Lincoln Electric K2532-1 User manual

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MAGNUM®100SG SPOOL GUN
OPERATOR’S MANUAL
IMT913-A
August, 2010
Copyright © Lincoln Global Inc.
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 EQUIP-
MENT WITHOUT READING
THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.

FORENGINE
poweredequipment.
1.a.Turntheengineoffbeforetroubleshootingandmaintenance
workunlessthemaintenanceworkrequiresittoberunning.
____________________________________________________
1.b.Operateenginesinopen,well-ventilated
areasorventtheengineexhaustfumes
outdoors.
____________________________________________________
1.c.Donotaddthefuelnearanopenflameweld-
ingarcorwhentheengineisrunning.Stop
theengineandallowittocoolbeforerefuel-
ingtopreventspilledfuelfromvaporizingon
contactwithhotenginepartsandigniting.Do
notspillfuelwhenfillingtank.Iffuelisspilled,
wipeitupanddonotstartengineuntilfumes
havebeeneliminated.
____________________________________________________
1.d.Keepallequipmentsafetyguards,coversanddevicesinposi-
tionandingoodrepair.Keephands,hair,clothingandtools
awayfromV-belts,gears,fansandallothermovingparts
whenstarting,operatingorrepairingequipment.
____________________________________________________
1.e.Insomecasesitmaybenecessarytoremovesafety
guardstoperformrequiredmaintenance.Remove
guardsonlywhennecessaryandreplacethemwhenthe
maintenancerequiringtheirremovaliscomplete.
Alwaysusethegreatestcarewhenworkingnearmoving
parts.
___________________________________________________
1.f.Donotputyourhandsneartheenginefan.
Donotattempttooverridethegovernoror
idlerbypushingonthethrottlecontrolrods
whiletheengineisrunning.
___________________________________________________
1.g.Topreventaccidentallystartinggasolineengineswhile
turningtheengineorweldinggeneratorduringmaintenance
work,disconnectthesparkplugwires,distributorcapor
magnetowireasappropriate.
i
SAFETY
i
ARCWELDINGCANBEHAZARDOUS.PROTECTYOURSELFANDOTHERSFROMPOSSIBLESERIOUSINJURYORDEATH.
KEEPCHILDRENAWAY.PACEMAKERWEARERSSHOULDCONSULTWITHTHEIRDOCTORBEFOREOPERATING.
Readandunderstandthefollowingsafetyhighlights.Foradditionalsafetyinformation,itisstronglyrecommendedthatyou
purchaseacopyof“SafetyinWelding&Cutting-ANSIStandardZ49.1”fromtheAmericanWeldingSociety,P.O.Box351040,
Miami,Florida33135orCSAStandardW117.2-1974.AFreecopyof“ArcWeldingSafety”bookletE205isavailablefromthe
LincolnElectricCompany,22801St.ClairAvenue,Cleveland,Ohio44117-1199.
BESURETHATALLINSTALLATION,OPERATION,MAINTENANCEANDREPAIRPROCEDURESARE
PERFORMEDONLYBYQUALIFIEDINDIVIDUALS.
WARNING
ELECTRICAND
MAGNETICFIELDS
maybedangerous
2.a.Electriccurrentflowingthroughanyconductorcauses
localizedElectricandMagneticFields(EMF).Welding
currentcreatesEMFfieldsaroundweldingcablesand
weldingmachines
2.b.EMFfieldsmayinterferewithsomepacemakers,and
weldershavingapacemakershouldconsulttheirphysician
beforewelding.
2.c.ExposuretoEMFfieldsinweldingmayhaveotherhealth
effectswhicharenownotknown.
2.d.Allweldersshouldusethefollowingproceduresinorderto
minimizeexposuretoEMFfieldsfromtheweldingcircuit:
2.d.1.
Routetheelectrodeandworkcablestogether-Secure
themwithtapewhenpossible.
2.d.2.Nevercoiltheelectrodeleadaroundyourbody.
2.d.3.Donotplaceyourbodybetweentheelectrodeand
workcables.Iftheelectrodecableisonyourright
side,theworkcableshouldalsobeonyourrightside.
2.d.4.Connecttheworkcabletotheworkpieceascloseas
possibletotheareabeingwelded.
2.d.5.Donotworknexttoweldingpowersource.
1.h.Toavoidscalding,donotremovethe
radiatorpressurecapwhentheengineis
hot.
ForDieselEngines:Dieselengineexhaustand
someofitsconstituentsareknowntotheState
ofCaliforniatocausecancer,birthdefects,and
otherreproductiveharm.
ForGasolineEngines:Theengineexhaustfrom
thisproductcontainschemicalsknowntothe
StateofCaliforniatocausecancer,birthdefects,
orotherreproductiveharm.
CALIFORNIAPROPOSITION65WARNINGS
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.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 refuel-
ing 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.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in posi-
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.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
i
SAFETY
i
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.
WARNING
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:
2.d.1.
Route the electrode and work cables together - Secure
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.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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.
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.
CALIFORNIA PROPOSITION 65 WARNINGS
OPERATOR’S MANUAL

