Lincoln Electric K3269-1 User manual

FORENGINE
powered equipment.
1.a. Turn theengineoffbeforetroubleshootingandmaintenance
work unless themaintenanceworkrequiresittoberunning.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent theengineexhaustfumes
outdoors.
____________________________________________________
1.c. Do not add thefueln
earanopenflameweld-
ing arcorwhentheengineisrunning.Stop
theengineandallowittocoolbeforerefuel-
ingtopreventspilledfuelfromvaporizingon
contact with hotenginepartsandigniting.Do
notspillfuelwhenfillingtank.Iffuelisspilled,
wipe it up anddonotstartengineuntilfumes
have been eliminated.
____________________________________________________
1.d. Keep allequip
mentsafetyguards,coversanddevicesinposi-
tion andingoodrepair.Keephands,hair,clothingandtools
away from V-belts, gears, fans and allothermovingparts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it maybenece
ssarytoremovesafety
guardstoperform required maintenance. Remove
guards only when necessary andreplacethemwhenthe
maintenance requiringtheir removaliscomplete.
Always use thegreatestcarewhenworkingnearmoving
parts.
___________________________________________________
1.f. Do not putyourh
andsneartheenginefan.
Do notattempttooverridethegovernoror
idler by pushing on thethrottlecontrolrods
while theengineisrunning.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning theengin
eorweldinggeneratorduringmaintenance
work, disconnect thesparkplugwires,distributorcap or
magneto wire as appropriate.
i
SAFETY
i
ARC WELDING CANBEHAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDRENAWAY.PACEMAKERWEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read andunderstandthefollowingsafetyhighlights.Foradditional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting -ANSI Standard Z49.1” from theAmericanWelding Society, P.O. Box 351040,
Miami, Florida33135orCSAStandardW117.2-1974.AFreecopyof“ArcWelding Safety” booklet E205isavailable from the
Lincoln Electric Company, 22801 St.ClairAvenue,Cleveland,Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURESARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
ELECTRIC AND
MAGNETIC FIELDS
maybedangerous
2.a. Electric currentflowingthrough any conductor causes
localizedElectric and Magnetic Fields (EMF). Welding
currentcreates EMF fieldsaround 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 EMFfieldsinweldingmayhaveotherhealth
effects which are now notknown.
2.d. Allweldersshoulduse thefollowingproceduresinorderto
minimize exposure to EMFfieldsfromtheweldingcircuit:
2.d.1. Route the electrode and workcablestogether - Secure
them with tape when possible.
2.d.2. Never coiltheelectrode lead around your body.
2.d.3. Do notplaceyourbodybetweentheelectrodeand
work cables. If theelectrodecableisonyourright
side, theworkcableshouldalsobeonyourrightside.
2.d.4. Connect theworkcabletotheworkpieceascloseas
possible to theareabeingwelded.
2.d.5. Do notworknexttoweldingpowersource.
1.h. To avoid scalding, do notremovethe
radiator pressure capwhentheengineis
hot.
For Diesel Engines: Diesel engine exhaust and
some of itsconstituentsareknowntotheState
of California to cause cancer, birth defects, and
other reproductive harm.
For Gasoline Engines: The engine exhaust from
this product contains chemicals knowntothe
StateofCaliforniatocause cancer, birth defects,
or other reproductive harm.
CALIFORNIAPROPOSITION65WARNINGS
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
MAGNUM® PRO 100SG SPOOL GUN
OPERATOR’S MA UAL
IMT10137
November, 2012
Copyright © Lincoln Global Inc.
Safety Depends on You
Lincoln arc welding and c tting
eq ipment is designed and b ilt
with safety in mind. However,
yo r overall safety can be
increased by proper installation ...
and tho ghtf l operation on yo r
part. DO OT I STALL, OPER-
ATE OR REPAIR THIS EQUIP-
ME T WITHOUT READI G
THIS MA UAL A D THE
SAFETY PRECAUTIO S CO -
TAI ED THROUGHOUT. And,
most importantly, think before yo
act and be caref l.

