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IM886
LINCOLN WELDING ARMS April, 2006
For use with machine “K� Numbers: K1778-1, K1779-XX use with machine
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 thought-
ful 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
Copyright © 2006 Lincoln Global Inc.
� 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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel 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, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� 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.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. 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 before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating pro-
ducts.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés possible
1. Protegez-vous contre la secousse électrique:
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
a. Les circuits à l’électrode et à la piéce sont sous tension
endroits éloignés de la zone de travail, on augmente le risque
quand la machine à souder est en marche. Eviter toujours
de voir passer le courant de soudage par les chaines de lev-
tout contact entre les parties sous tension et la peau nue
age, câbles de grue, ou autres circuits. Cela peut provoquer
ou les vétements mouillés. Porter des gants secs et sans
des risques d’incendie ou d’echauffement des chaines et des
trous pour isoler les mains.
câbles jusqu’� ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
9. Assurer une ventilation suffisante dans la zone de soudage.
metallique ou des grilles metalliques, principalement dans
Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande
galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse.
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
10. Ne pas souder en présence de vapeurs de chlore provenant
defonctionnement.
d’opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l’eau pour le
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
refroidir.
du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension
ou autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
11. Pour obtenir de plus amples renseignements sur la sûreté,
total de la tension à vide des deux machines.
voir le code “Code for safety in welding and cutting� CSA
f. Si on utilise la machine à souder comme une source de
Standard W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
PRÉCAUTIONS DE SÛRETÉ POUR
contre les chutes dans le cas ou on recoit un choc. Ne jamais
LES MACHINES À SOUDER À
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, I’installation et l’entretien du poste seront
l‘arc. effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables. 3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres 4. Garder tous les couvercles et dispositifs de sûreté à leur
de l’huile, tels que les gants en cuir, chemise épaisse, pan- place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �93
zones où l’on pique le laitier.
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
� For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then
“Product Registration�. Please complete the form and submit your registration.
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:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi vi
TABLE OF CONTENTS
Page
Product Description ...................................................................................................1
Common Equipment Packages.................................................................................2
Specification and Design Features...........................................................................3
________________________________________________________________________
Installation .......................................................................................................Section A
Non-Saftey Standard Information ..........................................................................A-1
Location .................................................................................................................A-1
Product Specification Installation............................................................A-1 Thru A-4
Recommended Cable Sizes ..................................................................................A-4
Adjusting for Wire Feeder Weight..........................................................................A-5
Adjusting the Welding Arm Travel .........................................................................A-5
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
Shielding Gas Connection .....................................................................................B-1
________________________________________________________________________
Accessories .....................................................................................................Section C
Options / Accessories, Mini Console Assembly Instructions.................C-1 Thru C-4
________________________________________________________________________
Maintenance ....................................................................................................Section D
Routine Maintenance ............................................................................................D-1
Dimension Print ...............................................................................................Section F
________________________________________________________________________
1 1
PRODUCT DESCRIPTION
PRODUCT SUMMARY RECOMMENDED PROCESSES AND
EQUIPMENT
General Physical Description
The Lincoln Welding Arms create an organized work RECOMMENDED PROCESSES
environment. The models available are:
� 6000 series Stanchion Mount for bolting to an � GMAW (including GMAW-P, GMAW-STT if sup-
appropriately prepared floor. ported by the power source and wire feeder.)
� FCAW
All welding arms are constructed with strong steel tub-
ing. The design is light weight yet stiff, and provides PROCESS LIMITATIONS
for clever cable routing. When using optional vacuum
equipment, the tubes provide a sleek path for fume � The arms are not suitable for SAW because of the
and dust extraction. weight of a typical SAW system.
For further flexibility, an optional lift truck platform is RECOMMENDED EQUIPMENT
available, making it easy to transport the welding arm
about the work site. The welding arms are compatible with the following
wire feeders:
Order the optional mini-console for compressed air, � Power Feed 10 and Power Feed 10M
electric and vacuum connections at the wire feeder. � Power Feed 10 Dual and Power Feed 10M Dual
� LN-10
� DH-10
General Functional Description � LF-72
The welding arms suspend the wire feeder and weld-
ing cables above the floor, allowing the work area to EQUIPMENT LIMITATIONS
be fully devoted to fabrication. Control cables, elec-
trode liners, electrode cables, shielding gas hoses, � The total weight of all equipment, guns and cables
etc. are neatly routed through the tubing of the arm for mounted to or hanging from the welding arm must
protection. not exceed 150 lb. (68kg).
