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IM10024
MAXsa™ 22 & 29 WIRE DRIVES
July(R2), 2009
For use with machines having Code Numbers: 11615, 11616
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 thought-
ful 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
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
CALIFORNIA PROPOSITION 65 WARNINGS
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 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.
1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
FOR ENGINE
powered equipment. hot.
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.
ELECTRIC AND
____________________________________________________
MAGNETIC FIELDS
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. 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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ʻ95
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
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,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and within applicable OSHA PEL and
should be as close as possible to the area being welded. ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
3.e. Ground the work or metal to be welded to a good electrical stances, outdoors, a respirator may be required.
(earth) ground. Additional precautions are also required when welding
on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace 5. b. The operation of welding fume control equipment is affected
damaged insulation. by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
3.g. Never dip the electrode in water for cooling. cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.h. Never simultaneously touch electrically “hot” parts of periodically thereafter to be certain it is within applicable
electrode holders connected to two welders because voltage OSHA PEL and ACGIH TLV limits.
between the two can be the total of the open circuit voltage
of both welders. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
3.i. When working above floor level, use a safety belt to protect The heat and rays of the arc can react with solvent vapors to
yourself from a fall should you get a shock. form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.j. Also see Items 6.c. and 8.
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
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Jan ‘09
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
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing 8.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate cir- Electrical Code, all local codes and the manufacturer’s
cuits. This can create fire hazards or overheat lifting chains recommendations.
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturer’s recommendations.
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.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
Jan ‘09
iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions zones où lʼon pique le laitier.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 6. Eloigner les matériaux inflammables ou les recouvrir afin de
antes: prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de

1. Protegez-vous contre la secousse électrique: la masse. Un court-circuit accidental peut provoquer un
Sûreté Pour Soudage A L’Arc
échauffement et un risque dʼincendie.

a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours 8. Sʼassurer que la masse est connectée le plus prés possible
tout contact entre les parties sous tension et la peau nue de la zone de travail quʼil est pratique de le faire. Si on place
ou les vétements mouillés. Porter des gants secs et sans la masse sur la charpente de la construction ou dʼautres
trous pour isoler les mains. endroits éloignés de la zone de travail, on augmente le risque
b. Faire trés attention de bien sʼisoler de la masse quand on de voir passer le courant de soudage par les chaines de lev-
soude dans des endroits humides, ou sur un plancher age, câbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques dʼincendie ou dʼechauffement des chaines et des
les positions assis ou couché pour lesquelles une grande câbles jusquʼà ce quʼils se rompent.
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble 9. Assurer une ventilation suffisante dans la zone de soudage.
de soudage et la machine à souder en bon et sûr état Ceci est particuliérement important pour le soudage de tôles
defonctionnement. galvanisées plombées, ou cadmiées ou tout autre métal qui
d.Ne jamais plonger le porte-électrode dans lʼeau pour le produit des fumeés toxiques.
refroidir.
e. Ne jamais toucher simultanément les parties sous tension 10. Ne pas souder en présence de vapeurs de chlore provenant
des porte-électrodes connectés à deux machines à souder dʼopérations de dégraissage, nettoyage ou pistolage. La
parce que la tension entre les deux pinces peut être le chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
total de la tension à vide des deux machines. du solvant pour produire du phosgéne (gas fortement toxique)
f. Si on utilise la machine à souder comme une source de ou autres produits irritants.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de 11. Pour obtenir de plus amples renseignements sur la sûreté,
soudage. voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, LES MACHINES À SOUDER À
donc:
TRANSFORMATEUR ET À
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du ray-
REDRESSEUR
onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc. 1. Relier à la terre le chassis du poste conformement au code de
b. Porter des vêtements convenables afin de protéger la lʼélectricité et aux recommendations du fabricant. Le dispositif
peau de soudeur et des aides contre le rayonnement de de montage ou la piece à souder doit être branché à une
lʻarc. bonne mise à la terre.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables. 2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres 3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan- er à lʼinterrupteur à la boite de fusibles.
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ʻ93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation 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.
Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
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.
vi TABLE OF CONTENTS vi
Page
Product Description .....................................................................................................................A-1

Installation ..........................................................................................................Section A
Recommended Processes ..........................................................................................................A-1

Process Limitations .....................................................................................................................A-1
Equipment Limitations .................................................................................................................A-1
Common Equipment ....................................................................................................................A-1
General Information .....................................................................................................................A-2
Design Features ...................................................................................................................A-2
Location of Components ......................................................................................................A-2
Specifications ..............................................................................................................................A-3
Safety Precautions. .....................................................................................................................A-4
Non-Safety Standard Equipment..........................................................................................A-4
Input and Ground Connections ............................................................................................A-4
Location and Mounting .........................................................................................................A-4
High Frequency Protection ...................................................................................................A-4
Power Wave® AC/DC1000 SD Systems Connections ................................................................A-5
Mounting Dimensions ...........................................................................................................A-5
Connection Diagram.............................................................................................................A-5
Changing Wire Drive Configuration .............................................................................................A-6
Wire Feed Mechanism.................................................................................................................A-7
Gear Ratio Conversion Kits .........................................................................................................A-7
Electrode Connectios ..................................................................................................................A-8
Remote Sense Lead Specifications.............................................................................................A-8
TC-3 Travel Carriage ...................................................................................................................A-9
Installation............................................................................................................A-10 thru A12
________________________________________________________________________________
Routine operation ........................................................................................................................B-1

Operation ...........................................................................................................................Section B
Starting Techniques .............................................................................................................B-1

Head Positioning ..................................................................................................................B-2
________________________________________________________________________________
Options and Accessories Website ..............................................................................C-1

Accessory ...........................................................................................................Section C
Motor Conversion Kit For (142:1 NA Style Wire Drives)........................................C-1

Sub-Arc Contact Assemblies ....................................................................C2 thru C-8
Vertical Head Adjuster...........................................................................................C-9
Horizontal Head Adjuster.....................................................................................C-10
K129 Tiny TwinArc Kit .........................................................................................C-11
K225 Sub-Arc TwinArc Kit ...................................................................................C-13
K281 Solid Wire Straightener for TwinArc ...........................................................C-15
________________________________________________________________________________
Safety Precautions ................................................................................................D-1

Maintenance........................................................................................................Section D
Routine and Periodic Engine Maintenance ...........................................................D-1

Calibration Specification ........................................................................................D-1
________________________________________________________________________________
Safety Precautions.................................................................................................E-1
Troubleshooting .................................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide ..........................................................................................E-2
________________________________________________________________________________
________________________________________________________________________________
Wiring Diagrams and Dimension Print .............................................................Section F
________________________________________________________________________________
Parts List ....................................................................................................................P-623
A-1 PRODUCT DESCRIPTION A-1
PRODUCT SUMMARY
The MAXsa™ series of Automatic Wire Drives are

designed for hard automation, submerged arc weld-
ing. The heavy-duty gearbox and feed plate have
many years of proven reliability while a new perma-
nent magnet motor has been added.
The MAXsa™ 22 & 29 WIRE DRIVES consist of a

high torque motor and gearbox assembly with a
heavy-duty feed plate housing knurled drive rolls for
positive, accurate wire feeding of heavy welding wire.
Depending on which options are used, the MAXsa™
has many axes of rotation for ease of fixturing and
locating
RECOMMENDED PROCESSES
• The MAXsa™ series of wire drive packages are

best suited for submerged arc welding.
PROCESS LIMITATIONS
• MIG welding
• Robotic applications
EQUIPMENT LIMITATIONS
The MAXsa™ series of wire drives cannot be used

with the NA3, NA-4, or NA-5 series of Lincoln
Automatics.
COMMON EQUIPMENT PACKAGES
Basic Package
• K2803-1 Power Wave® AC/DC 1000 SD
• K2814-1 MAXsa™ 10 Controller/Feed Head
• K2370-1 MAXsa™ 22 Wire Drive
Basic Package with optional kits:
• K2803-1 Power Wave® AC/DC 1000 SD
• K2311-1 MAXsa™ Motor Retrofit Kit
• K2312-2 MAXsa™ 29 Wire Drive
• K2626-2 Wire Drive Controller (for fixture

builders that do not require the
MAXsa™ 10 Controller).

A-2 GENERAL INFORMATION A-2
• Closed-loop speed control.

DESIGN FEATURES - MAXsa™ 22
• Knurled drive rolls.

• Heavy cast aluminum gearbox housing and feed plate assembly.
• Wire straightener.
• Cross Seam Adjuster
• Flux Hopper (not shown)
• Mounting Hardware for accessories
• 32Vdc permanent magnet, high torque motor.
• Conversion kits included to change speed range.
FIGURE A.1 - LOCATION OF MAXsa™ 22 COMPONENTS
Connection
Box
Mounting
Cross Seam
Hardware
Adjuster
Drive Motor
Drive Rolls
Gear Box

A-3 INSTALLATION A-3
• Closed-loop speed control.

DESIGN FEATURES - MAXsa™ 29
• Knurled drive rolls.

