Home

Lincoln Electric 400 Welder User Manual

Contents

1. Aux Power Stud Panel Left Side 50 Amp Circuit _ 4 Breaker N isis Screw g als A gt 23 1 Using 716 wrench disconnect stator lead 6 from the auxiliary power stud on the left side of the control box See Figure F 22 17 With a 3 8 wrench disconnect lead 5 from the center ground stud nearest the control transformer See Figure F 22 18 Using a phillips screw driver remove lead 3 from the top 50A circuit breaker for the 120 240V receptacle See Figure F 22 NOTE This lead must be wound two turns clock wise through the toroid opposite in direction from leads 6A 19 Disconnect lead 5A from the auxiliary power ground stud left side of the control box next to the 120V circuit breaker See Figure F 22 20 Using a 3 8 wrench remove the two screws holding the control box to the top of the fan baffle VANTAGE 400 LINCOLN 8 dios TROUBLESHOOTING amp REPAIR dibus STATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 23 DOOR REMOVAL LIFT FRAME WELDMENT Return to Section TOC
2. EI HE Sls 0 2 olo IT VANTAGE 400 WIRING DIAGRAM c 5 ELECTRICAL SYMBOLS PER E1537 5 D ALL CASEFRONT COMPONENTS SHOWN VIEWED FROM REAR RECTIFIER BRIDGE AUXILIARY POWER LEADS PASS THROUGH STATOR AUXILIARY WINDINGS B1 NEG TOROID THREE TIMES IN DIRECTION INDICATED dla B4 NEG 6 3 E sy o V V 6A 5 B1 NEG B4 NEG 261 C 2045 4 4 4 ili 50MV 400AMPS 3 4 4 Q 206S N E W4 amp W5 W2 amp W3 W1 amp W6 RT g WELDING OUTPUT 3 BOULE 4A 6 o TERMINAL Wav R2 sc 2 5 206A 9 i B7B8 CHOPPER OIO GROUNDED BY PCB3 STATOR 3B GND L 4A 3c GND C P MOUNTING 0 13 AED M GND M m w OE IN ES V8 NAA NSW xb No i i 13 J10 o 2088 BYPASS FILTER 240V 120 240V ASSEMBLY 15 3PH 6 db Q GND D Qo 208 GND J Cast 9 eer so stupon WELDING OUTPUT L1 CHOKE 13C 13 23 25 MODE SELECTO R SWITCH POWER RECEPTACLE PANEL 5B a PANEL 208A 5D ala TERMMAL n V4 J 0 218 2 STATOR 42V WINDING 6A 206A SWITCH CONTACTS cc A 10A 5H SPIOWN IN 14 220 A og 200B 200A 200 POSITION
3. M UU P H UP P C A THs SCHEMATIC UGED AME BOARDS PROPRIETARY 4 CONFIDENTIAL DIMEN PARTIES AG PEGUE VE DONORS WANIEN OF TYPE COMMON ANALOG CONTROLS PAGE 15005 0 MOT 7 SUBJECT SCHEMATIC ANALOG CONTROL Eg EE EP IT 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 ELECTRIC VANTAGE 400 ELECTRICAL DIAGRAMS G 10 SCHEMATIC IDLER PC BD G4828 2 1 qu a 4 32 E Fel 212 kler gt E T E de E 212 de da i 12 zeczrd 1 vr TE cq 2 2 Poe 70 Hb IL l M NOE x x n T p i ade E zx Hood Sede dM Ej PATE S E 1 25 dis d ENS T m ao m AH 7 e exp en UU Ns des T CC m 1 du mus ur Ian M the Dil gnus ona 15 T Jim ic inr
4. 265 Bot 1 A 11 s p V E Lh tes 11 er Qe ic EHR EL DHEOBEAI ZH ELZUCIBILOL ETAT CACIO WFO UTHERWIEE le Ikni 1 ESS CTHERUIEE SEEZIFTEDI DOC APD ufa TAGE SAALE AF OChRECTIOK RE i a Ju 21 LINCOLN ABD KOT ODLFLILATIA JPME 5 LTDBDIDEMTIAD tp enka dm user ree av FLOPROSD wJTROJT HE PITTEN PEdHISTIM DLGTAL d TURF INEHTS LH 1 vw aw T SSSINTED CPEUIT SERED HEN CHANGE EUUIPREST TTBE BLARU aE ECT HG THE HTESCAaNzE 05 Lo WE EF SJELI DTA Ra DT THE EXACT Ras eR l d jsepsiras 7 268939 COMPUNENTS OF OF EZHISOLS TEC CIACH WUYE Uni
5. Section G Parts Manual P 528 400 LINCOLN Return to Master Return to Master TOC O v 9 Return to Master all TABLE OF CONTENTS INSTALLATION SECTION nt INSIAQUNAUON M P A 1 Technical SDpeGIIICallOTIS te vene OE Un ph qn e ig om cy KERR pa etes A 2 e a2 92 A 3 VRD Voltage Reduction Device A 3 Location and 2 A 3 cedum eP PL C 7 rTPPT A 3 aed 3 ___ __ __ ______ _ __ _ ___ _ 3 High Altitude Operation A 4 High Temperature Operation A 4 Cold Weather Operation A 4 TOWING rm A 4 rr A 4 Pre Operation Engine Service A 4 5 5 Engine COON
6. 5 Battery Connections 1 5 Muffler Outlet PIDE Se we ee eee ee ews eee SEE eee ee A 5 5 pinea 5 ene ace 6 Machine Grounqin a 2001 2 oa de Be A 6 Welding Terminals A 6 Welding Output Cables A 6 Cable Installation dk ps caro cowed We Reb eee eben es EUR ac REE eee PEERS X A 6 Auxiliary Power Receptacles and 06 A 7 Standby Power Connections A 7 Premises WINO 8 Connection of Lincoln Electric Wire Feeders A 9 A 10 VANTAGE 400 LINCOLN 8 iia INSTALLATION iain TECHNICAL SPECIFICATIONS 400 2410 1 2410 2 INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities PERKINS cu in Itrs System K2410 1 4 cylinder 135 6 2 2 12VDC Battery amp Fuel 15 gal 404C 22 32 7 HP Hi
7. Bc 1 E a 231 il bak JI 7 des 1 E tera be T a l 5 M oT 2b tt Lt v cor ks H fo ig a Faut Lomp 1 THES alin OJO O O e CIS 01 0 0 gt cic 5 2 2 we ulne Ie Pu Tina _ Sol un CAPHCIICRS PED i CTZ25209 DT ER J E SPOTTED ae DTHEXMISE SURF LABELS DIS I amp 4207 LESA USSU T v rap ant Pris Ay coer Toon ot FRE LECTIE T nea Mr Bs TLIN gt Er GILL LA LOATA NG JE LER TOR Bv G Joa ACT DLCLICRTED 2 amp JULM 1 1 TTA Pak Ts OF dT PUSPOS UP EGP DRIVES 3 UF jeep YE mcg a 0088
8. B 6 Downhill Pipe Stick Welding 0 B 6 TG ore ge tie a ee Pee eae aes eee B 7 Typical Current Ranges for Tungsten Electrodes B 7 s Wire Welding CV 21 B 8 GOUGING 5 55 ee eee eae wee Yee bee B 8 rrr 8 O Simultaneous Welding and Power Loads B 8 Extension Cord Recommendations B 8 O O 9 gt VANTAGE 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or V e electrode with skin or wet clothing e Insulate yourself from
9. 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC C 3 ACCESSORIES udi ENGINE WELDERS LN 25 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL K857 REMOTE CONTROL WARNING Do not operate with panels open e Keep guards in place Disconnect NEGATIVE Battery lead Keep away from moving parts before servicing Only qualified personnel should install use e Do not touch electrically live parts or service this equipment OPTIONAL K857 REMOTE CONTROL 6 PIN AMPHENOL AMPHENOL LN 25 WIRE FEEDER WORK CLIP LEAD TO WORK TO WORK ELECTRODE CABLE WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE PLACE THE MODE SWITCH IN THE CV WIRE POSITION D PLACE THE WELDING TERMINALS SWITCH IN THE WELD TERMINALS ON POSITION PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 10 27 2000 24787 1 ENGINE WELDERS LN 25 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL K444 1 REMOTE CONTROL Do not operate with panels open Keep guards in place Disconnect NEGATIVE Battery lead Keep away from moving parts before servicing Only qualified personnel should install use e Do not to
10. q HL W11 Grqw rie e 982 LEDS B5 2 C HLWS o3 ec OMIT nn HL W6 HL W4 LED2 Voltage from HL W9 Rectifier HL W8 LED3 B4 B5 B6 Chopper Working SL302 SETS 51301 5114 PROCEDURE REMOVAL 7 Remove the Power Module assembly from the machine TERMINAL LEADS Perform the Chopper Module Capacitor i Heavy lead W11 4 Disconnect leads 23 and 25 at their in line B5 Heavy lead W5 Small lead 13 couplings ee 5 Using the 7 16 socket wrench remove the fol lowing leads Label the leads before removal Cut cable ties as needed Note placement of WA 1 Turn the engine off 2 Perform the Case Cover Removal leads and fasteners screw lock washer flat washer small lead heavy lead P lead W9 Small lead 302 6 Using a 3 8 socket wrench remove the three screws holding the power module assembly to its brackets on the vertical baffle Remove the plastic strip with the top two screws Be sure to support the Power Module as you remove the last screw 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 02 gt 9 cic 5 Slo c Return to Section TOC Return to Master TOC did TROUBLESHOOTING amp REPAIR CHOPPER MODULE REMOVAL AND REPLACEMENT CONTINUED REPLACEMENT 1 Mou
11. aS 2 Soo 8 9739 lt 5 tc gt 2 6 Y Ss SS MC caxo gp gt 2 NN gt 40 c W nN H e lt 2 KAW GARY C Su D e c O gt Q WORD 5505 59968 mis IT ASSAN 0 PES 2 2 L VS 5858 8 Fels 2555 A YS T O O _ ost lt lt ss 5 gt oO c M 9 NO 2 22 eg t NU LO 3 525 25 29 p E S E OR 3 58598 Bo 55 g n e 3 DO y LL h PANN oc g C x NERA Bogs Bf 0 gy SooS 5 6028 KAY N e 2 Z O NS 27 TJEN gt O 2 O O VF 998 558 00 ON 3 Co5 2 os 8 a N ES RA 29 ZCO 502 vA m 5 S 2 lt p 20285 gt 556 lt 252 DOB CBG o 5 5 829tg obs 529 5 o D F 2 o 52825 LEQ sue 9 p 2 LLI t 999 5925 946 D 054 SI ToT Oot S o o 285 O55 ir D Z EEL N used for this test 1 v F 31 QOL 491S8 N uJnjeH 95
12. aad rit Lac OIo O O za CIS olg Ole gt olg cic 5 5 GENERAL INFORMATION ee Fa oa Ted 18 1 3 SUPPLY VOLTAGE A FORMER 57 COMMON DONMECTION GOMER TION EARTH CORNEC TOON THES USED M Get PROPRETARY amp CONFIDENTIAL FPR Gaur EOS E CT NE MM Er DESIEN erm EQUIPMENT COMMON ANALOG CONTROLS 01 OF 05 WETHOUT AFFECTING THE INTERCHANGE mn EY ME 5 Got EUM DE eer am SUBJECT SCHEMATIC ANALOG CONTROL A COMMON CUE UMEEN 1 RAW 7 3 G 5806 200 UA NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Master TOC Return to Section TOC ELECTRIC VANTAGE 400 0 6 ELECTRICAL DIAGRAMS di SCHEMATIC WELD CONTROL PC BD G5506 PAGE 2 OF 5 WELING CONTROL WITH CURRENT TORRE on START CONTROL 28 AUTORATIC AGATE LiACAL 2 419 REF Return to Section Return to Master TOC DATA 1 7 X aita SRM Return to Section Return to Master TOC ommo
13. 15 DE _ PAMANT DAT LEED TOM le MS LABELS i SUPPLY VOLTAGE MET A USED TM AbD 6109 Thess CONTAIN PROPTIETAHY BY LINCOLN GURL AMD HAY BE COMM PROPRIETARY amp COHFIDEMTIAL CONTR ee Eee Sue Tar XPRESS WHITTON PERMIT SN CF LR N EQUIPMENT TYPE COMMON ANALOG CONTROLS GGO 3 OF 45 i mene Rim SUBJECT SCHEMATIC ANALOG CONTROL 8887 E d atas fone BAA a NALE pasaon NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ELECTRIC VANTAGE 400 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OIo O O za CIS olg Ole gt olg cic 5 5 Return to Section Return to Master TOC G 8 ELECTRICAL DIAGRAMS G 8 SCHEMATIC WELD CONTROL PC BD G5506 PAGE 4 OF 5 START TID SUPPLY 4B 5V_REF 4C j ROR a ERE eism DN 2 4 SENSE CIRCUIT Bn iO HF ti B i 102v AUF BREAK ARE DETECT Seo 1 E Ras ei WAIT a Biwi AMPS
14. 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC A 10 Connection of the LN 25 to the VANTAGE 400 Shut off welder before making any electrical con nections The LN 25 with or without an internal contactor may be used with the VANTAGE 400 See the appropriate connection diagram in Section F NOTE The LN 25 K431 Remote Control Module and K432 Remote Cable are not recommended for use with the VANTAGE 400 1 Shut the welder off 2 For electrode Positive connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder 3 Attach the single lead from the front of the LN 25 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current 4 Set the MODE switch to the CV WIRE position 5 Set the WELD TERMINALS switch to WELD TERMINALS ON 6 Set the ARC CONTROL knob to 0 initially and adjust to suit 7 Set the IDLE switch to the AUTO position When not welding the VANTAGE 400 engine will be at the low idle speed If you are using an LN 25 with an internal contactor the electrode is not ener gized until the gun trigger is closed
15. POURS Sola 2007 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 ELECTRIC VANTAGE 400 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 Return to Section Return to Master TOC O O e E G 13 SCHEMATIC BY PASS STABILIZER PC BOARD 522530 300 SINCE COMPONENTS CR CIRCUITRY ON DESIGN INFORMATION PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INFORMATION REFERENCE ELECTRICAL DIAGRAMS G 13 ARC STABILIZER CAPACITOR ARC STABILIZER RESISTOR C9 10 SuF SW CONNECTION MADE THROUGH 250VAC CONNECTION MADE THROUGH HOLE WITH SOLDER PAD HOLE WITH SOLDER PAD T 00047 F 0607 F 0 6057uF A 2 00047 F 09047 F 0 004 U U 3000V 3000V 3000 3000 janv a aon 3090 3000V 3000V 3000V GND GND CONNECTION MADE THROUGH SOLDER PAD AND SCREW TO STEEL STANDOFF ON MACHINE LAST NO USED GENERAL INFORMATION E 2 ELECTRICAL SYMBOLS PER E1537 C 9 CAPACITORS MFO 027 S0V UNLESS OTHERWISE SPECIFIED RESISTORS Ghms 1 4W UNLESS OTHERWISE SPECIFIED LABELS P DIODES 1A 00V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE POWER SUPPLY SOURCE POINT M COMMON CONNECTION FRAME CONNECTION EARTH
16. dz 208 ds SE LL VOS O gt RAN AV O LO S202 5 9 SONG 9 gt lt 5 N y SEEDS C 2 0090 5 5 gt LLI 4 2 lt 5 d 7 0 O ox 9 Ges gt 505056 62 25 c o LL 75 1 C SoOGSorzg LLI 2 gn selago OQog amp 5o x 5 2 lt o B 285 5 c 2265 656 5 59 995909 5 o uos 8 PED TEx ps 5 oO ee 9 o as g oP gt Z gt Sco s c oce Foz g X O c 5 58 E YF SOBs O Oo O 73 99585 0 LLI doo s LO F 28 1 UIN JOY NOL uunjeH 1 UIN JOY UIN JOY OOL uunjeH Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 29 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repair
17. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 400 LINCOLN diis TROUBLESHOOTING amp REPAIR dili Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Return to Section TOC Return to Master TOC The engine will not idle down to low RPM The machine has nor mal weld and auxiliary output continued Manually move the idle solenoid plunger to the idle position If the solenoid engages and holds in the idle position the idle pull coil may be bad If the solenoid does not hold in the low idle position remove plug P6 from the control PC Board and wait about 30 seconds If the engine drops to low idle check for damage or buildup of conductive material on or around the bypass filter assembly and the output terminals the engine still does not drop to low idle the control PC Board is probably defective Replace it Check that leads Z3 and 76 are properly routed through the toroidal current sensor Each lead must have two turns and must pass through the sensor in the opposite directions The leads should be wrapped tightly and tie wrapped in place Check the toroidal curr
18. a iro oa F 47 otator Voltage 5 544585555 __ 51 Stator Short Circuit Ground Test F 55 Output Rectifier Bridge F 57 g Chopper Module Function Test F 61 2 Chopper Module Resistance Test F 65 E Weld Control Board PWM Gate Signal Test F 69 Weld Control Feedback Test 71 Control Potentiometer and Mode Switch Resistance F 75 Remote Receptacle Resistance 1 51 F 79 Voltage Waveforms F 82 F 86 Removal and Replacement Procedures F 87 F 103 Output Rectifier Bridge and Choke Removal and Replacement F 87 Chopper Module Removal Replacement 91 g Stator Rotor Removal and 1 F 95 2 Retest after Repall cer 104 VANTAGE 400 LINCOLN 8 Return to Section Retur
19. 75B to PIN J 31 500K or Higher Resistance should be very low The Ohmmeter should read about the same value as one would get by touching the two meter probes together mm e Return to Section TOC Return to Master TOC OO O HS 02 gt gt cic 5 5 o Return to Section TOC Return to Master TOC VANTAGE 400 LINCOLN 8 dian TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY e e 5 HIGH IDLE NO LOAD 51 gt 5 16 4 ms cc NE tA 50V 5ms Return to Section TOC Return to Master TOC 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 are connected at machine 120 VAC receptacle HS 0 cc gt 9 cic 5 5 c SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC 400 LINCOLN TROUBLESHOOTING 4 REPAIR Pid NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY MAX CONTROL POT HIGH IDLE
20. EIMIE RMP OER S OF IH l PS VTEO CISELY HAr EHZ CE Wei AL ie ISEE ABIL Ia eee uer LDF JJ pns HERES Ue CIE i ele ARE Pin FT d Jerr 5 pig J OPRAC 1 1217 74020 3760 Cue HOMER senna Lined 823 2 i 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 ELECTRIC VANTAGE 400 G 11 Iva NALITHM HL Jid ANY HO Sed L SO od MN YR LE tye TA AAT CIAO BOLLYWOOD SNIWINDI SIHI WIIN3QHNO 9 VANTAGE 400 031310305 55271840 AMT 1217395 SSL SSS SUDISISH CSIs 2SIMMSMIG SSM OH GuDUIJUdMO tt LESTA STORMS RUSTE re bl g NOLLYAHOINI HANJA aad SOD 0A ELECTRICAL DIAGRAMS NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ELECTRIC SCHEMATIC CHOPPER PC BD L127
21. FOR WIRE FEEDER 21 WORK SENSE 4 Lead 5 and lead 7 or 9 This checks for a connection between the auxiliary winding and the weld winding See Wiring Diagram 5 Lead 5 and lead W1 W2 W3 This checks for a connection the auxiliary wind ing and the weld winding See Wiring Diagram 6 Lead 7 or 9 and lead W1 W2 or WS This checks for a connection between the exciter winding and the weld winding See Wiring Diagram If any of the above readings is less than 500 000 500k ohms check for damaged contaminated or shorted wiring or components between the test points and the stator winding If necessary dis connect and isolate the stator leads as close to the stator winding as possible See wiring diagram If the low resistance is determined to be between the windings within the stator the stator is defective and should be replaced NOTE The field bridge rectifier and field capacitor may appear to function normally when tested inde pendently But may malfunctions when placed under the stress of normal operation For this rea son It is recommended that the bridge rectifier and capacitor be replaced with known good compo nents before replacing the stator VANTAGE 400 LINCOLN 2 F 56 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC
22. NOTE Many PC Board Assemblies are now totally encapsulated surface mounted and or multi layered and are therefore considered to be unserviceable Assembly drawings of these boards are no longer provided O v 9 Return to Master VANTAGE 400 LINCOLN 8 G 2 ELECTRICAL DIAGRAMS G 2 WIRING DIAGRAM COMPLETE MACHINE G5481
23. STANDBY POWER CONNECTIONS The VANTAGE 400 is suitable for temporary stand by or emergency power using the engine manufactur er s recommended maintenance schedule The VANTAGE 400 can be permanently installed as a standby power unit for 240 VAC 3 wire single phase 50 amp 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 Install the double pole double throw switch between the power company meter and the premis es disconnect Switch rating must be the same or greater than the customer s premises disconnect and service over current protection Take necessary steps to assure load is limited to the capacity of the generator by installing a 50 amp 240 VAC double pole circuit breaker Maximum rated load for each leg of the 240 VAC auxiliary is 50 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 engine and or alternator wind ings Install 50 amp 120 240 VAC plug NEMA 14 50P 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 or as part number T12153 9 Plug this cable into the 50 A
24. 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 39 TROUBLESHOOTING amp REPAIR F 39 ROTOR RESISTANCE AND GROUND TEST STATIC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the rotor winding is open shorted or grounded MATERIALS NEEDED Miscellaneous hand tools Ohmmeter Analog type meter required for dynamic resistance test Wiring Diagram 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC TROUBLESHOOTING 4 REPAIR ROTOR RESISTANCE AND GROUND TEST STATIC CONTINUED FIGURE F 9 ROTOR BRUSH LEADS SLIP RINGS TEST PROCEDURE 1 Tur
25. 400 LINCOLN 8 F 103 TROUBLESHOOTING 4 REPAIR didis RETEST AFTER REPAIR Retest a machine If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics f you repair or replace any electrical components Return to Section TOC Return to Master TOC ENGINE OUTPUT Mode No Load RPM Load RPM Low Idle 1300 1400 High Idle 1860 1890 1800 WELDER DC STICK OUTPUT ARC control 10 Mode Selector Output Control Open Circuit Load Volts Load Amps Switch Volts Stick 55 60 3638 Return to Master TOC WELDER CV WIRE OUTPUT ARC Control 10 Selector Open Circuit d V Return to Section TOC TOUCH START ARC Control 10 selector Jpen Circul Switch Voltage 10 15 18 22 TIG Minimum 10 15 Short Circuit HS 02 gt 9 cic 5 5 o AUXILIARY POWER OUTPUT Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps Voltage Voltage 230 264 216 252 115 132 108 126 Upper limit reflects cold machine voltage will be below 132 264 for machine at normal operating temperature olo e e 42 VOLT WIRE FEEDER POWER i Open Circuit Voltage Load Volts 3 40 50 38 48 325 ole 5 gt VANTAGE 400 LINCOLN e TABLE OF CONTENTS D
26. TO COBRAMATIC WIRE FEED CABINET INPUT CABLE PLUG HS 02 gt 9 cic 5 Slo c 14 PIN AMPHENOL TO WORK ELECTRODE CABLE TO WIRE FEED CABINET 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 WIRE FEEDER VOLTAGE WHICH CAN DAMAGE THE CONTROL CIRCUIT THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B SET THE WIRE FEEDER VOLTMETER TO THE POSITION THE POSA START FEATURE WILL NOT OPERATE UNLESS THIS SWITCH IS SET TO MATCH THE POLARITY OF THE ELECTRODE CABLE N C POSITION THE MODE SWITCH CV WIRE 10 27 2000 Return to Section TOC Return to Master TOC S24787 10 VANTAGE 400 LINCOLN 8 8 5 VANTAGE 400 LINCOLN joe C 8 NOL 4921S ey NOL 491Se A NOL 491Se A NOL 5 01 DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg ad TABLE OF CONTENTS MAINTENANCE SECTION D 1 9 i 5 Saf
27. TROUBLESHOOTING 4 REPAIR Observe Safety Guidelines detailed the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION ENGINE PROBLEMS The machine welds but it will not There may be poor connections in maintain a steady output the control wiring at the weld con continued trol P C Board or the chopper board Pull each plug from the weld P C board and thoroughly inspect the terminals in both the plugs and the P C Board recepta cles Make sure the connections are clean and the pins are proper ly seated in the plastic plug hous ing Check for loose or damaged pins and faulty crimps Check for damaged wiring and poor connections in the 13 14 and the 23 and 25 leads between the chopper module and weld con trol Board The output control or the arc con trol potentiometer may be defec tive or grounded The mode switch may also be faulty Perform the The Amphenol receptacles may be contaminated or defective Perform the REMOTE RECEPTA CLE RESISTANCE TEST Replace the weld control P C Board CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 400 LINCOLN Return to Section Return to Master TO
28. IMPORTANT Both the high and low idle settings are adjusted at the solenoid 1 Check that the linkage attaching the solenoid to the engine speed control lever is properly aligned and in good condition It is more important that the solenoid linkage be more precisely aligned when in the high speed de energized position 2 Check to be sure the spring located inside the rubber boot is not broken or missing In the default de energized position the spring should be holding the solenoid in the high speed position See Figure F 5 NOTE Low idle RPM must be set and the adjustment nuts tightened before the high idle RPM is adjusted Low Idle adjustment 1 With engine running and no load applied to the machine place the idle switch in the AUTO IDLE position Wait for the idle solenoid to energize and the engine speed to drop and stabilize to low idle RPM 2 Ifthe low idle RPM requires adjustment loosen the low idle adjustment jam nuts Turn both nuts so they are clear of the swivel fitting Rotate the swivel fitting until the engine speed has been set to between 1200 and 1400 RPM Hold the swivel fitting in position while tighten ing the first jam nut against the swivel fitting and then tighten the second jam nut against the first Do not adjust at engine stop lever the low idle RPM and then proceed to the high idle adjustment High idle adjustment 1 With engine running place the idl
29. Set the IDLE switch to the HIGH position See Section C for additional Connection Diagrams VANTAGE 400 LINCOLN 2 E TABLE OF CONTENTS OPERATION SECTION E Operati n E 1 Precautions usen ware mier WE B 2 O General ______ ___ _ ___ ___ 2 For Auxiliary Power 4 4 4 4 2 2 B 2 Engine Operation 224 4 B 2 Add FUel 22652 oc 40Ga0520n085 abe Pada aso ae B 2 Break Period RE ders nhe Fo woe B 2 Welder Controls B 3 B 4 5 Engine B 5 5 5 Starting and Stopping the Engine B 5 B 6 O c Welding 527324 a ae ROSEO 6 cr Duty Cycle and Electrode Information B 6 Constant Current Stick Welding
30. The WELD CONTROL BOARD may be faulty oee the Start Up diag nostic chart Check plug ZP1 on the control P C Board Plug should be prop erly seated and the pins in both the plug and the P C Board jack must be clean and fit tightly together There may be a poor connection between the weld control P C Board and the amphenol recepta cles Check for continuity between the following terminals See Wiring Diagram and Control Inner Connection Diagram P1 10 to 6 pin amphenol pin and to pin 14 amphenol pin P 1 11 to 6 pin amphenol pin A and to 14 amphenol pin E P 1 14 to 6 pin amphenol pin B and to 14 pin amphenol The weld control P C Board may be defective CAUTION If for any reason you do not understand the test procedures or unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o c F 11 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine seems to be locked into the CC stick mode of opera tion The arc quality is
31. VANTAGE 400 B For use with machines having Code Numbers 11186 11462 Return to Master TOC View Safety Info Safety Depends on You Lincoln arc welding and cutting equip ment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANU AL AND THE SAFETY PRECAU TIONS CONTAINED THROUGH OUT And most importantly think before you act and be careful Return to Master TOC View Safety Info eje uw 1 EIE Gio 1 c amp gt SERVICE MANUAL LI NCOLN Copyright 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 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC View Safety Info SAFETY A WARNING 4 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 can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING can b
32. gt 9 cic 5 Slo Return to Section TOC Return to Master TOC F 56 TROUBLESHOOTING amp REPAIR STATOR SHORT CIRCUIT amp GROUND TEST CONTINUED FIGURE F 13 WELD CONTROL BOARD AMPHENOL 1 GROUND CONTACTOR CONTROL REMOTE CONTROL 2 TIMES THRU FERRITE LEADS 75A 76A amp 77A TEST PROCEDURE 1 Perform Case Cover Removal Procedure 2 Perform Capacitor Discharge Procedure Unplug anything that may be connected to the auxiliary receptacles or the 14 pin amphenol 4 Disconnect and isolate GND E lead from the bottom ground screw inside the left case front See control Inner Connection diagram See Figure F 13 5 Disconnect the 5 and 6 leads from the field bridge rectifier See Wiring Diagram 6 Using an ohmmeter check the resistance between chassis ground and each of the fol lowing points Resistance should read very high 500 000 500K ohms minimum 1 Pin 1 at the 14 pin amphenol and the 5 lead that had been disconnected from the ground screw this checks for a connection between the wire feed winding and the aux winding 2 Pin 1 of the 14 pin amphenol and lead 7 or 9 This checks for a connection between the wire feed winding and the exciter wind ing 3 Pin 1 of the 14 amphenol an lead W1 W2 or W3 This checks for a connection between the wire feed winding and the weld winding h 120 VAC FOR WIRE FEEDER gt 40
33. ing the Output Rectifier to the mounting bracket You will need to reach through the large access holes on either side of the rectifier to reach these nuts Remove the Output Rectifier from the machine VANTAGE 400 Removing the Output Choke 1 Remove the heavy leads from the choke Carefully mark the leads for accurate re connection and also note the order and position of the leads in multiple lead con nections 2 Remove the three long bolts lock washers and nuts holding the choke the mounting bracket in the machine base Note that there is no bolt in the lower right corner of the choke 3 Carefully remove the choke REPLACEMENT PROCEDURE Replacing the Output Choke 1 LINCOLN 2 Reconnect the choke leads Place the choke into the machine so that the three mounting holes in the choke line up with the holes in the mounting bracket Insert the three long bolts through the choke and the mounting bracket Place a lock washer and nut on the end of each bolt and tighten Position the leads bolts washers and nuts exactly as they had been originally connected Tighten the connection securely F 88 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo c Return to Section TOC Return to Master TOC F 89 1 TROUBLESHOOTING amp REPAIR F 89 OUTPUT REC
34. 0115 0 am Hold function awosl dascatenps r f o approxdtmely 5ndecafter welding stop _ During this holWedrsmbay dmai point will blink ENGINE S STARTER SOLENOID SHUT DOWN COI L Battery voltage 56 12 6 valtsest 262 14 voltgi ra 9 ohne running ENGINE at Y5 STARTER gt gt LEAD COLOR CODE COMPONENT VALUE UNI 5 238 243 P56 5P B BLACK OR GRAY CAPACI DR MBNOLTS G GREEN TOCONNECTOR 1 ce 0 ORANGE RESISTOR OHMS WATTS CONNECTOR PIN NUMBERS GROUND F i W WHI E EX 12 PIN CONNEOR e ENGINE Y YELIOW CONNECTOR CONNECTOR GROUND LI 12 6 LABELS 2 COMM ON y 7 12 77 FRAME GROUND LATCH EARTH GROUND VI EWOF CONNECTOR ON PC BOARD THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC MANUEAG TUBING TOLERAN ANCEY DESIGN INFORMATION REFERENCE UNLESS OTHERWISE SPECIFIED TOLERANCE EQUIPMENT TYPE VANTAGE 400 P ERKIN S PAGE 1 OF 2 3 PLACE DECIMALS IS 002 DRAWNBY Maglietta 55388 e DOCUMENT DOCUMENT GLES IS 5 O G i T MATERIAL DO NOT SCALE THIS DRAWING 28 NA 10 26 2006 2 1
