Lincoln Electric K1802-1 User's Manual
Contents
1. MAGNUM 300 amp 400 LINCOLN MAGNUM 300 amp 400 LINCOLN E Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese TE 2 Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pieces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung e isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da e isole se da peca e terra OBEHOM ST NEMCE F PMN fe Ft TRA ELE MLMPT APSSAMMEBS 1 tii CHEMIE ul ous il gt jay Quali Y sound ay 9 il plat ALLY US deua V au Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos e 9203 v 6008 COTRIETEX UC IR EEA BET TER BI e 228 Ac2. 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 liners KP1950 7 KP1950 8 KP 1955 1 and KP1955 2 Before fully seating the liner bushing it will be nec essary 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 For all K466 connector kits except K466 3 and K466 4 tighten the set screw in the cable connec tor or For K466 3 and K466 4 screw in the connector cap provided in the kit until it seats on the face of the bushing Then insert the appropriate piece of liner material into the connector cap and tighten the set screw Three pieces of liner material are included in these connector kits to help guide the electrode through the connector cap The piece with the smallest inner diameter is designed for 045 1 2 mm maximum diameter electrode The next largest diameter is for 1 16 1 6 mm maximum diameter electrode The largest diameter piece of liner mate rial is for 5 64 2 0 mm maximum diameter elec trode Be sure the cable is straight and then trim the liner to the length shown in Figure 1 a gauge is includ ed on the wrench provided with the connection kit for gauging the cut off length on 300 and 400 amp gun tubes Remove any burrs from the end of the liner GUN TU
3. HU AL Ek ORBE EL e SESS ET BS EIOSUR XR SERT LE Ko gaol wel 4 OPAT Z cils Mdb gall lja Jedd y sl AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO TE Chinese Korean LEIA E COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR EFBRULETF AU TL CRHORSMEK HS TFE V HAMA MERE JE HE GE B SM ALL SUAS SIAD Zla RAS SHSM BFC O aad gi zil y J al gll g la sig aat LINCOLN e World s Leader in Welding and Cutting Products e 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
4. 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 amp Cutting ANSI Standard 249 1 from the American Welding Society 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 N FOR ENGINE 1h To avoid scalding do not remove the al ae radiator pressure cap when the engine is powered equipment NU Hi P 1 Turn the engine off before troubleshooting and maintenance 3 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 3 0 ELECTRIC AND MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld S may be dangerous ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF field
5. 5 1 16 T e 4B1 KP2024 1 KP1930 2 1933 2 1928 2 466 2 May also be used with other gases reduced rating up to 30 Feeder Kits installed on the gun at the factory MAGNUM 300 amp 400 LINCOLN 1 INSTALLATION 1 Read this entire installation section before you start installation SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring e Insulate yourself from the work and ground e Always wear dry insulating gloves Only qualified personnel should install use or service this equipment CONNECTOR KIT INSTALLATION TO GUN CABLE Most models of Magnum 300 and Magnum 400 gun cables except K1802 1 and K2286 1 are shipped as generic assemblies and must be assembled with a K466 connector kit See REPLACEMENT PARTS sec tion Chart E for proper kit The Magnum 400 Gun K2286 1 has a factory installed feeder end connector K466 1 amp 8 INSTALLATION For Lincoln Feeders a Remove brass cable connector and insulation tube see Figure 1 from the K466 1 kit Slide the insula tion tube onto the connector from the threaded end and screw it onto the feeder end of the gun cable Tighten the connection with the wrench provided b Remove the molded gas plug fitting on the side of the feeder end handle and replace it with the barbed brass fitting provided in the kit The included wrench will fit b
6. MAGNUM 300 amp 400 LINCOLN 4 GENERAL DESCRIPTION A 4 MAGNUM 400 SHORT NECK 400 amperes at reduced duty cycle 40 WITH CO GAS Contact Tips Gas Product Cable Wire Size Standard Diffuser Cable Gun Tube Number Length m in mm Duty Assembly Liner 60 K541 1 10 ft 035 0 9 KP2020 1B1 3 0 045 1 2 2B1 KP2024 1 1932 1 2023 1 1933 1 1928 2 541 2 12 ft 035 KP2020 1B1 3 6 045 2B1 KP2024 1 1932 1 2023 1 1933 1 1928 2 541 3 15 ft 035 0 KP2020 1B1 4 5 045 2B1 KP2024 1 KP1932 1 KP2023 1 KP1933 1 KP1928 2 May also be used with other gases at reduced rating up to 3096 MAGNUM 400 SHORT NECK COMPLETE ASSEMBLY WITH FEEDER CONNECTOR 400 amperes 40 WITH GAS Contact Tips Gas Product Cable Wire Size Heavy Diffuser Cable Gun Tube Feeder Number Length m in mm Duty Assembly Liner 60 Type K541 21 15 ft 035 A KP2021 1B1 Miller 4 5 045 2B1 KP2024 1 KP1930 2 KP1933 1 KP1928 2 K466 3 K541 22 151 052 1 3 KP2021 3B1 Miller 4 5 1 16 T D 4B1 KP2024 1 KP1930 2 KP1933 2 KP1928 2 K466 3 K541 23 15 ft 035 s KP2021 1B1 Lincoln 4 5 045 2B1 KP2024 1 KP1930 2 KP1933 1 KP1928 2 K466 1 541 24 15 11 052 KP2021 3B1 Lincoln 4 5 1 16 He 4B1 KP2024 1 KP1930 2 KP1933 2 KP1928 2 K466 8 K541 25 15 ft 035 0 KP2021 1B1 Tweco 4 5 045 2B1 KP2024 1 KP1930 2 KP1933 1 KP1928 2 K466 2 K541 26 15 ft 052 1 3 KP2021 3B1 Tweco 4
