage at the control board
from J8 pin 8 to common. Voltage should be
approximately -.025 VDC.
3. Slowly turn the control potentiometer CW. The
voltage should steadily increase from approximately -.025 VDC in the minimum position to

approximately 5.00 VDC in the maximum position. Also, the display on the control panel
should steadily increase from 50-575.
4. If step 2 or 3 fails, turn off the machine. At J8
pins 5,8, & 9, perform a resistance check of the
fine control potentiometer (the control potentiometer is a 10K ohm potentiometer). See
Figure F.27. Also, check continuity of all fine control potentiometer leads and LOCAL/REMOTE
switch. If any of the leads, switch or potentiometer fails the resistance check, replace the
faulty component.
5. If the leads, switch and potentiometer pass the
resistance check, disconnect the J8 from the
control board and start the machine. Check the
voltage from J8 pin 9 to common. The voltage
should be approximately 5.11 VDC. Check the
voltage from J8 pin 5 to common. The voltage
should be approximately -.049 VDC. If either
voltage check fails, replace the PC board.
6. Repeat steps 2-4 with the LOCAL/REMOTE
switch in the REMOTE position and a remote
control potentiometer hooked up to either
amphenol. When doing any continuity checks,
be sure to include the RF bypass PC board and
associated leads.
7. When the test is complete, replace the control
board cover and close the control panel.

Figure F.27 Control Board Plug J8 location

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F-56

TROUBLESHOOTING AND REPAIR

Pin #5

C112

Pin #8

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J20

Pin #9

J22

Plug J8
J2

J6

J5

J8

J7

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J1

J4

COMMANDER 400

F-57

F-57

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TROUBLESHOOTING & REPAIR

RANGE SWITCH TEST

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION
This test will determine whether the range switch is defective. Failure or intermittent failure
of the range switch can cause erratic weld output.

MATERIALS NEEDED
5/16 Nut Driver

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Multi-Meter
Commander 400 Wiring Diagram (See the electrical diagrams section of this manual)
Control PC Board Layout (See the electrical diagrams section of this manual)

This procedure takes approximately 30 minutes to perform.

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COMMANDER 400

F-58

F-58

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TROUBLESHOOTING AND REPAIR

RANGE SWITCH TEST (continued)
TEST PROCEDURE
NOTE: In this test procedure, the positive output
stud is used for common.

2. Put the range switch in the CV position on stick &

wire machines, or in the 90 tap on stick only
machines.

1. Using the 5/16 nut driver, open the control panel

and tilt out. Remove the control board cover.
Start the machine.

3. Check the voltage at the control board from J7

pin 10 to common at each tap on the range
switch. See Figure F.28. See table F.1 below for
approximate voltage reading from each tap.

WARNING

4. If any of the voltages in the table are incorrect,

replace the range switch.

There are high voltages present inside

the control box while the machine is
running. THE VOLTAGES ARE HIGH
ENOUGH TO KILL. Use extreme caution to avoid the backside of the
receptacles, breakers, and terminal
strip while checking voltages inside the control
box.

5. If the test is complete, replace the control board

cover and close the control panel.

Table F.1
Range Switch Position

Voltage

CV tap

.580 Vdc (if so equipped)

90 tap

.937 Vdc

120 tap

1.29 Vdc

180 tap

1.65 Vdc

230 tap

2.00 Vdc

270 tap

2.36 Vdc

400 tap

2.69 Vdc

50-575 tap

3.06 Vdc

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COMMANDER 400

F-59

TROUBLESHOOTING & REPAIR

RANGE SWITCH TEST (continued)

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F-59

Figure F.28 Control Board Plug J7

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C112

J20

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J2

J6

J5

J8

J7

J22

J1

J4

Plug J7
Pin #1

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Pin #7

Pin #10

COMMANDER 400

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F-60

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NOTES

COMMANDER 400

F-60

F-61

F-61

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TROUBLESHOOTING & REPAIR

SHUNT CALIBRATION TEST

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION
This test will determine whether the 600 amp shunt is out of calibration.

MATERIALS NEEDED
5/16 Nut Driver
Multi-Meter
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Resistive Grid Bank

Commander 400 Wiring Diagram (See the electrical diagrams section of this manual)
Control PC Board Layout (See the electrical diagrams section of this manual)

This procedure takes approximately 40 minutes to perform.

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COMMANDER 400

F-62

F-62

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TROUBLESHOOTING AND REPAIR

SHUNT CALIBRATION TEST (continued)
TEST PROCEDURE
NOTE: In this test procedure, the positive output
stud is used for common.
1. Using the 5/16 nut driver, open the control panel
and tilt out. Remove the control board cover.
Start the machine.

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WARNING
There are high voltages present
inside the control box while the
machine is running. THE VOLTAGES
ARE HIGH ENOUGH TO KILL. Use
extreme caution to avoid the backside of the receptacles, breakers, and
terminal strip while checking voltages inside the
control box.

2. Set the range switch to the CC/General fabrication tap. Using the fine control pot, set the preset amps on the display to 300 amps.
3. Using a grid bank, load the machine to 300 amps
at 25 volts using an external ammeter and voltmeter.
4. At the control board, measure the voltage from
J1 pin 3 (pos. lead) to J1 pin 2 (neg. lead). See
Figure F.29. The voltage should be 25 mVDC +/5%. The current reading on the display should
be within +/- 5% with the external ammeter. See
Figure F.29.
5. If step 4 fails, the shunt is out of calibration and
must be replaced.
6. If the test is complete, replace the control board
cover and close the control panel.

Figure F.29 Control Board Plug J1

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C112

J20

J2

J6

J5

J8

J7

J22

J1

J4

Plug J1

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-Pin #2

+Pin #3

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COMMANDER 400

F-63

F-63

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EXCITER VOLTAGE FEEDBACK TEST

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

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TROUBLESHOOTING & REPAIR

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION
This test will determine whether the exciter voltage module is reading each exciter phase
voltage back to the control board accurately. An inaccurate reading can cause the control
board to shut down the machine with an ECH or ECL error code when operating the
machine at high currents.

MATERIALS NEEDED
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None

This procedure takes approximately 20 minutes to perform.

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COMMANDER 400

F-64

F-64

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TROUBLESHOOTING AND REPAIR

EXCITER VOLTAGE FEEDBACK TEST (continued)
TEST PROCEDURE
1. Set the machine to the following settings, then
start the machine:
Control dial to 1 (min)
Range dial to 90A max
Idler switch in the Auto position

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Output control source (2-4) switch in the

Welding Terminals Remotely Controlled
position.
2. As the unit powers up, the display will step thru
its initialization sequence. As soon as the display shows ---, the user must toggle the idler
switch from Auto to High 5 times in 5 seconds. The display will read tal, then 000. The
idler switch must be returned to the Auto position. If the user misses toggling the Idler switch
5 times in 5 seconds, the machine will default to
normal operation, and step 1 & 2 must be repeated.

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3. Toggle the 2-4 switch to the Welding Terminals

Always On position. The display will read the
phase 1 no load exciter voltage. The voltage
should be between 400-525 Vac. Return the 2-4
switch to the Welding Terminals Remotely
Controlled position.
4. Toggle the Idler switch from Auto to High,
then back to Auto. The display should read
001. Repeat step 3 to read the phase 2 no load
exciter voltage.
5. Toggle the idler switch from Auto to High,
then back to Auto. The display should read
002. Repeat step 3 to read the phase 3 no load
exciter voltage.

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6. For machines equipped with G2713-1 boards,

toggle the Idler switch once from Auto to
High. The display should read 003. For
machines equipped with G2713-2 & 3 boards,
toggle the idler switch 3 times from Auto to
High to Auto till the display reads 000
again.
7. Turn the control dial to 10 (max). Toggle the 2-4
switch to the Welding Terminals Always On
position. Apply a grid load so that the machines
output is 565-585 amps at a minimum of 30 VDC.
The display will read the phase 1 exciter voltage
under load. Record the phase 1 exciter voltage
under load. Return the 2-4 switch to the
Welding Terminals Remotely Controlled position.
8. Toggle the Idler switch from Auto to High,
then back to Auto. The display should read
001 (or 004 for machines equipped with
G2713-1 board). Repeat step 7 to read the
phase 2 exciter voltage under load.
9. Toggle the idler switch from Auto to High,
then back to Auto. The display should read
002 (or 005 for machines equipped with
G2713-1 board). Repeat step 7 to read the
phase 3 exciter voltage under load.
10. If all exciter voltage readings on the display are
correct, the exciter board is properly calibrated
and the test is complete. If the average of the
three exciter voltage readings under load is under
350VAC, then the board must be replaced.

COMMANDER 400

F-65

F-65

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TROUBLESHOOTING & REPAIR

EXCITER CAPACITOR BANK TEST

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION
This test will determine whether there are any bad capacitors in the exciter capacitor bank.
Low capacitance in the bank can cause lack of full weld output and can cause the control
board to shut down the machine with an ECH or ECL error code when operating the
machine at high currents.

MATERIALS NEEDED
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Refer to Case Cover Removal section for tools needed to remove side panels.
Capacitance Meter
7/16 Nut Driver
Crescent Wrench

This procedure takes approximately 35 minutes to perform.

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COMMANDER 400

F-66

F-66

EXCITER CAPACITOR BANK TEST (continued)

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TROUBLESHOOTING AND REPAIR

1001/1003/1005/1007 with a capacitance meter.

The capacitance value should be 240 uf +/- 5%.

WARNING
Check for voltage across capacitors.
Voltages could be high and dangerous. Discharge capacitors with a
high wattage (50 Ohm min.) resistor if
necessary before performing tests.

TEST PROCEDURE

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1. With the engine off, disconnect the negative battery cable.

2. Refer to the Case Cover Removal section and
remove the left side engine and stator cover
panel.

6. Measure
capacitance
from
multi-lead
1018/1020/1022/1024
to
multi-lead
1017/1019/1021/1023 with a capacitance meter.
The capacitance value should be 240 uf +/- 5%.
7. Measure
capacitance
from
multi-lead
1010/1012/1014/1016
to
multi-lead
1009/1011/1013/1015 with a capacitance meter.
The capacitance value should be 240 uf +/- 5%.
8. If any of the capacitance values in steps 5-7 are
incorrect, then all the capacitors in that phase
must be replaced.

4. Pull the sleeving back and disconnect the three

bolted exciter connections using a 7/16 nut driver and crescent wrench.

9. If the test is complete, reconnect the 3 bolted

connections for the T1,T2, & T3 leads from the
stator and exciter module, and capacitor leads.
Make sure that the T1,T2, & T3 stator leads are
matched to the T1,T2,& T3 leads from the exciter
module respectively. Mismatching the leads will
cause the --- or CRS to be stuck on the display at power up, and no weld output. Cover
each bolted connection with sleeving after
reconnection.

5. Measure
capacitance
1002/1004/1006/1008

10. Reinstall the left side engine and stator cover

panels per the Case Cover Removal section.

3. Locate the point at which the capacitor bank

leads are bolted to the T1, T2, & T3 leads coming
from the stator and L10953-1 exciter feedback
module. See Figure F.30.

from
to

multi-lead
multi-lead

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Figure F.30 Control Board Plug J1

T1

WARNING

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T2
T3

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COMMANDER 400

F-67

F-67

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TROUBLESHOOTING & REPAIR

CONTROL BOARD POWER SUPPLY TEST

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION
This test will determine whether the weld control power supply from the control board that
supplies power to the weld control circuit, display, 2-4 switch circuit, and CV SCR drive circuit is defective. A defective power supply can cause loss of weld output and loss of weld
control.

MATERIALS NEEDED
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5/16 Nut Driver

Multi-Meter
Commander 400 Wiring Diagram (See the electrical diagrams section of this manual)
Control PC Board layout (See the electrical diagrams section of this manual)

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This procedure takes approximately 40 minutes to perform.

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COMMANDER 400

F-68

F-68

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TROUBLESHOOTING AND REPAIR

CONTROL BOARD POWER SUPPLY TEST (continued)
TEST PROCEDURE
NOTE 1: In this test procedure, the positive output
stud is used for common.
NOTE 2: This test procedure does not test the engine
control power supply portion of the control
board.
1. Using the 5/16 nut driver, open the control panel
and tilt out. Remove the control board cover.

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2. Using the control PC board layout, locate capacitor C112 (Figure F.31) and scrape the environmental coating off the negative lead. Start the
machine.

WARNING
There are high voltages present inside
the control box while the machine is
running. THE VOLTAGES ARE HIGH
ENOUGH TO KILL. Use extreme caution to avoid the backside of the receptacles, breakers, and terminal strip while checking
voltages inside the control box.

3. Refer to the Stator Voltage Test, step 10, to test

the E1-E2 stator winding that powers the control
PC board. If the voltage is correct, proceed to
step 4. If the voltage is incorrect, shut down the
machine, unplug J2, restart the machine, and
check the voltage again at J2 pins 1 to 4. If the
voltage is still incorrect, abort the Control Board
Power Supply Test and proceed to the Stator
Resistance Test.
4. With the machine running, measure the voltages at
the control board per the following table.
5. If any of the voltage checks in the Table F.2 below
are incorrect, replace the control board.
6. If the test is complete, replace the control board
cover and close the control panel.

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Table F.2
Measurement Point
J5 pin 2 to common
J4 pin 6 to common
J5 pin 7 to common
C112 neg. lead to common
J8 pin 2 to J8 pin 3
J20 pin 3 to J20 pin 4

Voltage
15 VDC +/- 5%
10 VDC +/- 5%
5 VDC +/- 5%
-10 VDC +/- 5%
24 VDC +/- 5%
15 VDC +/- 5%

Description
+15V supply for display
+10V supply for weld control & exciter module
+5V supply for microprocessor
-10V supply for weld control
+24V supply for 2-4 circuit
+15V supply for CV SCR gate drive circuit

Figure F.31 Control Board Plugs C112 & J2

C112
Pin #1

Pin #2

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C112

J20

J22

Pin #3

Pin #4

Plug J2
J2

J6

J5

J8

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J7

J1

J4

COMMANDER 400

F-69

F-69

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TROUBLESHOOTING & REPAIR

STATOR RESISTANCE TEST

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION
This test will determine whether there are shorts, opens, or grounds in any of the stator windings. An open, shorted or grounded winding can cause lack of output.

MATERIALS NEEDED

5/16 Nut Driver

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Refer to Case Cover Removal section for tools needed to remove side panels and
shroud.

7/16 Nut Driver

2 Multi-Meters
Crescent Wrench

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This procedure takes approximately 45 minutes to perform.

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COMMANDER 400

F-70

F-70

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TROUBLESHOOTING AND REPAIR

STATOR RESISTANCE TEST (continued)

TEST PROCEDURE

6. Disconnect J2 from the control board.

1. With the engine off, disconnect the negative battery cable. Make sure that there is nothing
plugged into the 115V and 230V receptacles.

7. Using an Ohmmeter check for continuity

between each weld lead (W1-W6) to the T1
exciter lead. There should be no continuity
between these leads.

2. Using the 5/16 nut driver, open up the control

panel and tilt out. Remove the control board
cover.

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3. Refer to the Case Cover Removal section and

remove left side engine and stator cover panels,
and the front shroud.
4. Pull the sleeving back, and disconnect all weld
leads (W1-W6) from the SCR/Diode weld bridge
using the 7/16 nut driver and crescent wrench.
5. Locate the point at which the capacitor bank
leads are bolted to the T1,T2 & T3 leads coming
from the stator and L10953-1 exciter module.
Pull the sleeving back and disconnect the three
bolted exciter connections using a 7/16 nut driver and crescent wrench.