35. Because the filter fits tightly over the outlet tube to create the critical seal there will be some initial resistance similar to breaking Rotate the the seal jar Gently move the end of the filter 1 Remove the Filter E j el while back and forth to break the seal then rotate while pulling straight out Avoid knocking the filter straight out against the housing If your air cleaner has a safety filter replace it every third primary filter change Remove the safety filter as you would the primary filter Make sure you cover the air cleaner outlet tube to avoid any unfiltered contaminant dropping into the engine Clean Both Surfaces of the Outlet Tube and Check the Vacuator Valve Use a clean cloth to wipe the filter sealing surface and the inside of the outlet tube Contaminant on the sealing surface could hinder an effective seal and cause leakage Make sure that all contaminant 15 removed before the new filter is inserted Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear Engine manufacturers say that it takes only a few grams of dirtto dust an engine Be careful not to damage the sealing area on the tube Wipe both sides of the outlet tube clean Outer edge of the outlet tube outlet tube If your air cleaner is equipped with a Vacuator Valve Visually check and physically squeeze to make sure the valve is flexible and not inverted damaged or plu
36. FUEL SHUTDOWN SOLENOID TEST The engine shuts down shortly Try resetting the breaker If it trips Repeated tripping and resetting of after starting and trips the battery again do not attempt to use the the circuit breaker can damage it circuit breaker CB5 machine or alter its trip point If the breaker has been ripped and reset many Contact a Lincoln Authorized Field times it should be replaced Service Shop Examine the CB5 circuit breaker run stop switch Start button Shut down and idle solenoid engine protection board fuel gauge and sender and all the wiring connecting these compo nents Look for damaged or out of place wiring that may be in contact with other conductors or chassis ground Perform the IDLER SOLENOID Perform the The Engine Protection PC Board may be defective CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o c Return to Section TOC Return to Master TOC aii TROUBLESHOOTING amp REPAIR dd Observe Safety Guidelines detailed in the beginning of this manual PROBLE
37. K2636 1 TRAILER Two wheeled trailer with optional fender and light package For highway use consult applicable federal state and local laws regarding possible additional requirements Comes standard with a Duo Hitch a 2 Ball and Lunette Eye combination hitch Order K2636 1 Trailer K2639 1 Fender amp Light Kit K2640 1 Cable Storage Rack K903 1 SPARK ARRESTOR Includes a heavy gage steel approved spark arrestor clamp and adapter for mounting to the muf fler exhaust pipe K704 ACCESSORY SET Includes 35 ft 10m of electrode cable and 30 ft 9 1m of work cable head shield work clamp electrode holder Cables are rated at 400 amps 10096 duty cycle K857 25 ft 7 6m or K857 1 100 ft 30 4m REMOTE CONTROL Portable control provides same dial range as the output control on the welder Has a convenient 6 pin plug for easy connection to the welder K802N POWER PLUG KIT Provides four 120 volt plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240 volts 50 amps K802R POWER PLUG KIT Provides four 120 volt plugs rated at 15 amps each and one dual voltage full KVA plug rated at 120 240 volts 50 amps 112153 9 50 120 240V POWER PLUG 1 112153 10 50 240V POWER PLUG 3 K1816 1 FULL KVA ADAPTER KIT Plugs into the 120 240V NEMA 14 50R receptacle on the case front which accepts 4 prong plugs and converts it to a NEMA 6 50R receptacle which accepts 3
38. NOLOAD Return to Section TOC Return to Master TOC 4 50V 5ms Return to Section TOC Return 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 are connected at weld output terminals HS 02 gt 9 cic 5 Slo c SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC 400 LINCOLN 8 ae TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY MACHINE LOADED TO 300 AMPS AT 27 VOLTS Trig 15V CH1 Return to Section TOC Return to Master TOC _ NE 20V 1115 Return to Section Return to Master TOC This is the typical DC output voltage generated from a properly operating machine Note that each vertical divi sion represents 20 volts and that each horizontal division represents 1 millisecond in time The machine was loaded with a resis tance grid bank to 300 amps at 27 volts NOTE Scope probes are connected at weld output terminals HS 02 gt 9 cic 5 Slo c SCOPE SETTINGS Volts Div Hori
39. Return to Master TOC CENTER PANEL FUEL TANK SUPPORTS Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo In steps 21 25 lift frame weldment fuel tank 23 With a 3 8 wrench remove the nuts lock supports and fan baffle are removed as a unit washers and flat washers from the two studs See Figure F 23 that hold the fan baffle to the machine base 21 Using a 3 8 wrench remove the two bolts at top that hold the firewall to the lift frame weld 24 Using a 3 4 wrench remove the four bolts ment lock washers and nuts from the bottom of the lift frame weldment 22 Using a 1 2 wrench remove the two bolts at bottom that hold the firewall to the lift frame 25 Carefully remove the lift frame weldment fuel weldment tank supports and attached fan baffle You will need to lift the fan baffle off the two studs on the machine base then cock it slightly to remove it Return to Section TOC Return to Master TOC VANTAGE 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC HS 02 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC Return to Master TOC F 101 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 24 DOOR REMOVAL
40. STATOR ENGINE MOUNTING BOLTS amp BOLTS 4 FAN NUT STATOR REMOVAL PROCEDURE 1 Using a 1 2 wrench remove the four fan blade mounting bolts and lock washers See Figure F 24 Using a 1 1 8 wrench remove the fan nut Remove the fan noting the direction for reassembly Using the gear puller remove the fan hub Using a 3 8 wrench remove the two bolts and flat washers holding the bearing in place Using a 1 2 wrench remove the two nuts lock washers and carriage bolts holding the gener ator mounting plate to the machine base Support the stator with a hoist Place wooden blocks under the engine to support it when the stator is removed Using a 9 16 wrench remove the eight bolts and lock washers holding the stator to the engine Remove the stator from the engine It may be necessary to pry and slide it free VANTAGE 400 LINCOLN 8 F 101 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC TROUBLESHOOTING 4 REPAIR diia STATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 25 DOOR REMOVAL FLEX PLATE BLOWER SEGMENT 4 ROTOR REMOVAL PROCEDURE REASSEMBLY NOTES 1 Support the rotor with a hoist Heassemble the rotor and stator
41. See Figure F 10 See the wiring dia windings to the stator exciter winding Perform the Engine Throttle Adjustment Test and Set the RUN STOP switch to RUN and the the Stator Short Circuit and Ground Test IDLE switch to HIGH Start the engine and f the voltage is lower than 145 but higher allow the RPM to stabilize for about 15 to 30 than 120 the engine RPM may be too low or seconds there may be problems in the windings or other The meter should read 145 to 175 VDC exciter circuit components or connections Perform the Throttle Adjustment Set the RUN STOP switch to STOP Test and then perform the testing described If the meter reading is normal this test is com below under the heading the voltage mea plete sures about 3 to 5 VDC If the voltage measures zero very near zero the rotor flashing circuit may be faulty or the rotor may be shorted Perform the Rotor Resistance and Ground Test and the Flashing Voltage Test VANTAGE 400 F 44 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC v 9 45 10 11 12 19 14 15 TROUBLESHOOTING amp REPAIR F 45 ROTOR VOLTAGE TEST CONTINUED If the meter reading indicates battery volt age about 12 to 14 VDC the rotor ma
42. iw 8 SHUNT LIRCUIT 2 HOLES lt 4 yi amp A 3 START GHD ce Cn M ll REF nx Mp Rz 823 E qun me Liew Lc LOGIC LO SENSE CURRENT EMNENE HUET DO e lie I oo NET 0 SUPPLY PONT CHH COMMECTION 3 7 ERME COrpECTUR L EARTH COHHECTIDH M 04197 AND PROPRIETARY amp CONFIDENTIAL HR JT RUE GRAL PE ere TYPE COMMON ANALOG CONTROLS ee wer SUBJECT SCHEMATIC ANALOG CONTROL PCB arr Dese Ey NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual VANTAGE 400 0 9 ELECTRICAL DIAGRAMS dii SCHEMATIC WELD CONTROL PC BD G5506 PAGE 5 OF 5 4 dex ety Ess m 7 lt mb Return to Section TOC Return to Master TOC LEFT FEST FAR OR 482 LET wads EC iv 10 Zu Fie clu TO
43. output voltage VOLTS and current AMPS A memory feature holds the display of both meters on for seven seconds after welding is stopped This allows the operator to read the actual current and voltage just prior to when welding was ceased While the display is being held the left most deci mal point in each display will be flashing The accu of the meters is 3 WELD MODE SELECTOR SWITCH Provides four selectable welding modes CV WIRE DOWNHILL PIPE CC STICK TOUCH START TIG VANTAGE 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC B 4 GROUND STUD the CV WIRE CC STICK and DOWNHILL PIPE modes and has different functions in these modes This control is not active in the TIG mode CC STICK mode In this mode the ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or crisp arc Increasing the dial from 10 soft to 10 crisp increases the short circuit current and prevents sticking of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with a setting at 0 DOWNHILL PIPE mode In this mode the ARC CONTROL dial sets the short c
44. 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 souder iv SAFETY iv PRECAUTIONS DE SURETE B 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 un 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
45. to B3 and B5 to and between the welder output terminals See Figure F 16 See the wiring diagram 400 LINCOLN TROUBLESHOOTING amp REPAIR CHOPPER MODULE FUNCTION TEST CONTINUED TEST PROCEDURE CONTINUED 13 If about 58 VDC is present at chopper module 16 If the 20 kHz signal is present the chopper terminals B2 to B3 and B5 to B6 but not module is defective Replace at the output terminals there is a problem 17 If the 20 kHz signal is not present perform the between the chopper module and one of the output terminals Check for damaged conduc tors or faulty connections on leads W7 W8 18 If the weld control board is producing a PWM Return to Section TOC Return to Master TOC W9 and W10 Also check the shunt the gate signal check th e 23 and 25 leads for choke and the connections at the back of the damaged conductors and faulty connections output terminals See the wiring diagram between the control PC board and the chopper module 14 If the voltage at terminals B2 to B3 and B5 to B6 of the Chopper module is significantly 19 If testing is complete Perform the Case Cover higher than 58 VDC check for an open R4 or ae load resistor see the Control Inner Connection diagram Also check for damaged conductors or faulty connections at leads 302 and 302 See wiring diagram 15 If the voltage at terminals B2 to B3 and B5 to B6 of the chopper module is very
46. uJnjeH 491S8 N 0 945 UJn 9H DOL uonoes uunjeg DOL 0 2 5 uunjeg 301 uonoes uunjeg DOL uonoes uunjeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC F 32 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST CONTINUED Vibratach Method A Vibratach is used to measure the vibrations caused by the running engine It can be positioned anywhere where the engine vibration is reasonably strong The best results will likely be obtained by opening the top engine cover and placing the Vibratach directly against the top of the engine Read and understand the manufacturer s instruc tions for the Vibratach 1 Start the engine and place the idle switch in the HIGH IDLE position Make sure that there is no load on the machine 2 Position and adjust the Vibratach it should read between 1860 and 1890 RPM 3 Move the idle switch to the AUTO IDLE posi tion and wait for the idle solenoid to energize and the engine RPM to drop and stabilize at the low idle RPM 4 Position and adjust the Vibratach it should read between 1300 and 1400 RPM If either of the readings is incorrect proceed to the ADJUSTMENT PROCE DURE THROTTLE ADJUSTMENT PROCEDURE
47. 2 cc 6 691 10 RECEPTACLE INPUT CABLE TO WORK ELECTRODE CABLE TO CONTROL MODULE CAUTION BE SURE THAT CONTROL MODULE MODE SWITCH IS IN THE LINCOLN CONTACT CLOSURE POSITION BEFORE ATTEMPTING TO OPERATE CONTROL MODULE INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND OR POWER SOURCE ANY INCREASE OF THE IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE Fie AN INCREASE IN THE AC WIRE FEEDER VOLTAGE WHICH CAN DAMAGE THE CONTROL CIRCUIT THE ENGINE GOVERNOR SETTING IS PRE SET o AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL m WELDING CABLES MUST SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION p CONNECT WELDING CABLES OUTPUT STUDS FOR DESIRED POLARITY olo PLACE THE MODE SWITCH IN THE CV WIRE POSITION PLACE WELDING TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION cic N D PLACE IDLER SWITCH IN HIGH IDLE POSITION 5 10 27 2000 524787 8 VANTAGE 400 LINCOLN EM ACCESSORIES ENGINE WELDERS K930 TIG MODULE CONNECTION DIAGRAM WARNING Do not operate with panels open Keep guards in place Disconnect NEGATIVE Battery lead Keep away from moving parts before servicing Only qualified personnel should install use Do n
48. 27 9 P d CURRENT TT SELECT ONTROL BINT LIMITS VRD J7 10 FOR AUSTRIAN VANTAGE 575 CURRENT EEDBACK AVERAGE 15V ABSOLUTE SWI TCH 215 CURRENT EEDBACK WELD MES amp FOLDBACK O O J7 2 lt lt STUD O STU e p PRESET 2065 6 2 lt lt VALUE VOLTAGE 4 D SHUNT 50mV 4400 5 araom 2 ONY x80 FEEDBACK 8 47 5 o TU Ja lt LR WELD 0115 ene duo PWM SIGNAL Z2VON MUTI CHOPPER STUD is PWM BOARD Qo gt STUD FOR WELD CONTROL 47 Sho m olg STU rare pd 2 47 5 0 1 iod CONTROL BINT CONTROL 3 10 PWM OMMON 5 m 5V CIRCUIT 47 5hm J STUD 3 12 STUD 217 C CC J7 8B C ANN STUD ARC ARC CONTROL el KE awn coNTROL POT 844 CIRCUITRY J7 6 C AAN 10V 7 7 STUD STUD 5 OUTPUT iX VARIABLE PINCH CONTROL POT J7 4 KX PIPE ARC FORCE CONTROL VARIABLE ARC FORCE POINT das d T SELECT SEE SPECIFIC MACHI NE SCHEMATIC FOR DETAILS ON THE TOEND OF THEEMOTE POT IN TE m WHAT PARTS OF THE G4107 64109 ANEEUSED LEAD OLOR ODE COMPONENT WLUE UNS OUTPUT CONTROL x Es APPLICATI ALL CIRCUITS ARE USED ALL THE TI ME BLACK CAPACITOR MDI LTS STUD Bor LET Wei REMOTE t J2 ENGINE 12V CONTROL FUNCTI ONS RESISTOR OHNS WATTS UBL ape LEN 3 CHOPPER PWM POWERTHERMAL OVERLOAD IF USEDLT
49. 8 When the gun trigger is closed the current sensing circuit will cause the VANTAGE 400 engine to go to the high idle speed the wire will begin to feed and the welding process started When welding is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed CAUTION If you are using an LN 25 without an internal con tactor the electrode will be energized when the VANTAGE 400 is started INSTALLATION WARNING 10 CONNECTION OF SPOOL K487 25 AND COBRAMATIC TO VANTAGE 400 Shut the welder off Connect per instructions on the appropriate con nection diagram in CONNECTION OF PRINCE XL SPOOL GUN TO THE VANTAGE 400 Connection of the Prince XL Spool Gun requires the use of the K1849 1 Adapter Module Shut the Welder off For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder Connect the Control Cable of the Spool Gun to the Adapter Module and connect the Control Cable of the Adapter Module to the Welder Connect the Gas Hose Set the MODE switch to the CV WIRE position Set the WELD TERMINALS switch to WELD TER MINALS ON the ARC CONTROL knob to 0 initially and adjust to suit
50. 9 BRUSH SHUTDOWN IDLER 222 CB6 BRUSH o 206 41 42 Lo GLOW GLOWPLUG SOLENOID SOLENOID ml 21 3 PLUGS BUTTON i 41A comp l WRE EEDER aS Ai VOLTMTER f ac POSITIVE BRUSH CONNECTED T SM Tm 208B 4 2 2 nd 56 V 55 SHOWN A gt e 32 O 32A HOUR METER 256 HIGH POSITION id di osi 4 42VAC 22 4 GND OUTPUT CONTROL ARC CONTROL WELDING TERMINAL HIGH IDLER 238c 226 227 WORK 42 2 us GROUND STUD IN UPPER CONTROL PANEL CCW gt CONTROL SWITCH CONTROL y 1 R2 SHOWN LIN ALWAYS ON POSITION AUTO SWITCH J 20 768 GND B ITI im mor O contactor 80 758 BACK BACK 005 um START BUTTON 77 76 75 277 278 279 2A Ce 2 gt A 2 2 2 lt 2 236A o o 238B o D GROUND 6 GND A 4 LY OIL PRESSURE 0 14 VRD Pid 477 n SENSOR amp SWITCH n VRD SWITCH FERRI E ON N 6 PIN REMOTE o VRD 228 O SENSOR 235 4 2 E 3 VOLTMETER 4 3 T 4 ATA AA TOT RUN STOP CONTROL B gt 276B TA EN m OIL COOLANT SWITCH COOLANT TEMPERATURE contactor 626758 2 1 mdme ws wo lots ata 4 297 299 298 PR
51. CABLE TO WIRE FEED UNIT CAUTION TO WORK 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 WIRE FEEDER VOLTAGE WHICH CAN DAMAGE THE CONTROL CIRCUIT THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL PLACE THE MODE SWITCH IN THE CV WIRE POSITION PLACE WELDER TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N B CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE N C WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N D PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 10 27 2000 24787 3 Do not operate with panels open Keep guards in place Disconnect NEGATIVE Battery lead away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment 14 PIN CABLE PLUG 584 CONTROL CABLE OPTIONAL 857 6 PIN REMOTE CONTROL AMPHENOL TO WORK ELECTRODE CABLE LATION TO WIRE FEED UNIT 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 WIRE FEEDER VOLTAGE
52. Fuel Tank Seal A fel Return to Section TOC Return to Master TOC Battery 8 lt Right Side Service Access Door Right Case Side PROCEDURE 1 Turn the engine off 9 With the help of an assistant carefully remove the roof Replace the fuel 2 Using the 3 8 wrench remove the battery cover Slide the battery out and disconnect the 10 With the 3 8 wrench remove the right case negative battery cable side and the left case side See Figure F 1 HS 02 gt 9 cic 5 Slo 3 Unlatch and open the right side service access door See Figure F 1 4 Slide the door back 8 to notch in rail Lift left hinge from track Slide door forward 2 to notch in rail and lift right hinge from track 5 Remove access door 6 With the 1 2 wrench remove the exhaust pipe rain cap 7 Remove the fuel tank cap gasket and the lift bail cover seal 8 Remove the screws mounting the roof in place Return to Section TOC Return to Master TOC VANTAGE 400 LINCOLN 2 dinis TROUBLESHOOTING amp REPAIR mes CASE COVER REMOVAL AND REPLACEMENT PROCEDURE CONTINUED REASSEMBLY PROCEDURE 1 Install components in reverse order of removal 2 Be sure components align correctly Return to
53. IM i V M Teeny m pue Oy LY 2A ES Wee ee Ina 2 z iv Fa 1 ity mm i T T eps zi iso Fils i Tz ss zi Lridem vellaqe i pE tendi u 3 See D a WO HELIX HN 4 SG I 1 En Vr M os Cus fus Cur peut ae a F pm ae xf gg Lo 0 ee amp Rx iu al l 4 n doby LJ alt Ur ave ar Lu sg E P 87 00 as A x 8 iia Em Mur Swrzh i INE NE M Piller 5 _ 1 EIE eag zx PEE TTI r1 mi And Protec on Lig 11 EN 1 Toe Return to Section Return to Master TOC 1 d 777 1 Al p a E apes e c Ji iu dg etes 47 oL 4 Frere Cee th 80926 2 poA buat oleenid Ae TEE i G iato UE E p M a OP I Te 4 i on k i XM i Z Ii Edd i 7 uth belt
54. NOL 5 NOL 5 NOL 5 NOL 5 01 DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 51 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TESTS Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the stator is able to produce correct voltage from of its windings It will only yield meaning data if the engine high idle speed is correct 1860 to 1890 RPM and approximately 160 VDC is present across the rotor slip rings NOTE The slip ring voltage will most likely be correct if
55. 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 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Rotor and Stator MATERIALS NEEDED Misc Hand Tools Return to Section TOC Return to Master TOC HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC 400 LINCOLN 8 did TROUBLESHOOTING amp REPAIR idi STATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE olo e e CONTINUED 5 g FIGURE F 19 FUEL TANK REMOVAL p gt 5 5 LEADS 229 5 7 PLUG FUEL LINES 0912 915 2 2 U BOLTS 2 ac 5 2 c PROCEDURE 1 Turn the engine off 5 Turn the fuel off at the shutoff valve Remove and plug the fuel return line See Figure F 19 2 Perform the Case Cover Removal Procedure including the output panel 6 Remove and plug the lower fuel line Pull it through the firewall See Figure F 19 Return to Section TOC Return to Master TOC 3 Perform the Output Rectifier Bridge and Choke Removal Procedure 7 Using a 9 16 socket wrench remove the four lock nuts washers and rubber
56. Test Result 5 Reconnect all leads Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC v 9 O D D 3 E D 6 chopper module screw connection should be lightened to 50 60 inch pounds 7 Perform the Case Cover Replacement procedure VANTAGE 400 LINCOLN 8 Return to Section TOC Return to Master TOC 68 5 VANTAGE 400 LINCOLN joe F 68 NOL 5 NOL 5 NOL 5 NOL 5 01 DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 69 TROUBLESHOOTING amp REPAIR WELD CONTROL BOARD PWM GATE SIGNAL TEST 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 detail
57. Turn the engine off 6 Remove leads W4 W5 W10 from the positive terminal of the Rectifier and remove 2 Perform the Case Cover Removal procedure leads W6 and W11 from the negative terminal 3 Perform the Chopper Module Capacitor Position these leads so they do not come to Discharge procedure contact with any part of the rectifier Figure F 15 See the wiring diagram Electrically isolate the three phase input terminals of the output bridge rectifier as follows 4 Mark leads W1 W2 and W3 so they can be properly reconnected after the test is complete Remove these leads and position them so they do not come in contact with any part of the rec tifier See Figure F 15 See wiring diagram Electrically isolate the DC output terminals of the rectifier 5 Mark the leads connected to the positive and negative terminals of the output bridge rectifier to assure that they can be reconnected prop erly See Figure F 15 400 LINCOLN 59 59 TROUBLESHOOTING 4 REPAIR OUTPUT RECTIFIER BRIDGE TEST CONTINUED 7 Check for grounds by placing one of the ohm meter probes on a clean unpainted metal sur face of the machine Touch the other probe to each of the five rectifier terminals The resis tance to chassis ground from each terminal NOTE A digital Ohmmeter is not recommended for this test A typical digital Ohmmeter does not provide enough voltage or current flow to reliably test th
58. a OIo O O za CIS olg Ole gt olg cic 5 5 ee GENERAL INFORMATION _ ELECTRO SYM BH Egat CAPACITORS 4 URLCES OTHERWISE SPECIFU RESISTING UNLESS SPECIFIED DIES My OTHERMISE SPECIFIED vob Lov ON od m mom moe m mcm Home 2 mm gt 00107 AMO 8429 5 PROPRIETARY amp uw m PUER Ne P PY UE PAGE dz OF 05 CC LENT KT BEET ean A 5 COMPOAENTS Dit CIRCUITRY OF CONTAINS HAVING COMMOM CILE HUMBER PROVED 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 ELECTRIC VANTAGE 400 Return to Section Return to Master TOC Return to Section TOC CIS olg Olc gt olg cic 5 5 Return to Section Return to Master TOC Return to Master TOC G 7 ELECTRICAL DIAGRAMS mr SCHEMATIC WELD CONTROL PC BD G5506 PAGE 3 OF 5 POWER BLOCKS FUR 5 POWER SUPPLY 15V 3B 2 9 40 100VDC M OPERATION E 5 on 64109 17510 8
59. about 75VDC The current is applied through a solid state switch to an inductor By 70 80VDC ri Hence the name Chopper The biggest advantage of chopper technology is the high speed control of the arc similar to the inverter machines A block diagram for this is as follows INDUCTOR AND DIODE turning the switch on and off current in the inductor and the arc can be controlled The following diagram depicts the current flow in the system when the switch is open and closed CURRENT WITH SWITCH OPEN m CURRENT WITH SWITCH CLOSED When the switch is closed current is applied through the inductor to the arc When the switch opens current stored in the inductor sustains flow in the arc and through the diode The repetition rate of switch closure is 20Khz which allows ultra fast control of the arc By varying the ratio of on time versus off time of the switch Duty Cycle the current applied to the arc is con trolled This is the basis for Chopper Technology Controlling the switch in such a way as to produce superior welding 400 LINCOLN 8 8 5 VANTAGE 400 LINCOLN joe E 8 491S8 N 0 uJnjeH 491S8 N 0 95 0 uJnjeH QOL 945 UJn 9H DOL uonoes uunjeg DOL uonoes uunjeg 301 uonoes uunjeg DOL uonoes uunjeg 1 TABLE CONTE
60. at least one of the AC output volt ages is correct MATERIALS NEEDED Miscellaneous hand tools Voltmeter Test pins 400 LINCOLN 8 51 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC F 52 TROUBLESHOOTING amp REPAIR F 52 STATOR VOLTAGE TESTS CONTINUED FIGURE F 11 RECEPTACLE LEAD LOCATIONS TYPICAL CONTACTOR 4 CONTROL REMOTE CONTROL 2 TIMES THRU FERRITE LEADS 75A 76A amp 77A TEST PROCEDURE 1 Perform the Case Cover Removal plocedure NOTE Voltage tests of the 120 and 120 240 VAC receptacles can be performed by placing the meter probes directly into the appropriate connection slots in the front of the receptacles rather than testing at the lead connections described below lf the meter probes are not long enough to make contact with the conductors inside the receptacles test pins may be used To test the 120 VAC auxiliary winding 1 Connect the volt ohmmeter probes to either 120 VAC receptacle as follows 2 Forthe upper receptacle place the probes direct ly into receptacle or connect to leads Z3D and 75A See Figure F 11 See wiring diagram For the lower receptacle place the probes direct ly into the receptacle or connect to leads 6E and 58 See Figure F 11 See wiring diagram AM
61. check the level on the dipstick EE THEORY OF OPERATION n Add oil if necessary to bring the level up to the full mark Do not overfill Close engine door Check radiator for proper coolant level Fill if nec essary e See Engine Owner s Manual for specific oil and coolant recommendations ADD FUEL Stop engine while fueling Do not smoke when fueling sparks and flame away from tank not leave unattended while fueling DIESEL FUEL Wipe up spilled fuel and allow can cause fire fumes to clear before starting engine Do not overfill tank fuel expan sion may cause overflow DIESEL FUEL ONLY Remove the fuel tank cap Fill the tank DO NOT FILL THE TANK TO THE POINT OF OVERFLOW Replace the fuel cap and tighten securely See Engine Owner s Manual for specific fuel recom mendations BREAK IN PERIOD CAUTION The engine will use a small amount of oil during its break in period The break in period is about 50 run ning hours Check the oil every four hours during break in Change the oil after the first 50 hours of operation and every 200 hours thereafter Change the oil filter at each oil change During break in subject the Welder to moderate loads Avoid long periods running at idle Before stopping the engine remove all loads and allow the engine to cool several minutes VANTAGE 400 LINCOLN Return to Section Return t
62. do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o dii TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed the beginning of this manual PROBLEMS SYMPTOMS The machine will weld but the welding arc is COLD The engine runs normally and the aux power is normal POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Make sure the machine is properly set for the electrode and process is being used Check electrode size mode switch setting and amps or voltage setting If gas is used make sure of correct type and gas flow Make sure the process does not demand more power than the machine can produce If the current is correct try increas ing the ARC CONTROL setting Check for loose or faulty connec tions at the weld output terminals and welding cable connections Check for good connections between the work cable and the work piece The work cable should be attached to clean metal as Close to the weld area as possi ble The work clamp must be in good condition with good spring tension The
63. etc To prevent dangerous electric shock other equipment to which this engine driven welder supplies power must WARNING Be grounded to the frame of the welder using grounded type plug or be double insulated Do not ground the machine to a pipe that carries explosive or combustible material When this welder is mounted on a truck or trailer its frame must be electrically bonded to the metal frame of the vehicle Use a 8 or larger copper wire connected between the machine grounding stud and the frame of the vehicle When this engine driven welder is con nected to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See further connection instructions in the sec tion entitled Standby Power well as the article on grounding in the latest 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 which has been effectively grounded The National Electrical Code lists a number of alter nate means of grounding electrical equipment A machine grounding stud marked with the is provided on the front of the welder WELDING TERMINALS The VANTAGE 400 is equipped with a toggle switch
