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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