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Lincoln Electric 12716, Operator'S Manual, Page: 54 / 64

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Lincoln Electric 12716 Operator'S Manual Download Page 54

E-3

TROUBLESHOOTING

FRONTIER

®

 400X 

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed. 

WWW.LINCOLNELECTRIC.COM/LOCATOR

PROBLEMS 

(SYMPTOMS)

POSSIBLE  

CAUSE

RECOMMENDED 

COURSE OF ACTION

Battery does not stay charged. 

Engine will not idle down to low 
speed. 

Engine will not go to high idle when 
attempting to weld. 

Engine will not go to high idle when 
using auxiliary power. 

1. Faulty battery.
2. Faulty engine alternator.
3. Loose or broken lead in charging

circuit.

4. Loose fan belt may need tighten-

ing.

1. Idler switch in HIGH idle position,

make sure switch is set to AUTO.

2. Faulty Idler Switch.
3. Faulty Idle Relay.

1. Poor work lead connection to

work. Poor lead connections to
machine.

2. Welding output is OFF. (No open

circuit voltage at output studs)

3. Faulty Idle Relay.

1. Broken wire in auxiliary current

sensor wiring.

2. Auxiliary power load is less than

100W.

3. Faulty Auxiliary Sense Toroid.

If all recommended possible areas 
of misadjustment have been 
checked and the problem persists, 

Contact your local Lincoln 

Authorized Field Service Facility. 

FUNCTION PROBLEMS

Observe all Safety Guidelines detailed throughout this manual

4. Faulty Idle Relay.

Summary of Contents for 12716

Page 1: ...chines having Code Numbers 12716 12717 12781 13202 Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Exper...

Page 2: ...l area IN A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop...

Page 3: ...belts gears fans and all other moving parts when starting operating or repairing equipment 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards o...

Page 4: ...d conform to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personne...

Page 5: ...ing current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and...

Page 6: ...3 6 5 3 34 45 108 3 0 5 0 4 8 065165 4 45 5 0 6 5 54 54 0 8 3044 5 0 0 3 05 0 530 0 5 0 4 3 05 065165 0 530 3 05 8 5 3 4 4403 0 5 0 3 4 3044 8 3 3 4 561 9 1 3044 3 05 4 561 9 1 6 3 4 561 9 1 3044 8 3...

Page 7: ...ANCE SECTION D 3065 1 3 0 5 5 3 5 3 6 5 34 00 4 45 3 1 00 5 55 3 0 5 5 5 5 1 5 4 8 3 4 5 5 TROUBLESHOOTING SECTION E WIRING CONNECTION DIAGRAMS AND DIMENSION PRINT SECTION F PARTS LIST PARTS LINCOLNEL...

Page 8: ...4 GRAPHIC SYMBOLS A V FRONTIER 400X DigFX...

Page 9: ...g graphics appear on the Frontier or in the manual Stop Start Glow Plug Receptacle Electrode Type Diameter Material Thickness Productivity Metrics Arc Hours Auxiliary Hours Utilization Rate Standby Ho...

Page 10: ...S 10 to 45 Volts QTY 2 1 1 RECEPTACLES Receptacle 120 VAC Duplex 5 20R GFCI Protected 240 VAC Three Phase 15 50R 120 240 VAC Single Phase 14 50R Circuit Breaker 20 Amps 50 Amps 50 Amps AGENCY APPROVA...

Page 11: ...on resulting in engine shut down DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under be covered with a steel plate at least 06 1 6mm thick which should extend no...

Page 12: ...LTITUDE OPERATION At higher altitudes output derating may be necessary HIGH TEMPERATURE OPERATION At temperatures above 104 F 40 C output voltage derating may be necessary For maximum output current r...

Page 13: ...stable under conditions of use Do not exceed maximum rated loads for components such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Do not mount the welder using r...

Page 14: ...by disconnecting negative cable reinstalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery at engine foot BATTERY ACID can burn eyes and skin Wear g...

Page 15: ...auxiliary power capacity rating in watts is equivalent to volt amperes at unity power factor The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissible current of...

Page 16: ...load for each leg of the 240 VAC auxiliary is 50 amps Loading above the rated output will reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor drive...

Page 17: ...d cable 6 Check and tighten the connections periodically Loose connections will cause the output terminals to overheat The terminals may eventually melt Do not cross the welding cables at the output t...

