Lincoln Electric IM865 User Manual

IM865

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TANDEM MIG 800 AMPERAGE WELDING TORCH

February, 2005

Safety Depends on You

Lincoln arc welding and cutting
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.

Models:

S22693-121, -122, -123, -124, -133

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

OPERATOR’S MANUAL

Copyright © 2005 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii

SAFETY

ii

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 or wet clothing. Wear dry, hole-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
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
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 reel, welding head, nozzle 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.

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.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

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. Never simultaneously touch electrically “hot” parts 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.

5.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

vapors

Mar ‘95

to

iii

SAFETY

iii

WELDING 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 welding sparks from starting a fire.

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding 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 the
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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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 glasses 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
increase the possibility of the welding current passing
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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
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 holder 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. Read and follow the instructions on compressed gas
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.

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. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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___________________________________________________________________________

vv

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

“Product Registration”. Please complete the form and submit your registration.

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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.

vi

TABLE OF CONTENTS

Page

Installation………………………………………………………………...……...…….Section A

Technical Specifications...............................................................................................A-1

General Description .....................................................................................................A-2

Torch Mounting …....…………………………………………………..…...…………..……A-2

Liner Installation ..………………………………………………………..……………..……A-2

Contact Tip and Diffuser Installation.....……………………………………..………….…A-3

Connecting the Torch to the Welding Equipment ..…….………………………..……….A-3
Contact Tip Selection ..……………………………………………………..………….……A-3

Contact Tip Size...........................................................................................................A-4

Wire Straighteners.………………………………………………………..…………………A-4

Operation ........................................................................................................... Section B

Electrodes and Equipment ...........................................................................................B-1

Making a Weld .............................................................................................................B-1

Avoiding Wire Feeding Problems.................................................................................B-1

Shielding Gas Delivery.................................................................................................B-1

Air Blast Cleaning.........................................................................................................B-1

Nozzle Reaming...........................................................................................................B-2

Anti-spatter Spray ........................................................................................................B-2

Maintenance .………………………………………………………………..….…..…Section C

Contact Tip Replacement ............................................................................................C-1

Liner Replacement.......................................................................................................C-1

Contact Tip Alignment..................................................................................................C-2

Torch Dimensional Print...............................................................................................C-3

Torch Alignment Tool (L10430-1) Dimensional Print ...........................................C-4, C-5

Trouble Shooting................................................................................................Section D

Safety Precautions......................................................................................................D-1

How to use Troubleshooting Guide.............................................................................D-1

Troubleshooting Guide................................................................................................D-2

Parts List .....................................................................................................................P520

vi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Tandem MIG Torch (800 amp)

Tandem MIG Torch Cable Length Availability

Product number

Torch Cable length

Shipping weight

A-1

S22693-121

S22693-122

S22693-123

S22693-124

S22693-133

10 ft cable assembly

8 ft cable assembly

6 ft cable assembly

4 ft cable assembly

12 ft cable assembly

28.6 lbs.

25.2 lbs.

21.8 lbs.

18.4 lbs.

32.0 lbs.

Shielding Gas Flow Rate

Minimum 35 scfh / electrode (70 scfh total) Maximum 70 scfh / electrode (140 scfh total)

Water Cooling

Flow rate: Minimum 0.45 gal/min Flow pressure: Minimum 40 psi

Lead Electrode size

0.035" to 0.062" diameter

Trail Electrode size

0.035" to 0.062" diameter

Duty Cycle

350 amps at 100% per electrode / 700 amps total

400 amps at 60% per electrode / 800 amps total

Maximum current draw per electrode 500 amps

Torch and Cable assembly weights

Torch body: 6.8 lbs (cables elevated 1 ft above torch body, 4ft from torch body)

800 AMP TANDEM MIG TORCH

A-2

INSTALLATION

A-2

GENERAL DESCRIPTION

The Tandem MIG 800 Amp Welding Torch is
designed to deliver two wire electrodes to a single
weld pool. The wire electrodes are electrically isolated
from one another providing independent parameter
control of both electrodes. The torch has two separate
wire spacing options. The torch is designed primarily
for robotic applications utilizing wire electrodes in the
diameters of .035 through .062 inches. Torch ratings
are based on the use of shielding gas mixtures con­taining a minimum of 82% argon gas.

