WIRE FEEDER
MANUAL NO: U5278
OWNER'S
MANUAL
FOR
WIRE FEEDER
MODEL: CM-741
DO
NOT
U5278
DESTROY
IMPORTANT: Read and understand the entire contents of this
manual, with special emphasis on the safety material throughout
the manual, before installing, operating, or maintaining this
equipment. This equipment and this manual are for use only by
persons trained and experienced in the safety operation of welding
equipment. Do not allow untrained persons to install, operate or
maintain this equipment. Contact your distributor if you do not
fully understand this manual.
DAIHEN Corporation
WELDING PRODUCTS DIVISION
May 19, 2004
Upon contact, advise MODEL and MANUAL
NO.
Notice
:
Machine export to Europe
This product does not meet the requirements specified in the EC Directives which are the EU safety
ordinance that was enforced starting on January 1, 1995. Please make sure that this product is not
allowed to bring into the EU after January 1, 1995 as it is.
The same restriction is also applied to any country which has signed the EEA accord.
Please ask us before attempting to relocate or resell this product to or in any EU member country or
any other country which has signed the EEA accord.
No. U5278
TABLE OF CONTENTS
1. SAFETY INFORMATION・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
2
2. ARC WELDING SAFETY PRECAUTIONS・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
2
3. CHECKING OF QUANTITY OF THE ACCESSORIES・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
8
4. NAME OF PARTS・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
8
5. CARRYING AND INSTALLING OF THE WIRE FEEDER・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
9
6. CONNECTION PROCEDURE・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 10
7. WELDING PREPARATION・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 13
8. MAINTENANCE AND TROUBLESHOOTING・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 18
9. PARTS LIST・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 20
10. SPECIFICATIONS・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 27
―1―
No. U5278
1. SAFETY INFORMATION
The following safety alert symbols and signal words are used throughout this manual to
identify various hazards and special instructions.
WARNING
WARNING gives information regarding possible personal injury
or loss of life.
CAUTION
CAUTION refers to minor personal injury or possible equipment
damage.
2. ARC WELDING SAFETY PRECAUTIONS
‹
WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
Be sure to:
・Keep children away.
・Keep pacemaker wearers away until consulting a doctor.
‹
Read and understand the summarized safety information given below and the original
principal information that will be found in the PRINCIPAL SAFETY STANDARDS.
‹
Have only trained and experienced persons perform installation, operation, and
maintenance of this equipment.
‹
Use only well maintained equipment. Repair or replace damaged parts at once.
ARC WELDING is safe when precautions are taken.
―2―
No. U5278
2. ARC WELDING SAFETY PRECAUTIONS (continued)
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work
circuits are electrically live whenever the output is on. The power line and internal circuits of
this equipment are also live when the line disconnect switch is on. When arc welding all metal
components in the torch and work circuits are electrically live.
1. Do not touch live electrical parts.
2. Wear dry insulating gloves and other body protection that are free of holes.
3. Insulate yourself from work and ground using dry insulating mats or covers.
4. Be sure to disconnect the line disconnect switch before installing, changing torch parts
or maintaining this equipment.
5. Properly install and ground this equipment according to its Owner’s Manual and national,
state, and local codes.
6. Keep all panels and covers of this equipment securely in place.
7. Do not use worn, damaged, undersized, or poorly spliced cables.
8. Do not touch electrode and any metal object if POWER switch is ON.
9. Do not wrap cables around your body.
10. Turn off POWER switch when not in use.
ARC RAYS can burn eyes and skin: FLYING SPARKS AND HOT METAL can
cause injury. NOISE can damage hearing.
Arc rays from the welding process produce intense heat and strong ultraviolet rays that can
burn eyes and skin.
Noise from some arc welding can damage hearing.
1. Wear face shield with a proper shade of filter (See ANSI Z 49.1 listed in PRINCIPAL
SAFETY STANDARDS) to protect your face and eyes when welding or watching a welder
work.
2. Wear approved safety goggles. Side shields recommended.
3. Use protective screens or barriers to protect others from flash and glare: warn others not
to look at the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather)
and foot protection.
5. Use approved earplugs or earmuffs if noise level is high.
Chipping and grinding can cause flying metal. As welds cool, they can throw off slag.
