Lincoln Electric ACTIV8 Operator'S Manual Download Page 1

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Operator’s Manual

ACTIV8

™

Register your machine:

www.lincolnelectric.com/registration

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

IM10085-A

| Issue D ate

May-16

For use with machines having Code Numbers:

11770, 12198

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

Summary of Contents for ACTIV8

Page 1: ...ation Authorized Service and Distributor Locator www lincolnelectric com locator IM10085 A Issue Date May 16 Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 11770 1219...

Page 2: ...he general area IN A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you...

Page 3: ...y guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 e...

Page 4: ...ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suita...

Page 5: ...lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow NFPA 51B Standard f...

Page 6: ...compatible This may require additional protection measures h the time of day that welding or other activities are to be carried out The size of the surrounding area to be considered will depend on th...

Page 7: ...2 Case Front Controls B 3 Internal Controls B 4 B 5 Rear Controls B 5 Constant Current Operation B 6 Setting Arc Sensing wire Feed Speed For Constant Current Operation B 6 B 7 Making a Weld B 8 _____...

Page 8: ...50 C RATED CURRENT INPUT VOLTAGE TECHNICAL SPECIFICATIONS ACTIV8 K2999 1 HEIGHT WIDTH DEPTH WEIGHT 11 8 Inches 7 6 Inches 19 8 Inches 27lbs 298 mm 193mm 503 mm 12 2kg SPOOL SIZE CAPABILITY 8 200mm Dia...

Page 9: ...late the hanging device from the wire feeder enclosure HIGH FREQUENCY PROTECTION Locate the ACTIV8 away from radio controlled machinery The normal operation of the ACTIV8 may adversely affect the oper...

Page 10: ...lier of this condition Oil or grease in the presence of high pressure oxygen is explosive 3 Stand to one side away from the outlet and open the cylinder valve for an instant This blows away any dust o...

Page 11: ...aligns with the thumb screw hole in the feedplate Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned 10 Tighten the socket head cap screw 10 to 14 ft lbs 1...

Page 12: ...Steel Stainless wires between 3 and 5 WARNING LOADING SPOOLS OF WIRE Keep hands hair clothing and tools away from rotating equipment Do not wear gloves when threading wire or changing wire spool Only...

Page 13: ...ec onds after the gun trigger is released Do not operate with covers panels or guards removed or open Only qualified personnel should perform mainte nance work The ACTIV8 comes with a K1500 2 gun adap...

Page 14: ...6 XX KP1697 XX See Magnum Literature K1803 XX Description ACTIV8 Drive Roll Kit Welding Gun CC power Source Welding Cables POWER SOURCE TO ACTIV8 CABLE CONNECTION DIAGRAMS K K2999 1 KP1696 XX KP1697 X...

Page 15: ...position K K2999 1 KP1696 XX KP1697 XX See Magnum Literature K1803 XX Description ACTIV8 Drive Roll Kit Welding Gun CC power Source Welding Cables Work clip Work Electrode ACTIV8 RANGER 250 250 LPG RA...

Page 16: ...A 8 Place CV CC switch in the feeder in the CV position CV 250 CV 300 Work Electrode Jumper Work clip ACTIV8 FIGURE A 8 K K2999 1 KP1696 XX KP1697 XX See Magnum Literature K1841 XX K852 95 K484 Descri...

Page 17: ...ith gun trigger electrode and drive mechanism Only qualified persons should install use or service this machine are hot to work and ground Turn off the Welding Power Source before installing or changi...

Page 18: ...ure plate chemistry and temperature weldment design fabrication methods and ser vice requirements The available range of the ACTIV8 wire feeder may not be suitable for all applications and the builder...

Page 19: ...e The patented features on the wire drive offer tool less changing of the drive rolls and wire guides for quick spool changes A tachometer controlled motor powers the patented drive rolls for smooth s...

Page 20: ...depressed when the feeder is powered up the feeder will not activate Release and then press the gun trigger to begin welding 3 WORK LEAD Always turn power off at the welding power source before moving...

Page 21: ...he gun FIGURE B 2 1 5 2 3 6 8 7 4 When gas purging the gas solenoid valve will energize but neither the power source output nor the drive motor will be turned on The Gas Purge switch is useful for set...

Page 22: ...ntinue to feed wire until the gun trigger is again pulled and then released 4 CV CC SWITCH The CV CC switch sets the wire feed speed con trol method for the wire feeder Place the rocker switch in the...

Page 23: ...rocedure plate chemistry and temperature weldment design fab rication methods and service requirements The available range of the ACTIV8 wirefeeder may not be suitable for all applications and the bui...

Page 24: ...ure B 5 Lincoln Electric does NOT recommend constant current semiautomatic welding for applications which need to meet specified weld metal chemical or mechanical property requirements or weld quality...

Page 25: ...TIV8 electrode and work cable to the power source for the polarity and process to be used Check that the appropriate power source set tings are made for the procedure to be used Refer to the power sou...

Page 26: ...040 045 1 0 1 2mm 052 1 4mm 1 16 1 6mm 068 1 7mm 5 64 2 0mm KP KIT KP1696 030S KP1696 035S KP1696 045S KP1696 052S KP1696 1 KP1696 2 KP1697 035C KP1697 045C KP1697 052C KP1697 1 16C KP1697 068 KP1697...

