Page 1
GMAW
Push-Pull Gun
OPERATOR'S MANUAL
IM774
MK 091-0525
December 2006
Rev. E
CobraMAX
™
Model numbers K2252-1 & K2252-2
Safety Depends on You
Lincoln arc welding 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.
OPERATOR’S MANUAL
Sales and Service through Subsidiaries and Distibutors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
Copyright © 2006 Lincoln Global Inc.
World's Leader in Welding and Cutting Products
Page 2
Page 3
Safety Considerations
Table of Contents
Installation
Technical Specications .....................................................................................1
Support Equipment Required .............................................................................1
Coolant Recommendations ................................................................................1
Gun Lead Connections ......................................................................................1
............................................................................... Section A
Operation .................................................................................Section B
General ..............................................................................................................2
Controls and Settings .........................................................................................2
Drive Roll and Idler Rolls....................................................................................3
Accessories .............................................................................Section C
Optional Kits .......................................................................................................4
Conduits .............................................................................................................4
Snake Skins .......................................................................................................4
Contact Tips .......................................................................................................5
Gas Cups ...........................................................................................................5
Maintenance ............................................................................Section D
Periodic Maintenance.........................................................................................6
Maintenance Tools ............................................................................................. 6
Recommended Spare Parts List ........................................................................6
Troubleshooting .......................................................................Section E
Troubleshooting Guide .......................................................................................8
Testing The Gun .................................................................................................8
Appendices ..............................................................................Section F
Diagrams / Parts List ..........................................................................................9
Mechanical .......................................................................................................10
Electrical...........................................................................................................15
Safety Warnings
Warranty
CobraMAX™ Owner's Manual
Page 4
Declaration of Conformity for
European Community (CE) Products
Note This information is provided for units with CE certication (see rating label on unit).
Manufacturer’s Name:
16882 Armstrong Ave.
Irvine, CA 92606
Declares that the product: CobraMAX
conforms to the following Directives and Standards:
Arc Welding Equipment Part I: Welding Power Sources: IEC 60974-1
MK Products, Inc.
™
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic Compatibility (EMC) Directive: 89/336/EEC
Standards
(September 1998 - Second Edition)
Arc Welding Equipment: Wirefeed Systems: IEC 974-5
(September 1997 - Draft Revision)
Degrees of Protection Provided by Enclosures (IP Code): IEC 529:1989
(November 1989 - First Edition)
Insulation Coordination For Equipment With Low-Voltage Systems:
Part I: Principles, Requirements and Tests: IEC 664-1: 1992
(October 1992 - First Edition)
Electromagnetic Compatibility, (EMC): EN 50199
(August 1995)
Torches And Guns For Arc Welding, EN 50078
CobraMAX™ Owner's Manual
Page 5
CobraMAX™ Owner's Manual - Page i
Page 6
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin o r wet clothing. Wear dry, ho le- free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
mu st b e p er forme d und er e lec tr ica ll y h az ard ou s
con ditions (i n damp loc ations or while wearing we t
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode re el, welding head, no zzl e or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Ne ver simult an eousl y touch electr ically “h ot” p arts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a. Weldi ng m ay p roduce fum es a nd g ases
hazardous to health. Avoid breathing these
fumes and gases. When weld ing , k eep
your head out of the fum e. U se e noug h
ventilation and/or exhaust at the arc to keep
fumes and gases away from the br eathing zo ne. When
we ldi ng with el ect ro des wh ich req ui re spe cia l
ve nti la ti on s uc h as s tainl es s or h ard f ac in g (se e
in st ru ct io ns o n c on ta in er o r M SD S) o r on l ea d o r
cadmium p lat ed steel an d other metals o r coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
us in g local e xh au st o r me ch anica l v entil at io n. I n
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
al so r equ ir ed w hen w eldin g on g alv an ize d st eel .
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause i nju ry or deat h. Al ways use enou gh vent ilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
ma ter ia l s afety data she et (MS DS ) a nd fol lo w y our
employerʼs safety practices. MSDS forms are available from
yo ur w eld in g d is tri bu tor o r fro m the m anufa ct ure r.
5.f. Also see item 1.b.
