Lincoln Electric DX450 - Manuals

Lincoln Electric DX450 – Manual in PDF format online.

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Manual

Manual Lincoln Electric DX450

Summary

Page 2 - SAFETY; PERFORMED ONLY BY QUALIFIED INDIVIDUALS.; WARNING; ELECTRIC AND; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

DX450 (RED-D-ARC) FOR ENGINEpowered 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 exhau...

Page 3 - ii

DX450 (RED-D-ARC) ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing...

Page 4 - iii; Refer to

iii SAFETY iii DX450 (RED-D-ARC) FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations...

Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ; PRÉCAUTIONS DE SÛRETÉ POUR

iv SAFETY iv DX450 (RED-D-ARC) Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. P...

Page 6 - Please Examine Carton and Equipment For Damage Immediately

v v TThhaannkk Y Yoouu for selecting one of our QUALITY products. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for qu...

Page 7 - vi; TABLE OF CONTENTS

vi vi TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A...

Page 9 - INSTALLATION; INPUT - DIESEL ENGINE; ENGINE

DX450 (RED-D-ARC) A-1 INSTALLATION A-1 1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced. * To Top of enclosure, add 10.68”(271.3mm) to top of exhaus...

Page 10 - SAFETY PRECAUTIONS; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n a t; LOCATION AND VENTILATION

A-2 INSTALLATION DX450 (RED-D-ARC) A-2 SAFETY PRECAUTIONS Only qualified personnel should install, use, or service this equipment. Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’sm a n u a l s u p p l i e d w i t h y o u r w e l d e r . I t i n c l u d e s...

Page 11 - Cold weather starting:; TOWING; VEHICLE MOUNTING; PRE-OPERATION ENGINE SERVICE; OIL

A-3 INSTALLATION DX450 (RED-D-ARC) A-3 HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary. For maximum rating, derate the machine 1.0% for every 2000 ft. (610m) up to 6000 ft. (1828m) and 2.0% for every 2000 ft. (610m) over 6000 ft. (1828m). Due to new EPA and other local ...

Page 13 - ELECTRICAL CONNECTIONS

A-5 INSTALLATION A-5 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, othe...

Page 14 - STANDBY POWER CONNECTIONS; AUXILIARY POWER RECEPTACLES

STANDBY POWER CONNECTIONS T h e D X 4 5 0 i s s u i t a b l e f o r t e m p o r a r y , s t a n d b y o r emergency power using the engine manufacturer’s recommended maintenance schedule. The DX450 can be permanently installed as a standby power unit for 240 VAC, 3 wire, single phase, 50 amp service...

Page 15 - xyz; CONNECTION OF DX450 TO PREMISES WIRING; state and local requirements.

A-7 INSTALLATION DX450 (RED-D-ARC) A-7 xyz xyz HUBBELL CS6365C WH ITE CONNECTION OF DX450 TO PREMISES WIRING WARNING • Only a licensed, certified, trained electrician should install the machine to a premises or residential electrical system. Be certain that: • The installation complies with the Nati...

Page 16 - C O N N E C T I O N O F L I N C O L N E L E C T R I C

A-8 INSTALLATION DX450 (RED-D-ARC) A-8 C O N N E C T I O N O F L I N C O L N E L E C T R I C WIRE FEEDERS Connection of LN-7 or LN-8 to the DX450 1. Shut the welder off. 2. Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F. 3. Set the "WIRE FEEDER VOLTM...

Page 17 - • Shut the welder off.

A-9 INSTALLATION DX450 (RED-D-ARC) A-9 Spool Gun (K487-25) and Cobramatic to DX450 • Shut the welder off. • Connect per instructions on the appropriate connec- tion diagram in Section F. Connection of the LN-25 to the DX450 Shut off welder before making any electrical con- nections. ----------------...

Page 18 - OPERATION; GENERAL DESCRIPTION; ENGINE OPERATION; • D o n o t l e a v e u n a t t e n d e d; DIESEL FUEL

B-1 OPERATION B-1 SAFETY PRECAUTIONS Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’sm a n u a l s u p p l i e d w i t h y o u r w e l d e r . I t i n c l u d e si m p o r t a n t s a f e t y p r e c a u t i o n s , d e t a i l e d e n g i n estarting, ope...

Page 19 - WELDING CONTROLS; D I G I TA L O U T P U T M E T E R S -

B-2 OPERATION B-2 WELDING CONTROLS (Figure B.1) 1. O U T P U T C O N T R O L - T h e O U T P U T d i a l i s used to preset the output voltage or current as dis- played on the digital meters for the five welding modes. When in the CC-STICK, ARC GOUGING or CV-WIRE modes and when a remote control is c...

Page 20 - DOWNHILL PIPE mode:; WELD OUTPUT TERMINALS WITH FLANGE

B-3 OPERATION B-3 4. ARC CONTROL - The ARC CONTROL dial is active in the CV-WIRE, CC-STICK and DOWNHILL PIPE modes, and has different functions in these modes. This control is not active in the TIG and ARC GOUGING mode. CC-STICK mode: In this mode, the ARC CONTROL dial sets the short circuit current...