7. Magnum Connector Kit they can be used with any Lincoln LN 7 or LN 25 semiautomatic wire feeder The K466 1 should also be used with the LN 8 or LN 9 when feed ing 052 and smaller electrodes An optional K481 Magnum Fast Connect Gas Tube Kit is available to provide tool less gas tube connection to Lincoln wire feeders Non GMA model wire feeders require an optional gas solenoid valve The 300 and 400 guns can also be used with any wire feeder equipped with a Tweco 1 2 3 350 or 4 wire feed adapter kit by using the K466 2 Magnum Connector Kit With the K466 3 or K466 4 Magnum connector kits it is possible to connect Magnum 300 and 400 guns directly to a variety of Miller and Hobart wire feeders respectively The K466 5 connector kit allows connection of Magnum 300 and 400 guns to an L Tec feeder con nector assembly L Tec feeders require a feeder con nector assembly similar to a Tweco adapter in order to connect to a gun and cable The K466 5 contains a brass connector to permit Magnum guns to be con nected to this feeder connector assembly The K466 6 connector kit allows connection of Magnum 300 and 400 guns to a Lincoln Wirematic The K466 7 connector kit allows connection of Magnum 300 and 400 guns to Hobart Series 2000 Wire Feeders The K466 8 connector kit allows connection of Magnum 300 and 400 guns to LN8 LN9 when 1 16 and larger electrode is used The K466 9 connector kit allows connection of K4
8. Service Facility for technical troubleshooting assistance before you proceed 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS POSSIBLE CAUSE REMEDY PROBLEMS Poor arc striking with sticking or a Improper procedures or a See Gas Metal Arc Welding blast offs weld porosity narrow techniques Guide GS100 and ropy looking bead or electrode stubbing into plate while welding b Improper gas shielding 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 Hemove gun liner and check rubber seal for any sign of deterioration or damage Be sure set screw in brass connector is in place and tightened against the liner bushing Tip seizes in diffuser a 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 are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MAGNUM 300 amp 400 LINCOLN
9. connector end of the gun and cable into the connector receptacle on the outgoing side of the feeder wire drive Tighten the hand screw to clamp down on the connector c Insert the control cable plug from the feeder trigger circuit into the mating socket on the gun cable con nector handle d Slide the free end of the flexible hose mounted to the gun in K466 4 Installation Section onto the gas fitting on the Hobart wire feeder Move the corre sponding tubing clamp down near the end of the tube to assure a good gas seal CONNECTION TO L TEC ADAPTED FEEDERS Gun and cable assemblies which were assembled with a K466 5 connection kit will connect easily to an L Tec feeder equipped with an L Tec feeder connector assembly L Tec feeders require this connector assem bly similar to a Tweco adapter to connect with a gun and cable a Check that the adapter and feeder outgoing guide as well as the drive roll are appropriate for the elec trode size being used b Fully push the brass connector end of the gun cable into the brass adapter on the outgoing side of the feeder wire drive Secure the cable using the hand screw set screw or pin MAGNUM 300 amp 400 LINCOLN B 5 INSTALLATION c Insert the control cable plug from the feeder trigger circuit into the mating socket on the gun cable con nector handle For machines with a twist lock trig ger lead receptacle if the L Tec gun control cable does not easily connect with
10. ft 052 A KP2020 3B1 6 1 1 16 4B1 KP2024 1 KP1932 1 KP2023 1 KP1933 2 KP1928 2 K471 14 25 ft 052 V KP2020 3B1 7 6 1 16 P 4B1 KP2024 1 KP1932 1 KP2023 1 KP1933 2 KP1928 2 K471 5 10 ft 1 16 1 6 KP2020 4B 1 3 0 5 64 2 n 5B1 KP2024 1 KP1932 1 KP2023 1 KP1933 3 KP1928 2 K471 9 12 ft 1 16 1 KP2020 4B1 3 6 5 64 2 5B1 KP2024 1 KP2023 1 KP2023 1 KP 1933 3 1928 2 471 6 15 ft 1 16 1 6 KP2020 4B1 4 5 5 64 2 e 5B1 KP2024 1 KP2023 1 KP2023 1 KP1933 3 KP1928 2 K471 12 20 ft 1 16 1 6 KP2020 4B1 6 1 5 64 2 0 5B1 KP2024 1 KP1932 1 KP2023 1 KP1933 3 KP1928 2 K471 15 25 ft 1 16 1 6 KP2020 4B1 7 6 5 64 o 5B1 KP2024 1 KP1932 1 KP2023 1 KP1933 3 KP1928 2 May also be used with other gases at reduced rating up to 50 AK2286 1 Magnum 400 Gun has a factory installed feeder end connector MAGNUM 400 COMPLETE ASSEMBLY WITH TWECO CONNECTOR 400 amperes AT 60 DUTY CYCLE WITI CYCLE WITH CO GAS Contact Tips Gas Product Cable Wire Size Standard Diffuser Cable Gun Tube Number Length m in mm Duty Assembly Liner 60 K471 21 15 ft 035 d KP2020 1B1 4 5 045 2B1 KP2024 1 KP1932 1 KP2023 1 KP1933 1 KP1928 2 471 22 15 ft 052 V KP2020 3B1 4 5 1 16 4B1 KP2024 1 KP1932 1 2023 1 1933 2 1928 2 K471 23 15 ft 1 16 1 6 KP2020 4B1 4 5 5 64 2 25 5B1 KP2024 1 KP 1932 1 2023 1 KP1933 3 KP1928 2 May also be used with other gases at reduced rating up to 50
