Cougar Push-Pull Gun - Uncategorized LINCOLN ELECTRIC - Free user manual and instructions

Product Type	Push-Pull Welding Gun
Brand	Lincoln Electric
Model	Cougar Push-Pull Gun
Category	Uncategorized
Weight	Approx. 18 lbs (8.2 kg)
Dimensions (L x W x H)	24 x 10 x 10 in (61 x 25 x 25 cm)
Power Input	115 V or 230 V AC, 50/60 Hz
Wire Feed Speed Range	80 - 800 in/min (2 - 20 m/min)
Duty Cycle	60% at 300 A
Compatible Wire Diameter	0.030 - 0.045 in (0.8 - 1.2 mm) aluminum
Drive Roll System	Push-Pull with knurled drive rolls
Cooling	Fan-cooled motor
Safety Features	Trigger lock, thermal overload protection
Maintenance	Periodic cleaning of drive rolls and liner; replace gun nozzle as needed
Spare Parts Availability	Contact Lincoln Electric authorized distributors
Warranty	1 year limited warranty

Frequently Asked Questions - Cougar Push-Pull Gun LINCOLN ELECTRIC

Can the Cougar Push-Pull Gun be used with any Lincoln Electric power source?

The Cougar Push-Pull Gun is designed to work with Lincoln Electric power sources that have a push-pull interface, such as the Power Wave series. Check your power source's compatibility in the manual.

What wire sizes are compatible with this gun?

It supports aluminum wire diameters from 0.030 to 0.045 inches (0.8 to 1.2 mm). For steel or other wires, consult the manual.

How do I adjust wire feed speed on the Cougar gun?

Wire feed speed is controlled by the power source. The gun has a potentiometer knob that sends a signal to the feeder; adjust as needed for proper arc characteristics.

What is the maximum amperage for continuous welding?

At 300 A, the duty cycle is 60% (6 minutes of welding per 10-minute cycle). Higher currents reduce duty cycle.

How to clean the liner of the push-pull gun?

Use compressed air to blow out the liner regularly. For stubborn debris, remove the liner and clean with a suitable solvent. Ensure it's dry before reassembly.

Why is the wire feeding erratically?

Possible causes: worn drive rolls, clogged liner, incorrect tension, or damaged wire. Inspect drive rolls, clean liner, and check wire condition. Adjust tension knob on the gun.

Can I use this gun for MIG welding steel?

While primarily for aluminum, it can weld steel with appropriate wire and liners. However, the push-pull feature is optimized for soft wires like aluminum.

What replacement parts are commonly needed?

Common replacements include contact tips, nozzles, drive rolls, and liners. Use only Lincoln Electric genuine parts for best performance.

How to store the gun when not in use?

Store in a dry, dust-free area. Coil the cable loosely, avoid kinking. Keep the gun hung or placed on a clean surface to prevent damage.

Is the gun compatible with a spool gun?

No, the Cougar is a push-pull gun that uses a separate wire feeder. It is not interchangeable with a spool gun.

USER MANUAL Cougar Push-Pull Gun LINCOLN ELECTRIC

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.

Technical illustration of a handheld electric drill with threaded grip and trigger mechanism (no text or symbols)

OPERATOR'S MANUAL

LINCOLN® ELECTRIC

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLNELECTRIC.

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.

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.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON'T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Safety Data Sheet (SDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

Illustration of a person in protective gear using a welding torch to burn or operate (no text or symbols present)

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

Silhouette of a person wearing a welding helmet and holding a tool, no text or symbols present

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A: WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects, or other reproductive harm.

• Always start and operate the engine in a well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.

For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of "Safety in Welding & Cutting - ANSI Standard Z49.1" from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of "Arc Welding Safety" booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWERED EQUIPMENT.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits are electrically "hot" when the welder is on. Do

not touch these "hot" parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.
  • DC Manual (Stick) Welder.
  • AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically "hot".
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically "hot" parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see It ems 6.c. and 8.

