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INSTALLATION

DUAL 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 /- 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.

Summary of Contents for Dual Maverick 450

Page 1: ...achines having Code Numbers 12723 Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Experts at lincolnelec...

Page 2: ...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 s...

Page 3: ...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...

Page 4: ...m 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 s...

Page 5: ...nt 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 N...

Page 6: ...e 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 con...

Page 7: ...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 componen...

Page 8: ...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 B...

Page 9: ...BLESHOOTING 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...

Page 10: ...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 Vo...

Page 11: ...he resistance of the output circuit is above 200 ohms The VRD requires that the welding cable connections be kept in good electrical condition because poor connections will contribute to poor starting...

Page 12: ...rge 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 Ma...

Page 13: ...ws 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 tra...

Page 14: ...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...

Page 15: ...to 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...

Page 16: ...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 th...

Page 17: ...r using a grounded type plug or be double insulated Do not ground the machine to a pipe that carries explosive or combustible material When this welder is mounted on a truck or trailer its frame must...

Page 18: ...apacity is 6 600 Watts Continuous of 50 Hz single phase power and 13 000 Watts continuous of 50 Hz three phase power STANDBY POWER CONNECTIONS The Dual Maverick 450 is suitable for temporary standby o...

Page 19: ...electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of...

Page 20: ...the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder Attach the single lead from the front of the feeder t...

Page 21: ...gh voltage regulation can cause the capac itative elements to fail Surge protection transient protection and additional loading is recom mended for 100 fail safe opera tion DO NOT RUN THESE DEVICES WI...

Page 22: ...operator safety when welding is performed in environments with increased hazard of electric shock such as wet areas and hot humid sweaty conditions FOR AUXILIARY POWER Start the engine and set the IDL...

Page 23: ...Start off 8 To restart engine firmly tap and hold electrode to work for 0 1 to 1 sec Ensure there is direct contact between metal part of the electrode and work 9 Pull electrode away from work and wai...

Page 24: ...ng may require longer glow plug operations STOPPING THE ENGINE Switch the RUN IDLE STOP switch to STOP This turns off the voltage supplied to the shutdown solenoid A backup shutdown can be accomplishe...

Page 25: ...s a good connection of the work clamp to the job The work clamp should be connected as close as practical to where the welding will be performed For Re Striking Electrodes Some electrodes form a cone...

Page 26: ...Dual Maverick 450 can be used in a wide variety of DC TIG welding applications In general the Touch Start feature allows contamination free starting without the use of a Hi frequency unit If desired t...

Page 27: ...in the CC STICK mode only at the same output settings Use the selector knob to choose stick mode from the home screen Operation in other modes may produce erratic outputs and large output imbalances b...

Page 28: ...NEOUS WELDING AND AUXILIARY POWER LOADS It must be noted that the specified auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in table B 5 TABLE B 5 D...

Page 29: ...OB rotate adjusts values push confirms the selected value or choice Note When Dual Maverick 450 is first started it will return to the screen that was shown when the machine was turned off HOME SCREEN...

Page 30: ...for options 100 A F E Output OFF Arc Force 10 Press knob for options Remote ON 100 A F E Arc Force 10 Output OFF Stick Welding Basic OCV 225 A 15 1 V Output ON Arc Force 10 Stick Welding Basic Arc is...

Page 31: ...elding easier For a smooth arc with less spatter use less Arc Force For a crisp arc with more penetration use more Arc Force Press knob to continue Press knob to select Set MINIMUM for Remote Control...

Page 32: ...Output Override OFF OUTPUT CONTROLLED BY TORCH FOOT PEDAL SWITCH ON OUTPUT ALWAYS ON Press knob to select Output ON MIG Settings Pinch Mode 4 Press knob to select Pinch Mode Press knob to select MIG...

Page 33: ...is left Green Normal operation Yellow Service is required soon Red Service is overdue After service has been performed on an item press and hold the knob for 5 second to reset the service interval tim...

Page 34: ...in Stick at 150 amps set point before entering setup menu Failure to do so will not allow welder to enter calibration mode VARIABLE SPEED ON OFF Turn the variable speed function off when desired weld...

Page 35: ...ctory Settings Press knob to select Auto Start No Load Period Period 10 120 min 120 Autostart time Press knob to select Brightness 100 Display Brightness Press knob for 5 sec to confirm Factory Reset...

Page 36: ...vious number Entry of the Supervisor PIN is similar to the Operator PIN Operator PIN Supervisor PIN Press knob to select 8 1 2 3 8 1 2 3 ON OFF Rotate the knob to turn the PIN on or off Press the knob...

Page 37: ...to continue ECG Fault Code 0 Engine Part Perkins 403D 11Tap Weld PCB HW G9022 1 Weld PCB SW A 17 Machine K K4833 1 Code 12723 Display CR9060 Mode Stick Welding Ensure in Stick Mode and Output Volts 50...

Page 38: ...to enter the correct K and Code may result in permanent damage to the welder If correct k and Code entered The Welder will be accepted Press knob to select Display Brightness Diagnostic Information Ne...

Page 39: ...IES K2636 1 Medium Trailer K2639 1 Fender Kit K2640 1 Cable Rack K2641 2 Four Wheel Trailer K857 Remote Control K857 1 Remote Control K2613 5A1 Ln 25 PRO with K126 PRO Gun K126 12 K126 PRO Gun KP1696...

Page 40: ...esel fuel for 2 to 3 seconds Repeat the above drainage procedure until diesel fuel is detected in the container Check coolant level in the coolant recovery bottle WEEKLY Blow out the machine with low...

Page 41: ...tself and distribute the sealing pressure evenly To complete a tight seal apply pressure by hand at the outer rim of the filter not the flexible center Avoid pushing on the center of the urethane end...

Page 42: ...er and low pressure water When draining the entire contents of the system remove radiator cap Pull drain hose through the battery access door in the base and open shut off valve until system is empty...

Page 43: ...g from an external charger disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads Failure to do so can result in damage to the internal char...

Page 44: ...possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms t...

Page 45: ...roblem persists Contact your local Lincoln Authorized Field Service Facility 2 Inspect for loose or corroded battery terminals 3 Battery circuit circuit breaker CB4 has tripped Located on upper contro...

Page 46: ...place No output control with remote 1 Verify the remote control is not turned on Remote ON appears on the bottom left of the screen whenever the remote is turned on 2 Verify the remote control is turn...

Page 47: ...of range No Check throttle wiring Recalibrate Reset throttle settings 7 Throttle position IVS signal mis match No may restrict acceleration Verify wiring on throttle and IVS Check throttle and IVS pa...

Page 48: ...TE TOROID BLACK ROTOR EXCITER FIELD BLACK W U V 2C A B C SPEED SENSOR ACTUATOR 233 5G 57 57N 58 58N 66 GND A GND K B 234 86 5 4 3 2 1 12 11 10 9 8 7 6 12 1 2 11 10 3 4 9 8 5 6 7 ENGINE CONTROLLER ECG...

Page 49: ...5 75 146 9 90 251 5 27 04 686 8 30 04 763 28 86 732 9 36 08 916 4 39 09 992 9 31 04 788 5 22 44 570 65 00 1651 43 07 1093 9 59 50 1511 3 33 40 848 3 F 2 DIMENSION PRINT DUAL MAVERICK 450...

Page 50: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra...

Page 51: ...d Entl ftung des Arbeitsplatzes l Mantenha seu rosto da fuma a l Use ventila o e exhaust o para remover fumo da zona respirat ria l Turn power off before servicing l Desconectar el cable de ali mentac...

Page 52: ...tomer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any respon sibility for updating or correcting any such information o...

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