MK Products Cobra Gold Gooseneck User Manual
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Welding Torch
OWNERS MANUAL
16882 Armstrong Ave., Irvine, California 92606 TEL(949)863-1234 FAX(949)474-1428 www.mkproducts.com
SAFETY CONSIDERATIONS
ELECTRIC ARC WELDING EQUIPMENT
CAUTION : READ BEFORE ATTEMPTING INSTALLATION, OPERATION
OR MAINTENANCE OF THIS EQUIPMENT
1-1 INTRODUCTION
This equipment is intended for ultimate
application by commercial/industrial users
and for operation by persons trained and
experienced in the use and maintenance of
welding equipment. Operation should not
be undertaken without adequate training
in the use of such equipment. Training
is available from many public and private
schools or similar facilities.
Safe practices in the installation, operation
and maintenance of this equipment requires
proper training in the art, a careful study
of the information provided with the equipment, and the use of common sense.
Rules for safe use are generally provided
by suppliers of welding power sources,
compressed gas suppliers, and electrode
suppliers. Careful compliance with these
rules will promote safe use of this equipment.
The following Safety Rules cover some
of the more generally found situations.
READ THEM CAREFULLY. In case of
any doubt, obtain qualied help before
proceeding.
1-2 GENERAL PRECAUTIONS
A. Burn Prevention
ELECTRIC ARC WELDING PRODUCES
HIGH INTENSITY HEAT AND ULTRAVIOLET RADIANT ENERGY WHICH MAY
CAUSE SERIOUS AND PERMANENT
EYE DAMAGE AND WHICH MAY DAMAGE
ANY EXPOSED SKIN AREAS.
Wear helmet with safety goggles or glasses
with side shields underneath, appropriate
lter lenses or plates (protected by clear
cover glass). This is a must for welding
or cutting (and chipping) to protect the
eyes from radiant energy and ying metal.
Replace cover glass when broken, pitted,
or spattered.
Medical rst aid and eye treatment. First
aid facilities and a qualied rst aid person
should be available for each shift unless
medical facilities are close by for immediate
treatment of ash burns of the eyes and
skin burns.
Wear protective clothing - leather (or
asbestos) gauntlet gloves, hat, and high
safety-toe shoes. Button shirt collar and
pocket aps, and wear cufess trousers to
avoid entry of sparks and slag.
Avoid oily or greasy clothing. A spark
may ignite them.
Flammable hair preparations should not
be used by persons intending to weld
or cut.
Hot metal such as electrode stubs and
work pieces should never be handled
without gloves.
Ear plugs should be worn when working
on overhead or in a conned space. A
hard hat should be worn when others work
overhead.
B. Toxic Fume Prevention
WARNING: The use of this product may result
in exposure to chemicals known to the State
of California to cause cancer and birth defects
or other reproductive harm.
Adequate ventilation. Severe discomfort,
illness or death can result from fumes, vapors,
heat, or oxygen enrichment or depletion that
welding (or cutting) may produce. Prevent
them with adequate ventilation. NEVER
ventilate with oxygen.
Lead-, cadmium-, zinc-, mercury-, berylliumbearing and similar materials, when welded
or cut, may produce harmful concentrations
of toxic fumes. Adequate local exhaust
ventilation must be used, or each person in
the area, as well as the operator, must wear
an air-supplied respirator. For beryllium, both
must be used.
Metals coated with or containing materials
that emit toxic fumes should not be heated
unless coating is removed form the work
surface, the area is well ventilated, or the
operator wears an air-supplied respirator.
Work in a conned space only while it is being
ventilated and, if necessary, while wearing an
air-supplied respirator.
Gas leaks in a conned space should be
avoided. Leaked gas in large quantities can
change oxygen concentration dangerously.
Do not bring gas cylinders into a conned
space.
Leaving conned space, shut OFF gas supply
at source to prevent possible accumulation
of gases in the space if downstream valves
have been accidentally opened or left open.
Check to be sure that the space is safe before
reentering it.
Vapors from chlorinated solvents can be
decomposed by the heat of the arc (or ame)
to form PHOSGENE, a highly toxic gas,
and other lung and eye irritating products.
