Lincoln Electric IMt913 User Manual [en, es, fr]

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MAGNUM®100SG SPOOL GUN

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPER-

ATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,

most importantly, think before you act and be careful.

August, 2010

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

magnetowireasappropriate. work,disconnectthesparkplugwires,distributorcapor turningtheengineorweldinggeneratorduringmaintenance

2.d.5.Donotworknexttoweldingpowersource.

1.g.Topreventaccidentallystartinggasolineengineswhile

___________________________________________________

possibletotheareabeingwelded.

2.d.4.Connecttheworkcabletotheworkpieceascloseas

side,theworkcableshouldalsobeonyourrightside.

whiletheengineisrunning. workcables.Iftheelectrodecableisonyourright

idlerbypushingonthethrottlecontrolrods Donotattempttooverridethegovernoror

2.d.3.Donotplaceyourbodybetweentheelectrodeand

1.f.Donotputyourhandsneartheenginefan.

___________________________________________________

2.d.2.Nevercoiltheelectrodeleadaroundyourbody. parts. Alwaysusethegreatestcarewhenworkingnearmoving

themwithtapewhenpossible. maintenancerequiringtheirremovaliscomplete.

2.d.1.

Routetheelectrodeandworkcablestogether-Secure guardsonlywhennecessaryandreplacethemwhenthe guardstoperformrequiredmaintenance.Remove

minimizeexposuretoEMFfieldsfromtheweldingcircuit:

1.e.Insomecasesitmaybenecessarytoremovesafety

2.d.Allweldersshouldusethefollowingproceduresinorderto

____________________________________________________

effectswhicharenownotknown. whenstarting,operatingorrepairingequipment.

2.c.ExposuretoEMFfieldsinweldingmayhaveotherhealth

awayfromV-belts,gears,fansandallothermovingparts tionandingoodrepair.Keephands,hair,clothingandtools beforewelding.

1.d.Keepallequipmentsafetyguards,coversanddevicesinposiweldershavingapacemakershouldconsulttheirphysician

____________________________________________________

2.b.EMFfieldsmayinterferewithsomepacemakers,and

havebeeneliminated. wipeitupanddonotstartengineuntilfumes weldingmachines

notspillfuelwhenfillingtank.Iffuelisspilled, currentcreatesEMFfieldsaroundweldingcablesand

contactwithhotenginepartsandigniting.Do localizedElectricandMagneticFields(EMF).Welding

ingtopreventspilledfuelfromvaporizingon

2.a.Electriccurrentflowingthroughanyconductorcauses

theengineandallowittocoolbeforerefuelingarcorwhentheengineisrunning.Stop

1.c.Donotaddthefuelnearanopenflameweld-

maybedangerous

____________________________________________________

MAGNETICFIELDS ELECTRICAND

outdoors. areasorventtheengineexhaustfumes

1.b.Operateenginesinopen,well-ventilated

____________________________________________________

workunlessthemaintenanceworkrequiresittoberunning.

1.a.Turntheengineoffbeforetroubleshootingandmaintenance

hot.

poweredequipment.

radiatorpressurecapwhentheengineis

FORENGINE

1.h.Toavoidscalding,donotremovethe

PERFORMEDONLYBYQUALIFIEDINDIVIDUALS. BESURETHATALLINSTALLATION,OPERATION,MAINTENANCEANDREPAIRPROCEDURESARE

LincolnElectricCompany,22801St.ClairAvenue,Cleveland,Ohio44117-1199. Miami,Florida33135orCSAStandardW117.2-1974.AFreecopyof“ArcWeldingSafety”bookletE205isavailablefromthe purchaseacopyof“SafetyinWelding&Cutting-ANSIStandardZ49.1”fromtheAmericanWeldingSociety,P.O.Box351040, Readandunderstandthefollowingsafetyhighlights.Foradditionalsafetyinformation,itisstronglyrecommendedthatyou

KEEPCHILDRENAWAY.PACEMAKERWEARERSSHOULDCONSULTWITHTHEIRDOCTORBEFOREOPERATING. ARCWELDINGCANBEHAZARDOUS.PROTECTYOURSELFANDOTHERSFROMPOSSIBLESERIOUSINJURYORDEATH.

otherreproductiveharm.

orotherreproductiveharm. ofCaliforniatocausecancer,birthdefects,and

StateofCaliforniatocausecancer,birthdefects, someofitsconstituentsareknowntotheState

thisproductcontainschemicalsknowntothe ForDieselEngines:Dieselengineexhaustand

ForGasolineEngines:Theengineexhaustfrom

CALIFORNIAPROPOSITION65WARNINGS

WARNING

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

For Diesel Engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

____________________________________________________

1.d. Keep all equipment safety guards,covers and devices in posi-

____________________________________________________

1.e. In some cases it may be necessary to remove safety

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

tion and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

For Gasoline Engines: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

Route the electrode and work cables together - Secure

2.d.1.

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

zonesoùlʼonpiquelelaitier.

soudage.Utiliserdeslunettesavecécranslaterauxdansles

5.Toujoursporterdeslunettesdesécuritédanslazonede

sdesûretéàleurplace.

4.Gardertouslescouverclesetdispositif

onssansrevers,etchaussuresmontantes.

tal

delʼhuile,telsquelesgantsencuir,chemiseépaisse,paneràlʼinterrupteuràlaboitedefusibles.

soudage.Seprotégeravecdesvêtementsdeprotectionlibres

3.Avantdefairesdestravauxàlʼinterieurdeposte,ladebranch-

4.Desgouttesdelaitierenfusionsontémisesdelʼarcde

effectuésparunélectricienqualifié.

soudageàlʼaidedʼécransappropriésetnon-inflammables.

