MK Products Prince XL User manual

Prince™ XL/Spool Gun
16882 Armstrong Avenue, Irvine, California 92606 TEL [phone] FAX [phone]
Product Description Prince XL/Spool Gun
MK Manual Part Number 091-0384
MK Form Number PXL G/SG
NWSA Form Number 550
Effective with Serial Number 98100011
Voltage Rating 24 VDC
Printing/Revision Date July2000 E
This manual applies
to the following
torch model numbers
212-XXX
213-XXX
216-XXX

SAFETY CONSIDERATIONS
ELECTRIC ARC WELDING EQUIPMENT
CAUTION : READ BEFORE ATTEMPTING INSTALLATION, OPERATION OR
MAINTENANCE OF THIS EQUIPMENT
1-1 INTRODUCTION
This equipment is intended for ultimate
application by commercial/industrial
usersandforoperationbypersonstrained
and experienced in the use and
maintenance of welding equipment.
Operation should not be undertaken
without adequate training in the use of
such equipment. Training is available
from many public and private schools or
similar facilities.
Safe practices in the installation,
operation and maintenance of this
equipmentrequirespropertraininginthe
art, a careful study of the information
providedwiththeequipment,andtheuse
of common sense. Rules for safe use
are generally provided by suppliers of
weldingpower sources, compressed gas
suppliers, and electrode suppliers.
Careful compliance with these rules will
promote safe use of this equipment.
The following Safety Rules cover some
of the more generally found situations.
READ THEM CAREFULLY. In case of
any doubt, obtain qualified help before
proceeding.
1-2 GENERAL PRECAUTIONS
A. Burn Prevention
ELECTRIC ARC WELDING
PRODUCES HIGH INTENSITY HEAT
AND ULTRAVIOLET RADIANT
ENERGY WHICH MAY CAUSE
SERIOUS AND PERMANENT EYE
DAMAGE AND WHICH MAY DAMAGE
ANY EXPOSED SKIN AREAS.
Wear helmet with safety goggles or
glasses with side shields underneath,
appropriate filter lenses or plates
(protected by clear cover glass). This is
a must for welding or cutting (and
chipping)to protect the eyes from radiant
energy and flying metal. Replace cover
glass when broken, pitted, or spattered.
Medical first aid and eye treatment. First
aid facilities and a qualified first aid
person should be available for each shift
unless medical facilities are close by for
immediatetreatment of flash burns of the
eyes and skin burns.
Wear protective clothing - leather (or
asbestos) gauntlet gloves, hat, and high
safety-toe shoes. Button shirt collar and
pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Avoid oily or greasy clothing. A spark
may ignite them.
Flammable hair preparations should not
be used by persons intending to weld or
cut.
Hotmetal such as electrode stubs and work
pieces should never be handled without
gloves.
Ear plugs should be worn when working on
overhead or in a confined space. A hard
hat should be worn when others work
overhead.
B. Toxic Fume Prevention
WARNING: The use of this product may
result in exposure to chemicals known to
the State of California to cause cancer and
birth defects or other reproductive harm.
Adequate ventilation. Severe discomfort,
illness or death can result from fumes,
vapors, heat, or oxygen enrichment or
depletion that welding (or cutting) may
produce. Prevent them with adequate
ventilation. NEVER ventilate with oxygen.
Lead-, cadmium-, zinc-, mercury-,
beryllium-bearing and similar materials,
when welded or cut, may produce harmful
concentrations of toxic fumes. Adequate
local exhaust ventilation must be used, or
each person in the area, as well as the
operator, must wear an air-supplied
respirator. For beryllium, both must be
used.
Metals coated with or containing materials
that emit toxic fumes should not be heated
unless coating is removed form the work
surface, the area is well ventilated, or the
operator wears an air-supplied respirator.
Work in a confined space only while it is
being ventilated and, if necessary, while
wearing an air-supplied respirator.
Gas leaks in a confined space should be
avoided. Leakedgas in large quantities can
changeoxygenconcentrationdangerously.
Do not bring gas cylinders into a confined
space.
Leaving confined space, shut OFF gas
supply at source to prevent possible
accumulation of gases in the space if
downstream valves have been accidentally
opened or left open. Check to be sure that
the space is safe before reentering it.
Vapors from chlorinated solvents can be
decomposed by the heat of the arc (or
flame) to form PHOSGENE, a highly toxic
gas, and other lung and eye irritating
products. The ultraviolet (radiant) energy
of the arc can also decompose
trichloroethylene and perchloroethylene
vapors to form phosgene. DO NOT WELD
or cut where solvent vapors can be drawn
into the welding or cutting atmosphere or
where the radiant energy can penetrate to
atmospheres containing even minute
amounts of trichloroethylene or
perchloroethylene.
C. Fire and Explosion Prevention
Causes of fire and explosion are:
combustibles reached by the arc, flame,
flying sparks, hot slag, or heated
material, misuse of compressed gases
and cylinders, and short circuits.
BE AWARE THAT flying sparks or falling
slag can pass through cracks, along
pipes, through windows or doors, and
throughwall orflooropenings, out ofsight
of the goggled operator. Sparks can fly
many feet.
To prevent fires and explosion:
Keepequipment clean andoperable, free
of oil, grease, and (in electrical parts) of
metallic particles that can cause short
circuits.
Ifcombustibles are in area, do NOT weld
or cut. Move the work if practicable, to
anarea free of combustibles. Avoidpaint
spray rooms, dip tanks, storage areas,
ventilators. Ifthe work cannot be moved,
movecombustibles at least 35 feet away,
outof reach ofsparksand heat; orprotect
against ignition with suitable and snug-
fitting, fire-resistant covers or shields.
Walls touching combustibles on opposite
sides should not be welded on (or cut).
Walls, ceilings, and floor near work
should be protected by heat-resistant
covers or shields.
Fire watcher must be standing by with
suitable fire extinguishing equipment
during and for some time after welding
or cutting if:
1. Appreciable combustibles (including
building construction) are within 35 feet.
2. Appreciable combustibles are further
than35 feet, butcanbe ignited bysparks.
3. Openings (concealed or visible) in
floors or walls within 35 feet may expose
combustibles to sparks.
4. Combustibles adjacent to walls,
ceilings, roofs, or metal partitions can be
ignited by radiant or conducted heat.
Hot work permit should be obtained
before operation to ensure supervisor’s
approvalthat adequate precautions have
been taken.
Afterwork is done, check that areaisfree
of sparks, glowing embers, and flames.
An empty container that held
combustibles, or that can produce
flammable or toxic vapors when heated,
must never be welded on or cut, unless
container has first been cleaned in
accordance with industry standards.
This includes: a thorough steam or
caustic cleaning (or a solvent of water

