ACTIVE8. Operator s Manual. IM10085-A Issue D ate Mar-14 Lincoln Global, Inc. All Rights Reserved.

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1 Operator s Manual ACTIVE8 For use with machines having Code Numbers: 11770, Save for future reference Register your machine: Authorized Service and Distributor Locator: Date Purchased Code: (ex: 10859) Serial: (ex: U ) IM10085-A Issue D ate Mar-14 Lincoln Global, Inc. All Rights Reserved.

2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC. Please examine Carton and equipment For damage immediately م فوك مو م ف م ى لم ىو ى م ى م ىو موط ى لمهف فل فى م ف ن ىف م م. مى فك مو ق ىمكم ى ف ف مو ىفهف م فوك مو ق ملف مق م ىو.لم ىمكم ى م ىو مو م ى مو ف ف ك safety depends on you و ى属 ى ق ل ف لم هى مل ى م ى م ه ى ك ل ف ه ىل م属 ك ف ك ىج ق لم فم ك ى مق فك منف ف م م م属 ب.ل ى ى منف. ف ى ف م ن وه و ل ف... ى ف ف ى م DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS م نمق ىو ف ى ل ء THROUGHOUT. CONTAINED. نم فك مق ل ف كف WARNING لم 属 ن مق ى ف ن ى مو م مو 属 فم ف م م ف ىوش.منى ن ي ى ف م ى م لى ف كف م CAUTION لم 属 ن مق ى ف ن ى مو م مو 属 فم ف م م ف ىوش. م ى م ىو مهف فل ي ى ف م ى لى ف KeeP your head out of the Fumes. م ص.ك ف مو م ك مه DON T ف مكم نى م م م ى كم ك ف属 ف مك ف ىل م قف فم ف ف.ك ف مو ن منفس فى م فح مو مق ل ف READ ه ى ف属 مو ل ف (سءسح) مموس ف فء م ىف ك ف فم ف فو مقف. فى م ف ه ىل م属 ن USE ENOUGH VENTILATION مم و ق ك ف مو ف فو م.فم ف ف م مه مو ل ف م» ه ىو فم ق ن م فه ل ف م ن مو مق ف ى ف ى م ف ف OUTDOORS IN A LARGE ROOM OR.( 属 مق ممس) م ن مو ن لفمو مم نى م ف ملف ن ف属 ف م ن مو مم فن USE NATURAL DRAFTS.مكفن مو فو مذ. ى م مم ف م مل نة.لم كموك مق ل و م ى ف ى م ل ف م مو ف ه ىل م属 wear CorreCt eye, ear & body ProteCtion م مو ه ىل م属 و ى属 مكفن ل ف م م PROTECT م ف م ىن ن ملف ه م و ى属 ل ف لم ىن م.( ٤٩.١ غ ةسخء ممس) ك ف ل ف م ف ه ىل م属 ن ل ق PROTECT م属 ه ىل ك ى ه ىو ك م ى كم و ى属 و ف ن مو فم م ه ل ف ف ن -م ف ن ه ىو ك. ق وهىو ل ف ه ىههم و ى属 م ف ه ل ف و ف ن م ف ن مو PROTECT. مى فق مم ك م ى كم مق ف م ى ن ى كم AREAS IN SOME.م فى ف. ى ىل ك ل ه ى ى م ى م م ى كم BE SURE ججء شء فم ف 属 ى م ف ه منف فم属 ء.س حةش سخدةشءصشةس جءة ذس لفو ى م وكىو属 فى م ف م ىف ك DO NOT WELD OR CUT م م ف مو م مك ف ق ل ف»فو و ى属 كف ك ى ممق. مه فل م م م ى ىوش.لم فم ك فىكم م ف لم ف لم ىف DO NOT WELD OR CUT وهىو م فم م فك موش. م ف ممق م فو ى ف ى م و ى属 ى فكم. م فه م ن كى م فم ف ى فكم ف ى ىللء فكى فوكم فمو م ى مك م ن مل ى ك فه لم م ك PROTECT. فن فك مو مل ى ك م فن ك ف ل ف ك و. ى ك ىك فكى كم م ف ن ف لمل ه م م م ف مل ى ك BE SURE.فم ف ه ىل م属 ن ل ف»فو م ىن فى م ف REMOVE ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT.

3 SAFETY SECTION A: WARNINGS CALIFORNIA PROPOSITION 65 WARNINGS م ىه م مىء 属 م ف م ى ك ى ن م ل ف فو م م ىه م م مىء مو ل ف كمنمل و ىق مك فك م فك فى نى ف ن م ف س مو. فو م ى ك ل م م ىه م ى فا 属 فكى موك ىف ك ك ل ىو ن فو م م ىه م موش مو كمنمل و ىق مك فك م فك فى نى ف ن م ف س مو. فو م ى ك ل م 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. ف ى ىللف ء. وهى وهىو منف ه ى属 ن مو ل ف مل ل ف لفمز ف م فوك فو لمل م كم ه ى ى ى ف ن ى منف مو ن تم ٤٩.١ غ ل فل ف س ةسخء - ه ى ڤ ه ىل مط ى منفستم ن ك ٣٣١٣٥ فلى ء ى فىح ٣٥١٠٤٠.د.ذ مىك س ه ىل مط فكى م ء تم منفس ه ىل مط ك ءتم ن ك مم ء ء. ١١٧.٢-١٩٧٤ ط ل فل ف س ءس ٢٢٨٠١ ف كى كم ك ىج مو ن م قف ىف ف ى ٢٠٥ م ق.١١٩٩-٤٤١١٧ ىود ل ف م م م م ء ىف. س BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. FOR ENGINE POWERED EQUIPMENT. ل ف م ك ل ف ه منف م ى م ف ممث.ل. ١ ممث. ىف م ل ه ى ل ف ى ى ى مكى مل ن ف 属 ف ل ف ه ىو ك ىفو ل فو ف ه ى مو ف ل ف فن فمه مق-ض ه ى ىف م ه ى ف م ه ى ف مو 属. م ى م ل ف ه منف م م ف مكم مق ف ى م فك م ة.م. ١ مو 属 ل ف ه م مز.مك ف م ىف لم ى م ن م ه ى ى م مك ف م ىف مو مو 属 مو مكف م ل ف ف مكم مو 属 م فك م فم ه مو م ف 属 ء.م م ك ى ف م ىمو. ف ه ى فم ه ى 属 م ف ء. فن م ىه م مو فم ل فو ء.ن. ١ ك م و مو ه ىو ق م لى م ه مو ملى م.ه ى ى م ىه م مو م ىو 属 ل ه ى م ىو 属 م ىه م م ى فه ه ى ف ف ملىككف م م ش.ه. ١ 属 مك ف م ىف ه ى ل ف م مه ه ىل م 属 م ىه م مو م ى 属 م هف فك قى ىل م ى 属 ه ف مو كم ك ىل.م فى ف ف فىلف مو م م ل ه ىل فك لى ف ش.و. ١ hot. ى م ىه م مو مو 属 فك م م ه ى و م ق م نمق نن م ىه م مو ش.ف. ١ مو م 属 مك ف م ىف ل ف.ه ى مق ى م ى م 属 مك ف م ىف لم ف ى م - م 属 م ى م ىه م م ف م د.ق. ١. ل م ن فو م م ىه م مو م فم ف م ف ن م ف فم م ن مو للف ء.ك. ١.ه ى ى م ىه م مو مو 属 ك ف ه ىل م 属 م نمق ك ى 属 ف ل ف م ىه م مو س ن م ن لم ى م م ه ى م نم ف م ىه م و و ى 属 كف ك ه ى»ى ف ه ى ىن مو 属 م ن ى ء.ه ى ى هى ل ف ى م ىه م ف ل ل ف ى م ى 属 لم ى ى م ن نة. ف.لم ف ى ى م ممق م فو م ن ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS ك ل ك ف وه و ه ى 属 ن م ك كى كم.ف. ٢ ه ىل مط.(ءح ) ل مىء كى م هفح ل ف كى كم لم»ى فك م فك ه ىل م 属 ل ف م قفك ه ىل م 属 ل ف ل مىن ءح م فم ك م ك م ىوكف مل م 属 ل ف م ف مكف م و ى 属 م من م ى ف ل مىن ءح.ق. ٢ م نمق فىكى و ىمو ك ل و م ف مكف ف ه ى فو.ه ىل م 属 كمننم و فمو مو م فو ف ه ىل م 属 ى ل مىن ءح م.ك. ٢ 属 م ف وكىو 属 属. مل ى م لمك ه ى属 ن مو م ل و مل م属 ء.ل. ٢ : ى ك ىك ه ىل م属 مو ن ل مىن ءح م م م»ى ى ى م كمس - مو مه م قفك 属 ل ف مل كم م مو م ز. ١.ل. ٢.م قى مو属 م ف و ى属 مو. ل ق ل ف لفم مل كم م مو ى ك م مخ. ٢.ل. ٢ 属 ل ف مل كم م مو مم属 مق ل ق مكف ء. ٣.ل. ٢ مو ملى وهى ى م قفك مل كم م مو نة. م قفك.ملى وهى مق ف ل و م قفك 属 - ف م ك ف مكمى属 مو م قفك 属 مو كم. ٤.ل. ٢.لمل م属 ه ىمق فم ف مو م قى.مك م属 ه ىل م属 م 属 ء. ٥.ل. ٢ 3

