Lincoln Electric Magnum User Manual
TM
Package
TM
Featuring Our New
(see page ...24)
Magnum EXPRESS
Arc Welding Guns
for Semiautomatic Gas-Shielded Welding
Optimize Your Welding System!
Wire
Power Source
Feeder Gun Connector Gun
Gun Consumables The Lincoln Welding Arc
Critical Links:
A Systems Approach
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 wire, wire feeder and a Lincoln Magnum Gun
perform in harmony to produce one great weld after another.
A Total System Focused on Arc Welding
Why Choose a Lincoln
Welding System?
Productivity, Ease-of-Use, Peace-of-Mind
•
•
•
•
•
Hundreds of welding field sales engineers
2
Technical assistance, cost reduction
and productivity programs
Thousands of knowledgeable and
responsive Lincoln distributors
Innovative approach to product
designs and customer solutions
Global presence
• Magnum's Patent Pending
Handle grip design
provides balance, reduces
operator fatigue and offers
a sure, confident grip
Comfortable Handle
• Three Layer Insulated
Gooseneck Construction
• Durable Abrasion-Resistant
Gun Cable Outer Jacket
• Proprietary Wound Liner
Durable Construction
• Guaranteed Parts and Service
Support wherever you are
Complete Support Systems
• Quick-change gooseneck
• Screw on (Not Crimped) Gun
Cable Connections
• Spare Trigger Lead
• One Piece Trigger Assembly
Field Serviceable
1. Choose operating
amperage range
2. Select a specific gun
3. Select a gun connector
4. Select additional consumables
Easy to Specify & Order
• Interchangeable Gun
Connectors, Nozzles and
Goosenecks
• Large Selection of Industry
Standard Nozzle and Contact
Tip Types
Adapts to Your Application
What you should
know about
Guns
Magnum
Guns
Optimize Your Welding System!
Magnum guns are designed by a total welding systems
company. Many other gun companies deliver guns . . .
and only guns.
That's not always the best solution. Why? Because the
gun is not the only component, or critical link in the
welding system.
Here at Lincoln Electric, we design, test and re-test the
performance of every component in the arc welding
system. We are one of the only manufacturers in the
industry that brings welding equipment, wire, parts,
service and expertise from a single, focused team.
That means we can commit to delivering total process
solutions – from the power source to the wire and feeder –
to the gun that delivers the arc.
We study how the gun delivers not only wire, but welding
current and shielding gas to the weld – your weld. We
assure that our gun is designed to work with the equipment
purchased, and that it is rugged enough to work in service
for a very long time. Optimize the welding system with
Magnum Guns from Lincoln Electric.
3
Not Only Will Magnum Guns Optimize
Your Welding System, But They’ll AlsoIncrease…
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 insulation materials.
• The gun tube is buffed to a high shine which helps reflect
radiant heat from the weld.
• Abrasion-resistant, extruded rubber jacket adds strength
and long life to the cable.
• Repairable cable connections and a spare internal trigger
lead allow user to easily service the cable.
• Liners made with a spring steel jacket and a low
friction core are available for feeding aluminum wire.
• The fiberglass handle with non-slip grooves is designed
to minimize size and maximize comfort and control.
• Gun cable contains a pure copper conductor with high
strand count for cool operation and maximum flexibility.
EASE-OF-USE
• Can be connected to virtually any wire feeder in the
industry.
• Improved, more intuitive part numbers for easier
reference and ordering.
• Adjustable hanger provides convenient means for storing
guns between welds.
• Magnum gun expendables are compatible with other
leading brands.
PEACE-OF-MIND
• Lincoln Electric provides technical assistance, cost
reduction and productivity programs.
• When Magnum guns increase your productivity and
welding quality right out of the box…everybody wins.
• The welding gun is the final critical link in your welding
performance – why risk all your research and investment
on less than Magnum?
• Optimize Your Welding Systems!
4
Don’t Be Under Gunned!
