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Lincoln Electric VANTAGE IM883-A User's Manual

1. 007 10 VANTAGE 400 LINCOLN DIMENSION PRINT F 11 F 11 298217 OIOVA 5 O1ISOd3Q A HOQVIQVH HOLOW 400 VANTAGE LINCOLN E Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese te BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra emos
2. NYO HOIHM 830333 201 OV JHL NI 3SV3SONI NV ASNVS 39 VMNIT 31LLOSH L HO ONILLAS 9NIDNVHO 4101 SHL 30 3SV3SONI Mi LNdLNO 31038 01 104005 YAMOd 40 1 1 HHOM OL SLO3NNOO NOLLO3NNOO YSLSWLIOA Y30334 WA NOLLO3NNOO 324005 H3MOd 09 P OVA 8 2n o t DIAGRAMS OWA TN LAdLAO 9NIGT3M 7 0 193NNOO ON pn 5324108 YACTAM 3NION3 NO 0351 LON 1 9 8 0 3 5 jueuudinbe 14 2 6 10 esn j ejsu pjnous Ajuo sued desye eoejd ui deey e 9333 34IM OL 318v 300819313 NOUT OL 9N 1d sialadvav TVSS3AIND 2987 TONSHdV sued Ajeoujoe e jou 3ALLVO3N 12euuoosiq e sjoued ejejedo jou ONINHVM 7 d NOLL23NNOO 31d VOV 3 18V9 10 1 09 7984 OL SS3Q 13M 3NION3 VANTAGE 400 LINCOLN E DIAGRAMS F 7 F 7 8 8 705 0002 22 01 NOILISOd HOI NI HOLIMS 417101 39V1ld ON NOILISOd Q3TIOs LNOO AT310IN3H OL HOLIMS S IVNIINSH3 L ONIQT3M 39 1 NOILISOd AYIM AD IHL NI HOLIMS SGOW 39VId
3. 0393 OL NOLNVO 318 0 300419313 OL SLOWSY 9 d 114V9 1OH LNOO 7893 41479 ZNTOL juewudinbe 14 2 5 10 sured 1291199 9 jou pjnous peuuosied peyrjenb e sued Aeme desye 12euuoosiq e eoejd ui sjoued jou e ONINHVM 7 NOLLO3NNOO Z N1 SH3Q 13M 3NI9N3 VANTAGE 400 LINCOLN E 6 8 705 4 0002 22 01 8341530 SV NOILISOd HOI OLAV NI HOLIMS 44101 39V1d TN NOLLISOd GATIONLNOD ATSLOWSY OL HOLIMS STVNINYSAL ON NOILISOd NI HOLIMS 39V1d 318 0 300819313 SHL 30 ALIIV AHL HOLVN OL HOLIMS YSLAWLIOA Y30334 NOILISOd 341530 50015 LNdLNO OL 318V9 ONIGTAM LOANNOO ON WANVA 9 395 SNOILVOMddV 399 ANY ALVIGAWWI 40 371949 ANY LNAYYNSD JHL 30 38 LSNW 318V9 ONICTAM WANVW 0 20 OM 3NION3 NI 931511 SNOLLV2I3I934S Wd 3AO8V 1 LON OG SHL 135 334 SI ONILLAS YONYAAOD ANIONS TOHLNOO NYO HOIHM 830333 OV 3
4. 141 10 pjnous AIUO e sued dooye eoe d ui deeye ONINHVM WV 10 1 09 SLOWSY TWNOILdO sued jou eJoJeq 3ALLVO3N 12euuoosiq e uedo sjeued ejejedo jou oq e AHL SSOUIVY SC N TI SH3Q 13M ANISNA VANTAGE 400 LINCOLN E 18 1756 F 3 0002 22 01 DIAGRAMS F 3 NOILISOd HOI NI HOLIMS 44101 39 1 NOILISOd NI HOLIMS SGOW 300819373 40 ALIS V 10d JHL HOLVN OL HOLIMS YSLAWLIOA 830333 38IM AHL NOLLISOd ALISIV TOd 381830 58718 LAdLNO OL S318V9 ONIGTAM LO3NNOO ON WANVI 33 SNOILYONddY ANY 31VIG3ININI 40 41949 ANY LN3S80 30 38 LSNW 318V9 9NILVH3dO JHL NI 031511 SNOILVOISIOAdS LSNPAY LON Od AHOLOVA SHL 135 3 SI ONILL3S 9 ANION JHL LINDYIO TONLNOD IHL HOIHM 39V L 10A 83033 OV IHL NI 3SV38ONI ASNVO TIM TILLOUHL JHL 9NIGISSAO 138 HONH3AO9 JHL ONIONVHO 3NION3 3701 30 3SV38ONI
5. ATUSHELTFEL su e 4B EST e 8544 2858 1 e 2c Su ASL ge pal 2319 gl AA DE dus ule Keep flammable materials away Mantenga el material combustible fuera del de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos EVA AIX ng Judo Aal e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo HAUSHERMRELTTF 119 Bo STE HZHH dis due Lily algi pis dau 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 PROCE
6. VANTAGE 400 LINCOLN E DIAGRAMS F 8 F 8 6 8 705 8341530 SV NOILISOd HOI NI HOLIMS 414101 39V1d TN NOILISOd TOHLNO9 310IN3H NI HOLIMS 1041 02 LAdLNO 39 ON NOLLISOd 911 NI HOLIMS SGOW 3HL39Vld 6341530 58715 LNdLNO OL 318V9 ONIGTAM LOANNOO 9NI L V33dO 33 SNOILVOrTadv ANY 31VI3NINI 40 319A9 ANY JHL ALIO Va VO 3 0 30 38 LSNW S318V9 830 OM 3NION3 3H NI 031511 SNOILVOISIOAdS 3AO08V LSNPAV LON OG 7 AHOLO V4 LV 135 4 SI 9NILL3S HONH3AO9 3NION3 TOHLNOO 39 VIAVG NYO HOIHM 39V L10A 830334 201 NI 3SV3SONI NV ASNVS 3TLLOSH L AHL ONIGIHS3AO ONILLAS HONS3AOS 3NISN3 AHL 30 5 4 OL HOLIMS 131 NO 5 2 96 m 3004193173 uc 1003 0 8 9264 u SNILLIA 1 99 OL 579 JONJHANY HALINMOT4 MOLE jueuwdinbe si Jo sued Ajeouioeje jou pinoys jeuuosied peyijenb e sued pee JALLVO3N
7. 30 38 1 31899 SNIQT3M 318 0 300812313 OL OL QV31 420333 1041409 SALOWSY 168H IWNOILdO 9 jueuudinbe 14 eorues JO sued Ajeoujoeje jou esn jejsui jeuuosjed AIUO sued J3ALLVON 12euuoosiq e ui sjeued jou ONINHVM 7 TOULNOD 31034 58 TWNOILdO WV49VIQ AHL SSOUIVY 9 ANISNA 400 LINCOLN E DIAGRAMS F 2 F 2 8728 0002 22 01 0341530 SV NOILISOd 4101 HOI YO OLAV NI HOLIMS 44101 39 1 3N NOILISOd S IVNIINS3 L OD SHL NI HOLIMS S IVNIINS3 L 9NIQT3M SHL 39V NOILISOd AHL NI HOLIMS SGOW 39Vld 1899 300819313 AHL 30 AU 10d JHL HOLVW OL HOLIMS YSLANLIOA 3534333 JHL NOILISOd 934 34 401 58015 LAdLAO OL 531979 9NIQT3M LOANNOO WANVW 395 5 ANY 40 41949 ANY ALIOVaVO 30 38 LSNN 31899 ONIO OM 114v9 300812313 OL OL 0931410 4202331 TOYLNOD 310 54 WNOILdO 9
8. AOLLISOd d SE NMOHS vor SLOVINOD HOLMS 4 AZ 4011 LE e CONG 1 55 2 1ndino9NGUM anis ANNONO HOLIMS HOL2313S 5 WIRING DIAGRAM 98 85 AGZIOZL Nove our NU 5 17 KEEN s E 4 i T d A gt 9 raw 9 mn wor 282 t 9 voor o 4 2902 27205 902 OH 504558 50428 SdWv00r AWOS O 5702 LNNHS SOd ANNHS SOd D 9 Lesch zg a G31V2IGNI S3WLL SONIGNIM HOLVLS SSVd 390149 23 NMOHS 140449599 TIV 42913 Yad STOSWAS TV2R4L23 13 007 39V LNVA
9. ui desye uedo s eued jou d NOLLO3NNOO L Z8SLH SH3Q TSM 400 LINCOLN Jequinu 10 01 91A 1 5 si 4 10 5 2 you 10 SI 141 310 F 10 1875 9 h 8 NMOGLNHS 52 6 Lem ae 4 6 tI 8 A 1 u 182d TIOHLNOO NO anis ZI Ia ES M er 955 ASE Si es SS 9 2 5 i Bt ATI f is 3944 agoz eR 4016 f e o s dN9 6 4 hoss A j Coen H
10. 4341530 58115 LAdLNO OL 531979 ONIGTAM LO3NNOO 40 319A9 303 9371 38 LSAW S3 18V9 ONIGTAM WANVW ANIONS JHL NI 9151 5301191519395 3AO8V 15 LON OG AYOL V4 LV 135 334 SI ONILLAS YONYSAOS 3NION3 JHL LINDYID TONLNOD NYO HOIHM 39 V L10A 830334 FIM OV NI 3SV3HONI NV 3570 39 VXNIT31LLOSH L FHL 9NIGISSI3AO ONILLAS HONSH3AO9 ONIONVHO HOIH JHL 30 3SV3HONI 7224005 YAMOd YO ANY FINGOW 1 1 OL NI L10S38 1002 NOILISOd HOLIMS TOHLNOI 3 194340 OL ONILdWALLV 340338 NOILISOd 3408019 12 1 02 NIOONIT NI SI HOLIMS SGOW TOHLNO9 LVHL 3 18 38 NOUT TINGON 1 41 OL 318V9 300819313 OL 3199 1 7719143924 01 169 Nid 9 2 i 9 10045 592 7874 FINGOW 1041409 SE 95 88 Y30334 Nid t m jueuudinbe 14 10 sued jou og e esn eisui jeuuosied AIUO e sued peg Ajegeg 3ALLVO3N 2 9 2 e ui desye uedo sjaued jou ONINHVM 77 NOLLO3NNOO NN9 100dS 2877 887 01 1699 SH3TT3M
11. eoe d ui dose sjeued jou e ONINHVM 77 NOLLO3NNOO 1 069 SYIATIM ANIONS VANTAGE 400 LINCOLN E 01 28178 9 0002 22 01 OL HOLIMS AOW NOILISOd 781872 300819313 SHL 40 ALI V JHL HOLVW OL LAS SI HOLIMS SIHL SS3TNn 94943340 LON 93911933 LYVLS VSOd JHL NOILISOd OL YALAWLIOA 830333 195 33 5 AYALA ANY SLVIGAWWI 40 41949 ANY LNAYYND JHL 803 3 0 38 15 S3 18V9 ONIGTAM WANVW ONLLVeI3dO YSCTAM JHL 931511 SNOILVOISIOAdS 3AO8V LON Od AHOLOV LV 135 334 SI ONILL3S YONYSAOD TOMLNOO JHL HOIHM SOVLIOA 830333 OV JHL NI SSVSYONI NV ASNVS 3TLLOSH JHL 9NIGIHSSAO ONILLAS HONSH3AO9 ONIDNVHO Ad 3NION3 40 3SV38ONI 13 9333 OL 318 2 390419913 OL tc JON3HdlAV a 51899 LAdNI 0333 9LLVIAVHSOO OL jueuudinboe 14 10 sued jou oe esn ejsui pjnous jeuuosiod AIUO e sued 3ALLVO3N 12901 028 e
12. 1 4 300 400 Amps 450 550 Amps AUXILIARY POWER Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings providing no welding current is being drawn Simultaneous Welding and Auxiliary Power Loads The auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in the following table VANTAGE 400 Simultaneous Welding and Power Loads 1 PHASE WATTS 11 000 11 000 8 000 4700 1700 0 AMPS 46 46 33 20 7 0 OR WATTS 3 PHASE BOTH 1 amp 3 PHASE WATTS AMPS 11 000 11 000 OR 8000 4 700 1 700 0 AMPS 41 37 31 23 8 0 17 000 15 400 13 000 9400 3400 0 6 400 CE Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table Maximum Allowable Cord Length in ft m for Conductor Size 4 AWG 15 120 1800 30 9 40 12 75 23 125 38 175 53 300 91 20 120 2400 30 9 15 88 7 138 42 225 69 15 240 3600 60 18 75 23 150 46 225 ROBE ENTRETENU 20 240 4800 60 18 100 30 175 53 275 84 450 137 9500 50 15 90 27 150 46 225 69 Conductor size is based on maximum 2 0 voltage drop VANTAGE 400 LINCOL
13. Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 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 787 standards 4 b Use suitable clothing made from durable flame resistant SE AUG 06 LINCOLN 8 material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screeni
14. VANTAGE 400 LINCOLN 8 2 TROUBLESHOOTING 2 Observe all Safety Guidelines detailed throughout this manual Authorized Field Service Facility Engine will not crank Battery is low Charge Battery 2 Loose battery cable connections Inspect clean and tighten terminals Faulty engine starter motor Contact authorized local Engine Service Shop Engine will crank but not start Fuel shut off valve on Main Fuel Filter in the OFF position Open valve vertical position of handle Fuel Filters dirty clogged Check and replace main filter element and or Inline Fuel Filter Out of fuel Fill tank and bleed fuel system High coolant temperature or low oil pressure indictor lights lit If all recommended possible areas Check oil and coolant levels Fill misadjustment have been required Check for loose or bro checked and the problem persists ken fan belt Contact your local Lincoln Faulty fuel shutdown solenoid Authorized Field Service Facility Check that shutdown solenoid is functioning properly and not bind ing contact authorized engine service shop Faulty fuel pump Check for fuel flow through filters Contact autho rized local Engine Service Shop Engine shuts down shortly after High coolant temperature or low starting oil pressure indictor light lit Change oil and oil filters and fill to proper level Check and fill coolant level Check for loose or broken fan belt
