DX450 Operator Manual - Red-D

DX450 Operator Manual - Red-D
RED-D-ARC
DX450
For use with machines having Code Numbers:
11512, 11561
IM962-A
RETURN TO MAIN MENU
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 READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.
And, most importantly, think before you act and be careful.
1-800-245-3660
North America’s Largest Fleet of Welding Equipment
September, 2008
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SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE
powered equipment.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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 exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.5. Do not work next to welding power source.
Mar ʻ95
DX450 (RED-D-ARC)
ii
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
DX450 (RED-D-ARC)
iii
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SAFETY
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
Jan, 07
6.j. Do not use a welding power source for pipe thawing.
DX450 (RED-D-ARC)
iv
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SAFETY
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 suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
DX450 (RED-D-ARC)
Mar. ʻ93
v
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Thank You
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!
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 our customers based on the best information in our possession at that time. We are not in a position to warrant or guarantee such advice, and assume no
liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any
warranty of fitness for any customerʼs particular purpose, with respect to such information or advice. As a matter
of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within the
control of, and remains the sole responsibility of the customer. Many variables beyond our control affect the
results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code (if available)______________________________________________________
Serial Number (if available)__________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
vi
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TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications .......................................................................................................A-1
Safety Precautions ........................................................................................................A-2
VRD (Voltage Reduction Device) ..................................................................................A-2
Location and Ventilation ................................................................................................A-2
Stacking ........................................................................................................................A-2
Angle of Operation ........................................................................................................A-2
Lifting.............................................................................................................................A-2
High Altitude Operation .................................................................................................A-3
High Temperature Operation ........................................................................................A-3
Cold Weather Operation ......................................................................................................A-3
Towing ..................................................................................................................................A-3
Vehicle Mounting ..................................................................................................................A-3
Pre-Operation Engine Service..............................................................................................A-3
Oil ..................................................................................................................................A-3
Fuel ...............................................................................................................................A-4
Engine Coolant..............................................................................................................A-4
Battery Connections ......................................................................................................A-4
Muffler Outlet Pipe ........................................................................................................A-4
Spark Arrester ...............................................................................................................A-4
Remote Control .............................................................................................................A-4
Electrical Connections ..........................................................................................................A-5
Machine Grounding ..............................................................................................................A-5
Welding Terminals................................................................................................................A-5
Welding Output Cables ........................................................................................................A-5
Cable Installation..................................................................................................................A-5
Auxiliary Power Receptacles and Plugs ...............................................................................A-6
Standby Power Connections ................................................................................................A-6
Premises Wiring ...................................................................................................................A-7
Connection of Lincoln Electric Wire Feeders................................................................A-8, A-9
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
General Description..............................................................................................................B-1
For Auxiliary Power ..............................................................................................................B-1
Engine Operation..................................................................................................................B-1
Add Fuel ...............................................................................................................................B-1
Break in Period .....................................................................................................................B-1
Welder Controls .............................................................................................................B-2,B-3
Engine Controls ....................................................................................................................B-4
Starting and Stopping the Engine ...........................................................................B-4,B-5
Welding Operation................................................................................................................B-5
Duty Cycle and Electrode Information...........................................................................B-5
Constant Current (Stick) Welding .........................................................................................B-5
Downhill Pipe (Stick) Welding................................................................................B-5, B-6
Tig Welding ...................................................................................................................B-6
Typical Current Ranges for Tungsten Electrodes .........................................................B-6
Wire Welding-CV...........................................................................................................B-7
Arc Gouging ..................................................................................................................B-7
Auxiliary Power.....................................................................................................................B-7
Simultaneous Welding and Power Loads .....................................................................B-7
Extension Cord Recommendations...............................................................................B-7
________________________________________________________________________________
Accessories .....................................................................................................Section C
Field Installed Options / Accessories ...............................................................................C-1
________________________________________________________________________________
vii
TABLE OF CONTENTS
Maintenance......................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance ............................................................................................D-1
Engine Service Items.............................................................................................D-1
Engine Oil Change..........................................................................................D-2
Engine Oil Filter Change.................................................................................D-2
Air Cleaner .....................................................................................................D-2
Service Instructions And Installation Tips for Engine Air Filter .......................D-3
Cooling System .....................................................................................................D-4
Fan Belt...........................................................................................................D-4
Fuel .................................................................................................................D-4
Bleeding the Fuel System ...............................................................................D-4
Fuel Filter ........................................................................................................D-5
Engine Adjustment ..........................................................................................D-5
Battery Maintenance .......................................................................................D-5
Servicing Optional Spark Arrestor ...................................................................D-5
Welder / Generator Maintenance ........................................................................D-6
Storage ...........................................................................................................D-6
Cleaning..........................................................................................................D-6
Brush Removal and Replacement ..................................................................D-6
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-6
________________________________________________________________________
Connection Diagrams, Wiring Diagrams and Dimension Print...................Section F
________________________________________________________________________
Parts List .....................................................................................................P-582 Series
________________________________________________________________________
vii
A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - DX450 (K2712-1)
INPUT - DIESEL ENGINE
Make/Model
Description
Speed (RPM)
4 cylinder
35.4 HP
1800 RPM
High Idle 1880
KUBOTA
2403-M
Displacement
cu. in. (ltrs.)
Starting
System
Capacities
148.5(2.4)
Full Load 1800
Low Idle 1400
12VDC Battery &
Fuel: 20 gal.
starter
(75 L)
Bore x Stroke inch (mm) (Group 34; 650 Oil: 10Qts. (9.5L)
3.43” X 4.03”
cold crank amps)
(87.1 x 102.4mm)
40 Amp
Radiator Coolant:
Alternator
8.0 Qts. (7.6L)
RATED OUTPUT @ 104° F (40° C) - WELDER
Welding Process
DC Constant Current
Welding Output
Current/Voltage/Duty Cycle
400A / 36V / 100%
450A / 32V / 100%
300A / 32V / 100%
250A / 30V / 100%
400A / 36V / 100%
450A / 32V / 100%
400A / 36V / 100%
DC Pipe Current
Touch-Start™TIG
DC Constant Voltage
Arc Gouging
Output Range
Max. Weld OCV
@Rated Load RPM
30 TO 500 AMPS
40 TO 300 AMPS
20 TO 250 AMPS
RATED OUTPUT @ 104° F
2
60 Volts
14 TO 36 VOLTS
90 TO 450 AMPS
(40° C).- GENERATOR
Auxiliary Power 1
12,000 Watts Peak, / 11,000 Watts Continuous, 60 Hz 120/240 Volts Single Phase
19,000 Watts Peak, / 17,000 Watts Continuous, 60 Hz, 240 Volts 3-Phase
ENGINE
LUBRICATION
EMISSIONS
Full Pressure
EPA Tier 4 Interim
with Full Flow Filter
Compliant
AIR CLEANER
FUEL SYSTEM
Mechanical Fuel Pump, Auto air bleed
system, Electric shutoff solenoid, Indirect fuel injector.
GOVERNOR
Electronic
ENGINE IDLER
MUFFLER
ENGINE PROTECTION
Low noise Muffler:
Shutdown on low oil
Single Element
Automatic Idler
Top outlet can be rotated.
pressure & high engine
Made from long life, aluminized steel.
coolant temperature
ENGINE WARRANTY: 2 years / 2000 hours, all non-electric components, 3 years major non-electric components . See Perkins warranty for details.
MACHINE SPECIFICATIONS
RECEPTACLES
AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS
(2)120VAC Duplex (5-20R)GFCI Protected
(1) 120/240VAC Dual Voltage
Full KVA (NEMA SSR-50R)
(1) 240VAC 3-Phase (15-50R)
Two 20AMP for Two Duplex Receptacle
(1) 50AMP for Dual Voltage and for
3-Phase (3-pole)
10AMP for Battery Charging Circuit
10AMP for 42V Wire Feeder Power
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
35.94* in.
25.30 in
60.00 in.
913 mm
643 mm
1524 mm
WEIGHT
1245lbs. (565kg.)
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 exhaust pipe. Add 6.67”(169.4mm) to top of Lift Bail.
2. Reduced to less than 32V in the CC-stick Mode when VRD (VOLTAGE REDUCTION DEVICE) is on.
DX450 (RED-D-ARC)
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 manufacturerʼs
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 electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
-----------------------------------------------------------------------ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
-----------------------------------------------------------------------MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operatorʼs manual.
Only qualified personnel should install,
use, or service this equipment.
VRD (VOLTAGE REDUCTION DEVICE)
The VRD feature provides additional safety in the CC-Stick
mode especially in an environment with a higher risk of
electric shock such as wet areas and hot humid sweaty
conditions.
The VRD reduces the OCV (Open Circuit Voltage) at the
welding output terminals while not welding to less than 13V
DC when the resistance of the output circuit is above 200Ω
(ohms).
The VRD requires that the welding cable connections be
kept in good electrical condition because poor connections
will contribute to poor starting. Having good electrical connections also limits the possibility of other safety issues
such as heat-generated damage, burns and fires.
The machine is shipped with the VRD switch in the “Off”
position. To turn it “On” or “Off”.
• Turn the engine “Off”.
• Disconnect the negative battery cable.
• Lower the control panel by removing 4 front
panel screws. (See Figure A.1)
• Place the VRD switch in the “On” or “Off” position.
(See Figure A.1)
With the VRD switch in the “On” position, the VRD lights
are enabled.
REMOVE 4 FRONT PANEL
SCREWS TO ACCESS
(VRD) SWITCH
LOCATION AND VENTILATION
The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to
avoid restricting the cooling air outlets. Also, locate
the welder so that the engine exhaust fumes are properly vented to an outside area.
STACKING
DX450 machines cannot be stacked.
ANGLE OF OPERATION
Engines are designed to run in the level condition
which is where the optimum performance is achieved.
The maximum angle of continuous operation is 25
degrees in all directions, 35 degrees Intermittent (less
than 10 minutes continuous) in all directions. If the
engine is to be operated at an angle, provisions must
be made for checking and maintaining the oil level at
the normal (FULL) oil capacity in the crankcase.
When operating the welder at an angle, the effective
fuel capacity will be slightly less than the amount
specified.
LIFTING
The DX450 weighs approximately 1391lbs. (631kg.)
with a full tank of fuel, 1245lbs. (565kg) less fuel. A lift
bail is mounted to the machine and should always be
used when lifting the machine.
DX450 (RED-D-ARC)
A-3
WARNING
• Lift only with equipment of adequate lifting capacity.
• Be sure machine is stable when lifting.
• Do not lift this machine using lift
bail if it is equipped with a heavy
accessory such as trailer or gas
cylinder.
