WIRE FEEDER IM775-A MK 091-0612

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October 2007

OPERATOR’S MANUAL

Cobramatic ®

K2259-1
For use with code 11480

Safety Depends on You

Lincoln arc welding equipment is
designed and built with safety
in mind. However, your overall
safety can be increased by proper
installation...and thoughtful oper-
ation 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.

Copyright © 2007 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
Table of Contents

Safety Guidelines .................................................................................................i-vi

Installation ................................................................................................. Section A

Technical Specifications ............................................................................................................... 1
Machine Grounding...................................................................................................................... 1
Mounting Location........................................................................................................................ 1
Input Power Connections ............................................................................................................. 1
Wire Threading Procedure ........................................................................................................... 1
Welding Gun Connections ........................................................................................................... 3

Operations .................................................................................................Section B
General Description ..................................................................................................................... 3
Recommended Processes and Equipment.................................................................................. 4
Controls and Settings................................................................................................................... 4
PosaStart® Operating Procedure ................................................................................................. 6
Remote Operation........................................................................................................................ 7

Accessories ...............................................................................................Section C
Optional Kits................................................................................................................................. 7

Maintenance ..............................................................................................Section D
Routine Maintenance ................................................................................................................... 7
Testing the Feeder ....................................................................................................................... 8
Testing the Gun ............................................................................................................................ 8

Troubleshooting.........................................................................................Section E
Troubleshooting Guide ................................................................................................................. 9

Diagrams/Parts List .................................................................................. Section F

Diagrams Table of Contents........................................................................................................11
Main P.C. Board Connections .................................................................................................... 13
Cabinet and Gun Hook-Up......................................................................................................... 14
Mechanical ................................................................................................................................. 15
Electrical..................................................................................................................................... 23

Safety Warnings

Warranty

Cobramatic® Owner’s Manual

Declaration of Conformity for
European Community (CE) Products
Note This information is provided for units with CE certification (see rating label on unit).

Manufacturer’s Name: MK Products, Inc.

16882 Armstrong Ave.
Irvine, CA 92606

Declares that the product: Cobramatic®

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

Electromagnetic Compatibility (EMC) Directive: 89/336/EEC

Standards

Arc Welding Equipment Part I: Welding Power Sources: IEC 60974-1

(September 1998 - Second Edition)

Arc Welding Equipment: Wirefeed Systems: IEC 974-5

(September 1997 - Draft Revision)

Degrees of Protection Provided by Enclosures (IP Code): IEC 529:1989

(November 1989 - First Edition)

Insulation Coordination For Equipment With Low-Voltage Systems:

Part I: Principles, Requirements and Tests: IEC 664-1: 1992
(October 1992 - First Edition)

Electromagnetic Compatibility, (EMC): EN 50199

(August 1995)

Torches And Guns For Arc Welding, EN 50078

Cobramatic® Owner’s Manual

Cobramatic® Safety - page i

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Cobramatic® Safety - page iii

Cobramatic® Safety - page iv
Cobramatic® Safety - page v

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Cobramatic® Safety - page vi

Section A Installation
Technical Specifications
Wire Diameter Capacity ............................. .030” - .045” Solid and Hard wire
...................................................................... .030” - 1/16” Aluminum
Wire Capacity ...................................................... 12” Standard
(Insulated or Non-Insulated)
Power Input ......................................................... 42 VAC 50/60 Hz,
............................................................................... 150 Watts Peak (3 amps)
Weight .................................................................. 42 pounds
Shipping Weight ................................................. 47 pounds
Support Equipment Required
C.V. or C.C. Power Source of Sufficient Capacity for Your Needs.
Regulated Gas Supply and Hoses.
Properly Sized Power Leads from Power Source to Wire Feeder and Ground.
Coolant Recommendations (for Water Cooled Guns)
Water Source and Hose Capable of Providing a Minimum of 1 qt/min. at 45
p.s.i. when using water cooled guns.
MK Recommended Coolant Solution:
1 part ethylene glycol
3 parts distilled water
1 teaspoon liquid glycerin
Check coolant periodically to remain within limits of the following:
A. Coolant Flow rate - 1 quart/minute at 45 p.s.i.
B. Resistivity - 10K ohms/centimeter
C. Ph Range - 5.5-8.5
D. Particle Size - .005”

Machine Grounding
The Cobramatic® and GMAW wire feeders are grounded to the power source
through the input cable. The power source grounding terminal must be prop-
erly connected to electrical ground per the power source operating manual.

Mounting Location
The cabinet should be placed in a location where it can be protected from
damage. Lead lengths and accessibility must also be considered when
installing the cabinet.

