Lincoln Electric Magnum User manual

Arc Welding Guns
for Semiautomatic Gas-Shielded Welding
Optimize Your Welding System!
TM
Featuring Our New
Magnum EXPRESSTM Package
(see page ...24)

Wire
Power Source
Feeder Gun Connector Gun Gun Consumables The Lincoln Welding Arc
A Total System Focused on Arc Welding
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.
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Critical Links:
A Systems Approach
Why Choose a Lincoln
Welding System?
Productivity, Ease-of-Use, Peace-of-Mind
•
Technical assistance, cost reduction
and productivity programs
•
Hundreds of welding field sales engineers
•
Thousands of knowledgeable and
responsive Lincoln distributors
•
Innovative approach to product
designs and customer solutions
•
Global presence

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• 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
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.
Magnum
Guns

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!
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Not Only Will Magnum Guns Optimize
Your Welding System, But They’ll Also Increase…
Don’t Be Under Gunned!

Gun Consumables
Match an Industry
Standard Design
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
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
Rugged Strain Relief System
• Enhances feedability by reducing acute gun cable angles
• Protects your cable liner
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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

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.
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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
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-MateTM (Euro)
Miller®
Tweco-Adapted®
Hobart®
ESAB®
Tubes/Goosenecks
60º
45º
82º
Contact Tips
Standard
Heavy Duty
Tapered
Notched
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.
Customize Your Gun!
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Multiple nozzle & contact tip types for specific applications

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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 that simply drives
you to the right gun for your application.
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.
Use this quick and easy four step process to
select the right gun and all your accessories

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Choose a Gun with the Right
Operating Amperage Range
S
T
E
P
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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.
Select the 400 for most .045”, .052” or 1/16” MIG,
UltraCore™ or Metalshield®(gas-shielded) operations.
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®or UltraCore™ (gas-shielded
flux-cored) applications.
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®140T, 140C,180T and 180C. Includes gun
connector.
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 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 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.

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Amperage Rating
60% Duty Cycle
CO2Shielding Gas
200 A
Net Weight
9 - 12 lbs.
(4.0 - 5.4 kg)
Wire Diameter Range
.025” - .045”
(0.6 mm - 1.2 mm)
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