Lincoln Electric Welder SVM133 B User Manual
RETURN TO MAIN INDEX  
SVM133-B  
September, 2002  
TM  
Commander 400  
For use with machine code numbers: 9978, 9979, 10580, 10581  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be in-  
creased by proper installation . . .  
and thoughtful operation on  
your part. DO NOT INSTALL,  
OPERATE OR REPAIR THIS  
EQUIPMENT WITHOUT  
READING THIS MANUAL AND  
THE SAFETY PRECAUTIONS  
CONTAINED THROUGHOUT.  
And, most importantly, think  
before you act and be careful.  
SERVICE MANUAL  
Copyright © 2002 Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
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.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
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.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.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
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.  
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.  
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.  
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.  
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.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
COMMANDER 400  
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iii  
iii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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.  
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.  
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.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
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.  
•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.  
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).  
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.  
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.  
FOR ELECTRICALLY  
powered equipment.  
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.  
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 manufacturer’s  
recommendations.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
COMMANDER 400  
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iv  
iv  
SAFETY  
zones où l’on pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
8. S’assurer que la masse est connectée le plus prés possible de  
la zone de travail qu’il est pratique de le faire. Si on place la  
masse sur la charpente de la construction ou d’autres endroits  
éloignés de la zone de travail, on augmente le risque de voir  
passer le courant de soudage par les chaines de levage,  
câbles de grue, ou autres circuits. Cela peut provoquer des  
risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher met-  
allique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état defonc-  
tionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à soud-  
er parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
Mar. ‘93  
COMMANDER 400  
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v
v
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  
Installation  
Section A-1  
TABLE OF CONTENTS  
- INSTALLATION SECTION -  
Technical Specifications..............................................................................................................A-2  
Safety Precautions......................................................................................................................A-3  
Location and Ventilation..............................................................................................................A-3  
Storing ..................................................................................................................................A-3  
Stacking................................................................................................................................A-3  
Angle of Operation................................................................................................................A-3  
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  
Welding Cable 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  
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) Low Idle 1350  
@ 1800 RPM Full Load 1800  
High Idle 1900  
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”  
(100mm x 120mm)  
RATED OUTPUT - WELDER  
Duty Cycle  
Welding Output  
Volts at Rated Amps  
400 amps (DC Constant Current)  
400 amps (DC Constant Voltage)  
40 volts  
40 volts  
100%  
500 amps (DC Constant Current)  
500 amps (DC Constant Voltage)  
40 volts  
40 volts  
60%  
OUTPUT - WELDER AND GENERATOR  
Welding Range  
Open Circuit Voltage  
Auxiliary Power1  
40 - 575 Amps  
64-74 OCV  
120/240 VAC  
in 7 Ranges (Stick model)  
or 8 Ranges (Stick & Wire model)  
10,000 Watts, 60 Hz.  
100% Duty Cycle  
@1915 RPM  
PHYSICAL DIMENSIONS  
HEIGHT2  
42.0 in.  
WIDTH  
31.5 in.  
800.1 mm  
DEPTH  
WEIGHT  
63.1 in.  
1650 lbs.(748 kg)  
(Stick model)  
1683 lbs.(763 kg)  
(Stick & Wire model)  
1066.8 mm  
1602.7 mm  
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.  
COMMANDER 400  
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A-3  
A-3  
INSTALLATION  
Read this entire installation section before you  
start installation.  
LOCATION AND VENTILATION  
The welder should be located to provide an unrestrict-  
ed 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.  
SAFETY PRECAUTIONS  
WARNING  
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.  
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 can’t be accidentally damaged from construction  
activities, moving vehicles, and other hazards.  
ELECTRIC SHOCK can kill.  
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.  
• Do not touch electrically live  
parts such as output terminals or  
internal wiring.  
3. Remove the battery, recharge it, and adjust the  
electrolyte level. Store the battery in a dry, dark  
place.  
• Insulate yourself from the work  
and ground.  
• Always wear dry insulating  
gloves.  
4. See your engine operation manual for further infor-  
mation on fuel and engine preservation.  
ENGINE EXHAUST can kill.  
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  
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.  
MOVING PARTS can injure.  
• Do not operate with doors open  
or guards off.  
• Stop the engine before servicing.  
• Keep away from moving parts.  
See additional safety information at the front of this  
manual.  
Only qualified personnel should install, use, or ser-  
vice this equipment.  
COMMANDER 400  
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A-4  
A-4  
INSTALLATION  
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.  
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.  
4. Typical conditions of use, such as travel speed,  
roughness of surface on which the trailer will be  
operated, environmental conditions, and likely  
maintenance.  
WARNING  
FALLING EQUIPMENT can cause injury.  
5. Proper preventative maintenance of trailer.  
6. Conformance with federal, state and local laws.1  
Do not lift this machine using lift bail if  
it is equipped with a heavy accessory  
such as a trailer.  
1 Consult applicable federal, state and local laws regarding  
specific requirements for use on public highways.  
Lift only with equipment of adequate  
lifting capacity. Be sure machine is sta-  
ble when lifting.  
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.  
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:  
a. Open the engine compartment door.  
WARNING  
b. Locate the 2 access holes on the upper middle  
region of compartment wall just below the lift bail.  
• Stop the engine and allow it to cool before fueling.  
• Do not smoke when fueling.  
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.  
• Fill the fuel tank at a moderate rate and  
do not overfill.  
d. Secure the lift bail with 2 thread forming screws.  
The screws are provided in the shipped loose  
parts bag.  
• 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.  
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 spe-  
cific 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.  
TOWING  
The recommended trailer for use with this equipment  
(1)  
for road, in-plant and yard towing by a vehicle  
is  
Lincoln’s K953-1. If the user adapts a non-Lincoln trail-  
er, he must assume responsibility that the method of  
attachment and usage does not result in a safety haz-  
ard nor damage the welding equipment. Some of the  
factors to consider are as follows:  
Check oil level after every 4 hours of running time dur-  
ing the first 35 hours of operation.  
NOTE: This machine is equipped with an engine pro-  
tection 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.  
1. Design capacity of trailer vs. the weight of the  
Lincoln equipment and likely additional attach-  
ments.  
2. Proper support of, and attachment to, the base of  
the welding equipment so that there will be no  
undue stress to the trailer’s framework.  
For more oil fill and service information, see the  
Maintenance section of this manual.  
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 man-  
ual for more details about fuel.  
•
Wear gloves and eye protection and be care-  
ful when working near a battery, follow the  
instructions printed on the battery.  
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.  
The Commander 400 is shipped with the  
negative battery cable disconnected.  
–
+
Before you operate the machine, make sure the IGNI-  
TION switch is in the OFF position and attach the dis-  
connected 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  
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.  
NOTE: Before starting the engine, open the fuel shut-  
off valve (lever to be in line with hose) located on the  
side of the fuel pre-filter/water separator housing.  
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  
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.  
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 owner’s manual for  
procedures and frequency).  
CAUTION  
An incorrect arrester may lead to damage to the engine  
or adversely affect performance.  
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  
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 mount-  
ing rail. (See size recommendations below.) For posi-  
tive 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 tight-  
ened 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  
PRESS  
AMPS  
0
0
0
0
0
0
H
O
U
R
S
120 VOLT  
RECEPTACLES  
CV WORK -  
WELD OUTPUT  
TERMINAL  
-
+
-
240 VOLT RECEPTACLE  
GROUND STUD  
WELD OUTPUT TERMINALS  
(ELECTRODE + & CC WORK -)  
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  
250  
Duty Cycle  
100%  
Up to 200 ft.  
1 AWG  
200 to 250 ft.  
1/0 AWG  
400  
100%  
3/0 AWG  
4/0 AWG  
COMMANDER 400  
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A-7  
A-7  
INSTALLATION  
NOTE: The two 120VAC outlets of the 120/240VAC  
receptacle cannot be paralleled. They are on two dif-  
ferent phases.  
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.).  
The auxiliary power receptacles should be used with  
only three-wire, grounded type plugs or approved dou-  
ble-insulated tools with two-wire plugs. The current rat-  
ing 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.  
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,  
or  
STANDBY POWER CONNECTIONS  
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 con-  
nected to the system earth ground. See further con-  
nection 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.  
The Commander 400 is suitable for temporary,  
standby or emergency power using the engine manu-  
facturer’s 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 follow-  
ing information can be used as a guide by the electri-  
cian for most applications. Refer to the connection  
diagram shown in Figure A.2.  
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  
1. Install the double-pole, double-throw switch between  
the power company meter and the premises discon-  
nect.  
The switch rating must be the same or greater than the  
customer’s premises disconnect and service over  
current protection.  
marked with the  
the welder.  
symbol is provided on the front of  
2. Take the necessary steps to assure the load is limit-  
ed 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.  
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:  
• Two 15 amp-120VAC duplex GFCI receptacles  
(5-15R)  
• One 50 amp-120/240VAC receptacle (14-50R)  
3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-  
50) 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.  
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.  
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  
N
LOAD  
DOUBLE POLE DOUBLE THROW  
SWITCH RATING TO BE THE SAME  
AS OR GREATER THAN PREMISES  
SERVICE OVERCURRENT  
PROTECTION.  
PREMISES  
DISCONNECT AND  
SERVICE  
OVERCURRENT  
PROTECTION  
GROUND  
45AMP  
240 VOLT  
DOUBLE  
POLE  
CIRCUIT  
50 AMP, 120/240  
VOLT PLUG  
NEMA TYPE 14-50  
240 VOLT  
BREAKER  
GND  
N
50 AMP, 120/240 VOLT  
RECEPTACLE  
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  
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  
Commander 400 Settings With K799 Hi-Freq./K930-1 Tig Module....................................B-11  
Wire Feed (Constant Voltage) Welding.....................................................................................B-12  
Auxiliary Power .........................................................................................................................B-12  
Simultaneous Welding and Auxiliary Power Loads ............................................................B-12  
COMMANDER 400  
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B-2  
B-2  
OPERATION  
WARNING  
OPERATING INSTRUCTIONS  
Read and understand this entire section before operat-  
ing your Commander 400.  
ENGINE EXHAUST can kill.  
SAFETY INSTRUCTIONS  
WARNING  
• Use in open, well ventilated areas or  
vent exhaust to the outside.  
• Do not stack anything on or near the  
engine.  
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.  
MOVING PARTS can injure.  
• Do not operate this equipment with any  
of its doors open or guards off.  
• Stop the engine before servicing it.  
• Keep away from moving parts.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrodes with your skin or wet clothing.  
Only qualified personnel should install, use, or ser-  
vice this equipment.  
• Insulate yourself from the work and  
ground.  
• Always wear dry insulating gloves.  
GENERAL DESCRIPTION  
FUMES AND GASES can be dan-  
gerous.  
The Commander 400 is a diesel engine driven welding  
power source. The machine uses a brushless asyn-  
chronous 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.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
WELDING SPARKS can cause  
fire or explosion.  
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.  
• Keep flammable material away.  
• Do not weld on containers that have held  
combustibles.  
This machine is controlled by a high quality microcon-  
troller. The microcontroller provides high speed control  
of the weld process as well as the engine protection  
features.  
ARC RAYS can burn.  
• Wear eye, ear, and body protection.  
COMMANDER 400  
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B-3  
B-3  
OPERATION  
• 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 con-  
nection to premises wiring.  
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.  
• Weld and AC auxiliary power at the same time (with-  
in machine total capacity).  
OTHER FEATURES  
• Deutz 3-cylinder, air/oil cooled diesel engine.  
Designed for long life, easy maintenance and excel-  
lent fuel economy.  
GENERATOR  
The Commander 400 provides smooth 120/240 VAC  
output for auxiliary power and emergency standby  
power.  
• 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 alter-  
nator output and fuel level.  
DESIGN FEATURES  
(All Models)  
• Indicator lights for low oil pressure, high oil tempera-  
ture, engine alternator low output/broken belt and low  
fuel level.  
FOR STICK WELDING  
• Excellent DC constant current output for stick weld-  
ing applications.  
• Automatic low fuel shutdown before running out of  
fuel.  
• 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.  
• Engine hour meter standard on all models.  
• Extended range 25 gallon (94.6 l) fuel tank.  
• Fuel pre-filter/water separator with “dry” change ele-  
ment.  
• 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.  
• Automatic idler reduces engine speed when not weld-  
ing or drawing auxiliary power. This feature reduces  
fuel consumption and extends engine life.  
• Remote control capability standard on all models.  
• Single side engine service with over the top access to  
the engine.  
• Selection of “hot” or “cold” output terminals with a tog-  
gle 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.  
• 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).  
• Two 15 amp 120 VAC duplex receptacles with GFCI  
protection for up to 30 amps of 120 VAC power.  
COMMANDER 400  
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B-4  
B-4  
OPERATION  
ADDITIONAL DESIGN FEATURES  
WELDING CAPABILITY  
(Stick & Wire Model only)  
The Commander 400 is rated at 400 amps, 40 volts at  
100% duty cycle. The weld current is variable from 40  
to 575 amps.  
FOR WIRE WELDING  
• One constant voltage position for all wire welding. A  
12 to 45V range across the entire current output  
range.  
• Excellent arc characteristics with MIG (GMAW) and  
Inner shield (FCAW) welding.  
• A Wire Feeder connector for quick connection of the  
control cable.  
• A built in “Electronic Contactor” for “Cold” electrode  
when not welding.  
• The 3 digit display has the additional feature of pre-  
setting the open circuit voltage and displaying the  
actual voltage during welding.  
•
Designed for use with the following Lincoln wire feeders.  
•LN-25  
•LN-8  
•LN-23P  
•NA-3  
•LN-7  
•Spool Gun &  
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  
3
2
4
5
6
7
1
8
9
9
OIL  
FUEL  
TEMP  
PRESS  
AMPS  
0
0
0
0
0
0
11  
12  
H
O
U
R
S
10  
23  
13  
17  
22  
21  
24  
-
20  
+
-
15  
16  
18  
19  
14  
ENGINE CONTROLS  
(Figure B.1, Items 1 through 8)  
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 addi-  
tional 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 hav-  
ing to bleed the system.  
See Figure B.1 for the location of the following fea-  
tures:  
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.  
2. START PUSHBUTTON: Energizes the starter  
motor to crank the engine. With the engine RUN-  
STOP 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.  
COMMANDER 400  
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B-6  
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 tem-  
perature 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.  
b. When the electrode touches the work or  
power is drawn for lights or tools (approxi-  
mately 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 approxi-  
mately 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.  
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.  
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.  
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 reg-  
ulator 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 (mini-  
mum 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.  
• 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 main-  
tenance.  
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.  
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.  
COMMANDER 400  
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B-7  
B-7  
OPERATION  
With the switch in the “WELDING TERMINALS  
ALWAYS ON” position, the contactor is closed and  
the welding terminals are always “Hot.”  
WELDER CONTROLS (Figure B.1 Items 9  
through 14 )  
9. OUTPUT RANGE SWITCH AND OUTPUT CON-  
TROL: 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.  
With the switch in the “WELDING TERMINALS  
REMOTELY CONTROLLED” position, the contac-  
tor 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.  
TABLE B.1 OUTPUT RANGE SWITCH AND OUT-  
PUT CONTROL FUNCTIONS  
When the triggering device is pressed the contac-  
tor is closed and the welding terminals are “Hot.”  
When the triggering device is released the con-  
tactor is opened and the welding terminals are  
“Cold.”  
Range  
Switch1  
Control2  
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.  
Sloped Output for  
Pipe Welding.  
(all models)  
6 Range  
Settings  
90, 120, 180,  
230, 270, 400  
(Max. current on  
each setting)  
For remote control, set the toggle switch in the  
“REMOTE” position.  
Provides a fine  
adjustment of  
welding current  
or voltage from  
Min (1) to Max  
(10) within each  
range  
Constant Current  
Output for  
For control at the welder control panel, set the  
toggle switch in the “LOCAL” position.  
1 Range setting  
50-575 Amps  
Fabrication and  
General Purpose  
Welding (This set-  
ting also used for  
TIG) (all models)  
13. 6 - PIN CONNECTOR: The 6-pin connector locat-  
ed 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.  
1 Range setting  
12 to 40 Volts  
Constant Voltage  
Output for Wire  
Welding (Stick &  
Wire model only)  
1
If the OUTPUT RANGE switch is positioned between settings, the  
previous setting is maintained until the switch is properly positioned  
on a setting.  
2 The OUTPUT CONTROL also controls O.C.V. while in the 6 sloped  
output ranges.  
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 TER-  
MINALS REMOTELY CONTROLLED,” is used to  
control the operation of the “solid state contactor,”  
which allows for the selection of “Hot” or “Cold”  
welding terminals.  
COMMANDER 400  
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B-8  
B-8  
OPERATION  
AUXILIARY POWER CONTROLS  
(Figure B.1 Items 15 - 19 )  
ENGINE OPERATION  
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.  
1. Open the engine compartment door and check that  
the fuel shutoff valve located to the left of the fuel fil-  
ter 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 recep-  
tacles.  
16. 50 AMP CIRCUIT BREAKERS: These circuit  
breaker provide separate overload current protec-  
tion for each 120V circuit at the 240V receptacle.  
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.  
17. 120VAC RECEPTACLES: These two 120VAC (5-  
15R) 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 fur-  
ther information about these receptacles. Also  
refer to “Auxiliary Power Operation” later in this  
section.  
6. Press and hold the engine START button for a min-  
imum of 2 seconds.  
7. Release the engine START button when the engine  
starts.  
18. 15 AMP CIRCUIT BREAKERS: These circuit  
breakers provide separate overload current pro-  
tection for each 120V receptacle.  
8. Check that the indicator lights are off. If the LOW  
FUEL light is on , the engine will shut down 30 min-  
utes after starting. If any other indicator light is on  
after starting, the engine will shut down in a few  
seconds. Investigate any indicated problem.  
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.  
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.  
WIRE FEEDER MODE CONTROLS  
(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 elec-  
trode cable connects to the “-” terminal.  
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.  
21. 15 AMP CIRCUIT BREAKER: This circuit breaker  
provides overload protection for the 14-pin con-  
nector.  
22. VOLTMETER +/- SWITCH: Changes the polarity  
display on the wire feeder.  
23. VOLTS-AMPS SWITCH: Switches the display  
between volts and amps.  
24. 14 - PIN CONNECTOR: For quick connection of  
wire feeder control cable.  
COMMANDER 400  
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B-9  
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 scenar-  
ios.  
Table B.2 Deutz F3L 912 Engine Fuel Consumption  
BREAK-IN PERIOD  
Deutz F3L 912 Running Time for  
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 accom-  
plished. Check the oil level twice a day during the  
break-in period (about 200 running hours).  
44.2 Hp  
@ 1800 RPM  
25 gallons  
(Hours)  
Low Idle - No  
.30 gallons/hour  
Load 1350 RPM (1.36 liters/hour)  
83.3  
32.1  
13.6  
High Idle - No  
.78 gallons/hour  
Load 1900 RPM ( 3.55 liters/hour)  
CAUTION  
DC CC Weld  
Output 400  
Amps @ 40  
Volts  
1.84 gallons/hour  
( 8.36 liters/hour)  
During break-in, subject the Commander 400 to heavy  
loads. Avoid long periods running at idle. Before stop-  
ping the engine, remove all loads and allow the engine  
to cool several minutes.  
Auxiliary Power 1.32 gallons/hour  
10,000 VA (6.00 liters/hour)  
18.9  
The heavy loading of the engine during break-in, with-  
in the rating of the machine, is recommended to prop-  
erly 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 sub-  
stance 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 run-  
ning periods during the break-in period may result in a  
glaze forming on the engine cylinder walls and the  
rings not seating properly. No amount of loading will  
properly seat the piston rings after they are glazed  
over.  
COMMANDER 400  
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B-10  
B-10  
OPERATION  
GENERAL WELDING  
WELDER OPERATION  
The seventh position of the OUTPUT RANGE switch is  
designed for horizontal welds with all types of elec-  
trodes, especially low hydrogen. The OUTPUT CON-  
TROL 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.  
STICK WELDING  
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 CON-  
TROL adjusts the current from minimum to maximum  
within each range. Open circuit voltage is also con-  
trolled by the OUTPUT CONTROL in the slope con-  
trolled 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.  
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 out-  
put setting depending on the tungsten electrode size.  
The Commander 400 can be used without a TIG mod-  
ule 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.  
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 CON-  
TROL for 175 amps.  
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.  
COMMANDER 400  
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B-11  
B-11  
OPERATION  
Table B.3 TYPICAL CURRENT RANGES1 FOR TUNGSTEN ELECTRODES2  
DCEN (-)  
DCEP (+)  
Approximate Argon Gas Flow Rate  
C.F.H. (l/min.)  
Tungsten  
Electrode  
Diameter  
in. (mm)  
TIG TORCH  
Nozzle  
1%, 2%  
Thoriated  
Tungsten  
1%, 2%  
Thoriated  
Tungsten  
Aluminum  
Stainless Steel  
4,5  
Size  
3
3
3
0 .010 (.25)  
0.020 (.50)  
0.040 (1.0)  
2-15  
5-20  
15-80  
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  
1/16  
(1.6)  
70-150  
10-20  
5-10  
(3-5)  
9-13  
(4-6)  
#5, #6  
3/32  
1/8  
(2.4)  
(3.2)  
150-250  
250-400  
15-30  
25-40  
13-17 (6-8)  
15-23 (7-11) 11-15  
11-15  
(5-7)  
(5-7)  
#6, #7, #8  
5/32  
3/16  
1/4  
(4.0)  
(4.8)  
(6.4)  
400-500  
500-750  
750-1000  
40-55  
55-80  
80-125  
21-25 (10-12) 13-17 (6-8)  
23-27 (11-13) 18-22 (8-10)  
28-32 (13-15) 23-27 (11-13)  
#8, #10  
1
When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shield-  
ing gases.  
2 Tungsten electrodes are classified as follows by the American Welding Society (AWS):  
Pure  
EWP  
1% Thoriated  
2% Thoriated  
EWTh-1  
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.  
3
DCEP is not commonly used in these sizes.  
4 TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:  
# 4 = 1/4 in.  
# 5 = 5/16 in.  
# 6 = 3/8 in.  
# 7 = 7/16 in.  
# 8 = 1/2 in.  
#10 = 5/8 in.  
(6 mm)  
(8 mm)  
(10 mm)  
(11 mm)  
(12.5 mm)  
(16 mm)  
5 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 “WELD-  
ING 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 “WELD-  
ING TERMINALS REMOTELY CONTROLLED” posi-  
tion. 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 prop-  
er signal to open and close the solid state contactor in the  
Commander).  
COMMANDER 400  
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B-12  
B-12  
OPERATION  
The following receptacles are provided:  
WIRE FEED (CONSTANT VOLTAGE)  
WELDING  
• Two 15 amp-120VAC duplex FGCI receptacles  
(5-15R)  
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 instruc-  
tions in “Controls and Settings” in this section of the  
manual.  
• 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.  
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) elec-  
trodes and solid wires for MIG (GMAW).  
NOTE: The two 120VAC outlets of the 120/240VAC  
receptacle cannot be paralleled. They are on two dif-  
ferent phases.  
The auxiliary power receptacles should be used with  
only three-wire, grounded type plugs or approved dou-  
ble-insulated tools with two-wire plugs. The current rat-  
ing 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.  
For any electrodes, the procedures should be kept  
within the rating of this machine. For additional elec-  
trode information, see Lincoln publications N-675, GS-  
100 and GS-210.  
AUXILIARY POWER  
WARNING  
SIMULTANEOUS WELDING AND AUXIL-  
IARY POWER LOADS  
Be sure that any electrical equipment plugged into the  
generator AC power receptacles can withstand a ±10%  
voltage and a ±3% frequency variation.  
The auxiliary power ratings above are with no welding  
load. Simultaneous welding and power loads are spec-  
ified 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).  
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.  
