Lincoln Electric Welder 400 AU User Manual
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IM10048  
VANTAGE ®400 (AU)  
March, 2010  
For use with machines having Code Numbers:  
11687  
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 thoughtful operation on your  
part. DO NOT INSTALL, OPER-  
ATE OR REPAIR THIS EQUIP-  
MENT WITHOUT READING  
THIS MANUAL AND THE SAFE-  
TY PRECAUTIONS CONTAINED  
THROUGHOUT. And, most  
importantly, think before you act  
and be careful.  
Equipped with VRD (VOLTAGE REDUCTION DEVICE)  
See Installation and Operation sections for an explanation.  
OPERATOR’S MANUAL  
Copyright © Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
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  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and within applicable OSHA PEL and  
ACGIH TLV limits using local exhaust or mechanical  
ventilation. In confined spaces or in some circum-  
stances, outdoors, a respirator may be required.  
Additional precautions are also required when welding  
on galvanized steel.  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5. b. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of  
the equipment, maintenance of the equipment and the spe-  
cific welding procedure and application involved. Worker  
exposure level should be checked upon installation and  
periodically thereafter to be certain it is within applicable  
OSHA PEL and ACGIH TLV limits.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.d. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
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.  
Jan ‘09  
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SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
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.  
If this is not possible, cover them to prevent  
the welding sparks from starting a fire.  
process used and properly operating  
regulators designed for the gas and  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
• Away from areas where they may be struck or subjected to  
physical damage.  
• A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact  
can cause overheating and create a fire hazard.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
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 follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available  
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma  
022690-9101.  
6.j. Do not use a welding power source for pipe thawing.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
Jan ‘09  
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SAFETY  
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  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
8. S’assurer que la masse est connectée le plus prés possible  
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  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher  
metallique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
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  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
2. Autant que possible, I’installation et l’entretien du poste seront  
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  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Mar. ‘93  
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SAFETY  
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  
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SAFETY  
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  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
CUSTOMER ASSISTANCE POLICY  
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-  
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln  
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-  
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-  
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any 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.  
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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 the Engine........................................................................................................B-4  
Fuel Consumption.........................................................................................................B-4  
Stopping the Engine.............................................................................................................B-5  
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  
________________________________________________________________________________  
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TABLE OF CONTENTS  
Maintenance......................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
Routine Maintenance ............................................................................................D-1  
Engine Service Items.............................................................................................D-1  
Engine Oil Change..........................................................................................D-2  
Engine Oil Filter Change.................................................................................D-2  
Air Cleaner .....................................................................................................D-2  
Service Instructions And Installation Tips for Engine Air Filter .......................D-3  
Cooling System .....................................................................................................D-4  
Fan Belt...........................................................................................................D-4  
Fuel.................................................................................................................D-4  
Bleeding the Fuel System...............................................................................D-4  
Fuel Filter........................................................................................................D-5  
Engine Adjustment..........................................................................................D-5  
Battery Maintenance .......................................................................................D-5  
Servicing Optional Spark Arrestor ...................................................................D-5  
Welder / Generator Maintenance ........................................................................D-6  
Storage ...........................................................................................................D-6  
Cleaning..........................................................................................................D-6  
Brush Removal and Replacement ..................................................................D-6  
________________________________________________________________________  
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-641  
________________________________________________________________________  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - VANTAGE® 400 (AU) (K32038-1)  
INPUT - DIESEL ENGINE  
Make/Model Description  
Code No.  
Speed (RPM) Displacement  
cu. in. (ltrs.)  
Starting  
System  
Capacities  
4 cylinder  
27.6 HP  
135.6(2.2)  
12VDC Battery  
High Idle 1565  
&
starter  
Oil:  
1500 RPM  
Bore x Stroke  
(Group 34; 650 8.45Qts. (8.0L) Fuel: 20 gal.  
(75.7 L)  
Perkins 404D-22  
naturally aspirated Full Load 1500 cold crank amps)  
water cooled  
3.43” X 3.64”  
65 Amp Alternator  
Radiator Coolant:  
Diesel Engine Low Idle 1200 (87.1mm x 92.5mm) W / Built in Regulator 8.0Qts. (7.6L)  
RATED OUTPUT @ 104° F (40° C) - WELDER  
Welding Process  
Welding Output  
Current/Voltage/Duty Cycle  
350A / 34V / 100%  
Output Range  
Max. Weld OCV  
@Rated Load RPM  
DC Constant Current  
DC Pipe Current  
Touch-Start™TIG  
DC Constant Voltage  
Arc Gouging  
30 TO 400 AMPS  
40 TO 300 AMPS  
20 TO 250 AMPS  
14 TO 34 VOLTS  
90 TO 400 AMPS  
300A / 32V / 100%  
(2)  
60 Volts  
250A / 20V / 100%  
350A / 34V / 100%  
350A / 34V / 100%  
60 Volts  
.
RATED OUTPUT @ 40° C (104° F) - GENERATOR  
Auxiliary Power (1)  
14,000 Watts Peak / 13,200 Watts Continuous, 50 Hz 400 Volts 3-Phase  
(3)  
6,900 Watts Peak / 6,900 Watts Continuous, 50 Hz 230 Volts 1-Phase  
Sound Levels (Sound power: 96 dB Lwa)  
ENGINE  
LUBRICATION  
Full Pressure  
with Full Flow Filter  
EMISSIONS  
FUEL SYSTEM  
GOVERNOR  
Mechanical  
Mechanical Fuel Pump, Auto air bleed  
system, Electric shutoff solenoid, Indirect fuel injector.  
EPA Tier IV Interim  
AIR CLEANER  
ENGINE IDLER  
MUFFLER  
Low noise Muffler:  
Top outlet can be rotated.  
Made from long life, aluminized steel.  
ENGINE PROTECTION  
Shutdown on low oil  
pressure & high engine  
coolant temperature  
Single Element  
Automatic Idler  
ENGINE WARRANTY: 2 years / 2000 hours, all non-electric components, 3 years major non-electric compo-  
nents . See Perkins warranty for details.  
PHYSICAL DIMENSIONS  
HEIGHT  
WIDTH  
27.00 in  
686 mm  
DEPTH  
WEIGHT  
(4)  
35.94 in.  
60.00 in.  
1524 mm  
1230 lbs. (559kg.)  
913 mm  
(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 30V in the CC-stick Mode when VRD (VOLTAGE REDUCTION DEVICE) is on.  
(3) Maximum per circuit breaker rating.  
(4) To Top of enclosure. Add 7.35 (186.7mm) to top of exhaust. Add 3.87”(98.3mm) to top of Lift Bail.  
VANTAGE® 400 (AU)  
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A-2  
A-2  
INSTALLATION  
MACHINE SPECIFICATIONS  
Receptacles  
400V (3 Ph) x 1  
230V (1 Ph) x 2  
14 Pin Connector  
6 Pin Connector  
Residual Current Device (RCD)  
4-pole, 40Amp  
(30mA trip current)  
Circuit Breakers (Thermal/Magnetic)  
3 Phase, 20 Amp x 1  
1 phase, 15 Amp x 2  
10A for Engine Battery Charging Circuit  
10A for Wire Feeder Power  
Other Circuit Breakers  
(5)  
Center-Tapped to ground.  
VANTAGE® 400 (AU)  
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A-3  
A-3  
INSTALLATION  
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  
guards off.  
LOCATION AND VENTILATION  
• Stop engine before servicing.  
• Keep away from moving parts.  
------------------------------------------------------------------------  
See additional warning information at  
The welder should be located to provide an unrestrict-  
ed flow of clean, cool air to the cooling air inlets and to  
avoid restricting the cooling air outlets. Also, locate  
the welder so that the engine exhaust fumes are prop-  
erly vented to an outside area.  
front of this operator’s manual.  
Only qualified personnel should install,  
use, or service this equipment.  
STACKING  
VANTAGE® 400 (AU) machines cannot be stacked.  
VRD (VOLTAGE REDUCTION DEVICE)  
ANGLE OF OPERATION  
The VRD feature provides additional safety in the CC-Stick  
mode especially in an environment with a higher risk of  
electric shock such as wet areas and hot humid sweaty  
conditions.  
Engines are designed to run in the level condition  
which is where the optimum performance is achieved.  
The maximum angle of continuous operation is 25  
degrees in all directions, 35 degrees Intermittent (less  
than 10 minutes continuous) in all directions. If the  
engine is to be operated at an angle, provisions must  
be made for checking and maintaining the oil level at  
the normal (FULL) oil capacity in the crankcase.  
The VRD reduces the OCV (Open Circuit Voltage) at the  
welding output terminals while not welding to less than 13V  
DC when the resistance of the output circuit is above 200⏐  
(ohms).  
The VRD requires that the welding cable connections be  
kept in good electrical condition because poor connections  
will contribute to poor starting. Having good electrical con-  
nections also limits the possibility of other safety issues  
such as heat-generated damage, burns and fires.  
When operating the welder at an angle, the effective  
fuel capacity will be slightly less than the amount  
specified.  
LIFTING  
The VANTAGE® 400 (AU) weighs approximately  
1383 lbs. (627kg.) with a full tank of fuel, 1230 lbs.  
(559kg.) less fuel. A lift bail is mounted to the machine  
and should always be used when lifting the machine.  
The machine is shipped with the VRD switch in the “ON”  
position. To turn it “On” or “Off”:  
• Turn the engine “Off”.  
• Disconnect the negative battery cable.  
• Lower the control panel by removing 4 front  
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 (AU)  
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A-4  
A-4  
INSTALLATION  
1. Design capacity of trailer vs. weight of Lincoln  
equipment and likely additional attachments.  
2. Proper support of, and attachment to, the base of  
the welding equipment so there will be no undue  
stress to the framework.  
3. Proper placement of the equipment on the trailer to  
insure stability side to side and front to back when  
being moved and when standing by itself while  
being operated or serviced.  
WARNING  
• Lift only with equipment of ade-  
quate lifting capacity.  
• Be sure machine is stable when lift-  
ing.  
