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Operator's Manual
Maverick
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Date Purchased
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IM10617
| Issue D ate Feb - 22
© Lincoln Global, Inc. All Rights Reserved.
325X
®
For use with machines having Code Numbers:
12797
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Summary of Contents for Lincoln Electric Maverick 325X
- Page 1 Operator’s Manual Maverick 325X ® For use with machines having Code Numbers: 12797 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
- Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
- Page 3 P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2. A Free copy of “Arc Welding Safety” booklet E205 2.a. Electric current owing through any conductor is available from the Lincoln Electric Company, 22801 causes localized Electric and Magnetic Fields (EMF). St. Clair Avenue, Cleveland, Ohio 44117-1199.
- Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
- Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
- Page 6 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.
- Page 7 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 recommen- dations.
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Page 8: Table Of Contents
TABLE OF CONTENTS INSTALLATION ...........................SECTION A GRAPHIC SYMBOLS..........................A-1 TECHNICAL SPECIFICATIONS - MAVERICK® 325X (K3581-1) ..............A-2 SAFETY PRECAUTIONS ..........................A-3 VRD (VOLTAGE REDUCTION DEVICE) ....................... A-3 LOCATION AND VENTILATION ........................A-4 STORING ............................A-4 STACKING ............................A-4 ANGLE OF OPERATION ..........................A-4 LIFTING ............................ - Page 9 SET-UP ............................B-18 MACHINE SELECT ..........................B-21 CROSSLINC: ON/OFF ..........................B-21 SPOOL GUN CALIBRATION........................B-22 ENGINE SERVICE KIT ..........................B-22 PRODUCTIVITY METRICS ........................B-23 ACCESSORIES ..........................SECTION C MAINTENANCE...........................SECTION D SAFETY PRECAUTIONS..........................D-1 ROUTINE AND PERIODIC MAINTENANCE....................D-1 ENGINE MAINTENANCE ........................... D-1 AIR FILTER ............................D-1 FUEL FILTERS ............................
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Page 10: Installation
MAVERICK 325X INSTALLATION ® GRAPHIC SYMBOLS The following graphics appear in the Maverick or in the manual. Warning or Caution Hot Surface Earth Ground Instructions Fire or explosion Circuit Breaker Fumes and Gases Battery explosion Welding Amperage Explosion Battery acid Welding Voltage Arc Rays System Factory Reset... -
Page 11: Technical Specifications - Maverick® 325X (K3581-1
MAVERICK 325X INSTALLATION ® INSTALLATION TECHNICAL SPECIFICATIONS - MAVERICK ® 325X (K3581-1) INPUT - DIESEL ENGINE DISPLACEMENT STARTING MAKE/MODEL DESCRIPTION SPEED (RPM) CU. IN. (LTRS.) SYSTEM CAPACITIES 3 CYLINDER 54.80 (0.898) FUEL: 12 GAL. (45.4 L) 24.8 HP (18.5 kW) HIGH IDLE 3600 12 VDC OIL: .97 GAL. -
Page 12: Safety Precautions
MAVERICK 325X INSTALLATION ® The machine is shipped with the VRD switch in the “OFF” position. SAFETY PRECAUTIONS To turn it "ON" or "OFF": Only qualified personnel should install, 1. Switch the Run - Stop switch to the Stop position. use, or service this equipment. -
Page 13: Location And Ventilation
770 lbs. (349 kg) without fuel. Lift Environmental limitations welder ONLY using the lift bail. The Maverick 325X is IP23 rated for use in an outdoor environment. WARNING The machine should not be subjected to falling water during use nor should any parts of it be submerged in water. -
Page 14: High Altitude Operation
READ the engine operating and maintenance instructions supplied with this machine. At temperatures above 40°C (104°F), output voltage derating may be necessary. While operating the Maverick 325X WARNING continuously (100% Duty Cycle) at an ambient temperature of 40°C, a weld output of 10.7 KW should not be exceeded. -
Page 15: Fuel - Use Diesel Fuel Only
MAVERICK 325X INSTALLATION ® FUEL - USE DIESEL FUEL ONLY IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN: Low sulphur or ultra low sulphur fuel in US & Canada. a) Installing new battery. Fill the fuel tank with clean, fresh diesel fuel. The b) Using a booster. -
Page 16: Case Front Controls
MAVERICK 325X INSTALLATION ® FIGURE A.3 - CASE FRONT CONTROLS interlock switch prevents battery drain if the switch is left in CASE FRONT CONTROLS the RUN position and the engine is not operating. 1. LCD SCREEN, IP67 RATED OPERATOR A - The LCD screen 5. - Page 17 MAVERICK 325X INSTALLATION ® 10. 20 AMP CIRCUIT BREAKERS (2) - Protects the two single phase - GFCI 120V receptacles. 11. 50 AMP CIRCUIT BREAKER - Protects the 240V, single phase receptacle. 12. GFCI-120V DUPLEX RECEPTACLES (2) 13. 240VAC SINGLE PHASE RECEPTACLE 14.
