IM435-A
MAGNUM© 200FM
TM March, 2008
Fast-Mate Gun and Cable Assemblies
K498
Models
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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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
Copyright © Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� 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
SAFETY
i i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
powered equipment. radiator pressure cap when the engine is
hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
Mar ʻ95
magneto wire as appropriate.
SAFETY
ii ii
ARC RAYS can burn.
ELECTRIC SHOCK can
kill. 4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
FUMES AND GASES
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
can be dangerous.
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
3.c. In semiautomatic or automatic wire welding, the electrode,
ventilation such as stainless or hard facing (see
electrode reel, welding head, nozzle or semiautomatic
instructions on container or MSDS) or on lead or
welding gun are also electrically “hot�.
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
3.d. Always be sure the work cable makes a good electrical
low as possible and below Threshold Limit Values (TLV)
connection with the metal being welded. The connection
using local exhaust or mechanical ventilation. In
should be as close as possible to the area being welded.
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.e. Ground the work or metal to be welded to a good electrical
also required when welding on galvanized steel.
(earth) ground.
5. b. The operation of welding fume control equipment is affected
3.f. Maintain the electrode holder, work clamp, welding cable and
by various factors including proper use and positioning of
welding machine in good, safe operating condition. Replace
the equipment, maintenance of the equipment and the spe-
damaged insulation.
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.g. Never dip the electrode in water for cooling.
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
3.h. Never simultaneously touch electrically “hot� parts of
electrode holders connected to two welders because voltage
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
between the two can be the total of the open circuit voltage
coming from degreasing, cleaning or spraying operations.
of both welders.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.i. When working above floor level, use a safety belt to protect
ucts.
yourself from a fall should you get a shock.
5.d. Shielding gases used for arc welding can displace air and
3.j. Also see Items 6.c. and 8.
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
SAFETY
iii iii
WELDING and CUTTING CYLINDER may explode
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting� (ANSI � Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
� A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically “hot� parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned�. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances�, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,� available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
FOR ELECTRICALLY
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
powered equipment.
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
8.b. Install equipment in accordance with the U.S. National
increase the possibility of the welding current passing
Electrical Code, all local codes and the manufacturerʼs
through lifting chains, crane cables or other alternate cir-
recommendations.
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
6.h. Also see item 1.c.
Jan, 07
6.I. Read and follow NFPA 51B � Standard for Fire Prevention
During Welding, Cutting and Other Hot Work�, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
SAFETY
iv iv
Mar. ʻ93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
Thank You •â?¢â?? 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 equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change � This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
� For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then
“Product Registration�. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
TABLE OF CONTENTS vi
vi
Page
Installation.......................................................................................................................Section A
Safety Precautions .............................................................................................................A-1
Liner Installation ...................................................................................................................A-1
Contact Tip and Gas Nozzle Installation ..............................................................................A-1
Connector to Fast-Mate Compatible Feeder ........................................................................A-1
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions .............................................................................................................B-1
General Description and Product Numbers Table................................................................B-1
Electrodes and Equipment ...................................................................................................B-2
Making a Weld......................................................................................................................B-2
Avoiding Wire Feeding Problems .........................................................................................B-2
________________________________________________________________________________
Maintenance ....................................................................................................Section D
Removal, Installation and Trimming Instructions for MAGNUM® Liners...............D-1
Gun Tubes and Nozzles ........................................................................................D-1
Gun Cables............................................................................................................D-2
Cable Cleaning ...............................................................................................D-2
Cable Repair ...................................................................................................D-2
Gun Tube End Repair.........................................................................D-2,D-3
Wire Feeder End Repair.....................................................................D-4,D-5
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide....................................................................................E-2,E-4
________________________________________________________________________
Parts Pages .................................................................P202-G,-G.1, P202-D.2,-D.3,-D.4
________________________________________________________________________
INSTALLATION
A-1 A-1
Choose the gas nozzle as appropriate for the
Read this entire installation section before you
GMAW process to be used. Typically, the contact
start installation.
tip end should be flush to .12� (3.0 mm) extended
for the short-circuiting transfer process and .12�
SAFETY PRECAUTIONS (3.0 mm) recessed for spray transfer. For the
Outershield (FCAW) process, 1/4� (6.4 mm) recess
is recommended.
WARNING
ELECTRIC SHOCK can kill.