AUG 06
ii
SAFETY
ii
CobraMAX™ Owner's Manual - Page ii
Page 7
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Insta ll equip ment in acc ordance with the U. S. Natio nal
Electri cal Code, al l local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
CYLINDER may explode
if damaged.
7.a. Us e on ly com pr es se d ga s cy li nd er s
containing the correct shielding gas for the
pr ocess u sed a nd pr operl y ope ra ti ng
re gulat or s de si gn ed f or t he gas an d
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. A lwa ys ke ep cylin ders i n an up rig ht po sit ion se curel y
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode ho lder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. R ead and f ol low the i ns tructio ns on c ompre ss ed ga s
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
Jan, 07
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the we ldi ng spark s fr om st art ing a fire.
Re membe r th at we ld in g spa rk s an d h ot
materials from welding can easily go through small cracks
an d o pe nings to a dj acent ar ea s. Avoid we ld ing near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for th e
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
Co ntain er s a nd P ip in g T hat Hav e H el d H aza rd ou s
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glas ses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
inc rea se t he p oss ibility of the welding curre nt p ass ing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, availabl e
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
iii
SAFETY
iii
CobraMAX™ Owner's Manual - Page iii
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CobraMAX™ Owner's Manual - Page iv
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CobraMAX™ Owner's Manual - Page v
Page 10
Thank You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CobraMAX™ Owner's Manual
Page 11
Section A Installation
Technical Specications
Wire Capacity
.030" - .045" (0.6mm - 1.2mm) solid and hard wire
.030" - 1/16" (0.8mm - 1.6mm) aluminum and cored wire
Wire Speed
800 IPM (20.3 mpm) Max at rated feeder input voltage (120VAC / 42VAC)
Duty Cycle
All ratings are using Argon gas
200 Amps/25 Volts Air cooled - 60%
250 Amps/25 Volts Water cooled - 60%
Support Equipment Required
• C.V. or C.C. power source of sufcient capacity for your needs.
• Regulated gas supply and hoses.
• Properly sized power leads from power source to wire feeder and
ground.
• Water source and hose capable of providing a minimum of 1 quart
(.95 liter) / min. at 45 psi when using water cooled guns.
Coolant Recommendations
Use a name-brand additive, which does not contain reactive sulphur or
chlorine and does not react with copper, brass or aluminum or create a
custom mix using this formula:
Use 3 Gallons (11.4 Liters) Distilled water.
Use 1 Gallon (3.8 Liters) ethylene glycol.
Use 1 tsp (5 ml) liquid glycerin
The Coolant rate should be 1 quart (.95 liter) / minute at 35 p.s.i.
Gun Lead Connections
Power Cable - Air Cooled
A #2 AWG power cable is used on the CobraMAX™ air cooled gun. The gun
end is threaded into the gun body with torque requirments of 100+5 IN-LB.
The power cable tting connects to the power block in the Cobramatic® wire
feed cabinet.
Power Cable - Water Cooled
The CobraMAX™ water cooled gun utilizes a power/water cable with a #4
AWG cable inside a 5/8” (16MM) diameter hose. The gun end is threaded
into the gun body with torque requirements of 100+5 IN-LB.
IMPORTANT
Water cooled guns MUST be WATER cooled.
Conduit
The CobraMAX™ gun comes standard with a poly-lined conduit, for feeding
aluminum wire. The longer tting with a shallow groove is used on the gun
end. A set screw located on top of the gun handle secures the conduit in
place.
CobraMAX™ Owner's Manual - Page 1
Page 12
Gas Hose
The gas hose is secured over the barbed gas tting with a tie wrap. The
cabinet end of the gas hose uses our standard gas tting (1/8” - 27 nps).
Water Hose
If so equipped, one end of the water hose is secured over the barbed water
tting with a tie wrap and the other end is connected to the center tting on
the power block.
Electric Cable
A seven conductor control cable is used on the CobraMAX™ gun. The gun
end of the control cable is secured to the gun with a boot clamp and soldered
to the pot assembly, tirgger and water leads. Slack is left in the electric cable
as it exits the back of the gun to prevent cable breakage. The cabinet end
has a seven pin “W” clocked amphenol connector.
