Lincoln Electric COUGAR K2704-3 User's Manual
Contents
1. EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion 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 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 NN 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 LINCOLN amp Exposure to EMF fields in welding may have other health effects which are now not known 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 4 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cab2. M10032 August 2009 COUGAR Push Pull GUN Models K2704 2 K2704 3 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 OPERATOR S MANUAL LINCOLN E e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY 44 WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline 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
3. OMACHBICT ORBRLTF St WwFY TK A SA FAAS 8 AEE FF e HEMMER CMRI MEERA BRA Chinese RER i aL FER BEERS o YzzFel SH7IAS BelowAle e Ho AHS HEHH do Yel Ar e S XACESE 2728 OM AIS HHPI AS 2241742114 557 ARSHIAIS y Odl oe La ad sa O Atlus UL AL J y Ud abil o A Gils Vil Aal lin Jadi vo CLAY gal hia js d 494 Serial Aale viet Al dl ai YA y il ABB Ge a ax s LEIA E COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR FE gt MMPRHOX A OHRBEEK MA EFBRLTK SU CL TRHORSRMEK HT FS aM at MR RA MERE URBE RH BA A RRR FR BO REM MRT RANA ER EME ol sol SSE HAMAS Giel PALO HARA CAPAS EPA Gigi all veel Al sl Catia Al Lila Jub al gli y all oig gil Sall illa ag l y ca u L 14 NOTES LINCOLN E World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com LNC 0016 7 09
4. pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support 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 Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL 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 eguipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Jan 09
5. Down position movespressure roller to wire Operate wire drive release lever and see pressure roller move b Drive roll with two wire grooves Narrow groove feeds 035 0 9 mm diameter wire Wide groove feeds 3 64 inch 1 2 mm diameter wire Gun is shipped with wide groove or 3 64 in operating position toward handle Reverse roller for 035 inch 0 9 mm diameter wire Gas nozzle directs gas flow around arc Unthread gas nozzle to see contact tip and gas diffuser Push pull gun is shipped with 3 64th inch 1 2 mm contact tip installed Cable assembly for power control and gas Hold gun and become familiar with gun s weight and balance CONNECTING TO POWER SOURCE 7 PIN 1 Power source must be off and power cord PUSH PULL disconnected SE Cl 2 Connect Push Pull Gun to wire feeder by inserting power plug to the machine 3 Connect 7 Pin control cable plug to power source receptacle 4 Reconnect power and turn on machine AO GRAY e gt TORCH D 8 O _ YELLOW MOTOR a i WHITE UK 3 CW GREEN 2 a BLUE al W CLOCKED ge O BROWN 7 TORCH CONNECTOR ro PNK TRIGGER VIEWED FROM FRONT OF CONNECTOR mA 7 PIN AMPHENOL CONNECTOR PRESSURE GAS CABLE R LES GUN NOZZLE ALLIE ASSEMBLY FAR SIDE BARREL CONTACT TIP Sg il l 4 1e TOR E bel i LE ll WIRE SPEED CONTROL Jl GAS Leg DIFFUSOR ym LINCOLN POWER NEAR Maer l T
6. Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil 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 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 Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN CYLINDER may explode If damaged Ae 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
7. Troubleshooting Guide PROBLEM SYMPTOMS REMEDY No arc wire feed or gas flow Cable connections loose Trigger switch loose or defective Welder not turned on Welder not plugged in Cable or adapter cable damaged O R N O R N A Check all power connections Fix switch or replace Turn on welder power Plug in Inspect and replace No arc weak arc 1 Poor ground connection to work 2 Power cable connection loose 3 Voltage set too low 4 Tip too large for wire size 5 Wire feed speed too slow Check ground connection Check connections if defective replace cable or connectors Adjust to proper voltage Change tip size Increase wire feed speed No wire feed 1 Feeding small diameter wire with large groove on drive roller Wire drive release open Wire welded to tip Wire push pull empty in machine Tip too small for wire Kink or bend in wire o oO BR bh Control cable loose Drive roller worn Pressure roller stuck 0 Roller spring loose or broken O N o oO BR bh O N Change position of wire drive roller Close wire drive release Peel wire off tip or use new tip Insert new push pull Insert correct tip Pull wire through tip or start new wire end Check all connections Replace Replace or lubricate 0 Replace Wire feed too fast or too
