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Lincoln Electric 400 manual

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Table of contents for the manual

  • Page 1

    V ANT A GE ® 400 SVM182-A April, 201 1 For use with machines having Code Numbers: 1 1 186, 1 1462 SER VICE MANUAL • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 888.935.3877 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com • W orld's Leader in W elding and Cutting Pr[...]

  • Page 2

    V ANT AGE® 400 SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _____________________[...]

  • Page 3

    SAFETY ii ii V ANT AGE® 400 FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. A void 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 re[...]

  • Page 4

    V ANT AGE® 400 SAFETY iii iii FOR ELECTRICALL Y 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 wit[...]

  • Page 5

    SAFETY iv iv V ANT AGE® 400 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 suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: [...]

  • Page 6

    I I - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - V ANT AGE® 400 Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 7

    T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 V ANT AGE® 400 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 8

    INST ALLA TION A-2 A-2 V ANT AGE® 400 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. * T o T op of enclosure, add 10.68”(271.3mm) to top of exhaust pipe. Add 6.67”(169.4mm) to top of Lift[...]

  • Page 9

    INST ALLA TION A-3 A-3 V ANT AGE® 400 SAFETY PRECAUTIONS Only qualified personnel should install, use, or service this equipment. 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 start- ing, operating and mai[...]

  • Page 10

    INST ALLA TION A-4 A-4 V ANT AGE® 400 HIGH AL TITUDE OPERA TION At higher altitudes, output derating may be necessary . For max- imum rating, derate the machine 2.5% to 3.5% for every 1000 ft. (305m). Due to new EP A and other local emissions regulations, modifications to the engine for high altitude are restricted within the United States. For us[...]

  • Page 11

    INST ALLA TION A-5 A-5 V ANT AGE® 400 O I L The V ANT AGE® 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 fo[...]

  • Page 12

    INST ALLA TION A-6 A-6 V ANT AGE® 400 ELECTRICAL CONNECTIONS MACHINE GROUNDING Because this portable engine driven welder creates its own power , it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.) T o prevent dangerous electric shock, other equipment to which this engi[...]

  • Page 13

    INST ALLA TION A-7 A-7 V ANT AGE® 400 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 . ST ANDBY POWER CONNECTIONS The V A[...]

  • Page 14

    INST ALLA TION A-8 A-8 V ANT AGE® 400 CONNECTION OF V ANT AGE® 400 TO PREMISES W ARNING • Only a licensed, certified, trained electrician should install the machine to a premises or residential elec- trical system. Be certain that: • The installation complies with the National Electrical Code and all other applicable electrical codes. • The[...]

  • Page 15

    INST ALLA TION A-9 A-9 V ANT AGE® 400 CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS CONNECTION OF LN-7 OR LN-8 TO THE V ANT AGE® 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 VOL TMETER" switch to either "+" or "-"[...]

  • Page 16

    INST ALLA TION A-10 A-10 V ANT AGE® 400 CONNECTION OF SPOOL GUN (K487-25) AND COBRAMA TIC TO V ANT AGE® 400 • Shut the welder off. • Connect per instructions on the appropriate con- nection diagram in Section C . CONNECTION OF PRINCE XL SPOOL GUN TO THE V ANT AGE® 400 Connection of the Prince XL Spool Gun requires the use of the K1849-1 Adap[...]

  • Page 17

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 V ANT AGE® 400 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 18

    THEOR Y OF OPERA TION B-2 B-2 V ANT AGE® 400 SAFETY PRECAUTIONS 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. ---------------------------[...]

  • Page 19

    THEOR Y OF OPERA TION B-3 B-3 V ANT AGE® 400 WELDING CONTROLS (Figure B.1) 1. OUTPUT CONTROL- The OUTPUT dial is used to preset the output voltage or current as displayed on the digital meters for the four welding modes. When in the CC-STICK, DOWNHILL PIPE or CV - WIRE modes and when a remote control is connect- ed to the 6-Pin or 14-Pin Connector[...]

  • Page 20

    THEOR Y OF OPERA TION B-4 B-4 V ANT AGE® 400 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 [...]

  • Page 21

    THEOR Y OF OPERA TION B-5 B-5 V ANT AGE® 400 TYPICAL V ANT AGE® 400 FUEL CONSUMPTION T ABLE B.2 PERKINS Gal./Hr (Liters/Hr) .26 (.97) .42 (1.57) 1.18 (4.46) 1.24 (4.68) .90 (3.42) Running T ime for 15 gallons / hours 58.59 36.06 12.74 12.14 16.62 Low Idle - No Load 1400 R.P .M. High Idle - No Load 1880 R.P .M. DC W eld Output 400 Amps @ 36 V olts[...]

