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IM475-A
MAGNUM ® 550 GUN & CABLE ASSEMBLY 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 thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
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 before welding.
and devices in position and in good
repair.Keep hands, hair, clothing and tools 2.c. Exposure to EMF fields in welding may have other health
away from V-belts, gears, fans and all other effects which are now not known.
moving parts when starting, operating or
repairing equipment. 2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
____________________________________________________
2.d.1. Route the electrode and work cables together - Secure
1.e. In some cases it may be necessary to remove safety
them with tape when possible.
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.2. Never coil the electrode lead around your body.
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
2.d.3. Do not place your body between the electrode and
parts.
work cables. If the electrode cable is on your right
___________________________________________________
side, the work cable should also be on your right side.
1.f. Do not put your hands near the engine fan. Do not attempt
to override the governor or idler by pushing on the throttle
control rods while the engine is running. 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
turning the engine or welding generator during maintenance 2.d.5. Do not work next to welding power source.
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Mar ʻ95
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
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
échauffement et un risque dʼincendie.
Sûreté Pour Soudage A LʼArc
8. Sʼassurer que la masse est connectée le plus prés possible
1. Protegez-vous contre la secousse électrique:
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
a. Les circuits à lʼélectrode et à la piéce sont sous tension
endroits éloignés de la zone de travail, on augmente le risque
quand la machine à souder est en marche. Eviter toujours
de voir passer le courant de soudage par les chaines de lev-
tout contact entre les parties sous tension et la peau nue
age, câbles de grue, ou autres circuits. Cela peut provoquer
ou les vétements mouillés. Porter des gants secs et sans
des risques dʼincendie ou dʼechauffement des chaines et des
trous pour isoler les mains.
câbles jusquʼà ce quʼils se rompent.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
9. Assurer une ventilation suffisante dans la zone de soudage.
metallique ou des grilles metalliques, principalement dans
Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande
galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse.
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
10. Ne pas souder en présence de vapeurs de chlore provenant
defonctionnement.
dʼopérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
refroidir.
du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension
ou autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
11. Pour obtenir de plus amples renseignements sur la sûreté,
total de la tension à vide des deux machines.
voir le code “Code for safety in welding and cutting� CSA
f. Si on utilise la machine à souder comme une source de
Standard W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
LES MACHINES À SOUDER À
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
TRANSFORMATEUR ET À
du corps.
REDRESSEUR
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi quʼun verre blanc afin de se protéger les yeux du ray- lʼélectricité et aux recommendations du fabricant. Le dispositif
onnement de lʼarc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde lʼarc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
lʻarc. effectués par un électricien qualifié.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables. 3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
er à lʼinterrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres 4. Garder tous les couvercles et dispositifs de sûreté à leur
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan- place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ʻ93
zones où lʼon pique le laitier.
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
General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1, A-2
Connector Kit Installation to Gun Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
K613-1 & -6 Installation (for Lincoln Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
K613-2 Installation (for Tweco® Adapted and Lincoln DH-10, LN-10, PF-10 & STT-10 Feeders). . A-3
K613-3 Installation (for Miller® Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
K613-4 Installation (for Older Hobart® Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
K613-5 Installation (for Hobart® Series 2000 Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Liner Installation and Trimming Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Rotating the Gun Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Conract Tip and Gas Nozzle Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Connection to Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Connection to Lincoln Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Connection to Tweco Adapted and Lincoln DH-10, LN-10, PF-10 & STT-10 Feeders . . A-5
Connection to Miller Feeders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Connection to Older Hobart Feeders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Connection to Hobart Series 2000 Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Installation of Optional Gun Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
__________________________________________________________________________________________
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Electrodes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
__________________________________________________________________________________________
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Removal, Installation and Trimming Instructions for MAGNUM® Liners . . . . . . . . . . . . . D-1
Gun Tubes and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Gun Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Cable Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Cable Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Gun Tube End Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1, D-2
Wire Feeder End Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Thread Sizes for MAGNUM® 550 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
__________________________________________________________________________________________
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
__________________________________________________________________________________________
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-202-P
__________________________________________________________________________________________
INSTALLATION
A-1 A-1
GENERAL DESCRIPTION
The MAGNUM® 550 GMA gun and cable assembly has been designed to meet NEMA specification EW3 for welding with steel elec-
trode using the GMAW (gas metal arc welding) and the gas-shielded FCAW (flux-cored arc welding) processes:
MAGNUUMâ„? 550
500 AMPS AT 60% DUTY CYCLE WITH CO2 GAS
500 AMPS AT 40% DUTY CYCLE WITH MIXED GAS
Product Gun Cable Wire Size Contact Gas Coarse Coarse Thread Cable Gun
Number Length in. (mm) Tips Diffuser Thread Nozzle Insulator Liner Tube
ft. (m) Nozzle Assembly 60°
K598-1 10ft. (3.0m) .035� (0.9mm) KP56S-SW KP26CT-62 KP36CT KP45-3545-15 KP1951-1
KP16S-35
.045� (1.2mm) .625 I.D.
KP16S-45
.12 Rec.