FALLING
EQUIPMENT can
cause injury.
A-3
INSTALLATION
• Do not lift machine if lift bail is
damaged.
• Do not operate machine while
suspended from lift bail.
1. Design capacity of trailer vs. weight of Lincoln equipment and
likely additional attachments.
2. Proper support of, and attachment to, the base of the welding
equipment so there will be no undue stress to the framework.
3. Proper placement of the equipment on the trailer to insure
stability side to side and front to back when being moved and
when standing by itself while being operated or serviced.
4. Typical conditions of use, i.e., travel speed; roughness of surface on which the trailer will be operated; environmental conditions; like maintenance.
5. Conformance with federal, state and local laws.(1)
(1) Consult applicable federal, state and local laws regarding specific requirements for use on public highways.
VEHICLE MOUNTING
--------------------------------------------------------------------------------
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 emissions regulations, modifications to the engine for
high altitude are restricted within the United States. If
required contact an authorized Perkins engine field service
shop to determine if any adjustments can be made for operation in higher elevations.
HIGH TEMPERATURE OPERATION
At temperatures above 104°F(40°C), Welder output derating
is necessary. For maximum output ratings, derate the
welder output 2 volts for every 18°F(10°C) above
104°F(40°C).
WARNING
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
• Distribute, balance and secure loads so vehicle
is stable under conditions of use.
• Do not exceed maximum rated loads for components such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
• Follow vehicle manufacturerʼs instructions.
------------------------------------------------------------------------
Cold weather starting:
PRE-OPERATION ENGINE SERVICE
With a fully charged battery and the proper oil, the
engine should start satisfactorily down to -15°F(26C°). If the engine must be frequently started at or
below 0°F (-18°C), it may be desirable to install coldstarting aides. The use of No. 1D diesel fuel is recommended in place of No. 2D at temperatures below
23°F (-5°C). Allow the engine to warm up before
applying a load or switching to high idle.
READ the engine operating and maintenance instructions supplied with this machine.
Note: Extreme cold weather starting may require
longer glow plug operation.
WARNING
Under no conditions should ether or other starting
fluids be used with this engine!
------------------------------------------------------------------------
TOWING
Use a recommended trailer for use with this equipment for road,
in-plant and yard towing by a vehicle(1). If the user adapts a
non-Lincoln trailer, he must assume responsibility that the
method of attachment and usage does not result in a safety
hazard or damage the welding equipment. Some of the factors
to be considered are as follows:
WARNING
• Stop engine and allow to cool before fueling.
• Do not smoke when fueling.
• Fill fuel tank at a moderate rate and do not overfill.
• Wipe up spilled fuel and allow fumes to clear
before starting engine.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
OIL
The DX450 is shipped with the engine crankcase filled with high
quality SAE 10W-30 Oil that meets classification CG-4 or CH-4 for
diesel engines. Check the oil level before starting the engine. If it is
not up to the full mark on the dip stick, add oil as required. Check
the oil level every four hours of running time during the first 50 running hours. Refer to the engine Operatorʼs Manual for specific oil
recommendations and break-in information. The oil change interval
is dependent on the quality of the oil and the operating environment. Refer to the Engine Operatorʼs Manual for more details on
the proper service and maintenance intervals.
DX450 (RED-D-ARC)
A-4
A-4
INSTALLATION
FUEL
USE DIESEL FUEL ONLYLow Sulphur fuel or ultra low sulphur fuel in USA and
CANADA only.
The standard muffler included with this welder does
not qualify as a spark arrester. When required by local
regulations, a suitable spark arrester, such as the
K903-1 must be installed and properly maintained.
WARNING
WARNING
• Fill the fuel tank with clean, fresh fuel. The capacity of
the tank is 20 gals. (75.7 ltrs). When the fuel gauge
reads empty the tank contains approximately 2 gals.
(7.6ltrs.) of reserve fuel.
NOTE: A fuel shut off valve is located on the pre-filter/sediment filter. Which should be in the closed
position when the welder is not used for extended periods of time.
--------------------------------------------------------------------------------
ENGINE COOLING SYSTEM
WARNING
Air to cool the engine is drawn in the side and exhausted through radiator & case back. It is important that the
intake and exhaust air is not restricted. Allow a minimum clearance of 1ft. (0.6m) from the case back and 16
in. (406mm) from either side of the base to a vertical
surface.
--------------------------------------------------------------------------------
BATTERY CONNECTION
CAUTION
Use caution as the electrolyte is a strong acid that can
burn skin and damage eyes.
-------------------------------------------------------------------------------The DX450 is shipped with the negative battery cable disconnected. Make certain that the RUN-STOP switch is in
the STOP position. Remove the two screws from the battery
tray using a screwdriver or a 3/8"(10mm) socket. Attach the
negative battery cable to the negative battery terminal and
tighten using a 1/2"(13mm) socket or wrench.
NOTE: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the battery with the correct polarity. (See Battery in
“Maintenance Section”)
MUFFLER OUTLET PIPE
Using the clamp provided secure the outlet pipe to the
outlet tube with the pipe positioned such that it will
direct the exhaust in the desired direction. Tighten
using a 9/16"(14mm) socket or wrench.
SPARK ARRESTER
Some federal, state or local laws may require that
gasoline or diesel engines be equipped with exhaust
spark arresters when they are operated in certain
locations where unarrested sparks may present a fire
hazard.
An incorrect spark arrestor may lead to damage to
the engine or adversely affect performance.
------------------------------------------------------------------------
REMOTE CONTROL
The DX450 is equipped with a 3-pin and a 14-pin connector. When in the CC-STICK, CV-WIRE OR
GOUGE modes and when a remote control is connected to the 3-pin Connector, the auto-sensing circuit
automatically switches the OUTPUT control from control at the welder to remote control.
When in TOUCH START TIG mode and when a
Amptrol is connected to the 3-Pin Connector, the
OUTPUT dial is used to set the maximum current
range of the CURRENT CONTROL of the Amptrol.
When in the DOWNHILL PIPE mode and when a
remote control is connected to the 3-Pin or 14-Pin
connector, the output control is used to set the maximum current range of the remote.
EXAMPLE: When the OUTPUT CONTROL on the
welder is set to 200 amps the current range on the
remote control will be 40-200 amps, rather than the
full 40-300 amps. Any current range that is less than
the full range provides finer current resolution for more
fine tuning of the output.
In the CV-WIRE mode, if the feeder being used has a
voltage control when the wire feeder control cable is
connected to the 14-Pin Connector, the auto-sensing
circuit automatically makes OUTPUT CONTROL inactive and the wire feeder voltage control active.
Otherwise, the OUTPUT CONTROL is used to preset
the voltage.
The 14-pin connector is used to directly connect a
wire feeder control cable. In the CV-WIRE mode,
when the control cable is connected to the 14-pin connector, the auto-sensing circuit automatically makes
the Output Control inactive and the wire feeder voltage control active.
WARNING
NOTE: When a wire feeder with a built in welding
voltage control is connected to the 14-pin connector, do not connect anything to the 3-pin connector.
------------------------------------------------------------------------
DX450 (RED-D-ARC)
A-5
A-5
INSTALLATION
WELDING OUTPUT CABLES
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, other equipment
to which this engine driven welder supplies power
must:
With the engine off connect the electrode and work
cables to the output studs. The welding process dictates the polarity of the electrode cable. These connections should be checked periodically and tightened
with a 3/4"(19mm) wrench.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
WARNING
• Be grounded to the frame of the welder using a
grounded type plug or be double insulated.
• Do not ground the machine to a pipe that carries
explosive or combustible material.
-----------------------------------------------------------------------When this welder is mounted on a truck or trailer, its
frame must be electrically bonded to the metal frame
of the vehicle. Use a #8 or larger copper wire connected between the machine grounding stud and the
frame of the vehicle. When this engine driven welder
is connected to premises wiring such as that in a
home or shop, its frame must be connected to the
system earth ground. See further connection instructions in the section entitled "Standby Power
Connections" as well as the article on grounding in the
latest National Electrical Code and the local code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into
the ground for at least ten feet and having no insulated joints, or to the metal framework of a building
which has been effectively grounded.
The National Electrical Code lists a number of alternate means of grounding electrical equipment. A
machine grounding stud marked with the symbol
is provided on the front of the welder.
Cable Length
0-100 Ft. (0-30 meters)
Cable Size for
400 Amps
60% Duty Cycle
2 / 0 AWG
100-150 Ft. (30-46 meters)
2 / 0 AWG
150-200 Ft. (46-61 meters)
3 / 0 AWG
TABLE A.1
CABLE INSTALLATION
Install the welding cables to your DX450 as follows.
1. The engine must be OFF to install welding cables.
2. Remove the flanged nuts from the output terminals
.
3. Connect the electrode holder and work cables to
the weld output terminals. The terminals are identified on the case front.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding (the
“work”) is properly connected to the work clamp and
cable.
6. Check and tighten the connections periodically.
WELDING TERMINALS
The DX450 is equipped with a toggle switch for selecting "hot" welding terminal when in the "WELD TERMINALS ON" position or "cold" welding terminal when in
the "REMOTELY CONTROLLED" position.
CAUTION
• Loose connections will cause the output terminals to overheat. The terminals may eventually
melt.
• Do not cross the welding cables at the output terminal connection. Keep the cables isolated and
separate from one another.
------------------------------------------------------------------------
DX450 (RED-D-ARC)
A-6
A-6
INSTALLATION
AUXILIARY POWER RECEPTACLES
STANDBY POWER CONNECTIONS
Start the engine and set the “IDLER” control switch to the
“High Idle” mode. Voltage is now correct at the receptacles
for auxiliary power. This must be done before a tripped
GFCI module can be reset properly. See the MAINTENANCE section for more detailed information on testing
and resetting the GFCI module.
The DX450 is suitable for temporary, standby or
emergency power using the engine manufacturerʼs
recommended maintenance schedule.
The auxiliary power of the DX450 consists of two 20 Amp120 VAC (5-20R) duplex receptacles with GFCI protection,
one 50 Amp 120/240 VAC (SS2-50R) receptacle and one
50 Amp 240VAC Three-Phase (15-50R) receptacle.
The auxiliary power capacity is 12,000 watts Peak, 11,000
Watts Continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to voltamperes at unity power factor. The max permissible current
of the 240 VAC output is 50amps.
The 240 VAC output can be split to provide two separate
120 VAC outputs with a max permissible current of 50
Amps per output to two separate 120 VAC branch circuits
(these circuits cannot be paralleled). Output voltage is within ± 10% at all loads up to rated capacity.