15. 6 ator would like to control the current level by changing the arc length The OUTPUT CONTROL dial adjusts the full output range for pipe welding The ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or more forceful digging arc crisp Increasing the number from 10 soft to 10 crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is preferred for root and hot passes A softer arc is preferred for fill and cap pass es where weld puddle control and deposition stacking of iron are key to fast travel speeds This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with the dial set at O 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 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 TABLE B 3 OPERATION B 6 contamination Then the tungsten is gently lifted off the work in a rocking motion which establishes the arc When in the TOUCH STA
16. and be careful when working near battery e Follow instructions printed on battery CLEANING THE BATTERY 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 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 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 CHARGING THE BATTERY When you charge jump replace or otherwise con nect battery cables to the battery be sure the polarity is correct Improper polarity can damage the charging circuit The VANTAGE 400 positive battery termi nal has a red terminal cover 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 reconn
17. device and is electrically off until a remote switch is depressed 9 WELD TERMINALS CONTROL SWITCH In the Wu Wc Ge or Wu V WIRE OCH OCV Not Weld Terminals Red Not Reduced Weld Terminals Remotely Controlled Gun Trigger Closed No Lights Green No OCV Weld Terminals Remotely Controlled Gun Trigger Open Red or Green Depends on Weld Voltage Applicable No Output Pn Process is Low Voltage Process is Low Voltage is normal for the lights to alternate between colors while welding 400 LINCOLN 4 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 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 motor to crank the engine Energizes the starter 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 t
18. state and local laws regarding specific requirements for use on public high ways VEHICLE MOUNTING 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 Follow vehicle manufacturer s instructions PRE OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc tions supplied with this machine A WARNING 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 VANTAGE 400 LINCOLN 8 4 OIL d The VANTAGE 400 is shipped with the engine crankcase filled with high quality SAE 10W 30 Oil that meets classification CG 4 or CH 4 for diesel engines Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Check the oil level every four hours of run ning time during the first 50 running hours Refer to the engine Operator s Manual for specific
19. 3NIDN3 AHL 3SV38DNI LINN 13343 38IM OL 31875 390312913 DIAGRAMS 3182 4 2 5697 DfYld 319 2 LAdN 8 OL jueuudinbe 14 ales JO syed jou esn ejsui pnoys jauuosied peyijenb AIUO e sued Aeme 4 e 3ALLVO3N 1 euuoo sig e eoejd ui uedo sjoued jou ONINHVM 77 F 5 WV49VIQ NOILOANNOD 8 SH3Q 13M VANTAGE 400 LINCOLN E 1 181 5 0002 22 01 F 6 LN3S809 IWDINIXVIN NOILONALSNI 398008 YAMOd OL 43434 339933 19134 339 8 58731 35012 OL NOILV TOSI 381 LNdLNO ONIQTAM 303 TWNOIS V LVHL SH30334 Ol ATIWNGIAIGNI 50731 GASANN 3LVINSNI ON NOILISOd JHL NI HOLIMS 3HL 39Vld 31870 300819313 AHL 30 JHL HOLVIN OL HOLIMS YALAWLIOA 930334 NOLLISOd ALII V TOd 0441530 401 58015 LAdLNO OL S318V9 ONIGTAM LOANNOO ON NOILVOr1dav 30 319A9 ANY 303 937 38 LSAW 318V9 ONIGTAM ANIDNA NI Q31STTSNOLLVOIJIO3dS 3409Y 15 LON OG 7 AHOLOVA LV 135 334 SI 9NILL3S YONYSAOD TOHINOO
20. Wares GC TR IGoont NOTES 59 90 DI era WOE 3 Engine NOTE 189 fesat 8 including Engine 140517050 CL amp mesran Water separator element Lincoln M20840 A te constr SCS CT DI Atmaordebetwer LL L R Memetordivebet I Wwrertamercheckmarberesurem element 7 DonadsonfP amp zi engine breather L P clearances 006 exhaust 008 nuts and bolts for tightness BEE or engine damage Inspect Clean 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 26354 VM VANTAGE 400 LINCOLN D 2 ENGINE OIL CHANGE A 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 Be sure the
21. be properly tested at least once every month or whenever it is tripped To properly test and reset the GFCI receptacle If the receptacle has tripped first carefully remove any load and check it for damage If the equipment has been shut down it must be restarted The equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input terminals The circuit breaker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI recep tacle This will assure normal GFCI operation Plug a night light with an ON OFF switch or other product such as a lamp into the GFCI receptacle and turn the product ON Push the Test button located on the GFCI recepta cle The night light or other product should go OFF Push the Reset button again The light or other product should go again If the light or other product remains ON when the Test button is pushed the GFCI is not working prop or has been incorrectly installed miswired your GFCI is not working properly contact a qualified certified electrician who can assess the situation rewire the GFCI if necessary or replace the device VANTAGE 400 LINCOLN 8 EM TROUBLESHOOTING E HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by L
22. because poor connections will contribute to poor starting Having good electrical con nections also limits the possibility of other safety issues Such as heat generated damage burns and fires The machine is shipped with the VRD switch in the Off position To turn it On or Off Turn the engine Off Disconnect the negative battery cable Lower the control panel Place the VRD switch in the On or Off position With the VRD switch in the On position the VRD lights are enabled INSTALLATION A 2 LOCATION AND VENTILATION 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 STACKING VANTAGE 400 machines cannot be stacked ANGLE OF OPERATION Engines are designed to run in the level condition which is where the optimum performance is achieved The maximum angle of continuous operation is 25 degrees in all directions 35 degrees Intermittent less than 10 minutes continuous in all directions If the engine is to be operated at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the amount specified LIFTING The VANTAGE 400 w
23. 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 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 The National Electrical Code lists a number of alter nate means of grounding electrical equipment A machine grounding stud marked with the is provided on the front of the welder WELDING TERMINALS The VANTAGE 400 is equipped with a toggle switch for selecting hot welding terminal when in the WELD TERMINALS position or cold welding terminal when the REMOTELY CONTROLLED position INSTALLATION A 5 WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs The welding process dic tates the polarity of the electrode cable These con nections should be checked periodically and tightened with a 3 4 wrench Table A 1 lists recommended cable sizes and lengths for rated c
24. oil recom mendations and break in information The oil change interval is dependent on the quality of the oil and the operating environment Refer to the Engine Operator s Manual for more 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 Fill the fuel tank with clean fresh fuel The capacity of the tank is 15 gals 57 Itrs When the fuel gauge reads empty the tank contains approximately 2 gals 7 6ltrs of reserve fuel WARNING NOTE fuel shut off valve is located on the filter sediment filter Which should be in the closed position when the welder is not used for extended periods of time WARNING ENGINE COOLING SYSTEM Air to cool the engine is drawn in the side and exhausted through radiator amp case back It is important that the intake and exhaust air is not restricted Allow a minimum clearance of 1ft 0 6m from the case back and 16in 406mm from either side of the base to a vertical surface CAUTION BATTERY CONNECTION Use caution as the electrolyte is a strong acid that can burn skin and damage eyes The VANTAGE 400 is shipped with the negative bat tery cable disconnected Make certain that the RUN STOP switch is in the STOP position Remove the two screws from the battery tray using screwdriver or 3 8 socket Attach the negative battery cable to the negative battery
