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NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

VANTAGE ® 400
For use with machines having Code Numbers:
11186, 11462, 11785, 11920, 12305,
12319, 11463, 11464, 12195, 11296,
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12308, 11687, 11959, 12307, 11297,

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11787, 11921, 12303, 11511, 11576,

11954, 11961, 12304, 12597, 12559

SERVICE MANUAL
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SVM182-A | Issue Date 11-Apr

© Lincoln Global, Inc. All Rights Reserved.
 KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc. Use
corrective lenses if necessary to
stay a reasonable distance away
from the arc.
READ and obey the Material Safety
Data Sheet (MSDS) and the warning
label that appears on all containers
of welding materials.
SAFETY DEPENDS ON YOU
Service and repair should be performed by only USE ENOUGH VENTILATION or
Lincoln Electric Factory Trained Personnel. Unauthorized exhaust at the arc, or both, to keep
repairs performed on this equipment may result in danger the fumes and gases from your breathing zone and the general area.
to the technician and machine operator and will invali- IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
date your factory warranty. For your safety and to avoid adequate if you keep your head out of the fumes (See below).
Electrical Shock, please observe all safety notes and pre-
cautions detailed throughout this manual.
USE NATURAL DRAFTS or fans to keep the fumes away from your
face.
If you develop unusual symptoms, see your supervisor. Perhaps the
welding atmosphere and ventilation system should be checked.

WARNING
WEAR CORRECT EYE, EAR & BODY PROTECTION
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life. PROTECT your eyes and face with welding helmet properly fitted and
with proper grade of filter plate (See ANSI Z49.1).
CAUTION PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
This statement appears where the information must be followed to leggings, and high boots.
avoid minor personal injury or damage to this equipment. PROTECT others from splatter, flash, and glare with
protective screens or barriers.
IN SOME AREAS, protection from noise may be
appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.

SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously had
been in contact with hazardous substances unless they are properly
cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release highly
toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat, mechanical
shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
 SAFETY

SECTION A: 1.d. Keep all equipment safety guards, covers and

devices in position and in good repair.Keep

WARNINGS
hands, hair, clothing and tools away from
V-belts, gears, fans and all other moving
parts when starting, operating or repairing
equipment.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines 1.e. In some cases it may be necessary to remove safety guards
to perform required maintenance. Remove guards only when
Diesel engine exhaust and some of its constituents are known necessary and replace them when the maintenance requiring
to the State of California to cause cancer, birth defects, and other their removal is complete. Always use the greatest care when
reproductive harm. working near moving parts.
Gasoline Engines
1.f. Do not put your hands near the engine fan. Do not attempt to
The engine exhaust from this product contains chemicals known override the governor or idler by pushing on the throttle control
to the State of California to cause cancer, birth defects, or other rods while the engine is running.
reproductive harm.
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.
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS 1.h. To avoid scalding, do not remove the radiator
INJURY OR DEATH. KEEP CHILDREN AWAY. pressure cap when the engine is hot.
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 ELECTRIC AND
or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety”
booklet E205 is available from the Lincoln Electric Company, 22801
MAGNETIC FIELDS MAY
St. Clair Avenue, Cleveland, Ohio 44117-1199. BE DANGEROUS
BE SURE THAT ALL INSTALLATION, OPERATION, 2.a. Electric current flowing through any conductor
MAINTENANCE AND REPAIR PROCEDURES ARE causes localized Electric and Magnetic Fields
PERFORMED ONLY BY QUALIFIED INDIVIDUALS. (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.
FOR ENGINE POWERED 2.c. Exposure to EMF fields in welding may have other health effects
EQUIPMENT. which are now not known.
1.a. Turn the engine off before troubleshooting 2.d. All welders should use the following procedures in order to
and maintenance work unless the minimize exposure to EMF fields from the welding circuit:
maintenance work requires it to be running.
2.d.1. Route the electrode and work cables together - Secure
1.b. Operate engines in open, well-ventilated areas or vent the engine them with tape when possible.
exhaust fumes outdoors. 2.d.2. Never coil the electrode lead around your body.
1.c. Do not add the fuel near an open flame 2.d.3. Do not place your body between the electrode and work
welding arc or when the engine is running. cables. If the electrode cable is on your right side, the
Stop the engine and allow it to cool before work cable should also be on your right side.
refueling to prevent spilled fuel from 2.d.4. Connect the work cable to the workpiece as close as
vaporizing on contact with hot engine parts possible to the area being welded.
and igniting. Do not spill fuel when filling tank. 2.d.5. Do not work next to welding power source.
If fuel is spilled, wipe it up and do not start engine until fumes
have been eliminated.

ii
 SAFETY

ELECTRIC SHOCK ARC RAYS CAN BURN.

CAN KILL.
3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover
electrically “hot” when the welder is on. Do plates to protect your eyes from sparks and the rays of the arc
not touch these “hot” parts with your bare skin when welding or observing open arc welding. Headshield and
or wet clothing. Wear dry, hole-free gloves to insulate hands. filter lens should conform to ANSI Z87. I standards.

3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant material
Make certain the insulation is large enough to cover your full area to protect your skin and that of your helpers from the arc rays.
of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if screening and/or warn them not to watch the arc nor expose
welding must be performed under electrically themselves to the arc rays or to hot spatter or metal.
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
FUMES AND GASES
equipment: CAN BE DANGEROUS.
• Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
• AC Welder with Reduced Voltage Control. fumes and gases. When welding, keep your head out of the
fume. Use enough ventilation and/or exhaust at the arc to
3.c. In semiautomatic or automatic wire welding, the electrode,
keep fumes and gases away from the breathing zone. When
electrode reel, welding head, nozzle or semiautomatic welding
welding with electrodes which require special
gun are also electrically “hot”.
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection should cadmium plated steel and other metals or coatings
be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure
as low as possible and within applicable OSHA
3.e. Ground the work or metal to be welded to a good electrical (earth) PEL and ACGIH TLV limits using local exhaust
ground. or mechanical ventilation. In confined spaces or
in some circumstances, outdoors, a respirator
3.f. Maintain the electrode holder, work clamp, welding cable and may be required. Additional precautions are also
welding machine in good, safe operating condition. Replace required when welding on galvanized steel.
damaged insulation.
5. b. The operation of welding fume control equipment is affected
3.g. Never dip the electrode in water for cooling. by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.h. Never simultaneously touch electrically “hot” parts of electrode welding procedure and application involved. Worker exposure
holders connected to two welders because voltage between level should be checked upon installation and periodically
the two can be the total of the open circuit voltage of both thereafter to be certain it is within applicable OSHA PEL and
welders. ACGIH TLV limits.

3.i. When working above floor level, use a safety belt to protect 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
yourself from a fall should you get a shock. coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
3.j. Also see Items 6.c. and 8. phosgene, a highly toxic gas, and other irritating products.

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.

iii
 SAFETY

WELDING AND CUTTING CYLINDER MAY EXPLODE IF

SPARKS CAN CAUSE DAMAGED.
FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing
6.a. Remove fire hazards from the welding area. the correct shielding gas for the process used
If this is not possible, cover them to prevent and properly operating regulators designed for
the welding sparks from starting a fire. Remember that welding the gas and pressure used. All hoses, fittings,
sparks and hot materials from welding can easily go through etc. should be suitable for the application and
small cracks and openings to adjacent areas. Avoid welding near maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely chained to
6.b. Where compressed gases are to be used at the job site, special an undercarriage or fixed support.
precautions should be used to prevent hazardous situations. Refer 7.c. Cylinders should be located:
to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the
operating information for the equipment being used. • Away from areas where they may be struck or subjected
to physical damage.
6.c. When not welding, make certain no part of the electrode circuit
is touching the work or ground. Accidental contact can cause • A safe distance from arc welding or cutting operations
overheating and create a fire hazard. and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the electrically “hot” parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances 7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have when opening the cylinder valve.
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of 7.f. Valve protection caps should always be in place and hand tight
Containers and Piping That Have Held Hazardous Substances”, except when the cylinder is in use or connected for use.
AWS F4.1 from the American Welding Society (see address
7.g. Read and follow the instructions on compressed gas cylinders,
above).
associated equipment, and CGA publication P-l, “Precautions
6.e. Vent hollow castings or containers before heating, cutting or for Safe Handling of Compressed Gases in Cylinders,” available
welding. They may explode. from the Compressed Gas Association 1235 Jefferson Davis
Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
FOR ELECTRICALLY
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework
POWERED EQUIPMENT.
or other locations away from the welding area increase the 8.a. Turn off input power using the disconnect
possibility of the welding current passing through lifting chains, switch at the fuse box before working on the
crane cables or other alternate circuits. This can create fire equipment.
hazards or overheat lifting chains or cables until they fail.
8.b. Install equipment in accordance with the U.S. National Electrical
6.h. Also see item 1.c. Code, all local codes and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During 8.c. Ground the equipment in accordance with the U.S. National
Welding, Cutting and Other Hot Work”, available from NFPA, 1 Electrical Code and the manufacturer’s recommendations.
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 infor-
mation.

Welding Safety
Interactive Web Guide
for mobile devices

iv
v SAFETY v

ELECTROMAGNETIC The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The

COMPATABILITY (EMC)
surrounding area may extend beyond the boundaries of the premises.

METHODS OF REDUCING EMISSIONS

CONFORMANCE
Products displaying the CE mark are in conformity with European Mains Supply
Community Council Directive of 3 May 1989 on the approximation of Welding equipment should be connected to the mains supply
the laws of the Member States relating to electromagnetic compat- according to the manufacturer’s recommendations. If interference
ibility (89/336/EEC). It was manufactured in conformity with a national occurs, it may be necessary to take additional precautions such
standard that implements a harmonized standard: EN 60974-10 as filtering of the mains supply. Consideration should be given
Electromagnetic Compatibility (EMC) Product Standard for Arc Welding to shielding the supply cable of permanently installed welding
Equipment. It is for use with other Lincoln Electric equipment. It is equipment, in metallic conduit or equivalent. Shielding should be
designed for industrial and professional use. electrically continuous throughout its length. The shielding should be
connected to the welding power source so that good electrical contact
is maintained between the conduit and the welding power source
INTRODUCTION enclosure.
All electrical equipment generates small amounts of electromagnetic Maintenance of the Welding Equipment
emission. Electrical emission may be transmitted through power lines or
radiated through space, similar to a radio transmitter. When emissions The welding equipment should be routinely maintained according
are received by other equipment, electrical interference may result. to the manufacturer’s recommendations. All access and service
Electrical emissions may affect many kinds of electrical equipment; doors and covers should be closed and properly fastened when the
other nearby welding equipment, radio and TV reception, numerical welding equipment is in operation. The welding equipment should not
controlled machines, telephone systems, computers, etc. Be aware that be modified in any way except for those changes and adjustments
interference may result and extra precautions may be required when a covered in the manufacturers instructions. In particular, the spark
welding power source is used in a domestic establishment. gaps of arc striking and stabilizing devices should be adjusted and
maintained according to the manufacturer’s recommendations.
INSTALLATION AND USE Welding Cables
The user is responsible for installing and using the welding equipment The welding cables should be kept as short as possible and should be
according to the manufacturer’s instructions. If electromagnetic positioned close together, running at or close to floor level.
disturbances are detected then it shall be the responsibility of the
Equipotential Bonding
user of the welding equipment to resolve the situation with the
technical assistance of the manufacturer. In some cases this remedial Bonding of all metallic components in the welding installation and
action may be as simple as earthing (grounding) the welding circuit, adjacent to it should be considered. However, metallic components
see Note. In other cases it could involve construction of an electro- bonded to the work piece will increase the risk that the operator
magnetic screen enclosing the power source and the work complete could receive a shock by touching these metallic components and the
with associated input filters. In all cases electromagnetic disturbances electrode at the same time. The operator should be insulated from all
must be reduced to the point where they are no longer troublesome. such bonded metallic components.
Note: The welding circuit may or may not be earthed for safety reasons accord-
ing to national codes. Changing the earthing arrangements should only be
Earthing of the Workpiece
authorized by a person who is competent to access whether the changes Where the workpiece is not bonded to earth for electrical safety, not
will increase the risk of injury, e.g., by allowing parallel welding current
return paths which may damage the earth circuits of other equipment.
connected to earth because of its size and position, e.g., ships hull
or building steelwork, a connection bonding the workpiece to earth
may reduce emissions in some, but not all instances. Care should be
ASSESSMENT OF AREA
taken to prevent the earthing of the work piece increasing the risk
Before installing welding equipment the user shall make an of injury to users, or damage to other electrical equipment. Where
assessment of potential electromagnetic problems in the surrounding necessary, the connection of the workpiece to earth should be made
area. The following shall be taken into account: by a direct connection to the work piece, but in some countries where
a. other supply cables, control cables, signaling and telephone cables; direct connection is not permitted, the bonding should be achieved by
above, below and adjacent to the welding equipment; suitable capacitance, selected according to national regulations.
b. radio and television transmitters and receivers; Screening and Shielding
c. computer and other control equipment; Selective screening and shielding of other cables and equipment
in the surrounding area may alleviate problems of interference.
d. safety critical equipment, e.g., guarding of industrial equipment;
Screening of the entire welding installation may be considered for
e. the health of the people around, e.g., the use of pacemakers and special applications.
hearing aids; 1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic
f. equipment used for calibration or measurement Compatibility (EMC) product standard for arc welding equipment.”
g. the immunity of other equipment in the environment. The user
shall ensure that other equipment being used in the environment is
compatible. This may require additional protection measures;
h. the time of day that welding or other activities are to be carried out.

VANTAGE 400
vi SAFETY vi

As a rule of thumb, for many mild steel electrode, if the air is visibly Ventilation
clear and you are comfortable, then the ventilation is generally
adequate for your work. The most accurate way to determine if the There are many methods which can be selected by the user to
worker exposure does not exceed the applicable exposure limit for provide adequate ventilation for the specific application. The
compounds in the fumes and gases is to have an industrial hygienist following section provides general information which may be helpful
take and analyze a sample of the air you are breathing. This is in evaluating what type of ventilation equipment may be suitable for
particularly important if you are welding with stainless, hardfacing your application. When ventilation equipment is installed, you should
or Special Ventilation products. All Lincoln MSDS have a maximum confirm worker exposure is controlled within applicable OSHA PEL
fume guideline number. If exposure to total fume is kept below that and/or ACGIH TLV. According to OSHA regulations, when welding and
number, exposure to all fume from the electrode (not coatings or cutting (mild steels), natural ventilation is usually considered sufficient
plating on the work) will be below the TLV. to meet requirements, provided that:
There are steps that you can take to identify hazardous substances 1. The room or welding area contains at least 10,000 cubic feet
in your welding environment. Read the product label and material (about 22’ x 22’ x 22’) for each welder.
safety data sheet for the electrode posted in the work place or in 2. The ceiling height is not less than 16 feet.
the electrode or flux container to see what fumes can be reasonably 3. Cross ventilation is not blocked by partitions, equipment, or other
expected from use of the product and to determine if special structural barriers.
ventilation is needed. Secondly, know what the base metal is and
determine if there is any paint, plating, or coating that could expose 4. Welding is not done in a conned space.
you to toxic fumes and/or gases. Remove it from the metal being Spaces that do not meet these requirements should be equipped with
welded, if possible. If you start to feel uncomfortable, dizzy or mechanical ventilating equipment that exhausts at least 2000 CFM of
nauseous, there is a possibility that you are being overexposed to air for each welder, except where local exhaust hoods or booths, or
fumes and gases, or suffering from oxygen deficiency. Stop welding air-line respirators are used.
and get some fresh air immediately. Notify your supervisor and Important Safety Note:
co-workers so the situation can be corrected and other workers can
avoid the hazard. Be sure you are following these safe practices, When welding with electrodes which require special
the consumable labeling and MSDS to improve the ventilation in your ventilation such as stainless or hardfacing (see instructions
area. Do not continue welding until the situation has been corrected. on container or MSDS) or on lead or cadmium plated steel
NOTE: The MSDS for all Lincoln consumables is available on Lincoln’s web- and other metals or coatings which produce hazardous
site: www.lincolnelectric.com
fumes, keep exposure as low as possible and below
Before we turn to the methods available to control welding fume exposure limit values (PEL and TLV) for materials in the
exposure, you should understand a few basic terms: fume using local exhaust or mechanical ventilation. In
Natural Ventilation is the movement of air through the conned spaces or in some circumstances, for example
workplace caused by natural forces. Outside, this is usually the outdoors, a respirator may be required if exposure cannot
wind. Inside, this may be the flow of air through open windows be controlled to the PEL or TLV. (See MSDS and chart of
and doors. TLV and PEL for Typical Electrode Ingredients.) Additional
precautions are also required when welding on galvanized
Mechanical Ventilation is the movement of air through the steel.
workplace caused by an electrical device such as a portable fan
or permanently mounted fan in the ceiling or wall.
Source Extraction (Local Exhaust) is a mechanical device
used to capture welding fume at or near the arc and filter
contaminants out of the air.
The ventilation or exhaust needed for your application depends upon
many factors such as:
• Workspace volume
• Workspace configuration
• Number of welders
• Welding process and current
• Consumables used (mild steel, hardfacing, stainless, etc.)
• Allowable levels (TLV, PEL, etc.)
• Material welded (including paint or plating)
• Natural airflow
Your work area has adequate ventilation when there is enough
ventilation and/or exhaust to control worker exposure to hazardous
materials in the welding fumes and gases so the applicable limits for
those materials is not exceeded. See chart of TLV and PEL for Typical
Electrode Ingredients, the OSHA PEL (Permissible Exposure Limit), and
the recommended guideline, the ACGIH TLV (Threshold Limit Value),
for many compounds found in welding fume.

VANTAGE 400
vii SAFETY vii

BIBLIOGRAPHY AND SUGGESTED READING ANSI, Standard Z49.1, Safety in Welding, Cutting and Allied
Processes. Z49.1 is now available for download at no charge at http://
ANSI Z87.1, Practice for Occupational and Educational Eye and Face www.lincolnelectric.com/community/safety/ or at the AWS website
Protection, American National Standards Institute, 11 West 42nd http://www.aws.org.
Street, New York, NY 10036.
AWS F1.1, Method for Sampling Airborne Particulates Generated by
Arc Welding and Your Health: A Handbook of Health Information for Welding and Allied Processes.
Welding. Published by The American Industrial Hygiene Association,
2700 Prosperity Avenue, Suite 250, Fairfax, VA 22031-4319. AWS F1.2, Laboratory Method for Measuring Fume Generation Rates
and Total Fume Emission of Welding and Allied Processes.
NFPA Standard 51B, Cutting and Welding Processes, National Fire
Protection Association, 1 Batterymarch Park, P.O. Box 9146, Quincy, AWS F1.3, Evaluating Contaminants in the Welding Environment: A
MA 02269-9959. Strategic Sampling Guide.
OSHA General Industry Standard 29 CFR 1910 Subpart Q. OSHA AWS F1.5, Methods for Sampling and Analyzing Gases from Welding
Hazard Communication Standard 29 CFR 1910.1200. Available from and Allied Processes.
the Occupational Safety and Health Administration at http://www. AWS F3.2, Ventilation Guide for Welding Fume Control.
osha.org or contact your local OSHA office. AWS F4.1, Recommended Safe Practices for the Preparation for
The following publications are published by The American Welding Welding and Cutting of Containers and Piping That Have Held
Society, P.O. Box 351040, Miami, Florida 33135. AWS publications Hazardous Substances.
may be purchased from the American Welding society at http://www. AWS SHF, Safety and Health Facts Sheets. Available free of charge
aws.org or by contacting the AWS at 800-443-9353. from the AWS website at http://www.aws.org.

LISTED BELOW ARE SOME TYPICAL INGREDIENTS IN WELDING ELECTRODES AND

THEIR TLV (ACGIH) GUIDELINES AND PEL (OSHA) EXPOSURE LIMITS
INGREDIENTS CAS No. TLV mg/m3 PEL mg/m3
Aluminum and/or aluminum alloys (as AI)***** 7429-90-5 10 15
Aluminum oxide and/or Bauxite***** 1344-28-1 10 5**
Barium compounds (as Ba)***** 513-77-9 **** ****
Chromium and chromium alloys or compounds (as Cr)***** 7440-47-3 0.5(b) .005(b)
Fluorides (as F) 7789-75-5 2.5 2.5
Iron 7439-89-6 10* 10*
Limestone and/or calcium carbonate 1317-65-3 10 15
Lithium compounds (as Li) 554-13-2 10* 10*
Magnesite 1309-48-4 10 15
Magnesium and/or magnesium alloys and compounds (as Mg) 7439-95-4 10* 10*
Manganese and/or manganese alloys and compounds (as Mn)***** 7439-96-5 0.2 5.0(c)
Mineral silicates 1332-58-7 5** 5**
Molybdenum alloys (as Mo) 7439-98-7 10 10
Nickel***** 7440-02-0 1.5 1
Silicates and other binders 1344-09-8 10* 10*
Silicon and/or silicon alloys and compounds (as Si) 7440-21-3 10* 10*
Strontium compounds (as Sr) 1633-05-2 10* 10*
Zirconium alloys and compounds (as Zr) 12004-83-0 5 5

Supplemental Information:
(*) Not listed. Nuisance value maximum is 10 milligrams per cubic c) Values are for manganese fume. STEL (Short Term Exposure
meter. PEL value for iron oxide is 10 milligrams per cubic meter. Limit) is 3.0 milligrams per cubic meter. OSHA PEL is a ceiling
TLV value for iron oxide is 5 milligrams per cubic meter. value.
(**) As respirable dust. (****) There is no listed value for insoluble barium compounds. The
TLV for soluble barium compounds is 0.5 mg/m3.
(*****) Subject to the reporting requirements of Sections 311, 312,
and 313 of the Emergency Planning and Community Right-to- TLV and PEL values are as of April 2006. Always check Material
Know Act of 1986 and of 40CFR 370 and 372. Safety Data Sheet (MSDS) with product or on the Lincoln Electric
website at http://www.lincolnelectric.com
(b) The PEL for chromium (VI) is .005 milligrams per cubic meter
as an 8 hour time weighted average. The TLV for water-soluble
chromium (VI) is 0.05 milligrams per cubic meter. The TLV for
insoluble chromium (VI) is 0.01 milligrams per cubic meter.

VANTAGE 400
viii NOTES viii

VANTAGE 400
I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - I

Page
Safety.................................................................................................................................................................................. ii-viii

Installation, Operation, Accessories, Maintenance............................................................................ See Instruction Manual

Theory of Operation.................................................................................................................................................... Section E

Troubleshooting and Repair....................................................................................................................................... Section F

Electrical Diagrams....................................................................................................................................................Section G

VANTAGE® 400
E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Battery, Starter, Engine, Rotor, Stator, Engine Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Weld Windings, Rectifier, Chopper Modules and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3

Weld Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

Insulated Gate Bipolar Transistor (IGBT) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

Pulse Width Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6

Chopper Technology Fundamentals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7

FIGURE E.1 — VANTAGE® 400 BLOCK LOGIC DIAGRAM.

WORK
THREE-PHASE TERMINAL
RECTIFIER
-

CHOPPER MODULE
+ ELECTRODE
IGBT TERMINAL
80 VDC
CHOKE SHUNT +
POWER TO

STATOR W F C
POWER TO CONTROL BOARD

VRD

I E U I
D E
N VRD FEEDBACK R D
30
L D
D R L
E I VRD B E E
W N VOLTAGE REDUCTION A N

FEEDBACK
G
VRD PWM C T
K
SWITCH SIGNAL
(OFF) VOLT
R G
GLOW PLUGS
WELD
.
.D

VRD
R
V.