Page 18: ...welding cables unspool the cables Avoid leaving more than 30 feet of cable on each storage spool and for best performance completely unspool the welding cables For long work piece lengths a sliding g...

Page 19: ...lder For electrode negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder Installation diagrams for common setups are included on the following pages...

Page 20: ...1 K909 7 K2485 2 K2483 2 K910 1 K2487 1 Description Product Number QTY Frontier 400X Welder Generator K3484 1 1 LN 25X Wire Feeder 1 K126 PRO Innershield 350A FCAW S Welding Gun 1 Electrode Cable 2 0...

Page 21: ...QTY Frontier 400X Welder Generator K3484 1 1 PTA 26V TIG Torch 25 ft 7 6 m 1 Foot Pedal 1 Electrode Cable 2 0 50 ft 15 3 m Black 2 Electrode Cable 2 0 10 ft 3 1 m Black 1 Work Clamp 1 Cable Connectors...

Page 22: ...ode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside Do not stack an...

Page 23: ...k the level on the dipstick recommendations STARTING THE ENGINE 2 3 engine before starting if needed Then press and hold the START button until the machine turns over Release the engine START button i...

Page 24: ...bota D1503 M Fuel Consumption Full Tank equals 20 gal 75 7L GAL HR L HR RUN TIME HRS WITH FULL TANK Low Idle no load 0 43 1 63 46 39 0 29 1 09 69 58 0 58 2 21 34 29 0 80 3 01 25 17 1 12 4 26 17 79 1 2...

Page 25: ...a In the OFF position the engine will turn off b In the HIGH IDLE position the engine runs at the high idle speed controlled by the governor c In the AUTO IDLE position the idler operates as follows 7...

Page 26: ...information about this receptacle FRONTIER 400X 12 240 VAC THREE PHASE RECEPTACLE A NEMA 15 50R receptacle that provides 240 VAC three phase auxiliary power This receptacle has a 50 amp rating 13 50A...

Page 27: ...X READY SET WELD is a guided setup feature that provides a recommended output range based off a given material material thickness electrode type and electrode diameter 2 3 4 5 6 9 7 8 10 1 3 REMOTE BU...

Page 28: ...eristics of the Frontier 400X power source The proper weld mode should be used based off desired application Many variables beyond the control of The Lincoln Electric Company affect the results obtain...

Page 29: ...Red Critical A warning message will appear The operator will need to click to acknowledge it Next to the engine indicators are weld setting and operation indicators From top to bottom OFF 6 WELDING M...

Page 30: ...l automatically return to the weld mode screen This allows the operator to read the actual current and voltage just prior to when welding was ceased The accuracy of the meters is 3 When CrossLinc wire...

Page 31: ...press the knob to view additional arc options welding performance The options available will depend on the weld mode selected Welding settings are remembered between each weld mode output range that...

Page 32: ...to prevent the electrode from sticking during welding It provides a temporary increase in current when the arc length becomes very short Increasing the value from 10 Soft to 10 Crisp increases the sh...

Page 33: ...en Touch Start and Scratch Start Touch Start is a cleaner process needing only a light quick touch of the tungsten to the work piece Scratch start requires dragging the tungsten across the work much l...

Page 34: ...Engine Status Screen provides information about the engine servicing and operation In the MAIN MENU use the knob to scroll and press to select the ENGINE SCREEN See Figure B 11 FIGURE B 11 If a yellow...

Page 35: ...required A warning indicator will appear if a service item is nearing the end of its service life The default warning SETTINGS menu Green Normal operation Yellow Service is required soon Red Service i...

Page 36: ...tion Enable or disable weld modes depending on preferences FIGURE B 17 Engine Service Alerts Change the percentage of item life remaining before an alert will be displayed Clock Set Display the local...

Page 37: ...ce to remain unlocked and the machine to be restarted throughout the day without needing to reenter the PIN The MANAGING RESTRICTIONS section of the settings menu may be used to restrict unauthorized...

Page 38: ...the Settings Menu 4 A countdown timer appears on the top of the user interface to indicate the remaining time until shutdown FIGURE B 20 To restart the engine remotely tap the stick electrode to the...

Page 39: ...memory is saved with a remote control connected the remote control must be connected for the memory to function PRODUCTIVITY METRICS The Productivity Metrics screen provides information and statistic...

