Operator’s Manual
Model SPG
Spool Gun
Spool Gun
WARNING: Do not assemble, install, or operate this equipment without reading ALL of this manual
and the safety precautions and warnings illustrated in this manual.
KDAR Company Tel: 314-692-8555
1 Mulch Lane Fax: 314-692-8578
St. Louis, MO 63044 Web Site: www.hotmaxtorches.com
SAFETY PRECAUTIONS AND WARNINGS
PLEASE READ BEFORE USING EQUIPMENT
WARNING
ELECTRIC SHOCK CAN KILL.
The input circuits are live and hot when the power is on
Do not touch live electrical parts
Wear dry, hole free insulated work gloves and body protection when operating
Do not touch torch components if in contact with the work piece or ground
Always turn off power before cleaning, checking, or changing parts
Properly ground this piece of equipment per state and federal requirements
Inspect and replace any worn or damaged torch cables or leads
Keep all panels and covers securely in place
Keep away from the torch tip and weld arc when trigger is pressed
Ground the metal or work piece to the ground cable (Earth Clamp)
Never dip the tip into water to cool or attempt to use welder in or under water
This DC equipment holds a lot of power in the off position, before touching, make sure voltage is
near zero on input capacitors before touching any parts.
Keep children away from this equipment
Protect yourself and others from possible injury
Pacemaker wearers should consult with their doctor before operating
Read and follow all instructions in this manual before operating
All installation, operation, and maintenance procedures are to be per-
formed only by qualified individuals
ARC RAYS CAN BURN SKIN AND EYES
Arc rays when welding produce intense ultraviolet and infrared rays that can burn skin and eyes
Wear face protection, either helmet or shield, when operating. ANSI Z49.1 approved shade #9 rec-
ommended for all cutting currents less than 300 amperes. The lens should conform to ANSI Z87.1
standards for testing.
Wear approved safety glasses with side shields under the face protection
Warn others not to stare at the arc as it can cause damage to the eyes. Provide barriers to protect
other workers in the area from the arc while operating
Wear flame resistant gloves, clothing, and shoes when operating
FUMES AND GASES CAN BE HAZARDOUS
Arc welding produces fumes and gases and breathing these gases is hazardous to your health
Keep your head out of the fumes and do not breath the fumes while welding
Work only in a confined area if it has sufficient ventilation, or while wearing an air supplied respi-
rator. Fumes from welding deplete the oxygen supply and can be harmful. Always be sure there is
ample breathing air
Read the MSDS sheets and the instructions from manufacturers for metals to be welded, coatings,
and cleaners
Do not use the welder near hydrocarbon vapors coming from degreasing, cleaning, or spraying
operations. The heat and rays can react with solvent vapors to create the gas phosgene, a very toxic
gas and other irritating gases
Do not weld coated metals, such as galvanized, lead, or cadmium plated steel. Before welding, all
plating must be removed. The area must be well ventilated or an air supplied hood must be used.
The coatings and chemicals when burned cause highly irritating and toxic fumes.
Do not weld containers with toxic, flammable, or reactive elements stored in them. They must be
emptied and properly prepared before welding.
KDAR Company 1
WELDING SPARKS CAN CAUSE INJURY, FIRE, OR EXPLOSION
Remove all flammable materials from the welding area
Always have a charged fire extinguisher available in the welding area
When not welding make sure the welding tip is not grounded, this causes a heat build up and possi-
ble fire
Avoid welding near hydraulic lines, fuel lines, electrical cords, air hoses, or welding guns and ca-
bles
Sparks and hot metal fly out from the work area when welding, wear approved safety glasses with
side shields under approved helmets, wear proper body and hand protection, and wear flame resistant ear plugs to keep sparks from entering the ears
CYLINDERS CAN EXPLODE IF DAMAGED
Gas cylinders contain gas under very high pressure. If damaged they can result in that cylinder ex-
ploding. Gas cylinders are a major part of metalworking and must be treated with care.