Input Power Connections

Your Wire Feeder comes factory ready with a harness to plug directly into all
14 pin Lincoln Power Sources equipped with 42 VAC auxiliary.
The 42 VAC is connected to the PC Board on terminal strip J5 #1 (neutral-
white) and #2 (hot-black) and Ground (green) to the Cabinet chassis. See
diagram in the appendix.

Wire Threading Procedure

Wire Spool Installation
Release latches, and open right side door of cabinet.
Remove spool retainer nut from spindle hub.

Cobramatic® Owner’s Manual - page 1

Raise wire retainer bar to latched position.
Install wire spool onto spindle hub so that wire feeds from bottom of spool
towards slave motor. Make sure that the hole in the wire spool aligns with
pin on spindle hub. The white dot on the end of the spindle hub will aid in
this alignment.
Replace the spool retainer nut.
Lower the wire retainer bar onto the spool.
Wire Spool Drag Setting
NOTE:
Standard factory setting of the Spindle Tension Knob is set for All
Other Wires.

There are two visible position settings for this Knob, IN - All Other Wires
(Fig. 1) and, OUT - .030”/.035” Al Only (Fig. 2). The Spindle Tension Knob
must be set to match the Wire Size Selector Switch on the Cobramatic® front
panel.
To change this setting, it is easier done without the spool of wire on the spin-
dle. Remove the wire spool retainer nut and re-install it reversed back onto
the Spindle Tension Knob (Fig. 3). In the “Tool Mode”, the square shaped
end of the retainer fits onto the Knob. Grab the retainer nut and turn in the
COUNTER-CLOCKWISE direction until it stops. The Knob is now set to the
OUT position (.030”/.035” AL Only).

IN - All other wires OUT - .030/.035 Aluminum ONLY Wire Spool Retainer In "Tool Mode";
Figure 1 Figure 2 used to change spindle drag.
Figure 3
To reset the Knob back to the factory setting of All Other Wires, use the
retainer nut as described above, and turn in the CLOCKWISE direction until
it stops. The Spindle Knob is now set to the IN position. Turning the retainer
nut and Spindle Knob in this direction may require more effort, since turning
CLOCKWISE is working against a spring.
Load wire spool onto spindle according to the previous instructions.
Replace the spool retainer nut.
Lower the wire retainer bar onto the spool.
Wire Threading Procedure
Place wire size selector switch on front panel to the correct position for the
wire being used.
Loosen end of wire from spool and cut off any kinked or bent portions.
Unreel and straighten out first 6” to 8” of wire.
Raise wire type lever on the slave motor assembly of gun to center position.
Route wire into inlet guide, along drive roll groove, and into wire conduit.
Flip wire type lever to display name of wire type being used.
When using a Cobra® Gold or Prince® XL gun tighten the gun pressure
adjusting knob so the wire will be picked up and fed through the contact tip.
Proper tension is achieved when wire does not slip if a small amount of pres-
Cobramatic® Owner’s Manual - page 2
sure is added to the wire as it exits the tip.
Wire Retainer Bar
The design of the patented Cobramatic® Wire Retainer Bar performs two very
important and very basic functions of the wire feeder: a) spool drag tension,
and b) wire maintenance on the spool.
The spool drag tension is set by lowering the wire retainer bar onto the sur-
face of the wire inside of the spool. The spring tension of the wire retainer
bar applies enough pressure on the spool so that when the gun trigger is
released, engaging the brake pall, the spool does not overrun kicking wire off
the spool.
Wire maintenance on the spool is performed by the applied pressure of the
wire retainer bar spread across the coiled wire on the spool. The replace-
able pad (P/N 437-0255) of the wire retainer bar is designed to hold the wire
on the spool, maintaining the smooth layering of the wire and keeping it from
jumping off, and possibly, electrically shorting to the cabinet chassis.

Welding Gun Connections

Control Cable
The 7-Pin “W” Clocked connector screws onto the mating receptacle on the
front panel of the wire feeder. This provides all electrical signals (motor volt-
age, potentiometer control & trigger) to and from the feeder to the gun.
Water Inlet (For Water Cooled Guns)
Front panel access to connect the water hose to the middle fitting on the
power block.
Wire Conduit Inlet
Front panel access to attach conduit to front of slave motor assembly.
Power Cable Inlet
Front panel access to attach power cable (air or water) to top of power block.
Guns with ring lugs, MUST connect to top bolt of power block.
Gas Inlet
Front panel access to attach gas hose to bottom fitting of power block.
Work Cable (Ground)
Connect a work lead of sufficient size and length between the proper output
stud on the power source and the work. Be sure the connection to the work
makes tight metal to metal electrical contact. Improper work lead connec-
tions can result in poor arc initiation and unsatisfactory weld results.
Consult welding power supply manufacturer for proper work lead sizing.

