Lincoln Electric Maverick 260X Operator's Manual

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Operator's Manual

Maverick

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10691-A

260X

e t

Mar - 24

For use with machines having Code Numbers:

13228

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Summary of Contents for Lincoln Electric Maverick 260X

Page 1 Operator’s Manual Maverick 260X ® For use with machines having Code Numbers: 13228 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 KEEP YOUR HEAD OUT OF THE FUMES. A QUALITY PRODUCT BY 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 flowing 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 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. All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter.
Page 7 SAFETY 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. Welding equipment should be connected to the mains supply according to the manufacturer’s recommen- dations.
Page 8 TABLE OF CONTENTS INSTALLATION ...........................SECTION A 260X (K5272-1) 260X OPERATION ..........................SECTION B...
Page 9 ..........................ACCESSORIES ..........................SECTION C MAINTENANCE...........................SECTION D TROUBLESHOOTING ........................SECTION E DIAGRAMS ..........................SECTION F PARTS LIST....................PARTS.LINCOLNELECTRIC.COM...
Page 10 MAVERICK 260X 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 MAVERICK 260X INSTALLATION ® INSTALLATION TECHNICAL SPECIFICATIONS - MAVERICK 260X (K5272-1) 36.55 (0.599) 2 CYLINDER FUEL: 12 GAL. (45.4 L) 3820 Kubota 16.8 HP (12.5 kW) OIL: .66 GAL. (2.5 L) Z602 3600 RPM RADIATOR COOLANT: 2650 DIESEL ENGINE 0.74 GAL. (3.1 L) WELDING RATED OUTPUT @ 104˚F(40˚C) - IEC RATING...
Page 12 MAVERICK 260X INSTALLATION ® SAFETY PRECAUTIONS Only qualified personnel should install, use, or service this equipment. WARNING FIGURE A.1 Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.
Page 13 The Maverick 260X weighs approximately 705 lbs. (320 kg) Environmental limitations with a full tank of fuel, 620 lbs. (281 kg) without fuel. Lift The Maverick 260X is IP23S 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 9840 (3000) 11480 (3500) PRE-OPERATION ENGINE SERVICE HIGH TEMPERATURE OPERATION may be necessary. While operating the Maverick 260X WARNING 40º C, a weld output of 9.0 KW should not be exceeded. Keep hands away from the engine muffler or HOT engine parts.
Page 15 MAVERICK 260X INSTALLATION ® FUEL - USE DIESEL FUEL ONLY IMPORTANT: Low sulphur or ultra low sulphur fuel in US & Canada. NEGATIVE GROUND. 260X ENGINE COOLANT WARNING HOT COOLANT can burn skin. Do not remove cap if radiator is hot. MUFFLER OUTLET PIPE SPARK ARRESTOR BATTERY CONNECTION...
Page 16 MAVERICK 260X INSTALLATION ® FIGURE A.3 - CASE FRONT CONTROLS CASE FRONT CONTROLS LCD SCREEN, IP67 RATED OPERATOR A - BATTERY CIRCUIT BREAKER - USB PORT - 6-PIN REMOTE CONTROL CONNECTOR - holds the This 8. 7-PIN SPOOL GUN CONNECTION filter GLOW PLUG PUSH BUTTON - 9.
Page 17 MAVERICK 260X INSTALLATION ® 10. 20 AMP CIRCUIT BREAKERS (2) - Protects the two single 11. 50 AMP CIRCUIT BREAKER - . e l 12. GFCI-120V DUPLEX RECEPTACLES (2) 13. 240VAC SINGLE PHASE RECEPTACLE 14. POSITIVE WELD TERMINAL - 15. NEGATIVE WELD TERMINAL - 16.
Page 18 MAVERICK 260X 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 MAVERICK 260X INSTALLATION ® REMOTE CONTROL CABLE INDUCTANCE AND ITS EFFECTS ON WELDING The Maverick® 260X 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 MAVERICK 260X INSTALLATION ® WIRE WELDING SET-UP, SPOOL GUN FIGURE A.6 K586-1 Deluxe Regulator and hose kit Work Clamp & Cable (K2150-1) Spool Gun with mechanical gas valve (K3569-2) 260X 260X. flow FIGURE A.7 TORCH FUNCTIONS GRAY TORCH MOTOR YELLOW BLACK TORCH GREEN...
Page 21 GFCI receptacle and have it replaced by an authorized service center. 260X is fluctuations The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product. A-12...
Page 22 MAVERICK 260X INSTALLATION ® CONNECTION OF ACROSS THE ARC WIRE FEEDERS TO THE MAVERICK ® 260X 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...
Page 24 Remove the fuel tank cap. • Fill the tank. DO NOT FILL THE TANK TO THE POINT OF GENERAL DESCRIPTION OVERFLOW. The Maverick 260X is a diesel engine-driven welding power ® • Replace the fuel cap and tighten securely. source. The machine uses an •...
Page 25 MAVERICK 260X OPERATION ® FIGURE B.1 Engine Service Side View RECOMMENDED APPLICATIONS 260X 260X 260X BREAK-IN PERIOD 260X GENERATOR 260X AUTO-START INSTRUCTION CAUTION During break-in, subject the Welder to moderate loads. Avoid long periods running at idle. Before stopping the engine, remove all loads and allow the engine to cool several minutes.
