Magnum Pro 100SG - Welding machine LINCOLN ELECTRIC - Free user manual and instructions

USER MANUAL Magnum Pro 100SG LINCOLN ELECTRIC

FORENGINE powered equipment. 1.a. Turn theengineoffbeforetroubleshootingandmaintenance work unless themaintenanceworkrequiresittoberunning. 1.b.Operate engines in open, well-ventilated areas or vent th eengineexhaustfumes 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 repairin g 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. SAFETY 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

IMT10137 November, 2012 Copyright © Lincoln Global Inc. Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPER-

ATE OR REPAIR THIS EQUIP-

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 physicianbefore 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 - Securethem with tape when possible. 2.d.2. Never coiltheelectrode lead around your body. 2.d.3. Do notplaceyourbodybetweentheelectrodeand work cables. If theelectrodecableisonyourrightside, theworkcableshouldalsobeonyourrightside.2.d.4. Connect theworkcabletotheworkpieceascloseaspossible 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, andother 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

IMT10137 November, 2012 Copyright © Lincoln Global Inc. Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPER-

ATE OR REPAIR THIS EQUIP-

TAINED THROUGHOUT. And, most importantly, think before you act and be careful.vv TThhaannkk YYoouu for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below: WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life. This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. CAUTION On-Line Product Registration - Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “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.

le code “Code for safetyinwelding and cutting” CSA Standard W117.2-1974.

TThhaannkk YYoouu for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below: WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life. This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. CAUTION On-Line Product Registration - Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “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.

le code “Code for safetyinwelding and cutting” CSA Standard W117.2-1974.

PRO100SG Spool Gun Aluminum GMAW (MIG), DC electrode positive polarity with 100% argon welding shielding gas. Aluminum only: alloys 4043 or 5356 Solid wire 0.030 or 0.035 inches (0.8 or 0.9 mm) 1 lb. weight, nominal 4 inch diameter spool 130 amps at 30% for 10-minute basis

3.5 lbs. with cable but without case or spool

10.0±0.2 feet In inches: 15.75 long x 10.50 high x 4.25 thick max., without case or gun cable. Semiautomatic (manually-guided) Air-cooled

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

6. One M21182 electrical harness with toggle switch.

!& %"!!' !"! &% &'$% (See Figure 1.A for Items 1 thru 6)

1. Gas Nozzle and Contact Tip.

2. Straightened Gun Tube Assembly.

3. 1/4-Turn Locking Collar.

4. Trigger Assembly.

5. Spool Cover: Provides easy, wide-

open access to spool and wire drive.

6. Locking Knob: Captive in spool

cover. (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.

9. Three Captive Hex Nuts.

PRO100SG Spool Gun Aluminum GMAW (MIG), DC electrode positive polarity with 100% argon welding shielding gas. Aluminum only: alloys 4043 or 5356 Solid wire 0.030 or 0.035 inches (0.8 or 0.9 mm) 1 lb. weight, nominal 4 inch diameter spool 130 amps at 30% for 10-minute basis

3.5 lbs. with cable but without case or spool

10.0±0.2 feet In inches: 15.75 long x 10.50 high x 4.25 thick max., without case or gun cable. Semiautomatic (manually-guided) Air-cooled

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

6. One M21182 electrical harness with toggle switch.

!& %"!!' !"! &% &'$% (See Figure 1.A for Items 1 thru 6)

1. Gas Nozzle and Contact Tip.

2. Straightened Gun Tube Assembly.

3. 1/4-Turn Locking Collar.

4. Trigger Assembly.

5. Spool Cover: Provides easy, wide-

open access to spool and wire drive.

6. Locking Knob: Captive in spool

cover. (See Figure A.2 for these following items)

7. Integrated Single-Piece Cable:

Pro design provides neat and clean appearance; sim- plifies cable management and reduces entanglements.

9. Three Captive Hex Nuts.

Spool Cover and left handle removed Machine Connections

3. Idle Roll Assembly: Non-adjustable

tension setting for all specified wires

4. Incoming Wire Guide: Highly wear-

5. P6 Connector Control Leads: Motor

Power and Trigger. (See Maintenance Section for more details)

6. Welding Power and Shielding Gas

Machine connection (Sealed with 2 o-rings).

7. Locking Knob: 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).

Spool Cover and left handle removed Machine Connections

3. Idle Roll Assembly: Non-adjustable

tension setting for all specified wires

4. Incoming Wire Guide: Highly wear-

5. P6 Connector Control Leads: Motor

Power and Trigger. (See Maintenance Section for more details)

6. Welding Power and Shielding Gas

Machine connection (Sealed with 2 o-rings).

7. Locking Knob: 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).

. 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

4. Remove ten 5/16“ hex screws from

5. Remove screws from cover.

( is the location of two 3/4” long screws.

