Lincoln Electric VANTAGE 400-I User manual

Operator’s Manual
VANTAGE
®
400-I
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IM10207-D | Issue D ate May-21
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
12366, 12509, 12636,
12691,13199
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to talk to a Service Representative
Hours of Operation:
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no later than the following business day.
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Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
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.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, 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.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you develop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting -
ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine
exhaust fumes outdoors.
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 to
prevent spilled fuel from vaporizing 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.
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.
1.e. In some cases it may be necessary to remove safety 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.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. 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.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
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
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
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.
2.d.3. Do not place your 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.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018

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.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
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 Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. 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
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
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.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018

WELDING AND CUTTING
SPARKS CAN 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.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
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.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018

2
TABLE OF CONTENTS
Page
Installation ................................................................................................................................................Section A
Technical Specifications................................................................................................................................A-1
Machine Specifications .................................................................................................................................A-2
Safety Precautions...................................................................................................................................A-3
VRD (Voltage Reduction Device) ............................................................................................................A-3
Location and Ventilation........................................................................................................................A-3
Stacking ...............................................................................................................................................A-3
Angle of Operation ................................................................................................................................A-3
Lifting......................................................................................................................................................A-4
High Altitude Operation.........................................................................................................................A-4
High Temperature Operation.................................................................................................................A-4
Cold Weather Starting..............................................................................................................................A-4
Towing .................................................................................................................................................A-4
Vehicle Mounting ..................................................................................................................................A-4
Pre-Operation Engine Service........................................................................................................................A-5
Oil ........................................................................................................................................................A-5
Fuel......................................................................................................................................................A-5
Engine Cooling System .........................................................................................................................A-5
Battery Connection ...............................................................................................................................A-5
Muffler Outlet Pipe................................................................................................................................A-5
Spark Arrester ......................................................................................................................................A-5
Remote Control........................................................................................................................................A-6
Electrical Connections...................................................................................................................................A-6
Machine Grounding...............................................................................................................................A-6
Welding Terminals................................................................................................................................A-6
Welding Output Cables ............................................................................................................................A-7
Cable Installation .....................................................................................................................................A-7
Auxiliary Power .............................................................................................................................................A-7
Standby Power Connections..........................................................................................................................A-7
Connection of Lincoln Electric Wire Feeders ............................................................................................A-8, A-9
_________________________________________________________________________________________
Operation Section B
Safety Precautions .......................................................................................................................................B-1
General Description.......................................................................................................................................B-1
For Auxiliary Power .......................................................................................................................................B-1
Engine Operation............................................................................................................................................B-1
Add Fuel .......................................................................................................................................................B-1
Break in Period .............................................................................................................................................B-1
Welding Controls ...................................................................................................................................B-2, B-3
Engine Controls.............................................................................................................................................B-4
Starting the Engine ...............................................................................................................................B-4
Stopping the Engine..............................................................................................................................B-5
Welder Operation ..........................................................................................................................................B-5
Duty Cycle and Electrode Information ...................................................................................................B-5
Constant Current (Stick) Welding ..........................................................................................................B-5
Fuel Consumption.................................................................................................................................B-5
Downhill Pipe (Stick) Welding ...............................................................................................................B-6
Tig Welding ..........................................................................................................................................B-6
Typical Current Ranges for Tungsten Electrodes ...................................................................................B-6
Wire Welding-CV...................................................................................................................................B-7
Arc Gouging..........................................................................................................................................B-7
Auxiliary Power .............................................................................................................................................B-7
Simultaneous Welding and Power Loads...............................................................................................B-7
Extension Cord Length Recommendations ............................................................................................B-7
_________________________________________________________________________________________
Accessories .............................................................................................................................Section C
Field Installed Options / Accessories .........................................................................................................C-1
_________________________________________________________________________________________