Gun Consumables
Match an Industry
Standard Design
One Piece Replaceable
Trigger Assembly
• Easy to replace as a unit—simply plug in
a new assembly
• Can also be opened and serviced
• High quality silver contacts for long life and
clean electrical signals
• Full travel mechanical trigger mechanism
(NOT a micro-switch) can be easily felt
through a welding glove
Comfortable Handle Design
• Patent Pending Magnum Grip Design—Unique grip
design provides balance, reduces operator fatigue
and offers a sure, confident grip
• Natural Grip Trigger position feels right from the
first minute of the day to the end of the Shift
Rotatable Gooseneck (Gun Tube)
• 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 your gun anywhere, any way
Rugged Strain Relief System
• Enhances feedability by reducing acute gun cable angles
• Protects your cable liner
Pure copper conductor
with high strand count
for cool operation and
maximum flexibility
Gun connectors for all
popular feeders
400 amp Dual Procedure and
Dual Schedule guns provide
an added measure of control
on tough applications
5
Always Available:
Our Quick-turn 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
Gas Diffuser
Standard
Tip Recessed
For Slip-On Nozzle
For Fixed Nozzle
Specialty
Nozzles
Fixed, Tip Flush
Fixed, Tip Recessed
CT-Coarse Thread
Slip-On, Adjustable
Slip-On, Tip Recessed
Nozzle Insulator
Adjustable Slip-on
Coarse Thread
Connectors
Lincoln
®
Lincoln Fast-Mate
TM
(Euro)
Miller®
Tweco-Adapted
®
Hobart®
ESAB
®
Tubes/Goosenecks
60º
45º
82º
Contact Tips
Standard
Heavy Duty
Tapered
Notched
Gun Consumables
A Critical Link that Can Make
the Difference
• Industry standard design compatibility
allows use on competitive guns
• Industry standard part numbers are
easy to order
• Wide variety of consumables for
every application
• Tight manufacturing tolerances
deliver consistent arc performance
• Tested durability delivers long life
• Improved electrical conductivity and
wire feedability
• Convenient Packaging Options
- Including Bulk Packages
Customize Your Gun!
Choose a gun nozzle for your welding style.
Select a gooseneck that will help you get
into tight spaces. Whatever your skill level
or personal style demands, Lincoln has what
you need.
Multiple nozzle & contact tip types for specific applications
7
Four Easy
Steps
Use this quick and easy four step process to
select the right gun and all your accessories
Choose operating amperage range:
1
2
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 that simply drives
you to the right gun for your application.
3
4
Select a gun connector (Magnum 200–550):
Match your gun to your wire feeder by manufacturer
and/or gun connector type.
Select additional consumables:
- Pick up a pack of extra contact tips.
- Choose a nozzle for your welding style.
- Order replacement gas diffusers or gun liners.
- Select a gooseneck that will help you get
into tight spaces.
or
Select a Magnum Express.
8
Choose a Gun with the Right
S
T
E
P
1
Operating Amperage Range
200 amps
300 amps
400 amps
Magnum 200 Gun
A small, lightweight gun intended for light job shop and
fabrication applications. Best suited for welding on thin
materials using .025–.030” wire.
Magnum 300 Gun
This popular Magnum gun is intended for most
.035–.045” wire diameter applications in job shops,
production or manufacturing. Standard equipment on the
current Lincoln Power MIG
®
350MP wire feeder/welder.
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.
Select the 400 for most .045”, .052” or 1/16” MIG,
UltraCore™ or Metalshield
®
(gas-shielded) operations.
500 or 600 amps
100 amps
250 amps
Magnum 550 Gun–500 or 600 amps
Choose our 550 gun equipped with 500 or 600 amp
consumables for high amperage, large wire diameter
welding, including up to .052” and .062” MIG or
3/32–1/8” Outershield
flux-cored) applications.
®
or UltraCore™ (gas-shielded
Magnum 100L Gun
Extremely small, lightweight gun that's great for most
home, farm and small shop projects, auto-body work
and light maintenance or repair applications. Standard
equipment on current Lincoln SP-135T and SP-175T,
Power MIG
connector.