4 SAFETY ELECTRIC SHOCK CAN KILL. م ف ى ك ىك (ل ه ) 属 ل ف مل كم م موش.ف. ٣ ء. ى مل م 属 مو مو 属 تم وتم فكى كم م ى م فق و ى 属 ف تم وتم م مو وك. ل فو م ف ى م ه مم ن-م و ل فمط.ه ىو ك م 属 ARC RAYS CAN BURN. كم م ف م ك ل ف م ىن م مو و ى 属 ل مىو ف م ص ه ىل م 属 مو 属 ك ف مو ن ف مو ل ف ف ن م م ل و م م ىن ل ف ل مىو لفمب.ه ىل م 属 ك ف م ه ى م ق. ل فل ف ة. ٨٧ غ ةسخء ن ك.ف. ٤. ى ف ى ل ه ى ل ه ل ف 属 ن ن م م ف ة.ق. ٣ فم ف ن م ك وه م مه ف ى ى ف ى مو ىف مك م فح.ل ه ل ف 属 و ى 属 كف ك فكى و ن 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:. مل مط (م ىط) مهف ض ف ء كى ف فى مس ط. مل مط ( كى س) ف فح ء ط. مهف ض لمك لمز و ى属 مل مط ء ط مل كم م مو ه ىل م属 م ى属 كى ف ف كى ف فى م ة.ك. ٣ ه ىل م属 كى ف فى م م»» لفمو ه ىل م属 مم مل كم م.تم وتم فكى كم م ف م ف ه فى م ف ف ى م -م ف ن م قف ل ن ملف ه ىو ك م قف ى م ص. ف ك ف مو ن م مو ن فو ل ف ى كم م قف ف ن- م قف ى و ى 属 م م ق فم مو كم ذ م م ك ف مو وك ف 属 مو ف 属 /ل ف ه ى مم ك. ف م م ف و ف ك ف مو م م مو.ق. ٤.ك. ٤ فكى كم م ل ه ف م ف م قفك 属 مو م مق ف 属 ء.ل. ٣ ل و ى كم ك موش.لمل م 属 ه ىمق ف م مو و ى 属 ى كم ك.لمل م 属 ه ىمق فم ف مو م قى ف م ك ف مق (و فم) فكى كم م ل ه ف لمل م 属 مق ف م 属 مو ل ا.م. ٣.ل ه ل ف م قفك ه ىل م 属 ف ك 属 مل و مل كم م مو ىف ىفح مكف مز. ى ىل ك ه ى ف م منف ل ه ى م ىوكف ه ىل م 属. ى ف ى لمهف فل.ن. ٣.ه ى ك ن م ف 属 ى مل كم م مو ىل م مخ.ه. ٣ مل كم م ن ف تم وتم فكى كم م وك م ف ى م مخ.و. ٣ مو مم 属 مق مهف م فكمق مل م 属 属 لم كم ك مل و و ق ن مهف ى ك ىك م مو ن ف مو مق فك 属. مل م 属 كم مق منف ف م م م ن م قف ه ى 属 موط. ك و ف مه ل و فن ف ن ن م.ى. ٣.٨ ل ف.ك. ٦ م ة مم ء.ي. ٣ FUMES AND GASES CAN BE DANGEROUS. م فه ل ف م ن مك ل ف ه ىل مط.ف. ٥ م مو ه ىو فم ق لى ء.و فمو ل ف»فو.م ن مو ن لفمو مم ه ىل م 属 موط. م فه ل ف م ن م ن مم ك ف مو ف فو م /ل ف ى ف ى م وه م م ص when welding.م» ه ىو فم ق مو ن ف 属 ف م فه ل ف 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 ventilation. in confined spaces or in some circumstances, outdoors, a respirator may be required. additional precautions are also required when welding on galvanized steel. ق لم كمننف ى م ى م ك م ن ه ىل م 属 ن ى ف م موش.ق.٥ مو ن ه ى ى ى ل ف م م ه ىل ك ى كفن ى ف كىنىكم مو ل ف م ى م مو ن مك ف م ىف م ى م م م م ط.لم ى ى فكى ف ل ف م لمك ه ىل م 属 فكىل ى م ل ف ى ف ف ى لم كموك مق ل و م م ل ف ج ذ ءبسد م قفكى ف ىو ى 属 ى ى ىف مك مق م نفم مو. ى ى ضجش بةا ء ف ق فك ل و لم ف ى وك فم ى فك ى ل م 属 ء.ك. ٥ موش. ى ف م ه ى ف ه ى فم ك ه ى فم همل ن ه ى ك ن ف م و ى 属 كفم فك ك ف مو ن ف ل ف فمو. ك ل ه ى ف ى ى مو ل ف فه كى وهىو ف م مه و م فك ل ف ىف مكف ىل فك ه ىل م 属 ك ف ن لم م فه ه ىل مىوس.ل. ٥ ى فىكم م ى ف ى م وه م م ف 属 ء.و فمل ي ى.منف ى ىف ه ىو فم ق م ى فم ف لم ىن ك ىو ن ى ك ى لا م كفن ف مو ل ف مل ل ف لفمز.م. ٥ مو ه ىل ك ى لم مق م قف ك مو ل ف م ى م لا م م 属 ن ل ف (سءسح) ممو ف فل منف فى م ف ه ىل م 属 ن م قف ىف ف م ف ن سءسح. مكى كف منف. م كفن ف مو ن قى ىل.ق. ١ م ى مم ء.ن. ٥ 4