LIGHTS

MECHANICAL
CONTROL
ROTOR
STARTER ENGINE
ROTATION
SLIP
BOARD VOLTMETER
RINGS

+ AMMETER
- REMOTE
ALT AMPHENOL
ALTERNATOR ARC OUTPUT PROCESS/RANGE
CONTROL CONTROL SELECTOR
SOL SOL OIL PRESS
RUN/STOP
SWITCH (RUN) S
ENGINE
SENSORS
10 + 30 42 VAC TO 14 PIN AMPHENOL
FOR WIRE FEEDER
H
U TEMP AUXILIARY WINDINGS
I
T D
D L
O
+ W
E
R
240 VAC
N AUX 30
BATTERY CURRENT 240VAC
TORROID RECEPTACLE
-
ALT FLASH

AUX. FEEDBACK

ROTOR 120VAC
FLASH RECEPTACLED (2)

LOW IDLE COMMAND

ENGINE PROTECTION
Y IDLER CONTROL
ENGINE P.C. BOARD
TROUBLE Y
LIGHT ALTERNATOR
LIGHT

VANTAGE® 400
E-2 THEORY OF OPERATION E-2

FIGURE E.2 — GENERAL DESCRIPTION, BATTERY, ENGINE, ROTOR, STATOR & ENGINE PROTECTION
WORK
THREE-PHASE TERMINAL
RECTIFIER
-

CHOPPER MODULE
+ ELECTRODE
IGBT TERMINAL
80 VDC
CHOKE SHUNT +

POWER TO
STATOR W F C

POWER TO CONTROL BOARD

VRD
I E U I
D E
N VRD FEEDBACK R D
30
L D
D R L
E I VRD B E E
W N VOLTAGE REDUCTION A N

FEEDBACK
G
VRD PWM C T
K
SWITCH SIGNAL

VOLT
(OFF)
R G
GLOW PLUGS
WELD

.
.D
VRD

R
V.
LIGHTS

MECHANICAL
CONTROL
ROTOR
STARTER ENGINE
ROTATION
SLIP
BOARD VOLTMETER
RINGS

+ AMMETER
- REMOTE
ALT AMPHENOL
ALTERNATOR ARC OUTPUT PROCESS/RANGE
CONTROL CONTROL SELECTOR
SOL SOL OIL PRESS
RUN/STOP
SWITCH (RUN) S
ENGINE
SENSORS
10 + 30 42 VAC TO 14 PIN AMPHENOL
FOR WIRE FEEDER
H
U TEMP AUXILIARY WINDINGS
I
T D
D L
O
+ W
E
R
240 VAC
N AUX 30
BATTERY CURRENT 240VAC
TORROID RECEPTACLE
-
ALT FLASH

AUX. FEEDBACK

ROTOR 120VAC
FLASH RECEPTACLED (2)

LOW IDLE COMMAND

ENGINE PROTECTION
Y IDLER CONTROL
ENGINE P.C. BOARD
TROUBLE Y
LIGHT ALTERNATOR
LIGHT

GENERAL DESCRIPTION fed through the pull coil PC board to the rotor field
coil via a brush and slip ring configuration. This
The Vantage® 400 is a diesel engine-driven welding excitation or “flashing” voltage magnetizes the rotor
power source capable of producing 450 amps at lamination. This rotating magnet induces a voltage in
32VDC at a 100% duty cycle. The engine is coupled the stationary windings of the main alternator stator.
to a brush-type alternating current generator. This AC The stator houses a three-phase weld winding, a
output is rectified and controlled by Chopper Technology 120/240VAC single-phase auxiliary winding, and a
to produce DC current for multi-purpose welding 42VAC wire feeder power winding.
applications. The Vantage® 400 is also capable of
producing 11,000 watts of AC auxiliary power at 100% The engine alternator supplies charging current for
duty cycle. 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,
BATTERY, ENGINE, ROTOR, malfunction of the engine’s alternator system or a
STATOR, PULL COIL BOARD AND low fuel condition. The idler solenoid is mechanically
connected to the engine’s throttle linkage. If no welding
PERIPHERAL BOARD – ENGINE or auxiliary current is being drawn from the Vantage®
400, the Pull Coil board activates the idler solenoid,
PROTECTION which then brings the engine to a low idle state. When
The 12VDC battery powers the engine starter motor output current is sensed, either weld or auxiliary, the
and also supplies power to the Pull Coil PC board, Weld Control PC board deactivates the idler solenoid,
Peripheral PC board and associated circuitry. When and the engine returns to high RPM.
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
E-3 THEORY OF OPERATION E-3

FIGURE E.3 — WELD WINDINGS, RECTIFIER, CHOPPER MODULES & FEEDBACK

WORK
THREE-PHASE TERMINAL
RECTIFIER
-

CHOPPER MODULE
+ ELECTRODE
IGBT TERMINAL
80 VDC
CHOKE SHUNT +

POWER TO
STATOR W F C

POWER TO CONTROL BOARD

VRD
I E U I
D E
N VRD FEEDBACK R D
30
L D
D R L
E I VRD B E E
W N VOLTAGE REDUCTION A N

FEEDBACK
G
VRD PWM C T
K
SWITCH SIGNAL

VOLT
(OFF)
R G
GLOW PLUGS
WELD

.
.D
VRD

R
V.
LIGHTS

MECHANICAL
CONTROL
ROTOR
STARTER ENGINE
ROTATION
SLIP
BOARD VOLTMETER
RINGS

+ AMMETER
- REMOTE
ALT AMPHENOL
ALTERNATOR ARC OUTPUT PROCESS/RANGE
CONTROL CONTROL SELECTOR
SOL SOL OIL PRESS
RUN/STOP
SWITCH (RUN) S
ENGINE
SENSORS
10 + 30 42 VAC TO 14 PIN AMPHENOL
FOR WIRE FEEDER
H
U TEMP AUXILIARY WINDINGS
I
T D
D L
O
+ W
E
R
240 VAC
N AUX 30
BATTERY CURRENT 240VAC
TORROID RECEPTACLE
-
ALT FLASH

AUX. FEEDBACK

ROTOR 120VAC
FLASH RECEPTACLED (2)

LOW IDLE COMMAND

ENGINE PROTECTION
Y IDLER CONTROL
ENGINE P.C. BOARD
TROUBLE Y
LIGHT ALTERNATOR
LIGHT

WELD WINDINGS, RECTIFIER, This “chopped” DC output is applied through choke

coils and a shunt to the welding output terminals.
POWER MODULES AND The choke functions as a current filter, and it helps to
FEEDBACK balance the outputs of the two power modules. Free-
wheeling diodes are incorporated in the power modules
The three-phase stator weld windings are connected to to provide a current path for the stored energy in the
a three-phase rectifier bridge. The resultant DC voltage choke when the IGBTs are turned off. See Chopper
is applied to four paralleled capacitors incorporated Technology in this section.
within each of the two power modules. There are two
capacitors in each module. These capacitors function Output voltage and current feedback information is
as filters and also as power supplies for the IGBTs. fed to the Weld Control PC board. This information is
See IGBT Operation in this section. The IGBTs act sensed from the output terminal circuits and the shunt.
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
E-4 THEORY OF OPERATION E-4

FIGURE E.4 — WELD CONTROL BOARD

WORK
THREE-PHASE TERMINAL
RECTIFIER
-

CHOPPER MODULE
+ ELECTRODE
IGBT TERMINAL
80 VDC
CHOKE SHUNT +

POWER TO
STATOR W F C

POWER TO CONTROL BOARD

VRD
I E U I
D E
N VRD FEEDBACK R D
30
L D
D R L
E I VRD B E E
W N VOLTAGE REDUCTION A N

FEEDBACK
G
VRD PWM C T
K
SWITCH SIGNAL

VOLT
(OFF)
R G
GLOW PLUGS
WELD

D.
VRD

R.
V.
LIGHTS

MECHANICAL
CONTROL
ROTOR
STARTER ENGINE
ROTATION
SLIP
BOARD VOLTMETER
RINGS

+ AMMETER
- REMOTE
ALT AMPHENOL
ALTERNATOR ARC OUTPUT PROCESS/RANGE
CONTROL CONTROL SELECTOR
SOL SOL OIL PRESS
RUN/STOP
SWITCH (RUN) S
ENGINE
SENSORS
10 + 30 42 VAC TO 14 PIN AMPHENOL
FOR WIRE FEEDER
H
U TEMP AUXILIARY WINDINGS
I
T D
D L
O
+ W
E
R
240 VAC
N AUX 30
BATTERY CURRENT 240VAC
TORROID RECEPTACLE
-
ALT FLASH

AUX. FEEDBACK

ROTOR 120VAC
FLASH RECEPTACLED (2)

LOW IDLE COMMAND

ENGINE PROTECTION
Y IDLER CONTROL
ENGINE P.C. BOARD
TROUBLE Y
LIGHT ALTERNATOR
LIGHT

WELD CONTROL BOARD

The 80 VDC derived from the filter capacitors on and output terminal circuits. The circuitry on the Weld
the Power Modules, supplies various regulated DC Control PC board determines how the output should be
voltages to operate the Weld Control PC board circuitry. controlled to optimize welding results, and it sends the
It also supplies two regulated DC voltages to operate correct PWM signals to the IGBT driver circuits. The
the IGBT driver circuitry on the two Power Modules. Weld Control PC board also commands the thermal
light and the voltmeter and ammeter (some items may
The Weld Control PC board monitors the operator
be optional).
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
E-5 THEORY OF OPERATION E-5

FIGURE E.5 – IGBT OPERATION

INSULATED GATE BIPOLAR

TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are Drawing B shows the IGBT in an active mode. When
semiconductors well suited for high frequency switching the gate signal, a positive DC voltage relative to the
and high current applications. source, is applied to the gate terminal of the IGBT,
it is capable of conducting current. A voltage supply
Drawing A shows an IGBT in a passive mode. There
connected to the drain terminal will allow the IGBT
is no gate signal, zero volts relative to the source, and
to conduct and supply current to circuit components
therefore, no current flow. The drain terminal of the
coupled to the source. Current will flow through the
IGBT may be connected to a voltage supply; but since
conducting IGBT to downstream components as long
there is no conduction the circuit will not supply current
as the positive gate signal is present. This is similar to
to components connected to the source. The circuit is
turning ON a light switch.
turned off like a light switch in the OFF position.

VANTAGE® 400
E-6 THEORY OF OPERATION E-6

FIGURE E.6 – TYPICAL IGBT OUTPUTS

MINIMUM OUTPUT

(Dwell or Off Time)

2 sec 48 sec
50 sec

MAXIMUM OUTPUT

(Dwell or Off Time)

48 sec

50 sec

PULSE WIDTH MODULATION

The term PULSE WIDTH MODULATION is used to The positive portion of the signal represents one IGBT
describe how much time is devoted to conduction group conducting for 2 microsecond. The dwell time (off
in the cycle. Changing the pulse width is known as time) is 48 microseconds. Since only 2 microseconds of
MODULATION. Pulse Width Modulation (PWM) is the the 50-microsecond time period is devoted to conducting,
varying of the pulse width over the allowed range of a the output power is minimized.
cycle to affect the output of the machine.
MAXIMUM OUTPUT
MINIMUM OUTPUT
By holding the gate signals on for 48 microseconds
By controlling the duration of the gate signal, the IGBT and allowing only 2 microseconds of dwell time (off
is turned on and off for different durations during a time) during the 50-microsecond cycle, the output is
cycle. The top drawing shows the minimum output maximized. The darkened area under the top curve
signal possible over a 50-microsecond time period. can be compared to the area under the bottom curve.
The more darkened area under the curve, the more
power is present.

VANTAGE® 400
E-7 THEORY OF OPERATION E-7

CHOPPER TECHNOLOGY
FUNDAMENTALS
The new era of welding machines such as the Hence the name “Chopper.” The biggest advantage®
Vantage® 500, employ a technology whereby a DC of chopper technology is the high-speed control of the
source is turned on and off (chopped up) at high speed, arc, similar to the inverter machines. A block diagram
then smoothed through an inductor to control an arc. for this is as follows:

EXTERNAL DC SOLID STATE INDUCTOR

ARC
SOURCE SWITCH AND DIODE

ARC
CONTROL

In this system, the engine drives a three-phase By turning the switch on and off, current in the inductor
alternator, which generates power that is rectified and the arc can be controlled. The following diagram
and ­filtered to produce about 75VDC. The current is depicts the current flow in the system when the switch
applied through a solid state switch to an inductor. is open and closed.

INDUCTOR
SWITCH
ARC
70-80VDC
DIODE

CURRENT WITH SWITCH OPEN

CURRENT WITH SWITCH CLOSED

When the switch is closed, current is applied through arc. By varying the ratio of on time versus off time of
the inductor to the arc. When the switch opens, the switch (Duty Cycle), the current applied to the arc is
current stored in the inductor sustains flow in the arc controlled. This is the basis for Chopper Technology:
and through the diode. The repetition rate of switch Controlling the switch in such a way as to produce
closure is 20Khz, which allows ultra-fast control of the superior welding.

VANTAGE® 400
E-8 NOTES E-8

VANTAGE® 400
F-1 TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR F-1

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

How to Use Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3

Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4 - F-20

Case Cover Removal and Replacement Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-21

Chopper Module Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-25

Fuel Shutdown Solenoid Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-27

Engine Throttle Adjustment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-29

Idler Solenoid Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-33

Engine Alternator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-35

Brush and Slip Ring Service Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-37

Rotor Resistance and Grounding Test (Static). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-39

Rotor Resistance and Ground Test (Dynamic). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-41

Rotor Voltage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-43

Flashing Voltage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-47

Stator Voltage Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-51

Stator Short Circuit & Ground Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-55

Output Rectifier Bridge Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-57

Chopper Module Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-61

Chopper Module Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-65

Weld Control Board PWM Gate Signal Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-69

Weld Control Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-71

Control Potentiometer and Mode Switch Resistance Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-75

Remote Receptacle Resistance Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-79

Voltage Waveforms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-82 - F-86

Output Rectifier Bridge and Choke Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-87

Chopper Module Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-91

Stator/Rotor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-95

Retest after Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-104

VANTAGE® 400
F-2 TROUBLESHOOTING & REPAIR F-2

HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed throughout this manual.
---------------------------------------------------------------------------------------------------------------------------
This Troubleshooting Guide is provided to Step 3. RECOMMENDED COURSE OF ACTION
help you locate and repair possible machine The last column labeled “Recommended
malfunctions. Simply follow the three-step Course of Action” lists the most likely
procedure listed below. components that may have failed in your
machine. It also specifies the appropriate
Step 1. LOCATE PROBLEM (SYMPTOM). test procedure to verify that the subject
Look under the column labeled “PROBLEM component is either good or bad. If there are
(SYMPTOMS)”. This column describes a number of possible components, check the
possible symptoms that the machine components in the order listed to eliminate
may exhibit. Find the listing that best one possibility at a time until you locate the
describes the symptom that the machine cause of your problem.
is exhibiting. Symptoms are grouped into
the following categories: output problems, All of the referenced test procedures
function problems, welding problems, engine referred to in the Troubleshooting Guide
problems and output problems. are described in detail at the end of this
chapter. Refer to the Troubleshooting and
Step 2. PERFORM EXTERNAL TESTS. Repair Table of Contents to locate each
The second column labeled “POSSIBLE specific Test Procedure. All of the specified
AREAS OF MISADJUSTMENT(S)” lists test points, components, terminal strips, etc.
the obvious external possibilities that may can be found on the referenced electrical
contribute to the machine symptom. Perform wiring diagrams and schematics. Refer to
these tests/checks in the order listed. In the Electrical Diagrams Section Table of
general, these tests can be conducted Contents to locate the appropriate diagram.
without removing the case wrap-around
cover.

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.
-----------------------------------------------------------------------------------------------------------------------------------

VANTAGE® 400
F-3 TROUBLESHOOTING & REPAIR F-3

PC BOARD TROUBLESHOOTING PROCEDURES

- Remove the PC board from the static-shielding bag
WARNING and place it directly into the equipment. Don’t set the
ELECTRIC SHOCK PC board on or near paper, plastic or cloth which
can kill. could have a static charge. If the PC board can’t
be installed immediately, put it back in the static-
• Have an electrician install and shielding bag.
service this equipment. Turn the
input power OFF at the fuse box - If the PC board uses protective shorting jumpers,
before working on equipment. Do don’t remove them until installation is complete.
not touch electrically hot parts.
- 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
CAUTION proper failure analysis.
Sometimes machine failures appear to be due to 4. Test the machine to determine if the failure
PC board failures. These problems can sometimes symptom has been corrected by the replacement
be traced to poor electrical connections. To avoid PC board.
problems when troubleshooting and replacing PC
boards, please use the following procedure: NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. D
 etermine to the best of your technical ability
that the PC board is the most likely component NOTE: Allow the machine to heat up so that all
causing the failure symptom. electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected. 5. R
 emove the replacement PC board and substitute
it with the original PC board to recreate the
3. If the problem persists, replace the suspect PC original problem.
board using standard practices to avoid static
a. I f the original problem does not reappear
electrical damage and electrical shock. Read
by substituting the original board, then the
the warning inside the static resistant bag and
PC board was not the problem. Continue to
perform the following procedures:
look for bad connections in the control wiring
PC board can be damaged by static electricity. harness, junction blocks, and terminal strips.

- R e m o v e y o u r b o d y ’ s s t a t i c b. I f the original problem is recreated by the

charge before opening the substitution of the original board, then the
static-shielding bag. Wear an PC board was the problem. Reinstall the
anti-static wrist strap. For safety, replacement PC board and test the machine.
use a 1 Meg ohm resistive cord 6. A
 lways indicate that this procedure was followed
connected to a grounded part of when warranty reports are to be submitted.
ATTENTION the equipment frame.
Static-Sensitive NOTE: Following this procedure and writing on the
Devices - I f you don’t have a wrist strap, warranty report, “INSTALLED AND SWITCHED PC
Handle only at touch an un-painted, grounded, BOARDS TO VERIFY PROBLEM,” will help avoid
Static-Safe part of the equipment frame. denial of legitimate PC board warranty claims.
Workstations Keep touching the frame to
prevent static build-up. Be sure
not to touch any electrically live
parts at the same time.

- Tools which come in contact with the PC board must

be either conductive, anti-static or static-disipative.

VANTAGE® 400
F-4 TROUBLESHOOTING & REPAIR F-4

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major mechanical or electrical 1. Contact your local Lincoln 1. Contact the Lincoln Electric
damage is evident. Authorized Field Service Service Department at
Facility. 1-888-935-3877.

No welding output or auxiliary Check for loose or faulty Check the brushes for wear and
power. The engine operates connections in the auxiliary circuit proper contact to the rotor slip
normally. to the output receptacles, and/ rings
or the weld circuit to the output
terminals. SEE WIRING DIAGRAM. Perform the Brush and Slip Ring
Service Procedure.
Check the brushes for wear ad
proper contact to the rotor slip Check for flashing voltage at slip
rings. rings (3-5 Volts [email protected] 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.

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.

VANTAGE® 400
F-5 TROUBLESHOOTING & REPAIR F-5

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
No welding output in any mode. Place the Welding Terminals Check for damaged conductors
The auxiliary output is normal. switch in the “WELD TERMINALS or faulty connections on the
The engine operates normally. ON” If the problem is solved and heavy current carrying leads that
there is a control cable, wire connect the output studs to the
feeder, amptrol, or arc start switch Chopper module and to the Output
connected, the fault may lie in the Rectifier. Also check the shunt
above attached accessories. and the choke assemblies for
damage and faulty connections.
If the correct OCV is present at the
weld output terminals, check the Check the Welding Terminals
welding cables, connectors, work Switch and the associated leads.
clamp, electrode holder, etc. For See Wiring Diagram.
loose or faulty connections.
Check gate leads #23 and #25
and Weld Control Board power
leads #13 and #14 for loose or
faulty connections. See Wiring
Diagram.

Perform the Chopper Module

Function Test.

Perform the STATOR VOLTAGE TEST.

Perform the OUTPUT RECTIFIER

TEST.

The WELD CONTROL board may

be faulty.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

VANTAGE® 400
F-6 TROUBLESHOOTING & REPAIR F-6

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
No output in PIPE MODE. Make sure VRD ON/OFF toggle Check the connections at the VRD
Outputs normal in other modes. switch is in the off position. ON/OFF switch.
Faulty CONTROL PC BOARD. Check the VRD on off switch for
Faulty VRD display board. proper function/continuity.
See VRD functional description
VRD lights don’t light up. Ensure VRD ON/OFF switch is in Check connections at the VRD
the “ON” position. ON/OFF switch.
VRD light may be burned out, Check the VRD on off switch for
replace both VRD lights. proper?
Faulty VRD display P.C. Board. See VRD functional description.
No auxiliary power at one or Check for loose or faulty Perform the Stator Voltage Test.
more receptacles or at the 14 pin connections at the output Check the wiring between the
Amphenol. receptacles or 14 pin amphenol. auxiliary receptacle and the main
Weld output is normal and the Check for tripped circuit breaker stator.
engine operates normally. and/or tripped GFCI receptacles.
The machine has low welding The engine RPM may be low. Then engine high idle speed may
output and low auxiliary output. The brushes may be sticking, be low. Perform the Engine Throttle
poorly seated or slip rings dirty. 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.

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.

VANTAGE® 400
F-7 TROUBLESHOOTING & REPAIR F-7

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
FUNCTION PROBLEMS
The machine will weld but the Make sure the machine is properly The engine RPM may be too
welding arc is “COLD”. The set for the electrode and process low. Perform the Engine Throttle
engine runs normally and the is being used. Check electrode Adjustment Test.
auxiliary power is normal. size, mode switch setting, and Connect the machine to a
amps or voltage setting. If gas is resistive load bank. Connect an
used make sure of correct type accurate ammeter and volt meter
and gas flow. to the output of the machine.
Make sure the process does not Connect a tachometer, Hz meter
demand more power than the or another method to measure
machine can produce. engine RPM. Place the mode
If the current is correct try switch in “CC-STICK, turn the
increasing the “ARC CONTROL” output control to maximum idle
setting. switch to “HIGH” terminal switch
Check for loose or faulty to “WELD TERMINALS ON”.
connections at the weld output Nothing else attached or plugged
terminals and welding cable into machine (No aux., no control
connections. cables). Start the machine allow
Check for good connections the engine to reach normal
between the work cable and operating temperature. Apply a
the work piece. The work cable load with the load bank. Load to
should be attached to clean metal, 300 Amps, 32 Volts, 100% Duty
as close to the weld area as Cycle.
possible. The work clamp must The engine should maintain 3350
be in good condition with good RPM.
spring tension. If the engine cannot maintain the
The weld cables may be too long, RPM make sure there is a supply
or too small diameter causing of clean fresh fuel.
excessive voltage drop. Check the fuel filter and the air
The weld cables may be coiled, filter.
or wrapped around metal racks or Replace any filter that is dirty; or
reels. This can cause excessive damaged.
inductance in the weld circuit. If this doesn’t help have the engine
Try welding with a short set of serviced.
adequately sized weld cables. 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 FEEDBACK TEST.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

VANTAGE® 400
F-8 TROUBLESHOOTING & REPAIR F-8

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
FUNCTION PROBLEMS
The machine will weld but the If the maximum weld output cannot
welding arc is “COLD”. The be obtained even though the
engine runs normally and the front panel displays are reading
auxiliary power is normal. accurately, check for damaged
(continued) 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.