Page 40: ...ble B 2 above For optimal performance when arc gouging it is recommended to set the machine to HIGH IDLE NOTE If desired the CV WIRE mode can be used for arc gouging applications Maximum current setti...

Page 41: ...The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle MODES Connect a wire feeder to the Frontier 400X and set welder controls...

Page 42: ...d Watts 1800 3600 2400 4800 6000 7200 9000 12000 30 60 9 18 40 75 30 60 12 23 9 18 75 150 50 100 90 75 23 46 15 30 27 23 125 225 88 175 150 120 100 38 69 27 53 46 37 30 175 350 138 275 225 175 150 125...

Page 43: ...der K2641 2 Full KVA Power Plug Kit FRONTIER 400X Activ8X Pipe optimized for cross country pipe welding Order K4717 1 Full KVA Adaptor on engine driven welders for portable power sources needing APEX...

Page 44: ...mote Control the machine to switch between welding processes adjust welding parameters recall saved memories and start stop the machine from a distance Order K5265 1 TIG ACCESSORIES Pro Torch PTA 26 T...

Page 45: ...ne Use Personal Protective Equipment PPE including safety glasses dust mask and gloves to avoid injury This also applies to persons who enter the work area MOVING PARTS can injure Do not operate with...

Page 46: ...fer to Table D 1 at the end of this section for various engine maintenance components AIR FILTER engine life could result Never run the engine without the air cleaner Rapid engine wear will result fro...

Page 47: ...f and distribute the sealing pressure evenly To complete a tight seal apply pressure by hand at the outer rim of the filter not the flexible center Avoid pushing on the center of the urethane end cap...

Page 48: ...e coolant level by observing the level in the radiator Add 50 50 antifreeze water solution if the level is low by removing the radiator cap and adding coolant into the radiator Fill up to the To drain...

Page 49: ...ternal charger discon attach the charger leads After the battery is charged reconnect to do so can result in damage to the internal charger components Follow the instructions of the battery charger ma...

Page 50: ...ay between the pulleys For tightness requirements please refer to the Engine Owner s Manual NAMEPLATES WARNING DECALS MAINTENANCE Whenever routine maintenance is performed on this machine or at least...

Page 51: ...D should turn red Then press the RESET button The STATUS LED should turn green If the STATUS LED does not turn red and green as indicated or An electric shock can result in serious injury or death Alw...

Page 52: ...ghout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM L...

Page 53: ...e battery cable connections which may need Inspected cleaned or tightened 4 Faulty wiring in engine starting circuit 1 Out of fuel 2 Fuel shut off valve is in the off posi tion make sure the valve lev...

Page 54: ...2 Faulty engine alternator 3 Loose or broken lead in charging circuit 4 Loose fan belt may need tighten ing 1 Idler switch in HIGH idle position make sure switch is set to AUTO 2 Faulty Idler Switch 3...

Page 55: ...t OK No welding output Auxiliary output OK No auxiliary power 1 Faulty Idle Relay 1 Broken lead in rotor circuit 3 Faulty rotor 1 Faulty remote kit 2 Faulty output control potentiometer 3 Faulty outpu...

Page 56: ...ASS THROUGH TOROID THREE TIMES IN DIRECTION INDICATED 3 GND E 6 3D 5D LINE LOAD GFCI LINE LOAD GFCI SILVER J12 GREEN BLACK WHITE GRAY RED GREEN BLACK WHITE GRAY RED 3F 5B 5C 3E GND H GND G 6F 5E 6G J7...

Page 57: ...GRAY GREEN GND H GND G Fuel Level 229 Coolant temp J1 20 J1 21 D2 65A 66A 4200MFD 300V 5 J47 8 4 1 3 2 4 1 J46 65 66 40V BUS BOARD 66 65 CB4 10A 46 45 45 46A 46A 45 GND J C D E S2 5 PIN REMOTE B A ARC...

Page 58: ...2 25 57 2 20 60 523 3 28 95 735 3 29 50 749 3 60 00 1524 0 10 00 254 N A N A CENTER OF GRAVITY WITH OIL IN ENGINE COOLANT IN RADIATOR AND EMPTY FUEL TANK N B CASEFRONT GRAPHICS MAY NOT MATCH ALL CODE...

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Page 62: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 63: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 64: ...or communications Moreover the provision of such information or technical information does not create expand or alter any warranty on our products Any express or implied warranty that might arise fro...

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