FORENGINE
powered equipment.
1.a. Turn theengineoffbeforetroubleshootingandmaintenance
work unless themaintenanceworkrequiresittoberunning.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent theengineexhaustfumes
outdoors.
____________________________________________________
1.c. Do not add thefueln
earanopenflameweld-
ing arcorwhentheengineisrunning.Stop
theengineandallowittocoolbeforerefuel-
ingtopreventspilledfuelfromvaporizingon
contact with hotenginepartsandigniting.Do
notspillfuelwhenfillingtank.Iffuelisspilled,
wipe it up anddonotstartengineuntilfumes
have been eliminated.
____________________________________________________
1.d. Keep allequip
mentsafetyguards,coversanddevicesinposi-
tion andingoodrepair.Keephands,hair,clothingandtools
away from V-belts, gears, fans and allothermovingparts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it maybenece
ssarytoremovesafety
guardstoperform required maintenance. Remove
guards only when necessary andreplacethemwhenthe
maintenance requiringtheir removaliscomplete.
Always use thegreatestcarewhenworkingnearmoving
parts.
___________________________________________________
1.f. Do not putyourh
andsneartheenginefan.
Do notattempttooverridethegovernoror
idler by pushing on thethrottlecontrolrods
while theengineisrunning.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning theengin
eorweldinggeneratorduringmaintenance
work, disconnect thesparkplugwires,distributorcap or
magneto wire as appropriate.
i
SAFETY
i
ARC WELDING CANBEHAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDRENAWAY.PACEMAKERWEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read andunderstandthefollowingsafetyhighlights.Foradditional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting -ANSI Standard Z49.1” from theAmericanWelding Society, P.O. Box 351040,
Miami, Florida33135orCSAStandardW117.2-1974.AFreecopyof“ArcWelding Safety” booklet E205isavailable from the
Lincoln Electric Company, 22801 St.ClairAvenue,Cleveland,Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURESARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
ELECTRIC AND
MAGNETIC FIELDS
maybedangerous
2.a. Electric currentflowingthrough any conductor causes
localizedElectric and Magnetic Fields (EMF). Welding
currentcreates EMF fieldsaround 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 EMFfieldsinweldingmayhaveotherhealth
effects which are now notknown.
2.d. Allweldersshoulduse thefollowingproceduresinorderto
minimize exposure to EMFfieldsfromtheweldingcircuit:
2.d.1. Route the electrode and workcablestogether - Secure
them with tape when possible.
2.d.2. Never coiltheelectrode lead around your body.
2.d.3. Do notplaceyourbodybetweentheelectrodeand
work cables. If theelectrodecableisonyourright
side, theworkcableshouldalsobeonyourrightside.
2.d.4. Connect theworkcabletotheworkpieceascloseas
possible to theareabeingwelded.
2.d.5. Do notworknexttoweldingpowersource.
1.h. To avoid scalding, do notremovethe
radiator pressure capwhentheengineis
hot.
For Diesel Engines: Diesel engine exhaust and
some of itsconstituentsareknowntotheState
of California to cause cancer, birth defects, and
other reproductive harm.
For Gasoline Engines: The engine exhaust from
this product contains chemicals knowntothe
StateofCaliforniatocause cancer, birth defects,
or other reproductive harm.
CALIFORNIAPROPOSITION65WARNINGS
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
MAGNUM® PRO 100SG SPOOL GUN
OPERATOR’S MA UAL
IMT10137
November, 2012
Copyright © Lincoln Global Inc.
Safety Depends on You
Lincoln arc welding and c tting
eq ipment is designed and b ilt
with safety in mind. However,
yo r overall safety can be
increased by proper installation ...
and tho ghtf l operation on yo r
part. DO OT I STALL, OPER-
ATE OR REPAIR THIS EQUIP-
ME T WITHOUT READI G
THIS MA UAL A D THE
SAFETY PRECAUTIO S CO -
TAI ED THROUGHOUT. And,
most importantly, think before yo
act and be caref l.

