Magnum 100SG SPOOL GUN User Manual

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
K2532-1 Magnum
®
100SG 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
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.
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3
4
5
6
2
A-1
Plastic Bag

Magnum 100SG SPOOL GUN Specifications

General

Brand	Magnum
Model	100SG SPOOL GUN
Category	Welding System
Language	English

Summary

SAFETY PRECAUTIONS AND COMPONENT IDENTIFICATION

Electrical Shock and General Safety Warnings

Warns about electric shock, proper usage, and identifies key spool gun components visually.

ADDITIONAL SAFETY PRECAUTIONS

Welding Machine and Spool Gun Safety

Advises reading manuals, wearing PPE, and highlights electrical and environmental hazards.

SELECTOR SWITCH INSTALLATION

Electrical Shock Warning for Switch Installation

Alerts users to disconnect power before installation to prevent electric shock.

Step-by-Step Switch Installation

ELECTRICAL CONNECTIONS TO WELDING MACHINE

Adapter Harness and Machine Port Connections

Spot Timer and Final Connector Checks

LOADING ALUMINUM WIRE

Wire Loading Procedure

Wire Threading and Spooling

Final Wire Pull and Tension Check

CONNECTING THE GUN TO THE WELDING MACHINE

Pre-Connection Steps

Advises disconnecting power and ensuring the gun locking knob is loosened before connecting.

Gun Cable and Connector Attachment

Guides users on fully inserting the gun cable, noting the master keyway, and checking connector seating.