CONNECTION TO FAST-MATE COMPATIBLE
� Have an electrician install and ser-
vice this equipment. FEEDERS
� Turn the input power off at the fuse
FM model gun cable assemblies will connect easily to
box before working on equipment.
any feeder equipped with a European style gun con-
nector or any Lincoln wire feeder equipped with a
� Do not touch electrically hot parts.
K489 Series FastMate Adapter Kit. To install an
� Be sure to discharge capacitors with
optional K489 Series kit see the instructions provided
the procedure outlined in the
with the kit. (See Table A.1)
Maintenance Section of this manual
before working in that area of the
equipment. a. Check that the feeder outgoing guide, as well as
--------------------------------------------------------------------- the drive roll, are appropriate for the electrode size
LINER INSTALLATION being used. When using a Fast-Mate Adapter Kit,
be certain the adapter guide tube is also properly
sized.
LINER INSTALLATION
b. Align and fully engage the brass connector end of
NOTE: FM models, using Fast-Mate connector, are
the gun cable into the mating connector on the out-
shipped with factory installed liner. To change
going side of the feeder wire drive. Secure the
liner in these models, see maintenance sec-
cable connection by snuggling the Fast-Mate con-
tion.
nector collar nut.
TABLE A.1
CONTACT TIP AND GAS NOZZLE INSTALLATION
WIRE FEEDER ADAPTER KITS FOR (FM)
WIRE FEEDER TYPE
PRODUCT NO.
NOTE: FM models are shipped ready to weld with the
proper tip and gas nozzle installed. If you Lincoln LN-7 Series, LN-8, LN-9
K489-1
choose to change the contact tip or nozzle,
see the instructions below. Lincoln LN-25
K489-2
a. Choose the correct size contact tip for the elec- Miller
K489-3
trode being used (wire size is stenciled on the side
Turbo Adapter
K489-4
of the contact tip) and screw it snugly into the gas
diffuser.
Hobart
K489-5
b. Be sure the nozzle insulator is fully screwed onto
L-Tec
K489-6
the diffuser and does not block the gas holes in the
diffuser.
LN-10, DH-10,STT-10
K489-7
Power Feed 10, LN-15
c. Slip the appropriate gas nozzle onto the nozzle
insulator. Either a .62� (15.9 mm) or .50� (12.7 mm)
I.D. slip-on gas nozzle may be used and should be
selected based on the welding application.
MAGNUM® 200FM
OPERATION
B-1 B-1
GENERAL DESCRIPTION
Read and understand this entire section before
operating your machine.
SAFETY PRECAUTIONS The MAGNUM® 200FM amp GMA guna nd cable
assembly has been designed to meet NEMA specifi-
WARNING cation EW3 for welding with steel electrode using the
GMAW (gas metal arc welding) and gas-shielded
ELECTRIC SHOCK can kill. FCAW (flux-cored arc welding) processes:
� Do not touch electrically live parts such as
The K498 MAGNUM® 200FM gun is factory installed
output terminals or internal wiring.
with a Fast-Mate (European style) wire feeder connec-
� Insulate yourself from the work and ground.
� Always wear dry insulating gloves. tor for “all-in-one� GMAW feeder connection. A single
connector attaches welding current, wire liner, welding
FUMES AND GASES gas, and trigger control leads to feeder. An optional
can be dangerous. K489-1 MAGNUM® Fast-Mate Adapter allows the use
� Keep your head out of fumes. of these guns with any Lincoln LN-7, LN-8, LN-9 and
� Use ventilation or exhaust to
SP200 wire feeder. An optional K489-2 MAGNUM®
remove fumes from breathing
Fast-Mate Adapter is required for the LN-25.
zone.
WELDING, CUTTING and For best results when welding mild and alloy steels, it
GOUGING SPARKS is recommended that L-50 or Super Arc L-56 Lincoln
can cause fire or explosion solid wire electrodes be used for the GMAW process
and OS70 or OS71 Lincoln Outershield® cored elec-
� Keep flammable material away.
trodes for the gas-shielded FCAW process.
� Do not weld, cut or gouge on containers
that have held combustibles.
ARC RAYS
can burn.
� Wear eye, ear and body
protection.
Only qualified personnel should operate this equip-
ment. Observe all safety information throughout this
manual.