Section B Operation
General
The AC slave motor in the feeder runs at a fast, constant speed, but has very
low torque. It is always trying to feed more wire than the gun motor wants,
and when the gun motor gets all the wire it wants, the slave motor automati-
cally slows, preventing a bird’s nest. Because of the low torque produced
by the slave motor, a combination drag and electric brake system is used to
prevent wire overrun rather than relying on spindle tension alone. The spool
drag tension is produced by the patented Wire Retainer Bar mechanism to
keep the wire slightly taut. The 24 VDC gun “pull” motor is controlled by a
solid state speed control in the cabinet and through a potentiometer located
in the gun.

Cobramatic® Owner’s Manual - page 3

The normal operating sequence of the wire feeder can be viewed on the
board itself via sequence LED’s. When the system is triggered, the green
Trigger LED (L3) and the yellow Gas Solenoid LED (L1) illuminate simultane-
ously. The red Contactor/Wire Feed LED (L2) illuminates after the prepurge
time. The blue Arc On LED (LED) illuminates as the arc is established. When
the trigger is released the normal LED operating sequence is blue, green and
red (L4, L3, & L2) turn off simultaneously followed by the yellow (L1) after the
postpurge time has elasped (Figure 4).
Yellow LED Red LED when
when solenoid wire feeds/con- Green LED Blue LED
opens. tactor closes. when triggered. when arc established
L1 L2 L3 L4

Figure 4 - L1, L2, L3 & L4

FOR REFERENCE, SEE MAIN P.C. BOARD CONNECTIONS PICTURE IN SECTION F
Recommended Processes and Equipment
The Cobramatic® is recommended for use in the GMAW and FCAW weld-
ing applications. It is recommended for use with constant voltage power
sources. The Cobramatic® is capable of feeding wires (diameter capacity)
ranging from .030” through .045” solid/cored and .030” through 1/16” alumi-
num.

Controls and Settings

On/Off Switch
Placing the switch in the “ON” position energizes the feeder circuitry and the
power indicator light.
Wire Size Selector Switch
The wire size selector switch changes the torque of the slave motor for the
wire you are using. When in the .030” - .035” aluminum only position, the
slave motor produces approximately 1 1/2 lbs inches and approximately
4 1/2 lbs inches when in the all other wires position.

NOTE:
Operating the cabinet with the switch in the wrong
position will cause wire feed difficulties.

PosaStart Switch & Run Speed Setting

The Posa Start Run-in Speed Control, located on the front panel, provides
wire speed adjustment for slow wire run-in. This setting tracks as a percent-
age of the welding wire speed setting. Once the arc has been established,
the wire feed speed automatically changes from the slow run-in speed to the
welding wire speed set on the gun potentiometer.
PosaStart operation and configuration is explained later in this section.
Trigger Normal/Trigger Latched
This switch configures the electronic Trigger Latching mechanism. In the
Trigger Normal mode, pull and hold the trigger to start welding functions
- release to stop welding functions. In the Trigger Latched mode, pull and

Cobramatic® Owner’s Manual - page 4

release trigger to start welding functions - pull trigger again and release to
stop welding functions.
The Prepurge/Postpurge functions are pre-configured to provide a preset
amount of pre & postpurge gas time; 0.25 and 2.0 second respectively. The
default factory position of this jumper is horizontal (top right) across pins.
Changing the position of the JP3 jumper changes the configuration of the pre
& postpurge sequences. Refer to Figure 5 for the desired pre and postpurge
sequence. Once the desired sequence is selected, relocate on JP3 jumper
from its horizontal default pattern (top right) to its new vertical sequence posi-
turn.

Figure 5

Pre-Purge Settings & Adjustments (JP2)

The Pre-Purge Jumper/Pot Configuration at JP2 has 3 available settings:
0.25 sec. fixed, variable from 0-1 sec. or variable from 0-5 seconds.
By default, the twin two-pin jumpers, across rows 1 & 3, are configured for
0.25 sec. Just to the left of the jumpers is a ¾-turn potentiometer (pot) which
is used with both variable settings. For the 0-1 sec. range, move the jumpers
across rows 3 & 5. For the 0-5 second range, move the jumpers across rows
5 & 7 (Figure 6a).

Rows 1 & 3: 0.25 sec. fixed Rows 3 & 5: 0-1 sec. Rows 5 & 7: 0-5 sec.
Figure 6a

Timing adjustment for the variable settings are as follows: Move the jumpers
to either variable setting location. Turn potentiometer screw (Small flat or
cross-head) half way. Pull gun trigger and count time between red contactor
wire feed LED (L2) and yellow Gas Solenoid LED (L1). Adjust pot screw as
necessary.