11. leads to the terminal strip For a machine that requires a twist lock gun control cable connection continue to use the L Tec gun control cable provid ed with the L Tec wire feeder connector assembly Connect the twist lock plug to the proper receptacle on the machine K466 6 K466 7 K466 9 and K466 10 Installation Wirematic Hobart Series 2000 Feeders SP100T Type and Lincoln 10 Series Feeders a Remove brass cable connector see Figure 1 from the connector kit and screw it onto the feeder end of the gun cable Tighten the connection with the wrench provided Check that the molded gas plug fitting is sealing the gas fitting hole in the side of the feeder end handle Attach the gun control cable provided to the trigger connector on the front of the wire feeder LINER INSTALLATION AND TRIMMING INSTRUCTIONS Installation of KP1932 KP1936 and KP1955 series liners a b BRASS CABLE CONNECTOR Lay the gun and cable straight on a flat surface Make sure that the set screw in the connector end is backed out so as not to damage liner or liner FEEDER END CABLE HANDLE INSULATION TUBE K466 1 ONLY MOLDED GAS PLUG SET SCREW LINER ASSEMBLY LINER BUSHING TO BE SEATED TIGHT AGAINST BRASS CABLE CONNECTOR Figure 1 GUN HANDLE CLAMPING SCREW INSTALLATION B 2 bushing Remove and save the gas nozzle nozzle insulator and gas diffuser from the end of the gun tube assembly
12. soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 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 pan talons sans revers et chaussures montantes LINCOLN geri Relier 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 Mar 93 V V for selecting QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have i
13. the socket the gun control cable that came with the K466 5 kit can be used To do this cut off the gun control leads as close to the forked terminals as possible and skin back the leads 7 16 11 mm Remove the twist lock plug from the L Tec control cable and connect it to the K466 5 cable Make sure the outer jacket of the connector is caught within the plug s strain relief CONNECTION TO LINCOLN WIREMATIC HOBART SERIES 2000 FEEDERS OR SP100T TYPE FEEDERS Gun cable asssemblies which were assembled with a K466 6 K466 7 or K466 9 Connection Kit will connect easily to a feeder a Check that the adapter and feeder outgoing guide as well as the drive roll are appropriate for the elec trode size being used b Fully push the brass connector end of the gun cable into the outgoing side of the feeder wire drive Secure the cable using the hand screw on the wire feeder c Insert the control cable plug from the feeder trigger Circuit into the mating socket on the gun cable con nector handle CONNECTION TO LINCOLN 10 SERIES FEEDERS Gun cable assemblies which were assembled with a K466 10 Connection Kit or K471 21 thru 23 gun and cable assemblies will connect easily to a 10 Series feeder a Check that the K1500 2 gun adapter is in place on the wire feeder Check that the feeder guide tubes as well as the drive roll s are appropriate for the electrode size being used b Fully push the brass connector end of the gu
14. used provided the two colors used are the same at both ends The extra lead is a spare that can be used if one of the other leads breaks Check that the cable boot and both halves of the strain relief are on the cable Slip the connector nut CABLE INNER TUBE CONNECTOR TUBE 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 inside diameter of the cable inner tube until the copper strands are butted against the gun tube connector shoulder Keeping the copper strands against the shoulder pull the connector nut over the copper strands engage the gun tube connec tor threads and tighten in place Refer to Figure 3 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 ensures the inner core does not kink while assembling or tightening COPPER STRANDS CABLE Figure 3 4 CONNECTOR NUT GUN TUBE CONNECTOR OR INCOMING CONNECTOR ON OV eee MAGNUM 300 8 400 LINCOLN D 3 Pull the cut off lead terminals off the trigger assem bly and connect the re
15. 32 1 KP2023 1 1933 3 1928 2 470 9 12 ft 1 16 1 6 KP2020 4B1 3 6 5 64 2 0 5B1 KP2024 1 1932 1 2023 1 1933 3 1928 2 1 16 1 6 KP2020 4B1 5 64 2 0 5B1 KP2024 1 KP1932 1 KP2023 1 KP1933 3 KP1928 2 May also be used with other gases at reduced rating up to 5096 AK1802 1 Magnum 300 Gun has a factory installed feeder end connector MAGNUM 300 amp 400 LINCOLN GENERAL DESCRIPTION A 3 MAGNUM 400 400 amperes AT 60 DUTY CYCLE WITH CO GAS Contact Tips Gas Product Cable Wire Size Standard Diffuser Cable Gun Tube Number Length m in mm Duty Assembly Liner 60 K471 1 10 ft 035 0 9 KP2020 1B1 3 0 045 1 2 2B1 KP2024 1 KP1932 1 KP2023 1 KP1933 1 KP1928 2 K471 7 12 ft 035 0 9 KP2020 1B1 3 6 045 1 2 2B1 KP2024 1 KP1932 1 KP2023 1 KP1933 1 KP1928 2 K471 2 15 ft 035 D KP2020 1B1 K2286 1 4 5 045 2B1 KP2024 1 KP 1932 1 KP2023 1 KP 1933 1 KP1928 2 K471 10 20 ft 035 0 9 KP2020 1B1 6 1 045 2 2B1 KP2024 1 KP1932 1 KP2023 1 KP1933 1 KP1928 2 K471 13 25 ft 035 M sy KP2020 1B1 7 6 045 2B1 KP2024 1 KP1932 1 KP2023 1 KP1933 1 KP1928 2 K471 3 10 ft 052 KP2020 3B1 3 0 1 16 S 4B1 KP2024 1 KP1932 1 KP2023 1 KP1933 2 KP1928 2 K471 8 12 ft 052 A KP2020 3B1 3 6 1 16 4B1 KP2024 1 KP1932 1 KP2023 1 KP1933 2 KP1928 2 471 4 15 ft 052 3 KP2020 3B1 4 5 1 16 d 4B1 KP2024 1 KP1932 1 KP2023 1 KP1933 2 KP1928 2 K471 11 20