vv
TThhaannkkYYoouufor 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 “Support” and then “Register
Your Product”. 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 customerʼs 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.
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protectionlireetobserver toutes lesinstructions
et les précautionsdesûretéspecifiquesquiparraissentdansce
manuelaussibienque les précautionsdesûretégénéralessuiv-
antes:
Sûreté Pour Soudage A L Arc
1. Protegez-vous contre la secousse électrique:
a. Lescircuits à l électrode et à la piécesontsoustension
quand la machine à souder estenmarche. Eviter toujours
toutcontactentreles partiessoustensionetlapeaunue
ou lesvétements mouillés.Porter desgantssecsetsans
trouspourisolerles mains.
b. Faire trés attention de bien s isoler de la massequandon
soude dans desendroitshumides, ou surunplanchermet-
allique ou des grilles metalliques, principalement dans
lespositionsassisoucouchépourlesquellesune grande
partieducorpspeutêtreencontactaveclamasse.
c. Maintenirleporte-électrode,lapincedemasse,lecâblede
soudage et la machine à souder en bonetsûr étatdefonc-
tionnement.
d.Nejamaisplongerleporte-électrode dans l eau pour le
refroidir.
e. Ne jamais touchersimultanémentlespartiessoustension
desporte-électrodesconnectés à deux machinesàsouder
parce quelatensionentrelesdeuxpincespeutêtreletotal
de la tension à vide desdeuxmachines.
f. Si on utiliselamachine à souder comme unesourcede
courantpoursoudagesemi-automatique, ces precautions
pour le porte-électrode s applicuent aussi au pistolet de
soudage.
2. Dans le casdetravailaudessusduniveaudusol,seprotéger
contre leschutesdanslecasouonrecoitunchoc.Nejamais
enrouler le câble-électrodeautour de n importequellepartie du
corps.
3. Un coup d arc peut être plus sévère qu un coup de soliel, donc:
a. Utiliserunbon masqueavecunverrefiltrantappropriéainsi
qu un verre blanc afindeseprotéger lesyeuxdurayon-
nement de l arc et des projectionsquandonsoudeou
quand on regarde l arc.
b. Porter desvêtements convenables afindeprotégerlapeau
de soudeur et desaidescontrelerayonnement de lʻarc.
c. Protéger l autre personnel travaillant à proximitéau
soudage à l aide d écransappropriésetnon-inflammables.
4. Desgouttesdelaitierenfusionsontémises de l arc de
soudage. Se protégeravecdesvêtementsdeprotectionlibres
de l huile, tels que lesgantsencuir,chemiseépaisse,pan-
talonssansrevers,etchaussuresmontantes.
5. Toujours porter deslunettesdesécuritédanslazonede
soudage. Utiliser deslunettesavecécranslaterauxdansles
zones où l on pique le laitier.
6. Eloigner les matériaux inflammablesoules recouvrir afin de
prévenir tout risque d incendiedûaux étincelles.
7. Quandonnesoude pas, poserlapince à une endroit isolé de
la masse.Uncourt-circuit accidental peut provoquerun
échauffementetunrisque d incendie.
8. S assurer quelamasse est connectéeleplus prés possible de
la zonedetravail qu il est pratiquedelefaire.Sionplace la
masse surlacharpentedelaconstructionoud autres endroits
éloignésdelazonedetravail,onaugmentelerisquedevoir
passerlecourantdesoudage par les chainesdelevage,
câblesdegrue,ouautres circuits. Cela peut provoquer des
risques d incendieoud echauffement des chainesetdes
câbles jusqu àcequ ilsserompent.
9. Assurer une ventilation suffisante danslazonedesoudage.
Ceci est particuliérement important pourlesoudagedetôles
galvanisées plombées,oucadmiéesoutout autre métal qui
produit des fumeés toxiques.
10.Nepas souderenprésencedevapeursdechlore provenant
d opérations de dégraissage, nettoyage ou pistolage. La
chaleuroules rayonsdel arc peuvent réagir avec les vapeurs
du solvant pour produireduphosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenirdeplus amples renseignements surlasûreté, voir
le code “Code for safetyinwelding and cutting” CSA Standard
W117.2-1974.
PRÉCAUTIONSDESÛRETÉ POUR
LES MACHINESÀSOUDERÀ
TRANSFORMATEURETÀ
REDRESSEUR
1. Relier à la terrelechassisduposte conformementaucode de
l électricitéetaux recommendationsdufabricant.Ledispositif
de montageoulapiece à souder doit être branché à une
bonne miseàlaterre.
2. Autant que possible, I installationetl entretienduposte seront
effectués parunélectricien qualifié.
3. Avantdefaires des travaux à l interieurdeposte,ladebranch-
er à l interrupteur à la boitedefusibles.
4. Garder tous les couverclesetdispositifsdesûreté à leur place.

