Lincoln Electric K498-1 User manual

K479-13
K479-14
Operator’s Manual
Fast Mate Guns Series
K Number:
K498-1
K479-2
K479-4
K575-2
K1723-1
K1723-2
K1723-3
K2950-2-FM-45
K2951-2-FM-45
K2952-2-FM-45
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM435-B | Issue Date Dec-18
© Lincoln Global, Inc. All Rights Reserved.

THANK YOU FOR SELECTING
AQUALITYPRODUCTBY
LINCOLN ELECTRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
Whenthisequipmentisshipped,titlepassestothepurchaser
uponreceiptbythecarrier.Consequently,claimsformaterial
damaged in shipment must be made by the purchaser against the
transportationcompanyatthetimetheshipmentisreceived.
SAFETY DEPENDS ON YOU
Lincolnarcweldingandcuttingequipmentisdesignedandbuilt
with safety in mind. However, your overall safety can be increased
byproperinstallation...andthoughtfuloperationonyourpart.
DO NOTINSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUTREADINGTHISMANUALANDTHESAFETY
PRECAUTIONSCONTAINEDTHROUGHOUT.And,mostimportantly,
think before you act and be careful.
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 befollowed
toavoidminorpersonalinjuryordamagetothisequipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T gettooclosetothearc.
Usecorrectivelensesifnecessary
to stay a reasonable distance
awayfrom thearc.
READ andobeytheSafetyData
Sheet(SDS)andthewarninglabel
thatappearsonallcontainersof
weldingmaterials.
USE ENOUGH VENTILATION or
exhaustatthearc,orboth,to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS , natural ventilation maybe
adequateifyoukeepyourheadoutofthefumes(Seebelow).
USENATURALDRAFTS orfanstokeepthefumesaway
from your face.
Ifyoudevelopunusualsymptoms,seeyoursupervisor.
Perhaps the welding atmosphere and ventilationsystem
should be checked.
WEARCORRECTEYE,EAR&
BODY PROTECTION
PROTECT your eyesandfacewithwelding helmet
properlyfittedandwithpropergradeoffilterplate
(See ANSIZ49.1).
PROTECT yourbodyfromweldingspatterandarc
flash with protective clothing including woolen
clothing,flame-proofapronandgloves,leather
leggings, and highboots.
PROTECT othersfromsplatter,flash,andglare
withprotectivescreens orbarriers.
INSOMEAREAS ,protectionfromnoisemaybeappropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DONOTWELDORCUT containersormaterialswhichpreviously
had been in contact with hazardous substances unless they are
properlycleaned.Thisisextremelydangerous.
DONOTWELDORCUT painted orplatedpartsunlessspecial
precautions with ventilation have been taken. They can release
highly toxic fumes orgases.
Additional precautionary measures
PROTECT compressedgascylindersfromexcessiveheat,
mechanicalshocks,andarcs;fastencylinderssotheycannotfall.
BESURE cylinders arenevergroundedorpartofan
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYSHAVEFIREFIGHTINGEQUIPMENTREADYFOR
IMMEDIATEUSEANDKNOWHOWTOUSEIT.
Safety 01 of 04 - 5/16/2018

SAFETY
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 etseq.)
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.
Readandunderstandthefollowingsafetyhighlights.For
additional safety information, it is strongly recommended
thatyoupurchaseacopyof“Safety inWelding&Cutting-
ANSIStandard Z49.1” fromtheAmericanWeldingSociety,
P.O.Box351040,Miami,Florida33135orCSAStandard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205isavailablefromtheLincolnElectricCompany,
22801St.ClairAvenue,Cleveland,Ohio44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turntheengineoffbeforetroubleshooting
and maintenance work unless the
maintenance work requires it to berunning.
1.b. Operateenginesinopen,well-ventilated areas orvent theengine
exhaust fumesoutdoors.
1.c. Donotaddthefuelnearanopenflamewelding
arcorwhentheengineisrunning.Stopthe
engineandallowittocoolbeforerefuelingto
preventspilledfuelfromvaporizingoncontact
withhotenginepartsandigniting.Donotspillfuelwhenfilling
tank.Iffuelisspilled,wipeitupanddonotstartengineuntil
fumes have beeneliminated.
1.d. Keep all equipment safety guards, covers
anddevicesinpositionandingoodrepair.
Keephands,hair,clothingandtoolsaway
fromV-belts,gears,fansandallother
movingpartswhenstarting,operatingor
repairing equipment.
1.e. Insomecasesitmaybenecessarytoremovesafetyguardsto
performrequiredmaintenance.Removeguardsonlywhen
necessary and replace them when the maintenance requiring
theirremovaliscomplete.Alwaysusethegreatestcarewhen
working near movingparts.
1.f. Donotputyourhandsneartheenginefan.Donotattemptto
overridethegovernororidlerbypushingonthethrottlecontrol
rods while the engine isrunning.
1.g. Topreventaccidentallystartinggasolineengineswhileturning
theengineorweldinggeneratorduringmaintenancework,
disconnectthesparkplugwires,distributorcapormagnetowire
as appropriate.
1.h. Toavoidscalding,donot removethe radiator
pressurecapwhentheengineishot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electriccurrentflowingthroughanyconductor
causeslocalizedElectricandMagneticFields(EMF).
WeldingcurrentcreatesEMFfieldsaroundweldingcables
and welding machines
2.b. EMFfieldsmayinterferewithsomepacemakers,and
welders having a pacemaker should consult their physician
before welding.
2.c. ExposuretoEMFfieldsinweldingmayhave other health effects
which are now notknown.
2.d. Allweldersshouldusethefollowingproceduresinorderto
minimizeexposuretoEMFfieldsfromtheweldingcircuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Nevercoiltheelectrodeleadaroundyourbody.
2.d.3. Donotplaceyourbodybetweentheelectrodeandwork
cables.Iftheelectrodecableisonyourrightside,the
workcableshouldalsobeonyourrightside.
2.d.4. Connecttheworkcabletotheworkpieceascloseaspos-
sibleto the areabeing welded.
2.d.5. Donotworknexttoweldingpowersource.
Safety 02 of 04 - 5/16/2018
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
WARNING: Breathingdieselengineexhaust
exposesyoutochemicalsknowntotheState
of California to cause cancer and birth
defects,
or other reproductive harm.
• Alwaysstartandoperatetheenginein
a well-ventilatedarea.
• Ifinanexposedarea,venttheexhausttotheoutside.
• Donotmodifyortamperwiththeexhaustsystem.
• Donotidletheengineexceptasnecessary.
For more information go to
www.P65 warnings.ca.gov/diesel

