Lincoln Electric 12881 Operator's Manual
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Lincoln Electric 12881 Operator's Manual

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Operator's Manual
Dual Maverick
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10537
| Issue D ate May-21
© Lincoln Global, Inc. All Rights Reserved.
®
450 (AU)
For use with machines having Code Numbers:
12881
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 lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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  • Page 1 Operator’s Manual Dual Maverick ® 450 (AU) For use with machines having Code Numbers: 12881 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.
  • 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 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 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 recommenda- tions.

  • Page 8: Table Of Contents

    TABLE OF CONTENTS 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 ............................A-4 FUEL - USE DIESEL FUEL ONLY .......................A-5...
  • Page 9 PREVENTING BATTERY DISCHARGE ......................D-4 PREVENTING BATTERY BUCKLING ......................D-4 CHARGING THE BATTERY ........................D-4 BATTERY LOCKOUT SWITCH........................D-4 TROUBLESHOOTING ........................SECTION E DIAGRAMS ..........................SECTION F PARTS LIST....................PARTS.LINCOLNELECTRIC.COM CONTENT/DETAILS MAY BE CHANGED OR UPDATED WITHOUT NOTICE. FOR MOST CURRENT INSTRUCTION MANUALS, GO TO PARTS.LINCOLNELECTRIC.COM.

  • Page 10: Installation

    DUAL MAVERICK ® 450 (AU) INSTALLATION INSTALLATION TECHNICAL SPECIFICATIONS - ® DUAL MAVERICK 450 (AU) (K4393-1) CODE 12881 INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Dry Capacities cu. in. (ltrs.) System 3 cylinder High Idle 3000 69 (1.1) 12VDC Battery &...

  • Page 11: Vrd (Voltage Reduction Device

    DUAL MAVERICK ® 450 (AU) 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, use, or service this equipment. 1. Switch the High Idle/Run - Stop switch to the Stop position. 2.

  • Page 12: Location And Ventilation

    DUAL MAVERICK ® 450 (AU) INSTALLATION STORING LOCATION AND VENTILATION The welder should be located to provide an unrestricted flow of 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 clean, cool air to the cooling air inlets and to avoid restricting the accidentally damaged from construction activities, moving cooling air outlets.

  • Page 13: High Altitude Operation

    DUAL MAVERICK ® 450 (AU) INSTALLATION HIGH ALTITUDE OPERATION VEHICLE MOUNTING The naturally aspirated engine will run correctly up to an attitude WARNING 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 Improperly mounted concentrated loads may cause naturally aspirated engine.

  • Page 14: Fuel - Use Diesel Fuel Only

    DUAL MAVERICK ® 450 (AU) INSTALLATION FUEL - USE DIESEL FUEL ONLY IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN: Fill the fuel tank with clean, fresh diesel fuel. The a) Installing new battery. capacity of the fuel tank is approximately 20 gallons b) Using a booster.

  • Page 15: Case Front Controls

    DUAL MAVERICK ® 450 (AU) INSTALLATION CASE FRONT CONTROLS DOWNHILL PIPE and CC-STICK modes if a remote control is connected to the 6-Pin or 14 Pin Connectors, the output is 1. LCD SCREEN, IP67 RATED OPERATOR A - The LCD screen controlled by the remote and the output control on the displays information about welding mode, output voltage or machine is used to set the maximum current range for the...
  • Page 16 DUAL MAVERICK ® 450 (AU) INSTALLATION 7. 15 AMP CIRCUIT BREAKER (2) - Auxiliary output breaker protects the 230V, single phase receptacle. 8. 25 AMP CIRCUIT BREAKER - Auxiliary output breaker protects the 400V, three phase receptacle. 9. 230VAC SINGLE PHASE RECEPTACLE (QTY 2) - protected by 15 Amp circuit breaker and is IP66 rated 10.

  • Page 17: Welding Terminals

    DUAL MAVERICK ® 450 (AU) 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. (Figure terminals provided.

