wire feeder - OTC Daihen

MANUAL NO: U5971
OWNER'S
MANUAL
FOR
WIRE FEEDER
MODEL: CM-741U
DO
NOT
U5971
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
2nd Edition, June 1, 2009
Upon contact, advise MODEL and MANUAL NO.
4-1-057-2
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.
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 ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
28
―1―
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.
1. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
Be sure to:
・Keep children away.
・Keep pacemaker wearers away until consulting a doctor.
2. Read and understand the summarized safety information given below and the original
principal information that will be found in the PRINCIPAL SAFETY STANDARDS.
3. Have only trained and experienced persons perform installation, operation, and
maintenance of this equipment.
4. Use only well-maintained equipment. Repair or replace damaged parts at once.
ARC WELDING is safe when precautions are taken.
―2―
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.
Leaving piled-up dust in the welding machine may cause insulation deterioration and result in
electrical shock and fire.
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 electrodes or 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.
11. Remove dust by blowing moisture-free compressed air on each part periodically.
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 face shield or 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 proper body protection to protect skin.
―3―
2. ARC WELDING SAFETY PRECAUTIONS (continued)
WELDING can cause fire and explosion.
Sparks and spatter fly off from the welding arc. The flying sparks, 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.
Leaving piled-up dust in the welding machine may cause insulation deterioration and result in
electrical shock and 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 power cable for base metal 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. Do not use the welding power source for anything 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, arc may be generated and cause damage by a fire if the wire contacts
the frame or the work piece.
15. Remove dust by blowing moisture-free compressed air on each part periodically.
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 arc rays 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―
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 handle 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 if you are authorized by the
manufacturer.
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―
2. ARC WELDING SAFETY PRECAUTIONS (continued)
ARC WELDING work areas are potentially hazardous.
FALLING or MOVING machines can cause serious injury.
1. When hanging the welding power source by a crane, do not use the carrying handle.
2. Put the welding power source and wire feeder solidly on a flat surface.
3. Do not pull the welding power source across a floor laid with cables and hoses.
4. Do not put wire feeder on the welding power source.
5. Do not put the welding power source or wire feeder where they will pit or fall.
WELDING WIRE can cause puncture wounds.
1. Do not press the gun trigger until instructed to do so.
2. Do not point the gun toward any part of the body, other people, or any metal when
threading welding wire.
―6―
PRINCIPAL SAFETY STANDARDS
Arc welding equipment – Installation and use, Technical Specification
IEC 62081, from International Electro technical Commission
Arc welding equipment Part 5: Wire feeders IEC 60974-5, 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.
W080904
―7―
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 Switch cord
Terminal
Vinyl cap
④ Hose cover
③
Specification
Quantity
U5971R00
U5971S00
100-0816
100-0817
U1997C03
1
1
2
2
2
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 adapter 6.3
Control cable 10P
Feed rolls 7.2 Frame
―8―
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―
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
Gas regulator
Standard Composition
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.
Welding torch
Remote control cable
Remote control
(Optional)
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―
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
Welding torch is connected with the part torch adapter of Wire feeder, fixing bolt is tightened, and
welding torch is fixed.
Wire feeder
Fixing bolt
CAUTION
● Please tighten fixing bolt surely to fix
Torch.
Otherwise, it causes the electric shock
and a fire by feeding power the defect.
Torch adapter
Welding torch
“WT●●●●-S(M)(L)UT” series
[Note] This product can connect following welding torch by the standard.
OTC CO2/MAG Welding torch
“WT3510- S(M)(L)UT” series, “WT4000- S(M)(L)UT” series
When following welding torch is connected, it is necessary to prepare option parts and option kit
separately.
OTC CO2/MAG Welding torch
“WT5000- S(M)(L)UT” series
OTC MIG Welding torch
“WTA200-SUT, “WTA300-SUT”, “WTAW400-SUT”
―11―
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―
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―
7. WELDING PREPERATION (continued)
7.2 Mounting of the Feed Roll
Groove for 0.045in
[1.2mm] wire size
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 straightener.