TABLE B.4 Commander 400 Simultaneous Welding and Power Loads  
Welding  
Permissible  
Permissible Auxiliary  
Current in Amperes  
Output Range Welding Output  
Setting  
Power - Watts  
(Unity Power  
Factor)  
@120 V ±10% * @ 240 V ±10%  
50-575  
400  
270  
230  
180  
120  
90  
500A/40V  
400A/36V  
270A/31V  
230A/29V  
180A/27V  
120A/25V  
90A/24V  
None  
None  
3000  
6000  
7500  
9500  
9500  
0
0
28  
56**  
70**  
88**  
88**  
0
0
14  
28  
35  
44  
44  
* 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 K867 Universal Adapter........................................................C-5  
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  
COMMANDER 400  
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C-2  
C-2  
ACCESSORIES  
TIG WELDING  
OPTIONS/ACCESSORIES  
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.  
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.  
K936-3 Control Cable  
K870 Foot Amptrol  
Also available:  
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  
K963 Hand Amptrol  
K814 Arc Start Switch  
K937-22 Control Cable Extension  
K937-45 Control Cable Extension  
K844-1 Water Valve  
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.  
HIGH FREQUENCY GENERATORS FOR TIG  
APPLICATIONS  
K704 Accessory Kit - Includes 35 feet (10 m) of elec-  
trode 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.  
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 generat-  
ing equipment. The high frequency bypass network  
supplied with the K799 Hi-Freq Unit does NOT need  
to be installed into the Commander 400.  
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 require-  
ments.)  
The Commander 400 and any high frequency generat-  
ing equipment must be properly grounded. See the  
K799 Hi-Freq Unit and the K930-1 TIG Module operat-  
ing manuals for complete instructions on installation,  
operation, and maintenance.  
K953-1 Trailer  
K958-1 Ball Hitch  
K958-2 Lunette Eye Hitch  
K959-1 Fender & Light Kit  
K965-1 Cable Storage Rack  
SEMIAUTOMATIC WELDING ACCESSORIES  
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.  
LN-25 Wire Feeder - This portable wire feeder is capa-  
ble of CC/CV wire feed welding.  
LN-7 or LN-8 Wire Feeders - Semiautomatic, constant  
K899-1 Spark Arrestor Kit - Easily mounts to stan-  
speed wire feeder. For CV operation only.  
dard muffler.  
LN-23P Wire Feeder - This portable wire feeder is  
capable of CV operation. K350-1 adapter kit is  
required.  
K949-1 Oil Drain Kit - Includes ball valve, hose and  
clamp.  
NOTE: Gas-shielded welding requires a Magnum Gun.  
Gasless welding requires an Inner shield Gun.  
STICK WELDING  
Magnum Spool Gun (K487-25) - A lightweight, semi-  
automatic wire feeder for aluminum welding with argon  
gas. Has built-in remote wire speed control in the han-  
dle. Requires the K488 SG Control Module with appro-  
priate control cable. Includes 25 feet (7.6 meters) of  
power cable.  
K704 Accessory Kit which includes:  
• Electrode holder and cable.  
• Ground clamp and cable.  
• Head shield.  
COMMANDER 400  
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C-3  
C-3  
ACCESSORIES  
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS  
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.  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not operate with panels open.  
• Disconnect NEGATIVE (-) BATTERY  
LEAD before servicing.  
4. Connect the K291 or K404 input cable to the LN-7.  
5. Place the IDLER switch in the “HIGH” position.  
• Do not touch electrically live parts.  
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 set-  
ting is preset at the factory — do not adjust above  
RPM specifications listed in this manual.  
MOVING PARTS can injure.  
• Keep guards in place.  
• Keep away from moving parts.  
• Only qualified personnel should install,  
use or service this equipment.  
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 “-” depend-  
ing on the polarity chosen.  
8. Set the RANGE switch to “WIRE WELDING CV.”  
1. Shut the welder off.  
9. Set the WELDING TERMINALS switch to “WELD-  
ING TERMINAL REMOTELY CONTROLLED.”  
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.  
10. Adjust wire feed speed at the LN-7.  
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  
LN-7  
WIRE  
FEEDER  
81  
42  
41  
INSULATE UNUSED  
LEADS INDIVIDUALLY  
}
31  
32  
31  
32  
2
14 PIN  
AMPHENOL  
2
4
4
+
CV-  
21  
21  
K291 OR K404  
INPUT CABLE  
K867 UNIVERSAL  
ADAPTER PLUG  
GND  
GND  
GREEN  
75  
75  
76  
77  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
76  
77  
TO WORK  
K775 OPTIONAL  
SPLICE LEADS  
REMOTE CONTROL  
AND INSULATE  
COMMANDER 400  
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C-4  
C-4  
ACCESSORIES  
CONNECTION OF THE LN-7 TO THE  
COMMANDER 400 USING K584 INPUT  
CABLE ASSEMBLY (SEE FIGURE C.2.)  
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 set-  
ting is preset at the factory — do not adjust above  
RPM specifications listed in this manual.  
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.  
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.  
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.  
7. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
3. Connect the K584-XX Input Cable Assembly to the  
LN-7.  
8. Set the RANGE switch to “WIRE WELDING CV.”  
4. Connect the K584-XX input cable assembly to the  
14 pin amphenol on the Commander 400.  
9. Set the WELDING TERMINALS switch to “WELD-  
ING TERMINALS REMOTELY CONTROLLED.”  
5. Place the IDLER switch in the “HIGH” position.  
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  
AMPHENOL  
K857 REMOTE  
CONTROL  
+
CV-  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
TO WORK  
COMMANDER 400  
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C-5  
C-5  
ACCESSORIES  
CONNECTION OF THE LN-8 TO THE  
COMMANDER 400 USING K867  
CAUTION  
UNIVERSAL ADAPTER (SEE FIGURE C.3.)  
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 set-  
ting is preset at the factory — do not adjust above  
RPM specifications listed in this manual.  
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.  
6. Set the LOCAL/REMOTE switch to “REMOTE.”  
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.  
7. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
8. Set the RANGE switch to “WIRE WELDING CV.”  
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.  
9. Set the WELDING TERMINALS switch to “WELD-  
ING 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.  
FIGURE C.3  
COMMANDER 400/LN-8 WITH K867 ADAPTER CONNECTION DIAGRAM  
SPARE  
82  
LN-8  
WIRE  
81  
42  
41  
INSULATE UNUSED  
FEEDER  
LEADS INDIVIDUALLY  
}
31  
32  
31  
32  
2
2
14 PIN  
AMPHENOL  
4
4
+
CV-  
21  
21  
GND  
K196  
INPUT CABLE  
K867 UNIVERSAL  
ADAPTER PLUG  
GND  
75  
76  
77  
A
ELECTRODE CABLE  
TO WIRE FEED UNIT  
B
C
TO WORK  
SPLICE LEADS  
AND INSULATE  
COMMANDER 400  
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C-6  
C-6  
ACCESSORIES  
CONNECTION OF THE LN-8 TO THE  
COMMANDER 400 USING K595 INPUT  
CABLE ASSEMBLY (SEE FIGURE C.4.)  
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 set-  
ting is preset at the factory — do not adjust above  
RPM specifications listed in this manual.  
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.  
6. Set the LOCAL/REMOTE switch to “REMOTE.”  
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.  
7. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
8. Set the RANGE switch to “WIRE WELDING CV.”  
3. Connect the K595-XX Input Cable Assembly to the  
LN-8.  
9. Set the WELDING TERMINALS switch to “WELD-  
ING TERMINALS REMOTELY CONTROLLED.”  
4. Connect the K595-XX to the 14 pin amphenol on  
the Commander 400.  
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  
+
CV-  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
TO WORK  
COMMANDER 400  
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C-7  
C-7  
ACCESSORIES  
CONNECTION OF THE LN-23P TO THE  
COMMANDER 400 USING K350-1  
ADAPTER (SEE FIGURE C.5.)  
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 set-  
ting is preset at the factory — do not adjust above  
RPM specifications listed in this manual.  
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.  
NOTE: Figure C.5 shows the electrode connected for  
negative polarity.  
5. Set the VOLTMETER switch to negative.  
6. Set the RANGE switch to “WIRE WELDING CV.”  
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.  
7. Set the WELDING TERMINALS switch to ‘WELD-  
ING TERMINALS REMOTELY CONTROLLED.”  
8. Set the LOCAL/REMOTE switch according to  
whether you are controlling the welder at the  
machine or remotely.  
4. Place the IDLER switch in the “AUTO” position.  
9. Adjust wire feed speed and voltage at the LN-23P.  
FIGURE C.5  
COMMANDER 400/LN-23P CONNECTION DIAGRAM  
14 PIN  
AMPHENOL  
ADAPTER  
KIT  
LN-23P  
WIRE FEEDER  
6 PIN  
AMPHENOL  
K350-1  
CV-  
+
ELECTRODE  
TO WORK  
ELECTRODE CABLE  
TO WORK  
COMMANDER 400  
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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  
If you are using an LN-25 without an internal contac-  
tor, the electrode will be “HOT” when the Commander  
400 is started.  
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.  
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 ‘WELD-  
ING 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 “-” depend-  
ing on the polarity chosen.  
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.  
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.  
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  
TO WORK  
+
CV-  
TO WORK  
ELECTRODE CABLE  
COMMANDER 400  
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C-9  
C-9  
ACCESSORIES  
5. Place the IDLER switch on the Commander 400 in  
the “HIGH” position.  
CONNECTION OF THE K488 SG CONTROL  
MODULE AND K487 MAGNUM SPOOL GUN  
TO THE COMMANDER 400 (SEE FIGURE  
C.7.)  
CAUTION  
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 set-  
ting 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.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
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.  
7. Set the VOLTMETER switch to “+” or “-” depend-  
ing on the polarity chosen.  
3. Connect the K691-10 input cable as shown in  
Figure C.7.  
8. Set the RANGE switch to “WIRE WELDING CV.”  
4. Set the slide switch on the SG Control Module to  
the “Lincoln” position.  
9. Set the WELDING TERMINALS switch to “WELD-  
ING TERMINALS REMOTELY CONTROLLED.”  
CAUTION  
10. Adjust wire feed speed at the SG Control Module.  
NOTE: For remote control, a K857 remote control is  
required. Connect it to the 6 pin amphenol.  
Be sure this switch is set to the “Lincoln” (contact clo-  
sure) 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.  
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  
6 PIN REMOTE  
RECEPTACLE  
K691-10  
INPUT CABLE  
ELECTRODE  
TO WORK  
ELECTRODE CABLE  
TO CONTROL MODULE  
TO WORK  
COMMANDER 400  
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C-10  
C-10  
NOTES  
COMMANDER 400  
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Section D-1  
Section D-1  
TABLE OF CONTENTS  
-MAINTENANCE-  
Maintenance .........................................................................................................................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  
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  
Welder/Generator Maintenance....................................................................................D-11  
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  
COMMANDER 400  
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D-2  
D-2  
MAINTENANCE  
SAFETY PRECAUTIONS  
WARNING  
ROUTINE AND PERIODIC  
MAINTENANCE  
ENGINE MAINTENANCE  
• Have qualified personnel do all maintenance and  
troubleshooting work.  
CAUTION  
• Turn the engine off before working inside the  
machine.  
To prevent the engine from accidentally starting, dis-  
connect the negative battery cable before servicing the  
engine.  
• Remove covers or guards only when necessary to  
perform maintenance and replace them when the  
maintenance requiring their removal is complete.  
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 fre-  
quent service may be required, depending on your spe-  
cific application and operating conditions.  
• If covers or guards are missing from the machine,  
get replacements from a Lincoln Distributor.  
Read the Safety Precautions in the front of this manu-  
al and in the instruction manual for the diesel engine  
used with your machine before working on the  
Commander 400.  
OIL: Check the oil level after every 8 hours of opera-  
tion or daily. BE SURE TO MAINTAIN THE OIL  
LEVEL.  
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.  
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 temper-  
atures, change the oil more frequently.  
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 specifi-  
cations for various ambient temperatures. Always  
check the level with the dipstick before adding  
more oil.  
4. Reinstall the oil fill cap and the dipstick.  
COMMANDER 400  
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D-3  
D-3  
MAINTENANCE  
FIGURE D.1 – OIL DRAIN AND REFILL  
MAX  
MIN  
OIL FILL CAP  
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 temper-  
atures, change the oil filter more frequently. See Table  
D.1 for recommended maintenance intervals. See  
Table D.2 for replacement oil filters.  
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 (usu-  
ally 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.  
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.  
FUEL: At the end of each day's use, refill the fuel tank  
to minimize moisture condensation and dirt contamina-  
tion in the fuel line. Do not overfill; leave room for the  
fuel to expand.  
2. Remove the old filter (spin it off) and discard it (2).  
Wipe off the filter mounting surface and adapter.  
See Figure D.1.  
Refer to your engine operation manual for recom-  
mended grade of fuel.  
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.  
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.  
COMMANDER 400  
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D-4  
D-4  
MAINTENANCE  
FUEL FILTERS:  
7. Re-insert the large white volume plug into the  
upper cavity.  
WARNING  
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.  
When working on the fuel system:  
• Keep unshielded lights away, do not  
smoke !  
9. Screw on the cap ring and tighten hand tight.  
• Do not spill fuel !  
10. Remember to open the fuel shutoff valve (Lever in  
line with the hose) before starting the engine.  
The Commander 400 is equipped with a Fuel Pre-  
Filter/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 Pre-  
Filter/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).  
Water Separator Element: The water separator ele-  
ment is a two-stage filter with a special filtration/water  
separating media. An expanded water reservoir pro-  
vides maximum protection against water in the fuel.  
The recommended change interval for the water sepa-  
rator element is 1,000 hours. See Figure D.2 and fol-  
low 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.  
Fuel Pre-Filter/Water Separator Assembly: The pre-  
filter is a 150 micron screen designed to protect against  
gross fuel contamination of the water separator ele-  
ment 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 exces-  
sive fuel contamination is suspected or a sudden fall-  
off in engine performance is detected the pre-filter  
screen should be inspected and cleaned. See Figure  
D.2 and follow this procedure:  
2. Rotate the quick change ring (located just below fil-  
ter header) clockwise approximately 1/2 turn and  
slide it down and off the element.  
3. Grasp the element and pull down with a slight rock-  
ing 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 O-  
ring.  
3. Remove the large white volume plug located direct-  
ly under the center cap in the upper cavity of the fil-  
ter 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.  
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.  
FUEL  
SHUTOFF  
VALVE  
FILTER  
HEADER  
QUICK  
CHANGE  
RING  
CAP  
RING  
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-fil-  
ter screen contacts the floor of the upper cavity.  
COMMANDER 400  
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D-5  
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 prop-  
er orientation now established, apply additional  
pressure to seat the element in the filter header. You  
should feel the element “pop” into place when prop-  
erly seated.  
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 does-  
n’t matter which one) of arrows located on the out-  
side of the ring should be located directly under the  
air vent valve.  
6. Open the fuel shutoff valve (lever in line with the  
hose).  
NOTE: The element will only go on one way. Never use  
excessive force when mounting the element to the  
header.  
7. Open the air vent valve on the front of the filter head-  
er 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  
SECONDARY  
FUEL FILTER  
OIL  
FILTER  
COMMANDER 400  
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D-6  
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.  
3. Remove loose dirt from the element with com-  
pressed air or a water hose directed from inside out.  
Compressed Air: 100 psi maximum with nozzles  
at least one inch away from the  
element.  
AIR FILTER:  
Water Hose:  
40 psi maximum without nozzle.  
CAUTION  
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.  
Excessive air filter restriction will result in reduced  
engine life.  
5. Rinse elements from inside out with a gentle stream  
of water (less than 40 psi) to remove all suds and  
dirt.  
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 fil-  
ter if necessary. Service the air cleaner regularly  
according to your engine operation manual.  
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 dam-  
aged elements. Protect the element from dust and  
damage during drying and storage.  
1. Locate the air filter canister located behind the  
engine door on the top of the engine.  
2. Remove the air filter element.  
8. Reinstall the air filter element.  
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.  
COMMANDER 400  
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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.  
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).  
COOLING BLOWER BELT: The following procedure  
should be followed to replace the cooling blower belt:  
1. Allow the machine to cool.  
8. Reinstall the engine end panel. Reattach the nega-  
tive battery cable. Slide in and refasten the battery  
holder.  
2. Unfasten and slide the battery holder out from the  
welder.  
9. Check the cooling blower belt tension after 100  
hours of operation.  
3. Disconnect the negative battery cable.  
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.  
FIGURE D.4 – COOLING BLOWER BELT REPLACEMENT AND ADJUSTING  
1
2
4
3
COMMANDER 400  
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D-8  
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.  
1First 50 Hours  
and Every 250  
• Change engine oil.  
• Change oil filter.  
Hours Thereafter • Change fuel filter.  
• Check fan belt.  
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.  
1125 Hours for severe conditions.  
COMMANDER 400  
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D-9  
D-9  
MAINTENANCE  
Table D.2  
ENGINE MAINTENANCE PARTS  
ITEM  
MANUFACTURER  
PART NUMBER  
Air Cleaner Element  
Donaldson  
AC  
P181052  
A302C  
Cooling Blower Belt  
Oil Filter Element  
Lincoln  
Gates  
T13536-3  
7585  
Deutz  
Purolator  
Napa  
1174418  
PER2168  
1820  
Fram  
PH3776  
Fuel Filter Element  
Deutz  
Purolator  
Napa  
1174423  
PC42  
3358  
Fram  
P4102  
Water Separator Element  
Fuel Pre-Filter Screen  
Battery  
Lincoln  
Stanadyne  
M16890-C  
31572  
Lincoln  
Stanadyne  
M16890-B  
29575  
BCI  
Group  
34  
COMMANDER 400  
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D-10  
D-10  
MAINTENANCE  
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  
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).  
GASES FROM BATTERY can explode.  
• Keep sparks, flame, and cigarettes away  
from battery.  
BATTERY ACID can burn eyes and skin.  
CHECKING ELECTROLYTE LEVEL: If battery cells  
are low, fill them to the neck of the filler hole with dis-  
tilled water and recharge. If one cell is low, check for  
leaks.  
• Wear gloves and eye protection and be  
careful when working near a battery.  
Follow the instructions printed on the  
battery.  
To prevent EXPLOSION when:  
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.  
• 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 cir-  
cuit board can result from incorrect connection.  
When you charge, jump, replace, or otherwise connect  
battery cables to the battery, be sure the polarity is cor-  
rect. Improper polarity can damage the charging cir-  
cuit. The Commander 400 charging system is NEG-  
ATIVE GROUND. The positive (+) battery terminal has  
a red terminal cover.  
• 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.  
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 bat-  
tery cable first and the negative cable last. Failure to  
do so can result in damage to the internal charger com-  
ponents.  
• 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.  
Follow the instructions of the battery charger manufac-  
turer 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 termi-  
nals 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 bat-  
tery 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.  
COMMANDER 400  
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D-11  
D-11  
MAINTENANCE  
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.  
WELDER/GENERATOR  
MAINTENANCE  
STORAGE: Store the Commander 400 in clean, dry,  
protected areas.  
RECEPTACLES: Keep the electrical receptacles in  
good condition. Remove any dirt, oil, or other debris  
from their surfaces and holes.  
CLEANING: Blow out the generator and controls peri-  
odically with low pressure air. Do this at least once a  
week in particularly dirty areas.  
CABLE CONNECTIONS: Check the welding cable  
connections at the weld output terminals often. Be  
sure that the connections are always tight.  
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.  
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 loca-  
tions, 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.  
COMMANDER 400  
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D-12  
D-12  
MAINTENANCE  
FIGURE D.5 - MAJOR COMPONENT LOCATIONS  
1. CASE DOOR ASSEMBLY  
2. ENGINE  
1
3. SHUTDOWN SOLENOID  
4. IDLER SOLENOID  
5. REAR PANEL ASSEMBLY  
6. BASE  
7. FRONT PANEL ASSEMBLY  
8. CONTROL PANEL  
9. SCR/DIODE RECTIFIER  
BRIDGE ASSEMBLY  
10. FUEL TANK  
11. CAPACITOR BANK  
12. ROTOR/STATOR  
13. CASE TOP AND SIDES  
2
3
13  
12  
11  
10  
7
4
5
5
9
6
8
7
COMMANDER 400  
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Section E-1  
Section E-1  
TABLE OF CONTENTS  
-THEORY OF OPERATION SECTION-  
Theory 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  
Induction Generators .............................................................................................................E-6  
SCR/DIODE  
OUTPUT  
OUTPUT  
CHOKE  
BRIDGE  
NEGATIVE  
TERMINAL  
CV  
TERMINAL  
SHUNT  
POSITIVE  
TERMINAL  
F
E
E
FEEDBACK  
STARTER  
D
B
A
C
K
ALTERNATOR  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SCR GATE SIGNALS  
SHUTDOWN  
SOLENOID  
EXCITER  
WINDINGS  
CV  
BOARD  
IDLER  
SOLENOID  
BATTERY  
42VAC  
METER  
115VAC  
MAIN  
CONTROL  
BOARD  
EXCITER  
14 PIN  
CAPACITORS  
REMOTE  
SWITCH  
AMPHENOL  
115/230VAC  
RECEPTACLE  
BY-PASS  
PC  
BOARD  
6 PIN  
AMPHENOL  
FINE  
ENGINE  
SENSORS  
OUTPUT  
CONTROL  
ENGINE  
PROTECTION  
BOARD  
EXCITER VOLTAGE  
FEEDBACK  
BOARD  
CURRENT/ MODE  
SELECTOR  
SWITCH  
12VDC  
FIGURE E.1 – COMMANDER 400 BLOCK LOGIC DIAGRAM  
COMMANDER 400  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR AND STATOR  
SCR/DIODE  
OUTPUT  
OUTPUT  
CHOKE  
BRIDGE  
NEGATIVE  
TERMINAL  
CV  
TERMINAL  
SHUNT  
POSITIVE  
TERMINAL  
F
E
E
FEEDBACK  
STARTER  
D
B
A
C
K
ALTERNATOR  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SCR GATE SIGNALS  
SHUTDOWN  
SOLENOID  
EXCITER  
WINDINGS  
CV  
BOARD  
IDLER  
SOLENOID  
BATTERY  
42VAC  
METER  
115VAC  
MAIN  
CONTROL  
BOARD  
EXCITER  
14 PIN  
CAPACITORS  
REMOTE  
SWITCH  
AMPHENOL  
115/230VAC  
RECEPTACLE  
BY-PASS  
PC  
BOARD  
6 PIN  
AMPHENOL  
FINE  
ENGINE  
SENSORS  
OUTPUT  
CONTROL  
ENGINE  
PROTECTION  
BOARD  
EXCITER VOLTAGE  
FEEDBACK  
BOARD  
CURRENT/ MODE  
SELECTOR  
SWITCH  
12VDC  
control board for the idler solenoid, which is mechani-  
cally coupled to the engine's throttle linkage.  
GENERAL DESCRIPTION  
The Commander 400 is a diesel engine driven welding  
power source. The machine uses a brushless asyn-  
chronous alternating current generator for DC stick  
electrode welding and for 120/240 VAC auxiliary stand-  
by 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 diesel engine is coupled to a brushless asynchro-  
nous three-phase alternating current induction genera-  
tor. See Induction Generators. The excitation or  
"flashing" voltage is developed in the exciter windings  
and capacitor configuration. The rotor, which is manu-  
factured by casting aluminum through steel lamination,  
is mechanically coupled to the engine. Through exci-  
tation 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 stick and wire model has a CV terminal for con-  
stant voltage wire welding.  
BATTERY, STARTER, ENGINE,  
ROTOR AND STATOR  
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 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.  