The ultraviolet (radiant) energy of the arc
can also decompose trichloroethylene and
perchloroethylene vapors to form phosgene.
DO NOT WELD or cut where solvent vapors
can be drawn into the welding or cutting
atmosphere or where the radiant energy
can penetrate to atmospheres containing
even minute amounts of trichloroethylene or
perchloroethylene.
C. Fire and Explosion Prevention
Causes of re and explosion are: combustibles
reached by the arc, ame, ying sparks,
hot slag, or heated material, misuse of
compressed gases and cylinders, and short
circuits.
BE AWARE THAT ying sparks or falling slag
can pass through cracks, along pipes,
through windows or doors, and through wall
or oor openings, out of sight of the goggled
operator. Sparks can y many feet.
To prevent res and explosion:
Keep equipment clean and operable, free
of oil, grease, and (in electrical parts) of
metallic particles that can cause short
circuits.
If combustibles are in area, do NOT weld
or cut. Move the work if practicable, to
an area free of combustibles. Avoid paint
spray rooms, dip tanks, storage areas,
ventilators. If the work cannot be moved,
move combustibles at least 35 feet away,
out of reach of sparks and heat; or protect
against ignition with suitable and snugtting, re-resistant covers or shields.
Walls touching combustibles on opposite
sides should not be welded on (or cut).
Walls, ceilings, and oor near work should
be protected by heat-resistant covers or
shields.
Fire watcher must be standing by with
suitable fire extinguishing equipment
during and for some time after welding
or cutting if:
1. Appreciable combustibles (including
building construction) are within 35 feet.
2. Appreciable combustibles are further
than 35 feet, but can be ignited by sparks.
3. Openings (concealed or visible) in
oors or walls within 35 feet may expose
combustibles to sparks.
4. Combustibles adjacent to walls, ceilings,
roofs, or metal partitions can be ignited by
radiant or conducted heat.
Hot work permit should be obtained before
operation to ensure supervisor’s approval
that adequate precautions have been
taken.
After work is done, check that area is free of
sparks, glowing embers, and ames.
An empty container that held combustibles,
or that can produce ammable or toxic
vapors when heated, must never be welded
on or cut, unless container has first
been cleaned in accordance with industry
standards.
This includes: a thorough steam or caustic
cleaning (or a solvent of water washing,
depending on the combustible’s solubility),
followed by purging and inerting with
nitrogen or carbon dioxide, and using
protective equipment.
Water-lling just below working level may
substitute for inerting.
A container with unknown contents should
be cleaned (see paragraph above). Do
NOT depend on sense of smell or sight to
determine if it is safe to weld or cut.
Cobra Gold Owner's Manual Page i
Hollow castings or containers must be
vented before welding or cutting. They
can explode.
Explosive atmospheres. NEVER weld or
cut where the air may contain ammable
dust, gas, or liquid vapors (such as
gasoline).
D. Compressed Gas Equipment
The safe handling of compressed gas
equipment is detailed in numerous industry
publications. The following general rules
cover many of the most common situations.
1. Pressure Regulators
Regulator relief valve is designed to protect
only the regulator from overpressure; it is
not intended to protect any downstream
equipment. Provide such protection with
one or more relief devices.
Never connect a regulator to a cylinder
containing gas other than that for which the
regulator was designed.
Remove faulty regulator from service
immediately for repair (rst close cylinder
valve). The following symptoms indicate
a faulty regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure
continues to rise with downstream valve
closed.
Faulty Gauge - if gauge pointer does
not move off stop pin when pressurized,
nor returns to stop pin after pressure
release.
Repair. Do NOT attempt repair. Send faulty
regulators for repair to manufacturer ’s
designated repair center, where special
techniques and tools are used by trained
personnel.
2. Cylinders
Cylinders must be handled carefully to
prevent leaks and damage to their walls,
valves, or safety devices:
Avoid electrical circuit contact with cylinders
including third rails, electrical wires, or
welding circuits. They can produced short
circuit arcs that may lead to a serious
accident. (See 1-3C)
ICC or DOT marking must be on each
cylinder. It is an assurance of safety when
the cylinder is properly handled.