2.Autantquepossible,Iʼinstallationetlʼentretienduposteseront

c.Protégerlʼautrepersonneltravaillantàproximitéau

desoudeuretdesaidescontrelerayonnementdelʻarc. bonnemiseàlaterre.

b.Porterdesvêtementsconvenablesafindeprotégerlapeau demontageoulapieceàsouderdoitêtrebranchéàune

quandonregardelʼarc. lʼélectricitéetauxrecommendationsdufabricant.Ledispositif

projectionsquandonsoudeou

nementdelʼarcetdes

1.Relieràlaterrelechassisduposteconformementaucodede

quʼunverreblancafindeseprotégerlesyeuxdurayon-

a.Utiliserunbonmasqueavecunverrefiltrantappropriéainsi

REDRESSEUR

3.Uncoupdʼarcpeutêtreplussévèrequʼuncoupdesoliel,donc:

TRANSFORMATEURETÀ

corps.

LESMACHINESÀSOUDERÀ

enroulerlecâble-électrodeautourdenʼimportequellepartiedu

contreleschutesdanslecasouonrecoitunchoc.Nejamais

PRÉCAUTIONSDESÛRETÉPOUR

rotéger

2.Danslecasdetravailaudessusduniveaudusol,sep

soudage.

pourleporte-électrodesʼapplicuentaussiaupistoletde

courantpoursoudagesemi-automatique,cesprecautions

W117.2-1974.

f.Sionutiliselamachineàsoudercommeunesourcede

lecode“Codeforsafetyinweldingandcutting”CSAStandard delatensionàvidedesdeuxmachines.

ûreté,voir

11.Pourobtenirdeplusamplesrenseignementssurlas parcequelatensionentrelesdeuxpincespeutêtreletotal

desporte-électrodesconnectésàdeuxmachinesàsouder

ouautresproduitsirritants. e.Nejamaistouchersimultanémentlespartiessoustension

dusolvantpourproduireduphosgéne(gasfortementtoxique) refroidir.

chaleuroulesrayonsdelʼarcpeuventréagiraveclesvapeurs électrodedanslʼeaupourle

d.Nejamaisplongerleporte-

dʼopérationsdedégraissage,nettoyageoupistolage.La tionnement.

10.Nepassouderenprésencedevapeursdechloreprovenant soudageetlamachineàsouderenbonetsûrétatdefonc-

c.Maintenirleporte-électrode,lapincedemasse,lecâblede

produitdesfumeéstoxiques. partieducorpspeutêtreencontactaveclamasse.

galvaniséesplombées,oucadmiéesoutoutautremétalqui lespositionsassisoucouchépourlesquellesunegrande

Ceciestparticuliérementimportantpourlesoudagedetôl alliqueoudesgrillesmetalliques,principalementdans

9.Assureruneventilationsuffisantedanslazonedesoudage. soudedansdesendroitshumides,ousurunplanchermet-

b.Fairetrésattentiondebiensʼisolerdelamassequandon

câblesjusquʼàcequʼilsserompent. pourisolerlesmains.

trous

risquesdʼincendieoudʼechauffementdeschainesetdes oulesvétementsmouillés.Porterdesgantssecsetsans

câblesdegrue,ouautrescircuits.Celapeutprovoquerdes toutcontactentrelespartiessoustensionetlapeaunue

passerlecourantdesoudageparleschainesdelevage, quandlamachineàsouderestenmarche.Evitertoujours

éloignésdelazonedetravail,onaugmentelerisquedevoir

a.Lescircuitsàlʼélectrodeetàlapiécesontsoustension

massesurlacharpentedelaconstructionoudʼautresendroits

placela

lazonedetravailquʼilestpratiquedelefaire.Sion

1.Protegez-vouscontrelasecousseélectrique:

8.Sʼassurerquelamasseestconnectéelepluspréspossiblede

SûretéPourSoudageALArc

échauffementetunrisquedʼincendie. antes:

lamasse.Uncourt-circuitaccidentalpeutprovoquerun manuelaussibienquelesprécautionsdesûretégénéralessuiv-

7.Quandonnesoudepas,poserlapinceàuneendroitisoléde etlesprécautionsdesûretéspecifiquesquiparraissentdansce

Pourvotrepropreprotectionlireetobservertouteslesinstructions

prévenirtoutrisquedʼincendiedûauxétincelles.

6.Eloignerlesmatériauxinflammablesoulesrecouvrirafinde

PRÉCAUTIONSDESÛRETÉ

SAFETY

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 secousse électrique:

a. Les circuits à lʼélectrode et àla piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous

pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans

les positions assis ou couchépour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pincedemasse,lecâblede

soudage et la machine à souder en bon et sûr état defonc- tionnement.

d.Ne jamais plonger le porte-

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deuxpinces peut être letotal de la tension à vide des deux machines.

f.Sionutilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode sʼapplicuent aussi au pistolet de soudage.

2. Dans le cas de travail au dessus du niveau du sol,sep contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler lecâble-électrode autour de nʼimporte quelle partie du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié ainsi

quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre lerayonnement de lʻarc.

c. Protéger lʼautre personnel travaillant àproximité au

soudage àlʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de soudage. Se protéger avec des vêtements de protection libres de lʼhuile, tels que les gants en cuir, chemise épaisse, pantal

ons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les

zones oùlʼon pique le laitier.

électrode dans lʼeau pour le

rotéger

projections quand on soude ou

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû auxétincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidentalpeut provoquer un échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possiblede la zone de travailquʼil est pratique de le faire. Si on masse sur la charpente de la construction ou dʼautres endroits éloignésdela zone de travail, on augmente lerisque de voir passer le courant de soudage par les chaines de levage,

câbles de grue, ou autres circuits. Cela peut provoquer des risques dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼilsserompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôl galvanisées plombées, ou cadmiées ou tout autre métalqui produit des fumeéstoxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur las le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

place la

ûreté, voir

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier àla terre le chassis du poste conformement au code de lʼélectricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branchéàune bonne mise àla terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travauxàlʼinterieur de poste, la debranch- er àlʼinterrupteur àla boite de fusibles.

4. Garder tous les couvercles et dispositif

sdesûretéàleur place.

Thank

You

for selecting a QUALITY product by Lincoln Electric. We want you

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customers particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you!

CUSTOMER ASSISTANCE POLICY

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your equipment nameplate.

Model Name and Sales Spec Number (K-xxx) _____________________________________

Date of Purchase __________________________________

Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above.