SAFETY
Safety 3 of 04 - 5/16/2018
FUMES AND GASES
CAN BE DANGEROUS.
ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically“hot”whenthewelderison.Do
nottouchthese“hot” partswithyourbareskinorwetclothing.
Weardry,hole-freeglovestoinsulatehands.
3.b. Insulateyourselffromworkandgroundusingdryinsulation.
Makecertaintheinsulationislargeenoughtocoveryourfullarea
ofphysicalcontactwithworkandground.
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:
• SemiautomaticDCConstantVoltage(Wire)Welder.
• DC Manual (Stick)Welder.
• ACWelderwithReducedVoltageControl.
3.c. Insemiautomaticorautomaticwirewelding,theelectrode,
electrodereel, welding head, nozzle or semiautomatic welding
gun are also electrically“hot”.
3.d. Alwaysbesuretheworkcablemakesagoodelectrical
connection with the metal being welded. The connection should
beascloseaspossibletotheareabeingwelded.
3.e. Groundtheworkormetaltobeweldedtoagoodelectrical(earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
weldingmachineingood,safeoperatingcondition.Replace
damaged insulation.
3.g. Neverdiptheelectrodeinwaterforcooling.
3.h. Neversimultaneouslytouchelectrically“hot”partsofelectrode
holdersconnectedtotwoweldersbecausevoltage betweenthe
two can bethetotal of theopencircuitvoltage ofboth
welders.
3.i. Whenworkingabovefloorlevel,useasafetybelttoprotect
yourselffromafallshouldyougetashock.
3.j. Also see Items 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Useashieldwiththeproperfilterandcoverplatestoprotectyour
eyesfromsparksandtheraysofthearcwhenweldingor
observingopenarcwelding.Headshieldandfilterlensshould
conformto ANSIZ87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
toprotectyourskinandthatofyourhelpersfromthearcrays.
4.c. Protect other nearby personnel with suitable, non-flammable
screeningand/orwarnthemnottowatchthearcnorexpose
themselvestothearcraysortohotspatterormetal.
5.a. Weldingmayproducefumesandgases
hazardous to health. Avoid breathingthese
fumesandgases.Whenwelding,keepyourheadoutofthefume.
Useenoughventilationand/orexhaustatthearctokeepfumes
andgasesawayfromthebreathingzone.Whenwelding
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5.b. .Theoperationofweldingfumecontrolequipmentisaffected
byvariousfactorsincludingproperuseandpositioningof
theequipment,maintenanceoftheequipmentandthe
specificweldingprocedureandapplicationinvolved.Worker
exposure level should be checked upon installation and
periodicallythereaftertobecertainitiswithinapplicable
OSHAPELand ACGIH TLVlimits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heatandraysofthearccanreactwithsolventvaporstoform
phosgene,ahighlytoxicgas,andotherirritatingproducts.
5.d. Shielding gases used for arcwelding can displace air and cause
injuryordeath.Alwaysuseenoughventilation,especiallyin
confinedareas,toinsurebreathingairissafe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet(SDS) and followyour employer’s safety
practices.SDSformsareavailablefromyourwelding
distributororfromthemanufacturer.
5.f. Also see item1.b.

