MAGNUM PROTHRU THE ARM ROBOTIC TORCH

MAGNUM PRO THRU THEARM ROBOTIC TORCH

OPERATORSMANUAL

IM10071-AApril 2013

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,your overall safety can beincreased by proper installation... and thoughtful operation onyour part. DO NOT INSTALL,OPERATE OR REPAIR THISEQUIPMENT WITHOUT READ-ING THIS MANUAL AND THESAFETY PRECAUTIONS CON-TAINED THROUGHOUT. And,most importantly, think beforeyou act and be careful.

ModelsK2917-100iC K3353-100iC K3353-100iCW K3359-100iC K3359-100iCA K3359-100iCWK2917-100iC/6L K3353-100iC/6L K3353-100iC/6LW K3359-100iC/6L K3359-100iC/6LA K3359-100iC/6LWK2917-120iC K3353-120iC K3353-120iCW K3359-120iC K3359-120iCA K3359-120iCWK2917-120iC/10L K3353-120iC/10L K3353-120iC/10LW K3359-120iC/10L K3359-120iC/10LA K3359-120iC/10LW

Sales and Service through Subsidiaries and Distributors Worldwide

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBSITE: www.lincolnelectric.com

World's Leader in Welding and Cutting Products

Copyright Lincoln Global Inc.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of Safety in Welding & Cutting - ANSI Standard Z49.1 from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.3.a. The electrode and work (or ground) circuits

are electrically hot when the welder is on.Do not touch these hot parts with your bareskin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder. DC Manual (Stick) Welder. AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically hot.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically hot parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanicalventilation. In confined spaces or in some circum-stances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.

5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturers instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployers safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.f. Also see item 1.b.

iiiSAFETYiii

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturersrecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturers recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located: Away from areas where they may be struck or subjected tophysical damage.

A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically hot parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,Precautions for Safe Handling of Compressed Gases inCylinders, available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.

Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to Safety in Welding and Cutting (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen cleaned. For information, purchase RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

ivSAFETYiv

PRCAUTIONS DE SRETPour votre propre protection lire et observer toutes les instructionset les prcautions de sret specifiques qui parraissent dans cemanuel aussi bien que les prcautions de sret gnrales suiv-antes:

Sret Pour Soudage A LArc1. Protegez-vous contre la secousse lectrique:

a. Les circuits llectrode et la pice sont sous tensionquand la machine souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vtements mouills. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trs attention de bien sisoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couch pour lesquelles une grandepartie du corps peut tre en contact avec la masse.

c. Maintenir le porte-lectrode, la pince de masse, le cblede soudage et la machine souder en bon et sr tatdefonctionnement.

d.Ne jamais plonger le porte-lectrode dans leau pour lerefroidir.

e. Ne jamais toucher simultanment les parties sous tensiondes porte-lectrodes connects deux machines souderparce que la tension entre les deux pinces peut tre letotal de la tension vide des deux machines.

f. Si on utilise la machine souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-lectrode sapplicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protgercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le cble-lectrode autour de nimporte quelle partiedu corps.

3. Un coup darc peut tre plus svre quun coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriainsi quun verre blanc afin de se protger les yeux du ray-onnement de larc et des projections quand on soude ouquand on regarde larc.

b. Porter des vtements convenables afin de protger lapeau de soudeur et des aides contre le rayonnement delarc.

c. Protger lautre personnel travaillant proximit ausoudage laide dcrans appropris et non-inflammables.

4. Des gouttes de laitier en fusion sont mises de larc desoudage. Se protger avec des vtements de protection libresde lhuile, tels que les gants en cuir, chemise paisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de scurit dans la zone desoudage. Utiliser des lunettes avec crans lateraux dans leszones o lon pique le laitier.

6. Eloigner les matriaux inflammables ou les recouvrir afin deprvenir tout risque dincendie d aux tincelles.

7. Quand on ne soude pas, poser la pince une endroit isol dela masse. Un court-circuit accidental peut provoquer unchauffement et un risque dincendie.

8. Sassurer que la masse est connecte le plus prs possiblede la zone de travail quil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dautresendroits loigns de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, cbles de grue, ou autres circuits. Cela peut provoquerdes risques dincendie ou dechauffement des chaines et descbles jusqu ce quils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particulirement important pour le soudage de tlesgalvanises plombes, ou cadmies ou tout autre mtal quiproduit des fumes toxiques.

10. Ne pas souder en prsence de vapeurs de chlore provenantdoprations de dgraissage, nettoyage ou pistolage. Lachaleur ou les rayons de larc peuvent ragir avec les vapeursdu solvant pour produire du phosgne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sret,voir le code Code for safety in welding and cutting CSAStandard W 117.2-1974.

PRCAUTIONS DE SRET POURLES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR

1. Relier la terre le chassis du poste conformement au code dellectricit et aux recommendations du fabricant. Le dispositifde montage ou la piece souder doit tre branch unebonne mise la terre.

2. Autant que possible, Iinstallation et lentretien du poste seronteffectus par un lectricien qualifi.

3. Avant de faires des travaux linterieur de poste, la debranch-er linterrupteur la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sret leurplace.

vv

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask LincolnElectric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customers particular purpose,with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying these types of fabrication methods and service requirements.

Subject to Change This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.comfor any updated information.

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your equipment nameplate or product carton label.