16. 97 to SP100T and related wire feeders The K466 10 connector kit allows connection of Magnum 300 and 400 guns to a 10 Series wire feeder For best results when welding mild and alloy steels it is recommended that L 50 or L 56 Lincoln solid wire electrodes be used for the GMAW process and OS70 or OS71 Lincoln Outershield cored electrodes for the gas shielded FCAW process WARNING e Do not touch electrically live parts such as output terminals or inter nal wiring MAGNUM 300 8 400 LINCOLN 2 GENERAL DESCRIPTION A 2 MAGNUM 300 300 amperes AT 60 DUTY CYCLE WITH CO GAS Contact Tips Gas Product Cable Wire Size Standard Diffuser Cable Gun Tube Number Length m in mm Duty Assembly Liner 60 K470 1 10 ft 035 0 9 KP2020 1B1 3 0 045 1 2 2B1 KP2024 1 KP1932 1 KP2023 1 KP1933 1 KP1928 2 K470 7 12 ft 035 0 9 KP2020 1B1 3 0 045 1 2 2B1 KP2024 1 KP1932 1 KP2023 1 KP1933 1 KP1928 2 K470 2 15 ft 035 0 9 KP2020 1B1 K1802 14 4 5 045 1 2 2B1 KP2024 1 KP1932 1 KP2023 1 1933 1 1928 2 470 3 10 ft 052 1 3 KP2020 3B1 3 0 1 16 1 6 4B1 KP2024 1 1932 1 2023 1 1933 2 1928 2 470 8 12 ft 052 1 3 KP2020 3B1 3 6 1 16 1 6 4B1 KP2024 1 KP1932 1 KP2023 1 KP1933 2 KP1928 2 K470 4 15 ft 052 1 3 KP2020 3B1 4 5 1 16 1 6 4B1 KP2024 1 KP1932 1 KP2023 1 KP1933 2 KP1928 2 K470 5 10 ft 1 16 1 6 KP2020 4B1 3 0 5 64 2 0 5B1 KP2024 1 KP19
17. AA nig Sa AL a gti Wear eye ear and body protection Prot jase los ojos los 0140 y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo e H BRUSH RBRELTE SU OMR HRANA A oz H 201 555372 sli due Lully Guides Cl gal diea 9 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 UNFALLVERH TUNGSVORSCHRIFTEN 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 piracion Mantenga la cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te a cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de
18. BE 4 9 16 14 3 mm LINER TRIM LENGTH SET SCREW GAS DIFFUSER NOZZLE INSULATOR GAS NOZZLE MAGNUM 300 amp 400 LINCOLN 3 INSTALLATION B 3 CAUTION f Screw the gas diffuser onto the end of the gun tube and tighten with the wrench provided g Tighten the set screw in the side of the gas diffuser against the cable liner using the Allen wrench pro vided 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 INSTALLATION OF M18732 SERIES LINERS FOR FEEDING ALUMINUM ELECTRODE 1 Lay the gun out straight on a flat surface and remove the gas nozzle A For all K466 except K466 3 and K466 4 connec tions back out the set screw in the connector end with a 5 64 2 0 mm Allen wrench B For all K466 3 and K466 4 connections Remove the connector cap C Back out the set screw in the diffuser for guns that have a set screw in the diffuser 2 Remove the 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 A For all K466 3 and K466 4 connections If the liner is going to be replaced with a different size liner loosen the set screw on the connector cap and replace the liner material with the correct size 3 Mark the liner 3 16 5 mm from
19. L 4 ARC RAYS can burn N e 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 1 set for the proper flow rate b Position electrode over joint End of the electrode should be slightly off the work c Lower welding helmet close gun trigger and begin welding Hold the gun so the contact tip to work distance gives the correct electrical stickout as required for the procedure being used d 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 e If the optional interlocking trigger is installed With the trigger pulled in all the way the trigger can be slid forward into the interlock position release the interlock squeeze the trigger and pull back 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 mm length guns d Do not allow dolly wheels or trucks to run over cables e Keep cable clean by following maintenance instructi
20. MAGNUM 300 and 400 IM381 D GMA GUN 4 CABLE ASSEMBLIES 7 Models K470 K1802 1 K471 K2286 1 K541 K574 is now located in IM646 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 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 EEE OPERATOR S MANUAL to ISO 9001 Requirements CERTIFICATE NUMBER 30273 LI NCOLN Copyright 2005 Lincoln Global Inc e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY WARNING 1 CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY
21. able or hunting arc PROBLEMS Gun cable kinked and or twisted Wire jammed in gun and cable Incorrect drive rolls and guide tubes Gun cable liner dirty Worn drive rolls Electrode rusty 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 work cables or poor ground connections Loose electrode connections MAGNUM 300 amp 400 LINCOLN a Keep as straight as possible Inspect cable and replace if necessary 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 necessary 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 are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field
