Lincoln Electric K498 Manual Download Page 12

D-2

MAINTENANCE

D-2

Pull gun tube out from gun handle. To reinstall,
insert the gun tube, push in as far as possible, and
retighten screws.

GUN CABLES

CABLE CLEANING

Clean cable liner after using approximately 300
pounds (136 kg) of electrode. Remove the cable from
the wire feeder and lay it out straight on the floor.
Remove the contact tip from the gun. Using an air
hose and only partial pressure, gently blow out the
cable liner from the gas diffuser end.

Excessive pressure at the start may cause the dirt
to form a plug.

Flex the cable over its entire length and again blow
out the cable. Repeat this procedure until no further
dirt comes out.

CABLE REPAIR

The Magnum 200FM gun features the use of
repairable cable connectors. If the cable ever gets
severely damage, it may be cut shorter and repaired
by the user. Repair cables as follows:

GUN TUBE END REPAIR

(Requires 2 S19492-2

Terminals)

a. Remove the cable liner per Removal, Installation

and Trimming Instructions on page D-1.

b. Remove the gun tube per Gun Tubes and Nozzles

Section of pages D-1 and D2.

c. Remove three #6 screws from the gun handle, sep-

arate the two halves, and remove the cable from
the handle along with the trigger assembly.

d. Remove gun tube connector from cable by

unscrewing connector nut from gun tube connec-
tor. If the cable inner tube is difficult to remove from
the connector assembly, carefully slit it lengthwise
with a knife up to the brass connector.

e. Uncouple the strain relief by pushing its outer

housing toward the middle of the cable. Move the
strain relief and the cable boot toward the middle of
the cable, past the damaged section.

f. Cut off the damaged section of cable and strip off

the outer jacket as shown in Figure 2. Be careful
not to cut the insulation on the control wires while
stripping jacket. Strip the red and white control
leads 1/4 inch (6.4 mm) from the end and crimp a
new S19492-2 terminal to each lead.

NOTE:

The cable contains three control leads. Any
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.

g. Check that the cable boot and both halves of the

MAGNUM 200FM

CAUTION

FIGURE 2

Summary of Contents for K498

Page 1: ...n 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 Mo...

Page 2: ...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...

Page 3: ...cal earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for coo...

Page 4: ...vent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic...

Page 5: ...iv SAFETY iv Mar 93...

Page 6: ...ion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number __________...

Page 7: ...____________________________________________________________ Maintenance Section D Removal Installation and Trimming Instructions for Magnum Liners D 1 Gun Tubes and Nozzles D 1 Gun Cables D 2 Cable C...

Page 8: ...he procedure outlined in the Maintenance Section of this manual before working in that area of the equipment WARNING Choose the gas nozzle as appropriate for the GMAW process to be used Typically the...

Page 9: ...K498 1 15 ft 035 0 9 KP2020 1B1 KP2026 1 KP1935 2 KP2025 1 KP1934 1 KP2028 1 4 5 045 1 2 2B2 K498 2 10 ft 035 0 9 KP2020 1B1 KP2026 1 KP1935 2 KP2025 1 KP1934 1 KP2028 1 3 0 045 1 2 2B2 K498 3 15 ft...

Page 10: ...e gives the correct electrical stickout as required for the procedure being use d To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out Follow wire fe...

Page 11: ...NSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM LINERS NOTICE The variation in cable lengths prevents the interchangeability of liners Once a liner has been cut for a particular gun it should not be...

Page 12: ...per Gun Tubes and Nozzles Section of pages D 1 and D2 c Remove three 6 screws from the gun handle sep arate the two halves and remove the cable from the handle along with the trigger assembly d Remove...

Page 13: ...ull the connector nut over the copper strands engage the gun tube connector 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 co...

Page 14: ...past the damaged section Remove and save the cable clamp NOTE If sliding the cable handle becomes difficult try rotating it 180 e Remove incoming connector from cable by unscrewing connector nut from...

Page 15: ...g 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...

Page 16: ...E CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally...

Page 17: ...ize 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...

Page 18: ...seizes 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 Guid...

Page 19: ...NOTES MAGNUM 200FM...

Page 20: ...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 21: ...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 22: ...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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