Section B Operation
General
The CobraMAX™ gun maintains a constant, steady, uniform wire feed speed,
regardless of curved or looped wire conduit. The constant push exerted
by the slave motor in the cabinet, combined with the pull of the gun motor,
causes the wire to literally oat friction-free through the wire conduit. The
24VDC gun motor is controlled by a three and three-quarter (3 3/4) turn
potentiometer in the gun handle.
Controls and Settings
Potentiometer
The laterally-positioned potentiometer is located in the lower end of the
handle, providing up to 800 ipm with 3 3/4 turns.
Micro Switch
The micro switch assembly consists of the micro switch and leads.
Trigger Sensitivity
The amount of trigger level travel can
be shortened for a "quicker" or "more
responsive" action.
A more sensitive trigger lever is
produced by reducing the gap between
the trigger lever and the micro switch
lever. By turning-in the trigger sensitivity
adjustment screw, it closed the gap
between the trigger lever and the micro
switch lever.
This will enable the operator to increase
the sensitivity of the trigger lever.
Sensitivity Adjustment
With the wire feeder turned on (with
or without welding wire loaded), turn
the screw in until the micro-switch is
activated. Once activated, the tortch and
wire feeder motors will begin feeding
wire. Retract the screw accordingly until
the system is deactivated and adjusted to
the operators' liking.
CobraMAX™ Owner's Manual - Page 2
Page 13
Drive Roll and Idler Rolls
General
The CobraMAX™ gun comes standard with a knurled drive roll and a grooved
idler roll, which will handle both steel and aluminum wire with diameters from
.030-1/16 inch. Optional insulated V-groove drive rolls are also available for
aluminum wire if desired (see optional kits).
Drive roll tension is accomplished with a unique spring-loaded pressure
screw. The CobraMAX™ comes from the factory with the pressure
adjustment screw preset. NO ADJUSTMENT IS REQUIRED FOR
ALL SIZES AND TYPES OF WIRES.
Drive Roll Installation/Removal
Note:
Neither of the handles needs to be removed to access the
drive or idler rolls
1. Pull the cam lever away from the idler roll. This will relieve the pressure
against the drive roll (as shown in Figure 1).
2. Align the drive roll removal tool (P/N 931-0100) over the ats of the drive
roll (as shown in Figure 2). Hold the gun with one hand or on a table
top, with the other hand give the removal tool a quick snap-turn in the
CLOCKWISE DIRECTION.
3. Once the drive roll is loose, continue to spin drive roll in the clockwise
direction to remove the drive roll from the gun.
4. Install a new drive roll on the left-hand threaded shaft. The drive roll will
self-tighten when it is feeding wire.
Cam Lever
Figure 1
Figure 2
Idler Roll Installation and Removal
(Reference Figure 3)
1. Using a slot type screwdriver, loosen idler screw, taking care not to lose
lock washer under idler roll.
2. Insert new idler roll and lock washer onto screw, insuring that idler groove
is toward top and lock washer is beneath.
Figure 3
3. Tighten.
NOTE: Lock washer must be under idler roll or it will not turn freely.
CobraMAX™ Owner's Manual - Page 3
Page 14
Section C Accessories LE P/N MK P/N
Optional Kits
Insulated Drive Roll Kits are used to prevent preheating of the wire which
may soften it and clog the liner. This picking up of current at the drive rolls
rather than at the contact tip is usually not a problem unless using too large
of a contact tip or excessively oxidized aluminum wire.
Insulated Groove Drive Roll Kit .......................... KP1594-030 ....... 005-0640
For .030" (0.8mm) dia. aluminum wire. Includes insulated groove drive roll
and insulated idler roll assy.
Insulated Groove Drive Roll Kit .......................... KP1594-035 ....... 005-0716
For .035" (0.9mm) dia. aluminum wire. Includes insulated groove drive roll
and insulated idler roll assy.
Insulated Groove Drive Roll Kit ................................. N/A .............. 005-0642
For .040" (1.0mm) dia. aluminum wire. Includes insulated groove drive roll
and insulated idler roll assy.
Insulated Groove Drive Roll Kit ......................... KP1594-3/64 ...... 005-0718
For 3/64" (1.2mm) dia. aluminum wire. Includes insulated groove drive roll
and insulated idler roll assy.