COMMANDER 400  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.3 – EXCITER FEEDBACK, CONTROL BOARD, LOCAL AND REMOTE CONTROL  
SCR/DIODE  
OUTPUT  
OUTPUT  
CHOKE  
BRIDGE  
NEGATIVE  
TERMINAL  
CV  
TERMINAL  
SHUNT  
POSITIVE  
TERMINAL  
F
E
E
FEEDBACK  
STARTER  
D
B
A
C
K
ALTERNATOR  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SCR GATE SIGNALS  
SHUTDOWN  
SOLENOID  
EXCITER  
WINDINGS  
CV  
BOARD  
IDLER  
SOLENOID  
BATTERY  
42VAC  
METER  
115VAC  
MAIN  
CONTROL  
BOARD  
EXCITER  
14 PIN  
CAPACITORS  
REMOTE  
SWITCH  
AMPHENOL  
115/230VAC  
RECEPTACLE  
BY-PASS  
PC  
BOARD  
6 PIN  
AMPHENOL  
FINE  
ENGINE  
SENSORS  
OUTPUT  
CONTROL  
ENGINE  
PROTECTION  
BOARD  
EXCITER VOLTAGE  
FEEDBACK  
BOARD  
CURRENT/ MODE  
SELECTOR  
SWITCH  
12VDC  
The Commander 400 is controlled by a high quality  
microcontroller, which is the main circuit element of the  
control board.  
EXCITER FEEDBACK, CONTROL  
BOARD, LOCAL AND REMOTE  
CONTROL  
The control board also supplies operating voltages and  
control signals to the CV board, the meter board, and  
the engine protection board.  
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 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 cur-  
rent/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.  
COMMANDER 400  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.4 – WELD WINDING, OUTPUT BRIDGE, OUTPUT CHOKE AND CV CAPACITORS  
SCR/DIODE  
OUTPUT  
OUTPUT  
CHOKE  
BRIDGE  
NEGATIVE  
TERMINAL  
CV  
TERMINAL  
SHUNT  
POSITIVE  
TERMINAL  
F
E
E
FEEDBACK  
STARTER  
D
B
A
C
K
ALTERNATOR  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SCR GATE SIGNALS  
SHUTDOWN  
SOLENOID  
EXCITER  
WINDINGS  
CV  
BOARD  
IDLER  
SOLENOID  
BATTERY  
42VAC  
METER  
115VAC  
MAIN  
CONTROL  
BOARD  
EXCITER  
14 PIN  
CAPACITORS  
REMOTE  
SWITCH  
AMPHENOL  
115/230VAC  
RECEPTACLE  
BY-PASS  
PC  
BOARD  
6 PIN  
AMPHENOL  
FINE  
ENGINE  
SENSORS  
OUTPUT  
CONTROL  
ENGINE  
PROTECTION  
BOARD  
EXCITER VOLTAGE  
FEEDBACK  
BOARD  
CURRENT/ MODE  
SELECTOR  
SWITCH  
12VDC  
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 volt-  
age filtering and help maintain a constant arc voltage at  
the output terminals.1  
WELD WINDING, OUTPUT BRIDGE,  
OUTPUT CHOKE AND CV CAPACI-  
TORS  
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.  
The shunt, which is in series with the positive output  
terminal, provides current feedback to the control  
board.  
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.  
1CV Board and CV Capacitors are present on stick and wire  
model only.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
COMMANDER 400  
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E-5  
E-5  
THEORY OF OPERATION  
FIGURE E.6 – SCR OPERATION  
SCR OPERATION  
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 cur-  
rent. 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 nor-  
mally 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 out-  
put. If the gate firing occurs later in the cycle, the con-  
duction time is less, resulting in lower SCR output.  
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 sig-  
nal 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.  
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 con-  
trolled by the Gate.  
Commander 400  
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E-6  
E-6  
THEORY OF OPERATION  
INDUCTION GENERATORS  
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 mag-  
netized rotor in the form of torque and rotational speed.  
The majority of this energy is magnetically delivered to  
the stator weld coils.  
The Commander 400 utilizes  
a
brushless  
Asynchronous Induction Generator to convert mechan-  
ical 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 direc-  
tion 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 pro-  
vides out-of-phase current or reactive power for excita-  
tion. The capacitors used in the Commander 400 pro-  
vide 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 gener-  
ator is equal to that used by an induction motor of the  
same size.  
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  
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  
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  
COMMANDER 400  
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F-2  
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 malfunc-  
tions. Simply follow the three-step procedure list-  
ed below.  
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 sub-  
ject 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.  
Step 1. LOCATE PROBLEM (SYMPTOM). Look  
under the column labeled “PROBLEM” (SYMP-  
TOMS). This column describes possible symp-  
toms that the machine may exhibit. Find the list-  
ing 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.  
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 elec-  
trical wiring diagrams and schematics. Refer to  
the Electrical Diagrams Section Table of Contents  
to locate the appropriate diagram.  
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 con-  
ducted without removing the case cover.  
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.  
Commander 400  
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F-3  
F-3  
TROUBLESHOOTING & REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
WARNING  
• Remove the PC Board from the static-shielding bag  
and place it directly into the equipment. Don’t set the  
PC Board on or near paper, plastic or cloth which  
could have a static charge. If the PC Board can’t be  
installed immediately, put it back in the static-shielding  
bag.  
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.  
• If the PC Board uses protective shorting jumpers,  
don’t 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 prob-  
lems when troubleshooting and replacing PC boards,  
please use the following procedure:  
• If you return a PC Board to The Lincoln Electric  
Company for credit, it must be in the static-shielding  
bag. This will prevent further damage and allow prop-  
er failure analysis.  
4. Test the machine to determine if the failure symp-  
tom has been corrected by the replacement PC  
board.  
1. Determine to the best of your technical ability that  
the PC board is the most likely component causing  
the failure symptom.  
NOTE: Allow the machine to heat up so that all electri-  
cal components can reach their operating temperature.  
2. Check for loose connections at the PC board to  
assure that the PC board is properly connected.  
5. Remove the replacement PC board and substitute  
it with the original PC board to recreate the original  
problem.  
3. If the problem persists, replace the suspect PC  
board using standard practices to avoid static elec-  
trical damage and electrical shock. Read the warn-  
ing inside the static resistant bag and perform the  
following procedures:  
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 termi-  
nal strips.  
PC Board can be damaged by  
static electricity.  
b. If the original problem is recreated by the  
substitution of the original board, then the  
PC board was the problem. Reinstall the  
replacement PC board and test the  
machine.  
• Remove your body’s static charge  
before opening the static-shield-  
ing bag. Wear an anti-static wrist  
strap. For safety, use a 1 Meg  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
ohm resistive cord connected to a  
grounded part of the equipment  
frame.  
6. Always indicate that this procedure was followed  
when warranty reports are to be submitted.  
• If you don’t have a wrist strap,  
touch an unpainted, grounded,  
part of the equipment frame.  
Keep touching the frame to pre-  
vent static build-up. Be sure not  
to touch any electrically live parts  
at the same time.  
Workstations  
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.  
Reusable  
Container  
Do Not Destroy  
• Tools which come in contact with the PC Board must  
be either conductive, anti-static or static-dissipative.  
Commander 400  
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F-4  
F-4  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical damage 1. Contact your local Lincoln 1. Contact the Lincoln Electric  
is evident.  
Authorized Field Service Facility.  
Service Department. 1-800-833-  
9353 (WELD).  
1. Check for loose or faulty con-  
nections on the heavy current  
carrying leads between the out-  
put bridge and the output termi-  
nals. Also check for broken  
leads at the weld choke. See  
the Wiring Diagram.  
No welding output in either CV or 1. Place the Welding Terminals  
Stick modes. Auxiliary power is nor-  
mal and engine operates normally.  
switch in the “ALWAYS ON”posi-  
tion. If the problem is solved, the  
fault may be in the external con-  
trol cable (if used), Leads #2 and  
#4. 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.  
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  
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 out-  
puts.  
output  
terminals  
of  
the  
Commander 400.  
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 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, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-  
800-833-9353 (WELD).  
Commander 400  
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F-5  
F-5  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
“---” or “CRS” stuck on display when 1. Contact your local Lincoln 1. Check for loose or faulty connec-  
machine is powered up. No welding  
output in both stick and CV modes.  
Engine operates normally and auxil-  
iary power is normal.  
Authorized Field Service shop.  
tions 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 connec-  
tions.  
2. Check for loose or faulty connec-  
tions 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 1. If the remote control unit is not 1. Perform the Fine Control  
or no control of output. The auxil-  
iary power is OK. The engine is  
operating normal.  
connected to the machine, make  
sure the Local/Remote switch  
(S1) is in the “Local” position.  
Potentiometer Test.  
2. Perform the Stator Voltage Test.  
3. Perform the SCR/Diode Bridge  
2. If a remote control unit is con-  
nected, and the machine oper-  
ates normally when the switch is  
in the “Local” position, the  
remote control cable or unit may  
be faulty. Check or replace.  
Test.  
1. The engine speed may be low.  
Normal high idle (no load) is  
1900 RPM.  
The machine has low welding out-  
put and low auxiliary output.  
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.  
4. The engine may have lost horse-  
power 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, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-  
800-833-9353 (WELD).  
COMMANDER 400  
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F-6  
F-6  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Low or no constant voltage (CV) 1. Make sure the wire feeder, con- 1. Perform the Range Switch  
welding output. Constant current  
(CC) and the auxiliary power are  
operating normally.  
trol cable and welding cables are  
connected correctly.  
Test.  
2. Check for poor connections at  
J21 pins 1 & 4 at the CV daugh-  
ter board. This is CVSCR gate  
drive output. Will not affect  
welding in the general fab or  
pipe taps.  
2. Make sure the range switch is in  
the correct position.  
3. Check the heavy current carry-  
ing cables associated with the  
CV output terminal. See the  
Wiring Diagram.  
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 volt-  
age feedback input. Will not  
affect welding in the general fab  
or pipe taps.  
4. Perform the Control Board  
Power Supply Test.  
The machine powers down within 1. Contact your local Lincoln 1. Check to make sure that the  
machine has an L10953-1  
Exciter Feedback Module Asbly.  
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.  
Authorized Field Service Shop.  
2. Check for loose or faulty con-  
nections 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.  
3. Check for loose or faulty con-  
nections 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 wave-  
forms as illustrated in the  
Oscilloscope  
Section.  
Waveforms  
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, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-  
800-833-9353 (WELD).  
Commander 400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-7  
F-7  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No welding output in either CV or 1. Contact your local Lincoln 1. Check for loose or faulty con-  
stick modes. Also no auxiliary  
power. Engine operates normally.  
Authorized Field Service Shop.  
nections 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 mod-  
ule 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.  
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. 1. Check the circuit breakers CB1 1. Check the GFCI receptacles and  
The engine operates normally and  
the welding output is normal.  
thru CB4. Reset if tripped.  
associated wires for loose or  
faulty connections. See the  
Wiring Diagram.  
2. Check the GFCI receptacles.  
Reset if tripped.  
2. Check the continuity of leads #3,  
#5, #5A and #6 from the exciter  
windings to their respective tie  
points. See the Wiring Diagram.  
3. Check for loose or faulty plugs at  
the power receptacles.  
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, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-  
800-833-9353 (WELD).  
COMMANDER 400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-8  
F-8  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
Engine will not idle down to low 1. Make sure the Idler switch (S4) 1. Perform the Idler Solenoid Test.  
speed. Machine has normal weld  
and auxiliary power.  
is in the “AUTO” position.  
2. Make sure the control board  
mounting/grounding screws are  
tight.  
2. Make sure there is not an exter-  
nal load on either the weld ter-  
minals or the auxiliary recepta-  
cles.  
3. Check leads #226, #227, #237 &  
#254 for loose or faulty connec-  
tions. See the Wiring Diagram.  
3. Check for mechanical restriction  
in the solenoid linkage.  
4. Check solenoid waveforms as  
illustrated in the Oscilloscope  
Waveforms Section.  
5. Check to make sure that leads  
#227 & #232 at the B1 & B3 ter-  
minals on the control board are  
not swapped. See the Wiring  
Diagram.  
Engine will not go to high idle when 1. Make sure the welding cables 1. Check the current sensing toroid  
attempting to weld or use auxiliary  
power. Output is normal when Idler  
switch is in the “HIGH” position.  
Automatic idle function works prop-  
erly when the auxiliary power is  
loaded.  
and connections are tight.  
for loose or faulty connections.  
CV models only. See the Wiring  
Diagram.  
NOTE: The automatic idler may  
not function if the auxiliary  
power is loaded to less 2. Make sure the toroid and lead  
than 150 watts.  
assembly are assembled cor-  
rectly. CV models only. See the  
Wiring Diagram.  
3. Check the shunt and associated  
leads for loose or faulty connec-  
tions. 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, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-  
800-833-9353 (WELD).  
COMMANDER 400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-9  
F-9  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ENGINE PROBLEMS  
The machine goes to low idle but 1. Make sure there is NOT an 1. The idler solenoid linkage may  
does not stay at low idle.  
external load (auxiliary or weld)  
connected to the Commander  
400.  
be misadjusted or damaged.  
2. The idler solenoid hold-in circuit-  
ry may be faulty. Check leads  
#237 and #226 for loose or faulty  
connections. See the Wiring  
Diagram.  
3. Perform the Idler Solenoid Test.  
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.  
The engine will not crank or cranks 1. Check for loose, faulty, or cor- 1. The starter motor, solenoid or  
very slowly.  
roded battery cable connections.  
push button may be faulty.  
Check or replace.  
2. Check the leads and connec-  
tions at the starter solenoid and 2. The engine may be hard to  
the start push button.  
crank due to a mechanical fail-  
ure in the engine.  
3. The battery may be faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-  
800-833-9353 (WELD).  
Commander 400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-10  
F-10  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine cranks but will not start. 1. Check for adequate fuel supply. 1. Check leads #274 & #240A at  
J50 (exciter voltage plug) for  
2. Make sure the fuel shut off valve  
loose or faulty connections.  
is in the open position (lever is in  
line with the hose).  
See the Wiring Diagram.  
2. Perform  
the  
Shutdown  
3. The battery voltage may be too  
low. If it is less than 11VDC,  
Solenoid Test.  
charge or replace the battery. 3. Check leads #224, #225, #240  
Check the charging system.  
and #262 for loose or faulty con-  
nections.  
Diagram.  
See the Wiring  
4. If the engine temperature light is  
lit, check the engine cooling sys-  
tem.  
4. Make sure the control board  
mounting/grounding screws are  
tight.  
5. Check solenoid waveforms as  
illustrated in the Oscilloscope  
Waveforms Section.  
6. Check to make sure that J4 &  
J23 are not swapped at the con-  
trol board. See the Wiring  
Diagram.  
The engine shuts down shortly after 1. Check for adequate fuel supply. 1. Perform  
the  
Shutdown  
start. Initialize sequence is normal  
(see Initialization Sequence sec-  
tion).  
Solenoid Test.  
2. If any indicator light is lit when  
the engine shuts down, that 2. If possible check solenoid wave-  
particular system has faulted.  
Check system.  
forms as illustrated in the  
Oscilloscope Waveforms sec-  
tion.  
3. Check for loose, faulty, or cor-  
roded battery cable connec- 3. The control board may be faulty.  
tions.  
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, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-  
800-833-9353 (WELD).  
COMMANDER 400  
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F-11  
F-11  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The battery does not stay charged. 1. Check for loose, faulty or cor- 1. Perform the Charging Circuit  
roded battery cable connec-  
tions.  
Test.  
2. The battery may be faulty.  
Check or replace.  
The Fine Control on the 1. Make sure the Remote/Local 1. Perform the Fine Control  
Commander 400 does not work  
properly.  
switch (S1) is in the “LOCAL”  
position.  
Potentiometer Test.  
3. The control board may be faulty.  
Remote output control not function- 1. Make sure the Remote/Local 1. Perform the Fine Control  
ing correctly.  
switch (S1) is in the “REMOTE”  
position.  
Potentiometer Test.  
2. Check the Remote/Local switch  
(S1) and associated leads. See  
the Wiring Diagram.  
2. The remote control unit or cable  
may be faulty.  
replace.  
Repair or  
3. The RF Bypass PC Board (CV  
models) may be faulty. See the  
Wiring Diagram.  
The Remote Protection PC  
Board (Stick models) may be  
faulty. See the Wiring Diagram.  
4. Check amphenols and asso-  
ciated leads. See the Wiring  
Diagram.  
The wire feeder does not work 1. Check the circuit breaker CB5. 1. With the engine at high idle  
when connected to the machine’s  
14 pin amphenol.  
Reset if tripped.  
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 wire feeder control cable  
may be faulty.  
replace.  
Check or  
3. The wire feeder may be faulty.  
Check or replace.  
2. The RF bypass board (CV mod-  
ules only) may be faulty. See  
the Wiring Diagram.  
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, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-  
800-833-9353 (WELD).  
COMMANDER 400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-12  
F-12  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The welding arc is “cold.” The 1. Check for loose or faulty con- 1. Using a voltmeter, check for the  
engine runs normally. The auxiliary  
power is normal.  
nections at the weld output ter-  
minals and welding cable con-  
nections.  
correct OCV at the weld termi-  
nals. If the correct voltage is  
present, then check for loose  
connections on the heavy cur-  
rent carrying leads inside the  
2. The welding cables may be too  
long or coiled, causing an  
excessive voltage drop.  
machine.  
Diagram.  
See the Wiring  
3. Check to make sure that the  
machine settings match the  
weld application.  
2. If the OCV is low, perform the  
Engine Throttle Adjustment  
Test.  
4. If a remote control unit is not  
connected to the machine, make  
sure the Local/Remote switch  
(S1) is in the “LOCAL” position.  
3. Perform the SCR/Diode Bridge  
Test.  
4. Perform the Stator Voltage Test.  
5. If the remote control unit is con- 5. Perform the Range Switch Test.  
nected, and the machine oper-  
6. Perform the Fine Control  
ates normally when the switch is  
Potentiometer Test.  
in the “LOCAL” position, the  
remote control cable or unit may  
be faulty. Check or replace.  
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.  
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.  
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, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-  
800-833-9353 (WELD).  
COMMANDER 400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-13  
F-13  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
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 daugh-  
ter 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 feed-  
back input. Will not affect weld-  
ing in the general fab or pipe  
taps.  
13. Check the weld & CV chokes (if  
so equipped) for turn to turn  
shorts.  
14. Check all waveforms as illus-  
trated in the Oscilloscope  
Waveforms Section.  
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, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-  
800-833-9353 (WELD).  
COMMANDER 400  
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F-14  
F-14  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
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 auxil-  
iary power is normal.  
1. Check to make sure that the  
machine settings match the  
weld application.  
1. Perform the Range Switch  
Test.  
2. Perform the Fine Control  
Potentiometer Test.  
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. Check for poor connections at  
the J1 molex plug at the control  
board. Also, perform the Shunt  
Calibration Test.  
3. If a remote control unit is con-  
nected, and the machine oper-  
ates normally when the switch  
is in the “Local” position, the  
remote control cable or unit  
4. Check for poor connections at  
J4 pins 1, 2, 3, 6, & 7 at the con-  
trol board. Also, perform the  
Exciter Voltage Feedback  
Test.  
may be faulty.  
replace.  
Check or  
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.  
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 feed-  
back input. Will not affect weld-  
ing in the general fab or pipe  
taps.  
8. Check for poor connection at  
J21 pins 1 & 4 at the CV daugh-  
ter 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, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-  
800-833-9353 (WELD).  
COMMANDER 400  
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F-15  
F-15  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
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 auxil-  
iary power is normal. (Continued)  
10. Check all waveforms as illus-  
trated in the Oscilloscope  
Wave forms Section.  
11. Perform the Control Board  
Power Supply Test.  
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.  
1. Check to make sure that the  
machine settings match the  
weld application.  
1. Check for poor connections at  
J4 pins 1, 2, 3, 6 & 7 at the con-  
trol pc board. Also, perform the  
Exciter Voltage Feedback  
Test.  
2. Check to make sure the prop-  
per carbon arc rod is being  
used. The maximum carbon  
arc rod for the Commander 400  
is 5/16”.  
2. Check for loose or faulty con-  
nections or wires at the T1, T2,  
or T3 capacitor connection  
block and back to the capacitor  
bank. On machines equipped  
3. Attempt to arc gouge at a less-  
er current, if the application will  
permit.  
with  
L10953-1  
Exciter  
Feedback module asbly, check  
leads T1, T2, & T3 for faulty  
connections.  
4. If the machine shuts down  
while arc gouging in the gener-  
al fab tap, use the CV tap  
instead. This is also an accept-  
able process.  
3. Check for loose or faulty con-  
nections at leads 268, 269 &  
270 from the exciter pc board  
to J4 pins 1, 2 & 3 on the con-  
trol 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.  
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, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-  
800-833-9353 (WELD).  
COMMANDER 400  
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F-16  
F-16  
TROUBLESHOOTING & REPAIR  
COMMANDER 400 INITIALIZATION SEQUENCE  
AND ERROR CODE EXPLANATIONS  
When the Commander 400 is started, the display flashes several messages during initializa-  
tion. They usually go by so fast you cannot see them. Each message correlates to an ini-  
tialization 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 microcontroller’s 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 trou-  
bleshooting diagnosis.  
If the unit begins to shut down first and then the error code appears, this is not a microcon-  
troller initiated shutdown. In this case the unit has shut down due to lack of fuel, engine fail-  
ure, etc.  
COMMANDER 400  
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F-17  
F-17  
TROUBLESHOOTING & REPAIR  
COMMANDER 400 WITH G2713-1 CONTROL BOARD  
ERROR CODES DURING  
INITIALIZATION SEQUENCE  
DEFINITION / SYMPTOM  
CORRECTIVE ACTION  
300  
Program is stuck in ROM/RAM  
check.  
Replace control board.  
bAd uP  
400  
ROM/RAM is corrupt.  
Replace control board.  
Program is stuck in power supply  
stabilization.  
Perform the Control Board  
Power Supply Test.  
Replace control board.  
Replace control board.  
600  
700  
Program is stuck in register  
initialization and Interrupt  
enables.  
Program is stuck in calibration  
constant loading.  
Check exciter voltage waveforms  
as illustrated in the Oscilloscope  
Waveforms Section.  
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.  
500  
or  
---  
Perform the Stator Voltage  
Exciter Winding Test.  
Perform the Engine Throttle  
or  
Adjustment Test.  
Program is stuck waiting for  
program stabilization and loading  
of exciter voltage register table.  
Perform the Exciter Capacitor  
Bank Test.  
Check leads #268, #269, & #270  
from J50 to J4 at the control  
board for loose or faulty connec-  
tions. 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  
F-18  
TROUBLESHOOTING & REPAIR  
COMMANDER 400 WITH G2713-1 CONTROL BOARD  
ERROR CODES DURING  
INITIALIZATION SEQUENCE  
DEFINITION / SYMPTOM  
CORRECTIVE ACTION  
CSS  
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  
or  
Perform the Stator Voltage  
Exciter Winding Test.  
ECL  
The exciter voltage is out of  
range (greater than 550 or less  
than 140VAC).  
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 connec-  
tions. 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  
F-19  
TROUBLESHOOTING & REPAIR  
COMMANDER 400 WITH G2713-1 CONTROL BOARD  
ERROR CODES DURING  
INITIALIZATION SEQUENCE  
DEFINITION / SYMPTOM  
CORRECTIVE ACTION  
LCH  
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 con-  
nections 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.  
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.  
Err  
XIRQ error (illegal external  
interrupt request).  
If the problem persists, the  
control board may be faulty.  
COMMANDER 400  
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F-20  
F-20  
TROUBLESHOOTING & REPAIR  
COMMANDER 400 WITH G2713-1 CONTROL BOARD  
ERROR CODES DURING  
INITIALIZATION SEQUENCE  
DEFINITION / SYMPTOM  
CORRECTIVE ACTION  
Ert  
Esi  
RTI error (illegal return from  
interrupt).  
SWI error (illegal software  
interrupt request).  
If a High Frequency unit is being  
used, make sure it is connected  
properly. There may be high fre-  
quency intrusion from another  
source in the immediate area.  