64. excessive water accumulation or sediment Empty fuel pre filter ENGINE ADJUSTMENT OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 1890 RPM no load Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop BATTERY MAINTENANCE To access the battery remove the battery tray from the front of the machine with 3 8 nut driver or flat head screw driver Pull the tray out of machine far enough to disconnect the negative and then positive battery cables The tray can then be tilted and lifted to remove the entire tray and battery from the machine for easy service WARNING GASES FROM BATTERY explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new bat tery last CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect _ negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery first then connect negative lead to nega tive batt
65. for selecting hot welding terminal when in the WELD TERMINALS ON position or cold welding terminal when in the REMOTELY CONTROLLED position WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs The welding process dic tates the polarity of the electrode cable These con nections should be checked periodically and tightened with a 3 4 wrench 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 TABLE A 1 TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 400 Amps 60 Duty Cycle 2 0 AWG Cable Length 0 100 Ft 0 30 meters 100 150 Ft 30 46 meters 2 0 AWG 150 200 Ft 46 61 meters 3 0 AWG CABLE INSTALLATION Install the welding cables to your VANTAGE 400 as follows 1 The engine must be OFF to install welding cables 2 Remove the flanged nuts from the output terminals 3 Connect the electrode holder and work cables to the weld output terminals The terminals are identified on the case front 4 Tighten the flanged nuts securely 5 Be certain that the metal piece you are welding the work is properly connected to the work clamp and cable 6 Check and tighten the connections periodically CAUTION Loose connections wi
66. function when connected to the 14 pin amphenol Machine operates normally in the CC STICK mode and has normal AC auxiliary output WELDING PROBLEMS It is normal for one of the displays to be off when there is no load across the weld output terminals In CV mode only the VOLTS display will be illuminated in all other modes only the AMPS dis play will be illuminated When welding both displays should be reading actual welding parameters Check the circuit breaker CB1 if using a a120 Volt AC wire feeder Check CB8 if using a 42 VAC wire feeder Reset breaker in tripped Check the Amphenol receptacle for damaged corroded or dirty contact pins The wire feeder control cable may be defective The wire feeder may be defective Both the AMPS and VOLTS displays use the same part num bered display unit If one of the digital displays appears to be func tioning normally it can be used to test the weld control P C Board output to the malfunctioning dis play owap the display board connec tors on the weld control board they are both the same if the good display functions normally in bad displays place then the P C Board is good and only the mal functioning display should be replaced If the known good display still malfunctions then the weld control P C board is defective and should be replaced Use a volt meter to check for the presents of supply voltage at the 14 pin Amphenol
67. isn t grounded With the engine off check the resistance between chassis ground and the weld out put terminals The resistance should be very high a minimum of 500 000 500k Ohms The weld control system may be grounded or malfunctioning Perform the CONTROL POTEN IOMETER and MODE SWITCH TEST and the REMOTE RECEP TACLE RESISTANCE TEST The Chopper module may be defective Perform the CHOPPER ODULE RESISTANCE TEST CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC OO O HS 02 gt 9 cic 5 5 o Return to Section Return to Master TOC Return to Master TOC F 12 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION The machine welds normally in all modes and the range of weld out put seems normal but one or both of the front panel displays is blank incorrect welding value or dis plays parts of numbers A control cable type feeder does not
68. l aide d crans appropri s et non inflammables 3 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 4 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 zones l on pique le laitier 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 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 400 LINCOLN MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams
69. low or not present use the frequency counter to check for the presents of a 20 kHZ PWM signal between leads 23 and 25 where they con nect to the chopper module PC board Return to Section TOC Return to Master TOC HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC 400 LINCOLN 8 F 64 NOTES VANTAGE 400 LINCOLN joe F 64 NOL 5 NOL 5 NOL 5 NOL 5 01 DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 65 TROUBLESHOOTING amp REPAIR CHOPPER MODULE RESISTANCE TEST 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 saf
70. o DISPLAY BOARD SCHEMATC 2065 1620 8 5 d um 31 2308 NOL TAGE 2080 3 16 boambnc m E at welder positive DLE COMMAND 00 LOW DLE E 17 shunt 1 2 305 9 21 76 41 Swich closed for idle nins p J 55 3 CONTROL 10 0 VRD WELD CONT ROK 3 1425 DER SWI TCH 239 0 2 HM 11 BMS 15 37 PC BOARD 13 256 DE SOL 10 V Jaz J1 11 PNG5507 1 TOAMP HENOL J 55 4 PULLCOI L J 55 2 REMOTE 15 0 WELD ERM SW TOAMPHENOL NT TIF duy FTF SESHEET 20R T 219 57 SIMLI EID 243 33 d TOR LER 5 R2 CONTROL BOARD olo SCHEMATE 120175 RUN 238C t 277 2388 405 32 TOROID Senses auxiliary power obdi Wat 260 HB gt Generator ends 63 pab hr outyhr rd itdi mes 3 4 Secon 5581 opposi treeatii ons 261 BB p olo ROTOR FASHING 250 59 200 J 53 250 413 E 3 2 Jumperequir dr a tp N 1800 N D wi tpa ai 64 110 _ _ 015 119 START BUTTON of engehectricalm syst a comm to SW CH TOT a framergunde gati Rotor Flashing 12 volts 777 238A Q 0 5 amps Meters pdiay settpoiod t por when not welding 1 1 WELD AMMETER WELDVOLTMETER Meters pdiay actalatls vamds awhemel di ng 3 en 160
71. operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test checks for faults in the rotor winding while these windings are being stressed by the mechanical forces encountered during normal operation MATERIALS NEEDED Miscellaneous hand tools Ohmmeter Analog type meter required for dynamic resistance test Wiring Diagram Note This test is best performed with a good quality analog type ohmmeter Many digi tal meters will not provide stable or accurate Resistance readings while the rotor is spin ning 400 LINCOLN 8 41 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO IHS ojeg O0 Ola gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 42 TROUBLESHOOTING amp REPAIR F 42 ROTOR RESISTANCE AND GROUND TEST DYNAMIC CONTINUED TEST PROCEDURE This test requires that the brushes and slip rings are clean in good condition and are properly seated 1 Perform the brush and slip ring service orocedure if
72. output cur rent is sensed either weld or auxiliary the Weld Control PC board deactivates the idler solenoid and the engine returns to high RPM NOTE Unshaded areas of Block Logic Diagram are the subject of discussion VANTAGE 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO ojeg WO gt 9 cic 5 5 c Return to Section TOC Return to Master TOC ES THEORY OF OPERATION ES FIGURE E 3 WELD WINDINGS RECTIFIER CHOPPER MODULES amp FEEDBACK STATOR GLOW PLUGS d MECHANICAL ROTATION STARTER ENGINE SLIP RINGS RUN STOP SWITCH RUN ENGINE PROTECTION IDLER CONTROL ENGINE BOARD TROUBLE LIGHT ALTERNATOR LIGHT WELD WINDINGS RECTIFIER POWER MODULES AND FEEDBACK The three phase stator weld windings are connected to a three phase rectifier bridge The resultant DC voltage is applied to four paralleled capacitors incorporated within each of the two power modules There are two capacitors in each module These capacitors function as filters and also as power supplies for the IGBTs See IGBT Operation in this section The IGBTs act as high speed switches operating at 20KHZ These devices are switched on and off by the Weld Control PC board through pulse width modulation circuitry See Pulse Width Modulation in this section CHOPPER MODU
73. power at one or more receptacles or at the 14 pin Amphenol Weld output is normal and the engine operates normally The machine has low welding out put and low auxiliary output POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Make sure VRD ON OFF toggle switch is in the off position Faulty CONTROL PC BOARD Faulty VRD display board Ensure VRD ON OFF switch is in the ON position VRD light may be burned out replace both VRD lights Faulty VRD display P C Board Check for loose or faulty connec tions at the output receptacles or 14 pin amphenol Check for tripped circuit breaker and or tripped GFCI receptacles The engine RPM may be low The brushes may be sticking poorly seated or slip rings dirty RECOMMENDED COURSE OF ACTION Check the connections at the VRD ON OFF switch Check the VRD on off switch for proper function continuity See functional description Check connections at the VRD ON OFF switch Check the VRD on off switch for proper See VRD functional description Perform the Stator Voltage Test Check the wiring between the aux receptacle and the main sta tor Then engine high idle speed may be low Throttle Test Electronic Idler Full load speed should be about 3500 RPM Inspect and if neces sary service the brushed and slip rings per the Brush and Slip Ring Perform the Rotor Voltage Test Perform the CAUTION If for any reason you
74. receptacle 120 Volt AC power supplied through pins A and J 421 VAC power is supplied through pins and K Perform the STATOR VOLTAGE CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o c Return to Section TOC Return to Master TOC F 13 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS An Across the Arc type wire feeder does not function when connected to the weld output of the machine The Vantage operated normally in the CC STICK mode and has normal AC auxiliary output The engine will not crank when the start button is pushed POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check that the welding terminals switch is the WELD NALS ON position Check the that WELD MODE switch is in the correct position for the process being used typically CV WIRE mode Check for poor weld cable connec tions between the feeder and the welder output terminal and between the work and the other outpu
75. right side engine service access doors Place a highly visible mark on the engine cool ing fan blade See Figure F 4 Connect the strobe tach according to the man ufacturer s instructions Start the engine and place the idle switch in the HIGH IDLE position Make sure that there is no load on the machine Direct the strobe tach light on the fan blade that had been marked earlier and synchronize the light with the rotating mark See the strobe tach manufacturer instructions The tach should read between 1860 and 1890 RPM AS 2 AON IG 2 555 Move the idle switch to the AUTO IDLE posi tion and wait for the idle solenoid to energize and the engine RPM to drop and stabilize at the low idle RPM Synchronize the strobe tach to read the low idle RPM Low idle speed should be 1300 1400 RPM If either of the readings is incorrect proceed to the THROTTLE ADJUSTMENT PROCE DURE in this section 400 LINCOLN F 30 servers 77776 63 0 2 T 958 Lm 552 DN Q O oig E lt W ola gt gt Q I oc O gt A Doe D TODO O 2 E 9 os 2226 n 265 gp lt 1 Pu 3255 LL A wo gt gt Oct z5o 8 pt a 298 v 4786 lt oo a
76. safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the shutdown solenoid resistance values are normal and also determine if it will function normally when energized with 12 VDC MATERIALS NEEDED Wiring Diagram Volt Ohmmeter Miscellaneous hand tools 12 volt D C power source an automotive battery works well 400 LINCOLN 8 28 O Z o 2 gt gt 5 2 LU e d 2 lt gt 2 ot D v Qu Se 5 5 a5 56 B 8 2 2 B9 Bg 9 2 IK 5 DA I6 8 CRANS 58 9 855 BG a3 NW ES 2255 9 5 8 gt cle 8 Sy SS SEN AS 595 2 Be 4995 28 oo 9 7 S 2 Ane 9 5 AS VA A 9 3 c m O i x Soe FE Be o o d Org 2 co 090 Go O TT O 9 2 Soo 92 29 599 5 9 5 tasg L T 5 4 Qo o gt MG R e c Lu
77. 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 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 ca
78. switch to the STOP position If the meter reads normal voltage of 3 to 5 VDC this test is complete If the meter reading indicates battery voltage about 12 to 14 VDC The rotor may be open or the brushes may be faulty or not making proper contact with the slip rings Perform the Rotor Resistance Test Perform the Brush and Slip Ring Service If the voltage measures zero or very near zero this condition could be caused by a poor connection or a defective component in the flashing circuit or a shorted rotor winding Perform the Rotor Resistance Test Refer to the wiring diagram pull plug P 23 from the control PC board and inspect each terminal Make sure that all terminals both on the board and in the plug are clean and in good condition and that the pins are securely crimped to the flex leads Perform the follow ing additional test Switch the RUN STOP switch to the RUN position Use a voltmeter to check for the presents of about 12VDC battery voltage at the following locations on the engine protection idle control p c b Lead 45S B1 to Lead 4232 J31 1 Lead 55 B1 to Lead 4232F J31 2 Lead 55 B1 to Lead 200 J33 5 NOTE Lead 232 supplies 12VDC battery volt age to the engine protection PC board whenever the run stop switch is in the run position Lead 200 supplies DC flashing voltage from the control PC board to the positive slip ring t
79. tends to draw dirt into the fuel system Also check the crankcase oil level and add oil if indicated ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE 20 50 HOURS EVERY 100 HOURS OR 3 MONTHS EVERY 250 HOURS OR 6 MONTHS EVERY 500 HOURS OR 12 MONTHS EVERY 1000 HOURS ENGINE SERVICE NOTE 2 MAINTENANCE ITEM 1 Concentration of Antifreeze S80 WaterEthylene Glycol Engine oi eve NOTE ired Return to Section TOC Return to Master TOC 5 qt 9 Engine oil NOTE 1 amp 3 8 45at 8L Including filter Engine oil filter Perkins 140517050 C Drain water separator amp fuel strainer aaa Water separator element Lincoln M20840 A Alternator drive belt wear l Alternator drive belt Perkins 080109107 R a a Tension of altemator dive bet _ R Air fiter earier check may be raure UU U E R T Fuel filter canister erkins 130366120 Renew the engine breather o o Tighten cylinderhead Electrical systems nuts and bolts fortighiness Contact Perkins Leaks or engine damage 22 001 HS 02 gt 9 cic 5 5 c R B E a c E E E B E B Battery Inspect C Clean R Replace 1 Consult Engine Operators Man
80. the ammeter to the weld output terminals per the equipment manufacturer s instructions also connect the voltmeter probes across the weld output terminals 6 Start the machine and apply a load of about 200 Amps as shown on the external amme ter If the machine will not produce 200 amps apply as much load as you can 7 Compare the readings shown on the external ammeter and voltmeter to the amps and volts displayed on the front panel of the machine 8 If the readings shown on the front panel dis plays are about the same or very close to the reading on the external meters the feedback is probably good and this test is complete 11 If the readings differ significantly continue with this procedure Turn off the engine and release the load from the weld terminals The load bank and ammeter should remain connected but the load should be released Perform the Case Cover Removal Locate plugs P3 and P6 on the control PC board See figure 1 Remove the plugs and check for dirt corrosion damaged expanded or incorrectly positioned terminals Repair or replace wiring components as needed and reconnect the plugs to the control board Restart the machine and apply a load across the weld terminals that measures about 200 amps If the machine will not produce 200 amps of current apply as much load as you can Using the voltmeter measure and note the DC voltage at the weld output terminals Che
81. this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will determine if the weld control PC board is receiving accurate current and volt age feedback from the weld circuit This test will only yield usable information if the machine is producing some weld output MATERIALS NEEDED Digital Multi meter suitable for accurate readings in both the millivolt and normal weld voltage ranges Resistive load bank Ammeter suitable for accurate readings of normal welding current Often built into the load bank Wiring diagram Control Inner Connection diagram VANTAGE 400 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 0 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 72 TROUBLESHOOTING amp REPAIR F 72 WELD CONTROL FEEDBACK TEST CONTINUED TEST PROCEDURE 1 Place the idle switch in the HIGH IDLE posi tion 2 Place the mode switch in the CC STICK position 3 Place the weld terminals switch in the WELD TERMINALS ON position 4 Make sure that nothing is plugged into either Amphenol receptacle 5 Connect the resistive load bank and
82. used in these sizes 4 TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 6 mm 5 5 16 in 8 mm 6 3 8 in 10 mm 7 7 16 in 11 mm 8 _ in 12 5 mm 10 5 8 in 16 mm 5 TIG torch nozzles are typically made from alumina ceramic Special applications may require lava nozzles which are less prone to breakage but cannot withstand high temperatures and high duty cycles VANTAGE 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC THEORY OF OPERATION Bd Set the WELDING TERMINALS switch to the REMOTELY CONTROLLED position This will keep the oolid State contactor open and provide a cold elec trode until the Amptrol or Arc Start Switch is pressed When using the TIG Module the OUTPUT CONTROL on the VANTAGE 400 is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module NOTE The TIG process is to receive a low voltage welding process There is no difference in operation with the VRD or for this mode For indicator light operation see Table B 1 WIRE WELDING CV Connect a wire feeder to the 400 according to the instructions in INSTALLATION INSTRUCTIONS Section The 400 in the CV WIRE mode permits it to be used with a broad range of flux cored wire Innershield and Outershield electrod
83. weld cables may be too long or too small diameter causing excessive voltage drop The weld cables may be coiled or wrapped around metal racks or reels This can cause excessive inductance in the weld circuit Try welding with a short set of ade quately sized weld cables RECOMMENDED COURSE OF ACTION The engine RPM may be too low Perform the Engine Throttle Adjustment Test Connect the machine to a resistive load bank Connect an accurate ammeter and volt meter to the out put of the machine Connect a tachometer Hz meter or another method to measure engine RPM Place the mode switch in CC STICK turn the output control to maximum idle switch to HIGH terminal switch to WELD TERMI NALS ON Nothing else attached or plugged into machine No aux no control cables Start the machine allow the engine to reach normal operating temperature Apply a load with the load bank Load to 300 Amps 32 Volts 100 Duty Cycle The engine should maintain 3350 RPM If the engine cannot maintain the RPM make sure there is a supply of clean fresh fuel Check the fuel filter and the air fil ter Replace any filter that is dirty or damaged If this doesn t help have the engine serviced Compare the volt and amp read ings displayed on the machine with that of the load bank If these are significantly different perform the WELD CONTROL FEED CAUTION If for any reason you do not understand the t
84. 15 OIo O O olg Q9 gt cic 5 c NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ELECTRIC VANTAGE 400 G 4 SCHEMATIC COMPLETE MACHINE G5597 PAGE 2 ELECTRICAL DIAGRAMS EN 170 Fie E ENGINEERING CONTROLLED CHANGE DETAIL REVISED LEAD 208C ROUTING o 26599 MANUFACTURER No 2 SI MPLI FI ED CONTROL BOARD SCHEMATI C E 15V TRANSFORMER AUX Lary AUXI LAN XK CURRENT SENSE SENSE mee STUD 3 3V WEL DI NG 13 4 3 8 lt TERMI NAL ES 5 V CONTROL BOARD 2 ee ee 40 100VDC CONTROL 2 POWER FROM SWI TCH m CHOPPER BOARD NPUT SHOW IN EMAYS 4 03164 12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS ON POSITION J1 3 lt lx BV ALL CIQUITS ON ONNECTOR DLER J3 7 lt STUD CONTROL SHOWN IN HI GHSITOO 03 14 IDE SWITCH ENSE STUD FRAME IS COMMON FOR r TO IDLEOLENO D CIRCUITS _ 15VCOM
85. 17 1CO G 11 NOL 01 NOL 01 NOL 5 01 NOL 5 01 DOL DOL DOL DOL uonoes 0 12 ELECTRICAL DIAGRAMS Gre SCHEMATIC OCV INDICATOR PC BD G4406 2D0 Fie 5 8 5 m gt vA TAGE TEEBBaz4 CULT 1 x js is ut gt eje STA i 97 1 5 gh D 2 335 5 pu i ie z ai niv LLL 1 siu in ss oap Ses 4 RA e toU _ 5y tyg Mur uw d p c EN c 1 35 S8 e 4 Clu TI a 2 Oo j 9 C run i 5 FUMER SUPALY 15 cr 1 at eu j AS Fir f s i JA GYA i 22 4 CT 3v d vec TRES gt XT d veal Hz op 2 i dis _ i i i X45 irs 415 15 EH 4 145 1 EIC 8 C H r eee rans 23 Xl 2 gal T T BP Hel 1 iy
86. 2 4 2 22 2 2 222 2 2 4 D 7 __ D 7 or Brush Removal and D 7 GFCI Receptacle Testing and Resetting Procedure D 7 Major Component Location 6 D 8 O 9 9 VANTAGE 400 LINCOLN 8 De MAINTENANCE SAFETY PRECAUTIONS Read the Safety Precautions in the front of this O manual and the Engine Owner s Manual before T WARNIN working on this machine 5 9 E G e Have qualified personnel do all maintenance Keep all equipment safety guards covers and ele and troubleshooting work devices in position and in good repair Keep hands hair clothing and tools away from the HE Turn the engine off before working inside the gears fans and all other moving parts when c c machine or servicing the engine starting operating or repairing the equipment Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete If guards are missing from the machine obtain replacements from a Lincoln Distributor See Operating Manual Parts List Routine Maintenance At the end of each day s use refill the fuel tank to minimize moisture condensation in the tank Running out of fuel
87. 777 ENGINE CONTROL CIRCUITS Sorte ack 0 Vis gt 42 5 oy ENG NEPROTECTI ONI DLEPC BOARD DE ONTROL DE ONTROL ER ORUM Lowl d THERMAL SUTDOWN i 8560 O CURRENT LIMITS C J1 13 lt REGULATI N NODE O J1 12 lt E Fir MACHI NE DIETI Y TABLE ACH 11 a PI I UMPEREDTO SELECT COE HOLD 45V HOL D SS jas 0109 4 oa MACHI NE on f o d VANTAGE 500 MODE BLNK PULLED OW AND HG gt gt 44 Alc Pa i Y J1 6 N QOKBACK TO FLASH J4 a ae gt VANTAGE 575 lt lt LOGI C DECIMAL BINT gt 5 ally ally l Slo l k AIR VANTAGE 500 gt J46 VANTAGE 300 15 lt gt 47 4 DI SPLAY 2 J48 4 FRAME FRAME i E 24 0 METER 4I NPT Q 2V 1V 1000N METER u _ _ E 515 7 16 lt lt X 10 oO METERS OPTI ON VANTAGE CC J7 15 ON OFF 5V ON J5 1 NO J4 CR J5 ON RANGER 250 NO n wen RAU AN gt J5 3 MODE BLNK PULLED DW AND HG gt 454 iene aren avon SELECTOR 3 TE N QOKBACK TO FLASH J55 e ct ca SW TCH DECIMAL BINT AUST RAIAN a J7 12 lt lt gt gt 45 6 VOLTMETER VANTAGE 575 SES A L S J57 DISPLAY 3POSITION 7006 d SWITCH Y PPE er J5 8 1 gt 1459 METER INPU Q 2V 1V 100 0N METER eV CV MODE 45 10 METER
88. AGE FEEDBACK J4 CONNECTOR ON RANGER 250 UD m Q Q REMOTE 18 5 5 CONNECTOR ON RANGER 250 i 1 1 CONTROL POT e 6 SHUNT CURRENT FEEDBACK LABELS BS D 1 OUTPUT CONTROL ARC FORCE MODE SELECT ca olo 77 FRAME ROUND LATCH 15 EARTH GROUND VIEW OFCONNECTOR ON amp BOARD STUD STUD 5 DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC ES ERATO VANTAGE 400 PERKINS pace 2or2 he ON 3 PLAGE DECIMALS IS 002 DRAWNBY Maglietta 5388 DOCUMENT DOCUMENT 8 eomer MACHINE a ONO SORE THE DATING NONE 22115 5597 16 6 5 22 S ir NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual VANTAGE 400 0 5 ELECTRICAL DIAGRAMS ds SCHEMATIC WELD CONTROL PC BD G5506 PAGE 1 OF 5 Return to Section TOC Return to Master TOC NOM 66402 1 510 Return to Section Return to Master TOC ROME SELECTOR SWITCH Le Sake SHOWN LPCETNS FOR FHE iE
89. Attach the meter leads to the battery terminals pc groune i me pat iy telly nal Place the positive meter probe on the bat being careful to position them so they stay f clear of moving parts while the engine is run formingon SACK Lead 238 See F 7 See Wiring 9 Diagram iis PE Pi 10 The meter should read about 13 7 to 14 2 tion start the engine and allow it to run at high VDC idle speed for about 15 to 30 seconds 11 Move the positive probe to the DT terminal ine Meter the back of the alternator Lead 243C See VDC Figure F7 merer once ME 12 The meter should read about 13 7 to 14 2 tor is producing adequate power to charge the VDC battery and this test is complete If the voltage is significantly higher than the 13 the meter reads correctly check the connec tions between the alternator and the battery above values the alternator is not properly d See wiring diagram regulating the battery charging voltage and should be replaced If the voltage reads the 14 If the voltage at both of the above test points same or less than the measurement taken reads the same or less than the battery voltage when the engine was not running proceed measurement taken when the engine was not with the following tests running the alternator is defective Repair or Turn off the engine disconnect the mete
90. C Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o Return to Section Return to Master TOC F 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The weld output can not be adjust ed with the front panel output con trol knob in one or mode weld modes The weld output terminals have normal OCV open circuit voltage The AC auxiliary power is normal and the engine operated normally The machine front panel output control is still active when the remote control unit is connected to one of the Front Panel Amphenols POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS Remote control devices completely disables the front output in all modes except touch start TIG mode Make sure there is nothing plugged into the Amphenol recep tacles Check for dirt or moisture contami nation in either the 6 pin or the 14 pin amphenol This condition is normal in the TOUCH START TIG MODE See the operators manual The remote control unit may be defective Check the Amphenol receptacles Look for damage or corroded con tact pins in the receptacle and in the plug of the remote control unit F 10 RECOMMENDED COURSE OF ACTION Perform the REMOTE RECEPTA CLE RESISTANCE TEST The output control potentiometer ay be defective Perform the TANCE TEST
91. COLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC F 88 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND REPLACEMENT CONTINUED REMOVAL PROCEDURE Turn the engine off 2 Remove negative battery cable 3 Perform the Case Cover Removal proce 4 Perform the Chopper Module Capacitor Discharge procedure Remove the four screws holding the case front to the base of the machine Remove all plugs and leads from the weld control and pull coil PC boards Be sure to mark the leads and plugs so they can be properly re connected See wiring dia gram Remove the screws holding the D4 diode bridge and the CR1 engine protection relay to the center baffle assembly and allow these components to remain attached to the case front wiring Remove any additional wring and cable ties as needed Carefully mark leads for accu rate re connection owing the case front to the side to permit access to the Output Rectifier and Choke Removing the Output Rectifier 10 11 12 Hemove the heavy leads from the output rectifier Carefully mark the leads for accurate re connection and also note the order and position of multiple lead con nections Hemove the nuts and lock washers hold
92. ER LAYER lt INJECTING LAYER B ACTIVE Drawing B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the source 15 applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply con nected to the drain terminal will allow the IGBT to con duct and supply current to circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the posi tive gate signal is present This is similar to turning ON a light switch VANTAGE 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC ES THEORY OF OPERATION ES FIGURE E 6 TYPICAL IGBT OUTPUTS MINIMUM OUTPUT 2 48 sec 50 u sec Dwell or Off Time MAXIMUM OUTPUT 48 sec PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the cycle Changing the pulse width is known as MODU LATION Pulse Width Modulation PWM is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during a cycl
