Lincoln Electric MAGNUM 550 Bedienungsanleitung

MAGNUM ®550 GUN & CABLE ASSEMBLY

OPERATOR’S MANUAL

Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built

with safety in mind. However, your

overall safety can be increased by

proper installation ... and thought-

ful operation on your part. DO

NOT INSTALL, OPERATE OR

REPAIR THIS EQUIPMENT

WITHOUT READING THIS

MANUAL AND THE SAFETY

PRECAUTIONS CONTAINED

THROUGHOUT. And, most

importantly, think before you act

and be careful.

IM475-A

March, 2008

• Sales 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 Products •

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.

SAFETY

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 ʻ95

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

SAFETY

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks and

the rays of the arc when welding or observing

open arc welding. Headshield and filter lens

should conform 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.

ELECTRIC SHOCK can

kill.

3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.

Do not touch these “hot” parts with your bare

skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(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 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 welders.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASES

can be dangerous.

5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases. When welding, keep

your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) or on lead or

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected

by various factors including proper use and positioning of

the equipment, maintenance of the equipment and the spe-

cific welding procedure and application involved. Worker

exposure level should be checked upon installation and

periodically thereafter to be certain it is within applicable

OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon

vapors

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors

form phosgene, a highly toxic gas, and other irritating prod-

ucts.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,

especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employerʼs safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

AUG 06

iii

SAFETY

iii

FOR ELECTRICALLY

powered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturerʼs

recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturerʼs recommendations.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the

process used and properly operating

regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

Jan, 07

WELDING and CUTTING

SPARKS can

cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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 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 hazardous

situations. Refer to “Safety in Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the

equipment being used.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact

can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances

inside. They can cause an explosion even

though

they have

been “cleaned”. For information, purchase “Recommended

Safe Practices for the

Preparation

for Welding and Cutting of

Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil

free protective garments such as leather gloves, heavy shirt,

cuffless trousers, high shoes and a cap over your hair. Wear

ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a

welding area.

6.g. Connect the work cable to the work as close to the welding

area as practical. Work cables connected to the building

framework or other locations away from the welding area

increase the possibility of the welding current passing

through lifting chains, crane cables or other alternate cir-

cuits. 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 thawing.

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions

et les précautions de sûreté specifiques qui parraissent dans ce

manuel aussi bien que les précautions de sûreté générales suiv-

antes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher

metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état

defonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder

parce que la tension entre les deux pinces peut être le

total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-électrode sʼapplicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de nʼimporte quelle partie

du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray-

onnement de lʼarc et des projections quand on soude ou

quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de

soudage. Se protéger avec des vêtements de protection libres

de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible

de la zone de travail quʼil est pratique de le faire. Si on place

la masse sur la charpente de la construction ou dʼautres

endroits éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques dʼincendie ou dʼechauffement des chaines et des

câbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

dʼopérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,

voir le code “Code for safety in welding and cutting” CSA

Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de

lʼélectricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branché à une

bonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch-

er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

place.

Mar. ʻ93

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.

The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims

for material damaged in shipment must be made by the purchaser against the transportation company at the

time the shipment is received.

Please record your equipment identification information below for future reference. This information can be

found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you

have recorded above. The code number is especially 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 form on the back of the warranty statement included in the literature packet

accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

“Product Registration”. Please complete the form and submit your registration.

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-

ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln

Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-

sion at that 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, including any warranty of fitness for any customerʼs 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 manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control

of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in

applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com

for any updated information.

Page

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A

General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1, A-2

Connector Kit Installation to Gun Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

K613-1 & -6 Installation (for Lincoln Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

K613-2 Installation (for Tweco® Adapted and Lincoln DH-10, LN-10, PF-10 & STT-10 Feeders)

. .

A-3

K613-3 Installation (for Miller® Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-3

K613-4 Installation (for Older Hobart® Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-4

K613-5 Installation (for Hobart® Series 2000 Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-4

Liner Installation and Trimming Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Rotating the Gun Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Conract Tip and Gas Nozzle Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Connection to Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Connection to Lincoln Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Connection to Tweco Adapted and Lincoln DH-10, LN-10, PF-10 & STT-10 Feeders

. . A-5

Connection to Miller Feeders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Connection to Older Hobart Feeders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Connection to Hobart Series 2000 Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Installation of Optional Gun Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

__________________________________________________________________________________________

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

Electrodes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

__________________________________________________________________________________________

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D

Removal, Installation and Trimming Instructions for MAGNUM® Liners . . . . . . . . . . . . . D-1

Gun Tubes and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Gun Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Cable Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Cable Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Gun Tube End Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1, D-2

Wire Feeder End Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

Thread Sizes for MAGNUM® 550 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4

