For use with machines having Code Numbers: 11186, 11462
VANTAGE 400
LINCOLN
ELECTRIC
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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
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• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Page 2
ii
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.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.
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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
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iiii
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
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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
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iiiiii
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.
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VANTAGE® 400
Page 5
iviv
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
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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.
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ENGINE
LUBRICATION EMISSIONSFUEL 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 IDLERMUFFLER ENGINE PROTECTION
Single ElementAutomatic IdlerTop 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.
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VANTAGE® 400
Page 9
A-3A-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.
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.
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VANTAGE® 400
Page 10
A-4A-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.
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.
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.
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.
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VANTAGE® 400
Page 11
A-5A-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.
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.
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
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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.
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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.
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
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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.
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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.
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.
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NOTE: The 240 V receptacle has two 120 V circuits,
but are of opposite polarities and cannot be paralleled.
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VANTAGE® 400
Page 14
A-8A-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
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• 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.
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VANTAGE® 400
Page 15
A-9A-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.
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VANTAGE® 400
Page 16
A-10A-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.
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If you are using an LN-25 without an internal contactor, the electrode will be energized when the
VANTAGE® 400 is started.
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VANTAGE® 400
Page 18
B-2B-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.
• 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.
• 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
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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.
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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.
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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.
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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-4B-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.
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)
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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.
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MODEVRD "ON"VRD "OFF"
CC-STICK OCVGreen (OCV Reduced)
CV-WIRE OCVRed (OCV Not Reduced)
PIPEOCVGreen (No Output)
ARC GOUGING
TIGOCVGreen (Process is Low Voltage)
* It is normal for the lights to alternate between colors while welding.
VANTAGE® 400
TABLE B.1
VRD INDICATOR LIGHTS
WhileRed 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
WhileRed or Green
Welding (Depends on Weld Voltage) *
WhileNot Applicable (No Output)
Welding
OCV Green (No Output)
While Not Applicable (No Output)
Welding
WhileGreen (Process is Low Voltage)
Welding
Gun Trigger OpenNo Lights
Page 21
B-5B-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
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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.
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VANTAGE® 400
Page 22
B-6B-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.
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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.
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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-7B-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.
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(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):
PureEWP
1% ThoriatedEWTh-1
2% ThoriatedEWTh-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
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• 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.
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VANTAGE® 400
Page 26
C-2C-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:
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
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)
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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.
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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-3C-3
ACCESSORIES
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VANTAGE® 400
Page 28
C-4C-4
ACCESSORIES
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VANTAGE® 400
Page 29
C-5C-5
ACCESSORIES
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VANTAGE® 400
Page 30
C-6C-6
ACCESSORIES
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VANTAGE® 400
Page 31
C-7C-7
2
9/03
ACCESSORIES
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VANTAGE® 400
Page 32
C-8C-8
NOTES
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VANTAGE® 400
Page 34
D-2D-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.)
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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.
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-3D-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.
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.
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.
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VANTAGE® 400
Page 38
D-6D-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!
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VANTAGE® 400
Page 39
D-7D-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.
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VANTAGE® 400
Page 40
D-8D-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
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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 ChopperTechnology 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.
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.
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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-4E-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
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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).
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.
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VANTAGE® 400
Page 46
E-6E-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.
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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-7E-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.
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VANTAGE® 400
Page 48
E-8E-8
NOTES
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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
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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.
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VANTAGE® 400
Page 51
F-3F-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.
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- Tools which come in contact with the PC board must
be either conductive, anti-static or static-disipative.
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VANTAGE® 400
Page 52
F-4F-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.
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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.
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VANTAGE® 400
Page 53
F-5F-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.
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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.
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VANTAGE® 400
Page 54
F-6F-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.
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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.
