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Lincoln Electric Magnum manual

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Table of contents for the manual

  • Page 1

    Ar c W elding Guns for Semiautomatic Gas-Shielded W elding Optimize Y our W elding System! TM Featuring Our New Magnum EXPRESS TM Package (see page ...24)[...]

  • Page 2

    Wire Power Source Feeder Gun Connector Gun Gun Consumables The Lincoln W elding Arc A T otal System Focused on Arc W elding Making good welds is a lot like making good music. A carefully tuned set of instruments perform together in pleasing harmony . A power source, welding wir e, wire feeder and a Lincoln Magnum Gun perform in harmony to produce o[...]

  • Page 3

    3 • Magnum's Patent Pending Handle grip design provides balance, r educes operator fatigue and offers a sure, confident grip Comfortable Handle • Three Layer Insulated Gooseneck Construction • Durable Abrasion-Resistant Gun Cable Outer Jacket • Proprietary W ound Liner Durable Construction • Guaranteed Parts and Service Support where[...]

  • Page 4

    PRODUCTIVITY • One-piece modular trigger assembly is molded out of high heat resistant thermoset material to withstand heat and spatter and ensure long life. • Gun tube design optimizes fine wire welding performance. The outside of the gun tube is armored with an electrically insulated metal jacket, eliminating wear problems of other softer ins[...]

  • Page 5

    Gun Consumables Match an Industry Standard Design Rotatable Gooseneck (Gun T ube) • Just loosen a single Allen screw to unlock and rotate the gooseneck into a position that is most comfortable for your current job • Especially useful to complete high quality welds even in tight spaces or awkward joint locations Rotatable Gun Hanger • Hang you[...]

  • Page 6

    Always A vailable: Our Quick-tur n Pledge Need gun consumables or parts in a hurry? Contact us via phone, fax or email to order the parts you need. That's our pledge. 6[...]

  • Page 7

    Gun Consumables A Critical Link that Can Make the Differ ence • Industry standard design compatibility allows use on competitive guns • Industry standard part numbers ar e easy to order • W ide variety of consumables for every application • Tight manufacturing tolerances deliver consistent arc performance • T ested durability delivers lon[...]

  • Page 8

    8 Four Easy Steps 1 2 3 4 Choose operating amperage range: Select an amperage range for your application, based on your knowledge of the thickness of material and your equipment capability . Select a specific gun: At a glance, you can choose a wire diameter range and gun type, along with basic wire feeder connection type and gun cable length—and [...]

  • Page 9

    9 Choose a Gun with the Right Operating Amperage Range S T E P 1 250 amps 200 amps 400 amps 300 amps 500 or 600 amps 100 amps Magnum 400 Gun With a longer gooseneck and a higher copper strand count cable than the 300, the 400 gun is built for operator comfort when welding with the greater heat levels generated by higher amperage applications. Selec[...]

  • Page 10

    10 Amperage Rating 60% Duty Cycle CO 2 Shielding Gas 200 A Net W eight 9 - 12 lbs. (4.0 - 5.4 kg) Wire Diameter Range .025” - .045” (0.6 mm - 1.2 mm) 10[...]

  • Page 11

    11 A small, lightweight gun intended for light job shop and fabrication applications. Best suited for welding on thin materials using .025–.030” wire. 200 200 amps Select a Gun for Y our Application S T E P 2 GUN WIRE DIAMETER GUN CONNECTOR GUN CONNECTOR Open-End Gun Package Open-End Fast-Mate Gun Package Wire Feeder Connector: - Open-End: Feed[...]

  • Page 12

    12 Choose a Gun Connector S T E P 3 MFG. WIRE FEEDER MODEL CONNECTOR KITS FOR ST ANDARD GUNS T weco ® Adapted Hobart ® ESAB ® Miller ® Lincoln LN-7 Series, LN-742, LN-8, LN-9 Series LN-25 (Up to .052" (1.4 mm) Wire) LN-8, LN-9 Series, LN-25 (1/16" (1.6 mm) & Larger Wire) LF-72, LF-74 Series Power Feed ® 10M, LN-10, DH-10, STT -10[...]

