Lincoln Electric MAGNUM 400 DUAL, IM646-A User Manual
®
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MAGNUM 400 DUAL PROCEDURE
GMA GUN & CABLE ASSEMBLIES
IM646-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
K574
K1722
K1722
K574
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATORʼS 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.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
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.
TABLE OF CONTENTS
Page
Installation ..................................................................................................................... Section A
General Description ......................................................................................................A-1, A-2
Connector Kit Installation to Gun Cable ............................................................................. A-3
K466-1 &-8 Installation ................................................................................................ A-3
K466-2 Installation ...................................................................................................... A-3
K466-3 Installation ...................................................................................................... A-3
K466-5 Installation ...................................................................................................... A-4
K466-7, & -10 Installation ............................................................................................ A-4
Liner Installation & Trimming Instructions ........................................................................... A-5
Installation of M18732 Series Liners for Feeding Aluminum Electrode................................A-5
Contact Tip and Gas Nozzle Installation ............................................................................ A-6
Connection to Feeder ......................................................................................................... A-6
Connection to Lincoln Feeders ................................................................................... A-6
Connection to Adapted Feeders ................................................................................. A-7
Connection to Miller Feeders ...................................................................................... A-7
Connection to Hobart 2000 Feeders ........................................................................... A-7
Connection to -10 Series Feeders .............................................................................. A-7
_______________________________________________________________________________________
Operation ....................................................................................................................... Section B
Electrodes and Equipment ................................................................................................. B-1
Making a Weld .................................................................................................................... B-1
Avoiding Wire Feeding Problems ....................................................................................... B-1
_______________________________________________________________________________________
vivi
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 (K574 & K1722 Models) ................................................................................ D-1
Gun Tube End Repair .................................................................................................. D-1
Wire Feeder End Repair .............................................................................................. D-4
Thread Sizes for 400 Amp Consumables .....................................................................D-7
_______________________________________________________________________________________
Troubleshooting ........................................................................................................... Section E
_______________________________________________________________________________________
Parts Lists ...................................................................................................... P202-L and P202-X
_______________________________________________________________________________________
MAGNUM® 400 DUAL PROCEDURE GUNS
A-1
INSTALLATION
A-1
GENERAL DESCRIPTION
The Magnum®™ 400 DP Dual Procedure GMA gun
and cable assemblies have 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. Magnum® 400 DP guns and cables are specifically designed for use with wire feeders with dual procedure capabilities. The K574 gun is equipped with a
two position trigger. Pulling the trigger in part of the
way will engage the first procedure set at the feeder.
Pulling the trigger the rest of the way will engage the
second procedure. An interlocking trigger is available
as a parts order. The K1722 Magnum® 400 DP Dual
Proecdure gun and cables are also designed for use
with wire feeders with dual procedure capabilities. The
guns are equipped with a rocker switch that is used to
select one of two welding procedures.
The K574 and K1722 are designed for use with K466
connector kits. The proper connector can be installed
the same as with any Magnum® Gun. The gun control cable connections however must be tailored to
each specific machine. The K574 comes with control
wires but no specific connectors are provided. The
K1722 has a connector that will mate with any Lincoln
-10 series wire feeder.
The Magnum® 400 DP guns are not factory equipped
with a feeder end connector. With the K466-1
Magnum® Connector Kit, they can be used with any
Lincoln LN-7 or LN-25 semiautomatic wire feeder. The
K466-1 should also be used with the LN-8 or LN-9
when feeding .052 and smaller electrodes. 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.
The K466-6 connector kit allows connection of
Magnum® 400 DP guns to a Lincoln Wirematic.
The K466-7 connector kit allows connection of
Magnum® 400 DP guns to Hobart Series 2000 Wire
Feeders.
The K466-8 connector kit allows connection of
Magnum® 400 DP guns to an LN8 or LN9 when 1/16
and larger electrode is used.
The K466-9 connector kit allows connection of K497
to SP100T and related wire feeders.
The K466-10 connector kit allows connection of
Magnum® 400 DP guns to a 10 Series wire feeder.
The Magnum® 400 DP gun and cable assemblies are
fully compatible for use with comparable Tweco gun
size tips, diffusers, gas nozzles, and cable liners. The
Magnum® GMA gun family offers an expanding line of
quality, long life, expendable replacement parts and
accessories.
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.
WARNING
• Do not touch electrically live parts
such as output terminals or internal
wiring
------------------------------------------------------------------------
The 400 DP guns can also be used with any wire
feeder equipped with a Tweco® #1, 2, 3, 350 or 4 wire
feed adapter kit by using the K466-2 Magnum®
Connector Kit.
With the K466-3 or K466-4 Magnum® connector kits,
it is possible to connect Magnum® 400 guns directly
to a variety of Miller and Hobart wire feeders, respectively.
The K466-5 connector kit allows connection of
Magnum® 400 DP guns to an L Tec feeder connector
assembly. L-Tec feeders require a feeder connector
assembly (similar to a Tweco® adapter) in order to
connect to a gun and cable. The K466-5 contains a
brass connector to permit Magnum® guns to be connected to this feeder connector assembly.
