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MAGNUM
®
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 thought-
ful operation 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.
• 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
550 GUN & CABLE ASSEMBLY
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
IM475-A
March, 2008
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Related Manuals for Lincoln Electric MAGNUM 550
Summary of Contents for Lincoln Electric MAGNUM 550
- Page 1 IM475-A MAGNUM 550 GUN & CABLE ASSEMBLY ® March, 2008 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 thought- ful operation on your part.
- Page 2 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.
- Page 3 SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
- Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
- Page 5 SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
- Page 6 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.
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Page 7: Table Of Contents
TABLE OF CONTENTS Page Installation ............Section A General Description. -
Page 8: Installation
INSTALLATION GENERAL DESCRIPTION The MAGNUM® 550 GMA gun and cable assembly has been designed to meet NEMA specification EW3 for welding with steel elec- trode using the GMAW (gas metal arc welding) and the gas-shielded FCAW (flux-cored arc welding) processes: MAGNUUM™... - Page 9 INSTALLATION The K598 MAGNUM® guns are not factory equipped For best results when welding mild and alloy steels, it with a feeder end connector. With the K613-1 MAG- is recommended that L-50 or L-56 Lincoln solid wire NUM® Connector Kit, they can be used with any electrodes be used for the GMAW process and Lincoln LN-7 or LN-25 semiautomatic wire feeder.
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Page 10: Connector Kit Installation To Gun Cable
INSTALLATION INSTALLATION WARNING K613-1 & K613-6 Installation (For Lincoln Feeders) ELECTRIC SHOCK can kill. a. Remove brass cable connector and insulation tube • Have a qualified individual install (See Figure 1) from the K613-1 kit. Slide the insu- and service this equipment. lation tube onto the connector from the threaded end and screw it onto the feeder end of the gun •... -
Page 11: K613-4 Installation (For Older Hobart Feeders)
INSTALLATION K613-4 Installation (For Older Hobart Feeders) Slide one end of the tubing onto the barbed connec- tor on the feeder end cable handle (step b) and a. Remove brass cable connector (See Figure 1) move the clamp down near the end of the tube to from the K613-4 kit and screw it on to the feeder assure a good gas seal. -
Page 12: Rotating The Gun Tube
INSTALLATION For K613-3 and K613-4, screw in the connectorcap The proper nozzle should be selected based on the provided in the kit until it seats on the face of the welding application. Different diameter self insulated bushing. Then insert the appropriate piece of liner gas nozzles are also available to allow gas-shielded, material into the connector cap and tighten the set flux-cored welding. -
Page 13: Connection To Older Hobart Feeders
GUN RECEPTACLE GAS INLET FOR material are included in each kit. MAGNUM 550 GUN Fully push the brass connector end of the gun and cable into the connector receptacle on the outgoing side of the feeder wire drive. Tighten the hand screw to clamp down on the connector. -
Page 14: Operation
OPERATION OPERATION c. Lower welding helmet, close gun trigger, and begin welding. Hold the gun so the contact tip to work distance gives the correct electrical stickout Electrodes and Equipment as required for the procedure being used. The MAGNUM® 550 guns and cables have been d. -
Page 15: Maintenance
MAINTENANCE MAINTENANCE b. Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as WARNING required. ELECTRIC SHOCK can kill. c. To remove gun tube from gun, loosen socket- • Have a qualified individual install head clamping screw in handle with 3/16”... - Page 16 MAINTENANCE e. Cut off the damaged section of cable and strip off the outer jacket as shown in Figure 3. Be careful not to cut the insulation on the control wires while stripping jacket. Strip the red and white control leads .25”...
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Page 17: Wire Feeder End Repair
MAINTENANCE Install gun tube per section entitled “Gun Tube NOTE: For best results, insert a .250” (6.4mm) and Nozzles”. diameter rod through the connector and into core of cable approximately 11.00” (280mm) when k. Install and trim liner per installation instructions. pushing the connector tube into the cable core tube. - Page 18 MAINTENANCE THREAD SIZES FOR K598-1 thru -14 MAGNUM 550 CONSUMABLES USED WITH An KP1951-1 or -2 Gun Tube (Tweco® NO. 6) M17 X 2 M12 X 1.5 M8 X 1.25 THREAD SIZES FOR K598-15 thru -18 MAGNUM 550 CONSUMABLES USED WITH An KP1952-3 Gun Tube (Tweco®...
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Page 19: 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. - Page 20 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Drive rolls turn, but wire will not feed or a. Gun cable kinked and/or twisted. a. Keep as straight as possible. Inspect wire feeding is rough. cable and replace if necessary.
- Page 21 NOTES MAGNUM® 550...
- Page 22 NOTES MAGNUM® 550...
- Page 23 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
- Page 24 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. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 25 • 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...