On-Line Product Registration

Please Examine Carton and Equipment For Damage Immediately

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet

• For On-Line Registration: Go to our

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

accompanying this machine and fax the form per the instructions printed on it.

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

“Product Registration”. Please complete the form and submit your registration.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

TABLE OF CONTENTS

Page Installation Section--------------------------------------------------------------------------------A Technical Specification---------------------------------------------------------------------------A-1 Unpacking the Spool Gun-----------------------------------------------------------------------A-1 Safety Precautions--------------------------------------------------------------------------------A-2 Locating Spool Gun Components And Features------------------------------------------A-2 Assembly of Items Inside the Magnum Spool Gun---------------------------------------A-3 Welding Machines--------------------------------------------------------------------------------A-4 Recommended Welding Machines-----------------------------------------------------------A-5 Spool Gun / Wire Drive Selector Switch Installation--------------------------A-6 thru A-9 Routine Welding Machine Preparation------------------------------------------------------A-10 Preparing the Spool Gun-----------------------------------------------------------------------A-10 Loading Aluminum-----------------------------------------------------------------A-10 thru A-13 Connecting the Gun to the Welding Machine--------------------------------------------A-13 __________________________________________________________________

PERATION Section----------------------------------------------------------------------------------B

Safety Precaution---------------------------------------------------------------------------------B-1 Product Description-------------------------------------------------------------------------------B-1 Machine Speed and Voltage tap Settings--------------------------------------------B-1, B-2 Welding Procedures------------------------------------------------------------------------------B-3 __________________________________________________________________

Maintenance Section------------------------------------------------------------------------------ D Safety Precautions--------------------------------------------------------------------------------D-1

Routine and Periodic Maintenance-----------------------------------------------------------D-1 Recommended Tools-----------------------------------------------------------------------------D-1

Cleaning and Inspections-----------------------------------------------------------------------D-1 P6 Connector Pin-Out----------------------------------------------------------------------------D-1 Gas Diffuser Replacement----------------------------------------------------------------------D-1 Liner Assembly Replacement or Cleaning--------------------------------------------------D-2 Drive Roll Replacement--------------------------------------------------------------------------D-2 Idle Roll Assembly Replacement--------------------------------------------------------------D-3 Gun Tube Assembly Replacement------------------------------------------------------------D-3 Wire Drive Assembly Removal And Installation--------------------------------------------D-4 Trigger Assembly Replacement----------------------------------------------------------------D-4 Welding Cable Assembly Replacement-----------------------------------------------D-4, D-5 Correcting Wire Shaving issues--------------------------------------------------------------D-5 __________________________________________________________________

TABLE OF CONTENTS

Page Troubleshooting Section -------------------------------------------------------------------------E Safety Precautions--------------------------------------------------------------------------------E-1 How To Use Trouble Shooting Guide---------------------------------------------------------E-1 Troubleshooting----------------------------------------------------------------------------E-2 to E-4 ____________________________________________________________________ Diagrams Section -----------------------------------------------------------------------------------F Wiring Diagrams------------------------------------------------------------------------------------F-1 ____________________________________________________________________ Parts List--------------------------------------------------------------------------------P-554 Series ____________________________________________________________________

INSTALLATION

TECHNICAL SPECIFICATIONS - MAGNUM®100SG SPOOL GUN K2532-1

MODEL

WELDING PROCESS

WIRE ALLOYS

WIRE SIZES (DIAMETERS)

SPOOL SIZE

RATED WELDING CURRENT AND DUTY CYCLE

OVERALL WEIGHT

CABLE LENGTH

OVERALL SIZE (BOUNDING BOX)

METHOD OF GUIDANCE

METHOD OF COOLING

K2532-1 Magnum®100SG Spool Gun

Aluminum GMAW (MIG), DC electrode positive polarity with 100% argon welding shielding gas.

Aluminum only: alloys 4043 or 5356

Solid wire 0.030 or 0.035 inches (0.8 or 0.9 mm)

1 lb. weight, nominal 4 inch diameter spool

130 amps at 30% for 10-minute basis

3.5 lbs. with cable but without case or spool

10.0±0.2 feet

In inches: 15.75 long x 10.50 high x 4.25 thick max.,

without case or gun cable.

Semiautomatic (manually-guided)

Air-cooled

UNPACKING THE SPOOL GUN

The spool gun is factory-assembled and tested, and then packed in its own cushioned carrying case. It is shipped fully-equipped to weld with 0.035 inch diameter aluminum wire. After opening the case, check that it contains the following items:

1. One fully assembled K2532-1 spool gun.

2. One T11862-65 Conical Compression Spring for use with alloy 5356 wire (spool not included).

3. One spool of 0.035 aluminum alloy 4043 wire

4. Three S19726-3 contact tips

5. One instruction manual (IM913)

6. One M21182 electrical harness with toggle switch.

Plastic Bag

A-1

INSTALLATION

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

-----------------------------------------------------------------------------------------------------

LOCATING SPOOL GUN COMPONENTS AND FEATURES

(See Figure 1.A for Items 1 thru 6)

1. Gas Cone Assembly and Contact Tip.

2. Straightened Gun Tube Assembly.

3. 1/4-Turn Locking Collar.

4. Trigger Assembly.

5. Spool Cover: Provides easy, wide- open access to spool and wire drive.

6. Locking Knob: Captive in spool cover.

FIGURE A.1

(See Figure A.2 for these following items)

7. Integrated Single-Piece Cable: The Magnum neat and clean appearance; simplifies cable management and reduces entanglements.

