Lincoln Electric K498 Manual Download Page 2

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes 
outdoors.

____________________________________________________

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
refueling to prevent spilled fuel from vaporiz-
ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In  some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

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.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

i

SAFETY

i

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.

WARNING

Mar ‘95

ELECTRIC AND 
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes 

localized Electric and Magnetic Fields (EMF). Welding 
current creates EMF fields around welding cables and 
welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

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

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do  not place your body between the electrode and

work cables. If the electrode cable is on your right 
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.

2.d.5. Do not work next to welding power source.

1.h. To  avoid scalding, do not remove the

radiator pressure cap when the engine is
hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

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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