8. dl SAFETY i PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions 6 et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et a la pi ce sont sous tension quand la machine a souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tres attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couche pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le cable de soudage et la machine a souder en bon et sur tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s a deux machines a souder parce que la tension entre les deux pinces peut tre le total de la tension a vide des deux machines Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soud
9. 6 0 27 28 250 6 4 180 3 8 10 0 25 30 260 6 6 200 1 2 12 0 25 31 270 6 9 220 3 4 20 0 25 31 290 7 4 250 Short arc transfer COUGAR Push Pull Gun ACCESSORIES MAINTENANCE ACCESSORIES consult Lincoln Sales Bulletin E12 16 The following accessories are available for the Cougar push pull gun 035 3 64 Aluminum Drive Roll Kit Features two grooves for feeding aluminum wire The smaller groove feeds 035 wire The larger groove feeds 3 64th wire Order KP2876 1 1 16 Aluminum Drive Roll Kit Features two grooves each capable of feeding 1 16 Aluminum wire Order KP2876 2 Barrel Liner 45 60 Barrels Liner for feeding up to1 16 wire Order KP2879 1 Barrel Liner 180 Straight Barrel Liner for feeding up to1 16 wire Order KP2879 2 Gun Barrel 60 degree air cooled gun barrel 45 degree air cooled gun barrel 180 degree air cooled gun barrel Order KP2877 60 Order KP2877 45 Order KP2877 180 MAINTENANCE Safety Precautions Do not operate with covers removed y Disconnect input power from welder before installing gun Do not touch electrically hot part Only qualified persons should install use or service this machine ELECTRIC SHOCK can kill When finished welding be sure to turn power source off and close valve on gas cylinder Working with flying or falling objects can cause serious eye injuries Protective eyeware
10. The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L 5 f LINCOLN 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 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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
11. 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 within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ven tilation In confined spaces or in some circumstances outdoors a respirator may be required Additional pre cautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker expo sure level should be checked upon installation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 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 Read and und
12. groove for feeding 035 0 9mm wire to accommodate changes in the wire size used Changing between the grooves simply requires reversing the drive roll A Drive Roll Orientation 1 Drive roll is scribed with wire groove size For appropriate groove orientation ensure desired size callout is facing up and visible B Changing Drive Roll Orientation 1 Flip lid open then move release lever to the up position 2 Unscrew thumb screw and remove drive roll 035 e 3 64 DRIVE ROLL X PRESSURE ADJUSTMENT COUGAR Push Pull Gun OPERATING INSTRUCTIONS Making A Weld 1 Check that the push pull gun power control and gas connec tions are correct for the power source being used Check that the gas supply is turned on Check wire push pull for an ade guate supply of wire 2 See Procedure Settings below for wire feed speed and voltage settings Set these controls depending on the weld ing wire and base metal thickness being used 3 Connect work clamp to metal being welded Work clamp must make good electrical contact to the workpiece The workpiece must also be grounded as stated in Arc Welding Safety Precautions 4 Connect power to welder and turn ON 5 Prepare to purge gas line by first releasing wire drive Push wire drive release lever to the UP position to avoid feeding wire WARNING Gun body and contact tip become electrically energized when gun trigge
13. it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 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 1 h To avoid scalding do not remove the FOR ENGINE EE E not remove th powered eguipment ANS Mi Y eg or pressure cap when the engine Is 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 3 areas or vent the engine exhaust fumes amp outdoors ELECTRIC AND MAGNETIC FIELDS _ Sta bb 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 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing 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
