RoboKing® - MK Products
Contents
1. M K PRODUCTS INC 16882 ARMSTRONG AVE IRVINE CALIFORNIA 92606 TEL 949 863 1234 FAX 949 474 1428 www mkproducts com2. French ATTENTION WARNUNG Portuguese ATEN AO Japanese Chinese Korean Jiaj Do not touch electrically live parts or electrode with skin or wet clothing insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aisiese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stramf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung isolieren Sie sich von den Elektroden und dem Erdboden Nao toque paries el tricas e elec trodos a pele ou roupa molha da Isole se da e terra OARPORMMBS E KA OCH OKIMPP ZDSKHEFERE NTUSBELT FSU e BEER SAR Se OFRET HER er SY38 SU EE SO S z 2494 MAE H n i Juil qos oai VO FECE t At Aut la DE deua Vile Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos S e i8 8 3 Sb CERE TENER x uie ng AL AA O Wear
3. 2 16mm Spray 1 5 8 41 3mm 621 0164 063 1 6mm 075 1 9mm Gas Cups Standard Water Cooled Cup No 10 5 8 15 9mm 3 76 2 621 0065 Optional Air Cooled Cups No 6 3 8 9 5mm 1 43 36 5mm 621 0170 No 8 1 27 12 7mm 1 43 36 5mm 621 0159 No 10 5 8 15 9mm 1 43 36 5mm 621 0160 Requires Cup Adapter P N 621 0101 amp Cup Nut P N 449 0193 TorcH LINERS Liners for Barrels 030 035 0 8 0 9 mm White Teflon Aluminum 615 0542 045 062 1 2 1 6mm White Teflon Aluminum 615 0538 030 045 0 8 1 2mm Steel Spiral Steel Hard wire 615 0543 RoboKing Owner s Manual Page 5 Section D Section E MAINTENANCE Maintenance of the torch will normally consist of a general cleaning of the wire guide system including tubes drive rolls and conduits at regular intervals Remove spatter build up from inside of nozzles with a hardwood stick The only parts on the RoboKing system that are subject to normal wear are the conduit contact tips gas cups front body liners wire guides drive and idler rolls A supply of these parts should be maintained on hand If repairs do become necessary any part can easily be replaced by a qualified shop maintenance personnel Your RoboKing System is designed to provide years of reliable service Normal wear and component failure may require occasional service The number of units in operation and the impo
4. obtain quali fied help before proceeding 1 2 GENERAL PRECAUTIONS A Burn Prevention ELECTRIC ARC WELDING PRODUCES HIGH INTENSITY HEAT AND ULTRAVIOLET RADI ANT ENERGY WHICH MAY CAUSE SERIOUS AND PERMANENT EYE DAMAGE AND WHICH MAY DAMAGE ANY EXPOSED SKIN AREAS Wear helmet with safety goggles or glasses with side shields underneath appropriate filter lenses or plates protected by clear cover glass This is a must for welding or cutting and chipping to protect the eyes from radiant energy and flying metal Replace cover glass when broken pitted or spattered Medical first aid and eye treatment First aid facilities and a qualified first aid person should be available for each shift unless medical facili ties are close by for immediate treatment of flash burns of the eyes and skin burns Wear protective clothing leather or asbestos gauntlet gloves hat and high safety toe shoes Button shirt collar and pocket flaps and wear cuffless trousers to avoid entry of sparks and slag Avoid oily or greasy clothing A spark may ignite them Flammable hair preparations should not be used by persons intending to weld or cut Hot metal such as electrode stubs and work pieces should never be handled without gloves Ear plugs should be worn when working on overhead or in a confined space A hard hat should be worn when others work overhead B Toxic Fume Prevention WARNING The use of this product may result in exposure
5. 1955 MK Warranty Repair Stations for MK Products Current as of 10 11 02 Please visit our website for up to date listing www mkproducts com AIRGAS MID SOUTH BILUS WELDER REPAIR MUNN SUPPLY Tulsa OK Oklahoma City OK Enid OK 918 582 0885 OKLAHOMA WELDERS SUPPLY Madill OK 580 795 5561 405 232 4799 580 234 4120 ARC SYSTEMS SERVICES Central Point OR 541 665 2676 COMPANY dba ELECTRICAL CONSTRUCTION COMPANY Portland OR 800 452 1511 INDUSTRIAL SOURCE Eugene OR 541 344 1438 WELDER SERVICE amp REPAIR Redmond OR 541 548 8711 ALLWELD EQUIPMENT REPAIR Pittsburgh PA 412 821 8460 J A CUNNINGHAM EQUIPMENT INC Philadelphia PA 215 426 6650 VALLEY NATIONAL GASES Pittsburgh PA 412 281 1835 0 ARO CAROLINA WELDER SVC Lake City SC 843 687 0413 INDUSTRIAL MACHINE REPAIRS Rogersville TN 423 272 8199 BY DESIGN Columbia PA 717 681 9494 JOSEPH PINTO JR EQUIPMENT CO E Lansdowne PA 610 259 4100 NEXAIR Memphis TN 901 523 6821 GEOVIC WELDING SUPPLY Milton PA 717 742 9377 POWER SOURCE REPAIR INC Collingdale PA 610 532 6460 NATIONAL RENTAL amp REPAIR Knoxville TN 423 584 6390 QUALITY WELD G EQUIPMENT Nashville TN 615 726 5282 TRAMCO Bristol TN 423 968 4499 AIRGAS SOUTHWEST INC Austin TX 512 835 0202 AIRGAS SOUTHWEST INC
6. 403 279 3432 WELDTEC B C 604 545 3886 A PHT Group Company Beijing China 86 10 6858 8395 A amp A WELDER SERVICES LTD Saskatoon Saskatchewan 306 934 1601 BARRY HAMEL EQUIPMENT LTD Coquitlam B C 604 945 9313 GPR INDUSTRIES 1994 LTD Grande Prairie Alberta 780 532 5900 LADEL LTD Quebec 819 376 6577 for MK Products Current as of 10 11 02 Please visit our website for up to date listing www mkproducts com ARC amp GENERATOR REPAIR Garson Ontario 705 525 2141 D TECH WELD SERVICES Regina Saskatchewan 306 586 9353 HYPERDYNAMICS TECHNOLOGIES LTD Pickering Ontario 905 683 9938 LeBLANC ELECTRO TECH INC Boucherville Quebec 450 449 5244 MK Warranty Repair Stations B HARRIS WELDING SVCS Dartmouth Nova Scotia 902 468 6255 ELECTRO MECANIK INC Sainte Foy Quebec 418 683 1724 INDUSTRIAL ELECTRONIC SERVICES Calgary Alberta 403 279 3432 M R T REPAIR CENTER INC Montreal Quebec 514 648 0800 OZARK ELEC MARINE LTD St Johns Newfoundland 709 726 4554 PEEL ENGINES Mississauga Ontario 905 670 1535 PROMOTECH ELECTRIQUE INC Fleurimont Quebec 819 822 2111 WELDERS SUPPLY Winnipeg Manitoba 204 772 9476 WELDERTECH Calgary Alberta 403 279 3432 WELDTEC B C 604 545 3886 D PHT Group Company Beijing China 86 10 6858 8395 Spanish AVISO DE PRECAUCION
7. Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o exhaust o para remover fumo da zona respirat ria ta APOWNtMTESCUC MAC EE E D ESAE seis 9071 8 AH 7714 Akan ge FS gaal ja d Aa Janda e Maul ge ysi power off before servicing Desconectar 8 cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhaiten opere com as tampas removidas e Desligue a corrente antes de fazer servigo N n toque as partes el tricas nuas gt POM TERA vFE BT DFS e SL CH gas L AMT Ac e Do not operate with panel open guards off No operar con panel abierto guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis ahertos ou guardas removidas