vv
TThhaannkkYYoouufor 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 “Support” and then “Register
Your Product”. 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 customerʼs 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.
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protectionlireetobserver toutes lesinstructions
et les précautionsdesûretéspecifiquesquiparraissentdansce
manuelaussibienque les précautionsdesûretégénéralessuiv-
antes:
Sûreté Pour Soudage A L Arc
1. Protegez-vous contre la secousse électrique:
a. Lescircuits à l électrode et à la piécesontsoustension
quand la machine à souder estenmarche. Eviter toujours
toutcontactentreles partiessoustensionetlapeaunue
ou lesvétements mouillés.Porter desgantssecsetsans
trouspourisolerles mains.
b. Faire trés attention de bien s isoler de la massequandon
soude dans desendroitshumides, ou surunplanchermet-
allique ou des grilles metalliques, principalement dans
lespositionsassisoucouchépourlesquellesune grande
partieducorpspeutêtreencontactaveclamasse.
c. Maintenirleporte-électrode,lapincedemasse,lecâblede
soudage et la machine à souder en bonetsûr étatdefonc-
tionnement.
d.Nejamaisplongerleporte-électrode dans l eau pour le
refroidir.
e. Ne jamais touchersimultanémentlespartiessoustension
desporte-électrodesconnectés à deux machinesàsouder
parce quelatensionentrelesdeuxpincespeutêtreletotal
de la tension à vide desdeuxmachines.
f. Si on utiliselamachine à souder comme unesourcede
courantpoursoudagesemi-automatique, ces precautions
pour le porte-électrode s applicuent aussi au pistolet de
soudage.
2. Dans le casdetravailaudessusduniveaudusol,seprotéger
contre leschutesdanslecasouonrecoitunchoc.Nejamais
enrouler le câble-électrodeautour de n importequellepartie du
corps.
3. Un coup d arc peut être plus sévère qu un coup de soliel, donc:
a. Utiliserunbon masqueavecunverrefiltrantappropriéainsi
qu un verre blanc afindeseprotéger lesyeuxdurayon-
nement de l arc et des projectionsquandonsoudeou
quand on regarde l arc.
b. Porter desvêtements convenables afindeprotégerlapeau
de soudeur et desaidescontrelerayonnement de lʻarc.
c. Protéger l autre personnel travaillant à proximitéau
soudage à l aide d écransappropriésetnon-inflammables.
4. Desgouttesdelaitierenfusionsontémises de l arc de
soudage. Se protégeravecdesvêtementsdeprotectionlibres
de l huile, tels que lesgantsencuir,chemiseépaisse,pan-
talonssansrevers,etchaussuresmontantes.
5. Toujours porter deslunettesdesécuritédanslazonede
soudage. Utiliser deslunettesavecécranslaterauxdansles
zones où l on pique le laitier.
6. Eloigner les matériaux inflammablesoules recouvrir afin de
prévenir tout risque d incendiedûaux étincelles.
7. Quandonnesoude pas, poserlapince à une endroit isolé de
la masse.Uncourt-circuit accidental peut provoquerun
échauffementetunrisque d incendie.
8. S assurer quelamasse est connectéeleplus prés possible de
la zonedetravail qu il est pratiquedelefaire.Sionplace la
masse surlacharpentedelaconstructionoud autres endroits
éloignésdelazonedetravail,onaugmentelerisquedevoir
passerlecourantdesoudage par les chainesdelevage,
câblesdegrue,ouautres circuits. Cela peut provoquer des
risques d incendieoud echauffement des chainesetdes
câbles jusqu àcequ ilsserompent.
9. Assurer une ventilation suffisante danslazonedesoudage.
Ceci est particuliérement important pourlesoudagedetôles
galvanisées plombées,oucadmiéesoutout autre métal qui
produit des fumeés toxiques.
10.Nepas souderenprésencedevapeursdechlore provenant
d opérations de dégraissage, nettoyage ou pistolage. La
chaleuroules rayonsdel arc peuvent réagir avec les vapeurs
du solvant pour produireduphosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenirdeplus amples renseignements surlasûreté, voir
le code “Code for safetyinwelding and cutting” CSA Standard
W117.2-1974.
PRÉCAUTIONSDESÛRETÉ POUR
LES MACHINESÀSOUDERÀ
TRANSFORMATEURETÀ
REDRESSEUR
1. Relier à la terrelechassisduposte conformementaucode de
l électricitéetaux recommendationsdufabricant.Ledispositif
de montageoulapiece à souder doit être branché à une
bonne miseàlaterre.
2. Autant que possible, I installationetl entretienduposte seront
effectués parunélectricien qualifié.
3. Avantdefaires des travaux à l interieurdeposte,ladebranch-
er à l interrupteur à la boitedefusibles.
4. Garder tous les couverclesetdispositifsdesûreté à leur place.

