Lincoln Electric Dual Maverick 450 Operator's Manual
Operator’s Manual
Dual Maverick®450
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IM10481 | Issue D ate Feb-19
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
12723
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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 ELEC TRIC.
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 de velop 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 possible 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 It ems 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
SAFETY
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
3
SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special
applications
1.
_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”
INSTALLATION ...........................................................................................................................SECTION A
TECHNICAL SPECIFICATIONS...................................................................................................................A-1
VRD (VOLTAGE REDUCTION DEVICE).......................................................................................................A-2
LOCATION AND VENTILATION ..................................................................................................................A-3
STORING ............................................................................................................................................A-3
STACKING ............................................................................................................................................A-3
ANGLE OF OPERATION ............................................................................................................................A-3
LIFTING ............................................................................................................................................A-3
HIGH ALTITUDE OPERATION ....................................................................................................................A-4
HIGH TEMPERATURE OPERATION ............................................................................................................A-4
TOWING ............................................................................................................................................A-4
VEHICLE MOUNTING................................................................................................................................A-4
PRE-OPERATION ENGINE SERVICE...........................................................................................................A-4
OIL ............................................................................................................................................A-4
FUEL - USE DIESEL FUEL ONLY ...............................................................................................................A-5
ENGINE COOLANT ...................................................................................................................................A-5
BATTERY CONNECTION ...........................................................................................................................A-5
MUFFLER OUTLET PIPE ...........................................................................................................................A-5
SPARK ARRESTOR...................................................................................................................................A-5
CASE FRONT CONTROLS.........................................................................................................................A-6
WELDING TERMINALS .............................................................................................................................A-8
WELDING OUTPUT CABLES......................................................................................................................A-8
MACHINE GROUNDING.............................................................................................................................A-8
REMOTE CONTROL .................................................................................................................................A-9
AUXILIARY POWER RECEPTACLES ..........................................................................................................A-9
STANDBY POWER CONNECTIONS............................................................................................................A-9
CONNECTION OF WIRE FEEDERS WITH CONTROL CABLE (14 PIN)..........................................................A-10
CONNECTION OF ACROSS THE ARC WIRE FEEDERS TO THE DUAL MAVERICK
®
450 ..............................A-11
OPERATION ................................................................................................................................SECTION B
GENERAL DESCRIPTION ..........................................................................................................................B-1
FOR AUXILIARY POWER: ..........................................................................................................................B-1
ENGINE OPERATION ................................................................................................................................B-1
ADD FUEL ............................................................................................................................................B-2
HAND PRIMER BUTTON...........................................................................................................................B-2
BREAK-IN PERIOD ...................................................................................................................................B-2
RECOMMENDED APPLICATIONS..............................................................................................................B-2
GENERATOR............................................................................................................................................B-2
ENGINE OPERATION ................................................................................................................................B-3
TYPICAL FUEL CONSUMPTION.................................................................................................................B-3
WELDER OPERATION...............................................................................................................................B-4
PARALLELING..........................................................................................................................................B-6
AUXILIARY POWER OPERATION................................................................................................................B-7
DISPLAY OPERATION...............................................................................................................................B-8
ACCESSORIES ............................................................................................................................SECTION C
MAINTENANCE...........................................................................................................................SECTION D
ROUTINE AND PERIODIC MAINTENANCE..................................................................................................D-1
ENGINE MAINTENANCE ...........................................................................................................................D-1
AIR FILTER ............................................................................................................................................D-1
FUEL FILTERS .........................................................................................................................................D-3
COOLING SYSTEM...................................................................................................................................D-3
NAMEPLATES / WARNING DECALS MAINTENANCE ..................................................................................D-3
WELDER / GENERATOR MAINTENANCE ..................................................................................................D-3
FAN BELT CHANGE..................................................................................................................................D-3
OIL CHANGE............................................................................................................................................D-3
BATTERY HANDLING ...............................................................................................................................D-4
PREVENTING ELECTRICAL DAMAGE.........................................................................................................D-4
PREVENTING BATTERY DISCHARGE.........................................................................................................D-4
PREVENTING BATTERY BUCKLING ...........................................................................................................D-4
CHARGING THE BATTERY ........................................................................................................................D-4
4
TABLE OF CONTENTS
TROUBLESHOOTING ...................................................................................................................SECTION E
DIAGRAMS ................................................................................................................................SECTION G
PARTS LIST...............................................................................................PARTS.LINCOLNELECTRIC.COM
CONTENT/DETAILS MAY BE CHANGED OR UPDATED WITHOUT NOTICE. FOR MOST CURRENT INSTRUCTION
MANUALS, GO TO PARTS.LINCOLNELECTRIC.COM.