  • Page 13

    200 200 amps 2 1b 1a 4a 4b 3a 3b 3c K466-1 K466-2 K466-3 K466-4 K466-5 K466-6 K466-7 K466-8 K466-10 1a 1b 4a 4b 1a 4a 4b 1c 1b 1a 4a 4b 3b 1b 1c 2 2 3a 3c 2 1 4a 4b 2 1 4b 4a 2 1 4b 4a 2 1b 3a 4b 1 3b 3c 4a 2 1 4b 4a 13 Gun Connector Included Parts[...]

  • Page 14

    14 TIP Standard Duty Heavy Duty Tapered 10 Bulk 10 Bulk 10 Bulk 10 Bulk Notched (Alum.) QTY. WIRE DIAMETER .025" (0.6mm) .030" (0.8mm) .035" (0.9mm) .040" (1.0mm) .045" (1.2mm) KP14-25 KP2020-6B1 KP14-30 KP2020-7B1 KP14-35 KP2020-1B1 KP14-40 KP2020-8B1 KP14-45 KP2020-2B1 KP14-25-B100 KP2020-6B2 KP14-30-B100 KP2020-7B2 KP14-[...]

  • Page 15

    Gas Diffuser Assembly Diffuser Gas Diffuser Assembly 5 Bulk QTY. WIRE DIAMETER .025"–.030" (0.6–0.8mm) .035"–.045" (1) (0.9–1.2mm) .025"–.045" (2) (0.6–1.2mm) KP52-25 KP2026-2 KP2051-1 (2) — KP52-25-B25 KP2026-2B1 KP52FN (1) KP2026-3 KP52FN-B25 (1) KP2026-3B1 KP2051-1B1 (2) — KP52FN (1) KP2026-3 KP52FN-[...]

  • Page 16

    16 Amperage Rating 60% Duty Cycle CO 2 Shielding Gas 300 A Net W eight 9 - 12 lbs. (4.0 - 5.4 kg) Wire Diameter Range .025” - 5/64” (0.6 mm - 2.0 mm)[...]

  • Page 17

    300 300 amps Select a Gun for Y our Application S T E P 2 This popular Magnum gun is intended for most .035–.045” wire diameter applications in job shops, pr oduction or manufacturing. Standard equipment on the current Lincoln Power MIG ® 350MP wire feeder/welder . GUN WIRE DIAMETER GUN CONNECTOR GUN CONNECTOR GUN CONNECTOR Open- End Fast- Mat[...]

  • Page 18

    18 Choose a Gun Connector S T E P 3 MFG. WIRE FEEDER MODEL CONNECTOR KITS FOR ST ANDARD GUNS F ASTMA TE ™ ADAPTER KITS FM GUNS Lincoln T weco ® Adapted Hobart ® ESAB ® Miller ® Single Procedure Single Procedure K466-8 K466-10 K466-10 K466-6 K466-2 K466-1 K466-7 K466-4 K466-5 K466-3 K489-1 — K489-7 K489-8 — K489-4 K489-1 K489-5 K489-5 — [...]

  • Page 19

    K489-1, 2, 3, 4, 5, 7, 8 2 1b 1a 4a 4b 3a 3b 3c K466-1 K466-2 K466-3 K466-4 K466-5 K466-6 K466-7 K466-8 K466-10 1a 1b 4a 4b 1a 4a 4b 1c 1b 1a 4a 4b 3b 1b 1c 2 2 3a 3c 2 1 4a 4b 2 1 4b 4a 2 1 4b 4a 2 1b 3a 4b 1 3b 3c 4a 2 1 4b 4a 19 300 300 amps Gun Connector Included Parts[...]

