Lincoln Electric MAGNUM 350 User's Manual
Contents
1. Si Slip on gas nozzle Pull to remove shown he on to install BE e Pull to finish removing the fume collection nozzle Install nozzle by pushing then twisting clockwise Do not over tighten the nozzle PERIODIC REPLACEMENT PARTS bk Gas diffuser Gun tube assembly KP2738 1 ke Contact tip Li tte ee Fume tube assembly KP2739 1 right hand threads Mean dus y Vacuum hose cover KP2736 1 removal direction Installation torque 41 to 47 in lbs Liner assemblies See Table A 2 MAGNUM PRO 350 and 550 FUME GUNS LINCOLN A 6 INSTALLATION A 6 5 REMOVING THE FUME TUBE ASSEMBLY See figure A 7 Figure A 7 e Loosen locking collar counter clockwise right hand threads on fume tube Gas diffuser may remain in place e Fume tube removed CONSUMABLE PARTS See Table A 3 KP2747 1 Contact tips Gas diffuser assembly Gas nozzle assembly 5 8 inch opening KP2743 2 62R Fume collection nozzles See Figure A 6 CONNECT THE GUN TO THE WIRE FEEDER 1 Make sure that the gun locking knob is loosened Insert the gun into the gun conductor block and tighten the gun locking knob 2 Make the gas connection from the feeder to the gun if required 3 Plug the trigger harness into the gun s Y connector Plug the trigger harness connector into the recep tacle on the front of the feeder CONNECT THE GUN TO THE FUME COLLECTION SYSTEM 1 Speed setting for Lincoln Min2. For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it e For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below 44 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 OF CONTENTS Page Installation EE Section A CHOS D CO ATOS a ener eee A 1 Unpacking the Spool Gun iii A 2 Fume Gun Familiarization a cnc cinco A 2 Assembly of Fume Gun Internal Parts A 2 A 3 Dale Fl CAC OM Snes toas A 3 Compatibility of Welding Machines and Wire Feeders occccccocccncccocccnnccnoncncnonaconnnnnnos A 3 Preparing the Fume Gun for Welding cc ccccceccsseeeecceeeeeeeeeeeeecseeeseeeseaeseeesaeeeeseas A 3 Select and Install a Wire Feeder Connection K Kit A 4 Select and I
3. IM990 MAGNUM PRO 350 and 550 FUME GUNS sever eon 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 opera tion on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful TYPE K2649 1 K2650 1 OO OPERATOR S MANUAL ISO 9001 Designed and Manufactured Under a CERTIFICATE NUMBER 30273 LI NCOLN e Copyright Lincoln Global Inc e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY 44 WARNING n CALIFORNIA PROPOSITION 65 WARNINGS For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm For Gasoline Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOC
4. Lincoln Super Arc Super Glide Innershield and Outershield brand products MAXIMUM WIRE SIZES DIAMETERS BY WELDING PROCESSES Both Models 1 16 inch solid wire GMAW K2649 1 1 16 inch cored wire FCAW and FCAW GS K2650 1 3 32 inch cored wire FCAW and FCAW GS RATED WELDING CURRENT AND DUTY CYCLE 10 MINUTE BASIS K2649 1 350 amps at 100 all processes K2650 1 550 amps at 100 FCAW and FCAW GS K2650 1 450 amps at 100 GMAW OVERALL WEIGHT K2649 1 17 5 lbs K2650 1 20 0 lbs CABLE LENGTH 15 0 0 2 feet METHOD OF GUIDANCE Semiautomatic manually guided METHOD OF COOLING Air cooled MAGNUM PRO 350 and 550 FUME GUNS LINCOLN A 2 INSTALLATION A 2 UNPACKING THE FUME GUN Fume guns are factory assembled and tested Both gun models are shipped with a FCAW fume collection nozzle installed Contact tips for 0 045 and 3 32 Diameter Wire are also installed on the 350 and 550 models respectively After opening the packaging check that it contains 1 fully assembled fume gun 1 GMAW fume collection nozzle and 1 instruction man ual IM990 FUME GUN FAMILIARIZATION 550 amp model shown GUN HANDLE Figure A 1 Items 1 thru 10 1 1 8 Turn Fume Collection Nozzle FCAW self shielded version shown 2 Heavy Duty Slip On Gas Nozzle Assembly 3 Heavy Duty Gas Diffuser Assembly with Magnum Pro Contact Tip 4 Fume Tube Assembly with Integral Gun Hanger and Locking Collar Gun Han
5. STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN e Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone e Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca e Use ventilac o e exhaust o para remover fumo da zona respirat ria 6E1i LPSHRERT US KA Fab CRACHECTIMELT FSU CDSE o FREE Fh Bk aa e aiser 2347 42 BelsHiAle e Soco 237 28 MASP siet 2 H4H142104 SDE ASaHala a ge LA dal sut cl gaal bus ja dal Jaial yA a AN Ab op ll sat i e Turn power off before servicing e 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 e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e zt ez REALCE PARC ETERAS z STT F LA TE AGT ER e A HAS HERAS Abus al ail JA y Ji sde e Do not operat
