Lincoln Electric Magnum PRO 250 LX User Manual

Operator’s Manual
Magnum
®
PRO 250 LX & LX GT
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
IM10484 | Issue D ate Nov-16- 18
© Lincoln Global, Inc. All Rights Reserved.
K Number:
K3569-2 Magnum PRO 250 LX GT
K3570-2 Magnum PRO 250 LX
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)

Lincoln Electric Magnum PRO 250 LX Specifications

General

Type	MIG Gun
Amperage Range	250A
Duty Cycle	60% at 250A
Welding Process	MIG (GMAW)
Wire Size Range	0.023 - 0.045 in (0.6 - 1.2 mm)
Cable Length	15 ft (4.5 m)
Gas	CO2

Summary

General Safety Precautions

Examine Carton and Equipment for Damage

Inspect carton and equipment for damage upon receipt and file claims with carrier if needed.

Personal Safety Responsibilities

Emphasizes user responsibility for safe installation, operation, repair, and fume avoidance.

Protective Gear and Special Situations

Details essential protective gear and specific measures for hazardous materials and painted/plated parts.

Section A: Warnings

California Proposition 65 Warnings

Specific warnings required by the State of California regarding diesel exhaust and welding fumes.

Arc Welding Hazards and Pacemaker Warning

Highlights arc welding dangers and advises pacemaker wearers to consult a doctor.

Engine Powered Equipment and EMF Safety

Covers safety for engine equipment and warns about Electric and Magnetic Fields (EMF) hazards.

Electrical, Arc, and Fume Hazards

Electric Shock Dangers

Emphasizes the extreme danger of electric shock and provides precautions to avoid it.

Arc Ray Burns and Eye Protection

Advises using proper shielding and protective clothing to prevent burns from arc rays.

Welding Fumes and Gas Dangers

Details health risks of welding fumes/gases and recommends ventilation/respiratory protection.

Fire, Explosion, and Cylinder Safety

Fire and Explosion Prevention

Warns about fire/explosion risks from welding sparks/spatter and recommends prevention measures.

Compressed Gas Cylinder Safety

Provides critical safety instructions for handling compressed gas cylinders to prevent explosions.

Electrically Powered Equipment Safety

Covers installation and grounding requirements for electrically powered welding equipment.

Installation Overview

Technical Specifications and Product Description

Lists key specs and describes features/use of the spool gun.

Included Components and Limitations

Lists package contents and outlines product limitations for voltage and applications.

Detailed Specifications

Detailed specs including wire capacity, speed, duty cycle, weight, and coolant type.

Unpacking and Parts Identification

Safety Precautions Before Unpacking

Highlights critical safety steps to follow before unpacking and installing the spool gun.

Spool Gun Components List

Identifies all components of the spool gun and their corresponding part numbers.

Spool Gun Familiarization and Connection

Understanding Spool Gun Features

Familiarizes users with the spool gun's handle, trigger, wire speed control, and drive mechanism.

Connecting to Power Source

Provides step-by-step instructions for safely connecting the spool gun to the welding power source.

Operation Overview and Setup

General Operation Safety Warnings

Lists critical safety warnings related to electric shock, welding sparks, arc rays, and fumes during operation.

Selecting Electrode Wire

Guides users on how to select the appropriate electrode wire based on base metal and desired weld characteristics.

Loading Electrode Wire

Step-by-Step Wire Loading Procedure

Detailed instructions for loading the electrode wire into the spool gun, including tip and nozzle setup.

Drive Roll Groove Selection

Drive Roll Orientation for Wire Size

Explains how to orient the drive roll for different wire sizes (.030"-.035" and 3/64").

Changing Drive Roll Orientation

Provides instructions on how to reverse the drive roll for correct wire groove positioning.

Making a Weld

Pre-Weld Checks and Setup

Details essential checks for connections, gas supply, and wire spool before starting a weld.

Welding Procedure Steps

Step-by-step guide on how to perform the actual welding process with the spool gun.

Main Machine Operation Reference

Refers to the main machine's manual for calibration and operation specifics.

Procedure Settings

4043 Aluminum Wire Settings

Provides recommended settings for arc volts, wire speed, and amps for 4043 aluminum wire.

Argon Shielding Gas Flow Rates

Lists recommended gas flow rates for argon shielding gas based on material thickness and welding position.

Optional Kits and Accessories

Extension Cable and Steel Drive Rolls

Details optional 50-foot extension cable and steel drive rolls for different wire sizes.

Front End Expendables and Tips

Lists optional front-end parts like diffusers, nozzles, insulators, and contact tips.

Maintenance Procedures

Maintenance Safety Warnings

Crucial safety instructions to follow before performing any maintenance on the spool gun.

Routine Maintenance Tasks

Outlines regular maintenance tasks like cleaning wire shavings and inspecting parts.

Troubleshooting Guide

How to Use the Troubleshooting Guide

Explains the three-step process for diagnosing and resolving machine malfunctions.

Troubleshooting Safety Precautions

Emphasizes safety precautions, especially electric shock, before performing troubleshooting.

Troubleshooting Common Issues

No Arc, Wire Feed, or Gas Flow Issues

Lists possible causes and solutions for no arc, weak arc, or no wire feed.

Gas Flow and Oxidation Problems

Addresses issues related to low or no gas flow and oxidized work surfaces.

Component Testing Procedures

Motor and Potentiometer Tests

Details how to test the continuity and resistance of the motor and potentiometer.

Trigger Switch Continuity Test

Explains the procedure for testing the continuity of the trigger switch.

Component Replacement and Adjustment

Trigger Replacement and Set Screw Adjustment

Provides steps for replacing and adjusting the trigger mechanism on the spool gun.

Mechanical Valve Replacement Procedure

Outlines the procedure for replacing the mechanical valve assembly in the torch body.

Customer Assistance Policy

Disclaimer on Advice and Information

States Lincoln Electric's policy on providing advice and information, disclaiming liability.

Product Selection and Use Responsibility

Clarifies that customer responsibility for product selection and use remains solely with the customer.