Lincoln Electric 300FM Welder User Manual
Contents
1. lA a Do not operate with panel open guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgehause oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes Na0 opere com os paineis abertos ou guardas removidas ENEUALEEGE DE EHE L yuy p EAL CA Be EE TIM Ek a d Te Wel Haim SE nis fua Ga Ala Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Japanese Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR PMP RHO H OBRBELI MA TRALEE TTEN HERE XEM KI KE Ra HE TE b BN BB ll R W ES SE HI 5 2838 3434 Ab ER E RP IR HHS RRR ME ae ZIRX SAS RHC a Lal lagla al pli aqil s T ma LINCOLN 8 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 com2. p grt mM FI mL DRESSES 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 BT O BETI E REHE L TEEI EEA C Ett TE T erus WE Wear eye ear and body protection Prot jase los ojos los 01005 y el cuerpo Prot gez vos yeux vos oreilles et voire corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo ob SREB ez mo Sear ud a diye cl jul i 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 UNFAL
3. RETURN TO MAIN MENU MAGNUM 300FM and 400FM IM389 C Fast Mate Gun and Cable Assemblies Models K478 K479 K575 is now located in IM647 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 OPERATOR S MANUAL kaw Tt ru i 1809001 mmm MEN x W y Designed and Manufactured Under Quality Program ABS Quality Evalu LINCOLN 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 i SAFETY wr san O CALIFORNIA PROPOSITION 65 WARNINGS A 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 Die
4. SOUDER TRANSFORMATEUR ET REDRESSEUR 1 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 MAGNUM FAST MATE LINCOLN P V V for selecting a QUALITY product by Lincoln Electric We want you 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 possession at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such information or advice We expressly disclaim any warranty of any kind including
5. STRANDING 1 65 41 9 mm SKIN FIGURE E 2 CABLE INNER TUBE TUBE N STRANDS CONNECTOR NUT imc GUN TUBE CONNECTOR OR CABLE INCOMING CONNECTOR CONTROL LEAD FIGURE E 3 STRAIN RELIEF HOUSING GUN HOUSING rF TRAIN RELIEF CABLE BOOT x CABLE ASSEMBLY __ FIGURE E 4 MAGNUM FAST MATE LINCOLN D 5 e Remove the incoming connector from the cable by unscrewing the connector nut from the incoming connector 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 Cut the cable control wires where they meet the cable jacket or else unsolder the connection where they connect to the terminal lead assembly lf you cut the wires strip the cut end 3 8 inch 9 5 mm from the end g Cut off the damaged section of cable and strip off the outer jacket as shown in Figure E 2 Be careful not to cut the insulation on the control wires while stripping the jacket Strip the red and white control leads 3 8 inch 9 5 mm from the end NOTE The cable contains three control leads Any two control leads can be used provided the two col ors used are the same at both ends The extra lead is a spare that can be used if one of the other leads breaks h Check that the cable boot boot nut cable handle strain relief housing and collar nut are on the cabl
6. Where Purchased 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 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 CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment MAGNUM FAST MATE LINCOLN P vi TABLE OF CONTENTS Page General Descriptlon Section A hist LC Cr Section B Req
7. DUTY CYCLE WITH MIXED GAS Wire Size in mm 035 0 9 045 1 2 Contact Tips Standard Duty KP14 35 45 TABLE A 2 Gas Diffuser Assembly Gas Nozzle KP24A 62 Insulator KP44 3545 15 Gun Tube 60 KP1928 1 K479 2 035 0 9 045 1 2 KP14 35 45 KP24A 62 KP44 3545 15 KP1928 1 K479 3 052 1 3 1 16 1 6 KP14 52 116 KP24A 62 KP44 116 15 KP1928 1 K479 4 052 1 3 1 16 1 6 KP14 52 116 KP24A 62 KP44 116 15 KP1928 1 K479 5 1 16 1 6 5 64 2 0 KP14 116 564 KP24A 62 KP44 564 15 KP1928 1 K479 6 1 16 1 6 5 64 2 0 KP14 116 564 KP24A 62 KP44 564 15 KP1928 1 K479 7 035 0 9 045 1 2 KP14 35 45 KP24A 62 KP44 3545 15 KP1928 1 K479 8 052 1 3 1 16 1 6 KP14 52 116 KP24A 62 KP44 116 15 KP1928 1 K479 9 1 16 1 6 5 64 2 0 KP14 116 564 KP24A 62 KP44 564 15 KP1928 1 K479 10 035 0 9 045 1 2 14 35 45 KP24A 62 KP44 3545 25 KP1928 1 K479 11 052 1 3 1 16 1 6 KP14 52 116 KP24A 62 KP44 116 25 KP1928 1 K479 12 1 16 1 6 5 64 2 0 KP14 116 564 KP24A 62 KP44 564 25 KP1928 1 K479 13 035 0 9 045 1 2 KP14 35 45 KP24A 62 KP44 3545 25 KP1928 1 K479 14 052 1 3 1 16 1 6 KP14 52 116 KP24A 62 KP44 116 25 KP1928 1