Post-Purge Settings & Adjustments (JP1)

The Post-Purge Jumper/Pot Configuration at JP1 has 2 available settings: 2
sec. fixed and variable from 0-5 seconds.
By default, the two-pin jumper across the top-and-middle pins, is configured
for 2 sec. Just to the left of the jumper is a ¾-turn pot which is used with the
variable setting. For the 0-5 second range, move the jumper from the top-
and-middle to the middle-and-bottom pins (Figure 6b).

Cobramatic® Owner’s Manual - page 5

Middle/Bottom: 0-5 sec. Top/Middle: 2 sec fixed
Figure 6b
Timing adjustment for the variable settings are as follows: Move the jumpers
to variable setting location. Turn potentiometer screw (Small flat or cross-
head) half way. Upon release of gun trigger, count time between yellow Gas
Solenoid LED (L1) and green Trigger LED (L3). Adjust as necessary.

Posa Start Operating Procedure

CAUTION:
Do not operate this wire feeder on a power source having a high-fre-
quency (HF) starting circuit until the high frequency feature has been
turned off or disabled. Failure to disable the HF will result in damage
to the PosaStart circuitry of the main board.

General
The Posa Start Run-in Speed Control, located on the front panel, provides
adjustment for slow wire run-in. Once the arc has been established, the wire
feed speed is automatically changed from the slow run-in speed to the weld-
ing speed set on the gun potentiometer.
The Posa Start feature allows the Cobramatic® feeder and gun to be used
in conjunction with constant current DC welding power sources of open cir-
cuit voltage in excess of 55 volts - also, any constant voltage welding power
source capable of a minimum of 50 amps.
Once the PosaStart circuit has transferred from slow run-in to weld speed,
the blue LED (L4) illuminates (Figure 7).

Blue LED
when PosaStart engages.
L4

Figure 7
CV/CC Posa Start Operations
NOTE:
CV Posa Start does not need welding voltage sensing lead.

The default factory setting is CV mode. Attach Cobramatic® cabinet to CV

power source according to the installation instructions.
Turn the Cobramatic® cabinet to the “ON” position and the Posa Start to the
“OFF” position. Adjust power source to desired voltage for your weld condi-
tion. Depress gun trigger and adjust wire feed speed at gun to match voltage
setting.
Turn the Posa Start switch to the “ON” position. Depress gun trigger and,

Cobramatic® Owner’s Manual - page 6

using Run-in Speed Control, adjust wire feed rate to approximately 50% of
welding wire speed set at gun.
Initiate an arc, and adjust wire feed speed at gun until correct condition is
achieved. At the moment when welding wire speed transition occurs, L4 will
illuminate.

POSA START WIRE SPEED NOTE:

Because the Posa Start Run-in Speed always remains a percentage
of the actual welding wire feed rate, the Posa Start run-in speed
will always slow down or speed up proportional to any
adjustment you now make at the gun. Therefore, if you slow down
the welding wire feed speed, you will have to increase
the Run-in Speed setting.

Remote Operation: Input/Ouput

The terminal strip TB1(reference Appendix pages) allows for external input
signals for remote operation of the feeder as well as output signals for volt-
age and wire speed measurements, for a wide variety of automatic and semi-
automatic applications. By making connections across specific points of
TB1, such functions as the trigger and motor speed control can be controlled
using an external source, such as a controller interface or a PLC (program-
mable logic controller).

Figure 8

Section C Accessories
None available.

Section D Maintenance
Routine Maintenance
Your Cobramatic® is designed to provide years of reliable service. Normal
wear and component failure may require occasional service.
The number of units in operation and the importance of minimal “down time”
will determine to what extent spare parts should be stocked on hand.
If repairs do become necessary, any part can easily be replaced by qualified
shop maintenance personnel.
Maintenance of the gun will normally consist of a general cleaning of the wire
guide system, including tubes, drive rolls, and conduits at regular intervals.
Remove spatter build-up from inside of nozzles with a hardwood stick.
The only parts on the Cobramatic® system that are subject to normal wear
are the conduit, contact tips, gas cups, front body liners, wire guides, drive
and idler rolls. A supply of these parts should be maintained on hand.

Cobramatic® Owner’s Manual - page 7

Testing the Feeder
Testing the Input Power Circuits
The AC circuits are protected by pico-fuses F1 and F2 (see page 13 for
location). If these continually fail, especially when powering up the cabi-
net, remove the connectors for the components that draw on this power, J6
(Brake Solenoid), J7 (Slave Motor) and J5-3 & 4 (AC Contactor - if used)
from the P.C. Board. Replace fuses and retrigger system. If fuses does not
fail, isolate the problem by plugging in J4, J7, and J5-3,4 one at a time until
the fuses fail.
Testing the Speed Control
NOTE:
The gun should be tested prior to testing circuitry on the main board.
Gun amphenol must be connected to the Cobramatic® to perform the
following tests.