TABLE OF CONTENTS
3
Page
Maintenance ..............................................................................................................................Section D
Safety Precautions.......................................................................................................................D-1
Routine Maintenance ....................................................................................................................D-1
Engine Service Items ...................................................................................................................D-1
Engine Oil Change ........................................................................................................D-1, D-2
Engine Oil Filter Change .......................................................................................................D-2
Air Cleaner ...........................................................................................................................D-2
Service Instructions And Installation Tips for Engine Air Filter ...............................................D-3
Cooling System............................................................................................................................D-4
Tightening the Fan Belt ........................................................................................................D-4
Fuel .....................................................................................................................................D-4
Bleeding the Fuel System.....................................................................................................D-4
Fuel Filter.............................................................................................................................D-5
Engine Adjustment..................................................................................................................D-5
Battery Maintenance...............................................................................................................D-5
Cleaning the Battery.............................................................................................................D-5
Checking the Electrolyte Level..............................................................................................D-5
Charging the Battery ............................................................................................................D-5
Servicing Optional Spark Arrestor ...........................................................................................D-5
Welder / Generator Maintenance................................................................................................D-6
Storage ................................................................................................................................D-6
Cleaning...............................................................................................................................D-6
Brush Removal and Replacement.........................................................................................D-6
________________________________________________________________________________
Troubleshooting.......................................................................................................................Section E
How to Use Troubleshooting Guide...............................................................................................E-1
Troubleshooting Guide....................................................................................................E-2 thru E-6
________________________________________________________________________________
Connection Diagrams, Wiring Diagrams and Dimension Print..............................................Section F
________________________________________________________________________________
Parts List ........................................................................................................parts.lincolnelectric.com
Content/details may be changed or updated without notice. For most current Instruction Manuals, go to
parts.lincolnelectric.com.
________________________________________________________________________________

Welding Output
Current/Voltage/Duty Cycle
300A / 32V / 100%
350A / 28V / 100%
400A / 23V / 100%
300A / 32V / 100%
250A / 30V / 100%
300A / 32V / 100%
350A / 28V / 100%
300A / 32V / 100%
A-1
INSTALLATIONVANTAGE®400-I
(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.
*Engine warranty may vary outside of the USA. (See Engine warranty for details).
** To Top of enclosure, add 7.88”(200.2mm) to top of exhaust pipe. Add 4.012”(101.9mm) to top of Lift Bail.
(2) Reduced to less than 30V in the stick mode when VRD (Voltage Reduction Devise) is on.
TECHNICAL SPECIFICATIONS - VANTAGE®400-I (K4169-1)
INPUT - DIESEL ENGINE
RATED OUTPUT @ 104° F (40° C) - WELDER
HEIGHT WIDTH DEPTH WEIGHT
35.94** in. 25.30 in 60.00 in. 1035 lbs. (469kg.)
913 mm 643 mm 1524 mm
LUBRICATION EMISSIONS FUEL SYSTEM GOVERNOR
Full Pressure EPA Mechanical Fuel Pump, Auto air bleed Mechanical
with Full Flow Filter Tier 4 Interim Compliant system Electric shutoff solenoid Indirect fuel injector. Electronic
AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION
Low noise Muffler: Shutdown on low oil
Single Element Automatic Idler Top outlet can be rotated. pressure & high engine
Made from long life, aluminized steel. coolant temperature
ENGINE WARRANTY: 2 year complete (parts and labor) 3rd. year major components (parts and labor)
Welding Process
DC Constant Current
DC Pipe Current
Touch-Start™TIG
DC Constant Voltage
Output Range
20 TO 410 AMPS
40 TO 300 AMPS
20 TO 250 AMPS
14 TO 32 VOLTS
Max. Weld OCV
@Rated Load RPM
60 Volts(2)
Auxiliary Power (1)
60 Hz 220 Volt, 16A, Single Phase
12,500 Watts Peak, /11,000 Watts Continuous, 60 Hz, 380 Volt, 16A, 3-Phase
PHYSICAL DIMENSIONS
ENGINE
RATED OUTPUT @ 104° F (40° C).- GENERATOR
Make/Model
K4169-1
Kubota*
V1505
Description
4 Cylinder
naturally
aspirated
Water Cooled
Diesel Engine
Horsepower
@ 1800 RPM
22 HP
Operating
Speed (RPM)
High
1890 RPM
Full Load
1800 RPM
Low Idle
1350 RPM
Displacement cu. in. (ltrs.)
Bore x Stroke inch (mm)
91.41(1.5)
3.07 x 3.09 (78 x 78 )
Starting
Systems
12VDC Battery
and starter
(Group 34; Battery
535 cold
crank amps)
Battery Charger
Capacities
Fuel: 20gal.(75.7L)
Oil: 6.4qts.(6.0L)
Radiator
Coolant:
7.2qts.(6.8L)
LIFT BAIL WEIGHT RATING 2300 LBS. (1043KG.) MAXIMUM
Arc Gouging 90 to 300 AMPS

