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IM774
GMAW
MK 091-0525
December 2006
Rev. E
Push-Pull Gun
OPERATOR'S MANUAL
™
CobraMAX
Model numbers K2252-1 & K2252-2
Safety Depends on You
Lincoln arc welding equipment
is designed and built with safety
in mind. However, your over-
all 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 befo
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Table of Contents Safety Considerations Installation ............................................................................... Section A Technical Specifications .....................................................................................1 Support Equipment Required .............................................................................1 Coolant Recommendations ................................................................................1 Gun Lead Connections ...........
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Declaration of Conformity for European Community (CE) Products Note This information is provided for units with CE certification (see rating label on unit). Manufacturer’s Name: MK Products, Inc. 16882 Armstrong Ave. Irvine, CA 92606 ™ Declares that the product: CobraMAX conforms to the following Directives and Standards: Directives Low Voltage Directive: 73/23/EEC Electromagnetic Compatibility (EMC) Directive: 89/336/EEC Standards Arc Welding Equipment Part I: Welding Power Sources: IEC
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CobraMAX™ Owner's Manual - Page i
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ii ii SAFETY E L E C T R I C S H O C K c a n ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. T h e e l e c t r o d e a n d w o r k ( o r g r o u n d ) c i r c u i t s the rays of the arc when welding or observing a r e e l e c t r i c a l l y “ h o t ” w h e n t h e w e l d e r i s o n . open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. s
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iii iii SAFETY W E L D I N G a n d C U T T I N G CYLINDER may expl ode SP ARKS can if damag ed. cause fire or explosion. 7.a. U s e o n l y c o m p r e s s e d g a s c y l i n d e r s 6.a. Remove fire hazards fro m the welding area. c o n t a i n i n g t h e c o r r e c t s h i e l d i n g g a s f o r t h e If this is not possible, cover them to prevent p r o c e s s u s e d a n d p r o p e r l y o p e r a t i n g t h e w e l d i n g s p a r k s f r o m s t a r t i n g a f i r e . r e g u l a t
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CobraMAX™ Owner's Manual - Page iv
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CobraMAX™ Owner's Manual - Page v
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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln E
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Section A Installation Technical Specifications Wire Capacity .030" - .045" (0.6mm - 1.2mm) solid and hard wire .030" - 1/16" (0.8mm - 1.6mm) aluminum and cored wire Wire Speed 800 IPM (20.3 mpm) Max at rated feeder input voltage (120VAC / 42VAC) Duty Cycle All ratings are using Argon gas 200 Amps/25 Volts Air cooled - 60% 250 Amps/25 Volts Water cooled - 60% Support Equipment Required • C.V. or C.C. power source of sufficient capacity for your needs. • Regulated gas supply and hoses.
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Gas Hose The gas hose is secured over the barbed gas fitting with a tie wrap. The cabinet end of the gas hose uses our standard gas fitting (1/8” - 27 nps). Water Hose If so equipped, one end of the water hose is secured over the barbed water fitting with a tie wrap and the other end is connected to the center fitting on the power block. Electric Cable ™ A seven conductor control cable is used on the CobraMAX gun. The gun end of the control cable is secured to the gun with a boot clamp and
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Drive Roll and Idler Rolls General ™ The CobraMAX gun comes standard with a knurled drive roll and a grooved idler roll, which will handle both steel and aluminum wire with diameters from .030-1/16 inch. Optional insulated V-groove drive rolls are also available for aluminum wire if desired (see optional kits). Drive roll tension is accomplished with a unique spring-loaded pressure ™ screw. The CobraMAX comes from the factory with the pressure adjustment screw preset. NO ADJUSTMENT IS RE
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Section C Accessories LE P/N MK P/N Optional Kits Insulated Drive Roll Kits are used to prevent preheating of the wire which may soften it and clog the liner. This picking up of current at the drive rolls rather than at the contact tip is usually not a problem unless using too large of a contact tip or excessively oxidized aluminum wire. Insulated Groove Drive Roll Kit ..........................KP1594-030 ....... 005-0640 For .030" (0.8mm) dia. aluminum wire. Includes insul
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Contact Tips Heavy Duty Contact Tip - 3/8" Diameter* Wire Size Tip ID Arc Tip Length MK Part No LE Part No .030” (0.8mm) .040” (1.0mm) Spray 1.57” (39.9mm) 621-0390-25 KP2217-1B1 Short 1.82” (46.2mm) 621-0396-25 -- .035” (0.9mm) .045” (1.1mm) Spray 1.57” (39.9mm) 621-0391-25 KP2217-2B1 † 621-0391-250 †† 621-0391-500 .035" (0.9mm) .045" (1.1mm) Short 1.82” (46.2mm) 621-0397-25 -- .045" (1.1mm) .054" (1.37mm) Short 1.82” (46.2mm) 621-0398-25 -- 3/64” (1.2mm) .054” (1.37mm) Spray 1.57” (39.9mm) 621
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Gun Barrel Liners MK P/N LE P/N Description 615-0341 Spiral Steel, .030 - .045" (0.8mm - 1.1mm) -- 621-0423 KP2247-1 CobraMAX™ Tip Extender 615-0248 Spiral Steel Liner for Tip Extender -- 615-0177 Bulk Teflon liner material for .030 - .035" -- 931-0137 KP2226-1 Teflon Liner Package, 5 pieces Section D Maintenance Periodic Maintenance ® Your Cobramatic System is designed to provide years of reliable service. Maintenance of the gun will normally consist of a general cleaning of the wire guide
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Section E Troubleshooting Trouble Cause Remedy 115 VAC Control fuse in feeder/ Replace fuse. Control box blown. No wire feed at gun, Micro-switch defective/not Replace switch. Check switch feeder not operating, i.e., no being activated. for operation. slave motor or brake solenoid. Check micro-switch wires for Broken electrical cable. continuity. 24 VAC Control fuse in feeder/ Check motor leads for shorts; Control box blown. then replace fuse. Check potentiometer with Bad Potentiometer.
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Troubleshooting Guide Regardless of which gun or feeder used, all MK Products’ push-pull guns operate on the same principle. The slave motor in the feeder runs at a fast, constant speed, but has very low torque. It is always trying to feed more wire than the gun motor wants, and when the motor gets all it wants, it slows the slave motor, preventing a bird’s nest. Because of the low torque produced by the slave motor, a brake system is used to prevent wire overrun rather than tension. T
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Section F Appendices Diagrams / Parts List 001-1420 CobraMAX™ Exploded View . . . . . . . . . . . . . . . . . . 12 003-2141 Front Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . 14 Ultra-Flex Air Cooled Lead Assembly. . . . . . . . . . . . . . . . . . . . 15 Water Cooled Lead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 16 Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 CobraMAX™ Owner's Manual - Page 9
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CobraMAX™ Exploded View CobraMAX™ Owner's Manual - Page 10 ITEMS 25 AND 44 NOT SHOWN FOR CLARITY APPLY ITEM 49 TO CONTACT SURFACES APPLY ITEM 48 BEFORE INSTALLING APPLY ITEM 45 TO CONTACT SURFACES APPLY ITEM 45 TO THREADS APPLY ITEM 46 TO THREADS APPLY ITEM 47 TO THREADS TORqUE REqUIRES 100+5 IN-LB
