Table of Contents
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Operator's Manual
Magnum
400A & 500A Guns
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10520
| Issue D ate Mar-19
© Lincoln Global, Inc. All Rights Reserved.
®
PRO Water-Cooled
For use with Code Numbers:
K4521-2-FM-45
K4521-2-10-45
K4522-2-FM-45
K4522-2-10-45
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Table of Contents
Related Manuals for Lincoln Electric MAGNUM PRO 400A Series
Summary of Contents for Lincoln Electric MAGNUM PRO 400A Series
- Page 1 Operator’s Manual ® Magnum PRO Water-Cooled 400A & 500A Guns For use with Code Numbers: K4521-2-FM-45 K4521-2-10-45 K4522-2-FM-45 K4522-2-10-45 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM10520 | Issue D ate Mar-19 ©...
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Page 2: Safety Depends On You
THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY... -
Page 3: Section A: Warnings
W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. -
Page 4: Electric Shock Can Kill
SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”... - Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
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Page 6: Installation
® MAGNUM PRO WATER-COOLED 400A & 500A GUNS INSTALLATION... -
Page 7: General Description
® MAGNUM PRO WATER-COOLED 400A & 500A GUNS INSTALLATION General Description The Magnum PRO 400A Water Cooled Gun is rated at 400 amperes 100% duty cycle using mixed gas and cooled with water at a flow rate of .58 gallons per minute (2.2 liters per minute). The Magnum PRO 400A Water-Cooled Gun is equipped to run .035"- 5/64"... -
Page 8: Safety Precautions
® MAGNUM PRO WATER-COOLED 400A & 500A GUNS INSTALLATION INSTALLATION Magnum PRO 400A K4521-2-10-45 Read this entire installation section before you Contact tip .045 – KP2745-045 start installation. Gas Diffuser – KP4380-1 Nozzle 500A, Thread-On, 1/8R 5/8 ID – KP4523-1-62R SAFETY PRECAUTIONS Liner .035-.045 –... -
Page 9: Fast-Mate Gun Installation
® MAGNUM PRO WATER-COOLED 400A & 500A GUNS INSTALLATION Fast-Mate Gun installation K466-1& -8 Installation (For Lincoln Feeders) The Magnum PRO 400A & 500A Water-Cooled Guns come in two a. Remove brass cable connector and insulation tube from the varieties, Fast-Mate™ back end connections and K466-10 back K466-1 kit. -
Page 10: Liner Installation And Trimming Instructions
® MAGNUM PRO WATER-COOLED 400A & 500A GUNS INSTALLATION Connection to water coolers. liner installation anD triMMinG The water cooler should be rated for .58 gallons per minute instructions (2.2 liters per minute) at 60 psi (4.08 atm) or greater. The connectors on the gun water hoses have a male quick connect a. -
Page 11: Operation
MAGNUM ® PRO WATER-COOLED 400A & 500A GUNS OPERATION OPERATION MaKinG a WelD Do not attempt to use this equipment until you Note: Water cooled guns will have a higher voltage drop along the have thoroughly read all operating and mainte- length of the cable than air cooled guns. -
Page 12: Expendable Replacement Parts
MAGNUM ® PRO WATER-COOLED 400A & 500A GUNS ACCESSORIES ACCESSORIES EXPENDABLE REPLACEMENT PARTS Description Part Number Wire Diameter (In.) Wire Diameter (mm) CABLE LINER KP44-3545-15 .035-.045" 0.9-1.2 mm For Cables 15' (4.5 m) and less KP44-116-15 .052-1/16" 1.3-1.6 mm (Steel Wire) KP44-564-15 1/16-5/64 1.6-2.0 mm... - Page 13 MAGNUM ® PRO WATER-COOLED 400A & 500A GUNS ACCESSORIES 4. Cut hose clamps from hoses, use cutting pliers and disconnect them from the connector block. The blue and proceDure to chanGe the GoosenecK 400a black hoses carry water through the torch. anD 500a Guns FIGURE C.3 WARNING...
- Page 14 MAGNUM ® PRO WATER-COOLED 400A & 500A GUNS ACCESSORIES 10. Connect the blue water hose to the copper tubing with the 13. Place the other half of the handle, being careful to not pinch four o-rings on it and crimp it using crimp clamps. the trigger leads, and ensure that it fits well in the other handle half.
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Page 15: Maintenance
MAGNUM ® PRO WATER-COOLED 400A & 500A GUNS MAINTENANCE MAINTENANCE FIGURE D.1 Periodically remove and clean the nozzle, contact tip and gas diffuser. Replace the nozzle if damaged. Regular use of an anti- spatter compound will reduce the adherence of spatter and ease its removal. -
Page 16: Troubleshooting
MAGNUM ® PRO WATER-COOLED 400A & 500A GUNS TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 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. - Page 17 MAGNUM ® PRO WATER-COOLED 400A & 500A GUNS TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEM POSSIBLE AREAS OF RECOMMENDED COURSE OF ACTION (SYMPTOMS) MISADJUSTMENT(S) Drive rolls turn, but wire will Gun cable kinked and/or twisted. Keep as straight as possible. Inspect cable and replace not feed or wire feeding is if necessary.
- Page 18 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
- Page 19 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
- Page 20 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.