The torch is designed for easy maintenance.
The aluminum construction of the gooseneck outer
jacket and mounting /clamping assemblies defines the
lightweight low profile of the torch. The long goose­neck design is provided for ease of robot program­ming for access to restricted welding joints.
A single water-cooling source to circulate water
through the nozzle assembly establishes torch cool­ing. The aluminum mounting and clamping assembly
serves as an added cooling feature providing a heat
sink to draw heat from the contact tip area and goose­necks.

For hard automation applications and for use with
robots that do not have collision sensing software, a
heavy-duty collision sensor is recommended
(M17809).

The collision sensor must be of proper rating to
withstand the high inertia stopping and starting associ­ated with robot high-speed motion without tripping the
sensor.

LINER INSTALLATION

1. Lay the torch and cable on a flat surface and
extend cables straight.

2. Remove contact tip and diffuser.

3. With cables straightened, loosen 3/8" liner nut
from power pin. Grip liner with pliers and slowly
remove.

Power Pin

3/8" Liner Nut

The torch may be operated as either a Tandem con­figuration with two wire electrodes, or as a single wire
torch for special applications. Because of the size of
the Tandem MIG nozzle, during single wire operation
gas delivery through both diffusers is required.

TORCH MOUNTING

The torch mounting arm is an integral part of the torch
mounting and clamping assembly, and should not be
removed or altered. The mounting arm is designed to
place the welding arc at the center line of a robot
mounting plate for programming ease. The arm is fur­nished with a .647" hole for inserting a S22637 torch
mounting locking wedge. The mounting wedge is
designed to secure the torch to a common .75 " diam­eter torch collision sensor shaft.

Due to the weight of the torch and rapid movement of
many robotic applications it is recommended that a
rigid mount be used to secure the torch to a robot
arm. The rigid mount S22693-172 is to be used in
conjunction with robot collision sensing software.

4. With dry compressed air blow cable cavity free of
any accumulated dust or filings.

5. Feed replacement liner through cable assembly
using short strokes to avoid kinking. Twist liner
clockwise if necessary.

6. Seat liner retainer O-ring to inside shoulder bore

of power pin by tightening the 3/8" liner nut.

7. Replace diffusers, tighten securely.

8. With liner extending through torch body (contact
tip removed), trim liner to a 5/16" length.

5/16 "
Extension

NOTE: The S22693-172 rigid mount is a dummy colli­sion sensor. It is not designed to sense a torch colli­sion. For proper operator and equipment protection
the S22693-172 rigid mount should only be used in
conjunction with robotic arm collision sensing soft­ware.

800 AMP TANDEM MIG TORCH

9. Remove any burr from end of liner that may
obstruct wire feeding.

10. Replace contact tip and gas nozzle.

A-3

INSTALLATION

A-3

CONTACT TIP AND DIFFUSER
INSTALLATION

The welding torch is equipped with specially designed
diffusers. The diffuser is of a low profile design to
accommodate the Tandem torch design. The diffuser
is required to provide a current path to the contact tip
and must be secured tightly. The diffuser also serves
as a means to seat and secure the Nozzle Retainer
Insulator. Be sure that the Nozzle Retainer Insulator is
in good condition before replacing the diffusers. Once
it is determined that the insulator is in good condition,
place the insulator against the Retainer Assembly with
the recessed diffuser seating area facing away from
the Retainer Assembly.

Retainer
Assembly

Nozzle
Retainer
Insulator

Shielding gas delivery must be provided for both the
lead and trail wire electrodes. Gas is delivered to the
diffuser area through the unicable conductor cable
attached to each wire feeder. A 10-inch gas hose
assembly with 5/8-18 barred inert gas fitting is provid­ed with the wire feeder. The fitting is to be threaded
into the wire feeder female gas outlet fitting. The gas
hose should be slid on to the barbed nipple on the
torch power pin. Using clamp provided, clamp hose to
barbed torch power pin fitting Slide, second clamp
over loose end of hose. Slide the loose end of hose
over the barbed pin at wire feeder gas outlet. Clamp
hose to barbed pin.

CONTACT TIP SELECTION

The torch is configured to accept two different diffuser
and contact tip designs, a taper lock contact tip and
diffuser and a conventional full threaded contact tip
and diffuser design. As standard, the Tandem MIG
800 Amp Welding Torch is supplied with taper lock dif­fusers.

Taper Lock System

Recessed
Diffuser

Diffuser

Center insulator on gooseneck end and begin thread­ing diffuser (clockwise) in place, tighten securely. The
contact tip must be firmly tightened to insure proper
current conduction and electrode extension distance.