7. If machine has a plastic handle ,

MACHINE NAME K-NUMBER CODE NUMBER

. 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

4. Remove ten 5/16“ hex screws from

5. Remove screws from cover.

( is the location of two 3/4” long screws.

7. If machine has a plastic handle ,

MACHINE NAME K-NUMBER CODE NUMBER

?4=@ $18:A1";59 from spot timer harness J9 (6-pin). :991/?" ;59to 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-??417:/6593?-.>:9-77 /:991/?:=>-=17-?/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

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

?4=@ $18:A1";59 from spot timer harness J9 (6-pin). :991/?" ;59to 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-??417:/6593?-.>:9-77 /:991/?:=>-=17-?/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

1. Disconnect input power to the machine.

2. Machine polarity setting: Set to DC electrode positive

polarity per the machine’s Instruction Manual.

3. Gas 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 "MAGNUM

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. WARNING INSTALLATION A-9 A-10

15. Remove the plug button from the

16. Plug button is no longer needed.

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.

20. Reinstall screw into plastic handle (if

1. Disconnect input power to the machine.

2. Machine polarity setting: Set to DC electrode positive

polarity per the machine’s Instruction Manual.

3. Gas 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 "MAGNUM

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. WARNING INSTALLATION A-9 A-10

15. Remove the plug button from the

16. Plug button is no longer needed.

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.

20. Reinstall screw into plastic handle (if

7. Guide straightened wire through inlet

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. Go to step

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. Grasp 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

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. Gently pull open the idle roll

7. Guide straightened wire through inlet

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. Go to step

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. Grasp 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

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. Gently pull open the idle roll

12. Cut off excess wire 1 to 2 inches

from gas diffuser. Install properly- sized contact tip slightly past hand- tight. Install gas nozzle and hand- tighten. FIGURE A.17

13. Reinstall spool cover. 1: tuck

cover’s tab in place at arrow and hold with thumb. 2: swing cover closed. 3: finger-tighten locking knob. 4: check for uniform fit all around cover. FIGURE A.18

1. Disconnect input power to the

2. Make sure that the gun locking knob

is loosened. (See Figure 20).

3. Fully insert gun cable connection

(welding power and gas supply) into machine. Note that the master Key way for P6 connector is located at the arrow. FIGURE A.19

4. Check that the cable connector’s

end is flush with insulator at A. Tighten gun locking knob (B) onto cable connector. FIGURE A.20

12. Cut off excess wire 1 to 2 inches

from gas diffuser. Install properly- sized contact tip slightly past hand- tight. Install gas nozzle and hand- tighten. FIGURE A.17

13. Reinstall spool cover. 1: tuck

cover’s tab in place at arrow and hold with thumb. 2: swing cover closed. 3: finger-tighten locking knob. 4: check for uniform fit all around cover. FIGURE A.18

1. Disconnect input power to the

2. Make sure that the gun locking knob

is loosened. (See Figure 20).

3. Fully insert gun cable connection

(welding power and gas supply) into machine. Note that the master Key way for P6 connector is located at the arrow. FIGURE A.19

4. Check that the cable connector’s

end is flush with insulator at A. Tighten gun locking knob (B) onto cable connector. FIGURE A.20 MAGNUM

• Reliable, low-price aluminum welding accessory for novice and experienced welders.

• Completely enclosed system.

• All combinations of specified aluminum alloys and wire diameters can be fed with the same drive roll and liner assembly.

• Gun cable compactly integrates welding current and gas supplies with gun control functions.

• Uses reliable gun and feeder hardware from Lincoln’s Magnum® 100L Gun, Innershield guns, and small Power Mig products.

• Reliable, low-price aluminum welding accessory for novice and experienced welders.

• Completely enclosed system.

• All combinations of specified aluminum alloys and wire diameters can be fed with the same drive roll and liner assembly.

• Gun cable compactly integrates welding current and gas supplies with gun control functions.

• Uses reliable gun and feeder hardware from Lincoln’s Magnum® 100L Gun, Innershield guns, and small Power Mig products.

B-3 After choosing the proper welding wire for your application, load the aluminum wire, connect the gun and cable to the welding machine. (See Installation Section). WELDING PROCEDURES

1. Read and understand Arc Welding Safety

Precautions located throughout this manual and the Welding Machine’s Instruction Manual. Also for helpful hints in welding see (LTW1) the Learn to Weld manual which is supplied with the welding machine.

2. Obtain and use the proper personal protective

equipment for welding. Connect the WORK (welding ground) cable(-) to piece(s) being welded. Make sure gas hose from cylinder’s regulator is connected to welder’s gas INLET. Open cylinder’s gas valve.

3. Connect input power to the machine.

4. Turn the machine’s power switch to "on". Set

wire speed and voltage tap settings to tables which are provided in the beginning of this section.