To test the motor voltage circuit and measure how much voltage is being
delivered to the gun motor, place a voltmeter across diode test points TP1 &
TP2 and pull gun trigger. A reading between 0 VDC & 28 VDC+/- should be
observed, as the gun potentiometer is varied (Figure 9).
Motor Demand Motor Voltage
Test Point Test Point
TP3 TP2
Motor Voltage
Test Point
TP1
Figure 9

Testing the Gun

Motor Check
Remove the amphenol connector from the cabinet.
Using the gun amphenol, check the resistance across pins “A” and “B”
(motor leads). The resistance across the motor should be between 5-10
ohms.
If an open circuit or short exists, check the motor leads and motor indepen-
dently.
Testing the Potentiometer - “W” Clocked
Using the gun amphenol, check the resistance across pin “D” (wiper) and
pin “C”. The resistance should vary from 0 - 5K ohms as you turn pot.
Check the resistance across pin “D” (wiper) and pin “G”. The resistance
should vary from 5K - 0 ohms as you turn pot.
Testing the Micro Switch
Using the gun amphenol, check for continuity across pins “E” and “F” when
the trigger is pressed.

Cobramatic® Owner’s Manual - page 8

Section E Troubleshooting
Troubleshooting
Symptom Cause Remedy
No wire feed at gun, feeder not oper- F1 & F2 fuse(s) in feeder failed. Check AC circuit. Replace fuse(s).
ating, i.e., no slave motor or brake
F3 (4 amp) fuse in feeder failed. Check motor leads for shorts then
solenoid.
replace fuse.
Micro-switch defective/not being acti- Replace switch. Check switch for
vated. Broken electrical cable. operation. Check micro switch wires
for continuity.
Loose J2, J3, P.C. board connector. Check J2, J3 connectors.

Brake solenoid inoperative. Solenoid defective. Replace solenoid.

Loose connector at J6. Check J6 connector.
No wire feed at gun, feeder operating Bad potentiometer. Check potentiometer with meter.
properly.
Bad gun motor. Check/Replace motor.
Broken electrical cable. Check motor and potentiometer wires
for continuity.
Bad speed control/PCB. Check/Replace P.C. board.
Wire feeds, but welding wire is not Loose or no cable power supply con- Check all power connections.
energized. nections.
Contactor control cable loose or in Check power supply owner’s manual
wrong position. for location and type of contactor signal
required, i.e. closing contacts or AC.
Welding power source not working Check power supply for proper
correctly. operation.
Wire feeds erratically. Dirty or worn conduit. Blow out or replace conduit.
Incorrect pressure on drive rolls. Adjust pressure at gun (Gold or Prince)
Idler roll stuck in gun. Check for lock washer under idler roll,
or replace if damaged or worn.
Wrong size contact tip. See contact tip table.
Wire feeds one speed only. Bad potentiometer. Check with meter.
Broken electrical cable in lead assy. Check potentiometer wires for continu-
ity or shorts.
Bad speed control. Check/Replace P.C. boards.
Wire walks out of drive rolls. Idler roll upside-down. Place groove in idler roll toward the
top.
Rear wire guide missing. Replace wire guide.
Trigger inoperable or not operating Trigger mode configuration. Check front panel Trigger Normal/
correctly. Latched toggle switch.
Purge not operating correctly. Jumper incorrectly configured. Gas Check jumper location per Jumper
solenoid malfunctioning. Table in Appendix. Check cable con-
nections to gas solenoid Check valve
in gun.
No PosaStart Wire Speed Transition Welding power cable and/or gun power Welding power cable to bottom bolt.
cable connected to wrong bolt on Gun power cable to top bolt.
power block.
Welding current not being sensed. Check current sensor in power block.
Remote Functions Not Working Wires not connected at TB1 Reseat all wire connections at TB1.

Cobramatic® Owner’s Manual - page 9

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Cobramatic® Owner’s Manual

Section F Appendices

Diagrams/Parts List
Main P.C. Board Connections................................................... 13
Cabinet and Gun Connections ................................................. 14
001-4022 Cobramatic® Assembly ............................................. 15
003-2237 Cobramatic® Front Panel Assembly ......................... 17
003-2068 Cobramatic® Slave Motor Assembly......................... 18
003-2063 Cobramatic® Power Block Assembly ........................ 19
003-2146 Cobramatic® Spindle Assembly ................................ 20
003-2137 Gas Solenoid Assembly ........................................... 21
843-0496 LE Cobramatic® Control Cable ................................. 22
071-0402 LE Cobramatic® Block Diagram................................ 23
071-0400 Cobramatic® Main P.C. Board .................................. 24
071-0367 Cobramatic® Gun Connections................................. 26
Input/Output Configuration for TB1........................................... 27

