Magnum 100SG SPOOL GUN Installation Manual
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Magnum 100SG SPOOL GUN Installation Manual

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TECHNICAL SPECIFICATIONS - MAGNUM
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
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 it contains the following items:
1. One fully assembled K2532-1 spool gun.
2. One T11862-65 Conical Compression Spring for use with alloy 5356 wire (spool
not included).
3. One spool of 0.035 aluminum alloy 4043 wire
4. Three S19726-3 contact tips
5. One instruction manual (IM913)
6. One M21182 electrical harness with toggle switch.
1
INSTALLATION
K2532-1 Magnum
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
3
2
Plastic Bag
A-1
®
100SG SPOOL GUN K2532-1
®
100SG Spool Gun
5
4
6

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Summary of Contents for Magnum 100SG SPOOL GUN

  • Page 1 INSTALLATION TECHNICAL SPECIFICATIONS - MAGNUM ® 100SG SPOOL GUN K2532-1 MODEL K2532-1 Magnum ® 100SG Spool Gun Aluminum GMAW (MIG), DC electrode positive WELDING PROCESS polarity with 100% argon welding shielding gas. WIRE ALLOYS Aluminum only: alloys 4043 or 5356 WIRE SIZES (DIAMETERS) Solid wire 0.030 or 0.035 inches (0.8 or 0.9 mm)

  • Page 2: Installation Safety Precautions

    6. Locking Knob: Captive in spool cover. Left Side View (See Figure A.2 for these following items) 7. Integrated Single-Piece Cable: FIGURE A.2 The Magnum design provides ® neat and clean appearance; sim- plifies cable management and reduces entanglements. 8. Standard Durable Strain Relief Clamp.

  • Page 3: Spool Gun

    INSTALLATION ASSEMBLY OF ITEMS INSIDE THE MAGNUM SPOOL GUN ® FIGURE A,3 TOP VIEW Spool Cover and left handle removed MASTER KEY Machine Connections P6 CONNECTOR PINOUT 1. Liner Assembly feeds all specified 7. Locking Knob: Independently retains wire. the wire spool on the spindle.

  • Page 4: Installation

    INSTALLATION SAFETY PRECAUTIONS WELDING MACHINES CAUTION • Read and understand the welding machineʼs instruction manu- al and all hazard warnings on equipment and in the manual. • Wear the proper personal protective equipment for welding, including but not limited to, safety glasses, hearing protection, welding helmet, welding gloves, and welding leathers.
  • Page 5 INSTALLATION RECOMMENDED WELDING MACHINES INSTALLATION OF M21182 HARNESS K-NUMBER CODE NUMBER MACHINE NAME AND SELECTOR SWITCH NOT REQUIRED POWER MIG 216 K2816-1 11588 POWER MIG 215XT K2700-1 11521 NOT REQUIRED POWER MIG 180C K2473-1 11257 REQUIRED REQUIRED POWER MIG 140C K2471-1 11255 POWER MIG 180 DUAL...

  • Page 6: Spool Gun / Wire Drive Selector Switch Installation

    INSTALLATION NOTE: Installation of the M21182 harness and spool gun selector switch is not required for all machines. If a spool gun switch is pre-installed in the machineʼs wire drive compartment, then the SPOOL GUN / WIRE DRIVE SLECTOR SWITCH INSTALLATION SECTION can be disregarded. SPOOL GUN / WIRE DRIVE SELECTOR SWITCH INSTALLATION...

  • Page 7: Electrical Connections

    INSTALLATION ELECTRICAL CONNECTIONS 544A (Male) 543A (Female) Toggle Switch J7 (10-pin) J8 (6-pin) P8 (6-pin) 10. Connect harness P7 (10-pin) to P7 (10-pin) board J3 (10-pin). 8. Adapter harness. All 6 connections shown are used, and each one is IF MACHINE DOES NOT HAVE OPTIONAL unique.
  • Page 8 INSTALLATION 544A 543A 12.C. Connect adapter harness P8 (6- 11.D. Find assembled pair of machine pin) to spot timer harness J9 (6- terminals (leads 543A & 544A) pin). and disconnect. Go to step 13. IF MACHINE DOES HAVE OPTIONAL SPOT TIMER.

  • Page 9: Mounting The Switch

    INSTALLATION MOUNTING THE SWITCH 18. Install switch into panel hole. Ensure washer tab is fully seated into smaller hole. 15. Remove the plug button from the panel hole. 19. Reinstall mounting nut onto switch. 16. Plug button is no longer needed. Wrench tighten.

  • Page 10: Preparing The Spool Gun

    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 PREPARING THE SPOOL GUN WARNING ELECTRIC SHOCK CAN KILL.
  • Page 11 INSTALLATION 4. Extend approximately 12 inches LOADING ALUMINUM WIRE of wire from spool. Straighten it out by back-bending it. Use care 1. Remove gas cone and contact tip. to prevent the wire from dereeling. Remove spool cover by unscrewing FIGURE A.8 captive locking knob.
  • Page 12 INSTALLATION 10a. Alloy 4043: Roll up remaining wire 7. Guide straightened wire through inlet back onto spool and place spool wire guide and toward drive roll groove. onto gun spindle. Install locking knob and finger-tighten. Go to step FIGURE A.11 FIGURE A.14 10b.
  • Page 13 INSTALLATION CONNECTING THE GUN TO THE 12. Cut off excess wire 1 to 2 inches from gas diffuser. Install properly- WELDING MACHINE sized contact tip slightly past hand- tight. Install gas cone and hand- 1. Disconnect input power to the tighten.

This manual is also suitable for:

K2532-1

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