MAGNUM® 200FM
200 AMPS AT 60% DUTY CYCLE WITH CO2 GAS
150 AMPS AT 60% DUTY CYCLE WITH MIXED GAS
(TABLE B.1)
Gun Contact
Description
Cable Tips Gas
Length Wire Size Standard Diffuser Gas Cable Gun Tube
Product
(m) in. (mm) Duty Assembly Nozzle Insulator Liner 60°
Number
K498-1 15 ft. .035 (0.9) KP14-35 KP52 KP22-50 KP32 KP42-4045-15 KP2028-1
(4.5) .045 (1.2) -45
K498-2 10 ft. .035 (0.9) KP14-35 KP52 KP22-50 KP32 KP42-4045-15 KP2028-1
(3.0) .045 (1.2) -45
K498-3 15 ft. .025 (0.6) KP14-25 KP52-23 KP22-50 KP32 KP42-25-15 KP2028-1
(4.5) .030 (0.8) -30
K498-4 10 ft. .025 (0.6) KP14-25 KP52-23 KP22-50 KP32 KP42-25-15 KP2028-1
(3.0) .030 (0.8) -30
K498-5 12 ft. .025 (0.6) KP14-25 KP52-23 KP22-50 KP32 KP42-25-15 KP2028-1
(3.6) .030 (0.8) -30
K498-6 12 ft. .035 (0.9) KP14-35 KP52 KP22-50 KP32 KP42-4045-15 KP2028-1
(3.6) .045 (1.2) -45
MAGNUM® 200FM
OPERATION
B-2 B-2
ELECTRODES AND EQUIPMENT AVOIDING WIRE FEEDING
PROBLEMS
The MAGNUM® 200FM gun and cable has been
designed for use with Lincoln L-50 and L-56, solid Wire feeding problems can be avoided by observing
steel wire electrodes for the GMAW process and the following gun handling procedures:
Lincoln Outershield® cored electrodes for the gas- a. Do not kink or pull cable around sharp corners.
shielded FCAW process. Refer to the appropriate
Lincoln Process and Procedure Guidelines for the b. Keep the electrode cable as straight as possible
electrode used for information on recommended elec- when welding or loading electrode through cable.
trical and visible stickouts.
c. Avoid wrapping excess cable around handle or
MAKING A WELD
front of wire feeder.
d. Do not allow dolly wheels or trucks to run over
a. Check that the welding power source is on and that cables.
the shielding gas supply is set for the proper flow
rate. e. Keep cable clean by following maintenance instruc-
tions.
b. Position electrode over joint. End of the electrode
should be slightly off the work.
f. Use only clean, rust-free electrode. The Lincoln
electrodes have proper surface lubrication.
c. Lower welding helmet, close gun trigger and begin
welding. Hold the gun so the contact tip to work
g. Replace contact tip when the arc starts to become
distance gives the correct electrical stickout as
unstable or the contact tip end is fused or
required for the procedure being use.
deformed.
d. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out. Follow wire feeder instruction manual if using a
trigger interlock circuit.
MAGNUM® 200FM
MAINTENANCE
D-1 D-1
REMOVAL, INSTALLATION AND
g. Screw the gas diffuser onto the end of the gun tube
TRIMMING INSTRUCTIONS FOR
and securely tighten.
MAGNUM® LINERS h. Tighten the set screw in the side of the gas diffuser
against the cable liner using a 5/64� (2.0 mm) Allen
NOTICE: The variation in cable lengths prevents the wrench.
interchangeability of liners. Once a liner has been cut
CAUTION
for a particular gun, it should not be installed in another
gun, unless it can meet the liner cut off length require-
This screw should be gently tightened. Over-
ment. Liners are shipped with the jacket of the liner
tightening will split or collapse the liner and cause
extended the proper amount.
poor wire feeding.
a. Remove the gas nozzle and nozzle insulator.
Loosen the set screw located in the side of the dif-
GUN TUBES AND NOZZLES
fuser with 5/64� (2.0 mm) Allen wrench (provided
with the gun).
a. Replace worn contact tips as required.
b. Remove the gas diffuser from gun.
b. Remove spatter from inside of gas nozzle and from
c. Lay gun and cable out straight on a flat surface. tip after each 10 minutes of arc time or as required.