5 SAFETY WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION. نة.فم ف ه ىل م 属 مو ن ل ف»فو م ىن م مز.ف. ٦ مو م م مو م ك م قى ى ىو ه ىل م 属 فو مق م مز.م ىن ف ه ى ف ن ف ه ىل م 属 وه و ه ى فم فك ه ىل م 属 ن فى م ف و ل ف ف فم ه ىل م 属 لى ء. فم ف مكفيلف ه ى م ل ف كف ك ف.م قف ىف ف ىلفم مو ى ه ى م م ىن ف م فب. م ى كى ف ل و فىكم م ى ق ي مو ف لم مق م ف م فه لم م ك م موط.ق. ٦. ى ف ى ل ف»فو م م لم مق ل و ى فكم ( ٤٩.١ غ ل فل ف س ةسخء) تمه ى ل ف ه ىل مط ى منفستم منمز.لم ه ىمق م ى م مو ن ى ف ن ى ه ى ف م مو ل ف ى ى ك ىك مل كم م مو ن ف ىف مك م ف ه ىل م 属 موط.ك. ٦ م فك فك كف ك ف ملىككء.ل ه 属 مو ه ىوك.ل ف»فو م ىن ف م فم ك ل ف ه ى فمو م مو ى م ىف ك ل ف ل م 属 ك فمو ء.ل. ٦ ى 属 م لمك وك فو م ى م ف ممق م فو م م.ملى ى مك ف ق ن ف كى م قف ف ن م فك ممق م فو مو وه و م م ى م ف م فك فك موش منفس لمل م كمزتم م فوك ى ف ن ى ء.تملم فم كتم ن ه ى ل ف ه ىل مط ن ى ف ف م ذ مو ن مكى كف ذ تم مك ف ق س ل ف»فب ل مب م فب فوش ه ى ىذ ل ف م ىف م للف مم ) مىك س ه ىل مط فكى م ء مو ن ٤.١ ء سطء.(م قف ه ى ك ه ى فمو م نمق م ىف ك ه ى فك 属 و مض.م. ٦.مل م ف موش.ه ىل م 属 مم ن ى فمط.ك ف ه ىل م 属 مو ن 属 و م ف م ف ل ف ف س م نن ك ىو فمو م ه مو فم ف وك م فه م ى كم ه فم فمط. ىفو م فك ف ل ف م و وهىو م فم 属 ف 属 ء. مكف لم ىن ك ى ى ى ن ه ىل م 属 مو 属.فم ف ه ىل م 属 ف ى مو 属 ل مىو ملى و ى 属 م ف ه منف.ن. ٦ فم ف ه ىل م 属 مو م ك ف 属 مو م قفك 属 مو كم.ه. ٦ 属 م ف ن ه ىل ى ق مو لم كم ك م قفك ط. فكى كف ف مو م فم ك ى فم ف ه ىل م 属 مو ن ف 属 ف ى فك مو ىفوك ه ى نى وه و ه ى ف م ك ه ىل م 属 مو ن ى ىقى م ىن م فم ك فك ىوش. ى ك ىك م ف م ف مو م قفك م ف ك. ىفن مو ى م قفك ىفوك ه ى نى فمو م ل ف»فو.ك. ١ م ى مم ء.و. ٦ CYLINDER MAY EXPLODE IF DAMAGED. ه ى ىف ك مل ى ك فه لم م ك م ص.ف. ٧ لم مك مو ن فه ه ىل مىو كم ك مو ن لم هى مل ف هم ه ى ف م م ل ف ه ى ىن م و ء.لم م م ل ف فه مو ل ف ى فكى ف مو ن م قف ى مق ل و.ك م. ى ىل ك ل ه ى لم ىف ىف لم ىفوك م كم ى ى وهى ف ى مل ى ك مم ف 属 ء.ق. ٧. لم ىن مهفى فك مل ف :لم فك مق ل و مل ى.ك. ٧ لم كميق ك مق ف مو م مو属 فم ف ن ف属 ء ط.مهف فل فكى و ى ف م ه ى ك ه ىل م属 ك ف ن مك ف ىل منف ء ط.م ف ن ف فمو ن مك مو ف ل ف مو ف مل و مل كم م مل كم م مو 属 ف م مخ.ل. ٧. مل ى ك ف وك ف تم وتم فكى كم م م م ف مل ى ك مو ن ف 属 ف مكفن ل ف لفمو ممث.م. ٧.م ف مل ى ك مو ه ى م مو 属 وهى ل فو ل ف مكف ى مق ف 属 ف ل و فك ى كم م فض.م ن لم كم ك م ى ى مل ى ك مو مو 属 مك م.ن. ٧ مل ى ك فه لم م ك ى ك ى مو 属 ن ل ف لفمز.ه. ٧ ن ى فكم ذتم -ذ ى فكى ق ءا ل ف م ى م لم فىك ف م قف ىف ف تم مل ى ى م فا لم م ن ه ى ل فب منفس ى فء مننمت ١٢٣٥ ى فىك ء فا لم م مو ن.٢٢٢٠٢ ءض ه ى ء ف 属 وهىب FOR ELECTRICALLY POWERED EQUIPMENT. كم ك ىل مو ه ى م 属 ى نن ش.ف. ٨ مو ه ى 属 م نمق ق م ن مو ف وك ى 属. م ى م فكى كم ف ى فخ.س.ص مو و ى 属 مك فل ككف ى م ى م ف ة.ق. ٨. ى فل م كم لا م كفن ف مو ل ف مل ك فك ف مل ف ى فخ.س.ص مو و ى 属 مك فل ككف ى م ى م مو ل ا.ك. ٨. ى فل م كم لا م كفن ف مو ل ف مل فكى كم ه ى ء ى م م ذ م ىء ن ل فل ف س تم ٥١ ءذءخ 属 ن ل ف لفمز ١ ءذءخ ن م قف ىف ف تم ط ب مو د ل ف ه ى ه ىل مط.٩١٠١-٠٢٢٦٩٠ فح ك ى ر ٩١٠١ ق دذ فذ وك ف م ف.ه ى 属 فو م ى ن مك م 属 ه ىل م 属 ف م ء.ة. ٦.ي. ٦ refer to for additional safety information. Welding Safety Interactive Web Guide for mobile devices 5

