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IM889-A
®
VANTAGE 400 (CE) April, 2008
11296, 11297, 11463, 11464
For use with machines having Code Numbers:
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
SAFETY
i i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
powered equipment. radiator pressure cap when the engine is
hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar 95
SAFETY
ii ii
ARC RAYS can burn.
ELECTRIC SHOCK can
kill. 4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
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
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
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
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
your head out of the fume. Use enough
� DC Manual (Stick) Welder.
ventilation and/or exhaust at the arc to keep
� AC Welder with Reduced Voltage Control.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
3.c. In semiautomatic or automatic wire welding, the electrode,
ventilation such as stainless or hard facing (see
electrode reel, welding head, nozzle or semiautomatic
instructions on container or MSDS) or on lead or
welding gun are also electrically “hot�.
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
3.d. Always be sure the work cable makes a good electrical
low as possible and below Threshold Limit Values (TLV)
connection with the metal being welded. The connection
using local exhaust or mechanical ventilation. In
should be as close as possible to the area being welded.
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.e. Ground the work or metal to be welded to a good electrical
also required when welding on galvanized steel.
(earth) ground.
5. b. The operation of welding fume control equipment is affected
3.f. Maintain the electrode holder, work clamp, welding cable and
by various factors including proper use and positioning of
welding machine in good, safe operating condition. Replace
the equipment, maintenance of the equipment and the spe-
damaged insulation.
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.g. Never dip the electrode in water for cooling.
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
3.h. Never simultaneously touch electrically “hot� parts of
electrode holders connected to two welders because voltage
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
between the two can be the total of the open circuit voltage
coming from degreasing, cleaning or spraying operations.
of both welders.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.i. When working above floor level, use a safety belt to protect
ucts.
yourself from a fall should you get a shock.
5.d. Shielding gases used for arc welding can displace air and
3.j. Also see Items 6.c. and 8.
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
SAFETY
iii iii
CYLINDER may explode
WELDING and CUTTING
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
6.a. Remove fire hazards from the welding area.
process used and properly operating
If this is not possible, cover them to prevent
regulators designed for the gas and
the welding sparks from starting a fire.
pressure used. All hoses, fittings, etc. should be suitable for
Remember that welding sparks and hot
the application and maintained in good condition.
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
7.b. Always keep cylinders in an upright position securely
hydraulic lines. Have a fire extinguisher readily available.
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
7.c. Cylinders should be located:
special precautions should be used to prevent hazardous
� Away from areas where they may be struck or subjected to
situations. Refer to “Safety in Welding and Cutting� (ANSI
physical damage.
Standard Z49.1) and the operating information for the
equipment being used.
� 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
7.d. Never allow the electrode, electrode holder or any other
can cause overheating and create a fire hazard.
electrically “hot� parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
7.e. Keep your head and face away from the cylinder valve outlet
proper steps have been taken to insure that such procedures
when opening the cylinder valve.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
7.f. Valve protection caps should always be in place and hand
been “cleaned�. For information, purchase “Recommended
tight except when the cylinder is in use or connected for
Safe Practices for the Preparation for Welding and Cutting of
use.
Containers and Piping That Have Held Hazardous
Substances�, AWS F4.1 from the American Welding Society
7.g. Read and follow the instructions on compressed gas
(see address above).
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
6.e. Vent hollow castings or containers before heating, cutting or
Cylinders,� available from the Compressed Gas Association
welding. They may explode.
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
FOR ELECTRICALLY
cuffless trousers, high shoes and a cap over your hair. Wear
powered equipment.
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
6.g. Connect the work cable to the work as close to the welding
the equipment.
area as practical. Work cables connected to the building
framework or other locations away from the welding area
8.b. Install equipment in accordance with the U.S. National
increase the possibility of the welding current passing
Electrical Code, all local codes and the manufacturer s
through lifting chains, crane cables or other alternate cir-
recommendations.
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer s recommendations.
6.h. Also see item 1.c.
6.I. Read and folllow NFPA 51B � Standard for Fire Prevention Jan, 07
During Welding, Cutting and Other Hot Work�, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
SAFETY
iv iv
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
échauffement et un risque d incendie.
Sûreté Pour Soudage A L Arc
8. S assurer que la masse est connectée le plus prés possible
1. Protegez-vous contre la secousse électrique:
de la zone de travail qu il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d autres
a. Les circuits à l électrode et à la piéce sont sous tension
endroits éloignés de la zone de travail, on augmente le risque
quand la machine à souder est en marche. Eviter toujours
de voir passer le courant de soudage par les chaines de lev-
tout contact entre les parties sous tension et la peau nue
age, câbles de grue, ou autres circuits. Cela peut provoquer
ou les vétements mouillés. Porter des gants secs et sans
des risques d incendie ou d echauffement des chaines et des
trous pour isoler les mains.
câbles jusqu à ce qu ils se rompent.
b. Faire trés attention de bien s isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
9. Assurer une ventilation suffisante dans la zone de soudage.
metallique ou des grilles metalliques, principalement dans
Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande
galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse.
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
10. Ne pas souder en présence de vapeurs de chlore provenant
defonctionnement.
d opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l eau pour le
chaleur ou les rayons de l arc peuvent réagir avec les vapeurs
refroidir.
du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension
ou autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
11. Pour obtenir de plus amples renseignements sur la sûreté,
total de la tension à vide des deux machines.
voir le code “Code for safety in welding and cutting� CSA
f. Si on utilise la machine à souder comme une source de
Standard W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s applicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR
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
LES MACHINES À SOUDER À
enrouler le câble-électrode autour de n importe quelle partie
TRANSFORMATEUR ET À
du corps.
REDRESSEUR
3. Un coup d arc peut être plus sévère qu un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu un verre blanc afin de se protéger les yeux du ray- l électricité et aux recommendations du fabricant. Le dispositif
onnement de l arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, I installation et l entretien du poste seront
l arc. effectués par un électricien qualifié.
c. Protéger l autre personnel travaillant à proximité au
soudage à l aide d écrans appropriés et non-inflammables. 3. Avant de faires des travaux à l interieur de poste, la debranch-
er à l interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l arc de
soudage. Se protéger avec des vêtements de protection libres 4. Garder tous les couvercles et dispositifs de sûreté à leur
de l huile, tels que les gants en cuir, chemise épaisse, pan- place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. 93
zones où l on pique le laitier.
SAFETY
v v
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national codes.
Changing the earthing arrangements should only be authorized by a person who is compe-
tent to access whether the changes will increase the risk of injury, e.g., by allowing parallel
welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
L10093 3-1-96H
SAFETY
vi vi
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer s recommenda-
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-
tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-
lems of interference. Screening of the entire welding installation may be considered for special applications.
1
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.�
L10093 3-1-96H
vii vii
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to 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 customer s 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.
viii viii
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications ................................................................................................A-1,A-2
Safety Precautions ........................................................................................................A-3
VRD (Voltage Reduction Device) ..................................................................................A-3
Location and Ventilation ................................................................................................A-3
Stacking ........................................................................................................................A-3
Angle of Operation ........................................................................................................A-3
Lifting.............................................................................................................................A-3
High Altitude Operation .................................................................................................A-4
High Temperature Operation ........................................................................................A-4
Cold Weather Operation ...............................................................................................A-4
Towing...........................................................................................................................A-4
Vehicle Mounting...........................................................................................................A-4
Pre-Operation Engine Service..............................................................................................A-4
Oil ..................................................................................................................................A-5
Fuel ...............................................................................................................................A-5
Engine Coolant..............................................................................................................A-5
Battery Connections ......................................................................................................A-5
Muffler Outlet Pipe ........................................................................................................A-5
Spark Arrester ...............................................................................................................A-5
Remote Control .............................................................................................................A-5
Electrical Connections ..........................................................................................................A-6
Machine Grounding .......................................................................................................A-6
Welding Terminals ........................................................................................................A-6
Welding Output Cables .................................................................................................A-6
Cable Installation...........................................................................................................A-6
Auxiliary Power Receptacles and Plugs ...............................................................................A-7
Standby Power Connections ................................................................................................A-7
Connection of Lincoln Electric Wire Feeders.................................................................A-7,A-8
________________________________________________________________________________
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-5
Tig Welding and Current Range for Tungsten Electrodes....................................................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
________________________________________________________________________________
ix
ix 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
________________________________________________________________________
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
________________________________________________________________________
INSTALLATION
A-1 A-1
TECHNICAL SPECIFICATIONS - VANTAGE® 400 (CE) (K2502-1, -2, -3, -4)
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
Code No. cu. in. (ltrs.) System
Perkins 404C-22 4 cylinder 135.6(2.2) 12VDC Battery
27.6 HP High Idle 1565 & starter Oil: Fuel: 15 gal.
K2502-1, -2
11296, 11297 1500 RPM Bore x Stroke (Group 34; 650 8.45Qts. (8.0L) (57 L)
naturally aspirated Full Load 1500 cold crank amps) Fuel: 20 gal.
