Daihen OTC CM-7401 User manual

MANUAL NO:U5279
OWNER'S MANUAL
FOR
WIRE FEEDER
MODEL: CM-7401 U5279
DO NOT DESTROY
IMPORTANT: Read and understand the entire contents of this
manual, with special emphasis on the safety material throughout
the manual, before installing, operating, or maintaining this
equipment. This equipment and this manual are for use only by
persons trained and experienced in the safety operation of welding
equipment. Do not allow untrained persons to install, operate or
maintain this equipment. Contact your distributor if you do not
fully understand this manual.
ＤＡＩＨＥＮ Ｃｏｒｐｏｒａｔｉｏｎ WELDING PRODUCTS DIVISION
November 20, 2003
Upon contact, advise MODEL and MANUAL NO.

No. U5279
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TABLE OF CONTENTS
1. SAFETY INFORMATION･･････････････････････････････････････････････････････････ 2
2. ARC WELDING SAFETY PRECAUTIONS･･･････････････････････････････････････････ 2
3. CHECKING OF QUANTITY OF THE ACCESSORIES･･････････････････････････････････ 6
4. NAME OF PARTS･････････････････････････････････････････････････････････････････6
5. CARRYING AND INSTALLING OF THE WIRE FEEDER････････････････････････････････ 7
6. CONNECTION PROCEDURE･･･････････････････････････････････････････････････････ 8
7. WELDING PREPARATION･････････････････････････････････････････････････････････ 11
8. MAINTENANCE AND TROUBLESHOOTING･･････････････････････････････････････････ 15
9. PARTS LIST･･････････････････････････････････････････････････････････････････････ 17
10. SPECIFICATIONS･････････････････････････････････････････････････････････････････24

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1. SAFETY INFORMATION
The following safety alert symbols and signal words are used throughout this manual to identify
various hazards and special instructions.
WARNING WARNING gives information regarding possible personal injury
or loss of life.
CAUTION CAUTION refers to minor personal injury or possible equipment
damage.
2. ARC WELDING SAFETY PRECAUTIONS
WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
Be sure to:
・Keep children away.
・Keep pacemaker wearers away until consulting a doctor.
Read and understand the summarized safety information given below and the original
principal information that will be found in the PRINCIPAL SAFETY STANDARDS.
Have only trained and experienced persons perform installation, operation, and
maintenance of this equipment.
Use only well maintained equipment. Repair or replace damaged parts at once.
ARC WELDING is safe when precautions are taken.

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2. ARC WELDING SAFETY PRECAUTIONS (continued)
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work
circuits are electrically live whenever the output is on. The power line and internal circuits of
this equipment are also live when the line disconnect switch is on. When arc welding all metal
components in the torch and work circuits are electrically live.
1. Do not touch live electrical parts.
2. Wear dry insulating gloves and other body protection that are free of holes.
3. Insulate yourself from work and ground using dry insulating mats or covers.
4. Be sure to turn off the line disconnect switch before installing, changing torch parts or
maintaining this equipment.
5. Properly install and ground this equipment according to its Owner’s Manual and national,
state, and local codes.
6. Keep all panels and covers of this equipment securely in place.
7. Do not use worn, damaged, undersized, or poorly spliced cables.
8. Do not touch electrode and any metal object if POWER switch is ON.
9. Do not wrap cables around your body.
10. Turn off POWER switch when not in use.
WELDING can cause fire and explosion.
Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, spatter, hot
base metal, and hot equipment can cause fire and explosion. Accidental contact of electrode or
welding wire to metal object can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metals.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 33ft. (10m) of the welding arc. If this is not possible, tightly,
cover them with approved covers.
4. Be alert that welding sparks and hot metals from welding can easily pass through cracks
and openings into adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can ignite a hidden fire.
7. Do not weld on closed containers such as tanks or drums.
8. Connect base metal side cable as close to the welding area as possible to prevent the
welding current from traveling along unknown paths and causing electric shock and fire
hazards.
9. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
10. Do not use the welding power source for other than arc welding.
11. Wear oil-free protective garments such as leather gloves, a heavy shirt, cuffless trousers,
boots, and a cap.
12. A loose cable connection can cause sparks and excessive heating.
13. Tighten all cable connections.
14. Never wear contact lenses while welding and in the welding areas.