6. 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 posi tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts Exposure to EMF fields in welding may have other health 1 e 1 8 when starting operating or repairing equipment In some cases it may be necessary to remove safety 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 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running qe 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 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 2 0 1 Route the electrode and work cables together Secure them with tape when possible 2 0 2
7. Use only compressed gas cylinders et containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located 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 PL Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s
8. n neet 8 SE 055 CIAT A OTAN SUEZ HS EN ER qa AU Hr A2 e sel AA WBA DAR AA YA gy yl la gali Y 0 dl ds IN d wl Laly ALA guiado Jali DUA daua de Y je aoe e Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos etit uont G ENILTUENERCA Ed A A ess az Ac AP OMS Aa Gide A Ja ALUM Aal awe O e Wear eye ear and body protection o 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 Kor perschutz e Use protec o para a vista ouvido e corpo e E HRUS HICRERELTF AU ORM FRARPHRAR A ez 72 Bo ESE AS ot Ale dis Auer de Lily gadag cl yal ae La 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
9. recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations SAFETY iv PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et a la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher 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 toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux mac
10. 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 from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN amp RES X sl CYLINDER may explode N DATE if damaged za
11. ED WIRE INTO THE GUN S 1 Refer to welding wire literature for proper machine and feeder settings and proper usage 2 Select specified welding wire 3 Load specified welding wire into the feeder 4 Connect the gun to the welding machine per the Installation Section 5 Reconnect power to the welding machine and wire feeder 6 Feed wire through the gun and contact tip lt may be necessary to temporarily remove the contact tip to feed wire Reinstall the tip if it was removed MAKE THE WELD 1 Obtain and use the proper personal protective equipment for welding See Safety Precautions in the Installation Section and at the beginning of this Instruction Manual 2 Cut off the wire so that it extends about 1 4 inches from the contact tip 3 Verify that the input power is connected to the machine and wire feeder 4 Flip the machine s and feeder s power switches to on 5 Flip the fume extractor s power switch to on Set the extractor to the correct operating speed 6 CTWD contact tip to work distance and push GMAW or drag FCAW angle Read the filler wire instructions to determine the correct CTWD and angle values for the selected welding procedure and position the gun accordingly The protruding welding wire should not contact the workpiece Protect the eyes and pull the trigger to begin weld ing Adjust the hand travel speed of the gun to achieve a proper weld The emerging wire shou
12. Never coil the electrode lead around your body 2 0 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded 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 e Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic we
13. TOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society 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 Mm FOR ENGINE 03 1 h ee scalding do les the z al SC radiator pressure cap when the engine is powered equipment Sak 8 i 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running Z SN Hf 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop 0 the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing 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 2 a Electric current flowing through any conductor causes localized
14. c tion manual Contact tip size too small for wirel9 Replace contact tip with one that is the diameter used correct size Sluggish wire feed when trigger is pulled 1 Drive roll is worn or galled Clean drive roll or replace drive roll Machine s wire feed speed setting is 2 Increase wire feed speed too low Wire is obstructed somewhere along 3 Check for obstructions remove any the wire feed path in the gun wire shavings remove kinked wire remove and clean or replace gun tube liner See Maintenance Section Low motor voltage See Troubleshooting section in weld ing machine s instruction manual 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 PRO 350 and 550 FUME GUNS LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Intermittent wire feed when trigger elt Drive roll has become galled 1 Remove and then clean or replace drive roll See Maintenance Section Wire has become kinked along its feed 2 Manually pull wire slowly thru gun until unkinked wire emerges Poor fume extraction Fume powder deposits are blocking oft Remove the powd