Remove all possible forms of RF  
intrusion.  
EIO  
ECP  
ECE  
IOT error (illegal op code trap).  
COP time-out error.  
CME error (slow or stopped  
processor clock).  
If the problem persists, the  
control board may be faulty.  
EO5  
IC3  
OC5 unintended execution.  
IC3 unintended execution.  
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.  
COMMANDER 400  
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F-21  
F-21  
TROUBLESHOOTING & REPAIR  
COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD  
ERROR CODES DURING  
INITIALIZATION SEQUENCE  
DEFINITION / SYMPTOM  
CORRECTIVE ACTION  
uP  
Program is stuck in ROM/RAM  
check.  
Replace control board.  
bAd uP  
CAL  
ROM/RAM is corrupt.  
Replace control board.  
Replace control board.  
Program is stuck in calibration  
constant loading.  
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.  
Perform the Stator Voltage  
Exciter Winding Test.  
Program is stuck waiting for  
program stabilization and loading  
of exciter voltage register table.  
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 connec-  
tions. 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  
F-22  
TROUBLESHOOTING & REPAIR  
COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD  
ERROR CODES DURING  
INITIALIZATION SEQUENCE  
DEFINITION / SYMPTOM  
CORRECTIVE ACTION  
SSr  
Processor is not reading a valid  
range control switch position.  
Check for proper selector  
switch/handle alignment.  
Perform the Range Switch Test.  
Check the exciter voltage wave-  
forms as illustrated in the  
EHC  
The exciter voltage level is too  
high (greater than 550VAC).  
Oscilloscope Waveforms Section.  
Perform the Stator Voltage Exciter  
Winding Test.  
Perform the Engine Throttle  
Adjustment Test.  
ECL  
CSS  
The exciter voltage level is too  
low (less than 140VAC).  
Perform the Exciter Capacitor  
Bank Test.  
Check leads #268, #269 & #270  
from J50 to J4 at the control  
board for loose or faulty connec-  
tions. Also check the T1, T2, &  
T3 lead connections from the  
exciter module to the stator and  
capacitor bank leads.  
The processor is not receiving  
zero cross signals properly or the  
engine RPM is too high.  
COMMANDER 400  
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F-23  
F-23  
TROUBLESHOOTING & REPAIR  
COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD  
ERROR CODES  
WHILE RUNNING  
DEFINITION / SYMPTOM  
CORRECTIVE ACTION  
LCH  
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.  
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. If the problem persists,  
the control board may be faulty.  
COMMANDER 400  
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F-24  
F-24  
TROUBLESHOOTING & REPAIR  
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.  
COMMANDER 400  
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F-25  
F-25  
TROUBLESHOOTING & REPAIR  
COMMANDER 400 WITH G2713-2 or -3 CONTROL BOARD  
ERROR CODES  
WHILE RUNNING  
DEFINITION / SYMPTOM  
CORRECTIVE ACTION  
Ert  
RTI error (illegal return from  
interrupt).  
Esi  
SWI error (illegal software  
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.  
EIO  
ECP  
ECE  
IOT error (illegal op code trap).  
COP time-out error.  
CME error (slow or stopped  
processor clock).  
EO5  
IC3  
OC5 unintended execution.  
IC3 unintended execution.  
If the problem persists, the  
control board may be faulty.  
COMMANDER 400  
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F-26  
F-26  
TROUBLESHOOTING & REPAIR  
COMMANDER 400 WITH G2713-2 OR -3 CONTROL BOARD  
ERROR CODES WHILE  
DEFINITION / SYMPTOM  
CORRECTIVE ACTION  
RUNNING  
ECH  
The exciter voltage is too high  
(greater than 550 VAC).  
Check exciter voltage waveforms  
as illustrated in the Oscilloscope  
Waveforms Sections.  
Perform the Stator Voltage  
The exciter voltage is too low (less  
than 140 VAC).  
ECL  
CSS  
Exciter Winding Test.  
Perform the Engine Throttle  
Adjustment Test.  
Perform the Exciter Capacitor  
Bank Test.  
The processor is not receiving  
zero cross signals properly or the  
engine RPM is too high.  
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-27  
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.  
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 trou-  
bleshooting 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  
3/8" Nut driver or Socket Wrench  
7/16" Wrench  
5/16" Nut Driver  
This procedure takes approximately 35 minutes to perform.  
COMMANDER 400  
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F-28  
F-28  
TROUBLESHOOTING & REPAIR  
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)  
FIGURE F.1 – DOOR CHAIN REMOVAL  
DOOR  
ASSEMBLY  
CHAIN  
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  
COMMANDER 400  
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F-29  
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  
LEFT SIDE PANEL  
THREE SCREWS  
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  
2 SCREWS  
OUTSIDE  
2 SCREWS  
UNDER  
COMMANDER 400  
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F-30  
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 bot-  
tom end screws from the left side engine  
cover panel. See Figure F.4. Remove the  
center screw. Remove the panel.  
FIGURE F.4 – LEFT SIDE ENGINE COVER REMOVAL  
LEFT SIDE  
ENGINE COVER PANEL  
LOOSEN  
TWO END SCREWS  
REMOVE CENTER SCREW  
8. Using the 3/8" wrench, remove the screws  
from the front roof assembly.  
10. Remove the screws from the lower front left  
and right side panels. The bottom end  
screws need only to be loosened.  
9. Remove the fuel cap and rubber seal.  
Carefully lift and remove the front roof  
assembly. Replace the fuel cap.  
11. Remove the panels.  
Commander 400  
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F-31  
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 assem-  
bly. Do NOT remove the phillips head  
screws. Lower the panel. See Figure F.5.  
FIGURE F.5 – FRONT CONTROL PANEL REMOVAL  
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  
SHROUD ASSEMBLY  
REMOVE 2 SCREWS,  
EACH SIDE  
COMMANDER 400  
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F-32  
F-32  
TROUBLESHOOTING & REPAIR  
CASE FRONT KNOBS - REMOVAL AND REPLACEMENT PROCEDURE  
Removal  
Side View  
(Pull)  
(Pull)  
Knob  
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  
Flat  
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.  
COMMANDER 400  
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F-33  
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 elec-  
trical 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 troubleshoot-  
ing 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  
External 12VDC supply ( 30 amps required)  
Wiring Diagram  
Volt/Ohmmeter  
This procedure takes approximately 40 minutes to perform.  
COMMANDER 400  
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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  
HOLD-IN COIL  
(SMALLER  
TERMINALS  
TOP AND BOTTOM  
#226 AND #237)  
IDLER  
SOLENOID  
TEST PROCEDURE  
CAUTION  
1. Turn the engine off.  
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.  
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.  
3. Check the pull-in coil resistance by discon-  
necting lead #227 from the B1 terminal at  
the control board and measuring the resis-  
tance 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.  
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.  
Check the hold-in coil resistance by discon-  
necting J3 from the control board and mea-  
suring across pins 3 & 4. Normal coil resis-  
tance 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.  
7. If the linkage is intact and the solenoid does  
not operate correctly when 12VDC is applied,  
the solenoid may be faulty. Replace.  
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.  
8. Replace the harness leads to the correct  
terminals. See Figure F. 8 and the Wiring  
Diagram. Replace any previously removed  
wire wraps.  
4. Using the external 12VDC voltage supply,  
apply 12VDC to the larger idler solenoid ter-  
minals (#227+ to #254-). The solenoid  
should activate.  
8a. Using the control PC board layout, locate  
Q21 on the control board. Scrape the envi-  
ronmental 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 ser-  
vice access door. Replace the control board  
and close the control panel.  
COMMANDER 400  
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F-35  
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 elec-  
trical 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 troubleshoot-  
ing 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  
External 12VDC supply ( 30 amps required)  
Wiring Diagram  
Volt/Ohmmeter  
This procedure takes approximately 40 minutes to perform.  
COMMANDER 400  
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F-36  
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  
HOLD-IN COIL  
(SMALLER TERMINALS  
EACH SIDE  
#224 AND #240)  
IDLER  
SOLENOID  
TEST PROCEDURE  
CAUTION  
1. Turn the engine off.  
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.  
2. Unlatch, lift and secure the right side engine  
service access door. Using a 5/16” nut dri-  
ver, open up the control panel and tilt out.  
Remove the control board cover  
3. Check the pull-in coil resistance by discon-  
necting lead #262 from the B2 terminal at  
the control board and measuring the resis-  
tance 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.  
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.  
Check the hold-in coil resistance by discon-  
necting 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.  
7. If the linkage is intact and the solenoid does  
not operate correctly when 12VDC is applied,  
the solenoid may be faulty. Replace.  
If either coil resistance is incorrect, the  
wiring may be faulty. Inspect the solenoid  
leads for faulty or loose connections.  
8. Replace the harness leads to the correct ter-  
minals. See Figure F.9 and the Wiring  
Diagram. Replace any previously removed  
wire wraps.  
If the lead connections are OK, recheck the  
coil resistances directly across the solenoid.  
If the coil resistances are incorrect, the sole-  
noid may be faulty. Replace.  
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.  
4. Using the external 12VDC voltage supply,  
apply 12VDC to the larger shutdown sole-  
noid terminals (#262+ to #225-). The sole-  
noid should activate.  
9. Close and secure the right side engine ser-  
vice access door. Replace the control board  
cover and close the control panel.  
COMMANDER 400  
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F-37  
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 elec-  
trical 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 troubleshoot-  
ing 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  
Slot head screw driver  
7/16" wrench  
10mm wrench  
White or red marking pencil  
Strobe-tach, frequency counter, or oscilloscope  
3/8” wrench  
This procedure takes approximately 25 minutes to perform.  
COMMANDER 400  
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F-38  
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  
5. Start the engine and direct the strobe-tach  
light on the blower paddle. Synchronize it to  
the rotating mark.  
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.)  
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.  
4. Connect the strobe-tach according to the  
manufacturer's instructions.  
COMMANDER 400  
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F-39  
F-39  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
6. If either of the readings is incorrect, adjust  
the throttle as follows:  
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.  
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.  
Oscilloscope Method  
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.  
1. Connect the oscilloscope to the 115 VAC  
receptacle, according to the manufacturer’s  
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 AUXIL-  
IARY) HIGH IDLE - NO LOAD in this sec-  
tion of the manual.  
Frequency Counter Method  
1. Plug the frequency counter into one of the  
115 VAC auxiliary receptacles.  
2. If either waveform periods is incorrect,  
adjust the throttle as follows:  
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.  
Adjust HIGH IDLE: Use the 10mm wrench  
to loosen the locking nut. See Figure F.11  
for location of the adjusting screw and lock-  
ing nut. Turn the threaded screw counter-  
clockwise to increase the HIGH IDLE speed.  
Adjust the speed until the period is 15.8 mil-  
liseconds. Retighten the locking nut.  
3. If either of the readings is incorrect, adjust  
the throttle as follows:  
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 millisec-  
onds. Retighten the locking nut.  
Adjust HIGH IDLE: Use the 10mm wrench  
to loosen the locking nut. See Figure F.11  
for location of the adjusting screw and lock-  
ing nut. Turn the threaded screw counter-  
clockwise to increase the HIGH IDLE speed.  
Adjust the speed until the frequency reads  
63 Hz. Retighten the locking nut.  
COMMANDER 400  
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F-40  
F-40  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.11 - HIGH IDLE ADJUSTMENT  
BOSCH  
903  
5 7 0 0 8 1 6  
80D 410/3R  
PES 3A  
0 400 463 12  
LOCKING  
NUT  
ADJUSTING  
SCREW  
FIGURE F.12 - LOW IDLE ADJUSTMENT  
BOSCH  
903  
5 7 0 0 8 1 6  
80D 410/3R  
PES 3A  
0 400 463 12  
ADJUSTING  
COLLAR  
LOCKING NUT  
COMMANDER 400  
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F-41  
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 elec-  
trical 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 troubleshoot-  
ing 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.  
COMMANDER 400  
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F-42  
F-42  
TROUBLESHOOTING & REPAIR  
STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued)  
FIGURE F.13 – CONTROL BOARD PLUG J6 LOCATION  
P e l 9 9 6  
PLUG J6  
4. Using the 5/16” nut driver, remove the control  
TEST PROCEDURE  
board cover. See Figure F.13.  
1. Turn off the engine.  
5. Locate and remove molex plug J6 from the  
control board. See Figure F.13.  
2. Disconnect the welding cables from the  
welding output terminals.  
3. Perform the Case Removal Procedure  
(including front shroud removal).  
COMMANDER 400  
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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  
SNUBBER  
BOARD  
LOCATION  
(LEFT SIDE,  
BELOW  
C1  
C2  
C7  
C3  
FUEL TANK)  
COMMANDER SNUBBER  
6. Using the 3/8” nut driver, locate and remove  
8. Locate and remove lead #204B from resistor  
R1 (50 ohms, 100 Watts). See Figure F.15.  
the snubber board cover. See Figure F.14.  
7. Locate and remove molex plug J30 from the  
snubber board. See Figure F.14.  
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  
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.  
b. If a low resistance is measured in both  
meter polarities, diode DD is shorted.  
Replace diode DD.  
NOTE: Do not disassemble the heat sink.  
c. If a high resistance is measured in both  
meter polarities, diode DD is open.  
Replace diode DD.  
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.  
13. Test diodes DA, DB and DC for proper oper-  
ation using the same procedure described in  
Step 12.  
a. Reverse the meter leads and measure the  
resistance from the cathode to the anode  
of SCR A. See Figure F.16.  
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 proce-  
dure.)  
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.  
a. Reverse the meter leads and measure the  
resistance from cathode (+probe) to  
anode (-probe) of diode DD. The resis-  
tance should be high. See Figure F.16.  
COMMANDER 400  
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F-45  
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 elec-  
trical 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 troubleshoot-  
ing 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.  
COMMANDER 400  
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F-46  
F-46  
TROUBLESHOOTING & REPAIR  
ACTIVE SCR TEST (continued)  
FIGURE F.17 – CONTROL BOARD PLUG J6 LOCATION  
P e l 9 9 6  
PLUG J6  
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  
6. Using the 3/8” nut driver, locate and remove  
the snubber board cover. See Figure 18.  
(including front shroud removal).  
3. Disconnect the welding cables from the  
welding output terminals.  
7. Locate and remove molex plug J30 from the  
snubber board. See Figure F.18.  
4. Using the 5/16” nut driver, remove the con-  
trol board cover. See Figure F.17.  
FIGURE F.18 – SNUBBER BOARD PLUG J30 LOCATION  
PLUG J30  
SNUBBER  
BOARD  
LOCATION  
(LEFT SIDE,  
BELOW  
C1  
C2  
C7  
C3  
FUEL TANK)  
COMMANDER SNUBBER  
COMMANDER 400  
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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.  
FIGURE F.20 - HEAT SINK TEST POINTS  
ANODE  
REMOVE  
INSULATING PAINT  
CATHODE  
9. Remove the red insulating paint from the  
heat sink test points. See Figure F.20.  
NOTE: Do not disassemble the heat sinks.  
COMMANDER 400  
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F-48  
F-48  
TROUBLESHOOTING & REPAIR  
ACTIVE SCR TEST (continued)  
FIGURE F.21 - SCR TESTER CIRCUIT AND SCR CONNECTIONS  
R2  
SW1  
+
V
R1  
SW2  
6 VOLT  
LANTERN  
BATTERY  
R1 = 4 ohms/10 watts  
R2 = 3 ohms/10 watts  
A
G
SCR  
UNDER  
TEST  
C
REMOVE  
INSULATING  
PAINT  
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  
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 prop-  
erly. 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 high-  
er. If lower, replace the battery.  
17. Open switch SW-1.  
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.  
19. Close switch SW-1.  
12. Connect the tester to the SCR A as shown  
in Figure F.21.  
a. Connect tester lead (A) to the anode.  
b. Connect tester lead (C) to the cathode.  
c. Connect tester lead (G) to the gate.  
13. Close switch SW-1.  
20. Read meter for zero voltage.  
a. If the voltage is zero, the SCR is func-  
tioning.  
NOTE: Switch SW-2 should be open.  
14. Read meter for zero voltage.  
b. If the voltage is higher than zero, the  
SCR is shorted.  
a. If the voltage reading is higher than  
zero, the SCR is shorted.  
21. Perform the Active Test Procedure outlined  
in Steps 12-20 for SCRs B and C.  
15. Close or keep closed switch SW-1.  
22. Replace all SCR assemblies that do not  
pass the above tests.  
16. Close switch SW-2 for 2 seconds. Release  
and read meter.  
23. Replace all molex plugs onto the control  
board and snubber board. Reconnect lead  
#204B resistor R1.  
a. If the voltage is 3-6 volts while the  
switch is closed and after the switch is  
open, the SCR is functioning.  
24. Replace the snubber board cover and con-  
trol board cover.  
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.  
25. Replace all case covers. (See the Case  
Cover Removal and Replacement pro-  
cedure.)  
COMMANDER 400  
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F-49  
F-49  
TROUBLESHOOTING & REPAIR  
CHARGING CIRCUIT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
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 troubleshoot-  
ing 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  
Volt/Ohmmeter  
5/16" Nut driver  
3/8" Nut driver  
Wiring Diagram  
This procedure takes approximately 25 minutes to perform.  
COMMANDER 400  
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F-50  
F-50  
TROUBLESHOOTING & REPAIR  
CHARGING CIRCUIT TEST (continued)  
FIGURE F.22 – ENGINE ALTERNATOR LOCATION  
#239  
#285(#281)  
#238  
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.  
TEST PROCEDURE  
1. Turn the engine off.  
2. Perform the Case Cover Removal  
Procedure up to Step 7.  
3. Locate the engine alternator. See Figure F.22.  
4. Start the engine and run it at high idle (1900  
RPM).  
8. If the correct flashing voltage is present and  
the charging output voltage is low or missing,  
the engine alternator may be faulty.  
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.  
9. Stop the engine and check alternator V-belt  
for proper tension. See the engine operation  
manual.  
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.  
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.  
COMMANDER 400  
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F-51  
F-51  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
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 troubleshoot-  
ing assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the correct AC voltages are being generated from the stator  
windings.  
MATERIALS NEEDED  
Volt/Ohmmeter  
3/8" Nut driver  
Wiring Diagram  
7/16" Wrench  
This procedure takes approximately 55 minutes to perform.  
COMMANDER 400  
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F-52  
F-52  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST (continued)  
FIGURE F.23 – CONTROL BOX STUD TERMINALS  
T1 STUD  
#6 LEADS  
T2 STUD  
#5 LEADS  
T3 STUD  
#3 LEADS  
TEST PROCEDURE – Auxiliary Power  
Windings Test  
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.  
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.  
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.  
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.  
COMMANDER 400  
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F-53  
F-53  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST (continued)  
FIGURE F.24 – SCR/DIODE RECTIFIER BRIDGE LEADS  
WIRE  
COMMANDER 400  
+
STICK and WIRE  
d W  
IRE  
STI  
W2/W5  
W1/W4  
W3/W6  
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.  
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.  
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  
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.  
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  
P e l 9 9 6  
PLUG J2  
COMMANDER 400  
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F-54  
F-54  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TEST (continued)  
FIGURE F.26 – EXCITER LEADS T1, T2, T3  
ARNING  
W
T1  
T2  
T3  
15. Using the voltmeter carefully check for 460  
TEST PROCEDURE – Exciter Winding  
Voltage Test  
- 550VAC from T1 to T2.  
16. Using the voltmeter carefully check for 460  
11. Turn the engine off.  
- 550VAC from T2 to T3.  
12. Locate the exciter leads T1, T2 and T3. See  
Figure F.26.  
17. Using the voltmeter carefully check for 460  
- 550VAC from T3 to T1.  
13. Carefully pierce the insulation on leads T1,  
T2 and T3 for voltage measurements.  
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.  
CAUTION  
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.  
Make the smallest possible puncture away from  
any sheet metal parts. Reinsulate these punc-  
tures at the end of this test.  
18. Replace the front shroud and all case covers  
that were removed. (See the Case Cover  
Removal Procedure.)  
14. Start the engine and run it at high idle (1900  
RPM).  
COMMANDER 400  
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F-55  
F-55  
TROUBLESHOOTING & REPAIR  
FINE CONTROL POTENTIOMETER 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 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  
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.  
COMMANDER 400  
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F-56  
F-56  
TROUBLESHOOTING AND REPAIR  
FINE CONTROL POTENTIOMETER TEST (continued)  
approximately 5.00 VDC in the maximum posi-  
tion. Also, the display on the control panel  
should steadily increase from 50-575.  
TEST PROCEDURE  
NOTE: In this test procedure, the positive output  
stud is used for common.  
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 poten-  
tiometer is a 10K ohm potentiometer). See  
Figure F.27. Also, check continuity of all fine con-  
trol potentiometer leads and LOCAL/REMOTE  
switch. If any of the leads, switch or poten-  
tiometer fails the resistance check, replace the  
faulty component.  
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 fab-  
rication tap. 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 back-  
side of the receptacles, breakers, and  
terminal strip while checking voltages inside the  
control box.  
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.  
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 approxi-  
mately -.025 VDC in the minimum position to  
7. When the test is complete, replace the control  
board cover and close the control panel.  
Figure F.27 Control Board Plug J8 location  
Pin #5  
C112  
Pin #9  
Pin #8  
J20  
J22  
Plug J8  
J2  
J1  
J6  
J5  
J8  
J7  
J4  
COMMANDER 400  
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F-57  
F-57  
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  
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.  
COMMANDER 400  
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F-58  
F-58  
TROUBLESHOOTING AND REPAIR  
RANGE SWITCH TEST (continued)  
2. Put the range switch in the CV position on stick &  
TEST PROCEDURE  
wire machines, or in the 90 tap on stick only  
machines.  
NOTE: In this test procedure, the positive output  
stud is used for common.  
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.  
1. Using the 5/16” nut driver, open the control panel  
and tilt out. Remove the control board cover.  
Start the machine.  
4. If any of the voltages in the table are incorrect,  
replace the range switch.  
WARNING  
5. If the test is complete, replace the control board  
cover and close the control panel.  
There are high voltages present inside  
the control box while the machine is  
running. THE VOLTAGES ARE HIGH  
ENOUGH TO KILL. Use extreme cau-  
tion to avoid the backside of the  
receptacles, breakers, and terminal  
strip while checking voltages inside the control  
box.  
Table F.1  
Range Switch Position  
Voltage  
.580 Vdc (if so equipped)  
.937 Vdc  
CV tap  
90 tap  
1.29 Vdc  
120 tap  
180 tap  
230 tap  
270 tap  
400 tap  
50-575 tap  
1.65 Vdc  
2.00 Vdc  
2.36 Vdc  
2.69 Vdc  
3.06 Vdc  
COMMANDER 400  
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F-59  
F-59  
TROUBLESHOOTING & REPAIR  
RANGE SWITCH TEST (continued)  
Figure F.28 Control Board Plug J7  
C112  
J20  
J22  
J2  
J1  
J6  
J5  
J8  
J7  
J4  
Plug J7  
Pin #1  
Pin #7  
Pin #10  
COMMANDER 400  
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F-60  
F-60  
NOTES  
COMMANDER 400  
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F-61  
F-61  
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  
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.  
COMMANDER 400  
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F-62  
F-62  
TROUBLESHOOTING AND REPAIR  
SHUNT CALIBRATION TEST (continued)  
2. Set the range switch to the CC/General fabrica-  
tion tap. Using the fine control pot, set the pre-  
set amps on the display to 300 amps.  
TEST PROCEDURE  
NOTE: In this test procedure, the positive output  
stud is used for common.  
3. Using a grid bank, load the machine to 300 amps  
at 25 volts using an external ammeter and volt-  
meter.  
1. Using the 5/16” nut driver, open the control panel  
and tilt out. Remove the control board cover.  
Start the machine.  
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.  