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2. ARC WELDING SAFETY PRECAUTIONS (continued)
Rotating parts may cause injuries. Be sure to observe the following.
If hands, fingers, hair or clothes are put near the fan’s rotating parts or wire feeder’s feed roll,
injuries may occur.
1. Do not use this equipment if the case and the cover are removed.
2. When the case is removed for maintenance/inspection and repair, certified or experienced
operators must perform the work. Erect a fence, etc. around this equipment to keep others
away from it.
3. Do not put hands, fingers, hair or clothes near the rotating fans or wire feed roll.
ARC WELDING work areas are potentially hazardous.
FALLING or MOVING machine can cause serious injury.
Use both eyebolts, if installed, to lift the welding power source.
Put the welding power source and wire feeder solidly on a flat surface.
Do not pull the welding power source across a floor laid with cables and hoses.
Do not put wire feeder on the welding power source.
Do not put the welding power source and wire feeder where they will pit or fall.
WELDING WIRE can cause puncture wounds.
Do not press gun trigger until instructed to do so.
Do not point gun toward any part of the body, other people, or any metal when threading
welding wire.

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PRINCIPAL SAFETY STANDARDS
Arc welding equipment – Installation and use, Technical Specification
IEC 62081, from International Electrotechnical Commission
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.
Government Printing Office.
Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.2,
from American Welding Society.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That
Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from
American Welding Society.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas
Association.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards
Association, Standards Sales.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1,
from American National Standards Institute.
Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association.

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3. CHECKING OF QUANTITY OF THE ACCESSORIES
Make sure that you have the items below before you use the wire feeder.
Wire feeder
Wire feeder Accessory
4. NAMES OF PARTS
Refer to the page indicated in for details.
Pressure handles
Wire reel hub
Frame
Torch socket
Feed rolls
Control cable 10P
Feed motor
Pressure roll holder
910
12
No. Description Specification Quantity
①Gas hose (3m) K5430A00 1
②Hose cover U1997C03 1
12
16
Gas supply inlet 10
11 12
13

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5. CARRYING AND INSTALLING OF THE WIRE FEEDER
5.1 Transportation
WARNING
Observe the following to avoid damage to the wire feeder or physical injury when carrying the
equipment.
● Do not touch the charging parts inside or outside the wire feeder.
● Disconnect the wire feeder from the welding power source by turning off the line
disconnect switch in the power box to avoid an electric shock before carrying the
equipment.
● Be sure to detach the wire reel from the fire feeder before lifting the equipment to
the high places by a crane.
5.2 Installation
WARNING
When installing the wire feeder, follow the instructions below to avoid occurrence of fires during
welding and physical damage by fume gas.
● Do not place the welding machine near combustible materials and flammable gas.
● Remove combustible materials to prevent dross coming into contact with
combustible objects. If that not possible, cover them with noncombustible covers.
● To avoid gas poisoning and danger of suffocation, wear a gas mask or adequately
ventilate when using the welding machine in the place regulated by a local law.
● To prevent disorder or poisoning caused by fume, wear a gas mask or weld at a
partial exhaust facility approved by the local regulation.
● Adequately ventilate or wear a gas mask when using the welding machine in a
tank, a boiler, a hold of a ship, because heavier gas such as carbon dioxide or
argon gases are drifting there.
● When using the welding machine at a narrow space, comply with a trained
supervisor’s directions. And be sure to wear a gas mask.
● Do not operate the welding machine near the place where degreasing, cleansing,
and spraying are performed. Otherwise, poisonous gas may be generated.
● Be sure to wear a gas mask or adequately ventilate when welding a coating steel
plate. (Poisonous gas and fume may be generated.)
● Do not place the welding power source, wire feeder, torch, and control cable
(including the extension cable) in an area where the equipment can become wet.
INSTALLATION PLACE
Follow the instructions below when selecting an installation place of the wire feeder.
● Do not install the wire feeder in the indoor place subject to direct sunlight and rain.
● Install the wire feeder in the place where the ambient temperature is between -10 ˚C and +40
˚C.
● Do not place the welding power source, wire feeder, torch, and control cable (including the
extension cable) in an area where the equipment can become wet.
● Use a wind shield to protect arc from a wind blow when welding on a windy day.