• Do not lift this machine using lift  
bail if it is equipped with a heavy  
accessory such as trailer or gas  
cylinder.  
4. Typical conditions of use, i.e., travel speed; rough-  
ness of surface on which the trailer will be operat-  
ed; environmental conditions; like maintenance.  
FALLING  
• Do not lift machine if lift bail is  
damaged.  
EQUIPMENT can  
cause injury.  
(1)  
5. Conformance with federal, state and local laws.  
• Do not operate machine while  
suspended from lift bail.  
(1) Consult applicable federal, state and local laws regarding spe-  
cific requirements for use on public highways.  
------------------------------------------------------------------------  
HIGH ALTITUDE OPERATION  
VEHICLE MOUNTING  
At higher altitudes, output derating may be necessary. For  
maximum rating, derate the machine 2.5% to 3.5% for every  
1000 ft. (305 m). Due to new EPA and other local emissions  
regulations, modifications to the engine for high altitude are  
restricted within the United States. For use above 6000  
ft.(1828 m) an authorized Perkins engine field service shop  
should be contacted to determine if any adjustments can be  
made for operation in higher elevations.  
WARNING  
Improperly mounted concentrated loads may  
cause unstable vehicle handling and tires or other  
components to fail.  
• Only transport this Equipment on serviceable  
vehicles which are rated and designed for such  
loads.  
• Distribute, balance and secure loads so vehicle  
is stable under conditions of use.  
• Do not exceed maximum rated loads for compo-  
nents such as suspension, axles and tires.  
• Mount equipment base to metal bed or frame of  
vehicle.  
HIGH TEMPERATURE OPERATION  
At temperatures above 104°F(40°C), Welder output derating  
is necessary. For maximum output ratings, derate the  
welder output 2 volts for every 18°F(10°C) above  
104°F(40°C).  
Cold weather starting:  
• Follow vehicle manufacturer’s instructions.  
------------------------------------------------------------------------  
With a fully charged battery and the proper oil, the  
engine should start satisfactorily down to -15°F(-  
26C°). If the engine must be frequently started at or  
below 0°F (-18°C), it may be desirable to install cold-  
starting aides. The use of No. 1D diesel fuel is recom-  
mended in place of No. 2D at temperatures below  
23°F (-5°C). Allow the engine to warm up before  
applying a load or switching to high idle.  
PRE-OPERATION ENGINE SERVICE  
READ the engine operating and maintenance instruc-  
tions supplied with this machine.  
WARNING  
Note: Extreme cold weather starting may require  
longer glow plug operation.  
• Stop engine and allow to cool before fueling  
• Do not smoke when fueling.  
• Fill fuel tank at a moderate rate and do not over-  
fill.  
• Wipe up spilled fuel and allow fumes to clear  
before starting engine.  
• Keep sparks and flame away from tank.  
------------------------------------------------------------------------  
WARNING  
Under no conditions should ether or other starting  
fluids be used with this engine!  
------------------------------------------------------------------------  
TOWING  
Use a recommended trailer for use with this equip-  
ment for road, in-plant and yard towing by a vehi-  
cle(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 dam-  
age the welding equipment. Some of the factors to be  
considered are as follows:  
VANTAGE® 400 (AU)  
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A-5  
A-5  
INSTALLATION  
OIL  
MUFFLER OUTLET PIPE  
The VANTAGE® 400 (AU) is shipped with the engine crankcase  
filled with high quality SAE 10W-30 Oil that meets classification CG-  
4 or CH-4 for diesel engines. Check the oil level before starting the  
engine. If it is not up to the full mark on the dip stick, add oil as  
required. Check the oil level every four hours of running time during  
the first 50 running hours. Refer to the engine Operator’s Manual for  
specific oil recommendations and break-in information. The oil  
change interval is dependent on the quality of the oil and the operat-  
ing environment. Refer to the Engine Operator’s Manual for more  
Using the clamp provided secure the outlet pipe to the outlet tube  
with the pipe positioned such that it will direct the exhaust in the  
desired direction. Tighten using a 9/16"(14mm) socket or wrench.  
SPARK ARRESTER  
Some federal, state or local laws may require that gasoline or diesel  
engines be equipped with exhaust spark arresters when they are  
operated in certain locations where unarrested sparks may present  
a fire hazard. The standard muffler included with this welder does  
not qualify as a spark arrester. When required by local regulations,  
a suitable spark arrester, such as the K903-1 must be installed and  
properly maintained.  
details on the proper service and maintenance intervals.  
FUEL  
DIESEL FUEL ONLY-Low sulphur fuel or ultra low sulphur  
fuel in U.S.A. and Canada.  
WARNING  
An incorrect spark arrestor may lead to damage to the engine  
or adversely affect performance.  
------------------------------------------------------------------------  
REMOTE CONTROL  
WARNING  
• Fill the fuel tank with clean, fresh fuel. The capacity of the  
tank is 20 gals.(75.7 ltrs). When the fuel gauge reads empty  
the tank contains approximately 2 gals. (7.6 ltrs.) of reserve  
fuel.  
NOTE: A fuel shut off valve is located on the pre-fil-  
ter/sediment filter. Which should be in the closed posi-  
tion when the welder is not used for extended periods  
The VANTAGE® 400 (AU) is equipped with a 6-pin and a 14-pin  
connector. The 6-pin connector is for connecting the K857 or K857-  
1 Remote Control or for TIG welding, the K870 foot Amptrol or the  
K963-3 hand Amptrol. When in the CC-STICK, ARC GOUGING or  
CV-WIRE modes and when a remote control is connected to the 6-  
pin Connector, the auto-sensing circuit automatically switches the  
OUTPUT control from control at the welder to remote control.  
of time.  
------------------------------------------------------------------------  
ENGINE COOLING SYSTEM  
When in the DOWNHILL PIPE mode and when REMOTE CON-  
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-  
PUT CONTROL of the REMOTE.  
WARNING  
Air to cool the engine is drawn in the side and exhausted  
through radiator & case back. It is important that the intake and  
exhaust air is not restricted. Allow a minimum clearance of 12  
in. (305 mm) from the case back and 16 in.(406 mm) from either  
side of the base to a vertical surface.  
------------------------------------------------------------------------  
BATTERY CONNECTION  
Example: When the OUTPUT CONTROL on the welder is set to  
200 amps the current range on the REMOTE CONTROL will be 40-  
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  
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-  
mum current range of the CURRENT CONTROL of the Amptrol.  
Use caution as the electrolyte is a strong acid that can burn  
skin and damage eyes.  
------------------------------------------------------------------------  
The VANTAGE® 400 (AU) is shipped with the negative battery  
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-  
nected to the 14-pin connector, the auto-sensing circuit  
automatically makes the Output Control inactive and  
the wire feeder voltage control active.  
cable disconnected. Make certain that the RUN-STOP switch is in  
the STOP position. Remove the two screws from the battery tray  
using a screwdriver or a 3/8" socket. Attach the negative battery  
cable to the negative battery terminal and tighten using a 1/2" sock-  
et or wrench.  
CAUTION  
NOTE: This machine is furnished with a wet charged battery; if  
unused for several months, the battery may require a booster  
charge. Be careful to charge the battery with the correct polarity.  
(See Battery in “Maintenance Section”)  
NOTE: When a wire feeder with a built in welding  
voltage control is connected to the 14-pin connec-  
tor, do not connect anything to the 6-pin connec-  
tor.  
------------------------------------------------------------------------  
VANTAGE® 400 (AU)  
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A-6  
A-6  
INSTALLATION  
WELDING OUTPUT CABLES  
ELECTRICAL CONNECTIONS  
With the engine off connect the electrode and work  
cables to the output studs. The welding process dic-  
tates the polarity of the electrode cable. These con-  
nections should be checked periodically and tightened  
with a 3/4" (19mm) wrench.  
MACHINE GROUNDING  
Because this portable engine driven welder creates its  
own power, it is not necessary to connect its frame to  
an earth ground, unless the machine is connected to  
premises wiring (home, shop, etc.)  
Table A.1 lists recommended cable sizes and lengths  
for rated current and duty cycle. Length refers to the  
distance from the welder to the work and back to the  
welder. Cable diameters are increased for long cable  
lengths to reduce voltage drops.  
To prevent dangerous electric shock, other equipment  
to which this engine driven welder supplies power  
must:  
WARNING  
TABLE A.1  
• Be grounded to the frame of the welder using a  
grounded type plug or be double insulated.  
• Do not ground the machine to a pipe that carries  
explosive or combustible material.  
TOTAL COMBINED LENGTH OF  
ELECTRODE AND WORK CABLES  
Cable Size for  
------------------------------------------------------------------------  
Cable Length  
400 Amps  
60% Duty Cycle  
2 / 0 AWG  
When this welder is mounted on a truck or trailer, its  
frame must be electrically bonded to the metal frame  
of the vehicle. Use a #8 or larger copper wire connect-  
ed between the machine grounding stud and the  
frame of the vehicle. When this engine driven welder  
is connected to premises wiring such as that in a  
home or shop, its frame must be connected to the  
system earth ground. See further connection instruc-  
tions in the section entitled "Standby Power  
Connections" as well as the article on grounding in the  
latest National Electrical Code and the local code.  
0-100 Ft. (0-30 meters)  
2 / 0 AWG  
3 / 0 AWG  
100-150 Ft. (30-46 meters)  
150-200 Ft. (46-61 meters)  
CABLE INSTALLATION  
Install the welding cables to your VANTAGE® 400  
(AU) as follows.  
In general, if the machine is to be grounded, it should  
be connected with a #8 or larger copper wire to a solid  
earth ground such as a metal water pipe going into  
the ground for at least ten feet and having no insulat-  
ed joints, or to the metal framework of a building  
which has been effectively grounded.  
1. The engine must be OFF to install welding cables.  
2. Remove the flanged nuts from the output terminals.  
3. Connect the electrode holder and work cables to  
the weld output terminals. The terminals are identi-  
fied on the case front.  
