Lincoln Electric Magnum PRO 100SG Bedienungsanleitung

Oper tor’s M nu l

IMT10402 | Issue D ate May-17

For use with Pro uct Numbers:

K4360-1

Magnum®PRO 100SG

www.lincolnelectric.com/register

Authorized Service nd Distributor Loc tor:

www.lincolnelectric.com/locator

Need Help? C ll 1.888.935.3877

to talk to a Service Representative

Hours of Oper tion:

8:00 AM to 6:00 PM (ET) Mon. thru Fri.

After hours?

Use “Ask the Experts” at lincolnelectric.com

A Lincoln Service Representative will contact you

no later than the following business ay.

For Service outside the USA:

Email: [email protected]

S ve for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

THANK YOU FOR SELECTING

A QUALITY PRODUCT BY

LINCOLN ELECTRIC.

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.

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, OPERATE OR REPAIR THIS EQUIPMENT

WITHOUT READING THIS MANUAL AND THE SAFETY

PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,

think before you act and be careful.

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.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.

Use corrective lenses if necessary

to stay a reasonable distance

away from the arc.

READ and obey the Safety Data

Sheet (SDS) and the warning label

that appears on all containers of

welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to

keep the fumes and gases from

your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away

from your face.

If you develop unusual symptoms, see your supervisor.

Perhaps the welding atmosphere and ventilation system

should be checked.

WEAR CORRECT EYE, EAR &

BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate

(See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen

clothing, flame-proof apron and gloves, leather

leggings, and high boots.

PROTECT others from splatter, flash, and glare

with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously

had been in contact with hazardous substances unless they are

properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release

highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat,

mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an

electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust

exposes you to chemicals known to the State

of California to cause cancer and birth defects,

or other reproductive harm.

• Always start and operate the engine in a

well-ventilated area.

• If in an exposed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

For more information go to

www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or

cutting, produces fumes or gases which contain

chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California

Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm

www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECT

YOURSELF AND OTHERS FROM POSSIBLE SERIOUS

INJURY OR DEATH. KEEP CHILDREN AWAY.

PACEMAKER WEARERS SHOULD CONSULT WITH

THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For

additional safety information, it is strongly recommended

that you purchase a copy of “Safety in Welding & Cutting -

ANSI Standard Z49.1” from the American Welding Society,

P.O. Box 351040, Miami, Florida 33135 or CSA Standard

W117.2-1974. A Free copy of “Arc Welding Safety” booklet

E205 is available from the Lincoln Electric Company,

22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,

MAINTENANCE AND REPAIR PROCEDURES ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWERED

EQUIPMENT.

1.a. Turn the engine off before troubleshooting

and maintenance work unless the

maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine

exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding

arc or when the engine is running. Stop the

engine and allow it to cool before refueling to

prevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when filling

tank. If fuel is spilled, wipe it up and do not start engine until

fumes have been eliminated.

1.d. Keep all equipment safety guards, covers

and devices in position and in good repair.

Keep hands, hair, clothing and tools away

from V-belts, gears, fans and all other

moving parts when starting, operating or

repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to

perform required maintenance. Remove guards only when

necessary and replace them when the maintenance requiring

their removal is complete. Always use the greatest care when

working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to

override the governor or idler by pushing on the throttle control

rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning

the engine or welding generator during maintenance work,

disconnect the spark plug wires, distributor cap or magneto wire

as appropriate.

1.h. To avoid scalding, do not remove the radiator

pressure cap when the engine is hot.

ELECTRIC AND

MAGNETIC FIELDS MAY

BE DANGEROUS

2.a. Electric current flowing through any conductor

causes localized Electric and Magnetic Fields (EMF).

Welding current creates EMF fields around 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 EMF fields in welding may have other health effects

which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work

cables. If the electrode cable is on your right side, the

work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-

sible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK

CAN KILL.

3.a. The electrode and work (or ground) circuits are

electrically “hot” when the welder is on. Do

not touch these “hot” parts with your bare skin or wet clothing.

Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full area

of physical contact with work and ground.

In addition to the normal safety precautions, if

welding must be performed under electrically

hazardous conditions (in damp locations or while

wearing wet clothing; on metal structures such as

floors, gratings or scaffolds; when in cramped

positions such as sitting, kneeling or lying, if there

is a high risk of unavoidable or accidental contact

with the workpiece or ground) use the following

equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic welding

gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection should

be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth)

ground.