  • Page 22

    THEOR Y OF OPERA TION B-6 B-6 V ANT AGE® 400 WELDER OPERA TION 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 INFORMA TION For any electrode the procedures should be kept with- in th[...]

  • Page 23

    THEOR Y OF OPERA TION B-7 B-7 V ANT AGE® 400 When in the TOUCH ST ART TIG mode and when a Amptrol is connected to the 6-Pin connector the OUT- PUT CONTROL dial is used to set the maximum cur- rent range of the current control of the Amptrol. The ARC CONTROL is not active in the TIG mode. T o STOP a weld, simply pull the TIG torch away from the wor[...]

  • Page 24

    THEOR Y OF OPERA TION B-8 B-8 V ANT AGE® 400 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 AUXILIAR Y POWER: Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of [...]

  • Page 25

    T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 V ANT AGE® 400 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Factory Installed Options / Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 26

    ACCESSORIES C-2 C-2 V ANT AGE® 400 FIELD INST ALLED OPTIONS / ACCES- SORIES K2641-2 FOUR WHEELED STEERABLE Y ARD TRAILER For in plant and yard towing. Comes standard with a Duo-Hitch™, a 2” Ball and Lunette Eye combination Hitch. K2636-1 TRAILER - T wo-wheeled trailer with optional fender and light package. For highway use, consult applicable [...]

  • Page 27

    ACCESSORIES C-3 C-3 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 28

    ACCESSORIES C-4 C-4 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 29

    ACCESSORIES C-5 C-5 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 30

    ACCESSORIES C-6 C-6 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 31

    ACCESSORIES C-7 C-7 V ANT AGE® 400 2 9/03 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 32

    NOTES C-8 C-8 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 33

    T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 V ANT AGE® 400 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 34

    MAINTENANCE D-2 D-2 V ANT AGE® 400 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T u rn th e en gin e o ff be for e w or kin g i ns ide th e machine or servicing the engine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal i[...]

  • Page 35

    MAINTENANCE D-3 D-3 V ANT AGE® 400 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 of f. Disconnect the negative bat- tery cable to ensure safety . • Locate oil drain hose and valve[...]

  • Page 36

    MAINTENANCE D-4 D-4 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 37

    MAINTENANCE D-5 D-5 V ANT AGE® 400 COOLING SYSTEM HOT COOLANT can burn skin. • Do not remove cap if radiator is hot. ------------------------------------------------------------------------ Check the coolant level by observing the level in the radiator and recovery bottle. Add 50/50 antifreeze / water solution if the level is close to or below t[...]

  • Page 38

    MAINTENANCE D-6 D-6 V ANT AGE® 400 FUEL FIL TER 1. Check the fuel filter and fuel pre-filter for water accu- mulation or sediment. 2. Replace the fuel filter if it is found with excessive water accumulation or sediment. Empty fuel pre- filter . ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an author[...]

  • Page 39

    MAINTENANCE D-7 D-7 V ANT AGE® 400 WELDER / GENERA TOR 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 REMOV AL AND REPLACEMENT : It’s normal for the brushes and slip rings to wear and dar[...]

  • Page 40

    MAINTENANCE D-8 D-8 V ANT AGE® 400 1. Case Front & Control Panel Assembly 2. Output Panel Assembly 3. Power Module Panel Assembly 4. Generator & Rotor Assembly 5. Base, Fuel T ank & Battery Assembly 6. Engine Assembly 7. Case Back & Radiator Assembly 8. Case Cover MAJOR COMPONENT LOCA TION 8 8 4 4 2 2 1 1 5 5 6 6 7 7 3 3 [...]

  • Page 41

    T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 V ANT AGE® 400 FIGURE E.1 — V ANT AGE® 400 BLOCK LOGIC DIAGRAM. 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[...]

  • Page 42

    THEOR Y OF OPERA TION E-2 E-2 V ANT AGE® 400 FIGURE E.2 — GENERAL DESCRIPTION, BA TTERY , ENGINE, ROTOR, ST A TOR & ENGINE PROTECTION 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 M[...]

  • Page 43

    THEOR Y OF OPERA TION E-3 E-3 V ANT AGE® 400 FIGURE E.3 — WELD WINDINGS, RECTIFIER, CHOPPER MODULES & FEEDBACK 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 VOL TM[...]

  • Page 44

    THEOR Y OF OPERA TION E-4 E-4 V ANT AGE® 400 FIGURE E.4 — WELD CONTROL BOARD 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 VOL TMETER AMMETER PWM SIGNAL VRD VOL T AGE [...]

  • Page 45

    THEOR Y OF OPERA TION E-5 E-5 V ANT AGE® 400 INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT s are semicon- ductors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefor[...]

  • Page 46

    THEOR Y OF OPERA TION E-6 E-6 V ANT AGE® 400 PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION is used to describe how much time is devoted to conduction in the cycle. Changing the pulse width is known as MODU- LA TION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of t[...]

