Lincoln Electric MAGNUM IM647-A User's Manual
Contents
1. 228 Hc AIX ZL 3l sU e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo e B HAUSHERMRELTTF amp UV f8 RIR E J J 42 5 SIRI BR 19 50 SlSst As due Lily gadag cl yal aa J 3 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 HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un venti2. Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 2 ARC RAYS burn 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 standards 4 b Use suitable clothing made from durable flame resistant 5 f LINCOLN 8 material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non fla
3. MAGNETIC FIELDS 359 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety ihe ad minimize exposure to EMF fields from the welding circuit 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 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 1 f Do not put your hands near the engine fan D Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your
4. A 3 Connection to Fast Mate Compatible A 3 Installation of the K489 7 and K573 1 Fast Mate Adapter Kits A 3 Operation EE Section B Electrodes and 1 42 909 B 1 Making a Weld B 1 Avoiding Wire Feeding Problems B 1 Maintenance 222 2 9 dme Re Ax xu RE ERR lk all kok adek meee Section D Removal Installation and Trimming Instructions for Magnum Liners D 1 Gun Tubes 22465 D 2 Gun Cables inn eee benne l ah e ER om e Re W od does D 2 Cable 0 1 D 2 Cable Repair Gun End D 2 Cable Repair Wire Feeder End D 5 Thread Sizes for Magnum 400 Consumables D 7 Troubleshooting 4 2 Section E PartS L S s i sn kal n se deme anan gene ki e waw ka a a eae P202 M and P202 Y MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN m INSTALLATION GENERAL DESCRIPTION WARNING Do not touch electrically live parts such as output terminals or internal wiring The Magnum 400 DP Dual Procedure FM gun and cable assemblies have been designed to meet NEMA specifica
5. A WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or inter nal wiring Insulate yourself from the work and ground Always wear dry insulating gloves Only qualified personnel should install use or service this equipment The K575 K1723 Magnum FM guns are factory installed with a Fast Mate European style wire feed er connector for all in one GMAW feeder connection A single connector attaches welding current wire liner shielding gas and trigger control leads to the feeder An optional K489 7 Magnum Fast Mate Adapter is available for use with Lincoln 10 Series wire feeders An optional K573 1 Magnum Fast Mate Adapter is available for use with the LN 9 equipped with a dual procedure kit NOTE These guns are shipped with a factory installed liner To change the liner in these models or to install special liners for use with aluminum wire see the section on liner removal instructions in the MAINTENANCE section CONTACT TIP AND GAS NOZZLE INSTALLATION Choose the correct size contact tip for the elec trode being used wire size is stenciled on the side of the contact tip and screw it snugly into the gas diffuser 2 Be sure the nozzle insulator is fully screwed onto the gun tube and does not block the gas holes in the diffuser NOTE Insulator is not required when using the optional fixed gas nozzles O Slip the appropriate gas
6. du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POU R contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER u TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier LINCOLN Relier
7. 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 Turn off input power using the disconnect Switch at the fuse box before working on the equi
8. 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 A Cutting ANSI Standard 249 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 AN FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 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 vaporiz ing 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 ELECTRIC AND
9. and or dirty Worn or improper size cable liner Partially flashed melted or improper size contact tip Contact tip worn or incorrect size Worn or undersize ground cables or poor ground connections Loose electrode connections a Keep as straight as possible Inspect cable and replace if nec essary Remove wire from gun and cable feed in new wire Note any obstruction Replace liner if necessary Be sure the wire diameter being used is stamped on drive rolls and guide tubes Replace if nec essary Clean liner or replace Replace or reverse split drive roll type Replace the electrode if it is rusty Replace cable liner Replace the contact tip Replace contact tip Inspect repair or replace as necessary Be sure the following connections are tight electrode cable to wire feeder and power source work cable to power source and work gun cable to wire feeder contact block gun nozzle to body and contact tip to nozzle CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE
10. and trim the exposed copper and inner tube back 50 inch Strip all four control leads 125 inch back and crimp a new 58053 169 terminal to each lead Apply heat shrink tubing or electrical tape to terminals to prevent electrical contact with other terminals See Figure E 2 COPPER STRANDING r 1 65 42mm m 2 15 55mm E 2 For K1723 models Cut off damaged section of cable and strip off the outer jacket 1 65 inches back Be careful not to cut the insulation on the control wires while stripping jack et Strip all four control leads 25 inch back and crimp a new 519492 2 terminal to both the black lead and the white lead Remove the leads connected to the red and blue control leads from the cutoff cable and solder these leads to the blue and red leads of the newly trimmed cable Insulate connections with heat shrink tubing or tape See Figure E 3 1 4 6 4mm SKIN 4 CONTROL LEADS CONTROL LEADS INN ER TUBE 41 9mm SKIN Figure E 3 MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN D 4 MAINTENANCE D 4 g Check that the cable boot and both halves of the strain relief are on the cable Slip the connector nut over the copper strands with the thread end out Orient gun tube connector so machined flat is on the same side of the cable as the red and white control leads Assemble gun tube connector to cable by forcing the steel tube of the connector into the i
11. 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 Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying 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 refer to www lincolnelectric com for any updated information 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 Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on
12. la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place v v for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such
13. machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs
14. this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment Installation 2 2 2222 Rm mmm R RR rmm ELTE E Rm mm RR Eqs Section A General Descriptlon 1 A 1 A 2 Contact and Gas Nozzle Installation
15. COURSE OF ACTION Poor arc striking with sticking or a Improper procedures or tech a See Gas Metal Arc Welding blast offs weld porosity narrow niques Guide GS100 and ropy looking bead or electrode stubbing into plate while welding b Improper gas shielding b Clean gas cone Make certain that gas diffuser is not restricted Make certain that gas cylinder is not empty or turned off Make certain gas solenoid valve is operating and gas flow rate is proper Remove gun liner and check rub ber seal for any sign of deterio ration or damage Be sure set Screw in brass connector is in place and tightened against the liner bushing Tip seizes in diffuser a Tip overheating due to prolonged a Do not exceed current and duty or excessive high current and or cycle rating of gun duty cycle welding A light application of high temperature antiseize lubricant such as Lincoln E2067 Graphite Grease may be applied to tip threads CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 NOTES MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 5 5 MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 E 5 NOTES MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 NO
16. GUNS LINCOLN 8 D 6 K ASS S SES Ke SES oS VS SSS IW COLLAR NUT DETAIL TOP VIEW 4 10 04mm MAINTENANCE CENTRAL ADAPTER ASSEMBLY ERMINAL LEAD ASSEMBLY STRAIN RELIEF CONNECTOR NUT D 6 CABLE HANDLE BOOT NUT CABLE BOOT STRAIN RELIEF HOUSING INCOMING CONNECTOR ASSEMBLY LEAD CONNECTIONS MIDDLE PIN BLACK MIDDLE PIN WHITE OUTSIDE PIN BLUE OUTSIDE PIN RED Figure E 7 NOTE For best results insert a 219 240 5 6 6 1 mm diameter rod through the connector and into core of cable approximately 5 00 127 mm when pushing the connector tube into the cable core tube To tighten hold the connector in place while turning the nut then remove the rod from the core This procedure assures the inner core does not kink while assembling or tightening Solder the control leads to the leads extending from the connector assembly Insulate each solder connection using either heat shrink tubing or elec trical tape The black and white leads should be soldered to the two middle connector leads and the red and blue leads should be soldered to the two outside leads Tape the leads in place in the necked down area of the connector Keeping the leads as close to the connector and nut as possi ble tape the insulated soldered connections to the cable in the area between the cable jacket and connector nut This must be done n