The machine welds but it will not This condition may be normal in The machine may not be
maintain a steady output. the Downhill Pipe Mode. The maintaining the correct RPM.
downhill pipe mode allows the arc Perform the THROTTLE ADJUSTMENT
current to increase and decrease TEST.
slightly as the arc length changes. If the engine will not maintain the
Check that the electrode is correct load RPM, the engine may
of good quality, dry and free be servicing fuel, air, and fuel
from contamination. Try using filters should be checked.
some Lincoln Electrode, and
setting the machine per Lincoln Check internal cables and leads
recommendation. that connect the weld winding
If shielding gas is used, check that of the stator, chopper module
the gas and gas flow are correct. and the shunt, choke and output
Check for damaged, pinched or terminals. See the wiring diagram.
leaking gas lines. Look for damaged conductors or
Check for proper work, and faulty connections.
electrode leads and connections
(size, length, coils, or bad
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.

VANTAGE® 400
F-9 TROUBLESHOOTING & REPAIR F-9

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
ENGINE PROBLEMS
The machine welds but it will not There may be poor connections
maintain a steady output. in the control wiring at the weld
(continued) 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.

The Amphenol receptacles may

be contaminated or defective.
Perform the REMOTE RECEPTACLE
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.

VANTAGE® 400
F-10 TROUBLESHOOTING & REPAIR F-10

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
ENGINE PROBLEMS
The weld output can not be Remote control devices completely Perform the REMOTE RECEPTACLE
adjusted with the front panel disables the front output in all RESISTANCE TEST.
output control knob in one or mode modes except touch start TIG The output control potentiometer
weld modes. The weld output mode. Make sure there is nothing may be defective. Perform the
terminals have normal OCV (open plugged into the Amphenol CONTROL POTENTIOMETER AND
circuit voltage). The AC auxiliary receptacles. MODE SWITCH RESISTANCE TEST.
power is normal and the engine Check for dirt or moisture The WELD CONTROL BOARD
operated normally. contamination in either the 6 pin or may be faulty.
the 14 pin amphenol.
See the Start-Up and OCV
diagnostic chart.

The machine front panel output This condition is normal in the Check plug #P1 on the control
control is still active when the “TOUCH START TIG MODE”. P.C. Board. Plug should be
remote control unit is connected to See the operators manual. properly seated and the pins in
one of the Front Panel Amphenols. The remote control unit may be both the plug and the P.C. Board
defective. jack must be clean and fit tightly
Check the Amphenol receptacles. together.
Look for damage or corroded
contact pins in the receptacle and There may be a poor connection
in the plug of the remote control between the weld control
unit. P.C. Board and the amphenol
receptacles. Check for continuity
between the following terminals.
See Wiring Diagram and Control
Inner-Connection 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.

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.

VANTAGE® 400
F-11 TROUBLESHOOTING & REPAIR F-11

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
ENGINE PROBLEMS
The machine seems to be locked Check the position of the Check that plug P-7 is fully
into the “CC-stick” mode of WELD MODE selector switch. seated into the weld control P.C.
operation. The switch should positively snap board socket. See Control Inner-
into each mode position and Connection diagram.
should not feel gritty or get stuck Check for corroded, dirty, or
between positions. 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
POTENTIOMETER AND MODE SWITCH
RESISTANCE TEST.
The Weld control P.C. Board may
be faulty.

The arc quality is poor with The ARC CONTROL may be set Check that the weld circuit isn’t
excessive spatter. The arc heat too high. grounded. With the engine off,
can be controlled and maintained The output control may be set too check the resistance between
normally, the auxiliary output is high for the electrode being used. chassis ground and the weld
normal and the engine operates Check that the electrode is of output terminals. The resistance
normally. good quality, dry and free from should be very high, a minimum of
contamination. Try using some 500,000 (500k) Ohms.
Lincoln Electrode, and setting The weld control system may
the machine per Lincoln’s be grounded or malfunctioning.
recommendation. Perform the CONTROL
If shielding gas is used, check that POTENTIOMETER and MODE SWITCH
the gas and gas flow are correct. TEST, and the REMOTE RECEPTACLE
Check for damaged, pinched, or RESISTANCE TEST.
leaking gas lines.
Check for proper work, and The Chopper module may be
electrode leads and connections defective. Perform the CHOPPER
(size, length, coils, or bad MODULE RESISTANCE TEST.
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.

VANTAGE® 400
F-12 TROUBLESHOOTING & REPAIR F-12

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
WELDING PROBLEMS
The machine welds normally in It is normal for one of the displays Both the “AMPS” and “VOLTS”
all modes and the range of weld to be off when there is no load displays use the same part
output seems normal, but one or across the weld output terminals. numbered display unit. If one of
both of the front panel displays is In “CV” - mode only the “VOLTS” the digital displays appears to be
blank, incorrect welding value, or display will be illuminated, in all functioning normally, it can be
displays parts of numbers. other modes only the “AMPS” used to test the weld control P.C.
display will be illuminated. Board output to the malfunctioning
When welding both displays display.
should be reading actual welding Swap the display board
parameters. 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 Check the circuit breaker CB1 if Use a volt meter to check for the
not function when connected to using a a120 Volt AC wire feeder. presents of supply voltage at the
the 14 pin amphenol. Machine Check CB8 if using a 42 VAC wire 14 pin Amphenol receptacle. 120
operates normally in the feeder. Reset breaker in tripped. Volt AC power supplied through
“CC-STICK” mode and has normal Check the Amphenol receptacle pins A and J, 421 VAC power is
AC auxiliary output. for damaged, corroded or dirty supplied through pins I and K.
contact pins. Perform the STATOR VOLTAGE TEST.

The wire feeder control cable may

be defective.
The wire feeder may be defective.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

VANTAGE® 400
F-13 TROUBLESHOOTING & REPAIR F-13

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
An Across-the-Arc type wire feeder Check that the welding Use a voltmeter to check for the
does not function when connected terminals switch is in the presence of about 58 VDC open
to the weld output of the machine. “WELD TERMINALS ON” position. circuit voltage (OCV) across the
The Vantage® operated normally Check the that WELD MODE output studs of the machine.
in the CC-STICK mode, and has switch is in the correct position for If the OCV is low, there may
normal AC auxiliary output. the process being used, typically be a problem with the mode
“CV-WIRE” mode. switch. Perform the CONTROL
Check for poor weld cable POTENTIOMETER AND WELD MODE
connections between the feeder SWITCH RESISTANCE TEST.
and the welder output terminal,
and between the work and the If there is no OCV, see the
other output terminal. troubleshooting sections for “No
Check that the wire feeder’s work weld output in any mode”.
sensing lead is properly connected
to the work piece and is in good
condition.
The wire feeder may be defective.
The engine will not crank when the Check the circuit breaker (CB5). Check the wiring and the
start button is pushed. Reset if tripped. connections at the starter motor,
Make sure the run/stop switch is in glow plug button, CB5 circuit
the “RUN” position. breaker, run / stop switch and the
Check for loose or faulty battery start button. See wiring diagram.
cable connections. See wiring Check the chassis ground
diagram. connections between the engine
The battery may be low or faulty. block and the negative battery
If the battery will not accept a terminal. Place the run/stop switch
charge replace it. to the “RUN” position. Press the
The starter or starter solenoid may start button, while checking for
be faulty (have the engine serviced voltage between a good clean
at an authorized engine repair chassis ground connection (-)
shop). 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.

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.

VANTAGE® 400
F-14 TROUBLESHOOTING & REPAIR F-14

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
The battery does not stay charged. Check for loose, corroded, or Perform the ENGINE ALTERNATOR
faulty connections at the battery. TEST.
Check for loose or damaged There may be a defective
alternator drive belt. component or faulty wiring,
The battery may be faulty. ,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 engine cranks when the start The battery voltage may be low The fuel solenoid may be
button is pressed but will not start. (normally results in slow cranking faulty or not operating properly.
speed). The batter should be Check lead #233, and #262 and
checked and recharged if it is not perform the FUEL SHUT DOWN
producing adequate voltage, and SOLENOID TEST.
replace if it will not accept a full
charge. The Engine Protection Board may
Make sure the glow plug button be faulty.
is pressed while pressing the
start button. See the operator’s The engine may be in need of
manual, or the operation section mechanical repairs.
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.

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.

VANTAGE® 400
F-15 TROUBLESHOOTING & REPAIR F-15

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

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

The engine shuts down shortly Check for adequate supply of The oil pressure switch or coolant
after starting. clean fresh fuel. temperature switch may be faulty.
Check fuel and air filters, replace if Make sure the engine has oil and
necessary. oil pressure and engine is not
Check oil level, add oil as overheated.
required. Look for oil leakage. Disconnect lead 234 from Engine
Check for loose or faulty battery Protection PC Board, of engine
cable connections. continues to run oil pressure
switch or Temperature Switch is
faulty.
Check for faulty run/stop switch.
Check for damaged insulation in
the wiring between the engine
protection relay and the oil
pressure and coolant temperature
switches. See wiring diagram.

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.

VANTAGE® 400
F-16 TROUBLESHOOTING & REPAIR F-16

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
The engine shuts down shortly Check for poor electrical
after starting. 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.
The engine shuts down shortly Try resetting the breaker. If it trips Repeated tripping and resetting of
after starting and trips the battery again do not attempt to use the the circuit breaker can damage it,
circuit breaker (CB5). machine. or alter its trip point. If the breaker
has been ripped and reset many
Contact a Lincoln Authorized Field times, it should be replaced.
Service Shop. Examine the CB5 circuit breaker,
run/stop switch. Start button.
Shut-down and idle solenoid,
engine protection board, fuel
gauge and sender, and all
the wiring connecting these
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.

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.

VANTAGE® 400
F-17 TROUBLESHOOTING & REPAIR F-17

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
The engine will not develop full The fuel may be old or The engine may be in need of
power. contaminated. Supply the engine adjustment or repair.
with clean fresh fuel.
The fuel filter may be clogged,
replace if necessary.
The air filter may be clogged,
replace if necessary.
The engine will not idle down Make sure the idle switch is in Perform the IDLER SOLENOID TEST.
to low RPM. The machine has the “AUTO IDLE” position. Make Check for damaged wiring or faulty
normal weld and auxiliary output. sure there is no external load on connections at the idle solenoid,
the weld terminals or the auxiliary the engine protection PC Board,
power receptacles. the run/stop switch and the start
Check for mechanical restrictions button.
in the idler solenoid linkage. 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.

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.

VANTAGE® 400
F-18 TROUBLESHOOTING & REPAIR F-18

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
The engine will not idle down Manually move the idle solenoid
to low RPM. The machine has plunger to the idle position. If the
normal weld and auxiliary output. solenoid engages and holds in the
(continued) 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
diagram.
If the engine still does not drop to
low idle the control PC Board is
probably defective. Replace it.
Check that leads #3 and #6
are properly routed through the
toroidal current sensor.
Each lead must have two turns
and must pass through the sensor
in the opposite directions. See
the wiring diagram. The leads
should be wrapped tightly and tie
wrapped in place.
Check the toroidal current sensor
for any signs of damage.
Check leads #260 and #261 for
poor connections and damage
to the conductors and insulation
between the toroid current sensor
and the P3 connector in the
control PC Board.
Unplug plug P3 from the control
PC Board and check for damaged,
dirty, or corroded pins.

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.

VANTAGE® 400
F-19 TROUBLESHOOTING & REPAIR F-19

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
The engine will not idle down Measure the resistance of toroidal
to low RPM. The machine has current sensor. Measure between
normal weld and auxiliary output. #P-3 and #P-4, the resistance
(continued) should be 4.1 Ohms.
If the sensor is shorted or open
replace it.
The control board may be bad.
The engine will not go to high The load on the auxiliary Check that leads #3 and #6
idle when using auxiliary power. receptacle may be too low. are properly routed through the
Auxiliary power is normal when The automatic idle system will not toroidal current sensor.
the idler switch is in the “HIGH” function reliably if the low is less Each lead must have two turns
idle position, the automatic idle than 100 Watts. and must pass through the
function works properly when The device connected to the sensor in the opposite directions.
welding. auxiliary power may be defective See wiring diagram. The leads
try another device. should be wrapped tightly and tie
Make sure the connections to the wrapped in place.
auxiliary device are tight. Check the toroidal current sensor
Some device are designed to for any signs of damage.
sense for adequate input power. Check leads #260 and #261 for
Product of this type may not poor connections and damage
turn on due to low voltage and to the conductors and insulation
frequency of the idling machine. between the toroid current sensor
If this happens the current draw and the P3 connector in the
will likely be insufficient to activate control PC board.
the automatic idle system. Device Unplug plug P3 from the control
of this type may require that the PC board and check for damaged,
Idler switch be in the “HIGH IDLE” dirty, or corroded pins.
position. 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.

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.

VANTAGE® 400
F-20 TROUBLESHOOTING & REPAIR F-20

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
The engine will not go to high idle Check that the welding cables Check the leads and connections
when striking arc. The automatic are in good working condition and at the SHUNT at the Positive
idle system functions normally the connections are tight. Make output stud. Check lead 204S and
when using auxiliary power. sure the work clamp is attached to 206S for continuity from the shunt
Welding and auxiliary outputs are clean, bare metal. to J-6 on the Weld Control Board.
normal when the idle switch is in Check the pins and connections
the “HIGH IDLE” position. at J-6 and J on the Weld Control
Board.
The weld control P.C. Board may
be defective.
The engine will not go to high idle Check that the welding cables The weld control P.C. Board may
when attempting to strike and arc, and the auxiliary power lead be defective.
or when a load is applied to any of connections are tight.
the auxiliary power receptacles.

The engine goes to low idle, but Make sure there are no auxiliary The Idler solenoid linkage may be
will not stay low idle. loads on either the weld terminals damaged or out of adjustment.
or the auxiliary receptacles. Make sure the solenoid plunger
Check that the welding cables is able to fully ease against the
and the auxiliary cables and the internal stop of the solenoid coil
auxiliary power lead connections assembly.
are tight and that the insulation is The low idle RPM may be too
not damaged. 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.

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.

VANTAGE® 400
F-21 TROUBLESHOOTING & REPAIR F-21

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 trouble-
shooting 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

VANTAGE® 400
F-22 TROUBLESHOOTING & REPAIR F-22

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTIN-

UED)
FIGURE F.1 – CASE COVER REMOVAL

Roof

Lift Bale Seal

Fuel Tank Seal

Fuel Tank Cap

Left Case Side

Battery
Drawer

Right Side Service

Access Door
Right Case Side
PROCEDURE
1. Turn the engine off. 9. With the help of an assistant, carefully remove
the roof. Replace the fuel cap.
2. Using the 3/8” wrench, remove the battery
cover. Slide the battery out and disconnect the 10. With the 3/8” wrench, remove the right case
negative battery cable. side and the left case side. See Figure F.1.
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
F-23 TROUBLESHOOTING & REPAIR F-23

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTIN-

UED)
REASSEMBLY PROCEDURE
1. Install components in reverse order of removal.
2. Be sure components align correctly.
3. Reconnect battery and replace battery door.

VANTAGE® 400
F-24 NOTES F-24

VANTAGE® 400
F-25 TROUBLESHOOTING & REPAIR F-25

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 trouble-
shooting 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

VANTAGE® 400
F-26 TROUBLESHOOTING & REPAIR F-26

CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE (CONTINUED)

FIGURE F.2 - CHOPPER MODULE CAPACITOR TERMINAL DISCHARGE

INSULATED
PLIERS

B1 B4

B2 B5

B3 B6

INSULATED
GLOVES
NEVER USE A SHORTING STRAP TO
WARNING DISCHARGE CAPACITORS. If the Lincoln
ELECTRIC SHOCK can kill. recommended resistor, or an equivalent resistor
is used, the capacitors can be discharged by
• Do not touch electrically hot parts. holding the resistor with insulated pliers and using
•P
rior to performing preventative the resistor terminals to bridge Chopper Module
maintenance, perform the following terminals B1 to B2, and B4 to B5. DO NOT
capacitor discharge procedure to TOUCH THE TERMINALS OR METAL PARTS OF
avoid electric shock. THE PLIERS WITH YOUR BARE HANDS. Hold
the resistor in place for about 10 seconds.
If another type of resistor is used, jumper leads
DISCHARGE PROCEDURE may need to be attached to the resistor. The
1. Turn the engine off. leads can then be used to connect terminals
B1 to B2, and B4 to B5.
2. Perform the Case Cover Removal Procedure.
4. Using the volt/ohmmeter, check the voltage
NOTE: It is necessary to remove the fuel cap across B1 and B2, then B4 and B5. It should
in order to take the case cover off the be zero volts in both cases.
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.

VANTAGE® 400
F-27 TROUBLESHOOTING & REPAIR F-27

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 trouble-
shooting 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)

VANTAGE® 400
F-28 TROUBLESHOOTING & REPAIR F-28

FUEL SHUTDOWN SOLENOID TEST (CONTINUED)

FIGURE F.3 - FUEL SHUTDOWN SOLENOID LOCATION

SHUTDOWN SOLENOID
IDLE SOLENOID

LIN
C
ELOLN
EC

VA
TR
IC

NTA
GE4
00

TEST PROCEDURE
1. Turn the engine off. 6. Using an external 12VDC supply, apply voltage
to the coil leads, (black-) to (white+). The
2. Open the right side engine service access door.
solenoid should activate.
3. Locate the fuel solenoid, located on top of the
If the solenoid does not operate correctly
engine.
when 12VDC is applied, the solenoid may be
4. Locate and unplug harness connection 56. Cut defective. Replace.
any necessary cable ties. See Figure F.4. See
 e-connect fuel solenoid and replace any
R
Wiring Diagram.
previously removed cable ties.
5. Check the coil resistance, (black wire to red
7. If finished testing, close the engine service
wire). The normal resistance is approximately
access doors.
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
F-29 TROUBLESHOOTING & REPAIR F-29

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 trouble-
shooting 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

VANTAGE® 400
F-30 TROUBLESHOOTING & REPAIR F-30

ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)

FIGURE F.4 - STROBE MARK LOCATION

STROBE
TACH
MARK

TEST PROCEDURE

Strobe-Tach Method
1. Turn the engine off 7. Move the idle switch to the “AUTO IDLE” position
and wait for the idle solenoid to energize, and
2. Open the top and right side engine service the engine RPM to drop and stabilize at the low
access doors. idle RPM.
3. Place a highly visible mark on the engine 8. Synchronize the strobe-tach to read the low idle
cooling fan blade. See Figure F.4. RPM.
4. Connect the strobe-tach according to the Low idle speed should be 1300-1400 RPM.
manufacturer’s instructions.
If either of the readings is incorrect, proceed to
5. Start the engine and place the idle switch in the the THROTTLE ADJUSTMENT PROCEDURE later in
“HIGH IDLE” position. Make sure that there is this section.
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.
 he tach should read between 1860 and 1890
T
RPM.

VANTAGE® 400
F-31 TROUBLESHOOTING & REPAIR F-31

ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)

FIGURE F.5 - SOLENOID

SHUTDOWN SOLENOID

IDLE SOLENOID
LOW SPEED ADJ.

DO NOT TOUCH
FOR LOW SPEED

LIN
C
ELOLN
EC

VA
TR
IC

NTA
GE4
00

HIGH SPEED ADJ.

Frequency Counter Method

NOTE: A dedicated frequency counter can be used 3. Move the idle switch to the “AUTO IDLE” position
for this test, but many high quality digital and wait for the idle solenoid to energize, and
multimeters also have this function, and can the engine RPM to drop and stabilize at the low
be easily utilized. See the manufacturer idle RPM.
instructions for your frequency counter or
 he frequency should read between 43.3 and
T
multimeter.
46.6 Hz.
1. Set your frequency counter per the meter
If either of the readings is incorrect, proceed to
manufacturer instructions, and plug it into one
the THROTTLE ADJUSTMENT PROCEDURE later in
of the 120VAC auxiliary receptacles.
this section.
2. Start the engine and place the idle switch in the
NOTE: For the VANTAGE® 400, and any other
“HIGH IDLE” position. Make sure that there is
Lincoln Electric 1800 RPM (4 Pole)
no load on the machine.
machine, engine RPM can be determined
 he frequency should read between 62.0 and
T by multiplying the frequency, in Hz. By 30.
63.0 Hz. (Example: 30 Hz * 62 = 1860RPM)

VANTAGE® 400
F-32 TROUBLESHOOTING & REPAIR F-32

ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)

Vibratach Method NOTE: L

ow idle RPM must be set, and the
adjustment nuts tightened, before the
A Vibratach is used to measure the vibrations
high idle RPM is adjusted.
caused by the running engine. It can be positioned
anywhere where the engine vibration is reasonably
strong. The best results will likely be obtained
Low Idle adjustment:
by opening the top engine cover and placing the
Vibratach directly against the top of the engine. 1. With engine running and no load applied to the
machine, place the idle switch in the “AUTO
Read and understand the manufacturer’s
IDLE” position. Wait for the idle solenoid to
instructions for the Vibratach.
energize and the engine speed to drop and
1. Start the engine and place the idle switch in the stabilize to low idle RPM.
“HIGH IDLE” position. Make sure that there is
2. If the low idle RPM requires adjustment, loosen
no load on the machine.
the low idle adjustment jam nuts. Turn both nuts
2. Position and adjust the Vibratach; it should read so they are clear of the swivel fitting. Rotate the
between 1860 and 1890 RPM. swivel fitting until the engine speed has been
set to between 1200 and 1400 RPM. Hold the
3. Move the idle switch to the “AUTO IDLE” position
swivel fitting in position while tightening the
and wait for the idle solenoid to energize, and
first jam nut against the swivel fitting, and then
the engine RPM to drop and stabilize at the low
tighten the second jam nut against the first. Do
idle RPM.
not adjust at engine stop lever.
4. Position and adjust the Vibratach; it should read
3. Re-check the low idle RPM, and then proceed
between 1300 and 1400 RPM.
to the high idle adjustment.
If either of the readings is incorrect,
proceed to the “THROTTLE ADJUSTMENT
PROCEDURE”. High idle adjustment:
THROTTLE ADJUSTMENT PROCEDURE 1. With engine running, place the idle switch in
the “HIGH IDLE” position. The solenoid should
IMPORTANT: Both the high and low idle settings
immediately de-energize, allowing the engine to
are adjusted at the solenoid.
increase to high idle speed.
1. Check that the linkage attaching the solenoid
2. If the high idle RPM requires adjustment,
to the engine speed control lever is properly
loosen the high idle adjustment screw jam at
aligned and in good condition. It is more
engine lever + high speed stop nut and turn
important that the solenoid linkage be more
the adjusting screw until the engine speed
precisely aligned when in the high speed
is between 1860 and 1890 RPM. Hold the
(de-energized position).
adjusting screw in position while tightening the
2. Check to be sure the spring located inside jam nut against the solenoid plunger.
the rubber boot is not broken or missing. In
3. Re-check the high idle RPM.
the default, (de-energized) position the spring
should be holding the solenoid in the high 4. Close the engine service access doors and shut
speed position. See Figure F.5. off the engine.