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6. CONNECTION PROCEDURE
CAUTION
Follow the instructions below to avoid electric shock.
∗Do not touch the charging parts, as this will result in fatal shock and severe burns.
● Do not touch the charging parts of the welding machine.
● Have a qualified electric engineer ground the case of the welding power source and the base
metal or jig electrically connected, following a local low.
● Disconnect the wire feeder from the welding power source by turning off the line disconnect
switch in the power box to avoid an electric shock before grounding the welding power source
or base metal and connecting the cables or hoses.
● Do not use a cable with lack of capacity or a cable seriously damaged.
● Tighten and insulate the connections of cables.
●
Firmly attach the cover of the welding machine after connection of the cables.
●
Do not place the welding power source, wire feeder, torch, and control cable (including the
extension cable) in an area where the equipment can become wet.
6.1 Connecting to the Welding Power Source and to the Gas Flow Rate Regulator
Standard Composition
NOTE: Standard composition consists of the parts indicated in . Preparation of the parts except the standard
composition is required to use the wire feeder.
*Available in 5 m, 10 m, 15 m, and 20 m.
Follow the steps below to connect to the welding power source and to the gas flow rate regulator.
1. Ground the base metal (if required by local laws or codes).
2. Connect between the negative output terminal for the base metal and the base metal with the base metal cable.
3. Attach the torch cable to the positive output terminal for the torch.
4. After removing the right-side plate of the wire feeder, attach the torch cable to the M10 terminal.
5. Plug the control cable for the wire feeder (10P) into the wire feeder socket on the welding power source.
6. Attach the gas hose to the gas supply inlet on the wire feeder.
7. Connect the welding torch to the wire feeder.
Welding
power
source
Wire feeder
Base metal cable*
Welding torch
Remote control cable
Gas hose*
Gas cylinder*
Remote control
(
O
p
tional
)
Firmly attach the DINSE connectors
by turning the connectors in the
clockwise direction.
Gas flow rate regulator
Control cable
Torch cable*

No. U5279
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6. CONNECTION PROCEDURE (continued)
6.2 Connecting of the Torch Cable
WARNING
∗Touching the charging parts may result in fatal electric shock and severe burns.
● Do not touch the charging parts of the welding machine.
● Have a qualified electric engineer ground the case of the welding power source and the base
metal or jig electrically connected in accordance with a local low.
● Disconnect the wire feeder from the welding power source by turning off the line disconnect
switch in the power box to avoid an electric shock before the welding power source or base
metal and connecting the cables or hoses.
● After connecting the cables, cover the power source with the cover or case.
● When using the welding machine in such a humid environment as construction site, on the
steel plate, or on steel structure, install a leakage breaker.
CAUTION
● Use the proper torch cable that matches the welding current.
Applicable current (Rated current) Cable thickness
200 A 38mm2 or more
350 A* 60mm2or more
500 A 80mm2or more
* When performing pulse welding using the welding power source with 350 A applicable current
and a 17m or more cable, use the thicker cable by one rank.
6.3 Connecting of the Welding Torch
CAUTION
● Ensue that the torch connector is firmly attached. If the connector is not fully inserted, there
may be a risk of fire, burns, and product damage.
Torch cable
Insulating tape
M10 nut
Take care to firmly attach
the torch cable to prevent
the cable from being
bottomed on the frame
and on the terminal block.
Put around the terminals
with insulating tape.
Welding torch
Adapter nut
Feed metal
Gas connection metal
Before connecting a wire feeder to a
welding torch, make sure that the
feed metal and gas connection
metal are inserted into the welding
torch until restricted and that the
adapter nut is properly inserted
into the welding torch. (Forcible
insertion of the adapter nut may
result in damage to the threads of
the metals.
)