8. Field Service Facility for technical troubleshooting assistance before you proceed E 2 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS RECOMMENDED SYMPTOMS Piri r COURSE OF ACTION FUNCTION PROBLEMS 1 Drive rolls turn but wire will not A Gun cable kinked and or twisted feed or wire feeding is rough B Wire jammed in gun and cable C Incorrect drive rolls and guide tubes D Gun cable liner dirty E Worn drive rolls F Electrode rusty and or dirty G Worn or improper size cable liner H Partially flashed melted or improper size contact tip A Keep as straight as possible Inspect cable and replace if nec essary B Remove wire from gun and cable feed in new wire Note any obstruction Replace liner if nec essary sure the wire diameter being used is stamped on drive rolls and guide tubes Replace if nec essary D Clean liner or replace E Replace or reverse split drive roll type F Replace the electrode if it is rusty G Replace cable liner H Replace the contact tip 2 Variable or hunting arc A Contact tip worn or incorrect size B Worn or undersize ground cables or poor ground connections C Loose electrode connections A Replace contact tip B Inspect repair or replace as necessary C Be sure the following connec tions are tight electrode cable to wire feeder and power source work cable t
9. and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 5 d Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 5 e Read and understand the manufacturer s instructions for this 5 f AUG 06 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 MAGNUM FAST MATE LINCOLN P SAFETY AZ 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 contac
10. 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 MAGNUM FAST MATE LINCOLN P 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 a Les circuits l lectrode et la piece 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 met allique 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 defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais touc
11. explosion Keep flammable material away ARC RAYS can burn 4 Wear eye ear body protection EZ a Check that the welding power source is on and that the shielding gas supply is set for the proper flow rate b Position electrode over joint End of the electrode should be slightly off the work 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 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 AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun handling procedures a Do not kink or pull the cable around sharp corners b Keep the electrode cable as straight as possible when welding or loading electrode through the cable Avoid wrapping excess cable around the handle or front of the wire feeder especially on longer 20 and 25 foot 6 0 and 7 5 m length guns d Do not allow dolly wheels or trucks to run over the cables Keep the cable clean by following the maintenance instructions f Use only clean rust free electrode All the recom mended Lincoln electrodes have the proper surface lubrication 9 Replace the contact tip when the arc starts to become unstable or the
12. three control leads Any two control leads can be used provided the two col ors used are the same at both ends The extra lead is a spare that can be used if one of the other leads breaks 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 the gun tube connector so the machined flat is on the same side of the cable as the red and white control leads Assemble the gun tube connec tor to the cable by forcing the steel tube of the con nector 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 con nector threads and tighten in place Refer to Figure E 3 NOTE For best results insert a rod through the connector and into the core of the cable mately 5 00 127 mm when pushing the connector tube into the cable core tube A 219 240 5 6 6 1 mm diameter rod is required for 300 and 400 amp cables 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 Pull the cut off lead terminals off the trigger assem bly and connect the replacement control lead termi nals j Position the
13. K479 15 1 16 1 6 5 64 2 0 KP14 116 564 KP24A 62 MAGNUM FAST MATE LINCOLN KP44 564 25 KP1928 1 B 1 INSTALLATION B 1 INSTALLATION WARNING ELECTRICAL SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts The K478 and K479 Magnum FM guns are factory installed with a Fast Mate European style wire feeder 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 Optional Magnum Fast Mate Adapters allow the use of these guns with Lincoln and competative wire feed ers See the Parts Section Chart E for information on which Fast Mate Adapter Kit to use with various equipment NOTE These guns are shipped with factory installed liner To change the liner in these models see the sec tion on liner removal instructions in the Maintenance section CONTACT TIP AND GAS NOZZLE INSTALLATION 8 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 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 optiona