washing,depending on thecombustible’s
solubility), followed by purging and
inerting with nitrogen or carbon dioxide,
and using protective equipment.
Water-filling just below working levelmay
substitute for inerting.
A container with unknown contents
should be cleaned (see paragraph
above). Do NOT depend on sense of
smell or sight to determine if it is safe to
weld or cut.
Hollow castings or containers must be
vented before welding or cutting. They
can explode.
Explosive atmospheres. NEVER weld
or cut where the air may contain
flammable dust, gas, or liquid vapors
(such as gasoline).
D. Compressed Gas Equipment
The safe handling of compressed gas
equipment is detailed in numerous
industry publications. The following
general rules cover many of the most
common situations.
1. Pressure Regulators
Regulator relief valve is designed to
protect only the regulator from
overpressure;itis not intended to protect
any downstream equipment. Provide
such protection with one or more relief
devices.
Never connect a regulator to a cylinder
containing gas other than that for which
the regulator was designed.
Remove faulty regulator from service
immediatelyfor repair (first close cylinder
valve). The following symptoms indicate
a faulty regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure
continues to rise with downstream valve
closed.
Faulty Gauge - if gauge pointer does not
move off stop pin when pressurized, nor
returnsto stop pin after pressurerelease.
Repair. Do NOT attempt repair. Send
faulty regulators for repair to
manufacturer’s designated repair center,
where special techniques and tools are
used by trained personnel.
2. Cylinders
Cylinders must be handled carefully to
prevent leaks and damage to their walls,
valves, or safety devices:
Avoid electrical circuit contact with
cylinders including third rails, electrical
wires, or welding circuits. They can
produced short circuit arcs that may lead
to a serious accident. (See 1-3C)
ICC or DOT marking must be on each
cylinder. It is an assurance of safety
when the cylinder is properly handled.
Identifying gas content. Use only
cylinders with name of gas marked on
them; do not rely on color to identify gas
content. Notify supplier if unmarked.
NEVERDEFACEoraltername,number,
or other markings on a cylinder. It is
illegal and hazardous.
Empties: Keep valves closed, replace caps
securely; mark MT; keep them separate
from FULLS, and return promptly.
Prohibited use. Never use a cylinder or its
contents for other than its intended use,
NEVER as a support or roller.
Locate or secure cylinders so they cannot
be knocked over.
Passageways and work areas. Keep
cylinders clear of areas where they may be
stuck.
Transporting cylinders. With a crane, use
a secure support such as a platform or
cradle. Do NOT lift cylinders off the ground
by their valves or caps, or by chains, slings,
or magnets.
DoNOT exposecylindersto excessiveheat,
sparks,slag, and flame, etc. thatmaycause
rupture. Do not allow contents to exceed
55 degrees C (130 degrees F.) Cool with
water spray where such exposure exists.
Protect cylinders, particularly valves from
bumps, falls, falling objects, and weather.
Replace caps securely when moving
cylinders.
Stuck valve. Do NOT use a hammer or
wrench to open a cylinder valve that cannot
be opened by hand. Notify your supplier.
Mixing gases. NEVER try to mix any gases
in a cylinder.
NEVER refill any cylinder.
Cylinder fittings should never be modified
or exchanged.
3. Hose
Prohibited use. Never use hose other than
that designed for the specified gas. A
general hose identification rule is: red for
fuel gas, green for oxygen, and black for
inert gases.
Use ferrules or clamps designed for the
hose (not ordinary wire or other substitute)
as a binding to connect hoses to fittings.
No copper tubing splices. Use only
standard brass fittings to splice hose.
Avoid long runs to prevent kinks and abuse.
Suspend hose off ground to keep it from
being run over, stepped on, or otherwise
damaged.
Coil excess hose to prevent kinks and
tangles.
Protecthose from damage by sharp edges,
and by sparks, slag, and open flame.
Examinehose regularly for leaks, wear,and
loose connections. Immerse pressured
hose in water; bubbles indicate leaks
Repair leaky or worn hose by cutting area
out and splicing. Do NOT use tape.
4. Proper Connections
Cleancylindervalve outlet of impurities that
may clog orifices and damage seats before
connecting regulator. Except for hydrogen,
crack valve momentarily, pointing outlet
away from people and sources of ignition.
Wipe with a clean, lintless cloth.
Match regulator to cylinder. Before
connecting, check that the regulator label
and cylinder marking agree, and that the
regulator inlet and cylinder outlet match.
NEVERConnect a regulatordesignedfor
a particular gas or gases to a cylinder
containing any other gas.
Tighten connections. When assembling
threadedconnections, clean and smooth
seats where necessary. Tighten. If
connection leaks, disassemble, clean,
and retighten, using properly fitting
wrench.
Adapters. UseaCGA adapter (available
fromyoursupplier) between cylinder and
regulator, if one is required. Use two
wrenches to tighten adapter marked
RIGHT and LEFT HAND threads.
Regulator outlet (or hose) connections
may be identified by right hand threads
for oxygen and left hand threads (with
groovedhex on nut orshank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through
suitable vent before opening cylinder (or
manifold valve) by turning adjusting
screw in (clockwise). Draining prevents
excessive compression heat at high
pressure seat by allowing seat to open
onpressurization. Leave adjusting screw
engaged slightly on single-stage
regulators.
Stand to side of regulator while opening
cylinder valve.
Open cylinder valve slowly so that
regulator pressure increases slowly.
When gauge is pressurized (gauge
reaches regulator maximum) leave
cylinder valve in following position: for
oxygenand inert gases, openfullyto seal
stem against possible leak; for fuel gas,
opento less than one turn to permit quick
emergency shut-off.
Usepressurecharts(availablefromyour
supplier) for safe and efficient
recommended pressure settings on
regulators.
Check for leaks on first pressurization
andregularly thereafter. Brushwithsoap
solution. Bubbles indicate leaks. Clean
off soapy water after test; dried soap is
combustible.
E. User Responsibilities
Follow all Safety Rules.
Remove leaky or defective equipment
from service immediately for repair.
Read and follow user manual
instructions.
F. Leaving Equipment Unattended
Close gas supply at source and drain
gas.
G. Rope Staging-Support
Ropestaging-support should notbeused
forwelding or cuttingoperation;rope may
burn.
1-3 ARC WELDING
Comply with precautions in 1-1, 1-2, and
thissection. Arc Welding,properlydone,
isa safe process, but a careless operator
invites trouble. The equipment carries