The National Electrical Code lists a number of alter-  
nate means of grounding electrical equipment. A  
machine grounding stud marked with the symbol  
is provided on the front of the welder.  
4. Tighten the flanged nuts securely.  
5. Be certain that the metal piece you are welding (the  
“work”) is properly connected to the work clamp and  
cable.  
WELDING TERMINALS  
The VANTAGE® 400 (AU) is equipped with a toggle  
switch for selecting "hot" welding terminal when in the  
"WELD TERMINALS ON" position or "cold" welding  
terminal when in the "REMOTELY CONTROLLED"  
position.  
6. Check and tighten the connections periodically.  
CAUTION  
• Loose connections will cause the output termi-  
nals to overheat. The terminals may eventually  
melt.  
• Do not cross the welding cables at the output ter-  
minal connection. Keep the cables isolated and  
separate from one another.  
------------------------------------------------------------------------  
VANTAGE® 400 (AU)  
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A-7  
A-7  
INSTALLATION  
CONNECTION OF LINCOLN ELECTRIC  
WIRE FEEDERS  
Connection of LN-15 to the VANTAGE® 400 (AU)  
AUXILIARY POWER  
The auxiliary power capacity is 14,000 watts Peak,  
13,200 Watts Continuous of 50 Hz, three phase  
power. The auxiliary power capacity rating in watts is  
equivalent to volt-amperes at unity power factor. The  
max permissible current of the 400 VAC output is 22  
amps. Output voltage is within 10% at all loads up  
to the rated capacity.  
1. Shut the welder off.  
2. For electrode Positive, connect the electrode  
cable to the "+" terminal of the welder and work  
cable to the "-" terminal of the welder. For elec-  
trode Negative, connect the electrode cable to the  
"-" terminal of the welder and work cable to the "+"  
terminal of the welder.  
Single phase power is:  
• 6,900 Watts Peak / 6,900 Watts Continuous, 50 Hz  
230 Volts 1-Phase (Euro).  
3. Across The-Arc Model:  
STANDBY POWER CONNECTIONS  
• Attach the single lead from the front of the LN-15  
to work using the spring clip at the end of the  
lead. This is a control lead to supply current to  
the wire feeder motor; it does not carry welding  
current.  
The machine is suitable for temporary, standby or  
emergency power using the engine manufacturer’s  
recommended maintenance schedule.  
The machine can be permanently installed as a  
standby power unit for 400 VAC, 3 phase, 20 amp  
service.  
• Set the "WELD TERMINALS" switch to "WELD  
TERMINALS ON".  
• When the gun trigger is closed, the current sens-  
ing circuit will cause the VANTAGE® 400 (AU)  
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.  
WARNING  
Connections must be made by a licensed electri-  
cian who can determine how the power can be  
adapted to the particular installation and comply  
with all applicable electrical codes.  
4. Control Cable Model:  
• Take necessary steps to assure load is limited  
to the capacity of the VANTAGE® 400 (AU).  
• Connect Control Cable between Engine Welder  
and Feeder.  
• Only a licensed, certified, trained electrician  
should install the machine to a premises or resi-  
dential electrical system. Be certain that:  
• Set the "WELD TERMINALS" switch to  
"REMOTELY CONTROLLED"  
• The installation complies with the National  
Electrical Code and all other applicable electri-  
cal codes.  
5. Set the MODE switch to the "CV-WIRE " position.  
6. Set the "WIRE FEEDER VOLTMETER" switch to  
either "+" or "-" as required by the electrode polari-  
ty being used.  
• The premises is isolated and no feedback into  
the utility system can occur. Certain laws  
require the premises to be isolated before the  
generator is linked to the premises. Check your  
local requirements.  
7. Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
-----------------------------------------------------------------------  
8. Set the "IDLE" switch to the "AUTO" position.  
9. When the gun trigger is closed, the current sens-  
ing circuit will cause the VANTAGE® 400 (AU)  
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 (AU)  
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A-8  
A-8  
INSTALLATION  
WARNING  
Connection of the LN-25 to the VANTAGE® 400  
(AU) Shut off welder before making any electrical  
connections.  
------------------------------------------------------------------------  
The LN-25 with or without an internal contactor may  
be used with the VANTAGE® 400 (AU). See the  
appropriate 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 (AU).  
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 (AU)  
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 (AU)  
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 (AU) is started.  
------------------------------------------------------------------------  
VANTAGE® 400 (AU)  
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B-1  
B-1  
OPERATION  
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-  
essary).  
WARNING  
• See Engine Owner’s Manual for specific oil and  
coolant recommendations.  
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.  
WARNING  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
ADD FUEL  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Stop engine while fueling.  
• Do not smoke when fueling.  
• Keep sparks and flame away  
from tank.  
• Insulate yourself from work and  
ground  
• Always wear dry insulating gloves.  
• Do not leave unattended while  
fueling.  
• Always operate the welder with the  
hinged door closed and the side pan-  
els in place.  
• Wipe up spilled fuel and allow  
fumes to clear before starting  
DIESEL FUEL  
can cause fire.  
engine.  
• Read carefully the Safety Precautions page  
before operating this machine. Always follow  
these and any other safety procedures included  
in this manual and in the Engine Instruction  
Manual.  
• Do not overfill tank, fuel  
expansion may cause over-  
flow.  
DIESEL FUEL ONLY-Low sulphur fuel or ultra low  
sulphur fuel in U.S.A. and Canada.  
-----------------------------------------------------------------------  
• Remove the fuel tank cap.  
GENERAL DESCRIPTION  
The VANTAGE® 400 (AU) is a diesel engine powered  
DC multi-process welding power source and AC  
power generator. The engine drives a generator that  
supplies three phase power for the DC welding circuit,  
single phase and Three Phase power for the AC auxil-  
iary outlets. The DC welding control system uses state  
• Fill the tank. DO NOT FILL THE TANK TO THE  
POINT OF OVERFLOW.  
• Replace the fuel cap and tighten securely.  
C
of the art Chopper Technology  
ing performance.  
for superior weld-  
• See Engine Owner’s Manual for specific fuel recom-  
mendations.  
T
R
The VANTAGE® 400 (AU) is fitted with a selectable  
VRD(Voltage Reduction Device). The VRD operates  
in the CC-Stick mode reducing the OCV to <30 volts  
increasing operator safety when welding is performed  
in environments with increased hazard of electric  
shock.  
BREAK-IN PERIOD  
The engine will use a small amount of oil dur-  
ing its “break-in” period. The break-in period is about  
50 running hours.  
Check the oil every four hours during break-in.  
Change the oil after the first 50 hours of operation and  
every 200 hours thereafter. Change the oil filter at  
each oil change.  
FOR AUXILIARY POWER:  
Start the engine and set the IDLER control switch to  
the desired operating mode. Full power is available  
regardless of the welding control settings providing no  
welding current is being drawn.  
CAUTION  
During break-in, subject the Welder to moderate  
loads. Avoid long periods running at idle. Before  
stopping the engine, remove all loads and allow  
the engine to cool several minutes.  
ENGINE OPERATION  
Before Starting the Engine:  
• Be sure the machine is on a level surface.  
• Open side engine door and remove the engine oil  
dipstick and wipe it with a clean cloth. Reinsert the  
dipstick and check the level on the dipstick.  
------------------------------------------------------------------------  
VANTAGE® 400 (AU)  
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B-2  
B-2  
OPERATION  
FIGURE B.1  
1
11  
9
2
3
10  
14  
15  
4
13  
12  
17  
7
8
16  
22  
21  
20  
24  
23  
5
18  
19  
6
When in the TOUCH START TIG mode and when an Amptrol is  
connected to the 6-Pin Connector, the OUTPUT dial is used to  
set the maximum current range of the CURRENT CONTROL of  
the Amptrol.  
WELDING CONTROLS (Figure B.1)  
1. OUTPUT CONTROL- The OUTPUT dial is used to preset the  
output voltage or current as displayed on the digital meters for the  
five welding modes. When in the CC-STICK, ARC GOUGING or  
CV-WIRE modes and when a remote control is connected to the  
6-Pin or 14-Pin Connector, the auto-sensing circuit automatically  
switches the OUTPUT CONTROL from control at the welder to  
the remote control.  
2. DIGITAL OUTPUT METERS-The digital meters allow the  
output voltage (CV-WIRE mode) or current (CC-STICK, DOWN-  
HILL PIPE, ARC GOUGING and TIG modes) to be set prior to  
welding using the OUTPUT control dial. During welding, the  
meter display the actual output voltage (VOLTS) and current  
(AMPS). A memory feature holds the display of both meters on  
for seven seconds after welding is stopped. This allows the oper-  
ator to read the actual current and voltage just prior to when  
welding was ceased.  
When in the DOWNHILL PIPE mode and when REMOTE CON-  
TROL is connected to the 6-Pin or 14-Pin Connector, the OUT-  
PUT CONTROL is used to set the maximum current range of the  
OUTPUT 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 +/-  
3%.  
Example: When the OUTPUT CONTROL on the welder is set to  
200 amps the current range on the REMOTE CONTROL will be  
40-200 amps rather than the full 40-300 amps. Any current range  
that is less than the full range provides finer current resolution for  
more fine tuning of the output.  
3. WELD MODE SELECTOR SWITCH-  
(Provides five selectable welding modes)  
CV-WIRE  
In the CV-WIRE mode, if the feeder being used has a voltage con-  
trol when the wire feeder control cable is connected to the 14-Pin  
Connector, the auto-sensing circuit automatically makes OUTPUT  
CONTROL inactive and the wire feeder voltage control active.  
Otherwise, the OUTPUT CONTROL is used to preset the voltage  
ARC GOUGING  
DOWNHILL PIPE  
CC-STICK  
TOUCH START TIG  
VANTAGE® 400 (AU)  
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B-3  
B-3  
OPERATION  
4. ARC CONTROL- The ARC CONTROL dial is active in  
the CV-WIRE, CC-STICK and DOWNHILL PIPE modes, and  
has different functions in these modes. This control is not  
active in the TIG and ARC GOUGING mode.  