8. Check for continuity from the weld leads to the

J2 plug pins 1 & 2 at the control board. There
should be no continuity between these leads.
See Figure F.31.
9. Check for continuity from the weld leads to frame
ground. There should be no continuity between
these leads.
10. Check for continuity from J2 pins 1 & 4 to the T1
exciter lead. There should be no continuity
between these leads.
11. Check for continuity from J2 pins 1 & 4 to frame
ground. There should be no continuity between
these leads.
12. Construct the circuit shown below. See Figure
F.32.

Figure F.32

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V1

J50
S1

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12V
CAR
BATTERY

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1 OHM
300 W

VOLTAGE LEADS MUST

BE TO THE WINDING
SIDE OF THIS CONNECTION

J51

COMMANDER 400

V2

STATOR
WINDING
UNDER
TEST

F-71

F-71

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STATOR RESISTANCE TEST (continued)

TEST PROCEDURE
14. Connect the test leads J50 and J51 to the stator
winding under test. Close S1 and read the voltages at V1 and V2, then open S1 IMMEDIATELY.
Damage can occur to the stator winding under
test if S1 is left in the on position for too long.
CAUTION: The 1 ohm resistor will also become
hot very quickly and can burn to the touch.
Leaving the circuit on for too long can also cause
the winding to heat up causing errors in measurements.

15. Use the following equation to determine the

winding resistance:
V2/V1 = winding resistance in ohms.
16. Disconnect J50 and J51 from the stator winding
under test. Check the resistance of all the stator
windings by repeating steps 13 & 14 and using
Table F.3 below.

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Table F.3

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TROUBLESHOOTING AND REPAIR

Stator Winding Under Test

Resistance

W1 - W2

.009 ohms +/- 20%

W3 - W4

.009 ohms +/- 20%

W5 - W6

.009 ohms +/- 20%

T1 - T2

.130 ohms +/- 20%

T2 - T3

.130 ohms +/- 20%

T3 -T1

.130 ohms +/- 20%

E1 - E2 (J2 Plug)

.170 ohms +/- 20%

NOTE: The resistances in the above table are to be

measured with the windings at an approximate temperature of 25 degrees Celsius
(room temp.). Measuring after the windings
are heated up can cause errors in the above
table.

18. If the test is complete, reconnect the 3 bolted

connections for the T1, T2, & T3 leads from the
stator and exciter module, and capacitor leads.
Make sure that the T1, T2, & T3 stator leads are
matched to the T1, T2, & T3 leads from the
exciter module respectively. Mismatching the
leads will cause the --- or CRS to be stuck on
the display at power up, and no weld output.
Cover each bolted connection with sleeving after
reconnection. Replace Plug J2. Reinstall the left
side engine and stator cover panels and the front
shroud per the Case Cover Removal section.

17. If any of the continuity checks fail in steps 7 thru

16, then the stator is bad. Replace.

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COMMANDER 400

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NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)

HIGH IDLE NO LOAD OUTPUT CURRENT CONTROL AT MAXIMUM

15.8 ms

0 volts

This is the typical auxiliary output

voltage generated from a properly
operating machine. Note that each
vertical division represents 50 volts
and that each horizontal division represents 5 milliseconds in time.

Note: Scope probes connected at

machine 115VAC receptacle.

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SCOPE SETTINGS

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F-72

TROUBLESHOOTING & REPAIR

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F-72

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Volts/Div.....................50V/Div.
Horizontal Sweep .....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal

COMMANDER 400

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TROUBLESHOOTING & REPAIR

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (STICK)
MAX TAP MAX CONTROL POT HIGH IDLE NO LOAD

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F-73

0 volts

This is the typical DC open circuit output voltage generated from a properly
operating machine. Note that each
vertical division represents 50 volts
and that each horizontal division represents 5 milliseconds in time.

Note: Scope probes connected at

STICK welding output terminals.

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SCOPE SETTINGS

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Volts/Div.....................50V/Div.
Horizontal Sweep .....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal

COMMANDER 400

F-73

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NORMAL WELD VOLTAGE WAVEFORM (STICK CC)

MACHINE LOADED TO 400AMPS AT 40 VOLTS

0 volts

This is the typical DC output voltage

generated from a properly operating
machine. Note that each vertical
division represents 20 volts and that
each horizontal division represents 5
milliseconds in time.
The machine was loaded with a
resistance grid bank to 400 amps at
40 volts.
Note: Scope probes connected at
STICK welding output terminals.

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SCOPE SETTINGS

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F-74

TROUBLESHOOTING & REPAIR

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F-74

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Volts/Div.....................20V/Div.
Horizontal Sweep .....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal

COMMANDER 400

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TROUBLESHOOTING & REPAIR

NORMAL WELD VOLTAGE WAVEFORM (WIRE CV)
MACHINE LOADED TO 400AMPS AT 40 VOLTS

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F-75

0 volts

This is the typical DC output voltage

generated from a properly operating
machine. Note that each vertical
division represents 20 volts and that
each horizontal division represents 5
milliseconds in time.
The machine was loaded with a
resistance grid bank to 400 amps at
40 volts.
Note: Scope probes connected at
WIRE welding output terminals.

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SCOPE SETTINGS

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Volts/Div.....................20V/Div.
Horizontal Sweep .....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal

COMMANDER 400

F-75

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TROUBLESHOOTING & REPAIR

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV TAP)
MAX CONTROL POT HIGH IDLE NO LOAD

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F-76

0 volts

This is the typical DC open circuit

output voltage generated from a
properly operating machine. Note
that each vertical division represents
20 volts and that each horizontal
division represents 5 milliseconds in
time.

Note: Scope probes connected at

WIRE welding output terminals.

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SCOPE SETTINGS

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Volts/Div.....................20V/Div.
Horizontal Sweep .....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal

COMMANDER 400

F-76

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TROUBLESHOOTING & REPAIR

2V

100 ms

2V

The scope pictures above are typical

waveforms seen directly across the
pull and hold terminals on both the
Idle and Shutdown solenoids when
they are operating normally.

Note: Voltages across the shutdown

solenoid coils may be slightly lower
than these waveforms since the
engine alternator may not be running.

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SCOPE SETTINGS

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F-77

NORMAL SOLENOID PULL & HOLD COIL WAVEFORMS

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F-77

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Volts/Div.......................2V/Div.
Horizontal ..............100ms/Div.
Coupling.............................DC
Trigger.........................Internal

COMMANDER 400

100 ms

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F-78

TROUBLESHOOTING & REPAIR

F-78

ABNORMAL SOLENOID PULL & HOLD COIL WAVEFORMS

20 ms

1V

200 MV

5 ms

SCOPE SETTINGS

SCOPE SETTINGS

Volts/Div.......................1V/Div.
Horizontal Sweep ...20 ms/Div.
Coupling.............................DC
Trigger.........................Internal

Volts/Div...............200 MV/Div.
Horizontal Sweep .....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal

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The scope pictures above are examples of a short at the output of both
the pull and the hold coil circuits on
the control PC board. The overcurrent circuits in the pull and hold coil
circuits will shut down the circuit when
an overcurrent is sensed, preventing
damage to the circuit. The waveform
on the left will cause the solenoid to
not pull in. The waveform on the right
will cause the solenoid to pull in, then
drop out. Check for shorted solenoid
coils and grounded leads.

COMMANDER 400

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TYPICAL EXCITER VOLTAGE FEEDBACK WAVEFORMS

1V

2 ms
This is the typical waveform output
from each of the three phases from
the Exciter Feedback Module
(L10953-1) at high idle/no load under
normal operation. The peak should
measure between 3.5 - 4.5 Vdc, and
the period should measure approximately 8.0 - 9.0 ms (make sure that
the machine is set up to the proper
high idle rpm before making this
measurement by performing the
Engine Throttle Adjustment Test).
This waveform can be viewed at the
following points on the control board:
J4 pin 1 to pin 7
J4 pin 2 to pin 7
J4 pin 3 to pin 7

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SCOPE SETTINGS

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F-79

TROUBLESHOOTING & REPAIR

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F-79

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Volts/Div.......................1V/Div.
Horizontal ..................2ms/Div.
Coupling.............................DC
Trigger.........................Internal

COMMANDER 400

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ABNORMAL EXCITER VOLTAGE FEEDBACK WAVEFORMS

1V

2 ms
This is an example of a bad waveform at one of the Exciter Module
outputs (J4 pin 3 to pin 7).
Note: The distortion in the waveform
that causes the period to be in
excess of 9.5 ms. Any distortion that causes a period in
excess of 9.0 ms requires the
Exciter Module to be replaced.
This distorted waveform can
cause machine shutdowns
with CSS, ECL, & ECH
error codes on the display,
and can cause CRS and ---
error codes at power-up. It
can also cause flare-ups and
welds that are too hot, spattery, or cannon balling.

SCOPE SETTINGS

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Volts/Div.......................1V/Div.
Horizontal ..................2ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-80

TROUBLESHOOTING & REPAIR

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F-80

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COMMANDER 400

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F-81

TROUBLESHOOTING & REPAIR

CONTROL PC BOARD REMOVAL, REPLACEMENT,
AND CALIBRATION
WARNING

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
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Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

DESCRIPTION
This procedure will aid the technician in the removal and replacement of the control printed
circuit board. Stick and wire models also require a calibration procedure whenever a control
board is replaced. This procedure is provided here following the reassembly steps.

MATERIALS NEEDED

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5/16" Nut driver

Phillips head screw driver
Volt/ohmmeter (for stick and wire model calibration only)

This procedure takes approximately 40 minutes to perform.

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COMMANDER 400

F-81

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F-82

TROUBLESHOOTING & REPAIR

CONTROL PC BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.33 MOLEX PLUG REMOVAL

ENGINE PROTECTION
BOARD MOLEX PLUG
Pel996

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CV BOARD
MOLEX PLUG
CONTROL BOARD
MOLEX PLUGS

PROCEDURE
Before starting the following procedure, refer to
the topic PC Board Troubleshooting
Procedures at the beginning of this section.
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1. Turn off the engine.

2. Using the 5/16" nut driver, remove the front
control cover assembly.

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3. Using the 5/16" nut driver, remove the control

board cover.
4. Locate and carefully remove the molex type
plugs from the control board, engine protection board and CV board (if used). See Figure
F.33 and the Wiring Diagram.

COMMANDER 400

F-82

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F-83

F-83

TROUBLESHOOTING & REPAIR

CONTROL PC BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.34 CONTROL BOARD LEADS

B1/227
Pel996

B2/262

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B3/232

5. Remove lead #227 from terminal B1 on the

control board. See Figure F. 34.
6. Remove lead # 262 from terminal B2 on the
control board. See Figure F.34.

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7. Remove lead #232 from terminal B3 on the

control board. See Figure F.34.
8. Note lead placement and routing through
insulation for reassembly.
9. Using the phillips head screw driver, remove
the control board mounting screws. Note the
location of the different types of screws for
reassembly. The machine screws have lock
washers and flat washers, and they mount
the board to welded nuts. The sheet metal
screws mount to the nylon standoffs.
10. Carefully remove the control board assembly.
Note insulation placement for reassembly.

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11. Using the phillips head screw driver, carefully remove the engine protection board and
CV board (if used).

14. Using the phillips head screw driver, mount

the control board with the appropriate mounting screws. The machine screws have lock
washers and flat washers, and they mount
the board to welded nuts. Make sure these
are secure since they are used to ground the
control board. The sheet metal screws
mount to the nylon standoffs.
15. Attach the leads to the control board. Note
lead placement and routing through insulation.
Lead #227 to terminal B1. See Figure F. 34.
Lead # 262 to terminal B2. See Figure F.34.
Lead #232 to terminal B3. See Figure F.34.
16. Carefully connect the molex type plugs to the
control board, engine protection board and
CV board (if used). See Figure F.33 and the
Wiring Diagram.
17. Using the 5/16" nut driver, install the control
board cover and the front control cover
assembly.
18. Perform the following calibration procedure.

REASSEMBLY
12. Using the phillips head screw driver, carefully assemble the engine protection board and
CV board (if used) to the new control board.
13. Carefully fit the control board assembly in
place. Note insulation placement.

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COMMANDER 400

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F-84

TROUBLESHOOTING & REPAIR

CONTROL PC BOARD REMOVAL AND REPLACEMENT (continued)
to AUTO. The display should read 003.

CALIBRATION PROCEDURE
(Stick and Wire Model Only)
1. Set the front control panel as follows:
Control dial to 0 (Min.).
Range dial to the Wire Welding setting.
Idler switch in the Auto position.
Volts/Amps switch to the volts position.
Output Control switch to the Welding
Terminals Remotely Controlled position.

2. Connect the volt/ohm meter across the +

and - WIRE (CV) terminals.
3. Start the unit.

WARNING
While the unit is running
there are high voltages
present inside the control
box.
THE VOLTAGES
ARE HIGH ENOUGH TO
KILL. Keep hands out of
the control box while the unit is running.

8. Set the Output Control switch to the WELDING TERMINALS ALWAYS ON position.
9. Turn the Control dial until the display reads
19.0. Assure that there is no load applied to
the unit.
10. Toggle the Idler switch to HIGH and back
to AUTO continually until the voltage on the
voltmeter across the studs reads 19.0 .2
volts. If 19.0 .2 volts is passed by, continue
to toggle the Idler switch to HIGH and back
to AUTO and the voltage will eventually
wrap around to a value below 19 volts.
Continue to toggle the idler switch and try to
attain 19.0 .2 volts again. Once the voltage
across the terminals does read 19.0 .2
volts, proceed to the next step.
11. Set the Output Control switch to the WELDING TERMINALS REMOTELY CONTROLLED position.
12. You have now completed the calibration procedure. Disconnect the volt/ohmmeter.

4. As the unit begins to run, the display will step

quickly through its initialization sequence. As
soon as the display shows three dashes
(---) begin to toggle the Idler switch from
AUTO to HIGH. You must toggle the
switch a total of 5 times in 5 seconds from the
time that the dashes appeared on the display.
Failure to due so will result in the unit defaulting to normal operation. The switch must be
returned to the AUTO position once the test
mode has been accessed. The display
should read 000, indicating the step number
of the self test to be executed.
5. Toggle the idler switch to HIGH and back
to AUTO. The display should read 001.

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6. Toggle the idler switch to HIGH and back

to AUTO. The display should read 002.
7. Toggle the idler switch to HIGH and back

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COMMANDER 400

F-84

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F-85

TROUBLESHOOTING & REPAIR

SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT

WARNING

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
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Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

DESCRIPTION
This procedure will aid the technician in the removal and replacement of the shutdown
solenoid.

MATERIALS NEEDED

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7/16" Wrench
Long slot head screw driver
Needle nose pliers

This procedure takes approximately 60 minutes to perform.

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COMMANDER 400

F-85

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F-86

F-86

TROUBLESHOOTING & REPAIR

SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT (continued)
FIGURE F.35 SHUTDOWN SOLENOID LEAD CONNECTIONS

PULL-IN COIL
(LARGER TERMINALS
EACH SIDE
#225 AND #262)

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SHUTDOWN
SOLENOID

IDLER
SOLENOID

HOLD-IN COIL
(SMALLER TERMINALS
EACH SIDE
#224 AND #240)

PROCEDURE
1. Turn the engine off.

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2. Unlatch, lift and secure the right side engine

access door.

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3. Locate and remove the four spade connectors

that attach the shutdown solenoid terminals to
the wiring harness leads (#224, #240, #225
and #262). See Figure F.35. Cut the cable tie.

