Home

Lincoln Electric SVM133-B User's Manual

1.
2.
3.
4. NOTE ITEM REQ D PART NO IDENTIFICATION ITEM REQ D PART NO IDENTIFICATION B 1 82 3 __ 113157 16 RT ANGLE TAB R22 1 R229 R236 R28 1 R287 C2 C10 C23 C24 C54 C71 C85 20 516668 5 022750 R290 R311 R314 R316 8318 091 D C89 C92 C94 C100 C 127 C 128 R323 R324 R33 1 8338 R339 038 037 R459 130 131 C 138 145 C 150 R346 R348 R349 R350 R356 gt lt AO 2b D C151 C152 R358 R36 1 R377 R382 R430 035 41 2s s R458 C28 C46 C51 5 513490 42 1 0 35 R462 R463 R470 R47 1 508 Q 48352 183635 m F Q r 9 5 C7 C21 2 s13490 138 12007 100 R509 R523 4833 T 1 613490 63 47750 R4 R5 R11 R12 91 R92 6 __ 519400 5620 562 1 4W l EE R457 C 14 C20 C25 C36 C39 33 s16668 11 1 50 R9 R90 188 R438 4 _ 519400 3321 3
5. 2 ITEM REQ D PART 2 C1 1 516668 6 8 C2 24 C7 C8 5 516668 5 022 50 L5 66 2 5 16668 8 330pF 100 C9 1 5 13490 95 24994 OU LI LIE 2 516668 11 wd 90 Ed 1 olo49U0 29 4 7 35 PS L9684 1 COMMANDER 400 METER AN 1 D2 lt 112199 1 144004 c at DZ 1 T 12702 29 dir m p Re DZ2 1 T12702 27 1N4740 EE J40 1 522025 5 CONNECTOR MOLEX MI NI RT L 81 8 M LED 1 LED2 LED3 3 517395 5 LED DISPLAY Br 01 02 2 T12704 68 234401 2 20 6 1 1 Rie a3 1 T12704 69 2N4403 a cat 04 1 1 12704 13 IC PKG MOSFET SS E 05 1 12704 62 3A 100V TRANSISTOR sx R1 1 519400 2211 2 21K 1 4W T R2 R3 R4 R5 RB R7 R8 R9 26 5 19400 1000 100 1 4W Li RIS to 50 Oi ake R10 R11 R12 R13 R14 R15 BE m R16 R17 18 R19 R20 R21 aem R22 R23 R24 R25 R26 R30 m E
6. 9 jo ele 5 5 Bla D 6 2 ala ITEM REQ D PART NO DESCRIPTION C1 C2 C3 C4 C5 5 S16668 11 1 50 C6 1 S 13490 93 27 35 C10 1 516668 5 022 50 01 02 03 04 05 5 712199 1 144004 o DZ 1 DZ2 2 T12702 27 144740 DZ3 DZ4 DZ5 DZ6 112702 4 114747 elg 19596 1 qe e uos t E P22 1 21135 14 MOLEX CONNECTOR 9 5 O 23 1 52035 1 8 HEADER wn n5 co gt T4 E IBS 55 01 1 12704 68 2 4401 eee EIE cre ee R1 1 _ 519400 1080 10 174W P ES 2 Ed R2 1 S 19400 2211 2 21K 1 4W 9 XXX ia 2 lt R3 R4 R6 R7 R12 R14 R20 9 5 19400 4751 4 75K Macar Bi ac 5 Lip 9 CT IBI R5 R15 2 S 19400 2212 22 IK 1 4W e X EL R12 R8 S 19400 4750 475 1 4W EM mne gms R9 5 19400 68 12 68 IK 1 4W INCOME en R10 5 19400 3011 3 01K 1 4W T9 3 Sas SS
7. D TE uir Plug J1 Pin 2 Pin 3 COMMANDER 400 LINCOLN F 63 F 63 TROUBLESHOOTING amp 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 Retum to Section TOC Retum to Master TOC 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 op
8. Return to Master TOC Return to Section TOC common J3 V common BATT R443 142901 100 OVERCURRENT SIGNA 284403 078 22K lt rt 033 1N5402 common common common 20V BATT TOLER Di INTERFACE 2 ES START UP SIGNAL n 020 FROM MCU 4 5V IDLE SOLENOID DRIVE 22 1K PBA IDLE SIGNAL 08 122 20V BATT El FROM MCU PALIGRA 9 gt ol PRES Lame A lt lt 122 107 1 OIL TEMP Lamp 10 ENG PROTECT START UP INTERFACE 23 gt SOL V V PCB LAMP J22 DRIVER
9. SWITCH INPUT 15 CVSCR 00 50 L 1 epai MCU SHUNT 2 04 T 128 JV E xem V A SWITCH INPUT Return to Master TOC Return to Section TOC eme 54HC132 Sie 233 x26 V 039 04 7 Ger T 097 77 FRAME TO CONTROL BOARD SWITCH INTERFACE TO OPTION BOARDI DISCRETE INPUTS MCU commen PHASE 2 EXCITER F B 12 46 33 2K EXCITER FB o lt R423 A316 D67 mw CV MODE 5 OUTPUT ZERO CROSS DETECTOR xs gt D3 111014 Ces 22 50 ci53 a gt 5 v Er x 066 R533 mE m xao cise 5 al 33
10. SCR GATE DISABLE al 2 je e lt m 5 7 10 17 3 5 DRIVE FOR E SCR B C48 150p 50 TRIG common 1000 T TRIG common 0047 RE 19047 HSV CVSCR Bo bs 25 Sov 2 4 SWITCH INPUT 5 1 2 o o o 8 E o 8 B SENSE TOROID pi oie TO see SCR C GATE 185406 AUXILIARY CURRENT SENSE INPUT 1N5406 m 1 7 D Sv J4 He gt gt GATE DRIVE FOR SCR J6 gt s 204A common 45V MCU 9
11. Section E General Descripton E 2 Battery Starter Engine Rotor and E 2 Exciter Feedback Control Board Local and Remote Control E 3 Weld Winding Output Bridge Output Choke and CV Capacitors E 4 SCR gelu E 5 Ind ction Geheralors iret teneri E xx Pese e exo poder Funes E 6 5 8 pn 8 STARTER ALTERNATOR ROTATION ENGINE SCR GATE SIGNALS SHUTDOWN SOLENOID EXCITER BATTERY SOLENOID 115VAC 14 PIN EXCITER CAPACITORS AMPHENOL 115 230 RECEPTACLE REMOTE SWITCH Y 4 2 8 3 14 AMPHENOL FINE OUTPUT BOARD EXCITER VOLTAGI FEEDBACK CURRENT MODE SELECTOR SWITCH 12VDC FIGURE E 1 COMMANDER 400 BLOCK LOGIC DIAGRAM Retum to Master TOC COMMANDER 400 LINCOLN 8 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC E 2 THEORY OF E 2 OPERATION FIGURE E 2 BATTERY STARTER ENGINE ROTOR AND STATOR SCR DIODE
12. LN 8 INSULATE UNUSED WIRE LEADS INDIVIDUALLY FEEDER P Bw U Ru 81 NN U 5 gt 14 PIN N 2 4 AMPHENOL gt 21 L 9 K867 UNIVERSAL y ADAPTER PLUG GND INPUT CABLE ELECTRODE CABLE 75 4 TO WIRE FEED UNIT 76 B TO WORK M 77 SPLICE LEADS AND INSULATE COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC C 6 C 6 ACCESSORIES CONNECTION OF THE LN 8 TO THE COMMANDER 400 USING K595 INPUT CABLE ASSEMBLY SEE FIGURE C 4 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 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 3 Connect the K595 XX Input Cable Assembly to the LN 8 4 Connect the K595 XX to the 14 pin amphenol on the Commander 400 5 Place the IDLER switch in the HIGH position CAUTION Any increase of the high idle engine RPM by changing the governor setting or over
13. 10 Aibaliary POWOLI edu ure B 12 AcCeSSOL GS n fa eg du Section Section D Theory Of Operation oen ere onu etes Ra ue Section E Troubleshooting and m enemies Section F Electrical Diagrams et e nace eb a ua Section G Parts P267 Series COMMANDER 400 LINCOLN 5 Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION 4 Installation 8 EUER A 2 Safety 5 s de ore d cei es A 3 Locaton and A 3 UH A 3 ERR Angle of Operation EE A 3 Nim E A E 4 y High Altitude 4 0000 4 TOWING ERUNT 4 Pre Operation Engine Service 4 5 4 WU eI E A 5 Gooling 5 Battery 5 Muffler Outlet PIpe 2 A 5 Spark Arrested oie em t E Pepsi A 5 Electrical Output
14. common common 10 PULL f 45V BATT 5V AUX Ae RCURRENT SIGNAI 10V X 33074A TO PULL FET DRAINS 1 80 common 20V RUN STOP SWITCH SOL EP BOARD CN 76 f common MCU common 4476 ae 330744 2 T 39 2K IMPONENT 45V AUX SPARE COMPONENTS M M STOP gt 8457 12V oe mm common BATT DRAN RUN 3101 common R473 gt f 475 40938 common 33074A 4 47 5K 052 2 xia e TO ENGINE PRO xa 7 515128 5 1 76 0 BORD gt Raid ERA 1 GND 10 0K common BATT 330p 71 common BATT 100 TO EP BOARD J22 V common BATT V common BATT V BATT common V common BATT OPERATOR ANALOG INP
15. of this manual COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION FUEL 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 Maintenancel sections of this man ual for more details about fuel The Commander 400 is protected by a low fuel shutdown to prevent the engine from running out of fuel The machine will indicate a low fuel condition by turning on the low fuel light A time of 30 minutes will elapse once the low fuel light illuminates before the machine will shutdown A restart of the machine will restart the timer to allow the operator to override this feature The amount of reserve fuel remaining in the tank after the first shutdown will vary from machine to machine The operator must determine the amount of fuel remaining before re starting the machine Running out of fuel may require bleeding the fuel injection pump 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 Remove the plastic cap covering the fuel tank filler neck and install the fuel cap COOLING SYSTEM The Deutz e
16. COMMANDER 400 LINCOLN F 47 F 47 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE F 19 RESISTOR R1 LOCATION Retum to Section TOC Retum to Master TOC g PP RESISTOR R1 213 LEAD 204 8138 JF HE 8 Locate and remove lead 204B from resistor R1 50 ohms 100 Watts See Figure F 19 FIGURE F 20 HEAT SINK TEST POINTS Vigo 510 gt 818 HE cic REMOVE ANODE INSULATING PAINT CATHODE 9 Remove the red insulating paint from the NOTE Do not disassemble the heat sinks heat sink test points See Figure F 20 Retum to Master TOC 8 c 5 9 8 COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 48 REMOVE INSULATING PAINT TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE 21 SCR TESTER CIRCUIT AND SCR CONNECTIONS 6 VOLT 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 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 12 Connect the tester to the SCR A as shown in Figure F 21 a Connect tester l
17. TO MOTHER CONTROL PCB TO REMOTE LOCAL SWITCH 1 TO REMOTE CONTROL AMPHENOL NOTES N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E 2056 ON 2 PLACE DECIMALS 1 02 THE LINCOLN ELECTRIC CO Ch ge Sht No XA ON PLACE DECIMALS IS 002 _ 12 15 95A ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V RESISTORS Ohms DIODES 1 400V FILE M17948_1AA THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A SCALE NONE DR BK DATE _5 16 95 1 4W UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED LAST NO USED L 5 UNLESS OTHERWISE SPECIFIED 0 8 LABELS 4 SUPPLY VOLTAGE POWER SUPPLY SOURCE POINT COMMON CONNECTION 7 7 FRAME CONNECTION EARTH GROUND CONNECTION DE COMMANDER G 21 REMO
18. 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 30 F 30 TROUBLESHOOTING amp REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE continued 6 Carefully lift the door assembly from the 7 Using the 3 8 wrench loosen the two bot machine 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 4 REMOVE CENTER SCREW 8 Using the 3 8 wrench remove the screws 10 Remove the screws from the lower front left from the front roof assembly and right side panels The bottom end 9 Remove the fuel cap and rubber seal sprawe pnto esened Carefully lift and remove the front roof 11 Remove the panels assembly Replace the fuel cap Commander 400 LINCOLN 8 F 31 F 31 TROUBLESHOOTING amp 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 Retum to Section TOC Retum to Master TOC FIGURE F 5 FRONT CONTROL PANEL REMOVAL FRONT CONTROL PANEL LOWERED lt lt ARROWS INDICATE SCREW LOCATIONS Retu
19. DC Trigger Internal Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN F 74 F 74 TROUBLESHOOTING amp REPAIR NORMAL WELD VOLTAGE WAVEFORM STICK CC MACHINE LOADED TO 400AMPS AT 40 VOLTS Retum to Section TOC Retum to Master TOC 0 volts Retum to Section TOC Retum to Master TOC 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 Retum to Master TOC 8 8 Note Scope probes connected at STICK welding output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN F 75 F 75 TROUBLESHOOTING amp REPAIR NORMAL WELD VOLTAGE WAVEFORM WIRE CV MACHINE LOADED TO 400AMPS AT 40 VOLTS Retum to Section TOC Retum to Master TOC 0 volts Retum to Section TOC Retum to Master TOC This is the typical DC output voltage generated from a properly operating machine Note that eac
20. Section Options ACCeSSOTIGS aec eite tera ir dece Lr eed da e dec A eren C 2 E C 2 TG Welding 2 Semiautomatic Welding nennen tnn C 2 Connection of Lincoln Electric Wire C 3 Connection of the LN 7 using K867 Universal C 3 Connection of the LN 7 using K584 Input Cable C 4 Connection of the LN 8 using K867 Universal 5 Connection of the LN 8 using K595 Input Cable C 6 Connection of the LN 23P using K350 1 Adapter Kit C 7 Connection of the LN 25 Across the Arc C 8 5 Connection of the K488 SG Control Module and K487 Magnum Spool Gun C 9 i B 4 2 8 i B 4 2 8 i COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC ACCESSORIES OPTIONS ACCESSORIES The following options acc
21. LL a E 31 31 e X ES 32 32 1 4 14 PIN X 2 2 AMPHENOL N 4 4 cv N 21 21 5 Q K867 UNIVERSAL GND p ADAPTER PLUG P GND GREEN ELECTRODE CABLE 12 o 15 TO WIRE FEED UNIT 76 76 M 77 77 775 OPTIONAL SPLICE LEADS REMOTE CONTROL AND INSULATE LINCOLN Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC C 4 ACCESSORIES CONNECTION OF THE LN 7 TO THE COMMANDER 400 USING K584 INPUT CABLE ASSEMBLY SEE FIGURE C 2 1 Shut the welder off 2 Connect the electrode cable from the LN 7 to the terminal of the welder Connect the work cable to the CV Wire terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application 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 3 Connect the K584 XX Input Cable Assembly to the LN 7 4 Connect the K584 XX input cable assembly to the 14 pin amphenol on the Commander 400 5 Place the IDLER switch in the HIGH position CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle link
22. TERMINAL os TERMINAL x SOL p M a STARTER p ALTERNATOR ENGINE rotation ROTOR SHUTDOWN SOLENOID UL c T EXCITER TT Lt IDLER BATTERY Q SOLENOID Ww 115VAC EXCITER CAPACITORS 115 230VAC RECEPTACLE 14 PIN AMPHENOL 6 PIN AMPHENOL ENGINE SENSORS EXCITER VOLTAGE FEEDBACK BOARD 12VDC 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 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 OUTPUT CHOKE EGATIVE O TERMINAL gt SCR GATE SIGNALS
23. 22701 760 i 780 cov feo 0 gt 0 40 EX 2 Y GROUND 2 242H FRAME GROUND 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 262 227 SOLENOID GROUND STUD ON ENGINE LOCAL 1 SWITCH P e FINE CONTROL POT cw 759 VEVEPIROM 778 CV DAUGHTER T 77 PANEL PANEL WIRES 224 2 SELECTOR 5 pg 26 6 204 VIEWED gg FROM BACKI SEE CHAR SWITCH m 281 323 i PC BOARD 1 2 B3 ENGINE PROT 8 BOARD stantes stee B STAND OFF Bi 82 B3 ci BATT 6 1 741 4 _ L T j ed 299 P E FRAME GROUND SELECTOR SWITCH 58 BOLT ON PANEL TO PCB HARNESS SENDER BRACKET HOUR METER 2398 471 2426 239A X AMMETER INSTRUMENT PANEL GROUND SCREW IN CONTROL BOX ENGINE TO PANEL HARNESS POSITION NAMEPLATE SETTING NO RUNCTION WR WELDING CV START BUTTON PRESSURE SWITCH y J16 16 lt 1 lt 2 lt 228A 3 241A 4 242D 5 242E 229A 6 lt 229 rcu sensor lt 7 SENSO
24. R27 R28 2 519400 3011 PE T fat gm id R29 1 1 19400 4751 818 P EN R3 1 R32 R33 R34 R35 R36 8 5 19400 20 0 20 1 4W HE w R37 R38 2 8 R39 1 S 19400 2000 200 1 4W 5 5 840 R4 1 R42 3 S 19400 10RO 10 1 4W 5 X 1 X2 X3 3 41530059 X4 1 S 17900 23 DIG INTEG DUAL FLIP FLOP I C 55 X5 1 S17900 8 14 PIN I C 55 X6 1 2191242099 HEU jo EIE CAPACITORS MFD VOLTS L9684 1 le RESISTORS OHMS 9 27 96F NOTE Lincoln Electric assumes responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components 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 LINCOLN amp ine LINCOLN Y machine COMMANDER 400 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC jo ojo E 5 5 t 515 ge ple o o Return to Section TOC Return to Master TOC G 21 SCHEMATIC REMOTE PROTECTION PC BOARD LINCOLN B TO OUTPUT CONTROL SOURCE SWITCH 56 ELECTRICAL DIAGRAMS
25. SCR 1 CATH e CVSCR CO GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 19 CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED 0 5 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 0 3 4 NOTES DIODES 1 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY POWER SUPPLY SOURCE POINT NOT USED NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 5 COMMON CONNECTION NUMBER 7 FRAME CONNECTION THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO FILE M17741 1AE EARTH GROUND CONNEC Xt AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO UNLESS OTHERWISE SPECIFIED TOLERANCE LAST CHANGE ON HOLES SIZES PER E 2056 THE LINCOLN ELECTRIC CO FOUE COMMANDER 400 S amp W ON 2 PLACE DECIMALS IS 02 ON PLACE DECIMALS IS 002 12 13 96 CLEVELAND OHIO U S A CV CONTROL PC BRD SCHEMATIC ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE 1 TO AGREE SCALE NONE BE WITH PUBLISHED STANDARDS LEBAB DATE 9 14 94 BS sPspo M1774 Return to Section TOC Return to Master TOC NOTE This diag
26. 0 0 i i 6 Welding Cable Connections entrent cet rna A 6 Y Machine Groufiding inciden 7 Auxiliary Power Receptacles 2 004444444420 tn tnt tetnesn tn tn sns tata sa sesenta A 7 Standby Power 7 Connection Of The Commander 400 To Premises A 8 E Y 4 2 8 amp COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION TECHNICAL SPECIFICATIONS Commander 400 INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting System Deutz 3 oylinder High Idle 1900 173 cu in 12VDC battery Fuel 25 gal F3L 912 Diesel 44 2 HP 33kw Low Idle 1350 2 827 L amp Starter 94 6 L Engine 1800 RPM Full Load 1800 Bore x Stroke Oil 8 5 Qts 8 04 3 94 x 4 72 100mm x 120mm RATED OUTPUT WELDER Duty Cycle Welding Output Volts at Rated Amps 400 amps DC Constant Current 40 volts 400 amps DC Constant Voltage 40 volts 500 amps DC Constant Current 40 volts 500 amps DC Constant Voltage 40 volts OUTPUT WELDER AND GENERATOR Welding Range Open Circuit Voltage
27. Section F 1 Section F 1 TABLE OF CONTENTS 3 TROUBLESHOOTING amp REPAIR SECTION 5 d Troubleshooting amp Repair Section 12 4 4 4 4 42 222 Section F How to Use Troubleshooting een nennen F 2 PC Board Troubleshooting Procedures F 3 Troubleshooting n MN 4 F 15 Initialization Sequence and Commander 400 Error Code Explanations F 16 Error Codes with 02713 1 Control F 17 Error Codes with G2713 2 or 3 Control F 21 Test F 27 Case Cover Removal and Replacement Procedure F 27 Case Front Knobs Removal and Replacement F 32 sro M F 33 e Shutdown Solenoid Test eene enne tne nnns F 35 Engine Throttle Adjustment enne nnne F 37 5 Static SCR Diode Rectifier Bridge Test F 41 d Active SCR M F 45 gt Charging Circuit F 49 Stator Voltage sphere iain F 51 Fine Control Potentiometer F 55 D esi ite
28. CONTROL FUEL LEVEL PCB TO FUEL SHUT DOWN LOGIC INP 12 Return to Section Return to Master TOC COMMON EPD 45V OV BATI ON OFF INPUT A A gt 4 e COMMON ee 2 SEC LAMPS 45V 10 ON TEST TIMER LM2901 R20 Q1 FROM SENSE 2N4401 ME X1 CONNECTION ON ALT ALT VOLTAGE F B 10 0K P23 TO ALT SHUT R10 LM2901 DOWN LOGIC INP 301K DZ2 c3 5 V 1W 50V COMMON COMMON COMMON o o 8 5 Ll o o i p o uU 8 B o T GENERAL INFORMATION FILE 17500_1 SOMMER OMMON OS ELECTRICAL SYMBOLS PER E1537 45V BATT LM2901 CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS xi NOTES DIODES 1A 40V UNLESS OTHERWISE SPECIFIED
29. D 124 D125 D132 D133 R207 1 519400 1502 15K 1 4W 124 A RES 072 1 T12702 11 1N4745 R209 1 519400 3741 3 74K 1 4M C652 KXXXX x DZ 10 0229 DZ35 0236 0237 7 112702 29 1N4744 R2 16 R43 1 R432 R537 4 519400 4752 47 5K 1 4W HIEN epee 0z51 0238 0240 228 R495 2 S 19400 1004 1749 Eee LII Hx 3 X KX 0216 0717 0218 0719 4 12702 52 1N4733A R233 1 S 19400 3923 392K 1 4W M 2 ERIS Taa Rm2 X 0232 0246 0247 0248 0250 6 T12702 33 1453478 R247 R263 R264 R427 R428 13 19400 2000 200 1 4W x20 XXXX rasp 8494 O 0251 R436 R450 R451 R524 525 a 4 FTT aaa 0742 1 r12702 41 1N53598 ZENER DIODE R526 R527 R528 Ges 0243 1 r12702 40 1 4735 R250 1 519400 75 75 1 4W 950 H Wi J2 2 520351 4 HEADER R251 1 519400 68 1 1 174W cs mer U3 1 52035 1 6 HEADER R254 1 5 19400 39R2 39 2 1 4W Q 1 520351 8 HEADER R255 1 __ 519400 2469 24 9 1 44 5 l SIS 13 0258 05 1 s20351 16 HEADER R282 R283 R284 3 __ 14648 4 5W 40 OHM RESISTOR ole us ele Je 1 520351 10 RT ANGLE HEADER R292 R293 R294 R447 R448 6 519400 1550 15 1 4W On T R387 7 1_ 520351 14 HEADER R449 S ol Jel a pm 8 1 s20351 12 HEADER R295 1 __ 519400 3382 33 2 174W tios Ld NIS 5 3 te ea 020 1 521134 19 MOLEX CONNECTOR R299 R464 2 _ 519400 3922 39 2
30. OOO Y Pin 8 Pin Z9 00 5 5 o 5 ae ri r4 Plug J8 COMMANDER 400 LINCOLN F 57 F 57 TROUBLESHOOTING amp 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 Retum to Section TOC Retum to Master TOC 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 Retum to Section TOC Retum to Master TOC MATERIALS NEEDED 5 16 Nut Driver Multi M eter Commander 400 Wiring Diagram See the electrical diagram
31. 40 ENGINE PCB HARNESS START BUTTON 1 SELECTOR SWITCH 38 5 1 82 POSITION WAMEPLATE SETTING AUX CURRENT 237 NO FUNCTION WELDED STUD FUNCTION ON OUTPUT PANEL See IDLE 1 90 MAX gm AN Eo IN 230 SOLENOID GROUND C HOUR METER STUD ON ENGINE 2398 T 17 PANEL TO PANEL WIRES 270 MAX ae 400 MAX 50 575 7828 2320 232F Spon IN CONTROL BOK 2 OIL 247 A oe J16 P16 LL PRESS o TEMP FUEL xi d 2 OIL TEMP SENSOR amp SWITCH 2 4 EA 7 o cod ter o Qi CD TAB 228A 3 oui E 233A STUD ON EN NSOR 949 0 MOUNT CHANNEL 7 T Camac a ee i GREEN z jo ojo E 5 5 t 515 ge ple o o Ed w re Ome 242 5 249 2426 229A 6 229 SENSOR T1 INSULATED STUD BIER lt 1 IN CONTROL BOX Mr CONTROL PANEL ENGINE HARNESS TO PANEL WIRES 2398 8 239 GROUND SCREW FI 9 ENGINE HARNESS TAB M 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 LINCOLN COMMANDER 400 Return to Section TOC Retur
32. C ENGINE PROTECTION 5 CH o BOARD MOLEX PLUG m AES 2 CV BOARD 000 MOLEX PLUG 2 E 0 o Q Y CONTROL BOARD 00 0 9 519 MOLEX PLUGS he E 518 p gt 818 PROCEDURE Before starting the following procedure refer to Using the 5 16 nut driver remove the control the topic Board Troubleshooting board cover Procedures the beginning of this section 4 Locate and carefully remove the molex type 1 Turn off the engine plugs from the control board engine protec tion board and CV board if used See Figure 2 Using the 5 16 nut driver remove the front F 33 and the Wiring Diagram control cover assembly Retum to Master TOC B 8 Retum to Section Retum to Master TOC COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 83 TROUBLESHOOTING amp REPAIR CONTROL PC BOARD REMOVAL AND REPLACEMENT continued FIGURE F 34 CONTROL BOARD LEADS 5 Remove lead 227 from terminal B1 on the 14 control board See Figure F 34 6 Remove lead 262 from terminal B2 on the control board See Figure 34 7
33. gt 2 2 Return to Section Return to Master TOC F 56 TROUBLESHOOTING AND REPAIR FINE CONTROL POTENTIOMETER TEST continued F 56 TEST PROCEDURE NOTE this test procedure the positive output stud is used for common 1 Using the 5 16 nut driver open the control panel and tilt out Remove the control board cover Put the LOCAL REMOTE switch in the LOCAL position Set the range switch to the general 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 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 approximately 5 00 VDC in the maximum posi tion Also the display on the control panel should steadily increase from 50 575 If step 2 or 3 fails turn off the machine At J8 pins 5 8 amp 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
34. 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC B 12 OPERATION WIRE FEED CONSTANT VOLTAGE WELDING Stick and Wire models only Connect a wire feeder to the Commander 400 see the section and set the welder controls according to the instruc tions in Controls and Settings in this section of the manual The Stick and Wire model of the Commander 400 with its CV tap permits it to be used with a broad range of flux cored wire inner shield and Outer shield elec trodes and solid wires for MIG GMAW 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 Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand a 10 voltage and a 3 frequency variation 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 FGCI receptacles 5 15 One 50 amp 120 240VAC receptacle 14 508 The 50 amp receptacle has a maximum permissible output of 44 amps However it can be split to power two separate single
35. 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 Retum to Master TOC 8 8 Retum to Section TOC Retum to Master TOC COMMANDER 400 F 79 F 79 TROUBLESHOOTING amp REPAIR TYPICAL EXCITER VOLTAGE FEEDBACK WAVEFORMS Retum to Section TOC Retum to Master TOC Retum to Section TOC Retum to Master TOC 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 Retum to Master TOC 8 8 J4 pin 1 to pin 7 J4 pin 2 to pin 7 J4 pin 3 to pin 7 SCOPE SETTINGS Volts Div
36. D 11 sten oO nOD D 11 Name plat I D 11 2 D 11 5 6 D 11 8 Cable Connections reb SUE D 11 z Major Component D 12 B 8 i x COMMANDER 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC MAINTENANCE SAFETY PRECAUTIONS WARNING Have qualified personnel do all maintenance and troubleshooting work Turn the engine off before working inside the machine Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete f 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 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 ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE
37. AI PLADE DECALS 6 006 TEES CLEVELAND OHIO U S A _ AMPHENOL BYPASS SCHEMATIC MATERIAL TOLERANCE t TO AGREE SCALE __NONE SHT DR _ EB FV DATE 3 9 95 B SUP S D G No M17900 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN COMMANDER 400 Return to Section TOC Return to Master TOC Return to Section TOC ojo Ele 5 5 o 515 818 ple o o jo Return to Section TOC Return to Master TOC Return to Master TOC G 7 PC BOARD ASSEMBLY AMPHENOL BYPASS PC BOARD COMMANDER 400 amp A ELECTRICAL DIAGRAMS G 7 ITEM REQ D PART NO IDENTIFICATION C 005040506 _ e f 6 T2189 CAPACITORS MFD VOLTS INDUCTANCE HENRYS 9892 1 12 13 96 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 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 an
38. MOLEX CONNECTORS ground stud i 3 cua a on e 55505 TET 77 200v common FLTR 3 5 Les gt XS v 1 000000 7 GENERAL INFORMATION LAST ND USED S R 58 0 53 E ELECTRICAL SYMBOLS PER E1537 CAPACITORS 022 50 UNLESS OTHERWISE SPECIFIED es RESISTORS Ohms 1 4 UNLESS OTHERWISE SPECIFIED LABELS NOTES DIODES 1A 400v IUNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET X 330748 SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE x5 T X26 WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY POWER SUPPLY SOURCE POINT gt NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON COOJ NJ common conection 7 7 FRAME CONNECTION i i FILENAME 4485 36 ET Ln Grau Coe Cr 2 PLACE DECIMALS IS 2 MEU panier AL ANGLES S 5 OF A DEGRE CLEVELAND OHIO U S A SCHEMATIC 4 layer version cone SPARE COMPONENTS Wie EVI TO
39. Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 86 F 86 TROUBLESHOOTING amp 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 d ge HOLD IN COIL SMALLER TERMINALS IDLER EACH SIDE SOLENOID 224 AND 240 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 4262 See Figure F 35 Cut the cable tie 2 Unlatch lift and secure the right side engine access door COMMANDER 400 F 87 F 87 TROUBLESHOOTING amp REPAIR SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT continued FIGURE F 36 SHUTDOWN SOLENOID LINKAGE ARM ASSEMBLY gt 8 4 MOUNTING FASTENERS 9 8 FE PIVOT PIN G 6 SPACER 3 4 WASHER 2 PLAIN gt 8 8 WASHER EE RETAINING 81 RING cic 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 5 5 Using the long screw driver and needl
40. 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 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 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 4 Connect the K196 input cable to the LN 8 5 Place the IDLER switch in the HIGH position CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 6 Setthe LOCAL REMOTE switch to REMOTE 7 VOLTMETER switch to or depend ing on the polarity chosen 8 Setthe RANGE switch to WIRE WELDING CV 9 Setthe WELDING TERMINALS switch to WELD ING TERMINALS REMOTELY CONTROLLED 10 Adjust wire feed speed and voltage at the LN 8 FIGURE C 3 COMMANDER 400 LN 8 WITH K867 ADAPTER CONNECTION DIAGRAM
41. CAUTION To prevent the engine from accidentally starting dis connect the negative battery cable before servicing the engine See Table D 1 for a summary of maintenance intervals for the items listed below Follow either the hourly or the calendar intervals whichever come first More fre quent service may be required depending on your spe cific application and operating conditions OIL Check the oil level after every 8 hours of opera tion or daily BE SURE TO MAINTAIN THE OIL LEVEL Change the oil the first time between 25 and 50 hours of operation Then under normal operating conditions change the oil as specified in Table D 1 If the engine is operated under heavy load or in high ambient 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 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 Use high quality oil viscosity grade 10W40 Consult the engine manual for 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 Retum to Section TOC Retum to Master TOC Retum
42. LUMPY Section D 1 Section D 1 TABLE OF CONTENTS 8 MAINTENANCE 8 Maintenance Mem Section D PRECAUTIONS a E R a D 2 Routine and Periodic 2 4 000 D 2 8 Engine ccc eee vade eh na D 2 Change the Oil ttc D 2 Change the Oil Filler rtr Ernest nd ERE PH D 3 iad D 3 D 4 Bleeding the Fuel System 0 10 nennen trenes nnns D 6 Air c D 6 5 Cooling System ierit ka D 7 5 Cooling Blower Belt renean ete Rx pag D 7 Engine Maintenance Schedule sese D 8 Engine Maintenance D 9 8 Battery Maintenance irnir ree D 10 j Cleaning the Battery n D 10 Checking Specific Gravity 2 D 10 Checking Electrolyte Level sess D 10 Charging the Battery 5 ctii Eg ee Pen boe oo D 10 Welder Generator D 11 Sir
43. NOTE Gas shielded welding requires a Magnum Gun Gasless welding requires an Inner shield Gun 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 488 SG Control Module with appro priate control cable Includes 25 feet 7 6 meters of power cable COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC C 3 C 3 ACCESSORIES CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS A WARNING ELECTRIC SHOCK can kill 0 Do not operate with panels open Disconnect NEGATIVE BATTERY LEAD before servicing Do not touch electrically live parts MOVING PARTS can injure Keep guards place Keep away from moving parts Only qualified personnel should install use or service this equipment AX CONNECTION OF THE LN 7 TO THE COMMANDER 400 USING K867 UNIVERSAL ADAPTER SEE FIGURE C 1 1 Shut the welder off 2 Connect the electrode cable from the LN 7 to the terminal of the welder Connect the work cable to the CV Wire terminal of the welder 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 chan
44. Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place 93 COMMANDER 400 LINCOLN 5 MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Lr m i iv Section Technical Specificatioris a ELE eee ines A 2 Safety 3 Location and A 3 Pre Operation Engine Service 4 eene nennen nens inttr tens snnt 4 Electrical Output A 6 Connection Of Commander 400 Premisis 0 A 8 MM Section B rice B 2 General 5 Q 2 Recommended B 3 Design Feat c 3 Welding Capability eee devine Fu p 4 Controls and Settings eter reser 5 Engine Operation aai 8 Welder Operation
45. Retum to Section TOC Retum to Master TOC 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 Retum to Section TOC Retum to Master TOC This procedure takes approximately 65 minutes to perform Retum to Master TOC 8 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN F 42 F 42 TROUBLESHOOTING amp REPAIR STATIC SCR DIODE RECTIFIER BRIDGE TEST continued FIGURE F 13 CONTROL BOARD PLUG J6 LOCATION Retum to Master TOC Retum to Section TOC 9 8 0 0 PLUG J6 5 9 HE gt E HE E ii TEST PROCEDURE 4 Using the 5 16 nut driver remove the control board cover See Figure F 13 1 Turn off the engine 5 Locate and remove molex plug J6 from the 2
46. Retum to Section TOC Retum to Master TOC 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 Retum to Master TOC 8 8 This procedure takes approximately 25 minutes to perform Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 38 F 38 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 10 BLOWER PADDLE MARKED FOR STROBE TACH METHOD MARK BLOWER PADDLE HERE TEST PROCEDURE Strobe Tach Method 5 Start the engine and direct the strobe tach light on the blower paddle Synchronize it to 1 Conduct this procedure with the engine OFF the rotating mark 2 Unlatch lift and secure the right side engine With the machine at HIGH IDLE the tach service access Perform Case Cover should read between 1890 and 1915 RPM Removal and Replacement Procedure through Step 11 For Strobe Tach method With the machine at LOW IDLE the tach only 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
47. SUPPLY VOLTAGE NET e M SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY Tuc O POWER SUPPLY SOURCE POINT NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 57 COMMON CONNECTION FUN EH NUMBER ipe FRAME CONNECTION C 10 COMMON THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO EARTH GROUND CONNEC T AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO UNLESS OTHERWISE SPECIFIED TOLERANCE EQUIP i ON HOLES SIZES PER 2056 12 15 95A THE LINCOLN ELECTRIC CO COMMANDER 400 ON 2 PLACE DECIMALS IS 02 ON PLACE DECIMALS IS 002 CLEVELAND OHIO U S A sugJecr ENGINE PROTECTION P C BD SCHEMATIC e ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t AGREE SCALE NONE COMMON WITH PUBLISHED STANDARDS ie DATE 05 12 05 EV Sup pd WI M17500 LM2901 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E COMMANDER 400 E ELECTRICAL DIAGRAMS ole PC BOARD ASSEMBLY ENGINE PROTECTION PC BOARD
48. TROUBLESHOOTING amp REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 1 DOOR CHAIN REMOVAL Retum to Section TOC Retum to Master TOC DOOR ASSEMBLY Retum to Section TOC Retum to Master TOC PROCEDURE 1 Turn the engine off 2 Unlatch and open engine service access door Retum to Master TOC 3 Using the 7 16 wrench remove the chain from the door assembly See Figure 8 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN F 29 F 29 TROUBLESHOOTING amp 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 Retum to Section TOC Retum to Master TOC LEFT SIDE PANEL THREE SCREWS Retum to Section TOC Retum to Master TOC 5 Using the 3 8 wrench remove the two at the ends of the hinge See Figure screws under the hinge While supporting When these screws are removed the door the door assembly remove the two screws assembly will be free to fall FIGURE F 3 DOOR HINGE SCREW LOCATIONS 2 SCREWS OUTSIDE Retum to Master TOC 5 8 9 8 N 2 SCREWS UNDER Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 8
49. TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TEST continued FIGURE F 24 SCR DIODE RECTIFIER BRIDGE LEADS Retum to Master TOC Retum to Section TOC W2 W5 W1 WA W3 W6 Q PE 18 gt 818 TEST PROCEDURE Weld and PC 10 Check for approximately 42VAC at leads E1 8 Board Windings Test to E2 located at plug J2 on the control board See Figure 25 Do not remove the plug from 7 Check for 48 55VAC at leads W1 WA to leads the control board 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 8 Check for 48 55VAC at leads W2 W5 to leads faulty connections See the Wiring Diagram W3 W6 located at the SCR Diode Bridge See Then proceed to the Exciter Winding Voltage Figure F 24 and the Wiring Diagram 9 Check for 48 55VAC at leads W3 W6 to leads B 5 W1 WA located at the SCR Diode Bridge See Figure F 24 and the Wiring Diagram 3 4 FIGURE 25 CONTROL BOARD PLUG 2 LOCATION 818 x R PLUG J2 8 Retum to Section Retum to Master TOC COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section
50. The switch rating must be the same or greater than the customer s premises disconnect and service over current protection 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 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 4 Plug this cable into the 50 ampere 120 240 volt receptacle on the Commander 400 case front COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION FIGURE A 2 CONNECTION OF THE COMMANDER 400 TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR xoc Pd 60 Hz 3 Wire COMPANY Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTE
51. c e o 2 z E Return to Section Return to Master TOC o O 2 7 v gt 4 5 tc F 70 F 70 TROUBLESHOOTING AND REPAIR STATOR RESISTANCE TEST continued TEST PROCEDURE 6 Disconnect J2 from the control board 1 With the engine off disconnect the negative bat 7 Using an Ohmmeter check for continuity tery cable Make sure that there is nothing between each weld lead W1 W6 to the T1 plugged into the 115V and 230V receptacles exciter lead There should be no continuity between these leads 2 Using the 5 16 nut driver open up the control panel and tilt out Remove the control board 8 Check for continuity from the weld leads to the cover J2 plug pins 1 amp 2 at the control board There should be no continuity between these leads 3 Refer to the Case Cover Removal section and See Figure 1 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 4 Pull the sleeving back and disconnect all weld these leads 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 amp 4 to the T1 exciter lead There should be no continuity 5 Locate the point at which the capacitor bank between these leads leads are bolted to the T1 T2 amp T3 leads com
52. 1 4W 2 XXXX XX 22 1 521134 14 MOLEX CONNECTOR R322 R328 R38 1 3 _ 519400 68 12 IK 1744 a mem F X XXX KX L3 1 r12218 7 330uH R342 1 519400 4753 475K 1 4W 9 104 ex XIX LS L6 L7 L8 4 12218 13 CHOKE 1 8UH 15 4 6A R347 R351 2 112300 81 5 watt 0 5 1X OHM RESISTOR XXXX XX Xx 1 LED2 LED3 3 13657 3 GREEN LED R362 1 619400 1212 12 IK 1 4W WY cS E ZT dau 1 2 OCI 3 0C1 4 OC16 8 515000 10 ISOLATOR R422 R455 2 518400 2001 2 0K 1 4W lt Vah E Josif 23 teat OOF loci 7 OCI 9 10 R434 1 14648 20 150 5 WATT RESISTOR e T 02327 pl 0 1 09 010 3 12704 73 IC PKG MOSFET SS R439 R456 R457 R458 R459 5 __ 112300 77 1 OHMS 7WATT WI RE WOUND l t ES cxx 02 03 04 05 06 07 08 011 34 T12704 68 2N4401 R441 1 _ 519400 8252 82 5 1 4W T gt mL 013 016 018 019 020 023 R467 R538 2 518380 5 THERMI STOR a 4 E KFY 027 028 029 032 034 036 R469 1 T13165 11 2 7 OHM 5 WATT RESISTOR lt i L120 TTT Rage R203 xx 037 039 040 041 043 044 R503 504 2 5 19400 2002 20K 1 4W E B 4 23 1 L3 045 047 048 049 050 051 R429 R517 R530 8534 4 _ 519400 5 111 5 1 4M 052 053 R522 1 519400 1503 150 1 4W 8 E 114 cx O 015 031 2 s18395 16 H S ASBLY 55 T1 1 520375 3 TRAN
53. 1 4W UNLESS OTHERWISE SPECIFIED OR CIRCUITRY OF CONTROLS HAVING COMMON CODE NUMBER DIODES 1A 400 UNLESS OTHERWISE SPECIFIED COMMON CONNECTIO EARTH GROUND CONNECTION Ch ge Sht No B EQUIP UNLESS OTHERWISE SPECIFIED TOLERANCE g 400 ON HOLES SIZES PER 2056 XA E LINCOLN ELECTRIC CO ON 2 PLACE DECIMALS IS_ 02 CLEVELAND OHIO U S A BD SCHEMATIC ON 3 PLACE DECIMALS IS 002 12 15 95 i SUBJECT ON ALL ANGLES IS 5 OF A DEGREE scaLE NONE SHT MATERIAL TOLERANCE TO AGREE ICI rH PUB ts Um 22 33 94 pue EV SUP S D G 0 5 21298 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 3 COMMANDER 400 et ELECTRICAL DIAGRAMS G 11 PC BOARD ASSEMBLY BYPASS PC BOARD 04 4 50 04 2 98 4 15 Return to Section TOC Return to Master TOC Q D PART NO IDENTIFICATION 4 5 6 7 8 9 10 11 15 11577 52 0047 005 1400 C12 013 14 15 016 017 C18 TPT 1P2 1P3 1P4 1P5 113640 16 _ CAPACITORS MFD VOLTS INDUCTANCE HENRYS 9 TD X Return to Section TOC Return to Master TOC L9573 1 10 11 96B X g X X V jo ojo E
54. C 8 ACCESSORIES CONNECTION OF THE LN 25 TO THE COMMANDER 400 ACROSS THE SEE FIGURE C 6 1 Shut the welder off 2 Connect the electrode cable from the LN 25 to the terminal of the welder Connect the work cable to the CV terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application 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 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 4 Place the IDLER switch in the AUTO position CAUTION If you are using an LN 25 without an internal contac tor the electrode will be HOT when the Commander 400 is started 5 Set the RANGE switch to WIRE WELDING CV 6 Set the WELDING TERMINALS switch to WELD ING TERMINALS ALWAYS ON 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 CAUTION Electrode is always HOT FIGURE C 6 COMMANDER 400 LN 25 ACROSS THE ARC CONNECTION DIAGRAM M AMPHENOL BN A AMPHENOL 14 PIN ay _ OPTIONAL K
55. Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 115 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 62 BLOWER PADDLE FLEX PLATE REMOVAL ROTOR FLEX ROTOR REMOVAL PROCEDURE 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 WARNING The rotor will be free to fall when the bolts are removed 2 Using the hoist carefully remove the rotor and flex plate assembly BLOWER PADDLE REASSEMBLY NOTES 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 1 INSTALL ROTOR Support the rotor with the hoist Install the blower paddles and flex plate to the engine flyweel 2 INSTALL STATOR Be sure the engine is blocked securely and the stator is supported with the hoist Install the stator to the engine with the eight bolts and lock washers Install the bottom flywheel cover to the stator frame with three bolts and lock washers Install the fan blade making sure that it faces the prop er direction with the fan nut and four Allen head cap screws Check the air gap for 012 minimum COMMANDER 400 F 116 F
56. 1 400V UNLESS OTHERWISE SPECIFIED SUPPLY C POWER SUPPLY SOURCE POINT COMMON CONNECTION N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY f 7 FRAME CONNECTION NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE EARTH GROUND CONNECTION NUMBER FILE M17637 1AC UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E 2056 ON 2 PLACE DECIMALS IS amp 02 _ XA LAST NO USED COMMON NOTES NOTE ALL UNMARKED RESISTORS 100 OHMS Ch ge Sht No EQUIP THE LINCOLN ELECTRIC CO TYPE ON 3 PLACE DECIMALS IS 002 12 15 95A ON ALL ANGLES IS 5 OF A DEGREE CLEVELAND OHIO U S A SUBJECT MATERIAL TOLERANCE t TO AGREE 9 27 96F SCALE NONE WITH PUBLISHED STANDARDS COMMANDER 400 METER P C BOARD SCHEMATIC SHT DR BK DATE _ 05 12 94 SUP S D G M 17687 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual COMMANDER 400 LINCOLN B ELECTRICAL DIAGRAMS oe PC BOARD ASSEMBLY METER PC BOARD
57. 45 2 16668 8 330pF 100 R30 R36 R97 R98 R99 R 100 107 34 5 19400 1000 100 1 4 L R 1 aes d dE A O 47 1 513490 107 5600 35 117 120 129 R 131 R 176 R230 BG meia TES ES 48 1 516668 9 150pF 100 R23 1 R248 R249 R320 R326 R330 ld 56 C57 2 5 16668 1 22pF 100 R333 R380 R387 R4 18 R477 R478 LLLILLI T T c60 1 513490 85 27 50 R485 R486 R487 R488 R49 1 8492 x24 LL me esa e 02 62 1 5 13490 92 3300750 R493 R494 R500 s Sra Sls 65 C76 C 107 C 109 C 149 5 _ 513490 25 4 7735 R33 R34 R4 1 R224 R227 R234 23 19400 4751 4 75K ED SIBITTTTTT e elg 72 293 C101 3 513490 95 33 80 R235 R237 R286 R32 1 R327 C102 UT c22 C86 C88 2 T11577 26 17100 R379 R453 R480 R48 1 R482 biji R330 Razh 83241 117 1 616668 7 820pF 50 R483 R484 R506 8507 5 16 E zh oaj Ape pre UE 133 C 134 C 135 3 11577 52 0047 005 1400 R53 1 R535 DI 08332 R a 137 1 513490 19 1 8 20 R37 R340 R420 3 __ 519400 8250 825 1 4W PITT 8 XXXXXXXXXx 125 Rasa 14322 D 1 08 09 010 017 030 037 39 112199 1 14004 R102 R122 R143 R222 R256 12 519400 4750 475 1 44 T gt J XXXXX OX XX mS 05 1 052 062 066 067 069 R359 R363 R498 R499 50 1 x D Dx x X xx 1 5 L D70 07 1 072 080 081 087 R502 R505 4 X26 2 sd LT D88 0
58. 74HC164 74 164 74HC164 a V Q2 2N4401 Return to Section TOC Return to Master TOC 2N4403 Q3 o 8 B o o o 8 E J40 74HC164 DATA lt 1 lt 825 J40 74HC164 74HC164 RESET 1 DATA 1 VCC RESET 2 clock lt 3 lt R26 CLOCK 1 DATA 2 4 SET CLOCK 2 15V 01 2 191 4 02 J40 0 GND 54HC74 NC 2 lt GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 8 42 0 5 CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED 6 12 02 2 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 0 2 DIODES
59. CMOS PLD 56 xX x5 8 T ET PSE vi 1 516665 5 8 0 MHZ x gt i CAPACITORS MFD VOLTS XXyxyx X x Xxxx RESISTORS OHMS 10 22 99B Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is 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 m ELECTRICAL DIAGRAMS SCHEMATIC CV CONTROL BOARD Return to Section TOC Return to Master TOC J20 15 CVSCR CV STUD 6 J21 Return to Section TOC Return to Master TOC J20 gt 2 gt oci MODE ENABLE 10407 35 FROMMCU ve S GATE DRIVE FOR SCR 1 GATE J20 SCR 1 562 o E 5 5 t 515 ge ple o o
60. COMMANDER 400 LINCOLN 5 F 69 F 69 TROUBLESHOOTING amp 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 Retum to Section TOC Retum to Master TOC 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 Retum to Section TOC Retum to Master TOC 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 Retum to Master TOC 8 8 This procedure takes approximately 45 minutes to perform Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o
61. REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 56 ENGINE GROUNDING LEAD B 8 X Retum to Master TOC ENGINE GROUNDING LINCOLN 5 LEAD ATTACHMENT 618 POINT 18 gt 818 ali 16 Using the 11 16 socket wrench remove the 21 Label and remove the 285 lead from the grounding lead from the top of the engine engine alternator using the 3 8 wrench pell housing See Figure E36 22 Label and remove the 238 lead from the 17 Cut any necessary cable ties to free the har engine alternator using the 7 16 wrench 4 the erigine stator 23 Clear the wiring harness for engine stator y removal by cutting any necessary cable ties 18 Using the 11 16 wrench remove leads 24 Using the 1 2 wrench remove the three gg bundled leads W1 W4 W2 W5 W3 W6 from the SCR diode rectifier bridge assembly 9 5 19 Using the slot head screw driver remove y lead 231 231 from the starter motor solenoid 8 E 20 Label and remove the 239 lead from the E 5 engine alternator using the 3 8 wrench Yiu 5 RE 2 g 8 ili 46 COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 4 Retum to Master F 111 F 111 TROUBLESHOOTING amp RE
62. 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 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 16 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 17 CV board if used REASSEMBLY 19 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 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 Attach the leads to the control board Note lead placement and routing through insula tion 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
63. Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 54 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TEST continued FIGURE F 26 EXCITER LEADS T1 T2 T3 T1 T2 T3 TEST PROCEDURE Exciter Winding Voltage Test 11 Turn the engine off 12 Locate the exciter leads T1 T2 and T3 See Figure F 26 13 Carefully pierce the insulation on leads T1 T2 and T3 for voltage measurements CAUTION Make the smallest possible puncture away from any sheet metal parts Reinsulate these punc tures at the end of this test 14 Start the engine and run it at high idle 1900 RPM 15 Using the voltmeter carefully check for 460 550VAC from T1 to T2 16 Using the voltmeter carefully check for 460 550VAC from T2 to T3 17 Using the voltmeter carefully check for 460 from to T1 If the Exciter Winding Voltage Test is OK and any of the other voltage checks are low or missing the stator may be faulty Check for shorted or grounded windings in the stator 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 18 Replace the front shroud and all case covers that were removed See the Removal Procedure COMMANDER 400 F 55 F 55 TROUBLESHOOTING amp REPAIR FINE CONTROL POTENTIOMETER TEST WAR
64. TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The welding arc is The engine runs normally The auxiliary power is normal Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Check for loose or faulty con nections at the weld output ter minals and welding cable con nections The welding cables may be too long or coiled causing an excessive voltage drop Check to make sure that the machine settings match the weld application If a remote control unit is not connected to the machine make sure the Local Remote switch S1 is in the LOCAL position If the 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 RECOMMENDED COURSE OF ACTION 1 Using a voltmeter check for the 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 machine See the Wiring Diagram the is low perform the Engine Throttle Adjustment Perform the Bridge Perform the Stator Voltage Test Perform the Range Switch Test 6 Perform the Fine Control Potentiometer Test Check fro poor connections at the J1 molex plug at the control board and at the shunt Als
65. backup shut down can be accomplished by shutting off the fuel valve located on the fuel filter housing BREAK IN PERIOD The engine used to supply power for your welder is a heavy duty industrial engine It is designed and built for rugged use It is very normal for any engine to use small quantities of oil until the break in is accom plished Check the oil level twice a day during the break in period about 200 running hours CAUTION 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 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 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 TYPICAL FUEL CONSUMPTION Refer to Table B 2 for typical fu
66. 116 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued LEAD RECONNECTION CHECKLIST SCR Diode rectifier bridge assembly Engine Stator leads W1 W4 W2 W5 and W3 W6 Retum to Section TOC Retum to Master TOC Engine grounding strap to engine Leads 242E and 229 to fuel level sensor Exciter board O Leads 224 240 225 and 262 to shut Stator leads T1 T2 and to studs down solenoid 1 Leads 226 237 227 and 254 to the Control board box idler solenoid Leads 228 and 234 to oil pressure sensor D Plug J2 S y Leads 233A and 241 to oil temperature O Leads 5 and 5A to neutral T2 stud center 3 a sensor Lead 6 to T1 stud top and toroid assembly 2 Grounding lead to top of engine bell housing note number of turns and direction J Leads 236 2368 236C 231 and 7 Lead to b es 2 pi 1 5 231 to starter motor solenoid ion number ar HITS eno diee x O Leads 239 285 and 238 to engine alter nator 91 510 93 gt 818 TE cic 91 5 RE gt 8 8 46 COMMANDER 400 F 117 F 117 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine If itis rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics OR f you repair or replace any electrical components EN
67. 16 socket wrench remove the including removing the front four nuts washers and rubber washers from shroud the fuel tank mounting U bolts See Figure F 49 4 Using the 3 8 wrench remove leads 242 and 4229 from the fuel level sensor See 8 Carefully remove the U bolts and lift the fuel Figure F 49 Label the leads for reassembly tank away from the machine COMMANDER 400 F 107 F 107 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 50 REAR PANEL ASSEMBLY REMOVAL DETAILS PANEL NI ASSEMBLY A A MOUNTING SCREWS 4 Retum to Section Retum to Master TOC Retum to Section TOC Retum to Master TOC 9 Using the 3 8 wrench remove the screws 10 Lift and remove the rear panel assembly holding the rear panel assembly to the machine base See Figure F 50 11 Using the 9 16 wrench remove the engine grounding strap See Figure F 51 FIGURE 51 GROUNDING STRAP REMOVAL ENGINE GROUNDING STRAP LOCATION Retum to Master TOC 8 8 Retum to Section Retum to Master TOC COMMANDER 400 Retum to Section TOC Retum to Master TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC F 108 F 108 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLA
68. 7 7 16 8 1 2 in 10 5 8 in 6 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 1 Set the OUTPUT RANGE switch to the 50 575 setting Fabrication and General Purpose 2 Set the IDLER switch to the HIGH 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 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 SETTINGS WHEN USING THE K930 1 TIG MODULE 1 Set the OUTPUT RANGE switch to the 50 575 Setting Fabrication and General Purpose 2 Set the IDLER switch to the AUTO position 3 Set the LOCAL REMOTE switch to the REMOTE position 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 COMMANDER 400 Retum to Section TOC Retum to Section TOC 5
69. E 5 5 t 515 ge ple o o 227 H 7 270 MAX SOLENOID GROUND 400 MAX STUD ON ENGINE 50 575 f X INSULATED STUD prm IN CONTROL BOX HOUR METER PT 6 J10 2398 H3 NOTE DIODE APPEARS ON 115 230V 2426 SENBER _ MODELS BUT REPLACED BY LEAD d BRACKET PANEL TO PCB HARNESS STARTER 285 ON NEWER MODELS SOLENOID 286 2320 GIL PRESSURE SWITCH STARTING MOTOR 12 VOLT T1 INSULATED STUD J16 P16 HOH sensor BATTERY IN CONTROL BOX AMMETER lt x 5 lt 26 TEMP SENSOR amp SWITCH STUD ON ENGINE 3 MOUNT CHANNEL 4 5 242E OT 6 229 INT G STUD ON ENGINE Te 27 ENGINE TO PANEL HARNESS p sensor ENGINE TO PANEL HARNESS 8 GROUND SCREW 9 lt IN CONTROL BOX ENGINE GROUND 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 Return to Section TOC Return to Master TOC LINCOLN ron COMMANDER 400 ELECTRICAL DIAGRAMS aa WIRING DIAGRAM STICK MODEL CODE 10580 CONNECTOR CAVITY NUMBERING SEQUENCE VIEW
70. ENGINE PROTECTION BOARD CURRENT MODE SELECTOR SWITCH 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 The shunt which is in series with the positive output terminal provides current feedback to the control board 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 LINCOLN 5 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC E 5 E 5 THEORY OF OPERATION FIGURE E 6 SCR OPERATION INPUT OUTPUT NOTE AS THE GATE ANODE PULSE IS APPLIED LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED SCR OPERATION A silicon controlled rectifier SCR is a three terminal device used to control rather large currents to a load An SCR acts very much like a switch When a gate 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
71. F 57 61 Exciter Voltage Feedback Test eese F 63 Exciter Capacitor Bank ana a aa Ea Riaan F 65 Control Board Power Supply F 67 Stator Resistance Test ie en e Ra bebe sin Fass ERR Etage RE F 69 Oscilloscope F 72 Normal Open Circuit Voltage Waveform 115 VAC F 72 Normal Open Circuit Voltage Waveform Stick Max F 73 Normal Weld Voltage Waveform Stick CC Machine Loaded 10 400 Amps at 40 Volts eei 74 5 Normal Weld Voltage Waveform Wire CV Machine Loaded 3 io 400 Amps at 40 F 75 gt Normal Open Circuit Voltage Waveform Wire CV F 76 2 Normal Solenoid Pull amp Hold Coil Waveforms F 77 Abnormal Solenoid Pull 4 Hold Coil F 78 Typical Exciter Voltage Feedback F 79 c Abnormal Exciter Voltage Feedback Waveforms 2 F 80 Replacement Procedures 22244 ASER ARR F 81 Control PC Board Removal Replacement and Calibration F 81 Shutdown Solenoid Removal
72. For negative polarity welding the work cable connects to the terminal and the electrode cable connects to the terminal COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION AUXILIARY POWER CONTROLS Figure B 1 ltems 15 19 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 Operation later in this section 16 50 AMP CIRCUIT BREAKERS These circuit breaker provide separate overload current protec tion for each 120V circuit at the 240V receptacle 17 120VAC RECEPTACLES These two 120VAC 5 15R receptacles with GFCI protection provide 120VAC for auxiliary power The receptacles have 20 amp total rating Refer Power in the Installation section for fur ther information about these receptacles Also refer to Auxiliary Power Operation later in this section 18 15 AMP CIRCUIT BREAKERS These circuit breakers provide separate overload current pro tection for each 120V receptacle 19 GROUND STUD Provides a point for connecting the machine ca
73. Master TOC O o 9 5 tc F 68 F 68 TROUBLESHOOTING AND REPAIR CONTROL BOARD POWER SUPPLY TEST continued TEST PROCEDURE NOTE 1 In this test procedure the positive output stud is used for common NOTE 2 This test procedure does not test the engine control power supply portion of the control board 1 Using the 5 16 nut driver open the control panel and tilt out Remove the control board cover 2 Using the control PC board layout locate capaci tor C112 Figure F 31 and scrape the environmen 3 tal coating off the negative lead Start the 5 machine WARNING 6 e There are high voltages present inside 5 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 Voltage Measurement Point J5 pin 2 to common J4 pin 6 to common J5 pin 7 to common C112 neg lead to common J8 pin 2 to J8 pin 3 J20 pin 3 to J20 pin 4 15 596 10 596 5 VDC 596 10 VDC 596 24 596 15 596 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 c
74. PHASE 1 ZERO CROSS 163 lt 4 Pi METER CURRENT SENSE A D e R50 V SELECTOR SWITCH 10K CIRCUIT INPUT T MCGBHCII TO AMPHENOL 2 4 MCU common REMOTE POT MCU common CRYSTA us n 225 TL lo 888 C57 x Mc sommo ronem OUTPUT RANGE 2 SELECTOR SWITCH R506 R507 33 224 1227 TO AMPHENOL 1 A CV OPTION 1 common ACU con CONTROL POT 3 27 97B Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E ron COMMANDER 400 Gris ELECTRICAL DIAGRAMS G 13 SCHEMATIC CONTROL PC BOARD PART 2 18 WELD OUTPUTS FEEDBACK OO INPUTS Bri Au n 9 TO 50 EXCITER FB i
75. Retum to Master TOC 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 ENGINE CONTROLS Figure B 1 Items 1 through 8 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 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 th
76. Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC TROUBLESHOOTING amp 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 amp 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 u
77. SS SS 7 R11 R21 R25 3 S19400 1001 IK 1 4 COMMANDER 400 i eese SE R13 1 519400 5111 5 11 1 4W ENGINE PROTECTION 4 R16 R18 R24 3 S 19400 1002 10 1 4W 1 1 n 1 R23 1 519400 5112 51 IK 1 4W 5 e R26 R27 R28 R29 R30 R31 8 S 19400 2670 267 1 4W R32 R33 2 2 X1 1 515128 11 14 PIN QUAD COMPARATOR EIE 1 15 102 4 PERRIPHERAL DRIVER ARRAYS SS 29 m n LL LL x CAPACITORS MFD VOLTS 8 14 98C RESISTORS OHMS jo Ele 5 5 t 5 lt 81 8 cit Ble o o NOTE Lincoln Electric assumes responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components 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 LINCOLN amp ine LINCOLN Y machine COMMANDER 400 ELECTRICAL DIAGRAMS G 19 SCHEMATIC METER PC BOARD i d 15V Return to Master TOC Return to Section TOC xi X2 X3
78. 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 6 LOCAL REMOTE switch to REMOTE K857 remote control is used Set the switch to LOCAL if no remote control is used 7 Set VOLTMETER switch to or depend ing on the polarity chosen 8 Set RANGE switch to WIRE WELDING CV 9 Setthe WELDING TERMINALS switch to WELD ING TERMINALS REMOTELY CONTROLLED 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 FIGURE C 7 COMMANDER 400 K691 K488 K487 SPOOL GUN CONNECTION DIAGRAM 115 RECEPTACLE f J K488 SG CONTROL MODULE K487 25 SPOOL GUN 4 14 PIN WIRE FEEDER RECEPTACLE N 6 PIN REMOTE RECEPTACLE TO WORK ELECTRODE L ELECTRODE CABLE TO WORK TO CONTROL MODULE 7 K691 10 INPUT CABLE COMMANDER 400 C 10 NOTES COMMANDER 400 LINCOLN 0 C 10 DOL WINDY DOL WINDY DOL OF DOL OF 201 uon2es UMY DOLL uon2es 201 uon2es LUMPY DOLL
79. common BATT common V7 JS FUEL Lv LMI PULL meon V common BATT 392K nfa 027 J22 a gt ALT VOLTS LAMP J V R240 xa xs LOAK M common BATT 0122 MCU 5 AUX 1M2301 e mmon IB T common BATT common 5V 5V MCU 287 x5 953 8444 R521 2 tee LAMPS ON OFF 122 common BATT st ae common BATT 1227 Lm2aai ur gt PAL INTERFACE FROM 2 SEC TIMER gt UE us Se 051 2N4403 oci EP mra W OVERCURRENT sicNaL lt gt 042 065 SHUTDOWN pies 1N5402 ALL LAMPS ON INTERFACE V LOW FUEL FROM MCU Y Y 7 R361 common BATT SHUTDOWN SIGNAL common common 10 0k Return to Master TOC FROM Mi common BATT k llV SUL 5V BATT Return to Section TOC s E m T e lt RI36 PULL COIL OVERCURRENT 10 0K PROTECTION
80. may vary slightly above or below 3 If either of the readings is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 10mm wrench to loosen the locking nut See Figure 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 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 12 Adjust the collar to change the amount of throw in the lever arm until the frequency reads 47 Hz Retighten the locking nut Oscilloscope Method 1 Connect the oscilloscope to the 115 VAC receptacle according to the 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 in this sec tion of the manual 2 If either waveform periods is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 10mm wrench to loosen the locking nut See Figure 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 th
81. 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 COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION LIFTING The Commander 400 weights 1650 748 kg Stick model 1683 16 763 kg Stick amp Wire model A lift bail is provided for lifting with a hoist A WARNING FALLING EQUIPMENT can cause injury Do not lift this machine using lift bail if it is equipped with a heavy accessory such as a trailer Lift only with equipment of adequate lifting capacity Be sure machine is sta ble when lifting The 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 b Locate the 2 access holes on the upper middle region of compartment wall just below the lift bail c Use the lifting str
82. 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 Retum to Section TOC Retum to Master TOC 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 Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 96 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued FIGURE F 43 SCR DETAILS GATE ANODE SPECIAL INSTRUCTIONS 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 CATHODE OUTER METAL RING CAUTION
83. replacement of the engine and stator assembly This is necessary in order to gain access the stator and or rotor Retum to Section TOC Retum to Master TOC 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 Retum to Master TOC 8 8 This procedure takes approximately 8 hours to perform Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC F 106 F 106 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 49 FUEL TANK REMOVAL DETAILS C FUEL LEVEL SENSOR FUEL RETURN LINE 04 b U BOLT 2 7 PREPARATION AND LEAD REMOVAL PROCEDURE 1 Turn the engine off 5 Turn the fuel off at the shutoff valve Remove 2 Using the 3 8 and 1 2 wrenches remove the and plug the fuel return line See Figure F 49 battery cover and disconnect battery 6 Remove and plug the lower fuel line See Remove the battery by sliding it out Figure F 49 3 Perform the Case Cover Removal 7 Using the 9
84. settings when using either of these units for DC TIG welding See 400 Settings When Using the K799 Hi Freq Unit Settings When Using the K930 1 TIG Module See the Accessories section for recommended equipment for TIG welding COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION Table B 3 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES DCEN DCEP Tungsten Electrode p 1 2 Diameter Thoriated Tungsten 1 2 Thoriated Tungsten 2 15 5 20 15 80 70 150 150 250 250 400 400 500 500 750 750 1000 Approximate Argon Gas Flow Rate C F H I min Stainless Steel 3 8 3 8 m 2 4 fs 2 4 TIG TORCH Nozzle Size 1 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shield ing gases Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 196 Thoriated EWTh 1 2 Thoriated EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications DCEP is not commonly used in these sizes TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 in 5 5 16 6 3 8 in
85. the machine settings match the weld application If the remote control unit is not connected to the machine make sure the Local Remote switch S1 is in the Local position 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 RECOMMENDED COURSE OF ACTION 1 Perform the Range Switch Perform the Fine Control Potentiometer Test Check for poor connections at the J1 molex plug at the control board Also perform the Shunt Calibration Test Check for poor connections at J4 pins 1 2 3 6 amp 7 atthe con trol board Also perform the Exciter Voltage Feedback 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 Check for poor connections along lead 204 at the diode bridge and at J6 pin 4 molex plug at the control board This is control board common 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 Check for poor connection at J21 pins 1 amp 4 at the CV daugh ter board This is CVSCR gate drive output Will not aff
86. the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 COMMANDER 400 Retum to Master TOC Retum to Master T
87. the strobe tach according to the manufacturer s instructions COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC 8 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 4 Retum to Master F 39 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued 6 If either of the readings is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 10mm wrench to loosen the locking nut See Figure 1 for location of the adjusting screw and locking nut Turn the threaded screw counter clockwise to increase the HIGH IDLE speed Adjust the speed until the tach reads between 1890 and 1915 RPM Retighten the locking nut Adjust LOW IDLE First make sure there is no load on the machine Set the IDLE switch to AUTO and wait for the engine to change to low idle speed Use the 7 16 wrench to loosen the solenoid lever arm locking nut See Figure Adjust the collar to change the amount of throw in the lever arm until the tach reads between 1325 and 1400 RPM Retighten the locking nut Frequency Counter Method 1 Plug the frequency counter into one of the 115 VAC auxiliary receptacles 2 Start the engine and check the frequency counter At HIGH IDLE 1900 RPM the counter should read 63 Hz At LOW IDLE 1400 RPM the counter should read 47 Hz Note that these are median measurements hertz readings
88. to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC MAINTENANCE FIGURE D 1 OIL DRAIN AND REFILL d 29 ne 4 ANSA 57 lj amp l Jc 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 0 1 for recommended maintenance intervals See Table D 2 for replacement oil filters Change the oil filter as follows 1 Remove the oil drain plug Drain the oil from the engine and allow the oil filter to drain See Figure D 1 2 Remove the old filter spin it off and discard it 2 Wipe off the filter mounting surface and adapter See Figure D 1 3 Fill the new filter with fresh engine oil Apply a thin coat of new oil to the rubber gasket on the new oil filter 4 Spinthe 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 H lt MIN OIL FILL CAP 5 Refill the engine with the proper amount and type of oil as described in the Change the Oil section above Start t
89. 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 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued FIGURE F 44 RECTIFIER BRIDGE ASSEMBLY BRACKET DETAILS SCREWS 4 PROCEDURE 8 Inspect the mounting surfaces of each new Turn the engine off Rum a Remove all burrs and wipe clean Do not Perform ihe use steel wool or any abrasive cleanser Assembly Removal procedure on the SCR mounting surfaces Using the 7 16 wrench the mounting 9 Apply a thin 0 001 to 0 003 layer of PEN bracket for the SCRidiode rectifier bridge ETROX A 13 Lincoln Electric 2529 or assembly bracket See Figure F 44 PENETROX A heat sink compound to each Alternately loosen nuts 1 2 turn each until heat sinks SCR mounting surface heat sinks are loose Remove nuts and leaf a Care must be used to prevent foreign spring IT IS RECOMMENDED THAT NEW material contamination of the SCR to HARDWARE LEAF SPRING AND HOUS heat sink junction ING BE USED FOR REASSEMBLY 10 Place the new SCR between the heat sinks Remove the old SCR B
90. weld process as well as the engine protection features COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC B 3 B 3 OPERATION RECOMMENDED APPLICATIONS WELDER The Commander 400 Stick model provides excellent constant current DC welding output for stick SMAW welding The Commander 400 Stick amp Wire model also provides excellent constant voltage DC welding output for MIG GMAW and Inner shield FCAW welding GENERATOR The Commander 400 provides smooth 120 240 VAC output for auxiliary power and emergency standby power DESIGN FEATURES All Models FOR STICK WELDING Excellent DC constant current output for stick weld ing applications 40 to 400 amps output in six slope controlled ranges for out of position and pipe electrodes 50 to 575 amps constant current output in one general purpose welding range 9 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 Remote control capability standard on all models 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 desig
91. wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine Return to Section TOC Return to Master TOC LINCOLN amp wrens COMMANDER 400 G3 ELECTRICAL DIAGRAMS WIRING DIAGRAM STICK amp WIRE MODEL CODE 9979 CONNECTOR CAVITY NUMBERING SEQUENCE 3D VIEWED FROM COMPONENT SIDE OF BOARD 5D NEXT AVAILABLE 287 pore 4 1008 1002 1004 1006 a 1 2 f STUD T1 ON 240 269 274 272 M NO CONNECTION d CONNECTION BLOCK 208 ON NEWER MODELS 1 204A b RECTIFIER 1009 1013 1 1 1 1 1 1 1 1 5 POS 1011 J50 EXCITER VOLTAGE 246 FEEDBACK BOARD ICONNECTIONS TO 2048 600 AMP CURRENT CAPACITORS MADE 4 SHUNT SENSE TOROID 240 uF EYELET BOLTED 5 1 1012 Return to Section TOC Return to Master TOC 285 205A BYPASS PC BOARD ELECTRODE POLARITY OUTPUT STUD T2 ON 2 CHOKE FRAME CAPACITOR GROUND O CONNECTION BLOCK O ace Cy CHOKE 288 208A SOME OLDER M 1 223 SELECTOR VIEWED SWITCH gg FROM BACK FINE CONTROL SEE CHART POT m REMOTE 7 9 25 LOCAL 5 9 214 STUD T3 ON S OUTPUT pie switch f 1
92. 0740 ZERO CROSS DETECTOR MCU common PHASE 3 EXCITER 13 R323 EXCITER FB 4 7 VOLTAGE TO 85 0 IN SENSE CIRCUIT 5 87 OUT MCU common Gy J6 10v lt lt m gt SCR GATE EXCITER FB 1 00 x38 alm ZERO CROSS DETECTOR T 33074A 54HC132 Y 562 GATE DRIVE SCR 50v 4 75 Return to Master TOC Return to Section TOC MODE VOLTAGE F B TO CV CONTROL BOARD VOLTAGE 0 TO 850v IN 12 Ins V J CVSCR common _ CC STUD R207 SENSE CIRCUIT TO 5 8 OU EXCITER FB 71 24 150 2 a a w 1 lt Eur OPTION 1 4A J8 475 L8 lt 144007 POWER 34 10 0K p le Qu Ly 1 iva TENABLE eu 47 SUPPLY YE T
93. 1V Div Horizontal 2ms Div gio Coupling DC Trigger Internal JE gt 818 Jr cuc COMMANDER 400 F 80 F 80 TROUBLESHOOTING amp REPAIR ABNORMAL EXCITER VOLTAGE FEEDBACK WAVEFORMS Retum to Section TOC Retum to Master TOC Retum to Section TOC Retum to Master TOC 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 amp 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 Retum to Master TOC 8 8 Volts Div 1V Div Horizontal 2ms Div Coupling DC Trigger Internal Yiu PP 5 A gt 818 JE cu COMMANDER 400 F 81 F 81 TROUBLESHOOTING amp REPAIR CONTROL PC BOARD REMOVAL REPLACEMENT AND CALIBRATION WARNING Retum to Section TOC Retum to Master TOC Service and repair should be performed by only Lincoln Electric facto
94. 204 resistor R1 24 Replace the snubber board cover and con trol board cover 25 Replace all case covers See the Case Cover Removal and Heplacement pro cedure COMMANDER 400 LINCOLN F 48 _ E sw2 A R1 4 ohms 10 watts NZ R2 3 ohms 10 watts SCR G UNDER TEST 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 F 49 F 49 TROUBLESHOOTING amp 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 Retum to Section TOC Retum to Master TOC 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 Retum to Section TOC Retum to Master TOC MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver 3 8 Nut d
95. 3 for faulty connections See the Wiring Diagram Perform the Exciter Capacitor Bank Test Check for a short across the weld bridge plates Disconnect leads 3 5 amp 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 Check fro shorts or opens in the stator by performing the Resistance Test Perform the Power Supply Test No auxiliary power at receptacles The engine operates normally and the welding output is normal Check the circuit breakers CB1 thru Reset if tripped Check the GFCI receptacles Reset if tripped Check for loose or faulty plugs at the power receptacles Check the GFCI receptacles and associated wires for loose or faulty connections See the Wiring Diagram Check the continuity of leads 3 5 and 6 from the exciter windings to their respective tie points 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 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retu
96. 32 174 m 851 Seal a 53 C42 C52 C55 C59 C61 R 10 R94 R109 R184 519400 2431 2 43K 1 44 Bl DX I I Rigo X R456 C73 C75 C98 C99 C 102 I3 R170 R252 R253 261 7 19400 47R5 47 5 1 4W Raj n x x C 103 C 106 C 108 C 114 C 115 R435 R473 g 1 ngo E X ne ER 120 C124 C132 C136 C 144 R 15 R27 R497 3 5 19400 2211 2 21 1 4 5 z frag ras 882 IR 148 C 153 C 154 C 155 C156 C 158 R 16 R23 R105 R 125 R242 8 _ 519400 22 13 221K 174W 4r 4 27 0 m 19 C I9 C 143 3 s13490 121 1000 35 R335 R355 R360 T jone 015 r BR A s mie m C 16 1 s13490 97 100 20 R 17 R22 R460 R466 R5 15 5 _ 519400 1003 100K 1 4W eee SAOS p uM 17 118 2 516668 4 2700pF 50 R18 1 5 19400 1301 1 3K 1 4W M CY R347 L 8 22 C70 C 125 3 513490 39 18 15 819 1 _ 519400 5 110 511 1 4W 5 047 05 C31 C32 C53 3 S 13490 135 1 0 50 R20 R446 2 5 19400 8251 8 25K 1 4W Mr EL C40 C112 C113 C 116 C 122 amp 513490 66 47 35 R2 1 R468 2 519400 2210 221 1 4W EE NA 123 R25 R38 R296 R297 R298 9 519400 1080 10 1 4W LL E d 5 B C4 1 C139 C 146 C 147 4 11577 58 0047 3000V R443 R444 RB 10 8521 m Se Sox 44 C 104 C 105 C119 4 520500 4 00477 10007 R28 R3 10 R357 3 519400 6813 681K 1 4W 1 02 a n Li
97. 34 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 Using the 5 16 nut driver install the control board cover and the front control cover assembly Perform the following calibration procedure COMMANDER 400 83 B1 227 B2 262 B3 232 F 84 F 84 TROUBLESHOOTING amp REPAIR CONTROL PC BOARD REMOVAL AND REPLACEMENT continued ar 3 E CALIBRATION PROCEDURE to AUTO The display should read 003 818 Stick and Wire Model Only 8 Set the Output Control switch to the WELD E 1 Setthe front control panel as follows ING TERMINALS ALWAYS position oc Control dial to 0 Min 9 Turn the Control dial until the display reads Range dial to the Wire Welding setting 19 0 Assure that there is no load applied to Idler switch in the Auto position the unit Volts Amps switch to the volts position 10 Toggle the Idler switch to HIGH and back Output Control switch to the Welding to AUTO continually until the voltage on the Terminals Remotely Controlled position 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 2 Connect the volt ohm meter across the g to AUTO and the voltage will eventually a
98. 444 1 REMOTE CONTROL LN 25 N WIRE FEEDER WORK CLIP LEAD X TO WORK ELECTRODE CABLE COMMANDER 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC C 9 ACCESSORIES CONNECTION OF THE K488 SG CONTROL MODULE AND K487 MAGNUM SPOOL GUN TO THE COMMANDER 400 SEE FIGURE C7 1 Shut the welder off 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 3 Connect the K691 10 input cable as shown in Figure C 7 4 Set the slide switch on the SG Control Module to the Lincoln position CAUTION Be sure this switch is setto 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 5 Place the IDLER switch on the Commander 400 in the HIGH position CAUTION Any increase of the high idle engine RPM by
99. 5 5 t 515 818 E E ple o o BYPASS 30 1 48 Return to Section TOC Return to Master TOC 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 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 ELECTRICAL DIAGRAMS 6 12 SCHEMATIC CONTROL PC BOARD PART 1 ge 20V PRE IRI OIL PRESSURE BATT 20V BATT SHUTDOWN ne sy INPUT 017 m 1 08 30V x SOLENOID DRIVE OIL TEMP Sw 5 Dig gt F 018 NI i SAFETY SWITCH 122 18A 30V A ae ev 025 EXCITER CAP FUEL LEVEL SEND 2 gt n 2 4401 15A TERMINAL COVER A PULL t 60 FROM OIL rs 01 J22 L A 30V A PRESS SWITCH 38 ALT SENSE 14 014 18 028 common 2N4401 035 016 57 2N4403 0134 2938 ai 2 20957 LN2901 100 mmon BATT 0240 145402 common BATT V SUN ESH x J
