Lincoln Electric TANDEM IM666-A manual

T andem MIG T orch OPERA TOR’S MANUAL IM666-A February, 2005 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 T[...]

FOR ENGINE powered equipment. 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. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

vi vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .......................................................................................................A-1 General Description .........................[...]

A-1 INST ALLA TION TANDEM MIG TORCH A-1 TECHNICAL SPECIFICA TIONS - T andem MIG T orch Product Number G3494-2, 2A G3494-3, 3A G3494-4, 4A G3494-5, 5A G3494-6, 6A Gun Cable Length 4 ft (1.2 m) 6 ft (1.8 m) 8 ft (2.4 m) 10 ft (3.0 m) 12 ft (3.6m) 65 scfh (31 liters/min) minimum .45 gal/min at 40 psi (1700 ml/min at 2.7 bar) T andem MIG T orch Cable L[...]

A-2 INST ALLA TION TANDEM MIG TORCH A-2 GENERAL DESCRIPTION The Tandem MIG torch delivers two wire electrodes to the weld pool. The wires are insulated from each other for the purpose of independent arc regulation. When welding, the wires or arcs are oriented one behind the other. The torch provides a small but rugged housing for delivering the two[...]

A-3 INST ALLA TION TANDEM MIG TORCH A-3 CABLE ASSEMBL Y Three cable assemblies deliver the necessary power and cooling fluids to the torch. a) G3494-X Series: Two of the cable assemblies supply power, wire and water cooling to each side of the torch. The third bundle is made up of the nozzle water cooling hoses, the air blast line and the shielding[...]

A-4 INST ALLA TION TANDEM MIG TORCH A-4 LINER INST ALLA TION AND TRIMMING INSTRUCTIONS a ) Lay the torch and cable on a flat surface and straighten the cables. b) With a 12 mm open-end wrench, unscrew the nut on the cable connector that restrains the liner. Remove the nozzle, and then remove both dif- fusers. c) Remove the old liners. d) Insert the[...]

A-5 INST ALLA TION TANDEM MIG TORCH A-5 b) Push the end connector from torch into K489-7 Fast-Mate adapter on the wire feeder, and then tighten the locking nut. Do this for both of the torch power cables. c) Attach the water lines from the torch power cables to a supply of cooling water. d) Connect the water lines from the nozzle bundle to the Tand[...]

A-6 INST ALLA TION TANDEM MIG TORCH A-6 MOUNTING THE T ORCH Always insulate the torch from any equipment or fixturing. Use M19190 Bracket Arm to Torch Body Insulator if necessary. (See Figure 4, Torch mounting dimensions) Check to make sure the cables are free to flex and do not get tangled or caught on other equipment. Do not let the cables drag o[...]

WIRE STRAIGHTENERS Use a wire straightener with each wire drive. Failure to use a wire straightener may result in inconsis- tent welds and weld bead placement. T AIL GAS COVERAGE The Tandem Mig process is capable of establishing wide weld bead profiles at higher than usual travel speeds. When performing large weldments at these high travel speeds t[...]

B-1 OPERA TION TANDEM MIG TORCH B-1 ELECTRODES AND EQUIPMENT TheTandem MIG torch has been designed for use with 0.035" through 5/64" (0.9 mm to 1.9 mm) Lincoln solid steel MIG wires and metal core wires. Refer to the appropriate Lincoln Process and Procedure Guidelines for further information on welding settings. MAKING A WELD • When us[...]

C-1 ACCESSORIES C-1 GENERAL OPTIONS / ACCESSORIES The following options/accessories are available for your Tandem MIG Torch from your local Lincoln Distributor. K489-7 Connector Kit - Magnum Fast-Mate Adapter Liners Steel, Stainless and Metal Cored Electrodes S24198-10 .035-.045" / 0.9-1.2mm, 9 ft.(2.7m) S24198-12 .035-.045" / 0.9-1.2mm, [...]

D-1 MAINTENANCE D-1 T ORCH SHIELD REPLACEMENT It is important that the torch shield be inspected and replaced on a routine basis. The torch shields (S24432, -1, -A, -1A) are designed to protect the more expensive overmolded assembly of the Tandem torch from arc and heat induced erosion. The shields must be inspected and replaced on a routine basis.[...]

D-2 MAINTENANCE D-2 CONT ACT TIP REPLACEMENT Each application will dictate the frequency of contact tip replacement. Higher amperage higher duty cycle operations will require more frequent contact tip replacement. The condition of the contact tip greatly effects the welding performance. A routine tip replace- ment schedule should be established and[...]

E-1 TROUBLESHOOTING E-1 TANDEM MIG TORCH If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair[...]

E-2 TROUBLESHOOTING E-2 TANDEM MIG TORCH Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLE[...]

E-3 TROUBLESHOOTING E-3 TANDEM MIG TORCH Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLE[...]

NOTES TANDEM MIG TORCH[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE PARA EL U[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes fro[...]

• 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 • World's Leader in Welding and Cutting Products •[...]