Lincoln Electric VANTAGE 400 User Manual

Page 1
For use with machines having Code Numbers: 11186, 11462
VANTAGE 400
LINCOLN
ELECTRIC
RETURN TO MAIN MENU
Safety Depends on You
Lincoln arc welding and cutting equip­ment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE
OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANU­AL AND THE SAFETY PRECAU­TIONS CONTAINED THROUGH­OUT. And, most importantly, think
before you act and be careful.
VANTAGE
SVM182-A
April, 2011
®
400
View Safety Info View Safety Info View Safety Info View Safety Info
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Page 2
i i

SAFETY

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause can­cer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
___________________________________________________
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
VANTAGE® 400
Page 3
ii ii
SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
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. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
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 ven­tilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional pre­cautions are also required when welding on galvanized steel.
5. b. 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 expo­sure level should be checked upon installation and periodi­cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating prod­ucts.
vapors
to
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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
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.
5.f. Also see item 1.b.
VANTAGE® 400
Page 4
iii iii
SAFETY
WELDING and CUTTING SPARKS can cause fire or explosion.
6.a. 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.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f. 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.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
Remove fire hazards from the welding area.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode if damaged.
7.a. Use only compressed gas cylinders
If
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.
containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 5
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv­antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc­tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon­nement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.
VANTAGE® 400
1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Page 6
I I
RETURN TO MAIN MENU
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-528
VANTAGE® 400
Page 7
A-1 A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
TABLE OF CONTENTS - INSTALLATION SECTION
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
VRD (Voltage Reduction Device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Location and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Pre-Operation Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Muffler Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Welding Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Auxiliary Power Receptacles and Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Standby Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Premises Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
Connection of Lincoln Electric Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9, A-10
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 8
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - VANTAGE® 400 (K2410-1) (K2410-2)
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
PERKINS cu. in. (ltrs.) System
(K2410-1) 4 cylinder 135.6(2.2)
404C-22 32.7 HP High Idle 1880 starter (57 L)
1800 RPM
naturally aspirated Full Load 1800 cold crank amps)
(K2410-2) water cooled
404D-22 Diesel Engine Low Idle 1400 (87.1 x 92.5mm) W / Built in Regulator 8.0 Qts. (7.6L)
Bore x Stroke inch (mm)
3.43 X 3.64
12VDC Battery &
(Group 34; 650
65 Amp Alternator Radiator Coolant:
Fuel: 15 gal.
Oil: 8.45Qts. (8L)
RATED OUTPUT @ 104° F (40° C) - WELDER
Welding Process
DC Constant Current
DC Pipe Current
Touch-Start™TIG
DC Constant Voltage
Welding Output
Current/Voltage/Duty Cycle
400A / 36V / 100% 450A / 32V / 100%
300A / 32V / 100% 250A / 30V / 100% 400A / 36V / 100% 450A / 32V / 100%
Output Range
30 TO 500 AMPS
40 TO 300 AMPS 20 TO 250 AMPS
14 TO 36 VOLTS
Max. Weld OCV
@Rated Load RPM
60 Volts
2
RATED OUTPUT @ 104° F (40° C).- 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
1
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
35.94* in. 25.30 in 60.00 in. 913 mm 643 mm 1524 mm
1230 lbs. (559kg.)
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
ENGINE
LUBRICATION EMISSIONS FUEL SYSTEM GOVERNOR
Full Pressure (K2410-1) EPA Tier II Mechanical Fuel Pump, Auto air bleed system Mechanical with Full Flow Filter (K2410-2) EPA Tier
AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION
Single Element Automatic Idler Top outlet can be rotated. pressure & high engine
ENGINE WARRANTY: 2 years / 2000 hours, all non-electric components, 3 years major non-electric compo­nents . See Perkins warranty for details.
4 Interim Electric shutoff solenoid, Indirect fuel injector.
Low noise Muffler: Shutdown on low oil
Made from long life, aluminized steel. coolant temperature
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) 240VAC 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.
* To 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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 9
A-3 A-3
INSTALLATION
SAFETY PRECAUTIONS
LOCATION AND VENTILATION
WARNING
The welder should be located to provide an unrestrict-
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 electrode with skin or wet clothing.
• 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.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do 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.
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
VANTAGE® 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. The 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 spec­ified.
LIFTING
The VANTAGE® 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.
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 200Ω (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 con­nections also limits the possibility of other safety issues such as heat-generated damage, burns and fires.
The machine is shipped with the VRD switch in the “Off” position. To turn it “On” or “Off”:
• Turn 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 10
A-4 A-4
WARNING
• Lift only with equipment of ade­quate lifting capacity.
• Be 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 • Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
--------------------------------------------------------------------------------
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary. For max­imum rating, derate the machine 2.5% to 3.5% 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 deter­mine if any adjustments can be made for operation in higher ele­vations.
HIGH TEMPERATURE OPERATION
At temperatures above 104°F(40°C), Welder output derating is necessary. For maximum output ratings, derate the welder out­put 2 volts for every 18°F
COLD WEATHER STARTING:
(10°
C) above 104°F(40°C).
INSTALLATION
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 sta­bility 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 sur­face on which the trailer will be operated; environmental con­ditions; like maintenance.
5. Conformance with federal, state and local laws.
(1) Consult applicable federal, state and local laws regarding specific requirements for use on public high-
ways.
VEHICLE MOUNTING
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.
• Do not exceed maximum rated loads for compo­nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of vehicle.
• Follow vehicle manufacturer’s instructions.
------------------------------------------------------------------------
(1)
WARNING
With a fully charged battery and the proper oil, the engine should start satisfactorily down to -15°F(-26C°). If the engine must be frequently started at or below 0°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 tempera­tures 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.
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 non­Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard or dam­age the welding equipment. Some of the factors to be consid­ered are as follows:
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instruc­tions 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 over­fill.
• Wipe up spilled fuel and allow fumes to clear before starting engine.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 11
A-5 A-5
OIL
The VANTAGE® 400 is shipped with the engine crankcase filled with high quality SAE 10W-30 Oil that 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-
nance intervals.
FUEL
USE DIESEL FUEL ONLY
WARNING
• Fill the fuel tank with clean, fresh fuel. The capacity of the tank is 15 gals. (57 ltrs). When the fuel gauge reads empty the tank contains approximately 2 gals. (7.6ltrs.) of reserve fuel.
INSTALLATION
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 bat­tery with the correct polarity. (See Battery in Maintenance Section)
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 loca­tions where unarrested sparks may present a fire haz­ard. 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
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 & 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.
------------------------------------------------------------------------
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 for TIG welding, the K870 foot Amptrol or the K936-3 hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CV­WIRE modes and when a remote control is connected to the 6-pin Connector, the auto-sensing circuit auto­matically 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 OUT­PUT 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
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
The VANTAGE® 400 is shipped with the negative bat­tery cable disconnected. Make certain that the RUN­STOP 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" sock­et or wrench.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
NOTE: When a wire feeder with a built in welding voltage control is connected to the 14-pin connec­tor, do not connect anything to the 6-pin connec­tor.
----------------------------------------------------------------------
VANTAGE® 400
Page 12
A-6 A-6
ELECTRICAL CONNECTIONS
MACHINE GROUNDING
Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.)
To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must:
INSTALLATION
WELDING OUTPUT CABLES
With the engine off connect the electrode and work cables to the output studs. The welding process dic­tates the polarity of the electrode cable. These con­nections 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
WARNING
• Be grounded to the frame of the welder using a 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 con­nected to premises wiring such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the sec­tion entitled Standby Power Connections as well as the article on grounding in the latest National Electrical Code and the local code.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
0-100 Ft. (0-30 meters)
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
CABLE INSTALLATION
Install the welding cables to your VANTAGE® 400 as follows.
1. The engine must be OFF to install welding cables.
Cable Size for
400 Amps
60% Duty Cycle
2 / 0 AWG
2 / 0 AWG
3 / 0 AWG
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 alter­nate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.
WELDING TERMINALS
The VANTAGE® 400 is equipped with a toggle switch for selecting "hot" welding terminal when in the "WELD TERMINALS ON" position or "cold" welding terminal when in the "REMOTELY CONTROLLED" position.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 will 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
Page 13
A-7 A-7
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 recepta­cle.
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 (15­50R) 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 equiva­lent to volt-amperes at unity power factor. The max per­missible current of the 240 VAC output is 50amps.
The 240 VAC output can be split to provide two sepa­rate 120 VAC outputs with a max permissible current of 50 Amps 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 V GFCI 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 GFCI 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 recepta­cle.
INSTALLATION
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.
STANDBY POWER CONNECTIONS
The VANTAGE® 400 is suitable for temporary, stand­by or emergency power using the engine manufactur­er’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 premis­es 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 wind­ings.
• Install a 50 amp, 120/240 VAC plug (NEMA Type 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 Amp, 120/240 Volt recep­tacle on the case front.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
NOTE: The 240 V receptacle has two 120 V circuits, but are of opposite polarities and cannot be paralleled.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 14
A-8 A-8
240 Volt
60 Hz. 3-Wire
Service
POWER
COMPANY
METER
240 VOLT
120 VOLT
120 VOLT
LOAD
N
NEUTRAL BUS
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GND
N
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
240 VOLT
GROUNDED CONDUCTOR
50AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE
INSTALLATION
CONNECTION OF VANTAGE® 400 TO PREMISES
• Only a licensed, certified, trained electrician should install the machine to a premises or residential elec­trical system. Be certain that:
• The installation complies with the National Electrical Code and all other applicable electrical codes.
WARNING
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
• 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.
• A double pole, double throw transfer switch in conjunction with the properly rated double throw circuit
breaker is connected between the generator power and the utility meter.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 15
A-9 A-9