6 SAFETY ELECTROMAGNETIC COMPATIBILITY (EMC) ConFormanCe فم و ى 属 ى ن ك ى م ف ف مو ه ى ف ىل ك ل ذ ن ى ف ى ف مو ١٩٨٩ فح ٣ ن م ى كم ىء ىك ى - ف ك كى م هف كم م ه ى ف م م ف س مق مح مو ن 属 ف مو ف ى ف ف و ى 属 ى ن ك ى لم كفن ف ف 属 ة.( /٨٩/٣٣٦) ى ىقى ١٠-٦٠٩٧٤ خ :ل فل ف لم»ى فو ف م م ى فو ل فل ف ه ىل مط ك ء ن ل فل ف س ك ل ذ ( ح ) ى ىقى ف كى م هف كم ى ة. م ى م كى كم ك ىج مو و ى 属 م ن ى ة. م ى.م ف ى من ل ف فى ل ى ن لم هى مل introduction كى م هف كم م ن ف ف م ف م مه م ى م فكى كم م ء م ى م属 وه و لم ى ف مق ف ى ى م فكى كم. ى ى م موط. م ى ف ىلف ف ف ى ى مكف وه و لم فىلف مك م من م ى فكى كم م م ى م مو ق لم ىمكم م ف ى ى م فكى كم م ن ل ى ف كمننف ف ى ى م فكى كم. م ف ى مكم ضش ل ف ىلف م ى م ه ىل م属 ق فم مو م ى م.ك م م ك م م و م م م ىوكف لم ك فكى م مق ف ى فكم ف م ل ف م ف مك م من م ى فو م ف属 ف م -قف م كى م ل ف ى لم ى مك م属 ه ىل م属 ف مو属 لم ى م. م و ى installation and use م ى م ه ىل م属 مو ه ى ل ف ه ى ف ى ن م قى م ى م موش كى م هف كم م نة. ى ك ى لا م كفن ف مو ه ىل ككف مو ن ى ىقى م مو مق فو ى مو لم كم مل م ف مك فق ىل مو و ى属 ى ف ى مو م م م ى م ه ىل م属 مو ن م فىلم م ىو م فك م ة. م كفن ف مو ن مك ف ى ف فكى وكم ى ك ىك ه ىل م属 مو (ه ىل ه) ه ىو فم ف م ى ف مق ف ى كف - كم م ف ن ى ك ك م ى ل ك ى م فك مو ة.م خ مم م م ك 属 مو ل ف مك م属 مو ه ى ك م مم ك كى م هف مك فق ىل كى م هف كم م م فك ف ة. م ىن ى لم فىك ف و ى属.م م ق مه م ف مو م مو属 ى مو لمك لم مق Note: Theweldingcircuitmayormaynotbeearthedforsafetyreasons accordingtonationalcodes.changingtheearthingarrangementsshould onlybeauthorizedbyapersonwhoiscompetenttoaccesswhetherthe changeswillincreasetheriskofinjury,e.g.,byallowingparallelwelding currentreturnpathswhichmaydamagetheearthcircuitsofotherequipment. assessment of area ف م ف فو م مو م ى م ه ىل م属 ه ى ف ى م نم ه ىل مو ى م ق كى م هف كم م فى م ن م م ف : ككف ى م ف مق فو ه ى属 ن موش.فم ف م قفك م و م م ل ف ه ى ف هى م قفك ك م قفك مو.ف م ى م ه ىل م属 مو مكفيلف ل ف 属 مق م قف م ىمكم ل ف م ى ف ى ى م م ل ف ىلف.ق م ى م ك مو ل ف م ك.ك م ى م فى ل ى ن ه ىل ف ه.ه.م م ى م فكى ى ك منف.ل ل ف م ف مكف ن م مو.ه.م ل ف م م مو ن و فمو مو.م لىف ه ى فمو م م فم ى ف قى فك ن لم م ى م.ن فو م موش. م ى م مو ى م ى م مو ن ى ى مو.ه ى م ى م مو ى لم ه ىمق م ى م مو فو م م م فم ى كم ف ى ىللف م ى م ف ىوش.م قى ف ك. لمى فك مق م ف مى ى ى كف مو ه ىل م属 فو فل ن م ى مو.و مو ل م مل ى 属 لم ملى ك مق فم ف ه ىل مو ن م»ى موش موش.مكف ه ى ف م ف فو مى ى ى كف مو ل ف ه ىل ى ق مو ن م ك. م ى م مو ن مى فل ق مو ل مق ل م م ف فم ف ه ىل methods of reducing emissions Mains Supply ىف مو لم كم ك مق ل و م ى م ه ىل مط مك م من م ى نة. ى فل م كم لا م كفن ف مو ه ىل ككف ف وك ى فكم ف ى ىللف م ف ف مكم مق ف ى كك م ىه مق ل و ى ف ملى. ىف مو ن ه ى م ىن ه ىل م属 لم ف ى م ف م ن م قفك مو ه ىل مىو مق ل و ه ىل مىوس. م ف ى م ى ل ك كى ف م ى م ى م مق ل و ه ىل مىو موش.و ه م ى وه و ى ك فكى كم م كف ك فكى كم م ل ه فو مك م属 ه ىل م属 مو لم كم ك مك م属 ه ىل م属 مو ل ف ى ل ك مو مم属 مق لم ىف ىف ى.م ك م Maintenance of the Welding Equipment ه ىل ككف لم ىف ىف م ى مق ل و م ى م ه ىل م属 موش ل مكى م ل ف مككف ء. ى فل م كم لا م كفن ف مو ه ىل م属 مو مو属 لم م فن م ل ف لم ك مق ل و م ك ل ف مق ل و م ى م ه ىل م属 موش. ى ف م ى ى م ى م م يلف ل ف مه فوك م و ن مك م ف属 ف ى لمىنىل ف مو ف كى ف ة. ى ك ى م كفن ف مو ى لم م ك ل ف لم يلف مق ل و مكى مل ه ى»ى ىقف ل ف ه ى ى ك ف ن فه. ى فل م كم لا م كفن ف مو ه ىل ككف لم ىف ىف Welding Cables مق ل و ل ف م قى ف و ف م مق ل و م قفك ه ىل م属 موش. م م ن م ك ف ه ى مو مه م ك لم ى ى Equipotential Bonding ل ف ى ف ف ى ه ىل م属 مو ى م ك كى ف م ف ن ه ىل م ك كى ف م م م属 ب.لم ملى ك مق ل و ى مكفيلف ل ك ف م مو فو ى مو م فم ك ى ى属 مكمى 属 مو لمل ق مو ل ف م ك كى ف م م مو ه ىوك ق ك و ف م ىمكم ف ن لم ف ى مق ل و ف م موش.م ى م ف مو ف مل كم م. م ك كى ف م لمل ق وك Earthing of the Workpiece منف فكى كم م ن و فم لمل ق ى مكمى属 مو م موط و ىو.ه.م ى ى ل ف م»ى ى ن م فكمق و فم لم كم ك ف و فم مكمى属 مو ه ىل ق ى كم ك ف 属 مم ه ىل ى ق م ف مق ل و م ف. مك ف ى ف ق م ى ى ى م مك لم ي ى ن ى مو ه ى فم ك ى مكمى 属 مو ن ه ىو فم مو م م ف مكم م موط. م ى م فكى كم م مو مهف فل م كم ىل ف ق ملف مق ل و و فم مكمى属 مو ن ى كم ك مو كم ىل م مو属 مى ك م ى ق مكمى 属 مو ى كم ك ق لم مىوكف مق ل و ه ىل ق مو لم ى م ى ى كم ك. ى ف هم ف ى ف ه ىل ككف لم كم م مك ف ىكف فك م قف ى Screening and Shielding ى م ى م ل ف م قفك مو ن ه ىل مىو ل ف ه ى مم ك م ى كم مس.مك م من م ى ن م ق م فى م ف ف فم ف ه ىل مو ن لم ملى ك مق ف ى ف ف ى ه ىل م属 م ى م مو ن ه ى مم كس. ى فكى ف فىكم كى م هف كم تم :١٠-٦٠٩٧٤ خ ى لم ىف ك م ف م ه ىلمكم مو ن ى ذ ١ تم. م ى م ه ىل م属 ك ف ن ل فل ف ك ل ( ح ) ى ىقى ف

7 viii TABLE OF CONTENTS Page viii Installation...Section A TechnicalSpecifications...A-1 SafetyPrecautions...A-2 Location...A-2 HighFrequencyProtection...A-2 WeldCableSizes...A-2 TriggerConnector...A-3 ShieldingGasConnection...A-3 WireDriveConfigurations...A-4 ProceduretoInstallDriveRollsandWireGuides...A-4 PressureArmAdjustment...A-5 LoadingSpoolsofWire...A-5 GunConnection...A-6 PowerSourcetoCableConnectionDiagrams...A-7thruA-9 ProceduretoInstallConduitBushingfortheWireFeederUnit...A-10 Operation...Section B SafetyPrecautions...B-1 GraphicSymbolsthatappearonthisMachineorinthisManual...B-1 ProductionDescription...B-2 DutyCycle...B-2 RecommendedProcesses...B-2 ProcessLimitations...B-2 EquipmentLimitations...B-2 RecommendedPowerSources...B-2 CaseFrontControls...B-3 InternalControls...B-4,B-5 RearControls... B-5 ConstantCurrentOperation...B-6 SettingArcSensingwireFeedSpeedForConstantCurrentOperation...B-6,B-7 MakingaWeld...B-8 Accessories...Section C OptionalKitsandAccessories...C-1thruC-3 Maintenance...Section D SafetyPrecautions...D-1 RoutineMaintenance...D-1 PeriodicMaintenance...D-1 CalibrationSpecification...D-2 Troubleshooting...Section E SafetyPrecautions...E-1 HowtoUseTroubleshootingGuide...E-1 TroubleshootingGuide...E-2,E-3 Wiring Diagram & Dimension Prints...Section F Parts Pages...P-677

8 A-1 INSTALLATION TECHNICAL SPECIFICATIONS (K2999-1) A-1 INPUT VOLTAGE VDC(4InputAmperes) RATED CURRENT 330Amps60%DutyCycle ELECTRODE DIAMETERS and SPEED RANGE Electrode ElectrodeSize SpeedRange Solid Steel FluxCored " ( mm) ipm /64"( m/min) ( mm) PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTHWEIGHT SPOOLSIZECAPABILITY 11.8Inches7.6Inches 19.8Inches 27lbs (298mm)(193mm) (503mm) (12.2kg) 8(200mm)Dia. TEMPERATURE RANGE OPERATINGTEMPERATURE: STORAGETEMPERATURE: 14 Fto104 F(-10 Cto40 C) 14 Fto122 F(-10 Cto50 C) EN IEC