Model Name and Sales Spec Number (K-xxx) _____________________________________

Date of Purchase __________________________________

Whenever you request replacement parts for or information on this equipment always supply the informationyou have recorded above.

On-Line Product Registration- Register your machine with Lincoln Electric either via fax or over the Internet.

For faxing: Complete the form on the back of the warranty statement included in the literature packetaccompanying this machine and fax the form per the instructions printed on it.

For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose Support and then RegisterYour Product. Please complete the form and submit your registration.

vivi

PageGeneral Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section AGeneral DescriptIon, Recommended Processes and Equipment. . . . . . . . . . . . . . . . . . . . . . A-1Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2Magnum Pro Thru the Arm For 100iC, 100iC/6L Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3Magnum Pro Thru the Arm For 120iC Robots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4Magnum Pro Thru the Arm For 120iC/10L Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

__________________________________________________________________________________________

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B(Standard Robot Assembly)Connecting Torch to Robot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1Connecting Cable to Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1,B-2Connecting Gooseneck and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Electrodes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

(Wire Brake Information)Connecting Torch to Robot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4Connecting Cable to Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4, B-5Installation of Nose Cone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5Connecting Gooseneck and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

__________________________________________________________________________________________

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C(Optional Air Blast)Connecting Torch to Robot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1Connecting Cable to Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1,C-2Installation of Nose Cone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3Connecting Gooseneck and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Electrodes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

__________________________________________________________________________________________

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section DRemoval, Installation and Trimming Instructions for All Magnum Liners . . . . . . . . . . . . D-1Gun Tubes and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1Cable Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1To Replace Wire Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

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Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E__________________________________________________________________________________________

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-202-AG__________________________________________________________________________________________

A-1GENERAL DESCRIPTION

MAGNUM PRO THRU THE ARM ROBOTIC TORCH

A-1

GENERAL DESCRIPTION

The Magnum Pro product line is designed for heavyduty applications and possesses market leading rat-ings and simplicity in maintenance.

The Magnum Pro Thru the Arm Robotic Torch hasbeen designed to meet specifications for welding withsteel electrode using the GMAW (gas metal arc weld-ing) and gas-shielded FCAW (flux-cored arc welding)processes.

The Magnum Pro Thru the Arm Robotic Torch israted for 550 amps at 100% duty cycle with 100%CO2 shielding gas. It is rated at 375 amps at 100%duty cycle with mixed gas.

The Thru-arm Torch is designed for use with theFanuc ARC Mate 100iC, 100iC/6L, 120iC and120iC/10L. Models are factory equipped with a feederconnector for most Lincoln robot-mounted feeders (i.e.4R90, 4R100 4R220).

Do not touch electrically live partssuch as output terminals or inter-nal wiring.

------------------------------------------------------------------------RECOMMENDED PROCESSES ANDEQUIPMENT

RECOMMENDED PROCESSES GMAW, GMAW-P, GMAW-STT, FCAW, FCAW-SS

PROCESS LIMITATIONS This product is not recommended for submerged

arc welding.

EQUIPMENT LIMITATIONS Robots: K2917-100iC, K2917-100iC/6L, K2917-120iC and K2917-

120iC/10L, K3353-100iC, K3353-100iC/6L, K3353-120iC,K3353-120iC/10L, K3353-100iCW, K3353-100iC/6LW, K3353-120iCW, K3353-120iC/10LW, K3359-100iC, K3359-100iC/6L,K3359-120iC, K3359-120iC/10L, K3359-100iCA, K3359-100iC/6LA, K3359-120iCA, K3359-120iC/10LA, K3359-100iCW, K3359-100iC/6LW, K3359-120iCW, K3359-120iC/10LW are specifically designed to be used withthe Fanuc ARC Mate 100iC, 100iC/6L, 120iCand 120iC/10L respectively. Because the cablesare routed through the robot and have a preciselength, these welding torches cannot be used onany other model robot.

Activation limits are as follows: J6 Axis [+/-270]

Wirefeeders: K2917, K3353 and K3359 Series are not compati-

ble with the Power Feed 10R. They are designedonly to work with nested wire feeders such asthe 4R90, 4R100 and 4R220.

It is not recommended that the K2917, K3353 orK3359 Series be used with any non robot-mount-ed wirefeeder.

COMMON EQUIPMENT PACKAGES

The available replacement parts for the Thru-arm areshown in Table A.1.

KP2918/KP2919 series gooseneck are used inK2917 torches.

KP3354/KP3355 series goosneck are used inK3353 and K3359 torches.

TABLE A.1

MAGNUM PRO THRU THE ARMREPLACEMENT EQUIPMENT

Product Number Description

KP2918-22 Tregaskiss 22 TCP Gooseneck


KP2919-22 Binzel 22 TCP Gooseneck








KP2920-1 Breakaway Disc

KP3066-100iC Cable Assembly, Fanuc 100iC

KP3066-100iC/6L Cable Assembly, Fanuc 100iC/6L

KP3066-120iC Cable Assembly, Fanuc 120iC

KP3066-120iC/10L Cable Assembly, Fanuc 120iC/10L

WARNING



A-2

SPECIFICATIONS: K2917-100iC, K2917-100iC/6L, K2917-120iC, K2917-120iC/10L, K3353-100iC, K3353-100iC/6L, K3353-120iC, K3353-120iC/10L, K3353-100iCW, K3353-100iC/6LW, K3353-120iCW, K3353-120iC/10LW,K3359-100iC, K3359-100iC/6L, K3359-120iC, K3359-120iC/10L,K3359-100iCA, K3359-100iCW, K3359-100iC/6LA, K3359-100iC/6LW,K3359-120iCA, K3359-120iCW, K3359-120iC/10LA, K3359-120iC/10LW

Magnum Pro Thru the Arm Series - Rated Output

Welding Processes

Duty Cycle Amperes Mixed Gas Amperes CO240% 575 845

60% 460 700

80% 400 610

100% 375 550

Process

GMAW-Pulsed

GMAW-STT

FCAW- Gas Shielded

Electrode DiameterRange

.035 5/64"(0.9 2.0 mm)

Output Range (Amperes)

375A @ 100%460A @ 60%

Wire Feed Speed Range

See wire feeder literature.