5. Flip toggle selector switch inside of machine to

Pro 100SG" position. Press and hold trigger for about 5 seconds to purge hose. Be sure the Gas flow rate is set to 20 to 50 SCFH thru the spool gun. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this main- tenance.

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

• Do not touch electrically hot parts.

• #2 Phillips screw-driver

• Slotted screw-driver

• 5/16 inch nut driver

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

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

• 3.0 mm metric allen wrench (drive roll screw)

• Tape measure or 6-inch scale

• Tachometer (optional) *Note: Two meters are used for simultaneously measuring drive motor’s voltage and current.

CLEANING AND INSPECTIONS

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

• Wipe off dust and debris.

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

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

6. Cut off the aluminum wire so that it extends

about 1/4 inches from the contact tip.

7. CTWD (Contact Tip to Work Distance): Position

the gun so that the contact tip is nominally 3/8 inches from the joint and tilted with a push angle toward it. The aluminum wire should not contact the workpiece. (See figure B.1) FIGURE B.1

8. Protect the eyes and pull the trigger to begin

9. Adjust the hand travel speed of the gun to

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

10. Release the trigger to stop welding.

GAS DIFFUSER REPLACEMENT

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

1. Remove gas nozzle and contact tip.

2. Carefully grasp gun tube with pliers

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

3. Install gas diffuser and thread into

place in gun tube. Tighten diffuser to 41 to 47 in.-lbs. with Torque Wrench. Pin No.

B-3 After choosing the proper welding wire for your application, load the aluminum wire, connect the gun and cable to the welding machine. (See Installation Section). WELDING PROCEDURES

1. Read and understand Arc Welding Safety

Precautions located throughout this manual and the Welding Machine’s Instruction Manual. Also for helpful hints in welding see (LTW1) the Learn to Weld manual which is supplied with the welding machine.

2. Obtain and use the proper personal protective

equipment for welding. Connect the WORK (welding ground) cable(-) to piece(s) being welded. Make sure gas hose from cylinder’s regulator is connected to welder’s gas INLET. Open cylinder’s gas valve.

3. Connect input power to the machine.

4. Turn the machine’s power switch to "on". Set

wire speed and voltage tap settings to tables which are provided in the beginning of this section.

5. Flip toggle selector switch inside of machine to

Pro 100SG" position. Press and hold trigger for about 5 seconds to purge hose. Be sure the Gas flow rate is set to 20 to 50 SCFH thru the spool gun. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this main- tenance.

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

• Do not touch electrically hot parts.

• #2 Phillips screw-driver

• Slotted screw-driver

• 5/16 inch nut driver

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

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

• 3.0 mm metric allen wrench (drive roll screw)

• Tape measure or 6-inch scale

• Tachometer (optional) *Note: Two meters are used for simultaneously measuring drive motor’s voltage and current.

CLEANING AND INSPECTIONS

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

• Wipe off dust and debris.

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

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

6. Cut off the aluminum wire so that it extends

about 1/4 inches from the contact tip.

7. CTWD (Contact Tip to Work Distance): Position

the gun so that the contact tip is nominally 3/8 inches from the joint and tilted with a push angle toward it. The aluminum wire should not contact the workpiece. (See figure B.1) FIGURE B.1

8. Protect the eyes and pull the trigger to begin

9. Adjust the hand travel speed of the gun to

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

10. Release the trigger to stop welding.

GAS DIFFUSER REPLACEMENT

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

1. Remove gas nozzle and contact tip.

2. Carefully grasp gun tube with pliers

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

3. Install gas diffuser and thread into

place in gun tube. Tighten diffuser to 41 to 47 in.-lbs. with Torque Wrench. Pin No.

LINER ASSEMBLY REPLACEMENT

1. Replacement liner assemblies are fac-

tory-made to the correct length. No cut- ting is required. The same liner fits all specified wire sizes and alloys:

2. Remove gas nozzle, contact tip, and

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

3. Liner removal: Grasp liner with Needle

nose pliers at point A. Gently work liner toward cable connector until the liner is loose in it. Be careful not to scrape liner’s gas-tight seal (point B) on con- nector. Withdraw liner out of gun tube (arrow C). (See figure D.2) FIGURE D.2 3a. Clean out old liner by blowing out with shop air or obtain a new replacement liner.

4. Slide liner, seal-end first, into gun tube.

Grasp liner with pliers at A. Gently push liner into connector. B. Check that liner passes through slot in wire feeder. C. Stop pushing when liner is 1.00 to

1.25 inches from end of gun tube.

(See figure D.3) FIGURE D.3

5. Liner installation: See step 4 above.

6. Reinstall gas diffuser (see Figure D.1)

and thread into place. Allow the diffuser to push the liner into its final position. Tighten to 41 to 47 in.-lbs. with a torque wrench.

7. Reinstall contact tip and gas nozzle.

sizes and alloys (See Table D.1).