Page 27: ...1 2m long with Ground Clamp and Twist Mate to Lug 2 0 Cable 9 2 7m long Includes Twist Mate to Lug 1 0 cable of length xx Includes Twist Mate to Twist mate 1 0 Cable of length xx for length 25 7 6m T...

Page 28: ...c tors Magnum 550 guns and com patible with Tweco 5 Gun Receiver Bushing for gun with K466 3 Lincoln gun connec tors compatible with Miller guns Incoming Bushing for Lincoln Conduit Deluxe Adjustable...

Page 29: ...nal strip Only qualified personnel should install use or service this equipment WARNING SAFETY PRECAUTIONS ROUTINE MAINTENANCE Routine maintenance consists of periodically blowing out the machine usin...

Page 30: ...51 IPM proceed to step 8 If not unplug J3 insert shorting plug into Control PC Board J3 shorts pins 4 8 and adjust WFS knob to 49 to 51 IPM and remove the shorting plug 8 Set WFS knob to 300 IPM 9 Mea...

Page 31: ...AUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it...

Page 32: ...or has spatter 6 Improper gun liner tip drive rolls and or inner wire guide 7 Incorrect tension arm pressure on the drive rolls 8 The spindle brake is too tight 9 Worn drive roll 1 Connect the work le...

Page 33: ...rushes on the motor are worn 1 The tachometer is connected improperly 2 The tachometer has failed 1 Wrong size worn and or melted contact tip 2 Worn work cable or poor work connection 3 Wrong polarity...

Page 34: ...y 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 th...

Page 35: ...F 2 DIMENSION PRINT F 2 ACTIV8 L16081 A 02 19 57 19 80 7 60 13 CIRCLE 11 X 14 ELLIPSE 11 73...

Page 36: ...NOTES ACTIV8...

Page 37: ...ACTIV8 P 677 P 677 PARTS LIST FOR ACTIV8...

Page 38: ...ACTIV8 09 15 2011 P 677 A P 677 A ILLUSTRATION OF SUB ASSEMBLIES 1 1 2 2 3 3...

Page 39: ...below to determine which sub assembly page and column the desired part is located on for your particular code machine P 677 A 1 P 677 A 1 ACTIV8 For Code 11770 12198 CODE NO 11770 1 1 1 1 12198 1 1 1...

Page 40: ...le Brass T15008 1 X Flex Tube T10642 325 1 X Ground Lead Assembly S17211 7 1 X 05 31 2012 Use only the parts marked x in the column under the heading number called for in the model index page Indicate...

Page 41: ...ACTIV8 NOTES...

Page 42: ...ACTIV8 09 15 2011 P 677 C P 677 C Plastic Case Assembly 1A 1A 3 3 2 2 1B 1B 5 5 13A 13A13B 13B 13C 13C 7 7 1D 1D 1E 1E 1C 1C...

Page 43: ...go Not Shown L16002 8 Part of L16002 NSS 1 X 7 Decal Lincoln Logo L16002 9 Part of L16002 NSS 1 X 8 Decal Product Name Not Shown L16002 10 Part of L16002 NSS 1 X 9 Decal Product Name Not Shown L16002...

Page 44: ...32 35 35 27 27 2B 2B 5A 5A 37 37 39 39 38 38 40 40 3 3 30A 30A 30B 30B 31A 31A 31B 31B 23 23 24 24 22 22 21 21 20 20 19 19 18 18 4B 4B 4E 4E 7A 7A 9 9 10 10 13 13 14 14 11 11 8A 8A 8B 8B 4G 4G 4F 4F 6...

Page 45: ...X 7B Set Screw Not Shown S11604 21 1 X 8A Cover M19999 1 X 8B Thread Forming Screw S9225 102 1 X 9 Drive Roll Shaft Assembly S25638 2 X 10 Retainer S25403 2 X 11 Wire Guide Assembly KP2071 3 1 X 12A...

Page 46: ...38 Decal 2 Step Trigger Interlock L16002 6 Part of L16002 NSS 1 X 39 Decal CV CC L16002 7 Part of L16002 NSS 1 X 40 Decal Panel L16002 4 Part of L16002 NSS 1 X Oct 13 ACTIV8 Use only the parts marked...

Page 47: ...ACTIV8 NOTES...

Page 48: ...ACTIV8 10 17 2011 P 677 E P 677 E P C Boards Fan Contactor Assembly 10A 10A 17A 17A 18A 18A 18B 18B 19B 19B 17B 17B 9A 9A 6A 6A 7A 7A 7D 7D 8 8 5A 5A 14A 14A 21 21 20 20 14B 14B...

Page 49: ...6 P20 P61 J7 Not Shown G6754 1 X X 14A Cord Grip Connector S19999 5 1 X X 14B Conduit Lock Nut T14370 2 1 X X 17A Solenoid Assembly M17294 8 1 X X 17B Conduit Lock Nut T14370 1 1 X X 18A Flex Tube T10...

Page 50: ...ACTIV8 NOTES...

Page 51: ...NOTES ACTIV8...

Page 52: ...tomer 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...

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