The Three-Phases auxiliary power capacity is 19,000 watts
peak, 17,000 watts continuous. The maximum current is 45
amps.
The DX450 can be permanently installed as a standby
power unit for 240 VAC, 3 wire, single phase, 50 amp
service. Connections must be made by a licensed
electrician who can determine how the 120/240 VAC
power can be adapted to the particular installation and
comply with all applicable electrical codes.
• Install the double-pole, double-throw switch
between the power company meter and the premises disconnect. Switch rating must be the same or
greater than the customerʼs premises disconnect
and service over current protection.
• Take necessary steps to assure load is limited to
the capacity of the generator by installing a 50 amp,
240 VAC double pole circuit breaker. Maximum
rated load for each leg of the 240 VAC auxiliary is
50 amperes. Loading above the rated output will
reduce output voltage below the allowable - 10% of
rated voltage which may damage appliances or
other motor-driven equipment and may result in
overheating of the engine and/or alternator windings.
120 V DUPLEX RECEPTACLES AND GFCI MODULES
A GFCI Module protects the two 120V auxiliary power
receptacles.
A GFCI (Ground Fault Circuit Interrupter) is a device to protect against electric shock should a piece of defective
equipment connected to it develop a ground fault. If this situation should occur, the GFCI module will trip, removing
voltage from the output of the receptacle. If a GFCI module
is tripped see the MAINTENANCE section for detailed
information on testing and resetting it. A GFCI module
should be properly tested at least once every month.
The 120 V auxiliary power receptacles should only be used
with three wire grounded type plugs or approved double
insulated tools with two wire plugs. The current rating of
any plug used with the system must be at least equal to the
current capacity of the associated receptacle.
NOTE: The 240 V receptacle has two 120 V circuits, but
are of opposite polarities and cannot be paralleled.
All auxiliary power is protected by circuit breakers. The
120V has 20 Amp circuit breakers for each duplex receptacle. The 120/240V Single Phase and the 240V ThreePhases have a 50 Amp 3-pole Circuit Breaker that disconnects both hot leads and all Three Phases simultaneously.
• Install a 50 amp, 120/240 VAC plug to the doublepole circuit breaker using No. 6, 4 conductor cable
of the desired length.
• Plug this cable into the 50 Amp, 120/240 Volt receptacle on the case front.
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 laws require
the premises to be isolated before the generator
is linked to the premises. Check your local
requirements.
------------------------------------------------------------------------
DX450 (RED-D-ARC)
A-7
INSTALLATION
A-7
CONNECTION OF DX450 TO PREMISES WIRING
HUBBELL CS6365C
xyz
xyz
TE
HI
W
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 generator is linked to the premises. Check your
state and local requirements.
• A double pole, double throw transfer switch in conjunction with the properly rated double throw
circuit breaker is connected between the generator power and the utility meter.
DX450 (RED-D-ARC)
A-8
INSTALLATION
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
Connection of LN-7 or LN-8 to the DX450
A-8
4. Control Cable Model:
• Connect Control Cable between Engine Welder
and Feeder.
1. Shut the welder off.
• Set the "WELD TERMINALS" switch to
"REMOTELY CONTROLLED"
2. Connect the LN-7 or LN-8 per instructions on the
appropriate connection diagram in Section F.
• Set the MODE switch to the "CV-WIRE " position.
3. Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode being
used.
4. Set the "MODE" switch to the "CV WIRE " position.
5. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
6. Set the "WELD TERMINALS" switch to the
"REMOTELY CONTROLLED" position.
7. Set the "IDLE" switch to the "HIGH" position.
Connection of LN-15 to the DX450
• Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode polarity being used.
• Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
• Set the "IDLE" switch to the "AUTO" position.
• When the gun trigger is closed, the current sensing circuit will cause the DX450 engine to go to
the high idle speed, the wire will begin to feed
and the welding process started. When welding is
stopped, the engine will revert to low idle speed
after approximately 12 seconds unless welding is
resumed.
1. Shut the welder off.
2. For electrode Positive, connect the electrode
cable to the "+" terminal of the welder and work
cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable to the
"-" terminal of the welder and work cable to the "+"
terminal of the welder.
3. Across The-Arc Model:
• Attach the single lead from the front of the LN-15
to work using the spring clip at the end of the
lead. This is a control lead to supply current to
the wire feeder motor; it does not carry welding
current.
• Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON".
• When the gun trigger is closed, the current sensing circuit will cause the DX450 engine to go to
the high idle speed, the wire will begin to feed
and the welding process started. When welding
is stopped, the engine will revert to low idle
speed after approximately 12 seconds unless
welding is resumed.
DX450 (RED-D-ARC)
A-9
INSTALLATION
A-9
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 connections.
-----------------------------------------------------------------------The LN-25 with or without an internal contactor may
be used with the DX450 . See the appropriate connection diagram in Section F.
• Connect per instructions on the appropriate connection diagram in Section F.
1. Shut the welder off.
2. For electrode Positive, connect the electrode
cable from the LN-25 to the "+" terminal of the
welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the electrode cable from the LN-25 to the "-" terminal of
the welder and work cable to the "+" terminal of
the welder.
3. Attach the single lead from the front of the LN-25
to work using the spring clip at the end of the lead.
This is a control lead to supply current to the wire
feeder motor; it does not carry welding current.
4. Set the MODE switch to the "CV-WIRE " position.
5. Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON"
6. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
7. Set the "IDLE" switch to the "AUTO" position.
When not welding, the DX450 engine will be at
the low idle speed. If you are using an LN-25 with
an internal contactor, the electrode is not energized until the gun trigger is closed.
8. When the gun trigger is closed, the current sensing circuit will cause the DX450 engine to go to
the high idle speed, the wire will begin to feed and
the welding process started. When welding is
stopped, the engine will revert to low idle speed
after approximately 12 seconds unless welding is
resumed.
CAUTION
If you are using an LN-25 without an internal contactor, the electrode will be energized when the
DX450 is started.
------------------------------------------------------------------------
DX450 (RED-D-ARC)
B-1
B-1
OPERATION
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
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 electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
• Always operate the welder with the hinged door
closed and the side panels in place.
• Read carefully the Safety Precautions page
before operating this machine. Always follow
these and any other safety procedures included
in this manual and in the Engine Instruction
Manual.
GENERAL DESCRIPTION
The DX450 is a diesel engine powered DC multiprocess welding power source and AC power generator. The engine drives a generator that supplies three
phase power for the DC welding circuit, single phase
and Three Phase power for the AC auxiliary outlets.
The DC welding control system uses state of the art
Chopper Technology CT for superior welding performance.
R
The DX450 is fitted with a selectable VRD(Voltage
Reduction Device). The VRD operates in the CC-Stick
mode reducing the OCV to <13 volts, increasing operator safety when welding is performed in environments with increased hazard of electric shock such as
wet areas and hot, humid sweaty conditions.
FOR AUXILIARY POWER:
Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings providing no
welding current is being drawn.
ENGINE OPERATION
Before Starting the Engine:
• Be sure the machine is on a level surface.
• Open side engine door and remove the engine oil
dipstick and wipe it with a clean cloth. Reinsert the
dipstick and check the level on the dipstick.
• Add oil (if necessary) to bring the level up to the full
mark. Do not overfill. Close engine door.
• Check radiator for proper coolant level. (Fill if necessary).
• See Engine Ownerʼs Manual for specific oil and
coolant recommendations.
WARNING
ADD FUEL
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
• Do not leave unattended
while fueling.
• Wipe up spilled fuel and allow
DIESEL FUEL
fumes to clear before starting
can cause fire.
engine.
• Do not overfill tank, fuel
expansion may cause overflow.
Diesel Fuel Only-Low Sulphur Fuel or Ultra Low
Sulphur in USA and Canada.
-----------------------------------------------------------------------• Remove the fuel tank cap.
• Fill the tank. DO NOT FILL THE TANK TO THE
POINT OF OVERFLOW.
• Replace the fuel cap and tighten securely.
• See Engine Ownerʼs Manual for specific fuel recommendations.
BREAK-IN PERIOD
The engine will use a small amount of oil during its
“break-in” period. The break-in period is about 50 running hours. Check the oil every four hours during
break-in.
Change the oil after the first 50 hours of operation and
every 200 hours thereafter. Change the oil filter at
each oil change.
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.
------------------------------------------------------------------------
DX450 (RED-D-ARC)
B-2
B-2
OPERATION
FIGURE B.1
11
1
1
9
2
10
3
13
4
14
12
15
8
16
17
7
18
21
19
22
20
6
5
WELDING CONTROLS (Figure B.1)
1. OUTPUT CONTROL- The OUTPUT dial is
used to preset the output voltage or current as displayed 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 connected to the 3-Pin or 14-Pin Connector, the autosensing circuit automatically switches the OUTPUT
CONTROL from control at the welder to the remote
control.
When in the DOWNHILL PIPE mode and when a
remote control is connected to the 3-Pin or 14-Pin
connector, the output control is used to set the maximum current range of the remote.
EXAMPLE: When the OUTPUT CONTROL on the
welder is set to 200 amps the current range on the
remote control will be 40-200 amps, rather than the
full 40-300 amps. Any current range that is less than
the full range provides finer current resolution for
more fine tuning of the output.
In the CV-WIRE mode, if the feeder being used has
a voltage control when the wire feeder control cable
is connected to the 14-Pin Connector, the autosensing circuit automatically makes OUTPUT CONTROL inactive and the wire feeder voltage control
active. Otherwise, the OUTPUT CONTROL is used
to preset the voltage
When in the TOUCH START TIG mode and when
an Amptrol is connected to the 3-Pin Connector, the
OUTPUT dial is used to set the maximum current
range of the CURRENT CONTROL of the Amptrol.
2. DIGITAL OUTPUT METERS- The digital
meters allow the output voltage (CV-WIRE mode)
or current (CC-STICK, DOWNHILL PIPE, ARC
GOUGING and TIG modes) to be set prior to welding using the OUTPUT control dial. During welding,
the meter display the actual output voltage
(VOLTS) and current (AMPS). A memory feature
holds the display of both meters on for seven seconds after welding is stopped. This allows the operator to read the actual current and voltage just prior
to when welding was ceased.
While the display is being held the left-most decimal point in each display will be flashing. The
accuracy of the meters is +/- 3%.
3. WELD MODE SELECTOR SWITCH(Provides five selectable welding modes)
CV-WIRE
ARC GOUGING
DOWNHILL PIPE
CC-STICK
TOUCH START TIG
DX450 (RED-D-ARC)
B-3
B-3
OPERATION
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 (arc-force) during stick welding
to adjust for a soft or crisp arc. Increasing the dial from –10
(soft) to +10 (crisp) increases the short circuit current and
prevents sticking of the electrode to the plate while welding.
