Lincoln Electric Magnum 300 Operator'S Manual Download Page 1

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Magnum

Magnum PRO Curve

Operator’s Manual

MAGNUM

& MAGNUM

PRO CURVE 300 & 400

GMA GUN and CABLE ASSEMBLY

Register your machine:

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

IM381-H

| Issue D ate Dec-15

For use with models:

K470-[ ]

K1802-1

K471-[ ]

K2286-1

K541-[ ]

K2951-[ ]
K2952-[ ]
K3055-[ ]

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

Magnum 300, 400 & PRO Curve 400 meet the

following specification(s):

IEC 60974-7:2013

GB 15579.7:2013

Summary of Contents for Magnum 300

Page 1: ...ervice and Distributor Locator www lincolnelectric com locator IM381 H Issue Date Dec 15 Lincoln Global Inc All Rights Reserved For use with models K470 K1802 1 K471 K2286 1 K541 K2951 K2952 K3055 Save for future reference Date Purchased Code ex 10859 Serial ex U1060512345 Magnum 300 400 PRO Curve 400 meet the following specification s IEC 60974 7 2013 GB 15579 7 2013 ...

Page 2: ...N A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR BODY PROTECTION PROTECT your eyes and face with welding helmet properly fitted...

Page 3: ...ers 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 th...

Page 4: ...m to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES CAN BE DANGEROUS 5 a Welding may produce fumes an...

Page 5: ...ent passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 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...

Page 6: ...er Feeders B 3 Connection to Hobart Feeders B 4 Connection to L Tec Adapted Feeders B 4 Connection to Lincoln Wirematic Hobart Series 2000 or SP100T Feeders B 4 Connection to 10 Series Feeders B 5 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 Gun Tubes ...

Page 7: ...connector kits it is possible to connect MAGNUM MAGNUM PRO CURVE 300 and 400 guns directly to a variety of Miller and Hobart wire feeders respectively The K466 5 connector kit allows connection of MAGNUM MAGNUM PRO CURVE 300 and 400 guns to an L Tec feeder connector assembly L Tec feeders require a feeder connector assembly similar to a Tweco adapter in order to connect to a gun and cable The K466...

Page 8: ... 16 1 6 KP14 116 3 6 5 64 2 0 564 KP54A KP24A 62 KP34A KP44 564 15 KP1928 2 K470 6 15 ft 1 16 1 6 KP14 116 4 5 5 64 2 0 564 KP54A KP24A 62 KP34A KP44 564 15 KP1928 2 Description Gun Contact Tips Gas Product Cable Wire Size Heavy Diffuser Gas Cable Gun Tube Feeder Number Length m in mm Duty Assembly Nozzle INSULATOR Liner 60 Type 15 ft 035 0 9 KP2744 035 Lincoln 10 Series K2951 2 10 45 4 5 045 1 2 ...

Page 9: ...5 1 2 45 KP54A KP24A 62 KP34A KP44 3545 15 KP1928 2 K471 2 15 ft 035 0 9 KP14 35 K2286 1 4 5 045 1 2 45 KP54A KP24A 62 KP34A KP44 3545 15 KP1928 2 K471 10 20 ft 035 0 9 KP14 35 6 1 045 1 2 45 KP54A KP24A 62 KP34A KP44 3545 25 KP1928 2 K471 13 25 ft 035 0 9 KP14 35 7 6 045 1 2 45 KP54A KP24A 62 KP34A KP44 3545 25 KP1928 2 K471 3 10 ft 052 1 3 KP14 52 3 0 1 16 1 6 116 KP54A KP24A 62 KP34A KP44 116 1...

Page 10: ...K541 25 15 ft 035 0 9 KP14 35 Tweco 4 5 045 1 2 45 KP54A KP24A 62 KP44 3545 15 KP1928 2 K466 2 K541 26 15 ft 052 1 3 KP14 52 Tweco 4 5 1 16 1 6 116 KP54A KP24A 62 KP44 116 15 KP1928 2 K466 2 Feeder Kits installed on the gun at the factory A 4 A 4 MAGNUM 400 SHORT NECK 400 AMPS AT 50 DUTY CYCLE WITH CO2 GAS 400 AMPS AT 40 DUTY CYCLE WITH MIXED GAS MAGNUM 400 SHORT NECK COMPLETE ASSEMBLY WITH FEEDER...

Page 11: ...5 1 10 ft 045 1 2 KP2744 045 KP2746 1 KP2742 1 62R KP2773 2 KP2925 60 3 0 K3055 2 15 ft 045 1 2 KP2744 045 KP2746 1 KP2742 1 62R KP2773 2 KP2925 60 4 5 K3055 3 20 ft 045 1 2 KP2744 045 KP2746 1 KP2742 1 62R KP2773 2 KP2925 60 6 1 K3055 4 25 ft 045 1 2 KP2744 045 KP2746 1 KP2742 1 62R KP2773 2 KP2925 60 7 6 MAGNUM PRO CURVE 400 SHORT NECK 400 AMPS AT 50 DUTY CYCLE WITH CO2 GAS 400 AMPS AT 40 DUTY C...