  • Page 20

    TIP Standard Duty Heavy Duty Tapered 10 Bulk 10 Bulk 10 Bulk 10 Bulk Notched (Alum.) QTY. WIRE DIAMETER .025" (0.6mm) .030" (0.8mm) .035" (0.9mm) .040" (1.0mm) .045" (1.2mm) KP14-25 KP2020-6B1 KP14-30 KP2020-7B1 KP14-35 KP2020-1B1 KP14-40 KP2020-8B1 KP14-45 KP2020-2B1 KP14-25-B100 KP2020-6B2 KP14-30-B100 KP2020-7B2 KP14-35-[...]

  • Page 21

    NOZZLE QTY . NOZZLE DIAMETER (1) Requires KP34A, Nozzle Insulator Assembly (2) Requires KP34CT , Nozzle Insulator Assembly 1 = Qty . in pack Bulk = Qty . of 25 Adjustable Slip-on (1) Nozzle Recessed Slip-on (1) Nozzle Coarse Thread (2) Nozzle Tip Recessed 1/8" (3.2mm) Tip Recessed 1/4" (6.4mm) Tip Recessed Tip T apered Heavy Duty Tip Flus[...]

  • Page 22

    22 TUBE 45º 60º 82º 10 Bulk 10 Bulk 10 Bulk QTY . RA TED (AMPS) 300 400 NOTE: 300 & 400 amp gun tubes can be used with 200 amp guns. Use corresponding amperage gas diffuser , nozzle, and nozzle insulator . 10 = Qty . in pack Bulk = N/A KP1929-2 — KP1929-1 — — — — — KP1928-2 — KP1928-1 — — — — — — — KP1941-1 — ?[...]

  • Page 23

    LINER 1 Bulk 1 Bulk QTY . DIAMETER Cable Liner (300 amps) Continued LINER 1 Bulk 1 Bulk QTY . DIAMETER (1) A KP2024-1 Gas Diffuser is required when using a KP44-564-15 Cable Liner in a non-Magnum gun. (2) Recommended for aluminum wire welding. Recommended maximum cable length is 10 ft. (3.0m). (3) Requires KP54A Gas Diffuser . 1 = Qty . in Pack Bul[...]

  • Page 24

    24 ST ART WELDING... ...STOP TINKERING GRAB THE Industr y's Best... PRODUCTUVITY • No assembly , no mistakes. • Designed to maximize feedability and keep you welding. • 100% field serviceable. EASE-OF-USE • Interchangeable components and one of the industry’ s widest array of parts. • Rotatable goose necks provide easy access to aw[...]

  • Page 25

    GUN WIRE DIAMETER GUN CONNECTOR GUN CONNECTOR GUN CONNECTOR Open- End Fast- Mate Gun Package Open- End Fast- Mate Gun Package Open- End Fast- Mate Gun Package Wire Feeder Connector: - Open-End: Feeder end of the gun is open. A separate Gun Connector Kit is required. (See Gun Connector Kit Section). - Fast-Mate™: Also known as Euro-Connect. Gun Pa[...]

  • Page 26

    Choose a Gun Feeder Connector S T E P 3 CONNECTOR KITS FOR ST ANDARD GUNS F ASTMA TE ™ ADAPTER KITS FOR FM GUNS Single Procedure Dual Procedure/ Dual Schedule Dual Procedure/ Dual Schedule Single Procedure — See note 1 K466-10 — — K573-1 K489-7 — MFG. WIRE FEEDER MODEL CONNECTOR KITS FOR ST ANDARD GUNS Lincoln T weco ® Adapted Hobart ® [...]

  • Page 27

    K489-1, 2, 3, 4, 5, 7, 8 2 1b 1a 4a 4b 3a 3b 3c K466-1 K466-2 K466-3 K466-4 K466-5 K466-6 K466-7 K466-8 K466-10 1a 1b 4a 4b 1a 4a 4b 1c 1b 1a 4a 4b 3b 1b 1c 2 2 3a 3c 2 1 4a 4b 2 1 4b 4a 2 1 4b 4a 2 1b 3a 4b 1 3b 3c 4a 2 1 4b 4a 400 400 amps 27 Gun Connector Included Parts[...]