This can also increase spatter. It is recommended that the
ARC CONTROL be set to the minimum number without
electrode sticking. Start with a setting at 0.
DOWNHILL PIPE mode: In this mode, the ARC CONTROL
dial sets the short circuit current (arc-force) during stick
welding to adjust for a soft or a more forceful digging arc
(crisp). Increasing the number from –10 (soft) to +10 (crisp)
increases the short circuit current which results in a more
forceful digging arc. Typically a forceful digging arc is preferred for root and hot passes. A softer arc is preferred for fill
and cap passes where weld puddle control and deposition
("stacking" of iron) are key to fast travel speeds. It is recommended that the ARC CONTROL be set initially at 0.
CV-WIRE mode: In this mode, turning the ARC CONTROL
clock wise from –10 (soft) to +10 (crisp) changes the arc
from soft and washed-in to crisp and narrow. It acts as an
inductance/pinch control. The proper setting depends on the
procedure and operator preference. Start with a setting of 0.
5. WELD OUTPUT TERMINALS WITH FLANGE
NUT- Provides a connection point for the electrode and
work cables.
6. GROUND STUD-
Provides a connection point for
connecting the machine case to earth ground.
7. 14-PIN CONNECTOR- For attaching wire feeder control cables. Includes contactor closure circuit, auto-sensing
remote control circuit, and 42V power. The remote control
circuit operates the same as the 6 Pin Amphenol.
8. 3-PIN CONNECTOR- For attaching optional remote
control equipment. Includes auto-sensing remote control
circuit.
9. WELD TERMINALS CONTROL SWITCH- In the
WELD TERMINALS ON position, the output is electrically
hot all the time. In the REMOTELY CONTROLLED position, the output is controlled by a wire feeder or amptrol
device, and is electrically off until a remote switch is
depressed.
10. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to
the polarity of the electrode.
11. VRD (Voltage Reduction Device) INDICATOR LIGHTS- On the front panel of the DX450
are two indicator lights. A red light when lit indicates
OCV(Open Circuit Voltage) is equal to or greater than
30V and a green light when lit indicates OCV(Open
Circuit Voltage) is less than 30V.
The VRD “On/Off” switch inside the control panel
must be “On” for the VRD function to be active and
the lights to be enabled. When the machine is first
started with VRD enabled, both lights will illuminate
for 5 seconds.
These lights monitor the OCV(Open Circuit Voltage)
and weld voltage at all times. In the CC-Stick mode
when not welding the green light will illuminate indicating that the VRD has reduced the OCV to less
than 30V. During welding the red light will illuminate
whenever the arc voltage is equal to or greater than
30V. This means that the red and green light may
alternate depending on the weld voltage. This is normal operation.
If the red light remains illuminated when not welding
in the CC-stick mode, the VRD is not functioning
properly. Please refer to your local field service shop
for service.
If the VRD is turned “On” and the lights donʼt come
“On”, refer to the trouble shooting section.
TABLE B.1
VRD INDICATOR LIGHTS
MODE
VRD "ON"
VRD "OFF"
CC-STICK OCV
Green (OCV Reduced)
While
Red or Green
Welding (Depends on Weld Voltage) *
CV-WIRE OCV
Red (OCV Not Reduced)
Weld Terminals On
Red (OCV Not Reduced)
Weld Terminals Remotely Controlled
Gun Trigger Closed
Green (No OCV)
Weld Terminals Remotely Controlled
Gun Trigger Open
No Lights
While
Red or Green
Welding (Depends on Weld Voltage) *
PIPE
OCV
Green (No Output)
While
Not Applicable (No Output)
Welding
ARC GOUGING OCV
Green (No Output)
While
Not Applicable (No Output)
Welding
TIG
OCV
Green (Process is Low Voltage)
While
Green (Process is Low Voltage)
Welding
* It is normal for the lights to alternate between colors while welding.
DX450 (RED-D-ARC)
B-4
B-4
OPERATION
ENGINE CONTROLS:
18. ELECTRIC FUEL GAUGE- The electric fuel
12. RUN/STOP SWITCH -
gauge gives accurate and reliable indication as to how
much fuel is in the fuel tank.
-RUN position energizes the engine prior to starting.
STOP position stops the engine. The oil pressure interlock switch prevents battery drain if the switch is left in
the RUN position and the engine is not operating.
19. COOLANT TEMPERATURE GAUGE- A indicator of engine coolant temperature.
20. OIL PRESSURE GAUGE- A indicator of engine
13. GLOW PLUG PUSH BUTTON • When pushed activates the glow plugs. Glow plug
should not be activated for more than 20 seconds continuously.
14. START PUSH BUTTON - Energizes the starter
motor to crank the engine.
15. IDLER SWITCH- Has two positions as follows:
1) In the HIGH position, the engine runs at the high idle
speed controlled by the engine governor.
2) In the AUTO position, the idler operates as follows:
• When switched from HIGH to AUTO or after starting
the engine, the engine will operate at full speed for
approximately 12 seconds and then go to low idle
speed.
• When the electrode touches the work or power is
drawn for lights or tools (approximately 100 Watts minimum), the engine accelerates and operates at full
speed.
• When welding ceases or the AC power load is turned
off, a fixed time delay of approximately 12 seconds
starts. If the welding or AC power load is not restarted
before the end of the time delay, the idler reduces the
engine speed to low idle speed.
• The engine will automatically return to high idle speed
when there is welding load or AC power load reapplied.
16. ENGINE HOUR METER- Displays the total time
that the engine has been running. This meter is useful
for scheduling prescribed maintenance.
Oil Pressure.
21. BATTERY CHARGING LIGHT- A warning indicator light for Low/No battery charge. The light is off when
the systems are functioning properly. The light will
come on if there is a Low/No battery condition but the
machine will continue to run.
Note: The light may or may not come on when the RUNSTOP switch is in the "ON" position. After starting
the engine the light will go off unless a Low/No
battery charge condition exists.
STARTING THE ENGINE
1. Remove all plugs connected to the AC power receptacles.
2. Set IDLER switch to AUTO.
3. Press Glow Plug Button and hold 15 to 20 seconds.
4. Set the RUN/STOP switch to RUN.
5. Press START button until the engine starts or for up to 10
seconds. Continue to hold the glow plug button for up to
an additional 10 seconds.
6. Release the engine START button immediately when the
engine starts.
7. The engine will run at high idle speed for approximately
12 seconds and then drop to low idle speed. Allow the
engine to warm up at low idle for several minutes before
applying a load and/or switching to high idle. Allow a
longer warm up time in cold weather.
17. CIRCUIT BREAKER- For protection of Battery
Charging Circuit.
TABLE B.2
TYPICAL DX450 FUEL CONSUMPTION
Low Idle - No Load
1400 R.P.M.
High Idle - No Load
1800 R.P.M.
DC Weld Output
500 Amps @ 40Volts
20,000 Watts 3 Phase
12,000 Watts 1 Phase
KUBOTA V2403M
Gal./Hr (Liters/Hr)
.42(1.58)
Running Time for
20 gallons / hours
48.03
.60(2.28)
33.18
1.57(5.93)
12.76
1.63(6.16)
12.29
1.28 (4.83)
15.67
NOTE: This data is for reference only. Fuel consumption is
approximate and can be influenced by many factors, including
engine maintenance, environmental conditions and fuel quality.
DX450 (RED-D-ARC)
B-5
OPERATION
NOTE: If the unit fails to start turn Run/Stop switch
to off and repeat step 3 through step 7 after
waiting 30 seconds.
CAUTION
• Do not allow the starter motor to run continuously
for more than 20 seconds.
• Do not push the START button while the engine
is running because this can damage the ring
gear and/or the starter motor.
• IF the Engine Protection or Battery Charging
Lights do “not” turn off shortly after starting the
engine shut off the engine immediately and
determine the cause.
----------------------------------------------------------------------NOTE: When starting for the first time, or after and
extended period of time of not operating, it will take
longer than normal to start because the fuel pump has
to fill the fuel system. For best results, bleed the fuel
system as indicated in Maintenance Section of this
manual.
STOPPING THE ENGINE
Remove all welding and auxiliary power loads and
allow the engine to run at low idle speed for a few
minutes to cool the engine.
STOP the engine by placing the RUN-STOP switch in
the STOP position.
NOTE: A fuel shut off valve is located on the fuel pre-filter.
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 within the rating of the machine. For information on electrodes and their proper application see
(www.lincolnelectric.com) or the appropriate Lincoln
publication.
The DX450 can be used with a broad range of DC stick
electrodes. The MODE switch provides two stick welding
settings as follows:
B-5
The ARC CONTROL dial sets the short circuit current
(arc-force) during stick welding to adjust for a soft or
crisp arc. Increasing the number from -10(soft) to
+10(crisp) increases the short circuit current and prevents sticking of the electrode to the plate while welding.
This can also increase spatter. It is recommended that
the ARC CONTROL be set to the minimum number
without electrode sticking. Start with the dial set at 0.
NOTE: Due to the low OCV with the VRD on, a
very slight delay during striking of the electrodes
may occur. Due to the requirement of the resistance in the circuit to be low for a VRD to operate, a
good metal-to-metal contact must be made
between the metal core of the electrode and the
job. A poor connection anywhere in the welding
output circuit may limit the operation of the VRD.
This includes a good connection of the work clamp
to the job. The work clamp should be connected as
close as practical to where the welding will be performed.
A. For New Electrodes
E6010 - Touch, Lift to Start the Arc
E7018, E7024 - Touch, Rock Back and Forth in
Joint, Lift .
Once the arc is started, normal welding technique
for the application is then used.
B. For Re-Striking Electrodes
Some electrodes form a cone at the end of the
electrode after the welding arc has been broken,
particularly iron powder and low hydrogen electrodes. This cone will need to be broken off in order
to have the metal core of the electrode make contact.
E6010 - Push, Twist in Joint, Lift
E7018, E7024 - Push, Rock Back and Forth in
Joint, Lift.
Once the arc is started, normal welding technique
for the application is then used.
For other electrodes the above techniques should
be tried first and varied as needed to suit operator
preference. The goal for successful starting is good
metal to metal contact.
For indicator light operation, see table B.1.
CONSTANT CURRENT (CC-STICK)
WELDING
DOWNHILL PIPE Welding
The CC-STICK position of the MODE switch is designed
for horizontal and vertical-up welding with all types of
electrodes, especially low hydrogen. The OUTPUT CONTROL dial adjusts the full output range for stick welding.