22. eeders ss B 5 ODETAMOM Mee Section C Electrodes and Equipment 2 C 1 rE REA ES E E E mana C 1 Avoiding Wire Feeding Problems ss C 1 E Section Removal Installation and Trimming Instructions for Magnum Liners D 1 G n TUDES NAS 1 C10 gig O E a ana 1 CADIS ea ee ROSE O r D 1 Cable Repair K470 K471 8 K541 Models D 1 G n Tupe End NER TNT D 1 Wire Feeder End Repair sccccecicoesicvctacoetecantaconsuneaiuncicestecandtcusdiavadewectadselasedthioeleneaiienboanes D 3 Thread Sizes for 300 and 400 Amp D 5 eee Section Pars asl lcqe e P202 C MAGNUM 300 amp 400 LINCOLN vi A 1 GENERAL DESCRIPTION A 1 GENERAL DESCRIPTION The Magnum 300 amp and 400 amp GMA gun and cable assemblies have been designed to meet NEMA specification EW3 for welding with steel electrode using the GMAW gas metal arc welding and gas shielded FCAW flux cored arc welding processes Most models of Magnum 300 and 400 guns are not factory equipped with a feeder end connector except K1802 1 and K2286 1 they have a factory installed feeder end connector With the K466 1
23. 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 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 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment 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 95 iv SAFETY iv PRECAUTIONS DE SURETE Pour votre propre protection lire 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 UArc 1 Protegez vous contre la secousse lectrique a Les circuits a lectrode et la pi ce sont sous tension guand la machine souder est en marche Eviter toujo
24. fore 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 circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode 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 Cylinders should be located e Away from areas where they may be struck or subjected to physical damage eA safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode
25. h is explained below A 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 damage to this equipment Vi TABLE OF CONTENTS Page General Reg ge Section A Iucicupl ge Section B Connector Kit Installation to Gun Cable 4 B 1 1 5 1 KADES ici cde Omm B 1 K466 4 Installation ee TE 1 Sr SA 2 K466 6 7 9 amp 10 Installation e 2 ASS OO eo MAAE NE NE B 2 Contact Tip and Gas Nozzle Installation B 3 Connection to Feeder aaa B 3 Connection to Lincoln Feeders annee essence B 3 Connection to Tweco Adapted Feeders 3 Connection to Miller Feeders 22 2 2 B 3 Connection to Hobart Feeders 4 Connection to L Tec Adapted Feeders nenne B 4 Connection to Lincoln Wirematic Hobart Series 2000 or SP100T Feeders B 4 Connection to 10 Series F
26. he work cable should also be on your right side AX 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 d 5 Do not work next to welding power source turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN gud 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 6 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 e AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electr
27. llation and trimming instructions for Magnum liners see LINER INSTALLATION in INSTALLATION section 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 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 ALL K470 K471 amp K541 MODELS The Magnum 300 and Magnum 400 guns feature the use of repairable cable connectors If the cable ever gets seve
28. n bringing this product to vou Please Examine Carton and Eguipment 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 Whenever you request replacement parts or information on 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 e 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 e 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 eac
29. n cable into the gun adapter on the outgoing side of the feeder wire drive and secure the cable using the hand screw c Insert the control cable plug from the feeder trigger circuit into the mating socket on the gun cable con nector handle MAGNUM 300 amp 400 LINCOLN 1 OPERATION C 1 ELECTRODES AND EQUIPMENT The Magnum 300 and Magnum 400 guns and cables have been designed for use with Lincoln L 50 and L 56 solid steel wire electrodes for the GMAW process and Lincoln Outershield cored electrodes for the gas shielded FCAW process Refer to the appro priate Lincoln Process and Procedure Guidelines for the electrode used for information on recommended electrical and visible stickouts MAKING A WELD A 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 ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or internal wiring e Insulate yourself from the work and ground e Always wear dry insulating gloves 23 FUMES AND GASES can be dangerous e Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion e Keep flammable material away Z