  • Page 47

    THEOR Y OF OPERA TION E-7 E-7 V ANT AGE® 400 CHOPPER TECHNOLOGY FUNDAMENT ALS The new era of welding machines such as the V antage® 500, employ a technology whereby a DC source is turned on and of f (chopped up) at high speed, then smoothed through an inductor to control an arc. Hence the name “Chopper .” The biggest advantage® of chopper te[...]

  • Page 48

    NOTES E-8 E-8 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 49

    T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR F-1 F-1 V ANT AGE® 400 T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 50

    TROUBLESHOOTING & REP AIR F-2 F-2 V ANT AGE® 400 This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPT OM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that [...]

  • Page 51

    TROUBLESHOOTING & REP AIR F-3 F-3 V ANT AGE® 400 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that [...]

  • Page 52

    Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perf orm the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION TROUBLESHOOTING & REP AIR F[...]

  • Page 53

    Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perf orm the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION TROUBLESHOOTING & REP AIR F[...]

  • Page 54

    Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perf orm the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION TROUBLESHOOTING & REP AIR F[...]

  • Page 55

    The machine will weld but the welding arc is “COLD”. The engine runs normally and the aux- iliary power is normal. 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 proces[...]

  • Page 56

    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. T ry using some Lincoln Electrode, and setting t[...]

  • Page 57

    Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perf orm the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION TROUBLESHOOTING & REP AIR F[...]

  • Page 58

    Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perf orm the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION TROUBLESHOOTING & REP AIR F[...]

  • Page 59

    Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perf orm the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION TROUBLESHOOTING & REP AIR F[...]

  • Page 60

    Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perf orm the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION TROUBLESHOOTING & REP AIR F[...]

  • Page 61

    The engine will not crank when the start button is pushed. 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 dia- gram. The battery may be low or faulty . If the battery will not accept a charge replace it. The starter or sta[...]

  • Page 62

    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 butto[...]

  • Page 63

    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 ha[...]

  • Page 64

    Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perf orm the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION TROUBLESHOOTING & REP AIR F[...]

  • Page 65

    Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perf orm the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION TROUBLESHOOTING & REP AIR F[...]

  • Page 66

    Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perf orm the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION TROUBLESHOOTING & REP AIR F[...]

  • Page 67

    Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perf orm the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION TROUBLESHOOTING & REP AIR F[...]

  • Page 68

    Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perf orm the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION TROUBLESHOOTING & REP AIR F[...]

  • Page 69

    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 thr[...]

  • Page 70

    Battery Drawer Left Case Side Roof Lift Bale Seal Fuel T ank Seal Right Side Service Access Door Right Case Side Fuel T ank Cap FIGURE F .1 – DOOR REMOV AL CASE COVER REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) PROCEDURE 1. T urn the engine of f. 2. Using the 3/8" wrench, remove the battery cover . Slide the battery out and disconnect the[...]

  • Page 71

    CASE COVER REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-23 F-23 V ANT AGE® 400 REASSEMBL Y PROCEDURE 1. Install components in reverse order of removal. 2. Be sure components align correctly . 3. Reconnect battery and replace battery door . Return t o Section T OC Return t o Section T OC Return t o Section T OC Ret[...]

  • Page 72

    NOTES F-24 F-24 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 73

    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 thr[...]

  • Page 74

    B1 B2 B3 B6 B5 B4 INSULA TED GLOVES INSULA TED PLIERS FIGURE F .2 - CHOPPER MODULE CAP ACITOR TERMINAL DISCHARGE CHOPPER MODULE CAP ACITOR DISCHARGE PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-26 F-26 V ANT AGE® 400 ELECTRIC SHOCK can kill. • Do not t ouch electrically hot par ts . • P rior to performing pre v entativ e maintenance ,[...]

  • Page 75

    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 thr[...]

  • Page 76

    V ANT AGE 400 LINCOLN ELECTRIC SHUTDOWN SOLENOID IDLE SOLENOID FIGURE F .3 - FUEL SHUTDOWN SOLENOID LOCA TION FUEL SHUTDOWN SOLENOID TEST (CONTINUED) TEST PROCEDURE 1. T urn the engine of f. 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 [...]

  • Page 77

    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 thr[...]

  • Page 78

    STROBE T ACH MARK FIGURE F .4 - STROBE MARK LOCA TION ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) TEST PROCEDURE Strobe-T ach Method 1. T urn the engine of f 2. open the top and right side engine service access doors. 3. Place a highly visible mark on the engine cool- ing fan blade. See Figure F .4. 4. Connect the strobe-tach according to the man- [...]