6. Wear approved face shield or safety goggles. Side shields recommended.
7. Wear proper body protection to protect skin.
―3―
No. U5278
2. ARC WELDING SAFETY PRECAUTIONS (continued)
WELDING can cause fire and explosion.
Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, spatter, hot
base metal, and hot equipment can cause fire and explosion. Accidental contact of electrode or
welding wire to metal object can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metals.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 10m (33ft) of the welding arc. If this is not possible, tightly,
cover them with approved covers.
4. Be alert that welding sparks and hot metals from welding can easily pass through cracks
and openings into adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can ignite a hidden fire.
7. Do not weld on closed containers such as tanks or drums.
8. Connect base metal side cable as close to the welding area as possible to prevent the
welding current from traveling along unknown paths and causing electric shock and fire
hazards.
9. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
10. Does not use the welding power source for other than arc welding.
11. Wear oil-free protective garments such as leather gloves, a heavy shirt, cuffless trousers,
boots, and a cap.
12. A loose cable connection can cause sparks and excessive heating.
13. Tighten all cable connections.
14. When there is an electrical connection between a work piece and the frame of wire feeder
or the wire reel stand, are may be generated and cause damage by a fire if the wire contacts
the frame or the work piece.
FUMES AND GASES can be hazardous to your health.
Arc welding produce fumes and gases. Breathing these fumes and gases can be hazardous to
your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. Ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDS) and the manufacturer’s instructions on
metals, consumables, coatings, and cleaners.
5. Do not weld or cut in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.
6. Work in a confined space only if it is well ventilated, or while wearing an air-supplied
respirator. Shielding gases used for welding can displace air causing injury or death.
Be sure the breathing air is safe.
―4―
No. U5278
2. ARC WELDING SAFETY PRECAUTIONS (continued)
CYLINDER can explode if damaged.
A shielding gas cylinder contains high-pressure gas. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding process, be sure to treat them carefully.
1. Use only correct shielding gas cylinders, gas regulator, hoses, and fittings designed for the
specific application; maintain them in good condition.
2. Protect compressed gas cylinders from excessive heat, mechanical shock, and arcs.
3. Keep the cylinder upright and securely chained to a stationary support or a rack to prevent
falling or tipping.
4. Keep cylinders away from any welding or other electrical circuit.
5. Never touch cylinder with welding electrode.
6. Read and follow instructions on compressed gas cylinders, associated equipment, and the
CGA publication P-1 listed in PRINCIPAL SAFETY STANDARDS.
7. Turn face away from valve outlet when opening cylinder valve.
8. Keep protective cap in place over valve except when gas cylinder is in use or connected for
use.
9. Do not disassemble or repair the gas regulator except for the person authorized by the
manufacturer of them.
Rotating parts may cause injuries. Be sure to observe the following.
If hands, fingers, hair or clothes are put near the fan’s rotating parts or wire feeder’s feed roll,
injuries may occur.
1. Do not use this equipment if the case and the cover are removed.
2. When the case is removed for maintenance/inspection and repair, certified or experienced
operators must perform the work. Erect a fence, etc. around this equipment to keep others
away from it.
3. Do not put hands, fingers, hair or clothes near the rotating fans or wire feed roll.
―5―
No. U5278
2. ARC WELDING SAFETY PRECAUTIONS (continued)
ARC WELDING work areas are potentially hazardous.
FALLING or MOVING machine can cause serious injury.
‹ When hanging the welding power source by a crane, do not use the carrying handle.
‹ Put the welding power source and wire feeder solidly on a flat surface.
‹ Do not pull the welding power source across a floor laid with cables and hoses.
‹ Do not put wire feeder on the welding power source.
‹ Do not put the welding power source and wire feeder where they will pit or fall.
WELDING WIRE can cause puncture wounds.
‹ Do not press gun trigger until instructed to do so.
‹ Do not point gun toward any part of the body, other people, or any metal when threading
welding wire.
―6―
No. U5278
PRINCIPAL SAFETY STANDARDS
Arc welding equipment – Installation and use, Technical Specification
IEC 62081, from International Electro technical Commission
Arc welding equipment Part 1: Welding power sources IEC 60974-1, from International Electro
technical Commission
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.
Government Printing Office.
Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.2,
from American Welding Society.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have
Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American
Welding Society.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas
Association.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards
Association, Standards Sales.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1,
from American National Standards Institute.
Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association.
NOTE: The codes listed above may be improved or eliminated. Always refer to the updated codes.
M040521
―7―
No. U5278
3. CHECKING OF QUANTITY OF THE ACCESSORIES
Make sure that you have the items below before you use the wire feeder.
Wire feeder
Wire feeder
Accessory
No.
Description
① Gas hose (9.8ft [3m])
② Hose cover
③ Cable joint
Specification
Quantity
K5430A00
U1997C03
4734-027
1
2
1
4. NAMES OF PARTS
Refer to the section indicated in
for details.
Feed motor 8.1
Gas supply inlet 6.4
Pressure roll holder
Wire reel hub 7.1 7.3
Pressure handles 7.2
Torch socket 6.3
Gas connecting fittings
Control cable 10P
Feed rolls 7.2 Frame
―8―
No. U5278
5. CARRYING AND INSTALLING OF THE WIRE FEEDER
5.1 Transportation
WARNING
Observe the following to avoid damage to the wire feeder or physical injury when carrying the
equipment.
● Do not touch the charging parts inside or outside of the wire feeder.
● Disconnect the welding power source by turning off the line disconnect switch in
the power box to avoid an electric shock before carrying the equipment.
● Be sure to detach the wire reel from the fire feeder before lifting the equipment to
the high places by a crane.
5.2 Installation
WARNING
When installing the wire feeder, follow the instructions below to avoid occurrence of fires during
welding and physical damage by fume gas.
● Do not place the welding machine near combustible materials and flammable gas.
● Remove combustible materials to prevent dross coming into contact with
combustible objects. If that not possible, cover them with noncombustible covers.
● To avoid gas poisoning and danger of suffocation, wear a gas mask or adequately
ventilate when using the welding machine in the place regulated by a local law.
● To prevent disorder or poisoning caused by fume, wear a gas mask or weld at a
partial exhaust facility approved by the local regulation.
● Adequately ventilate or wear a gas mask when using the welding machine in a
tank, a boiler, a hold of a ship, because heavier gas such as carbon dioxide or
argon gases are drifting there.
● When using the welding machine at a narrow space, comply with a trained
supervisor’s directions. And be sure to wear a gas mask.
● Do not operate the welding machine near the place where degreasing, cleansing,
and spraying are performed. Otherwise, poisonous gas may be generated.
● Be sure to wear a gas mask or adequately ventilate when welding a coating steel
plate. (Poisonous gas and fume may be generated.)
● Do not place the welding power source, wire feeder, torch, and control cable
(including the extension cable) in an area where the equipment can become wet.
INSTALLATION PLACE
Follow the instructions below when selecting an installation place of the wire feeder.
● Do not install the wire feeder in the indoor place subject to direct sunlight and rain.
● Install the wire feeder in the place where the ambient temperature is between -10 ˚C and +40
˚C.
● Do not place the welding power source, wire feeder, torch, and control cable (including the
extension cable) in an area where the equipment can become wet.
● Use a wind shield to protect arc from a wind blow when welding on a windy day.
―9―
No. U5278
6. CONNECTION PROCEDURE
CAUTION
Follow the instructions below to avoid electric shock.
∗ Do not touch the charging parts, otherwise this will result in fatal shock and severe burns.
● Do not touch the charging parts of the welding machine.
● Have a qualified electric engineer ground the case of the welding power source and the base
metal or jig electrically connected, following a local low.
● Disconnect the welding power source by turning off the line disconnect switch in the power
box to avoid an electric shock before grounding the welding power source or base metal and
connecting the cables or hoses.
● Do not use a cable with lack of capacity or a cable seriously damaged.
● Tighten and insulate the connections of cables.
● Firmly attach the cover of the welding machine after connection of the cables.
● Do not place the welding power source, wire feeder, torch, and control cable (including the
extension cable) in an area where the equipment can become wet.
6.1 Connecting to the Welding Power Source and to the Gas regulator
Standard Composition
Gas regulator
Gas hose*
Gas cylinder
Control cable
Welding
power
source
Torch cable*
Wire feeder
Firmly attach the DINSE connectors
by turning the connectors in the
clockwise direction.
