Daihen OTC CM-743-U, Owner'S Manual

Page 1: ...OWNER S MANUAL WIRE FEEDER MODEL CM 743 U Ensure to read this instruction manual thoroughly for safe and proper use of the product DAIHEN Corporation U30104 December 16 2015 Manual No U30104 1...

Page 2: ...starting on January I 1995 Please make sure that this product is not alfowed 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...

Page 3: ...AFETY PRECAUTIONS 2 3 CHECKING OF QUANTITY OF THE ACCESSORIES 9 4 NAMES OF PARTS 9 5 CARRYING AND INSTALLING OF THE WIRE FEEDER 10 6 CONNECTION PROCEDURE 12 7 WELDING PREPERATION 17 8 MAINTENANCE AND...

Page 4: ...throughout this manual to identify various hazards and special instructions WARNING CAUTION WARNING gives information regarding possible personal injury or loss of life CAUTION refers to minor persona...

Page 5: ...vice is manufactured using state of the art technology and according to recognised safety standards If used incorrectly or misused however it can cause injury or death to the operator or a third party...

Page 6: ...etal object if POWER switch is ON Do not wrap cables around your body When the wire feeder is not in use or the work is interrupted for a long time shut off the power of all units Blow dry air to part...

Page 7: ...ep 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 ca...

Page 8: ...ng injury or death Be sure the breathing air is safe CYLINDER can explode if damaged A shielding gas cylinder contains high pressure gas If damaged a cylinder can explode Since gas cylinders are norma...

Page 9: ...y external force and a shock to side door Otherwise it maybe broken and in trouble Polycarbonate parts can be weakened or damaged by solvents and oils If the side door or covers are damaged repair or...

Page 10: ...repair shut offthe welding power Do not put hands fingers hair or clothes near the rotating fans or wire feed roll ARC WELDING work areas are potentially hazardous FALLING or MOVING machine can cause...

Page 11: ...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 Nation...

Page 12: ...OSE 3m SWITCH CORD TERMINAL VINYL CAP HOSE COVER HEXAGON SOCKET SCREW KEY M4 IINAMES OF PARTS Refer to the section indicated in D for details Specification U5971ROO U5971SOO 100 0816 100 0817 U1997C03...

Page 13: ...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...

Page 14: ...n Do not place the welding power source wire feeder torch and contrail cable including the extension cable in an area where the equipment can become wet Install the wire feeder in the place where is a...

Page 15: ...nect the wire feeder from 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 con...

Page 16: ...dedicated cables and hoses having different length are provided For details refer to information in 9 14 Optional Accessory ICD Ground the base metal Connect the power cable for base metal between th...

Page 17: ...nnect the gas hose after fixing to the stand as physical injuries may result from the gas cylinder falling down Attach a proper gas regulator to the gas cylinder Failure to observe this requirement ma...

Page 18: ...ecting 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...

Page 19: ...standard specifications OTC C02 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 optional parts and optional kit se...

Page 20: ...being used are installed r Use feed rolls suited to the wire size Using an improper feed roll will cause it slip to disable normal wire feed or deform the wire resulting in improper welding Procedure...

Page 21: ...WELDING PREPERATION Continued Wire size mark I I Go next page When replacement of feed rolls are needed __ ________________ for replacement IWhen suitable feed rolls are already installed I 18 p ___...

Page 22: ...re size Wire size mark For example The feed roll of 01 6 wire size is built Hexagon socket head cap screw M4X16 2 pieces roll Groove A Groove B Wire size mark for Groove B Wire size mark for Groove A...

Page 23: ...ft fully tighten the cap to prevent falling In case a breakage crack or deformation is found in the wire reel shaft or cap do not use but replace it Fitting of Wire Fit the wire following the procedur...

Page 24: ...d WELDING PREPERATION Continued ORearcover 6 Center guide f Inlet liner 21 Wire O Outlet guide...

Page 25: ...spond to the one set with the left pressure handle Recommended wire pressure adjustment Wire diameter Pressure Wire straightener 0mm inch handle scale scale 1 6 1 16 2 3 2 3 Hard aluminum 1 2 3 64 1 2...

Page 26: ...brake disk to the wire reel shaft as illustrated below with care placed to the mounting direction In the event that the brake pad and the brake disk are used in wrong directions the hexagon head bolt...

Page 27: ...In addition operation can also be made with the inching button of the remote controller optional accessory In this case adjustment can be made with the current knob of the remote controller Adjustmen...

Page 28: ...nued 7 6 When attaching the wire reel cover K5951QOO OPTIONAL ACCESSORY When attaching the wire reel cover perform the procedure shown below p Wire reel hub Rear cover 25 M10X25 Recommended tightening...

Page 29: ...nected firmly 0 0 8 Is there not crack or break in parts and sheet metals inside wire feeder 0 9 Is there not portion of wiring inside wire feeder that is beginning to break 0 10 Is there no loosening...

Page 30: ...BROWN SOL DC25V 308 PURPLE Torch voltage direct detecting A 309 ORANGE Base metal direct detecting Encoder driving voltage SV Encoder plus A 60PPR Encoder plus B 60PPR Encoder driving voltage GND OV I...