3.f. Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode

holders connected to two welders because voltage

between the

two can be the total of the open circuit voltage of both

welders.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your

eyes from sparks and the rays of the arc when welding or

observing open arc welding. Headshield and filter lens should

conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material

to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES

CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases. When welding, keep your head out of the fume.

Use enough ventilation and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. When welding

hardfacing (see instructions on container or SDS)

or on lead or cadmium plated steel and other

metals or coatings which produce highly toxic

fumes, keep exposure as low as possible and

within applicable OSHA PEL and ACGIH TLV limits

using local exhaust or mechanical ventilation

unless exposure assessments indicate otherwise.

In confined spaces or in some circumstances,

outdoors, a respirator may also be required.

Additional precautions are also required when

welding

on galvanized steel.

5. b. The operation of welding fume control equipment is affected by

various factors including proper use and positioning of the

equipment, maintenance of the equipment and the specific

welding procedure and application involved. Worker exposure

level should be checked upon installation and periodically

thereafter to be certain it is within applicable OSHA PEL and

ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors

coming from degreasing, cleaning or spraying operations. The

heat and rays of the arc can react with solvent vapors to form

phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and

cause

injury or death. Always use enough ventilation, especially in

confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

Safety Data Sheet (SDS) and follow your employer’s safety

practices. SDS forms are available from your welding

distributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 5/16/2018

WELDING AND CUTTING

SPARKS CAN CAUSE

FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If

this is not possible, cover them to prevent the welding sparks

from starting a fire. Remember that welding sparks and hot

materials from welding can easily go through small cracks and

openings to adjacent areas. Avoid welding near hydraulic lines.

Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special

precautions should be used to prevent hazardous situations.

Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)

and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is

touching the work or ground. Accidental contact can cause

overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances inside.

They can cause an explosion even though they have been

“cleaned”. For information, purchase “Recommended Safe

Practices for the Preparation for Welding and Cutting of

Containers and Piping That Have Held Hazardous Substances”,

AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free

protective garments such as leather gloves, heavy shirt, cuffless

trousers, high shoes and a cap over your hair. Wear ear plugs

when welding out of position or in confined places. Always wear

safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area

as practical. Work cables connected to the building framework or

other locations away from the welding area increase the

possibility of the welding current passing through lifting chains,

crane cables or other alternate circuits. This can create fire

hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention During

Welding, Cutting and Other Hot Work”, available from NFPA, 1

Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IF

DAMAGED.

7.a. Use only compressed gas cylinders containing

the correct shielding gas for the process used

and properly operating regulators designed for

the gas and pressure used. All hoses, fittings,

etc. should be suitable for the application and

maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to

an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected

to physical damage.

• A safe distance from arc welding or cutting operations

and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight

except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,

associated equipment, and CGA publication P-l, “Precautions for

Safe Handling of Compressed Gases in Cylinders,” available from

the Compressed Gas Association, 14501 George Carter Way

Chantilly, VA 20151.

FOR ELECTRICALLY

POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical

Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

MAGNUM®PRO 100SG

TABLE OF CONTENTS

PAE

Installaton Secton.....................................................................................................................................................A

Technical Specification..............................................................................................................................................A-1

Unpacking the Spool un...........................................................................................................................................A-1

Safety Precautions.....................................................................................................................................................A-2

Locating Spool un Components And Features.......................................................................................................... A-2

Assembly of Items Inside the Magnum Spool un......................................................................................................A-3

Routine Welding Machine Preparation........................................................................................................................A-4

Preparing the Spool un............................................................................................................................................ A-4

Loading Aluminum.....................................................................................................................................................A-4

Connecting the un to the Welding Machine..............................................................................................................A-6

Operaton Secton.......................................................................................................................................................B

Safety Precaution......................................................................................................................................................B-1

Product Description...................................................................................................................................................B-1

Welding Procedures...................................................................................................................................................B-1

Optons and Accessores Secton..............................................................................................................................C

Ma ntenance Sect on.................................................................................................................................................D

Safety Precautions....................................................................................................................................................D-1

Routine and Periodic Maintenance.............................................................................................................................D-1

Recommended Tools.................................................................................................................................................D-1

Cleaning and Inspections...........................................................................................................................................D-1

P6 Connector Pin-Out................................................................................................................................................D-1

as Diffuser Replacement......................................................................................................................................... D-1

Liner Assembly Replacement or Cleaning..................................................................................................................D-2

Drive Roll Replacement.............................................................................................................................................D-2