MAGNUM® 400 DUAL PROCEDURE GUNS
A-2
INSTALLATION
MAGNUM® 400 Dual Procedure
400 AMPS at 60% DUTY CYCLE WITH CO2GAS
400 AMPS at 50% DUTY CYCLE WITH MIXED GAS
A-2
Description
Product Cable Wire Size Standard Diffuser Gas Cable Gun Tube
Number Length (m) in. (mm) Duty Assembly Nozzle Insulator Liner 60°
K574-1 (4.5) .045 (1.2) -45 KP54A KP24A-62 KP34A KP44-3545-15 KP1928-1
K574-2 (4.5) 1/16 (1.6) -116 KP54A KP24A-62 KP34A KP44-116-15 KP1928-1
K574-3 (4.5) 5/64 (2.0) -564 KP54A KP24A-62 KP34A KP44-564-15 KP1928-1
K574-4 (7.6) .045 (1.2) -45 KP54A KP24A-62 KP34A KP44-3545-25 KP1928-1
K574-5 (7.6) 1/16 (1.6) -116 KP54A KP24A-62 KP34A KP44-116-25 KP1928-1
K574-6 (7.6) 5/64 (2.0) -564 KP54A KP24A-62 KP34A KP44-564-25 KP1928-1
K1722-1 (3.0) .045 (1.2) -45 KP54A KP24A-62 KP34A KP44-3545-15 KP1928-1
K1722-2 (4.5) .045 (1.2) -45 KP54A KP24A-62 KP34A KP44-3545-15 KP1928-1
K1722-3 (7.6) .045 (1.2) -45 KP54A KP24A-62 KP34A KP44-3545-25 KP1928-1
Gun Contact Tips Gas
15 ft .035 (0.9) KP14-35
15 ft .052 (1.3) KP14-52
15 ft 1/16 (1.6) KP14-116
25 ft .035 (0.9) KP14-35
25 ft .052 (1.3) KP14-52
25 ft 1/16 (1.6) KP14-116
10 ft. .035 (0.9) KP14-35
15 ft. .035 (0.9) KP14-35
25 ft. .035 (0.9) KP14-35
MAGNUM® 400 DUAL PROCEDURE GUNS
A-3
Read this entire installation section before you
start installation.
INSTALLATION
A-3
K466-1& -8 INSTALLATION (For Lincoln Feeders)
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.
------------------------------------------------------------------------
Only qualified personnel should install, use or
service this equipment.
CONNECTOR KIT INSTALLATION TO GUN
CABLE
The K574 and K1722 Magnum® 400 dual procedure
cables are shipped as generic assemblies and must
be assembled with a connector kit.
NOTE: The K574 Magnum® 400 DP gun and cable is
not only shipped with a generic wire feeder end, it
is also shipped with generic gun control assemblies. The brass connector can be installed per
K466 instructions, but the gun control cable must
be tailored, by the user, to the specific machine.
To install on an LN-9 Lincoln wire feeder equipped
with a dual procedure kit, connect the cable marked
"1" to pin receptacles "A" and "C" of a S12020-6
five pin Amphenol plug (optional). (S12024-1 cable
clamp is required to secure the Amphenol plug to
the cable.) Connect the cable marked "2" to pin
receptacles "A" and "C" of a S12020-16 three pin
Amphenol plug (optional). (S12024-4 cable clamp
is required to secure Amphenol plug to the cable.)
To install on a DH-10 Lincoln wire feeder, a
S12024-12 cable clamp and a S12020-6 five pin
Amphenol plug are required. Slip the two control
cables through the cable clamp and connect the
two control cables to the Amphenol plug. Connect
the two leads of cable marked “1" to pins A & C and
connect the two leads of cable marked “2" to pins D
& E. Connect the cable clamp to the plug and
secure the leads.
a. Remove brass cable connector and insulation tube
(see Figure B.1) from the 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 with the wrench provided.
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. The included wrench will fit both the gas plug and barbed fitting.
c. The gun control cable provided is not used.
d. Place one tubing clamp onto each end of the flexi-
ble tubing provided, approximately 2” (51 mm) 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 ensure a good gas seal.
NOTE: An optional K481 Magnum® Fast-Connect
Gas Tube Kit is available to provide tool-less gas
tube connection to Lincoln wire feeders. Install per
the instructions included with the kit.
K466-2 INSTALLATION (For Adapted Feeders and
-10 Series Lincoln Feeders)
a. Remove brass cable connector (see Figure B.1)
from the kit and screw it onto the feeder end of the
gun cable. Tighten the connection with the wrench
provided.
b. Check that the molded gas plug fitting is sealing
the gas fitting hole in the side of the feeder end
handle.
K466-3 INSTALLATION (For Miller Feeders; i.e.
Millermatic 200, Cricket, S-32P, 54D...)
a. Remove brass cable connector (see Figure B.1)
from the kit and screw it onto the feeder end of the
gun cable. Tighten the connection with the wrench
provided.
b. Check that the molded gas plug fitting is sealing
the gas fitting hole in the side of the feeder end
handle.
The K1722 Magnum® 400DP gun and cable is
equipped with a control cable that attaches to a
Lincoln -10 series wire feeder. For other wire feeders the control cable has to be rewired with the
appropriate connectors to fit the wire feeder.
MAGNUM® 400 DUAL PROCEDURE GUNS
c. The gun control cable provided is not used.
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