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VANTAGE® 400
Page 55
F-7F-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 TOCReturn to Section TOCReturn to Section TOCReturn 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 TOCReturn to Master TOCReturn to Master TOCReturn to Master TOC
VANTAGE® 400
Page 56
F-8F-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 TOCReturn to Section TOCReturn to Section TOCReturn 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 TOCReturn to Master TOCReturn to Master TOCReturn to Master TOC
VANTAGE® 400
Page 57
F-9F-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 TOCReturn to Section TOCReturn to Section TOCReturn 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 TOCReturn to Master TOCReturn to Master TOCReturn to Master TOC
VANTAGE® 400
Page 58
F-10F-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 TOCReturn to Section TOCReturn to Section TOCReturn 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 TOCReturn to Master TOCReturn to Master TOCReturn to Master TOC
VANTAGE® 400
Page 59
F-11F-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 TOCReturn to Section TOCReturn to Section TOCReturn 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 TOCReturn to Master TOCReturn to Master TOCReturn to Master TOC
VANTAGE® 400
Page 60
F-12F-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 TOCReturn to Section TOCReturn to Section TOCReturn 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 TOCReturn to Master TOCReturn to Master TOCReturn to Master TOC
VANTAGE® 400
Page 61
F-13F-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 TOCReturn to Section TOCReturn to Section TOCReturn 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 TOCReturn to Master TOCReturn to Master TOCReturn to Master TOC
VANTAGE® 400
Page 62
F-14F-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 TOCReturn to Section TOCReturn to Section TOCReturn 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 TOCReturn to Master TOCReturn to Master TOCReturn to Master TOC
VANTAGE® 400
Page 63
F-15F-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 DOWNSOLENOID 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 TOCReturn to Section TOCReturn to Section TOCReturn 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 TOCReturn to Master TOCReturn to Master TOCReturn to Master TOC
VANTAGE® 400
Page 64
F-16F-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 TOCReturn to Section TOCReturn to Section TOCReturn 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 TOCReturn to Master TOCReturn to Master TOCReturn to Master TOC
VANTAGE® 400
Page 65
F-17F-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 TOCReturn to Section TOCReturn to Section TOCReturn 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 TOCReturn to Master TOCReturn to Master TOCReturn to Master TOC
VANTAGE® 400
Page 66
F-18F-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. Seethe 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 TOCReturn to Section TOCReturn to Section TOCReturn 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 TOCReturn to Master TOCReturn to Master TOCReturn to Master TOC
VANTAGE® 400
Page 67
F-19F-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 TOCReturn to Section TOCReturn to Section TOCReturn 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.
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VANTAGE® 400
Page 68
F-20F-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.
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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.
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VANTAGE® 400
Page 69
F-21F-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
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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-22F-22
TROUBLESHOOTING & REPAIR
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.1 – DOOR REMOVAL
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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-23F-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.
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VANTAGE® 400
Page 72
F-24F-24
NOTES
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VANTAGE® 400
Page 73
F-25F-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
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• 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.
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VANTAGE® 400
Page 75
F-27F-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)
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VANTAGE® 400
Page 76
VANTAGE 400
LINCOLN
ELECTRIC
SHUTDOWN SOLENOID
IDLE SOLENOID
F-28F-28
TROUBLESHOOTING & REPAIR
FUEL SHUTDOWN SOLENOID TEST (CONTINUED)
FIGURE F.3 - FUEL SHUTDOWN SOLENOID LOCATION
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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-29F-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
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VANTAGE® 400
Page 78
STROBE
TACH
MARK
F-30F-30
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)
FIGURE F.4 - STROBE MARK LOCATION
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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-31F-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)
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VANTAGE® 400
Page 80
F-32F-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.
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VANTAGE® 400
Page 81
F-33F-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
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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-35F-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
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VANTAGE® 400
Page 84
243
238
BACK OF ALTERNATOR
F-36F-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.
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VANTAGE® 400
Page 85
F-37F-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
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VANTAGE® 400
Page 86
BRUSHES
SLIP RINGS
#200A
#200B
#201
F-38F-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 resistancetest.
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.
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VANTAGE® 400
Page 87
F-39F-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
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VANTAGE® 400
Page 88
BRUSHES
SLIP RINGS
#200A
#200B
#201
-
+
F-40F-40
TROUBLESHOOTING & REPAIR
ROTOR RESISTANCE AND GROUND TEST (STATIC) (CONTINUED)
FIGURE F.9 - ROTOR BRUSH LEADS
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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-41F-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.
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VANTAGE® 400
Page 90
F-42F-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 serviceprocedure 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 CaseCover 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.
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VANTAGE® 400
Page 91
F-43F-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
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VANTAGE® 400
Page 92
BRUSHES
SLIP RINGS
#200A
#200B
#201
-
+
F-44F-44
TROUBLESHOOTING & REPAIR
ROTOR VOLTAGE TEST (CONTINUED)
FIGURE F.10 - LEAD LOCATIONS
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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 GroundTest 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 higherthan 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 AdjustmentTest, and then perform the testing described
below, under the heading “If the voltage mea-
sures about 3 to 5 VDC”
Page 93
F-45F-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 andSlip 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 GroundTest.
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.
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VANTAGE® 400
Page 94
F-46F-46
NOTES
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VANTAGE® 400
Page 95
F-47F-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
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VANTAGE® 400
Page 96
F-48F-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 5VDC, 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.
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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.
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VANTAGE® 400
Page 97
F-49F-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 CaseCover Replacement procedure.
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VANTAGE® 400
Page 98
F-50F-50
NOTES
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VANTAGE® 400
Page 99
F-51F-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
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VANTAGE® 400
Page 100
F-52F-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)
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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.
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