25. position Poor work lead connection to work Make sure work clamp is tightly connected to clean base metal Weld Terminals switch in wrong VRD Lights don t light up position Place switch in Weld Terminals On position when welding without control cable Faulty PC board or welder alterna tor Ensure VRD ON OFF switch is in the ON position If light is burned out replace both VRD lights Faulty OCV indicator PC board If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility 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 LINCOLN 8 DIAGRAMS F 1 F 1 481905 0002 2 0 0341530 SV NOILISOd 4101 HOI OLAV HOLIMS 44101 2 1 NOILISOd IVNIINS3 L SHL NI HOLIMS S IVNIINSI3 L 9NIQT3M 39V Id NOILISOd 34IM A9 3H L NI HOLIMS SGOW SHL 39V Id 31870 390819313 30 ALIS 10d JHL OL HOLIMS S3 L3IAL 10A 934333 JHL NOILISOd Ad 10d 34153 58015 1NdINO OL 531979 ONIQTIM LOANNOO WANVW 0 33 1 ANY 31VIQ3WIAI 40 41949 ALNG ANY ALIOVdVO
26. terminal and tighten using a 1 2 socket or wrench INSTALLATION 4 NOTE This machine is furnished with wet charged battery if unused for several months the battery may require a booster charge Be careful to charge the bat tery with the correct polarity See Battery in Maintenance Section MUFFLER OUTLET PIPE Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction Tighten using a 9 16 socket or wrench SPARK ARRESTER Some federal state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations a suitable spark arrester such as the K903 1 must be installed and properly maintained WARNING An incorrect spark arrestor may lead to damage to the engine or adversely affect performance REMOTE CONTROL The VANTAGE 400 is equipped with a 6 pin and a 14 pin connector The 6 pin connector is for connecting the K857 or K857 1 Remote Control or for TIG weld ing the K870 foot Amptrol or the K963 3 hand Amptrol When in the CC STICK DOWNHILL PIPE CV WIRE modes and when a remote control is connected to the 6 pin Connector the auto sensing circuit automatically
27. use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cove 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 Once the filter is in place secure the service cover Caution 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 6 Check Connectors for Tight 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 VANTAGE 400 LINCOLN 0 4 MAINTENANCE COOLING SYSTEM WARNING COOLANT can burn skin Do not remove cap if radiator is hot 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 To drain the coolant ope
28. will come on and the engine will shutdown when there is Low Oil Pressure and or the Coolant is Over Temperature Note The light remains off when the RUN STOP switch is in the ON position prior to starting the engine However if the engine is not started within 60 seconds the light will come on When this happens the RUN STOP switch must be returned to the OFF posi tion to reset the engine protection system and light 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 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 indica tor of engine coolant temperature 21 OIL PRESSURE GAUGE A indicator of engine Oil Pressure STARTING THE ENGINE 1 Remove all plugs connected to the AC power recepta cles IDLER switch to AUTO 23 lt gt Press Glow Plug Button and hold 15 to 20 seconds Set the RUN STOP switch to RUN 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 Release the engine S
29. 00 Watts Peak 17 000 Watts Continuous 60 Hz 240 Volts 3 Phase PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 35 94 in 25 30 in Op 1230 Ibs 559kg 913 mm 643 mm 1524 mm LUBRICATION EMISSIONS ____FUEL SYSTEM GOVERNOR Full Pressure K2410 1 EPA Tier Il Mechanical Fuel Pump Auto air bleed system Mechanical with Full Flow Filter K2410 2 EPA Tier 4 interim Electric shutoff solenoid Indirect fuel injector Low noise Muffler Shutdown on low oil Top outlet can be rotated pressure amp high engine Made from long life aluminized steel coolant temperature ENGINE WARRANTY 2 years 2000 hours all non electric components 3 years major non electric compo nents See Perkins warranty for details MACHINE SPECIFICATIONS RECEPTACLES AUXILIARY POWER CIRCUIT OTHER CIRCUIT BREAKERS 2 120VAC GFCI Duplex 5 20R Two 20AMP for Two Duplex Receptacle 10AMP for Battery Charging Circuit 1 120 240VAC Dual Voltage 1 50AMP for Dual Voltage and for 10AMP for 42V Wire Feeder Power Full KVA 14 50R 3 Phase 3 pole 1 240VAC 3 Phase 15 50R 1 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced To Top of enclosure add 10 68 271 3mm to top of exhaust pipe Add 6 67 169 4mm to top of Lift Bail 2 Reduced to less than 32V in the CC stick
30. 32 10 12 11 13 13 15 4 5 6 5 6 6 7 8 8 10 1 When used with 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 1 Thoriated 2 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 is not commonly used in these sizes 4 TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 6 5 5 16 8 6 3 8 in 10 7 7 16 in 11 8 _ 12 5 10 5 8 in 16 mm 5 TIG torch nozzles are typically made from alumina ceramic Special applications may require lava nozzles which are less prone to breakage but cannot withstand high temperatures and high duty cycles VANTAGE 400 LINCOLN 7 Set the IDLER Switch to the AUTO position Set the WELDING TERMINALS switch to the REMOTELY CONTROLLED position This will keep the Solid State contactor open and provide a cold elec trode until the Amptrol or Arc Start Switch is pressed When using the TIG Module the OUTPUT CONTROL on the VANTAGE 400 is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Modul
31. 40V POWER PLUG 3 Phase K1816 1 FULL KVA ADAPTER KIT Plugs into the 120 240V NEMA 14 50R receptacle on the case front which accepts 4 prong plugs and converts it to NEMA 6 50R receptacle which accepts 3 prong plugs For connection of Lincoln equipment with NEMA 6 50 Plug K1858 1 SERVICE INDICATOR KIT Provides a GO NO GO visu al indication of air cleaner element useful service life Filter service based on restriction readings allows the longest life possible from the filter and best engine protection K2679 1 COLD WEATHER HEATER AND TARP KIT For engine starting and operation in extreme cold weather condi tions down to 40 F 40 C with the use of OW40 synthetic oil and arctic diesel fuel includes 120VAC engine block heater and radia tor grill tarp WIRE FEEDER OPTIONS 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 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 Ib 4 5 6 8kg spools Magnum Gun and Magnum Gun Connector Kit are required for gas shielded welding Innershield Gun is required for gasless welding 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 Ki
32. BRAL Fe DAT ECH AHS Do not operate with panel open or guards off No operar con panel abierto guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas SIPH 0 x edo Yee Sa Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG BIR Chinese Korean oe lua dul sui CEU Aa jl Jani e ell oe call 9 SL dall e Aya y cils jal 1 Ja ye AUI d LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR 2 kl RA 4890 CL TRHOKRASRMEL Ef EE DO SE TE ft RO BA LL RE EX LE FR AO SRE 0 HYRAS SISAR HAL ett SO 7 Je ETM scr Saal alal dl Gala quil Jud al oig S ll cilia L LINCOLN World s Leader in Welding and Cutting Products Sales and Service thr
33. DURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria 78 5758 2475 HHPI Ask 71927 7 amp HZHH e power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten 20 opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas 7 9 2 EF
34. E SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 749 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS 744 FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 1 To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling
35. FCI receptacle should be properly tested at least once every month The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle NOTE The 240 V receptacle has two 120 V circuits but are of opposite polarities and cannot be paralleled auxiliary power is protected by circuit breakers The 120V has 20 Amp circuit breakers for each duplex receptacle The 120 240V Single Phase and the 240V Three Phases have a 50 Amp 3 pole Circuit Breaker that disconnects both hot leads and all Three Phases simultaneously STANDBY POWER CONNECTIONS The VANTAGE 400 is suitable for temporary standby or emergency power using the engine manufacturer s recommended maintenance schedule The VANTAGE 400 can be permanently installed as a standby power unit for 240 VAC 3 wire single phase 50 amp service Connections must be made by a licensed electrician who can determine how the 120 240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes Install the double pole double throw switch between the power company meter and the premis es disconnect Switch rating must be the same or greater than the customer s premises disconnect and service over current protection Take necessary st