TABLE OF CO TE TS
Page
Installation Section--------------------------------------------------------------------------------A
Technical Specification---------------------------------------------------------------------------A-1
Unpacking the Spool un-----------------------------------------------------------------------A-1
Safety Precautions--------------------------------------------------------------------------------A-2
Locating Spool un Components And Features------------------------------------------A-2
Assembly of Items Inside the Magnum Pro Spool un ---------------------------------------A-3
Welding Machines--------------------------------------------------------------------------------A-4
Recommended Welding Machines-----------------------------------------------------------A-5
Spool un / Wire Drive Selector Switch Installation--------------------------A-6 thru A-9
Routine Welding Machine Preparation------------------------------------------------------A-10
Preparing the Spool un-----------------------------------------------------------------------A-10
Loading Aluminum-----------------------------------------------------------------A-10 thru A-13
Connecting the un to the Welding Machine--------------------------------------------A-13
__________________________________________________________________
OPERATIO 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
as Diffuser Replacement----------------------------------------------------------------------D-1
Liner Assembly Replacement or Cleaning--------------------------------------------------D-2
Drive Roll Replacement--------------------------------------------------------------------------D-2
Idle Roll Assembly Replacement--------------------------------------------------------------D-3
un 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 CO TE TS
Page
Troubleshooting Section -------------------------------------------------------------------------E
Safety Precautions--------------------------------------------------------------------------------E-1
How To Use Trouble Shooting uide---------------------------------------------------------E-1
Troubleshooting----------------------------------------------------------------------------E-2 to E-4
____________________________________________________________________
Diagrams Section -----------------------------------------------------------------------------------F
Wiring Diagrams------------------------------------------------------------------------------------F-1
____________________________________________________________________
Parts List--------------------------------------------------------------------------------P-554 Series
____________________________________________________________________

TABLE OF CO TE TS
Page
Installation Section--------------------------------------------------------------------------------A
Technical Specification---------------------------------------------------------------------------A-1
Unpacking the Spool un-----------------------------------------------------------------------A-1
Safety Precautions--------------------------------------------------------------------------------A-2
Locating Spool un Components And Features------------------------------------------A-2
Assembly of Items Inside the Magnum Pro Spool un ---------------------------------------A-3
Welding Machines--------------------------------------------------------------------------------A-4
Recommended Welding Machines-----------------------------------------------------------A-5
Spool un / Wire Drive Selector Switch Installation--------------------------A-6 thru A-9
Routine Welding Machine Preparation------------------------------------------------------A-10
Preparing the Spool un-----------------------------------------------------------------------A-10
Loading Aluminum-----------------------------------------------------------------A-10 thru A-13
Connecting the un to the Welding Machine--------------------------------------------A-13
__________________________________________________________________
OPERATIO 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
as Diffuser Replacement----------------------------------------------------------------------D-1
Liner Assembly Replacement or Cleaning--------------------------------------------------D-2
Drive Roll Replacement--------------------------------------------------------------------------D-2
Idle Roll Assembly Replacement--------------------------------------------------------------D-3
un 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 CO TE TS
Page
Troubleshooting Section -------------------------------------------------------------------------E
Safety Precautions--------------------------------------------------------------------------------E-1
How To Use Trouble Shooting uide---------------------------------------------------------E-1
Troubleshooting----------------------------------------------------------------------------E-2 to E-4
____________________________________________________________________
Diagrams Section -----------------------------------------------------------------------------------F
Wiring Diagrams------------------------------------------------------------------------------------F-1
____________________________________________________________________
Parts List--------------------------------------------------------------------------------P-554 Series
____________________________________________________________________

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K3269-1 MA NUM®PRO100S Spool un
Aluminum MAW (MI ), 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
' " &%"!!'
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 fully assembled K3269-1 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 S28172-1 contact tips
5. One instruction manual (IMT10137)
6. One M21182 electrical harness with toggle switch.
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(See Figure 1.A for Items 1 thru 6)
1. as Nozzle and Contact Tip.
2. Straightened un 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®Pro design provides
neat and clean appearance; sim-
plifies cable management and
reduces entanglements.
8. Standard Durable Strain Relief
Clamp.
9. Three Captive Hex Nuts.
M
A
G
N
U
M
P
R
O
1
0
0
S
G
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K3269-1 MA NUM®PRO100S Spool un
Aluminum MAW (MI ), 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
' " &%"!!'
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 fully assembled K3269-1 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 S28172-1 contact tips
5. One instruction manual (IMT10137)
6. One M21182 electrical harness with toggle switch.
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(See Figure 1.A for Items 1 thru 6)
1. as Nozzle and Contact Tip.
2. Straightened un 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®Pro design provides
neat and clean appearance; sim-
plifies cable management and
reduces entanglements.
8. Standard Durable Strain Relief
Clamp.
9. Three Captive Hex Nuts.
M
A
G
N
U
M
P
R
O
1
0
0
S
G
®
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 
&!"()
Spool Cover and left
handle removed
Machine Connections
11
22
44
33
P6 CONNECTOR PINOUT
MASTER KEY





