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IM10032
June, 2011
TM
COUGAR
Push Pull GUN
Models: K2704-2, K2704-3
Safety depends on you. . .
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation...and thoughtful
operation on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think before
you act and be careful.
OPERATORʼS MANUAL
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216 486.1751 WEB SITE: www.lincolnelectric.com
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Table of Contents
Summary of Contents for Lincoln cougar k2704-2
- Page 1 June, 2011 COUGAR Push Pull GUN Models: K2704-2, K2704-3 Safety depends on you. . . Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation...and thoughtful operation on your part.
- Page 2 Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER- FORMED ONLY BY QUALIFIED INDIVIDUALS.
- Page 3 SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
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Page 4: Iii Safety
SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used properly... - Page 5 SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté...
- Page 6 Thank You for selecting one of our QUALITY products. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
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Page 7: Table Of Contents
TABLE OF CONTENTS SAFETY PRECAUTIONS ............................i-v TABLE OF CONTENTS..............................1 GENERAL INFORMATION ............................2 PRODUCT DESCRIPTION............................2 SPECIFICATIONS ................................2 RECOMMENDED PROCESSES AND EQUIPMENT ....................2 INSTALLATION.................................3, 4 UNPACKING THE PUSH-PULL GUN ..........................3 PUSH-PULL GUN FAMILARIZATION DIAGRAM ......................4 OPERATING INSTRUCTIONS..........................5-7 SAFETY PRECAUTIONS .............................5 SET-UP PROCEDURE ..............................5 SELECTING ELECTRODE WIRE ..........................5 LOADING ELECTRODE WIRE ............................5 INSTALLING BARREL LINER ............................5... -
Page 8: General Information
The gun is intended for use with Power Wave C300, Power Feed metal cathode cleaning effect. 10M, Power Feed 25M and Power Mig 350MP Power Sources. For other applications, contact your local Lincoln Electric sales office or distributor. The push-pull gun is ideal for aluminum fabrication in industrial shops, automobile body shops, marinas and for the advanced hob- byist. -
Page 9: Installation
COUGAR™ Push Pull Gun - INSTALLATION Unpacking the Push-Pull Gun Safety Precautions Unpacking the Push-Pull Gun – Read "Safety Precautions" in the Operating Manual before Carefully unpack your Cougar™ Push-Pull Gun and attach the proceeding. Only personnel that have read and understood Barrel Assembly, and make sure you have all of the parts shown the Operating Manual should install and operate this equipment. -
Page 10: Push-Pull Gun Familarization Diagram
3. Connect 7-Pin control cable plug to power source receptacle. 4. Reconnect power and turn on machine. 7 PIN AMPHENOL CONNECTOR PRESSURE ROLLER CABLE NOZZLE (FAR SIDE) ASSEMBLY BARREL CONTACT WIRE SPEED CONTROL DIFFUSOR DRIVE ROLL LINCOLN POWER TRIGGER (NEAR SIDE) PLUG HANDLE... -
Page 11: Operating Instructions
COUGAR™ Push Pull Gun - OPERATING INSTRUCTIONS Safety Precautions used. Consult your local dealer or appropriate AWS publication for help in selecting an appropriate alloy type and wire size. Also refer to, "Procedure Settings" later in this chapter, for wire sizes used with typical base metal thicknesses and procedure set- WARNING tings. -
Page 12: Drive Roll Groove Selection
COUGAR™ Push Pull Gun - OPERATING INSTRUCTIONS Drive Roll Groove Selection RELEASE LEVER The drive roll has two grooves. A wider groove for feeding 3/64” RELEASE LEVER (.047) wire and a narrow groove for feeding .035” (0.9mm) wire to accommodate changes in the wire size used. Changing between the grooves simply requires reversing the drive roll. -
Page 13: Making A Weld
COUGAR™Push Pull Gun - OPERATING INSTRUCTIONS Making A Weld Re-engage wire drive by pushing release lever to down posi- Check that the push-pull gun power, control, and gas connec- tion to feed wire. tions are correct for the power source being used. Check that the gas supply is turned on. -
Page 14: Accessories
COUGAR™ Push Pull Gun ACCESSORIES/MAINTENANCE ACCESSORIES (consult Lincoln Sales Bulletin E12.16) The following accessories are available for the Cougar™ push-pull gun. .035-3/64" Aluminum Drive Roll Kit Features two grooves for feeding aluminum wire. The smaller Wire Conduits groove feeds .035 wire. The larger groove feeds 3/64th wire. -
Page 15: Troubleshooting Guide
COUGAR™ Push Pull Gun Troubleshooting Guide PROBLEM SYMPTOMS REMEDY No arc, wire feed, or gas flow. 1. Cable connections loose. 1. Check all power connections. 2. Trigger switch loose or defective. 2. Fix switch or replace. 3. Welder not turned on. 3. - Page 16 COUGAR™ Push Pull Gun Troubleshooting Guide TESTING THE TORCH Motor Check. Remove the torch connector from the cabinet. Using the torch Control Cable Connector, check the resistance across pins “A” and “B” (motor leads). The resistance across the motor should be between 5-10 ohms.
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Page 17: Replacement Parts List Diagram
COUGAR™ Push Pull Gun REPLACEMENT PARTS LIST AND DIAGRAM ITEM PART ITEM PART DESCRIPTION DESCRIPTION KP2877-180 180 Degree Air-Cooled Gun Barrel S26374-34 50' Cable Assembly - Cougar S26374-31 Motor Assembly S26374-35 Cable Cover 25 S26374-6 Wire Drive Cover S26374-36 Cable Cover 50' S26374-14 Potentiometer Assembly S26374-37... - Page 18 COUGAR™ LX Push Pull Gun REPLACEMENT PARTS LIST AND DIAGRAM S26374-14 ITEM NO. PART NO. DESCRIPTION COMMENTS S26374-31 Motor Assembly S26374-7 Pressure Lever S26374-8 Pivot Arm S26374-9 Set Screw, Pressure Roll S26374-10 Pressure Adjustment Knob Assembly S26374-11 Ball Bearing KP2876-1 Drive Roll Kit AL .035-3/64"...
- Page 19 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 20 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
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- Page 22 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...