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding hardfacing (see instructions on container or SDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation unless exposure assessments indicate otherwise. In confined spaces or in some circumstances, outdoors, a respirator may also be required. Additional precautions are also required when welding on galvanized steel.

1. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
   5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.
   5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
   5.e. Read and understand the manufacturer's instructions for this equipment and the consumables to be used, including the Safety Data Sheet (SDS) and follow your employer's safety practices. SDS forms are available from your welding distributor or from the manufacturer.
   5.f. Also see item 1.b.

WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to "Safety in Welding and Cutting" (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been "cleaned". For information, purchase "Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances", AWS F4.1 from the American Welding Society (see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B "Standard for Fire Prevention During Welding, Cutting and Other Hot Work", available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.
• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically "hot" parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-I, "Precautions for Safe Handling of Compressed Gases in Cylinders," available from the Compressed Gas Association, 14501 George Carter Way Chantilly, VA 20151.

FOR ELECTRICALLY POWERED EQUIPMENT.

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

Refer to

http://www.lincolnelectric.com/safety for additional safety information.

PRÉCAUTIONS DE SÛRETÉ

SAFETY PRECAUTIONS ....i-v

TABLE OF CONTENTS....1

GENERAL INFORMATION....2

PRODUCT DESCRIPTION....2

SPECIFICATIONS 2

RECOMMENDED PROCESSES AND EQUIPMENT 2

INSTALLATION....3,4

UNPACKING THE PUSH-PULL GUN ....3

PUSH-PULL GUN FAMILARIZATION DIAGRAM ....4

OPERATING INSTRUCTIONS....5-7

SAFETY PRECAUTIONS....5

SET-UP PROCEDURE....5

SELECTING ELECTRODE WIRE 5

LOADING ELECTRODE WIRE 5

INSTALLING BARREL LINER....5

DRIVE ROLL GROOVE SELECTION 6

MAKING A WELD 7

PROCEDURE SETTINGS....7

SETTING GAS FLOW RATE....7

ACCESSORIES 8

MAINTENANCE....8

TROUBLESHOOTING GUIDE....9,10

REPLACEMENT PARTS LIST DIAGRAM....11,12

PRODUCT DESCRIPTION

The Cougar™ push-pull gun is a lightweight, handheld combined semiautomatic wire feeder and welding gun, designed primarily for aluminum welding using argon shielding gas. The cable included with the push-pull gun allows welding up to 25 (7.62m) or 50 feet (15.2m) from the power source.

The gun is intended for use with Power Wave C300, Power Feed 10M, Power Feed 25M and Power Mig 350MP Power Sources. For other applications, contact your local Lincoln Electric sales office or distributor.

The push-pull gun is ideal for aluminum fabrication in industrial shops, automobile body shops, marinas and for the advanced hobbyist.

RECOMMENDED PROCESSES AND EQUIPMENT

The push-pull gun can be used to weld aluminum and aluminum alloys using Gas Metal Arc Welding or GMAW (also known as MIG) process, which requires a supply of shielding gas. Argon is normally used due to its smooth, stable arc, good metal transfer, and low cost. Positive polarity gives good penetration and affords a base metal cathode cleaning effect.

SPECIFICATIONS

Model CougarTM Push-Pull Gun withRemote Wire Speed Control

Wire Capacity .035"-1/16" (0.8mm-1.6mm)Aluminum and cored wire

Wire Speed 800 IPM MAX.

Duty Cycle 300 amps @ 60% Argon Gas

Shipping Weight 25 Ft. (7.6m) - 17 Lbs. (7.7Kg.)50 Ft. (15.2m) - 31 Lbs. (14Kg)

Supplied with:

KP2744-364A, 3/64" Contact Tip (Installed)KP2744-035A, .035 Contact TipKP2746-1, Gas Diffuser (Installed)KP2742-1-62R, Gas Nozzle (Installed)KP2773-2, Insulator (Installed)KP2876-1, Drive Roll (.035-3/64)Service WrenchInstruction Manual

Unpacking the Push-Pull Gun

Safety Precautions

- Read "Safety Precautions" in the Operating Manual before proceeding. Only personnel that have read and understood the Operating Manual should install and operate this equipment.