9 A-2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS INSTALLATION. Turn the input power OFF at the disconnect switch or fuse box before attempting to connect or disconnect input power lines, output cables or control cables. Only qualified personnel should perform this installation. Do not touch metal portions of the work clip when the welding power source is on. Do not attach the work clip to the wire feeder. Connect the work clip directly to the work, as close as possible to the welding arc. Turn power off at the welding power source before disconnecting the work clip from the work. Only use on power sources with open circuit voltages less than 110 V DC LOCATION For best wire feeding performance, place the on a stable and dry surface. Keep the wire feeder in the upright position. Do not operate thewirefeederonanangledsurfaceofmorethan 15degrees. Donotsubmergethe. INSTALLATION A-2 TheACTIV8isratedIP23andissuitableforoutdoor useintheuprightposition. Thehandleofthe isintendedformoving thewirefeederabouttheworkplaceonly. Whensuspendingawirefeederinahangingdevice, insulate the hanging device from the wire feeder enclosure. HIGH FREQUENCY PROTECTION Locate the away from radio controlled machinery. The normal operation of the may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment WELD CABLE SIZES CAUTION Table A.1 located below are copper cable sizes recommended for different currents and duty cycles. Lengthsstipulatedarethedistancefromthewelderto work and back to the welder again. Cable sizes are increasedforgreaterlengthsprimarilyforthepurpose ofminimizingcabledrop. TABLE A.1 RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167 F or 75 C)** CABLESIZESFORCOMBINEDLENGTHSOFELECTRODEANDWORKCABLES AMPERES PERCENT DUTY 0 to 50Ft. 50 to 100Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft. CYCLE (0 to15m) (15 to 30m) (30 to 46m) (46 to 61m) (61 to 76m) & or /0 1/0 2/0 3/0 2/ /0 1/0 2/0 3/0 2/ /0 2/0 2/0 3/0 3/ /0 2/0 2/0 3/0 3/0 3/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 2/0 3/0 3/0 4/0 4/0 4/0 **Tabledvaluesareforoperationatambienttemperaturesof104 F(40 C)andbelow.Applicationsabove104 F(40 C)mayrequirecables largerthanrecommended,orcablesratedhigherthan167 F(75 C).

10 A-3 TRIGGER CONNECTOR Thereisonecircularconnectorfortheguntriggeron thefrontofthe Picture C D E B A Function 5-pintrigger connectorfor push-guns only. Pin A B C D E SHIELDING GAS CONNECTION WARNING INSTALLATION Wiring 15volt Notused Trigger 83%WFSswitch 15volt CYLINDER may explode if damaged. Keep cylinder upright and chained to support. Keep cylinder away from areas where it may be damaged. Never lift welder with cylinder attached. Never allow welding electrode to touch cylinder. Keep cylinder away from welding or other live electrical circuits. BUILD UP OF SHIELDING GAS MAY HARM HEALTH OR KILL. Shut off shielding gas supply when not in use. See American National Standard Z-49.1, "Safety in Welding and Cutting Published by the American Welding Society Maximuminletpressureis100psi.(6.9bar.) Installtheshieldinggassupplyasfollows: 1.Securethecylindertopreventitfromfalling. 2.Remove the cylinder cap. Inspect the cylinder valves and regulator for damaged threads, dirt, dust, oil or grease. Remove dust and dirt with a clean cloth. DO NOT ATTACH THE REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT! Informyourgassupplier ofthiscondition.oilorgreaseinthepresenceofhigh pressureoxygenisexplosive. 3.Stand to one side away from the outlet and open the cylindervalveforaninstant.thisblowsawayanydust or dirt which may have accumulated in the valve outlet. A-3 4.Attach the flow regulator to the cylinder valve and tightentheunionnut(s)securelywithawrench.note: if connecting to 100% CO 2 cylinder, insert regulator adapter between regulator and cylinder valve. If adapterisequippedwithaplasticwasher,besureitis seatedforconnectiontotheco 2 cylinder. 5.Attachoneendoftheinlethosetotheoutletfittingof theflowregulator.attachtheotherendtothewelding systemshieldinggasinlet.tightentheunionnutswith awrench. 6.Before opening the cylinder valve, turn the regulator adjusting knob counterclockwise until the adjusting springpressureisreleased. 7.Standingtooneside,openthecylindervalveslowlya fraction of a turn. When the cylinder pressure gage stopsmoving,openthevalvefully. 8.The flow regulator is adjustable. Adjust it to the flow rate recommended for the procedure and process beingusedbeforemakingaweld.

11 A-4 WIRE DRIVE CONFIGURATION (SeeFigureA.1) CHANGING THE GUN RECEIVER BUSHING WARNING ELECTRIC SHOCK can kill. Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. Do not touch electrically live parts. When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released. Do not operate with covers, panels or guards removed or open. Only qualified personnel should perform maintenance work Toolsrequired: 1/4"hexkeywrench. Note:Somegunbushingsdonotrequiretheuseof thethumbscrew. 1.Turnpoweroffattheweldingpowersource. 2.Removetheweldingwirefromthewiredrive. 3.Removethethumbscrewfromthewiredrive. 4.Removetheweldinggunfromthewiredrive. 5.Loosen the socket head cap screw that holds the connectorbaragainstthegunbushing. Important: Do not attempt to completely remove the socket head cap screw. 6.Remove the outer wire guide, and push the gun bushingoutofthewiredrive.becauseoftheprecision fit, light tapping may be required to remove thegunbushing. 7.Disconnect the shielding gas hose from the gun bushing,ifrequired. FIGURE A.1 INSTALLATION A-4 8.Connect the shielding gas hose to the new gun bushing,ifrequired. 9. Rotatethegunbushinguntilthethumbscrewhole aligns with the thumb screw hole in the feedplate. Slide the gun receiver bushing into the wire drive andverifythethumbscrewholesarealigned. 10.Tightenthesocketheadcapscrew10to14ft-lbs (13.5to19.0Nm). 11.Insert the welding gun into the gun bushing and tightenthethumbscrew. PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES WARNING Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. Do not touch electrically live parts. When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released. Do not operate with covers, panels or guards removed or open. Only qualified personnel should perform maintenance work Turnpoweroffattheweldingpowersource. 2.Releasetheidlerollpressurearm. 3.Removetheouterwireguidebyturningtheknurled thumbscrews counter-clockwise to unscrew them fromthefeedplate. 4.Rotate the triangular lock and remove the drive rolls. THUMB SCREW GUN RECEIVER BUSHING CONNECTOR BLOCK SOCKET HEAD CAP SCREW OUTER WIRE GUIDE 5.Removetheinnerwireguide. 6.Insert the new inner wire guide, groove side out, overthetwolocatingpinsinthefeedplate. 7.Install a drive roll on each hub assembly secure withthetriangularlock. 8.Install the outer wire guide by aligning it with the pinsandtighteningtheknurledthumbscrews. 9.Closetheidlearmandengagetheidlerollpressure arm.adjustthepressureappropriately. LOOSEN TIGHTEN

12 A-5 PRESSURE ARM ADJUSTMENT INSTALLATION LOADING SPOOLS OF WIRE A-5 WARNING ELECTRIC SHOCK can kill. Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. Do not touch electrically live parts. When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released. Do not operate with covers, panels or guards removed or open. Only qualified personnel should perform maintenance work The pressure arm controls the amount of force the driverollsexertonthewire.properadjustmentofthe pressure arm gives the best welding performance. Many welding problems can be attributed to setting thepressurearmtoohighandcausingwiredeformation. Set the pressure arm to minimum amount that providesreliablefeeding. Setthepressurearmasfollows: Coredwires between1and3 Steel,Stainlesswires between3and5 Keep hands, hair, clothing and tools away from rotating equipment. Do not wear gloves when threading wire or changing wire spool. Only qualified personnel should install, use or service this equipment SPOOL RETAINER Whenloadingandremovingthe8 spoolsmakesure that the wing nut(inside the wire reel spindle hub) is turned 90 from the wire reel spindle locking tabs. If thewingnutispositionedinlinewiththelockingtabs, the tabs cannot be depressed to load or unload the wirespool.(seefiga.2) The wire spool must be pushed all the way on the spindle so that both the spindle s tabs will hold it in place. The wire spool will rotate counter clockwise whenwireisde-reeled. SPOOL BRAKE WARNING Adjust the spool brake with wire spool installed, to provide enough friction to stop wire overrun. To adjust the brake turn the wing nut clockwise to increase the brake, and counterclockwise to loosen thebrake. FIGURE A.2 Excessivebrakeforcemaycausemotorthermaloverloadsorweldingproblems. WIRE REEL SPINDLE MOUNTING TABS WING NUT