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 back-  
side of the receptacles, breakers, and  
terminal strip while checking voltages inside the  
control box.  
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  
C112  
J20  
J22  
J2  
J1  
J6  
J5  
J8  
J7  
J4  
Plug J1  
-Pin #2  
+Pin #3  
COMMANDER 400  
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F-63  
F-63  
TROUBLESHOOTING & REPAIR  
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.  
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  
None  
This procedure takes approximately 20 minutes to perform.  
COMMANDER 400  
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F-64  
F-64  
TROUBLESHOOTING AND REPAIR  
EXCITER VOLTAGE FEEDBACK TEST (continued)  
TEST PROCEDURE  
6. For machines equipped with G2713-1 boards,  
1. Set the machine to the following settings, then  
start the machine:  
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.  
Control dial to 1 (min)  
Range dial to 90A max  
Idler switch in the “Auto” position  
Output control source (2-4) switch in the  
“Welding Terminals Remotely Controlled”  
position.  
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 machine’s  
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” posi-  
tion.  
2. As the unit powers up, the display will step thru  
its’ initialization sequence. As soon as the dis-  
play shows “---”, the user must toggle the idler  
switch from “Auto” to “High” 5 times in 5 sec-  
onds. The display will read “tal”, then “000”. The  
idler switch must be returned to the “Auto” posi-  
tion. 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 repeat-  
ed.  
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.  
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.  
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.  
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.  
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.  
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.  
COMMANDER 400  
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F-65  
F-65  
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  
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.  
COMMANDER 400  
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F-66  
F-66  
TROUBLESHOOTING AND REPAIR  
EXCITER CAPACITOR BANK TEST (continued)  
1001/1003/1005/1007 with a capacitance meter.  
The capacitance value should be 240 uf +/- 5%.  
WARNING  
6. Measure  
capacitance  
from  
to  
multi-lead  
multi-lead  
Check for voltage across capacitors.  
Voltages could be high and danger-  
ous. Discharge capacitors with a  
high wattage (50 Ohm min.) resistor if  
necessary before performing tests.  
1018/1020/1022/1024  
1017/1019/1021/1023 with a capacitance meter.  
The capacitance value should be 240 uf +/- 5%.  
7. Measure  
capacitance  
from  
to  
multi-lead  
multi-lead  
1010/1012/1014/1016  
1009/1011/1013/1015 with a capacitance meter.  
The capacitance value should be 240 uf +/- 5%.  
TEST PROCEDURE  
8. If any of the capacitance values in steps 5-7 are  
incorrect, then all the capacitors in that phase  
must be replaced.  
1. With the engine off, disconnect the negative bat-  
tery cable.  
2. Refer to the “Case Cover Removal” section and  
remove the left side engine and stator cover  
panel.  
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 dis-  
play at power up, and no weld output. Cover  
each bolted connection with sleeving after  
reconnection.  
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.  
4. Pull the sleeving back and disconnect the three  
bolted exciter connections using a 7/16” nut dri-  
ver and crescent wrench.  
10. Reinstall the left side engine and stator cover  
5. Measure  
capacitance  
from  
to  
multi-lead  
multi-lead  
panels per the “Case Cover Removal” section.  
1002/1004/1006/1008  
Figure F.30 Control Board Plug J1  
ARNING  
W
T1  
T2  
T3  
COMMANDER 400  
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F-67  
F-67  
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 cir-  
cuit is defective. A defective power supply can cause loss of weld output and loss of weld  
control.  
MATERIALS NEEDED  
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 40 minutes to perform.  
COMMANDER 400  
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F-68  
F-68  
TROUBLESHOOTING AND REPAIR  
CONTROL BOARD POWER SUPPLY TEST (continued)  
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”.  
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.  
4. With the machine running, measure the voltages at  
the control board per the following table.  
2. Using the control PC board layout, locate capaci-  
tor C112 (Figure F.31) and scrape the environmen-  
tal coating off the negative lead. Start the  
machine.  
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.  
WARNING  
There are high voltages present inside  
the control box while the machine is  
running. THE VOLTAGES ARE HIGH  
ENOUGH TO KILL. Use extreme cau-  
tion to avoid the backside of the recep-  
tacles, breakers, and terminal strip while checking  
voltages inside the control box.  
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  
Voltage  
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  
15 VDC +/- 5%  
10 VDC +/- 5%  
5 VDC +/- 5%  
-10 VDC +/- 5%  
24 VDC +/- 5%  
15 VDC +/- 5%  
J20 pin 3 to J20 pin 4  
+15V supply for CV SCR gate drivecircuit  
Figure F.31 Control Board Plugs C112 & J2  
C112  
Pin #1  
Pin #2  
C112  
J20  
J22  
Pin #3  
Pin #4  
Plug J2  
J2  
J1  
J6  
J5  
J8  
J7  
J4  
COMMANDER 400  
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F-69  
F-69  
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 wind-  
ings. An open, shorted or grounded winding can cause lack of output.  
MATERIALS NEEDED  
Refer to “Case Cover Removal” section for tools needed to remove side panels and  
shroud.  
5/16” Nut Driver  
7/16” Nut Driver  
2 Multi-Meters  
Crescent Wrench  
This procedure takes approximately 45 minutes to perform.  
COMMANDER 400  
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F-70  
F-70  
TROUBLESHOOTING AND REPAIR  
STATOR RESISTANCE TEST (continued)  
6. Disconnect J2 from the control board.  
TEST PROCEDURE  
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.  
1. With the engine off, disconnect the negative bat-  
tery cable. Make sure that there is nothing  
plugged into the 115V and 230V receptacles.  
2. Using the 5/16” nut driver, open up the control  
panel and tilt out. Remove the control board  
cover.  
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.  
3. Refer to the “Case Cover Removal” section and  
remove left side engine and stator cover panels,  
and the front shroud.  
9. Check for continuity from the weld leads to frame  
ground. There should be no continuity between  
these leads.  
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.  
10. Check for continuity from J2 pins 1 & 4 to the T1  
exciter lead. There should be no continuity  
between these leads.  
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 dri-  
ver and crescent wrench.  
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  
V1  
J50  
S1  
1 OHM  
300 W  
STATOR  
12V  
CAR  
BATTERY  
VOLTAGE LEADS MUST  
BE TO THE WINDING  
SIDE OF THIS CONNECTION  
WINDING  
UNDER  
TEST  
V2  
J51  
COMMANDER 400  
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F-71  
F-71  
TROUBLESHOOTING AND REPAIR  
STATOR RESISTANCE TEST (continued)  
15. Use the following equation to determine the  
TEST PROCEDURE  
winding resistance:  
14. Connect the test leads J50 and J51 to the stator  
winding under test. Close S1 and read the volt-  
ages 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 mea-  
surements.  
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.  
Table F.3  
Stator Winding Under Test  
W1 - W2  
Resistance  
.009 ohms +/- 20%  
.009 ohms +/- 20%  
.009 ohms +/- 20%  
.130 ohms +/- 20%  
.130 ohms +/- 20%  
.130 ohms +/- 20%  
.170 ohms +/- 20%  
W3 - W4  
W5 - W6  
T1 - T2  
T2 - T3  
T3 -T1  
E1 - E2 (J2 Plug)  
NOTE: The resistances in the above table are to be  
measured with the windings at an approxi-  
mate 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.  
COMMANDER 400  
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F-72  
F-72  
TROUBLESHOOTING & REPAIR  
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 rep-  
resents 5 milliseconds in time.  
Note: Scope probes connected at  
machine 115VAC receptacle.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 400  
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F-73  
F-73  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (STICK)  
MAX TAP – MAX CONTROL POT – HIGH IDLE – NO LOAD  
0 volts  
This is the typical DC open circuit out-  
put voltage generated from a properly  
operating machine. Note that each  
vertical division represents 50 volts  
and that each horizontal division rep-  
resents 5 milliseconds in time.  
Note: Scope probes connected at  
“STICK” welding output terminals.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 400  
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F-74  
F-74  
TROUBLESHOOTING & REPAIR  
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.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 400  
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F-75  
F-75  
TROUBLESHOOTING & REPAIR  
NORMAL WELD VOLTAGE WAVEFORM (WIRE CV)  
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  
“WIRE” welding output terminals.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 400  
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F-76  
F-76  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV TAP)  
MAX CONTROL POT – HIGH IDLE – NO LOAD  
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.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 400  
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F-77  
F-77  
TROUBLESHOOTING & REPAIR  
NORMAL SOLENOID PULL & HOLD COIL WAVEFORMS  
100 ms  
2 V  
2 V  
100 ms  
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.  
SCOPE SETTINGS  
Volts/Div.......................2V/Div.  
Horizontal ..............100ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 400  
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F-78  
F-78  
TROUBLESHOOTING & REPAIR  
ABNORMAL SOLENOID PULL & HOLD COIL WAVEFORMS  
200 MV  
5 ms  
20 ms  
1V  
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  
The scope pictures above are exam-  
ples of a short at the output of both  
the pull and the hold coil circuits on  
the control PC board. The overcur-  
rent 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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F-79  
F-79  
TROUBLESHOOTING & REPAIR  
TYPICAL EXCITER VOLTAGE FEEDBACK WAVEFORMS  
1 V  
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 approxi-  
mately 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  
SCOPE SETTINGS  
Volts/Div.......................1V/Div.  
Horizontal ..................2ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 400  
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F-80  
F-80  
TROUBLESHOOTING & REPAIR  
ABNORMAL EXCITER VOLTAGE FEEDBACK WAVEFORMS  
1 V  
2 ms  
This is an example of a bad wave-  
form 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 distor-  
tion 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, “spat-  
tery”, or “cannon balling”.  
SCOPE SETTINGS  
Volts/Div.......................1V/Div.  
Horizontal ..................2ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
COMMANDER 400  
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F-81  
F-81  
TROUBLESHOOTING & REPAIR  
CONTROL PC BOARD REMOVAL, REPLACEMENT,  
AND CALIBRATION  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
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 troubleshoot-  
ing assistance before you proceed. Call 1-800-833-9353 (WELD).  
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  
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.  
COMMANDER 400  
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F-82  
F-82  
TROUBLESHOOTING & REPAIR  
CONTROL PC BOARD REMOVAL AND REPLACEMENT (continued)  
FIGURE F.33 – MOLEX PLUG REMOVAL  
ENGINE PROTECTION  
BOARD MOLEX PLUG  
P e l 9 9 6  
CV BOARD  
MOLEX PLUG  
CONTROL BOARD  
MOLEX PLUGS  
PROCEDURE  
3. Using the 5/16" nut driver, remove the control  
board cover.  
Before starting the following procedure, refer to  
the topic “PC Board Troubleshooting  
Procedures” at the beginning of this section.  
4. Locate and carefully remove the molex type  
plugs from the control board, engine protec-  
tion board and CV board (if used). See Figure  
F.33 and the Wiring Diagram.  
1. Turn off the engine.  
2. Using the 5/16" nut driver, remove the front  
control cover assembly.  
COMMANDER 400  
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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  
B2/262  
B3/232  
P e l 9 9 6  
5. Remove lead #227 from terminal B1 on the  
control board. See Figure F. 34.  
14. Using the phillips head screw driver, mount  
the control board with the appropriate mount-  
ing 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.  
6. Remove lead # 262 from terminal B2 on the  
control board. See Figure F.34.  
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.  
15. Attach the leads to the control board. Note  
lead placement and routing through insula-  
tion.  
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.  
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.  
10. Carefully remove the control board assembly.  
Note insulation placement for reassembly.  
11. Using the phillips head screw driver, careful-  
ly remove the engine protection board and  
CV board (if used).  
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, careful-  
ly 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.  
COMMANDER 400  
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F-84  
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)  
8. Set the Output Control switch to the “WELD-  
ING TERMINALS ALWAYS ON” position.  
1. Set the front control panel as follows:  
9. Turn the “Control” dial until the display reads  
“19.0.” Assure that there is no load applied to  
the unit.  
”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.  
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.  
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  
11. Set the Output Control switch to the ‘WELD-  
ING TERMINALS REMOTELY CON-  
TROLLED” position.  
box.  
THE VOLTAGES  
ARE HIGH ENOUGH TO  
KILL. Keep hands out of  
the control box while the unit is running.  
12. You have now completed the calibration pro-  
cedure. 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 default-  
ing 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.”  
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  
COMMANDER 400  
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F-85  
F-85  
TROUBLESHOOTING & REPAIR  
SHUTDOWN SOLENOID 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 elec-  
trical 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 troubleshoot-  
ing assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This procedure will aid the technician in the removal and replacement of the shutdown  
solenoid.  
MATERIALS NEEDED  
7/16" Wrench  
Long slot head screw driver  
Needle nose pliers  
This procedure takes approximately 60 minutes to perform.  
COMMANDER 400  
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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)  
SHUTDOWN  
SOLENOID  
HOLD-IN COIL  
(SMALLER TERMINALS  
EACH SIDE  
#224 AND #240)  
IDLER  
SOLENOID  
PROCEDURE  
1. Turn the engine off.  
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.  
2. Unlatch, lift and secure the right side engine  
access door.  
COMMANDER 400  
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F-87  
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  
4. Using the 7/16" wrench, remove the three  
REASSEMBLY  
nuts, two bolts and three lock washers mount-  
ing the shutdown solenoid assembly to the  
engine. See Figure F.36.  
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.  
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.  
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.  
6. Carefully remove the solenoid assembly.  
7. Replace any faulty parts and reassemble the  
solenoid assembly.  
11. Close the right side engine access door.  
COMMANDER 400  
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F-88  
F-88  
NOTES  
COMMANDER 400  
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F-89  
F-89  
TROUBLESHOOTING & REPAIR  
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 elec-  
trical 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 troubleshoot-  
ing 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  
5/16" Nut driver  
3/8" Wrench  
1/2" Wrench  
3/4" Wrench  
11/32" Wrench  
This procedure takes approximately 80 minutes to perform.  
COMMANDER 400  
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F-90  
F-90  
TROUBLESHOOTING & REPAIR  
SCR/DIODE RECTIFIER BRIDGE  
REMOVAL AND REPLACEMENT (continued)  
FIGURE F.37 – SCR/DIODE RECTIFIER BRIDGE DETAILS  
WIRE  
COMMANDER 400  
+
STICK and WIRE  
ICK  
and W  
IRE  
STI  
#209 (small)  
#209A (large)  
SHUNT  
REMOVE BOLT  
AT POSITIVE  
HEAT SINK  
PLATE (LOWER)  
#204C  
STATOR WELD  
WINDING LEADS  
PROCEDURE  
6. Using the 1/2" wrench, remove the shunt  
from the positive heat sink plate (lower). See  
Figure F.37 and the Wiring Diagram.  
1. Turn the engine off.  
2. Perform the Case Cover Removal  
Procedure (including front shroud removal).  
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.  
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.  
7. Using the 5/16" nut driver, remove the control  
board cover.  
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.  
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.  
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.  
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  
WIRE  
COMMANDER 400  
+
STICK and WIRE  
an  
d W  
IRE  
STI  
#207 FROM STICK  
OUTPUT TERMINAL  
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  
SNUBBER  
BOARD  
LOCATION  
(LEFT SIDE,  
BELOW  
FUEL TANK)  
COMMANDER 400  
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F-92  
F-92  
TROUBLESHOOTING & REPAIR  
SCR/DIODE RECTIFIER BRIDGE  
REMOVAL AND REPLACEMENT (continued)  
FIGURE F.40 – RESISTOR R1 LOCATION  
RESISTOR R1  
LEAD #204B  
12. Using the 11/32" wrench, remove the #204B  
lead from the R1 (50 Ohm -100 Watt) resis-  
tor. See Figure F.40. Cut any necessary  
cable ties and clear leads for SCR/diode rec-  
tifier bridge assembly removal.  
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.  
NOTE: Be sure to replace any cut cable ties on  
reassembly. Otherwise, the leads may catch in  
the blower.  
FIGURE F.41 – RECTIFIER BRIDGE BRACKET DETAILS  
GROMMET  
BRACKET  
SCREWS (4)  
COMMANDER 400  
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F-93  
F-93  
TROUBLESHOOTING & REPAIR  
SCR/DIODE RECTIFIER BRIDGE  
REMOVAL AND REPLACEMENT (continued)  
FIGURE F.42 – SCR/DIODE RECTIFIER BRIDGE ASSEMBLY REMOVAL  
RECTIFIER  
15. Carefully lift and slide the SCR/diode rectifier  
bridge assembly out the left side of the  
machine. See Figure F.42.  
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 con-  
trol board. Replace any cable ties cut during  
removal. Using the 5/16" nut driver, install  
the control board cover.  
REASSEMBLY  
16. Carefully lift and slide the SCR/diode rectifier  
bridge assembly into the machine from the  
left side. See Figure F.42.  
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 wind-  
ing leads to the SCR/diode rectifier bridge  
assembly. Replace any cable ties cut during  
removal.  
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.  
19. Using the 11/32" wrench, attach the #204B  
lead to the R1 (50 Ohm -100 Watt) resistor.  
See Figure F.40.  
24. Replace the front shroud and all case covers  
that were removed. (See the Case Cover  
Removal and Replacement Procedure.)  
NOTE: Be sure to replace any cable ties cut dur-  
ing removal. Otherwise, the leads may catch in  
the blower.  
20. Connect plug J30 to the snubber board.  
Install the snubber board cover using the 3/8"  
wrench.  
COMMANDER 400  
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F-94  
F-94  
NOTES  
COMMANDER 400  
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F-95  
F-95  
TROUBLESHOOTING & REPAIR  
SCR 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 elec-  
trical 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 troubleshoot-  
ing assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the SCRs from the output rectifier  
heat sink for maintenance or replacement.  
MATERIALS NEEDED  
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.  
COMMANDER 400  
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F-96  
F-96  
TROUBLESHOOTING & REPAIR  
SCR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.43 – SCR DETAILS  
SPECIAL INSTRUCTIONS  
CAUTION  
NOTE: Before disassembling the existing rectifi-  
er, 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.  
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  
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F-97  
F-97  
TROUBLESHOOTING & REPAIR  
SCR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.44 – RECTIFIER BRIDGE ASSEMBLY BRACKET DETAILS  
GROMMET  
BRACKET  
SCREWS (4)  
8. Inspect the mounting surfaces of each new  
PROCEDURE  
SCR.  
1. Turn the engine off.  
a. Remove all burrs and wipe clean. Do not  
use steel wool or any abrasive cleanser  
on the SCR mounting surfaces.  
2. Perform the SCR/Diode Rectifier Bridge  
Assembly Removal procedure.  
3. Using the 7/16” wrench, remove the mounting  
bracket for the SCR/diode rectifier bridge  
assembly bracket. See Figure F.44.  
9. Apply a thin (0.001” to 0.003”) layer of PEN-  
ETROX A-13 (Lincoln Electric #E2529) or  
PENETROX A, heat sink compound, to each  
heat sink’s SCR mounting surface.  
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 HOUS-  
ING BE USED FOR REASSEMBLY.  
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  
SCR’s 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.  
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.  
7. Polish each heat sink’s mounting surface  
using NO. 000 fine steel wool. Wipe surface  
clean with a lint-free cloth or paper towel.  
COMMANDER 400  
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F-98  
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  
machine’s cap screw. NOTE WHICH  
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 pic-  
tured.)  
THREAD IS ON YOUR CAP SCREWS  
BEFORE PROCEEDING TO THE ASSEM-  
BLY PROCEDURE. Two different designs of  
leaf springs and housings have been used to  
clamp the SCR to the rectifier. The two dif-  
ferent 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 pro-  
cedures. The assembly procedure will be dif-  
ferent depending upon the thread on the cap  
screws. A 1/4-28 thread requires a different  
tightening procedure than a 1/4-20 thread.  
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.  
COMMANDER 400  
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F-99  
F-99  
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-  
NOTE: This procedure can only be used with  
28 cap screws.  
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.  
4. Tighten first cap screw 1/2 turn.  
3. Tighten second cap screw 1/2 turn.  
4. Tighten first cap screw 1/2 turn.  
5. Tighten second cap screw 1/2 turn.  
6. Tighten first cap screw 1/4 turn. STOP.  
7. Assembly now has the proper clamping force.  
8. Perform the Active SCR Test.  
5. Tighten second cap screw 1/2 turn.  
6. Tighten first cap screw 1/4 turn. STOP.  
7. Assembly now has the proper clamping force.  
8. Perform the Active SCR Test.  
COMMANDER 400  
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F-100  
F-100  
TROUBLESHOOTING & REPAIR  
SCR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.47 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING  
PROCEDURE FOR  
FIGURE F.48 – CLAMP ASSEMBLY  
THE 5/8 INCH WIDE SPRING  
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.  
3. Place the steel pressure pad in the housing  
with the 1/8 inch wide standoff facing up. See  
Figure F.47.  
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.  
COMMANDER 400  
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F-101  
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  
NOTE: This procedure can only be used with  
1/4-28 cap screws.  
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.  
4. Tighten first cap screw 1/2 turn.  
3. Tighten second cap screw 1/2 turn.  
4. Tighten first cap screw 1/2 turn.  
5. Tighten second cap screw 1/2 turn.  
6. Tighten first cap screw 1/2 turn.  
5. Tighten second cap screw 1/4 turn.  
6. Tighten first cap screw 1/8 turn.  
7. Tighten second cap screw 1/4 turn. STOP.  
8. Assembly now has the proper clamping force.  
9. Perform the Active SCR Test.  
7. Tighten second cap screw 1/8 turn. STOP.  
8. Assembly now has the proper clamping force.  
9. Perform the Active SCR Test.  
AFTER REPLACING THE SCRs  
Follow the steps in the SCR/Diode Rectifier  
Bridge Removal and Replacement procedure  
to reassemble the machine.  
COMMANDER 400  
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F-102  
F-102  
NOTES  
COMMANDER 400  
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F-103  
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 elec-  
trical 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 troubleshoot-  
ing 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  
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.  
COMMANDER 400  
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F-104  
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.  
a. Start the nuts for diodes with steel studs  
by hand and then torque them according  
to the following table.  
2. Perform the SCR/Diode Bridge Removal  
Procedure.  
3. Loosen the appropriate diode nut and  
remove the diode that is to be replaced.  
b. Run the nuts for diodes with copper studs  
on all the way by hand then torque them  
according to Table F.4 below.  
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.  
c. Turn the nuts a minimum of 1/2 turn more  
while torquing.  
5. Polish each heat sink’s mounting surface  
using No. 000 fine steel wool. Wipe the sur-  
face clean with a lint-free cloth or paper  
towel.  
Table F.4  
DIODE STUD  
SIZE  
FOOT-  
POUNDS  
INCH-  
POUNDS  
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.  
3/4-16  
3/8-24  
1/4-28  
25-27  
10±.5  
300-324  
125+0/-5  
22-25  
7. Apply a thin (0.003” to 0.007”) uniform layer  
of E1868 (Dow Corning 340) heat sink com-  
pound to the heat sink mounting surface.  
9. Perform SCR/Diode Bridge Replacement  
Procedure.  
a. Do not apply compound to the diode stud  
or mounting threads.  
10. Install the case top and sides.  
b. The diode threads must be clean and  
free of defects so that the nut can be fin-  
ger tightened before applying torque. A  
“slip” type torque wrench must be used to  
tighten the diode nut.  
COMMANDER 400  
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F-105  
F-105  
TROUBLESHOOTING & REPAIR  
ENGINE, STATOR/ROTOR 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 elec-  
trical 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 troubleshoot-  
ing assistance before you proceed. Call 1-800-833-9353 (WELD).  
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  
This procedure takes approximately 8 hours to perform.  
COMMANDER 400  
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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  
U-BOLT (2)  
PREPARATION AND LEAD REMOVAL  
PROCEDURE  
1. Turn the engine off.  
5. Turn the fuel off at the shutoff valve. Remove  
and plug the fuel return line. See Figure F.49.  
2. Using the 3/8" and 1/2" wrenches, remove the  
battery cover and disconnect the battery.  
