Lincoln Electric Frontier 400X

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

The Lincoln Electric Frontier® 400X is a diesel engine-driven welding power source designed for multi-process welding and auxiliary power generation. It is available in two models: the Frontier® 400X and the Frontier® 400X Pipe, with the latter offering a specialized Pipe (SMAW) weld mode.

Function Description:

The Frontier® 400X provides constant current DC welding output for Stick (SMAW) and TIG (GTAW) welding, as well as constant voltage DC welding output for MIG (GMAW), Innershield (FCAW), Outershield (FCAW-G), and Metal Core (GMAW-C) welding. It can also be used for Arc Gouging with carbons up to 5/16" (8.0 mm) in diameter. In addition to welding, the machine provides 120/240 VAC single-phase and 240 VAC three-phase auxiliary power for jobsite tools and emergency standby power. The welding control system utilizes state-of-the-art Chopper Technology® for superior welding performance and a robust 7-inch graphical user interface display for simplified controls and advanced features. A key feature is CrossLinc® Technology, which enables remote control of welding output via weld cables, eliminating the need for a separate control cable.

Important Technical Specifications:

The Frontier® 400X is powered by either a Perkins® 403F-15T or a Kubota D1503-M EPA Tier 4 Final Compliant diesel engine.

Perkins Engine: 24.7 HP (18.4 kW) turbocharged water-cooled diesel engine with a displacement of 91.0 cu. in. (1.5L).
Kubota Engine: 24.8 HP (18.5 kW) water-cooled diesel engine with a displacement of 91.0 cu. in. (1.5L).
Fuel Tank Capacity: 20 US gallons (75.7L).
Oil Capacity: 6.40 qts. (6.0L) for Perkins, 5.90 qts. (5.6L) for Kubota.
Radiator Coolant Capacity: 7.20 qts. (6.8L).
Starting System: 12 VDC battery and starter, manual glow plugs, BCI Group Size 34 battery (650 Cold Crank Amps).
Engine Speed: High Idle 1800 RPM, Low Idle 1440 RPM, Full Load 1800 RPM.
Welding Output @ 104°F (40°C):
- 100% Duty Cycle: 325 Amps (DC multi-purpose) at 33 Volts.
- 60% Duty Cycle: 400 Amps (DC multi-purpose) at 26 Volts.
Welding Mode Output Ranges:
- Stick (SMAW): 30-400 Amps.
- Flux-Cored Self-Shielded (FCAW-S), MIG (GMAW), Flux-Cored Gas-Shielded (FCAW-G): 10 to 45 Volts.
- Arc Gouging (CAC-A): 60-400 Amps.
- DC TIG (GTAW): 5-400 Amps.
- Pipe (SMAW) (Frontier 400X Pipe model only): 30-400 Amps.
Open Circuit Voltage: 60 VDC Avg @1800 RPM, 71 VDC Peak @1800 RPM.
Auxiliary Power:
- 10,000 Watts Continuous / 11,500 Watts Peak, Single Phase (120 V/240 V, 60 Hz).
- 11,000 Watts Continuous / 12,500 Watts Peak, Three Phase (240 V, 60 Hz).
Receptacles: Two 120 VAC Duplex (5-20R) GFCI Protected (20 Amps each), one 240 VAC Three Phase (15-50R) (50 Amps), one 120/240 VAC Single Phase (14-50R) (50 Amps).
Physical Dimensions: Height 35.94 in. (913 mm), Width 25.30 in. (643 mm), Depth 60.00 in. (1524 mm).
Weight: 1035 lbs. (469 kg) (approximate weight less fuel).
Ingress Protection Rating: IP23.
IEC Standard: 60974-1.

Usage Features:

User Interface: A graphical user interface allows for easy navigation and selection of weld modes and settings.
Weld Mode Selection: Users can choose from Stick (SMAW), Flux-Cored Self-Shielded Wire (FCAW-S), Flux-Cored Gas-Shielded Wire (FCAW-G), MIG (GMAW), Gouging (CAC-A), TIG (GTAW), and Pipe (SMAW) (on Pipe model).
Weld Mode Settings: Each mode offers fine-tuning options like Arc Force, Hot Start, and Pinch to optimize arc performance.
VRD (Voltage Reduction Device): Reduces OCV at welding output terminals to less than 30 VDC when not welding, enhancing safety. VRD switches for CC and CV modes can be turned ON or OFF.
CrossLinc® Technology: Allows remote control of welding output (voltage or amperage) directly from a compatible wire feeder or remote control connected via the weld cables, eliminating the need for a separate control cable.
Memory Mode: Features four global memory slots to save and recall preferred weld modes and settings.
Auto-Stop/Start: A fuel-saving feature that automatically shuts off the engine after a period of inactivity and restarts it remotely when welding is needed. Configurable "No Load Period" and "Standby Period."
Productivity Metrics: Tracks Arc Hours, Auxiliary Hours, Utilization Percentage, Standby Hours, and Fuel Saved with Auto-Start, providing insights into machine usage.
Engine Status Screen: Displays real-time information on engine coolant temperature, oil pressure, battery voltage, and fuel level. It also monitors service intervals for oil, air filter, water separator, fuel filter, engine coolant, and alternator belt.
TIG Welding: Supports both Touch Start TIG (cleaner, less contamination) and Scratch Start TIG. Pulsed TIG can be activated by adjusting frequency to minimize burn-through on thin materials.
Pipe (SMAW) Mode: Specifically designed for downhill pipe welding, offering DigFX™™ arc tuning controls to adjust machine response time for optimal arc and puddle characteristics based on electrode, material, joint fit-up, and user technique.

Maintenance Features:

Routine and Periodic Maintenance: Daily checks include engine oil level, fuel tank refill to minimize moisture, draining water from the fuel pre-filter/water separator, cleaning the machine interior, and inspecting components for damage.
Engine Maintenance: Detailed schedules for engine oil and filter, air cleaner, fuel filter and delivery system, alternator belt, battery, and cooling system are provided.
Air Filter Service Indicator: Provides a visual Go/No-Go indication of filter service life, located inside the service door.
Fuel Filter Replacement: Step-by-step instructions for changing fuel filters, including closing the fuel shutoff valve, cleaning the area, filling the new filter with clean fuel, and lubricating the o-ring seal.
Cooling System: Instructions for checking and replacing coolant, emphasizing the use of a 50/50 antifreeze/water solution.
Battery Handling: Warnings and instructions for safe battery connection, charging, and preventing discharge and buckling.
Nameplates/Warning Decals: Regular inspection and replacement of illegible nameplates and labels are recommended.
GFCI Module: The machine is equipped with GFCI-protected 120 VAC duplex receptacles. Instructions for testing and resetting the GFCI are provided, with different procedures for modules manufactured before and after October 2021.
Troubleshooting Guide: A comprehensive guide to diagnose and resolve common machine malfunctions, categorized by symptoms and possible causes, with recommended courses of action.