Page 26 260X OPERATION ® ENGINE OPERATION TYPICAL FUEL CONSUMPTION STARTING THE ENGINE 260X Engine for various operating settings. TABLE B.1 filter TYPICAL MAVERICK 260X FUEL CONSUMPTION 0.212 (0.80) 56.50 2650 RPM 0.383 (1.45) 31.32 3825 RPM 100A @ 24V 25.06 0.479 (1.812) 22.53...
Page 27 MAVERICK 260X OPERATION ® WELDER OPERATION DOWNHILL PIPE Welding DUTY CYCLE ELECTRODE INFORMATION digging arc. 260X can be used with a broad range of DC Constant Current (CC-STICK) Welding Figure A.2 Electrode Work Lead...
Page 28 MAVERICK 260X OPERATION ® Maverick ® 260X settings when using the K930-2 TIG Module TIG Welding 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 •...
Page 29 MAVERICK 260X OPERATION ® TABLE B.2 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES WIRE WELDING-CV ARC GOUGING 260X according to the 260X can be used for Arc Gouging with carbons up to 260X in the CV-WIRE mode, permits it to be used 1/4”...
Page 30 MAVERICK 260X OPERATION ® AUXILIARY POWER OPERATION SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS no welding load. TABLE B.3 MAVERICK ® 260X SIMULTANEOUS WELDING AND POWER LOADS Simultaneous Welding and Power Loads (120/240V AUX) Single Current Aux Power Single Phase Amps (240V) 9000 37.5...
Page 31 4. BACK - Goes back to the previous screen 5. SELECTOR KNOB - rotate adjusts values, push confirms the selected value or choice NOTE: When Maverick 260X 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 MAVERICK 260X 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 260X OPERATION ® Stick Options Remote Start Force 175 A Press knob to select Stick Welding Remote Control Stick Welding ARC FORCE Set MAXIMUM for Set MINIMUM for Remote Control Remote Control Force Press knob Press knob Press knob to select to select to select...
Page 34 MAVERICK 260X 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 MAVERICK 260X OPERATION ® CROSSLINC benefits 260X. When the weld output is ON the 260X. The B-12...
Page 36 MAVERICK 260X 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 MAVERICK 260X 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 MAVERICK 260X 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 MAVERICK 260X OPERATION ® ENGINE STATUS SCREEN Air Filter, Fan Belt and Fuel Filter. Brush life is also monitored. is left. 35 hours remaining Fuel Water Brush Filter Filter Seprtr Life Belt Press and hold knob to reset: 380.5 12.7 V...
Page 40 MAVERICK 260X 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 MAVERICK 260X 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 260X 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 260X 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.
Page 44 MAVERICK 260X 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 MAVERICK 260X OPERATION ® Productivity Metrics PRODUCTIVITY METRICS Produc ty Metr cs Eng ne Fuel za on Aux ary Sa ed w/ Runn ng Percent Hours Hours Auto-Start 70.1% Standby Hours Press and hold knob to reset: 70.1% 380.5...
Page 46 MAVERICK 260X ACCESSORIES ® ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES K2639-1 Fender Kit K2640-1 Cable Rack K2635-1 Two 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 MAVERICK 260X 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 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.
Page 49 MAVERICK 260X MAINTENANCE ® FAN BELT CHANGE FUEL FILTERS When changing the fan belt, ensure the replacement fan is 34.5 inches, cogged style. WARNING Proper fan belt tension is a deflection of between 7 to 9 mm (0.28 to 0.35 in.) when the belt is pressed in the middle of the span.
Page 50 Tighten nuts on battery clamp until snug. 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 260X ® positive (+) battery terminal has a red terminal cover.
Page 51 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 260X TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION AUXILIARY OUTPUT ENGINE idle. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
Page 53 MAVERICK 260X TROUBLESHOOTING ® PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION WELDING No weld output. clean base metal. screen whenever the remote is turned on. No output control with remote. Output control range is limited while using a remote. cables.
Page 54 MAVERICK 260X WIRING DIAGRAM ®...
Page 55 MAVERICK 260X DIMENSION PRINT ®...
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 No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE 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 Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
Page 60 Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying...

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