Lincoln Electric IM788 manual GUN and Cable Maintenance, For Magnum 100L GUN

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D-2

MAINTENANCE

D-2

 

 

 

 

GUN AND CABLE

MAINTENANCE

FOR MAGNUM™ 100L GUN

Gun Cable Cleaning

Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, 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.

Contact Tips, Nozzles, and Gun Tubes

1.Dirt can accumulate in the contact tip hole and restrict wire feeding. After each spool of wire is used, remove the contact tip and clean it by push- ing a short piece of wire through the tip repeatedly. Use the wire as a reamer to remove dirt that may be adhering to the wall of the hole through the tip.

2.Replace worn contact tips as required. A variable or “hunting” arc is a typical symptom of a worn con- tact tip. To install a new tip, 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.

3.Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required.

4.Be sure the gas nozzle is fully screwed onto the

diffuser for gas shielded processes. For the Innershield® process, the gasless nozzle should be screwed onto the diffuser.

5.To remove gun tube from gun, remove gas nozzle or gasless nozzle and remove diffuser from gun tube. Remove both collars from each end of the gun handle and separate the handle halves. Loosen the locking nut holding the gun tube in place against the gun end cable connector . Unscrew gun tube from cable connector. To install gun tube, screw the locking nut on the gun tube as far as possible. Then screw the gun tube into the cable connector until it bottoms. Then unscrew (no more than one turn) the gun tube until its axis is perpendicular to the flat sides of the cable connec- tor and pointed in the direction of the trigger. Tighten the locking nut so as to maintain the proper relationship between the gun tube and the cable connector. Replace the gun handle, trigger and dif- fuser. Replace the gas nozzle or gasless nozzle.

CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM

 

Contact Tip

Cable Liner

Drive Roll

 

 

 

 

 

 

Components shipped with

KP2039-1B1(In Gun)

KP1937-3

KP1881-1

SP-135 PLUS

.025” (0.6mm)

.030-.035”

2 Smooth grooves

 

KP2039-2B1(Loose)

(0.8-0.9 mm)

Small .023-.025” (Stenciled .025)

 

.030” (0.8mm)

 

Large .030-.035” (Stenciled .030-.035)

 

 

 

 

 

 

K549-1 .035” (0.9mm)

KP2039-3B1

KP1937-3

KP666-035CUse Large groove

Innershield Welding Kit

.035” (0.9mm)

.035 (0.9mm)

 

 

 

 

 

 

 

 

 

 

 

 

 

THESE PARTS

 

K663-2 .035 (0.9mm)

KP2078-1B1

KP1959-1

S24220 (Drive roll)

} NOT SOLD

 

Aluminum

.035A (0.9mm)

.035” (0.9mm)

S24219 (Idle roll)

SEPARATELY

 

 

 

 

 

 

KP666-035C

 

 

Stenciled

 

 

 

2 Knurled grooves for .035” (0.9mm)

 

 

 

 

 

 

• If .030 Solid wire feeding is desired obtain an KP2039-2B1 Contact Tip, an KP1937-2 Cable Liner and an KP1881-1 Drive Roll (Smaller Groove).

ΔRecommended for best feeding performance.

SP-135 PLUS

SP-135 PLUS

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Contents SP-135 Plus California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéOn-Line Product Registration Please Examine Carton and Equipment For Damage ImmediatelyTable of Contents Technical Specifications SP-135 Plus InstallationRead entire installation section before starting Safety PrecautionsInstallation Identify and Locate ComponentsWork Cable Installation Work Clamp InstallationSelect Suitable Location StackingConnecting Gun Cable to the SP-135 GUN InstallationGAS Connection PlusFigure A.5 Input ConnectionsRequirements For Rated Output Code Requirements for Input ConnectionsRequirements For Maximum Output Operation Observe all safety information throughout this manualFumes and Gases can be dangerous Welding Sparks can cause fire or explosionDesign Features Advantages Controls and SettingsGeneral Description Welding CapabilityWelding Operations Wire LoadingSequence of Operation Wire Threading Friction Brake AdjustmentMaking a Weld Shielding GasCleaning Tip And Nozzle Changing Machine Over to Feed Other Wire SizesProcess Guidelines Overload Protection Wire Feed Overload ProtectionOutput Overload Thermal ProtectionApplication Chart Optional Accessories AccessoriesK586-1 Deluxe Adjustable Gas Regulator Hose Kit Innershield Fcaw Conversion Replacement PartsMaintenance Safety Precautions MaintenanceItems Requiring no Maintenance Routine and Periodic MAINTE- NanceConfiguration of Components in Wire Feeding System GUN and Cable MaintenanceFor Magnum 100L GUN Contact Tip Cable Liner Drive RollChanging Drive Roll Changing the Contact TIPGUN Handle Parts Changing LinerLiner trim length for gun with red trigger Magnum 100L Remove any burrs from the end of the linerHOW to USE Troubleshooting Guide TroubleshootingProblems Possible Areas Symptoms Misadjustments Troubleshooting GuideRecommended Course of Action Feeding Problems GAS Flow Problems High Voltage Wiring DiagramsPrecaucion Warnung

IM788 specifications

The Lincoln Electric IM788 is a cutting-edge industrial welding inverter known for its advanced features and technologies that enhance productivity and efficiency in various welding applications. This machine is specifically designed to cater to the demands of high-performance environments while maintaining reliability and ease of use.

One of the standout features of the IM788 is its multi-process capability. It offers MIG, TIG, and stick welding options, making it a versatile choice for welders who work with a diverse range of materials and thicknesses. This flexibility enables operators to switch processes seamlessly without compromising on performance, thereby increasing overall productivity.

The IM788 is equipped with Lincoln Electric's exclusive Synchronized Arc Control Technology, which optimizes the arc characteristic for different materials and welding conditions. This technology helps to achieve cleaner and more precise welds, minimizing the need for post-weld finishing. Additionally, the machine offers a broad range of voltage and amperage settings, allowing for fine-tuning based on specific project requirements.

Another significant attribute of the IM788 is its built-in intelligence. The machine incorporates advanced microprocessor control, which enhances user interface capabilities and allows for easy adjustments to welding parameters. The intuitive digital display provides real-time feedback on settings and performance, enabling operators to make informed decisions and adjustments as needed.

Durability is also a key characteristic of the Lincoln Electric IM788. Its hardened metal case ensures protection against harsh working conditions, while internal components are designed to withstand heavy usage. This robust construction not only extends the machine's lifespan but also maintains consistent performance even in demanding environments.

The IM788's compact design and lightweight construction make it portable and easy to transport, allowing welders to move it effortlessly between job sites. Coupled with its energy-efficient operation, this inverter contributes to lower operational costs, making it an economical investment for both small workshops and large industrial operations.

In summary, the Lincoln Electric IM788 stands out for its multi-process capabilities, advanced welding technologies, user-friendly interface, and robust design. These features make it an ideal choice for professionals seeking a reliable and efficient welding solution. Whether for fabrication shops, construction sites, or maintenance applications, the IM788 delivers exceptional performance and versatility, solidifying its position as a leading welding inverter in the market.
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