6000 series arms feature counterbalance springs to � When using the optional K1779-1 platform, a mini-
equalize the weight of the feeder and to allow the mum weight of 300lb (136kg) must be secured to
operator to choose the working height. The operator the platform to prevent tipping.
simply glides the arm into position and begins to weld.
WELDING ARMS
2 2
COMMON EQUIPMENT PACKAGES
6000 Series Stanchion Mount
(For Details and Assembly of Items Below, See Accessories Section)
ITEM DESCRIPTION
K1778-1 6000 series arm with stanchion.
K1779-1 Lift Truck Platform
K1779-13 Single electrode liner kit.
K1779-7 Dual gas cylinder holder kit.
K1779-8 Wire spindle mounting bracket.
K162-1 Spindle Kit
K1779-11 Mini-Console
K1779-9 Universal feeder mounting bracket.
K1778-1
6000 Series Arm
K1779-13
Single Electrode
Liner Kit
K1778-8
Wire Spindle
Mounting Bracket K1779-9
K162-1 Universal Wire
Spindle Kit Feeder Bracket
K1779-11
Mini-Console
K1779-7
Dual Gas
Cylinder Holder
Kit
K1779-1
Lift Truck
Platform
WELDING ARMS
3 3
SPECIFICATIONS
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
-20°C to +40°C (-04° to +104°F) -40°C to +85°C (-40° to +185°F)
DESIGN FEATURES
� 360° rotation with the 6000 series stanchion
secured directly to the floor.
� 180° rotation with the 6000 series stanchion mount-
ed to the optional lift truck platform.
� Organized work areas for improved productivity.
� Longer life of cables, welding guns, hoses.
� Welding controls at an ergonomic position.
� Small footprint gives more room to work.
� Compressed air, vacuum and electrical connections
at the wire feeder when using the optional mini-con-
sole.
WELDING ARMS
A-1 A-1
INSTALLATION
SAFETY PRECAUTIONS � Moving welding arm parts can cause serious per-
sonal injury. Keep hands away from pinch points
WARNING and from the spring rod clevis and swivel plates.
� Falling welding arm can cause serious personal
ELECTRIC SHOCK can kill. injury and equipment damage.
� Turn the input power OFF at the � Unbalanced welding arm can cause serious person-
welding power source before instal-
al injury and equipment damage. Do not remove
lation or changing drive rolls and/or
the wire feeder unless the tension clevis is fully
guides.
retracted against the spring holder.
� Do not touch electrically live parts.
� A minimum weight of 300 lb. (136 kg) must be
� When inching with the gun trigger,
electrode and drive mechanism are secured to the platform to prevent tipping. The plat-
"hot" to work and ground and could form must be level. Do not remove power source or
remain energized several seconds weight from the platform unless the arm has been
after the gun trigger is released.
secured. The arm will tip over if the weight is
� Welding power source must be connected to
removed from the platform.
system ground per the National Electrical Code
or any applicable local codes.
LOCATION
� Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
The Welding Arms are suitable for indoor environ-
ments only.
NON-STANDARD SAFETY INFORMATION
PRODUCT SPECIFIC INSTALLATION
� This equipment is not designed for and should not
INSTRUCTIONS.
be used for lifting, supporting or transporting people.
� Always inspect the welding arm and accessories
Erecting the Welding Arm
before use and before placing into storage.
� Ensure the travel path is clear before moving the
6000 series Stanchion Mount and Platform Mount.
welding arm.
� Never shock or side load the welding arm.
1. Remove the top and sides from the crate.
� Do not attempt to drag loads across the ground with
the welding arm.
� Do not place ladders or climb on an unrestrained
welding arm.
� Do not use platform arms as lift truck attachments.
� Do not move welding arms with the gas cylinders
attached.
� The overall stability and safety of a welding arm
depends on its foundation or supports. When erect-
ing to an existing structure it is important that the
2. Remove mounting block at rear of the arm.
superimposed forces are assessed by a qualified
engineer and written approval obtained.
� Welding arms must be mounted onto a suitable
foundation and a suitably qualified person should be
consulted.
� Do not let the welding arm crash into any travel
stops, objects or persons.
� Regularly inspect the welding arm, and in the event
of the following defects, refer the welding arm to a
Competent Person for thorough examination: struc-
3. Remove the mounting block at the front of the arm.
tural defects, damage, distortion or cracked welds,
loose or missing bolts, damaged or missing stops,
difficulty in slewing or welding arm slews on it owns,
any other visibly defects or operational difficulties.
� Springs are under pressure. Do not service or
adjust the springs.
