Lincoln Electric RED-D-ARC DX450 Operator'S Manual Download Page 47

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DX450 (RED-D-ARC)

Summary of Contents for RED-D-ARC DX450

Page 1: ...afety 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 For use with machines having Code Numbers 11512 11561 North America s Largest Fleet of Welding Equi...

Page 2: ...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 i...

Page 3: ...ter 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 FUMES AND GASES can be dangerous 5 a Welding may produ...

Page 4: ...enings 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 elect...

Page 5: ...crans appropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le l...

Page 6: ...______________________________ Date Purchased___________________________________________________________________________ Where Purchased_________________________________________________________________________ Whenever you request replacement parts or information on this equipment always supply the information you have recorded above CUSTOMER ASSISTANCE POLICY The business of our company is manufa...

Page 7: ...n 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 Welder Controls B 2 B 3 Engine Controls B 4 Starting and Stopping the Engine B 4 B 5 Welding Operation B 5 Duty Cycle and Electrode...

Page 8: ...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 ...

Page 9: ...LEANER 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 Welding Process DC Constant Current DC Pipe Current Touch Start TIG DC Constant Voltage Arc Gouging Output Range 30 TO 500 AMPS 40 TO 300 AMPS 20 TO 250 AMPS 14 TO 36 VOLTS 90 TO 45...

Page 10: ... 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 p...

Page 11: ... or serviced 4 Typical conditions of use i e travel speed roughness of sur face on which the trailer will be operated environmental con ditions like maintenance 5 Conformance with federal state and local laws 1 1 Consult applicable federal state and local laws regarding specific require ments for use on public highways WARNING Lift only with equipment of adequate lifting capacity Be sure machine i...

Page 12: ...ith a built in welding voltage control is connected to the 14 pin connec tor do not connect anything to the 3 pin connec tor FUEL USE DIESEL FUEL ONLY Low Sulphur fuel or ultra low sulphur fuel in USA and CANADA only 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 N...

Page 13: ...ud marked with the symbol is provided on the front of the welder WELDING TERMINALS The DX450 is equipped with a toggle switch for select ing hot welding terminal when in the WELD TERMI NALS ON position or cold welding terminal when in the REMOTELY CONTROLLED position WARNING WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs The welding process dic ...

Page 14: ...odule can be reset properly See the MAINTE NANCE section for more detailed information on testing and resetting the GFCI module The auxiliary power of the DX450 consists of two 20 Amp 120 VAC 5 20R duplex receptacles with GFCI protection one 50 Amp 120 240 VAC SS2 50R receptacle and one 50 Amp 240VAC Three Phase 15 50R receptacle The auxiliary power capacity is 12 000 watts Peak 11 000 Watts Conti...

Page 15: ... with the National Electrical Code and all other applicable electrical codes The premises is isolated and no feedback into the utility system can occur Certain state and local laws require the premises to be isolated before the generator is linked to the premises Check your state and local requirements A double pole double throw transfer switch in conjunction with the properly rated double throw c...

Page 16: ...ring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current Set the WELD TERMINALS switch to WELD TERMINALS ON When the gun trigger is closed the current sens ing circuit will cause the DX450 engine to go to the high idle speed the wire will begin to feed and the welding process started When welding is stopped the engine will...

Page 17: ...ork using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current 4 Set the MODE switch to the CV WIRE position 5 Set the WELD TERMINALS switch to WELD TERMINALS ON 6 Set the ARC CONTROL knob to 0 initially and adjust to suit 7 Set the IDLE switch to the AUTO position When not welding the DX450 engine will be at the...

Page 18: ...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 bri...

Page 19: ...to the 14 Pin Connector the auto sensing circuit automatically makes OUTPUT CON TROL inactive and the wire feeder voltage control active Otherwise the OUTPUT CONTROL is used to preset the voltage When in the TOUCH START TIG mode and when an Amptrol is connected to the 3 Pin Connector the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol 2 DIGITAL OUTPUT MET...

