Lincoln Electric IM646-A User's Manual
Contents
1. 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 ACTION This column provides a course of action for the Possible Cause generally it states to contact you local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact you local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Drive rolls turn but wire will not feed or wire feeding is rough Variable or hunting arc a Gun cable kinked and or twisted b Wire jammed in gun and cable Incorrect drive rolls and guide tubes Gun cable liner dirty Worn drive rolls Electrode rusty and or dirty Worn or improper size cable liner Partially flashed melted or improper size contact tip Contact tip worn or inco2. LINCOLN 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 B 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 A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 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 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
3. tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou a
4. 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 installation and trimming instructions for Magnum liners see LINER INSTALLATION in the 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
5. SIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 0 105 electrodos bajo carga con la piel o ropa moja 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 N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pe a e terra MRPORABA MARHE j T 7 229 5 SH f 1048 ES ATUSRELTFEL e B BA zk IR zk 4p 5J 2j ERRARE 254 2 39 CERACRHMALHHER ecran BASS Xe Su nig 249 AXIS OAL Gaal ye 29 ON yl iU Sil Al Gulal dus Je Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos 4 483J 0C amp J EVA o 0J HAW dh ess Hc AIX Jus 3l sU ae e Wear eye ear and bo
6. a dual procedure kit connect the cable marked 1 to pin receptacles A and C of a S12020 6 five pin Amphenol plug optional 512024 1 cable clamp is required to secure the Amphenol plug to the cable Connect the cable marked 2 to pin receptacles A and C of a S12020 16 three pin Amphenol plug optional S12024 4 cable clamp is required to secure Amphenol plug to the cable To install on a DH 10 Lincoln wire feeder a S12024 12 cable clamp and S12020 6 five Amphenol plug are required Slip the two control cables through the cable clamp and connect the two control cables to the Amphenol plug Connect the two leads of cable marked 1 to pins A amp C and connect the two leads of cable marked 2 to pins D amp E Connect the cable clamp to the plug and secure the leads The K1722 Magnum 400DP gun and cable is equipped with a control cable that attaches to a Lincoln 10 series wire feeder For other wire feed ers the control cable has to be rewired with the appropriate connectors to fit the wire feeder K466 1 amp 8 INSTALLATION For Lincoln Feeders a Remove brass cable connector and insulation tube see Figure B 1 from the kit Slide the insulation 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 b
7. cable straight on a flat surface b Make sure that the set screw in the connector end is backed out so as not to damage liner or liner bushing Remove and save the gas nozzle nozzle insulator and gas diffuser from the end of the gun tube assembly c Insert a new untrimmed liner into the connector end of the cable Be sure the liner bushing is sten ciled appropriately for the wire size being used NOTE For KP44N and KP45N liner series 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 d Before installing the gas diffuser fully seat the liner bushing in the connector and 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 includ ed in these connector kits to help guide the elec trode 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 material is for 5 64 2 0
8. especially on longer 20 and 25 ft 6 1 and 7 6 m length guns d Do not allow dolly wheels or trucks to run over cables e Keep cable clean by following maintenance instruc tions f Use only clean rust free electrode The Lincoln elec trodes have proper surface lubrication 9 Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 8 1 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 used to feed steel wire are shipped with the jacket of the liner extended the prop er 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 B 1 IN INSTALLATION FOR EACH OR For K466 3 and K466 4 CONNECTIONS
9. 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 for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we
10. 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 400 amp gun tubes to allow either spray or short circuiting transfer welding Choose the gas nozzle as appropriate for the GMAW process to be used Typically the contact tip end should be flush to 12 3 mm extended for the short circuiting transfer process and 12 3 recessed for spray transfer and for the Outershield7 FCAW process CONNECTION TO FEEDER NOTE The K574 Magnum 400 DS is shipped with generic gun control cables therefore Section c will not apply The gun control cables must be tailored by the user to each specific wire feeder The cables are identified as procedure 1 and 2 To install on Lincoln wirefeeders equipped with a dual procedure kit connect the cable marked 1 to the 5 pin amphenol located on the feeder case front The cable marked 2 should be connected to the 3 pin amphenol located on the dual procedure box 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 9 with a dual procedure kit 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 wi