Physical Dimensions and Temperature RangesModel

K2917-100iCK3353-100iC

K3353-100iCWK3359-100iCAK3359-100iCW

K2917-100iC/6LK2917-120iC

K3353-100iC/6LK3353-100iC/6LWK3359-100iC/6LAK3359-100iC/6LW

K3353-120iCK3353-120iCWK3359-120iCAK3359-120iCW

K2917-120iC/10LK3353-120iC/10L

K3353-120iC/10LWK3359-120iC/10LAK3359-120iC/10LW

Cable Length

3ft (.9m)

3.5ft (1.1m)

4ft (1.2m)

Weight

5.50 lbs (2.5 kg)

5.75 lbs (2.6 kg)

6.00 lbs (2.7 kg)

OPERATING TEMPERATURE RANGE-4F to 104F (-20C to 40C)

STORAGE TEMPERATURE RANGE-40F to 185F (-40C to 85C)



A-3

MAGNUM PRO THRU THE ARM FOR 100iC ROBOT550 AMPS AT 100% DUTY CYCLE WITH CO2 GAS

375 AMPS AT 100% DUTY CYCLE WITH MIXED GAS

MAGNUM PRO THRU THE ARM FOR 100iC/6L ROBOT550 AMPS AT 100% DUTY CYCLE WITH CO2 GAS


MAGNUM PRO THRU THE ARM FOR 120iC ROBOT550 AMPS AT 100% DUTY CYCLE WITH CO2 GAS


Gun CableLength (m)

3 ft. (.9)

3 ft. (.9)

3 ft. (.9)

Wire SizeRangein. (mm)

.035 (0.9)5/64 (2.0)

.035 (0.9)5/64 (2.0)

.035 (0.9)5/64 (2.0)

Contact TipsStandard

Duty

KP2745-035RKP2745-045R

KP2745-040

Gas DiffuserAssembly

KP2747-1

KP2747-2

GasNozzle

KP2743-1-62R

KP2743-1-62R

Insulator

KP2773-1

KP2773-1

Cable Liner

KP45-3545-15

KP45-3545-6

Gun Tube 45

KP2919-45

KP3355-45

Jump Liner

KP3364-1W ONLY

Description

ProductNumber

K2917-100iCK3353-100iCK3353-100iCW

K3010-100iC(Ready Pak)

K3359-100iCK3359-100iCAK3359-100iCW(Ready Pak)

Gun CableLength (m)

3.5 ft. (1.1)

3.5 ft. (1.1)

3.5 ft. (1.1)

Wire Size Rangein. (mm)

.035 (0.9)5/64 (2.0)

.035 (0.9)5/64 (2.0)

.035 (0.9)5/64 (2.0)


Duty

KP2745-035RKP2745-045R

KP2745-040


KP2747-1

KP2747-1

GasNozzle

KP2743-1-62R

KP2743-1-62R

Insulator

KP2773-1

KP2773-1

Cable Liner

KP45-3545-15

KP45-3545-6

Gun Tube 45

KP2919-45

KP3355-45

Jump Liner

KP3364-1W ONLY

Description

ProductNumber

K2917-100iC/6LK3353-100iC/6LK3353-100iC/6LW

K3010-100iC/6L(Ready Pak)

K3359-100iC/6LK3359-100iC/6LAK3359-100iC/6LW

(Ready Pak)

Gun CableLength (m)

3.5 ft. (1.1)

3.5 ft. (1.1)

3.5 ft. (1.1)


.035 (0.9)5/64 (2.0)

.035 (0.9)5/64 (2.0)

.035 (0.9)5/64 (2.0)


Duty

KP2745-035RKP2745-045R

KP2745-040


KP2747-1

KP2747-1

GasNozzle

KP2743-1-62R

KP2743-1-62R

Insulator

KP2773-1

KP2773-1

Cable Liner

KP45-3545-15

KP45-3545-6

Gun Tube 45

KP2919-45

KP3355-45

Jump Liner

KP3364-1W ONLY

Description

ProductNumber

K2917-120iCK3353-120iCK3353-120iCW

K3011-120iC(Ready Pak)

K3359-120iCK3359-120iCAK3359-120iCW

(Ready Pak)



A-4

MAGNUM PRO THRU THE ARM FOR 120iC/10L ROBOT550 AMPS AT 100% DUTY CYCLE WITH CO2 GAS


Gun CableLength (m)

4 ft. (1.2)

4 ft. (1.2)

4 ft. (1.2)


.035 (0.9)5/64 (2.0)

.035 (0.9)5/64 (2.0)

.035 (0.9)5/64 (2.0)


Duty

KP2745-035RKP2745-045R

KP2745-040


KP2747-1

KP2747-1

GasNozzle

KP2743-1-62R

KP2743-1-62R

Insulator

KP2773-1

KP2773-1

Cable Liner

KP45-3545-15

KP45-3545-6

Gun Tube 45

KP2919-45

KP3355-45

Jump Liner

KP3364-1W ONLY

Description

ProductNumber

K2917-120iC/6LK3353-120iC/10LK3353-120iC/10LW

K3011-120iC/6L(Ready Pak)

K3359-120iC/10LK3359-120iC/10LAK3359-120iC/10LW

(Ready Pak)

J6 AXIS: +/- 270

ROBOT ARM

ROBOT ACTIVATION LIMITS

B-1INSTALLATIONB-1


Read this entire installation section before youstart installation.