15. cablel3 Damaged control leads along are shorted together or commonly cable repair if possible shorted to either welding or acces Otherwise replace gun cable sory switch circuits 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 PRO 350 and 550 FUME GUNS LINCOLN amp NOTES MAGNUM PRO 350 and 550 FUME GUNS LINCOLN amp NOTES MAGNUM PRO 350 and 550 FUME GUNS LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O Japanese ta SI e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e No toque las partes o los electrodos bajo carga con la piel o ropa moja da e 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 e 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 e 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 e Isole se da peca e terra CWERPORAMA MARHE 7 PONE ATANU E eHIT SE MAG A NTUSRELTITFAL er
16. d in place Do not use these fume guns for arc gouging QF the electrode s polarity requirement per the instruc tion manuals Gas selection Connect gas supply to either the machine s or the feeder s gas solenoid valve Set the gas mixer if required to the specified gas com position Gas flow rate Set the supply regulator to deliver a gas flow rate of 50 to 70 SCFH thru the fume gun MAGNUM PRO 350 and 550 FUME GUNS LINCOLN A 4 INSTALLATION A 4 SELECT AND INSTALL A WIRE FEEDER CONNECTION K KIT TABLE A 1 Wire Feeder Data Kit No for Gun Model Manufacturer Model 350 amp 550 amp LN 7 LN 8 amp LN 9 series LN 25 0 052 max K466 1 LN 742 LN 7 LN 8 amp LN 9 series LN 25 1 16 min LN 742 K466 8 LF 72 LN 74 K466 10 Lincoln Electric Series 10 feeders LN 15 PF 10M PF 15M K466 10 Power MIG amp Wirematic series feeders K466 6 LN 7 LN 8 4 LN 9 series 0 052 max none LN 8 4 LN 9 series 1 16 min none Series 10 feeders PF 10M none Tweco Adapted No 2 3 and 4 guns K466 2 Intellimatic Side Kick D 51A Porta MIG Millermatic 130 300 4 35 S 42GL S 52A amp S 54A Swing Arc Dual amp Single S 22 S 325S 52D 54D 54E 60 amp 70 series Dualmatic 27 70 H3S H4S H6S Hobart Mega Conds 27 44 45 70 70S 2000 series 17 Hefty Digamig EH1 5 amp 11 SEH 4 amp 5 SWM11 4 11B 12 13 23 24 25 26 35 VAM2 Note that the Magnum Pro 350 and 550 amp fume guns use the
17. e with panel open or guards off e No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas eil Ph ARAL tz CTMRRATEELEWUTEK St EE EEE MERKLE x e Edo Gel Lae 2134 OAS dal y Gils 3 gal lia Jad Yo Aalt cul Aull dl Aa Ais Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO ZE ES BIR Chinese LEIA E COMPREENDA AS INSTRU OES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR KU ET GEET ENEE CEA BA EFBRLTF EW TL TRHORSREL HED T PEt BA st MPD MIM REM Ao RA BA A JR RE EX 6 FA RU SR IF A ME RODAR AR ECKE EE oo ko D Alo HYE lt A SAL FAP ARA LATA E ETM BELICE Jarl ala QU dl Gah ani y Llei Jub ah ll y lll s i SOU call lla s i y a L LINCOLN e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
18. e you proceed MAGNUM PRO 350 and 550 FUME GUNS LINCOLN amp E 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Low or no shielding gas flow Out of gas 1 Check that an adequate gas sup ply is available Gas supply is turned off or discon 2 Check that all gas supply valves nected are open Gas supply flow regulator s 3 Check that gas flow is set between improperly set 50 to 70 SCFH Machine s gas solenoid valve has 4 See machine s instruction manual malfunctioned Blockage in gun along gas path Gently blow out debris from core tube Gun cable kinked or flattened Attempt to straighten out cable or replace cable Blockage due to excessive spatter 7 Clean or replace gas cone or gas accumulation on gas cone or gas diffuser diffuser Excessive gas leakage from sup 18 Find and repair all leaks ply 10 Gas leakage at gun to feeder 10 Damaged o rings replace both connection seals Gun connector not fully inserted into machine See Maintenance Section Wire feeder runs or begins feeding Defective trigger contacts closed 1 Replace trigger See wire without pulling the gun trigger or dirty Maintenance Section Defective closed trigger circuit in 2 See machine s instruction manual the welding machine Trigger lead s inside gun
