Lincoln Electric IM475 User Manual

MAGNUM®550 GUN & CABLE ASSEMBLY

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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.

IM475-A

March, 2008

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

OPERATOR’S MANUAL

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.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.

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.

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

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 suiv­antes:

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.

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 lev­age, 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.

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 ray­onnement 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, pan­talons 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.

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 debranch­er à lʼinterrupteur à la boite de fusibles.

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

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

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)

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

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

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

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

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

__________________________________________________________________________________________

TABLE OF CONTENTS

Page

. .

A-3
A-3
A-4
A-4

. . A-5

vi

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

__________________________________________________________________________________________

A-1

INSTALLATION

A-1

GENERAL DESCRIPTION

The MAGNUM® 550 GMA gun and cable assembly has been designed to meet NEMA specification EW3 for welding with steel elec­trode using the GMAW (gas metal arc welding) and the gas-shielded FCAW (flux-cored arc welding) processes:

MAGNUUM™ 550

500 AMPS AT 60% DUTY CYCLE WITH CO2 GAS

500 AMPS AT 40% DUTY CYCLE WITH MIXED GAS

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)

.045” (1.2mm)

K598-2 12 ft. (3.6m) .035” (0.9mm)

.045” (1.2mm)

K598-3 15 ft. (4.5m) .035” (0.9mm)

.045” (1.2mm)

K598-4 25 ft. (7.5m) .035” (0.9mm)

.045” (1.2mm)

K598-5 10 ft. (3.0m) .052” (1.3mm)

1/16” (1.6mm)

K598-6 12 ft. (3.6m) .052” (1.3mm)

1/16” (1.6mm)

K598-7 15 ft. (4.5m) .052” (1.3mm)

1/16” (1.6mm)

K598-8 25 ft. (7.5m) .052” (1.3mm)

1/16” (1.6mm)

K598-9 10 ft. (3.0m) 5/64” (2.0mm)

3/32” (2.4mm)

K598-10 12 ft. (3.6m) 5/64” (2.0mm)

3/32” (2.4mm)

K598-11 15 ft. (4.5m) 5/64” (2.0mm)

3/32” (2.4mm)

K598-12 10 ft. (3.0m) 7/64” (2.8mm)

1/8” (3.2mm)

K598-13 12 ft. (3.6m) 7/64” (2.8mm)

1/8” (3.2mm)

K598-14 15 ft. (4.5m) 7/64” (2.8mm)

1/8” (3.2mm)

K598-15 15 ft. (4.5m) .035" (0.9mm)

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.

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.

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

1/8" (3.2mm)

KP16S-35
KP16S-45

KP16S-35
KP16S-45

KP16S-35
KP16S-45

KP16S-35
KP16S-45

KP16S-52

KP16S-116

KP16S-52

KP16S-116

KP16S-52

KP16S-116

KP16S-52

KP16S-116

KP16S-564
KP16S-332

KP16S-564
KP16S-332

KP16S-564
KP16S-332

KP16S-764

KP16S-18

KP16S-764

KP16S-18

KP16S-764

KP16S-18

KP15H-35
KP15H-45

KP15H-764

KP15H-18

KP56S-SW KP26CT-62 KP36CT KP45-3545-15 KP1951-1

KP56S-SW KP26CT-62 KP36CT KP45-3545-15 KP1951-1

KP56S-SW KP26CT-62 KP36CT KP45-3545-15 KP1951-1

KP56S-SW KP26CT-62 KP36CT KP45-3545-25 KP1951-1

KP56S-SW KP26CT-62 KP36CT KP45-116-15 KP1951-1

KP56S-SW KP26CT-62 KP36CT KP45-116-15 KP1951-1

KP56S-SW KP26CT-62 KP36CT KP45-116-15 KP1951-1

KP56S-SW KP26CT-62 KP36CT KP45-116-25 KP1951-1

KP56S-H

KP56S-H

KP56S-H

KP56S-H

KP56S-H

KP56S-H

KP55SW KP25CT-62 KP35CT KP45-3545-15 KP1951-3

KP55-H

.625 I.D.
.12 Rec.

.625 I.D.
.12 Rec.

.625 I.D.
.12 Rec.

.625 I.D.
.12 Rec.

.625 I.D.
.12 Rec.

.625 I.D.
.12 Rec.

.625 I.D.
.12 Rec.