Protect gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs
Always keep cylinders in an upright position securely fastened to a fixed support
Valve protection caps should always be in place and hand tight except when the cylinder is in use
Keep all cylinders away from any welding or electrical circuits
Never allow the arc from a welder to contact a cylinder
Never cut any type of pressurized cylinder, an explosion could result
Always turn your face away from the valve when opening the cylinder
Read and follow all instructions on compressed gas cylinders, associated equipment, and CGA pub-
lication P-1 listed in the Safety Standards before using
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS
Electric current used in arc welding can create Electro-Magnetic Fields (EMF)
Magnetic fields can affect pacemakers and wearers should avoid proximity to EMF. Wearers need to
contact their doctors before operating this type of equipment
Exposure to EMF during operation of this equipment may have other health effects which are not
yet known
Route the work and torch cables together and not around your body
Do not place your body between the torch cable and the ground cable. They both need to be on the
same side of your body when operating
Do not work next to the welding machine
ELECTRICALLY POWERED EQUIPMENT
Disconnect power source or disconnect the switch at the fuse box before working on any equipment
Only install equipment using the US National Electrical Code, all local codes, and the manufactur-
er’s recommendations
Ground the equipment in accordance with the US National Electrical Code
HOT PARTS CAN CAUSE SERIOUS BURNS
Do not touch hot parts without wearing protection.
Allow the torch to cool sufficiently before working with parts that could potentially be hot.
KDAR Company 2
NOISE CAN DAMAGE HEARING
Prolonged noise exposure from welding equipment can cause damage if levels of noise exceed the
OSHA standards
Wear approved hearing protectors
Warn other workers nearby of the high noise level and hazard
CALIFORNIA PROPOSITION 65 WARNINGS
Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause
birth defects, and in some cases, cancer. (California Health and Safety Code Section 25249.5 et seq.)
PRINCIPAL SAFETY STANDARDS
AMERICAN WELDING SOCIETY
AWS C5.2, Recommended Practices for Plasma Arc Cutting
AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting
OSHA STANDARDS
OSHA 29 CFR 1910, Safety and Health Standards
NATIONAL FIRE PROTECTION ASSOCIATION
NFPA Standard 70, National Electric Code
NFPA Standard 51B, Cutting and Welding Processes
AMERICAN NATIONAL STANDARDS INSTITUTE
ANSI Standard Z87.1, Safe Practices for Occupation and Educational Eye and Face Protection
ANSI Standard Z49.1, Safety in Welding and Cutting
CGA Publication P-1
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Specifications
Model SPG - Spool Gun
Welding Process Aluminum/Flux Core/Steel/Stainless Steel
Wire Sizes .030 or .035 (.8 or .9 mm)
Spool Size 4 Inch Diameter
Duty Cycle at Rated Welding Current See Welder Specifications
Weight 7 lbs
Cable Length 20.0 Feet
Cooling Method See Welder Specifications
Table 1
Features & Benefits
Plug It, Switch It, Use It.
20’ Gun Lead
See Through Wire & Drive Cover
Adjustable Wire Tension
Holds 4” Spool
Welds Up To 1/4” Aluminum
Fits 125, 135, 175 and 250 Amp Hot Max
Welders Equipped With Pre-Wired Spool Gun
Switch.
Welds with Aluminum, Stainless Steel, Flux
Core and Solid Steel Wire.
2 Year Limited Warranty
Notes
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Safety Considerations
Warning
Electric Shock Can Kill
Only qualified personnel should attempt to install this equipment.
Turn off the input power at the power panel or disconnect switch and discharge capaci-
tors before working inside the equipment.
Take care not to touch electrically hot parts
Make sure the unit is switched off before plugging it into a the power outlet.
Installation/Setup
Package Contents
1. Spool Gun and Lead Assembly
2. Spool Cover
3. 1 Lb Spool .030 Aluminum Wire
4. Spool Tension Spring
5. Spool Tension Adjustment Nut
6. Shielding Nozzle
7. .030 Contact Tip
8. Manual
2
7
6
1
Notes
3
4
5
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Installation/Setup
Selecting A Location
The WFG Welder should be placed where clean cool air can easily flow through the vents in the front of the
unit. Dirt and dust can be drawn into the unit resulting in excessive operating temperatures and shutdowns,
therefore, dirt and dust around the unit should be kept to a minimum.
