Full Text Searchable PDF User Manual
505 Oakwood Rd. Lake Zurich, IL 60047
ph: 847-550-0033 fx: 847-550-0444
email: sales@cmindustries.com
www.cmindustries.com
July 2017
v17.5.1
DO NOT INSTALL, OPERATE, OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS OPERATING MANUAL
Operating Manual and Parts List
Air-Cooled MIG Torches for
Hollow Wrist Robots
KR502HW
MADE IN USA
All reference to genuine manufacture’s equipment numbers, and/or trade names or trademarks are for identification and convenience only.
The trademarks and trade names are the property of their respective owners. ® Indicates a registered trade name or product name, that is the property of the above-named companies.
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Complete Assembly Overview ....................................................
Installation & Removal of Consumables ....................................
Installation & Removal of Cable Assembly ..................................
Installation of Clutch ...................................................................
Installation & Removal of X.KOOL
TM
Neck ..................................
Technical Data ..............................................................................
Parts List for Solid Mount ............................................................
Parts List for Solid Mount w/ X.Kool ........................................
Parts List for Solid Mount w/ Wire Brake ....................................
Parts List for Clutch Mount ..........................................................
KR502HW Ordering Instructions .................................................
Nozzle & Gas Diffuser Selection .................................................
Checking Fixture .........................................................................
Nozzle Cleaning Station ..............................................................
General Safety ..............................................................................
Table of Contents
2
Nozzle
-Push slip-on nozzle until it bottoms on the insulator.
-Pull slip-on nozzle off to remove it.
®
TM
CMI Taper Lock Contact Tip
-Thread tip into retaining head and tighten.
-Unscrew to remove (use pliers if tight).
Gas Diffuser
-Screw onto the end of neck.
(Use 5/8” wrench to tighten)
-Unscrew to remove.
Neck Insulator
-Slip onto the front of the neck.
-Unscrew retaining head and pull off to remove.
Neck
-Push neck into torch body.
(Make sure the pins line up with the slot inside the Torch Body)
-To remove, loosen the neck clamp under the collar.
-Pull neck out.
Neck Clamp
-Turn collar on torch body to expose screw.
-Once neck is inserted, tighten screw
using a 4mm Hex wrench to secure
neck in place.
-Turn collar to to hide screw hole
Hollow Wrist Body
Spacer
M5 Screws
M4 Screws
Insulating Disc
-Line up pin to pinhole
on robot
(Use M4 screws to hold to robot)
Torch Body Cover
Spacer
Sleeve
Complete Assembly Overview
for Solid Mount System
-Installation & Removal of Consumables-
3
Removal
- Remove the neck from the hollow wrist torch body.
- Pull the power pin out of the wire feeder and remove the liner.
- Unscrew the (3) buttonhead screws on the torch body cover.
- Slide off the torch body cover and sleeve and loosen the M4 screw on the cable connector.
- Pull the front of the cable assembly from the cable connector.
- Remove the cable assembly from the robot.
Power Pin
Cable Assembly
Cable Connector
Installation of New Cable Assembly
- Install the insulating disc by lining up the pin to the pin hole of the turning disk, and use the (4) M4 screws to tighten.
- Line up the torch body w/ spacer with the pin hole of the insulating disc and screw in the (4) M5 screws
that hold the torch body to the insulating disc.
- Slide the cable assembly through the robot arm. Do not connect the power pin.
- Push the front of the cable assembly into the torch body and tighten the M4 screw of the cable connector.
- Slide on the spacer sleeve over the torch body and spacer, then the torch body cover over the torch
body and tighten the (3) buttonhead screws.
- Install the liner through the power pin, and make sure the power pin is connected to the wire feeder properly.
(Tighten set screw if necessary.)
- Install the neck without consumables and cut the liner to the proper length as needed.
Cable Assembly Overview
-Installation & Removal of Cable Assembly-
4
Installing the Clutch
- Begin with removing the disc from the clutch.
- Install the clutch disc to the face of the robot with
the screws that were provided.
- Install the clutch to the disc by lining up the locating
pins and using a hex wrench to tighten the (6) M4 screws.
- Feed the cable assembly through the robot and push
it through the clutch.
- Once the cable assembly and the wires of the cable assembly are
throught the clutch, take the cover off the torch body and attach
the it to the cable assembly with the (1) M5 clamp screw.
- Connect the male terminals of the power cable to the female
terminals of the clutch.
- Carefully tuck the wires back into the clutch, and begin
pushing the torch body and cable assembly back towards the robot.
- Line up the locating pin of the torch body with the clutch and press fit together.