Remote control cable
Remote control
(Optional)
Welding torch
Base metal cable*
NOTE:
Standard composition consists of the parts indicated in
. Preparation of the
parts except the standard composition is required to use the wire feeder.
*Available in 16ft [5m], 33ft [10m], 49ft [15m], and 66ft [20m].
Follow the steps below to connect to the welding power source and to the gas regulator.
1. Ground the base metal (if required by local laws or codes).
2. Connect between the negative output terminal for the base metal and the base metal with the base metal
cable.
3. Attach the torch cable to the positive output terminal of the welding power source.
4. Plug the control cable for the wire feeder (10P) into the wire feeder socket on the welding power source.
5. Attach the gas hose to the gas supply inlet on the wire feeder.
6. Connect the welding torch to the wire feeder.
7. Connect the torch cable to the power cable of the welding torch.
―10―
No. U5278
6. CONNECTION PROCEDURE (continued)
6.2 Connection of the Torch Cable
WARNING
∗
Touching the charging parts may result in fatal electric shock and severe burns.
● Do not touch the charging parts of the welding machine.
● Have a qualified electric engineer ground the case of the welding power source and the base
metal or jig electrically connected in accordance with a local low.
● Disconnect the welding power source by turning off the line disconnect switch in the power
box to avoid an electric shock before the welding power source or base metal and connecting
the cables or hoses.
● After connecting the cables, cover the power source with the cover or case.
● When using the welding machine in such a humid environment as construction site, on the
steel plate, or on steel structure, install a leakage breaker.
CAUTION
● Use the proper torch cable that matches the welding current.
Welding current
Cable thickness
200 A
AWG 1 [38mm2] or more
350 A
AWG 0 [60mm2] or more
500 A
AWG 3/0 [80mm2] or more
* When performing pulse welding using a 56ft [17m] or more cable, use the thicker cable by one
rank.
6.3 Connection of the welding torch
1. Remove the guide adapter from the wire feeder, insert the outlet guide into the guide adapter and
attach the guide adapter to the conduit of the welding torch. Use proper sized outlet guide adjusted
to the wire size.
Guide Adapter
Outlet Guide
Welding Torch
2. Insert the guide adapter to the
Bolt (M6)
―11―
No. U5278
6. CONNECTION PROCEDURE (continued)
6.4 Connection of the Gas Hose
WARNING
● You may suffer from danger of suffocation caused by lack of oxygen when
shield gas keeps drifting in a closed place. Be sure to turn off the shield gas
at the main when the welding power source is not in use.
WARNING
● Be sure to connect the gas hose after fixing to the stand, as physical injuries may result
from falling down of gas cylinder.
● Attach a proper gas regulator to the gas cylinder. Failure to observe the demand may result
in physical injuries. The gas regulator for high pressure gas must be used.
Gas regulator
Gas cylinder
Gas inlet
Follow the steps below to connect to the gas regulator.
1. Firmly connect the gas hose to the gas supply inlet located on the rear side of the wire feeder.
2. Mount the gas regulator on the gas cylinder by tightening the nut for attaching the gas cylinder .
3. Connect the gas hose to the gas supply outlet on the gas regulator.
NOTE: Firmly tighten the nuts using a monkey wrench, etc. to connect the gas hose and gas
regulator.
―12―
No. U5278
7. WELDING PREPERATION
7.1 Fitting of Wire
1. Loosen the screw to clamp the cap knob.
2. Detach the cap knob from the wire reel shaft.
3. Mount the wire reel on the wire reel shaft.
NOTE: Put the wire reel stop pin into the wire reel stop hole.
Wire reel stop pin
Wire reel stop hole
Clamp screw
Wire reel shaft
To loosen the cap knob, turn the
knob counter-clockwise.
Cap knob
To tighten the cap knob, turn the
knob clockwise.
4. Firmly tighten the cap knob.
5. Align the hole in the cap knob with the wire reel stop hole, then fasten the clamp screw to
prevent the cap knob from dropping.
CAUTION
● When hanging the wire feeder, firmly fix
the cap knob and clamp screw to prevent
the device from dropping.