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.


Insulate yourself from the work andground.

Always wear dry insulating gloves.------------------------------------------------------------------------(STANDARD ROBOT ASSEMBLY)

CONNECTING TORCH TO ROBOT ARM,FANUC MODEL 100iC, 100iC/6L, 120iC OR120iC/10L(See Figure B.1)

1. Removing Torch Assembly from packagingDisassemble the Torch Assembly:

Remove the 2 sets of 4 Socket Head Cap ScrewsItem 1, holding the Nose Cone Item 2, to the HousingItem 3 and the Housing to the Breakaway Disc Item4.

2. Assemble the Breakaway Disc to the J6 axis Item 5 ofthe robot, making sure the Scribe Mark is facing up.Secure with the (4) M4 Screws Item 6 provided.Torque to 6-8 in-lbs (.9-1.1Nm).

3. Assemble the Housing to the Breakaway Disc. AlignScribe Marks and secure with Long Socket HeadCaps Screws. Torque to 8-10 in-lbs (.9-1.1Nm).

4. Assemble the Nose Cone assembly to the Housing.Align Scribe Marks and secure with remainingSocket Head Caps Screws. Torque to 8-10 in-lbs.(.9-1.1Nm).

WARNING

1345

6

2

FIGURE B.1

Scribe Marks

CONNECTING CABLE ASSEMBLY TOROBOT(See Figure B.2)1. Remove Magnum Liner Item 1 and Cable Assembly

Item 2 from packaging. Lay both Items on a flat sur-face to be assembled.

2. Trim Magnum Liner to approximately 5.5ft.(1.7m).Insert liner into Feeder Connector Assembly andsecure with Set Screw Item 3.

FIGURE B.2

3. Pull back cable cover and grip cable behind front hexand crimp. With the robot axis J5 rotated down 90,insert hex thru housing until it passes thru andsecure with attached Socket Head Cap Screw Item1. Push cable cover forward until it snaps intobreakaway disc. (See Figure B.3)

FIGURE B.3

1

23

Cable Cover

Hex and Crimp

Robot Axis J5 rotated down 901

B-2INSTALLATION


B-2

4. Insert Feeder Connector thru Robot Arm cavity andinto wire feeder and secure. Make sure that thecable is not twisted when installed. Connect gashose to gas fitting on feeder connector. (See FigureB.4) Adjust feeder location until approximately 1-1/2 inch cable rise as shown in robot front viewbelow.

FIGURE B.4

CONNECTING GOOSENECK AND CON-SUMABLES(See Figure B.5)

Remove plug cover from nose cone. Loosen setscrew. Insert gooseneck into nose cone (spot-facefacing up) and secure with set screw. Replace plugcover. Trim Magnum liner to 5/8(16.0mm) stick outfrom end of gooseneck. Attach desired Magnum Proconsumables to gooseneck.

SET SCREWSET SCREWPLUG COVERPLUG COVER

SPOT FACESPOT FACEON GOOSENECKON GOOSENECK

GUN TUBE (GOOSENECK)GUN TUBE (GOOSENECK)

GAS DIFFUSERGAS DIFFUSER TIPTIP

GAS NOZZLE GAS NOZZLE

INSULATOR INSULATOR

LINER TRIMLINER TRIMLENGTHLENGTH

5/8" (16.0 mm)5/8" (16.0 mm)

FIGURE B.5

INSERT FEEDER CONNECTOR END HERE.MAKE SURE THE CABLEIS NOT TWISTED.

ROBOT ARM

FEEDER CONNECTOR END

GAS FITTING

1-1/2 IN.PROVIDE CABLE RISE (ROBOT FRONT VIEW)

B-3INSTALLATIONB-3


ELECTRODES AND EQUIPMENT

The (Thru the Arm Robotic Torch) has been designedfor use with Lincoln GMAW wire electrodes. Refer tothe appropriate Lincoln Process and ProcedureGuidelines for the electrode used for information onrecommended electrical and visible stickouts.

MAKING A WELD

When using an open arc process, it is necessaryto use eye, head, and body protection.




Always wear dry insulating gloves.------------------------------------------------------------------------

FUMES AND GASES can be danger-ous.

Keep your head out of fumes.

Use ventilation or exhaust toremove fumes from breathing zone.

------------------------------------------------------------------------

WELDING SPARKS can cause fire orexplosion.

Keep flammable material away.------------------------------------------------------------------------

ARCRAYS can burn.

Wear eye, ear and body protection.

------------------------------------------------------------------------Only qualified personnel should operate thisequipment.