17. IN RELIEF SWITCH STRAIN RELIEF HOUSING CABLE BOOT Ti 12 GUN HOUSING CABLE ASSEMBLY SWITCH WIRES TO RED LEAD TO BLUE LEAD GUN TUBE TRIGGER ASSEMBLY TRIGGER WIRES Figure E 6 j Position the cable boot and strain relief on the cable so it fits in cable handle cavity and lock the strain relief in place by pushing the two halves together k Assemble cable in left side of gun handle Assemble trigger into the proper handle cavity For K1723 also assemble the rocker switch in the f groves provided in the handle Assemble right side of gun handle and tighten the screws that hold the handle together See Figures E 5 and E 6 WIRE FEEDER END REPAIR K575 AND K1723 See Figure E 7 g a Remove the cable liner per previous instructions b Loosen the boot nut Slide the boot nut and boot toward the middle of the cable past the damaged section h c Rotate the collar nut until the screw anchoring the cable handle is visible Remove the screw and save it d Slide the cable handle and collar nut toward the middle of the cable past the damaged section Remove the strain relief housing from the strain relief and slide both toward the middle of the cable past the damaged section On older cables remove and save the cable clamp that was used in place of the strain relief NOTE If sliding the cable handle becomes difficult try rotating it 180 Remove inco
18. MAGNUM 400 DUAL PROCEDURE M647 A FM GUN amp CABLE ASSEMBLIES MES Models K575 K1723 RETURN TO MAIN MENU Safety Depends on You Lincoln arc welding and cutting equipment 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful CU OPERATOR S MANUAL 150 9001 XS BRE 6 e RA Designed and Manufactured Under a Quality Program Certified by NCOLN e Copyright Lincoln Global Inc 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 l SAFETY i AA WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND
19. R Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG BIR Chinese Q amp all dll ad e bie jiya d aah Jil 4 Ye cial us J sde Gils 13 ai UA Jaki y e e Gul Al LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR 15MM PBN A A OHERBELK BA 7EM U CT uv TRHOKRASME WO C F SEU BA EE WR II XE A A D S WK JE fit B BA LR FA ER EA RIRH E dE 8 Sp PJ B A BS 55 EJ ECKE 0 HYE Gelli Sigi EPEA BHC Saal ua lal 448 dl Gala Si Jud al gll cael Gail gal lala ag ls LINCOLN B 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
20. TES MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG SIR Chinese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 0 105 electrodos bajo carga con la piel o ropa moja a Aislese del trabajo de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pe a e terra e X rh Zitt J Z 5 Pr fk 4648 SE ATUSRELTFEL 40 0 3 RAT CA e i B oem mtis eri SHS RE SH sE Sup OAR e 24 31 5 Ss nA Jui ull gw ui dai Quali ye J el alga AA Aal P deux ule die Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos RAPTUEDORTO BEER EVA e 18 59 HAW dh 588 T fE3B PH
21. best results when welding mild and alloy steels it is recommended that L 50 or Super Arc L 56 Lincoln solid wire electrodes be used for the FMW process and Lincoln Outershield cored electrodes for the gas shielded FCAW process MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 2 INSTALLATION A 2 MAGNUM 400 FM Dual Procedure 400 AMPS at 60 DUTY CYCLE WITH CO2 GAS 400 AMPS at 50 DUTY CYCLE WITH MIXED GAS Gun Contact Tips Gas Product Cable Wire Size Standard Diffuser Gun Tube Number Length m in mm Duty Assembly 60 035 0 9 14 35 045 1 2 45 KP24A 62 44 3545 15 1928 1 055 1 3 14 52 575 2 1 16 1 6 116 KP24A 62 KP44 116 15 1928 1 1 16 1 6 KP14 116 K575 3 5 64 2 0 564 KP24A 62 KP44 564 15 KP1928 1 035 0 9 KP14 35 K575 4 045 1 2 45 KP24A 62 KP44 3545 25 1928 1 052 1 3 14 52 575 5 1 16 1 6 116 KP24A 62 KP44 116 25 1928 1 1 16 1 6 KP14 116 K575 6 5 64 2 0 564 KP24A 62 KP44 564 25 1928 1 035 0 9 14 35 1723 1 045 1 2 45 KP24A 62 KP44 3545 15 1928 1 035 0 9 KP14 35 K1723 2 045 1 2 45 KP24A 62 KP44 3545 15 1928 1 035 0 9 KP14 35 K1723 3 045 1 2 45 KP24A 62 KP44 3545 25 1928 1 MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 A 3 INSTALLATION A 3 Read this entire installation section before you start installation SAFETY PRECAUTIONS