6. Bring down the pressure handle, then raise the pressure roll holder.
7. After pulling out the wire, thread it from the pilot to outlet guide through the center guide.
8. Return the pressure reel holder first, the pressure handle.
Pressure roll holder
Center guide
Pressure handle
Pressure handle
Outlet guide
Pilot
―13―
No. U5278
7. WELDING PREPERATION (continued)
Groove for 0.045in
[1.2mm] wire size
7.2 Mounting of the Feed Roll
Confirmation of the wire size marked on the feed roll
Use the right groove of the feed roll for the wire size.
The feed roll of φ0.045in [1.2mm] wire size is mounted on the
CM-741 wire feeder when shipping.
Wire size mark
Replacement of the feed roll
1. Remove the hexagon socket cap screws fixing the feed roll.
2. Bring down the pressure handle, and then lift the pressure roll holder.
3. Separate the feed roll from the wire feeder by pulling out the feed roll.
4. Mount the new feed roll, with the wire size marked on the wire feeder facing out.
Feed roll
・ For aluminum welding
1. Remove the pressure roll.
2. Change the center guide for aluminum.
3. Attach the middle gear and feed roll for aluminum.
4. Attach the wire straightner.
Hexagon socket cap screws
Wire straightener
Pilot
Inlet guide
Center guide
Guide adapter
Feed roll
(Pressure roll)
Middle gear
―14―
No. U5278
7. WELDING PREPERATION (continued)
Adjusting of the wire pressure and straightener
• Set to the proper wire pressure for the wire type by turning the pressure handle.
• The numeral on the pressure scale set with the right pressure handle should be correspond to the
one set with the left pressure handle.
Recommended wire pressure adjustment
Wire pressure scale
Solid wire
Flux cored wire
4-5
3-4
φ 1/16in [1.6mm], φ 5/64in [2.0mm]
3-4
2-3
φ 0.045in [1.2mm], φ 0.052in [1.4mm]
0.035in
[0.9mm],
[
1.0mm]
2
3
φ
φ
Wire diameter
φ 0.030in [0.8mm]
1-2
7.3 Adjusting of the wire reel hub
After performing inching operation, take care to adjust the brake of the wire reel hub to prevent the
wire from going too slack. The brake has been properly adjusted before shipment. Therefore,
readjustment of the brake is not required for welding in standard welding conditions.
How to adjust the wire reel hub
1. Detach the cap knob from the wire reel shaft.
2. Adjustment of the brake can be achieved by turning the hexagon bolt (M10).
Wire reel shaft
To brake more quickly,
turn the bolt clockwise.
Hexagon bolt (M10)
To brake more slowly, turn
the bolt counter-clockwise.
Cap knob
―15―
No. U5278
7. WELDING PREPERATION (continued)
7.4 Feeding Wire by Inching Operation
WARNING
● Do not look into the tip hole to check for the rate of wire feeding while inching.
CAUTION
● Keep away your hands, fingers, hair or clothes from the rotating parts of the feed
roll, etc. to prevent you from being caught into the rotating parts while inching.
After straightening the welding torch, feed the wire by
pressing the INCHING key. (the INCHING lamp located at
the upper right of the INCHING key lights up). When the
wire appears from the end of the torch, press the INCHING
key again (the INCHING lamp goes out). Cut the wire at
about 0.4in [10mm] from the end of the tip. Wire feed
speed can be adjusted by turning the parameter adjusting
knob.
Parameter adjusting knob
インチング
INCHING key
WARNING
Touching the charging parts may cause fatal electric shocks and burns.
● Never touch the charging parts in the wire and wire feeder.
The parts indicated as
in the figure below are the charging parts during
welding.
Wire
―16―
No. U5278
7. WELDING PREPERATION (continued)
7.5 Hanging the Wire Feeder
Hanging bracket (optional)
CAUTION
● When hanging the wire feeder, firmly fix the
cap knob and clamp screw to prevent the
device from dropping.
● Do not use the carrying handle of the wire
feeder to hang the wire feeder.
Screw to clamp the cap knob
Carrying handle
―17―
No. U5278
8. MAINTENANCE AND TROUBLESHOOTING
8.1 Carrying Out Maintenance
WARNING
● Do not touch the charging parts inside or outside of the wire feeder.
● Disconnect the welding power source by turning off the line disconnect switch in
the power box to avoid an electric shock before carrying the equipment.
No.