Identifying gas content. Use only cylinders
with name of gas marked on them; do not
rely on color to identify gas content. Notify
supplier if unmarked. NEVER DEFACE or
alter name, number, or other markings on a
cylinder. It is illegal and hazardous.
Empties: Keep valves closed, replace caps
securely; mark MT; keep them separate
from FULLS, and return promptly.
Prohibited use. Never use a cylinder or its
contents for other than its intended use,
NEVER as a support or roller.
Locate or secure cylinders so they cannot
be knocked over.
Passageways and work areas. Keep
cylinders clear of areas where they may
be stuck.
Transporting cylinders. With a crane, use
a secure support such as a platform or
cradle. Do NOT lift cylinders off the ground
by their valves or caps, or by chains, slings,
or magnets.
Do NOT expose cylinders to excessive heat,
sparks, slag, and ame, etc. that may cause
rupture. Do not allow contents to exceed 55
degrees C (130 degrees F.) Cool with water
spray where such exposure exists.
Protect cylinders, particularly valves from
bumps, falls, falling objects, and weather.
Replace caps securely when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench
to open a cylinder valve that cannot be opened
by hand. Notify your supplier.
Mixing gases. NEVER try to mix any gases
in a cylinder.
NEVER rell any cylinder.
Cylinder ttings should never be modied
or exchanged.
3. Hose
Prohibited use. Never use hose other than that
designed for the specied gas. A general hose
identication rule is: red for fuel gas, green for
oxygen, and black for inert gases.
Use ferrules or clamps designed for the hose
(not ordinary wire or other substitute) as a
binding to connect hoses to ttings.
No copper tubing splices. Use only standard
brass ttings to splice hose.
Avoid long runs to prevent kinks and abuse.
Suspend hose off ground to keep it from
being run over, stepped on, or otherwise
damaged.
Coil excess hose to prevent kinks and
tangles.
Protect hose from damage by sharp edges,
and by sparks, slag, and open ame.
Examine hose regularly for leaks, wear, and
loose connections. Immerse pressured hose
in water; bubbles indicate leaks
Repair leaky or worn hose by cutting area out
and splicing. Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that
may clog orices and damage seats before
connecting regulator. Except for hydrogen,
crack valve momentarily, pointing outlet away
from people and sources of ignition. Wipe
with a clean, lintless cloth.
Match regulator to cylinder. Before connecting, check that the regulator label and cylinder
marking agree, and that the regulator inlet
and cylinder outlet match. NEVER Connect
a regulator designed for a particular gas
or gases to a cylinder containing any other
gas.
Tighten connections. When assembling
threaded connections, clean and smooth
seats where necessary. Tighten. If connection
leaks, disassemble, clean, and retighten,
using properly tting wrench.
Adapters. Use a CGA adapter (available from
your supplier) between cylinder and regulator,
if one is required. Use two wrenches to
tighten adapter marked RIGHT and LEFT
HAND threads.
Regulator outlet (or hose) connections may
be identied by right hand threads for oxygen
and left hand threads (with grooved hex on
nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through
suitable vent before opening cylinder (or
manifold valve) by turning adjusting screw
in (clockwise). Draining prevents excessive
compression heat at high pressure seat by
allowing seat to open on pressurization.
Leave adjusting screw engaged slightly on
single-stage regulators.
Stand to side of regulator while opening
cylinder valve.
Open cylinder valve slowly so that regulator
pressure increases slowly. When gauge
is pressurized (gauge reaches regulator
maximum) leave cylinder valve in following
position: for oxygen and inert gases, open
fully to seal stem against possible leak;
for fuel gas, open to less than one turn to
permit quick emergency shut-off.
Use pressure charts (available from your
supplier) for safe and efficient recommended pressure settings on regulators.
Check for leaks on rst pressurization
and regularly thereafter. Brush with soap
solution. Bubbles indicate leaks. Clean
off soapy water after test; dried soap is
combustible.
E. User Responsibilities
Follow all Safety Rules.
Remove leaky or defective equipment from
service immediately for repair. Read and
follow user manual instructions.
F. Leaving Equipment
Unattended
Close gas supply at source and drain
gas.
