Lincoln Electric Welding System IM883 A User Manual
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IM883-A  
VANTAGE ®400  
April, 2008  
For use with machines having Code Numbers:  
11186, 11462  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However, your  
overall safety can be increased by  
proper installation ... and thought-  
ful operation on your part. DO  
NOT INSTALL, OPERATE OR  
REPAIR THIS EQUIPMENT  
WITHOUT READING THIS  
MANUAL AND THE SAFETY  
PRECAUTIONS CONTAINED  
THROUGHOUT. And, most  
importantly, think before you act  
and be careful.  
Equipped with VRD (VOLTAGE REDUCTION DEVICE)  
See Installation and Operation sections for an explanation.  
OPERATOR’S MANUAL  
Copyright © Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically 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 equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
• AC Welder with Reduced Voltage Control.  
ventilation and/or exhaust at the arc to keep  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
5. b. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of  
the equipment, maintenance of the equipment and the spe-  
cific welding procedure and application involved. Worker  
exposure level should be checked upon installation and  
periodically thereafter to be certain it is within applicable  
OSHA PEL and ACGIH TLV limits.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
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.  
3.j. Also see Items 6.c. and 8.  
5.e. Read and understand the manufacturerʼs instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employerʼs safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
AUG 06  
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SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
6.a. Remove fire hazards from the welding area.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
If this is not possible, cover them to prevent  
process used and properly operating  
the welding sparks from starting a fire.  
regulators designed for the gas and  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact  
can cause overheating and create a fire hazard.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
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  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturerʼs  
recommendations.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturerʼs recommendations.  
6.h. Also see item 1.c.  
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available  
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma  
022690-9101.  
Jan, 07  
6.j. Do not use a welding power source for pipe thawing.  
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SAFETY  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque dʼincendie dû aux étincelles.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque dʼincendie.  
Sûreté Pour Soudage A LʼArc  
8. Sʼassurer que la masse est connectée le plus prés possible  
de la zone de travail quʼil est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou dʼautres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques dʼincendie ou dʼechauffement des chaines et des  
câbles jusquʼà ce quʼils se rompent.  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à lʼélectrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien sʼisoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher  
metallique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
d.Ne jamais plonger le porte-électrode dans lʼeau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode sʼapplicuent aussi au pistolet de  
soudage.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
dʼopérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de nʼimporte quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi quʼun verre blanc afin de se protéger les yeux du ray-  
onnement de lʼarc et des projections quand on soude ou  
quand on regarde lʼarc.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
lʻarc.  
c. Protéger lʼautre personnel travaillant à proximité au  
soudage à lʼaide dʼécrans appropriés et non-inflammables.  
1. Relier à la terre le chassis du poste conformement au code de  
lʼélectricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront  
effectués par un électricien qualifié.  
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-  
er à lʼinterrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de lʼarc de  
soudage. Se protéger avec des vêtements de protection libres  
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où lʼon pique le laitier.  
Mar. ʻ93  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
CUSTOMER ASSISTANCE POLICY  
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-  
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln  
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-  
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-  
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,  
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or  
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any  
warranty with respect to the sale of our products.  
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control  
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in  
applying these types of fabrication methods and service requirements.  
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com  
for any updated information.  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the  
time the shipment is received.  
Please record your equipment identification information below for future reference. This information can be  
found on your machine nameplate.  
Product _________________________________________________________________________________  
Model Number ___________________________________________________________________________  
Code Number or Date Code_________________________________________________________________  
Serial Number____________________________________________________________________________  
Date Purchased___________________________________________________________________________  
Where Purchased_________________________________________________________________________  
Whenever you request replacement parts or information on this equipment, always supply the information you  
have recorded above. The code number is especially important when identifying the correct replacement parts.  
On-Line Product Registration  
- Register your machine with Lincoln Electric either via fax or over the Internet.  
• For faxing: Complete the form on the back of the warranty statement included in the literature packet  
accompanying this machine and fax the form per the instructions printed on it.  
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then  
“Product Registration”. Please complete the form and submit your registration.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.  
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TABLE OF CONTENTS  
Page  
Installation.......................................................................................................................Section A  
Technical Specifications.......................................................................................................A-1  
Safety Precautions........................................................................................................A-2  
VRD (Voltage Reduction Device)..................................................................................A-2  
Location and Ventilation................................................................................................A-2  
Stacking ........................................................................................................................A-2  
Angle of Operation ........................................................................................................A-2  
Lifting.............................................................................................................................A-2  
High Altitude Operation.................................................................................................A-3  
High Temperature Operation ........................................................................................A-3  
Cold Weather Operation ...............................................................................................A-3  
Towing...........................................................................................................................A-3  
Vehicle Mounting...........................................................................................................A-3  
Pre-Operation Engine Service..............................................................................................A-3  
Oil..................................................................................................................................A-4  
Fuel ...............................................................................................................................A-4  
Engine Coolant..............................................................................................................A-4  
Battery Connections......................................................................................................A-4  
Muffler Outlet Pipe ........................................................................................................A-4  
Spark Arrester...............................................................................................................A-4  
Remote Control.............................................................................................................A-4  
Electrical Connections..........................................................................................................A-5  
Machine Grounding.......................................................................................................A-5  
Welding Terminals ........................................................................................................A-5  
Welding Output Cables .................................................................................................A-5  
Cable Installation...........................................................................................................A-5  
Auxiliary Power Receptacles and Plugs...............................................................................A-6  
Standby Power Connections................................................................................................A-6  
Premises Wiring...................................................................................................................A-7  
Connection of Lincoln Electric Wire Feeders.................................................................A-8,A-9  
________________________________________________________________________________  
Operation.........................................................................................................................Section B  
Safety Precautions ..............................................................................................................B-1  
General Description..............................................................................................................B-1  
For Auxiliary Power ..............................................................................................................B-1  
Engine Operation..................................................................................................................B-1  
Add Fuel...............................................................................................................................B-1  
Break in Period.....................................................................................................................B-1  
Welder Controls.............................................................................................................B-2,B-3  
Engine Controls....................................................................................................................B-4  
Starting and Stopping the Engine .................................................................................B-4  
Fuel Consumption.........................................................................................................B-4  
Welding Operation................................................................................................................B-5  
Duty Cycle and Electrode Information...........................................................................B-5  
Constant Current (Stick) Welding..................................................................................B-5  
Typical Current Ranges for Tungsten Electrodes .........................................................B-5  
Downhill Pipe (Stick) Welding .......................................................................................B-6  
Tig Welding ...................................................................................................................B-6  
Wire Welding-CV...........................................................................................................B-7  
Arc Gouging ..................................................................................................................B-7  
Auxiliary Power.....................................................................................................................B-7  
Simultaneous Welding and Power Loads .....................................................................B-7  
Extension Cord Recommendations...............................................................................B-7  
________________________________________________________________________________  
Accessories.....................................................................................................Section C  
Field Installed Options / Accessories ...............................................................................C-1  
________________________________________________________________________________  
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TABLE OF CONTENTS  
Maintenance......................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
Routine Maintenance ............................................................................................D-1  
Engine Service Items.............................................................................................D-1  
Engine Oil Change..........................................................................................D-2  
Engine Oil Filter Change.................................................................................D-2  
Air Cleaner .....................................................................................................D-2  
Service Instructions And Installation Tips for Engine Air Filter .......................D-3  
Cooling System .....................................................................................................D-4  
Fan Belt...........................................................................................................D-4  
Fuel.................................................................................................................D-4  
Bleeding the Fuel System...............................................................................D-4  
Fuel Filter........................................................................................................D-5  
Engine Adjustment..........................................................................................D-5  
Battery Maintenance .......................................................................................D-5  
Servicing Optional Spark Arrestor ...................................................................D-5  
Welder / Generator Maintenance ........................................................................D-6  
Storage ...........................................................................................................D-6  
Cleaning..........................................................................................................D-6  
Brush Removal and Replacement ..................................................................D-6  
GFCI Receptacle Testing and Resetting Procedure.......................................D-6  
________________________________________________________________________  
Troubleshooting..............................................................................................Section E  
How to Use Troubleshooting Guide.......................................................................E-1  
Troubleshooting Guide.............................................................................E-2 thru E-6  
________________________________________________________________________  
Connection Diagrams, Wiring Diagrams and Dimension Print...................Section F  
________________________________________________________________________  
Parts List.................................................................................................................P-528  
________________________________________________________________________  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - VANTAGE 400 (K2410-1) (K2410-2)  
INPUT - DIESEL ENGINE  
Make/Model  
Description  
Speed (RPM)  
Displacement  
Starting  
Capacities  
PERKINS  
cu. in. (ltrs.)  
System  
(K2410-1)  
404C-22  
4 cylinder  
32.7 HP  
135.6(2.2)  
12VDC Battery &  
starter  
Fuel: 15 gal.  
(57 L)  
High Idle 1880  
Full Load 1800  
Low Idle 1400  
1800 RPM  
naturally aspirated  
water cooled  
Bore x Stroke inch (mm) (Group 34; 650 Oil: 8.45Qts. (8L)  
cold crank amps)  
(K2410-2)  
404D-22  
3.43 X 3.64  
65 Amp Alternator Radiator Coolant:  
W / Built in Regulator 8.0 Qts. (7.6L)  
Diesel Engine  
(87.1 x 92.5mm)  
RATED OUTPUT @ 104° F (40° C) - WELDER  
Welding Process  
Welding Output  
Current/Voltage/Duty Cycle  
400A / 36V / 100%  
Output Range  
Max. Weld OCV  
@Rated Load RPM  
DC Constant Current  
450A / 32V / 100%  
30 TO 500 AMPS  
60 Volts2  
DC Pipe Current  
Touch-Start™TIG  
300A / 32V / 100%  
250A / 30V / 100%  
400A / 36V / 100%  
450A / 32V / 100%  
40 TO 300 AMPS  
20 TO 250 AMPS  
DC Constant Voltage  
14 TO 36 VOLTS  
.
RATED OUTPUT @ 104° F (40° C) - GENERATOR  
1
Auxiliary Power  
12,000 Watts Peak, / 11,000 Watts Continuous, 60 Hz 120/240 Volts Single Phase  
19,000 Watts Peak, / 17,000 Watts Continuous, 60 Hz, 240 Volts 3-Phase  
PHYSICAL DIMENSIONS  
HEIGHT  
35.94* in.  
913 mm  
WIDTH  
25.30 in  
643 mm  
DEPTH  
60.00 in.  
1524 mm  
WEIGHT  
1230 lbs. (559kg.)  
ENGINE  
LUBRICATION  
EMISSIONS  
(K2410-1) EPA Tier II  
FUEL SYSTEM  
GOVERNOR  
Full Pressure  
Mechanical Fuel Pump, Auto air bleed system  
Mechanical  
with Full Flow Filter (K2410-2) EPA Tier 4 interim Electric shutoff solenoid, Indirect fuel injector.  
Compliant  
ENGINE IDLER  
AIR CLEANER  
MUFFLER  
ENGINE PROTECTION  
Low noise Muffler:  
Shutdown on low oil  
Single Element  
Automatic Idler  
Top outlet can be rotated.  
pressure & high engine  
coolant temperature  
Made from long life, aluminized steel.  
ENGINE WARRANTY: 2 years / 2000 hours, all non-electric components, 3 years major non-electric compo-  
nents . See Perkins warranty for details.  
