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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 LINCOLNELECTRIC ® Copyright © 2003 Lincoln Global Inc. World’s Leader in Welding and Cutting Prodcuts 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: Prince® XL - Owner's Manual -Page i Prince® XL - Owner's Manual -Page ii Prince® XL - Owner's Manual -Page iii Prince® XL - Owner's Manual -Page iv Prince® XL - Owner's Manual -Page v Thank You For selecting a quality product. We want you to take pride in operating this product...as much pride as we have in bringing the product to you! 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. Model Name & Number _____________________ Code & Serial Number _____________________ Date of Purchase _____________________ Whenever you request replacements parts for, or information on this equipment always supply the information you have recorded above. Read this Owner’s 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. Prince® XL - Owner's Manual -Page vi Table of Contents SAFETY CONSIDERATIONS .................................................... I-VI INSTALLATION ........................................................ SECTION A TECHNICAL SPECIFICATIONS ............................................................... 3 SUPPORT EQUIPMENT REQUIRED...........................................................3 TORCH LEAD CONNECTION................................................................3 INSTALLING SPOOL ASSEMBLY ............................................................. 4 INTERCONNECTIONS ...................................................................... 5 OPERATION .......................................................... SECTION B GENERAL ............................................................................... 4 BARRELS ................................................................................ 6 CONTROLS AND SETTINGS................................................................. 6 DRIVE ROLL AND IDLER ROLLS ............................................................ 7 ACCESSORIES......................................................... SECTION C CONTACT TIPS .......................................................................... 8 BARREL LINERS .......................................................................... 8 BARREL ASSEMBLIES ...................................................................... 9 OPTIONAL BARRELS ...................................................................... 9 OPTIONAL KITS..........................................................................9 OPTIONAL ACCESSORIES .................................................................. 9 PRINCE SPOOL GUN CONTROLS ..........................................................10 FINNED COPPER GAS CUPS...............................................................8 MAINTENANCE........................................................ SECTION D PERIODIC MAINTENANCE .................................................................11 RECOMMENDED SPARE PARTS LIST........................................................13 TROUBLESHOOTING ................................................... SECTION E TROUBLESHOOTING GUIDE ...............................................................14 TESTING THE TORCH.....................................................................16 APPENDICES.......................................................... SECTION F DIAGRAMS/PARTS LIST..................................................................17 MECHANICAL ...........................................................................18 ELECTRICAL ............................................................................25 MK REPAIR STATIONS SAFETY WARNINGS WARRANTY THIS PAGE INTENTIONALLY BLANK SECTION A INSTALLATION TECHNICAL SPECIFICATIONS PRINCE® XL TORCH - 25’-P/N K2296-2 Wire Capacity • .023”-.045” (0.6 - 1.2mm) solid and hard wire • .030” - 1/16” (0.8 - 1.6mm) aluminum and cored wire Wire Speed • 750 ipm (19.0 mpm) max. Duty Cycle - 100% All ratings are at 25V using Argon Gas • 200 Amps Air cooled standard, using Air/Water barrel Torch weight (less leads & standard barrels) • 36.4 oz. (1.02 kilogram) PRINCE® XL SPOOL...