  • Page 79

    V ANT AGE 400 LINCOLN ELECTRIC SHUTDOWN SOLENOID IDLE SOLENOID LOW SPEED ADJ. DO NOT TOUCH FOR LOW SPEED HIGH SPEED ADJ. FIGURE F .5 - SOLENOID ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) Frequency Counter Method NOTE: A dedicated frequency counter can be used for this test, but many high quality digital mul- timeters also have this function, and c[...]

  • Page 80

    ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) Vibratach Method A V ibratach 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 en[...]

  • Page 81

    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 thr[...]

  • Page 82

    BLACK RED P-55 J-55 IDLE SOLENOID CONNECTOR (LEAD ENTRY VIEW) IDLE SOLENOID WIRING HARNESS CONNECTOR (LEAD ENTRY VIEW) 1 3 2 4 WHITE PULL 3 1 4 2 226 232L 227 ENGINE PROTECTION IDLE CONTROL P .C.B. 12 VOL T + RUN ENGINE PROTECTION IDLE CONTROL P .C.B. COMMON HOLD FIGURE F .6 - PLUG(S) PIN LOCA TION IDLER SOLENOID TEST (CONTINUED) TEST PROCEDURE 1. [...]

  • Page 83

    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 thr[...]

  • Page 84

    243 238 BACK OF AL TERNA TOR FIGURE F .7 - LEAD LOCA TIONS ENGINE AL TERNA TOR TEST (CONTINUED) TEST PROCEDURE 1. T urn the engine of f. 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 sta[...]

  • Page 85

    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 thr[...]

  • Page 86

    BRUSHES SLIP RINGS #200A #200B #201 FIGURE F .8 – BRUSH & SLIP RING LOCA TIONS BRUSH AND SLIP RING SERVICE PROCEDURE (CONTINUED) 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[...]

  • Page 87

    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 thr[...]

  • Page 88

    BRUSHES SLIP RINGS #200A #200B #201 - + FIGURE F .9 - ROTOR BRUSH LEADS ROT OR RESIST ANCE AND GROUND TEST (ST A TIC) (CONTINUED) TEST PROCEDURE 1. T urn the engine of f. 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. [...]

  • Page 89

    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 thr[...]

  • Page 90

    ROT OR RESIST ANCE AND GROUND TEST (DYNAMIC) (CONTINUED) TEST PROCEDURE This test requires that the brushes and slip rings are clean, in good condition, and are properly seated. 1. Perform the brush and slip ring service procedure if necessary . 2. Insulate the lead wires that had been discon- nected from the brushes during the static rotor resista[...]

  • Page 91

    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 thr[...]

  • Page 92

    BRUSHES SLIP RINGS #200A #200B #201 - + FIGURE F .10 - LEAD LOCA TIONS ROT OR VOL T AGE TEST (CONTINUED) TEST PROCEDURE 1. Perform the Case Cover Removal procedure. 2. Connect the voltmeter probes to the brush ter- minals. See Figure F .10. See the wiring dia- gram. 3. Set the RUN/STOP switch to “RUN” and the IDLE switch to “HIGH”. Start th[...]

  • Page 93

    ROT OR VOL T AGE 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 mak- ing proper contact with the slip rings. Perform the Rotor Resistance T est , and Brush and Slip Ring Service Procedure . 1 1. If the voltage measures about 3 to 5 VDC , the gene[...]

  • Page 94

    NOTES F-46 F-46 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 95

    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 thr[...]

  • Page 96

    FLASHING VOL T AGE 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 con- nections are clean and tight. 3. Remove leads 234 and 235 from the oil pres- sure switch. Insulate or position the lead so it cannot come in contact with chassis [...]

  • Page 97

    FLASHING VOL T AGE 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 proba- bly 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 dia- gram.[...]

  • Page 98

    NOTES F-50 F-50 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 99

    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 thr[...]

  • Page 100

    FIGURE F .1 1 RECEPT ACLE LEAD LOCA TIONS (TYPICAL) ST A T OR VOL T AGE TESTS (CONTINUED) TEST PROCEDURE 1. Perform the Case Cover Removal procedure. NOTE: V oltage tests of the 120 and 120/240 V AC receptacles can be performed by placing the meter probes directly into the appropriate connection slots in the front of the receptacles rather than tes[...]

  • Page 101

    FIGURE F .12 - RECTIFIER BRIDGE DET AIL ST A T OR VOL T AGE TESTS (CONTINUED) T o test the 120 V AC wire feeder supply: NOTE: The wire feeder AC voltage supply tests require that the meter probes be inserted into the Amphenol connection cavities. Care should be taken to avoid damaging or expanding the termi- nals when inserting the probes. NOTE: Th[...]