8. Standard Durable Strain Relief Clamp.

9. Three Captive Hex Nuts.

design provides

A-2

Left Side View

FIGURE A.2

Right Side View

INSTALLATION

P6 CONNECTOR PINOUT

MASTER KEY

ASSEMBLY OF ITEMS INSIDE THE MAGNUM®SPOOL GUN

FIGURE A,3

Machine Connections

1. Liner Assembly feeds all specified wire.

2. Drive Roll: This Drive Roll feeds all specified wires.

3. Idle Roll Assembly: Non-adjustable tension setting for all specified wires

4. Incoming Wire Guide: Highly wearresistant.

5. P6 Connector Control Leads: Motor Power and Trigger. (See Maintenance Section for more details)

6. Welding Power and Shielding Gas Machine connection (Sealed with 2 o-rings).

TOP VIEW

Spool Cover and left handle removed

7. Locking Knob: Independently retains the wire spool on the spindle.

8. Liner Assembly: Includes a gas seal with the cable connector and is the outgoing wire guide.

9. Only 4 sub-assemblies: gun tube; cable; wire drive; trigger.

10. Conical spring (not shown) serves

as the spool brake (use only with aluminum alloy 5356).

A-3

INSTALLATION

SAFETY PRECAUTIONS

WELDING MACHINES

CAUTION

• Read and understand the welding machineʼs instruction manual and all hazard warnings on equipment and in the manual.

• Wear the proper personal protective equipment for welding, including but not limited to, safety glasses, hearing protection, welding helmet, welding gloves, and welding leathers.

-----------------------------------------------------------------------------------------------------

SPOOL GUN

WARNING

ELECTRIC SHOCK CAN KILL.

• The spool of wire may fall out of the gun if the locking knob is not installed.

• Metal parts may be at welding voltage (electrically "hot").

• Metal parts remain at welding voltage for several seconds after trigger is released. Read warning label on gun.

• This product shall not be used in precipitation, or in wet or damp locations.

------------------------------------------------------------------------------------------------------

A-4

INSTALLATION

RECOMMENDED WELDING MACHINES

MACHINE NAME

POWER MIG 216

POWER MIG 215XT

POWER MIG 180C POWER MIG 140C

POWER MIG 180 DUAL

POWER MIG 180C AU

POWER MIG 180C CE

POWER MIG 140T POWER MIG 180T

PRO CORE 125

PRO MIG 140

WELD PAK 125 HD

WELD PAK 140 HD

MIG PAK 140

EASY CORE 125

EASY MIG 140

WORK PAK 125

CORE PACK 125

PRO MIG 180

WELD PAK 180HD

MIG PAK 180

SP-140T

SP-180T

EASY MIG 180

NOTE: THE MACHINE CODE NUMBER IS LISTED ON THE BACK OF THE MACHINE.

K-NUMBER

K2816-1 K2700-1 K2473-1 K2471-1 K3018-1 K2668-1 K2661-1 K2470-1 K2472-1

K2479-1

K2480-1

K2513-1

K2514-1

K2658-1

K2696-1

K2697-1

K2699-1

K2785-1

K2481-1

K2515-1

K2659-1

K2688-1

K2689-1

K2698-1

CODE NUMBER

11588 11521 11257 11255 11659 11444 11442 11254 11256 11631 11300 11634 11173 11632 11302 11635 11303 11636 11440 11633 11503 11637 11504 11638 11506 11639 11550 11646 11175 11647 11304 11648 11441 11658 11501 11649 11502 11650 11505

INSTALLATION OF M21182 HARNESS AND SELECTOR SWITCH

NOT REQUIRED NOT REQUIRED

REQUIRED REQUIRED

NOT REQUIRED

REQUIRED REQUIRED REQUIRED REQUIRED

SPOOL GUN USE NOT AVAILABLE

REQUIRED

NOT REQUIRED

REQUIRED

SPOOL GUN USE NOT AVAILABLE

REQUIRED

NOT REQUIRED

REQUIRED

NOT REQUIRED

REQUIRED

SPOOL GUN USE NOT AVAILABLE

REQUIRED

NOT REQUIRED

REQUIRED

SPOOL GUN USE NOT AVAILABLE

REQUIRED

SPOOL GUN USE NOT AVAILABLE

REQUIRED REQUIRED REQUIRED REQUIRED REQUIRED REQUIRED REQUIRED REQUIRED REQUIRED REQUIRED REQUIRED REQUIRED REQUIRED

A-5

INSTALLATION

NOTE: Installation of the M21182 harness and spool gun selector switch is

not required for all machines. If a spool gun switch is pre-installed in the machineʼs wire drive compartment, then the SPOOL GUN / WIRE DRIVE SLECTOR SWITCH INSTALLATION SECTION can be disregarded.

SPOOL GUN / WIRE DRIVE SELECTOR SWITCH INSTALLATION

. Install the M21182 electrical adapter

harness that came with the spool gun per the following instructions.

ELECTRIC SHOCK CAN KILL.

WARNING

2. Disconnect input power from the machine.

5. Remove screws from cover.

(A) is the location of two 3/4” long

screws.

------------------------------------------------

OPEN THE MACHINE

3. Remove two 5/16“ hex hinge screws from door.

4. Remove ten 5/16“ hex screws from cover.

6. Remove cover.

7. If machine has a plastic handle (A), then remove screw (B).

A-6

ELECTRICAL CONNECTIONS

544A (Male)

543A (Female)

INSTALLATION

Toggle Switch

7 (10-pin)

J8 (6-pin)

P7 (10-pin)

P8 (6-pin)

8. Adapter harness. All 6 connections shown are used, and each one is unique.

(Proceed as follows)

9. A. Remove P3 (10-pin) from board J3 (10-pin).

10. Connect harness P7 (10-pin) to

board J3 (10-pin).

IF MACHINE DOES NOT HAVE OPTIONAL SPOT TIMER.

(11.A. thru 11.D.)

11.A. Remove P5 (6-pin) from

board J5 (6-pin).

11.B. Connect P5 (6-pin) to har-

ness J8 (6-pin).

9.B. Connect P3 (10-pin) to har-

ness J7 (10-pin).

11.C. Connect harness P8 (6-pin)

to board J5 (6-pin).

A-7

INSTALLATION

544A

543A

11.D. Find assembled pair of machine terminals (leads 543A & 544A) and disconnect. Go to step 13.

IF MACHINE DOES HAVE OPTIONAL SPOT TIMER. (12.A. thru 12.D.)

12.A. Remove P5 (6-pin) from spot

timer harness J9 (6-pin).

12.C. Connect adapter harness P8 (6pin) to spot timer harness J9 (6-

pin).