100. 9 1 Oil Drain Kit Includes ball valve hose and clamp STICK WELDING K704 Accessory Kit which includes Electrode holder and cable Ground clamp and cable Head shield TIG WELDING Magnum TIG Torch Magnum Parts Kit and Argon gas K930 1 TIG Module not required for scratch start DC TIG welding K936 3 Control Cable K870 Foot Amptrol Also available K963 Hand Amptrol K814 Arc Start Switch K937 22 Control Cable Extension K937 45 Control Cable Extension K844 1 Water Valve HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The 799 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 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 SEMIAUTOMATIC WELDING ACCESSORIES 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 speed wire feeder For CV operation only LN 23P Wire Feeder This portable wire feeder is capable of CV operation K350 1 adapter kit is required
101. 97 098 0100 0101 0103 R112 R113 R124 R130 5 19400 1001 174W 9 XX XX Xx m 4 45 1653 oo D 104 0105 0106 0 107 D 108 R146 R151 R152 R174 MX 5 ET xXx 0 109 D110 D111 D113 0127 R 178 R212 R240 R260 8277 ps 1 SE 8 D 128 0129 0130 0131 R3 19 R325 R329 R332 R352 107 art fRESEL E X 02 03 092 3 712705 32 1547600 R364 R378 R383 8388 R389 HT dem 111 4 1 11 4 093 2 12705 47 45 200V R390 R437 R440 R442 def Lx ier nm EIE D 14 089 090 091 094 5 T712705 37 145822 SCHOTTKY BARRIER OI ODE R445 R465 R472 R474 R475 paa man BEI D 18 1 S18395 14 DIODE HS ASBLY R476 R5 18 R520 1529 R532 TTTT uu x4 6254 032 033 2 712 199 2 144007 R533 R536 4 036 12705 52 DI ODE 1218 604 400 FR R 173 R244 R276 3 519400 3570 357 1 44 Ab Li 253 D41 1 T12702 19 IN4742A R175 1 S 19400 2672 26 7K 1 4W mel mL Bl xe dsl Er 058 059 060 061 4 __ 112705 29 DI ODE R189 1 519400 7681 7 88K 1 4W R33 5 E t R251 IDes 078 0134 3 T12705 14 DI ODE R 198 1 5 19400 1501 1 5K 1 4 KX XX pm 1227 2114 0115 0116 0117 0118 14 712705 23 1458 18 R200 1 619400 6191 19 1 44 d Ed Gy JER D 119 0120 0121 0122 0123 R203 R423 2 519400 3322 33 2K 1 4 3 5 el nye ES
102. AC duplex GFCI receptacles 5 158 One 50 amp 120 240VAC receptacle 14 508 The 50 amp receptacle has a maximum permissible output of 44 amps However it can be split to power two separate single phase 120VAC branch circuits each capable of 44 amps output NOTE The two 120VAC outlets of the 120 240VAC receptacle cannot be paralleled They are on two 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 STANDBY POWER CONNECTIONS 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 1 Install the double pole double throw switch between the power company meter and the premises discon nect
103. AGED SCALE NONE WITH PUBLISHED STANDARDS T orn 55 00 6 19 95 OK PST ___________ A485 4 UNLESS OTHERWISE SPECIFIED TOLERANCE t EQUIP ON HOLES SIZES PER 2856 THE LINCOLN ELECTRIC CO TYPE COMMANDER 400 CONTROL PCB MCU common Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp rand COMMANDER 400 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E pz o uU 8 B Return to Section TOC o o g v o 8g 5 L4 Return to Master TOC G 14 ELECTRICAL DIAGRAMS G 14 PC BOARD ASSEMBLY CONTROL PC BOARD
104. Auxiliary Power 40 575 Amps 64 74 OCV 120 240 VAC in 7 Ranges Stick model 10 000 Watts 60 Hz or 8 Ranges Stick amp Wire model 01915 RPM 10095 Duty Cycle PHYSICAL DIMENSIONS WEIGHT 1650 5 748 kg Stick model 1683 16 763 kg Stick amp Wire model 1 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 1096 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 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Y 4 2 8 4 Retum to Master INSTALLATION Read this entire installation section before you start installation 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 ELECTRIC SHOCK can kill N e Do not touch electrically live parts such as output terminals or internal wiring e Insulate yourself from the work and ground e Always wear dry gloves insulating ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust out
105. CEMENT 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 IDLER EACH SIDE SOLENOID 224 AND 240 12 Label and remove the four leads 224 240 13 Label and remove leads 226 237 227 225 and 262 from the shutdown solenoid and 254 from the idler solenoid See Figure See Figure F 52 Cut any necessary cable F 53 Cut any necessary cable ties 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 LINCOLN 5 F 109 F 109 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 54 OIL PRESSURE SENSOR LEAD REMOVAL Retum to Section TOC Retum to Master TOC OIL PRESSURE SENSOR 18 gt 818 i 14 Label remove leads 228 and 234 15 Label and remove leads 23 and 241 from the oil pressure sensor See Figure from the oil temperature sensor See Figure F 54 F 55 FIGURE F 55 OIL TEMPERATURE SENSOR LEAD REMOVAL Retum to Master TOC 8 8 SENSOR Retum to Section TOC Retum to Master TOC COMMANDER 400 F 110 F 110 TROUBLESHOOTING amp
106. CTION PREMISES DISCONNECT AND SERVICE 45AMP GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE 50 AMP 120 240 CIRCUIT VOLT PLUG 240 VOLT BREAKER NEMA TYPE 14 50 N A 50 AMP 120 240 VOLT un On ee RECEPTACLE NOTE No 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS COMMANDER 400 LINCOLN 5 Section B 1 Section B 1 TABLE OF CONTENTS OPERATION SECTION 8 Operation iit e ee ene ede Section B g Safety instructo MS treno cix tena bnt demas etapa bo en do D debe Bad d RR RR DR a x ce B 2 General Ire dei B 2 8 Recommended B 3 Design B 3 Welding Gapabllity 5 oreet tree ite ae 4 Controls and sc ter B 5 Engine Controls 2 tdt ni ocu unu tepore RENT B 5 Welder Controls EUER B 7 Auxiliary Power Controls B 8 5 Wire Feeder Mod 8 8 25 UTE 8 3 Starting 8 STOPPING the ENGNG etae Fee d 9 8 E D 9 Typical Fuel anae 9 10 Stick Weldi
107. DED COURSE OF ACTION Contact the Lincoln Electric Service Department 1 800 833 9353 WELD No welding output in either CV or Stick modes Auxiliary power is nor mal and engine operates normally Place the Welding Terminals 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 Check the welding cables clamps and electrode holder for loose or faulty connections With the engine at high idle 1900 RPM and the machine in the general fab tap Check for the presence of 70VDC at the output terminals of the Commander 400 Check the welding 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 terminal switch S6 and leads 2 amp 4 back Check for poor connections at J6 pins 1 2 amp 3 molex plug at the control PC board Also check leads G1 G2 amp G3 to each SCR These are SCR gate drive out puts Check leads W1 thru W6 for loose or faulty connections See the wiring diagram Perform the Stator Voltage Test 6 Perform the SCR Diode Bridge 7 frest 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 te
108. Disconnect the welding cables from the control board See Figure F 13 welding output terminals 3 Perform the Case Removal Procedure including front shroud removal Retum to Master TOC 8 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN F 43 F 43 TROUBLESHOOTING amp REPAIR 5 STATIC SCR DIODE RECTIFIER BRIDGE TEST continued 5 FIGURE F 14 SNUBBER BOARD PLUG J30 LOCATION 2 2 8 PLUG J30 SNUBBER BOARD LOCATION LEFT SIDE BELOW FUEL TANK Retum to Section TOC Retum to Master TOC 6 Using the 3 8 nut driver locate and remove 8 Locate and remove lead 2048 from resistor the snubber board cover See Figure F 14 R1 50 ohms 100 Watts See Figure F 15 7 Locate and remove molex plug J30 from the snubber board See Figure F 14 FIGURE 15 RESISTOR R1 LOCATION Retum to Master TOC 8 8 RESISTOR R1 LEAD 204 Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 44 TROUBLESHOOTING amp REPAIR STATIC SCR DIODE RECTIFIER BRIDGE TEST co
109. ED FROM COMPONENT SIDE OF BOARD NEXT AVLB 287 CAPACITOR 2048 2065 EXCITER VOLTAGI kO O Iconnections To EDPACK BOAR Y 5 CAPACITORS MADE 1 VIA BOLTED 5 CONNECTIONS ____ BYPASS PC STATOR BOARD Return to Section TOC Return to Master TOC SELECTOR SWITCH S8 VIEWED FROM wee 9 f 9 45 2 26 219 9 715 3 STAINLESS STEEL FNECONTROL UBBER PC BOARD STAND 5 n 5 M TOROID TOROID 76B 75 778 LI P LI OFF AUXILIARY BYPASS PCB a LOCAL e B5 1 SWITCH E CONTROL HARNESS CONTROL HARNESS ALWAYS ON QUTPUT REMOTELY CONTROLLED Return to Section TOC Return to Master TOC CONNECTIONS ON CONTROL BOARD VIEWED AS INSTALLED KON CONTROL HARNESS MOTHER CONTROL PC BOARD 1 760 lt 750 lt ne 0 19 racer ENGINE PROT e 24 F GROUND a BOARD OFF STAINLESS STEEL LI STAND OFF AMPHENOL2 TOROID LI REMOTE CONTROL 11111117 NEUTRAL T2 STUD T603 8 lt IN CONTROL BOX REMOTE PROTECTION AUX POWER GROUND SCREW ON CONTROL PANEL FRAME GROUND FRAME GROUND _
110. EDED Volt Ohmmeter 3 8 Nut driver Wiring Diagram 7 16 Wrench Retum to Master TOC 5 8 9 8 This procedure takes approximately 55 minutes to perform Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN F 52 F 52 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TEST continued 8 FIGURE F 23 CONTROL BOX STUD TERMINALS 9 2 818 E eese T1 STUD 6 LEADS T2 STUD 5 LEADS T3 STUD 2 3 LEADS Q PP 9 2 818 JE TEST PROCEDURE Auxiliary Power Windings Test 1 Turn off the engine 5 Check for 230 250VAC at leads 6A to 3A at the stud terminals inside the control box See 2 Perform the Case Cover Removal the Wiring Diagram and Figure F 23 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 Retum to Master TOC B 8 If any of the above voltage checks are low or missing check the associated leads for loose or faulty connections the Wiring Diagram Then proceed to the Exciter Winding Voltage Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN F 53 F 53
111. ER E 2056 XA ON 2 PLACE DECIMALS 18_ 02 CLEVELAND OHIO U S A ON PLACE DECIMALS IS 002 12 15 95 ON ALL ANGLES IS 5 OF A DEGREE scaLe NONE a SHT MATERIAL TOLERANCE t TO AGREE E ICI WT PUBLISHED STANDARDS DR B K BATE 12 29 94 EV SUP S D C 52211 AUX PROTECTION BD SCHEMATIC SUBJE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN COMMANDER 400 ELECTRICAL DIAGRAMS e PC BOARD ASSEMBLY AUXILIARY PROTECTION PC BOARD Return to Section TOC Return to Master TOC R XICIARY PROTECTION Return to Section TOC Return to Master TOC ITEM REQ D PARI NO DESCRIPTION 84 B5 86 B7 4 13157 14 TERMI NAL Go td 12 SL 0047 or 005 1400 CIZ o o o 8 5 L4 o o E pz o uU 8 B L9749 1 12 15 95A Return to Section TOC Return to Master TOC 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 not available from
112. ES 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 WARNING 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 3 Using grid bank load the machine to 300 amps at 25 volts using an external ammeter and volt meter 4 At the control board measure the voltage from J1 pin 3 pos lead to J1 pin 2 neg lead See Figure 29 The voltage should be 25 mVDC 5 The current reading on the display should be within 5 with the external ammeter See Figure F 29 5 If step 4 fails the shunt is out of calibration and must be replaced 6 If the test is complete replace the control board cover and close the control panel Figure F 29 Control Board Plug J1 Ss ia 4L 4 1 L t Pas B SOY d 112
113. GINE OUTPUT Mode No Load RPM Load RPM Low Idle 1325 1400 High Idle 1890 1915 Retum to Section TOC Retum to Master TOC 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 Retum to Section TOC Retum to Master TOC AUXILIARY POWER OUTPUT 230 Volt Receptacle 115 Volt Receptacle Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps Voltage Voltage 230 250 224 44 6 115 132 108 126 13 16 Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN F 118 NOTES COMMANDER 400 LINCOLN 0 F 118 DOL WINDY DOL WINDY DOL OF DOL OF DOL uono2es o DOL uono2es o uirgo DOL uono2es o UMY DOL uon2es oy uua Retum to Master TOC Retum to Master TOC Y 4 2 8 Retum to Master TOC G 1 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section 222 00 1 Section G Wiring Diagram Stick Model Code 9978 eene nnns G 2 Wiring Diagram Stick amp Wire Model Code 9979 G 3 Wiring Diagram Stick Model Code 10580 G 4 Wiring D
114. HOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued FIGURE F 47 HOUSING AND PRESSURE PAD FOR 5 8 WIDE LEAF SPRING 5 8 PROCEDURE FOR 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 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 FIGURE F 48 CLAMP ASSEMBLY HEX NUT HEAT SINK HEAT SINK HOUSING e 87 LEAF SPRING CAP SCREW COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 101 F 101 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued CLAMPING PROCEDURE FOR 1 4 28 CAP SCREW
115. INE MOTHER PROT CONTROL PC BOARD B1 B2 B3 y 240 uF CONTROL HARNESS CONTROL HARNESS OUTPUT 1 CONTROL p ALWAYS ON SOURCE OUTPUT REMOTELY CONTROLLED Return to Section TOC Return to Master TOC 7 CONTROL HARNESS CONTROL 10800 76D 6s gt 76D 75D 3 lt PESE 4p Le Hd e lt 7m i ENGINE PROT 9 au T 4 e BOARD J23 STAINLESS STEEL 1770 2421 F GROUND STAINLESS STEEL STAND OFF AMPHENOL 2 COMMON BATT METER STAND OFF mem exa nc NEUTRAL T2 STUD PCB IN CONTROL BOX optional f CEE FA 11117777 9 z AUX POWER GROUND SCREW NO CONNECTION 239A 247 ON CONTROL PANEL ms FRAME GROUND ON NEWER MODELS A FRAME GROUND GND D 2421 GND E 240 i SELECTOR SWITCH S8 POSITION NAMEPLATE SETTING 1 NO FUNCTION AUX CURRENT 2 NO FUNCTION LINE HOT LOAD HOT 9 J12 GND F WELDED STUD SENSE TOROID ON OUTPUT PANEL 90 MAX 120 MAX WHITE
116. Ifthe test is complete replace the control board cover and close the control panel Table 1 Range Switch Position CV tap 90 tap 120 tap 180 tap 230 tap 270 tap 400 tap 50 575 tap 580 Vdc if so equipped 937 Vdc 1 29 Vdc 1 65 Vdc 2 00 Vdc 2 36 Vdc 2 69 Vdc 3 06 Vdc COMMANDER 400 LINCOLN P Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC J2 1 1 TROUBLESHOOTING amp REPAIR RANGE SWITCH TEST continued Figure F 28 Control Board Plug J7 Plug J7 Pin 10 COMMANDER 400 LINCOLN Pin 7 ae F 60 NOTES COMMANDER 400 LINCOLN 8 F 60 DOL WINDY DOL WINDY DOL OF DOL OF 201 uon2es UMY DOLL uon2es 201 uon2es LUMPY DOLL LUMPY F 61 F 61 TROUBLESHOOTING amp 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
117. LINCOLN CORRECTIVE ACTION Replace control board Replace control board Replace control board Check exciter voltage waveforms as illustrated in the Waveforms Section Perform the Stator Voltage Exciter Winding Test Perform the Engine Throttle Adjustment Test Perform the Exciter Capacitor Bank Test Check leads 268 269 amp 270 from J50 to J4 at the control board for loose or faulty connec tions Also check the T1 T2 amp T3 lead connections from the Exciter Module to the stator and capacitor bank leads Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 22 F 22 TROUBLESHOOTING amp REPAIR COMMANDER 400 WITH G2713 2 or 3 CONTROL BOARD ERROR CODES DURING INITIALIZATION SEQUENCE DEFINITION SYMPTOM Processor is not reading a valid range control switch position The exciter voltage level is too high greater than 550VAC The exciter voltage level is too low less than 140VAC The processor is not receiving zero cross signals properly or the engine RPM is too high COMMANDER 400 LINCOLN CORRECTIVE ACTION Check for proper selector switch handle alignment Perform the Range Switch Test Check the exciter voltage wave forms as illustrated in the Oscilloscope Waveforms Section Perform the Stator Voltage Excit
118. LINE 1 180 230 270 400 50 575 o 8 z 8 o 2 Pj o 8 B SOLENOID GROUND LINE HOT LOAD HOT HOUR METER STUD ON ENGINE 1 120V J11 298 2 PANEL TO PANEL WIRES NOTE DIODE APPEARS ON SOME MODELS LINE STARTER WHITE PANEL TO PCB HARNESS SENDER BART SOLENOID BUT REPLACED BY 286 LEAD 285 ON NEWER 232C Z 2 MODELS OIL PRESSURE SWITCH STARTING T3 amp SENSOR MOTOR INSULATED STUD Jie Ta E esos 55 12 VOLT IN CONTROL BOX BATTERY J10 AMMETER ie 8 Nm SILVER 2 GIL TEMP SENSOR amp SWITCH 120 240V LOW 228A lt _ STUD ON ENGINE 3 pere rp 929 MOUNT CHANNEL V 24A 4 2420 lt 5 lt SO 220A 6 229 SENSOR 239 STUD ON Sua ENGINE SILVER 7 ma 1 INSULATED STUD E Auc IN CONTROL BOX CONTROL PANEL ENGINE HARNESS TO PANEL WIRES 8 GROUND SCREW 9 lt ENGINE HARNESS FI 5C ENGINE GROUND STUD ON GENERATOR MOUNT CHANNEL 1 16 98E L9041 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The
119. LTER HEADER QUICK CAP CHANGE RING RING COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC 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 NOTE The element will only go on one way Never use excessive force when mounting the element to the header 5 Slide the quick change ring up over the element and rotate counter clockwise until an audible click or pop is heard If you do not hear the click you have not rotated the ring far enough and the element is not in the locked position Another indication that the ring is in the locked position is that one set it 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 Open the fuel shutoff valve lever in line with the hose Open the air vent valve on the front of the filter head er until fuel emerges
120. 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 LINCOLN amp ine LINCOLN Y machine COMMANDER 400 e ELECTRICAL DIAGRAMS G 10 SCHEMATIC BYPASS PC BOARD USES 85414 S Return to Section TOC Return to Master TOC CC STUD B2 x To a ST SDN ES Ci C2 22uf m 22 4UOVdc 4 Vdc Return to Section TOC Return to Master TOC ojo E 5 5 t 515 ge ple o o THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OFTHE LINCOLN ELECTRIC CO GENERAL INFORMATION LABELS ILE 52129815D SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING ELECTRICAL SYMBOLS PER E1537 SUPPLY VOLTAGE NET 7 FRAME CONNECTION THE INTERCHANGEABILITY OF COMPLETE BOARD CAPACITORS MFD 0047 14001 UNLESS OTHERWISE SPECIFIED C POWER SUPPLY SOURCE POINT THIS DIAGRAM NOT SHOW THE EXACT COMPONENTS RESISTORS Ohms
121. NING Retum to Section TOC Retum to Master TOC 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 Retum to Section TOC Retum to Master TOC 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 Retum to Master TOC 8 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515
122. NTROL BOARD ERROR CODES WHILE RUNNING DEFINITION SYMPTOM RTI error illegal return from interrupt SWI error illegal software interrupt request IOT error illegal op code trap COP time out error CME error slow or stopped processor clock OC5 unintended execution IC3 unintended execution COMMANDER 400 LINCOLN CORRECTIVE ACTION If a High Frequency unit is being used make sure it is connected properly There may be high frequency intrusion from another source in the immediate area Remove all possible forms of intrusion If the problem persists the control board may be faulty Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 26 F 26 TROUBLESHOOTING amp REPAIR COMMANDER 400 WITH G2713 2 OR 3 CONTROL BOARD ERROR CODES WHILE RUNNING DEFINITION SYMPTOM The exciter voltage is too high greater than 550 VAC The exciter voltage is too low less than 140 VAC The processor is not receiving zero cross signals properly or the engine RPM is too high COMMANDER 400 LINCOLN CORRECTIVE ACTION Check exciter voltage waveforms as illustrated in the Oscilloscope Waveforms Sections Perform the Stator Voltage Exciter Winding Test Perform the Engine Throttle Adjustment Test Perform the Ex
123. OC Y 4 2 8 amp Retum to Master TOC SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour souda
124. OTE Figure C 5 shows the electrode connected for negative polarity 3 Connect the K350 1 adapter to the 6 pin amphenol on the LN 23P and the 14 pin amphenol of the Commander 400 as indicated in Figure C 5 4 Place the IDLER switch in the AUTO position CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 5 Setthe VOLTMETER switch to negative 6 Set RANGE switch to WIRE WELDING CV 7 Setthe 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 9 Adjust wire feed speed and voltage at the LN 23P FIGURE C 5 COMMANDER 400 LN 23P CONNECTION DIAGRAM 14 PIN AMPHENOL A ADAPTER ul Kir 2 Pu LN 23P 5 6 PIN K350 1 AMPNENOL WIRE FEEDER TO WORK ELECTRODE SS 1 UN i y ELECTRODE CABLE TO WORK COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC
125. PAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE 57 EXCITER BOARD COVER REMOVAL MOUNTING NUTS 3 EXCITER EXCITER BOARD COVER MOUNTING SCREW 25 Using the 3 8 nut driver remove the exciter 26 board cover This is sealed and may require some gentle prying to dislodge See Figure 57 WARNING ELECTRIC SHOCK can kill Do not operate with panels open 27 Disconnect NEGATIVE BATTERY LEAD before ser vicing Do not touch electrically live parts 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 With the 7 16 wrench remove the three brass nuts and label and remove the T1 T2 and T3 stator leads only from the studs Cut any necessary cable ties With the 5 16 nut driver remove the screws and drop the case front to access the control box Remove the control board cover COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 112 28 29 30 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMO
126. PUT 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 TABLE B 1 OUTPUT RANGE SWITCH AND OUT PUT CONTROL FUNCTIONS Range Switch Sloped Output for 6 Range 12 Pipe Welding Settings all models 90 120 180 230 270 400 Max current on each setting Provides a fine 1 Range setting adjustment of 50 575 Amps welding current or voltage from 13 Min 1 to Max 10 within each range Constant Current Welding This set ting also used for all models 14 Constant Voltage Range setting Output for Wire 12 to 40 Volts Welding Stick amp 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 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 toggle switch on the control panel labeled WELDING TERMINALS ALWAYS ON and WELDING TER MINALS REMOTELY CONTROLLED is used to control the oper
127. R HEN WK OIL TEMP SENSOR amp SWITCH 241 senson 233 L sWircH 12 VOLT BATTERY STUD ON ENGINE MOUNT CHANNEL STUD ON GENERATOR MOUNT CHANNEL STUD ON ENGINE ENGINE TO PANEL HARNESS 2398 lt 8 lt 9 ENGINE GROUND 15 98A 11009 COMMANDER 400 ida ELECTRICAL DIAGRAMS as SCHEMATIC AMPHENOL BYPASS PC BOARD 00621 N Return to Section TOC Return to Master TOC TO OUTPUT CONTROL SOURCE SWITCH TO MOTHER CONTROL PCB 75 Return to Section TOC Return to Master TOC TO REMOTELOCAL SWITCH jo ojo E 5 5 t 515 ge ple o o FILENAME M17900 1 GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 Re CAPACITORS 022 50 UNLESS OTHERWISE SPECIFIED 5 6 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS L 6 DIODES 1 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET NOTES O POWER SUPPLY SOURCE POINT SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 5 COMMON CONNECTION WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY 7 FRAME CONNECTION NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE UNLESS OTHERWISE SPECIFIED TOLERANCE XE THE LINCOLN ELECTRIC CO
128. REMOTE SWITCH ENGINE PROTECTION BOARD CURRENT MODE SELECTOR SWITCH control board for the idler solenoid which is mechani cally coupled to the engine s throttle linkage 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 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 Retum to Section TOC Retum to Section TOC 9 8 9 8 Retum to Section TOC R
129. Retum to Section TOC Retum to Master TOC 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 Retum to Section TOC Retum to Master TOC MATERIALS NEEDED 5 16 Nut Driver M ulti M eter 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 Retum to Master TOC 8 8 This procedure takes approximately 40 minutes to perform Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN 5 Return to Section TOC Q 2 5 2 5 tc Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC F 62 TROUBLESHOOTING AND REPAIR SHUNT CALIBRATION TEST continued F 62 TEST PROCEDURE NOTE n this test procedure the positive output stud is used for common 1 Using the 5 16 nut driver open the control panel and tilt out Remove the control board cover Start the machine There are high voltages present inside the control box while the machine is running THE VOLTAG
130. Return to Master TOC Return to Master TOC O PN gt o 9 gt a 2 gt tc Return to Master TOC View Safety Info View Safety Info 9 gt o 2 gt CUm SERVICE MANUAL View Safety Info SVM133 B September 2002 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 LINCOLN 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 SAFETY WARNING 5 A CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other r
131. S NOTE This procedure can only be used with 1 4 28 cap screws 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 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure CLAMPING PROCEDURE FOR 1 4 20 CAP SCREWS NOTE This procedure can only be used with 1 4 20 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do not 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 2 Tighten first cap screw 1 4 turn 2 Tighten first cap screw 1 4 turn 3 Tighten second cap screw 1 2 turn 3 Tighten second cap screw 1 2 turn 4 Tighten first cap screw 1 2 turn 4 Tighten first cap screw 1 2 turn 5 Tighten second cap screw 1 2 turn 5 Tighten second cap screw 1 4 turn 6 Tighten first cap screw 1 2 turn 6 Tighten first cap screw 1 8 turn 7 Tighten second cap screw 1 4 turn STOP 7 Tighten second cap screw 1 8 turn STOP 8 Assembly now has the proper clamping force 8 Assembly now has the proper clamping force 9 Perform the Active SCR Test 9 Perform the Active SCR Test AFTER REPLACING THE SCRs Follow the steps in the Bridge Removal and Replaceme