8. eye ear and body protection Prot jase los ojos 10 o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und perschutz Use protec o para vista ouvido corpo H ERU STECOUSR amp UC AAR ER SHSIURNIS A ek 719 Eo 5337 Selz Age ule Uy cl ace asas READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones travail Vermeiden Sie das
9. is located in the top center of the torch when viewed from the rear Water Hose The water hose is pushed on to the inlet tube of the front body The Water tube is located in the lower left of the torch when viewed from the rear Electric Cable A seven conductor control cable is used on RoboKing Torch although only 2 conductors are used The torch end of the control cable is secured to the back of the torch with a cable clamp and the wires are connected to the motor through a connector The cabinet end has a 7 pin W clocked Amphenol connector See schematic for wiring information OPERATION GENERAL DESCRIPTION The RoboKing is designed to be used in automation processes and is unique in its design from other torches made by MK Products The RoboKing Torch maintains a constant steady uniform feed speed regardless of curved or looped wire conduit The constant push exerted by the slave motor in the cabinet combined with the pull of the torch motor causes the wire to literally float friction free through the wire conduit The 24 volt DC torch motor is controlled by the speed control the Cobramatic cabinet There is no trigger in the torch to start the arc this is controlled by means of an outboard control Motor Gear Box A 19 5 1 24VDC motor gear box is used on this version of the RoboKing Torch The motor gear box attaches to the angle head with three 3 Allen screws The torch serial number is stamped on the ang
10. to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Adequate ventilation Severe discomfort illness or death can result from fumes vapors heat or oxygen enrichment or depletion that welding or cutting may produce Prevent them with adequate ventilation NEVER ventilate with oxygen Lead cadmium zinc mercury beryllium bearing and similar materials when welded or cut may pro duce harmful concentrations of toxic fumes Ade quate local exhaust ventilation must be used or each person in the area as well as the operator must wear an air supplied respirator For beryllium both must be used Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed form the work surface the area is well ventilated or the operator wears an air supplied respirator Work in a confined space only while it is being ventilated and if necessary while wearing an air supplied respirator Gas leaks in a confined space should be avoided Leaked gas in large quantities can change oxygen concentration dangerously Do not bring gas cylin ders into a confined space Leaving confined space shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been acciden tally opened or left open Check to be sure that the space is safe before reentering it Vapors from chlorinated solve
11. 371 5688 B amp H ELECTRIC Seymour IN 812 522 5607 HARRISON ELECTRIC INC Michigan City IN 219 879 0444 SUTTON GARTEN COMPANY Indianapolis IN 317 264 3236 ELECTRICAL ENGRG A EQUIPMENT Des Moines IA 515 266 8890 SUPERIOR WELDING SUPPLY Waterloo IA 319 236 9660 WRIGHT WELDING SUPPLY Ft Dodge IA 515 576 0640 D D AEROFORM CORPORATION Coffeyville KS 620 251 1430 KANOX Hutchinson KS 316 665 5551 GENERAL WELDING PRODUCTS Louisville KY 502 635 5218 RED D ARC Lexington KY 800 245 3660 WELDING EQUIPMENT Louisville KY 502 636 0545 0 ANA RED BALL OXYGEN CO Shreveport LA 318 425 3211 WELDERS EQUIPMENT CO Broussard LA 337 837 5701 AR AND CCM MECH ELEC REPAIR SERVICE Owings MD 301 855 7508 AIMTEK WELDING SUPPLY Auburn MA 508 832 5035 MK Warranty Repair Stations for MK Products Current as of 10 11 02 Please visit our website for up to date listing www mkproducts com ANN ARBOR WELDING SUPPLY APEX WELDING GASES amp SUPPLY CO Ypsilanti MI 734 572 0444 Muskegon Heights MI 616 722 3185 AUTOMATIC WELD Midland MI 517 496 9245 GREAT LAKES EQUIPMENT Clare MI 517 386 4630 HAMILTON ELECTRIC CO Saginaw MI 517 799 6291 Saginaw MI 517 793 9696 SIMPKINS ELECTRICAL SVC Michigan Center MI 517 764 7766 SOUTHPARK WELDING Marysville MI 810 364 6521 WELD
12. 9670 PRAXAIR DISTRIBUTION PRAXAIR DISTRIBUTION INC R J KATES ARC RENTS Bakersfield CA San Diego CA Signal Hill CA 661 321 9922 619 565 6960 562 989 3212 RED D ARC INC SIMS ORANGE WELDING SUPPLY SOUTHWEST WELDER REPAIR Carson CA Santa Ana CA Fontana CA 310 233 3327 SWEINHART ELEC CO INC Long Beach CA 714 521 9100 714 549 9393 909 357 1661 MK Warranty Repair Stations 015015711910 AIRGAS INTERMOUNTAIN INC Colorado Springs CO 719 473 1947 6 WELDING amp INDUSTRIAL SUPPLY CO Waterford CT 800 962 0285 for MK Products Current as of 10 11 02 Please visit our website for up to date listing www mkproducts com WELDERS amp EQUIP SVC amp TESTING Littleton CO 303 932 8755 TECH AIR Milford CT 203 783 1834 WESTERN SLOPE WELDER REPAIR Grand Junction CO 970 243 9616 B A AR KEEN COMPRESSED GAS New Castle DE 302 594 4555 URIDA A amp I SPECIALTIES Lehigh Acres FL 941 368 7435 AAA GENERATOR amp PUMP Ft Myers FL 941 332 1136 ACTION WELDING SUPPLY Jacksonville FL 904 786 2254 AMVEL CORPORATION ELECTRICAL WELDERS SERVICE HAUN SYSTEMS REPAIR INC Miami FL Orlando FL Winter Park FL 305 592 5678 407 999 5214 407 681 6064 HOLOX J K CIRCUIT TECHNOLOGY ROPER ELECTRIC MOTOR Ocala FL Boynton Beach FL SERVICE 352 351 4417 561 733 7859 Panama City FL 850 769 6643 SMITTY S WELDE
