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Lincoln Electric 400FM manual

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Table of contents for the manual

  • Page 1

    MA GNUM 300FM and 400FM Fast-M ate ™ Gun and Cable Assemblies OPERA T ORʼS MANUAL IM389-C March, 2008 Safety Depends on Y ou 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 INST ALL, OPERA T[...]

  • Page 2

    i SAFETY i MAGNUM® F AST -MA TE™ FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ___________[...]

  • Page 3

    ii SAFETY ii MAGNUM® F AST -MA TE™ ARC RA YS can burn. 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. 4.b. Use suitable clothing made from durable flame-resistant mate[...]

  • Page 4

    iii SAFETY iii MAGNUM® F AST -MA TE™ FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ʼs recommendations. 8.c. Ground the equipment in accor[...]

  • Page 5

    iv SAFETY iv MAGNUM® F AST -MA TE™ 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 L ʼArc 1. Protegez-vous contre la secousse élec[...]

  • Page 6

    MAGNUM® F AST -MA TE™ 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy[...]

  • Page 7

    Page General DescriptIon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Required Cable Connection Kits . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 8

    GENERAL DESCRIPTION Description Gun Contact Tips Gas Product Cable Wire Size Standard Diffuser Gas Cable Gun T ube Number Length (m) in. (mm) Duty Assembly Nozzle Insulator Liner 60° 10 ft. .035 (0.9) KP14-35 K478-1 (3.0) .045 (1.2) -45 KP54A KP24A-62 KP34A KP44-3545-15 KP1928-2 15 ft. .035 (0.9) KP14-35 K478-2 (4.5) .045 (1.2) -45 KP54A KP24A-62 [...]

  • Page 9

    GENERAL DESCRIPTION MAGNUM® F AST -MA TE™ Description Gun Contact Tips Gas Product Cable Wire Size Standard Diffuser Gas Cable Gun T ube Number Length (m) in. (mm) Duty Assembly Nozzle Insulator Liner 60° 10 ft. .035 (0.9) KP14-35 K479-1 (3.0) .045 (1.2) -45 KP54A KP24A-62 KP34A KP44-3545-15 KP1928-1 15 ft. .035 (0.9) KP14-35 K479-2 (4.5) .045 [...]

  • Page 10

    INST ALLA TION INST ALLA TION ELECTRICAL SHOCK can kill. • Have an electrician install and ser- vice this equipment. • T urn 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 fo[...]

  • Page 11

    OPERA TION OPERA TION 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 GMA W process and Lincoln Outershield ® cored electrodes for the gas-shielded FCA W process. Refer to the appro- priate Lincoln Process and Procedure Guid[...]

  • Page 12

    MAGNUM® F AST -MA TE™ REMOV AL, INST ALLA TION 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 t[...]

  • Page 13

    MAGNUM® F AST -MA TE™ 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. Remove spatter f[...]

  • Page 14

    MAINTENANCE CABLE REP AIR 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 T ube End Repair (K478 and K479) (Requires 2 #S19492-2 T erminals) a) Remove the cable liner per “Removal I[...]

  • Page 15

    FIGURE E.4 MAINTENANCE MAGNUM® F AST -MA TE™ CABLE CONTROL LEAD INNER TUBE COPPER STRANDING CONTROL LEAD 1.65 (41.9 mm) SKIN * USE .38" (9.5 mm) SKIN FOR - FEEDER END OF FM MODELS .25" (6.4 mm) SKIN *- (BOTH CONTROL LEADS) FIGURE E.2 FIGURE E.3 D-4 D-4[...]

  • Page 16

    4.10 (104 mm) Terminal Lead Assembly Cable Handle Central Adapter Assembly Collar Nut Incoming Connector Assembly Connector Nut Cable Boot Strain Relief Strain Relief Housing Boot Nut - FIGURE E.5 MAINTENANCE e) Remove the incoming connector from the cable by unscrewing the connector nut from the incoming connector . If the cable inner tube is dif [...]

  • Page 17

    MAINTENANCE MAGNUM® F AST -MA TE™ THREAD SIZES FOR MAGNUM® 300 & 400 CONSUMABLES D-6 D-6[...]

  • Page 18

    TROUBLESHOOTING MAGNUM® F AST -MA TE™ 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. CAUTION This T roubleshooting Guide is provided to help you locate and repa[...]

  • Page 19

    TROUBLESHOOTING MAGNUM® F AST -MA TE™ Observe all Safety Guidelines detailed througout this manual 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. CAUTION FUNCTI[...]

  • Page 20

    TROUBLESHOOTING MAGNUM® F AST -MA TE™ Observe all Safety Guidelines detailed througout this manual 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. CAUTION FUNCTI[...]

  • Page 21

    NOTES MAGNUM® F AST -MA TE™[...]

  • Page 22

    MAGNUM® F AST -MA TE™ NOTES[...]

  • Page 23

    W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA [...]

  • Page 24

    W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fume[...]

  • Page 25

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com • World's Leader in W elding and Cutting Products •[...]