• Heavy cast aluminum gearbox housing and feed plate assembly.
• Wire straightener.
• 32Vdc permanent magnet, high torque motor.
• Conversion kits included to change speed range.
FIGURE A.2 - LOCATION OF MAXsa™ 29 COMPONENTS
Connection
Box
Wire Straightener
Mounting
Drive Motor
Gear Box Drive Rolls

A-4 SPECIFICATIONS A-4
TECHNICAL SPECIFICATIONS - MAXsa™ 22 & 29 WIRE DRIVES

Spec. Type 142:1 Speed Ratio 95:1 Speed Ratio 57:1 Speed Ratio
Wire Size Wire Size Wire Size
K2370-2 MAXsa™ 22
Speed Solid Cored Speed Solid Cored Speed Solid Cored
10-200 7/32 5/32 10-300 1/8 5/32 40-500 1/16 3/32
K2312-2 MAXsa™ 29
Wire Feeders - Input Voltage and Current
Voltage Input Amperes
32V DC 7 Amps (max.)
PHYSICAL DIMENSIONS
K2312-2 12.0 in. (305 mm) 14.0in (355mm) 10.0in (254mm) 35.0lbs (15.9kg)
MODEL HEIGHT WIDTH DEPTH WEIGHT
K2370-2 14.0in (355mm) 10.0in (254mm) 80.0lbs (36.3kg)

K2311-1 8.0 in. (203 mm) 6.0in (152mm) 5.0in (127mm) 10.0lbs (4.5kg)
TEMPERATURE RANGES
-4°F to 104°F (-20°C to 40°C) -40°F to 185°F (-40°C to 85°C)

OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
WELDING PROCESSES
Process Electrode Diameter Range Output Range (Amperes) Wire Feed Speed Range
SAW .045” – 7/32" (1.2 – 5.6 mm) 200 - 2000+ 10 - 500 ipm (.25 – 11.43 m/minute)
(with paralleled machines)

SAFETY PRECAUTIONS
Read this entire installation section before you
start installation.
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should per-
form this installation.
• Turn the input power OFF at the dis-
connect switch or fuse box before
working on this equipment. Turn off
the input power to any other equip-
ment connected to the welding sys-
tem at the disconnect switch or fuse
box before working on the equip-
ment.
• Do not touch electrically hot parts.
-------------------------------------------------------------
NON-STANDARD SAFETY INFORMATION
CAUTION
The PF-10S series of wire drives may be at weld-
ing voltage potential when the output of the power
source is active.
------------------------------------------------------------------------
INPUT AND GROUND CONNECTIONS
Only a qualified electrician should connect the
MAXsa™ 22 & 29 WIRE DRIVES. Wire Drive
Installation should be made in accordance with the
appropriate National Electrical Code, all local codes
and the information in this manual.
LOCATION AND MOUNTING
The MAXsa™ Wire Drivewill operate in harsh environ-
ments.
HIGH FREQUENCY PROTECTION
Locate the MAXsa™ Wire Driveaway from radio con-
trolled machinery.

SYSTEM CONNECTIONS (See Figure A.3)

POWER WAVE® AC/DC 1000 SD SUBARC Mounting Dimensions
The MAXsa™ Wire Drive can be mounted by using
Diagram shown is for a single arc system. Refer to the the four 3/8-16 tapped holes or the two 0.562 through
power source manual for additional connection holes. See mounting hole locations (See Figure A.4).
options (Multi-arc and/or parallel machines).
FIGURE A.3 - CONNECTION DIAGRAM
K2803-1
Power Wave® AC/DC 1000
K1543-XX or
K2683-XX
Arclink Cable
K2814-1
MAXsa™ 10
K1795-XX
14-Pin Cable
K2370-2
MAXsa™ 22
67 Lead
K231-XX Electrode
Contact Nozzle Weld Cable
K1811-XX
Sense Lead
Work
Work Weld Cable
FIGURE A.4 - MOUNTING DIMENSIONS
.62 2.50
3/8-16 TAPPED HOLE .41
(4 PLACES)
4.70 .50
2.69 2.50
4.24
.50
.96
ø.562 (2 HOLES)
7.70

5. Carefully disconnect the Motor leads from the har-

CHANGING THE WIRE DRIVE
CONFIGURATION ness by pulling the quick-connect terminals apart.
The MAXsa™ 22 & 29 WIRE DRIVES can be recon- 6. Reverse the motor leads and reconnect the quick-
figured to fit in any hard automation application. connect terminals (see the Wiring Diagram).
As shipped, the MAXsa™ 22 & 29 WIRE DRIVES 7. Carefully replace the wire harness back into the
Drive Rolls rotate clockwise to feed the wire down. Connection Box and place back onto the Motor
Reconfiguring the Wire Drive per Figure A.3 may housing locating over the Motor lead grommet.
require reversing the direction of the motor. This is Ensure that the tachometer leads are completely
accomplished by reversing the motor polarity so that covered by the Channel that snaps into the
the wire will feed correctly. Follow these instructions to Connection Box. The Connection Box assembly
reverse the motor polarity. See the Wiring Diagram in should be pushed all the way up to the Motor-to-
Section F of this manual Gearbox Adapter Plate.
1. Remove all power from the MAXsa™ Wire Drives. 8. Before securing the Connection Box to the Motor
housing with the Band Strap, ensure that none of
2. Disconnect the Control Cable from the MAXsa™ the harness leads are being pinched underneath
Wire Drive Connection Box. the edges of the Connection Box and Channel.
3. Loosen the fastener from the Band Strap to the 9. Place the Band Strap into the "T" slot on the side
Connection Box, which secures the assembly to the of the Connection Box and wrap it around the
Motor housing, and expose the leads inside of the Motor housing.
Connection Box.
10. Replace the fastener between the Band Strap and
4. Locate the Motor leads that go from the Motor to the Connection Box. Tighten so that the Connection
the Control Cable connector on the inside of the Box cannot move on the Motor housing.
Connection Box.
FIGURE A.3
Loosen Socket
Head Screw to Rotate
Motor/Gearbox Assembly
Remove ConnectionBox
to Change Motor Polarity
Loosen Socket
Rotate Head Screw to Rotate
Rotate Feedplate

4. Pull the gear from the shaft using the screws as a

WIRE FEED MECHANISM
All MAXsa™ Wire Drive units are shipped with 142:1 pulling device.
ratio gears. Conversion kits are included to change to
either 95:1 or 57:1 ratio depending on wire size to be 5. Be certain woodruff key is properly located on the
used. shaft. Screw the adapter plate and motor assembly
mounting screws into the new fiber input helical
As shipped, the drive mechanism parts are designed to gear from the stenciled side and place the gear on
feed 3/32 through 7/32(2.4mm - 6.0mm) wire. Other the shaft. Replace plain washer, tighten the hex
wire sizes will require different drive rolls and guide nut, and remove the adapter plate and motor
tubes. See table A.1. assembly mounting screws from the gear.
The Idle Roll pressure will need to be adjusted for the 6. Support the pinion properly and, with the proper
wire being used. The indicator shows two settings - size punch, drive the roll pin that holds the pinion
.035 - 3/32” (0.9 - 2.4mm) out of the shaft. Pull the pinion off. Remove the
.120.- 7/32” (3.0 - 6.0mm) Ring Magnet from the pinion gear and snap it onto
The tension adjustment is to be made after loading the the new pinion gear. Before installing the new pin-
wire into the drive rolls. ion gear with the Ring Magnet onto the motor shaft,
ensure that the flat washer is located at the bottom
NOTE: Lower tension may need to be needed to pre- of the shaft. Install the new pinion and replace the
vent crushing of some cored wires or softer roll pin.
alloy solid wires.
7. Cover the teeth of the motor pinion and the input
gear with a non-fluid molydisulfide type grease such
as Non-Fluid Oil Corporationʼs A-29 Special/MS
GEAR RATIO CONVERSION KITS (See
Lubricant. This grease can be scooped from the
instruction sheet included with the conversion kit
cavity of the gear case.

for graphic illustration.)
1. Remove the 2 hex head screws and the 2 slot head 8. Reassemble the motor to the gearbox. Make sure
screws holding the Motor to the Wire Drive Gearbox the gears mesh properly and the adapter plate
assembly. locating bead is in its cavity. Replace and tighten
the four screws removed in step 1.
2. Remove existing Adapter Plate and Motor Assembly.
3. Take the two long screws removed in step 1 and

IMPORTANT
screw one into each of the tapped holes located on
See the MAXsa™ 10, or power source manual for
the face of fiber input helical gear. Insert the screws
instructions on configuring the system for the
through the full thickness of the gear, and using a
new gear ratio.
screwdriver wedged between the screws to prevent
rotation, remove the hex nut that holds the gear to
the shaft. Remove plain washer.
TABLE A.1 - DRIVE ROLL KITS
KP1899 DRIVE ROLL KIT INCLUDED WITH KIT

Drive Roll Drive Roll Incoming Outgoing
Kit Number Wire Sizes & Types Part Number No. required Guide Guide
KP1899-1 3/32-7/32” Wires KP1885-1 2 KP2116-2 KP1963-1

KP1899-2 1/16-3/32” Wires KP1886-1 2 KP2116-1 KP2097-2
KP1899-3 .035-.052” Solid Wire KP1887-1 1 KP1967-1 KP2097-1
KP1899-4 .045-.052” Cored Wire KP1892-1 2 KP1967-1 KP2097-1
NOTE: Twinarc drive rolls are included with the ATwinarc kits.

