Lincoln Electric IM774 User Manual

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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

Copyright © 2006 Lincoln Global Inc.

World's Leader in Welding and Cutting Products

Sales and Service through Subsidiaries and Distibutors Worldwide

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

Safety Considerations

Table of Contents

Installation

Technical Specications .....................................................................................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

Declaration of Conformity for

European Community (CE) Products

Note This information is provided for units with CE certication (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

CobraMAX™ Owner's Manual - Page i

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

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SAFETY

ii

CobraMAX™ Owner's Manual - Page ii

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.

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SAFETY

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CobraMAX™ Owner's Manual - Page iii

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CobraMAX™ Owner's Manual - Page v