11. mm maximum diam eter electrode e Be sure the cable is straight and then trim the liner to the length shown in Figure B 1 a gauge is included on the wrench provided with the connec tion kit for gauging the cut off length on 300 and 400 amp gun tubes Remove any burrs from the end of the liner f Screw the gas diffuser onto the end of the gun tube and tighten with the wrench provided 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 KP1958 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
12. narrow niques Guide GS100 and ropy looking bead or electrode stubbing into plate while welding b Improper gas shielding b Clean gas cone Make certain that gas diffuser is not restricted Make certain that gas cylinder is not empty or turned off Make certain gas solenoid valve is operating and gas flow rate is proper Remove gun liner and check rub ber seal for any sign of deterio ration or damage Be sure set Screw in brass connector is in place and tightened against the liner bushing Tip seizes in diffuser a Tip overheating due to prolonged a Do not exceed current and duty or excessive high current and or cycle rating of gun duty cycle welding A light application of high temperature antiseize lubricant such as Lincoln E2067 Graphite Grease may be applied to tip threads CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 8 5 MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 5 MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 5 MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 5 MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese
13. of the electrode should be slightly off the work d Lower welding helmet close gun trigger and begin welding Hold the gun so the contact tip to work dis tance gives the correct electrical stickout as required for the procedure being used e To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out Follow wire feeder instruction manual if using a trigger interlock circuit f When using a K574 Magnum 400 Dual Procedure gun and cable the trigger operates as follows Pulling the trigger in part of the way will engage the first procedure set at the feeder Pulling the trigger the rest of the way will engage the Second procedure If the optional interlocking trigger is installed With the trigger pulled in all the way the trigger can be slid forward into the interlock position release interlock squeeze trigger and pull back g When using the K1722 Magnum 400 with dual pro cedure switch the trigger only starts and stops the welding The procedure is changed by actuating the rocker switch that is built into the top of the gun AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun handling procedures a Do not kink or pull cable around sharp corners b Keep the electrode cable as straight as possible when welding or loading electrode through cable c Avoid wrapping excess cable around handle or front of wire feeder
14. strands with the thread end out Orient gun tube connector so machined flat is on the same side of the cable as the red and white control leads Assemble gun tube connector to cable by forcing the steel tube of the connector into the inside diameter of the cable inner tube until the copper strands are butted against the gun tube CABLE INNER TUBE CONN CABLE ECTOR TUBE CONNECTOR NUT connector shoulder Keeping the copper strands against the shoulder pull the connector nut over the copper strands engage the gun tube connector threads and tighten in place See Figure GUN TUBE CONNECTOR OR INCOMING CONNECTOR Figure E 3 NOTE For best results insert a 219 240 5 6 6 1mm diameter rod through the connector and into core of cable approximately 5 00 127 mm when pushing the connector tube into the cable core tube To tighten hold the connector in place while turning the nut then remove the rod from the core This pro cedure assures the inner core does not kink while assembling or tightening STRAIN RELIEF HOUSING 4 CABLE BOOT h For K574 Pull the cut off lead terminals off the trigger assem bly and connect the replacement control lead ter minals See Figure E 4 CABLE ASSEMBLY GUN HOUSING GUN TUBE
15. the cable Repeat this procedure until no further dirt comes out CABLE REPAIR CABLE REPAIR FOR K574 amp K1722 MODELS Magnum 400 Dual Procedure guns and cables fea ture the use of repairable cable connectors If the cable ever gets severely damaged it may be cut shorter and repaired by the user GUN TUBE END CABLE REPAIR FOR K574 AND 1722 Requires 4 S8053 169 Terminals for K574 or 2 519492 2 terminals for 1722 a Remove the cable liner per previous instructions b Remove the gun tube per previous instructions c Remove the 6 screws from the gun handle sepa rate the two halves and remove the cable from the handle along with the trigger assembly for the K574 guns Before removing the trigger assembly carefully note trigger lead wiring as it will be impor tant to reconnect these properly For the K1722 also remove the rocker switch MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 8 COPPER STRANDING CABLE MAINTENANCE Va 3 2mm SKIN 4 CONTROL LEADS CONTROL LEAD INNER TUBE Figure d Remove gun tube connector from cable by unscrewing connector nut from gun tube connec tor If the cable inner tube is difficult to remove from the connector assembly carefully slit it length wise with a knife up to the brass connector 2 Uncouple the strain relief by pushing its outer housing toward the middle of the cable Move the strain relief and the cable boot toward the middle of th