Perkins 404D-22
water cooled Radiator Coolant: (75.7 L)
3.43� X 3.64� 65 Amp Alternator
K2502-3,-4
Diesel Engine Low Idle 1200 (87.1mm x 92.5mm) 8.0Qts. (7.6L)
W / Built in Regulator
11463, 11464
RATED OUTPUT @ 104° F (40° C) - WELDER
Welding Output
Welding Process Output Range Max. Weld OCV
Current/Voltage/Duty Cycle @Rated Load RPM
350A / 34V / 100%
DC Constant Current 30 TO 400 AMPS
300A / 32V / 100%
DC Pipe Current 40 TO 300 AMPS 60 Volts (2)
250A / 30V / 100%
Touch-Startâ„¢TIG 20 TO 250 AMPS
350A / 34V / 100%
DC Constant Voltage 14 TO 34 VOLTS
60 Volts
350A / 34V / 100%
Arc Gouging 90 TO 400 AMPS
RATED OUTPUT @ 40° C (104° F).- GENERATOR
Auxiliary Power (1)
14,000 Watts Peak / 13,200 Watts Continuous, 50 Hz 400 Volts 3-Phase (Euro/UK)
6,900 Watts Peak(3) / 6,900 Watts Continuous, 50 Hz 230 Volts 1-Phase (Euro)
3,400 Watts Peak(3) / 3,400 Watts Continuous, 50 Hz 230 Volts 1-Phase (UK)
3,400 Watts Peak(3) / 3,400 Watts Continuous, 50 Hz 115 Volts 1-Phase (UK)
Sound Levels (Sound power: 96 dB Lwa)
MACHINE SPECIFICATIONS
MODEL NUMBERS K2502-1, -3 (UK) K2502-2, -4 (EUROPE)
400V (3 Ph) x 1
Receptacles 400V (3 Ph) x 1
230V (1 Ph) x 2
230V (1 Ph) x 1
14 Pin Connector
115V x 1 (4)
6 Pin Connector
14 Pin Connector
6 Pin Connector
4-pole, 25Amp
Residual Current Device (RCD) 4-pole, 25Amp
(30mA trip current)
(30mA trip current)
3 Phase,25 Amp x 1
Circuit Breakers (Thermal/Magnetic) 3 Phase,25 Amp x 1
1 phase, 15 Amp x 2
1 phase, 15 Amp x 3
10A for Engine Battery Charging Circuit
Other Circuit Breakers
10A for Wire Feeder Power
ENGINE
LUBRICATION EMISSIONS FUEL SYSTEM GOVERNOR
Full Pressure (Codes 11296, 11297) EPA Tier Il Mechanical
Mechanical Fuel Pump, Auto air bleed
with Full Flow Filter (Codes 11463, 11464) EPA Tier IV Interim system, Electric shutoff solenoid, Indirect fuel injector.
Compliant
AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION
Low noise Muffler: Shutdown on low oil
Single Element Automatic Idler Top outlet can be rotated. pressure & high engine
Made from long life, aluminized steel. coolant temperature
ENGINE WARRANTY: 2 years / 2000 hours, all non-electric components, 3 years major non-electric compo-
nents . See Perkins warranty for details.
(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.
(2)
Reduced to less than (32V for Codes 11296, 11297)(30V for Codes 11463, 11464) in the CC-stick Mode when VRD (VOLTAGE REDUCTION DEVICE) is on.
(3)
Maximum per circuit breaker rating.
(4)
Center-Tapped to ground.
VANTAGE® 400 (CE)
INSTALLATION
A-2 A-2
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
35.94 in. 27.00 in 60.00 in.
(5)
1230 lbs. (559kg.)
913 mm 686 mm 1524 mm
To Top of enclosure. Add 7.35 (186.7mm) to top of exhaust. Add 3.87�(98.3mm) to top of Lift Bail.
(5)
VANTAGE® 400 (CE)
INSTALLATION
A-3 A-3
SAFETY PRECAUTIONS FIGURE A.1
WARNING (VRD)-VOLTAGE REDUCTION DEVICE
SWITCH IS LOCATED IN THIS AREA.
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts or
electrode with skin or wet clothing.
� Insulate yourself from work and
ground
� Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
� Use in open, well ventilated areas or
vent exhaust outside.
REMOVE 4 FRONT PANEL
SCREWS TO ACCESS
(VRD) SWITCH
------------------------------------------------------------------------
MOVING PARTS can injure.
� Do not operate with doors open or
LOCATION AND VENTILATION
guards off.
� Stop engine before servicing.
� Keep away from moving parts. The welder should be located to provide an unrestrict-
------------------------------------------------------------------------ ed flow of clean, cool air to the cooling air inlets and to
See additional warning information at avoid restricting the cooling air outlets. Also, locate
front of this operator s manual. the welder so that the engine exhaust fumes are prop-
erly vented to an outside area.
Only qualified personnel should install,
use, or service this equipment. STACKING
VANTAGE 400 (CE) machines cannot be stacked.
VRD (VOLTAGE REDUCTION DEVICE)
ANGLE OF OPERATION
The VRD feature provides additional safety in the CC-Stick
Engines are designed to run in the level condition
mode especially in an environment with a higher risk of
which is where the optimum performance is achieved.
electric shock such as wet areas and hot humid sweaty
The maximum angle of continuous operation is 25
conditions.
degrees in all directions, 35 degrees Intermittent (less
than 10 minutes continuous) in all directions. If the
The VRD reduces the OCV (Open Circuit Voltage) at the
engine is to be operated at an angle, provisions must
welding output terminals while not welding to less than 13V
be made for checking and maintaining the oil level at
DC when the resistance of the output circuit is above 200
(ohms). the normal (FULL) oil capacity in the crankcase.
The VRD requires that the welding cable connections be When operating the welder at an angle, the effective
kept in good electrical condition because poor connections fuel capacity will be slightly less than the amount
will contribute to poor starting. Having good electrical con- specified.
nections also limits the possibility of other safety issues
such as heat-generated damage, burns and fires. LIFTING
The VANTAGE 400 (CE) weighs approximately 1345
The machine is shipped with the VRD switch in the “Off�
lbs.(611kg.) for [Codes 11296, 11297] and 1383 lbs.
position. To turn it “On� or “Off�:
(627kg.) for [Codes 11463, 11464] with a full tank of
� Turn the engine “Off�.
fuel 1230 lbs. (559kg.) less fuel. A lift bail is mounted
� Disconnect the negative battery cable.
to the machine and should always be used when lift-
� Lower the control panel by removing 4 front
ing the machine.
panel screws. (See Figure A.1)
� Place the VRD switch in the “On or “Off� position.
(See Figure A.1)
With the VRD switch in the “On� position, the VRD lights
are enabled.
VANTAGE® 400 (CE)
INSTALLATION
A-4 A-4
WARNING 1. Design capacity of trailer vs. weight of Lincoln equipment and
likely additional attachments.
� Lift only with equipment of ade-
2. Proper support of, and attachment to, the base of the welding
quate lifting capacity.
equipment so there will be no undue stress to the framework.
� Be sure machine is stable when lift-
3. Proper placement of the equipment on the trailer to insure
ing.
stability side to side and front to back when being moved and
� Do not lift this machine using lift
when standing by itself while being operated or serviced.
bail if it is equipped with a heavy
4. Typical conditions of use, i.e., travel speed; roughness of sur-
accessory such as trailer or gas
face on which the trailer will be operated; environmental con-
cylinder.
ditions; like maintenance.
FALLING � Do not lift machine if lift bail is
5. Conformance with federal, state and local laws.(1)
EQUIPMENT can damaged. (1) Consult applicable federal, state and local laws regarding specific requirements for use on public high-
cause injury. � Do not operate machine while ways.
VEHICLE MOUNTING
suspended from lift bail.
--------------------------------------------------------------------------------
WARNING
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary. For Improperly mounted concentrated loads may
maximum rating, derate the machine 2.5% to 3.5% for every cause unstable vehicle handling and tires or other
1000 ft. (305 m). Due to new EPA and other local emissions components to fail.
regulations, modifications to the engine for high altitude are
restricted within the United States. For use above 6000 � Only transport this Equipment on serviceable
ft.(1828 m) an authorized Perkins engine field service shop vehicles which are rated and designed for such
should be contacted to determine if any adjustments can be loads.
made for operation in higher elevations. � Distribute, balance and secure loads so vehicle
is stable under conditions of use.
HIGH TEMPERATURE OPERATION � Do not exceed maximum rated loads for compo-
At temperatures above 104°F(40°C), Welder output derating nents such as suspension, axles and tires.
is necessary. For maximum output ratings, derate the � Mount equipment base to metal bed or frame of
welder output 2 volts for every 18°F(10°C) above vehicle.
104°F(40°C). � Follow vehicle manufacturer s instructions.
------------------------------------------------------------------------
Cold weather starting:
PRE-OPERATION ENGINE SERVICE
With a fully charged battery and the proper oil, the
engine should start satisfactorily down to -15°F(- READ the engine operating and maintenance instruc-
26C°). If the engine must be frequently started at or tions supplied with this machine.
below 0°F (-18°C), it may be desirable to install cold-
WARNING
starting aides. The use of No. 1D diesel fuel is recom-
mended in place of No. 2D at temperatures below
23°F (-5°C). Allow the engine to warm up before � Stop engine and allow to cool before fueling
applying a load or switching to high idle. � Do not smoke when fueling.