ELECTRODE CONNECTIONS REMOTE SENSE LEAD SPECIFICATIONS
Because the Power Wave® AC/DC 1000 SD can pro- The MAXsa™ 22 & 29 Wire Drives has an ELEC-
duce either a DC positive, DC negative or AC output the TRODE sense lead extending from the connection
electrode and work connections do not need to be box that is mounted to the motor. This sense lead is
reversed for the different polarities. Additionally no DIP critical to the accuracy of the Power Wave® welding
switch changes are required to switch between the dif- process. A ring terminal is provided at the end of the
ferent polarities. All of this is controlled internally by the lead. This lead must be extended and connected to
Power Wave® AC/DC. The following directions apply to the electrode connection at the nozzle. This connec-
all polarities: tion should be made as close to the welding arc as
possible. Use at least a 12 AWG wire with a proper
Connect the electrode cable(s) to the "ELECTRODE" sized ring terminal. Use a screw with a lock washer
stud(s) on the power source . Connect the other to the and nut to make the connection, then insulate the con-
contact assembly at the Wire Drive. Be sure the connection with electrical tape. Proper care should be
nection makes tight metal-to-metal electrical contact. taken to protect the sense lead from becoming discon-
The electrode cable should be sized according to the nected or damaged. The loss of a sense lead connec-
specifications given in Table A.1. tion can adversely affect welding performance. The
system may have multiple sense lead configurations
NOTE: On the Power Wave® 1000 SD, the Electrode available. Consult the power source manual on how to
studs are on the lower left rear corner of the configure the power source for the sense leads.
machine. On older units they are on the lower
left front corner. On those machines, the NOTE: The WORK sense lead (21) for the MAXsa™
cables can be routed through the oval hole in 22 & 29 Wire Drives system is typically con-
the cable tray before being connected to the nected at the back of the Power Wave®
output terminals. AC/DC 1000 SD. If the MAXsa™ wire drive is
to be used in an older system, (PF10A and/or
K2344-X) the WORK sense lead must be
brought out of the motor connection box and
TABLE A.1 - Output Cable Guidelines
Total Cable Length

connected to the workpiece.
Electrode and Work
ft (m) Duty Cycle Number of Cable Size
Combined
Parallel Cables Copper
0 (0) to 250 (76.2) 80% 2 4/0 (120 mm2)
0 (0) to 250 (76.2) 100% 3 3/0 (95 mm2)
When using inverter type power sources like the

Power Wave®, use the largest welding (electrode and
work) cables that are practical. When using AC appli-
cations the current can reach very high levels. Voltage
drops due to cable resistance can become excessive,
leading to poor welding characteristics if undersized
welding cables are used.

K325 - TC-3 TRAVEL CARRIAGE
The TC-3 travel carriage is available in two models.

Both are “High Capacity” and suitable for multiple arc
welding. FIGURE A.5
5” to 70”/min (127mm to 1.88M/mim)

K325HC-S (Standard - 952:1 ratio)
15” to 270”/min (381mm to 6.86M/min)

K325-HC-F (High Speed - 254:1 ratio) 19”
(483mm)
NOTE: Although the carriages can be set for speeds

down to zero, speed variations increase dra-
matically with uneven loading when operated
below the recommended minimum speeds.
The maximum amount of equipment that a K325 car-

riage can safely carry is shown in Table A.2
It is important when mounting wire reels,and other

equipment to the TC-3 Travel Carriage that there is a
minimum of overhung weight. The Wire Drive mount-
ings are to be such that the heads are within 19”
(483mm) from the front of the carriage as shown in
Figure A.5.
TABLE A.2 - MAXIMUM EQUIPMENT LOAD FOR TC-3
MULTIPLE ARC OPERATION TANDEM TWINARC®
Two MAXsa™ Three MAXsa™ Two MAXsa™

Wire Drives and Controls Wire Drives and Controls Wire Drives and Controls
Two Wire Reels Three Wire Reels Four Wire Reels(60# Coils)
(60 # Coils) (60# Coils) Centrally Located
Two K29 Three K29 Two K29
Vertical Adjusters Vertical Adjusters Vertical Adjusters
Two K96 Three K96 Two K96
Horizontal Adjusters Horizontal Adjusters Horizontal Adjusters
Flux Hopper Flux Hopper Flux Hopper
150# of Auxiliary Equipment No Auxiliary No Auxiliary

Centrally Located over TC-3 Equipment Equipment

NOTE: To install a MAXsa™ 29 Wire Drive order a

INSTALLATION
The TC-3 comes factory assembled to fit an 8” Mounting Bracket (M6769) and the appropri-
(203mm) beam. See print G1458 for instructions to ate Head Support (K29 or M8232).
use it on 10” (254mm) or 12” (305mm) beams.
5. Use an ohmmeter to be sure that the Wire Reel
The Carriage Release Handle, the Wire Reel Support shaft and the Wire Drive Mounting Bracket are
Bracket and the Wire Drive Support Bracket are not electrically isolated from the TC-3 frame.
factory mounted. They should be mounted to the car-
riage before it is placed on the beam per the following With the release handle all the way down, set the car-
instructions. riage on the beam. It should run freely along the
beam. With the release handle in the up position the
1. Insert the clutch handle into the hole on the right drive gear should engage the track and hold the car-
side of the carriage so that the end of the handle is riage securley in position.
goes into the lift yoke.
If the MAXsa™ 10 Control Box is to be mounted to the
2. Line up the hole in the handle and the hole in the TC-3:
lift yoke and insert the roll pin that came taped to
the handle. Drive in the roll pin until it is flush with 1. Attach the K2462-1 bracket to the left side of the
the yoke. carriage per the instructions included with the
bracket.
3. a. If the MAXsa™ 10 Control Box is not going to
be mounted on the carriage, mount the Wire NOTE: Make certain that there is enough clearance to
Reel Support Bracket to the left front corner of the left of the beam to accomodate the K2462-
the carriage using the hardware provided. 1 bracket
b. Do not mount the Wire Reel Support if the 2. Mount the MAXsa™ 10 Control Box to the brack-
K2462-1 Control Box Mounting Bracket for the et and connect the 4 pin connector from the
MAXsa™ 10 is to be mounted on the carriage. Travel Control to the mating receptacle on the
Another means of mounting the wire must be bottom of the MAXsa™ 10 Control Box.
used such as a K390 or a user supplied support
for a K299 or K162-1 Spindle Kit (ordered sepa- Keep the load on the TC-3 as uniform as practical.
rately). Install cables so that they move smoothly with the car-
riage. Clamp the weld cables to the carriage using the
NOTE: Do not mount the K2462-1 Bracket for the cable clamp on the left rear corner.
MAXsa™ 10 Control Box until after the car-
riage is placed on the beam. After all of the equipment has been mounted to the
carriage, the tracking of the drive gear and the bear-
4. Install the Wire Drive Mounting Bracket that is sup- ings should be checked.
plied with the MAXsa™ 22, using the hardware
and insulators provided. See Figure A.6.
FIGURE A.6 - WIRE DRIVE MOUNTING
Wire Reel
Mounting Bracket
MAXsa™ 10
Clutch
Mounting Bracket Wire Drive Mounting
Handle
(K2462-1) Bracket (M6769)
Head Support
(M8232)

INCLINED OPERATION OF TC-3
1. The beam should have a Knurled Drive Flange and

the TC-3 should have the straight toothed Drive
Gear (T13586 - ordered separately).
CAUTION
When the carriage is used in an inclined application
the unit is free to move whenever the Carriage
Release Handle is pulled down. This may happen
even if a counter balance weight is used. With a prop-
er counterbalance and if the flux hopper and wire
reel(s) are mounted off of the carriage, this “free-
wheeling” is less likely to occur since the changing
weight will not affect the counterbalance.
2. With a tilt of 5° or less, a counterbalance is typical-

ly not required (see CAUTION).
3. A tilt in excess of 5° will require a counter weight

as shown in Figure A.10. The amount of coun-
teweight will depend on the tilt angle and the
amount of load on the carriage. Beam angles
should be limited to 10° or less.
FIGURE A.10 - INCLINED OPERATION
Pulley
Carriage
Beam Weight

FIGURE A.7 - DRIVE GEAR TRACKING
Incorrect
ADD Shims
Shims
Full Face .88” Beam Incorrect

Drive Gear Contact Drive Rail REMOVE Shims
DRIVE GEAR TRACKING FIGURE A.8 - BEARING TRACKING
The TC-3 is shimmed at the factory so that the drive

gear sits flat against a .88” (22mm) flange when the
release handle is in the up position. If the flange
dimension is other than .88” (22mm) the shims under
the TC-3 gear box mounting will have to be changed
accordingly. See Figure A.7.
CORRECT PATTERN INCORRECT PATTERNS
Full Face Bearing Bearing is not flat
NOTE: TC-3 units are shipped with a helical tooth

Contact Against Drive Rail
drive wheel that is suitable for use on a

smooth drive rail. A straight tooth gear
FIGURE A.9 BEARING SHIMS
(T13586) is available for use on a drive rail
with a straight cut knurl.
CARRIAGE BEARING TRACKING
Bearing tracking can be checked by placing a strip of

white paper over the area where the bearings ride.
With the drive gear disengaged (handle down), move
the carriage over the strips. If the tracking is correct
the bearings will leave a uniform trace on the paper.
See Figure A.8. If traces are not corrrect add shims as
necessary. See Figure A.9.
Shim Here