VANTAGE® 400
F-33 TROUBLESHOOTING & REPAIR F-33

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 trouble-
shooting 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
 iscellaneous Hand Tools
M
External 12VDC Supply (30 amps) (automotive battery works well)
Wiring Diagram
Volt/Ohmmeter

VANTAGE® 400
F-34 TROUBLESHOOTING & REPAIR F-34

IDLER SOLENOID TEST (CONTINUED)

FIGURE F.6 - PLUG(S) PIN LOCATION

P-55 J-55

COMMON 232L
3 1 1 3 12 VOLT + RUN
BLACK
226 227
4 2 2 4
WHITE RED ENGINE PROTECTION ENGINE PROTECTION
PULL HOLD IDLE CONTROL P.C.B. IDLE CONTROL P.C.B.

IDLE SOLENOID IDLE SOLENOID

CONNECTOR WIRING HARNESS
(LEAD ENTRY VIEW) CONNECTOR
(LEAD ENTRY VIEW)

TEST PROCEDURE 6. Using the external 12VDC supply, apply 12VDC

to the pull-in coil leads at pins 3+ and 4- (black
1. Turn the engine off. wire to white wire). The solenoid should activate.
2. Open the right side engine service access door. REMOVE THE VOLTAGE IMMEDIATELY to
avoid damage to the unit.
3. Locate the idler solenoid mounted right side of
engine. 
Apply 12VDC to the hold-in coil at pin #3 (black
wire +) and pin #2 (red wire -). While the
4. Locate and unplug harness connection P-55. voltage is applied, manually move the solenoid
Cut any necessary cable ties. See Wiring to the low idle position. The solenoid plunger
Diagram. should hold this position until the voltage is
5. Using the volt/ohmmeter, check the pull-in coil removed. See Figure F.6.
resistance, pins 3 and 4 (black wire to white 7. If either coil does not operate as described,
wire). The normal resistance is less than check for mechanical restrictions or other
0.2 ohms. Check the hold-in coil resistance, problems with the linkage.
pins 3 and 2 (black wire to red wire). The 8. If the linkage is intact and the solenoid does not
normal resistance is approximately 11 ohms. operate correctly when the 12VDC is applied,
Check the resistance between pin 3 (black the solenoid may be faulty. Replace.
wire) and a clean, unpainted chassis ground.
The resistance should be very high. 500,000 9. Re-connect idle solenoid and replace any
Ohms or more. If any of the above resistance previously removed cable ties.
values are incorrect, the solenoid may be faulty. 10. If finished testing, close the engine service
Replace. See Figure F.6. access door.

VANTAGE® 400
F-35 TROUBLESHOOTING & REPAIR F-35

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 trouble-
shooting 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

VANTAGE® 400
F-36 TROUBLESHOOTING & REPAIR F-36

ENGINE ALTERNATOR TEST (CONTINUED)

FIGURE F.7 - LEAD LOCATIONS

BACK OF ALTERNATOR

238 243

TEST PROCEDURE 9. Make sure the idle switch is still in the “high”
position, start the engine, and allow it to run at
1. Turn the engine off.
high idle speed for about 15 to 30 seconds.
2. Open the engine access door and check the
10. Place the negative meter probe on a good
voltage at the battery terminals. It should be
chassis ground, or the negative battery terminal.
approximately 12 volts DC.
Place the positive meter probe on the battery
3. Attach the meter leads to the battery terminals, terminal on the back of the alternator. (Lead
being careful to position them so they stay clear #238) See Figure F.7. See Wiring Diagram.
of moving parts while the engine is running.
11. The meter should read about 13.7 to 14.2 VDC.
4. Place the idle switch in the “HIGH IDLE”
12. Move the positive probe to the DT terminal on
position, start the engine, and allow it to run at
the back of the alternator. (Lead 243C) See
high idle speed for about 15 to 30 seconds.
Figure F7.
5. The meter should read about 13.7 to 14.2 VDC.
13. The meter should read about 13.7 to 14.2 VDC.
6. If the meter reads correctly the engine alternator
14. If the meter reads correctly, check the
is producing adequate power to charge the
connections between the alternator and the
battery and this test is complete.
battery. See wiring diagram.
7. If the voltage is significantly higher than the
15. If the voltage at both of the above test points
above values, the alternator is not properly
reads the same or less than the battery voltage
regulating the battery charging voltage and
measurement taken when the engine was not
should be replaced. If the voltage reads the
running, the alternator is defective. Repair or
same or less than the measurement taken
replace it.
when the engine was not running, proceed with
the following tests.
8. Turn off the engine, disconnect the meter from
the battery, and open the engine access door
on the left side of the machine.

VANTAGE® 400
F-37 TROUBLESHOOTING & REPAIR F-37

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 trouble-
shooting 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
 olt/Ohmmeter
V
Miscellaneous Hand Tools
500 or 600 grit emery cloth
180 grit sand paper

VANTAGE® 400
F-38 TROUBLESHOOTING & REPAIR F-38

BRUSH AND SLIP RING SERVICE PROCEDURE (CONTINUED)

FIGURE F.8 – BRUSH & SLIP RING LOCATIONS
SLIP RINGS BRUSHES

#200A

#200B

#201

TEST PROCEDURE Cleaning slip rings:

1. Perform the Case Cover Removal Procedure. 1. In the event that the slip rings have become
dirty, discolored or mildly pitted, it will be
2. Examine brushes and slip rings. The slip rings,
necessary to clean them, using very fine, 500
brush holder, and brushes should be clean and
or 600 grit sand paper or a 220 or 320 grit
free from oil or grease. The brushes should be
commutator stone.
making good, continuous contact with the slip
rings. Seating Brushes:
3. The brushes should be of sufficient length and 1. If brushes have been replaced, repositioned, or
have adequate spring tension. Generally, the are not making full contact with the slip rings,
brushes should be replaced if either brush it may be necessary to re-seat them. This can
has less than 1/4” remaining before it reaches be done by placing a strip of 180 grit sandpaper
the end of its travel. Spring tension should be between the slip rings and the brushes, with
sufficient to hold the brushes firmly against the the abrasive side against the brushes. Pull the
slip rings. sandpaper strip around the circumference of
the slip rings in the direction of rotor rotation
4. The brushes should be removed from the brush
only. Repeat this procedure until the surface
holder and examined. The terminals should be
of each brush is in full contact with its matching
clean. The shunt, (braided lead connecting the
slip ring.
carbon brush to the terminal) should be in good
condition and firmly connected to the carbon 2. Use a low pressure compressed air to
brush and to the connection terminal. thoroughly blow the carbon, commutator stone,
and sandpaper dust from the machine before
5. If the slip rings are discolored, display evidence
operating.
of excessive sparking, or the brushes have
worn prematurely; these may be signs of a 3. Perform the Case Cover Replacement Procedure
grounded or shorted rotor. Perform the Rotor
NOTE: See Figure F.8 for general locations.
Resistance Test.
6. Check for evidence of sticking brushes. Sticking
brushes will normally result in the slip rings
being pitted and discolored from excessive
arcing. Another sign of sticking brushes is
instability or loss of both weld and auxiliary
output, but the machine may begin to work
properly, for a short time, after being jarred or
moved.
7. If there is any evidence that the brushes may
have been sticking in the brush holders, a new
brush holder and brush assembly should be
installed.

VANTAGE® 400
F-39 TROUBLESHOOTING & REPAIR F-39

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 trouble-
shooting 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

VANTAGE® 400
F-40 TROUBLESHOOTING & REPAIR F-40

ROTOR RESISTANCE AND GROUND TEST (STATIC) (CONTINUED)

FIGURE F.9 - ROTOR BRUSH LEADS

SLIP RINGS BRUSHES

#200A

#200B

+
#201

TEST PROCEDURE
1. Turn the engine off. 5. Measure the resistance to ground. Place one
meter probe on either of the slip rings. Place
2. Perform the Case Cover Removal Procedure.
the other probe on any good unpainted chassis
3. Locate and label the leads from the rotor brush ground. The resistance should be very high, at
holder assembly. See Figure F.9. Using the least 500,000 (500k) ohms.
needle nose pliers, remove the leads. This will
6. If the test does not meet the resistance specifi-
electrically isolate the rotor windings.
cations, then the rotor may be faulty and should
4. Using the ohmmeter, check the rotor winding be replaced.
resistance across the slip rings. See Figure
7. If this test meets the resistance specifications,
F.9. Normal resistance is approximately 25
continue testing using the dynamic rotor resis-
ohm, at 77º F. (25º C.).
tance and ground test.

VANTAGE® 400
F-41 TROUBLESHOOTING & REPAIR F-41

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 trouble-
shooting 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.

VANTAGE® 400
F-42 TROUBLESHOOTING & REPAIR F-42

ROTOR RESISTANCE AND GROUND TEST (DYNAMIC) (CONTINUED)

TEST PROCEDURE 4. Shut off engine, and move one of the ohmmeter
leads to a good clean chassis ground.
This test requires that the brushes and slip rings
are clean, in good condition, and are properly 5. Restart the engine and run it at high idle speed
seated. (1860-1890 RPM). The resistance should be
very high, at least 500,000 (500k) ohms.
1. Perform the Brush and Slip Ring Service Procedure
if necessary. 6. If the resistance readings differ significantly
from the values indicated, re-check the brushes
2. Insulate the lead wires that had been and the brush spring tension. If the brushes
disconnected from the brushes during the static and slip rings are good, replace the rotor.
rotor resistance test. Position and secure
them so they cannot become damaged by the 7. If all testing is finished, perform the Case Cover
spinning rotor. Replacement procedure.
3. Securely attach the ohmmeter leads to the *NOTE: The resistance of the windings will change
brush terminals. Use clips or terminals to with temperature. Higher temperatures
attach the leads BEFORE starting the engine. will produce higher resistance, and
lower temperatures will produce lower
4. Start the engine and run it at high idle speed resistance.
(1860-1890 RPM). The resistance should read
approximately 25Ω at 77ºF (25º C.)

VANTAGE® 400
F-43 TROUBLESHOOTING & REPAIR F-43

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 trouble-
shooting 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

VANTAGE® 400
F-44 TROUBLESHOOTING & REPAIR F-44

ROTOR VOLTAGE TEST (CONTINUED)

FIGURE F.10 - LEAD LOCATIONS

SLIP RINGS BRUSHES

#200A

#200B

#201 +

TEST PROCEDURE
1. Perform the Case Cover Removal Procedure. 8. If voltage is higher than 175 VDC, the engine
RPM may be too high, or there may be voltage
2. Connect the voltmeter probes to the brush intrusion from one of the higher voltage stator
terminals. See Figure F.10. See the wiring windings to the stator exciter winding. Perform
diagram. the Engine Throttle Adjustment Test, and the
3. Set the RUN/STOP switch to “RUN” and the Stator Short Circuit and Ground Test.
IDLE switch to “HIGH”. Start the engine and 9. If the voltage is lower than 145, but higher
allow the RPM to stabilize for about 15 to 30 than 120, the engine RPM may be too low, or
seconds. there may be problems in the windings or other
The meter should read 145 to 175 VDC. exciter circuit components or connections.
Perform the Engine Throttle Adjustment Test,
4. Set the RUN/STOP switch to “STOP” and then perform the testing described below,
5. If the meter reading is normal, this test is under the heading “If the voltage measures about
complete. 3 to 5 VDC”.
6. If the voltage measures zero or very near zero,
the rotor flashing circuit may be faulty or the
rotor may be shorted.
7. Perform the Rotor Resistance and Ground Test
and the Flashing Voltage Test.

VANTAGE® 400
F-45 TROUBLESHOOTING & REPAIR F-45

ROTOR VOLTAGE TEST (CONTINUED)

10. I
f the meter reading indicates battery 16. Be sure that there are no leads of any kind
voltage, about 12 to 14 VDC, the rotor may across any of the stator windings, except the
be open, or the brushes may be faulty or not 6A - 5H winding. Examine stator wiring for
making proper contact with the slip rings. damage, pinched leads, chafed insulation, etc.
Perform the Rotor Resistance Test, and Brush If necessary, disconnect and isolate the stator
and Slip Ring Service Procedure. output leads as close to the starter as possible.
See wiring diagram.
11. I f the voltage measures about 3 to 5 VDC, the
generator is not building-up to normal output 17. All of these disconnected leads should be
even though the flashing circuit appears to be insulated, and/or positioned so they cannot
functioning normally. This condition could be come in contact with any other wiring or
caused by one of several failed components or chassis ground and cannot be damaged by
connections. Continue with the following test. moving parts when the engine is running.
12. Check the field bridge rectifier, and capacitor; 18. Re-start the machine and measure the rotor
also check the wiring and terminals connecting voltage.
them. See the wiring diagram.
19. If rotor voltage continues to read significantly
13. Perform the Rotor Resistance Test. lower than 120 VDC, the Stator is probably
defective and should be replaced.
14. Perform the Stator Short Circuit and Ground Test.
NOTE: The field bridge rectifier and field capacitor
15. When the Stator short circuit and ground test
may appear to function normally when
has been completed, reconnect leads 6 and 5H
tested independently, but may malfunction
to the field bridge rectifier, (D3). All other stator
when placed under the stress or
leads should remain disconnected and isolated
normal operation. For this reason, It is
at this time.
recommended that the bridge rectifier and
the capacitor be replaced with known good
components before replacing the stator.

VANTAGE® 400
F-46 NOTES F-46

VANTAGE® 400
F-47 TROUBLESHOOTING & REPAIR F-47

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 trouble-
shooting 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

VANTAGE® 400
F-48 TROUBLESHOOTING & REPAIR F-48

FLASHING VOLTAGE TEST (CONTINUED)

TEST PROCEDURE 13. Refer to the wiring diagram, pull plug P-31
.
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 14. Switch the RUN/STOP switch to the “RUN”
come in contact with chassis ground or any position.
other wiring. See Wiring Diagram. 15. Use a voltmeter to check for the presents of
NOTE: Disconnecting leads 234 and 235 bypass about 12VDC, battery voltage, at the following
the oil-pressure switch and simulates a locations on the engine protection/ idle control
running engine. p.c.b.
4. Place
 the RUN/STOP switch in the “RUN” (-) Lead #5S (B1) to (+) Lead #232 (J31-1)
position. (The engine protection light should (-) Lead #5S (B1) to (+) Lead #232F (J31-2)
remain off.)
(-) Lead #5S (B1) to (+) Lead #200 (J33-5)
5. Connect
 the voltmeter probes to brush terminals.
NOTE: Lead #232 supplies 12VDC battery voltage
6. Measure
 the voltage; it should read about 3 to to the engine protection PC board whenever
5 VDC. the run/stop switch is in the run position.
7. Set
 the RUN/STOP switch to the “STOP” Lead #200 supplies DC flashing voltage from the
position. control PC board to the positive slip ring through.
8. If
 the meter reads normal voltage of 3 to 5 VDC, 16. If battery voltage is present at all of the above
this test is complete. points; check the top grounding stud on inside
9. If
 the meter reading indicates battery voltage, left case from and lead #5H, also check leads
about 12 to 14 VDC, The rotor may be open, or #200, #200B, R3. Make sure all terminals are
the brushes may be faulty or not making proper crimped tightly to the flex leads and arc free of
contact with the slip rings. corrosion.
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.

VANTAGE® 400
F-49 TROUBLESHOOTING & REPAIR F-49

FLASHING VOLTAGE TEST (CONTINUED)

17. If battery voltage is present at leads #232 20. Set the RUN/STOP switch to the “STOP”
and #232F, but not present at leads #200 position.
The engine protection / idle P.C.B. board is
21. Re-connect lead #234 to the oil pressure
probably defective. Replace.
switch.
18. If battery voltage is present at lead #232, but
22. If testing is completed, perform the Case Cover
not present at leads #232F or #200 check the
Replacement Procedure.
engine protection wiring per the wiring diagram.
19. 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.

VANTAGE® 400
F-50 NOTES F-50

VANTAGE® 400
F-51 TROUBLESHOOTING & REPAIR F-51

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 trouble-
shooting 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

VANTAGE® 400
F-52 TROUBLESHOOTING & REPAIR F-52

STATOR VOLTAGE TESTS (CONTINUED)

FIGURE F.11 RECEPTACLE LEAD LOCATIONS (TYPICAL)

GROUND
AMPHENOL 1
CONTACTOR
CONTROL
C B A
D 120 VAC FOR WIRE FEEDER
L K J
E M N I
REMOTE
F G 40 VAC FOR WIRE FEEDER
CONTROL H

21 WORK SENSE
KEY

L4

2 TIMES THRU FERRITE

LEADS 75A, 76A, & 77A

TEST PROCEDURE 3. Start the engine and run it at high idle (1860-
1890 RPM).
1. Perform the Case Cover Removal Procedure.
4. Check the AC voltage reading. It should read
NOTE: Voltage tests of the 120 and 120/240
between 115 and 132 VAC.
VAC receptacles can be performed by
placing the meter probes directly into the To test the 240 VAC auxiliary winding:
appropriate connection slots in the front of
1. Connect the meter probes to leads #6F and
the receptacles rather than testing at the
#3E where they connect to the 120/240VAC
lead connections described below. If the
receptacle, or insert the probes into the 240 VAC
meter probes are not long enough to make
connection slots in the front of the receptacle.
contact with the conductors inside the
See Figure F.11. See wiring diagram.
receptacles, test pins may be used.
2. Start the engine and run it at high idle (1860-
To test the 120 VAC auxiliary winding:
1890 RPM).
1. Connect the volt/ohmmeter probes to either 120
3. Check the AC voltage reading. It should read
VAC receptacle as follows.
between 230 and 264 VAC.
2. For the upper receptacle, place the probes
4. If these voltage readings are not within the
directly into receptacle, or connect to leads
specified limits, check for tripped or defective
#3D and #5A. See Figure F.11. See wiring
circuit breakers, loose connections, or broken
diagram.
wires between the test points and the stator
 or the lower receptacle, place the probes
F windings. If there are no wiring problems, and
directly into the receptacle, or connect to the circuit breakers are not tripped or defective,
leads #6E and 5B. See Figure F.11. See the stator is defective and should be replaced.
wiring diagram.

VANTAGE® 400
F-53 TROUBLESHOOTING & REPAIR F-53

STATOR VOLTAGE TESTS (CONTINUED)

FIGURE F.12 - RECTIFIER BRIDGE DETAIL

To test the 120 VAC wire feeder supply: 1. Connect the voltmeter probes to pins “A” (lead
#32) and “J” (lead #31) of the 14 pin Amphenol.
NOTE: The wire feeder AC voltage supply tests
See figure #3 and wiring diagram.
require that the meter probes be inserted
into the Amphenol connection cavities. 2. Start the engine and run it at high idle (1860 to
Care should be taken to avoid damaging 1890 RPM).
or expanding the terminals when inserting
3. The AC voltage reading should be between 115
the probes.
and 132 VAC.
NOTE: The 120 VAC power supplied to the 14 pin
4. If these voltage readings are not within
Amphenol connector originates from the
specifications, check for a tripped or defective
same winding that supplies the 120 VAC
circuit breaker, faulty connections, or broken
receptacles. If the machine has previously
wires between the test points and the stator
passed 120VAC auxiliary winding test,
windings. See wiring diagram.
this test can only reveal problems in
connections or components between the
Amphenol and the stator winding.

VANTAGE® 400
F-54 TROUBLESHOOTING & REPAIR F-54

STATOR VOLTAGE TESTS (CONTINUED)

To test the 42 VAC wire feeder winding: To test the three-phase weld winding:
1. Connect
 the voltmeter probes to pins “I” 1. Locate weld winding leads W1/W6, W2/W3,
(lead 41A) and “K” (lead #42A) of the 14 pin and W4/5 where they connect to the three-
Amphenol. See Figure F.11. phase output bridge rectifier. See Figure
F.12. See wiring diagram.
2. Start
 the engine and run it at high idle (1860 to
1890 RPM). 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 VAC. 3. Check for about 60 to 65 VAC from leads W1/
W6, W2/W3, and W4/5.
4. If
 these voltage readings are not within the
specified limits, check for a tripped or defective 4. If these voltage readings are not within the
circuit breakers, loose connections, or broken specified limits, check for loose connections or
wires between the test points and the stator broken wires between the test points and the
windings. If there are no wiring problems, and stator windings. If there are no wiring problems,
the circuit breakers are not tripped or defective, the stator is defective and should be replaced.
the stator is defective and should be replaced.
* These values are maximum for a cold machine.

VANTAGE® 400
F-55 TROUBLESHOOTING & REPAIR F-55

STATOR SHORT CIRCUIT & GROUND 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 trouble-
shooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION
This test will determine if there are undesirable electrical connections between the Stator
Windings and chassis ground, or between individual Windings within the Stator.
This test should be performed if flashing voltage is present at the Rotor Slip Rings, Rotor
resistance, Field Bridge Rectifier, Field Capacitor and all associated wiring are proven to
be good, but the Stator output voltage fails to build-up to normal levels, or is too high in
one or more, but not all, of the Windings.

MATERIALS NEEDED

Miscellaneous Hand Tools
Ohm Meter

VANTAGE® 400
F-56 TROUBLESHOOTING & REPAIR F-56

STATOR SHORT CIRCUIT & GROUND TEST (CONTINUED)

FIGURE F.13 - WELD CONTROL BOARD

GROUND
AMPHENOL 1
CONTACTOR
CONTROL
C B A
D 120 VAC FOR WIRE FEEDER
L K J
E M N I
REMOTE
F G 40 VAC FOR WIRE FEEDER
CONTROL H

21 WORK SENSE
KEY

L4

2 TIMES THRU FERRITE

LEADS 75A, 76A, & 77A

TEST PROCEDURE
1. Perform Case Cover Removal Procedure. 4) Lead #5 and lead #7 or #9. (This checks for
a connection between the auxiliary winding
2. Perform Capacitor Discharge Procedure. and the weld winding). See Wiring Diagram.
3. Unplug anything that may be connected to the 5) Lead #5 and lead W1, W2, or W3. (This
auxiliary receptacles or the 14 pin amphenol. checks for a connection the auxiliary
4. Disconnect and isolate GND-E lead from the winding and the weld winding.) See Wiring
bottom ground screw inside the left case front. Diagram.
See control Inner-Connection diagram. See 6) Lead #7 or #9 and lead W1, W2, or W3.
Figure F.13. (This checks for a connection between the
5. Disconnect the #5 and #6 leads from the field exciter winding and the weld winding.) See
bridge rectifier. See Wiring Diagram. Wiring Diagram.
6. Using an ohmmeter, check the resistance If any of the above readings is less than 500,000
between chassis ground and each of the (500k) ohms, check for damaged, contaminated,
following points; Resistance should read very or shorted wiring or components between the
high, 500,000 (500K) ohms minimum. test points and the stator winding. If necessary,
disconnect and isolate the stator leads as close
1) Pin 1 at the 14 pin amphenol, and the #5 to the stator winding as possible. See wiring
lead that had been disconnected from the diagram. If the low resistance is determined to be
ground screw. (this checks for a connection between the windings within the stator, the stator
between the wire feed winding and the is defective and should be replaced*.
auxiliary winding.)
NOTE: T
 he field bridge rectifier and field
2) Pin 1 of the 14 pin amphenol and lead capacitor may appear to function normally
#7 or #9. (This checks for a connection when tested independently. But may
between the wire feed winding and the malfunctions when placed under the stress
exciter winding.) of normal operation. For this reason, It is
3) Pin 1 of the 14 pin amphenol an lead W1, recommended that the bridge rectifier and
W2, or W3. (This checks for a connection capacitor be replaced with known good
between the wire feed winding and the weld components before replacing the stator.
winding).

VANTAGE® 400
F-57 TROUBLESHOOTING & REPAIR F-57

OUTPUT RECTIFIER BRIDGE 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 trouble-
shooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION
This test will determine if the Rectifier is grounded, or if there are any failed Diode groups.
NOTE: This test will not be able to detect individual open diodes within a group.