30. n the front of the Miller feeder K466 4 INSTALLATION For Hobart Feeders a Remove brass cable connector see Figure 1 from the K466 4 kit and screw it onto the feeder end of the gun cable Tighten the connection with the wrench provided b Remove the molded gas plug fitting on the side of the feeder end handle and replace it with the barbed brass fitting provided in the kit The included wrench will fit both the gas plug and barbed fitting c Attach the phone plug connector of the gun control cable provided to the trigger connector on the front of the Hobart feeder d Place one tubing clamp onto each end of the flexi ble tubing provided approximately 2 51 mm in from each end Slide one end of the tubing onto the barbed connector on the feeder end cable handle step b and move the clamp down near the end of the tube to assure a good gas seal K466 5 INSTALLATION For L Tec Feeders a Remove brass cable connector see Figure 1 from the K466 5 kit and screw it onto the feeder end of the gun cable Tighten the connection with the wrench provided b Check that the molded gas plug fitting is sealing the gas fitting hole in the side of the feeder end handle MAGNUM 300 amp 400 LINCOLN 2 For L Tec machines that require trigger lead con nections to be made at a terminal strip located with in the machine L Tec 225 a gun control cable with forked terminals is provided Connect the terminat ed
31. nals NOTE The cable contains three control leads Any two control leads can be used provided the two colors used are the same at both ends The extra lead is a spare that can be used if one of the other leads breaks a Remove the cable liner per Removal Installation and Trimming Instruction b Remove the feeder end connector molded gas plug or barbed fitting cable handle nut plastic GUN HOUSING STRAIN RELIEF CABLE ASSEMBLY CABLE BOOT GUN TUBE CONTROL WIRES TRIGGER ASSEMBLY Figure 4 MAGNUM 300 amp 400 LINCOLN D 4 MAINTENANCE D 4 CONNECTOR COVER CABLE BOOT CABLE p V AV M M os de Be s W CABLE HANDLE STRAIN RELIEF HOUSING STRAIN RELIEF pa 468 119 mm GAS PLUG PRESS HERE TO OR FITTING REMOVE THE CABLE FEEDER END REMOVE THE A KA Z S SSSS AN dc iN Aa eee lt A s d NN NV s Us Ei m kee lx CABLE HANDLE NUT 43 11 INCOMING Figure 5 f Check that the cable boot and cable handle are on the cable Slip the connector nut over the copper strands with the threaded end out Assemble incoming connector to 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 c
32. nd 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 1 mm extended for the short circuiting transfer process and 12 3 1 mm recessed for spray transfer For the Outershield FCAW process 1 8 3 mm recess is recommended MAGNUM 300 amp 400 LINCOLN 4 INSTALLATION B 4 CONNECTION TO FEEDER CONNECTION TO LINCOLN FEEDERS Gun cable assemblies which were assembled with a K466 1 or 8 Connection Kit will connect easily to any Lincoln LN 7 LN 8 LN 9 SP 200 or LN 25 feeder a Check that the drive roll s and feeder guide tubes are appropriate for the electrode size being used b Fully push the brass connector end of the gun cable into the conductor block on the outgoing side of the feeder wire drive Secure the cable using the hand screw or set screw in the conductor block c Insert the control cable plug from the feeder trigger circuit into the mating socket on the feeder end cable handle See K466 1 Installation Section d Slide the free end of the flexible hose onto the barbed gas fitting on the front of the Lincoln feeder See K466 1 or 8 Installation Section Move the corresponding tubing clamp down near the end of the tube to assure a good gas seal CONNECTION TO ADAPTED FEEDERS Gun cable assemblies which were assembled with a K466 2 Connec
33. ode 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 LINCOLN amp Also see item 1 b ARC RAYS can burn 4 Use a shield with the proper filter and cover 2 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 787 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 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
34. onnector threads and tight en in place Refer to Figure 3 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 ensures the inner core does not kink while assembling or tightening Position the plastic strain relief such that the tapered end is 4 68 119 mm from the incoming connector see Figure 5 Lock into place with steel housing Plastic strain relief may overhang cable jacket a maximum of 43 11 mm g Position cable boot and cable handle on cable and assemble replacement control wire terminals in place on the cable handle Insert connector cover in place Install tailpiece and fasten to cable handle with cable handle nut Refer to Figure 5 h Replace the molded gas plug or barbed fitting and feeder end connector Install and trim liner per Liner Installation Section MAGNUM 300 amp 400 LINCOLN 0 5 MAINTENANCE D 5 THREAD SIZES FOR MAGNUM 300 8 400 CONSUMABLES 97 16 18 3 8 24 1 4 28 MAGNUM 300 amp 400 LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS POSSIBLE CAUSE REMEDY Drive rolls turn but wire will not feed or wire feeding is rough Vari