B-1 OPERATION B-1
ROUTINE OPERATION
Once the procedures and parameters are properly set 2. On-the-fly Starting - refers to starting the weld
at the controller the operator should be able to make after the travel begins to get a “scratch” start.
production welds without changing those settings. A Normally this type of starting requires the use of a
typical weld sequence is as follows: ʻrun-onʼ tab to insure proper weld deposition at the
beginning of the weld.
1. Before starting, make sure that:
a. Use the Set-Up Menue of the MAXsa™ 10
a. There is enough wire on the reel(s) to finish to set the travel to start with the START
the weld. button.
b. The flux hopper is filled with new or proper- b. Follow the Hot Starting procedure.
ly screened flux.
Cold Starting - refers to starting the weld with the
2. Energize the power source and wait for it to stabi- Wire Drive Head stationary and the electrode touching
lize (all Status LEDʼs Green). the work.
3. Position the Wire Feed Head at the start of the a. This procedure is not recommended for the
weld. Be sure the TC-3 Carriage or travel mecha- Power Wave® AC/DC 1000 / MAXsa™ 22
nism is set to move in the proper direction & 29 WIRE DRIVES combinations but may
work OK with smaller diameter wires and
4. Set the travel switch for “Automatic Travel” if the proper setting of the Start parameters.
“Hand Travel” position was used to position the
feed head in Step 3. b. Follow Hot Starting procedure but omit
“step c”.
STARTING TECHNIQUES
1. Hot Starting - refers to starting the weld with the

HEAD POSITION ADJUSTMENTS
Wire Drive head stationary and the wire not touch- The MAXsa™ 22 & 29 WIRE DRIVES can be easily
ing the workpiece. adjusted to any weld position. The most often used
adjustments are available on both the MAXsa™ 22
a. Always cut the end of the wire to a sharp and the MAXsa™ 29 Wire drives. See Figure B.1
point.
Turn the Cross Seam Adjuster (MAXsa™ 29) to keep
b. Press Feed Forward until the wire touches the arc in the joint as necessary. With a MAXsa™ 22,
the work piece and the flux hopper acti- a K96 or some other means of horizontal adjustment
vates to put flux around the starting point. is recommended. See Figure B.2
c. Press Feed Reverse to retract the wire 1/8” The entire Wire Drive can be moved into or out of the
to 1/4” (3.2-6.4mm). Mounting Bracket (M6789). If using a K29 Vertical Lift
Adjuster it can be locked in either the horizontal or
d. Use the Set-Up menu of the MAXsa™ 10 vertical position once the vertical position is set. See
or remote controller to determine whether Figure B.3.
the travel will begin with Start Button
pressed or with weld current (preferred). If the Wire Drive is rotated to a position where the
faceplate is upside down, the contact nozzle and the
e. Press the START button to initiate the weld. wire straightner and guide tubes will need to be
reversed. The polarity of the motor will also need to be
f. Press the STOP button to begin the stop- changed so the wire feeds in the proper direction. See
ping sequence. the Installation Section, Changing the Wire Drive
Configuration for instructions on changing the motor
h. If necessary, press the Feed Reverse to polarity.
move the electrode out of the way.
MAXSA™ 22 & 29 WIRE DRIVES

B-2 OPERATION B-2
FIGURE B.1 - FEED HEAD ADJUSTMENT
The Cross Seam Adjuster

Can Be Mounted to the
Loosen this Socket Top or Bottom of the
Head Screw to Adjust Gear Box
Faceplate Angle
5/16”
Allen
Wrench Feed Head Rotates
Face-plate Rotates 360° Around the
360° Around the Motor Axis
Drive Roll Shaft
FIGURE B.2 - HORIZONTAL ADJUSTMENT

This Adjustment Can be
Locked by Tightening
Two Socket Head Screws
Turn Handle
to adjust
MAXsa 29
MAXsa 22
Rotating the K96 Allows
for 2” Movement in
any Direction in the
Horizontal Plane
2”
2 1/2”
Cross Seam Adjuster K96 Horizontal Adjuster
FIGURE B.3 - VERTICAL ADJUSTMENT
Use This Screw

K29 Clamps Can Be Set Head May Be Rotated
To Lock Vertical
to Restrict In and Out Motion Around the Vertical Axis
Position
to Distances up to 3 3/4”
K96
Loosen to Rotate
Entire Head Around
Mounting Axis
With K29
Head
Loosen Screw
Mounting
With Standard Mounting (M6767) With Standard Mounting (M6767)

or K29 Vertical Adjuster or K96 Horizontal Adjuster

C-1 ACCESSORIES C-1
OPTIONS AND ACCESSORIES are

available at www.lincolnelectric.com
Follow these steps:
1. Go to www.lincolnelectric.com
2. In the Search field type E9.181 and click on the

Search icon (or hit ʻEnterʼ on the keyboard).
3. On the Results page, scroll down to the

Equipment list and click on E9.181.
All of the information for the Power Wave System

accessories can be found in this document.
NA Style Wire Drives)--This convertion kit con-

K2311-1 Motor Conversion Kit (for 142:1
verts old NA style wire drives to MAXsa™ 22 & 29

WIRE DRIVES.
1. Remove the 2 hex head screws and the 2 slot head
screws holding the Motor to the Wire Drive Gearbox
assembly.
2. Remove existing Adapter Plate and Motor Assembly.
3. The Conversion Kit Motor is shipped configured for a
142:1 gear ratio. The existing gearbox must be con-
figured for a 142:1 gear ratio for the Conversion Kit to
assemble correctly. If both assemblies are not con-
figured for the same gear ratio, this must be done
before continuing. (See Gear Ratio Conversion Kit
instructions.)
4. Cover the teeth of the new Motor pinion gear with a
non-fluid molydisulfide type grease such as Non-Fluid
Oil Corporationʼs A-29 Special/MS Lubricant. This
grease can be scooped from the cavity of the gear
case First Chamber.
5. Reassemble the new Adapter Plate and Motor
Assembly on the Wire Drive Gearbox; making sure
the gears mesh properly and the Adapter Plate locat-
ing bead is in its cavity. Replace and tighten the 4
screws removed in step 1.

C-2 ACCESSORIES C-2
Connect the lug on the electrode cables from the

power source to the tab on the contact nozzle
SUBMERGED ARC CONTACT
and tighten the bolt and nut. See Figure C.1.

ASSEMBLIES
Operation - DO NOT completely straighten the

K231-[X/XX] CONTACT NOZZLE
The K231- [x/xx] is used for submerged arc weld- electrode. A slight curvature is required in the
ing with currents generally under 600 amps. electrode to insure good electrical contact inside
Higher currents can be used but result in some- the contact tip.
what faster tip wear. The outer flux cone deposits
flux around the arc for full coverage with mini- Maintenance - Replace the contact tip when it
mum flux consumption. no longer provides accurate wire location or good
electrical contact. Rusty and dirty wire or exces-
Contact tips for the electrode diameter specified sively high currents increase tip wear. Always
on the order are shipped with each nozzle. A dif- keep replacement tips in stock.
ferent contact tip is required for each electrode
diameter used. To replace the contact tip, first loosen the retain-
ing wing nut and remove the flux cone body.
Installation - Nozzles ordered for 3/32” (2.4 mm) Then unscrew the tip and replace it.
electrode include a liner and a contact tip
adapter. Screw the adapter into the end of the A special socket head screw holds the nozzle
nozzle and the contact tip into the adapter. body to the insulator. If the nozzle body becomes
loose, remove the nozzle from the head, tighten
Insert the outgoing wire guide from the wire feed the screw and reassemble nozzle.
head into the top of the K231 and install the
assembly in position on the bottom of the wire Extensions - The K231 nozzle can be extended
feed head. Lock it in position using the two if necessary. Order part number S12003 for a 5”
clamps provided with the head. (127mm) extension or make any length per draw-
ing in Figure C.2.
Connect one end of the rubber flux hose to the
tube at the bottom of the flux hopper. Fit the
short copper tube in the other end of the rubber
FIGURE C.2 - EXTENSION
hose then insert the copper tube into the hole in

the flux cone body. See Figure C.1
+
1/32”x45° 60° _ 2° Remove Sharp
Chamfer Corner
CAUTION - Pushing the copper tube too far into

the flux cone body will cause a short
9/16-18
Class 2 Fit 1/2”
between the cone and nozzle if the

cone touches the work.
1/8”
1/2”
FIGURE C.1 - K231
Material - Hard Drawn
Socket Head As Copper or Heat Treatable
Screw Req’d Copper Alloy
Weld Cable
33/64”Drill 11/16” deep
Connection
9/16-18 Tap 9/16” deep
Class 2 Fit
Flux Wing 1/32”x45°
Hose Screw Chamfer
Break 3/4”
Copper Flux Cone
Corner
“A” Dia. (See Table)
Tube Body
Wire Size “A” Dim.
5/64-3/32(2.0-2.4mm) 1/8 (3.2mm)
1.8-5/32 (3.2-4.0mm) 3/16 (4.8mm)
Flux Cone
3/16 -7/32(4.8-5.6mm) 1/4 (6.4mm)