MATERIALS NEEDED
 iscellaneous Hand Tools
M
Analog Ohmmeter or Diode Tester (For testing diodes)
Ohm Meter (any type for ground test)

VANTAGE® 400
F-58 TROUBLESHOOTING & REPAIR F-58

OUTPUT RECTIFIER BRIDGE TEST (CONTINUED)

FIGURE F.14

DC+

D1 D3 D5

AC1 X1
D2 D4 D6
DC-

AC2

AC3

TEST PROCEDURE
1. Turn the engine off. 6. Remove leads W4, W5, and W10 from the
positive terminal of the Rectifier, and remove
2. Perform the Case Cover Removal Procedure. leads W6 and W11 from the negative terminal.
3. Perform the Chopper Module Capacitor Discharge Position these leads so they do not come to
Procedure. contact with any part of the rectifier. See Figure
F.15. See the wiring diagram..

Electrically isolate the three-phase input
terminals of the output bridge rectifier as
follows:
4. Mark leads W1, W2, and W3 so they can be
properly reconnected after the test is complete.
Remove these leads and position them so they
do not come in contact with any part of the
rectifier. See Figure F.15. See wiring diagram.
Electrically isolate the DC output terminals
of the rectifier:
5. Mark the leads connected to the positive
and negative terminals of the output bridge
rectifier to assure that they can be reconnected
properly. See Figure F.15.

VANTAGE® 400
F-59 TROUBLESHOOTING & REPAIR F-59

OUTPUT RECTIFIER BRIDGE TEST (CONTINUED)

7. Check for grounds by placing one of the ohm NOTE: A digital Ohmmeter is not recommended
meter probes on a clean, unpainted metal for this test. A typical digital Ohmmeter
surface of the machine. Touch the other does not provide enough voltage or current
probe to each of the five rectifier terminals. flow to reliably test the diodes used in this
The resistance to chassis ground from each rectifier.
terminal should be very high, 500,000 (500K)
10. Test all of the diode groups per the Table F.1.
ohms minimum. If the resistance reading is
less than specified, the rectifier is grounded and
should be replaced.
8. If using diode checker or a multimeter with
diode check functionality, read and understand
the instructions that accompany your test
equipment.
9. If using an analog ohmmeter, the forward bias
test will indicate low resistance and the reverse
bias test will indicate high resistance. Precise
ohm values for this test will vary depending on
the test equipment used.

FIGURE F.15 - SHUNT/RECTIFIER LEADS

TOP OUTPUT
W1 RECTIFIER
W2 CENTER BRIDGE
W3 BOTTOM

OR

CHOPPER BOARD

VANTAGE® 400
F-60 TROUBLESHOOTING & REPAIR F-60

TABLE F.1 – DIODE TEST TABLE

Test Instrument

(+) Lead (-) Lead Diode Bias

and Expected
Test Result

AC1 DC(+) FORWARD BIAS

(Low Resistance)
Rectifier Terminal Connections

AC2 DC(+) FORWARD BIAS

(Low Resistance)

AC3 DC(+) FORWARD BIAS

(Low Resistance)

DC(-) AC1 FORWARD BIAS

(Low Resistance)

DC(-) AC2 FORWARD BIAS

(Low Resistance)

DC(-) AC3 FORWARD BIAS

(Low Resistance)

AC1 DC(-) REVERSE BIAS

(High Resistance)

AC2 DC(-) REVERSE BIAS

(High Resistance)

AC3 DC(-) REVERSE BIAS

(High Resistance)

DC(+) AC1 REVERSE BIAS

(High Resistance)

DC(+) AC2 REVERSE BIAS

(High Resistance)

DC(+) AC3 REVERSE BIAS

(High Resistance)
11. Reconnect all leads.
12. Perform the Case Cover Replacement Procedure.

VANTAGE® 400
F-61 TROUBLESHOOTING & REPAIR F-61

CHOPPER MODULE FUNCTION 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 trouble-
shooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION
This test will help determine if the Chopper Module is functioning properly, and receiving
the correct input from the Output Rectifier and Control PC Board.
This test can only provide meaningful results if the machine is producing normal AC
auxiliary output.

MATERIALS NEEDED
 iscellaneous Hand Tools
M
Digital Multi-Meter
Frequency counter or digital multi-meter with frequency counter function.
Wiring Diagram
Control Inner-Connection Diagram

VANTAGE® 400
F-62 TROUBLESHOOTING & REPAIR F-62

CHOPPER MODULE FUNCTION TEST (CONTINUED)

FIGURE F.16 - CHOPPER MODULE CONNECTIONS

23
LED1 (B1,B2,B3) 25 LED4
Chopper Working PWM Signal

HL W11
L12683-1

B8
HL W6 B1 B4
LED4
LED1
LED2
B2 LED3 B5 HL W5

B3 B6
HL W4

LED2
Voltage from
HL W9 Rectifier HL W8
LED3 (B4,B5,B6)
Chopper Working
SL302

SL13
SL301
SL14

TEST PROCEDURE 9. If the correct voltage is present at terminals

B1- to B2+ and B4- to B5+ of the chopper
1. Perform the Case Cover Removal Procedure. module, check for DC voltage at the chopper
2. Make sure that there is nothing plugged into module terminals B2+ to B3-, and B5+ to B6-,
either of the Amphenol receptacles. If significant voltage is present, disconnect
leads #23 and #25 from the chopper module
3. Place idle switch in the “HIGH” position. PC board. If voltage is still present, the copper
4. Place the mode switch in the “CC-STICK” module is shorted and should be replaced.
position. 10. If the voltage drops to 0 VDC after the #23 and
5. Place the Welding Terminal switch in the #25 leads have been disconnected, the control
“REMOTELY CONTROLLED” position. PC board is driving the chopper module when
it should not be doing so. Reconnect the #23
6. Start the engine and allow it to stabilize at high and #25 leads and perform the Weld Control
idle RPM. Board Gate Drive Test.
7. Check for 80 to 100 VDC at terminals B1- to 11. Reconnect leads #23 and #25, and place
B2+ and B4- to B5+ of the chopper module. the Welding Terminal switch in the “WELD
See wiring diagram and figure #1. TERMINALS ON” position.
8. If the correct DC voltage is not present at 12. Check for about 58 VDC between Chopper
terminals B1- to B2+ and B4- to B5+, check Module Terminals B2+ to B3-, and B5+ to B6
for damaged conductors or faulty connections and between the welder output terminals. See
between the chopper module, the output Figure F.16. See the wiring diagram.
rectifier, and the stator weld winding. See
Figure F.17. See the wiring diagram. Perform
the Stator Voltage Tests, and the Output Rectifier
Test.

VANTAGE® 400
F-63 TROUBLESHOOTING & REPAIR F-63

CHOPPER MODULE FUNCTION TEST (CONTINUED)

TEST PROCEDURE (CONTINUED)

13. If about 58 VDC is present at chopper module 16. If the 20 kHz signal is present, the chopper
terminals B2+ to B3-, and B5+ to B6-, but not module is defective. Replace.
at the output terminals, there is a problem 17. If the 20 kHz signal is not present, perform the
between the chopper module and one of Weld Control Board PWM Gate Signal Test.
the output terminals. Check for damaged
conductors or faulty connections, on leads W7, 18. If the weld control board is producing a PWM
W8, W9, and W10. Also check the shunt, the gate signal, check th e#23 and #25 leads for
choke, and the connections at the back of the damaged conductors and faulty connections
output terminals. See the wiring diagram. between the control PC board and the chopper
module.
14. If the voltage at terminals B2+ to B3-, and B5+
to B6- of the Chopper module is significantly 19. If testing is complete, Perform the Case Cover
higher than 58 VDC, check for an open R4 load Replacement Procedure.
resistor. See the Control Inner-Connection
diagram. Also check for damaged conductors
or faulty connections at leads #302 and #302.
See wiring diagram.
15. If the voltage at terminals B2+ to B3-, and B5+
to B6- of the chopper module is very low, or not
present, use the frequency counter to check for
the presents of a 20 kHZ PWM signal between
leads #23 +and #25-, where they connect to
the chopper module PC board.

VANTAGE® 400
F-64 NOTES F-64

VANTAGE® 400
F-65 TROUBLESHOOTING & REPAIR F-65

CHOPPER MODULE 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 trouble-
shooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION
This test will help determine if the Chopper Module is shorted. This test can only detect
some problems in the “Power” section of the module. Problems in some other PC board
components may not be detected.

MATERIALS NEEDED
 iscellaneous Hand Tools
M
Digital Ohmmeter
Wiring Diagram

VANTAGE® 400
F-66 TROUBLESHOOTING & REPAIR F-66

CHOPPER MODULE RESISTANCE TEST (CONTINUED)

TEST PROCEDURE
1. Perform the Case Cover Removal Procedure. 4. Use a digital Ohmmeter to test the module per
Table F.2.
2. Perform the Capacitor Discharge Procedure.
3. Check that all of the leads connected to the
chopper module terminals are clearly marked to
facilitate reassembly. Remove all of the leads
from the chopper module and position them so
they do not make electrical contact with any
part of the module. See the wiring diagram.

VANTAGE® 400
F-67 TROUBLESHOOTING & REPAIR F-67

CHOPPER MODULE RESISTANCE TEST (CONTINUED)

FIGURE F.2 - DIODE TEST TABLE

OHMMETER
OHMMETER READING

(+) Lead (-) Lead Diode Bias

and Expected
Test Result

B5 B6 6K to 9K
Chopper Terminal Connections

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 higher

B2 B4 400k or higher

B4 B3 200k or higher

B3 B4 400k or higher

5. R
 econnect all leads.
6. The chopper module screw connection should be lightened to 50-60 inch-pounds.
7. Perform the Case Cover Replacement Procedure.

VANTAGE® 400
F-68 NOTES F-68

VANTAGE® 400
F-69 TROUBLESHOOTING & REPAIR F-69

WELD CONTROL BOARD PWM GATE SIGNAL 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 trouble-
shooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION
This test will determine if the Weld Control PC Board is able to produce the PWM (Pulse
Width Modulated) gate signal needed to control the IGBTs (Insulated Gate Bipolar
Transistor) on the Chopper Module. This test will also verify that the Control PC Board
can turn the PWM gate signal on and off properly.

MATERIALS NEEDED
 igital Multi-Meter
D
Frequency Counter or digital Multi-meter with frequency counter function
Wiring Diagram
Control Inner-Connection Diagram

VANTAGE® 400
F-70 TROUBLESHOOTING & REPAIR F-70

WELD CONTROL BOARD PWM GATE SIGNAL TEST (CONTINUED)

TEST PROCEDURE
1. Perform the Case Cover Removal Procedure. 14. If the 80 to 100 VDC supply voltage is present
at the weld control PC board, but there is no
2. Unplug any device that may be attached PWM gate signal, check the voltage between
to either the 6 pin or the 14 pin Amphenol leads #2+ (P1-4) and #4 (P1-3). See figure #1
receptacles.
The voltage should be about 0 VDC.
3. Place the idle switch in the “HIGH IDLE”
position. 15. If about 5 VDC is detected, the welding terminal
control circuit is open. Check for damaged
4. Place the mode switch in the “CC-STICK” leads for faulty connections at leads #2 and
position. #4; also check for a defective welding terminal
5. Place the Weld terminals switch in the “WELD switch. See the wiring diagram.
TERMINALS ON” position. 16. If the PWM signal remains after the welding
6. Start the engine and let it run and stabilize at terminal switch has been placed in the
high idle RPM. “REMOTELY CONTROLLED” position, check
the voltage between leads #2+ (P1-4) and #4-
7. Locate plug P3 on the control PC board. See (P1-3) at the control PC board.
Control Inner-Connection diagram.
17. If the voltage reads 0 or very near 0, Check
8. Use the frequency counter to test for 20kHz for damaged insulation at leads #2 and #4,
PWM gate signal between leads #23+ (P3-10) also check for a shorted welding terminal
and #25- (P3-9). switch, or damaged or contaminated Amphenol
9. If the 20KHz gate signal is present, place receptacle. See the wiring diagram.
the weld terminals switch in the ”REMOTELY 18. If the above wiring and components are
CONTROLLED” position. The gate signal undamaged and functioning properly, the
should turn off. control PC board is defective and should be
10. If the 20 KHz gate signal responds as described replaced.
above, this test is complete. 19. If the voltage reads about 5 VDC, and the
11. If there is no 20 KHz gate signal, test for the PWM signal remains, the control PC board is
presents of 80 to 100 VDC, at leads 13+ (P3- defective and should be replaced.
8) to 14- (P3-16) of the weld control PC board. 20. Perform the Case Cover Replacement Procedure.
12. If voltage is very low or not present, check
leads #13 and #14 for faulty or damaged wiring
or connections between the control PC board
and the chopper module.
13. Test for 80 to 100 VDC at the terminals where
the #13 and #14 leads connect to the chopper
module. See the wiring diagram. If there is
no voltage at the chopper module, perform the
chopper module function test.

VANTAGE® 400
F-71 TROUBLESHOOTING & REPAIR F-71

WELD CONTROL FEEDBACK 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 trouble-
shooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION
This test will determine if the Weld Control PC Board is receiving accurate current and
voltage feedback from the weld circuit.
This test will only yield usable information if the machine is producing some weld output.

MATERIALS NEEDED

Digital Multi-meter suitable for accurate readings in both the millivolt and normal
weld voltage ranges.
Resistive Load Bank
Ammeter, suitable for accurate readings of normal welding current. (Often built into
the load bank.
Wiring Diagram
Control Inner-Connection Diagram

VANTAGE® 400
F-72 TROUBLESHOOTING & REPAIR F-72

WELD CONTROL FEEDBACK TEST (CONTINUED)

TEST PROCEDURE
1. Place the idle switch in the “HIGH IDLE” 9. If the readings differ significantly, continue with
position. this procedure
2. Place the mode switch in the “CC-STICK” 10. Turn off the engine and release the load
position. from the weld terminals. (The load bank and
ammeter should remain connected, but the
3. Place the weld terminals switch in the load should be released.)
“WELD TERMINALS ON” position.
11. Perform the Case Cover Removal Procedure.
4. Make sure that nothing is plugged into either
Amphenol receptacle. 12. Locate plugs P3 and P6 on the control PC
board. See figure #1. Remove the plugs and
5. Connect the resistive load bank and the check for dirt, corrosion, damaged, expanded,
ammeter to the weld output terminals per the or incorrectly positioned terminals. Repair or
equipment manufacturer’s instructions; also replace wiring components as needed and
connect the voltmeter probes across the weld reconnect the plugs to the control board.
output terminals.
13. Restart the machine and apply a load across
6. Start the machine and, apply a load of about the weld terminals that measures about 200
200 Amps, as shown on the external ammeter. amps. If the machine will not produce 200
If the machine will not produce 200 amps, apply amps of current, apply as much load as you
as much load as you can. can.
7. Compare the readings shown on the external 14. Using the voltmeter, measure and note the DC
ammeter and voltmeter to the amps and volts voltage at the weld output terminals.
displayed on the front panel of the machine.
15. Check the voltage between leads #204S+ (P6-
8. If the readings shown on the front panel 1) and lead #208B- (P3-15) at the control PC
displays are about the same or very close to the board Molex plugs. The voltage should be the
reading on the external meters, the feedback is same as was measured at the weld terminals.
probably good, and this test is complete.

VANTAGE® 400
F-73 TROUBLESHOOTING & REPAIR F-73

WELD CONTROL FEEDBACK TEST (CONTINUED)

16. If the voltage readings are different, check the 20. To calculate the correct millivolt signal for a
wiring and connections between the welding given load, you divide the number of amps
terminals and the control PC board. See the displayed on the ammeter by 8.
wiring diagram.
 xample: If your ammeter reads 75, (75/8
E
17. Connect the millivolt meter probes between = 9.4) If the shunt is working correctly,
lead #206S+ (P6-2) and lead 204S- (P6- and the wiring between the shunt and the
1). See Wiring Diagram. If the machine is control PC board is in good condition, the
currently producing 200 amps the millivolt meter connected at the control PC board
meter should read about 25 millivolts. should be reading about 9.4 millivolts.
18. If the machine cannot produce 200 amps of 21. If the millivolt reading is incorrect, check the
weld current, the correct millivolt signal will wiring between the shunt and the control
need to be calculated by dividing the reading PC board for damage, grounds, and faulty
displayed on the external ammeter by 8. See connections. If the wiring is good, the shunt
the following explanation. and lead assembly is faulty and should be
replaced.
19. The shunt used in this machine will produce
50 millivolts at a load of 400 amps, or 8 amps 22. Perform the Case Cover Replacement Procedure.
per millivolt.

VANTAGE® 400
F-74 NOTES F-74

VANTAGE® 400
F-75 TROUBLESHOOTING & REPAIR F-75

CONTROL POTENTIOMETER AND MODE SWITCH 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 trouble-
shooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION
This test will check the Output Control Potentiometer, Arc Control Potentiometer, Mode
Switch and associated wiring for damage, proper operation, tracking and grounds.

MATERIALS NEEDED
 igital Ohmmeter
D
Wiring Diagram
Control Inner-Connection Diagram

VANTAGE® 400
F-76 TROUBLESHOOTING & REPAIR F-76

CONTROL POTENTIOMETER AND MODE SWITCH RESISTANCE TEST

(CONTINUED)
TEST PROCEDURE
1. Turn the engine off 7. If the resistance is lower than 500k Ohms,
replace the potentiometer and mode switch plug
2. Perform the Case Cover Removal Procedure. and lead assembly, or replace the defective
3. Unplug P7 from control board, see control Inner- component within the assembly. See wiring
connection diagram, and visually check the diagram.
plug and attached wiring for damage, corrosion, 8. Perform the resistance tests per Table F.3.
improperly seated or damaged contact pins. P7
will remain unplugged for following test. 9. If the resistance readings are not as specified in
the table, replace the potentiometer and mode
4. Set the mode switch in the “CC-Stick” position. switch plug and lead assembly, or replace the
5. Test the resistance between each of the defective component. See the wiring diagram.
leads in P7 and a good clean chassis ground 10. If testing is complete, plug P7 back into the
connection. Be very careful that the connection control PC board and perform the Case Cover
pins in P7 are not damaged or spread out. Replacement Procedure.
6. The resistance should be very high. A reading
of 500,000 (500k) ohms or higher is acceptable.

VANTAGE® 400
F-77 TROUBLESHOOTING & REPAIR F-77

CONTROL POTENTIOMETER AND MODE RESISTANCE TEST

(CONTINUED)
TABLE F.3

POT/MODE SWITCH RESISTANCE TEST

MODE SWITCH OHMMETER
SETTING CONNECTION

CC-STICK P7-9 (#214) TO 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 P7-14 (#218) TO P7-16 (#222) 500K or Higher

CC-STICK P7-15 (#220) TO P7-16 (#222) 500K or Higher

TOUCH START TIG P7-15 (#220) TO P7-16 (#222) *

DOWNHILL PIPE P7-14 (#218) TO P7-16 (#222) *

CV-WIRE P7-9 (#214) TO P7-16 (#222) *

N/A P7-5 (#75) TO P7-1 (#77) about 10K

Ohms values should

sweep smoothly from 10K
P7-1 (#77) TO P7-4 (#76) to 0 when ARC CONTROL is
turned from Min. to Max.
N/A

N/A P7-6 (#279) TO P7-8 (#277) about 10K

Ohms values should

sweep smoothly from 10K
N/A P7-8 (#277) TO P7-7 (#278) to 0 when ARC CONTROL is
turned from Min. to Max.

* Resistance should be very low, The Ohmmeter should read about the same value as
one would get by touching the two meter probes together.

VANTAGE® 400
F-78 NOTES F-78

VANTAGE® 400
F-79 TROUBLESHOOTING & REPAIR F-79

REMOTE RECEPTACLE 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 trouble-
shooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION
This test will help determine if there is a problem with the Remote Receptacle control
wiring, relating to electrical tracking between other control conductors, power conductors,
or ground. This test also checks the function of the weld terminal switch.

MATERIALS NEEDED
 hm Meter
O
Wiring Diagram
Control Inner-Connection Diagram

VANTAGE® 400
F-80 TROUBLESHOOTING & REPAIR F-80

REMOTE RECEPTACLE RESISTANCE TEST (CONTINUED)

FIGURE F.17

AMPHENOL 1

C B A
D L K J
E M N I
F G H

TEST PROCEDURE
1. Turn the machine off. 7. If the resistance values are found to be too low,
due to contaminated electrical components in
2. Perform the Case Cover Removal Procedure. the Amphenol harness assembly. Try removing
3. Make sure that there are no devices of any kind the contamination and drying the components
plugged into either Amphenol receptacles. completely. If the resistance values are still too
low, replace the Amphenol harness assembly.
4. Remove Molex plug P1 from the control PC
board, see Control Inner-Connection Diagram. 8. If the values are incorrect for the last two tests
Examine the Molex plug and the receptacle in the table, (Pin C to Pin D) check the welding
on the control PC board for dirt, corrosion, terminal switch and the wiring connected to
damaged or out-of-position pins. Repair or that switch. See the wiring diagram. Repair
replace any damaged components. Position any faulty connections or replace the switch if
the P1 plug so it can not make electrical contact necessary.
with any other conductor or chassis ground. 9. Plug P1 back into the Control PC board.
5. Perform the following resistance tests shown 10. Perform the Case Cover Replacement Procedure.
in the following table. Be very careful not to
damage or spread any of the connection pins in
the Amphenol receptacle. See Table F.4.
6. If the measured resistance does not meet values
specified, check for damage, dirt or moisture
contamination in the Amphenol receptacles
and the P1 Molex plug. Check for damaged or
grounded wiring.

VANTAGE® 400
F-81 TROUBLESHOOTING & REPAIR F-81

REMOTE RECEPTACLE RESISTANCE TEST (continued)

TABLE - F.4
AMPHENOL RESISTANCE TEST
WELDING TERMINAL SWITCH SETTING OHMMETER CONNECTION OHMMETER READING

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 Higher

N/A PIN “G” (#75B) to PIN “E” (#77B) 500K or Higher

N/A PIN “G” (#75B) to PIN “F” (#76B) 500K or Higher

N/A PIN “G” (#75B) to PIN “H” (#21) 500K or Higher

N/A PIN “G” (#75B) to PIN “I” (#41A) 500K or Higher

N/A PIN “G” (#75B) to PIN “J” (#31) 500K or Higher

N/A PIN “G” (#75B) to PIN “K” (#42A) 500K or Higher

N/A PIN “F” (#76B) to PIN “A” (#42) 500K or Higher

N/A PIN “F” (#76B) to PIN “B” (GND-A) 500K or Higher

N/A PIN “F” (#76B) to PIN “C” (#2B) 500K or Higher

N/A PIN “F” (#76B) to PIN “D” (#4B) 500K or Higher

N/A PIN “F” (#76B) to PIN “E” (#77B) 500K or Higher

N/A PIN “F” (#76B) to PIN “H” (21) 500K or Higher

N/A PIN “F” (#76B) to PIN “I” (#41A) 500K or Higher

N/A PIN “F” (#76B) to PIN “J” (#31) 500K or Higher

N/A PIN “F” (#76B) to PIN “K” (#42A) 500K or Higher

N/A PIN “E” (#77B) to PIN “A” (#32) 500K or Higher

N/A PIN “E” (#77B) to PIN “B” (GND-2) 500K or Higher

N/A PIN “E” (#77B) to PIN “C” (#2B) 500K or Higher

N/A PIN “E” (#77B) to PIN “D” (#4B) 500K or Higher

N/A PIN “E” (#77B) to PIN “H” (#21) 500K or Higher

N/A PIN “E” (#77B) to PIN “I” (#41A) 500K or Higher

N/A PIN “E” (#77B) to PIN “J” (#31) 500K or Higher

N/A PIN “E” (#77B) to PIN “K” (42A) 500K or Higher

REMOTELY CONTROLLED PIN “C” (#2B) to PIN “D” (#4B) 500K or Higher

WELD TERMINALS ON PIN “C” (#2B) to PIN “D” (#4B) *

* Resistance should be very low, The Ohmmeter should read about the same value as one would get by touching the two
meter probes together.