A-1
INSTALLATIONDUAL MAVERICK®450
INSTALLATION
TECHNICAL SPECIFICATIONS DUAL MAVERICK®450 (K4381-1) CODE 12723
Make/Model Description Speed (RPM) Displacement Starting Dry Capacities
cu. in. (ltrs.) System
3 cylinder High Idle 3000 69 (1.1)
12VDC Battery &
Fuel: 20 gal.
Perkins
®
26.4 HP (19.7kw) starter (75.6 L)
403D-11 3000 RPM Full Load 3000
Bore x Stroke inch (mm)
Oil: 1.16 gal. (4.4L)
Diesel Engine
Low Idle 2100
3.03 X 3.19
Radiator Coolant:
(71 x 81mm) 5.0gal. (18.9L)
INPUT - DIESEL ENGINE
RATED OUTPUT @ 104°F(40°C) - WELDER
SINGLE MODE DUAL MODE
Duty Cycle Welding Volts at Rated Duty Cycle Welding Volts at Rated
Output Amps Output Amps
100% 350 A 34 Volts 100% 225 A 26 Volts
100% 450 A 26 volts 100% 210 A 28.4 Volts
OUTPUT @ 104°F (40°C) – WELDER AND GENERATOR
SINGLE MODE DUAL MODE
Welding Range Welding Range
50-450 Amps CC 30 – 225 Amps CC
30-370 Amps CV 30 – 230 Amps CV
20 - 255 Amps TIG 20 - 255 Amps TIG
Open Circuit Voltage Open Circuit Voltage
60 MAX OCV @ 3000 RPM 60 MAX OCV @ 3000 RPM
Auxiliary Power Auxiliary Power
220 VAC (2) x 6600 Watts, 50 Hz, Single Phase 220 VAC (2) x 6600 Watts, 50 Hz, Single Phase
380 VAC x 13000 Watts, 50 Hz, Three Phase 380 VAC x 13000 Watts, 50 Hz, Three Phase
PHYSICAL DIMENSIONS
Height
(2)
Width
(3)
Depth Weight
36.1 in 27.0 in. 65.0 in. 1155 lbs.
(917 mm) (686 mm) (1651 mm) (524 kg)
(Approx.)
Lift Bail weight rating 2130 lbs. (966 kg.) Maximum.
(1) Output rating in watts is equivalent to volt-amperes at unity power factor.
Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.
(2) Top of Enclosure, add 8.3” (211mm) for exhaust pipe, also add 3.65”(93mm) for metal skid.
(3) Without metal skid.
A-2
INSTALLATIONDUAL MAVERICK®450
SAFETY PRECAUTIONS
Only qualified personnel should install,
use, or service this equipment.
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.
VRD (VOLTAGE REDUCTION DEVICE)
The VRD feature provides additional safety in the Stick, Pipe, Tig
and Gouge modes 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":
1. Switch the High Idle/Run - Stop switch to the Stop position.
2. Remove the 8 screws on the upper panel (Fig A.1). Pull out
the panel to have access to the PC control boards (Fig A.1).
FIGURE A.1
3. Locate VRD switches (as marked in Fig A.2) on both PC
control boards. Left position on each switch indicates "OFF"
state; right position on each switch indicates "ON" state. PC
Control Board on the left is for settings for the left user. PC
Control board on the right is for settings for the right user.
FIGURE A.2
4. Set VRD switches as desired. Toggle left for “OFF”. Toggle
right for “ON”
5. Reinstall the upper panel with screws from Step 2. Turn on
the High Idle/Run switch. Confirm VRD status on the LCD
screen display related to that PC board.
When the VRD switch is in the "ON" position. The display will
show a green tab with "VOLTS<30". If the VRD switch is in the
"ON" position and stud voltage is above 30 volts or while welding,
the display will show a red tab with "VOLTS>30".
WARNING
A-3
INSTALLATIONDUAL MAVERICK®450
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. Locate the welder so that the engine exhaust
fumes are properly vented to an outside area.
DO NOT MOUNT OVER COMBUSTIBLE SURFACES
Where there is a combustible surface directly under
stationary or fixed electrical equipment, that surface should
be covered with a steel plate at least .06”(1.6mm) thick,
which should extend not less than 5.90”(150mm) beyond the
equipment on all sides.
STORING
1. Store the machine in a cool, dry place when it is not in use.
Protect it from dust and dirt. Keep it where it can’t be
accidentally damaged from construction activities, moving
vehicles, and other hazards.
2. Drain the engine oil and refill with fresh 10W30 oil. Run the
engine for about five minutes to circulate oil to all the parts.