C-3 ACCESSORIES C-3
Maintenance - Rusty or dirty wire and/or exces-

sively high welding currents increase wear on the
K226 CONTACT ASSEMBLY
The K226 assemblies are used for welding at currents contact jaws. When arcing occurs or the elec-
from 600 to 1000 amps. trode becomes loose in the jaws, remove the
jaws and ʻdressʼ them with a file. When neces-
Model K226-T - (2 tapered jaws)
3/32” and 1/8” (2.4 and 3.2mm) electrode
sary, the jaw inserts should be replaced.
Model K226-R - (1 tapered and 1 rectangular jaw) NOTE: Units made prior to 1979 did not have
1/8” thru 7/32” (3.2 - 5.6mm) electrode inserts. The replacement jaws will have
them.
Installation - Remove the two nozzle mounting
clamps from the wire drive. Insert the outgoing The contact jaws must be kept in line with the
wire guide from the wire feed head into the top of wire guide. Align the jaws as follows: (See Figure
the K226 and install the assembly in position on C.3)
the bottom of the wire feed head. Use the two
screws provided with the K226 to attach it to the 1. Loosen the stationary contact jaw screws.
wire drive. See Figure C.3.
2. Release the tension on the moveable jaw by
NOTE: Removing the 4 screws that hold the noz- loosening the screws holding the spring.
zle body to the mounting block allows the
nozzle to be rotated to any of four posi- 3 Place a straight 14” (or longer) piece of bare
tions 90° apart. See Figure C.3. 5/32” (4.0mm) wire through the wire guide
and into the drive rolls of the feed head.
Connect two (2) electrode cables to the contact
jaws (one under each 1/2-13 nut. Make sure that 4. Adjust the stationary contact so the wire
the cable lugs are flat against the copper and touches the jaw at the center of the groove
tighten the nuts securely. See Figure C.3. for the entire length of the jaw.
Slip the rubber flux hose that comes with the 5. Tighten the screws, remove the wire and re-
K226 on to the flux hopper valve. Fit the copper tighten the screws holding the spring to
tube into the other end and place it in the clip on apply tension to the moveable jaw. The
the lower jaw assembly. See Figure C.3. moveable jaw should move freely when fin-
ished.
FIGURE C.3 - K226 CONTACT NOZZLE ASSEMBLY
Use to Mount
to Wire Drive
Remove(4)
Screws to
Rotate Nozzle
Stationary
Contact
Attach Weld Spring
Cables Here
Moveable
Contact
K226-R Flux
Only Hose
Copper Tube
WORK NOZZLE
TRAVEL TRAVEL

C-4 ACCESSORIES C-4
7. Slide the center guide (G) up out of the pivot body

until the tang is above the window.
TM
K148 CONTACT NOZZLE AND K149 Linc-Fill
LONG STICKOUT EXTENSION
This nozzle is available in three models and can be 8. Place the Linc-Fill guide assembly into the nozzle
used for Innershield® or submerged arc processes. window, and then lower the center guide tube (G)
back down to its original position.
K148-A - For 3/32” and 1/8” (2.4 - 3.2mm) wire.
9. Line up the spot at the top of the center guide tube
K148-B - For 5/32” and3/16” (4.0 - 4.8mm) wire. (G) with the 3/8” (9.5 mm) tapped hole in the upper
pivot block (A) and put the 3/8” (9.5 mm) set screw
K148-C - For 1/16” to 5/64” (1.6 to 2.0mm) wire. (C) back into the hole and tighten securely.
FIG. C.4 - TYPICAL CONFIGURATIONS
Current Ratings
Innershield Welding:
A. Without Linc-Fill Attachment
600 amps, 100% duty, no water cooling

1100 amps, 100% duty, with water cooling
Submerged arc welding:
1100 amps, 100% duty, no water cooling
Innershield or Submerged Arc Welding:

B. With K149 Line-Fill Attachment
1100 amps, 100% duty, no water cooling K 148 K 148

With Water
Water Cooling Attachment
Cooling
When using currents over 600 amperes at high duty

K 148 & K 149
Attachment
cycles water cooling always increases contact tip life.

The cooling attachment, Part No. T12928 must be
FIG. C.5 - K149 INSTALLATION
ordered seperately. Installation instructions are includ-
ed in the kit. Connect the attachment to the water sup-
ply and the drain with rubber tubing obtained locally.
Water flow should be between 1/2 to 1 gallon (1.9 to
C A
3.8L) of tap water per minute.
K149 Installation (See Figure C.5)
1. Install the K149 attachment before mounting the

B
K148 nozzle on the welder.
2. Place a small C-clamp on the spring supporting

F
members (A) and (B) in such a manner that the

G H
spring can be compressed. Look up into the hole
in the end of contact tip and tighten the C-clamp
until the tang lifts off the surface of the tip.
E
3. Remove the 3/8” (9.5 mm) set screw (C) in the

D
body (A). 11
4. Remove the contact tip clamping nut (D) and the

contact tip.
12
5. Remove the brass thread protecting collar (E).

13
6. Remove the dirt shield (F) from the barrel of the
10
nozzle.
14

C-5 ACCESSORIES C-5
10. Line up the lower spot in the center guide tube (G)
with the 3/8” (9.5 mm) set screw (H) and tighten the
Operation
screw securely. The same contact tip, S13763, is used for 3/32” (2.4
mm) through 3/16” (4.8 mm) diameter electrodes.
11. Replace the brass thread protecting collar (E). It is S16388 is used for .062 (1.6 mm) and 5/64 (2.0 mm)
important that this protecting collar be pulled up electrode.
against its locating shoulder, otherwise the tip lock-
ing nut will not clamp the tip securely. Loading of Wire
12. Replace the contact tip and its clamping nut (D) Straighten the start end of the coil for at least eight inch-
and tighten securely. es, pass the end down through the appropriate wire
straightener. Inch the wire through the wire feeder and
13. Assemble the proper combination of extension the nozzle. When using .062 (1.6 mm) or 5/64 (2.0 mm)
guides (Items 12, 13 and 14) with locking nut (Item Innershield electrode with a K148-C nozzle, make sure
11) for the welding procedure to be used. that the wire is in the “vee” groove of the pressure tang.
For the .062 (1.6 mm) and 5/64 (2.0 mm) wire sizes, it
14. For Submerged Arc welding, screw the flux hose may be necessary to back off on the idle roll pressure
clamp (Item 10) onto the extension housing. so that there is little or no flattening of the wire.
Because the electrode is held against one point of the

contact tip, it wears a groove at that point. When the
K148 Nozzle Installation
To install the nozzle on the head, insert the outgoing groove is about one half the diameter of the electrode,
wire guide from the head into the nozzle assembly. rotate the contact tip to a new position per the instruc-
Place the combined assembly in position on the bottom tions below. Careful positioning of the contact tip will
of the wire feed roll box. Clamp it in place using the two provide four to six wear spots depending upon the elec-
clamps supplied with the head. trode size.
Before pulling the clamps up tight the nozzle must be When welding with the small diameter electrodes, it will
positioned relative to the travel direction as shown in be necessary to change contact position more frequent-
Figure C.6. This position is set so accidental contact ly since the amount of tip wear that can be tolerated is
between the work and the nozzle will not compress the much less. The tang should never be allowed to touch
contact pressure spring. If positioned otherwise, such the I.D. of the contact tip. If the groove is allowed to
accidental contact may cause arcing inside the contact wear until the tang touches the I.D. of the contact tip,
tip. welding current passes through the tang. This causes
After the nozzle is positioned in the proper relationship electrical wear and overheating of the tang and the con-
with the travel direction, the connector tab for the elec- tact tip. See Figure C.7.
trode cables can be moved to any of four positions 90
degrees apart. To change the tab, remove the two 1/4-
FIGURE C.7
20 hex head screws. ap the connector tab to loosen it
from the tapered collar on the nozzle body. Turn the tab
to the desired position. Replace and tighten the 1/4-20
screws.
Contact
Tip
FIGURE C.6 Tang

Electrode
Nozzle
Pivot
New Time to Too Late
Connector Rotate
Tab
To rotate the tip, clip the end of the electrode and inch it
Contact
up until it is free of the contact tip. Loosen the locking
Pressure
nut about one-half turn and pull the nozzle body to
Locking
Spring
relieve the pressure of the tang against the inside of the
Nut
contact tip hole. At this moment rotate the tip the proper
Nozzle
amount and then retighten the locking nut.

Contact Travel
Tip Work
Travel

C-6 ACCESSORIES C-6
To install a new contact tip proceed as follows: K285 Installation to the K148
1. Clip the end of the electrode and inch it up until it is 1. Remove the tension on the center guide tube using
free of the tip. a “C” clamp as shown in Figure C.8. Apply only
enough clamping force to relieve the tang pressure
2. Remove the contact tip locking nut.
from the contact tip.
3. Relieve the spring pressure of the contact tip against
the steel tang in the hole of the contact tip. To do 2. Remove the contact tip clamping nut and the con-
this, push the nozzle body so the steel tang is tact tip.
approximately centered in the 3/8” (9.5 mm) hole in
the contact tip. Under these conditions the contact
FIGURE C.8
tip can be easily removed from the nozzle body.
4 a. Before installing the new tip, make sure the

threads and the bottom surface of the nozzle are
clean and bright. These surfaces are current car-
rying areas and must be clean.
b. Push the nozzle body to one side to relieve the

pressure and insert the new contact tip.
5. a. Check the locking ring threads making sure

they are free or any foreign material. A small 3. Remove the brass thread protecting collar and
application of locally available high temperature slide the dirt shield off of the nozzle.
anti-seize compound or graphite grease on
these threads insure a longer thread life of the 4. Make sure that all the threads are clean and
two mating parts. replace the collar, the contact tip and the clamping
nut and remove the “C” clamp.
b. Replace the locking ring and tighten securely.
5. Loosen the hose clamps of the K285 entirely, place
6. Check the contact tip to be certain it is tight in the them around the nozzle and tighten them so that
nozzle body. If the tip is not tight, arcing will take the stationary part of the K285 covers the opening
place between the tip contact surface and the noz- in the nozzle body as shown in Figure C.9.
zle contact surface which will damage the nozzle
body. 6. Position the moveable section to the desired flux
height and tighten the wing nut.
7. Cut the flux hose to required length and connect as

K285 Concentric Flux Cone
The K285 Concentric Flux Cone is designed to fit on a shown.