14. L 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 the gas shield ed FCAW flux cored arc welding processes MAGNUM 300FM 300 AMPS 60 DUTY CYCLE WITH GAS 200 AMPS AT 60 DUTY CYCLE WITH MIXED GAS TABLE A 1 Description Gun Contact Tips Gas Product Cable Wire Size Standard Diffuser Gas Gun Tube Number Length m in mm Duty Assembly Nozzle Insulator 60 035 0 9 KP14 35 045 1 2 45 KP24A 62 44 3545 15 KP1928 2 035 0 9 KP14 35 045 1 2 45 KP24A 62 44 3545 15 KP1928 2 052 1 3 14 52 1 16 1 6 116 KP24A 62 KP44 116 15 KP1928 2 052 1 3 KP14 52 1 16 1 6 116 KP24A 62 44 116 15 1928 2 1 16 1 6 14 116 5 64 2 0 564 KP24A 62 KP44 564 15 KP1928 2 1 16 1 6 KP14 116 5 64 2 0 564 KP24A 62 KP44 564 15 KP1928 2 035 0 9 KP14 35 045 1 2 45 KP24A 62 44 3545 15 KP1928 2 052 1 3 KP14 52 1 16 1 6 116 KP24A 62 44 116 15 1928 2 1 16 1 6 14 116 5 64 2 0 564 KP24A 62 KP44 564 15 KP1928 2 MAGNUM FAST MATE LINCOLN A 2 GENERAL DESCRIPTION A 2 MAGNUM 400FM Description Product Number K479 1 Gun Cable Length m 400 AMPS 60 DUTY CYCLE WITH GAS 400 AMPS AT 50
15. LVERHUTUNGSVORSCHRIFTEN 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 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 ventilateur 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 e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria ka J z bi t BT3 EL T TR RL TT CET Li ER E TE EE ill BR E WESTH Bales ap miro H l d Jaa da elli alal a Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten Na0 opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas amp xILPTLBA EZXCEUS ETRAZ est Tat Fit BE
16. OLN P 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 Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 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 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 MAGNUM FAST MATE LINCOLN 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
17. anual Stick Welder AC Welder with Reduced Voltage Conitrol 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 RAYS burn 4 a Use shield with the filter 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 material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitab
18. any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products 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
19. cable boot and the strain relief on the cable so it fits in the cable handle cavity and lock the strain relief in place by pushing the two halves together x Assemble the cable in the left side of the gun dle Assemble the trigger into the proper handle cavity Assemble the right side of the gun handle and tighten the three screws that hold the handle together Refer to Figure E 4 Install the gun tube per Gun Tubes and Nozzles m Install and trim the liner per Liner Installation and Trimming Instructions Wire Feeder End Repair K478 and K479 FM Models Only a Remove the cable liner per Removal Installation and Trimming Instructions for Magnum Liners b Loosen the boot nut Slide the boot nut and boot toward the middle of the cable past the damaged section 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 collar nut and strain relief housing 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 MAGNUM FAST MATE LINCOLN pa MAINTENANCE KIN e 6 mao ven 2 G a 201 USE 38 9 5 mm SKIN FOR FEEDER END OF FM MODELS CONTROL LEAD TUBE
20. ch 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 FAST MATE LINCOLN NOTES MAGNUM FAST MATE LINCOLN P NOTES MAGNUM FAST MATE LINCOLN P Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O Chinese Do not touch electrically live paris or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 0 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 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 e terra SASTOEN S SPRL ATHA pIE r Z n k h Tu TT 1 s REB ME Ek es Hi l LE REF Ji St E IB ences BE LE e nx
21. contact tip end is fused or deformed MAGNUM FAST MATE LINCOLN P D 1 MAINTENANCE D 1 REMOVAL INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM LINERS FEEDING STEEL WIRE KP1933 KP1936 and KP1955 series 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 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 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 includ ed on the wrench provided with the connection kit for gauging the cut off length Remove any burrs from the end of the lin