11. VRD (Voltage Reduction Device) INDICATOR  
LIGHTS - On the front panel of the VANTAGE® 400 (AU)  
are two indicator lights. A red light when lit indicates  
OCV(Open Circuit Voltage) is equal to or greater than 30V  
and a green light when lit indicates OCV(Open Circuit  
Voltage) is less than 30V.  
CC-STICK mode: In this mode, the ARC CONTROL dial sets  
the short circuit current (arc-force) during stick welding to  
adjust for a soft or crisp arc. Increasing the dial from –10  
(soft) to +10 (crisp) increases the short circuit current and  
prevents sticking of the electrode to the plate while welding.  
This can also increase spatter. It is recommended that the  
ARC CONTROL be set to the minimum number without elec-  
trode sticking. Start with a setting at 0.  
The VRD “On/Off” switch inside the control panel must be  
“On” for the VRD function to be active and the lights to be  
enabled. When the machine is first started with VRD  
enabled, both lights will illuminate for 5 seconds.  
These lights monitor the OCV(Open Circuit Voltage) and  
weld voltage at all times. In the CC-Stick mode when not  
welding the green light will illuminate indicating that the  
VRD has reduced the OCV to less than 30V. During weld-  
ing the red light will illuminate whenever the arc voltage is  
equal to or greater than 30V. This means that the red and  
green light may alternate depending on the weld voltage.  
This is normal operation.  
DOWNHILL PIPE mode: In this mode, the ARC CONTROL  
dial sets the short circuit current (arc-force) during stick weld-  
ing to adjust for a soft or a more forceful digging arc (crisp).  
Increasing the number from –10 (soft) to +10 (crisp) increas-  
es the short circuit current which results in a more forceful  
digging arc. Typically a forceful digging arc is preferred for  
root and hot passes. A softer arc is preferred for fill and cap  
passes where weld puddle control and deposition ("stacking"  
of iron) are key to fast travel speeds. It is recommended that  
the ARC CONTROL be set initially at 0.  
If the red light remains illuminated when not welding in the  
CC-stick mode, the VRD is not functioning properly. Please  
refer to your local field service shop for service.  
CV-WIRE mode: In this mode, turning the ARC CONTROL  
clock wise from –10 (soft) to +10 (crisp) changes the arc from  
soft and washed-in to crisp and narrow. It acts as an induc-  
tance/pinch control. The proper setting depends on the pro-  
cedure and operator preference. Start with a setting of 0.  
If the VRD is turned “On” and the lights don’t come “On”,  
refer to the trouble shooting section.  
5. WELD OUTPUT TERMINALS WITH FLANGE  
TABLE B.1  
NUT- Provides a connection point for the electrode and  
work cables.  
VRD INDICATOR LIGHTS  
MODE  
CC-STICK OCV  
While  
VRD "ON"  
Green (OCV Reduced)  
Red or Green  
VRD "OFF"  
Welding (Depends on Weld Voltage) *  
6. GROUND STUD-  
Provides a connection point for  
connecting the machine case to earth ground.  
CV-WIRE  
OCV  
Red (OCV Not Reduced)  
Weld Terminals On  
Red (OCV Not Reduced)  
Weld Terminals Remotely Controlled  
Gun Trigger Closed  
Green (No OCV)  
Weld Terminals Remotely Controlled  
Gun Trigger Open  
Red or Green  
7. 14-PIN CONNECTOR- For attaching wire feeder control  
cables. Includes contactor closure circuit, auto-sensing  
remote control circuit, and 42V power. The remote control  
circuit operates the same as the 6-Pin Amphenol.  
No Lights  
While  
Welding (Depends on Weld Voltage) *  
8. 6-PIN CONNECTOR- For attaching optional remote con-  
PIPE  
ARC  
OCV  
Green (No Output)  
While  
Not Applicable (No Output)  
trol equipment. Includes auto-sensing remote control circuit.  
Welding  
OCV  
Green (No Output)  
9. WELD TERMINALS CONTROL SWITCH- In the  
WELD TERMINALS ON position, the output is electrically hot  
all the time. In the REMOTELY CONTROLLED position, the  
output is controlled by a wire feeder or amptrol device, and is  
electrically off until a remote switch is depressed.  
GOUGING While  
Welding  
OCV  
Not Applicable (No Output)  
TIG  
Green (Process is Low Voltage)  
Green (Process is Low Voltage)  
While  
Welding  
* It is normal for the lights to alternate between colors while welding.  
10. WIRE FEEDER VOLTMETER SWITCH:  
Matches the polarity of the wire feeder voltmeter to the  
polarity of the electrode.  
VANTAGE® 400 (AU)  
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B-4  
B-4  
OPERATION  
18. ENGINE PROTECTION LIGHT- A warning indi-  
cator light for Low Oil Pressure and/or Coolant Over  
Temperature. The light is off when the systems are  
functioning properly. The light will come on and the  
engine will shutdown when there is Low Oil Pressure  
and/or the Coolant is Over Temperature.  
ENGINE CONTROLS:  
12. RUN/STOP SWITCH - RUN position energizes the  
engine prior to starting. STOP position stops the  
engine. The oil pressure interlock switch prevents bat-  
tery drain if the switch is left in the RUN position and  
the engine is not operating.  
Note: The light remains off when the RUN-STOP switch  
is in the "ON" position prior to starting the engine. How  
ever if the engine is not started within 60 seconds the  
light will come on. When this happens the RUN-STOP  
switch must be returned to the "OFF" position to reset  
the engine protection system and light.  
13. GLOW PLUG PUSH BUTTON  
-
• When pushed activates the glow plugs. Glow plug  
should not be activated for more than 20 seconds con-  
tinuously.  
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  
the systems are functioning properly. The light will  
come on if there is a Low/No battery condition but the  
machine will continue to run.  
15. IDLER SWITCH- Has two positions as follows:  
1) In the HIGH position, the engine runs at the high idle  
speed controlled by the engine governor.  
2) In the AUTO position, the idler operates as follows:  
• When switched from HIGH to AUTO or after starting  
the engine, the engine will operate at full speed for  
approximately 12 seconds and then go to low idle  
speed.  
• When the electrode touches the work or power is  
drawn for lights or tools (approximately 100 Watts mini-  
mum), the engine accelerates and operates at full  
speed.  
• When welding ceases or the AC power load is turned  
off, a fixed time delay of approximately 12 seconds  
starts. If the welding or AC power load is not restarted  
before the end of the time delay, the idler reduces the  
engine speed to low idle speed.  
Note: The light may or may not come on when the RUN-  
STOP switch is in the "ON" position. It will come on during  
cranking and stay on until the engine starts. After starting  
the engine the light will go off unless a Low/No battery  
charge condition exists.  
20. COOLANT TEMPERATURE GAUGE- A indica-  
tor of engine coolant temperature.  
21. OIL PRESSURE GAUGE- A indicator of engine  
Oil Pressure.  
22. CIRCUIT BREAKER  
• The engine will automatically return to high idle speed  
when there is welding load or AC power load reapplied.  
23. ENGINE STOP SWITCH- Shut down Engine.  
16. ELECTRIC FUEL GAUGE- The electric fuel  
gauge gives accurate and reliable indication as to how  
much fuel is in the fuel tank.  
24. BATTERY DISCONNECT SWITH- Provides  
Lockout / Tagout capability.  
17. ENGINE HOUR METER- Displays the total time  
that the engine has been running. This meter is useful  
for scheduling prescribed maintenance.  
STARTING THE ENGINE  
1. Remove all plugs connected to the AC power recepta-  
cles.  
TABLE B.2  
2. Set IDLER switch to AUTO.  
TYPICAL VANTAGE® 400 (AU) FUEL CONSUMPTION  
PERKINS 404D-22  
Gal./Hr (Liters/Hr)  
Running Time ( Hours)  
20 gallon tank  
3. Press Glow Plug Button and hold 15 to 20 seconds.  
4. Set the RUN/STOP switch to RUN.  
5. Press START button until the engine starts or for up to 10  
seconds. Continue to hold the glow plug button for up to  
an additional 10 seconds.  
6. Release the engine START button immediately when the  
engine starts.  
7. The engine will run at high idle speed for approximately  
12 seconds and then drop to low idle speed. Allow the  
engine to warm up at low idle for several minutes before  
applying a load and/or switching to high idle. Allow a  
longer warm up time in cold weather.  
Low Idle - No Load  
1200 R.P.M.  
High Idle - No Load  
1565 R.P.M.  
DC Weld Output  
350 Amps @ 34Volts  
13,200 Watts 3 Phase  
.29(1.10)  
.43(1.63)  
68.96  
46.51  
1.27(4.81)  
15.75  
14.81  
1.35(5.11)  
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 (AU)  
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B-5  
B-5  
OPERATION  
The ARC CONTROL dial sets the short circuit current  
(arc-force) during stick welding to adjust for a soft or  
crisp arc. Increasing the number from -10(soft) to  
+10(crisp) increases the short circuit current and pre-  
vents sticking of the electrode to the plate while welding.  
This can also increase spatter. It is recommended that  
the ARC CONTROL be set to the minimum number  
without electrode sticking. Start with the dial set at 0.  
NOTE: If the unit fails to start turn Run/Stop switch  
to off and repeat step 3 through step 7 after  
waiting 30 seconds.  
CAUTION  
• Do not allow the starter motor to run continuously  
for more than 20 seconds.  
• Do not push the START button while the engine  
is running because this can damage the ring  
gear and/or the starter motor.  
• If the Engine Protection or Battery Charging  
Lights do “not” turn off shortly after starting the  
engine shut off the engine immediately and  
determine the cause.  
------------------------------------------------------------------------  
NOTE: When starting for the first time, or after and  
extended period of time of not operating, it will take  
longer than normal to start because the fuel pump  
has to fill the fuel system. For best results, bleed the  
fuel system as indicated in Maintenance Section of  
this manual.  