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 uide: Highly wear-
resistant.
5. P6 Connector Control Leads: Motor
Power and Trigger. (See
Maintenance Section for more
details)
6. Welding Power and Shielding as
Machine connection (Sealed with 2
o-rings).
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).
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------------------------------------------------------------------------------------------------------
 
&!"()
Spool Cover and left
handle removed
Machine Connections
11
22
44
33
P6 CONNECTOR PINOUT
MASTER KEY





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 uide: Highly wear-
resistant.
5. P6 Connector Control Leads: Motor
Power and Trigger. (See
Maintenance Section for more
details)
6. Welding Power and Shielding as
Machine connection (Sealed with 2
o-rings).
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).
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1. Install the M21182 electrical adapter
harness that came with the spool gun
per the following instructions.
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5>/:991/? 59;@?
;:B1= 2=:8 ?41
8-/4591
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3. Remove two 5/16“ hex hinge screws
from door.
4. Remove ten 5/16“ hex screws from
cover.
5. Remove screws from cover.
( is the location of two 3/4” long
screws.
6. Remove cover.
7. If machine has a plastic handle ,
then remove screw .
)$  



 
RECOMMENDED WELDING MACHINES
MACHINE NAME K-NUMBER CODE NUMBER INSTALLATION OF M21182 HARNESS
AND SELECTOR SWITCH
POWER MIG 216
POWER MIG 180C
POWER MIG 140C
POWER MIG 180 DUAL
POWER MIG 180C (AU)
POWER MIG 180C (CE)
PRO CORE 125T WELDER
PRO MIG 140T WELDER
WELD PAK 125HD WELDER
WELD PAK 140HD WELDER
MIG PAK 140 WELDER
EASY CORE 125 WELDER
EASY MIG 140 WELDER
CORE PAK 125 WELDER
PRO MIG 180T WELDER
WELD PACK 180HD WELDER
MIG PAK 180 WELDER
SP-140T
SP-180T
EASY MIG 180 WELDER
K2816-2
K2473-2
K2471-2
K3018-2
K2668-1
K2661-1
K2479-1
K2480-1
K2513-1
K2514-1
K2658-1
K2696-1
K2697-1
K2785-1
K2481-1
K2515-1
K2659-1
K2688-2
K2689-2
K2698-1
11817
11820
11804
11828
11444
11442
11631
11634
11632
11635
11636
11633
11637
11639
11646
11647
11648
11805
11822
11650
NOT REQUIRED
REQUIRED
REQUIRED
NOT REQUIRED
REQUIRED
REQUIRED
SPOOL GUN USE NOTAVAILABLE
NOT REQUIRED
SPOOL GUN USE NOTAVAILABLE
NOT REQUIRED
NOT REQUIRED
SPOOL GUN USE NOTAVAILABLE
NOT REQUIRED
SPOOL GUN USE NOTAVAILABLE
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED

 %&&!
!&9>?-77-?5:9 :2 ?41 4-=91>>-90 >;::7 3@9>171/?:= >B5?/4 5>
9:?=1<@5=102:=-778-/4591>2->;::73@9>B5?/45>;=159>?-771059?41
8-/4591K> B5=1 0=5A1 /:8;-=?819? ?419 ?41 %"!! '   )$ $(
%&!$%)& %&&! %&! /-9.105>=13-=010
 %&&!
%"!!' )$$(
%&!$%)&
 %&&!
1. Install the M21182 electrical adapter
harness that came with the spool gun
per the following instructions.
&$J%! 
5>/:991/? 59;@?
;:B1= 2=:8 ?41
8-/4591
------------------------------------------------
!" & 
3. Remove two 5/16“ hex hinge screws
from door.
4. Remove ten 5/16“ hex screws from
cover.
5. Remove screws from cover.
( is the location of two 3/4” long
screws.
6. Remove cover.
7. If machine has a plastic handle ,
then remove screw .
)$  



