CMW-145 - OTC Daihen

CMW-145 - OTC Daihen
DAIHEN corporaion
MODEL : CMW-145 U4283
IMPORTANT: Read and understand the entire contents of this
manual, with special emphasis on the safety material throughout
the manuai, 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.
May 15, 2000
[Upon contact, advise MODEL and MANUAL NO]
No. U4283
P. 1/21
1. SAFETY INFORMATION +eeescrecrrceracostecarererorverercer. 2
2. ARC WELDING SAFETY PRECAUTIONS --eeeseíreorirececeneas 2
3. CHECKING OF PACKAGE CONTENTS e evoccarecarecarencem. 8
4. EACH DESIGNATION AND OPERATION +eeeexrromereeerecee. 8
6. CONNECTION <+eroremeoceoaraciconereearerarerererercacan. « 10
7. WELDING PREPARATION 14000000000 06000660604 RAS 11
9 PARTS LIST «=.«esseccosarerennanoracanesceraorercccnrareroaaeo 15
10. SPECIFICATIONS -..e.eccrcerccrionrcosareacerarenrenenaonono 21
No. U4283
P. 2/21
The following safety alert symbols and signal words are used throughout this manual to
identify various hazards and special instructions.
A W ARNING WARNING gives information regarding possible personal
injury or loss of life. |
A CAUTION CAUTION refers to minor personal injury or possible
equipment damage.
“ARC WELDING can be hazardous.
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
€ 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.
No. U4283
P. 3/21
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work
circuits are electrically live whenever the output 1s 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 hve 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 turn off the line disconnect switch before installing, changing torch parts or
maintaining this equipment.
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.
Do not wrap cables around your body.
Q. Turn off POWER switch when not in use.
ZA ARC RAYS can bum eyes and skin: FLYING SPARKS AND HOT
NX 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 7 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 |
No. U4283
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.
Protect yourself and others from flying sparks and hot metals.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 10m (35£t.) of the welding arc. If this is not possible, tightly,
cover them with approved covers.
Be alert that welding sparks and hot metals from welding can easily pass through cracks and
openings into adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can ignite a hidden fire.
Do not weld on closed containers such as tanks or drums.
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.
Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
Do not use the welding power source for other than arc welding.
Wear oil-free protective garments such as leather gloves, a heavy shirt, cuffiess trousers,
boots, and a cap.
A loose cable connection can cause sparks and excessive heating.
Tighten all cable connections.
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 1s safe. |
No. U4283
P. 5/21
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.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the
specific application; maintain them in good condition.
Protect compressed gas cylinders from excessive heat, mechanical shock, and arcs.
Keep the cylinder upright and securely chained fo a stationary support or a rack to prevent
falling or tipping.
Keep cylinders away from any welding or other electrical circuit.
Never touch cylinder with welding electrode.
Read and follow instructions on compressed gas cylinders, associated equipment, and the
CGA publication P-1 listed in PRINCIPAL SAFETY STANDARDS. |
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when gas cylinder is in use or connected for
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.
Do not use this equipment if the case and the cover are removed.
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.
Do not put hands, fingers, hair or clothes near the rotating fans or wire feed roll.
No. U4283
P. 6/21
ARC WELDING work areas are potentially hazardous.
FALLING or MOVING machine can cause serious injury.
® Use both eyebolts, if installed, to lift the welding power source.
Ф Put the welding power source and wire feeder solidly on a flat surface.
Ф Do not pull the welding power source across a floor laid with cables and hoses.
Ф 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. |
No. U4283
P. 7/21
Arc welding equipment — Installation and use, Technical Specification
IEC 62081, from International Electrotechnical Commission
Safety in Welding and Cutting, ANSI Standard 749.1, 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
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
287.1, from American National Standards Institute.
Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection
No. U4283
E. 8/21
* Check of quantity at open the package.
[1Wire feeder
— | * Standard accessories
— Description — Specification | Q'ty
Wire straightener | K1821J00 1
Wire guide __|. _ U1962D02 1
Conduit adapter —- — K420B09 1
_ Hexagon rod spanner - No. 5 (Мб) 1
Warning label — NK5441 1
* Stick the warning label on the place near feed roll.