19. end of the gun tube Deburr the end of the liner Reinstall gas diffuser by threading into place Tighten to 41 to 47 in lbs with wrench Reinstall contact tip gas nozzle and fume collec tion nozzle MAGNUM PRO 350 and 550 FUME GUNS LINCOLN amp D 2 MAINTENANCE D 2 TRIGGER AND SWITCH LEAD ROUTINGS Gun Handle See Figure D 1 ACCESSORY A Secure both sleeved groups to the copper cable Route the trigger red and white and accessory blue and black leads following the steps shown below Proper routing Provides adequate slack so that the handle can rotate to its trigger up or trigger down positions without damaging or disconnecting the leads Avoids fume air flow blockage and unnecessary restrictions through the handle Start with trigger and gun tube in the trigger down position See Figure B 1 Operation Section Run sleeved accessory switch leads blue and black parallel to gun centerline Rear end of sleev ing right side in photo is even with copper cable nut end Run sleeved trigger leads red and white parallel to gun centerline and next to accessory leads sleeving Rear end of sleeving right side in photo is even with copper cable nut end Remove slack in both pairs of control leads here cone with a cable tie Do not attach any unsleeved leads here Route trigger leads in a loop over and then under neath the gun tube Trigger leads emerge from under the gun tube pas
20. ered deposits gun passages at the fume collection nozzle or fume tube Excessive air currents Block off air drafts Gun has excessive air leaks Check for loose hose clamps or detached hoses Trigger and accessory switch leads 4 Reroute leads See Maintenance are blocking fume air flow Section Fume extraction equipment is switched off Switch on or plug in extraction equip ment Fume extraction equipment is non 16 See Troubleshooting section in extrac functional tor s instruction manual Fume extraction equipment has 7 Clean or replace filters per equipment blocked filters instructions Lincoln Miniflex extractor is set to lowf8 Set to high speed speed Vacuum hose is partially or completely 9 Attempt to straighten out hose or flattened or blocked remove blockage otherwise replace hose 10 Vacuum hose is punctured or torn 110 Punctures Patch hose with tape Tears Replace hose Frequent occurrence of contact tip burn back 1 Improper welding parameters or tech 1 See welding wire literature for proper nique example ESO is too short settings 2 Wire may be feeding intermittently 2 See symptoms on intermittent or slug gish wire feed 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
21. erviceable or maintainable parts inside of the trigger 1 Remove swivel assembly at rear of handle counter clockwise right hand threads remove fume tube s locking collar from handle and remove left side of handle 2 Slide trigger out of right handle half Disconnect red and white leads from trigger Use care to prevent damage to electrical leads and the terminals 3 Connect red and white leads to the new trigger Either lead may be connected to either trigger pin non polarized connections 4 Slide new trigger into place and reassemble the gun Be careful not to pinch any leads between gun handle halves In general the 350 and 550 gun cables have no ser viceable or maintainable parts Here are the only types of cable service that may be performed without removing or replacing an entire gun cable e Replace both o rings on the gun s power and gas connector see Table A 1 Installation Section e Repair the gun s four 19 AWG control leads by splicing and soldering them back together and then reinsulating them with heat shrink tubing See Figure A 3 Installation Section and Trigger Assembly Replacement for a description of the connections e Otherwise a damaged gun cable should be replaced as follows Remove liner assembly per this section Liner Assembly Cleaning or Replacement Remove gun tube assembly per this section Gun Tube Replacement Do not remove spiders or gun tube lock Disc
22. g 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 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 ca
