Daihen OTC CM-741U User manual
MANUAL NO: U30007
OWNER'S MANUAL
FOR
WIRE FEEDER
MODEL: CM-741U 1U30007
DO NOT DESTROY
IMPORTANT: Read and understand the entire contents of this
manual, with special emphasis on the safety material throughout
the manual, before installing, operating, or maintaining this
equipment. This equipment and this manual are for use only by
persons trained and experienced in the safety operation of welding
equipment. Do not allow untrained persons to install, operate or
maintain this equipment. Contact your distributor if you do not
fully understand this manual.
DAIHEN Corporation
WELDING PRODUCTS DIVISION
June22, 2011
Upon contact, advise MODEL and MANUAL NO.
4-1-063-2
Notice : Machine export to Europe
This product does not meet the requirements specified in the EC Directives which are the EU safety
ordinance that was enforced starting on January 1, 1995. Please make sure that this product is not
allowed to bring into the EU after January 1, 1995 as it is.
The same restriction is also applied to any country which has signed the EEA accord.
Please ask us before attempting to relocate or resell this product to or in any EU member country or
any other country which has signed the EEA accord.
―1―
TABLE OF CONTENTS
1. SAFETY INFORMATION ････････････････････････････････････････････････････････ 2
2. ARC WELDING SAFETY PRECAUTIONS ･･･････････････････････････････････････ 2
3. CHECKING OF QUANTITY OF THE ACCESSORIES ････････････････････････････ 8
4. NAME OF PARTS ･･･････････････････････････････････････････････････････････････ 8
5. CARRYING AND INSTALLING OF THE WIRE FEEDER ･････････････････････････ 9
6. CONNECTION PROCEDURE ･･･････････････････････････････････････････････････ 11
7. WELDING PREPARATION ･･････････････････････････････････････････････････････ 14
8. MAINTENANCE AND TROUBLESHOOTING ････････････････････････････････････ 20
9. PARTS LIST ･････････････････････････････････････････････････････････････････････ 22
10. SPECIFICATIONS ･･･････････････････････････････････････････････････････････････ 30
－ 1 －
―2―
1. SAFETY INFORMATION
The following safety alert symbols and signal words are used throughout this manual to
identify various hazards and special instructions.
WARNING
WARNING gives information regarding possible personal injury
or loss of life.
CAUTION
CAUTION refers to minor personal injury or possible equipment
damage.
2. ARC WELDING SAFETY PRECAUTIONS
WARNING
ARC WELDING can be hazardous.
1. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
Be sure to:
・Keep children away.
・Keep pacemaker wearers away until consulting a doctor.
2. Read and understand the summarized safety information given below and the original
principal information that will be found in the PRINCIPAL SAFETY STANDARDS.
3. Have only trained and experienced persons perform installation, operation, and
maintenance of this equipment.
4. Use only well-maintained equipment. Repair or replace damaged parts at once.
ARC WELDING is safe when precautions are taken.
－ 2 －
―3―
2. ARC WELDING SAFETY PRECAUTIONS (continued)
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work
circuits are electrically live whenever the output is on. The power line and internal circuits of
this equipment are also live when the line disconnect switch is on. When arc welding all metal
components in the torch and work circuits are electrically live.
Leaving piled-up dust in the welding machine may cause insulation deterioration and result in
electrical shock and fire.
1. Do not touch live electrical parts.
2. Wear dry insulating gloves and other body protection that are free of holes.
3. Insulate yourself from work and ground using dry insulating mats or covers.
4. Be sure to disconnect the line disconnect switch before installing, changing torch parts
or maintaining this equipment.
5. Properly install and ground this equipment according to its Owner’s Manual and national,
state, and local codes.
6. Keep all panels and covers of this equipment securely in place.
7. Do not use worn, damaged, undersized, or poorly spliced cables.
8. Do not touch electrodes or any metal object if POWER switch is ON.
9. Do not wrap cables around your body.
10. Turn off POWER switch when not in use.
11. Remove dust by blowing moisture-free compressed air on each part periodically.
ARC RAYS can burn eyes and skin: FLYING SPARKS AND HOT METAL can
cause injury. NOISE can damage hearing.
Arc rays from the welding process produce intense heat and strong ultraviolet rays that can
burn eyes and skin.
Noise from some arc welding can damage hearing.
1. Wear face shield with a proper shade of filter (See ANSI Z 49.1 listed in PRINCIPAL
SAFETY STANDARDS) to protect your face and eyes when welding or watching a welder
work.
2. Wear approved face shield or safety goggles. Side shields recommended.
3. Use protective screens or barriers to protect others from flash and glare: warn others not
to look at the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather)
and foot protection.
5. Use approved earplugs or earmuffs if noise level is high.
Chipping and grinding can cause flying metal. As welds cool, they can throw off slag.
6. Wear proper body protection to protect skin.
－ 3 －
―4―
2. ARC WELDING SAFETY PRECAUTIONS (continued)
WELDING can cause fire and explosion.
Sparks and spatter fly off from the welding arc. The flying sparks, hot metal, spatter, hot base
metal and hot equipment can cause fire and explosion. Accidental contact of electrode or
welding wire to metal object can cause sparks, overheating, or fire.
Leaving piled-up dust in the welding machine may cause insulation deterioration and result in
electrical shock and fire.