16. 1 Gun Tube End Repair eene A bka e D 1 Wire Feeder Erid Rpalr ced eerte tree D 4 Thread Sizes for 400 Amp Consumables esee eene D 7 Troubleshooting Section E Parts AWE KO K WERTE AR AA V R P202 L and P202 X MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN vi 1 INSTALLATION 1 GENERAL DESCRIPTION The Magnum 400 DP Dual Procedure GMA gun and cable assemblies have been designed to meet NEMA specification EW3 for welding with steel elec trode using the GMAW gas metal arc welding and gas shielded FCAW flux cored arc welding process es Magnum 400 DP guns and cables are specifical ly designed for use with wire feeders with dual proce dure capabilities The K574 gun is equipped with a two position trigger Pulling the trigger in part of the way will engage the first procedure set at the feeder Pulling the trigger the rest of the way will engage the second procedure An interlocking trigger is available as a parts order The 1722 Magnum 400 DP Dual Proecdure gun and cables are also designed for use with wire feeders with dual procedure capabilities The guns are equipped with a rocker switch that is used to select one of two welding procedures The K574 and K1722 are designed for use with K466 connector kits The proper connector can be installed the same as with any Magnum Gun The gun con trol
17. 16 1 6 116 KP24A 62 KP44 116 15 KP1928 1 KP14 116 564 KP24A 62 KP44 564 15 KP1928 1 KP14 35 45 KP24A 62 KP44 3545 25 KP1928 1 KP14 52 116 KP24A 62 KP44 116 25 KP1928 1 KP14 116 564 KP24A 62 KP44 564 25 KP1928 1 035 0 9 KP 14 35 K1722 1 045 1 2 45 KP24A 62 KP44 3545 15 1928 1 035 0 9 KP14 35 K1722 2 045 1 2 45 KP24A 62 KP44 3545 15 1928 1 KP14 35 KP24A 62 KP44 3545 25 1928 1 MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN A 3 INSTALLATION A 3 Read this entire installation section before you start installation SAFETY PRECAUTIONS A WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or inter nal wiring Insulate yourself from the work and ground Always wear dry insulating gloves Only qualified personnel should install use or service this equipment CONNECTOR KIT INSTALLATION TO GUN CABLE The K574 and K1722 Magnum 400 dual procedure cables are shipped as generic assemblies and must be assembled with a connector kit NOTE The K574 Magnum 400 DP gun and cable is not only shipped with a generic wire feeder end it is also shipped with generic gun control assem blies The brass connector can be installed per K466 instructions but the gun control cable must be tailored by the user to the specific machine To install on an LN 9 Lincoln wire feeder equipped with
18. ALLATION K466 5 INSTALLATION For L Tec Feeders equipped with an L Tec feeder connector assembly MIG 35 314A 225 a Remove brass cable connector see Figure B 1 from the 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 The gun control cable provided is not used K466 7 and K466 10 Installation Hobart Series 2000 Feeders and Lincoln 10 Series Feeders a Remove brass cable connector see Figure B 1 from the connector 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 The gun control cable provided is not used FEEDER END CABLE HANDLE INSULATION TUBE K466 1 ONLY BRASS CABLE CONNECTOR MOLDED GAS PLUG SET SCREW LINER ASSEMBLY LINER BUSHING TO BE SEATED TIGHT AGAINST BRASS CABLE CONNECTOR Figure B 1 CLAMPING SCREW GUN HANDLE GUN TUBE SET ScnEW GAS DIFFUSER NOZZLE INSU GAS NOZZLE we LATOR MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 9 6 14 3 mm LINER TRIM LENGTH 5 INSTALLATION A 5 LINER INSTALLATION AND TRIMMING INSTRUCTIONS Installation of KP44 and 44 liner series a Lay the gun and
19. Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations iv SAFETY iv PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut
20. Figure E 4 MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 8 4 1722 Connect the black lead and the white lead to the gun trigger Connect the other leads to the rocker switch leads See Figure E 5 STRAIN RELIEF STRAIN RELIEF HOUSING CABLE BOOT GUN HOUSING MAINTENANCE SWITCH CABLE ASSEMBLY SWITCH WIRES D 4 TO RED LEAD TRIGGER ASSEMBLY TRIGGER WIRES Figure E 5 j Position the cable boot and strain relief on the cable so it fits in cable handle cavity and lock the strain relief in place by pushing the two halves together k Assemble cable in left side of gun handle Assemble trigger into the proper handle cavity For K1722 also assemble the rocker switch in the groves provided in the handle Assemble right side of gun handle and tighten the screws that hold the handle together See Figures E 4 and E 5 GAS PLUG OR FITTING a 468 119mm WIRE FEEDER END REPAIR K574 AND K1722 a Remove the cable liner per previous instructions b Remove the feeder end connector molded gas plug or barbed fitting cable handle nut plastic tailpiece and connector cover See Figure E 6 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 counterclockwise as viewed from the feeder end CONNECTOR COVER CAB