Pressure holder
/ Pressure roll
Pressure handie
co hnection
%4-180NE Ya 18UNK
(Gas "IN“side)
Feed roll
Plos £ ock et
No. U4283
В | | Р. 9/21
5.1 Transportation
Observe the following to prevent troubles in running and breakage of the welder,
@ When carrying or transferring the wire feeder, be sure to turn OFF input
power supply by the switch of the distribution box.
5 (O When carrying the wire feeder to height, remove the wire from wire feeder.
5.2 Installation
In installing the welder, observe the following to prevent occurrence of fires by welding and
physical damage by fume gas. |
: |@ро not install the welder near combustible materials and inflammable gas.
| Remove combustible materials not to attach the spatter to them.
If not removed, cover combustible materials with the noncombustible cover.
er or preventing gas-poisoning at choking, use local exhaust equipment or use
protectors for respiration.
en welding at narrow space, ventilate the place sufficiently or wear the
protectors for respiration, and work under supervision by a trained
supervisor. |
@ Observe the following when selecting a installation place.
* Less humidity, dirt and dust. And do not expose welding machine to direct sun light,
wind and rain.
* Ambient temperature is —10~40°C.
* There is not window.
(Use a wind shield to protect arc from wind, otherwise blow hole may be caused.)
No. U4283 _
Р. 10/21 |
@Be sure to turn OFF the line disconnect switch before connection.
@Sccurely tighten connecting parts of cables.
@ Water cooled type
Gas bumb _ CO, gas flow meter regulator
Uni-cord power cable Wire feeder
Gas hose |
/ Conduit
== ===)
Gas hose
| A Control cable
- Control cable
Wire drum
CO, welding torch
Welding cable -
> | To welding power source
Base metal side cable
No. U4283
o | P. 11/21
7.1 Fitting of wire
| Check of wire size of the feed roll and pressure roll |
Pressure holder «О | Check that fitting of the feed roll and pressure roll
| ДД Pressure ol _ matches with the welding wire size.
Mark .
(5) pressure handle .
Fit the feed roll to be able to see the same marking
numeric value as the wire size to be used.
Ji or Filing of wire |
O Bring down the pressure handle.
= © Raise the pressure roll holder. |
- @ Pull out the wire to let it through the conduit
connection adapter, and insert it into the outlet
Feed rol! guide. (Refer to Fig. 3)
® Return the pressure roll holder and the pressure
handle, in this holder.
|Adjusting of pressure and straightener |
© Rotate the pressure handle to set pressure force matching the wire diameter.
Aluminum Steel Pressure handle scale
Hard | | |
24 1.6 4~35
1.6 | | 12 3~4
1.2 — | 1.0 | 72.3
No. U4283
p. 12 121
7.2 Wire feeding by inching operation
@Do not look into the chip hole to check on sending of the wire in inching,
eDo not put your hands, fingers, hair and clothes near the rotating parts of the
feeding roll, etc. in inching. Biting may occur, causing injuries.
Touching the electrification parts may cause fatal electric shook
and burn.
O Never touch the charge parts of wire and wire feeder.
@Be sure to attach the wire reel cover to prevent the electrical shock and wire
ZZZZ part is indicated to charging part at welding,
Pressure holder
| Pressure roll
| Pressure handle
Yo” -(BUNF — 7 ¢ A L + A y — ra
(Conduit Connection в) - 4
(Cas "IN ви)
Feed roll
No. U4283
P. 13/21
8.1 Inspection in working —
Parts | - Inspection point Trouble {~~ Measures
Pressure scale |@Is pressure force Pressure force is too |Match pressure force with
matching with the wire [week or too strong, the value of Wire pressure
diameter? adjustment recommended
| | | Jin item 7.1. 5
Inlet guide O Are not chips and Chips and dusts are left. [Remove chips and dusts.
