Lincoln Electric IM435 User Manual

MAGNUM©200FM

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TM

Fast-Mate Gun and Cable Assemblies

IM435-A

March, 2008

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 thoughtful 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.

Models

K498

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

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.

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 Gasoline Engines

i

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 vaporiz­ing 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.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

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.

___________________________________________________

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.

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.

Mar ʻ95

ii

SAFETY

ii

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.

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.

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.

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.

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 spe­cific 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
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 prod­ucts.

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.

vapors

AUG 06

to

iii

SAFETY

iii

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

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.

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

6.f.
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 cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

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.

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.

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.

Jan, 07

iv

SAFETY

iv

Mar. ʻ93

Thank You

vv

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!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. 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 posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation 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.

CUSTOMER ASSISTANCE POLICY

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

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

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:

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

WARNING

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

CAUTION

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

vi

TABLE OF CONTENTS

Page

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

Safety Precautions.............................................................................................................A-1

Liner Installation ...................................................................................................................A-1

Contact Tip and Gas Nozzle Installation ..............................................................................A-1

Connector to Fast-Mate Compatible Feeder ........................................................................A-1

________________________________________________________________________________

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

Safety Precautions.............................................................................................................B-1

General Description and Product Numbers Table................................................................B-1

Electrodes and Equipment ...................................................................................................B-2

Making a Weld......................................................................................................................B-2

Avoiding Wire Feeding Problems .........................................................................................B-2

________________________________________________________________________________

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

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

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

Gun Cables............................................................................................................D-2

Cable Cleaning ...............................................................................................D-2

Cable Repair ...................................................................................................D-2

Gun Tube End Repair.........................................................................D-2,D-3

Wire Feeder End Repair.....................................................................D-4,D-5

________________________________________________________________________

vi

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

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide....................................................................................E-2,E-4

________________________________________________________________________

Parts Pages.................................................................P202-G,-G.1, P202-D.2,-D.3,-D.4

________________________________________________________________________

A-1

INSTALLATION

A-1

Read this entire installation section before you
start installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and ser­vice this equipment.

• Turn the input power off at the fuse
box before working on equipment.

• Do not touch electrically hot parts.

• Be sure to discharge capacitors with
the procedure outlined in the
Maintenance Section of this manual
before working in that area of the
equipment.

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

LINER INSTALLATION

LINER INSTALLATION

Choose the gas nozzle as appropriate for the
GMAW process to be used. Typically, the contact
tip end should be flush to .12” (3.0 mm) extended
for the short-circuiting transfer process and .12”
(3.0 mm) recessed for spray transfer. For the
Outershield (FCAW) process, 1/4” (6.4 mm) recess
is recommended.

CONNECTION TO FAST-MATE COMPATIBLE
FEEDERS

FM model gun cable assemblies will connect easily to
any feeder equipped with a European style gun con­nector or any Lincoln wire feeder equipped with a
K489 Series FastMate Adapter Kit. To install an
optional K489 Series kit see the instructions provided
with the kit. (See Table A.1)

a. Check that the feeder outgoing guide, as well as

the drive roll, are appropriate for the electrode size
being used. When using a Fast-Mate Adapter Kit,
be certain the adapter guide tube is also properly
sized.

NOTE: FM models, using Fast-Mate connector, are

shipped with factory installed liner. To change
liner in these models, see maintenance sec­tion.

CONTACT TIP AND GAS NOZZLE INSTALLATION

NOTE: FM models are shipped ready to weld with the

proper tip and gas nozzle installed. If you
choose to change the contact tip or nozzle,
see the instructions below.

a. Choose the correct size contact tip for the elec-

trode being used (wire size is stenciled on the side
of the contact tip) and screw it snugly into the gas
diffuser.

b. Be sure the nozzle insulator is fully screwed onto

the diffuser and does not block the gas holes in the
diffuser.

c. Slip the appropriate gas nozzle onto the nozzle

insulator. Either a .62” (15.9 mm) or .50” (12.7 mm)
I.D. slip-on gas nozzle may be used and should be
selected based on the welding application.

b. Align and fully engage the brass connector end of

the gun cable into the mating connector on the out­going side of the feeder wire drive. Secure the
cable connection by snuggling the Fast-Mate con­nector collar nut.

TABLE A.1

WIRE FEEDER ADAPTER KITS FOR (FM)

PRODUCT NO.