INSTALLATION
CONNECTION OF LINCOLN ELEC­TRIC 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 VAN­TAGE® 400
4. Control Cable Model:
• Connect Control Cable between Engine Welder and Feeder.
• Set the "WELD TERMINALS" switch to "REMOTELY CONTROLLED"
• Set the MODE switch to the "CV-WIRE " position.
• Set the "WIRE FEEDER VOLTMETER" switch to either "+" or "-" as required by the electrode polar­ity being used.
• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
• Set the "IDLE" switch to the "AUTO" position.
• 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.
1. Shut the welder off.
2. 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 "-" ter­minal of the welder and work cable to the "+" ter­minal of the welder.
3. Across The-Arc Model:
• Attach the single lead from the front of the LN-15 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.
• Set the "WELD TERMINALS" switch to "WELD TERMINALS ON".
• 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 16
A-10 A-10
INSTALLATION
WARNING
Connection of the LN-25 to the VANTAGE® 400 Shut off welder before making any electrical con­nections.
------------------------------------------------------------------------
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.
CONNECTION OF SPOOL GUN (K487-25) AND COBRAMATIC TO VANTAGE® 400
• Shut the welder off.
Connect per instructions on the appropriate con­nection diagram in Section C.
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.
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 ener­gized until the gun trigger is closed.
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
• Set the MODE switch to the "CV-WIRE " position.
• Set the "WELD TERMINALS" switch to "WELD TER­MINALS ON".
• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
• Set the “IDLE” switch to the “HIGH” position.
See Section C for additional Connection Diagrams.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
If you are using an LN-25 without an internal con­tactor, the electrode will be energized when the VANTAGE® 400 is started.
------------------------------------------------------------------------
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 17
B-1 B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
For Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Add Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Break in Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3,B-4
Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Starting and Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5, B-6
TABLE OF CONTENTS - OPERATION SECTION
Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Duty Cycle and Electrode Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Constant Current (Stick) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Downhill Pipe (Stick) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Typical Current Ranges for Tungsten Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Wire Welding-CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Simultaneous Welding and Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Extension Cord Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 18
B-2 B-2
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 electrode with skin or wet clothing.
• Insulate yourself from 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.
THEORY OF OPERATION
• 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 nec­essary).
• See Engine Owner’s Manual for specific oil and coolant recommendations.
ADD FUEL
DIESEL FUEL
can cause fire.
------------------------------------------------------------------------
• Remove the fuel tank cap.
WARNING
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away from tank.
• Do not leave unattended while fueling.
• Wipe up spilled fuel and allow fumes to clear before starting engine.
• Do not overfill tank, fuel expan­sion may cause overflow.
DIESEL FUEL ONLY
GENERAL DESCRIPTION
The VANTAGE® 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 cir­cuit, single phase and Three Phase power for the AC auxiliary outlets. The DC welding control system uses
state of the art Chopper Technology (CT™) for superi­or welding performance.
• 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 recom­mendations.
BREAK-IN PERIOD
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
The Vantage® 400 is fitted with a selectable VRD(Voltage Reduction Device). The VRD operates in the CC-Stick mode reducing the OCV to <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:
• Be 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 check the level on the dipstick.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
CAUTION
The engine will use a small amount of oil during its “break-in” period. The break-in period is about 50 run­ning 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
Page 19
B-3 B-3
1
THEORY OF OPERATION
FIGURE B.1
11
2
9
3
10
4
14
13
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
12
17
16
20
5
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 CV­WIRE modes and when a remote control is connect­ed to the 6-Pin or 14-Pin Connector, the auto-sens­ing 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-sens­ing circuit automatically makes OUTPUT CONTROL inactive and the wire feeder voltage control active. Otherwise, the OUTPUT CONTROL is used to pre­set the voltage
When in the TOUCH START TIG mode and when an Amptrol is connected to the 6-Pin Connector, the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
2.
DIGITAL OUTPUT METERS-
allow the output voltage (CV-WIRE mode) or cur­rent (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 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 deci­mal point in each display will be flashing. The accu­racy of the meters is +/- 3%.
3. WELD MODE SELECTOR SWITCH-
(Provides four selectable welding modes)
VANTAGE® 400
15
8
7
21
18
19
6
The digital meters
CV-WIRE
DOWNHILL PIPE CC-STICK TOUCH START TIG
Page 20
B-4 B-4
THEORY OF OPERATION
4. ARC CONTROL- The ARC CONTROL dial is active in
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 circuit current (arc-force) during stick weld­ing to adjust for a soft or a 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 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 ARC 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 induc­tance/pinch control. The proper setting depends on the pro­cedure and operator preference. Start with a setting of 0.
5. WELD OUTPUT TERMINALS WITH FLANGE
Provides a connection point for the electrode and
NUT-
work cables.
10. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to the polarity of the electrode.
11. VRD (Voltage Reduction Device) INDICA­TOR LIGHTS-
400 are two indicator lights. A red light when lit indi­cates
OCV(Open Circuit Voltage) is equal to or
than 30V and a green light when lit indicates
OCV(Open Circuit Voltage)
The 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 and weld voltage at all times. In the CC-Stick mode when not welding the green light will illuminate indi­cating that the VRD has reduced the OCV to less than 30V. During welding the red light will illuminate when­ever 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 opera­tion.
If the red light remains illuminated when 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 “On”, refer to the trouble shooting section.
On the front panel of the Vantage
greater
is less than 30V.
OCV(Open Circuit Voltage)
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
6. GROUND STUD- Provides a connection point for
connecting the machine case to earth ground.
7. 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.
8. 6-PIN CONNECTOR- For attaching optional remote
control equipment. Includes auto-sensing remote control cir­cuit.
9. WELD TERMINALS CONTROL SWITCH- In the
WELD TERMINALS ON position, the output is electrically hot all the time. In the REMOTELY CONTROLLED posi­tion, the output is controlled by a wire feeder or amptrol device, and is electrically off until a remote switch is depressed.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
MODE VRD "ON" VRD "OFF"
CC-STICK OCV Green (OCV Reduced)
CV-WIRE OCV Red (OCV Not Reduced)
PIPE OCV Green (No Output)
ARC GOUGING
TIG OCV Green (Process is Low Voltage)
* It is normal for the lights to alternate between colors while welding.
VANTAGE® 400
TABLE B.1
VRD INDICATOR LIGHTS
While Red or Green Welding (Depends on Weld Voltage) *
Weld Terminals On Red (OCV Not Reduced) Weld Terminals Remotely Controlled Gun Trigger Closed Green (No OCV) Weld Terminals Remotely Controlled
While Red or Green Welding (Depends on Weld Voltage) *
While Not Applicable (No Output) Welding OCV Green (No Output) While Not Applicable (No Output)
Welding
While Green (Process is Low Voltage) Welding
Gun Trigger Open No Lights
Page 21
B-5 B-5
ENGINE CONTROLS:
12. RUN/STOP SWITCH - RUN position energizes the
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.
THEORY OF OPERATION
18. ENGINE PROTECTION LIGHT- A warning indi-
cator light for Low Oil Pressure and/or Coolant Over Temperature.The light is off when the systems are func­tioning properly. The light will come on and the engine will shutdown when there is Low Oil Pressure and/or the Coolant is Over Temperature.
13. GLOW PLUG PUSH BUTTON -
• When pushed activates the glow plugs. Glow plug should not be activated for more than 20 seconds con­tinuously.
14. START PUSH BUTTON - Energizes the starter
motor to crank the engine.
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 approx­imately 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 min­imum), the engine accelerates and operates at full speed.
• When welding ceases or the 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 before the end of the time delay, the idler reduces the engine speed to low idle speed.
• The engine will automatically return to high idle speed when there is welding load or AC power load reapplied.
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
TYPICAL VANTAGE® 400 FUEL CONSUMPTION
Low Idle - No Load 1400 R.P.M. High Idle - No Load 1880 R.P.M. DC Weld Output 400 Amps @ 36 Volts 17,000 Watts 3 Phase 11,000 Watts 1 Phase
PERKINS
Gal./Hr (Liters/Hr)
.26 (.97)
.42 (1.57)
1.18 (4.46)
1.24 (4.68) .90 (3.42)
Running Time for
15 gallons / hours
58.59
36.06
12.74
12.14
16.62
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 RUN­STOP switch must be returned to the "OFF" position to reset the engine protection system and light.
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.
Note: The light may or may not come on when the RUN­STOP switch is in the "ON" position. It will come on dur­ing 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.
20. COOLANT TEMPERATURE GAUGE-A indica-
tor of engine coolant temperature.
21. 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.
3. Press Glow Plug Button and hold 15 to 20 seconds.
4. 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.
6. 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 warm up time in cold weather.
high idle. Allow a longer
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
NOTE: This data is for reference only. Fuel consump­tion is approximate and can be influenced by many fac­tors, including engine maintenance, environmental conditions and fuel quality.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 22
B-6 B-6
NOTE: If the unit fails to start turn Run/Stop switch to
off and repeat step 3 through step 7 after wait­ing 30 seconds.
CAUTION
• Do 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 starter motor.
• IF the Engine Protection or Battery Charging Lights do “not” turn off shortly after starting the engine shut off the engine immediately and deter­mine 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 min­utes to cool the engine.
THEORY OF OPERATION
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 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 the dial set at 0.
NOTE: Due to the low OCV 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 con­nection 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 with­in the rating of the machine. For information on elec­trodes and their proper application see (www.lincoln­electric.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 horizontal and vertical-up welding with all types of electrodes, especially low hydrogen. The OUTPUT CON­TROL dial adjusts the full output range for stick welding.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
B. For Re-Striking Electrodes
Some electrodes form a cone at the end of the elec­trode after the welding arc has been broken, partic­ularly 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-of­position" and "down hill" pipe welding where the oper­ator would like to control the current level by changing the arc length.
VANTAGE® 400
Page 23
B-7 B-7
The OUTPUT CONTROL dial adjusts the full output range for pipe welding.
THEORY OF OPERATION
When in the TOUCH START TIG mode and when a Amptrol is connected to the 6-Pin connector the OUT­PUT CONTROL dial is used to set the maximum cur-
The ARC CONTROL dial sets the short circuit current
rent range of the current control of the Amptrol.
(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 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. This can also increase spatter.
It is recommended that the ARC CONTROL be set to the
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 cur­rent to the Touch Start level.
To reinitiate the arc, retouch the tungsten to the work and lift. Alternatively, the weld can be stopped by releasing the Amptrol or arc start switch.
minimum number without electrode sticking. Start with the dial set at 0.
NOTE: With the VRD switch in the “ON” position there is no output in the DOWNHILL PIPE mode.
For indicator
light operation, see Table B.1.
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.
TIG WELDING
The settings are for reference.
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 cur­rent 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 contami­nation. Then, the tungsten is gently lifted off the work in a
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.
rocking motion, which establishes the arc.
TABLE B.3
TYPICAL CURRENT RANGES
Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH
Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)