See the MAINTENANCE section of this manual for details on
changing oil.
3. Remove the battery, recharge it, and adjust the electrolyte
level. Store the battery in a dry, dark place.
STACKING
Dual Maverick®450 machines cannot be stacked.
ANGLE OF OPERATION
To achieve optimum engine performance the
Dual Maverick®450 should be run in a level position.
The maximum angle of operation for the machine is 35 degrees
continuous in all directions.
When operating the welder at an angle, provisions must be made
for checking and maintaining the oil level at the normal (FULL) oil
capacity. The effective fuel capacity will be slightly less than the
specified 20 gal.(75.7 ltrs.).
LIFTING
The Dual Maverick®450 weighs approximately 1294 lbs.(587 kg)
with a full tank of fuel, 1155 lbs.(524kg) without fuel. A lift bail
and fork pockets are installed on the machine. Lift welder ONLY
using the lift bail or fork pockets.
FALLING EQUIPMENT can cause
injury.
• Lift only with equipment of adequate
lifting capacity.
• Be sure machine is stable when lifting.
• Do not lift this machine using lift bail if it is equipped
with a heavy accessory such as trailer or gas cylinder.
• Do not lift machine if lift bail is damaged.
• Do not operate machine while suspended from lift bail.
• DO NOT EXCEED MAXIMUM LIFT BAIL WEIGHT
RATING.
( SEE TECHNICAL SPECIFICATIONS PAGE)
CAUTION
WARNING
A-4
INSTALLATIONDUAL MAVERICK®450
HIGH ALTITUDE OPERATION
The naturally aspirated engine will run correctly up to an attitude
of 600 m (2000 ft.) If the engine is to operate at an attitude above
this, an increase in smoke may be seen. This is normal for a
naturally aspirated engine.
HIGH TEMPERATURE OPERATION
At temperatures above 40°C (104°F), output voltage derating may
be necessary. For maximum output current ratings, follow the
table below.
DESERT DUTY RATINGS
TOWING
The recommended trailer for use with this equipment for road, inplant and yard towing by a vehicle
(1)
is Lincoln’s K2636-1. 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 nor 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 that there will be no undue stress to the trailer’s
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.
4. Typical conditions of use, such as travel speed, roughness of
surface on which the trailer will be operated, and
environmental conditions.
5. Proper preventative maintenance of trailer.
6. Conformance with federal, state and local laws(1).
(1) Consult applicable federal, state and local laws regarding specific require-
ments for use on public highways.
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 manufacture’s instructions.
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instructions supplied
with this machine.
• Keep hands away from the engine muffler
or HOT engine parts.
• Stop engine and allow to cool before
fuelling.
• Do not smoke when fuelling.
• 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.
OIL
The Dual Maverick®450 is shipped with the engine
crankcase filled with high quality SAE 10W-30 oil (API class CD or
better). Check the engine oil levels 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
35 running hours. Refer to the engine Operator’s Manuals for
specific oil recommendations 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 Manuals for
the proper service and maintenance intervals.
WARNING
AMPS 450 450 425 400
VOLTS 26 26 26 26
DUTY CYCLE 100% 90% 60% 60%
AMBIENT TEMP 40 45 50 55
WARNING
A-5
INSTALLATIONDUAL MAVERICK®450
FUEL - USE DIESEL FUEL ONLY
Fill the fuel tank with clean, fresh diesel fuel. The
capacity of the fuel tank is approximately 20 gallons
(75.7 liters). See engine Operator’s Manual for specific
fuel recommendations. Running out of fuel may require bleeding
the fuel injection pump.
NOTE: Before starting the engine, open the fuel shutoff valve on
the fuel filter located on the liftbale.
ENGINE COOLANT
HOT COOLANT can burn skin.
Do not remove cap if radiator is hot.
The welder is shipped with the engine and radiator
filled with a 50% mixture of ethylene glycol and
water. See the MAINTENANCE section and the
engine Operator’s Manual for more information on
coolant.
BATTERY CONNECTION
GASES FROM BATTERY can explode.
Keep sparks, flame and cigarettes away from
battery.
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY — disconnect negative
cable from old battery first and connect 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 negative battery lead
at engine foot.
BATTERY ACID can burn eyes and
skin.
• Wear gloves and eye protection and be
careful when working near battery.
• Follow instructions printed on battery.
IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN:
a) Installing new battery.
b) Using a booster.
Use correct polarity — NEGATIVE GROUND.
The Dual Maverick®450 is shipped with the negative battery
cable disconnected. Before you operate the machine, make sure
the High Idle / Run - Stop switch is in the STOP position and
attach the disconnected cable securely to the negative (-) battery
terminal.