NOTE: Due to the low OCV with the VRD on, a  
very slight delay during striking of the electrodes  
may occur. Due to the requirement of the resis-  
tance in the circuit to be low for a VRD to operate, a  
good metal-to-metal contact must be made  
between the metal core of the electrode and the  
job. A poor connection anywhere in the welding  
output circuit may limit the operation of the VRD.  
This includes a good connection of the work clamp  
to the job. The work clamp should be connected as  
close as practical to where the welding will be per-  
formed.  
A. For New Electrodes  
STOPPING THE ENGINE  
E6010 - Touch, Lift to Start the Arc  
E7018, E7024 - Touch, Rock Back and Forth in  
Joint, Lift .  
Remove all welding and auxiliary power loads and  
allow the engine to run at low idle speed for a few  
minutes to cool the engine.  
Once the arc is started, normal welding technique  
for the application is then used.  
STOP the engine by placing the RUN-STOP switch in  
the STOP position.  
NOTE: A fuel shut off valve is located on the fuel pre-  
B. For Re-Striking Electrodes  
filter.  
Some electrodes form a cone at the end of the  
electrode after the welding arc has been broken,  
particularly iron powder and low hydrogen elec-  
trodes. This cone will need to be broken off in order  
to have the metal core of the electrode make con-  
tact.  
WELDER OPERATION  
DUTY CYCLE  
Duty Cycle is the percentage of time the load is being  
applied in a 10 minute period. For example a 60% duty  
cycle, represents 6 minutes of load and 4 minutes of no  
load in a 10 minute period.  
E6010 - Push, Twist in Joint, Lift  
E7018, E7024 - Push, Rock Back and Forth in  
Joint, Lift.  
ELECTRODE INFORMATION  
For any electrode the procedures should be kept with-  
in the rating of the machine. For information on elec-  
trodes and their proper application see  
(www.lincolnelectric.com) or the appropriate Lincoln  
publication.  
Once the arc is started, normal welding technique  
for the application is then used.  
For other electrodes the above techniques should  
be tried first and varied as needed to suit operator  
preference. The goal for successful starting is good  
metal to metal contact.  
The VANTAGE® 400 (AU) can be used with a broad  
range of DC stick electrodes. The MODE switch provides  
two stick welding settings as follows:  
For indicator light operation, see table B.1.  
CONSTANT CURRENT (CC-STICK) WELDING  
DOWNHILL PIPE Welding  
The CC-STICK position of the MODE switch is designed  
for horizontal and vertical-up welding with all types of  
electrodes, especially low hydrogen. The OUTPUT CON-  
TROL dial adjusts the full output range for stick welding.  
This slope controlled setting is intended for "out-of-  
position" and "down hill" pipe welding where the oper-  
ator would like to control the current level by changing  
the arc length.  
VANTAGE® 400 (AU)  
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B-6  
B-6  
OPERATION  
When in the TOUCH START TIG mode and when a  
Amptrol is connected to the 6-Pin connector the OUT-  
PUT CONTROL dial is used to set the maximum cur-  
rent range of the current control of the Amptrol.  
The OUTPUT CONTROL dial adjusts the full output  
range for pipe welding.  
The ARC CONTROL dial sets the short circuit current  
(arc-force) during stick welding to adjust for a soft or  
more forceful digging arc (crisp). Increasing the number  
from -10(soft) to +10(crisp) increases the short circuit  
current which results in a more forceful digging arc.  
The ARC CONTROL is not active in the TIG mode. To  
STOP a weld, simply pull the TIG torch away from the  
work.  
When the arc voltage reaches approximately 30 Volts  
the arc will go out and the machine will reset the cur-  
rent to the Touch Start level.  
Typically a forceful digging arc is preferred for root and  
hot passes. A softer arc is preferred for fill and cap pass-  
es where weld puddle control and deposition (“stacking”  
of iron) are key to fast travel speeds. This can also  
increase spatter.  
To reinitiate the arc, retouch the tungsten to the work  
and lift. Alternatively, the weld can be stopped by  
releasing the Amptrol or arc start switch.  
It is recommended that the ARC CONTROL be set to the  
minimum number without electrode sticking. Start with  
the dial set at 0.  
The VANTAGE® 400 (AU) can be used in a wide vari-  
ety of DC TIG welding applications. In general the  
‘Touch Start’ feature allows contamination free start-  
ing without the use of a Hi-frequency unit. If desired,  
the K930-2 TIG Module can be used with the VAN-  
TAGE® 400 (AU). The settings are for reference.  
NOTE: With the VRD switch in the “ON” position there is  
no output in the DOWNHILL PIPE mode. For indicator  
light operation, see table B.1.  
TIG WELDING  
VANTAGE® 400 (AU) settings when using the K930-2  
TIG Module with an Amptrol or Arc Start Switch:  
• Set the MODE Switch to the TOUCH START TIG  
setting.  
The TOUCH START TIG setting of the MODE switch is  
for DC TIG (Tungsten Inert Gas) welding. To initiate a  
weld, the OUTPUT CONTROL dial is first set to the  
desired current and the tungsten is touched to the work.  
During the time the tungsten is touching the work there is  
very little voltage or current and, in general, no tungsten  
contamination. Then, the tungsten is gently lifted off the  
work in a rocking motion, which establishes the arc.  
• Set the "IDLER" Switch to the "AUTO" position.  
• Set the "WELDING TERMINALS" switch to the  
"REMOTELY CONTROLLED" position.  
TABLE B.3  
(1)  
(2)  
TYPICAL CURRENT RANGES  
FOR TUNGSTEN ELECTRODES  
Tungsten Electrode  
Diameter in. (mm)  
DCEN (-)  
DCEP (+)  
Approximate Argon Gas Flow  
Flow Rate C.F.H. ( l /min.)  
TIG TORCH  
Nozzle Size (4), (5)  
1%, 2% Thoriated  
Tungsten  
1%, 2% Thoriated Aluminum  
Tungsten  
Stainless Steel  
.010  
0.020  
0.040  
(.25)  
(.50)  
(1.0)  
2-15  
5-20  
15-80  
(3)  
(3)  
(3)  
3-8  
5-10  
5-10  
(2-4)  
(3-5)  
(3-5)  
3-8  
5-10  
5-10  
(2-4)  
(3-5)  
(3-5)  
#4, #5, #6  
1/16  
(1.6)  
70-150  
10-20  
5-10  
(3-5)  
9-13  
(4-6)  
#5, #6  
3/32  
1/8  
(2.4)  
(3.2)  
150-250  
250-400  
15-30  
25-40  
13-17  
15-23  
(6-8)  
(7-11)  
11-15  
11-15  
(5-7)  
(5-7)  
#6, #7, #8  
5/32  
3/16  
1/4  
(4.0)  
(4.8)  
(6.4)  
400-500  
500-750  
750-1000  
40-55  
55-80  
80-125  
21-25  
23-27  
28-32  
(10-12)  
(11-13)  
(13-15)  
13-17  
18-22  
23-27  
(6-8)  
(8-10)  
(11-13)  
#8, #10  
(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.  
(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):  
Pure  
EWP  
1% Thoriated  
2% Thoriated  
EWTh-1  
EWTh-2  
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.  
(3) DCEP is not commonly used in these sizes.  
(4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:  
# 4 = 1/4 in.  
# 5 = 5/16 in.  
# 6 = 3/8 in.  
# 7 = 7/16 in.  
# 8 = _ in.  
(6 mm)  
(8 mm)  
(10 mm)  
(11 mm)  
(12.5 mm)  
(16 mm)  
#10 = 5/8 in.  
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures  
and high duty cycles.  
VANTAGE® 400 (AU)  
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B-7  
B-7  
OPERATION  
This will keep the "Solid State" contactor open and provide a  
"cold" electrode until the Amptrol or Arc Start Switch is pressed.  
ARC GOUGING  
The VANTAGE® 400 (AU) can be used for arc gouging. For  
optimal performance, set the MODE switch to ARC GOUGING.  
When using the TIG Module, the OUTPUT CONTROL on the  
VANTAGE® 400 (AU) is used to set the maximum range of the  
CURRENT CONTROL on the TIG Module or an Amptrol if con-  
nected to the TIG Module.  
Set the OUTPUT CONTROL knob to adjust output current to  
the desired level for the gouging electrode being used accord-  
ing to the ratings in the following Table B.4.  
NOTE: The TIG process is to receive a low voltage welding  
process. There is no difference in operation with the  
VRD “On” or “Off” for this mode. For indicator light oper-  
ation, see table B.1.  
TABLE B.4  
Carbon Diameter  
Current Range (DC, electrode  
positive)  
1/8" (3.2mm)  
5/32" (4.0mm)  
3/16" (4.8mm)  
1/4" (6.4mm)  
60-90 Amps  
90-150 Amps  
200-250 Amps  
300-400 Amps  
WIRE WELDING-CV  
Connect a wire feeder to the VANTAGE® 400 (AU) according  
to the instructions in INSTALLATION INSTRUCTIONS Section.  
The ARC CONTROL is not active in the ARC GOUGING Mode.  
The ARC CONTROL is automatically set to maximum when the  
ARC GOUGING mode is selected which provides the best ARC  
GOUGING performance.  
The VANTAGE® 400 (AU) in the CV-WIRE mode, permits it to  
be used with a broad range of flux cored wire (Innershield and  
Outershield) electrodes and solid wires for MIG welding (gas  
metal arc welding). Welding can be finely tuned using the ARC  
CONTROL. Turning the ARC CONTROL clockwise from –10  
(soft) to +10 (crisp) changes the arc from soft and washed-in to  
crisp and narrow. It acts as an inductance/pinch control. The  
proper setting depends on the procedure and operator prefer-  
ence. Start with the dial set at 0.  
Note: With the VRD switch in the “ON” position there is no out-  
put in the Arc Gouging Mode. For indicator light operation, see  
table B.1.  
AUXILIARY POWER:  
Start the engine and set the IDLER control switch to the desired  
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  
Voltage) is not reduced. For indicator light operation,  
see table B.1.  