1. Protect yourself and others from flying sparks and hot metals.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 10m (33ft) of the welding arc. If this is not possible, tightly,
cover them with approved covers.
4. Be alert that welding sparks and hot metals from welding can easily pass through cracks
and openings into adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can ignite a hidden fire.
7. Do not weld on closed containers such as tanks or drums.
8. Connect power cable for base metal as close to the welding area as possible to prevent the
welding current from traveling along unknown paths and causing electric shock and fire
hazards.
9. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
10. Do not use the welding power source for anything other than arc welding.
11. Wear oil-free protective garments such as leather gloves, a heavy shirt, cuffless trousers,
boots, and a cap.
12. A loose cable connection can cause sparks and excessive heating.
13. Tighten all cable connections.
14. When there is an electrical connection between a work piece and the frame of wire feeder
or the wire reel stand, arc may be generated and cause damage by a fire if the wire contacts
the frame or the work piece.
15. Remove dust by blowing moisture-free compressed air on each part periodically.
FUMES AND GASES can be hazardous to your health.
Arc welding produce fumes and gases. Breathing these fumes and gases can be hazardous to
your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. Ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDS) and the manufacturer’s instructions on
metals, consumables, coatings, and cleaners.
5. Do not weld or cut in locations near degreasing, cleaning, or spraying operations.
The heat and arc rays can react with vapors to form highly toxic and irritating gases.
6. Work in a confined space only if it is well ventilated, or while wearing an air-supplied
respirator. Shielding gases used for welding can displace air causing injury or death.
Be sure the breathing air is safe.
－ 4 －
―5―
2. ARC WELDING SAFETY PRECAUTIONS (continued)
CYLINDER can explode if damaged.
A shielding gas cylinder contains high-pressure gas. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding process, be sure to handle them carefully.
1. Use only correct shielding gas cylinders, gas regulator, hoses, and fittings designed for the
specific application; maintain them in good condition.
2. Protect compressed gas cylinders from excessive heat, mechanical shock, and arcs.
3. Keep the cylinder upright and securely chained to a stationary support or a rack to prevent
falling or tipping.
4. Keep cylinders away from any welding or other electrical circuit.
5. Never touch cylinder with welding electrode.
6. Read and follow instructions on compressed gas cylinders, associated equipment, and the
CGA publication P-1 listed in PRINCIPAL SAFETY STANDARDS.
7. Turn face away from valve outlet when opening cylinder valve.
8. Keep protective cap in place over valve except when gas cylinder is in use or connected for
use.
9. Do not disassemble or repair the gas regulator except if you are authorized by the
manufacturer.
WARNING
● Do not alter or remodel our products.
● You may get injured or have your equipment damaged because of fire, failure or
malfunction caused by altering or remodeling the product.
● The warranty does not cover any altered or remodeled products.
Rotating parts may cause injuries. Be sure to observe the following.
If hands, fingers, hair or clothes are put near the fan’s rotating parts or wire feeder’s feed roll,
injuries may occur.
1. Do not use this equipment if the case and the cover are removed.
2. When the case is removed for maintenance/inspection and repair, certified or experienced
operators must perform the work. Erect a fence, etc. around this equipment to keep others
away from it.
3. Do not put hands, fingers, hair or clothes near the rotating fans or wire feed roll.
－ 5 －
―6―
2. ARC WELDING SAFETY PRECAUTIONS (continued)
ARC WELDING work areas are potentially hazardous.
FALLING or MOVING machines can cause serious injury.
1. When hanging the welding power source by a crane, do not use the carrying handle.
2. Put the welding power source and wire feeder solidly on a flat surface.
3. Do not pull the welding power source across a floor laid with cables and hoses.
4. Do not put wire feeder on the welding power source.
5. Do not put the welding power source or wire feeder where they will pit or fall.
WELDING WIRE can cause puncture wounds.
1. Do not press the gun trigger until instructed to do so.
2. Do not point the gun toward any part of the body, other people, or any metal when
threading welding wire.
－ 6 －
―7―
PRINCIPAL SAFETY STANDARDS
Arc welding equipment – Installation and use, Technical Specification
IEC 62081, from International Electro technical Commission
Arc welding equipment Part 5: Wire feeders IEC 60974-5, from International Electro technical
Commission
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.
Government Printing Office.
Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.2,
from American Welding Society.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have
Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American
Welding Society.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas
Association.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards
Association, Standards Sales.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1,
from American National Standards Institute.
Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association.
NOTE: The codes listed above may be improved or eliminated. Always refer to the updated codes.
W080904
－ 7 －
―8―
3. CHECKING OF QUANTITY OF THE ACCESSORIES
Make sure that you have the items below before you use the wire feeder.
Wire feeder
Wire feeder Accessory
4. NAMES OF PARTS
Refer to the section indicated in for details.
No. Description Specification Quantity
①Gas hose (9.8ft [3m]) U5971R00 1
②Switch cord U5971S00 1
③Terminal 100-0816 2
Vinyl cap 100-0817 2
④Hose cover U1997C03 2
Pressure handles
Wire reel hub
Frame
Torch adapter
Feed rolls
Control cable 10P
Feed motor
Pressure roll holder
6.3
7.2
7.2
8.1
Gas supply inlet 6.4
7.1 7.3
－ 8 －
Table of contents
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