COMMANDER 400

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F-87

TROUBLESHOOTING & REPAIR

SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT (continued)
FIGURE F.36 SHUTDOWN SOLENOID LINKAGE ARM ASSEMBLY

MOUNTING
FASTENERS

PIVOT PIN
SPACER
WASHER
PLAIN
WASHER
RETAINING
RING

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4. Using the 7/16" wrench, remove the three

nuts, two bolts and three lock washers mounting the shutdown solenoid assembly to the
engine. See Figure F.36.
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F-87

5. Using the long screw driver and needle nose

pliers, carefully remove the retaining ring,
plain washer, spacer washer and pivot pin
from the linkage arm assembly. See Figure
F.36.
6. Carefully remove the solenoid assembly.
7. Replace any faulty parts and reassemble the
solenoid assembly.

REASSEMBLY
8. Using the long screw driver and needle nose
pliers, carefully assemble the retaining ring,
plain washer, spacer washer and pivot pin to
the linkage arm assembly. See figure F.36.
9. Using the 7/16" wrench, mount the shutdown
solenoid assembly to the engine with three
nuts, two bolts and three lock washers.
10. Attach the four spade connectors from the
wiring harness leads (#224, #240, #225 and
#262) to the shutdown solenoid terminals.
See Figure F.35. Replace the cable tie.

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11. Close the right side engine access door.

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COMMANDER 400

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F-88

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NOTES

COMMANDER 400

F-88

TROUBLESHOOTING & REPAIR

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F-89

SCR/DIODE RECTIFIER BRIDGE

REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION
This procedure will aid the technician in the removal and replacement of the SCR/Diode
rectifier bridge assembly.

MATERIALS NEEDED

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5/16" Nut driver

3/8" Wrench
1/2" Wrench
3/4" Wrench
11/32" Wrench

This procedure takes approximately 80 minutes to perform.

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COMMANDER 400

F-89

F-90

TROUBLESHOOTING & REPAIR

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F-90

SCR/DIODE RECTIFIER BRIDGE

REMOVAL AND REPLACEMENT (continued)
FIGURE F.37 SCR/DIODE RECTIFIER BRIDGE DETAILS

COMMANDER 4
WIRE

STICK and WIRE

00
STI

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#209 (small)
SHUNT
REMOVE BOLT
AT POSITIVE
HEAT SINK
PLATE (LOWER)

#209A (large)

#204C
STATOR WELD
WINDING LEADS

PROCEDURE
1. Turn the engine off.

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2. Perform the Case Cover Removal

Procedure (including front shroud removal).
3. Using the 1/2" wrench, remove the stator weld
winding leads from the SCR/diode rectifier
bridge assembly. See Figure F.37 and the
Wiring Diagram. Cut any necessary cable ties
and clear the leads.
4. Using the 1/2" wrench, remove lead #209
(small) and #209A (large) from the negative
(upper) heat sink plate. See Figure F.37 and
the Wiring Diagram.

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5. Using the 1/2" wrench, remove the heavy

#204C lead from the positive heat sink plate
(lower). See Figure F.37 and the Wiring
Diagram.

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6. Using the 1/2" wrench, remove the shunt

from the positive heat sink plate (lower). See
Figure F.37 and the Wiring Diagram.
NOTE: The "DD" diode pigtail lead and the three
small #204, #204A and #204B leads are also
incorporated in the bolted connection. They can
stay in place.
7. Using the 5/16" nut driver, remove the control
board cover.
8. Remove plug J6 and the toroid assembly from
the control board. Remove plug J6 and leads
from the control box. Cut any necessary cable
ties.

COMMANDER 400

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F-91

F-91

TROUBLESHOOTING & REPAIR

SCR/DIODE RECTIFIER BRIDGE
REMOVAL AND REPLACEMENT (continued)
FIGURE F.38 NEGATIVE STICK OUTPUT TERMINAL

COMMANDER 4
WIRE

00

STICK and WIRE

STI

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#207 FROM STICK

OUTPUT TERMINAL

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9. Using the 3/4" wrench, remove lead #207 from

the negative "stick" output terminal. See
Figure F.38 and the Wiring Diagram. Cut any
necessary cable ties.

10. Locate and remove the snubber board cover

using the 3/8" wrench. See Figure F.39.
11. Remove plug J30 from the snubber board.
See the Wiring Diagram. Clear leads for the
SCR/diode rectifier bridge assembly
removal.

FIGURE F.39 SNUBBER BOARD COVER REMOVAL

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SNUBBER
BOARD
LOCATION
(LEFT SIDE,
BELOW
FUEL TANK)

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COMMANDER 400

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F-92

TROUBLESHOOTING & REPAIR

SCR/DIODE RECTIFIER BRIDGE
REMOVAL AND REPLACEMENT (continued)
FIGURE F.40 RESISTOR R1 LOCATION

RESISTOR R1
LEAD #204B

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12. Using the 11/32" wrench, remove the #204B

lead from the R1 (50 Ohm -100 Watt) resistor. See Figure F.40. Cut any necessary
cable ties and clear leads for SCR/diode rectifier bridge assembly removal.
NOTE: Be sure to replace any cut cable ties on
reassembly. Otherwise, the leads may catch in
the blower.

13. Remove the capacitor leads and grommet

from the rectifier bridge bracket. See Figure
F.41.
14. Using the 3/8" wrench, remove the four (2 on
each side) screws from the rectifier bridge
bracket. See Figure F.41.

FIGURE F.41 RECTIFIER BRIDGE BRACKET DETAILS

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GROMMET

BRACKET

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SCREWS (4)

COMMANDER 400

F-92

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F-93

TROUBLESHOOTING & REPAIR

SCR/DIODE RECTIFIER BRIDGE
REMOVAL AND REPLACEMENT (continued)
FIGURE F.42 SCR/DIODE RECTIFIER BRIDGE ASSEMBLY REMOVAL

RECTIFIER

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15. Carefully lift and slide the SCR/diode rectifier

bridge assembly out the left side of the
machine. See Figure F.42.

REASSEMBLY
16. Carefully lift and slide the SCR/diode rectifier
bridge assembly into the machine from the
left side. See Figure F.42.
17. Using the 3/8" wrench, install the four (2 on
each side) screws holding the SCR/diode
rectifier bridge assembly rectifier bridge
bracket. See Figure F.41.
18. Attach the capacitor leads and grommet to
the rectifier bridge bracket. See Figure F.41.

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19. Using the 11/32" wrench, attach the #204B

lead to the R1 (50 Ohm -100 Watt) resistor.
See Figure F.40.
NOTE: Be sure to replace any cable ties cut during removal. Otherwise, the leads may catch in
the blower.

21. Using the 3/4" wrench, attach lead #207 to

the negative "stick" output terminal. Replace
any cable ties cut during removal.
22. Feed plug J6 and the toroid assembly into
the control box. Connect plug J6 to the control board. Replace any cable ties cut during
removal. Using the 5/16" nut driver, install
the control board cover.
23. Using the 1/2" wrench, attach the shunt to
the positive heat sink plate (lower). Attach
the heavy #204C lead from the positive heat
sink plate (lower). Attach lead #209 (small)
and #209A (large) to the negative (upper)
heat sink plate. Attach the stator weld winding leads to the SCR/diode rectifier bridge
assembly. Replace any cable ties cut during
removal.
24. Replace the front shroud and all case covers
that were removed. (See the Case Cover
Removal and Replacement Procedure.)

20. Connect plug J30 to the snubber board.

Install the snubber board cover using the 3/8"
wrench.

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COMMANDER 400

F-93

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F-94

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NOTES

COMMANDER 400

F-94

TROUBLESHOOTING & REPAIR

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F-95

SCR REMOVAL AND REPLACEMENT

WARNING

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
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Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

DESCRIPTION
The following procedure will aid the technician in removing the SCRs from the output rectifier
heat sink for maintenance or replacement.

MATERIALS NEEDED

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NO.000 Fine Steel Wool

Penetrox A-13 (Lincoln E2529) or Penetrox A
7/16 Open end wrench
Allen head type wrenches

This procedure takes approximately 50 minutes to perform.

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COMMANDER 400

F-95

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F-96

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (continued)
FIGURE F.43 SCR DETAILS

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SPECIAL INSTRUCTIONS
NOTE: Before disassembling the existing rectifier, note toward which heat sink the outer metal
ring of the power SCR is mounted. Also, note the
positioning of the gate lead of the SCR. Failure to
reinstall the new SCR in the same orientation as
the original may result in subsequent damage to
the new SCR and other components of the
welder. See Figure F.43.

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CAUTION
The unclamping and clamping procedure outlined
below is critical for the prevention of internal SCR
damage. Failure to follow this procedure may
result in subsequent damage of the SCR. Handle
all SCRs with care.

COMMANDER 400

F-96

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F-97

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (continued)
FIGURE F.44 RECTIFIER BRIDGE ASSEMBLY BRACKET DETAILS

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GROMMET

BRACKET

SCREWS (4)

8. Inspect the mounting surfaces of each new

SCR.

PROCEDURE
1. Turn the engine off.
2. Perform the SCR/Diode Rectifier Bridge
Assembly Removal procedure.

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3. Using the 7/16 wrench, remove the mounting

bracket for the SCR/diode rectifier bridge
assembly bracket. See Figure F.44.
4. Alternately loosen nuts 1/2 turn each until
heat sinks are loose. Remove nuts and leaf
spring. IT IS RECOMMENDED THAT NEW
HARDWARE, LEAF SPRING AND HOUSING BE USED FOR REASSEMBLY.
5. Remove the old SCR.
6. Clean the area on the heat sink around the
SCR mounting surface, using a putty knife or
similar tool. DO NOT SCRATCH THE SCR
MOUNTING SURFACE.

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7. Polish each heat sinks mounting surface

using NO. 000 fine steel wool. Wipe surface
clean with a lint-free cloth or paper towel.

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a. Remove all burrs and wipe clean. Do not

use steel wool or any abrasive cleanser
on the SCR mounting surfaces.
9. Apply a thin (0.001 to 0.003) layer of PENETROX A-13 (Lincoln Electric #E2529) or
PENETROX A, heat sink compound, to each
heat sinks SCR mounting surface.
a. Care must be used to prevent foreign
material contamination of the SCR to
heat sink junction.
10. Place the new SCR between the heat sinks.
Be sure that the outer metal ring of the SCR
is facing toward the same heat sink as the old
SCRs metal ring. Be sure that the roll pin of
the heat sink engages the hole in the SCR.
The SCR contact surfaces must sit flat
against both heat sink surfaces.

COMMANDER 400

F-97

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F-98

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (continued)
FIGURE F.45 1/2 WIDE LEAF SPRING

11. Go to the procedure below that matches your

machines cap screw.
NOTE WHICH
THREAD IS ON YOUR CAP SCREWS
BEFORE PROCEEDING TO THE ASSEMBLY PROCEDURE. Two different designs of
leaf springs and housings have been used to
clamp the SCR to the rectifier. The two different designs can be identified by the size of
the leaf spring. One design uses a 1/2 inch
wide leaf spring, and the other uses a 5/8
inch wide spring. The different designs
require different assembly and clamping procedures. The assembly procedure will be different depending upon the thread on the cap
screws. A 1/4-28 thread requires a different
tightening procedure than a 1/4-20 thread.

4. Insert clamp assembly through heat sinks.

Install nuts. Tighten clamp nuts equally on
cap screws until finger tight. (See Figure
F.46. Heat sinks may not be exactly as pictured.)
5. Reinspect the SCR for proper seating.
FIGURE F.46 CLAMP ASSEMBLY

PROCEDURE FOR THE 1/2 INCH

WIDE SPRING
1. Place a piece of sleeving around each cap
screw.
2. Insert cap screws through the leaf spring.
Orient the leaf spring so that its ends are
curved upward toward the cap screw heads.
See Figure F.45. Pressing on the cap screw
heads should produce a rocking motion of
the spring in its housing. If the spring does
NOT rock, it is installed upside down.
Remove the spring and turn it over. Check
for rocking motion. See Figure F.45.
3. Insert cap screws and leaf spring into the
plastic housing.

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COMMANDER 400

F-98

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F-99

TROUBLESHOOTING & REPAIR

F-99

SCR REMOVAL AND REPLACEMENT (continued)

CLAMPING PROCEDURE
FOR 1/4-28 CAP SCREWS

CLAMPING PROCEDURE
FOR 1/4-20 CAP SCREWS

NOTE: This procedure can only be used with 1/428 cap screws.

NOTE: This procedure can only be used with

1/4-20 cap screws.

Do not use cap screws with any other type thread

or new SCR will be damaged.

Do not use cap screws with any other type thread

or new SCR will be damaged.

Do not over tighten cap screws. The leaf spring

will apply the required clamping force to the SCR.

Do not over tighten cap screws. The leaf spring

will apply the required clamping force to the SCR.

1. Do not turn the nuts. While holding the nuts

stationary, turn the cap screws only with the
following procedure.

1. Do not turn the nuts. While holding the nuts

stationary, turn the cap screws only with the
following procedure.

2. Tighten first cap screw 1/4 turn.

2. Tighten first cap screw 1/4 turn.

3. Tighten second cap screw 1/2 turn.

3. Tighten second cap screw 1/2 turn.

4. Tighten first cap screw 1/2 turn.

4. Tighten first cap screw 1/2 turn.

5. Tighten second cap screw 1/2 turn.

5. Tighten second cap screw 1/2 turn.

6. Tighten first cap screw 1/4 turn. STOP.

6. Tighten first cap screw 1/4 turn. STOP.

7. Assembly now has the proper clamping force.

7. Assembly now has the proper clamping force.

8. Perform the Active SCR Test.

8. Perform the Active SCR Test.

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COMMANDER 400

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TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (continued)
FIGURE F.47 HOUSING AND PRESSURE PAD FOR 5/8 WIDE LEAF SPRING

PROCEDURE FOR
THE 5/8 INCH WIDE SPRING

FIGURE F.48 CLAMP ASSEMBLY

1. Place a piece of sleeving around each cap

screw.
2. Insert cap screws through the leaf spring. The
leaf spring is flat so the orientation of the leaf
spring does not matter.

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3. Place the steel pressure pad in the housing

with the 1/8 inch wide standoff facing up. See
Figure F.47.

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F-100

4. Insert cap screws and leaf spring into plastic

housing being sure that the steel pressure pad
remains in position. Pressing on the cap
screw heads should produce a rocking action
of the spring in its housing.
5. Insert the clamp assembly through the heat
sinks. Install nuts. Tighten the clamp nuts
equally on the cap screws until finger tight. Be
sure that the leaf spring is not cocked in the
housing. See Figure F.48. Heat sinks may
not be exactly as pictured.
6. Reinspect the SCR for proper seating.

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COMMANDER 400

F-100

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F-101

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (continued)
CLAMPING PROCEDURE
FOR 1/4-28 CAP SCREWS

CLAMPING PROCEDURE
FOR 1/4-20 CAP SCREWS

NOTE: This procedure can only be used with

1/4-28 cap screws.

NOTE: This procedure can only be used with

1/4-20 cap screws.

Do not use cap screws with any other type thread

or new SCR will be damaged.

Do not use cap screws with any other type thread

or new SCR will be damaged.

Do not over tighten cap screws. The leaf spring

will apply the required clamping force to the SCR.

Do not over tighten cap screws. The leaf spring

will apply the required clamping force to the SCR.

1. Do not turn the nuts. While holding the nuts

stationary, turn the cap screws only with the
following procedure.

1. Do not turn the nuts. While holding the nuts

stationary, turn the cap screws only with the
following procedure.