Page 31: ...below when replacing the outlet guide 1 Open the side door 2 Remove the feed cover 3 Bring down the pressure handle then raise the pressure roll holder 4 Rewind the wire to reel 5 Remove the torch fro...

Page 32: ...tention paid to the direction ofthe outlet guide Inserting direction Short 9 Align the groove of outlet guide and the cutout of stopper plate then move the stopper plate downward to lock the outlet gu...

Page 33: ...or nor replace the brush Target for life and replacement of feed motor The life of the feeding motor is approximately 3 000 to 4 000 hours In addition the life varies with the load conditions and ambi...

Page 34: ...TROUBLESHOOTING Continued 8 4 Replace the center guide Replace the center guide following the procedure shown below Rewind the wire to reel 31 Turn the wire reel counter clockwise and insert the wire...

Page 35: ...U30104EOO 8 U30104HOO 9 U30038FOO 10 U30104XOO 1 1 1 U30104YOO Description DRIVE CASE DRIVE UNIT FRAME TORCH ADAPTOR N0 4 FRONT PANEL REAR PANEL CONTROL CABLE REAR COVER WIRE REEL HUB 2P RECEPTACLE HO...

Page 36: ...AME 1 2 K5951B02 SIDE DOOR 1 3 K5951B03 PIN 1 4 K5951B04 REAR FRAME 1 4 1 HEXAGON SOCKET HEAD BOLT 4 5 K5951B05 BASE FRAME 1 5 1 CAP SCREW 2 6 K5951806 SIDE FRAME 1 6 1 CAP SCREW 2 7 K5951B07 DOOR KNO...

Page 37: ...r 9 6 4 K5951WOO COMMON MODE COIL 1 5 U30104GOO GAS LINE 1 Assembly refer 9 5 5 1 PHILLIPS HEXAGON HEAD BOLT 2 M5X10 6 K5952B02 HANGER BRACKET 1 6 1 PHILLIPS HEXAGON HEAD BOLT 2 M5X10 7 K5952B03 DRIVE...

Page 38: ...U30023TOO PRESSURE ROLL HOLDER L 1 5 U30023WOO PRESSUREROLLHOLDER R 1 6 L10595804 COIL SPRING 1 7 L10595805 PRESSURE SPRING HOLDER 2 8 L10595806 PRESSURE HANDLE 2 9 WASHER SMALL 2 M6 1 1 0 L10595807 P...

Page 39: ...LENOID VALVE 1 2 U4179D01 HOSE ELBOW 1 3 RECEPTACLE HOUSING 1 ELR 02V 3 1 PIN CONTACT 2 SLM 41T P1 3E 4 TETRON HOSE 1 4X9 TR 4 Length 15 4 390mm 5 EAR CLAMP 4 MH 4 6 P9400P02 HOSE ELBOW 1 7 U30104G01...

Page 40: ...ST Continued 9 6 Feed Motor Fig 6 Ref Part number Description Q ty Remarks Nlo 1 W W03729 FEED MOTOR 1 2 U30024L01 MOTOR MOUNT 1 2 1 CAP SCREW 3 M6X16 See 9 4 Wire Feeder Fig 6 Feed Motor Assembly U30...

Page 41: ...D HEAD SCREW MOUNTING PIN BASE HEXAGON SOCKET HEAD BOLT REEL STAND HEXAGON SOCKET HEAD BOLT SPRING WASHER WASHER REEL STAND COVER HINGE PHILLIPS HEXAGON HEAD BOLT HANDLE GRIP KNURLING KNOB WIRE REEL C...

Page 42: ...er Description Q ty Remarks No 1 U30104F01 FRONT PANEL 1 1 1 CROSS RECESSED HEAD SCREW 6 IM4X8 2 U30104F02 CONNECTOR PANEL 1 2 1 CROSS RECESSED HEAD SCREW 2 IM4X8 3 U30104F03 COVER PLATE 1 3 1 CROSS R...

Page 43: ...ROSS RECESSED HEAD SCREW 4 IM4X8 2 K5952R02 COVER PANEL B 1 2 1 SHEET METAL SCREW 3 IM3X6 3 U30104R02 COVER PLATE 1 3 1 PHILLIPS ROUND HEAD SCREW 2 IM3X6 4 RUBBER BUSH 1 C 30 SG 36A EP UL 5 RUBBER BUS...

Page 44: ...LIST Continued 9 10 Rear Cover Fig 10 Ref Part number Description Q ty Remarks No 1 K5951B11 HOUSING B 1 1 1 HEXAGON SOCKET HEAD BOLT 4 IM4X15 2 RUBBER BUSH 1 C 30 SG 26A EP UL Fig 10 Rear Cover U3010...

Page 45: ...ty Remarks No number 1 U30104Y01 HOSE BRACKET 1 2 U5185J01 CABLE CLAMP 1 2 1 PHILLIPS HEXAGON HEAD BOLT 2 M5X15 3 U1997C02 HOSE CLAMP 1 3 1 PHILLIPS HEXAGON HEAD BOLT 2 M5X15 4 U1997C03 HOSE COVER 1...