  • Page 102

    ST A T OR VOL T AGE TESTS (CONTINUED) T o test the 42 V AC wire feeder winding: 1. Connect the voltmeter probes to pins “I” (lead 41A) and “K” (lead #42A) of the 14 pin Amphenol. See Figure F .1 1. 2. Start the engine and run it at high idle (1860 to 1890 RPM). 3. The AC voltage reading should be between 40 and 50 V AC. 4. If these voltage [...]

  • Page 103

    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 thr[...]

  • Page 104

    FIGURE F .13 - WELD CONTROL BOARD ST A T OR SHORT CIRCUIT & GROUND TEST (CONTINUED) TEST PROCEDURE 1. Perform Case Cover Removal Procedure . 2. Perform Capacitor Discharge Procedure . 3. Unplug anything that may be connected to the auxiliary receptacles or the 14 pin amphenol. 4. Disconnect and isolate GND-E lead from the bottom ground screw in[...]

  • Page 105

    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 thr[...]

  • Page 106

    FIGURE F .14 OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) TEST PROCEDURE 1. T urn the engine of f. 2. Perform the Case Cover Removal procedure. 3. Perform the Chopper Module Capacitor Discharge procedure. Electrically isolate the three-phase input terminals of the output bridge rectifier as follows: 4. Mark leads W1, W2, and W3 so they can be properly [...]

  • Page 107

    CHOPPER BOARD W1 W2 W3 OUTPUT RECTIFIER BRIDGE TOP CENTER BOTTOM FIGURE F .15 - SHUNT/RECTIFIER LEADS OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) 7. Check for grounds by placing one of the ohm meter probes on a clean, unpainted metal sur- face of the machine. T ouch the other probe to each of the five rectifier terminals. The resis- tance to chassis g[...]

  • Page 108

    TROUBLESHOOTING & REP AIR F-60 F-60 V ANT AGE® 400 (+) Lead (-) Lead Diode Bias and Expected T est Result AC1 DC(+) FORW ARD BIAS (Low Resistance) AC2 DC(+) FORW ARD BIAS (Low Resistance) AC3 DC(+) FORW ARD BIAS (Low Resistance) DC(-) AC1 FORW ARD BIAS (Low Resistance) DC(-) AC2 FORW ARD BIAS (Low Resistance) DC(-) AC3 FORW ARD BIAS (Low Resis[...]

  • Page 109

    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 thr[...]

  • Page 110

    B1 B2 B3 B6 B5 B4 23 25 SL302 SL301 HL W9 HL W4 HL W6 SL14 SL13 B8 HL W8 HL W5 HL W11 LED1 LED1 LED4 LED4 LED2 LED2 LED3 LED3 L12683-1 LED1 (B1,B2,B3) Chopper Working LED3 (B4,B5,B6) Chopper Working LED4 PWM Signal LED2 V oltage from Rectif ier FIGURE F .16 - CHOPPER MODULE CONNECTIONS CHOPPER MODULE FUNCTION TEST (CONTINUED) TEST PROCEDURE 1. Perf[...]

  • Page 111

    CHOPPER MODULE FUNCTION TEST (CONTINUED) TEST PROCEDURE (CONTINUED) 13. If about 58 VDC is present at chopper module terminals B2+ to B3-, and B5+ to B6-, but not at the output terminals, there is a problem between the chopper module and one of the output terminals. Check for damaged conduc- tors or faulty connections, on leads W7, W8, W9, and W10.[...]

  • Page 112

    NOTES F-64 F-64 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 113

    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 thr[...]

  • Page 114

    CHOPPER MODULE RESIST ANCE TEST (CONTINUED) TEST PROCEDURE 1. Perform the Case Cover Removal Procedure . 2. Perform the Capacitor Discharge Procedure . 3. Check that all of the leads connected to the chopper module terminals are clearly marked to facilitate reassembly . Remove all of the leads from the chopper module and position them so they do no[...]

  • Page 115

    FIGURE F .2 - DIODE TEST T ABLE CHOPPER MODULE RESIST ANCE TEST (CONTINUED) TROUBLESHOOTING & REP AIR F-67 F-67 V ANT AGE® 400 (+) Lead (-) Lead Diode Bias and Expected T est Result B5 B6 6K to 9K B6 B5 6K to 9K B4 B5 200k or higher B5 B4 400k or higher B4 B6 200k or higher B6 B4 400k or higher B2 B3 6K to 9K B3 B2 6K to 9K B4 B2 200k or highe[...]

  • Page 116

    NOTES F-68 F-68 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 117

    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 thr[...]

  • Page 118

    WELD CONTROL BOARD PWM GA TE SIGNAL TEST (CONTINUED) TEST PROCEDURE 1. Perform the Case Cover Removal Procedure . 2. Unplug any device that may be attached to either the 6 pin or the 14 pin Amphenol recep- tacles. 3. Place the idle switch in the “HIGH IDLE” posi- tion. 4. Place the mode switch in the “CC-STICK” position. 5. Place the Weld t[...]

