IM381-D MAGNUM ® 300 and 400 GMA GUN & CABLE ASSEMBLIES October, 2005 Models K470 K471 K541 K1802-1 K2286-1 K574 is now located in IM646 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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 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. 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. I standards. 3.b.
iii iii SAFETY WELDING 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. 6.b.
iv iv SAFETY 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi vi TABLE OF CONTENTS Page General Description ..................................................................................................... Section A Installation .................................................................................................................... Section B Connector Kit Installation to Gun Cable ............................................................................. B-1 K466-1 &-8 Installation ...............................................................
A-1 A-1 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 gasshielded FCAW (flux-cored arc welding) processes. Most models of Magnum 300 and 400 guns are not factory equipped with a feeder end connector, except K1802-1 and K2286-1, (they have a factory installed feeder end connector).
A-2 A-2 GENERAL DESCRIPTION MAGNUM 300 (300 amperes) AT 60% DUTY CYCLE WITH CO2 GAS* Description Gun Cable Length (m) Wire Size in. (mm) Contact Tips Standard Duty Gas Diffuser Assembly Gas Nozzle Insulator Cable Liner Gun Tube 60° 10 ft. (3.0) .035 (0.9) .045 (1.2) KP2020-1B1 -2B1 KP2024-1 KP1932-1 KP2023-1 KP1933-1 KP1928-2 12 ft. (3.0) .035 (0.9) .045 (1.2) KP2020-1B1 -2B1 KP2024-1 KP1932-1 KP2023-1 KP1933-1 KP1928-2 K470-2 / K1802-1∆ 15 ft. (4.5) .035 (0.9) .045 (1.
A-3 A-3 GENERAL DESCRIPTION MAGNUM 400 (400 amperes)AT 60% DUTY CYCLE WITH CO2 GAS* Description Gun Cable Length (m) Wire Size in. (mm) Contact Tips Standard Duty Gas Diffuser Assembly Gas Nozzle Insulator Cable Liner Gun Tube 60° 10 ft. (3.0) .035 (0.9) .045 (1.2) KP2020-1B1 -2B1 KP2024-1 KP1932-1 KP2023-1 KP1933-1 KP1928-2 12 ft. (3.6) .035 (0.9) .045 (1.2) KP2020-1B1 -2B1 KP2024-1 KP1932-1 KP2023-1 KP1933-1 KP1928-2 K471-2/ K2286-1∆ 15 ft. (4.5) .035 (0.9) .045 (1.
A-4 A-4 GENERAL DESCRIPTION MAGNUM 400 SHORT NECK (400 amperes at reduced duty cycle) 40% WITH CO2 GAS* Description Product Number K541-1 K541-2 K541-3 Gun Cable Length (m) Wire Size in. (mm) Contact Tips Standard Duty Gas Diffuser Assembly Gas Nozzle Insulator Cable Liner Gun Tube 60° 10 ft. (3.0) .035 (0.9) .045 (1.2) KP2020-1B1 -2B1 KP2024-1 KP1932-1 KP2023-1 KP1933-1 KP1928-2 12 ft. (3.6) .035 (0.9) .045 (1.
B-1 INSTALLATION Read this entire installation section before you start installation. B-1 K466-2 INSTALLATION (For Tweco Adapted Feeders) a. Remove brass cable connector (see Figure 1) from the K466-2 kit and screw it onto the feeder end of the gun cable. Tighten the connection with the wrench provided. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Insulate yourself from the work and ground.
B-2 INSTALLATION c. For L-Tec machines that require trigger lead connections to be made at a terminal strip located within the machine (L-Tec 225), a gun control cable with forked terminals is provided. Connect the terminated leads to the terminal strip. For a machine that requires a twist-lock gun control cable connection, continue to use the L-Tec gun control cable provided with the L-Tec wire feeder connector assembly. Connect the twist-lock plug to the proper receptacle on the machine.