1
2
3
4
Problem
Wire gets deformed.
Wire is not fed.
Pressure roll does not
rotate smoothly.
Shield gas is not
supplied
when
pressing
the
torch
switch.
Cause
Wire pressure is too strong.
Feed roll of wrong wire size is
used.
Feed roll and pressure roll are
worn.
Poor contact or breakdown in
the control cable.
Poor contact or breakdown in
the encoder cable
Poor contact or breakdown in
the voltage detection cable
Trouble with the motor
Wire pressure is too weak.
Dust and chip are accumulated
on the outlet guide and on the
feed roll.
Failure of the pressure roll
holder.
The discharge valve of the gas
cylinder is closed.
Lack of gas pressure in the gas
cylinder
Failure of gas solenoid valve
5
6
7
Shield gas supply does
not stop.
Defective gas hoses
Wire is not fed
smoothly through the
wire reel.
Failure of gas solenoid valve
Crack in the gas hose
Adjustment of the brake is either
too strong or too weak.
―18―
Solution
Refer to “Recommended wire
adjustment” in Section 7.2.
Replace it with the feed roll of
proper wire size.
Replace the feed roll and the
pressure roll with a new ones.
Check the socket. Check the
cables and replace with new ones if
necessary.
Replace the motor with a new one.
Refer to “Recommended wire
adjustment” in Section 7.2.
Remove the dust and chip.
Replace it with a new one.
Open the valve.
Check gas pressure.
After checking the gas solenoid
valve, replace it with new one.
Check the socket. Check the
cables and replace with new one.
Replace them with new one.
Refer to “Adjustment of the wire
reel hub” in Section 7.3.
No. U5278
8. MAINTENANCE AND TROUBLESHOOTING (continued)
< Schematic Diagram>
Base metal
direct
detection (-)
CAUTION
● Never attempt to disassemble the feed motor. This may result in damage to the wire feeder.
● Never check the amount of brushing friction or replace the brush.
Service life of the brush varies depending on ambient temperature and welding condition, etc., but
normally the service life is about 4,000 hours. (If the machine is operated for six hours a day, the
service life of the brush will be about two years). Periodical replacement of the feed motor is
recommended.
―19―
No. U5278
9. PARTS LIST
9.1 Main body and Wiring
•
Please contact your local dealer to order parts. (See the back cover for telephone and fax
numbers, and mailing addresses.)
Ref.
No.
1
2
3
4
5
5-1
6
7
7-1
7-2
7-3
8
9
10
11
12
13
14
15
16
16-1
17
18
19
19-1
20
21
22
23
24
25
Part number
CM-7401
U5185U00
K970H90
4739-013
U5185C01
U5185C02
3361-219
U5185C03
U5209C01
4739-490
4739-491
4739-489
U5278C02
U5209B00
U5278J01
U5185J09
U5185J04
4739-492
U5185X00
U5185F00
U5185E00
4730-422
4739-494
U5185J07
U5185J08
3361-405
U5191B00
U5185J01
U1997C02
U1997C03
U5185J05
4730-002
Description
Frame
Strike
Support
Cover
Screw with knob
Washer
Side plate
Rear cover
Grommet with film
Grommet with film
Grommet with film
Panel
Wire feeder
Guide Adapter
Power terminal block
Terminal block bracket
Terminal block
Encoder cable
Motor cable
Control cable
Metal socket
Wire reel hub
Plate
Clamp screw
E-snap ring
Common mode coil
Cable clamp
Hose clamp
Hose cover
Wire reel cover
Receptacle
―20―
Q’ty
1
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
(1)
1
1
1
1
1
1
1
2
1
1
Remarks
Assembly
With coating
With coating and a screen
With coating
With coating and a screen
With a feed motor
Assembly
Assembly
Assembly
E-4
Assembly
2P
No. U5278
9. PARTS LIST (continued)
14
15
20
13
12
10
9
11
19
24
18
17
5
4
7
1
3
2
22
23
25
21
6
8
26
25
Fig. 1
Main Body and Wiring Assembly
―21―
16
No. U5278
9. PARTS LIST (continued)
9.2 Wire Feeder
Ref.
No.