K148 (with or without the K149 attachment) or on a
K129 Tiny Twin-Arc® nozzle. This attachment
FIGURE C.9 - K148
deposits the flux so that it surrounds the electrode(s).
NOTE: If using a K149 extension, the electrical stick-

out will be limited to 4” (102mm).
The K285 consists of two pieces that are electrically

isolated from each other. The stationary segment is
Wing Nut
clamped to the nozzle and the moveable portion

which supports the flux hose and the concentric cone
Flux
allows for vertical adjustment of the flux cone.

Hose Hose
Clamps
Moveable
Section
Travel
Direction

C-7 ACCESSORIES C-7
K285 Installation with K149 K285 installation with the K129
1. Install the K149 to the K148 per the instructions. 1. Unscrew the hose clamps enough so they can slip
over the tip holder clamping nut.
2. Loosen the hose clamps of the K285 entirely, place
them around the nozzle and tighten them so that 2. Position the stationary portion of the K285 as
the stationary part of the K285 is directly opposite shown in Figure C.11 and tighten the clamps.
the K149 arm. See Figure C.10
3. Position the moveable section to the desired flux
NOTE: The lower hose clamp must be positioned so it height and tighten the wing nut.
does not touch the arm of the K149.
4. Due to the 7° angle of the tips it may be necessary
4. Position the moveable section to the desired flux to pivot the cone as shown. Remove the outermost
height and tighten the wing nut. Use the center or screws from each side of the cone. tilt the cone
lower tapped hole depending on the electrical and put the two screws into the rear of the cone.
stickout Tighten all 4 screws.
5. Cut the flux hose to required length and connect as 5. Cut the flux hose to required length and connect as
shown. shown.
FIGURE C.10 - K285/K149 FIGURE C.11 - K285/K129
IMPORTANT
K285 on ALL Nozzles
After the K285 is installed to any of the compatible

nozzles, use an ohmmeter or a test light to insure
proper insulation (no continuity) between the copper
flux cone and the nozzle body

C-8 ACCESSORIES C-8
K285 Used in Horizontal Fillet Applications
1. With K148 or K148/K149 combination - After the c. Loosen the K285 hose clamps and rotate the flux
K285 has been attched to the nozzle body: cone unit about 40 to 45° and retighten the
clamps.
a. Set the head and nozzle to the desired electrode
angle. d. Slide the K285 flux cone dowm to about 1/8”
(3.0mm) away from both the vertical and horizon-
b. Loosen the two hold down screws that hold the tal plates and tigten the wing screw. See Figure
nozzle to the faceplate and rotate the entire C.12.
assembly 40 to 45° and retighten the screws.
c. Feed the electrode to the proper stickout and

K285 in Deep Narrow Gap Applications
position it in the joint. For narrow, deep groove welds it may be necessary to
remove the copper cone from the moveable arm of
d. Slide the K285 flux cone dowm to about 1/8” the K285
(3.0mm) away from both the vertical and horizon-
tal plates and tigten the wing screw. See Figure NOTE: In Horizontal fillet pplications, the flux hopper
C.12. will not function properly if fastened to the
faceplate of the wire drive. Mount the Flux
2. With the K129 Tiny Twin-Arc® Nozzle - After the hopper directly above the K285 flux entry
K285 has been attached to the nozzle body: point. Flux hose angles should be no greater
than 35° to ensure good flux flow from the
a. Set the head and nozzle to the desired electrode hopper to the cone.
angle.
b. Feed the electrode theough the tips to the proper

stickout and place the nozzle into the welding
position.
FIGURE C.12 - K285 IN HORIZONTAL FILLET APPLICATION

C-9 ACCESSORIES C-9
K29 VERTICAL HEAD ADJUSTER
Automatic welding applications frequently require rais- 4. Slide the Head Adjustment Lock (A) over the end
ing and/or lowering of the feed head assembly. The of the Mounting Bracket (M).
K29 provides an easy method of accomplishng this
task by simply turning a crank handle. A height varia- 5. Align the hole of the Head Adjustnent Lock with
tion of 4” (102mm) is possible with this attachment. the groove in the Mounting Bracket and drive in
the 1/4” Roll Pin (B).
6. Using the 1/2” x 2.75 Locking Screw, tighten the

FIGURE C.13 - K29
Head Adjustment Lock with the open slot in the up

position.
7. Slide the Vertical Head Lift Adjuster (E) into the

Mounting Bracket (M) and tighten the Draw Bolt
Nut (K).
8. Install the two Clamps (D), one on each side of the

Head Adjustment Lock with the hardware provid-
ed.
NOTE: If a K96 Horizontal Adjuster is to be used,

install it now per the instructions provided. If
not, proceed to Step 9.
9. With the Draw Bolt (J) and the Lock Nut (H) in
place, raise the Feed Head in to position on the up
and down lift shaft (N) and tighten the Lock Nut.
10. Drive the 5/16” Roll Pin (G) back in to itʼs original
position.
Installation
Check the package for the following items (See Figure

Adjustment and Locking
C.13): Rotational movement of the lifting mechanism is kept

to a minimum by the spring loaded, wedge shaped pin
1. Head Adjustment Lock (A) (X) that is always in contact with the vertical slide. The
2. 1/4” (6.3mm) diameter Roll Pin (B) Socket Head Screw (Y) on the right side of the K29
3. 12”-13x2.75” Hex Head Locking Screw (C) housing is used as a locking mechanism to keep the
4. Two adjustable clamps with hardware (D) head at a desired height.
5. Vertical Head Lift Adjuster (E)
NOTE: Extreme tightening of the locking screw may
To install the K29, proceed as follows: cause the wedge to jam so that the lift cannot
move in either direction. If this occurs, back
1. If the Feed Head (F) is already mounted to the the screw out two turns and tap on it to
Head Support (E), be sure that the lock nut (H) on release the wedge.
the Feed Head Draw Bolt (J) is tight, and drive out
the Roll Pin (G) with a 5/16” punch.
2. While supporting the Feed Head, loosen the lock-

ing nut (H) and remove the head from the Head
Support (E).
3. Loosen the Lock Nut (K) on the Draw Bolt (L) and
remove the Head Support (E) from the Mounting
Bracket (M).

C-10 ACCESSORIES C-10
K96 HORIZONTAL HEAD ADJUSTER FIGURE C.14 - K96

The K96 provides an easy means of moving the Feed
Head in a horizontal direction by simply turning a
crank handle. It provides 2” (51mm) of travel and can
be mounted directly to the Head Support or to a K29
Vertical Lift Adjuster.
Installation (See Figure C.14)
1. If the Feed Head is already mounted, make sure

that the Lock Nut (H) on the Feed Head Draw Bolt
(J) is tight and drive out the Roll Pin (G) with a
5/16” punch.
2. While supporting the head, loosen the Lock Nut

(H) and remove the Feed Head
NOTE: If a K29 Vertical Head Adjuster is to be used,

install it now per the instructions provided.
3. With the Draw Bolt (A) in place, fit the K96

Horizontal Adjuster (D) over the shaft of the Head
Support (E) or the K29 (Eʼ ) if used.
4. Drive in the 1/4” Roll Pin that comes with the K96.
5. With the Draw Bolt (J) and the Lock Nut (H) in
place, raise the Feed Head in to position on the
shaft of the Horizontal Adjuster and tighten the
Lock Nut.
6. Drive the 5/16” Roll Pin (G) back in to itʼs original

position.
7. Mount the Crank Handle on whichever side is

most convenient by removing the two bolts and
rotating the housing 180° and replacing the bolts.
See Figure C.15.
FIGURE C.15
Place Handle in
Either of Two
Positions
Remove Two Bolts

and Rotate Housing

FIGURE C.16 - K129 TINY TWINARC® COMPONENTS
1
D
F A
7
6
C
3
3
5
B 4
4
A - Drive Rolls 1 - Nozzle Assembly
B - Guide Tubes 2 - Guide Tubes
C - Idle Roll Arm 3 - Locking Collar
D - Incoming Wire Guide 4 - Contact Tip(s)
E - Drive Roll Spacer 5 - Tip Holder
F - Key 6 - Connection Tab
7 - Mounting Block
K129 TINY TWINARC® KIT Drive Kit for use with the K129-1/16 kit.
Twin arc welding is a process where two wires of the

INSTALLATION
same size are fed through a nozzle by a single wire

drive. The K129-x/xx can be used for wire sizes .045”
A. For .045” through 5/64”(1.0-2.0mm) Wires
through 3/32” (1.0 - 2.4mm). 1. Remove the following items from the standard
Feed Head.
The gear ratio of the MAXsa™ 22 & 29 WIRE DRI- • The wire straightener
VES as shipped is 142:1. This may not provide • The nozzle assembly
enough wire speed for the procedure. Conversion kits • Both upper and lower guide tubes
for 95:1 or 57:1 ratio are also shipped with the • The drive rolls
MAXsa™ 22 & 29 WIRE DRIVES units. See the • The idle roll assembly
instrucutions included with those kits or in this manual • The tension spring assembly
to change the gear ratio. NOTE: The idle roll arm pivot pin is held in place by
a set screw that is accessed from the outgo-
Each assembly listed below comes with a wire reel, a ing surface of the faceplate.
reel brake, shaft and mounting bracket and all of the
wire drive components for the particular wire size. 2. Place the new double grooved drive roll (A) on
the shaft with the key. Replace the clamping
K129-1/16 .045” thru 1/16” (1.0 -1.6mm) Wires washer and the locking nut and tighten securely.
K129-5/64 5/64” (2.0mm) Wire .
K129-3/32 3/32” (2.4mm) Wire
NOTE: For .045” or .052” wire order KP1901-1 Wire