 
RECOMMENDED WELDING MACHINES
MACHINE NAME K-NUMBER CODE NUMBER INSTALLATION OF M21182 HARNESS
AND SELECTOR SWITCH
POWER MIG 216
POWER MIG 180C
POWER MIG 140C
POWER MIG 180 DUAL
POWER MIG 180C (AU)
POWER MIG 180C (CE)
PRO CORE 125T WELDER
PRO MIG 140T WELDER
WELD PAK 125HD WELDER
WELD PAK 140HD WELDER
MIG PAK 140 WELDER
EASY CORE 125 WELDER
EASY MIG 140 WELDER
CORE PAK 125 WELDER
PRO MIG 180T WELDER
WELD PACK 180HD WELDER
MIG PAK 180 WELDER
SP-140T
SP-180T
EASY MIG 180 WELDER
K2816-2
K2473-2
K2471-2
K3018-2
K2668-1
K2661-1
K2479-1
K2480-1
K2513-1
K2514-1
K2658-1
K2696-1
K2697-1
K2785-1
K2481-1
K2515-1
K2659-1
K2688-2
K2689-2
K2698-1
11817
11820
11804
11828
11444
11442
11631
11634
11632
11635
11636
11633
11637
11639
11646
11647
11648
11805
11822
11650
NOT REQUIRED
REQUIRED
REQUIRED
NOT REQUIRED
REQUIRED
REQUIRED
SPOOL GUN USE NOTAVAILABLE
NOT REQUIRED
SPOOL GUN USE NOTAVAILABLE
NOT REQUIRED
NOT REQUIRED
SPOOL GUN USE NOTAVAILABLE
NOT REQUIRED
SPOOL GUN USE NOTAVAILABLE
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED
REQUIRED

 %&&!
11.D. Find assembled pair of machine
terminals (leads 543A & 544A)
and disconnect. o to step 13.
 !%(!"&! %"!&
&$
?4=@
$18:A1";59 from spot
timer harness J9 (6-pin).
:991/?" ;59to adapter
harness J8 (6-pin).
:991/?-0-;?1=4-=91>>"
;59 to spot timer harness J9 (6-
pin).
12.D. Find assembled pair of machine
terminals (leads 543A & 544A)
and disconnect.
13. Connect terminals:
 connect machine male (lead
543A) to adapter harness female
(lead 543A).
 connect machine female (lead
544A) to adapter harness male
(lead 544A).
9>@=1?4-??417:/6593?-.>:9-77
/:991/?:=>-=17-?/410/7:>10



"
"


"




 %&&!
 
&$! &! %
8. Adapter harness. All 6 connections
shown are used, and each one is
unique. (Proceed as follows)
9. A. $18:A1";59 from board
J3 (10-pin).
9.B. :991/?";59 to har-
ness J7 (10-pin).
:991/?4-=91>>";59 to
board J3 (10-pin).
 !% !&(!"&! 
%"!&&$ ?4=@
$18:A1";59 from
board J5 (6-pin).
:991/?";59 to har-
ness J8 (6-pin).
:991/?4-=91>>";59
to board J5 (6-pin).
Toggle Switch
P8 (6-pin)
P7 (10-pin)
J8 (6-pin)
J7 (10-pin)
543A
(Female)
544A
(Male)

"
"


"
"

"

"


 %&&!
11.D. Find assembled pair of machine
terminals (leads 543A & 544A)
and disconnect. o to step 13.
 !%(!"&! %"!&
&$
?4=@
$18:A1";59 from spot
timer harness J9 (6-pin).
:991/?" ;59to adapter
harness J8 (6-pin).
:991/?-0-;?1=4-=91>>"
;59 to spot timer harness J9 (6-
pin).
12.D. Find assembled pair of machine
terminals (leads 543A & 544A)
and disconnect.
13. Connect terminals:
 connect machine male (lead
543A) to adapter harness female
(lead 543A).
 connect machine female (lead
544A) to adapter harness male
(lead 544A).
9>@=1?4-??417:/6593?-.>:9-77
/:991/?:=>-=17-?/410/7:>10



"
"


"




 %&&!
 
&$! &! %
8. Adapter harness. All 6 connections
shown are used, and each one is
unique. (Proceed as follows)
9. A. $18:A1";59 from board
J3 (10-pin).
9.B. :991/?";59 to har-
ness J7 (10-pin).
:991/?4-=91>>";59 to
board J3 (10-pin).
 !% !&(!"&! 
%"!&&$ ?4=@
$18:A1";59 from
board J5 (6-pin).
:991/?";59 to har-
ness J8 (6-pin).
:991/?4-=91>>";59
to board J5 (6-pin).
Toggle Switch
P8 (6-pin)
P7 (10-pin)
J8 (6-pin)
J7 (10-pin)
543A
(Female)
544A
(Male)

"
"


"
"

"

"


