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Lincoln Electric K471 manual

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Table of contents for the manual

  • Page 1

    MA GNUM 300 and 400 GMA GUN & CABLE ASSEMBLIES OPERA T OR’S MANUAL IM381-D October , 2005 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 TE OR REP [...]

  • Page 2

    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 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 material to protect your skin[...]

  • Page 4

    iii SAFETY iii 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 ’ s recommendations. 8.c. Ground the equipment in accordance with the U.S. Nat[...]

  • Page 5

    iv SAFETY iv 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 ’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits [...]

  • Page 6

    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 for quick reference. Pay[...]

  • Page 7

    T ABLE OF CONTENTS Page General Description ..................................................................................................... Sectio n A Installation .................................................................................................................. .. Section B Connector Kit Installation to Gun Cable ............[...]

  • Page 8

    GENERAL DESCRIPTION MAGNUM 300 & 400 A-1 A-1 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 GMA W (gas metal arc welding) and gas- shielded FCA W (flux-cored arc welding) processes. Most models of Magnum 300 and 400 g[...]

  • Page 9

    GENERAL DESCRIPTION MAGNUM 300 & 400 A-2 A-2 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° K470-1 10 ft. .035 (0.9) KP2020-1B1 (3.0) .045 (1.2) -2B1 KP2024-1 KP1932-1 KP2023-1 KP1933-1 KP1928-2 K470-7 12 ft. .035 (0.9) KP2020-1B[...]

  • Page 10

    GENERAL DESCRIPTION MAGNUM 300 & 400 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° K471-21 15 ft. .035 (0.9) KP2020-1B1 (4.5) .045 (1.2) -2B1 KP2024-1 KP1932-1 KP2023-1 KP1933-1 KP1928-2 K471-22 15 ft. .052 (1.3) KP2020-3B1 (4.5[...]

  • Page 11

    GENERAL DESCRIPTION MAGNUM 300 & 400 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° K541-1 10 ft. .035 (0.9) KP2020-1B1 (3.0) .045 (1.2) -2B1 KP2024-1 KP1932-1 KP2023-1 KP1933-1 KP1928-2 K541-2 12 ft. .035 (0.9) KP2020-1B1 (3.6) [...]

  • Page 12

    INST ALLA TION MAGNUM 300 & 400 Read this entire installation section before you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. ----------------------------[...]

  • Page 13

    INST ALLA TION MAGNUM 300 & 400 c. For L-T ec machines that require trigger lead con- nections to be made at a terminal strip located with- in the machine (L-T ec 225), a gun control cable with forked terminals is provided. Connect the terminat- ed leads to the terminal strip. For a machine that requires a twist-lock gun control cable connectio[...]

  • Page 14

    INST ALLA TION f. Screw the gas diffuser onto the end of the gun tube and tighten with the wrench provided. g. T ighten the set screw in the side of the gas diffuser against the cable liner using the Allen wrench pro- vided. This screw should only be gently tightened. Overtightening will split or collapse the liner and cause poor wire feeding. ----[...]

  • Page 15

    INST ALLA TION MAGNUM 300 & 400 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 . a. Check that the drive roll(s) and feeder guide tubes are appropriate for the electrode size being used. b.[...]

  • Page 16

    INST ALLA TION c. Insert the control cable plug from the feeder trigger circuit into the mating socket on the gun cable con- nector handle. For machines with a twist-lock trig- ger lead receptacle, if the L-T ec gun control cable does not easily connect with the socket, the gun control cable that came with the K466-5 kit can be used. T o do this, c[...]

  • Page 17

    OPERA TION 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 electr odes for the GMA W process and Lincoln Outershield cor ed electrodes for the gas-shielded FCAW pr ocess. Refer to the appro- priate Lincoln Process and Pr ocedure Guidelines for the electro[...]

  • Page 18

    MAINTENANCE REMOV AL, INST ALLA TION 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 anoth- er gun, unless it can meet the liner cut off length requir ement. Liners are shipped with the jacket of [...]

  • Page 19

    MAINTENANCE e. Uncouple the strain relief by pushing its outer housing toward the middle of the cable. Move the strain relief and the cable boot towar d the middle of the cable, past the damaged section. f. Cut off the damaged section of cable and strip of f the outer jacket as shown in Figure 2. Be car eful not to cut the insulation on the control[...]

  • Page 20

    MAINTENANCE h. Pull the cut-off lead terminals of f the trigger assem- bly and connect the replacement contr ol lead ter- minals. 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 [...]

  • Page 21

    MAINTENANCE 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. Assemble incoming connector to cable by forcing the steel tube of the connector into the inside diameter of the cable inner tube until the copper strands are butted against the incoming connector shou[...]

  • Page 22

    MAINTENANCE MAGNUM 300 & 400 THREAD SIZES FOR MAGNUM 300 & 400 CONSUMABLES D-5 D-5[...]

  • Page 23

    TROUBLESHOOTING MAGNUM 300 & 400 Observe all Safety Guidelines detailed throughout 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 PROBLEMS [...]

  • Page 24

    TROUBLESHOOTING MAGNUM 300 & 400 Observe all Safety Guidelines detailed throughout 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 PROBLEMS [...]

  • Page 25

    NOTES MAGNUM 300 & 400[...]

  • Page 26

    NOTES MAGNUM 300 & 400[...]

  • Page 27

    W ARNING A VISO DE 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 EL [...]

  • Page 28

    W ARNING A VISO DE 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 EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes fro[...]

  • Page 29

    • 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 •[...]