The WFG Welder should be placed on a stable, level surface suitable to hold the unit’s weight.
Components and Controls
1. Trigger Assembly
2. Spool Tension Knob
3. Spool Tension Spring
4. Shielding Gas Nozzle
5. Contact Tip
6. Wire Tension Adjustment Knob
7. Wire Drive Roll
8. Idle Roll
9. Lead Cable
10. Straight Gun Tube
11. Spool Cover
12. Spool Cover Retaining Knob
5
7
8
4
6
Notes
10
1
9
2
12
3
11
6 KDAR Company
Installation/Setup
Warning
Always unplug the welder before connecting or disconnecting the Ground Clamp cable
and/or the Gun Cable.
Ground Clamp & Spool Gun Connection
Ground Cable Attachment: Follow instr uctions
provided with the welder
Gun Installation
1. Insert the male connector on the gun cable into the
gun cable connection port (1). With the connector
all the way in the connector block tighten the wing
nut on the top of the connector block to secure the
gun.
2. Connect the gun lead terminal to the gun lead con-
nector (2).
3. Switch the gun selector switch to the spool gun
option (3).
Welder Set Up—Gas
1. Set the welder for GMAW welding with positive
electrode polarity, connect the cable coming from
the wing nut on the connector block to the positive
(+) output terminal and the ground lead to the negative (-) output terminal. Make sure all connections are tight. See welder manual for gas connection instructions.
Welder Set Up—Flux Core
1. Set the welder for FCAW welding with negative
electrode polarity. The cable coming out of the
wing nut (6) on the connector block is attached to
the negative (-) output terminal and the ground
lead is connected to the positive (+) terminal.
3
1
2
Notes
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Installation/Setup
Loading Wire
1. Remove the shielding gas nozzle and the contact tip.
2. Remove the spool cover by turning the spool
cover retaining knob counterclockwise.
3. Remove the spool retention spring and knob by
turning the knob counterclockwise.
4. Place the spool of wire on the wire spindle
with the wire coming off of the top of the spool
toward the nozzle end.
5. Replace the retention spring and knob and
tighten until the spool does not turn freely. Do
not over tighten, the spool should be able to
turn with about 2 pounds of pull on the wire.
6. Loosen the wire tension adjustment knob.
7. Extend a few inches of wire, cut off bent or
kinked wire. Straighten the wire by back bending the wire.
8. Guide the wire through the wire guide inlet to
the drive roll grove.
9. Once past the drive roll, guide the wire into the
tube liner.
10. Continue pushing the wire through until it ex-
tends 2 inches past the gas diffuser.
11. Slide the contact tip over the wire and thread it
into the gas diffuser.
12. Slide the shielding gas nozzle over the wire
and contact tip and thread it onto the gas diffuser.
13. Tighten the spool tension adjustment knob to
increase the pressure of the drive wheel on the
wire being fed.
14. Reinstall the spool cover and cover retaining
knob.
15. Turn the welder on pull the trigger to insure
wire feeds properly.
16. The gun is ready to begin welding.
17. See welder manual for power and wire feed
control information.
Warning
Electric Shock Can Kill
Do not touch live electrical parts
of the electrode with skin or wet
clothing.
Insulate yourself from work and
ground.
Always wear insulated gloves and keep them
dry.
Fumes & Gases Can Be Hazardous
Welders and Spool Guns should
only be used in a well ventilated area
or with an exhaust system.
Keep your head away from the fumes.
Arc Rays Can Burn Skin and
Eyes
Always were eye, ear and body
protection.
Cutting Sparks Can Cause In-
jury, Fire , or Explosion
Do not use near flammable mate-
rial.
Do not weld on containers that have held com-
bustibles.
KDAR Company 8
Troubleshooting
Problem Possible Cause Action
No wire feed. 1. Machine is off or unplugged. 1. Turn on or plug in machine.
2. Selector switch not set to spool
gun.
3. Contact tip burn back. 3. Replace contact tip.
4. Bird nest (wire tangled in gun). 4. Remove bird nest & re-feed wire.
5. Undersized contact tip. 5. Replace with correct sized tip.
Intermittent wire feed when trigger is
pulled.