13. ES ROBOKING Lead Assemblies Water Cooled Cable Assemblies d 4 Water Electrical f Length Conduit Power Cable Cable Gas Hose WaterHose Snake Skin 15 4 5m 615 0007 001 2521 005 0268 001 0537 001 0529 931 0110 25 7 6m 615 0008 001 2524 005 0269 001 0538 001 0530 931 0122 RoboKing Owner s Manual Page 10 BARREL ASSEMBLIES 615 0538 x 481 1582 451 0977 261 0381 621 0163 621 0065 303 0012 O Rings Lu 261 0380 003 1989 Straight 003 1983 003 1990 22 degree 005 1954 45 degree 003 1985 Optional 6 621 0170 8 621 0159 10 621 0160 ROBOKING Barrel Assemblies RoboKing Owner s Manual Page 11 ELECTRICAL Torch Functions Lo S A d lt 5 EE W Clocked Amphenol Connector Viewed from front of connector Torch Lead Cabinet End Amphenol Connector RoboKing Owner s Manual Page 12 GEAR Box AssEMBLY 321 0027 Screw 419 0020 Spring 003 0767 Output Shaft Assy 515 0198 Internal Ring Retainer 551 0741 421 1267 Helicoil Gear Box Housina 415 007 501 0720 431 0015 Machine ldler Arm ldler Arm Screw Ball Bearing 421 2106 Dowel Fin p oui 431 436 Gear Box Assy Set Screw Modified 003 1260 rev A RoboKing Owner s Manual Page 13 ALABAMA AIRGAS SOUTH INC Birmingham AL 205 251 6835 KIBRO INC Theodore AL 251 653 4672 RNR INC db
14. Houston TX 713 462 8027 DENISON OXYGEN Denison TX 903 465 3369 FT WORTH WELDERS SUPPLY INC Ft Worth TX 817 332 8696 GPC SERVICES INC San Angelo TX 915 655 4545 LEKTROTECH INC Greenville TX 903 454 7146 L ANADA A amp A WELDER SERVICES LTD Saskatoon Saskatchewan 306 934 1601 MK Warranty Repair Stations for MK Products Current as of 10 11 02 Please visit our website for up to date listing www mkproducts com ARC amp GENERATOR REPAIR Garson Ontario 705 525 2141 B HARRIS WELDING SVCS Dartmouth Nova Scotia 902 468 6255 BARRY HAMEL EQUIPMENT LTD Coquitlam B C 604 945 9313 D TECH WELD SERVICES Regina Saskatchewan 306 586 9353 ELECTRO M CANIK INC Sainte Foy Quebec 418 683 1724 GPR INDUSTRIES 1994 LTD Grande Prairie Alberta 780 532 5900 HYPERDYNAMICS TECHNOLOGIES LTD Pickering Ontario 905 683 9938 INDUSTRIAL ELECTRONIC SERVICES Calgary Alberta 403 279 3432 LADEL LTD Quebec 819 376 6577 LeBLANC ELECTRO TECH INC Boucherville Quebec 450 449 5244 M R T REPAIR CENTER INC Montreal Quebec 514 648 0800 OZARK ELEC MARINE LTD St Johns Newfoundland 709 726 4554 PEEL ENGINES Mississauga Ontario 905 670 1535 PROMOTECH LECTRIQUE INC Fleurimont Quebec 819 822 2111 WELDERS SUPPLY Winnipeg Manitoba 204 772 9476 WELDERTECH Calgary Alberta
15. ING METALS INC Madison Heights MI 248 585 0480 WESAR COMPANY Three Rivers MI 616 483 9125 0 AIRGAS NORTH CENTRAL Albert Lea MN 507 373 2411 SAGINAW WELDING SUPPLY CO x CAPITOL CITY WELDING SUPPLY St Paul MN 651 224 4843 MINNEAPOLIS OXYGEN CO Minneapolis MN 612 588 8855 OXYGEN SERVICE CO St Paul MN 612 644 7273 0 SUPPLY INC St Louis MO 324 644 3500 NORDAN SMITH WELDING SUPPLY Hattiesburg MS 601 545 1800 ADA PG WALKER Springfield MO 417 862 1745 3D SUPPLIES INC Jackson MS 601 353 3330 SIERRA WELDING SUPPLY CO Sparks NV 775 359 0542 WELDING SYSTEMS SVC Raymond NH 603 895 4700 INDUSTRIAL ELEC SERV CO Hawthorne NJ 973 423 1212 ROD S SERVICE INC St Louis MO 314 721 6000 MK Warranty Repair Stations 0 DELO WELDING SUPPLY Syracuse NY 315 478 2188 JACKSON WELDING SUPPLY Rochester NY 585 235 2920 for MK Products Current as of 10 11 02 Please visit our website for up to date listing www mkproducts com DYNAMIC WELD G amp REPAIR Bayshore NY 631 643 1308 HAUN WELDING SUPPLY Syracuse NY 315 463 5241 ARO A ADAMS WELDER REPAIR amp ELECTRICAL SERVICE INC Nashville NC 252 459 1960 HOLOX LTD Colfax NC 336 996 1974 M amp L WELDER REPAIR Asheville NC 828 250 9353 MACHINE amp
16. MIL PRODUCTS RoboKing C Product Description MK Part Number MK Form Number NWSA Form Number Effective with Serial 41500 Number 22VDC Printing Revision November 2002 E Date This manual applies Io tbe following 218 model numbers 16882 Armstrong Ave Irvine California 92606 TEL 949 863 1234 FAX 949 474 1428 www mkproducts com SAFETY CONSIDERATIONS ELECTRIC ARC WELDING EQUIPMENT CAUTION READ BEFORE ATTEMPTING INSTALLATION OPERATION ORMAINTENANCE OF THIS EQUIPMENT 1 1 INTRODUCTION This equipment is intended for ultimate appli cation by commercial industrial users and for operation by persons trained and experienced in the use and maintenance of welding equip ment Operation should not be undertaken with out adequate training in the use of such equip ment Training is available from many public and private schools or similar facilities Safe practices in the installation operation and maintenance of this equipment requires proper training in the art a careful study of the informa tion provided with the equipment and the use of common sense Rules for safe use are gen erally provided by suppliers of welding power sources compressed gas suppliers and elec trode suppliers Careful compliance with these rules will promote safe use of this equipment The following Safety Rules cover some of the more generally found situations READ THEM CAREFULLY In case of any doubt
17. OKAMPAK ERYALEEE T MMES Uu Cau e Eat IS EE ABTA sel Hum YEH gall he Ja ye ie Al git Spanish AVISO DE PRECAUCION French ATTENTION WARNUNG Portuguese ATEN AO Chinese Korean Arabic x LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR ES PEHD D DHFR k lt MA ETHMLTF SL CL TRHORSME H ET EH RA TEE DE 7 eil HAP Sei TE EFSM ug Aan palal Ad d S i d AAA oig gail ladet Cat Page intentionally blank LIMITED WARRANTY Effective March 1 2001 This warranty supersedes all previous MK Products warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY MK Products Inc Irvine California warrants that all new and unused equipment furnished by MK Products is free from defect in workmanship and material as of the time and place of delivery by MK Products No warranty is made by MK Products with respect to trade accessories or other items manufactured by others Such trade accessories and other items are sold subject to the warranties of their respective manufacturers if any MK Products warranty does not apply to components having normal useful lif
18. R SERVICE West Palm Beach FL 561 845 1224 TRI GAS Miami FL 305 592 3180 TRI STATE SALES amp LEASING Lake City FL 904 397 3340 TRI TECH Sarasota FL 941 758 3825 B amp W INDUSTRIAL SERVICES Augusta GA 706 738 8722 DC ELECTRIC INC Aiea HI 808 483 8900 NORCO Boise ID 208 336 1643 V A ELECTRICAL MOTORS CENTER INC Hialeah FL 305 825 3327 Mc CULLOUGH ELEC MOTOR SVC Atlanta GA 404 688 5251 ROSSITER ELECTRIC Idaho Falls ID 208 529 3665 MK Warranty Repair Stations for MK Products Current as of 10 11 02 Please visit our website for up to date listing n r mlipradurte ram 6 CMS ELECTROMECHANICAL FRED ARMS ELECTRIC MOTOR INDUSTRIAL WELDER SERVICES INC REPAIR REBUILDERS Galesburg IL Stone Park IL Alsip IL 309 342 4125 888 964 3526 RELIABLE EQUIPMENT REPAIR Hamel IL 618 633 5000 DIANA AGA GAS INC Hammond IN 219 989 9030 COX EQUIPMENT COMPANY Indianapolis IN 317 241 8881 MODERN SUPPLY CO INC Evansville IN 812 425 9353 0 AIRGAS NORTH CENTRAL Des Moines IA 515 266 1111 708 343 6262 ROCKFORD INDUSTRIAL WELDING SUPPLY Rockford IL 815 226 1900 AIRGAS MID AMERICA INC Evansville IN 800 424 8905 EVANSVILLE ARMATURE INC Evansville IN 812 428 9034 PRAXAIR DISTRIBUTION INC Speedway IN 317 481 4550 CEDAR RAPIDS WELDING SUPPLY Cedar Rapids IA 319 365 1466 708