� Fill fuel tank at a moderate rate and do not over-
Note: Extreme cold weather starting may require 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 (CE)
INSTALLATION
A-5 A-5
OIL MUFFLER OUTLET PIPE
The VANTAGE 400 (CE) is shipped with the engine crankcase filled Using the clamp provided secure the outlet pipe to the outlet tube
with high quality SAE 10W-30 Oil that meets classification CG-4 or with the pipe positioned such that it will direct the exhaust in the
CH-4 for diesel engines. Check the oil level before starting the desired direction. Tighten using a 9/16"(14mm) socket or wrench.
engine. If it is not up to the full mark on the dip stick, add oil as
SPARK ARRESTER
required. Check the oil level every four hours of running time during
the first 50 running hours. Refer to the engine Operator s Manual for Some federal, state or local laws may require that gasoline or diesel
specific oil recommendations and break-in information. The oil engines be equipped with exhaust spark arresters when they are
change interval is dependent on the quality of the oil and the operat- operated in certain locations where unarrested sparks may present
ing environment. Refer to the Engine Operator s Manual for more a fire hazard. The standard muffler included with this welder does
details on the proper service and maintenance intervals. 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
WARNING
fuel in U.S.A. and Canada.
WARNING An incorrect spark arrestor may lead to damage to the engine
or adversely affect performance.
� Fill the fuel tank with clean, fresh fuel. The capacity of the
------------------------------------------------------------------------------------------
tank is (15 gals.[57 ltrs] for codes 11296, 11297)(20 gals.[75.7
REMOTE CONTROL
ltrs] for codes 11463, 11464). When the fuel gauge reads
empty the tank contains approximately 2 gals. (7.6 ltrs.) of
The VANTAGE 400 (CE) is equipped with a 6-pin and a 14-pin con-
reserve fuel.
nector. The 6-pin connector is for connecting the K857 or K857-1
NOTE: A fuel shut off valve is located on the pre-fil-
Remote Control or for TIG welding, the K870 foot Amptrol or the
ter/sediment filter. Which should be in the closed posi-
K963-3 hand Amptrol. When in the CC-STICK, ARC GOUGING or
tion when the welder is not used for extended periods
CV-WIRE modes and when a remote control is connected to the 6-
of time.
pin Connector, the auto-sensing circuit automatically switches the
------------------------------------------------------------------------------------------
OUTPUT control from control at the welder to remote control.
ENGINE COOLING SYSTEM
When in the DOWNHILL PIPE mode and when REMOTE CON-
WARNING TROL is connected to the 6-Pin or 14-Pin Connector, the OUTPUT
CONTROL is used to set the maximum current range of the OUT-
Air to cool the engine is drawn in the side and exhausted PUT CONTROL of the REMOTE.
through radiator & case back. It is important that the intake and
exhaust air is not restricted. Allow a minimum clearance of 12 Example: When the OUTPUT CONTROL on the welder is set to
in. (305 mm) from the case back and 16 in.(406 mm) from either 200 amps the current range on the REMOTE CONTROL will be 40-
side of the base to a vertical surface. 200 amps rather than the full 40-300 amps. Any current range that
------------------------------------------------------------------------------------------ is less than the full range provides finer current resolution for more
BATTERY CONNECTION fine tuning of the output.
WARNING When in TOUCH START TIG mode and when a Amptrol is connect-
ed to the 6-Pin Connector, the OUTPUT dial is used to set the maxi-
Use caution as the electrolyte is a strong acid that can burn mum current range of the CURRENT CONTROL of the Amptrol.
skin and damage eyes.
The 14-pin connector is used to directly connect a wire feeder con-
------------------------------------------------------------------------------------------
trol cable. In the CV-WIRE mode, when the control cable is con-
The VANTAGE 400 (CE) is shipped with the negative battery cable
nected to the 14-pin connector, the auto-sensing circuit
disconnected. Make certain that the RUN-STOP switch is in the
automatically makes the Output Control inactive and
STOP position. Remove the two screws from the battery tray using
the wire feeder voltage control active.
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
CAUTION
wrench.
NOTE: When a wire feeder with a built in welding
NOTE: This machine is furnished with a wet charged battery; if
voltage control is connected to the 14-pin connec-
unused for several months, the battery may require a booster
tor, do not connect anything to the 6-pin connec-
charge. Be careful to charge the battery with the correct polarity.
tor.
(See Battery in “Maintenance Section�)
------------------------------------------------------------------------
VANTAGE® 400 (CE)
INSTALLATION
A-6 A-6
WELDING OUTPUT CABLES
ELECTRICAL CONNECTIONS
With the engine off connect the electrode and work
cables to the output studs. The welding process dic-
MACHINE GROUNDING tates the polarity of the electrode cable. These con-
Because this portable engine driven welder creates its nections should be checked periodically and tightened
own power, it is not necessary to connect its frame to with a 3/4" (19mm)wrench.
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
To prevent dangerous electric shock, other equipment welder. Cable diameters are increased for long cable
to which this engine driven welder supplies power lengths to reduce voltage drops.
must:
TABLE A.1
WARNING
TOTAL COMBINED LENGTH OF
� Be grounded to the frame of the welder using a
ELECTRODE AND WORK CABLES
grounded type plug or be double insulated.
� Do not ground the machine to a pipe that carries Cable Size for
explosive or combustible material. 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 2 / 0 AWG
100-150 Ft. (30-46 meters)
of the vehicle. Use a #8 or larger copper wire connect-
ed between the machine grounding stud and the 3 / 0 AWG
150-200 Ft. (46-61 meters)
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- CABLE INSTALLATION
tions in the section entitled "Standby Power Install the welding cables to your VANTAGE 400 (CE)
Connections" as well as the article on grounding in the as follows.
latest National Electrical Code and the local code.
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 2. Remove the flanged nuts from the output terminals.
earth ground such as a metal water pipe going into
the ground for at least ten feet and having no insulat- 3. Connect the electrode holder and work cables to
ed joints, or to the metal framework of a building the weld output terminals. The terminals are identi-
which has been effectively grounded. fied on the case front.
The National Electrical Code lists a number of alter- 4. Tighten the flanged nuts securely.
nate means of grounding electrical equipment. A
machine grounding stud marked with the symbol 5. Be certain that the metal piece you are welding (the
is provided on the front of the welder. “work�) is properly connected to the work clamp and
cable.
WELDING TERMINALS
The VANTAGE 400 (CE) is equipped with a toggle 6. Check and tighten the connections periodically.
switch for selecting "hot" welding terminal when in the
CAUTION
"WELD TERMINALS ON" position or "cold" welding
terminal when in the "REMOTELY CONTROLLED"
position. � 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 (CE)
INSTALLATION
A-7 A-7
CONNECTION OF LINCOLN ELECTRIC
AUXILIARY POWER
WIRE FEEDERS
The auxiliary power capacity is 14,000 watts Peak, Connection of LN-15 to the VANTAGE 400 (CE)
13,200 Watts Continuous of 50 Hz, three phase
power. The auxiliary power capacity rating in watts is 1. Shut the welder off.
equivalent to volt-amperes at unity power factor. The
max permissible current of the 400 VAC output is 22 2. For electrode Positive, connect the electrode
amps. Output voltage is within ± 10% at all loads up cable to the "+" terminal of the welder and work
to the rated capacity. cable to the "-" terminal of the welder. For elec-
trode Negative, connect the electrode cable to the
Single phase power is: "-" terminal of the welder and work cable to the "+"
� 6,900 Watts Peak / 6,900 Watts Continuous, 50 Hz terminal of the welder.
230 Volts 1-Phase (Euro).
� 3,400 Watts Peak / 3,400 Watts Continuous, 50 Hz 3. Across The-Arc Model:
230 Volts 1-Phase (UK).
� 3,400 Watts Peak / 3,400 Watts Continuous, 50 Hz � Attach the single lead from the front of the LN-15
115 Volts 1-Phase (UK). to work using the spring clip at the end of the
lead. This is a control lead to supply current to
STANDBY POWER CONNECTIONS the wire feeder motor; it does not carry welding
current.
The machine is suitable for temporary, standby or
� Set the "WELD TERMINALS" switch to "WELD
emergency power using the engine manufacturer s
TERMINALS ON".
recommended maintenance schedule.
� When the gun trigger is closed, the current sens-
The machine can be permanently installed as a
ing circuit will cause the VANTAGE 400 (CE)
standby power unit for 400 VAC, 3 phase, 22 amp
engine to go to the high idle speed, the wire will
service.
begin to feed and the welding process started.
When welding is stopped, the engine will revert
WARNING to low idle speed after approximately 12 seconds
unless welding is resumed.
Connections must be made by a licensed electrician
4. Control Cable Model:
who can determine how the power can be adapted to
the particular installation and comply with all applica-
� Connect Control Cable between Engine Welder
ble electrical codes.
and Feeder.
� Take necessary steps to assure load is limited to
� Set the "WELD TERMINALS" switch to
the capacity of the VANTAGE 400 (CE).
"REMOTELY CONTROLLED"
� Only a licensed, certified, trained electrician
should install the machine to a premises or resi-
5. Set the MODE switch to the "CV-WIRE " position.
dential electrical system. Be certain that:
6. Set the "WIRE FEEDER VOLTMETER" switch to
� The installation complies with the National
either "+" or "-" as required by the electrode polari-
Electrical Code and all other applicable electri-
ty being used.
cal codes.