Page 46: ...D05 STOPPER PLATE 1 4 1 K5951D06 STOPPER BOLT 1 4 2 WASHER 1 IM5 4 3 SPRING WASHER 1 IM5 4 4 SHRINKAGE TUBE 1 INPE 25 12 5 2 5 5 K5975D01 COPPER BAR 1 5 1 HEXAGON HEAD BOLT 1 IM10X25 5 2 WASHER 1 IM10...

Page 47: ...uPARTS LIST Continued Fig 12 Torch Adaptor N0 4 K5975DOO 44...

Page 48: ...EAD BOLT 4 IM4X16 5 K5439COO PRESSURE ROLL 2 6 HEXAGON SOCKET HEAD BOLT 2 IM6X30 7 WASHER SMALL 2 IM6 8 L10595000 DRIVE GEAR 1 8 1 PHILLIPS HEXAGON HEAD BOLT 1 IM4X15 9 K5951TOO FEED COVER 1 1 1 0 K59...

Page 49: ...el V type groove for 045 052 K5439805 FEED ROLL 1 2 1 2 2 For steel V type groove for 045 045 K5439B06 FEED ROLL 1 4 1 4 2 For steel V type groove for 052 052 K5439B07 FEED ROLL 1 6 1 6 2 For steel V...

Page 50: ...3 Outlet guide NO 4 AL1 6 1 For aluminum N0 4 1 16 Black K5975G32 Outlet guide NO 5 AL1 2 1 For aluminum N0 5 3 64 Black K5975G33 Outlet guide NO 5 AL1 6 1 For aluminum N0 5 1 16 Black K5951J55 Center...

Page 51: ...QUICK CONNECTOR 1 IFA3076 3 K5951H01 WATER PLATE 1 3 1 CROSS RECESSED HEAD SCREW 2 IM4X8 4 MICRO CLAMP 2 IMH 5 5 TETRON HOSE 1 6X11 Length 26 0 660mm 6 H10K37 AL CLAMP PIPE 2 7 K5951G02 NUT 2 8 K5975L...

Page 52: ...2 1 CAP SCREW 3 K59S1J55 CENTER GUIDE AL 4 L10595POO GEAR 5 K5975G22 OUTLET GUIDE N0 4 AL1 2 6 U5204J07 INLET GUIDE 7 K5951U10 LINER ADAPTOR 8 K5951U11 INLET LINER 8 3 1 Q ty 1 4 4 1 2 1 1 1 1 Remarks...

Page 53: ...PTOR 1 2 K5977DOO CENTRAL ADAPTOR 1 3 K59 77J01 OUTLET GUIDE 0 9 1 2 1 4 K5977C01 FRONT PANEL LABEL 1 4 1 CROSS RECESSED HEAD SCREW 6 M4X8 5 U30104F03 COVER PLATE 1 5 1 CROSS RECESSED HEAD SCREW 2 M4X...

Page 54: ...O 9 Other optional parts Part number De scription Q ty Remarks K5968AOO ANALOG PANEL 350A 1 K5980AOO ANALOG PANEL SOOA 1 FCR 226 C02 gas regulator with heater 1 Max gas flow rate 25 liter min NP 201 C...

Page 55: ...re 040 9 WTA300 SUT Aluminum K5975G22 2 wire 3 64 10 Aluminum K5975G23 wire 1 16 11 Aluminum K5975G32 3 wire 3 64 WTAW400 SUT 12 Aluminum K5975G33 wire 1 16 13 WT3500 S M L D Steel wire 035 045 14 WT3...

Page 56: ...er 1 97 0 50mm0 Applicable wire reel External diameter Max 11 8 0 300mm0 Wide 4 05 103mm Mass of applicable wire Max 55 1 lbs 25kg Temperature range 14 104 F 10 40 C Moisture range 20 80 no condensati...

Page 57: ...5000 LUT 200A 60 WTA200 SUT 300A 50 WTA300 SUT 400A 100 Liquid WTAW400 SUT cooling When using these torches changing of the torch connection to Central Adaptor K5977DOO is required 10 3 Standard Acces...

Page 58: ...RISPECIFICATIONS Continued 10 4 External View CM 743 U Type Wire Feeder 4 8 122mm I 23 2 590mm 15 5 393mm 14 3 363mm E E E e t _ I o 55...

Page 59: ...eder Option Full cover 5 4 1J6mm 11 5 291mn 22 s 571mm I I 28 5 724mm 37 4 950mm 591TY 1 CM 743 U Type Wire Feeder Option For voltage detection 18 r 475mm 59mm 10 0 254mm 5 6ft 1 7m 24 1 611mm 56 11 5...

Page 60: ...yuan Hsien Taiwan Phone 886 3 461 3962 Fax 886 3 434 2394 OTC DAIHEN Asia Co Ltd 23 43 16th F l Sorachai Building 23 Soi 63 Sukhumvit Road Klongtonnua Wattana Bangkok 10110 Thailand Phone 66 2 714 320...