2. Replace the drive roll if its feeding

groove has become worn or cannot be cleaned of galled aluminum.

3. Drive roll removal: Remove wire from

the wire drive. Unlock drive roll by rotat- ing twist-lock in either direction. (See figure D.4 and figure D.5) .

4. Twist-lock is rotated to the locked posi-

tion, securing drive roll in place. FIGURE D.4

5. Twist-lock is rotated to the unlocked

position, allowing drive roll removal. FIGURE D.5 MAINTENANCE D-3

6. Drive roll may be removed with pliers, as

shown in figure D.6. It may be helpful to relieve the idle roll tension during this step. FIGURE D.6

8. Install the drive roll by reversing the

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

1. Replace if it is degraded from use; for

example, it is becoming galled with alu- minum deposits.

2. Remove drive roll. (See Maintenance

3. Remove both idle roll assembly retaining

screws and washers.(See figure D.7) FIGURE D.7

4. Using Needle nose pliers, slowly pull the

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

5. Insert the new idle roll assembly into the

wire drive with the correct orientation, (See figures D.8 and D.9). Correct orientation. Note that lower spring is not visible in bore of idle roll bearing at arrow. FIGURE D.8 Incorrect orientation. Note that lower spring is visible in bore of idle roll bearing at arrow. FIGURE D.9

6. Using Needle nose pliers, push the new

idle roll assembly into the wire drive until it is fully seated.

7. Reinstall the retaining screws and wash-

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

1. Replace if it is degraded from use; for

example, its insulating tube is breaking down.

2. Remove liner assembly. (See

Maintenance Section)

3. Remove left side of handle. Loosen gun

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

Twist-lock Locked position Twist-lock Unlocked position Idle Roll Tension Retaining screws and washers RIGHT WRONGMAINTENANCE D-2

LINER ASSEMBLY REPLACEMENT

1. Replacement liner assemblies are fac-

tory-made to the correct length. No cut- ting is required. The same liner fits all specified wire sizes and alloys:

2. Remove gas nozzle, contact tip, and

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

3. Liner removal: Grasp liner with Needle

nose pliers at point A. Gently work liner toward cable connector until the liner is loose in it. Be careful not to scrape liner’s gas-tight seal (point B) on con- nector. Withdraw liner out of gun tube (arrow C). (See figure D.2) FIGURE D.2 3a. Clean out old liner by blowing out with shop air or obtain a new replacement liner.

4. Slide liner, seal-end first, into gun tube.

Grasp liner with pliers at A. Gently push liner into connector. B. Check that liner passes through slot in wire feeder. C. Stop pushing when liner is 1.00 to

1.25 inches from end of gun tube.

(See figure D.3) FIGURE D.3

5. Liner installation: See step 4 above.

6. Reinstall gas diffuser (see Figure D.1)

and thread into place. Allow the diffuser to push the liner into its final position. Tighten to 41 to 47 in.-lbs. with a torque wrench.

7. Reinstall contact tip and gas nozzle.

sizes and alloys (See Table D.1).

2. Replace the drive roll if its feeding

groove has become worn or cannot be cleaned of galled aluminum.

3. Drive roll removal: Remove wire from

the wire drive. Unlock drive roll by rotat- ing twist-lock in either direction. (See figure D.4 and figure D.5) .

4. Twist-lock is rotated to the locked posi-

tion, securing drive roll in place. FIGURE D.4

5. Twist-lock is rotated to the unlocked

position, allowing drive roll removal. FIGURE D.5 MAINTENANCE D-3

6. Drive roll may be removed with pliers, as

shown in figure D.6. It may be helpful to relieve the idle roll tension during this step. FIGURE D.6

8. Install the drive roll by reversing the

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

1. Replace if it is degraded from use; for

example, it is becoming galled with alu- minum deposits.

2. Remove drive roll. (See Maintenance

3. Remove both idle roll assembly retaining

screws and washers.(See figure D.7) FIGURE D.7

4. Using Needle nose pliers, slowly pull the

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

5. Insert the new idle roll assembly into the

wire drive with the correct orientation, (See figures D.8 and D.9). Correct orientation. Note that lower spring is not visible in bore of idle roll bearing at arrow. FIGURE D.8 Incorrect orientation. Note that lower spring is visible in bore of idle roll bearing at arrow. FIGURE D.9

6. Using Needle nose pliers, push the new

idle roll assembly into the wire drive until it is fully seated.

7. Reinstall the retaining screws and wash-

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

1. Replace if it is degraded from use; for

example, its insulating tube is breaking down.

2. Remove liner assembly. (See

Maintenance Section)

3. Remove left side of handle. Loosen gun

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

Twist-lock Locked position Twist-lock Unlocked position Idle Roll Tension Retaining screws and washers RIGHT WRONGMAINTENANCE D-4

4. Obtain a new replacement gun tube (if need-

ed). Remove locking nut from old gun tube and install onto new gun tube. Nut should be fully threaded finger-tight against the insulating tube.