A-2
INSTALLATIONVANTAGE®400-I
RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS
(1) 220V Euro Style (1) 16Amp for Single Phase and 3-Phase (3-pole) 10AMP for Engine Battery
(1) 380V Euro Style Charging Circuit
10AMP for 42V Wire Feeder Power
MACHINE SPECIFICATIONS

A-3
INSTALLATIONVANTAGE®400-I
LOCATION AND VENTILATION
The welder should be located to provide an unrestricted 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 properly vented to an outside area.
STACKING
VANTAGE®400-I 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 20 degrees in all directions, 30 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 capaci-
ty will be slightly less than the amount specified.
SAFETY PRECAUTIONS
Only qualified personnel should install,
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
-----------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground
• Always wear dry insulating gloves.
-----------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
-----------------------------------------------------------
MOVING PARTS can injure.
• Do 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.
WARNING
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 13V DC when the resistance
of the output circuit is above 200Ω (ohms).
The VRD requires that the welding cable connections be kept in good
electrical condition because poor connections will contribute to poor
starting. Having good electrical connections 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 by removing 4 front panel
screws.
(See Figure A.1)
• Place the VRD switch in the “On” or “Off” position. (See Figure
A.1)
With the VRD switch in the “On” position, the VRD lights are enabled.
(VRD)-VOLTAGE REDUCTION DEVICE
SWITCH IS LOCATED IN THIS AREA.
REMOVE 4 FRONT PANEL
SCREWS TO ACCESS
(VRD) SWITCH
FIGURE A.1

A-4
INSTALLATIONVANTAGE®400-I
VEHICLE MOUNTING
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
components such as suspension, axles and
tires.
• Mount equipment base to metal bed or frame of
vehicle.
• Follow vehicle manufacturer’s instructions.
----------------------------------------------------------------------------
WARNING
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:
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 surface on
which the trailer will be operated; environmental conditions; like
maintenance.
5. Conformance with federal, state and local laws.(1)
(1) Consult applicable federal, state and local laws regarding specific requirements for use on public highways.
LIFTING
The VANTAGE®400-I weighs approximately 1190 lbs. (540kg.)
with a full tank of fuel (1035 lbs. (470kg.) less fuel). A lift bail is
mounted to the machine and should
always be used when lifting the machine.
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary. For maximum
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 authorized engine field service shop should
be contacted to determine if any adjustments can be made for operation
in higher elevations.
HIGH TEMPERATURE OPERATION
At temperatures above 104°F (40°C), Welder output derating is
necessary. For maximum output ratings, derate the welder
output 2 volts for every 18°F (10°C) above 104°F (40°C).
COLD WEATHER STARTING:
With a fully charged battery and the proper oil, the engine should
start satisfactorily down to 5°F (-15°C). If the engine must be
frequently started at or below 23°F (-5°C), it may be desirable to
install cold-starting aides. The use of No. 1D diesel fuel is rec-
ommended in place of No. 2D at temperatures below 23°F
(-5°C). Allow the engine to warm up before applying a load or
switching to high idle.
Note: Extreme cold weather starting may require longer glow
plug operation.
Under no conditions should ether or other starting
fluids be used with this engine!
--------------------------------------------------------------------
WARNING
• Lift only with equipment of adequate
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 acces-
sory such as trailer or gas cylinder.
FALLING • Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
---------------------------------------------------------------------------
WARNING