36. HAZARDOUS The maximum allowable high idle speed for this machine is 1890 RPM no load Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop BATTERY MAINTENANCE 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 WARNING we GASES FROM BATTERY can explode e Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and con nect to new battery last CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery first then connect negative lead to neg ative battery lead at engine foot BATTERY ACID can burn eyes and skin Wear gloves and eye protection
37. IM883 A VANTAGE 400 For use with machines having Code Numbers 11186 11462 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Equipped with VRD VOLTAGE REDUCTION DEVICE See Installation and Operation sections for an explanation OPERATOR S MANUAL 180 9001 E LINCOLN 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 CALIFORNIA PROPOSITION 65 WARNINGS gt Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBL
38. Mode when VRD VOLTAGE REDUCTION DEVICE is on VANTAGE 400 LINCOLN 8 2 SAFETY PRECAUTIONS WARNING 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 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 MOVING PARTS can injure not operate with doors open or guards off Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual Only qualified personnel should install use or service this equipment VRD VOLTAGE REDUCTION DEVICE The VRD feature provides additional safety in the CC Stick mode especially in an environment with a higher risk of electric shock such as wet areas and hot humid sweaty conditions The VRD reduces the OCV Open Circuit Voltage at the welding output terminals while not welding to less than 32V DC when the resistance of the output circuit is above 2000 ohms The VRD requires that the welding cable connections be kept in good electrical condition
39. N 1 ACCESSORIES 1 FIELD INSTALLED OPTIONS ACCES SORIES K2641 2 FOUR WHEELED STEERABLE YARD TRAILER For in plant and yard towing Comes standard with a Duo Hitch a 2 Ball and Lunette Eye combination Hitch K2636 1 TRAILER Two wheeled trailer with optional fender and light package For highway use consult applicable federal state and local laws regarding possible additional requirements Comes standard with a Duo Hitch a 2 Ball and Lunette Eye combination hitch Order K2636 1 Trailer K2639 1 Fender amp Light Kit K2640 1 Cable Storage Rack K903 1 SPARK ARRESTOR Includes a heavy gage steel approved spark arrestor clamp and adapter for mounting to the muffler exhaust pipe K704 ACCESSORY SET Includes 35 ft 10m of electrode cable and 30 ft 9 1m of work cable head shield work clamp electrode holder Cables are rated at 400 amps 10096 duty cycle K857 25 ft 7 6m or K857 1 100 ft 30 4m REMOTE CONTROL Portable control provides same dial range as the output control on the welder Has a convenient 6 pin plug for easy connection to the welder K802N POWER PLUG KIT Provides four 120 volt plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240 volts 50 amps K802R POWER PLUG KIT Provides four 120 volt plugs rated at 15 amps each and one dual voltage full KVA plug rated at 120 240 volts 50 amps T12153 9 50 AMP 120 240V POWER PLUG 1 Phase T12153 10 50 AMP 2
40. OLIMS N waz a HOLIMS HOSN3S NOUISOA NOS EIDEL En Szeen HOLIMS 1NV1009 I s E dOLS NnM Dez ER M3L3NLT0A de 9 9 We 3103 Nid pL e HOLIMS HOSN3S 3unssasd V dNo lt asez z eo Ka ez Ae ai Di 8v vor ova as LUVLS m oui Tounoa M HOL 310W3H HOLIMS IOLLISOd SAVMTV NMOHS OU i lt HOLIMS 1ONLNOD 5 TOULNOD ONLS pez yya TIVNIWH3 L 7OMINOO LNdLNO ii NOLIISOd HOIH YILIN YN KH NI NMOHS yoz oz NOLLVNIWV T OL 15 ONRI 4115 1 HSNUEAAILISOd n EE pe DONS TOS 9NTd MOT 3 NMOGLNHS Hsnua eg 002 9002 Ee Ge EE
41. RT 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 ARC CONTROL is not active in the TIG mode To STOP a weld simply pull the TIG torch away from the Work When the arc voltage reaches approximately 30 Volts the arc will go out and the machine will reset the cur rent to the Touch Start level To reinitiate the arc retouch the tungsten to the work and lift Alternatively the weld can be stopped by releasing the Amptrol or arc start switch The VANTAGE 400 can be used in a wide variety of DC TIG welding applications In general the Touch Start feature allows contamination free starting with out the use of a Hi frequency unit If desired the K930 2 TIG Module can be used with the VANTAGE 400 The settings are for reference VANTAGE 400 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 TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES 2 Tungsten Electrode Diameter in mm DCEN DCEP Approximate Argon Gas Flow Flow Rate C F H 1 min TIG TORCH Nozzle Size 4 5 1 2 Thoriated 1 2 Thoriated Aluminum Stainless Steel Tungsten Tungsten 2 15 2 4 5 20 3 5 15 80 3 5 70 150 E 5 10 3 5 150 250 250 400 19 17 6 8 15 23 7 11 400 500 500 750 750 1000 21 25 23 27 28
42. SV3SONI NV 3570 3TLLOSH JHL SNIGIHS3AO ONILLAS HONSH3AOS HOIH 30 ASVAYONI 0993 OL NOUT 9189 300819313 OL DIAGRAMS 31870 10 1 05 069 41875 TONSHdNV CYZ NTOL juewudinbe siu 10 sued jou esn je sul pjnous jeuuosied peyipenb AIUO e sued Aeme desye 3ALLVO3N 12euuoo siq eoejd ui deeye uedo sjeued ejejedo jou oq e ONINHVM 7 F 4 NOLLO3NNOO CRIN H SH3Q013M ANISNA VANTAGE 400 LINCOLN 5 9 8 vcS 0005 77 NOLLISOd NI HOLIMS 44141 32VId 714V2 390312313 AHL AO HOLVW OL HDLIMS YALAWLIOA 830334 38IM AHL NOILISOd ALI 10d QHIS3G 401 SGNLS LAdLNO OL 31895 LOANNOD ON IWANVW ONILV41dO 33S SNOILVOlTddV ANY 31LVIQINMI 30 TTDAD ANY JHL ALIDVdV 934034 HO LSNW S318V2 DNIQTJM IWANVW ONILV 4340 83Q713M ANIDNA SHL NI Q31ST1 SNOILVD11123dS 3AO8V 15 LON Od AYOLIV4 FHL 435 344 SI DNILLAS HONH3AOD 3NIDN3 JHL LINDYID TOHLNOO NYD H2IHM 39V LL10A 830334 3HIM JHL NI 3SV3HDNI NV ASNWD ADVANI FTLLOYHL 3H L BNIGIHH3AO ONILLAS HONH3AOD JHL DNIDNVHO
43. Start engine and look for leaks Faulty oil pressure switch or other engine component Contact authorized local Engine Service Shop 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 LINCOLN E 3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Engine shuts down while under al 1 Engine runs rough High radiator coolant tempera 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 Dirty fuel or air filters Inspect and clean replace filters as needed Inspect and clean replace filters as needed Water in fuel If water found in Battery does not stay charged Engine alternator trouble light is on while machine is running tank Empty fuel tank and refill then purge fuel lines Faulty battery Replace 2 Loose connections at battery or alternator Clean and tighten con nections Faulty engine alternator or charg Engine will not idle down to low speed er modu
44. TART button immediately 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 D 0 when VANTAGE 400 LINCOLN 5 OPERATION B 5 NOTE ff 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 the Engine Protection or Battery Charging Lights do not turn off shortly after starting the engine shut off the engine immediately and determine the cause NOTE When starting for the first time or after and extended period of time of not operating it will take longer than normal to start because the fuel pump has to fill the fuel system For best results bleed the fuel system as indicated in Maintenance Section of this manual STOPPING THE ENGINE 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 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 fi
45. TrOUDIOSNOOTING Section How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 thru E 6 Connection Diagrams Wiring Diagrams and Dimension Print Section F Parts 9 e tren cox Paseo ce uc a eun Coda P 528 vii 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS VANTAGE 400 K2410 1 K2410 2 INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities PERKINS cu in Itrs System K2410 1 4 cylinder 135 6 2 2 12VDC Battery amp Fuel 15 gal 404 22 32 7 High Idle 1880 starter 57 L 1800 RPM Bore x Stroke inch mm Group 34 650 Oil 8 45Qts 8L naturally aspirated Full Load 1800 cold crank amps K2410 2 water cooled 343 X 3 64 65 Amp Alternator Radiator Coolant 404D 22 Diesel Engine Low Idle 1400 87 1 92 in Regulator 8 0 Qts 7 6L RATED OUTPUT 104 F 40 C WELDER Welding Process Welding Output Output Range Max Weld OCV Current Voltage Duty Cycle Rated Load RPM 400A 36V 10096 DC Constant Current 450A 32V 100 30 TO 500 AMPS DC Pipe Current 300A 32V 10096 40 TO 300 AMPS 60 Volts Touch Start TIG 250A 30V 100 20 TO 250 AMPS 400A 36V 10096 DC Constant Voltage 450A 32V 100 14 TO 36 VOLTS RATED OUTPUT 104 40 C GENERATOR Auxiliary Power 12 000 Watts Peak 11 000 Watts Continuous 60 Hz 120 240 Volts Single Phase 19 0
46. a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 1 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipm
47. arce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour pr
48. at meets S and C grade service classifi cations 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 MAINTENANCE OIL FILTER CHANGE 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 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 Start the engine and check for oil filter leaks Stop the engine and check the oil level If neces sary add oil to the upper limit mark on the dipstick WARNING Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explosion could result CAUTION run the engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn into the engine AIR CLEANER The diesel engine is equipped with a dry type air filter Never apply oil t