MACHINE SPECIFICATIONS  
RECEPTACLES  
AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS  
(2) 120VAC GFCI Duplex (5-20R)  
(1) 120/240VAC Dual Voltage  
Full KVA (14-50R)  
Two 20AMP for Two Duplex Receptacle  
(1) 50AMP for Dual Voltage and for  
3-Phase (3-pole)  
10AMP for Battery Charging Circuit  
10AMP for 42V Wire Feeder Power  
(1) 240VAC 3-Phase (15-50R)  
1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within 10% at all loads up to  
rated capacity. When welding, available auxiliary power will be reduced.  
* To Top of enclosure, add 10.68”(271.3mm) to top of exhaust pipe. Add 6.67”(169.4mm) to top of Lift Bail.  
2. Reduced to less than 32V in the CC-stick Mode when VRD (VOLTAGE REDUCTION DEVICE) is on.  
VANTAGE® 400  
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A-2  
A-2  
INSTALLATION  
SAFETY PRECAUTIONS  
LOCATION AND VENTILATION  
WARNING  
The welder should be located to provide an unrestrict-  
ed flow of clean, cool air to the cooling air inlets and to  
avoid restricting the cooling air outlets. Also, locate  
the welder so that the engine exhaust fumes are prop-  
erly vented to an outside area.  
Do not attempt to use this equipment until you  
have thoroughly read the engine manufacturerʼs  
manual supplied with your welder. It includes  
important safety precautions, detailed engine  
starting, operating and maintenance instructions,  
and parts lists.  
STACKING  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
VANTAGE 400 machines cannot be stacked.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
ANGLE OF OPERATION  
Engines are designed to run in the level condition  
which is where the optimum performance is achieved.  
The maximum angle of continuous operation is 25  
degrees in all directions, 35 degrees Intermittent (less  
than 10 minutes continuous) in all directions. If the  
engine is to be operated at an angle, provisions must  
be made for checking and maintaining the oil level at  
the normal (FULL) oil capacity in the crankcase.  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
When operating the welder at an angle, the effective  
fuel capacity will be slightly less than the amount  
specified.  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
• Keep away from moving parts.  
------------------------------------------------------------------------  
See additional warning information at  
LIFTING  
The VANTAGE 400 weighs approximately 1345lbs.  
(611kg.) with a full tank of fuel 1230lbs.(559kg) less  
fuel. A lift bail is mounted to the machine and should  
always be used when lifting the machine.  
front of this operatorʼs manual.  
Only qualified personnel should install,  
use, or service this equipment.  
VRD (VOLTAGE REDUCTION DEVICE)  
The VRD feature provides additional safety in the CC-Stick  
mode especially in an environment with a higher risk of  
electric shock such as wet areas and hot humid sweaty  
conditions.  
The VRD reduces the OCV (Open Circuit Voltage) at the  
welding output terminals while not welding to less than 32V  
DC when the resistance of the output circuit is above 200Ω  
(ohms).  
The VRD requires that the welding cable connections be  
kept in good electrical condition because poor connections  
will contribute to poor starting. Having good electrical con-  
nections also limits the possibility of other safety issues  
such as heat-generated damage, burns and fires.  
The machine is shipped with the VRD switch in the “Off”  
position. To turn it “On” or “Off”:  
• Turn the engine “Off”.  
• Disconnect the negative battery cable.  
• Lower the control panel.  
• Place the VRD switch in the “On or “Off” position.  
With the VRD switch in the “On” position, the VRD lights  
are enabled.  
VANTAGE® 400  
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A-3  
A-3  
INSTALLATION  
1. Design capacity of trailer vs. weight of Lincoln equipment and  
likely additional attachments.  
WARNING  
2. Proper support of, and attachment to, the base of the welding  
equipment so there will be no undue stress to the framework.  
3. Proper placement of the equipment on the trailer to insure  
stability side to side and front to back when being moved and  
when standing by itself while being operated or serviced.  
4. Typical conditions of use, i.e., travel speed; roughness of sur-  
face on which the trailer will be operated; environmental con-  
ditions; like maintenance.  
• Lift only with equipment of ade-  
quate lifting capacity.  
• Be sure machine is stable when lift-  
ing.  
• Do not lift this machine using lift  
bail if it is equipped with a heavy  
accessory such as trailer or gas  
cylinder.  
• Do not lift machine if lift bail is  
damaged.  
(1)  
5. Conformance with federal, state and local laws.  
FALLING  
EQUIPMENT can  
cause injury.  
(1) Consult applicable federal, state and local laws regarding specific requirements for use on public high-  
ways.  
• Do not operate machine while  
suspended from lift bail.  
VEHICLE MOUNTING  
--------------------------------------------------------------------------------  
WARNING  
HIGH ALTITUDE OPERATION  
At higher altitudes, output derating may be necessary. For max-  
imum rating, derate the machine 2.5% to 3.5% for every 1000 ft.  
(305m). Due to new EPA and other local emissions regulations,  
modifications to the engine for high altitude are restricted within  
the United States. For use above 6000 ft.(1828 m) an autho-  
rized Perkins engine field service shop should be contacted to  
determine if any adjustments can be made for operation in high-  
er elevations.  
Improperly mounted concentrated loads may  
cause unstable vehicle handling and tires or other  
components to fail.  
• Only transport this Equipment on serviceable  
vehicles which are rated and designed for such  
loads.  
• Distribute, balance and secure loads so vehicle  
is stable under conditions of use.  
HIGH TEMPERATURE OPERATION  
• Do not exceed maximum rated loads for compo-  
nents such as suspension, axles and tires.  
• Mount equipment base to metal bed or frame of  
vehicle.  
At temperatures above 104°F(40°C), Welder output derating is  
necessary. For maximum output ratings, derate the welder out-  
put 2 volts for every 18°F(10°C) above 104°F(40°C).  
• Follow vehicle manufacturerʼs instructions.  
------------------------------------------------------------------------  
Cold weather starting:  
With a fully charged battery and the proper oil, the engine  
should start satisfactorily down to -15°F(-26C°). If the engine  
must be frequently started at or below 0°F (-18°C), it may be  
desirable to install cold-starting aides. The use of No. 1D  
diesel fuel is recommended in place of No. 2D at tempera-  
tures below 23°F (-5°C). Allow the engine to warm up before  
applying a load or switching to high idle.  
PRE-OPERATION ENGINE SERVICE  
READ the engine operating and maintenance instruc-  
tions supplied with this machine.  
WARNING  
• Stop engine and allow to cool before fueling  
• Do not smoke when fueling.  
Note: Extreme cold weather starting may require  
• Fill fuel tank at a moderate rate and do not over-  
fill.  
longer glow plug operation.  
• Wipe up spilled fuel and allow fumes to clear  
before starting engine.  
WARNING  
• Keep sparks and flame away from tank.  
------------------------------------------------------------------------  
Under no conditions should ether or other starting  
fluids be used with this engine!  
------------------------------------------------------------------------  
TOWING  
Use a recommended trailer for use with this equipment for road,  
in-plant and yard towing by a vehicle(1). If the user adapts a  
non-Lincoln trailer, he must assume responsibility that the  
method of attachment and usage does not result in a safety  
hazard or damage the welding equipment. Some of the factors  
to be considered are as follows:  
VANTAGE® 400  
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A-4  
OIL  
A-4  
INSTALLATION  
NOTE: This machine is furnished with a wet charged  
battery; if unused for several months, the battery may  
require a booster charge. Be careful to charge the bat-  
tery with the correct polarity. (See Battery in  
“Maintenance Section”)  
The VANTAGE 400 is shipped with the engine  
crankcase filled with high quality SAE 10W-30 Oil that  
meets classification CG-4 or CH-4 for diesel engines.  
Check the oil level before starting the engine. If it is  
not up to the full mark on the dip stick, add oil as  
required. Check the oil level every four hours of run-  
ning time during the first 50 running hours. Refer to  
the engine Operatorʼs Manual for specific oil recom-  
mendations and break-in information. The oil change  
interval is dependent on the quality of the oil and the  
operating environment. Refer to the Engine Operatorʼs  
Manual for more details on the proper service and  
maintenance intervals.  
MUFFLER OUTLET PIPE  
Using the clamp provided secure the outlet pipe to the  
outlet tube with the pipe positioned such that it will  
direct the exhaust in the desired direction. Tighten  
using a 9/16" socket or wrench.  
SPARK ARRESTER  
Some federal, state or local laws may require that  
gasoline or diesel engines be equipped with exhaust  
spark arresters when they are operated in certain  
locations where unarrested sparks may present a fire  
hazard. The standard muffler included with this welder  
does not qualify as a spark arrester. When required by  
local regulations, a suitable spark arrester, such as  
the K903-1 must be installed and properly maintained.  
FUEL  
DIESEL FUEL ONLY-Low sulphur fuel or ultra  
low sulphur fuel in U.S.A. and Canada.  
WARNING  
• Fill the fuel tank with clean, fresh fuel. The  
capacity of the tank is 15 gals. (57 ltrs). When  
the fuel gauge reads empty the tank contains  
approximately 2 gals. (7.6ltrs.) of reserve fuel.  
WARNING  
An incorrect spark arrestor may lead to damage to  
the engine or adversely affect performance.  
------------------------------------------------------------------------  
REMOTE CONTROL  
WARNING  
NOTE: A fuel shut off valve is located on the pre-  
filter/sediment filter. Which should be in  
the closed position when the welder is not  
used for extended periods of time.  
The VANTAGE 400 is equipped with a 6-pin and a 14-  
pin connector. The 6-pin connector is for connecting  
the K857 or K857-1 Remote Control or for TIG weld-  
ing, the K870 foot Amptrol or the K963-3 hand  
Amptrol. When in the CC-STICK, DOWNHILL PIPE,  
or CV-WIRE modes and when a remote control is  
connected to the 6-pin Connector, the auto-sensing  
circuit automatically switches the OUTPUT control  
from control at the welder to remote control.  
------------------------------------------------------------------------  
WARNING  
ENGINE COOLING SYSTEM  
Air to cool the engine is drawn in the side and  
exhausted through radiator & case back. It is  
important that the intake and exhaust air is not  
restricted. Allow a minimum clearance of 1ft.  
(0.6m) from the case back and 16in.(406mm) from  
either side of the base to a vertical surface.  
When in TOUCH START TIG mode and when a  
Amptrol is connected to the 6-Pin Connector, the  
OUTPUT dial is used to set the maximum current  
range of the CURRENT CONTROL of the Amptrol.  
The 14-pin connector is used to directly connect a  
wire feeder control cable. In the CV-WIRE mode,  
when the control cable is connected to the 14-pin con-  
nector, the auto-sensing circuit automatically makes  
the Output Control inactive and the wire feeder volt-  
age control active  
------------------------------------------------------------------------  
CAUTION  
BATTERY CONNECTION  
Use caution as the electrolyte is a strong acid that  
can burn skin and damage eyes.  
------------------------------------------------------------------------  
The VANTAGE 400 is shipped with the negative bat-  
tery cable disconnected. Make certain that the RUN-  
STOP switch is in the STOP position. Remove the two  
screws from the battery tray using a screwdriver or a  
3/8" socket. Attach the negative battery cable to the  
negative battery terminal and tighten using a 1/2"  
socket or wrench.  
WARNING  
NOTE: When a wire feeder with a built in welding  
voltage control is connected to the 14-pin connec-  
tor, do not connect anything to the 6-pin connec-  
tor.  
------------------------------------------------------------------------  
VANTAGE® 400  
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A-5  
A-5  
INSTALLATION  
WELDING OUTPUT CABLES  
ELECTRICAL CONNECTIONS  
With the engine off connect the electrode and work  
cables to the output studs. The welding process dic-  
tates the polarity of the electrode cable. These con-  
nections should be checked periodically and tightened  
with a 3/4" wrench.  