- Use the (6) M4 screws to secure the torch body to the clutch.
- Slide on the torch body cover and secure it with the (3) M4 buttonhead screws.
- Slide the rubber boot for the clutch over the torch body over and fit it into the groove of the clutch,
making sure none of the interals are visible.
1
2
Clutch Assembly
-Installation of Torch Assembly with Clutch-
5
- Slide the X.KOOL
TM
neck into the torch body and tighten the neck clamp screw.
- Pull the 2 black water lines through the torch body cover.
- Connect the female coupler fitting to it’s male counterpart.
- Install the consumables the same as the standard KR502 neck.
Female Coupler Fitting
Male Coupler Fitting
Installing the X.KOOL
TM
Neck
Installation of Water Lines
- Install the torch body to the robot.
- Start with the torch body cover off of the torch body.
- Run both water lines through the holes of the torch body cover so that the quick disconnects are
hanging out the front.
- Next, with the water lines lined up so they are on the top of the torch, find the 2 holes in the torch body
base the lines will run through, and feed them through the torch body base and through the arm of the robot.
(Make sure to push enough hose though so that you can pull from the back of the 1’ cable cover.)
- Attach the torch body cover to the torch body with the water lines facing the top of the torch.
- Once you’ve pushed the water lines through the robot, attached the torch body cover, and out of the 1’ foot
cable cover, carefully pull the rest of the 15’ of water hose so that you have the desired length at the front.
Run lines
-Installation of Water Lines & Neck-
6
NOTE: Ratings are based on tests that comply with NEMA ARC Welding Section Standard 11-6-1975 for Duty Cycle.
The time period of one complete cycle shall be 10 minutes (60%=6 minutes) National Electrical Manufacturers Association
2101 L Street N.W. Washington D.C. 20037.
Torch Amperage Ratings
Mixed Gas
500 AMP
CO2
600 AMP
60% Duty Cycle
Mixed Gas
350 AMP
CO2
500 AMP
100% Duty Cycle
Kool Run Torch Model
KR502HW
C
-
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
B
16.632” [422.4]
17.094” [434.2]
15.945” [405.0]
18.495” [470.0]
17.323” [440.0]
20.465” [520.0]
19.292” [490.0]
A
180°
22°
45°
22°
45°
22°
45°
NECK
KR502-180
KR502-22
KR502-45
KR502-22L1
KR502-45L1
KR502-22L2
KR502-45L2
Clutch Mount w/ Wire Brake
C
-
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
B
15.451” [392.4]
15.913” [404.2]
14.764” [375.0]
17.314” [440.0]
16.142” [410.0]
19.284” [490.0]
18.111” [460.0]
A
180°
22°
45°
22°
45°
22°
45°
NECK
KR502-180
KR502-22
KR502-45
KR502-22L1
KR502-45L1
KR502-22L2
KR502-45L2
Clutch Mount
*Wire Stick-Out = 15mm
A
B
C
C
-
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
B
16.238” [412.4]
16.700” [424.2]
15.551” [395.0]
16.920” [460.0]
16.930” [430.0]
20.070” [510.0]
18.352” [480.0]
A
180°
22°
45°
22°
45°
22°
45°
NECK
KR502-180
KR502-22
KR502-45
KR502-22L1
KR502-45L1
KR502-22L2
KR502-45L2
Solid Mount w/ Wire Brake
C
-
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
B
15.057” [382.4]
15.519” [394.2]
14.370” [365.0]
16.920” [430.0]
15.748” [400.0]
18.890” [480.0]
17.717” [450.0]
A
180°
22°
45°
22°
45°
22°
45°
NECK
KR502-180
KR502-22
KR502-45
KR502-22L1
KR502-45L1
KR502-22L2
KR502-45L2
Solid Mount
*Wire Stick-Out = 15mm
A
B
C
Technical Data
TCP Dimensions &
Std. Neck Options
7
10
9
8
7h
7g
7f
7d
7e
7c
7b
7a
7
6
5
4
3
2
1
1.
152-xx-xxP
See
Page
10
“
Plated Nozzle Selection
”
2.
CMI TAPER LOCK
TM
CONTACT TIP
155-1-030 Heavy
Duty,
.030”
(0.8mm)
155-1-035 Heavy
Duty,
.035”
(0.9mm)
155-1-040 Heavy
Duty,
.040”
(1.0mm)
155-1-045 Heavy
Duty,
.045”
(1.2mm)
155-1-364 Heavy
Duty,
3/64”
(1.3mm)
155-1-052 Heavy
Duty,
.052”
(1.4mm)
155-1-062 Heavy
Duty,
.062”
(1.6mm)
155-1-564 Heavy
Duty,
5/64”
(2.0mm)
155-1-332 Heavy
Duty,
3/32”
(2.4mm)
155-2-xxx Heavy
Duty
Tapered
Contact
Tip
155-3-xxx Extra
Heavy
Duty
Contact
Tip
155-7-xxx Heavy
Duty
CrZr
Contact
Tip
3.
154-Rxxx
See
Page
10
“Gas
Diffuser
Selection”
4.
KR50-1 Neck
Insulator
5.
KR502-22 Neck,
22°
KR502-45 Neck,
45°
KR502-180
Neck,
180°
6.
KR502-6
O-Ring
7.
KHW-200A1 Solid Mount Assembly - ABB
IRB 1600ID
KHW-200D1 Solid
Mount
Assembly
-
OTC
AX MV4AP/ AX MV4LAP
KHW-200F
Solid
Mount
Assembly
-
Fanuc/
Motoman MA1440
KHW-200M
Solid
Mount
Assembly
-
Motoman
[excludes MA1440]
7a. KHW-201 Hollow
Wrist
Torch
Body
[Included in ITEM 7]
7b. KHW-211 Hollow Wrist Torch Body Cover
[Included in ITEM 7]
7c. Not Sellable M4x0.7x17
SHCS
[Included in ITEM 7]
7d. KHW-103 Spacer
-
Fanuc/Motoman
[Included in ITEM 7]
KHW-105 Spacer
-
ABB/OTC
7e. KHW-104 Spacer
Sleeve
[Included in ITEM 7]
7f. Not Sellable M5x0.8x18
SHCS
[Included in ITEM 7]
7g. KHW-AB160 Insulating Disc - ABB IRB 1600ID
KHW-FA100 Insulating
Disc
-
Fanuc/Motoman
MA1440
KHW-MM1
Insulating
Disc
-
Motoman
KHW-OAX1 Insulating Disc - OTC AX MV4AP/MV4LAP
7h. Not Sellable M4x0.7x12 SHCS
[Fanuc/Motoman]
8.
KHW-A160
Cable
Assembly,
ABB
IRB
1600ID
KHW-A261
Cable
Assembly,
ABB
IRB
2600ID
1.65
KHW-F100 Cable
Assembly,
Fanuc
100iC,
100iC-12
KHW-F100-6L
Cable
Assembly,
Fanuc
100iC-6L,
100iC-7L
KHW-F100-8L
Cable
Assembly,
Fanuc
100iC-8L
KHW-F120 Cable
Assembly,
Fanuc
120iC
KHW-F120-10L Cable Assembly, Fanuc 120iC-10L,120iC-12L
KHW-F710-12L Cable Assembly, Fanuc M-710iC-12L
KHW-M140
Cable
Assembly,
Motoman
EA
/
MA1400
KHW-M190
Cable
Assembly,
Motoman
EA
/
MA1900
KHW-M310
Cable
Assembly,
Motoman
MA3100
KHW-M144
Cable
Assembly,
Motoman
MA1440
KHW-OMV4 Cable
Assembly,
OTC
AX
MV4AP/MV4LAP
9.
KDP-101
Power
Pin,
Miller
®
KDP-103
Power
Pin,
Panasonic
®
KDP-104
Power
Pin,
Tweco
®
#4
KDP-106
Power
Pin,
OTC
®
KDP-107
Power
Pin,
Fronius
®
KDP-108
Power
Pin,
Lincoln
®
“4R”
KDP-109
Power
Pin,
Lincoln
®
“AutoDrive
®
S
10. 164-30-6
Liner,
6’,
.030”
164-45-6
Liner,
6’,
.035”
-
.045”
164-45A-6 Liner,
6’,
.035”
-
.045”
(for Lincoln
®
AutoDrive
®
S Only)
164-116-6 Liner,
6’,
.045”
-
1/16”
164-116TF-6 Teflon Liner, 6’, 3/64” - 1/16”
ITEM PART
# DESCRIPTION
Exploded View & Parts List
for Solid Mount
8
14
13
12
11h
11g
11f
11d
11e
11c
11b
11a
11
10
9
8
7
6
5
4
3
2
1
1.
152-xx-xxP
See
Page
10
“
Plated Nozzle Selection
”
2.
CMI TAPER LOCK
TM
CONTACT TIP
155-1-030 Heavy
Duty,
.030”
(0.8mm)
155-1-035 Heavy
Duty,
.035”
(0.9mm)
155-1-040 Heavy
Duty,
.040”
(1.0mm)
155-1-045 Heavy
Duty,
.045”
(1.2mm)
155-1-364 Heavy
Duty,
3/64”
(1.3mm)
155-1-052 Heavy
Duty,
.052”
(1.4mm)
155-1-062 Heavy
Duty,
.062”
(1.6mm)
155-1-564 Heavy
Duty,
5/64”
(2.0mm)
155-1-332 Heavy
Duty,
3/32”
(2.4mm)
155-2-xxx Heavy
Duty
Tapered
Contact
Tip
155-3-xxx Extra
Heavy
Duty
Contact
Tip
155-7-xxx Heavy
Duty
CrZr
Contact
Tip
3.
154-Rxxx
See
Page
10
“Gas
Diffuser
Selection”
4.
KR512-22
X.KOOL
Neck, 22°
KR512-45
X.KOOL
Neck, 45°
KR512-180 X.KOOL
Neck, 180°
5.
KR512-1 X.KOOL
Quick
Disconnect
6.
KR512-1-15
X.KOOL
Water
Line,
15’
(each)
[Includes ITEM 5]
7.
KR512-14B X.KOOL
Cable
Cover
Robot
Bracket
8. Not Sellable M5x0.8x35
SHCS
[Included in ITEM 7]
9.
KR512-14C X.KOOL
Cable
Cover,
14”
10. KR502-6
O-Ring
11.
KHX-200A1 Solid Mount Assembly - ABB
IRB 1600ID
KHX-200D1
Solid
Mount
Assembly
-
OTC
AX MV4AP/ AX MV4LAP
KHX-200F Solid
Mount
Assembly
-
Fanuc/
Motoman MA1440
KHX-200M
Solid
Mount
Assembly
-
Motoman
[excludes MA1440]
11a.
KHW-201 Hollow
Wrist
Torch
Body
[Included in ITEM 11]
11b.
KHX-211
Hollow
Wrist
Torch
Body
Cover
[Included in ITEM 11]
11c. Not Sellable M4x0.7x17
SHCS
[Included in ITEM 11]
11d.
KHW-103 Spacer
-
Fanuc/Motoman
[Included in ITEM 11]
KHW-105 Spacer
-
ABB
11e.
KHW-104 Spacer
Sleeve
[Included in ITEM 11]
11f. Not Sellable M5x0.8x18
SHCS
[Included in ITEM 11]
11g.
KHW-xxxxxx Insulating
Disc
[Included in ITEM 11]
11h. Not Sellable M4x0.7x12 SHCS
[Fanuc/Motoman]
12. KHX-A160 XK Cable Assembly, ABB IRB 1600ID
KHX-A261 XK Cable Assembly, ABB IRB 2600ID 1.65
KHX-A262 XK Cable Assembly, ABB IRB 2600ID 1.85
KHX-F100 XK
Cable
Assembly,
Fanuc 100iC, 100iC-12
KHX-F100-6 XK Cable Assembly, Fanuc 100iC-6L, 100iC-7L
KHX-F100-8 XK
Cable
Assembly,
Fanuc
100iC-8L
KHX-F120 XK
Cable
Assembly,
Fanuc
120iC
KHX-F120-10 XK Cable Assembly, Fanuc 120iC-10L,120iC-12L
KHX-F710-12L XK Cable Assembly, Fanuc M-710iC-12L
KHX-M140
XK Cable Assembly, Motoman EA / MA1400
KHX-M190 XK Cable Assembly, Motoman EA / MA1900
KHX-M310
XK
Cable
Assembly,
Motoman
MA3100
KHX-M144
XK
Cable
Assembly,
Motoman
MA1440
KHX-OMV4
XK Cable Assembly, OTC AX MV4AP/MV4LAP
13. KDP-101
Power
Pin,
Miller
®
KDP-103
Power
Pin,
Panasonic
®
KDP-104
Power
Pin,
Tweco
®
#4
KDP-105
Power
Pin,
Tweco
®
#5
KDP-106
Power
Pin,
OTC
®
KDP-107
Power
Pin,
Fronius
®
KDP-108
Power
Pin,
Lincoln
®
“4R”
KDP-109
Power
Pin,
Lincoln
®
“AutoDrive
®
S
14. 164-30-6
Liner,
6’,
.030”
164-45-6
Liner,
6’,
.035”
-
.045”
164-45A-6 Liner,
6’,
.035”
-
.045”
(for Lincoln
®
AutoDrive
®
S Only)
164-116-6 Liner,
6’,
.045”
-
1/16”
164-116TF-6 Teflon Liner, 6’, 3/64” - 1/16”
ITEM PART
# DESCRIPTION
Exploded View & Parts List
for Solid Mount w/ X.KOOL
9
15
14
13
7h
7g
7f
7d
7e
7c
7b
7a
7
6
8
9
10
11
12
5
4
3
2
1
1.
152-xx-xxP
See
Page
10
“
Plated Nozzle Selection
”
2.
CMI TAPER LOCK
TM
CONTACT TIP
155-1-030 Heavy
Duty,
.030”
(0.8mm)
155-1-035 Heavy
Duty,
.035”
(0.9mm)
155-1-040 Heavy
Duty,
.040”
(1.0mm)
155-1-045 Heavy
Duty,
.045”
(1.2mm)
155-1-364 Heavy
Duty,
3/64”
(1.3mm)
155-1-052 Heavy
Duty,
.052”
(1.4mm)
155-1-062 Heavy
Duty,
.062”
(1.6mm)
155-1-564 Heavy
Duty,
5/64”
(2.0mm)
155-1-332 Heavy
Duty,
3/32”
(2.4mm)
155-2-xxx Heavy
Duty
Tapered
Contact
Tip
155-3-xxx Extra
Heavy
Duty
Contact
Tip
155-7-xxx Heavy
Duty
CrZr
Contact
Tip
3.
154-Rxxx
See
Page
10
“Gas
Diffuser
Selection”
4.
KR50-1 Neck
Insulator
5.
KR502-22 Neck,
22°
KR502-45 Neck,
45°
KR502-180
Neck,
180°
6.
KR502-6
O-Ring
7.
KWB-200A1 Solid Mount Assembly - ABB
IRB 1600ID
KWB-200D1 Solid
Mount
Assembly
-
OTC
AX MV4AP/ AX MV4LAP
KWB-200F Solid
Mount
Assembly
-
Fanuc/
Motoman MA1440
KWB-200M
Solid
Mount
Assembly
-
Motoman
[excludes MA1440]
7a. KWB-201
Hollow
Wrist
Torch
Body
[Included in ITEM 7]
7b. KWB-211
Hollow
Wrist
Torch
Body
Cover
[Included in ITEM 7]
7c. Not Sellable M4x0.7x17
SHCS
[Included in ITEM 7]
7d. KHW-103 Spacer
-
Fanuc/Motoman
[Included in ITEM 7]
KHW-105 Spacer
-
ABB/OTC
7e. KHW-104 Spacer
Sleeve
[Included in ITEM 7]
7f. Not Sellable M5x0.8x18
SHCS
[Included in ITEM 7]
7g. KHW-AB160 Insulating Disc - ABB IRB 1600ID
KHW-FA100 Insulating
Disc
-
Fanuc/Motoman
MA1440
KHW-MM1
Insulating
Disc
-
Motoman
KHW-OAX1 Insulating Disc - OTC AX MV4AP/MV4LAP
7h. Not Sellable M4x0.7x12 SHCS
[Fanuc/Motoman]
8.
164-45J Jump
Liner,
.045“
164-116J
Jump
Liner,
1/16“
9.
KWB-GT1 Wire
Brake
Wire
Guide
Tool
10. KWB-G045 Wire Brake Wire Guide, .045”
KWB-G116
Wire
Brake
Wire
Guide,
1/16”
11. KWB-V1 Wire
Brake
Valve
12. KWB-A18-15 Wire Brake Air Line, 15’
13. KHW-xxx
See
Page
6
14. KDP-101
Power
Pin,
Miller
®
KDP-103
Power
Pin,
Panasonic
®
KDP-104
Power
Pin,
Tweco
®
#4
KDP-106
Power
Pin,
OTC
®
KDP-107
Power
Pin,
Fronius
®
KDP-108
Power
Pin,
Lincoln
®
“4R”
KDP-109
Power
Pin,
Lincoln
®
“AutoDrive
®
S
15. 164-30-6
Liner,
6’,
.030”
164-45-6
Liner,
6’,
.035”
-
.045”
164-45A-6 Liner,
6’,
.035”
-
.045”
(for Lincoln
®
AutoDrive
®
S Only)
164-116-6 Liner,
6’,
.045”
-
1/16”
164-116TF-6 Teflon Liner, 6’, 3/64” - 1/16”
ITEM PART
# DESCRIPTION
Exploded View & Parts List
for Solid Mount w/ Wire Brake
10
10
9
8
7h
7g
7f
7e
7d
7c
7b
7a
7
6
5
4
3
2
1
1.
152-xx-xxP
See
Page
10
“
Plated Nozzle Selection
”
2.
CMI TAPER LOCK
TM
CONTACT TIP
155-1-030 Heavy
Duty,
.030”
(0.8mm)
155-1-035 Heavy
Duty,
.035”
(0.9mm)
155-1-040 Heavy
Duty,
.040”
(1.0mm)
155-1-045 Heavy
Duty,
.045”
(1.2mm)
155-1-364 Heavy
Duty,
3/64”
(1.3mm)
155-1-052 Heavy
Duty,
.052”
(1.4mm)
155-1-062 Heavy
Duty,
.062”
(1.6mm)
155-1-564 Heavy
Duty,
5/64”
(2.0mm)
155-1-332 Heavy
Duty,
3/32”
(2.4mm)
155-2-xxx Heavy
Duty
Tapered
Contact
Tip
155-3-xxx Extra
Heavy
Duty
Contact
Tip
155-7-xxx Heavy
Duty
CrZr
Contact
Tip
3.
154-Rxxx
See
Page
10
“Gas
Diffuser
Selection”
4.
KR50-1 Neck
Insulator
5.
KR502-22 Neck,
22°
KR502-45 Neck,
45°
KR502-180
Neck,
180°
6.
KR502-6
O-Ring
7.
KHC-200A1 Clutch Mount Assy - ABB
IRB 1600ID
KHC-200D1
Clutch
Mount
Assy
-
OTC
AX MV4AP/ AX MV4LAP
KHC-200F Clutch
Mount
Assy
-
Motoman
MA1440/2010
KHC-200M
Clutch
Mount
Assy
-
Motoman
[excludes MA1440]
7a. KHW-201 Hollow
Wrist
Torch
Body
[Included in ITEM 7]
7b. KHW-211 Hollow Wrist Torch Body Cover
[Included in ITEM 7]
7c. Not Sellable M4x0.7x17
SHCS
[Included in ITEM 7]
7d. KHC-101
Safety
Clutch
Rubber
Cover
7e. KHC-100
Safety
Clutch
7f. Not Sellable M4x0.7x12 SHCS
[Included in ITEM 7]
7g. KHW-AB16C Clutch Transition Disc - ABB IRB 1600ID
KHW-FA1C
Clutch
Transition
Disc
-
Motoman
MA1440
KHW-MM1C Clutch
Transition
Disc
-
Motoman
KHW-OAX1C Clutch Transition Disc - OTC AX
MV4AP/MV4LAP
KHW-OB4C Clutch Transition Disc - OTC AII B4/B4L
7h. Not Sellable M6x1.0x10 SHCS
[ABB]
Not Sellable M4x0.7x10 SHCS
[Motoman]
Not Sellable M5x0.8x10 SHCS
[OTC]
8.
KHC-A160 Clutch Cable Assy, ABB IRB 1600ID
KHC-A261 Clutch Cable Assy, ABB IRB 2600ID 1.65
KHC-M140
Clutch Cable Assy, Motoman EA / MA1400
KHC-M190
Clutch Cable Assy, Motoman EA / MA1900
KHC-M310
Clutch Cable Assy, Motoman MA3100
KHC-M144
Clutch Cable Assy, Motoman MA1440
KHC-OMV4
Clutch Cable Assy, OTC AX MV4AP/MV4LAP
KHC-OB41 Clutch Cable Assy, OTC AII B4
KHC-OB42 Clutch Cable Assy, OTC AII B4L
9.
KDP-101
Power
Pin,
Miller
®
KDP-103
Power
Pin,
Panasonic
®
KDP-104
Power
Pin,
Tweco
®
#4
KDP-106
Power
Pin,
OTC
®
KDP-107
Power
Pin,
Fronius
®
KDP-108
Power
Pin,
Lincoln
®
“4R”
KDP-109
Power
Pin,
Lincoln
®
“AutoDrive
®
S
10. 164-30-6
Liner,
6’,
.030”
164-45-6
Liner,
6’,
.035”
-
.045”
164-45A-6 Liner,
6’,
.035”
-
.045”
(for Lincoln
®
AutoDrive
®
S Only)
164-116-6 Liner,
6’,
.045”
-
1/16”
164-116TF-6 Teflon Liner, 6’, 3/64” - 1/16”
ITEM PART
# DESCRIPTION
Exploded View & Parts List
for Clutch Mount
11
Brand and product names shown above are trademarks of their respective owners.
Subject to Change – The information presented in this spec sheet is accurate to the best of our knowledge at the time of printing. Please visit CMIndustries.com for the most up-to-date information.
____________________________________________________________________________________________________________________________________________________________________________________
A
Lincoln
®
AutoDrive
®
S
E
Euro
F
Fronius
®
M
Miller
®
O
OTC
®
/ Daihen
®
P
Panasonic
®
R
Lincoln
®
“4R”
T
Tweco
®
#4
W
Tweco
®
#5
R
Power Pin
A
.030”
B
.035”
C
.040”
D
.045”
E
3/64”
F
.052”
G
.062”
H
5/64”
I
3/32”
Aluminum App
w/ Teflon Liner
P
.035” Al
Q
3/64” Al
R
.062” Al
A
Wire Size
1
155-1-xxx
2
155-2-xxx
3
155-3-xxx
7
155-7-xxx
1
Contact Tip
6
5
154-R505
6
154-R506
7
154-R507
8
154-R508
Gas Diffuser
Light Duty Conical
A
1/2”, 1/8” Tip Recess
B
5/8”, 1/8” Tip Recess
C
1/2”, 1/4” Tip Recess
D
1/2”, Flush Tip
E
1/2”, 1/8” Tip Stickout
F
5/8”, 1/8” Tip Stickout
G
1/2”, 1/4” Tip Stickout
Light Duty Bottleneck
I
1/2”, 1/8” Tip Recess
J
1/2”, Flush Tip
K
1/2”, 1/8” Tip Stickout
L
1/2”, 1/4” Tip Stickout
Heavy Duty Conical
N
1/2”, 1/8” Tip Recess
O
5/8”, 1/8” Tip Recess
P
5/8”, 1/4” Tip Recess
Q
5/8”, Flush Tip
R
5/8”, 1/8” Tip Stickout
S
5/8”, 1/4” Tip Stickout
Heavy Duty Bottleneck
U
5/8”, 1/8” Tip Recess
V
5/8”, Flush Tip
W
5/8”, 1/8” Tip Stickout
X
Custom Nozzle
Q
Nozzle
Air-Cooled
22
22°
KR502-22
45
45°
KR502-45
18
180°
KR502-180
23
22°, Long
KR502-22L1
46
45°, Long
KR502-45L1
24
22°, X-Long
KR502-22L2
47
45°, X-Long
KR502-45L2
X.KOOL
X1
22°
KR512-22
X2
45°
KR512-45
X3
180°
KR512-180
X4
22°
KR512-22L1
X5
45°
KR512-45L1
X6
22°
KR512-22L2
X7
45°
KR512-45L2
48
45° for G1
KR502-48
337mm
TCP
XX
- Designates
a letter and
number
for
custom
applications
45
Neck
ABB
A1
IRB 1600ID
A2
IRB 2600ID 1.65
A3
IRB 2600ID 1.85
Fanuc
F1
100iC, 100iC-12
F2
100iC-6L, 100iC-7L
F3
120iC
F4
120iC-10L, 120iC-12L
F5
100iC-8L
F6
M-710iC-12L
Motoman
M1
EA1400, MA1400
M2
EA1900, MA1900
M3
MA3100
M4
MA1440
M5
MA2010
M6
EA1400N
OTC
D1
AX MV4AP/MV4LAP
XX
- Designates a letter
and number for
custom
applications
F2
Robot Make & Model
A
A
Solid Mount
B
Solid Mount
+ Wire Brake
C
Clutch Mount
D
Clutch Mount
+ Wire Brake
S
Solid Mount
Fixed Rotation
T
Clutch Mount
Fixed Rotation
Type
H2
Torch Model
Kool Run
TM
KR502HW Series Robotic MIG Torches
__________________________________________________________
Ordering Information
12
Tapered (Robotic)
for Thread-On Nozzles
Part# 154-R508
8
Heavy Duty
for Thread-On Nozzles
Part# 154-R507
7
Tapered (Robotic)
for Slip-On Nozzles
Part# 154-R506
6
Heavy Duty
for Slip-On Nozzles
Part# 154-R505
5
Order
Code
Gas Diffuser Selection
Part #
Thread-On Nozzle
152-60-50*
152-60-62*
152-61-50*
152-62-50*
152-63-50*
152-63-62*
152-64-50*
152-65-50*
152-66-50*
152-67-50*
152-68-50*
152-70-50*
152-70-62*
152-71-62*
152-72-62*
152-73-62*
152-74-62*
152-75-62*
152-76-62*
152-77-62*
Part #
Slip-On Nozzle
152-10-50*
152-10-62*
152-11-50*
152-12-50*
152-13-50*
152-13-62*
152-14-50*
152-15-50*
152-16-50*
152-17-50*
152-18-50*
152-30-50*
152-30-62*
152-31-62*
152-32-62*
152-33-62*
152-34-62*
152-35-62*
152-36-62*
152-37-62*
Order
Code Description
Light Duty Conical Nozzles
A 1/2” Bore, 1/8” Tip Recess
B 5/8” Bore, 1/8” Tip Recess
C 1/2” Bore, 1/4” Tip Recess
D
1/2” Bore, Flush Tip
E 1/2” Bore, 1/8” Tip Stickout
F 5/8” Bore, 1/8” Tip Stickout
G 1/2” Bore, 1/4” Tip Stickout
___________________________________________________________________________
Light Duty Bottleneck Nozzles
I 1/2” Bore, 1/8” Tip Recess
J 1/2” Bore, Flush Tip
K 1/2” Bore, 1/8” Tip Stickout
L 1/2” Bore, 1/4” Tip Stickout
[These nozzles are available in brass upon request]
___________________________________________________________________________
Heavy Duty Conical Nozzles
N 1/2” Bore, 1/8” Tip Recess
O 5/8” Bore, 1/8” Tip Recess
P 5/8” Bore, 1/4” Tip Recess
Q 5/8” Bore, Flush Tip
R 5/8” Bore, 1/8” Tip Stickout
S 5/8” Bore, 1/4” Tip Stickout
___________________________________________________________________________
Heavy Duty Bottleneck Nozzles
U 5/8” Bore, 1/8” Tip Recess
V
5/8” Bore, Flush Tip
W 5/8” Bore, 1/8” Tip Stickout
___________________________________________________________________________
X = Custom Nozzle -
Call for availability on special requested bore and tip recess
*
All nozzles available in non-plated material upon request
Plated Nozzle Selection
PART # DESCRIPTION
IMPORTANT NOTE:
Neck Checking Fixture
not for use of any other necks
except for KR502 & KR502HW
Warning!
Do NOT tighten lever
without neck insterted
into Neck Holder Block.
Neck Checking Fixture
Nozzle Cleaning Stations Part #
Model 2100E2 650-25-580
Model 2100E2 w/ WC-95E 650-25-584
Key Features
-Easy to set up.
-External momentary switches for
testing cycle and spray.
-Adjustable V-block designed to hold
just about any nozzle.
-All pneumatic and electronic valves
are located internally.
-Optional Wire Cutter can be attached
to the unit.
Cut
Spray
Clamp
CM Industries Nozzle Cleaning Stations clean the nozzle and sprays anti-spatter.
Increase your productivity by providing better gas flow, extending consumable life,
and decreasing down-time. An optional Wire Cutter ensures a precise cut
for optimum arc-start and an exact TCP.
Nozzle Cleaning Station
CALIFORNIA PROPOSITION 65 WARNING
This product contains chemicals, including lead, know to the State of California to cause cancer,
birth defects, or other reproductive harm. Wash hands after use.
(California Health & Safety Code Section 25249.5)
LOUD NOISE can damage hearing.
• Always wear protective hearing devices to ensure protection when noise levels
exceed OSHA standards
FUMES AND GASES can be hazardous to your health.
• Keep your head out of the fumes
• Use enough ventilation or exhaust at the arc to keep fumes and gases from
your breathing zone, and general area.
• Fumes from cutting and welding can deplete air quality, causing injury or
death. Always wear an air supplied respirator in confined areas, or if breathing
air is not safe.
ELECTRIC SHOCK can kill.
• Always wear dry installing gloves
• Do not touch live electrical parts.
• Always disconnect power source before hooking up or changing electrodes,
nozzles and other parts.
ARC RAYS can injure eyes and burn skin
• Always wear correct eye, ear, and body protection
• Always wear a welding helmet with the proper grade filter lens. Protect yourself
and others from spatter arc flash rays by using protective screens, barriers and
welding curtains.
• Always wear protective gloves and clothing to cover exposed skin. This will
aid in the prevention of arc and spatter burns.
WELDING SPARKS can cause fire or explosion
• Do not weld near flammable material
• Do not weld on closed containers.
• Remove combustibles from the work area and/or provide a fire watch.
• Avoid oily or greasy clothing as a spark may ignite them.
Read and follow the manufacturer’s instructions, employer’s safety practices, and Material Safety Data Sheets (MSDSs).
Only qualified personnel should install, use, or service this material and/or equipment.
WARNING