Remove the liner nut from the connector end of the
cable and pull liner out of cable. c. To remove gun tube from gun, loosen socket-head
clamping screw in handle with 3/16� (4.8 mm) Allen
d. Insert a new untrimmed liner into the connector end wrench. Remove gas nozzle and nozzle insulator
of the cable. Be certain that the liner busing is sten- and also loosen small set screw in the diffuser
ciled appropriately for the wire size being used. using 5/64� (2.0 mm) Allen wrench.
NOTE: Small set screw in the diffuser must be
e. Fully seat the liner bushing into the connector.
Finger tighten the liner nut onto the cable connector. loosened, otherwise liner could be dam-
aged when attempting to remove gun tube.
f. With the cable straight, trim liner to 1-1/4� (31.8
mm). Remove any burrs from the end of the liner.
FIGURE 1
MAGNUM® 200FM
MAINTENANCE
D-2 D-2
FIGURE 2
GUN TUBE END REPAIR (Requires 2 S19492-2
Pull gun tube out from gun handle. To reinstall,
insert the gun tube, push in as far as possible, and Terminals)
retighten screws.
a. Remove the cable liner per Removal, Installation
and Trimming Instructions on page D-1.
GUN CABLES
b. Remove the gun tube per Gun Tubes and Nozzles
CABLE CLEANING Section of pages D-1 and D2.
Clean cable liner after using approximately 300 c. Remove three #6 screws from the gun handle, sep-
pounds (136 kg) of electrode. Remove the cable from arate the two halves, and remove the cable from
the wire feeder and lay it out straight on the floor. the handle along with the trigger assembly.
Remove the contact tip from the gun. Using an air
hose and only partial pressure, gently blow out the d. Remove gun tube connector from cable by
cable liner from the gas diffuser end. unscrewing connector nut from gun tube connec-
tor. If the cable inner tube is difficult to remove from
CAUTION the connector assembly, carefully slit it lengthwise
with a knife up to the brass connector.
Excessive pressure at the start may cause the dirt
to form a plug. e. Uncouple the strain relief by pushing its outer
housing toward the middle of the cable. Move the
Flex the cable over its entire length and again blow strain relief and the cable boot toward the middle of
out the cable. Repeat this procedure until no further the cable, past the damaged section.
dirt comes out.
f. Cut off the damaged section of cable and strip off
the outer jacket as shown in Figure 2. Be careful
CABLE REPAIR not to cut the insulation on the control wires while
stripping jacket. Strip the red and white control
The MAGNUM® 200FM gun features the use of leads 1/4 inch (6.4 mm) from the end and crimp a
repairable cable connectors. If the cable ever gets new S19492-2 terminal to each lead.
severely damage, it may be cut shorter and repaired
NOTE: The cable contains three control leads. Any
by the user. Repair cables as follows:
two control leads can be used, provided the
two colors used are the same at both ends.
The extra lead is a spare that can be used
if one of the other leads breaks.
MAGNUM® 200FM
MAINTENANCE
D-3 D-3
FIGURE 3
NOTE: For best results, insert a .175�/.197� (4.5-
g. Check that the cable boot and both halves of the
strain relief are on the cable. Slip the connector nut 5.0 mm) diameter rod through the connec-
over the copper strands with the thread end out. tor and into core of cable approximately
Orient gun tube connector so machined flat is on 5.00� (127 mm) when pushing the connec-
the same side of the cable as the red and white tor tube into the cable core tube. To tighten,
control leads. Assemble gun tube connector to hold the connector in place while turning
cable by forcing the steel tube of the connector into the nut. Then remove the rod from the core.
the inside diameter of the cable inner tube until the This procedure ensures the inner core does
copper strands are butted against the gun tube not kink while assembling or tightening.
connector shoulder. Keeping the copper strands
against the shoulder, pull the connector nut over h. Pull the cut-off lead terminals off the trigger assem-
the copper strands, engage the gun tube connector bly and connect the replacement control lead termi-
threads, and tighten in place. Refer to Figure 3. nals.
FIGURE 4
MAGNUM® 200FM
MAINTENANCE
D-4 D-4
FIGURE 5
i. Position the cable boot and strain relief on the d. Slide the cable handle and collar nut toward the
cable so it fits in cable handle cavity and lock the middle of the cable past the damaged section.
strain relief in place by pushing the two halves Remove and save the cable clamp.
together.
NOTE: If sliding the cable handle becomes difficult,
j. Assemble cable in left side of gun handle. try rotating it 180°.