2. Tighten first cap screw 1/4 turn.

2. Tighten first cap screw 1/4 turn.

3. Tighten second cap screw 1/2 turn.

3. Tighten second cap screw 1/2 turn.

4. Tighten first cap screw 1/2 turn.

4. Tighten first cap screw 1/2 turn.

5. Tighten second cap screw 1/2 turn.

5. Tighten second cap screw 1/4 turn.

6. Tighten first cap screw 1/2 turn.

6. Tighten first cap screw 1/8 turn.

7. Tighten second cap screw 1/4 turn. STOP.

7. Tighten second cap screw 1/8 turn. STOP.

8. Assembly now has the proper clamping force.

8. Assembly now has the proper clamping force.

9. Perform the Active SCR Test.

9. Perform the Active SCR Test.

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AFTER REPLACING THE SCRs

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F-101

Follow the steps in the SCR/Diode Rectifier

Bridge Removal and Replacement procedure
to reassemble the machine.

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COMMANDER 400

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F-102

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NOTES

COMMANDER 400

F-102

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F-103

TROUBLESHOOTING & REPAIR

MOUNTING OF STUD TYPE DIODES TO ALUMINUM
HEAT SINKS
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION
The following procedure will aid the technician in mounting stud type diodes to the aluminum
heat sinks on the Commander 400.

MATERIALS NEEDED

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5/16 Nut driver

1/2 Open end wrench
Lincoln E1868 (Dow Corning 340) Heat Sink Compound
Slip type torque wrench
No. 000 fine steel wool

This procedure takes approximately 30 minutes to perform.

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COMMANDER 400

F-103

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F-104

TROUBLESHOOTING & REPAIR

MOUNTING OF STUD TYPE DIODES TO ALUMINUM
HEAT SINKS (continued)

8. Tighten the diode nuts to the specifications in

the following table.

PROCEDURE
1. Turn the engine off.
2. Perform the SCR/Diode Bridge Removal
Procedure.

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3. Loosen the appropriate diode nut and

remove the diode that is to be replaced.
4. Clean the area on the heat sink around the
diode mounting surface using a putty knife or
similar tool. DO NOT SCRATCH THE DIODE
MOUNTING SURFACE.
5. Polish each heat sinks mounting surface
using No. 000 fine steel wool. Wipe the surface clean with a lint-free cloth or paper
towel.
6. Inspect the mounting surfaces of each new
diode. Remove all burrs and wipe clean. Do
not use steel wool or any abrasive cleanser
on the diode mounting surface.
7. Apply a thin (0.003 to 0.007) uniform layer
of E1868 (Dow Corning 340) heat sink compound to the heat sink mounting surface.

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a. Do not apply compound to the diode stud

or mounting threads.

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F-104

a. Start the nuts for diodes with steel studs

by hand and then torque them according
to the following table.
b. Run the nuts for diodes with copper studs
on all the way by hand then torque them
according to Table F.4 below.
c.

Turn the nuts a minimum of 1/2 turn more

while torquing.

Table F.4
DIODE STUD
SIZE

FOOTPOUNDS

INCHPOUNDS

3/4-16
3/8-24
1/4-28

25-27
10.5

300-324
125+0/-5
22-25

9. Perform SCR/Diode Bridge Replacement

Procedure.
10. Install the case top and sides.

b. The diode threads must be clean and

free of defects so that the nut can be finger tightened before applying torque. A
slip type torque wrench must be used to
tighten the diode nut.

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COMMANDER 400

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F-105

TROUBLESHOOTING & REPAIR

ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT

WARNING

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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

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Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

DESCRIPTION
This procedure will aid the technician in the removal and replacement of the engine and
stator assembly. This is necessary in order to gain access the stator and/or rotor.

MATERIALS NEEDED
5/16" Nut driver
3/8" Wrench
1/2" Wrench
9/16" Socket Wrench
11/16" Socket Wrench
7/16" Wrench
3/4" Wrench
3/4" Socket Wrench
Slot head screw driver
Hoist (CHECK WEIGHT LIMITATIONS)
Pliers
5/8" Wrench
1/4" Allen type wrench
1-13/32" Socket wrench

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This procedure takes approximately 8 hours to perform.

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COMMANDER 400

F-105

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F-106

F-106

TROUBLESHOOTING & REPAIR

ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.49 FUEL TANK REMOVAL DETAILS

FUEL RETURN LINE

FUEL LEVEL SENSOR

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U-BOLT (2)

PREPARATION AND LEAD REMOVAL

PROCEDURE
1. Turn the engine off.

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2. Using the 3/8" and 1/2" wrenches, remove the

battery cover and disconnect the battery.
Remove the battery by sliding it out.
3. Perform the Case Cover Removal
Procedure (including removing the front
shroud).
4. Using the 3/8" wrench, remove leads #242E
and #229 from the fuel level sensor. See
Figure F.49. Label the leads for reassembly.

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5. Turn the fuel off at the shutoff valve. Remove

and plug the fuel return line. See Figure F.49.
6. Remove and plug the lower fuel line. See
Figure F.49.
7. Using the 9/16" socket wrench, remove the
four nuts, washers and rubber washers from
the fuel tank mounting U-bolts. See Figure
F.49.
8. Carefully remove the U-bolts and lift the fuel
tank away from the machine.

COMMANDER 400

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TROUBLESHOOTING & REPAIR

FIGURE F.50 REAR PANEL ASSEMBLY REMOVAL DETAILS

REAR
PANEL
ASSEMBLY

MOUNTING
SCREWS
(4)

BASE

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9. Using the 3/8" wrench, remove the screws

holding the rear panel assembly to the
machine base. See Figure F.50.

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F-107

ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

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F-107

10. Lift and remove the rear panel assembly.

11. Using the 9/16" wrench, remove the engine
grounding strap. See Figure F.51.

FIGURE F.51 GROUNDING STRAP REMOVAL

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ENGINE GROUNDING
STRAP LOCATION

COMMANDER 400

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F-108

F-108

TROUBLESHOOTING & REPAIR

ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.52 SHUTDOWN SOLENOID LEAD REMOVAL

PULL-IN COIL
(LARGER TERMINALS
EACH SIDE
#225 AND #262)

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SHUTDOWN
SOLENOID

IDLER
SOLENOID

12. Label and remove the four leads #224, #240,

#225 and #262 from the shutdown solenoid.
See Figure F.52. Cut any necessary cable
ties.

HOLD-IN COIL
(SMALLER TERMINALS
EACH SIDE
#224 AND #240)

13. Label and remove leads #226, #237, #227

and #254 from the idler solenoid. See Figure
F.53 Cut any necessary cable ties.

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FIGURE F.53 IDLER SOLENOID LEAD REMOVAL

PULL-IN COIL
(LARGER TERMINALS
TOP AND BOTTOM
#227 AND #254)

SHUTDOWN
SOLENOID

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HOLD-IN COIL
(SMALLER
TERMINALS
TOP AND BOTTOM
#226 AND #237)

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IDLER
SOLENOID

COMMANDER 400

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TROUBLESHOOTING & REPAIR

FIGURE F.54 OIL PRESSURE SENSOR LEAD REMOVAL

OIL
PRESSURE
SENSOR

14. Label and remove leads #228 and #234

from the oil pressure sensor. See Figure
F.54.

15. Label and remove leads #233A and #241

from the oil temperature sensor. See Figure
F.55.

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FIGURE F.55 OIL TEMPERATURE SENSOR LEAD REMOVAL

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OIL
TEMPERATURE
SENSOR

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F-109

ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

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F-109

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COMMANDER 400

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F-110

TROUBLESHOOTING & REPAIR

ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.56 ENGINE GROUNDING LEAD

ENGINE GROUNDING
LEAD ATTACHMENT
POINT

16. Using the 11/16" socket wrench, remove the

grounding lead from the top of the engine
bell housing. See Figure F.56.

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17. Cut any necessary cable ties to free the harness assembly from the engine/stator
assembly.

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F-110

18. Using the 11/16" wrench, remove leads

#236A, #236B and #236C from the starter
motor solenoid.

21. Label and remove the #285 lead from the

engine alternator using the 3/8" wrench.
22. Label and remove the #238 lead from the
engine alternator using the 7/16" wrench.
23. Clear the wiring harness for engine/stator
removal by cutting any necessary cable ties.
24. Using the 1/2" wrench, remove the three
bundled leads (W1-W4, W2-W5 and W3-W6)
from the SCR/diode rectifier bridge assembly.

19. Using the slot head screw driver, remove

lead #231A and #231B from the starter
motor solenoid.
20. Label and remove the #239 lead from the
engine alternator using the 3/8" wrench.

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COMMANDER 400

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F-111

TROUBLESHOOTING & REPAIR

ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.57 EXCITER BOARD COVER REMOVAL
MOUNTING
NUTS (3)
EXCITER
BOARD

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EXCITER
BOARD
COVER

BRASS
NUTS (3)

MOUNTING
SCREW

25. Using the 3/8" nut driver, remove the exciter

board cover. This is sealed and may require
some gentle prying to dislodge. See Figure
F.57.

WARNING

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Do not operate with panels

open.
Disconnect NEGATIVE (-)
BATTERY LEAD before servicing.
Do not touch electrically live parts.

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26. Check for voltage at the three studs . If voltage is present, do not proceed. Call the
Lincoln Electric Service Dept. at 1-800-8339353.
With the 7/16" wrench, remove the three nuts
and washers that mount the exciter board to
the three studs. With the 1/4" nut driver,
remove the lower mounting screw from the
exciter board.

ELECTRIC SHOCK can kill.

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F-111

27. With the 7/16" wrench, remove the three

brass nuts and label and remove the T1, T2
and T3 stator leads (only) from the studs. Cut
any necessary cable ties. With the 5/16 nut
driver, remove the screws and drop the case
front to access the control box. Remove the
control board cover.

COMMANDER 400

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F-112

TROUBLESHOOTING & REPAIR

F-112

ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.58 CONTROL BOARD PLUG J2 LOCATION

Pel996

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PLUG J2

28. Locate and remove plug J2 from the control

board. See Figure F. 58. Thread plug J2 out
of the control box.
29. Label leads 5 and 5A at the neutral T2 stud
(center stud) in the control box. Using the
7/16" wrench remove the leads. See Figure
F.59.

31. Label the #3 lead from the T3 stud in the control box. Using the 7/16" wrench, remove the
#3 lead from the control box. Remove the #3
lead from the toroid assembly. See Figure
F.59. Note the number of turns and the direction of the lead through the toroid hole. See
the Wiring Diagram. Clear the leads for stator removal.

30. Using the 7/16" wrench remove lead #6 from

the T1 stud (top stud) in the control box.
Label and remove the lead from the control
box. Remove the #6 lead from the toroid
assembly. See Figure F.59. Note the number of turns and the direction of the lead
through the toroid hole. See the Wiring
Diagram. Cut any necessary cable ties.
FIGURE F.59 CONTROL BOX STUD TERMINALS

T1 STUD
#6 LEADS
T2 STUD
#5 LEADS

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T3 STUD
#3 LEADS

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COMMANDER 400

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F-113

TROUBLESHOOTING & REPAIR

ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.60 VERTICAL BAFFLE /ENGINE MOUNT REMOVAL

CV
CAPACITOR
AND SCR
ASSEMBLY

STATOR AND
ENGINE
MOUNTS
LIFT
FRAME
LIFT FRAME VERTICAL
ASSEMBLY
BAFFLE

FUEL TANK
SUPPORT
RAIL

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32. Using the 3/8" wrench, remove the eight

screws that mount the lift frame vertical baffle to the lift frame assembly. See Figure
F. 60. Also remove the engine access door
chain, noting its placement and length for
reassembly.

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F-113

33. Using the 1/2" wrench, remove the two

screws holding the CV capacitor and SCR
assembly to the fuel tank support rails. See
Figure F.60.
34. Move the CV capacitor and SCR assembly
toward the front of the machine to allow
clearance for the engine/stator removal.

36. Using the 3/4" wrench and socket wrench,

remove the four engine and stator mounting
nuts, spacers, rubber mounts and bolts. See
Figure F.60.
37. Using the hoist, carefully lift and remove the
engine/stator assembly, being careful to balance the unit. Be sure to remove the lead
bundles W1 through W6 from the lower left
side fan shroud. Set the engine/stator
assembly on secure blocks for support and
for the stator removal procedure. Be sure the
engine/stator assembly is secure on the
blocks.

35. Using the 1/2" wrench and 5/16" nut driver,

remove the tank/fan guard. See Figure F.60..

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COMMANDER 400

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F-114

TROUBLESHOOTING & REPAIR

F-114

ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.61 STATOR REMOVAL

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Stator/Engine
Mounting Bolts
and Lockwashers

Cap Screws (4)

Bottom Flywheel
Cover

Fan Hub

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Fan Nut

STATOR REMOVAL PROCEDURE

1. Using the 1/4" Allen wrench, remove the four
cap screws mounting the fan blade to the hub.
2. Using the 1-13/32" socket wrench, remove the
fan nut from the threaded shaft. Remove the
fan blade, taking note of placement for
reassembly. (Be sure not to place the fan on
backwards.)

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3. Using the 7/16" wrench, remove the three

bolts and lock washers holding the bottom flywheel cover to the stator frame assembly.
Remove the cover. See Figure F. 61.

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4. Using the 11/16" wrench, remove the eight

bolts and lock washers holding the stator
frame to the engine. Support the stator with
the hoist and make sure the engine is blocked
securely. See Figure F.61.
5. Remove the stator from the engine/rotor
assembly by prying and sliding the stator from
the engine.

COMMANDER 400

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F-115

TROUBLESHOOTING & REPAIR

F-115

ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.62 BLOWER PADDLE/FLEX PLATE REMOVAL

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ROTOR FLEX
PLATE

ROTOR

BLOWER PADDLE

ROTOR REMOVAL PROCEDURE

REASSEMBLY NOTES

1. Using the 5/8" wrench, remove the blower

paddles/rotor flex plate bolts and lock washers. See Figure F. 62. Support the rotor and
engine securely.

Reassemble the rotor and stator to the

Commander 400 by carefully retracing the disassembly procedure steps in reverse order. Keep
the following special points in mind as you proceed. Lead Reconnection Checklists are provided here as an aid to reassembly.

WARNING
The rotor will be free to fall when the bolts are
removed.

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2. Using the hoist, carefully remove the rotor and

flex plate assembly.

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1. INSTALL ROTOR: Support the rotor with the

hoist. Install the blower paddles and flex
plate to the engine flyweel.
2. INSTALL STATOR: Be sure the engine is
blocked securely and the stator is supported
with the hoist. Install the stator to the engine
with the eight bolts and lock washers. Install
the bottom flywheel cover to the stator frame
with three bolts and lock washers. Install the
fan blade, making sure that it faces the proper direction, with the fan nut and four Allen
head cap screws.
Check the air gap for .012 minimum.

COMMANDER 400

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F-116

TROUBLESHOOTING & REPAIR

F-116

ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

LEAD RECONNECTION CHECKLIST

SCR/Diode rectifier bridge assembly

Engine

Stator leads W1-W4, W2-W5 and W3-W6.

Engine grounding strap to engine

Leads #242E and #229 to fuel level sensor

Exciter board

Leads #224, #240, #225, and #262 to shutdown solenoid

Leads #226, #237, #227, and #254 to the

idler solenoid

Leads #228 and #234 to oil pressure sensor

Leads #233A and #241 to oil temperature

sensor

Grounding lead to top of engine bell housing

Leads #236A, #236B, #236C, #231A and

#231B to starter motor solenoid

Leads #239, #285, and #238 to engine alternator

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Stator leads T1, T2, and T3 to studs

Control board/box

Plug J2

Leads #5 and #5A to neutral T2 stud (center)

Lead #6 to T1 stud (top) and toroid assembly

(note number of turns and direction)

Lead #3 to T3 stud (bottom) and toroid

assembly (note number of turns and direction)

COMMANDER 400

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F-117

F-117

TROUBLESHOOTING & REPAIR

RETEST AFTER REPAIR

Retest a machine:
If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the
machines electrical characteristics. OR
If you repair or replace any electrical components.