7. Set the "ARC CONTROL" knob to "0" initially and
� The premises is isolated and no feedback into
adjust to suit.
the utility system can occur. Certain laws
require the premises to be isolated before the
8. Set the "IDLE" switch to the "AUTO" position.
generator is linked to the premises. Check your
local requirements.
9. When the gun trigger is closed, the current sens-
----------------------------------------------------------------------
ing circuit will cause the VANTAGE 400 (CE)
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 (CE)
INSTALLATION
A-8 A-8
WARNING
Connection of the LN-25 to the VANTAGE 400 (CE)
Shut off welder before making any electrical con-
nections.
------------------------------------------------------------------------
The LN-25 with or without an internal contactor may
be used with the VANTAGE 400 (CE). See the appro-
priate connection diagram in Section F.
NOTE: The LN-25 (K431) Remote Control Module
and (K432) Remote Cable are not recommended for
use with the VANTAGE 400 (CE).
1. Shut the welder off.
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.
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.
4. Set the MODE switch to the "CV-WIRE " position.
5. Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON"
6. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
7. Set the "IDLE" switch to the "AUTO" position.
When not welding, the VANTAGE 400 (CE)
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.
8. When the gun trigger is closed, the current sens-
ing circuit will cause the VANTAGE 400 (CE)
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.
CAUTION
If you are using an LN-25 without an internal con-
tactor, the electrode will be energized when the
VANTAGE 400 (CE) is started.
------------------------------------------------------------------------
VANTAGE® 400 (CE)
OPERATION
B-1 B-1
SAFETY PRECAUTIONS � 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-
WARNING essary).
� See Engine Owner s Manual for specific oil and
Do not attempt to use this equipment until you
coolant recommendations.
have thoroughly read the engine manufacturer s
manual supplied with your welder. It includes
important safety precautions, detailed engine
WARNING
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ADD FUEL
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts or � Stop engine while fueling.
electrode with skin or wet clothing.
� Do not smoke when fueling.
� Insulate yourself from work and
ground � Keep sparks and flame away
� Always wear dry insulating gloves. from tank.
� Do not leave unattended while
� Always operate the welder with the fueling.
hinged door closed and the side pan-
DIESEL FUEL � Wipe up spilled fuel and allow
els in place.
fumes to clear before starting
can cause fire.
engine.
� Read carefully the Safety Precautions page
� Do not overfill tank, fuel
before operating this machine. Always follow
these and any other safety procedures included expansion may cause over-
in this manual and in the Engine Instruction flow.
DIESEL FUEL ONLY-Low sulphur fuel or ultra low
Manual.
sulphur fuel in U.S.A. and Canada.
GENERAL DESCRIPTION ------------------------------------------------------------------------
� Remove the fuel tank cap.
The VANTAGE 400 (CE) is a diesel engine powered
DC multi-process welding power source and AC
� Fill the tank. DO NOT FILL THE TANK TO THE
power generator. The engine drives a generator that
POINT OF OVERFLOW.
supplies three phase power for the DC welding circuit,
single phase and Three Phase power for the AC auxil-
� Replace the fuel cap and tighten securely.
iary outlets. The DC welding control system uses state
of the art Chopper Technology CT for superior weld-
� See Engine Owner s Manual for specific fuel recom-
R
ing performance.
mendations.
The VANTAGE 400 (CE) is fitted with a selectable
BREAK-IN PERIOD
VRD(Voltage Reduction Device). The VRD operates
in the CC-Stick mode reducing the OCV to (<32 volts
The engine will use a small amount of oil during its
for Codes 11296, 11297), (<30 volts for Codes 11463,
“break-in� period. The break-in period is about 50 run-
11464) increasing operator safety when welding is
ning hours.
performed in environments with increased hazard of
electric shock.
Check the oil every four hours during break-in.
Change the oil after the first 50 hours of operation and
FOR AUXILIARY POWER: every 200 hours thereafter. Change the oil filter at
each oil change.
Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
CAUTION
regardless of the welding control settings providing no
welding current is being drawn.
During break-in, subject the Welder to moderate
ENGINE OPERATION loads. Avoid long periods running at idle. Before
stopping the engine, remove all loads and allow
Before Starting the Engine:
the engine to cool several minutes.
� 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 (CE)
OPERATION
B-2 B-2
FIGURE B.1
1 11
2 9
3
10
4
14
13
15
12 7
17 8
22
16
21
20
18
5 19
6
WELDING CONTROLS (Figure B.1) 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
1. OUTPUT CONTROL- The OUTPUT dial is used to preset the the Amptrol.
output voltage or current as displayed on the digital meters for the
2. DIGITAL OUTPUT METERS-The digital meters allow the
five welding modes. When in the CC-STICK, ARC GOUGING or
output voltage (CV-WIRE mode) or current (CC-STICK, DOWN-
CV-WIRE modes and when a remote control is connected to the
HILL PIPE, ARC GOUGING and TIG modes) to be set prior to
6-Pin or 14-Pin Connector, the auto-sensing circuit automatically
welding using the OUTPUT control dial. During welding, the
switches the OUTPUT CONTROL from control at the welder to
meter display the actual output voltage (VOLTS) and current
the remote control.
(AMPS). A memory feature holds the display of both meters on
for seven seconds after welding is stopped. This allows the oper-
When in the DOWNHILL PIPE mode and when REMOTE CON-
ator to read the actual current and voltage just prior to when
TROL is connected to the 6-Pin or 14-Pin Connector, the OUTPUT
welding was ceased.
CONTROL is used to set the maximum current range of the OUT-
PUT CONTROL of the REMOTE.
While the display is being held the left-most decimal point in
each display will be flashing. The accuracy of the meters is +/-
Example: When the OUTPUT CONTROL on the welder is set to
3%.
200 amps the current range on the REMOTE CONTROL will be
40-200 amps rather than the full 40-300 amps. Any current range
3. WELD MODE SELECTOR SWITCH-
that is less than the full range provides finer current resolution for
more fine tuning of the output. (Provides five selectable welding modes)
CV-WIRE
In the CV-WIRE mode, if the feeder being used has a voltage con- ARC GOUGING
trol when the wire feeder control cable is connected to the 14-Pin DOWNHILL PIPE
Connector, the auto-sensing circuit automatically makes OUTPUT CC-STICK
CONTROL inactive and the wire feeder voltage control active. TOUCH START TIG
Otherwise, the OUTPUT CONTROL is used to preset the voltage
VANTAGE® 400 (CE)
OPERATION
B-3 B-3
4. ARC CONTROL- The ARC CONTROL dial is active in the CV-WIRE, 10. WIRE FEEDER VOLTMETER SWITCH:
CC-STICK and DOWNHILL PIPE modes, and has different functions in Matches the polarity of the wire feeder voltmeter to the polarity of the
these modes. This control is not active in the TIG and ARC GOUGING electrode.
mode.
11. VRD (Voltage Reduction Device) INDICATOR LIGHTS- On
CC-STICK mode: In this mode, the ARC CONTROL dial sets the short cir-
the front panel of the VANTAGE 400 (CE) are two indicator lights. A red
cuit current (arc-force) during stick welding to adjust for a soft or crisp arc.
light when lit indicates OCV(Open Circuit Voltage) is equal to or greater
Increasing the dial from �10 (soft) to +10 (crisp) increases the short circuit
than (32V�), (30V�) and a green light when lit indicates OCV(Open Circuit
current and prevents sticking of the electrode to the plate while welding.
Voltage) is less than (32V�), (30V�).
This can also increase spatter. It is recommended that the ARC CONTROL
be set to the minimum number without electrode sticking. Start with a set-
ting 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
DOWNHILL PIPE mode: In this mode, the ARC CONTROL dial sets the machine is first started with VRD enabled, both lights will illuminate for 5
short circuit current (arc-force) during stick welding to adjust for a soft or a seconds.
more forceful digging arc (crisp). Increasing the number from �10 (soft) to
+10 (crisp) increases the short circuit current which results in a more force-
These lights monitor the OCV(Open Circuit Voltage) and weld voltage at all
ful digging arc. Typically a forceful digging arc is preferred for root and hot
times. In the CC-Stick mode when not welding the green light will illumi-
passes. A softer arc is preferred for fill and cap passes where weld puddle
nate indicating that the VRD has reduced the OCV to less than (32V�),
control and deposition ("stacking" of iron) are key to fast travel speeds. It is
(30Vâ—?). During welding the red light will illuminate whenever the arc volt-
recommended that the ARC CONTROL be set initially at 0.
age is equal to or greater than (32V�), (30V�). This means that the red
CV-WIRE mode: In this mode, turning the ARC CONTROL clock wise from and green light may alternate depending on the weld voltage. This is nor-
�10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp mal operation.
and narrow. It acts as an inductance/pinch control. The proper setting
depends on the procedure and operator preference. Start with a setting of If the red light remains illuminated when not welding in the CC-stick
0. 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 work cables. If the VRD is turned “On� and the lights don t come “On�, refer to the trou-
ble shooting section.
6. GROUND STUD- Provides a connection point for connecting the � For Codes 11296, 11297.
machine case to earth ground. â—? For Codes 11463, 11464.
