OTC CM-7401 Owner's Manual

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MANUAL NO:U5260

OWNER'S

MANUAL

FOR

WIRE FEEDER

MODEL: CM-7401 U5260

DO NOT DESTROY

IMPORTANT:

Read and understand the entire contents of this

manual, with special emphasis on the safety material throughout

the manual, 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.

ＤＡＩＨＥＮＣｏｒｐｏｒａｔｉｏｎ

WELDING PRODUCTS DIVISION

November 20, 2003

Upon contact, advise MODEL and MANUAL NO.

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Summary of Contents for OTC CM-7401

Page 1 MANUAL NO:U5260 OWNER'S MANUAL WIRE FEEDER MODEL: CM-7401 U5260 DO NOT DESTROY IMPORTANT: Read and understand the entire contents of this manual, with special emphasis on the safety material throughout the manual, 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.
Page 2: Table Of Contents
No. U5260 P. 1 / 27 TABLE OF CONTENTS 1. SAFETY INFORMATION･･････････････････････････････････････････････････････････ 2. ARC WELDING SAFETY PRECAUTIONS･･･････････････････････････････････････････ 3. CHECKING OF QUANTITY OF THE ACCESSORIES･･････････････････････････････････ 4. NAME OF PARTS･････････････････････････････････････････････････････････････････ 5. CARRYING AND INSTALLING OF THE WIRE FEEDER････････････････････････････････ 9 6. CONNECTION PROCEDURE･･･････････････････････････････････････････････････････ 10 7.
Page 3: Safety Information
No. U5260 P. 2 / 27 1. SAFETY INFORMATION The following safety alert symbols and signal words are used throughout this manual to identify various hazards and special instructions. WARNING gives information regarding possible personal injury WARNING or loss of life. CAUTION refers to minor personal injury or possible equipment CAUTION damage.
Page 4 No. U5260 P. 3 / 27 2. ARC WELDING SAFETY PRECAUTIONS (continued) ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuits are electrically live whenever the output is on. The power line and internal circuits of this equipment are also live when the line disconnect switch is on.
Page 5 No. U5260 P. 4 / 27 2. ARC WELDING SAFETY PRECAUTIONS (continued) 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.
Page 6 No. U5260 P. 5 / 27 2. ARC WELDING SAFETY PRECAUTIONS (continued) 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;...
Page 7 No. U5260 P. 6 / 27 2. ARC WELDING SAFETY PRECAUTIONS (continued) ARC WELDING work areas are potentially hazardous. FALLING or MOVING machine can cause serious injury. When hanging the welding power source by a crane, do not use the carrying handle. Put the welding power source and wire feeder solidly on a flat surface.
Page 8 No. U5260 P. 7 / 27 PRINCIPAL SAFETY STANDARDS Arc welding equipment – Installation and use, Technical Specification IEC 62081, from International Electro technical Commission Arc welding equipment Part 1: Welding power sources IEC 60974-1, from International Electro technical Commission Arc welding equipment Part 5: Wire feeder IEC 60974-5, from International Electro technical Commission Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society.
Page 9: Checking Of Quantity Of The Accessories
No. U5260 P. 8 / 27 3. CHECKING OF QUANTITY OF THE ACCESSORIES Make sure that you have the items below before you use the wire feeder. Wire feeder Wire feeder Accessory Description Specification Quantity Gas hose (3m) K5430A00 4. NAMES OF PARTS Refer to the page indicated in for details.
Page 10: Carrying And Installing Of The Wire Feeder
No. U5260 P. 9 / 27 5. CARRYING AND INSTALLING OF THE WIRE FEEDER 5.1 Transportation WARNING Observe the following to avoid damage to the wire feeder or physical injury when carrying the equipment. ● Do not touch the charging parts inside or outside the wire feeder. ●...
Page 11: Connection Procedure
No. U5260 P. 10 / 27 6. CONNECTION PROCEDURE CAUTION Follow the instructions below to avoid electric shock. ∗ Do not touch the charging parts, as this will result in fatal shock and severe burns. ● Do not touch the charging parts of the welding machine. ●...
Page 12 No. U5260 P. 11 / 27 6. CONNECTION PROCEDURE (continued) 8. Connect the water hose (condensed water) to the water connection (condensed water) of the back of wire feeder and the water connection (condensed water) in front of the water cooler. 9.