This slope controlled setting is intended for "out-ofposition" and "down hill" pipe welding where the operator would like to control the current level by changing
the arc length.
DX450 (RED-D-ARC)
B-6
B-6
OPERATION
The OUTPUT CONTROL dial adjusts the full output
range for pipe welding.
The ARC CONTROL dial sets the short circuit current
(arc-force) during stick welding to adjust for a soft or
more forceful digging arc (crisp). Increasing the number
from -10(soft) to +10(crisp) increases the short circuit
current which results in a more forceful digging arc.
Typically a forceful digging arc is preferred for root and
hot passes. A softer arc is preferred for fill and cap passes where weld puddle control and deposition (“stacking”
of iron) are key to fast travel speeds. This can also
increase spatter.
It is recommended that the ARC CONTROL be set to the
minimum number without electrode sticking. Start with
the dial set at 0.
NOTE: With the VRD switch in the “ON” position there is
no output in the DOWNHILL PIPE mode. For indicator
light operation, see table B.1.
TIG WELDING
The TOUCH START TIG setting of the MODE switch is
for DC TIG (Tungsten Inert Gas) welding. To initiate a
weld, the OUTPUT CONTROL dial is first set to the
desired current and the tungsten is touched to the work.
During the time the tungsten is touching the work there is
very little voltage or current and, in general, no tungsten
contamination. Then, the tungsten is gently lifted off the
work in a rocking motion, which establishes the arc.
TYPICAL CURRENT
Tungsten Electrode
DCEN (-)
1/16
3/32
1/8
5/32
3/16
1/4
To reinitiate the arc, retouch the tungsten to the work
and lift. Alternatively, the weld can be stopped by
releasing the Amptrol or arc start switch.
The DX450 can be used in a wide variety of DC TIG
welding applications. In general the ʻTouch Startʼ feature allows contamination free starting without the use
of a Hi-frequency unit. If desired, the K930-2 TIG
Module can be used with the DX450 . The settings are
for reference.
DX450 settings when using the K930-2 TIG Module
with an Amptrol or Arc Start Switch:
• Set the MODE Switch to the TOUCH START TIG
setting.
• Set the "IDLER" Switch to the "AUTO" position.
• Set the "WELDING TERMINALS" switch to the
"REMOTELY CONTROLLED" position.
DCEP (+)
TUNGSTEN ELECTRODES(2)
Approximate Argon Gas Flow
TIG TORCH
Flow Rate C.F.H. ( l /min.)
1%, 2% Thoriated
Tungsten
(.25)
(.50)
(1.0)
The ARC CONTROL is not active in the TIG mode. To
STOP a weld, simply pull the TIG torch away from the
work.
When the arc voltage reaches approximately 30 Volts
the arc will go out and the machine will reset the current to the Touch Start level.
TABLE B.3
RANGES (1) FOR
Diameter in. (mm)
.010
0.020
0.040
When in the TOUCH START TIG mode and when a
Amptrol is connected to the 6-Pin connector the OUTPUT CONTROL dial is used to set the maximum current range of the current control of the Amptrol.
1%, 2% Thoriated
Tungsten
Aluminum
3-8
5-10
5-10
Nozzle Size (4), (5)
Stainless Steel
2-15
5-20
15-80
(3)
(3)
(3)
(2-4)
(3-5)
(3-5)
3-8
5-10
5-10
(2-4)
(3-5)
(3-5)
#4, #5, #6
(1.6)
70-150
10-20
5-10
(3-5)
9-13
(4-6)
#5, #6
(2.4)
(3.2)
150-250
250-400
15-30
25-40
13-17
15-23
(6-8)
(7-11)
11-15
11-15
(5-7)
(5-7)
#6, #7, #8
(4.0)
(4.8)
(6.4)
400-500
500-750
750-1000
40-55
55-80
80-125
21-25
23-27
28-32
(10-12)
(11-13)
(13-15)
13-17
18-22
23-27
(6-8)
(8-10)
(11-13)
#8, #10
(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure
EWP
1% Thoriated
EWTh-1
2% Thoriated
EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.
(3) DCEP is not commonly used in these sizes.
(4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:
# 4 = 1/4 in.
(6 mm)
# 5 = 5/16 in.
(8 mm)
# 6 = 3/8 in.
(10 mm)
# 7 = 7/16 in.
(11 mm)
# 8 = 1/2 in.
(12.5 mm)
#10 = 5/8 in.
(16 mm)
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures
and high duty cycles.
DX450 (RED-D-ARC)
B-7
B-7
OPERATION
This will keep the "Solid State" contactor open and provide a
"cold" electrode until the Amptrol or Arc Start Switch is pressed.
When using the TIG Module, the OUTPUT CONTROL on the
DX450 is used to set the maximum range of the CURRENT
CONTROL on the TIG Module or an Amptrol if connected to the
TIG Module.
NOTE: The TIG process is to receive a low voltage welding
process. There is no difference in operation with the
VRD “On” or “Off” for this mode. For indicator light operation, see table B.1.
WIRE WELDING-CV
Connect a wire feeder to the DX450 according to the instructions in INSTALLATION INSTRUCTIONS Section.
The DX450 in the CV-WIRE mode, permits it to be used with a
broad range of flux cored wire (Innershield and Outershield)
electrodes and solid wires for MIG welding (gas metal arc welding). Welding can be finely tuned using the ARC CONTROL.
Turning the ARC CONTROL clockwise from –10 (soft) to +10
(crisp) changes the arc from soft and washed-in to crisp and
narrow. It acts as an inductance/pinch control. The proper setting depends on the procedure and operator preference. Start
with the dial set at 0.
NOTE: In the CV-Mode with VRD “On”, the OCV(Open Circuit
Voltage) is not reduced. For indicator light operation,
see table B.1.
ARC GOUGING
The DX450 can be used for arc gouging. For optimal
performance, set the MODE switch to ARC GOUGING.
Set the OUTPUT CONTROL knob to adjust output
current to the desired level for the gouging electrode
being used according to the ratings in the following
Table B.4.
TABLE B.4
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
The ARC CONTROL is not active in the ARC GOUGING Mode. The ARC CONTROL is automatically set
to maximum when the ARC GOUGING mode is
selected which provides the best ARC GOUGING performance.
NOTE: With the VRD switch in the “ON” position there
is no output in the Arc Gouging Mode. For indicator
light operation, see table B.1.
AUXILIARY POWER:
Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings providing no
welding current is being drawn.
Simultaneous Welding and Auxiliary Power Loads
The auxiliary power ratings are with no welding load.
Simultaneous welding and power loads are specified
in Table B.5.
TABLE B.5 DX450 SIMULTANEOUS WELDING AND POWER LOADS
WELD
1 PHASE
3 PHASE
BOTH 1 AND 3 PHASE
AMPS
WATTS
AMPS
WATTS
AMPS
WATTS
AMPS
0
11,000
46
17,000
41
11,000
100
11,100
46
15,400
37
11,000
PLUS
OR
200
8,000
33
13,000
31
OR 8,000
300
4,700
20
9,400
23
4,700
400
1,700
7
3,400
8
1,700
500
0
0
0
0
0
0
TABLE B.6
DX450 Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Current Voltage Load
(Amps) Volts (Watts)
15
120
1800
20
120
2400
15
240
3600
20
240
4800
44
240
9500
Maximum Allowable Cord Length in ft. (m) for Conductor Size
12 AWG
10 AWG
8 AWG
6 AWG
40
(12)
75
(23)
125
(38)
175
(53)
30
(9)
50
(15)
88
(27)
138
(42)
(18)
75
(23)
150
(46)
225
(69)
350
(107)
60
(18)
100
(30)
175
(53)
275
(84)
50
(15)
90
(27)
150
(46)
Conductor size is based on maximum 2.0% voltage drop.
14 AWG
30
(9)
60
DX450 (RED-D-ARC)
4 AWG
300
(91)
225
(69)
600
(183)
450
(137)
225
(69)
C-1
ACCESSORIES
FIELD INSTALLED OPTIONS /
ACCESSORIES
C-1
TIG OPTIONS
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 electrode cable and 30 ft. (9.1m) of work cable, headshield,
work clamp electrode holder. Cables are rated at 400
amps, 100% duty cycle.
K1858-1 Service Indicator Kit- Provides a GO / NO-GO
visual indication of air cleaner element useful service life.
Filter service based on restriction readings allows the
longest life possible from the filter and best engine protection.
K2641-2 Trailer - A 4-wheel steerable trailer for inplant and yard towing. Comes standard with a DuoHitch™, a 2” Ball and Lunette Eye combination hitch.
K1783-9 Pro -Torch® PTA-26V TIG Torch
Air Cooled 200 amp torch (2 piece) equipped with valve for
gas flow control. 25 ft. (7.6m) length.
KP509 Magnum Parts Kit for PTA-26V TIG Torch
Magnum Parts Kit provides all the torch accessories you
need to start welding. Parts kit provides collets, collet bodies, a black cap, alumina nozzles and tungstens in a variety
of sizes, all packaged in an easy to carry reclosable sack.
K2347-1 Precision TIG 185 Ready-Pak(For AC TIG)
K2350-1 Invertec® V205-T AC/DC One-Pak™ Package
(For AC TIG)
PLASMA CUTTING
K1601-1 Pro-Cut 55-Cuts metal using the 3-phase AC generator power from the engine driven welder. Accepts 3phase power.
WIRE FEEDER OPTIONS
K449 LN-25 - Includes internal contactor for across the arc
operation (no control cable). Provides “cold” electrode until
gun trigger is pressed. Includes gas solenoid. For spools up
to 44lb. (20 kg) spools.
K1870-1 LN-15 Across the Arc Wire Feeder.
Portable, lightweight, compact CC/CV unit for flux-cored and
MIG welding. Includes Gas Solenoid, adjustable flow meter
and internal contactor. For 10-15 lb. (4.5-6.8kg) spools.
Magnum Gun and Magnum Gun Connector Kit are required
for gas-shielded welding. Innershield Gun is required for
gasless welding.
K126-2 Magnum 350 Innershield Gun
K1802-1 Magnum 300 MIG Gun (for LN-25)
K470-2 Magnum 300 MIG Gun (for LN-15, Includes
Connector Kit)
K466-10 Connector Kit (for LN-15, K470-2)
K1500-1 Gun Receiver Bushing (for LN-15 & K126-2)
Note: See Wire Feeder IM manuals for appropriate Drive
Roll and Guide Tubes.
DX450 (RED-D-ARC)
D-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
Read the Safety Precautions in the front of this
manual and in the Engine Ownerʼs Manual before
working on this machine.
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. If guards are missing from the
machine, obtain replacements from a Lincoln
Distributor. (See Operating Manual Parts List.)