MACHINE GROUNDING  
Because this portable engine driven welder creates its  
own power, it is not necessary to connect its frame to  
an earth ground, unless the machine is connected to  
premises wiring (home, shop, etc.)  
Table A.1 lists recommended cable sizes and lengths  
for rated current and duty cycle. Length refers to the  
distance from the welder to the work and back to the  
welder. Cable diameters are increased for long cable  
lengths to reduce voltage drops.  
To prevent dangerous electric shock, other equipment  
to which this engine driven welder supplies power  
must:  
TABLE A.1  
WARNING  
TOTAL COMBINED LENGTH OF  
ELECTRODE AND WORK CABLES  
• Be grounded to the frame of the welder using a  
grounded type plug or be double insulated.  
• Do not ground the machine to a pipe that carries  
explosive or combustible material.  
Cable Size for  
Cable Length  
400 Amps  
60% Duty Cycle  
2 / 0 AWG  
------------------------------------------------------------------------  
0-100 Ft. (0-30 meters)  
When this welder is mounted on a truck or trailer, its  
frame must be electrically bonded to the metal frame  
of the vehicle. Use a #8 or larger copper wire connect-  
ed between the machine grounding stud and the  
frame of the vehicle. When this engine driven welder  
is connected to premises wiring such as that in a  
home or shop, its frame must be connected to the  
system earth ground. See further connection instruc-  
tions in the section entitled "Standby Power  
Connections" as well as the article on grounding in the  
latest National Electrical Code and the local code.  
2 / 0 AWG  
3 / 0 AWG  
100-150 Ft. (30-46 meters)  
150-200 Ft. (46-61 meters)  
CABLE INSTALLATION  
Install the welding cables to your VANTAGE 400 as  
follows.  
1. The engine must be OFF to install welding cables.  
In general, if the machine is to be grounded, it should  
be connected with a #8 or larger copper wire to a solid  
earth ground such as a metal water pipe going into  
the ground for at least ten feet and having no insulat-  
ed joints, or to the metal framework of a building  
which has been effectively grounded.  
2. Remove the flanged nuts from the output terminals  
.
3. Connect the electrode holder and work cables to  
the weld output terminals. The terminals are identi-  
fied on the case front.  
The National Electrical Code lists a number of alter-  
nate means of grounding electrical equipment. A  
machine grounding stud marked with the symbol  
is provided on the front of the welder.  
4. Tighten the flanged nuts securely.  
5. Be certain that the metal piece you are welding (the  
“work”) is properly connected to the work clamp and  
cable.  
WELDING TERMINALS  
6. Check and tighten the connections periodically.  
The VANTAGE 400 is equipped with a toggle switch  
for selecting "hot" welding terminal when in the  
"WELD TERMINALS ON" position or "cold" welding  
terminal when in the "REMOTELY CONTROLLED"  
position.  
CAUTION  
• Loose connections will cause the output termi-  
nals to overheat. The terminals may eventually  
melt.  
• Do not cross the welding cables at the output ter-  
minal connection. Keep the cables isolated and  
separate from one another.  
------------------------------------------------------------------------  
VANTAGE® 400  
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A-6  
A-6  
INSTALLATION  
All auxiliary power is protected by circuit breakers.  
The 120V has 20 Amp circuit breakers for each  
duplex receptacle. The 120/240V Single Phase and  
the 240V Three-Phases have a 50 Amp 3-pole Circuit  
Breaker that disconnects both hot leads and all Three  
Phases simultaneously.  
AUXILIARY POWER RECEPTACLES  
Start the engine and set the “IDLER” control switch to  
the “High Idle” mode. Voltage is now correct at the  
receptacles for auxiliary power. This must be done  
before a tripped GFCI receptacle can be reset proper-  
ly. See the MAINTENANCE section for more detailed  
information on testing and resetting the GFCI recepta-  
cle.  
STANDBY POWER CONNECTIONS  
The VANTAGE 400 is suitable for temporary, standby  
or emergency power using the engine manufacturerʼs  
recommended maintenance schedule.  
The auxiliary power of the VANTAGE 400 consists of  
two 20 Amp-120 VAC (5-20R) duplex receptacles with  
GFCI protection, one 50 Amp 120/240 VAC (14-50R)  
receptacle and one 50 Amp 240VAC Three-Phase (15-  
50R) receptacle.  
The VANTAGE 400 can be permanently installed as  
a standby power unit for 240 VAC, 3 wire, single  
phase, 50 amp service. Connections must be made  
by a licensed electrician who can determine how the  
120/240 VAC power can be adapted to the particular  
installation and comply with all applicable electrical  
codes.  
The auxiliary power capacity is 12,000 watts Peak,  
11,000 Watts Continuous of 60 Hz, single phase  
power. The auxiliary power capacity rating in watts is  
equivalent to volt-amperes at unity power factor. The  
max permissible current of the 240 VAC output is  
50amps.  
• Install the double-pole, double-throw switch  
between the power company meter and the premis-  
es disconnect. Switch rating must be the same or  
greater than the customerʼs premises disconnect  
and service over current protection.  
The 240 VAC output can be split to provide two sepa-  
rate 120 VAC outputs with a max permissible current  
of 50 Amps per output to two separate 120 VAC  
branch circuits (these circuits cannot be paralleled).  
Output voltage is within 10% at all loads up to rated  
capacity.  
• Take necessary steps to assure load is limited to  
the capacity of the generator by installing a 50  
amp, 240 VAC double pole circuit breaker.  
Maximum rated load for each leg of the 240 VAC  
auxiliary is 50 amperes. Loading above the rated  
output will reduce output voltage below the allow-  
able - 10% of rated voltage which may damage  
appliances or other motor-driven equipment and  
may result in overheating of the engine and/or  
alternator windings.  
The Three-Phases auxiliary power capacity is 19,000  
watts peak, 17,000 watts continuous. The maximum  
current is 45 amps.  
120 V GFCI DUPLEX RECEPTACLES  
A GFCI (Ground Fault Circuit Interrupter) electrical  
receptacle is a device to protect against electric shock  
should a piece of defective equipment connected to it  
develop a ground fault. If this situation should occur,  
the GFCI will trip, removing voltage from the output of  
the receptacle. If a GFCI receptacle is tripped see the  
MAINTENANCE section for detailed information on  
testing and resetting it. A GFCI receptacle should be  
properly tested at least once every month.  
• Install a 50 amp, 120/240 VAC plug (NEMA Type  
14-50P) to the double-pole circuit breaker using  
No. 6, 4 conductor cable of the desired length. (The  
50 amp, 120/240 VAC plug is available in the  
optional K802R plug kit or as part number T12153-  
9.)  
• Plug this cable into the 50 Amp, 120/240 Volt  
receptacle on the case front.  
The 120 V auxiliary power receptacles should only be  
used with three wire grounded type plugs or approved  
double insulated tools with two wire plugs. The current  
rating of any plug used with the system must be at  
least equal to the current capacity of the associated  
receptacle.  
NOTE: The 240 V receptacle has two 120 V circuits,  
but are of opposite polarities and cannot be paralleled.  
VANTAGE® 400  
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A-7  
A-7  
INSTALLATION  
CONNECTION OF VANTAGE 400 TO PREMISES WIRING  
WARNING  
• Only a licensed, certified, trained electrician should install the machine to a premises or residential  
electrical system. Be certain that:  
• The installation complies with the National Electrical Code and all other applicable electrical codes.  
• The premises is isolated and no feedback into the utility system can occur. Certain state and local  
laws require the premises to be isolated before the generator is linked to the premises. Check your  
state and local requirements.  
• A double pole, double throw transfer switch in conjunction with the properly rated double throw  
circuit breaker is connected between the generator power and the utility meter.  
VANTAGE® 400  
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A-8  
A-8  
INSTALLATION  
4. Control Cable Model:  
CONNECTION OF LINCOLN ELECTRIC  
WIRE FEEDERS  
• Connect Control Cable between Engine Welder  
and Feeder.  
Connection of LN-7 or LN-8 to the VANTAGE 400  
1. Shut the welder off.  
• Set the "WELD TERMINALS" switch to  
"REMOTELY CONTROLLED"  
• Set the MODE switch to the "CV-WIRE " position.  
2. Connect the LN-7 or LN-8 per instructions on the  
appropriate connection diagram in Section F.  
• Set the "WIRE FEEDER VOLTMETER" switch to  
either "+" or "-" as required by the electrode polar-  
ity being used.  
3. Set the "WIRE FEEDER VOLTMETER" switch to  
either "+" or "-" as required by the electrode being  
used.  
• Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
4. Set the "MODE" switch to the "CV WIRE " posi-  
tion.  
• Set the "IDLE" switch to the "AUTO" position.  
5. Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
• When the gun trigger is closed, the current sens-  
ing circuit will cause the VANTAGE 400 engine to  
go to the high idle speed, the wire will begin to  
feed and the welding process started. When  
welding is stopped, the engine will revert to low  
idle speed after approximately 12 seconds unless  
welding is resumed.  
6. Set the "WELD TERMINALS" switch to the  
"REMOTELY CONTROLLED" position.  
7. Set the "IDLE" switch to the "HIGH" position.  
Connection of LN-15 to the VANTAGE 400  
1. Shut the welder off.  
2. For electrode Positive, connect the electrode  
cable to the "+" terminal of the welder and work  
cable to the "-" terminal of the welder. For elec-  
trode Negative, connect the electrode cable to the  
"-" terminal of the welder and work cable to the "+"  
terminal of the welder.  
3. Across The-Arc Model:  
• Attach the single lead from the front of the LN-15  
to work using the spring clip at the end of the  
lead. This is a control lead to supply current to  
the wire feeder motor; it does not carry welding  
current.  
• Set the "WELD TERMINALS" switch to "WELD  
TERMINALS ON".  
• When the gun trigger is closed, the current sens-  
ing circuit will cause the VANTAGE 400 engine  
to go to the high idle speed, the wire will begin to  
feed and the welding process started. When  
welding is stopped, the engine will revert to low  
idle speed after approximately 12 seconds  
unless welding is resumed.  
VANTAGE® 400  
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A-9  
A-9  
INSTALLATION  
Spool Gun (K487-25) and Cobramatic to VANTAGE  
WARNING  
400  
Connection of the LN-25 to the VANTAGE 400  
Shut off welder before making any electrical con-  
nections.  
• Shut the welder off.  
• Connect per instructions on the appropriate connec-  
tion diagram in Section F.  
------------------------------------------------------------------------  
The LN-25 with or without an internal contactor may  
be used with the VANTAGE 400. See the appropriate  
connection diagram in Section F.  
Connection of PRINCE XL SPOOL GUN to the  
VANTAGE 400  
1. Shut the welder off.  
Connection of the Prince XL Spool Gun requires the  
use of the K1849-1 Adapter Module.  
2. For electrode Positive, connect the electrode  
cable from the LN-25 to the "+" terminal of the  
welder and work cable to the "-" terminal of the  
welder. For electrode Negative, connect the elec-  
trode cable from the LN-25 to the "-" terminal of  
the welder and work cable to the "+" terminal of  
the welder.  
• Shut the Welder off.  
• For electrode Positive, connect the electrode cable  
to the "+" terminal of the welder and work cable to  
the "-" terminal of the welder. For electrode  
Negative, connect the electrode cable "-" terminal of  
the welder and work cable to the "+" terminal of the  
welder.  
3. Attach the single lead from the front of the LN-25  
to work using the spring clip at the end of the lead.  
This is a control lead to supply current to the wire  
feeder motor; it does not carry welding current.  
• Connect the Control Cable of the Spool Gun to the  
Adapter Module and connect the Control Cable of  
the Adapter Module to the Welder.  