®
140T, 140C,180T and 180C. Includes gun
Magnum 250L Gun
Recommended for medium duty job shop and
production applications. Standard equipment on the
current Lincoln Power MIG 215 and Power MIG 255C
wire feeder/welders. Includes gun connector.
9
Amperage Rating
60% Duty Cycle
CO2Shielding Gas
200 A
Wire Diameter Range
.025” - .045”
(0.6 mm - 1.2 mm)
Net Weight
9 - 12 lbs.
(4.0 - 5.4 kg)
10
10
Select a Gun
S
T
E
P
2
for Your Application
A small, lightweight gun intended for light job shop
and fabrication applications. Best suited for
welding on thin materials using
.025–.030” wire.
Magnum Guns (200 amps)
200
200 amps
GUN WIRE DIAMETER
Standard
CABLE
LENGTH
10' (3.0m)
12' (3.6m)
15' (4.5m)
WIRE DIAMETER
.025”–.030” (0.6mm–0.8mm)
GUN CONNECTOR GUN CONNECTOR
Open-End Gun Package
—
—
K497-3
—
—
K497-20
.035”–.045” (0.9mm–1.2mm)
Open-End
K497-2
K497-6
K497-1
Included Parts
Contact Tip
Gas Diffuser
Gas Nozzle
Insulator
Cable Liner
Gun Tube (60º)
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.
- Lincoln 10 Series Pkg.: Includes K466-10 Lincoln 10 Series Gun Connector Kit.
.025: KP14-25 (KP2020-6)
.030: KP14-30 (KP2020-7)
KP52-23 (KP2026-2)
KP22-50 (KP1935-2)
KP32 (KP2025-1)
KP42-25-15 (KP1934-2)
KP2028-1
.035: KP14-35 (KP2020-1)
.045: KP14-45 (KP2020-2)
KP22-50 (KP1935-2)
KP42-4045-15 (KP1934-1)
Fast-Mate Gun Package
K498-2
K498-6
K498-1
KP52 (KP2026-1)
KP32 (KP2025-1)
KP2028-1
K497-21
—
—
Optional Feature
Gas Tube Kit
Fast Connect Gas Tube Kit provides
connection to Lincoln wire feeders.
Order K481
11
Choose a
S
T
E
P
3
Gun Connector
Gun Connectors (200 amps)
MFG. WIRE FEEDER MODEL CONNECTOR KITS
FOR STANDARD GUNS
Lincoln
®
Tweco
Adapted
®
Miller
Hobart
®
ESAB
Included
Parts
Connector
1
Assembly
Control
2
Cable
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
LN-15, Power Feed 15M
Power MIG
No. 2, 3 & 4 Guns
Intellimatic
Porto-MIG
300 & 35 (new) S-42GL, S-52A & S-54A
Swing Arc
S-32S, 52D, 54D & 54E, 60 & 70 Series
Dualmatic
Mega-Conds
®
2000 Series, 17 Hefty
Digamig®, EH1, 5 & 11, SEH-4 & 5
SWM11 & 11B, 12, 13, 23, 24, 25, 26, 35
VAM2
®
10M, LN-10, DH-10, STT-10
®
Series & Wire-MaticTM Series
®
, Side Kick®, D-51A
®
, Millermatic® 130,
®
-Dual & Single (new), S-22,
®
27/70, H3S, H4S & H6S
®
27, 44, 45, 70, 70S
®
K466-1
S18645 (a)
T7028-234 (b)
M15608
K466-2