  • Page 119

    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 thr[...]

  • Page 120

    WELD CONTROL FEEDBACK TEST (CONTINUED) TEST PROCEDURE 1. Place the idle switch in the “HIGH IDLE” posi- tion. 2. Place the mode switch in the “CC-STICK” position. 3. Place the weld terminals switch in the “WELD TERMINALS ON” position. 4. Make sure that nothing is plugged into either Amphenol receptacle. 5. Connect the resistive load ban[...]

  • Page 121

    WELD CONTROL FEEDBACK TEST (CONTINUED) 16. If the voltage readings are different, check the wiring and connections between the welding terminals and the control PC board. See the wiring diagram. 17. Connect the millivolt meter probes between lead #206S+ (P6-2) and lead 204S- (P6-1). See Wiring Diagram. If the machine is cur- rently producing 200 am[...]

  • Page 122

    NOTES F-74 F-74 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 123

    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 thr[...]

  • Page 124

    CONTROL POTENTIOMETER AND MODE SWITCH RESIST ANCE TEST (CONTINUED) TEST PROCEDURE 1. T urn the engine of f 2. Perform the Case cover Removal Procedure. 3. Unplug P7 from control board, see control Inner-connection diagram, and visually check the plug and attached wiring for damage, cor- rosion, improperly seated or damaged contact pins. P7 will rem[...]

  • Page 125

    CONTROL POTENTIOMETER AND MODE RESIST ANCE TEST (CONTINUED) TROUBLESHOOTING & REP AIR F-77 F-77 V ANT AGE® 400 T ABLE F .3 CC-STICK P7-9 (#214) TO P7-14 (#218) 500K or Higher CC-STICK P7-9 (#214) TO P7-15 (#220) 500K or Higher CC-STICK P7-9 (#214) TO P7-16 (#222) 500K or Higher CC-STICK P7-14 (#218) TO P7-15 (#220) 500K or Higher CC-STICK P7-1[...]

  • Page 126

    NOTES F-78 F-78 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 127

    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 thr[...]

  • Page 128

    FIGURE F .17 REMOTE RECEPT ACLE RESIST ANCE TEST (CONTINUED) TEST PROCEDURE 1. T urn the machine of f. 2. Perform the Case Cover Removal Procedure. 3. Make sure that there are no devices of any kind plugged into either Amphenol receptacles. 4. Remove Molex plug P1 from the control PC board, see Control Inner-Connection Diagram. Examine the Molex pl[...]

  • Page 129

    TROUBLESHOOTING & REP AIR F-81 F-81 V ANT AGE® 400 REMOTE RECEPT ACLE RESIST ANCE TEST (continued) T ABLE - F .4 N/A PIN “G” (#75B) to PIN “Å” (#32) 500K or Higher N/A PIN “G” (#75B) to PIN “B” (GND-A) 500K or Higher N/A PIN “G” (#75B) to PIN “C” (#2B) 500K or Higher N/A PIN “G” (#75B) to PIN “D” (#4B) 500K or [...]

  • Page 130

    NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM (1 15V AC SUPPL Y) HIGH IDLE – NO LOAD TROUBLESHOOTING & REP AIR F-82 F-82 V ANT AGE® 400 This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division rep- resents 5 milliseconds in time[...]

  • Page 131

    NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM (1 15V AC SUPPL Y) MAX CONTROL POT - HIGH IDLE - NO LOAD TROUBLESHOOTING & REP AIR F-83 F-83 V ANT AGE® 400 This is the typical DC open circuit out- put voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division rep- resent[...]

  • Page 132

    NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM (1 15V AC SUPPL Y) MACHINE LOADED TO 300 AMPS A T 27 VOL TS TROUBLESHOOTING & REP AIR F-84 F-84 V ANT AGE® 400 This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 1 millisec[...]

  • Page 133

    NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM (WIRE CV T AP) MAX CONTROL POT - HIGH IDLE - NO LOAD TROUBLESHOOTING & REP AIR F-85 F-85 V ANT AGE® 400 This is the typical DC open circuit out- put voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division rep- resents 5 [...]

  • Page 134

    NORMAL CIRCUIT VOL T AGE W A VEFORM (WIRE CV) MACHINE LOADED TO 300 AMPS A T 28 VOL TS TROUBLESHOOTING & REP AIR F-86 F-86 V ANT AGE® 400 This is the typical DC voltage gener- ated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 1 millisecond in time. The ma[...]

  • Page 135

    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 thr[...]