23. ger Handle Cooling Vents 7 Trigger Assembly SPST contacts non locking with Finger Extension Optional locking trigger assembly is available 8 Swivel and Bellows Assemblies increase gun flexi bility 9 Locking Collar amp Swivel allow Rapid Selection of Trigger Down shown or Trigger Up Positions 10 Low Profile Reusable Hose Clamps o O1 FIGURE A Gun Handle k Left side view FEEDER END Figure A 2 Items 1 thru 6 1 Low Profile Reusable Hose Clamps 2 Incoming Connector Assembly accommodates all standard Lincoln Magnum 300 400 and 550 feeder connection K kits Gas Plug Vacuum Connection Modular Trigger Terminal Housing Vacuum Hose and Cover Cover resists hot weld spatter can be quickly and easily replaced with hook amp eye closure along its entire length O O1 E W FIGURE A 2 Feeder End Right side view ASSEMBLY OF FUME GUN INTERNAL PARTS 550 amp model shown GUN HANDLE END Figure A 3 Items 1 thru 7 1 Two spiders support the handle and allow it to swiv el around the gun tube assembly for Trigger Down shown or Trigger Up Positions 2 Gun tube lock with roll pin prevents handle over rotation to avoid trigger lead damage 3 Accessory switch leads blue and black may serve as spare trigger leads 4 Trigger and accessory leads are routed to permit air flow and avoid lead damage 5 One piece copper electrical connector cone and gas hose barb fi
24. hines 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 rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c 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 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie du aux tincelles Quand on ne soude pas poser
25. iflex system High is preferred for maximum fume collection 2 Automatic Manual setting where available Set to Manual mode so that fume collection system will continue running after welding This ensures maxi mum cooling of the gun Fume collection system or gate valve to the gun may be shut off or closed after the gun has cooled for 10 minutes since the last weld MAGNUM PRO 350 and 550 FUME GUNS LINCOLN B 1 OPERATION B 1 SAFETY PRECAUTIONS Read and understand this entire section before operat ing the machine WARNING Ch O ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet cloth ing Insulate yourself from work and ground Always wear dry insulating gloves Read and follow Electric Shock Warnings in the Safety section if weld ing must be performed under electrical ly hazardous conditions such as weld ing in wet areas or on or in the work piece FUMES AND GASES can be dangerous Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS SE can cause fire or explosion Keep flammable material away e Do not weld on containers that have held combustibles ARC RAYS ys y can burn L Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual PRODUCT DESCRIPTION e Reliable indust
26. ing gas at the specified flow rate PPP PREPARING THE FUME GUN FOR WELDING e Read all safety information See the front of this instruction manual Perform the following sections in the order shown Prepare the Welding Machine and Wire Feeder as follows SAFETY PRECAUTIONS 44 WARNING ELECTRIC SHOCK CAN KILL Turn the input power OFF at the weld ing power source before installation or changing drive rolls and or guides e Do not touch electrically live parts e Magnum Pro Fume Guns When inching with the 1 Read all safety information in all related instruction manuals 2 Disconnect input power to the machine and the wire feeder 3 Machine and feeder polarity settings Set to match gun trigger electrode and drive mechanism are hot to work and ground and could remain ener gized several seconds after the gun trigger is released e Welding Machines Wire Feeders and Fume Extraction Equipment Read and understand the equipments instruction manuals and all hazard warnings on equipment and in the manuals Personal Protective Equipment Wear the proper personal protective equip y ment for welding including but not limited to safety glasses hearing protection protective footwear weld ing helmet welding gloves and weld ing leathers e This product shall not be used in precipitation or in wet or damp locations e Use these fume guns only with all consumable parts properly installe
27. 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 a ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PRECAUTIONS DE SURETE POUR LES MACHINES A SOUDER A TRANSFORMATEUR ET A REDRESSEUR Relier a la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de mo
28. ld stay with in the molten puddle and not overrun it This speed also should not be so slow that either the workpiece excessively melts or that the weld bead becomes excessively large Release the trigger to stop welding 10 Fume collection system or gate valve to the gun may be shut off or closed after the gun has cooled for 10 minutes since the last weld MAGNUM PRO 350 and 550 FUME GUNS LINCOLN amp C 1 ACCESSORIES ACCESSORIES OR OPTIONS e Optional dual procedure switch and modular trigger connection to wire feeder e Spoiler An optional ergonomic hand grip MAGNUM PRO 350 and 550 FUME GUNS LINCOLN amp C 1 D 1 MAINTENANCE D 1 RECOMMENDED TOOLS LINER ASSEMBLY CLEANING OR e Adjustable jaw pliers REPLACEMENT e Welding pliers optional e 7 16 inch open end wrench gas diffuser gas plug or fitting gun tube wrench flats 1 1 8 inch open end wrench incoming connector e 9 64 inch allen wrench handle screws e 5 64 inch allen wrench liner set screw e 3 4 inch open end wrench cable cone 7 8 inch open end wrench cable nut 4 e 3 32 inch dia drift gun tube lock removal Hammer e Wire cutter e Wire stripper o e Needlenose pliers e External snap ring pliers gun tube spiders 3 e Terminal crimping tool e Flashlight e Hand held electrical meter A Tape measure or 6 inch scale e Oetiker clamp tool e Oetiker clamp crimping tool 5 ROUTINE CLEANING AND 6 INSPECTIONS 1 Clean out f