14. slow 1 Wrong wire speed set for work Adjust wire feed speed Low or no gas flow Oxidation of work 1 Gas flow not set right 2 Cylinder out of gas 3 Cylinder valve closed 4 Leak in gas line 5 Leak in gun 6 Gas diffuser clogged O amp N Set proper flow rate Get new cylinder of gas Open cylinder valve Inspect and replace Check for missing gun tubes and or missing gun body cover Blow out gas diffuser openings Oxidized work arc unstable 1 Wrong welding polarity Check polarity Troubleshooting Guide TESTING THE TORCH COUGAR Push Pull Gun Motor Check Remove the torch connector from the cabinet Using the torch Control Cable Connector check the resistance across pins A and B motor leads The resistance across the motor should be between 5 10 ohms If an open circuit or short exist check the motor leads and motor independently Testing the Potentiometer Using the torch Control Cable Connector check the resistance across pin D wiper and pin C The resistance should vary from 5K O ohms Check the resistance across pin D wiper and pin G The resistance should vary from 5K 0 ohms Testing the Trigger Switch Using the torch Control Cable Connector check for continuity across pins E and F when the trigger is pressed e W CLOCKED CONNECTOR
15. DIAGRAM DESCRIPTION Motor Assembly Pressure Lever Pivot Arm Set Screw Pressure Roll Pressure Adjustment Knob Assembly Ball Bearing Drive Roll Kit AL 035 3 64 Drive Roll Kit AL 1 16 Thumb Screw Housing Potentiometer Potentiometer Assembly WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese Se FIR Korean Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pieces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da e Isole se da peca e terra oO REPORTA SH ITPRNEAHRTRBNUIE HMLMPT APYSSEPHEBs NTUWSRICL TFA O RRAK HT DEBATE AR EF IR o CHRARACRHMALF HE eA SAU SX be AS AA och onc e AT on L 20 HA HAL e Suz HAE HA HAL JA YA Gay Gill sl all Quali Y O y aa das ag G yl AS Lal ALLL ae NE Jel NS Tar le Y je po e Keep flammable materials away e Mantenga el material combustible fu
16. RIGGER PLUG R HANDLE COUGAR Push Pull Gun OPERATING INSTRUCTIONS Safety Precautions Do not touch electrically live parts or electrode with skin o or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves Keep your head out of fumes 2 oh SE e Use ventilation or exhaust to remove fumes from breathing zone Keep flammable material away a e Do not weld on containers that have held combustibles Wear eye ear and body protection K WARNING Electric shock can kill Fumes and gases can be dangerous to your health Arc rays can injure eyes and burn skin See additional warning information under Arc Welding Safely Precautions on inside of front cover of operating manual When inching the electrode and drive mechanism are always electrically energized and remain energized several seconds after the gun trigger is released Setup Procedure Selecting Electrode Wire Several alloy types of filler metals are available and the best choice depends on the type of base metals and the desired characteristics of the weldment such as ductility and strength corrosion resistance sustained service temperature and anodic treatment color matching In addition several wire sizes are available and the choice here will depend upon several fac tors including base metal thickness and the arc transfer process us
17. VIEWED FROM FRONT OF CONNECTOR GRAY YELLOW WHITE GREEN BLUE BROWN PINK TORCH FUNCTIONS ve TORCH MOTOR S3 Cw TORCH POT TORCH TRIGGER 10 COUGAR Push Pull Gun REPLACEMENT PARTS LIST AND DIAGRAM ITEM NO oOo N co O A N zech O PART NO KP2877 180 26374 31 S26374 6 S26374 14 S26374 23 S26374 24 S26374 25 S26374 33 S26374 95 S26374 104 S26374 46 S26374 44 S26374 28 N S Not Shown DESCRIPTION 180 Degree Air Cooled Gun Barrel Motor Assembly Wire Drive Cover Potentiometer Assembly Trigger Assembly Handle Front Handle Back Strain Relief Clamp Kit Barrel Nut Barrel Insulation Hose Barrel Inlet Guide O Ring Kit A C Barrel 25 Cable Assembly Cougar 11 PART NO S26374 34 S26374 35 S26374 36 S26374 37 S26374 38 S26374 39 S26374 40 S26374 41 S26374 42 S26374 60 S26374 61 S26374 32 DESCRIPTION 50 Cable Assembly Cougar Cable Cover 25 Cable Cover 50 Power Cable Assembly 25 Power Cable Assembly 50 Wire Conduit Assembly 25 Wire Conduit Assembly 50 Control Wire Assembly 25 Control Wire Assembly 50 Gas Hose Assembly 25 Gas Hose Assembly 50 Rear End Feeder Connection Kit ITEM NO PART NO S26374 31 S26374 7 S26374 8 S26374 9 S26374 10 S26374 12 KP2876 1 KP2876 2 S26374 63 S26374 15 S26374 14 COUGAR LX Push Pull Gun REPLACEMENT PARTS LIST AND