No. U5279
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6. CONNECTION PROCEDURE (continued)
6.4 Connecting of the Gas Hose
WARNING
● You may suffer from danger of suffocation caused by lack of oxygen when
shield gas keeps drifting in a closed place. Be sure to turn off the shield gas
at the main when the welding power source is not in use.
WARNING
● Be sure to connect the gas hose after fixing to the stand, as physical injuries may result
from falling down of gas cylinder.
● Attach a proper gas flow rate regulator to the gas cylinder. Failure to observe the demand
may result in physical injuries. The gas flow rate regulator for high pressure gas must be
used.
How to Make Gas Connection
1. Firmly connect the gas hose to the gas supply inlet located on the rear side of the wire feeder.
2. Mount the gas flow rate regulator on the gas cylinder by tightening the nut for attaching the gas
cylinder .
3. Connect the gas hose to the gas supply outlet on the gas flow rate regulator.
NOTE: Firmly tighten the nuts using a monkey wrench, etc. to connect the gas hose and gas
flow rate regulator.
Gas cylinder
Gas flow rate regulator
Gas inlet

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7. WELDING PREPERATION
7.1 Fitting of Wire
1. Loosen the screw to clamp the cap knob.
2. Detach the cap knob from the wire reel shaft.
3. Mount the wire reel on the wire reel shaft.
NOTE: Check the positions of the wire reel stop pin and the wire reel stop hole to insert and
fully seat the pin into the hole.
4. Firmly tighten the cap knob.
5. Align the hole in the cap knob with the wire reel stop hole, then cap the wire reel hole with the
clamp screw to prevent the cap knob from dropping.
6. Bring down the pressure handle, then raise the pressure roll holder.
7. After pulling out the wire, thread it from the pilot to outlet guide through the center guide.
8. Return the pressure reel holder first, the pressure handle.
CAUTION
● When hanging the wire feeder, firmly fix
the cap knob and clamp screw in
position to prevent the device from
dropping.
Wire reel shaft
Wire reel stop pin
Clamp screw
Cap knob
Wire reel stop hole
Pressure handle
Outlet guide
Pressure roll holder
Center guide
Pressure handle
Pilot
To tighten the cap knob, turn the
knob clockwise.
To loosen the cap knob, turn the
knob counter-clockwise.

No. U5279
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7. WELDING PREPERATION (continued)
7.2 Mounting of the Feed Roll
Confirming of the wire size marked on the feed roll
Use the proper feed roll for the wire size.
The feed roll of φ1.2 wire size is mounted on the CM-701 wire feeder.
Replacing of the feed roll
1. Remove the hexagon socket cap screws fixing the feed roll.
2. Bring down the pressure handle, and then lift the pressure roll holder.
3. Separate the feed roll from the wire feeder by pulling out the feed roll toward you.
4. Mount the feed roll, with the wire size marked on the wire feeder facing out.
Adjusting of the wire pressure and straightener
•Set to the proper wire pressure for the wire type by turning the pressure handle.
•The numeral on the pressure scale set with the right pressure handle should be correspond to the one
set with the left pressure handle.
Recommended wire pressure adjustment
Wire diameter Wire pressure scale
Solid wire Flux cored wire
φ1.6, φ2.0 4 - 5 3 - 4
φ1.2, φ1.4 3 - 4 2 - 3
φ0.9, φ1.0 2 - 3
φ0.8 1 - 2
Groove forφ1.2 wire size
Wire size mark
Hexagon socket cap screws
Feed roll