29. lding 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 ltems 6 c and 8 LINCOLN L ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Weldin
30. nstall Gun Consumable Parts A 5 Connect the Gun to the Wire teeder A 6 Connect the Gun to the Fume Collection System oocccccoccnccnncnccnncnnonnconcnnannnonanonos A 6 OPERATION rias Section B 1 Safety Precautions iassrocici n die emeree Dern B 1 Product Descriptio In WEE B 1 Selecting or Changing the Trigger Position cccccseeeeeeeceeeeeeeeaeeeeeeseaeeeesseaeeeeeeaees B 2 Prepare the Fume Gun for Welding B 3 Load Specified Wire into the Gun B 3 Make the E B 3 PC COS S ONO arista it di ia Section C 1 e A A ee eee ee Section D Recommended Tools iii D 1 Routine Cleaning and Inspections ss D 1 Gas Diffuser Replacement D 1 Liner Assembly Cleaning or Replacement D 1 Trigger and Accessory Switch Lead Routings s ssssensesernnenrenrrrrnrnresrrrnrnrreerereenne D 2 Gun H IEREN D 3 Trigger Assembly Replacement ns D 3 Gun Cable Assembly Replacement ccccssccccssececeeeeeceeeeeeseeeeeseeeeeeseeeessaaees D 3 D 4 Troubleshooting ranita cn in Section E How To Use Trouble Shooting Guide E 1 OMIS ee ln sra sean io E 2 to E 5 A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS MAGNUM PRO FUME GUNS MODELS K2649 1 Magnum Pro 350 amp Fume Gun K2650 1 Magnum Pro 550 amp Fume Gun WELDING PROCESSES GMAW MIG FCAW also FCAW SS and FCAW GS on ferrous base metals FILLER WIRE ALLOYS
31. ntage ou la piece a souder doit tre branche a une bonne mise a la terre Autant que possible l installation et 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 4 Garder tous les couvercles et dispositifs de s ret leur place LINCOLN amp V V for selecting a QUALITY product by Lincoln Electric We want you You to take pride in operating this Lincoln Electric Company product se 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 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 a
32. ny 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 equipment nameplate Model Name and Sales Spec Number K xxx Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet
33. onnect gun cable s red and white control leads from trigger assembly Disconnect gun cable s blue and black control leads from optional accessory switch if so equipped Disassemble the Y connector halves as follows See Figure A 2 and A 4 Installation Section as a guide e Disconnect the gun s Y connector from the vacuum source e Use the Oetiker tool to remove the gun s clamp from its vacuum hose e Slide the clamp and hose off of the Y con nector s inlet e Remove the 2 screws from the Y connector s modular trigger terminal housing e Remove the 3 screws from the Y connector e Separate the Y connector halves e Remove the modular trigger terminal housing halves and separate them MAGNUM PRO 350 and 550 FUME GUNS LINCOLN amp D 4 MAINTENANCE D 4 6 Remove the two trigger terminals from the modular trigger terminal housing 7 Remove the incoming connector assembly see Item 8 Figure A A Installation Section from the gun cable 8 Remove the damaged gun cable by sliding it rear ward from the vacuum hose 9 Install the new gun cable by sliding it forward through the vacuum hose 10 Reassemble gun by reversing steps 1 through 7 noting the following e Route trigger leads per this section Trigger and Accessory Switch Lead Routings see figure D 1 e Installation torques for both the incoming connector and gun tube assemblies 10 to 12 ft lbs The order of connection of the trigger
34. ossible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility 44 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 PRO 350 and 550 FUME GUNS LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS No wire feed occurs when trigger s 1 Machine is switched off or unplugged f1 Switch on or plug in machine Out of wire 2 Install full spool of specified wire Contact tip burnback 3 Replace contact tip Fully or partially blocked gun liner 4 Remove and clean or replace gun liner See Maintenance Section Bird nest 5 Cut out bird nest reload wire and check for proper wire alignment Defective trigger contacts open orl6 Replace trigger See Maintenance dirty Section Defective trigger circuit in gun Disconnect gun from machine and check trigger circuit for continuity No motor voltage or current from 8 See Troubleshooting section in weld machine ing machine s or wire feeder s instru