Cobramatic® Owner’s Manual - page 11

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Cobramatic® Owner’s Manual

Main P.C. Board Connections

P1 P2
Pre-Purge Post-Purge
Trim Pot Trim Pot
L4
Lit: Weld Speed TP3
(blue) Motor
Demand TB1
JP3 JP1 & JP2 Remote Input/Output
Gas Purge Jumper Adj. Gas Purge Jumper L3
Green (Trigger “on”)
J2
Gas Solenoid

TP2
Test Point
MTR VDC

TP1
Test Point
GROUND
L1
Gas “on” (yellow)
J11
Front Panel

L2
J1 Red (contactor
signal “on”)
Trigger
Normal/Latch
F2
Line Fuse

J4
Front Panel

J10 J7
Transformer Slave Motor

F1
J8 Line Fuse
Current Sensor

F3 J9
Brake Solenoid
Motor Fuse
J6 J5
Terminal Strip Terminal Strip

Control Cable
LE P/N L10708-1 MK P/N 843-0496

Input Power - 42 VAC Hot-Black

Input Power - 42 VAC Neutral-White

Chasis Ground (Green)

Closing Contacts Out
Closing Contacts Out
Weld Posa Start voltage sensing lead ground

Cobramatic® Owner’s Manual - page 13

Cabinet and Gun Connections

Input Connections Water Cooled Gun Connections

Coolant
Supply

Power/
Coolant Coolant In
Return

Shielding Coolant
Gas Return
Welding Gas
Power
Power
Cable
Input Air Cooled Gun

Shielding
Gas Gas
Welding
Power
Cobramatic® Owner’s Manual - page 14
Cobramatic 42 V Assembly
DISCLAIMER 001-4022
No. Qty. Part No. Description
Individual components shown in the exploded parts 1 1 003-0784 Assy Pawl Cobramatic
drawing may not necessarily appear like the true 2 1 003-2118 Assy PCB Main 42V
3 1 003-1723 Assy Xfmr 42V
components used. This drawing is for reference only. 4 - - -
5 1 003-2146 Assy Spindle Cobramatic
6 1 003-2063 Assy Power Block
7 1 003-2068 Assy Slave Motor 42V LE
8 1 003-2095 Assy Sol Brk 42V Top
9 1 003-2237 Assy Pnl Fr CB 42V LE
10 1 261-0635 Insulator Power Block
11 1 261-0634 Insulator Spool
12 4 301-0107 Foot Rbr W/Wshr #8 ID
13 35 336-0230 Scr Pan Phil 8-32 x 1/4 Blk
14 1 328-0063 Scr Sch 1/4-20 x 1-3/4 Blk
15 1 328-0258 Scr Sch 1/4-20 x 3 1/2 Stl
16 6 329-0002 Screw Hex 1/4-20 x 5/8
17 1 329-0208 Scr Hex 3/8-16 x 1.0
18 6 329-1007 Scr Hex Wshr Slt 6-32 x 3/8 st
19 4 329-1019 Scr Hex Wshr Slt 8-32 x 3/8 st
20 2 331-0049 Wshr Flt .261 ID x .625OD st
21 2 431-1650 Wshr Shldr .265ID x .365OD x .50OD
22 4 333-0009 Wshr Spr Lk 1/4
23 2 333-0023 Wshr Lk Ext Star #6
24 4 336-0228 Scr Pnh Ph 10-32 x 1/2 Stl Blk
25 6 342-0410 Spacer Stacking 6-32 x 0.53
26 3 345-0008 Nut Hex Lock 6-32
27 2 345-0009 Nut Hex Lock 8-32 St
28 2 345-0015 Nut Hex Lock 1/4-20 St
29 4 351-0089 Insert thread 10-32
30 1 351-0100 Bush Snap 1 5/8ID 2 Hole
31 2 351-0745 Bush Snap 15/16ID 1 1/8 Hole
32 1 351-0752 Bush Snap 1 1/8ID 1 1/2 Hole
33 1 351-0758 Bush Snap 9/16ID 3/4 Hole
34 1 351-0835 Snap Btn 1/2 Hole Blk
35 1 405-0909 Decal Electronic Connection
36 1 405-0886 Decal Warning T13297
37 2 405-0887 Decal Warning T13470
38 1 405-0888 Decal Warning T16196
39 1 405-0943 Decal Instructions Door Spool
40 2 405-0944 Decal Door Caution
41 1 405-0946 Serial no ID Plate 42V LE
42 6 411-0020 Tie Wrap
43 1 411-0157 Clamp Cable Strain Relief
44 4 415-0075 Hinge Cobramatic
45 2 415-0079 Latch Slide
46 1 415-0243 Handle Carry Black
47 1 419-0080 Spring Ext .219OC x .94LG
48 1 419-0089 Torsion Spring Restrainer CB
49 1 419-0090 Torsion Spring Catch
50 1 431-1608 Mandrel Catch Cobramatic
51 1 431-1609 Mandrel Restrainer Wire Cobramatic
52 - - -
53 1 436-0154 SS Pwr Pnl Cobramatic LE
54 1 438-0065 Paint Door Spl Cobramatic LE
55 1 438-0066 Paint Door Pwr Cobramatic LE
56 1 437-0242 Restrainer Wire Mold Cobramatic
57 1 437-0243 Catch Mold Restrainer CB
58 1 437-0255 Pad Restrainer Wire
59 1 438-0067 Paint Wrap CB LE
60 1 438-0068 Paint Top CB LE
61 1 843-0496 Cable Control 42V CB LE
62 A/R 823-0043 Thread Locking Cmpd Med Str
63 2 336-0029 Scr 8-32 3/8
64 2 333-0006 Washer #8
65 A/R 823-0050 Thread Locking Cmpd Low Str
66 REF 031-0067 Test Procedure
67 1 336-0006 Scr Pan Phil 6-32 x 1/2
68 2 341-0005 Nut Hex 6-32
69 2 336-0030 Scr Pan Phil 8-32 x 1/2 St
70 1 405-0947 Decal Pwr Pnl LE
71 2 405-0948 Decal Door LE
72 2 327-0121 Scr #10-32 x 3/8
73 1 003-2137 Assy Gas Solenoid
74 1 435-1464 Bracket Gas Solenoid