13 A-6 GUN CONNECTION WARNING INSTALLATION A-6 ELECTRIC SHOCK can kill. Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. Do not touch electrically live parts. When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released. Do not operate with covers, panels or guards removed or open. Only qualified personnel should perform maintenance work The comes with a K gun adapter installed.(seefigurea.3) Toinstallagun, 1.TurnpowerOFF. 2.Removethethumbscrew. 3.Pushthegunthecompletelyintothegunbushing. 4.Securetheguninplacewiththethumbscrew. 5.Connectthetriggercablefromtheguntothetrigger connectoronthefrontofthefeeder. Note:Not all gun bushings require the use of the thumbscrew. FIGURE A.3 GUN THUMB SCREW

14 A-7 INSTALLATION POWER SOURCE TO CABLE CONNECTION DIAGRAMS A-7 ACROSS THE ARC SET-UPS CC Power Sources with Output Terminals Always Hot (See Figure A.4) FIGURE A.4 CC Power Source Classics Big Red s Eagle 10,000 Plus Pipeliner 200D Without Wire Feed module SAE s Without CV Adapter Electrode Work Work clip IfthepowersourcehasaRemote/Localswitch,place theswitchinthelocalposition. PlacetheCV/CCswitchinthefeederinthe"CC"position. K# K KP1696-XX KP1697-XX SeeMagnumLiterature K1803-XX Description DriveRollKit WeldingGun CCpowerSource WeldingCables CV Power Sources with Stud Connectors and Remote/Local Switch (See Figure A.5) CV-400 CV-655 DC-400 DC-600 DC-655 V450-Pro Jumper Electrode FIGURE A.5 SAE 400 with CV adapter Engine Driven welder with Wire Feed Module Ranger 250 GXT Work Work clip Place the power source Remote/Local switch in the Localposition. PlaceCV/CCswitchinthefeederinthe"CV"position. K# K KP1696-XX KP1697-XX SeemagnumLiterature K1803-XX K484 Description DriveRollKit WeldingGun CVpowerSource WeldingCables JumperPlugkit

15 A-8 CV Power Sources with Stud Connectors and no Remote/Local Switch(See Figure A.6) INSTALLATION A-8 RANGER 250, 250 LPG RANGER 305G, 305D RANGER 10,000 RANGER 3 PHASE RANGER225, 225 GXT COMMANDER 300 VANTAGE 300, 400, 500 AIR VANTAGE 500 Electrode FIGURE A.6 Work Work clip PlaceCV/CCswitchinthefeederinthe"CV"position. K# K KP1696-XX KP1697-XX SeeMagnumLiterature K1803-XX Description DriveRollKit WeldingGun CCpowerSource WeldingCables CV Power Source with Twist-Mate Connectors and Remote/Local Switch. (See Figure A.7) FIGURE A.7 V350-Pr o CV 305 Electrode Work clip Work Place the power source Remote/Local switch in the Localposition. PlaceCV/CCswitchinthefeederinthe"CV"position. K# K KP1696-XX KP1697-XX SeeMagnumLiterature K1841-XX K Description DriveRollKit WeldingGun CVpowerSource WeldingCables Twist-MateCablePlug

16 A-9 CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.8) Jump er INSTALLATION FIGURE A.8 A-9 CV-250 CV-300 Electrode Work clip Work PlaceCV/CCswitchinthefeederinthe"CV"position. K# K KP1696-XX KP1697-XX SeeMagnumLiterature K1841-XX K K484 Description DriveRollKit WeldingGun CVpowerSource WeldingCables Twist-MateCablePlug JumperPlugkit

17 A-10 INSTALLATION PROCEDURE TO INSTALL CONDUIT BUSHING FOR THE WIRE FEEDER UNIT A-10 WARNING ELECTRIC SHOCK CAN KILL Turn off the Welding Power Source before installing or changing drive rolls and / or guides. When inching with gun trigger, electrode and drive mechanism are "hot" to work and ground. Only qualified persons should install, use or service this machine. PROCEDURE TO INSTALL CONDUIT BUSHING 1. Turn OFF Welding Power Source. 2. Loosen the set screw which secures the existing incoming guide bushing and remove the incoming guide bushing from the wire feed head (See Fig 1). WIRE FEED HEAD SET SCREW INCOMING GUIDE BUSHING FIG 1 3. Insert flex tube into new conduit bushing. Insert the thumb screw into the new conduit bushing and tighten the thumb screw. The thumb screw threads will lock the flex tube into place (See Fig. 2). 4. Install the new conduit bushing, flex tube and thumb screw into the wire feed head. 5. Tighten the set screw. CONDUIT BUSHING (PART OF K1546-2, INCOMING BUSHING KIT) WIRE FEED HEAD SET SCREW THUMB SCREW (PART OF K1546-2, INCOMING BUSHING KIT) FLEX TUBE (T ) FIG 2 A.01 M22832

18 B-1 SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. OPERATION B-1 GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL WARNING ELECTRIC SHOCK CAN KILL. Unless using COLD FEED feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases.. The work clip is energized any time the output of the welding power source is ON, even when the feeder is not welding. Do not touch electrically live part or electrode with skin or wet clothing. Insulate yourself from work and ground. Always wear dry insulating gloves. The serviceability of a product or structure utilizing the wire feeder is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the wire feeder. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of the wire feeder may not be suitable for all applications, and the builder/user is and must be solely responsible for welding settings FUMES AND GASSES can be dangerous. Keep your head out of fumes. Use ventilation or exhaust at the arc, or both, to remove fumes and gases from breathing zone and general area WELDING SPARKS can cause fire or explosion. Keep flammable material away ARC RAYS can burn. Wear eye, ear and body protection SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MAN- UAL U 0 U 1 U 2 I 1 I 2 INPUT POWER ON OFF WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT INPUT POWER DIRECT CURRENT OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION

19 B-2 OPERATION RECOMMENDED PROCESSES B-2 The wire drive feeds electrode for various processesasfollows:(seetableb.1) PROCESS LIMITATIONS PRODUCT DESCRIPTION Theisaportablefeederfor15lbs./8in. spoolsspecificallydesignedforshipyard(shipbuilding and offshore structure fabrication). This wire feeder will offer excellent feeding and welding performance withhardandsoftshellweldingwires.itwillbecompatiblewithanydccvand/orccpowersource. ThecomesfactoryequippedwithaK1500-2Magnum Tweco-compatiblestyle#2-#4gunbushing.OtherK1500seriesgunbushingsareavailableas fieldinstalledoptions. Thewithit spatentedfeaturesarespecially engineeredtobethemostruggedportablewirefeederavailable: Simple Controls WFS knob on the front; Cold Feed/Gas Purge, Trigger Interlock and CV/CC switchesinside. Across-The-ArcOperation(VoltageSensing) uses a work lead and a contactor for enabling welding current. Rating-330amp,60%dutycyclerating. Singlepottedcontrolboard designcommonality. Gas apparatus can be used for FCAW-G and GMAWprocesses. MAXTRAC Wire Drive System with two drive rollsallowsbestinclassfeedingperformance. The plastic case is molded from a high impact, flame retardant plastic for high durability and low weight. Theheartoftheisthe2rollMAXTRAC drive. The patented features on the wire drive offer tool-lesschangingofthedriverollsandwireguides for quick spool changes. A tachometer controlled motor powers the patented drive rolls for smooth, steadyfeedingwithoutslippage. GMAW-P procedures must be qualified by the customer. is not recommended for stitch or spot welding. EQUIPMENT LIMITATIONS The duty cycle of the wire feeder is 330A, 60%. Dutycycleisbasedupontheamountofweldingperformedina10minuteperiod. Themaximumspoolsizeis12.5lb,8 diameter. MaximumFCAWgunlengthis15ft. MaximumGMAWgunlengthis15ft. Push-pullgunsdonotworkwiththe. NotcompatiblewithK489-7Euroconnector. RECOMMENDED POWER SOURCES Ranger3Phase CV-305 Ranger225,225GXT CV-400 Ranger250 CV-655 Ranger305 DC-400 SAE-400 DC-600 Pipeliner200G DC-655 Classic300 InvertecV-350-Pro Vantage300 FlexTec450 Vantage400 Multi-Weld350 Vantage500 Ranger10,000 DUTY CYCLE The wire feeders are intended for semiautomaticuse.themaximumratingofthe isbasedupona60%dutycycle;welding6minutesof welding followed by 4 minutes of idling within a 10 minuteperiod. TABLE B.1 Process Wire Diameter Range Wire Feed Speed Range GMAW "( mm) FCAW /64"( mm) ipm( m/minute)