Insulated Groove Drive Roll Kit ......................... KP1594-1/16 ...... 005-0644
For .062" (1.6mm) dia. aluminum wire. Includes insulated groove drive roll
and idler insulated roll assy.
Replacement Kits
Handle Kit......................................................................................... 005-0700
Includes left and right handles, screws and drive roll door.
Trigger Kit..................................................................................... .... 005-0694
Trigger adjustment kit includes a spring and sensitivity adjustment screw
replacement for all Python®/CobraMAX™ guns.
Micro Switch Kit............................................................................... 005-0701
Replacement micro switch assembly for all Python®/CobraMAX™ guns.
Potentiometer Kit............................................................................. 005-0695
Replacement potentiometer assembly for all Python®/CobraMAX™ guns.
Barrel Insulator Kit .......................................................................... 005-0696
Replacement barrel insulator and taper lock nut.
Conduits
Flat spiral steel conduit for steel & cored wire
615-0208 ................................................................................... 15 ft./4.5m
615-0216 ................................................................................... 25 ft./7.6m
615-0218 ................................................................................. 50 ft./15.2m
Snake Skins
Snake Skin protective covers are now standard on all guns. You may order
spare replacement covers to protect the lead assy of the gun when the
factory one becomes damaged or worn. It can easily be replaced in the eld
by means of Velcro©.
Snake Skin Cover 13ft (for 15ft leads) ........................................931-0110
Snake Skin Cover 23ft (for 25ft leads) ....................................... 931-0122
Snake Skin Cover 48ft (for 50ft leads) ....................................... 931-0123
CobraMAX™ Owner's Manual - Page 4
Page 15
Contact Tips
Heavy Duty Contact Tip - 3/8" Diameter*
Wire Size Tip ID Arc Tip Length MK Part No LE Part No
.030” (0.8mm) .040” (1.0mm) Spray 1.57” (39.9mm) 621-0390-25 KP2217-1B1
Short 1.82” (46.2mm) 621-0396-25 --
.035” (0.9mm) .045” (1.1mm) Spray 1.57” (39.9mm) 621-0391-25 KP2217-2B1
621-0391-250
621-0391-500
.035" (0.9mm) .045" (1.1mm) Short 1.82” (46.2mm) 621-0397-25 --
.045" (1.1mm) .054" (1.37mm) Short 1.82” (46.2mm) 621-0398-25 --
3/64” (1.2mm)
(5356 Alloy)
.054” (1.37mm) Spray 1.57” (39.9mm)
621-0392-25 KP2217-3B1
621-0392-250
621-0392-500
3/64” (1.2mm)
(4043 Alloy)
.060” (1.5mm)
Spray 1.57” (39.9mm) 621-0393-25** KP2217-4B1
621-0393-250
621-0393-500
1/16” (1.6mm) .074” (1.9mm) Spray 1.57” (39.9mm) 621-0394-25 KP2217-5B1
.085” (2.16mm) Spray 621-0395-25
†
*
Use of tip removal tool is recommended
**This size tip furnished with gun
Also sold in quantities of 250
† †
Also sold in quantities of 500
†
††
†
††
†
††
Spring Loaded Tips
The use of the Spring Loaded Tips has shown to improve wire to tip
contact signicantly, especially while welding aluminum in DC Pulse Mode.
Incorporating a wrap-around spring material, a ceramic "puck" pushes up
against the wire forcing the wire to make 100% positive contact with the
internal face of the contact tip.
The constant touching of the wire to the tip eliminates "electrical gaps" in the
welding voltage sensing loop, which many welding power sources utilize for
sensing arc voltage values.