Page 13 No. U5260 P. 12 / 27 6. CONNECTION PROCEDURE (continued) 6.4 Connecting of the Gas Hose WARNING ● You may suffer from danger of suffocation caused by lack of oxygen when shield gas keeps drifting in a closed place. Be sure to turn off the shield gas at the main when the welding power source is not in use.
Page 14: Welding Preparation
No. U5260 P. 13 / 27 7. WELDING PREPERATION 7.1 Fitting of Wire 1. Loosen the screw to clamp the cap knob. 2. Detach the cap knob from the wire reel shaft. 3. Mount the wire reel on the wire reel shaft. NOTE: Check the positions of the wire reel stop pin and the wire reel stop hole to insert and fully seat the pin into the hole.
Page 15 Wire size mark Use the proper feed roll for the wire size. The feed roll of φ1.2 wire size is mounted on the CM-7401 wire feeder. Replacing of the feed roll 1. Remove the hexagon socket cap screws fixing the feed roll.
Page 16 No. U5260 P. 15 / 27 7. WELDING PREPERATION (continued) 7.3 Adjusting of the wire reel hub After performing inching operation, take care to adjust the brake of the wire reel hub to prevent the wire from going too slack. The bake has been properly adjusted before shipment. Therefore, readjustment of the brake is not required for welding in standard welding conditions.
Page 17 No. U5260 P. 16 / 27 7. WELDING PREPERATION (continued) WARNING Touching the charging parts may cause fatal electric shocks and burns. ● Never touch the charging parts in the wire and wire feeder. The parts indicated as in the figure are the charging parts during welding. Wire feeding parts Wire 7.5 Hanging the Wire Feeder...
Page 18: Maintenance And Troubleshooting
No. U5260 P. 17 / 27 8. MAINTENANCE AND TROUBLESHOOTING 8.1 Carrying Out Maintenance WARNING ● Do not touch the charging parts inside or outside the wire feeder. ● 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 carrying the equipment.
Page 19 No. U5260 P. 18 / 27 8. MAINTENANCE AND TROUBLESHOOTING (continued) < Schematic Diagram> 8.2 Replacing of the Outlet Guide Pressure handle Follow the procedures below when replacing the outlet guide. Torch socket 1. Bring down the pressure handle first, and then lift the pressure roll holder.
Page 20: Parts List
9.1 Main body and Wiring • Please contact your local dealer to order parts. (See the back cover for telephone and fax numbers, and mailing addresses.) Ref. Part number Description Q’ty Remarks CM-7401 U5260U00 Frame Assembly K970H90 Strike 4739-013 Support U5260C01...
Page 21 No. U5260 P. 20 / 27 9. PARTS LIST (continued) Fig. 1 Main Body and Wiring Assembly...
Page 22 No. U5260 P. 21 / 27 9. PARTS LIST (continued) 9.2 Wire Feeder Ref. Part number Description Q’ty Remarks U5185B01 Bracket None Hexagon socket cap screw M6 x 25 U5185B08 Coil screw U5185B02 Pressure roll holder pin U5185S00 Pressure roll holder (R) Assembly U5185T00 Pressure roll holder (L)
Page 23 No. U5260 P. 22 / 27 9. PARTS LIST (continued) Fig. 2 Wire Feeder Assembly...
Page 24 No. U5260 P. 23 / 27 9. PARTS LIST (continued) 9.3 Central Adapter Ref. Part number Description Q’ty Remarks BW0014 Plastic housing BW0014 None Set screw M8 x 8 AM6000 Euro central adaptor AM6000 U5204J04 Guide adaptor U5260J03 Feeder block None Hexagon Socket cap screw M8 x 25...
Page 25 No. U5260 P. 24 / 27 9. PARTS LIST (continued) 9.5 Optional Accessory (1) Extension cable/hose Power cable Applicable current (Rated current) 200 A 350 A 500 A Cable length Cable termination Model Model Model Connecto Connecto BKPDJ-3802 BKPDJ-6002** BKPDJ-8002 Connecto Connecto BKPDJ-3807...
Page 26 No. U5260 P. 25 / 27 9. PARTS LIST (continued) (2) Other Optional Parts Part number Description Q’ty Remarks K5463R02 Feed roll (1.0/1.2) for aluminum U5204B03 Center guide (1.0-1.6) for aluminum U2344C08 Pilot for aluminum aluminum kit U5204J07 Inlet guide for aluminum U5185P00 Gear...
Page 27: Specifications
No. U5260 P. 26 / 27 10. SPECIFICATIONS 10.1 Specifications Model CM-7401 (U5260) Mild steel 0.8 - 1.6 Stainless steel Applicable wire size Hard aluminum (1.0 - 1.6) Soft aluminum (1.2 - 1.6) Fire feeding rate Max. 22 m/min φ 50mm...
Page 28 No. U5260 P. 27 / 27 10. SPECIFICATIONS (continued)