20 B-3 (SeeCustomer Assistance Policy inthefrontofthis InstructionManual) CASE FRONT CONTROLS (See Figure B.1) FIGURE B.1 OPERATION Arc Voltage 15V 18V 21V 24V 27V Max WFS 440ipm 523ipm 609ipm 690ipm 783ipm B See Constant Current Operation for setting thewirefeedspeedwhenintheccmode. 2. TRIGGER CONNECTOR Thereisonecircularconnectorfortheguntrigger on the front of the. Note if the gun trigger is already depressed when the feeder is poweredup,thefeederwillnotactivate.release andthenpresstheguntriggertobeginwelding WORK LEAD Alwaysturnpoweroffattheweldingpowersource beforemovingtheworklead. Theworkleadattachestotheitembeingwelded. ITEM 1. WIRE FEED SPEED KNOB UsetheWireFeedSpeedKnobtoadjusttherate ofwirefeedspeed. WFS range: 50to800ipm DESCRIPTION 1 WireFeedSpeedKnob 2 5-pinguntriggerconnector 3 Worklead 4 ThermalLED 5 PolarityLED 4. THERMAL LED, MOTOR OVERLOAD The thermal LED illuminates when the wire drive motordrawstoomuchcurrent.ifthethermallight illuminates, the wire drive will automatically shutdown for up to 30 seconds to allow the motor to cool.tostartweldingagain,releasetheguntrigger, inspect the gun cable, liner (and conduit). Cleanandmakerepairsasnecessary.Startwelding again when the problem has been safely resolved. For best results, keep the gun cable and conduit as straight as possible. Perform regular maintenance and cleaning on the gun liner, conduit and gun. Always use quality electrode, such as L-50 orl-56fromlincolnelectric. 5. POLARITY LED ThepolarityLEDilluminateswhenthewirefeeder isconnectedtopositivepolarity. Because the wire feeder is powered by the arc voltage,thefullrangeofwirefeedspeedmaynot beavailableatlowvoltages.

21 B-4 INTERNAL CONTROLS (See Figure B.2) ITEM DESCRIPTION OPERATION B-4 When gas purging the gas solenoid valve will energize but neither the power source output nor thedrivemotorwillbeturnedon.thegaspurge switch is useful for setting the proper flow rate of shieldinggas. 1 PressureArm 2 ColdFeed/GasPurgeSwitch 3 2-Step/TriggerInterlockSwitch 4 CV/CCSwitch 5 SpoolRetainer 6 SpindleBrake 7 Gun Bushing, Thumb Screw and SocketHeadCapScrew. 8 DriveHub 1. PRESSURE ARM (See Installation Section forfunction.) 2. COLD FEED / GAS PURGE SWITCH Place the rocker (momentary) switch in the FOR- WARD position for cold feeding, or in the REAR positionforgaspurge. When cold feeding, the wire drive will feed electrodebutneitherthefeedplatenorthegassolenoid willbeenergized.adjustthespeedofcoldfeeding by rotating the WFS knob. Cold feeding, or "cold inching" the electrode is useful for threading the e l e c t r o d e through the gun STEP/ TRIGGER INTERLOCK SWITCH The 2-Step/Trigger Interlock switch changes the functionoftheguntrigger.2-steptriggeroperation turns welding on and off in direct response to the trigger.triggerinterlockoperationallowsweldingto continuewhenthetriggerisreleasedforcomforton longwelds. Place the rocker switch in the DOWN position for 2-Step operation or in the UP position for Trigger Interlockoperation. 2-Step Trigger 2-Step trigger operation is the most common. When the gun trigger is pulled, the welding power source energizes the electrode output and the wire feeder feedswireforwelding.the power source and wire feeder continue welding untilthetriggerisreleased. 1 FIGURE B

22 B-5 Trigger Interlock Trigger Interlock operation provides for operator comfort when making long welds. When the gun trigger is first pulled, the welding power source energizes the output and the wire feeder feeds wire for welding. The gun trigger is then released while the weld is made. To stop welding, the gun triggerispulledagain,andwhenitisreleasedthe weldingpowersourceoutputturnsoffandthewire feederstopsfeedingwire. CAUTION If the arc goes out while welding with trigger interlock operation, the electrode output from the welding power source remains energized and the wire feeder will continue to feed wire until the gun trigger is again pulled and then released CV/CC SWITCH OPERATION REAR CONTROLS (See Figure B.3) ITEM DESCRIPTION 1 ShieldingGasInletwithgasfilter 2 ElectrodeLead FIGURE B.3 B-5 TheCV/CCswitchsetsthewirefeedspeedcontrolmethodforthewirefeeder. PlacetherockerswitchintheUPpositionforCC operationorinthedownpositionforcvoperation. 1 2 IntheCCposition,the wirefeedspeedvaries duringwelding.thearc lengthismaintainedby changingthewirefeed speed. IntheCVposition,the wirefeedspeedremains constantduringwelding. Asteadyarcvoltageis regulatedbythepowersourcebyadjustingthearc current. 5. SPOOL RETAINER* 6. SPOOL BRAKE* 7. GUN BUSHING, THUMB SCREW AND SOCKET HEAD CAP SCREW* 8. DRIVE ROLLS AND WIRE GUIDES* * (See Installation Section forfunctions.)

23 B-6 The serviceability of a product or structure utilizing the wire feeder is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the wire feeder. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of the wirefeeder may not be suitable for all applications, and the builder/user is and must be solely responsible for welding settings. CONSTANT CURRENT OPERATION OPERATION TopresetthewirefeedspeedonCCpowersources: B-6 1.Set the Wire Feed Mode switch inside the to"cc". 2.RefertotheFigureB.4graphtodetermineccsettingofthewirefeedspeedknob.Selectthehorizontal line representing the Desired Wire Feed Speed.(SeeFigureB.4arrowfor375in/min.) 3.Select the diagonal line representing the Arc Volts.(SeeFigureB.4for29volts.) 4.Determine the vertical line representing the CC Wire Feed Speed setting where the above two lines cross.(see Figure B.4 arrow line for 450.) Set the wire feed speed knob to this value. Setting Wire Feed Speed in CC mode When Across the Arc models are operated with CC power sources, the wire feed speed changes as the arcvoltagechanges.whenthearcvoltageincreases, the wire feed speed will increase; and when the arc voltagedecreases,thewirefeedspeedwilldecrease. CCWFSdialsetting=desiredWFSx35 ArcVolts Example: = 375in/min.(HorizontalLine)x35 29ArcVolts(DiagonalLine) =452.5(VerticalLine) (SeeFigureB.4) Use 450 setting FIGURE B.4 V ARC VOLTS A constant voltage (CV) power source is recommended for fluxcored arc welding. (FCAW) and gas metal arc welding (GMAW) to obtain code quality results. However,thiswirefeedermayalso be used with a constant current (CC)powersourcetoobtainpassable results for noncritical quality applications CC M VM