G. Rope Staging-Support
Rope staging-support should not be used
for welding or cutting operation; rope may
burn.
1-3 ARC WELDING
Comply with precautions in 1-1, 1-2, and
this section. Arc Welding, properly done,
is a safe process, but a careless operator
invites trouble. The equipment carries high
currents at signicant voltages. The arc is
very bright and hot. Sparks y, fumes rise,
ultraviolet and infrared energy radiates,
weldments are hot, and compressed gases
may be used. The wise operator avoids
unnecessary risks and protects himself
and others from accidents.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly
bright. Its radiation can damage eyes,
penetrate lightweight clothing, reect from
light-colored surfaces, and burn the skin
and eyes. Skin burns resemble acute
sunburn; those from gas-shielded arcs
are more severe and painful. DON’T
GET BURNED; COMPLY WITH PRECAUTIONS.
1. Protective Clothing
Wear long-sleeve clothing in addition to
gloves, hat, and shoes. As necessary,
use additional protective clothing such as
leather jacket or sleeves, ameproof apron,
and re-resistant leggings. Avoid outer
garments of untreated cotton.
Cobra Gold Owner's Manual Page ii
Bare skin protection. Wear dark, substantial
clothing. Button collar to protect chest
and neck, and button pockets to prevent
entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. Eyes
may be damaged by radiant energy when
exposed to the electric arc, even when not
looking in the direction of the arc. Never
look at an electric arc without protection.
Welding helmet or shield containing a
lter plate shade no. 12 or denser must
be used when welding. Place over face
before striking arc.
Protect lter plate with a clear cover plate.
Cracked or broken helmet or shield should
NOT be worn; radiation can be passed
through to cause burns.
Cracked, broken, or loose filter plates
must be replaced IMMEDIATELY. Replace
clear cover plate when broken, pitted, or
spattered.
Flash goggles with side shields MUST
be worn under the helmet to give some
protection to the eyes should the helmet
not be lowered over the face before an arc
is struck. Looking at an arc momentarily
with unprotected eyes (particularly a high
intensity gas-shielded arc) can cause a
retinal burn that may leave a permanent
dark area in the eld of vision.
3. Protection of Nearby Personnel
Enclose the welding area. For production
welding, a separate room or enclosed bay is
best. In open areas, surround the operation
with low-reective, noncombustible screens
or panels. Allow for free air circulation,
particularly at oor level.
Viewing the weld. Provide face shields for
all persons who will be looking directly
at the weld.
Others working in area. See that all persons
are wearing ash goggles.
Before starting to weld, make sure that
screen aps or bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented
to the outside air. Carbon monoxide
can kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment’s rated capacity. Do not
overload arc welding equipment. It may
overheat cables and cause a re.
Loose cable connections may overheat or
ash and cause are.
Never strike an arc on a cylinder or other
pressure vessel. It creates a brittle area that
can cause a violent rupture or lead to such
a rupture later under rough handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed electrically hot conductors or
other bare metal in the welding circuit, or in
ungrounded, electrically-HOT equipment
can fatally shock a person whose body
becomes a conductor. DO NOT STAND,
SIT, LIE, LEAN ON, OR TOUCH a wet
surface when welding without suitable protection.
To protect against shock:
Keep body and clothing dry. Never work
in damp area without adequate insulation
against electrical shock. Stay on a dry
duckboard, or rubber mat when dampness or
sweat cannot be avoided. Sweat, sea water,
or moisture between body and an electrically
HOT part - or grounded metal - reduces the
body surface electrical resistance, enabling
dangerous and possibly lethal currents to ow
through the body.
1. Grounding the Equipment
When installing, connect the frames of each
unit such as welding power source, control,
work table, and water circulator to the building
ground. Conductors must be adequate to
carry ground currents safely. Equipment
made electrically HOT by stray currents may
shock, possibly fatally. Do NOT GROUND
to electrical conduit, or to a pipe carrying
ANY gas or a ammable liquid such as oil
or fuel.
Thre e-p hase connection. Che ck phase
requirement of equipment before installing. If
only three-phase power is available, connect
single-phase equipment to only two wires of
the three-phase line. Do NOT connect the
equipment ground lead to the third (live) wire,
or the equipment will become electrically
HOT - a dangerous condition that can shock,
possibly fatally.