5. Slide gun tube’s external threads through gun

tube mounting plate and screw the gun tube by hand into the cable connector until the nut pulls the mounting plate snug against the connector.

6. Tighten the nut and mounting plate to the con-

nector with Torque Wrench 10 to 12 ft.-lbs.

7. Reassemble gun. Be careful not to pinch any

leads between gun handle halves. WIRE DRIvE ASSEMBLY REMOvAL AND INSTALLATION

1. There are no serviceable or maintainable parts

inside of the wire drive.

2. Remove liner assembly (See Maintenance

Section figures D.2 and D.3).

3. Remove left side of handle.

4. Disconnect black and red leads from drive

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

5. Slide wire drive out of right handle half.

6. When reinstalling wire drive, note the proper

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

7. Reassemble gun. Be careful not to pinch any

leads between gun handle halves.

2. Remove liner assembly. (See Maintenance

3. Remove gun tube assembly. (See Maintenance

4. Remove wire drive assembly. (See Maintenance

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

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

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

4.813 inches from the end of the cable connector.

(See figure D.14) FIGURE D.14

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

mark as shown in figure D.15.

TRIGGER ASSEMBLY REPLACEMENT

1. There are no serviceable or maintainable parts

inside of the trigger.

2. Remove spool cover and left side of handle.

3. Slide trigger out of right handle half. Disconnect

both white leads from trigger. Use care to pre- vent damage to electrical leads and the termi- nals. (See Figure D.12) FIGURE D.12

4. Connect both white leads to the new trigger.

Either lead may be connected to either trigger pin (non-polarized connections).

5. Slide new trigger into place and reassemble the

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

WELDING CABLE ASSEMBLY

1. Generally, there are no serviceable or maintain-

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

• Damage to the four #22 AWG control leads at the gun cable’s welding machine end (P6 plug) may be repairable without removing or replacing the entire gun cable. The leads can be spliced and soldered back togeth- er, and then reinsulated with heat-shrink tubing. See Table D.1 in Maintenance Section for a description of the connec- tions.

• Otherwise, the damaged gun cable may be replaced. MAINTENANCE D-5 White Leads Consumable parts Periodicreplacementparts Tapered contact tip 0.030(0.8mm) S28172-7 Tapered contact tip 0.035(0.9mm) S28172-1 Gas diffuser (S28722) Gas nozzle (S28728-1) Gun tube assembly (S28729-1) Drive roll assembly (S26236-2) Liner assembly (S26612) KP2744-030TKP2744-035TKP3076-1KP3075-1-50FKP3325-1KP2529-2KP2632-110-pack10-pack1-piece1-piece1-piece1-piece1-piece TABLE D.2 Mark for strain relief “+” Terminal Red Dot Black Lead FIGURE D.15

8. Install the new gun cable. Pass the cable connec-

tor through the opening in the right handle, seat the strain relief in place, and then check to insure the cable is not kinked between strain relief and connector. Reassemble gun by reversing steps 2 through 5. CORRECTING WIRE SHAvING ISSUES

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

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

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

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

2. Visually check if wire is centered in the liner’s inlet

opening. Feed wire through the spool gun and note which side the shaving seems to occur.

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

Tube Replacement. Slightly loosen gun tube’s nut as shown.

4. Slide the gun tube in the mounting plate’s hole to

realign the wire and then retighten the nut as shown. Reassemble the gun.

5. Repeat steps 2 thru 4 until shaving is eliminated. A

light accumulation of fine dust is also permissible after feeding 1/4 of a spool during welding use.MAINTENANCE D-4

4. Obtain a new replacement gun tube (if need-

ed). Remove locking nut from old gun tube and install onto new gun tube. Nut should be fully threaded finger-tight against the insulating tube.

5. Slide gun tube’s external threads through gun

tube mounting plate and screw the gun tube by hand into the cable connector until the nut pulls the mounting plate snug against the connector.

6. Tighten the nut and mounting plate to the con-

nector with Torque Wrench 10 to 12 ft.-lbs.

7. Reassemble gun. Be careful not to pinch any

leads between gun handle halves. WIRE DRIvE ASSEMBLY REMOvAL AND INSTALLATION

1. There are no serviceable or maintainable parts

inside of the wire drive.

2. Remove liner assembly (See Maintenance

Section figures D.2 and D.3).

3. Remove left side of handle.

4. Disconnect black and red leads from drive

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

5. Slide wire drive out of right handle half.

6. When reinstalling wire drive, note the proper

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

7. Reassemble gun. Be careful not to pinch any

leads between gun handle halves.

2. Remove liner assembly. (See Maintenance

3. Remove gun tube assembly. (See Maintenance

4. Remove wire drive assembly. (See Maintenance

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

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

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

4.813 inches from the end of the cable connector.