- Power source must be turned "OFF" and power leads disconnected when installing this unit.

Unpacking the Push-Pull Gun

Carefully unpack your Cougar™ Push-Pull Gun and attach the Barrel Assembly, and make sure you have all of the parts shown below.

BARREL ASSEMBLY

Illustration of an open book with visible page lines (no text or symbols)

OPERATOR'S MANUAL

COUGAR™ - PUSH-PULL GUN

KP2744-035A Contact Tip .035 (0.9mm) Included

KP2744-364A Contact Tip . 3/64" (1.2mm) Installed on Barrel Assembly

KP2746-1 Gas Diffuser Installed on Barrel Assembly

KP742-1-62R Gas Nozzle Installed on Barrel Assembly

KP2773-2 Insulator Installed on Barrel Assembly

KP2876-1 Drive Roll (.035 / 3/64th) Installed

Service Wrench Included

Push-pull Gun Familiarization

Become familiar with your push-pull gun before connecting to welder. For features described below, refer to Figure on the next page.

1. Handle, gun can be used in either right or left hand.
2. Trigger operates welding power, gas flow, and wire feed.
3. Remote wire speed control, located behind the handle, controls the speed of the drive motor.
4. Open body cover by flipping lid and observe the following:

a. Wire drive release lever up position moves pressure roller away from drive roll to stop wire feed. Down position moves pressure roller to wire. Operate wire drive release lever and see pressure roller move.

b. Drive roll with two wire grooves. Narrow groove feeds .035 (0.9 mm) diameter wire. Wide groove feeds 3/64 inch (1.2 mm) diameter wire. Gun is shipped with wide groove or 3/64 in operating position (toward handle). Reverse roller for .035 inch (0.9 mm) diameter wire.
5. Gas nozzle directs gas flow around arc. Unthread gas nozzle to see contact tip and gas diffuser. Push-pull gun is shipped with 3/64th inch (1.2 mm) contact tip installed.
6. Cable assembly for power, control, and gas. Hold gun and become familiar with gun's weight and balance.

CONNECTING TO POWER SOURCE:

1. Power source must be "off" and power cord disconnected.
2. Connect Push-Pull Gun to wire feeder by inserting power plug to the machine
3. Connect 7-Pin control cable plug to power source receptacle.
4. Reconnect power and turn on machine.

7-PIN PUSH-PULL GUN RECEPTACLE

"W" CLOCKED CONNECTOR (VIEWED FROM FRONT OF CONNECTOR) A ○ GRAY B ○ YELLOW G ○ WHITE D ○ GREEN C ○ BLUE E ○ BROWN F ○ PINK TORCH FUNCTIONS TORCH MOTOR 1 2 3 4 5 6 CW TORCH POT TORCH TRIGGER

7 PIN AMPHENOL CONNECTOR CABLE ASSEMBLY PRESSURE ROLLER (FAR SIDE) GUN BARREL CONTACT TIP GAS NOZZLE LINCOLN POWER PLUG WIRE SPEED CONTROL DRIVE ROLL (NEAR SIDE) TRIGGER GAS DIFFUSOR HANDLE

Safety Precautions

• Do not touch electrically live parts or electrode with skin or wet clothing
  • Insulate yourself from work and ground.
  • Always wear dry insulating gloves.

• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.

• Keep flammable material away.
• Do not weld on containers that have held combustibles.

Illustration of a spray gun emitting particles with motion lines, alongside a silhouette of a person wearing a helmet (no text or symbols)

- Wear eye, ear and body protection..

WARNING: Electric shock can kill. Fumes and gases can be dangerous to your health. Arc rays can injure eyes and burn skin. See additional warning information under "Arc Welding Safely Precautions" on inside of front cover of operating manual. When inching, (the electrode and drive mechanism are always electrically energized and remain energized several seconds after the gun trigger is released.