highcurrents at significant voltages. The
arc is very bright and hot. Sparks fly,
fumesrise, ultraviolet andinfrared energy
radiates, weldments are hot, and
compressed gases may be used. The
wise operator avoids unnecessary risks
and protects himself and others from
accidents.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly
bright. Its radiation can damage eyes,
penetrate lightweight clothing, reflect
from light-colored surfaces, and burn the
skin and eyes. Skin burns resemble
acute sunburn; those from gas-shielded
arcsare more severeand painful. DON’T
GET BURNED; COMPLY WITH
PRECAUTIONS.
1. Protective Clothing
Wear long-sleeve clothing in addition to
gloves, hat, and shoes. As necessary,
use additional protective clothing such
as leather jacket or sleeves, flameproof
apron, and fire-resistant leggings. Avoid
outer garments of untreated cotton.
Bare skin protection. Wear dark,
substantial clothing. Button collar to
protect chest and neck, and button
pockets to prevent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. Eyes
maybe damaged byradiant energy when
exposed to the electric arc, even when
not looking in the direction of the arc.
Never look at an electric arc without
protection.
Welding helmet or shield containing a
filter plate shade no. 12 or denser must
be used when welding. Place over face
before striking arc.
Protectfilter plate witha clear coverplate.
Cracked or broken helmet or shield
should NOT be worn; radiation can be
passed through to cause burns.
Cracked, broken, or loose filter plates
must be replaced IMMEDIATELY.
Replace clear cover plate when broken,
pitted, or spattered.
Flash goggles with side shields MUST
be worn under the helmet to give some
protection to the eyes should the helmet
not be lowered over the face before an
arc is struck. Looking at an arc
momentarily with unprotected eyes
(particularlya high intensity gas-shielded
arc) can cause a retinal burn that may
leave a permanent dark area in the field
of vision.
3. Protection of Nearby Personnel
Enclosethe welding area. Forproduction
welding, a separate room or enclosed
bay is best. In open areas, surround the
operation with low-reflective,
noncombustiblescreens orpanels. Allow
forfreeaircirculation,particularlyatfloor
level.
Viewing the weld. Provide face shields
forall persons who will be lookingdirectly
at the weld.
Othersworking in area. See that all persons
are wearing flash goggles.
Before starting to weld, make sure that
screen flaps or bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented
to the outside air. Carbon monoxide can
kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment’s rated capacity. Do not
overload arc welding equipment. It may
overheat cables and cause a fire.
Loose cable connections may overheat or
flash and cause afire.
Never strike an arc on a cylinder or other
pressure vessel. It creates a brittle area
that can cause a violent rupture or lead to
such a rupture later under rough handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposedelectricallyhotconductorsorother
bare metal in the welding circuit, or in
ungrounded, electrically-HOT
equipment can fatally shock a person
whose body becomes a conductor. DO
NOT STAND, SIT, LIE, LEAN ON, OR
TOUCHa wet surfacewhenwelding without
suitable protection.
To protect against shock:
Keep body and clothing dry. Never work in
damp area without adequate insulation
against electrical shock. Stay on a dry
duckboard, or rubber mat when dampness
or sweat cannot be avoided. Sweat, sea
water, or moisture between body and an
electrically HOT part - or grounded metal -
reduces the body surface electrical
resistance, enabling dangerous and
possibly lethal currents to flow through the
body.
1. Grounding the Equipment
Wheninstalling, connect the frames of each
unit such as welding power source, control,
work table, and water circulator to the
building ground. Conductors must be
adequate to carry ground currents safely.
Equipment made electrically HOT by stray
currents may shock, possibly fatally. Do
NOT GROUND to electrical conduit, or to a
pipecarrying ANY gas or a flammable liquid
such as oil or fuel.
Three-phase connection. Check phase
requirement of equipment before installing.
If only three-phase power is available,
connectsingle-phase equipment toonlytwo
wires of the three-phase line. Do NOT
connect the equipment ground lead to the
third (live) wire, or the equipment will
become electrically HOT - a dangerous
condition that can shock, possibly fatally.
Beforewelding, check ground for continuity.
Besure conductors are touching bare metal
of equipment frames at connections.
If a line cord with a ground lead is provided
with the equipment for connection to a
switch box, connect the ground lead to
thegrounded switch box. Ifa three-prong
plug is added for connection to a
grounded mating receptacle, the ground
lead must be connected to the ground
prong only. If the line cord comes with a
three-prong plug, connect to a grounded
mating receptacle. Never remove the
ground prong from a plug, or use a plug
with a broken ground prong.
2. Connectors
Fully insulated lock-type connectors
should be used to join welding cable
lengths.
3. Cables
Frequently inspect cables for wear,
cracks, and damage. IMMEDIATELY
REPLACE those with excessively worn
or damaged insulation to avoid possibly
lethal shock from bared cable. Cables
withdamaged areasmaybe tapedtogive
resistance equivalent to original cable.
Keep cable dry, free of oil and grease,
andprotected from hot metal and sparks.
4. Terminals and Other Exposed Parts
Terminals and other exposed parts of
electrical units should have insulating
covers secured before operation.
5. Electrode Wire
Electrodewire becomes electrically HOT
when the power switch of gas metal-arc
welding equipment is ON and welding
gun trigger is pressed. Keep hands and
body clear of wire and other HOT parts.
6. Safety Devices
Safety devices such as interlocks and
circuit breakers should not be
disconnected or shunted out.
Beforeinstallation, inspection, or service
of equipment, shut OFF all power, and
remove line fuses (or lock or red-tag
switches) to prevent accidental turning
ON of power. Disconnect all cables from
welding power source, and pull all 115
volts line-cord plugs.
Do not open power circuit or change
polarity while welding. If, in an
emergency, it must be disconnected,
guard against shock burns or flash from
switch arcing.
Leaving equipment unattended. Always
shut OFF, and disconnect all power to
equipment.
Power disconnect switch must be
availablenear the welding power source.