19. WELDING SUPPLY MACHINE AND WELDING SUPPLY MACHINE AND WELDING CO CO SUPPLY CO Dunn NC Greenville NC Raleigh NC 910 892 4016 252 752 3089 919 772 9500 MACHINE AND WELDING NATIONAL WELDERS SUPPLY CO NATIONAL WELDERS SUPPLY SUPPLY CO High Point NC CO Winston Salem NC 336 723 9651 910 882 1110 Charlotte NC 704 392 7317 AGA GASES INC ALBRIGHT WELDING SUPPLY ALL ABOUT SERVICE Lima OH Wooster OH Wickliffe OH 419 228 2828 330 264 2021 440 516 0303 ARC EQUIPMENT COMPANY Struthers OH 333 750 9353 ARC SERVICES INC Toledo OH 419 478 6204 BELAIR PRODUCTS INC Akron OH 330 253 3116 BIG RIVER ELECTRIC Gallipolis OH 740 446 4360 MAINTENANCE UNLTD amp TOOL REPAIR Cincinnati OH 513 554 1313 RICK S WELDER REPAIR SERVICE Eastlake OH 440 269 1204 VALLEY NATIONAL GASES Lima OH 419 228 1008 VOLLMER ELECTRIC CO Columbus OH 614 476 8800 CnD MACHINE INC Canton OH 330 478 8811 O E MEYER CO Sandusky OH 419 621 4201 S D NOLD INC Lisbon OH 330 424 3134 VALLEY NATIONAL GASES Hilliard OH 614 771 1311 WEILER WELDING CO INC Dayton OH 937 222 8312 ELECTRIC WELDER REPAIR Cuyahoga Heights OH 216 271 5600 OHIO AIR PRODUCTS Canton OH 330 821 2771 VALLEY NATIONAL GASES Cincinnati OH 513 241 5840 VALLEY NATIONAL GASES Toledo OH 419 241 9114 WELDINGHOUSE INC Cleveland OH 216 524
20. a Rubey Engine amp Electric Anchorage AK 907 336 5152 ARIZONA PRAXAIR DISTRIBUTION INC Phoenix AZ 602 269 2151 11 APPLIED SERVICES INC Benton AR 501 860 6464 MK Warranty Repair Stations for MK Products Current as of 10 11 02 Please visit our website for up to date listing www mkproducts com DIXIE WELDING SUPPLY Attalla AL 256 538 6157 WELDING SUPPLY CO Prichard AL 334 457 8681 FAIRBANKS AERO SERVICES Fairbanks AK 907 479 6666 ALLSTATE ELECTRIC MOTOR CO Phoenix AZ 602 233 0500 ARKANSAS WELDING IND L SUPPLY Hot Springs AR 501 321 9922 DR ADVANCED WELDER REPAIR Commerce CA 323 263 7383 AIRGAS WEST INC Gardena CA 310 523 9355 INDUSTRIAL WELDING SERVICES Quinton AL 205 674 3258 WELDING MACHINE HOSPITAL Montgomery AL 334 832 9353 EL DORADO WELDING amp INDUSTRIAL SUPPLY El Dorado AR 870 863 4088 ALL PHASE WELDER REPAIR amp CONSULTING Sacramento CA 916 331 0595 ARC PRODUCTS San Diego CA 619 628 1022 ARCO WELDER REPAIR Santa Fe Springs CA 562 921 5240 ARK WELDER REPAIR Fresno CA 559 292 4714 CAL WELD SUPPLY Fresno CA 209 445 0131 DELTA TECH Sun Valley CA 818 767 4234 EMCO EAST WELD R REPAIR Concord CA 925 798 4411 FRESNO OXYGEN Fresno CA 559 233 6684 INDUSTRIAL WELDER REPAIR LaPuente CA 626 961 7643 NESCO WELDING SUPPLY Fontana CA 909 427
21. ate light weight clothing reflect from light colored sur faces and burn the skin and eyes Skin burns resemble acute sunburn those from gas shielded arcs are more severe and painful DONT GET BURNED COMPLY WITH PRE CAUTIONS 1 Protective Clothing Wear long sleeve clothing in addition to gloves hat and shoes As necessary use additional protective clothing such as leather jacket or sleeves flameproof apron and fire resistant leggings Avoid outer garments of untreated cotton Bare skin protection Wear dark substantial clothing Button collar to protect chest and neck and button pockets to prevent entry of sparks 2 Eye and Head Protection Protect eyes from exposure to arc Eyes may be damaged by radiant energy when exposed to the electric arc even when not looking in the direction of the arc Never look at an electric arc without protection Welding helmet or shield containing a filter plate shade no 12 or denser must be used when welding Place over face before striking arc Protect filter plate with a clear cover plate Cracked or broken helmet or shield should NOT be worn radiation can be passed through to cause burns Cracked broken or loose filter plates must be replaced IMMEDIATELY Replace clear cover plate when broken pitted or spattered Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before a
22. e of less than one 1 year such as relay points wire conduit tungsten and welding torch parts that come in contact with the welding wire including nozzles nozzle insulators and contact tips where failure does not result from defect in workmanship or material In the case of MK Products breach of warranty or any other duty with respect to the quality of any goods the exclusive remedies therefore shall be at MK Products option 1 repair 2 replacement 3 where authorized in writing by MK Products the reasonable cost of repair or replacement at our Irvine California plant or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Upon receipt of notice of apparent defect or failure MK Products shall instruct the claimant on the warranty claim procedures to be followed As a matter of general policy only MK Products may honor an original user s warranty claims on warranted equipment in the event of failure resulting from a defect within the following periods from the date of delivery of equipment to the original user 1 Torches Weldheads amp Water Recirculators 2 All Other Equipment 3 Repairs MK PRODUCTS INC 16882 ARMSTRONG AVE IRVINE CA 92714 TEL 949 863 1234 PRODUCTS Fax 949 474 1428 Classification of any item into the foregoing categories shall be at the sole discretion of MK Products Notif
23. erratically Adjust pressure at both feeder amp Idler roll stuck torch Incorrect pressure on drive rolls Check for lock washer under idler IIET Foll Sen roll or replace if damaged See specific cabinet control box Bad speed control owner s manual for speed control operation Wire feeds one speed only Place groove in idler roll toward Wire walks out of drive Idler roll upside down top rolls Wrong size contact tip See contact tip table Rear wire guide missing Replace wire guide RoboKing Owner s Manual Page 7 SECTION F APPENDICES DIAGRAMS AND PARTS LISTS EXPLODED VIEW CABLE ASSEMBLIES DARREL ASSEMBLIES ELECTRICAL GEAR Box ASSEMBLY RoboKing Owner s Manual Page 8 4 94 P9po dx3 9110805 0 6 dene 4294 gaGi Gev N z Bura O aupra 2210 205 ag 00 4 N Lege Resy 2861 00 198 Bu 800 608 Ji 1824 2126 4214 6220 61 euondo joy 40 2 101225 226 EXPLODED VIEW 124461 Buude LLOO 6lv 4nN AE 2126 000 926 4Inpuoo MAIG 126 00428 JUE 00 1980 260 2497 b ev X OZ v 2226 0900 92 4ooq LIZO LEV RoboKing Owner s Manual 9 CABLE ASSEMBLI