WELDING ARMS
A-2 A-2
INSTALLATION
7. Lift the stanchion assembly off the ground and
4. Remove the red arm from the crate. move to desired location.
8. Secure the stanchion to the floor per qualified engi-
neer specifications or secure the stanchion to the
optional platform. If using the platform, level the
platform before installing the stanchion. Install and
5. Remove the two 3/8" lag bolts from the base of the secure at least 300# of weight onto the platform. A
stanchion. Note: Do NOT remove the steel strap until welding power source may be sufficient for this pur-
the stanchion has been secured. pose. Verify the weight of the power source.
15.2�
15.2�
18�
6. Secure an adequate nylon strap or rope to the top
of the arm. Loop the strap behind the red mounting
triangle where it attaches to the pivot clutches. Slowly 9. Remove the six 1/2" x 1-1/4 bolts and lock washers
lift the arm out of the crate. from the rear of the arm.
WELDING ARMS
A-3 A-3
INSTALLATION
10. Install with arm section with the six 1/2" x 1-1/4 17. Slip the 4" (102 mm) of PVC tube over the gas
bolts and washers. hose(s).
18. Secure the welding arm to prevent movement.
WARNING
Secure the welding arm to prevent movement
before mounting wire feeder, cables, or any other
accessory.
------------------------------------------------------------------------
The Universal Wire Feeder Mounting Bracket has
holes for mounting:
� LF-72
� LN-10
� DH-10
� Power Feed 10 and Power Feed 10M
� Power Feed 10 Dual and Power Feed 10M Dual
11. Raise the front of the arm with a forklift or hoist
and attach to the appropriate hole in the clevis and 19. Compare the mounting holes of the wire feeder to
arm triangle. the mounting holes on the Universal Wire Drive
Bracket. If necessary, drill holes in the bracket.
12. Install the cover plate at the top of the stanchion.
13. Install the optional K1779-9 Universal Wire Feeder
Support Bracket.
14. Route the control cable, gas hose and electrode
cable through the center tube.
15. Slip the 3' (0.9m) long, 2" (51 mm) diameter black 20. Place the wire feeder onto the Universal Wire
hose over the assembled cables and hose at the Drive Bracket and attach with appropriate hard-
rear of the arm. ware. Use hardware that is vibration proof.
16. Slip the 1' (0.3m) long, 2" (51 mm) diameter black
hose over the assembled cables at the front of the
arm.
WELDING ARMS
A-4 A-4
INSTALLATION
21. Adjust the length of the cables and hoses coming 23. Secure the 3' (0.9m) long hose assembled in step
out of the front of the arm to permit connections to 14 to the cable assemble where it exits the rear of
the feeder. the arm.
22. Secure the cables and hoses to the K1779-9 feed- 24. After installing K1779-11 Mini Console, verify
er support by tightening the hose clamp around proper connections to the electrical outlet (neutral,
the 1' (0.3m) long hose. hot and ground circuits) by using a plug-in circuit
tester.
CAUTION
WELD CABLE SIZES
Before tightening the hose clamp, make sure that
the 4" (102 mm) PVC tube is around the gas hose See Table A.1 for recommended copper cable sizes,
where the clamp secures the assembly. This will currents and duty cycles. Lengths provided are the
prevent any restriction in the gas flow. distance from the welder to work and back to the
------------------------------------------------------------------------ welder again. Cable sizes are increased for greater
lengths primarily for the purpose of minimizing cable
drop.
TABLE A.1
WELDING ARMS
A-5 A-5
INSTALLATION
ADJUSTING FOR WIRE FEEDER WEIGHT ADJUSTING THE WELDING ARM TRAVEL
The holes in the arm triangle compensate for different (See Table A.2)
wire feeder weights. The top position, #1 is used for
heavy wire feeders. The bottom position, #7 is used The holes in the tension clevis adjust the welding arm
for light wire feeders. travel range.
Wire Feeder Arm triangle
hole position
LF-72 #5
LN-10, Power Feed 10, Power Feed 10M #4
DH-10, Power Feed 10 Dual, Power Feed 10M Dual #3
Maximum
Maximum Arm Angle
Arm Height
Minimum
Arm Angle
Minimum
Arm Height
Most people prefer position A.
To change the arm triangle position:
1. Turn off power at the welding power source.
2. Support the welding arm with a fork lift or hoist.
3. Remove the tension clevis bolt.
4. Raise or lower the arm until the desired tension cle-
vis hole aligns with the desired arm triangle hole.
5. Replace the tension clevis bolt.
6. Remove the supporting equipment.
To change the tension clevis position:
7. Turn off power at the welding power source.
8. Support the weld arm with a fork lift or hoist.
9. Remove the tension clevis bolt.
10. Raise or lower the arm until the desired tension
clevis hole aligns with the desired arm triangle
hole.