SAFETY
Safety 4 of 04 - 5/16/2018
WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Removefirehazardsfromtheweldingarea.If
thisisnotpossible,coverthemtopreventtheweldingsparks
fromstartingafire.Rememberthatweldingsparksandhot
materialsfromweldingcaneasilygothroughsmallcracksand
openingstoadjacent areas. Avoid welding near hydraulic lines.
Haveafireextinguisherreadilyavailable.
6.b. Wherecompressedgasesaretobeusedatthejobsite,special
precautionsshouldbeusedtopreventhazardoussituations.
Referto“Safety inWeldingandCutting” (ANSIStandardZ49.1)
andtheoperatinginformationfortheequipmentbeingused.
6.c. Whennotwelding,makecertainnopartoftheelectrodecircuitis
touchingtheworkorground.Accidentalcontactcancause
overheatingandcreateafirehazard.
6.d. Donotheat,cutorweldtanks,drumsorcontainersuntilthe
properstepshavebeentakentoinsurethatsuchprocedures
will not cause flammable or toxic vapors from substances inside.
Theycancauseanexplosioneventhoughtheyhavebeen
“cleaned”. For information, purchase “Recommended Safe
PracticesforthePreparationforWeldingandCuttingof
ContainersandPipingThatHaveHeldHazardousSubstances”,
AWSF4.1fromtheAmericanWeldingSociety
(see addressabove).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They mayexplode.
6.f. Sparksandspatterarethrownfromtheweldingarc.Wearoilfree
protective garments such as leather gloves, heavy shirt, cuffless
trousers,highshoesandacapoveryourhair.Wearearplugs
whenweldingoutofpositionorinconfinedplaces.Alwayswear
safetyglasseswithsideshieldswheninaweldingarea.
6.g. Connecttheworkcabletotheworkasclosetotheweldingarea
as practical. Work cables connected to the building framework or
otherlocationsawayfromtheweldingareaincreasethe
possibilityoftheweldingcurrentpassingthroughliftingchains,
cranecablesorotheralternatecircuits.Thiscancreatefire
hazardsoroverheatliftingchainsorcablesuntiltheyfail.
6.h. Also see item1.c.
6.I.ReadandfollowNFPA51B“Standard forFirePreventionDuring
Welding,CuttingandOtherHotWork”, availablefromNFPA,1
BatterymarchPark,PObox9101,Quincy,MA022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Useonlycompressedgas cylinders containing
thecorrectshieldinggasfortheprocessused
and properly operatingregulators designedfor
thegasandpressureused.Allhoses,fittings,
etc.shouldbesuitablefortheapplicationand
maintainedingoodcondition.
7.b. Always keep cylinders inan upright position securely chained to
anundercarriageorfixed support.
7.c. Cylinders should belocated:
• Awayfromareaswheretheymaybestruckorsubjected
to physicaldamage.
• A safe distance from arc welding or cutting operations
andanyothersourceofheat,sparks,orflame.
7.d. Never allow the electrode, electrode holder or any other
electrically“hot” partstotouchacylinder.
7.e. Keepyourheadandfaceawayfromthecylindervalveoutlet
when opening the cylinder valve.
7.f. Valve protection caps should always bein place and handtight
exceptwhenthecylinderisinuseorconnectedforuse.
7.g. Readandfollowtheinstructionsoncompressedgascylinders,
associatedequipment, andCGA publication P-l,“Precautions for
SafeHandlingofCompressedGasesinCylinders,” availablefrom
theCompressedGasAssociation,14501GeorgeCarterWay
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turnoffinputpowerusingthedisconnect
switchatthefuseboxbeforeworkingon
the equipment.
8.b. Installequipment inaccordance with theU.S. National Electrical
Code,alllocalcodesandthe manufacturer’s recommendations.
8.c. Groundtheequipment in accordance withtheU.S.National
ElectricalCodeandthemanufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.

FAST MATE GUNS SERIES
TABLE OF CONTENTS
INSTALLATION ..............................................................................................................................................SECTION A
LINER INSTALLATION ..................................................................................................................................................A-1
OPERATION ................................................................................................................................................SECTIONB
GENERAL DESCRIPTION.............................................................................................................................................B-1
ELECTRODES AND EQUIPMENT.................................................................................................................................B-1
MAKING A WELD...................................................................................................................................B-1
AVOIDING FEEDING PROBLEMS..................................................................................................................................B-1
PRODUCT NUMBERS TABLE.......................................................................................................................................B-1
MAINTENANCE .................................................................................................................. ............................SECTION D
REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR LINERS......................................................................D-1
GUN TUBES AND NOZZLES .........................................................................................................................................D-1
GUN CABLES ..........................................................................................................................................D-3
TROUBLESHOOTING........................................................................................................................SECTION F
PARTS LIST ................................................................................................................PARTS.LINCOLNELECTRIC.COM
CONTENT/DETAILS MAY BE CHANGED OR UPDATED WITHOUT NOTICE. FOR MOST CURRENT INSTRUCTION MANUALS,
GO TO PARTS.LINCOLNELECTRIC.COM.

FAST MATE GUNS SERIES
INSTALLATION
A-1
INSTALLATION
Readandunderstandthisentiresectionbeforeoperating
the machine.
WARNING
ELECTRIC SHOCK can kill.
• Haveanelectricianinstallandservice
this equipment.
• Turntheinputpoweroffatthefusebox
before working onequipment.
• Do not touch electrically hotparts.
• Besuretodischargecapacitorswiththeprocedure
outlinedintheMaintenanceSectionofthismanual
before working in that area of the equipment.
CONNECTION TO FAST-MATE COMPATIBLE
FEEDERS
FMmodelguncableassemblieswillconnecteasilytoanyfeeder
equipped with a European style gun connector orany Lincoln wire
feederequippedwithaK489SeriesFastMateAdapterKit.To
installanoptionalK489Serieskitseetheinstructionsprovided
with thekit.
a. Checkthatthefeederoutgoingguide,aswellasthedriveroll,
are appropriate for the electrode size being used. When using
aFast-MateAdapterKit,becertaintheadapterguidetubeis
also properlysized.
b. Alignandfullyengagethebrassconnectorendofthegun
cableintothematingconnectorontheoutgoingsideofthe
feeder wire drive. Secure the cable connection by snuggling
theFast-Mateconnectorcollarnut.
LINER INSTALLATION
NOTE: FM models, using Fast-Mate connector, are shipped with
factory installed liner. Tochange liner in these models, see
maintenance section.
CONTACT TIP AND GAS NOZZLE INSTALLATION
NOTE:FM models are shipped ready to weld with the proper tip
andgasnozzleinstalled.Ifyouchoosetochangethe
contacttipornozzle,seetheinstructionsbelow.
a. Choosethecorrectsizecontacttipfortheelectrodebeing
used(wiresizeisstenciledonthesideofthecontacttip)and
screwitsnuglyintothegas diffuser.
b. Besurethenozzleinsulatorisfullyscrewedontothediffuser
anddoesnotblockthegasholesinthediffuser.
c. Sliptheappropriategasnozzleontothenozzleinsulator.
Eithera.62” (15.9mm)or.50” (12.7mm)I.D.slip-ongas
nozzlemaybeusedandshouldbe selectedbasedonthe
welding application.
ChoosethegasnozzleasappropriatefortheGMAWprocess
tobeused.Typically,thecontacttipendshouldbeflushto
.12”(3.0mm)extendedfortheshort-circuitingtransfer
process and .12” (3.0 mm) recessed for spray transfer. For
the Outershield(FCAW)process,1/4”(6.4 mm) recessis
recommended.