1. Remove the items listed in Step “A” plus: 5. Insert the two long insulated wire guides (2) into
B. For 3/32 (2.4mm) Wire
• The drive roll key the Twinarc nozzle (1) making sure that they are
• The drive roll spacer seated in the holes in the mounting block (7).
Place the contact tip (4) or tip holder (5) into the
NOTE: The set screw that holds the drive roll spacer end of the nozzle making sure the tubes fit into
in place is accessible once the idle roll assem- the holes. Lock it securely in place with the lock-
bly is removed. ing collar (3). See Figure C.16.
2. Oil or grease the O.D. of the new shorter drive NOTE: For applications that require staggered or
roll spacer (E) and place it on the output shaft. cross seam wire placement rather than in-line,
Push it back as far as it will go and tighten the the contact tip or tip holder may be rotated.
set screw. Re-adjust the head position to maintain the
proper wire-to-work angle.
3. Place the new longer key (F) in the keyway.
For overlay applications a special “side by
4. Place the outer, center and second outer drive side” tip holder (part# S17728) that accepts
rolls (A) on the shaft. Replace the clamping standard contact tips is available.
washer and the locking nut and tighten securely.
6. Place the other guide tube (B) into the outgoing
side of the faceplate. Place the nozzle over the
guide tube and lock it in place with the two sock-
FIGURE C.17
et head screws
7. Bolt the electrode cable(s) of the proper size and

number, to the connection tab (6) using the hard-
Key Outer Drive Rolls
ware provided. If using multiple cables, use both

sides of the tab.
Locking
Drive Roll Center Clamping Nut
Output Spacer Drive Roll Washer E. Maintenance
Replace the Contact Tip(s) when they no longer pro-

Shaft
vide accurate wire placement or good electrical con-

tact. Before installing the new contact tip or tip holder:
See Figure C.17.
1. Make sure that the threads and bottom surface of
the nozzle are clean and bright. These are cur-
rent carrying surfaces and must be clean.
C. Nozzle Installation
1. install the new idle roll arm (C) using the pin and
set screw from the original assembly. . 2. Check that the locking collar is free of foriegn
material. A coating of locally available “anti-
2. Replace the tension spring and screw and adjust seize” compound or graphite grease will help
the tension screw to the .045-3/32 line on the insure longer thread life.
indicator plate.
3. Before replacing the contact tip or tip holder:
3. Insert one of the guide tubes (B) in the top of the a. Inch the wire past the end of the nozzle.
faceplate. Line up the holes in the guide tube b. Slide the long wire guides on to the wire
with the grooves in the drive rolls to insure proper making sure they are properly seated in the
wire feed mounting block (see Figure C.16).
c. Slide the new contact tip or tip holder over
NOTE: If using the K281 Twinarc Wire straightener, the wires again making sure that thewire
follow the supplied instructions and skip to guides are properly seated
Step 5. d. Replace the locking collar and tighten
securely
4. Put the dual ingoing wire guide (D) over the ingo-
ing guide tube and lock it down with the two “L”
shaped clamps from the wire straightener.

FIGURE C.18 - K225 TWINARC® COMPONENTS
F
E A
2
9
B
5 3
A - Drive Rolls
B - Guide Tubes
C - Idle Roll Arm
7
D - Drive Roll Spacer
E - Key 8
F - Nozzle Assembly 6
NOTE: The idle roll arm pivot pin is held in place by a

set screw that is accessed from the outgoing
K225 SUBMERGED ARC TWINARC® KIT
Twin arc welding is a process where two wires of the surface of the faceplate.
same size are fed through a nozzle by a single wire • The tension spring assembly
drive. The K225 Twinarc Kit can be used to weld with ` • The Drive Roll Spacer
5/64”, 3/32” or 1/8” (2.0,2.4,or3.2mm) electrodes. Both
wires must be the same size. NOTE: The set screw that holds the drive roll spacer
in place is accessible once the idle roll assem-
The gear ratio of the MAXsa™ 22 & 29 WIRE DRI- bly is removed.
VES as shipped is 142:1. This may not provide
enough wire speed for the procedure. Conversion kits 2. Oil or grease the O.D. of the new shorter drive
for 95:1 or 57:1 ratio are also shipped with the roll spacer (E) and place it on the output shaft.
MAXsa™ 22 & 29 WIRE DRIVES units. See the Push it back as far as it will go and tighten the
instructions included with those kits or in this manual set screw.
to change the gear ratio.
3. Place the new longer key (F) in the keyway.
Each assembly comes with a wire reel, a reel brake,
shaft and mounting bracket, a dual wire straightener 4. Place the outer, center and second outer drive
and all of the wire drive components for the particular rolls (A) on the shaft. Replace the clamping
wire size. See Figure C.18. washer and the locking nut and tighten securely.
See Figure C.19.
The Nozzle Assembly (F) has two spring loaded large
copper jaws (6) that press the electrodes against the
copper center block (4). This system provides good
elctrical contact and insures constant electrical stick-
FIGURE C.19
out (E.S.O.) It also helps to maintain acceptable noz-

zle temperatures during welding.
Key Outer Drive Rolls
INSTALLATION
1. Remove the following items from the standard

Locking
Drive Roll Center Clamping Nut
Feed Head.
Output Spacer Washer
Drive Roll
Shaft
• The wire straightener

• The nozzle assembly
• Both upper and lower guide tubes
• The drive rolls
• The idle roll assembly
Nozzle Installation (See Figure C.18)

Make sure that the mating surface (8) between the
IMPORTANT
1. install the new idle roll arm (C) using the pin and Center Block (4) and the Copper Bar (2). is bright,
set screw from the original assembly. clean and smooth. This junction carries the full weld
current.
2. Replace the tension spring and screw and adjust
the tension screw to the proper line on the indica-
tor plate.
FIGURE C.20
3. Insert one of the guide tubes (B) in the top of the

faceplate. Line up the holes in the guide tube
with the grooves in the drive rolls to insure proper
1
wire feed
4. Put the Dual Wire Straightener over the ingoing

guide tube and lock it down with the two “L”
2
shaped clamps
9
5. Place the other guide tube into the top of the

K225 Nozzle Assembly (F) and slide the guide
tube into the Wire Drive faceplate until the
mounting screws (1) can be started into the
tapped holes in the faceplate. Tighten both
5 3
screws.
NOTE: For applications that require staggered or

7
cross seam wire placement rather than in-line,

8
the nozzle can be rotated by loosening the

two1/4-20 socket head screws (9) that hold
6
the nozzle to the mounting base. If the desired

4
angle cannot be obtained, remove the screws

and put them into alternate holes. Retighten
when properly adjusted.
Maintenance
The most extensive contact wear takes place on the

6. Connect the weld cables of the proper size and center contact block. The side pressure jaws are
number to the copper bar (2). If using multiple made of a harder longer lasting material. Replace the
cables, use both sides of the bar. center block when there is no pressure on the wire
from the side contact jaws.
7. Route the flux hose from the flux hopper to the
clip (3) on the K225 nozzle. Make sure that the mating surface (8) between the
Center Block (4) and the Copper Bar (2). is bright,
8. Spacing between the electrodes is maintained by clean and smooth. This junction carries the full weld
the center block which comes in three sizes. The current.
.50 “ and .625” center blocks come with the kit. A
.375” block is also available. See the parts list for
the part number. To change the center block,
See Figure A-30:
• Loosen both of the Pressure Springs (5)
• Remove the two Socket Head Screws (7)
• Put a small amount of graphite grease on
the screw threads and install the new copper
block.
• Replace the two screws and tighten securely
• Tighten the four screws holding the Pressure
springs

4. Insert one wire through each of the guide block

holes.
K281 SOLID WIRE STRAIGHTENER FOR
TINY TWINARC®
The K281 wire straightener can be used to straighten 5. Push both wires through and between the rollers
.045” through 3/32” (1.0-2.4mm) wiress. It is recom- and down through the guide tube until they touch
mended for applications requiring long stickout and/or the drive roll(s). Press the Cold Inch to start the
where accurate wire placement is essential. The fol- wires through the wire drive.
lowing table shows the recommended maximum ele-
crical stick-out (ESO). 6. Replace the upper guide block making sure that
each wire is in its respective groove of both
ESO - Standard ESO - K281 rollers. Tighten the thumb screw.
Wire Size (mm) Wire Guide (mm) Straightener (mm)
7. Turn the adjusting knob until the moving arm is
.045” (1.0) 3/8” (9.5) 5/8” (16.0) approximately at the mid position of its total trav-
.052” (1.3) 1/2” (12.5) 3/4” (19.0) el.
1/16” (1.6) 3/4” (19.0) 1-1/4” (32.0) FIGURE C.21
5/64” (2.0) 1.00” (25.4) 1-3/4” (44.5)

3/32” (2.4) 1-1/4” (32) 2.0” (51)
E
GENERAL INFORMATION C
1. For best wire straightening the plane of the

D
K281rolls (A) should be as close as possible to

the plane of the wire reels.
B
2. The K281 moving arm (B) should be pointing

toward the wire reels and the adjusting knob (C)
should be away from the reels.
3. The K281 can be mounted to the wire drive in

two different positions. The head can then be
positioned to meet the above requirements.
INSTALLATION
Under Over
Straightened Straightened
1. Remove the Spring Wire Guide if installed.