__________________________________________________________________________________________

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

__________________________________________________________________________________________

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-202-P

__________________________________________________________________________________________

TABLE OF CONTENTS

A-1

INSTALLATION

MAGNUM® 550

A-1

GENERAL DESCRIPTION

The MAGNUM® 550 GMA gun and cable assembly has been designed to meet NEMA specification EW3 for welding with steel elec-

trode using the GMAW (gas metal arc welding) and the gas-shielded FCAW (flux-cored arc welding) processes:

Product Gun Cable Wire Size Contact Gas Coarse Coarse Thread Cable Gun

Number Length in. (mm) Tips Diffuser Thread Nozzle Insulator Liner Tube

ft. (m) Nozzle Assembly 60°

K598-1 10ft. (3.0m) .035” (0.9mm) KP16S-35 KP56S-SW KP26CT-62 KP36CT KP45-3545-15 KP1951-1

.045” (1.2mm) KP16S-45 .625 I.D.

.12 Rec.

K598-2 12 ft. (3.6m) .035” (0.9mm) KP16S-35 KP56S-SW KP26CT-62 KP36CT KP45-3545-15 KP1951-1

.045” (1.2mm) KP16S-45 .625 I.D.

.12 Rec.

K598-3 15 ft. (4.5m) .035” (0.9mm) KP16S-35 KP56S-SW KP26CT-62 KP36CT KP45-3545-15 KP1951-1

.045” (1.2mm) KP16S-45 .625 I.D.

.12 Rec.

K598-4 25 ft. (7.5m) .035” (0.9mm) KP16S-35 KP56S-SW KP26CT-62 KP36CT KP45-3545-25 KP1951-1

.045” (1.2mm) KP16S-45 .625 I.D.

.12 Rec.

K598-5 10 ft. (3.0m) .052” (1.3mm) KP16S-52 KP56S-SW KP26CT-62 KP36CT KP45-116-15 KP1951-1

1/16” (1.6mm) KP16S-116 .625 I.D.

.12 Rec.

K598-6 12 ft. (3.6m) .052” (1.3mm) KP16S-52 KP56S-SW KP26CT-62 KP36CT KP45-116-15 KP1951-1

1/16” (1.6mm) KP16S-116 .625 I.D.

.12 Rec.

K598-7 15 ft. (4.5m) .052” (1.3mm) KP16S-52 KP56S-SW KP26CT-62 KP36CT KP45-116-15 KP1951-1

1/16” (1.6mm) KP16S-116 .625 I.D.

.12 Rec.

K598-8 25 ft. (7.5m) .052” (1.3mm) KP16S-52 KP56S-SW KP26CT-62 KP36CT KP45-116-25 KP1951-1

1/16” (1.6mm) KP16S-116 .625 I.D.

.12 Rec.

K598-9 10 ft. (3.0m) 5/64” (2.0mm) KP16S-564 KP56S-H

KP26CT-75-R

KP36CT

KP45H-332-15

KP1951-2

3/32” (2.4mm) KP16S-332 .750 I.D.

.25 Rec.

K598-10 12 ft. (3.6m) 5/64” (2.0mm) KP16S-564 KP56S-H

KP26CT-75-R

KP36CT

KP45H-332-15

KP1951-2

3/32” (2.4mm) KP16S-332 .750 I.D.

.25 Rec.

K598-11 15 ft. (4.5m) 5/64” (2.0mm) KP16S-564 KP56S-H

KP26CT-75-R

KP36CT

KP45H-332-15

KP1951-2

3/32” (2.4mm) KP16S-332 .750 I.D.

.25 Rec.

K598-12 10 ft. (3.0m) 7/64” (2.8mm) KP16S-764 KP56S-H

KP26CT-75-R

KP36CT

KP45-18-15

KP1951-2

1/8” (3.2mm) KP16S-18 .750 I.D.

.25 Rec.

K598-13 12 ft. (3.6m) 7/64” (2.8mm) KP16S-764 KP56S-H

KP26CT-75-R

KP36CT

KP45-18-15

KP1951-2

1/8” (3.2mm) KP16S-18 .750 I.D.

.25 Rec.

K598-14 15 ft. (4.5m) 7/64” (2.8mm) KP16S-764 KP56S-H

KP26CT-75-R

KP36CT

KP45-18-15

KP1951-2

1/8” (3.2mm) KP16S-18 .750 I.D.

.25 Rec.

K598-15 15 ft. (4.5m) .035" (0.9mm) KP15H-35 KP55SW KP25CT-62 KP35CT KP45-3545-15 KP1951-3

KP15H-45 .62 I.D.

.12 Rec.

K598-16 15 ft. (4.5m) .052" (1.3mm) KP15H-53 KP55SW KP25CT-62 KP35CT KP45-116-15 KP1951-3

1/16" (1.6mm) KP15H-116 .62 I.D.

.12 Rec.

K598-17 15 ft. (4.5m) 5/64" (2.0mm) KP15H-564 KP55H KP25CT-75 KP35CT KP45H-332-15 KP1951-3

3/32" (2.4mm) KP15H-332 .75 I.D.

