RETURN TO MAIN MENU ® ® MAGNUM & MAGNUM PRO CURVE 200 GMA GUN and CABLE ASSEMBLY Models IM434-C November, 2010 K497 K2950 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 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. 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. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY 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 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 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! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
vi vi TAbLE OF CONTENTS Page Installation .......................................................................................................Section A Safety Precautions ..............................................................................................A-1 Connector Kit Installation to Gun Cable.................................................................A-1 K466-1.............................................................................................................A-1 K466-2....
A-1 INSTALLATION Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING A-1 K446-2 Installation (For Adapted Feeders) a. Remove brass connector (see Figure A-1) from the K466-2 kit and screw it onto the feeder end of the gun cable. Tighten the connection with the wrench provided. ELECTRIC SHOCK can kill. b. Check that the molded gas plug fitting is sealing the gas fitting hole in the side of the feeder end handle.
A-2 A-2 INSTALLATION c. For L-Tec machines that require lead connections to 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 connections, 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.
A-3 A-3 INSTALLATION FIGURE A.2 NOZZLE ASSEMBLY CONTACT TIP DIFFUSER TIGHT AGAINST BRASS CABLE CONNECTOR) LINER ASSEMBLY (LINER BUSHING TO BE SEATED INSULATOR GAS VENTED HOLE LENGTH LINER TRIM 9 / 16” (14.3mm) SET SCREW COLLAR ASSEMBLY GUN TUBE ASSEMBLY FEEDER END CABLE HANDLE GUN HANDLE FEEDER END CABLE HANDLE COLLAR ASSEMBLY GUN HANDLE GUN TUBE ASSEMBLY SET SCREW 9 / 16” (14.
A-4 INSTALLATION A-4 Connection to Adapted Feeders Connection to L-Tec Adapted Feeders Gun cable assemblies which were assembled with a K466-2 Connector Kit will connect easily to any properly adapted feeder. Gun cable assemblies which were assembled with a K466-5 Connector Kit will connect easily to an LTec feeder equipped with an L-Tec feeder connector assembly. L-Tec feeders require this connector assembly (similar to a Tweco® adapter) to connect with a gun and cable. a.
b-1 b-1 OPERATION Read and understand this entire section before operating your machine. GENERAL DESCRIPTION SAFETY PRECAUTIONS The MAGNUM® & MAGNUM® PRO CURVE 200 amp GMA gun and cable assembly has 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: See Table B.1 and Table B.2. WARNING ELECTRIC SHOCK can kill.
b-2 b-2 OPERATION MAGNUM® PRO CURVE 200 200 AMPS AT 60% DUTY CYCLE WITH CO2 GAS 150 AMPS AT 60% DUTY CYCLE WITH MIXED GAS (TAbLE b.2) Description Product Number K2950-2-10-45 K2950-2 Gun Contact Tips Gas Cable Wire Size Heavy Diffuser Length(m) in. (mm) Duty Assembly Gas Nozzle INSULATOR Cable Liner Gun Tube 60° 15 ft. (4.5) .035 (0.9) KP2744-035 .045 (1.2) KP2744-045 KP2746-1 KP2742-1-62R KP2773-2 KP44-3545-15 KP2924-60 15 ft. (4.5) .045 (1.
D-1 MAINTENANCE LINER REMOVAL AND REPLACEMENT NOTICE: 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. Removal, Installation and Trimming Instruction for K497 & K2950 (with K466 Connector Kit installed) a.
D-2 MAINTENANCE D-2 FIGURE D.2 NOTE: The cable contains three control leads. Any two control leads can be used, provided the two color used are the same at both ends. The extra lead is a spare that can be used if one of the other leads breaks 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.
D-3 D-3 MAINTENANCE FIGURE D.4 Wire Feeder End Repair (Requires 2 S19492-1 Terminals) a. Remove the cable liner per Removal, Installation, and Trimming Instructions in this section. b. Remove the feeder end connector, molded gas plug (or barbed fitting), cable handle nut, plastic tailpiece and connector cover (see Figure D.4).
E-1 TROUbLESHOOTING E-1 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.
E-2 E-2 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) POSSIbLE CAUSE Drive rolls turn, but wire will not feed of wire feeding is rough RECOMMENDED COURSE OF ACTION 1. Gun cable kinked and/or twisted. Keep as straight as possible. Inspect cable and replace if necessary. 2. Wire jammed in gun and cable. Remove wire from gun and cable — feed in new wire. Note any obstruction. Replace liner if necessary 3. Incorrect drive rolls and guide tubes.
l Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO l Keep flammable materials away. l Wear eye, ear and body protection. l Mantenga el material combustible l Protéjase los ojos, los oídos y el electrode with skin or wet clothing. l Insulate yourself from work and ground. l No toque las partes o los electrodos bajo carga con la piel o ropa mojada. l Aislese del trabajo y de la tierra.
l Keep your head out of fumes. l Use ventilation or exhaust to l Turn power off before servicing. l Do not operate with panel open or guards off. remove fumes from breathing zone. l Los humos fuera de la zona de res- piración. l Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. l Gardez la tête à l’écart des fumées. l Utilisez un ventilateur ou un aspira- l Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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