S18653 (a)
S19762 (b)
—
K466-3
S19760 (a)
S19761 (b)
KP2009-X (c)
M16325
K466-4
S19763 (a)
S19765 (b)
KP2009-X (c)
M16328
K466-5
S20044
M16520
K466-1
K466-8
K466-10
K466-10
K466-6
K466-2
K466-3
K466-4
K466-7
K466-5
K466-6
S18653
M16325
K466-7
S18653
—
K466-8
S18645-2
M15608
K466-10
S18653
M15608
3
Fittings
Connector
4
Tools
12
T10642-166 (a)
T14557-7 (b)
T13777-4 (c)
T11563-4 (a)
S18845 (b)
—
T11563-4 (a)
S18845 (b)
T11563-4 (a)
S18845 (b)
—
T10642-166 (a)
T14557-7 (b)
T13777-4 (c)
T11563-4 (a)
S18845 (b)
—
T11563-4
S18845
—
T11563-4
S18845
—
T11563-4 (a)
S18845 (b)
T10642-166
T14557-7
T13777-4
T11563-4
S18845
—
T11563-4
S18845
Gun Connector Included Parts
2
3a
200
200 amps
1b
1a
4a
1a
4a
2
4b
2
1c
4b
1
4b
4a
3b
3c
K466-1 K466-2
1b
1a
K466-3 K466-4
1a
2
3c
4a
1
4a
1b
4b
4a
4b
3a
3b
1b
1c
2
4b
K466-5 K466-6
2
4a
1
1
4b
K466-7 K466-8
2
4b
4a
K466-10
4b
1
2
1b
3a
3c
3b
4a
13
14
g
Choose Your
Consumables
S
T
E
P
4
Insulator for
Adjustable
Slip-on Nozzle
Gassless
Nozzle
Spot Nozzle
Standard
Duty
Heavy
Duty
Tapered
Notched
Adjustable
Slip-on
Nozzle
Contact Tips (200 amps)
TIP
QTY. WIRE DIAMETER
.025"
(0.6mm)
Standard
Duty
Heavy
Duty
Tapered
Notched
(Alum.)
10 = Qty. in Pack Bulk = Qty. of 100
10
Bulk
10
Bulk
10
Bulk
10
Bulk
KP14-25
KP2020-6B1
KP14-25-B100
KP2020-6B2
—
—
—
—
KP14T-25
KP2022-5B1
KP14T-25-B100
KP2022-5B2
—
—
—
—
(1)
.030"
(0.8mm)
KP14-30
KP2020-7B1
KP14-30-B100
KP2020-7B2
—
—
—
—
KP14T-30
KP2022-6B1
KP14T-30-B100
KP2022-6B2
KP2010-3B1
Recommended for aluminum wire weldin
(1)
—
—
—
.035"
(0.9mm)
KP14-35
KP2020-1B1
KP14-35-B100
KP2020-1B2
KP14H-35
KP2021-1B1
KP14H-35-B100
KP2021-1B2
KP14T-35
KP2022-1B1
KP14T-35-B100
KP2022-1B2
KP2010-4B1
—
—
—
KP14H-40-B100
KP14T-40-B100
(1)
.040"
(1.0mm)
KP14-40
KP2020-8B1
KP14-40-B100
KP2020-8B2
KP14H-40
KP2021-6B1
KP2021-6B2
KP14T-40
KP2022-7B1
KP2022-7B2
—
—
—
—
Part Number
Previous Part Number
.045"
(1.2mm)
KP14-45
KP2020-2B1
KP14-45-B100
KP2020-2B2
KP14H-45
KP2021-2B1
KP14H-45-B100
KP2021-2B2
KP14T-45
KP2022-2B1
KP14T-45-B100
KP2022-2B2
—
—
—
—
3/64"
(1.2mm)
KP14A-364
KP2020-9B1
KP14A-364-B100
KP2020-9B2
KP14H-364
KP2021-7B1
KP14AH-364-B100
KP2021-7B2
KP2010-5B1
(1)
—
—
—
—
(1)
—
—
—
Gas Nozzle/Insulator (200 amps)
Part Number
NOZZLE QTY. NOZZLE DIAMETER
.38"
(9.5mm)
Adjustable
Slip-on
Nozzle
Insulator
for Adj.