Before welding, check ground for continuity.
Be sure conductors are touching bare metal of
equipment frames at connections.
If a line cord with a ground lead is provided
with the equipment for connection to a switch
box, connect the ground lead to the grounded
switch box. If a three-prong plug is added for
connection to a grounded mating receptacle,
the ground lead must be connected to the
ground prong only. If the line cord comes with
a three-prong plug, connect to a grounded
mating receptacle. Never remove the ground
prong from a plug, or use a plug with a broken
ground prong.
2. Connectors
Fully insulated lock-type connectors should
be used to join welding cable lengths.
3. Cables
Frequently inspect cables for wear, cracks,
and damage. IMMEDIATELY REPLACE those
with excessively worn or damaged insulation
to avoid possibly lethal shock from bared
cable. Cables with damaged areas may
be taped to give resistance equivalent to
original cable.
Keep cable dry, free of oil and grease, and
protected from hot metal and sparks.
4. Terminals and Other Exposed Parts
Terminals and other exposed parts of electrical
units should have insulating covers secured
before operation.
5. Electrode Wire
Electrode wire becomes electrically HOT
when the power switch of gas metal-arc
welding equipment is ON and welding gun
trigger is pressed. Keep hands and body
clear of wire and other HOT parts.
6. Safety Devices
Safety devices such as interlocks and circuit
breakers should not be disconnected or
shunted out.
Before installation, inspection, or service of
equipment, shut OFF all power, and remove
line fuses (or lock or red-tag switches) to
prevent accidental turning ON of power.
Disconnect all cables from welding power
source, and pull all 115 volts line-cord
plugs.
Do not open power circuit or change polarity
while welding. If, in an emergency, it must
be disconnected, guard against shock
burns or ash from switch arcing.
Leaving equipment unattended. Always
shut OFF, and disconnect all power to
equipment.
Power disconnect switch must be available
near the welding power source.
Cobra Gold Owner's Manual Page iii
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 identication information below for future
reference. This information can be found on your machine nameplate.
Model Name & Number: ___________________________________
Code & Serial Number: ___________________________________
Date of Purchase: ________________________________________
Whenever you request replacement parts for r information on this
equipment, always supply the information you have recorded above.
Read this Owner’s 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.
Cobra Gold Owner's Manual - Page iv
Table of Contents
Safety Considerations ........................................................................i-iii
Installation ............................................................................... Section A
Technical Specications .....................................................................................3
Support Equipment Required .............................................................................3
Coolant Recommendations ................................................................................3
Torch Lead Connections ....................................................................................4
Operation .................................................................................Section B
General ..............................................................................................................4
Controls and Settings .........................................................................................5
Drive Roll and Idler Rolls....................................................................................5
Drive Roll Installation/Removal ..........................................................................6
Idler Roll Installation and Removal.....................................................................6
Accessories .............................................................................Section C
Contact Tips .......................................................................................................7
Gas Cups ...........................................................................................................7
Torch Liners........................................................................................................8
Optional Kits .......................................................................................................8
Accessories ........................................................................................................9
Maintenance ............................................................................Section D
Periodic Maintenance.......................................................................................10
Recommended Spare Parts List ...................................................................... 11
Troubleshooting .......................................................................Section E
Troubleshooting Guide .....................................................................................13
Testing The Torch .............................................................................................13
