.030 - 1/16" (0.8mm - 1.6mm) aluminum and cored wire
Controller
Cable
Air or Water
Cooled
Wire SpeedAMPSDuty Cycle
225 Amps/25 Volts60%
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
Page 9
®
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
Page 10
®
MAGNUM
PRO AL Gun
LEAD ASSY SPIRAL WRAP
INSTALLATION
GUN END, AIR COOLED
INSTALLATION
Spiral Wrap p/n: S29830-94
Spiral Wrap
Conduit
Power Cable
Conduit
A - 3
Page 11
®
MAGNUM
PRO AL Gun
GENERAL DESCRIPTION
The Lincoln Electric Magnum® Pro AL Gun gun maintains a
constant, steady, uniform wire feed speed. The constant push
exerted by the motor in the cabinet, combined with the pull of the
the wire conduit. The 24VDC gun motor is controlled by a three
and three-quarter (3 3/4) turn potentiometer in the gun handle.
CONTROLS AND SETTINGS
OPERATION
DRIVE ROLL AND IDLER ROLLS
Drive Roll Installation and Removal:
NOTE: Neither of the handles needs to be removed to access
the Drive or Idler Rolls.
1. Pull the Cam Lever away from the idler roll. This will relieve
the pressure against the drive roll.
2. Align the Drive Roll Removal Tool (P/N K3987-1) over the
Potentiometer:
• The laterally-positioned potentiometer is located in the gun
body, providing up to 800 ipm with 3 3/4 turns.
Micro Switch:
• The micro switch assembly consists of the micro switch, and
leads.
Trigger Sensitivity:
• The amount of trigger level travel can be shortened for a
"quicker" or "more responsive" action.
• A more sensitive trigger lever is produced by reducing the
gap between the trigger lever and the micro switch lever.
• By turning-in the Trigger Sensitivity Adjustment Screw, it
closes the gap between the trigger lever and the micro switch
lever - this enables the operator to increase the sensitivity of
the trigger lever.
Sensitivity Adjustment:
• With the wire feeder turned on (with or without welding wire
loaded), turn the screw in until the micro switch is activated.
• Once activated, the gun and wire feeder motors will begin
feeding wire.
• Retract the screw accordingly until the system is deactivated
and adjusted to the operators' liking.
hand or on a table top, with the other hand give the Removal
Tool a quick snap-turn in the CLOCKWISE DIRECTION.
3. Once the drive roll is loose, continue to spin drive roll in the
clockwise direction to remove the drive roll from the gun.
4. Install a new drive roll on the left-hand threaded shaft. The
drive roll will self-tighten when it is feeding wire.
Idler Roll Installation and Removal:
Please use the following drawing as a guide when needing to
reassemble prior to installing into the welding gun.
Micro Switch
Lever
Set Screw
Screw adjusted out of trigger, pre-setting the micro switch lever for
shorter trigger motion sensitivity.
B - 1
Page 12
ACCESSORIES
MAGNUM
®
PRO AL Gun
GENERAL OPTIONS/
550A Series Consumable Products
ACCESSORIES
KP3989-1 Insulated Groove Drive Roll Kit - For
.035" (0.9mm) dia. and .040" (1.0mm) dia.
aluminum wire. Includes insulated groove drive
roll and insulated idler roll assy.
KP3989-2 Insulated Groove Drive Roll Kit - For 3/64" (1.2mm) dia.
and .062" (1.6mm) dia.aluminum wire. Includes insulated groove
drive roll and insulated idler roll assy.
S29830-45 Handle Kit - Includes left and right handles, screws and
drive roll door.
S29830-48 Trigger Kit - Trigger adjustment kit includes a spring
and sensitivity adjustment screw replacement.
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
115/42 VAC Control fuse in feeder/Control
No wire feed at gun.
Wire feeds, but welding wire is not
energized.
Wire feeds erratically.
Wire feeds one speed only.
Wire walks out of drive rolls.Idler roll upside-down.Place groove in idler roll toward top.
box blown.
Micro-switch defective/not being activated.Replace switch. Check switch for operation.
Broken electrical cable.Check micro switch wires for continuity.
Loose or no cable connections.Check all power connections.
Welding power source.Check power source.
Dirty or worn conduit.Replace conduit.
Wrong size contact tip.See Contact tip table.
Idler roll stuck.Replace if damaged.
Bad potentiometer.Check with meter.
Broken electrical cable.
Bad speed control.
Replace fuse.
Check potentiometer wires for continuity or
short.
See specic cabinet/control owners manual
for speed control operation.