I STALLATIO
MAGNUM PRO 100SG
K3269-1
K3269-1
®
ROUTI E WELDI G MACHI E PREPARATIO
ELECTRIC SHOCK CA KILL.
1. Disconnect input power to the machine.
------------------------------------------------------------------------
2. Machine polarity setting: Set to DC electrode positive
polarity per the machine’s Instruction Manual.
3. as selection and flow rate: Connect 100% welding
grade argon gas supply to the machine’s 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 machine’s wire drive selector switch (behind the
access door) to "MA NUM®PRO100S ". (See Figure
A.4)
FIGURE A.4
WAR I G
PREPARI G THE SPOOL GU
ELECTRIC SHOCK CA 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.
WAR I G
I STALLATIO
A-9 A-10
MOU TI G 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.
Keep mounting nut for installation.
18. Install switch into panel hole.
Ensure washer tab is fully seated
into smaller hole.
19. Reinstall mounting nut onto switch.
Wrench tighten.
RE-ASSEMBLE MACHI E AS
FOLLOWS:
20. Reinstall screw into plastic handle (if
so equipped).
21. Reinstall cover.
22. Reinstall door.
23. Reconnect input power to the
machine.

I STALLATIO
MAGNUM PRO 100SG
K3269-1
K3269-1
®
ROUTI E WELDI G MACHI E PREPARATIO
ELECTRIC SHOCK CA KILL.
1. Disconnect input power to the machine.
------------------------------------------------------------------------
2. Machine polarity setting: Set to DC electrode positive
polarity per the machine’s Instruction Manual.
3. as selection and flow rate: Connect 100% welding
grade argon gas supply to the machine’s 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 machine’s wire drive selector switch (behind the
access door) to "MA NUM®PRO100S ". (See Figure
A.4)
FIGURE A.4
WAR I G
PREPARI G THE SPOOL GU
ELECTRIC SHOCK CA 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.
WAR I G
I STALLATIO
A-9 A-10
MOU TI G 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.
Keep mounting nut for installation.
18. Install switch into panel hole.
Ensure washer tab is fully seated
into smaller hole.
19. Reinstall mounting nut onto switch.
Wrench tighten.
RE-ASSEMBLE MACHI E AS
FOLLOWS:
20. Reinstall screw into plastic handle (if
so equipped).
21. Reinstall cover.
22. Reinstall door.
23. Reconnect input power to the
machine.

I STALLATIO
7. uide 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 roll’s
groove and toward gun tube liner.
FIGURE A.12
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
10a. Alloy 4043: Roll up remaining wire
back onto spool and place spool
onto gun spindle. Install locking
knob and finger-tighten. o 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
11. rasp the free end of the wire at the
gas diffuser and slowly pull approxi-
mately 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).
FIGURE A.16
A
I STALLATIO
A-11 A-12
LOADI G ALUMI UM WIRE
1. Remove gas nozzle 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
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
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
6. ently pull open the idle roll
assembly to expose the drive roll
groove.
FIGURE A.10
M
A
G
N
U
M
P
R
O
1
0
0
S
G
®
M
M
A
A
A
A
M
M
M
M
A
M
A
A
A
M
M
A
A
A
A
A
G
A
G
G
G
N
N
U
N
U
N
U
U
U
M
U
M
M
®
®
P
P
R
R
G
N
G
N
G
A
N
N
N
N
N
G
U
U
U
M
G
G
U
N
N
N
M
M
M
M
U
U
®
P
U
R
R
®
M
M
O
O
O
1
1
1
0
0
0
0
S
1
0
0
0
0
0
S
S
S
G
Alloy
Size

I STALLATIO
7. uide 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 roll’s
groove and toward gun tube liner.
FIGURE A.12
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
10a. Alloy 4043: Roll up remaining wire
back onto spool and place spool
onto gun spindle. Install locking
knob and finger-tighten. o 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
11. rasp the free end of the wire at the
gas diffuser and slowly pull approxi-
mately 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).
FIGURE A.16
A
I STALLATIO
A-11 A-12
LOADI G ALUMI UM WIRE
1. Remove gas nozzle 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
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
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
6. ently pull open the idle roll
assembly to expose the drive roll
groove.
FIGURE A.10
M
A
G
N
U
M
P
R
O
1
0
0
S
G
®
M
M
A
A
A
A
M
M
M
M
A
M
A
A
A
M
M
A
A
A
A
A
G
A
G
G
G
N
N
U
N
U
N
U
U
U
M
U
M
M
®
®
P
P
R
R
G
N
G
N
G
A
N
N
N
N
N
G
U
U
U
M
G
G
U
N
N
N
M
M
M
M
U
U
®
P
U
R
R
®
M
M
O
O
O
1
1
1
0
0
0
0
S
1
0
0
0
0
0
S
S
S
G
Alloy
Size