TABLE B.1
7. 14-PIN CONNECTOR- For attaching wire feeder control cables. VRD INDICATOR LIGHTS
MODE VRD "ON" VRD "OFF"
Includes contactor closure circuit, auto-sensing remote control circuit, and
CC-STICK OCV Green (OCV Reduced)
42V power. The remote control circuit operates the same as the 6 Pin While Red or Green
Amphenol. Welding (Depends on Weld Voltage) *
CV-WIRE OCV Red (OCV Not Reduced)
8. 6-PIN CONNECTOR- For attaching optional remote control equip- Weld Terminals On
Red (OCV Not Reduced)
ment. Includes auto-sensing remote control circuit. Weld Terminals Remotely Controlled
Gun Trigger Closed
9. WELD TERMINALS CONTROL SWITCH- In the WELD TERMI- Green (No OCV)
Weld Terminals Remotely Controlled
NALS ON position, the output is electrically hot all the time. In the Gun Trigger Open No Lights
REMOTELY CONTROLLED position, the output is controlled by a wire While Red or Green
Welding (Depends on Weld Voltage) *
feeder or amptrol device, and is electrically off until a remote switch is
PIPE OCV Green (No Output)
depressed. While Not Applicable (No Output)
Welding
ARC GOUGING OCV Green (No Output)
While Not Applicable (No Output)
Welding
TIG OCV Green (Process is Low Voltage)
While Green (Process is Low Voltage)
Welding
* It is normal for the lights to alternate between colors while welding.
VANTAGE® 400 (CE)
OPERATION
B-4 B-4
ENGINE CONTROLS: 18. ENGINE PROTECTION LIGHT- A warning indi-
cator light for Low Oil Pressure and/or Coolant Over
12. RUN/STOP SWITCH - RUN position energizes the
Temperature.The light is off when the systems are func-
engine prior to starting. STOP position stops the
tioning properly. The light will come on and the engine
engine. The oil pressure interlock switch prevents bat-
will shutdown when there is Low Oil Pressure and/or
tery drain if the switch is left in the RUN position and
the Coolant is Over Temperature.
the engine is not operating.
Note: The light remains off when the RUN-STOP switch
13. GLOW PLUG PUSH BUTTON - is in the "ON" position prior to starting the
� When pushed activates the glow plugs. Glow plug engine.However if the engine is not started within 60
should not be activated for more than 20 seconds con- seconds the light will come on. When this happens the
tinuously. 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. 19. BATTERY CHARGING LIGHT- A warning indica-
tor light for Low/No battery charge. The light is off when
15. IDLER SWITCH- Has two positions as follows: the systems are functioning properly. The light will
1) In the HIGH position, the engine runs at the high idle come on if there is a Low/No battery condition but the
speed controlled by the engine governor. machine will continue to run.
2) In the AUTO position, the idler operates as follows:
� When switched from HIGH to AUTO or after starting Note: The light may or may not come on when the RUN-
the engine, the engine will operate at full speed for STOP switch is in the "ON" position. It will come on during
approximately 12 seconds and then go to low idle cranking and stay on until the engine starts. After starting
speed. the engine the light will go off unless a Low/No battery
� When the electrode touches the work or power is charge condition exists.
drawn for lights or tools (approximately 100 Watts mini-
mum), the engine accelerates and operates at full 20. COOLANT TEMPERATURE GAUGE- A indica-
speed. tor of engine coolant temperature.
� When welding ceases or the AC power load is turned
off, a fixed time delay of approximately 12 seconds
21. OIL PRESSURE GAUGE- A indicator of engine
starts. If the welding or AC power load is not restarted
Oil Pressure.
before the end of the time delay, the idler reduces the
engine speed to low idle speed.
22. CIRCUIT BREAKER
� The engine will automatically return to high idle speed
when there is welding load or AC power load reapplied.
STARTING THE ENGINE
16. ELECTRIC FUEL GAUGE- The electric fuel 1. Remove all plugs connected to the AC power recepta-
cles.
gauge gives accurate and reliable indication as to how
2. Set IDLER switch to AUTO.
much fuel is in the fuel tank.
17. ENGINE HOUR METER- Displays the total time
3. Press Glow Plug Button and hold 15 to 20 seconds.
that the engine has been running. This meter is useful
4. Set the RUN/STOP switch to RUN.
for scheduling prescribed maintenance.
5. Press START button until the engine starts or for up to 10
TABLE B.2 seconds. Continue to hold the glow plug button for up to
TYPICAL VANTAGE 400 (CE) FUEL CONSUMPTION an additional 10 seconds.
PERKINS (404C-22), (404D-22) Running Time ( Hours) 6. Release the engine START button immediately when the
Gal./Hr (Liters/Hr) Codes 11296, 11297 Codes 11463, 11464 engine starts.
15 gallon tank 20 gallon tank 7. The engine will run at high idle speed for approximately
Low Idle - No Load 68.96
51.93
.29(1.10) 12 seconds and then drop to low idle speed. Allow the
1200 R.P.M.
engine to warm up at low idle for several minutes before
High Idle - No Load .43(1.63) 46.51
34.96
applying a load and/or switching to high idle. Allow a
1565 R.P.M.
longer warm up time in cold weather.
DC Weld Output 1.27(4.81) 15.75
11.80
350 Amps @ 34Volts
13,200 Watts 3 Phase 1.35(5.11) 14.81
11.11
NOTE: This data is for reference only. Fuel consumption is approxi-
mate and can be influenced by many factors, including engine mainte-
nance, environmental conditions and fuel quality.
VANTAGE® 400 (CE)
OPERATION
B-5 B-5
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
The ARC CONTROL dial sets the short circuit current
waiting 30 seconds.
(arc-force) during stick welding to adjust for a soft or
CAUTION 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.
� Do not allow the starter motor to run continuously
This can also increase spatter. It is recommended that
for more than 20 seconds.
the ARC CONTROL be set to the minimum number
� Do not push the START button while the engine
without electrode sticking. Start with the dial set at 0.
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
� If the Engine Protection or Battery Charging
very slight delay during striking of the electrodes
Lights do “not� turn off shortly after starting the
may occur. Due to the requirement of the resis-
engine shut off the engine immediately and
tance in the circuit to be low for a VRD to operate, a
determine the cause.
good metal-to-metal contact must be made
-----------------------------------------------------------------------
between the metal core of the electrode and the
NOTE: When starting for the first time, or after and
job. A poor connection anywhere in the welding
extended period of time of not operating, it will take
output circuit may limit the operation of the VRD.
longer than normal to start because the fuel pump has
This includes a good connection of the work clamp
to fill the fuel system. For best results, bleed the fuel
to the job. The work clamp should be connected as
system as indicated in Maintenance Section of this
close as practical to where the welding will be per-
manual.
formed.
STOPPING THE ENGINE
A. For New Electrodes
Remove all welding and auxiliary power loads and
E6010 - Touch, Lift to Start the Arc
allow the engine to run at low idle speed for a few
E7018, E7024 - Touch, Rock Back and Forth in
minutes to cool the engine.
Joint, Lift .
STOP the engine by placing the RUN-STOP switch in
Once the arc is started, normal welding technique
the STOP position.
for the application is then used.
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
WELDER OPERATION
electrode after the welding arc has been broken,
DUTY CYCLE particularly iron powder and low hydrogen elec-
trodes. This cone will need to be broken off in order
Duty Cycle is the percentage of time the load is being
to have the metal core of the electrode make con-
applied in a 10 minute period. For example a 60% duty
tact.
cycle, represents 6 minutes of load and 4 minutes of no
load in a 10 minute period.
E6010 - Push, Twist in Joint, Lift
ELECTRODE INFORMATION E7018, E7024 - Push, Rock Back and Forth in
Joint, Lift.
For any electrode the procedures should be kept with-
in the rating of the machine. For information on elec-
Once the arc is started, normal welding technique
trodes and their proper application see
for the application is then used.
(www.lincolnelectric.com) or the appropriate Lincoln
publication.
For other electrodes the above techniques should
be tried first and varied as needed to suit operator
The VANTAGE 400 (CE) can be used with a broad range
preference. The goal for successful starting is good
of DC stick electrodes. The MODE switch provides two
metal to metal contact.
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
This slope controlled setting is intended for "out-of-
electrodes, especially low hydrogen. The OUTPUT CON-
position" and "down hill" pipe welding where the oper-
VANTAGE® 400 (CE)
OPERATION
B-6 B-6
work in a rocking motion, which establishes the arc.
ator would like to control the current level by changing
the arc length.
When in the TOUCH START TIG mode and when a
The OUTPUT CONTROL dial adjusts the full output
Amptrol is connected to the 6-Pin connector the OUT-
range for pipe welding.
PUT CONTROL dial is used to set the maximum cur-
rent range of the current control of the Amptrol.
The ARC CONTROL dial sets the short circuit current
(arc-force) during stick welding to adjust for a soft or
The ARC CONTROL is not active in the TIG mode. To
more forceful digging arc (crisp). Increasing the number
STOP a weld, simply pull the TIG torch away from the
from -10(soft) to +10(crisp) increases the short circuit
work.
current which results in a more forceful digging arc.