(See figure D.14) FIGURE D.14

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

mark as shown in figure D.15.

TRIGGER ASSEMBLY REPLACEMENT

1. There are no serviceable or maintainable parts

inside of the trigger.

2. Remove spool cover and left side of handle.

3. Slide trigger out of right handle half. Disconnect

both white leads from trigger. Use care to pre- vent damage to electrical leads and the termi- nals. (See Figure D.12) FIGURE D.12

4. Connect both white leads to the new trigger.

Either lead may be connected to either trigger pin (non-polarized connections).

5. Slide new trigger into place and reassemble the

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

WELDING CABLE ASSEMBLY

1. Generally, there are no serviceable or maintain-

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

• Damage to the four #22 AWG control leads at the gun cable’s welding machine end (P6 plug) may be repairable without removing or replacing the entire gun cable. The leads can be spliced and soldered back togeth- er, and then reinsulated with heat-shrink tubing. See Table D.1 in Maintenance Section for a description of the connec- tions.

• Otherwise, the damaged gun cable may be replaced. MAINTENANCE D-5 White Leads Consumable parts PeriodicreplacementpartsTapered contact tip 0.030(0.8mm) S28172-7Tapered contact tip 0.035(0.9mm) S28172-1Gas diffuser (S28722)Gas nozzle (S28728-1)Gun tube assembly (S28729-1)Drive roll assembly (S26236-2)Liner assembly (S26612)KP2744-030TKP2744-035TKP3076-1KP3075-1-50FKP3325-1KP2529-2KP2632-110-pack10-pack1-piece1-piece1-piece1-piece1-pieceTABLE D.2 Mark for strain relief “+” Terminal Red Dot Black Lead FIGURE D.15

8. Install the new gun cable. Pass the cable connec-

tor through the opening in the right handle, seat the strain relief in place, and then check to insure the cable is not kinked between strain relief and connector. Reassemble gun by reversing steps 2 through 5. CORRECTING WIRE SHAvING ISSUES

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

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

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

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

2. Visually check if wire is centered in the liner’s inlet

opening. Feed wire through the spool gun and note which side the shaving seems to occur.

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

Tube Replacement. Slightly loosen gun tube’s nut as shown.

4. Slide the gun tube in the mounting plate’s hole to

realign the wire and then retighten the nut as shown. Reassemble the gun.

5. Repeat steps 2 thru 4 until shaving is eliminated. A

light accumulation of fine dust is also permissible after feeding 1/4 of a spool during welding use.TROUBLESHOOTING E-1 TROUBLESHOOTING E-2 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP- TOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Step 2. POSSIBLE CAUSE. The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute tothe machine symptom. Step 3. RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility. If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. WARNING Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED

No wire feed occurs when trigger is pulled Sluggish wire feed when trigger is pulled Drive roll turns in reverse direction.

1. Machine is switched off or unplugged.

2. Spool gun is out of wire.

3. Contact tip burnback.

4. Fully or partially blocked gun tube liner.

6. Machines toggle selector switch is not

set to spool gun mode.

7. Defective trigger. (contacts open)

8. Defective trigger circuit in gun.

9. Damaged spool gun motor.

10. No motor voltage or current from

11. Contact tip size too small for wire

1. Drive roll is worn or galled with alu-

2. Machines wire feed speed setting is

3. Wire is obstructed somewhere along

the wire feed path in the gun.

4. Low motor voltage.

1. Motor leads are connected in reverse.

1. Switch on or plug in machine.

4. Remove and clean or replace gun tube

liner. (See maintenance section)

5. Cut out bird nest, reload wire, and

check for proper wire alignment and wires mechanical resistance.

6. Flip switch to proper operating posi-

8. Disconnect gun from machine and

check trigger circuit for continuity.

11. Replace contact tip with one that is

2. Increase wire feed speed.

3. Check for obstructions: remove any

1. Connect properly. (See maintenance

section)TROUBLESHOOTING E-1 TROUBLESHOOTING E-2 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMP- TOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Step 2. POSSIBLE CAUSE. The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom. Step 3. RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility. If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

WARNING Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED

No wire feed occurs when trigger is pulled Sluggish wire feed when trigger is pulled Drive roll turns in reverse direction.

1. Machine is switched off or unplugged.

2. Spool gun is out of wire.

3. Contact tip burnback.

4. Fully or partially blocked gun tube liner.

6. Machines toggle selector switch is not

set to spool gun mode.

7. Defective trigger. (contacts open)

8. Defective trigger circuit in gun.

9. Damaged spool gun motor.

10. No motor voltage or current from

11. Contact tip size too small for wire

1. Drive roll is worn or galled with alu-

2. Machines wire feed speed setting is

3. Wire is obstructed somewhere along

the wire feed path in the gun.