Seating
Area

TORCH CONNECTION TO WIRE FEEDER

The Tandem MIG torch is furnished with a power pin
connection designed for direct installation to Lincoln
wire feeders: series Synergic 7 and Power Feed 10
Robotic Wire Feeder. (Power Feed 10 Robotic Wire
Feeders require installing a K1500-1 gun connector
prior to mounting torch.)

Seat the power pin of the welding torch into the power
block of the feeder until tight against power pin shoul­der. Secure in place with the locking screw provided
with the wire feeder. Welding current of the lead wire
feeder and the trail wire feeder is isolated through the
length of the torch.

Increased
Current
Conducting
Area

The taper lock system features a contact tip and dif­fuser design that allows for more surface contact
between the contact tip and the diffuser. The added
contact surface provided by the tapering of the seating
areas of the contact tip and diffuser provides an
enlarged current carrying path. The taper system is
designed to provide cooler operation and longer con­tact tip service life.

Contact tips have a dual thread starting point at 180
degrees from one another. The dual thread starting
points encourages quick installation and the ability to
rotate the contact tip 180 degrees for a longer life
cycle.

800 AMP TANDEM MIG TORCH

A-4

INSTALLATION

CONTACT TIP SIZE

Contact tips are available in standard sizes to match
the wire specifications of the welding torch (.035, .045,
.052 and .062 inches). Some Tandem applications
may require greater arc stability than others. If arc
instability due to electrical transfer through the contact
tip is encountered, an undersized contact tip may be
required. For .035" dia. wire use a .030" contact tip
and for .045" dia. use a .040" contact tip.

WIRE STRAIGHTENERS

Torch goosenecks' have a 22-degree bend for joint
accessibility. The bend provides a wire cast condition­ing that forces the welding wire against the contact tip
for positive electrical contact. If selected wire packag­ing counters the effect of the bent goosenecks a wire
straightener (K1733-1) placed at the wire feeder may
be required to re-establish a useable cast to the wire.

A-4

800 AMP TANDEM MIG TORCH

B-1

OPERATION

B-1

ELECTRODES AND EQUIPMENT

The Tandem MIG 800 amp torch has been designed
for use with 0.035" through 0.062" diameter Lincoln
Electric solid and metal cored steel GMAW wire weld­ing electrodes. Refer to the appropriate Lincoln
process and electrode selection guidelines for further
information on available electrodes and packaging.

MAKING A WELD

Observe all safety guidelines, read equipment operat­ing manuals thoroughly before operating equipment.

1. Check to make sure the welding power sources
are turned on and set to the correct parameters
and welding modes.

2. Verify that the shielding gas supply is on and set
for the correct flow rate.

3. Set the preflow and the post flow timers for both
wire feeders. Make sure the post flow is set long
enough to shield electrode extension as it cools
after burn back cycle.

4. Check to see that the water cooler is operating
properly. Check cooling fluid level and integrity of
cooling hoses.

5. Check all current carrying connections. All connec­tions should be tight: electrode cables, work
cables, torch to feeder connections, diffusers and
contact tips.

3. Keep torches cables as straight as possible or pro­vide a gradual bend in the cables when welding or
loading new wire.

4. Protect cables from rubbing against sharp surfaces
during operation.

5. Use only clean, rust free electrodes. Protect elec­trode packaging from collecting airborne contami­nates.

6. Replace contact tips and liners at regular intervals.

SHIELDING GAS DELIVERY

Adjust flow regulators for prescribed gas flow. Inspect
hoses regularly for wear or damage. Perform a soapy
water test on hoses if a leak is suspected. Avoid kink­ing or collapsing hoses with cable clamps. Insure that
diffusers and hose connections are properly seated
and tight. Always use an separate flow regulator for
each of the two gas lines.

AIR BLAST CLEANING

The welding torch is equipped with a separate gas
hose for the purpose of providing a high pressure air
blast through the nozzle area to clear loose spatter
that may have accumulated between the two dif­fusers.

The high pressure air is routed through the torch
retainer and exits into the nozzle through a series of
holes spaced in the retainer insulator.

6. If applicable, make sure the air blast is connected
and operational.

7. Check to see that the return earth ground is con­nected and all part clamping is activated.

8. Check torch alignment and ensure that torch or
part travel path is free from obstruction.

AVOIDING WIRE FEEDING PROBLEMS

Wire feeding problems can be avoided by observing
the following procedures:

1. Do not use a torch with cables that are longer than
necessary.

2. Do not kink or pull the torch cables around sharp
corners.

800 AMP TANDEM MIG TORCH

Air should be dry and free of oil or anti-spatter com­pound. Pressure should be adequate to free loose
spatter (50-100 psi).