5. Change the outlet guide for aluminum.
Hexagon socket cap screws
Wire straightener
Pilot
Inlet guide
Center guide
Outlet guide
Torch adapter
Feed roll
(Pressure roll)
Gear
―14―
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.
Wire material
Recommended wire pressure adjustment
Wire diameter
Pressure
(φ mm)
handle scale
(φinch)
Aluminum
Mild steel
Stainless steel
1.6
1.2
1.0
1.6
1.4
1.2
1.0
0.9
0.8
0.6
1/16”
3/64”
.040”
1/16”
.052”
.045”
.040”
.035”
.030”
.024”
Wire straightener
scale
2-3
1-2
1-2
3-4
3-4
2-3
2-3
2-3
1-2
1-2
2-3
3-4
4-5
(2-3)
(3-4)
(3-4)
(4-5)
(4-5)
(4-5)
(4-5)
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―
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.
Parameter adjusting knob
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.
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―
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―
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.
Problem
1 Wire gets deformed.
2
3
4
5
6
7
Cause
Wire pressure is too strong.
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.
Feed roll of wrong wire size is
used.
Feed roll and pressure roll are
worn.
Wire is not fed.
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
Replace the motor with a new one.
Wire pressure is too weak.
Refer to “Recommended wire
adjustment” in Section 7.2.
Dust and chip are accumulated Remove the dust and chip.
on the outlet guide and on the
feed roll.
Pressure roll does not Failure of the pressure roll
Replace it with a new one.
rotate smoothly.
holder.
The discharge valve of the gas Open the valve.
Shield gas is not
supplied when pressing cylinder is closed.
the torch switch.
Lack of gas pressure in the gas Check gas pressure.
cylinder
Failure of gas solenoid valve
After checking the gas solenoid
valve, replace it with new one.
Shield gas supply does Failure of gas solenoid valve
Check the socket. Check the cables
not stop.
and replace with new one.
Defective gas hoses
Crack in the gas hose
Replace them with new one.
Wire is not fed
Adjustment of the brake is Refer to “Adjustment of the wire reel
smoothly through the
either too strong or too weak.
hub” in Section 7.3.
wire reel.
―18―
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―
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
10-1
11
12
13
14
15
16
17
17-1
18
19
20
20-1
21
22
23
24
25
26
Part number
U5185U00
K970H90
4739-013
U5185C01
U5185C02
3361-219
U5281C03
U5971C04
4739-490
4739-491
4739-489
U5971C05
U5209B00
U5971D00
U5971D03
K5735B02
U5185J09
U5185J04
4739-492
U5185X00
U5185F00
U5185E00
4730-422
4739-494
U5185J07
U5185J08
3361-405
U5191B00
U5185J01
U2028H01
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
Torch adapter
Fixing bolt
Outlet guide NO.4 (0.9-1.2)
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
Cable 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
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, for “NO.4”
It is included in Torch adapter.
For steel (.035”-.045”)
Assembly
Assembly
Assembly
E-4
Assembly
2P
9. PARTS LIST (continued)
Fig. 1 Main Body and Wiring Assembly
―21―
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
None
U5185B08
U5185B02
U5185S00
U5185T00
K5439C00
U5158B03
U5185P00
U5439B12
3361-880
3361-884
U5185B04
U5185B05
4802-206
U5185B06
U3971B04
3361-895
U5185Q00
U5185B09
U5185B12
U5185B10
U5185B11
4739-043
U5185J06
U5185B13
3361-897
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 30
Assembly
Assembly
Assembly
Assembly
.035”-.040”/.045”
M4 x 16
M4 x 10
M6 x 20
2.5 x 14
M8 x 30
9.PARTS LIST (continued)
18
17
2
16
3
5
11
6
10
19
20
4
7
12
8
13
9
1
14
15
22
Fig. 2 Wire Feeder Assembly
9.3 Gas Piping Assembly
Ref.
