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IM962-B
January, 2010
RED-D-ARC
DX450
For use with machines having Code Numbers:
11512, 11561
OPERATOR’S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This welder is designed and built with safety 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 RE
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v for selecting one of our QUALITY products. We want you to take pride in operating this product ••• as much pride as we have in T Th ha an nk k Y Yo ou u bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for advice or information about their use of our products. We respond to ou
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vi vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ........................................................................................................A-2 VRD (Voltage Reduction Device).........................................
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vii vii TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................................................D-1 Engine Service Items.............................................................................................D-1
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - DX450 (K2712-1) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (ltrs.) System 4 cylinder 148.5(2.4) 12VDC Battery & Fuel: 20 gal. 35.4 HP High Idle 1880 starter (75 L) KUBOTA 1800 RPM Bore x Stroke inch (mm) (Group 34; 650 Oil: 10Qts. (9.5L) 2403-M Full Load 1800 3.43” X 4.03” cold crank amps) (87.1 x 102.4mm) 40 Amp Radiator Coolant:
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A-2 A-2 INSTALLATION SAFETY PRECAUTIONS FIGURE A.1 WARNING (VRD)-VOLTAGE REDUCTION DEVICE SWITCH IS LOCATED IN THIS AREA. 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. ------------------------------------------------------------------------ ELECTRIC SHOCK can kill. • Do not touch electrica
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A-3 A-3 INSTALLATION 1. Design capacity of trailer vs. weight of Lincoln equipment and WARNING likely additional attachments. • Lift only with equipment of adequate 2. Proper support of, and attachment to, the base of the welding lifting capacity. equipment so there will be no undue stress to the framework. 3. Proper placement of the equipment on the trailer to insure • Be sure machine is stable when lift- stability side to side and front to back when being moved and ing. when standing by it
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A-4 A-4 INSTALLATION The standard muffler included with this welder does FUEL not qualify as a spark arrester. When required by local USE DIESEL FUEL ONLY- regulations, a suitable spark arrester, such as the Low Sulphur fuel or ultra low sulphur fuel in USA and K903-1 must be installed and properly maintained. CANADA only. WARNING WARNING An incorrect spark arrestor may lead to damage to • Fill the fuel tank with clean, fresh fuel. The capacity of the engine or adversely affect pe
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A-5 A-5 INSTALLATION WELDING OUTPUT CABLES ELECTRICAL CONNECTIONS With the engine off connect the electrode and work cables to the output studs. The welding process dic- MACHINE GROUNDING tates the polarity of the electrode cable. These con- Because this portable engine driven welder creates its nections should be checked periodically and tightened own power, it is not necessary to connect its frame to with a 3/4"(19mm) wrench. an earth ground, unless the machine is connected to premises wir
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A-6 A-6 INSTALLATION STANDBY POWER CONNECTIONS AUXILIARY POWER RECEPTACLES The DX450 is suitable for temporary, standby or Start the engine and set the “IDLER” control switch to the emergency power using the engine manufacturer’s “High Idle” mode. Voltage is now correct at the receptacles recommended maintenance schedule. for auxiliary power. This must be done before a tripped GFCI module can be reset properly. See the MAINTE- NANCE section for more detailed information on testing The DX450 c
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A-7 A-7 INSTALLATION CONNECTION OF DX450 TO PREMISES WIRING HUBBELL CS6365C xyz 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 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 generat
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A-8 A-8 INSTALLATION 4. Control Cable Model: CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS • Connect Control Cable between Engine Welder and Feeder. Connection of LN-7 or LN-8 to the DX450 • Set the "WELD TERMINALS" switch to 1. Shut the welder off. "REMOTELY CONTROLLED" 2. Connect the LN-7 or LN-8 per instructions on the • Set the MODE switch to the "CV-WIRE " position. appropriate connection diagram in Section F. • Set the "WIRE FEEDER VOLTMETER" switch to 3. Set the "WIRE FEEDER VOLTMETER"
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A-9 A-9 INSTALLATION Spool Gun (K487-25) and Cobramatic to DX450 WARNING • Shut the welder off. Connection of the LN-25 to the DX450 Shut off welder before making any electrical con- • Connect per instructions on the appropriate connec- nections. tion diagram in Section F. ------------------------------------------------------------------------ The LN-25 with or without an internal contactor may be used with the DX450 . See the appropriate connec- tion diagram in Section F. 1. Shut the we
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B-1 B-1 OPERATION • Add oil (if necessary) to bring the level up to the full SAFETY PRECAUTIONS mark. Do not overfill. Close engine door. • Check radiator for proper coolant level. (Fill if nec- WARNING essary). • See Engine Owner’s Manual for specific oil and coolant recommendations. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes WARNING important safety precautions, detailed engine starting, operati
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B-2 B-2 OPERATION FIGURE B.1 11 111 1 9 2 10 3 13 4 14 12 15 8 16 17 7 18 21 19 22 20 6 5 When in the TOUCH START TIG mode and when WELDING CONTROLS (Figure B.1) an Amptrol is connected to the 3-Pin Connector, the 1. OUTPUT CONTROL- The OUTPUT dial is OUTPUT dial is used to set the maximum current used to preset the output voltage or current as dis- range of the CURRENT CONTROL of the Amptrol. played on the digital meters for the five welding modes. When in the CC-STICK, ARC GOUGING or 2. DIGIT
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B-3 B-3 OPERATION 10. WIRE FEEDER VOLTMETER SWITCH: 4. ARC CONTROL- The ARC CONTROL dial is active in Matches the polarity of the wire feeder voltmeter to the CV-WIRE, CC-STICK and DOWNHILL PIPE modes, the polarity of the electrode. and has different functions in these modes. This control is not active in the TIG and ARC GOUGING mode. 11. VRD (Voltage Reduction Device) INDICA- TOR LIGHTS- On the front panel of the DX450 CC-STICK mode: In this mode, the ARC CONTROL dial are two indicator lights.