A-5
INSTALLATIONVANTAGE®400-I
ENGINE COOLING SYSTEM
Air to cool the engine is drawn in the side and
exhausted through radiator & case back. It is
important that the intake and exhaust air is not
restricted. Allow a minimum clearance of 1ft.
(0.6m) from the case back and 16in.(406mm) from
either side of the base to a vertical surface.
----------------------------------------------------------------------------
BATTERY CONNECTION
Use caution as the electrolyte is a strong acid that
can burn skin and damage eyes.
----------------------------------------------------------------------------
The VANTAGE®400-I is shipped with the negative battery cable
disconnected. Make certain that the RUN-STOP switch is in the
STOP position. Remove the two screws from the battery tray
using a screwdriver or a 3/8" socket. Attach the negative battery
cable to the negative battery terminal and tighten using a 1/2"
socket or wrench.
NOTE: This machine is furnished with a wet charged battery; if
unused for several months, the battery may require a booster
charge. Be careful to charge the battery with the correct polarity.
(See Battery in “Maintenance Section”)
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
K1898-1 must be installed and properly maintained.
An incorrect spark arrestor may lead to damage
to the engine or adversely affect performance.
----------------------------------------------------------------------------
CAUTION
WARNING
WARNING
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instructions sup-
plied with this machine.
• Stop engine and allow to cool before fueling
• Do not smoke when fueling.
• Fill fuel tank at a moderate rate and do not
overfill.
• Wipe up spilled fuel and allow fumes to clear
before starting engine.
• Keep sparks and flame away from tank.
----------------------------------------------------------------------------
OIL
The VANTAGE®400-I is shipped with the engine crankcase filled
with high quality SAE 10W-30 Oil that meets classification CG-4
or CH-4 for diesel engines. Check the oil level before starting
the engine. If it is not up to the full mark on the dip stick, add oil
as required. Check the oil level every four hours of running time
during the first 50 running hours. Refer to the engine Operator’s
Manual for specific oil recommendations and break-in informa-
tion. 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.
• Fill the fuel tank with clean, fresh fuel. The
capacity of the tank is 20 gals. (75.7 ltrs). When
the fuel gauge reads empty the tank contains
approximately 2 gals. (7.6ltrs.) of reserve fuel.
NOTE: The fuel shut off valve should be in the
closed position when the welder is not
used for extended periods of time.
----------------------------------------------------------------------------
WARNING
WARNING
WARNING

A-6
INSTALLATIONVANTAGE®400-I
ELECTRICAL CONNECTIONS
MACHINE GROUNDING
Because this portable engine driven welder creates its own
power, it is not necessary to connect its frame to an earth
ground, unless the machine is connected to premises wiring
(home, shop, etc.)
To prevent dangerous electric shock, other equipment to which
this engine driven welder supplies power must:
• Be grounded to the frame of the welder using a
grounded type plug.
• Be double insulated.
• Do not ground the machine to a pipe that car-
ries 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 connected 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 instructions 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 con-
nected 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 insulated joints, or to the metal framework of
a building which has been effectively grounded.
The National Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding stud
marked with the symbol is provided on the front of the
welder.
WELDING TERMINALS
The VANTAGE®400-I is equipped with a toggle switch for select-
ing "hot" welding terminal when in the "WELD TERMINALS ON"
position or "cold" welding terminal when in the "REMOTELY
CONTROLLED" position.
REMOTE CONTROL
The VANTAGE®400-I is equipped with a 6-pin and a 14-pin con-
nector. When in the Arc Gouging or CV-WIRE modes and when a
remote control is connected to the 6-pin Connector, the
auto-sensing circuit automatically switches the OUTPUT control
from control at the welder to remote control.
When in TOUCH START TIG mode and when a Amptrol is con-
nected to the 6-Pin Connector, the OUTPUT dial is used to set the
maximum current range of the CURRENT CONTROL of the
Amptrol.
When in the CC-STICK or DOWNHILL PIPE mode and when a remote
control is connected to the 6-Pin or 14-Pin connector, the output control is
used to set the maximum current range of the remote.
EXAMPLE: When the OUTPUT CONTROL on the welder is set to 200
amps the current range on the remote control will be Min.-200 amps, rather
than the full Min.-Max. amps. Any current range that is less than the full
range provides finer current resolution for more fine tuning of the output.
The 14-pin connector is used to directly connect a wire feeder
control cable.
In the CV-WIRE mode, if the feeder being used has a volt-
age control when the wire feeder control cable is connected to the 14-Pin
Connector, the auto-sensing circuit automatically makes OUTPUT CONTROL
inactive and the wire feeder voltage control active. Otherwise, the OUTPUT
CONTROL is used to preset the voltage.
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 connector.
----------------------------------------------------------------------------
WARNING
WARNING