B-3 B-3 INSTALLATION f. Screw the gas diffuser onto the end of the gun tube and tighten with the wrench provided. g. Tighten the set screw in the side of the gas diffuser against the cable liner using the Allen wrench provided. 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.
B-4 INSTALLATION B-4 b. 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. CONNECTION TO FEEDER CONNECTION TO LINCOLN FEEDERS Gun cable assemblies which were assembled with a K466-1 or -8 Connection Kit will connect easily to any Lincoln LN-7, LN-8, LN-9, SP-200 or LN-25 feeder. c.
B-5 INSTALLATION c. Insert the control cable plug from the feeder trigger circuit into the mating socket on the gun cable connector handle. For machines with a twist-lock trigger lead receptacle, if the L-Tec gun control cable does not easily connect with the socket, the gun control cable that came with the K466-5 kit can be used. To do this, cut off the gun control leads as close to the forked terminals as possible and skin back the leads 7/16” (11 mm).
C-1 OPERATION ELECTRODES AND EQUIPMENT The Magnum 300 and Magnum 400 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. Refer to the appropriate Lincoln Process and Procedure Guidelines for the electrode used for information on recommended electrical and visible stickouts.
D-1 D-1 MAINTENANCE REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM 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 another gun, unless it can meet the liner cut off length requirement. Liners are shipped with the jacket of the liner extended the proper amount. a. Remove the gas nozzle and nozzle insulator. Loosen the set screw located in the side of the diffuser with 5/64 (2.
D-2 D-2 MAINTENANCE IN * S) ) SK LEAD m m 4 OL . R 6 ( T .25" H CON T (BO CABLE CONTROL LEAD INNER TUBE COPPER STRANDING CONTROL LEAD 1.65 (41.9 mm) SKIN Figure 2 e. Uncouple the strain relief by pushing its outer housing toward the middle of the cable. Move the strain relief and the cable boot toward the middle of the cable, past the damaged section. f. Cut off the damaged section of cable and strip off the outer jacket as shown in Figure 2.
D-3 MAINTENANCE h. Pull the cut-off lead terminals off the trigger assembly and connect the replacement control lead terminals. 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. k. Assemble cable in left side of gun handle. Assemble trigger into the proper handle cavity. Assemble right side of gun handle and tighten the three screws that hold the handle together. Refer to Figure 4. l.
D-4 D-4 MAINTENANCE 4.68 (119 mm) GAS PLUG OR FITTING FEEDER END CONNECTOR PRESS HERE TO REMOVE THE CABLE HANDLE NUT CONNECTOR COVER CABLE BOOT CABLE CABLE HANDLE CABLE HANDLE NUT TAIL PIECE STRAIN RELIEF HOUSING STRAIN RELIEF .43 (11 mm) MAX. INCOMING CONNECTOR Figure 5 f. Check that the cable boot and cable handle are on the cable. Slip the connector nut over the copper strands with the threaded end out.
D-5 MAINTENANCE THREAD SIZES FOR MAGNUM 300 & 400 CONSUMABLES MAGNUM 300 & 400 D-5
E-1 E-1 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE REMEDY PROBLEMS Drive rolls turn, but wire will not feed or wire feeding is rough. a. Gun cable kinked and/or twisted. a. Keep as straight as possible. Inspect cable and replace if necessary. b. Wire jammed in gun and cable. b. Remove wire from gun and cable – feed in new wire. Note any obstruction. Replace liner if necessary. c. Incorrect drive rolls and guide tubes. c.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE REMEDY PROBLEMS Poor arc striking with sticking or a. Improper procedures or “blast-offs”, weld porosity, narrow techniques. and ropy looking bead, or electrode b. Improper gas shielding. stubbing into plate while welding. a. See “Gas Metal Arc Welding Guide” (GS100). b. Clean gas cone. Make certain that gas diffuser is not restricted.
NOTES MAGNUM 300 & 400
NOTES MAGNUM 300 & 400
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
• 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.