Remove the battery by sliding it out.  
6. Remove and plug the lower fuel line. See  
Figure F.49.  
3. Perform the Case Cover Removal  
Procedure (including removing the front  
shroud).  
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.  
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.  
8. Carefully remove the U-bolts and lift the fuel  
tank away from the machine.  
COMMANDER 400  
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F-107  
F-107  
TROUBLESHOOTING & REPAIR  
ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.50 – REAR PANEL ASSEMBLY REMOVAL DETAILS  
REAR  
PANEL  
ASSEMBLY  
MOUNTING  
SCREWS  
(4)  
BASE  
9. Using the 3/8" wrench, remove the screws  
holding the rear panel assembly to the  
machine base. See Figure F.50.  
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  
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)  
SHUTDOWN  
SOLENOID  
HOLD-IN COIL  
(SMALLER TERMINALS  
EACH SIDE  
IDLER  
SOLENOID  
#224 AND #240)  
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.  
13. Label and remove leads #226, #237, #227  
and #254 from the idler solenoid. See Figure  
F.53 Cut any necessary cable ties.  
FIGURE F.53 – IDLER SOLENOID LEAD REMOVAL  
PULL-IN COIL  
(LARGER TERMINALS  
TOP AND BOTTOM  
#227 AND #254)  
SHUTDOWN  
SOLENOID  
HOLD-IN COIL  
(SMALLER  
TERMINALS  
TOP AND BOTTOM  
#226 AND #237)  
IDLER  
SOLENOID  
COMMANDER 400  
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F-109  
F-109  
TROUBLESHOOTING & REPAIR  
ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
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.  
FIGURE F.55 – OIL TEMPERATURE SENSOR LEAD REMOVAL  
OIL  
TEMPERATURE  
SENSOR  
COMMANDER 400  
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F-110  
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.  
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.  
17. Cut any necessary cable ties to free the har-  
ness assembly from the engine/stator  
assembly.  
23. Clear the wiring harness for engine/stator  
removal by cutting any necessary cable ties.  
18. Using the 11/16" wrench, remove leads  
#236A, #236B and #236C from the starter  
motor solenoid.  
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.  
COMMANDER 400  
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F-111  
F-111  
TROUBLESHOOTING & REPAIR  
ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.57 – EXCITER BOARD COVER REMOVAL  
MOUNTING  
NUTS (3)  
EXCITER  
BOARD  
EXCITER  
BRASS  
BOARD  
COVER  
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.  
26. Check for voltage at the three studs . If volt-  
age is present, do not proceed. Call the  
Lincoln Electric Service Dept. at 1-800-833-  
9353.  
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.  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not operate with panels  
open.  
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.  
• Disconnect NEGATIVE (-)  
BATTERY LEAD before ser-  
vicing.  
• Do not touch electrically live parts.  
COMMANDER 400  
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F-112  
F-112  
TROUBLESHOOTING & REPAIR  
ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.58 – CONTROL BOARD PLUG J2 LOCATION  
P
e
l
9
9
6
PLUG J2  
28. Locate and remove plug J2 from the control  
board. See Figure F. 58. Thread plug J2 out  
of the control box.  
31. Label the #3 lead from the T3 stud in the con-  
trol 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 direc-  
tion of the lead through the toroid hole. See  
the Wiring Diagram. Clear the leads for sta-  
tor removal.  
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.  
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 num-  
ber 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  
T3 STUD  
#3 LEADS  
COMMANDER 400  
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F-113  
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  
FUEL TANK  
SUPPORT  
RAIL  
FRAME  
VERTICAL  
BAFFLE  
LIFT FRAME  
ASSEMBLY  
32. Using the 3/8" wrench, remove the eight  
screws that mount the lift frame vertical baf-  
fle to the lift frame assembly. See Figure  
F. 60. Also remove the engine access door  
chain, noting its placement and length for  
reassembly.  
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 bal-  
ance 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.  
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.  
35. Using the 1/2" wrench and 5/16" nut driver,  
remove the tank/fan guard. See Figure F.60..  
COMMANDER 400  
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F-114  
F-114  
TROUBLESHOOTING & REPAIR  
ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.61 – STATOR REMOVAL  
Stator/Engine  
Mounting Bolts  
and Lockwashers  
Cap Screws (4)  
Bottom Flywheel  
Cover  
Fan Hub  
Fan Nut  
STATOR REMOVAL PROCEDURE  
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.  
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.)  
5. Remove the stator from the engine/rotor  
assembly by prying and sliding the stator from  
the engine.  
3. Using the 7/16" wrench, remove the three  
bolts and lock washers holding the bottom fly-  
wheel cover to the stator frame assembly.  
Remove the cover. See Figure F. 61.  
COMMANDER 400  
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F-115  
F-115  
TROUBLESHOOTING & REPAIR  
ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.62 – BLOWER PADDLE/FLEX PLATE REMOVAL  
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 wash-  
ers. See Figure F. 62. Support the rotor and  
engine securely.  
Reassemble the rotor and stator to the  
Commander 400 by carefully retracing the disas-  
sembly procedure steps in reverse order. Keep  
the following special points in mind as you pro-  
ceed. Lead Reconnection Checklists are provid-  
ed here as an aid to reassembly.  
WARNING  
1. INSTALL ROTOR: Support the rotor with the  
hoist. Install the blower paddles and flex  
plate to the engine flyweel.  
The rotor will be free to fall when the bolts are  
removed.  
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 prop-  
er direction, with the fan nut and four Allen  
head cap screws.  
2. Using the hoist, carefully remove the rotor and  
flex plate assembly.  
Check the air gap for .012” minimum.  
COMMANDER 400  
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F-116  
F-116  
TROUBLESHOOTING & REPAIR  
ENGINE, STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
LEAD RECONNECTION CHECKLIST  
SCR/Diode rectifier bridge assembly  
❒ Stator leads W1-W4, W2-W5 and W3-W6.  
Engine  
❒ Engine grounding strap to engine  
❒ Leads #242E and #229 to fuel level sensor  
Exciter board  
❒ Stator leads T1, T2, and T3 to studs  
❒ Leads #224, #240, #225, and #262 to shut-  
down solenoid  
❒ Leads #226, #237, #227, and #254 to the  
Control board/box  
idler solenoid  
❒ Plug J2  
❒ Leads #228 and #234 to oil pressure sensor  
❒ Leads #5 and #5A to neutral T2 stud (center)  
❒ Leads #233A and #241 to oil temperature  
sensor  
❒ Lead #6 to T1 stud (top) and toroid assembly  
(note number of turns and direction)  
❒ Grounding lead to top of engine bell housing  
❒ Lead #3 to T3 stud (bottom) and toroid  
assembly (note number of turns and direc-  
tion)  
❒ Leads #236A, #236B, #236C, #231A and  
#231B to starter motor solenoid  
❒ Leads #239, #285, and #238 to engine alter-  
nator  
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  
machine’s 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  
WELDER DC (STICK) OUTPUT  
Range Switch  
Fine Control  
Open Circuit  
Load Volts  
Load Amps  
Volts  
Maximum  
Maximum  
70  
40  
500  
WELDER CV (WIRE) OUTPUT  
Range Switch  
Fine Control  
Open Circuit  
Load Volts  
Load Amps  
Volts  
Maximum  
Maximum  
48  
40  
500  
AUXILIARY POWER OUTPUT  
230 Volt Receptacle  
115 Volt Receptacle  
Open Circuit  
Voltage  
Load Volts  
Load Amps  
Open Circuit  
Voltage  
Load Volts  
Load Amps  
230 - 250  
224  
44.6  
115 - 132  
108 - 126  
13 - 16  
COMMANDER 400  
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F-118  
F-118  
NOTES  
COMMANDER 400  
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G-1  
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  
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 Schematic.......................................................................................................G-19  
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  
COMMANDER 400  
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G-2  
G-2  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - STICK MODEL (CODE 9978)  
3D  
5D  
CONNECTOR CAVITY NUMBERING SEQUENCE  
(VIEWED FROM COMPONENT SIDE OF BOARD)  
NOTE:  
1008  
T1  
1002  
1006  
1004  
287  
NEXT AVLB.  
5D  
5
273  
7
240A  
268  
3
NO CONNECTION  
ON NEWER MODELS.  
270  
1
STUD T1 ON  
CAPACITOR  
272  
6
274  
4
3D  
10  
269  
2
G1  
G2  
G3  
204A  
CONNECTION BLOCK  
206  
RECTIFIER  
ASSEMBLY  
8
9
204S  
206S  
207  
1009  
1013  
J50  
1015  
EXCITER VOLTAGE  
FEEDBACK BOARD  
1011  
POS.  
W2  
CONNECTIONS TO  
CAPACITORS MADE  
STAINLESS STEEL  
STAND-OFF  
204B  
600 AMP  
SHUNT  
W5  
VIA EYELET BOLTED  
CONNECTIONS  
SCR  
C
240 uF  
SCR  
B
SCR  
A
BYPASS PC  
BOARD  
W4  
W3  
DD  
ELECTRICAL SYMBOLS PER E1537  
W6  
1010  
STATOR  
FRAME GROUND  
1014  
50 Ohm  
NOTE: ONLY ON  
SOME OLDER  
MODELS  
1012  
1016  
100  
W
OUTPUT  
CHOKE  
STUD T2 ON  
CAPACITOR  
209  
W6  
W3  
DB  
DC  
DA  
CONNECTION BLOCK  
T2  
W1  
NEG.  
CC  
W4  
W5  
223  
260  
261  
204  
1021  
1017  
217  
1
4
6
SELECTOR  
SWITCH  
S8  
4
1
3
5
1019  
1023  
2
3
2
T3  
3D  
(VIEWED FROM BACK)  
(SEE SELECT SWITCH CHART)  
W1  
W2  
218  
219  
5
216  
215  
6
9
W6  
4
J31  
J30  
240 uF  
77C  
76C  
7
3
2
FINE CONTROL  
POT  
A
SNUBBER PC BOARD  
220  
221  
STAINLESS STEEL  
STAND-OFF  
5D  
214  
213  
8
AUXILIARY BYPASS PCB  
222  
1018  
1022  
REMOTE/  
LOCAL  
1
CW  
1024  
T3  
1020  
SWITCH  
S1  
B4  
B5  
B6  
B7  
STUD T3 ON  
VIEWED FROM  
75  
FRAME GROUND  
EXCITER  
76B  
77B  
BACK  
CAPACITOR  
G3  
206S  
204S  
G1  
206  
CONNECTION BLOCK  
270  
268  
274  
273  
WINDINGS  
279  
280  
207  
10  
269  
272  
204A  
G2  
2
75B  
76  
76  
8
77  
256  
10  
CONTROL HARNESS  
4
77  
9
75  
5
255  
11  
1001  
1005  
1003  
1007  
9A  
T1  
T2  
2
2B  
OUTPUT  
CONTROL  
SOURCE  
S6  
5K  
6
2
3
1
2
9
1
12  
2
4
5
6
1
2
3
4
1
8
4
7
3
7
8
3
4
6
7
3
5J  
6
8A  
5A  
5
240 uF  
ALWAYS ON  
OUTPUT REMOTELY  
CONTROLLED  
213  
1
J1  
1002  
1006  
J4  
J6  
J8  
1004  
4
1008  
4B  
214  
215  
216  
2
CONNECTIONS ON CONTROL BOARD  
(VIEWED AS INSTALLED)  
1
250  
3
4
CONTROL HARNESS  
ENGINE  
PROT.  
2
251  
252  
253  
MOTHER  
CONTROL  
217  
218  
219  
220  
BOARD  
3
4
6
5
6
7
8
9
PC BOARD  
J5  
SPI  
1
2
3
4
5
A
B
C
2D  
77D  
76D  
75D  
4D  
J23  
B2  
B1  
B3  
5J  
8A  
REMOTE  
4B  
2B  
SCI  
75D  
J7  
E1  
E2  
3
J2 J6 J5 J8 J7 J1  
J4 J3  
8
CONTROL  
76D  
4D  
5K  
15  
16  
221  
222  
5A  
5
75B  
77C  
4
3
2
1
D
E
9A  
TRIGGER  
GROUND  
10  
11  
12  
ENGINE PROT.  
J3  
2D  
J61  
6
3
STAINLESS STEEL  
STAND-OFF  
J23  
5D  
5E  
BOARD  
77D  
J40  
6
7
8
242I  
F
STAINLESS STEEL  
STAND-OFF  
B1  
B3  
B2  
5C  
COMMON BATT.  
AMPHENOL  
2
METER  
13  
14  
NEUTRAL T2 STUD  
IN CONTROL BOX  
6
7
1
5
6
5
2
3
4
1
8
3
4
76C  
PCB  
REMOTE PROTECTION PCB  
(optional)  
E2  
E1  
1
4
J2  
NOTE:  
AUX. POWER  
227  
232  
GROUND SCREW  
ON CONTROL PANEL  
229B  
224  
237  
247  
246  
NO CONNECTION  
239A  
5G  
262  
285  
226  
234  
233  
243  
FRAME GROUND  
245  
ON NEWER MODELS.  
GND-C  
FRAME GROUND  
240  
GND-D  
GND-E  
242I  
240A  
240  
ENGINE TO PCB HARNESS  
8
GND-A  
8A  
SELECTOR SWITCH (S8)  
POSITION NAMEPLATE SETTING  
NO FUNCTION  
START BUTTON  
S2  
LOAD HOT  
280  
279  
GND-E  
GND-D  
LINE HOT  
232A  
232  
256  
233  
120  
V
HOLD  
COIL  
GND-F  
HOLD  
COIL  
J12  
1
224  
225  
5K  
240  
262  
226  
227  
237  
254  
AUX. CURRENT  
SENSE TOROID  
232H  
267  
2
3
4
5
6
7
8
9
NO FUNCTION  
90 MAX  
WELDED STUD  
HIGH  
AUTO  
IDLER  
9A  
SHUTDOWN  
SOLENOID  
ON OUTPUT PANEL  
IDLE  
SOLENOID  
RUN  
GFCI  
5G  
WHITE  
LINE  
5H  
LOAD  
SWITCH  
S3  
5J  
8A  
120 MAX  
180 MAX  
230 MAX  
270 MAX  
400 MAX  
50-575  
WHITE  
PULL  
COIL  
PULL  
COIL  
STOP  
S4  
8
236B  
231A  
5J  
233A  
255  
236A  
9A  
9
SOLENOID GROUND  
STUD ON ENGINE  
LINE HOT  
LOAD HOT  
5C  
HOUR  
236A  
236C  
METER  
239B  
-
120  
V
J11  
8A  
5J  
PANEL TO PANEL WIRES  
NOTE: DIODE APPEARS  
ON SOME MODELS  
BUT REPLACED BY  
LEAD 285 ON NEWER  
MODELS.  
231A  
242G  
STARTER  
SOLENOID  
GFCI  
5E  
239A  
LOAD  
LINE  
BOLT ONTO  
9A  
5K  
PANEL TO PCB HARNESS  
WHITE  
WHITE  
SENDER BRK’T  
286  
231B  
WHITE  
232C  
5K  
(+)  
(-)  
232B  
OIL PRESSURE SWITCH  
SENSOR  
STARTING  
MOTOR  
T3  
&
232F  
D2  
3A  
ALTERNATOR  
229B  
245  
232A  
246  
INSULATED STUD  
IN CONTROL BOX  
247  
12 VOLT  
9
15A  
228  
SENSOR  
3
6
P16  
234  
J16  
OIL  
PRESS.  
SWITCH  
243  
CB4  
BATTERY  
G
WK  
FUEL  
GND-C  
AMMETER  
TEMP.  
S
1
285  
3B  
J10  
OIL TEMP. SENSOR  
SENSOR  
&
SWITCH  
2
SILVER  
TAB  
120/240V  
LOW  
PRESS.  
S
S
STUD ON ENGINE  
MOUNT CHANNEL  
LOW  
ALT.  
TEMP.  
228A  
EXC  
LARGE  
TAB  
3
4
5
SENSE  
POS  
15A  
50A  
FUEL  
233A  
-
-
-
241  
3D  
-
281  
241A  
242D  
229A  
CB3  
CB2  
3A  
NEG  
SWITCH  
241A  
232G  
242C  
229A  
238  
228A  
236C  
232D  
232E  
242E  
229  
12  
FUEL LVL.  
SENSOR  
11  
242A  
239  
STUD ON  
ENGINE  
242G  
6
7
8
9
SMALL  
TAB  
50A  
6B  
GND-H  
242  
242B  
SILVER  
TAB  
CB1  
242D  
238  
T1 INSULATED STUD  
IN CONTROL BOX  
239  
239B  
ENGINE HARNESS TO PANEL WIRES  
WHITE  
TERM.  
CONTROL PANEL  
GROUND SCREW  
GND-F  
ENGINE HARNESS  
SILVER  
TAB  
5H  
6A  
5C  
12  
ENGINE GROUND  
242  
5C  
STUD ON GENERATOR  
MOUNT CHANNEL  
11  
1-16-98E  
L9041  
3D  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-3  
G-3  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - STICK & WIRE MODEL (CODE 9979)  
CONNECTOR CAVITY NUMBERING SEQUENCE  
(VIEWED FROM COMPONENT SIDE OF BOARD)  
6
3D  
1002  
6
NEXT AVAILABLE 287  
5D  
3
3
1008  
T1  
1006  
1004  
240A  
5D  
5
273  
7
268  
3
270  
1
STUD T1 ON  
CAPACITOR  
NOTE:  
NO CONNECTION  
ON NEWER MODELS  
274  
4
272  
6
3D  
10  
269  
2
279  
CONNECTION BLOCK  
6
6
206  
280  
G1  
G2  
G3  
204A  
RECTIFIER  
ASSEMBLY  
277  
G4  
3
3
8
9
204S  
206S  
208  
207  
1009  
1013  
POS.  
206A  
J50  
1015  
EXCITER VOLTAGE  
FEEDBACK BOARD  
1011  
1012  
1019  
204C  
204B  
SCR  
1
W5  
CONNECTIONS TO  
CAPACITORS MADE  
ELECTRICAL SYMBOLS PER E1537  
600 AMP  
SHUNT  
W2  
CURRENT  
OROID  
SENSE  
T
DE  
SCR  
C
VIA EYELET BOLTED  
CONNECTIONS  
SCR  
B
SCR  
A
240 uF  
206A  
285  
285A  
BYPASS PC  
BOARD  
W1  
30,000 uF  
W4  
DD  
ELECTRODE  
NEG.  
POS.  
1010  
STATOR  
1014  
POLARITY  
SWITCH  
1016  
OUTPUT  
CHOKE  
L1  
FRAME  
GROUND  
STUD T2 ON  
C1-C4  
209  
S5  
CAPACITOR  
21  
DB  
DC  
DA  
CONNECTION BLOCK  
T2  
CC  
208A  
NEG.  
223  
W3  
W6  
260  
261  
204  
209A  
284B  
284A  
284  
W4  
W1  
NOTE: ONLY ON  
SOME OLDER  
MODELS  
CV CHOKE  
L2  
CV  
1021  
1017  
208A  
1023  
T3  
3D  
W2  
W3  
(VIEWED  
SELECTOR  
SWITCH  
217  
240 uF  
FROM BACK)  
SEE CHART  
S8  
77C  
76C  
FINE CONTROL  
POT  
W5  
W6  
218  
219  
5D  
21  
5
4
216  
1
4
6
4
3
2
3
1
2
1018  
1022  
REMOTE/  
215  
7
3
CW  
LOCAL  
2
2B  
1024  
T3  
1020  
A
V
A
220  
221  
J31  
J30  
214  
213  
SWITCH  
S1  
8
2
VOLT/AMP  
SWITCH  
S9  
282  
283  
STUD T3 ON  
VIEWED FROM  
BACK  
OUTPUT  
CONTROL  
SOURCE  
S6  
222  
75  
SNUBBER PC BOARD  
EXCITER  
77B  
76B  
3
6
3
6
ALWAYS ON  
CAPACITOR  
9
1
CONNECTION BLOCK  
WINDINGS  
OUTPUT REMOTELY  
CONTROLLED  
76  
77  
4B  
4
1001  
1005  
206  
G3  
206S  
G1  
2
75B  
76  
8
256  
270  
268  
273  
274  
1003  
1007  
4
77  
9
75  
5
255  
11  
T2  
T1  
279  
4
280  
8
207  
10  
269  
2
272  
6
204A  
G2  
2
204S  
3
6
5A  
5
240 uF  
6
2
3
1
1
10  
12  
5
1
2
3
4
1
8
9
4
7
3
7
3
4
6
7
RF BYPASS  
PC BOARD  
21  
1002  
1006  
J20  
1004  
1008  
J
31  
213  
1
1
6
J1  
115AC  
J4  
A
D
C
H
E
F
J6  
32A  
4E  
2E  
21  
214  
215  
216  
2
J8  
7
5
CONNECTIONS ON CONTROL BOARD  
(VIEWED AS INSTALLED)  
J21  
77C  
4
253  
3
4
J61  
4
8
3
2
5
75B  
CONTACTOR  
WORK  
5A  
G4  
282  
MOTHER  
CONTROL  
PC BOARD  
CV  
BOARD  
252  
251  
250  
ENGINE  
PROT.  
BOARD  
3
2
E1  
76C  
2B  
E2  
217  
218  
219  
220  
5
6
7
8
9
5D  
5E  
4B  
1
5
32A  
77E  
76E  
75E  
3
6
J5  
5C  
77E  
6
4
3
2
277  
REMOTE  
J21  
J23  
SPI  
4E  
NEUTRAL T2 STUD  
IN CONTROL BOX  
J7  
CONTROL  
283  
208  
B1 B2 B3  
31  
5H  
6
7
8
76E  
2E  
G
I
J62  
J2  
J5 J8 J7  
J1  
J6  
J4 J3  
75E  
221  
222  
SCI  
1
5
1
4
2
3
10  
11  
12  
AUX. POWER  
GROUND SCREW  
IN CONTROL BOX  
ENGINE PROT.  
BOARD  
K
B
J3  
STAINLESS STEEL  
STAND-OFF  
5G  
J23  
242H  
J40  
CV DAUGHTER BOARD  
GROUND  
GND-C  
8A  
B1  
B3  
B2  
COMMON BATT.  
METER  
PCB  
CB5 15AMP  
13  
14  
GND-D  
GND-E  
AMPHENOL  
1
5
2
1
5
6
5
6
7
2
3
4
1
8
3
4
242I  
242H  
75D  
77D  
A
77D  
76D  
75D  
4D  
8
6
REMOTE  
CONTROL  
GND-A  
J60  
E2  
E1  
1
4
B
C
1
2D  
76D  
4D  
J2  
3
4
GND-E  
GND-D  
LINE HOT  
LOAD HOT  
262  
229B  
224  
237  
247  
246  
239A  
115  
V
GND-F  
J12  
D
E
F
227  
232  
226  
234  
233  
243  
285  
245  
CONTACTOR  
GROUND  
WELDED STUD  
FRAME GROUND  
240  
2D  
ON OUTPUT PANEL  
GFCI  
5G  
LOAD  
LINE  
240A  
242I  
WHITE  
WHITE  
8
240  
AMPHENOL  
2
SELECTOR SWITCH (S8)  
242I  
FRAME GROUND  
5J  
242H  
POSITION  
NAMEPLATE SETTING  
9A  
9
ENGINE TO PCB HARNESS  
1
2
NO FUNCTION  
LINE HOT  
LOAD HOT  
5C  
WIRE WELDING CV  
232A  
232  
233  
115  
V
J11  
HOLD  
COIL  
START BUTTON  
S2  
HOLD  
COIL  
3
90 MAX.  
224  
240  
262  
226  
227  
237  
254  
4
5
120 MAX.  
180 MAX.  
256  
232H  
267  
5H  
SHUTDOWN  
SOLENOID  
IDLE  
SOLENOID  
9
GFCI  
5E  
RUN  
LINE  
LOAD  
S3  
WHITE  
WHITE  
6
7
8
9
230 MAX.  
270 MAX.  
400 MAX.  
50-575  
PULL  
PULL  
COIL  
HIGH  
IDLER  
225  
STOP  
COIL  
SWITCH  
WHITE  
SOLENOID GROUND  
STUD ON ENGINE  
AUTO  
S4  
233A  
32  
5K  
236A  
T3  
231A  
236B  
INSULATED STUD  
IN CONTROL BOX  
15A  
255  
3
6
CB4  
HOUR  
METER  
239B  
-
236A  
GND-C  
3B  
J10  
115/230V  
NOTE: DIODE APPEARS ON  
SOME MODELS BUT  
BOLT ON  
SENDER  
BRACKET  
PANEL TO PANEL WIRES  
236C  
231A  
242G  
REPLACED BY LEAD  
285 ON NEWER MODELS.  
15A  
239A  
STARTER  
SOLENOID  
3D  
PANEL TO PCB HARNESS  
CB3  
CB2  
3A  
231B  
286  
11  
12  
232C  
232B  
(+)  
(-)  
285  
OIL PRESSURE SWITCH  
&
SENSOR  
STARTING  
MOTOR  
50A  
232F  
50A  
6B  
229B  
D2  
3A  
245  
232A  
246  
247  
CB1  
12  
12 VOLT  
BATTERY  
228  
SENSOR  
OIL  
P16  
234  
T1 INSULATED STUD  
IN CONTROL BOX  
J16  
243  
ALT.  