FAST MATE GUNS SERIES
OPERATION
B-1
OPERATION
Readandunderstandthisentiresectionbeforeoperating
the machine.
WARNING
ELECTRIC SHOCK can kill.
• Donottouchelectricallylivepartssuch
asoutputterminalsorinternal wiring.
• Insulateyourselffromtheworkand
ground.
• Always wear dry insulatinggloves.
FUMES AND GASES can
be dangerous.
• Keepyourheadoutoffumes.
• Useventilationorexhausttoremove
fumes from breathingzone.
WELDING SPARKS can cause fire
or explosion.
• Keep flammable material away.
• Donotwelduponcontainerswhichhave
held combustibles.
ARC RAYS can burn.
• Wear eye, ear and bodyprotection.
GENERAL DEScRIpTION
TheMagnum
®
200FMandMagnumProCurve
®
200FMgunand
cableassemblieshavebeendesignedtomeetNEMAspecification
EW3forweldingwithsteelelectrodeusingtheGMAW(gasmetal
arcwelding)andgas-shieldedFCAW(flux-coredarcwelding)
processes:
The Magnum
®
200FM and Magnum Pro Curve
®
200 FMguns are
factoryinstalledwithaFast-Mate(Europeanstyle)wirefeeder
connectorfor“all-in-one”GMAWfeederconnection.Asingle
connectorattachesweldingcurrent,wireliner,weldinggas,and
triggercontrolleadstofeeder.AnoptionalK489-1MAGNUM
®
Fast-MateAdapterallowstheuseofthesegunswithanyLincoln
LN-7,LN-8,LN-9andSP200wirefeeder.AnoptionalK489-2
Magnum®Fast-MateAdapterisrequiredfortheLN-25.
Forbestresultswhenweldingmildandalloysteels,itis
recommendedthatL-50orSuperArcL-56Lincolnsolidwire
electrodesbeusedfortheGMAWprocessandOS70orOS71
LincolnOutershield
®
coredelectrodesforthegas-shieldedFCAW
process.
ELEcTRODES AND EQUIpMENT
TheMAGNUM®200FMgunandcablehasbeendesignedforuse
withLincolnL-50andL-56,solidsteelwireelectrodesforthe
GMAWprocessandLincolnOutershield®coredelectrodesforthe
gas-shielded FCAW process. Refer to the appropriate Lincoln
ProcessandProcedureGuidelinesfortheelectrodeusedfor
information on recommended electrical and visiblestickouts.
MAKING A WELD
a. Checkthattheweldingpowersourceisonandthatthe
shieldinggassupplyissetfortheproperflowrate.
b. Position electrode over joint.End ofthe electrode should
be slightly off thework.
c. Lowerweldinghelmet,closeguntriggerandbegin
welding.Holdthegunsothecontacttiptoworkdistance
givesthecorrectelectricalstickoutasrequiredforthe
procedure beinguse.
d. Tostopwelding,releasetheguntriggerandthenpull
thegunawayfromtheworkafterthearcgoesout.
Followwirefeederinstructionmanualifusingatrigger
interlock circuit.
AVOIDING WIRE FEEDING pROBLEMS
Wirefeedingproblemscanbeavoidedbyobservingthefollowing
gun handling procedures:
a. Donotkinkorpullcablearoundsharpcorners.
b. Keep the electrode cable as straight as possible when welding
orloading electrode through cable.
c. Avoid wrapping excess cable around handle or front of wire
feeder.
d. Donotallowdollywheelsortruckstorunovercables.
e. Keepcablecleanbyfollowingmaintenanceinstructions.
f. Useonlyclean,rust-freeelectrode.TheLincoln electrodes
have proper surfacelubrication.
g. Replacecontacttipwhenthearcstartstobecomeunstableor
thecontacttipendisfusedordeformed.