K598-2 12 ft. (3.6m) .035� (0.9mm) KP56S-SW KP26CT-62 KP36CT KP45-3545-15 KP1951-1
KP16S-35
.045� (1.2mm) .625 I.D.
KP16S-45
.12 Rec.
K598-3 15 ft. (4.5m) .035� (0.9mm) KP56S-SW KP26CT-62 KP36CT KP45-3545-15 KP1951-1
KP16S-35
.045� (1.2mm) .625 I.D.
KP16S-45
.12 Rec.
K598-4 25 ft. (7.5m) .035� (0.9mm) KP56S-SW KP26CT-62 KP36CT KP45-3545-25 KP1951-1
KP16S-35
.045� (1.2mm) .625 I.D.
KP16S-45
.12 Rec.
K598-5 10 ft. (3.0m) .052� (1.3mm) KP56S-SW KP26CT-62 KP36CT KP45-116-15 KP1951-1
KP16S-52
1/16� (1.6mm) .625 I.D.
KP16S-116
.12 Rec.
K598-6 12 ft. (3.6m) .052� (1.3mm) KP56S-SW KP26CT-62 KP36CT KP45-116-15 KP1951-1
KP16S-52
1/16� (1.6mm) .625 I.D.
KP16S-116
.12 Rec.
K598-7 15 ft. (4.5m) .052� (1.3mm) KP56S-SW KP26CT-62 KP36CT KP45-116-15 KP1951-1
KP16S-52
1/16� (1.6mm) .625 I.D.
KP16S-116
.12 Rec.
K598-8 25 ft. (7.5m) .052� (1.3mm) KP56S-SW KP26CT-62 KP36CT KP45-116-25 KP1951-1
KP16S-52
1/16� (1.6mm) .625 I.D.
KP16S-116
.12 Rec.
K598-9 10 ft. (3.0m) 5/64� (2.0mm) KP56S-H KP26CT-75-R KP36CT KP45H-332-15 KP1951-2
KP16S-564
3/32� (2.4mm) .750 I.D.
KP16S-332
.25 Rec.
K598-10 12 ft. (3.6m) 5/64� (2.0mm) KP56S-H KP26CT-75-R KP36CT KP45H-332-15 KP1951-2
KP16S-564
3/32� (2.4mm) .750 I.D.
KP16S-332
.25 Rec.
K598-11 15 ft. (4.5m) 5/64� (2.0mm) KP56S-H KP26CT-75-R KP36CT KP45H-332-15 KP1951-2
KP16S-564
3/32� (2.4mm) .750 I.D.
KP16S-332
.25 Rec.
K598-12 10 ft. (3.0m) 7/64� (2.8mm) KP56S-H KP26CT-75-R KP36CT KP45-18-15 KP1951-2
KP16S-764
1/8� (3.2mm) .750 I.D.
KP16S-18
.25 Rec.
K598-13 12 ft. (3.6m) 7/64� (2.8mm) KP56S-H KP26CT-75-R KP36CT KP45-18-15 KP1951-2
KP16S-764
1/8� (3.2mm) .750 I.D.
KP16S-18
.25 Rec.
K598-14 15 ft. (4.5m) 7/64� (2.8mm) KP56S-H KP26CT-75-R KP36CT KP45-18-15 KP1951-2
KP16S-764
1/8� (3.2mm) .750 I.D.
KP16S-18
.25 Rec.
K598-15 15 ft. (4.5m) .035" (0.9mm) KP55SW KP25CT-62 KP35CT KP45-3545-15 KP1951-3
KP15H-35
.62 I.D.
KP15H-45
.12 Rec.
K598-16 15 ft. (4.5m) .052" (1.3mm) KP15H-53 KP55SW KP25CT-62 KP35CT KP45-116-15 KP1951-3
1/16" (1.6mm) KP15H-116 .62 I.D.
.12 Rec.
K598-17 15 ft. (4.5m) 5/64" (2.0mm) KP15H-564 KP55H KP25CT-75 KP35CT KP45H-332-15 KP1951-3
3/32" (2.4mm) KP15H-332 .75 I.D.
.12 Rec.
K598-18 15 ft. (4.5m) 7/64" (2.8mm) KP55-H KP25CT-75 KP35CT KP45-18-15 KP1951-3
KP15H-764
1/8" (3.2mm) .75 I.D.
KP15H-18
.12 Rec.
MAGNUM® 550
INSTALLATION
A-2 A-2
The K598 MAGNUM® guns are not factory equipped For best results when welding mild and alloy steels, it
with a feeder end connector. With the K613-1 MAG- is recommended that L-50 or L-56 Lincoln solid wire
NUM® Connector Kit, they can be used with any electrodes be used for the GMAW process and
Lincoln LN-7 or LN-25 semiautomatic wire feeder. The Lincoln Outershield® cored electrodes for the gas-
K613-1 can also be used with the LN-8 or LN-9 when shielded FCAW process.
feeding .052 and smaller electrodes. For additional
Connector Kits see the “P-202 ACCESSORIES� sec- Liners are available for feeding the harder (5356)
tion of this manual. An optional K481 MAGNUM® 3/64" or 1/16" aluminum electrode. The liners have a
Fast-Connect Gas Tube Kit is available to provide flat spring steel jacket with a frictionless core.
tool-less gas tube connection to Lincoln wire feeders. Although these liners are provided in 15 ft. lengths, 10
Non-GMA model wire feeders require an optional gas ft. cable lengths are recommended to reduce feeding
solenoid valve. problems. See the “P-202 ACCESSORIES� section of
this manual.