Page 12: ... provide tool less gas tube connection to Lincoln wire feeders Install per the instructions sent with the kit K466 2 INSTALLATION For Tweco Adapted Feeders a Remove brass cable connector see Figure 1 from the K466 2 kit and screw it onto the feeder end of the gun cable Tighten the connection with the wrench provided b Check that the molded gas plug fitting is sealing the gas fitting hole in the si...

Page 13: ...r end of the cable Be sure the liner bushing is stenciled appropriately for the wire size being used d NOTE For liners KP44N and KP45N Before fully seating the liner bushing it will be nec essary to trim the liner s inner tube flush with the liner bushing using a sharp blade After trimming remove any burrs from inner tube and insure that the opening is fully open For all K466 connector kits except...

Page 14: ...nd K466 4 tighten the set screw in the cable connector B For K466 3 and K466 4 screw in the connector cap 5 For guns with a diffuser set screw tighten the set screw in the side of the gas diffuser against the cable liner using the Allen wrench provided This screw should only be gently tightened Overtightening will split or collapse the liner and cause poor wire feeding 6 Replace the nozzle insulat...

Page 15: ... that the gun liner connector cap liner drive rolls and guide tubes are appropriate for the elec trode size being used 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 circuit into the mating socket on the...

Page 16: ...l are appropriate for the elec trode size being used b Fully push the brass connector end of the gun cable into the outgoing side of the feeder wire drive Secure the cable using the hand screw on the wire feeder c Insert the control cable plug from the feeder trigger circuit into the mating socket on the gun cable con nector handle CONNECTION TO LINCOLN 10 SERIES FEEDERS Gun cable assemblies which...

Page 17: ...ply 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 Hold the gun so the contact tip to work dis tance gives the correct electrical stickout as required for the procedure being used d To stop welding release the gun trigger and then pull the gun away from the work after th...

Page 18: ... 2 0 mm Allen wrench Note Set screw is not found on K2951 K2952 and K3055 NOTE 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 as possible and retighten screws GUN CABLES CABLE CLEANING Clean cable liner after using approximately 300 pounds 136 kg ...

Page 19: ...e red and white con trol leads Assemble gun tube connector to cable by forcing the steel tube of the connector into the inside diam eter 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 connector nut over the copper strands engage the gun tube connector threads and tight en in place Refer to...

Page 20: ... 5 NOTE In order to remove the cable handle nut the tail of the connector cover must be depressed and the cable handle nut rotated 1 4 turn counterclock wise as viewed from the feeder end c Remove incoming connector from cable by unscrewing connector nut from incoming connector If the cable inner tube is difficult to remove from the connector assembly carefully slit it lengthwise with a knife up t...

Page 21: ...move the rod from the core This procedure ensures the inner core does not kink while assembling or tightening Position the plastic strain relief such that the tapered end is 4 68 119 mm from the incoming connector see Figure 5 Lock into place with steel housing Plastic strain relief may overhang cable jacket a maximum of 43 11 mm g Position cable boot and cable handle on cable and assemble replace...

Page 22: ...MAINTENANCE MAGNUM MAGNUM PRO CURVE GUNS THREAD SIzES FOR MAGNUM 300 400 CONSUMABLES THREAD SIzES FOR MAGNUM PRO CURVE 300 400 CONSUMABLES 1 2 20 1 4 20 D 5 D 5 ...

Page 23: ...d POSSIBLE 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 it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln...

Page 24: ...proper size cable liner 8 Partially flashed melted or improper size contact tip 1 Contact tip worn or incorrect size 2 Worn or undersize work cables or poor ground connections 3 Loose electrode connections 1 Keep as straight as possible Inspect cable and replace if necessary 2 Remove wire from gun and cable feed in new wire Note any obstruction Replace liner if necessary 3 Be sure the wire diamete...

Page 25: ...eizes in diffuser 1 Improper procedures or techniques 2 Improper gas shielding 1 Tip overheating due to prolonged or excessive high current and or duty cycle welding 1 See Gas Metal Arc Welding Guide GS100 2 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 prop...

Page 26: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra l Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension l Isolez vous du travail et de la terre l Berühren Sie keine stromführenden Teile oder Elektroden mit ...

Page 27: ... und Entlüftung des Arbeitsplatzes l Mantenha seu rosto da fumaça l Use ventilação e exhaustão para remover fumo da zona respiratória l Turn power off before servicing l Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio l Débranchez le courant avant l entre tien l Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten l Não o...

Page 28: ...stomer s 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 manufactur...

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