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INSTALLATION

TECHNICAL SPECIFICATIONS - MAGNUM

®

100SG SPOOL GUN K2532-1

MODEL

WELDING PROCESS

WIRE ALLOYS

WIRE SIZES (DIAMETERS)

SPOOL SIZE

RATED WELDING CURRENT
AND DUTY CYCLE

OVERALL WEIGHT

CABLE LENGTH

OVERALL SIZE (BOUNDING BOX)

METHOD OF GUIDANCE

METHOD OF COOLING

K25

3

2-1 

M

agnum

®

100S

G

 S

p

ool 

G

un

Aluminum 

GM

AW 

(M

I

G)

, DC electrode 

p

ositive 

p

olarit

y

 with 100% argon welding shielding gas.

Aluminum onl

y

: allo

y

s 404

3

 or 5

3

56

Solid wire 0.0

3

0 or 0.0

3

5 inches 

(

0.8 or 0.9 mm

)

1 lb. weight, nominal 4 inch diameter s

p

ool

1

3

0 am

p

s at 

3

0% 

f

or 10-minute basis

3

.5 lbs. with cable but without case or s

p

ool

10.0±0.2 

f

eet

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

without case or gun cable.

Semiautomatic 

(

manuall

y

-guided

)

Air-cooled

UNPACKING THE SPOOL GUN

The s

p

ool gun is 

f

actor

y

-assembled and tested, and then 

p

acked in its own cush-

ioned carr

y

ing case. It is shi

pp

ed 

f

ull

y

-e

q

ui

pp

ed to weld with 0.0

3

5 inch diameter alu-

minum wire. A

f

ter o

p

ening the case, check that it contains the 

f

ollowing items:

1.  One 

f

ull

y

 assembled K25

3

2-1 s

p

ool gun.

2.  One T11862-65 Conical Com

p

ression S

p

ring 

f

or use with allo

y

 5

3

56 wire 

(

s

p

ool

not included

)

.

3

.  One s

p

ool o

f

 0.0

3

5 aluminum allo

y

 404

3

 wire

4.  Three S19726-

3

 contact ti

p

s

5.  One instruction manual 

(

I

M

91

3)

6.  One 

M

21182 electrical harness with toggle switch.

1

3

4

5

6

2

A-1

Plastic Bag

Summary of Contents for 100SG SPOOL GUN

Page 1: ...ith cable but without case or spool 10 0 0 2 feet In inches 15 75 long x 10 50 high x 4 25 thick max without case or gun cable Semiautomatic manually guided Air cooled UNPACKING THE SPOOL GUN The spool gun is factory assembled and tested and then packed in its own cush ioned carrying case It is shipped fully equipped to weld with 0 035 inch diameter alu minum wire After opening the case check that...

Page 2: ...neat and clean appearance sim plifies cable management and reduces entanglements 8 Standard Durable Strain Relief Clamp 9 Three Captive Hex Nuts FIGURE A 1 Left Side View 1 4 3 5 5 2 FIGURE A 2 Right Side View 7 8 9 A 2 INSTALLATION SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL Turn the input power OFF at the welding power source before installation or changing drive rolls and or guides Do not touch ...

Page 3: ...ll specified wires 4 Incoming Wire Guide Highly wear resistant 5 P6 Connector Control Leads Motor Power and Trigger See Maintenance Section for more details 6 Welding Power and Shielding Gas Machine connection Sealed with 2 o rings 7 Locking Knob 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...

Page 4: ...fety glasses hearing protection welding helmet welding gloves and welding leathers SPOOL GUN ELECTRIC SHOCK CAN KILL The spool of wire may fall out of the gun if the locking knob is not installed Metal parts may be at welding voltage electrically hot Metal parts remain at welding voltage for several seconds after trigger is released Read warning label on gun This product shall not be used in preci...

Page 5: ...2481 1 K2515 1 K2659 1 K2688 1 K2689 1 K2698 1 CODE NUMBER 11588 11521 11257 11255 11659 11444 11442 11254 11256 11631 11300 11634 11173 11632 11302 11635 11303 11636 11440 11633 11503 11637 11504 11638 11506 11639 11550 11646 11175 11647 11304 11648 11441 11658 11501 11649 11502 11650 11505 INSTALLATION OF M21182 HARNESS AND SELECTOR SWITCH NOT REQUIRED NOT REQUIRED REQUIRED REQUIRED NOT REQUIRED...

Page 6: ...SPOOL GUN WIRE DRIVE SELECTOR SWITCH INSTALLATION 1 Install the M21182 electrical adapter harness that came with the spool gun per the following instructions ELECTRIC SHOCK CAN KILL 2 Disconnect input power from the machine OPEN THE MACHINE 3 Remove two 5 16 hex hinge screws from door 4 Remove ten 5 16 hex screws from cover 5 Remove screws from cover A is the location of two 3 4 long screws 6 Remo...

Page 7: ...ect P3 10 pin to har ness J7 10 pin 10 Connect harness P7 10 pin to board J3 10 pin IF MACHINE DOES NOT HAVE OPTIONAL SPOT TIMER 11 A thru 11 D 11 A Remove P5 6 pin from board J5 6 pin 11 B Connect P5 6 pin to har ness J8 6 pin 11 C Connect harness P8 6 pin to board J5 6 pin Toggle Switch P8 6 pin P7 10 pin J8 6 pin J7 10 pin 543A Female 544A Male J3 P3 P3 J7 J3 P7 P5 J5 P5 J8 P8 J5 ...

Page 8: ...apter harness J8 6 pin 12 C Connect adapter harness P8 6 pin to spot timer harness J9 6 pin 12 D Find assembled pair of machine terminals leads 543A 544A and disconnect 13 Connect terminals A connect machine male lead 543A to adapter harness female lead 543A B connect machine female lead 544A to adapter harness male lead 544A 14 Ensure that the locking tabs on all connectors are latched closed 543...

Page 9: ...t from switch Keep mounting nut for installation 18 Install switch into panel hole Ensure washer tab is fully seated into smaller hole 19 Reinstall mounting nut onto switch Wrench tighten RE ASSEMBLE MACHINE AS FOLLOWS 20 Reinstall screw into plastic handle if so equipped 21 Reinstall cover 22 Reinstall door 23 Reconnect input power to the machine ...

Page 10: ...ve Set the supply regulator to deliver a gas flow rate of 20 to 50 SCFH thru the spool gun 4 Flip the machineʼs wire drive selector switch behind the access door to Magnum 100SG See Figure A 4 FIGURE A 4 WARNING PREPARING THE SPOOL GUN ELECTRIC SHOCK CAN KILL 1 Disconnect input power to the machine 2 The Conical Spring is used as the spool brake only when feeding the stronger and harder aluminum a...

Page 11: ...loy 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 assembly to expose the drive roll groov...

Page 12: ...maining wire back onto spool and place spool onto gun spindle Install locking knob and finger tighten Go to step 11 FIGURE A 14 10b Alloy 5356 Install Conical Spring small end first onto gun spindle A Roll up remaining wire back onto spool and place spool onto gun spindle Install locking knob and finger tighten FIGURE A 15 11 Grasp the free end of the wire at the gas diffuser and slowly pull appro...

Page 13: ...heck for uniform fit all around cover FIGURE A 18 CONNECTING THE GUN TO THE WELDING MACHINE 1 Disconnect input power to the machine 2 Make sure that the gun locking knob is loosened See Figure 20 3 Fully insert gun cable connection welding power and gas supply into machine Note that the master Key way for P6 connector is located at the arrow FIGURE A 19 4 Check that the cable connectorʼs end is fl...

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