Setup Procedure

Selecting Electrode Wire

Several alloy types of filler metals are available, and the best choice depends on the type of base metals and the desired characteristics of the weldment, such as ductility and strength, corrosion resistance, sustained service temperature, and anodic treatment color matching. In addition, several wire sizes are available, and the choice here will depend upon several factors, including base metal thickness and the arc transfer process

used. Consult your local dealer or appropriate AWS publication 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 settings.

Installing Conduit Liner:

1. Laying torch out straight remove positioning nut, then insert your liner, tapered end first, all the way into torch until it stops. NOTE: You should see the liner through the holes in the inlet guide this will help make sure liner is fully installed.

Inlet Guide with Liner Inspection Hole Liner Positioning Nut

1. While torch is still laying out straight adjust your O-Ring and collet so that they will fit up inside of the power-pin when positioning nut is installed.

Positioning Nut Collet O-Ring

1. Reinstall the positioning nut securely, then trim rest of liner flush with positioning nut, accordingly to fit up to drive rolls.

3D rendered mechanical component with cylindrical shaft and flanged end (no text or symbols)

Installing Barrel Liner

1. Unscrew barrel inlet guide
2. Unscrew barrel liner from inlet guide
3. Reverse procedure with new liner. Be sure to install liner with tapered end toward contact tip, and liner is fully threaded into inlet guide.

Torch Barrel Neck Liner Barrel Inlet Guide

Drive Roll Groove Selection

The drive roll has two grooves. A wider groove for feeding 3/64" (.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 up and visible.
B. Changing Drive Roll Orientation
1. Flip lid open, then move release lever to the up position.
2. Unscrew thumb screw and remove drive roll

RELEASE LEVER PRESSURE ADJUSTMENT KNOB

.035" 3/64" THUMB SCREW DRIVE ROLL

Making A Weld

1 Check that the push-pull gun power, control, and gas connections are correct for the power source being used. Check that the gas supply is turned on. Check wire push-pull for an adequate supply of wire.
2. See "Procedure Settings", below for wire feed speed and voltage settings. Set these controls depending on the welding wire and base metal thickness being used.
3. Connect work clamp to metal being welded. Work clamp must make good electrical contact to the workpiece. The workpiece must also be grounded as stated in "Arc Welding Safety Precautions".
4. Connect power to welder and turn "ON".
5. Prepare to purge gas line by first releasing wire drive. Push wire drive release lever to the UP position, to avoid feeding wire.

WARNING: Gun body and contact tip become electrically energized when gun trigger is pressed and remain so for several seconds after trigger is released.

1. Press and hold gun trigger for about 5 seconds to purge gas line. If adjustable regulator or metering valve is installed, adjust gas flow per, "Setting Gas Flow Rate".

2. Re-engage wire drive by pushing release lever to down position to feed wire.

3. Momentarily squeeze trigger and verify that wire feeds properly. Trim wire to approximately 1/4" (6 mm) from end of contact tip.

WARNING: When using an open arc process, it is necessary to use correct eye, ear, head, and body protection.

1. Position gun over joint at 10^ pushing angle. End of wire may be lightly touching the work.
2. Lower welding helmet, close gun trigger, and begin welding. Hold the gun so that the contact tip to work distance is about 1/2 inch (13 mm).
3. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out.
4. When no more welding is to be done, close valve on gas cylinder, momentarily operate trigger to release gas pressure in line and turn off power source.
5. Note that clogged tips can often be salvaged by peeling away melted wire.

Procedure Settings

The following procedure settings for 4043 aluminum wire and argon gas can be used as starting points for developing specific welding procedures:

