Daihen OTC CM-741U Owner's Manual
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Daihen OTC CM-741U Owner's Manual

Daihen OTC CM-741U Owner's Manual

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MANUAL NO: U30007
OWNER'S
MANUAL
FOR
WIRE FEEDER
MODEL: CM-741U 1U30007
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.
DAIHEN Corporation
WELDING PRODUCTS DIVISION
June22, 2011
Upon contact, advise MODEL and MANUAL NO.
4-1-063-2

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  • Page 1 Do not allow untrained persons to install, operate or maintain this equipment. Contact your distributor if you do not fully understand this manual. DAIHEN Corporation WELDING PRODUCTS DIVISION June22, 2011 Upon contact, advise MODEL and MANUAL NO.
  • Page 2 Notice : Machine export to Europe This product does not meet the requirements specified in the EC Directives which are the EU safety ordinance that was enforced starting 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.

  • Page 3: Table Of Contents

    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 ･････････････････････････ 6. CONNECTION PROCEDURE ･･･････････････････････････････････････････････････ 7. WELDING PREPARATION ･･････････････････････････････････････････････････････ 8.

  • Page 4: Safety Information

    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 5 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 6 2. ARC WELDING SAFETY PRECAUTIONS (continued) WELDING can cause fire and explosion. Sparks and spatter fly off from the welding arc. The flying sparks, 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 7 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 handle them carefully. Use only correct shielding gas cylinders, gas regulator, hoses, and fittings designed for the specific application;...
  • Page 8 2. ARC WELDING SAFETY PRECAUTIONS (continued) ARC WELDING work areas are potentially hazardous. FALLING or MOVING machines can cause serious injury. 1. When hanging the welding power source by a crane, do not use the carrying handle. 2. Put the welding power source and wire feeder solidly on a flat surface. 3.
  • Page 9 PRINCIPAL SAFETY STANDARDS Arc welding equipment – Installation and use, Technical Specification IEC 62081, from International Electro technical Commission Arc welding equipment Part 5: Wire feeders IEC 60974-5, from International Electro technical Commission Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.

  • Page 10: Checking Of Quantity Of The Accessories

    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 ① Description Specification Quantity ② Gas hose (9.8ft [3m]) U5971R00 ③ Switch cord U5971S00 ④...

  • Page 11: Carrying And Installing Of The Wire Feeder

    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 ● Do not touch the charging parts inside or outside of the wire feeder. ●...
  • Page 12 5. CARRYING AND INSTALLING OF THE WIRE FEEDER(continued) WARNING When using the wire feeder at a high place or in hung condition, observe the following ● For hanging the wire feeder, use a metal hanger structured to prevent falling and hang the precautions to prevent serious personal injury due to fallen wire feeder or wire reel.

  • Page 13: Connection Procedure

    6. CONNECTION PROCEDURE CAUTION Follow the instructions below to avoid electric shock. ● Do not touch the charging parts of the welding machine. ● Have a qualified electric engineer ground the case of the welding power source and the Do not touch the charging parts, otherwise this will result in fatal shock and severe burns. ∗...
  • Page 14 6. CONNECTION PROCEDURE (continued) 6.2 Connection of the Torch Cable WARNING ● Do not touch the charging parts of the welding machine. ● Have a qualified electric engineer ground the case of the welding power source and the Touching the charging parts may result in fatal electric shock and severe burns. ∗...
  • Page 15 6. CONNECTION PROCEDURE (continued) 6.4 Connection of the Gas Hose ● You may suffer from danger of suffocation caused by lack of oxygen when WARNING 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 16: Welding Preparation

    7. WELDING PREPERATION 7.1 Fitting of Wire ● When the wire is set on the wire reel shaft, fully tighten the cap to prevent falling. WARNING ● In case a breakage, crack or deformation is found in the wire reel shaft or cap, do not use but replace it.
  • Page 17 7. WELDING PREPERATION (continued) 7.2 Mounting of the Feed Roll Groove for 0.045in [1.2mm] wire size The feed roll of φ0.045in [1.2mm] wire size is mounted on the Confirmation of the wire size marked on the feed roll Use the right groove of the feed roll for the wire size. Wire size mark CM-741 wire feeder when shipping.
  • Page 18 7. WELDING PREPERATION (continued) Adjusting of the wire pressure and straightener • Set to the 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 handle.
  • Page 19 7. WELDING PREPERATION (continued) 7.4 Feeding Wire by Inching Operation ● Do not look into the tip hole to check for the rate of wire feeding while inching. WARNING ● Keep away your hands, fingers, hair or clothes from the rotating parts of the feed CAUTION roll, etc.
  • Page 20 7. WELDING PREPERATION (continued) 7.5 Hanging the Wire Feeder ● When hanging the wire feeder, firmly fix the CAUTION Hanging bracket (optional) ● Do not use the carrying handle of the wire cap knob and clamp screw to prevent the device from dropping.
  • Page 21 7. WELDING PREPERATION (continued) How to attach the hanging bracket 1. Remove hexagon head bolt (M10X16) and Nut (M8) (3pieces) and remove the wire reel hub from the reel bracket. 2. Disassemble the wire reel hub, replace hexagon head bolt (M8X16) (3 pieces) with hexagon head bolt (M8X25) (3 pieces) of the hanging bracket accessory and reassemble the wire reel hub to its original condition.