iv
SAFETY
iv
PRÉCAUTIONSDESÛRETÉ
Pourvotrepropreprotectionlireetobservertouteslesinstructions
etlesprécautionsdesûretéspecifiquesquiparraissentdansce
manuelaussibienquelesprécautionsdesûretégénéralessuiv-
antes:
SûretéPourSoudageALArc
1.Protegez-vouscontrelasecousseélectrique:
a.Lescircuitsàlʼélectrodeetàlapiécesontsoustension
quandlamachineàsouderestenmarche.Evitertoujours
toutcontactentrelespartiessoustensionetlapeaunue
oulesvétementsmouillés.Porterdesgantssecsetsans
trouspourisolerlesmains.
b.Fairetrésattentiondebiensʼisolerdelamassequandon
soudedansdesendroitshumides,ousurunplanchermet-
alliqueoudesgrillesmetalliques,principalementdans
lespositionsassisoucouchépourlesquellesunegrande
partieducorpspeutêtreencontactaveclamasse.
c.Maintenirleporte-électrode,lapincedemasse,lecâblede
soudageetlamachineàsouderenbonetsûrétatdefonc-
tionnement.
d.Nejamaisplongerleporte-électrodedanslʼeaupourle
refroidir.
e.Nejamaistouchersimultanémentlespartiessoustension
desporte-électrodesconnectésàdeuxmachinesàsouder
parcequelatensionentrelesdeuxpincespeutêtreletotal
delatensionàvidedesdeuxmachines.
f.Sionutiliselamachineàsoudercommeunesourcede
courantpoursoudagesemi-automatique,cesprecautions
pourleporte-électrodesʼapplicuentaussiaupistoletde
soudage.
2.Danslecasdetravailaudessusduniveaudusol,seprotéger
contreleschutesdanslecasouonrecoitunchoc.Nejamais
enroulerlecâble-électrodeautourdenʼimportequellepartiedu
corps.
3.Uncoupdʼarcpeutêtreplussévèrequʼuncoupdesoliel,donc:
a.Utiliserunbonmasqueavecunverrefiltrantappropriéainsi
quʼunverreblancafindeseprotégerlesyeuxdurayon-
nementdelʼarcetdesprojectionsquandonsoudeou
quandonregardelʼarc.
b.Porterdesvêtementsconvenablesafindeprotégerlapeau
desoudeuretdesaidescontrelerayonnementdelʻarc.
c.Protégerlʼautrepersonneltravaillantàproximitéau
soudageàlʼaidedʼécransappropriésetnon-inflammables.
4.Desgouttesdelaitierenfusionsontémisesdelʼarcde
soudage.Seprotégeravecdesvêtementsdeprotectionlibres
delʼhuile,telsquelesgantsencuir,chemiseépaisse,pan-
talonssansrevers,etchaussuresmontantes.
5.Toujoursporterdeslunettesdesécuritédanslazonede
soudage.Utiliserdeslunettesavecécranslaterauxdansles
zonesoùlʼonpiquelelaitier.
6.Eloignerlesmatériauxinflammablesoulesrecouvrirafinde
prévenirtoutrisquedʼincendiedûauxétincelles.
7.Quandonnesoudepas,poserlapinceàuneendroitisoléde
lamasse.Uncourt-circuitaccidentalpeutprovoquerun
échauffementetunrisquedʼincendie.
8.Sʼassurerquelamasseestconnectéelepluspréspossiblede
lazonedetravailquʼilestpratiquedelefaire.Sionplacela
massesurlacharpentedelaconstructionoudʼautresendroits
éloignésdelazonedetravail,onaugmentelerisquedevoir
passerlecourantdesoudageparleschainesdelevage,
câblesdegrue,ouautrescircuits.Celapeutprovoquerdes
risquesdʼincendieoudʼechauffementdeschainesetdes
câblesjusquʼàcequʼilsserompent.
9.Assureruneventilationsuffisantedanslazonedesoudage.
Ceciestparticuliérementimportantpourlesoudagedetôles
galvaniséesplombées,oucadmiéesoutoutautremétalqui
produitdesfumeéstoxiques.
10.Nepassouderenprésencedevapeursdechloreprovenant
dʼopérationsdedégraissage,nettoyageoupistolage.La
chaleuroulesrayonsdelʼarcpeuventréagiraveclesvapeurs
dusolvantpourproduireduphosgéne(gasfortementtoxique)
ouautresproduitsirritants.
11.Pourobtenirdeplusamplesrenseignementssurlas
ûreté,voir
lecode“Codeforsafetyinweldingandcutting”CSAStandard
W117.2-1974.
PRÉCAUTIONSDESÛRETÉPOUR
LESMACHINESÀSOUDERÀ
TRANSFORMATEURETÀ
REDRESSEUR
1.Relieràlaterrelechassisduposteconformementaucodede
lʼélectricitéetauxrecommendationsdufabricant.Ledispositif