E - 2
Page 17
®
MAGNUM
HEAD ASSY DIAGRAM - MAGNUM
PRO AL Gun
®
PRO AL Gun K3355, K3356, K3357, K3358
DIAGRAMS
No.Part No.Description
1S29830-1Assy Cam Idler Arm
2S29830-6Front Body Assy, A/W
®
3S29830-48Assy Trigger Magnum
4S29830-50Kit Assy Pot Magnum
5S29830-10Assy Rear Body Magnum
6S29830-47Kit Assy Micro Swx Magnum
Pro AL Gun
®
Pro AL Gun
®
Pro AL Gun
®
Pro AL Gun
7S29830-13Motor 24VDC, Standard
8
Scr FH Phil 82 4-40 x 3/8 SST
9Scr FH Phil 82 4-40 5/8 SST
10Scr Button 4-40 x 1/2 SST
included in S29830-51
11Wshr SPR LK #6 SST
12Scr Soc. HD Cap #4-40, SST
13included in S29830-45Screw SHC 4-40 x 1/2 SST
14
15Scr Soc HD Cap #1-72 x 3/8 LG SST
included in S29830-51
Scr SHC 6-32 x 3/8 SST
16For reference onlyLabel
17S29830-98Handle Decal
18included in S29830-45Scr Shoulder 1/8, Door MX
19S29830-85Strap Motor
20
21
included in S29830-45Kit Handle Magnum
®
Pro Scorpion: includes item 13, 17, 18 and 22
22S29830-15Door
F - 1
Page 18
®
MAGNUM
FRONT BODY ASSY DIAGRAM - MAGNUM® PRO AL Gun K3355, K3356, K3357, K3358
PRO AL Gun
DIAGRAMS
No.Part No.Description
1KP3992-1Assy Idler Roll Insulated Knurl
2
3
-Not available separately
4included in S29830-51Scr Soc. HD. Cap #4-40 SST
5S29830-880.29 x 0.047 x 0.32 Comp. Spring
6S29830-891/8 x 7/8 SST Dowel Pin
7included in S29830-51Idler Adjusting Screw
8S29830-86Idler Arm
9S29830-87Clamp Body
10KP3390-1Assy Drive Roll Insulated Knurl
F - 2
Page 19
®
MAGNUM
A/W GUN TUBE ASSY DIAGRAM - MAGNUM® PRO AL Gun K3355, K3356
PRO AL Gun
DIAGRAMS
No.Part NumberDescription
1-Not available separately
2
3Insulator Gun Tube
4
5O-Ring 0.301ID x 0.07W
included in S29830-49
included in S29830-83
Assy Nut Gun Tube
O-Ring 0.489ID x 0.07W
6S29830-90Ring Ret Ext 1/4OD x 0.023W
7-See Consumable Section for options and part numbers
8KP3376-1Liner Package
9
-See Consumable Section for options and part numbers10
11
F - 3
Page 20
®
MAGNUM
W/C GUN TUBE ASSY DIAGRAM - MAGNUM® PRO AL Gun K3357, K3358
PRO AL Gun
DIAGRAMS
No.Part No.Description
1-Not available separately
2
3Insulator Gun Tube
included in S29830-49
Assy Nut Gun Tube
4S29830-92Insulator Nozzle with Five O-Rings
5
6O-Ring .301 ID x .07 W
included in S29830-83
O-Ring .489 ID x .07 W
7S29830-90Retaining Ring 5/8 Shaft
8S29830-91Ring Ret 0.500 Dia Shaft Spiral SST
9-See Consumable Section for options and part numbers
10S29830-93Retaining Nut W/C
11KP3376-1Liner Package
12
13
-See Consumable Section for options and part numbers
F - 4
Page 21
®
Swivel Joint Molded
MAGNUM
AIR COOLED LEAD ASSY DIAGRAM - MAGNUM® PRO AL Gun K3355, K3356
PRO AL Gun
DIAGRAMS
No.Description15' Part No.25' Part No.35' Part No.50' Part No.