1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel
Tungsten Tungsten
0.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6
0.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)
0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8 1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10 3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10) 1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)
(1)
FOR TUNGSTEN ELECTRODES
(2)
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
(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 used in these sizes. (4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:
(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
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
# 4 = 1/4 in. (6 mm) # 5 = 5/16 in. (8 mm) # 6 = 3/8 in. (10 mm) # 7 = 7/16 in. (11 mm) # 8 = _ in. (12.5 mm) #10 = 5/8 in. (16 mm)
and high duty cycles.
VANTAGE® 400
Page 24
B-8 B-8
THEORY OF OPERATION
• Set the "WELDING TERMINALS" switch to the "REMOTELY CONTROLLED" position. This will keep the "Solid State" contactor open and provide a "cold" elec­trode 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 “On” or “Off” for this mode. For indicator light operation, see Table B.1.
WIRE WELDING-CV
Connect a wire feeder to the VANTAGE® 400 according to the instructions in INSTALLATION INSTRUCTIONS Section.
The VANTAGE® 400 in the CV-WIRE mode, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes 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 washed-in 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 “On”, the OCV(Open
Circuit Voltage) is not reduced. For indicator light operation, see Table B.1.
TABLE B.5
ARC GOUGING
The VANTAGE® 400 can be used for arc gouging. For opti­mal 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
Carbon Diameter
Current Range (DC, electrode
positive)
1/8" 60-90 Amps
5/32" 90-150 Amps
3/16" 200-250 Amps
1/4" 300-400 Amps
5/16” 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Current
(Amps)
15 20 15 20 44
Weld
Amps
0 100 200 300 400 500
Voltage
Volts
120 120 240 240 240
VANTAGE® 400 Simultaneous Welding and Power Loads
PLUS
1 PHASE
WATTS AMPS
11,000 46 11,000 46
8,000 33
OR
4700 20 1700 7
00
WATTS AMPS
3 PHASE
17,000 41 15,400 37 13,000 31
OR
9400 23 3400 8
00
BOTH 1 & 3 PHASE
WATTS AMPS
11,000 ­11,000 -
8,000 ­4,700 ­1,700 -
TABLE B.6
VANTAGE® 400 (CE) Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Load
(Watts)
1800 2400 3600 4800 9500
14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
30
60
(9)
(18)
Conductor size is based on maximum 2.0% voltage drop.
Maximum Allowable Cord Length in ft. (m) for Conductor Size
40 30 75 60
(12)
(9) (23) (18)
75
50 150 100
50
(23) (15) (46) (30) (15)
125
88 225 175
90
(38) (27) (69) (53) (27)
175 138 350 275 150
VANTAGE® 400
00
(53) (42)
(107)
(84) (46)
300 225 600 450 225
(91)
(69) (183) (137)
(69)
Page 25
C-1 C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Factory Installed Options / Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3 / C-7
TABLE OF CONTENTS - ACCESSORIES SECTION
Engine Welders/LN25 Across the Arc with Optional K857 Remote Control . . . . . . . . . . . . . . . . . . . . .C-3
Engine Welders/LN25 Across the Arc with Optional K444-1 Remote Control . . . . . . . . . . . . . . . . . . .C-3
Engine Welders/LN25 with K624-1 42 Volt Remote Output Control Module . . . . . . . . . . . . . . . . . . . .C-4
Engine Welders / LN7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
Engine Welders / LN742 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5
Engine Welders / LN8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5
Engine Welders to K867 Control Cable Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6
Engine Welders / K691-10 / K488 / K487 Spool Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6
Engine Welders / K930 TIG Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7
Engine Welders / K1587-1 CobraMatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 26
C-2 C-2
ACCESSORIES
FIELD INSTALLED OPTIONS / ACCES­SORIES
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.
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 & 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 muf­fler 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, 100% duty cycle.
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 lb. (4.5-6.8kg) spools.
Magnum Gun and Magnum Gun Connector Kit are required for gas-shielded welding. Innershield Gun is required for gas­less 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 & K126-2)
K487-25 Magnum SG Spool Gun
Hand held semiautomatic wire feeder. Requires SG Control Module and Input Cable.
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.
T12153-9 50 AMP, 120/240V POWER PLUG (1-Phase) T12153-10 50 AMP, 240V POWER PLUG (3-Phase)
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-prong plugs.) For connection of Lincoln equipment with NEMA 6-50 Plug.
K1858-1 SERVICE INDICATOR KIT- Provides a GO / NO-GO visu­al indication of air cleaner element useful service life. Filter service based on restriction readings allows the longest life possible from the filter and best engine protection.
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 con­nection, 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® 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 bod­ies, a black cap, alumina nozzles and tungstens in a variety of sizes, all packaged in an easy to carry reclosable sack.
K870 Foot Amptrol® K963-3 Hand Amptrol® K2347-1 Precision TIG 185 Ready-Pak(For AC TIG)
K2350-1 Invertec® V205-T AC/DC One-Pak™ Package (For AC TIG)
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
K2679-1 COLD WEATHER HEATER AND TARP KIT
For engine starting and operation in extreme cold weather conditions down to -40ºF / -40ºC (with the use of OW40 synthetic oil and arctic diesel fuel), includes 120VAC engine block heater, and radiator grill tarp.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 nected for 1-phase input power.
VANTAGE® 400
kit, if con-
Page 27
C-3 C-3
ACCESSORIES
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 28
C-4 C-4
ACCESSORIES
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 29
C-5 C-5
ACCESSORIES
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 30
C-6 C-6
ACCESSORIES
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 31
C-7 C-7
2
9/03
ACCESSORIES
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 32
C-8 C-8
NOTES
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 33
D-1 D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Engine Service Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
TABLE OF CONTENTS - MAINTENANCE SECTION
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Engine Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Service Instructions And Installation Tips for Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
Engine Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
Welder / Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7
Brush Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7
GFCI Receptacle Testing and Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 34
D-2 D-2
I
C
C
I
I
R
R
I
I
I
I
I
R
R
R
R
R
I
I
I
I
R
R
R
Battery
Leaks or engine damage
Injector performance
All nuts and bolts for tightness
Electrical systems
Valve clearances
Tighten cylinder head
Renew the engine breather
Air filter element
Air filter (earlier check may be required)
Alternator drive belt
Alternator drive belt wear
Tension of alternator driv e belt
F
Water separator element
uel filter canister
Drain water separator & fuel strainer
Engine oil filter
Engine oil (NOTE 1 & 3)
Engine oil level (NOTE 1)
Coolant (NOTE 3)
Concentration of Antifreeze
Coolant Level
MAINTENANCE ITEM
S26354 VM
Contact Perkins
Intake .008", exhaust .008"
Donaldson #P821575
Perkins #080109107
Perkins #130366120
Lincoln # M20840-A
Perkins #140517050
8.45
qt.,
8L
(Including filter)
9.5 qt., 9.0 L
50/50 Water/Et hylene Glycol
TYPE OR QUANTITY
(3) Fill slowly! Ensure correct quantity is used.
Above operations to be carried out by trained personnel with referencetothe works hop manual where necessary.
Thesepreventive maintenance periods applytoaverage conditions of operation. If necessary, use shorter peroids.
I = Inspect C = Clean R = Replace
Notes:
(1) Consult Engine Operators Manual for oil recommendations.
(2) Consult Engine OperatorsManual for additionalmaintenanceschedule information.
ENGINE SERVICE
ENGINE SERVICE (NOTE 2)
EVERY DAY OR EVERY 8 HOURS
EVERY 100 HOURS OR 3 MONTHS
EVERY 250 HOURS OR 6 MONTHS
EVERY 1000 HOURS
FIRST SERVICE (20 / 50 HOURS)
EVERY 500 HOURS OR 12 MONTHS
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
• Have qualified personnel do all maintenance and troubleshooting work.
• Turn the engine off before working inside the machine or servicing the engine.
• Remove guards only whe n n e c e s s ary 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.)
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Read the Safety Precautions in the front of this manual and in the Engine Owner’s Manual before working on this machine.
Keep all equipment safety guards, covers, and devices in position and in good repair. Keep hands, hair, clothing, and tools away from the gears, fans, and all other moving parts when starting, operating, or repairing the equipment.
------------------------------------------------------------
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 tends to draw dirt into the fuel system. Also, check the crankcase oil level and add oil if indicated.
Page 35
D-3 D-3
MAINTENANCE
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 bat­tery 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 90 drain the oil into a suitable container for disposal.
• Close the drain valve by rotating lever 90
• Re-fill the crankcase to the upper limit mark on the dipstick with the recommended oil (see engine oper­ation manual OR engine service items decal OR below). Replace and tighten the oil filler cap secure­ly.
• Push oil drain hose and valve back into unit, re-con­nect 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 man­ner 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 API 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 in a diesel engine or damage may result. It IS permissible to use an oil that meets S and C grade service classi­fications.)
counterclockwise. Pull to open and
°
clockwise.
°
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 fil­ter. Note: Care should be taken during filter removal to not disrupt or damage in any way the 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.
WARNING
• Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explo­sion 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
SAE 10W30 is recommended for general, all tempera­ture use, 5F to 104F (-15C to 40C).
See engine owner’s manual for more specific informa­tion on oil viscosity recommendations.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 36
D-4 D-4
MAINTENANCE
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 37
D-5 D-5
COOLING SYSTEM
MAINTENANCE
FUEL
WARNING
HOT COOLANT
• 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 radi­ator 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 refill 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.
can burn skin.
CAUTION
At the end of each day’s use, refill the fuel tank to min­imize moisture condensation and dirt contamination in the fuel line. Do not overfill; leave room for the fuel to expand.
Use only fresh No. 2D diesel fuel, the use of No. 1D diesel fuel is recommended in place of No. 2D at tem­peratures 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:
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 dur­ing 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 lbs.(9 Kg).
1. Fill the fuel tank with fuel.
2. Open the fuel shut off valve.
3. Loosen bleed fitting on the fuel injector manifold.
4. 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 prim­ing lever. Tighten bleed fitting on injector manifold.
5. Follow normal STARTING procedures until engine starts.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 38
D-6 D-6
MAINTENANCE
FUEL FILTER
1. Check the fuel filter and fuel pre-filter for water accu­mulation or sediment.
2. Replace the fuel filter if it is found with 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.
CLEANING THE BATTERY
Keep the battery clean by wiping it with a damp cloth when dirty. If the terminals appear corroded, discon­nect the battery cables and wash the terminals with an ammonia solution or a solution of 1/4 pound (0.1113 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 bat­tery compartment, and surrounding areas with clear water. Coat the battery terminals lightly with petroleum jelly or a non-conductive grease to retard corrosion. Keep the battery clean and dry. Moisture accumulation on the battery can lead to more rapid discharge and early battery failure.
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 cor­rect. Improper polarity can damage the charging cir­cuit. The VANTAGE® 400 positive (+) battery terminal has a red terminal cover.
WARNING
GASES FROM BATTERY can 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 bat­tery 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 nega­tive battery lead at engine foot.
BATTERY ACID can burn eyes and skin.
Wear gloves and eye protection and
be careful when working near bat­tery.
Follow instructions printed on bat-
tery.
If you need to charge the battery with an external charger, disconnect the negative cable first, then the positive cable before you attach the charger leads. After the battery is charged, reconnect the positive bat­tery cable first and the negative cable last. Failure to do so can result in damage to the internal charger com­ponents. Follow the instructions of the battery charger manufac­turer for proper charger settings and charging time.
SERVICING OPTIONAL SPARK ARRESTOR
Clean every 100 hours.
WARNING
• MUFFLER MAY BE HOT
• ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTER!
• DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER!
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 39
D-7 D-7
MAINTENANCE
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 over­haul is necessary.
CAUTION
• Do not attempt to polish slip rings while the engine is running.
WARNING