THIS PAGE INTENTIONALLY BLANK

Table of Contents
INTRODUCTION.................................................................................... 7
Section 1 SPECIFICATIONS.................................................................................. 8
Section 2 CONTACT TIPS - AIR COOLED BARREL ASSY. ................................. 9
Section 3 GAS CUPS - AIR COOLED BARREL ASSY.......................................... 9
Section 4 CONTACT TIPS - WATER COOLED BARREL ASSY. .........................10
Section 5 SPRING LOADED CONTACT TIPS - Water Cooled Barrel Assy .......10
Section 6 GAS CUPS - WATER COOLED BARREL ASSY. .................................10
Section 7 TORCH BARREL LINERS....................................................................11
Section 8 BARREL ASSEMBLIES .......................................................................11
Section 9 KOOL CUP ADAPTER and CUPS .......................................................12
Section 10 GAS CUP and CONTACT TIPS - 48°...................................................12
Section 11 OPTIONAL KITS...................................................................................13
Section 12 OPTIONAL 12”AND 18”WATER COOLED STRAIGHT
AND CURVED BARREL ASSEMBLIES ...............................................13
Section 13 OPTIONAL ACCESSORIES ................................................................14
Section 14 MAINTENANCE TOOLS.......................................................................14
Section 15 INTERCONNECTIONS .........................................................................15
Section 16 OPERATION .........................................................................................16
Section 17 INSTALLING SPOOL ASSEMBLY .....................................................19
Section 18 SPOOL GUN SETUP ............................................................................20
Section 19 MAINTENANCE ....................................................................................20
Section 20 TROUBLESHOOTING ..........................................................................21
Section 21 TESTING THE TORCH .........................................................................23
Section 22 Prince XL, Head Body, Exploded View...............................................25
Section 23 Prince XL, Exploded View...................................................................26
Section 24 Prince XL, Spool Gun 25ft...................................................................27
Section 25 Air Cooled Straight Barrel Assy. 7”Exploded View .........................28
Section 26 Air Cooled 45°Barrel Assy. 7”Exploded View .................................29
Section 27 Water Cooled Straight Barrel Assy. 7”Exploded View ....................30
Section 28 Water Cooled 45°Barrel Assy. 7”Exploded View ............................31
Section 29 Taper Lock Nut Assembly, Exploded View ........................................32
Section 30 1 lb. Spool Assembly, Exploded View ................................................33
Section 31 AIR COOLED LEAD ASSY. ..................................................................34
Section 32 WATER COOLED LEAD ASSY.............................................................35
Section 33 SPOOL GUN LEAD ASSY. ...................................................................36
Section 34 PRINCE SPOOL GUN CONTROLS .....................................................37
Section 35 ORDERING INFORMATION .................................................................38

Prince™ XL/Spool Gun - Owner's Manual Page 7
Introduction
This manual details the installation and operation of your PrinceTMXL Torch,
and PrinceTMXL Spool Gun.
These torches have 7 pin “W” clocked amphenol connectors and are de-
signed for use with Cobramatic cabinets model numbers 150-003, 150-004,
150-203 and 150-204. To use these torches on older style cabinets with
plastic doors (MK3A, MK3A PS) , a 7 pin “W” clocked amphenol kit, P/N 005-
0162, must be used.
A variety of Weld Control Boxes are available to adapt the Prince™XL spool
gun to the power source you are using (see section 34 & 35 for details). A
secondary Contactor Box (P/N 001-3066), is also available for those power
supplies not having there own contactor. Consult the Weld Control Selector
Guide (P/N 091-0458) for various welding equipment interfacing.
The Prince™XL and Prince™XL Spool Gun bodies are identical except for
the lead assemblies and spool portion.
The Prince™XL utilizes our patented EZ Lock™ design which allows the
operator to remove or rotate the barrel without the use of tools.
The Prince™XL air cooled version comes standard with a straight air cooled
barrel assembly (P/N 003-1980) and uses the same contact tips and gas
cups as the MK Cobra® Gooseneck torch. A rotating air cooled barrel
assembly (P/N 003-1986) is available as a spare part.
The Prince™XL water cooled version comes standard with a straight water
cooled barrel assembly (P/N 003-1973) and uses the same contact tips, cups
and adapter as the King Cobra® torch. A rotating water cooled barrel assem-
bly (P/N 003-1987) is available as a spare part.
The wire speed control knob is located on the bottom of the torch handle and
provides 3-3/4 turns of rotation, with a maximum speed of 900 ipm.
An important feature of the Prince™XL spool gun assembly is that it can be
converted from a spool gun into a Push-Pull system to be used with the
Cobramatic® Cabinet. Simply remove the spool assembly and wire guide
adapter and liner, and install a conduit of the appropriate length. The power
lug on the power cable assembly can be attached to the upper hole on the
power block assembly in the Cobramatic® Cabinet. Remove the hole plug
and secure cable assembly using a hex head screw 3/8” - 16 x 3/4 (P/N 329-
0055) and a flat washer 1/2” (P/N 331-0176).
The Prince™ XL Spool gun assembly has been redesigned to improve and
simplify the spool drag tension settings. By eliminating the guesswork of
setting the correct drag tension, the operator can now focus on the actual
welding. The new “patented” brake assembly automatically self-adjusts to the
ever-changing spool tension as the coiled wire is reduced in diameter off the
spool. The new brake assembly maintains the wire “level on the spool” and
prevents unspooling and potential wire
entanglements.
This new brake assembly can be installed onto any existing Prince™ XL gun
and can be used in place of the existing spool kit assemblies. No parts of the
new kit can be used with the old kit or existing handles. The new spool kit (P/
N 005-0632) includes new handles, trigger, trigger pin, all handle screws and
spool assembly. See Optional Kits on page 7 for part numbers for these two
new kits.