demontageoulapieceàsouderdoitêtrebranchéàune
bonnemiseàlaterre.
2.Autantquepossible,Iʼinstallationetlʼentretienduposteseront
effectuésparunélectricienqualifié.
3.Avantdefairesdestravauxàlʼinterieurdeposte,ladebranch-
eràlʼinterrupteuràlaboitedefusibles.
4.Gardertouslescouverclesetdispositifsdesûretéàleurplace.
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûretéspecifiques qui parraissent dans ce
manuelaussi bien que les précautions de sûretégénérales suiv-
antes:
Sûreté Pour Soudage A LArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et àlapiéce sont sous tension
quand la machine àsouder est en marche. Eviter toujours
tout contact entre les parties sous tension et lapeau 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 met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couchépour lesquelles une grande
partie du corpspeut être en contact avec la masse.
c. Maintenir leporte-électrode, lapincedemasse,lecâblede
soudage et la machine àsouder en bon et sûrétat defonc-
tionnement.
d.Nejamais plonger leporte-électrode dans lʼeau pour le
refroidir.
e. Nejamais toucher simultanément les parties sous tension
des porte-électrodes connectésàdeuxmachines àsouder
parce que la tension entre les deuxpinces peut être letotal
de la tension àvide des deuxmachines.
f.Sionutilise la machine àsouder comme une source de
courant pour soudage semi-automatique, ces precautions
pour leporte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travailau dessus du niveau du sol,seprotéger
contre les chutes dans le cas ou on recoit un choc. Nejamais
enrouler lecâble-électrode autour de nʼimporte quellepartie du
corps.
3. Un coupdʼarc peut être plus sévère quʼun coupde soliel, donc:
a. Utiliser un bon masque avec un verre filtrant appropriéainsi
quʼun verre blanc afin de se protéger les yeuxdu rayon-
nement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger lapeau
de soudeur et des aides contre lerayonnement de lʻarc.
c. Protéger lʼautre personneltravaillant àproximitéau
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, telsque les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécuritédans lazone de
soudage. Utiliser des lunettes avec écrans laterauxdans les
zones oùlʼon pique lelaitier.
6. Eloigner les matériauxinflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dûauxétincelles.
7. Quand on ne soude pas, poser lapince àune endroit isolé de
la masse. Un court-circuit accidentalpeut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectéeleplus préspossiblede
lazone de travailquʼilest pratique de lefaire. Si on place la
masse sur la charpente de la construction ou dʼautres endroits
éloignésdelazone de travail, on augmente lerisque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Celapeut provoquer des
risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼilsserompent.
9. Assurer une ventilation suffisante dans lazone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métalqui
produit des fumeéstoxiques.
10. Nepas 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
ûreté, voir
le code “Code for safetyin welding and cutting”CSA Standard
W 117.2-1974.
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
lʼélectricitéet auxrecommendations du fabricant. Le dispositif
de montage ou lapiece àsouder doit être branchéàune
bonne mise àla terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectuéspar 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 dispositifsdesûretéàleur place.

