Lincoln Electric MAGNUM &MAGNUM PROCURVE 200 K2950 Operator'S Manual Download Page 16

f. Check that the cable boot and cable handle are on

the  cable.  Slip  the  connector  nut  over  the  copper
strands  with  the  threaded  end  out.  Assemble
incoming  connector  to  cable  by  forcing  the  steel
tube  of  the  connector  into  the  inside  diameter  of
the  cable  inner  tube  tube  until  the  copper  strands
are  butted  against  the  incoming  connector  shoul-
der. Keeping the copper strands against the shoulder,
pull  the  connector  nut  over  the  copper  strands,
engage the incoming connector threads, and tight-
en in place. Refer to Figure D.2.

NOTE:

For  best  results,  insert  a  .175/.197  inch  (4.5-

5.0 mm) diameter rod through the connector and into
core  of  cable  approximately  5.00”  (127  mm)  when
pushing  the  connector  tube  into  the  cable  core  tube.
To  tighten,  hold  the  connector  in  place  while  turning
the nut, and remove the rod from the core. This proce-
dure  ensures  the  inner  core  does  not  kink  while
assembling or tightening.
g. Position cable boot and cable handle on cable and

assemble  replacement  control  wire  terminals  in
place  on  the  cable  handle.  Insert  connector  cover
in place. Install tailpiece and fasten to cable handle
with cable handle nut. Refer Figure D.4.

h. Replace  the  molded  gas  plug  (or  barbed  fitting)

and feeder end connector.

i. Install  and  trim  liner  per  Liner  Installation  in  this

section.

D-3

MAINTENANCE

D-3

Wire  Feeder  End  Repair 

(Requires  2  S19492-1

Terminals)
a. Remove  the  cable  liner  per  Removal,  Installation,

and Trimming Instructions in this section.

b. Remove  the  feeder  end  connector,  molded  gas

plug  (or  barbed  fitting),  cable  handle  nut,  plastic
tailpiece  and  connector  cover  (see  Figure  D.4).

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 inch turn counter-
clockwise as viewed from the feeder end.

c. Remove  incoming  connector  from  cable  by

unscrewing  connector  nut  from  incoming  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.

d. Move  the  cable  boot  and  cable  handle  toward  the

middle of the cable past the damaged section.

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

the outer jacket as shown in Figure D.1. 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 S19492-1 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.

MAGNUM® & MAGNUM® PRO CURVE 200 GUNS

WARNING

FIGURE D.4

ELECTRIC SHOCK CAN KILL.

• Do not touch electrically live parts
such as output terminals or internal
wiring.

Summary of Contents for MAGNUM &MAGNUM PROCURVE 200 K2950

Page 1: ...eration 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 care...

Page 2: ...KER 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...

Page 3: ...r 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 of both welde...

Page 4: ...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 job site special precautions should be used to prevent...

Page 5: ...opri 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 paisse pa...

Page 6: ...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 incl...

Page 7: ...n B 1 Electrodes and Equipment B 2 Making a Weld B 2 Avoid Wire Feeding Problems B 2 ________________________________________________________________________ Maintenance Section D Liner Removal D 1 Re...

Page 8: ...rking in that area of the equipment K446 2 Installation For Adapted Feeders a Remove brass connector see Figure A 1 from the K466 2 kit and screw it onto the feeder end of the gun cable Tighten the co...

Page 9: ...ling the gas diffuser fully seat the liner bushing in the connector and For K466 1 K466 2 K466 5 and K2950 tighten the set screw in the cable connector OR For K466 3 and K466 4 screw in the connector...

Page 10: ...r Kit will connect easily to any Lincoln LN 7 LN 8 LN 9 SP200 or LN 25 feeder a Check that the drive roll s and feeder guide tubes are appropriate for the electrode size being used b Fully push the br...

Page 11: ...ss adapter on the outgoing side of the feeder wire drive Secure the cable using the hand screw or set screw in the adapter c Insert the control cable plug from the feeder trigger circuit into the mati...

Page 12: ...MAGNUM Fast Connect Gas Tube Kit is available to provide tool less gas tube connection to Lincoln wire feeders Non GMA model wire feeders require an optional gas solenoid valve The K497 gun can also...

Page 13: ...rigger interlock circuit AVOIDING WIRE FEEDING PRObLEMS Wire feeding problems can be avoided by observing the following gun handling procedures a Do not kink or pull cable around sharp corners b Keep...

Page 14: ...ion and Trimming Instruction for K497 K2950 with K466 Connector Kit installed a For gun and cables using a K466 1 K466 2 or K466 5 connector kit locate and loosen two set screws which are used to hold...

Page 15: ...re D 2 NOTE For best results insert a 175 197 inch 4 5 5 0 mm diameter rod through the connector and into core of cable approximately 5 00 inch 127 mm when pushing the connector tube into the cable co...

Page 16: ...3 MAINTENANCE D 3 Wire Feeder End Repair Requires 2 S19492 1 Terminals a Remove the cable liner per Removal Installation and Trimming Instructions in this section b Remove the feeder end connector mol...

Page 17: ...ed 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...

Page 18: ...if it is rusty 7 Worn or improper size cable liner Replace cable liner 8 Partially flashed melted or improper size contact tip Replace the contact tip 1 Contact tip worn or incorrect size Replace con...

Page 19: ...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...

Page 20: ...d Entl ftung des Arbeitsplatzes l Mantenha seu rosto da fuma a l Use ventila o e exhaust o para remover fumo da zona respirat ria l Turn power off before servicing l Desconectar el cable de ali mentac...

Page 21: ...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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