93. ESSURE TEMPERATURE FUEL SHOWN IN RUN POSITION SENSOR amp SWITCH 236 SWITCH 5 E5 eZag 3 are Vv 241 3 508 9 lt 20 0 296 GROUND F gt GND B a 7 D q d FH gt X NA ALA 1 zh PAL STOP 4 232L i X 0 6 Q7 2 AW 460 5 of 229 O FUEL LEVEL i o SENSOR d FERI E dL FERI E 50 4226 58 58 2088 2068 VRD DISPLAY 229 Mri ae 2 2 PCB4 232C 232F 2 AU STARTER Pls did i hje tld T H lii ranm ENOID soy BATTERY ue cx 222 0 sie 56 58 eG 5M SE KC sb MOTOR RR n FERRI E VOLT METER CONTROL MODE SEL AMMETER CHOPPER POWER PWM THERMAL 5 10 B3 a A ALTERNATOR TWSTEDPAIR VRD WELD BOARD 201247 25 UPPER CONTROL PANEL 4 TBNS i B4 PCB1 4310 Op 226 GENERATOR SUPPORT 855 1 112 B2 nn 8 g RAS 234 9 d 1 2 0 9 ENGINE BLOCK T1 16 9 12 7 4 ul ta _ 2 AMPHENOL L D ENGINE PERIPHERAL _ E 9 IDLER ENGINE SHUTDOWN 2 49 8 i 6 1 figo ems 5 B pu 22222 25222 5 2 481 LINCOLN ELECTRIC CLEVELAND OHIO U S A e 0 gt cic 5 2 NOTE Th
94. GROUNG CONNECTION THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL 19 OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC EQUIPMENT TYPE SW TIG 175 amp 275 DOCUMENT HAVING A COMMON CODE NUMBER 8 22 2006 numer CRM38150 A 5 22530 300 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 522530 NOT SCALE THIS DRAWING 0 WITHOUT AFFECTING THE INTERCHANGE DRAWN BY FM VANTAGE 400 uns ELECTRICAL DIAGRAMS BOARD ASSEMBLY BY PASS STABILIZER PC BOARD L10121 3 LC LO 7 1 CHANGE DETAIL REVISED BOARD BLANK INFORMATION REFERENCES PART NUMBER DESCRIPTION CT C2 5 06 C7 C8 8 T1157788K 0047 3000 20 CAPACITOR POLYPROPYLENE METALLIZED 250VAG IS o o _ rere as fre siston 707 MOV S2OVRMS 50420MM P C BOARD BLANK INFORMATION BUY COMPLETE AS L10121 D 2 LAYER BOARD PER E3281 CAPACITORS MFD VOLTS WITH LEAD FREE HASL SURFACE FINISH INDUCTANCE HENRYS MAKES 12 BOARDS PER PANEL SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION 9 i Return to Master ITEM PARTNO NO IDENTIFICATION 1
95. IAGRAM SECTION un 2 Diagrams RR i Re G 1 9 Wiring Diagram Complete Machine 25481 G 2 EE Schematic Complete Machine G5597 Page 1 G 3 Schematic Complete Machine G5597 2 G 4 Schematic Weld Control PC Board G5506 1 G 5 Schematic Weld Control PC Board G5506 2 G 6 B Schematic Weld Control PC Board G5506 3 G 7 Schematic Weld Control PC Board 85506 4 G 8 10 Schematic Weld Control PC Board 05506 5 G 9 c Schematic Idler PC Board G4828 2 G 10 Schematic Chopper Board L12717 1C0 G 11 Schematic Indicator PC Board G4406 2DO G 12 Schematic By Pass Stabilizer PC Board 822530 3DO G 13 PC Board Assembly By Pass Stabilizer PC Board L10121 3 G 14
96. INCREASE IN THE AC WIRE FEEDER VOLTAGE WHICH CAN DAMAGE THE CONTROL CIRCUIT THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE PLACE THE MODE SWITCH IN THE CV WIRE POSITION D PLACE WELDER TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 10 27 2000 24787 5 ENGINE WELDERS LN 8 CONNECTION DIAGRAM A WARNING Do not operate with panels open Keep guards in place Disconnect NEGATIVE Battery lead Keep away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment 14 PIN CABLE PLUG K595 CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT 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 WIRE FEEDER VOLTAGE WHICH CAN DAMAGE THE CONTROL CIRCUIT THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER O
97. LACEMENT PROCEDURE CONTINUED FIGURE F 21 BRUSHHOLDER LEAD REMOVAL PROCEDURE 12 Label and remove brush leads 201 and 14 Using a 3 8 wrench remove the brush holder 200B from the brush holder assembly assembly The Piggy backed leads connect closest to the stator terminations See Figure F 21 15 Using the 1 2 wrench disconnect leads 68A and 69A at their bolted connections beneath 13 Pull the harness containing plug J30 the the power module assembly Label the leads brush leads and the field bridge rectifier for reassembly Cut any necessary cable ties through the bushing in the firewall See Figure F 22 Figure F 20 VANTAGE 400 LINCOLN 2 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC TROUBLESHOOTING 4 REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 22 CONTROL amp OUTPUT PANELS REAR VIEW
98. LE 5 10 3d AUXILIARY CURREN TORROID WORK THREE PHASE TERMINAL RECTIFIER ELECTRODE TERMINAL VRD FEEDBACK SWITCH SIGNAL OFF CONTROL BOARD mr o AOPUuUumriiT VOLT FEEDBACK POWER TO CONTROL BOARD VOLTMETER AMMETER C U PROCESS RANGE CONTROL CONTROL SELECTOR 42 VAC TO 14 PIN AMPHENOL FOR WIRE FEEDER 240VAC RECEPTACLE AUX FEEDBACK 120VAC RECEPTACLED 2 LOW IDLE COMMAND This chopped DC output is applied through choke coils and a shunt to the welding output terminals The choke functions as a current filter and it helps to bal ance the outputs of the two power modules Free wheeling diodes are incorporated in the power mod ules to provide a current path for the stored energy in the choke when the IGBTs are turned off See Chopper Technology this section Output voltage and current feedback information is fed to the Weld Control PC board This information is sensed from the output terminal circuits and the shunt NOTE Unshaded areas of Block Logic Diagram are the subject of discussion VANTAGE 400 LINCOLN 8 Return to Section Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC 9 v gt E Return to Master E 4 THEORY OF OPERATION FIGURE E 4 WELD CONTR
99. LTERNATOR 5 LIGHT i LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC THEORY OF OPERATION ais FIGURE E 2 GENERAL DESCRIPTION BATTERY ENGINE ROTOR STATOR amp ENGINE PROTECTION STATOR GLOW PLUGS LL IL MECHANICAL ROTATION STARTER ENGINE L RINGS OO RUN STOP SWITCH RUN BATTERY 5 MEN ENGINE PROTECTION IDLER CONTROL ENGINE TROUBLE Y P C BOARD LIGHT ALTERNATOR LIGHT GENERAL DESCRIPTION The Vantage 400 is a diesel engine driven welding power source capable of producing 450 amps at 32VDC at a 100 duty cycle The engine is coupled to a brush type alternating current generator This AC output is rectified and controlled by Technology jo produce DC current for multi purpose welding applications The Vantage 400 is also capa ble of producing 11 000 watts of AC auxiliary power at 10096 duty cycle BATTERY ENGINE ROTOR STATOR PULL COIL BOARD AND PERIPHERAL BOARD ENGINE PROTECTION The 12VDC battery powers the engine starter motor and also supplies power to the Pull Coil PC board Peripheral PC board and associated circuitry When the engine which is mechanically coupled to the rotor i
100. MS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The engine starts but shuts down Make sure the glow plug button is The shut down fuel solenoid immediately when the start button pressed while pushing the start be faulty or not operating properly is released button and held until the engine Check lead 233 and 262 and protection light turns off 5 SEC perform the ONDS MAXIMUM AFTER THE See wiring ENGINE STARTS See the oper diagram ator s manual or the operating The check for the presents of 12 section of this manual for proper volts at the lead 233 when start starting procedure button is pushed Check 5 Check the oil level and lead 231 Be certain that the engine is not overheated The Engine Protection Board may Check that the machine had ade be faulty quate supply of fresh clean fuel The fuel filter may be clogged The engine may have inadequate Replace if necessary oil pressure Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC The oil pressure switch or coolant temperature switch may be faulty The engine shuts down shortly Check for adequate supply of The oil pressure switch or coolant after starting clean fresh fuel temperature switch may be faulty Check fuel and air filters replace if Make sure the engine has oil and necessary oil pressure and engine is not Check oil level add oil as overheated required Look for oil leakage Disconnect lea
101. MS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The engine will not develop full The fuel may be old or contami The engine may be in need of power nated Supply the engine with adjustment or repair clean fresh fuel The fuel filter may be clogged replace if necessary The air filter may be clogged replace if necessary The engine will not idle down to Make sure the idle switch is in the Perform the IDLER SOLENOID low RPM The machine has nor AUTO IDLE position Make sure TEST mal weld and auxiliary output there is no external load on the Check for damaged wiring or faulty weld terminals or the auxiliary connections at the idle solenoid power receptacles the engine protection PC Board Check for mechanical restrictions the run stop switch and the start in the idler solenoid linkage button Check for loose or damaged wiring or faulty connections at leads 7405 and 226 227 and connections J P 55 2 and J P 55 4 control PC board P2 5 and engine protection board J32 2 B3 and J31 8 et idle switch in the AUTO posi tion Set the mode switch to the CC STICK position Make sure that no load is applied to either the weld or auxiliary output Start the machine and allow it to run for about 30 seconds Manually move the idle solenoid plunger to the idle position If the solenoid engages and holds in the idle position the idle pull coil may be bad
102. NDARDS UNITS MATERIAL APPROVAL PROJECT REFERENCE SONOTSCRETHSDRANNG Prom iw UF Bec 92007 Roo CRM34432 10121 1 110121 3 Insight NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTRIC VANTAGE 400 EN 168 SOLID EDGE Return to Section TOC Return to Master TOC
103. NG THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE AC WIRE FEEDER VOLTAGE WHICH CAN DAMAGE THE CONTROL CIRCUIT THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL WELDING CABLES MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO N E MATCH THE POLARITY OF THE ELECTRODE CABLE L L L L N C PLACE THE MODE SWITCH IN THE CV WIRE POSITION 4 N D INSULATE EACH UNUSED LEADS INDIVIDUALLY 7 29 TO FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT USE ISOLATION K867 WIRE RELAY TO CLOSE LEADS 2 amp 4 SEE DETAIL 10 FEEDER REFER POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW Return to Master TOC e LE 10 27 2000 24787 7 ENGINE WELDERS K691 10 K488 K487 SPOOL GUN CONNECTION DIAGRAM SPOOL GUN S 5 Do not operate with panels open Keep guards in place Disconnect NEGATIVE Battery lead Keep away from moving parts c o before servicing Only qualified personnel should install use e Do not touch electrically live parts or service this equipment PI v Ola 95 14 PIN WIRE FEEDER K488 SG 2 RECEPTACLE CONTROL MODULE K487 25 5
104. NTS TROUBLESHOOTING 4 REPAIR F s 5 Troubleshooting and Repair F 1 5 How to Use Troubleshooting Guide F 2 5 Board Troubleshooting Procedures F 3 Troubleshooting Guide 4 20 21 F 82 Case Cover Removal and Replacement Procedure F 21 Chopper Module Capacitor Discharge Procedure F 25 Fuel Shutdown Solenoid Test F 27 Engine Throttle Adjustment Test F 29 Idler Solenoid Test F 33 5 Engine Alternator TeSt uua ndr Reaper isiad trn am dr eed ides ed ow a ws F 35 Brush and Slip Ring Service Procedure F 37 5 Rotor Resistance and Grounding Test Static F 39 Rotor Resistance and Ground Test Dynamic 41 u XIP F 43 Flashing Voltage NOSE
105. OL BOARD E 4 STATOR gt GLOW PLUGS TH oo MECHANICAL ROTATION STARTER ENGINE SLIP RINGS ALTERNATOR RUN STOP SWITCH RUN OIL PRESS SENSORS TEMP ROTOR ENGINE PROTECTION IDLER CONTROL ENGINE TROUBLE LIGHT ALTERNATOR LIGHT WELD CONTROL BOARD The 80 VDC derived from the filter capacitors on the Power Modules supplies various regulated DC volt ages to operate the Weld Control PC board circuitry also supplies two regulated DC voltages to operate the IGBT driver circuitry on the two Power Modules The Weld Control PC board monitors the operator con trols arc control output and process range selector It compares these commands to the current and volt age feedback information it receives from the shunt IGBT Sey ae 10 3d AUXILIARY AUX CURREN TORROID WORK THREE PHASE TERMINAL RECTIFIER ELECTRODE TERMINAL i VRD FEEDBACK p VRD VOLTAGE REDUCTION VED PWM SWITCH SIGNAL OFF RD CONTROL BOARD 2 mr g FEEDBACK POWER TO CONTROL BOARD VOLT VOLTMETER AMMETER Al UTPUT PROCESS RANGE CONTROL CONTROL SELECTOR 42 VAC TO 14 PIN AMPHENOL FOR WIRE FEEDER 240VAC RECEPTACLE AUX FEEDBACK 120 2 LOW IDLE COMMAND and output terminal circuits The circuitry on the Weld Control
106. OMMENDED COURSE OF ACTION Check for damaged conductors or faulty connections on the heavy current carrying leads that connect the output studs to the Chopper module and to the Output Rectifier Also check the shunt and the choke assemblies for damage and faulty connections Check the Welding Terminals Switch and the associated leads See Wiring Diagram Check gate leads 23 725 Weld Control Board power leads 13 and 14 for loose or faulty connections See Wiring Perform the Chopper Module Function Test Perform the STATOR VOLTAGE TEST Perform the OUTPUT RECTIFIER The WELD CONTROL board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 400 LINCOLN Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o c Return to Section TOC Return to Master TOC di TROUBLESHOOTING amp REPAIR dii Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS No output in PIPE MODE Outputs normal in other modes VRD lights don t light up No auxiliary
107. PAIR CHOPPER MODULE REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the Chopper Module Assembly Note The Chopper Module assembly is removed and replaced as a unit It contains no serviceable parts MATERIALS NEEDED Miscellaneous hand tools Electrical thermal joint compound Dow Corning 400 LINCOLN 8 F 91 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 010 0 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC TROUBLESHOOTING 4 REPAIR CHOPPER MODULE REMOVAL AND REPLACEMENT CONTINUED FIGURE F 18 MODULE LEAD LOCATIONS 23 LED1 B1 B2 B3 2 lt LED4 Chopper 2 PWM Signal al Sad
108. PC board determines how the output should be controlled to optimize welding results and it sends the correct PWM signals to the IGBT driver circuits The Weld Control PC board also commands the thermal light and the voltmeter and ammeter some items may be optional NOTE Unshaded areas of Block Logic Diagram are the subject of discussion VANTAGE 400 LINCOLN 2 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC ES THEORY OF OPERATION ES FIGURE E 5 IGBT OPERATION BODY REGION BUFFER LAYER INJECTING LAYER DRAIN A PASSIVE INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT is a type of transistor IGBTs are semicon ductors well suited for high frequency switching and high current applications Drawing A shows an IGBT in a passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain terminal of the IGBT may be connected to a voltage supply but since there is no conduction the circuit will not supply current to components connected to the source The circuit is turned off like a light switch in the OFF position DRAIN DRIFT REGION POSITIVE VOLTAGE BODY REGION lt DRAIN DRIFT REGION lt BUFF
109. PERATING MANUAL WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE PLACE IDLER SWITCH IN HIGH POSITION 4 14 2000 S24787 6 400 LINCOLN 8 ACCESSORIES ENGINE WELDERS 867 CONTROL CABLE ADAPTER CONNECTION DIAGRAM Jo 5 5 WARNING v 9 Do not operate with panels open Keep guards in place 9 9 Disconnect NEGATIVE Battery lead e Keep away from moving parts before servicing Only qualified personnel should install use E Do not touch electrically live parts or service this equipment 14 PIN ojo AMPHENOL K867 UNIVERSAL 82 NOT USED ON ENGINE WELDER Ei SPARE o T ADAPTER PLUG 2 01 CONNECT TOGETHER FOR ND 4 oJ WELDING OUTPUT gt 41 o N E 42 VAC 42 9 ONE 115 32 o Q E __ GND o POWER SOURCE FRAME CONNECTION 21 WIRE FEEDER VOLTMETER CONNECTION TO WORK CONNECTS TO WORK TERMINAL OF POWER SOURCE 77 10K 76 4 REMOTE OUTPUT CONTROL CAUTION ELECTRODE CABLE TO WIRE FEED UNIT MIN ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDI
110. PHENOL 1 GROUND 120 FOR WIRE FEEDER gt 40 FOR WIRE FEEDER 21 WORK SENSE 3 Start the engine and run it at high idle 1860 1890 RPM 4 Check the AC voltage reading It should read between 115 and 132 VAC To test the 240 VAC auxiliary winding 1 Connect the meter probes to leads 6F and 3E where they connect to the 120 240VAC recepta cle or insert the probes into the 240 VAC con nection slots in the front of the receptacle See Figure F 11 See wiring diagram 2 Start the engine and run it at high idle 1860 1890 RPM 3 Check the AC voltage reading It should read between 230 and 264 VAC 4 If these voltage readings are not within the spec ified limits check for tripped or defective circuit breakers loose connections or broken wires between the test points and the stator windings If there no wiring problems and the circuit breakers are not tripped or defective the stator is defective and should be replaced VANTAGE 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC HS 02 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC Return to Master TOC F 53 TROUBLESHOOTING amp REPAIR F 53 STATOR VOLTAGE TESTS CONTINUED FIGURE F 12 RECTIFIER BRIDGE DETAIL POS W6 W11 W3 We W1 W4 W5 W10 To test the 120 VAC wire feed
111. Return to Master TOC F 57 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the rectifier is grounded or if there are any failed diode groups NOTE This test will not be able to detect individual open diodes within a group MATERIALS NEEDED Miscellaneous hand tools Analog Ohmmeter or diode tester For testing diodes Ohm meter any type for ground test 400 LINCOLN 8 F 57 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 5 Return to Section Return to Master TOC TROUBLESHOOTING 4 REPAIR diis OUTPUT RECTIFIER BRIDGE TEST CONTINUED FIGURE F 14 DC AC1 X1 DC AC2 AC3 TEST PROCEDURE 1
112. SEE BLANK INFO P C BOARD BLANK ae 3 OJO O O 0 0 o 0 2 N F N G 5 4 50 04 ____ 3 80 04 3 462 8 450 5 5 d 505 5 MANUFACTURED AS x 8 N C SQUEEZE TOGETHER ITEMS C1 C4 TP1 AND O 1 900 5 lt 5 9 2 BEFORE APPLYING SEALANT L10121 3DO x _ C 5 gt N D APPLY SEALANT AS SHOWN 5 KEEP THIS AREA FREE OF ENCAPSULATION AND IDEN CODE x BOTTOM OF BOARD PER e N G TIN ALL EXPOSED COPPER WITH SOLDER IN THIS AREA p gt XXRKXXXXXXXXXXXX BOTH SIDES OF BOARD MAKE PER E1911 ROHS 9 338 350 NO ICICLES OR SOLDER BLOBS ARE PERMITTED ENCAPSULATE WITH E1844 WITHIN 0 5 0 BOTH SIDES 2 COATS 2 0 TEST PER E3553 B D SCHEMATIC REFERENCE 22530 3D0 N D ALL COMPONENTS AND MATERIALS USED IN THIS ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 INCLUDE 522772 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC UNLESS OTHERWISE SPECIFIED TOLERANCE Ex EQUIPMENT TYPE SW TIG 175 amp 275 in mE 228 EYPASS STABILIZER P C BOARD ARSENE Du REVISION WITH PUBLISHED STA
113. SI SW XH 7 200uK6 oil pressur 100 WMS 7951 CONTACTS EIE NE OT IPRESSUR SHOWN FI 2 vo STATOR dris 31 234 o cp TaN CAPACI DRS 1 DC BUS VOL TAGE 4 WELD _ BOARD Low oil 2068 FLYBACK 90 100 HI DLE ve WINDINGS pressum DIODES 12 orsus hi gh ar d t NEGATI VE 22 GT FOUR POLE 180RPM ALTERNATOR Eno arotar tiam S OUTPUT A A circuitnute mi TEMPERATURE delay amine TERM NAL PWM Signal to Chopper start Tempeat gh 2s cate sanal YELLOW BOARD tempetare 500 60 5 COLD ewe SCHEMATC 50 100 O v 210 12V0LTS RUN 11 G 42 ROTOR FBLD gt E VRD OFF POR a OpenCi r c Viol ts 00 gt Min 5 4142 cc 58 58 l 58 p Tig 12 12 C 61 2088 5H E b a HOUR 5 gt PowerSuppl y 0 61 3066 lt 5 HAR VRD ON 237 Eh REVOLVING FALD 244 033 M Board N RESISTANCE APPROX e J 31 10263 Openci rcWiot ts 1 3 TO 5 AQOPHASE 25 HOIS 751 Max Min 0 5 IPHASE 12 p 1413 Weld voltsRED2 ight on 3 TO 6 1001 5 120 D o TWISTED TWISTED TWISTED Swit chiPager 5 ROTOR FELD GROUT LANP E PAIR PAR PAIR 1 60 540 pes an SupplWoltage Pipe Mode niot _ Regul ator J 60 13 VAROnve with g 9 8 SI MLI ED BOARD 2045 1608 gt A
114. Section TOC Return to Master TOC 3 Reconnect battery and replace battery door Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo c Return to Section TOC Return to Master TOC 400 LINCOLN 8 24 5 VANTAGE 400 LINCOLN joe F 24 95 0 491S8 N 0 95 0 uJnjeH QOL 945 UJn 9H 301 uonoes uunjeg DOL uonoes uunjeg 301 uonoes uunjeg DOL uonoes uunjeg diss TROUBLESHOOTING amp REPAIR CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will insure that the large capacitors in the chopper module have been dis charged This procedure should be per
115. TAGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the rotor winding is operating at normal charge MATERIALS NEEDED Miscellaneous hand tools Voltmeter Wiring Diagram 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC HS 02 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC Return to Master TOC F 44 TROUBLESHOOTING amp REPAIR ROTOR VOLTAGE TEST CONTINUED FIGURE F 10 LEAD LOCATIONS SLIP RINGS TEST PROCEDURE LINCOLN 2 BRUSHES Perform the Case Cover Removal procedure 8 If voltage is higher than 175 VDC the engine RPM may be too high or there may be voltage Connect the voltmeter probes to the brush ter intrusion from one of the higher voltage stator minals
116. TIFIER BRIDGE AND CHOKE REMOVAL AND REPLACEMENT CONTINUED Replacing the Output Rectifier Place the Output Rectifier into the machine so that its mounting studs fit into the holes in the bracket Place a lock washer and a nut on each stud and tighten Apply a thin film of electrical joint com 6 pound Dow Corning between the sur faces of the W leads and the Output Hectifier Reconnect the Output Rectifier positioning the leads bolts washers and nuts exactly as hey had been originally connected Tighten all of the connections securely See Wiring Diagram Swing the case front back into position Attach the case front to the machine base with four screws 400 LINCOLN 8 5 Reconnect all of the leads and plugs that were disconnected during the removal pro cedure and replace any cable ties that were removed Perform the Case Cover Removal 90 5 VANTAGE 400 LINCOLN joe F 90 NOL 5 NOL 5 NOL 5 NOL 5 01 DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 91 TROUBLESHOOTING amp RE
117. TO P7 16 222 CV WIRE P7 9 214 TO P7 16 222 P7 5 75 TO P7 1 77 about 10K Ohms values should sweep smoothly from 10K to 0 when ARC CONTROL is P7 1 77 TO P7 4 76 turned from Min to Max P7 6 279 TO P7 8 277 about 10K Ohms values should sweep smoothly from 10K to 0 when ARC CONTROL is 7 8 277 TO 7 7 278 turned from Min to Max Resistance should be very low The Ohmmeter should read about the same value as one would get by touching the two meter probes together VANTAGE 400 LINCOLN 8 78 5 VANTAGE 400 LINCOLN joe F 78 NOL 4921S ey NOL 491Se A NOL 491Se A NOL 5 01 DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 79 TROUBLESHOOTING amp REPAIR REMOTE RECEPTACLE RESISTANCE TEST 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
118. WHICH CAN DAMAGE THE CONTROL CIRCUIT THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE N C PLACE THE MODE SWITCH IN THE CV WIRE POSITION N D PLACE IDLER SWITCH IN HIGH POSITION 10 27 2000 524787 4 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC HS 02 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC Return to Master TOC ACCESSORIES S ENGINE WELDERS LN 742 CONNECTION DIAGRAM WARNING Do not operate with panels open e Keep guards in place Disconnect NEGATIVE Battery lead Keep away from moving parts before servicing Only qualified personnel should install use e Do not touch electrically live parts or service this equipment 14 PIN AMPHENOL TO LN 742 INPUT CABLE PLUG K592 CONTROL CABLE TO WORK ELECTRODE CABLE CAUTION TO WIRE FEED UNIT ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN
119. a X 2 gr EM lu RN em D 49 i Y ger gt PRELET PRESET DIT Von 35 wA METER Gat 1 IN 1 IWIT UTR elc 3 gt amp RIGHT MOST DETIMAL 5 3 Sr VOLTHETER 4I 5 PT COMMON VETER PSET ACT 1 D e oO SA v MM i E 2 uie ay W VOLIMETER OISPLAYS PRESET m 64107 LEFT PT gus TL C on aan a ona on nn a a nn ee an an PNE UU um Gm METER PRESET S 5 i OIO Eg cls QS 9 det edi E g BATTER c SU BATTERY CHARGE c c Sm al ii gt ROTATION nl BATTEHT SENGE CIRCUIT GENERAL INFORMATION _ ELECTRICAL SYMBOLS E1G37 TUES QA LESS OTHERWISE SUPPLY VOLTAGE MET L F wER POINT COMMON gos 56107 1 EARTH GROUND CONNECTION u SS X SS X SS SS SS X SS
120. age continues to read significantly lower than 120 VDC the Stator is probably defective and should be replaced Note The field bridge rectifier and field capacitor may appear to function normally when tested inde pendently but may malfunction when placed under the stress or normal operation For this reason It is recommended that the bridge rectifier and the capacitor be replaced with known good compo nents before replacing the stator 400 LINCOLN 8 F 46 NOTES VANTAGE 400 LINCOLN joe F 46 NOL 4921S ey NOL 491Se A NOL 491Se A NOL 5 01 DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 47 TROUBLESHOOTING amp REPAIR FLASHING VOLTAGE TEST Engine Not Running 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
121. air cleaner and try again The cover should go on with no extra force Once the filter is in place secure the service cover Caution NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners and will void the warranty 6 Check Connectors for Tight Fit Make sure that all mounting bands clamps bolts and connections in the entire air cleaner system are tight Check for holes in piping and repair if needed Any leaks in your intake piping will send dust directly to the engine VANTAGE 400 LINCOLN 2 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC HOT COOLANT can burn skin Do not remove cap if radiator is hot Check the coolant level by observing the level in the radiator and recovery bottle Add 50 50 antifreeze water solution if the level is close to or below the LOW mark do not fill above the FULL mark Remove radi ator cap and add coolant to radiator Fill up to the top of the tube in the radiator filler neck which includes a connecting hose coming from the thermostat housing To drain the coolant open the valve at the bottom of the radiator Open the radiator cap to allow complete drainage Tighten the valve and refi
122. al laws 1 Consult applicable federal state and local laws regarding specific requirements for use on public high Ways VEHICLE MOUNTING WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use not exceed maximum rated loads compo nents such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacturer s instructions PRE OPERATION ENGINE SERVICE HEAD the engine operating and maintenance instruc tions supplied with this machine WARNING Stop engine and allow to cool before fueling Do not smoke when fueling Fill fuel tank at a moderate rate and do not over fill Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt gt cic 5 5 o Return to Section TOC Return to Master TOC m INSTALLATION OIL VANTAGE 400 is shipped with the engine crankcase filled with high quality SAE 10W 30 Oil tha
123. ant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 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 within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ven tilation In confined spaces or in some circumstances outdoors a respirator may be required Additional pre cautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker expo sure level should be checked upon installation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV lim
124. bles or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow 518 Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing AA d 57 7 7 Use only compressed gas cylinders CYLINDER may explode if damaged containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they 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 compressed gas cylinders associated equ
125. c 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 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts c Exposure to EMF fields in welding may have other health when starting operating or repairing equipment effects which are now not known O O 0 9 All welders should use the following procedures order to Some cases 10 TOMOVE minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 1 Route the electrode and work cables together Secure Always use the greatest care when working near moving them with tape when possible parts 2 4 2 Never coil the electrode lead around your body 1 1 Do not put your hands near the engine fan 2 d 3 Do not place your body between the electrode and Do not attempt to override the governor or work cabl
126. ck the voltage between leads 2045 P6 1 and lead 208B P3 15 at the control PC board Molex plugs The voltage should be the same as was measured at the weld terminals 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo c Return to Section TOC Return to Master TOC F 73 TROUBLESHOOTING amp REPAIR F 73 WELD CONTROL FEEDBACK TEST CONTINUED If the voltage readings are different check the wiring and connections between the welding terminals and the control PC board See the wiring diagram Connect the millivolt meter probes between lead 2065 P6 2 and lead 2045 P6 1 See Wiring Diagram If the machine is cur rently producing 200 amps the millivolt meter should read about 25 millivolts If the machine cannot produce 200 amps of weld current the correct millivolt signal will need to be calculated by dividing the reading displayed on the external ammeter by 8 See the following explanation he shunt used in this machine will produce 50 millivolts at a load of 400 amps or 8 amps per millivolt 20 21 22 To calculate the correct millivolt signal for a given load you divide the number of amps displayed on the ammeter by 8 Example If your ammeter reads 75 75 8 9 4 If the shunt is working correctly an