VANTAGE® 400
F-82 TROUBLESHOOTING & REPAIR F-82

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)

HIGH IDLE – NO LOAD

16.4 ms

0 volts

50V 5ms

This is the typical auxiliary output

voltage generated from a properly
operating machine. Note that each
vertical division represents 50 volts
and that each horizontal division rep-
resents 5 milliseconds in time.
NOTE: Scope probes are connected
at machine 120 VAC receptacle.

SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep..... 5 ms/Div.
Coupling............................. DC
Trigger......................... Internal

VANTAGE® 400
F-83 TROUBLESHOOTING & REPAIR F-83

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)

MAX CONTROL POT - HIGH IDLE - NO LOAD

CH1

0 volts

50V 5ms

This is the typical DC open circuit out-

put voltage generated from a properly
operating machine. Note that each
vertical division represents 50 volts
and that each horizontal division rep-
resents 5 milliseconds in time.
NOTE: Scope probes are connected
at weld output terminals.

SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep..... 5 ms/Div.
Coupling............................. DC
Trigger......................... Internal

VANTAGE® 400
F-84 TROUBLESHOOTING & REPAIR F-84

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)

MACHINE LOADED TO 300 AMPS AT 27 VOLTS

Trig +15V CH1

0 volts

20V 1ms

This is the typical DC output voltage

generated from a properly operating
machine. Note that each vertical
division represents 20 volts and that
each horizontal division represents 1
millisecond in time.
The machine was loaded with a resis-
tance grid bank to 300 amps at 27
volts.
NOTE: Scope probes are connected
at weld output terminals.

SCOPE SETTINGS
Volts/Div......................20V/Div
Horizontal Sweep..... 1 ms/Div.
Coupling............................. DC
Trigger......................... Internal

VANTAGE® 400
F-85 TROUBLESHOOTING & REPAIR F-85

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV TAP)

MAX CONTROL POT - HIGH IDLE - NO LOAD

0 volts

50V 5ms

This is the typical DC open circuit out-

put voltage generated from a properly
operating machine. Note that each
vertical division represents 50 volts
and that each horizontal division rep-
resents 5 milliseconds in time.
NOTE: Scope probes are connected
at weld output terminals.

SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep..... 5 ms/Div.
Coupling............................. DC
Trigger......................... Internal

VANTAGE® 400
F-86 TROUBLESHOOTING & REPAIR F-86

NORMAL CIRCUIT VOLTAGE WAVEFORM (WIRE CV)

MACHINE LOADED TO 300 AMPS AT 28 VOLTS

0 volts

20V 1ms

This is the typical DC voltage gen-

erated from a properly operating
machine. Note that each vertical
division represents 20 volts and that
each horizontal division represents 1
millisecond in time.
The machine was loaded with a resis-
tance grid bank to 300 amps at 28
volts.
NOTE: Scope probes are connected
at weld output terminals.

SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep..... 1 ms/Div.
Coupling............................. DC
Trigger......................... Internal

VANTAGE® 400
F-87 TROUBLESHOOTING & REPAIR F-87

OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND

REPLACEMENT

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 trouble-
shooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION
The following procedure will aid the technician in removing and replacing the Output
Rectifier Bridge and the Choke in the Vantage® 400.

MATERIALS NEEDED
 iscellaneous Hand Tools
M
Penetrox Heat Sink Compound (Lincoln Part T12837-1)

VANTAGE® 400
F-88 TROUBLESHOOTING & REPAIR F-88

OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND

REPLACEMENT (CONTINUED)
REMOVAL PROCEDURE Removing the Output Choke
1. Turn the engine off. 1. Remove the heavy leads from the choke. Carefully
mark the leads for accurate re-connection, and
2. Remove negative battery cable. also note the order and position of the leads in
3. Perform the Case Cover Removal Procedure. multiple lead connections.
4. Perform the Chopper Module Capacitor Discharge 2. Remove the three long bolts, lock washers and
Procedure. nuts holding the choke the mounting bracket in
the machine base. Note that there is no bolt in
5. Remove the four screws holding the case front the lower right corner of the choke.
to the base of the machine.
3. Carefully remove the choke.
6. Remove all plugs and leads from the weld
control and pull coil PC boards. Be sure to
mark the leads and plugs so they can be
properly re-connected. See wiring diagram.
REPLACEMENT PROCEDURE
Replacing the Output Choke
7. Remove the screws holding the D4 diode
bridge and the CR1 engine protection relay to 1. Place the choke into the machine so that the
the center baffle assembly, and allow these three mounting holes in the choke line up with
components to remain attached to the case the holes in the mounting bracket.
front wiring.
2. Insert the three long bolts through the choke
8. Remove any additional wring and cable ties and the mounting bracket. Place a lock washer
as needed. Carefully mark leads for accurate and nut on the end of each bolt and tighten.
re-connection.
3. Reconnect the choke leads. Position the
9. Swing the case front to the side to permit leads, bolts, washers, and nuts exactly as they
access to the Output Rectifier and Choke. had been originally connected. Tighten the
connection securely.

Removing the Output Rectifier

10. Remove the heavy leads from the output
rectifier. Carefully mark the leads for accurate
re-connection, and also note the order and
position of multiple lead connections.
11. Remove the nuts and lock washers holding the
Output Rectifier to the mounting bracket. You
will need to reach through the large access
holes on either side of the rectifier to reach
these nuts.
12. Remove the Output Rectifier from the machine.

VANTAGE® 400
F-89 TROUBLESHOOTING & REPAIR F-89

OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND

REPLACEMENT (CONTINUED)
Replacing the Output Rectifier
1. Place the Output Rectifier into the machine so 5. Reconnect all of the leads and plugs that were
that its mounting studs fit into the holes in the disconnected during the removal procedure,
bracket. Place a lock washer and a nut on each and replace any cable ties that were removed.
stud and tighten. 6. Perform the Case Cover Removal Procedure.
2. Apply a thin film of Penetrox heat sink compound
(Lincoln Part T12837-1) between the surfaces
of the “W” leads and the Output Rectifier.
Reconnect the Output Rectifier, positioning the
leads, bolts, washers, and nuts exactly as hey
had been originally connected. Tighten all of
the connections securely. See Wiring Diagram.
3. Swing the case front back into position.
4. Attach the case front to the machine base with
four screws.

VANTAGE® 400
F-90 NOTES F-90

VANTAGE® 400
F-91 TROUBLESHOOTING & REPAIR F-91

CHOPPER MODULE REMOVAL AND REPLACEMENT

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 trouble-
shooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Chopper
Module Assembly.
NOTE: The Chopper Module assembly is removed and replaced as a unit. It contains no
serviceable parts.

MATERIALS NEEDED
 iscellaneous Hand Tools
M
Penetrox Heat Sink Compound (Lincoln Part T12837-1)

VANTAGE® 400
F-92 TROUBLESHOOTING & REPAIR F-92

CHOPPER MODULE REMOVAL AND REPLACEMENT (CONTINUED)

FIGURE F.18 - MODULE LEAD LOCATIONS

23
LED1 (B1,B2,B3) 25 LED4
Chopper Working PWM Signal

HL W11
L12683-1

B8
HL W6 B1 B4
LED4
LED1
LED2
B2 LED3 B5 HL W5

B3 B6
HL W4

LED2
Voltage from
HL W9 Rectifier HL W8
LED3 (B4,B5,B6)
Chopper Working
SL302

SL13
SL301
SL14

PROCEDURE

REMOVAL
1. Turn the engine off. 7. Remove the Power Module assembly from the
2. Perform the Case Cover Removal Procedure. machine.

3. Perform the Chopper Module Capacitor Discharge

Procedure.
4. Disconnect leads 23 and 25 at their in-line TERMINAL LEADS
couplings.
Heavy lead W11,
5. Using the 7/16” socket wrench, remove the B4 Small lead 14
following leads. Label the leads before removal.
Heavy lead W5,
Cut cable ties as needed. Note placement of B5 Small lead 13
leads and fasteners: screw, lock washer, flat
washer, small lead, heavy lead. Heavy lead W8
B6
6. Using a 3/8” socket wrench, remove the three
screws holding the power module assembly to
Heavy lead W6
its brackets on the vertical baffle. Remove the B1
plastic strip with the top two screws. Be sure to
Heavy lead W4,
support the Power Module as you remove the B2 Small lead 301
last screw.
Heavy lead W9,
B3 Small lead 302

VANTAGE® 400
F-93 TROUBLESHOOTING & REPAIR F-93

CHOPPER MODULE REMOVAL AND REPLACEMENT (CONTINUED)

REPLACEMENT
1. Mount the heat sink to the brackets on the 4. Replace any cable ties cut at disassembly.
vertical baffle with the three 3/8” screws. Mount 5. When procedures are complete, perform the
the plastic strip with the top two screws. Case Cover Replacement Procedure.
2. Connect leads 23 and 25 at their in-line
couplers.
3. Using a 7/16” wrench, attach the heavy leads
and small leads as follows. Note placement
of leads and fasteners: screw, lock washer,
flat washer, small lead, heavy lead. Apply a
thin coating of Penetrox heat sink compound
(Lincoln Part T12837-1) to the mating surfaces
(but not the threads). Tighten the fasteners to
between 50-60 in-lbs.

VANTAGE® 400
F-94 NOTES F-94

VANTAGE® 400
F-95 TROUBLESHOOTING & REPAIR F-95

STATOR/ROTOR 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 trouble-
shooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Rotor and
Stator.

MATERIALS NEEDED
Misc Hand Tools

VANTAGE® 400
F-96 TROUBLESHOOTING & REPAIR F-96

STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)
FIGURE F.19 – FUEL TANK REMOVAL

LEADS #229
AND #5J

PLUG
FUEL
LINES

U-BOLTS (2)

PROCEDURE
1. Turn the engine off. 5. Turn the fuel off at the shutoff valve. Remove
and plug the fuel return line. See Figure F.19.
2. Perform the Case Cover Removal Procedure,
including the output panel. 6. Remove and plug the lower fuel line. Pull it
through the firewall. See Figure F.19.
3. Perform the Output Rectifier Bridge and Choke
Removal Procedure. 7. Using a 9/16” socket wrench, remove the four
lock nuts, washers, and rubber washers from
4. Using a 3/8” wrench, remove leads #229 (white) the fuel tank mounting U-bolts. See Figure
and #5J from the fuel level sensor. See Figure F.19.
F.19. Label the leads for reassembly.
8. Carefully remove the U-bolts and lift the fuel
tank from the machine.

VANTAGE® 400
F-97 TROUBLESHOOTING & REPAIR F-97

STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)
FIGURE F.20 – PLUG AND LEAD REMOVAL

#200
200A

#6A

5H
#201A-

FILTER FIELD DIODE

CAPACITOR RECTIFIER BRIDGE

PROCEDURE
9. Disconnect plug J30 at the right front side. See 11. Label and remove leads 5H, 200, 200A, 6A,
Figure F.20. 201A, 5H from the field bridge rectifier. See
Figure F.20.
10. Using the slot head screw driver, disconnect
leads #200B, #200A(+) and #201A(-) from the
filter capacitor. Label the leads.

VANTAGE® 400
F-98 TROUBLESHOOTING & REPAIR F-98

STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)
FIGURE F.21 – BRUSHHOLDER LEAD REMOVAL

#200A

#200B

#201

PROCEDURE
12. Label and remove brush leads #201(-) and 14. Using a 3/8” wrench, remove the brush holder
#200B(+) from the brush holder assembly. assembly.
(The Piggy-backed leads connect closest to 15. Using the 1/2” wrench, disconnect leads #68A
the stator terminations.) See Figure F.21. and #69A at their bolted connections beneath
13. Pull the harness containing plug J30, the brush the power module assembly. Label the leads
leads, and the field bridge rectifier through the for reassembly. Cut any necessary cable ties.
bushing in the firewall. See Figure F.20. See Figure F.22.

VANTAGE® 400
F-99 TROUBLESHOOTING & REPAIR F-99

STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)
FIGURE F.22 – CONTROL & OUTPUT PANELS - REAR VIEW

50 Amp
Circuit
Breaker

Ground
Aux. Power Stud
Screw
(Panel Left Side)

16. Using a 7/16” wrench, disconnect stator lead 19. Disconnect lead #5A from the auxiliary power
#6 from the auxiliary power stud on the left side ground stud (left side of the control box, next
of the control box. See Figure F.22. to the 120V circuit breaker). See Figure F.22.
17. With a 3/8” wrench, disconnect lead #5 from 20. Using a 3/8” wrench, remove the two screws
the center ground stud (nearest the control holding the control box to the top of the fan
transformer). See Figure F.22. baffle.
18. Using a phillips screw driver, remove lead
#3 from the top 50A circuit breaker for the
120/240V receptacle. See Figure F.22.
NOTE: This lead must be wound two turns
clockwise through the toroid (opposite in
direction from leads #6A).

VANTAGE® 400
F-100 TROUBLESHOOTING & REPAIR F-100

STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)
FIGURE F.23 – LIFT FRAME REMOVAL

LIFT FRAME
WELDMENT

CENTER PANEL

FUEL TANK
SUPPORTS

FAN BAFFLE

BASE

In steps 21 - 25, the lift frame weldment, fuel tank 24. Using a 3/4” wrench, remove the four bolts,
supports, and fan baffle are removed as a unit. lock washers, and nuts from the bottom of the
See Figure F.23. lift frame weldment.
21. Using a 3/8” wrench, remove the two bolts 25. Carefully remove the lift frame weldment, fuel
(at top) that hold the firewall to the lift frame tank supports, and attached fan baffle. You
weldment. will need to lift the fan baffle off the two studs
on the machine base, then cock it slightly to
22. Using a 1/2” wrench, remove the two bolts (at
remove it.
bottom) that hold the firewall to the lift frame
weldment.
23. With a 3/8” wrench, remove the nuts, lock
washers, and flat washers from the two studs
that hold the fan baffle to the machine base.

VANTAGE® 400
F-101 TROUBLESHOOTING & REPAIR F-101

STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)
FIGURE F.24 – STATOR REMOVAL
STATOR / ENGINE
MOUNTING BOLTS &
LOCK WASHERS (8)

BEARING

BOLTS (4)

FAN HUB

FAN NUT

MOUNTING {
PLATE

STATOR REMOVAL PROCEDURE

1. Using a 1/2” wrench, remove the four fan blade 5. Using a 1/2” wrench, remove the two nuts,
mounting bolts and lock washers. See Figure lock washers, and carriage bolts holding the
F.24. generator mounting plate to the machine base.
2. Using a 1 1/8” wrench, remove the fan 6. Support the stator with a hoist. Place wooden
nut. Remove the fan, noting the direction for blocks under the engine to support it when the
reassembly. stator is removed.
3. Using the gear puller, remove the fan hub. 7. Using a 9/16” wrench, remove the eight bolts
and lock washers holding the stator to the
4. Using a 3/8” wrench, remove the two bolts and engine.
flat washers holding the bearing in place.
8. Remove the stator from the engine. It may be
necessary to pry and slide it free.

VANTAGE® 400
F-102 TROUBLESHOOTING & REPAIR F-102

STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)
FIGURE F.25 – ROTOR REMOVAL

FLEX PLATE

BLOWER
SEGMENT (4)

ROTOR

ROTOR REMOVAL PROCEDURE REASSEMBLY NOTES

1. Support the rotor with a hoist. Reassemble the rotor and stator to the Vantage®
400 by carefully retracting the disassembly
2. Using a 5/16” wrench, remove the flex plate
procedure steps in reverse order. Keep the
bolts, lock washers, and four blower segments.
following special points in mind as you proceed.
See Figure F.25.
1. INSTALL ROTOR: Support the rotor with the
WARNING hoist. Install the blower segments and flex
plate to the engine flywheel.
The rotor will be free to fall when the bolts are
removed. 2. INSTALL STATOR: Be sure the engine is
blocked securely and the stator is supported by
the hoist. Install the stator to the engine with
3. Using the hoist, carefully remove the rotor and the eight bolts and lock washers. Install the
flex plate assembly. fan blade, making sure that it faces the proper
direction, with the fan nut and four cap screws.
3. Check the air gap for .012” minimum.

VANTAGE® 400
F-103 TROUBLESHOOTING & REPAIR F-103

STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)
FIGURE F.29 – ROTOR REMOVAL & REPLACEMENT

FLEX PLATE

BLOWER
SEGMENT (4)

ROTOR

PROCEDURE
1. Remove the screws and disc clamping bars 4. Assemble the coupling disc and clamping ring
from the rotor coupling disc, and remove the to the rotor hub. The surface of the disc with
rotor. the stamping burrs should be against the rotor
hub. The side of the clamping ring with the
NOTE: Earlier machines used three 0.31” thick radius should be placed against the coupling
clamping bars and later models use six disc. See Figure F.29.
0.14” thick clamping bars arranged in three
sets of two bars each. 5. Insert the screws with lock washers and evenly
tighten to a torque of 17 to 19 Ft-Lbs.
If the rotor is to be replaced, remove the screws,
rotor clamping ring and coupling disc from the rotor 6. Lift the rotor assembly with the hoist and lifting
hub. straps and recheck the engine flywheel and
coupling disk for anything that might prevent
Replacing the Rotor proper seating.
1. Whenever the rotor and stator are separated, it 7. To attach the coupling disk to the engine
is highly recommended that a new bearing and flywheel, align the screw holes and insert the
tolerance ring be installed when the rotor and six screws, with lock washers, through the disc
stator are reassembled. clamping bars and the coupling disc and into
2. Examine the rotor, coupling disc, clamping ring, the engine flywheel.
clamping bars, screws, lock washers, and the 8. Evenly tighten all the screws to a torque of 17
engine flywheel. Make sure that all of the parts to 19 Ft-Lbs.
are clean and in good condition.
3. Install a new bearing on the rotor shaft.

VANTAGE® 400
F-104 TROUBLESHOOTING & REPAIR F-104

RETEST AFTER REPAIR

Retest a machine:
• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the
machine’s electrical characteristics. OR
• If you repair or replace any electrical components.

ENGINE OUTPUT
Mode No Load RPM Load RPM
Low Idle 1300 - 1400 N/A
High Idle 1860 - 1890 1800

WELDER DC (STICK) OUTPUT (ARC control @ -10)

Mode Selector Output Control Open Circuit Load Volts Load Amps
Switch Volts
Stick (CC) Maximum 55-60 36-38 400

WELDER CV (WIRE) OUTPUT (ARC Control @ +10)

Mode Selector Output Control Open Circuit Load Volts Load Amps
Switch Voltage
CV Maximum 55-60 36-38 290-310
CV Minimum 55-60 17-19 220

TOUCH START TIG (ARC Control @ +10)

Mode Selector Output Control Open Circuit Load Volts Load Amps
Switch Voltage
TIG Maximum 10-15 18-22 240-260
TIG Minimum 10-15 Short Circuit 18-28

AUXILIARY POWER OUTPUT

240 Volt Receptacle 120 Volt Receptacles
Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps
Voltage Voltage
230-264* 216-252 50 115-132 108-126 20

* Upper limit reflects cold machine, voltage will be below 132/264 for machine at normal operating temperature.

42 VOLT WIRE FEEDER POWER

Open Circuit Voltage Load Volts Load Amps
40-50 38-48 8.5

VANTAGE® 400
G-1 TABLE OF CONTENTS - DIAGRAM SECTION G-1

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

Wiring Diagram - Complete Machine (G5481). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2

Schematic – Complete Machine (G5597 Page 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3

Schematic – Complete Machine (G5597 Page 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4

Schematic – Weld Control PC Board – (G5506 Page 1)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5

Schematic – Weld Control PC Board – (G5506 Page 2)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6

Schematic – Weld Control PC Board – (G5506 Page 3)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7

Schematic – Weld Control PC Board – (G5506 Page 4)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8

Schematic – Weld Control PC Board – (G5506 Page 5)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9

Schematic – Idler PC Board (G4828-2)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10

Schematic – Chopper PC Board (L12717-1C0)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11

Schematic – OCV Indicator PC Board (G4406-2D0)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12

Schematic – By Pass / Stabilizer PC Board (S22530-3D0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-13

PC Board Assembly – By Pass / Stabilizer PC Board (L10121-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-14

Wiring Diagram - Complete Machine (G7138 Codes 11785, 11920) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-15

Schematic - Complete Machine (G6379 Codes 11785, 11920) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-16

* NOTE: M
 any PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered
and are therefore considered to be unserviceable. Assembly drawings of these boards are no
longer provided.