NOTE: Do not deliver anti-spatter compound or clean­ing fluids through the air blast hose. Fluids applied
through the air blast hose will shorten the life of the
retainer and insulator and adversely affect welding
performance.

B-2

OPERATION

NOZZLE REAMING STATIONS

During robotic applications a reamer should be
employed to keep the nozzle clean. Reaming the noz­zle between welds will reduce the down time associat­ed with manual torch cleaning. The M18426-1 ream­ing station is an option that is recommended for noz­zle cleaning.

ANTI-SPATTER SPRAY

Anti-spatter compound may be used to keep weld
spatter from accumulating in the nozzle. Anti-spatter
should not be applied through the air blast line. Only
dry air should be used for air blast functions.

Anti-spatter may be applied to the interior of the noz­zle from an external sprayer. The M18426-1 reaming
station comes equipped with an external spraying sta­tion for this purpose. Care should be taken to apply
the right amount of anti-spatter to the internal area of
the nozzle. Too much anti-spatter will cause diffuser
clogging and weld porosity. Only a very light covering
of anti-spatter is required to keep the spatter from
clinging to the nozzle.

B-2

800 AMP TANDEM MIG TORCH

C-1

MAINTENANCE

C-1

CONTACT TIP REPLACEMENT

Each application will dictate the frequency of contact
tip replacement. Higher amperage, higher duty cycle
operations will require more frequent contact tip
replacement. The condition of the contact tip greatly
effects the welding performance of the Tandem MIG
process. A routine contact tip replacement schedule
should be established and adhered to. For general
operations contact tips should be changed at the
beginning of every shift.

LINER REPLACEMENT

Wire condition, plant environment and the wire con­sumption rate will dictate how often a liner should be
changed. Welding operations using small diameter
welding wire will require a more frequent contact tip
change interval than operations using larger diameter
welding wires. For general operations using .045 " dia
wire, liners should be changed or cleaned after
approximately 2000 lbs. of wire use.

GOOSENECK REPLACEMENT

The Tandem torch is designed with two separate
goosenecks that extend from the mounting and
clamping arm assembly. The goosenecks are config­ured as a left and a right gooseneck, they are not
interchangeable. Goosenecks require replacement
when they become bent or the outer cover becomes
damaged.

6. Replace damaged gooseneck with replacement
gooseneck making sure that the gooseneck is
properly identified as either a left or right goose­neck. (Left and right are determined by viewing
the torch from the nozzle end.)

7. Place newly assembled unicable and gooseneck
back into the back plastic housing.

8. Place nylon spacer between the two flat surfaces
of the gooseneck brass connector. (Flat surfaces
should be aligned parallel to each other.)

9. Seat back hosing inside the recessed lip of the
lower portion of clamping assembly.

10. Install upper half of clamping assembly after

seating goosenecks and plastic housing.

11. Loosely tighten the five hex head screws of

clamping house.

12.Install gooseneck insulators onto both goose-

necks.

13. Slide nozzle retainer over goosenecks and

gooseneck insulators. (Necks should be free to
rotate as the new retainer is slid into place.)

14. Install nozzle insulator over ends of goosenecks.

15. Install gas diffusers.

16. Install contact tips.

Replacement Procedure

1. Disconnect the water supply and return hoses as
well as the air blast hose.

2. Remove the five hex head screws (5/32" allen)
securing the upper housing of the torch clamping
assembly.

3. Remove torch diffusers, nozzle insulator and
retainer.

4. Lift upper portion of clamping assembly from
lower, slide back the black plastic back housing to
expose gooseneck to unicable connection.

5. Free the connection form the clamping assembly
and with one 1" and one 3/4"" wrench unscrew
gooseneck from unicable brass junction fitting.

800 AMP TANDEM MIG TORCH

17. Check contact tip alignment. Alignment should
be at equal angles and square to the body of the
torch. (use L10430-1 alignment tool).

18. Once contact tips are aligned, securely tighten
the five hex head screws of clamping assembly.

19. Recheck alignment after tightening the clamping
assembly.

20. Reinstall gas and water hoses.

C-2

MAINTENANCE

C-2

CONTACT TIP ALIGNMENT

During gooseneck replacement or after a torch colli­sion it may be required to check the contact tip align­ment. If using a robot, it is recommended that a tool
center pointer is placed in the robotic cell to define the
location of the lead wire. A second locating station
should be installed that provides two locating pins that

will check the alignment of the lead and trail wire.