4. Set the MODE switch to the "CV-WIRE " position.  
• Connect the Gas Hose.  
5. Set the "WELD TERMINALS" switch to "WELD  
TERMINALS ON"  
• Set the MODE switch to the "CV-WIRE " position.  
6. Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
• Set the "WELD TERMINALS" switch to "WELD  
TERMINALS ON".  
7. Set the "IDLE" switch to the "AUTO" position.  
When not welding, the VANTAGE 400 engine will  
be at the low idle speed. If you are using an LN-25  
with an internal contactor, the electrode is not  
energized until the gun trigger is closed.  
• Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
• Set the “IDLE” switch to the “HIGH” position.  
8. When the gun trigger is closed, the current sens-  
ing circuit will cause the VANTAGE 400 engine to  
go to the high idle speed, the wire will begin to  
feed and the welding process started. When weld-  
ing is stopped, the engine will revert to low idle  
speed after approximately 12 seconds unless  
welding is resumed.  
CAUTION  
If you are using an LN-25 without an internal con-  
tactor, the electrode will be energized when the  
VANTAGE 400 is started.  
------------------------------------------------------------------------  
VANTAGE® 400  
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B-1  
B-1  
OPERATION  
• Add oil (if necessary) to bring the level up to the full  
mark. Do not overfill. Close engine door.  
• Check radiator for proper coolant level. (Fill if nec-  
essary).  
SAFETY PRECAUTIONS  
WARNING  
• See Engine Ownerʼs Manual for specific oil and  
coolant recommendations.  
Do not attempt to use this equipment until you  
have thoroughly read the engine manufacturerʼs  
manual supplied with your welder. It includes  
important safety precautions, detailed engine  
starting, operating and maintenance instructions,  
and parts lists.  
WARNING  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
ADD FUEL  
• Stop engine while fueling.  
• Do not smoke when fueling.  
• Keep sparks and flame away  
from tank.  
• Do not leave unattended  
while fueling.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
• Always wear dry insulating gloves.  
• Always operate the welder with the hinged door  
closed and the side panels in place.  
• Wipe up spilled fuel and allow  
fumes to clear before starting  
DIESEL FUEL  
can cause fire.  
• Read carefully the Safety Precautions page  
before operating this machine. Always follow  
these and any other safety procedures included  
in this manual and in the Engine Instruction  
Manual.  
engine.  
• Do not overfill tank, fuel  
expansion may cause over-  
flow.  
DIESEL FUEL ONLY- Low sulphur fuel or ultra low  
sulphur fuel in U.S.A. and Canada.  
------------------------------------------------------------------------  
• Remove the fuel tank cap.  
GENERAL DESCRIPTION  
The VANTAGE 400 is a diesel engine powered DC  
multi-process welding power source and 120 / 240  
volt AC power generator. The engine drives a genera-  
tor that supplies three phase power for the DC weld-  
ing circuit, single phase and Three Phase power for  
the AC auxiliary outlets. The DC welding control sys-  
• Fill the tank. DO NOT FILL THE TANK TO THE  
POINT OF OVERFLOW.  
• Replace the fuel cap and tighten securely.  
™
tem uses state of the art Chopper Technology (CT  
)
• See Engine Ownerʼs Manual for specific fuel recom-  
mendations.  
for superior welding performance.  
The Vantage 400 is fitted with a selectable  
VRD(Voltage Reduction Device). The VRD operates  
in the CC-Stick mode reducing the OCV to <13 volts,  
increasing operator safety when welding is performed  
in environments with increased hazard of electric  
shock.  
BREAK-IN PERIOD  
The engine will use a small amount of oil during its  
“break-in” period. The break-in period is about 50 run-  
ning hours.  
Check the oil every four hours during break-in.  
Change the oil after the first 50 hours of operation and  
every 200 hours thereafter. Change the oil filter at  
each oil change.  
FOR AUXILIARY POWER:  
Start the engine and set the IDLER control switch to  
the desired operating mode. Full power is available  
regardless of the welding control settings providing no  
welding current is being drawn.  
CAUTION  
ENGINE OPERATION  
During break-in, subject the Welder to moderate  
loads. Avoid long periods running at idle. Before  
stopping the engine, remove all loads and allow  
the engine to cool several minutes.  
Before Starting the Engine:  
• Be sure the machine is on a level surface.  
------------------------------------------------------------------------  
• Open side engine door and remove the engine oil  
dipstick and wipe it with a clean cloth. Reinsert the  
dipstick and check the level on the dipstick.  
VANTAGE® 400  
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B-2  
B-2  
11  
OPERATION  
FIGURE B.1  
1
2
9
3
4
10  
14  
13  
12  
17  
15  
8
7
16  
21  
18  
19  
20  
5
6
WELDING CONTROLS (Figure B.1)  
2. DIGITAL OUTPUT METERS-The digital  
meters allow the output voltage (CV-WIRE mode)  
or current (CC-STICK,DOWN HILL PIPE and TIG  
modes) to be set prior to welding using the OUT-  
PUT control dial. During welding, the meter display  
the actual output voltage (VOLTS) and current  
(AMPS). A memory feature holds the display of  
both meters on for seven seconds after welding is  
stopped. This allows the operator to read the actual  
current and voltage just prior to when welding was  
ceased.  
1. OUTPUT CONTROL- The OUTPUT dial is  
used to preset the output voltage or current as dis-  
played on the digital meters for the four welding  
modes. When in the CC-STICK, DOWNHILL PIPE  
or CV-WIRE modes and when a remote control is  
connected to the 6-Pin or 14-Pin Connector, the  
auto-sensing circuit automatically switches the  
OUTPUT CONTROL from control at the welder to  
the remote control.  
While the display is being held the left-most deci-  
mal point in each display will be flashing. The  
accuracy of the meters is +/- 3%.  
In the CV-WIRE mode, if the feeder being used has  
a voltage control when the wire feeder control cable  
is connected to the 14-Pin Connector, the auto-  
sensing circuit automatically makes OUTPUT CON-  
TROL inactive and the wire feeder voltage control  
active. Otherwise, the OUTPUT CONTROL is used  
to preset the voltage  
3. WELD MODE SELECTOR SWITCH-  
(Provides four selectable welding modes)  
CV-WIRE  
DOWNHILL PIPE  
CC-STICK  
When in the TOUCH START TIG mode and when  
an Amptrol is connected to the 6-Pin Connector, the  
OUTPUT dial is used to set the maximum current  
range of the CURRENT CONTROL of the Amptrol.  
TOUCH START TIG  
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B-3  
B-3  
OPERATION  
10. WIRE FEEDER VOLTMETER SWITCH:  
4. ARC CONTROL- The ARC CONTROL dial is active in  
the CV-WIRE, CC-STICK and DOWNHILL PIPE modes,  
and has different functions in these modes. This control is  
not active in the TIG mode.  
Matches the polarity of the wire feeder voltmeter to  
the polarity of the electrode.  
11. VRD (Voltage Reduction Device) INDICA-  
TOR LIGHTS- On the front panel of the Vantage  
400 are two indicator lights. A red light when lit indi-  
cates OCV(Open Circuit Voltage) is equal to or  
greater than 32V and a green light when lit indicates  
OCV(Open Circuit Voltage) is less than 32V.  
CC-STICK mode: In this mode, the ARC CONTROL dial  
sets the short circuit current (arc-force) during stick welding  
to adjust for a soft or crisp arc. Increasing the dial from –10  
(soft) to +10 (crisp) increases the short circuit current and  
prevents sticking of the electrode to the plate while welding.  
This can also increase spatter. It is recommended that the  
ARC CONTROL be set to the minimum number without  
electrode sticking. Start with a setting at 0.  
The VRD “On/Off” switch inside the control panel  
must be “On” for the VRD function to be active and  
the lights to be enabled. When the machine is first  
started with VRD enabled, both lights will illuminate  
for 5 seconds.  
DOWNHILL PIPE mode: In this mode, the ARC CONTROL  
dial sets the short circuit current (arc-force) during stick  
welding to adjust for a soft or a more forceful digging arc  
(crisp). Increasing the number from –10 (soft) to +10 (crisp)  
increases the short circuit current which results in a more  
forceful digging arc. Typically a forceful digging arc is pre-  
ferred for root and hot passes. A softer arc is preferred for fill  
and cap passes where weld puddle control and deposition  
("stacking" of iron) are key to fast travel speeds. It is recom-  
mended that the ARC CONTROL be set initially at 0.  
These lights monitor the OCV(Open Circuit Voltage)  
and weld voltage at all times. In the CC-Stick mode  
when not welding the green light will illuminate indi-  
cating that the VRD has reduced the OCV to less  
than 32V. During welding the red light will illuminate  
whenever the arc voltage is equal to or greater than  
32V. This means that the red and green light may  
alternate depending on the weld voltage. This is nor-  
mal operation.  
CV-WIRE mode: In this mode, turning the ARC CONTROL  
clock wise from –10 (soft) to +10 (crisp) changes the arc  
from soft and washed-in to crisp and narrow. It acts as an  
inductance/pinch control. The proper setting depends on the  
procedure and operator preference. Start with a setting of 0.  
If the red light remains illuminated when not welding  
in the CC-stick mode, the VRD is not functioning  
properly. Please refer to your local field service shop  
for service.  
5. WELD OUTPUT TERMINALS WITH FLANGE  
NUT- Provides a connection point for the electrode and  
If the VRD is turned “On” and the lights donʼt come  
“On”, refer to the trouble shooting section.  
work cables.  
6. GROUND STUD-  
Provides a connection point for  
TABLE B.1  
connecting the machine case to earth ground.  
VRD INDICATOR LIGHTS  
MODE  
CC-STICK OCV  
While  
VRD "ON"  
Green (OCV Reduced)  
Red or Green  
VRD "OFF"  
No Lights  
7. 14-PIN CONNECTOR- For attaching wire feeder con-  
trol cables. Includes contactor closure circuit, auto-sensing  
remote control circuit, and 120V and 42V power. The  
remote control circuit operates the same as the 6 Pin  
Amphenol.  
Welding (Depends on Weld Voltage) *  
CV-WIRE OCV  
Red (OCV Not Reduced)  
Weld Terminals On  
Red (OCV Not Reduced)  
Weld Terminals Remotely Controlled  
Gun Trigger Closed  
8. 6-PIN CONNECTOR- For attaching optional remote  
control equipment. Includes auto-sensing remote control  
circuit.  
Green (No OCV)  
Weld Terminals Remotely Controlled  
Gun Trigger Open  
While  
Red or Green  
Welding (Depends on Weld Voltage) *  
PIPE  
TIG  
OCV  
Green (No Output)  
9. WELD TERMINALS CONTROL SWITCH- In the  
WELD TERMINALS ON position, the output is electrically  
hot all the time. In the REMOTELY CONTROLLED posi-  
tion, the output is controlled by a wire feeder or amptrol  
device, and is electrically off until a remote switch is  
While  
Not Applicable (No Output)  
Welding  
OCV  
Green (Process is Low Voltage)  
Green (Process is Low Voltage)  
While  
Welding  
depressed.  
* It is normal for the lights to alternate between colors while welding.  
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B-4  
B-4  
OPERATION  
17. ENGINE HOUR METER- Displays the total time  
that the engine has been running. This meter is useful  
for scheduling prescribed maintenance.  
ENGINE CONTROLS:  
12. RUN/STOP SWITCH - RUN position energizes the  
engine prior to starting. STOP position stops the  
engine. The oil pressure interlock switch prevents bat-  
tery drain if the switch is left in the RUN position and  
the engine is not operating.  