FAST MATE GUNS SERIES
OPERATION
B-2
TABLE B.1 MAGNUM 200 FM
200 AMP @ 60% DUTY CYCLE WITH CO2 GAS
150 AMP @ 60% DUTY CYCLE WITH MIXED GAS
Product
Number
Gun Cable
Length (m)
WireSizein.
(mm)
Contact Tips
Standard Duty
Gas Diffuser
Assembly
Gas Nozzle
Insulator
Cable Liner
GunTube60°
K498-1
15 FT.
(4.5)
.035 (0.9)
.045 (1.2)
KP14-35
KP14-45
KP52
KP22-50
KP32
KP42-4045-15
KP2924-60
TABLE B.2 - TABLE. MAGNUM 400 FM
400 AMP @ 60% DUTY CYCLE WITH CO2GAS
400 AMP @ 50% DUTY CYCLE WITH MIXED GAS
Product
Number
Gun Cable
Length (m)
WireSizein.
(mm)
Contact Tips
Standard Duty
Gas Diffuser
Assembly
Gas Nozzle
Insulator
Cable Liner
GunTube60°
K479-2
15FT.(4.5)
.035 (0.9)
.045 (1.2)
KP14-35
KP14-45
KP54A
KP24A-62
KP34A
KP44-3545-15
KP1928-1
K479-4
15FT.(4.5)
.052 (1.3)
1/16 (1.6)
KP14-52
KP14-116
KP54A
KP24A-62
KP34A
KP44-116-15
KP1928-1
K479-13
25FT.(7.6)
.035 (0.9)
.045 (1.2)
KP14-45
KP54A
KP24A-62
KP34A
KP44-3545-25
KP1928-1
K479-14
25FT.(7.6)
.052 (1.3)
1/16 (1.6)
KP14-116
KP54A
KP24A-62
KP34A
KP44-116-25
KP1928-1
TABLE B.3 MAGNUM 400 FM DUAL SCHEDULE
400 AMP @ 60% DUTY CYCLE WITH CO2 GAS
400 AMP @ 50% DUTY CYCLE WITH MIXED GAS
Product
Number
Gun Cable
Length (m)
WireSizein.
(mm)
Contact Tips
Standard Duty
Gas Diffuser
Assembly
Gas Nozzle
Insulator
Cable Liner
GunTube60°
K575-2
15FT.(4.5)
.052 (1.3)
1/16 (1.6)
KP14-52
KP14-116
KP54A
KP24A-62
KP34A
KP44-116-15
KP1928-1
TABLE B.4 - MAGNUM 400 FM DOUBLE PROCEDURE
400 AMP @ 60% DUTY CYCLE WITH CO2 GAS
400 AMP @ 50% DUTY CYCLE WITH MIXED GAS
Product
Number
Gun Cable
Length (m)
WireSizein.
(mm)
Contact Tips
Standard Duty
Gas Diffuser
Assembly
Gas Nozzle
Insulator
Cable Liner
GunTube60°
K1723-1
10FT.(3.0)
.035 (0.9)
.045 (1.2)
KP14-35
KP14-45
KP54A
KP24A-62
KP34A
KP44-3545-15
KP1928-1
K1723-2
15FT.(4.5)
.035 (0.9)
.045 (1.2)
KP14-35
KP14-45
KP54A
KP24A-62
KP34A
KP44-3545-15
KP1928-1
K1723-3
25FT.(7.6)
.035 (0.9)
.045 (1.2)
KP14-35
KP14-45
KP54A
KP24A-62
KP34A
KP44-3545-25
KP1928-1

FAST MATE GUNS SERIES
OPERATION
B-3
TABLE B.5 - MAGNUM PRO CURVE 200 FM
200 AMP @ 60% DUTY CYCLE WITH CO2 GAS
150 AMP @ 60% DUTY CYCLE WITH MIXED GAS
Product
Number
Gun Cable
Length (m)
WireSizein.
(mm)
Contact Tips
Standard Duty
Gas Diffuser
Assembly
Gas Nozzle
Insulator
Cable Liner
GunTube60°
K2950-2-
FM-45
15FT.(4.5)
.035 (0.9)
.045 (1.2)
KP2744-035
KP2744-045
KP2746-1
KP2742-1-
62R
KP2773-2
KP42-4045-15
KP2924-60
TABLE B.6 - MAGNUM PRO CURVE 300 FM
300 AMP @ 60% DUTY CYCLE WITH CO2 GAS
200 AMP @ 60% DUTY CYCLE WITH MIXED GAS
Product
Number
Gun Cable
Length (m)
WireSizein.
(mm)
Contact Tips
Standard Duty
Gas Diffuser
Assembly
Gas Nozzle
Insulator
Cable Liner
GunTube60°
K2951-2-
FM-45
15FT.(4.5)
.035 (0.9)
.045 (1.2)
KP2744-035
KP2744-045
KP2746-1
KP2742-1-
62R
KP2773-2
KP44-3545-15
KP2924-60
TABLE B.7 - MAGNUM PRO CURVE 400 FM
400 AMP @ 60% DUTY CYCLE WITH CO2 GAS
400 AMP @ 50% DUTY CYCLE WITH MIXED GAS
Product
Number
Gun Cable
Length (m)
WireSizein.
(mm)
Contact Tips
Standard Duty
Gas Diffuser
Assembly
Gas Nozzle
Insulator
Cable Liner
GunTube60°
K2952-2-
FM-45
15FT.(4.5)
.035 (0.9)
.045 (1.2)
KP2744-035
KP2744-045
KP2746-1
KP2742-1-
62R
KP2773-2
KP44-3545-15
KP2924-60

FAST MATE GUNS SERIES
MAINTENANCE
D-1
MAINTENANCE
REMOVAL, INSTALLATION AND TRIMMING INSTRUc-
TIONS FOR LINERS
See Figure D.1, D.2 and D.3
NOTICE:Thevariationincablelengths preventstheinterchange-
abilityofliners.Oncealinerhasbeencutforaparticulargun,it
shouldnotbeinstalledinanothergun,unlessitcanmeettheliner
cutofflengthrequirement.Linersareshippedwiththejacketof
thelinerextendedtheproperamount.
a. Removethegasnozzleandnozzleinsulator.Loosentheset
screwlocatedinthesideofthediffuserwith5/64” (2.0mm)
Allenwrench(provided withthegun).
b. Removethe gasdiffuserfromgun.
c. Laygunandcableoutstraightonaflatsurface.Removethe
linernutfromtheconnectorendofthecableandpulllinerout
of cable.
d. Insertanewuntrimmedlinerintotheconnectorendofthe
cable.Becertainthatthelinerbusingisstenciledappro-
priatelyforthewiresizebeingused.
e. Fully seat the liner bushing into the connector. Finger tighten
the liner nutonto the cable connector.
f. Withthecablestraight,trimlinerto1-1/4” (31.8mm).
Removeanyburrsfromtheendoftheliner.
g. Screwthegasdiffuserontotheendoftheguntubeand
securely tighten.
h. Tightenthesetscrewinthesideofthegasdiffuseragainst
thecablelinerusinga5/64”(2.0mm)Allenwrench.
GUN TUBES AND NOZZLES
a. Replaceworncontacttipsasrequired.
b. Removespatterfrominsideofgasnozzleandfromtipafter
each10minutesofarctimeorasrequired.
c. Toremove gun tube from gun,loosen socket-head clamping
screwinhandlewith3/16”(4.8mm)Allenwrench.Remove
gasnozzleandnozzleinsulatorandalsoloosensmallset
screwinthediffuserusing5/64”(2.0mm)Allenwrench.
NOTE:Smallsetscrewinthediffusermustbeloosened,
otherwise liner could be damaged when attempting to
remove gun tube.
Pullguntubeoutfromgunhandle.Toreinstall,insertthegun
tube,pushinasfaraspossible,andretightenscrews.
WARNING
Thisscrewshouldbegentlytightened.Over-tighteningwill
split orcollapse the liner andcausepoorwire feeding.