4. Low motor voltage.

1. Motor leads are connected in reverse.

1. Switch on or plug in machine.

4. Remove and clean or replace gun tube

liner. (See maintenance section)

5. Cut out bird nest, reload wire, and

check for proper wire alignment and wires mechanical resistance.

6. Flip switch to proper operating posi-

8. Disconnect gun from machine and

check trigger circuit for continuity.

11. Replace contact tip with one that is

2. Increase wire feed speed.

3. Check for obstructions: remove any

1. Connect properly. (See maintenance

section)TROUBLESHOOTING E-3 TROUBLESHOOTING E-4 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED

Intermittent wire feed when trigger is pulled.Frequent occurrence of contact tip burn-back.Poor weld bead appearance (porosity ordull gray oxidized surface).1. Wire is mechanically binding along itsfeed path inside gun.2. Drive roll has become loose on huband output shaft.3. Drive roll has become galled with alu-minum.4. Wire has become kinked along its feedpath.

5. Idle roll assembly is installed back-

wards.6. Liner assembly is shaving wire.

1. Improper welding parameters or tech-

nique. (Example: CTWD (Contact Tipto Work Distance) is incorrect.

2. Wire may be feeding intermittently.

1. No gas flow.2. Low gas flow.3. Improper or contaminated shielding

4. Welding in a windy environment..

5. Improper electrode polarity.

6. Improper welding parameters or tech-

nique.1. Check that wire is properly alignedinside gun.2. Check that drive roll is securely fas-tened in place by SHCS (socket headcap screw); replace hub and twist-lockif worn.3. Remove and then clean or replace drive roll. (See Maintenance Section)

4. Manually pull wire slowly thru gun until

unkinked wire emerges.5. Install properly. (See MaintenanceSection)6. Check that wire is properly aligned at liner inlet; realign gun tube with wire drive. (See Correcting Wire Shaving Issues Maintenance Section)

1. See Operation Section for proper

Welding information.2. See symptoms on intermittent or slug-gish wire feed.1. See symptom "Low or no gas flow"2. See symptom "Low or no gas flow"

3. Check that the gas supplys labeling

reads 100% argon. Temporarily usealternate, known gas supply and checkfor appearance improvement.4. Erect a wind shield or move to a non- windy location before welding.

5. Reconnect machines welding output

to electrode positive polarity.6. See Operation Section for information. Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED

Low or no shielding gas flow. Wire feeder runs or begins feeding wire without pulling the gun trigger.

2. Gas supply is turned off or discon-

3. Gas supply flow regulator is

4. Machineʼs gas solenoid valve has

5. Blockage in gun along gas path.

6. Gun cable kinked or flattened.

7. Blockage due to excessive spatter

accumulation on gas nozzle or gas diffuser.

8. Excessive gas leakage from sup-

9. Gas leakage in gun between liner

assembly and cable connector.

10. Gas leakage at gun-to-feeder

1. Defective trigger. (contacts closed)

2. Defective (closed) trigger circuit in

the welding machine.

3. Trigger lead(s) inside gun cable

are shorted together or commonly shorted to either welding or motor circuits.

1. Check that an adequate gas sup-

2. Check that all gas supply valves

3. Check that gas flow is set between

5. Gently blow out debris from core

6. Attempt to straighten out cable, or

8. Find and repair all leaks.

9. Replace liner assembly. (See

Maintenance Section)

10. Damaged o-rings: replace both

seals. Gun connector not fully inserted into machine (See Installation Section).

1. Replace trigger. (See

3. Damaged control leads between

machineʼs P6 connector and cable; repair if possible. Otherwise, replace gun cable. (See Maintenance Section) for both.TROUBLESHOOTING E-3 TROUBLESHOOTING E-4 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED

Intermittent wire feed when trigger is pulled. Frequent occurrence of contact tip burn- back. Poor weld bead appearance (porosity or dull gray oxidized surface).

1. Wire is mechanically binding along its

feed path inside gun.

2. Drive roll has become loose on hub

3. Drive roll has become galled with alu-

4. Wire has become kinked along its feed

5. Idle roll assembly is installed back-

6. Liner assembly is shaving wire.

1. Improper welding parameters or tech-

nique. (Example: CTWD (Contact Tip to Work Distance) is incorrect.

2. Wire may be feeding intermittently.

3. Improper or contaminated shielding

4. Welding in a windy environment..

5. Improper electrode polarity.

6. Improper welding parameters or tech-

1. Check that wire is properly aligned

2. Check that drive roll is securely fas-

tened in place by SHCS (socket head cap screw); replace hub and twist-lock if worn.

3. Remove and then clean or replace

drive roll. (See Maintenance Section)

4. Manually pull wire slowly thru gun until

unkinked wire emerges.