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)  
0
100  
200  
300  
(WATTS)  
13,200  
10,600  
7,400  
3,400  
1,100  
0
(AMPS @ 400V, 3-PHASE)  
19.0  
15.3  
10.7  
4.9  
1.6  
0
350  
MAX  
TABLE B.6  
VANTAGE® 400 (AU) Extension Cord Length Recommendations  
(Use the shortest length extension cord possible sized per the following table.)  
Current Voltage Load  
(Amps) Volts (Watts)  
Maximum Allowable Cord Length in ft. (m) for Conductor Size  
12 AWG 10 AWG 8 AWG 6 AWG  
14 AWG  
4 AWG  
15  
20  
15  
20  
44  
120  
120  
240  
240  
240  
1800  
2400  
3600  
4800  
9500  
30  
(9)  
40  
(12)  
(9)  
(23)  
(18)  
75  
(23)  
(15)  
(46)  
(30)  
(15)  
125  
(38)  
(27)  
(69)  
(53)  
(27)  
175  
(53)  
(42)  
(107)  
(84)  
(46)  
300  
(91)  
(69)  
(183)  
(137)  
(69)  
30  
75  
60  
50  
150  
100  
50  
88  
225  
175  
90  
138  
350  
275  
150  
225  
600  
450  
225  
60  
(18)  
Conductor size is based on maximum 2.0% voltage drop.  
VANTAGE® 400 (AU)  
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C-1  
C-1  
ACCESSORIES  
FIELD INSTALLED OPTIONS /  
ACCESSORIES  
K449 LN-25 - Includes internal contactor for across the arc  
operation (no control cable). Provides “cold” electrode until  
gun trigger is pressed. Includes gas solenoid. For spools up  
to 44 LBS (20Kg).  
K903-1 SPARK ARRESTOR - Includes a heavy gage steel,  
approved spark arrestor, clamp and adapter for mounting to  
the muffler exhaust pipe.  
K1870-1 LN-15 Across the Arc Wire Feeder.  
Portable, lightweight, compact CC/CV unit for flux-cored and  
MIG welding. Includes Gas Solenoid, adjustable flow meter  
and internal contactor. For 10-15 lb. (4.5-6.8kg) spools.  
K704 ACCESSORY SET - Includes 35 ft. (10m) of elec-  
trode cable and 30 ft. (9.1m) of work cable, headshield,  
work clamp electrode holder. Cables are rated at 400  
amps, 100% duty cycle.  
Magnum Gun and Magnum Gun Connector Kit are required  
for gas-shielded welding. Innershield Gun is required for  
gasless welding.  
K857 25 ft (7.6m) or K857-1 100 ft. (30.4m) REMOTE  
CONTROL  
Portable control provides same dial range as the output con-  
trol on the welder. Has a convenient 6 pin plug for easy con-  
nection to the welder.  
K126-2 Magnum 350 Innershield Gun  
K1802-1 Magnum 300 MIG Gun (for LN-25)  
K470-2 Magnum 300 MIG Gun (for LN-15, Includes  
Connector Kit)  
K466-10 Connector Kit (for LN-15, K470-2)  
K1500-1 Gun Receiver Bushing (for LN-15 & K126-2)  
K1858-1 Service Indicator Kit- Provides a GO / NO-GO  
visual indication of air cleaner element useful service life.  
Filter service based on restriction readings allows the  
longest life possible from the filter and best engine protec-  
tion.  
Note: See Wire Feeder IM manuals for appropriate Drive  
Roll and Guide Tubes.  
TIG OPTIONS  
K1783-9 Pro -Torch® PTA-26V TIG Torch  
Air Cooled 200 amp torch (2 piece) equipped with valve for  
gas flow control. 25 ft. (7.6m) length.  
K2641-2 Trailer - A 4-wheel steerable trailer for in-  
plant and yard towing. Comes standard with a Duo-  
Hitch™, a 2” Ball and Lunette Eye combination hitch.  
KP509 Magnum Parts Kit for PTA-26V TIG Torch  
Magnum Parts Kit provides all the torch accessories you  
need to start welding. Parts kit provides collets, collet bod-  
ies, a black cap, alumina nozzles and tungstens in a variety  
of sizes, all packaged in an easy to carry reclosable sack.  
K2642-1 Polarity/Multi-Process Switch- For easy polarity  
switching. Example: DC- stick root pass on pipe and DC+  
stick for hot, fill and cap passes. Also for an easy process  
change. Example DC+ stick root pass on pipe and DC_  
innershield self shielded flux core wire for hot, fill and gap  
passes. 6 and 14 pin remote connections can be made to  
this unit. For all lincoln Chopper technology engine-drive  
welders Mounts on roof with Docking Kit.  
K870 Foot Amptrol®  
K963-3 Hand Amptrol®  
K2535-1 Precision TIG 225 Ready-Pak(For AC TIG)  
K2663-1 Docking Kit-Secures Polarity/Multi-Process  
Switch, mounts on the roof of all Lincoln Chopper technolo-  
gy engine-drives.  
K2350-2 Invertec® V205-T AC/DC One-Pak™ Package  
(For AC TIG)  
PLASMA CUTTING  
WIRE FEEDER OPTIONS  
K1601-1 Pro-Cut 55-Cuts metal using the 3-phase AC gen-  
erator power from the engine driven welder. Accepts 3-  
phase power.  
K2613-1 LN-25 PRO PORTABLE WIRE FEEDER-The  
MAXTRAC® wire drive enhances performance, while the  
replacement case, and many other upgrade options that can  
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)  
KP1696-1 Drive Roll Kit- Includes: 2 V groove drive  
rolls and inner wire guide for Steel Wires. (Used on  
LN-25 Pro)  
VANTAGE® 400 (AU)  
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D-1  
D-1  
MAINTENANCE  
SAFETY PRECAUTIONS  
Read the Safety Precautions in the front of this  
manual and in the Engine Owner’s Manual before  
working on this machine.  
WARNING  
• Have qualified personnel do all maintenance  
and troubleshooting work.  
Keep all equipment safety guards, covers, and  
devices in position and in good repair. Keep  
hands, hair, clothing, and tools away from the  
gears, fans, and all other moving parts when  
starting, operating, or repairing the equipment.  
------------------------------------------------------------------------  
• Turn the engine off before working inside the  
machine or servicing the engine.  
• Remove guards only when necessary to  
perform maintenance and replace them when  
the maintenance requiring their removal is  
complete. If guards are missing from the  
machine, obtain replacements from a Lincoln  
Distributor. (See Operating Manual Parts List.)  
Routine Maintenance  
At the end of each day’s use, refill the fuel tank to  
minimize moisture condensation in the tank. Running  
out of fuel tends to draw dirt into the fuel system.  
Also, check the crankcase oil level and add oil if  
indicated.  
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  
I
I
Coolant Level  
I
Concentration of Antifreeze  
R Coolant (NOTE 3)  
Engine oil level (NOTE 1)  
50/50 Water/Ethylene Glycol  
9.5 qt., 9.0 L  
R
R
R
R
Engine oil (NOTE 1 & 3)  
Engine oil filter  
qt.,  
(Including filter)  
8.45  
L
8
Perkins #140517050  
C
Drain water separator & fuel strainer  
Water separator element  
Fuel filter canister  
R
R
Lincoln # M20840-A  
Perkins #130366120  
I
I
Tension of alternator drive belt  
Alternator drive belt wear  
R Alternator drive belt  
Air filter (earlier check may be required)  
Air filter element  
Perkins #080109107  
Donaldson #P821575  
C
R
R Renew the engine breather  
I Tighten cylinder head  
I Valve clearances  
Intake .008", exhaust .008"  
Contact Perkins  
I Electrical systems  
I All nuts and bolts for tightness  
Injector performance  
I
I
I
Leaks or engine damage  
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 (AU)  
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D-2  
D-2  
MAINTENANCE  
ENGINE OIL CHANGE  
OIL FILTER CHANGE  
Drain the engine oil while the engine is warm to assure  
rapid and complete draining. It is recommended that  
each time the oil is changed the oil filter be changed as  
well.  
• Drain the oil.  
• Remove the oil filter with an oil filter wrench and  
drain the oil into a suitable container. Discard the  
used filter. Note: Care should be taken during filter  
removal to not disrupt or damage in any way the fuel  
lines.  
• Be sure the unit is off. Disconnect the negative bat-  
tery cable to ensure safety.  
• Locate oil drain hose and valve in bottom of base  
and pull through the hole in the battery access panel  
on the welder.  
• Clean the filter mounting base and coat the gasket  
of the new filter with clean engine oil.  
• Screw the new filter on by hand until the gasket con-  
tacts the mounting base. Using an oil filter wrench,  
tighten the filter an additional 1/2 to 7/8 of a turn.  
• Refill the crankcase with the specified amount of the  
recommended engine oil. Reinstall the oil filler cap  
and tighten securely.  
• Open oil drain valve by lifting up spring loaded lever  
and rotate 90 counterclockwise. Pull to open and  
°
drain the oil into a suitable container for disposal.  
• Close the drain valve by rotating lever 90 clockwise.  
°
• Start the engine and check for oil filter leaks.  
• Re-fill the crankcase to the upper limit mark on the  
dipstick with the recommended oil (see engine oper-  
ation manual OR engine service items decal OR  
below). Replace and tighten the oil filler cap secure-  
ly.  
• Stop the engine and check the oil level. If neces-  
sary, add oil to the upper limit mark on the dipstick.  
• Push oil drain hose and valve back into unit, re-con-  
nect negative battery cable, and close doors and  
engine top cover before restarting unit.Wash your  
hands with soap and water after handling used motor  
oil. Please dispose of used motor oil in a manner  
that is compatible with the environment. We suggest  
you take it in a sealed container to your local service  
station or recycling center for reclamation. DO NOT  
throw it in the trash; pour it on the ground or down a  
drain.  
WARNING  
• Never use gasoline or low flash point solvents  
for cleaning the air cleaner element. A fire or  
explosion could result.  
CAUTION  
• Never run the engine without the air cleaner.  
Rapid engine wear will result from contaminants,  
such as dust and dirt being drawn into the  
engine.  