When the arc voltage reaches approximately 30 Volts
Typically a forceful digging arc is preferred for root and
the arc will go out and the machine will reset the cur-
hot passes. A softer arc is preferred for fill and cap pass-
rent to the Touch Start level.
es where weld puddle control and deposition (“stacking�
of iron) are key to fast travel speeds. This can also
To reinitiate the arc, retouch the tungsten to the work
increase spatter.
and lift. Alternatively, the weld can be stopped by
It is recommended that the ARC CONTROL be set to the releasing the Amptrol or arc start switch.
minimum number without electrode sticking. Start with
the dial set at 0. The VANTAGE 400 (CE) can be used in a wide vari-
ety of DC TIG welding applications. In general the
NOTE: With the VRD switch in the “ON� position there is
Touch Start feature allows contamination free start-
no output in the DOWNHILL PIPE mode. For indicator
ing without the use of a Hi-frequency unit. If desired,
light operation, see table B.1.
the K930-2 TIG Module can be used with the VAN-
TAGE 400 (CE). The settings are for reference.
TIG WELDING
VANTAGE 400 (CE) settings when using the K930-2
The TOUCH START TIG setting of the MODE switch is
TIG Module with an Amptrol or Arc Start Switch:
for DC TIG (Tungsten Inert Gas) welding. To initiate a
� Set the MODE Switch to the TOUCH START TIG
weld, the OUTPUT CONTROL dial is first set to the
setting.
desired current and the tungsten is touched to the work.
During the time the tungsten is touching the work there is
� Set the "IDLER" Switch to the "AUTO" position.
very little voltage or current and, in general, no tungsten
contamination. Then, the tungsten is gently lifted off the
TABLE B.3
RANGES (1) FOR TUNGSTEN ELECTRODES(2)
TYPICAL CURRENT
Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH
Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)
1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel
Tungsten Tungsten
.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6
0.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)
0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (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 EWTh-1
2% Thoriated 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. (6 mm)
# 5 = 5/16 in. (8 mm)
# 6 = 3/8 in. (10 mm)
# 7 = 7/16 in. (11 mm)
# 8 = _ in. (12.5 mm)
#10 = 5/8 in. (16 mm)
(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.
VANTAGE® 400 (CE)
OPERATION
B-7 B-7
Voltage) is not reduced. For indicator light operation,
� Set the "WELDING TERMINALS" switch to the
see table B.1.
"REMOTELY CONTROLLED" position.
ARC GOUGING
This will keep the "Solid State" contactor open and provide a
"cold" electrode until the Amptrol or Arc Start Switch is pressed. The VANTAGE 400 (CE) can be used for arc gouging. For opti-
mal performance, set the MODE switch to ARC GOUGING.
When using the TIG Module, the OUTPUT CONTROL on the
VANTAGE 400 (CE) is used to set the maximum range of the Set the OUTPUT CONTROL knob to adjust output current to
CURRENT CONTROL on the TIG Module or an Amptrol if con-
TABLE B.4
nected to the TIG Module.
Carbon Diameter Current Range (DC, electrode
NOTE: The TIG process is to receive a low voltage welding
positive)
process. There is no difference in operation with the
1/8" (3.2mm) 60-90 Amps
VRD “On� or “Off� for this mode. For indicator light oper-
5/32" (4.0mm) 90-150 Amps
ation, see table B.1.
3/16" (4.8mm) 200-250 Amps
WIRE WELDING-CV 1/4" (6.4mm) 300-400 Amps
Connect a wire feeder to the VANTAGE 400 (CE) according to The ARC CONTROL is not active in the ARC GOUGING Mode.
the instructions in INSTALLATION INSTRUCTIONS Section. The ARC CONTROL is automatically set to maximum when the
ARC GOUGING mode is selected which provides the best ARC
The VANTAGE 400 (CE) in the CV-WIRE mode, permits it to be GOUGING performance.
used with a broad range of flux cored wire (Innershield and
Outershield) electrodes and solid wires for MIG welding (gas Note: With the VRD switch in the “ON� position there is no out-
metal arc welding). Welding can be finely tuned using the ARC put in the Arc Gouging Mode. For indicator light operation, see
CONTROL. Turning the ARC CONTROL clockwise from �10 table B.1.
(soft) to +10 (crisp) changes the arc from soft and washed-in to
AUXILIARY POWER:
crisp and narrow. It acts as an inductance/pinch control. The
proper setting depends on the procedure and operator prefer- Start the engine and set the IDLER control switch to the desired
ence. Start with the dial set at 0. operating mode. Full power is available regardless of the weld-
ing control settings providing no welding current is being drawn.
NOTE: In the CV-Mode with VRD “On�, the OCV(Open Circuit
Simultaneous Welding and Auxiliary Power Loads
The auxiliary power ratings are with no welding load.
Simultaneous welding and power loads are specified in Table
B.5.
TABLE B.5
SIMULTANEOUS WELDING AND AUXILIARY POWER OUTPUT
WELDING OUTPUT AUXILIARY POWER OUTPUT AUXILIARY POWER OUTPUT
(AMPS) (AMPS @ 400V, 3-PHASE)
(WATTS)
0 19.0
13,200
100 15.3
10,600
200 10.7
7,400
300 4.9
3,400
350 1.6
1,100
MAX 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
15 120 1800 30 (9) 40 (12) 75 (23) 125 (38) 175 (53) 300 (91)
20 120 2400 30 (9) 50 (15) 88 (27) 138 (42) 225 (69)
15 240 3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)
20 240 4800 60 (18) 100 (30) 175 (53) 275 (84) 450 (137)
44 240 9500 50 (15) 90 (27) 150 (46) 225 (69)
Conductor size is based on maximum 2.0% voltage drop.
VANTAGE® 400 (CE)
ACCESSORIES
C-1 C-1
FIELD INSTALLED OPTIONS / KP1696-1 Drive Roll Kit- Includes: 2 V groove drive
ACCESSORIES rolls and inner wire guide for Steel Wires. (Used on
LN-25 Pro)
K903-1 SPARK ARRESTOR - Includes a heavy gage steel,
K449 LN-25 - Includes internal contactor for across the arc
approved spark arrestor, clamp and adapter for mounting to
operation (no control cable). Provides “cold� electrode until
the muffler exhaust pipe.
gun trigger is pressed. Includes gas solenoid. For spools up
to 44 LBS (20Kg).
K704 ACCESSORY SET - Includes 35 ft. (10m) of elec-
trode cable and 30 ft. (9.1m) of work cable, headshield,
K1870-1 LN-15 Across the Arc Wire Feeder.
work clamp electrode holder. Cables are rated at 400
Portable, lightweight, compact CC/CV unit for flux-cored and
amps, 100% duty cycle.
MIG welding. Includes Gas Solenoid, adjustable flow meter
and internal contactor. For 10-15 lb. (4.5-6.8kg) spools.
K857 25 ft (7.6m) or K857-1 100 ft. (30.4m) REMOTE
CONTROL
Magnum Gun and Magnum Gun Connector Kit are required
Portable control provides same dial range as the output con-
for gas-shielded welding. Innershield Gun is required for
trol on the welder. Has a convenient 6 pin plug for easy con-
gasless welding.
nection to the welder.
K126-2 Magnum 350 Innershield Gun
K1802-1 Magnum 300 MIG Gun (for LN-25)
K1858-1 Service Indicator Kit- Provides a GO / NO-GO
K470-2 Magnum 300 MIG Gun (for LN-15, Includes
visual indication of air cleaner element useful service life.
Connector Kit)
Filter service based on restriction readings allows the
K466-10 Connector Kit (for LN-15, K470-2)
longest life possible from the filter and best engine protec-
K1500-1 Gun Receiver Bushing (for LN-15 & K126-2)
tion.
Note: See Wire Feeder IM manuals for appropriate Drive
K2641-2 Trailer - A 4-wheel steerable trailer for in- Roll and Guide Tubes.
plant and yard towing. Comes standard with a Duo-
TIG OPTIONS
Hitch�, a 2� Ball and Lunette Eye combination hitch.
K1783-9 Pro -Torch® PTA-26V TIG Torch
K2642-1 Polarity/Multi-Process Switch- For easy polarity Air Cooled 200 amp torch (2 piece) equipped with valve for
switching. Example: DC- stick root pass on pipe and DC+ gas flow control. 25 ft. (7.6m) length.
stick for hot, fill and cap passes. Also for an easy process
change. Example DC+ stick root pass on pipe and DC_ KP509 Magnum Parts Kit for PTA-26V TIG Torch
innershield self shielded flux core wire for hot, fill and gap Magnum Parts Kit provides all the torch accessories you
passes. 6 and 14 pin remote connections can be made to need to start welding. Parts kit provides collets, collet bod-
this unit. For all lincoln Chopper technology engine-drive ies, a black cap, alumina nozzles and tungstens in a variety
welders Mounts on roof with Docking Kit. of sizes, all packaged in an easy to carry reclosable sack.
K2663-1 Docking Kit-Secures Polarity/Multi-Process
Switch, mounts on the roof of all Lincoln Chopper technolo- K870 Foot Amptrol®
gy engine-drives. K963-3 Hand Amptrol®
K2535-1 Precision TIG 225 Ready-Pak(For AC TIG)
K2627-2 Remote Output Control with 120V AC
Receptacle- Remote Output Control box with two 120V AC K2350-2 Invertec® V205-T AC/DC One-Pak� Package
receptacles having GFCI (Ground Fault Circuit Interrupter) (For AC TIG)
protection.