Appendices ..............................................................................Section F
Diagrams / Parts List ........................................................................................17
Mechanical .......................................................................................................18
Electrical...........................................................................................................22
MK Warranty Repair Stations
Safety Warnings
Warranty
Cobra Gold Owner's Manual - Page 1
THIS PAGE INTENTIONALLY BLANK
Cobra Gold Owner's Manual - Page 2
Section A Installation
Technical Specications
Wire Capacity
.023inch - .045inch (0.8mm - 1.2mm) solid and hard wire
.030inch - 1/16inch (0.8mm - 1.6mm) aluminum and cored wire
Wire Speed
800 IPM (20mpm) Max. at rated feeder Input Voltage (120VAC / 42VAC)
Duty Cycle
Air Cooled Torches (211 series) ......................................... 200 amps @50%
Air Cooled Torches (Finned Copper Cup) ........................ 200 amps @100%
Air Cooled Torches (Heavy Duty Finned Copper Cup) .... 225 amps @100%
Water Cooled Torches (210 series) .................................... 250 amps @50%
Water Cooled Torches (Finned Copper Cup) ................... 225 amps @100%
Water Cooled Torches
(Heavy Duty Finned Copper Cup) ...................................... 250 amps @100%
Water Cooled Torches
with Optional Heavy Duty Finned Gas Cup ...................... 300 amps @50%
All ratings are at 25 volts max. using Argon Gas
Shipping Weight (approximate)
Air Cooled
15ft. (4.5m) ....................................... 13 lbs. (5.9 Kg)
25ft. (7.6m) ....................................... 18 lbs. (8.2 Kg)
50ft. (15.2m) ..................................... 33 lbs. (14.96 Kg)
Water Cooled
15ft. (4.5m) ....................................... 14 lbs. (6.35 Kg)
25ft. (7.6m) ....................................... 20 lbs. (9.07 Kg)
50ft. (15.2m) ..................................... 35 lbs. (15.88 Kg)
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 35 p.s.i. when using water cooled torches.
Coolant Recommendations
Use a name-brand additive, which does not contain reactive sulphur or
chlorine and does not react with copper, brass or aluminum.
Use 3 Quarts (2.85 Liters) Distilled water.
Use 1 Quart (.95 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.
Cobra Gold Owner's Manual - Page 3
Section A
(Cont.)
Torch Lead Connections
Power Cable
IMPORTANT - PLEASE NOTE
——————————————————————————————
Water cooled torches use a #4 AWG power cable inside
a exible hose. Because of the size of cable used,
these torches MUST be WATER COOLED.
——————————————————————————————
The torch tting is screwed into the back of the torch block using a conductive
sealant. Air cooled torches, on the other hand, use a #2 AWG power cable,
which is secured to the torch in the same manner. The power cable tting on
the other end connects to the power block inside the Cobramatic feeder.
Conduit
The Cobra Gooseneck comes standard with a Teon-lined conduit. The torch
end is secured with a setscrew accessible through a hole in the handle.
The other end is connected to the wire feeder. Spiral steel conduits are
available when using hard and cored wires.
Gas Hose
The gas hose is pushed on to the inlet tube of the front body, and then
secured with a plastic cable tie. The gas inlet tube is located in the middle of
the torch block, when viewed from the rear.
Water Hose
The water hose is pushed on to the inlet tube of the front body. The other end
goes to the return side of the water recirculator. The Water tube is located
in the upper right of the torch block, when viewed from the rear. Air cooled
torches do not have a Water Hose.
Electric Cable
A seven conductor control cable is used on the Gooseneck Torch. The torch
end of the control cable is secured to the back of the torch with a cable clamp
and the wires are joined to the motor, pot, and micro switch through two
connectors. The cabinet end has a 7 pin “W” clocked Amphenol connector.
See the schematic in the appendix for wiring information.
Section B Operation
General
The patented Cobra Gooseneck Torch 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 torch motor, causes the wire to literally oat friction-free through the
wire conduit. The 24VDC torch motor is controlled by a three (3)-turn
potentiometer in the torch handle.
Cobra Gold Owner's Manual - Page 4
Section B
(Cont.)
Controls and Settings
Potentiometer
The potentiometer is located on the left hand side of the torch and provides
three (3) turns of adjustment. A special pot nut and O-Ring provides drag on
the knob and also secures the pot to the handle.
Trigger, Gas Valve and Micro Switch
The torch trigger is designed so that when it is partially depressed, gas ow
starts via the valve located in the torch body, prior to ignition of the arc. When
the trigger is partially released after welding (extinguishing the arc), gas ow
continues until the trigger is fully released; built-in pre and post gas ow.
The micro switch is wired “Normally Open” and secured to the torch block
with two (2) screws. An insulator between the torch block and micro switch
prevents accidental shorting of the switch leads. The trigger pin reaches
through the handle and activates the micro switch just before the trigger
bottoms out on the handle.