No.
1
2
3
4
Part number
4813-001
U4179D01
U5971G01
U1997D02
Description
Q’ty
Gas solenoid valve
Hose elbow
Gas connector
Flange
1
1
1
1
Remarks
W-31156
3
4
1
2
Fig. 3 Gas Piping Assembly
―23―
9. PARTS LIST (continued)
9.4 Optional Accessory
(1)Extension cable/hose
Control cable (10P)
Cable length
33ft [10m]
49ft [15m]
BKCPJ-1010
BKCPJ-1015
16ft [5m]
BKCPJ-1005
Model
66ft [20m]
BKCPJ-1020
Gas hose
5/8-18
Nozzle
(Gas hose (φ6xφ13mm))
Gas
Gas
Part No.
U5971R01
U5971R02
Description
Q’ty
2
2
Gas nut
Nozzle
(2) Feed roll, pressure roll, gear
Wire Material
Wire Diameter
(Groove type of roll)
(mm)
(inch)
1.4 / 1.6
.052”, 1/16”
1.2 / 1.4
.045”, .052”
1.2 / 1.2
.045”, .045”
1.4 / 1.4
.052”, .052”
Mild Steel
1.6 / 1.6
1/16”, 1/16”
Stainless Steel
0.6
/
0.8
.024”, .030”
(V type groove)
1.6 / 2.0
1/16”, 5/64”
1.2 / 1.6
.045”, 1/16”
0.9-1.0 / 1.2
.035”-.040”, .045”
.030”, .035”-.040”
0.8 / 0.9-1.0
1.0 / 1.2
.040”, 3/64”
Aluminum
1.2 / 1.6
3/64”, 1/16”
(U type groove)
1.6 / 2.0
1/16”
1.6 / 2.4
1/16”, 3/32”
1.0 / 1.2
.040”, 3/64”
Aluminum
1.2 / 1.6
3/64”, 1/16”
(V type groove)
1.6 / 2.0
1/16”
1.6 / 2.4
1/16”, 3/32”
Part No.
U5185P00
5/8-18
Nozzle
Description
Gear
Feed
Roll
K5439B01
K5439B04
K5439B05
K5439B06
K5439B07
K5439B09
K5439B10
K5439B11
K5439B12
K5439B13
K5463R02
K5463R03
K5463R04
K5463R05
K5463V02
K5463V03
K5463V04
K5463V05
Q’ty
2
For steel
4
For aluminum
―24―
Remarks
Q’ty
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Pressure
Roll
K5439C00
K5439C00
K5439C00
K5439C00
K5439C00
K5439C00
K5439C00
K5439C00
K5439C00
K5439C00
K5463R02
K5463R03
K5463R04
K5463R05
K5463V02
K5463V03
K5463V04
K5463V05
Remarks
Q’ty
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
9. PARTS LIST (continued)
(3) Outlet guide, center guide, pilot
Description
Part No.
K5735B01
Outlet guide NO.4 (0.6-0.9)
K5735B03
Outlet guide NO.4 (1.2-1.6)
K5735B13
Outlet guide NO.5 (1.2-1.6)
K5735B21
Outlet guide NO.4 (AL1.0)
K5735B22
Outlet guide NO.4 (AL1.2)
K5735B23
Outlet guide NO.4 (AL1.6)
K5735B32
Outlet guide NO.5 (AL1.2)
K5735B33
Outlet guide NO.5 (AL1.6)
U5185B05
Center guide ( 1.0-1.6 )
U5204B02
Center guide ( 0.8-1.0 )
U5204B03
Center guide ( 1.0-1.6 )
U5185J06
Pilot
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
Remarks
For steel (.023”-035”)
For steel (.045”-1/16”)
For steel (.045”-1/16”)
For aluminum (.040”), black
For aluminum (3/64”), black
For aluminum (1/16”), black
For aluminum (3/64”), black
For aluminum (1/16”), black
For steel (.040”-1/16”)
For aluminum (.030”-.040”), white
For aluminum (.040”-1/16”), black
For steel
(4) Wire straightener
Part No.