2. Drive roll has become galled with
3. Wire has become kinked. 3. Manually pull wire through until
Wire does not feed steady. 1. Wire Tension Knob not adjusted 1. Adjust tension on drive wheel by
1. Wire is binding inside the gun. 1. Check that wire is properly aligned
metal.
2. Flip switch to spool gun.
inside the gun.
2. Clean or replace the drive roll.
kinked section is freed.
Poor weld appearance (porosity or
Oxidized surface).
No or low gas flow.
6. Regulator set improperly. 6. Set flow to 30-60 SCFH.
1. No gas flow. 1. See below.
2. Low gas flow. 2. See below.
3. Improper or contaminated shielding gas.
4.Excessive air flow or windy environment.
5. Wrong electrode polarity. 5. Wire for electrode positive.
1. Out of gas. 1. Refill or replace tank.
2. Gas supply is turned off. 2. Turn on gas supply.
3. Gas supply is disconnected. 3. Connect gas supply.
4. Cable kinked or flattened. 4. Straighten cable.
5. Gas leak. 5. Find and repair leak.
3. Confirm proper gas mixture is being used. Change gas and check for
improved appearance.
4. Change welding location or shield
the work area.
Note: For problems that can not be corrected by following the troubleshooting procedures listed above; please contact KDAR Company. NEVER attempt to work on any part
of the spool gun not listed above. Unauthorized repairs to the unit may result in danger to
the operator and will void the factory warranty.
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Notes
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Warranty
KDAR Company, and its affiliates, warrants that
the spool gun covered under this warranty is free
from defects in material and workmanship for two
years from the date of purchase. This warranty is
extended to the original purchaser who uses the
product in a consumer application (personal, residential or household usage). All welders covered
under this limited warranty which are used in
commercial applications (i.e. income producing)
are warranted to be free from defects in material
and workmanship for 2 Years from the date of
original purchase when properly registered. The
product covered under this warranty is the SPG
Spool Gun.
KDAR Company, and its affiliates, will repair or
replace, at KDAR’s sole discretion, parts found to
be defective in material or workmanship within
the warranty period. Warranty service will be
scheduled according to the normal work flow and
business hours of the service center doing the
work as well as the availability of replacement
parts. All decisions from KDAR Company regarding this limited warranty shall be final.
Original Purchaser’s Responsibility:
1. Retain the original cash register receipt as
proof of purchase.
2. Follow manual instructions regarding the care
and operation of your welder.
3. If warranty work is required, DO NOT RE-
TURN THIS WELDER TO THE RETAILER. Contact KDAR Company for instr uc-
tions. Visit www.hotmaxtorches.com or call
KDAR Company M-F 8AM-5PM CST to locate the nearest Authorized Service Center.
Not Covered:
1. Transportation charges for sending or delivering the welder to the Authorized Service Center or returning the repaired or replacement
welder back to the customer. These charges are
the responsibility of the customer.
2. Damages caused by ordinary wear, abuse, rain,
freeze damage, negligence, accident or failure
to operate or maintain the welder in accordance
with the instructions in the operator’s manual
supplied with the welder.
3. Damage caused by unauthorized repair or al-
terations.
Exclusions and Limitations:
KDAR Company makes no other warranty of
any kind, express or implied. Implied warranties, including warranties of merchantability
and of fitness for a particular purpose, are
hereby disclaimed. The warranty service described above is the exclusive remedy under
this warranty; liability for incidental and conse-
quential damages is excluded to the extent per-
mitted by law.
This warranty gives you specific legal rights, and
you may have other rights which vary from state to
state. Some states do not allow a disclaimer of implied warranties, or the exclusion of incidental and
consequential damages, so the above disclaimers
and exclusions may not apply to you.
For warranty service or to obtain service parts
or accessories:
Call: 314-692-8555 M-F 8-5 PM, CST
Visit: www.hotmaxtorches.com
Write: KDAR Company
1 Mulch Lane
St. Louis, MO 63044
KDAR Company
1 Mulch Lane
St. Louis, MO 63044
Phone: 314-692-8555 Fax: 314-692-8578
Rev. 1—03/28/2013
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