SWITCH  
FUEL  
G
WHITE  
TERM.  
AMMETER  
WK  
PRESS.  
TEMP.  
S
1
2
5H  
6A  
OIL TEMP. SENSOR  
SENSOR  
&
SWITCH  
11  
LOW  
PRESS.  
S
STUD ON ENGINE  
MOUNT CHANNEL  
S
ALTERNATOR  
281  
LOW  
TEMP.  
FUEL  
228A  
241A  
242D  
229A  
EXC  
3
4
5
-
SENSE  
-
-
233A  
-
241  
POS  
NEG  
3D  
241A  
SWITCH  
232G  
242C  
229A  
STAINLESS STEEL  
238  
228A  
236C  
232D  
232E  
STAND-OFF  
242E  
229  
242A  
FUEL LVL.  
SENSOR  
STUD ON GENERATOR  
MOUNT CHA  
239  
242G  
STUD ON  
ENGINE  
NNEL  
AUXILIARY BYPASS PCB  
6
7
8
9
242  
242B  
242D  
ENGINE TO PANEL HARNESS  
238  
B4  
9A  
B5  
B6  
B7  
8A  
239  
ENGINE TO PANEL HARNESS  
239B  
INSTRUMENT PANEL  
GROUND SCREW  
IN CONTROL BOX  
GND-F  
GND-H  
FRAME  
GROUND  
5C  
ENGINE GROUND  
5C  
242  
5K  
5J  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-4  
G-4  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - STICK MODEL (CODE 10580)  
3D  
5D  
CONNECTOR CAVITY NUMBERING SEQUENCE  
(VIEWED FROM COMPONENT SIDE OF BOARD)  
1008  
T1  
1002  
1006  
1004  
287  
NEXT AVLB.  
5D  
5
273  
7
240A  
9
268  
3
270  
1
272  
6
274  
4
3D  
10  
269  
2
CAPACITOR  
G1  
G2  
G3  
204A  
RECTIFIER  
1
4
3
1
6
6
5
1
7
8
204S  
206S  
207  
ASSEMBLY  
204B  
6
10  
12  
2
1009  
1013  
J3 ,J31,J60  
J8  
J6 ,J50  
J50  
1015  
EXCITER VOLTAGE  
FEEDBACK BOARD  
1011  
1
3
1
9
8
1
7
POS.  
W2  
CONNECTIONS TO  
CAPACITORS MADE  
VIA BOLTED  
STAINLESS STEEL  
STAND-OFF  
600 AMP  
SHUNT  
W5  
W3  
SCR  
C
240 uF  
SCR  
B
SCR  
A
4
16  
14  
8
1
CONNECTIONS  
J1,J2  
BYPASS PC  
BOARD  
,J30  
J5  
W4  
W3  
J7  
DD  
ELECTRICAL SYMBOLS PER E1537  
W6  
1010  
1017  
STATOR  
FRAME GROUND  
1014  
1021  
50 Ohm  
100  
4
8
1012  
1019  
1016  
W
OUTPUT  
CHOKE  
209  
W6  
DB  
DC  
DA  
5
T2  
W1  
NEG.  
CC  
,J23 ,J61  
TOROID  
J4  
W4  
W5  
223  
260  
261  
204  
217  
1
1023  
SELECTOR SWITCH  
S8  
4
2
3
TOROID  
T3  
3D  
(VIEWED FROM BACK)  
W1  
W2  
218  
219  
5
216  
215  
(SEE SELECT SWITCH CHART)  
6
9
W6  
4
J30  
240 uF  
77C  
76C  
7
3
2
FINE CONTROL  
POT  
A
SNUBBER PC BOARD  
220  
221  
STAINLESS STEEL  
STAND-OFF  
5D  
214  
213  
8
AUXILIARY BYPASS PCB  
222  
1018  
1022  
REMOTE/  
LOCAL  
SWITCH  
S1  
1
CW  
1024  
T3  
1020  
B4  
B5  
B6  
B7  
VIEWED FROM  
75  
FRAME GROUND  
EXCITER  
76B  
77B  
BACK  
G3  
206S  
G1  
1
206  
270  
1
268  
274  
273  
WINDINGS  
279  
280  
8
207  
10  
269  
2
272  
6
204A  
G2  
2
204S  
2
75B  
6
76  
76  
77  
256  
CONTROL HARNESS  
4
77  
75  
5
255  
1001  
1002  
1005  
1006  
1003  
1004  
1007  
1008  
9A  
T1  
T2  
2
2B  
5K  
8
11  
12  
2
3
9
1
10  
4
5
1
2
3
4
8
9
4
7
3
7
3
4
6
7
3
5J  
6
OUTPUT  
CONTROL  
SOURCE  
S6  
8A  
5A  
5
240 uF  
ALWAYS ON  
OUTPUT REMOTELY  
CONTROLLED  
213  
1
J1  
J4  
J6  
J8  
4
4B  
214  
215  
216  
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
CONNECTIONS ON CONTROL BOARD  
(VIEWED AS INSTALLED)  
1
2
3
4
6
8
15  
16  
250  
CONTROL HARNESS  
ENGINE  
PROT.  
251  
252  
253  
MOTHER  
217  
218  
219  
220  
BOARD  
CONTROL  
PC BOARD  
TOROID  
J5  
SPI  
SCI  
1
2
3
4
5
6
7
8
A
B
C
2D  
77D  
76D  
75D  
4D  
J23  
B2  
B1  
B3  
5J  
8A  
REMOTE  
CONTROL  
4B  
2B  
75D  
J7  
E1  
E2  
3
J2 J6 J5J8 J7 J1  
J4 J3  
76D  
4D  
5K  
9A  
221  
222  
5A  
5
75B  
77C  
4
3
2
1
D
E
TRIGGER  
GROUND  
ENGINE PROT.  
J3  
2D  
J61  
6
3
STAINLESS STEEL  
STAND-OFF  
J23  
5D  
5E  
BOARD  
77D  
J40  
242I  
F
STAINLESS STEEL  
STAND-OFF  
B1  
B3  
B2  
5C  
COMMON BATT.  
AMPHENOL  
2
METER  
NEUTRAL T2 STUD  
IN CONTROL BOX  
1
5
6
5
6
7
2
3
4
1
8
3
4
76C  
PCB  
REMOTE PROTECTION PCB  
(optional)  
E2  
E1  
1
4
J2  
AUX. POWER  
227  
232  
GROUND SCREW  
229B  
243  
224  
237  
247  
246  
239A  
5G  
262  
ON CONTROL PANEL  
285  
226  
234  
233  
FRAME GROUND  
245  
GND-C  
GND-D  
GND-E  
FRAME GROUND  
240  
242I  
240A  
240  
ENGINE TO PCB HARNESS  
8
GND-A  
8A  
SELECTOR SWITCH (S8)  
POSITION NAMEPLATE SETTING  
START BUTTON  
S2  
LOAD HOT  
280  
279  
GND-E  
GND-D  
LINE HOT  
232A  
232  
256  
255  
233  
120  
V
HOLD  
COIL  
GND-F  
HOLD  
COIL  
J12  
1
2
3
4
NO FUNCTION  
NO FUNCTION  
90 MAX  
224  
225  
5K  
9A  
5J  
8A  
240  
226  
227  
237  
254  
AUX. CURRENT  
SENSE TOROID  
232H  
267  
WELDED STUD  
HIGH  
AUTO  
IDLER  
SHUTDOWN  
SOLENOID  
ON OUTPUT PANEL  
IDLE  
SOLENOID  
RUN  
GFCI  
5G  
WHITE  
LINE  
5H  
LOAD  
WHITE  
SWITCH  
S3  
120 MAX  
PULL  
COIL  
PULL  
COIL  
STOP  
S4  
262  
5
6
7
8
9
180 MAX  
230 MAX  
270 MAX  
400 MAX  
50-575  
8
236B  
231A  
5J  
233A  
236A  
9A  
9
SOLENOID GROUND  
STUD ON ENGINE  
LINE HOT  
LOAD HOT  
5C  
HOUR  
236A  
236C  
METER  
239B  
-
120  
V
J11  
8A  
5J  
PANEL TO PANEL WIRES  
231A  
242G  
STARTER  
GFCI  
5E  
239A  
LOAD  
WHITE  
LINE  
WHITE  
BOLT ONTO  
SENDER BRK'T  
9A  
5K  
PANEL TO PCB HARNESS  
232C  
SOLENOID  
286  
WHITE  
5K  
(+)  
(-)  
232B  
OIL PRESSURE SWITCH  
SENSOR  
STARTING  
MOTOR  
T3  
&
232F  
229B  
245  
232A  
246  
INSULATED STUD  
IN CONTROL BOX  
247  
12 VOLT  
9
15A  
228  
241  
SENSOR  
3
6
P16  
234  
J16  
OIL  
SWITCH  
243  
CB4  
BATTERY  
G
WK  
FUEL  
GND-C  
AMMETER  
-
TEMP.  
PRESS.  
1
2
3
4
5
6
7
8
9
285  
3B  
J10  
OIL TEMP. SENSOR  
SENSOR  
&
SWITCH  
SILVER  
120/240V  
LOW  
S
S
S
ALTERNATOR  
PRESS.  
STUD ON ENGINE  
MOUNT CHANNEL  
LOW  
TAB  
ALT.  
TEMP.  
228A  
EXC  
LARGE  
TAB  
SENSE  
15A  
FUEL  
233A  
-
-
-
3D  
POS  
NEG  
241A  
242D  
229A  
CB3  
3A  
SWITCH  
241A  
232G  
229A  
238  
228A  
236C  
232D  
232E  
242E  
229  
12  
FUEL LVL.  
SENSOR  
11  
242A  
242D  
242C  
239  
STUD ON  
ENGINE  
242G  
SMALL  
TAB  
50A  
50A  
6B  
GND-H  
242  
242B  
242  
SILVER  
TAB  
CB1  
CB2  
238  
T1 INSULATED STUD  
IN CONTROL BOX  
239  
239B  
ENGINE HARNESS TO PANEL WIRES  
WHITE  
TERM.  
CONTROL PANEL  
GROUND SCREW  
GND-F  
ENGINE HARNESS  
SILVER  
TAB  
5H  
6A  
5C  
12  
ENGINE GROUND  
5C  
STUD ON GENERATOR  
MOUNT CHANNEL  
11  
3D  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-5  
G-5  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - STICK & WIRE MODEL (CODE 10581)  
CONNECTOR CAVITY NUMBERING SEQUENCE  
(VIEWED FROM COMPONENT SIDE OF BOARD)  
6
3D  
6
NEXT AVAILABLE 287  
5D  
1008  
3
3
1
3
1
2
1
1
5
4
1002  
1006  
1004  
240A  
9
5D  
5
273  
7
268  
3
270  
1
NOTE:  
274  
4
272  
6
3D  
10  
269  
2
3
4
4
6
5
8
6
10  
8
279  
T1  
NO CONNECTION  
ON NEWER MODELS  
6
6
206  
J3  
J1,J2  
J4 ,J23  
J6,J20  
280  
G1  
G2  
G3  
204A  
277  
G4  
3
3
1
9
1
7
6
1
8
8
7
RECTIFIER  
204S 206S  
208  
ASSEMBLY  
207  
1009  
1013  
16  
12  
14  
POS.  
J50  
1015  
EXCITER VOLTAGE  
FEEDBACK BOARD  
1011  
J5  
204C  
J8  
SCR  
1
J7  
W5  
CONNECTIONS TO  
CAPACITORS MADE  
VIA BOLTED  
206A  
ELECTRICAL SYMBOLS PER E1537  
600 AMP  
SHUNT  
204B  
W2  
CURRENT  
SENSE TOROID  
DE  
SCR  
C
SCR  
B
SCR  
A
240 uF  
206A  
CONNECTIONS  
285  
285A  
BYPASS PC  
BOARD  
W1  
30,000 uF  
W4  
DD  
ELECTRODE  
POLARITY  
SWITCH  
NEG.  
POS.  
1010  
1017  
STATOR  
1014  
1021  
1012  
1019  
1016  
OUTPUT  
L1  
FRAME  
CHOKE  
C1-C4  
209  
GROUND  
S5  
21  
DB  
DC  
DA  
T2  
CC  
208A  
NEG.  
223  
W3  
W6  
260  
261  
204  
209A  
284B  
284A  
284  
W4  
W1  
CV CHOKE  
L2  
CV  
208A  
1023  
T3  
3D  
W2  
W3  
(VIEWED  
SELECTOR  
SWITCH  
217  
240 uF  
FROM BACK)  
SEE CHART  
S8  
216  
77C  
76C  
FINE CONTROL  
POT  
W5  
W6  
218  
219  
5D  
21  
5
4
6
1
4
2
3
1018  
1022  
REMOTE/  
215  
7
3
2
CW  
LOCAL  
2
2B  
1024  
T3  
1020  
A
V
220  
221  
J30  
214  
213  
SWITCH  
S1  
8
VOLT/AMP  
SWITCH  
S9  
282  
VIEWED FROM  
BACK  
OUTPUT  
222  
75  
EXCITER  
77B  
76B  
3
6
3
6
ALWAYS ON  
283  
CONTROL  
SOURCE  
S6  
9
1
WINDINGS  
OUTPUT REMOTELY  
CONTROLLED  
A
76  
77  
4B  
4
1001  
1002  
1005  
1006  
206  
8
G3  
3
206S  
G1  
2
75B  
6
76  
8
256  
270  
1
268  
3
273  
7
274  
5
1003  
1004  
1007  
1008  
4
77  
9
75  
5
255  
11  
T2  
T1  
279  
4
280  
8
207  
10  
269  
2
272  
6
204A  
6
G2  
204S  
3
6
5A  
5
240 uF  
2
3
2
9
1
10  
12  
1
2
3
4
1
4
7
4
7
RF BYPASS  
PC BOARD  
21  
J20  
J
31  
213  
1
2
3
4
5
6
7
8
9
10  
11  
12  
1
6
J1  
115AC  
J4  
A
J6  
32A  
4E  
214  
215  
216  
J8  
7
CONNECTIONS ON CONTROL BOARD  
J21  
77C  
5
D
4
3
2
1
5
6
7
8
253  
252  
251  
(VIEWED AS INSTALLED)  
J61  
4
8
3
2
5
75B  
CONTACTOR  
WORK  
5A  
G4  
282  
MOTHER  
CV  
C
H
E
2E  
ENGINE  
E1  
76C  
2B  
E2  
BOARD  
PROT.  
CONTROL  
BOARD  
217  
218  
219  
220  
21  
5D  
5E  
4B  
PC BOARD  
250  
32A  
77E  
76E  
75E  
3
6
J5  
5C  
77E  
76E  
6
4
3
2
277  
REMOTE  
CONTROL  
J21  
J23  
F
SPI  
SCI  
4E  
NEUTRAL T2 STUD  
IN CONTROL BOX  
J7  
283  
208  
B1 B2 B3  
31  
G
I
J62  
J2  
J5 J8 J7  
J1 J4 J3  
J6  
75E  
221  
222  
2E  
1
1
5H  
4
2
3
5
AUX. POWER  
ENGINE PROT.  
K
B
J3  
GROUND SCREW  
IN CONTROL BOX  
STAINLESS STEEL  
STAND-OFF  
5G  
BOARD  
J23  
242H  
J40  
CV DAUGHTER BOARD  
GROUND  
GND-C  
GND-D  
GND-E  
8A  
B1  
B3  
B2  
COMMON BATT.  
METER  
PCB  
CB5 15AMP  
13  
14  
AMPHENOL  
1
5
2
6
1
3
4
1
5
6
5
6
7
2
3
4
1
8
3
4
242I  
242H  
75D  
77D  
2D  
76D  
4D  
A
B
C
77D  
76D  
75D  
4D  
8
REMOTE  
CONTROL  
GND-A  
J60  
E2  
E1  
1
4
J2  
LOAD HOT  
GND-E  
GND-D  
LINE HOT  
262  
229B  
224  
237  
247  
246  
239A  
115  
V
GND-F  
J12  
D
E
F
227  
232  
226  
234  
233  
243  
285  
245  
CONTACTOR  
GROUND  
WELDED STUD  
FRAME GROUND  
240  
2D  
ON OUTPUT PANEL  
GFCI  
5G  
LOAD  
WHITE  
LINE  
240A  
242I  
WHITE  
8
240  
AMPHENOL  
2
SELECTOR SWITCH (S8)  
242I  
FRAME GROUND  
5J  
242H  
POSITION  
NAMEPLATE SETTING  
9A  
9
ENGINE TO PCB HARNESS  
1
2
3
4
5
6
7
8
9
NO FUNCTION  
WIRE WELDING CV  
90 MAX.  
120 MAX.  
180 MAX.  
230 MAX.  
270 MAX.  
400 MAX.  
50-575  
LINE HOT  
LOAD HOT  
5C  
232A  
232  
233  
115  
V
J11  
HOLD  
COIL  
START BUTTON  
S2  
HOLD  
COIL  
224  
240  
262  
226  
227  
237  
254  
256  
232H  
267  
5H  
SHUTDOWN  
SOLENOID  
IDLE  
SOLENOID  
9
GFCI  
5E  
RUN  
LINE  
LOAD  
WHITE  
S3  
WHITE  
PULL  
PULL  
COIL  
HIGH  
IDLER  
225  
STOP  
COIL  
SWITCH  
WHITE  
SOLENOID GROUND  
STUD ON ENGINE  
AUTO  
S4  
233A  
32  
5K  
236A  
T3  
231A  
236B  
INSULATED STUD  
IN CONTROL BOX  
15A  
255  
3
6
CB4  
HOUR  
METER  
239B  
-
236A  
GND-C  
3B  
J10  
BOLT ON  
SENDER  
BRACKET  
PANEL TO PANEL WIRES  
236C  
231A  
115/230V  
242G  
15A  
50A  
239A  
STARTER  
SOLENOID  
3D  
PANEL TO PCB HARNESS  
232C  
CB3  
3A  
286  
11  
12  
232B  
(+)  
(-)  
285  
OIL PRESSURE SWITCH  
&
SENSOR  
SWITCH  
STARTING  
MOTOR  
50A  
232F  
6B  
229B  
245  
232A  
246  
247  
CB1  
12  
CB2  
12 VOLT  
228  
SENSOR  
G
OIL  
P16  
234  
T1 INSULATED STUD  
IN CONTROL BOX  
J16  
243  
ALT.  
BATTERY  
FUEL  
WHITE  
TERM.  
AMMETER  
-
WK  
PRESS.  
TEMP.  
1
2
3
4
5
6
7
8
9
5H  
6A  
OIL TEMP. SENSOR  
SENSOR  
&
SWITCH  
11  
LOW  
S
STUD ON ENGINE  
MOUNT CHANNEL  
S
S
-
PRESS.  
ALTERNATOR  
LOW  
TEMP.  
FUEL  
228A  
241A  
242D  
229A  
EXC  
-
SENSE  
-
233A  
241  
POS  
NEG  
3D  
241A  
SWITCH  
232G  
229A  
STAINLESS STEEL  
238  
228A  
236C  
232D  
232E  
STAND-OFF  
242E  
229  
242A  
242D  
FUEL LVL.  
SENSOR  
242C  
STUD ON GENERATOR  
239  
242G  
STUD ON  
ENGINE  
ANNEL  
MOUNT CH  
AUXILIARY BYPASS PCB  
242  
242B  
ENGINE TO PANEL HARNESS  
238  
B4  
B5  
B6  
B7  
8A  
239  
ENGINE TO PANEL HARNESS  
239B  
INSTRUMENT PANEL  
GROUND SCREW  
IN CONTROL BOX  
GND-F  
GND-H  
FRAME  
5C  
GROUND  
ENGINE GROUND  
5C  
242  
9A  
5K  
5J  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-6  
G-6  
ELECTRICAL DIAGRAMS  
SCHEMATIC - AMPHENOL BYPASS PC BOARD  
1 7 9 M 0 0  
J62  
5
L4  
J61  
J61  
J61  
J61  
J61  
J60  
J60  
J60  
J60  
J60  
J60  
1
5
4
1
.39mH  
C4  
.0047  
3000V  
J62  
J62  
4
4E  
2E  
L5  
2
3
4
5
4B  
2B  
4D  
.39mH  
C5  
.0047  
3000V  
TP1  
150V  
80J  
1
TO "OUTPUT CONTROL SOURCE" SWITCH  
L1  
2D  
.39mH  
C1  
.0047  
3000V  
J62  
J62  
J62  
2
6
3
75E  
77E  
76E  
L2  
2
6
3
TO MOTHER CONTROL PCB  
75B  
77C  
76C  
75D  
77D  
76D  
.39mH  
C2  
.0047  
3000V  
TP2  
150V  
80J  
L6  
.39mH  
C6  
.0047  
3000V  
TP4  
150V  
80J  
TP3  
150V  
80J  
TO "REMOTELOCAL" SWITCH  
L3  
J61  
J61  
8
7
.39mH  
C3  
.0047  
3000V  
FILENAME: M17900_1AB  
GENERAL INFORMATION  
ELECTRICAL SYMBOLS PER E1537  
LAST NO. USED  
R-  
C-  
L-  
_
6
6
CAPACITORS  
RESISTORS  
DIODES  
=
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
LABELS  
=
Ohms  
(
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
SUPPLY  
VOLTAGE NET  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
NOTES :  
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
COMPLETE BOARD, THIS DIAGRAM MAY  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF  
A
FRAME CONNECTION  
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING  
NUMBER.  
A
COMMON CODE  
EARTH GROUND CONNECTION  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
ON HOLES SIZES PER E-2056  
Ch’ge.Sht.No.  
XB-UF  
EQUIP.  
TYPE  
COMMANDER 400 STICK & WIRE  
AMPHENOL BYPASS SCHEMATIC  
THE LINCOLN ELECTRIC CO.  
CLEVELAND, OHIO U.S.A.  
ON  
ON  
2
3
PLACE DECIMALS IS  
PLACE DECIMALS IS  
+
+
.O2  
.OO2  
12-13-96  
SUBJECT  
ON ALL ANGLES IS  
+
.5 OF  
A
DEGREE  
NONE  
SCALE  
MATERIAL TOLERANCE ("t") TO AGREE  
WITH PUBLISHED STANDARDS  
SHT.  
M17900  
JB  
I.E.B.  
/
F.V.  
3/9/95  
CHK.  
SUP’S’D’G.  
DR.  