Cobramatic® Owner’s Manual - page 15

THIS PAGE INTENTIONALY BLANK

Cobramatic® Owner’s Manual

Front Panel Assembly
003-2176

Cobramatic® Owner’s Manual - page 17

No. Qty. Part No. Description
1 1 003-1332 Assy Cable Ribbon 26C
2 1 003-1631 Cable Power Assy.
3 1 003-2001 PCB Front Panel 42V CB
003-2237 Front Panel Assembly

4 1 301-0023 Gromment Panel Mount

5 1 341-0050 Nut 3/8-32 St.
6 2 345-0004 Nut Hex Lock 4-40
7 1 401-0012 Knob 1.0 Blk DISCLAIMER
8 1 436-0153 Silkscreen Pnl Fr Lincoln CB Individual components shown in the exploded parts
9 1 003-1642 Assy con 7P”W”CB drawing my not necessarily appear like the true
10 1 003-2138 Assy Swx Trigger Latch components used. This drawing is for reference only.
Slave Motor Assembly
003-2068
No. Qty. Part No. Description
1 1 003-0176 Assy Knob Conduit
2 1 003-2113 Assy Torque Mtor 42V
3 1 328-0024 Scr Shc B-32 x 3/B Stl
4 4 328-0259 Scr Shc B-32 x 1-1/B Stl
5 1 330-0258 Scr Shldr 1/4 x 1/4 x 10-24
6 1 333-0006 Washer Spring Lock #8
7 1 345-0018 Nut lock 5-16-18
8 1 419-0085 Spring Comp 1/32 x DD .40
9 1 419-0211 Spring Comp OD 5/8 x 1/16
10 1 431-1576 Bolt Swing Mod
11 1 435-1582 Plate Locater Slave Motor
12 1 437-0231 Housing slave Motor Mold
13 1 437-0231 Handle Mold Slave Motor
14 1 437-0232 Arm Idler Mold Slave Motor
15 1 437-0245 Cap Bearing Mold

Cobramatic® Owner’s Manual - page 18

16 1 437-0254 Sleeve Spring
17 1 501-0118 Bearing 1.125 x .50 x .31
18 1 501-0156 Bearing .875 x .38 x .28
19 1 501-0207 Bearing Idler roll
003-2068 Slave Motor Assembly

20 1 507-0130 Shaft Gear

21 1 511-0206 Drive Roll
22 1 753-0062 Guide Wire Inlet Nylon
23 A/R 823-0043 Loctite Threadlocking
24 A/R 835-0001 Grease Mobilux 2
25 A/R 823-0051 Loctite Retaining Compound
26 A/R 031-0167 Test Procedure
Apply pipe thread sealant

Apply anti-corrosive compound

A
A Torque: 140 in-lb to 150 in-lb
B Torque: 92 in-lb to 108 in-lb

A
Power Block Assembly
003-2063
A No. Qty. Part No. Description
1 1 003-1243 Assy Sensor Posa-Start
2 1 313-0021 Stud Receiver Push-on
3 2 329-0054 Scr Hex 3/8-16 x 5/8
A 4 1 331-0002 Washer Flat #6 Stl
5 2 331-0777 Washer Flat 0.391 ID x 0.875 OD
6 1 333-0252 Wshr Lk Star-in #6 St.
7 2 336-0005 Scr Pn Ph 6-32 x .375
8 1 342-0395 Spacer Current Sensor
9 - - -
A