24. ersonnel 2 Cylinders Cylinders must be handled carefully to prevent leaks and damage to their walls valves or safety devices Avoid electrical circuit contact with cylinders including third rails electrical wires or welding circuits They can produced short circuit arcs that may lead to a serious accident See 1 3C ICC or DOT marking must be on each cylinder It is an assurance of safety when the cylinder is properly handled Identifying gas content Use only cylinders with name of gas marked on them do not rely on color to identify gas content Notify supplier if unmarked NEVER DEFACE or alter name number or other markings on a cylinder It is illegal and hazardous Empties Keep valves closed replace caps securely mark MT keep them separate from FULLS and return promptly Prohibited use Never use a cylinder or its con tents for other than its intended use NEVER as a support or roller Locate or secure cylinders so they cannot be knocked over Passageways and work areas Keep cylinders clear of areas where they may be stuck Transporting cylinders With a crane use a secure support such as a platform or cradle Do NOT lift cylinders off the ground by their valves or caps or by chains slings or magnets Do NOT expose cylinders to excessive heat sparks slag and flame etc that may cause rupture Do not allow contents to exceed 55 degrees C 130 degrees F Cool with water spray where such expo
25. he welding circuit or in ungrounded electrically HOT equipment can fatally shock a person whose body becomes a conductor DO NOT STAND SIT LIE LEAN ON OR TOUCH a wet surface when welding without suitable protection To protect against shock Keep body and clothing dry Never work in damp area without adequate insulation against electrical shock Stay on a dry duckboard or rubber mat when dampness or sweat cannot be avoided Sweat sea water or moisture between body and an electrically HOT part or grounded metal reduces the body surface electrical resis tance enabling dangerous and possibly lethal currents to flow through the body 1 Grounding the Equipment When installing connect the frames of each unit such as welding power source control work table and water circulator to the building ground Conductors must be adequate to carry ground currents safely Equipment made electri cally HOT by stray currents may shock possibly fatally Do NOT GROUND to electrical conduit or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel Three phase connection Check phase require ment of equipment before installing If only three phase power is available connect single phase equipment to only two wires of the three phase line Do NOT connect the equipment ground lead to the third live wire or the equip ment will become electrically HOT a dangerous condition that can shock possibly fatally Befo
26. hields Walls touching combustibles on opposite sides should not be welded on or cut Walls ceil ings and floor near work should be protected by heat resistant covers or shields Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if 1 Appreciable combustibles including building construction are within 35 feet 2 Appreciable combustibles are further than 35 feet but can be ignited by sparks 3 Openings concealed or visible in floors or walls within 35 feet may expose combustibles to sparks 4 Combustibles adjacent to walls ceilings roofs or metal partitions can be ignited by radi ant or conducted heat Hot work permit should be obtained before operation to ensure supervisor s approval that adequate precautions have been taken After work is done check that area is free of sparks glowing embers and flames An empty container that held combustibles or that can produce flammable or toxic vapors when heated must never be welded on or cut unless container has first been cleaned in accordance with industry standards This includes a thorough steam or caustic cleaning or a solvent of water washing depending on the combustible s solubility fol lowed by purging and inerting with nitrogen or carbon dioxide and using protective equipment Water filling just below working level may sub stitute for inerting A container with
27. ication of any failure must be made in writing within 30 days of such failure Acopy of the invoice showing the date of sale must accompany products returned for warranty repair or replacement All equipment returned to MK Products for service must be properly packaged to guard against damage from shipping MK Products will not be responsible for any damages resulting from shipping Normal surface transportation charges both ways for products returned for warranty repair or replacement will be borne by MK Products except for products sold to foreign markets ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTA TION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT WHICH BUT FOR THIS PROVI SION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANT ABILITY OR OF FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TOANYANDALL EQUIPMENT FURNISHED BY MK PRODUCTS IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING MK PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COMMERCIAL INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE MK PRODUCTS WARRANTIES DO NOT EXTEND TO AND NO RE SELLER IS AUTHORIZED TO EXTEND MK PRODUCTS WARRANTIES TO ANY CONSUMER DATE March 1 2001
28. ily pointing outlet away from people and sources of ignition Wipe with a clean lintless cloth Match regulator to cylinder Before connecting check that the regulator label and cylinder marking agree and that the regulator inlet and cylinder outlet match NEVER Connect a regulator designed for a particular gas or gases to a cylinder containing any other gas Tighten connections When assembling threaded connections clean and smooth seats where neces sary Tighten If connection leaks disassemble clean and retighten using properly fitting wrench Adapters Use a CGA adapter available from your supplier between cylinder and regulator if one is required Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads Regulator outlet or hose connections may be identified by right hand threads for oxygen and left hand threads with grooved hex on nut or shank for fuel gas 5 Pressurizing Steps Drain regulator of residual gas through suitable vent before opening cylinder or manifold valve by turn ing adjusting screw in clockwise Draining pre vents excessive compression heat at high pressure seat by allowing seat to open on pressurization Leave adjusting screw engaged slightly on single stage regulators Stand to side of regulator while opening cylinder valve Open cylinder valve slowly so that regulator pres sure increases slowly When gauge is pressurized gauge reaches regulator maximum leave c
