Routine And Periodic Maintenance - Lincoln Electric Magnum PRO 100SG Operator's Manual

MAGNUM PRO 100SG
MAINTENANCE
WARNING
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the welding
power source before installation or
changing drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode and drive
mechanism are "hot" to work and ground and could
remain energized several seconds after the gun trigger
is released.
• Do not operate with covers, panels or guards removed
or open.
• Only qualified personnel should perform maintenance
work.

ROUTINE aND PERIODIC MaINTENaNCE

Check weld cables.
Clean and tighten all welding cable connections.
Recommended Tools
• #2 Phillips screw-driver
• Slotted screw-driver
• 5/16 inch nut driver
• Torque Wrench
• Adjustable-jaw pliers
• 7/16 inch open-end wrench (gas diffuser)
• 9/16 inch open-end wrench (gun tube nut)
• Welding pliers (optional)
• Wire cutter
• Wire stripper
• Needle nose pliers
• Terminal crimping tool
• Flashlight
• Hand-held electrical meter *
• 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 volt-
age 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.
P6 Connector Pin-Out
Pin No. Function
1
TRIGGER
2
TRIGGER
3
+ MOTOR
4
- MOTOR
Master Key
1
2
3
4
GAS DIFFUSER REPLACEMENT
This part may need to be replaced if it has accumulated excessive
spatter and cannot be cleaned:
1. Remove gas cone and contact tip.
2. Carefully grasp gun tube with pliers to prevent accidentally
loosening gun tube. Gas diffuser has right-hand threads.
FIGURE D.1
Loosen gas diffuser with wrench. (See 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.
D-1
MAINTENANCE
TABLE D.1
Gun Cable Lead Color
WHITE
WHITE
RED
BLACK