Assemble trigger into the proper handle cavity.
Assemble right side of gun handle and tighten the e. Remove incoming connector from cable by
three screws that hold the handle together. Refer unscrewing connector nut from incoming connec-
to Figure 4. tor. If the cable inner tube is difficult to remove from
the connector assembly, carefully slit it lengthwise
k. Install gun tube per Gun Tubes and Nozzles with a knife up to the brass connector.
Section on page D-1.
f. Cut the cable control wires where they meet the
l. Install and trim liner per Removal, Installation and cable jacket or else unsolder the connection where
Trimming Instructions on page D-1. they connect to the terminal lead assembly. If you
cut the wires, strip the cut end 3/8� (9.5 mm) from
the end.
WIRE FEEDER END REPAIR
g. Cut off the damaged section of cable and strip off
a. Remove the cable liner per Removal, Installation, the outer jacket as shown in Figure 2. Be careful
and Trimming Instructions on page D-1. not to cut the insulation on the control wires while
stripping jacket. Strip red and white control leads
b. Loosen the boot nut. Slide the boot nut and boot 3/8� (9.5 mm) from the end.
toward the middle of the cable past the damaged
NOTE: The cable contains three control leads. Any
section.
two control leads can be used, provided the
c. Rotate the collar nut until the screw anchoring the two colors used are the same at both ends.
cable handle is visible. Remove the screw and The extra lead is a spare that can be used
save it. if one of the other leads breaks.
MAGNUM® 200FM
MAINTENANCE
D-5 D-5
h. Check that the cable boot, boot nut, cable handle, m. Install and trim liner per Removal, Installation and
and collar nut are on the cable. Slip the connector Trimming Instructions on page D-1.
nut over the copper strands with the threaded end
WARNING
out. Orient the connector assembly so the red and
white control leads will have the straightest possi-
ble routings to the sockets on the back side of the
ELECTRIC SHOCK can kill.
connector. Assemble the incoming connector to the
cable by forcing the steel tube of the connector into � Do not touch electrically live parts such
the inside diameter of the cable inner tube until the as output terminals or internal wiring.
copper strands are butted against the incoming
connector solder. Keeping the copper strands
against the shoulder, pull the connector nut over
the copper strands, engage the incoming connec-
tor threads, and tighten in place. Refer to Figure 3.
NOTE: For best results, insert a .175�/.197� (4.5-
5.0 mm) diameter rod through the connec-
tor and into core of cable approximately
5.00� (127 mm) when pushing the connec-
tor tube into the cable core tube. To tighten,
hold the connector in place while turning
the nut. Then remove the rod from the core.
This procedure assures the inner core does
not kink while assembling or tightening.
i. Solder the terminal lead assemblies from step (f) to
the control leads stripped in step (g). Insulate both
soldered connections using either heat shrink tub-
ing or electrical tape.
j. Fully insert the two control lead pins into the sock-
ets on the incoming connector. Tape the leads in
place in the necked down area of the connector.
Keeping the leads as close to the connector and
nut as possible, tape the insulated, soldered con-
nections and the spare lead to the cable in the area
between the cable jacket and connector nut. This
must be done neatly and kept as low as possible or
the cable handle will not slide over this area.
k. Install the cable clamp on the cable jacket within
1/8� (3.2 mm) from the end of the jacket and tight-
en.
l. Slide the collar nut and cable handle over the con-
nection and into place. Anchor the cable handle
with the screw removed in step (c). Slide the boot
and boot nut into place and tighten.
NOTE: If the cable handle becomes difficult to slide
over connection, try rotating it.
MAGNUM® 200FM
TROUBLESHOOTING
E-1 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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions. This column provides a course of action for the
Step 3. RECOMMENDED COURSE OF ACTION
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
Step 1. LOCATE PROBLEM (SYMPTOM).
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
The second column labeled “POSSIBLE CAUSE� lists
Step 2. POSSIBLE CAUSE.
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
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.