18. ENGINE PROTECTION LIGHT- A warning indi-  
cator light for Low Oil Pressure and/or Coolant Over  
Temperature.The light is off when the systems are func-  
tioning properly. The light will come on and the engine  
will shutdown when there is Low Oil Pressure and/or  
the Coolant is Over Temperature.  
13. GLOW PLUG PUSH BUTTON  
-
• When pushed activates the glow plugs. Glow plug  
should not be activated for more than 20 seconds con-  
tinuously.  
Note: The light remains off when the RUN-STOP switch  
is in the "ON" position prior to starting the  
engine.However if the engine is not started within 60  
seconds the light will come on. When this happens the  
RUN-STOP switch must be returned to the "OFF" posi-  
tion to reset the engine protection system and light.  
14. START PUSH BUTTON  
-
Energizes the starter  
motor to crank the engine.  
15. IDLER SWITCH- Has two positions as follows:  
1) In the HIGH position, the engine runs at the high idle  
speed controlled by the engine governor.  
19. BATTERY CHARGING LIGHT- A warning indica-  
tor light for Low/No battery charge. The light is off when  
the systems are functioning properly. The light will  
come on if there is a Low/No battery condition but the  
machine will continue to run.  
2) In the AUTO position, the idler operates as follows:  
• When switched from HIGH to AUTO or after starting  
the engine, the engine will operate at full speed for  
approximately 12 seconds and then go to low idle  
speed.  
Note: The light may or may not come on when the RUN-  
STOP switch is in the "ON" position. It will come on during  
cranking and stay on until the engine starts. After starting  
the engine the light will go off unless a Low/No battery  
charge condition exists.  
• When the electrode touches the work or power is  
drawn for lights or tools (approximately 100 Watts mini-  
mum), the engine accelerates and operates at full  
speed.  
• When welding ceases or the AC power load is turned  
off, a fixed time delay of approximately 12 seconds  
starts. If the welding or AC power load is not restarted  
before the end of the time delay, the idler reduces the  
engine speed to low idle speed.  
20. COOLANT TEMPERATURE GAUGE-A indica-  
tor of engine coolant temperature.  
• The engine will automatically return to high idle speed  
when there is welding load or AC power load reapplied.  
21. OIL PRESSURE GAUGE- A indicator of engine  
Oil Pressure.  
16. ELECTRIC FUEL GAUGE- The electric fuel  
gauge gives accurate and reliable indication as to how  
much fuel is in the fuel tank.  
STARTING THE ENGINE  
1. Remove all plugs connected to the AC power recepta-  
cles.  
2. Set IDLER switch to AUTO.  
TABLE B.2  
3. Press Glow Plug Button and hold 15 to 20 seconds.  
4. Set the RUN/STOP switch to RUN.  
TYPICAL VANTAGE 400 FUEL CONSUMPTION  
PERKINS 404C-22 & 404D-22  
Running Time for  
15 gallons / hours  
5. Press START button until the engine starts or for up to  
10 seconds. Continue to hold the glow plug button for up  
to an additional 10 seconds.  
Gal./Hr (Liters/Hr)  
Low Idle - No Load  
1400 R.P.M.  
.26 (.97)  
58.59  
36.06  
6. Release the engine START button immediately  
the engine starts.  
when  
High Idle - No Load  
1880 R.P.M.  
.42 (1.57)  
7. The engine will run at high idle speed for approximately  
12 seconds and then drop to low idle speed. Allow the  
engine to warm up at low idle for several minutes before  
applying a load and/or switching to high idle. Allow a  
longer warm up time in cold weather.  
DC Weld Output  
1.18 (4.46)  
1.24 (4.68)  
.90 (3.42)  
400 Amps @ 36 Volts  
17,000 Watts 3 Phase  
11,000 Watts 1 Phase  
12.74  
12.14  
16.62  
NOTE: This data is for reference only. Fuel consump-  
tion is approximate and can be influenced by many  
factors, including engine maintenance, environmental  
conditions and fuel quality.  
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B-5  
B-5  
OPERATION  
TROL dial adjusts the full output range for stick weld-  
NOTE: If the unit fails to start turn Run/Stop switch  
ing.  
to off and repeat step 3 through step 7 after  
waiting 30 seconds.  
The ARC CONTROL dial sets the short circuit current  
(arc-force) during stick welding to adjust for a soft or  
crisp arc. Increasing the number from -10(soft) to  
+10(crisp) increases the short circuit current and pre-  
vents sticking of the electrode to the plate while welding.  
This can also increase spatter. It is recommended that  
the ARC CONTROL be set to the minimum number  
without electrode sticking. Start with the dial set at 0.  
CAUTION  
• Do not allow the starter motor to run continuously  
for more than 20 seconds.  
• Do not push the START button while the engine  
is running because this can damage the ring  
gear and/or the starter motor.  
NOTE: Due to the low OCV with the VRD on, a  
very slight delay during striking of the electrodes  
may occur. Due to the requirement of the resis-  
tance in the circuit to be low for a VRD to operate, a  
good metal-to-metal contact must be made  
between the metal core of the electrode and the  
job. A poor connection anywhere in the welding  
output circuit may limit the operation of the VRD.  
This includes a good connection of the work clamp  
to the job. The work clamp should be connected as  
close as practical to where the welding will be per-  
formed.  
• IF the Engine Protection or Battery Charging  
Lights do “not” turn off shortly after starting the  
engine shut off the engine immediately and  
determine the cause.  
-----------------------------------------------------------------------  
NOTE: When starting for the first time, or after and  
extended period of time of not operating, it will take  
longer than normal to start because the fuel pump has  
to fill the fuel system. For best results, bleed the fuel  
system as indicated in Maintenance Section of this  
manual.  
STOPPING THE ENGINE  
A. For New Electrodes  
Remove all welding and auxiliary power loads and  
allow the engine to run at low idle speed for a few  
minutes to cool the engine.  
E6010 - Touch, Lift to Start the Arc  
E7018, E7024 - Touch, Rock Back and Forth in  
Joint, Lift .  
STOP the engine by placing the RUN-STOP switch in  
Once the arc is started, normal welding technique  
for the application is then used.  
the STOP position.  
NOTE: A fuel shut off valve is located on the fuel pre-  
filter.  
B. For Re-Striking Electrodes  
Some electrodes form a cone at the end of the  
electrode after the welding arc has been broken,  
particularly iron powder and low hydrogen elec-  
trodes. This cone will need to be broken off in order  
to have the metal core of the electrode make con-  
tact.  
WELDER OPERATION  
DUTY CYCLE  
Duty Cycle is the percentage of time the load is being  
applied in a 10 minute period. For example a 60% duty  
cycle, represents 6 minutes of load and 4 minutes of no  
load in a 10 minute period.  
E6010 - Push, Twist in Joint, Lift  
E7018, E7024 - Push, Rock Back and Forth in  
Joint, Lift.  
ELECTRODE INFORMATION  
For any electrode the procedures should be kept with-  
in the rating of the machine. For information on elec-  
trodes and their proper application see  
(www.lincolnelectric.com) or the appropriate Lincoln  
publication.  
Once the arc is started, normal welding technique  
for the application is then used.  
For other electrodes the above techniques should  
be tried first and varied as needed to suit operator  
preference. The goal for successful starting is good  
metal to metal contact.  
The VANTAGE 400 can be used with a broad range of  
DC stick electrodes. The MODE switch provides two  
stick welding settings as follows:  
For indicator light operation, see table B.1.  
CONSTANT CURRENT (CC-STICK) WELDING  
DOWNHILL PIPE Welding  
The CC-STICK position of the MODE switch is designed  
for horizontal and vertical-up welding with all types of  
electrodes, especially low hydrogen. The OUTPUT CON-  
This slope controlled setting is intended for "out-of-  
position" and "down hill" pipe welding where the oper-  
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B-6  
B-6  
OPERATION  
contamination. Then, the tungsten is gently lifted off the  
ator would like to control the current level by changing  
work in a rocking motion, which establishes the arc.  
the arc length.  
When in the TOUCH START TIG mode and when a  
Amptrol is connected to the 6-Pin connector the OUT-  
PUT CONTROL dial is used to set the maximum cur-  
rent range of the current control of the Amptrol.  
The OUTPUT CONTROL dial adjusts the full output  
range for pipe welding.  
The ARC CONTROL dial sets the short circuit current  
(arc-force) during stick welding to adjust for a soft or  
more forceful digging arc (crisp). Increasing the number  
from -10(soft) to +10(crisp) increases the short circuit  
current which results in a more forceful digging arc.  
Typically a forceful digging arc is preferred for root and  
hot passes. A softer arc is preferred for fill and cap pass-  
es where weld puddle control and deposition (“stacking”  
of iron) are key to fast travel speeds. This can also  
increase spatter.  
It is recommended that the ARC CONTROL be set to the  
minimum number without electrode sticking. Start with  
the dial set at 0.  
NOTE: With the VRD switch in the “ON” position there is  
no output in the DOWNHILL PIPE mode. For indicator  
light operation, see table B.1.  
The ARC CONTROL is not active in the TIG mode. To  
STOP a weld, simply pull the TIG torch away from the  
work.  
When the arc voltage reaches approximately 30 Volts  
the arc will go out and the machine will reset the cur-  
rent to the Touch Start level.  
To reinitiate the arc, retouch the tungsten to the work  
and lift. Alternatively, the weld can be stopped by  
releasing the Amptrol or arc start switch.  
The VANTAGE 400 can be used in a wide variety of  
DC TIG welding applications. In general the ʻTouch  
Startʼ feature allows contamination free starting with-  
out the use of a Hi-frequency unit. If desired, the  
K930-2 TIG Module can be used with the VANTAGE  
400. The settings are for reference.  
TIG WELDING  
VANTAGE 400 settings when using the K930-2 TIG  
Module with an Amptrol or Arc Start Switch:  
The TOUCH START TIG setting of the MODE switch is  
for DC TIG (Tungsten Inert Gas) welding. To initiate a  
weld, the OUTPUT CONTROL dial is first set to the  
desired current and the tungsten is touched to the work.  
During the time the tungsten is touching the work there is  
very little voltage or current and, in general, no tungsten  
• Set the MODE Switch to the TOUCH START TIG  
setting.  
TABLE B.3  
(1)  
(2)  
TYPICAL CURRENT RANGES  
FOR TUNGSTEN ELECTRODES  
Tungsten Electrode  
Diameter in. (mm)  
DCEN (-)  
DCEP (+)  
Approximate Argon Gas Flow  
Flow Rate C.F.H. ( l /min.)  
TIG TORCH  
Nozzle Size (4), (5)  
1%, 2% Thoriated  
Tungsten  
1%, 2% Thoriated Aluminum  
Tungsten  
Stainless Steel  
.010  
(.25)  
2-15  
5-20  
(3)  
(3)  
(3)  
3-8  
(2-4)  
(3-5)  
(3-5)  
3-8  
(2-4)  
(3-5)  
(3-5)  
#4, #5, #6  
0.020  
0.040  
(.50)  
(1.0)  
5-10  
5-10  
5-10  
5-10  
15-80  
1/16  
(1.6)  
70-150  
10-20  
5-10  
(3-5)  
9-13  
(4-6)  
#5, #6  
3/32  
1/8  
(2.4)  
(3.2)  
150-250  
250-400  
15-30  
25-40  
13-17  
15-23  
(6-8)  
11-15  
11-15  
(5-7)  
(5-7)  
#6, #7, #8  
(7-11)  
5/32  
3/16  
1/4  
(4.0)  
(4.8)  
(6.4)  
400-500  
500-750  
750-1000  
40-55  
55-80  
80-125  
21-25  
23-27  
28-32  
(10-12)  
(11-13)  
(13-15)  
13-17  
18-22  
23-27  
(6-8)  
#8, #10  
(8-10)  
(11-13)  
(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.  