18. as ou on recoit un choc Ne jamais le code Code for safety in welding and cutting CSA Standard W 117 2 1974 enrouler le c ble lectrode autour de n importe quelle partie du PRECAUTIONS DE SU RETE POU R fae LES MACHINES A SOUDER A Un coup d arc peut tre plus s vere qu un coup de soliel donc TRANSFORMATEU R ET A REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi Ou un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de I huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier LINCOLN amp RE Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece a souder doit tre branche a une bonne mise a la terre Autant que possible l installation et l ent
19. e pas poser la pince a une endroit isol de la masse Un court circuit accidental peut provoquer un echauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage cables de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des cables jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre metal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Si on utilise la machine a souder comme une source de 11 Pour obtenir de plus amples renseignements sur la s ret voir courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le c
20. ed Consult your local dealer or appropriate AWS publication for help in selecting an appropriate alloy type and wire size Also refer to Procedure Settings later in this chapter for wire sizes used with typical base metal thicknesses and procedure set tings Installing Conduit Liner 1 Laying torch out straight remove positioning nut then insert your liner tapered end first all the way into torch until it stops NOTE You should see the liner through the holes in the inlet guide this will help make sure liner is fully installed Inlet Guide with Liner Inspection Hole 2 While torch is still laying out straight adjust your O Ring and col let so that they will fit up inside of the power pin when positioning nut is installed Positioning Nut Collet 3 Reinstall the positioning nut securely then trim rest of liner flush with positioning nut accordingly to fit up to drive rolls IR Installing Barrel Liner 1 Unscrew barrel inlet guide 2 Unscrew barrel liner from inlet guide 3 Reverse procedure with new liner Be sure to install liner with tapered end toward contact tip and liner is fully threaded into inlet guide y Neck Barrel Torch Liner Inlet 4 Barrel Guide COUGAR Push Pull Gun OPERATING INSTRUCTIONS Drive Roll Groove Selection The drive roll has two grooves A wider groove for feeding 3 64 047 wire and a narrow
21. era del rea de trabajo e Gardez a l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos oO MA1PIUVEODOBMTOR ER HEXSICULTEENE EA o PIS A an T4 tL 1 F IE Fr o eddy 228 SC AIX Ola Ana Sa Judo ALl yl awe Wear eye ear and body protection o Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und Kor perschutz Use prote o para a vista ouvido e corpo o E HRUSHICRBRELTE bs ORR HERASESDIARAMR ez H Sol Sears ASolNAlL dal de ple Lily uy i gai ga o A 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 HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Turn power off before servicing Do not operate with panel open or Use vent
22. erstand 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 Also see item 1 b Jan 09 6 j SAFETY gt Z WELDING and CUTTING 7 gt 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 Remember that welding sparks and hot 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 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 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 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 though they have been cleaned For information purchase Recommended
23. he following argon flow rates depending on base metal thickness and welding position ARGON SHIELDING GAS FLOW RATES Flow Rates In cf hr l min Material Thickness In Inches and mm Welding Position 1 16 1 6 mm Flat 30 11 8 3 32 to 3 16 Flat Vertical 35 2 4 to 4 8 mm Horizontal Overhead 14 1 4 to 3 8 Flat Vertical 35 14 6 3 to 9 5 mm Flat Vertical 35 16 5 Horizontal Overhead 40 18 9 3 4 19 mm Flat Vertical 35 16 5 Horizontal Overhead 40 18 9 Wire Metal Wire Amps Size Thickness Speed DC in mm ga in mm Arc Volts ipm mpm 030 0 8 22 030 0 8 13 140 200 5 1 40 20 036 1 0 13 1414 240 6 1 40 18 048 1 2 14 1514 290 7 4 50 16 060 1 6 15 1614 340 8 6 60 14 075 2 0 16 1774 370 9 4 70 12 105 2 5 16 18 430 10 9 90 10 135 3 5 24 26 460 11 7 110 3 16 5 0 24 26 500 12 7 150 1 4 6 0 28 29 560 14 2 180 3 8 10 0 28 30 600 15 2 200 035 0 9 22 030 0 8 13 140 150 3 8 40 20 036 1 0 13 14 175 44 40 18 048 1 2 13 144 215 55 50 16 060 1 6 Weu 250 64 60 14 075 2 0 14164 270 68 70 12 105 2 5 16 18 320 8 1 90 10 135 3 5 24 26 410 10 4 110 3 16 5 0 24 26 450 11 4 150 1 4 6 0 26 28 530 13 5 180 3 8 10 0 26 29 560 14 2 200 1 2 12 0 26 30 600 15 2 220 3 64 1 2 10 135 3 5 20 2174 180 4 6 110 3 16 5 0 20 21 220 5 6 150 1 4