Spring Loaded Contact Tip - 3/8" Diameter*
Wire Size Tip ID Arc Tip Length MK Part No LE Part No
.030” (0.8mm) .040” (1.0mm) Spray 1.57” (39.9mm) 621-0331 KP2662-1
.035” (0.9mm) .045” (1.1mm) Spray 1.57” (39.9mm) 621-0332 KP2662-2
3/64” (1.2mm) .054” (1.37mm) Spray 1.57” (39.9mm) 621-0333 KP2662-3
3/64” (1.2mm) .060” (1.5mm) Spray 1.57” (39.9mm) 621-0334 KP2662-4
1/16” (1.6mm) .074” (1.9mm) Spray 1.57” (39.9mm) 621-0335 KP2262-5
*
Use of tip removal tool is recommended
Gas Cups
*standard - furnished with gun
Gas Cups
Cup Size Cup I.D. MK P/N LE P/N
No. 6 3/8" (9.5mm) 621-0420 KP2249-1
No. 8* 1/2" (15.8mm) 621-0421 KP2250-1
No. 10 5/8" (15.8mm) 621-0422 KP2251-1
CobraMAX™ Owner's Manual - Page 5
Page 16
Gun Barrel Liners
MK P/N LE P/N Description
615-0341
--
621-0423 KP2247-1 CobraMAX™ Tip Extender
615-0248
615-0177
--
--
931-0137 KP2226-1 Teon Liner Package, 5 pieces
Section D Maintenance
Periodic Maintenance
Your Cobramatic® System is designed to provide years of reliable service.
Maintenance of the gun will normally consist of a general cleaning of the wire
guide system, including barrel, drive rolls, and conduit at regular intervals
Remove spatter build-up from inside of nozzles with a hardwood stick.
The only parts on the Cobramatic® system that are subject to normal wear
are the conduit, contact tips, gas cups, front body liners, wire guides, drive
and idler rolls. A supply of these parts should be maintained on hand.
The number of units in operation and the importance of minimal “down time”
will determine to what extent spare parts should be stocked on hand. See
the “Recommended Spare Parts List” for the most commonly replaced parts.
If repairs do become necessary, qualied shop maintenance personnel can
easily replace any part.
Spiral Steel, .030 - .045" (0.8mm - 1.1mm)
Spiral Steel Liner for Tip Extender
Bulk Teon liner material for .030 - .035"
Maintenance Tools
Tool Part Number
Drive Roll Removal Tool 931-0100
Recommended Spare Parts List
Qty. Part No. Description
1
1
1
1 437-0253 Drive roll door
2 005-0694 Trigger assy kit
2 005-0695 Potentiometer assy kit
1 005-0700 Handle kit
2 005-0701 Micro switch assy kit
10
5
LE KP2072-30
MK 615-0601-15
LE KP2072-28
MK 615-0601-25
LE KP2072-29
MK 615-0601-50
LE KP2219-1
MK 511-0101
LE KP2220-1
MK 005-0686
Drive Roll Removal Tool
931-0100
Conduit - 15 ft
Conduit - 25 ft
Conduit - 50 ft
Drive roll
Idler roll kit
Knurled Drive Roll
LE P/N KP2219-1
MK P/N 511-0101
Idler Roll Kit
LE P/N KP2220-1
MK P/N 005-0686
CobraMAX™ Owner's Manual - Page 6
MICRO SWITCH ASSY
005-0701
Page 17
Section E Troubleshooting
Trouble Cause Remedy
115 VAC Control fuse in feeder/
No wire feed at gun,
feeder not operating, i.e., no
slave motor or brake solenoid.
No wire feed at gun, feeder
operating properly
Wire feeds, but welding wire is
not energized.
Wire feeds erratically.
Wire feeds one speed only.
Wire walks out of the drive
rolls.
Control box blown.
Micro-switch defective/not
being activated.
Broken electrical cable.
24 VAC Control fuse in feeder/
Control box blown.
Bad Potentiometer.
Broken Electrical Cable
Bad Speed control/PCB.
Loose or no cable connections. Check all power connections.
Contactor control cable loose or
in wrong position
Welding power source. Check power source.
Dirty or worn conduit. Blow out or replace conduit.
Wrong size contact tip. See contact tip table.
Idler roll stuck.
Bad potentiometer. Check with meter.
Broken electrical cable.
Bad speed control.
Idler roll upside-down.
Rear wire guide missing. Replace wire guide.
Replace fuse.
Replace switch. Check switch
for operation.
Check micro-switch wires for
continuity.
Check motor leads for shorts;
then replace fuse.
Check potentiometer with
meter.
Check motor and potentiometer
for continuity.
See specic cabinet/control
box owners manual for speed
control operation.
Check power supply owners
manual for location and type of
contactor signal required.
Check for lock washer under
idler roll, or replace if damaged.
Check potentiometer wires for
continuity or short.