GFCI RECEPTACLE TESTING AND RESET­TING PROCEDURE
The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To proper­ly 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.
• The 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 GFCI recep­tacle. This will assure normal GFCI 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 GFCI recepta­cle. The night-light or other product should go "OFF".
• Push the "Reset" button, again. The light or other product should go "ON" again.
• 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.
If the light or other product remains "ON" when the "Test" button is pushed, the GFCI is not working prop­erly or has been incorrectly installed (miswired). If your GFCI is not working properly, contact a qualified, certi­fied electrician who can assess the situation, rewire the GFCI if necessary or replace the device.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 40
D-8 D-8
88
44
22
11
55
66
77
33
MAINTENANCE
1. Case Front & Control Panel Assembly
2. Output Panel Assembly
3. Power Module Panel Assembly
4. Generator & Rotor Assembly
5. Base, Fuel Tank & Battery Assembly
6. Engine Assembly
7. Case Back & Radiator Assembly
8. Case Cover
MAJOR COMPONENT LOCATION
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 41
E-1 E-1
W
E
L
D
W
I
N
D
I
N
G
30
AUXILIARY
WINDINGS
10 + 30
ROTOR
+
REMOTE AMPHENOL
ARC CONTROL
OUTPUT CONTROL
PROCESS/RANGE SELECTOR
WELD CONTROL BOARD
THREE-PHASE RECTIFIER
WORK TERMINAL
ELECTRODE TERMINAL
CHOPPER MODULE
IGBT
CHOKE
VOLTMETER
AMMETER
PWM SIGNAL
VRD VOLTAGE REDUCTION
VRD FEEDBACK
VRD LIGHTS
R
G
VRD SWITCH (OFF)
SHUNT
AUX. FEEDBACK
120VAC RECEPTACLED (2)
AUX CURRENT TORROID
42 VAC TO 14 PIN AMPHENOL FOR WIRE FEEDER
240 VAC 30
240VAC RECEPTACLE
LOW IDLE COMMAND
F E E D B A C K
C U R R E N T
I D L E
V.R.D.
POWER TO CONTROL BOARD
POWER TO
VRD
80 VDC
VOLT
FEEDBACK
+
-
ENGINE
GLOW PLUGS
MECHANICAL ROTATION
STARTER
ALTERNATOR
BATTERY
OIL PRESS
TEMP
ROTOR FLASH
ENGINE PROTECTION IDLER CONTROL P.C. BOARD
STATOR
SLIP RINGS
+
-
RUN/STOP SWITCH (RUN)
ENGINE SENSORS
ENGINE TROUBLE LIGHT
Y
ALT
SOL SOL
ALT FLASH
S H U T D O W N
I D L E R
+
-
Y
ALTERNATOR LIGHT
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Battery, Starter, Engine, Rotor, Stator, Engine Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Weld Windings, Rectifier, Chopper Modules and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Weld Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Insulated Gate Bipolar Transistor (IGBT) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Pulse Width Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
Chopper Technology Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
FIGURE E.1 — VANTAGE® 400 BLOCK LOGIC DIAGRAM.
VANTAGE® 400
Page 42
E-2 E-2
W
E
L
D
W
I
N
D
I
N
G
30
AUXILIARY
WINDINGS
10 + 30
ROTOR
+
REMOTE AMPHENOL
ARC CONTROL
OUTPUT CONTROL
PROCESS/RANGE SELECTOR
WELD CONTROL BOARD
THREE-PHASE RECTIFIER
WORK TERMINAL
ELECTRODE TERMINAL
CHOPPER MODULE
IGBT
CHOKE
VOLTMETER
AMMETER
PWM SIGNAL
VRD VOLTAGE REDUCTION
VRD FEEDBACK
VRD LIGHTS
R
G
VRD SWITCH (OFF)
SHUNT
AUX. FEEDBACK
120VAC RECEPTACLED (2)
AUX CURRENT TORROID
42 VAC TO 14 PIN AMPHENOL FOR WIRE FEEDER
240 VAC
30 240VAC RECEPTACLE
LOW IDLE COMMAND
F E E D B A C K
C U R R E N T
I D L E
V.R.D.
POWER TO CONTROL BOARD
POWER TO
VRD
80 VDC
VOLT
FEEDBACK
+
-
ENGINE
GLOW PLUGS
MECHANICAL ROTATION
STARTER
ALTERNATOR
BATTERY
OIL PRESS
TEMP
ROTOR FLASH
ENGINE PROTECTION IDLER CONTROL P.C. BOARD
STATOR
SLIP RINGS
+
-
RUN/STOP SWITCH (RUN)
ENGINE SENSORS
ENGINE TROUBLE LIGHT
Y
ALT
SOL SOL
ALT FLASH
S H U
T D O W N
I D L E R
+
-
Y
ALTERNATOR LIGHT
THEORY OF OPERATION
FIGURE E.2 — GENERAL DESCRIPTION, BATTERY, ENGINE, ROTOR, STATOR & ENGINE PROTECTION
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 Chopper Technology to produce DC current for multi-purpose welding applications. The Vantage® 400 is also capa­ble of producing 11,000 watts of AC auxiliary power at 100% 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, is started and running, the 12 VDC battery voltage is
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
VANTAGE® 400
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 station­ary 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 feed­er power winding.
The engine alternator supplies charging current for the battery circuit. The Peripheral board monitors the engine sensors and will shut the engine off in the event of low oil pressure, engine over temperature, malfunc­tion of the engine’s alternator system or a low fuel con­dition. 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 Pull Coil board activates the idler solenoid, which then brings the engine to a low idle state. When output cur­rent is sensed, either weld or auxiliary, the Weld Control PC board deactivates the idler solenoid, and the engine returns to high RPM.
Page 43
E-3 E-3
W
E
L
D
W
I
N
D
I
N
G
30
AUXILIARY
WINDINGS
10 + 30
ROTOR
+
REMOTE AMPHENOL
ARC CONTROL
OUTPUT CONTROL
PROCESS/RANGE SELECTOR
WELD CONTROL BOARD
THREE-PHASE RECTIFIER
WORK TERMINAL
ELECTRODE TERMINAL
CHOPPER MODULE
IGBT
CHOKE
VOLTMETER
AMMETER
PWM SIGNAL
VRD VOLTAGE REDUCTION
VRD FEEDBACK
VRD LIGHTS
R
G
VRD SWITCH (OFF)
SHUNT
AUX. FEEDBACK
120VAC RECEPTACLED (2)
AUX CURRENT TORROID
42 VAC TO 14 PIN AMPHENOL FOR WIRE FEEDER
240 VAC
30 240VAC RECEPTACLE
LOW IDLE COMMAND
F E E D B A C K
C U R R E N T
I D L E
V.R.D.
POWER TO CONTROL BOARD
POWER TO
VRD
80 VDC
VOLT
FEEDBACK
+
-
ENGINE
GLOW PLUGS
MECHANICAL ROTATION
STARTER
ALTERNATOR
BATTERY
OIL PRESS
TEMP
ROTOR FLASH
ENGINE PROTECTION IDLER CONTROL P.C. BOARD
STATOR
SLIP RINGS
+
-
RUN/STOP SWITCH (RUN)
ENGINE SENSORS
ENGINE TROUBLE LIGHT
Y
ALT
SOL SOL
ALT FLASH
S H U
T D O W N
I D L E R
+
-
Y
ALTERNATOR LIGHT
THEORY OF OPERATION
FIGURE E.3 — WELD WINDINGS, RECTIFIER, CHOPPER MODULES & FEEDBACK
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
VANTAGE® 400
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. Free­wheeling diodes are incorporated in the power mod­ules to provide a current path for the stored energy in the choke when the IGBTs are turned off. See Chopper Technology in 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.
Page 44
E-4 E-4
W
E
L
D
W
I
N
D
I
N
G
30
AUXILIARY
WINDINGS
10 + 30
ROTOR
+
REMOTE AMPHENOL
ARC CONTROL
OUTPUT CONTROL
PROCESS/RANGE SELECTOR
WELD CONTROL BOARD
THREE-PHASE RECTIFIER
WORK TERMINAL
ELECTRODE TERMINAL
CHOPPER MODULE
IGBT
CHOKE
VOLTMETER
AMMETER
PWM SIGNAL
VRD VOLTAGE REDUCTION
VRD FEEDBACK
VRD LIGHTS
R
G
VRD SWITCH (OFF)
SHUNT
AUX. FEEDBACK
120VAC RECEPTACLED (2)
AUX CURRENT TORROID
42 VAC TO 14 PIN AMPHENOL FOR WIRE FEEDER
240 VAC
30 240VAC RECEPTACLE
LOW IDLE COMMAND
F E E D B A C K
C U R R E N T
I D L E
V.R.D.
POWER TO CONTROL BOARD
POWER TO
VRD
80 VDC
VOLT
FEEDBACK
+
-
ENGINE
GLOW PLUGS
MECHANICAL ROTATION
STARTER
ALTERNATOR
BATTERY
OIL PRESS
TEMP
ROTOR FLASH
ENGINE PROTECTION IDLER CONTROL P.C. BOARD
STATOR
SLIP RINGS
+
-
RUN/STOP SWITCH (RUN)
ENGINE SENSORS
ENGINE TROUBLE LIGHT
Y
ALT
SOL SOL
ALT FLASH
S H U T D O W N
I D L E R
+
-
Y
ALTERNATOR LIGHT
THEORY OF OPERATION
FIGURE E.4 — WELD CONTROL BOARD
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WELD CONTROL BOARD
The 80 VDC derived from the filter capacitors on the Power Modules, supplies various regulated DC volt­ages to operate the Weld Control PC board circuitry. It 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 con­trols (arc control, output, and process/range selector). It compares these commands to the current and volt­age feedback information it receives from the shunt
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
VANTAGE® 400
and output terminal circuits. The circuitry on the Weld Control 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).
Page 45
E-5 E-5
THEORY OF OPERATION
FIGURE E.5 – IGBT OPERATION
INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semicon­ductors 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.
Drawing B shows the IGBT in an active mode. When the gate signal, a positive DC voltage relative to the source, is applied to the gate terminal of the IGBT, it is capable of conducting current. A voltage supply con­nected to the drain terminal will allow the IGBT to con­duct and supply current to circuit components coupled to the source. Current will flow through the conducting IGBT to downstream components as long as the posi­tive gate signal is present. This is similar to turning ON a light switch.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 46
E-6 E-6
MINIMUM OUTPUT
MAXIMUM OUTPUT
50
50
sec
sec
sec
48
sec
(Dwell or Off Time)
(Dwell or Off Time)
48
sec
2
THEORY OF OPERATION
FIGURE E.6 – TYPICAL IGBT OUTPUTS
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 MODU­LATION. 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 cycle. The top drawing shows the minimum output sig­nal possible over a 50-microsecond time period.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
VANTAGE® 400
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 conduct­ing, 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 maxi­mized. 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.
Page 47
E-7 E-7
THEORY OF OPERATION
CHOPPER TECHNOLOGY FUNDAMENTALS
The new era of welding machines such as the Vantage® 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
In this system, the engine drives a three-phase alter­nator, which generates power that is rectified and filtered to produce about 75VDC. The current is applied through a solid state switch to an inductor. By
SOLID STATE
SWITCH
ARC
CONTROL
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.
ARC
SWITCH
70-80VDC
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
DIODE
CURRENT WITH SWITCH CLOSED
INDUCTOR
ARC
CURRENT WITH SWITCH OPEN
varying the ratio of on time versus off time of the switch (Duty Cycle), the current applied to the arc is con­trolled. This is the basis for Chopper Technology: Controlling the switch in such a way as to produce superior welding.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 48
E-8 E-8
NOTES
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 49
F-1 F-1
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4 - F-20
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-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
Engine Alternator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-35
Brush and Slip Ring Service Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37
Rotor Resistance and Grounding Test (Static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39
Rotor Resistance and Ground Test (Dynamic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-41
Rotor Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43
Flashing Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47
Stator Voltage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-51
Stator Short Circuit & Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-55
Output Rectifier Bridge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-57
Chopper Module Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-61
Chopper Module Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-65
Weld Control Board PWM Gate Signal Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-69
Weld Control Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-71
Control Potentiometer and Mode Switch Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-75
Remote Receptacle Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-79
Voltage Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-82 - F-86
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-87 - F-103
Output Rectifier Bridge and Choke Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-87
Chopper Module Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-91
Stator/Rotor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-95
Retest after Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-104
VANTAGE® 400
Page 50
F-2 F-2
TROUBLESHOOTING & 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 pos­sible symptoms that the machine may exhib­it. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into the following categories: output problems, function prob­lems, 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 con­tribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted with­out removing the case wrap-around cover.
Step 3. RECOMMENDED COURSE OF ACTION
The last column labeled “Recommended Course of Action” lists the most likely com­ponents that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject com­ponent is either good or bad. If there are a number of possible components, check the components in the order listed 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 of Contents to locate the appropriate diagram.
to eliminate
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 51
F-3 F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
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 prob­lems when troubleshooting and replacing PC boards, please use the following procedure:
1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.
2. Check for loose connections at the PC board to assure that the PC board is properly connected.
3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:
PC board can be damaged by static electricity.
- Remove your body’s static charge before opening the static­shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected
ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations
to a grounded part of the equipment frame.
- If you don’t have a wrist strap, touch an un-painted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.
- Remove the PC board from the static-shielding bag and place it directly into the equipment. Don’t set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can’t be installed immediately, put it back in the static-shield­ing bag.
- If the PC board uses protective shorting jumpers, don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop­er failure analysis.
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, and 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 w as 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
- Tools which come in contact with the PC board must be either conductive, anti-static or static-disipative.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 52
F-4 F-4
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)