29. ion you have recorded above Read this Owner s 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 Printed in the U S A MK Products Inc Table of Contents SAFETY CONSIDERATIONS AAA IN NSTALLATION SECTION TECHNICAL SPECIFICATIONS SuPPORT EQUIPMENT REQUIRED CooLANT RECOMMENDATIONS TorcH LEAD CONNECTIONS OPERATION s s SECTION B GENERAL Motor GEAR Box DRIVE AND IDLER ROLLs Drive Kits OPTIONAL ACCESSORIES CONTACT 5 Gas Cups TORCH LINERS APPENDICES a a SECTION F MK REPAIR STATIONS SAFETY WARNINGS LIMITED WARRANTY This page intentionally blank SECTION C INSTALLATION TECHNICAL SPECIFICATIONS Wire Capacity 030 045 0 8mm 1 2mm solid and hard wire 030 1 16 0 8mm 1 6mm aluminum and cored wire Wire Speed 800 IPM 20mpm Max at rated feeder Input Voltage 120VAC 42VAC Duty Cycle Water Cooled model 218 series 400 amps 100 500 amp rating when used with 2 optional Power Cable All ratings are at 25 volts max using Argon Gas Shipping Weight 15 4 5m 15 Ibs 6 8 Kg 25 7 6m 19 Ibs 8 6 Kg Support EQUIPMENT REQIRED oR Powe
30. ked torch wiring diagram for infomation about pin outs and locations Motor Check Remove the torch connector from the cabinet Using the torch Amphenol connector check the resistance across pins A and B motor leads The resistance across the motor should be between 5 10 ohms If an open circuit or short exist check the motor leads and motor independently TROUBLESHOOTING GUIDE Trouble No wire feed at torch Control fuse in feeder Control box feeder not operating l e blown no slave motor or brake solenoid Replace fuse Broken electrical cable Check motor leads for continuity 24VAC control fuse in feeder Check motor leads for shorts then Control box blown replace fuse No wire feed at torch Broken electrical cable Check motor leads for continuity feeder operating properly See specific cabinet control box Bad speed control PCB owner s manual for speed control operation Check power supply owner s Wire feeds but welding Contactor control cable loose or in manual for locations and type of wire is not energized wrong position contactor signal required l e closing or 115VAC Welding power source Check power source Loose or no cable connections Check all power connections Excessive spool drag pressure Decrease spool drag pressure Dirty or worn conduit Blow out or replace conduit Adjust pressure at both feeder amp torch Wire feeds
31. l self tighten when feeding wire Idler Roll Installation and Removal 1 Using a slot type screwdriver loosen idler screw taking care not to lose lock washer under idler roll 2 Insert new idler roll and lock washer onto screw insuring that idler groove is toward top and lock washer is beneath 3 Tighten GROOVE TOWARDS TOP Figure 2 NOTE Lock washer must be under idler roll or it will not turn freely RoboKing Owner s Manual Page 3 SECTION ACCESSORIES Drive Rous Kits Insulated Drive Roll Kits are used to prevent preheating of the wire which may soften it and clog the liner This picking up of current at the drive rolls rather than at the contact tip is usually not a problem usless using too large of a contact tip or excessively oxidized aluminum wire Insulated Groove Drive Roll Kit 005 0640 For 030 0 8mm dia aluminum wire Includes insulated drive roll P N 511 0150 and idler roll assy P N 003 1870 Insulated Groove Drive Roll Kit 005 0641 For 035 0 9mm dia aluminum wire Includes insulated drive roll P N 511 0151 and idler roll assy P N 003 1870 Insulated Groove Drive Roll Kit 005 0642 For 040 1 0mm dia aluminum wire Includes insulated drive roll P N 511 0152 and idler roll assy P N 003 1870 Insulated Groove Drive Roll Kit 005 0643 For 045 1 2mm dia aluminum wire Includes insulated drive roll P N 511 0153 and idler roll assy P N 003 1870 Insulated Groove D
32. le head There are no spare parts for the motor gear box it must be replaced as a whole unit DRIVE AND IDLER ROLLS General The RoboKing comes setup from the factory with the drive roll amp idler roll requested at the time of order Other sizes of grooved drive rolls for aluminum wire are also available see Optional Kits Use Knurled drive rolls for all steel applications One set will feed all wire diameters from 030 0 8mm to 1 6 1 6mm Drive roll tension is accomplished by means of a pressure adjusting screw located on the left hand side of the torch Proper tension is achieved when wire does not slip when a small amount of pressure is added to the wire as it exits the tip RoboKing Owner s Manual Page 2 IMPORTANT NOTE Over tightening of the drive rolls will cause excessive knurling and or deformation of the wire When the complete system is set up properly wire will feed out of the end of the torch and fall on the ground forming a uniform circle If it forms a spiral or spring then there is too much tension in the system Please refer to the Cabinet Owners Manual for adjustment to the tension setting detailed there THIS IS THE NUMBER ONE CAUSE OF POOR WIRE FEED PERFORMANCE Drive Roll Installation Removal Please Note Drive rolls have a LEFT HAND thread Remove the drive roll with small nose pliers by turning the drive roll clockwise Install new drive roll on motor shaft using left hand thread Drive roll wil