22. dure until no further dirt comes out MAGNUM FAST MATE LINCOLN P D 3 MAINTENANCE D 3 CABLE REPAIR The Magnum 300 FM and Magnum 400 FM guns feature the use of repairable cable connectors If the cable ever gets severely damaged it may be cut short er and repaired by the user Repair cables as follows Gun Tube End Repair K478 and K479 Requires 2 S19492 2 Terminals Remove the cable liner per Removal Instructions for Magnum Liners b Remove the gun tube per Gun Tubes and Nozzles 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 Remove the gun tube connector from the cable by unscrewing the connector nut from the gun tube connector 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 2 2 Uncouple the strain relief by pushing its outer hous ing toward the middle of the cable Move the strain relief and the cable boot toward the middle of the cable past the damaged section f Cut off the damaged section of the cable and strip off the outer jacket as shown in Figure E 2 Be care ful not to cut the insulation on the control wires while stripping the jacket Strip the red and white control leads 1 4 inch 6 4 mm from the end and crimp a new 819492 2 terminal to each lead NOTE The cable contains
23. e Slip the connector nut over the copper strands with the threaded end out Orient the connector assem bly 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 connector threads and tighten in place Refer to Figure E 3 Central Adapter Assembly 4 10 104 mm Terminal Lead Assembly Cable Handle MAINTENANCE D 5 NOTE For best results insert a rod through the connector and into the core of the cable mately 5 00 127 mm when pushing the connector tube into the cable core tube A 219 240 5 6 6 1 mm diameter rod is required for 300 and 400 amp cables 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 terminal lead assemblies from step f to the control leads stripped in step Insulate both soldered connections using either heat shrink tub ing or electrical tape Fully insert the two control lead pins into the sock ets on the incoming connect
24. e Secure the cable connection by snugging the Fast Mate connector collar nut INSTALLATION OF THE K489 FAST MATE ADAPTER KITS See Chart E in the PARTS section for information on which Fast Mate Adapter Kit to use with various equip ment Refer to the installation instructions that were sent with the kit for detailed installation instructions MAGNUM FAST MATE LINCOLN P C 1 OPERATION C 1 OPERATION ELECTRODES AND EQUIPMENT The Magnum 300 FM and Magnum 400 FM 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 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 Lincoln Outershield cored electrodes for the gas shielded FCAW process MAKING A WELD WARNING TX e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground FUMES AND GASES can be danger OUS AR Keep your head out of fumes NE WELDING SPARKS can cause fire or Te Use ventilation or exhaust to remove fumes from breathing zone
25. er f Screw the gas diffuser onto the end of the gun tube and tighten with the wrench provided 9 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 LINER TRIM LENGTH 9 16 14 3 mm LINER NUT GAS DIFFUSER NOZZLE Mia GAS NOZZLE Figure E 1 INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM LINERS FEEDING ALUMINUM WIRE KP1958 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 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 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 a
26. gainst the cable liner using the Allen wrench provided MAGNUM FAST MATE LINCOLN P D 2 MAINTENANCE D 2 CAUTION 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 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 loos ened 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 the 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 proce
27. her simultan ment les parties sous tension des porte lectrodes connect s deux machines 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 enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel 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 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zone
28. l fixed gas nozzles 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 1 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 cir cuiting 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 feeder equipped with a European style gun con nector or Lincoln or competative wire feeder equipped with the proper K489 Fast Mate Adapter Kit See the Parts Section Chart E for information on which Fast Mate Adapter Kit to use with various equipment 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 the adapter guide tube is also properly sized Align and fully engage brass connector end of the gun cable into the mating connector on the out going side of the feeder wire driv
29. le non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker expo sure level should be checked upon installation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 5 c Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat
30. o 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 FAST MATE LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed througout this manual PROBLEMS RECOMMENDED SYMPTOMS PARER aie COURSE OF ACTION FUNCTION PROBLEMS 3 Poor arc striking with sticking or A Improper procedures or tech A See Gas Metal Arc Welding blast offs weld porosity narrow niques Guide GS 100 and ropy looking bead or elec trode stubbing into plate while B Improper gas shielding B Clean gas nozzle Make certain welding 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 rubber seal for any sign of de terioration or damage Be sure set screw in brass connector is in place and tightened against the liner bushing 4 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 tem perature antiseize lubricant su
31. om vaporizing on localized Electric Magnetic Fields Welding contact with hot engine parts and igniting Do current creates EMF fields 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 Keep all equipment safety guards covers before welding 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 minimize exposure to EMF fields from the welding circuit 1 e In some cases it may be necessary to remove safety 2 d 1 Route the electrode and work cables together Secure guards to perform required maintenance Remove them with tape when possible guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 2 Never coil the electrode lead around your body Always use the greatest care when working near moving parts 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right Do not put your hands near the engine fan Do no
32. or Tape the leads in place in the necked down area of the connector Keeping the leads as close to the connector and nut as possible tape the insulated soldered connec tions and the spare lead to the cable in the area between the cable jacket and connector nut This must be done neatly and kept as low as possible or the cable handle will not slide over this area Position the strain relief to the dimension shown in Figure E 5 and secure with the strain relief housing On older cables install the cable clamp on the cable jacket within 1 8 3 2 mm from the end of the jack et and tighten m Slide the collar nut and cable handle over the con 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 connecition try rotating it n Install and trim the liner per Removal Installation and Trimming Instructions for Magnum Liners Strain Relief Strain Relief Housing Boot Nut Connector Nut Collar Nut Incoming Connector Assembly Cable Boot FIGURE E 5 MAGNUM FAST MATE LINCOLN MAINTENANCE THREAD SIZES FOR MAGNUM 300 amp 400 CONSUMABLES MAGNUM FAST MATE LINC
33. rom NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing 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 compressed gas cylinders associated equipment and CGA publication P I 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
34. s 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 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 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 10 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 PR CAUTIONS DE S RET POUR LES MACHINES
35. sel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMIED ONLY BY QUALIFIED INDIVIDUALS eN FOR ENGINE 0 A lu 1 To avoid scalding do not remove the powered equipment n h lt Ea pressure cap when the engine is 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes 9 outdoors t AR ELECTRIC AND 3 MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld 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 fr
36. t attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance 2 d 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropriate MAGNUM FAST MATE LINCOLN P SAFETY ii 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 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 M
37. t 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 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 circuits 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 f
38. uired Cable Connection Kits B 1 Contact and Gas Nozzle Installation B 1 Connection to Fast Mate Compatible B 1 Installation of the K489 Fast Mate Adapter B 1 Per Yee eee hee Section Electrodes and C 1 Making Weld 24224 x a a dat deanna ed dad weed Poteau C 1 Avoiding Wire Feeding C 1 Maintenance em kla kak du REA ER eedem RR d Rn Section D Removal Installation and Trimming Instructions for Magnum Liners D 1 Gun Tubes 2 D 2 Gun PPP D 2 Cable Cleanilig mari ane xi kendi ase p ana d l w ae avay Pr p wall PRR an hae D 2 Cable Repair for K478 479 1 D 3 Thread Sizes for Magnum 300 and 400 Consumables D 6 Troubleshooting Section E Parts L S S m a Aa n w QA Ka alava ad Ab d a P202 D MAGNUM FAST MATE LINCOLN vi A 1 GENERA
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