Description
U5204H00
Wire straightener
K970G72
Pilot
U2344C08
U5204M02
Inlet guide
U5204J07
Q’ty
1
1
1
1
1
Remarks
For steel
For aluminum
For steel
For aluminum
Pressure roll
Pilot (For steel)
Outlet guide
Pilo
(Torch
Inlet guide
Wire
Center guide
Feed
―25―
9. PARTS LIST (continued)
(5) Torch adapter kit
#5-1. 2-1.6
(1-1)
(1-2)
(1-3)
#5-AL1. 2
Ref. No.
1
1-1
1-2
1-3
Part No.
Description
K5735C00 Torch adapter kit
Torch adapter
K5735B13 Outlet guide NO.5 (1.2-1.6)
K5735B32 Outlet guide NO.5 (AL1.2)
Q’ty
1
(1)
(1)
(1)
Remarks
The following parts are contained.
for “NO.5”
For steel (.040”-1/16”)
For aluminum (3/64”), black
(6) Water cooling kit
(1-2)
5/8-18UNF
Left-hand screw
(1-4)
Color : Red
(1-1)
Color : Blue
(1-3)
Ref. No.
1
1-1
1-2
1-3
1-4
Part No.
Description
K5735D00 Water cooling kit
K5735H00 Supply water hose
4739-549 Quick connector (red)
4739-550 Quick connector (blue)
U5971J02 Fitting plate
(7) Aluminum kit
Part No.
K5735E00
K5463R02
U5204B03
U5185P00
U5204H00
U2344C08
U5204J07
U5191F00
K5735B22
Description
Aluminum kit
Feed roll ( 1.0 / 1.2 )
Center guide ( 1.0-1.6 )
Gear
Wire straightener
Pilot
Inlet guide
Reel adapter
Outlet guide NO.4 (AL1.2)
Q’ty
Remarks
1
The following parts are contained.
(2)
(1)
(1)
(2)
Q’ty
1
(4)
(1)
(2)
(1)
(1)
(1)
(1)
(1)
(8) Other optional parts
Part No.
Description
U5191E00
Wire reel cover
K5439E00
Q’ty
1
1
―26―
Remarks
The following parts are contained.
.040”, 3/64”
.040”, 1/16”, black
For wire straightener
For wire straightener
Remarks
Plastic half cover
Plastic full cover
Table for Option parts and option KIT
Option parts and option KIT
NO.
Torch series
Welding wire
Outlet guide
Torch adapter KIT Water cooling KIT
1
Steel wire .035"-.045" (K5735B02)*1
WT3510-S(M)(L)UT
2
Steel wire .052"
K5735B03
3
Steel wire .035"-.045" (K5735B02)*1
WT4000-S(M)(L)UT
4
Steel wire .052"-1/16"
K5735B03
5 WT5000-S(M)(L)UT Steel wire .045"-1/16" (K5735B13)*3
K5737C00
6
Aluminum wire .040"
K5735B21
WTA200-SUT
7
Aluminum wire .3/64"
(K5735B22)*2
8
Aluminum wire .040"
K5735B21
9 WTA300-SUT
Aluminum wire .3/64"
(K5735B22)*2
10
Aluminum wire .1/16"
K5735B23
11
Aluminum wire .3/64"
(K5735B32)*3
WTAW400-SUT
K5737C00
K5735D00
12
Aluminum wire .1/16"
K5735B33
*1 : It is a standard building in Wire feeder.
*2 : It is attached to Aluminum KIT.
*3 : It is attached to Torch adapter KIT.