Keep all equipment safety guards, covers, and
devices in position and in good repair. Keep
hands, hair, clothing, and tools away from the
gears, fans, and all other moving parts when
starting, operating, or repairing the equipment.
-----------------------------------------------------------Routine Maintenance
At the end of each dayʼs use, refill the fuel tank to
minimize moisture condensation in the tank. Running
out of fuel tends to draw dirt into the fuel system.
Also, check the crankcase oil level and add oil if
indicated.
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE (50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 150 HOURS OR 4 MONTHS
EVERY 30O HOURS OR 9 MONTHS
EVERY 400 HOURS OR 12 MONTHS
EVERY 500 HOURS OR 15 MONTHS
EVERY 600 HOURS OR 18 MONTHS
ENGINE SERVICE (NOTE 2)
MAINTENANCE ITEM
I
I
R
I
R
R
R
R
C
R
C
I
I
R
C
R
I
I
I
I
I
Coolant level
Concentration of antifreeze
Coolant (NOTE 3)
Engine oil level (NOTE 1)
Engine oil (NOTE 1 & 3)
Engine oil filter
Drain water separator & fuel strainer
Fuel filter canister
Fuel pre-filter element
Tension of alternator drive belt
Alternator drive belt wear
Alternator drive belt
Air filter (earlier check may be req'd)
Air filter element
Valve clearances
Electrical systems
All nuts and bolts for tightness
Leaks or engine damage
Battery
TYPE OR QUANTITY
50/50 Water/Ethylene Glycol
9.5 qts., 9.0L
10.0 qts., 9.5L (including filter)
Kubota #16414-32430
Kubota #16631-43560
Kubota #15831-43380
Kubota # 17480-97010
Donaldson # P821575
Intake .0071"-.0086", Exhaust .0071"-.0086"
I = Inspect
C = Clean
R = Replace
Notes:
(1) Consult Engine Operators Manual for oil recommendations.
(2) Consult Engine Operators Manual for additional maintenance schedule information.
(3) Fill slowly! ensure quantity is used.
Above operations to be carried out by trained personnel with reference to the workshop manual
where necessary. These preventive maintenance periods apply to average conditions of
operation. If necessary, use shorter periods.
S27632
DX450 (RED-D-ARC)
D-2
D-2
MAINTENANCE
ENGINE OIL CHANGE
OIL FILTER 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.
• Drain the oil.
• Be sure the unit is off. Disconnect the negative battery cable to ensure safety.
• Locate oil drain hose and valve in bottom of base
and pull through the hole in the battery access panel
on the welder.
• Open oil drain valve by lifting up spring loaded lever
and rotate 90° counterclockwise. Pull to open and
drain the oil into a suitable container for disposal.
• Close the drain valve by rotating lever 90° clockwise.
• Re-fill the crankcase to the upper limit mark on the
dipstick with the recommended oil (see engine operation manual OR engine service items decal OR
below). Replace and tighten the oil filler cap securely.
• Push oil drain hose and valve back into unit, re-connect negative battery cable, and close doors and
engine top cover before restarting unit.Wash your
hands with soap and water after handling used motor
oil. Please dispose of used motor oil in a manner that
is compatible with the environment. We suggest you
take it in a sealed container to your local service station or recycling center for reclamation. DO NOT
throw it in the trash; pour it on the ground or down a
drain.
Use motor oil designed for diesel engines that meets
requirements for API service classification
CC/CD/CE/CF/CF-4/CG-4 or CH-4.
ACEA E1/E2/E3. Always check the API service label
on the oil container to be sure it includes the letters
indicated. (Note: An S-grade oil must not be used in a
diesel engine or damage may result. It IS permissible
to use an oil that meets S and C grade service classifications.)
SAE 10W30 is recommended for general, all temperature use, 5F to 104F (-15C to 40C).
• Remove the oil filter with an oil filter wrench and
drain the oil into a suitable container. Discard the
used filter. Note: Care should be taken during filter
removal to not disrupt or damage in any way the fuel
lines.
• Clean the filter mounting base and coat the gasket
of the new filter with clean engine oil.
• Screw the new filter on by hand until the gasket contacts the mounting base. Using an oil filter wrench,
tighten the filter an additional 1/2 to 7/8 of a turn.
• Refill the crankcase with the specified amount of the
recommended engine oil. Reinstall the oil filler cap
and tighten securely.
• Start the engine and check for oil filter leaks.
• Stop the engine and check the oil level. If necessary, add oil to the upper limit mark on the dipstick.
WARNING
• Never use gasoline or low flash point solvents
for cleaning the air cleaner element. A fire or
explosion could result.
CAUTION
• Never run the engine without the air cleaner.
Rapid engine wear will result from contaminants,
such as dust and dirt being drawn into the
engine.
------------------------------------------------------------------------
AIR CLEANER
The diesel engine is equipped with a dry type air filter.
Never apply oil to it. Service the air cleaner as follows:
Replace the element every 500 hours of operation.
Under dusty conditions, replace sooner.
See engine ownerʼs manual for more specific information on oil viscosity recommendations.
DX450 (RED-D-ARC)
D-3
D-3
MAINTENANCE
Service Instructions
Single- and Two-Stage Engine Air Cleaners
Inspect the New Filter for Damage
Remove the Filter
Rotate the
filter while
pulling
straight out.
Unfasten or unlatch the
service cover. Because
the filter fits tightly over the
outlet tube to create the critical seal, there will
be some initial resistance, similar to breaking
the seal on a jar. Gently move the end of the filter
back and forth to break the seal then rotate while
pulling straight out. Avoid knocking the filter
against the housing.
If your air cleaner has a safety filter, replace it every third primary
filter change. Remove the safety filter as you would the primary
filter. Make sure you cover the air cleaner outlet tube to avoid any
unfiltered contaminant dropping into the engine.
Clean Both Surfaces of the Outlet Tube
and Check the Vacuator™ Valve
Use a clean cloth to wipe the filter sealing surface and the inside of
the outlet tube. Contaminant on the sealing surface could hinder an
effective seal and cause leakage. Make sure that all contaminant is
removed before the new filter is inserted. Dirt accidently transferred
to the inside of the outlet tube will reach the engine and cause
wear. Engine manufacturers say that it takes only a few grams of
dirt to "dust" an engine! Be careful not to damage the sealing area
on the tube.
Wipe both sides
of the outlet
tube clean.
Outer edge of the
outlet tube
Inspect the new filter carefully, paying attention to
the inside of the open end, which is the
sealing area. NEVER install a damaged
filter. A new Donaldson radial seal
filter may have a dry lubricant on the
seal to aid installation.
Insert the New Radial Seal Filter Properly
If you're servicing the safety filter, this should be seated into
position before installing the primary filter.
Insert the new filter carefully. Seat
the filter by hand, making certain it is
completely into the air cleaner housing
before securing the cover in place.
The critical sealing area will stretch
slightly, adjust itself and distribute the sealing pressure evenly. To
complete a tight seal, apply pressure by hand at the outer rim of
the filter, not the flexible center. (Avoid pushing on the center of the
urethane end cap.) No cover pressure is required to hold the seal.
NEVER use the service cover to push the filter into place! Using the
cover to push the filter in could cause damage to the housing, cover
fasteners and will void the warranty.
If the service cover hits the filter before it is fully in place, remove
the cover and push the filter (by hand) further into the air cleaner
and try again. The cover should go on with no extra force.
Once the filter is in place, secure the service cover.
Inner edge of the
outlet tube
If your air cleaner is equipped with a Vacuator Valve
Visually check and physically squeeze to make sure the
valve is flexible and not inverted, damaged or plugged.
Caution
NEVER use the service cover to
push the filter into place! Using
the cover to push the filter in could
cause damage to the housing, cover
fasteners and will void the warranty.
Inspect the Old
Filter for Leak Clues
Visually inspect the old filter for any signs
of leaks. A streak of dust on the clean side
of the filter is a telltale sign. Remove any
cause of leaks before installing new filter.
Check Connectors for Tight Fit
Make sure that all mounting bands, clamps, bolts, and connections
in the entire air cleaner system are tight. Check for holes in piping
and repair if needed. Any leaks in your intake piping will send dust
directly to the engine!
DX450 (RED-D-ARC)
D-4
D-4
MAINTENANCE
FUEL: Diesel Fuel Only - Low Sulphur Fuel
COOLING SYSTEM
or Ultra Low Sulphur Fuel in U.S.A. and
CANADA only.
WARNING
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 the level is close to or below the
"LOW" mark. do not fill above the "FULL" mark.
Remove radiator cap and add coolant to radiator. Fill
up to the top of the tube in the radiator filler neck
which includes a connecting hose coming from the
thermostat housing.
To drain the coolant, open the valve at the bottom of
the radiator. Open the radiator cap to allow complete
drainage. (Tighten the valve and refill with a 50/50
antifreeze/water solution.) Use an automotive grade
(low silicate) ethylene glycol antifreeze. The cooling
system capacity is11.5 quarts (10.9L). Squeeze upper
and lower radiator hoses while filling to bleed air from
system coolant. Replace and tighten the radiator cap.
CAUTION
Always premix the antifreeze and clean tap water
before adding to the radiator. It is very important
that a precise 50/50 solution be used with this
engine year round. This gives proper cooling during hot weather and freezing protection to -34° F (37° C).
Cooling solution exceeding 50% ethylene glycol
can result in engine overheating and damage to
the engine. Coolant solution must be premixed
before adding to radiator.
------------------------------------------------------------------------
At the end of each dayʼs use, refill the fuel tank to minimize moisture condensation and dirt contamination in
the fuel line. Do not overfill; leave room for the fuel to
expand.
Use only fresh No. 2D diesel fuel, the use of No. 1D
diesel fuel is recommended in place of No. 2D at temperatures below 23°F (-5°C). Do not use kerosene.
See the Engine Operator's Manual for instructions on
replacing the fuel filter.
BLEEDING THE FUEL SYSTEM
You may need to bleed air from the fuel system if the
fuel filter or fuel lines have been detached, the fuel
tank has been ran empty or after periods of long storage. It is recommended that the fuel shutoff valve be
closed during periods of non-use.
WARNING
To avoid personal injury, do not bleed a hot
engine. This could cause fuel to spill onto a hot
exhaust manifold, creating a danger of fire.
-----------------------------------------------------------------------Bleed the fuel system as follows:
1.
2.
3.
4.
Fill the fuel tank with fuel.
Open the fuel shut off valve.
Loosen bleed fitting on the fuel injector manifold.