Drive Roll and Idler Rolls
General
The Gooseneck torch comes standard with knurled drive rolls, which will
handle wire diameters from .023 through 1/16 inch. Optional insulated
V-groove drive rolls are also available for improved feeding of aluminum wire
(see Optional Kits).
Drive roll tension is accomplished by means of a pressure-adjusting screw
located on the left hand side of the torch. Proper tension is achieved when
wire does not slip if a small amount of pressure is added to the wire as it
exits the tip.
----------- IMPORTANT -----------
NOTE: Over-tightening of the drive rolls will cause excessive knurling and/or
deformation of the wire. When the complete system is setup properly,
feeding wire out of the end of the torch and letting fall on the ground should
form a large uniform circle. If it forms a spiral or spring then there is too
much tension in the system, please refer to the Cabinet Owners Manual for
adjustment to the tension setting.
INCORRECT DRIVE ROLL TENSION IS THE NUMBER ONE
CAUSE OF POOR WIRE FEED PERFORMANCE
---------------------------------------------
Cobra Gold Owner's Manual - Page 5
S
Section B
(Cont.)
Drive Roll Installation/Removal
Note
Neither of the handles needs to be removed to access the Drive or Idler
Rolls.
1. Using a 5/32" hex wrench, loosen the Idler Roll tension screw. This will
relieve the pressure against the drive roll.
2. Align the Drive Roll Removal Tool (P/N 931-0100) over the ats of the
drive roll. Hold the torch with one hand or on a table top, with the
other hand give the Removal Tool a quick snap-turn in the CLOCKWISE
DIRECTION.
Figure 1
3. Once the drive roll is loose, continue to spin drive roll in the clockwise
direction to remove the drive roll from the torch.
4. Install a new drive roll on the left-hand threaded shaft. The drive roll will
self-tighten when it is feeding wire.
Idler Roll Installation and Removal
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.
IDLER
ROLL
LOCK
WASHER
SPRING
GROOVE
TOWARD
TOP
IDLER
ARM
SCREW
Figure 2
3. Tighten.
4. Using a 5/32" hex wrench, turn the Idler Roll tension screw into the
gearbox housing to adjust the pressure against the drive roll.
NOTE: Lock washer must be under idler roll or it will not turn freely.
Cobra Gold Owner's Manual - Page 6
Section C Accessories
Spray Arc
Contact Tips
Short Arc
ediuGrotceleSpiTtcatnoC
eziSeriW eziSeriW
eziSeriW eziSeriW **.D.IpiT **.D.IpiT
eziSeriW
)mm6.0(”320.
)mm6.0(”320.
)mm8.0(”030.
)mm8.0(”030.
)mm8.0("030.
)mm8.0("030.
ro
ro
)mm9.0("530.
)mm9.0("530.
)mm9.0(”530.
)mm9.0(”530.
)mm2.1(”540. )mm3.1(”350. yarpS )mm83(”2/1-1 7230-126
)mm2.1("540.
)mm2.1("540.
ro
ro
)mm3.1(”250.
)mm3.1(”250.
)mm6.1(”61/1 )mm9.1(”570. yarpS )mm83(”2/1-1 5700-126
)mm6.1(”61/1
)mm6.1(”61/1
* Standard - Furnished with torch. ** All tips stamped with tip I.D.
NOTE: As a rule of thumb, use the smaller I.D. tip for steel, stainless steel and the
5000 series aluminum. Softer alloys such as the 1000 and 4000 series aluminum
require more clearance and, therefore, use a larger I.D. tip.