11. Replace the tension clevis bolt.
12. Remove the supporting equipment.
TABLE A.2
WELDING ARMS
B-1 B-1
OPERATION
7. Standing to one side, open the cylinder valve slowly a
SAFETY PRECAUTIONS
fraction of a turn. When the cylinder pressure gage stops
moving, open the valve fully.
SHIELDING GAS CONNECTION
8. The flow regulator is adjustable. Adjust it to the flow rate
WARNING recommended for the procedure and process being used
before making a weld.
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.
------------------------------------------------------------------------
Maximum inlet pressure is 100 psi.(6.9bar)
Install the shielding gas supply as follows:
1. Secure the cylinder to prevent it from falling.
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 DAM-
AGE IS PRESENT! Inform your gas supplier of this con-
dition. Oil or grease in the presence of high pressure oxy-
gen is explosive.
3. Stand to one side away from the outlet and open the
cylinder valve for an instant. This blows away any dust or
dirt which may have accumulated in the valve outlet.
4. Attach the flow regulator to the cylinder valve and tighten
the union nut(s) securely with a wrench. Note: if connect-
ing to 100% CO 2 cylinder, insert regulator adapter
between regulator and cylinder valve. If adapter is
equipped with a plastic washer, be sure it is seated for
connection to the CO2 cylinder.
5. Attach one end of the inlet hose to the outlet fitting of the
flow regulator. Attach the other end to the welding system
shielding gas inlet. Tighten the union nuts with a wrench.
6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting spring
pressure is released.
WELDING ARMS
C-1 C-1
ACCESSORIES
OPTIONS AND ACCESSORIES MINI CONSOLE ASSEMBLY INSTRUCTIONS
(See Firgure C.2)
K1779-11 Mini Console
(See Firgure C.1)
1. Assemble the vacuum inlet to the front of the Mini
Console Body using the M6 nuts and bolts provided.
The mini console adds more useful functions to the
welding arms. Included with the mini console are: 2. Install the 1/4" short anchor couplers to the front of the
Mini Console Body.
� 1/2" threaded female bulkhead fitting with 25ft. (7.6
3. Insert the 1/4" NPT male thread 3/8" hard hose connector
m) of braided air hose for compressed air connec-
into the rear of the anchor coupler using teflon tape to
tions. seal the threads.
4. Remove the rear lower knock out in the electrical box and
� Duplex receptacle with 25ft. (7.6 m) of 12/3 SJ cord
install the romex connector.
and male plug, rated for 15 amps.
5. Insert the two 1/4"-20 x 1-1/2" carriage bolts into the two
� Panel mounted vacuum inlet connector (female) and holes at the front of the K1779-9 feeder support.
two flexible hoses.
6. Mount the Mini Console Body to the bottom of the feeder
support and secure with nut and washer inside the con-
� Welding gun hanger bracket.
sole.
� Mounting hardware. 7. Feed the electrical cable and 3/8" braided air hose
through the 2" structural tube of the right side on the arm.
The mini console bolts to the underside of the
Universal Wire Feeder bracket for quick installation.
FIGURE C.1
WELDING ARMS
C-2 C-2
ACCESSORIES
8. Extend the hose and cable(s) out through the right 19. Make final electrical connections by installing a
front 2" tube about 32" and then feed them through plug to the end of the electrical cable. Plug into an
one of the 15" long black 2" hoses. Feed the cables approved GFI outlet.
and black tube through the right tube of the back of
the mini console. The back cover should be facing 20. Install the appropriate air fitting to the end of the
forward with the two pipes extending to the rear and 3/8" braided air hose and connect to an air supply.
the two mounting brackets facing up towards the
universal feeder support. 21. After installing K1779-11 Mini Console, verify
proper connections to the electrical outlet (neutral,
9. Connect the 3/8" braided air hose and gear clamp hot and ground circuits) by using a plug-in circuit
to the hose connector mounted on the Mini Console tester.
Body.
10. Feed the electrical cable through the romex con- FIGURE C.2
nector and attach the 120 VAC receptacle. Install
the receptacle and cover plate.
11. Install a quick disconnect air fitting (not included)
to the front of the short anchor coupler.
12. Verify all connections.
13. Slip the 5" piece of 2" spiral hose over the rear of
the vacuum inlet.
14. Install the Mini Console Rear Cover, making sure
the 5" long, 2" spiral hose slips over the left pipe of
the rear cover and compresses as the panel is
screwed into place. Install the two top outside #8
x 1/2" self drilling screws first and then pivot the
rear cover to allow the three bottom screws to be
installed. Tighten all five screws. Drill two 1/8"
diameter holes through the prepunched bottom
outside holes in the mini console into the back
cover. Install and tighten two #8 - 1/2" long
screws.