22. 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 95 LINCOLN SAFETY 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
23. e arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 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 Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b AUG 06 SAFETY WELDING and CUTTING SPARKS 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 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 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 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 Do no
24. eatly and kept as low as possible or the cable handle will not slide over this area Position the strain relief as shown in Figure E 7 Lock the strain relief in place by sliding the strain relief housing over the strain relief On older cables install the cable clamp on the cable jacket within 1 8 3 2mm from the end of the jacket and tight en k Slide the collar nut and cable handle over the con l nection and into place Anchor the cable handle with the screw removed in step c Slide the boot and boot nut into place and tighten NOTE If the cable handle becomes difficult to slide over the connection try rotating it Install and trim the liner per previous instructions MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 D 7 MAINTENANCE D 7 THREAD SIZES FOR MAGNUM 400 CONSUMABLES f 9 16 18 3 8 24 8 327 1 4 28 MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simpl
25. er using the Allen wrench provided A CAUTION This screw should only be gently tightened Overtightening will split or collapse the liner and cause poor wire feeding h Replace the nozzle insulator and gas nozzle LINER TRIM LENGTH 9 16 14 3 mm GAS DIFFUSER 7 NOZZLE NAT GAS NOZZLE Figure E 1 INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM LINERS FEEDING ALUMINUM WIRE 1958 series liners 1 Lay the gun out straight on a flat surface and remove the gas nozzle and nozzle insulator A Remove the liner nut from the connector end of the cable B Back out the set screw in the diffuser for guns that have a set screw in the diffuser 2 Remove ihe liner and insert a new untrimmed liner into the connector end of the cable Check that the coils of the spring liner can be seen through the holes in the gas diffuser 3 Mark the liner 3 16 5 mm from the end of the liner guide Pull the liner partially out and cut off the liner at the mark using a sharp knife 4 Screw the brass liner nipple onto the liner and fully seat the liner busing into the liner guide A Replace the liner nut and finger tighten 5 For guns with a diffuser set screw tighten the set screw in the side of the gas diffuser against the cable liner using the Allen wrench provided MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 D 2 MAINTENANCE D 2 A CAUTION This screw should only be gently tightened Overtightening w
26. g gloves 9 FUMES AND GASES be danger AR ous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone E WELDING SPARKS cause fire or explosion Keep flammable material away 2 4 ARC RAYS can burn Z Y Wear eye ear and body protection Only qualified personnel should operate this equipment a Check that the welding power source is on and that the shielding gas supply is set for the proper flow rate b For the Magnum 400 with dual procedure switch set the rocker switch to the desired procedure c Position electrode over joint End of the electrode should be slightly off the work d Lower welding helmet close gun trigger and begin welding Hold the gun so the contact tip to work dis tance gives the correct electrical stickout as required for the procedure being used e To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out Follow wire feeder instruction manual if using a trigger interlock circuit f When using a K575 Magnum 400 Dual Procedure gun and cable the trigger operates as follows Pulling the trigger in part of the way will engage the first procedure set at the feeder Pulling the trigger the rest of the way will engage the second procedure If the optional interlocking trigger is installed With the trigger pulled in all the way the trigger can be slid forward i