132. S OHMS jo Ele 5 5 o t 5 lt 2 2 cit Ble o o NOTE Lincoln Electric assumes responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components 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 LINCOLN amp ine LINCOLN Y machine COMMANDER 400 Rud ELECTRICAL DIAGRAMS ol SCHEMATIC ENGINE PROTECTION PC BOARD 00921 FROM OIL TEMP SWITCH OIL TEMP SWITCH F B TO OIL TEMP SHUT P23 DOWN LOGIC INPUT P22 5 e 6 9 gt TO ALT i LED NE 00 TO OIL 2 oi 15 PRESS LED poo 02 TO OIL gt 03 TEMP LED COMMON COMMON 04 TO FUEL FROM FUEL LEVEL SENDER V 22 LVL LED POST ON FUEL GAUGE P23 51 BATT 06 vc CLAMP MC1413BP DZ5 LAMP DRIVER 20V 1W DZ4 076 20 20 M COMMON EPD 1W 1W e e 12V 7 COMMON 1 22 Return to Master Return to Section TOC
133. SFORMER PCB PWM gt S za lt XX 02 1 025 2 T12704 54 N CHANNEL FET SS X1 1 522119 8 55 ROM ASSEMBLY o Cus cxx 022 033 035 038 042 5 112704 69 2N4403 2 1 15458 4 8 PIN IC 1 m lt 2 046 1 620106 1 HEXFET W H S ASBLY 59 X31 2 _ 517200 24 QUAD 2 INPUT SCHMITT TRIG NAND SS K XXXXXXXXX B QH 8 5 R1 14 R86 R96 4 519400 1372 13 7 1 44 x5 1 _ 515128 11 14 PIN QUAD COMPARATOR 5 eX wm R2 R93 R85 128 R 142 R243 14 s19400 2212 22 1 174W x7 1 515128 20 AMPLIFIER x T TT O Li bad R285 R34 1 R343 R384 R413 X9 X20 X28 X30 4 515128 18 QUAD 0P X Ix x XX ssl R452 R46 1 R479 X13 X16 2 518395 3 HEAT SINK ASBLY i X X 5 lele R3 R42 R43 R44 R50 85 61 s19400 1002 10K 174W X14 1 __ 15102 3 RESET 1 C UNDERVOLT SENSING CIR 59 Q A TTT R87 R101 X15 1 815128 16 LINEAR INTEGRATED CIRCUIT X kJ IppyA 103 R106 R110 118 R121 x18 1 515128 5 5V REG WC M R 123 R136 R140 R 144 R 145 X2 1 X29 2 _ 515018 15 14 PIN SS ls XX 5 N d 114 ee tt cx xc 143 R185 R187 R202 R2 13 X22 X26 2 S 150 18 18 ARRAY CLAMP NG X X S x s am xO R2 15 R2 17 R218 R219 R220 X24 1 S 150 18 9 CMOS 145388 SS X m gig 5 EEES X27 1 522019 1
134. SWITCH 75 VIEWED FROM CAPACITOR CONTROL f ALWAYS ON 768 BACK i i CONNECTION BLOCK a SOURCE OUTPUT REMOTELY i CONTROLLED RF BYPASS Pc BOARD Return to Section TOC Return to Master TOC CONNECTIONS ON CONTROL BOARD VIEWED AS INSTALLED cv ENGINE CONTROL BOARD PROT BOARD PC BOARD o CONTACTOR WORK 21 E gt REMOTE NEUTRAL T2 STUD CONTROL IN CONTROL BOX gt J7 ITTTTTTT B1 B2 B3 INE PROT i BOARD STAINLESS STEEL STAND OFF COMMON BATT 1 AUX POWER GROUND SCREW IN CONTROL BOX lt GROUND GND C CV DAUGHTER BOARD GND D 085 15AMP GND E LOAD HOT 442 GND F WELDED STUD ON OUTPUT PANEL FRAME GROUND 240 AMPHENOL 2 FRAME GROUND SELECTOR SWITCH S8 POSITION NAMEPLATE SETTING ENGINE HARNESS NO FUNCTION 224 TINE LOAD HOT J11 WIRE WELDING CV oan 1 HOLD oux 5 120 MAX SHUTDOWN SOLENOID 5 180 MAX i ou 230 1 ojo
135. TE PROTECTION P C BD SCHEMATIC FV SUP S D G 2 NO M 17948 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual COMMANDER 400 E ELECTRICAL DIAGRAMS ina PC BOARD ASSEMBLY REMOTE PROTECTION PC BOARD Return to Section TOC Return to Master TOC o REMOTE PROTECTION X _ NEN D E door TEM FEM _ REQD PARTNO ITEM ITEM REQ D PART NO IDENTIFICATION C1 C2 C4 05 111577 58 0047 3000V SOO 9182480 HEADER J60 518248 6 HEADER DOO a 518248 8 CONNECTOR Li L2 L3 14 15 T12218 9 00000 N TP2 13640 16 gt lt Return to Section TOC Return to Master TOC J61 gt lt gt lt J60 gt lt gt L5 L3 L SAP TTA L9924 1 12 15 95A jo ojo E 5 5 o 515 2 8 ple o o jo Return to Section TOC Return to Master TOC 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 qual
136. UTS 111014 L ci2 M C 081 50v OUTPUT RANGE SELECT 07 6 22 Vss MCU Common PHASE EXCITER GAP 47084 MCU common Cosmetic Trace PHASE 2 EXCITER 05 4 PHASE 1 EXCITER A D4 lt 2 4 SWITCH PCO SCRI GATE INTERFACE C 6 2 LOW FUEL INTERFACE PC2 lt MCU A 0 g o 8 5 o wn 8 B m C133 rx 0047 T iov common ENGINE SHUTDOWN OUTPUT PBO lt LAMP ON OFF INTERFACE V A SWITCH CIRCUIT PC4 AUX CURRENT SENSE PCI SCI 39s SPI INTERFACE IDLE SWITCH INPUT 5 Pd 2 5 v INTERFACE 2 m 1 00M IDLE SIGNAL 5 j 2 COMMON JO 5V MCU R228 ds 3 CLOCK MCU common PHASE C SCR PHASE B SCR PHASE SCR VOLTAGE SENSE A DO lt ENGINE STARTUP SIGNAL PB4 lt 6 4 75 475 CC VOLTAGE SENSEA 03 FINE CURRENT FINE POT 8 02 lt 6 1 00M CONTROL POT ON RD CROSS CENTRO PRAGE HASE 3 ZERO CROSS PHASE 2 ZERO CROSS 02 z
137. VAL AND REPLACEMENT continued FIGURE F 58 CONTROL BOARD PLUG J 2 LOCATION OM it C PLUG J2 M ve ESN Locate and remove plug J2 from the control board See Figure F 58 Thread plug J2 out of the control box 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 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 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 FIGURE 59 CONTROL BOX STUD TERMINALS T1 STUD 6 LEADS T2 STUD 5 LEADS T3 STUD 3 LEADS F 112 COMMANDER 400 LINCOLN 5 F 113 F 113 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT cont
138. age 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 6 LOCAL REMOTE switch to REMOTE K857 remote control is used Set the switch to LOCAL if no remote control is used 7 Setthe VOLTMETER switch to or depend ing on the polarity chosen 8 Setthe RANGE switch to WIRE WELDING CV 9 Setthe WELDING TERMINALS switch to WELD ING TERMINALS REMOTELY CONTROLLED 10 Adjust wire feed speed at the LN 7 NOTE For remote control a K857 control is required Connect it to the 6 pin amphenol FIGURE C 2 COMMANDER 400 LN 7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM LN 7 INPUT CABLE PLUG 5 2 595 CONTROL CABLE 14 AMPHENOL 2 2 OPTIONAL K857 REMOTE oe 5 CONTROL L ELECTRODE CABLE TO WIRE FEED UNIT TO WORK COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC 5 ACCESSORIES CONNECTION OF THE LN 8 TO THE COMMANDER 400 USING K867 UNIVERSAL ADAPTER SEE FIGURE C 3 1 Shutthe welder off 2 Connect the electrode cable from the LN 8 to the
139. aintained An optional spark arrester kit is available for your Commander 400 See the Accessories section of this manual for more information CAUTION An incorrect arrester may lead to damage to the engine or adversely affect performance COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION ELECTRICAL OUTPUT CONNECTIONS See Figure A 1 for the location of the 120 and 240 volt receptacles weld output terminals and ground stud 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 CAUTION Loose connections will cause the output terminals to overheat The terminals may eventually melt Do not cross the welding cables at the output terminal connection Keep the cables isolated and separate from one another When welding at a considerable distance from the welder be sure you use a
140. 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 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 either voltage check fails replace the PC board 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 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 HH 9 Dag ew 5 w Bem TT T i
141. and F 85 SCR Diode Rectifier Bridge Removal and F 89 SCR Removal and F 95 Mounting Stud Type Diodes to Aluminum Heat F 103 Engine Stator Rotor Removal and F 105 Retest After F 117 Q 2 5 COMMANDER 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC TROUBLESHOOTING amp 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 1 LOCATE PROBLEM SYMPTOM Look under the col
142. ap to raise the lift bail to the full upright position This will align the mounting holes on the lift bail with the access holes d Secure the lift bail with 2 thread forming screws The screws are provided in the shipped loose parts bag HIGH ALTITUDE OPERATION At higher altitudes output derating may be necessary Some engine adjustments may be required Contact a Deutz Service Representative TOWING The recommended trailer for use with this equipment for road in plant and yard towing by a vehicle 1 is 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 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 3 Proper placement of the equipment on the trailer to insure stability side to side and front to back when the trailer is being moved and when standing by itself 4 Typical conditions of use such as travel speed roughness of surface on which the trailer will be operated environmental conditions and likely maintenance Proper preventative maintenance of trailer Conformance with federal state and loca
143. apacitance from 1002 1004 1006 1008 to 10 1001 1003 1005 1007 with a capacitance meter The capacitance value should be 240 uf 5 Measure capacitance from multi lead 1018 1020 1022 1024 to multi lead 1017 1019 1021 1023 with a capacitance meter The capacitance value should be 240 uf 5 Measure capacitance from multi lead 1010 1012 1014 1016 to multi lead 1009 1011 1013 1015 with a capacitance meter The capacitance value should be 240 uf 596 If any of the capacitance values in steps 5 7 are incorrect then all the capacitors in that phase must be replaced If the test is complete reconnect the 3 bolted connections for the T1 T2 amp T3 leads from the stator and exciter module and capacitor leads Make sure that the T1 T2 amp T3 stator leads are matched to the T1 T2 amp 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 Reinstall the left side engine and stator cover panels per the l Case Cover Removal section Figure F 30 Control Board Plug J1 T1 T2 T3 COMMANDER 400 LINCOLN 5 F 67 F 67 TROUBLESHOOTING amp 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
144. 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 7 Re insert the large white volume plug into the upper cavity 8 Place the O ring onto the angled seal surface of the filter header and re install the plastic cap Make sure its flange rests on the O ring 9 Screw on the cap ring and tighten hand tight 10 Remember to open the fuel shutoff valve Lever in line with the hose before starting the engine Water Separator Element The water separator 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 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 0 2 FUEL PRE FILTER WATER SEPARATOR ASSEMBLY FUEL SHUTOFF VALVE FI
145. ases or the AC power load is turned off a fixed time delay of approxi mately 15 seconds starts If the welding or AC power load is not restarted before the end of the time delay the idler reduces the engine speed to low idle speed e The engine will automatically return to high idle speed when the welding load or AC power load is reapplied Idler Operational Exceptions When the WELDING TERMINALS switch is in the WELDING TERMINALS REMOTELY CONTROLLED position the idler will operate as follows a When the triggering device Amptrol Arc Start Switch etc is pressed the engine will accelerate and operate at full soeed provided a welding load is applied within approximately 15 seconds f the triggering device remains pressed but no welding load is applied within approximately 15 seconds the engine will return to low idle speed f 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 COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION WELDER CONTROLS Figure items 9 through 14 9 OUT
146. ason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD COMMANDER 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 11 F 11 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The battery does not stay charged Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Check for loose faulty or cor roded battery cable connec tions The battery may be faulty Check or replace RECOMMENDED COURSE OF ACTION 1 Perform the Charging Circuit The Fine Control the Commander 400 does not work properly Make sure the Remote Local switch 51 is in the LOCAL position 1 Perform the Fine Control Potentiometer Test The control board may be faulty Remote output control not function ing correctly Make sure the Remote Local switch S1 is in the REMOTE position The remote control unit or cable may be faulty Repair or replace 1 Perform the Fine Control Potentiometer Test Check the Remote Local switch S1 and associated leads Se
147. ation of the solid state contactor which allows for the selection of Hot or Cold welding terminals With the switch in the WELDING TERMINALS ALWAYS ON position the contactor is closed and the welding terminals are always Hot With the switch in the WELDING TERMINALS REMOTELY CONTROLLED position the 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 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 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 For remote control set the toggle switch in the position For control at the welder control panel set the toggle switch in the LOCAL position 6 PIN CONNECTOR The 6 pin connector locat ed on the control panel allows for connection of Remote Control accessories 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
148. ce the cooling blower belt 1 2 Allow the machine to cool Unfasten and slide the battery holder out from the welder 3 Disconnect the negative battery cable 4 Remove the engine end panel for access to the engine See Figure D 4 Loosen the alternator mounting bolts 1 2 3 and rotate the alternator toward the engine 6 Remove the old cooling blower belt and install a new one Push outward on the alternator 4 and adjust the cold belt tension to 63 73 Ibs 10 15 mm maximum deflection midway between any two pulleys Tighten bolts 1 2 3 Reinstall the engine end panel Reattach the nega tive battery cable Slide in and refasten the battery holder Check the cooling blower belt tension after 100 hours of operation FIGURE D 4 COOLING BLOWER BELT REPLACEMENT AND ADJUSTING COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 4 Retum to Master FREQUENCY MAINTENANCE TABLE D 1 DEUTZ ENGINE MAINTENANCE SCHEDULE MAINTENANCE REQUIRED Daily or Before Starting Engine Fill fuel tank Check oil level Check air cleaner for dirty loose or damaged parts Replace if necessary Check air intake and cooling areas clean as necessary First 50 Hours and Every 250 Hours Th
149. citer Capacitor Bank Test Check leads 268 269 amp 270 from J50 to J4 at the control board for loose or faulty connections Also check the T1 T2 amp T3 lead connections from the Exciter Module to the stator and capacitor bank leads F 27 F 27 TROUBLESHOOTING amp 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 Retum to Section TOC Retum to Master TOC 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 Retum to Section TOC Retum to Master TOC MATERIALS NEEDED 3 8 Nut driver or Socket Wrench 7 16 Wrench 5 16 Nut Driver Retum to Master TOC 8 8 This procedure takes approximately 35 minutes to perform Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN F 28 F 28
150. d may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN je machine COMMANDER 400 ELECTRICAL DIAGRAMS Ge SCHEMATIC AUXILIARY PROTECTION PC BOARD Return to Section TOC Return to Master TOC EUTRAL 1 EUTRAL 2 Return to Section TOC Return to Master TOC jo ojo E 5 5 t 9 ge ple o o THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OFTHE COLN ELECTRIC CO ENERAL INFORMATION LABELS Fe COMPONENTS OR CIRCUITRY ON PRINTED RCUIT BOARD MAY CHANGE WITHOUT AFFECTING ELECTRICAL SYMBOLS PER E1537 SUPPLY VOLTAGE NET FRAME CONNECTION E INTERCHANGEABILITY OF A COMPLETE BOARD CAPACITORS MFD 0047 14 0 V UNLESS OTHERWISE SPECIFIED E POWER SUPPLY 500 D S DIAGRAM NOT SHOW THE EXACT COMPONENTS ESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED RCE POINT CIRCUITRY OF CONTROLS HAVING COMMON CODE NUMBER ODES 14 4000 UNLESS OTHERWISE SPECIFIED COMMON CONNECTIO EARTH GROUND CONNECTION UNLESS OTHERWISE SPECIFIED TOLERA Ch ge Sht No E LINCOLN CTRIC CO ee COMMAN AU ON HOLES SIZES P
151. detailed throughout this manual Retum to Section TOC Retum to Master TOC 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 Retum to Section TOC Retum to Master TOC This procedure takes approximately 80 minutes to perform Retum to Master TOC 8 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC F 90 F 90 TROUBLESHOOTING amp REPAIR SCR DIODE RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued FIGURE F 37 SCR DIODE RECTIFIER BRIDGE DETAILS SHUNT REMOVE BOLT AT POSITIVE HEAT SINK PLATE LOWER STATOR WELD WINDING LEADS 209 small 209 large 204 PROCEDURE 1 2 Turn the engine off Perform the Case Cover Removal Procedure including front shroud removal Using th
152. e the Wiring Diagram 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 Check amphenols and asso ciated leads See the Wiring Diagram The wire feeder does not work when connected to the machine s 14 pin amphenol Check the circuit breaker CB5 Reset if tripped 2 The wire feeder control cable may be faulty Check or replace 3 The wire feeder may be faulty Check or replace With the engine at high idle speed Check for the presence of 115VAC at leads 31 pin J and 32 pin A at the 14 pin amphenol If the voltage is missing or low Check for loose or broken connections See the Wiring Diagram Also check CB5 for proper operation 2 The RF bypass board CV mod ules only may be faulty See the Wiring Diagram 3 Perform Stator Voltage Test CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD COMMANDER 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 12 F 12 TROUBLESHOOTING amp REPAIR
153. e 1 2 wrench remove the stator weld winding leads from the SCR diode rectifier bridge assembly See Figure 37 and the Wiring Diagram Cut any necessary cable ties and clear the leads 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 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 6 Using the 1 2 wrench remove the shunt from the positive heat sink plate lower See Figure F 37 and the Wiring Diagram NOTE The DD diode pigtail lead and the three small 204 204A and 204B leads are also incorporated in the bolted connection They can stay in place 7 Using the 5 16 nut driver remove the control board cover 8 Remove plug J6 and the toroid assembly from the control board Remove plug J6 and leads from the control box Cut any necessary cable ties COMMANDER 400 LINCOLN 5 F 91 F 91 TROUBLESHOOTING amp REPAIR SCR DIODE RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued FIGURE F 38 NEGATIVE STICK OUTPUT TERMINAL Retum to Master TOC Retum to Section TOC 207 FROM STICK OUTPUT TERMINAL B 8 4 Retum to Master TOC 9 Using the 3 4 wrench remove lead 207 from 10 Locate and remove the snubber board cover t
154. e 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 Retum to Section TOC Retum to Master TOC This procedure takes approximately 40 minutes to perform Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN 8 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 34 F 34 TROUBLESHOOTING amp 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 TEST PROCEDURE 1 Turn the engine off 2 Unlatch lift and secure the right side engine service access door Using a 5 16 open the control panel and tilt out Remove the control board cover 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 3227 to the B1 te
155. e 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 ponenis Follow the instructions of the battery charger manufac turer for proper charger settings and charging time COMMANDER 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC MAINTENANCE WELDER GENERATOR MAINTENANCE STORAGE Store the Commander 400 in clean dry protected areas CLEANING Blow out the generator and controls peri odically with low pressure air Do this at least once a week in particularly dirty areas NAME 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
156. e diode nut 8 Tighten the diode nuts to the specifications in the following table a Start the nuts for diodes with steel studs by hand and then torque them according to the following table b Run the nuts for diodes with copper studs on all the way by hand then torque them according to Table F 4 below Turn the nuts a minimum of 1 2 turn more while torquing Table F 4 DIODE STUD FOOT INCH SIZE POUNDS POUNDS 3 4 16 25 27 300 324 3 8 24 102 5 125 0 5 1 4 28 22 25 9 Perform SCR Diode Bridge Replacement 10 Install the case top and sides COMMANDER 400 F 105 F 105 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT WARNING Retum to Section TOC Retum to Master TOC 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
157. e locking nut Adjust LOW IDLE First make sure there is no load on the machine Set the IDLE switch to AUTO and wait for the engine to change to low idle speed Use the 7 16 wrench to loosen the solenoid lever arm locking nut See Figure 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 COMMANDER 400 LINCOLN F 39 F 40 LOCKING ADJUSTING SCREW NUT COMMANDER 400 LINCOLN E FIGURE F 11 HIGH IDLE ADJ USTMENT FIGURE F 12 LOW IDLE ADJ USTMENT TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued z 0 lt 2 24 5 ao e F 40 DOL WINDY DOL WINDY DOL OF DOL OF 201 uon2es UMY 201 uon2es UMY 201 uon2es LUMPY DOLL LUMPY F 41 F 41 TROUBLESHOOTING amp 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
158. e nose the linkage arm assembly See figure F 36 piers retaining ng 9 Using the 7 16 wrench mount the shutdown 6 5 plain washer spacer washer and pivot 5 from ihe linkage arm assembly See Figure solenoid assembly to the engine with three 4 F 36 9 9 nuts two bolts and three lock washers 8 8 10 Attach the four spade connectors from the E 6 Carefully remove the solenoid assembly wiring harness leads 8224 240 225 and E 5 7 Replace any faulty parts and reassemble the 262 to the shutdown solenoid terminals solenoid assembly See Figure F 35 Replace the cable tie 11 Close the right side engine access door Retum to Section TOC Retum to Master TOC COMMANDER 400 F 88 NOTES COMMANDER 400 LINCOLN 0 F 88 DOL WINDY DOL WINDY DOL OF DOL OF 201 uon2es UMY DOLL uon2es 201 uon2es LUMPY DOLL LUMPY F 89 F 89 TROUBLESHOOTING amp 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
159. e 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 COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Y 4 2 Retum to Master TOC 4 OPERATION 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 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 the light turns on the engine protection system will stop the engine Check for proper oil level and add oil if necessary Chec
160. e sure that the outer metal ring of the SCR Clean the area on the heat sink around the is facing toward the same heat sink as the old SCR mounting surface using a putty knife or SCR s metal ring Be sure that the roll pin of similar tool DO NOT SCRATCH THE SCR the heat sink engages the hole in the SCR MOUNTING SURFACE The SCR contact surfaces must sit flat against both heat sink surfaces 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 F 97 F 98 F 98 TROUBLESHOOTING amp REPAIR 5 SCR REMOVAL AND REPLACEMENT continued FIGURE F 45 1 2 WIDE LEAF SPRING 82 5 4 quu SPRING CURVATURE 1 2 lt EXAGGERATED Q 9 11 Go to the procedure below that matches your 4 Insert clamp assembly through heat sinks c I machine s cap screw NOTE WHICH Install nuts Tighten clamp nuts equally on 8 THREAD IS ON YOUR SCREWS cap screws until finger tight See Figure 9 BEFORE PROCEEDING TO THE ASSEM F 46 Heat sinks may not be exactly as pic gt gle BLY PROCEDURE Two different designs of tured leaf springs and housings have been used to 5 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 FIGURE F 46 CLAMP ASSEMBLY wide leaf spring and the other use
161. ead 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 NOTE Switch SW 2 should be open 14 Read meter for zero voltage a If the voltage reading is higher than zero the SCR is shorted 15 Close or keep closed switch SW 1 16 Close switch SW 2 for 2 seconds Release and read meter a the voltage is 3 6 volts while the switch is closed and after the switch is open the SCR is functioning b If the voltage is 3 6 volts only when the switch is closed or if there is no voltage when the switch is closed the SCR is defective LANTERN BATTERY NOTE Be sure the battery is functioning prop A low battery can affect the results of the test Repeat Battery Test Procedure in Step 11 if needed 17 Open switch SW 1 18 Reconnect the tester leads F 21 See Figure a Connecttester lead A to the cathode b Connect tester lead C to the anode c Disconnect test lead 19 Close switch SW 1 20 Read meter for zero voltage G from the gate a Ifthe voltage is zero the SCR is func tioning b If the voltage is higher than zero the SCR is shorted 21 Perform the Active Test Procedure outlined in Steps 12 20 for SCRs B and C 22 Replace all SCR assemblies that do not pass the above tests 23 Replace all molex plugs onto the control board and snubber board Reconnect lead
162. ect welding in the general fab or pipe taps Check the weld amp 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 LINCOLN Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 15 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The welding arc is hot spattery cannonballs or flares up The engine runs normally The auxil iary power is normal Continued Machine shuts down while arc gouging and all lamp indicators on front panel ECL or CCS appears on display as machine is shutting down Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Check to make sure that the machine settings match the weld application 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 Attempt to arc gouge at a less er current if the application will permit If the machine shuts d