K489-1

K489-2

K489-3

K489-4

K489-5

K489-6

K489-7

WIRE FEEDER TYPE

Lincoln LN-7 Series, LN-8, LN-9

Lincoln LN-25

Miller

Turbo Adapter

Hobart

L-Tec

LN-10, DH-10,STT-10

Power Feed 10, LN-15

MAGNUM® 200FM

B-1

OPERATION

Read and understand this entire section before
operating your machine.

B-1

GENERAL DESCRIPTION

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

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

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES
can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to
remove fumes from breathing

zone.

WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion

• Keep flammable material away.

not weld, cut or gouge on contai

• Do

that have held combustibles.

ners

The MAGNUM® 200FM amp GMA guna nd cable
assembly has been designed to meet NEMA specifi­cation EW3 for welding with steel electrode using the
GMAW (gas metal arc welding) and gas-shielded
FCAW (flux-cored arc welding) processes:

The K498 MAGNUM® 200FM gun is factory installed
with a Fast-Mate (European style) wire feeder connec­tor for “all-in-one” GMAW feeder connection. A single
connector attaches welding current, wire liner, welding
gas, and trigger control leads to feeder. An optional
K489-1 MAGNUM® Fast-Mate Adapter allows the use
of these guns with any Lincoln LN-7, LN-8, LN-9 and
SP200 wire feeder. An optional K489-2 MAGNUM®
Fast-Mate Adapter is required for the LN-25.

For best results when welding mild and alloy steels, it
is recommended that L-50 or Super Arc L-56 Lincoln
solid wire electrodes be used for the GMAW process
and OS70 or OS71 Lincoln Outershield

®

cored elec-

trodes for the gas-shielded FCAW process.

ARC RAYS
can burn.

• Wear eye, ear and body
protection.

Only qualified personnel should operate this equip­ment. Observe all safety information throughout this
manual.

MAGNUM® 200FM

200 AMPS AT 60% DUTY CYCLE WITH CO2 GAS

150 AMPS AT 60% DUTY CYCLE WITH MIXED GAS

(TABLE B.1)

Description Gun Contact

Product
Number (m) in. (mm) Duty Assembly Nozzle Insulator Liner 60°

K498-1 15 ft. .035 (0.9) KP14-35 KP52 KP22-50 KP32 KP42-4045-15 KP2028-1

K498-2 10 ft. .035 (0.9) KP14-35 KP52 KP22-50 KP32 KP42-4045-15 KP2028-1

K498-3 15 ft. .025 (0.6) KP14-25 KP52-23 KP22-50 KP32 KP42-25-15 KP2028-1

K498-4 10 ft. .025 (0.6) KP14-25 KP52-23 KP22-50 KP32 KP42-25-15 KP2028-1

K498-5 12 ft. .025 (0.6) KP14-25 KP52-23 KP22-50 KP32 KP42-25-15 KP2028-1

K498-6 12 ft. .035 (0.9) KP14-35 KP52 KP22-50 KP32 KP42-4045-15 KP2028-1

Cable Tips Gas

Length Wire Size Standard Diffuser Gas Cable Gun Tube

(4.5) .045 (1.2) -45

(3.0) .045 (1.2) -45

(4.5) .030 (0.8) -30

(3.0) .030 (0.8) -30

(3.6) .030 (0.8) -30

(3.6) .045 (1.2) -45

MAGNUM® 200FM

B-2

OPERATION

B-2

ELECTRODES AND EQUIPMENT

The MAGNUM® 200FM gun and cable has been
designed for use with Lincoln L-50 and L-56, solid
steel wire electrodes for the GMAW process and
Lincoln Outershield
shielded FCAW process. Refer to the appropriate
Lincoln Process and Procedure Guidelines for the
electrode used for information on recommended elec­trical and visible stickouts.

®

cored electrodes for the gas-

MAKING A WELD

a. Check that the welding power source is on and that

the shielding gas supply 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
distance 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 feeder instruction manual if using a
trigger 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 the electrode cable as straight as possible

when welding or loading electrode through cable.

c. Avoid wrapping excess cable around handle or

front of wire feeder.

d. Do not allow dolly wheels or trucks to run over

cables.

e. Keep cable clean by following maintenance instruc-

tions.

f. Use only clean, rust-free electrode. The Lincoln

electrodes have proper surface lubrication.

g. Replace contact tip when the arc starts to become

unstable or the contact tip end is fused or
deformed.

MAGNUM® 200FM

D-1

MAINTENANCE

D-1

REMOVAL, INSTALLATION 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 installed in another
gun, unless it can meet the liner cut off length require­ment. Liners are shipped with the jacket of the liner
extended the proper amount.

a. Remove the gas nozzle and nozzle insulator.