The tips should be in line with the O.D. of the drive
2. Remove the K129 Ingoing Guide Tube. rollsfor initial strightening adjustment. If the wires bow
to the right when inched down through the tips they
3. Insert the new Ingoing Wire Guide (with ceramic are being over straightened. If the wires bow to the
inserts) that comes with the K281. left, they are being understraightened. Adjust the knob
until the wires come out parallel and uniform.
4. Position the K281 over the wire guide as outlined
above and tighten the two hex head screws. Depending on how the wire enters the K281, there
may be some side bow. Slight rotation of the K281
WIRE LOADING AND ADJUSTMENT may eliminate this condition.
1. Turn the adjusting knob (C) to the maximum Once the wire is sufficiently straight, the tip orientation
open position. can be changed to whatever angle between “in-line”
and “cross seam” is required.
2. Remove the top ingoing guide block (D) by loos-
ening the thumb screw (E). NOTE: For overlay applications with Tiny Twinarc, a
special side by-side tipholder (Part # S17728
3. Straighten the first 10” (254mm) of each wire (the is available that accepts standard tips.
straighter the wire the easier to load).

D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS SENSE LEAD FUSE
the sense leads! The sensing lead circuit is current

There should never be any current flowing through
protected in the Power Wave® AC/DC 1000 SD.

WARNING
If the MAXsa™ 22 & 29 Wire Drives are used in an
older system, a fuse in series with the #21 sense lead
ELECTRIC SHOCK can kill.
in the wire drive Connection Box protects the sense
lead circuit from weld current due to incorrect configu-
• Only Qualified personnel should
ration. If this fuse ever opens, check the sense lead

perform this maintenance.
configuration to ensure proper connections. The fuse

• Turn the input power OFF at the
must be replaced with a comparable fuse with a rating
disconnect switch or fuse box
of less than 1 amp before welding. The fuse being
before working on this equipment.
open or missing would have the same effect on the
welding as having a disconnected sense lead.
• Do not touch electrically hot parts.
ROUTINE MAINTENANCE
• Check weld cables, control cables and gas hoses for
cuts.
• Clean and tighten all weld terminals.
• Inspect and clean drive rolls and inner wire guide
and replace if worn.
PERIODIC MAINTENANCE
• Every six months check the motor brushes. Replace
them if they are less than 1/4" long.
• Every year inspect the gearbox and coat the gear
teeth with a moly-disulfide filled grease. DO NOT
use graphite grease.
CALIBRATION SPECIFICATION
All calibration is factory set on the MAXsa™ Wire Drive.
To verify the wire feed speed:
• Adjust the wire feed speed to 100 in/min (2.54m/min)
and provide a COLD FEED Signal.
• Measure the actual wire feed speed with a calibrated
wire feed speed tachometer K283).
• The measured wire feed speed should be within ±2%
of the set value.
NOTE: If a K283 is not available, feed wire for 15 sec-
onds and measure the wire. Repeat several
times to get an average measurement. It should
be 25” (635mm) +/-2%.

E-1 TROUBLESHOOTING E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions. This column provides a course of action for the
Step 3. RECOMMENDED COURSE OF ACTION
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
Step 1. LOCATE PROBLEM (SYMPTOM).
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
The second column labeled “POSSIBLE CAUSE” lists

Step 2. POSSIBLE CAUSE.
the obvious external possibilities that may contribute

to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

E-2 TROUBLESHOOTING E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Drive rolls turn, but wire will not 1. Wire jammed or kinked on route
feed or wire feeding is rough or through wire drive. Remove wire
uneven. from wire drive, then feed in new
wire. Note any obstruction.
2. Incorrect drives rolls and/or

guide tubes, or incorrect pres-
sure setting. Ensure drive rolls
and/or guide tubes are stamped
with wire diameter being used.
Replace if necessary. Check for
proper pressure setting.
3. Worn drive rolls. Replace, or

reverse if split type.
4. Partially flashed or melted con-

tact tip. Replace contact tip. If all recommended possible areas
of misadjustments have been
checked and the problem persists,
Variable or "hunting" arc. 1. Contact tip worn or incorrect
size. Replace contact tip.
contact your local Lincoln
Authorized Field Service Facility.
2. Worn or undersized work cables

or poor connections to work.
Inspect and repair, or replace as
necessary.
3. Loose electrode connections.

The following connections must
be tight: electrode cable to wire
drive and power source, work
cable to power source and work,
contact tip to nozzle.
4. Rusty electrode. Replace elec-

trode.
Wire consistently runs at the wrong Gear ratio is not set properly. See
speed the MAXsa™ 10 or the Power
Wave® AC/DC 1000 Operatorʼs
Manual to set the proper gear ratio.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
F-1
DIAGRAMS

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
F-2
.62 2.50
3/8-16 TAPPED HOLE .41
(4 PLACES)
4.70 .50
2.69 2.50
4.24
.50
.96
O .562 (2 HOLES)
7.70
CENTERLINE OF WIRE
CENTERLINE OF WIRE
3.50
12.04
DIMENSION PRINT

6.16 6.16
5.19
2.60
2.82
2.48 .21 13.56
4.22
9.82
A.01
L13370
F-2
Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
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
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.
PRECAUCION Aislese del trabajo y de la tierra.
French Ne laissez ni la peau ni des vête- Gardez à l’écart de tout matériel Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
Isolez-vous du travail et de la terre.
German Berühren Sie keine stromführenden Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
Não toque partes elétricas e elec- Mantenha inflamáveis bem guarda- Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or
Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
Los humos fuera de la zona de res- Spanish
Desconectar el cable de ali- No operar con panel abierto o
piración.
Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
Gardez la tête à l’écart des fumées. Débranchez le courant avant l’entre- N’opérez pas avec les panneaux French
Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
Vermeiden Sie das Einatmen von Strom vor Wartungsarbeiten Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
Mantenha seu rosto da fumaça. Não opere com as tampas removidas. Mantenha-se afastado das partes
Use ventilação e exhaustão para Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. Não opere com os paineis abertos ATENÇÃO
Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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RETURN TO MAIN MENU

For use with machines having Code Numbers: 11615, 11616

Safety Depends on You

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

1.h. To avoid scalding, do not remove the

2.d.4. Connect the work cable to the workpiece as close as

5.e. Read and understand the manufacturer’s instructions for this

5.f. Also see item 1.b.

6.j. Do not use a welding power source for pipe thawing.

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

7. Quand on ne soude pas, poser la pince à une endroit isolé de

échauffement et un risque dʼincendie.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

On-Line Product Registration

Product Description .....................................................................................................................A-1

Recommended Processes ..........................................................................................................A-1

Routine operation ........................................................................................................................B-1

Starting Techniques .............................................................................................................B-1

Options and Accessories Website ..............................................................................C-1

Motor Conversion Kit For (142:1 NA Style Wire Drives)........................................C-1

Safety Precautions ................................................................................................D-1

Routine and Periodic Engine Maintenance ...........................................................D-1

How to Use Troubleshooting Guide.......................................................................E-1

The MAXsa™ series of Automatic Wire Drives are

The MAXsa™ 22 & 29 WIRE DRIVES consist of a

• The MAXsa™ series of wire drive packages are

The MAXsa™ series of wire drives cannot be used

COMMON EQUIPMENT PACKAGES

• K2803-1 Power Wave® AC/DC 1000 SD

• K2814-1 MAXsa™ 10 Controller/Feed Head

• K2370-1 MAXsa™ 22 Wire Drive

Basic Package with optional kits:

• K2803-1 Power Wave® AC/DC 1000 SD

• K2311-1 MAXsa™ Motor Retrofit Kit

• K2312-2 MAXsa™ 29 Wire Drive

• K2626-2 Wire Drive Controller (for fixture

MAXsa™ 22 & 29 WIRE DRIVES

• Closed-loop speed control.

• Knurled drive rolls.

FIGURE A.1 - LOCATION OF MAXsa™ 22 COMPONENTS

MAXsa™ 22 & 29 WIRE DRIVES

• Closed-loop speed control.

• Knurled drive rolls.

FIGURE A.2 - LOCATION OF MAXsa™ 29 COMPONENTS

Gear Box Drive Rolls

MAXsa™ 22 & 29 WIRE DRIVES

TECHNICAL SPECIFICATIONS - MAXsa™ 22 & 29 WIRE DRIVES

32V DC 7 Amps (max.)

K2370-2 14.0in (355mm) 10.0in (254mm) 80.0lbs (36.3kg)

-4°F to 104°F (-20°C to 40°C) -40°F to 185°F (-40°C to 85°C)

MAXsa™ 22 & 29 WIRE DRIVES

MAXsa™ 22 & 29 WIRE DRIVES

SYSTEM CONNECTIONS (See Figure A.3)

FIGURE A.3 - CONNECTION DIAGRAM

FIGURE A.4 - MOUNTING DIMENSIONS

MAXsa™ 22 & 29 WIRE DRIVES

5. Carefully disconnect the Motor leads from the har-