  • Page 28

    TIP Standard Duty Heavy Duty T apered 10 Bulk 10 Bulk 10 Bulk 10 Bulk Notched (Alum.) QTY . WIRE DIAMETER .025" (0.6mm) .030" (0.8mm) .035" (0.9mm) .040" (1.0mm) .045" (1.2mm) KP14-25 KP2020-6B1 KP14-30 KP2020-7B1 KP14-35 KP2020-1B1 KP14-40 KP2020-8B1 KP14-45 KP2020-2B1 KP14-25-B100 KP2020-6B2 KP14-30-B100 KP2020-7B2 KP14-3[...]

  • Page 29

    NOZZLE QTY . NOZZLE DIAMETER (1) Requires KP34A, Nozzle Insulator Assembly (2) Requires KP34CT , Nozzle Insulator Assembly 1 = Qty . in pack Bulk = Qty . of 25 Adjustable Slip-on (1) Nozzle Recessed Slip-on (1) Nozzle Coarse Thread (2) Nozzle Tip Recessed 1/8" (3.2mm) Tip Recessed 1/4" (6.4mm) Tip Recessed Tip T apered Heavy Duty Tip Flus[...]

  • Page 30

    TUBE 45º 60º 82º 10 Bulk 10 Bulk 10 Bulk QTY . RA TED (AMPS) 300 400 NOTE: 300 & 400 amp gun tubes can be used with 200 amp guns. Use corresponding amperage gas diffuser , nozzle, and nozzle insulator . 10 = Qty . in pack Bulk = N/A KP1929-2 — KP1929-1 — — — — — KP1928-2 — KP1928-1 — — — — — — — KP1941-1 — — ?[...]

  • Page 31

    LINER 1 Bulk 1 Bulk QTY . DIAMETER Cable Liner (400 amps) Continued LINER 1 Bulk 1 Bulk QTY . DIAMETER (1) A KP2024-1 Gas Diffuser is required when using a KP44-564-15 Cable Liner in a non-Magnum gun. (2) Recommended for aluminum wire welding. Recommended maximum cable length is 10 ft. (3.0m). (3) Requires KP54A Gas Diffuser . 1 = Qty . in Pack Bul[...]

  • Page 32

    32 Amperage Rating 60% Duty Cycle CO 2 Shielding Gas 550 A Net W eight 12 -23 lbs. (5.4 10.4 kg) Wire Diameter Range .052” - 1/8” (1.3 mm - 3.2 mm)[...]

  • Page 33

    33 Select a Gun for Y our Application S T E P 2 Choose our 550 gun equipped with 500 or 600 amp consumables for high amperage, large wir e diameter welding, including up to .052” and .062” MIG or 3/32–1/8” Outershield ® or UltraCore™ (gas-shielded flux-cor ed) applications. 550 500 & 600 amps GUN WIRE DIAMETER GUN CONNECTOR GUN CONNE[...]

  • Page 34

    34 Choose a Gun Connector Magnum 550 (500 & 600 amps) S T E P 3 MFG. WIRE FEEDER MODEL CONNECTOR KITS FOR ST ANDARD GUNS Lincoln T weco ® Adapted Hobart ® Miller ® LN-7 Series, LN-8, LN-9 Series (Up to .052" (1.4 mm) Wire) LN-8, LN-9 Series, (1/16" (1.6 mm) & Larger Wire) Power Feed ® 10M, LN-10, DH-10, STT -10 No. 2, 3 & [...]

  • Page 35

    35 550 500 & 600 amps 2 1b 1a 4 3b 3a K613-1 K613-2 K613-3 K613-4 K613-5 K613-6 K613-7 3c 1 3 4 2 3c 4 1c 1b 1a 4 3b 1c 1b 2 3a 3c 1a 1b 4 2 1 4 3b 3c 3a 2 1 4 2 Gun Connector Included Parts[...]