VANTAGE® 400
 G-2 ELECTRICAL DIAGRAMS G-2
WIRING DIAGRAM - COMPLETE MACHINE - (G5481)
Return to Section TOC
Return to Master TOC

VANTAGE 400 WIRING DIAGRAM

ELECTRICAL SYMBOLS PER E1537
ALL CASEFRONT COMPONENTS SHOWN VIEWED FROM REAR
- RECTIFIER BRIDGE AUXILIARY POWER LEADS PASS THROUGH STATOR AUXILIARY WINDINGS
B1-NEG TOROID THREE TIMES IN DIRECTION INDICATED
B4-NEG 6 3
POS-SHUNT POS-SHUNT
6A 5
B1-NEG B4-NEG
+ 204S 6
260
261 5A

B2-POS
50MV=400AMPS
B5-POS
3 4 4

+
206S W4 & W5 W2 & W3 W1 & W6
14 14C
B2-POS B5-POS
B4
CB1 6D 6E
CB3
+

50A
3 POLE 4A 6C
W ELDING OUTPUT 20A
B1 W3 W2 3C
TERMINAL W3 W2
206C 3D
B5 32A
CB2 20A
B2
206A 206 B7 B8 CHOPPER LINE ERMI
T NALS
6F
Return to Section TOC

3E
Return to Master TOC

GROUNDED BY STATOR 3B GND-L 4A 3C GND-C

MOUNTING 13A 13 PCB3 WELD
6D
13C W4 W1 3D 6E HOT HOT
B6 W4 WINDINGS W1
B3 J11
GND-M 23 25
J12
X Z

R4
W5 W6
W5 W6 GND-C X Y
BYPASS FILTER GND-L J13 Y J10 W WHITE WHITE
240V 120/240V GND-D GND-E
208D
ASSEMBLY 15 3PH 6C 5D
5B 5C
5A
GND-D
208 GND-J
B3 CHOKE GND-E
GND-K 5
B6 CHOKE
I

NEUTRAL STUD ON
5C
MODE SELECTOR SWITCH GROUND STUD ON AUXILIARY
5B
AUXILIARY POWER
RECEPTACLE PANEL
W ELDING OUTPUT L1 CHOKE 13C 13 23 25 S5 POWER RECEPTACLE PANEL
208A 5D
TERMINAL CV
214 1 31 31
218 PIPE 2 STATOR 42V WINDING 6A
206A SWITCH CONTACTS CC 3 A 10A 5H
SHOWN IN "+" 220 4 - 200A 200
42 201 200B
POSITION TIG

+
CB6 BRUSH BRUSH SHUTDOWN IDLER

+
222
206B 41 42B 5H GLOW GLOW PLUG SOLENOID SOLENOID
4200MFD
300V
- PLUGS BUTTON
21 41A 41A COIL HOLD PULL
WIRE F
EEDER 42A 42B
ROTOR 6A 239 COIL COIL
VOLTMETER POSITIVE BRUSH CONNECTED TO
SWITCH SLIP RING NEAREST TO THE RED WHT
208A 208C LAMINATION BLK
208B 201 201A
P56 P55
J 31 SHOWN IN J56 J55
115VAC 256
A 32 32A HOUR METER "HIGH" POSITION
262 5P 1 232L 4
I 41A
42VAC GND-J OUTPUT CONTROL ARC CONTROL WELDING TERMINAL - HIGH IDLER 238C 226 227

+
K 42A
WORK H 21 GND-M
GROUND STUD IN UPPER CONTROL PANEL CCW CCW CONTROL SWITCH CONTROL
E 77B GND-A
R1 R2 10K
SHOWN IN "ALWAYS ON" POSITION AUTO SWITCH
REMOTE 4
VIEWED 10K VIEWED
Return to Section TOC
Return to Master TOC

F 76B GND-B
CONTROL FROM FROM 4A
263 5T 5U
257 CB5
CONTACTOR
G 75B BACK BACK 10A START BUTTON
D 4B 77 76 75 277 278 279 2A
C 2B 2 236A 238B
GROUND B GND-A OIL PRESSURE
14 PIN REMOTE VRD 296 296A 238A SENSOR & SWITCH
231 SWITCH
NOTE: ON VRD 234
FERRITE ON VRD RED 228 SENSOR 235
LEADS 75 A 6 PIN
A & 76 REMOTE 244 247 GREEN 13C 14C
(3 TU
RNS) 77A VOLTMETER AMMETER RUN/STOP G WK
A 77B
REMOTE 76A
CONTROL B 76B
75A OIL COOLANT SWITCH COOLANT TEMPERATURE
OFF
CONTACTOR
C 75B
2A M1 M3 M5 M9 M1 M3 M5 M9 297 299 298 PRESSURE TEMPERATURE FUEL SHOWN IN "RUN" POSITION
236B
SENSOR & SWITCH
D 2B M2 M4 M6 M10 215 298 296A M2 M4 M6 M10 236A SWITCH
4A 216 296
E 4B 241 SENSOR 235
ALT ENG 1 RUN
GROUND F GND-B 4 1 4 1 4
PROT
1 5 1 3 J53 J52 J51 STOP 232L
J61 J60 229 FUEL LEVEL
FERRITE FERRITE 6 10 4 6 5J SENSOR
5U 238A
232B 5M 232C 5L 232K 5K 232B 232K 232
5R 5R 208B 206B VRD DISPLAY 228 231
241 229
PCB4
214
216
M10

222

232C
208C
218
220

M10

232F
M9

257
M6

M9
M1

M3

25
23

14

STARTER +
M2
M6

M4
M5
M2
M3
M1

M4
M5

215

279
278
277
77

261
260

256
76
75

250

250

13

1 5 1 1 5 1 8 5S 227 SOLENOID
8 238 STARTING
5S 5T 5L 5J MOTOR
12V BATTERY
5G 5M 5K 5P
6 10 9 16 6 10 9 16 B1
-
405
243
244

200

J5 J7 J4 J3
5 ALTERNATOR
FERRITE ON
TWISTED PAIR
VOLT METER CONTROL, MODE SEL. AMMETER CHOPPER, POWER, PWM, THERMAL 10
247
263
B3 12 VOLT GROUND STUD
ON UPPER CONTROL PANEL + D+
VRD WELD BOARD 262
4 TU
RNS B4 243
J31 226 GENERATOR SUPPORT
Return to Section TOC

PCB1
Return to Master TOC

232F
76A

1 GND-K
77A
75A

1
400

232 3 2 B2
405

5G

234
400

J33 J32 ENGINE BLOCK

4
2

1 6
J6 16 9 J1 J2 12 7 4 6 3 4
206S 2
1 SHUNT
AMPHENOL,I.D. ENGINE,PERIPHERAL IDLER/ENGINE SHUTDOWN PCB2 271
204S 6 1
8 1 B
G5481
R

CLEVELAND, OHIO, U.S.A.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
®

") TO A
VANTAGE® 400
 G-3 ELECTRICAL DIAGRAMS G-3
SCHEMATIC - COMPLETE MACHINE - (G5597 PAGE 1)
Return to Section TOC
Return to Master TOC

G5597 ENGINEERING CONTROLLED CHANGE DETAIL: REVISED LEAD 208C ROUTING.

MANUFACTURER: No
+12VOLTS RUN

Shunt on back of positive OIL

output terminal FUEL PRESS. TEMP.
SHUNT Located in top of fuel tank
POSITIVE 4 1 4 1 4 1
50MV=400 AMPS FUEL LVL.
OUTPUT Rectifier is located on left side of interior SENSOR
Chopper module is located on right side of panel behind upper control panel. Located in engine block
TERMINAL CURRENT LEVEL
204S IGBT'
S, FL
YBACK DIODES AND interior panel behind upper control panel. 229 Right side, rear
FEED BACK SIGNAL
206S FILTE
R CAPACITORS ARE NTEGRAL
I THREE PHASE
Located on back of 206B
TO CHOPPER MODULES AND NOT
CHOPPPPER PC BOARD RECTIFI
ER
60 TO 65AC VPHASE T
O PHASE
5J O EMPTY
230 HMS
241
output panel 206A 13C AT HIGH IDL
E
BY-PASS INDI
VIDUALLY REPLACEABLE. 30 H
OMS F
ULL 228
between terminals WIREFEEDER 13
PC BOARD VOLTMETER +COM W1 W6 Oil
Pressure
Switch
21 W1 W6
208 POLARITY B2 B5 closes on low 10 H
OMS @ 0PSI
208A SWITCH R4 is located above x6
7,200uF oil pressur
e. O @ 75PS1
100 HMS
rectifier on upper left R4 ENGINE PROTECTION/
CONTACTS 50OHM + Located on rear OILPRESSURE
Ferrite on Lead 208A interior panel behind IDLE CONTROL
SHOW N NI "+" 100 W R
FILTE W2
2 turns 208C upper control panel. W2
STATOR of control panel (J31-6)
234
208B
ON
POSITI CAPACITORS (6) DC BUS VOLTAGE W ELD PC BOARD left side. Low oil
W3 SWITCH SENDER
206B FLYBACK 90+/-10V
DC @ HI DLE
I W3 WINDINGS pressure
or
Choke mounted behind DIODES (12) high
output terminal panel. 247 (J31
-4) tempera
ture
NEGATIVE B3 IGBT (16) B1 FOUR POLE 1800
RPM ALTERNATOR Engine protection
E B4 shutdown
C W4 W5 circuit.
nute
1 mi TEMPERATURE
OUTPUT B6 W4 W5 delay on
ngine
e
CHOKE PWM Signal to Chopper
TERMINAL 15 volt @ 20 kHz
start. Temper
aturewitch
S
SENDER
(SIM
PLIFI
ED gh hi SWITCH
closes on
B7 B8 GATE SI
GNAL G. YELLOW
EN tempera
ture. OHMS COLD
500-600
Located on front panel PROT. LAMP
BOARD
50-100 OHM
S HOT
Return to Section TOC

SCHEMATIC)
Return to Master TOC

14 Located in engine thermostat housing on

14C Left side of engine
+12VOLTS RUN
41
Field capacitor located on lower rear of
V AC
42 OLT ROTOR FIELD fan baffle on right side of machine.
WIRE F
EEDER SLI
P RINGS Voltage
Regulator (J31-1)
232
VRD O"FF" POWER 200
OpenCircuit
Volts: Diode Bridge located on upper control
200A
Max Min 42 + panel, right rear.
160 DC
V
CC 58 58 3 3200uf
CV 58 58 296 RED 299 (J61
-4) +10Volts
Pipe 58 26 Ferrite onTwisted Pair Auxiliary power to front 300vdc
Tig 12 12 4 turns - (J61-1)
208B panel receptacles via circuit
breakers on front panel. 201
6A 5H Located on front
control panel.
HOUR
12 volt ground stud
PowerSupply + (J61-8)
206B 5
METER
on rear of upper
to Control 296A GRN 297 (J61
-9) 4 244 (J33
-1) control panel.
VRD O
"N" REVOLVING FIELD
OpenCircuit
Volts:
Board AC AUX.POWER
3 TO 5 - AC 1201PHASE
V 5A
RESISTANCE APPROX. (J31-10
) 263 + _
25 HMS
O @ 75F
Max Min 6A O
T 5 -120 VAC 1PHASE
14 13 Weld voltsRED
>32,
light on 3 TO 6 - AC 2401PHASE
V
CC 12 12 120 OLT
V AC
CV 58 58 298 (J61
-10) +15DC Weld voltsGREEN
<32, light on 3, 4NDA 6 - 240 VAC 3PHASE (J31-9)
262
POWER FOR YELLOW
Pipe --- ---
*
Tig 12 12
TWISTED
PAIR
TWISTED
PAIR
TWISTED
PAIR
Switching
Supply
Power
Voltage
+ (J60-6)
14C
6
6A
ROTOR FI
ELD CI
RCUIT ALT.
LAMP

NOTE: Pipe Mode

s not
i - (J60-1)
13C
* Regulator 5H
23 (J3-10)
25 (J3-9)

13 (J3-8)
14 (J3-16)
VRD
active
On with PLIFI
(SIM ED BOARD
204S (J6-1) VDR DISPLAY PC BOARD SCHEMATIC)
206S (J6-2)
Located under VRD Control PCBd on the back of the control panel
ARC VOLTAGE F
EEDBACK SI
GNAL Located on front (2
J31-232F)
208C Control board
(J3-15) moncom
is control panel.
10 V at welder positive
ut outp LOW I
DLE COMM AND (0
V @ LOW I
DLE)
77 (J7-
1) and shunt (J2-5)
405
Located in engine GLOW PLUGS GLOW PLUG BUTTON SWITCH
OUTPUT 0-10 V J55-3
intake manifold
K R1
CONTROL 10 76 (J7-
4)
VRD WELD CONTROL(J3-14)
257
0 V Swich closed for high idle. Located on front J55 is located
IDLER SWITCH 239 control panel. 0.2 HMO 11 HOMS
0 V 75 (J7-
5) (J3-7)
256 15 V near idle solenoid.
PC BOARD IDLE SOL. IDLE SOL.
10 V 2A (TOAMPHENOL) J55-4 PULLCOIL P55-3 HOLD COIL J55-2
77A (J1-11) P/N G5507-1 15 V
(J1-4)
2 227 (B3)
(TOAMPHENOL) REMOTE -15 V
W/O( POT.)
(J1-14) Located on back of W ELD TERM.SW.
Return to Section TOC

76A P55-4 P55-2

Return to Master TOC

CONTROL 10
K (J1-3)
4 Located on right side of engine
control panel. 0 V
0 V 4A (TOAMPHENOL) inside engine access door
75A (J1-10)
(SEE SHEET 2 OR F (J7-9)
214 CV 226 (J31
-8)
279 -6)
(J7 SIMPLIFI ED PIPE 243 (J33
-6)
ARC (J7-14)
218 MO DE
CONTROL BOARD CC
K R2
CONTROL 10 278 -7)
(J7
SCHEMATI C) SWITCH +12VOLTS RUN
TIG 238C
220
(J7-15)
277 -8)
(J7 Located on front 238B
(J7-16)
222 control panel.
Located on VRD control mounting 405 (J32
-2) 12 volt ground
TOROID:Senses auxiliary power e load
idler.
to activat (J7-2)
215 bracket. Shown in "ON" position RUN-STOP SWIT
CH stud on rear of
260 -4)
(J3 3/4 Second 5S B1)
(
Generator leads
and 63 pas
s through
torroid
3 times in (J7-10)
216 SHOWN N
I RUNPOS. Located on auxiliary upper control
oppositerections.
di 261 -3)
(J3 236B Timer panel.
VRD
232D output panel
(J1-5)
00 4 SWITCH ROTOR FL
ASHING
CB A 10 200 (J33
-5)
250 -5)
(J3
Located on wiring behind (J1-12)
400
receptacles. 250 -1)
(J3 400 I.D. JUMPER (Part of round plug and lead assembly.)
(J1-8)
00 4 Located on front
Jumper required for outp
ut. 236A
control panel.
5G (J2-3) (J1-13)
400
Control board associated
circuits with part
J2 are (J4-110)
to (J5-110)
to 232H START BUTTON
of engine
electrical
em syst
andrea comm
on to SWITCH
Ferrite on meter leads Rotor Flashing: +12 volts
frameround
g negative
( attery
b rminal).
te
@ 0.5 amps
12 volt ground stud on rear of upper control panel. 238A until rator
gene ds
buil
up
Meters play
dis setpoin
t voltsmps
or when
a not welding. 231
Meters play
dis actual
olts vand
mps awhenwelding. then +160 voltsps.
@ 0 am
Weld Voltmeter and Ammeter W ELD AMM ETER W ELD VOLTMETER 238
are standard on Vantage 400 Hold function displays
ual volts
dact
amps
an rfo
approxim
ately 5 nds
secoafter welding
s. stop
During this holdhe display
right
most deci
tmal point will blink. Located in injection pump
ENGINE
J 31 STARTER on right side of engine
115V
AC SOLENOID SHUT DOW N COIL
A 32
Battery voltage: J56
I 41A
42VAC 12.6 volts
at rest 262
K 42A 14 volts
gine
en 9 Ohms
running Located on left ENGINE vF
at 75
W ORK H 21
side of engine
A 77B STARTER LEAD COLOR CODE: COM PONENT VALUE UNITS:
REMOTE E 77A block at flywheel
76B REMOTE 77B P56 5P
CONTROL B CONTROL F 76A + housing. 238 243 B-BLACK OR GRAY CAPACITOR: MF
D/VOLTS
C 75B 76B Battery is located in the G-GREEN
G 75A 12 OLT
V RESISTOR:OHMS/W ATTS
75B TOCONNECTOR J1 lower left front of O-ORANGE
D 2B CONTACTOR
D 4A machine behind lower BATTERY +
4B 4B R-RED OR PINK
E control panel. Ground stud on CONNECTOR PIN NUMBERS:
C 2A D+ U-BLUE
GROUND F GND-B 2B generator cross
Ferrite on Leads 75A & 76A EX.12 PIN CONNEC
TOR
Return to Section TOC

GROUND B GND-A W-W HITE

Return to Master TOC

FRAME support.
3 turns ENGINE Y-YELLOW 1 2 6
CONNECTOR CONNECTOR GROUND ALTERNATOR
LABELS:
Located on left side
of engine near COMM ON
radiator fan. 7 12
FRAME GROUND LATCH

EARTH GROUND VIEWOF CONNECTOR ON PC BOARD

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE: DESIGN INFORMATION REFERENCE:
EQUIPMENT TYPE: VANTAGE 400 (PERKINS) 2
1 OF ___
PAGE ___

SOLID EDGE
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: Maglietta G5388 DOCUMENT DOCUMENT
ON ALL ANGLES IS ± .5 OF A DEGREE
SCALE:
SUBJECT: MACHINE SCHEMATIC NUMBER: REVISION:
EN-170

MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: BAM

WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED: NONE
MATERIAL
DISPOSITION: NA APPROVAL
DATE:
10/26/2006 PROJECT
NUMBER:CRM22115-GA
G5597 C

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®

VANTAGE® 400
 G-4 ELECTRICAL DIAGRAMS G-4
SCHEMATIC - COMPLETE MACHINE - (G5597 PAGE 2)
Return to Section TOC
Return to Master TOC

G5597 ENGINEERING CONTROLLED CHANGE DETAIL: REVISED LEAD 208C ROUTING.

MANUFACTURER: No

SIMPLIFIED CONTROL BOARD SCHEMATIC

+15V
TRANSFORMER
J3-3 AUXILLARY
AUXIL
IARY CURRENT
SENSE SENSE
TOROID +5V
+ STUD +3.3V
WELDING J3-4 + J3-8
TERMINAL +15V CONTROL BOARD
POWER FROM 40-100VDC
CONTROL (2)
J1-4 CHOPPER BOARD INPUT
SWITCH
SHOWN IN LWAYS
"A (4) 2-4 S
ENSE - J3-16 -15V
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
ON" PO
SITION J1-3
+ STUD (ALL CIR
CUITS ON CONNECTOR J
2)
+15V +15V COM
IDLER J3-7 + STUD
CONTROL IDLE SWITCH SENSE
SHOWN IN "HIGH"
SITION
PO J3-14

+ STUD

FRAME IS COMMON FOR J2-5 TO IDLE

SOLENOID CIRCUITS
+15V +15VCOM ON ENGINEPROTECTION IDLER
/ PC BOARD
FRAME ENGINE CONTROL CIRCUITS DIODEONLY ON -E
0 Volt
s
IDL
E CONTROL IDLE CONTROL VERSIONAND ABOVE LowIdl
e
THERMAL S
HUTDOWN (if
used)
+15V
CURRENT LI
MITS
Return to Section TOC
Return to Master TOC

J1-13 REGULATION MODE

J1-12
MACHINE IDENTIT
Y TABLE: MACH SEL 1 ON /OFF +(5V=ON)
J1-8 J4-1
PINS JUMPERED TO SELECT MACHINE HOLD (+5V=HOLD)
J4-2
J1-5 J1-6 J1-7 J1-8 MACHINE
RANGER 250 G&D J1-7 MACH SEL 2 MACHINE / J4-3 FRAME
J1-13 RANGER 305 G&D
J1-13 VANTAGE 500 MACH SEL 3
MODE BLI
NK (PULLED LOW AND HIGH J4-4
+ STUD
J1-6 L
IN OOKBACK TO FLASH J4-5
J1-13
J1-13
VANTAGE 575
AIR VANTAGE 500
LOGIC DECIMAL POINT)
J4-6 AMMETER J2-3
J1-12 J1-13 VANTAGE 300
J1-5 MACH SEL 4 (CPU) J4-7 DISPLAY
J4-8 FRAME FRAME
+15V
J4-9 METER (+)INPUT 0(-2V)1V= 1000ON METER
+ STUD
J7-16 J4-10 METER (-
)INPUT

+ STUD METERS OPTIONAL ON VANTAGE

TIG MODE
J7-15 ON /OFF +(5V=ON) NO J4 OR J5 ON RANGER 250
J5-1
HOLD(+5V=HOLD)
TIG PIPE MODE J5-2
J7-14 (NOT AV
AILABLE ONAUSTRALIAN
4 VANTAGE 575) J5-3
CC N/A J5-4
MODE J7-13 NK (PULLED LOW AND HIGH
BLI
3 IN OOKBACK
L TO FLASH J5-5
SELECTOR
DECIMAL POINT)
SWITCH A J5-6
(AUSTRAI
LI
AN J7-12
N/A VOLTMETER
VANTAGE 575 SES
U A J5-7 DISPLAY
3 POSITION TOGGL
E 2
SWITCH) N/A J5-8
PIPE J7-11
1 J5-9 METER (+)INPUT 0(-2V)1V = 100.0
ON METER
CV CV MODE J5-10 METER (-
)INPUT
J7-9
+ STUD
CURRENT
(216)
SELECT CONTROL P
OINT LIMITS,
VRD ENABLE
J7-10 (FOR AUSTRA
LI
AN VANTAGE 575) CURRENT F
EEDBACK AVERAGE,
VRD ABSOLUTE,

THERMAL SHUTDOW N
+15V
SWITCH (215) CURRENT F
EEDBACK DISPLAY WELD AMPS & FOLDBACK
J7-2
Return to Section TOC

+ STUD
Return to Master TOC

+ STUD + G4107
(ONLY)
PRESET DISPLAY
PRESET
(206S) J6-2 - VALUE
- G4109
VOLTAGE
(ONLY) + CURRENT F
EEDBACK
SHUNT 50mV =400 AMPS 47.5 ohms FEEDBACK
x80 47.5hmo
+ DISPLAY WELD VOLTS PWM SIGNAL (+12V ON MULTIMETER) CHOPPER
(204S) J6-1 FEEDBACK J3-9
+ STUD is COMMON BOARD
+ STUD FOR WELD CONTROL PWM 47.5hmo
J3-11
CIRCUITS
REGULATING CHOPPER
- STUD - (208B)
J3-15 VOLTAGE FEEDBACK

CONTROL P
OINT
AMPLIFIER
CONTROL 47.5hmo
J3-10
PWM COMM ON

CIRCUIT 47.5hmo
+5V +5V
+ STUD
J3-12
+ STUD
(277)
J7-8 + STUD

(278) ARC
10K J7-7 CONTROL
ARC CONTROLPOT
CIRCUITRY
(279)
J7-6

+10V
+ STUD + STUD
OCV
(77)
J7-1 TOUCH START
VARIABLE PINCH
OUTPUT 10K (76)
CONTROL POT J7-4 PIPE ARC FORCE CONTROL
VARIABLE ARC FORCE POINT
(75)
J7-5 LOCAL SELECT SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
FIXED ARC FORCE
THE TOPEND OF THEEMOTE
R POT IN NI EACH
WHAT PARTS OF THE G4107/G4109 ARE USED LEAD COLOR CODE: COMPONENT VALUE UNITS:
TIG MODE IS
THE ETTING
S OF THE LOCA
L PRESET PRESET CONNECTORS
OUTPUT CONTROL POT. APPLICATION
. NOT ALL CIRCUITS ARE USED ALL THE TIME. B-BLACK CAPACITOR: F
MD/VOLTS
+ STUD FIXED HOT START J1 AMPHENOL & MACHINE ID JUMPER G-GREEN
IN VERY
E OTHER MODE,THE REMOTE TIG MODE +10V RESISTOR:OHMS/WATTS
POT WILLSET MACHINE TO XMA
OUTPUT.
REMOTE +5V J2 ENGINE 12V CONTROL FUNCTIONS O-ORANGE
(77B) R-RED
J1-11 J3 CHOPPER PWM, POWERTHERMAL
( IN, OVERLOAD IF USED
),VOLTAGE FEEDBACK U-BLUE CONNECTOR PINNUMBERS:
Return to Section TOC

J4 AMMETER N
(O CONNECTOR ON RANGER 250)
Return to Master TOC

+ STUD W-WHITE EX. 12 NPI

CONNECTOR
REMOTE (76B) ALL OTHER MODES J5 VOLTMETER NO
( CONNECTOR ON RANGER 250) Y-YELLOW
10K 1 2 6
J1-14 J6 SHUNT/CURRENT FEEDBACK
CONTROL POT LABELS:
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT COMM ON
(75B)
J1-10 7 12
FRAME GROUND LATCH
EARTH GROUND VIEW OFCONNECTOR ON PC BOARD
+ STUD + STUD
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE: DESIGN INFORMATION REFERENCE:
EQUIPMENT TYPE: VANTAGE 400 (PERKINS) 2
2 OF ___
PAGE ___

SOLID EDGE
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: Maglietta G5388 DOCUMENT DOCUMENT
ON ALL ANGLES IS ± .5 OF A DEGREE
SCALE:
SUBJECT: MACHINE SCHEMATIC NUMBER: REVISION:
EN-170

MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: BAM

WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED: NONE
MATERIAL
DISPOSITION: NA APPROVAL
DATE:
10/26/2006 PROJECT
NUMBER:CRM22115-GA
G5597 C

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®

VANTAGE® 400
 G-5 ELECTRICAL DIAGRAMS G-5
SCHEMATIC - WELD CONTROL PC BD. (G5506 PAGE 1 OF 5)
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®

VANTAGE® 400
 G-6 ELECTRICAL DIAGRAMS G-6
SCHEMATIC - WELD CONTROL PC BD. (G5506 PAGE 2 OF 5)
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®

VANTAGE® 400
 G-7 ELECTRICAL DIAGRAMS G-7
SCHEMATIC - WELD CONTROL PC BD. (G5506 PAGE 3 OF 5)
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®

VANTAGE® 400
 G-8 ELECTRICAL DIAGRAMS G-8
SCHEMATIC - WELD CONTROL PC BD. (G5506 PAGE 4 OF 5)
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®

VANTAGE® 400
 G-9 ELECTRICAL DIAGRAMS G-9
SCHEMATIC - WELD CONTROL PC BD. (G5506 PAGE 5 OF 5)
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®

VANTAGE® 400
 G-10 ELECTRICAL DIAGRAMS G-10
SCHEMATIC - IDLER PC BD (G4828-2)
Return to Section TOC
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Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®

VANTAGE® 400
 G-11 ELECTRICAL DIAGRAMS G-11
SCHEMATIC - CHOPPER PC BD (L12717-1CO)
Return to Section TOC
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Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®

VANTAGE® 400
 G-12 ELECTRICAL DIAGRAMS G-12
SCHEMATIC -OCV INDICATOR PC BD (G4406-2D0)
Return to Section TOC
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Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®

VANTAGE® 400
 G-13 ELECTRICAL DIAGRAMS G-13
SCHEMATIC - BY PASS / STABILIZER PC BOARD (S22530-3D0)
Return to Section TOC
Return to Master TOC
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Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®

VANTAGE® 400
 G-14 ELECTRICAL DIAGRAMS G-14
PC BOARD ASSEMBLY - BY PASS / STABILIZER PC BOARD (L10121-3)
Return to Section TOC
Return to Master TOC

L10121-3 ENGINEERING CONTROLLED CHANGE DETAIL: REVISED P.C. BOARD BLANK INFORMATION REFERENCES QTY PART NUMBER DESCRIPTION
MANUFACTURER: No
C1, C2, C3, C4, C5, C6, C7, C8 8 T11577-58K CAPACITOR,CD,.0047,3000V,20%
CAPACITOR,POLYPROPYLENE METALLIZED
C9 1 S13490-155
FILM,PPMF,15MF,250VAC,10%
R1 1 T14648-25 RESISTOR,WW,5W,10,5%,SQ
TP1, TP2 2 T13640-18 MOV,320VRMS,150J,20MM
P.C. BOARD BLANK INFORMATION
BUY COMPLETE AS L10121-D (2 LAYER BOARD PER E3281 CAPACITORS = MFD/VOLTS
WITH LEAD FREE HASL SURFACE FINISH). INDUCTANCE = HENRYS
MAKES 12 BOARDS PER PANEL.
SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION
ITEM REQ'D PART NO. IDENTIFICATION
1 1 SEE BLANK INFO. P.C. BOARD BLANK

3 .16 OZ E2861 SEALANT

Return to Section TOC
Return to Master TOC

N.F., N.G.