Use motor oil designed for diesel engines that meets  
requirements for API service classification  
CC/CD/CE/CF/CF-4/CG-4 or CH-4.  
------------------------------------------------------------------------  
ACEA E1/E2/E3. Always check the API service label  
on the oil container to be sure it includes the letters  
indicated. (Note: An S-grade oil must not be used in a  
diesel engine or damage may result. It IS permissible  
to use an oil that meets S and C grade service classifi-  
cations.)  
AIR CLEANER  
The diesel engine is equipped with a dry type air filter.  
Never apply oil to it. Service the air cleaner as follows:  
Replace the element every 500 hours of operation.  
Under dusty conditions, replace sooner.  
SAE 10W30 is recommended for general, all tempera-  
ture use, 5F to 104F (-15C to 40C).  
See engine owner’s manual for more specific informa-  
tion on oil viscosity recommendations.  
VANTAGE® 400 (AU)  
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D-3  
D-3  
MAINTENANCE  
Service Instrructions  
Single- and Two-Stage Engine Air Cleaners  
Inspect the New Filter for Damage  
Remove the Filter  
Inspect the new filter carefully, paying attention to  
the inside of the open end, which is the  
sealing area. NEVER install a damaged  
filter. A new Donaldson radial seal  
filter may have a dry lubricant on the  
seal to aid installation.  
Unfasten or unlatch the  
service cover. Because  
the filter fits tightly over the  
outlet tube to create the critical seal, there will  
be some initial resistance, similar to breaking  
the seal on a jar. Gently move the end of the filter  
back and forth to break the seal then rotate while  
pulling straight out. Avoid knocking the filter  
against the housing.  
Rotate the  
filter while  
pulling  
straight out.  
Insert the New Radial Seal Filter Properly  
If you're servicing the safety filter, this should be seated into  
position before installing the primary filter.  
If your air cleaner has a safety filter, replace it every third primary  
filter change. Remove the safety filter as you would the primary  
filter. Make sure you cover the air cleaner outlet tube to avoid any  
unfiltered contaminant dropping into the engine.  
Insert the new filter carefully. Seat  
the filter by hand, making certain it is  
completely into the air cleaner housing  
before securing the cover in place.  
Clean Both Surfaces of the Outlet Tube  
and Cheeck the Vacuator™ Valve  
The critical sealing area will stretch  
Use a clean cloth to wipe the filter sealing surface and the inside of  
the outlet tube. Contaminant on the sealing surface could hinder an  
effective seal and cause leakage. Make sure that all contaminant is  
removed before the new filter is inserted. Dirt accidently transferred  
to the inside of the outlet tube will reach the engine and cause  
wear. Engine manufacturers say that it takes only a few grams of  
dirt to "dust" an engine! Be careful not to damage the sealing area  
on the tube.  
slightly, adjust itself and distribute the sealing pressure evenly. To  
complete a tight seal, apply pressure by hand at the outer rim of  
the filter, not the flexible center. (Avoid pushing on the center of the  
urethane end cap.) No cover pressure is required to hold the seal.  
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  
fasteners and will void the warranty.  
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  
Inner edge of the  
outlet tube  
Caution  
outlet tube  
NEVER use the serviice coovver to  
push the ffilter innto placcee! Using  
the cover tto push thhe filterr in could  
cause damaage to thhee housingg, cover  
fastenerss and will void the warranty.  
If your air cleaner is equipped with a Vacuator Valve  
Visually check and physically squeeze to make sure the  
valve is flexible and not inverted, damaged or plugged.  
Inspect the Old  
Filter foor Leak Clues  
Check Connnectorrs for Tiight Fit  
Make sure that all mounting bands, clamps, bolts, and connections  
in the entire air cleaner system are tight. Check for holes in piping  
and repair if needed. Any leaks in your intake piping will send dust  
directly to the engine!  
Visually inspect the old filter for any signs  
of leaks. A streak of dust on the clean side  
of the filter is a telltale sign. Remove any  
cause of leaks before installing new filter.  
VANTAGE® 400 (AU)  
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D-4  
D-4  
MAINTENANCE  
FUEL  
COOLING SYSTEM  
DIESEL FUEL ONLY-Low sulphur fuel or ultra  
low sulphur fuel in U.S.A. and Canada.  
WARNING  
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  
the fuel line. Do not overfill; leave room for the fuel to  
expand.  
• Do not remove cap if radiator is  
hot.  
Use only fresh No. 2D diesel fuel, the use of No. 1D  
diesel fuel is recommended in place of No. 2D at tem-  
peratures below 23°F (-5°C). Do not use kerosene.  
------------------------------------------------------------------------  
Check the coolant level by observing the level in the  
radiator and recovery bottle. Add 50/50 antifreeze /  
water solution if the level is close to or below the  
"LOW" mark. do not fill above the "FULL" mark.  
Remove radiator cap and add coolant to radiator. Fill  
up to the top of the tube in the radiator filler neck  
which includes a connecting hose coming from the  
thermostat housing.  
See the Engine Operator's Manual for instructions on  
replacing the fuel filter.  
BLEEDING THE FUEL SYSTEM  
You may need to bleed air from the fuel system if the  
fuel filter or fuel lines have been detached, the fuel  
tank has been ran empty or after periods of long stor-  
age. It is recommended that the fuel shutoff valve be  
closed during periods of non-use.  
To drain the coolant, open the valve at the bottom of  
the radiator. Open the radiator cap to allow complete  
drainage. (Tighten the valve and refill with a 50/50  
antifreeze/water solution.) Use an automotive grade  
(low silicate) ethylene glycol antifreeze. The cooling  
system capacity is 8.0 quarts (7.6L.). Squeeze upper  
and lower radiator hoses while filling to bleed air from  
system coolant. Replace and tighten the radiator cap.  
WARNING  
To avoid personal injury, do not bleed a hot  
engine. This could cause fuel to spill onto a hot  
exhaust manifold, creating a danger of fire.  
------------------------------------------------------------------------  
CAUTION  
Bleed the fuel system as follows:  
Always premix the antifreeze and clean tap water  
before adding to the radiator. It is very important  
that a precise 50/50 solution be used with this  
engine year round. This gives proper cooling dur-  
ing hot weather and freezing protection to -34° F (-  
37° C).  
1. Fill the fuel tank with fuel.  
2. Open the fuel shut off valve.  
3. Loosen bleed fitting on the fuel injector manifold.  
4. Operate hand priming lever until fuel comes out the  
bleed screw on the injector manifold. This could  
take 20-30 seconds of rapid operation of the prim-  
ing lever. Tighten bleed fitting on injector manifold.  
5. Follow normal STARTING procedures until engine  
starts.  
Cooling solution exceeding 50% ethylene glycol  
can result in engine overheating and damage to  
the engine. Coolant solution must be premixed  
before adding to radiator.  
------------------------------------------------------------------------  
Periodically remove the dirt from the radiator fins.  
Periodically check the fan belt and radiator hoses.  
Replace if signs of deterioration are found.  
TIGHTENING THE FAN BELT  
If the fan belt is loose, the engine can overheat and  
the battery lose its charge. Check tightness by press-  
ing on the belt midway between the pulleys. It should  
deflect about .25 in.(6.4 mm) under a load of 20 lbs.(9  
Kg).  
VANTAGE® 400 (AU)  
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D-5  
D-5  
MAINTENANCE  
CLEANING THE BATTERY  
FUEL FILTER  
1. Check the fuel filter and fuel pre-filter for water  
Keep the battery clean by wiping it with a damp cloth  
when dirty. If the terminals appear corroded, discon-  
nect the battery cables and wash the terminals with an  
ammonia solution or a solution of 1/4 pound (0.1113  
kg) of baking soda and 1 quart (0.9461L) of water. Be  
sure the battery vent plugs (if equipped) are tight so  
that none of the solution enters the cells.  
accumulation or sediment.  
2. Replace the fuel filter if it is found with excessive  
water accumulation or sediment. Empty fuel pre-fil-  
ter.  
OVERSPEED IS HAZARDOUS  
After cleaning, flush the outside of the battery, the bat-  
tery compartment, and surrounding areas with clear  
water. Coat the battery terminals lightly with petroleum  
jelly or a non-conductive grease to retard corrosion.  
Keep the battery clean and dry. Moisture accumula-  
tion on the battery can lead to more rapid discharge  
and early battery failure.  
The maximum allowable high idle speed for this  
machine is 1890 RPM, no load. Do NOT tamper  
with governor components or setting or make any  
other adjustments to increase the maximum  
speed. Severe personal injury and damage to the  
machine can result if operated at speeds above  
maximum.  
CHECKING THE ELECTROLYTE LEVEL  
If battery cells are low, fill them to the neck of the filler  
hole with distilled water and recharge. If one cell is  
low, check for leaks.  
ENGINE ADJUSTMENT  
Adjustments to the engine are to be made only by a  
Lincoln Service Center or an authorized Field Service  
Shop.  
CHARGING THE BATTERY  
BATTERY MAINTENANCE  
When you charge, jump, replace, or otherwise con-  
nect battery cables to the battery, be sure the polarity  
is correct. Improper polarity can damage the charging  
circuit. The VANTAGE® 400 (AU) positive (+) battery  
terminal has a red terminal cover.  
To access the battery, remove the battery tray from  
the front of the machine with 3/8” nut driver or flat  
head screw driver. Pull the tray out of machine far  
enough to disconnect the negative and then positive  
battery cables. The tray can then be tilted and lifted to  
remove the entire tray and battery from the machine  
for easy service.  
If you need to charge the battery with an external  
charger, disconnect the negative cable first, then the  
positive cable before you attach the charger leads.  
After the battery is charged, reconnect the positive  
battery cable first and the negative cable last. Failure  
to do so can result in damage to the internal charger  
components.  
WARNING  
GASES FROM BATTERY can explode.  
● Keep sparks, flame and cigarettes  
away from battery.  
Follow the instructions of the battery charger manu-  
facturer for proper charger settings and charging time.  