A-7
INSTALLATIONVANTAGE®400-I
AUXILIARY POWER
The auxiliary power capacity is 10,500 watts Peak, 14,500
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 380 VAC
output is 16 amps. Output voltage is within ± 10% at all loads
up to rated capacity.
Single phase power is:
• 3,500 Watts Peak / 3,500 Watts Continuous, 60 Hz
220 Volts 1-Phase (Euro).
STANDBY POWER CONNECTIONS
The machine is suitable for temporary, standby or emergency
power using the engine manufacturer’s recommended mainte-
nance schedule.
The machine can be permanently installed as a standby power
unit for 380 VAC, three phase,
16 amp service.
Connections must be made by a licensed electrician who can
determine how the power can be adapted to the particular
installation and comply with all applicable electrical codes.
• Take necessary steps to assure load is limited to the capacity
of the VANTAGE®400-I.
WELDING OUTPUT CABLES
With the engine off connect the electrode and work cables to the
output studs. The welding process dictates the polarity of the
electrode cable. These connections should be checked periodical-
ly and tightened with a 3/4" wrench.
Table A.1 lists recommended cable sizes and lengths for rated
current and duty cycle. Length refers to the distance from the
welder to the work and back to the welder. Cable diameters are
increased for long cable lengths to reduce voltage drops.
TABLE A.1
CABLE INSTALLATION
Install the welding cables to your VANTAGE®400-I 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 out-
put terminals. The terminals are identified 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.
• Loose connections will cause the output termi-
nals to overheat. The terminals may eventually
melt.
• Do not cross the welding cables at the output
terminal connection. Keep the cables isolated
and separate from one another.
-----------------------------------------------------------------------------
CAUTION
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
0-100 Ft. (0-30 meters)
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
Cable Size for
400 Amps
60% Duty Cycle
2 / 0 AWG
2 / 0 AWG
3 / 0 AWG

A-8
INSTALLATIONVANTAGE®400-I
CONNECTION OF ACROSS THE ARC WIRE FEEDERS
TO THE VANTAGE®400-I
These connections instructions apply to both the LN-25 Pro
and Activ8 models. The feeders have an internal contactor
and the electrode is not energized until the gun trigger is
closed. When the gun trigger is closed the wire will begin to
feed and the welding process is started.
• Shut the welder off.
• For electrode Positive, connect the electrode cable to the
"+" terminal of the welder and work cable to the "-" termi-
nal of the welder. For electrode Negative, connect the elec-
trode cable "-" terminal of the welder and work cable to
the "+" terminal of the welder.
• Attach the single lead from the front of the feeder 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 (See Figure A.8).
• Set the MODE switch to the "CV-WIRE" position (See Figure
A.7).
• Set the "WELD TERMINALS" switch to "WELD TERMINALS
ON"
• Set the "ARC CONTROL" knob to "0" initially and adjust to
suit.
•
Set
the
“REMOTE/LOCAL” switch to “LOCAL” control.
FIGURE A.2
FIGURE A.3
Connect Spool Gun (K487-25) to VANTAGE®400-I
• Shut the welder off.
• Connect per instructions on the appropriate connection dia-
gram in Section F.
Set Mode to
CV Wire
Weld
Terminals On Set to Local