ENGINE OUTPUT
Mode
Low Idle
High Idle

No Load RPM
1325 - 1400
1890 - 1915

Load RPM
NA
1800

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WELDER DC (STICK) OUTPUT

Range Switch

Fine Control

Maximum

Maximum

Open Circuit
Volts
70

Load Volts

Load Amps

40

500

Load Volts

Load Amps

40

500

WELDER CV (WIRE) OUTPUT

Range Switch

Fine Control

Maximum

Maximum

Open Circuit
Volts
48

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AUXILIARY POWER OUTPUT

Open Circuit
Voltage
230 - 250

230 Volt Receptacle

Load Volts
Load Amps
224

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44.6

Open Circuit
Voltage
115 - 132

COMMANDER 400

115 Volt Receptacle

Load Volts
Load Amps
108 - 126

13 - 16

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F-118

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NOTES

COMMANDER 400

F-118

Return to Master TOC

G-1

ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
ELECTRICAL DIAGRAMS SECTION

Electrical Diagrams Section ..........................................................................................Section G

Wiring Diagram - Stick Model (Code 9978)................................................................................G-2
Wiring Diagram - Stick & Wire Model (Code 9979).....................................................................G-3
Wiring Diagram - Stick Model (Code 10580)...............................................................................G-4
Wiring Diagram - Stick & Wire Model (Code 10581)...................................................................G-5
Amphenol Bypass PC Board Schematic .....................................................................................G-6
Amphenol Bypass PC Board Layout ...........................................................................................G-7

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Auxiliary Protection PC Board Schematic ...................................................................................G-8

Auxiliary Protection PC Board Layout .........................................................................................G-9
Bypass PC Board Schematic ....................................................................................................G-10
Bypass PC Board Layout...........................................................................................................G-11
Control PC BOARD SCHEMATIC Part 1...................................................................................G-12
Control PC BOARD SCHEMATIC Part 2...................................................................................G-13
Control PC BOARD Layout .......................................................................................................G-14
CV Control PC Board Schematic...............................................................................................G-15
CV Control PC Board Layout.....................................................................................................G-16
Engine Protection PC Board Schematic....................................................................................G-17
Engine Protection PC Board Layout..........................................................................................G-18

Meter PC Board Layout .............................................................................................................G-20

Remote Protection PC Board Schematic ..................................................................................G-21
Remote Protection PC Board Layout ........................................................................................G-22
Snubber PC Board Schematic...................................................................................................G-23
Snubber PC Board Layout.........................................................................................................G-24

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Meter PC Board Schematic .......................................................................................................G-19

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COMMANDER 400

G-1

G-2

ELECTRICAL DIAGRAMS

WIRING DIAGRAM - STICK MODEL (CODE 9978)

3D

5D

C O N N E C TO R C AV I T Y N U M B E R I N G S E QU E N C E

NOTE:

1008

1006

1004

1009

240A

273

G2

G1

G3

206

RECTIFIER
ASSEMBLY

10

204S

206S

207

EXCITER VOLTAGE

W5
SCR C

SCR B

SCR A

STAINLESS STEEL
STAND-OFF

600 AMP
SHUNT

204B

BYPASS PC

W4
1010

DD

W6

STATOR

1014
1012

CAPACITOR
CONNECTION BLOCK

W6

W3
W1

T2

DB

DA

NOTE: ONLY ON
SOME OLDER
MODELS

NEG.

CC

1019

W4

W5

1021

1017

1023

260

223

261

SWITCH

217

S8

(VIEWED FROM BACK)

(SEE SELECT SWITCH CHART)

W1

W2

W6
240 uF

218

1018

STAINLESS STEEL
STAND-OFF

1022

1007

S1

T2

9A
5K

5J

5A

75

76B

213

214

215

76C

76D

76D

75D

4D

4D

2D

77D

REMOTE
CONTROL

217

218

219

220

TRIGGER

G3

G1

206
207

204A

G2

204S

10

11 12

1 2

10

9
10

J1

J4

J6

CONNECTIONS ON CONTROL BOARD

(VIEWED AS INSTALLED)

ENGINE

M OT H E R
C O N T RO L
P C B OA R D

BOARD

J23

J7

J5

B1 B2 B3

SPI

252

253

6
8

J4 J3

15

E N G I N E P ROT.
J23
B OA R D

16

14

B2

B3

NOTE:

GND-D

1
4

(optional)

224

FRAME GROUND

279

SENSE TOROID

L OA D
WHITE

GREEN

SHUTDOWN

IDLE

262

COIL

237
HIGH

IDLER
SWITCH

SOLENOID

PULL

227

RUN

5C

H OT

J11

HOUR

METER

236C

PANEL TO PANEL WIRES

239A

232B

T3
IN CONTROL BOX

J10

3
BLACK

CB4

232F

INSULATED STUD

15A
3B

BLACK

243
AMMETER

BUT REPLACED BY
LEAD 285 ON NEWER

231B

236C

L OW
PRESS.

228A

FUEL
S
T E M P.

232G

241A
232D

50A

50A
BLACK

6B

CB2

TAB

IN CONTROL BOX

12

242B

SILVER

T1 INSULATED STUD

5C
11

3D

SILVER

242

241A

4
5

242E

229

229A

TAB

239B

8
9

285
ALTERNATOR

O I L T E M P. S E N S O R & S W I T C H

228A

241

233A

SENSOR

MODELS.
12 VOLT
BATTERY

3A

WK

LARGE

SENSE

TAB

POS

SWITCH

(-)

EXC

STUD ON ENGINE
MOUNT CHANNEL

281

NEG

FUEL LVL.

239

SENSOR

STUD ON
ENGINE

SMALL

GND-H

TAB

7
ENGINE HARNESS TO PANEL WIRES

GROUND SCREW

SWITCH

242D

242D

CONTROL PANEL

6A

TAB

D2

234

SENSOR
G

SILVER

232E
242G

CB1

228

1
L OW
FUEL

229A

242A

242C

P16

J16

(+)

STARTING
MOTOR

245

238

OIL PRESSURE SWITCH

& SENSOR

229B

3D
3A

246

T E M P.

S
A LT.

15A
CB3
12

232A

247

OIL
P R E S S.

120/240V

WHITE

ON SOME MODELS

286
232C

5K

5H

NOTE: DIODE APPEARS

231A
STARTER
SOLENOID

B O LT O N TO
SENDER BRKT

PANEL TO PCB HARNESS

5K

5E

NO FUNCTION
NO FUNCTION
90 MAX
120 MAX
180 MAX
230 MAX
270 MAX
400 MAX
50-575

236A

242G

5J
9A

236B

233A

236A

NAMEPLATE SETTING

1
2
3
4
5
6
7
8
9

S3
231A

267

STUD ON ENGINE

239B

8A

SELECTOR SWITCH (S8)

POSITION

SOLENOID GROUND

WHITE

WHITE
TERM.

240A

240
START BUTTON
S2

233

STOP

AUTO

S4

254

COIL

232
232H

255

L OA D
WHITE

LINE
WHITE

HOLD
COIL

226

SOLENOID

PULL

225
8A

L OA D

9A

240

BLACK

GREEN

9A
H OT

HOLD
COIL

224

5J

232A

256
5K

AUX. CURRENT

5J

11

246
243

240

280
GND-F

J12
WHITE
LINE

GND-C

233

245

242I

H OT

L OA D

5G

GFCI

229B

247

239A

ENGINE TO PCB HARNESS

H OT

WELDED STUD
ON OUTPUT PANEL

GFCI
GND-D

GREEN

232
262

234

GND-A

8A
LINE

120 V

BLACK

227

237
226

285

GND-E
8

GND-E

METER
PCB

COMMON BATT.

J2

NO CONNECTION
ON NEWER MODELS.

FRAME GROUND

GND-C

E2
E1

J40

STAND-OFF

B1

13

STAINLESS STEEL

12

251

SCI

J2 J6 J5 J8 J7 J1

J3

11

AMPHENOL 2

250

PROT.

REMOTE PROTECTION PCB

LINE

Return to Master TOC

280

272

255

J8

221
222

F GROUND

242I

STAND-OFF

AUX. POWER
GROUND SCREW
ON CONTROL PANEL

5G

120 V

Return to Section TOC

279

206S

273

274

268
269

256
77

216

STAINLESS STEEL

NEUTRAL T2 STUD
IN CONTROL BOX

75D

1
J61

5C

J60

77C

5E

Return to Master TOC

75B

2B

5K
9A

Return to Section TOC

4B

8A

77D

6 5

E1

E2

2D

CONTROL HARNESS

76

75

ALWAYS ON
OUTPUT REMOTELY
CONTROLLED

4B

SNUBBER PC BOARD

75B
4

1008

5D

J31

2B
OUTPUT
CONTROL
SOURCE
S6

1006

77B

CONTROL HARNESS

8A

5J

213

76

77

1004

214

222
9

270

T1

240 uF

1002

A
8

CW

VIEWED FROM
BACK

WINDINGS

1005
1003

J30

215
3

SWITCH

B7

FRAME GROUND

EXCITER

216
4

221

LOCAL

T3

1001

REMOTE/

B6

B5

B4

CAPACITOR
CONNECTION BLOCK

220

POT
AUXILIARY BYPASS PCB

1024

1020

CONTROL HARNESS

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FINE CONTROL

STUD T3 ON

6
219

76C

77C

5D

204
SELECTOR

T3

3D

ELECTRICAL SYMBOLS PER E1537

OUTPUT
CHOKE

209

DC

BOARD

FRAME GROUND

50 Ohm
100 W

W3

1016

STUD T2 ON

204

240 uF

P O S.

W2

CONNECTIONS TO
CAPACITORS MADE
VIA EYELET BOLTED
CONNECTIONS

261

J50

1015

FEEDBACK BOARD

5H

287

NEXT AVLB.

ON NEWER MODELS.

204A

1013
1011

5A

( V I E W E D F RO M C O M P O N E N T S I D E O F B OA R D )

NO CONNECTION
3D

272

274

269

5D

268

270
T1

260

1002
STUD T1 ON

CAPACITOR
CONNECTION BLOCK

223

Return to Master TOC

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G-2

238
239
ENGINE HARNESS

242
GND-F
5C

ENGINE GROUND

STUD ON GENERATOR
MOUNT CHANNEL

1-16-98E
L9041

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

G-3

ELECTRICAL DIAGRAMS

WIRING DIAGRAM - STICK & WIRE MODEL (CODE 9979)

6
5D

268

270

240A

273

274

269

T1

3D

272

J50

1015

G2

G1

10

G3

204C

207

285
DD

R2-12

R3-12

OUTPUT
CHOKE

L1

S5

POS.

21

CC

W3

W4

W1

260

223

261

204

209A

1023

284A

CV CHOKE

W6

1021
1019

NEG.

ELECTRODE
POLARITY
SWITCH

FRAME
GROUND

DC

T2

1017

206A

BYPASS PC
BOARD

C1-C4

209

DB

DA

ELECTRICAL SYMBOLS PER E1537

CURRENT

SENSE TOROID

285A

30,000 uF

1016

STUD T2 ON

206A

600 AMP
SHUNT

DE

SCR C

SCR B

SCR A

W1

STATOR

1014
1012

206
3

208

SCR 1

204B

W2

W4

CAPACITOR
CONNECTION BLOCK

206S

NOTE:
NO CONNECTION
ON NEWER MODELS

P O S.

CONNECTIONS TO
CAPACITORS MADE
VIA EYELET BOLTED
CONNECTIONS

1010

204S

280

RECTIFIER
ASSEMBLY

W5

FEEDBACK BOARD

240 uF

G4

277

204A

EXCITER VOLTAGE

300W

1013
1011

279

6
1

1009

NEXT AVAILABLE 287

1008

1006

1004

CONNECTOR CAVITY NUMBERING SEQUENCE

(VIEWED FROM COMPONENT SIDE OF BOARD)

5D

1002

CAPACITOR
CONNECTION BLOCK

R1-50

3D

STUD T1 ON

100 W

Return to Master TOC

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G-3

284B

284

NEG.

CV

L2

208A
NOTE: ONLY ON
SOME OLDER
MODELS

208A

T3

2B

1024

1020
STUD T3 ON

EXCITER
T3

OUTPUT
CONTROL
SOURCE
S6

WINDINGS

S1

75

76B

283

VIEWED FROM
BACK

77B

1007

1
RF BYPASS
PC BOARD

21

1006
1004

1008

31

76C
2B
4B

REMOTE

76E

76E

256
77

268

270
255

REMOTE

CONTACTOR

L OA D
WHITE

LINE
WHITE

GROUND

219

220

280

272

77D

76D

75D

4D

2D

242I

207

204A

G2

204S

1 2

GREEN

LINE

H OT

L OA D

CV
BOARD

ENGINE
PROT.
BOARD

J21

SHUTDOWN

BLACK

J2 J6 J5 J8 J7 J1

J4 J3

14

B3

B2

J60

E2

E1

262

237
226

227

234

229B

247

239A
232

233

245

246
243

237

256

WHITE

232

RUN
254

COIL

15A

233

IDLER
SWITCH

HIGH

S4

AUTO

S3

STOP
267

233A

236A

METER

BOLT ON

PANEL TO PANEL WIRES

236C

SENDER

S TA RT E R
SOLENOID

PANEL TO PCB HARNESS

BLACK

CB1

CB2

243

T1 INSULATED STUD
IN CONTROL BOX

AMMETER

6A

180 MAX.

230 MAX.

270 MAX.

400 MAX.

50-575

231B

238

236C

228A

FUEL

T E M P.
S

L OW
P R E S S.

S
T E M P.

232G

241A
232D

229A
242G

AUXILIARY BYPASS PCB

242B

B7

5C

SWITCH

241A

242D

229A

241

239B

8
9

233A

SENSOR

SENSE

POS

SWITCH

242E
229

12 VOLT
BATTERY

3A

WK

O I L T E M P. S E N S O R & S W I T C H

EXC

(-)

STUD ON ENGINE
MOUNT CHANNEL

281

NEG

FUEL LVL.
SENSOR

STUD ON GENERATOR
MOUNT CHANNEL

239
242

7
ENGINE TO PANEL HARNESS

GROUND SCREW
IN CONTROL BOX

D2

234

SENSOR

A LT E R N ATO R

228A

242D

INSTRUMENT PANEL

8A

228

232E

242A

242C

FRAME
GROUND

P16

2
L OW
FUEL

(+)

STARTING
MOTOR

3D

285

245

J16

246

229B

232A

247

OIL
P R E S S.

11

5J

90 MAX.
120 MAX.

286
OIL PRESSURE SWITCH & SENSOR

232F

12

5K

WIRE WELDING CV

3
4

232C

5H

B6

NOTE: DIODE APPEARS ON

SOME MODELS BUT
REPLACED BY LEAD
285 ON NEWER MODELS.

231A

BRACKET

239A

3D

6B

A LT.

B5

236B

NO FUNCTION

236A

239B

232B

STAINLESS STEEL
STAND-OFF

231A

NAMEPLATE SETTING

255
HOUR

3A

50A

50A

WHITE
TERM.

START BUTTON
S2

232H

SOLENOID

PULL

227

242G
CB3

240A

SELECTOR SWITCH (S8)

232A

HOLD
COIL

226

11

12

J2
224

STUD ON ENGINE

3
BLACK

IN CONTROL BOX

3B

J40

METER
PCB

COMMON BATT.