35. ons f Use only clean rust free electrode The Lincoln electrodes 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 300 amp 400 LINCOLN D 1 MAINTENANCE D 1 REMOVAL INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM LINERS 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 requirement Liners are shipped with the jacket of the liner extended the proper amount a Remove the gas nozzle and nozzle insulator Loosen the set screw located in the side of the dif fuser with 5 64 2 0 mm Allen wrench provided with the gun or connector kit b Remove the gas diffuser from gun c Lay gun and cable out straight on a flat surface For all K466 except K466 3 and K466 4 Connections Loosen set screw located in the brass cable con nector at the wire feeder end of the cable using the same 5 64 2 0 mm Allen wrench Pull liner out of cable REFER TO FIGURE 1 IN INSTALLATION FOR EACH lt OR gt For K466 3 and K466 4 CONNECTIONS Remove the connector cap with the wrench provid ed Pull liner out of cable If the liner is going to be replaced with a different size liner loosen set screw on the connector cap and remove piece of liner material d For insta
36. oth the gas plug and barbed fitting c Attach the round connector of the gun control cable provided to the trigger connector on the front of the Lincoln feeder NOTE Both the plug and socket are keyed and must be properly oriented d Place one tubing clamp onto each end of the flexi ble tubing provided approximately 2 51 mm in from each end Slide one end of the tubing onto the barbed connector on the feeder end cable handle step b and move the clamp down near the end of the tube to ensure a good gas seal NOTE An optional K481 Magnum Fast Connect Gas Tube Kit is available to provide tool less gas tube con nection to Lincoln wire feeders Install per the instruc tions sent with the kit K466 2 INSTALLATION For Tweco Adapted Feeders a Remove brass cable connector see Figure 1 from the K466 2 kit and screw it onto the feeder end of the gun cable Tighten the connection with the wrench provided b Check that the molded gas plug fitting is sealing the gas fitting hole in the side of the feeder end handle K466 3 INSTALLATION For Miller Feeders a Remove brass cable connector see Figure 1 from the K466 3 kit and screw it onto the feeder end of the gun cable Tighten the connection with the wrench provided b Check that the molded gas plug fitting is sealing the gas fitting hole in the side of the feeder end handle c Attach the round connector of the gun control cable provided to the trigger connector o
37. placement control lead ter minals Position the cable boot and strain relief on the cable so it fits in cable handle cavity and lock the MAINTENANCE D 3 tailpiece and connector cover see Figure 5 NOTE In order to remove the cable handle nut the tail of the connector cover must be depressed and the cable handle nut rotated 1 4 turn counterclock wise as viewed from the feeder end strain relief in place by pushing the two halves together c Remove incoming 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 lengthwise with a knife up to the brass connector k Assemble cable in left side of gun handle Assemble trigger into the proper handle cavity Assemble right side of gun handle and tighten the three screws that hold the handle together Refer to Figure 4 d Move the cable boot and cable handle toward the middle of the cable past the damaged section Install gun tube per Gun Tubes and Nozzles Section e Cut off the damaged section of cable and strip off the outer jacket as shown in Figure 2 Be careful not to cut the insulation on the control wires while stripping jacket Strip the red and white control leads 1 4 inch 6 4 mm from the end and crimp a new S19492 1 terminal to each lead m Install and trim liner per Liner Installation Section WIRE FEEDER END REPAIR Requires 2 19492 1 Termi
38. rely damaged it may be cut shorter and repaired by the user Repair cables as follows GUN TUBE END REPAIR Requires 2 19492 2 Terminals a Remove the cable liner per Removal Installation and Trimming Instructions b Remove the gun tube per Gun Tubes and Nozzles Section c Remove three 6 screws from the gun handle sep arate the two halves and remove the cable from the handle along with the trigger assembly d Remove gun tube connector from cable by unscrewing connector nut from gun tube connec tor If the cable inner tube 1 difficult to remove from the connector assembly carefully slit it lengthwise with a knife up to the brass connector MAGNUM 300 amp 400 LINCOLN D 2 MAINTENANCE D 2 CABLE eo CONTROL LEAD INNER TUBE COPPER STRANDING CONTROL LEAD 1 65 se 9 mm SKIN s Figure 2 e Uncouple the strain relief by pushing its outer over the copper strands with the thread end out 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 Cut off the damaged section of cable and strip off the outer jacket as shown in Figure 2 Be careful not to cut the insulation on the control wires while stripping jacket Strip the red and white control leads 1 4 inch 6 4 mm from the end and crimp a new S19492 2 terminal to each lead NOTE The cable contains three control leads Any two control leads can be