1
1-1
2
3
4
5
6
7
8
9
9-1
9-2
10
11
12
13
14
14-1
15
16
17
18
19
19-1
20
21
21-1
22
Part number
U5209B01
U5185B08
U5185B02
U5185S00
U5185T00
K5439C00
U5158B03
U5185P00
U5439B12
U5185B04
U5185B05
4802-206
U5185B06
U3971B04
U5185Q00
U5185B09
U5185B12
U5185B10
U5185B11
U5185J06
U5185B13
U5185B14
Description
Bracket
Hexagon socket cap screw
Coil spring
Pressure roll holder pin
Pressure roll holder (R)
Pressure roll holder (L)
Pressure roll
Driving roll shaft
Gear
Feed roll (0.9-1.0/1.2)
Hexagon socket cap screw
Bolt
Guide block
Center guide
Feed motor
Insulating board
Insulating bush
Flat head screw
Drive gear
Pressure spring holder
Compression spring
Pressure handle
Pressure bolt
Spring pin
Pilot
Insulating bush
Hexagon bolt
Insulating board
―22―
Q’ty
1
2
1
2
1
1
2
2
2
2
4
4
1
1
1
1
3
3
1
2
2
2
2
2
1
2
2
1
Remarks
M6 x 25
Assembly
Assembly
Assembly
Assembly
M4 x 16
M4 x 10
M6 x 20
2.5 x 14
M8 x 30
No. U5278
9.PARTS LIST (continued)
18
17
2
16
3
5
11
6
10
19
20
4
7
12
8
13
9
1
Fig. 2
15
14
21
22
Wire Feeder Assembly
9.3 Central Adapter
Ref.
No.
1
2
3
4
Part number
4813-001
U4179D01
U1997D01
U1997D02
Description
Q’ty
Gas solenoid valve
Hose elbow
Gas connector
Flange
1
1
1
1
3
4
1
2
Fig. 3
Gas Piping Assembly
―23―
Remarks
W-31156
No. U5278
9. PARTS LIST (continued)
9.5 Optional Accessory
(1)Extension cable/hose
Control cable (10P)
Model
16ft [5m]
BKCPJ-1005
Cable length
33ft [10m]
49ft [15m]
BKCPJ-1010
BKCPJ-1015
66ft [20m]
BKCPJ-1020
16ft [5m]
BKGG-0605
Cable length
33ft [10m]
49ft [15m]
BKGG-0610
BKGG-0615
66ft [20m]
BKGG-0620
Gas hose
Model
(2) Other Optional Parts
Feeder Assy
Pressure Roll
Pilot (For Steel)
Guide Adapter
Inlet Guide
Pilot
Feed Roll
Wire Straightener
1.Roll ( Select by welding process )
Wire
Wire Material
Diameter
1.4 / 1.6
1.2 / 1.4
1.2 / 1.2
1.4 / 1.4
Mild Steel
1.6 / 1.6
Stainless Steel 0.6 / 0.8
1.6 / 2.0
1.2 / 1.6
0.9-1.0 / 1.2
0.8 / 0.9-1.0
1.0 / 1.2
1.2 / 1.6
Aluminum
1.6 / 2.0
1.6 / 2.4
Feed
Roll
K5439B01
K5439B04
K5439B05
K5439B06
K5439B07
K5439B09
K5439B10
K5439B11
K5439B12
K5439B13
K5463R02
K5463R03
K5463R04
K5463R05
Q’ty
2
2
2
2
2
2
2
2
2
2
2
2
2
2
―24―
Pressure
Roll
K5439C00
K5439C00
K5439C00
K5439C00
K5439C00
K5439C00
K5439C00
K5439C00
K5439C00
K5439C00
K5463R02
K5463R03
K5463R04
K5463R05
Center Guide
Q’ty
2
2
2
2
2
2
2
2
2
2
2
2
2
2
No. U5278
9. PARTS LIST (continued)
2.Accessories
Part No.
