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TROUBLESHOOTING

MAGNUM® FAST-MATE™

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local

Lincoln Authorized Field Service Facility

for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions.  Simply follow the three-step
procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM
(SYMPTOMS)”.  This column describes
possible symptoms that the machine may
exhibit.  Find the listing that best describes
the symptom that the machine is exhibiting. 

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE
CAUSE” lists the obvious external possibili-
ties that may contribute to the machine
symptom.  

Step 3. RECOMMENDED COURSE OF
ACTION

This column provides a course of action for
the Possible Cause.

If you do not understand or are unable to
perform the Recommended Course of Action
safely, contact you local Lincoln Authorized
Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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.

__________________________________________________________________________

WARNING

E-1

E-1

Summary of Contents for K478

Page 1: ...ation 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 carefu...

Page 2: ...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...

Page 3: ...e in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage...

Page 4: ...ding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the jo...

Page 5: ...ns appropri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise pa...

Page 6: ...pecially 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 f...

Page 7: ...B 1 Operation Section C Electrodes and Equipment C 1 Making a Weld C 1 Avoiding Wire Feeding Problems C 1 Maintenance Section D Removal Installation and Trimming Instructions for Magnum Liners D 1 Gu...

Page 8: ...KP24A 62 KP34A KP44 564 15 KP1928 2 15 ft 1 16 1 6 KP14 116 K478 6 4 5 5 64 2 0 564 KP54A KP24A 62 KP34A KP44 564 15 KP1928 2 12 ft 035 0 9 KP14 35 K478 7 3 6 045 1 2 45 KP54A KP24A 62 KP34A KP44 354...

Page 9: ...928 1 12 ft 035 0 9 KP14 35 K479 7 3 6 045 1 2 45 KP54A KP24A 62 KP34A KP44 3545 15 KP1928 1 12 ft 052 1 3 KP14 52 K479 8 3 6 1 16 1 6 116 KP54A KP24A 62 KP34A KP44 116 15 KP1928 1 12 ft 1 16 1 6 KP14...

Page 10: ...d flush and recessed design for the 300 and 400 amp guns The proper nozzle should be selected based on the welding application Different length fixed nozzles are also available to fit 300 and 400 amp...

Page 11: ...the shielding gas supply is set for the proper flow rate b Position electrode over joint End of the electrode should be slightly off the work c Lower welding helmet close gun trigger and begin welding...

Page 12: ...m the end of the liner f Screw the gas diffuser onto the end of the gun tube and tighten with the wrench provided g Tighten the set screw in the side of the gas diffuser against the cable liner using...

Page 13: ...Small set screw in the diffuser must be loos ened otherwise liner could be damaged when attempting to remove gun tube Pull gun tube out from gun handle To reinstall insert the gun tube push in as far...

Page 14: ...e con nector into the inside diameter of the cable inner tube until the copper strands are butted against the gun tube connector shoulder Keeping the copper strands against the shoulder pull the conne...

Page 15: ...NTENANCE MAGNUM FAST MATE CABLE CONTROL LEAD INNER TUBE COPPER STRANDING CONTROL LEAD 1 65 41 9 mm SKIN USE 38 9 5 mm SKIN FOR FEEDER END OF FM MODELS 25 6 4 mm SKIN BOTH CONTROL LEADS FIGURE E 2 FIGU...

Page 16: ...onnector 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 E 3 NOTE For...

Page 17: ...MAINTENANCE MAGNUM FAST MATE THREAD SIZES FOR MAGNUM 300 400 CONSUMABLES D 6 D 6...

Page 18: ...SE The second column labeled POSSIBLE CAUSE lists the obvious external possibili ties that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of ac...

Page 19: ...cable liner H Partially flashed melted or improper size contact tip A Contact tip worn or incorrect size B Worn or undersize ground cables or poor ground connections C Loose electrode connections A Ke...

Page 20: ...es in diffuser A Improper procedures or tech niques B Improper gas shielding A Tip overheating due to prolonged or excessive high current and or duty cycle welding A See Gas Metal Arc Welding Guide GS...

Page 21: ...NOTES MAGNUM FAST MATE...

Page 22: ...MAGNUM FAST MATE NOTES...

Page 23: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 24: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 25: ...and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Pr...

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