B-1
OPERATIONVANTAGE®400-I
SAFETY PRECAUTIONS
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
--------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
• 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-I is a diesel engine powered DC multi-
process welding power source and 300 / 220 volt AC power gen-
erator. The engine drives a generator that supplies three phase
power for the DC welding 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 (CT™) for superior
welding performance.
The VANTAGE®400-I is fitted with a selectable VRD(Voltage
Reduction Device). The VRD operates in the CC-Stick mode
reducing the OCV to <13 volts, increasing operator safety when
welding is performed in environments with increased hazard of
electric shock such as wet areas and hot, humid sweaty condi-
tions.
FOR AUXILIARY POWER:
Start the engine and set the IDLER control switch to the desired
operating mode. Full power is available regardless of the welding
control settings providing no welding current is being drawn.
ENGINE OPERATION
Before Starting the Engine:
• Be sure the machine is on a level surface.
• Open side engine door and remove the engine oil dipstick and
wipe it with a clean cloth.
Reinsert the dipstick and check the level on the dipstick.
• Add oil (if necessary) to bring the level up to the full mark. Do
not overfill. Close engine door.
• Check radiator for proper coolant level. (Fill if necessary).
• See Engine Owner’s Manual for specific oil and coolant rec-
ommendations.
ADD FUEL
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
• Do not overfill tank, fuel expan-
sion may cause overflow.
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 OVER-
FLOW.
• Replace the fuel cap and tighten securely.
• See Engine Owner’s Manual for specific fuel recommenda-
tions.
BREAK-IN PERIOD
The engine will use a small amount of oil during its “break-in”
period. The break-in period is about 50 running hours. Check the
oil every four hours during break-in.
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.
--------------------------------------------------------------------
WARNING
WARNING
CAUTION
DIESEL FUEL
can cause fire.

B-2
OPERATIONVANTAGE®400-I
1
9
11
18
8
4
10
5
7
12
13
15
6
20
14
19
16
17
2
3
FIGURE B.1
WELDING CONTROLS (Figure B.1)
1. OUTPUT CONTROL- The OUTPUT dial is used to preset the
output voltage or current as displayed on the digital meters for the five
welding modes. When in the ARC GOUGING or CV-WIRE modes and
when a remote control is connected to the 6-Pin or 14-Pin Connector,
the auto-sensing circuit automatically switches the OUTPUT CONTROL
from control at the welder to the remote control.
When in the CC-STICK or DOWNHILL PIPE mode and when a remote
control is connected to the 6-Pin or 14-Pin connector, the output
control is used to set the maximum current range of the remote.
EXAMPLE: When the OUTPUT CONTROL on the welder is set to 200
amps the current range on the remote control will be Min.-200 amps,
rather than the full Min.-Max. amps. Any current range that is less
than the full range provides finer current resolution for more fine tun-
ing of the output.
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
CONTROL inactive and the wire feeder voltage control active.
Otherwise, the OUTPUT CONTROL is used to preset the voltage.
When in the TOUCH START TIG mode and when an Amptrol is con-
nected to the 6-Pin Connector, the OUTPUT dial is used to set the
maximum current range of the CURRENT CONTROL of the Amptrol.
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 OUTPUT
control dial. During welding, the meter display the actual output volt-
age (VOLTS) and current (AMPS). A memory feature holds the display
of both meters on for seven seconds after welding is stopped. This
allows the operator to read the actual current and voltage just prior to
when welding was ceased.
While the display is being held the left-most decimal point in each
display will be flashing. The accuracy of the meters is +/- 3%.
3. WELD MODE SELECTOR SWITCH-
(Provides Five selectable welding modes)
CV-WIRE
ARC GOUGING
DOWNHILL PIPE
CC-STICK
TOUCH START TIG