544A

543A

12.D. Find assembled pair of machine

terminals (leads 543A & 544A) and disconnect.

12.B. Connect P5 (6-pin) to adapter

harness J8 (6-pin).

13. Connect terminals:

(A) connect machine male (lead

543A) to adapter harness female (lead 543A).

(B) connect machine female (lead

544A) to adapter harness male (lead 544A).

14. Ensure that the locking tabs on all

connectors are latched closed.

A-8

INSTALLATION

MOUNTING THE SWITCH

15. Remove the plug button from the panel hole.

18. Install switch into panel hole. Ensure washer tab is fully seated into smaller hole.

16. Plug button is no longer needed. Discard.

17. Remove mounting nut from switch. Keep mounting nut for installation.

19. Reinstall mounting nut onto switch. Wrench tighten.

RE-ASSEMBLE MACHINE AS FOLLOWS:

20. Reinstall screw into plastic handle (if so equipped).

21. Reinstall cover.

22. Reinstall door.

23. Reconnect input power to the machine.

A-9

INSTALLATION

ROUTINE WELDING MACHINE PREPARATION

WARNING

ELECTRIC SHOCK CAN KILL.

1. Disconnect input power to the machine.

------------------------------------------------------------------------

2. Machine polarity setting: Set to DC electrode positive

polarity per the machineʼs Instruction Manual.

3. Gas selection and flow rate: Connect 100% welding

grade argon gas supply to the machineʼs gas solenoid valve. Set the supply regulator to deliver a gas flow rate of 20 to 50 SCFH thru the spool gun.]

4. Flip the machineʼs wire drive selector switch (behind the access door) to "Magnum® 100SG". (See Figure A.4)

FIGURE A.4

PREPARING THE SPOOL GUN

WARNING

ELECTRIC SHOCK CAN KILL.

1. Disconnect input power to the machine.

------------------------------------------------------------------------

2. The Conical Spring is used as the spool brake only when feeding the stronger and harder aluminum alloy 5356. The Conical Spring must be removed from the spool gun whenever using the softer aluminum alloy 4043.

A-10

INSTALLATION

LOADING ALUMINUM WIRE

1. Remove gas cone and contact tip. Remove spool cover by unscrewing captive locking knob.

FIGURE A.5

2. Remove locking knob from spindle bolt by unscrewing it.

FIGURE A.6

4. Extend approximately 12 inches of wire from spool. Straighten it out by back-bending it. Use care to prevent the wire from dereeling.

FIGURE A.8

5. Cut off bent end of wire, leaving

straight section.

FIGURE A.9

3. Select wire alloy and diameter need- ed. Alloy 4043 and 0.035 wire size shown. Remove packaging and data sheet from wire spool.

FIGURE A.7

Size

Alloy

6. Gently pull open the idle roll assembly to expose the drive roll groove.

FIGURE A.10

A-11

INSTALLATION

7. Guide straightened wire through inlet wire guide and toward drive roll groove.

FIGURE A.11

8. While holding open the idle roll, slide end of wire through drive rollʼs groove and toward gun tube liner.

FIGURE A.12

10a. Alloy 4043: Roll up remaining wire

back onto spool and place spool onto gun spindle. Install locking knob and finger-tighten. Go to step

11.

FIGURE A.14

10b. Alloy 5356: Install Conical Spring,

small end first, onto gun spindle (A). Roll up remaining wire back onto spool and place spool onto gun spindle. Install locking knob and finger-tighten.

FIGURE A.15

9. Slide the wire into the liner until it extends approximately 1 inch beyond the end of the gas diffuser. Release idle roll tab without snapping it.

FIGURE A.13

11. Grasp the gas diffuser and slowly pull approximately 12 to 24 inches of wire through the spool gun. There should only be 1 to 2 lbs. of resistance. If force is greater than 2 lbs. wire is binding in the gun (also see Troubleshooting guide).

free end of the wire at the

FIGURE A.16

A-12

INSTALLATION

12. Cut off excess wire 1 to 2 inches from gas diffuser. Install properly-

sized contact tip slightly past handtight. Install gas cone and handtighten.

FIGURE A.17

13. Reinstall spool cover. 1: tuck coverʼs tab in place at arrow and hold with thumb. 2: swing cover closed. 3: finger-tighten locking knob. 4: check for uniform fit all around cover.

FIGURE A.18

CONNECTING THE GUN TO THE WELDING MACHINE

1. Disconnect input power to the machine.

2. Make sure that the gun locking knob

is loosened. (See Figure 20).

3. Fully insert gun cable connection (welding power and gas supply) into

machine. Note that the master Key way for P6 connector is located at the arrow.

FIGURE A.19

P6 Connector Key way

4. Check that the cable connectorʼs

end is flush with insulator at A. Tighten gun locking knob (B) onto cable connector.

FIGURE A.20

A-13

NOTES

MAGNUM 100SG

OPERATION

SAFETY PRECAUTIONS

• Uses reliable gun and feeder hardware from Lincolnʼs Magnum® 100L Gun, Innershield

Read and understand this entire section before

guns, and small Power Mig products.

operating the machine.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

• Read and follow “Electric Shock Warnings” in the Safety section if welding must be performed under electrically hazardous conditions such as welding in wet areas or on or in the workpiece.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

MACHINE SPEED AND VOLTAGE TAP SETTINGS

MAX

3/16 in. 5

10 ga 4

3.5

12 ga

4.5

14 ga 4

3.5

F.5

16 ga 3

18 ga

1.5

20 ga 2

1.5

22 ga

Thickness

Tap

Weldment

Speed

Voltage

Speed

Voltage

0.0300.035 Wire Size:

Alloy:

4043 POWER MIG 180C MACHINE

6.5

3/16 in. 8

6.5

10 ga

7.5

12 ga

5.5

14 ga 5

16 ga 4

18 ga 3

20 ga 2

22 ga

Thickness

Tap

Weldment

Speed

Voltage

Speed

Voltage

0.030

0.035

Wire Size:

Alloy:

5356 POWER MIG 180T MACHINE

6.5

3/16 in. 5

10 ga

4.5

3.5

12 ga

4.5

3.5

14 ga 3

3.5

16 ga 2

3.5

18 ga

2.5

1.5

20 ga 2

1.5

22 ga

Thickness

Tap

Weldment

Speed

Voltage

Speed

Voltage

0.0300.035 Wire Size:

4043

Alloy: POWER MIG 180T MACHINE

Alloy:

Wire Size:

Weldment

Thickness

22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 10 ga

3/16 in.