Major mechanical or electrical damage is evident.

No welding output or auxiliary power. The engine operates nor­mally.
POSSIBLE AREAS OF MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Contact your local Lincoln Authorized Field Service Facility.
Check for loose or faulty connec­tions in the auxiliary circuit to the output receptacles, and/or the weld circuit to the output terminals.
SEE WIRING DIAGRAM.
Check the brushes for wear ad proper contact to the rotor slip rings.
RECOMMENDED COURSE OF ACTION
1. Contact the Lincoln Electric Service Department at 1-888­935-3877.
Check the brushes for wear and proper contact to the rotor slip rings
Perform the Brush and Slip Ring
Service Procedure.
Check for flashing voltage at slip rings (3-5 Volts DC@.5 amp until generator builds up, then 160 Volts) See FLASHING VOLTAGE
TEST.
Check Field rectifier and capacitor.
Perform the Rotor Voltage Test.
Perform the Stator Voltage Test.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 53
F-5 F-5
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
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 feed­er, amptrol, or arc start switch con­nected, 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.
RECOMMENDED 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 nd #25 and Weld Control Board power leads #13 and #14 for loose or faulty connections. See Wiring
Diagram.
Perform the Chopper Module Function Test.
CAUTION
Perform the STATOR VOLTAGE TEST.
Perform the OUTPUT RECTIFIER TEST.
The WELD CONTROL board may be faulty.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 54
F-6 F-6
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)
POSSIBLE AREAS OF MISADJUSTMENT(S)
OUTPUT PROBLEMS

No output in PIPE MODE. Outputs normal in other modes.

VRD lights don’t light up. Ensure VRD ON/OFF switch is in

No auxiliary 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 out­put and low auxiliary output.
Make sure VRD ON/OFF toggle switch is in the off position. Faulty CONTROL PC BOARD. Faulty VRD display board.
the “ON” position. VRD light may be burned out, replace both VRD lights. Faulty VRD display P.C. Board.
Check for loose or faulty connec­tions 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 VRD 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 aux­iliary receptacle and the main sta­tor.
Then engine high idle speed may be low. Perform the Engine
Throttle Test (Electronic Idler).
Full load speed should be about 3500 RPM. Inspect and if neces­sary service the brushed and slip rings per the Brush and Slip Ring
Service.
Perform the Rotor Voltage Test. Perform the Stator Voltage Test.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 55
F-7 F-7
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)
The machine will weld but the welding arc is “COLD”. The engine runs normally and the aux­iliary 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 increas­ing the “ARC CONTROL” setting. Check for loose or faulty connec­tions 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 possi­ble. The work clamp must be in good condition with good spring tension. The 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 ade­quately 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 out­put of the machine. Connect a tachometer, Hz meter or another method to measure engine RPM. Place the mode switch in “CC­STICK, turn the output control to maximum idle switch to “HIGH” terminal switch to “WELD TERMI­NALS 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 fil­ter. Replace any filter that is dirty; or damaged. If this doesn’t help have the engine serviced. Compare the volt and amp read­ings displayed on the machine with that of the load bank. If these are significantly different, perform the WELD CONTROL FEED-
BACK TEST.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 56
F-8 F-8
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)
The machine will weld but the welding arc is “COLD”. The engine runs normally and the aux­iliary power is normal. (continued)
POSSIBLE AREAS OF MISADJUSTMENT(S)
FUNCTION PROBLEMS
RECOMMENDED COURSE OF ACTION
If the maximum weld output can­not be obtained even though the front panel displays are reading accurately, check for damaged conductors and lose or damaged connections the large current car­rying conductor connect the stator, output rectifier, chopper modules, choke, shunt, and output termi­nals. See the Wiring Diagram. If all these connections are good perform the ROTOR VOLTAGE
TEST, the STATOR VOLTAGE TEST, the OUTPUT RECTIFIER TEST, and the CHOPPER MOD­ULE RESISTANCE TEST. Perform the CONTROL POTEN­TIOMETER AND MODE RESIS­TANCE TEST. Perform the REMOTE RECEPTA­CLE RESISTANCE TEST.
Replace the Control P.C. Board.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

The machine welds but it will not maintain a steady output.

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 recommenda­tion. 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 elec­trode leads and connections (size, length, coils, or bad connections). The machine may not be maintain­ing the correct RPM.
Perform the THROTTLE ADJUSTMENT TEST.
If the engine will not maintain the correct load RPM, the engine may be servicing fuel, air, and fuel fil­ters 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 damaged conductors or faulty con­nections.
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 57
F-9 F-9
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)

The machine welds but it will not maintain a steady output. (continued)

