Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii; ELECTRIC SHOCK can kill.
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TABLE OF CONTENTS
TABLE OF CONTENTS Page General Description ..................................................................................................... Section A Installation .................................................................................................................... Section B Conne...
Page 8 - GENERAL DESCRIPTION
GENERAL DESCRIPTION MAGNUM 300 & 400 A-1 A-1 GENERAL DESCRIPTION The Magnum™ 300 amp and 400 amp GMA gun andcable assemblies have been designed to meet NEMAspecification EW3 for welding with steel electrodeusing the GMAW (gas metal arc welding) and gas-shielded FCAW (flux-cored arc welding) proc...
Page 11 - MAGNUM 400 SHORT NECK (400 amperes at reduced duty cycle) 40% WITH CO
GENERAL DESCRIPTION MAGNUM 300 & 400 Description Gun Contact Tips Gas Product Cable Wire Size Standard Diffuser Gas Cable Gun Tube Number Length (m) in. (mm) Duty Assembly Nozzle Insulator Liner 60° K541-1 10 ft. .035 (0.9) KP2020-1B1 (3.0) .045 (1.2) -2B1 KP2024-1 KP1932-1 KP2023-1 KP1933-1 KP1...
Page 12 - INSTALLATION; CONNECTOR KIT INSTALLATION TO GUN CABLE
INSTALLATION MAGNUM 300 & 400 Read this entire installation section before youstart installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals orinternal wiring. • Insulate yourself from the work and ground. • Always wear dry insulat...
Page 14 - CAUTION
INSTALLATION f. Screw the gas diffuser onto the end of the gun tube and tighten with the wrench provided. g. Tighten the set screw in the side of the gas diffuser against the cable liner using the Allen wrench pro-vided. This screw should only be gently tightened.Overtightening will split or collaps...
Page 15 - CONNECTION TO FEEDER
INSTALLATION MAGNUM 300 & 400 CONNECTION TO FEEDER CONNECTION TO LINCOLN FEEDERS Gun cable assemblies which were assembled with aK466-1 or -8 Connection Kit will connect easily to anyLincoln LN-7, LN-8, LN-9, SP-200 or LN-25 feeder. a. Check that the drive roll(s) and feeder guide tubes are appr...
Page 17 - OPERATION; ELECTRODES AND EQUIPMENT; AVOIDING WIRE FEEDING PROBLEMS
OPERATION ELECTRODES AND EQUIPMENT The Magnum 300 and Magnum 400 guns and cableshave been designed for use with Lincoln L-50 andL-56, solid steel wire electrodes for the GMAWprocess and Lincoln Outershield cored electrodes forthe gas-shielded FCAW process. Refer to the appro-priate Lincoln Process a...
Page 18 - MAINTENANCE; GUN TUBES AND NOZZLES
MAINTENANCE REMOVAL, INSTALLATION AND TRIMMINGINSTRUCTIONS FOR MAGNUM LINERS NOTE: The variation in cable lengths prevents the interchangeability of liners. Once a liner has been cutfor a particular gun, it should not be installed in anoth-er gun, unless it can meet the liner cut off lengthrequireme...
Page 22 - THREAD SIZES FOR MAGNUM 300 & 400 CONSUMABLES
MAINTENANCE MAGNUM 300 & 400 THREAD SIZES FOR MAGNUM 300 & 400 CONSUMABLES D-5 D-5
Page 23 - TROUBLESHOOTING; PROBLEMS
TROUBLESHOOTING MAGNUM 300 & 400 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting...
Page 25 - NOTES