vv
Thank
Y
You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product •••
as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual 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:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
On-Line Product Registration
- 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
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. 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.
Please Examine Carton and Equipment For Damage Immediately
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.

TABLE OF CONTENTS
Page
Installation Section--------------------------------------------------------------------------------A
Technical Specification---------------------------------------------------------------------------A-1
Unpacking the Spool Gun-----------------------------------------------------------------------A-1
SafetyPrecautions--------------------------------------------------------------------------------A-2
Locating Spool Gun Components And Features------------------------------------------A-2
AssemblyofItems 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
__________________________________________________________________
OPERATION Section----------------------------------------------------------------------------------B
SafetyPrecaution---------------------------------------------------------------------------------B-1
Product Description-------------------------------------------------------------------------------B-1
Machine Speed and Voltage tapSettings--------------------------------------------B-1, B-2
Welding Procedures------------------------------------------------------------------------------B-3
__________________________________________________________________
Maintenance Section------------------------------------------------------------------------------ D
SafetyPrecautions--------------------------------------------------------------------------------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 AssemblyReplacement or Cleaning--------------------------------------------------D-2
Drive Roll Replacement--------------------------------------------------------------------------D-2
Idle Roll AssemblyReplacement--------------------------------------------------------------D-3
Gun Tube AssemblyReplacement------------------------------------------------------------D-3
Wire Drive AssemblyRemoval And Installation--------------------------------------------D-4
Trigger AssemblyReplacement----------------------------------------------------------------D-4
Welding Cable AssemblyReplacement-----------------------------------------------D-4, D-5
Correcting Wire Shaving issues--------------------------------------------------------------D-5
__________________________________________________________________

TABLE OF CONTENTS
Page
Troubleshooting Section -------------------------------------------------------------------------E
SafetyPrecautions--------------------------------------------------------------------------------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®100SGSpool Gun
Aluminum GMAW (MIG), DC electrode positive
polaritywith 100% argon welding shielding gas.
Aluminum only: alloys 4043or 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 cush-
ioned carrying case. It is shipped fully-equipped to weld with 0.035 inch diameter alu-
minum wire. After opening the case, check that it contains the following items:
1. One fullyassembled K2532-1 spool gun.
2. One T11862-65 Conical Compression Spring for use with alloy5356 wire (spool
not included).
3. One spool of0.035 aluminum alloy4043wire
4. Three S19726-3contact tips
5. One instruction manual (IM913)
6. One M21182 electrical harness with toggle switch.
1
3
4
5
6
2
A-1
Plastic Bag

LOCATING SPOOL GUN COMPONENTS AND FEATURES
(See Figure 1.A for Items 1 thru 6)
1. Gas Cone Assemblyand 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.
(See Figure A.2 for these following items)
7. Integrated Single-Piece Cable:
The Magnum®design provides
neat and clean appearance; sim-
plifies cable management and
reduces entanglements.
8. Standard Durable Strain Relief
Clamp.
9. Three Captive Hex Nuts.
FIGURE A.1
Left Side View
14
35
5
2
FIGURE A.2
Right Side View
78
9
A-2
INSTALLATION
SAFETY PRECAUTIONS
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.
-----------------------------------------------------------------------------------------------------
WARNING

INSTALLATION
ASSEMBLY OF ITEMS INSIDE THE MAGNUM®SPOOL GUN
FIGURE A,3
A-3
TOP VIEW
Spool Cover and left
handle removed
Machine Connections
1
2
4
3
P6 CONNECTOR PINOUT
MASTER KEY
6
9
7
8
1
1. Liner Assemblyfeeds 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: Highlywear-
resistant.
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).
7. Locking Knob: Independentlyretains
the wire spool on the spindle.
8. Liner Assembly: Includes a gas seal
with the cable connector and is the
outgoing wire guide.
9. Only4 sub-assemblies: gun tube;
cable; wire drive; trigger.
10. Conical spring (not shown)serves
as the spool brake (use onlywith
aluminum alloy5356).
4
3
2

INSTALLATION
SAFETY PRECAUTIONS
WELDING MACHINES
• Read and understand the welding machineʼs instruction manu-
al 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
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
CAUTION
WARNING

INSTALLATION
A-5
RECOMMENDED WELDING MACHINES
MACHINE NAME
NOTE: THE MACHINE CODE NUMBER IS LISTED ON THE BACK OF THE MACHINE.
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
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
SPOOL GUN USE NOT AVAILABLE
SPOOL GUN USE NOT AVAILABLE
SPOOL GUN USE NOT AVAILABLE
SPOOL GUN USE NOT AVAILABLE
REQUIRED
NOT REQUIRED
REQUIRED
REQUIRED
NOT REQUIRED
REQUIRED
NOT REQUIRED
REQUIRED
REQUIRED
NOT REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED

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.
INSTALLATION
SPOOL GUN / WIRE DRIVE
SELECTOR SWITCH
INSTALLATION
1. Install the M21182 electrical adapter
harness that came with the spool gun
per the following instructions.
ELECTRIC SHOCK CAN KILL.
2. Disconnect input
power from the
machine.
------------------------------------------------
OPEN THE MACHINE
3. Remove two 5/16“hex hinge screws
from door.
4. Remove ten 5/16“hex screws from
cover.
5. Remove screws from cover.
(A) is the location oftwo 3/4”long
screws.
6. Remove cover.
7. Ifmachine has a plastic handle (A),
then remove screw (B).
WARNING
A
A
B
A-6

INSTALLATION
A-7
ELECTRICAL CONNECTIONS
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).
9.B. Connect P3 (10-pin) to har-
ness J7 (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).
11.C. Connect harness P8 (6-pin)
to board J5 (6-pin).
Toggle Switch
P8 (6-pin)
P7 (10-pin)
J8 (6-pin)
J
7 (10-pin)
543A
(Female)
544A
(Male)
J3
P3
P3
J7
J3
P7
P5
J5
P5
J8
P8
J5

INSTALLATION
11.D. Find assembled pair ofmachine
terminals (leads 543A & 544A)
and disconnect. Go to step13.
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.B. Connect P5 (6-pin) to adapter
harness J8 (6-pin).
12.C. Connect adapter harness P8 (6-
pin) to spot timer harness J9 (6-
pin).
12.D. Find assembled pair ofmachine
terminals (leads 543A & 544A)
and disconnect.
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.
543A
544A
J9
P5
P5
J8
J9
P8
543A
544A
A
B
A-8

INSTALLATION
A-9
MOUNTING THE SWITCH
15. Remove the plug button from the
panel hole.
16. Plug button is no longer needed.
Discard.
17. Remove mounting nut from switch.
Keepmounting nut for installation.
18. Install switch into panel hole.
Ensure washer tab is fullyseated
into smaller hole.
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.

INSTALLATION
ROUTINE WELDING MACHINE PREPARATION
ELECTRIC SHOCK CAN KILL.
1. Disconnect input power to the machine.
------------------------------------------------------------------------
2. Machine polaritysetting: Set to DC electrode positive
polarityper the machineʼs Instruction Manual.
3. Gas selection and flow rate: Connect 100% welding
grade argon gas supplyto the machineʼs gas solenoid
valve. Set the supplyregulator to deliver a gas flow rate
of20 to 50 SCFH thru the spool gun.]
4. Flipthe machineʼs wire drive selector switch (behind the
access door)to "Magnum® 100SG". (See Figure A.4)
FIGURE A.4
WARNING
PREPARING THE SPOOL GUN
ELECTRIC SHOCK CAN KILL.
1. Disconnect input power to the machine.
------------------------------------------------------------------------
2. The Conical Spring is used as the spool brake onlywhen
feeding the stronger and harder aluminum alloy5356.
The Conical Spring must be removed from the spool gun
whenever using the softer aluminum alloy4043.
WARNING
A-10

INSTALLATION
A-11
LOADING ALUMINUM WIRE
1. Remove gas cone and contact tip.
Remove spool cover byunscrewing
captive locking knob.
FIGURE A.5
2. Remove locking knob from spindle
bolt byunscrewing it.
FIGURE A.6
3. Select wire alloyand diameter need-
ed. Alloy4043and 0.035 wire size
shown. Remove packaging and data
sheet from wire spool.
FIGURE A.7
4. Extend approximately12 inches
ofwire from spool. Straighten it
out byback-bending it. Use care
to prevent the wire from dereeling.
FIGURE A.8
5. Cut off bent end ofwire, leaving
straight section.
FIGURE A.9
6. Gentlypull open the idle roll
assemblyto expose the drive roll
groove.
FIGURE A.10
Alloy
Size

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 ofwire through drive rollʼs
groove and toward gun tube liner.
FIGURE A.12
9. Slide the wire into the liner until it
extends approximately1 inch beyond
the end ofthe gas diffuser. Release
idle roll tab without snapping it.
FIGURE A.13
10a. Alloy4043: Roll upremaining wire
back onto spool and place spool
onto gun spindle. Install locking
knob and finger-tighten. Go to step
11.
FIGURE A.14
10b. Alloy5356: Install Conical Spring,
small end first, onto gun spindle
(A). Roll upremaining wire back
onto spool and place spool onto
gun spindle. Install locking knob
and finger-tighten.
FIGURE A.15
11. Graspthe free end ofthe wire at the
gas diffuser and slowlypull approxi-
mately12 to 24 inches ofwire
through the spool gun. There should
onlybe 1 to 2 lbs. ofresistance. If
force is greater than 2 lbs. wire is
binding in the gun (also see
Troubleshooting guide).
FIGURE A.16
A
A-12