33. n arc is struck Looking at an arc momentarily with unprotected eyes particularly a high intensity gas shielded arc can cause retinal burn that may leave a permanent dark area in the field of vision 3 Protection of Nearby Personnel Enclose the welding area For production weld ing a separate room or enclosed bay is best In open areas surround the operation with low reflective noncombustible screens or panels Allow for free air circulation particularly at floor level Viewing the weld Provide face shields for all persons who will be looking directly at the weld Others working in area See that all persons are wearing flash goggles Before starting to weld make sure that screen flaps or bay doors are closed B Toxic Fume Prevention Comply with precautions in 1 2B Generator engine exhaust must be vented to the outside air Carbon monoxide can kill C Fire and Explosion Prevention Comply with precautions in 1 2C Equipment s rated capacity Do not overload arc welding equipment It may overheat cables and cause a fire Loose cable connections may overheat or flash and cause afire Never strike an arc on a cylinder or other pres Sure vessel It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling D Compressed Gas Equipment Comply with precautions in 1 2D E Shock Prevention Exposed electrically hot conductors or other bare metal in t
34. nd circuit break ers should not be disconnected or shunted out Before installation inspection or service of equip ment shut OFF all power and remove line fuses or lock or red tag switches to prevent accidental turning ON of power Disconnect all cables from welding power source and pull all 115 volts line cord plugs Do not open power circuit or change polarity while welding If in an emergency it must be discon nected guard against shock burns or flash from Switch arcing Leaving equipment unattended Always shut OFF and disconnect all power to equipment Power disconnect switch must be available near the welding power source lii selecting a quality product We want you to take QU pride in operating this product as much pride as we have in bringing the 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 Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacements parts for or information on this equipment always supply the informat
35. nts can be decom posed by the heat of the arc or flame to form PHOSGENE a highly toxic gas and other lung and eye irritating products The ultraviolet radiant energy of the arc can also decompose trichloroeth ylene and perchloroethylene vapors to form phos gene DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmo sphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene C Fire and Explosion Prevention Causes of fire and explosion are combustibles reached by the arc flame flying sparks hot slag or heated material misuse of compressed gases and cylinders and short circuits BE AWARE THAT flying sparks or falling slag can pass through cracks along pipes through windows or doors and through wall or floor openings out of sight of the goggled operator Sparks can fly many feet To prevent fires and explosion Keep equipment clean and operable free of oil grease and in electrical parts of metallic particles that can cause short circuits If combustibles are in area do NOT weld or cut Move the work if practicable to an area free of combustibles Avoid paint spray rooms dip tanks storage areas ventilators If the work cannot be moved move combustibles at least 35 feet away out of reach of sparks and heat or protect against ignition with suitable and snug fitting fire resistant covers or s
36. r SOURCE OF SUFFICIENT CAPACITY FOR YOUR NEEDS Regulated gas supply and hoses Properly sized power leads from power source to wire feeder and ground Water source and hose capable of providing a minimum of 1 qt liter min at 45 p s i when using water cooled torches CooLant RECOMMENDATION Use a name brand additive which does not contain reactive sulphur or chlorine and does not react with copper brass or aluminum Here s also mixture that works well Use 3 Gallons 11 4 Liters deionized water NOT DISTILLED Use 1 Gallon 3 8 Liters ethleyne glycol Use 1 tsp 5 ml liquid glycerin per gallon 3 8 Liters of mixture The Coolant rate should be 1 qt liter minute at 35 p s i TorcH LEAD CONNECTIONS Power Cable The torch fitting is screwed into the back of the torch block using a conductive sealant RoboKing torches use a 4 AWG power cable which is secured to the torch in the same manner The power cable fitting on the other end connects to the power block inside the Cobramatic feeder ALL ROBOKING TORCHES MUST BE WATER COOLED Conduit The RoboKing comes standard with a teflon lined conduit The torch end is secured with a set screw accessable through a hole in the handle under RoboKing Owner s Manual Page 1 SEcTION B the rear Handle nut Spiral steel conduits are available when using hard and cored wires Gas Hose The gas hose is pushed on to the inlet tube of the front body The gas inlet tube
37. re welding check ground for continuity Be sure conductors are touching bare metal of equipment frames at connections If a line cord with a ground lead is provided with the equipment for connection to a switch box connect the ground lead to the grounded switch box If a three prong plug is added for connection to a grounded mating receptacle the ground lead must be connected to the ground prong only If the line cord comes with a three prong plug connect to a grounded mating receptacle Never remove the ground prong from a plug or use a plug with a broken ground prong 2 Connectors Fully insulated lock type connectors should be used to join welding cable lengths 3 Cables Frequently inspect cables for wear cracks and damage IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable Cables with damaged areas may be taped to give resistance equivalent to original cable Keep cable dry free of oil and grease and pro tected from hot metal and sparks 4 Terminals and Other Exposed Parts Terminals and other exposed parts of electrical units should have insulating covers secured before operation 5 Electrode Wire Electrode wire becomes electrically HOT when the power switch of gas metal arc welding equipment is ON and welding gun trigger is pressed Keep hands and body clear of wire and other HOT parts 6 Safety Devices Safety devices such as interlocks a