  • Page 18: Remote Control

    DUAL MAVERICK ® 450 (AU) INSTALLATION REMOTE CONTROL CABLE INDUCTANCE AND ITS EFFECTS ON WELDING The Dual Maverick ® 450 (AU) is equipped with a 6-pin and a 14- pin connector. The 6-pin connector is for connecting the K857 or Excessive cable inductance will cause the welding performance to K857-1 Remote Control or for TIG welding, the K870 foot Amptrol degrade.

  • Page 19: Connection Of Wire Feeders With Control Cable (14 Pin

    DUAL MAVERICK ® 450 (AU) INSTALLATION CONNECTION OF WIRE FEEDERS WITH CONTROL CABLE (14 PIN) WARNING Shut off welder before making any electrical connections. CONNECTION OF LF-72, LF-74, FLEX FEED 74 HT, FLEX FEED 84, LN-25 PRO DUAL POWER TO THE ®...

  • Page 20: Connection Of Across The Arc Wire Feeders To The Dual Maverick ® 450 (Au

    DUAL MAVERICK ® 450 (AU) INSTALLATION CONNECTION OF ACROSS THE ARC WIRE FEEDERS ® TO THE DUAL MAVERICK 450 (AU) These connections instructions apply to both the LN-25 Pro and Activ8 models. The feeders have an internal contactor and the electrode is not energized until the gun trigger is closed.
  • Page 21 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-12...

  • Page 22: Operation

    DUAL MAVERICK ® 450 (AU) OPERATION OPERATION FOR AUXILIARY POWER: SAFETY PRECAUTIONS Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding Read and understand this entire section before control settings providing no welding current is being drawn.

  • Page 23: Recommended Applications

    450 (AU) is not recommended for pipe thawing. BREAK-IN PERIOD Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we offer. While it is normal to GENERATOR see a small amount of crankcase oil consumption during initial The Dual Maverick ®...

  • Page 24: Engine Operation

    DUAL MAVERICK ® 450 (AU) OPERATION ENGINE OPERATION TYPICAL FUEL CONSUMPTION STARTING THE ENGINE Refer to Table B.2 for typical fuel consumption of the Dual Maverick ® 450 (AU) Engine for various operating settings. 1. Open the engine service compartment door and check that TABLE B.2 the fuel shutoff valve on the fuel filter separator located on TYPICAL DUAL MAVERICK 450 (AU)

  • Page 25: Welder Operation

    DUAL MAVERICK ® 450 (AU) OPERATION WELDER OPERATION DOWNHILL PIPE Welding DUTY CYCLE This slope controlled mode is intended for "out-of-position" and Duty Cycle is the percentage of time the load is being applied in a "down hill" pipe welding where the operator would like to control 10 minute period.
  • Page 26 DUAL MAVERICK ® 450 (AU) OPERATION TIG Welding If desired, the K930-2 TIG Module can be used with the Dual The TOUCH START TIG is for DC TIG (Tungsten Inert Gas) welding. Maverick ® 450 (AU). The settings are for reference. To initiate a weld, the selector knob is used to set to the desired Dual Maverick ®...

  • Page 27: Paralleling

    DUAL MAVERICK ® 450 (AU) OPERATION TABLE B.3 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 28: Auxiliary Power Operation

    DUAL MAVERICK ® 450 (AU) OPERATION AUXILIARY POWER OPERATION SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding It must be noted that the specified auxiliary power ratings are with control settings, if no welding current is being drawn.