POSSIBLE AREAS OF MISADJUSTMENT(S)
ENGINE PROBLEMS
RECOMMENDED COURSE OF ACTION
There may be poor connections in the control wiring at the weld con­trol 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 recepta­cles. Make sure the connections are clean and the pins are proper­ly seated in the plastic plug hous­ing. 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 con­trol P.C. Board.
The output control or the arc con­trol potentiometer may be defec­tive or grounded. The mode switch may also be faulty. Perform the POTENTIOMETER AND
MODE SWITCH RESISTANCE TEST.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 58
F-10 F-10
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)
The weld output can not be adjust­ed with the front panel output con­trol 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 recep­tacles. Check for dirt or moisture contami­nation 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 con­tact pins in the receptacle and in the plug of the remote control unit.
RECOMMENDED COURSE OF ACTION
Perform the REMOTE RECEPTA­CLE RESISTANCE TEST.
The output control potentiometer may be defective. Perform the
CONTROL POTENTIOMETER AND MODE SWITCH RESIS­TANCE TEST.
The WELD CONTROL BOARD may be faulty.
See the Start-Up and OCV diag­nostic chart.
Check plug #P1 on the control P.C. Board. Plug should be prop­erly 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 recepta­cles. Check for continuity between the following terminals. See Wiring Diagram and Control Inner­Connection Diagram. P1-10 to 6 pin amphenol pin “C” and to pin 14 amphenol pin “G”. P-1-11 to 6 pin amphenol pin “A” and to 14 pin amphenol pin “E”. P-1-14 to 6 pin amphenol pin “B” and to 14 pin amphenol pin “F”. The weld control P.C. Board may be defective.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 59
F-11 F-11
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)
The machine seems to be locked into the “CC-stick” mode of opera­tion.
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 posi­tions.
RECOMMENDED COURSE OF ACTION
Check that plug P-7 is fully seated into the weld control P.C. board socket. See Control Inner­Connection diagram. Check for corroded, dirty, or dam­aged 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 con­trol 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 CONTROL POTEN-
TIOMETER AND MODE SWITCH RESISTANCE TEST.
The Weld control P.C. Board may be faulty.
The arc quality is poor with exces­sive spatter. The arc heat can be controlled and maintained normal­ly, the auxiliary output is normal and the engine operates normally.
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 recommen­dation. 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 elec­trode leads and connections (size, length, coils, or bad connections).
Check that the weld circuit isn't grounded. With the engine off, check the resistance between chassis ground and the weld out­put 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-
TIOMETER and MODE SWITCH TEST, and the REMOTE RECEP­TACLE RESISTANCE TEST.
The Chopper module may be defective. Perform the CHOPPER
MODULE RESISTANCE TEST.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 60
F-12 F-12
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)
The machine welds normally in all modes and the range of weld out­put seems normal, but one or both of the front panel displays is blank, incorrect welding value, or dis­plays parts of numbers.
POSSIBLE AREAS OF MISADJUSTMENT(S)
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” dis­play will be illuminated. When welding both displays should be reading actual welding parameters.
RECOMMENDED COURSE OF ACTION
Both the “AMPS” and “VOLTS” displays use the same part num­bered display unit. If one of the digital displays appears to be func­tioning normally, it can be used to test the weld control P.C. Board output to the malfunctioning dis­play. Swap the display board connec­tors 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 mal­functioning display should be replaced.
If the known good display still malfunctions then the weld control P.C. board is defective and should be replaced.
A control cable type feeder does not function when connected to the 14 pin amphenol. Machine operates normally in the “CC­STICK” mode and has normal AC auxiliary output.
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.
Use a volt meter to check for the presents of supply voltage at the 14 pin Amphenol receptacle. 120 Volt AC power supplied through pins A and J, 421 VAC power is supplied through pins I and K. Perform the STATOR VOLTAGE
TEST.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 61
F-13 F-13
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
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 in the “WELD TERMI­NALS 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 connec­tions between the feeder and the welder output terminal, and between the work and the other output 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). Reset if tripped. Make sure the run/stop switch is in the “RUN” position. Check for loose or faulty battery cable connections. See wiring dia­gram. 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).
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 CONTROL POTEN-
TIOMETER AND WELD MODE SWITCH RESISTANCE TEST.
If there is no OCV, see the trou­bleshooting sections for “No weld
output in any mode”.
Check the wiring and the connec­tions 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 con­nection (-) and lead #231 (+) 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 breaker. See wiring diagram. If battery voltage is present, the starter motor or solenoid may be defective, or the engine may be prevented from turning due a mechanical failure.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 62
F-14 F-14
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)
POSSIBLE AREAS OF MISADJUSTMENT(S)
OUTPUT PROBLEMS

The battery does not stay charged. Check for loose, corroded, or

faulty connections at the battery. Check for loose or damaged alter­nator drive belt. The battery may be faulty.

The engine cranks when the start button is pressed but will not start.

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 manu­al, or the operation section of this manual for proper starting proce­dure. 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 ENGINE ALTERNA­TOR TEST.
There may be a defective compo­nent 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 63
F-15 F-15
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)

The engine starts but shuts down immediately when the start button is released.

POSSIBLE AREAS OF MISADJUSTMENT(S)
OUTPUT PROBLEMS
Make sure the glow plug button is pressed while pushing the start button, and held until the engine protection light turns off (5 SEC­ONDS MAXIMUM AFTER THE ENGINE STARTS.). See the oper­ator’s manual, or the operating section of this manual for proper starting procedure. Check the oil level. Be certain that the engine is not overheated. Check that the machine had ade­quate supply of fresh, clean fuel. The fuel filter may be clogged. Replace if necessary.
RECOMMENDED COURSE OF ACTION
The shut down fuel solenoid may be faulty or not operating properly. Check lead #233 and #262 and perform the FUEL SHUT DOWN SOLENOID TEST. See wiring diagram. The check for the presents of 12 volts at the lead #233, when start button is pushed. Check CB5, and lead #231.
The Engine Protection Board may be faulty.
The engine may have inadequate oil pressure.
The oil pressure switch or coolant temperature switch may be faulty.

The engine shuts down shortly after starting.

Check for adequate supply of clean fresh fuel. Check fuel and air filters, replace if necessary. Check oil level, add oil as required. Look for oil leakage. Check for loose or faulty battery cable connections.
The oil pressure switch or coolant temperature switch may be faulty. Make sure the engine has oil and oil pressure and engine is not overheated. Disconnect lead 234 from Engine Protection PC Board, of engine 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 pro­tection relay and the oil pressure and coolant temperature switches.
See wiring diagram.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 64
F-16 F-16
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)

The engine shuts down shortly after starting.

The engine shuts down shortly after starting and trips the battery circuit breaker (CB5).

POSSIBLE AREAS OF MISADJUSTMENT(S)
OUTPUT PROBLEMS
Try resetting the breaker. If it trips again do not attempt to use the machine.
Contact a Lincoln Authorized Field Service Shop.
RECOMMENDED COURSE OF ACTION
Check for poor electrical connec­tions at the run/stop switch, and the fuel shutdown solenoid. See
wiring diagram.
The fuel solenoid may be faulty. Perform the FUEL SHUTDOWN
SOLENOID TEST.
Repeated tripping and resetting of the circuit breaker can damage it, or alter its trip point. If the breaker has been ripped and reset many times, it should be replaced. 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 compo­nents. Look for damaged or out of place wiring that may be in contact with other conductors or chassis ground. See wiring diagram. Perform the IDLER SOLENOID
TEST. Perform the FUEL SHUTDOWN SOLENOID TEST.
The Engine Protection PC Board may be defective.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 65
F-17 F-17
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)

The engine will not develop full power.

The engine will not idle down to low RPM. The machine has nor­mal weld and auxiliary output.
POSSIBLE AREAS OF MISADJUSTMENT(S)
OUTPUT PROBLEMS
The fuel may be old or contami­nated. Supply the engine with clean fresh fuel. The fuel filter may be clogged, replace if necessary. The air filter may be clogged, replace if necessary.
Make sure the idle switch is in the “AUTO IDLE” position. Make sure there is no external load on the weld terminals or the auxiliary power receptacles. Check for mechanical restrictions in the idler solenoid linkage.
RECOMMENDED COURSE OF ACTION
The engine may be in need of adjustment or repair.
Perform the IDLER SOLENOID
TEST.
Check for damaged wiring or faulty connections at the idle solenoid, the engine protection PC Board, the run/stop switch and the start button. Check for loose or damaged wiring or faulty connections at leads #405 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). See
wiring diagram.
Set idle switch in the “AUTO” posi­tion. 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 66
F-18 F-18
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)
The engine will not idle down to low RPM. The machine has nor­mal weld and auxiliary output.
(continued)
POSSIBLE AREAS OF MISADJUSTMENT(S)
OUTPUT PROBLEMS
RECOMMENDED COURSE OF ACTION
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. See wiring dia-
gram.
If the engine still does not drop to low idle the control PC Board is probably defective. Replace it. Check that leads #3 and #6 are properly routed through the toroidal current sensor. Each lead must have two turns and must pass through the sensor in the opposite directions. See the 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 con­trol PC Board. Unplug plug P3 from the control PC Board and check for damaged, dirty, or corroded pins.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 67
F-19 F-19
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)
The engine will not idle down to low RPM. The machine has nor­mal 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 func­tion works properly when welding.
POSSIBLE AREAS OF MISADJUSTMENT(S)
OUTPUT PROBLEMS
The load on the auxiliary recepta­cle 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 auxil­iary power may be defective try another device. Make sure the connections to the auxiliary device are tight. Some device are designed to sense for adequate input power. Product of this type may not turn on due to low voltage and frequen­cy of the idling machine. If this happens the current draw will like­ly be insufficient to activate the automatic idle system. Device of this type may require that the Idler switch be in the “HIGH IDLE” posi­tion.
RECOMMENDED COURSE OF ACTION
Measure the resistance of toroidal current sensor. Measure between #P-3 and #P-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 are 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 con­trol PC board. Unplug 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 resis­tance should be 10-14 Ohms. If the sensor is shorted or open replace it. The control P.C. Board may be defective.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 68
F-20 F-20
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS (SYMPTOMS)

The engine will not go to high idle when striking arc. The automatic idle system functions normally when using auxiliary power. Welding and auxiliary outputs are normal when the idle switch is in the “HIGH IDLE” position.

The engine will not go to high idle when attempting to strike and arc, or when a load is applied to any of the auxiliary power receptacles.

The engine goes to low idle, but will not stay low idle.