―27―
K5735E00
Aluminum KIT
-
9. PARTS LIST (continued)
10. SPECIFICATIONS
10.1 Specifications
Model
CM-741U
(.024”)*, (.030”), .035”, .040”, .045”, (.052”), (1/16”)
(0.6)*, (0.8), 0.9, 1.0, 1.2, (1.4), (1.6)
Max. 72.2 ft/min [ 22m/min ]
1.97”φ [ 50mmφ ]
Max. 11.8”φ [ 300mmφ ]
inch
mm
Applicable wire size
Wire feeding rate
Shaft diameter
Applicable wire reel
External diameter
Wide
4.05” [ 103mm ]
Mass of applicable wire
Max. 55.1 lb [ 25kg ]
Mass
28.6 lb [ 13 kg ]
* When using φ .024” (0.6mm) wire, add the welding mode (optional) to the welding power source.
10.2 Available Welding Torch
Rated
current
Duty
cycle
350 A
400 A
500 A
200 A
300 A
60%
60%
60%
60%
50%
400 A
100%
Cooling
method
10ft [ 3m ]
Cable length
For mild steel
13ft [ 4m ]
15ft [ 4.5m ]
20ft [ 6m ]
For aluminum
10ft [ 3m ]
Air
cooling
WT3510-SUT
WT4000-SUT
WT5000-SUT
-
-
WT3510-MUT
WT4000-MUT
WT5000-MUT
-
WT3510-LUT
WT4000-LUT
WT5000-LUT
-
WTA200-SUT
WTA300-SUT
Liquid
cooling
-
-
-
-
WTAW400-SUT
10.3 Standard Accessory
Part number
K5439C00
K5439B12
K5735B02
U5971R00
U5971S00
100-0816
100-0817
U1997C03
Description
Pressure roll
Feed roll ( 0.9-1.0/1.2 )
Outlet guide NO.4 (0.9-1.2)
Gas hose
Switch cord
Terminal
Vinyl cap
Hose cover
―28―
Q’ty
(2)
(2)
(1)
1
1
2
2
2
Remarks
Pre-installed
Pre-installed, .035”-.040” / .045”
Pre-installed, .035”-.045”
Attached, (9.8ft [3m])
Attached
Attached
Attached
Attached
External view of CM-741U Wire feeder
unit: in [mm]
10. SPECIFICATIONS (continued)
―29―
DAIHEN Corporation
4-1, Koyocho-nishi,Higashinada-ku,
Kobe, Hyogo 658-0033
Phone: +81-78-275-2006, Fax: +81-78-845-8159
DAIHEN, INC. DAYTON OFFICE
1400 Blauser Drive
Tipp City, Ohio 45371, USA
Phone: +1-937-667-0800, Fax: +1-937-667-0885
OTC DAIHEN EUROPE GmbH.
Krefelder Strasse 675-677,
D-41066 Mönchengladbach, GERMANY
Phone: +49-2161-6949710, Fax: +49-2161-6949711
OTC Industrial (Shanghai) Co.,Ltd.
17F Majesty Building, 138 Pu Dong Da Dao Shanghai
The People's Republic of China
Post Code: 200120
Phone: +86-21-5882-8633, Fax: +86-21-5882-8846
OTC (Taiwan) Co.,Ltd.
2F No. 153, Huanbei Rd., Chung Li City,
Taoyuan Hsien, Taiwan R.O.C.
Phone: +886-3-461-3962, Fax: +886-3-434-2394
OTC DAIHEN Asia Co.,Ltd.
23/43, 16th Fl.Sorachai Building,
23 Soi 63 Sukhumvit Road,
Klongtonnua, Wattana, Bangkok 10110, Thailand
Phone: +66-2-714-3201, Fax: +66-2-714-3204
OTC DAIHEN Korea Co.,Ltd
11B/L Hyeongok Industrial Complex, 463-1 Hyeongok-ri,
Cheongbuk-myeon, Pyeongtaek, Gyeonggi-do, 451-831, Republic of Korea
Phone: +82-31-686-7459, Fax: +82-31-686-7465
Upon contact, advise MODEL and MANUAL NO.
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