Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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 fumesoutdoors. ...
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼsrecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
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 seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
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...
Page 7 - TABLE OF CONTENTS; MAGNUM® 400 DUAL PROCEDURE GUNS
TABLE OF CONTENTS Page Installation ..................................................................................................................... Section A General Description ......................................................................................................A-1, A-2Connec...
Page 8 - INSTALLATION; GENERAL DESCRIPTION; • Do not touch electrically live parts
A-1 INSTALLATION MAGNUM® 400 DUAL PROCEDURE GUNS A-1 GENERAL DESCRIPTION The Magnum®™ 400 DP Dual Procedure GMA gunand cable assemblies have been designed to meetNEMA specification EW3 for welding with steel elec-trode using the GMAW (gas metal arc welding) andgas-shielded FCAW (flux-cored arc weldi...
Page 9 - MAGNUM® 400 Dual Procedure
A-2 INSTALLATION 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 KP44-3545-1...
Page 11 - K 4 6 6 - 5 I N S T A L L A T I O N
A-4 INSTALLATION A-4 K 4 6 6 - 5 I N S T A L L A T I O N ( F o r L - T e c F e e d e r s 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 thegun cable. Tighten the connection wi...
Page 12 - LINER INSTALLATION AND TRIMMING INSTRUCTIONS; CAUTION
A-5 INSTALLATION 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 linerbushing. Remove and save the gas n...
Page 13 - CONTACT TIP AND GAS NOZZLE INSTALLATION; CONNECTION TO FEEDER; CONNECTION TO LINCOLN FEEDERS
A-6 INSTALLATION 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 sideof the contact tip) and screw it snugly into the gasdiffuser. b. Be sure the nozzle insulator is fully screwed onto the gun tube and d...
Page 14 - CONNECTION TO MILLER FEEDERS
A-7 INSTALLATION A-7 CONNECTION TO MILLER FEEDERS Gun and cable assemblies which were assembledwith a K466-3 Connector Kit will connect easily to avariety 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 ...
Page 15 - OPERATION; ELECTRODES AND EQUIPMENT; AVOIDING WIRE FEEDING PROBLEMS
B-1 OPERATION B-1 MAGNUM® 400 DUAL PROCEDURE GUNS ELECTRODES AND EQUIPMENT The Magnum® 400 Dual Procedure guns and cableshave been designed for use with Lincoln L-50 andSuper Arc L-56, solid steel wire electrodes for theGMAW process and Lincoln Outershield7 cored elec-trodes for the gas-shielded FCA...
Page 16 - MAINTENANCE; GUN TUBES AND NOZZLES; CABLE CLEANING; CABLE REPAIR
D-1 MAINTENANCE D-1 MAGNUM® 400 DUAL PROCEDURE GUNS R E M O VA L , I N S TA L L AT I O N A N DT R I M M I N G I N S T R U C T I O N S F O RMAGNUM® LINERS NOTE: The variation in cable lengths prevents the interchangeability of liners. Once a liner has been cutfor a particular gun, it should not be in...
Page 22 - THREAD SIZES FOR MAGNUM® 400 CONSUMABLES
D-7 D-7 MAGNUM® 400 DUAL PROCEDURE GUNS THREAD SIZES FOR MAGNUM® 400 CONSUMABLES MAINTENANCE
Page 23 - TROUBLESHOOTING
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 Thi...
Page 24 - PROBLEMS
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 techni...
Page 26 - NOTES