Lincoln Electric Dual Maverick 200 Operator's Manual
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Lincoln Electric Dual Maverick 200 Operator's Manual

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Operator's Manual
Dual Maverick
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10546
| Issue D ate Nov - 21
© Lincoln Global, Inc. All Rights Reserved.
200/200X
®
For use with machines having Code Numbers:
12765
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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  • Page 1 Operator’s Manual Dual Maverick 200/200X ® For use with machines having Code Numbers: 12765 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2. A Free copy of “Arc Welding Safety” booklet E205 2.a. Electric current owing through any conductor is available from the Lincoln Electric Company, 22801 causes localized Electric and Magnetic Fields (EMF). St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • Page 6 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommen- dations.

  • Page 8: Table Of Contents

    TABLE OF CONTENTS INSTALLATION ...........................SECTION A GRAPHIC SYMBOLS..........................A-1 TECHNICAL SPECIFICATIONS - DUAL MAVERICK® 200/200X (K4382-1) ..........A-2 SAFETY PRECAUTIONS ..........................A-3 VRD (VOLTAGE REDUCTION DEVICE) ....................... A-3 LOCATION AND VENTILATION ........................A-4 STORING ............................A-4 STACKING ............................A-4 ANGLE OF OPERATION ..........................A-4 LIFTING ............................
  • Page 9 SET-UP ............................B-19 MACHINE SELECT ..........................B-23 CROSSLINC: ON/OFF ..........................B-23 SPOOL GUN CALIBRATION........................B-24 ENGINE SERVICE KIT ..........................B-24 PRODUCTIVITY METRICS ........................B-25 ACCESSORIES ..........................SECTION C MAINTENANCE...........................SECTION D SAFETY PRECAUTIONS..........................D-1 ROUTINE AND PERIODIC MAINTENANCE....................D-1 ENGINE MAINTENANCE ........................... D-1 AIR FILTER ............................D-1 FUEL FILTERS ............................

  • Page 10: Installation

    DUAL MAVERICK ® 200/200X INSTALLATION GRAPHIC SYMBOLS The following graphics appear in the Maverick or in the manual. Warning or Caution Hot Surface Earth Ground Instructions Fire or explosion Circuit Breaker Fumes and Gases Battery explosion Welding Amperage Explosion Battery acid Welding Voltage Arc Rays System Factory Reset...

  • Page 11: Technical Specifications - Dual Maverick 200/200X (K4382-1)

    DUAL MAVERICK ® 200/200X INSTALLATION INSTALLATION TECHNICAL SPECIFICATIONS - DUAL MAVERICK 200/200X (K4382-1) ® INPUT - DIESEL ENGINE DISPLACEMENT STARTING MAKE/MODEL DESCRIPTION SPEED (RPM) CU. IN. (LTRS.) SYSTEM CAPACITIES 54.80 (0.898) FUEL: 20 GAL. (75.7 L) 3 CYLINDER HIGH IDLE 3600 12 VDC OIL: .97 GAL.

  • Page 12: Safety Precautions

    DUAL MAVERICK ® 200/200X INSTALLATION SAFETY PRECAUTIONS The machine is shipped with the VRD switch in the “OFF” position. To turn it "ON" or "OFF": Only qualified personnel should install, 1. Switch the High Idle/Run - Stop switch to the Stop position. use, or service this equipment.

  • Page 13: Location And Ventilation

    DUAL MAVERICK ® 200/200X INSTALLATION When the VRD switch is in the "ON" position. Th display will show a green tab with "VOLTS<30". If the VRD switch is in the "ON" STORING position and stud voltage is above 30 volts or while welding, the 1.

  • Page 14: High Altitude Operation

    READ the engine operating and maintenance instructions supplied with this machine. At temperatures above 40°C (104°F), output voltage derating may be necessary. While operating the Dual Maverick 200/200X WARNING continuously (100% Duty Cycle) at an ambient temperature of 40°C, a weld output of 9.2 KW should not be exceeded.

  • Page 15: Fuel - Use Diesel Fuel Only

    DUAL MAVERICK ® 200/200X INSTALLATION FUEL - USE DIESEL FUEL ONLY IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN: Low sulphur or ultra low sulphur fuel in US & Canada. a) Installing new battery. Fill the fuel tank with clean, fresh diesel fuel. The b) Using a booster.