• Use ventilation or exhaust to remove fumes

from breathing zone.

WELDING SPARKS can cause fire or explosion

• Keep flammable material away.

• Do not weld on containers that have held

combustibles.

ARC RAYS can burn.

• Wear eye, ear and body protection.

Observe additional Safety Guidelines detailed in the beginning of this manual.

Alloy:

Wire Size:

Weldment Thickness

22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 10 ga

3/16 in.

------------------------------------------------------------

PRODUCT DESCRIPTION

• Reliable, low-price aluminum welding accessory

for novice and experienced welders.

• Completely enclosed system.

• All combinations of specified aluminum alloys

and wire diameters can be fed with the same drive roll and liner assembly.

• Gun cable compactly integrates welding current

and gas supplies with gun control functions.

Alloy:

Wire Size:

Weldment Thickness

22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 10 ga

3/16 in.

POWER MIG 180T MACHINE

4043

0.035

Speed

0.030

Voltage

Ta p

2.5

3.5

4.5

6.5

A A A B D E

E E

1.5

1.5 2 3

3.5

3.5 4 5

POWER MIG 180T MACHINE

5356

0.035

Speed

0.030

Voltage

Ta p

5.5

7.5

B D E E

8 8

2 2 3 4 5 6

6.5

POWER MIG 180C MACHINE

4043

0.035

Speed

0.030

Voltage

Ta p

4.5

G 4 5

J 5

MAX

1.5

1.5 3

3.5 4

3.5 4 5

Voltage

Ta p

A A A B D D E E

Voltage

Ta p

A A B B C E E E

Voltage

Ta p

D D E

F. 5

J J

MAX

B-1

OPERATION

Alloy:

Wire Size:

Weldment Thickness

22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 10 ga

3/16 in.

Alloy:

Wire Size:

Weldment Thickness

22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 10 ga

3/16 in.

POWER MIG 180C MACHINE

5356

0.030

Speed

Voltage

3.5 5 6 7 8 8 9

MAX

POWER MIG 140T MACHINE

0.030

Speed

Voltage

2.5

3.5 4 4

4.5

N/A N/A

Ta p

C D E F

Ta p

A A B D E

E N/A N/A

Speed

2.5 3

3.5

4.5

5.5

6 6 7

4043

Speed

1.5 2

2.5 3 3 3

N/A N/A

0.035

Voltage

Ta p

C D E F G H

MAX

Voltage

Ta p

A B C D E

E N/A N/A

POWER MIG 140C MACHINE

Alloy:

Wire Size:

Weldment Thickness

3/16 in.

Alloy:

Wire Size:

Weldment Thickness

3/16 in.

Speed

22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 10 ga

3 3 5 6

6.5 7

N/A N/A

POWER MIG 140C MACHINE

Speed

2 2 3 4 3 5

N/A N/A

0.030

Voltage

0.030

Voltage

Ta p

E E F G

MAX

N N/A

Ta p

E E

E.5

MAX

N/A N/A

4043

5356

Speed

2.5

4.5

5.5 5

5.5

N/A N/A

Speed

1.5

1.5 3 3 3 4

N/A N/A

0.035

Voltage

Ta p

E E F G J

MAX

N/A N/A

0.035

Voltage

Ta p

E E F G J

MAX

N/A N/A

Alloy:

Wire Size:

Weldment

Thickness

22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 10 ga

3/16 in.

POWER MIG 140T MACHINE

5356

0.030

Speed

Voltage

3 3 5 5 6

6 N/A N/A

Ta p

A A B D D

E N/A N/A

Speed

2.5

2.5 4

4.5 5 5

N/A N/A

0.035

Voltage

Ta p

A A B D D

E N/A N/A

Wire Size:

Weldment Thickness

3/16 in.

B-2

Alloy:

22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 10 ga

Weld-Pak 125 MACHINE

4043

0.030

Speed

Voltage

2.5

2.5 3 3

3.5

N/A N/A

Tap

N/A N/A

Speed

B B C D E E

2 2 2

2.5 3

3.5

N/A N/A

0.035

Voltage

Tap

B B C D E

E N/A N/A

N/A

3/16 in.

N/A

10 ga

5.5

12 ga

14 ga

4.5

16 ga

4.5

18 ga

2.5

20 ga

2.5

22 ga

Tap

Thickness

Voltage

Speed

Voltage

Weldment

Speed

0.030

0.035 Wire Size:

Alloy:

5356 Weld-Pak 125 MACHINE

Wire Size:

Weldment

Thickness

Weld-Pak 125 MACHINE

Alloy:

Speed

22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 10 ga

3/16 in.

N/A N/A

2.5

4.5

5356

Speed

2 2 4

4.5 5

5.5

N/A N/A

0.035

Voltage

Tap

A B C D E

E N/A N/A

0.030

Voltage

Tap

A B C

E N/A N/A

After choosing the proper welding wire for your application, load the aluminum

wire, connect the gun and cable to the welding machine. (See Installation Section).

WELDING PROCEDURES

1. Read and understand Arc Welding Safety Precautions located throughout this manual and the Welding Machineʼs Instruction Manual. Also for helpful hints in welding see (LTW1) the Learn to Weld manual which is supplied with the welding machine.

2. Obtain and use the proper personal protective equipment for welding. Connect the WORK (welding ground) cable(-) to piece(s) being welded. Make sure gas hose from cylinderʼs regulator is connected to welderʼs gas INLET. Open cylinderʼs gas valve.