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7. WELDING PREPERATION (continued)
7.3 Adjusting of the wire reel hub
After performing inching operation, take care to adjust the brake of the wire reel hub to prevent the wire
from going too slack. The bake has been properly adjusted before shipment. Therefore, readjustment of
the brake is not required for welding in standard welding conditions.
How to adjust the wire reel hub
1. Detach the cap knob from the wire reel shaft.
2. Adjustment of the brake can be achieved by turning the hexagon bolt (M10).
7.4 Feeding Wire Feeding by Performing Inching Operation
WARNING
● Do not look into the tip hole to check for the rate of wire feeding while inching.
CAUTION
● Keep away your hands, fingers, hair or clothes from the rotating parts of the feed
roll, etc. to prevent you from being caught into the rotating parts while inching.
After straightening the welding torch, feed the wire by pressing
the INCHING key. (the INCHING lamp located at the upper right
of the INCHING key lights up). When the wire appears from the
end of the torch, press the INCHING key again (the INCHING
lamp goes out). Cut the wire at about 10 mm from the end of the
torch. Wire feed rate can be adjusted by turning the parameter
adjusting knob.
Wire reel shaft
Hexagon bolt (M10)
Cap knob
To brake more quickly,
turn the bolt clockwise.
To brake more slowly, turn
the bolt counter-clockwise.
インチング
INCHING key
Parameter adjusting knob

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7. WELDING PREPERATION (continued)
WARNING
Touching the charging parts may cause fatal electric shocks and burns.
● Never touch the charging parts in the wire and wire feeder.
The parts indicated as in the figure are the charging parts during welding.
7.5 Hanging the Wire Feeder
CAUTION
● When hanging the wire feeder, firmly fix the cap
knob and clamp screw in position to prevent the
device from dropping.
● Do not use the carrying hand of the wire feeder to
hang the wire feeder.
Wire
Wire feeding parts
Screw to clamp the cap knob
Hanging bracket (optional)
Carrying handle

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8. MAINTENANCE AND TROUBLESHOOTING
8.1 Carrying Out Maintenance
WARNING
● Do not touch the charging parts inside or outside the wire feeder.
● Disconnect the wire feeder from the welding power source by turning off the line
disconnect switch in the power box to avoid an electric shock before carrying the
equipment.
No. Problem Cause Solution
1 Wire gets deformed. Wire pressure is too strong. Refer to
“Recommended wire
adjustment” in Section
7.2.
Feed roll of wrong wire size is
used. Replace it with the feed roll of proper wire size.
Feed roll and pressure roll are
worn. Replace the feed roll and the pressure roll
with a new ones.
2 Wire is not fed. Poor contact and breakdown in
the control cable. Check the socket. Check the cables and
replace with new ones.
Poor contact and breakdown in
the encoder cable
Poor contact and breakdown in
the voltage detection cable
Trouble with the motor Replace the motor with
a new.
Wire pressure is too weak. Refer to
“Recommended wire
adjustment” in Section
7.2.
Dust and chip are accumulated
on the outlet guide and on the
feed roll.
Remove the dust and
chip.
3 Pressure roll does not rotate
smoothly. Failure of the pressure roll holder. Replace it with a new.
4 Shield gas is not supplied when
pressing the torch switch. The discharge valve is closed of the gas cylinder. Open the valve.
Lack of gas pressure in the gas
cylinder Check gas pressure.
Failure of gas solenoid valve After checking the gas
solenoid valve, replace
it with new ones.
5 Shield gas supply does not stop. Failure of gas solenoid valve Check the socket.
Check the cables and
replace with new ones.
6 Defective gas hoses Crack in the gas hose Replace them with new
ones.
7 Wire does not fed smoothly
through the wire reel. Adjustment of the brake is either too strong or too weak. Refer to “Adjustment of the wire reel hub” in
Section 7.3.