(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):  
Pure  
EWP  
1% Thoriated  
2% Thoriated  
EWTh-1  
EWTh-2  
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.  
(3) DCEP is not commonly used in these sizes.  
(4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:  
# 4 = 1/4 in.  
# 5 = 5/16 in.  
# 6 = 3/8 in.  
# 7 = 7/16 in.  
# 8 = _ in.  
(6 mm)  
(8 mm)  
(10 mm)  
(11 mm)  
(12.5 mm)  
(16 mm)  
#10 = 5/8 in.  
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures  
and high duty cycles.  
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B-7  
B-7  
OPERATION  
• Set the "IDLER" Switch to the "AUTO" position.  
ARC GOUGING  
The VANTAGE 400 can be used for arc gouging. For opti-  
mal performance, set the MODE switch to CC-STICK and  
the ARC CONTROL to +10.  
• Set the "WELDING TERMINALS" switch to the  
"REMOTELY CONTROLLED" position. This will keep the  
"Solid State" contactor open and provide a "cold" elec-  
trode until the Amptrol or Arc Start Switch is pressed.  
Set the OUTPUT CONTROL knob to adjust output current  
to the desired level for the gouging electrode being used  
according to the ratings in the following Table B.4.  
When using the TIG Module, the OUTPUT CONTROL on  
the VANTAGE 400 is used to set the maximum range of the  
CURRENT CONTROL on the TIG Module or an Amptrol if  
connected to the TIG Module.  
TABLE B.4  
Carbon Diameter  
Current Range (DC, electrode  
NOTE: The TIG process is to receive a low voltage welding  
process. There is no difference in operation with the  
VRD “On” or “Off” for this mode. For indicator light  
operation, see table B.1.  
positive)  
1/8"  
5/32"  
3/16"  
1/4"  
60-90 Amps  
90-150 Amps  
200-250 Amps  
300-400 Amps  
450-550 Amps  
WIRE WELDING-CV  
Connect a wire feeder to the VANTAGE 400 according to  
the instructions in INSTALLATION INSTRUCTIONS  
Section.  
The VANTAGE 400 in the CV-WIRE mode, permits it to be  
used with a broad range of flux cored wire (Innershield and  
Outershield) electrodes and solid wires for MIG welding (gas  
metal arc welding). Welding can be finely tuned using the  
ARC CONTROL. Turning the ARC CONTROL clockwise  
from –10 (soft) to +10 (crisp) changes the arc from soft and  
washed-in to crisp and narrow. It acts as an induc-  
tance/pinch control. The proper setting depends on the pro-  
cedure and operator preference. Start with the dial set at 0.  
5/16”  
AUXILIARY POWER:  
Start the engine and set the IDLER control switch to  
the desired operating mode. Full power is available  
regardless of the welding control settings providing no  
welding current is being drawn.  
Simultaneous Welding and Auxiliary Power Loads  
The auxiliary power ratings are with no welding load.  
Simultaneous welding and power loads are specified  
in the following table.  
NOTE: In the CV-Mode with VRD “On”, the OCV(Open  
Circuit Voltage) is not reduced. For indicator light  
operation, see table B.1.  
TABLE B.5  
VANTAGE 400 Simultaneous Welding and Power Loads  
Weld  
Amps  
0
1 PHASE  
3 PHASE  
BOTH 1 & 3 PHASE  
WATTS  
AMPS  
46  
46  
33  
20  
7
WATTS  
AMPS  
41  
37  
31  
23  
8
WATTS  
11,000  
11,000  
8,000  
4,700  
1,700  
0
AMPS  
11,000  
11,000  
8,000  
4700  
1700  
0
17,000  
15,400  
13,000  
9400  
3400  
0
-
100  
200  
300  
400  
500  
-
-
OR  
OR  
PLUS  
-
-
0
0
0
TABLE B.6  
VANTAGE 400 (CE) Extension Cord Length Recommendations  
(Use the shortest length extension cord possible sized per the following table.)  
Current Voltage Load  
Maximum Allowable Cord Length in ft. (m) for Conductor Size  
(Amps) Volts (Watts)  
14 AWG  
12 AWG  
10 AWG  
8 AWG  
6 AWG  
4 AWG  
15  
20  
15  
20  
44  
120  
120  
240  
240  
240  
1800  
2400  
3600  
4800  
9500  
30  
60  
(9)  
40  
(12)  
(9)  
75  
(23)  
(15)  
(46)  
(30)  
(15)  
125  
(38)  
(27)  
(69)  
(53)  
(27)  
175  
(53)  
(42)  
(107)  
(84)  
(46)  
300  
(91)  
(69)  
30  
75  
60  
50  
150  
100  
50  
88  
225  
175  
90  
138  
350  
275  
150  
225  
600  
450  
225  
(18)  
(23)  
(18)  
(183)  
(137)  
(69)  
Conductor size is based on maximum 2.0% voltage drop.  
VANTAGE® 400  
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C-1  
C-1  
FIELD INSTALLED OPTIONS / ACCEAS-CCESSORIES  
WIRE FEEDER OPTIONS  
SORIES  
K449 LN-25 - Includes internal contactor for across the arc  
operation (no control cable). Provides “cold” electrode until  
gun trigger is pressed. Includes gas solenoid.  
K2641-2 FOUR WHEELED STEERABLE YARD TRAILER  
For in plant and yard towing. Comes standard with a Duo-Hitch™, a  
2” Ball and Lunette Eye combination Hitch.  
K1870-1 LN-15 Across the Arc Wire Feeder.  
Portable, lightweight, compact CC/CV unit for flux-cored and  
MIG welding. Includes Gas Solenoid, adjustable flow meter  
and internal contactor. For 10-15 lb. (4.5-6.8kg) spools.  
K2636-1 TRAILER - Two-wheeled trailer with optional fender and  
light package. For highway use, consult applicable federal, state,  
and local laws regarding possible additional requirements. Comes  
standard with a Duo-Hitch™, a 2” Ball and Lunette Eye combination  
hitch. Order:  
Magnum Gun and Magnum Gun Connector Kit are required  
for gas-shielded welding. Innershield Gun is required for  
gasless welding.  
K2636-1 Trailer  
K2639-1 Fender & Light Kit  
K2640-1 Cable Storage Rack  
K126-2 Magnum 350 Innershield Gun  
K1802-1 Magnum 300 MIG Gun (for LN-25)  
K470-2 Magnum 300 MIG Gun (for LN-15, Includes  
Connector Kit)  
K903-1 SPARK ARRESTOR - Includes a heavy gage steel,  
approved spark arrestor, clamp and adapter for mounting to the  
muffler exhaust pipe.  
K466-10 Connector Kit (for LN-15, K470-2)  
K1500-1 Gun Receiver Bushing (for LN-15 & K126-2)  
K704 ACCESSORY SET - Includes 35 ft. (10m) of electrode cable  
and 30 ft. (9.1m) of work cable, head shield, work clamp electrode  
holder. Cables are rated at 400 amps, 100% duty cycle.  
K487-25 Magnum SG Spool Gun  
Hand held semiautomatic wire feeder. Requires SG Control  
Module and Input Cable.  
K857 25 ft (7.6m) or K857-1 100 ft. (30.4m) REMOTE CONTROL  
Portable control provides same dial range as the output control on  
the welder. Has a convenient 6 pin plug for easy connection to the  
welder.  
K488 SG Control Module (For Magnum Spool Gun)  
The Interface between the power source and the spool gun.  
Provides control of the wire speed and gas flow. For use  
with a K487-25 spool gun.  
K691-10 Input Cable (For SG Control Module)  
For Lincoln engine power sources with 14-pin MS-type con-  
nection, separate 115V NEMA receptacles and output stud  
connections.  
K802N POWER PLUG KIT  
Provides four 120 volt plugs rated at 20 amps each and one dual  
voltage, full KVA plug rated at 120/240 volts, 50 amps.  
Note: See Wire Feeder IM manuals for appropriate Drive  
K802R POWER PLUG KIT  
Roll and Guide Tubes.  
Provides four 120 volt plugs rated at 15 amps each and one dual  
voltage, full KVA plug rated at 120/240 volts, 50 amps.  
TIG OPTIONS  
K1783-9 Pro -Torch® PTA-26V TIG Torch  
Air Cooled 200 amp torch (2 piece) equipped with valve for  
gas flow control. 25 ft. (7.6m) length.  
T12153-9 50 AMP, 120/240V POWER PLUG (1-Phase)  
T12153-10 50 AMP, 240V POWER PLUG (3-Phase)  
KP509 Magnum Parts Kit for PTA-26V TIG Torch  
K1816-1 FULL KVA ADAPTER KIT  
Magnum Parts Kit provides all the torch accessories you  
need to start welding. Parts kit provides collets, collet bod-  
ies, a black cap, alumina nozzles and tungstens in a variety  
of sizes, all packaged in an easy to carry reclosable sack.  
Plugs into the 120/240V NEMA 14-50R receptacle on the case front  
(which accepts 4-prong plugs) and converts it to a NEMA 6-50R  
receptacle, (which accepts 3-prong plugs.) For connection of  
Lincoln equipment with NEMA 6-50 Plug.  
K870 Foot Amptrol®  
K1858-1 SERVICE INDICATOR KIT- Provides a GO / NO-GO visu-  
al indication of air cleaner element useful service life. Filter service  
based on restriction readings allows the longest life possible from  
the filter and best engine protection.  
K963-3 Hand Amptrol®  
K2347-1 Precision TIG 185 Ready-Pak(For AC TIG)  
K2350-1 Invertec® V205-T AC/DC One-Pak™ Package  
(For AC TIG)  
K2679-1 COLD WEATHER HEATER AND TARP KIT  
For engine starting and operation in extreme cold weather condi-  
tions down to -40ºF / -40ºC (with the use of OW40 synthetic oil and  
arctic diesel fuel), includes 120VAC engine block heater, and radia-  
tor grill tarp.  
PLASMA CUTTING  
Cuts metal using the 3-phase AC generator power from the  
engine driven welder. Accepts 3-phase or 1-phase input  
power. Requires the K1816-1 Full KVA adapter kit, if con-  
nected for 1-phase input power.  
K1580-1 Pro-Cut 55  
VANTAGE® 400  
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D-1  
D-1  
MAINTENANCE  
Read the Safety Precautions in the front of this  
manual and in the Engine Ownerʼs Manual before  
working on this machine.  
SAFETY PRECAUTIONS  
WARNING  
• Have qualified personnel do all maintenance  
and troubleshooting work.  
Keep all equipment safety guards, covers, and  
devices in position and in good repair. Keep  
hands, hair, clothing, and tools away from the  
gears, fans, and all other moving parts when  
starting, operating, or repairing the equipment.  
------------------------------------------------------------  
• Turn the engine off before working inside the  
machine or servicing the engine.  
• Remove guards only when necessary to  
perform maintenance and replace them when  
the maintenance requiring their removal is  
complete. If guards are missing from the  
machine, obtain replacements from a Lincoln  
Distributor. (See Operating Manual Parts List.)  
Routine Maintenance  
At the end of each dayʼs use, refill the fuel tank to  
minimize moisture condensation in the tank. Running  
out of fuel tends to draw dirt into the fuel system.  
Also, check the crankcase oil level and add oil if  
indicated.  
VANTAGE® 400  
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D-2  
D-2  
MAINTENANCE  
ENGINE OIL CHANGE  
OIL FILTER CHANGE  
Drain the engine oil while the engine is warm to assure  
rapid and complete draining. It is recommended that  
each time the oil is changed the oil filter be changed as  
well.  