24 B-7 CONSTANT CURRENT OPERATION (SeeFigureB.5) CAUTION Lincoln Electric does NOT recommend constant current semiautomatic welding for applications which need to meet specified weld metal chemical or mechanical property requirements or weld quality requirements Most semiautomatic welding processes perform better usingconstantvoltagepowersources. Weldingcodesusuallydonotaddressthepowersource selection or specifically, whether the welding process is tobeoperatedintheconstantvoltageorconstantcurrent mode.instead,codestypicallyspecifylimitationsonthe current, voltage, heat input and preheat temperature based on the material to be welded. The intention is to assurethatproperweldmaterialpropertieswilldevelop. OPERATION B-7 If the contact tip to work distance is properly maintained,asatisfactoryoperatingvoltagerangemaybe achieved, and a sound weld may result. However, when a welder uses a longer contact tip to work distance, an arc-sensing wire feeder compensates by increasingthewirefeedspeedtoregulatethevoltage. Evenifthevoltageandcurrentremainunchanged,the increased wire feed speed may result in a deposition ratewellbeyondthespecifiedrangeoftheelectrode. Undertheseconditions,thespecifiedweldmetalpropertiesmaynotbeachieved. Constant voltage power sources deliver large current surgestostabilizethearcwhentheelectrodeisshortedorthearclengthisveryshort.however,aconstant current power source does not provide such a response to stabilize the arc. It may be difficult to achieverequiredweldmetalproperties,ortoachieve therequiredqualityofweldsneededtopassnondestructivetests,whensuchweldsaremadeunderconstantcurrentoperation. Welding is sometimes performed using constant current power sources. The operation can be more convenient becauseitmayallowtheuseofanexistingstick(smaw) powersourceandthepowersourcecanbeplacedata distant location without any provision for adjusting the outputsettings. Forthesereasons,LincolnElectricdoesNOT recommend constant current semiautomatic welding for applicationswhichneedtomeetspecifiedweldmetal chemicalormechanicalpropertyrequirementsorweld qualityrequirements. Forconstantcurrentoperation,thepowersourceissetto deliverthespecifiedcurrent.thepowersourceregulates thiscurrentregardlessofchangesintheweldingcircuit, including cable length, electrode diameter, wire feed speed,contacttiptoworkdistance,etc. Changesinthewirefeedspeed(WFS)orcontacttip toworkdistance(ctwd)affectthearcvoltagewhen constant current power sources are used. Lowering the wire feed speed raises the voltage, raising the wirefeedspeedlowersthevoltage.lengtheningthe contact tip to work distance raises the voltage, shorteningthecontacttiptoworkdistancelowersthevoltage. FIGURE B.5 Constant Current Power Source + Current Welding Cable (Electrode) Wire Feeder WFS GUN AND CABLE ASSEMBLY CTWD - Current Welding Cable (Work)

25 B-8 MAKING A WELD OPERATION Theserviceabilityofaproductorstructureutilizingthe wirefeederisandmustbethesoleresponsibilityofthebuilder/user.manyvariablesbeyondthe control of The Lincoln Electric Company affect the results obtained in using the wire feeder. Thesevariablesinclude,butarenotlimitedto,welding procedure, plate chemistry and temperature, weldmentdesign,fabricationmethodsandservicerequirements. The available range of the wire feedermaynotbesuitableforallapplications,andthe builder/user is and must be solely responsible for weldingsettings. Closethedooronthe. Checkthatthepowersourceisturnedoff. Connect the work cable to the metal to be welded. Theworkcablemustmakegoodelectricalcontactto thework.theworkmustalsobegroundedasstated in"arcweldingsafetyprecautions". Connect the electrode and work cable to the power source for the polarity and process to be used.checkthattheappropriatepowersourcesettingsaremadefortheproceduretobeused.(refer to the power source operating and connection instructions.) Placetheconvenientlyneartheworkarea inasafelocationtominimizeexposuretoweldspatterandtoavoidsharpbendsintheguncable. Connecttheworkcliptothework. Besurethepropercontacttipforthewiresizebeing usedisinthegun. Turn on the welding power source, as well as the shieldinggassupply(ifused.) Cut the electrode within approximately 3/8" (10mm) oftheendofthecontacttipforsolidwireandwithin 3/4"(19mm)oftheextensionguideforcoredwire. Positiontheelectrodeoverthejoint.Theendofthe electrodeshouldbeslightlyoffthework. Lower welding helmet, close the gun trigger and begin welding. Hold the gun so the contact tip to workdistancegivesthecorrectelectricalstickoutas requiredfortheprocedurebeingused. Tostopwelding,releasetheguntriggerandthepull thegunawayfromthework. B-8

26 C-1 OPTIONAL KITS AND ACCESSORIES ACCESSORIES C-1 DRIVE ROLL KITS, 2 ROLL DRIVE WIRE TYPE ELECTRODE SIZE KP KIT SteelWires: "( mm).035"(0.9mm).045"(1.2mm).052"(1.4mm) "( mm).040"(1.0mm) KP S KP S KP S KP S KP KP Includes:2Vgroove drive rolls and inner wireguide. CoredWires: "( mm) "( mm).052"(1.4mm) 1/16"(1.6mm).068"(1.7mm) 5/64"(2.0mm) KP C KP C KP C KP1697-1/16C KP KP1697-5/64 Includes: 2 Knurled drive rolls and inner wireguide.

27 C-2 ACCESSORIES C-2 K PlasticCase K K1840-xx WorkandFeederCablesPackage. WeldPowerCable,Twist-MatetoLug. Includes: Twist-Mate to Lug 2/0 cable 14' (1.2m) long with Ground Clamp, and Twist-Mate to Lug 2/0 Cable 9' (2.7m)long. Includes:Twist-MatetoLug, 1/0cableoflength"xx". K1841-xx K WeldPowerCable, Twist-MatetoTwist-Mate. Twist-MatePlug. Includes:acompleteengineeredplasticcase. Includes:Twist-MatetoTwistmate,1/0Cableoflength xx forlength25 (7.6m).Twist- MatetoTwist-mate,2/0Cable oflength xx forlength 50 (15.2). Includes:Twist-MatePlug, rubberboot,(2)setscrews. K Tweco Style Cam-LockAdapter PlugforWork&ElectrodeCables. Includes:Tweco StyleCam- LockAdapterPlugfor2/0 (70mm2)cable,rubberboot, (2)setscrews,(1)Fillister headscrew. K1842-xx WeldPowerCable,LugtoLug. Includes:LugtoLug,3/0 Cableoflength"xx"forlengths upto60'(18.3m).lugtolug, 4/0Cableoflength"xx"for lengthsgreaterthan60' (18.3m). KP ShieldingGasFilter Includesonein-lineshielding gasfilter. K FlowMeterKit Includesonein-lineflowmeter assembly.

28 C-3 ACCESSORIES C-3 K910-1 K910-2 K GroundClamp GroundClamp GunReceiverBushing(forguns withk466-1lincolngunconnectors;innershieldandsubarcguns) Includes:One300Amp GroundClamp. Includes:One500Amp GroundClamp. Includes:Gunreceiverbushing,setscrewandhexkey wrench. K484 JumperPlugKit Includes:14pincircular connectorwithjumperfor leads2-4.foruseinpower sourcesforturningtheweld terminals"on"atalltimes. K K K K K586-1 K283 GunReceiverBushing(forguns withk466-2,k466-10lincolngun connectors;magnum200/300/400 gunsandcompatiblewithtweco #2-#4) GunReceiverBushing(forguns withk613-7lincolngunconnectors;magnum550gunsandcompatiblewithtweco #5) GunReceiverBushing(forgun withk466-3lincolngunconnectors;compatiblewithmiller guns.) IncomingBushingforLincoln Conduit DeluxeAdjustableGasRegulator. WireFeedSpeedMeter Includes:Gunreceiverbushingwithhosenipple,setscrew andhexkeywrench. Includes:Gunreceiverbushingwithhosenipple,setscrew andhexkeywrench. Includes:Gunreceiverbushingwithhosenipple,setscrew andhexkeywrench. Includes:FeedPlateIncoming Bushingsconnectdirectlytowire conduit(notincluded),forusein boomsystem,longdistances,or largepayoffpackages.bushings canbeusedwithanywireconduit (K515orK565).For1/16-1/8in diameterwire. NOTE: T FlexTube RequiredwithK Includes:DeluxeGasRegulator formixedgases,adapterforco 2 and10'(3.0m)hose. Includes:Awirefeedspeed meterwithdigitaldisplay.