1.00
4.50 ±.04
3.80±.04
(3.462) (3.450)

XXXXXXXXXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXXXXXXXXX
R1
XXXXXXXXXXXXX

BYPASS/STABILIZER
1
C5

C6

C7

C8

TP2
NOTES: MANUFACTURED AS:
XXXXXXXXXXX N.C. SQUEEZE TOGETHER ITEMS C1-C4, TP1 AND

C9
(1.900) XXX C5-C9, TP2 BEFORE APPLYING SEALANT.
XXX L10121-3D0
Return to Section TOC
Return to Master TOC

XXXXXXXXXXX
N.D. APPLY SEALANT AS SHOWN.

N.F. KEEP THIS AREA FREE OF ENCAPSULATION, TOP AND IDENTIFICATION CODE
C1

C2

C3

C4

TP1

L10121-3
N.H. BOTTOM OF BOARD.
XXXXXXXXXXX N.G. TIN ALL EXPOSED COPPER WITH SOLDER IN THIS AREA,
XXX XXXXXXXXXXXXX BOTH SIDES OF BOARD. MAKE PER E1911-ROHS
(.338) (.350) N.H. NO ICICLES OR SOLDER BLOBS ARE PERMITTED ENCAPSULATE WITH E1844,
WITHIN 0.5" 0 (BOTH SIDES). 2 COATS.
0 TEST PER E3553-B

0 3 SCHEMATIC REFERENCE: S22530-3D0

(.438) (4.250)
N.C.,
N.D.

ALL COMPONENTS AND MATERIALS USED IN THIS

ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.

FOR PARTS ORDERS ONLY:

Return to Section TOC
Return to Master TOC

INCLUDE S22772PRINT

PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056 CONTROL: SCALE:
UNLESS OTHERWISE SPECIFIED TOLERANCE: CLEVELAND
1:1
EQUIPMENT TYPE: SW TIG 175 & 275 1
1 OF ___
PAGE ___

SOLID EDGE
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: fivory IF PRINTED DOCUMENT DOCUMENT
ON ALL ANGLES IS ± .5 OF A DEGREE @ A2 SIZE SUBJECT: BYPASS/STABILIZER P.C. BOARD ASSEMBLY
NUMBER: REVISION:
EN-168

MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: -

WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED: -
UNITS:
INCH
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE: 9-7-
2007
PROJECT
NUMBER: CRM34432
REFERENCE:
L10121-1
L10121-3 C
Insight

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
®
machine.
VANTAGE® 400
 G-2 ELECTRICAL DIAGRAMS G-2
WIRING DIAGRAM - COMPLETE MACHINE - (G5481)
Return to Section TOC
Return to Master TOC

VANTAGE 400 WIRING DIAGRAM

ELECTRICAL SYMBOLS PER E1537
ALL CASEFRONT COMPONENTS SHOWN VIEWED FROM REAR
- RECTIFIER BRIDGE AUXILIARY POWER LEADS PASS THROUGH STATOR AUXILIARY WINDINGS
B1-NEG TOROID THREE TIMES IN DIRECTION INDICATED
B4-NEG 6 3
POS-SHUNT POS-SHUNT
6A 5
B1-NEG B4-NEG
+ 204S 6
260
261 5A

B2-POS
50MV=400AMPS
B5-POS
3 4 4

+
206S W4 & W5 W2 & W3 W1 & W6
14 14C
B2-POS B5-POS
B4
CB1 6D 6E
CB3
+

50A
3 POLE 4A 6C
W ELDING OUTPUT 20A
B1 W3 W2 3C
TERMINAL W3 W2
206C 3D
B5 32A
CB2 20A
B2
206A 206 B7 B8 CHOPPER LINE ERMI
T NALS
6F
3E
Return to Section TOC

3C GND-C
Return to Master TOC

GROUNDED BY STATOR 3B GND-L 4A

MOUNTING 13A 13 PCB3 WELD
6D
13C W4 W1 3D 6E HOT HOT
B6 W4 WINDINGS W1
B3 J11
GND-M 23 25
J12
X Z

R4
W5 W6
W5 W6 GND-C X Y
BYPASS FILTER GND-L J13 Y J10 W WHITE WHITE
240V 120/240V GND-D GND-E
208D 6C
ASSEMBLY 15 3PH 5D
5B 5C
5A
GND-D
208 GND-J
B3 CHOKE GND-E
GND-K 5
B6 CHOKE
I

NEUTRAL STUD ON
5C
MODE SELECTOR SWITCH GROUND STUD ON AUXILIARY
5B
AUXILIARY POWER
RECEPTACLE PANEL
W ELDING OUTPUT L1 CHOKE 13C 13 23 25 S5 POWER RECEPTACLE PANEL
208A 5D
TERMINAL CV
214 1 31 31
218 PIPE 2 STATOR 42V WINDING 6A
206A SWITCH CONTACTS CC 3 A 10A 5H
SHOWN IN "+" 220 4 - 200A 200
42 201 200B
POSITION TIG

+
CB6 BRUSH BRUSH SHUTDOWN IDLER

+
222
206B 41 42B 5H GLOW GLOW PLUG SOLENOID SOLENOID
4200MFD
300V
- PLUGS BUTTON
21 41A 41A COIL HOLD PULL
WIRE F
EEDER 42A 42B
ROTOR 6A 239 COIL COIL
VOLTMETER POSITIVE BRUSH CONNECTED TO
SWITCH SLIP RING NEAREST TO THE RED WHT
208A 208C LAMINATION BLK
208B 201 201A
P56 P55
J 31 SHOWN IN J56 J55
115VAC 256
A 32 32A HOUR METER "HIGH" POSITION
262 5P 1 232L 4
I 41A
42VAC GND-J OUTPUT CONTROL ARC CONTROL WELDING TERMINAL - HIGH IDLER 238C 226 227

+
K 42A
WORK H 21 GND-M
GROUND STUD IN UPPER CONTROL PANEL CCW CCW CONTROL SWITCH CONTROL
E 77B GND-A
R1 R2 10K
SHOWN IN "ALWAYS ON" POSITION AUTO SWITCH
REMOTE 4
VIEWED 10K VIEWED
Return to Section TOC

F 76B GND-B
Return to Master TOC

CONTROL FROM FROM 4A

263 5T 5U
257 CB5
CONTACTOR
G 75B BACK BACK 10A START BUTTON
D 4B 77 76 75 277 278 279 2A
C 2B 2 236A 238B
GROUND B GND-A OIL PRESSURE
14 PIN REMOTE VRD 296 296A 238A SENSOR & SWITCH
231 SWITCH
NOTE: ON VRD 234
FERRITE ON VRD RED 228 SENSOR 235
LEADS 75 A 6 PIN
A & 76 REMOTE 244 247 GREEN 13C 14C
(3 TU
RNS) 77A VOLTMETER AMMETER RUN/STOP G WK
A 77B
REMOTE 76A
CONTROL B 76B
75A OIL COOLANT SWITCH COOLANT TEMPERATURE
OFF
CONTACTOR
C 75B
2A M1 M3 M5 M9 M1 M3 M5 M9 297 299 298 PRESSURE TEMPERATURE FUEL SHOWN IN "RUN" POSITION
236B
SENSOR & SWITCH
D 2B M2 M4 M6 M10 215 298 296A M2 M4 M6 M10 236A SWITCH
4A 216 296
E 4B 241 SENSOR 235
ALT ENG 1 RUN
GROUND F GND-B 4 1 4 1 4
PROT
1 5 1 3 J53 J52 J51 STOP 232L
J61 J60 229 FUEL LEVEL
FERRITE FERRITE 6 10 4 6 5J SENSOR
5U 238A
232B 5M 232C 5L 232K 5K 232B 232K 232
5R 5R 208B 206B VRD DISPLAY 228 231
241 229
PCB4
214
216
M10

222

208C

232C
218
220

M10

232F
M9

257
M6

M9
M1

M3

25
23

14

+
M2

STARTER
M6

M4
M5
M2
M3
M1

M4
M5

215

279
278
277
77

261
260

256
76
75

250

250

13

1 5 1 1 5 1 8 5S 227 SOLENOID
8 238 STARTING
5S 5T 5L 5J MOTOR
12V BATTERY
5G 5M 5K 5P
6 10 9 16 6 10 9 16 B1
-
405
243
244

200
J5 J7 J4 J3
5 10 ALTERNATOR
FERRITE ON
TWISTED PAIR
VOLT METER CONTROL, MODE SEL. AMMETER CHOPPER, POWER, PWM, THERMAL
247
263
B3 12 VOLT GROUND STUD
ON UPPER CONTROL PANEL + D+
VRD WELD BOARD 262
4 TU
RNS B4 243
J31 226 GENERATOR SUPPORT
PCB1
Return to Section TOC

232F
Return to Master TOC

76A

GND-K
77A
75A

1 1
400

232 3 2 B2
405

5G

234
400

J33 J32 ENGINE BLOCK

4
2

1 6
J6 16 9 J1 J2 12 7 4 6 3 4
206S 2
1 SHUNT
AMPHENOL,I.D. ENGINE,PERIPHERAL IDLER/ENGINE SHUTDOWN PCB2 271
204S 6 1
8 1 B
G5481
R

CLEVELAND, OHIO, U.S.A.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

VANTAGE® 400
¤

") TO A
G-15 ELECTRICAL DIAGRAMS G-15
Wiring Diagram Complete Machine - G7138 codes 11785, 11920

VANTAGE 400 WIRING DIAGRAM

ELECTRICAL SYMBOLS PER E1537
ALL CASEFRONT COMPONENTS SHOWN VIEWED FROM REAR
AUXILIARY POWER LEADS PASS THROUGH STATOR AUXILIARY WINDINGS
TOROID THREE TIMES IN DIRECTION INDICATED
- RECTIFIER BRIDGE 6 3
B1-NEG
B4-NEG 5
POS-SHUNT POS-SHUNT 261 6A 5A
260
6
B1-NEG B4-NEG
+ 204S 6E 4
B2-POS 3 4
50MV=400AMPS
B5-POS
CB1
-

+
206S W4 & W5 J11
14 14C W2 & W3 W1 & W6
50A
6D J12
B2-POS B5-POS 4A 6C
B4 3 POLE
+

3C
WELDING OUTPUT SILVER SILVER
B1 W3 W2 3D
TERMINAL W3 W2 5B 5E
206C
B5
CB2 3F CB3 6G
B2 GND-C 20A 20A
3B GND-L 4A 3C
206A 206 B7 B8 CHOPPER 6D 3E 6F
GROUNDED BY STATOR 3D 6E
MOUNTING 13A 13 PCB3 WELD
13C W4 W1 32A HOT HOT

LOAD

LOAD
WINDINGS

LINE
W4 W1 X Z

LINE
B6 GFCI
GND-M
B3
23 25 GND-C X Y GFCI
J13 J10 WHITE WHITE

R4
W5 W6 GND-L Y W
W5 W6 240V GND-D
120/240V
BYPASS FILTER 3PH 6C 5D 5F
208D GND-D 5C
ASSEMBLY 15 GND-J GND-E GND-E
208 GND-K 5 5A
B3 CHOKE NEUTRAL STUD ON
GROUND STUD ON AUXILIARY 5F
B6 CHOKE AUXILIARY POWER
I

MODE SELECTOR SWITCH POWER RECEPTACLE PANEL 5C RECEPTACLE PANEL

L1 CHOKE 13C 13 23 25 S5 5D
208A WELDING OUTPUT 31 31
TERMINAL CV 6A
214 10
217 GOUGE 1 STATOR 42V WINDING 32A
206A SWITCH CONTACTS 218 PIPE 2 10A 5H
SHOWN IN "+" - 200A 200
CC 3 A 42 201 200B
POSITION

+
220 4 CB6 BRUSH BRUSH SHUTDOWN IDLER

+
TIG
206B
222 41 42A 5H 6A GLOW GLOW PLUG SOLENOID SOLENOID
4200MFD
300V
- PLUGS BUTTON
21 41A 41A COIL HOLD PULL
WIRE FEEDER 42A
ROTOR 6A 239 COIL COIL
VOLTMETER POSITIVE BRUSH CONNECTED TO
SWITCH SLIP RING NEAREST TO THE RED WHT
208A 208C LAMINATION BLK
208B 201 201A
P56 P55
J 31 SHOWN IN J56 J55
115VAC 256
A 32 32A HOUR METER "HIGH" POSITION
262 5P 1 232L 4
I 41A 5N
42VAC GND-J OUTPUT CONTROL ARC CONTROL WELDING TERMINAL - HIGH IDLER 238C 226 227

+
K 42A
WORK H 21 GND-M
GROUND STUD IN UPPER CONTROL PANEL CCW CCW CONTROL SWITCH CONTROL
E 77B GND-A
R1 R2 10K
SHOWN IN "ALWAYS ON" POSITION AUTO SWITCH
REMOTE 4
VIEWED 10K VIEWED
F 76B GND-B
CONTROL FROM FROM 4A
263 5T 5U
257 CB5
CONTACTOR
G 75B BACK BACK 10A START BUTTON
D 4B 77 76 75 277 278 279 2A
C 2B 2 236A 238B
GROUND B GND-A OIL PRESSURE
14 PIN REMOTE VRD 296 296A 238A SENSOR & SWITCH
231 SWITCH
NOTE: ON VRD 234
FERRITE ON 6 PIN REMOTE VRD RED 228 SENSOR 235
LEADS 75A & 76A 244 247 GREEN 13C 14C
(3 TURNS) A
77A VOLTMETER AMMETER RUN/STOP G WK
77B
REMOTE 76A
CONTROL B 76B
75A OIL COOLANT SWITCH COOLANT TEMPERATURE
OFF
CONTACTOR
C 75B
2A M1 M3 M5 M9 M1 M3 M5 M9 297 299 298
PRESSURE TEMPERATURE FUEL SHOWN IN "RUN" POSITION
236B
SENSOR & SWITCH
D 2B M2 M4 M6 M10 215 298 296A M2 M4 M6 M10 236A SWITCH
4A 216 296
E 4B 241 SENSOR 235
ENG 1
GROUND F GND-B ALT 4 1 4 1 4 RUN
PROT
1 5 1 3 J53 J52 J51 STOP 232L
J61 J60 229 FUEL LEVEL
FERRITE FERRITE
5U 6 10 4 6 5J SENSOR
232B 5M 238A
232C 5L 232K 5K 232B 232K 232
5R 5R 208B 206B VRD DISPLAY 228
231
241 229
PCB4
214
216
M10

217

222

232C
208C
218
220

M10

232F
M9

257
M6

M3

M9
M1

25
23

14

+
M2

STARTER
M6

M4
M2
M3

M5
M1

M4
M5

215

279
278
277
77

260
261

256
76
75

250

250

13

1 5 1 1 5 1 8 5S 227 SOLENOID
8 238 STARTING
5S 5T 5L 5J MOTOR
12V BATTERY
5G 5M 5K 5P
6 10 9 16 6 10 9 16 B1
-
243

405
244

200

J5 J7 J4 J3
5 10 ALTERNATOR
FERRITE ON
TWISTED PAIR
VOLT METER CONTROL, MODE SEL. AMMETER CHOPPER, POWER, PWM, THERMAL
247
263
B3 12 VOLT GROUND STUD
ON UPPER CONTROL PANEL +D+
4 TURNS VRD WELD BOARD 262
B4 5N 243
J31 226 GENERATOR SUPPORT
PCB1 232F
76A

GND-K
77A
75A

1 1
400

232 B2
405

5G

234
400

J33 J32 ENGINE BLOCK

4
2

1 6
J6 16 9 J1 J2 12 7 3
206S 2 4
1 SHUNT
AMPHENOL,I.D. ENGINE,PERIPHERAL IDLER/ENGINE SHUTDOWN PCB2 271
204S 6 1
8
1 B
G7138PRINT
R

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-
CLEVELAND, OHIO, U.S.A.

vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
VANTAGE® 400
¤
G-16 ELECTRICAL DIAGRAMS G-16
Schematic Complete Machine - G6379 Codes 11785, 11920 Page 1
#

'$ ! # #%
#
SHUNT
50MV=400 AMPS
## # # # # # !
&$ # # $ # ) " ) " ) " # # !
$#
) C 0 # # $# # $ # )
! *
"#
! )"
" # "#
+COM ! *, #
" #
B2 B5 ! " 2
# % .0 $ 1 78 9355$93 =7>(? (8<535 " 2 .* "
## ) " <4 8<= <78 ;9355$93!
# # $# * /
( # 0 7. &#& "
0 +,#" - #)
+ - # <= <78
/ " 2 ;9355$93 <9
&$ ! $# +" - " ?7@?
# ). +,#" )- >3A;396>$93
B3 +" - 4@743 ;9<>3(>7<4
B1 B4 5?$>'<=4
(79($7>! " A74$>3
B6 '386: <4 34@743
CHOKE 7@468 >< ?<;;39 5>69>!
"* &<8> 2 D E 3A;396>$93 =7>(?
B7 B8 (8<535 <4 ?7@? >3A;396>$93! *
* "
") # # $ $ #
") + - # #
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(# # "
# $ # $#
<8>6@3
3@$86><9 +,#" "- #
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;34 79($7> <8>5 # 1#
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7;3 64' <$@3 <'35 693 4<>

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< 1 2 6
#
#
# 7 12
LATCH

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-
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED

vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
T

machine.
VANTAGE® 400
¤ ") TO AGREE
W
G-17 ELECTRICAL DIAGRAMS G-17
Schematic Complete Machine - G6379 Codes 11785, 11920 Page 2

/"*

J3-3

/*
+ STUD /#!#
J3-4 + J3-8
/"*
) "
(2)
J1-4
J (4) ) - J3-16 "*
=/0- '5 .8 & & 8 > (5 62 6 ( 6&8 56'
J J1-3
+ STUD + , -
/"* /"*
+ STUD
J3-7

J J J3-14

+ STUD

( . ' &5 56(5 J2-5

/"* /"*
62 6 &568 5 & & 8' <8>5
<= '83
+7% $53'-
/"*

J1-13
J1-12
" +/* K -
J1-8 J4-1
+/* K -
, J4-2
J1-5 J1-6 J1-7 J1-8 MACHINE J1-7 J4-3
J1-12 J1-13 VANTAGE 400
+ J4-4
J1-6
# + STUD
J4-5
-
J4-6
J1-5 ) + - J4-7
J2-3

J4-8
/"*
J4-9 +/- + -" K"
+ STUD
J7-16 J4-10 +-

+ STUD
J7-15 +/* K - J5-1
+/* K -
J5-2
J7-14 +
* *.*- J5-3

+ J5-4
) J7-13
J5-5
-
J5-6
I # J7-12
J5-7
! J5-8
J7-11
" J5-9 +/- + -" K" !
J5-10 +-
J7-9
+ STUD
CURRENT
+ " -
LIMITS,
J7-10 AVERAGE,
/"* ABSOLUTE,
+ "*- & FOLDBACK

/
J7-2 + STUD

/ G4107
(ONLY)

+ - J6-2 -
G4109
(ONLY) +
* A K) 47.5 ohms
x80
).!* <?A
/ + ) -
+/" -
J6-1 J3-9
= '8 # &5 56
+ STUD (5 , &568 5 PWM ).!* <?A
& & 8' J3-11
+ -
J3-15
REGULATING CHOPPER
AMPLIFIER ).!* <?A
CONTROL J3-10
CIRCUIT ).!* <?A
/* /*
+ STUD
J3-12
+ STUD
+ ..-
J7-8 + STUD

+ . - ARC
" J7-7 CONTROL
CIRCUITRY
+ . -
J7-6

+10V
+ STUD + STUD
OCV
+..-
J7-1 TOUCH START
VARIABLE PINCH
" +. -
J7-4 PIPE ARC FORCE CONTROL
VARIABLE ARC FORCE POINT
+.*-
J7-5 LOCAL FIXED ARC FORCE SELECT
!
FIXED HOT START
," L ,
0
+ STUD
TIG MODE +10V
REMOTE /*
, "
!
+.. - ,# 0 0+ -0
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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-
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THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED

vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
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machine.
VANTAGE® 400
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