Wire Metal Size in. (mm)	Wire Amps Thickness		Arc Volts	Speed ipm (mpm)	DC (+)
	ga.	in. (mm)
.030 (0.8)	22	.030 (0.8)	13-14^(1)	200 (5.1)	40
	20	.036 (1.0)	13-14^(1)	240 (6.1)	40
	18	.048 (1.2)	14-15^(1)	290 (7.4)	50
	16	.060 (1.6)	15-16^(1)	340 (8.6)	60
	14	.075 (2.0)	16-17^(1)	370 (9.4)	70
	12	.105 (2.5)	16-18^(1)	430 (10.9)	90
	10	.135 (3.5)	24-26	460 (11.7)	110
	3/16	(5.0)	24-26	500 (12.7)	150
	1/4	(6.0)	28-29	560 (14.2)	180
	3/8	(10.0)	28-30	600 (15.2)	200
.035 (0.9)	22	.030 (0.8)	13-14^(1)	150 (3.8)	40
	20	.036 (1.0)	13-14^(1)	175 (4.4)	40
	18	.048 (1.2)	13-14^(1)	215 (5.5)	50
	16	.060 (1.6)	14-16^(1)	250 (6.4)	60
	14	.075 (2.0)	14-16^(1)	270 (6.9)	70
	12	.105 (2.5)	16-18^(1)	320 (8.1)	90
	10	.135 (3.5)	24-26	410 (10.4)	110
	3/16	(5.0)	24-26	450 (11.4)	150
	1/4	(6.0)	26-28	530 (13.5)	180
	3/8	(10.0)	26-29	560 (14.2)	200
	1/2	(12.0)	26-30	600 (15.2)	220
3/64(1.2)	10	.135 (3.5)	20-21^(1)	180 (4.6)	110
	3/16	(5.0)	20-21^(1)	220 (5.6)	150
	1/4	(6.0)	27-28	250 (6.4)	180
	3/8	(10.0)	25-30	260 (6.6)	200
	1/2	(12.0)	25-31	270 (6.9)	220
	3/4	(20.0)	25-31	290 (7.4)	250

(1) Short arc transfer.

Setting Gas Flow Rate

Gas handling systems having adjustable flow valves should be set for the following argon flow rates, depending on base metal thickness and welding position.

ARGON SHIELDING GAS FLOW RATES

Material Thickness In Inches and (mm)	Welding Position	Flow Rates In cf/hr (l/mln)
1/16 (1.6 mm)	Flat	30(11.8)
3/32 to 3/16(2.4 to 4.8 mm)	Flat, Vertical, Horizontal, Overhead	35(14)
1/4 to 3/8(6.3 to 9.5 mm)	Flat, Vertical, Flat Vertical, Horizontal, Overhead	35 (14)35 (16.5)40 (18.9)
3/4 (19 mm)	Flat, Vertical Horizontal, Overhead	35 (16.5)40 (18.9)

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

Features two grooves for feeding aluminum wire. The smaller groove feeds .035 wire. The larger groove feeds 3/64th wire. Order KP2876-1

1/16" Aluminum Drive Roll Kit

Features two grooves, each capable of feeding 1/16" Aluminum wire Order KP2876-2

Barrel Liner (45°, 60° Barrels)

Liner for feeding up to1/16" wire. Order KP2879-1

Barrel Liner (180° Straight Barrel)

Liner for feeding up to1/16" wire. Order KP2879-2

Gun Barrel

60 degree air-cooled gun barrel Order KP2877-60 45 degree air-cooled gun barrel Order KP2877-45

180 degree air-cooled gun barrel Order KP2877-180

Wire Conduits

25 foot .035"-1/16" Wire Diameter Order KP2881-25 50 foot .035"-1/16" Wire Diameter Order KP2881-50

Gas Diffuser

Diffuser designed to accept thread on gas nozzles Order KP2746-1

Gun Tube Insulator

For insulation of gas nozzle Order KP2773-2

Gas Nozzle

.50 Thread on Nozzle (Tip Recessed) Order KP2742-1-50R .62 Thread on Nozzle (Tip Recessed) Order KP2742-1-62R

Contact Tips

.035 Order KP2744-035A 3/64" Order KP2744-364A 3/64" (5356) ^1 . 1/16" Order KP2744-116A

Order KP2744-364A5356

^1 . For use on lower amperage applications with 5356 wire. Features a smaller tip inner diameter to reduce arc flaring.