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Page 18: Welding Terminals
MAVERICK 325X INSTALLATION ® WELDING TERMINALS WELDING OUTPUT CABLES From the main screen select MIG / FCAW / TIG welding. Press With the engine off, connect the electrode and work cables to the knob to select screen that shows Weld Output Override. terminals provided. -
Page 19: Remote Control
MAVERICK 325X INSTALLATION ® REMOTE CONTROL CABLE INDUCTANCE AND ITS EFFECTS ON WELDING The Maverick® 325X is equipped with a 6-pin connector. The 6- pin connector is for connecting the K857 or K857-1 Remote Excessive cable inductance will cause the welding performance to Control or for TIG welding, the K870 foot Amptrol or the K963-3 degrade. -
Page 20: Wire Welding Set-Up, Spool Gun
MAVERICK 325X INSTALLATION ® WIRE WELDING SET-UP, SPOOL GUN FIGURE A.6 Electrode Positive (+) shown K586-1 Deluxe Regulator and hose kit Work Clamp & Cable (K2150-1) Spool Gun with mechanical gas valve (K3569-2) In the spool gun mode, the weld output is controlled by the trigger spool gun pot being adjusted all the way to CCW the user may of the spool gun. -
Page 21: Auxiliary Power Receptacles
For equipment affected by momentary voltage fluctuations, install a plug-in surge suppressor on the receptacles feeding the equipment. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product. A-12... -
Page 22: Connection Of Across The Arc Wire Feeders To The Maverick ® 325X
MAVERICK 325X INSTALLATION ® CONNECTION OF ACROSS THE ARC WIRE FEEDERS TO THE MAVERICK 325X ® These connections instructions apply to both the LN-25X Pro, Activ8X and CrossLinc models. • Shut the welder off. • For electrode Positive, connect the electrode cable to the "+" terminal of the welder and work cable to the "-"... - Page 23 DO NOT USE THESE DEVICES WITH THIS PRODUCT. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product. A-14...
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Page 24: Operation
MAVERICK 325X OPERATION ® OPERATION FOR AUXILIARY POWER SAFETY PRECAUTIONS Start the engine and set the IDLER control switch to the desired Read and understand this entire section before operating mode. Full power is available regardless of the welding operating your Maverick 325X. -
Page 25: Recommended Applications
The Maverick 325X is not recommended for pipe thawing. ® Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil consumption during initial... -
Page 26: Engine Operation
TABLE B.1 the fuel shutoff valve on the fuel filter separator located on the lift bale is in the open position. TYPICAL MAVERICK 325X FUEL CONSUMPTION VARIABLE SPEED ON 2. Check for proper oil level and coolant level. Close engine service compartment door. -
Page 27: Welder Operation
MAVERICK 325X OPERATION ® WELDER OPERATION DOWNHILL PIPE Welding DUTY CYCLE This slope controlled mode is intended for "out-of-position" and "down hill" pipe welding where the operator would like to control Duty Cycle is the percentage of time the load is being applied in a the current level by changing the arc length. - Page 28 MAVERICK 325X OPERATION ® TIG Welding Maverick 325X settings when using the K930-2 TIG Module ® with an Amptrol or Arc Start Switch: The TOUCH START TIG is for DC TIG (Tungsten Inert Gas) welding. • Set the MODE to the TOUCH START TIG setting. To initiate a weld, the selector knob is used to set to the desired •...