127. commended in place of No 2D at tem peratures below 23 F 5 C Do not use kerosene See the Engine Operator s Manual for instructions on replacing the fuel filter BLEEDING THE FUEL SYSTEM You may need to bleed air from the fuel system if the fuel filter or fuel lines have been detached the fuel tank has been ran empty or after periods of long storage It is recommended that the fuel shutoff valve be closed during periods of non use WARNING To avoid personal injury do not bleed a hot engine This could cause fuel to spill onto a hot exhaust manifold creating a danger of fire Bleed the fuel system as follows Fill the fuel tank with fuel Open the fuel shut off valve Loosen bleed fitting on the fuel injector manifold Operate hand priming lever until fuel comes out the bleed screw on the injector manifold This could take 20 30 seconds of rapid operation of the prim ing lever Tighten bleed fitting on injector manifold 5 Follow normal STARTING procedures until engine Starts mare hem VANTAGE 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC e MAINTENANCE zii FUEL FILTER 1 Check the fuel filter and fuel pre filter for water accu mulation or sediment 2 Replace the fuel filter if it is found with
128. d 234 from Engine Check for loose or faulty battery Protection PC Board of engine cable connections continues to run oil pressure switch or Temperature Switch is faulty Check for faulty run stop switch Check for damaged insulation in the wiring between the engine pro tection relay and the oil pressure and coolant temperature switches See wiring diagram OO O HS 02 gt 9 cic 5 5 o c CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o Return to Section Return to Master TOC diis TROUBLESHOOTING amp REPAIR dbi Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The engine shuts down shortly after starting Check for poor electrical connec tions at the run stop switch and the fuel shutdown solenoid wiring diagram e fuel solenoid may be faulty Perform the
129. d Power Loads 1 PHASE 3 PHASE WATTS WATTS AMPS 11 000 17 000 41 11 000 15 400 37 8 000 13 000 34 OR 4700 9400 23 4 700 1700 3400 8 1 700 0 0 0 0 BOTH 1 83 PHASE WATTS AMPS 11 000 11 000 PLUS 8 000 OO IHS ojeg WO gt 9 cic 5 5 TABLE B 6 VANTAGE 400 CE Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table Current Voltage Maximum Allowable Cord Length in ft m for Conductor Size 4 AWG 15 120 1800 30 9 40 12 75 23 125 38 175 53 300 91 20 120 2400 930 9 50 15 88 27 138 42 225 69 15 240 3600 60 18 75 23 150 46 225 69 350 107 600 183 4800 60 18 100 30 175 53 275 84 450 137 9500 50 5 90 27 150 46 69 Conductor size is based maximum 2 0 voltage drop Return to Section TOC Return to Master TOC VANTAGE 400 LINCOLN 2 ii TABLE OF CONTENTS ACCESSORIES SECTION ud PCCCSSONCS 1 9 Factory Installed Options Accessories C 2 2 Connection Diagrams HS TERCER de Set n E E S D ue C 3 C 7 Engine Welders LN25 Across the Arc with Opti
130. d be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the engine alternator is properly charging the battery MATERIALS NEEDED Miscellaneous hand tools Volt meter Wiring Diagram 400 LINCOLN 8 F 35 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC F 36 TROUBLESHOOTING amp REPAIR ENGINE ALTERNATOR TEST CONTINUED FIGURE F 7 LEAD LOCATIONS BACK OF ALTERNATOR 238 TEST PROCEDURE Turn the engine off 8 Make sure the idle switch is still in the high Open the engine access door and check the 2 Eae E E voltage at the battery terminals It should be 9 approximately 12 volts 9 Place the negative meter probe on a good
131. d the wiring between the shunt and the control PC board is in good condition the meter connect ed at the control PC board should be reading about 9 4 millivolts If the millivolt reading is incorrect check the wiring between the shunt and the control PC board for damage grounds and faulty con nections If the wiring is good the shunt and lead assembly is faulty and should be replaced Perform the Case Cover Replacement 400 LINCOLN 8 F 74 NOTES VANTAGE 400 LINCOLN joe F 74 NOL 4921S ey NOL 491Se A NOL 491Se A NOL 5 01 DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg TROUBLESHOOTING 4 REPAIR CONTROL AND MODE SWITCH RESISTANCE TEST 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 trou bleshooting assistance before
132. 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 de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais LES MACHINES SOUDER A enrouler le c ble lectrode autour de n importe quelle partie du TRANSFORMATEU R ET 2 Dans le cas de travail au dessus du niveau du sol prot ger corps REDRESSEUR d arc peut tre plus s vere qu un coup de soliel donc a Utiliser bon masque avec un verre filtrant ainsi qu un verre blanc afin de se prot ger les yeux du nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc 2 Prot ger l autre personnel travaillant proximit au soudage
133. detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help determine if there is a problem with the remote receptacle control wiring relating to electrical tracking between other control conductors power conductors or ground This test also checks the function of the weld terminal switch MATERIALS NEEDED Ohm Meter Wiring Diagram Control Inner Connection diagram 400 LINCOLN 8 F 79 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 02 cc gt 9 cic 5 Slo Return to Section TOC Return to Master TOC F 80 TROUBLESHOOTING amp REPAIR REMOTE RECEPTACLE RESISTANCE TEST CONTINUED FIGURE F 17 AMPHENOL 1 TEST PROCEDURE 1 2 Turn the machine off Perform the Make sure that there are no devices of any kind plugged into either Amphenol receptacles Case Cover Removal Remove Molex plug P1 from the control PC board see Control Inner Connection Diagram Examine the Molex plug and the receptacle on the control PC board for dirt corrosion dam aged or out of position pins Repair or replace any damaged components Position
134. e The top drawing shows the minimum output sig nal possible over a 50 microsecond time period 50 usec Dwell or ium The positive portion of the signal represents one IGBT group conducting for 2 microsecond The dwell time off time is 48 microseconds Since only 2 microseconds of the 50 microsecond time period is devoted to conduct ing the output power is minimized MAXIMUM OUTPUT By holding the gate signals on for 48 microseconds and allowing only 2 microseconds of dwell time off time during the 50 microsecond cycle the output is maxi mized The darkened area under the top curve can be compared to the area under the bottom curve The more darkened area under the curve the more power is present 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC E THEORY OF OPERATION ES CHOPPER TECHNOLOGY FUNDAMENTALS new era of welding machines such as the Vantage amp 500 employ a technology whereby a DC source is turned on and off chopped up at high speed then smoothed through an inductor to control an arc EXTERNAL DC SOURCE SOLID STATE SWITCH ARC CONTROL In this system the engine drives a three phase alter nator which generates power that is rectified and fillered to produce
135. e AC power load is turned off a fixed time delay of approximately 12 seconds starts If the welding or AC power load is not restarted 24 before the end of the time delay the idler reduces the engine speed to low idle speed engine will automatically return to high idle speed when there is welding load or AC power load reapplied Note The light may or may not come on when the RUN STOP switch is in the ON position It will come on dur ing cranking and stay on until the engine starts After starting the engine the light will go off unless a Low No battery charge condition exists Return to Section TOC Return to Master TOC 20 COOLANT TEMPERATURE GAUGE A indica tor of engine coolant temperature OIL PRESSURE GAUGE A indicator of engine Oil Pressure STARTING THE ENGINE 1 Remove all plugs connected to the AC power receptacles 2 Set IDLER switch to AUTO J 3 Press Glow Plug Button hold 15 to 20 seconds Set the RUN STOP switch to RUN 5 Press START button until the engine starts or for up to 10 seconds Continue to hold the glow plug button for up to an additional 10 seconds Release the engine START button immediately when the engine starts 7 The engine will run at high idle speed for approximately 12 seconds and then drop to low idle speed Allow the engine to warm up at low idle for several minutes before applying a load and or switching to high idle Allow a longer warm up t
136. e activated for more than 20 seconds con Temperature The light is off when the systems are func tioning properly The light will come on and the engine will shutdown when there is Low Oil Pressure and or the Coolant is Over Temperature Note The light remains off when the RUN STOP switch is in the ON position prior to starting the engine However if the engine is not started within 60 seconds the light will come on When this happens the RUN STOP switch must be returned to the OFF position to reset the engine protection system and light tinuously 14 START PUSH BUTTON motor to crank the engine Energizes the starter 19 BATTERY CHARGING LIGHT A warning indica tor light for Low No battery charge The light is off when the systems are functioning properly The light will come on if there is a Low No battery condition but the machine will continue to run 15 IDLER SWITCH Has two positions as follows 1 In the HIGH position the engine runs at the high idle speed controlled by the engine governor 2 In the AUTO position the idler operates as follows When switched from HIGH to AUTO or after starting the engine the engine will operate at full speed for approx imately 12 seconds and then go to low idle speed When the electrode touches the work or power is drawn for lights or tools approximately 100 Watts min imum the engine accelerates and operates at full speed When welding ceases or th
137. e diodes used in this recti fier should be very high 500 000 500K ohms minimum If the resistance reading is less than specified the rectifier is grounded and should be replaced Return to Section TOC Return to Master TOC 10 Test all of the diode groups per the Table 8 If using diode checker or a multimeter with diode check functionality read and understand the instructions that accompany your test equipment o lo 9 If using an analog ohmmeter the forward bias O test will indicate low resistance and the reverse bias test will indicate high resistance Precise i ohm values for this test will vary depending on the test equipment used s 3 FIGURE F 15 SHUNT RECTIFIER LEADS Dio c yo POS NEG 7 TOP OUTPUT W1 RECTIFIER w2 7 lt CENTER BRIDGE W3 3 gt BOTTOM We 9 S W1 a W4 W5 W6 W11 9 8 W10 ete FROM SHUNT cys 2 c JO e i 0919 p gt cys E CHOPPER BOARD VANTAGE 400 LINCOLN 8 TROUBLESHOOTING 4 REPAIR F 60 TABLE F 1 DIODE TEST TABLE Diode Bias Lead Lead and Expected Test Result AC1 DC FORWARD BIAS Low Resistance AC2 C FORWARD BIAS Low Resistance AC3 DC DC DC AC AC2 AC3 Return to Section TOC Return to Master TOC FORWARD BIAS Low Resistance AC1 FORWARD BIAS Low Resistance 2 FORWARD BIAS Low Resistance Ret
138. e hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Return to Master TOC 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 249 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 FOR ENGINE 5 1 h To avoid scalding do not remove the 1 radiator pressure cap when the engine is powered equipment AN a hot 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas vent the engine exhaust fumes 4 outdoors Return to Master TOC 1 c Do not add the fuel near an open flame weld 2 be dangerous ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magneti
139. e maintain ing the correct RPM If the maximum weld output can not be obtained even though the front panel displays are reading accurately check for damaged conductors and lose or damaged connections the large current car rying conductor connect the stator output rectifier chopper modules choke shunt and output termi nals If all these connections are good perform the the thel OUTPUT RECTIFIER and the CHOPPER MOD Perform the TIOMETER AND MODE RESIS Perform the Heplace the Control P C Board Perform the THROTTLE ADJUSTMENT TEST If the engine will not maintain the correct load RPM the engine may be servicing fuel air and fuel fil ters should be checked Check internal cables and leads that connect the weld winding of the stator chopper module and the shunt choke and output terminals See the wiring diagram Look for nections CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC OO O HS 02 gt 9 cic 5 5 o c Return to Section TOC Return to Master TOC Return to Master TOC
140. e switch in the HIGH IDLE position The solenoid should immediately de energize allowing the engine to increase to high idle speed 2 f the high idle RPM requires adjustment loosen the high idle adjustment screw jam at engine lever high speed stop nut and turn the adjusting screw until the engine speed is between 1860 and 1890 RPM Hold the adjusting screw in position while tightening the jam nut against the solenoid plunger Re check the high idle RPM Close the engine service access doors and shut off the engine 400 LINCOLN F 32 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 33 TROUBLESHOOTING amp REPAIR F 33 IDLER SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proc
141. ective component See the Test the resistance between each of the leads wiring diagram in P7 and a good clean chassis ground con 140 f testing is complete plug P7 back into the nection Be very careful that the connection control PC board and perform the Case Cover pins in P7 are not damaged or spread out Replacement procedure 6 The resistance should be very high A reading of 500 000 500k ohms or higher is accept able Return to Section TOC Return to Master TOC OO IHS ojeg O0 Ola gt 9 cic 5 5 c Return to Section TOC Return to Master TOC 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC gt 9 TROUBLESHOOTING 4 REPAIR idi CONTROL POTENTIOMETER AND MODE RESISTANCE TEST CONTINUED TABLE F 3 POT MODE SWITCH RESISTANCE TEST MODE SWITCH OHMMETER SETTING CONNECTION CC STICK P7 9 214 TO 7 14 218 CC STICK P7 9 214 TO P7 15 220 500K or Higher CC STICK P7 9 214 TO P7 16 222 500K or Higher CC STICK P7 14 218 TO P7 15 220 500K or Higher CC STICK 7 14 218 TO P7 16 222 500K or Higher CC STICK P7 15 220 TO P7 16 222 500K or Higher TOUCH START TIG P7 15 220 TO P7 16 222 DOWNHILL PIPE P7 14 218
142. ed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will determine if the weld control PC board is able to produce the PWM Pulse Width Modulated gate signal needed to control the IGBTs Insulated Gate Bipolar Transistor on the chopper module This test will also verify that the control PC board can turn the PWM gate signal on and off properly MATERIALS NEEDED Digital Multi meter Frequency counter or digital Multi meter with frequency counter function Wiring Diagram Control Inner Connection diagram 400 LINCOLN 8 F 69 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 o c Return to Section TOC Return to Master TOC F 70 TROUBLESHOOTING amp REPAIR WELD CONTROL BOARD PWM GATE SIGNAL TEST CONTINUED TEST PROCEDURE 1 Perform the Case Cover Removal Unplug any device that may be attached to either the 6 pin or the 14 pin Amphenol recep tacles Place the idle switch in the HIGH IDLE posi tion Place the mode switch in the CC STICK position Place the Weld terminals switch in the TERMINALS ON posi
143. ee 0 31 thick clamping bars and later models use six 0 14 thick clamping bars arranged in three sets of two bars each If the rotor is to be replaced remove the screws rotor clamping ring and coupling disc from the rotor hub Replacing the Rotor 1 Whenever the rotor and stator are separated it is highly recommended that a new bearing and tolerance ring be installed when the rotor and stator are reassembled 2 Examine the rotor coupling disc clamping ring clamping bars screws lock washers and the engine flywheel Make sure that all of the parts are clean and in good condition 3 Install a new bearing on the rotor shaft Assemble the coupling disc and clamping ring to the rotor hub The surface of the disc with the stamping burrs should be against the rotor hub The side of the clamping ring with the radius should be placed against the coupling disc See Figure F 29 Insert the screws with lock washers and evenly tighten to a torque of 17 to 19 Ft Lbs Lift the rotor assembly with the hoist and lifting straps and recheck the engine flywheel and coupling disk for anything that might prevent proper seating To attach the coupling disk to the engine fly wheel align the screw holes and insert the six screws with lock washers through the disc clamping bars and the coupling disc and into the engine flywheel Evenly tighten all the screws to a torque of 17 to 19 Ft Lbs
144. eed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the idler solenoid resistance values are normal and also deter mine if it will function normally when it is energized with 12VDC MATERIALS NEEDED Miscellaneous hand tools External 12VDC supply 30 amps automotive battery works well Wiring Diagram Volt Ohmmeter 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC HS 02 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR IDLER SOLENOID TEST CONTINUED FIGURE F 6 PLUG S PIN LOCATION IDLE SOLENOID CONNECTOR LEAD ENTRY VIEW TEST PROCEDURE 12 VOLT RUN ENGINE PROTECTION IDLE CONTROL P C B 227 IDLE SOLENOID WIRING HARNESS CONNECTOR LEAD ENTRY VIEW Turn the engine off 6 Using the external 12VDC supply apply 12VDC to the pull in coil leads at pins 3 and Open the right side engine service access 4 black wire to white wire The solenoid door should activate REMOVE THE VOLTAGE Locate the idler solenoid mounted right side of IMMEDIATELY to avoid damage to the unit engine Apply 12VDC to the hold in coil at pin 3 black Locate and unplug harness connection P 55 wire and pin 2 red wire While the volt Cut any necessary cable ties See Wiring age is applied man
145. ely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the chopper module is shorted This test can only detect some problems in the Power section of the module Problems in some other PC board components may not be detected MATERIALS NEEDED Miscellaneous hand tools Digital Ohmmeter Wiring diagram 400 LINCOLN 8 F 65 TROUBLESHOOTING amp REPAIR CHOPPER MODULE RESISTANCE TEST CONTINUED TEST PROCEDURE 1 Perform the Case Cover Removal 4 Use digital Ohmmeter to test the module per Table F2 2 2 Perform the Capacitor Discharge Procedure 3 Check that all of the leads connected to the chopper module terminals are clearly marked to facilitate reassembly Remove all of the leads from the chopper module and position them so they do not make electrical contact with any part of the module See the wiring diagram Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo c Return to Section TOC Return to Master TOC 400 LINCOLN TROUBLESHOOTING amp REPAIR CHOPPER MODULE RESISTANCE TEST CONTINUED FIGURE F 2 DIODE TEST TABLE OHMMETER ADI Diode Bias Lead Lead and Expected
146. engine Made from long life aluminized steel coolant temperature WARRANTY 2 years 2000 hours all non electric components 3 years major non electric compo nents See Perkins warranty for details MACHINE SPECIFICATIONS RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS 2 120VAC GFCI Duplex 5 20R Two 20AMP for Two Duplex Receptacle 10AMP for Battery Charging Circuit 1 120 240VAC Dual Voltage 1 50AMP for Dual Voltage and for 10AMP for 42V Wire Feeder Power Full KVA 14 50R 3 Phase 3 pole 1 240 3 Phase 15 50R 1 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced Top of enclosure add 10 68 271 3mm to top of exhaust pipe Add 6 67 169 4mm to top of Lift Bail 2 Reduced to less than 32V in the CC stick Mode when VRD VOLTAGE REDUCTION DEVICE is on Return to Section TOC Return to Master TOC 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC idi INSTALLATION idi SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied wi
147. ent sensor for any signs of damage Check leads 260 and 261 for poor connections and damage to the conductors and insulation between the toroid current sensor and the P3 connector in the con trol PC Board Unplug plug P3 from the control PC Board and check for damaged dirty or corroded pins Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 5 o CAUTION If for any reason you do not understand the test procedures or unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 400 LINCOLN Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o c Return to Section TOC Return to Master TOC F 19 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The engine will not idle down to low RPM The machine has nor mal weld and auxiliary output continued The engine will not go to high idle when using auxiliary power Auxiliary power is normal when the idler switch is in the HIGH idle position the automatic idle func tion works properl
148. er motor the Engine Protection or Battery Charging Lights do not turn off shortly after starting the engine shut off the engine immediately and deter mine the cause NOTE When starting for the first time or after an extended period of time of not operating it will take longer than normal to start because the fuel pump has to fill the fuel system For best results bleed the fuel system as indicated in the Maintenance Section of this manual STOPPING THE ENGINE Remove all welding and auxiliary power loads and allow the engine to run at low idle speed for a few min utes to cool the engine STOP the engine by placing the RUN STOP switch in the STOP position NOTE A fuel shut off valve is located on the fuel pre filter WELDER OPERATION DUTY CYCLE Duty Cycle is the percentage of time the load is being applied in a 10 minute period For example a 60 duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period ELECTRODE INFORMATION For any electrode the procedures should be kept with in the rating of the machine For information on elec trodes and their proper application see www lincoln electric com or the appropriate Lincoln publication The VANTAGE 400 can be used with a broad range of DC stick electrodes The MODE switch provides two stick welding settings as follows CONSTANT CURRENT CC STICK WELDING The CC STICK position of the MODE switch is designed for horizo
149. er supply NOTE The wire feeder AC voltage supply tests require that the meter probes be inserted into the Amphenol connection cavities Care should be taken to avoid damaging or expanding the termi nals when inserting the probes NOTE The 120 VAC power supplied to the 14 pin Amphenol connector originates from the same winding that supplies the 120 VAC receptacles the machine has previously passed 120VAC auxil lary winding test this test can only reveal problems connections or components between the Amphenol and the stator winding NEG ww Y FROM SHUNT Connect the voltmeter probes to pins A lead 32 and J lead 31 of the 14 pin Amphenol See figure 3 and wiring diagram Start the engine and run it at high idle 1860 to 1890 RPM The AC voltage reading should be between 115 and 132 VAC If these voltage readings are not within specifi cations check for a tripped or defective circuit breaker faulty connections or broken wires between the test points and the stator wind ings See wiring diagram VANTAGE 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo c Return to Section TOC Return to Master TOC F 54 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TESTS CONTINUED To test the 42 VAC wire feeder winding 1 Connec
150. ery lead at engine foot BATTERY ACID can burn eyes and skin Wear gloves and eye protection and be careful when working near bat tery Follow instructions printed on bat tery CLEANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty If the terminals appear corroded discon nect the battery cables and wash the terminals with an ammonia solution or a solution of 1 4 pound 0 1113 kg of baking soda and 1 quart 0 9461L of water Be sure the battery vent plugs if equipped are tight so that none of the solution enters the cells After cleaning flush the outside of the battery the bat tery compartment and surrounding areas with clear water Coat the battery terminals lightly with petroleum jelly or a non conductive grease to retard corrosion Keep the battery clean and dry Moisture accumulation on the battery can lead to more rapid discharge and early battery failure CHECKING THE ELECTROLYTE LEVEL If battery cells are low fill them to the neck of the filler hole with distilled water and recharge If one cell is low check for leaks CHARGING THE BATTERY 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 VANTAGE 400 positive battery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the nega
151. es If the electrode cable is on your right idler by pushing on the throttle control rods side the work cable should also be on your right side M Y while the engine is running A Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while d 5 Do not work next to welding power source turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Return to Master TOC VANTAGE 400 LINCOLN Return to Master Return to Master TOC O O 2 9 Return 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 6 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 kneeling or lying if there is a high risk of unavo
152. es and solid wires for MIG welding gas metal arc welding Welding can be finely tuned using the ARC CONTROL Turning the ARC CONTROL clockwise from 10 soft to 10 crisp changes the arc from soft and to crisp and narrow It acts as an inductance pinch control The proper setting depends on the procedure and operator preference Start with the dial set at 0 NOTE In the CV Mode with VRD the OCV Open Circuit Voltage is not reduced For indicator light operation see Table 1 TABLE B 5 ARC GOUGING The VANTAGE 400 can be used for arc gouging For opti mal performance set the MODE switch to CC STICK and the ARC CONTROL to 10 Set the OUTPUT CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following Table B 4 TABLE B 4 Current Range DC electrode positive arbon Diameter 1 8 60 90 5 5 32 90 150 Amps 3 16 200 250 Amps 1 4 300 400 Amps 450 550 Amps AUXILIARY POWER Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings providing no welding current is being drawn Simultaneous Welding and Auxiliary Power Loads The auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in the following table VANTAGE 400 Simultaneous Welding an
153. est procedures or unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o c di TROUBLESHOOTING amp REPAIR dbi Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION The machine will weld but the welding arc is COLD The engine runs normally and the aux power is normal continued The machine welds but it will not maintain a steady output FUNCTION PROBLEMS This condition may be normal in the Downhill Pipe Mode The downhill pipe mode allows the arc current to increase and decrease slightly as the arc length changes Check that the electrode is of good quality dry and free from contamination Try using some Lincoln Electrode and setting the machine per Lincoln recommenda tion If shielding gas is used check that the gas and gas flow are correct Check for damaged pinched or leaking gas lines Check for proper work and elec trode leads and connections size length coils or bad connections The machine may not b
154. ety Precautions c D 2 E Routine Maintenance skankin ayak E AT D 2 Engine Service 5 D 3 Engine OIl Change vee eee see ee ee D 3 Engine Oil Filter Change D 3 PIPCICONCr wey D 3 is Service Instructions And Installation Tips for Engine Air Filter D 4 Cooling System D 5 9 Poll Del ney es ener bane aan E NES RE REPE D 5 Fuel 222222 2 2 2 22 2 2 2 2 2 2 2 2 22 2 D 5 Bleeding the Fuel System D 5 xU bz qe D 6 zasn eelui O D 6 Battery MAUNCRANCe En D 6 O Servicing Optional Spark Arrestor D 6 D id Welder Generator Maintenance D 7 z Storage 2 22 2 2
155. for proper starting proce dure Make sure the fuel valve on the fuel sediment filter is in the open position Check that the machine has an adequate supply of fresh clean fuel The fuel filter may be clogged replace if necessary Check the oil level RECOMMENDED COURSE OF ACTION Perform the There may be a defective compo nent or faulty wiring causing a current draw when the run stop switch is in the stop position Check the Run Stop switch the glow plug button the alternator and the starter solenoid Also check for damaged wiring and insulation If the engine charging system is operating properly but the battery is not staying charged the battery is defective and should be replaced The fuel solenoid may be faulty or not operating properly Check lead 233 and 262 and perform the FUEL SHUT DOWN SOLE NOID TEST The Engine Protection Board may be faulty The engine may be in need of mechanical repairs CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 400 LINCOLN Return to Section TOC Return to Master TOC TROUBLESHOOTING 4 REPAIR Observe Safety Guidelines detailed the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTO
156. formed whenever work is to be attempted on or near the chopper module Return to Section TOC Return to Master TOC MATERIALS NEEDED Miscellaneous hand tools Volt Ohmmeter Resistor 25 1000 ohms and 25 watts minimum Lincoln part 510404 114 works well for this purpose Jumper leads Wiring Diagram OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC HS 02 gt 9 cic 5 5 Return to Section TOC Return to Master TOC Return to Master TOC F 26 TROUBLESHOOTING amp REPAIR CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE CONTINUED FIGURE F 2 CHOPPER MODULE CAPACITOR TERMINAL DISCHARGE WARNING ELECTRIC SHOCK can kill Do not touch electrically hot parts e Prior to performing preventative maintenance perform the following capacitor discharge procedure to avoid electric shock DISCHARGE PROCEDURE 1 Turn the engine off 2 Perform the Case Cover Removal procedure NOTE It is necessary to remove the fuel cap in order to take the case cover off the machine Be sure the fuel cap is ON when discharging the chopper module capaci tors 3 Locate the chopper module and capacitor assembly on the inner machine baffle See Fig
157. fuel lines Clean the filter mounting base and coat the gasket of the new filter with clean engine oil Screw the new filter on by hand until the gasket con tacts the mounting base Using an oil filter wrench tighten the filter an additional 1 2 to 7 8 of a turn Refill the crankcase with the specified amount of the recommended engine oil Reinstall the oil filler cap and tighten securely Start the engine and check for oil filter leaks Stop the engine and check the oil level If necessary add oil to the upper limit mark on the dipstick A WARNING Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explo sion could result CAUTION Never run the engine without the air cleaner Rapid engine wear will result from contaminant s such as dust and dirt being drawn into the engine AIR CLEANER The diesel engine is equipped with a dry type air filter Never apply oil to it Service the air cleaner as follows Replace the element every 500 hours of operation Under dusty conditions replace sooner VANTAGE 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC d MAINTENANCE sd Service Instructions Single and Two Stage Engine Air Cleaners Unfasten or unlatch the service cover
158. gged Inspect the Old Filter for Leak Clues Visually inspect the old filter for any signs of leaks A streak of dust on the clean side of the filter is a telltale sign Remove any cause of leaks before installing new filter 4 Inspect the New Filter for Damage Inspect new filter carefully paying attention to the inside of the open end whichis the sealing area NEVER install a damaged filter A new Donaldson radial seal filter may have a dry lubricant on the seal to aid installation 5 Insert the New Radial Seal Filter Properly If you re servicing the safety filter this should be seated into position before installing the primary filter Insert the new filter carefully Seat the filter by hand making certain it is completely into the air cleaner housing before securing the cover in place The critical sealing area will stretch slightly adjust itself and distribute the sealing pressure evenly To complete a tight seal apply pressure by hand at the outer rim of the filter not the flexible center Avoid pushing on the center of the urethane end cap No cover pressure is required to hold the seal NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners and will void the warranty If the service cover hits the filter before it is fully in place remove the cover and push the filter by hand further into the
159. gh Idle 1880 starter 57 L 1800 RPM Bore x Stroke inch mm Group 34 650 Oil 8 45Qts 8L naturally aspirated Full Load 1800 cold crank amps K2410 2 water cooled 3 43 X 3 64 65 Amp Alternator Radiator Coolant 404D 22 Diesel Engine Low Idle 1400 87 1 x 92 5mm Built in Regulator 8 0 Qts 7 6L RATED OUTPUT 104 F 40 C WELDER Welding Process Welding Output Output Range Max Weld OCV Current Voltage Duty Cycle Rated Load RPM 400A 36V 10096 DC Constant Current 450A 32V 10096 30 TO 500 AMPS DC Pipe Current 60 Volts Touch Start TIG 400A 36V 100 DC Constant Voltage 450A 32V 10096 14 TO 36 VOLTS RATED OUTPUT 104 F 40 GENERATOR Auxiliary Power 12 000 Watts Peak 11 000 Watts Continuous 60 Hz 120 240 Volts Single Phase 19 000 Watts Peak 17 000 Watts Continuous 60 Hz 240 Volts 3 Phase PHYSICAL DIMENSIONS Return to Section TOC Return to Master TOC LE Return to Master TOC o 643 mm 1524 mm O JO ENGINE S S LUBRICATION EMISSIONS GOVERNOR 9 Full Pressure K2410 1 EPA Tier Il Mechanical Fuel Pump Auto air bleed syste Mechanical with Full Flow Filter K2410 2 EPA Tier 4 Interim Electric shutoff solenoid Indirect fuel injector S Low noise Muffler Shutdown on low oil Single Element Automatic Idler Top outlet can be rotated pressure amp high
160. hipped with the negative bat tery cable disconnected Make certain that the RUN STOP switch is in the STOP position Remove the two screws from the battery tray using a screwdriver or a 3 8 socket Attach the negative battery cable to the negative battery terminal and tighten using a 1 2 sock et or wrench A 5 NOTE This machine is furnished with a wet charged battery if unused for several months the battery may require a booster charge Be careful to charge the bat tery with the correct polarity See y in MUFFLER OUTLET PIPE 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 Tighten using a 9 16 socket or wrench SPARK ARRESTER Some federal state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain loca tions where unarrested sparks may present a fire haz ard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations a suitable spark arrester such as the K903 1 must be installed and properly maintained WARNING An incorrect spark arrestor may lead to damage to the engine or adversely affect performance REMOTE CONTROL The VANTAGE 400 is equipped with a 6 pin and a 14 pin connector The 6 pin connector is for connecting the K857 or K857 1 Remote Control or f
161. hrough 15 If battery voltage is present at all of the above points check the top grounding stud on inside left case from and lead also check leads 7200 2008 R3 Make sure all terminals are crimped tightly to the flex leads and arc free of corrosion 400 LINCOLN F 48 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo c Return to Section TOC Return to Master TOC F 49 TROUBLESHOOTING amp REPAIR FLASHING VOLTAGE TEST CONTINUED If battery voltage is present at leads 232 232F but not present at leads 200 The engine protection idle P C B board is proba bly defective Replace If battery voltage is present at lead 7232 but not present at leads 232F or 200 check the engine protection wiring per the wiring dia gram If battery voltage is not present at lead 7232 check wiring per wiring diagram and check the run stop switch Also check the ground PC board chassis ground wire lead 5 and the stud where it connects to the chassis Set the RUN STOP switch to the STOP position 20 Re connect lead 7234 to the oil pressure switch 21 If testing is completed perform the Case Cover Replacement procedure 400 LINCOLN 8 F 49 50 5 VANTAGE 400 LINCOLN joe F 50
162. idable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder 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 6 c and 8 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 Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resist
163. igging arc is preferred for root and hot passes softer arc is preferred for fill and cap passes where weld puddle control and deposition stacking of iron are key to fast travel speeds This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with the dial set at O NOTE With the VRD switch in the ON position there is no output in the DOWNHILL PIPE mode For indicator light operation see Table 1 TIG WELDING The TOUCH START TIG setting of the MODE switch is for DC TIG Tungsten Inert Gas welding To initiate a weld the OUTPUT CONTROL dial is first set to the desired cur rent and the tungsten is touched to the work During the time the tungsten is touching the work there is very little voltage or current and in general no tungsten contami nation Then the tungsten is gently lifted off the work in a rocking motion which establishes the arc When in the TOUCH START TIG mode and when a Amptrol is connected to the 6 Pin connector the OUT PUT CONTROL dial is used to set the maximum cur rent range of the current control of the Amptrol The ARC CONTROL is not active in the TIG mode To STOP a weld simply pull the TIG torch away from the work When the arc voltage reaches approximately 30 Volts the arc will go out and the machine will reset the cur rent to the Touch Start level To reinitiate the arc retouch the tungsten to the wor
164. ime in cold weather 16 ELECTRIC FUEL GAUGE The electric fuel gauge gives accurate and reliable indication as to how much fuel is in the fuel tank 17 ENGINE HOUR METER Displays the total time that the engine has been running This meter is useful for scheduling prescribed maintenance TABLE B 2 6 TYPICAL VANTAGE 400 FUEL CONSUMPTION PERKINS Running Time for Gal Hr Liters Hr 15 gallons hours 18 4 46 24 4 68 90 3 42 OO O HS 0910 02 gt 9 cic 5 5 o 1 18 4 46 12 74 1 24 4 68 12 14 1652 NOTE This data is for reference only Fuel consump tion is approximate and can be influenced by many fac tors including engine maintenance environmental conditions and fuel quality Return to Section TOC Return to Master TOC VANTAGE 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC udi THEORY OF OPERATION ES NOTE If the unit fails to start turn Run Stop switch to off and repeat step 3 through step 7 after wait ing 30 seconds CAUTION not allow the starter motor to run continuously for more than 20 seconds Do not push the START button while the engine Is running because this can damage the ring gear and or the start
165. ipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment 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 Refer to http Awww lincolnelectric com safety for additional safety information VANTAGE 400 LINCOLN Return to Master Return to Master TOC O O 2 9 Return to Master Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce 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 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
166. ircuit current arc force during stick weld ing to adjust for a soft or a more forceful digging arc crisp Increasing the number from 10 soft to 10 crisp increas es the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is preferred for root and hot passes A softer arc is preferred for fill and cap passes where weld puddle control and deposition stacking of iron are key to fast travel speeds It is recommended that the CONTROL be set initially at 0 CV WIRE mode In this mode turning the ARC CONTROL clock wise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an induc tance pinch control The proper setting depends on the pro cedure and operator preference Start with a setting of O WELD OUTPUT TERMINALS WITH FLANGE NUT Provides a connection point for the electrode and work cables Provides a connection point for connecting the machine case to earth ground 14 PIN CONNECTOR For attaching wire feeder con trol cables Includes contactor closure circuit auto sensing remote control circuit and 120V and 42V power The remote control circuit operates the same as the 6 Pin Amphenol 6 PIN CONNECTOR For attaching optional remote control equipment Includes auto sensing remote control cir Cuit WELD TERMINALS CONTROL SWITCH In the WELD TERMINALS ON position the output is electrically hot a
167. is diagram is for reference only It may not be accurate for all machines covered this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine ELECTRIC VANTAGE 400 es ELECTRICAL DIAGRAMS G 3 SCHEMATIC COMPLETE MACHINE G5597 PAGE 1 E D 266449 ENGINEERING CONTROLLED CHANGE DETAIL REVISED LEAD 208C ROUTING MANUFACTURER No 2 12V 0LTS RUN gt 1 q C SHUNT 215 POSI TI 50MV 400 AMPS FUEL LVL OUTPUT SENSOR a TERM NAL Ts CURRENT EVEL 2045 FEED BACK SIGNAL 5 DIODES AND uM 2068 2065 FILTECAPACI DRS ARE CHOPPPPER PC BOARD THREE PHASE 60 TO 6ACPHASE D PHASE 206A TOCHOPPER MODULES AND NOT 13C ATHIGH E 5 230 WMS EMPTY WREFEEDER NDVIDUALLY REPLACEABLE ja 30 BMS BLL VOLTMETER 1 5 wi ive Oi PressuSwitch POLARI Y B2 ve closes on 0 10 BMS OP
168. its 5 c 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 prod ucts 5 d Shielding gases used for arc welding can displace air and Cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 5 e Read and understand the manufacturer s instructions for this 5 f 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 Also see item 1 b VANTAGE 400 LINCOLN Return to Master Return to Master TOC O O 2 9 Return to Master 6 j SAFETY WELDING and CUTTING gt SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjcent 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
169. k and lift Alternatively the weld can be stopped by releasing the Amptrol or arc start switch The VANTAGE 400 can be used in a wide variety of DC TIG welding applications In general the Touch Start feature allows contamination free starting without the use of a Hi frequency unit If desired the K930 2 TIG Module can be used with the VANTAGE 400 The settings are for reference VANTAGE 400 settings when using the K930 2 TIG Module with an Amptrol or Arc Start Switch Set the MODE Switch to the TOUCH START TIG setting Set the IDLER Switch to the AUTO position TABLE B 3 TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES DCEN DCEP Approximate Argon Gas Flow Flow Rate C F H 1 min 196 296 Thoriated 196 296 Thoriated Aluminum Stainless Steel Tungsten Tungsten TIG TORCH Nozzle Size 4 5 Tungsten Electrode Diameter in mm 2 15 4 5 6 5 20 15 80 70 150 150 250 250 400 400 500 5 6 6 7 8 8 10 500 750 750 1000 1 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shielding gases 2 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 1 Thoriated EWTh 1 2 Thoriated EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications 3 DCEP is not commonly
170. ker See wiring diagram battery voltage is present the starter motor or solenoid may be defective or the engine may be prevented from turning due a mechanical failure CAUTION If for any reason you do not understand the test procedures or unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 400 LINCOLN F 14 F 14 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o PROBLEMS SYMPTOMS The battery does not stay charged The engine cranks when the start button is pressed but will not start POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check for loose corroded or faulty connections at the battery Check for loose or damaged alter nator drive belt The battery may be faulty The battery voltage may be low normally results in slow cranking speed The batter should be checked and recharged if it is not producing adequate voltage and replace if it will not accept a full charge Make sure the glow plug button is pressed while pressing the start button See the operator s manu al or the operation section of this manual
171. le and Input Cable K488 SG Control Module For Magnum Spool Gun The Interface between the power source and the spool gun Provides control of the wire speed and gas flow For use with a K487 25 spool gun K691 10 Input Cable For SG Control Module For Lincoln engine power sources with 14 pin MS type con nection separate 115V NEMA receptacles and output stud connections Note See Wire Feeder IM manuals for appropriate Drive Roll and Guide Tubes TIG OPTIONS K1783 9 Pro Torch amp PTA 26V TIG Torch Air Cooled 200 amp torch 2 piece equipped with valve for gas flow control 25 ft 7 6m length KP509 Magnum Parts Kit for PTA 26V TIG Torch Magnum Parts Kit provides all the torch accessories you need to start welding Parts kit provides collets collet bod ies a black cap alumina nozzles and tungstens in a variety of sizes all packaged in an easy to carry reclosable sack K870 Foot Amptrol amp K963 3 Hand Amptrol amp K2347 1 Precision TIG 185 Ready Pak For AC TIG K2350 1 Invertec V205 T AC DC One Pak Package For AC TIG PLASMA CUTTING K1580 1 Pro Cut 55 Cuts metal using the 3 phase AC generator power from the engine driven welder Accepts 3 phase or 1 phase input power Requires the K1816 1 Full KVA adapter kit if con nected for 1 phase input power 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC
172. ll cause the output termi nals to overheat The terminals may eventually melt Do not cross the welding cables at the output ter minal connection Keep the cables isolated and separate from one another VANTAGE 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 o c Return to Section TOC Return to Master TOC id INSTALLATION aid AUXILIARY POWER RECEPTACLES Start the engine and set the IDLER control switch to the High Idle mode Voltage is now correct at the receptacles for auxiliary power This must be done before a tripped GFCI receptacle can be reset properly See the MAINTENANCE section for more detailed information on testing and resetting the GFCI recepta The auxiliary power of the VANTAGE 400 consists of two 20 Amp 120 VAC 5 20R duplex receptacles with GFCI protection one 50 Amp 120 240 VAC 14 50R receptacle and one 50 Amp 240VAC Three Phase 15 50R receptacle The auxiliary power capacity is 12 000 watts Peak 11 000 Watts Continuous of 60 Hz single phase power The auxiliary power capacity rating in watts is equiva lent to volt amperes at unity power factor The max per missible current of the 240 VAC output is 50amps The 240 VAC output can be split to provide two sepa rate 120 VAC outputs with a max permissible current of 50 Amps
173. ll the time In the REMOTELY CONTROLLED posi tion the output is controlled by a wire feeder or amptrol device and is electrically off until a remote switch is depressed 1 1 CV WIRE While Red or Green Welding Depends on Weld Voltage THEORY OF OPERATION ET 4 ARC CONTROL The ARC CONTROL dial is active in 0 WIRE FEEDER VOLTMETER SWITCH Matches the polarity of the wire feeder voltmeter to the polarity of the electrode VRD Voltage Reduction Device INDICA TOR LIGHTS On the front panel of the Vantage 400 are two indicator lights A red light when lit indi cates OCV Open Circuit Voltage is equal to or greater than 30V and a green light when lit indicates OCV Open Circuit Voltage is less than 30V VRD On Off switch inside the control panel must be On for the VRD function to be active and the lights to be enabled When the machine is first started with VRD enabled both lights will illuminate for 5 seconds These lights monitor the OCV Open Circuit Voltage and weld voltage at all times In the CC Stick mode when not welding the green light will illuminate indi cating that the VRD has reduced the OCV to less than 30V During welding the red light will illuminate when ever the arc voltage is equal to or greater than 30V This means that the red and green light may alternate depending on the weld voltage This is normal opera tion If the red light remains illuminated whe
174. ll with a 50 50 antifreeze water solution Use an automotive grade low silicate ethylene glycol antifreeze The cooling system capacity is 8 0 quarts 7 6L Squeeze upper and lower radiator hoses while filling to bleed air from system coolant Replace and tighten the radiator cap CAUTION Always premix the antifreeze and clean tap water before adding to the radiator It is very important that a precise 50 50 solution be used with this engine year round This gives proper cooling dur ing hot weather and freezing protection to 34 F 37 C Cooling solution exceeding 50 ethylene glycol can result in engine overheating and damage to the engine Coolant solution must be premixed before adding to radiator Periodically remove the dirt from the radiator fins Periodically check the fan belt and radiator hoses Replace if signs of deterioration are found TIGHTENING THE FAN BELT If the fan belt is loose the engine can overheat and the battery lose its charge Check tightness by pressing on the belt midway between the pulleys It should deflect about 25 in 6 4 mm under a load of 20 Ibs 9 Kg nid MAINTENANCE nid COOLING SYSTEM WARNING FUEL At the end of each day s use refill the fuel tank to min imize moisture condensation and dirt contamination in the fuel line Do not overfill leave room for the fuel to expand Use only fresh No 2D diesel fuel the use of No 1D diesel fuel is re
175. mp 120 240 Volt recep tacle on the case front 400 LINCOLN 8 Return to Section Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC v 9 Return to Master idi INSTALLATION id CONNECTION OF VANTAGE 400 TO PREMISES 240 VOLT GROUNDED CONDUCTOR 60 Hz 3 Wire COMPANY m Service METER NEUTRAL BUS LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES DISCONNECT AND SERVICE 50AMP GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 1 N N 50 AMP 120 240 VOLT p RECEPTACLE NOTE No 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS WARNING Only a licensed certified trained electrician should install the machine to a premises or residential elec trical system Be certain that installation complies with the National Electrical Code and all other applicable electrical codes The premises is isolated and no feedback into the utility system can occur Certain state and local laws require the premises to be isolated before the generator is linked to the premises Check your state and local requirements double pole double thr
176. n not welding in the CC stick mode the VRD is not functioning properly Please refer to your local field service shop for service If the VRD is turned On and the lights don t come refer to the trouble shooting section TABLE B 1 VRD INDICATOR LIGHT VRD ON MODE VRD OFF 5 Green Reduced While Red or Green Welding Depends on Weld Voltage Hed OCV Not Reduced Weld Terminals On Red OCV Not Reduced Weld Terminals Remotely Controlled Gun Trigger Closed Green No OCV Weld Terminals Remotely Controlled Gun Trigger Open No Lights PIPE Green No Output While Not Applicable No Output Welding ARC GOUGING Green No Output While Not Applicable No Output Welding Green Process is Low Voltage Green Process is Low Voltage It is normal for the lights to alternate between colors while welding VANTAGE 400 LINCOLN 2 Return to Section Return to Master TOC B 5 THEORY OF OPERATION B 5 ENGINE CONTROLS 18 ENGINE PROTECTION LIGHT A warning indi 12 RUN STOP SWITCH RUN position energizes the cator light for Low Oil Pressure and or Coolant Over 13 engine prior to starting STOP position stops the engine The oil pressure interlock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating GLOW PLUG PUSH BUTTON pushed activates the glow plugs Glow plug should not b
177. n the engine off 2 Perform the Case Cover Removal procedure 3 Locate and label the leads from the rotor brush holder assembly See Figure F 9 Using the needle nose pliers remove the leads This will electrically isolate the rotor windings 4 Using the ohmmeter check the rotor winding resistance across the slip rings See Figure F 9 Normal resistance is approximately 25 ohm at 77 F 25 Measure the resistance to ground Place one meter probe on either of the slip rings Place the other probe on any good unpainted chassis ground The resistance should be very high at least 500 000 500 ohms If the test does not meet the resistance speci fications then the rotor may be faulty and should be replaced If this test meets the resistance specifications continue testing using the dynamic rotor resis tance and ground test 400 LINCOLN F 40 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 41 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE AND GROUND TEST DYNAMIC Also referred to as flying resistance test 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
178. n to Master TOC Return to Section TOC Return to Master TOC OO IHS ojeg O0 Ola gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 2 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories output problems function prob lems wire feeding 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 con tribute to the machine symptom Perform these tests checks in the order listed general these tests can be c
179. nd terminal 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 VANTAGE 400 LINCOLN 8 TROUBLESHOOTING 4 REPAIR Observe Safety Guidelines detailed the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Major mechanical or electrical 1 Contact your local Lincoln 1 Contact the Lincoln Electric damage is evident Authorized Field Service Service Department at 1 888 Facility 935 3877 Return to Section TOC Return to Master TOC No welding output or auxiliary Check for loose or faulty connec Check the brushes for wear and power The engine operates nor tions in the auxiliary circuit to the proper contact to the rotor slip mally output receptacles and or the rings weld circuit to the output terminals Perform the Check the brushes for wear ad proper contact to the rotor slip Check for flashing voltage at slip rings rings 3 5 Volts DC 5 amp until generator builds up then 160 Volts See FLASHING VOLTAGE Re
180. necessary 2 Insulate the lead wires that had been discon nected from the brushes during the static rotor resistance test Position and secure them so they cannot become damaged by the spinning rotor 3 Securely attach the ohmmeter leads to the brush terminals Use clips or terminals to attach the leads BEFORE starting the engine 4 Start the engine and run it at high idle speed 1860 1890 RPM The resistance should read approximately 25O at 77 F 25 C 4 Shut off engine and move one of the ohmme ter leads to a good clean chassis ground 5 Restart the engine and run it at high idle speed 1860 1890 RPM The resistance should be very high at least 500 000 500 ohms D If the resistance readings differ significantly from the values indicated re check the brush es and the brush spring tension If the brush es and slip rings are good replace the rotor 7 Ifall testing is finished perform the Cover Replacement procedure NOTE The resistance of the windings will change with temperature Higher temperatures will produce higher resistance and lower temper atures will produce lower resistance VANTAGE 400 LINCOLN 2 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 43 TROUBLESHOOTING amp REPAIR F 43 ROTOR VOL
181. 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 1 888 935 3877 TEST DESCRIPTION This test checks the flashing voltage with the engine stopped by simulating a running con dition MATERIALS NEEDED Miscellaneous hand tools Voltmeter Wiring Diagram 400 LINCOLN 8 F 47 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC F 48 TROUBLESHOOTING amp REPAIR FLASHING VOLTAGE TEST CONTINUED TEST PROCEDURE Perform the Case Cover Removal Make sure that the battery is fully charged and in good condition and the battery con nections are clean and tight Remove leads 234 235 from the oil pres sure switch Insulate or position the lead so it cannot come in contact with chassis ground or any other wiring See Wiring Diagram NOTE Disconnecting leads 234 and 235 bypass the oil pressure switch and simulates a running engine 4 12 Place the RUN STOP switch in the RUN position The engine protection light should remain off Connect the voltmeter probes to brush ter minals Measure the voltage it should read about 3 to 5 VDC Set the RUN STOP
182. nt the heat sink to the brackets on the ver 4 Replace any cable ties cut at disassembly tical baffle with the three 3 8 screws Mount the plastic strip with the top two screws 5 When procedures are complete perform the Case Cover RHeplacement procedure 2 Connect leads 23 and 25 at their in line cou plers 3 Using a 7 16 wrench attach the heavy leads and small leads as follows Note placement of leads and fasteners screw lock washer flat washer small lead heavy lead Apply a thin coating of electrical thermal joint compound Dow Corning to the mating surfaces but not the threads Tighten the fasteners to between 50 60 in Ibs 400 LINCOLN 8 F 93 F 94 NOTES VANTAGE 400 LINCOLN joe F 94 NOL 4921S ey NOL 491Se A NOL 491Se A NOL 5 01 DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes uunjeg didi TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE 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