5. Install properly. (See Maintenance

6. Check that wire is properly aligned at

liner inlet; realign gun tube with wire drive. (See Correcting Wire Shaving Issues Maintenance Section)

1. See Operation Section for proper

Welding information.

2. See symptoms on intermittent or slug-

1. See symptom "Low or no gas flow"

2. See symptom "Low or no gas flow"

3. Check that the gas supplys labeling

reads 100% argon. Temporarily use alternate, known gas supply and check for appearance improvement.

4. Erect a wind shield or move to a non-

windy location before welding.

5. Reconnect machines welding output

to electrode positive polarity.

6. See Operation Section for information.

Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED

Low or no shielding gas flow. Wire feeder runs or begins feedingwire without pulling the gun trigger.1. Out of gas.

2. Gas supply is turned off or discon-

3. Gas supply flow regulator is

4. Machineʼs gas solenoid valve has

malfunctioned.5. Blockage in gun along gas path.6. Gun cable kinked or flattened.

7. Blockage due to excessive spatter

accumulation on gas nozzle or gas diffuser.8. Excessive gas leakage from sup-ply.

9. Gas leakage in gun between liner

assembly and cable connector.

10. Gas leakage at gun-to-feeder

connection.1. Defective trigger. (contacts closed)

2. Defective (closed) trigger circuit in

the welding machine.

3. Trigger lead(s) inside gun cable

are shorted together or commonly shorted to either welding or motor circuits.

1. Check that an adequate gas sup-

ply is available.2. Check that all gas supply valvesare open.3. Check that gas flow is set between20 to 50 SCFH.4. See machineʼs instruction manual.5. Gently blow out debris from coretube.

6. Attempt to straighten out cable, or

replace cable. (See Maintenance Section)

7. Clean or replace gas nozzle or

gas diffuser.8. Find and repair all leaks.

9. Replace liner assembly. (See

Maintenance Section)

10. Damaged o-rings: replace both

seals. Gun connector not fully inserted into machine (See Installation Section).

1. Replace trigger. (See

Maintenance Section)2. See machineʼs instruction manual3. Damaged control leads between machineʼs P6 connector and cable; repair if possible. Otherwise, replace gun cable. (See Maintenance Section) for both.WIRING DIAGRAM F-1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. NOTES

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. NOTES

MANUAL Y LAS PRECAU-

MANUAL Y LAS PRECAU-

2.52.54.55.555.5N/AN/A

le code “Code for safetyinwelding and cutting” CSA Standard W117.2-1974.

le code “Code for safetyinwelding and cutting” CSA Standard W117.2-1974.

N/A N/A PriseTension

N/A N/A PriseTension

N/A N/A PriseTension

N/A N/A PriseTension

N/A N/A PriseTension

N/A N/A PriseTension

N/A N/A PriseTension

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

shown in figure D.15. FIGURE D.15

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

This parts list is provided as an informative guide only. It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electric’s official Parts Book (BK-34). When ordering parts, always refer to Lincoln Electric’s official Parts Book (BK-34) for the latest pages.

This parts list is provided as an informative guide only. It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electric’s official Parts Book (BK-34). When ordering parts, always refer to Lincoln Electric’s official Parts Book (BK-34) for the latest pages.

3A3A 1A Gun Handle (Right Half), Includes: G5666 1 X X 1B Warning Decal S25815 1 X X 1/4-20 x 2.50 HHS CF000114 1 X X #6-32 HN CF000005 3 X X Push Nut S18535-2 1 X X 2A Wire Drive Assembly, Includes: G5707 1 X X Twistlock Drive Roll Assembly KP2529-2 1 X X Hub M20860 1 X X Twist Lock S26238 1 X X Metric Screw T14731-72 1 X X Loctite 242 or Equivalent (1 drop reqʼd to lock Screw into place)

Use only the parts marked “X” the column 1 for Magnum. Use only the parts marked “X” in column 2 for Magnum Pro. # Indicates a change this printing. P-554-C.1

3A3A 1A Gun Handle (Right Half), Includes: G5666 1 X X 1B Warning Decal S25815 1 X X 1/4-20 x 2.50 HHS CF000114 1 X X #6-32 HN CF000005 3 X X Push Nut S18535-2 1 X X 2A Wire Drive Assembly, Includes: G5707 1 X X Twistlock Drive Roll Assembly KP2529-2 1 X X Hub M20860 1 X X Twist Lock S26238 1 X X Metric Screw T14731-72 1 X X Loctite 242 or Equivalent (1 drop reqʼd to lock Screw into place)

Use only the parts marked “X” the column 1 for Magnum. Use only the parts marked “X” in column 2 for Magnum Pro. # Indicates a change this printing. P-554-C.1

This parts list is provided as an informative guide only. It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electric’s official Parts Book (BK-34). When ordering parts, always refer to Lincoln Electric’s official Parts Book (BK-34) for the latest pages.

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