49. ature holds the display of both meters on for seven seconds after welding is stopped This allows the operator to read the actual current and voltage just prior to when welding was ceased While the display is being held the left most deci mal point in each display will be flashing The accuracy of the meters is 3 WELD MODE SELECTOR SWITCH Provides four selectable welding modes CV WIRE DOWNHILL PIPE STICK When in the TOUCH START TIG mode and when Geer TOUCH START TIG 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 400 LINCOLN 3 OPERATION B 3 4 ARC CONTROL The ARC CONTROL dial is active in the CV WIRE CC STICK and DOWNHILL PIPE modes and has different functions in these modes This control is not active in the TIG mode 1 CC STICK mode In this mode the ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or crisp arc Increasing the dial from 10 soft to 10 crisp increases the short circuit current and prevents sticking of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with a setting at 0 DOWNHILL PIPE mode In this mode the ARC CONTROL dial sets the short circuit current arc force during sti
50. body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 4 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 2 d 5 Do not work next to welding power source Mar 95 LINCOLN 8 SAFETY ELECTRIC SHOCK can 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 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 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 Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder
51. ck welding to adjust for a soft or a more forceful digging arc crisp Increasing the number from 10 soft to 10 crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is pre ferred for root and hot passes A softer arc is preferred for fill and cap passes where weld puddle control and deposition stacking of iron are key to fast travel speeds It is recom mended that the CONTROL be set initially at 0 CV WIRE mode In this mode turning the ARC CONTROL clock wise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance pinch control The proper setting depends on the procedure and operator preference Start with a setting of 0 5 WELD OUTPUT TERMINALS WITH FLANGE NUT Provides a connection point for the electrode and work cables 6 GROUND STUD Provides a connection point for connecting the machine case to earth ground 10 WIRE FEEDER VOLTMETER SWITCH Matches the polarity of the wire feeder voltmeter to the polarity of the electrode VRD Voltage Reduction Device INDICA TOR LIGHTS On the front panel of the Vantage 400 are two indicator lights A red light when lit indi cates OCV Open Circuit Voltage is equal to or greater than 32V and a green light when lit indicates OCV Open Circuit Voltage is less than 32V The VRD On Off switch inside the control panel must b
52. 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 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 VANTAGE 400 LINCOLN 8 OPERATION B 2 FIGURE 1 WELDING CONTROLS Figure B 1 1 OUTPUT CONTROL The OUTPUT dial is used to preset the output voltage or current as dis played on the digital meters for the four welding modes When in the CC STICK DOWNHILL PIPE or CV WIRE modes and when a remote control is connected to the 6 Pin or 14 Pin Connector the auto sensing circuit automatically switches the OUTPUT CONTROL from control at the welder to the remote control In the CV WIRE mode if the feeder being used has a voltage control when the wire feeder control cable is connected to the 14 Pin Connector the auto sensing circuit automatically makes OUTPUT CON TROL inactive and the wire feeder voltage control active Otherwise the OUTPUT CONTROL is used to preset the voltage 2 DIGITAL OUTPUT METERS The digital meters allow the output voltage CV WIRE mode or current CC STICK DOWN HILL PIPE and TIG modes to be set prior to welding using the OUT PUT control dial During welding the meter display the actual output voltage VOLTS and current AMPS A memory fe
53. e NOTE The TIG process is to receive a low voltage welding process There is no difference in operation with the VRD or Off for this mode For indicator light operation see table B 1 WIRE WELDING CV Connect a wire feeder to the VANTAGE 400 according to the instructions in INSTALLATION INSTRUCTIONS Section The VANTAGE 400 in the CV WIRE mode permits it to be used with a broad range of flux cored wire Innershield and Outershield electrodes and solid wires for MIG welding gas metal arc welding Welding can be finely tuned using the ARC CONTROL Turning the ARC CONTROL clockwise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an induc tance pinch control The proper setting depends on the pro cedure and operator preference Start with the dial set at 0 NOTE In the CV Mode with VRD On the OCV Open Circuit Voltage is not reduced For indicator light operation see table B 1 TABLE B 5 OPERATION B 7 ARC GOUGING The VANTAGE 400 can be used for arc gouging For opti mal performance set the MODE switch to CC STICK and the CONTROL to 10 Set the OUTPUT CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following Table B 4 TABLE B 4 Current Range DC electrode positive arbon Diameter 1 8 60 90 Amps 5 32 90 150 Amps 3 16 200 250 Amps
54. e 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 indi cating that the VRD has reduced the OCV to less than 32V During welding the red light will illuminate whenever the arc voltage is equal to or greater than 32V This means that the red and green light may alternate depending on the weld voltage This is nor mal operation 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 If the VRD is turned On and the lights don t come refer to the trouble shooting section TABLE B 1 VRD INDICATOR LIGHTS MOD VRD ON VRD OFF 7 14 PIN CONNECTOR For attaching wire feeder con trol cables Includes contactor closure circuit auto sensing remote control circuit and 120V and 42V power The remote control circuit operates the same as the 6 Pin Amphenol 8 6 PIN CONNECTOR For attaching optional remote control equipment Includes auto sensing remote control circuit WELD TERMINALS ON position the output is electrically hot all the time In the REMOTELY CONTROLLED posi tion the output is controlled by a wire feeder or amptrol
55. e 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 alwa
56. e high idle speed the wire will begin to feed and the welding process started When weld ing is stopped the engine will revert to low idle Speed after approximately 12 seconds unless welding is resumed CAUTION If you are using an LN 25 without an internal tactor the electrode will be energized when the VANTAGE 400 is started Spool Gun K487 25 and Cobramatic to VANTAGE 400 Shut the welder off Connect per instructions on the appropriate connec tion diagram in Section F Connection of PRINCE XL SPOOL GUN to the VANTAGE 400 Connection of the Prince XL Spool Gun requires the use of the K1849 1 Adapter Module Shut the Welder off For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder Connect the Control Cable of the Spool Gun to the Adapter Module and connect the Control Cable of the Adapter Module to the Welder Connect the Gas Hose Set the MODE switch to the CV WIRE position Set the WELD TERMINALS switch to WELD TERMINALS Set the ARC CONTROL knob to initially and adjust to suit Set the IDLE switch to the HIGH position VANTAGE 400 LINCOLN 8 1 OPERATION B 1 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipm
57. e the sealing area on the tube Wipe both sides of the outlet tube clean Outer edge of the outlet tube Inner edge of the outlet tube 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 for Leak Clues 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 d Inspect the New Filter for Damage Inspect the new filter carefully paying attention to the inside of the open end which isthe sealing area NEVER install a damaged W filter A new Donaldson radial seal filter may have a dry lubricant on the seal to aid installation 5 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 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 The critical sealing area will stretch 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