Prince™ XL/Spool Gun - Owner's Manual Page 8
Section 1 SPECIFICATIONS
PRINCE™XL TORCH
Wire Capacity
• .023” -.045” (0.6 - 1.2mm) solid and hard wire
• .030” - 1/16” (0.8 - 1.6mm) aluminum and cored wire
Wire Speed*
• 900 ipm (22.9 mpm) max.
Duty Cycle
•150 Amps/25 Volts Air cooled standard
•200 Amps/25 Volts Air cooled using optional Kool Cup Adaptor
H.D. (P/N 003-1487), #10 Gas Cup for Kool
Cup Adapter (P/N 621-0386) and Cup
Retaining Nut (P/N 449-0193)
•300 Amps/25 Volts Water cooled standard using W/C Cup
Adaptor (P/N 621-0101), #8 A/C Gas Cup
(P/N 621-0159) and Cup Retaining Nut
(P/N 449-0193)
•400 Amps/25 Volts Water cooled using optional W/C Cup
(P/N 621-0065)
All above Duty Cycle ratings are with Argon Gas
Torch weight (less leads)
•Air cooled - 36.4 oz. (1.02 kilogram)
•Water cooled - 38.4 oz (1.08 kilogram)
PRINCE™XL SPOOL GUN
Wire Capacity
•.023”- .045”(0.6 - 1.2mm) solid and hard wire
•.030”- 1/16”(0.8 - 1.6mm) aluminum and cored
wire
Wire Speed*
•900 ipm (22.9 mpm) max.
Spool Size
•4 inches (101.6mm)
Duty Cycle
•150 Amps/25 Volts Air cooled standard
•200 Amps/25 Volts Air cooled using optional Kool Cup Adaptor
H.D. (P/N 003-1487), #10 Gas Cup for Kool
Cup Adapter (P/N 621-0386) and Cup
Retaining Nut (P/N 449-0193)
All above Duty Cycle ratings are with Argon Gas
Torch weight (less wire & leads)
•Air cooled - 46.5 oz (1.3 kilogram)
*Maximum ipm varies depending on input voltage, wire size
and the control box used.

Prince™XL/Spool Gun - Owner's Manual Page 9
Section 2 Contact Tips - Air Cooled Barrel Assembly
Section 3 Gas Cups - Air Cooled Barrel Assembly
Spray arc tip
Short arc tip
Contact Tips for Prince XL Air Cooled Torch
Wire Size Tip I.D. ** Arc Length Part No.
.023" (0.6mm) .030" (0.8mm) Spray 1-1/2" (38mm) 621-0057
.030" (0.8mm) Short 1-3/4" (44mm) 621-0328
.030" (0.8mm) .036" (0.9mm) Spray 1-1/2" (38mm) 621-0325
.036" (0.9mm) Short 1-3/4" (44mm) 621-0326
.030" (0.8mm)
or
.035" (0.9mm)
.040" (1.0mm) Spray 1-1/2" (38mm) 621-0076
.040" (1.0mm) Short 1-3/4" (44mm) 621-0077
.035" (0.9mm) .044" (1.1mm) Spray 1-1/2" (38mm) 621-0001
.044" (1.1mm) Short 1-3/4" (44mm) 621-0002
.045" (1.2mm) .053" (1.3mm) Spray 1-1/2" (38mm) 621-0327
.045" (1.2mm)
or
.052" (1.3mm)
.060" (1.5mm) Spray 1-1/2" (38mm) 621-0003*
.060" (1.5mm) Short 1-3/4" (44mm) 621-0286
1/16" (1.6mm) .075" (1.9mm) Spray 1-1/2" (38mm) 621-0075
1/16" (1.6mm) .085" (2.1mm) Spray 1-1/2" (38mm) 621-0153
.085" (2.1mm) Short 1-3/4" (44mm) 621-0154
* Standard - Furnished with torch.
All tips stamped withtip I.D. contact.tbl
NOTE: As a rule of thumb, use the smaller I.D. tip for steel, stainless steel and the 5000 series
aluminum. Softer alloys such as the 1000 and 4000 series aluminum require more clearance
and, therefore, use a larger I.D. tip.
Gas Cups for Prince XL Air Cooled Torch
SIZE I.D. PART NO.
5 1/4" (6.4mm) 621-0079
6 3/8" (9.5mm) 001-0137
8 1/2" (12.7mm) 001-0138*
10 5/8" (15.8mm) 001-0139
*Standard - Furnished with torch
Use genuine MK parts

Prince™XL/Spool Gun - Owner's Manual Page 10
Section 4 Contact Tips - Water Cooled Barrel Assembly
Section 6 Gas Cups - Water Cooled Barrel Assembly
Section 5 Spring Loaded Contact Tips - Water Cooled Barrel Assembly
Spring Loaded Contact Tips
for Prince XL Water Cooled Torch
P/N Tip I.D. Tip Length
621-0202 0.044"(1.1 mm) 1-5/8" / 41.3 mm lg
621-0203 0.053"(1.4 mm) 1-5/8" / 41.3 mm lg
621-0204 0.060"(1.5 mm) 1-5/8" / 41.3 mm lg
621-0205 0.075"(1.9 mm) 1-5/8" / 41.3 mm lg
Note: To remove contact tip when using full water cooled gas cup (P/N 621-0065) the contact
tip removal tool (P/N 931-0002) must be used.
Contact Tips for PrinceXL Water Cooled Torch
Wire size Tip I.D. Arc Tip Length Part No.
.030"(0.8mm) .040"(1.0mm) Spray
Short 1-5/8"(41.3mm) 1-7/8"(47.6mm) 621-0158 621-0165
.035"(0.9mm) .044"(1.0mm) Spray
Short 1-5/8"(41.3mm) 1-7/8"(47.6mm) 621-0157 621-0166
.045"(1.2mm) .053"(1.35mm) Spray
Short 1-5/8"(41.3mm) 1-7/8"(47.6mm) 621-0161 621-0167
.052"(1.4mm) .060"(1.5mm) Spray
Short 1-5/8"(41.3mm) 1-7/8"(47.6mm) 621-0162* 621-0168
.063"(1.6mm) .075"(1.9mm) Spray
Short 1-5/8"(41.3mm) 1-7/8"(47.6mm) 621-0163 621-0169
.063"(1.6mm) .085"(2.16mm) Spray 1-5/8"(41.3mm) 621-0164
.093"(2.3 mm) .113"(2.8 mm) Spray 1-5/8"(41.3mm) 621-0215
* Standard - furnished with torch
To remove contact tip when using fulll water cooled gas cup (P/N 621-0065) the contact tip
removal tool (P/N 931-0002) must be used.
Water Cooled Cup for Prince XL Water Cooled Torch
Cup Size Cup I.D. Cup Length Part Number
No. 10 5/8" (15.9mm) 3" (76.2mm) 621-0065
Air Cooled Cups for Prince XL Water Cooled Torch
Cup Size Cup I.D. Cup Length Part Number
No. 6 3/8" (9.5mm) 1.43" (36.5mm) 621-0170
No.8 1/2" (12.7mm) 1.43" (36.5mm) 621-0159*
No. 10 5/8" (15.9mm) 1.43" (36.5mm) 621-0160
*Standard - supplied with torch
To use air cooled gas cups, you must order a cup retaining nut (449-0193*) and a water cooled
cup adaptor (621-0101*)