AVOIDING WIRE FEEDINGPROBLEMS

Wire feeding problems can be avoided by observing thefollowing gun handling procedures:

1. Keep the electrode cable as straight as possible whenwelding or loading electrode through cable.

2. Keep cable clean by following maintenance instruc-tions.

3. Use only clean, rust-free electrode. The Lincoln elec-trodes have proper surface lubrication.

4. Replace contact tip when the arc starts to becomeunstable or the contact tip end is fused or deformed.

WARNING

B-4INSTALLATION


B-4


SAFETY PRECAUTIONSELECTRIC SHOCK can kill.




(WIRE BRAKE UNIT)

CONNECTING TORCH TO ROBOT ARM,FANUC MODEL 100ic, 100ic/6L, 120iC, OR120iC/10L(See Figure B.6)


Remove the set of 4 Socket Head Cap Screws Item1, the Housing Item 2 and the Housing to theBreakaway Disc Item 3.



FIGURE B.6

CONNECTING CABLE ASSEMBLY TOROBOT(See Figure B.7)

1. Remove Magnum liner ITEM 1, Cable AssemblyITEM 2 and Air hose ITEM 6 from packaging. Layitems on a flat surface to be assembled.

2. Push Air Hose ITEM 6 thru access hole on CableHandle ITEM 4 until approximately 4 inches protrudesfrom front. If hose does not feed freely, proceed tostep 3. Otherwise, proceed to step 6.

3. Remove Feeder Connecter Assembly ITEM 5 fromCable Handle ITEM 4. Remove cable handle fromcable assembly. Feed air hose thru cable handleaccess hole until approximately 4 inches protrudesfrom front of cable cover.

4. Slide cable handle onto cable asembly; align flats andinstall. If at any time hose is not free to move, removeand rotate cable handle 180 degrees clockwise andreinstall.

5. Install Feeder Connector ITEM 5 and torque to 12 ft-lbs (16.27 N-M).

6. Insert liner into feeder connector assembly and securewith set screw ITEM 3. Trim liner flush to 1/16 inchprotrusion from front connector.

FIGURE B.7

WARNING

4 IN.

1

2

5 3

4PUSH AIR HOSE THRU ACCESS HOLE HERE

AIR HOSE

FLUSH TO 1/16

6

1234

5

Scribe Marks

B-5INSTALLATION


B-5

7. Remove plug cover ITEM 4. Pull back cable coverand grip cable cable behind front hex / crimp. Withrobot axis J5 rotated down 90 degrees, insert hexthru housing until it passes thru. Push cable coverforward until it snaps into Breakaway Disk.

8. Connect Air Hose ITEM 1 to Wire Brake ITEM 2.

9. Slide Nose Cone ITEM 3 into Torch Cable ITEM 5until it bottoms. Secure with attached Socket HeadCap screw ITEM 7. Reinstall plug cover ITEM 4.Ensure that air hose is not kinked during thisprocess. Align scribe marks and secure nose conewith remaining Socket Head Cap Screws ITEM 6.Torque to 8-10 in-lbs. (0.9 - 1.1 N-m) (See FigureB.8)

FIGURE B.8

10. Push approximately 2 inches of air hose into torchcable on feeder connector end to ensure that airhose is slack at all times.

11. Insert Feeder Connector and air hose thru RobotArm cavity; secure feeder connection. Make surethat the cable is not twisted when installed.Connect gas hose to gas fitting on feeder connec-tor. (See Figure B.9) Adjust feeder location untilapproximately 1-1/2 inch cable rise as shown inrobot front view below.

Cable Cover


1

2

3

6

4

5

Hex and Crimp

7

FIGURE B.9



GAS FITTINGAIR HOSE

ROBOT ARM


B-6INSTALLATION


B-6

CONNECTING GOOSENECK AND CON-SUMABLES (See Figure B.10)

Slide Jump Liner into desired gooseneck assemblyfrom gooseneck rear. Remove plug cover from nosecone. Loosen set screw. Insert gooseneck into nosecone (spot-face facing up) and secure with set screw.Replace plug cover. Trim jump liner to 5/8" (16.0 mm)stickout from end of gooseneck. Attach desiredMagnum Pro comsumables to gooseneck.

SET SCREWSET SCREW PLUG COVERPLUG COVER

JUMP LINERJUMP LINER

SPOT FACESPOT FACEON GOOSENECKON GOOSENECK GUN TUBE (GOOSENECK)GUN TUBE (GOOSENECK)

GAS DIFFUSERGAS DIFFUSERTIPTIP


INSULATOR INSULATOR


5/8" (16.0 mm)5/8" (16.0 mm)

FIGURE B.10

C-1ACCESSORIESC-1



SAFETY PRECAUTIONS





(OPTIONAL AIR BLAST UNIT )NON WIRE BRAKE ONLY

CONNECTING TORCH TO ROBOT ARM,FANUC MODEL 100iC, 100iC/6L, 120iC OR120iC/10L(See Figure C.1)


Remove the set of 4 Socket Head Cap Screws Item1, the Housing Item 2 and the Housing to theBreakaway Disc Item 3.



WARNING

1234

5

FIGURE C.1

Scribe Marks

CONNECTING CABLE ASSEMBLY TOROBOT(See Figure C.2)

1. Remove Magnum liner ITEM 1, Cable AssemblyITEM 2 and Air Hose ITEM 6 from packaging. Layitems on a flat surface to be assembled.

2. Push Air Hose ITEM 6 thru access hole on CableHandle ITEM 4 until approximately 5 inches pro-trudes from front. If hose does not feed freely, pro-ceed to step 3. Otherwise, proceed to step 6.