58. eceptacle can be reset proper ly See the MAINTENANCE section for more detailed information on testing and resetting the GFCI recepta cle The auxiliary power of the VANTAGE 400 consists of two 20 Amp 120 VAC 5 20R duplex receptacles with GFCI protection one 50 Amp 120 240 VAC 14 50R receptacle and one 50 Amp 240VAC Three Phase 15 50R receptacle The auxiliary power capacity is 12 000 watts Peak 11 000 Watts Continuous of 60 Hz single phase power The auxiliary power capacity rating in watts is equivalent to volt amperes at unity power factor The max permissible current of the 240 VAC output is 50amps The 240 VAC output can be split to provide two sepa rate 120 VAC outputs with a max permissible current of 50 Amps per output to two separate 120 VAC branch circuits these circuits cannot be paralleled Output voltage is within 1096 at all loads up to rated capacity The Three Phases auxiliary power capacity is 19 000 watts peak 17 000 watts continuous The maximum current is 45 amps 120 V GFCI DUPLEX RECEPTACLES A GFCI Ground Fault Circuit Interrupter electrical receptacle is a device to protect against electric shock should a piece of defective equipment connected to it develop a ground fault If this situation should occur the GFCI will trip removing voltage from the output of the receptacle If a GFCI receptacle is tripped see the MAINTENANCE section for detailed information on testing and resetting it A G
59. ect the positive battery cable first and the negative cable last Failure to do so can result in damage to the internal charger components Follow the instructions of the battery charger manu facturer for proper charger settings and charging time SERVICING OPTIONAL SPARK ARRESTOR Clean every 100 hours WARNING MUFFLER ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTER DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER VANTAGE 400 LINCOLN 8 D 6 WELDER GENERATOR MAINTENANCE STORAGE Store in clean dry protected areas CLEANING Blow out the generator and controls peri odically with low pressure air Do this at least once a week in particularly dirty areas BRUSH REMOVAL AND REPLACEMENT It s nor mal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary CAUTION Do not attempt to polish slip rings while the engine is running WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equip ment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and pre cautions MAINTENANCE D 6 GFCI RECEPTACLE TESTING AND RESET TING PROCEDURE The GFCI receptacle should
60. ed operating mode Full power is available regardless of the welding control settings providing no welding current is being drawn ENGINE OPERATION Before Starting the Engine 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 Add oil if necessary to bring the level up to the full mark Do not overfill Close engine door e Check radiator for proper coolant level Fill if nec essary See Engine Owner s Manual for specific oil and coolant recommendations WARNING ADD FUEL Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling DIESEL FUEL Wipe up spilled fuel and allow can cause fire fumes to clear before starting engine Do not overfill tank fuel expansion may cause over flow DIESEL FUEL ONLY Low sulphur fuel or ultra low sulphur fuel in U S A and Canada Remove the fuel tank cap Fill the tank DO NOT FILL THE TANK TO THE POINT OF OVERFLOW Replace the fuel cap and tighten securely See Engine Owner s Manual for specific fuel recom mendations BREAK IN PERIOD 7 The engine will use a small amount of oil during its break in period The break in period is about 50 run ning hours Check the oil every four hours
61. eighs approximately 1345lbs 611kg with a full tank of fuel 1230lbs 559kg less fuel A lift bail is mounted to the machine and should always be used when lifting the machine VANTAGE 400 LINCOLN 8 3 INSTALLATION 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 FALLING EQUIPMENT can cause injury Do not lift machine if lift bail is damaged Do not operate machine while suspended from lift bail HIGH ALTITUDE OPERATION At higher altitudes output derating may be necessary For max imum rating derate the machine 2 5 to 3 5 for every 1000 ft 305m Due to new EPA and other local emissions regulations modifications to the engine for high altitude are restricted within the United States For use above 6000 ft 1828 m an autho rized Perkins engine field service shop should be contacted to determine if any adjustments can be made for operation in high er elevations HIGH TEMPERATURE OPERATION At temperatures above 104 F 40 C Welder output derating is necessary For maximum output ratings derate the welder out put 2 volts for every 18 F 10 C above 104 F 40 C Cold weather starting With a fully charged battery and the proper oil the engine should start satisfactorily down to 15 F 26C If the engine mus
62. ent in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations SAFETY PR CAUTIONS S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder p
63. ent 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 Always operate the welder with the hinged door closed and the side panels in place 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 GENERAL DESCRIPTION The VANTAGE 400 is a diesel engine powered DC multi process welding power source and 120 240 volt AC power generator The engine drives a genera tor that supplies three phase power for the DC weld ing circuit single phase and Three Phase power for the AC auxiliary outlets The DC welding control sys tem uses state of the art Chopper Technology for superior welding performance The Vantage 400 is fitted with selectable VRD Voltage Reduction Device The VRD operates in the CC Stick mode reducing the OCV to 13 volts increasing operator safety when welding is performed in environments with increased hazard of electric shock FOR AUXILIARY POWER Start the engine and set the IDLER control switch to the desir
64. eps to assure load is limited to the capacity of the generator by installing a 50 amp 240 VAC double pole circuit breaker Maximum rated load for each leg of the 240 VAC auxiliary is 50 amperes Loading above the rated output will reduce output voltage below the allow able 1096 of rated voltage which may damage appliances or other motor driven equipment and may result in overheating of the engine and or alternator windings Install 50 amp 120 240 VAC plug NEMA Type 14 50P to the double pole circuit breaker using No 6 4 conductor cable of the desired length The 50 amp 120 240 VAC plug is available in the optional K802R plug kit or as part number T12153 9 Plug this cable into the 50 Amp 120 240 Volt receptacle on the case front VANTAGE 400 LINCOLN 8 7 INSTALLATION 7 CONNECTION OF VANTAGE 400 TO PREMISES WIRING 240 VOLT 240 Volt POWER 60 Hz Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES DISCONNECT AND GROUND OVERCURRENT PROTECTION DOUBLE POLE 50 AMP 120 240 VOLT PLUG BREAKER NEMA TYPE 14 50 1 50 AMP 120 240 VOLT Mud Nr 0 NOTE No 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS WARNING Only a licensed certified trained electrician sh
65. f con nected for 1 phase input power 400 LINCOLN 8 D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING Have qualified personnel do all maintenance and troubleshooting work 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 Read the Safety Precautions in the front of this manual and in the Engine Owner s Manual before working on this machine 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 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 PTENGINESERTICE NOTE WERE Coolant bevel Cheese sons
66. gine will not shut off Engine does not develop full power Low weld and auxiliary output Engine runs rough Auxiliary power load is less than 100 watts may not respond with less than a 100 watt load Set idler to High Faulty PC board Control or Idler Faulty idler solenoid Check for bent linkage or broken spring Faulty PC board Control or Idler Fuel filter clogged Replace Air filter clogged clean or replace High idle setting incorrect check and adjust if required Valves out of adjustment Fuel contaminated with water or sediment Check fuel pre filter and empty of water bleed fuel system Replace fuel in tank if needed Broken spring on Idle Solenoid solenoid linkage binding Faulty PC board Control or Idler low idle speed set too low on idle solenoid 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 Fuel filter dirty clogged Replace Air filter dirty clogged Replace Air Filter Element Fouled fuel injector s Contact authorized Engine Service Shop Fuel contaminated with water Check water separator for water Clean and replace as needed Replace fuel in tank Cracked or loose fuel hose Replace hose and tighten clamps Valves out of adjustment Contact authorized local Engine Service S
67. he 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 E6010 Touch Lift to Start the Arc E7018 E7024 Touch Rock Back and Forth in Joint Lift Once the arc is started normal welding technique for the application is then used B For Re Striking Electrodes Some electrodes form a cone at the end of the electrode after the welding arc has been broken particularly iron powder and low hydrogen elec trodes This cone will need to be broken off in order to have the metal core of the electrode make con tact E6010 Push Twist in Joint Lift E7018 E7024 Push Rock Back and Forth in Joint Lift 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 For indicator light operation see table B 1 DOWNHILL PIPE Welding This slope controlled setting is intended for out of position and down hill pipe welding where the oper VANTAGE 400 LINCOLN