24. ilation or exhaust to guards off remove fumes from breathing zone WA Fl N N G e Los humos fuera de la zona de res Desconectar el cable de ali e No operar con panel abierto o pan prarion mentaci n de poder de la m quina guardas quitadas AVISO D E e Mantenga la cabeza fuera de los antes de iniciar cualquier servicio humos Utilice ventilaci n o i PRECAUCION aspiraci n para gases e Gardez la t te l cart des fum es e D branchez le courant avant l entre e N op rez pas avec les panneaux French Utilisez un ventilateur ou un aspira tien ouverts ou avec les dispositifs de teur pour ter les fum es des zones protection enlev s ATT E NTI O N de travail Vermeiden Sie das Einatmen von e Strom vor Wartungsarbeiten Anlage nie ohne Schutzgehause German Schweibrauch abschalten Netzstrom v llig ff oder Innenschutzverkleidung in e Sorgen Sie f r gute Be und nen Maschine anhalten Betrieb setzen WAR N U NG Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca e N o opere com as tampas removidas e Mantenha se afastado das partes P tuguese e Use ventilac o e exhaust o para e Desligue a corrente antes de fazer moventes A remover fumo da zona respiratoria Servigo e N o opere com os paineis abertos ATE N CAO e N o toque as partes el tricas nuas ou guardas removidas tEs LAPSRMeBTFLEIICLT O TH 2 HE XIV O NXNRPAN ERVALEEE Japanese FU PSB FER FE CM RIBTER LEU TEA ndo I
25. ion and use of specific products sold by us is solely within the control of and remains the sole responsibility of the customer Many variables beyond our control affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing 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 Code Number or Date Code if available Serial Number if available Date Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above 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 44 WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of
26. les If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source SAFETY 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 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded
27. life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS SAFETY Ee EE Lu TABLE OPOCONTENTS 2 cea eciesinsacsorsseseqetabdiasnacanebncnpsanedtmenetasaseseecetsteaeteczsserstenensinetiessenons opens 1 GENERAL INFORMATION sustancial 2 PRODUCTS SRP H e DE 2 CIO Y r HI I RR I RP AR RY Y A RH Y TA RAF NN 2 RECOMMENDED PROCESSES AND EQUIPMENT cisco CO CW Gegen 2 SELON a ES 3 4 UNPACKING TRE P SR PULLGUNS en OODD DARODD nnaR 3 PUSH PULL GUN FAMILARIZATION DIAGRAM asian 4 OPERATING INSTRUC TION E 5 7 AFE TY is MO coords ab 5 SE FUP PROCEDURE oi iii 5 SELECTINC ELECTRODE MIRE RFC EON EU EA O TOO 5 LOADING ELECTRODE WIRE 2 esse sas nine 5 INSTALLING BARREL EINEN 5 DRIVE ROLCOROOVE RL ant t a eenecipneerineananeceamecinnteneoeeater tasetegeceeeaestce 6 DE PAIA EE o Eo 7 PROCEDURE SET TN cS eee ee re ia 7 SETANG GAS FLOW oeste FN NF TN 7 ee 8 MAINTENANCE ee ee NFFNN NNF FFYN 8 TROUBLESHOOTING ONDES a da on 9 10 REPLACEMENT FARTS LIS T DIAGRAM ME 11 12 COUGAR Push Pull Gun GENERAL INFORMATION PRODUCT DESCRIPTION The Cougar push pull gun is a lightweight handheld combined semiautomatic wire feeder and welding gun designed primarily for aluminum welding using argon shielding gas The cable included with the push pull gun allows welding up to 25 7 62m or 50 feet 15 2m from the power
28. n the Operating Manual before proceeding Only personnel that have read and understood Unpacking the Push Pull Gun Carefully unpack your Cougar Push Pull Gun and attach the Barrel Assembly and make sure you have all of the parts shown the Operating Manual should install and operate this equipment below Power source must be turned OFF and power leads disconnected when installing this unit BARREL ASSEMBLY KP2744 035A KP2744 364A KP2746 1 OPERATOR S KP742 1 62R MANUAL KP2773 2 KP2876 1 COUGAR PUSH PULL GUN Contact Tip 035 0 9mm Contact Tip 3 64 1 2mm Gas Diffuser Gas Nozzle Insulator Drive Roll 035 3 64th Service Wrench Included Installed on Barrel Assembly Installed on Barrel Assembly Installed on Barrel Assembly Installed on Barrel Assembly Installed Included COUGAR Push Pul Gun INSTALLATION Push pull Gun Familiarization Become familiar with your push pull gun before connecting to welder For features described below refer to Figure on the next page 1 Handle gun can be used in either right or left hand 2 Trigger operates welding power gas flow and wire feed 3 Remote wire speed control located behind the handle con trols the speed of the drive motor 4 Open body cover by flipping lid and observe the following a Wire drive release lever up position moves pressure roller away from drive roll to stop wire feed