Loosen the set screw located in the side of the dif­fuser with 5/64” (2.0 mm) Allen wrench (provided
with the gun).

b. Remove the gas diffuser from gun.

c. Lay gun and cable out straight on a flat surface.

Remove the liner nut from the connector end of the
cable and pull liner out of cable.

d. Insert a new untrimmed liner into the connector end

of the cable. Be certain that the liner busing is sten­ciled appropriately for the wire size being used.

g. Screw the gas diffuser onto the end of the gun tube

and securely tighten.

h. Tighten the set screw in the side of the gas diffuser

against the cable liner using a 5/64” (2.0 mm) Allen
wrench.

CAUTION

This screw should be gently tightened. Over­tightening will split or collapse the liner and cause
poor wire feeding.

GUN TUBES AND NOZZLES

a. Replace worn contact tips as required.

b. Remove spatter from inside of gas nozzle and from

tip after each 10 minutes of arc time or as required.

c. To remove gun tube from gun, loosen socket-head

clamping screw in handle with 3/16” (4.8 mm) Allen
wrench. Remove gas nozzle and nozzle insulator
and also loosen small set screw in the diffuser
using 5/64” (2.0 mm) Allen wrench.

e. Fully seat the liner bushing into the connector.

Finger tighten the liner nut onto the cable connector.

f. With the cable straight, trim liner to 1-1/4” (31.8

mm). Remove any burrs from the end of the liner.

NOTE: Small set screw in the diffuser must be

loosened, otherwise liner could be dam­aged when attempting to remove gun tube.

FIGURE 1

MAGNUM® 200FM

D-2

MAINTENANCE

FIGURE 2

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.

CAUTION

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 connec­tor. 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.

MAGNUM® 200FM

D-3

MAINTENANCE

FIGURE 3

D-3

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

strain relief are on the cable. Slip the connector nut
over the copper strands with the thread end out.
Orient gun tube connector so machined flat is on
the same side of the cable as the red and white
control leads. Assemble gun tube connector to
cable by forcing the steel tube of the connector into
the inside diameter 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 tighten in place. Refer to Figure 3.

NOTE: For best results, insert a .175”/.197” (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. Then remove the rod from the core.
This procedure ensures the inner core does
not kink while assembling or tightening.

h. Pull the cut-off lead terminals off the trigger assem-

bly and connect the replacement control lead termi­nals.

FIGURE 4

MAGNUM® 200FM

D-4

MAINTENANCE

FIGURE 5

D-4

i. Position the cable boot and strain relief on the

cable so it fits in cable handle cavity and lock the
strain relief in place by pushing the two halves
together.

j. Assemble cable in left side of gun handle.

Assemble trigger into the proper handle cavity.
Assemble right side of gun handle and tighten the
three screws that hold the handle together. Refer
to Figure 4.

k. Install gun tube per Gun Tubes and Nozzles

Section on page D-1.

l. Install and trim liner per Removal, Installation and

Trimming Instructions on page D-1.

WIRE FEEDER END REPAIR

a. Remove the cable liner per Removal, Installation,

and Trimming Instructions on page D-1.

b. Loosen the boot nut. Slide the boot nut and boot

toward the middle of the cable past the damaged
section.

c. Rotate the collar nut until the screw anchoring the

cable handle is visible. Remove the screw and
save it.

d. Slide the cable handle and collar nut toward the

middle of the cable 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 incoming connec­tor. 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.

f. Cut the cable control wires where they meet the

cable jacket or else unsolder the connection where
they connect to the terminal lead assembly. If you
cut the wires, strip the cut end 3/8” (9.5 mm) from
the end.

g. 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 red and white control leads
3/8” (9.5 mm) from the end.

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® 200FM

D-5

MAINTENANCE

D-5

h. Check that the cable boot, boot nut, cable handle,

and collar nut are on the cable. Slip the connector
nut over the copper strands with the threaded end
out. Orient the connector assembly so the red and
white control leads will have the straightest possi­ble routings to the sockets on the back side of the
connector. Assemble the incoming connector to the
cable by forcing the steel tube of the connector into
the inside diameter of the cable inner tube until the
copper strands are butted against the incoming
connector solder. Keeping the copper strands
against the shoulder, pull the connector nut over
the copper strands, engage the incoming 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 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. Then remove the rod from the core.
This procedure assures the inner core does
not kink while assembling or tightening.

m. Install and trim liner per Removal, Installation and

Trimming Instructions on page D-1.

WARNING

ELECTRIC SHOCK can kill.

