Daihen OTC CM-7401 Owner's Manual
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Daihen OTC CM-7401 Owner's Manual

Daihen OTC CM-7401 Owner's Manual

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MANUAL NO:U5279
OWNER'S
MANUAL
FOR
WIRE FEEDER
MODEL: CM-7401 U5279
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
November 20, 2003
Upon contact, advise MODEL and MANUAL NO.

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  • Page 1 MANUAL NO:U5279 OWNER'S MANUAL WIRE FEEDER MODEL: CM-7401 U5279 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. U5279 P. 1 / 25 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････････････････････････････････ 7 6. CONNECTION PROCEDURE･･･････････････････････････････････････････････････････ 8 7.

  • Page 3: Safety Information

      No. U5279 P. 2 / 25 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. U5279 P. 3 / 25 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. U5279 P. 4 / 25 2. ARC WELDING SAFETY PRECAUTIONS (continued) Rotating parts may cause injuries. Be sure to observe the following. If hands, fingers, hair or clothes are put near the fan’s rotating parts or wire feeder’s feed roll, injuries may occur.
  • Page 6 No. U5279 P. 5 / 25 PRINCIPAL SAFETY STANDARDS Arc welding equipment – Installation and use, Technical Specification IEC 62081, from International Electrotechnical 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. Government Printing Office.

  • Page 7: Checking Of Quantity Of The Accessories

      No. U5279 P. 6 / 25 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 ① Gas hose (3m) K5430A00 ②...

  • Page 8: Carrying And Installing Of The Wire Feeder

    No. U5279 P. 7 / 25 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. ● 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 9: Connection Procedure

      No. U5279 P. 8 / 25 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. ● Have a qualified electric engineer ground the case of the welding power source and the base metal or jig electrically connected, following a local low.
  • Page 10 No. U5279 P. 9 / 25 6. CONNECTION PROCEDURE (continued) 6.2 Connecting of the Torch Cable WARNING ∗ Touching the charging parts may result in fatal electric shock and severe burns. ● 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 base metal or jig electrically connected in accordance with a local low.
  • Page 11   No. U5279 P. 10 / 25 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 12: Welding Preparation

    No. U5279 P. 11 / 25 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 13   No. U5279 P. 12 / 25 7. WELDING PREPERATION (continued) 7.2 Mounting of the Feed Roll Groove forφ1.2 wire size Confirming of the wire size marked on the feed roll 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-701 wire feeder.
  • Page 14 No. U5279 P. 13 / 25 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 15   No. U5279 P. 14 / 25 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 16: Maintenance And Troubleshooting

    No. U5279 P. 15 / 25 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 17   No. U5279 P. 16 / 25 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. 1. Bring down the pressure handle first, and then lift the Torch socket pressure roll holder.

  • Page 18: Parts List

    No. U5279 P. 17 / 25 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 CM-7401 U5185U00...
  • Page 19   No. U5279 P. 18 / 25 9. PARTS LIST (continued) Fig. 1 Main Body and Wiring Assembly...
  • Page 20 No. U5279 P. 19 / 25 9. PARTS LIST (continued) 9.2 Wire Feeder Ref. Part number Description Q’ty Remarks U5185B00 Bracket Hexagon socket cap M6 x 25 screw U5185B08 Coil screw Pressure roll holder U5185B02 Pressure roll holder U5185S00 Assembly Pressure roll holder U5185T00 Assembly...
  • Page 21   No. U5279 P. 20 / 25 Fig. 2 Wire Feeder Assembly...
  • Page 22 No. U5279 P. 21 / 25 9. PARTS LIST (continued) 9.3 Central Adapter Ref. Part number Description Q’ty Remarks U5185D01 Power metal U5185D02 Outlet guide (0.9-1.2) E-snap ring 3361-405 E-snap ring K3985E03 Block U5185D03 Feeder block Hexagon Socket cap M8 x 25 screw U5185D04 Small nut...
  • Page 23   No. U5279 P. 22 / 25 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 CSRT CSRT BKPT-3802 BKPT-6002 BKPT-8002 CSRT Connecto...
  • Page 24 No. U5279 P. 23 / 25 9. PARTS LIST (continued) (2) Other Optional Parts Part number Description Q’ty Remarks K5439B01 Feed roll (1.4/1.6) K5439B03 Feed roll (0.8/0.9) K5439B04 Feed roll (1.2/1.4) K5439B05 Feed roll (1.2/1.2) K5439B06 Feed roll (1.4/1.4) K5439B07 Feed roll (1.6/1.6) K5439B08 Feed roll (0.9/1.2)

  • Page 25: Specifications

      No. U5279 P. 24 / 25 10. SPECIFICATIONS 10.1 Specifications Model CM-7401(AIR COOLING) Applicable wire size (0.6)*, (0.8), (0.9), 1.0, 1.2, (1.4), (1.6) Wire Solid wire, Flux cored wire Fire feeding rate Max. 22 m/min φ 50mm Applicable wire reel Shaft diameter Max.
  • Page 26 No. U5279 P. 25 / 25 10. SPECIFICATIONS (continued)

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