38. rive Roll Kit 005 0644 For 062 1 6mm dia aluminum wire Includes insulated drive roll P N 511 0154 and idler roll assy P N 003 1870 Knurled Drive Roll 511 0101 Idler Roll Kit 005 0686 OPTIONAL ACCESSORIES Flat Spiral Steel Conduit Standard Conduit for steel amp cored wire with additional protective cover 615 0208 15 ft 4 5m 001 0774 615 0216 25 ft 7 6m 001 0775 25 ft 7 6m NOTE The protective cover is used to help protect the conduit from burns Snake Skin protective boot covers are now standard on all torches You may order spare repleacement covers to protect the lead assy of the torch when the factory one becomes damaged or worn It can eaily be replaced in the field be means of a side zipper Snake Skin Cover 13ft for 15ft leads 931 0110 Snake Skin Cover 23ft for 25ft leads 931 0122 RoboKing Owner s Manual Page 4 CoNTAcT TIPS Standard Contact Tips Spray 1 5 8 41 3mm 621 0158 Short 1 7 8 47 6mm 621 0165 Spray 1 5 8 41 3mm 621 0157 Short 1 7 8 47 6mm 621 0166 Spray 1 5 8 41 3mm 621 0161 Short 1 7 8 47 6mm 621 0167 Spray 1 5 8 41 3mm 621 0162 Short 1 7 8 47 6mm 621 0168 Spray 1 5 8 41 3mm 621 0163 Short 1 7 8 47 6mm 621 0169 030 0 8mm 040 1 0mm 035 0 9mm 044 1 0mm 045 1 2mm 053 1 35mm 045 or 052 060 1 5mm 063 1 6mm 075 1 9mm Spray 1 5 8 41 3mm 621 0163 Short 1 7 8 47 6mm 621 0169 063 1 6mm 085
39. rtance of minimal down time will determine to what extent spare parts should be stocked on hand See the Recommended spare parts list for the most commonly replaced parts RECOMMENDED SPARE PARTS Qty Part Number Description 615 0007 Conduit 15 615 0008 Conduit 25 511 0101 Knurled Drive Roll 005 0686 Idler Roll for steel lt ee GOLD IDLER ROLL KIT DRIVE ROLL 005 0686 511 0101 TROUBLESHOOTING Regardless of which torch or feeder used all MK Products push pull guns operate on the same principle The 115 42 VAC slave motor in the feeder runs at a fast constant speed but has very low torque It is always trying to feed more wire than the torch motor wants and when the motor gets all it wants it slows the slave motor preventing a bird s nest Because of the low torque produced by the slave motor a brake system is used to prevent wire overrun rather than tension The drag adjustment in the spindle is used simply to keep the wire slightly taut so it will not pull off the spool while feeding wire The high torque 24 VDC torch motor is controlled by a solid state speed control The torch motor is connected to the cabinet control box via a control RoboKing Owner s Manual Page 6 cable and Amphenol If this cable becomes damaged a variety of symptoms can occur depending on which wire s break To test check each wire for continuity and shorts TESTING THE ToRcH See W cloc
40. sure exists Protect cylinders particularly valves from bumps falls falling objects and weather Replace caps securely when moving cylinders Stuck valve Do NOT use a hammer or wrench to open a cylinder valve that cannot be opened by hand Notify your supplier Mixing gases NEVER try to mix any gases in a cylinder NEVER refill any cylinder Cylinder fittings should never be modified or exchanged 3 Hose Prohibited use Never use hose other than that designed for the specified gas A general hose identification rule is red for fuel gas green for oxygen and black for inert gases Use ferrules or clamps designed for the hose not ordinary wire or other substitute as a binding to connect hoses to fittings No copper tubing splices Use only standard brass fittings to splice hose Avoid long runs to prevent kinks and abuse Sus pend hose off ground to keep it from being run over stepped on or otherwise damaged Coil excess hose to prevent kinks and tangles Protect hose from damage by sharp edges and by sparks slag and open flame Examine hose regularly for leaks wear and loose connections Immerse pressured hose in water bubbles indicate leaks Repair leaky or worn hose by cutting area out and splicing Do NOT use tape 4 Proper Connections Clean cylinder valve outlet of impurities that may clog orifices and damage seats before con necting regulator Except for hydrogen crack valve momentar
41. unknown contents should be cleaned see paragraph above Do NOT depend on sense of smell or sight to determine if itis safe to weld or cut Hollow castings or containers must be vented before welding or cutting They can explode Explosive atmospheres NEVER weld or cut where the air may contain flammable dust gas or liquid vapors such as gasoline D Compressed Gas Equipment The safe handling of compressed gas equip ment is detailed in numerous industry publica tions The following general rules cover many of the most common situations 1 Pressure Regulators Regulator relief valve is designed to protect only the regulator from overpressure it is not intended to protect any downstream equipment Provide such protection with one or more relief devices Never connect a regulator to a cylinder contain ing gas other than that for which the regulator was designed Remove faulty regulator from service immedi ately for repair first close cylinder valve The following symptoms indicate a faulty regulator Leaks if gas leaks externally Excessive Creep if delivery pressure continues to rise with downstream valve closed Faulty Gauge if gauge pointer does not move off stop pin when pressurized nor returns to stop pin after pressure release Repair Do NOT attempt repair Send faulty regulators for repair to manufacturer s desig nated repair center where special techniques and tools are used by trained p
42. ylinder valve in following position for oxygen and inert gases open fully to seal stem against possible leak for fuel gas open to less than one turn to permit quick emergency shut off Use pressure charts available from your supplier for safe and efficient recommended pressure set tings on regulators Check for leaks on first pressurization and regularly thereafter Brush with soap solution Bubbles indi cate leaks Clean off soapy water after test dried soap is combustible E User Responsibilities Follow all Safety Rules Remove leaky or defective equipment from ser vice immediately for repair Read and follow user manual instructions F Leaving Equipment Unattended Close gas supply at source and drain gas G Rope Staging Support Rope staging support should not be used for welding or cutting operation rope may burn 1 3 ARC WELDING Comply with precautions in 1 1 1 2 and this section Arc Welding properly done is a safe process but a careless operator invites trouble The equipment carries high currents at signifi cant voltages The arc is very bright and hot Sparks fly fumes rise ultraviolet and infrared energy radiates weldments are hot and com pressed gases may be used The wise operator avoids unnecessary risks and protects himself and others from accidents A Burn Protection Comply with precautions in 1 2 The welding arc is intense and visibly bright Its radiation can damage eyes penetr
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