Lincoln KP1507-035A, KP1507-1-16A, KP1507-3-32A, KP1507-3-64A, KP1507-040A User Manual

Aluminum Drive Roll Kits

KP1507 Series

INSTALLATION INSTRUCTIONS

Table of Contents

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

General Description . . . . . . . . . . . . . . . . . . . . . .1

Contents of Kit . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Conduit & Bushing . . . . . . . . . . . . . . . . . . . . . .3

Drive Roll & Wire Guide . . . . . . . . . . . . . . . . . .4

Pressure Door Spring . . . . . . . . . . . . . . . . . . .5

Operation & Feeding Recommendations . . . . . .7

Fast Mate Guide Tubes . . . . . . . . . . . . . . . . . .7

Guns, Liners and Tips . . . . . . . . . . . . . . . . . . .8

IM614

October, 1997

SAFETY

Follow all safety guidelines in your power source and feeder operators manuals and any additional guidelines
covered in this manual.

GENERAL DESCRIPTION

The KP1507 series of drive roll kits contain a number of components, in addition to the drive rolls, to optimize the
wire feeder for aluminum feeding. These components are specifically designed to protect the aluminum wire
from abrasion and deformation, thereby avoiding many common aluminum feeding problems.

The provided plastic wire conduit and conduit bushing protect the wire from abrasion on it’s way into the wire
guides. The low friction plastic split wire guides protect the wire from abrasion, and support the wire as close as
possible to the drive rolls. The drive rolls have a special groove shape and finish. In addition, lower pressure
springs are provided for installation in the pressure door (except for kit KP1507-3/32A (2.4mm)). These springs
are optimized for aluminum feeding.

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KIT SIZES & CONTENTS

The table and figure below lists and illustrates the various K1507 series aluminum drive roll kits for the various
wire sizes. Also listed are the components included in each kit.

Drive Roll Kit KP1507-035A KP1507-040A KP1507-3/64A KP1507-1/16A KP1507-3/32A

Metric Wire Size 0,9 mm 1,0 mm 1,2 mm 1,6 mm 2,4 mm
English Wire Size .035 in .040 in 3/64 in (.047) 1/16 in (.063) 3/32 in (.094)

Included Items
1 Drive Rolls S22944-035A* S22944-040A* S22944-3/64A* S22944-1/16A* S22944-3/32A*

(Qty 4))

2 Inner Wire M18796-1 M18796-1 M18796-2 M18796-3 M18796-4

Guide

3 Outer Wire S22737-1 S22737-1 S22737-1 S22737-1 S22737-1

Guide

4 Conduit S23750-1 S23750-1 S23750-1 S23750-1 S23750-2

Bushing

5 Pressure T11862-57 T11862-57 T11862-57 T11862-57 Use Original

Spring

6 Knurled Knob S22933 S22933 S22933 S22933 S22933

Assembly

7 Flex Tube T10642-226 T10642-226 T10642-226 T10642-226 T10642-226

(Magnum Conduit)

8 Trust Washer T14043 T14043 T14043 T14043 T14043

(Qty 2)

9 1/8 Socket (T11563-2) (T11563-2) (T11563-2) (T11563-2) (T11563-2)

Key

10 5/32 Socket (T11563-5) (T11563-5) (T11563-5) (T11563-5) (T11563-5)

Key

11 7/64 Socket (T11563-6) (T11563-6) (T11563-6) (T11563-6) (T11563-6)

Key

*Drive rolls are packaged in quantities of 2 when ordered as a replacement part.

Item 1 Item 2 Item 3

Drive Rolls (Qty 4) Inner Wire Guide Outer Wire Guide

Item 4

Conduit Bushing

Item 5 Item 6

Pressure Springs (Qty 2) Knurled Knob Assembly

Item 7 Item 8

Conduit

Thrust Washers (Qty 2)

Figure 1 - Aluminum Drive Roll Kit Components

Items 9,10 & 11

Hex Keys

KP1507 SERIES ALUMINUM DRIVE ROLL KIT

2

INSTALLATION INSTRUCTIONS

Feed Head

Knurled Knob
Item 6

Conduit Bushing
Item 4

Set screw
location

Conduit
Item 7

WARNING

ELECTRIC SHOCK Can Kill

1. CONDUIT AND BUSHING
INSTALLATION

Refer to figure 2 and follow the following steps:

1. Turn off the welding power source.

• Only qualified persons should perform
this installation.

• Turn off the welding power source before installing
or changing drive rolls or guides.

• When inching with the gun trigger, the electrode and
drive mechanism are electrically “hot”.

------------------------------------------------------------------------

The installation instructions are divided into three sec­tions:

1. Conduit bushing and conduit installation

2. Drive roll and wire guide installation

3. Pressure door spring installation (all kits except
KP1507-3/32A).

Note: Installation of the included pressure door
springs is not required, but is recommended for opti­mum wire feeding performance.

Figure 2 - Conduit Bushing and Conduit Installation

2.Loosen the set screw which secures the existing
incoming guide bushing and remove the bushing.

3. Thread the thumb screw into the new bushing.

Install the new conduit bushing into the wire feed
head.

Recommended Conduit Length:
Power Feed 10 13.0 in. (330 mm) as provided
LN-10, STT-10 11.5 in. (290 mm)
DH-10 10.0 in (250 mm)
Power Feed 11 1.0 in (25 mm)

4. FOR LINCOLN CONDUIT: Measure the conduit

and cut to the desired length. A tubing cutter makes
the best cut. A hacksaw or utility knife may also be
used.

5. Back out the thumb screw from the bushing insert

the conduit. Tighten the thumb screw. The thumb
screw threads will lock the conduit in place.

KP1507 SERIES ALUMINUM DRIVE ROLL KIT

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