FAST MATE GUNS SERIES
MAINTENANCE
D-2
FIGURE D.1 MAGNUM
FIGURE D.2 MAGNUM PRO
FIGURE D.3
GUN TUBE ASSEMBLY
9 / 16” (14.3mm)
LINER TRIM
LENGTH
INSULATOR
DIFFUSER
CONTACT TIP
NOZZLE ASSEMBLY

FAST MATE GUNS SERIES
MAINTENANCE
D-3
GUN CABLES
See Figure D.3, D.4 & D.5
CABLE CLEANING
Cleancablelinerafterusingapproximately300pounds(136kg)
ofelectrode.Removethecablefromthewirefeederandlayitout
straightonthefloor.Removethecontacttipfromthegun.Using
anairhoseandonlypartialpressure,gentlyblowoutthecable
linerfrom thegas diffuser end.
Excessivepressureatthestartmaycausethedirttoformaplug.
Flexthecableoveritsentirelengthandagainblowoutthecable.
Repeatthisprocedureuntilnofurtherdirtcomesout.
CABLE REPAIR
The gun features the use of repairable cable connectors. Ifthe
cableevergetsseverelydamage,itmaybecutshorterand
repairedbytheuser.Repaircablesasfollows:
GUNTUBEENDREPAIR (Requires2S19492-2Terminals)
a. Removethecable linerperRemoval, Installation and
TrimmingInstructions onpage D-1.
b. RemovetheguntubeperGunTubesandNozzlesSectionof
pages D-1 andD2.
c. Removethree#6screwsfromthegunhandle,separatethe
twohalves,andremovethecablefromthehandlealongwith
the triggerassembly.
d. Removeguntubeconnectorfromcablebyunscrewing
connectornutfromguntubeconnector.Ifthecableinnertube
isdifficulttoremovefromtheconnectorassembly,carefully
slititlengthwisewithaknifeuptothebrassconnector.
e. Uncouple the strain relief by pushing its outer housing toward
themiddleofthecable.Movethestrainreliefandthecable
boottowardthemiddleofthecable,pastthedamaged
section.
f. Cutoffthedamagedsectionofcableandstripofftheouter
jacketasshowninFigure 2.Becarefulnottocutthe
insulationonthecontrolwireswhilestrippingjacket.Stripthe
redandwhitecontrolleads1/4inch(6.4mm)fromtheend
andcrimpanewS19492-2terminaltoeachlead.
NOTE:Thecablecontainsthree controlleads.Anytwocontrol
leadscanbeused,providedthetwocolorsusedare
thesameatbothends.Theextraleadisasparethat
canbeusedifoneoftheotherleadsbreaks.
g. Checkthatthecablebootandbothhalvesofthestrainrelief
areonthecable.Sliptheconnectornutoverthecopper
strandswiththethreadendout.Orientguntubeconnectorso
machinedflatisonthesamesideofthecableastheredand
white control leads.Assemble gun tube connector to cable by
forcingthesteeltubeoftheconnectorintotheinside
diameterofthecableinnertubeuntilthecopperstrandsare
butted against the gun tube connector shoulder. Keeping the
copperstrandsagainsttheshoulder,pulltheconnectornut
overthecopperstrands,engagetheguntubeconnector
threads,andtighteninplace.RefertoFigure3.
NOTE:Forbestresults,inserta.175”/.197”(4.5-5.0mm)
diameterrodthroughtheconnectorandintocoreof
cable approximately 5.00” (127 mm) when pushing the
connector tube into the cable core tube.Totighten, hold
theconnectorinplacewhileturningthenut.Then
removetherodfromthecore.Thisprocedureensures
theinnercoredoesnotkinkwhileassemblingor
tightening.
h. Pullthecut-offleadterminalsoffthetriggerassemblyand
connectthereplacementcontrolleadterminals.
i. Positionthecablebootandstrainreliefonthecablesoitfits
incablehandlecavityandlockthestrainreliefinplaceby
pushingthetwohalvestogether.
j. Assemble cable in left side of gun handle.Assemble trigger
intotheproperhandlecavity.Assemblerightsideofgun
handleandtightenthethreescrewsthatholdthehandle
together.Referto Figure4.
k. InstallguntubeperGunTubesandNozzlesSectiononpage
D-1.
l. Install and trim liner perRemoval, Installation andTrimming
Instructions on pageD-1.
GUN TUBE END CABLE REPAIR K1723 (Requires 2
#S19492-2 terminals)
a. Removethecablelinerperpreviousinstructions.
b. Removetheguntubeperpreviousinstructions.
c. Remove the #6 screws from the gun handle, separate the two
halves,andremovethecablefromthehandlealongwiththe
triggerassemblyfortheK575guns.Beforeremovingthe
triggerassembly,carefullynotetriggerleadwiringasitwill
be important to reconnect these properly. For the K1723 also
remove the rockerswitch.
d. Removeguntubeconnectorfromcablebyunscrewing
connectornutfromguntubeconnector.Ifthecableinnertube
isdifficulttoremovefromtheconnectorassembly,carefully
slititlengthwisewithaknifeuptothebrassconnector.
e. Uncouple the strain relief by pushing its outer housing toward
themiddleofthecable.Movethestrainreliefandthecable
boottowardthemiddleofthecable,pastthedamaged
section.
f. ForK575models Cutoffdamagedsectionofcableandstrip
offtheouterjacket2.15inchesback.Becarefulnottocutthe
insulationonthecontrolwireswhilestrippingjacket.Pull
controlleadsbackandtrimtheexposedcopperandinner
tubeback.50inch.Stripallfourcontrolleads.125inchback
andcrimp anew S8053-169terminal toeach lead.Apply
heatshrinktubingorelectricaltapetoterminalstoprevent
electricalcontactwithotherterminals.(SeeFigureE.2).
g. Cutoffdamagedsectionofcableandstripofftheouterjacket
1.65inchesback.Becarefulnottocuttheinsulationonthe
controlwireswhilestrippingjacket.Stripallfourcontrolleads
.25inchbackandcrimpanewS19492-2terminaltoboththe
black lead and the white lead. Remove the leads connected to
theredandbluecontrolleadsfromthecutoffcableand
soldertheseleadstotheblueandredleadsofthenewly
trimmedcable.Insulateconnectionswithheatshrinktubing
ortape.(SeeFigure E.3).