POSITION

IDLE

COIL

GREEN

INSULATED STUD

15A

STAND-OFF

B1

240

262

32

T3

CB4

BLACK

5K

J10
115/230V

STAINLESS STEEL

12

SOLENOID GROUND

5E

251

FRAME GROUND

240

WHITE

GND-C

250

E N G I N E P ROT.
J23
B OA R D

J3

11

252

1
6
SCI

10

253

3
2

SPI

B1 B2 B3

FRAME GROUND

SOLENOID

PULL

225

10

240

HOLD
COIL

224

5H
L OA D
WHITE

J23

J7

5C

H OT

J11
LINE
WHITE

J6

J5

285

242H

115 V

J1

GFCI

6
1

2D
76D
4D

242I

5J

222

75D
77D

ENGINE TO PCB HARNESS

BLACK

206

G3

G1

206S

273

274
279

269

11 12

CONNECTIONS ON CONTROL BOARD

(VIEWED AS INSTALLED)

M OT H E R
C O N T RO L
P C B OA R D

221

CV DAUGHTER BOARD

10

AMPHENOL 2

5G

9A

J4

242H

GND-F
WELDED STUD
ON OUTPUT PANEL

GFCI

13

CONTROL

GND-D

1
5

242H

242I

GND-A

J12

J8

AMPHENOL 1

L OA D H OT

H OT

218

10

GREEN

2E

GND-E

LINE

115 V

217

K
GROUND

CB5 15AMP

GND-D
8

GND-E

215
216

AUX. POWER
GROUND SCREW
IN CONTROL BOX

GND-C

8A

5H
5G

208

J62

75E

283

4E

75E

277

G4
282

77E

CONTROL

31

J61

21

77C
75B

2E

77E

4E

H
E

NEUTRAL T2 STUD
IN CONTROL BOX

32A

5C

WORK

5E

214

J21
1

CONTACTOR

E1

E2
5D

7
5

5A

213

1
6

32A

J20

J
A

Return to Master TOC

76

75

5A

1002

Return to Master TOC

75B
4

115AC

Return to Section TOC

J31

76

77

9A

6
240 uF

B4

T2

T1

SNUBBER PC BOARD

213

J30

214

2
222

221

2
1003

215

3
A

220

SWITCH

282

OUTPUT REMOTELY
CONTROLLED

4B

1005

V
VOLT/AMP
SWITCH
S9

ALWAYS ON

(VIEWED
FROM BACK)
SEE CHART

S8
216

CW

LOCAL

219

REMOTE/

CAPACITOR
CONNECTION BLOCK

1001

218

POT

1022

261

Return to Master TOC

FINE CONTROL

21
1018

Return to Section TOC

76C

77C

W6

W5

Return to Section TOC

SELECTOR
SWITCH

217

240 uF
5D

260

W3

204

W2

223

3D

ENGINE TO PANEL HARNESS

STUD ON
ENGINE

238

239
GND-F

5C

ENGINE GROUND
242

GND-H

1-16-98E
L8910

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

5D

CONNECTOR CAVITY NUMBERING SEQUENCE

NEXT AVLB.

3D
8

G3

204A
RECTIFIER
ASSEMBLY

10

204S

206S

J50

1015

FEEDBACK BOARD

240 uF

W2

W6

T2

1019

3D

W3

1023

DB

DA

W1

W6

1018

STAINLESS STEEL
STAND-OFF

1022

T3

T2
6

5K
5J

75

76B

VIEWED FROM
BACK

77D

TOROID

75D

76D

76D

75D

4D

4D

2D

77D

REMOTE
CONTROL

GREEN

GND-D

GFCI

HOT

9A

SHUTDOWN

240

76

218

219

J11

IDLE

262

COIL

HOUR METER

BLACK

BLACK

GREEN

CB3

243
AMMETER

3D

3A

238

12
50A

50A
BLACK

206
207

1 2

3 4

3 4

E2

E1

J1

9 10

J4

J6
1

ENGINE

BOARD

J23
J2 J6 J5 J8 J7 J1

250

PROT.

B1 B2 B3

J5

SPI
SCI

J4 J3

251

252

253

6
8
15

ENGINE PROT.
J23
BOARD

J3
B1 B2 B3
1

16
STAINLESS STEEL

J40

STAND-OFF

METER
PCB

COMMON BATT.
6

(optional)

J2

232A

224

226

227

237
234

262

232

229B

247

239A

233

245

246

243

FRAME GROUND

232

HIGH

RUN
STOP
267

231A 236B

236C

PANEL TO PANEL WIRES

S
-

ALT.

236C

6B

CB2

229B

TEMP.

242A
242B

232D

229A

228A

3
4

241

WK

233A

SENSOR

242E

229

TAB

8
9

LARGE

SENSE

TAB

FUEL LVL.
SENSOR

SMALL
TAB

239
ENGINE HARNESS

12 VOLT
BATTERY

285

POS

SWITCH

242D
229A
239B

MOTOR

234

SWITCH

OIL TEMP. SENSOR & SWITCH

242D
SILVER

242

TAB

SENSOR
G

2
241A

232E
242G

ENGINE HARNESS TO PANEL WIRES

GROUND SCREW

228

1
LOW
FUEL

P16

J16
SILVER

(+)

STARTING

OIL PRESSURE SWITCH

& SENSOR

245

FUEL

241A

231A
STARTER
SOLENOID

BOLT ONTO
SENDER BRK'T

CONTROL PANEL

5C
11

232G

TAB

IN CONTROL BOX

246

S
-

242C
SILVER

T1 INSULATED STUD

6A

3D

228A

232A

NAMEPLATE SETTING
NO FUNCTION
NO FUNCTION
90 MAX
120 MAX
180 MAX
230 MAX
270 MAX
400 MAX
50-575

286

232C

TEMP.
LOW
PRESS.

1
2
3
4
5
6
7
8
9

233A

PANEL TO PCB HARNESS

247

OIL
PRESS.

SELECTOR SWITCH (S8)

POSITION

S3

236A

240A

240
START BUTTON
S2

233

232H

AUTO

S4

WHITE

236A

15A

BLACK

STUD ON ENGINE

232B

232F
6

Return to Master TOC

IN CONTROL BOX

Return to Section TOC

INSULATED STUD

15A
3B

CB1

204A

G2

CONNECTIONS ON CONTROL BOARD

(VIEWED AS INSTALLED)

J7

8
10

13

IDLER
SWITCH
254

COIL

242G

T3

CB4

12

SOLENOID GROUND

5K

5H

G3

G1

204S

240

SOLENOID

PULL

227

239A

9A

J10

WHITE
TERM.

280

272

MOTHER
CONTROL
PC BOARD

221

237

239B

8A

120/240V

11

12

BLACK

5C

279

206S

273

274

268
269

J8

222

255

LOAD
WHITE

5E

255

10 11 12

5K

GND-C

256

77

3
5

256

HOLD
COIL

226

SOLENOID

PULL

225

8A

LOAD HOT

LINE
WHITE

75B

285

HOLD
COIL

224

5J

GFCI

WHITE

,J61

SNUBBER PC BOARD

14

LINE

SENSE TOROID

5J

9A

5K

AUX. CURRENT

5J

J4 ,J23

J30

11

279

WELDED STUD
ON OUTPUT PANEL

LOAD
WHITE

120 V

ENGINE TO PCB HARNESS

280
GND-F

J12
WHITE
LINE

NEG.

242I

LOAD HOT

5G

,J30

TOROID

FRAME GROUND

GND-A

8A

GND-D

217

GND-E

8
LINE HOT

120 V

214
216

220

TRIGGER

REMOTE PROTECTION PCB

GND-C

4 5

AMPHENOL 2

STAND-OFF

AUX. POWER
GROUND SCREW
ON CONTROL PANEL

213

F GROUND

242I

STAINLESS STEEL

75

215

J60

J61

1 2

76C

GREEN

Return to Master TOC

77C

5C

5G

5H

75B

5E

Return to Section TOC

2B

5K
9A

NEUTRAL T2 STUD
IN CONTROL BOX

GND-E

4B

8A

ELECTRICAL SYMBOLS PER E1537

ALWAYS ON
OUTPUT REMOTELY
CONTROLLED

2D

6 5

E1

E2

3
5

3
J1,J2

213

4B

5D

16

J5

77B

CONTROL HARNESS

5A

214

222

CONTROL HARNESS

2B

1008

14

215

76

OUTPUT
CONTROL
SOURCE
S6

8A

5J

12

J8
8

216

221

77

1006
1004

6
7

CW

S1

9A

5A

J7

270

T1

240 uF

1002

WINDINGS

1007

SWITCH

B7

1005
1003

220

REMOTE/
LOCAL

B6

B5

B4

FRAME GROUND

EXCITER

1001

FINE CONTROL
POT

AUXILIARY BYPASS PCB

1024

1020

10

287

TOROID

218
219

76C

77C

5D

J6 ,J50
7

217

SWITCH S8

(VIEWED FROM BACK)

(SEE SELECT SWITCH CHART)

W1

W2

204
SELECTOR

T3

240 uF

CC
223

261

OUTPUT
CHOKE

209

DC

260

,J31,J60

BOARD

FRAME GROUND

50 Ohm
100 W

W3

W4

W5

1021

1017

DD

W6

1016

BYPASS PC

W4

STATOR

1014

SCR C

SCR B

SCR A

STAINLESS STEEL
STAND-OFF

600 AMP
SHUNT

204B

W5

J3

POS.

EXCITER VOLTAGE

CONNECTIONS TO
CAPACITORS MADE
VIA BOLTED
CONNECTIONS

207

1013
1011

1012

Return to Master TOC

G2

G1

204

1009

(VIEWED FROM COMPONENT SIDE OF BOARD)

240A

273
272

274

269

5D

268

270

T1

261

1008

1006

260

1002 1004

223

3D

CAPACITOR

1010

Return to Section TOC

G-4

ELECTRICAL DIAGRAMS

WIRING DIAGRAM - STICK MODEL (CODE 10580)

CONTROL HARNESS

Return to Master TOC

Return to Section TOC

G-4

EXC

(-)

ALTERNATOR

STUD ON ENGINE
MOUNT CHANNEL

NEG

239
238

STUD ON
ENGINE

GND-H
242
GND-F
5C

ENGINE GROUND

STUD ON GENERATOR
MOUNT CHANNEL

5-15-98A
L11008

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

G-5

ELECTRICAL DIAGRAMS

WIRING DIAGRAM - STICK & WIRE MODEL (CODE 10581)

10

G3

RECTIFIER
ASSEMBLY

1013

J50

1015

1011

EXCITER VOLTAGE

CONNECTIONS TO
CAPACITORS MADE
VIA BOLTED
CONNECTIONS

240 uF

285
DD

STATOR

1014
1012

1019

260

223

261

204

209A

284A

CV CHOKE

W6

207

W2

OUTPUT
CHOKE

L1

OUTPUT
CONTROL
SOURCE
S6

WINDINGS

GREEN

REMOTE

LOAD
WHITE

LINE
WHITE

CONTACTOR

LINE HOT

77D

76D

75D

4D

2D

242I

J62

2E

1
5

217

277
283
208

218

S5

POS.

NEG.

SHUTDOWN

75

4 5

75B

76

256

77

268

270

255

280

272

INSULATED STUD

15A

J10

IN CONTROL BOX

3B
WHITE

115/230V

7
9
10

10 11 12 1

1 2

J60

15A

E2

E1

CB1

BLACK

BLACK

WHITE
TERM.

CB2

243

T1 INSULATED STUD

AMMETER

J3
B1
1

B2 B3

236C

B4

B5

B6

228A

224

226

262

237
234

227

247

239A

232

5J

8A

245

229B
233

METER
PCB

246

243

FRAME GROUND

233A

236A

240A

SELECTOR SWITCH (S8)

231A 236B

NAMEPLATE SETTING

NO FUNCTION

WIRE WELDING CV

90 MAX.

120 MAX.

BOLT ON

236C

180 MAX.

230 MAX.

270 MAX.

400 MAX.

50-575

231A

BRACKET

STARTER
SOLENOID

286

229B

232G

S
-

LOW
PRESS.

TEMP.

241A
242A

242C

232D

229A

P16

J16

228

232E
242G

228A

241A

4
5

242E

229

239B

8
9

242

239

12 VOLT
BATTERY

WK

FUEL LVL.
SENSOR

(-)

ALTERNATOR

233A

SENSOR

SENSE
POS

SWITCH

242D

7
ENGINE TO PANEL HARNESS

MOTOR

234

SWITCH

(+)

STARTING

OIL TEMP. SENSOR & SWITCH

241

229A

242D

SENSOR
G

2
LOW
FUEL

285

OIL PRESSURE SWITCH & SENSOR

245

FUEL

TEMP.

242B

5C

267

232C
246

GROUND SCREW
IN CONTROL BOX

5K

J40

STAND-OFF

START BUTTON
S2

PANEL TO PCB HARNESS

INSTRUMENT PANEL

9A

STAINLESS STEEL

S3

SENDER

232A

B7

FRAME
GROUND

7
8

COMMON BATT.

233

STOP

AUTO

238

AUXILIARY BYPASS PCB

SCI

236A

232B

S
-

ALT.

251

J2

232

RUN

S4

STAINLESS STEEL
STAND-OFF

12

3D

252

250

5
SPI

B1 B2 B3

253

255

247

OIL
PRESS.

6A

9 10

J6

J5

J23
J4 J3

ENGINE PROT.
J23
BOARD

232H
HIGH

PANEL TO PANEL WIRES

239A

11

256
IDLER
SWITCH

254

COIL

232F

6B
IN CONTROL BOX

5H

232A
237

SOLENOID

PULL

227

239B

3D

3A

50A

3 4

3
2

POSITION

STUD ON ENGINE

HOUR METER

ENGINE
PROT.
BOARD

J21

11

CV
BOARD

J2 J6 J5 J8 J7 J1

14

6
1

242G

CB3

50A

207

204A

J1

J4

12

SOLENOID GROUND

3 4

CONNECTIONS ON CONTROL BOARD

(VIEWED AS INSTALLED)

J7

13

HOLD
COIL

226
IDLE

11

12

206

G3
G2

204S

240

262

32

T3

CB4

G1

206S

273

274
279

269

FRAME GROUND

240

COIL

GREEN

5K

GND-C

J30

J8

285

SOLENOID

PULL

225

BLACK

5E

213

240

HOLD
COIL

224

5H

BLACK

WHITE

LOAD
WHITE

214

222
9

221

5C

J11
LINE
WHITE

21

208A

(VIEWED
FROM BACK)
SEE CHART

S8

MOTHER
CONTROL
PC BOARD

219
220
222

75D
77D
2D
76D
4D

242H

LOAD HOT

115 V

16
J5

NEG.

ENGINE TO PCB HARNESS

GFCI

206A
ELECTRODE
POLARITY
SWITCH

AMPHENOL 2

242I

5J

9A

CV DAUGHTER BOARD

GROUND

5G
GREEN

GND-F

BLACK

Return to Master TOC

Return to Section TOC

242H

GND-A

LOAD HOT

WELDED STUD
ON OUTPUT PANEL

215

9 10

GFCI

76E

242H

CONTROL

GND-D

77E

AMPHENOL 1

242I

GND-E

214

CB5 15AMP

J12

K
GROUND

GND-D

213

216

GND-C

8A

282

5G

115 V

4E
75E

75E

G4

76E

76C
2B
4B

J21
J61

77E

E
F
G
I

AUX. POWER
GROUND SCREW
IN CONTROL BOX

7
5

21

77C
75B

REMOTE
CONTROL

5H

14
J7

J20

1
6

2E

32A

4E

5C

31

32A

D
C

WORK

5D

31

CONTACTOR

E1

E2

5E

215

221

1008

HOT

77B

1 2

1006

NEUTRAL T2 STUD
IN CONTROL BOX

12

76

RF BYPASS
PC BOARD

21

10
J6,J20

5A

LINE

77

115AC

Return to Master TOC

VIEWED FROM
BACK

1004

76B 75

S1

T2

T1

ELECTRICAL SYMBOLS PER E1537

216

220

SWITCH

282
283

OUTPUT REMOTELY
CONTROLLED

4B
1007

240 uF

GND-E

VOLT/AMP
SWITCH
S9

ALWAYS ON

219

Return to Master TOC

1005
1003

1002

218

POT
CW

LOCAL

Return to Section TOC

T3

1001

5A

Return to Section TOC

SELECTOR
SWITCH

217
FINE CONTROL

REMOTE/

EXCITER

208A

76C

77C

21

2B

1024

1020

J8

FRAME
GROUND

CV

W3

1022

BYPASS PC

L2

W6

W5
1018

J4 ,J23
1

206A

CURRENT

284B

284

6
J3

SENSE TOROID

T3

1023

J1,J2

POS.