MAINTENANCE

Safety Precautions

WARNING

Silhouette of a person in motion, possibly dancing or striking (no text or symbols)

• Do not operate with covers removed.
• Disconnect input power from welder before installing gun.
• Do not touch electrically hot part.
• Only qualified persons should install, use or service this machine.

ELECTRIC SHOCK

can kill.

When finished welding, be sure to turn power source off and close valve on gas cylinder.

WARNING

• Working with flying or falling objects can cause serious eye injuries.
• Protective eyeware such as safety specticals with side shields or goggles must be worn at all times.

FLYING FRAGMENTS

can cause eye injury.

Routine Maintenance

Periodically blow out or vacuum any metal wire shavings from Drive Roll area.

Inspect and replace any worn wire on inlet guide or barrel liner.

NOTE: Oil and spray cleaners can contaminate electrode wire and cause bad welds. They could also make wire drive rollers slip. Be careful when using any of these liquids on push-pull gun.

Carefully clean gun with a cleaner that is safe for plastic. Apply cleaner to rag and wipe gun. Do NOT spray cleaner on gun. Keep cable clean. Oil, grease gasoline, paint, and solvents degrade cable insulation.

Routine maintenance for consumable spare parts will depend on Duty Cycle and particular application.

Troubleshooting Guide

PROBLEM SYMPTOMS REMEDY

No arc, wire feed, or gas flow.	1. Cable connections loose.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	1. Check all power connections.
No arc, weak arc. 1. Poor ground connection to work. 1. Check ground connection.2. Power cable connection loose. 2. Check connections; if defective,replace cable or connectors.3. Voltage set too low. 3. Adjust to proper voltage4. Tip too large for wire size. 4. Change tip size.5. Wire feed speed too slow. 5. Increase wire feed speed.
No wire feed.	1. Feeding small diameter wire with large groove on drive roller.2. Wire drive release open.3. Wire welded to tip.4. Wire push-pull empty in machine. 4. Insert new push-pull.5. Tip too small for wire.6. Kink or bend in wire.7. Control cable loose.8. Drive roller worn.9. Pressure roller stuck.10. Roller spring loose or broken.	1. Change position of wire drive roller.2. Close wire drive release.3. Peel wire off tip or use new tip.5. Insert correct tip.6. Pull wire through tip or start new wire end.7. Check all connections.8. Replace.9. Replace or lubricate.10. Replace.
Wire feed too fast or too slow.	1. Wrong wire speed set for work.	1. Adjust wire feed speed.
Low or no gas flow. Oxidation of work.	1. Gas flow not set right.2. Cylinder out of gas.3. Cylinder valve closed.4. Leak in gas line.5. Leak in gun.6.Gas diffuser clogged 6. Blow out gas diffuser openings.	1. Set proper flow rate.2. Get new cylinder of gas.3. Open cylinder valve.4. Inspect and replace.5. Check for missing gun tubes and/or missing gun body cover.
Oxidized work, arc unstable.	1. Wrong welding polarity.	1. Check polarity.

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 resistance should vary from 5K - 0 ohms.Check the resistance across pin “D” (wiper) and pin “G”. The resistance should vary from 5K - 0 ohms.
Testing the Trigger Switch.	Using the torch Control Cable Connector, check for continuity across pins “E” and “F” when the trigger is pressed.

"W" CLOCKED CONNECTOR (VIEWED FROM FRONT OF CONNECTOR) A ○ GRAY B ○ YELLOW G ○ WHITE D ○ GREEN C ○ BLUE E ○ BROWN F ○ PINK TORCH FUNCTIONS TORCH MOTOR 1 5K 3 CW 12 TORCH POT TORCH TRIGGER

REPLACEMENT PARTS LIST AND DIAGRAM

Technical diagram of a firearm with numbered parts, including internal components and exploded view