Prince™XL/Spool Gun - Owner's Manual Page 11
Section 7 Torch Barrel Liners
Sections 8 Barrel Assemblies
150 Amps, Air Cooled
300 Amps, Water Cooled
200 Amps, Air Cooled,
with Kool Cup Adapter
400 Amps, Water Cooled,
with Water Cooled Cup
ALL BARRELS RATED AT 100% DUTY CYCLE
For barrel details see sections 25, 26, 27 and 28
Prince XL Torch Barrel Liners
Barrel
P/N Description Cooled Wire Type Wire Size Part No.
003-1980 Straight Air All Wires .030" - .063"(.8-1.6mm) 615-0537*
003-1980 Straight Air Optional All Wires .030" - .035"(.8-.9mm) 615-0544
003-1973 Straight Water All Wires .030" - .063"(.8-1.6mm) 615-0323*
003-1973 Straight Water Optional All Wires .030" - .035"(.8-.9mm) 615-0545
003-1986 Curved Air All Wires .030" - .063"(.8-1.6mm) 615-0539*
003-1986 Curved Air Optional All Wires .030" - .035"(.8-.9mm) 615-0546
003-1986 Curved Air Steel Wire Only .030" - .063"(.8-1.6mm) 615-0547
003-1987 Curved Water All Wires .030" - .063"(.8-1.6mm) 615-0539*
003-1987 Curved Water Optional All Wires .030" - .035"(.8-.9mm) 615-0546
003-1987 Curved Water Steel Wire Only .030" - .045"(.8-1.2mm) 615-0547
*Standard - furnished with torch
Bulk teflon liner material for .030 - .063" (.8-1.6mm) is P/N 615-0178
Bulk teflon liner material for .030 - .035" (.8-.9mm) is P/N 615-0177
NOTE: P/N 615-0547 is a spiral steel liner. All other liners are white teflon.
barl-lnr-man.tbl

Prince™XL/Spool Gun - Owner's Manual Page 12
Section 10 Gas Cup and Contact Tips - 48°
Note : Must be used with Kool Cup Adaptor H.D. and
Cup Retaining nut with straight Air Cooled Barrel Assembly.
Section 9 Kool Cup Adapter and Cups
Note : These parts are used on the air cooled straight or curved barrel
assemblies to increase the capacity from 150 amps to 200 amps @ 100% duty cycle.
Kool Cup Adapter Heavy Duty
Item No. Part No. Description
1 621-0388 #8 Gas Cup for Kool Cup Adapter
1 621-0386 #10 Gas Cup for Kool Cup Adapter
2 see page 9 Use standard Prince tips
3 003-1487 Kool Cup adapter H.D.
4 449-0193 Nut Cup Retainer
koolcup.tbl
48 Degree PrinceXL Air Cooled Torch
Cup and Tips
Must be used with Kool Cup Adapter H.D. and Cup Retaining Nut
Part No. Item # Description Wire Size
003-1487 3 Kool Cup Adapter H.D. N/A
449-0193 4 Cup Retaining Nut N/A
621-0375 1 48 Degree Curved Gas Cup N/A
621-0387 2 48 Degree Tip .040 ID .023"
621-0381 2 48 Degree Tip .045 ID .030"
621-0382 2 48 Degree Tip .052 ID .035"
621-0383 2 48 Degree Tip .060 ID .045"
621-0384 2 48 Degree Tip .075 ID 3/64" - 1/16"
621-0385 2 48 Degree Tip .085 ID 1/16"

Prince™XL/Spool Gun - Owner's Manual Page 13
Section 11 OPTIONAL KITS
Insulated Groove Drive Roll Kit ....................................................... 005-0640
For .030" (0.8mm) dia. aluminum wire.
Includes insulated drive roll P/N 511-0150 and idler roll assy. P/N 003-2097.
Insulated Groove Drive Roll Kit ....................................................... 005-0641
For .035" (0.9mm) dia. aluminum wire.
Includes insulated drive roll P/N 511-0151 and idler roll assy. P/N 003-2097.
Insulated Groove Drive Roll Kit ....................................................... 005-0642
For .040" (1.0mm)dia. aluminum wire.
Includes insulated drive roll P/N 511-0152 and idler roll assy. P/N 003-2097.
Insulated Groove Drive Roll Kit ....................................................... 005-0643
For .045" (1.2mm) dia. aluminum wire.
Includes insulated drive roll P/N 511-0153 and idler roll assy. P/N 003-2097.
Insulated Groove Drive Roll Kit ....................................................... 005-0644
For .062" (1.6mm) dia. aluminum wire.
Includes insulated drive roll P/N 511-0154 and idler roll assy. P/N 003-2097.
NOTE: Insulated drive roll kits are used to prevent preheating of the wire
which may soften it and clog the liner. This picking up of current at the drive
rolls rather than at the contact tip is usually not a problem unless using too
large of a contact tip or excessively oxidized aluminum wire.
Prince™XL Handle Kit .................................................................... 005-0633
Includes left and right handle with door, trigger and pin,and all handle screws.
Spool Adaptor Kit ............................................................................ 005-0632
Includes left and right handle with door, trigger and pin,and all handle screws.
Used to change a standard 212-xxx or 213-xxx series Prince™XL torch into a
Spool Gun.
7 Pin “W”Clocked Adaptor Kit ........................................................ 005-0162
Used to update a 150-001, 002, 150-101, 102 and 150-201,202 (plastic door
models MK3A and MK3A PS) Cobramatic cabinets to allow the use of the
Prince™XL and other “W”clocked torches.
Section 12 OPTIONAL (12” and 18”) Water Cooled Straight
and Curved Barrel Assemblies
12”Straight Water Cooled Barrel Assembly.................................... 003-2085
12”Curved Water Cooled Barrel Assembly..................................... 003-2086
18”Straight Water Cooled Barrel Assembly.................................... 003-2087
18”Curved Water Cooled Barrel Assembly..................................... 003-2088