163. ection TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 24 F 24 TROUBLESHOOTING amp REPAIR COMMANDER 400 WITH G2713 2 or 3 CONTROL BOARD ERROR CODES WHILE RUNNING DEFINITION SYMPTOM Unit has shut down because of low fuel Invalid range control switch position COMMANDER 400 LINCOLN CORRECTIVE ACTION 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 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 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 25 F 25 TROUBLESHOOTING amp REPAIR COMMANDER 400 WITH G2713 2 or 3 CO
164. el consumption of the Commander 400 engine for various operating scenar ios Table B 2 Deutz F3L 912 Engine Fuel Consumption Deutz F3L 912 Running Time for 44 2 Hp 25 gallons 1800 RPM Hours 30 gallons hour 1 36 liters hour High Idle No Load 1900 RPM 78 gallons hour 32 1 3 55 liters hour DC CC Weld Output 400 Amps 40 Volts Auxiliary Power 1 32 gallons hour 10 000 VA 6 00 liters hour 8 36 liters hour COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION WELDER OPERATION 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 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 se
165. ent Test Perform the Exciter Capacitor Bank Test Check leads 268 269 amp 270 from J50 to J4 at the control board for loose or faulty connec tions Also check the T1 T2 amp T3 lead connections from the exciter module to the stator and capacitor bank leads Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 18 F 18 TROUBLESHOOTING amp REPAIR COMMANDER 400 WITH G2713 1 CONTROL BOARD ERROR CODES DURING INITIALIZATION SEQUENCE DEFINITION SYMPTOM The processor is not receiving zero cross signals properly or the engine RPM is out of range or The exciter voltage is out of range greater than 550 or less than 140VAC COMMANDER 400 LINCOLN CORRECTIVE ACTION Check exciter voltage waveforms as illustrated in the Oscilloscope Waveforms Section Perform the Stator Voltage Exciter Winding Test Perform the Engine Throttle Adjustment Test Perform the Exciter Capacitor Bank Test Check leads 268 269 amp 270 from J50 to J4 at the control board for loose or faulty connec tions Also check the T1 T2 amp T3 lead connections from the Exciter Module to the stator and capacitor bank leads Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum
166. ent sensing toroid for loose or faulty connections CV models only See the Wiring Diagram Make sure the toroid and lead assembly are assembled cor rectly CV models only See the Wiring Diagram Check the shunt and associated leads for loose or faulty connec tions Stick models only 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 LINCOLN F 9 F 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS Make sure there is NOT an external load auxiliary or weld connected to the Commander 400 RECOMMENDED COURSE OF ACTION Retum to Section TOC Retum to Master TOC The machine goes to low idle but does not stay at low idle 1 The idler solenoid linkage may be misadjusted or damaged The idler solenoid hold in circuit ry may be faulty Check leads 237 and 226 for loose or faulty connections the Wiring Diagram 3 Perform the Idler Solenoid Test 4 Make sure the control board mounting grounding screws are tight Check solenoid waveforms as illustrated in the Oscillo
167. eproductive harm 5 Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS T FOR ENGINE us 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment AW ln 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Retum to Master TOC ELECTRIC AND 3 MAGNETIC FIELDS E may be dangerous Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric curre
168. er Winding Test Perform the Engine Throttle Adjustment Test Perform the Exciter Capacitor Bank Test Check leads 4268 4269 amp 270 from J50 to J4 at the control board for loose or faulty connec tions Also check the T1 T2 amp T3 lead connections from the exciter module to the stator and capacitor bank leads Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 23 F 23 TROUBLESHOOTING amp REPAIR COMMANDER 400 WITH G2713 2 or 3 CONTROL BOARD ERROR CODES WHILE RUNNING DEFINITION SYMPTOM The output current is too high greater than 750 amps for more than 1 second XIRQ error illegal external interrupt request COMMANDER 400 LINCOLN CORRECTIVE ACTION The machine may be over loaded Remove any external loads If the problem persists with no external load check the shunt leads and associated connects to the control board See the Wiring Diagram Perform 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 If the problem persists the control board may be faulty Retum to Section TOC Retum to S
169. erating the machine at high currents Retum to Section TOC Retum to Master TOC MATERIALS NEEDED None This procedure takes approximately 20 minutes to perform Retum to Master TOC 8 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN 5 Return to Section TOC Return to Master TOC o 2 5 2 3 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC F 64 F 64 TROUBLESHOOTING AND REPAIR EXCITER VOLTAGE FEEDBACK TEST continued TEST PROCEDURE 1 Set the machine to the following settings then start the machine Control dial to 1 min Range dial to 90A max Idler switch in the Auto position Output control source 2 4 switch in the Welding Terminals Remotely Controlled position 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 amp 2 must be repeat ed Toggle the 2 4 switch to the Welding Terminals Always On position The display will read the phase 1 no
170. ereafter Change engine oil Change oil filter 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 MAINTENANCE Table D 2 ENGINE MAINTENANCE PARTS ITEM MANUFACTURER PART NUMBER Air Cleaner Element Donaldson P181052 AC A302C Cooling Blower Belt Lincoln T13536 3 Gates 7585 Oil Filter Element Deutz 1174418 Purolator PER2168 Napa 1820 Fram PH3776 Retum to Section TOC Retum to Master TOC Fuel Filter Element Deutz 1174423 Purolator PC42 Napa 3358 Fram P4102 Retum to Section TOC Retum to Master TOC Water Separator Element Lincoln M16890 C Stanadyne 31572 Fuel Pre Filter Screen Lincoln M16890 B Stanadyne 29575 Battery BCI Group 34 Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Y 4 2 Retum to Master TOC MAINTENANCE BATTERY MAINTENANCE A WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery BATTERY ACID ca
171. essories 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 K857 28 ft 8 5 m or K857 1 100 ft 30 4 m Remote Control Portable control provides same dial range as the output control on the welder from a location up to the specified length from the welder Has convenient plug for easy connection to the welder The Commander 400 is equipped with a 6 pin connector for connecting the remote control and a toggle switch for selecting LOCAL output control or REMOTE output control K704 Accessory Kit Includes 35 feet 10 m of elec trode cable and 30 feet 9 m of work cable head shield work clamp and electrode holder Cable is rated at 500 amps 6096 duty cycle K953 1 Two Wheel Trailer For road in plant and yard towing Road towing with optional fender amp light kit For highway use consult applicable federal state and local laws regarding possible additional require ments K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender amp Light Kit K965 1 Cable Storage Rack K825 1 Ether Start Kit Provides maximum cold weather starting assistance for frequent starting below 10 F 12 2 Required Ether tank is not provided with kit K899 1 Spark Arrestor Kit Easily mounts to stan dard muffler K94
172. etum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC E 3 E 3 THEORY OF OPERATION FIGURE E 3 EXCITER FEEDBACK CONTROL BOARD LOCAL AND REMOTE CONTROL SCR DIODE OUTPUT Hore BRIDGE NEGATIVE STARTER ALTERNATOR MECHANICA ENGINE ROTATION SHUTDOWN SOLENOID EXCITER WINDINGS IDLER BATTERY 115VAC EXCITER CAPACITORS m 115 230 C BY PASS 9 6 BOARD AMPHENOL ENGINE SENSORS WWW TERMINAL 2 g Mn is pq POSITIVE SCR GATE SIGNALS gt REMOTE SWITCH T FINE C OUTPUT CONTROL ENGINE PROTECTION BOARD EXCITER VOLTAGE FEEDBACK BOARD 12VDC EXCITER FEEDBACK CONTROL BOARD LOCAL AND REMOTE CONTROL 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 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 CURRENT MODE SELECTOR SWITCH The Commander 400 is controlled by a high quality microcontroller which is the main circuit element of the control board The control boa
173. etum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC E 6 E 6 THEORY OF OPERATION INDUCTION GENERATORS The Commander 400 utilizes 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 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 COMMANDER 400
174. etum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 77 F 77 TROUBLESHOOTING amp REPAIR NORMAL SOLENOID PULL amp HOLD COIL WAVEFORMS 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 F 78 F 78 TROUBLESHOOTING amp REPAIR ABNORMAL SOLENOID PULL amp HOLD COIL WAVEFORMS Retum to Section TOC Retum to Master TOC PE A gt 8138 5 c SCOPE SETTINGS SCOPE SETTINGS Volts Div 1V Div Volts Div 200 MV Div Horizontal Sweep 20 ms Div Horizontal Sweep 5 ms Div Coupling DC Coupling DC Internal Trigger Internal
175. 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 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC D 6 MAINTENANCE BLEEDING THE FUEL SYSTEM In the event the engine is operated until it runs out of fuel you will need to bleed the fuel system in order to start the engine Refer to the engine operation manual AIR FILTER CAUTION Excessive air filter restriction will engine life result in reduced The air filter element is a dry cartridge type It can be cleaned and reused However damaged elements should not be reused Stop engine after 100 hours of running time and clean filter element Replace the fil ter if necessary Service the air cleaner regularly according to your engine operation manual 1 Locate the air filter canister located behind the engine door on the top of the engine 2 Remove the air filter element 3 Remove loose dirt from the element with com pressed air or a water hose directed from inside out Compressed Air 100
176. ge polarity shut the welder off and reverse the electrode and work cables at the Commander 400 output terminals 3 Connect the K867 Universal Adapter to the K291 or K404 input cable and the 14 pin amphenol of the Commander 400 as indicated in Figure C 1 Make the proper connections for local or remote control according to Figure C 1 4 Connect the K291 or K404 input cable to the LN 7 5 Place the IDLER switch in the HIGH position Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM Specifications listed in this manual 6 LOCAL REMOTE switch to REMOTE K775 remote control is used Set the switch to LOCAL if no remote control is used 7 VOLTMETER switch to or depend ing on the polarity chosen 8 Set RANGE switch to WIRE WELDING CV 9 Setthe WELDING TERMINALS switch to WELD ING TERMINAL REMOTELY CONTROLLED 10 Adjust wire feed speed at the LN 7 FIGURE C 1 COMMANDER 400 LN 7 WITH K867 ADAPTER CONNECTION DIAGRAM SPARE 82 81 INSULATE UNUSED NIE 42 LEADS INDIVIDUALLY FEEDER 41
177. ge semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 1 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les 6 zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer u
178. h 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 Retum to Master TOC 5 8 9 8 Note Scope probes connected at WIRE welding output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal 5 ms Div Coupling DC Trigger Internal Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN P F 76 F 76 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM WIRE CV TAP MAX CONTROL POT HIGH IDLE NO LOAD Retum to Section TOC Retum to Master TOC 0 volts Retum to Section TOC Retum to Master TOC 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 Retum to Master TOC 8 8 Note Scope probes connected at WIRE welding output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN Retum to Section TOC R
179. he 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 Ifthere 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 overfil See Figure D 1 FUEL Atthe 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 Refer to your engine operation manual for recom mended grade of fuel COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC MAINTENANCE FUEL FILTERS WARNING When working on the fuel system f Keep unshielded lights away do 4 smoke Do not spill fuel 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 Fuel Pre Filter Water Separator Assembly The pre filter i
180. he negative stick output terminal See using the 3 8 wrench See Figure F 39 Figure F 38 and the Wiring Diagram Cut any necessary cable ties 11 Remove plug J30 from the snubber board See the Wiring Diagram Clear leads for the SCR diode rectifier bridge assembly removal 8 g 2 FIGURE F 39 SNUBBER BOARD COVER REMOVAL 8 gt 818 JE cic SNUBBER BOARD LOCATION LEFT SIDE BELOW FUEL TANK Retum to Section TOC Retum to Master TOC COMMANDER 400 F 92 F 92 TROUBLESHOOTING amp REPAIR SCR DIODE RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued FIGURE F 40 RESISTOR R1 LOCATION Retum to Section TOC Retum to Master TOC Q ar AL 4 RESISTOR R1 8 8 LEAD 204 12 Using the 11 32 wrench remove the 204 13 Remove the capacitor leads and grommet lead from the R1 50 Ohm 100 Watt resis from the rectifier bridge bracket See Figure tor See Figure F 40 Cut any necessary 41 cable ties and clear leads for SCR diode tifier bridge assembly removal 14 Using the 3 8 wrench remove the four 2 on each side screws from the rectifier bridge NOTE Be sure to replace any cut cable ties on bracket See Figure F 41 reassembly Otherwise the leads may catch in the blower FIGURE F 41 RECTIFIER BRIDGE BRACKET DETAILS Retum to Master TOC F 8 9 8 SCREWS 4 Retum to Section Ret
181. heck 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 With the machine running measure the voltages at the control board per the following table If any of the voltage checks the Table 2 below are incorrect replace the control board If the test is complete replace the control board cover and close the control panel Description 15V supply for display 10 supply for weld control amp exciter module 5V supply for microprocessor 10V supply for weld control 24 supply for 2 4 circuit 15 supply for CV SCR gate drive circuit Figure F 31 Control Board Plugs C112 amp J2 ccu Mec ES ui C112 SOW SUL fme Pin 1 Pin X2 eO 71 Pin 4 Plug J2
182. iagram Stick amp Wire Model Code 10581 G 5 Amphenol Bypass PC Board 4 G 6 Amphenol Bypass PC Board 2 G 7 Auxiliary Protection PC Board Schematic 0000 eee G 8 Auxiliary Protection PC Board G 9 Bypass PC Board SchemMatlG Eee G 10 Bypass PG Board LayoUt ierit ti Dr dee epu iue or esa eeu ada elei d dct da d G 11 Control PC BOARD SCHEMATIC Part 1 nennen G 12 Control PC BOARD SCHEMATIC Part 2 nennen nennen tenens G 13 Control PG BOARD Layout intet Fete tr teo test ae G 14 CV Control PC Board Schematic sesssssssssssssssssseeee ener nnne nns G 15 CV Control PC Board nnns sn nennen G 16 Engine Protection PC Board G 17 Engine Protection PC Board 1 nnns n nene G 18 Meter PC Board Schematic seen entente enn snnt rennes G 19 Meter PO Board Layout iore ro Petar ibas aeos nir EEE G 20 Remote Protection PC Board 2 4 000000 G 21 Remote Protection PC Board G 22 Snubber PC Board 4 nennen
183. ical Diagrams Section Table of Contents to locate the appropriate diagram 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 LINCOLN Retum to Section TOC Retum to Section TOC 8 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the machine OFF before working on equipment not touch electrically hot parts 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 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 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 resi
184. in line with the hose The battery voltage may be too low If it is less than 11VDC charge or replace the battery Check the charging system Ifthe engine temperature light is lit check the engine cooling sys tem TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check leads 2274 amp 240 at J50 exciter voltage plug for loose or faulty connections See the Wiring Diagram 2 Perform the Solenoid Test Check leads 224 225 240 and 262 for loose or faulty con nections See the Wiring Diagram Shutdown Make sure the control board mounting grounding screws are tight Check solenoid waveforms as illustrated in the Oscilloscope Waveforms Section Check to make sure that J4 amp J23 are not swapped at the con trol board See the Wiring Diagram The engine shuts down shortly after start Initialize sequence is normal see Initialization Sequence sec Check for adequate fuel supply 2 If any indicator light is lit when the engine shuts down that particular system has faulted Check system Check for loose faulty or cor roded battery cable connec tions Check the Run Stop switch and associated leads for loose or faulty connections Shutdown 1 Perform the Solenoid Test If possible check solenoid wave forms as illustrated in the Oscilloscope Waveforms sec The control board may be faulty CAUTION If for any re
185. ine is operating normal If the remote control unit is not connected to the machine make sure the Local Remote switch 51 is in the Local position 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 Perform the Fine Control Potentiometer Test 2 Perform the Stator Voltage Test 3 Perform the SCR Diode Bridge The machine has low welding out put and low auxiliary output The engine speed may be low Normal high idle no load is 1900 RPM Engine Throttle Adjustment 2 Perform the 3 Perform the Exciter Capacitor 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 LINCOLN 5 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 6 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Low or no constant voltage CV welding output Constant cu
186. ing from the stator and L10953 1 exciter module 11 Check for continuity from J2 pins 1 amp 4 to frame Pull the sleeving back and disconnect the three ground There should be no continuity between bolted exciter connections using a 7 16 nut dri these leads ver and crescent wrench 12 Construct the circuit shown below See Figure 32 Figure F 32 J50 51 1 300 W 12V STATOR VOLTAGE LEADS MUST WINDING CAR BE TO THE WINDING BATTERY SIDE OF THIS CONNECTION UNDER TEST J51 COMMANDER 400 LINCOLN 5 Retum to Section TOC Return to Section TOC 5 5 9 Retum to Section Retum to Master TOC Retum to Master TOC Y 4 2 4 Retum to Master F 71 TROUBLESHOOTING AND REPAIR STATOR RESISTANCE TEST continued TEST PROCEDURE 15 Use the following equation to determine the winding resistance 14 Connect the test leads J 50 and J 51 to the stator winding under test Close S1 and read the volt V2 V1 winding resistance in ohms ages at V1 and V2 then open S1 IMMEDIATELY 16 Disconnect J 50 and J 51 from the stator winding Damage can occur to the stator winding under under test Check the resistance of all the stator test if 51 is left in the on position for too long windings by repeating steps 13 amp 14 and using CAUTION The 1 ohm resistor will also become Table F 3 below hot very quickly and can burn to the touch Leaving the circuit on fo
187. insufficient greasing 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 RECEPTACLES Keep the electrical receptacles in good condition Remove any dirt oil or other debris from their surfaces and holes CABLE CONNECTIONS Check the welding cable connections at the weld output terminals often Be sure that the connections are always tight COMMANDER 400 D 12 o 2 lt 9 z i S lt e BE 2E LLI lt tc a 19 a tc 2 o LL gt ep gt ip Lu LLI lt a o o e lt a lt 225 gOz c 2 gat O 2 FUESE Zea 2 lt oooucdoozrmecimrttco lt lt lt 4 c e ut DOL Sew WINDY DOL WINDY DOL OF DOL OF DOL o DOL uono2es o DOL uono2es o UMY DOL uon2es oy uua Section E 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION Retum to Master TOC Theory of Operation
188. inued FIGURE F 60 VERTICAL BAFFLE ENGINE MOUNT REMOVAL 82 814 cc CAPACITOR AND SCR ASSEMBLY STATOR AND 8 8 Retum to Section Y 4 2 4 Retum to Master 32 33 34 35 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 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 Move the CV capacitor and SCR assembly toward the front of the machine to allow clearance for the engine stator removal Using the 1 2 wrench and 5 16 nut driver remove the tank fan guard See Figure F 60 36 37 818 wy MOUNTS 9 4 FUEL TANK FRAME a SUPPORT 2 FRAME VERTICAL 8 8 RAIL ASSEMBLY BAFFLE Ar HE 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 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
189. 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 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 Commander 400 LINCOLN Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section R
190. ity 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 6 23 ELECTRICAL DIAGRAMS G 23 SCHEMATIC SNUBBER PC BOARD 777777772 J SCR A SCR B SCR C 8 5 ANODE BRIDGE ANODE ANODE dr 260 204 222 261 i 1 7 3 2 4 YN YN YN J32 3 30 5 5 2 2 2 C1 C2 C3 oq lc oui pm 400Ndc A A0V dc 400N dc 5 DW 10 c 10 C 10 2 4 C5 0047 0047 3000V JE 62 EE gje 0047 S 21252 8 E 1 16 98E NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E COMMANDER 400 me ELECTRICAL DIAGRAMS G 24 PC BOARD ASSEMBLY SNUBBER PC BOARD 04 3 00 04 EMD ITEM REQ D PART NO IDENTIFICATION Cci cC2 63 3 520500 3 22 400V C4 C5 C6 3 111577 58 0047 3000V S20351 4 HEADER Return to Section TOC Return to Master TOC 1 RI Ra R3 3 1 114648 25 105 7 CAPACITORS MFD VOLTS INDUCTANCE HENRYS Return to Section TOC Return to Master TOC jo ojo E 5 5 t 515 ge ple o o L 9572 1 12 15 95A 1 16 98E COMMANDER SNUBBER 0 30 2 70 NOTE Lincoln Electric assumes re
191. k cables If the electrode cable is on your right Do not put your hands near the engine fan Do not attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance d 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropriate Retum to Master TOC COMMANDER 400 Retum to Master TOC Retum to Master TOC Y 4 2 8 amp Retum to Master SAFETY 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 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 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
192. k 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 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 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 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 ce
193. kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items and 8 Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Head shield and filter lens should conform to ANSI 787 sta
194. l laws Consult applicable federal state and local laws regarding specific requirements for use on public highways PRE OPERATION ENGINE SERVICE Read and understand the information about the diesel engine in the Operation and Maintenance sections of this manual before you operate the Commander 400 WARNING Stop the engine and allow it to cool before fueling Do not smoke when fueling Ch 4 Wipe up spilled fuel and allow the fumes to clear before starting the engine Fill the fuel tank at a moderate rate and do not overfill Keep sparks and flame away from the tank oL 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 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 For more oil fill and service information see the
195. load exciter voltage The voltage should be between 400 525 Vac Return the 2 4 switch to the Welding Terminals Remotely Controlled position 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 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 10 For machines equipped with G2713 1 boards toggle the Idler switch once from Auto to High The display should read 003 For machines equipped with G2713 2 amp 3 boards toggle the idler switch 3 times from Auto to High to Auto till the display reads 000 again 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 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 Toggle the idler switch from Auto to High then back