• Drain the oil.  
• Remove the oil filter with an oil filter wrench and  
drain the oil into a suitable container. Discard the  
used filter. Note: Care should be taken during filter  
removal to not disrupt or damage in any way the fuel  
lines.  
• Be sure the unit is off. Disconnect the negative bat-  
tery cable to ensure safety.  
• Locate oil drain hose and valve in bottom of base  
and pull through the hole in the battery access panel  
on the welder.  
• Clean the filter mounting base and coat the gasket  
of the new filter with clean engine oil.  
• Screw the new filter on by hand until the gasket con-  
tacts the mounting base. Using an oil filter wrench,  
tighten the filter an additional 1/2 to 7/8 of a turn.  
• Refill the crankcase with the specified amount of the  
recommended engine oil. Reinstall the oil filler cap  
and tighten securely.  
• Open oil drain valve by lifting up spring loaded lever  
and rotate 90 counterclockwise. Pull to open and  
°
drain the oil into a suitable container for disposal.  
• Close the drain valve by rotating lever 90 clockwise.  
°
• Start the engine and check for oil filter leaks.  
• Re-fill the crankcase to the upper limit mark on the  
dipstick with the recommended oil (see engine oper-  
ation manual OR engine service items decal OR  
below). Replace and tighten the oil filler cap secure-  
ly.  
• Stop the engine and check the oil level. If neces-  
sary, add oil to the upper limit mark on the dipstick.  
• Push oil drain hose and valve back into unit, re-con-  
nect negative battery cable, and close doors and  
engine top cover before restarting unit.Wash your  
hands with soap and water after handling used motor  
oil. Please dispose of used motor oil in a manner  
that is compatible with the environment. We suggest  
you take it in a sealed container to your local service  
station or recycling center for reclamation. DO NOT  
throw it in the trash; pour it on the ground or down a  
drain.  
WARNING  
• Never use gasoline or low flash point solvents  
for cleaning the air cleaner element. A fire or  
explosion could result.  
CAUTION  
• Never run the engine without the air cleaner.  
Rapid engine wear will result from contaminants,  
such as dust and dirt being drawn into the  
engine.  
Use motor oil designed for diesel engines that meets  
requirements for API service classification  
CC/CD/CE/CF/CF-4/CG-4 or CH-4.  
------------------------------------------------------------------------  
AIR CLEANER  
ACEA E1/E2/E3. Always check the API service label  
on the oil container to be sure it includes the letters  
indicated. (Note: An S-grade oil must not be used in a  
diesel engine or damage may result. It IS permissible  
to use an oil that meets S and C grade service classifi-  
cations.)  
The diesel engine is equipped with a dry type air filter.  
Never apply oil to it. Service the air cleaner as follows:  
Replace the element every 500 hours of operation.  
Under dusty conditions, replace sooner.  
SAE 10W30 is recommended for general, all tempera-  
ture use, 5F to 104F (-15C to 40C).  
See engine ownerʼs manual for more specific informa-  
tion on oil viscosity recommendations.  
VANTAGE® 400  
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D-3  
D-3  
MAINTENANCE  
VANTAGE® 400  
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D-4  
D-4  
MAINTENANCE  
FUEL  
COOLING SYSTEM  
DIESEL FUEL ONLY-Low sulphur fuel or ultra  
WARNING  
low sulphur fuel in U.S.A. and Canada.  
HOT COOLANT can burn skin.  
At the end of each dayʼs use, refill the fuel tank to min-  
imize moisture condensation and dirt contamination in  
the fuel line. Do not overfill; leave room for the fuel to  
expand.  
• Do not remove cap if radiator is  
hot.  
Use only fresh No. 2D diesel fuel, the use of No. 1D  
diesel fuel is recommended in place of No. 2D at tem-  
peratures below 23°F (-5°C). Do not use kerosene.  
------------------------------------------------------------------------  
Check the coolant level by observing the level in the  
radiator and recovery bottle. Add 50/50 antifreeze /  
water solution if the level is close to or below the  
"LOW" mark. do not fill above the "FULL" mark.  
Remove radiator cap and add coolant to radiator. Fill  
up to the top of the tube in the radiator filler neck  
which includes a connecting hose coming from the  
thermostat housing.  
See the Engine Operator's Manual for instructions on  
replacing the fuel filter.  
BLEEDING THE FUEL SYSTEM  
You may need to bleed air from the fuel system if the  
fuel filter or fuel lines have been detached, the fuel  
tank has been ran empty or after periods of long stor-  
age. It is recommended that the fuel shutoff valve be  
closed during periods of non-use.  
To drain the coolant, open the valve at the bottom of  
the radiator. Open the radiator cap to allow complete  
drainage. (Tighten the valve and refill with a 50/50  
antifreeze/water solution.) Use an automotive grade  
(low silicate) ethylene glycol antifreeze. The cooling  
system capacity is 8.0 quarts (7.6L.). Squeeze upper  
and lower radiator hoses while filling to bleed air from  
system coolant. Replace and tighten the radiator cap.  
WARNING  
To avoid personal injury, do not bleed a hot  
engine. This could cause fuel to spill onto a hot  
exhaust manifold, creating a danger of fire.  
------------------------------------------------------------------------  
Bleed the fuel system as follows:  
CAUTION  
Always premix the antifreeze and clean tap water  
before adding to the radiator. It is very important  
that a precise 50/50 solution be used with this  
engine year round. This gives proper cooling dur-  
ing hot weather and freezing protection to -34° F (-  
37° C).  
1. Fill the fuel tank with fuel.  
2. Open the fuel shut off valve.  
3. Loosen bleed fitting on the fuel injector manifold.  
4. Operate hand priming lever until fuel comes out the  
bleed screw on the injector manifold. This could  
take 20-30 seconds of rapid operation of the prim-  
ing lever. Tighten bleed fitting on injector manifold.  
5. Follow normal STARTING procedures until engine  
starts.  
Cooling solution exceeding 50% ethylene glycol  
can result in engine overheating and damage to  
the engine. Coolant solution must be premixed  
before adding to radiator.  
------------------------------------------------------------------------  
Periodically remove the dirt from the radiator fins.  
Periodically check the fan belt and radiator hoses.  
Replace if signs of deterioration are found.  
TIGHTENING THE FAN BELT  
If the fan belt is loose, the engine can overheat and  
the battery lose its charge. Check tightness by press-  
ing on the belt midway between the pulleys. It should  
deflect about .25 in.(6.4 mm) under a load of 20 lbs.(9  
Kg).  
VANTAGE® 400  
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D-5  
D-5  
MAINTENANCE  
CLEANING THE BATTERY  
FUEL FILTER  
Keep the battery clean by wiping it with a damp cloth  
when dirty. If the terminals appear corroded, discon-  
nect the battery cables and wash the terminals with an  
ammonia solution or a solution of 1/4 pound (0.1113  
kg) of baking soda and 1 quart (0.9461L) of water. Be  
sure the battery vent plugs (if equipped) are tight so  
that none of the solution enters the cells.  
1. Check the fuel filter and fuel pre-filter for water  
accumulation or sediment.  
2. Replace the fuel filter if it is found with excessive  
water accumulation or sediment. Empty fuel pre-fil-  
ter.  
After cleaning, flush the outside of the battery, the bat-  
tery compartment, and surrounding areas with clear  
water. Coat the battery terminals lightly with petroleum  
jelly or a non-conductive grease to retard corrosion.  
Keep the battery clean and dry. Moisture accumula-  
tion on the battery can lead to more rapid discharge  
and early battery failure.  
OVERSPEED IS HAZARDOUS  
The maximum allowable high idle speed for this  
machine is 1890 RPM, no load. Do NOT tamper  
with governor components or setting or make any  
other adjustments to increase the maximum  
speed. Severe personal injury and damage to the  
machine can result if operated at speeds above  
maximum.  
CHECKING THE ELECTROLYTE LEVEL  
ENGINE ADJUSTMENT  
If battery cells are low, fill them to the neck of the filler  
hole with distilled water and recharge. If one cell is  
low, check for leaks.  
Adjustments to the engine are to be made only by a  
Lincoln Service Center or an authorized Field Service  
Shop.  
CHARGING THE BATTERY  
BATTERY MAINTENANCE  
When you charge, jump, replace, or otherwise con-  
nect battery cables to the battery, be sure the polarity  
is correct. Improper polarity can damage the charging  
circuit. The VANTAGE 400 positive (+) battery termi-  
nal has a red terminal cover.  
To access the battery, remove the battery tray from  
the front of the machine with 3/8” nut driver or flat  
head screw driver. Pull the tray out of machine far  
enough to disconnect the negative and then positive  
battery cables. The tray can then be tilted and lifted to  
remove the entire tray and battery from the machine  
for easy service.  
If you need to charge the battery with an external  
charger, disconnect the negative cable first, then the  
positive cable before you attach the charger leads.  
After the battery is charged, reconnect the positive  
battery cable first and the negative cable last. Failure  
to do so can result in damage to the internal charger  
components.  
WARNING  
GASES FROM BATTERY can explode.  
● Keep sparks, flame and cigarettes  
away from battery.  
Follow the instructions of the battery charger manu-  
facturer for proper charger settings and charging time.  
To prevent EXPLOSION when:  
● INSTALLING A NEW BATTERY — disconnect  
negative cable from old battery first and con-  
nect to new battery last.  
● CONNECTING A BATTERY CHARGER —  
remove battery from welder by disconnecting  
negative cable first, then positive cable and  
battery clamp. When reinstalling, connect  
negative cable last. Keep well ventilated.  
● USING A BOOSTER — connect positive lead to  
battery first then connect negative lead to neg-  
ative battery lead at engine foot.  
BATTERY ACID can burn eyes and  
skin.  
SERVICING OPTIONAL SPARK  
ARRESTOR  
Clean every 100 hours.  
WARNING  
• MUFFLER MAY BE HOT  
• ALLOW ENGINE TO COOL BEFORE INSTALLING  
THE SPARK ARRESTER!  
• DO NOT OPERATE ENGINE WHILE INSTALLING  
THE SPARK ARRESTER!  
●
Wear gloves and eye protection  
and be careful when working near  
battery.  
● Follow instructions printed on battery.  
VANTAGE® 400  
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D-6  
D-6  
MAINTENANCE  
GFCI RECEPTACLE TESTING AND RESET-  
TING PROCEDURE  
WELDER / GENERATOR  
MAINTENANCE  
The GFCI receptacle should be properly tested at  
least once every month or whenever it is tripped. To  
properly test and reset the GFCI receptacle:  
STORAGE: Store in clean, dry protected areas.  
• If the receptacle has tripped, first carefully remove  
any load and check it for damage.  
CLEANING: Blow out the generator and controls peri-  
odically with low pressure air. Do this at least once a  
week in particularly dirty areas.  
• If the equipment has been shut down, it must be  
restarted.  
• The equipment needs to be operating at high idle  
speed and any necessary adjustments made on the  
control panel so that the equipment is providing at  
least 80 volts to the receptacle input terminals.  
• The circuit breaker for this receptacle must not be  
tripped. Reset if necessary.  
BRUSH REMOVAL AND REPLACEMENT: Itʼs nor-  
mal for the brushes and slip rings to wear and darken  
slightly. Inspect the brushes when a generator over-  
haul is necessary.  
• Push the "Reset" button located on the GFCI recep-  
tacle. This will assure normal GFCI operation.  
• Plug a night-light (with an "ON/OFF" switch) or other  
product (such as a lamp) into the GFCI receptacle  
and turn the product "ON".  