35. rial quality welding gun primarily for experienced welders In a few seconds the trigger may be rotated 180 degrees to a trigger up or down position by the welding operator Neither tools nor gun disassembly is required e GMAW or FCAW fume collection nozzles may be selected for fume collection They can be easily and quickly installed or removed by hand The design tol erates dirt accumulation and heat without seizing in place e Optional dual procedure switch and modular trigger connection to wire feeder e Spoiler An optional ergonomic hand grip e Gun cable compactly integrates welding current wire feeding and gas supply with gun control functions MAGNUM PRO 350 and 550 FUME GUNS LINCOLN amp B 2 OPERATION B 2 SELECTING OR CHANGING THE TRIGGER POSITION See Figure B 1 FIGURE B 1 1 Trigger down position shown 4 Tighten locking collar clockwise 2 Loosen Locking Collar counter clockwise right hand threads on fune tube Le k Zeg a 5 Trigger up position shown A 3 Hold fume tube stationary Rotate handle Counter clockwise counter clockwise MAGNUM PRO 350 and 550 FUME GUNS LINCOLN amp B 3 OPERATION B 3 PREPARE THE FUME GUN FOR WELDING Also See Installation Section gt Read all safety information in this Instruction Manual 8 Verify that input power to the machine and the wire feeder is disconnected LOAD SPECIFI
36. s thru lead slot in gun handle and then connect to the trigger Either lead may be connected to either trigger pin non polarized connections Route accessory leads under and then over the gun tube Secure free ends of both leads to the gun tube with a cable tie When reassembling the gun be careful not to pinch any leads between gun handle halves FIGURE D 1 GUN HANDLE LEFT HALF REMOVED SEE STEPS 1 THRU 7 MAGNUM PRO 350 and 550 FUME GUNS LINCOLN D 3 MAINTENANCE D 3 GUN TUBE REPLACEMENT GUN CABLE ASSEMBLY REPLACEMENT e Replace if worn from use for example if gas diffuser threads are deforming 1 Remove consumables per this section Gas Diffuser Replacement 2 Remove swivel assembly at rear of handle ccw right hand threads remove fume tube s locking collar from handle and remove left side of handle 3 Use snap ring pliers to remove both spiders from the old gun tube Use hammer and drift to remove the gun tube lock from the old gun tube 4 Obtain a new replacement gun tube 5 Install spiders and gun tube lock onto the new gun tube 6 Install new gun tube to the gun end of the gun cable Tighten gun tube to gun cable with 10 to 12 ft lbs of torque 7 Reassemble gun Route the control leads inside of gun handle per this section Trigger and Accessory Switch Lead Routing Be careful not to pinch any leads between gun handle halves TRIGGER ASSEMBLY REPLACEMENT e There are no s
37. same connection kits as the Magnum 300 400 and 550 MIG gun products non Fastmate respectively Miller K466 3 ESAB MAGNUM PRO 350 and 550 FUME GUNS LINCOLN A 5 INSTALLATION A 5 SELECT AND INSTALL GUN 4 FUME COLLECTION NOZZLE See Figure A 6 CONSUMABLE PARTS Figure A 6 Forward Inlets Rear Inlets 1 LINER ASSEMBLY TABLE A 2 KP Nos for Gun Model Wire Diameter 350 amp 550 amp 0 035 KP44 3545 15 KP45 3545 15 0 045 KP44 3545 15 KP45 3545 15 0 052 KP44 116 15 KP45 116 15 1 16 KP44 116 15 KP45 116 15 5 64 none KP45H 332 15 3 32 none KP45H 332 15 KP2740 1 KP2740 2 e FCAW flux cored e GMAW MIG Note that the Magnum Pro 350 and 550 amp fume FCAW SS self shielded FCAVWW GS gasshielded guns use the same liner assemblies as the Magnum 300 and 550 MIG gun products respectively e Select the fume collection nozzle to match the weld Ing process 2 CONTACT TIP See Figure A 5 TABLE A 3 Wire 10 piece pack 100 piece pack Diameter __KP2745 035 KP2745 035 B100 KP2745 045 KP2745 045 B100 __KP2745 052 KP2745 052 B100 KP2745 116 KP2745 116 B100 550 __5 64 KP2745 564 KP2745 564 B100 amp 3 32 KP2745 332 KP2745 332 B100 3 GAS DIFFUSER CONTACT TIP AND GAS e Twist counter clockwise to begin removing the fume DIFFUSER collection nozzle right hand thread convention Figure A 5 A Fa Fi H dl F d A ge k j F g
38. termi nals red and white leads to the trigger assembly or in the Y connector is unimpor tant non polarized connections e Reassemble the Y connector by reversing steps shown in 5 Install a new liner if it does not meet the cut dimensional range given per this section Liner Assembly Cleaning or Replacement MAGNUM PRO 350 and 550 FUME GUNS LINCOLN amp E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE 44 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 SYMP TOMS 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 possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the P