27. gets severely damaged it may be cut shorter and repaired by the user GUN TUBE END CABLE REPAIR FOR K575 AND K1723 Requires 4 S8053 169 Terminals for K575 or 2 519492 2 terminals for K1723 a Remove the cable liner per previous instructions b Remove the gun tube per previous instructions c Remove the 6 screws from the gun handle sepa rate the two halves and remove the cable from the handle along with the trigger assembly for the K575 guns Before removing the trigger assembly carefully note trigger lead wiring as it will be impor tant to reconnect these properly For the K1723 also remove the rocker switch MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN COPPER STRANDING CABLE MAINTENANCE e 3 2mm SKIN 4 CONTROL LEADS CONTROL LEAD P INNER TUBE Figure d Remove gun tube connector from cable by unscrewing connector nut from gun tube connec tor If the cable inner tube is difficult to remove from the connector assembly carefully slit it length wise with a knife up to the brass connector 2 Uncouple the strain relief by pushing its outer housing toward the middle of the cable Move the strain relief and the cable boot toward the middle of the cable past the damaged section For K575 models Cut off damaged section of cable and strip off the outer jacket 2 15 inches back Be careful not to cut the insulation on the control wires while stripping jacket Pull control leads back
28. ill split or collapse the liner and cause poor wire feeding 6 Replace the nozzle insulator and gas nozzle GUN TUBES AND NOZZLES a Replace worn contact tips as required b Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required c To remove gun tube from gun loosen socket head clamping screw in handle with 3 16 4 8 mm Allen wrench Remove gas nozzle and nozzle insulator and also loosen small set screw in the diffuser using 5 64 2 0 mm Allen wrench NOTE Small set screw in the diffuser must be loosened otherwise liner could be damaged when attempting to remove gun tube Pull gun tube out from gun handle To reinstall insert the gun tube push in as far as possible and retighten screws GUN CABLES CABLE CLEANING Clean cable liner after using approximately 300 pounds 136 kg of electrode Remove the cable from the wire feeder and lay it out straight on the floor Remove the contact tip from the gun Using an air hose and only partial pressure gently blow out the cable liner from the gas diffuser end A CAUTION Excessive pressure at the start may cause the dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out CABLE REPAIR FOR K575 amp K1723 MODELS Magnum 400 Dual Procedure guns and cables fea ture the use of repairable cable connectors If the cable ever
29. irement Liners are shipped with the jacket of the liner extended the proper amount a Lay the gun and cable straight on a flat surface b Remove and save the gas nozzle and nozzle insu lator Make sure that the set screw in the gas dif fuser is backed out so as not to damage the liner Use the 5 64 2 0 mm Allen wrench provided Remove and save the gas diffuser from the end of the gun tube assembly Remove and save the liner nut from connector end c Remove old liner and insert a new untrimmed liner into the connector end of the cable Be sure the liner bushing is stenciled appropriately for the wire size being used NOTE For KP42 44N and KP45N liner series Before fully seating the liner bushing it will be necessary to trim the liner s inner tube flush with the liner bushing using a sharp blade After trimming remove any burrs from inner tube and insure that the opening is fully open d Before installing the gas diffuser fully seat the liner bushing in the connector end and install the liner nut and finger tighten e Be sure the cable is straight and then trim the liner to the length shown in Figure E 1 a gauge is included on the wrench provided with the connection kit for gauging the cut off length Remove any burrs from the end of the liner f Screw the gas diffuser onto the end of the gun tube and tighten with the wrench provided 0 Tighten the set screw in the side of the gas diffuser against the cable lin
30. is also prop erly sized 49 Align and fully engage the brass connector end of the gun cable into the mating connector on the out going side of the feeder wire drive Secure the cable connection by snugging the Fast Mate con nector collar nut INSTALLATION OF THE K489 7 AND ifa FAST MATE ADAPTER For K489 7 refer to M17806 installation instructions that are sent with the kit For K573 1 refer to 519389 installation instructions that are sent with the kit MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN P B 1 OPERATION B 1 ELECTRODES AND EQUIPMENT The Magnum 400 Dual Procedure guns and cables have been designed for use with Lincoln L 50 and Super Arc L 56 solid steel wire electrodes for the GMAW process and Lincoln Outershield7 cored elec trodes for the gas shielded FCAW process Refer to the appropriate Lincoln Process and Procedure Guidelines for the electrode used for information on recommended electrical and visible stickouts MAKING A WELD WARNING Do not attempt to use this equipment until you have thoroughly read all operating and mainte nance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists e ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or inter nal wiring Insulate yourself from the work and ground Always wear dry insulatin
31. lateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaga Use ventilac o e exhaust o para remover fumo da zona respirat ria LEET KKK ORAPHBICTHRRLTFSU OR REE 7E 9f 0R E k ih Ek HER SRE e ss SH7IAE goals 87I 8 amp Salat Ash 224121 5357 E ASA Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico e toque as partes el tricas nuas e XZTTLZA amp U ACRUD POR EF BRAY FE D 492CF v AHS AFEHHJAI2 Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas NRWPAN ERVALKEE TIRHIMRIFE L EUTTF EL CHRRTMMAARS MR AA 4E endo 2 dele ZZ
32. ming connector from cable by unscrewing connector nut from incoming connec tor If the cable inner tube is difficult to remove from the connector assembly carefully slit it length wise with a knife up to the brass connector Cut the cable control wires where they meet the cable jacket or else unsolder the connection where they connect to the terminal lead assembly If you cut the wires strip the cut end 1 4 inch 6 4 mm from the end Cut off the damaged section of cable and strip off the outer jacket as shown in Figure E 3 Be careful not to cut the insulation on the control wires while stripping jacket Strip all four control leads 1 4 inch 9 5 mm from the end Check that the cable boot boot nut cable handle collar nut strain relief and strain relief housing are on the cable Slip the connector nut over the cop per strands with the threaded end out Orient the connector assembly so the red and white control leads will have the straightest possible routings to the sockets on the back side of the connector Assemble the incoming connector to the cable by forcing the steel tube of the connector into the inside diameter of the cable inner tube until the copper strands are butted against the incoming connector shoulder Keeping the copper strands against the shoulder pull the connector nut over the copper strands engage the incoming connec tor threads and tighten in place Refer to Figure E 4 MAGNUM 400 FM DUAL PROCEDURE
33. mmable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 9 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 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 spe cific 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 limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of th
34. nozzle onto the nozzle insulator Adjustable gas nozzles are available with a 62 15 9 mm or 50 12 7 mm I D and in both standard flush and recessed design for the 300 and 400 amp guns The proper nozzle should be selected based on the welding application Different length fixed nozzles are also available to fit 300 and 400 amp gun tubes to allow either spray or short circuiting transfer welding Choose the gas nozzle as appropriate for the GMAW process to be used Typically the contact tip end should be flush to 12 3 mm extended for the short circuiting transfer process and 12 3 mm recessed for spray transfer and for the Outershield FCAW process CONNECTION TO FAST MATE COMPATIBLE FEEDERS FM model gun cable assemblies will connect easily to any Lincoln feeder equipped with a European style gun connector and which has dual procedure capabili ties An optional K489 7 Magnum Fast Mate Adapter is available for use with Lincoln 10 Series wire feed ers An optional K573 1 Magnum Fast Mate Adapter is available for use with the LN 9 equipped with a dual procedure kit The guns may also connect to any non Lincoln wire feeder that has a 4 pin Euro connector that is compatible with the Lincoln 4 pin Fast Mate connector 1 Check that the feeder outgoing guide as well as the drive roll are appropriate for the electrode size being used When using a Fast Mate Adapter Kit be certain that the adapter guide tube
