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MAGNUM
FM GUN & CABLE ASSEMBLIES
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
®
400 DUAL PROCEDURE
Models
RETURN TO MAIN MENU
OPERATORʼS MANUAL
• World's Leader in Welding and Cutting Products •
K575
K1723
Copyright © Lincoln Global Inc.
IM647-A
March, 2008
K1723
K575
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Related Manuals for Lincoln Electric MAGNUM IM647-A
Summary of Contents for Lincoln Electric MAGNUM IM647-A
- Page 1 ® MAGNUM 400 DUAL PROCEDURE FM GUN & CABLE ASSEMBLIES 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.
-
Page 2: California Proposition 65 Warnings
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: 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 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
Installation ............Section A General DescriptIon . -
Page 8: Installation
GENERAL DESCRIPTION WARNING • Do not touch electrically live parts such as output terminals or internal wiring ------------------------------------------------------------------------ The Magnum®™ 400 DP Dual Procedure FM 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 gas- shielded FCAW (flux-cored arc welding) processes. - Page 9 MAGNUM® 400 FM Dual Procedure 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) 15 ft .035 (0.9) K575-1 (4.5) .045 (1.2) 15 ft .052 (1.3) K575-2...
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Page 10: Contact Tip And Gas Nozzle Installation
Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or nal wiring. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. ------------------------------------------------------------------------ Only qualified personnel should install, use or service this equipment. -
Page 11: Operation
ELECTRODES AND EQUIPMENT The Magnum® 400 Dual Procedure guns and cables have been designed 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. -
Page 12: Maintenance
REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM® LINERS FEEDING STEEL WIRE (KP44 and KP44N liner series) 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 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. e) Uncouple the strain relief by pushing its outer housing toward the middle of the cable.
- Page 15 g) Check that the cable boot and both halves of the strain relief are on the cable. Slip the connector nut over the copper 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.
- Page 16 For K1723: Connect the black lead and the white lead to the gun trigger. Connect the other leads to the rocker switch leads. (See Figure E.6). STRAIN RELIEF STRAIN RELIEF HOUSING CABLE BOOT 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.
- Page 17 NOTE: For best results, insert 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 tighten, hold the connector in place while turning the nut, then remove the rod from the core.
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Page 18: Thread Sizes For Magnum® 400 Consumables
MAINTENANCE THREAD SIZES FOR MAGNUM® 400 CONSUMABLES MAGNUM® 400 FM DUAL PROCEDURE GUNS... -
Page 19: Troubleshooting
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 20 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Drive rolls turn, but wire will not feed or wire feeding is rough. 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 21 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Poor arc striking with sticking or “blast-offs”, weld porosity, narrow and ropy looking bead, or electrode stubbing into plate while welding. 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 22 NOTES MAGNUM® 400 FM DUAL PROCEDURE GUNS...
- Page 23 NOTES MAGNUM® 400 FM DUAL PROCEDURE GUNS...
- Page 24 NOTES MAGNUM® 400 FM DUAL PROCEDURE GUNS...
- Page 25 NOTES MAGNUM® 400 FM DUAL PROCEDURE GUNS...
- Page 26 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
- Page 27 Spanish PRECAUCION French ATTENTION German Portuguese Japanese Chinese Korean Arabic WARNING AVISO DE WARNUNG ATENÇÃO...
- Page 28 • 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...