An interlocking trigger is available as a parts order.
With the trigger pulled in all the way, the trigger can
be slid forward into the interlock position. To release
interlock, squeeze trigger and slide back. The trigger
is made of a spatter resistant material. See the “P-202
ACCESSORIES� section of this manual.
MAGNUM® 550
INSTALLATION
A-3 A-3
INSTALLATION
WARNING K613-1 & K613-6 Installation (For Lincoln Feeders)
ELECTRIC SHOCK can kill. a. Remove brass cable connector and insulation tube
� Have a qualified individual install (See Figure 1) from the K613-1 kit. Slide the insu-
and service this equipment. lation tube onto the connector from the threaded
end and screw it onto the feeder end of the gun
� Turn the input power for the power cable. Tighten the connection.
source off at the fuse box or disconnect switch
before working on this equipment. b. Remove the molded gas plug fitting on the side of
the feeder end handle and replace it with the
� Do not touch electrically hot parts such as out- barbed brass fitting provided in the kit.
put terminals or internal wiring.
---------------------------------------------------------------------- c. Attach the round connector of the gun control
cable provided to the trigger connector on the front
CONNECTOR KIT INSTALLATION TO GUN CABLE
of the Lincoln feeder.
NOTE: Both the plug and socket are keyed and
The K598 MAGNUM® 550 Guns and Cables are
must be properly oriented.
shipped as "generic" and must be assembled with
either a K613-1 Lincoln Connection Kit for standard
d. Place one tubing clamp onto each end of the flexi-
Lincoln wire feeders (LN-8 or LN9 using smaller than
ble tubing provided, approximately 2� (51mm) in
1/16 electrode), a K613-2 Tweco Adapted Feeder
from each end. Slide one end of the tubing onto
Connection Kit for wire feeders adapted for use with
the barbed connector on the feeder end cable
comparable size Tweco gun cables, a K613-3
handle (step b) and move the clamp down near
Connector Kit for a variety of Miller wire feeders, a
the end of the tube to assure a good gas seal.
K613-4 Connector Kit for a variety of older Hobart wire
feeders, a K613-5 Connector Kit for Hobart Series
NOTE: An optional K481 MAGNUM® Fast-
2000 wire feeders and K613-6 Connector Kit for LN-8
Connect Gas Tube Kit is available to provide tool-
or LN-9 wire feeders using 1/16 and larger electrode.
less gas tube connection to Lincoln wire feeders.
Each of the above connections are covered below.
Install per the instructions sent with the kit.
You may skip to the instructions that are appropriate
for your wire feeder.
K613-2 Installation (For Tweco Adapted Feeders
and Lincoln DH-10, LN-10, PF-10 and STT-10 )
a. Remove brass cable connector (See Figure 1)
from the K613-2 kit and screw it onto the feeder
end of the gun cable. Tighten the connection.
b. Check that the molded gas plug fitting is sealing
the gas fitting hole in the side of the feeder end
handle.
K613-3 Installation (For Miller Feeders)
a. Remove brass cable connector (See Figure 1)
from the K613-3 kit and screw it on to the feeder
end of the gun cable. Tighten the connection.
b. Check that the molded gas plug fitting is sealing
the gas fitting hole in the side of the feeder end
handle.
c. Attach the round connector of the gun control
cable provided to the trigger connector on the
front of the Miller feeder.
MAGNUM® 550
INSTALLATION
A-4 A-4
K613-4 Installation (For Older Hobart Feeders) Slide one end of the tubing onto the barbed connec-
tor on the feeder end cable handle (step b) and
a. Remove brass cable connector (See Figure 1) move the clamp down near the end of the tube to
from the K613-4 kit and screw it on to the feeder assure a good gas seal.
end of the gun cable. Tighten the connector.
K613-5 Installation (For Hobart Series 2000 Wire Feeders)
b. Remove the molded gas plug fitting on the side of
the feeder end handle and replace it with the
barbed brass fitting provided in the kit. a. Remove brass cable connector (see Figure 1)
c. Attach the phone plug connector of the gun con- from the K613-5 kit and screw it onto the feeder
trol cable provided to the trigger connector on the end of the gun cable. Tighten the connection.
front of the Hobart feeder. b. Check that the molded gas plug fitting is sealing
d. Place one tubing clamp onto each end of the flexi- the gas fitting hole in the side of the feeder end
ble tubing provided, approximately 2� (51mm) in handle.
from each end. c. Attach the Gun Control cable provided to the trig-
ger connector on the front of the wire feeder.