U5209B00
U5209J01
U5204J01
U5185B05
U5209M01
U5204B02
U5204B03
U5204B04
Description
Feeder Assy
Guide Adapter
Center Guide ( 1.0-1.6 )
Center Guide ( 2.0 )
Center Guide ( 0.8-1.0 )
Center Guide ( 1.0-1.6 )
Center Guide ( 2.0-2.4 )
U5185P00
Feed Gear
U5185J06
U5204H00
U5204M02
U5204J07
K970G72
U2344C08
U5185J05
U5191E00
K5439E00
U5191F00
K5439F00
U5191G00
Pilot
Wire Straightener
Inlet Guide( For Wire Straightener )
Pilot ( For Wire Straightener )
Wire Reel Cover
Reel Adapter
Caster
Hanging Bracket
―25―
Q’ty
1
1
1
1
1
1
1
1
2
4
1
1
1
1
1
1
1
1
1
1
1
1
Remarks
For Steel
For Aluminum
For Steel
For Steel
For Aluminum
For Aluminum
For Aluminum
For Steel
For Aluminum
For Steel
For Steel
For Aluminum
For Steel
For Aluminum
Vinyl Cover
Plastic Half Cover
Dustting Type
No. U5278
9. PARTS LIST (continued)
3. Water Kit
Part No. K5516A00
7/18-14UNF
5/8-18UNF
5/8-18UNF
Part No.
U5204N00
U5204P00
U5204G00
U5204F00
4. Aluminum Kit
Part No.
U5204J01
K5463R02
U5204B03
U5185P00
U2344C08
U5204J07
U5204H00
U5191F00
K5439E00
5/8-18UNF
Description
Remarks
Power Cable
Power Connection
Supply Water Hose
Condensate Water Hose
Q’ty
1
1
1
1
Part No. K5517A00
Description
Guide Adapter
Feed Roll ( 1.0 / 1.2 )
Center Guide ( 1.0-1.6 )
Feed Gear
Pilot ( For Wire Straightener )
Inlet Guide( For Wire Straightener )
Wire Straightener
Reel Adapter
Wire Reel Cover
Q’ty
1
4
1
4
1
1
1
1
1
Remarks
―26―
For Aluminum
Dustting Type
No. U5278
10. SPECIFICATIONS
10.1 Specifications
Model
Applicable wire size
CM-7401
(0.024” [0.6mm])*, (0.030” [0.8mm]), 0.035” [0.9mm],
[1.0mm], 0.045” [1.2mm], (0.052” [1.4mm]),
(1/16” [1.6mm])
Fire feeding rate
Max. 72.2 ft [ 22m ] /min
1.97” [ 50mm ]φ
Applicable wire reel
Shaft diameter
Max. 11.8” [ 300mm ]φ
External diameter
Wide
4.05” [ 103mm ]
Quantity of applicable wire
Max. 55.1 lb [ 25kg ]
Quantity
28.6 lb [ 13 kg ]
*When using φ 0.6 wire, add the welding mode (optional) to the welding power source.
10.2 Available Welding Torch
Rated
current
Duty
cycle
10ft [ 3m ]
Cable length
For mild steel
13ft [ 4m ]
15ft [ 4.5m ]
200 A
40%
200 A
70%
WTCMU-2001
250 A
70%
350 A
30%
WTC-3504*
350 A
70%
WTC-3503*
WTCMU-3503
430 A
70%
WTC-4301*
WTCMU-4301
500 A
70%
WTC-5002*
WTCMU-5002
*For WTC-3503,3504,4301,5002 guide adapter (U5209J01) is needed.
For aluminum
13ft [ 4m ]
WTCMU-2001
WTCMUA-2501
10.3 Standard Accessory
Description
Pressure roll
Feed roll (0.035” [0.9]-0.045” [1.0/1.2])
Gas hose
Hose cover
Cable joint
Part number
K5439C00
K5439B12
K5430A00
U1997C03
4734-027
―27―
Quantity
(2)
(2)
1
2
1
Remarks
Pre-installed
Pre-installed
BKGFF-0603 (10ft [3m])
Attached
Attached
10P
Control Cable
5.6ft [1.7m]
―28―
21.4 [543]
16.7 [423]
2.2
[55]
Wire Feeder
Guide Adapter
M14
4-φ7
4.6 [117]
External View of CM-7401 Wire Feeder
Gas Supply Inlet
9/16-18UNF
12.0 [305]
8.5 [215]
5.7 [146]
Gas Supply Inlet
9/16-18UNF
2P Receptacle
unit: in [mm]
Max.4.1 [103]
8.1 [206]
No. U5278
10. SPECIFICATIONS (continued)
13.8 [350]
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