OTC CMAW-7401, Owner'S Manual

Page 1: ...taining 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...

Page 2: ...arting 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 E...

Page 3: ...FETY PRECAUTIONS E2 3 CHECKING OF QUANTITY OF THE ACCESSORIES E8 4 NAME OF PARTS E8 5 CARRYING AND INSTALLING OF THE WIRE FEEDER E9 6 CONNECTION PROCEDURE E11 7 WELDING PREPARATION E15 8 MAINTENANCE A...

Page 4: ...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 t...

Page 5: ...ized or poorly spliced cables 8 Do not touch electrode and 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 ARC RAYS can burn eyes...

Page 6: ...ip when not in use 10 Does not use the welding power source for 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...

Page 7: ...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 repai...

Page 8: ...urce 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 we...

Page 9: ...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 Cod...

Page 10: ...cover Feed roll 7 2 Control cable 10P Wire reel hub 7 1 7 3 Gas supply inlet 6 4 Feed motor 8 2 Pressure roll holder Pressure handle 7 2 Frame Wire straightner 7 2 Torch socket 6 3 Water connection w...

Page 11: ...ear 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...

Page 12: ...t optional bracket of part number U30022Z00 Do not hang the wire feeder using the handle of the wire feeder as shown in the diagram below Do not install or hang the wire feeder in a posture resulting...

Page 13: ...low Disconnect 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 met...

Page 14: ...ach the gas hose to the gas supply inlet on the back side of the wire feeder refer 6 4 for details 7 Connect the welding torch to the wire feeder refer 6 3 for details 8 Connect the water hose to wate...

Page 15: ...power source with 350 A welding current and 17m or more cable use the thicker cable by one rank 6 3 Connecting of the Welding Torch CAUTION Ensue that the torch connector is firmly attached If the con...

Page 16: ...as cylinder Attach a proper gas regulator to the gas cylinder Failure to observe the demand may cause in physical injuries The gas regulator for high pressure gas must be used How to Make Gas Connecti...

Page 17: ...insert the stopper pin of the wire reel shaft into the wire reel stopper pin hole 4 Turn the cap counter clockwise to tighten it 5 Bring down the pressure handle then raise the pressure roll holder 6...

Page 18: ...he 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...

Page 19: ...em by referring to the diagram below Brake pad Install the felt surface toward the wire reel shaft side Hexagon head bolt M10X55 Cap Wire reel shaft Strong Weak Observe the following precautions to pr...

Page 20: ...e 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...

Page 21: ...ire Feeder CAUTION When hanging the wire feeder firmly fix the cap knob and clamp screw in position to prevent the device from dropping Do not use the carrying handle of the wire feeder to hang the wi...

Page 22: ...ing bracket installation Mount the brake pad to the wire reel shaft as illustrated below with care placed to the mounting direction Mount the brake disk to the wire reel shaft as illustrated below wit...

Page 23: ...her M8 and spring washer M8 3 pieces for each of the hanging bracket accessory in that order 4 Adjust the wire reel hub M10 24N m 245kgf cm M8 6N m 61kgf cm Recommended tightening torque Reel bracket...

Page 24: ...r contact or breakdown in the voltage detection cable Trouble with the motor Replace the motor if necessary Wire pressure is too weak Refer to Recommended wire adjustment in Section 7 2 Dust or chip i...

Page 25: ...utlet guide from the direction of the torch socket and then place the snap ring under the new outlet guide 5 Return the pressure roll holder first the pressure handle CAUTION Never attempt to disassem...

Page 26: ...azing copper or Inconel etc it is necessary to add the welding mode option to the welding power source For wire pressure adjustment of mild steel stainless steel or brazing wire refer to the section 7...

Page 27: ...h coating and a screen 8 1 4739 549 Quick connector 1 For water in red 8 2 4739 550 Quick connector 1 For water out blue 9 U5209B00 Wire feeding part 1 With a feed motor 10 U5185D00 Central adapter 1...

Page 28: ...E26 9 PARTS LIST continued 24 11 4 5 3 2 1 8 6 20 22 21 7 23 13 12 14 17 16 15 19 10 18 Fig 1 Main Body and Wiring Assembly...

Page 29: ...exagon socket cap screw 8 M4 x 16 8 2 3361 884 Bolt 8 M4 x 10 9 U5185B04 Guide block 1 10 U5204B03 Center guide 1 0 1 6 1 11 4802 206 Feed motor 1 12 U5185B06 Insulation board 1 13 U3971B04 Insulation...

Page 30: ...E28 7 8 22 5 3 2 4 10 9 17 16 15 18 11 12 1 13 20 14 6 9 PARTS LIST continued Fig 2 Wire Feeding Part Assembly...

Page 31: ...901 Hexagon socket cap screw 1 M8 x 25 4 U5185D04 Small nut 1 5 K3985E04 Hose connector 1 6 K3985E05 Sleeve 1 7 U5185V00 Switch cord 1 Assembly Fig 3 Central Adapter Assembly 9 4 Gas piping Fig 4 Ref...

Page 32: ...7 CSRT Connector BKPDT 3817 BKPDT 6017 22m CSRT CSRT BKPT 3822 BKPT 6022 BKPT 8022 CSRT Connector BKPDT 3822 BKPDT 6022 CSRT Crimp Style Ring Terminal When performing pulse welding using the welding p...

Page 33: ...ion Q ty Remarks U5185B05 Center guide 0 6 1 6 1 For steel U5204B02 Center guide 0 8 1 0 1 For aluminum white U5204B03 Center guide 1 0 1 6 1 For aluminum black U5185D05 Outlet guide 0 6 0 9 1 For ste...

Page 34: ...is necessary 10 2 Available Welding Torch Welding torch for aluminum or stainless steel Rated current Cooling method Duty cycle For aluminum For stainless steel 200 A Air 60 WTA200 SD 300 A 50 WTA300...

Page 35: ...E33 10 SPECIFICATIONS continued External View of CMAW 7401 type Wire Feeder part...

Page 36: ...hone 86 21 5882 8633 Fax 86 21 5882 8846 OTC Taiwan Co Ltd 2F No 153 Huanbei Rd Chung Li City Taoyuan Hsien Taiwan Phone 886 3 461 3962 Fax 886 3 434 2394 OTC DAIHEN Asia Co Ltd 23 43 16th F1 Sorachai...