Page 20: ... TERMINALS CONTROL SWITCH In the WELD TERMINALS ON position the output is electrically hot all the time In the REMOTELY CONTROLLED posi tion the output is controlled by a wire feeder or amptrol 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 ...

Page 21: ...he 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 ENGINE HOUR METER Displays the total time that the engine has been running This meter is useful for scheduling prescribed maintenance 17 CIRCUIT BREAKER For...

Page 22: ... is located on the fuel pre filter CAUTION The ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or crisp arc Increasing the number from 10 soft to 10 crisp increases the short circuit current and pre vents sticking of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimu...

Page 23: ...itch in the ON position there is no output in the DOWNHILL PIPE mode For indicator light operation see table B 1 TIG WELDING The TOUCH START TIG setting of the MODE switch is for DC TIG Tungsten Inert Gas welding To initiate a weld the OUTPUT CONTROL dial is first set to the desired current and the tungsten is touched to the work During the time the tungsten is touching the work there is very litt...

Page 24: ...h the VRD On or Off for this mode For indicator light oper ation see table B 1 WIRE WELDING CV Connect a wire feeder to the DX450 according to the instruc tions in INSTALLATION INSTRUCTIONS Section The DX450 in the CV WIRE mode permits it to be used with a broad range of flux cored wire Innershield and Outershield electrodes and solid wires for MIG welding gas metal arc weld ing Welding can be fin...

Page 25: ...tweight compact CC CV unit for flux cored and MIG welding Includes Gas Solenoid adjustable flow meter and internal contactor For 10 15 lb 4 5 6 8kg spools Magnum Gun and Magnum Gun Connector Kit are required for gas shielded welding Innershield Gun is required for gasless welding K126 2 Magnum 350 Innershield Gun K1802 1 Magnum 300 MIG Gun for LN 25 K470 2 Magnum 300 MIG Gun for LN 15 Includes Con...

Page 26: ...OR 3 MONTHS EVERY 150 HOURS OR 4 MONTHS EVERY 30O HOURS OR 9 MONTHS EVERY 400 HOURS OR 12 MONTHS EVERY 500 HOURS OR 15 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE NOTE 2 TYPE OR QUANTITY I I 50 50 Water Ethylene Glycol R 9 5 qts 9 0L I R R 10 0 qts 9 5L including filter R R Kubota 16414 32430 C R Kubota 16631 43560 C Kubota 15831 43380 I I R Kubota 17480 97010 C R Donaldson P821575 I Intake...

Page 27: ...the oil container to be sure it includes the letters indicated Note An S grade oil must not be used in a diesel engine or damage may result It IS permissible to use an oil that meets S and C grade service classifi cations SAE 10W30 is recommended for general all tempera ture use 5F to 104F 15C to 40C See engine owner s manual for more specific informa tion on oil viscosity recommendations OIL FILT...

Page 28: ...itself and distribute the sealing pressure evenly To complete a tight seal apply pressure by hand at the outer rim of the filter not the flexible center Avoid pushing on the center of the urethane end cap No cover pressure is required to hold the seal NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners an...

Page 29: ...igns of deterioration are found TIGHTENING THE FAN BELT If the fan belt is loose the engine can overheat and the battery lose its charge Check tightness by press ing on the belt midway between the pulleys It should deflect about 25 in 6 4 mm under a load of 20 lbs 9 Kg FUEL Diesel Fuel Only Low Sulphur Fuel or Ultra Low Sulphur Fuel in U S A and CANADA only At the end of each day s use refill the ...

Page 30: ...e to the machine can result if operated at speeds above maximum CLEANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty If the terminals appear corroded discon nect the battery cables and wash the terminals with an ammonia solution or a solution of 1 4 pound 0 1113 kg of baking soda and 1 quart 0 9461L of water Be sure the battery vent plugs if equipped are tight so t...

Page 31: ...utton again The light or other product should go ON again If the light or other product remains ON when the Test button is pushed the GFCI module is not work ing properly or has been incorrectly installed miswired If your GFCI module is not working properly contact a qualified certified electrician who can assess the situa tion rewire the GFCI module if necessary or replace the device WELDER GENER...