Center guide | dusts left around the
| | inlet of the inlet guide
and the feeding roll? | ВЕ
Feedrol ~~ |@Are the wire diameter ¡Wire diameter and the [Change to the feed roll
and the marking of the [marking do not match. [matching with the wire
feed roll matching? | diameter.
O Wire touching surface |The surface is worn. [Replace to new one.
condition. | |
Pressure roll ODoes the roll rotate — |The roll does not rotate [Replace to new one
| smoothly. | smoothly. | | | | |
Cable Os not the cable The coating is broken or|[Replace to new one.
coating broken, or is the cable is likely to be
not the cable liableto |disconnected.
be disconnected? ; |
@1Is not the connecting |The connecting partis {Firmly tighten.
- part loosened? loosened. |
Gas hose @Is not crazing Crazing is formed. Replace to new one.
No. U4283
P. 14/21
8.2 Yearly inspection
(1) Grease replacement of reduction gear
After removing aged grease, apply new one to the gear
Geared output
> shaft tooth surface and side faces as shown in figure.
= CO If this grease is not there, use the grease No.1 of each
Grease À Г a lithium type.
| Nu | Double gear a CAUTION
В EL | | Never fill the gear box with grease, otherwise motor will be
=r … burnt.
Grease |
| Pinion
Motor '
(2) Replacement of feed motor
“Never disassemble the feed motor. It is caused in troubles.
+ Never replace and check of brushing friction.
Usually service life of brush is about 4,000 hours (about two years, if it works six hours a day).
Replace the feed motor periodically.
Please order parts necessary for repair from OTC or its agents, indicating description, item
No., and part No..
9.1 Wire feeding reduction gear (Refer to Fig. 2)
No. U4283
P. 15/21
Item | Part No. Description Qty Remarks
1 | K1123B01 |Gear case | 1
2 4802-006 [Print motor 1 |PMEE-12CBB
3 | K1123B02 |Pinion 1 В
3-1 В 1CS type snap ring -— 1 |CSTW-10
4 | K1123B03 {Two speed gear oo
5 K1123B04 {Output shaft with gear 1 |
6 | 3361-206 ¡Key | 3 l4X4X8
7 | K1123B05 [Bush — 2 |
8 | K1123B06 |Insulating spacer 0 | Ш
9 | 3311-001 [Radial ball bearing 1 (No. 6000ZZ
10 | K1821C01 |Gear case | 2.
11 | K1822C02 |Insulating plate O1
12 | K1123C04. |Insulating sleeve 1 a
13 | 3311-008 [Radial ball bearing 5 |No. 6001LL
14 | K1822C01 |Bracket 1
15 | K1822C03 [Pressure roll holder (1) 1
16 | K1822C04 |Pressure roll holder (2) 1
17 | K1821C04 {Pressure roll pin 2
18 | K1821C05 [Fulcrum pin 3 1
19 | 3361-404 |E-type snap ring 6 |¢5
20 | K1822C05 [Pressure bolt 1
21 | U929CI6 [Pressure spring o
22 | K1123D01 {Pressure handle — Ib
23 {CS type snap ring 1 |CSTW-6
24 | K1123D03 [Spring bearing 1 | |
25 | K1123D05 [Pressure nut 1
26 | K1822C06 |Guide block 1
27 | K1822C07 |Center cuide 1
28 | K1822C09 [Feed axis 2.