183. ntal and vertical up welding with all types of electrodes especially low hydrogen The OUTPUT CON TROL dial adjusts the full output range for stick welding The ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or crisp arc Increasing the number from 10 soft to 10 crisp increases the short circuit current and pre vents sticking of the electrode to the plate while welding This can also increase spatter is recommended that the ARC CONTROL be set to the minimum number with out electrode sticking Start with the dial set at O NOTE Due to the low with the VRD on a very slight delay during striking of the electrodes may occur Due to the requirement of the resistance in the circuit to be low for a VRD to operate a good metal to metal contact must be made between the metal core of the electrode and the job A poor con nection anywhere in the welding output circuit may limit the operation of the VRD This includes a good connection of the work clamp to the job The work clamp should be connected as close as practical to where the welding will be performed A For New Electrodes E6010 Touch Lift to Start the Arc E7018 E7024 Touch Rock Back and Forth in Joint Lift Once the arc is started normal welding technique for the application is then used B For Re Striking Electrodes Some electrodes form a cone at the end of the elec trode after the welding arc ha
184. o Master TOC Return to Section TOC OO O HS 0910 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC Return to Master TOC WELDING CONTROLS Figure B 1 1 OUTPUT CONTROL The OUTPUT dial is used to preset the output voltage or current as displayed on the digital meters for the four welding modes When in the CC STICK DOWNHILL PIPE or CV WIRE modes and when a remote control is connect ed to the 6 Pin or 14 Pin Connector the auto sens ing circuit automatically switches the OUTPUT CONTROL from control at the welder to the remote control In the CV WIRE mode if the feeder being used has a voltage control when the wire feeder control cable is connected to the 14 Pin Connector the auto sens ing circuit automatically makes OUTPUT CONTROL inactive and the wire feeder voltage control active Otherwise the OUTPUT CONTROL is used to pre set the voltage When in the TOUCH START TIG mode and when an Amptrol 15 connected to the 6 Pin Connector the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol THEORY OF OPERATION FIGURE B 1 OO A LI 7 bob 2 DIGITAL OUTPUT METERS The digital meters allow the output voltage CV WIRE mode or cur rent CC STICK DOWN HILL PIPE and TIG modes to be set prior to welding using the OUTPUT control dial During welding the meter display the actual
185. onal K857 Remote Control C 3 Engine Welders LN25 Across the Arc with Optional 444 1 Remote Control C 3 Engine Welders LN25 with 624 1 42 Volt Remote Output Control Module C 4 T Engine Welders LN7 Ac EE 4 Engine Welders 742 5 Engine Welders 8 eb ewes dened 5 O c Engine Welders to K867 Control Cable Adapter 6 cr Engine Welders 691 10 K488 K487 Spool Gun C 6 Engine Welders K930 TIG Module C 7 Engine Welders K1587 1 CobraMatic C 7 9 VANTAGE 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC FIELD INSTALLED OPTIONS ACCES SORIES K2641 2 FOUR WHEELED STEERABLE YARD TRAILER For in plant and yard towing Comes standard with a Duo Hitch a 2 Ball and Lunette Eye combination Hitch
186. onducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are 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 chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table Contents to locate the appropriate diagram A CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 VANTAGE 400 LINCOLN F 2 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o Re
187. op erly or has been incorrectly installed miswired If your GFCI is not working properly contact a qualified certi fied electrician who can assess the situation rewire the GFCI if necessary or replace the device 400 LINCOLN 8 De D 8 Case Front amp Control Panel Assembly 1 2 Output Panel Assembly 5 Base Fuel Tank amp Battery Assembly 6 Engine Assembly 7 Case Back amp Radiator Assembly 3 Power Module Panel Assembly 8 Case Cover 4 Generator amp Rotor Assembly NOL Je1se N DOL Uorjoes MAJOR COMPONENT LOCATION JO 4e1sel N DOL 0 2 5 uunjeg VRE 22 NS UN NEN 2 Vies Gy KR we 7 JS VA A L CNS A We 277 SGU SN Jud h N Xs va 22 0 uJnjeH DOL 5 2 Gy 3777 1 77 4 GUT 177 7 MA 5 2 Ma iN 4 2 5 20 p 4p 0 uJn 19H DOL 400 LINCOLN TABLE OF CONTENTS THEORY OPERATION SECTION 5 Theory of Operation 552425554458 585545 1 9 we 5 General Description E 2 E Battery Starter Engine Rotor S
188. or TIG welding the K870 foot Amptrol or the K936 3 hand Amptrol When in the CC STICK DOWNHILL PIPE or CV WIRE modes and when a remote control is connected to the 6 pin Connector the auto sensing circuit auto matically switches the OUTPUT control from control at the welder to remote control When in TOUCH START TIG mode and when a Amptrol is connected to the 6 Pin Connector the OUT PUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol The 14 pin connector is used to directly connect a wire feeder control cable In the CV WIRE mode when the control cable is connected to the 14 pin connector the auto sensing circuit automatically makes the Output Control inactive and the wire feeder voltage control active WARNING NOTE When a wire feeder with a built in welding voltage control is connected to the 14 pin connec tor do not connect anything to the 6 pin connec tor VANTAGE 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 010 0 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC INSTALLATION hi ELECTRICAL CONNECTIONS MACHINE GROUNDING QD Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is connected to premises wiring home shop
189. ork using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current Set the WELD TERMINALS switch to WELD TERMINALS ON When the gun trigger is closed the current sens ing circuit will cause the VANTAGE 400 engine to go to the high idle speed the wire will begin to feed and the welding process started When welding is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed e Set the 4 Control Cable Model Connect Control Cable between Engine Welder and Feeder WELD TERMINALS REMOTELY CONTROLLED switch to Set the MODE switch to the CV WIRE position Set the WIRE FEEDER VOLTMETER switch 10 either or as required by the electrode polar ity being used Set the ARC CONTROL knob to 0 initially adjust to suit Set the IDLE switch to the AUTO position When the gun trigger is closed the current sens ing circuit will cause the VANTAGE 400 engine to go to the high idle speed the wire will begin to feed and the welding process started When weld ing is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed VANTAGE 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS
190. ory Trained Personnel Unauthorized repairs performed on this equip ment 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 pre cautions GFCI RECEPTACLE TESTING AND RESET TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped To proper ly test and reset the GFCI receptacle If the receptacle has tripped first carefully remove any load and check it for damage If the equipment has been shut down it must be restarted he equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input terminals The circuit breaker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the recep tacle This will assure normal operation Plug a night light with an ON OFF switch or other product such as a lamp into the GFCI receptacle and turn the product ON Push the Test button located on the recepta cle The night light or other product should go OFF Push the Reset button again The light or other product should go ON again If the light or other product remains ON when the Test button is pushed the GFCI is not working pr
191. ot touch electrically live parts or service this equipment Return to Section TOC Return to Master TOC REGULATOR FLOWMETER AMPHENOL lt D ARGON GAS TO GAS CYLINDER INPUT FITTING K936 1 CONTROL CABLE K870 FOOT AMPTROL ELECTRODE ao s K963 2 HAND AMPTROL J E OR K814 ARC START SWITCH TO WORK 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 WIRE FEEDER VOLTAGE WHICH CAN DAMAGE THE CONTROL CIRCUIT THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL B CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY PLACE THE MODE SWITCH IN THE POSITION D PLACE OUTPUT CONTROL SWITCH IN REMOTE CONTROL POSITION PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED Return to Section TOC Return to Master TOC 24787 9 ENGINE WELDERS K1587 1 COBRAMATIC CONNECTION DIAGRAM Do not operate with panels open Keep guards in place Disconnect NEGATIVE Battery lead Keep away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment
192. other sign of sticking brushes is instabili ty or loss of both weld and auxiliary output but the machine may begin to work properly for a short time after being jarred or moved W BRUSHES If there is any evidence that the brushes may have been sticking in the brush holders a new brush holder and brush assembly should be installed Cleaning slip rings In the event that the slip rings have become dirty discolored or mildly pitted it will be neces sary to clean them using very fine 500 or 600 grit sand paper or a 220 or 320 grit commutator stone Seating Brushes If brushes have been replaced repositioned or are not making full contact with the slip rings it may be necessary to re seat them This can be done by placing a strip of 180 grit sandpaper between the slip rings and the brushes with the abrasive side against the brushes Pull the sandpaper strip around the circumference of the slip rings in the direction of rotor rotation only Repeat this procedure until the surface of each brush is in full contact with its matching slip ring Use a low pressure compressed air to thorough ly blow the carbon commutator stone and sandpaper dust from the machine before operat ing Perform the Case Cover Replacement Note See Figure F 8 for general locations VANTAGE 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910
193. ow transfer switch in conjunction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter VANTAGE 400 LINCOLN 2 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO IHS ojeg O0 gt 9 cic 5 5 Return to Section TOC Return to Master TOC A 9 INSTALLATION A CONNECTION OF LINCOLN ELEC TRIC WIRE FEEDERS CONNECTION OF LN 7 OR LN 8 TO THE VANTAGE 400 1 Shut the welder off 2 Connect the LN 7 or LN 8 per instructions on the appropriate connection diagram in Section F 3 Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode being used 4 Set the MODE switch to the CV WIRE position 5 Set the ARC CONTROL knob to 0 initially and adjust to suit 6 Set the WELD TERMINALS switch to the REMOTELY CONTROLLED position 7 Set the IDLE switch to the HIGH position CONNECTION OF LN 15 TO THE VAN TAGE 400 1 2 Shut the welder off For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable to the ter minal of the welder and work cable to the ter minal of the welder 3 Across The Arc Model Attach the single lead from the front of the LN 15 to w
194. per output to two separate 120 VAC branch circuits these circuits cannot be paralleled Output voltage is within 10 at all loads up to rated capacity The Three Phases auxiliary power capacity is 17 000 watts peak 19 000 watts continuous The maximum current is 45 amps 120 DUPLEX RECEPTACLES A GFCI Ground Fault Circuit Interrupter electrical receptacle is a device to protect against electric shock should a piece of defective equipment connected to it develop a ground fault If this situation should occur the GFCI will trip removing voltage from the output of the receptacle If a receptacle is tripped see the MAINTENANCE section for detailed information on testing and resetting it A GFCI receptacle should be properly tested at least once every month The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated recepta NOTE The 240 V receptacle has two 120 V circuits but are of opposite polarities and cannot be paralleled All auxiliary power is protected by circuit breakers The 120V has 20 Amp circuit breakers for each duplex receptacle The 120 240V Single Phase and the 240V Three Phase have a 50 Amp 3 pole Circuit Breaker that disconnects both hot leads and all three phases simultaneously
195. plug plug P3 from the control PC board and check for damaged dirty or corroded pins Measure the resistance of the toroidal current sensor Measure between P 3 and P 4 the resis tance should be 10 14 Ohms If the sensor is shorted or open replace it The control P C Board may be defective CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o c Return to Section TOC Return to Master TOC dini TROUBLESHOOTING amp REPAIR en Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The engine will not go to high idle Check that the welding cables are Check the leads and connections when striking arc The automatic in good working condition and the at the SHUNT at the Positive out idle system functions normally connections are tight Make sure put stud Check lead 2045 and when using auxiliary power the work clamp is attached to 2065 for continuity from the shunt Welding and auxiliary outp
196. poor with exces sive spatter The arc heat can be controlled and maintained normal ly the auxiliary output is normal and the engine operates normally POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS Check the position of the WELD MODE selector switch The switch should positively snap into each mode position and should not feel gritty or get stuck between posi tions The ARC CONTROL may be set too high The output control may be set too high for the electrode being used Check that the electrode is of good quality dry and free from contamination Try using some Lincoln Electrode and setting the machine per Lincoln s recommen dation If shielding gas is used check that the gas and gas flow are correct Check for damaged pinched or leaking gas lines Check for proper work and elec trode leads and connections size length coils or bad connections RECOMMENDED COURSE OF ACTION Check that plug P 7 is fully seated into the weld control P C board Socket See Control Inner Connection diagram Check for corroded dirty or dam aged Molex terminals in plug P 7 also check for similar problems in socket J 7 on the weld control P C board Check the wiring between the con trol P C Board and the mode switch Look for poor crimp and solder connections as well as damaged wiring or insulation See wiring diagram Perform the The Weld control P C Board may be faulty Check that the weld circuit
197. prong plugs For connection of Lincoln equipment with NEMA 6 50 Plug K1858 1 SERVICE INDICATOR KIT Provides a GO NO GO visu al indication of air cleaner element useful service life Filter service based on restriction readings allows the longest life possible from the filler and best engine protection K2679 1 COLD WEATHER HEATER AND TARP KIT For engine starting and operation in extreme cold weather conditions down to 40 F 40 C with the use of OW40 synthetic oil and arctic diesel fuel includes 120VAC engine block heater and radiator grill tarp ACCESSORIES EE WIRE FEEDER OPTIONS K449 LN 25 Includes internal contactor for across the arc operation no control cable Provides cold electrode until gun trigger is pressed Includes gas solenoid K1870 1 LN 15 Across the Arc Wire Feeder Portable lightweight compact CC CV unit for flux cored and MIG welding Includes Gas Solenoid adjustable flow meter and internal contactor For 10 15 Ib 4 5 6 8kg spools Magnum Gun and Magnum Gun Connector Kit are required for gas shielded welding Innershield Gun is required for gas less welding K126 2 Magnum 350 Innershield Gun K1802 1 Magnum 300 MIG Gun for LN 25 K470 2 Magnum 300 MIG Gun for LN 15 Includes Connector Kit K466 10 Connector Kit for LN 15 K470 2 K1500 1 Gun Receiver Bushing for LN 15 amp K126 2 K487 25 Magnum SG Spool Gun Hand held semiautomatic wire feeder Requires SG Control Modu
198. put terminals HS 02 gt 9 cic 5 Slo c SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC 400 LINCOLN TROUBLESHOOTING 4 REPAIR OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND REPLACEMENT 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing and replacing the output rec tifier bridge and the choke the Vantage 400 MATERIALS NEEDED Miscellaneous hand tools Electrical joint compound Dow Corning Return to Section TOC Return to Master TOC OO IHS ojeg O0 Ola gt 9 cic 5 5 c Return to Section TOC Return to Master TOC 400 LIN
199. r from the battery and open the engine access door on the left side of the machine VANTAGE 400 LINCOLN 2 F 36 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 37 TROUBLESHOOTING amp REPAIR BRUSH AND SLIP RING SERVICE PROCEDURE Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure provides guidance in testing and maintaining the brush and slip ring sys tem MATERIALS NEEDED Volt Ohmmeter Miscellaneous hand tools 500 or 600 grit emery cloth 180 grit sand paper 400 LINCOLN 8 F 37 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 cc g
200. ric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 400 LINCOLN dad TROUBLESHOOTING amp REPAIR et CASE COVER REMOVAL AND REPLACEMENT PROCEDURE 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 8 TEST DESCRIPTION 5 This procedure will aid the technician the removal replacement of the case sheet 3 5 metal covers 5 5 MATERIALS NEEDED ss 3 8 wrench 1 2 wrench OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC 400 LINCOLN 8 dim TROUBLESHOOTING amp REPAIR mee CASE COVER REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 1 DOOR REMOVAL Return to Section TOC Return to Master TOC Lift Bale Seal PA
201. s Place idle switch in the HIGH position Place the mode switch in the CC STICK posi tion 5 Place the Welding Terminal switch in the REMOTELY CONTROLLED position 6 Start the engine and allow it to stabilize at high idle RPM 7 Check for 80 to 100 VDC at terminals B1 to B2 and B4 to B5 of the chopper module 11 See wiring diagram and figure 1 8 If the correct DC voltage is not present at ter minals B1 to B2 and B4 to 5 check for 12 damaged conductors or faulty connections between the chopper module the output recti fier and the stator weld winding See Figure F 17 See the wiring diagram Perform the and the If the correct voltage is present at terminals B1 to B2 and B4 to B5 of the chopper mod ule check for DC voltage at the chopper mod ule terminals B2 to B3 and B5 to 6 If sig nificant voltage is present disconnect leads 23 and 25 from the chopper module PC board If voltage is still present the copper module is shorted and should be replaced If the voltage drops to 0 VDC after the 23 and 25 leads have been disconnected the control PC board is driving the chopper module when it should not be doing so Reconnect the 723 and Z25 leads and perform the Weld Control Board Gate Drive Test Heconnect leads 23 and 25 and place the Welding Terminal switch in the WELD TERMI NALS ON position Check for about 58 VDC between Chopper Module Terminals B2
202. s been broken partic ularly iron powder and low hydrogen electrodes This cone will need to be broken off in order to have the metal core of the electrode make contact E6010 Push Twist in Joint Lift E7018 E7024 Push Rock Back and Forth in Joint Lift Once the arc is started normal welding technique for the application is then used For other electrodes the above techniques should be tried first and varied as needed to suit operator preference The goal for successful starting is good metal to metal contact For indicator light operation see Table B 1 DOWNHILL PIPE Welding This slope controlled setting is intended for out of position and down hill pipe welding where the oper ator would like to control the current level by changing the arc length 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 o Return to Section TOC Return to Master TOC E THEORY OF OPERATION E The OUTPUT CONTROL dial adjusts the full output range for pipe welding The ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or more forceful digging arc crisp Increasing the number from 10 soft to 10 crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful d
203. s performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION If the machine output is low or high this test will determine whether the engine is operat ing at the correct speed RPM during both HIGH and LOW idle conditions You can check using a strobe tach a frequency counter or a vibratach Directions for adjusting the throttle to the correct RPM are given MATERIALS NEEDED Miscellaneous hand tools and metric wrench set High visibility marker Strobe tach frequency counter or vibratach 400 LINCOLN 8 F 29 Return to Section Return to Master TOC Return to Section TOC HS 02 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST CONTINUED FIGURE F 4 STROBE MARK LOCATION STROBE TACH MARK TEST PROCEDURE Strobe Tach Method Turn the engine off open the top and
204. s started and running the 12 VDC battery voltage is tm IGBT ln 2240 10 3d AUXILIARY AUX t CURREN TORROID WORK THREE PHASE TERMINAL RECTIFIER ELECTRODE TERMINAL VRD FEEDBACK pie SWITCH SIGNAL OFF m AOPUUrmImIiT VOLT FEEDBACK POWER TO CONTROL BOARD VOLTMETER AMMETER R IT PROCESS RANGE CONTROL CONTROL SELECTOR 42 VAC TO 14 PIN AMPHENOL FOR WIRE FEEDER v AUX FEEDBACK 20VAC RECEPTACLED 2 LOW IDLE COMMAND fed through the pull coil PC board to the rotor field coil via a brush and slip ring configuration This excitation or flashing voltage magnetizes the rotor lamination This rotating magnet induces a voltage in the station ary windings of the main alternator stator The stator houses a three phase weld winding a 120 240VAC single phase auxiliary winding and a 42VAC wire feed er power winding The engine alternator supplies charging current for the battery circuit Peripheral board monitors the engine sensors and will shut the engine off in the event of low oil pressure engine over temperature malfunc tion of the engine s alternator system or a low fuel con dition The idler solenoid is mechanically connected to the engine s throttle linkage If no welding or auxiliary current is being drawn from the Vantage 400 the Coil board activates the idler solenoid which then brings the engine to a low idle state When
205. see engine oper ation manual OR engine service items decal OR below Replace and tighten the oil filler cap secure ly Push oil drain hose and valve back into unit re con nect negative battery cable and close doors and engine top cover before restarting unit Wash your hands with soap and water after handling used motor oil Please dispose of used motor oil in a man ner that is compatible with the environment We suggest you take it in a sealed container to your local service station or recycling center for reclamation DO NOT throw it in the trash pour it on the ground or down a drain Use motor oil designed for diesel engines that meets requirements for service classification CC CD CE CF CF 4 CG 4 or CH 4 ACEA E1 E2 E3 Always check the API service label on the oil container to be sure it includes the letters indicated Note An S grade oil must not be used ina diesel engine or damage may result It IS permissible to use an oil that meets S and C grade service classi fications SAE 10W30 is recommended for general all tempera ture use to 104F 15C to 400 See engine owner s manual for more specific informa tion on oil viscosity recommendations OIL FILTER CHANGE Drain the oil Remove the oil filter with an oil filter wrench and drain the oil into a suitable container Discard the used fil ter Note Care should be taken during filter removal to not disrupt or damage in any way the
206. t 9 cic 5 Slo c Return to Section TOC Return to Master TOC F 38 TEST PROCEDURE 1 Perform the Case Cover Removal Procedure 7 2 Examine brushes and slip rings The slip rings F 38 TROUBLESHOOTING amp REPAIR BRUSH AND SLIP RING SERVICE PROCEDURE CONTINUED FIGURE F 8 BRUSH amp SLIP RING LOCATIONS SLIP RINGS 9 S S brush holder and brushes should be clean and free from oil or grease The brushes should be making good continuous contact with the slip rings 1 The brushes should be of sufficient length and have adequate spring tension Generally the brushes should be replaced if either brush has less than 1 4 remaining before it reaches the end of its travel Spring tension should be suffi cient to hold the brushes firmly against the slip rings 1 The brushes should be removed from the brush holder and examined The terminals should be clean The shunt braided lead connecting the carbon brush to the terminal should be in good condition and firmly connected to the carbon brush and to the connection terminal If the slip rings are discolored display evidence of excessive sparking or the brushes have worn prematurely these may be signs of a grounded or shorted rotor Perform the rotor resistance 2 Check for evidence of sticking brushes Sticking brushes will normally result in the slip rings being pitted and discolored from excessive arc 3 ing An
207. t meets classification CG 4 or CH 4 for diesel engines Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Check the oil level every four hours of running time during the first 50 running hours Refer to the engine Operator s Manual for specific oil recommendations and break in information The oil change interval is dependent on the quality of the oil and the operating environment Refer to the Engine Operator s Manual for more details on the proper service and mainte FUEL nance intervals USE DIESEL FUEL ONLY m A WARNING Fill the fuel tank with clean fresh fuel The capacity of the tank is 15 gals 57 Itrs When the fuel gauge reads empty the tank contains approximately 2 gals 7 6ltrs of reserve fuel A WARNING NOTE A fuel shut off valve is located on the pre filter sediment filter Which should be in the closed position when the welder is not used for extended periods of time ENGINE COOLING SYSTEM WARNING Air to cool the engine is drawn in the side and exhausted through radiator amp case back It is important that the intake and exhaust air is not restricted Allow a minimum clearance of 1ft 0 6m from the case back and 16in 406mm from either side of the base to a vertical surface CAUTION BATTERY CONNECTION Use caution as the electrolyte is a strong acid that can burn skin and damage eyes The VANTAGE 400 is s
208. t of the equipment frame Keep touching the frame to prevent Static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC board must be either conductive anti static or static disipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag lf the PC board uses protective shorting jumpers don t remove them until installation is complete f 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 symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks a
209. t terminal Check that the wire feeder s work sensing lead is properly connected to the work piece and is in good condition The wire feeder may be defective Check the circuit breaker CB5 Heset if tripped Make sure the run stop switch is in the RUN position Check for loose or faulty battery cable connections See wiring dia gram The battery may be low or faulty If the battery will not accept a charge replace it The starter or starter solenoid may be faulty have the engine serviced at an authorized engine repair shop F 13 RECOMMENDED COURSE OF ACTION Use a voltmeter to check for the presence of about 58 VDC open circuit voltage OCV across the output studs of the machine If the OCV is low there may be a problem with the mode switch Perform the If there is no OCV see the trou bleshooting sections for output in any mode Check the wiring and the connec tions at the starter motor glow plug button CB5 circuit breaker run stop switch and the start button See wiring diagram Check the chassis ground connections between the engine block and the negative battery terminal Place the run stop switch to the RUN position Press the start button while checking for voltage between a good clean chassis ground con nection and lead 7231 at the starter solenoid See the wiring diagram If not voltage is present check the start button the run stop switch and the CB5 circuit ground brea
210. t the voltmeter probes to pins I lead 41A and lead 42A of the 14 pin Amphenol See Figure F 11 Start the engine and run it at high idle 1860 to 1890 RPM The AC voltage reading should be between 40 and 50 VAC If these voltage readings are not within the specified limits check for a tripped or defective circuit breakers loose connections or broken wires between the test points and the stator windings If there no wiring problems and the circuit breakers are not tripped or defec tive the stator is defective and should be replaced To test the three phase weld winding 1 Locate weld winding leads W1 W2 and W3 where they connect to the three phase output bridge rectifier See Figure F 12 See wiring diagram Start the engine and run it at high idle 1860 to 1890 RPM Check for about 60 to 65 VAC from leads W1 to W2 W2 to W3 and W1 to W3 If these voltage readings are not within the specified limits check for loose connections or broken wires between the test points and the stator windings If there are no wiring prob lems the stator is defective and should be replaced These values are maximum for a cold machine 400 LINCOLN F 54 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return