See specic cabinet/control
owners manual for speed
control operation.
Place groove in idler roll toward
top.
CobraMAX™ Owner's Manual - Page 7
Page 18
Troubleshooting Guide
Regardless of which gun or feeder used, all MK Products’ push-pull guns
operate on the same principle. The slave motor in the feeder runs at a fast,
constant speed, but has very low torque. It is always trying to feed more wire
than the gun motor wants, and when the motor gets all it wants, it slows the
slave motor, preventing a bird’s nest. Because of the low torque produced by
the slave motor, a brake system is used to prevent wire overrun rather than
tension. The drag adjustment in the feeder is used simply to keep the wire
slightly taut, so it will not pull off the spool while feeding wire.
The high torque 24VDC gun motor is controlled by a solid state speed
control located in the feeder, and a pot located in the gun. The gun motor,
potentiometer, and micro switch are connected to the cabinet/control box via
a control cable and amphenol connector. If this cable becomes damaged, a
variety of symptoms can occur, depending on which wire(s) break. To test,
check each wire for continuity and shorts.
Remember, the micro switch in the gun activates both the slave motor and
gun motor circuits in the cabinet. Therefore, if the slave motor and brake
solenoid operate, but the gun does not, look more toward the gun motor’s
24V circuits, speed control, control cable, or the gun motor. If nothing
operates, look more toward the slave motor’s input, micro switch leads, or
micro switch.
Testing The Gun
Reference the "W" clocked gun wiring diagram on
the CobraMAX™ electrical diagram (in appendix) for information
about pin-outs and locations.
Motor Check
Remove the gun connector from the cabinet.
Using the gun amphenol connector, check the resistance across pins “A”
and “B” (motor leads). The resistance across the motor should be between
5 - 10 ohms as the potentiometer is turned.
If an open circuit or short exist, check the motor leads and motor
independently.
Testing the Potentiometer - “W” Clocked
Using the gun amphenol connector, check the resistance across pin “D”
(wiper) and pin “C”. The resistance should vary from 0 - 5K ohms as the
potentiometer is turned.
Check the resistance across pin “D” (wiper) and pin “G”. The resistance
should vary from 5K - 0 ohms as the potentiometer is turned.
Testing the Micro Switch
Using the gun amphenol connector, check for continuity across pins “E” and
“F” when the trigger is pressed.
CobraMAX™ Owner's Manual - Page 8
Page 19
Section F Appendices
Diagrams / Parts List
001-1420 CobraMAX™ Exploded View . . . . . . . . . . . . . . . . . . 12
003-2141 Front Body Assembly
Ultra-Flex Air Cooled Lead Assembly
. . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . 15
Water Cooled Lead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wiring Diagram
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CobraMAX™ Owner's Manual - Page 9
Page 20
CobraMAX™ Exploded View
100+5 IN-LB
TORQUE REQUIRES
APPLY ITEM 49 TO CONTACT SURFACES
APPLY ITEM 48 BEFORE INSTALLING
APPLY ITEM 45 TO CONTACT SURFACES
APPLY ITEM 46 TO THREADS
APPLY ITEM 47 TO THREADS
ITEMS 25 AND 44 NOT SHOWN FOR CLARITY
APPLY ITEM 45 TO THREADS