29. r is pressed and remain so for several seconds after trigger is released 6 Press and hold gun trigger for about 5 seconds to purge gas line If adjustable regulator or metering valve is installed adjust gas flow per Setting Gas Flow Rate Procedure Settings The following procedure settings for 4043 aluminum wire and argon gas can be used as starting points for developing specific welding procedures 7 Re engage wire drive by pushing release lever to down posi tion to feed wire 8 Momentarily squeeze trigger and verify that wire feeds proper ly Trim wire to approximately 1 4 6 mm from end of contact tip WARNING When using an open arc process it is necesary to use correct eye ear head and body protection 9 Position gun over joint at 10 pushing angle End of wire may be lightly touching the work 10 Lower welding helmet close gun trigger and begin welding Hold the gun so that the contact tip to work distance is about 1 2 inch 13 mm 11 To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out 12 When no more welding is to be done close valve on gas cylin der momentarily operate trigger to release gas pressure in line and turn off power source 13 Note that clogged tips can often be salvaged by peeling away melted wire Setting Gas Flow Rate Gas handling systems having adjustable flow valves should be set for t
30. retien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 v v for selecting one of our QUALITY products We want you to take hank You pride in operating this product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask us for advice or information about their use of our products We respond to our customers based on the best informa tion in our possession at that time We are not in a position to warrant or guarantee such advice and assume no liability with respect to such information or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such informa tion or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products We are a responsive manufacturer but the select
31. source The gun is intended for use with Power Wave C300 Power Feed 10M Power Feed 25M and Power Mig 350MP Power Sources For other applications contact your local Lincoln Electric sales office or distributor The push pull gun is ideal for aluminum fabrication in industrial shops automobile body shops marinas and for the advanced hob byist SPECIFICATIONS Model Cougar Push Pull Gun with Remote Wire Speed Control 035 1 16 0 8mm 1 6mm Aluminum and cored wire 800 IPM MAX Wire Capacity Wire Speed Duty Cycle Shipping Weight 300 amps 60 Argon Gas 25 Ft 7 6m 17 Lbs 7 7Kg 50 Ft 15 2m 31 Lbs 14Kg Supplied with KP2744 364A 3 64 Contact Tip Installed KP2744 035A 035 Contact Tip KP2746 1 Gas Diffuser Installed KP2742 1 62R Gas Nozzle Installed KP2773 2 Insulator Installed KP2876 1 Drive Roll 035 3 64 Service Wrench Instruction Manual RECOMMENDED PROCESSES AND EQUIPMENT The push pull gun can be used to weld aluminum and aluminum alloys using Gas Metal Arc Welding or GMAW also known as MIG process which requires a supply of shielding gas Argon is normal ly used due to its smooth stable arc good metal transfer and low cost Positive polarity gives good penetration and affords a base metal cathode cleaning effect COUGAR Push Pull Gun INSTALLATION Unpacking the Push Pull Gun Safety Precautions Read Safety Precautions i
32. such as safety specticals with side shields or goggles must be worn at all times FLYING FRAGMENTS can cause eye injury Wire Conduits 25 foot 035 1 16 Wire Diameter 50 foot 035 1 16 Wire Diameter Order KP2881 25 Order KP2881 50 Gas Diffuser Diffuser designed to accept thread on gas nozzles Order KP2746 1 Gun Tube Insulator For insulation of gas nozzle Order KP2773 2 Gas Nozzle 50 Thread on Nozzle Tip Recessed 62 Thread on Nozzle Tip Recessed Order KP2742 1 50R Order KP2742 1 62R Contact Tips 035 Order KP2744 035A 3 64 Order KP2744 364A 3 64 5356 Order KP2744 364A5356 1 16 Order KP2744 116A 1 For use on lower amperage applications with 5356 wire Features a smaller tip inner diameter to reduce arc flaring Routine Maintenance Periodically blow out or vacum any metal wire shavings from Drive Roll area Inspect and replace any worn wire on inlet guide or barrel liner NOTE Oil and spray cleaners can contaminate electrode wire and cause bad welds They could also make wire drive rollers slip Be careful when using any of these liguids on push pull gun Carefully clean gun with a cleaner that is safe for plastic Apply cleaner to rag and wipe gun Do NOT spray cleaner on gun Keep cable clean Oil grease gasoline paint and solvents degrade cable insulation Routine maintenance for consumable spare parts will depend on Duty Cycle and particular application COUGAR Push Pull Gun
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