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MAGNUM
Fast-Mate™ Gun and Cable Assemblies
K575 is now located in IM647
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
• 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
RETURN TO MAIN MENU
®
300FM and 400FM
K478
Models
K479
OPERATORʼS MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
IM389-C
March, 2008
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric MAGNUM 300FM
Summary of Contents for Lincoln Electric MAGNUM 300FM
- Page 1 ® MAGNUM Fast-Mate™ Gun and Cable Assemblies K575 is now located in IM647 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...
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Page 2: California Proposition 65 Warnings
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: Electric Shock Can Kill
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. - Page 4 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 materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 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.
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Page 7: Table Of Contents
General DescriptIon ..........Section A Installation . -
Page 8: General Description
GENERAL DESCRIPTION GENERAL DESCRIPTION The Magnum® 300 amp and 400 amp GMA gun and cable assemblies have been designed to meet NEMA specification EW3 for welding with steel electrode using the GMAW (gas metal arc welding) and the gas-shield- ed FCAW (flux-cored arc welding) processes: 300 AMPS AT 60% DUTY CYCLE WITH CO 200 AMPS AT 60% DUTY CYCLE WITH MIXED GAS Description... - Page 9 400 AMPS AT 60% DUTY CYCLE WITH CO 400 AMPS AT 50% DUTY CYCLE WITH MIXED GAS Description Product Cable Wire Size Number Length (m) in. (mm) 10 ft. .035 (0.9) K479-1 (3.0) .045 (1.2) 15 ft. .035 (0.9) K479-2 (4.5) .045 (1.2) 10 ft.
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Page 10: Installation
INSTALLATION WARNING ELECTRICAL SHOCK can kill. • Have an electrician install and ser- vice this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. The K478 and K479 Magnum® FM guns are factory installed with a Fast-Mate (European style) wire feeder connector for “all-in-one”... -
Page 11: Operation
OPERATION ELECTRODES AND EQUIPMENT The Magnum® 300 FM and Magnum® 400 FM guns and cables have been designed for use with Lincoln L- 50 and L-56, solid steel wire electrodes for the GMAW process and Lincoln Outershield ® cored electrodes for the gas-shielded FCAW process. -
Page 12: Maintenance
REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM® LINERS FEEDING STEEL WIRE (KP1933, KP1936 and KP1955 series liners) NOTE: The variation in cable lengths prevents the interchangeability of liners. Once a liner has been cut for a particular gun, it should not be installed in anoth- er gun, unless it can meet the liner cut off length requirement. -
Page 13: Gun Tubes And Nozzles
CAUTION This screw should only be gently tightened. Overtightening will split or collapse the liner and cause poor wire feeding. ------------------------------------------------------------------------ 6. Replace the nozzle insulator and gas nozzle. GUN TUBES AND NOZZLES a. Replace worn contact tips as required. b. - Page 14 CABLE REPAIR The Magnum® 300 FM and Magnum® 400 FM guns feature the use of repairable cable connectors. If the cable ever gets severely damaged, it may be cut short- er and repaired by the user. Repair cables as follows: Gun Tube End Repair (K478 and K479) (Requires 2 #S19492-2 Terminals) a) Remove the cable liner per “Removal Instructions...
- Page 15 MAINTENANCE CABLE 1.65 (41.9 mm) SKIN FIGURE E.2 FIGURE E.3 FIGURE E.4 MAGNUM® FAST-MATE™ * USE .38" (9.5 mm) SKIN FOR - FEEDER END OF FM MODELS CONTROL LEAD INNER TUBE COPPER STRANDING CONTROL LEAD...
- Page 16 e) Remove the incoming connector from the cable by unscrewing the connector nut from the incoming connector. If the cable inner tube is difficult to remove from the connector assembly, carefully slit it lengthwise with a knife up to the brass connector. f) Cut the cable control wires where they meet the cable jacket or else unsolder the connection where they connect to the terminal lead assembly.
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Page 17: Thread Sizes For Magnum® 300 And 400 Consumables
MAINTENANCE THREAD SIZES FOR MAGNUM® 300 & 400 CONSUMABLES MAGNUM® FAST-MATE™... -
Page 18: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE 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 19: Troubleshooting
Observe all Safety Guidelines detailed througout this manual PROBLEMS (SYMPTOMS) 1. Drive rolls turn, but wire will not feed or wire feeding is rough. 2. Variable or “hunting” arc. 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. - Page 20 Observe all Safety Guidelines detailed througout this manual PROBLEMS (SYMPTOMS) 3. Poor arc striking with sticking or “blast-offs”, weld porosity, narrow and ropy looking bead, or elec- trode stubbing into plate while welding. 4. Tip seizes in diffuser. 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.
- Page 21 NOTES MAGNUM® FAST-MATE™...
- Page 22 NOTES MAGNUM® FAST-MATE™...
- Page 23 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 24 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE WARNUNG ATENÇÃO...
- 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...