  • Page 136

    OUTPUT RECTIFIER BRIDGE AND CHOKE REMOV AL AND REPLACEMENT (CONTINUED) REMOV AL PROCEDURE 1. T urn the engine of f. 2. Remove negative battery cable. 3. Perform the Case Cover Removal proce- dure . 4. Perform the Chopper Module Capacitor Discharge procedure . 5. Remove the four screws holding the case front to the base of the machine. 6. Remove all[...]

  • Page 137

    OUTPUT RECTIFIER BRIDGE AND CHOKE REMOV AL AND REPLACEMENT (CONTINUED) Replacing the Output Rectifier 1. Place the Output Rectifier into the machine so that its mounting studs fit into the holes in the bracket. Place a lock washer and a nut on each stud and tighten. 2. Apply a thin film of electrical joint com- pound, (Dow Corning) between the sur-[...]

  • Page 138

    NOTES F-90 F-90 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 139

    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 thr[...]

  • Page 140

    FIGURE F .18 - MODULE LEAD LOCA TIONS CHOPPER MODULE REMOV AL AND REPLACEMENT (CONTINUED) PROCEDURE REMOV AL 1. T urn the engine off. 2. Perform the Case Cover Removal Procedure . 3. Perform the Chopper Module Capacitor Discharge procedure . 4. Disconnect leads 23 and 25 at their in-line couplings. 5. Using the 7/16” socket wrench, remove the fol[...]

  • Page 141

    CHOPPER MODULE REMOV AL AND REPLACEMENT (CONTINUED) REPLACEMENT 1. Mount the heat sink to the brackets on the ver- tical baf fle with the three 3/8” screws. Mount the plastic strip with the top two screws. 2. Connect leads 23 and 25 at their in-line cou- plers. 3. Using a 7/16” wrench, attach the heavy leads and small leads as follows. Note pla[...]

  • Page 142

    NOTES F-94 F-94 V ANT AGE® 400 Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Section T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC Return t o Mast er T OC[...]

  • Page 143

    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 thr[...]

  • Page 144

    PLUG FUEL LINES U-BOL TS (2) LEADS #229 AND #5J { FIGURE F .19 – FUEL T ANK REMOV AL ST A T OR/ROT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) PROCEDURE 1. T urn the engine of f. 2. Perform the Case Cover Removal Procedure, including the output panel. 3. Perform the Output Rectifier Bridge and Choke Removal Procedure. 4. Using a 3/8” wren[...]

  • Page 145

    #201A- 5H #200 200A #6A FIL TER CAP ACITOR FIELD DIODE RECTIFIER BRIDGE FIGURE F .20 – DOOR REMOV AL ST A T OR/ROT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) PROCEDURE 9. Disconnect plug J30 at the right front side. See Figure F .20. 10. Using the slot head screw driver , disconnect leads #200B, #200A(+) and #201A(-) from the filter capaci[...]

  • Page 146

    #200A #200B #201 FIGURE F .21 – BRUSHHOLDER LEAD REMOV AL ST A T OR/ROT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) PROCEDURE 12. Label and remove brush leads #201(-) and #200B(+) from the brush holder assembly . (The Piggy-backed leads connect closest to the stator terminations.) See Figure F .21. 13. Pull the harness containing plug J30, [...]

  • Page 147

    50 Amp Circuit Breaker Ground Screw Aux. Power Stud (Panel Left Side) FIGURE F .22 – CONTROL & OUTPUT P ANELS - REAR VIEW ST A T OR/ROT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) 1. Using a 7/16” wrench, disconnect stator lead #6 from the auxiliary power stud on the left side of the control box. See Figure F .22. 17. With a 3/8” wr[...]

  • Page 148

    CENTER P ANEL LIFT FRAME WELDMENT BASE FUEL T ANK SUPPORTS F AN BAFFLE FIGURE F .23 – DOOR REMOV AL ST A T OR/ROT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) In steps 21 - 25, the lift frame weldment, fuel tank supports, and fan baffle are removed as a unit. See Figure F .23. 21. Using a 3/8” wrench, remove the two bolts (at top) that hol[...]

  • Page 149

    { ST A TOR / ENGINE MOUNTING BOL TS & LOCK W ASHERS (8) BEARING BOL TS (4) F AN NUT F AN HUB MOUNTING PLA TE FIGURE F .24 – DOOR REMOV AL ST A T OR/ROT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) ST A TOR REMOV AL PROCEDURE 1. Using a 1/2” wrench, remove the four fan blade mounting bolts and lock washers. See Figure F .24. 2. Using a [...]

  • Page 150

    FLEX PLA TE BLOWER SEGMENT (4) ROTOR FIGURE F .25 – DOOR REMOV AL ST A T OR/ROT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-102 F-102 V ANT AGE® 400 ROTOR REMOV AL PROCEDURE 1. Support the rotor with a hoist. 2. Using a 5/16” wrench, remove the flex plate bolts, lock washers, and four blower segments. See [...]