B-3
OPERATIONVANTAGE®400-I
4. ARC CONTROL- The ARC CONTROL dial is active in the CV-
WIRE, CC-STICK and DOWNHILL PIPE modes, and has different func-
tions in these modes. This control is not active in the TIG mode.
CC-STICK mode: In this mode, the ARC CONTROL dial sets the
short circuit current (arc-force) during stick welding to adjust for a soft
or crisp arc. Increasing the dial from –10 (soft) to +10 (crisp) increases
the short circuit current and prevents sticking of the electrode to the
plate while welding. This can also increase spatter. It is recommended
that the ARC CONTROL be set to the minimum number without elec-
trode sticking. Start with a setting at 0.
DOWNHILL PIPE mode: In this mode, the ARC CONTROL dial sets
the short circuit current (arc-force) during stick welding to adjust for a
soft or a more forceful digging arc (crisp). Increasing the number from –
10 (soft) to +10 (crisp) increases the short circuit current which results
in a more forceful digging arc. Typically a forceful digging arc is pre-
ferred for root and hot passes. A softer arc is preferred for fill and cap
passes where weld puddle control and deposition ("stacking" of iron)
are key to fast travel speeds. It is recommended that the ARC 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. POLARITY SWITCH- Select, ELECTRODE (+) or
ELECTRODE (-).
6. WIRE FEEDER VOLTMETER SWITCH-
Matches the polarity of the wire feeder voltmeter to the polarity of the
electrode.
7. 14-PIN CONNECTOR- For attaching wire feeder control
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.
9. WELD TERMINALS CONTROL SWITCH- In the
WELD TERMINALS ON position, the output is electrically hot all the
time. In the REMOTELY CONTROLLED position, the output is controlled
by a wire feeder or amptrol device, and is electrically off until a remote
switch is depressed.
10. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to the polarity
of the electrode.
11. VRD (Voltage Reduction Device) INDICA-
TOR LIGHTS- On the front panel of the Vantage 400-I
are two indicator lights. A red light when lit indicates OCV(Open
Circuit Voltage) is equal to or
greater than 30V and a green light
when lit indicates OCV(Open Circuit Voltage) is less than 30V.
The VRD “On/Off” switch inside the control panel must be “On”
for the VRD function to be active and the lights to be enabled.
When the machine is first started with VRD enabled, both lights
will illuminate for 5 seconds.
These lights monitor the
OCV(Open Circuit Voltage) and weld
voltage at all times. In the CC-Stick mode when not welding the
green light will illuminate indicating that the VRD has reduced
the OCV to less than 30V. During welding the red light will illu-
minate whenever the arc voltage is equal to or greater than
30V. This means that the red and green light may alternate
depending on the weld voltage. This is normal operation.
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 “On”, refer to
the trouble shooting section.
TABLE B.1
VRD INDICATOR LIGHTS
MODE VRD "ON" VRD "OFF"
CC-STICK OCV Green (OCV Reduced)
While Red or Green
Welding (Depends on Weld Voltage) *
CV-WIRE OCV Red (OCV Not Reduced)
Weld Terminals On
Red (OCV Not Reduced)
Weld Terminals Remotely Controlled
Gun Trigger Closed
Green (No OCV)
Weld Terminals Remotely Controlled
Gun Trigger Open No Lights
While Red or Green
Welding (Depends on Weld Voltage) *
PIPE OCV Green (No Output)
While Not Applicable (No Output)
Welding
ARC GOUGING OCV Green (No Output)
While Not Applicable (No Output)
Welding
TIG OCV Green (Process is Low Voltage)
While Green (Process is Low Voltage)
Welding
*It is normal for the lights to alternate between colors while welding.

