Main
VANTAGE400
SVM182-A
April, 2011
SERVICE MANUAL
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WARNING
ELECTRIC AND MAGNETIC FIELDS may be dangerous
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FUMES AND GASES can be dangerous.
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
VANTAGE 400
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FOR ELECTRICALLY powered equipment.
CYLINDER may explode if damaged.
WELDING and CUTTING SPARKS can cause fire or explosion.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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PRCAUTIONS DE SRET
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
TABLE OF CONTENTS - INSTALLATION SECTION
TECHNICAL SPECIFICATIONS - VANTAGE 400 (K2410-1) (K2410-2)
RATED OUTPUT @ 104 F (40 C) - WELDER
MACHINE SPECIFICATIONS
PHYSICAL DIMENSIONS ENGINE
RATED OUTPUT @ 104 F (40 C).- GENERATOR
SAFETY PRECAUTIONS
Only qualified personnel should install, use, or service this equipment.
See additional warning information at front of this operators manual.
VRD (VOLTAGE REDUCTION DEVICE)
LOCATION AND VENTILATION
HIGH ALTITUDE OPERATION
HIGH TEMPERATURE OPERATION
COLD WEATHER STARTING:
TOWING
VEHICLE MOUNTING
OIL
FUEL
ENGINE COOLING SYSTEM
BATTERY CONNECTION
MUFFLER OUTLET PIPE
ELECTRICAL CONNECTIONS
MACHINE GROUNDING
WELDING TERMINALS
WELDING OUTPUT CABLES
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
STANDBY POWER CONNECTIONS
AUXILIARY POWER RECEPTACLES
CONNECTION OF VANTAGE 400 TO PREMISES
CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS
CONNECTION OF LN-7 OR LN-8 TO THE VANTAGE 400
CONNECTION OF LN-15 TO THE VAN- TAGE 400
CONNECTION OF SPOOL GUN (K487-25) AND COBRAMATIC TO VANTAGE 400
CONNECTION OF PRINCE XL SPOOL GUN TO THE VANTAGE 400
TABLE OF CONTENTS - OPERATION SECTION
SAFETY PRECAUTIONS
GENERAL DESCRIPTION
FOR AUXILIARY POWER:
ENGINE OPERATION
ADD FUEL
DIESEL FUEL ONLY
WELDING CONTROLS
4. ARC CONTROL
5. WELD OUTPUT TERMINALS WITH FLANGE NUT-
6. GROUND STUD-
7. 14-PIN CONNECTOR-
8. 6-PIN CONNECTOR-
ENGINE CONTROLS:
12. RUN/STOP SWITCH
13. GLOW PLUG PUSH BUTTON
14. START PUSH BUTTON
15. IDLER SWITCH
WELDER OPERATION
STOPPING THE ENGINE
TIG WELDING
TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES
AUXILIARY POWER:
PLUS OR OR
ARC GOUGING
WIRE WELDING-CV
TABLE OF CONTENTS - ACCESSORIES SECTION
FIELD INSTALLED OPTIONS / ACCES- SORIES
WIRE FEEDER OPTIONS
TIG OPTIONS
PLASMACUTTING
C-3 C-3
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C-6 C-6
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TABLE OF CONTENTS - MAINTENANCE SECTION
SAFETY PRECAUTIONS
------------------------------------------------------------ Routine Maintenance
ENGINE SERVICE
ENGINE OIL CHANGE
OIL FILTER CHANGE
AIR CLEANER
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COOLING SYSTEM HOT COOLANT
TIGHTENING THE FAN BELT
FUEL
BLEEDING THE FUEL SYSTEM
FUEL FILTER
ENGINE ADJUSTMENT
BATTERY MAINTENANCE
OVERSPEED IS HAZARDOUS
CLEANING THE BATTERY
CHECKING THE ELECTROLYTE LEVEL
WELDER / GENERATOR MAINTENANCE
GFCI RECEPTACLE TESTING AND RESET- TING PROCEDURE
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TABLE OF CONTENTS-THEORY OF OPERATION SECTION
E-1 E-1
ENGINE
+
ROTOR
GENERAL DESCRIPTION
BATTERY, ENGINE, ROTOR, STATOR, PULL COIL BOARD AND PERIPHERAL BOARD ENGINE PROTECTION
E-3 E-3
FIGURE E.3 WELD WINDINGS, RECTIFIER, CHOPPER MODULES & FEEDBACK
ENGINE
WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK
E-4 E-4
FIGURE E.4 WELD CONTROL BOARD
ENGINE
+
WELD CONTROL BOARD
INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION
PULSE WIDTH MODULATION
CHOPPER TECHNOLOGY FUNDAMENTALS
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TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
PC BOARD TROUBLESHOOTING PROCEDURES
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FUNCTION PROBLEMS
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WELDING PROBLEMS
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CASE COVER REMOVAL AND REPLACEMENT PROCEDURE
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CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
REASSEMBLY PROCEDURE
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CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE
CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE (CONTINUED)
INSULATED GLOVES
INSULATED PLIERS
ELECTRIC SHOCK
DISCHARGE PROCEDURE
FUEL SHUTDOWN SOLENOID TEST
SHUTDOWN SOLENOID IDLE SOLENOID
FUEL SHUTDOWN SOLENOID TEST (CONTINUED)
ENGINE THROTTLE ADJUSTMENT TEST
STROBE TACH MARK
SHUTDOWN SOLENOID IDLE SOLENOID LOW SPEED ADJ. DO NOT TOUCH FOR LOW SPEED
HIGH SPEED ADJ.