21. H 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 49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS AN FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated ELECTRIC AND MAGNETIC FIELDS 359 may be dangero
22. LE BOOT CABLE CO DER END NECTOR CABLE HANDLE NUT TAIL PIECE INCOMING CONNECTOR CABLE HANDLE STRAIN RELIEF HOUSING STRAIN RELIEF 48 11 mm MAX Figure E 6 MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 8 D 5 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 length wise with a knife up to the brass connector d Move the cable boot cable handle and strain relief 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 E 2 Be careful not to cut the insulation of the control wires while stripping jacket Strip all four control leads 25 6 4 mm inch back f Check that the cable boot cable handle and strain relief 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 diam eter of the cable inner tube until the copper strands are butted against the incoming connector shoul der Keeping the copper strands against the shoul der pull the connector nut over the copper strands engage the incoming connector threads and tight en in place See Figure E 3 PROCEDURE MAINTENANCE D 5 NOTE For best results insert
23. MAGNUM 400 DUAL PROCEDURE 646 GMA GUN amp CABLE ASSEMBLIES 7 Models K574 K1722 RETURN TO MAIN MENU Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL ISO 9001 e Xe RENS Ix 57 XV jesigned LINCOLN Copyright O Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com l SAFETY i A WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEAT
24. TF EL CHRRTMMAARS WI B3 AA E endo Mel dele 2 1 Gils 13 ha Jaki y e Ad gl Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO tm SIR Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR A OHRBEEKK BA TRHOKRARMEK HTP SU BA KE Z1 XE AR JE Ot R BA DL Je FA ER B L7 AJ AZo SSE AUAAMS SAMAD HA HAR ESAT BEH malt QU gll Jub al c lasll gl gal gai LINCOLN B e 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
25. 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 tight en 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 Position the plastic strain relief such that the tapered end is 4 68 119 mm from the incoming connector See Figure E 6 Lock into place with steel housing Plastic strain relief may overhang cable jacket a maxi mum of 43 11 mm g Remove control cables from damaged section with a soldering iron Be sure control cables are still threaded through the connector cover Solder the base leads of the control cables to the gun cable leads For K574 the control cable for PROCEDURE 1 should be soldered to the black and white leads See Figure E 7 BLACK AND WHITE HEAT SHRINK TUBING OR ELECTRICAL TAPE 4 PLACES LAPE RED AND BLUE PROCEDURE 2 Figure E 7 MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 8 D 6 MAINTENANCE D 6 For K1722 E 8 Position the plastic strain relief such that the tapered end is 4 68 119 mm from the incoming con The control cable leads should be connected to the nector See Figure E 6 Lock into place with steel same color leads on the gun cable Insulate each of housing Plastic strain relief may overhang cable the solder connections with either h
26. a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b AUG 06 SAFETY WELDING and CUTTING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper
27. also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded abov
28. bles If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 2 d 5 Do not work next to welding power source Mar 95 LINCOLN SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder Welder with Reduced Voltage Co
29. c 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 2 The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable PEL and ACGIH limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene
30. cable connections however must be tailored to each specific machine The K574 comes with control wires but no specific connectors are provided The K1722 has a connector that will mate with any Lincoln 10 series wire feeder The Magnum 400 DP guns not factory equipped with a feeder end connector With the K466 1 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 feeding 052 and smaller electrodes An optional K481 Magnum Fast Connect Gas Tube Kit is avail able to provide tool less gas tube connection to Lincoln wire feeders Non GMA model wire feeders require an optional gas solenoid valve The 400 DP 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 400 guns directly to a variety of Miller and Hobart wire feeders respec tively The K466 5 connector kit allows connection of Magnum 400 DP guns to an L Tec feeder connector assembly L Tec feeders require a feeder connector assembly similar to 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 400 DP guns to a Li
31. dy protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo FRUSHICRBRELTE eu f RIR ARERFHRBAR 712 Zo dis due le Lily us cll en READ AND UNDERSTAND MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND CONSUMABLES TO USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n 0 aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schwe
32. e 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 TABLE CONTENTS Page Installation Section General DescriptioR io teri er tee et viv RR A 1 A 2 Connector Kit Installation to Gun Cable L EEE kk kk kk kk Ak kk RR A 3 K466 1 8 8 Imstallation Co