Operate hand priming lever until fuel comes out the
bleed screw on the injector manifold. This could
take 20-30 seconds of rapid operation of the priming lever. Tighten bleed fitting on injector manifold.
5. Follow normal STARTING procedures until engine
starts.
Periodically remove the dirt from the radiator fins.
Periodically check the fan belt and radiator hoses.
Replace if signs of deterioration are found.
TIGHTENING THE FAN BELT
If the fan belt is loose, the engine can overheat and
the battery lose its charge. Check tightness by pressing on the belt midway between the pulleys. It should
deflect about .25 in.(6.4 mm) under a load of 20 lbs.(9
Kg).
DX450 (RED-D-ARC)
D-5
D-5
MAINTENANCE
CLEANING THE BATTERY
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-filter.
OVERSPEED IS HAZARDOUS
The maximum allowable high idle speed for this
machine is 1850 RPM, no load. Do NOT tamper
with governor components or setting or make any
other adjustments to increase the maximum
speed. Severe personal injury and damage to the
machine can result if operated at speeds above
maximum.
ENGINE ADJUSTMENT
Keep the battery clean by wiping it with a damp cloth
when dirty. If the terminals appear corroded, disconnect the battery cables and wash the terminals with an
ammonia solution or a solution of 1/4 pound (0.1113
kg) of baking soda and 1 quart (0.9461L) of water. Be
sure the battery vent plugs (if equipped) are tight so
that none of the solution enters the cells.
After cleaning, flush the outside of the battery, the battery compartment, and surrounding areas with clear
water. Coat the battery terminals lightly with petroleum
jelly or a non-conductive grease to retard corrosion.
Keep the battery clean and dry. Moisture accumulation on the battery can lead to more rapid discharge
and early battery failure.
CHECKING THE ELECTROLYTE LEVEL
Adjustments to the engine are to be made only by a
Service Center or an authorized Field Service Shop.
If battery cells are low, fill them to the neck of the filler
hole with distilled water and recharge. If one cell is
low, check for leaks.
BATTERY MAINTENANCE
CHARGING THE BATTERY
To access the battery, remove the battery tray from
the front of the machine with 3/8” nut driver or flat
head screw driver. Pull the tray out of machine far
enough to disconnect the negative and then positive
battery cables. The tray can then be tilted and lifted to
remove the entire tray and battery from the machine
for easy service.
WARNING
GASES FROM BATTERY can explode.
● Keep sparks, flame and cigarettes
away from battery.
●
●
To prevent EXPLOSION when:
INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and connect to new battery last.
CONNECTING A BATTERY CHARGER —
remove battery from welder by disconnecting
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
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 DX450 positive (+) battery terminal has a
red terminal cover.
If you need to charge the battery with an external
charger, disconnect the negative cable first, then the
positive cable before you attach the charger leads.
After the battery is charged, reconnect the positive
battery cable first and the negative cable last. Failure
to do so can result in damage to the internal charger
components.
Follow the instructions of the battery charger manufacturer for proper charger settings and charging time.
SERVICING OPTIONAL SPARK
ARRESTOR
Clean every 100 hours.
WARNING
●
USING A BOOSTER — connect positive lead to
battery first then connect negative lead to negative battery lead at engine foot.
BATTERY ACID can burn eyes and skin.
● Wear gloves and eye protection
and be careful when working near
battery.
● Follow instructions printed on battery.
• MUFFLER MAY BE HOT
• ALLOW ENGINE TO COOL BEFORE INSTALLING
THE SPARK ARRESTER!
• DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTER!
DX450 (RED-D-ARC)
D-6
MAINTENANCE
D-6
GFCI MODULE TESTING AND RESETTING
PROCEDURE
WELDER / GENERATOR
MAINTENANCE
STORAGE: Store in clean, dry protected areas.
CLEANING: Blow out the generator and controls periodically with low pressure air. Do this at least once a
week in particularly dirty areas.
BRUSH REMOVAL AND REPLACEMENT: Itʼs normal for the brushes and slip rings to wear and darken
slightly. Inspect the brushes when a generator overhaul is necessary.
CAUTION
• Do not attempt to polish slip rings while the
engine is running.
WARNING
• Service and Repair should only be performed by
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.
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
load and check it for damage.
• If the equipment has been shut down, it must be
restarted.
• The equipment needs to be operating at high idle
speed and any necessary adjustments made on the
control panel so that the equipment is providing at
least 80 volts to the receptacle input terminals.
• The circuit breaker for this receptacle must not be
tripped. Reset if necessary.
• Push the "Reset" button located on the GFCI module.
This will assure normal GFCI operation.
• Plug a night-light (with an "ON/OFF" switch) or other
product (such as a lamp) into the Duplex receptacle
and turn the product "ON".
• Push the "Test" button located on the GFCI module.
The night-light or other product should go "OFF".
• Push the "Reset" button, again. The light or other
product should go "ON" again.
If the light or other product remains "ON" when the
"Test" button is pushed, the GFCI module is not working properly or has been incorrectly installed (miswired).
If your GFCI module is not working properly, contact a
qualified, certified electrician who can assess the situation, rewire the GFCI module if necessary or replace
the device.
DX450 (RED-D-ARC)
E-1
TROUBLESHOOTING
E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by 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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Authorized Field Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
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.
DX450 (RED-D-ARC)
E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Major Physical or Electrical Damage 1. Contact your local Authorized
is Evident.
Field Service Facility.
Engine will not "crank".
1. Battery is low, Charge Battery.
2. Loose battery cable connections.
Inspect, clean and tighten terminals.
3. Faulty engine starter motor.
Contact authorized local Engine
Service Shop.
Engine will "crank" but not start.
1. Fuel shut off valve on Main Fuel
Filter in the OFF position. Open
valve (vertical) position of handle.
2. Fuel Filters dirty/clogged. Check
and replace main filter element
and/or Inline Fuel Filter.
3. Out of fuel. Fill tank and bleed fuel
system.
4. High coolant temperature or low
oil pressure. (indictor lights lit)
Check oil and coolant levels. Fill if
required. Check for loose or broken fan belt.
5. Faulty fuel shutdown solenoid.
Check that shutdown solenoid is
functioning properly and not binding/ contact authorized engine
service shop.
6. Faulty fuel pump. Check for fuel
flow through filters. Contact authorized local Engine Service Shop.
Engine shuts down shortly after
starting.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Authorized
Field Service Facility.
1. High coolant temperature or low
oil pressure. (indictor light lit)
Change oil and oil filters and fill to
proper level. Check and fill coolant
level. Check for loose or broken
fan belt. Start engine and look for
leaks.
2. Faulty oil pressure switch or other
engine component. Contact
authorized local Engine Service
Shop.
CAUTION
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.
DX450 (RED-D-ARC)
E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Engine shuts down while under a 1. High radiator coolant temperaload.
ture. Reduce load if it is exceeding machine rating. Add coolant
to system if low. Clean fins on
radiator if dirty. Tighten fan belt if
loose. Remove objects blocking
or close to intake openings on
both sides of base and exhaust
end (case back).
Engine runs rough.
1. Dirty fuel or air filters. Inspect and
clean/replace filters as needed.
Inspect and clean/replace filters
as needed.
2. Water in fuel. If water found in
tank. Empty fuel tank and refill
then purge fuel lines.
1. Faulty battery. Replace.
Battery does not stay charged.
Engine alternator trouble light is on 2. Loose connections at battery or
alternator. Clean and tighten conwhile machine is running.
nections.
3. Faulty engine alternator or charger module. Consult authorized
Engine Service Shop.
Engine will not idle down to low
speed.
1. Idler switch in High idle position.
Set switch to Auto.
2. External load on welder or auxiliary power. Remove all external
loads.
3. Faulty Engine Control Unit or
Control P.C. board.
Engine will not go to high idle when
attempting to weld.
1. Poor work lead connection to
work. Make sure work clamp is
tightly connected to clean base
metal.
2. "Contactor" switch is in wrong
position. Set to "Welding On" when
welding without a control cable.
Refer to Operations chapter for proper use of this switch.
3. Faulty Engine Control Unit or
Control P.C. board.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Authorized Field
Service Facility.
CAUTION
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.
DX450 (RED-D-ARC)
E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
Engine will not go to high idle when
using auxiliary power.
1. Auxiliary power load is less than
100 watts. Idler may not respond
with less than a 100 watt load. Set
idler to "High".
2. Faulty sense toroid, Engine
Control Unit or Control P.C.
board.
Engine will not go to high idle
under weld or auxiliary loading.
1. Faulty Engine Control Unit or
Control P.C. board.
Engine does not develop full
power. Engine runs rough.
1. Fuel filter clogged, Replace.
2. Air filter clogged, clean or replace.
3. High idle setting incorrect, check
and adjust if required.
4. Valves out of adjustment.
5. Fuel contaminated with water or
sediment. Check fuel pre-filter
and empty of water, bleed fuel
system. Replace fuel in tank if
needed.
Engine will not go to high idle when
attempting to weld or using auxiliary power. Switching to manual
high idle does not work.
Engine will not shut off.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas
1. Faulty Engine Control Unit or of misadjustment have been
Control P.C. board
checked and the problem persists,
Contact your local Authorized
Field Service Facility.
1. Fuel Shutdown solenoid not functioning properly / linkage binding.
Stop engine by shutting off valve
located on main fuel filter.
Contact authorized local Engine
Service Shop.
Engine does not develop full power. 1. Fuel filter dirty/clogged. Replace.
Low weld and auxiliary output. 2. Air filter dirty/clogged. Replace Air
Engine runs rough.
Filter Element.
3. Fouled fuel injector(s). Contact
authorized Engine Service Shop.
4. Fuel contaminated with water.
Check water separator for water.
Clean and replace as needed.
Replace fuel in tank.
5. Cracked or loose fuel hose.
Replace hose and tighten clamps.
6. Valves out of adjustment. Contact
authorized local Engine Service
Shop.
CAUTION
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.
DX450 (RED-D-ARC)
E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
No welding power output.
1. Poor work lead connection to
work. Make sure work clamp is
tightly connected to clean base
metal.
2. "Weld Terminals" switch in wrong
position. Place switch in "Weld
Terminals On" position when
welding without control cable.
3. Faulty PC board or welder alternator.
Welder has output but no control.
1. Poor remote/control cable connection to 3-pin or 14-pin connector.
Check connections.
2. Faulty remote cable or faulty wire
feeder or wire feeder cable.
Replace if necessary.
3. Faulty control potentiometer or PC
board.
Wire feeder does not work when 1. Wire Feeder Power circuit breaker
open. Check 42V beaker and
control cable is connected to 14 pin
reset if tripped.
connector.
2. Faulty control cable. Repair or
replace cable.