35. nside diameter of the cable inner tube until the copper strands are butted against the gun tube CABLE INNER TUBE CONN CABLE ECTOR TUBE CONNECTOR NUT connector shoulder Keeping the copper strands against the shoulder pull the connector nut over the copper strands engage the gun tube connector threads and tighten in place See Figure 4 GUN TUBE CONNECTOR OR INCOMING CONNECTOR Figure E 4 NOTE For best results insert a 219 240 5 6 6 1mm diameter rod through the connector and into core of cable approximately 5 00 127 mm when pushing the connector tube into the cable core tube To tighten hold the connector in place while turning the nut then remove the rod from the core This pro cedure assures the inner core does not kink while assembling or tightening STRAIN RELIEF HOUSING CABLE BOOT h For K575 Pull the cut off lead terminals off the trigger assem bly and connect the replacement control lead ter minals See Figure E 5 CABLE ASSEMBLY GUN HOUSING GUN TUBE Figure E 5 MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 D 5 MAINTENANCE D 5 For K1723 Connect the black lead and the white lead to the gun trigger Connect the other leads to the rocker switch leads See Figure E 6 STRA
36. nto the interlock position To release interlock squeeze trigger and pull back g When using the K1723 Magnum 400 with dual pro cedure switch the trigger only starts and stops the welding The procedure is changed by actuating the rocker switch that is built into the top of the gun AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun handling procedures a Do not kink or pull cable around sharp corners b Keep the electrode cable as straight as possible when welding or loading electrode through cable c Avoid wrapping excess cable around handle or front of wire feeder especially on longer 20 and 25 ft 6 1 and 7 6 m length guns d Do not allow dolly wheels or trucks to run over cables e Keep cable clean by following maintenance instruc tions f Use only clean rust free electrode The Lincoln elec trodes have proper surface lubrication g Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN 8 1 D 1 REMOVAL INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM LINERS FEEDING STEEL WIRE KP44 and KP44N liner series NOTE The variation in cable lengths prevents the interchangeability of liners Once a liner has been cut for a particular gun it should not be installed in anoth er gun unless it can meet the liner cut off length requ
37. pment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations iv SAFETY iv PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et a la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux
38. t 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c 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
39. tion EW3 for welding with steel electrode using the GMAW gas metal arc welding and gas shielded FCAW flux cored arc welding processes Magnum 400 DP guns and cables are specifically designed for use with wire feeders with dual proce dure capabilities The K575 gun is equipped with a two position trigger Pulling the trigger in part of the way will engage the first procedure set at the feeder Pulling the trigger the rest of the way will engage the second procedure An interlocking trigger is available as a parts order The K1723 Magnum 400 DP Dual Proecdure gun and cables are also designed for use with wire feeders with dual procedure capabilities The guns are equipped with a rocker switch that is used to select one of two welding procedures The Fast Mate connector on the 400 Dual Procedure guns has four pins two for the trigger circuit and two for the dual procedure circuit and requires a dual procedure adapter or a wire feeder that is compatible with the 4 control pin connector The K575 and K 1723 have a 4 pin Fast Mate connector on the feeder end of the gun The four pin connector will interface with the four pin receptacle on the K489 7 or K573 1 Adapter The Magnum 400 DP gun and cable assemblies are fully compatible for use with comparable Tweco gun size tips diffusers gas nozzles and cable liners The Magnum FM gun family offers an expanding line of quality long life expendable replacement parts and accessories For
40. y 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 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibili ties that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact you local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact you local Lincoln 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 Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MAGNUM 400 FM DUAL PROCEDURE GUNS LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Drive rolls turn but wire will not feed or wire feeding is rough Variable or hunting arc a Gun cable kinked and or twisted b Wire jammed in gun and cable Incorrect drive rolls and guide tubes Gun cable liner dirty Worn drive rolls Electrode rusty
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