Page 21 - TYPICAL DX450 FUEL CONSUMPTION; GLOW PLUG PUSH BUTTON

TYPICAL DX450 FUEL CONSUMPTION TABLE B.2 KUBOTA V2403M Gal./Hr (Liters/Hr) .42(1.58) .60(2.28) 1.57(5.93) 1.63(6.16) 1.28 (4.83) Running Time for 20 gallons / hours 48.03 33.18 12.76 12.29 15.67 Low Idle - No Load 1400 R.P.M. High Idle - No Load 1800 R.P.M. DC Weld Output 500 Amps @ 40Volts 20,000 W...

Page 22 - STOPPING THE ENGINE; 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 with- in ...

Page 24 - ARC GOUGING

Carbon Diameter Current Range (DC, electrode positive) 1/8"(3.2mm) 60-90 Amps 5/32"(4.0mm) 90-150 Amps 3/16"9(4.8mm) 200-250 Amps 1/4"(6.4mm) 300-400 Amps 5/16"(8.0mm) 400-Max.Amps AUXILIARY POWER: Start the engine and set the IDLER control switch to the desired operating mode. F...

Page 25 - ACCESSORIES; FIELD INSTALLED OPTIONS /; WIRE FEEDER OPTIONS; KP509 Magnum Parts Kit for PTA-26V TIG Torch; PLASMA CUTTING

C-1 ACCESSORIES C-1 DX450 (RED-D-ARC) FIELD INSTALLED OPTIONS / ACCESSORIES K903-1 SPARK ARRESTOR - Includes a heavy gage steel, approved spark arrestor, clamp and adapter for mounting to the muffler exhaust pipe. K704 ACCESSORY SET - Includes 35 ft. (10m) of elec- trode cable and 30 ft. (9.1m) of w...

Page 26 - MAINTENANCE; Routine Maintenance; ENGINE SERVICE; (1) Consult Engine Operators Manual for oil recommendations.

D-1 MAINTENANCE D-1 DX450 (RED-D-ARC) SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • R e m o v e g u a r d s o n l y w h e n n e c e s s a r y t o perform maintenance and re...

Page 27 - ENGINE OIL CHANGE

D-2 MAINTENANCE D-2 ENGINE OIL CHANGE Drain the engine oil while the engine is warm to assure rapid and complete draining. It is recommended that each time the oil is changed the oil filter be changed as well. • Be sure the unit is off. Disconnect the negative bat- tery cable to ensure safety. • Loc...

Page 28 - Clean Both Surfaces of the Outlet Tube; Caution; S e r v i c e I n s t r u c t i o n s; S i n g l e - a n d Tw o - S t a g e E n g i n e A i r C l e a n e r s

D-3 MAINTENANCE D-3 DX450 (RED-D-ARC) Unfasten or unlatch theservice cover. Becausethe filter fits tightly over theoutlet tube to create the critical seal, there willbe some initial resistance, similar to breakingthe seal on a jar. Gently move the end of the filterback and forth to break the seal th...

Page 29 - COOLING SYSTEM

D-4 MAINTENANCE D-4 COOLING SYSTEM HOT COOLANT can burn skin. • Do not remove cap if radiator is hot. ------------------------------------------------------------------------ Check the coolant level by observing the level in the radiator and recovery bottle. Add 50/50 antifreeze / water solution if ...

Page 30 - ENGINE ADJUSTMENT

D-5 MAINTENANCE D-5 FUEL FILTER 1. Check the fuel filter and fuel pre-filter for water accumulation or sediment. 2. Replace the fuel filter if it is found with excessive water accumulation or sediment. Empty fuel pre-fil- ter. ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Serv...

Page 31 - G F C I M O D U L E T E S T I N G A N D R E S E T T I N G

D-6 MAINTENANCE D-6 DX450 (RED-D-ARC) G F C I M O D U L E T E S T I N G A N D R E S E T T I N G PROCEDURE The GFCI module should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI module: • If the module has tripped, first carefully remove any...

Page 32 - TROUBLESHOOTING; Local Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE

E-1 TROUBLESHOOTING E-1 DX450 (RED-D-ARC) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guid...

Page 33 - Local Authorized Field Service Facility; PROBLEMS; Contact your local Authorized

E-2 TROUBLESHOOTING E-2 DX450 (RED-D-ARC) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting as...

Page 34 - Contact

E-3 TROUBLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before yo...

Page 35 - C o n t a c t y o u r l o c a l A u t h o r i z e d

E-4 TROUBLESHOOTING E-4 DX450 (RED-D-ARC) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting as...

Page 38 - DIAGRAMS

Page 44 - WIRING DIAGRAM; IR

F-7 WIRING DIAGRAM F-7 DX450 (RED-D-ARC) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is included with the machine. If the diagram is illegible, write to the Service Department for a replacement....

Page 45 - DIMENSION PRINT

F-8 DIMENSION PRINT F-8 DX450 (RED-D-ARC) L 1 3 8 5 7 A .0 1 25 .8 2 65 5. 8 27 .0 0 68 5. 8 55 .5 0 14 09 .7 2. 25 57 .2 5. 75 14 6. 0 35 .9 4 91 3. 0 24 .0 0 60 9. 6 39 .8 1 20 .6 0 52 3. 3 28 .9 5 73 5. 3 37 .0 5 94 1 60 .0 0 15 24 .0 N. A. N. A. C EN TE R O F G RA VI TY W IT H O IL IN E NG IN E,...

Page 46 - NOTES