.625 I.D.
.12 Rec.

KP26CT-75-R

.750 I.D.
.25 Rec.

KP26CT-75-R

.750 I.D.
.25 Rec.

KP26CT-75-R

.750 I.D.
.25 Rec.

KP26CT-75-R

.750 I.D.
.25 Rec.

KP26CT-75-R

.750 I.D.
.25 Rec.

KP26CT-75-R

.750 I.D.
.25 Rec.

.62 I.D.

.12 Rec.

.12 Rec.

.12 Rec.

KP25CT-75

.75 I.D.

.12 Rec.

KP36CT

KP36CT

KP36CT

KP36CT

KP36CT

KP36CT

KP35CT

KP45H-332-15

KP45H-332-15

KP45H-332-15

KP45-18-15

KP45-18-15

KP45-18-15

KP45-18-15

KP1951-2

KP1951-2

KP1951-2

KP1951-2

KP1951-2

KP1951-2

KP1951-3

MAGNUM® 550

A-2

INSTALLATION

A-2

The K598 MAGNUM® guns are not factory equipped
with a feeder end connector. With the K613-1 MAG­NUM® Connector Kit, they can be used with any
Lincoln LN-7 or
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” sec­tion 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.

LN-25 semiautomatic wire feeder. The

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 gas­shielded 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.

MAGNUM® 550

A-3

INSTALLATION

INSTALLATION

A-3

WARNING

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 out­put terminals or internal wiring.

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

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 insu­lation 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® Fast­Connect Gas Tube Kit is available to provide tool­less 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.

MAGNUM® 550

A-4

INSTALLATION

A-4

K613-4 Installation (For Older Hobart Feeders)

a. Remove brass cable connector (See Figure 1)

from the K613-4 kit and screw it on to the feeder
end of the gun cable. Tighten the connector.

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 phone plug connector of the gun con-

trol cable provided to the trigger connector on the
front of the Hobart feeder.

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

ble tubing provided, approximately 2” (51mm) in
from each end.

BRASS CABLE CONNECTORBRASS CABLE CONNECTOR

INSULATION TUBE (K613-1 & K613-6 ONLY)

SET SCREW

LINER ASSEMBLY

( LINER BUSHING TO BE TIGHTLY SEATED. )

FEEDER END HANDLE

FEEDER END HANDLE

SET SCREW

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.

K613-5 Installation (For Hobart Series 2000 Wire Feeders)

a. Remove brass cable connector (see Figure 1)

from the K613-5 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.

c. Attach the Gun Control cable provided to the trig-

ger connector on the front of the wire feeder.

LINER TRIM

LENGTH

SEE TABLE

GAS DIFFUSER

BELOW

COARSE THREAD INSULATOR ASSEMBLY

COARSE THREAD NOZZLE

Gun Diffuser Liner cut off length

K598-1 thru -14 KP56S-SW, KP56S-H .38” (9.5mm)

K598-15 thru -18 KP55SW, KP55, .50” (12.7mm)

KP55H, KP55S-SW,
KP55S-H

K598-15 thru -18 KP55S-SWL, KP55S-HL 1.00” (25.4mm)

Figure 1

LINER INSTALLATION AND TRIMMING INSTRUC­TIONS

a. Lay the gun and cable out straight on a flat sur-

face.

b. Make sure that the set screws in the connector

end and in the handle are backed out so as not to
damage liner or liner bushing. Remove and save
the coarse thread nozzle and coarse thread insu­lator assembly from the end of the gun tube
assembly.

c. Insert a new untrimmed liner into the connector end

of the cable. Be sure the liner bushing is stencilled
appropriately for the wire size being used.

NOTE: For liners KP45N-3545-15, KP45N-116-15,

gun tube assemblies KP1951-1 and KP1951-2.
Before fully seating the liner bushing, it will be nec­essary to trim the linerʼs inner tube flush with the
liner bushing using a sharp blade. After trrimming
remove any burs from inner tube and insure that the
opening is fully open.

d. Before installing the gas diffuser, fully seat the

liner bushing in the connector and:

For K613-1, K613-2, K613-5 and K613-6, tighten
the set screw in the cable connector.