WIRE FEEDER OPTIONS PLASMA CUTTING
K2613-1 LN-25 PRO PORTABLE WIRE FEEDER-The K1601-1 Pro-Cut 55-Cuts metal using the 3-phase AC gen-
MAXTRAC® wire drive enhances performance, while the erator power from the engine driven welder. Accepts 3-
replacement case, and many other upgrade options that can phase power.
be installed in less then five minutes aid in the serviceability.
KP1697-5/64 Drive Roll Kit- Includes: 2 polished U
groove drive rolls, outer wire guide and inner wire
guide for solid core wire. (Used on LN-25 Pro)
KP1697-068 Drive Roll Kit- Includes: 2 polished U
groove drive rolls, outer wire guide and inner wire
guide for solid core wire. (Used on LN-25 Pro)
VANTAGE® 400 (CE)
MAINTENANCE
D-1 D-1
SAFETY PRECAUTIONS Read the Safety Precautions in the front of this
manual and in the Engine Owner s Manual before
WARNING working on this machine.
� Have qualified personnel do all maintenance
Keep all equipment safety guards, covers, and
and troubleshooting work.
devices in position and in good repair. Keep
hands, hair, clothing, and tools away from the
� Turn the engine off before working inside the
gears, fans, and all other moving parts when
machine or servicing the engine.
starting, operating, or repairing the equipment.
------------------------------------------------------------
� Remove guards only when necessary to
Routine Maintenance
perform maintenance and replace them when
the maintenance requiring their removal is
complete. If guards are missing from the At the end of each day s use, refill the fuel tank to
machine, obtain replacements from a Lincoln minimize moisture condensation in the tank. Running
Distributor. (See Operating Manual Parts List.) out of fuel tends to draw dirt into the fuel system.
Also, check the crankcase oil level and add oil if
indicated.
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE (20 / 50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 250 HOURS OR 6 MONTHS
EVERY 500 HOURS OR 12 MONTHS
EVERY 1000 HOURS
ENGINE SERVICE (NOTE 2)
MAINTENANCE ITEM TYPE OR QUANTITY
Coolant Level
I
Concentration of Antifreeze 50/50 Water/Ethylene Glycol
I
R Coolant (NOTE 3) 9.5 qt., 9.0 L
Engine oil level (NOTE 1)
I
8.45 qt., 8 L (Including filter)
Engine oil (NOTE 1 & 3)
R R
Perkins #140517050
Engine oil filter
R R
Drain water separator & fuel strainer
C
R Water separator element Lincoln # M20840-A
Perkins #130366120
R Fuel filter canister
I Tension of alternator drive belt
I Alternator drive belt wear
Perkins #080109107
R Alternator drive belt
C Air filter (earlier check may be required)
Donaldson #P821575
R Air filter element
R Renew the engine breather
I Tighten cylinder head
Intake .008", exhaust .008"
I Valve clearances
I Electrical systems
I All nuts and bolts for tightness
Contact Perkins
I Injector performance
I Leaks or engine damage
I Battery
I = Inspect C = Clean R = Replace
Notes:
(1) Consult Engine Operators Manual for oil recommendations.
(2) Consult Engine Operators Manual for additional maintenance schedule
information.
(3) Fill slowly! Ensure correct quantity is used.
Above operations to be carried out by trained personnel with reference to the
workshop manual where necessary.
These preventive maintenance periods apply to average conditions of operation.
If necessary, use shorter peroids.
S26354 VM
VANTAGE® 400 (CE)
MAINTENANCE
D-2 D-2
ENGINE OIL CHANGE OIL FILTER CHANGE
Drain the engine oil while the engine is warm to assure � Drain the oil.
rapid and complete draining. It is recommended that
each time the oil is changed the oil filter be changed as � Remove the oil filter with an oil filter wrench and
well. drain the oil into a suitable container. Discard the
used filter. Note: Care should be taken during filter
� Be sure the unit is off. Disconnect the negative bat- removal to not disrupt or damage in any way the fuel
tery cable to ensure safety. lines.
� Locate oil drain hose and valve in bottom of base � Clean the filter mounting base and coat the gasket
and pull through the hole in the battery access panel of the new filter with clean engine oil.
on the welder.
� Screw the new filter on by hand until the gasket con-
� Open oil drain valve by lifting up spring loaded lever tacts the mounting base. Using an oil filter wrench,
and rotate 90° counterclockwise. Pull to open and tighten the filter an additional 1/2 to 7/8 of a turn.
drain the oil into a suitable container for disposal. � Refill the crankcase with the specified amount of the
recommended engine oil. Reinstall the oil filler cap
� Close the drain valve by rotating lever 90° clockwise. and tighten securely.
� 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-
� Stop the engine and check the oil level. If neces-
ation manual OR engine service items decal OR
sary, add oil to the upper limit mark on the dipstick.
below). Replace and tighten the oil filler cap secure-
ly.
WARNING
� 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
� Never use gasoline or low flash point solvents
hands with soap and water after handling used motor
for cleaning the air cleaner element. A fire or
oil. Please dispose of used motor oil in a manner
explosion could result.
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
CAUTION
throw it in the trash; pour it on the ground or down a
drain.
� Never run the engine without the air cleaner.
Rapid engine wear will result from contaminants,
Use motor oil designed for diesel engines that meets
such as dust and dirt being drawn into the
requirements for API service classification
engine.
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 The diesel engine is equipped with a dry type air filter.
diesel engine or damage may result. It IS permissible Never apply oil to it. Service the air cleaner as follows:
to use an oil that meets S and C grade service classifi-
cations.) 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 owner s manual for more specific informa-
tion on oil viscosity recommendations.
VANTAGE® 400 (CE)
MAINTENANCE
D-3 D-3
Service Instructions
Single- and Two-Stage Engine Air Cleaners
Inspect the New Filter for Damage
Remove the Filter
Inspect the new filter carefully, paying attention to
Unfasten or unlatch the
the inside of the open end, which is the
service cover. Because
sealing area. NEVER install a damaged
the filter fits tightly over the
filter. A new Donaldson radial seal
outlet tube to create the critical seal, there will filter may have a dry lubricant on the
be some initial resistance, similar to breaking seal to aid installation.
Rotate the
the seal on a jar. Gently move the end of the filter
filter while
pulling
back and forth to break the seal then rotate while
straight out.
pulling straight out. Avoid knocking the filter
against the housing.
Insert the New Radial Seal Filter Properly
If your air cleaner has a safety filter, replace it every third primary If you're servicing the safety filter, this should be seated into
filter change. Remove the safety filter as you would the primary position before installing the primary filter.
filter. Make sure you cover the air cleaner outlet tube to avoid any
Insert the new filter carefully. Seat
unfiltered contaminant dropping into the engine.
the filter by hand, making certain it is
completely into the air cleaner housing
Clean Both Surfaces of the Outlet Tube before securing the cover in place.
and Check the Vacuatorâ„? Valve The critical sealing area will stretch
Use a clean cloth to wipe the filter sealing surface and the inside of slightly, adjust itself and distribute the sealing pressure evenly. To
the outlet tube. Contaminant on the sealing surface could hinder an complete a tight seal, apply pressure by hand at the outer rim of
effective seal and cause leakage. Make sure that all contaminant is the filter, not the flexible center. (Avoid pushing on the center of the
removed before the new filter is inserted. Dirt accidently transferred urethane end cap.) No cover pressure is required to hold the seal.
to the inside of the outlet tube will reach the engine and cause NEVER use the service cover to push the filter into place! Using the
cover to push the filter in could cause damage to the housing, cover
wear. Engine manufacturers say that it takes only a few grams of
fasteners and will void the warranty.
dirt to "dust" an engine! Be careful not to damage the sealing area
on the tube.
If the service cover hits the filter before it is fully in place, remove
the cover and push the filter (by hand) further into the air cleaner
and try again. The cover should go on with no extra force.
Wipe both sides
of the outlet
tube clean. Once the filter is in place, secure the service cover.
Outer edge of the
Caution
Inner edge of the
outlet tube
outlet tube
NEVER use the service cover to
If your air cleaner is equipped with a Vacuator Valve push the filter into place! Using
Visually check and physically squeeze to make sure the the cover to push the filter in could
valve is flexible and not inverted, damaged or plugged. cause damage to the housing, cover
fasteners and will void the warranty.
Inspect the Old
Filter for Leak Clues
Check Connectors for Tight Fit
Visually inspect the old filter for any signs
Make sure that all mounting bands, clamps, bolts, and connections
of leaks. A streak of dust on the clean side
in the entire air cleaner system are tight. Check for holes in piping
of the filter is a telltale sign. Remove any and repair if needed. Any leaks in your intake piping will send dust
cause of leaks before installing new filter. directly to the engine!
VANTAGE® 400 (CE)
MAINTENANCE
D-4 D-4
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 day s use, refill the fuel tank to min-
imize moisture condensation and dirt contamination in
� Do not remove cap if radiator is
the fuel line. Do not overfill; leave room for the fuel to
hot.
expand.
Use only fresh No. 2D diesel fuel, the use of No. 1D
------------------------------------------------------------------------
diesel fuel is recommended in place of No. 2D at tem-
Check the coolant level by observing the level in the
peratures below 23°F (-5°C). Do not use kerosene.
radiator and recovery bottle. Add 50/50 antifreeze /
water solution if the level is close to or below the
See the Engine Operator's Manual for instructions on
"LOW" mark. do not fill above the "FULL" mark.
replacing the fuel filter.