  • Page 16: Case Front Controls

    DUAL MAVERICK ® 200/200X INSTALLATION FIGURE A.3 - CASE FRONT CONTROLS CASE FRONT CONTROLS DOWNHILL PIPE and CC-STICK modes if a remote control is connected to the 6-Pin or 14 Pin Connectors, the output is 1. LCD SCREEN, IP67 RATED OPERATOR A - The LCD screen controlled by the remote and the output control on the displays information about welding mode, output voltage or machine is used to set the maximum current range for the...
  • Page 17 DUAL MAVERICK ® 200/200X INSTALLATION 7. 20 AMP CIRCUIT BREAKER - Protects the 120V, single phase receptacle. 8. 20 AMP CIRCUIT BREAKER - Protects the 120V, single phase receptacle. 9. 50 AMP CIRCUIT BREAKER - Protects the 240V, single phase receptacle.

  • Page 18: Welding Terminals

    DUAL MAVERICK ® 200/200X INSTALLATION WELDING TERMINALS WELDING OUTPUT CABLES From the main screen select MIG / FCAW / TIG / ROOT WAVE With the engine off, connect the electrode and work cables to the welding. Press knob to select screen that shows Weld Output terminals provided.

  • Page 19: Remote Control

    DUAL MAVERICK ® 200/200X INSTALLATION REMOTE CONTROL CABLE INDUCTANCE AND ITS EFFECTS ON WELDING The Dual Maverick ® 200/200X is equipped with a 6-pin and a 14- pin connector. The 6-pin connector is for connecting the K857 or Excessive cable inductance will cause the welding performance to K857-1 Remote Control or for TIG welding, the K870 foot Amptrol degrade.

  • Page 20: Wire Welding Set-Up, Spool Gun

    DUAL MAVERICK ® 200/200X INSTALLATION WIRE WELDING SET-UP, SPOOL GUN FIGURE A.6 Electrode Positive (+) shown K586-1 Deluxe Gas Regulator and hose kit Work cable (part of K2150-1) Work clamp (part of K2150-1) Spool Gun with mechanical gas valve (K3569-2) In the spool gun mode, the weld output is controlled by the trigger spool gun pot being adusted all the way to CCW) the user may of the spool gun.

  • Page 21: Connection Of Wire Feeders With Control Cable (14 Pin

    200/200X center. • Due to the risk of power interruption, do not power life NOTE: The Dual Maverick 200/200X can operate two different support equipment from this machine. wire feeders at the same time. • Unplug accessories and tools before attempting •...

  • Page 22: Connection Of Across The Arc Wire Feeders To The Dual Maverick® 200/200X

    DUAL MAVERICK ® 200/200X INSTALLATION CONNECTION OF ACROSS THE ARC WIRE FEEDERS TO THE DUAL MAVERICK 200/200X ® These connections instructions apply to both the LN-25X Pro, Activ8X and CrossLinc models. • Shut the welder off. • For electrode Positive, connect the electrode cable to the "+" terminal of the welder and work cable to the "-"...
  • Page 23 DO NOT USE THESE DEVICES WITH THIS PRODUCT. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product. A-14...

  • Page 24: Operation

    DUAL MAVERICK 200/200X OPERATION ® OPERATION FOR AUXILIARY POWER SAFETY PRECAUTIONS Start the engine and set the IDLER control switch to the desired Read and understand this entire section before operating mode. Full power is available regardless of the welding operating your Dual Maverick 200/200X.

  • Page 25: Recommended Applications

    200/200X is not recommended for pipe BREAK-IN PERIOD thawing. Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we offer. While it is normal to GENERATOR see a small amount of crankcase oil consumption during initial The Dual Maverick ®...

  • Page 26: Engine Operation

    1. Open the engine service compartment door and check that TABLE B.1 the fuel shutoff valve on the fuel filter separator located on TYPICAL DUAL MAVERICK 200/200X the lift bale is in the open position. FUEL CONSUMPTION 2. Check for proper oil level and coolant level. Close engine service compartment door.

  • Page 27: Welder Operation

    DUAL MAVERICK ® 200/200X OPERATION WELDER OPERATION DOWNHILL PIPE Welding DUTY CYCLE This slope controlled mode is intended for "out-of-position" and "down hill" pipe welding where the operator would like to control Duty Cycle is the percentage of time the load is being applied in a the current level by changing the arc length.
  • Page 28 DUAL MAVERICK ® 200/200X OPERATION Dual Maverick ® 200/200X settings when using the K930-2 TIG TIG Welding Module with an Amptrol or Arc Start Switch: The TOUCH START TIG is for DC TIG (Tungsten Inert Gas) welding. • Set the MODE to the TOUCH START TIG setting. To initiate a weld, the selector knob is used to set to the desired •...

  • Page 29: Paralleling

    DUAL MAVERICK ® 200/200X OPERATION TABLE B.2 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5) 1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel...