POSSIBLE AREAS OF MISADJUSTMENT(S)
OUTPUT PROBLEMS
Check that the welding cables are in good working condition and the connections are tight. Make sure the work clamp is attached to clean, bare metal.
Check that the welding cables and the auxiliary power lead connec­tions are tight.
Make sure there are no auxiliary loads on either the weld terminals or the auxiliary receptacles. Check that the welding cables and the auxiliary cables and the auxil­iary power lead connections are tight and that the insulation is not damaged.
RECOMMENDED COURSE OF ACTION
Check the leads and connections at the SHUNT at the Positive out­put stud. Check lead 204S and 206S for continuity from the shunt to J-6 on the Weld Control Board. Check the pins and connections at J-6 and J on the Weld Control Board. The weld control P.C. Board may be defective.
The weld control P.C. Board may be defective.
The Idler solenoid linkage may be damaged or out of adjustment. Make sure the solenoid plunger is able to fully ease against the inter­nal stop of the solenoid coil assembly. The low idle RPM may be too low. Perform the ENGINE THROTTLE
ADJUSTMENT TEST.
The solenoid hold coil power cir­cuit may be defective. Perform the IDLER SOLENOID TEST. The solenoid hold coil power cir­cuit may be faulty. Check wiring and connections on lead #210A and lead #215. The weld control PC Board may be defective.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 69
F-21 F-21
TROUBLESHOOTING & REPAIR
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the case sheet metal covers.
MATERIALS NEEDED
3/8" wrench
1/2" wrench
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 70
Battery Drawer
Left Case Side
Roof
Lift Bale Seal
Fuel Tank Seal
Right Side Service Access Door
Right Case Side
Fuel Tank Cap
F-22 F-22
TROUBLESHOOTING & REPAIR
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.1 – DOOR REMOVAL
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
PROCEDURE
1. Turn the engine off.
2. Using the 3/8" wrench, remove the battery cover. Slide the battery out and disconnect the negative battery cable.
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.
VANTAGE® 400
9. With the help of an assistant, carefully remove the roof. Replace the fuel cap.
10. With the 3/8” wrench, remove the right case
side and the left case side. See Figure F.1.
Page 71
F-23 F-23
TROUBLESHOOTING & REPAIR
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
REASSEMBLY PROCEDURE
1. Install components in reverse order of removal.
2. Be sure components align correctly.
3. Reconnect battery and replace battery door.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 72
F-24 F-24
NOTES
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 73
F-25 F-25
TROUBLESHOOTING & REPAIR
CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting 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 dis­charged. This procedure should be performed whenever work is to be attempted on or near the chopper module.
MATERIALS NEEDED
Miscellaneous hand tools Volt/Ohmmeter Resistor (25-1000 ohms and 25 watts minimum)
Lincoln part #S10404-114 works well for this purpose Jumper leads Wiring Diagram
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 74
B1
B2
B3 B6
B5
B4
INSULATED
GLOVES
INSULATED
PLIERS
F-26 F-26
TROUBLESHOOTING & 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.
• 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 capaci­tors.
3. Locate the chopper module and capacitor assembly on the inner machine baffle. See
Figure F.2 and the Wiring Diagram.
NEVER USE A SHORTING STRAP TO DIS­CHARGE CAPACITORS. If 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 B4 to B5. DO NOT TOUCH THE TER­MINALS 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 75
F-27 F-27
TROUBLESHOOTING & REPAIR
FUEL SHUTDOWN SOLENOID TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
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)
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 76
VANTAGE 400
LINCOLN
ELECTRIC
SHUTDOWN SOLENOID
IDLE SOLENOID
F-28 F-28
TROUBLESHOOTING & REPAIR
FUEL SHUTDOWN SOLENOID TEST (CONTINUED)
FIGURE F.3 - FUEL SHUTDOWN SOLENOID LOCATION
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
TEST PROCEDURE
1. Turn the engine off.
2. Open the right side engine service access door.
3. Locate the fuel solenoid, located on top of the engine.
4. Locate and unplug harness connection 56. Cut any necessary cable ties. See Figure F.4. See Wiring Diagram.
5. Check the coil resistance, (black wire to red wire). The normal resistance is approximately 9 ohms. Check the Resistance between the black wire and a clean, unpainted chassis ground. The resistance should be very high, 500,000 Ohms or more. If any of the above resistance values are incorrect, the solenoid may be faulty. Replace.
VANTAGE® 400
6. Using an external 12VDC supply, apply volt­age to the coil leads, (black-) to (white+). The solenoid should activate.
If the solenoid does not operate correctly when 12VDC is applied, the solenoid may be defective. Replace.
Re-connect fuel solenoid and replace any previously removed cable ties.
7. If finished testing, close the engine service access doors.
Page 77
F-29 F-29
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
If the machine output is low or high, this test will determine whether the engine is operat­ing at the correct speed (RPM) during both HIGH and LOW idle conditions. You can check RPM 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
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 78
STROBE
TACH
MARK
F-30 F-30
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)
FIGURE F.4 - STROBE MARK LOCATION
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
TEST PROCEDURE
Strobe-Tach Method
1. Turn the engine off
2. open the top and right side engine service access doors.
3. Place a highly visible mark on the engine cool­ing fan blade. See Figure F.4.
4. Connect the strobe-tach according to the man­ufacturer’s instructions.
5. Start the engine and place the idle switch in the “HIGH IDLE” position. Make sure that there is no load on the machine.
6. 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.
VANTAGE® 400
7. Move the idle switch to the “AUTO IDLE” posi­tion and wait for the idle solenoid to energize, and the engine RPM to drop and stabilize at the low idle RPM.
8. 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 later in this section.
Page 79
VANTAGE 400
LINCOLN
ELECTRIC
SHUTDOWN SOLENOID
IDLE SOLENOID
LOW SPEED ADJ.
DO NOT TOUCH FOR LOW SPEED
HIGH SPEED ADJ.
F-31 F-31
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)
FIGURE F.5 - SOLENOID
Frequency Counter Method
NOTE: A dedicated frequency counter can be used for this test, but many high quality digital mul­timeters also have this function, and can be easily utilized. See the manufacturer instructions for your frequency counter or multimeter.
1. Set your frequency counter per the meter man­ufacturer instructions, and plug it into one of the 120VAC auxiliary receptacles.
2. Start the engine and place the idle switch in the “HIGH IDLE” position. Make sure that there is no load on the machine.
The frequency should read between 62.0 and
63.0 Hz.
3. Move the idle switch to the “AUTO IDLE” posi­tion and wait for the idle solenoid to energize, and the engine RPM to drop and stabilize at the low idle RPM.
The frequency should read between 43.3 and
46.6 Hz. If either of the readings is incorrect, proceed to
the THROTTLE ADJUSTMENT PROCE- DURE later in this section.
NOTE: For the VANTAGE® 400, and any other Lincoln Electric 1800 RPM (4 Pole) machine, engine RPM can be determined by multiplying the frequency, in Hz. By 30. (Example: 30 Hz * 62 = 1860RPM)
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 80
F-32 F-32
TROUBLESHOOTING & 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 instruc­tions 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” posi­tion 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 “THROTTLE ADJUSTMENT PROCE­DURE”.
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. If the 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 tighten­ing 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.
3. Re-check the low idle RPM, and then proceed to the high idle adjustment.
High idle adjustment:
THROTTLE ADJUSTMENT PROCEDURE
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 (de­energized 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.
1. With engine running, place the idle switch in the “HIGH IDLE” position. The solenoid should immediately de-energize, allowing the engine to increase to high idle speed.
2. If 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.
3. Re-check the high idle RPM.
4. Close the engine service access doors and shut off the engine.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 81
F-33 F-33
TROUBLESHOOTING & REPAIR
IDLER SOLENOID TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the idler solenoid resistance values are normal, and also deter­mine 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
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 82
BLACK
RED
P-55
J-55
IDLE SOLENOID CONNECTOR (LEAD ENTRY VIEW)
IDLE SOLENOID WIRING HARNESS CONNECTOR (LEAD ENTRY VIEW)
1
3
2
4
WHITE PULL
3
1
4
2
226
232L
227
ENGINE PROTECTION IDLE CONTROL P.C.B.
12 VOLT + RUN
ENGINE PROTECTION IDLE CONTROL P.C.B.
COMMON
HOLD
F-34 F-34
TROUBLESHOOTING & REPAIR
IDLER SOLENOID TEST (CONTINUED)
FIGURE F.6 - PLUG(S) PIN LOCATION
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
TEST PROCEDURE
1. Turn the engine off.
2. Open the right side engine service access door.
3. Locate the idler solenoid mounted right side of engine.
4. Locate and unplug harness connection P-55. Cut any necessary cable ties. See Wiring Diagram.
5. Using the volt/ohmmeter, check the pull-in coil resistance, pins 3 and 4 (black wire to white wire). The normal resistance is less than 0.2 ohms. Check the hold-in coil resistance, pins 3 and 2 (black wire to red wire). The normal resistance is approximately 11 ohms. Check the resistance between pin 3 (black wire) and a clean, unpainted chassis ground. The resis­tance should be very high. 500,000 Ohms or more. If any of the above resistance values are incorrect, the solenoid may be faulty. Replace. See Figure F.6.
6. Using the external 12VDC supply, apply
7. If either coil does not operate as described,
8. If the linkage is intact and the solenoid does
9. Re-connect idle solenoid and replace any pre-
10. If finished testing, close the engine service
VANTAGE® 400
12VDC to the pull-in coil leads at pins 3+ and 4- (black wire to white wire). The solenoid should activate. REMOVE THE VOLTAGE IMMEDIATELY to avoid damage to the unit.
Apply 12VDC to the hold-in coil at pin #3 (black wire +) and pin #2 (red wire -). While the volt­age is applied, manually move the solenoid to the low idle position. The solenoid plunger should hold this position until the voltage is removed. See Figure F.6.
check for mechanical restrictions or other prob­lems with the linkage.
not operate correctly when the 12VDC is applied, the solenoid may be faulty. Replace.
viously removed cable ties.
access door.
Page 83
F-35 F-35
TROUBLESHOOTING & REPAIR
ENGINE ALTERNATOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the engine alternator is properly charging the battery.
MATERIALS NEEDED
Miscellaneous hand tools Volt meter Wiring Diagram
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 84
243
238
BACK OF ALTERNATOR
F-36 F-36
TROUBLESHOOTING & REPAIR
ENGINE ALTERNATOR TEST (CONTINUED)
FIGURE F.7 - LEAD LOCATIONS
TEST PROCEDURE
1. Turn the engine off.
2. Open the engine access door and check the voltage at the battery terminals. It should be approximately 12 volts DC.
3. Attach the meter leads to the battery terminals, being careful to position them so they stay clear of moving parts while the engine is run­ning.
4. Place the idle switch in the “HIGH IDLE” posi­tion, start the engine, and allow it to run at high idle speed for about 15 to 30 seconds.
5. The meter should read about 13.7 to 14.2 VDC.
6. If the meter reads correctly the engine alterna­tor is producing adequate power to charge the battery and this test is complete.
6. If the voltage is significantly higher than the above values, the alternator is not properly regulating the battery charging voltage and should be replaced. If the voltage reads the same or less than the measurement taken when the engine was not running, proceed with the following tests.
7. Turn off the engine, disconnect the meter from the battery, and open the engine access door on the left side of the machine.