Remove radiator cap and add coolant to radiator. Fill
up to the top of the tube in the radiator filler neck
BLEEDING THE FUEL SYSTEM
which includes a connecting hose coming from the
thermostat housing.
You may need to bleed air from the fuel system if the
fuel filter or fuel lines have been detached, the fuel
To drain the coolant, open the valve at the bottom of
tank has been ran empty or after periods of long stor-
the radiator. Open the radiator cap to allow complete
age. It is recommended that the fuel shutoff valve be
drainage. (Tighten the valve and refill with a 50/50
closed during periods of non-use.
antifreeze/water solution.) Use an automotive grade
(low silicate) ethylene glycol antifreeze. The cooling
WARNING
system capacity is 8.0 quarts (7.6L.). Squeeze upper
and lower radiator hoses while filling to bleed air from
To avoid personal injury, do not bleed a hot
system coolant. Replace and tighten the radiator cap.
engine. This could cause fuel to spill onto a hot
exhaust manifold, creating a danger of fire.
CAUTION ------------------------------------------------------------------------
Bleed the fuel system as follows:
Always premix the antifreeze and clean tap water
1. Fill the fuel tank with fuel.
before adding to the radiator. It is very important
2. Open the fuel shut off valve.
that a precise 50/50 solution be used with this
3. Loosen bleed fitting on the fuel injector manifold.
engine year round. This gives proper cooling dur-
4. Operate hand priming lever until fuel comes out the
ing hot weather and freezing protection to -34° F (-
bleed screw on the injector manifold. This could
37° C).
take 20-30 seconds of rapid operation of the prim-
ing lever. Tighten bleed fitting on injector manifold.
Cooling solution exceeding 50% ethylene glycol
5. Follow normal STARTING procedures until engine
can result in engine overheating and damage to
starts.
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 (CE)
MAINTENANCE
D-5 D-5
CLEANING THE BATTERY
FUEL FILTER
Keep the battery clean by wiping it with a damp cloth
1. Check the fuel filter and fuel pre-filter for water when dirty. If the terminals appear corroded, discon-
accumulation or sediment. nect the battery cables and wash the terminals with an
ammonia solution or a solution of 1/4 pound (0.1113
2. Replace the fuel filter if it is found with excessive kg) of baking soda and 1 quart (0.9461L) of water. Be
water accumulation or sediment. Empty fuel pre-fil- sure the battery vent plugs (if equipped) are tight so
ter. that none of the solution enters the cells.
After cleaning, flush the outside of the battery, the bat-
OVERSPEED IS HAZARDOUS tery compartment, and surrounding areas with clear
The maximum allowable high idle speed for this water. Coat the battery terminals lightly with petroleum
machine is 1890 RPM, no load. Do NOT tamper jelly or a non-conductive grease to retard corrosion.
with governor components or setting or make any Keep the battery clean and dry. Moisture accumula-
other adjustments to increase the maximum tion on the battery can lead to more rapid discharge
speed. Severe personal injury and damage to the and early battery failure.
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
Adjustments to the engine are to be made only by a hole with distilled water and recharge. If one cell is
Lincoln Service Center or an authorized Field Service low, check for leaks.
Shop.
CHARGING THE BATTERY
BATTERY MAINTENANCE When you charge, jump, replace, or otherwise con-
To access the battery, remove the battery tray from nect battery cables to the battery, be sure the polarity
the front of the machine with 3/8� nut driver or flat is correct. Improper polarity can damage the charging
head screw driver. Pull the tray out of machine far circuit. The VANTAGE 400 (CE) positive (+) battery
enough to disconnect the negative and then positive terminal has a red terminal cover.
battery cables. The tray can then be tilted and lifted to
remove the entire tray and battery from the machine If you need to charge the battery with an external
for easy service. charger, disconnect the negative cable first, then the
positive cable before you attach the charger leads.
WARNING After the battery is charged, reconnect the positive
battery cable first and the negative cable last. Failure
GASES FROM BATTERY can explode. to do so can result in damage to the internal charger
G Keep sparks, flame and cigarettes
components.
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
SERVICING OPTIONAL SPARK
G
negative cable from old battery first and con-
ARRESTOR
nect to new battery last.
CONNECTING A BATTERY CHARGER � Clean every 100 hours.
G
remove battery from welder by disconnecting
WARNING
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
� MUFFLER MAY BE HOT
USING A BOOSTER � connect positive lead to
G
battery first then connect negative lead to neg- � ALLOW ENGINE TO COOL BEFORE INSTALLING
ative battery lead at engine foot. THE SPARK ARRESTER!
BATTERY ACID can burn eyes and
skin. � DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTER!
G Wear gloves and eye protection
and be careful when working near
battery.
Follow instructions printed on battery.
G
VANTAGE® 400 (CE)
MAINTENANCE
D-6 D-6
WELDER / GENERATOR
MAINTENANCE
STORAGE: Store in clean, dry protected areas.
CLEANING: Blow out the generator and controls peri-
odically with low pressure air. Do this at least once a
week in particularly dirty areas.
BRUSH REMOVAL AND REPLACEMENT: It s nor-
mal for the brushes and slip rings to wear and darken
slightly. Inspect the brushes when a generator over-
haul is necessary.
CAUTION
� Do not attempt to polish slip rings while the
engine is running.
WARNING
� 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.
VANTAGE® 400 (CE)
TROUBLESHOOTING
E-1 E-1
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 Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. 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- If you do not understand or are unable to perform the
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
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 (CE)
TROUBLESHOOTING
E-2 E-2
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
Authorized Field Service
is Evident.
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) If 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,
Contact your local Lincoln
ken fan belt.
Authorized Field Service Facility.
5. Faulty fuel shutdown solenoid.
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 1. High coolant temperature or low
starting. 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 (CE)
TROUBLESHOOTING
E-3 E-3
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
3. Faulty engine alternator or charg- misadjustment have been checked
er module. Consult authorized and the problem persists, Contact
Engine Service Shop. your local Lincoln Authorized
Field Service Facility.
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 (CE)
TROUBLESHOOTING
E-4 E-4
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- solenoid linkage binding, Faulty If all recommended possible areas
iary power. Switching to manual PC board (Control or Idler), low of misadjustment have been
high idle does not work. idle speed set too low on idle checked and the problem persists,
Contact your local Lincoln
solenoid.
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.
TROUBLESHOOTING
E-5 E-5
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 0
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.
If 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 beaker and checked and the problem persists,
Contact your local Lincoln
connector. reset if tripped.
2. Faulty control cable. Repair or Authorized Field Service Facility.
replace cable.
3. Faulty wire feeder. Replace wire
feeder.
No auxiliary power. 1. Open circuit breakers. Reset
breakers. If breakers keep trip-
ping, reduce power draw.
2. Faulty connections to auxiliary
receptacles. Check connections.
3. RCD tripped. Clear any ground
fault and reset RCD circuit by
pressing "Reset" button.
4. 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.
TROUBLESHOOTING
E-6 E-6
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. 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
5. Faulty Control Board. misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
No output in Pipe Mode. 1. Make sure VRD ON/OFF toggle Field Service Facility.
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.
VRD Lights don t light up. 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 (CE)
DIAGRAMS
F-1 F-1
VANTAGE® 400 (CE)
DIAGRAMS
F-2 F-2
VANTAGE® 400 (CE)
DIAGRAMS
F-3 F-3
VANTAGE® 400 (CE)
DIAGRAMS
F-4 F-4
VANTAGE® 400 (CE)
F-5
VANTAGE 400 (CE) UK WIRING DIAGRAM (CODES 11296, 11463)
VANTAGE® 400 (CE)
WIRING DIAGRAM
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included
F-5
with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
VANTAGE 400 (CE) EURO WIRING DIAGRAM (CODES 11297, 11464)
F-6
VANTAGE® 400 (CE)
WIRING DIAGRAM
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included
F-6
with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-7
55.50 2.25
1409.7 57.2
27.00 25.82
685.8 655.8
N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, COOLANT IN RADIATOR, AND EMPTY FUEL TANK.
6.03 5.75 36.06
153.25 146.0 915.9
28.95
735.3
20.60
523.3
VANTAGE® 400 (CE)
DIMENSION PRINT
46.47
1180.36
N.A.
39.81
35.94
913.0
1.78
45.1
16.25
412.8
1.27
32.3
24.00 28.13
609.6 714.5
60.00
1524.0
A
F-7
L12964
NOTES
VANTAGE® 400 (CE)
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
AVISO DE
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
PRECAUCION
da.
G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ATTENTION
ments mouillés entrer en contact inflammable. votre corps.
avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
German G Berühren Sie keine stromführenden G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
WARNUNG
Teile oder Elektroden mit Ihrem perschutz!
Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
ATENÇÃO trodos com a pele ou roupa molha- dos. corpo.
da.
G 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 UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
WARNING
G Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
Spanish
AVISO DE
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
piración. mentación de poder de la máquina guardas quitadas.
PRECAUCION
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
ATTENTION
l’entretien. ouverts ou avec les dispositifs de
G Utilisez un ventilateur ou un aspira-
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
WARNUNG
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
nen; Maschine anhalten!) Betrieb setzen!
G Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
ATENÇÃO
G Desligue a corrente antes de fazer moventes.
G Use ventilação e exhaustão para
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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