ITEM PART

NO. NO. DESCRIPTION

1 KP2877-180 180 Degree Air-Cooled Gun Barrel

2 S26374-31 Motor Assembly

3 S26374-6 Wire Drive Cover

4 S26374-14 Potentiometer Assembly

5 S26374-23 Trigger Assembly

6 S26374-24 Handle, Front

7 S26374-25 Handle, Back

8 S26374-33 Strain Relief Clamp Kit

9 S26374-95 Barrel Nut

10 S26374-104 Barrel Insulation Hose

11 S26374-46 Barrel Inlet Guide

N/S S26374-44 O-Ring Kit A/C Barrel

N/S S26374-28 25' Cable Assembly - Cougar

N/S = Not Shown

ITEM PART

NO. NO. DESCRIPTION

N/S S26374-34 50' Cable Assembly - Cougar

N/S S26374-35 Cable Cover 25

N/S S26374-36 Cable Cover 50'

N/S S26374-37 Power Cable Assembly 25'

N/S S26374-38 Power Cable Assembly 50'

N/S S26374-39 Wire Conduit Assembly 25'

N/S S26374-40 Wire Conduit Assembly 50'

N/S S26374-41 Control Wire Assembly 25'

N/S S26374-42 Control Wire Assembly 50'

N/S S26374-60 Gas Hose Assembly 25'

N/S S26374-61 Gas Hose Assembly 50'

N/S S26374-32 Rear End Feeder Connection Kit

REPLACEMENT PARTS LIST AND DIAGRAM

Technical diagram of a mechanical assembly with numbered parts, likely a valve or pump component.

3D mechanical component diagram showing a shaft and housing assembly (no text or symbols)

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 S26374-11 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

●Keep your head out of fumes.●Use ventilation or exhaust to remove fumes from breathing zone.	●Turn power off before servicing.	●Do not operate with panel open or guards off.	WARNING
●Los humos fuera de la zona de respiración.●Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases.	●Desconectar el cable de alimentación de poder de la máquina antes de iniciar cualquier servicio.	●No operar con panel abierto o guardas quitadas.	SpanishAVISO DE PRECAUCION
●Gardez la tête à l'écart des fumées.●Utilisez un ventilateur ou un aspirateur pour ôter les fumées des zones de travail.	●Débranchez le courant avant l'entre-tien.	●N'opérez pas avec les panneaux ouverts ou avec les dispositifs de protection enlevés.	FrenchATTENTION
●Vermeiden Sie das Einatmen von Schweibrauch!●Sorgen Sie für gute Be- und Entlüftung des Arbeitsplatzes!	●Strom vor Wartungsarbeiten abschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)	●Anlage nie ohne Schutzgehäuse oder Innenschutzverkleidung in Betrieb setzen!	GermanWARNUNG
●Mantenha seu rosto da fumaça.●Use ventilação e exhaustão para remover fumo da zona respiratória.	●Não opere com as tampas removidas.●Desligue a corrente antes de fazer serviço.●Não toque as partes elétricas nuas.	●Mantenha-se afastado das partes moventes.●Não opere com os paineis abertos ou guardas removidas.	PortugueseATENÇÃO
●ヒュームから頭を離すようにして下さい。●換気や排煙に十分留意して下さい。	●メンテナンス・サービスに取りかかる際には、まず電源スイッチを必ず切って下さい。	●パネルやカバーを取り外したままで機械操作をしないで下さい。	Japanese注意事項
●頭部遠離煙霧。●在呼吸區使用通風或排風器除煙。	●維修前切断電源。	●儀表板打閥或沒有安全罩時不準作業。	Chinese警告
●업궁로부터 용접가스를 업리하십시오.●호흡지역으로부터 용접가스를 제거하기 위해 가스제거기나 통풍기를 사용하십시오.	●보수전에 전원을 차단하십시오.	●판넬이 얼린 상태로 작동치 마십시오.	Korean위험
●ابعد رأسک بعیداً عن الدخان.●استعمل التهوية أو جهاز ضطط الدخان للخارج ●تلى تيحد الدخان عن المنظقة التي تنفس فيها.	●اقarseع التيار الكهرباني قبل القيام بأية صيانة.	●لا نشقل هذا الجهاز اذا كانت الاغطةالcoholicية_low่างة لبست عليه.	Arabicتحذير

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