TIG Torch - Welding machine LINCOLN ELECTRIC - Free user manual and instructions

USER MANUAL TIG Torch LINCOLN ELECTRIC

Operator’s Manual TIG TORCHES Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator IMT 10202 | Issue D ate Oct -14 © Lincoln Global, Inc. All Rights Reserved. Model Numbers: K4168-1 Water Cooled 20-250-25R K4168-2 Water Cooled 20H-320-25R Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345)

A QUALITY PRODUCT BY

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

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. WARNING CAUTION Safety 01 of 04 - 5/16/2018SECTION 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

YOURSELF AND OTHERS FROM POSSIBLE SERIOUS

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,

EQUIPMENT. 1.a. Turn the engine off before troubleshootingand maintenance work unless themaintenance work requires it to be running. 1.b. Operate engines in open, well-ventilated areas or vent the engineexhaust fumes outdoors. 1.c. Do not add the fuel near an open flame weldingarc or when the engine is running. Stop theengine and allow it to cool before refueling toprevent spilled fuel from vaporizing on contactwith hot engine parts and igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes 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 orrepairing equipment. 1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts. 1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running. 1.g. To prevent accidentally starting gasoline engines while turningthe engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magneto wireas appropriate. 1.h. To avoid scalding, do not remove the radiatorpressure cap when the engine is hot. ELECTRIC AND

BE DANGEROUS 2.a. Electric current flowing through any conductorcauses 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 physicianbefore welding. 2.c. Exposure to EMF fields in welding may have other health effectswhich are now not known. 2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:2.d.1. Route the electrode and work cables together - Securethem 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 workcables. If the electrode cable is on your right side, thework cable should also be on your right side.2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.2.d.5. Do not work next to welding power source. SAFETY Safety 02 of 04 - 5/16/2018ELECTRIC 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:

• 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.

CAN BE DANGEROUS. 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.

5. 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. SAFETY Safety 03 of 04 - 5/16/2018WELDING AND CUTTING

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-l, “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. SAFETY Safety 04 of 04 - 5/16/2018TORCH/REPLACEMENT PARTS

45V10R 45V04RM 45V08R 41V35 18CG 54N01 Torch body, red silicone Torch handle, fluted Gas hose, 25’ (7.6m) Power cable, 25’ (7.6m) Water hose, 25’ (7.6m) Medium Cap Cup gasket (Part of item 1) Collet Collet body Alumina nozzle Gas lens insulator Collet body gas lens Alumina nozzle gas lens Pigskin/Black nylon zipper cover Description

45V10R 45V04HR 45V08HR 41V35 18CG 54N01 Torch body, red silicone Torch handle, fluted Gas hose, 25’ (7.6m) Power cable, 25’ (7.6m) Water hose, 25’ (7.6m) Medium Cap Cup gasket (Part of item 1) Collet Collet body Alumina nozzle Gas lens insulator Collet body gas lens Alumina nozzle gas lens Pigskin/Black nylon zipper cover Description

Collet Part No. (Industry Ref.) Collet Body Part No. (Industry Ref.) Gas Lens Collet Body Part No. (Industry Ref.) Standard Nozzle Part No. (Industry Ref.) 0.08% Yttrium1.5% Lanthanum, 0.08% Zirconium, Good all around choice for both AC and DC, in welding low alloyed & non-corroding steels, aluminum, magnesium, titanium, nickel, and copper. 8KP510 Recommended Consumable Kit Size Qty. Part No. Ref. No. Description in. (mm)1KP2035-4B1 41V24 Back Cap Long )6.1( 61/1telloC22N311B3-9202PK1 )4.2( 23/3telloC32N311B4-9202PK1 )2.3( 8/1telloC42N311B5-9202PK1 1KP2031-3B1 13N27 Collet Body 1/16 (1.6)1KP2031-4B1 13N28 Collet Body 3/32 (2.4)1KP2031-5B1 13N29 Collet Body 1/8 (3.2) 1KP2017-2B1 13N09 Alumina Nozzle 5/16 (8.0) 1KP2017-3B1 13N10 Alumina Nozzle 3/8 (10.0) 1KP2017-4B1 13N11 Alumina Nozzle 7/16 (11.0) 1Tungsten Electrode, 2% Ceriated 1/16"x7.0" (1.6 x 178mm) 1Tungsten Electrode, 2% Ceriated 3/32"x7.0" (2.4 x 178mm) 1Tungsten Electrode, 2% Ceriated 1/8"x7.0" (3.2 x 178mm) For Machines with 1/2” Output Terminals The adapter kits contain the necessary accessories to connect between your gas regulator, power source and water supply. The adapter kits are required for proper connection and are ordered separately. K1622-4 TIG Adapter Kit K2505-2 V-TIG Torch Twist Mate

CONNECTION DIAGRAM K1622-4/K1622-5 Water Cooled Torch Connection to Power Source with Combined Gas/Power Twist-Mate Connections

Não opere com os paineis abertos ou guardas removidas. OPERATOR’S MANUALCustomer assistanCe PoliCy The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask

incoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products. Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements. Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.