33. e cable past the damaged section For K574 models Cut off damaged section of cable and strip off the outer jacket 2 15 inches back Be careful not to cut the insulation on the control wires while stripping jacket Pull control leads back and trim the exposed copper and inner tube back 50 inch Strip all four control leads 125 inch back and crimp a new 58053 169 terminal to each lead Apply heat shrink tubing or electrical tape to terminals to prevent electrical contact with other terminals See Figure E 1 COPPER STRANDING r 1 65 42mm m 2 15 55mm E 1 For K1722 models Cut off damaged section of cable and strip off the outer jacket 1 65 inches back Be careful not to cut the insulation on the control wires while stripping jack et Strip all four control leads 25 inch back and crimp a new 519492 2 terminal to both the black lead and the white lead Remove the leads connected to the red and blue control leads from the cutoff cable and solder these leads to the blue and red leads of the newly trimmed cable Insulate connections with heat shrink tubing or tape See Figure E 2 1 4 6 4mm SKIN 4 CONTROL LEADS CONTROL LEADS INN ER TUBE 41 9mm SKIN Figure E 2 MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 8 D 3 MAINTENANCE D 3 g Check that the cable boot and both halves of the strain relief are on the cable Slip the connector nut over the copper
34. e hand screw to clamp down on the connector c Insert the control cable plug into the mating socket on the wire feeder CONNECTION TO HOBART 2000 FEEDERS Gun and cable assemblies which were assembled with a K466 7 Connector Kit will connect easily to a variety of Hobart wire feeders a Check that the adapter and feeder outgoing guide as well as the drive roll are appropriate for the electrode 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 Connect the control cable plug into the mating socket on the wire feeder 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 gun 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 into the mating socket on the wire feeder MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN B 1 OPERATION B 1 ELECTRODES AND EQUIPMENT The Magnum 400 Dual Procedure guns and cables have been de
35. eat shrink tubing jacket a maximum of 43 11 mm or electrical tape Anchor leads as shown in Figure CONTROL CABLE HEAT SHRINK TUBING OR ELECTRICAL TAPE FOUR PLACES TAPE Figure E 8 h Position cable boot and cable handle on cable Replace the molded gas plug or barbed fitting Move the connector cover into position while and feeder end connector Install and trim liner per pulling control cables to take up the slack Install previous instructions tailpiece and fasten to cable handle with cable han dle nut Refer to Figure E 6 MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 8 D 7 MAINTENANCE D 7 THREAD SIZES FOR MAGNUM 400 CONSUMABLES 9 16 18 3 8 24 0 37 1 4 28 MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 8 TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS
36. ibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fuma a Use ventilac o e exhaust o para remover fumo da zona respirat ria eta A 5stEd4co5c uc Feu ORAVHELTIHELTFEL zz UE UR Ez e FE XR JEL zk HIR SR ER 8 zzv 532958 YHL SAXNACEFE Ash 7 17 7 amp oe lua dul bas jiya Jl Gill e Ael o all e lt 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 entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas e Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas XZTTLZA 4 U ACRUD WORM EFRBRAL FE FP AHS ail 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 e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas O SIPH ERAL EEE TIRHIRIFE L EUT
37. ncoln Wirematic The K466 7 connector kit allows connection of Magnum 400 DP guns to Hobart Series 2000 Wire Feeders The K466 8 connector kit allows connection of Magnum 400 DP guns to an LN8 or LN9 when 1 16 and larger electrode is used The K466 9 connector kit allows connection of K497 to SP100T and related wire feeders The K466 10 connector kit allows connection of Magnum 400 DP guns to a 10 Series wire feeder The Magnum 400 DP gun and cable assemblies are fully compatible for use with comparable Tweco gun size tips diffusers gas nozzles and cable liners The Magnum GMA gun family offers an expanding line of quality long life expendable replacement parts and accessories 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 A WARNING Do not touch electrically live parts such as output terminals or internal wiring MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 8 2 INSTALLATION A 2 MAGNUM 400 Dual Procedure 400 AMPS at 60 DUTY CYCLE WITH CO2 GAS 400 AMPS at 50 DUTY CYCLE WITH MIXED GAS Gun Contact Tips Gas Product Cable Wire Size Standard Diffuser 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 1928 1 052 1 3 14 52 1 3 1
38. ntrol 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 ARC RAYS can burn 4 8 Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant LINCOLN 8 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 ar