  • Page 22: Maintenance And Troubleshooting

    8. MAINTENANCE AND TROUBLESHOOTING 8.1 Carrying Out Maintenance ● Do not touch the charging parts inside or outside of the wire feeder. WARNING ● Disconnect the welding power source by turning off the line disconnect switch in the power box to avoid an electric shock before carrying the equipment. Problem Cause Solution...
  • Page 23 8. MAINTENANCE AND TROUBLESHOOTING (continued) <Schematic Diagram> Base metal direct detection (-) ● Never attempt to disassemble the feed motor. This may result in damage to the wire feeder. CAUTION ● Never check the amount of brushing friction or replace the brush. Service life of the brush varies depending on ambient temperature and welding condition, etc., but normally the service life is about 4,000 hours.

  • Page 24: Parts List

    9. 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 U5185U00 Frame Assembly K970H90 Strike 4739-013 Support U5185C01...
  • Page 25 9. PARTS LIST (continued) Fig. 1 Main Body and Wiring Assembly － 23 － ―23―...
  • Page 26 9. PARTS LIST (continued) 9.2 Wire Feeder Ref. Part number Description Q’ty Remarks U5209B01 Bracket None Hexagon socket cap screw M6 x 30 U5185B08 Coil spring U5185B02 Pressure roll holder pin U5185S00 Pressure roll holder (R) Assembly U5185T00 Pressure roll holder (L) Assembly K5439C00 Pressure roll...
  • Page 27 9.PARTS LIST (continued) Fig. 2 Wire Feeder Assembly 9.3 Gas Piping Assembly Ref. Part number Description Q’ty Remarks 4813-001 Gas solenoid valve W-31156 U4179D01 Hose elbow U5971G01 Gas connector U1997D02 Flange Fig. 3 Gas Piping Assembly － 25 － ―25―...
  • Page 28 9. PARTS LIST (continued) 9.4 Optional Accessory (1)Extension cable/hose Control cable (10P) Cable length 16ft [5m] 33ft [10m] 49ft [15m] 66ft [20m] Model BKCPJ-1005 BKCPJ-1010 BKCPJ-1015 BKCPJ-1020 Gas hose 5/8-18 (Gas hose (φ6xφ13mm)) 5/8-18 Nozzle Nozzle Gas nut Gas nut Part No.
  • Page 29 9. PARTS LIST (continued) (3) Outlet guide, center guide, pilot Part No. Description Q’ty Remarks K5735B01 Outlet guide NO.4 (0.6-0.9) For steel (.023”-035”) K5735B03 Outlet guide NO.4 (1.2-1.6) For steel (.045”-1/16”) K5735B13 Outlet guide NO.5 (1.2-1.6) For steel (.045”-1/16”) K5735B21 Outlet guide NO.4 (AL1.0) For aluminum (.040”), black K5735B22...
  • Page 30 9. PARTS LIST (continued) (5) Torch adapter kit #5－1. 2－１．6 (1-1) (1-2) (1-3) #5－AL1. 2 Ref. No. Part No. Description Q’ty Remarks K5735C00 Torch adapter kit The following parts are contained. Torch adapter for “NO.5” K5735B13 Outlet guide NO.5 (1.2-1.6) For steel (.040”-1/16”) K5735B32 Outlet guide NO.5 (AL1.2) For aluminum (3/64”), black...
  • Page 31 9. PARTS LIST (continued) － 29 － ―29―...

  • Page 32: Specifications

    10. SPECIFICATIONS 10.1 Specifications Model CM-741U inch (.024”)*, (.030”), .035”, .040”, .045”, (.052”), (1/16”) Applicable wire size (0.6)*, (0.8), 0.9, 1.0, 1.2, (1.4), (1.6) 1.97” φ [ 50mm φ ] Wire feeding rate Max. 72.2 ft/min [ 22m/min ] Max. 11.8” φ [ 300mm φ ] Shaft diameter Applicable wire reel External diameter...
  • Page 33 SPECIFICATIONS (continued) － 31 － ―31―...
  • Page 34 DAIHEN Corporation 4-1, Koyocho-nishi, Higashinada-ku, Kobe, Hyogo 658-0033 Phone: +81-78-275-2006, Fax: +81-78-845-8159 DAIHEN, Inc. DAYTON OFFICE 1400 Blauser Drive Tipp City, Ohio 45371, USA Phone: +1-937-667-0800, Fax: +1-937-667-0885 OTC DAIHEN EUROPE GmbH Krefelder Strasse 675-677, D-41066 Mönchengladbach, GERMANY Phone: +49-2161-6949710, Fax: +49-2161-6949711 OTC Industrial (Shanghai) Co.,Ltd.

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