Slip-on
Nozzle
Gasless
Nozzle
Spot
Nozzle
1 = Qty. in pack Bulk = Qty. of 25
1
(1)
Bulk
1
Bulk
1
Bulk
1
Bulk
KP22-37
KP1935-3
KP22-37-B25
KP1935-3B1
KP32
KP2025-1
KP32-B25
KP2025-1B1
KP1947-1
—
—
—
KP21-62-FAS
KP1956-1
—
—
(1)
Requires KP32, Nozzle Insulator Assembly
.50"
(12.7mm)
KP22-50
KP1935-2
KP22-50-B25
KP1935-2B1
KP32
KP2025-1
KP32-B25
KP2025-1B1
KP1947-1
—
—
—
KP21-62-FAS
KP1956-1
—
—
Previous Part Number
.62"
(15.9mm)
KP22-62
KP1935-1
KP22-62-B25
KP1935-1B1
KP32
KP2025-1
KP32-B25
KP2025-1B1
KP1947-1
—
—
—
KP21-62-FAS
KP1956-1
—
—
g
200
200 amps
Gas
Diffuser
Assembly
45º Gun Tube
60º Gun Tube
82º Gun Tube
Gas Diffuser (200 amps)
Diffuser
Gas
Diffuser
Assembly
5 = Qty. in Pack Bulk = Qty. of 25
QTY. WIRE DIAMETER
.025"–.030"
(0.6–0.8mm)
5
Bulk
KP52-25
KP2026-2
KP52-25-B25
KP2026-2B1
Gun Tubes (200 amps)
TUBE
45º
60º
82º
Gun Tube
Insulator
1 = Qty. in pack Bulk = N/A
QTY. RATED (AMPS)
1
Bulk
1
Bulk
1
Bulk
1
Bulk
KP2028-1
200
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Previous Part Number
.035"–.045"
(0.9–1.2mm)
KP52FN
KP2026-3
KP52FN-B25
KP2026-3B1
(1)
Permits use of 300 and 400 fixed nozzles with 200 amp gun and cable
(2)
Permits use of 100 amp contact tips with 200 amp gun and cable
(1)
(1)
(1)
KP2051-1
KP2051-1B1
.025"–.045"
(0.6–1.2mm)
(2)
—
(2)
—
300 400
KP1929-2
—
—
—
KP1928-2
—
—
—
—
—
—
—
—
—
—
—
NOTE: 300 & 400 amp gun tubes can be used with 200 amp guns.
Use corresponding amperage gas diffuser, nozzle, and nozzle insulator.
Part Number
(2)
or
KP52FN-B25
or
KP1929-1
KP1928-1
KP1941-1
(1)
KP52FN
KP2026-3
KP2026-3B1
—
—
—
—
—
—
—
—
—
—
—
—
—
(1)
Cable Liner
Cable Liner (200 amps)
LINER
15' Length
(trim to fit for)
- 10' -
- 12' -
- 15' -
1 = Qty. in Pack Bulk = Qty. of 10
QTY. DIAMETER
.025"– .030"
(0.6–0.8 mm)
1
Bulk
KP42-25-15
KP1934-2
KP42-25-15-B10
KP1934-2B1
Part Number
Previous Part Number
Aluminum
.030"– .035"
(0.8– 0.9 mm)
KP42-3035-15
KP1934-3
KP42-3035-15-B10
KP1934-3B1
(1)
Recommended for aluminum wire welding.
Recommended maximum cable len
.035"– .045
(0.9–1.2 mm)
KP42-4045-15
KP1934-1
KP42-4045-15-B10
KP1934-1B1
th for aluminum is 10 ft. (3.0m).
.035"– 3/64"(1)
(0.9–1.2 mm)
KP44N-3545-15
KP1955-1
KP44N-3545-15-B10
KP1955-1B1
(1)
15
Amperage Rating
60% Duty Cycle
CO2Shielding Gas
300 A
Wire Diameter Range
.025” - 5/64”
(0.6 mm - 2.0 mm)
Net Weight
9 - 12 lbs.
(4.0 - 5.4 kg)
16
Loading...