Idle Roll Assembly Replacement................................................................................................................................D-3

un Tube Assembly Replacement............................................................................................................................. D-3

Wire Drive Assembly Removal And Installation..........................................................................................................D-4

Trigger Assembly Replacement................................................................................................................................. D-4

Welding Cable Assembly Replacement.............................................................................................................. D-4, D-5

Correcting Wire Shaving issues................................................................................................................................. D-5

Troubleshoot ng Sect on.............................................................................................................................................E

Safety Precautions.....................................................................................................................................................E-1

How To Use Trouble Shooting uide..........................................................................................................................E-1

Troubleshooting..............................................................................................................................................E-2 to E-4

Dagrams Sect on........................................................................................................................................................F

Wiring Diagrams........................................................................................................................................................F-1

Parts L st .........................................................................................................................parts.l ncolnelectr c.com

Content/details may be changed or updated without notice. For most current Instruction Manuals,

go to Parts.lincolnelectric.com.

A-1

INSTALLATION

MAGNUM®PRO 100SG

INSTALLATION

TECHNICAL SPECIFICATIONS -

K4360-1 - Magnum PRO 100SG Spool Gun

PRODUCT DESCRIPTION

• 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.

• un cable compactly integrates welding current and gas

supplies with gun control functions.

• Uses reliable gun and feeder hardware from Lincoln’s

Magnum®PRO 100L un.

UNPaCkINg ThE SPOOl gUN

The spool gun is factory-assembled and tested, and then packed

in its own carrying case. It is shipped fully-equipped to weld with

0.035 inch diameter aluminum wire. After opening the case,

check that it contains the following items:

1. One fully assembled K4360-1 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 0.035 contact tips

5. One instruction manual

Welding Process

Aluminum MAW (MI ), DC electrode positive

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)

Spool Size

1 lb. weight, nominal 4 inch diameter spool

Rated Welding

Current and Duty

Cycle

130 amps at 30% for 10-minute basis

Overall Weight

3.5 lbs. with cable but without case or spool

Cable Length

10.0±0.2 feet

Overall Size

(bounding box)

In inches: 15.75 long x 10.50 high x 4.25 thick

max., without case or gun cable.

Method o Guidance

Semiautomatic (manually-guided)

Method o Cooling

Air-cooled

A-2

INSTALLATION

MAGNUM®PRO 100SG

SAFET 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 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.

WELDING MACHINES

• Read and understand the welding

machine’s instruction manual 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.

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 precipitation, or in wet

or damp locations.

lOCaTINg COMPONENTS aND FEaTURES

(See Figure 1.A for Items 1 thru 6)

1. as Cone Assembly and Contact Tip.

2. Straightened un 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.

FIGURE A.1

(See Figure A.2 for these following items)

7. Integrated Single-Piece Cable: The Magnum® design

provides neat and clean appearance; simplifies cable

management and reduces entanglements.

8. Standard Durable Strain Relief Clamp.

9. Three Captive Hex Nuts.

FIGURE A.2

WARNING

A-3

INSTALLATION

MAGNUM®PRO 100SG

aSSEMBlY OF INSIDE ITEMS

1. Liner Assembly: Includes a gas seal with the cable connector

and is the outgoing wire guide.

2. Drive Roll: This Drive Roll feeds all specified aluminum wires.

3. Idle Roll Assembly: Non-adjustable tension setting for all

specified wires

4. Incoming Wire uide: Highly wear-resistant.

5. P6 Connector Control Leads: Motor Power and Trigger. (See

Maintenance Section for more details)

6. Welding Power and Shielding as Machine connection

(Sealed with 2 o-rings).

7. Locking Knob: Independently retains the wire spool on the

spindle.

8. Only 4 sub-assemblies: gun tube; cable; wire drive; trigger.

9. Conical spring serves as the spool brake (use only with

aluminum alloy 5356).

FIGURE A.3

A-4

INSTALLATION

MAGNUM®PRO 100SG

WElDINg MaChINE PREPaRaTION

ELECTRIC SHOCK can kill.

Disconnect input power to the machine.

2. Machine polarity setting: Set to DC electrode positive polarity

per the machine’s Instruction Manual.

3. as 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® 100S ".

SPOOl gUN PREPaRaTION

ELECTRIC SHOCK can kill.

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.

LOADING ALUMINUM WIRE

1. Remove gas cone 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 diameter (size) and alloy needed. 0.035 wire size

and Alloy 4043 included with spool gun. Remove packaging

and data sheet from wire spool.

FIGURE A.7

WARNING

SIZE ALLOY

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