285A

240 uF
5D

BOARD

C1-C4

209

DC

208

CC

W3

W4

W1

1021

3D

DB

DA

30,000 uF

1016

T2

1017

206S

600 AMP
SHUNT

DE

SCR C

SCR B

SCR A

W1

280

SCR 1

204B

W2

W4
1010

204S

204C

W5

FEEDBACK BOARD

G4

277

204A

261

G2

G1

204

279

NOTE:
NO CONNECTION
206
ON NEWER MODELS

260

3D

272

R2-12

1009

NEXT AVAILABLE 287

R3-12

CONNECTOR CAVITY NUMBERING SEQUENCE

(VIEWED FROM COMPONENT SIDE OF BOARD)

240A

273

274

269

T1

5D

268

270

300W

1008

1006

223

5D

1002 1004

R1-50

3D

100 W

Return to Master TOC

Return to Section TOC

G-5

EXC

242
ENGINE TO PANEL HARNESS

STUD ON ENGINE
MOUNT CHANNEL

NEG

239

STUD ON GENERATOR
MOUNT CHANNEL

STUD ON
ENGINE

238
GND-F

5C

ENGINE GROUND
GND-H

5-15-98A
L11009

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

Return to Master TOC

G-6

ELECTRICAL DIAGRAMS

SCHEMATIC - AMPHENOL BYPASS PC BOARD

M 17900

Return to Section TOC

G-6

J62
5

L4

J61
1

J60
5

.39mH
C4
.0047

J62

3000V
L5

J61

4B

Return to Master TOC

Return to Section TOC

80J

3000V
L1

75B

75E

77E

76E

J62

3000V

TO MOTHER CONTROL PCB

2D

C1
.0047
L2

2E

J60

.39mH

J61

J62

.0047

150V

4E

4D

C5

TP1

J61

2B

.39mH

TO "OUTPUT CONTROL SOURCE" SWITCH

J60

J60
2

.39mH

75D

C2
TP2

.0047

150V

3000V

80J
J61

77C

L6

J62

J60
6

.39mH

77D

C6

TO "REMOTELOCAL" SWITCH

TP4

TP3

.0047

150V

150V

3000V

80J

80J

Return to Master TOC

Return to Section TOC

J61

76C

L3

J62

J60
3

.39mH

76D

C3
.0047

J61

3000V

FILENAME: M17900_1AB
GENERAL INFORMATION

LAST NO. USED

R-

ELECTRICAL SYMBOLS PER E1537

MFD ( .022/50V

CAPACITORS =
RESISTORS = Ohms (
DIODES =

1A, 400V

1/4W

C-

UNLESS OTHERWISE SPECIFIED)

LABELS

UNLESS OTHERWISE SPECIFIED)

(UNLESS OTHERWISE SPECIFIED)

SUPPLY

Return to Master TOC

Return to Section TOC

_
6
6

VOLTAGE NET

POWER SUPPLY SOURCE POINT

NOTES :
N.A.

L-

COMMON CONNECTION

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

FRAME CONNECTION

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

EARTH GROUND CONNECTION

NUMBER.
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2
ON ALL ANGLES IS + .5 OF A DEGREE

Chge.Sht.No.

THE LINCOLN ELECTRIC CO.

XB-UF

TYPE

CLEVELAND, OHIO U.S.A.

12-13-96

SCALE

MATERIAL TOLERANCE ("t") TO AGREE

WITH PUBLISHED STANDARDS

EQUIP.

DR.

I.E.B. / F.V.

DATE

SUBJECT

COMMANDER 400 STICK & WIRE

AMPHENOL BYPASS SCHEMATIC

NONE
3/9/95

CHK.

JB

SUPSDG.

SHT.
NO.

M 17900

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

C2

XXXXX
C3

XXXXX
C6

L1

C1

XXXXX

L2

XXXXX

XXXXXXXXX

J61

XXXXXXXXX

Return to Master TOC

J60

X
X
X

J62

C5

XXXXX

Return to Master TOC

XXXXX

NOTE:

REQ D

P ART NO.

ID EN TI F I CA T I ON

C1, C2, C3, C4, C5, C6

T11577-58

.0047/3000V

J60, J62

S18248-6

HEADER

J61

S18248-8

CONNECTOR

L1, L2, L3, L4, L5, L6

T12218-9

.39mH

TP1, TP2, TP3, TP4

T13640-16

80J

CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRYS

C4

IT EM
L4

L5

XXXXX

L6

Return to Master TOC

TP1
TP4

XXXXXXXXX
X

Return to Section TOC

TP2
TP3

S & W

L9892-1

COMMANDER 400

Return to Section TOC

XXXXXXXXX

Return to Section TOC

G-7

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY - AMPHENOL BYPASS PC BOARD

L3

Return to Master TOC

Return to Section TOC

G-7

L9892-1
12-13-96

Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

Return to Master TOC

ELECTRICAL DIAGRAMS

G-8

SCHEMATIC - AUXILIARY PROTECTION PC BOARD

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

G-8

XA
12-15-95

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

Return to Master TOC

Return to Section TOC

G-9

Return to Master TOC

Return to Master TOC

C12

X X

C11

C10

ITEM

C9

X
X
X
X

X
X
X
X
X

X X XX X XX X X
X
X X
X
X
B7
X
X
X
X
X
X
X
X
X
X
X
X
X
X X X X X X X X X X X X XX X X X

C8

L9749-1

B6

C7

X
XX

B5
C6

C5

X X

C4

C3

X X

X X X X
X XXX X X
X
X
X
X
X
X

C2

X
X
X
X
X

C1

Return to Section TOC

B4

Return to Section TOC

G-9

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY - AUXILIARY PROTECTION PC BOARD

AUXILIARY PROTECTION

REQD

PART NO.

DESCRIPTION

Return to Master TOC

Return to Section TOC

L9749-1
12-15-95A

NOTE:

Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

Return to Master TOC

ELECTRICAL DIAGRAMS

G-10

SCHEMATIC - BYPASS PC BOARD

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

G-10

XA
12-15-95

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

Return to Master TOC

Return to Section TOC

G-11

G-11

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY - BYPASS PC BOARD

~.04
4.50
2.98

~.04

4.15
ITEM

3.80

C1,C2,C3
C4,C5,C6,C7,C8,C9,C10,C11

T11577-52

IDENTIFICATION
.22/400V

C10
C9

xxxxx

TP1

C18

C17

C16

C15

C14

B1

.82
L9573-1

.60

xxxxxxxxxx
xx
x
x
x
x x xx x
TP4
x
x
x
x
C3
x
x
x
xx x x x x x x x x x xx
x
x
TP2
x
xx
x
x
x
xxx
C1
xxxxxxx
x
x
C8
x
x
xx
C7
xx
xx
x
C6
x
xx
xx
TP5

x x x xx
x
x
x
x
xx xxxx xxx x xxx x xxxx x
x
xx
x
x
xx
x
xx
x
xx
x
x
xxx
x
x
xx x
xx x
xxx
x
x
x
x
x x xx
x
x
x
x
x

TP3

T13640-16

.0047 or .005/1400
80J

BYPASS

x
xx
x

C5
C4

INDUCTANCE = HENRYS

L9573-1
10-11-96B

x
x
x
x
x
x
x
x
x
x

x
x
x
x xx
x
x
x
x
x

x
x

x
x

C11

xxx x

Return to Master TOC

15

PART NO.
S20500-3

CAPACITORS = MFD/VOLTS

xxx x

C12

C13

TP1,TP2,TP3,TP4,TP5

x
x

x
xx
xx
x
x
x

3.28

B3

x
x

Return to Section TOC

B2

C2

Return to Master TOC

C12,C13,C14,C15,C16,C17 ,C18

3.50

Return to Section TOC

REQ'D

xx

x
x xx x xxx

Return to Master TOC

Return to Section TOC

0
.30

1.48

0
NOTE:

Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

Return to Master TOC

G-12

ELECTRICAL DIAGRAMS

SCHEMATIC - CONTROL PC BOARD PART 1

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

G-12

A485
3-27-97B
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

Return to Master TOC

ELECTRICAL DIAGRAMS

G-13

SCHEMATIC - CONTROL PC BOARD PART 2

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

G-13

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

Return to Master TOC

Return to Master TOC

Return to Section TOC

Return to Section TOC

G-14

ITEM

X X X

X XX

XXXX
XXXXXX
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
XXXXXXXXX X

X X X X X X X XXX
X XX X X X X X X X X
X X X X X X X X XX
XX X X X X X X X X X

XXXX X
XXX XX
XXXXXXXX
XX X
X X X X X XX XXXX
X X XXX X XX XXXX

X
X

X X X

ITEM

REQ'D

PART NO.

IDENTIFICATION

XX
XX
X X
XX
XX
XX
X X

X X X X X XX
X
X
X
X XXXXX X
XXX X X X X X X X
X
X
XXX X X X X X X X
X
X
X XX X X X X X X X
XX XXXXX
XX X X X X X X X
XX XX X X XX
XX XX
X XX X X X
X X X XX XX
X
X X X XX XX
XX XX
X
X
X
X
X XX XX
XX X X X X X
X
X XX XX X X
X X
X
X
X
X
X X
X
XX
X
X X
X
X
X
X X
X
X
X
X
X X
X
X
X
X
X X
XXXXX XX XX X
X X

X
X
X

X
X

X
X
X

X X X X X

XXXXX X
X
X
X
XX X X XX

XXXXXXXXX
XXXX
XXXX
XXXXXXXXX

COMMANDER 400 CONTROL

IDENTIFICATION

X X
X X X X X X
X
X

G2713-3

PART NO.

X X

X
X
X

XXXXXXXXX
XXXX
XXXX
XXXXXXXXX

XX X X XXX X
X XX X X X X X X
XX X X
X X XX
X X X X X X X X
X

X X X X

X
X
X
X
X
X
X
X
X
X
X
X
X X X X X
X
X
X
X
X
X
X
X
X X X X X X X X X
X
X
X
X
X
X
X
X
X
X
X X X X
X X X
X X X X X
X
X X
X
X
X
X
X
X
X
X
X X
X
X
X X
X
X
XX
X
X
X
X
X
XX
X
X
X
XX
X
X
X
X
X
X
X
X
X
X
X
X
X X
X
X
X
X XX X X X X
XX
X
XX
X
X XX X X
XX X XX

NOTE:

REQ'D

XXXXXXX
X
X
X
X
X
X
X

Return to Master TOC

XX X

XX X X X X X
X X X X X
X
X
XX
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
XX
X X X XX

Return to Section TOC

X XX

X X XX X
X
XX X XX
X X XX

Return to Master TOC

XXX

X X
X X X X X X
X
XX X X
X X X X X XX
XX X X
X
X X X X X XX
X
X X X X X X X
XX
X
X XX X
X X XX X X
XX X X X X X X X X X X
X X X
X X
X
X X X X X X X X X X XXX X
X X X X XX
X
X
X
X
X X X X X X X X X X X XX X X X
X
X
X
X X X X X X X X X X X XX X X X X X X X X X X
X
X X X
XX
X
X X
X
X
XXX
X X
XX X
X
X
X
X X
XX X
X
X
X
X
X X X X X X
X
X X X X X X
X
X X X X X X X
X X X
X X XX X
X
X
X X X X X X X
X
X
X
X
X
X
X
X
X
X X X X X X X X
X X X X X X

Return to Section TOC

G-14

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY - CONTROL PC BOARD

X X
X X
XX

X X
XX X XXX
X
X X X XX
XX X X X X
XX
X
X
XX
X
X
X X X XX X
X
X
X
X X X

XXXX
X X X X XX
XX X X X X
XXXX

XXXX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX

XX
XX
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS

G2713-3
10-22-99B

Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

Return to Master TOC

G-15

ELECTRICAL DIAGRAMS

SCHEMATIC - CV CONTROL PC BOARD

M 17741

Return to Section TOC

G-15

+10v

+10v
J20
5

12

J20

14

X1

13

R10

J21

R11

100

C2

V/A SWITCH

1.00K

0.1

50V

com

com

J21

R12

+15 CVSCR

100

R6

R7

D3
5W
68

C3

5W

0.1

R13

Return to Master TOC

50V

68

10K

-CV STUD

J21

J20
7

D2
L1

R1

3.32K

R2

Return to Section TOC

J20
6

J20
3

.33mH

com

10K

Q2
100V
1A
J20
R3

CNY17-3

R14

R15

15.0K

1W

D1

FROM MCU

J20
J21

10.0

SCR 1 GATE

10.0K
6

10
7

20V

C5

28.0K

R16

R17

6.19K

6.81K

1W

SCR 1
562

R9

C1
1.8

R19

26.7K

10V

GATE DRIVE FOR

R8

J20

R18

DZ2

X1
5

R4

Return to Master TOC

1.00K

OCI1

CV MODE ENABLE

DZ1
15V

R5

Return to Section TOC

Q1
600mA
40V

562

com

475K

J20

J21

CVSCR COM

SCR 1 CATH

GENERAL INFORMATION

+10v

+10v

LAST NO. USED

R-

ELECTRICAL SYMBOLS PER E1537

MFD ( .022/50V

CAPACITORS =
2
4

Return to Master TOC

Return to Section TOC

X1

0.1
50V

NOTES :
N.A.

C4

X1

RESISTORS = Ohms (
DIODES =

C-

UNLESS OTHERWISE SPECIFIED)

LABELS

UNLESS OTHERWISE SPECIFIED)

(UNLESS OTHERWISE SPECIFIED)

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

9
8

UNLESS OTHERWISE SPECIFIED TOLERANCE

ON HOLES SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .O2

com

ON 3 PLACE DECIMALS IS + .OO2

ON ALL ANGLES IS + .5 OF A DEGREE

EARTH GROUND CONNECTION

FILE: M17741_1AE

THE LINCOLN ELECTRIC CO.

LAST CHANGE

EQUIP.

THE LINCOLN ELECTRIC CO.

XA
12-13-96

TYPE

CLEVELAND, OHIO U.S.A.

SCALE

MATERIAL TOLERANCE ("t") TO AGREE

WITH PUBLISHED STANDARDS

COMMON CONNECTION

THE LINCOLN ELECTRIC CO.

AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF

10

VOLTAGE NET

FRAME CONNECTION

THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY

X1

19

POWER SUPPLY SOURCE POINT

NUMBER.

11

D-

SUPPLY

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

NOT USED

33074A

com

1A, 400V

1/4W

DR.

I.E.B./JB

DATE

SUBJECT

COMMANDER 400 S & W

CV CONTROL PC BRD SCHEMATIC

NONE
9/14/94

CHK.

BS

SUPSDG.

SHT.
NO.

17741

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

D3
DZ1

Q2

Q1

D2

X
X

X
X

R6

D1

R2

R5

R1

C1

OCI1

R4

X
X

R7

X
X

02J

Return to Master TOC

CAPACITORS = MFD/VOLTS

Return to Section TOC

DESCRIPTION

R14

R15

R16

R17

R18

R19

DZ2

X1
C5

PART NO.

