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E-4

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

Engine goes to low idle but does 
not stay at low idle. 

No welding output or auxiliary
output.

Welder has some/ no output and no 
control. Auxiliary output 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 output control wiring.

1. Output terminals may be set to

Remote in the settings.

1. Open breakers may need to be

reset.

2. GFCI tripped.
3. Faulty breaker(s), receptacle, or

GFCI.

4. Faulty auxiliary circuit wiring.

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

2. Intermittent Auxiliary load
3. Remote trigger input is present.

Содержание 12716

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 59: ......

Страница 60: ......

Страница 61: ......

Страница 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...

Страница 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...

Страница 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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