211. tator Engine Protection E 2 Weld Windings Rectifier Chopper Modules and Feedback E 3 Weld Control Board usur x o RR ge y E E de Rex x e des E 4 Insulated Gate Bipolar Transistor IGBT Operation E 5 Pulse Width Modulation E 6 Chopper Technology Fundamentals E 7 9 v 9 a FIGURE E 1 VANTAGE 400 BLOCK LOGIC DIAGRAM WORK THREE PHASE TERMINAL RECTIFIER O ELECTRODE TERMINAL 5 bo 9 STATOR gt te E E 1 po B ee 9 VOLTAGE REDUCTION AN VRD d PWM Q pe mon SIGNAL 8 GLOW PLUGS ES E 8 G St 5 c m CONTROL as MECHANICAL ROTATION STARTER ENGINE ns BOARD VOLTMETER RINGS AMMETER OO ARC OUTPUT PROCESS RANGE OIL PRESS CONTROL CONTROL SELECTOR RUN STOP SWITCH RUN 42 14 PIN AMPHENOL FOR WIRE FEEDER 10 39 TEMP AUXILIARY AUX 3 BATTERY K CURREN 240 TORROID RECEPTACLE O AUX FEEDBACK ROTOR 120VAC FLASH RECEPTACLED 2 Z LOW IDLE COMMAND gt ENGINE PROTECTION IDLER CONTROL 9 ENGINE v P C BOARD c TROUBLE LIGHT A
212. tch See the wiring diagram If the PWM signal remains after the welding terminal switch has been placed in the REMOTELY CONTROLLED position check the voltage between leads 2 P1 4 and 4 P1 3 at the control PC board If the voltage reads O or very near 0 Check for damaged insulation at leads 2 and 4 also check for a shorted welding terminal switch or damaged or contaminated Amphenol receptacle See the wiring dia gram If the above wiring and components are undamaged and functioning properly the con trol PC board is defective and should be replaced If the voltage reads about 5 VDC and the PWM signal remains the control PC board is defective and should be replaced Perform the Case Cover Replacement Procedure VANTAGE 400 LINCOLN 2 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 71 TROUBLESHOOTING amp REPAIR F 71 WELD CONTROL FEEDBACK TEST 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
213. th your welder It includes important safety precautions detailed engine start ing operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill A Donottouch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 2 4 MOVING PARTS can injure not operate with doors open or guards off Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual Only qualified personnel should install use or service this equipment VRD VOLTAGE REDUCTION DEVICE The VRD feature provides additional safety in the CC Stick mode especially in an environment with a higher risk of electric shock such as wet areas and hot humid sweaty conditions The VRD reduces the OCV Open Circuit Voltage at the welding output terminals while not welding to less than 32V DC when the resistance of the output circuit is above 2000 ohms The VRD requires that the welding cable connections be kept in good electrical condition because poor connections will contribute to poor starting Having good electrical con nections also limits the possibility of other safety issues such as heat generated damage burns and fires The machine is shipped with the VRD s
214. the P1 plug so it can not make electrical contact with any other conductor or chassis ground Perform the following resistance tests shown in the following table Be very careful not to dam age or spread any of the connection pins in the Amphenol receptacle See Table F 4 If the measured resistance does not meet val ues specified check for damage dirt or mois ture contamination in the Amphenol recepta cles and the P1 Molex plug Check for dam aged or grounded wiring 7 9 10 If the resistance values found to be too low due to contaminated electrical components in the Amphenol harness assembly Try removing the contamination and drying the components completely If the resistance values are still too low replace the Amphenol harness assembly If the values are incorrect for the last two tests in the table Pin C to Pin D check the welding terminal switch and the wiring connected to that switch See the wiring diagram Repair any faulty connections or replace the switch if necessary Plug P1 back into the Control Pc board Perform the Case Cover Replacement 400 LINCOLN F 80 TROUBLESHOOTING 4 REPAIR REMOTE RECEPTACLE RESISTANCE TEST continued TABLE F 4 AMPHENOL RESISTANCE TEST OHMMETER OHMMETER READING SWITCH SETTING CONNECTION Return to Section TOC Return to Master TOC x
215. tion otart the engine and let it run and stabilize at high idle RPM Locate plug P3 on the control PC board See Control Inner Connection diagram Use the frequency counter to test for 20 2 PWM gate signal between leads 723 4 P3 10 and 25 P3 9 If the 20KHz gate signal is present place the weld terminals switch in the REMOTELY CONTROLLED position The gate signal should turn off If the 20 KHz gate signal responds as described above this test is complete If there is no 20 KHz gate signal test for the presents of 80 to 100 VDC at leads 13 8 to 14 P3 16 of the weld control PC board If voltage is very low or not present check leads 13 and 14 for faulty or damaged wiring or connections between the control PC board and the chopper module Test for 80 to 100 VDC at the terminals where the 713 and 714 leads connect to the chopper module See the wiring diagram If there is no voltage at the chopper module perform the chopper module function test 20 F 70 If the 80 to 100 VDC supply voltage is present at the weld control PC board but there is no PWM gate signal check the voltage between leads 2 P1 4 and Z4 P1 3 See figure 1 The voltage should be about 0 VDC If about 5 VDC is detected the welding termi nal control circuit is open Check for dam aged leads for faulty connections at leads 2 and 4 also check for a defective welding ter minal swi
216. tive cable first then the positive cable before you attach the charger leads After the battery is charged reconnect the positive bat tery cable first and the negative cable last Failure to do so can result in damage to the internal charger com ponents Follow the instructions of the battery charger manufac turer for proper charger settings and charging time SERVICING OPTIONAL SPARK ARRESTOR Clean every 100 hours WARNING MUFFLER MAY BE HOT e ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTER DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o c Return to Section TOC Return to Master TOC adi MAINTENANCE D WELDER GENERATOR MAINTENANCE STORAGE Store 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 BRUSH REMOVAL AND REPLACEMENT It s normal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary CAUTION not attempt to polish slip rings while the engine is running WARNING Service and Repair should only be performed by Lincoln Electric Fact
217. to Master TOC F 55 TROUBLESHOOTING amp REPAIR STATOR SHORT CIRCUIT amp GROUND TEST Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if there are undesirable electrical connections between the stator windings and chassis ground or between individual windings within the stator This test should be performed if flashing voltage is present at the rotor slip rings Rotor resistance field bridge rectifier field capacitor and all associated wiring are proven to be good but the stator output voltage fails to build up to normal levels or is too high in one or more but not all of the windings MATERIALS NEEDED Miscellaneous hand tools Ohm meter 400 LINCOLN 8 F 55 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02
218. to the Vantage 400 by carefully retracting the disassembly proce dure steps in reverse order Keep the following 2 Using a 5 16 wrench remove the flex plate special points in mind as you proceed bolts lock washers and four blower segments See Figure F 25 1 INSTALL ROTOR Support the rotor with the WARNING hoist Install the blower segments and flex plate The rotor will be free to fall when the bolts are to the engine My wheel removed 2 INSTALL STATOR Be sure the engine is blocked securely and the stator is supported by the hoist Install the stator to the engine with the eight bolts and lock washers Install the fan blade making sure that it faces the proper direction with the fan nut and four cap screws 3 Using the hoist carefully remove the rotor and flex plate assembly 3 Check the air gap for 012 minimum 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 Slo Return to Section TOC Return to Master TOC F 103 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 29 ROTOR REMOVAL amp REPLACEMENT FLEX PLATE BLOWER SEGMENT 4 PROCEDURE 1 Remove the screws and disc clamping bars from the rotor coupling disc and remove the rotor NOTE earlier machines used thr
219. trical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help determine if the chopper module is functioning properly and receiving the correct input from the output rectifier and control PC board This test can only provide meaningful results if the machine is producing normal AC aux output MATERIALS NEEDED Miscellaneous hand tools Digital Multi meter Frequency counter or digital multi meter with frequency counter function Wiring diagram Control Inner Connection diagram 400 LINCOLN 8 61 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC HS 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 62 F 62 TROUBLESHOOTING amp REPAIR CHOPPER MODULE FUNCTION TEST CONTINUED FIGURE F 16 CHOPPER MODULE CONNECTIONS 23 25 NY LED1 B1 B2 B3 ee HL W6 NC e ec HL W4 Les ST EX L LED IEE ee 1204 LED4 2 PWM Signal W11 HL W5 HL W8 LED3 B4 B5 B6 Chopper Working 5113 5114 Voltage from HL W9 Rectifier SL302 SL301 TEST PROCEDURE 1 Perform the Case Cover 9 2 Make sure that there is nothing plugged into either of the Amphenol receptacle
220. turn to Section TOC Return to Master TOC din TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES A WARNING N ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION 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 Ifthe problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame ATTENTION Static Sensitive Devices Handle only at Static Safe Workstations If you don t have a wrist strap touch an un painted grounded par
221. turn to Section TOC Return to Master TOC Check Field rectifier and capacitor Perform the Rotor Voltage Test Perform the Stator Voltage Test OO O HS 02 gt 9 cic 5 5 o c CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 02 gt 9 cic 5 5 o c Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS No welding output in any mode The auxiliary output is normal The engine operates normally POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Place the Welding Terminals switch in the WELD TERMINALS ON If the problem is solved and there is a control cab e wire feed er amptrol or arc start switch con nected the fault may lie in the above attached accessories If the correct OCV is present at the weld output terminals check the welding cables connectors work clamp electrode holder etc For loose or faulty connections di TROUBLESHOOTING amp REPAIR dii REC
222. ual for oil recommendations 2 Consult Engine Operators Manual for additional maintenance schedule information 3 Fill slowly Ensure correct quantity is used Above operations to be carried out by trained personnel with reference to the workshop manual where necessary These preventive maintenance periods apply to average conditions of operation If necessary use shorter peroids 526354 VM Return to Section TOC Return to Master TOC VANTAGE 400 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO IHS ojeg O0 gt 9 cic 5 5 Return to Section TOC Return to Master TOC Des MAINTENANCE nii ENGINE OIL CHANGE Drain the engine oil while the engine is warm to assure rapid and complete draining It is recommended that each time the oil is changed the oil filter be changed as well Be sure the unit is off Disconnect the negative bat tery cable to ensure safety Locate oil drain hose and valve in bottom of base and pull through the hole in the battery access panel on the welder Open oil drain valve by lifting up spring loaded lever and rotate 909 counterclockwise Pull to open and drain the oil into a suitable container for disposal Close the drain valve by rotating lever 909 clockwise Re fill the crankcase to the upper limit mark on the dipstick with the recommended oil
223. ually move the solenoid to Diagram the low idle position The solenoid plunger should hold this position until the voltage is Using the volt ohmmeter check the pull in coil removed See Figure F 6 resistance pins 3 and 4 black wire to white wire The normal resistance IS less than 0 2 7 f either coil does not operate as described ohms Check the hold in coil resistance pins check for mechanical restrictions or other prob 3 and 2 black wire to red wire The normal lems with the linkage resistance is approximately 11 ohms Check the resistance between pin 3 black wire and 8 If the linkage is intact and the solenoid does a clean unpainted chassis ground The resis not operate correctly when the 12VDC is tance should be very high 500 000 Ohms or applied the solenoid may be faulty Replace more If any of the above resistance values Re connect idle solenoid and replace any pre are incorrect the solenoid may be faulty viously removed cable ties Replace See Figure F 6 10 If finished testing close the engine service access door VANTAGE 400 LINCOLN F 34 ENGINE PROTECTION IDLE CONTROL P C B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 35 TROUBLESHOOTING amp REPAIR ENGINE ALTERNATOR TEST Service and repair shoul
224. uch electrically live parts or service this equipment 14 PIN AMPHENOL 6 PIN AMPHENOL OPTIONAL K444 1 REMOTE CONTROL LN 25 WIRE FEEDER WORK CLIP LEAD TO WORK TO WORK ELECTRODE CABLE N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE N C PLACE THE MODE SWITCH IN THE CV WIRE POSITION N D PLACE THE WELDING TERMINALS SWITCH IN THE WELD TERMINALS ON POSITION PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 10 27 2000 524787 2 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC HS 010 0 gt 9 cic 5 Slo c Return to Section TOC Return to Master TOC Return to Master TOC ACCESSORIES ii ENGINE WELDERS LN 25 WITH K624 1 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM WARNING Do not operate with panels open e Keep guards in place e Disconnect NEGATIVE Battery lead Keep away from moving parts before servicing e Only qualified personnel should install use e Do not touch electrically live parts or service this equipment 14 PIN CABLE PLUG K626 XX INPUT CABLE ASSEMBLY ELECTRODE
225. ure F 2 and the Wiring Diagram INSULATED PLIERS Fee INSULATED GLOVES NEVER USE A SHORTING STRAP TO DIS CHARGE CAPACITORS the Lincoln recom mended resistor or an equivalent resistor is used the capacitors can be discharged by holding the resistor with insulated pliers and using the resistor terminals to bridge Chopper Module terminals B1 to B2 and 4 to 5 DO NOT TOUCH THE TER MINALS OR METAL PARTS OF THE PLIERS WITH YOUR BARE HANDS Hold the resistor in place for about 10 seconds If another type of resistor is used jumper leads may need to be attached to the resistor The leads can then be used to connect terminals B1 to B2 and B4 to B5 4 Using the volt ohmmeter check the voltage across B1 and B2 then B4 and B5 It should be zero volts in both cases 400 LINCOLN F 26 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 27 TROUBLESHOOTING amp REPAIR F 27 FUEL SHUTDOWN SOLENOID TEST 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
226. urn to Section Return to Master TOC Return to Section TOC OO IHS ojeg O0 gt 9 cic 5 5 Return to Section TOC Return to Master TOC Return to Master TOC INSTALLATION A4 WARNING Lift only with equipment of ade quate lifting capacity sure machine is stable when lifting Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder FALLING EQUIPMENT can cause injury Do not lift machine if lift bail is damaged Do not operate machine while suspended from lift bail HIGH ALTITUDE OPERATION At higher altitudes output derating may be necessary For max imum rating derate the machine 2 596 to 3 596 for every 1000 ft 305m Due to new EPA and other local emissions regulations modifications to the engine for high altitude are restricted within the United States For use above 6000 ft 1828 m an authorized Perkins engine field service shop should be contacted to deter mine if any adjustments can be made for operation in higher ele vations HIGH TEMPERATURE OPERATION At temperatures above 104 F 40 C Welder output derating is necessary For maximum output ratings derate the welder out put 2 volts for every 18 F 10 C above 104 F 40 C COLD WEATHER STARTING With a fully charged battery and the proper oil the engine should start satisfactoril
227. urn to Section TOC Return to Master TOC FORWARD BIAS Low Resistance C REVERSE BIAS High Resistance DC REVERSE BIAS High Resistance DC REVERSE BIAS High Resistance DC 1 REVERSE BIAS High Resistance DC AC2 REVERSE BIAS High Resistance DC REVERSE BIAS High Resistance 11 Reconnect all leads 12 Perform the Case Cover replacement Procedure D DC D 1 JJ D 3 2 s 2 2 ct 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC VANTAGE 400 LINCOLN 2 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OO O HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC F 61 TROUBLESHOOTING amp REPAIR CHOPPER MODULE FUNCTION TEST 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 elec
228. uts are clean bare metal to J 6 on the Weld Control Board normal when the idle switch is in Check the pins and connections at the HIGH IDLE position J 6 and J on the Weld Control Board The weld control P C Board may be defective The engine will not go to high idle Check that the welding cables and The weld control P C Board may when attempting to strike and arc the auxiliary power lead connec be defective or when a load is applied to any of tions are tight the auxiliary power receptacles The engine goes to low idle but Make sure there are no auxiliary The Idler solenoid linkage may be will not stay low idle loads on either the weld terminals damaged or out of adjustment or the auxiliary receptacles Make sure the solenoid plunger is Check that the welding cables and able to fully ease against the inter the auxiliary cables and the auxil nal stop of the solenoid coil iary power lead connections are assembly tight and that the insulation is not The low idle RPM may be too low damaged Perform the The solenoid hold coil power cir cuit may be defective Perform the IDLER SOLENOID TEST The solenoid hold coil power cir cuit may be faulty Check wiring and connections on lead 210A and lead 215 The weld control PC Board may be defective CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Elect
229. washers from the fuel tank mounting U bolts See Figure 4 Using a 3 8 wrench remove leads 229 white F 19 and 5J from the fuel level sensor See Figure F 19 Label the leads for reassembly 8 Carefully remove the U bolts and lift the fuel tank from the machine Return to Section TOC Return to Master TOC 400 LINCOLN TROUBLESHOOTING 4 REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE 20 DOOR REMOVAL Return to Master TOC 200 200A 6 i 919 p gt 5H 3 i 201 FILTER FIELD DIODE CAPACITOR RECTIFIER BRIDGE is PROCEDURE 01 9 Disconnect plug J30 the right front side See 11 Label and remove leads 5H 200 200A Figure 20 201A 5H from the field bridge rectifier See 2159 Figure F 20 5 2 10 Using the slot head screw driver disconnect leads 200B 200A and 201A from the filter capacitor Label the leads Return to Section TOC Return to Master TOC VANTAGE 400 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC IHS ojeg WO gt 9 cic 5 Return to Section TOC Return to Master TOC diis TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REP
230. witch in the Off position To turn it On or Off the engine Off Disconnect the negative battery cable Lower the control panel Place the VRD switch in the On or Off position With the VRD switch in the On position the VRD lights are enabled 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 STACKING 400 machines cannot be stacked ANGLE OF OPERATION Engines are designed to run in the level condition which is where the optimum performance is achieved maximum angle of continuous operation is 25 degrees in all directions 35 degrees Intermittent less than 10 minutes continuous in all directions 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 amount spec ified LIFTING 400 weighs approximately 1345lbs 611kg with a full tank of fuel 1230lbs 559kg less fuel A lift bail is mounted to the machine and should always be used when lifting the machine 400 LINCOLN 8 Ret
231. work and ground Always wear dry insulating gloves Always operate the welder with the hinged door closed and the side panels in place Read carefully the Safety Precautions page before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Instruction Manual GENERAL DESCRIPTION The 400 is a diesel engine powered DC multi process welding power source and 120 240 volt AC power generator The engine drives a generator that supplies three phase power for the DC welding cir cuit single phase and Three Phase power for the AC auxiliary outlets The DC welding control system uses state of the art Chopper Technology for or welding performance The Vantage 400 is fitted with selectable VRD Voltage Reduction Device The VRD operates in the CC Stick mode reducing the OCV to lt 13 volts increasing operator safety when welding is performed in environments with increased hazard of electric shock FOR AUXILIARY POWER Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings providing no welding current is being drawn ENGINE OPERATION Before Starting the Engine sure the machine is on a level surface Open side engine door and remove the engine oil dipstick and wipe it with a clean cloth Reinsert the dipstick and
232. y be open or the brushes may be faulty or not mak ing proper contact with the slip rings Perform the Rotor Resistance Test and Slip Ring Service Procedure If the voltage measures about 3 to 5 VDC the generator is not building up to normal out put even though the flashing circuit appears to be functioning normally This condition could be caused by one of several failed compo nents or connections Continue with the fol lowing test Check the field bridge rectifier and capacitor also check the wiring and terminals connecting them See the wiring diagram Perform the Rotor Resistance Test Perform the Stator Short Circuit and Ground When the Stator short circuit and ground test has been completed reconnect leads 6 and 5H to the field bridge rectifier 03 All other stator leads should remain disconnected and isolated at this time 16 Be sure that there are no leads of any kind across any of the stator windings except the 6A 5H winding Examine stator wiring for damage pinched leads chafed insulation etc If necessary disconnect and isolate the stator output leads as close to the starter as possible See wiring diagram 17 All of these disconnected leads should be insu lated and or positioned so they cannot come in contact with any other wiring or chassis ground and cannot be damaged by moving parts when the engine is running 18 Re start the machine and measure the rotor voltage 19 If rotor volt
233. y down to 15 F 26C If the engine must be frequently started at or below O F 18 C it may be desirable to install cold starting aides The use of No 1D diesel fuel is recommended in place of No 2D at tempera tures below 23 F 5 C Allow the engine to warm up before applying a load or switching to high idle Note Extreme cold weather starting may require longer glow plug operation A WARNING Under no conditions should ether or other starting fluids be used with this engine TOWING Use a recommended trailer for use with this equipment for road in plant and yard towing by a vehicle 1 If the user adapts a non Lincoln trailer he must assume responsibility that the method of attachment and usage does not result in a safety hazard or dam age the welding equipment Some of the factors to be consid ered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework 3 Proper placement of the equipment on the trailer to insure sta bility side to side and front to back when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use i e travel speed roughness of sur face on which the trailer will be operated environmental con ditions like maintenance 5 Conformance with federal state and loc
234. y when welding POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS The load on the auxiliary recepta cle may be too low The automatic idle system will not function reliably if the low is less than 100 Watts The device connected to the auxil iary power may be defective try another device Make sure the connections to the auxiliary device are tight oome device are designed to sense for adequate input power Product of this type may not turn on due to low voltage and frequen cy of the idling machine If this happens the current draw will like ly be insufficient to activate the automatic idle system Device of this type may require that the Idler switch be in the HIGH IDLE posi tion F 19 RECOMMENDED COURSE OF ACTION Measure the resistance of toroidal current sensor Measure between ZP 3 and ZP 4 the resistance should be 4 1 Ohms If the sensor is shorted or open replace it The control board may be bad Check that leads 3 and 6 properly routed through the toroidal current sensor Each lead must have two turns and must pass through the sensor in the opposite directions See wiring diagram The leads should be wrapped tightly and tie wrapped in place Check the toroidal current sensor for any signs of damage Check leads 260 and 261 for poor connections and damage to the conductors and insulation between the toroid current sensor and the P3 connector in the con trol PC board Un
235. you proceed Call 1 888 935 3877 DESCRIPTION This test will check the Output Control potentiometer Arc Control potentiometer Mode owitch and associated wiring for damage proper operation tracking and grounds MATERIALS NEEDED Digital Ohmmeter Wiring Diagram Control Inner Connection Diagram Return to Section TOC Return to Master TOC HS 0910 02 gt 9 cic 5 5 c Return to Section TOC Return to Master TOC 400 LINCOLN 8 diii TROUBLESHOOTING amp REPAIR CONTROL AND MODE SWITCH RESISTANCE TEST e e CONTINUED 5 5 TEST PROCEDURE olz 1 Turn the engine off 7 f the resistance is lower than 500k Ohms replace the potentiometer and mode switch Perform the Case cover Removal Procedure plug and lead assembly or replace the defec Unplug P7 from control board see control tive component within the assembly See Inner connection diagram and visually check wiring diagram the plug and attached wiring for damage cor Perform the resistance tests per Table F 3 rosion improperly seated or damaged contact pins P7 will remain unplugged for following 2 If the resistance readings are not as specified test in the table replace the potentiometer and ME mode switch plug and lead assembly or Set the mode switch in the CC Stick position replace the def
236. zontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC 400 LINCOLN TROUBLESHOOTING 4 REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM WIRE MAX CONTROL POT HIGH IDLE NO LOAD Return to Section TOC Return to Master TOC O volts 50V 5ms Return to Section TOC Return 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 are connected at weld output terminals HS 02 gt 9 cic 5 Slo c SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC 400 LINCOLN 8 TROUBLESHOOTING amp REPAIR 58 NORMAL CIRCUIT VOLTAGE WAVEFORM WIRE CV MACHINE LOADED TO 300 AMPS AT 28 VOLTS Return to Section TOC Return to Master TOC volts Return to Section TOC Return to Master TOC This is the typical DC voltage gener ated from a properly operating machine Note that each vertical divi sion represents 20 volts and that each horizontal division represents 1 millisecond in time The machine was loaded with a resis tance grid bank to 300 amps at 28 volts NOTE Scope probes are connected at weld out

Download Pdf Manuals

Related Search

Related Contents

Manuale d`uso Mimaki JV34-260  1 安全のために必ず守ってください  山岳トイレ技術分野における検討内容と実施状況  FUMAGRI OPP - Agrodirect  Journal Alès Agglo n°17 - Octobre 2014    オーディオ・クリエーター LE インストールガイド CPU  ライカ レーザーグラス （レーザー距離計用レーザー可視グラス） [ Leica  Philips CUCINA HR7633 User's Manual  Dell OptiPlex 9030 Todo en uno Manual del propietario  

Copyright © All rights reserved. Failed to retrieve file