39. rass fitting provided in the kit The includ ed wrench will fit both the gas plug and barbed fit ting c The gun control cable provided is not used 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 connection to Lincoln wire feeders Install per the instructions included with the kit K466 2 INSTALLATION For Adapted Feeders and 10 Series Lincoln Feeders a Remove brass cable connector see Figure B 1 from the 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 i e Millermatic 200 Cricket S 32P 54D a Remove brass cable connector see Figure B 1 from the 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 The gun control cable provided is not used MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN 4 INST
40. re drive Secure the cable using the hand screw or set screw in the conductor block c Insert the control cable plug from the gun into the mating sockets on the wire feeder d Slide the free end of the flexible hose onto the barbed gas fitting on the front of the Lincoln feeder 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 Connection 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 electrode 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 into the mating socket on the wire feeder MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN A 7 INSTALLATION A 7 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 th
41. rrect size Worn or undersize ground cables or poor ground connections Loose electrode connections a Keep as straight as possible Inspect cable and replace if nec essary Remove wire from gun and cable feed in new wire Note any obstruction Replace liner if necessary Be sure the wire diameter being used is stamped on drive rolls and guide tubes Replace if nec essary Clean liner or replace Replace or reverse split drive roll type Replace the electrode if it is rusty Replace cable liner Replace the contact tip Replace contact tip Inspect repair or replace as necessary Be sure the following connections are tight electrode cable to wire feeder and power source work cable to power source and work gun cable to wire feeder contact block gun nozzle to body and contact tip to nozzle CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed LINCOLN 8 MAGNUM 400 DUAL PROCEDURE GUNS E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Poor arc striking with sticking or a Improper procedures or tech a See Gas Metal Arc Welding blast offs weld porosity
42. rte erede S EE A etnies K466 2 lA Te K466 3 Installation redis eene 266 5 n e bekan hek rek EL 466 7 10 Installation Liner Installation amp Trimming Instructions A 5 Installation of M18732 Series Liners for Feeding Aluminum Electrode A 5 Contact and Gas Nozzle Installation A 6 Connection to Feeder sise A 6 Connection to Lincoln Feeders yaya nl san tee A 6 Connection to Adapted Feeders sess A 7 Connection to Miller Feeders 2 0 0 nennen nnne ns A 7 Connection to Hobart 2000 Feeders A 7 Connection to 10 Series Feeders A 7 ODer atil HAN Section B Electrodes and Equipment iii B 1 Making a Weld m B 1 Avoiding Wire Feeding Problems nennen nnns B 1 Clntrc m Section D Removal Installation and Trimming Instructions for Magnum Liners D 1 Gun TUBES ANd NOZZIOS unten eue e D 1 ENTREE SNN DD J D 1 es Xe DEDE D 1 Cable Repair K574 amp K1722 Models D
43. signed for use with Lincoln L 50 and Super Arc L 56 solid steel wire electrodes for the GMAW process and Lincoln Outershield7 cored elec trodes for the gas shielded FCAW process Refer to the appropriate Lincoln Process and Procedure Guidelines for the electrode used for information on recommended electrical and visible stickouts MAKING A WELD WARNING Do not attempt to use this equipment until you have thoroughly read all operating and mainte nance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists e ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or inter nal wiring Insulate yourself from the work and ground Always wear dry insulating gloves 49 FUMES AND GASES danger AR ous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone lt hi WELDING SPARKS can cause fire or explosion Keep flammable material away 2 4 ARC RAYS can burn NT Y Wear eye ear and body protection Only qualified personnel should operate this equipment a Check that the welding power source is on and that the shielding gas supply is set for the proper flow rate b For the Magnum 400 with dual procedure switch set the rocker switch to the desired procedure c Position electrode over joint End
44. steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing
45. the connector cap and replace the liner material with the correct size 3 Mark the liner 3 16 5 mm from 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 A 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 MAGNUM 400 DUAL PROCEDURE GUNS LINCOLN P 6 INSTALLATION A 6 CONTACT TIP AND GAS NOZZLE INSTALLATION a Choose the correct size contact tip for the elec trode being used wire size is stenciled on the side of the contact tip and screw it snugly into the gas diffuser 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 62 15 9 mm or 50 12 7
46. us 2 8 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety ihe ad minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan D Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your body between the electrode and work ca
47. utres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POU R contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER u TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit
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