FAST MATE GUNS SERIES
MAINTENANCE
D-4
STRAIN RELIEF
SWITCH
T0 RED LEAD
CABLE ASSEMBLY
STRAIN RELIEF
HOUSING
SWITCH WIRES
TO BLUE LEAD
GUN TUBE
CABLE BOOT
GUN HOUSING
TRIGGER ASSEMBLY
WIRE FEEDER END REPAIR
a. RemovethecablelinerperRemoval,Installation,and
TrimmingInstructions onpage D-1.
b. Loosenthebootnut.Slidethebootnutandboottowardthe
middleofthecablepastthedamagedsection.
c. Rotatethecollarnutuntilthescrewanchoringthecable
handleisvisible.Removethescrewandsaveit.
d. Slidethecablehandleandcollarnuttowardthemiddleofthe
cable past the damaged section. Remove and save the cable
clamp.
NOTE:If sliding the cable handle becomes difficult, try rotating
it 180°.
e. Removeincomingconnectorfromcablebyunscrewing
connector nut from incoming connector. If the cable inner
tubeisdifficulttoremovefromtheconnectorassembly,
carefullyslititlengthwisewithaknifeuptothebrass
connector.
f. Cutthecablecontrolwireswheretheymeetthecablejacket
orelseunsoldertheconnectionwheretheyconnecttothe
terminalleadassembly.Ifyoucutthewires,stripthecutend
3/8” (9.5 mm) from the end.
g. Cutoffthedamagedsectionofcableandstripofftheouter
jacketasshowninFigure 2.Becarefulnottocutthe
insulationonthecontrolwireswhilestrippingjacket.Stripred
andwhitecontrolleads3/8”(9.5mm)fromtheend.
NOTE:Thecablecontainsthree controlleads.Anytwocontrol
leadscanbeused,providedthetwocolorsusedare
thesameatbothends.Theextraleadisasparethat
canbeusedifoneoftheotherleadsbreaks.
h. Checkthatthecableboot,bootnut,cablehandle,andcollar
nutareonthecable.Sliptheconnectornutoverthecopper
strandswiththethreadedendout.Orienttheconnector
assemblysotheredandwhitecontrolleadswillhavethe
straightestpossibleroutingstothesocketsonthebackside
oftheconnector.Assembletheincomingconnectortothe
cablebyforcingthesteeltubeoftheconnectorintotheinside
diameterofthecableinnertubeuntilthecopperstrandsare
buttedagainsttheincomingconnectorsolder.Keepingthe
copperstrandsagainsttheshoulder,pulltheconnectornut
overthecopperstrands,engagetheincomingconnector
threads,andtighteninplace.RefertoFigure3.
NOTE:Forbestresults,inserta.175”/.197” (4.5-5.0mm)
diameterrodthroughtheconnectorandintocoreofcable
approximately 5.00” (127 mm) when pushing theconnector
tubeintothecablecoretube.Totighten,holdtheconnector
inplacewhileturningthenut.Thenremovetherodfrom
thecore.Thisprocedureassurestheinnercoredoesnot
kinkwhileassemblingortightening.
ForK575:Pullthecut-offleadterminalsoffthetriggerassembly
andconnectthereplacementcontrolleadterminals.(See
Figure D.5).
ForK1723:Connecttheblackleadandthewhiteleadtothegun
trigger.Connecttheotherleadstotherockerswitchleads.
(See FigureD.6).
i. Soldertheterminalleadassembliesfromstep(f)tothe
control leadsstrippedinstep(g).Insulate bothsoldered
connections using either heat shrink tubing or electrical tape.
j. Fullyinsertthetwocontrolleadpinsintothesocketsonthe
incomingconnector.Tapetheleadsinplaceinthenecked
downareaoftheconnector.Keepingtheleadsasclosetothe
connectorandnutaspossible,tapetheinsulated,soldered
connectionsandthespareleadtothecableinthearea
betweenthecablejacketandconnectornut.Thismustbe
doneneatlyandkeptaslowaspossibleorthecablehandle
will not slide over this area.
NOTE: For best results, insert a .219"/240" (5.6/6.1mm) diameter
rodthroughtheconnectorandintocoreofcableapprox-
imately5.00"(127mm)whenpushingtheconnectortube
into thecablecore tube.Totighten,hold theconnector in
placewhileturningthenut,thenremovetherodfromthe
core.Thisprocedureassurestheinnercoredoesnotkink
while assembling ortightening.
FIGURE D.4
TRIGGER WIRES