BRASS CABLE CONNECTOR
SET SCREW
INSULATION TUBE (K613-1 & K613-6 ONLY)
LINER TRIM
LENGTH
SET SCREW FEEDER END HANDLE
SEE TABLE
BELOW
LINER ASSEMBLY
GAS DIFFUSER
( LINER BUSHING TO BE TIGHTLY SEATED. )
COARSE THREAD INSULATOR ASSEMBLY
Gun Diffuser Liner cut off length
COARSE THREAD NOZZLE
K598-1 thru -14 KP56S-SW, KP56S-H .38� (9.5mm)
K598-15 thru -18 KP55SW, KP55, .50� (12.7mm)
KP55H, KP55S-SW,
KP55S-H
K598-15 thru -18 KP55S-SWL, KP55S-HL 1.00� (25.4mm)
Figure 1
LINER INSTALLATION AND TRIMMING INSTRUC- NOTE: For liners KP45N-3545-15, KP45N-116-15,
TIONS gun tube assemblies KP1951-1 and KP1951-2.
Before fully seating the liner bushing, it will be nec-
a. Lay the gun and cable out straight on a flat sur- essary to trim the linerʼs inner tube flush with the
face. liner bushing using a sharp blade. After trrimming
b. Make sure that the set screws in the connector remove any burs from inner tube and insure that the
end and in the handle are backed out so as not to opening is fully open.
damage liner or liner bushing. Remove and save
the coarse thread nozzle and coarse thread insu- d. Before installing the gas diffuser, fully seat the
lator assembly from the end of the gun tube liner bushing in the connector and:
assembly.
For K613-1, K613-2, K613-5 and K613-6, tighten
c. Insert a new untrimmed liner into the connector end
the set screw in the cable connector.
of the cable. Be sure the liner bushing is stencilled
OR
appropriately for the wire size being used.
MAGNUM® 550
INSTALLATION
A-5 A-5
For K613-3 and K613-4, screw in the connectorcap The proper nozzle should be selected based on the
provided in the kit until it seats on the face of the welding application. Different diameter self insulated
bushing. Then insert the appropriate piece of liner gas nozzles are also available to allow gas-shielded,
material into the connector cap and tighten the set flux-cored welding. .62� (15.9mm). .75� (19.1mm) and
screw. Four pieces of liner material are included in .88� (22.4mm) diameter nozzles are available. The self
insulated gas nozzles provide a tip recess of 1/8�.
these connector kits to help guide the electrode
through the connector cap. The piece with the
Choose the gas nozzle as appropriate for the GMAW
smallest inner diameter is designed for .045�
process to be used. Typically, the contact tip end
(1.2mm) maximum diameter electrode. The next should be 1/8� (3 mm) recessed for spray transfer and
largest diameter is for 1/16� (1.6mm) maximum for the Outershield® (FCAW) process.
diameter electrode. The largest diameter piece of
liner material is for 1/8� (3.2mm) maximum diameter CONNECTION TO FEEDER
electrode. The next largest is for 3/32� (2.4mm) Connection to Lincoln Feeders
maximum diameter electrode. Gun cable assemblies which were assembled with a K613-1
or K613-6 Connection Kit will connect easily to any Lincoln
LN-7, LN-8, LN-9 or LN-25 feeder.
e. Be sure the cable is straight and then trim the liner
to the length shown in Figure 1. Remove any burrs
a. Check that the drive roll(s) and feeder guide tubes are
from the end of the liner. appropriate for the electrode size being used.
f. Screw the gas diffuser onto the end of the gun tube b. Fully push the brass connector end of the gun cable
and tighten. Be sure to use the proper diffuser size into the conductor block on the outgoing side of the
for the electrode being used. feeder wire drive. Secure the cable using the hand
screw or set screw in the conductor block.
g. For K598-1 thru -14: Tighten the set screw in the
c. Insert the control cable plug from the feeder trigger cir-
side of the gun handle against the cable liner. For
cuit into the mating socket on the feeder end cable han-
K598-15 thru -18: Tighten the set screw in the dif-
dle.
fuser against the cable liner.
CAUTION d. Slide the free end of the flexible hose (mounted to the
gun) onto the barbed gas fitting on the front of the
This screw should only be gently tightened. Over- Lincoln feeder. Move corresponding tubing clamp down
tightening will split or collapse the liner and cause near the end of the tube to assure a good gas seal.
poor wire feeding.
Connection to Tweco Adapted Feeders and Lincoln
------------------------------------------------------------------
DH-10, LN-10, PF-10 and STT-10 Feeders
ROTATING THE GUN TUBE Gun cable assemblies which were assembled with a K613-2
The gun tube can be rotated to any position desired by the Connection Kit will connect easily to any properly adapted
operator. Loosen the clamping screw, rotate the gun tube to feeder.
the desired position and retighten the clamping screw.
The gun can be operated with the trigger on top. Simply rotate a. Check that the adapter and feeder guide tubes, as well
the gun tube 180° and operate the gun with the trigger on top. as the drive roll(s), are appropriate for the electrode
size being used. For Lincoln feeders, check that the
CONTACT TIP AND GAS NOZZLE INSTALLATION K1500-3 Gun Adapter is in place.
a. Choose the correct size contact tip for the electrode b. Fully push the brass connector end of the gun cable
being used (wire size is stenciled on the side of the con- into the brass adapter on the outgoing side of the feed-
tact tip) and screw it snugly into the gas diffuser. er wire drive. Secure the cable using the hand screw or
set screw in the adapter.
b. Be sure the coarse thread insulator assembly is fully
screwed onto the gun tube and does not block the gas c. Insert the control cable plug from the feeder trigger cir-
holes in the diffuser. cuit into the mating socket on the gun cable connector
handle.
NOTE: The coarse thread insulator assembly is not
required when using the optional self insulated gas noz- Connection to Miller Feeders
zles. Gun and cable assemblies which were assembled with a
K613-3 Connection Kit will connect easily to a variety of
c. Screw the appropriate coarse thread nozzle onto the popular Miller wire feeders.
coarse thread insulator assembly. Coarse thread nozzles
are available with a .62� (15.9mm) or .75� (19.1mm) I.D., a. Check that the gun liner, connector cap liner, drive
and in both 1/8� recessed and 1/4� recessed design. roll(s) and guide tubes are appropriate for the electrode
size being used.
MAGNUM® 550
INSTALLATION
A-6 A-6
b. Fully push the brass connector end of the gun and h. Insert the control cable plug from the feeder trigger cir-
cable into the connector receptacle on the outgoing cuit into the mating socket on the gun cable connector.
side of the feeder wire drive. Tighten the hand screw to
clamp down on the connector.
c. Insert the control cable plug from the feeder trigger cir-
cuit into the mating socket on the gun cable connector
handle.
Connection to Older Hobart Feeders
GUN SLEAVE
Gun and cable assemblies which were assembled with a
GAS INLET
K613-4 Connection Kit will connect easily to a variety of
older Hobart wire feeders.
GUN RECEPTACLE KNOB
a. Check that the gun liner, connector cap liner, drive
roll(s) and guide tubes are appropriate for the electrode
GAS TUBE
GAS INLET RETAINING SCREWS
size being used. Four different diameter pieces of liner
material are included in each kit.
GUN RECEPTACLE
GAS INLET FOR
MAGNUM 550 GUN
b. Fully push the brass connector end of the gun and
cable into the connector receptacle on the outgoing
side of the feeder wire drive. Tighten the hand screw to
clamp down on the connector.
c. Insert the control cable plug from the feeder trigger cir-
cuit into the mating socket on the gun cable connector
Installation of Optional Gun Hanger (See Figure 2)
handle.
a. Remove gun tube from gun by loosening the
d. Slide the free end of the flexible hose (mounted to the
clamping screw with a 3/16� (4.8mm) Allen
gun) onto the gas fitting on the Hobart wire feeder.
wrench.
Move the corresponding tubing clamp down near the
end of the tube to assure a good gas seal.
b. Slip hanger into collar so notches on hanger fit
Connection to Hobart Series 2000 Wire Feeders into slot on I.D. of collar. Slip the two parts onto
Gun and cable assemblies which were assembled with a K613-5 the gun tube and hold in place by lightly tightening
connection kit will connect to a variety of Hobart series 2000 wire
the set screw in the collar with a 5/64� (2.0mm)
feeders. If the wire feeder has not been revised to accept a 500
Allen wrench.
amp gun receptacle, install the gas inlet provided with the K613-5
kit as follows:
c. Replace gun tube in gun and tighten socket head
a. Hold the gun receptacle and remove the gun receptacle
clamping screw. Position hanger on gun tube and
knob.Lower the gun receptacle.
tighten collar set screw.
b. Remove the two retaining screws that secure the gas
inlet to the wire feeder and pull the gas inlet out. Then
remove the gun sleeve. If the gun sleeve does not
come out easily, insert a screwdriver into the slot pro-
COLLAR SLOT
vided and pry the sleeve out.
c. Hold the gas tube with the hose attached and unscrew
the gas inlet. Screw the gas inlet provided with the kit
onto the gas tube.
HANGER NOTCH
GUN HANDLE
COLLAR SET SCREW
HANGER
d. Slide the gas inlet into the wire feeder with the wide
groove toward the drive rolls. Replace the retaining
screws to secure the gas inlet in place.
e. Raise the gun receptacle and reinstall the gun receptacle knob.
f. Check that the gun liner, guide tubes and drive rolls are
appropriate for the electrode size being used.
GUN TUBE
COLLAR
Figure 2
g. Fully push the brass connector end of the gun and
CLAMPING SCREW
cable into the gas inlet and tighten the gun receptacle
knob.
MAGNUM® 550
OPERATION
B-1 B-1
OPERATION c. Lower welding helmet, close gun trigger, and
begin welding. Hold the gun so the contact tip to
work distance gives the correct electrical stickout
Electrodes and Equipment
as required for the procedure being used.
The MAGNUM® 550 guns and cables have been
d. To stop welding, release the gun trigger and then
designed for use with Lincoln L-50 and L-56, solid
pull the gun away from the work after the arc goes
steel wire electrodes for the GMAW process and
out.
Lincoln Outershield® cored electrodes for the gas-
shielded flux-cored process. Refer to the appropriate
e. If the optional interlocking trigger is installed, the
Lincoln Process and Procedure Guidelines for the
trigger operates as follows:
electrode used for information on recommended elec-
trical and visible stickouts.
- Pull the trigger in to engage the feeder.
Making a Weld
- With the trigger pulled in all the way, the trigger
WARNING
can be slid forward into the interlock position.
ELECTRIC SHOCK can kill. - To release interlock, squeeze trigger and pull
� Do not touch electrically live parts or back.
electrode with skin or wet clothing.
Avoiding Wire Feeding Problems
� Insulate yourself from work and
ground.
� Always wear dry insulating gloves. Wire feeding problems can be avoided by observing
------------------------------------------------------------------------ the following gun handling procedures:
FUMES AND GASES can be danger-
ous. a. Do not kink or pull cable around sharp corners.
� Keep your head out of fumes.
� Use ventilation or exhaust to remove b. Keep the electrode cable as straight as possible
fumes from breathing zone. when welding or loading electrode through cable.
------------------------------------------------------------------------
WELDING SPARKS can cause fire or c. Avoid wrapping excess cable around handle or
explosion. front of wire feeder especially on 25 ft. (7.5m)
� Keep flammable material away. length guns.
� Do not weld on closed containers.
d. Do not allow dolly wheels or trucks to run over
------------------------------------------------------------------------ cables.
ARC RAYS can burn eyes and skin.
� Wear eye, ear and body e. Keep cable clean by following maintenance
protection. instructions.
------------------------------------------------------------ f. Use only clean, rust-free electrode. The Lincoln
electrodes have proper surface lubrication.
See additional warning information at g. Replace contact tip when the arc starts to become
front of this operatorʼs manual. unstable or the contact tip end is fused or
----------------------------------------------------------- deformed.
h. When using aluminum electrodes, 10 ft. maximum
cable length is recommended. If longer cable
a. Check that the welding power source is on and
lengths are used, cable should be kept as straight
that the shielding gas supply is set for the proper
as possible.
flow rate.
b. Position electrode over joint. End of the electrode
should be slightly off the work.
MAGNUM® 550
MAINTENANCE
D-1 D-1
MAINTENANCE b. Remove spatter from inside of gas nozzle and
from tip after each 10 minutes of arc time or as
WARNING required.
ELECTRIC SHOCK can kill.
c. To remove gun tube from gun, loosen socket-
� Have a qualified individual install
head clamping screw in handle with 3/16�
and service this equipment.
(4.8mm) Allen wrench. Remove coarse thread
nozzle and coarse thread insulator assembly.
� Turn the input power for the power
source off at the fuse box or disconnect switch
Pull gun tube out from gun handle. To reinstall,
before working on this equipment.
insert the gun tube, push in as far as possible,
and retighten screw.
� Do not touch electrically hot parts such as out-
put terminals or internal wiring.
GUN CABLES
----------------------------------------------------------------------
Cable Cleaning
Removal, Installation and Trimming Instructions
for MAGNUM® Liners
Clean cable liner after using approximately 300 lbs
(136 kg) of electrode. Remove the cable from the wire
NOTICE: The variation in cable lengths prevents the
feeder and lay it out straight on the floor. Remove the
interchangeability of liners. Once a liner has been cut
contact tip from the gun. Using an air hose and only
for a particular gun, it should not be installed in anoth-
partial pressure, gently blow out the cable liner from
er gun, unless it can meet the liner cut off length
the gas diffuser end.
requirement. Liners are shipped with the jacket of the
liner extended the proper amount.
CAUTION
a. Remove the gas nozzle and nozzle insulator. Excessive pressure at the start may cause the dirt
Loosen the set screw located in the side of the to form a plug.
handle or in the diffuser with 5/64� (2.0mm) Allen
wrench (provided with the gun or Connector Kit). Flex the cable over its entire length and again
blow out the cable. Repeat this procedure until no
b. Remove the gas diffuser from gun. further dirt comes out.
------------------------------------------------------------------
c. Lay gun and cable out straight on a flat surface.
Cable Repair
For K613-1 K613-2, K613-5 and K613-6 connections:
The MAGNUM® 550 guns feature the use of
repairable cable connectors. If the cable ever gets
Loosen set screw located in the brass cable con-
severely damaged, it may be cut shorter and repaired
nector at the wire feeder end of the cable using
by the user. Repair cables as follows:
the same 5/64� (2.0mm) Allen wrench. Pull liner
out of cable. (Refer to Figure 1).
Gun Tube End Repair (Requires 2 No. S19492-2
OR
Terminals
For K613-3 and K613-4 connections:
a. Remove the cable liner per Removal, Installation
and Trimming Instructions.
Remove the connector cap. Remove gun tube
and tap on end of liner to expose liner bushing on
b. Remove the gun tube per section entitled “Gun
wire feeder end of cable. Pull liner out of cable. If
Tubes and Nozzles�.
the liner is going to be replaced with a different
size liner, loosen set screw on the connector cap
c. Remove four #6 screws from the gun handle, sep-
and remove piece of liner material.
arate the two halves, and remove the cable from
the handle along with the trigger assembly.
d. For installation and trimming instructions for MAG-
NUM® liners, see Liner Installation and Trimming
d. Remove gun tube connector from cable by
Instructions.
unscrewing connector nut from gun tube connec-
tor. If the cable inner tube is difficult to remove
Gun Tubes and Nozzles
from the connector assembly, carefully slit it
lengthwise with a knife up to the brass connector.
a. Replace worn contact tips as required.
MAGNUM® 550
MAINTENANCE
D-2 D-2
e. Cut off the damaged section of cable and strip off
the outer jacket as shown in Figure 3. Be careful
not to cut the insulation on the control wires while
stripping jacket. Strip the red and white control
leads .25� (6.4mm) from the end and crimp a new
S19492-2 terminal to each lead.
CABLE INNER TUBE
CONNECTOR TUBE
NOTE: The cable contains four control leads. Any
two control leads can be used, provided the two
COPPER STRANDS
colors used are the same at both ends. The
CONNECTOR NUT
CABLE
extra leads are spares that can be used if one of
the other leads breaks.
f. Trim the inner tube to dimension shown.
GUN TUBE CONNECTOR OR
INCOMING CONNECTOR
.25" (6.4 mm) SKIN
(BOTH CONTROL LEADS)
Figure 4
CONTROL LEAD
INNER TUBE
h. Pull the cut-off lead terminals off the trigger
COPPER STRANDING
assembly and connect the replacement control
lead terminals.
CONTROL LEAD
i. Assemble cable in left side of gun handle.
.66" (16.5 mm)
Assemble trigger into the proper handle cavity.
2.45 (62.2 mm)
Assemble right side of gun handle and tighten the
CABLE SKIN LENGTH
four screws that hold the handle together. Refer to
Figure 3 Figure 5. NOTE: Be sure that protruded trigger
ears are placed in cavities of both handles.
g. Slip the connector nut over the copper strands
with the thread end out. Adjust gun tube connec-
tor so machined flat is on the same side of the
cable as the red and white control leads.
Assemble gun tube connector to cable by forcing
the steel tube of the connector into the inside
diameter of the cable inner tube until the copper
CABLE ASSEMBLY
strands are butted against the gun tube connector
GUN TUBE
GUN HOUSING
shoulder. Keeping the copper strands against the
shoulder, pull the connector nut over the copper
strands, engage the gun tube connector threads,
and tighten in place. Refer to Figure 4. GUN TUBE
CLAMPING SCREW
CONTROL WIRES
NOTE: For best results, insert a .250� (6.4mm)
TRIGGER ASSEMBLY
diameter rod through the connector and into core
HANDLE CAVITY
TRIGGER EAR
of cable approximately 5.00� (127mm) when push-
ing the connector tube into the cable core tube. To
tighten, hold the connector in place while turning
Figure 5
the nut, then remove the rod from the core. This
procedure assures the inner core does not kink
while assembling or tightening.
MAGNUM® 550
MAINTENANCE
D-3 D-3
NOTE: For best results, insert a .250� (6.4mm)
j. Install gun tube per section entitled “Gun Tube
and Nozzles�. diameter rod through the connector and into core
of cable approximately 11.00� (280mm) when
k. Install and trim liner per installation instructions. pushing the connector tube into the cable core
tube. To tighten, hold the connector in place while
Wire Feeder End Repair (Requires 2 No. S19492-1 turning the nut, then remove the rod from the
Terminals) core. This procedure assures the inner core does
a. Remove the cable liner per the Maintenance not kink while assembling or tightening.
Section.
Position the plastic strain relief such that the
b. Remove the feeder end connector, molded gas tapered end is 7.10� (180mm) from the incoming
plug (or barbed fitting), cable handle nut, plastic connector (See Figure 6). Lock into place with
tailpiece, and connector cover (See Figure 6). steel housing.
NOTE: In order to remove the cable handle nut,
the tail of the connector cover must be depressed g. Position cable boot and cable handle on cable
and the cable handle nut rotated 1/4 turn counter- and assemble replacement control wire terminals
clockwise as viewed from the feeder end. in place on the cable handle. Insert connector
cover in place. Install tailpiece and fasten to cable
c. Remove incoming connector from cable by handle with cable handle nut. Refer to Figure 6.
unscrewing connector nut from incoming connec-
tor. If the cable inner tube is difficult to remove h. Replace the molded gas plug (or barbed fitting)
from the connector assembly, carefully slit it and feeder end connector.
lengthwise with a knife up to the brass connector.
i. Install and trim liner per installation instructions.
d. Move the cable boot, cable handle, and strain
relief toward the middle of the cable past the dam-
aged section.
e. Cut off the damaged section of cable and strip off
the outer jacket as shown in Figure 3. Be careful
not to cut the insulation on the control wires while
7.10" (180 mm)
stripping jacket. Strip the red and white control
PRESS HERE TO
REMOVE THE CABLE
leads 1/4� (6.4mm) from the end and crimp a new
GAS PLUG HANDLE NUT
OR
S19492-1 terminal to each lead. Trim the inner
FITING
CONNECTOR COVER
CABLE
tube to dimensions shown.
TAIL PIECE CABLE BOOT
NOTE: The cable contains four control leads. Any
two control leads can be used, provided the two
colors used are the same at both ends. The extra
leads are spares that can be used if one of the
other leads breaks.