OPERATION

6. Cut off the aluminum wire so that it extends about 1/4 inches from the contact tip.

7. CTWD (Contact Tip to Work Distance): Position the gun so that the contact tip is nominally 3/8 inches from the joint and tilted with a push angle toward it. The aluminum wire should not contact the workpiece. (See figure B.1)

FIGURE B.1

8. Protect the eyes and pull the trigger to begin welding.

9. Adjust the hand travel speed of the gun to

achieve a proper weld. The emerging wire should stay within the molten puddle and not overrun it. This speed also should not be so slow that either the workpiece excessively melts, or the weld bead becomes excessively large.

10. Release the trigger to stop welding.

3. Connect input power to the machine.

4. Turn the machineʼs power switch to "on". Set wire speed and voltage tap settings to tables which are provided in the beginning of this section.

5. Flip toggle selector switch inside of machine to "Magnum® 100SG" position. Press and hold trigger for about 5 seconds to purge hose. Be sure the Gas flow rate is set to 20 to 50 SCFH thru the spool gun.

B-3

MAINTENANCE

P6 CONNECTOR PINOUT

MASTER KEY

P6 CONNECTOR PINOUT

MASTER KEY

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this maintenance.

• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

• Do not touch electrically hot parts.

-----------------------------------------------------

ROUTINE AND PERIODIC MAINTENANCE

RECOMMENDED TOOLS

• #2 Phillips screw-driver

• Slotted screw-driver

• 5/16 inch nut driver

• Torque Wrench

• Adjustable-jaw pliers

• 7/16 inch open-end wrench (gas diffuser)

• 9/16 inch open-end wrench (gun tube nut)

• Welding pliers (optional)

• Wire cutter

• Wire stripper

• Needle nose pliers

• Terminal crimping tool

• Flashlight

• Hand-held electrical meter *

• 3.0 mm metric allen wrench (drive roll screw)

• Tape measure or 6-inch scale

• Tachometer (optional)

*Note: Two meters are used for simultaneously

measuring drive motorʼs voltage and current.

P6 CONNECTOR PIN-OUT

- Motor

Black + Motor

Red

3 Trigger

White

2 Trigger

White

Pin No.

Function

Gun Cable Lead Color

Pin No.

1 2 3 4

TABLE D.1

Function

Trigger Trigger + Motor

- Motor

Gun Cable Lead Color

White White

Red

Black

GAS DIFFUSER REPLACEMENT

This part may need to be replaced if it has accumulated excessive spatter and cannot be cleaned:

1. Remove gas cone and contact tip.

2. Carefully grasp gun tube with pliers to prevent accidentally loosening gun tube. Gas diffuser has right-hand threads. Loosen gas diffuser with wrench. (See Figure D.1)

FIGURE D.1

CLEANING AND INSPECTIONS

• Vacuum out any aluminum shavings that may have accumulated inside of the gun. ( See Correcting Wire Shaving Issues in this section).

• Wipe off dust and debris.

• Check that the gun tube and its lock nut are properly tightened to the cable connector.

• Replace any warning or product identification decals that have become illegible.

3. Install gas diffuser and thread into place in gun tube. Tighten diffuser to 41 to 47 in.-lbs. with Torque Wrench.

D-1

MAINTENANCE

LINER ASSEMBLY REPLACEMENT OR CLEANING

1. Replacement liner assemblies are factory-made to the correct length. No cutting is required. The same liner fits all specified wire sizes and alloys:

2. Remove gas cone, contact tip, and gas

diffuser (see Gas Diffuser Replacement in this Section). Remove spool cover.

3. Liner removal: Grasp liner with Needle nose pliers at point A. Gently work liner toward cable connector until the liner is loose in it. Be careful not to scrape linerʼs gas-tight seal (point B) on connector. Withdraw liner out of gun tube (arrow C). (See figure D.2)

FIGURE D.2

3a. Clean out old liner by blowing out with

shop air or obtain a new replacement liner.

4. Slide liner, seal-end first, into gun tube. Grasp liner with pliers at

A. Gently push liner into connector. B. Check that liner passes through slot

in wire feeder.

C. Stop pushing when liner is 1.00 to

1.25 inches from end of gun tube. (See figure D.3)

6. Reinstall gas diffuser (see Figure D.1) and thread into place. Allow the diffuser to push the liner into its final position. Tighten to 41 to 47 in.-lbs. with a torque wrench.

7. Reinstall contact tip and gas cone.

DRIVE ROLL REPLACEMENT

1. The same drive roll fits all specified wire sizes and alloys (See Table D.1).

2. Replace the drive roll if its feeding groove has become worn or cannot be cleaned of galled aluminum.

3. Drive roll removal: Remove wire from the wire drive. Unlock drive roll by rotating twist-lock in either direction. (See figure D.4 and figure D.5) .

4. Twist-lock is rotated to the locked posi- tion, securing drive roll in place.

FIGURE D.4

Twist-lock Locked position

5. Twist-lock is rotated to the unlocked position, allowing drive roll removal.

FIGURE D.5

FIGURE D.3

5. Liner installation: See step 4 above.

Twist-lock Unlocked position

D-2

MAINTENANCE

6. Drive roll may be removed with pliers, as shown in figure D.6. It may be helpful to relieve the idle roll tension during this step.

FIGURE D.6

Idle Roll Tension

Correct orientation. Note that lower spring is not visible in bore of idle roll bearing at arrow.

FIGURE D.8

RIGHT

Incorrect orientation. Note that lower spring is visible in bore of idle roll bearing at arrow.

FIGURE D.9

WRONG

7. Clean the drive rollʼs groove or obtain a new replacement drive roll (if needed).

8. Install the drive roll by reversing the above steps 1 thru 7. Either side of the drive roll may be face-up.

IDLE ROLL ASSEMBLY REPLACEMENT

1. Replace if it is degraded from use; for

example, it is becoming galled with aluminum deposits.

2. Remove drive roll. (See Maintenance

Section)

3. Remove both idle roll assembly retaining

screws and washers.(See figure D.7)

FIGURE D.7

Retaining screws and washers

4. Using Needle nose pliers, slowly pull the

idle roll assembly out of the wire drive by equally working both sides of the tabbed idle roll spring.