  • Page 29: Display Operation

    DUAL MAVERICK ® 450 (AU) OPERATION FIGURE B.2 DISPLAY OPERATION: SEE FIG B.2 1. HOME - Brings up the home screen (main menu) 2. REMOTE CONTROL - Toggles the remote control MAVERICK ON / OFF 3. HELP - Displays additional information describing the function 4.
  • Page 30 DUAL MAVERICK ® 450 (AU) OPERATION STICK WELDING Stick Manual entry operates like a traditional welding machine. Simply Welding 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;...
  • Page 31 DUAL MAVERICK ® 450 (AU) OPERATION Stick Options 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. Remote Press the remote button on the display to toggle between control at the Control Force Range...
  • Page 32 DUAL MAVERICK ® 450 (AU) OPERATION MIG/FCAW WELDING Manual entry operates like a traditional welding machine. Simply MIG/FCAW-GS Welding 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;...
  • Page 33 DUAL MAVERICK ® 450 (AU) OPERATION Wire Diameter Wire Diameter 0.025” / 0.6mm Wire Feed 0.030” / 0.8mm Select Maximum WFS Speed Expected 0.035” / 0.9mm Wire 0.040” / 1.0mm Diameter Press knob 0.045” / 1.2mm for weld page 0.052” / 1.4mm Press knob to select Note: Select the maximum wire feed speed (WFS) that will be used during the welding session to ensure power...
  • Page 34 DUAL MAVERICK ® 450 (AU) OPERATION SET-UP The set-up allows for customization of the Maverick. Options Set-up available in the Set-up menu are: • AUTO-START: NO LOAD PERIOD • TAP START ACTIVE PERIOD Press knob to select • AUTO-START: ON/OFF •...
  • Page 35 DUAL MAVERICK ® 450 (AU) OPERATION Auto-Start: No Load Period Display Brightness Display Brightness Auto-Start: No Load Period Brightness: 100 Period (10-120 min): 120 Press knob to select Press knob to select Autostart time Restore Factory Settings Tap Start Active Period Tap Start Active Period Factory Reset Period (15-120 min): 30...
  • Page 36 DUAL MAVERICK ® 450 (AU) 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.
  • Page 37 DUAL MAVERICK ® 450 (AU) OPERATION Variable Speed Setup Diagnostic Info Diagnostic Information Variable Speed On/Off Engine Part #: Perkins 403D-11Tap Feature: ON Weld PCB HW: G9022-1 Weld PCB SW: A-17 Machine K#: K4833-1 Code #: 12723 Display #: CR9060 Press knob Press knob ECG Fault...
  • Page 38 DUAL MAVERICK ® 450 (AU) OPERATION MACHINE SELECT Display Brightness Diagnostic Information New PCB Calibration Variable Speed On/Off Restore Factory SettingsMachine Machine Select Press knob to select Enter the correct K# and Code # for the welder the PCB is being installed on.

  • Page 39: Accessories

    DUAL MAVERICK ® 450 (AU) ACCESSORIES ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES 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 KP1696-068 Drive Roll Kit K12038-2 Invertec PC610 Plasma K12048-1 Tomahawk 1025 Plasma...

  • Page 40: Maintenance

    DUAL MAVERICK ® 450 (AU) 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 41 DUAL MAVERICK ® 450 (AU) 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...

  • Page 42: Fuel Filters

    DUAL MAVERICK ® 450 (AU) 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 43: Battery Handling

    DUAL MAVERICK ® 450 (AU) MAINTENANCE BATTERY HANDLING PREVENTING BATTERY DISCHARGE Turn the RUN/STOP switch to stop when engine is not running. WARNING GASES FROM BATTERY can explode. PREVENTING BATTERY BUCKLING Keep sparks, flame and cigarettes away from Tighten nuts on battery clamp until snug. battery.
  • Page 44 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 45 DUAL MAVERICK ® 450 (AU) 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 46 DUAL MAVERICK ® 450 (AU) 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.
  • Page 47 DUAL MAVERICK ® 450 (AU) TROUBLESHOOTING ENGINE FAULT FLASH CODES ON ECG FLASH CODE WILL ENGINE NUMBER FAULT SHUTDOWN? CORRECTIVE ACTION Unit not calibrated ECM requires calibration Excessive engine speed Check over-speed parameter setting Check electrical interference Check wiring and connectors Check ECM ground connections Check actuator connections and fitment Engine speed unusually...
  • Page 48 DUAL MAVERICK ® 450 (AU) WIRING DIAGRAM G9022-1...
  • Page 49 DUAL MAVERICK ® 450 (AU) DIMENSION PRINT...
  • Page 50 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION 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 51 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 52 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.

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