STRAIN RELIEF CABLE HANDLE
FEEDER END
CONNECTOR
CABLE HANDLE NUT STRAIN RELIEF
f. Check that the cable boot, cable handle and strain
HOUSING
INCOMING CONNECTOR
relief are on the cable. Slip the connector nut over
the copper strands with the threaded end out.
Assemble incoming connector to cable by forcing
Figure 6
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
shoulder. Keeping the copper strands against the
shoulder, pull the connector nut over the copper
strands, engage the incoming connector threads,
and tighten in place. Refer to Figure 4.
MAGNUM® 550
MAINTENANCE
D-4 D-4
THREAD SIZES FOR K598-1 thru -14
MAGNUM 550 CONSUMABLES USED WITH
An KP1951-1 or -2 Gun Tube (Tweco® NO. 6)
M17 X 2
M12 X 1.5
M8 X 1.25
THREAD SIZES FOR K598-15 thru -18
MAGNUM 550 CONSUMABLES USED WITH
An KP1952-3 Gun Tube (Tweco® NO. 5)
5/8-18
7/16-20
#8-32
5/16-24
MAGNUM® 550
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. Simply follow the three-step
procedure listed below.
Look under the column labeled “PROBLEM
Step 3. RECOMMENDED COURSE OF
Step 1. LOCATE PROBLEM (SYMPTOM).
This column provides a course of action for
(SYMPTOMS)�. This column describes
ACTION
the Possible Cause.
possible symptoms that the machine may
exhibit. Find the listing that best describes
If you do not understand or are unable to
the symptom that the machine is exhibiting.
perform the Recommended Course of
Action safely, contact you local Lincoln
Authorized Field Service Facility.
The second column labeled “POSSIBLE
Step 2. POSSIBLE CAUSE.
CAUSE� lists the obvious external possibili-
ties that may contribute to the machine
symptom.
WARNING
ELECTRIC SHOCK can kill.
� Have a qualified individual install and
service this equipment.
� Turn the input power off at the fuse
box before working on equipment.
� Do not touch electrically hot parts.
---------------------------------------------------------------------
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® 550
TROUBLESHOOTING
E-2 E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Drive rolls turn, but wire will not feed or a. Gun cable kinked and/or twisted. a. Keep as straight as possible. Inspect
wire feeding is rough. cable and replace if necessary.
b. Wire jammed in gun and cable. b. Remove wire from gun and cable -
feed in new wire. Note any obstruc-
tion. Replace liner if necessary.
c. Incorrect drive rolls and guide tubes. c. Be sure the wire diameter being used
is stamped on drive rolls and guide
d. Gun cable liner dirty. tubes. Replace if necessary.
e. Worn drive rolls. d. Clean liner or replace.
e. Replace or reverse split drive roll
f. Electrode rusty and/or dirty. type.
g. Worn or improper size cable liner. f. Replace the electrode if it is rusty.
h. Partially flashed, melted, or improper g. Replace cable liner.
size contact tip. h. Replace the contact tip.
i. Incorrect diffuser. i. Be sure diffuser size is correct for the
electrode being used.
Variable or “hunting� arc. a. Contact tip worn or incorrect size. a. Replace contact tip.
b. Worn or undersize ground cables or b. Inspect - repair or replace as neces-
poor ground connections. sary.
c. Loose electrode connections. c. Be sure the following connections 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.
Poor arc striking with sticking or “Blast- a. Improper procedures or techniques. a. See “Gas Metal Arc Welding� (GS-
offs�, weld porosity, narrow and ropy 100).
looking bead, or electrode stubbing into b. Improper gas shielding. b. Clean gas nozzle, Make certain that
plate while welding. gas diffuser is not restricted. Make
certain that gas cylinder is not empty
or turned off. Make certain gas sole-
noid valve is operating and gas flow
rate is proper. Remove gun liner and
check rubber seal for any sign of
deterioration or damage. Be sure set
screw in brass connector is in place
and tightened against the liner bush-
ing.
Tip seizes in diffuser. a. Tip overheating due to prolonged or a. Do not exceed current and duty cycle
excessive high current and/or duty rating of gun. A light application of
cycle welding. high temperature antiseize lubricant
(such as Lincoln E2067 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® 550
NOTES
MAGNUM® 550
NOTES
MAGNUM® 550
WARNING
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
electrode with skin or wet clothing.
G Insulate yourself from work and
AVISO DE
ground.
Spanish
PRECAUCION
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
G Aislese del trabajo y de la tierra.
ATTENTION
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
WARNUNG
German G Berühren Sie keine stromführenden G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
ATENÇÃO
Portuguese
Elektroden und dem Erdboden!
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
G 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
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to guards off.
AVISO DE
remove fumes from breathing zone.
Spanish
PRECAUCION
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilación o
ATTENTION
aspiración para gases.
French
G Débranchez le courant avant G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- l’entretien. ouverts ou avec les dispositifs de
protection enlevés.
teur pour ôter les fumées des zones
WARNUNG
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
ATENÇÃO
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
G Não opere com os paineis abertos
serviço.
remover fumo da zona respiratória.
G 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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