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8. MAINTENANCE AND TROUBLESHOOTING (continued)
< Schematic Diagram>
8.2 Replacing of the Outlet Guide
Follow the procedures below when replacing the outlet guide.
1. Bring down the pressure handle first, and then lift the
pressure roll holder.
2. Forcibly insert a flathead screwdriver, etc. into the space
between the outlet guide and the snap ring to remove the
snap ring while holding the snap ring with long-nose pliers.
3. Remove the outlet guide by pushing it toward the torch
socket.
4. Insert a new outlet guide from the direction of the torch
socket, and then place the snap ring under the new outlet
guide.
5. Return the pressure roll holder first, the pressure handle.
CAUTION
● Never attempt to disassemble the feed motor. This may result in damage to the wire feeder.
● Never check the amount of brushing friction or replace the brush.
Service life of the brush varies depending on ambient temperature, etc., but normally the service life is
about 4,000 hours. (If the machine is operated for six hours a day, the service life of the brush will be
about two years). Periodical replacement of the feed motor is recommended.
Flathead screwdriver
Long-nose pliers
Outlet guide
Snap ring
Pressure handle
Torch socket

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9. PARTS LIST
9.1 Main body and Wiring
•Please contact your local dealer to order parts. (See the back cover for telephone and fax numbers,
and mailing addresses.)
Part number
Ref.
No. CM-7401 Description Q’ty Remarks
1 U5185U00 Frame 1 Assembly
2 K970H90 Strike 2
3 4739-013 Support 2
4 U5185C01 Cover 1 With coating
5 U5185C02 Screw with knob 1
5-1 3361-219 Washer 2
6 U5185C03 Side plate 1 With coating and a screen
7 U5158C04 Rear cover 1 With coating
7-1 4739-490 Grommet with film 1
7-2 4739-491 Grommet with film 1
7-3 4739-489 Grommet with film 1
8 U5185C05 Panel 1 With coating and a screen
9 U5185B00 Wire feeder 1 With a feed motor
10 U5185D00 Central adapter 1 Assembly
12 U5185N00 Power cable 1 Assembly
13 U5185J02 Power terminal block 1
14 U5185J04 Terminal block bracket 1
15 4739-492 Terminal block 1
16 U5185X00 Encoder cable 1 Assembly
17 U5185F00 Motor cable 1 Assembly
18 U5185E00 Control cable 1 Assembly
18-1 4730-422 Metal socket (1)
19 4739-494 Wire reel hub 1
20 U5185J07 Plate 1
21 U5185J08 Clamp screw 1
21-1 3361-405 E-snap ring 1 E-4
22 U5191B00 Common mode coil 1 Assembly
23 U5185J01 Cable clamp 1
24 U1997C02 Hose clamp 1
25 U1997C03 Hose cover 2
26 U5185J05 Wire reel cover 1

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9. PARTS LIST (continued)
Fig. 1 Main Body and Wiring Assembly
4
5
3
2
1
6
23
25
24
7
26
20
21
13
12
14
15
18
1716
22
9
10
19

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9. PARTS LIST (continued)
9.2 Wire Feeder
Ref.
No. Part number Description Q’ty Remarks
1 U5185B00 Bracket 1
1-1 -
Hexagon socket cap
screw 2 M6 x 25
2 U5185B08 Coil screw 1
3 U5185B02
Pressure roll holder
pin 2
4 U5185S00
Pressure roll holder
(R) 1 Assembly
5 U5185T00
Pressure roll holder
(L) 1 Assembly
6 K5439C00 Pressure roll 2 Assembly
7 U5158B03 Driving roll shaft 2
8 U5185P00 Gear 2 Assembly
9 U5439B00 Feed roll (1.0/1.2) 2
9-1 -
Hexagon socket cap
screw 4 M4 x 16
9-2 - Bolt 4 M4 x 10
10 U5185B04 Guide block 1
11 U5185B05 Center guide 1
12 4802-206 Feed motor 1
13 U5185B06 Insulating board 1
14 U3971B04 Insulating bush 3
14-1 - Flat head screw 3 M6 x 20
15 U5185Q00 Drive gear 1
16 U5185B09
Pressure screw
holder 2
17 U5185B12 Compression spring
2
18 U5185B10 Pressure handle
2
19 U5185B11 Pressure bolt 2
19-1 - Spring pin 2 2.5 x 14
20 U5185J06 Pilot 1
21 U5185B13 Insulating bush 2
21-1 - Hexagon bolt 2 M8 x 30
22 U5185B14 Insulating board 1
9. PARTS LIST (continued)