CobraMAX™ Owner's Manual - Page 10
Page 21
CobraMAX™ Parts List
Handle Kit: includes line items 18, 31,34,
and 37
1 005-0700
Tip HD Spray .060
1 1 Ref. 227 Series Ultra Flex Air Cooled Assembly 26 - -- --
1 1 Ref. 228 Series Ultra Flex Liquid Cooled Assembly 27 - -- --
2 1 002-0629 Assy Cam Idler Arm 28 1 421-0018 Dowel Pin 3/32 x 7/8 SST
3 1 002-0631 Brazed Rear Body 29 1 431-1549 Nut Drag Pot
No. Qty. Part No. Description No. Qty. Part No. Description
4 1 002-0635 Assy Brazed Barrel CobraMAX 30 1 003-2209 Wire Guide (includes item 16)
5 1 005-0695 Pot Assy Kit* 31 1 431-1622 Shoulder Screw 1/8 x 4-40
6 1 003-2125 Pot Knob Assy 32 1 431-1637 Hex Screw 3/8-20 x 3/8
7 1 005-0701 Micro Swx Assy Kit 33 1 431-3263 Locator Pot
8 1 003-2141 Assy CobraMAX Front Body 34 1 431-4054 Front Nut Cobra Gun
9 1 211-0077 Pitman Motor 35 1 435-1585 Strap Motor Python
11 12 303-0096 O-Ring .145 ID x .07 W 37 1 437-0253 Door Molded Python
10 1 003-2153 Gun Boot 36 1 003-0857 Trigger Assy
12 1 303-0540 O-Ring .426 ID x.07 W 38
CobraMAX™ Owner's Manual - Page 11
13 2 319-0254 Screw FH Phil 82 4-40 x 3/8 SST 39
16 1 321-0424 Set Screw 4-40 x .12 SST 42 1 621-0421 Assy Gas Cup #8 CobraMAX
14 1 319-0258 Screw FH Phil 82 4-40 x 5/8 SST 40 1 931-0137 5 Piece Telfon Liner Package
15 2 320-0084 Screw Button 4-40 x 3/16 ST 41 1 621-0393
17 1 321-1104 Set Screw Mod 43 0.30ft 737-0048 Tube Insulation 9AWG Clear
18 9 328-0012 Scr Shc 6-32 x 3/8 44 1 186-0102 Terminal block 2.5 nn, 4 pos
19 5 328-0025 Scr Shc 8-32 x 1/2 St. 45 A/R 823-0029 Naolox Compound
20 1 331-0311 Washer Flat 0.39 ID x 0.63 OD 46 A/R 823-0043 Thread Locking Cmpd Med Str
21 4 333-0005 Wshr Spr Lk #6 47 A/R 823-0050 Thread Locking Cmpd Low Str
22 4 333-0006 Wshr Spr Lk #8 48 A/R 835-0006 Silicon Lubricant
23 1 336-0020 Scr Ph Phil 4-40 x 5/16 SST 49 A/R 835-0011 Compound Grease
24 2 338-0153 Scr Shc 1-72 x 3/8 50 1 437-0268 MAX Pot Cover
25 5 411-0045 Tie Wrap
* Includes line items 12, 20, 29, and 33 assembled.
Page 22
003-2141 Front Body Assembly
NOTE: Items #3, 4, and 9
can be ordered together in
Kit LE P/N KP2220-1, MK
P/N 005-0686.
Front Body Assembly
No. Qty. Part No. Description
1 - - Not Available Separately
2 - - Not Available Separately
3 1 325-0206 SCR Ph 10-24-3/8
4 1 333-0082 Washer Lock 10
5 1 419-0092 Spring Comp 0.31 OD x 0.20 ID
6 1 421-0525 Pin Dowel 1/8 x 7/8 Sst
7 1 431-1663 Scr Adjust Idler
8 1 431-1598 Arm Idler
9 1
10 1
CobraMAX™ Owner's Manual - Page 12
LE KP2220-1
MK 005-0686
LE KP2219-1
MK 511-0101
003-2141
Assy Idler Wire Feed
Drive Roll
Page 23
Ultra-Flex Air Cooled Lead Assembly*
TORQUE REQUIRES
100+5 IN-LB
This power cable has a boot
that is common to many
assemblies but must be
removed from this end
when used on the
CobraMAX™.
*Leads shown for reference only
227 Series Ultra-Flex Cable Assemblies
Length Conduit Power Cable Electrical Cable Gas Hose Snake Skin
15"/4/5m 615-0601-15 001-2527 005-0690 001-0537 931-0110
25"/7.6m 615-0601-25 001-2528 005-0691 001-0538 931-0122
50'/15.2 615-0601-50 001-1042 005-0692 001-0665 931-0123
®
CobraMAX™ Owner's Manual - Page 13
Page 24
Water Cooled Lead Assembly*
This power cable has a boot
that is common to many
assemblies but must be
removed from this end
when used on the
CobraMAX™.