8. Make sure the idle switch is still in the “high” position, start the engine, and allow it to run at high idle speed for about 15 to 30 seconds.
9. Place the negative meter probe on a good chassis ground, or the negative battery termi­nal. Place the positive meter probe on the bat­tery terminal on the back of the alternator. (Lead #238) See Figure F.7. See Wiring Diagram.
10. The meter should read about 13.7 to 14.2 VDC.
11. Move the positive probe to the DT terminal on the back of the alternator. (Lead 243C) See Figure F7.
12. The meter should read about 13.7 to 14.2 VDC.
13. If the meter reads correctly, check the connec­tions between the alternator and the battery. See wiring diagram.
14. If the voltage at both of the above test points reads the same or less than the battery voltage measurement taken when the engine was not running, the alternator is defective. Repair or replace it.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 85
F-37 F-37
TROUBLESHOOTING & REPAIR
BRUSH AND SLIP RING SERVICE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure provides guidance in testing and maintaining the brush and slip ring sys­tem.
MATERIALS NEEDED
Volt/Ohmmeter Miscellaneous hand tools 500 or 600 grit emery cloth 180 grit sand paper
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 86
BRUSHES
SLIP RINGS
#200A
#200B
#201
F-38 F-38
TROUBLESHOOTING & REPAIR
BRUSH AND SLIP RING SERVICE PROCEDURE (CONTINUED)
FIGURE F.8 – BRUSH & SLIP RING LOCATIONS
TEST PROCEDURE
1. Perform the Case Cover Removal Procedure
2. Examine brushes and slip rings. The slip rings, 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.
3. 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 suffi­cient to hold the brushes firmly against the slip rings.
4. 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.
5. 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 test.
6. Check for evidence of sticking brushes. Sticking brushes will normally result in the slip rings being pitted and discolored from excessive arc­ing. Another sign of sticking brushes is instabili­ty 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.
7. 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:
1. In the event that the slip rings have become dirty, discolored or mildly pitted, it will be neces­sary to clean them, using very fine, 500 or 600 grit sand paper or a 220 or 320 grit commutator stone.
Seating Brushes:
1. 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.
2. Use a low pressure compressed air to thorough­ly blow the carbon, commutator stone, and sandpaper dust from the machine before operat­ing.
3. Perform the Case Cover Replacement
Procedure
Note: See Figure F.8 for general locations.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 87
F-39 F-39
TROUBLESHOOTING & REPAIR
ROTOR RESISTANCE AND GROUND TEST (STATIC)
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
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
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 88
BRUSHES
SLIP RINGS
#200A
#200B
#201
-
+
F-40 F-40
TROUBLESHOOTING & REPAIR
ROTOR RESISTANCE AND GROUND TEST (STATIC) (CONTINUED)
FIGURE F.9 - ROTOR BRUSH LEADS
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
TEST PROCEDURE
1. Turn 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 77º F. (25º C.).
VANTAGE® 400
5. 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 (500k) ohms.
6. If the test does not meet the resistance speci­fications, then the rotor may be faulty and should be replaced.
7. If this test meets the resistance specifications, continue testing using the dynamic rotor resis­tance and ground test.
Page 89
F-41 F-41
TROUBLESHOOTING & REPAIR
ROTOR RESISTANCE AND GROUND TEST (DYNAMIC)
(Also referred to as flying resistance test)
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
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 digi­tal meters will not provide stable or accurate Resistance readings while the rotor is spin­ning.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 90
F-42 F-42
TROUBLESHOOTING & REPAIR
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 procedure if necessary.
2. Insulate the lead wires that had been discon­nected 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 25Ω at 77ºF (25º C.)
4. Shut off engine, and move one of the ohmme­ter 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 (500k) ohms.
6. If the resistance readings differ significantly from the values indicated, re-check the brush­es and the brush spring tension. If the brush­es and slip rings are good, replace the rotor.
7. If all testing is finished, perform the Case Cover Replacement procedure.
*NOTE: The resistance of the windings will change with temperature. Higher temperatures will produce higher resistance, and lower temper­atures will produce lower resistance.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 91
F-43 F-43
TROUBLESHOOTING & REPAIR
ROTOR VOLTAGE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the rotor winding is operating at normal charge.
MATERIALS NEEDED
Miscellaneous hand tools Voltmeter Wiring Diagram
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 92
BRUSHES
SLIP RINGS
#200A
#200B
#201
-
+
F-44 F-44
TROUBLESHOOTING & REPAIR
ROTOR VOLTAGE TEST (CONTINUED)
FIGURE F.10 - LEAD LOCATIONS
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
TEST PROCEDURE
1. Perform the Case Cover Removal procedure.
2. Connect the voltmeter probes to the brush ter­minals. See Figure F.10. See the wiring dia­gram.
3. Set the RUN/STOP switch to “RUN” and the IDLE switch to “HIGH”. Start the engine and allow the RPM to stabilize for about 15 to 30 seconds.
The meter should read 145 to 175 VDC.
4. Set the RUN/STOP switch to “STOP”
5. If the meter reading is normal, this test is com­plete.
6. If the voltage measures zero or very near zero, the rotor flashing circuit may be faulty or the rotor may be shorted.
7. Perform the Rotor Resistance and Ground Test and the Flashing Voltage Test.
VANTAGE® 400
8. If voltage is higher than 175 VDC, the engine RPM may be too high, or there may be voltage intrusion from one of the higher voltage stator windings to the stator exciter winding. Perform the Engine Throttle Adjustment Test, and the Stator Short Circuit and Ground Test.
9. If the voltage is lower than 145, but higher than 120, the engine RPM may be too low, or there may be problems in the windings or other exciter circuit components or connections. Perform the Engine Throttle Adjustment Test, and then perform the testing described below, under the heading “If the voltage mea-
sures about 3 to 5 VDC”
Page 93
F-45 F-45
TROUBLESHOOTING & REPAIR
ROTOR VOLTAGE TEST (CONTINUED)
10. If the meter reading indicates battery volt-
age, 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, and Brush and Slip Ring Service Procedure.
11. If the voltage measures about 3 to 5 VDC, the generator is not building-up to normal out­put even though the flashing circuit appears to be functioning normally. This condition could be caused by one of several failed compo­nents or connections. Continue with the fol­lowing test.
12. Check the field bridge rectifier, and capacitor; also check the wiring and terminals connecting them. See the wiring diagram.
13. Perform the Rotor Resistance Test.
14. Perform the Stator Short Circuit and Ground Test.
15. When the Stator short circuit and ground test has been completed, reconnect leads 6 and 5H to the field bridge rectifier, (D3). 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 insu­lated, 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 voltage 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 inde­pendently, 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 compo­nents before replacing the stator.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 94
F-46 F-46
NOTES
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 95
F-47 F-47
TROUBLESHOOTING & REPAIR
FLASHING VOLTAGE TEST
(Engine Not Running)
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test checks the flashing voltage with the engine stopped, by simulating a running con­dition.
MATERIALS NEEDED
Miscellaneous hand tools Voltmeter Wiring Diagram
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 96
F-48 F-48
TROUBLESHOOTING & REPAIR
FLASHING VOLTAGE TEST (CONTINUED)
TEST PROCEDURE
1. Perform the Case Cover Removal Procedure.
2. Make sure that the battery is fully charged and in good condition, and the battery con­nections are clean and tight.
3. Remove leads 234 and 235 from the oil pres­sure 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. Place the RUN/STOP switch in the “RUN” position. (The engine protection light should remain off.)
5. Connect the voltmeter probes to brush ter-
minals.
6. Measure the voltage; it should read about 3 to
5 VDC.
7. Set the RUN/STOP switch to the “STOP” position.
8. If the meter reads normal voltage of 3 to 5 VDC, this test is complete.
9. 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.
11. 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 follow­ing additional test.
13. Switch the RUN/STOP switch to the “RUN” position.
14. 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 #5S (B1) to (+) Lead #232 (J31-1)
(-) Lead #5S (B1) to (+) Lead #232F (J31-2)
(-) Lead #5S (B1) to (+) Lead #200 (J33-5)
NOTE: Lead #232 supplies 12VDC battery volt­age 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 through.
15. If battery voltage is present at all of the
above points; check the top grounding stud on inside left case from and lead #5H, also check leads #200, #200B, R3. Make sure all terminals are crimped tightly to the flex leads and arc free of corrosion.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
10. Perform the Rotor Resistance Test.
Perform the Brush and Slip Ring Service Procedure.
11. 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.
12. Perform the Rotor Resistance Test.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 97
F-49 F-49
TROUBLESHOOTING & REPAIR
FLASHING VOLTAGE TEST (CONTINUED)
16. If battery voltage is present at leads #232 and #232F, but not present at leads #200 The engine protection / idle P.C.B. board is proba­bly defective. Replace.
17. If battery voltage is present at lead #232, but not present at leads #232F or #200 check the engine protection wiring per the wiring dia­gram.
18. If battery voltage is not present at lead #232, check wiring per wiring diagram, and check the run/stop switch. Also check the ground PC board chassis ground wire, lead #5K and the stud where it connects to the chassis.
19. Set the RUN/STOP switch to the “STOP” position.
20. Re-connect lead #234 to the oil pressure switch.
21. If testing is completed, perform the Case Cover Replacement procedure.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 98
F-50 F-50
NOTES
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 99
F-51 F-51
TROUBLESHOOTING & REPAIR
STATOR VOLTAGE TESTS
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
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 at least one of the AC output volt­ages is correct.
MATERIALS NEEDED
Miscellaneous hand tools Voltmeter Test pins
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
VANTAGE® 400
Page 100
F-52 F-52
AMPHENOL 1
KEY
E
C
D
A
B
L
K
J
M
N
F
G
H
I
CONTACTOR CONTROL
L4
GROUND
120 VAC FOR WIRE FEEDER
40 VAC FOR WIRE FEEDER
21 WORK SENSE
2 TIMES THRU FERRITE LEADS 75A, 76A, & 77A
REMOTE CONTROL
TROUBLESHOOTING & REPAIR
STATOR VOLTAGE TESTS (CONTINUED)
FIGURE F.11 RECEPTACLE LEAD LOCATIONS (TYPICAL)
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
TEST PROCEDURE
1. Perform the Case Cover Removal procedure.
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. If 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. For the upper receptacle, place the probes direct­ly into receptacle, or connect to leads #3D and #5A. See Figure F.11. See wiring diagram.
For the lower receptacle, place the probes direct­ly into the receptacle, or connect to leads #6E and 5B. See Figure F.11. See wiring diagram.
VANTAGE® 400
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 recepta­cle, or insert the probes into the 240 VAC con­nection 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 spec­ified limits, check for tripped or defective circuit breakers, loose connections, or broken wires between the test points and the stator windings. If there are no wiring problems, and the circuit breakers are not tripped or defective, the stator is defective and should be replaced.
Loading...