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Page 29: Paralleling
MAVERICK 325X OPERATION ® TABLE B.2 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5) 1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel... -
Page 30: Auxiliary Power Operation
MAVERICK 325X OPERATION ® AUXILIARY POWER OPERATION Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings, if no welding current is being drawn. For heavy loads set to HIGH IDLE and maximum weld output for maximum starting power. -
Page 31: Display Operation
4. BACK - Goes back to the previous screen 5. SELECTOR KNOB - rotate adjusts values, push confirms the selected value or choice NOTE: When Maverick 325X is first started, it will return to the screen that was shown when the machine was turned off. HOME SCREEN Pressing the Home button displays the home menu. -
Page 32: Stick Welding
MAVERICK 325X OPERATION ® STICK WELDING Manual entry operates like a traditional welding machine. Simply set the desired preset amperage or voltage and begin to weld. The “Preset” screen appears when welding is not active. It shows the amount of fuel on the left hand side; the weld mode in the lower left hand corner;... - Page 33 MAVERICK 325X OPERATION ® All weld modes support using a remote control like K857-1. Plug the remote into the 6 pin connector on the front of the machine. Press the remote button on the display to toggle between control at the remote and control at the knob on the machine.
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Page 34: Mig/Fcaw Welding
MAVERICK 325X OPERATION ® MIG/FCAW WELDING Manual entry operates like a traditional welding machine. Simply set the desired preset voltage and begin to weld. The “Preset” screen appears when welding is not active. It shows the amount of fuel on the left hand side; the weld mode in the lower left hand corner;... -
Page 35: Crosslinc
CrossLinc device’s instructions. Select the desired weld Indicator mode with the Maverick 325X. When the weld output is ON the CrossLinc device will automatically link to the Maverick 325X. The CrossLinc icon will appear on the screen to show active communication. -
Page 36: Spool Gun
MAVERICK 325X OPERATION ® SPOOL GUN Manual entry operates like a traditional welding machine. Simply set the desired preset amperage or voltage and begin to weld. The “Preset” screen appears when welding is not active. It shows the amount of fuel on the left hand side; the weld mode in the lower left hand corner;... -
Page 37: Spool Gun Synergic Control Mode
MAVERICK 325X OPERATION ® SPOOL GUN SYNERGIC CONTROL MODE The spool gun may be either set in “normal” control or “synergic” control. Synergic mode automatically adjusts the voltage when the wire feed speed is changed. Spool Gun Synergic Control Selection Recommended ranges Green box appears when user is in the recommended range... -
Page 38: Spot Time Mode
MAVERICK 325X OPERATION ® SPOOL GUN PULSE MODE Activating Spool Gun Pulse toggles both the voltage and wire feed speed between a peak and a low level. It is useful for lower heat input welding and creating the appearance of “stacked dimes” in aluminum. -
Page 39: Engine Status Screen
MAVERICK 325X OPERATION ® ENGINE STATUS SCREEN The Engine Status screen provides information about the engine servicing and operation. Five parts of the engine are monitored for service: Oil, Coolant, Air Filter, Fan Belt and Fuel Filter. Brush life is also monitored. To view detailed information about an item, rotate the knob until the item is highlighted in red. -
Page 40: Engine Info
MAVERICK 325X OPERATION ® ENGINE INFO The user can bring up the Engine Information screen by pressing the “?” button while on the landing page in any welding mode. In order to exit the Engine Information screen, press the back button or the encoder knob. -
Page 41: Set-Up
MAVERICK 325X OPERATION ® SET-UP • PRODUCTIVITY METRICS - Provides useful information and statistics regarding how the machine is being used. The set-up allows for customization of the Maverick. Options available in the Set-up menu are: • AUTO-START: NO LOAD PERIOD - When AUTO-START is enabled, the NO LOAD PERIOD is the period of time the machine can be running with no auxiliary or weld load before it automatically shuts down. - Page 42 MAVERICK 325X OPERATION ® DO NOT FORGET THE PIN! The PIN may only be reset by a Lincoln Authorized Service Shop. Rotate the knob to adjust the value of the PIN. Press the knob to advance to the next number. Press the BACK button to go the previous number.