  • Page 30: Auxiliary Power Operation

    DUAL MAVERICK ® 200/200X OPERATION AUXILIARY POWER OPERATION Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings, if no welding current is being drawn. For heavy loads set to HIGH IDLE and maximum weld output for maximum starting power.
  • Page 31 DUAL MAVERICK ® 200/200X OPERATION GFCI MODULE WARNING • An electric shock can result in serious injury or death. • Always perform the GFCI test before using the generator. If the GFCI system fails the test, the machine must be repaired by an authorized service center.

  • Page 32: Display Operation

    4. BACK - Goes back to the previous screen 5. SELECTOR KNOB - rotate adjusts values, push confirms the selected value or choice NOTE: When Dual Maverick 200/200X is first started, it will return to the screen that was shown when the machine was turned off.

  • Page 33: Stick Welding

    DUAL MAVERICK ® 200/200X OPERATION STICK WELDING Manual entry operates like a traditional welding machine. Simply set the desired preset amperage or voltage and begin to weld. The “Preset” screen appears when welding is not active. It shows the amount of fuel on the left hand side; the weld mode in the lower left hand corner;...
  • Page 34 DUAL MAVERICK ® 200/200X OPERATION Stick Options All weld modes support using a remote control like K857-1. Plug the remote into the 6 pin connector on the front of the machine. Remote 50-450A Force Press the remote button on the display to toggle between control at the remote and control at the knob on the machine.

  • Page 35: Mig/Fcaw Welding

    DUAL MAVERICK ® 200/200X OPERATION MIG/FCAW WELDING Manual entry operates like a traditional welding machine. Simply set the desired preset amperage or voltage and begin to weld. The “Preset” screen appears when welding is not active. It shows the amount of fuel on the left hand side; the weld mode in the lower left hand corner;...

  • Page 36: Crosslinc

    CrossLinc device’s instructions. Select the desired weld Indicator mode with the Dual Maverick 200/200X. When the weld output is ON the CrossLinc device will automatically link to the Dual Maverick. The CrossLinc icon will appear on the screen to show active communication.

  • Page 37: Spool Gun

    DUAL MAVERICK ® 200/200X OPERATION SPOOL GUN Manual entry operates like a traditional welding machine. Simply set the desired preset amperage or voltage and begin to weld. The “Preset” screen appears when welding is not active. It shows the amount of fuel on the left hand side; the weld mode in the lower left hand corner;...

  • Page 38: Spool Gun Synergic Control Mode

    DUAL MAVERICK ® 200/200X OPERATION SPOOL GUN SYNERGIC CONTROL MODE The spool gun may be either set in “normal” control or “synergic” control. Synergic mode automatically adjusts the voltage when the wire feed speed is changed. Synergic Control Selection Synergic Control Mode Info NOTE: After selecting Synergic Control, Wire Diameter the user is required to select their desired...

  • Page 39: Pulse Mode

    DUAL MAVERICK ® 200/200X OPERATION PULSE MODE Activating Spool Gun Pulse toggles both the voltage and wire feed speed between a peak and a low level. It is useful for lower heat input welding and creating the appearance of “stacked dimes” in aluminum.

  • Page 40: Engine Status Screen

    DUAL MAVERICK ® 200/200X OPERATION ENGINE STATUS SCREEN The Engine Status screen provides information about the engine servicing and operation. Five parts of the engine are monitored for service: Oil, Coolant, Air Filter, Fan Belt and Fuel Filter. To view detailed information about an item, rotate the knob until the item is highlighted in red.

  • Page 41: Engine Info

    DUAL MAVERICK ® 200/200X OPERATION ENGINE INFO While in Dual Mode, the user can bring up the Engine Information screen by pressing the “?” button while on the landing page in any welding mode. In order to exit the Engine Information screen, press the back button or the encoder knob.

  • Page 42: Set-Up

    DUAL MAVERICK ® 200/200X OPERATION • PRODUCTIVITY METRICS - Provides useful information and statistics regarding how the machine is being used. SET-UP The set-up allows for customization of the Maverick. Options available in the Set-up menu are: • AUTO-START: NO LOAD PERIOD - When AUTO-START is enabled, the NO LOAD PERIOD is the period of time the machine can be running with no auxiliary or weld load before it automatically shuts down.
  • Page 43 DUAL MAVERICK ® 200/200X OPERATION Auto-Start: No Load Period Display Brightness Display Brightness Auto-Start: No Load Period Period (10-120 min): 120 Brightness: 100 Press knob to select Press knob to select Autostart time Restore Factory Settings Tap Start Active Period Tap Start Active Period Factory Reset Period (15-120 min): 30...
  • Page 44 DUAL MAVERICK ® 200/200X OPERATION DO NOT FORGET THE PIN! The PIN may only be reset by a Lincoln Authorized Service Shop. Rotate the knob to adjust the value of the PIN. Press the knob to advance to the next number.
  • Page 45 DUAL MAVERICK ® 200/200X OPERATION Variable Speed Setup Diagnostic Info Diagnostic Information Variable Speed On/Off Engine Part #: Kubota D902 T4i Feature: ON Weld PCB HW: G9328-1 Weld PCB SW: D-17 Machine K#: K4382-1 Code #: 12765 Display #: S32886 Press knob ECG Fault Press knob...