Remove the insulating cap from the negative battery terminal.
Replace and tighten negative battery cable terminal. NOTE: This
machine is furnished with a wet charged battery; if unused for
several months, the battery may require a booster charge. Be sure
to use the correct polarity when charging the battery.
MUFFLER OUTLET PIPE
Remove the plastic plug covering the muffler outlet tube. 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 position.
SPARK ARRESTOR
Some federal, state or local laws may require that petrol or diesel
engines be equipped with exhaust spark arrestors when they are
operated in certain locations where unarrested sparks may
present a fire hazard. When required by local regulations, a
suitable spark arrestor, must be installed and properly maintained.
An incorrect arrestor may lead to damage to the engine or
adversely affect performance.
WARNING
WARNING
CAUTION
A-6
INSTALLATIONDUAL MAVERICK®450
CASE FRONT CONTROLS
1. LCD SCREEN, IP67 RATED OPERATOR A - The LCD screen
displays information about welding mode, output voltage or
current, engine status and machine settings. It allows
operator to select welding mode and read the output voltage
or current when presetting using the output control knob.
During welding, the screen displays the actual output voltage
(VOLTS) and current (AMPS). A memory feature holds the
screens on for 5 seconds after welding is stopped. This
allows the operator to read the actual current and voltage just
prior to when welding was ceased. In engine status section,
information about engine hours, filter condition, engine oil
and other service items are displayed..
2. OUTPUT CONTROL OPERATOR A - The OUTPUT KNOB is used
to preset the output voltage or current as displayed on the
LCD screen for the six 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
DOWNHILL PIPE and CC-STICK modes if a remote control is
connected to the 6-Pin or 14 Pin Connectors, the output is
controlled by the remote and the output control on the
machine is used to set the maximum current range for the
remote.
3. SINGLE/DUAL OPERATOR MODE SWITCH - The switch allows
the user to choose between Single Operator and Dual
Operator weld modes. Single Operator mode is when the
switch is in the “Left” position. Dual Operator mode is when
the switch is in the “Right” position.
4. 14-PIN WIRE FEEDER CONNECTION OPERATOR A - For
attaching wire feeder control cables. Includes contactor
closure circuit, auto-sensing remote control circuit, and 42V
power. The remote control circuit operates the same as the
6 Pin Amphenol. NOTE: That 115V is not available.
5. WIRE FEEDER POLARITY SWITCH - Matches the polarity of the
wire feeder voltmeter to the polarity of the electrode.
6. 6-PIN REMOTE CONTROL CONNECTOR OPERATOR A - For
attaching optional remote control equipment. Includes autosensing remote control circuit.
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18
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12 25
A-7
INSTALLATIONDUAL MAVERICK®450
7. 15 AMP CIRCUIT BREAKER - Auxiliary output breaker protects
the 220V, single phase receptacle.
8. 15 AMP CIRCUIT BREAKER - Auxiliary output breaker protects
the 220V, single phase receptacle.
9. 25 AMP CIRCUIT BREAKER - Auxiliary output breaker protects
the 380V, three phase receptacle.
10. 220VAC SINGLE PHASE AC EURO PLUGS (QTY 2) - European
(IEC-309) receptacle rated up to 16 amps and is IP44 rated.
11. 380V THREE PHASE AC EURO PLUG- European (IEC-309)
receptacle rated up to 32 amps and is IP44 rated.
12. POSITIVE AND NEGATIVE WELD TERMINAL OPERATOR A -
Provides a connection point for the electrode and work
cables.
13. GLOW PLUG PUSH BUTTON - When pushed activates the
glow plugs. Glow plug should not be activated for more than
20 seconds continuously.
14. 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 operating.
15. START PUSH BUTTON- Energizes the starter motor to crank
the engine.
16. EMERGENCY STOP – Push to stop the engine immediately.
The stop button needs to be manually reset after use in order
to turn on the engine again.
17. BATTERY BREAKER - For protection of Battery Charging
Circuit.
18. LCD SCREEN, IP67 RATED OPERATOR B
19. OUTPUT CONTROL OPERATOR B
20. 6-PIN REMOTE CONTROL CONNECTION OPERATOR B
21. WIRE FEEDER POLARITY SWITCH OPERATOR B
22. 14-PIN WIRE FEEDER CONNECTION OPERATOR B
23. RESIDUAL CURRENT DEVICE – 30mA- Instantly breaks the
auxiliary circuit to prevent serious harm from an ongoing
electric shock.
24. WIRE FEEDER CIRCUIT BREAKER- 42V WIRE FEEDER
BREAKERS
25. POSITIVE AND NEGATIVE WELD TERMINAL OPERATOR B
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