3. Remove Feeder Connecter Assembly ITEM 5 fromCable Handle ITEM 4. Feed air hose thru cable han-dle access hole until approximately 5 inches pro-trudes from front of cable cover.

4. Slide cable handle onto cable asembly; align flatsand install. If at any time hose is not free to move,remove and rotate cable handle 180 degrees clock-wise and reinstall.

5. Install Feeder Connector ITEM 5 and torque to 12 ft-lbs. (16.27 N-M).

6. Trim Magnum Liner to approximately 5.5ft.(1.7m).Insert liner into Feeder Connector Assembly andsecure with Set Screw Item 3.

5 IN.

1

2

3

4PUSH AIR HOSETHRU ACCESS HOLE HERE

AIR HOSE

5

6

FIGURE C.2

C-2ACCESSORIESC-2


7. Remove Plug Cover ITEM 9. Pull back cable coverand grip cable behind front hex and crimp. With therobot axis J5 rotated down 90, insert hex thru hous-ing until it passes thru. Push cable cover forwarduntil it snaps into breakaway disc.

8. Remove 5mm set screw from nose cone air blastport ITEM 1 and dicard. Install air blast fitting ITEM2, tighten until snug using 2.5mm allen key.

9. Press Air hose ITEM 6 into air blast fitting ITEM 2 onnose cone ITEM 7 to seat fully.

10. Assemble the Nose Cone ITEM 7 assembly to theHousing ITEM 3. Secure with attached SocketHead Cap screw ITEM 10. Reinstall plug coverITEM 9. Align Scribe Marks and secure with remain-ing Socket Head Caps Screws ITEM 8. Torque to 8-10 in-lbs. (.9-1.1Nm). (See Figure C.3)

FIGURE C.3

11. Push approximatently 2 inches of air hose into torchcable on feeder connector end to ensure that air blasthose is slack at all times.

12. Insert Feeder Connector and air blast hose thruRobot Arm cavity; secure feeder connection.Make sure that the cable is not twisted wheninstalled. Connect gas hose to gas fitting on feed-er connector. (See Figure C.4) Adjust feederlocation until approximately 1-1/2 inch cable riseas shown in robot front view below.

FIGURE C.4

1

2

3

4

5

6

7

8

Cable Cover

Hex and Crimp


9

10


ROBOT ARM


GAS FITTINGAIR BLAST HOSE


C-3ACCESSORIESC-3

CONNECTING GOOSENECK AND CON-SUMABLES(See Figure C.5)

Remove plug cover from nose cone. Loosen setscrew. Insert gooseneck into the nose cone (spot-facefacing up) and secure with set screw. Replace plugcover. Trim Magnum liner to 5/8(16.0mm) stick outfrom end of gooseneck. Attach desired Magnum Proconsumables to gooseneck.


SPOT FACESPOT FACEON GOOSENECKON GOOSENECK

GUN TUBE (GOOSENECK)GUN TUBE (GOOSENECK)

GAS DIFFUSERGAS DIFFUSER TIPTIP


INSULATOR INSULATOR


5/8" (16.0 mm)5/8" (16.0 mm)

SET SCREWSET SCREW

PLUG COVERPLUG COVER

FIGURE C.5

C-4ACCESSORIESC-4


ELECTRODES AND EQUIPMENT

The (Thru the Arm Robotic Torch) has been designedfor use with Lincoln GMAW wire electrodes. Refer tothe appropriate Lincoln Process and ProcedureGuidelines for the electrode used for information onrecommended electrical and visible stickouts.

MAKING A WELD

When using an open arc process, it is necessaryto use eye, head, and body protection.





FUMES AND GASES can be danger-ous.

Keep your head out of fumes.

Use ventilation or exhaust toremove fumes from breathing zone.

------------------------------------------------------------------------

WELDING SPARKS can cause fire orexplosion.

Keep flammable material away.------------------------------------------------------------------------

ARCRAYS can burn.


------------------------------------------------------------------------Only qualified personnel should operate thisequipment.

AVOIDING WIRE FEEDINGPROBLEMS

Wire feeding problems can be avoided by observing thefollowing gun handling procedures:

1. Keep the electrode cable as straight as possible whenwelding or loading electrode through cable.

2. Keep cable clean by following maintenance instruc-tions.

3. Use only clean, rust-free electrode. The Lincoln elec-trodes have proper surface lubrication.

4. Replace contact tip when the arc starts to becomeunstable or the contact tip end is fused or deformed.

WARNING

D-1MAINTENANCED-1


(See Figure D-2 for instructions 6,7)

6. Lay Cable Assembly out straight on a flat surface.7. Loosen set screw located in the brass feeder con-

nector using 5/64 (2.0 mm) Allen wrench. Pull linerout of cable.

FIGURE D.2

For installation and trimming instructions for Magnumliners and wire brake jump/liners see InstallationSection.

GUN TUBES AND NOZZLES(See Figure D-3)

1. Replace worn contact tips as required.2. Remove spatter from from contact tip, gas dif-

fuser, insulator and gun tube after each 10 min-utes of arc time or as required.

3. To remove gun tube from gun, loosen set screwin nose cone assembly with 3/16" (4.8 mm) Allenwrench.

4. Pull gun tube out from nose cone assembly. Toreinstall, insert the gun tube, push in as far aspossible, and line up spot face of gun tuberetighten Set Screw.