Page 32: ...labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Authorize...

Page 33: ...n Open valve vertical position of handle 2 Fuel Filters dirty clogged Check and replace main filter element and or Inline Fuel Filter 3 Out of fuel Fill tank and bleed fuel system 4 High coolant temperature or low oil pressure indictor lights lit Check oil and coolant levels Fill if required Check for loose or bro ken fan belt 5 Faulty fuel shutdown solenoid Check that shutdown solenoid is functio...

Page 34: ...base and exhaust end case back 1 Dirty fuel or air filters Inspect and clean replace filters as needed Inspect and clean replace filters as needed 2 Water in fuel If water found in tank Empty fuel tank and refill then purge fuel lines 1 Faulty battery Replace 2 Loose connections at battery or alternator Clean and tighten con nections 3 Faulty engine alternator or charg er module Consult authorized...

Page 35: ...ngine Control Unit or Control P C board 1 Faulty Engine Control Unit or Control P C board 1 Fuel filter clogged Replace 2 Air filter clogged clean or replace 3 High idle setting incorrect check and adjust if required 4 Valves out of adjustment 5 Fuel contaminated with water or sediment Check fuel pre filter and empty of water bleed fuel system Replace fuel in tank if needed 1 Faulty Engine Control...

Page 36: ...position when welding without control cable 3 Faulty PC board or welder alterna tor 1 Poor remote control cable connec tion to 3 pin or 14 pin connector Check connections 2 Faulty remote cable or faulty wire feeder or wire feeder cable Replace if necessary 3 Faulty control potentiometer or PC board 1 Wire Feeder Power circuit breaker open Check 42V beaker and reset if tripped 2 Faulty control cabl...

Page 37: ...re the electrode wire gas voltage current etc is correct for the process being used 3 Check for loose or faulty connec tions at the weld output terminals and welding cable connections 4 The welding cables may be too long or coiled causing an excessive voltage drop 5 Faulty Control Board 1 Make sure VRD ON OFF toggle switch is in the OFF position 2 Poor work lead connection to work Make sure work c...

Page 38: ...F 1 DIAGRAMS F 1 DX450 RED D ARC ...

Page 39: ...F 2 DIAGRAMS F 2 DX450 RED D ARC ...

Page 40: ...F 3 DIAGRAMS F 3 DX450 RED D ARC ...

Page 41: ...F 4 DIAGRAMS F 4 DX450 RED D ARC ...

Page 42: ...F 5 DIAGRAMS F 5 DX450 RED D ARC 2 9 03 ...

Page 43: ...F 6 DIAGRAMS F 6 DX450 RED D ARC ...

Page 44: ...SOR SWITCH COOLANT TEMPERATURE SENSOR SWITCH 201 BRUSH ROTOR 4200MFD BRUSH 201A 200A 201 300V 200B 5G 257 261 18GV ACTUATOR 34GV 20GV ENGINE SPEED SENSOR 17GV FUEL SHOWN IN HIGH POSITION IDLER CONTROL SWITCH AUTO HIGH 257 256 HOUR METER 2A 4A 4 2 WELDING TERMINAL CONTROL SWITCH SHOWN IN ALWAYS ON POSITION 218 222 4 GND C 120 240V J10 X Y Z X W Y GND L 5G 3C STATOR WELD WINDINGS W6 W6 W1 W1 W4 W5 W...

Page 45: ...55 8 27 00 685 8 55 50 1409 7 2 25 57 2 5 75 146 0 35 94 913 0 24 00 609 6 39 81 20 60 523 3 28 95 735 3 37 05 941 60 00 1524 0 N A N A CENTER OF GRAVITY WITH OIL IN ENGINE COOLANT IN RADIATOR AND EMPTY FUEL TANK 1 27 32 3 46 62 1184 15 12 50 317 5 29 38 746 3 ...

Page 46: ...NOTES DX450 RED D ARC ...

Page 47: ...NOTES DX450 RED D ARC ...

Page 48: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 49: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 50: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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