To prevent EXPLOSION when:  
● INSTALLING A NEW BATTERY — disconnect  
negative cable from old battery first and con-  
nect to new battery last.  
SERVICING OPTIONAL SPARK  
ARRESTOR  
● CONNECTING A BATTERY CHARGER —  
remove battery from welder by disconnecting  
negative cable first, then positive cable and  
battery clamp. When reinstalling, connect  
negative cable last. Keep well ventilated.  
Clean every 100 hours.  
WARNING  
• MUFFLER MAY BE HOT  
● USING A BOOSTER — connect positive lead to  
battery first then connect negative lead to neg-  
ative battery lead at engine foot.  
BATTERY ACID can burn eyes and  
skin.  
• ALLOW ENGINE TO COOL BEFORE INSTALLING  
THE SPARK ARRESTER!  
• DO NOT OPERATE ENGINE WHILE INSTALLING  
THE SPARK ARRESTER!  
------------------------------------------------------------------------  
●
Wear gloves and eye protection  
and be careful when working near  
battery.  
● Follow instructions printed on battery.  
VANTAGE® 400 (AU)  
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D-6  
D-6  
MAINTENANCE  
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 (AU)  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and  
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical  
Shock, please observe all safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
VANTAGE® 400 (AU)  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Major Physical or Electrical Damage 1. Contact your local Lincoln  
is Evident.  
Authorized Field Service  
Facility.  
Engine will not "crank".  
1. Battery is low, Charge Battery.  
2. Loose battery cable connections.  
Inspect, clean and tighten terminals.  
3. Faulty engine starter motor.  
Contact authorized local Engine  
Service Shop.  
Engine will "crank" but not start.  
1. Fuel shut off valve on Main Fuel  
Filter in the OFF position. Open  
valve (vertical) position of handle.  
2. Fuel Filters dirty/clogged. Check  
and replace main filter element  
and/or Inline Fuel Filter.  
3. Out of fuel. Fill tank and bleed  
fuel system.  
4. High coolant temperature or low  
oil pressure. (indictor lights lit)  
I
f all recommended possible areas  
Check oil and coolant levels. Fill of misadjustment have been  
if required. Check for loose or checked and the problem persists,  
broken fan belt.  
Contact your local Lincoln  
5. Faulty fuel shutdown solenoid. Authorized Field Service Facility.  
Check that shutdown solenoid is  
functioning properly and not bind-  
ing/ contact authorized engine  
service shop.  
6. Faulty fuel pump. Check for fuel  
flow through filters. Contact  
authorized local Engine Service  
Shop.  
Engine shuts down shortly after  
starting.  
1. High coolant temperature or low  
oil pressure. (indictor light lit)  
Change oil and oil filters and fill to  
proper level. Check and fill  
coolant level. Check for loose or  
broken fan belt. Start engine and  
look for leaks.  
2. Faulty oil pressure switch or other  
engine component. Contact  
authorized local Engine Service  
Shop.  
3. Faulty Idler/Protection Board.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
VANTAGE® 400 (AU)  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Engine shuts down while under a 1. High radiator coolant tempera-  
load.  
ture. Reduce load if it is exceed-  
ing machine rating. Add coolant  
to system if low. Clean fins on  
radiator if dirty. Tighten fan belt if  
loose. Remove objects blocking  
or close to intake openings on  
both sides of base and exhaust  
end (case back).  
Engine runs rough.  
1. Dirty fuel or air filters. Inspect and  
clean/replace filters as needed.  
Inspect and clean/replace filters  
as needed.  
2. Water in fuel. If water found in  
tank. Empty fuel tank and refill  
then purge fuel lines.  
Battery does not stay charged.  
1. Faulty battery. Replace.  
Engine alternator trouble light is on 2. Loose connections at battery or  
while machine is running.  
alternator. Clean and tighten con-  
nections.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
3. Faulty engine alternator or charg-  
er module. Consult authorized  
Engine Service Shop.  
Engine will not idle down to low 1. Idler switch in High idle position.  
speed.  
Set switch to Auto.  
2. External load on welder or auxil-  
iary power. Remove all external  
loads.  
3. Faulty PC board or idler sole-  
noid.  
Engine will not go to high idle when 1. Poor work lead connection to  
attempting to weld.  
work. Make sure work clamp is  
tightly connected to clean base  
metal.  
2. "Contactor" switch is in wrong  
position. Set to "Welding On" when  
welding without a control cable.  
Refer to Operations chapter for prop-  
er use of this switch.  
3. Faulty PC board. Low idle speed  
set to low.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
VANTAGE® 400 (AU)  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
1. Auxiliary power load is less than  
100 watts. Idler may not respond  
with less than a 100 watt load.  
Set idler to "High".  
Engine will not go to high idle when  
using auxiliary power.  
2. Faulty PC board.(Control or Idler).  
1. Faulty idler solenoid. Check for  
bent linkage or broken spring.  
Engine will not go to high idle  
under weld or auxiliary loading.  
2. Faulty PC board.(Control or Idler).  
1. Fuel filter clogged, Replace.  
2. Air filter clogged, clean or  
replace.  
Engine does not develop full  
power. Engine runs rough.  
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.  
I
f all recommended possible areas  
1. Broken spring on Idle Solenoid,  
solenoid linkage binding, Faulty  
PC board (Control or Idler), low  
idle speed set too low on idle  
solenoid.  
Engine will not go to high idle when  
attempting to weld or using auxil-  
iary power. Switching to manual  
high idle does not work.  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
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 will not shut off.  
1. Fuel filter dirty/clogged. Replace.  
2. Air filter dirty/clogged. Replace Air  
Filter Element.  
Engine does not develop full power.  
Low weld and auxiliary output.  
Engine runs rough.  
3. Fouled fuel injector(s). Contact  
authorized Engine Service Shop.  
4. Fuel contaminated with water.  
Check water separator for water.  
Clean and replace as needed.  
Replace fuel in tank.  
5. Cracked or loose fuel hose.  
Replace hose and tighten clamps.  
6. Valves out of adjustment. Contact  
authorized local Engine Service  
Shop.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
VANTAGE® 400 (AU)  
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E-5  
E-5  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
No welding power output.  
1. Poor work lead connection to  
work. Make sure work clamp is  
tightly connected to clean base  
metal.  
2. "Weld Terminals" switch in wrong  
position. Place switch in "Weld  
Terminals On" position when  
welding without control cable.  
3. Faulty PC board or welder alterna-  
tor.  
Welder has output but no control.  
1. Poor remote/control cable connec-  
tion to 6-pin or 14-pin connector.  
Check connections.  
2. Faulty remote cable or faulty wire  
feeder or wire feeder cable.  
Replace if necessary.  
3. Faulty control potentiometer or PC  
board.  
I
f all recommended possible areas  
Wire feeder does not work when 1. Wire Feeder Power circuit breaker of misadjustment have been  
control cable is connected to 14-pin open. Check 42V beaker and checked and the problem persists,  
connector.  
reset if tripped.  
Contact your local Lincoln  
2. Faulty control cable. Repair or  
replace cable.  
Authorized Field Service Facility.  
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.  
VANTAGE® 400 (AU)  
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E-6  
E-6  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
The welding arc is “cold.” The weld- 1. Make sure the MODE selector  
ing arc is not stable or is not satis- switch is in the correct position for  
factory. the engine runs normally. the process being used. (For exam-  
The auxiliary power is normal.  
No output in Pipe Mode.  
VRD Lights don’t light up.  
ple, CV-WIRE, PIPE, CC-STICK.)  
2. Make sure the electrode (wire, gas,  
voltage, current etc.) is correct for  
the process being used.  
3. Check for loose or faulty connec-  
tions at the weld output terminals  
and welding cable connections.  
4. The welding cables may be too long  
or coiled, causing an excessive  
voltage drop.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
5. Faulty Control Board.  
1. Make sure VRD ON/OFF toggle  
switch is in the “OFF” position.  
2. Poor work lead connection to  
work. Make sure work clamp is  
tightly connected to clean base  
metal.  
3. "Weld Terminals" switch in wrong  
position. Place switch in "Weld  
Terminals On" position when  
welding without control cable.  
4. Faulty PC board or welder alterna-  
tor.  
1. Ensure VRD ON/OFF switch is in  
the “ON” position.  
2. If light is burned out, replace both  
VRD lights.  
3. Faulty OCV indicator PC board.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
VANTAGE® 400 (AU)  
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F-1  
F-1  
DIAGRAMS  
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F-2  
F-2  
DIAGRAMS  
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F-3  
F-3  
DIAGRAMS  
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F-4  
F-4  
DIAGRAMS  
VANTAGE® 400 (AU)  
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F-5  
F-5  
WIRING DIAGRAM  
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F-6  
F-6  
DIMENSION PRINT  
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NOTES  
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NOTES  
VANTAGE® 400 (AU)  
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● Do not touch electrically live parts or  
electrode with skin or wet clothing.  
● Insulate yourself from work and  
ground.  
● Keep flammable materials away.  
● Wear eye, ear and body protection.  
WARNING  
Spanish  
● No toque las partes o los electrodos ● Mantenga el material combustible  
● Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
● Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
● Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
● Gardez à l’écart de tout matériel  
inflammable.  
● Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
● Isolez-vous du travail et de la terre.  
German  
● Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
● Isolieren Sie sich von den  
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
● Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
● Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE  
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-  
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
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● Keep your head out of fumes.  
● Use ventilation or exhaust to  
remove fumes from breathing zone.  
● Turn power off before servicing.  
● Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
● Los humos fuera de la zona de res-  
piración.  
● Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
● Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
● No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux  
tien.  
● Gardez la tête à l’écart des fumées.  
● Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
● Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
● Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
● Vermeiden Sie das Einatmen von  
Schweibrauch!  
● Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
● Não opere com as tampas removidas.  
● Desligue a corrente antes de fazer  
serviço.  
● Mantenha-se afastado das partes  
moventes.  
● Não opere com os paineis abertos  
ou guardas removidas.  
● Mantenha seu rosto da fumaça.  
● Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
● Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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