C4

R10

R9

R8

R3

R12

XXX
XXX
XXX
XXX

REQD

L1
C3

R11

R13

C2

L9560-1
J21

Return to Master TOC

Return to Master TOC

ITEM

Return to Master TOC

Return to Section TOC

G-16

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY - CV CONTROL PC BOARD

CV CONTROL

Return to Section TOC

Return to Section TOC

G-16

RESISTORS = OHMS

NOTE:

L9560
12-13-96

Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

TO OIL TEMP SHUT-

P23

DOWN LOGIC INPUT

R1

P22

P23

10.0

P22

C1

R2

50V

P22
10

COMMON (EPD)

COMMON (EPD)

P22

FROM FUEL LEVEL SENDER

POST ON FUEL GAUGE

+5V BATT

P23

Return to Master TOC

50V

1W

CW

14

15

O2

14

I3

O3

13

I4

O4

12

R28

267

R30

267

R32

267

R27
R29

267

R31

I5

O5

11

I6

O6

10

GND

D3

D4

D5

DZ3

LVL LED

DZ5

20V

20V

1W

1W
DZ4

DZ6

20V

20V

1W

1W

P22
COMMON (EPD)

+12V BATT.

13

68.1K

P22

P22

P22

R34

R5

22.1K
11

+5V BATT

+5V BATT
TO LAMPS

P23

ON/OFF INPUT

P22

1.00K

4.75K

R23

R21

ON TEST TIMER

51.1K

D1

LM2901

R16

R13

ALT VOLTAGE F.B.

CONNECTION ON ALT

5.11K

P23
R10

R25

DZ2

X1

C3

10V

0.1

1W

50V

1.00K

10.0K

C6

0.1
50V

27
35V

P22

1.00K
C4

C5

R18
10.0K

14

0.1

DOWN LOGIC INP

4.75K

4.75K

X1

TO ALT SHUT-

LM2901

R12

3.01K

R14

R20

Q1
2N4401

FROM SENSE

R11

Return to Master TOC

10.0K

R22

R24

2 SEC LAMPS

+5V BATT

Return to Section TOC

TO FUEL

R9

COMMON (EPD)

COMMON (EPD)

4.75K

COMMON (EPD)

R15

50V

22.1K

FILE: M17500_1BA

GENERAL INFORMATION
COMMON (EPD)

COMMON (EPD)

ELECTRICAL SYMBOLS PER E1537

LM2901

+5V BATT
10

X1

13

DIODES =

COMMON (EPD)
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY

THE LINCOLN ELECTRIC CO.

AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF

UNLESS OTHERWISE SPECIFIED TOLERANCE

P22

ON HOLES SIZES PER E-2056

12

ON 2 PLACE DECIMALS IS + .O2

COMMON (EPD)

R-

34

DZ-

C-

10

X-

D-

WITH PUBLISHED STANDARDS

VOLTAGE NET

FRAME CONNECTION

EARTH GROUND CONNECTION

EQUIP.

THE LINCOLN ELECTRIC CO.

12-15-95A

SCALE
DR.

B.K.

DATE

COMMANDER 400

TYPE

CLEVELAND, OHIO U.S.A.

MATERIAL TOLERANCE ("t") TO AGREE

COMMON (EPD)

SUPPLY

COMMON CONNECTION

Chge.Sht.No.

ON 3 PLACE DECIMALS IS + .OO2

(BATT)

(UNLESS OTHERWISE SPECIFIED)

THE LINCOLN ELECTRIC CO.

ON ALL ANGLES IS + .5 OF A DEGREE

TO COMMON

LABELS

POWER SUPPLY SOURCE POINT

NUMBER.

C10

X1

UNLESS OTHERWISE SPECIFIED)

UNLESS OTHERWISE SPECIFIED)

LAST NO. USED

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

LM2901

1A, 400V

1/4W

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

+5V BATT

NOTES :
N.A.

11

P22

MFD ( .022/50V

CAPACITORS =
RESISTORS = Ohms (

Return to Master TOC

TO OIL
TEMP LED

P23

COMMON (EPD)

COMMON (EPD)

Return to Section TOC

TO OIL
PRESS LED

P23

267

R33

TO ALT
LED

P23

267

CLAMP

267

P22

COMMON (EPD)

3.92K

I2

O1

LAMP DRIVER

5K
2

X3

16

12

R8

10V

X1

R4

4.75K

0.1

D2

DOWN LOGIC INP

4.75K
DZ1

I1

O0

TO FUEL SHUT-

LM2901

R6
C2

PCB

4.75K

R7

R3

FUEL LEVEL F.B.

I0

MC1413BP

CONTROL
4.75K

267

R26

P22

2.21K

Return to Master TOC

OIL TEMP SWITCH F.B.

FROM OIL TEMP SWITCH

0.1

Return to Section TOC

G-17

ELECTRICAL DIAGRAMS

SCHEMATIC - ENGINE PROTECTION PC BOARD

M 17500

Return to Section TOC

G-17

SUBJECT

ENGINE PROTECTION P.C. BD. SCHEMATIC

NONE
05-12-95

CHK.

FV

SUPSDG.

SHT.
NO.

M 17500

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

Return to Master TOC

Return to Section TOC

G-18

R9

R5

P22

DZ2

Return to Master TOC

PART NO.

DESCRIPTION

R14

C6

C4
R13
R12

R11

R10

R15

X1

R16

D1

C10

R20

R21

R23

R22

R24

R18

C5

R25

C1

R2

R1

Return to Master TOC

DZ1

D5

D4

D3

D2

C3

R7

C2

R8

Q1

REQD

R4

R6

R3

X3

R34

R26

R27

DZ3

DZ6

R32

R33

R29

DZ4

R28

DZ5

P23

XXX
XXX
XXX
XXX
XXX

R30

L9596- 1

R31

Return to Section TOC

ITEM

Return to Section TOC

G-18

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY - ENGINE PROTECTION PC BOARD

COMMANDER 400
ENGINE PROTECTION

CAPACITORS = MFD/VOLTS

L9596-1
8-14-98C

Return to Master TOC

Return to Section TOC

RESISTORS = OHMS

NOTE:

Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

COMMANDER 400

Downloaded from www.Manualslib.com manuals search engine

17637

Return to Master TOC

G-19

ELECTRICAL DIAGRAMS

SCHEMATIC - METER PC BOARD

M

Return to Section TOC

G-19

+5V
R31

R35

20.0

20.0

+15V

R32

R36

20.0

20.0

R33

R37

20.0

20.0

R34

R38

20.0

20.0

D1

+5V

R40

Q5
3A
100V

10.0
3

14

X6

R41

C9

R42

C10

.33

GND

50V

10.0

14

14

14

14

OUT

IN

10.0
1

0.1

C11
4.7

50V

35V

C2

X1
74HC164

C4

X3

74HC164

R39

C3

X2

74HC164

C7

X4
54HC74

C8

X5
HEXINV

200
DZ2
10V
1W
3

+5V

5
7

LED2

LED3

10

10

Q4

4.75K

1A
R30

R23

R22

R20

R21

R19

R18

R17

R16

R15

R14

R13

R12

R11

R10

R9

R8

R7

R6

R3

R5

100V
DZ1
15V

R2

1W

C1

2N4403

.0047

Q3

50V
Q1

R1

2N4401

+5V

+5V

+5V
X1

R28

3.01K

+5V
X2

X3

A1

A1

A1

A2

A2

A2

CLK

10

CLK

10

CLK

11

11

11

12

13

12

13

12

10

74HC164

R27

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2.21K

74HC164

3.01K

13

74HC164

+5V
13

R25

J40

R26

X5

X5

X5

12

11

X5

10

+15V

J40

C5

C6

330p

330p

50V

50V

RESET 1

DATA 1

CLOCK 1

SET 1

Q1

/Q1

GND

VCC
RESET 2

14
13

DATA 2

12

CLOCK 2

11

SET 2

GENERAL INFORMATION

10

X4

Q2

54HC74

N.C.

LAST NO. USED

ELECTRICAL SYMBOLS PER E1537

MFD ( .022/50V

CAPACITORS =

+15V IN

RESISTORS = Ohms (
DIODES =

C12

1A, 400V

1/4W

UNLESS OTHERWISE SPECIFIED)

LABELS

UNLESS OTHERWISE SPECIFIED)

(UNLESS OTHERWISE SPECIFIED)

50V

J40
COMMON

N.A.

NOTE: ALL UNMARKED RESISTORS = 100 OHMS

X5

X5

ON HOLES SIZES PER E-2056

J40

ON 2 PLACE DECIMALS IS + .O2

ON 3 PLACE DECIMALS IS + .OO2

VOLTAGE NET

ON ALL ANGLES IS + .5 OF A DEGREE

MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS

EARTH GROUND CONNECTION

FILE: M17637_1AC

NUMBER.
UNLESS OTHERWISE SPECIFIED TOLERANCE

DZ- 2

FRAME CONNECTION

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

Q- 5

12

D-

COMMON CONNECTION

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

42

C-

POWER SUPPLY SOURCE POINT

NOTES :

R-

SUPPLY

0.1

Return to Master TOC

+5V

J40
DATA

CLOCK

Return to Section TOC

LED1

9
10

R4

R29

2N4401

D2
Q2

R24

Return to Master TOC

Return to Section TOC

+15V

Chge.Sht.No.

EQUIP.

THE LINCOLN ELECTRIC CO.

XA

SCALE

9-27-96F

DR.

BK

DATE

COMMANDER 400

TYPE

CLEVELAND, OHIO U.S.A.

12-15-95A

METER P.C. BOARD SCHEMATIC

SUBJECT

NONE
05-12-94

CHK.

FV

SUPSDG.

SHT.
NO.

M 17637

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
COMMANDER 400

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G-20

G-20

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY - METER PC BOARD

ITEM

L9684-1

REQD

PART NO.

IDENTIFICATION

COMMANDER 400 METER

R40

R32

R31

LED2

LED3

C12

J4 0

R23

R19

R20

R21

R22

R12

R18

R11

R17

R24

R4

R3

R10

C7
X2
X4
C4

Return to Master TOC

C5

C6

LED1

R5

D2

Return to Section TOC

R34

R14

R30

DZ1

Return to Master TOC

R33

R27

R25

R26

R28

R15
R13

Return to Section TOC

R35

R39

DZ2

C8

D1

R6

R7

R8

R9

C1

C2

R2

C9

R16

Q3

Q4

R36

X5

C10

X1

Q2

R37

R38

C11
Q1

R29

Return to Master TOC

R42

Q5

R1

Return to Section TOC

R41

X6

X3

C3

CAPACITORS = MFD/VOLTS
RESISTORS = OHMS

NOTE:

L9684-1
9-27-96F

Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

COMMANDER 400

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L1

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J61

4B

3000V

150V

SOURCE" SWITCH S6

80J

4D

FRAME

L2

J61

Return to Master TOC

C1
.0047

TP1

2B

J60

.39mH

TO "OUTPUT CONTROL

Return to Section TOC

G-21

ELECTRICAL DIAGRAMS

SCHEMATIC - REMOTE PROTECTION PC BOARD

M 17948

Return to Section TOC

G-21

J60
1

.39mH

2D

C2
.0047
3000V

L3

J61

TO MOTHER CONTROL PCB

75B

FRAME

J60
2

.39mH

TO REMOTE CONTROL
AMPHENOL

75D

C3
.0047

TP2

3000V

150V
80J

77C

FRAME

L4

J61

J60
6

.39mH

77D

C4

TO "REMOTE/LOCAL"
SWITCH S1

TP4

TP3

.0047

150V

150V

3000V

80J

80J

L5

J61

76C

FRAME
J60

76D

.39mH
C5
3000V

Return to Master TOC

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.0047

FRAME

J61
J60

J61

J61

GENERAL INFORMATION

LAST NO. USED

L-

ELECTRICAL SYMBOLS PER E1537

MFD ( .022/50V

CAPACITORS =
RESISTORS = Ohms (

NOTES :
N.A.

DIODES =

1A, 400V

1/4W

LABELS

(UNLESS OTHERWISE SPECIFIED)

Return to Master TOC

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COMMON CONNECTION

NUMBER.

FRAME CONNECTION
THE LINCOLN ELECTRIC CO.

THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY

AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF

ON 2 PLACE DECIMALS IS + .O2

ON 3 PLACE DECIMALS IS + .OO2
ON ALL ANGLES IS + .5 OF A DEGREE

EARTH GROUND CONNECTION

FILE: M17948_1AA

THE LINCOLN ELECTRIC CO.

Chge.Sht.No.

EQUIP.

THE LINCOLN ELECTRIC CO.

XA

SCALE
DR.

BK

DATE

COMMANDER

TYPE

CLEVELAND, OHIO U.S.A.

12-15-95A

MATERIAL TOLERANCE ("t") TO AGREE

WITH PUBLISHED STANDARDS

VOLTAGE NET

POWER SUPPLY SOURCE POINT

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

ON HOLES SIZES PER E-2056

TP- 4

SUPPLY

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

UNLESS OTHERWISE SPECIFIED TOLERANCE

C-

UNLESS OTHERWISE SPECIFIED)

UNLESS OTHERWISE SPECIFIED)

SUBJECT

REMOTE PROTECTION P.C. BD. SCHEMATIC

NONE
5-16-95

CHK.

FV

SUPSDG.

SHT.
NO.

17948

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
COMMANDER 400

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G-22

G-22

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY - REMOTE PROTECTION PC BOARD

XXXXX
L9924-1
X
X
X
L4
X
XX X
X
X
X
X
X
X
X
X
L1
XXXXX
X
X
X
X
X X XXXXXXXXX
X
TP4
X
XXXXXX XXXXXXXX
C
1
X
X
XXXXXX
C2
X
X
XXXXXX
C3
X
X
XXXXXX
C5
X
X
XXXXXX
C4
X
X
XXXXXX
TP3

TP2

NOTE:

ITEM

TP1

ITEM

REQD

PART NO.

IDENTIFICATION

T11577-58

.0047/3000V

J60

S18248-6

HEADER

J61

S18248-8

CONNECTOR

L1, L2, L3, L4, L5

T12218-9

.39mH

TP1, TP2, TP3, TP4

T13640-16

80J

L2

C1, C2, C3, C4, C5

L3

L5

J61
J60

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REMOTE

PROTECTION

L9924-1
12-15-95A

Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

COMMANDER 400

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G-23

ELECTRICAL DIAGRAMS

SCHEMATIC - SNUBBER PC BOARD

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

G-23

1-16-98E

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
COMMANDER 400

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G-24

G-24

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY - SNUBBER PC BOARD

~.04
3.00
~.04

ITEMD

ITEM

REQ'D

PART NO.

IDENTIFICATION

4.70
L9572-1

4.40

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INDUCTANCE = HENRYS

X XX
XXX
XXX

3.50
3.30

X
XXXXXXX
X

X
X

Return to Section TOC

CAPACITORS = MFD/VOLTS

XXXXX
X
X
X
X
X
X
X
X
XXXXXXX XXXXXXX

9572-1

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12-15-95A
1-16-98E

.30
COMMANDER SNUBBER

0
0 .30
NOTE:

2.70

Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

COMMANDER 400

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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 column troubleshooting chart, please share this information with us. Please include the
machines code number and how the problem was resolved.

Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199

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SVM ERROR REPORTING FORM

FAX 216-481-2309

SVM Number ___________________________

Page Number if necessary__________________

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Your Company__________________________
Your Name_____________________________

Please give detailed description below:

___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
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SD287 01/99

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