CABLE CLEANINGClean cable liner after using approximately 150 (68kg) pounds of electrode. Remove the cable from thewire feeder. Remove the contact tip from the gun.Using an air hose and only partial pressure, gentlyblow out the cable liner from the diffuser end.

Excessive pressure at the start may cause thedirt to form a plug.

------------------------------------------------------------------------Flex the cable over its entire length and again blowout the cable. Repeat this procedure until no furtherdirt comes out.

CAUTION

GUN TUBE

3/16 SET SCREWSPOT FACEON GUN TUBE

GAS DIFFUSER

NOSE CONE ASSEMBLY

TIP

GAS NOZZLE

INSULATOR

LINER TRIMLENGTH

5/8" (16.0 mm)

Figure D.3

REMOVAL, INSTALLATION ANDTRIMMING INSTRUCTIONS FORMAGNUM LINERS

NOTE: The variation in cable lengths prevents theinterchangeability of liners. Once a liner hasbeen cut for a particular gun, it should not beinstalled in another gun, unless it can meet theliner cut off length requirement. Liners areshipped with the jacket of the liner extendedthe proper amount.

(See Figure D-1 for instructions 1-5)

1. Robot Axis J5 rotated down 90 to help removeCable Assembly.

2. Before sliding Cable Assembly out of Robot Armunfasten Gas Hose from Fitting and UntightenFastener from Autodrive Wire Drive which is hold-ing brass connector end.

3. Loosen the fasteners holding the hex connectionand feeder connection. Remove Cable Assemblyfrom robot.

4. Back out Cable Cover.

5. Back out Hex Connection.

FIGURE D.1

4. Back out Cable Cover

2. Before sliding Cable Assembly out of Robot Arm unfasten Gas Hose from Fitting and Untighten Fastener from Autodrive Wire Drive which is holding brass connector end.

5. Back out Hex Connection

3. LOOSEN HEX HEAD FASTENER THEN SLIDE CABLE ASSEMBLY OUT.

1. Robot Axis J5 rotated down 90 To help remove Cable Assembly

Replace Cable Liner

7. Loosen set screw located in the brass feeder connector using 5/64 (2.0 mm) Allen wrench. Pull liner out of cable.

6. Lay Cable Assembly out straight on a flat surface.

D-2MAINTENANCED-2

TO REPLACE THE WIRE BRAKE COMPO-NENTS, FOLLOW THESE STEPS:(See Section B-4 thru B-6 to help follow these stepsalso see Figure D.4)

1. Remove plug cover on nose cone. Loosen setscrew and remove gooseneck.

2. Remove plug cover from Housing. Loosen sockethead cap screw. Remove 4 socket head capscrews from front of Nose Cone AssemblyDisconnect air hose and remove nose cone assem-bly from torch assembly.

3. Loosen 2 socket head cap screws ITEM 6 andremove wire brake cap ITEM 5 from nose coneassembly. Remove spring ITEM 3 from pistonguide ITEM 2 and reserve. Remove piston guideITEM 2. Remove wire guide ITEM 1 from withinnose cone assembly.

4. Install new wire guide ITEM 1 by inserting thru frontof nose cone. Align wire access hole with wirebrake access port in nose cone.

5. Apply a small amount of thread sealant to threadson piston guide ITEM 2. Install and tighten pistonguide ITEM 2 thru nose cone access port untilthreads are no longer visible and piston guide ITEM2 is firmly seated. Carefully torque piston guideITEM 2 to 14-17 in.-lbs.(1.6-1.9Nm). Do not dam-age edges of piston guide, as this may cause edgeburrs on the piston guide ITEM 2 and damage Item5 brake cap cylinder bore. The shaft on piston ITEM4 can help align the piston guide when threadinginto wire guide ITEM 1.

6. Install the air fitting ITEM 7 in the air brake capITEM 5 with 2.5mm hex key to 3.5-4.0 in.-lbs.(.40-.46Nm).

7. Apply a liberal amount of silicone lubricant to the o-ring ITEM 8 on the wire brake piston ITEM 4.Reinstall the wire brake spring ITEM 3 into thepocket on the piston guide ITEM 2. Install the airbrake piston ITEM 4 thru the spring ITEM 3.

8. Push the air brake cap ITEM 5 over the pistonITEM 4 and secure with the 2 socket head capscrews ITEM 6. Torque screws to 2.5 to 3.5in-lbs.(.28-.40Nm)

Reinstall air hose, nose cone assembly in thereverse order from above.


1

35

PISTON SHAFTTHREAD SEALANTHERE

NOSE CONE ASSEMBLY

WIRE BRAKE ACCESS HOLE

WIRE ACCESS HOLE

246

78

FIGURE D.4

E-1TROUBLESHOOTINGE-1


If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions. Simply follow the three-stepprocedure listed below.

Step 1. LOCATE PROBLEM(SYMPTOM).Look under the column labeled PROBLEM(SYMPTOMS). This column describespossible symptoms that the machine mayexhibit. Find the listing that best describesthe symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled POSSIBLECAUSE lists the obvious external possibili-ties that may contribute to the machinesymptom.

Step 3. RECOMMENDED COURSE OFACTIONThis column provides a course of action forthe Possible Cause, generally it states tocontact you local Lincoln Authorized FieldService Facility.