Prince™XL/Spool Gun - Owner's Manual Page 14
Section 13 Optional Accessories
Standard Conduit with additional protective cover
15 ft./4.5m 001-0774
25 ft./7.6m 001-0775
35 ft./10.5m 001-1278
50 ft./15.0m 001-0777
Flat Spiral Steel Conduit for steel and cored wire
15 ft./4.5m 615-0208
25 ft./7.6m 615-0216
50 ft./15.0m 615-0218
*Kool Cup Adapter H.D. 003-1487
*Cup Retaining Nut 449-0193
*#10 Gas Cup for Kool Cup Adapter 621-0386
*All three items are needed to make Prince™XL air cooled torch 200 amps/25 volts
100% duty cycle.
#8 Gas Cup for Kool Cup Adapter 621-0388
25' 7 Pin Amphenol Extension Cable 005-0660
Used to extend the spool gun. Two cables may be joined together for 50'
extension. Power & gas cables not included.
Snake skin zipper cover
14' cover fits 15' lead 931-0110
24' cover fits 25' lead 931-0122
48’cover fits 50’lead 931-0123
Section 14 Maintenance Tools
MAINTENANCE TOOLS
TOOL PART NUMBER
Gas Valve Removal Tool 931-0584
Contact Tip Removal Tool 931-0002

Prince™XL/Spool Gun - Owner's Manual Page 15
NOTE:
The Posa Start feature permits the WC-1 to be used in
combination with any Constant Current DC power source
with an open circuit voltage in excess of 55 volts.
Section 15 Interconnections
POWER CABLE
GAS HOSE
CUSTOMER
SUPPLIED
GroundLead
WC-1 CONSTANT CURRENT
POSA START SENSING LEADS.
NOT NEEDED WITH CONSTANT VOLTAGE
SUPPLIES
red green
COUPLER - AW-430-RH
M.K. P/N 753-3377
CONSTANT VOLTAGE
OR
CONSTANT CURRENT
POWER SUPPLY
+_
CONTACTOR LEADS
PRINCE™XL SPOOL GUN
TO
WC-1 WELD CONTROL BOX
115VAC PLUG
WATER
POWER CABLE
PRINCE™XL TORCH
TO
COBRAMATIC I CABINET
(150-003, 150-203)
Weld Control Box
ELECTRICAL CABLE
ELECTRICAL
CABLE
WIRE CONDUIT
GAS HOSE
WATER HOSE -
OPTIONAL

Prince™XL/Spool Gun - Owner's Manual Page 16
Section 16 Operation
16.1 General
The Prince™XL torch was specifically designed to operate as both a push-
pull gun and spool gun. The 24 volt DC torch motor is controlled by a 3-3/4
turn potentiometer recessed in the pistol grip. The torch trigger is so de-
signed that when it is partially depressed, gas flow starts via the valve located
in the torch body - prior to ignition of the arc. When the trigger is partially
released after welding (extinguishing the arc), gas flow continues until the
trigger is fully released. Built-in pre and post gas flow. The gas cups and
contact tips used on the Prince™XL air cooled barrel are the same as those
used on the Cobra Gooseneck. The drive and idler rolls are also the same as
on the Cobra Gooseneck. The gas cups and contact tips used on the
Prince™XL water cooled barrel are the same as those used on the King
Cobra torch. The modular design allows parts to be replaced in sub assem-
blies for minimum spare parts inventory and less down time.
16.2 Barrels
16.2.1 Air Cooled
The Prince™XL air cooled systems (213-xxx and 216-xxx) come standard
with a straight barrel. An optional curved air cooled barrel assembly (P/N
003-1986) is also available as a spare part. The end of the air cooled barrels
have an adapter (P/N 003-2593) that is easily replaced if the cup threads
become damaged. The adapter is threaded onto the barrel. The barrel
assembly locks to the Prince™XL body using the patented EZ Lock™sys-
tem.
16.2.2 Water Cooled
The Prince™XL water cooled systems (212-xxx) come standard with a
straight water cooled barrel assembly. An optional curved water cooled barrel
assembly
(P/N 003-1987) is also available as a spare part.
16.2.3 Barrel Removal and installation
To remove a barrel assembly, loosen the patented EZ Lock™Taper lock nut
assy P/N 003-2572 (see page 21, item 1) 3/4 to 1 turn. This will push barrel
away from the body far enough so that it may be pulled out of the body.
To replace a barrel assembly, take care not to damage the “O”rings when
inserting into the body. Open the drive and idler roll door and seat the barrel
assembly until the inlet guide is almost touching the drive and idler roll and
the rear face of the barrel is flush with the aluminum body block (see dia-
gram). Tighten taper lock nut assembly firmly so that barrel cannot rotate.
16.2.4 Barrel Rotation
To rotate a barrel assembly, loosen the patented EZ Lock™Taper lock nut
assembly no more than 1 turn. Rotate barrel to the position of your choice
and retighten taper lock nut assembly firmly so that the barrel cannot rotate.
WARNING: Do not attempt to weld without the barrel being tightly
secured in the torch body, or damage to the barrel or body may result.

Prince™XL/Spool Gun - Owner's Manual Page 17
16.3 Potentiometer
The pot is located in the bottom of the pistol grip and provides 3-3/4 turns of
rotation and up to 900 ipm.
The pot is mounted to one side of a PC board and is held in place by a
support plate; both of which have slots that locate and secure the pot in the
handles. The other side of the PC board houses the motor connectors and
ribbon cable. Locking disks behind the pot knob provides a stop at the
minimum and maximum pot settings.
16.4 Micro Switch
The micro switch assembly (P/N 003-0568) consists of the micro switch,
leads, and connector. The assembly is secured to the torch block with two(2)
screws. An insulator between the torch block and micro switch prevents
accidential shorting of the switch leads. The leads are laid in the channel
under the motor and held in place with electrical tape.
16.5 Lead Assemblies
16.5.1 Power Cable - Air Cooled
A #2 AWG power cable is used on the Prince™XL air cooled torch. The torch
end is threaded into the torch body. The power cable fitting connects to the
Power Block
(P/N 003-1674) when using a Cobramatic®wire feed cabinet. When the
Prince™XL is purchased as a Spool Gun, the power cable comes standard
with a lug connector.
16.5.2 Power Cable - Water Cooled
Prince™XL water cooled torch utilizes a power/water cable with a #4AWG
cable inside a 5/8”(16MM) diameter hose. When water is used with this
cable and the #10 water cooled gas cup is used (P/N 621-0065), the system
is rated at 400 amps 100% duty cycle. If water is not used with this cable, the
system is rated at 100 amps 50% duty cycle.
16.5.3 Conduit
The Prince™XL Torch comes standard with a poly lined conduit, for running
aluminum wire. The longer fitting with a shallow groove is used on the torch
end. A set screw located on top of the torch handle secures the conduit in
place. A small spool liner (P/N 003-0198) is used on the spool gun and held
in place by the same set screw.
16.5.4 Gas Hose
The gas hose is secured over the barbed gas fitting with a tie wrap. The
cabinet end of the gas hose uses our standard gas fitting (1/8”- 27 nps),
whereas the spool gun uses a 5/8”- 18 IAA RH male gas fitting.
16.5.5 Water Hose
The water hose (if so equiped) is secured over the barbed water fitting with a
tie wrap.
16.5.6 Electric Cable
A seven conductor control cable is used on the Prince™XL Torch. The torch
end of the control cable is secured to the torch with a boot clamp and plugged
into the pot assembly and micro switch connectors. Slack is left in the electric
cable as it exits the back of the torch to prevent cable breakage. The cabinet
end has a seven pin "W" clocked amphenol connector. See page 17 for torch
electrical connections.

Prince™XL/Spool Gun - Owner's Manual Page 18
16.6 DRIVE AND IDLER ROLLS
16.6.1 GENERAL
The Prince™XL torch comes standard with knurled drive rolls which will
handle wire diameters from .023 - 1/16 inch. Optional grooved drive rolls are
also available for feeding aluminum wire if desired (see page 7).
Drive roll tension is accomplished by means of a pressure adjusting allen
screw located on the left hand side of the torch. Proper tension is achieved
when wire does not slip if a small amount of pressure is added to the wire as
it exits the tip.
NOTE: Over-tightening of the drive rolls will cause excessive knurling and/or
deformation of the wire.
16.6.2 DRIVE ROLL INSTALLATION & REMOVAL
Rotate drive roll by jogging drive motor with trigger switch or with finger tips
until slots line up with door.
Hold the drive roll with 3/8" open-end wrench.
Insert a slot type screwdriver into the slot on motor shaft, and turn screwdriver
CCW (left hand thread).
Install new drive roll on motor shaft using left hand thread. Drive roll will self-
tighten when feeding wire.
16.6.3 IDLER ROLL INSTALLATION & REMOVAL
Using a slot type screwdriver, loosen idler screw, taking care not to lose lock
washer under idler roll.
Insert new idler roll and lock washer onto screw, insuring that idler groove is
toward top and lock washer is beneath.
Tighten.
GROOVE
TOWARDS TOP
LOCK WASHER IDLER ARM

Prince™XL/Spool Gun - Owner's Manual Page 19
Section 17 Installing Spool Assembly
(Kit P/N 003-2021)
Loosen the screw that secures the conduit through access hole located on
top right rear handle with a 1/16" Allen wrench.
Remove conduit by pulling it out of the back of the gun.
Install spool liner, and secure with screw.
Remove both rear handle screws, and secure spool canister with longer
screws provided.
2 SCREWS
CONDUIT SECURING SCREW
SPOOL LINER
REAR WIRE
GUIDE
E-RING

Prince™XL/Spool Gun - Owner's Manual Page 20
Section 18 Spool Gun Setup
18.1 Loading Electrode Wire
Unscrew, and remove spool cover.
Apply tension to drive rolls, so the wire will be picked up and fed through the
contact tip.
Straighten out first six inches of wire and push through liner.
Jog trigger until wire is picked up by drive rolls and fed through contact tip.
Hold brake assembly back towards top of gun, load spool onto shaft with wire
coming off the bottom of the spool. Release brake assembly to rest on wire
surface.
Replace spool cover, making sure opening is over liner.
Note: The brake assembly is designed to automatically control spool drag
and keep the wire from jumping off the spool.
18.2 Disassembly Prince™XL/Spool Gun
Remove trigger pin with punch and remove trigger.
Remove six(6) handle screws and spool adapter if installed.
Remove barrel from gun, loosen barrel taper lock assembly and slide towards
cup. Leave barrel inserted in gun body.
Pull handles apart.
Section 19 MAINTENANCE
Maintenance of the torch will normally consist of a general cleaning of the
wire guide system, including tubes, drive rolls, and conduit at regular inter-
vals. The only parts on the gun that are subject to normal wear are the
conduit, contact tips, gas cups, drive rolls and barrel liners. A supply of those
parts should be maintained on hand.
Proper coolant is a very important part of keeping the water cooled
Prince™XL in good working condition. Any coolant which does not contain
reactive sulfur or chlorine, and which specifically does not react with copper,
brass or aluminum, may be used. One such mixture has proven extremely
successfull when used in conjunction with a water re-circulator. It consists of
the following 3:1 mixture:
Use 3 gallons deionized water (not distilled)
Use 1 gallon ethleyne glycol
Use 1 teaspoon liquid glycerin per gallon of mixture
The coolant flow rate should be 1 quart/minute at 35 p.s.i.