  • Page 36

    36 Choose Y our Consumables Magnum 550 (500 amps) S T E P 4 TIP Flux- Cored, Heavy Duty Solid Wire, Heavy Duty 10 Bulk 10 Bulk QTY . WIRE DIAMETER .035" (0.9mm) .045" (1.2mm) 3/64A" (1.2mm) .052" (1.3mm) 1/16" (1.6mm) KP15HFC-35 KP2055-1B1 KP15HFC-45 KP2055-2B1 — — KP15HFC-52 KP2055-3B1 KP15HFC-116 KP2055-4B1 — — ?[...]

  • Page 37

    Diffuser Standard Tip Recessed 3/32" (2.4mm) Tip Recessed 3/16" (4.8mm) Tip Recessed 5/8" (15.9mm) 1 Bulk 1 Bulk 1 Bulk 1 Bulk QTY . WIRE DIAMETER .035"–1/16" (0.9–1.6mm) 1/16"–5/64" (1.6–2.0mm) 3/32"–1/8" (2.4–3.2mm) KP55SW KP2058-1 KP55 KP2058-2 KP55H KP2058-3 KP55SW-B10 KP2058-1B1 KP55-B10[...]

  • Page 38

    38 60º Gun T ube 5º Bend 60º GUN TUBE 5º bend Radius 10 Bulk QTY . RA TED (AMPS) 500 10 = Qty . in pack Bulk = N/A KP1951-3 — — — Gun T ubes /550 Model (500 amps) LINER 1 Bulk 1 Bulk QTY . DIAMETER (1) For use with aluminum wire. Recommended maximum cable length is 10 ft. (3.0m) 1 = Qty . in Pack Bulk = Qty . of 10 KP45-3545-15 KP1950-1 .[...]

  • Page 39

    Choose Y our Consumables Magnum 550 (600 amps) S T E P 4 Contact Tips (600 amps) Continued TIP Heavy Duty 10 Bulk QTY . WIRE DIAMETER .035" (0.9mm) .045" (1.2mm) 3/64A" (1.2mm) .052" (1.3mm) 1/16" (1.6mm) KP16S-35 KP2054-1-B1 KP16S-45 KP2054-2B1 KP16S-35-B100 KP2054-1B2 KP16S-45-B100 KP2054-2B2 KP16AS-364 (1) KP2054-9-B1 KP[...]

  • Page 40

    WIRE DIAMETER .035–.1/16" (0.9–1.6mm) 5/64–.1/8" (2.0–3.2mm) Diffuser Gas Diffuser Assembly 1 Bulk QTY . KP56S-SW KP2057-1 KP56S-H KP2057-2 KP56S-SW-B10 KP2057-1B1 KP56S-H-B10 KP2057-2B1 10 = Qty . in Pack Bulk = Qty . of 10 Gas Diffuser (600 amps) Part Number Previous Part Number 40 LINER 1 Bulk 1 Bulk QTY . DIAMETER (1) For use [...]

  • Page 41

    41[...]

  • Page 42

    Amperage Rating 60% Duty Cycle CO 2 Shielding Gas 100 A Net W eight 9 - 12 lbs. (4.0 - 5.4 kg) Wire Diameter Range .025” - .045” (0.6 mm - 1.2 mm) 42[...]

  • Page 43

    43 Extremely small, lightweight gun that's gr eat for most home, farm and small shop projects, auto-body work and light maintenance or repair applications. Standar d equipment on current Lincoln SP-135T and SP-175T , Power MIG ® 140T , 140C, 180T and 180C. Includes gun connector . Select a Gun for your application S T E P 2 MIG Innershield® [...]

  • Page 44

    Choose Y our Consumables S T E P 3 44 TIP Standard Duty T apered 10 Bulk 10 Bulk QTY . WIRE DIAMETER .025" (0.6mm) .030" (0.8mm) .035" (0.9mm) .045" (1.2mm) KP11-25 KP2039-1B1 KP11-30 KP2039-2B1 KP11-35 KP2039-3B1 KP11-45 KP2039-4B1 KP11-25-B100 KP2039-1B2 KP11-30-B100 KP2039-2B2 KP11-35-B100 KP2039-3B2 KP11-45-B100 KP2039-4B2 K[...]

  • Page 45

    LINER 1 Bulk QTY . DIAMETER (1) Recommended for aluminum wire welding. Recommended maximum cable length for aluminum is 10 ft. (3.0m). 1 = Qty . in Pack Bulk = Qty . of 10 KP1937-3 — .025"–.035" (0.6–0.9 mm) Aluminum .035" (1) (0.9mm) .035"–.045" (0.9–1.2 mm) KP1937-3B1 — KP1959-1 (1) — — — KP45-40-15 KP19[...]

  • Page 46

    46 Amperage Rating 60% Duty Cycle CO 2 Shielding Gas 250 A Net W eight 8 lbs. (3.6 kg) Wire Diameter Range .025” - .045” (0.6 mm - 1.2 mm)[...]

  • Page 47

    47 Recommended for medium duty job shop and production applications. Standard equipment on the curr ent Lincoln Power MIG 215 and Power MIG ® 255C wire feeder/welders. Includes gun connector . Select a Gun for your application S T E P 2 GUN WIRE DIAMETER 250L Adjustable Gas Nozzle Fixed Gas Nozzle Fixed Gas Nozzle 250SP Contact Tip Gas Diffuser Ga[...]

  • Page 48

    TIP Standard Duty Heavy Duty Tapered 10 Bulk 10 Bulk 10 Bulk 10 Bulk Notched QTY. WIRE DIAMETER .025" (0.6mm) .030" (0.8mm) .035" (0.9mm) .040" (1.0mm) .045" (1.2mm) KP14-25 KP2020-6B1 KP14-30 KP2020-7B1 KP14-35 KP2020-1B1 KP14-40 KP2020-8B1 KP14-45 KP2020-2B1 KP14-25-B100 KP2020-6B2 KP14-30-B100 KP2020-7B2 KP14-35-B100 KP2[...]

  • Page 49

    Diffuser 1 Bulk 1 Bulk QTY. WIRE DIAMETER .025–.030" (0.6–0.8mm) .035–.045" (.09–1.2mm) KP52-25 KP2026-2 KP52 KP2026-1 KP52-25-B25 KP2026-2B1 KP52-B25 KP2026-1B1 KP2051-1 — KP2026-3 — — — — — 1 = Qt y . in Pack Bulk = Qt y . of 25 (1) Permits use of 100 am p Contact Ti p s and Nozzles with Ma g num 250L Gun Tube Adjust[...]

  • Page 50

    50 LINER 1 Bulk QTY . DIAMETER (1) Recommended for Aluminum wire welding. Recommended maximum cable length for aluminum is 10 ft. (3.0m). 1 = Qty . in Pack Bulk = Qty . of 10 KP42-25-15 KP1934-2 .025"–.030" (0.6–0.8 mm) Aluminum .035"–.3/64" (1) (0.9–1.2 mm) .030"–.035" (0.8–0.9 mm) .035"–.045" [...]

  • Page 51

    MACHINE GUN P ART NUMBER Power MIG 140C/140T Magnum 100L Power MIG 180C/180T Magnum 100L Power MIG 200 Magnum 250L Power MIG 215 Magnum 250L Power MIG 255 Magnum 250L Power MIG 255C Magnum 250L Power MIG 300 Magnum 300 Power MIG 350MP Magnum 300 SP-100 Magnum 100L SP-100-l Magnum 100L SP-100-T Magnum 100L SP-125 Plus Magnum 100L SP-130-T Magnum 100[...]

  • Page 52

    The Lincoln Electric Company 22801 St. Clair Avenue Cleveland, Ohio 44117-1199 P: 216-481-8100 F: 216-486-1751 www .lincolnelectric.com CUSTOMER ASSIST ANCE POLICY 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 cu[...]