FAST MATE GUNS SERIES
MAINTENANCE
D-5
k. Installthecableclamponthecablejacketwithin1/8”(3.2
mm)fromtheendofthejacketandtighten.
l. Slide the collar nut and cable handle over the connection and
intoplace.Anchorthecablehandlewiththescrewremoved
instep(c).Slidethebootandbootnutintoplaceandtighten.
WARNING
ELECTRIC SHOCK can kill.
Donottouchelectricallylivepartssuchasoutputterminals
or internal wiring.
NOTE:Ifthe cable handle becomes difficult toslide over
connection, try rotatingit.
m. Install andtrim liner per Removal, Installation andTrimming
Instructions on pageD-1.
FIGURE D.5
FIGURE D.6
(41.9mm SKIN)
FIGURE D.7
STRAIN RELIEF HOUSING
CABLE ASSEMBLY
GUN HOUSING
CABLE BOOT
GUN TUBE
RED &
BLUE WIRES TRIGGER ASSEMBLY
DETAIL
(TRIGGER WIRING)
BLACK &
WHITE WIRES
(4 CONTROL LEADS)
CABLE
CONTROL LEAD
1/4" (6.4mm) SKIN
(4 CONTROL LEADS)
CABLE
CONTROL LEADS

FAST MATE GUNS SERIES
MAINTENANCE
D-6
FIGURE D.8
FIGURE D.9
FIGURE D.10

FAST MATE GUNS SERIES
TROUBLESHOOTING
F-1
E
Observe all Safety Guidelines detailed throughout this manual
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
ServiceandRepairshouldonlybeperformedbyLincoln
Electric Factory Trained Personnel. Unauthorized repairs
performedonthisequipmentmayresultindangertothe
technicianandmachineoperatorandwillinvalidateyour
factorywarranty. ForyoursafetyandtoavoidElectrical
Shock,pleaseobserveallsafetynotesandprecautions
detailed throughout thismanual.
ThisTroubleshootingGuideisprovidedtohelpyoulocateand
repair possible machine malfunctions. Simply follow the three-
step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS).” This
columndescribespossiblesymptomsthatthemachinemay
exhibit.Findthelistingthatbestdescribesthesymptomthatthe
machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists the obvious
external possibilities that may contribute to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
Thiscolumnprovidesacourse ofaction for the Possible Cause,
generallyitstatestocontactyoulocalLincolnAuthorizedField
Service Facility.
Ifyoudonotunderstandorareunabletoperformthe
RecommendedCourseofActionsafely,contactyourlocal
LincolnAuthorizedFieldServiceFacility.
WARNING
ELECTRIC SHOCK can kill.
• Turnoffmachineatthedisconnectswitch
on the rear of the machine and remove
main power supply connections before
doing anytroubleshooting.

FAST MATE GUNS SERIES
TROUBLESHOOTING
F-2
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED COURSE OF ACTION
Driverollsturn,butwirewill
notfeedorwirefeedingis
rough.
a. Gun cable kinked and/or twisted.
a. Keepasstraightaspossible.Inspectcableand
replace ifnecessary.
b. Wire jammed in gun and cable.
b.Removewirefromgunandcable–geedinnew
wire.Noteanyobstruction.Replacelinerif
necessary.
c.Incorrectdriverollsandguidetubes.
c. Besurethewirediameterbeingusedisstamped
ondriverollsand guidetubes.Replaceif
necessary.
d. Gun cable liner dirty.
d. Clean liner or replace.
e. Worn drive rolls.
e. Replace or reverse split drive roll type.
f. Electroderustyand/ordirty.
f. Replacetheelectrodeifitis rusty.
g. Worn or improper size cable liner.
g. Replace cable liner.
h. Partiallyflashed,meltedorimpropersize
contact tip.
h. Replace the contact tip.
Variableor“hunting” arc.
a. Contact tip worn or incorrect size.
a. Replace contact tip.
b. Wornorundersizegroundcablesorpoor
groundconnections.
b. Inspect –repair or replace as necessary.
c. Loose electrode connections.
c. Be sure the following connections are tight:
electrodecabletowirefeederandpowersource,
workcabletopowersourceandwork,guncableto
wirefeedercontactblock,gunnozzletobodyand
contact tip tonozzle.
Poor arc striking with
stickingor“blast-offs”, weld
porosity,narrow andropy
lookingbead,orelectrode
stubbingintoplatewhile
welding.
a. Improper procedures or techniques.
a.See“Gas MetalArcWeldingGuide”(GS-100).
b. Improper gas shielding.
b. Cleangascone.Makecertainthatgasdiffuseris
notrestricted.makecertainthatgascylinderisnot
emptyorturnedoff.Makecertaingassolenoid
valveisoperatingandgasflowrateisproper.
Removegunlinerandcheckrubbersealforany
signofdeteriorationordamage.Besuresetscrew
in brass connector is in place and tightened
against the liner bushing.
Tip seizes in diffuser.
a. Tip overheating due to prolonged or
excessive high current and/or duty cycle
welding.
a. Donotexceedcurrentanddutycycleratingofgun.
Alightapplicationofhightemperatureantiseize
lubricant(suchasLincolnE2607GraphiteGrease)
maybeappliedtotipthreads.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR