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IM10032
August 2009
TM
COUGAR
Push Pull GUN
Models: K2704-2, K2704-3
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 thoughtful
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
• Wor
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matériaux inflammables ou les recouvrir afin de et les précautions de sûreté specifiques qui parraissent dans ce prévenir tout risque dʼincendie dû aux étincelles. manuel aussi bien que les précautions de sûreté générales suiv- antes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un Sûreté Pour Soudage A Lʼ
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v v for selecting one of our QUALITY products. We want you to take pride in operating this product ••• as much pride as we have in Thank You bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for advice or information about their use of our products. We respond to our customers based
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TABLE OF CONTENTS SAFETY PRECAUTIONS ...........................................................................................................................................i-v TABLE OF CONTENTS................................................................................................................................................1 GENERAL INFORMATION..........................................................................................................................................
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COUGAR™ Push Pull Gun - GENERAL INFORMATION PRODUCT DESCRIPTION RECOMMENDED PROCESSES AND EQUIPMENT The Cougar™ push-pull gun is a lightweight, handheld combined semiautomatic wire feeder and welding gun, designed primarily for The push-pull gun can be used to weld aluminum and aluminum aluminum welding using argon shielding gas. The cable included alloys using Gas Metal Arc Welding or GMAW (also known as MIG) with the push-pull gun allows welding up to 25 (7.62m) or 50 feet process, which requi
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COUGAR™ Push Pull Gun - INSTALLATION Unpacking the Push-Pull Gun Safety Precautions Unpacking the Push-Pull Gun – Read "Safety Precautions" in the Operating Manual before Carefully unpack your Cougar™ Push-Pull Gun and attach the proceeding. Only personnel that have read and understood Barrel Assembly, and make sure you have all of the parts shown the Operating Manual should install and operate this equipment. below. – Power source must be turned "OFF" and power leads disconnected when installin
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COUGAR™ Push Pull Gun - INSTALLATION Push-pull Gun Familiarization Become familiar with your push-pull gun before connecting to b.Drive roll with two wire grooves. Narrow groove feeds .035 (0.9 welder. For features described below, refer to Figure on the next mm) diameter wire. Wide groove feeds 3/64 inch (1.2 mm) page. diameter wire. Gun is shipped with wide groove or 3/64 in operating position (toward handle). Reverse roller for .035 1. Handle, gun can be used in either right or left hand. inc
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COUGAR™ Push Pull Gun - OPERATING INSTRUCTIONS used. Consult your local dealer or appropriate AWS publication Safety Precautions for help in selecting an appropriate alloy type and wire size. Also refer to, "Procedure Settings" later in this chapter, for wire sizes used with typical base metal thicknesses and procedure set- WARNING tings. • Do not touch electrically live Installing Conduit Liner: parts or electrode with skin or wet clothing 1. Laying torch out straight remove positioning nut, th
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COUGAR™ Push Pull Gun - OPERATING INSTRUCTIONS Drive Roll Groove Selection RELEASE LEVER LID The drive roll has two grooves. A wider groove for feeding 3/64” RELEASE LEVER (.047) wire and a narrow groove for feeding .035” (0.9mm) wire to accommodate changes in the wire size used. Changing between the grooves simply requires reversing the drive roll. A. Drive Roll Orientation 1. Drive roll is scribed with wire groove size. For appropriate groove orientation, ensure desired size callout is facing
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COUGAR™Push Pull Gun - OPERATING INSTRUCTIONS Making A Weld 7. Re-engage wire drive by pushing release lever to down posi- 1 Check that the push-pull gun power, control, and gas connec- tion to feed wire. tions are correct for the power source being used. Check that the gas supply is turned on. Check wire push-pull for an ade- 8. Momentarily squeeze trigger and verify that wire feeds proper- quate supply of wire. ly. Trim wire to approximately 1/4" (6 mm) from end of contact tip. 2. See "Procedu
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COUGAR™ Push Pull Gun ACCESSORIES/MAINTENANCE ACCESSORIES (consult Lincoln Sales Bulletin E12.16) The following accessories are available for the Cougar™ push-pull gun. .035-3/64" Aluminum Drive Roll Kit Wire Conduits Features two grooves for feeding aluminum wire. The smaller 25 foot .035"-1/16" Wire Diameter Order KP2881-25 groove feeds .035 wire. The larger groove feeds 3/64th wire. 50 foot .035"-1/16" Wire Diameter Order KP2881-50 Order KP2876-1 Gas Diffuser 1/16" Aluminum Drive Roll Kit Dif
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COUGAR™ Push Pull Gun Troubleshooting Guide PROBLEM SYMPTOMS REMEDY No arc, wire feed, or gas flow. 1. Cable connections loose. 1. Check all power connections. 2. Trigger switch loose or defective. 2. Fix switch or replace. 3. Welder not turned on. 3. Turn on welder power. 4. Welder not plugged in. 4. Plug in. 5. Cable or adapter cable damaged. 5. Inspect and replace No arc, weak arc. 1. Poor ground connection to work. 1. Check ground connection. 2. Power cable connection loose. 2. Check connect
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COUGAR™ Push Pull Gun Troubleshooting Guide TESTING THE TORCH Motor Check. Remove the torch connector from the cabinet. Using the torch Control Cable 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. Testing the Potentiometer. Using the torch Control Cable Connector, check the resistance across pin “D” (wiper) and pin “C”. The resista
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COUGAR™ Push Pull Gun REPLACEMENT PARTS LIST AND DIAGRAM 8 11 9 1 4 7 5 3 10 6 2 ITEM PART ITEM PART NO. NO. DESCRIPTION NO. NO. DESCRIPTION 1 KP2877-180 180 Degree Air-Cooled Gun Barrel N/S S26374-34 50' Cable Assembly - Cougar 2 S26374-31 Motor Assembly N/S S26374-35 Cable Cover 25 3 S26374-6 Wire Drive Cover N/S S26374-36 Cable Cover 50' 4 S26374-14 Potentiometer Assembly N/S S26374-37 Power Cable Assembly 25' 5 S26374-23 Trigger Assembly N/S S26374-38 Power Cable Assembly 50' 6 S26374-24 Han
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COUGAR™ LX Push Pull Gun REPLACEMENT PARTS LIST AND DIAGRAM 4 6 5 9 3 2 8 7 10 1 S26374-14 ITEM NO. PART NO. DESCRIPTION COMMENTS 1 S26374-31 Motor Assembly 2 S26374-7 Pressure Lever 3 S26374-8 Pivot Arm 4 S26374-9 Set Screw, Pressure Roll 5 S26374-10 Pressure Adjustment Knob Assembly 6 S26374-12 Ball Bearing 7 KP2876-1 Drive Roll Kit AL .035-3/64" 7 KP2876-2 Drive Roll Kit AL 1/16" 8 S26374-63 Thumb Screw 9 S26374-15 Housing, Potentiometer 10 S26374-14 Potentiometer Assembly 12
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Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. WARNING Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo. AVISO DE da. Aislese del trabajo y de la tierra. PRECAUCION French Ne laissez ni la peau ni des vête- Gar
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Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración. mentación de poder de la máquina guardas quitadas. AVISO DE Mantenga la cabeza fuera de los antes de iniciar cualquier servicio. humos. Utilice ventilación o PRECAUCION aspiración para gases.