196. m to Master TOC Retum to Master TOC TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Engine will not idle down to low speed Machine has normal weld and auxiliary power POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS Make sure the Idler switch S4 is in the AUTO position Make sure there is not an exter nal load on either the weld ter minals or the auxiliary recepta cles Check for mechanical restriction in the solenoid linkage TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Perform the Idler Solenoid Test 2 Make sure the control board mounting grounding screws are tight Check leads 226 227 237 amp 254 for loose or faulty connec tions See the Wiring Diagram Check solenoid waveforms as illustrated in the Oscilloscope Wavetorms Section Check to make sure that leads 227 amp 232 at the B1 amp B3 ter minals on the control board are not swapped See the Wiring Diagram Engine will not go to high idle when attempting to weld or use auxiliary power Output is normal when Idler switch is in the HIGH position Automatic idle function works prop erly when the auxiliary power is loaded 1 Make sure the welding cables and connections are tight NOTE The automatic idler may not function if the auxiliary power is loaded to less than 150 watts Check the curr
197. m to Section TOC Retum to Master TOC 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 Retum to Master TOC 8 8 SHROUD ASSEMBLY REMOVE 2 SCREWS EACH SIDE Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC Q 7 B 2 F 32 F 32 TROUBLESHOOTING amp REPAIR CASE FRONT KNOBS REMOVAL AND REPLACEMENT PROCEDURE Removal Side View pom Pull 7 gt Pull 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 a
198. mple 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 section of this manual for more information FIGURE A 1 COMMANDER 400 OUTPUT CONNECTIONS 120 VOLT RECEPTACLES CV WORK WELD OUTPUT TERMINAL 240 VOLT RECEPTACLE GROUND STUD WELD OUTPUT TERMINALS ELECTRODE amp 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 Duty Cycle Up to 200 ft 200 to 250 ft 250 100 1 AWG 1 0 AWG 400 100 3 0 AWG 4 0 AWG COMMANDER 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 E 3 Retum to Master INSTALLATION MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is connected to premises wiring home
199. mption and extends engine life Single side engine service with over the top access to the engine Copper alternator windings and high temperature insulation for dependability and long life COMMANDER 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC B 4 OPERATION ADDITIONAL DESIGN FEATURES Stick amp Wire Model only FOR WIRE WELDING One constant voltage position for all wire welding A 12 to 45V range across the entire current output range 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 WELDING CAPABILITY The Commander 400 is rated at 400 amps 40 volts at 10096 duty cycle The weld current is variable from 40 to 575 amps LN 25 LN 23P LN 7 LN 8 NA 3 Spool Gun amp K488 Module COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC
200. n chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre
201. n Some lights may turn off before starting Check the fuel gauge to make sure that there is an adequate fuel level 6 Press and hold the engine START button for a min imum of 2 seconds 7 Release the engine START button when the engine starts 8 Check that the indicator lights are off If the LOW FUEL light is on the engine will shut down 30 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 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 COLD WEATHER STARTING With a fully charged battery and the proper weight oil the engine should start satisfactorily even down to about 0 F If the engine must be frequently started below 10 F 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 COMMANDER 400 Retum to Section TOC Retum to Section TOC B 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION STOPPING THE ENGINE 1 Switch the RUN STOP switch to STOP This turns off the voltage supplied to the shut down solenoid A
202. n burn eyes and skin Wear gloves and eye protection and be careful when working near a battery Follow the instructions printed on the battery To prevent EXPLOSION when INSTALLING A NEW BATTERY Disconnect the negative cable from the old battery first and connect to the new battery last THE CORRECT POLARITY IS NEGATIVE GROUND Damage to the engine alternator and the printed cir cuit board can result from incorrect connection CONNECTING A BATTERY CHARGER Remove the battery from the welder by disconnecting the negative cable first then the positive cable and battery clamp When reinstalling connect the negative cable last Keep the area well ventilated USING A BOOSTER Connect the positive lead to the battery first then connect the negative lead to the engine foot To prevent BATTERY BUCKLING tighten the nuts on the battery clamp until snug 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 1 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 no
203. n 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 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 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 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 CHARGING THE BATTERY The Commander 400 is equipped with a wet charged battery The charging current is automatically regulated when the battery is low after starting the engine to a trickle current when the battery is fully charged When you charge jump replace or otherwise connect battery cables to the battery be sure the polarity is 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 If you need to charge the battery with an external charger disconnect the negative cable first then the positiv
204. n to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 8 B Return to Section TOC o o o 8 E Return to Master TOC G 5 ELECTRICAL DIAGRAMS WIRING DIAGRAM STICK amp WIRE MODEL CODE 10581 LINCOLN B NEUTRAL T2 STUD IN CONTROL BOX 5G 3D 1002 1004 1006 i 55 016 z EXCITER VOLTAGE Iconnections 10 FEEDBACK BOARD CAPACITORS MADE BOLTED CONNECTIONS _ STATOR AUK POWER BOX 9 WHITE WHITE o D 085 15AMP 2421 2426 ND A bod WELDED STUD ON OUTPUT PANEL LOAD WHITE T3 INSULATED STUD IN CONTROL BOX 6B T1 INSULATED STUD IN CONTROL BOX CONNECTOR CAVITY NUMBERING SEQUENCE VIEWED FROM COMPONENT SIDE OF BOARD NEXT AVAILABLE 287 4 RECTIFIER ASSEMBLY CURRENT SENSE TOROID OUTPUT 216 NO CONNECTION ON NEWER MODELS 206A BYPASSPO BOARD 1 fd GROUND ELECTRODE POLARITY SWITCH ay D 1 00 ie ON 1 SWITCH OUTPUT 1 7 AO 0 4E CONTACTOR lt WORK H rn ali REMOTE CONTROL 820 209 AMPHENOL 1 Ip REMOTE
205. nd WIRE CV terminals wrap around to a value below 19 volts 5 3 Start the unit Continue to toggle the idler switch and try to attain 19 0 2 volts again Once the voltage 3 5 WARNING across the terminals does read 19 0 2 18 While the unit is running volts proceed to the next step R there are high voltages 11 Set the Output Control switch to the WELD 8 i present inside the control ING TERMINALS REMOTELY CON box THE VOLTAGES TROLLED position 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
206. ndards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 Shielding gases used for arc welding can displace air and cause injury or death Al
207. ned to open and close the 2 and 4 leads in the amphenol receptacle 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 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 Weld and AC auxiliary power at the same time with in machine total capacity OTHER FEATURES e Deutz 3 cylinder air oil cooled diesel engine Designed for long life easy maintenance and excel lent fuel economy Engine protection system shuts the engine down for low oil pressure high oil temperature or a broken fan engine alternator belt Gauges for oil pressure oil temperature engine alter nator output and fuel level Indicator lights for low oil pressure high oil tempera ture engine alternator low output broken belt and low fuel level Automatic low fuel shutdown before running out of fuel Engine hour meter standard on all models Extended range 25 gallon 94 6 fuel tank Fuel pre filter water separator with dry change ele ment Automatic idler reduces engine speed when not weld ing or drawing auxiliary power This feature reduces fuel consu
208. ng T B 10 TUG 27 10 Commander 400 Settings With K799 Hi Freq K930 1 Tig B 11 Wire Feed Constant Voltage 12 Auxiliary POWER e B 12 8 Simultaneous Welding and Auxiliary Power B 12 3 8 E B 8 i x COMMANDER 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION OPERATING INSTRUCTIONS Read and understand this entire section before operat ing your Commander 400 SAFETY INSTRUCTIONS WARNING 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 ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dan gerous Keep your head out of fumes Z Use ventilation or exhaust to remove 7 fumes from breathing zone WELDING SPARKS can cause Gm fire or ex
209. ngine 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 BATTERY CONNECTIONS WARNING BATTERY ACID CAN BURN EYES AND amp SKIN Wear gloves and eye protection and be care ful when working near a battery follow the instructions printed on the battery n n 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 SPARK ARRESTER 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 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 m
210. nit 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 LINCOLN F 16 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 17 TROUBLESHOOTING amp REPAIR COMMANDER 400 WITH G2713 1 CONTROL BOARD ERROR CODES DURING INITIALIZATION SEQUENCE DEFINITION SYMPTOM Program is stuck in ROM RAM check ROM RAM is corrupt Program is stuck in power supply stabilization Program is stuck in register initialization and Interrupt enables Program is stuck in calibration constant loading 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 Program is stuck waiting for program stabilization and loading of exciter voltage register table COMMANDER 400 LINCOLN CORRECTIVE ACTION Replace control board Replace control board Perform the Control Board Power Supply Test Replace control board Replace control board Check exciter voltage waveforms as illustrated in the Oscilloscope Waveforms Section Perform the Stator Voltage Exciter Winding Test Perform the Engine Throttle Adjustm
211. nnne nns G 23 Sn bber PC Board Layout iit tee ond G 24 COMMANDER 400 G 1 6 2 ELECTRICAL DIAGRAMS iid WIRING DIAGRAM STICK MODEL CODE 9978 3D 5D CONNECTOR CAVITY NUMBERING SEQUENCE 1002 1004 1006 1008 NOTE VIEWED FROM COMPONENT SIDE OF BOARD NO CONNECTION NEXT AVLB STUD T1 ON CAPACITOR ON NEWER MODELS 1 3 CONNECTION BLOCK 287 RECTIFIER 10 ASSEMBLY Rd NES J50 95 1011 FEEDBACK BOARD ICONNECTIONS TO STAINLESS STEEL TICAPACITORS MADE STAND OFF AVIA EYELET BOLTED SHUNT 240 uF 212 ex BYPASS PC 1010 1014 BOARD ELECTRICAL SYMBOLS PER E1537 1012 Return to Section TOC Return to Master TOC 50 Ohm 4 NOTE ONLY ON OUTPUT SOME OLDER 0 6500 MODELS STUD T2 ON CAPACITOR CHOKE ooo CT CONNECTION BLOCK 8 J23 J61 1017 1019 SELECTOR SWITCH 58 TOROI D VIEWED FROM BACK TOROI D SEE SELECT SWITCH CHART we 4 JA 8 2 FINE CONTROL STAINLESS STEEL 1018 1022 LOCAL swircH STUD T3 ON FRAME GROUND 75 VIEWED FROM CAPACITOR BAN CONNECTION BLOCK 73 240 uF n 7 1002 4 J4 J 1008 CONNECTIONS ON CONTROL BOARD VIEWED AS INSTALLED ENG
212. ns 1 amp 4 atthe 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 amp 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 LINCOLN Retum to Section TOC Retum to Section TOC B 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 14 PROBLEMS SYMPTOMS The welding arc is hot spattery cannonballs or flares up The engine runs normally The auxil iary power is normal F 14 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Check to make sure that
213. nt procedure to reassemble the machine COMMANDER 400 F 102 NOTES COMMANDER 400 LINCOLN 0 F 102 DOL WINDY DOL WINDY DOL OF DOL OF 201 uon2es UMY DOLL uon2es 201 uon2es LUMPY DOLL LUMPY F 103 F 103 TROUBLESHOOTING amp 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 Retum to Section TOC Retum to Master TOC 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 Retum to Section TOC Retum to Master TOC This procedure takes app
214. nt flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician Keep all equipment safety guards covers before welding and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known Y 4 2 8 amp All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 some cases it may be necessary to remove safety 2 d 1 Route the electrode and work cables together Secure guards to perform required maintenance Remove them with tape when possible guards only when necessary and replace them when the maintenance requiring their removal is complete 2 4 2 Never coil the electrode lead around your Always use the greatest care when working near moving parts 2 d 3 Do not place your body between the electrode and wor
215. ntinued FIGURE 16 HEAT SINK AND SCR TEST POINTS DIODE DD E REMOVE INSULATING PAINT 9 Remove the red insulating paint from the heat sink test points See Figure F 16 NOTE Do not disassemble the heat sink 10 11 12 Measure the resistance from the anode to the cathode of SCR A using an analog volt ohmmeter multimeter set at R x 1000 scale See Figure F 16 a Reverse the meter leads and measure the resistance from the cathode to the anode of SCR A See Figure F 16 b If a low resistance is measured in either meter polarity SCR A is faulty Replace SCR A Test the resistance of SCR B and SCR using the same procedure described in Step 10 DIODES DA DB DC ANODE b If a low resistance is measured in both meter polarities diode DD is shorted Replace diode DD c high resistance is measured in both meter polarities diode DD is open Replace diode DD 13 Test diodes DA DB and DC for proper oper ation using the same procedure described in Step 12 14 Reconnect all leads and molex plugs 15 If this test did not identify the problem or to further test the SCRs go to the Active SCR If the test is complete connect plug J6 to the control board and plug J30 to the snubber board and reconnect lead 204 to resistor R1 Replace the covers to the two boards calde 9048 uengan al case cover See the P 9 Cover Removal and Replacement p
216. o perform the Shunt Calibration 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 Check for poor connections at J6 pins 1 2 amp 3 molex plug at the control board Also check leads G1 G2 amp 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 LINCOLN Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 13 F 13 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The welding arc is cold engine runs normally The auxiliary power is normal Continued Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS RECOMMENDED COURSE OF ACTION 11 Check for poor connection at J21 pi
217. own while arc gouging in the gener al fab tap use the CV tap instead This is also an accept able process RECOMMENDED COURSE OF ACTION 10 Check all waveforms as illus trated in the Wave forms Section 11 Perform the Control Board Power Supply Test Check for poor connections at J4 pins 1 2 3 6 amp 7 atthe con trol pc board Also perform the 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 amp T3 for faulty connections Check for loose or faulty con nections at leads 268 269 amp 270 from the exciter pc board to J4 pins 1 2 amp 3 on the con trol board 4 Perform the Exciter Capacitor Bank Test 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 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 LINCOLN Retum to Section TOC Retum to Section TOC 8 8
218. ox 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 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 209 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 Replace the front shroud and all case covers that were removed See the Removal and Replacement Procedure COMMANDER 400 F 93 F 94 NOTES COMMANDER 400 LINCOLN 0 F 94 DOL WINDY DOL WINDY DOL OF DOL OF 201 uon2es UMY DOLL uon2es 201 uon2es LUMPY DOLL LUMPY F 95 F 95 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT WARNING Retum to Section TOC Retum to Master TOC 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
219. p REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY HIGH IDLE NO LOAD OUTPUT CURRENT CONTROL AT MAXIMUM 15 8 ms H 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 LINCOLN F 73 F 73 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM STICK MAX CONTROL POT HIGH IDLE NO LOAD Retum to Section TOC Retum to Master TOC 0 volts Retum to Section TOC Retum to Master TOC 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 Retum to Master TOC 8 8 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling
220. perating the machine at high currents HE 8 o 2 3 Return to Master TOC 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC COMMANDER 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 66 F 66 TROUBLESHOOTING AND REPAIR EXCITER CAPACITOR BANK TEST continued WARNING e Check for voltage across capacitors Voltages could be high and danger ous Discharge capacitors with high wattage 50 Ohm min resistor if necessary before performing tests TEST PROCEDURE 1 With the engine off disconnect the negative bat tery cable Refer to the Cover Removal section and remove the left side engine and stator cover panel Locate the point at which the capacitor bank leads are bolted to the T1 T2 amp T3 leads coming from the stator and L10953 1 exciter feedback module See Figure F 30 Pull the sleeving back and disconnect the three bolted exciter connections using a 7 16 nut dri ver and crescent wrench multi lead multi lead Measure c
221. phase 120VAC branch circuits each capable of 44 amps output NOTE The two 120VAC outlets of the 120 240VAC receptacle cannot be paralleled They are on two 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 SIMULTANEOUS WELDING AND AUXIL IARY POWER LOADS 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 TABLE B 4 Commander 400 Simultaneous Welding and Power Loads Welding Output Range Setting Welding Output 500A 40V 400A 36V 270A 31V 230A 29V 180A 27V 120A 25V 90A 24V Permissible Power Watts Unity Power Factor Permissible Auxiliary Current in Amperes 0120 V 10 240 V 10 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 LINCOLN Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES 550 2 oos doo
222. plosion gt Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn 4 Wear eye ear and body protection EZ A WARNING ENGINE EXHAUST can kill 3 Use in open well ventilated areas or f 40 vent exhaust to the outside Do not stack anything on or near the engine MOVING PARTS can injure Do not operate this equipment with any of its doors open or guards off Stop the engine before servicing it AX Keep away from moving parts Only qualified personnel should install use or ser vice this equipment 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 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 addition a seventh general purpose welding range provides up to 575 amps of constant current welding output The engine is a 44 2 Hp 33kw 3 cylinder air oil cooled diesel made by Deutz This naturally aspirated 4 cycle engine features direct injection a Bosch in line injection pump and a Bosch mechanical governor This machine is controlled by a high quality microcon troller The microcontroller provides high speed control of the
223. psi maximum with nozzles at least one inch away from the element Water Hose 40 psi maximum without nozzle 4 Soak the element in a mild detergent solution for 15 minutes Do not soak more than 24 hours Swish the element around in the solution to help remove dirt 5 Rinse elements from inside out with a gentle stream of water less than 40 psi to remove all suds and dirt 6 Dry the element before reuse with warm air at less than 160 F 71 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 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 LINCOLN 5 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC D 7 MAINTENANCE COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically Consult the engine Operation Manual for the proper frequency and procedure COOLING BLOWER BELT The following procedure should be followed to repla
224. quest IOT error illegal op code trap COP time out error CME error slow or stopped processor clock OC5 unintended execution IC3 unintended execution Invalid range control switch position COMMANDER 400 LINCOLN CORRECTIVE ACTION 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 If the problem persists the control board may be faulty Check for proper selector switch handle alignment Check the selector switch and associated wiring See the Wiring Diagram If the problem persists the control board may be faulty Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 21 F 21 TROUBLESHOOTING amp REPAIR COMMANDER 400 WITH G2713 2 or 3 CONTROL BOARD ERROR CODES DURING INITIALIZATION SEQUENCE DEFINITION SYMPTOM Program is stuck in ROM RAM check ROM RAM is corrupt Program is stuck in calibration constant loading 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 Program is stuck waiting for program stabilization and loading of exciter voltage register table COMMANDER 400
225. r too long can also cause the winding to heat up causing errors in mea surements Table F 3 W1 W2 009 ohms 20 W3 W4 009 ohms 20 W5 W6 009 ohms 20 T1 T2 130 ohms 20 T2 T3 130 ohms 20 1 130 ohms 20 1 E2 2 Plug 170 ohms 20 NOTE The resistances in the above table are to 18 If the test is complete reconnect the 3 bolted measured with the windings at an approxi connections for the T1 T2 amp T3 leads from the mate temperature of 25 degrees Celsius stator and exciter module and capacitor leads room temp Measuring after the windings Make sure that the T1 T2 amp T3 stator leads are are heated up can cause errors in the above matched to the T2 amp leads from the table 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 J 2 Reinstall the left side engine and stator cover panels and the front shroud per the l 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 LINCOLN Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 72 F 72 TROUBLESHOOTING am
226. ram is for reference only It may not be accurate for all machines covered by this manual LINCOLN COMMANDER 400 ELECTRICAL DIAGRAMS G16 PC BOARD ASSEMBLY CV CONTROL PC BOARD ele 98 HE ES 818 REQ D PART NO DESCRIPTION C2 C3 C4 3 516668 11 1 50 C5 1 6 16668 5 022 50 D 1 02 03 3 T12199 1 144004 071 1 T12702 29 1 447440 ele 120 1 S21135 10 MOLEX CONNECTOR AE 24 121 1 520351 6 HEADER 5 OCI 1 S 15000 10 OPTO ISOLATOR 01 712704 68 244401 g O G2 T12704 73 IC MOSFET 55 EI gt R1 5 19400 3321 3 32K 1 4W R2 R13 R15 3 S 19400 1002 10K 1 4W R3 R11 2 S 19400 1001 IK 1 4W R5 1 S 19400 10RO 10 1 4W R6 R7 2 T 14648 18 68 5W Ls R8 R9 2 S 19400 5620 562 1 4W R10 R12 2 S 19400 1000 100 1 4W 515 R14 S 19400 1502 15K 1 4W 3 3 R16 519400 6191 6 19 1 4W 2 R17 5 19400 6811 6 81K 1 4W ele R18 S 19400 2672 26 7K 1 4W 25 R19 S 19400 2802 28 0K 1 4W E X1 515128 18 GUAD OP AMP L9560 CAPACITORS MFD VOLTS 12 13 96 RESISTOR
227. rd also supplies operating voltages and control signals to the CV board the meter board and the engine protection board The remote control and contactor signals are fed to the control board through the amphenols and the by pass board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion COMMANDER 400 Retum to Section TOC Retum to Section TOC 9 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC E 4 E 4 THEORY OF OPERATION FIGURE E 4 WELD WINDING OUTPUT BRIDGE OUTPUT CHOKE AND CV CAPACITORS SCR DIODE OUTPUT BRIDGE OUTPUT CHOKE STARTER ALTERNATOR ENGINE MECHANICAI ROTATION SHUTDOWN SOLENOID EXCITER BATTERY EXCITER CAPACITORS 115 230 RECEPTACLE ENGINE SENSORS EXCITER VOLTAGE FEEDBACK BOARD 12VDC 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 Operation A choke is connected between the negative side of the bridge and the negative output terminal This large inductor stores energy and provides filtering for the welding output of the Commander 400 POSITIVE O TERMINAL gt SCR GATE SIGNALS REMOTE SWITCH
228. removal procedure Be sure the engine stator assembly is secure on the blocks COMMANDER 400 LINCOLN 5 F 114 F 114 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 61 STATOR REMOVAL Retum to Section TOC Retum to Master TOC Stator Engine Mounting Bolts and Lockwashers Bottom Flywheel Cover B 8 4 Retum to Master TOC Fan Nut gig STATOR REMOVAL PROCEDURE 8 1 Using the 1 4 Allen wrench remove the four 4 Using the 11 16 wrench remove the eight 4 cap screws mounting the fan blade to the hub bolts and lock washers holding the stator frame to the engine Support the stator with 818 2 Using the 1 13 32 socket wrench remove the the hoist and make sure the engine is blocked fan nut from the threaded shaft Remove the securely See Figure 61 5 fan blade taking note of placement for eic reassembly Be sure not to place the fan 5 Remove the stator from the engine rotor backwards 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 Retum to Section TOC Retum to Master TOC COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section