  • Page 151

    FLEX PLA TE BLOWER SEGMENT (4) ROTOR FIGURE F .29 – ROTOR REMOV AL & REPLACEMENT ST A T OR/ROT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) PROCEDURE 1. Remove the screws and disc clamping bars from the rotor coupling disc, and remove the rotor . NOTE: earlier machines used three 0.31” thick clamping bars and later models use six 0.14?[...]

  • Page 152

    TROUBLESHOOTING & REP AIR F-104 F-104 V ANT AGE® 400 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’s electrical characteristics. OR • If you repair or replace any electrical components. ENGINE OUTPUT Mode No Load RPM Load[...]

  • Page 153

    T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 V ANT AGE® 400 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram - Complete Machine (G5481) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 154

    ELECTRICAL DIAGRAMS G-2 V ANT AGE ® 400 ® ®  WIRING DIAGRAM - COMPLETE MACHINE - (G5481) ") T O A CB 6 10A 42B 42 RE CTIF I ER BR I DGE 42A 41A 41 ST A RT BUTTON 222 MODE SELE CT OR S W ITCH 206A 214 S5 218 1 2 3 220 A 4 206S 208A + 50MV=400 A MPS W 4 & W5 W 2 & W3 W 1 & W6 204S ST AT OR 42V WI ND ING G5481 B 208 31 32 4B 21 [...]

  • Page 155

    ELECTRICAL DIAGRAMS G-3 V ANT AGE ® 400 ® ®  SCHEMA TIC - COMPLETE MACHINE - (G5597 P AGE 1) EN-170 S O L ID E D G E G5597 VA NTA GE 400 (PE R KINS ) MAC HI N E SC HEM ATIC NONE G5388 Ma gli e tt a BA M DO NO T SC AL E T HIS DR A WING D RAWN BY: DESIG N I NFO RMATI ON ENG I NEER: AP PRO VED : EQ UIP M ENT TYPE: SUBJECT: SCA L E: NA CRM22 115 [...]

  • Page 156

    ELECTRICAL DIAGRAMS G-4 V ANT AGE ® 400 ® ®  SCHEMA TIC - COMPLETE MACHINE - (G5597 P AGE 2) EN-170 S O L ID E D G E G5597 VA NTA GE 400 (PE R KINS ) MAC HI N E SC HEM ATIC NONE G5388 Ma gli e tt a BA M DO NO T SC AL E T HIS DR A WING D RAWN BY: DESIG N I NFO RMATI ON ENG I NEER: AP PRO VED : EQ UIP M ENT TYPE: SUBJECT: SCA L E: NA CRM22 115 [...]

  • Page 157

    ELECTRICAL DIAGRAMS G-5 V ANT AGE ® 400 ® ®  SCHEMA TIC - WELD CONTROL PC BD. (G5506 P AGE 1 OF 5) G-5 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Retu[...]

  • Page 158

    ELECTRICAL DIAGRAMS G-6 V ANT AGE ® 400 ® ®  SCHEMA TIC - WELD CONTROL PC BD. (G5506 P AGE 2 OF 5) G-6 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Retu[...]

  • Page 159

    ELECTRICAL DIAGRAMS G-7 V ANT AGE ® 400 ® ®  SCHEMA TIC - WELD CONTROL PC BD. (G5506 P AGE 3 OF 5) G-7 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Retu[...]

  • Page 160

    ELECTRICAL DIAGRAMS G-8 V ANT AGE ® 400 ® ®  SCHEMA TIC - WELD CONTROL PC BD. (G5506 P AGE 4 OF 5) G-8 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Retu[...]

  • Page 161

    ELECTRICAL DIAGRAMS G-9 V ANT AGE ® 400 ® ®  SCHEMA TIC - WELD CONTROL PC BD. (G5506 P AGE 5 OF 5) G-9 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Retu[...]

  • Page 162

    ELECTRICAL DIAGRAMS G-10 V ANT AGE ® 400 ® ®  SCHEMA TIC - IDLER PC BD (G4828-2) G-10 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master T OC[...]

  • Page 163

    ELECTRICAL DIAGRAMS G-11 V ANT AGE ® 400 ® ®  SCHEMA TIC - CHOPPER PC BD (L12717-1CO) G-11 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master[...]

  • Page 164

    ELECTRICAL DIAGRAMS G-12 V ANT AGE ® 400 ® ®  SCHEMA TIC -OCV INDICA T OR PC BD (G4406-2D0) G-12 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to [...]

  • Page 165

    ELECTRICAL DIAGRAMS G-13 V ANT AGE ® 400 ® ®  SCHEMA TIC - BY P ASS / ST ABILIZER PC BOARD (S22530-3D0) G-13 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TO[...]

  • Page 166

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]