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Lincoln Electric MAGNUM 400 DUAL PROCEDURE IM646-A manual

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Table of contents for the manual

  • Page 1

    MA GNUM 400 DU AL PROCEDURE GMA GUN & C ABLE ASSEMBLIES OPERA T ORʼS MANUAL IM646-A March, 2008 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 REP[...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. Turn 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 ski[...]

  • Page 4

    iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. Turn 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 manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. Natio[...]

  • 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 LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à[...]

  • 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 Installation .................................................................................................................. ... Section A General Description ......................................................................................................A-1, A -2 Connector Kit Installation to Gun Cable ............[...]

  • Page 8

    A-1 INST ALLA TION MAGNUM® 400 DUAL PROCEDURE GUNS A-1 GENERAL DESCRIPTION The Magnum®™ 400 DP Dual Procedure GMA gun and cable assemblies have been designed to meet NEMA specification EW3 for welding with steel elec- trode using the GMAW (gas metal arc welding) and gas-shielded FCAW (flux-cored arc welding) process- es. Magnum® 400 DP guns an[...]

  • Page 9

    A-2 INST ALLA TION MAGNUM® 400 DUAL PROCEDURE GUNS A-2 Description Gun Contact Tips Gas Product Cable Wire Size Standard Diffuser Gas Cable Gun Tube Number Length (m) in. (mm) Duty Assembly Nozzle Insulator Liner 60° 15 ft .035 (0.9) KP14-35 K574-1 (4.5) .045 (1.2) -45 KP54A KP24A-62 KP34A KP44-3545-15 KP1928-1 15 ft .052 (1.3) KP14-52 K574-2 (4.[...]

  • Page 10

    A-3 INST ALLA TION A-3 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 inter- nal wiring. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. ---------------------------------------[...]

  • Page 11

    A-4 INST ALLA TION A-4 K466-5 INSTALLATION (For L-Tec Feeders equipped with an L-Tec feeder connector assembly, MIG 35, MIG 31A, 225...) a. Remove brass cable connector (see Figure B.1) from the kit and screw it onto the feeder end of the gun cable. Tighten the connection with the wrench provided. b. Check that the molded gas plug fitting is sealin[...]

  • Page 12

    A-5 INST ALLA TION A-5 LINER INSTALLATION AND TRIMMING INSTRUCTIONS Installation of (KP44 and KP44N liner series) a. Lay the gun and cable straight on a flat surface. b. Make sure that the set screw in the connector end is backed out so as not to damage liner or liner bushing. Remove and save the gas nozzle, nozzle insulator, and gas diffuser from [...]

  • Page 13

    A-6 INST ALLA TION A-6 CONTACT TIP AND GAS NOZZLE INSTALLATION a. Choose the correct size contact tip for the elec- trode being used (wire size is stenciled on the side of the contact tip) and screw it snugly into the gas diffuser. b. Be sure the nozzle insulator is fully screwed onto the gun tube and does not block the gas holes in the diffuser. ([...]

  • Page 14

    A-7 INST ALLA TION A-7 CONNECTION TO MILLER FEEDERS Gun and cable assemblies which were assembled with a K466-3 Connector Kit will connect easily to a variety of popular Miller wire feeders. a. Check that the gun liner, connector cap liner, drive rolls and guide tubes are appropriate for the elec- trode size being used. b. Fully push the brass conn[...]

  • Page 15

    B-1 OPERA TION B-1 MAGNUM® 400 DUAL PROCEDURE GUNS 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[...]

  • Page 16

    D-1 MAINTENANCE D-1 MAGNUM® 400 DUAL PROCEDURE GUNS 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 requireme[...]

  • Page 17

    D-2 MAINTENANCE D-2 MAGNUM® 400 DUAL PROCEDURE GUNS CABLE CONTROL LEAD (4 CONTROL LEADS) CABLE CONTROL LEADS (4 CONTROL LEADS) (41.9mm SKIN) 1/4" (6.4mm) SKIN Figure E.1 Figure E.2 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 a[...]

  • Page 18

    D-3 MAINTENANCE D-3 MAGNUM® 400 DUAL PROCEDURE GUNS Figure E.3 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. Assemble gun tube [...]

  • Page 19

    D-4 MAINTENANCE D-4 MAGNUM® 400 DUAL PROCEDURE GUNS SWITCH WIRES T0 RED LEAD CABLE ASSEMBLY STRAIN RELIEF STRAIN RELIEF HOUSING CABLE BOOT GUN TUBE TRIGGER WIRES GUN HOUSING TRIGGER ASSEMBLY TO BLUE LEAD SWITCH Figure E.5 For K1722: Connect the black lead and the white lead to the gun trigger. Connect the other leads to the rocker switch leads. (S[...]

  • Page 20

    D-5 MAINTENANCE D-5 MAGNUM® 400 DUAL PROCEDURE GUNS c ) Remove incoming connector from cable by unscrewing connector nut from incoming 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. d) Move the cable boot, cable handle, and strain relie[...]

  • Page 21

    D-6 MAINTENANCE D-6 MAGNUM® 400 DUAL PROCEDURE GUNS Figure E.8 For K1722: The control cable leads should be connected to the same color leads on the gun cable. Insulate each of the solder connections with either heat shrink tubing or electrical tape. Anchor leads as shown in Figure E.8. Position the plastic strain relief such that the tapered end [...]

  • Page 22

    D-7 D-7 MAGNUM® 400 DUAL PROCEDURE GUNS THREAD SIZES FOR MAGNUM® 400 CONSUMABLES MAINTENANCE[...]

  • Page 23

    E-1 TROUBLESHOOTING E-1 MAGNUM® 400 DUAL PROCEDURE GUNS 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 Troubleshooting Guide is provided to help you l[...]

  • Page 24

    E-2 TROUBLESHOOTING E-2 MAGNUM® 400 DUAL PROCEDURE GUNS 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[...]

  • Page 25

    E-3 TROUBLESHOOTING E-3 MAGNUM® 400 DUAL PROCEDURE GUNS 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[...]

  • Page 26

    NOTES MAGNUM® 400 DUAL PROCEDURE GUNS[...]

  • Page 27

    NOTES MAGNUM® 400 DUAL PROCEDURE GUNS[...]

  • Page 28

    NOTES MAGNUM® 400 DUAL PROCEDURE GUNS[...]

  • Page 29

    NOTES MAGNUM® 400 DUAL PROCEDURE GUNS[...]

  • Page 30

    READ AND UNDERST AND THE MANUFACTURER’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 USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE V A A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR. LISEZ ET COMPRENEZ LE[...]

  • Page 31

    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. W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic G Keep your head out of fumes. G Use ventilation or exhaust to remove fumes from[...]

  • Page 32

    • 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 • World's Leader in Welding and Cutting Products •[...]