If the torch requires maintenance that will effect the
alignment of the lead or trail wire placement, the torch
should be removed from the robot or hard automation
work cell and the L10430-1 torch alignment tool
should be used to realign wire placement.

L10430-1 Torch Alignment Tool

5. Secure mounting bracket assembly of torch to

back mounting block of alignment fixture by
securing torch mounting arm to the keyed .750"
mounting dowel provided.

6. Loosen the 5 hex head screws of mounting

bracket that hold goosenecks in place.

7. Pivot goosenecks to align the two 5/8" extended

wires to the indictor marks on the front block of
alignment gauge.

8. Secure goosenecks in place by tightening the five

hex head screws.

9. Recheck wire alignment.

10. Remove torch from alignment fixture.

Alignment Procedure

1. Remove torch from automated equipment.

2. Remove torch nozzle assembly.

3. Select desired contact tip spacing by pivoting
front alignment block of alignment fixture to
correct spacing. (Two wire spacings are provided
5/16" standard and a 3/8" wide.)

4. With retainer, diffusers and contact tips in
place insert a straight portion of welding wire into
each contact tip to simulate a 5/8" wire extension
past the contact tip.

800 AMP TANDEM MIG TORCH

C-3

MAINTENANCE

S22693-XXX MIG 800 amp Torch

C-3

All dimensions in inches. Bracketed dimensions
are in [millimeters]

800 AMP TANDEM MIG TORCH

C-4

MAINTENANCE

L10430-1 Torch Alignment Tool

(Consisting of the following three parts)

1. Base dimensions (Part number L10430-3)

C-4

2. Check Block dimensions (Part number L10430-2)

800 AMP TANDEM MIG TORCH

C-5

MAINTENANCE

L10430-1 Torch Alignment Tool

3. Holding block dimensions

C-5

(Part number L10430-4)

800 AMP TANDEM MIG TORCH

D-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

D-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

800 AMP TANDEM MIG TORCH

D-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

D-2

The drive rolls turn, but wire will
not feed or wire feeding is rough.

Porosity in the weld.

1. Torch cable is kinked and /or twisted.

2. Wire jammed in torch or cable.

3. Incorrect or worn drive rolls and guide
tubes.

4. Partially flashed, melted or improper
contact tip size.

1. Welding surface is contaminated.

2. Insufficient gas coverage.

3. Excessive arc length.

4. Inoperative gas solenoid.

5. Contaminated shielding gas.

6. Excessive use of anti-spatter fluid.

1. Keep cable assembly as straight as

2. Check for any obstructions in cable

3. Be sure the wire diameter being used

4. Replace contact tip.

1. Remove dirt, oil, moisture, mill scale

2. Check for sufficient shielding gas flow

3. Check weld procedures, arc length

4. Check solenoid operation.

5. Check for leaks in gas hoses and gas

6. Check amount of anti-spatter being

possible. Inspect cable and replace if
necessary.

assembly. Check liner, replace if nec­essary.

matches the drive rolls and guide
tubes size.

and miscellaneous contamination
from part.

form source, or restriction in gas line.
Check for drafts that may force
shielding gas from welding arc.

should generally be less than 1/4"
and steady.

hose connections.
applied and accumulation in nozzle.

There is arcing in the nozzle.

The welding arc is inconsistent.

Inconsistent wire feeding.

1. Spatter build-up is bridging between
the nozzle and the contact tips, or
from contact tip to contact tip.

2. The torch is not insulated from part
tooling or fixture.

1. Worn or loose contact tip.

2. Loose connection in current path.

3. The wire conduit or liner is dirty or
worn.

1. Loose, worn or incorrect drive rolls.

2. Torch cable kinked or liner worn.

3. Wire pay-off dispenser malfunction­ing.

1. Remove spatter build-up on regular

2. Make sure torch is properly insulated.

1. Inspect contact tip, tighten and

2. Check electrode and work cable con-

3. Clean liner and conduit. Replace if

1. Inspect drive rolls, tighten, clean or

2. Check cable for severe bends or

3. Check dispenser, make sure moving

basis. Adjust weld procedure to
reduce spatter.

replace if necessary.
nections. Check torch connections at

wire feeder, diffuser and goosenecks.
necessary.

replace as necessary.
kinking. Check, and clean liner as

neccesary.
parts are free from obstruction and

welding wire is properly routed.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

800 AMP TANDEM MIG TORCH

NOTES

800 AMP TANDEM MIG TORCH

NOTES

800 AMP TANDEM MIG TORCH

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

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