15. Secure the two brackets of the back cover to the
four mounting holes in the universal feeder sup-
port using 1/4"-20 x 1" carriage bolts and lock
washers.
16. Slide the two 15" long x 2" diameter black hoses
over the rear of the back cover pipes.
17. Install the universal feeder support and mini con-
sole assembly to the arm making sure both 2"
diameter hoses fit over the outer structural tubes
of the arm.
18. Install a 20" long x 1-1/2" diameter hose over the
electrical cable and air hose at the rear of the arm
and slide it halfway into the tube to protect the
cable and hose from wear. Secure the hose with
an adhesive (not included.)
WELDING ARMS
C-3 C-3
ACCESSORIES
K1779-1 4' x 4' x 1" Lift Truck Platform. 3. Secure the assembled PVC tubing to the "A" and
"B" brackets using the gear clamps.
(See Figure C.3)
4. If a Spindle Mounting Kit is used, mount the "C"
bracket to the spindle Align the bracket as neces-
Platform for use with the 6000 series stanchion arm.
sary for proper wire alignment.
Install and secure at least 300 lb (136kg) of weight
onto the platform. A welding power source may be
5. Slide the liner conduit through the PVC tubing.
sufficient for this purpose. Verify the weight of the
Secure the liner conduit to the "C" bracket with the
power source.
split nylon sleeve and gear clamp.
FIGURE C.3
FIGURE C.4
48�
6�
48�
Counterweight 15.5�
location
6� 7�
16�
8� 8�
K1779-9 Universal Wire Feeder Bracket
3�
(See Figure C.5)
K1779-13 Single Electrode Liner Kit Bracket for holding the wire feeder at the end of the
arm. Includes bracket and mounting hardware.
(See Figure C.4)
FIGURE C.5
Includes liner, brackets and hardware for mounting to
a 6000 series arm.
Note: If using a wire feeder with dual drives, two liner
kits are required.
1. Mount the two "A" brackets and one "B" bracket to
the arm. Mount the brackets on either the right or
left side of the arm to match the wire drive location
on the wire feeder. The "A" brackets mount at the
front and middle of the arm. The "B" bracket
mounts towards the rear.
2. Assemble the three pieces of PVC tubing by firmly
inserting the plain ends into the expanded ends.
WELDING ARMS
C-4 C-4
ACCESSORIES
K1779-8 Wire Spindle Mounting Bracket
K1779-7 Dual Gas Cylinder Holder Kit
(See Figure C.7)
(See Figure C.6)
Bracket for mounting the mast and spindle at a lower,
Mounts directly to the stanchion. Includes bracket,
more convenient height.
chains and hardware.
Includes bracket and mounting hardware for mounting
WARNING the mast and spindle from a bench feeder or K1524-1
Universal Wire Reel stand. Mast and spindle not
included with K1779-8 Wire Spindle Mounting
� If the Dual Gas Cylinder Holder Kit is installed to
Bracket.
a Lift Truck Platform, the gas bottles must be
removed before the platform is lifted or moved. WARNING
� Do not remove the 180° travel stops from the
� Do not remove the 180° travel stops from the
arm if both the dual gas cylinder kit and the wire
arm if both the Dual Gas Cylinder Holder Kit and
spindle mounting kit are mounted to the arm. If
the Wire Spindle Mounting Kit are mounted to
the travel stops are removed, the wire spools
the arm. If the travel stops are removed, the
may impact the gas cylinders.
wire spools may impact the gas cylinders.
------------------------------------------------------------------------
------------------------------------------------------------------------
1. Mount the chain holder bracket to the welding arm FIGURE C.7)
stanchion.
2. Secure the bottle ring holder to either the lift truck
platform (if present) or directly to the floor.
3. Use the leveling bolts as necessary to correct for
uneven floors.
FIGURE C.6
Chain Holder
Bracket
Chain Holder
Holder
Bracket
Bottle Ring
Holder Leveling Bolts
WELDING ARMS
D-1 D-1
MAINTENANCE
ROUTINE MAINTENANCE
� Every 6 months, grease the pivot arm pivot point.
The grease fitting is located at the top of the
stanchion behind the cover plate.
� Inspect clutches at pivot point.
� Inspect condition of stops.
WELDING ARMS
F-1 F-1
DIMENSION PRINT
15� 9�
137�
24�
161�
103�
94�
WELDING ARMS
NOTES
WELDING ARMS
NOTES
WELDING ARMS
NOTES
WELDING ARMS
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
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 UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� 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
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