68. he 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 The engine will automatically return to high idle speed when there is welding load or AC power load reapplied 16 ELECTRIC FUEL GAUGE The electric fuel gauge gives accurate and reliable indication as to how much fuel is in the fuel tank TABLE B 2 TYPICAL VANTAGE 400 FUEL CONSUMPTION PERKINS 4040 22 amp 4040 22 Running Time for Gal Hr Liters Hr 15 gallons hours 26 97 58 59 42 1 57 36 06 1 18 4 46 1274 24 4 68 0 3 42 7 000 Watts 3 Phase 1 24 4 68 12 14 90 3 42 16 62 NOTE This data is for reference only Fuel consump tion is approximate and can be influenced by many factors including engine maintenance environmental conditions and fuel quality OPERATION B 4 17 ENGINE HOUR Displays the total time that the engine has been running This meter is useful for scheduling prescribed maintenance 18 ENGINE PROTECTION LIGHT warning indi cator light for Low Oil Pressure and or Coolant Over Temperature The light is off when the systems are func tioning properly The light
69. hop If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility 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 LINCOLN 8 5 TROUBLESHOOTING 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION No welding power output 1 Poor work lead connection to work Make sure work clamp is tightly connected to clean base metal Weld Terminals switch in wrong position Place switch in Weld Terminals On position when welding without control cable Faulty PC board or welder alterna tor Welder has output but no control Poor remote control cable connec tion to 6 pin or 14 pin connector Check connections Faulty remote cable or faulty wire feeder or wire feeder cable Replace if necessary Faulty control potentiometer or PC board If all recommended possible areas Wire feeder does not work 1 Wire Feeder Power circuit breakerlof misadjustment have been control cable is connected to 14 open Check 42V and 120V checked and the problem persists connector beakers and reset if tripped Contact your local Linco
70. in the fuel line Do not overfill leave room for the fuel to expand 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 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 A WARNING To avoid personal injury do not bleed a hot engine This could cause fuel to spill onto a hot exhaust manifold creating a danger of fire Bleed the fuel system as follows Fill the fuel tank with fuel Open the fuel shut off valve Loosen bleed fitting on the fuel injector manifold 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 APUN VANTAGE 400 LINCOLN D 5 MAINTENANCE D 5 FUEL FILTER 1 Check the fuel filter and fuel pre filter for water accumulation or sediment 2 Replace the fuel filter if it is found with excessive water accumulation or sediment Empty fuel pre fil ter OVERSPEED IS
71. incoln 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 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 Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom 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 If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility 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
72. ire Welding CV B 7 AEC GOUGING BEE B 7 Auxiliary POWER P B 7 Simultaneous Welding and Power Loads B 7 Extension Cord Recommendations essen nee B 7 races Section Field Installed Options C 1 vi TABLE OF CONTENTS Mamteuauee e Section D Safety Precautions iii D 1 Routine Maintenance nee D 1 Engine Service Items ns D 1 Engine Oil Change ET D 2 Engine Oil Filter Change D 2 Cleaner fin en nettes m D 2 Service Instructions And Installation Tips for Engine Air Filter D 3 COOLING 5 ME D 4 ree EE 0 4 FUG D 4 Bleeding the Fuel System D 4 ag D 5 Engine Adjustment nee D 5 Battery Maintenance D 5 Servicing Optional Spark Arrestor sese D 5 Welder Generator Maintenance A D 6 jc me EE D 6 Cl aNiN D 6 Brush Removal and D 6 Receptacle Testing and Resetting Procedure D 6
73. le Consult authorized Engine Service Shop Idler switch in High idle position Set switch to Auto External load on welder or auxil iary power Remove all external loads Faulty PC board or idler sole Engine will not go to high idle when attempting to weld noid Poor work lead connection to work Make sure work clamp is tightly connected to clean base metal 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 Faulty PC board Low idle speed set to low E 3 If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility 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 LINCOLN 8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Engine will not go to high idle when using auxiliary power Engine will not go to high idle under weld or auxiliary loading Engine does not develop full power Engine runs rough Engine will not go to high idle when attempting to weld or using auxil iary power Switching to manual high idle does not work En
74. ln Faulty control cable Repair or Authorized Field Service Facility replace cable Faulty wire feeder Replace wire feeder No auxiliary power GFCI Receptacle may have tripped Follow GFCI Receptacle Testing and Resetting Procedure in the MAINTENANCE section of this manual Faulty connections to auxiliary receptacles Check connections 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 LINCOLN 8 6 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual The welding arc is cold The weld 1 ing arc is not stable or is not satis factory the engine runs normally The auxiliary power is normal Make sure the MODE selector switch is in the correct position for the process being used For exam ple CV WIRE PIPE CC STICK Make sure the electrode wire gas voltage current etc is correct for the process being used Check for loose or faulty connec tions at the weld output terminals and welding cable connections The welding cables may be too long or coiled causing an excessive voltage drop Faulty Control Board No output in Pipe Mode Make sure VRD ON OFF toggle Switch is in the OFF
75. low idle speed after approximately 12 seconds unless welding is resumed VANTAGE 400 LINCOLN 9 INSTALLATION 9 WARNING Connection of the LN 25 to the VANTAGE 400 Shut off welder before making any electrical con nections The LN 25 with or without an internal contactor may be used with the VANTAGE 400 See the appropriate connection diagram in Section F 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 initially and adjust to suit 7 Set the IDLE switch to the AUTO position When not welding the VANTAGE 400 engine will be at the low idle speed If you are using an LN 25 with an internal contactor the electrode is not energized until the gun trigger is closed 8 When the gun trigger is closed the current sens ing circuit will cause the VANTAGE 400 engine to go to th
76. lter WELDER OPERATION DUTY CYCLE Duty Cycle is the percentage of time the load is being applied in a 10 minute period For example a 6096 duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period 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 The VANTAGE 400 can be used with a broad range of DC stick electrodes The MODE switch provides two stick welding settings as follows CONSTANT CURRENT CC STICK 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 weld ing 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 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 t
77. n Bie MAM TOWING em P e Vehicle Mounting Pre Operation Engine Gervice sin A 3 E EET A 4 gil ES A 4 4 Battery Connections is A 4 Muffler Outlet de A 4 p LS 4 R mol Controle 4 Electrical sen A 5 EE 5 Welding RE dl EE 5 Welding Output Cables AAA A 5 Cable Installation sn A 5 Auxiliary Power Receptacles and Plugs emen A 6 Standby Power Connections aceite eq A 6 Promises tut 7 Connection of Lincoln Electric Wire 5 8 9 PRE eee Section B Safety Precautions sisi B 1 General Description rade neu B 1 ForAuxiliary eec M 1 Engine Operation EE B 1 pM B 1 Break in Period 1 Welder Controls B 2 B 3 Engine COMMONS EE B 4 Starting and Stopping the Engine sse B 4 Fuel Consumption Welding Dc Duty Cycle and Electrode Information B 5 Constant Current Stick 2 5 Typical Current Ranges for Tungsten Electrodes B 5 Pipe Stick Welding ioter rece tentent ete eec dee rcs B 6 AMORE B 6 W
78. n 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 CAUTION Always premix the antifreeze and clean tap water before adding to the radiator It is very important that a precise 50 50 solution be used with this engine year round This gives proper cooling dur ing hot weather and freezing protection to 34 F 37 C 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 Ibs 9 Kg D 4 FUEL DIESEL FUEL ONLY Low sulphur fuel or ultra low sulphur fuel in U S A and Canada At the end of each day s use refill the fuel tank to min imize moisture condensation and dirt contamination
79. ng and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 9 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 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 s