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

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 tub­ing or electrical tape.

j. Fully insert the two control lead pins into the sock-

ets on the incoming connector. Tape the leads in
place in the necked down area of the connector.
Keeping the leads as close to the connector and
nut as possible, tape the insulated, soldered con­nections and the spare lead to the cable in the area
between the cable jacket and connector nut. This
must be done neatly and kept as low as possible or
the cable handle will not slide over this area.

k. Install the cable clamp on the cable jacket within

1/8” (3.2 mm) from the end of the jacket and tight­en.

l. Slide the collar nut and cable handle over the con-

nection and into place. Anchor the cable handle
with the screw removed in step (c). Slide the boot
and boot nut into place and tighten.

NOTE: If the cable handle becomes difficult to slide

over connection, try rotating it.

MAGNUM® 200FM

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “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 Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

MAGNUM® 200FM

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS

E-2

RECOMMENDED

COURSE OF ACTION

Drive rolls turn, but wire will not feed
or wire feeding is rough.

a. Gun cable kinked and/or twisted.

b. Wire jammed in gun and cable.

c. Incorrect drive rolls and guide

tubes.

d. Gun cable liner dirty.

e. Worn drive rolls.

f. Electrode rusty and/or dirty.

g. Worn or improper size cable liner.

h. Partially flashed, melted or

improper size contact tip.

a. Keep as straight as possible.

Inspect cable and replace if nec­essary.

b. Remove wire from gun and cable

– geed in new wire. Note any
obstruction. Replace liner if nec­essary.

c. Be sure the wire diameter being

used is stamped on drive rolls
and guide tubes. Replace if nec­essary.

d. Clean liner or replace.

e. Replace or reverse split drive roll

type.

f. Replace the electrode if it is

rusty.

g. Replace cable liner.

h. Replace the contact tip.

Variable or “hunting” arc.

a. Contact tip worn or incorrect size.

b. Worn or undersize ground cables

or poor ground connections.

c. Loose electrode connections.

a. Replace contact tip.

b. Inspect – repair or replace as

necessary.

c. Be sure the following connec-

tions are tight: electrode cable to
wire feeder and power source,
work cable to power source and
work, gun cable to wire feeder
contact block, gun nozzle to
body and contact tip to nozzle.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

MAGNUM® 200FM

E-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE AREAS OF

MISADJUSTMENTS

RECOMMENDED

COURSE OF ACTION

E-3

Poor arc striking with sticking or
“blast-offs”, weld porosity, narrow
and ropy looking bead, or electrode
stubbing into plate while welding.

Tip 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

Guide” (GS-100).

b. 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
proper.

Remove gun liner and check rub­ber seal for any sign of deteriora­tion or damage. Be sure set
screw in brass connector is in
place and tightened against the
liner bushing.

a. Do not exceed current and duty

cycle rating of gun.

A light application of high temper­ature antiseize lubricant (such as
Lincoln E2607 Graphite Grease)
may be applied to tip threads.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

MAGNUM® 200FM

NOTES

MAGNUM® 200FM

WARNING

Spanish

AVISO DE

PRECAUCION

l Do not touch electrically live 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 moja­da.

l Aislese del trabajo y de la tierra.

l Keep flammable materials away.

l Mantenga el material combustible

fuera del área de trabajo.

l Wear eye, ear and body protection.

l Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

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 Ihrem
Körper oder feuchter Kleidung!

l Isolieren Sie sich von den

Elektroden und dem Erdboden!

l Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

l Isole-se da peça e terra.

l Gardez à l’écart de tout matériel

inflammable.

l Entfernen Sie brennbarres Material!

l Mantenha inflamáveis bem guarda-

dos.

l Protégez vos yeux, vos oreilles et

votre corps.

l Tragen Sie Augen-, Ohren- und Kör-

perschutz!

l Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

l Keep your head out of fumes.
l Use ventilation or exhaust to

remove fumes from breathing zone.

l Turn power off before servicing.

l Do not operate with panel open or

guards off.

WARNING

l Los humos fuera de la zona de res-

piración.

l Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

l Gardez la tête à l’écart des fumées.
l Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

l Vermeiden Sie das Einatmen von

Schweibrauch!

l Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

l Mantenha seu rosto da fumaça.
l Use ventilação e exhaustão para

remover fumo da zona respiratória.

l Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

l Débranchez le courant avant

l’entretien.

l Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

l Não opere com as tampas removidas.
l Desligue a corrente antes de fazer

serviço.

l Não toque as partes elétricas nuas.

l No operar con panel abierto o

guardas quitadas.

l N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

l Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

l Mantenha-se afastado das partes

moventes.

l Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com