39. tting 6 Copper cable nut for high electrical conductivity 7 Two clamps non reusable secure the cable s core tube to its hose barb fittings FIGURE A 3 Gun Handle PES Left Half Removed 5 ae ez ne M mi MAA FEEDER END Figure A 4 Items 1 thru 8 1 Accessory switch leads blue and black may serve as spare trigger leads 2 Trigger and accessory leads are routed to permit air flow and avoid lead damage 3 One piece copper electrical connector cone and gas hose barb fitting 4 Copper cable nut for high electrical conductivity 5 Two clamps non reusable secure the cable s core tube to its hose barb fittings MAGNUM PRO 350 and 550 FUME GUNS LINCOLN amp A 3 INSTALLATION A 3 COMPATIBILITY OF WELDING MACHINES AND WIRE FEEDERS 6 Split Y connector halves allow the gun s feeder end to be easily serviced 7 Modular trigger terminal housing May be easily changed to dual procedure DP harness 8 Incoming connector assembly accepts existing wire 1 feeder connection K kits for Magnum 300 400 and 550 guns If the welding process requires welding gas FCAW GS GMAW or MIG then either the welding machine or feeder must be equipped with a gas solenoid valve to supply welding gas to the fume FIGURE A 4 gun Feeder End 4 Right Half Removed emeng a d 1 el bech gas mixer and regulator is required upstream of i the gas solenoid valve to supply specified blends of weld
40. ume collection nozzle fume tube assembly and handle cooling slots 2 Wipe off dust and debris 3 Clean out the inside of the liner assembly See Liner Assembly Cleaning or Replacecment Installation Section 4 Check that the gun tube and incoming connector assembly are properly tightened to the cable assembly 5 Replace any warning or product identification decals that have become illegible GAS DIFFUSER REPLACEMENT See Select and Install Consumable Parts Installation Section This part may need to be replaced if it has accumulat ed excessive spatter and cannot be cleaned 1 Remove fume collection nozzle gas nozzle and contact tip 2 Install gas diffuser and thread into place in gun tube Tighten diffuser to 41 to 47 in lbs with wrench e Clean out old liner by straightening out the gun and gently blowing out the liner with shop air or obtain a new liner assembly e Replacement liner assemblies are factory made to a length longer than the gun Cutting is required Straighten out the gun Remove fume collection nozzle gas nozzle contact tip and gas diffuser See Liner Assembly Cleaning or Replacecment Installation Section Loosen liner set screw and remove old liner by sliding it rearward from the gun Install new liner and retighten set screw Use care not to over tighten set screw or liner will be deformed and damaged Cut new liner to length measuring 0 500 to 0 625 inches from the
41. use injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe be Read and understand the manufacturer s instructions for this St 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 GL SAFETY 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 and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available NI WELDING and CUTTING 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 steps have been taken to insure that such procedures will not cause flammable or toxic vapors from
42. you proceed MAGNUM PRO 350 and 550 FUME GUNS LINCOLN amp E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed througout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS COURSE OF ACTION PROBLEMS 1 Improper welding parameters or technique example ESO is too short Frequent occurrence of contact tip burnback See welding wire literature for proper settings Wire may be feeding intermittent ly See symptoms on intermittent or sluggish wire feed Poor weld bead appearance porosi 1 No gas flow See symptom Low or no gas ty or dull gray oxidized surface flow Low gas flow See symptom Low or no gas flow Improper or contaminated shield 3 Check that the gas supply s label ing gas ing reads 100 argon Temporarily use alternate known gas supply and check for appear ance improvement Welding in a windy environment 4 Erect a wind shield or move to a non windy location before welding Improper electrode polarity Reconnect machine s welding output to proper electrode polarity Improper welding parameters or See welding wire literature for technique proper settings 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 befor
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