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IDLER SOLENOID TEST
BLACK RED
P-55 J-55
1
226
3
IDLE SOLENOID CONNECTOR (LEAD ENTRY VIEW)
ENGINE ALTERNATOR TEST
ENGINE ALTERNATOR TEST (CONTINUED)
BRUSH AND SLIP RING SERVICE PROCEDURE
BRUSH AND SLIP RING SERVICE PROCEDURE (CONTINUED)
ROTOR RESISTANCE AND GROUND TEST (STATIC)
BRUSHES SLIP RINGS #200A #200B
#201
-
+
ROTOR RESISTANCE AND GROUND TEST (STATIC) (CONTINUED)
ROTOR RESISTANCE AND GROUND TEST (DYNAMIC) (Also referred to as flying resistance test)
ROTOR RESISTANCE AND GROUND TEST (DYNAMIC) (CONTINUED)
ROTOR VOLTAGE TEST
BRUSHES SLIP RINGS #200A #200B #201
-
+
ROTOR VOLTAGE TEST (CONTINUED)
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FLASHING VOLTAGE TEST (Engine Not Running)
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FLASHING VOLTAGE TEST (CONTINUED)
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STATOR VOLTAGE TESTS
AMPHENOL 1
KEY
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STATOR SHORT CIRCUIT & GROUND TEST
STATOR SHORT CIRCUIT & GROUND TEST (CONTINUED)
OUTPUT RECTIFIER BRIDGE TEST
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CHOPPER BOARD
OUTPUT RECTIFIER BRIDGE TEST (CONTINUED)
OR
Rectifier Terminal Connections
CHOPPER MODULE FUNCTION TEST
B1 B2 B3 B6
B4
B5
CHOPPER MODULE FUNCTION TEST (CONTINUED)
TEST PROCEDURE (CONTINUED)
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CHOPPER MODULE RESISTANCE TEST
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CHOPPER MODULE RESISTANCE TEST (CONTINUED)
Chopper Terminal Connections
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WELD CONTROL BOARD PWM GATE SIGNAL TEST
WELD CONTROL BOARD PWM GATE SIGNAL TEST (CONTINUED)
WELD CONTROL FEEDBACK TEST
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WELD CONTROL FEEDBACK TEST (CONTINUED)
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CONTROL POTENTIOMETER AND MODE SWITCH RESISTANCE TEST
CONTROL POTENTIOMETER AND MODE RESISTANCE TEST
POT/MODE SWITCH RESISTANCE TEST
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REMOTE RECEPTACLE RESISTANCE TEST
REMOTE RECEPTACLE RESISTANCE TEST (CONTINUED)
AMPHENOL 1
E
C D
A
B LKJ MN FGH
AMPHENOL RESISTANCE TEST
HIGH IDLE NO LOAD
MAX CONTROL POT - HIGH IDLE - NO LOAD
MACHINE LOADED TO 300 AMPS AT 27 VOLTS
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV TAP)
MAX CONTROL POT - HIGH IDLE - NO LOAD
NORMAL CIRCUIT VOLTAGE WAVEFORM (WIRE CV)
MACHINE LOADED TO 300 AMPS AT 28 VOLTS
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REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
Replacing the Output Rectifier
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CHOPPER MODULE REMOVAL AND REPLACEMENT
CHOPPER MODULE REMOVAL AND REPLACEMENT (CONTINUED)
PROCEDURE
B4
B5
REMOVAL
CHOPPER MODULE REMOVAL AND REPLACEMENT (CONTINUED)
REPLACEMENT
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{
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{
STATOR REMOVAL PROCEDURE
FLEX PLATE BLOWER SEGMENT (4) ROTOR
ROTOR REMOVAL PROCEDURE
REASSEMBLY NOTES
Replacing the Rotor
RETEST AFTER REPAIR
ENGINE OUTPUT
WELDER DC (STICK) OUTPUT (ARC control @ -10)
WELDER CV (WIRE) OUTPUT (ARC Control @ +10)
TOUCH START TIG (ARC Control @ +10)
TABLE OF CONTENTS - DIAGRAM SECTION
* NOTE:
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - COMPLETE MACHINE - (G5481)
ET
E F
WI
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - (G5597 PAGE 1)
75A & 76
on Leads
Ferrite
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - (G5597 PAGE 2)
NOT ALL CIRCUITS ARE USED ALL THE TIME.
CUI
L CIR
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ELECTRICAL DIAGRAMS
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - BY PASS / STABILIZER PC BOARD (L10121-3)
ATI
NFORM
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