- Page 43 MAVERICK 325X OPERATION ® MACHINE SELECT Access the machine select feature only when replacing a pc board in the welder. Go to SETUP menu from the home page. Scroll through the menu items select machine setup. Enter the correct K# and Code # for the welder the PCB is being installed on.
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Page 44: Spool Gun Calibration
MAVERICK 325X OPERATION ® SPOOL GUN CALIBRATION ENGINE SERVICE KIT Engine Service Kit Feeding wire . . . RECOMMENDED SERVICE PARTS & FLUIDS: Oil: SAE 10W-30 oil (API class CD or better) Air Filter: Kubota Part# 1G319-11212 Fan Belt for Dual Mav: Kubota Part# 19805- 72530 Fan Belt for Single Mav: Kubota Part# 17472-97010 Fuel Filter: Kubota Part# 70000-43081... -
Page 45: Productivity Metrics
MAVERICK 325X OPERATION ® Productivity Metrics PRODUCTIVITY METRICS The Productivity Metrics screen provides information and statistics on how the machine is being utilized. Productivity Metrics Engine Fuel Five statistics of the machine are monitored: Arc Hours, Auxiliary Utilization Auxiliary Saved w/ Running Percent Hours... -
Page 46: Accessories
MAVERICK 325X ACCESSORIES ® ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES 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 KP1696-068 Drive Roll Kit K12038-2 Invertec PC610 Plasma K12048-1 Tomahawk 1025 Plasma... -
Page 47: Maintenance
MAVERICK 325X MAINTENANCE ® MAINTENANCE TABLE D.1 SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. - Page 48 MAVERICK 325X ® MAINTENANCE Service Instructions Service Instructions Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Inspect the New Filter for Damage Inspect the New Filter for Damage Remove the Filter Remove the Filter Inspect the new filter carefully, paying attention to Unfasten or unlatch the the inside of the open end, which is the service cover.
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Page 49: Fuel Filters
MAVERICK 325X MAINTENANCE ® FUEL FILTERS NAMEPLATES / WARNING DECALS MAINTENANCE Whenever routine maintenance is performed on this machine - or at least yearly - inspect all nameplates and labels for legibility. WARNING Replace those which are no longer clear. Refer to the parts list for the replacement item number. -
Page 50: Battery Handling
CHARGING THE BATTERY When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The Maverick 325X ® positive (+) battery terminal has a red terminal cover. -
Page 51: Troubleshooting
TROUBLESHOOTING How to Use Troubleshooting Guide WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. - Page 52 MAVERICK 325X TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION AUXILIARY OUTPUT No auxiliary power. 1. Check that the circuit breakers did not trip. If all recommended possible areas of 2.
- Page 53 MAVERICK 325X TROUBLESHOOTING ® PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION WELDING No weld output. 1. Verify the weld output is ON. A green icon with “Output ON” appears in the upper right corner of screen whenever weld output is ON. 2.
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Page 54: Engine Fault Flash Codes On Ecg
MAVERICK 325X TROUBLESHOOTING ® ENGINE FAULT FLASH CODES ON ECG J1939-73 WILL ENGINE FAULT CORRECTIVE ACTION SHUTDOWN? Turn off the machine. Disconnect the negative on the battery. Check Oil pressure error lead 234, connected to the oil pressure switch, located on the left side of the engine below the alternator. - Page 55 MAVERICK 325X WIRING DIAGRAM ®...
- Page 56 MAVERICK 325X DIMENSION PRINT ®...
- Page 57 This page intentionally left blank...
- Page 58 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish AVISO DE No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
- Page 59 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish AVISO DE Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
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Page 60: Customer Assistance Policy
We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.