39. s are available from your welding distributor or from the manufacturer Mar 95 SAFETY 77 WELDING SPARKS can gt 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 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 249 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 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 Vent hollow castings or containers be
40. s around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts l l Exposure to EMF fields in welding may have other health when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to 1 In some cases it may be necessary to remove safety ooi nej 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 2 d 1 Route the electrode and work cables together Secure Always use the greatest care when working near moving them with tape when possible parts 2 4 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or 2 d 3 Do not place your body between the electrode and idler by pushing on the throttle control rods work cables If the electrode cable is on your right while the engine is running side t
41. spatter or metal 2 FUMES AND GASES can be dangerous 5 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 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 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 form
42. the end of the liner guide or connector 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 or the con nector A For connector kits except K466 3 and K466 4 tighten the set screw in the cable connector B For K466 3 and K466 4 screw in the connector Cap 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 This screw should only be gently tightened Overtightening will split or collapse the liner and cause poor wire feeding 6 Replace the nozzle insulator and gas nozzle CONTACT TIP AND GAS NOZZLE INSTALLATION a Choose the correct size contact tip for the electrode being used wire size is stenciled on the side of the contact tip and screw it snugly into the gas diffuser b 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 c Slip the appropriate gas 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 The proper nozzle should be selected based on the welding application Different length fixed nozzles are also available to fit 300 a
43. tion Kit will connect easily to any prop erly adapted feeder a Check that the adapter and feeder outgoing guide as well as the drive roll are appropriate for the elec trode size being used b Fully push the brass connector end of the gun cable into the brass adapter on the outgoing side of the feeder wire drive Secure the cable using the hand screw or set screw in the adapter c Insert the control cable plug from the feeder trigger circuit into the mating socket on the gun cable con nector handle CONNECTION TO MILLER FEEDERS Gun and cable assemblies which were assembled with a K466 3 Connector Kit will connect easily to a variety of popular Miller wire feeders a Check that the gun liner connector cap liner drive rolls and guide tubes are appropriate for the elec trode size being used b Fully push the brass connector end of the gun and cable into the connector receptacle on the outgoing side of the feeder wire drive Tighten the hand screw to clamp down on the connector c Insert the control cable plug from the feeder trigger circuit into the mating socket on the gun cable con nector handle CONNECTION TO HOBART FEEDERS Gun and cable assemblies which were assembled with a K466 4 Connector Kit will connect easily to a variety of Hobart wire feeders a Check that the gun liner connector cap liner drive rolls and guide tubes are appropriate for the elec trode size being used b Fully push the brass
44. travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaga Use ventila o e exhaust o para remover fumo da zona respirat ria ORAV HELCTIHELTFEL e 7 5f UR aK BE SEER e 42274 SAE 21942 TE 242 AS Sele laa ge sul e gaal bi Jqa iggi aft ge call 9 Turn power off before servicing Desconectar el cable de ali mentacion de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig nen Maschine anhalten e N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas O 77 gt gt TRS Us e HEA ME Alina s l J gil jest ail e Do not operate with panel open or guards off No operar con panel abierto guardas guitadas Nop rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas i LE H
45. uand 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 pres 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 levage 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 du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 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 enrouler le c ble lectrode autour de n importe quelle partie PR CAUTIONS DE S RET POUR du corps LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de
46. urs 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 sisoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couche pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le cable de soudage et la machine a souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s a deux machines a soud er 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 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Q
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