OR

MAGNUM® 550

A-5

INSTALLATION

A-5

For K613-3 and K613-4, screw in the connectorcap
provided in the kit until it seats on the face of the
bushing. Then insert the appropriate piece of liner
material into the connector cap and tighten the set
screw. Four pieces of liner material are included in
these connector kits to help guide the electrode
through the connector cap. The piece with the
smallest inner diameter is designed for .045”
(1.2mm) maximum diameter electrode. The next
largest diameter is for 1/16” (1.6mm) maximum
diameter electrode. The largest diameter piece of
liner material is for 1/8” (3.2mm) maximum diameter
electrode. The next largest is for 3/32” (2.4mm)
maximum diameter electrode.

e. Be sure the cable is straight and then trim the liner

to the length shown in Figure 1. Remove any burrs
from the end of the liner.

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

and tighten. Be sure to use the proper diffuser size
for the electrode being used.

g. For K598-1 thru -14: Tighten the set screw in the

side of the gun handle against the cable liner. For
K598-15 thru -18: Tighten the set screw in the dif­fuser against the cable liner.

CAUTION

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

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

ROTATING THE GUN TUBE

The gun tube can be rotated to any position desired by the
operator. Loosen the clamping screw, rotate the gun tube to
the desired position and retighten the clamping screw.
The gun can be operated with the trigger on top. Simply rotate
the gun tube 180° and operate the gun with the trigger on top.

CONTACT TIP AND GAS NOZZLE INSTALLATION

The proper nozzle should be selected based on the
welding application. Different diameter self insulated
gas nozzles are also available to allow gas-shielded,
flux-cored welding. .62” (15.9mm). .75” (19.1mm) and
.88” (22.4mm) diameter nozzles are available. The self
insulated gas nozzles provide a tip recess of 1/8”.

Choose the gas nozzle as appropriate for the GMAW
process to be used. Typically, the contact tip end
should be 1/8” (3 mm) recessed for spray transfer and
for the Outershield® (FCAW) process.

CONNECTION TO FEEDER
Connection to Lincoln Feeders

Gun cable assemblies which were assembled with a K613-1
or K613-6 Connection Kit will connect easily to any Lincoln
LN-7, LN-8, LN-9 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 brass connector end of the gun cable

into the conductor block on the outgoing side of the
feeder wire drive. Secure the cable using the hand
screw or set screw in the conductor block.

c. Insert the control cable plug from the feeder trigger cir-

cuit into the mating socket on the feeder end cable han­dle.

d. Slide the free end of the flexible hose (mounted to the

gun) onto the barbed gas fitting on the front of the
Lincoln feeder. Move corresponding tubing clamp down
near the end of the tube to assure a good gas seal.

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

Gun cable assemblies which were assembled with a K613-2
Connection Kit will connect easily to any properly adapted
feeder.

a. Check that the adapter and feeder guide tubes, as well

as the drive roll(s), are appropriate for the electrode
size being used. For Lincoln feeders, check that the
K1500-3 Gun Adapter is in place.

a. Choose the correct size contact tip for the electrode

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 coarse thread insulator assembly is fully

screwed onto the gun tube and does not block the gas
holes in the diffuser.

NOTE: The coarse thread insulator assembly is not
required when using the optional self insulated gas noz­zles.

c. Screw the appropriate coarse thread nozzle onto the

coarse thread insulator assembly. Coarse thread nozzles
are available with a .62” (15.9mm) or .75” (19.1mm) I.D.,
and in both 1/8” recessed and 1/4” recessed design.

MAGNUM® 550

b. Fully push the brass connector end of the gun cable

into the brass 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 cir-

cuit into the mating socket on the gun cable connector
handle.

Connection to Miller Feeders

Gun and cable assemblies which were assembled with a
K613-3 Connection Kit will connect easily to a variety of
popular Miller wire feeders.

a. Check that the gun liner, connector cap liner, drive

roll(s) and guide tubes are appropriate for the electrode
size being used.

A-6

INSTALLATION

A-6

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 cir-

cuit into the mating socket on the gun cable connector
handle.

Connection to Older Hobart Feeders

Gun and cable assemblies which were assembled with a
K613-4 Connection Kit will connect easily to a variety of
older Hobart wire feeders.

a. Check that the gun liner, connector cap liner, drive

roll(s) and guide tubes are appropriate for the electrode
size being used. Four different diameter pieces of liner
material are included in each kit.

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 cir-

cuit into the mating socket on the gun cable connector
handle.

h. Insert the control cable plug from the feeder trigger cir-

cuit into the mating socket on the gun cable connector.

GUN SLEAVE

GAS INLET

GUN RECEPTACLE KNOB

GAS INLET RETAINING SCREWS

GUN RECEPTACLE

GAS TUBE

GAS INLET FOR
MAGNUM 550 GUN

Installation of Optional Gun Hanger (See Figure 2)

d. Slide the free end of the flexible hose (mounted to the

gun) onto the gas fitting on the Hobart wire feeder.
Move the corresponding tubing clamp down near the
end of the tube to assure a good gas seal.

Connection to Hobart Series 2000 Wire Feeders

Gun and cable assemblies which were assembled with a K613-5
connection kit will connect to a variety of Hobart series 2000 wire
feeders. If the wire feeder has not been revised to accept a 500
amp gun receptacle, install the gas inlet provided with the K613-5
kit as follows:
a. Hold the gun receptacle and remove the gun receptacle

knob.Lower the gun receptacle.

b. Remove the two retaining screws that secure the gas

inlet to the wire feeder and pull the gas inlet out. Then
remove the gun sleeve. If the gun sleeve does not
come out easily, insert a screwdriver into the slot pro­vided and pry the sleeve out.

c. Hold the gas tube with the hose attached and unscrew

the gas inlet. Screw the gas inlet provided with the kit
onto the gas tube.

d. Slide the gas inlet into the wire feeder with the wide

groove toward the drive rolls. Replace the retaining
screws to secure the gas inlet in place.

a. Remove gun tube from gun by loosening the

clamping screw with a 3/16” (4.8mm) Allen
wrench.

b. Slip hanger into collar so notches on hanger fit

into slot on I.D. of collar. Slip the two parts onto
the gun tube and hold in place by lightly tightening
the set screw in the collar with a 5/64” (2.0mm)
Allen wrench.

c. Replace gun tube in gun and tighten socket head

clamping screw. Position hanger on gun tube and
tighten collar set screw.

COLLAR SLOT

GUN HANDLE

COLLAR SET SCREW

HANGER NOTCH

HANGER

Raise the gun receptacle and reinstall the gun receptacle knob.

e.

f. Check that the gun liner, guide tubes and drive rolls are

appropriate for the electrode size being used.

g. Fully push the brass connector end of the gun and

cable into the gas inlet and tighten the gun receptacle
knob.

MAGNUM® 550

CLAMPING SCREW

Figure 2

GUN TUBE

COLLAR

B-1

OPERATION

B-1

OPERATION

Electrodes and Equipment

The MAGNUM® 550 guns and cables have been
designed for use with Lincoln L-50 and L-56, solid
steel wire electrodes for the GMAW process and
Lincoln Outershield® cored electrodes for the gas­shielded flux-cored process. Refer to the appropriate
Lincoln Process and Procedure Guidelines for the
electrode used for information on recommended elec­trical and visible stickouts.

Making a Weld

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from 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 SPARKS can cause fire or
explosion.

• Keep flammable material away.

• Do not weld on closed containers.

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

ARC RAYS can burn eyes and skin.

• Wear eye, ear and body
protection.

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 used.

d. To stop welding, release the gun trigger and then

pull the gun away from the work after the arc goes
out.

e. If the optional interlocking trigger is installed, the

trigger operates as follows:

- Pull the trigger in to engage the feeder.

- With the trigger pulled in all the way, the trigger
can be slid forward into the interlock position.

- To release interlock, squeeze trigger and pull
back.

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 especially on 25 ft. (7.5m)
length guns.

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

cables.

e. Keep cable clean by following maintenance

instructions.

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

See additional warning information at

front of this operatorʼs manual.

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

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.

MAGNUM® 550

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.

h. When using aluminum electrodes, 10 ft. maximum

cable length is recommended. If longer cable
lengths are used, cable should be kept as straight
as possible.

D-1

MAINTENANCE

D-1

MAINTENANCE

WARNING

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 out­put terminals or internal wiring.

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

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
handle or in the diffuser with 5/64” (2.0mm) Allen
wrench (provided with the gun or Connector Kit).

b. Remove the gas diffuser from gun.

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

For K613-1 K613-2, K613-5 and K613-6 connections:

Loosen set screw located in the brass cable con­nector at the wire feeder end of the cable using
the same 5/64” (2.0mm) Allen wrench. Pull liner
out of cable. (Refer to Figure 1).

OR

For K613-3 and K613-4 connections:

Remove the connector cap. Remove gun tube
and tap on end of liner to expose liner bushing on
wire feeder end of cable. Pull liner out of cable. If
the liner is going to be replaced with a different
size liner, loosen set screw on the connector cap
and remove piece of liner material.

d. For installation and trimming instructions for MAG-

NUM® liners, see Liner Installation and Trimming
Instructions.

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”
(4.8mm) Allen wrench. Remove coarse thread
nozzle and coarse thread insulator assembly.

Pull gun tube out from gun handle. To reinstall,
insert the gun tube, push in as far as possible,
and retighten screw.

GUN CABLES

Cable Cleaning

Clean cable liner after using approximately 300 lbs
(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® 550 guns feature the use of
repairable cable connectors. If the cable ever gets
severely damaged, it may be cut shorter and repaired
by the user. Repair cables as follows:

Gun Tube End Repair (Requires 2 No. S19492-2
Terminals
a. Remove the cable liner per Removal, Installation

and Trimming Instructions.

b. Remove the gun tube per section entitled “Gun

Tubes and Nozzles”.

c. Remove four #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.

MAGNUM® 550

D-2

MAINTENANCE

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

the outer jacket as shown in Figure 3. Be careful
not to cut the insulation on the control wires while
stripping jacket. Strip the red and white control
leads .25” (6.4mm) from the end and crimp a new
S19492-2 terminal to each lead.

NOTE: The cable contains four control leads. Any
two control leads can be used, provided the two
colors used are the same at both ends. The
extra leads are spares that can be used if one of
the other leads breaks.

f. Trim the inner tube to dimension shown.

.25"

(6.4 mm) SKIN

(BOTH CONTROL LEADS)

D-2

CABLE INNER TUBE

CONNECTOR TUBE

COPPER STRANDS

CONNECTOR NUT

CABLE

GUN TUBE CONNECTOR OR

INCOMING CONNECTOR

CONTROL LEAD

INNER TUBE

COPPER STRANDING

CONTROL LEAD

.66"

(16.5 mm)

2.45

(62.2 mm)

CABLE SKIN LENGTH

Figure 3

g. Slip the connector nut over the copper strands

with the thread end out. Adjust 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 4.

NOTE: For best results, insert a .250” (6.4mm)
diameter rod through the connector and into core
of cable approximately 5.00” (127mm) 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.

Figure 4

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

assembly and connect the replacement control
lead terminals.

i. Assemble cable in left side of gun handle.

Assemble trigger into the proper handle cavity.
Assemble right side of gun handle and tighten the
four screws that hold the handle together. Refer to
Figure 5. NOTE: Be sure that protruded trigger

ears are placed in cavities of both handles.

CABLE ASSEMBLY

GUN TUBE

TRIGGER ASSEMBLY

GUN TUBE
CLAMPING SCREW

CONTROL WIRES

HANDLE CAVITY

GUN HOUSING

TRIGGER EAR

Figure 5

MAGNUM® 550

D-3

MAINTENANCE

D-3

j. Install gun tube per section entitled “Gun Tube

and Nozzles”.

k. Install and trim liner per installation instructions.

Wire Feeder End Repair (Requires 2 No. S19492-1
Terminals)
a. Remove the cable liner per the Maintenance

Section.

b. Remove the feeder end connector, molded gas

plug (or barbed fitting), cable handle nut, plastic
tailpiece, and connector cover (See Figure 6).
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 counter­clockwise 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 to the brass connector.

d. Move the cable boot, cable handle, and strain

relief toward the middle of the cable past the dam­aged section.

NOTE: For best results, insert a .250” (6.4mm)
diameter rod through the connector and into core
of cable approximately 11.00” (280mm) 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.

Position the plastic strain relief such that the
tapered end is 7.10” (180mm) from the incoming
connector (See Figure 6). Lock into place with
steel housing.

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 to Figure 6.

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

and feeder end connector.

i. Install and trim liner per installation instructions.

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

the outer jacket as shown in Figure 3. Be careful
not to cut the insulation on the control wires while
stripping jacket. Strip the red and white control
leads 1/4” (6.4mm) from the end and crimp a new
S19492-1 terminal to each lead. Trim the inner
tube to dimensions shown.
NOTE: The cable contains four control leads. Any
two control leads can be used, provided the two
colors used are the same at both ends. The extra
leads are spares that can be used if one of the
other leads breaks.

f. Check that the cable boot, cable handle and strain

relief 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 until the copper
strands are butted against the incoming connector
shoulder. 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 4.

TAIL PIECE

FEEDER END

CONNECTOR

GAS PLUG
OR
FITING

7.10"

(180 mm)

PRESS HERE TO
REMOVE THE CABLE
HANDLE NUT

CONNECTOR COVER

STRAIN RELIEF

CABLE HANDLE NUT

INCOMING CONNECTOR

Figure 6

CABLE

CABLE BOOT

CABLE HANDLE

STRAIN RELIEF
HOUSING

MAGNUM® 550

D-4

MAINTENANCE

THREAD SIZES FOR K598-1 thru -14
MAGNUM 550 CONSUMABLES USED WITH
An KP1951-1 or -2 Gun Tube (Tweco® NO. 6)

M17 X 2

M12 X 1.5

M8 X 1.25

D-4

THREAD SIZES FOR K598-15 thru -18
MAGNUM 550 CONSUMABLES USED WITH
An KP1952-3 Gun Tube (Tweco® NO. 5)

5/8-18

7/16-20

#8-32

5/16-24

MAGNUM® 550

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.

__________________________________________________________________________

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

E-1

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.

WARNING

ELECTRIC SHOCK can kill.

• Have a qualified individual install and
service this equipment.

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

• Do not touch electrically hot parts.

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

Step 3. R E COMMENDED COURSE OF
ACTION

This column provides a course of action for
the Possible Cause.

If you do not understand or are unable to
perform the Recommended Course of
Action safely, contact you 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® 550

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

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

Variable or “hunting” arc.

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.

i. Incorrect diffuser.

a. Contact tip worn or incorrect size.
b. Worn or undersize ground cables or

poor ground connections.

c. Loose electrode connections.

a. Keep as straight as possible. Inspect

cable and replace if necessary.

b. Remove wire from gun and cable -

feed 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.
i. Be sure diffuser size is correct for the

electrode being used.

a. Replace contact tip.
b. Inspect - repair or replace as neces-

sary.
c. Be sure the following connections 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.

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

Tip seizes in diffuser.

a. Improper procedures or techniques.

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” (GS-

100).

b. Clean gas nozzle, Make certain that

gas diffuser is not restricted. Make

certain that gas cylinder is not empty

or turned off. Make certain gas sole-

noid 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 bush-

ing.

a. Do not exceed current and duty cycle

rating of gun. A light application of

high temperature antiseize lubricant

(such as Lincoln E2067 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® 550

NOTES

MAGNUM® 550

NOTES

MAGNUM® 550

WARNING

Spanish

AVISO DE

PRECAUCION

G Do not touch electrically live parts or

electrode with skin or wet clothing.

G Insulate yourself from work and

ground.

G No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

G Aislese del trabajo y de la tierra.

G Keep flammable materials away.

G Mantenga el material combustible

fuera del área de trabajo.

G Wear eye, ear and body protection.

G Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

G Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

G Isolez-vous du travail et de la terre.

G Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

G Isolieren Sie sich von den

Elektroden und dem Erdboden!

G Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

G Isole-se da peça e terra.

G Gardez à l’écart de tout matériel

inflammable.

G Entfernen Sie brennbarres Material!

G Mantenha inflamáveis bem guarda-

dos.

G Protégez vos yeux, vos oreilles et

votre corps.

G Tragen Sie Augen-, Ohren- und Kör-

perschutz!

G 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.

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

remove fumes from breathing zone.

G Turn power off before servicing.

G Do not operate with panel open or

guards off.

WARNING

G Los humos fuera de la zona de res-

piración.

G Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

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

teur pour ôter les fumées des zones
de travail.

G Vermeiden Sie das Einatmen von

Schweibrauch!

G Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

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

remover fumo da zona respiratória.

G Desconectar el cable de ali-

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

G Débranchez le courant avant

l’entretien.

G Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

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

serviço.

G Não toque as partes elétricas nuas.

G No operar con panel abierto o

guardas quitadas.

G N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

G Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

G Mantenha-se afastado das partes

moventes.

G 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 •

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