CAUTION  
• Do not attempt to polish slip rings while the  
engine is running.  
• Push the "Test" button located on the GFCI recepta-  
cle. The night-light or other product should go  
"OFF".  
WARNING  
• Push the "Reset" button, again. The light or other  
product should go "ON" again.  
• Service and Repair should only be performed by  
Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equip-  
ment 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 pre-  
cautions.  
If the light or other product remains "ON" when the  
"Test" button is pushed, the GFCI is not working prop-  
erly or has been incorrectly installed (miswired). If  
your GFCI is not working properly, contact a qualified,  
certified electrician who can assess the situation,  
rewire the GFCI if necessary or replace the device.  
VANTAGE® 400  
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E-1  
E-1  
TROUBLESHOOTING  
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 help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
VANTAGE® 400  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE  
RECOMMENDED  
(SYMPTOMS)  
CAUSE  
COURSE OF ACTION  
Major Physical or Electrical Damage 1. Contact your local Lincoln  
is Evident.  
Authorized Field Service  
Facility.  
Engine will not "crank".  
1. Battery is low, Charge Battery.  
2. Loose battery cable connections.  
Inspect, clean and tighten terminals.  
3. Faulty engine starter motor.  
Contact authorized local Engine  
Service Shop.  
Engine will "crank" but not start.  
1. Fuel shut off valve on Main Fuel  
Filter in the OFF position. Open  
valve (vertical) position of handle.  
2. Fuel Filters dirty/clogged. Check  
and replace main filter element  
and/or Inline Fuel Filter.  
3. Out of fuel. Fill tank and bleed fuel  
system.  
4. High coolant temperature or low  
oil pressure. (indictor lights lit)  
I
f all recommended possible areas  
Check oil and coolant levels. Fill if of misadjustment have been  
required. Check for loose or bro- checked and the problem persists,  
ken fan belt.  
Contact your local Lincoln  
5. Faulty fuel shutdown solenoid. Authorized Field Service Facility.  
Check that shutdown solenoid is  
functioning properly and not bind-  
ing/ contact authorized engine  
service shop.  
6. Faulty fuel pump. Check for fuel  
flow through filters. Contact autho-  
rized local Engine Service Shop.  
Engine shuts down shortly after  
starting.  
1. High coolant temperature or low  
oil pressure. (indictor light lit)  
Change oil and oil filters and fill to  
proper level. Check and fill coolant  
level. Check for loose or broken  
fan belt. Start engine and look for  
leaks.  
2. Faulty oil pressure switch or other  
engine component. Contact  
authorized local Engine Service  
Shop.  
3. Faulty Idler/Protection Board.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
VANTAGE 400  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE  
RECOMMENDED  
(SYMPTOMS)  
CAUSE  
COURSE OF ACTION  
Engine shuts down while under a 1. High radiator coolant tempera-  
load.  
ture. Reduce load if it is exceed-  
ing machine rating. Add coolant  
to system if low. Clean fins on  
radiator if dirty. Tighten fan belt if  
loose. Remove objects blocking  
or close to intake openings on  
both sides of base and exhaust  
end (case back).  
Engine runs rough.  
1. Dirty fuel or air filters. Inspect and  
clean/replace filters as needed.  
Inspect and clean/replace filters  
as needed.  
2. Water in fuel. If water found in  
tank. Empty fuel tank and refill  
then purge fuel lines.  
Battery does not stay charged.  
1. Faulty battery. Replace.  
Engine alternator trouble light is on 2. Loose connections at battery or  
while machine is running.  
alternator. Clean and tighten con-  
nections.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
3. Faulty engine alternator or charg-  
er module. Consult authorized  
Engine Service Shop.  
Engine will not idle down to low 1. Idler switch in High idle position.  
speed.  
Set switch to Auto.  
2. External load on welder or auxil-  
iary power. Remove all external  
loads.  
3. Faulty PC board or idler sole-  
noid.  
Engine will not go to high idle when 1. Poor work lead connection to  
attempting to weld.  
work. Make sure work clamp is  
tightly connected to clean base  
metal.  
2. "Contactor" switch is in wrong  
position. Set to "Welding On" when  
welding without a control cable.  
Refer to Operations chapter for prop-  
er use of this switch.  
3. Faulty PC board. Low idle speed  
set to low.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
VANTAGE® 400  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE  
RECOMMENDED  
(SYMPTOMS)  
CAUSE  
COURSE OF ACTION  
Engine will not go to high idle when 1. Auxiliary power load is less than  
using auxiliary power.  
100 watts. Idler may not respond  
with less than a 100 watt load. Set  
idler to "High".  
2. Faulty PC board.(Control or Idler).  
Engine will not go to high idle 1. Faulty idler solenoid. Check for  
under weld or auxiliary loading.  
bent linkage or broken spring.  
2. Faulty PC board.(Control or Idler).  
Engine does not develop full 1. Fuel filter clogged, Replace.  
power. Engine runs rough.  
2. Air filter clogged, clean or replace.  
3. High idle setting incorrect, check  
and adjust if required.  
4. Valves out of adjustment.  
5. Fuel contaminated with water or  
sediment. Check fuel pre-filter  
and empty of water, bleed fuel  
system. Replace fuel in tank if  
needed.  
Engine will not go to high idle when 1. Broken spring on Idle Solenoid,  
attempting to weld or using auxil-  
iary power. Switching to manual  
high idle does not work.  
solenoid linkage binding, Faulty If all recommended possible areas  
PC board (Control or Idler), low of misadjustment have been  
idle speed set too low on idle checked and the problem persists,  
solenoid.  
Contact your local Lincoln  
Authorized Field Service Facility.  
Engine will not shut off.  
1. Fuel Shutdown solenoid not func-  
tioning properly / linkage binding.  
Stop engine by shutting off valve  
located on main fuel filter. Contact  
authorized local Engine Service  
Shop.  
Engine does not develop full power. 1. Fuel filter dirty/clogged. Replace.  
Low weld and auxiliary output. 2. Air filter dirty/clogged. Replace Air  
Engine runs rough.  
Filter Element.  
3. Fouled fuel injector(s). Contact  
authorized Engine Service Shop.  
4. Fuel contaminated with water.  
Check water separator for water.  
Clean and replace as needed.  
Replace fuel in tank.  
5. Cracked or loose fuel hose.  
Replace hose and tighten clamps.  
6. Valves out of adjustment. Contact  
authorized local Engine Service  
Shop.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
VANTAGE® 400  
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E-5  
E-5  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE  
RECOMMENDED  
(SYMPTOMS)  
CAUSE  
COURSE OF ACTION  
No welding power output.  
1. Poor work lead connection to  
work. Make sure work clamp is  
tightly connected to clean base  
metal.  
2. "Weld Terminals" switch in wrong  
position. Place switch in "Weld  
Terminals On" position when  
welding without control cable.  
3. Faulty PC board or welder alterna-  
tor.  
Welder has output but no control.  
1. Poor remote/control cable connec-  
tion to 6-pin or 14-pin connector.  
Check connections.  
2. Faulty remote cable or faulty wire  
feeder or wire feeder cable.  
Replace if necessary.  
3. Faulty control potentiometer or PC  
board.  
I
f all recommended possible areas  
Wire feeder does not work when 1. Wire Feeder Power circuit breaker of misadjustment have been  
control cable is connected to 14 pin open. Check 42V and 120V checked and the problem persists,  
connector.  
beakers and reset if tripped.  
2. Faulty control cable. Repair or  
replace cable.  
Contact your local Lincoln  
Authorized Field Service Facility.  
3. Faulty wire feeder. Replace wire  
feeder.  
No auxiliary power.  
1. GFCI Receptacle may have  
tripped. Follow “GFCI Receptacle  
Testing and Resetting Procedure”  
in the MAINTENANCE section of  
this manual.  
2. Faulty connections to auxiliary  
receptacles. Check connections.  
3. Faulty PC board or welder alterna-  
tor.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
VANTAGE® 400  
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E-6  
E-6  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE  
RECOMMENDED  
(SYMPTOMS)  
CAUSE  
COURSE OF ACTION  
The welding arc is “cold.” The weld- 1. Make sure the MODE selector  
ing arc is not stable or is not satis- switch is in the correct position for  
factory. the engine runs normally. the process being used. (For exam-  
The auxiliary power is normal.  
No output in Pipe Mode.  
VRD Lights donʼt light up.  
ple, CV-WIRE, PIPE, CC-STICK.)  
2. Make sure the electrode (wire, gas,  
voltage, current etc.) is correct for  
the process being used.  
3. Check for loose or faulty connec-  
tions at the weld output terminals  
and welding cable connections.  
4. The welding cables may be too long  
or coiled, causing an excessive  
voltage drop.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
5. Faulty Control Board.  
1. Make sure VRD ON/OFF toggle  
switch is in the “OFF” position.  
2. Poor work lead connection to  
work. Make sure work clamp is  
tightly connected to clean base  
metal.  
3. "Weld Terminals" switch in wrong  
position. Place switch in "Weld  
Terminals On" position when  
welding without control cable.  
4. Faulty PC board or welder alterna-  
tor.  
1. Ensure VRD ON/OFF switch is in  
the “ON” position.  
2. If light is burned out, replace both  
VRD lights.  
3. Faulty OCV indicator PC board.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
VANTAGE® 400  
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F-1  
F-1  
DIAGRAMS  
VANTAGE® 400  
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F-2  
F-2  
DIAGRAMS  
VANTAGE® 400  
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F-3  
F-3  
DIAGRAMS  
VANTAGE® 400  
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F-4  
F-4  
DIAGRAMS  
VANTAGE® 400  
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F-5  
F-5  
DIAGRAMS  
VANTAGE® 400  
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F-6  
F-6  
DIAGRAMS  
VANTAGE® 400  
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F-7  
F-7  
DIAGRAMS  
VANTAGE® 400  
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F-8  
F-8  
DIAGRAMS  
VANTAGE® 400  
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F-9  
F-9  
DIAGRAMS  
VANTAGE® 400  
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F-10  
F-10  
WIRING DIAGRAM  
VANTAGE® 400  
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F-11  
F-11  
DIMENSION PRINT  
VANTAGE® 400  
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● Do not touch electrically live parts or  
electrode with skin or wet clothing.  
● Insulate yourself from work and  
ground.  
● Keep flammable materials away.  
● Wear eye, ear and body protection.  
WARNING  
Spanish  
● No toque las partes o los electrodos ● Mantenga el material combustible  
● Protéjase los ojos, los oídos y el  
cuerpo.  
bajo carga con la piel o ropa moja-  
da.  
● Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
AVISO DE  
PRECAUCION  
French  
● Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
● Gardez à l’écart de tout matériel  
inflammable.  
● Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
● Isolez-vous du travail et de la terre.  
German  
● Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
● Isolieren Sie sich von den  
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
● Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
● Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE  
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-  
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
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● Keep your head out of fumes.  
● Use ventilation or exhaust to  
remove fumes from breathing zone.  
● Turn power off before servicing.  
● Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
● Los humos fuera de la zona de res-  
piración.  
● Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
● Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
● No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
● Débranchez le courant avant  
l’entretien.  
● N’opérez pas avec les panneaux  
ouverts ou avec les dispositifs de  
protection enlevés.  
● Gardez la tête à l’écart des fumées.  
● Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ATTENTION  
German  
● Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
● Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
● Vermeiden Sie das Einatmen von  
Schweibrauch!  
● Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
● Não opere com as tampas removidas.  
● Desligue a corrente antes de fazer  
serviço.  
● Mantenha-se afastado das partes  
moventes.  
● Não opere com os paineis abertos  
ou guardas removidas.  
● Mantenha seu rosto da fumaça.  
● Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
● Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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