MAGNUM® 200FM
TROUBLESHOOTING
E-2 E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION
Drive rolls turn, but wire will not feed a. Gun cable kinked and/or twisted. a. Keep as straight as possible.
or wire feeding is rough. Inspect cable and replace if nec-
essary.
b. Wire jammed in gun and cable. b. Remove wire from gun and cable
� geed in new wire. Note any
obstruction. Replace liner if nec-
essary.
c. Incorrect drive rolls and guide c. Be sure the wire diameter being
tubes. used is stamped on drive rolls
and guide tubes. Replace if nec-
essary.
d. Gun cable liner dirty. d. Clean liner or replace.
e. Worn drive rolls. e. Replace or reverse split drive roll
type.
f. Electrode rusty and/or dirty. f. Replace the electrode if it is
rusty.
g. Worn or improper size cable liner. g. Replace cable liner.
h. Partially flashed, melted or h. Replace the contact tip.
improper size contact tip.
Variable or “hunting� arc. a. Contact tip worn or incorrect size. a. Replace contact tip.
b. Worn or undersize ground cables b. Inspect � repair or replace as
or poor ground connections. necessary.
c. Loose electrode connections. c. Be sure the following connec-
tions are tight: electrode cable to
wire feeder and power source,
work cable to power source and
work, gun cable to wire feeder
contact block, gun nozzle to
body and contact tip to nozzle.
CAUTION
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.
MAGNUM® 200FM
TROUBLESHOOTING
E-3 E-3
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION
Poor arc striking with sticking or a. Improper procedures or tech- a. See “Gas Metal Arc Welding
“blast-offs�, weld porosity, narrow niques. Guide� (GS-100).
and ropy looking bead, or electrode
stubbing into plate while welding. b. Improper gas shielding. b. Clean gas cone. Make certain
that gas diffuser is not restricted.
make certain that gas cylinder is
not empty or turned off. Make
certain gas solenoid valve is
operating and gas flow rate is
proper.
Remove gun liner and check rub-
ber seal for any sign of deteriora-
tion or damage. Be sure set
screw in brass connector is in
place and tightened against the
liner bushing.
Tip seizes in diffuser. a. Tip overheating due to prolonged a. Do not exceed current and duty
or excessive high current and/or cycle rating of gun.
duty cycle welding.
A light application of high temper-
ature antiseize lubricant (such as
Lincoln E2607 Graphite Grease)
may be applied to tip threads.
CAUTION
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.
MAGNUM® 200FM
NOTES
MAGNUM® 200FM
WARNING
l Do not touch electrically live parts or l Keep flammable materials away. l Wear eye, ear and body protection.
electrode with skin or wet clothing.
AVISO DE
l Insulate yourself from work and
ground.
Spanish
PRECAUCION
l No toque las partes o los electrodos l Mantenga el material combustible l Protéjase los ojos, los oÃdos y el
bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
ATTENTION
l Aislese del trabajo y de la tierra.
French l Ne laissez ni la peau ni des vête- l Gardez à l’écart de tout matériel l Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
avec des pièces sous tension.
WARNUNG
l Isolez-vous du travail et de la terre.
German l Berühren Sie keine stromführenden l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
ATENÇÃO
Portuguese
Elektroden und dem Erdboden!
l Não toque partes elétricas e elec- l Mantenha inflamáveis bem guarda- l Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
l Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND 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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
WARNING
l Keep your head out of fumes. l Turn power off before servicing. l Do not operate with panel open or
l Use ventilation or exhaust to guards off.
AVISO DE
remove fumes from breathing zone.
Spanish
PRECAUCION
l Los humos fuera de la zona de res- l Desconectar el cable de ali- l No operar con panel abierto o
piración. mentación de poder de la máquina guardas quitadas.
l Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilación o
ATTENTION
French
aspiración para gases.
l Débranchez le courant avant l N’opérez pas avec les panneaux
l Gardez la tête à l’écart des fumées.
l’entretien. ouverts ou avec les dispositifs de
l Utilisez un ventilateur ou un aspira-
protection enlevés.
teur pour ôter les fumées des zones
WARNUNG
de travail.
German
l Strom vor Wartungsarbeiten l Anlage nie ohne Schutzgehäuse
l Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
nen; Maschine anhalten!) Betrieb setzen!
l Sorgen Sie für gute Be- und
ATENÇÃO
Entlüftung des Arbeitsplatzes!
Portuguese
l Não opere com as tampas removidas. l Mantenha-se afastado das partes
l Mantenha seu rosto da fumaça.
l Desligue a corrente antes de fazer moventes.
l Use ventilação e exhaustão para
serviço. l Não opere com os paineis abertos
remover fumo da zona respiratória.
l Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� World's Leader in Welding and Cutting Products �
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