**.D.IpiT **.D.IpiT crA crA
**.D.IpiT
)mm8.0(”030. yarpS )mm83(”2/1-1 7500-126
)mm8.0(”030. trohS )mm44(”4/3-1 8230-126
)mm9.0(”630. yarpS )mm83(”2/1-1 5230-126
)mm9.0(”630. trohS )mm44(”4/3-1 6230-126
)
mm0.1(”040. yarpS )mm83(”2/1-1 6700-126
)mm0.1(”040. trohS )mm44(”4/3-1 7700-126
)mm1.1(”440. yarpS )mm83(”2/1-1 1000-126
)mm1.1(”440. trohS )mm44(”4/3-1 2000-126
)mm5.1(”060. yarpS )mm83(”2/1-1 *3000-126
)mm5.1(”060. trohS )mm44(”4/3-1 6820-126
)mm1.2(”580. yarpS )mm83(”2/1-1 3510-126
)mm1.2(”580. trohS )mm44(”4/3-1 4510-126
crA crA htgneLpiT htgneLpiT
crA
htgneLpiT htgneLpiT .oNtraP .oNtraP
htgneLpiT
.oNtraP .oNtraP
.oNtraP
Gas Cups
Standard Cup
eziS eziS
eziS eziS .D.I .D.I
eziS
55555
66666
8*8*8*8*8*
0101010101
*Standard - Furnished with torch
.D.I .D.I .oNtraP .oNtraP
.D.I
)mm4.6(”4/1 9700-126
)mm5.9(”8/3 7310-100
)mm7.21(”2/1 8310-100
)mm8.51(”8/5 9310-100
Heavy Duty
Finned Cup
spuCsaGdradnatS spuCsaGytuD-yvaeH
.oNtraP .oNtraP eziS eziS
.oNtraP
88888
eziS eziS .D.I .D.I
eziS
0101010101
.D.I .D.I .oNtraP .oNtraP
.D.I
)mm7.21(”2/1 6630-126
)mm8.51(”8/5 7630-126
.oNtraP .oNtraP
.oNtraP
Cobra Gold Owner's Manual - Page 7
Section C
(Cont.)
Torch Liners
.oNtraP .oNtraP
.oNtraP .oNtraP lairetaMreniL lairetaMreniL
.oNtraP
*5500-516 nolfeTneerG dradnatS munimulA
4820-516 leetSlaripS dradnatS deroC/leetS
8500-516 nolfeTneerG
7500-516 leetSlaripS
4500-516 dradnatS-nolfeT toofehtyb-kluB munimulA
30-516 nolfeTneerG
13
lairetaMreniL lairetaMreniL htgneL htgneL
lairetaMreniL
*Standard - Furnished with torch
Optional Kits
Insulated Drive Roll Kits
sreniLhcroTkcenesooG
htgneL htgneL epyTeriW epyTeriW
htgneL
7100-126htiwdesU
rednetxEpiT
7100-126htiwdesU
rednetxEpiT
0361-134htiwdesU
puCytuDyvaeH
denniFdnaretpadA
puCreppoC
epyTeriW epyTeriW
epyTeriW
munimulA
deroC/leetS
"360.-030.,sepyteriwllA
)mm6.2-8.0(
Insulated Groove Drive Roll Kits are used to prevent preheating of the
aluminum 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 for .030" (0.8mm) dia. wire ....... 005-0640
Includes insulated drive roll P/N 511-0150
and idler roll assembly P/N 003-1870.
Insulated Groove Drive Roll Kit for .035" (0.9mm) dia. wire ....... 005-0641
Includes insulated drive roll P/N 511-0151
and idler roll assembly P/N 003-1870.
Insulated Groove Drive Roll Kit for .040" (1.0mm) dia. wire ....... 005-0642
Includes insulated drive roll P/N 511-0152
and idler roll assembly P/N 003-1870.
Insulated Groove Drive Roll Kit for .045" (1.2mm) dia. wire ....... 005-0643
Includes insulated drive roll P/N 511-0153
and idler roll assembly P/N 003-1870.
Insulated Groove Drive Roll Kit for .062" (1.6mm) dia. wire ....... 005-0644
Includes insulated drive roll P/N 511-0154
and idler roll assembly P/N 003-1870.
Tip Extender
Tip Extender ......................................................................................621-0017
A tip extender is used if the torch cup or tip threads have been damaged or to
prevent damage. Longer liners are required when using a tip extender.
Long Teon Liner ........................................................................ 615-0058
Long Spiral Steel Liner ............................................................... 615-0057
Note:
If more than one tip extender is used, the liner must be purchased in bulk
and cut to size.
Cobra Gold Owner's Manual - Page 8
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