80. o it Service the air cleaner as follows Replace the element every 500 hours of operation Under dusty conditions replace sooner VANTAGE 400 LINCOLN D 3 MAINTENANCE D 3 Service instructions Single and Two Stage Engine Air Cleaners 1 Remove the Filter 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 Rotate the the seal on a jar Gently move the end of the filter i while back and forth to break the seal then rotate while pulling straight out Avoid knocking the filter straight out against the housing 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 Clean Both Surfaces of the Outlet Tube and Check the Vacuator Valve 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 notto damag
81. oduire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POU R contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER SE TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier LINCOLN 8 Relier la terre le chassis du
82. olvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 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 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 Also see item 1 b SAFETY WELDING and CUTTING gt SPARKS cause fire or explosion 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 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 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 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 Do not heat cut or weld tanks d
83. or elec trode Negative connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder Across The Arc Model Attach the single lead from the front of the LN 15 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current Set the WELD TERMINALS switch to WELD TERMINALS When the gun trigger is closed the current sens ing circuit will cause the VANTAGE 400 engine to go to the high idle speed the wire will begin to feed and the welding process started When welding is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed INSTALLATION A 8 4 Control Cable Model Connect Control Cable between Engine Welder and Feeder the WELD TERMINALS switch to REMOTELY CONTROLLED Set the MODE switch to the CV WIRE position Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode polar ity being used Set the CONTROL knob to O initially and adjust to suit Set the IDLE switch to the AUTO position When the gun trigger is closed the current sens ing circuit will cause the VANTAGE 400 engine to go to the high idle speed the wire will begin to feed and the welding process started When welding is stopped the engine will revert to
84. ough Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
85. ould install the machine to a premises or residential electrical system Be certain that installation complies with the National Electrical Code and all other applicable electrical codes The premises is isolated and no feedback into the utility system can occur Certain state and local laws require the premises to be isolated before the generator is linked to the premises Check your state and local requirements A double pole double throw transfer switch in conjunction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter VANTAGE 400 LINCOLN 8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of LN 7 or LN 8 to the VANTAGE 400 1 2 7 Shut the welder off Connect the LN 7 or LN 8 per instructions on the appropriate connection diagram in Section F Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode being used Set the MODE switch to the CV WIRE posi tion Set the ARC CONTROL knob to 0 initially and adjust to suit Set the WELD TERMINALS switch to the REMOTELY CONTROLLED position Set the IDLE switch to the HIGH position Connection of LN 15 to the VANTAGE 400 1 2 3 Shut the welder off For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder F
86. poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place for selecting QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advic
87. rums 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 Also see item 1 c 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 Do not use
88. switches the OUTPUT control from control at the welder to remote control When in TOUCH START TIG mode and when a Amptrol is connected to the 6 Pin Connector the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol The 14 pin connector is used to directly connect a wire feeder control cable In the CV WIRE mode when the control cable is connected to the 14 pin con nector the auto sensing circuit automatically makes the Output Control inactive and the wire feeder volt age control active WARNING NOTE When a wire feeder with a built in welding voltage control is connected to the 14 pin connec tor do not connect anything to the 6 pin connec tor VANTAGE 400 LINCOLN 8 5 ELECTRICAL CONNECTIONS MACHINE GROUNDING QD 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 To prevent dangerous electric shock other equipment to which this engine driven welder supplies power must WARNING 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 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
89. t K466 10 Connector Kit for LN 15 K470 2 K1500 1 Gun Receiver Bushing for LN 15 amp K126 2 K487 25 Magnum SG Spool Gun Hand held semiautomatic wire feeder Requires SG Control Module and Input Cable K488 SG Control Module For Magnum Spool Gun The Interface between the power source and the spool gun Provides control of the wire speed and gas flow For use with a K487 25 spool gun K691 10 Input Cable For SG Control Module For Lincoln engine power sources with 14 pin MS type con nection separate 115V NEMA receptacles and output stud connections Note See Wire Feeder IM manuals for appropriate Drive Roll and Guide Tubes TIG OPTIONS K1783 9 Pro PTA 26V TIG Torch Air Cooled 200 amp torch 2 piece equipped with valve for gas flow control 25 ft 7 6m length 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 K870 Foot Amptrol amp K963 3 Hand Amptrol amp K2347 1 Precision TIG 185 Ready Pak For AC TIG K2350 1 Invertec V205 T AC DC One Pak Package For AC TIG PLASMA CUTTING K1580 1 Pro Cut 55 Cuts metal using the 3 phase AC generator power from the engine driven welder Accepts 3 phase or 1 phase input power Requires the K1816 1 Full KVA adapter kit i
90. t be frequently started at or below 0 F 18 C it may be desirable to install cold starting aides The use of No 1D diesel fuel is recommended in place of No 2D at tempera tures below 23 F 5 Allow the engine to warm up before applying a load or switching to high idle Note Extreme cold weather starting may require longer glow plug operation WARNING Under no conditions should ether or other starting fluids be used with this engine TOWING Use a recommended trailer for use with this equipment for road in plant and yard towing by a vehicle 1 If the user adapts a non Lincoln trailer he must assume responsibility that the method of attachment and usage does not result in a safety hazard or damage the welding equipment Some of the factors to be considered are as follows A 3 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 4 Typical conditions of use i e travel speed roughness of sur face on which the trailer will be operated environmental con ditions like maintenance 5 Conformance with federal state and local laws 1 Consult applicable federal
91. to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety ad minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the or idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your
92. 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 Open oil drain valve by lifting up spring loaded lever and rotate 909 counterclockwise Pull to open and drain the oil into a suitable container for disposal Close the drain valve by rotating lever 909 clockwise 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 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 Use motor oil designed for diesel engines that meets requirements for 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 th
93. urrent 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 TABLE A 1 TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 400 Amps 60 Duty Cycle 2 0 AWG Cable Length 0 100 Ft 0 30 meters 100 150 Ft 30 46 meters 2 0 AWG 150 200 Ft 46 61 meters 3 0 AWG CABLE INSTALLATION Install the welding cables to your VANTAGE 400 as follows 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 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 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 LINCOLN 8 A 6 INSTALLATION A 6 AUXILIARY POWER RECEPTACLES Start the engine and set the IDLER control switch to the High Idle mode Voltage is now correct at the receptacles for auxiliary power This must be done before a tripped GFCI r
94. ys 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 TABLE CONTENTS Page Technical Specifications ss A 1 E e EE 2 Voltage Reduction Device A 2 VentllatiQni 2 irr do es Angle of Operatio

Lincoln Electric VANTAGE IM883-A User's Manual

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