  • Page 46: Machine Select

    DUAL MAVERICK ® 200/200X OPERATION MACHINE SELECT CROSSLINC: ON/OFF CrossLnc: On/Off Display Brightness FEATURE: ON Diagnostic Information New PCB Calibration Variable Speed On/Off Restore Factory SettingsMachine Machine Select Press knob to select Enter the correct K# and Code # for the welder the PCB is being installed on.

  • Page 47: Spool Gun Calibration

    DUAL MAVERICK ® 200/200X OPERATION SPOOL GUN CALIBRATION ENGINE SERVICE KIT Engine Service Kit This screen will remain for approximately 5 seconds as the wire feeds. During this process, the wire coming out of the spool gun will grow longer as a visual representative. B-24...

  • Page 48: Productivity Metrics

    DUAL MAVERICK ® 200/200X OPERATION Productivity Metrics PRODUCTIVITY METRICS The Productivity Metrics screen provides information and statistics on how the machine is being utilized. Five statistics of the machine are monitored: Arc Hours, Auxiliary Hours, Utilization Percent, Standby Hours and Fuel Saved w/ Auto- Start.

  • Page 49: Accessories

    DUAL MAVERICK ® 200/200X ACCESSORIES ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES K2636-1 Medium Trailer K2639-1 Fender Kit K2640-1 Cable Rack K2641-2 Four Wheel Trailer K857 Remote Control K857-1 Remote Control K2613-5A1 Ln-25 PRO with K126 PRO Gun K126-12 K126 PRO Gun KP1696-068 Drive Roll Kit K12038-2 Invertec PC610 Plasma K12048-1 Tomahawk 1025 Plasma...

  • Page 50: Maintenance

    DUAL MAVERICK ® 200/200X MAINTENANCE MAINTENANCE TABLE D.1 SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete.
  • Page 51 DUAL MAVERICK ® 200/200X MAINTENANCE Service Instructions Service Instructions Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Inspect the New Filter for Damage Inspect the New Filter for Damage Remove the Filter Remove the Filter Inspect the new filter carefully, paying attention to Unfasten or unlatch the the inside of the open end, which is the service cover.

  • Page 52: Fuel Filters

    DUAL MAVERICK ® 200/200X MAINTENANCE FUEL FILTERS NAMEPLATES / WARNING DECALS MAINTENANCE Whenever routine maintenance is performed on this machine - or at least yearly - inspect all nameplates and labels for legibility. WARNING Replace those which are no longer clear. Refer to the parts list for the replacement item number.

  • Page 53: Battery Handling

    DUAL MAVERICK ® 200/200X MAINTENANCE BATTERY HANDLING PREVENTING BATTERY DISCHARGE Turn the RUN/STOP switch to stop when engine is not running. WARNING GASES FROM BATTERY can explode. PREVENTING BATTERY BUCKLING Keep sparks, flame and cigarettes away from Tighten nuts on battery clamp until snug. battery.

  • Page 54: Troubleshooting

    TROUBLESHOOTING How to Use Troubleshooting Guide WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 55 DUAL MAVERICK ® 200/200X TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION AUXILIARY OUTPUT No auxiliary power. 1. Check that the circuit breakers did not trip. If all recommended possible areas of 2.
  • Page 56 DUAL MAVERICK ® 200/200X TROUBLESHOOTING PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION WELDING No weld output. 1. Verify the weld output is ON. A green icon with “Output ON” appears in the upper right corner of screen whenever weld output is ON. 2.

  • Page 57: Engine Fault Flash Codes On Ecg

    DUAL MAVERICK ® 200/200X TROUBLESHOOTING ENGINE FAULT FLASH CODES ON ECG J1939-73 WILL ENGINE FAULT CORRECTIVE ACTION SHUTDOWN? Turn off the machine. Disconnect the negative on the battery. Check Oil pressure error lead 234, connected to the oil pressure switch, located on the left side of the engine below the alternator.
  • Page 58 DUAL MAVERICK 200/200X WIRING DIAGRAM ® G9328-1...
  • Page 59 DUAL MAVERICK ® 200/200X DIMENSION PRINT...
  • Page 60 This page intentionally left blank...
  • Page 61 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish AVISO DE No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 62 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish AVISO DE Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.

  • Page 63: Customer Assistance Policy

    We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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