229. result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 olo O E 515 PEN iz g 9 2 E 0 xIx This procedure takes approximately 40 minutes to perform Return to Section TOC Return to Master TOC COMMANDER 400 LINCOLN Return to Section TOC Return to Section TOC Return to Master TOC Q 5 Return to Section TOC Return to Master TOC Return to
230. rews 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 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure CLAMPING PROCEDURE FOR 1 4 20 CAP SCREWS NOTE This procedure can only be used with 1 4 20 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do not 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 2 Tighten first cap screw 1 4 turn 2 Tighten first cap screw 1 4 turn 3 Tighten second cap screw 1 2 turn 3 Tighten second cap screw 1 2 turn 4 Tighten first cap screw 1 2 turn 4 Tighten first cap screw 1 2 turn 5 Tighten second cap screw 1 2 turn 5 Tighten second cap screw 1 2 turn 6 Tighten first cap screw 1 4 turn STOP 6 Tighten first cap screw 1 4 turn STOP 7 Assembly now has the proper clamping force 7 Assembly now has the proper clamping force 8 Perform the Active SCR Test 8 Perform the Active SCR Test COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 100 TROUBLES
231. riding 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 6 Setthe LOCAL REMOTE switch to REMOTE 7 Set VOLTMETER switch to or depend ing on the polarity chosen 8 Set RANGE switch to WIRE WELDING CV 9 Setthe WELDING TERMINALS switch to WELD ING TERMINALS REMOTELY CONTROLLED 10 Adjust wire feed speed and voltage at the LN 8 FIGURE C 4 COMMANDER 400 LN 8 WITH K595 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM TO LN 8 INPUT d A MU 14 PIN AMPHENOL 7 CV WORK CABLE PLUG K595 CONTROL CABLE L ELECTRODE CABLE TO WIRE FEED UNIT COMMANDER 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC 7 ACCESSORIES CONNECTION OF THE LN 23P TO THE COMMANDER 400 USING K350 1 ADAPTER SEE FIGURE C 5 1 Shut the welder off 2 Connect the electrode cable from the LN 23P to the CV Wire terminal of the welder Connect the work cable to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application N
232. river Wiring Diagram This procedure takes approximately 25 minutes to perform Retum to Master TOC 8 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC 5 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 50 239 50 TROUBLESHOOTING amp REPAIR CHARGING CIRCUIT TEST continued FIGURE F 22 ENGINE ALTERNATOR LOCATION 285 281 238 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 5 Set the voltmeter for DC volts and measure the DC volts at lead 239 to engine ground See the Wiring Diagram Normal is 12 5 to 14 5VDC 6 Set the voltmeter for DC volts and measure the DC volts at lead 238 to engine ground See the Wiring Diagram Normal is 12 5 to 14 5VDC 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 NOTE Some earlier machines may have a lead 281 instead of 4285 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 ea
233. rlier machines lead 281 carries the flashing voltage for the engine alternator Battery voltage should be present whenever the start button S2 is pushed See the Wiring Diagram 8 If the correct flashing voltage is present and the charging output voltage is low or missing the engine alternator may be faulty 9 Stop the engine and check alternator V belt for proper tension See the engine operation manual 10 Replace all case covers that were removed See the Case Cover Removal Procedure COMMANDER 400 LINCOLN F 51 F 51 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TEST WARNING Retum to Section Retum to Master TOC 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 Retum to Section TOC Retum to Master TOC MATERIALS NE
234. rminal at the control board Check the hold in coil resistance by discon necting J3 from the control board and mea suring across pins 3 amp 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 If the lead connections are OK recheck the coil resistance directly across the solenoid If the coil resistances are incorrect the solenoid may be faulty Replace 4 Using the external 12VDC voltage supply apply 12VDC to the larger idler solenoid ter minals 227 to 254 The solenoid should activate IDLER SOLENOID A CAUTION When the solenoid activates remove the voltage supply immediately Do not leave the external supply connected to terminals 227 and 254 for longer than three seconds Component damage could result The solenoid should deactivate when the 12VDC supply is removed 5 If the solenoid does not operate properly check for a mechanical restriction in the linkage 6 Using the external 12VDC voltage supply apply 12VDC to the smaller idler solenoid terminals for the hold in coil 226 to 237 Push in the solenoid plunger With 12VDC applied to the hold in coil the plunger should stay in until the 12VDC is removed 7 the linkage is intact and the solenoid does not operate correctly when 12VDC is applied the solenoid may be fa
235. roce analog ohmmeter set at R x 1000 scale The dure resistance should be low See Figure F 16 a Reverse the meter leads and measure the resistance cathode to anode probe of diode DD The resis tance should be high See Figure F 16 COMMANDER 400 LINCOLN F 45 F 45 TROUBLESHOOTING amp 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 Retum to Section TOC Retum to Master TOC 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 Retum to Section TOC Retum to Master TOC This procedure takes approximately 60 minutes to perform Retum to Mas
236. roximately 30 minutes to perform Retum to Master TOC 8 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 104 TROUBLESHOOTING amp REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS continued PROCEDURE Turn the engine off Perform the SCR Diode Bridge Removal Procedure Loosen the appropriate diode nut and remove the diode that is to be replaced 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 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 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 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 a Donot apply compound to the diode stud or mounting threads 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 th
237. rrect the wiring may be faulty Inspect the solenoid leads for faulty or loose connections If the lead connections are OK recheck the coil resistances directly across the solenoid If the coil resistances are incorrect the sole noid may be faulty Replace 4 Using the external 12VDC voltage supply apply 12VDC to the larger shutdown sole noid terminals 262 to 225 The sole noid should activate PULL IN COIL LARGER TERMINALS EACH SIDE 225 AND 262 HOLD IN COIL Ww SMALLER TERMINALS IDLER EACH SIDE SOLENOID 224 AND 240 A CAUTION When the solenoid activates remove the voltage supply immediately Do not leave the external supply connected to terminals 262 and 225 for longer than three seconds Component damage could result The solenoid should deactivate when the 12VDC supply is removed 5 If the solenoid does not operate properly check for a mechanical restriction in the linkage 6 Using the external 12VDC voltage supply apply 12VDC to the smaller solenoid terminals for the hold in coil 240 to 224 Push in the solenoid plunger With 12VDC applied to the hold in coil the plunger should stay in until the 12VDC is removed 7 If the linkage is intact and the solenoid does not operate correctly when 12VDC is applied the solenoid may be faulty Replace 8 Replace the harness leads to the correct ter minals See Figure F 9 and the Wiring Diagram Replace any previously removed
238. rrent CC and the auxiliary power are operating normally The machine powers down within seconds of power up and all lamp indicators on the front panel are lit ECL or CSS appears display as machine is shutting down POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Make sure the wire feeder con trol cable and welding cables are connected correctly Make sure the range switch is in the correct position Check the heavy current carry ing cables associated with the CV output terminal the Wiring Diagram 1 Contact your local Lincoln Authorized Field Service Shop TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Perform the Check for poor connections at J21 pins 1 amp 4 at the CV daugh ter board This is CVSCR gate drive output Will not affect welding in the general fab or pipe taps 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 Range Switch Control Board Power Supply Test Check to make sure that the machine has an 110953 1 Exciter Feedback Module Asbly 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 Mod
239. ry 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 Retum to Section TOC Retum to Master TOC MATERIALS NEEDED 5 16 Nut driver Phillips head screw driver Volt ohmmeter for stick and wire model calibration only Retum to Master TOC 8 8 This procedure takes approximately 40 minutes to perform Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN F 82 F 82 TROUBLESHOOTING amp REPAIR Q CONTROL PC BOARD REMOVAL AND REPLACEMENT continued 8 FIGURE F 33 MOLEX PLUG REMOVAL 2 8 8
240. s 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 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 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 6 Re install the pre filter screen into the upper cavity of the filter header making sure the four pull tabs
241. s a 5 8 inch wide spring The different designs HEX NUT require different assembly and clamping pro cedures The assembly procedure will be dif ferent depending upon the thread on the cap A screws A 1 4 28 thread requires a different tightening procedure than a 1 4 20 thread HEAT SINK PROCEDURE FOR THE 1 2 INCH lt WIDE SPRING i 1 Place a piece of sleeving around each cap SCR screw eg 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 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 HEAT SINK Retum to Master TOC 8 8 HOUSING LEAF SPRING 3 Insert cap screws and leaf spring into the plastic housing CAP SCREW Retum to Section TOC Retum to Master TOC COMMANDER 400 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 99 F 99 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued CLAMPING PROCEDURE FOR 1 4 28 CAP SCREWS NOTE This procedure can only be used with 1 4 28 cap screws Do not use cap sc
242. s section of this manual Control PC Board Layout See the electrical diagrams section of this manual Retum to Master TOC 8 8 This procedure takes approximately 30 minutes to perform Retum to Section TOC Retum to Master TOC COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC 5 5 9 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 58 F 58 TROUBLESHOOTING AND REPAIR RANGE SWITCH TEST continued TEST PROCEDURE NOTE In this test procedure the positive output stud is used for common 1 Using the 5 16 nut driver open the control panel and tilt out Remove the control board cover Start the machine WARNING There are high voltages present inside S 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 2 Putthe range switch in the CV position on stick amp wire machines or in the 90 tap on stick only machines 3 Check the voltage at the control board from J 7 pin 10 to common at each tap on the range switch See Figure F 28 See table F 1 below approximate voltage reading from each tap 4 f any of the voltages in the table are incorrect replace the range switch 5
243. scope Waveforms Section The control board may be faulty Replace Retum to Section TOC Retum to Master TOC The engine will not crank or cranks very slowly Check for loose faulty or cor roded battery cable connections Check the leads and connec The starter motor solenoid or push button may be faulty Check or replace tions at the starter solenoid and the start push button The engine may be hard to crank due to a mechanical fail The battery may be faulty ure mthe engine Retum to Master TOC 8 8 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 Retum to Section TOC Retum to Master TOC Commander 400 LINCOLN 5 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 10 F 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The engine cranks but will not start POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS Check for adequate fuel supply Make sure the fuel shut off valve is in the open position lever is
244. se to earth ground for the safest grounding procedure Refer to in the Installation section for proper machine grounding information WIRE FEEDER MODE CONTROLS Figure B 1 Items 20 24 Stick amp 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 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 ENGINE OPERATION STARTING THE ENGINE 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 4 Set the IDLER switch to AUTO 5 Set RUN STOP switch to RUN Observe that all engine protection lights momentarily turn o
245. shop etc To prevent dangerous electric shock other equipment powered by this engine driven welder must be grounded to the frame of the welder using grounded type plug or 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 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 machine grounding stud marked with the 32 symbol is provided on the front of the welder AUXILIARY POWER RECEPTACLES The Commander 400 can produce 10 000 watts of 60 Hz single phase auxiliary power The rating in watts is equivalent to volt amperes at unity power factor The output voltage is within 10 at all loads up to the rated capacity The following receptacles are provided Two 15 amp 120V
246. should read 002 7 Toggle the idler switch to HIGH and back Retum to Master TOC 8 8 Retum to Section Retum to Master TOC COMMANDER 400 F 85 F 85 TROUBLESHOOTING amp REPAIR SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT WARNING Retum to Section TOC Retum to Master TOC 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 Q PP DESCRIPTION 3 gt This procedure will aid the technician in the removal and replacement of the shutdown 818 solenoid ji id MATERIALS NEEDED 7 16 Wrench Long slot head screw driver Needle nose pliers This procedure takes approximately 60 minutes to perform Retum to Master TOC 8 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC 5 8 9 8
247. side Do not stack anything near the engine 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 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 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 2 Drain the engine oil and refill with fresh 10W30 oil Run the engine for about five minutes to circulate oil to all the parts See the Maintenance section of this manual for details on changing oil 3 Remove the battery recharge it and adjust the electrolyte level Store the battery in a dry dark place 4 See your engine operation manual for further infor mation on fuel and engine preservation STACKING Commander 400 machines CANNOT be stacked ANGLE OF OPERATION To achieve optimum engine performance the Commander 400 should be run in a level position The maximum angle of
248. sponsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components 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 Return to Section TOC Return to Master TOC Retum to Section TOC Retum to Master TOC Retum to Section TOC Retum to Master TOC 8 8 Retum to Section TOC Y 4 2 8 E 4 Retum to Master 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 LINCOLN 5
249. st repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD Commander 400 LINCOLN Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS or CRS stuck on display when machine is powered up No welding output in both stick and CV modes Engine operates normally and auxil iary power is normal Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Contact your local Lincoln Authorized Field Service shop RECOMMENDED COURSE OF ACTION 1 Check for loose or faulty connec 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 amp T3 for faulty connec tions Check for loose or faulty connec tions at leads 268 269 amp 270 from the exciter PC board to J4 pins 1 2 amp 3 on the control board Check the exciter waveforms as illustrated the Oscilloscope Waveforms Section The welding output is low with little or no control of output The auxil iary power is OK The eng
250. stant bag and perform the following procedures PC Board can be damaged by static electricity Remove your body s static charge before opening the static shield ing bag Wear an anti static wrist Aa ATTENTION strap For safety use a 1 Meg Static Sensitive ohm resistive cord connected to a Devices grounded part of the equipment Handle only at frame Static Safe f 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 Reusable Container Do Not Destroy Tools which come in contact with the PC Board must be either conductive anti static or static dissipative Remove the PC Board from the static shielding bag and place it directly into the equipment Don 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 the PC Board uses protective shorting jumpers don t remove them until installation is complete e 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 NOTE Allow
251. ter TOC 8 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Y 4 2 4 Retum to Master F 46 F 46 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE F 17 CONTROL BOARD PLUG J6 LOCATION PLUG J6 TEST PROCEDURE 1 Turn OFF the engine 5 2 Perform the Case Removal procedure 6 including front shroud removal 3 Disconnect the welding cables from the 7 welding output terminals 4 Using the 5 16 nut driver remove the con trol board cover See Figure F 17 Locate and remove molex plug J6 from the control board See Figure F 17 Using the 3 8 nut driver locate and remove the snubber board cover See Figure 18 Locate and remove molex plug J30 from the snubber board See Figure F 18 FIGURE F 18 SNUBBER BOARD PLUG J30 LOCATION PLUG J30 eee X EL WARNING SNUBBER BOARD LOCATION LEFT SIDE BELOW FUEL TANK
252. th 12VDC Retum to Section TOC Retum to Master TOC MATERIALS NEEDED External 12VDC supply 30 amps required Wiring Diagram Volt Ohmmeter This procedure takes approximately 40 minutes to perform Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC COMMANDER 400 LINCOLN Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 36 TROUBLESHOOTING amp REPAIR SHUTDOWN SOLENOID TEST continued FIGURE F 9 SHUTDOWN SOLENOID LEAD TERMINALS SHUTDOWN SOLENOID TEST PROCEDURE 1 Turn the engine off 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 Check the hold in coil resistance by discon necting J3 amp J4 from the control board and measuring across J3 pin 2 to J4 pin 5 Normal coil resistance is approximately 20 ohms Reconnect J3 at the control board If either coil resistance is inco
253. 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CYLINDER may explode damaged 2 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for
254. the machine to heat up so that all electri cal components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips 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 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims Commander 400 LINCOLN Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 4 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your local Lincoln Authorized Field Service Facility TROUBLESHOOTING GUIDE RECOMMEN
255. 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 If all exciter voltage readings on the display are correct the exciter board is properly calibrated and the test is complete If the average of the three exciter voltage readings under load is under 350VAC then the board must be replaced COMMANDER 400 LINCOLN F 65 F 65 TROUBLESHOOTING amp 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 Return to Section TOC Return to Master TOC 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 or error code when o
256. to Master TOC Retum to Master TOC Retum to Master TOC F 19 F 19 TROUBLESHOOTING amp REPAIR COMMANDER 400 WITH G2713 1 CONTROL BOARD ERROR CODES DURING INITIALIZATION SEQUENCE DEFINITION SYMPTOM The output current is too high greater than 750 amps for more than 1 second XIRQ error illegal external interrupt request COMMANDER 400 LINCOLN CORRECTIVE ACTION The machine may be over loaded Remove any external loads If the problem persists with no external load check the shunt leads and associated 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 If the problem persists the control board may be faulty Retum to Section TOC Retum to Section TOC 8 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 20 F 20 TROUBLESHOOTING amp REPAIR COMMANDER 400 WITH G2713 1 CONTROL BOARD ERROR CODES DURING INITIALIZATION SEQUENCE DEFINITION SYMPTOM RTI error illegal return from interrupt SWI error illegal software interrupt re
257. tting 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 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 GENERAL WELDING 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 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 2096 duty cycle 300 amps at a 6096 duty cycle and 250 amps at a 8096 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
258. ule Asbly check leads T1 T2 and T3 for fault connections Check for loose or faulty con nections at leads 268 269 amp 270 from the exciter PC Board to J4 pins 1 2 amp 3 on the control board possible check exciter wave forms as illustrated in the Section possible perform the 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 LINCOLN 5 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 7 F 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS No welding output in either CV or stick modes Also no auxiliary power Engine operates normally Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Contact your local Lincoln Authorized Field Service Shop RECOMMENDED COURSE OF ACTION 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 mod ule asbly check leads T1 T2 and T
259. ulty Replace 8 Replace the harness leads to the correct terminals See Figure F 8 and the Wiring Diagram Replace any previously removed wire wraps 8a Using the control PC board layout locate 021 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 LINCOLN F 35 F 35 TROUBLESHOOTING amp 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 Retum to Section TOC Retum to Master TOC 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 wi
260. um to Master TOC COMMANDER 400 Retum to Section TOC Retum to Section TOC 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 93 TROUBLESHOOTING amp 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 21 bridge assembly out the left side of the machine See Figure F 42 22 REASSEMBLY 16 Carefully lift and slide the SCR diode rectifier bridge assembly into the machine from the left side See Figure F 42 23 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 204 lead to the R1 50 Ohm 100 Watt resistor See Figure F 40 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 24 Using the 3 4 wrench attach lead 207 to the negative stick output terminal Replace any cable ties cut during removal Feed plug J6 and the toroid assembly into the control b
261. umn 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 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 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 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 Electr
262. way from the nameplate and the white nylon holding fingers of the knob base from top to bottom Replacement 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 LINCOLN F 33 F 33 TROUBLESHOOTING amp 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 Retum to Section TOC Retum to Master TOC 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 assistanc
263. ways use enough ventilation especially in confined areas to insure breathing air is safe 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 Mar 95 COMMANDER 400 Retum to Master TOC Retum to Master TOC Y 4 2 8 amp Retum to Master SAFETY 7 WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 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 Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure
264. wire wraps 8a Using the control PC board layout locate the Q25 on the control board Scrape the environmental coating from all three legs of the device and check the resistance between all three legs If there is continuity between any of the legs Q23 is bad Replace the control PC board 9 Close and secure the right side engine ser vice access door Replace the control board cover and close the control panel COMMANDER 400 LINCOLN F 36 F 37 F 37 TROUBLESHOOTING amp 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 Retum to Section TOC Retum to Master TOC 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

Lincoln Electric SVM133-B User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents