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F-1
DIAGRAMS
F-1
COMMANDER 500
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-
gram for your particular machine is pasted inside the machine on one of the enclosure panels.
WIRING DIAGRAM:
5M
6D
6C
9
GND-E
201B
200E
5H
6D
200C
200
226
237
224A
12
262A
234A
228A
233A
241A
281A
237A
6
12
264
232D
263
4B
2B
OPTIONAL ON
STANDARD MODEL
-
1
3
91
E
F
G
I
HOT (GOLD)
SILVER
J11
HOT (GOLD)
17
Y
SILVER
CONTROL HARNESS
R
TOROID
18
200B
P30
233
228
234
200D
281
224
241
201A
262B
5P
200A
239
226A
237A
VIEWED
41
75B
42
OUTPUT
31
CONTROL
(BLACK)
15
32
NEUTRAL
30VAC
CCW
BK
CONTROL
HOT(BLACK)
BROWN
14
16
BK
PRIMARY
120VAC
BR
30VAC
CONTROL
BR
13
YELLOW
R
5D
IGBT
DRIVER
PCB2
BOLTED
TO
RED
42VAC
HEATSINK
PCB
POWER
76C
76
236C
FROM
BACK
278A
PINCH POT
278
277
21B
+
-
2
31
32
4E
2D
J
77
4D
A
242I
D
POLARITY
C
SWITCH
277
H
278
1
25
22
75
23
21
31
32
TOROID
18
17
J14
RECTIFIER BRIDGE
SHUNT
-
50MV=400AMPS
14
13
1
5G
2
3
Y
4
6E
5
6
P16
78
16
15
J16
50A
TO THE LAMINATION
TO SLIP RING NEAREST
POSITIVE BRUSH CONNECTED
CONTROL
IDLER
5B
6D
5E
42VAC KIT
5C
5
42
SWITCH
CONTROL
6D
200D
200A
256
200E
SHOWN IN
5P
12
201
HOUR
200B
201A
231
236
232D
201B
CB4
6B
1 3
GOLD
SILVER
ALT.
TEMP.
LOW
PRESS.
GOLD
4
6
CB5
9
239A
CB2
20A
3
3
232L
232M
6A
AUXILIARY
NEUTRAL STUD
5F
BACK OF CONTROL
BOX "LEFT SIDE"
5D
232
236B
6F
201
BRUSH
5A
31
43
2
3
10A
-
BRUSH
+
5F
242
238
SOLENOID
5
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
"HIGH" POSITION
METER
-
5K
263
5F
CONTROL HARNESS
5H
POWER MODULE
76B
S6
236
231
6H
RIGHT SIDE
CB1
20A
OPTIONAL
OF CONTROL BOX
ON BOTTOM LEFT
GND-C
CB6
6C
EMPTY
GND-B
GND-D
A
6
5
16
281A
229A
5G
77B
J11
SILVER
11
50A
6E
CB3
8
3A
WITH 42V
VAC KIT
23A
A
B
C
D
E
F
25A
67
LOW
3
FUEL
G3583
5C
5
ENGINE HARNESS
12
5C
GROUNDING BOLT
ON ENGINE BLOCK
STUD ON ENGINE
MOUNTING FOOT
LEFT SIDE
XE
1
2C
75B
4
76C
RF BYPASS PCB
41
42
6
CAP.
MULTI-LEAD
108A
232P
17
18
B
21C
GOLD
SILVER
K
SENSOR
COIL
HOLD
COIL
PULL
SHUTDOWN
SENSOR
COIL
SENSOR
SWITCH
FUEL LVL.
OIL TEMP. SENSOR & SWITCH
OUTPUT PANEL
262B
WELD STUD ON
SOL.
SOL.
OIL PRESSURE SWITCH & SENSOR
SWITCH
WK
233
234
262
SENSE
NEG
EXC
MOTOR
STARTING
281
5R
FRAME
POS
G
242D
239
229
5N
236C
248
232J
236A
RUN
STOP
264
232H
32
HIGH
+
242I
232C
242B
110A
109A
5K
SHOWN IN
SWITCH
SHOWN IN
RUN/STOP
242E
"ALWAYS ON" POSITION
32
5J
5K
5L
229B
8
FUEL
B3
256
GND. STUD ON
B4
BOTTOM RIGHT OF
238
248
239A
236C
232
232K
1
J9
5
1
5L
J8
106A
107A
104A
102A
101A
103A
4
104A
102A
216
103A
222
218
219
213
217
220
214
101A
106A
105A
107A
108A
215
76
242H
242I
8
5E
5B
4
15-250
TIG
30-575A
8
STICK
CONTROL PANEL
GND. SCREW ON
7
500A
0A
35
250A
REMOTE
77
LOCAL
SWITCH SHOWN IN
TEMP
OIL
PRESS.
S
242B
CHRG.
241B
228B
7
6
1
J5
15A
3B
6A
COMMANDER 500 WIRING DIAGRAM
3
CORRESPONDING SETTINGS FOR TAP NUMBERS
(AS VIEWED FROM THE FRONT)
6A
3
4
5
42B
6
BLACK
RED
CONTROL HARNESS
OPTIONAL
ROTOR
CONTROL BOX
2B
4B
5G
START BUTTON
224A
2C
226
262A
4C
J6
237
90
242D
AUTO
77C
242A
"LOCAL" POSITION
229C
232B
S
232D
CONTROLLED
242C
238
BATT.
"RUN" POS.
262
232N
B2
B1
229
J30
32
5S
239
238
IDLE
224
228
241
77E
21C
2E
3
2
1
5
HEAT SINK
J13
CAP.
POSITION
POSITIVE POLARITY
J12
SWITCH SHOWN IN
6A
3
DIRECTIONS
IN OPPOSITE
6A
TOROID TWICE
PASS THROUGH
LEADS 3 & 6A
6A
3
RIGHT
1
247
232E
246
232F
245
232G
232A
232G
232L
232F
232M
232E
232K
232N
WELDING
SOURCE
3
6A
ALWAYS ON
REMOTELY
232A
227
229B
S
OIL
BLACK
6A
243
229A
229
J18
228A
241A
P18
4
J60
1
2D
4D
6
4
77D
75D
3
J62
76D
1
4E
2E
77E
75E
3
76E
TOROID
+
STARTER
STATOR
ALTERNATOR
AUXILIARY WINDINGS
1
P40
J40
6E
3
RED
"INSULATED STUD"
AUXILIARY POWER
6A
GND-E
AUXILIARY POWER
75E
242H
41
42
76E
3
+
3
4
WIRE
30-575A
150
EMPTY
2
90A
A
LEADS 238 & 236C TO BE
BOLTED TOGETHER AND
TAPED ON STANDARD
MODEL.
STUD
12VDC
1
INSULATED
5
50K
TOROID
229C
229B
241B
228B
6
5
J61
1
8
4C
77C
GND-C
5
11
115/230V
3
GND-D
5A
GND-B
203
222
213
67
214
215
216
(VIEWED FROM REAR)
SELECTOR SWITCH
BYPASS PCB
MOUNTING FOOT
12V BATTERY
STUD ON ENGINE
PCB1
DRIVER
IGBT
CAP.
CAP.
BOLTED
TO
HEATSINK
4
EMPTY
EMPTY
6
4
5
3
COIL
HOLD
(-)
-
PULL
226A
(+)
227
67
3
6A
261
260
LEADC 203 TO
PASS THRU TOROID
CONTROL
67A
ELECT.
WORK
+
67A
115VAC
CONTACTOR
77D
76D
WORK
75D
W2
W2
W3
W3
REMOTE
CONTROL
42VAC
GROUND
AMPHENOL 1
REMOTE
CONTACTOR
GROUND
AMPHENOL 2
STATOR
WELD
WINDINGS
W5
W4
W3
W5
W4
W2
LEFT
W1
15
W1
1
W6
W6
W3
217
23A
S5
16
R2
218
2
6
5
7
25A
219
8
220
A
9
MULTI-LEAD
CHOKE
L1
P14
HEAT SINK
22
21
13
14
23
25
4
6A
ONE TIME
W6
W1
W1
W6
W2
250 ohms
25 watts
ENGINE PROTECTION PCB
5M
ENGINE GROUND
BACK OF CONTROL BOX
GND STUD ON RIGHT SIDE
J7
J2
6
5
4
9
10
DISPLAY PCB
J4
16
CONTROL PCB
6
J3
J1
8
242H
5R
OPTIONAL ON STANDARD MODEL
R1
76B
75A
VIEWED
FROM
BACK
75
3
5
105A
21A
2
22A
3
2
90
4
1
91
110A
109A
CONTROL
TRANSFORMER
232
41
200C
300V
3200MFD
200
242
1
9
246
260
245
261
247
234A
243
5J
233A
77B
GOLD
SILVER
ENHANCED DIAGRAM