Lincoln Electric IM10168 User Manual

Operator’s Manual

For use with machines having Code Numbers:

K3355-[ ] K3356-[ ] K3357-[ ] K3358-[ ]

MAGNUM ®PRO AL Gun

For use with machines having Code Numbers:

K3355-[ ] K3356-[ ] K3357-[ ] K3358-[ ]

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10168 | Issue D ate Jul-13

SPECIAL SITUATIONS

SAFETY

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NOTES

TABLE OF CONTENTS

MAGNUM

PRO AL Gun

Page

Installation ...........................................................................................................................Section A

Technical Specications

Support Equipment Required............................................................................................ A-1

Installation Instructions ............................................................................................................ A-1

Gun Lead Connections...................................................................................................... A-3

Coolant Connections ......................................................................................................... A-3

Gun Tube Removal/Installation ......................................................................................... A-3

Lead Assy Spiral Wrap Installation .................................................................................... A-4

.......................................................................................................... A-1

Operation

............................................................................................................................ Section B

General Description................................................................................................................. B-1

Controls and Settings .............................................................................................................. B-1

Poentiometer ..................................................................................................................... B-1

Micro Switch ...................................................................................................................... B-1

Trigger Sensitivity .............................................................................................................. B-1

Sensitivity Adjustment ....................................................................................................... B-1

Drive Roll and Idler Rolls ......................................................................................................... B-1

Drive Roll Installation and Removal .................................................................................. B-1

Idler Roll Installation and Removal .................................................................................... B-1

General Options/Accessories

.......................................................................................... Section C

Cable Covers........................................................................................................................... C-1

Contact Tips ............................................................................................................................C-1

Nozzles.................................................................................................................................... C-1

Gun Tubes ............................................................................................................................... C-1

Maintenance ....................................................................................................................... Section D

Recommended Spare Parts List ............................................................................................. D-1

Troubleshooting

.................................................................................................................Section E

How to Use Troubleshooting Guide......................................................................................... E-1

Troubleshooting Guide ............................................................................................................ E-2

Diagrams .............................................................................................................................Section F

Diagrams / Parts List ................................................................................................................F-1

Electrical ...................................................................................................................................F-8

MAGNUM

PRO AL Gun

INSTALLATION

TECHNICAL SPECIFICATIONS - Magnum

Pro AL Gun AC (K3356, K3355), WC (K3358, K3357)

SPECIFICATIONS

Make/Model

K3356 - [ ] 7-Pin Air Cooled 800 IPM (20.3 mpm)

K3358 - [ ] 7-Pin Water Cooled 450 Amps/25 Volts

K3355 - [ ] 12-Pin Air Cooled 225 Amps/25 Volts

K3357 - [ ] 12-Pin Water Cooled 450 Amps/25 Volts

WIRE CAPACITY

.030 - 1/16" (0.8mm - 1.6mm) aluminum and cored wire

Controller Cable

Air or Water Cooled

Wire Speed AMPS Duty Cycle

225 Amps/25 Volts 60% Max. at rated feeder Input Voltage (42VAC)

SUPPORT EQUIPMENT REQUIRED

•

• Regulated gas supply and hoses.

• Properly sized power leads from power source to wire feeder and ground.

• Water source and hose capable of providing a minimum of 1 quart (.95 liter) / min.

at 45 p.s.i. when using water cooled guns.

(All ratings are using Argon Gas)

A - 1

MAGNUM

PRO AL Gun

GUN LEAD CONNECTIONS

POWER CABLE

Air Cooled

A #2 power cable is used on the Lincoln Electric Magnum® Pro

AL Gun.

• The gun and Power Pin ends are threaded into the gun body.

• These connections utilize a conductive sealant and are

Water Cooled

• Lincoln Electric Magnum

• When water is used with this cable and the #10 water cooled

• The gun end is threaded into the gun body.

• These connections utilize a conductive sealant and are

CONDUIT

• The Lincoln Electric Magnum® Pro AL Gun comes standard

•

• Both ends of the conduit are secured into the Power Pin

GAS HOSE

•

• The opposite end of the BLACK hose is pushed over a

• The hose retainer is re-usable and can be removed and

CONTROL CABLE

• A multi-conductor control cable is used on the Lincoln Electric

tightened with torque requirements of 100 + 5 IN-LB.

Pro AL Gun

utilizes a power/water cable with a #6 AWG cable inside a 5/16” diameter hose.

gas nozzle (P/N KP3375-1), the system is rated at 450 amps @ 60% duty cycle.

tightened with torque requirements of 100 + 5 IN-LB.

with a poly-lined conduit, for feeding aluminum wire.

end.

connector with a set screw.

end of the gun body and secured by twisting the hose retainer to the end of the hose (shown below).

re-installed as needed.

Magnum

Pro AL Gun 7 and 12 pin.

water cooled gun

COOLANT CONNECTIONS

• The ends of the coolant hose push the end of the rear connector and are secured by twisting the hose retainer to the end of the hose.

• The hose retainer is re-usable and can be removed and re-installed as needed.

• The BLUE coolant supply hose pushes over a and is secured by twisting the hose retainer to the end of the hose.

INSTALLATION

• The opposite end of the BLUE hose pushes into a threaded

•

in the Power Manifold.

• The opposite end of the RED hose pushes into a threaded return hose of the coolant recirculator.

• hoses are standard left-hand thread.

S29830-14

5/16” Hose Retainer

COOLANT RECOMMENDATIONS

• Use coolant (Aluminum protection),which does not contain reactive sulphur or chlorine and does not react with copper, brass or aluminum.

• Coolant is available in quantities of 1 gallon, 5 gallon (P/N KP3379-1), or a case of 4 gallons each (P/N KP3379-4).

• (1 qt/min) between 35 and 45psi. Contact the re-circulator

• pressure.

S29830-97*

Left-Hand Threaded Fitting

*Must be ordered together

S29830-96*

Nipple

GUN TUBE REMOVAL/ INSTALLATION

WARNING: Do not attempt to weld without the gun tube being tightly secured in the gun body, or damage to the gun tube or body may result.

a. To remove the gun tube assembly, loosen the taper lock nut until

it is clear of the threads. Pull gun tube out of the gun body.

b. To replace a gun tube assembly, open the drive and idler roll

door and seat the gun tube assembly until the plastic liner is almost touching the drive and idler roll (Figure 1) and the rear

block (Figure 2).

c. Take care not to damage the “O” rings when inserting into the

body. You should hear an audible "click" when the gun tube is inserted and seated.

d. T

cannot rotate.

Gun Tube Rotation

a. To rotate a gun tube assembly, loosen the taper lock nut

assembly no more than 1 turn.

b. Rotate gun tube to the position of your choice and retighten taper

Copper face of gun tube

Plastic liner

A - 2

Figure 2Figure 1

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