3. Faulty wire feeder. Replace wire
feeder.
1. Open circuit breakers. Reset
No auxiliary power.
breakers. If breakers keep tripping
reduce power draw.
2. GFCI module may have tripped.
Follow “GFCI Module Testing and
Resetting Procedure” in the MAINTENANCE section of this manual.
3. Faulty connections to auxiliary
receptacles. Check connections.
4. Faulty PC board or welder alternator.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Authorized
Field Service Facility.
CAUTION
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.
DX450 (RED-D-ARC)
E-6
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
The welding arc is “cold.” The weld- 1. Make sure the MODE selector
ing arc is not stable or is not satis- switch is in the correct position for
factory. the engine runs normally. the process being used. (For examThe auxiliary power is normal.
ple, CV-WIRE, PIPE, CC-STICK.)
2. Make sure the electrode (wire, gas,
voltage, current etc.) is correct for
the process being used.
3. Check for loose or faulty connections at the weld output terminals
and welding cable connections.
4. The welding cables may be too long
or coiled, causing an excessive
voltage drop.
If all recommended possible areas of
5. Faulty Control Board.
misadjustment have been checked
and the problem persists, Contact
your local Authorized Field
1. Make sure VRD ON/OFF toggle Service Facility.
No output in Pipe Mode.
switch is in the “OFF” position.
2. Poor work lead connection to
work. Make sure work clamp is
tightly connected to clean base
metal.
3. "Weld Terminals" switch in wrong
position. Place switch in "Weld
Terminals On" position when
welding without control cable.
4. Faulty PC board or welder alternator.
VRD Lights donʼt light up.
1. Ensure VRD ON/OFF switch is in
the “ON” position.
2. If light is burned out, replace both
VRD lights.
3. Faulty OCV indicator PC board.
CAUTION
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.
DX450 (RED-D-ARC)
F-1
DIAGRAMS
DX450 (RED-D-ARC)
F-1
F-2
DIAGRAMS
DX450 (RED-D-ARC)
F-2
F-3
DIAGRAMS
DX450 (RED-D-ARC)
F-3
F-4
DIAGRAMS
DX450 (RED-D-ARC)
F-4
F-5
9/03
DIAGRAMS
2
F-5
DX450 (RED-D-ARC)
F-6
DIAGRAMS
DX450 (RED-D-ARC)
F-6
A
B
C
75A
75B
76A
76B
77A
77B
9
206S
204S
2
J6 16
1 SHUNT
8
VRD WELD BOARD
PCB1
10
6
J5
VOLT METER
5
1
1
FERRITE
GND-M
GND-A
M1
1
9
16
6
J1
AMPHENOL,I.D.
J7
CONTROL, MODE SEL.
8
1
B3 CHOKE
B6 CHOKE
B3
B2
13C 13 23 25
23 25
B6
B5
B4
B4-NEG
B5-POS
B7 B8
B2-POS
13
13C
B1
14 14C
B1-NEG
OFF
ON
10
9
1
M3 M5 M9
M2 M4
M6 M10
AMMETER
12
J2
ENGINE,PERIPHERAL
6
J4
AMMETER
5
M1
8
16
J3
CHOPPER, POWER, PWM, THERMAL
FERRITE
298 296A
296
VRD
GROUND STUD IN UPPER CONTROL PANEL
32A
215
216
GND-J
15
13A
M3 M5 M9
M2 M4
M6 M10
VOLTMETER
41A
42A
L1 CHOKE
R4
1
7
200
200N
ALT
222
1GV
13GV
12GV
2GV
16GV
15GV
9GV
R1
CCW
VRD
RED
10
6
18 26
20GV
19GV
18GV
31GV
34GV
28GV
27GV
26GV
5
J61
299 298
208B 206B
297
296A
75
1
VRD
GREEN
296
VIEWED 10K
FROM
BACK
77
76
9 17 25 34
1 10
42A
CB6
10A
6
3
14C
279
10K
VRD DISPLAY
PCB4
4
J60
1
13C
VIEWED
FROM
BACK
278
277
R2
CCW
OUTPUT CONTROL ARC CONTROL
41
LEAD NOT USED
ON THIS MACHINE
41A
42
W6
W6
W1
W1
W1 & W6
STATOR 42V WINDING
A
W5
W5
W4
W4
STATOR
WELD
WINDINGS
W3 W2
W3 W2
W2 & W3
MODE SELECTOR
SWITCH S5
W4 & W5
CV
10
ROTOR
201
BRUSH
240V
3PH
J13
3B
4200MFD
300V
BRUSH
200B
SHOWN IN "ALWAYS ON" POSITION
4
4A
WELDING TERMINAL
CONTROL SWITCH
Y
5G
5M
5U
5L
5K
5J
228 232B 232I
5M 232H
6C
Z
261
4A
6D
6C
4
260
200A
5P
5H
200
6GV
256
234A
236D
236C
232B 232K
W
238B
GND-E
34GV
GND-K
RUN/STOP
SWITCH
232I
26GV
W
LOAD
LINE
6
6A
6A
W
4
5H
W
W
5D
31
5
S
B
238A
238A
5U
13GV
SENSOR
WK
SWITCH
262
27GV
231
D+
1G
L
+
230
28GV
ENGINE BLOCK
2
232H
12V BATTERY
3
1
A.03
G6260
GENERATOR SUPPORT
-
+
FUEL LEVEL
SENSOR
SWITCH
ALTERNATOR
STARTER
SOLENOID
SENSOR
COOLANT TEMPERATURE
SENSOR & SWITCH
G
12GV
231
OIL PRESSURE
SENSOR & SWITCH
17GV
20GV 5P
3
NEUTRAL STUD ON
AUXILIARY POWER
RECEPTACLE PANEL
4
230
7GV
5A
5A
STATOR AUXILIARY WINDINGS
ENGINE SPEED WATER TEMP
SENSOR
SENSOR
238 STARTING
MOTOR
229
5J
232H
241
231A
228
238B
SLIVER
J11
20A
B
START
BUTTON
18GV
B
GFCI
MODULE
W
ACTUATOR
16GV
SHOWN IN
"RUN" POSITION
10A
CB5
15GV
RUN
236B
20A
SILVER
J12
W
IDLER 238C
CONTROL
SWITCH
STOP
232C
W
6E
CB3
GFCI 20A
MODULE
SHOWN IN
"HIGH" POSITION
239
OIL
PRESSURE
236C
257
AUTO
B
LOAD
LINE
GLOW PLUG
BUTTON
GND-D
GLOW
PLUGS
HIGH
5D
1
W
32A
Y GND-C
6E
B
J51
232K 5K
229
4
X
120/240V
FUEL
232F
12 VOLT GROUND STUD
ON UPPER CONTROL PANEL
241 232C 232F
5L 232
3D
J10
3C
6D
20A
3D
CB2
AUXILIARY POWER LEADS PASS THROUGH
TOROID THREE TIMES IN DIRECTION INDICATED
HOUR METER
201A
6A
OIL
COOLANT
PRESSURE TEMPERATURE
2A
2
X
GND-L
4A
3C
6
GROUND STUD ON AUXILIARY
POWER RECEPTACLE PANEL
GND-D
GND-E
5
50A
3 POLE
CB1
3
POSITIVE BRUSH CONNECTED TO
SLIP RING NEAREST TO THE
LAMINATION
201
31
GND-J
GND-K
GND-C
GND-L
ALL CASEFRONT COMPONENTS SHOWN VIEWED FROM REAR
RECTIFIER BRIDGE
ENGINE CONTROL UNIT
7GV
6GV
17GV
3
2
TIG 4
CC
PIPE
GOUGE 1
243 9GV
244
220
218
217
214
CHOPPER
PCB3
B2-POS
B5-POS
B1-NEG
B4-NEG
POS-SHUNT
+
ELECTRICAL SYMBOLS PER E1537
DX450 (RED-D-ARC) WIRING DIAGRAM
WIRING DIAGRAM
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included
with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
FERRITE ON
TWISTED PAIR
4 TURNS
21
77B
76B
75B
4B
2B
GND-A
208B
31
32
41A
42A
208C
3 PIN REMOTE
M6
NOTE:
FERRITE ON
LEADS 75A & 76A
(3 TURNS)
REMOTE
CONTROL
F
G
D
C
B
J
A
I
K
H
E
WIRE FEEDER
VOLTMETER
SWITCH
21
206B
14 PIN REMOTE
GROUND
CONTACTOR
REMOTE
CONTROL
WORK
42VAC
115VAC
WELDING OUTPUT
TERMINAL
BYPASS FILTER
ASSEMBLY
GND-M
GROUNDED BY
MOUNTING
SWITCH CONTACTS
SHOWN IN "+"
POSITION
208A
206A
208A
208
208D
206
M9
M1
M2
M3
M4
M5
206A
+
I
WELDING OUTPUT
TERMINAL
M10
206C
222
206S
M1
-
M6
204S
M3
+
M2
50MV=400AMPS
M10
+
POS-SHUNT
400
218
220
277
M9
M4
M5
214
216
217
76A
400A
400A
250
25
23
260
261
250
244
31GV
405
77
215
400A
14
262
5G
243
232
200N
76
75
279
278
2
77A
4
75A
256
13
257
208C
262A
R3
+
-
-
-
DX450 (RED-D-ARC)
1GV
19GV
-
+
F-7
F-7
24.00
609.6
5.75
146.0
1.27
32.3
N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, COOLANT IN RADIATOR, AND EMPTY FUEL TANK.
39.81
35.94
913.0
27.00
685.8
12.50
317.5
25.82
655.8
20.60
523.3
29.38
746.3
28.95
735.3
37.05
941
60.00
1524.0
55.50
1409.7
N.A.
DX450 (RED-D-ARC)
A.01
46.62
1184.15
DIMENSION PRINT
L13857
2.25
57.2
F-8
F-8
NOTES
DX450 (RED-D-ARC)
NOTES
DX450 (RED-D-ARC)
● Do not touch electrically live parts or
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
● Keep flammable materials away.
● Wear eye, ear and body protection.
● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
fuera del área de trabajo.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
cuerpo.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Mantenha inflamáveis bem guarda-
dos.
● Use proteção para a vista, ouvido e
corpo.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes.
● Use ventilation or exhaust to
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
remove fumes from breathing zone.
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
tien.
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Strom vor Wartungsarbeiten
● No operar con panel abierto o
guardas quitadas.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
● Anlage nie ohne Schutzgehäuse
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
oder Innenschutzverkleidung in
Betrieb setzen!
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
● Mantenha-se afastado das partes
serviço.
● Não toque as partes elétricas nuas.
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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