1Assy Boot TorchS29830-2
2Assy Power Manifold, A/WS29830-3
3Assy Power Pin AdapterS29830-5
4Assy Rear Connector, A/WS29830-12
5Wrap Spiral Cord, 13 inS29830-94
6Cable CoverKP3378-15KP3378-25KP3378-35KP3378-50
7Washer Split Lock 0.27OD x 0.17ID x 0.04 thkincluded in S29830-51
8Screw SHC 4-40 x 1/2 SSTincluded in S29830-46
9Scr Shc 8-32 x 3/4 SSTincluded in S29830-51
10
LabelsFor reference only
11
12Tie Wrapincluded with item 26
13Tie Wrap Low Prof 14-9/16LG Blkincluded with item 6
14*Retainer 5/16 HoseS29830-14
15
16
Handle Kit: Includes item 8S29830-46
17
S29830-11
18Gas HoseS29830-21S29830-22S29830-23S29830-24
19Conduit Liner KP3991-15KP3991-25KP3991-35KP3991-50
20
21Heat Shrink Tubing 1/2" Dia x 1" Lg
22Cap Vinyl Round, Fit 3/16" -1/4" OD x 1/2" LG
27Assy Power Cable GlobalS29830-29S29830-30S29830-31S29830-32
* Hose Retainer is re-usable and can be removed and re-installed as needed
F - 5
Page 22
®
MAGNUM
WATER COOLED LEAD ASSY DIAGRAM - MAGNUM® PRO AL Gun K3357, K3358
PRO AL Gun
DIAGRAMS
No.Description15' Part No.25' Part No.35' Part No.50' Part No.
1Assy Boot TorchS29830-2
2Assy Power Manifold, A/WS29830-3
3Assy Power Pin AdapterS29830-5
®
4Assy Rear Connector A/W Magnum
Pro AL GunS29830-12
5Wrap Spiral Cord, 13 inS29830-94
6Cable CoverKP3378-15KP3378-25KP3378-35KP3378-50
7Washer Split Lock, 0.27OD x 0.17ID x 0.04 THKincluded in S29830-51
8Screw SHC 4-40 x 1/2 SSTincluded in S29830-46
9SCR SHC 8-32 x 3/4 SSTincluded in S29830-51
10
LabelsFor reference only
11
12Tie Wrap included with item 27
13Tie Wrap Low Prof 14-9/16LG Blkincluded with item 6
14Hose Retainer, 5/16S29830-14
®
15Swivel Joint Molded Magnum
16
Handle Kit: includes item 8S29830-46
17
Pro AL GunS29830-11
18Assy Hose Water REDS29830-16
19Assy Hose Water, BLUES29830-17S29830-18S29830-19S29830-20
20Assy Gas HoseS29830-21S29830-22S29830-23S29830-24
21Conduit Liner KP3991-15KP3991-25KP3991-35KP3991-50
22Conduit Tef TubeS29830-25S29830-26S29830-27S29830-28
23Heat Shrink Tubing 1/2" Dia x 1" LGFor reference only
24Compound Joint Noalox KitS29830-52
28Assy Power Cable/Water EuroS29830-33S29830-34S29830-35S29830-36
* Hose Retainer is re-usable and can be removed and re-installed as needed
F - 6
Page 23
®
MAGNUM
POWER MANIFOLD ASSY DIAGRAM - MAGNUM® PRO AL Gun K3355, K3356, K3357, K3358
PRO AL Gun
DIAGRAMS
No.Part No.Description
1included in S29830-51Set Screw Conduit
2S29830-95Fitting 1/8ID x 1/16-27 NPT
3-Not available separately
F - 7
Page 24
DIAGRAMS
MAGNUM
®
PRO AL Gun
Models K3356 and K3358
Models K3355 and K3357
F - 8
Page 25
NOTES
Page 26
WARNING
Spanish
AVISO DE
PRECAUCION
l Do not touch electrically live parts or
electrode with skin or wet clothing.
l Insulate yourself from work and
ground.
l No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
l Aislese del trabajo y de la tierra.
l Keep flammable materials away.
l Mantenga el material combustible
fuera del área de trabajo.
l Wear eye, ear and body protection.
l Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
l Ne laissez ni la peau ni des vêtements
mouillés entrer en contact avec des
pièces sous tension.
l Isolez-vous du travail et de la terre.
l Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den Elektroden
und dem Erdboden!
l Não toque partes elétricas e electro-
dos com a pele ou roupa molhada.
l Isole-se da peça e terra.
l Gardez à l’écart de tout matériel
inflammable.
l Entfernen Sie brennbarres Material!
l Mantenha inflamáveis bem guarda-
dos.
l Protégez vos yeux, vos oreilles et
votre corps.
l Tragen Sie Augen-, Ohren- und Kör-
perschutz!
l Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE
EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET
LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE
EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Page 27
l Keep your head out of fumes.
l Use ventilation or exhaust to remove
fumes from breathing zone.
l Turn power off before servicing.
l Do not operate with panel open or
guards off.
WARNING
l Los humos fuera de la zona de res-
piración.
l Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
l Gardez la tête à l’écart des fumées.
l Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
l Vermeiden Sie das Einatmen von
Schweibrauch!
l Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
l Mantenha seu rosto da fumaça.
l Use ventilação e exhaustão para
remover fumo da zona respiratória.
l Desconectar el cable de alimentación
de poder de la máquina antes de iniciar cualquier servicio.