MK Products RoboKing User Manual

Product Description RoboKing®

MK Part Number 091-0389

MK Form Number OM-RK

NWSA Form Number 550

RoboKing

®

Effective with Serial

Number

Voltage Rating 24VDC

Printing/Revision

Date

This manual applies

to the following torch

model numbers

41500

November 2002 E

218-XXX

16882 Armstrong Ave., Irvine, California 92606 TEL [phone] FAX [phone] www.mkproducts.com

SAFETY CONSIDERATIONS

ELECTRIC ARC WELDING EQUIPMENT

CAUTION : READ BEFORE ATTEMPTING INSTALLATION,

OPERATION ORMAINTENANCE 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 quali­ed 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 qualied 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
cufess 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 conned 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-, beryllium-bearing
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 conned space only while it is being
ventilated and, if necessary, while wearing an air­supplied respirator.

Gas leaks in a conned space should be avoided.
Leaked gas in large quantities can change oxygen
concentration dangerously. Do not bring gas cylin­ders into a conned space.

Leaving conned 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 snug-tting,
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
re 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 rst 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.

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

i

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 rell any cylinder.

Cylinder ttings should never be modied or
exchanged.

3. Hose

Prohibited use. Never use hose other than that
designed for the specied gas. A general hose
identication 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 orices 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
identied 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 single­stage 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 efcient 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 signi­cant 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, reect from light-colored sur­faces, and burn the skin and eyes. Skin
burns resemble acute sunburn; those from gas­shielded 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.

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 lter 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-

ii

reective, 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 are.

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.

Three-phase connection. Check phase require­ment of equipment before installing. If only
three-phase power is available, connect single­phase equipment to only two wires of the three­phase 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 line­cord 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.

iii

For selecting a quality product. We want you to take

Thank You

pride in operating this product...as much pride as we
have in bringing the 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.

Model Name & Number _____________________

Code & Serial Number _____________________

Date of Purchase _____________________

Whenever you request replacements parts for, or 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.

Printed in the U.S.A.

MK Products, Inc.

Table of Contents

Safety ConSiderationS .................................................... i-iv

inStallation ........................................................ SeCtion a

Technical SpecificaTionS ................................................................... 1

SupporT equipmenT required .............................................................. 1

coolanT recommendaTionS ................................................................. 1

Torch lead connecTionS .................................................................. 1

operation .......................................................... SeCtion B

General ................................................................................... 2

moTor Gear Box .......................................................................... 2

drive and idler rollS ..................................................................... 2

aCCeSSorieS ......................................................... SeCtion C

drive roll KiTS ........................................................................... 4

opTional acceSSorieS ...................................................................... 4

conTacT TipS .............................................................................. 5

GaS cupS .................................................................................. 5

Torch linerS .............................................................................. 5

MaintenanCe ........................................................ SeCtion d

recommended Spare parTS liST ............................................................. 6

trouBleShooting ................................................... SeCtion e

TeSTinG The Torch ........................................................................ 7

TrouBleShooTinG Guide ................................................................... 7

appendiCeS .......................................................... SeCtion f

MK r

epair StationS

Safety WarningS

liMited Warranty

This page intentionally blank

Section A inStAllAtion

technicAl SpecificAtionS

Wire Capacity

.030" - .045" (0.8mm - 1.2mm) solid and hard wire
.030" - 1/16" (0.8mm - 1.6mm) aluminum and cored wire

Wire Speed

800 IPM (20mpm) Max. at rated feeder Input Voltage (120VAC / 42VAC)

Duty Cycle

Water Cooled (model 218 series) - 400 amps @ 100%
500 amp rating when used with #2 optional Power Cable

All ratings are at 25 volts max. using Argon Gas

Shipping Weight

15' (4.5m) 15 lbs. (6.8 Kg)
25' (7.6m) 19 lbs. (8.6 Kg)

Support equipment reqired

C.V. or C.C. Power SourCe of SuffiCient 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 qt(liter) / min. at
45 p.s.i. when using water cooled torches.

coolAnt recommendAtion

Use a name-brand additive which does not contain reactive sulphur or
chlorine and does not react with copper, brass, or aluminum. Here's also
mixture that works well :

Use 3 Gallons (11.4 Liters) deionized water. (NOT DISTILLED)
Use 1 Gallon (3.8 Liters) ethleyne glycol.
Use 1 tsp (5 ml) liquid glycerin per gallon (3.8 Liters) of mixture

The Coolant rate should be 1 qt (liter) / minute at 35 p.s.i.

torch leAd connectionS

Power Cable

The torch tting is screwed into the back of the torch block using a conductive
sealant. RoboKing torches use a #4 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.

ALL ROBOKING TORCHES MUST BE WATER COOLED

Conduit

The RoboKing comes standard with a teon lined conduit. The torch end
is secured with a set screw accessable through a hole in the handle under

RoboKing Owner's Manual - Page 1

the rear Handle nut. 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. The gas inlet
tube is located in the top center of the torch when viewed from the rear.

Water Hose

The water hose is pushed on to the inlet tube of the front body. The Water
tube is located in the lower left of the torch when viewed from the rear.

Electric Cable

A seven conductor control cable is used on RoboKing Torch, although only
2 conductors are used. The torch end of the control cable is secured to the
back of the torch with a cable clamp and the wires are connected to the motor
through a connector. The cabinet end has a 7 pin “W” clocked Amphenol
connector. See schematic for wiring information.

Section B operAtion

GenerAl deScription

The RoboKing is designed to be used in automation processes and is unique
in its design from other torches made by MK Products. The RoboKing Torch
maintains a constant, steady, uniform 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 24 volt DC torch motor is
controlled by the speed control in the Cobramatic II cabinet.

There is no trigger in the torch to start the arc, this is controlled by means
of an outboard control.

motor GeAr Box

A 19.5:1 24VDC motor gear box is used on this version of the RoboKing
Torch. The motor gear box attaches to the angle head with three (3) Allen
screws. The torch serial number is stamped on the angle head. There are no
spare parts for the motor gear box; it must be replaced as a whole unit.

drive And idler rollS

General

The RoboKing comes setup from the factory with the drive roll & idler
roll requested at the time of order. Other sizes of grooved drive rolls for
aluminum wire are also available (see Optional Kits). Use Knurled drive
rolls for all steel applications. One set will feed all wire diameters from .030
(0.8mm) to 1/6"(1.6mm)

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 when a small amount of pressure is added to the wire
as it exits the tip.

RoboKing Owner's Manual - Page 2

----------- IMPORTANT ----------­NOTE:

Over-tightening of the drive rolls will cause excessive knurling and/or deformation

of the wire. When the complete system is set-up properly, wire will feed out of the

end of the torch and fall on the ground forming a 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 detailed there.

THIS IS THE NUMBER ONE CAUSE OF POOR WIRE FEED PERFORMANCE

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

Drive Roll Installation/Removal

Please Note : Drive rolls have a LEFT HAND thread.

Remove the drive roll with small nose pliers by turning the drive roll clockwise.

Install new drive roll on motor shaft using left hand thread. Drive roll will
self-tighten when 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.

3. Tighten.

IDLER

ROLL

LOCK

WASHER

SPRING

GROOVE

TOWARDS

TOP

IDLER

ARM

SCREW

Figure 2

NOTE:

Lock washer must be under idler roll or it will not turn freely.

RoboKing Owner's Manual - Page 3