B-4
OPERATIONVANTAGE®400-I
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 battery drain if
the switch is left in the RUN position and the engine is not operat-
ing.
13. GLOW PLUG PUSH BUTTON -
• When pushed activates the glow plugs. Glow plug should
not be activated for more than 20 seconds continuously.
14. START PUSH BUTTON - Energizes the starter motor to
crank the engine.
15. IDLER SWITCH- Has two positions as follows:
1) In the HIGH position, the engine runs at the high idle speed
controlled by the engine governor.
2) In the AUTO position, the idler operates as follows:
• When switched from HIGH to AUTO or after starting the engine, the
engine will operate at full speed for approximately 12 seconds and
then go to low idle speed.
• When the electrode touches the work or power is drawn for lights or
tools (approximately 100 Watts minimum), 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. POLARITY SWITCH- Provides two selectable welding
polarities: DC+ & DC-.
17. DASHBOARD GAUGE- The dash board gauge dis-
plays 5 gauges:
3a. OIL PRESSURE
The gauge displays the engine oil pressure when the
engine is running.
3b. ENGINE TEMPERATURE
The gauge displays the engine coolant temperature.
3c. HOUR METER
The hour meter displays the total time that the engine
has been running. This meter is a useful indicator for
scheduling preventive maintenance.
3d. FUEL LEVEL
Displays the level of diesel fuel in the fuel tank.
The operator must watch the fuel level closely to pre-
vent running out of fuel and possibly having to bleed
the system.
3e. BATTERY VOLTAGE INDICATOR
Displays the battery voltage and indicates that the
charging system is functioning properly.
18. ENGINE STOP SWITCH- Shuts down engine.
19. CIRCUIT BREAKER- For protection of Battery Charging
Circuit.
20. CIRCUIT BREAKER- For protection of 42V & 115V Wire
Feeder circuits.
STARTING THE ENGINE
1. Remove all plugs connected to the AC power receptacles.
2. Set IDLER switch to AUTO.
3. Press Glow Plug Button and hold 15 to 20 seconds.
4. Set the RUN/STOP switch to RUN.
5. Press START button until the engine starts or for up to 10 seconds.
Continue to hold the glow plug button for up to an additional 10 seconds.
6. Release the engine START button immediately when the engine starts.
7. The engine will run at high idle speed for approximately 12 seconds and
then drop to low idle speed. Allow the engine to warm up at low idle for
several minutes before applying a load and/or switching to high idle.
Allow a longer warm up time in cold weather.
NOTE: If the unit fails to start turn run/stop switch to off and repeat step 3
through step 7 after waiting 30 seconds.
• Do not allow the starter motor to run continuously for more than
20 seconds.
• Do not push the START button while the engine is running
because this can damage the ring gear and/or the starter motor.
• IF the Engine Protection or Battery Charging Lights do NOT turn
off shortly after starting the engine, shut off the engine immedi-
ately 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-filter.
CAUTION

WELDER OPERATION
DUTY CYCLE
Duty Cycle is the percentage of time the load is being applied in a 10
minute period. For example a 60% duty cycle, represents 6 minutes
of load and 4 minutes of no load in a 10 minute period.
ELECTRODE INFORMATION
For any electrode the procedures should be kept within the rat-
ing of the machine. For information on electrodes and their prop-
er application see (www.lincolnelectric.com) or the appropriate
Lincoln publication.
The VANTAGE®400-I 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 CONTROL dial adjusts the full output range
for stick welding.
The ARC CONTROL dial sets the short circuit current (arc-force) dur-
ing stick welding to adjust for a soft or crisp arc. Increasing the
number from -10(soft) to +10(crisp) increases the short circuit cur-
rent and prevents sticking of the electrode to the plate while weld-
ing. 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.
B-5
OPERATIONVANTAGE®400-I
TYPICAL VANTAGE®400-I FUEL CONSUMPTION
Kubota V1505
Gal./Hr (Liters/Hr)
.29 (1.10)
.40 (1.52)
.66 (2.50)
.87 (3.30)
1.17 (4.41)
1.10 (4.15)
.89 (3.36)
.73 (2.75)
.56 (2.14)
Running Time for
20 gallons - (Hours)
68.96
49.76
30.23
22.91
17.15
18.23
22.15
27.53
35.41
Low Idle - No Load 1350 R.P.M. (Kubota)
High Idle - No Load 1890 R.P.M. (Kubota)
DC Weld Output 150 Amps @ 20 Volts
DC Weld Output 250 Amps @ 24 Volts
DC Weld Output 300 Amps @ 32 Volts
10,000 Watts
7,500 Watts
5,000 Watts
2,500 Watts
NOTE: This data is for reference only. Fuel consumption is approximate and can be influenced by many factors, including
engine maintenance, environmental conditions and fuel quality.
NOTE: Due to the low OCV with the VRD on, a very slight delay
during striking of the electrodes may occur. Due to the require-
ment of the resistance in the circuit to be low for a VRD to oper-
ate, 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 con-
nected 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 appli-
cation 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 electrodes. This cone will need to be broken off in
order to have the metal core of the electrode make contact.
E6010 - Push, Twist in Joint, Lift.
E7018, E7024 - Push, Rock Back and Forth in Joint, Lift.
TABLE B.2