DATE  
NO.  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-7  
G-7  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - AMPHENOL BYPASS PC BOARD  
COMMANDER 400  
S & W  
XXXXXXXXX  
TP2  
L6  
TP3  
TP1  
L9892-1  
ITEM  
REQ’D  
IDENTIFICATION  
PART NO.  
L4  
L5  
.0047/3000V  
C1, C2, C3, C4, C5, C6  
6
2
1
TP4  
T11577-58  
S18248-6  
XXXXXXXXX  
HEADER  
CONNECTOR  
.39mH  
J60, J62  
J61  
S18248-8  
T12218-9  
T13640-16  
XXXXX  
X
X
L1, L2, L3, L4, L5, L6  
TP1, TP2, TP3, TP4  
6
4
C4  
80J  
XXXXX  
X
X
X
X
X
X
C5  
XXXXX  
X
C1  
CAPACITORS = MFD/VOLTS  
INDUCTANCE = HENRYS  
XXXXX  
X
C2  
XXXXX  
X
C3  
XXXXX  
X
L9892-1  
12-13-96  
C6  
XXXXX  
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 pro-  
vided 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-8  
G-8  
ELECTRICAL DIAGRAMS  
SCHEMATIC - AUXILIARY PROTECTION PC BOARD  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-9  
G-9  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - AUXILIARY PROTECTION PC BOARD  
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
B4  
B5  
B6  
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
X
X
X
L9749-1X  
X
X
X
X
X
X
X
X
X X  
X
X
X
X
X X  
X
X
AUXILIXARYXPROTECTION  
X
X
X
X
X X  
REQ’D PART NO.  
DESCRIPTION  
ITEM  
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 pro-  
vided 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-10  
G-10  
ELECTRICAL DIAGRAMS  
SCHEMATIC - BYPASS PC BOARD  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-11  
G-11  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - BYPASS PC BOARD  
~.04  
4.50  
2.98  
4.15  
~.04  
3.80  
ITEM  
REQ'D  
IDENTIFICATION  
.22/400V  
PART NO.  
S20500-3  
C1,C2,C3  
3
C4,C5,C6,C7,C8,C9,C10,C11  
C12,C13,C14,C15,C16,C17  
TP1,TP2,TP3,TP4,TP5  
15  
T11577-52  
.0047 or .005/1400  
,C18  
B2  
B3  
5
T13640-16  
80J  
3.50  
3.28  
x
x
C13  
C12  
C11  
x
x
x
CAPACITORS = MFD/VOLTS  
INDUCTANCE = HENRYS  
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
TP4  
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x x x  
x
C3  
x x  
x
x
x x  
x x  
x
x
x
x
x
x
x
x
x x  
C2  
x
x
x
x
x
x
x
x
x x  
x x x x x  
x
x
x
x
x
L9573-1  
10-11-96B  
x
x
x
x
x
x
x
x
TP2  
x
x
TP3  
C10  
x
x
x
xxx  
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  
C1  
x
x
x
x
x
xxxxxxx  
x C8  
x
x
x
x
x
x
xxCx9xx  
x
x
x
x
x
x
x
x
x C7  
x
B1  
x
x
x
x
x
x
x C6  
x
.82  
.60  
x
x
x
x
x
x
L9573-1  
C5  
x
x
x
x
x
x
x
x
C4  
BYPASS  
x
x
x
x
x x  
x x x  
0
1.48  
.30  
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 pro-  
vided 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-12  
G-12  
ELECTRICAL DIAGRAMS  
SCHEMATIC - CONTROL PC BOARD PART 1  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-13  
G-13  
ELECTRICAL DIAGRAMS  
SCHEMATIC - CONTROL PC BOARD PART 2  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-14  
G-14  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - CONTROL PC BOARD  
IDENTIFICATION  
ITEM  
IDENTIFICATION  
ITEM  
REQ'D  
PART NO.  
REQ'D  
PART NO.  
X X X X  
X
X
X
X
X
X X  
XXX  
X
X
X
X
X
X
X
XXXXXXX  
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
XXXX  
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
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
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
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 XX  
X X  
X
X
X X  
X
X
X
XX  
X
X
X
X
X
X
X
X
X
XXXX  
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
XXX  
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X  
XXX  
XX XX  
X
X
XXX  
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
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
XX  
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
XX  
X
X
X
X X  
X
X
X X  
X X  
X X  
X X  
X
X
X
X
X
XXXX  
XXXX  
XXXXXXX  
X
X
X
X
X
XX  
X X  
XXX  
X
X
X
X
X
X
XX XX  
X
X
X
X
X
XX XX  
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
XXXXXXXXX  
XXXX  
XXXXXXXXX  
X
X
XXXX  
X X X X  
X X X X  
X
X
X
X
X
X
X X  
X
X
X
X
X
XXXXXXXXX  
XXXX  
XXXXXXXXX  
X
X
X
X
X
XXXX  
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
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
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
X
X
X
X
CAPACITORS  
RESISTORS  
=
MFD/VOLTS  
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
= OHMS  
X
X
X
X
X
X
X
X X  
X X  
G2713-3  
10-22-99B  
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 pro-  
vided 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-15  
G-15  
ELECTRICAL DIAGRAMS  
SCHEMATIC - CV CONTROL PC BOARD  
M
1 7 7 4 1  
+10v  
+10v  
J20  
5
12  
J21  
14  
2
R10  
100  
R11  
X1  
13  
V/A SWITCH  
A
J20  
1.00K  
C2  
0.1  
50V  
8
V
com  
com  
J20  
6
J21  
5
R12  
100  
J20  
+15 CVSCR  
3
D3  
C3  
0.1  
50V  
5W  
68  
5W  
68  
10K  
-CV STUD  
J21  
6
J20  
7
D2  
L1  
3.32K  
.33mH  
com  
10K  
Q2  
100V  
1A  
R14  
R15  
R18  
R19  
J20  
Q1  
DZ1  
15V  
1W  
15.0K  
10.0K  
26.7K  
28.0K  
R3  
600mA  
40V  
2
1.00K  
J20  
OCI1  
1
6
5
DZ2  
5
CV MODE ENABLE  
FROM MCU  
CNY17-3  
10  
J21  
X1  
D1  
1
7
10.0  
SCR 1 GATE  
10V  
1W  
R16  
R17  
6.19K  
6.81K  
GATE DRIVE FOR  
SCR 1  
2
6
4
J20  
C1  
1.8  
20V  
1
562  
562  
com  
C5  
475K  
J20  
4
J21  
4
SCR 1 CATH  
CVSCR COM  
GENERAL INFORMATION  
ELECTRICAL SYMBOLS PER E1537  
LAST NO. USED  
R- 19  
+10v  
+10v  
C-  
D-  
5
3
CAPACITORS  
RESISTORS  
DIODES  
=
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
2
3
LABELS  
=
Ohms  
(
X1  
4
NOTES :  
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
1
SUPPLY  
VOLTAGE NET  
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
COMPLETE BOARD, THIS DIAGRAM MAY  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
C4  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF  
A
X1  
0.1  
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING  
NUMBER.  
A
COMMON CODE  
NOT USED  
50V  
FRAME CONNECTION  
33074A  
EARTH GROUND CONNECTION  
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY  
THE LINCOLN ELECTRIC CO.  
11  
9
FILE: M17741_1AE  
AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF  
THE LINCOLN ELECTRIC CO.  
X1  
8
UNLESS OTHERWISE SPECIFIED TOLERANCE  
ON HOLES SIZES PER E-2056  
LAST CHANGE  
EQUIP.  
TYPE  
10  
com  
COMMANDER 400 S & W  
THE LINCOLN ELECTRIC CO.  
CLEVELAND, OHIO U.S.A.  
XA  
ON  
ON  
2
3
PLACE DECIMALS IS  
PLACE DECIMALS IS  
+
+
.O2  
.OO2  
CV CONTROL PC BRD SCHEMATIC  
12-13-96  
SUBJECT  
com  
ON ALL ANGLES IS  
+
.5 OF  
A
DEGREE  
NONE  
SCALE  
MATERIAL TOLERANCE ("t") TO AGREE  
WITH PUBLISHED STANDARDS  
SHT.  
BS  
I.E.B./JB  
9/14/94  
DATE  
CHK.  
SUP’S’D’G.  
M
17741  
DR.  
NO.  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-16  
G-16  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - CV CONTROL PC BOARD  
REQ’D  
PART NO.  
DESCRIPTION  
ITEM  
L1  
R12  
XXX  
XXX  
XXX  
XXX  
R9  
X
X
X
X
R6  
R8  
C5  
R4  
Q1  
D2  
X
X
X
R7  
X
J 2 0  
L9560  
12-13-96  
CAPACITORS = MFD/VOLTS  
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 pro-  
vided 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-17  
G-17  
ELECTRICAL DIAGRAMS  
SCHEMATIC - ENGINE PROTECTION PC BOARD  
M
1 7 5 0 0  
OIL TEMP SWITCH F.B.  
FROM OIL TEMP SWITCH  
TO OIL TEMP SHUT-  
DOWN LOGIC INPUT  
P23  
5
P22  
9
P23  
7
R1  
6
TO ALT  
LED  
267  
267  
267  
267  
267  
267  
267  
267  
10.0  
P22  
R26  
R28  
R30  
R32  
R27  
R29  
R31  
C1  
P23  
4
P22  
2
1
16  
15  
14  
13  
12  
11  
I0  
O0  
O1  
TO OIL  
PRESS LED  
0.1  
X3  
2
3
4
5
6
7
8
50V  
I1  
P23  
8
I2  
O2  
P22  
TO OIL  
TEMP LED  
10  
I3  
O3  
R33  
P23  
3
COMMON (EPD)  
COMMON (EPD)  
I4  
O4  
TO FUEL  
LVL LED  
P22  
3
FROM FUEL LEVEL SENDER  
POST ON FUEL GAUGE  
I5  
O5  
10  
I6  
O6  
+5V BATT  
P23  
6
9
GND  
CLAMP  
MC1413BP  
D2  
D3  
D4 D5  
CONTROL  
PCB  
DZ3  
20V  
1W  
DZ5  
20V  
1W  
4.75K  
FUEL LEVEL F.B.  
LAMP DRIVER  
4.75K  
DZ4  
20V  
1W  
DZ6  
20V  
1W  
TO FUEL SHUT-  
DOWN LOGIC INP  
LM2901  
14  
R6  
8
9
COMMON (EPD)  
4.75K  
X1  
12  
C2  
0.1  
DZ1  
10V  
1W  
P22  
P22  
1
50V  
+12V BATT.  
COMMON (EPD)  
5K  
13  
4.75K  
R9  
2
1
P22  
68.1K  
CW  
3
P22  
8
COMMON (EPD)  
22.1K  
P22  
11  
+5V BATT  
3.92K  
+5V BATT  
TO LAMPS  
ON/OFF INPUT  
P23  
2
COMMON (EPD)  
4
P22  
COMMON (EPD)  
+5V BATT  
2 SEC LAMPS  
ON TEST TIMER  
10.0K  
D1  
1.00K  
51.1K  
LM2901  
R20  
4
5
Q1  
4.75K  
R25  
X1  
2N4401  
2
FROM SENSE  
CONNECTION ON ALT  
ALT VOLTAGE F.B.  
1.00K  
5.11K  
10.0K  
C6  
P23  
1
TO ALT SHUT-  
C5  
27  
LM2901  
R18  
R10  
R12  
DOWN LOGIC INP  
0.1  
4.75K  
35V  
6
7
10.0K  
50V  
3.01K  
4.75K  
X1  
14  
1
P22  
C3  
DZ2  
10V  
1W  
0.1  
1.00K  
50V  
COMMON (EPD)  
COMMON (EPD)  
C4  
0.1  
50V  
4.75K  
R15  
22.1K  
FILE: M17500_1BA  
GENERAL INFORMATION  
COMMON (EPD)  
COMMON (EPD)  
10  
ELECTRICAL SYMBOLS PER E1537  
LM2901  
CAPACITORS  
RESISTORS  
DIODES  
=
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
+5V BATT  
LABELS  
=
Ohms  
(
NOTES :  
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
X1  
SUPPLY  
VOLTAGE NET  
13  
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
11  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF  
A
COMPLETE BOARD, THIS DIAGRAM MAY  
LAST NO. USED  
3
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING  
NUMBER.  
A
COMMON CODE  
+5V BATT  
R- 34  
C- 10  
DZ-  
X-  
6
FRAME CONNECTION  
C10  
3
COMMON (EPD)  
X1  
D-  
5
EARTH GROUND CONNECTION  
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  
THE LINCOLN ELECTRIC CO.  
P22  
5
LM2901  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
ON HOLES SIZES PER E-2056  
Ch’ge.Sht.No.  
EQUIP.  
TYPE  
P22  
7
COMMANDER 400  
12  
THE LINCOLN ELECTRIC CO.  
CLEVELAND, OHIO U.S.A.  
12-15-95A  
ON  
ON  
2
3
PLACE DECIMALS IS  
PLACE DECIMALS IS  
+
+
.O2  
.OO2  
ENGINE PROTECTION P.C. BD. SCHEMATIC  
SUBJECT  
ON ALL ANGLES IS  
MATERIAL TOLERANCE ("t") TO AGREE  
WITH PUBLISHED STANDARDS  
+
.5 OF  
A
DEGREE  
TO COMMON  
(BATT)  
NONE  
SCALE  
SHT.  
COMMON (EPD)  
FV  
B.K.  
05-12-95  
CHK.  
SUP’S’D’G.  
M17500  
DR.  
DATE  
NO.  
COMMON (EPD)  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
COMMANDER 400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-18  
G-18  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - ENGINE PROTECTION PC BOARD  
REQ’D  
PART NO.  
DESCRIPTION  
ITEM  
L9596-1  
X3  
R8  
R7  
R14  
XXX  
XXX  
XXX  
XXX  
XXX  
Q1  
C4  
R13  
R12  
C6  
X1  
COMMANDER 400  
ENGINE PROTECTION  
L9596-1  
8-14-98C  
CAPACITORS = MFD/VOLTS  
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 pro-  
vided 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-19  
G-19  
ELECTRICAL DIAGRAMS  
SCHEMATIC - METER PC BOARD  
1 7 6 3 7  
M
+5V  
D1  
R31  
R35  
20.0  
+15V  
+5V  
20.0  
R40  
10.0  
Q5  
3A  
R32  
20.0  
R36  
20.0  
100V  
2
3
14  
14  
14  
14  
14  
X6  
R41  
10.0  
IN  
OUT  
R33  
20.0  
R37  
20.0  
C9  
C10  
0.1  
50V  
C11  
4.7  
35V  
C2  
C3  
C4  
C7  
C8  
X1  
X2  
X3  
X5  
R42  
10.0  
.33  
GND  
1
X4  
54HC74  
50V  
74HC164  
74HC164  
74HC164  
HEXINV  
R34  
20.0  
R38  
20.0  
7
7
7
7
7
R39  
200  
DZ2  
10V  
1W  
3
8
3
8
3
8
1
1
2
1
2
+15V  
2
4
5
6
7
9
+5V  
4
5
6
7
4
5
6
7
D2  
LED1  
LED2  
LED3  
Q2  
9
9
2N4401  
10  
10  
10  
4.75K  
Q4  
1A  
R30  
100V  
DZ1  
15V  
1W  
C1  
.0047  
50V  
2N4403  
Q3  
Q1  
R1  
2N4401  
+5V  
2.21K  
3
4
5
6
3
4
5
6
3
4
5
6
Q
Q
Q
Q
Q
Q
Q
A
B
C
D
E
F
Q
Q
Q
Q
Q
Q
Q
A
B
C
D
E
F
Q
Q
Q
Q
Q
Q
Q
A
B
C
D
E
F
+5V  
+5V  
X1  
X2  
X3  
1
1
1
A1  
A1  
A1  
2
8
9
13  
2
2
A2  
A2  
A2  
10  
10  
11  
8
10  
11  
8
CLK  
R
CLK  
R
CLK  
R
+5V  
11  
9
9
12  
12  
13  
12  
13  
G
Q
H
G
Q
H
G
Q
H
74HC164  
74HC164  
74HC164  
3.01K  
3.01K  
+5V  
+5V  
J40  
1
14  
13  
12  
11  
10  
1
RESET  
1
VCC  
RESET  
R25  
R26  
X5  
X5  
DATA  
2
3
4
5
6
7
13  
12  
11  
10  
9
2
DATA  
1
J40  
3
3
4
5
6
DATA  
2
CLOCK  
1
X5  
X5  
CLOCK  
SET  
Q1  
1
CLOCK  
2
+15V  
GENERAL INFORMATION  
ELECTRICAL SYMBOLS PER E1537  
SET  
2
LAST NO. USED  
C5  
330p  
50V  
C6  
/Q1  
R- 42  
C- 12  
Q-  
5
Q2  
X4  
54HC74  
330p  
50V  
DZ-  
2
J40  
2
8
CAPACITORS  
RESISTORS  
DIODES  
=
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
GND  
N.C.  
D-  
2
LABELS  
=
Ohms  
(
+15V IN  
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
C12  
0.1  
50V  
SUPPLY  
VOLTAGE NET  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
J40  
4
NOTES :  
COMMON  
NOTE: ALL UNMARKED RESISTORS  
FILE: M17637_1AC  
=
100 OHMS  
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
COMPLETE BOARD, THIS DIAGRAM MAY  
FRAME CONNECTION  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF  
A
1
2
8
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING  
NUMBER.  
A
COMMON CODE  
EARTH GROUND CONNECTION  
X5  
X5  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
ON HOLES SIZES PER E-2056  
Ch’ge.Sht.No.  
XA  
EQUIP.  
TYPE  
COMMANDER 400  
THE LINCOLN ELECTRIC CO.  
CLEVELAND, OHIO U.S.A.  
J40  
5
ON  
ON  
2
3
PLACE DECIMALS IS  
PLACE DECIMALS IS  
+
+
.O2  
.OO2  
9
METER P.C. BOARD SCHEMATIC  
12-15-95A  
9-27-96F  
SUBJECT  
ON ALL ANGLES IS  
+
.5 OF  
A
DEGREE  
NONE  
SCALE  
MATERIAL TOLERANCE ("t") TO AGREE  
WITH PUBLISHED STANDARDS  
SHT.  
BK  
05-12-94  
CHK.  
SUP’S’D’G.  
M17637  
FV  
DR.  
DATE  
NO.  
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  
REQ’D  
PART NO.  
IDENTIFICATION  
L9684-1  
COMMANDER 400 METER  
R40  
R41  
R42  
X6  
Q5  
C11  
X5  
Q1  
C10  
C9  
X1  
Q2  
Q3  
R16  
R15  
R14  
R13  
R5  
LED1  
LED2  
LED3  
C12  
Q4  
X2  
X4  
X3  
C3  
L9684-1  
9-27-96F  
CAPACITORS = MFD/VOLTS  
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 pro-  
vided 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-21  
G-21  
ELECTRICAL DIAGRAMS  
SCHEMATIC - REMOTE PROTECTION PC BOARD  
M
1 7 9 4 8  
L1  
J61  
2
J60  
4
4B  
4D  
.39mH  
C1  
.0047  
TP1  
150V  
80J  
TO "OUTPUT CONTROL  
SOURCE" SWITCH S6  
3000V  
FRAME  
FRAME  
L2  
J61  
3
J60  
1
2B  
2D  
.39mH  
C2  
.0047  
3000V  
L3  
J61  
4
J60  
2
TO REMOTE CONTROL  
AMPHENOL  
TO MOTHER CONTROL PCB  
75B  
77C  
76C  
75D  
77D  
76D  
.39mH  
C3  
.0047  
3000V  
TP2  
150V  
80J  
FRAME  
FRAME  
FRAME  
L4  
J61  
5
J60  
6
.39mH  
C4  
.0047  
3000V  
TP4  
150V  
80J  
TP3  
150V  
80J  
TO "REMOTE/LOCAL"  
SWITCH S1  
L5  
J61  
8
J60  
3
.39mH  
C5  
.0047  
3000V  
J61  
J61  
J61  
1
J60  
5
6
7
GENERAL INFORMATION  
ELECTRICAL SYMBOLS PER E1537  
LAST NO. USED  
L-  
5
5
4
C-  
CAPACITORS  
RESISTORS  
DIODES  
=
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
TP-  
LABELS  
=
Ohms  
(
NOTES :  
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
SUPPLY  
VOLTAGE NET  
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
COMPLETE BOARD, THIS DIAGRAM MAY  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF  
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING  
A
A
COMMON CODE  
NUMBER.  
FRAME CONNECTION  
EARTH GROUND CONNECTION  
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  
THE LINCOLN ELECTRIC CO.  
FILE: M17948_1AA  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
ON HOLES SIZES PER E-2056  
Ch’ge.Sht.No.  
XA  
EQUIP.  
TYPE  
COMMANDER  
THE LINCOLN ELECTRIC CO.  
CLEVELAND, OHIO U.S.A.  
ON  
ON  
2
3
PLACE DECIMALS IS  
PLACE DECIMALS IS  
+
+
.O2  
.OO2  
12-15-95A  
REMOTE PROTECTION P.C. BD. SCHEMATIC  
SUBJECT  
ON ALL ANGLES IS  
+
.5 OF  
A
DEGREE  
NONE  
SCALE  
MATERIAL TOLERANCE ("t") TO AGREE  
WITH PUBLISHED STANDARDS  
SHT.  
FV  
BK  
5-16-95  
CHK.  
SUP’S’D’G.  
M
17948  
DR.  
DATE  
NO.  
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  
REMOTE  
XXXXX  
L9924-1  
PROTECTION  
X
X
X
X
L4  
X
X
X
X
X
X
X
X
X
X
X
ITEM  
REQ’D  
IDENTIFICATION  
ITEM  
PART NO.  
L1  
XXXXX  
X
X
X
.0047/3000V  
C1, C2, C3, C4, C5  
5
1
1
T11577-58  
S18248-6  
X
HEADER  
CONNECTOR  
.39mH  
X
J60  
J61  
X
XXXXXXXXX  
X
TP4  
X
S18248-8  
T12218-9  
T13640-16  
XXXXXX  
XXXXXXXX  
X
L1, L2, L3, L4, L5  
TP1, TP2, TP3, TP4  
5
4
C1  
X
XXXXXX  
80J  
C2  
X
X
X
X
XXXXXX  
C3  
X
XXXXXX  
C5  
X
X
L9924-1  
12-15-95A  
XXXXXX  
C4  
X
XXXXXX  
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 pro-  
vided 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  
G-23  
ELECTRICAL DIAGRAMS  
SCHEMATIC - SNUBBER PC BOARD  
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  
ITEM  
REQ'D  
IDENTIFICATION  
PART NO.  
ITEMD  
~.04  
4.70  
L9572-1  
4.40  
CAPACITORS = MFD/VOLTS  
INDUCTANCE = HENRYS  
X X  
X
X
XX  
X
X
X
3.50  
3.30  
X
X
XXXXXXX  
X
X
XXXXX  
X
X
X
X
X
X
X
X
XXXXXXX XXXXXXX  
9572-1  
L
12-15-95A  
1-16-98E  
.30  
COMMANDER SNUBBER  
0
2.70  
0
.30  
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 pro-  
vided 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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SVM ERROR REPORTING FORM  
We need to know if there are errors in our manuals. We also value any suggestions as to  
additional tests or procedures that would make this SVM a better tool for you.  
If you discover new or different “Problems or Symptoms” that are not covered in the three col-  
umn troubleshooting chart, please share this information with us. Please include the  
machine’s code number and how the problem was resolved.  
Thank You,  
Technical Services Group  
Lincoln Electric Co.  
22801 ST. Clair Ave.  
Cleveland, Ohio 44117-1199  
FAX 216-481-2309  
SVM Number ___________________________  
Page Number if necessary__________________  
Your Company__________________________  
Your Name_____________________________  
Please give detailed description below:  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
SD287 01/99  
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