.12 Rec.

K598-18 15 ft. (4.5m) 7/64" (2.8mm) KP15H-764 KP55-H

KP25CT-75

KP35CT

KP45-18-15

KP1951-3

1/8" (3.2mm) KP15H-18 .75 I.D.

.12 Rec.

MAGNUUM™ 550

500 AMPS AT 60% DUTY CYCLE WITH CO2 GAS

500 AMPS AT 40% DUTY CYCLE WITH MIXED GAS

A-2

INSTALLATION

MAGNUM® 550

A-2

The K598 MAGNUM® guns are not factory equipped

with a feeder end connector. With the K613-1 MAG-

NUM® Connector Kit, they can be used with any

Lincoln LN-7 or

LN-25 semiautomatic wire feeder. The

K613-1 can also be used with the LN-8 or LN-9 when

feeding .052 and smaller electrodes. For additional

Connector Kits see the “P-202 ACCESSORIES” sec-

tion of this manual. An optional K481 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.

An interlocking trigger is available as a parts order.

With the trigger pulled in all the way, the trigger can

be slid forward into the interlock position. To release

interlock, squeeze trigger and slide back. The trigger

is made of a spatter resistant material. See the “P-202

ACCESSORIES” section of this manual.

For best results when welding mild and alloy steels, it

is recommended that L-50 or L-56 Lincoln solid wire

electrodes be used for the GMAW process and

Lincoln Outershield® cored electrodes for the gas-

shielded FCAW process.

Liners are available for feeding the harder (5356)

3/64" or 1/16" aluminum electrode. The liners have a

flat spring steel jacket with a frictionless core.

Although these liners are provided in 15 ft. lengths, 10

ft. cable lengths are recommended to reduce feeding

problems. See the “P-202 ACCESSORIES” section of

this manual.

A-3

INSTALLATION

MAGNUM® 550

A-3

INSTALLATION

CONNECTOR KIT INSTALLATION TO GUN CABLE

The K598 MAGNUM® 550 Guns and Cables are

shipped as "generic" and must be assembled with

either a K613-1 Lincoln Connection Kit for standard

Lincoln wire feeders (LN-8 or LN9 using smaller than

1/16 electrode), a K613-2 Tweco Adapted Feeder

Connection Kit for wire feeders adapted for use with

comparable size Tweco gun cables, a K613-3

Connector Kit for a variety of Miller wire feeders, a

K613-4 Connector Kit for a variety of older Hobart wire

feeders, a K613-5 Connector Kit for Hobart Series

2000 wire feeders and K613-6 Connector Kit for LN-8

or LN-9 wire feeders using 1/16 and larger electrode.

Each of the above connections are covered below.

You may skip to the instructions that are appropriate

for your wire feeder.

K613-1 & K613-6 Installation (For Lincoln Feeders)

a. Remove brass cable connector and insulation tube

(See Figure 1) from the K613-1 kit. Slide the insu-

lation tube onto the connector from the threaded

end and screw it onto the feeder end of the gun

cable. Tighten the connection.

b. Remove the molded gas plug fitting on the side of

the feeder end handle and replace it with the

barbed brass fitting provided in the kit.

c. Attach the round connector of the gun control

cable provided to the trigger connector on the front

of the Lincoln feeder.

NOTE: Both the plug and socket are keyed and

must be properly oriented.

d. Place one tubing clamp onto each end of the flexi-

ble tubing provided, approximately 2” (51mm) in

from each end. Slide one end of the tubing onto

the barbed connector on the feeder end cable

handle (step b) and move the clamp down near

the end of the tube to assure a good gas seal.

NOTE: An optional K481 MAGNUM® Fast-

Connect Gas Tube Kit is available to provide tool-

less gas tube connection to Lincoln wire feeders.

Install per the instructions sent with the kit.

K613-2 Installation (For Tweco Adapted Feeders

and Lincoln DH-10, LN-10, PF-10 and STT-10 )

a. Remove brass cable connector (See Figure 1)

from the K613-2 kit and screw it onto the feeder

end of the gun cable. Tighten the connection.

b. Check that the molded gas plug fitting is sealing

the gas fitting hole in the side of the feeder end

handle.

K613-3 Installation (For Miller Feeders)

a. Remove brass cable connector (See Figure 1)

from the K613-3 kit and screw it on to the feeder

end of the gun cable. Tighten the connection.

b. Check that the molded gas plug fitting is sealing

the gas fitting hole in the side of the feeder end

handle.

c. Attach the round connector of the gun control

cable provided to the trigger connector on the

front of the Miller feeder.

ELECTRIC SHOCK can kill.

• Have a qualified individual install

and service this equipment.

• Turn the input power for the power

source off at the fuse box or disconnect switch

before working on this equipment.

• Do not touch electrically hot parts such as out-

put terminals or internal wiring.

----------------------------------------------------------------------

WARNING

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