TORQUE REQUIRES
100+5 IN-LB
*Leads shown for reference only
228 Series Ultra-Flex Cable Assemblies
Length Conduit #4 Power/Water
15'/4.5m 615-0601-15 001-2521 005-0690 001-0537 001-0529 931-0110
25'/7.6m 615-0601-25 001-2524 005-0691 001-0538 001-0530 931-0122
50'/15.2m 615-0601-50 843-0338 005-0692 001-0665 001-0667 931-0123
Electrical
Cable
CobraMAX™ Owner's Manual - Page 14
Cable
Gas Hose Water Hose Snake Skin
®
Page 25
A
F
G
E
D
C
B
"W" Clocked
Amphenol Connector
Viewed from front of connector
E
C
A
B
D
G
F
+
-
TORCH
MOTOR
TORCH
POT
TORCH
TRIGGER
5K
Red
Red
Black
Black
Blue
Blue
Yellow
Yellow
Brown
Brown
White
White
Green
Green
1
3
2
Cabinet End
Amphenol Connector
Torch Functions
Torch Lead
CobraMAX™ Electrical
CobraMAX™ Owner's Manual - Page 15
Page 26
CobraMAX™ Owner's Manual - Page 16
Page 27
CobraMAX™ Owner's Manual - Page 17
Page 28
LIMITED WARRANTY
Effective October 1, 2006
This warranty supersedes all previous MK Products warranties and is
exclusive, with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY - MK Products Inc., Irvine, California
warrants that all new and unused equipment furnished by MK
Products is free from defects in workmanship and material as of
the time and place of delivery by MK Products. No warranty is
made by MK Products with respect to trade accessories or other
items manufactured by others. Such trade accessories and other
items are sold subject to the warranties of their respective manufacturers, if any.
MK Products’ warranty does not apply to components having
normal useful life of less than one (1) year, such as relay points,
wire conduit, tungsten, and welding gun parts that come in contact
with the welding wire, including gas cups, gas cup insulators, and
contact tips where failure does not result from defect in workmanship or material.
MK Products shall, exclusively remedy the limited warranty or
any duties with respect to the quality of goods, based upon the
following options:
(1) repair
(2) replacement
(3) where authorized in writing by MK Products, the reasonable
cost of repair or replacement at our Irvine, California plant.
As a matter of general policy only, MK Products may honor an
original user’s warranty claims on warranted equipment in the event
of failure resulting from a defect within the following periods from
the date of delivery of equipment to the original user:
1. Power Supplies and Wire Feed Cabinets ....... 3 years
2. Weldheads, Positioners, Prince XL and Prince XL
Spool Guns, Python, CobraMAX, Cobra SX, Cobra MX
......................................................................... 1 year
3. Sidewinder® Spool Gun, Prince SG Spool Guns,
Modules .......................................................180 days
4. Repairs/Exchanges/Parts ............................90 days
Classication of any item into the foregoing categories shall be at
the sole discretion of MK Products. Notication of any failure must
be made in writing within 30 days of such failure.
A copy of the invoice showing the date of sale must accompany
products returned for warranty repair or replacement.
All equipment returned to MK Products for service must be properly
packaged to guard against damage from shipping. MK Products
will not be responsible for any damages resulting from shipping.
Normal surface transportation charges (one way) for products
returned for warranty repair or replacement will be borne by MK
Products, except for products sold to foreign markets.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY, OR REPRESENTATION AS TO
PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT
WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE, OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE, WITH
RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MK PRODUCTS, IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS.
EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING, MK’s PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE
BY COMMERCIAL/INDUSTRIAL USERS AND FOR OPERATION BY
PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS
OR CONSUMER USE. MK PRODUCTS’ WARRANTIES DO NOT
EXTEND TO, AND NO RE-SELLER IS AUTHORIZED TO EXTEND
MK PRODUCTS’ WARRANTIES TO ANY CONSUMER.
USE O F O T HER T HAN
CONSUMABLES,
YOUR PRODUCT WARRANTY.
PARTS, AND ACCESSORIES MAY INVALIDATE
GENUINE
M K P R O D U C TS’
MK Products, Inc.
16882 Armstrong Ave.
Irvine, CA 92606
Tel (949)863-1234
Fax (949)474-1428
Sales and Service through Subsidiaries and Distibutors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
October 1, 2006
Copyright © 2006 Lincoln Global Inc.
World's Leader in Welding and Cutting Products
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