If you do not understand or are unable toperform the Recommended Course ofAction safely, contact you local LincolnAuthorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician andmachine operator and will invalidate your factory warranty. For your safety and to avoidElectrical Shock, please observe all safety notes and precautions detailed throughout this manual.__________________________________________________________________________

WARNING



Observe all Safety Guidelines detailed throughout this manual


CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE

RECOMMENDEDCOURSE OF ACTION

No wire feed occurs.

Sluggish wire feed.

Intermittent wire feed.

Frequent birdnesting or kinking ofwire in the gun cable.

Wire Brake not functioning.

1. Out of wire.2. Contact tip burn back.3. Fully or partially blocked gun liner.

4. Bird nest.

5. No motor voltage or current frommachine

6. Contact tip size too small for wirediameter used.

1. Drive roll is worn or galled

2. Machines wire feed speed set-ting is too low.

3. Wire is obstructed somewherealong the wire feed path in thegun.

4. Low motor voltage.

5. Gun cable is twisted.

6. Mechanical resistance to wirefeeding is too large

1. Drive roll has become galled.

2. Wire has become kinked along itsfeed path.

1 Wire shavings/lubricant is buildingup in the cable.

2 Cable liner is too large for wiresize.

1. Air not being supplied.2. Wire brake stuck closed.

1. Install full spool of specified wire.2. Replace contact tip.3. Remove and clean or replace gun

liner. 4. Cut out bird nest, reload wire, and

check for proper wire alignment.5. See Troubleshooting section in

welding machines or wire feed-ers instruction manual.

6.Replace contact tip with one thatis the correct size.

1. Clean drive roll or replace driveroll.

2. Increase wire feed speed.

3. Check for obstructions: removeany wire shavings; remove kinkedwire; remove and clean orreplace gun liner.

4. See Troubleshooting section inwelding machines instructionmanual.

5. Remove cable and reinstall perinstallation instructions.

6. Reposition robot so that cable isless twisted or bent.

1. Remove and then clean orreplace drive roll

2. Manually pull wire slowly thru gununtil unkinked wire emerges

1. Clean cable or replace cableliner.

2 Install the smallest possible linerwhich is specified for the wirebeing used (i.e. use a .052-1/16liner instead of a 1/16-5/64 linerwhen welding with 1/16 diameterwire.

1. Ensure proper air supply.2. Repair / Replace as needed



Observe all Safety Guidelines detailed throughout this manual


CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE

RECOMMENDEDCOURSE OF ACTION

Frequent occurrence of contact tipburnback.

Poor weld bead appearance.

1. Improper welding parameters ortechnique (example: ESO electri-cal stick out is too short).

2. Wire may be feeding intermittent-ly.

1. Improper electrode polarity.

2. Improper welding parameters ortechnique.

1. See welding wire literature forproper settings.

2. See symptoms on intermittent orsluggish wire feed.

1. Reconnect machines welding out-put to proper electrode polarity.

2. See welding wire literature forproper settings.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENO

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Arabic

READ AND UNDERSTAND THE MANUFACTURERS INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYERS SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Do not touch electrically live parts orelectrode with skin or wet clothing.

Insulate yourself from work andground.

No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

Aislese del trabajo y de la tierra.

Ne laissez ni la peau ni des vte-ments mouills entrer en contactavec des pices sous tension.

Isolez-vous du travail et de la terre.

Berhren Sie keine stromfhrendenTeile oder Elektroden mit IhremKrper oder feuchter Kleidung!

Isolieren Sie sich von denElektroden und dem Erdboden!

No toque partes eltricas e elec-trodos com a pele ou roupa molha-da.

Isole-se da pea e terra.

Keep flammable materials away.

Mantenga el material combustiblefuera del rea de trabajo.

Gardez lcart de tout matrielinflammable.

Entfernen Sie brennbarres Material!

Mantenha inflamveis bem guarda-dos.


Protjase los ojos, los odos y elcuerpo.

Protgez vos yeux, vos oreilles etvotre corps.

Tragen Sie Augen-, Ohren- und Kr-perschutz!

Use proteo para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRTICAS DE SEGURANA DO EMPREGADOR.

Keep your head out of fumes. Use ventilation or exhaust to

remove fumes from breathing zone.

Los humos fuera de la zona de res-piracin.

Mantenga la cabeza fuera de loshumos. Utilice ventilacin oaspiracin para gases.

Gardez la tte lcart des fumes. Utilisez un ventilateur ou un aspira-

teur pour ter les fumes des zonesde travail.

Vermeiden Sie das Einatmen vonSchweibrauch!

Sorgen Sie fr gute Be- undEntlftung des Arbeitsplatzes!

Mantenha seu rosto da fumaa. Use ventilao e exhausto para

remover fumo da zona respiratria.

Turn power off before servicing.

Desconectar el cable de ali-mentacin de poder de la mquinaantes de iniciar cualquier servicio.

Dbranchez le courant avant lentre-tien.

Strom vor Wartungsarbeitenabschalten! (Netzstrom vllig ff-nen; Maschine anhalten!)

No opere com as tampas removidas. Desligue a corrente antes de fazer

servio. No toque as partes eltricas nuas.

Do not operate with panel open orguards off.

No operar con panel abierto oguardas quitadas.

Noprez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevs.

Anlage nie ohne Schutzgehuseoder Innenschutzverkleidung inBetrieb setzen!

Mantenha-se afastado das partesmoventes.

No opere com os paineis abertosou guardas removidas.

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