6. Using Needle nose pliers, push the new idle roll assembly into the wire drive until it is fully seated.

7. Reinstall the retaining screws and washers. Do not use the screws to draw the idle roll into place. Reinstall the drive roll and wire into the wire drive.

GUN TUBE ASSEMBLY REPLACEMENT

1. Replace if it is degraded from use; for

example, its insulating tube is breaking down.

2. Remove liner assembly. (See

Maintenance Section)

3. Remove left side of handle. Loosen gun

tube nut with wrench. Nut has right-hand threads. Use adjustable pliers on gun tube mounting plate to prevent cable assembly from rotating in gun handle. (See figure D.10)

FIGURE D.10

5. Insert the new idle roll assembly into the wire drive with the correct orientation, (See figures D.8 and D.9).

D-3

MAINTENANCE

4. Obtain a new replacement gun tube (if need- ed). Remove locking nut from old gun tube and install onto new gun tube. Nut should be fully threaded finger-tight against the insulating tube.

5. Slide gun tubeʼs external threads through gun tube mounting plate and screw the gun tube by hand into the cable connector until the nut pulls the mounting plate snug against the connector.

6. Tighten the nut and mounting plate to the con- nector with Torque Wrench 10 to 12 ft.-lbs.

7. Reassemble gun. Be careful not to pinch any leads between gun handle halves.

WIRE DRIVE ASSEMBLY REMOVAL AND INSTALLATION

1. There are no serviceable or maintainable parts

inside of the wire drive.

2. Remove liner assembly (See Maintenance

Section figures D.2 and D.3).

3. Remove left side of handle.

4. Disconnect black and red leads from drive

motor. Use care to prevent damage to motorʼs fast-on electrical tabs.

5. Slide wire drive out of right handle half.

6. When reinstalling wire drive, note the proper

motor lead connection in the figure. Reconnect red motor lead to positive (+) terminal, marked with red dot at arrow. Reconnect black lead to other motor terminal. (See figure D.11)

“+” Terminal Red Dot

Black Lead

FIGURE D.11

7. Reassemble gun. Be careful not to pinch any

leads between gun handle halves.

D-4

TRIGGER ASSEMBLY REPLACEMENT

1. There are no serviceable or maintainable parts inside of the trigger.

2. Remove spool cover and left side of handle.

3. Slide trigger out of right handle half. Disconnect both white leads from trigger. Use care to prevent damage to electrical leads and the terminals. (See Figure D.12)

FIGURE D.12

White Leads

4. Connect both white leads to the new trigger. Either lead may be connected to either trigger pin (non-polarized connections).

5. Slide new trigger into place and reassemble the

gun. Be careful not to pinch any leads between gun handle halves.

WELDING CABLE ASSEMBLY REPLACEMENT

1. Generally, there are no serviceable or maintain-

able parts, except for both o-rings on the machineʼs power and gas connector; these seals may be replaced. However, there are options:

• Damage to the four #22 AWG control leads at

the gun cableʼs welding machine end (P6 plug) may be repairable without

removing or replacing the entire gun cable. The leads can be spliced and soldered back together, and then reinsulated with heat-shrink tubing. See Table D.1 in Maintenance Section for a description of the connections.

• Otherwise, the damaged gun cable may be replaced.

MAINTENANCE

2. Remove liner assembly. (See Maintenance Section)

3. Remove gun tube assembly. (See Maintenance Section)

4. Remove wire drive assembly. (See Maintenance

Section)

5. Disconnect trigger. Use adjustable pliers to

remove cable strain relief from right handle half. (See figure D.13)

6. Pull damaged cable out of the right handle half.

The cable connector will fit through the strain relief opening. Mark the new cable at a point 4.750 to

4.813 inches from the end of the cable connector. (See figure D.14)

7. Place the strain relief onto the new cable at the

mark as shown in figure D.15.

FIGURE D.13

FIGURE D.14

Liner assembly (S26612)

KP2632-1

1-piece

parts

Drive roll assembly (S26236-2)

KP2529-2

1-piece

replacement Periodic

Gun tube assembly (S19703-1)

KP2631-1

1-piece

Gas cone assembly (M16294)

KP1938-1

1-piece

Gas diffuser (S19728)

KP2040-1

1-piece

parts

Contact tip, 0.035 wire (S19726-3)

KP2039-3B1

10-pack

Consumable

Contact tip, 0.030 wire (S19726-2)

KP2039-2B1

10-pack

TABLE D.2

Consumable

parts

Periodic

replacement

parts

TABLE D.2

Contact tip, 0.030 wire (S19726-2)

Contact tip, 0.035 wire (S19726-3)

Gas diffuser (S19728)

Gas cone assembly (M16294)

Gun tube assembly (S19703-1)

Drive roll assembly (S26236-2)

Liner assembly (S26612)

Mark for strain relief

8. Install the new gun cable. Pass the cable connector through the opening in the right handle, seat the strain relief in place, and then check to insure the cable is not kinked between strain relief and connector. Reassemble gun by reversing steps 2 through 5.

CORRECTING WIRE SHAVING ISSUES

1. If the inlet of the liner assembly is shaving the alu-

minum wire (the wire is usually peeled off in curled chips) during feeding, the wire feed centerlines of the wire drive and the liner itself may be misaligned.

• This misalignment may occur whenever the gun tube, wire drive, or welding cable assemblies are replaced.

• A limited amount of adjustment is available at the gun tube mounting to possibly eliminate the shaving problem.

2. Visually check if wire is centered in the linerʼs inlet opening. Feed wire through the spool gun and note which side the shaving seems to occur.

3. Remove left side of handle. See Figure D.10 Gun

FIGURE D.15

Tube Replacement. Slightly

loosen gun tubeʼs nut

as shown.

4. Slide the gun tube in the mounting plateʼs hole to realign the wire and then retighten the nut as shown. Reassemble the gun.

5. Repeat steps 2 thru 4 until shaving is eliminated. A light accumulation of fine dust is also permissible after feeding 1/4 of a spool during welding use.

KP2039-2B1

KP2039-3B1

KP2040-1

KP1938-1

KP2631-1

KP2529-2

KP2632-1

10-pack

1-piece

D-5

+ 88 hidden pages