29 | K1822C10 |Spacer 3
29-1 | K1123B07 [Spacer 1;
30 | K1822C11 {Middle gear ] |
31 | K1821V00 |Feed roll (1.0) 2 {For steel
32 | K1822H00 {Pressure roll 2 {For steel
33 | U2344B09 |Guide adapter 1 |
34 | U785C09 |Plate spring 1
35 | U785C11 (Protection cover 1
36 | K1123C08 [Remote stopper 1
37 | K2571C01 |Gear case cover 1
Hexagon head bolt 2 |M6
No. U4283
{Wire guide
P. 16/21
Item| Part No. | Description Qty | Remarks
| K1821J00 [Wire straightener assembly (1) |
38 | K1821J01 [Wire straightener body — | |
39 | K1821J02 ¡Patch 1 |X
40 | K1821J03 |Adjusting screw 1 1%
41 | U2344C04 [Roller shaft 2 0% - |
42 | 3311-014 |Radial ball bearing 2 |% No. 6297ZZ
43 НО ¡E type snap ring ° 3 1% For 67
44 | U2344C05 [Slide shaft 1 |X |
45 | U69C02 |Bearing with gloove 1 Xx
46 | U2344C07 |Adapter 1
47 | U2344C08 |Pilot 1 >
48 0 [Narld knob 1 | KNI15
49 | U2344C10 |Inlet guide 1
> : Standard accessory
9.2 Others (Refer to Fig. 1)
Item| PartNo. | Description Q'ty Remarks
50 | U4283B00 |Framebody | 1 |
51 | U3698D00 |Gas hose assembly |
51-1| 4813-001 |Gas solenoid valve 1 [D.C25v
52 | U3698E00 [Control cable assembly 1 |
52-1] 4730-005 [Plug socket | 1 [4p
53 | U1779C01 ¡Cable clamp 1
54 | K2801W01 [Conduit connection metal (1)
54-11 K1687D02 [Conduit connection metal 1.
55 | U1997L02 {Insulating plate 1
56 | U1230B14 [Insulating washer 2 |
56-1 Hexagon head bolt — 2 |M6-35
57 | U785C09 Flat spring . | 1 |
57-1 E. Pan head screw 1 (MS5-12
58 | U785C11 [Protection cover 1 |
58-1 ~~ JRounded end screw 1 |M3-6
58-2 |. Nue = | 1 M3
58-33 | .. — |Spring washer 1 M3
59 | U1962D02 lo
No. U4283
P. 17/21
Fig. 1 Exploded view of wire feed reduction gear unit |
— € Standard accessory >
17/81 “d
Fig. 2 Exploded view of wire feed and pressure part
No. U4283
P. 19/21
Fig. 3 External view of conduit connection adapter
(Con Connection
(Gas "IN"side)
Plug socket
2-?/0,5 |
— (Attachment hole)
Fig. 4 External view of wire feeder
17/07 а
No. U4283
P. 21/21
10.1 Specifications
Моде! CMW-145
Roll method 4-roll driving method
Applicable wire size | Steel 1.0
Wire feed speed Max. 15m / min
10.2 Standard accessories | о
Description Parts No. Qty Remarks |
Feed roll (1.0) K1821V00 (2) [For steel and built in body
Pressure roll K1822H00 (2) |For steel and built in body
Wire straightener K1821J00 1 о | |
Wire guide U1962D02 1
Conduit adapter K420B09 1
Hexagon rod spanner ЕЕ 1 [No.5
Warning label
DAIHEN coporaion |
DAIHEN Corporation |
5-1, Minamisenrioka, Settsu-shi, Osaka 566-0021, Japan
Phone: +81-6-6317-2506, Fax: +81-6-6317-2583
1400 Blauser Drive
_ Tipp City, Ohio 45371, USA
Phone: +1-937-667-0800, Fax: +1-937-667-0885
Krefelder Str. 677, D-41066 Mónchengladbach, F.R. GERMANY
Phone: +49-2161-69-49710, Fax: +49-2161-69-49711
OTC industrial (Shanghai) Co.,Ltd.
7G Majesty Building, 138 Pu Dong Da Dao Shanghai
The People's Republic of China
Post Code: 200120 |
Phone: +86-21-58828633, Fax: +86-21-58828846
OTC (Taiwan) Co.,Ltd.
No. 63-4, Nan Yuan 2 Rd., Chung Li,
Taoyuan Hsien, Taiwan R.O.C.
Phone: +886-3-461-3962, Fax: +886-3-434-2394
OTC DAIHEN Asia Co.,Ltd.
60 / 86 Moo 19, Navanakorn Industrial Estate Phase 3,
Klong Nueng, Klong Luang, Pathumthani 12120
Phone: +66-2-909-4163, Fax: +66-2-909-4166
Upon contact, advise MODEL and MANUAL NO.
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