Cobramatic® Owner’s Manual - page 19

10 1 431-1612 Block Power CB
11 1 435-3038 Bracket Current Sensor
B
12 1 753-0112 Ftg 1/4npt Male to 5/8-18 Male
13 1 753-0114 Adptr 1/8npt x 1/8nps
003-2063 Power Block Assembly

14 1 753-0115 Bush 1/4npt Male to 1/8npt Fem

15 1 753-0466 Adptr 1/4npt Male to 5/8-18 Fem
16 3 753-0475 Adptr 1/4npt M to 5/8-18 Fem LH
17 A/R 823-0029 Anti-corrosion Compound
18 A/R 823-0043 Removable Threadlock Compound
19 A/R 823-0044 Pipe Thread Sealant
20 2 333-0011 Washer Spring Lock 3/8
Spindle Assembly
003-2146
No. Qty. Part No. Description
1 1 003-2139 Assy Bearing Spindle
2 3 330-3063 Scr Shldr Mod .25 x .63 10-24
3 3 331-0063 Wshr Flt .355 x .505
4 1 331-0095 Wshr Flt 11/32 x 3/4 sst
5 1 331-0313 Wshr Leather .75 ID x .125 Thk

Cobramatic® Owner’s Manual - page 20

6 1 345-0018 Nut Hex Lock 5/16-18 St
7 3 419-0059 Spg Comp .468 x .437 .056
8 1 419-0095 Spg Comp .85 x .69 x .75
003-2146 Spindle Assembly

9 1 431-1266 Plate Back-Up Ring

10 1 431-3726 Adapter Spiral Spindle
11 1 437-0258 Spool Retainer Nut
12 1 437-0260 Knob Tension Spindle
13 1 437-0260 Spacer Spindle
14 1 437-0645 Spindle
15 1 723-0059 Disk Ratchet Brake
16 1 751-0018 Cap .5 x .5 Lg Vinyl Black
Cobramatic® Owner’s Manual - page 21
Gas Solenoid Assy
003-2137
No. Qty. Part No. Description
1 2 153-0853 Pin Crimp
003-2137 Gas Solenoid Assembly

2 1 153-0868 Conn single row 3P

3 2 185-0476 Term slip-on female
4 1 405-0762 Label self-lam .8 x 1.4
5 1 552-0205 Assy gas connector
6 1 561-0017 Gas solenoid 24V
7 1 753-3285 Adptr FE 5/8-18 to M 1/8 NPT
8 2.50 FT 844-0089 Cable 22GA/2CNDT flex



#
! "

5

Wire List
Pin Wire Color Terminal
A Not Used
B Green Chassis 42 V Lincoln Cobramatic
C Red J9-3 Control Cable

Cobramatic® Owner’s Manual - page 22

D Orange J9-4 843-0496
E Not Used No. Qty. Part No. Description
F Not Used 1 1 153-1161 Conn, 14P, X Clocked
G Not Used 2 1 411-0035 Clamp, Cable
H Blue J9-2 3 1 301-0026 Boot, Cable, #12
I White J5-1 4 1 301-0021 Boot, Cable, #10
843-0496 LE Cobramatic® Control Cable

J Not Used 5 8 ft 844-0025 Cable, 7 Conductor, 10 Ga

K Black J5-2 6 5 185-0003 Lug, Spade, Insul, 18 Ga
L Not Used
NOTE: Posa Start lead from Cobramatic® 7 0.25 ft 739-0004 Tube, HT Shrink, 1/8
must be attached to working (welding)
M Not Used 8 1 185-0514 Lug, Ring, Insul, #6-18 Ga
ground.
N Not Used 9 7 405-0762 Label Self Laminate
071-0402 Cobramatic® Block Diagram

Cobramatic® Owner’s Manual - page 23

071-0400 Cobramatic® Main PC Board

Cobramatic® Owner’s Manual - page 24

071-0400 Cobramatic® Main PC Board

Cobramatic® Owner’s Manual - page 25

071-0367 Cobramatic® Gun Connections
and Front Panel Schematic

Cobramatic® Owner’s Manual - page 26

Input / Output Configuration for TB1
Monitor Wire Feed Speed
Use digital volt meter between: TB1 – 1(GND) and TB1 – 2(MSPD).
Measured value defined as: Reading x 100 = Wire Feed Speed.
Example: 3.54 VDC is equivalent to 354 IPM

MSPD

VOLT METER
GND
8
7
6
5
4
3
2
1

TB1

Remote/External Trigger
Install jumper between: TB1 – 1(GND) and TB1 – 3(TRIG) to trigger system.

TRIG

SW

GND
8
7
6
5
4
3
2
1

TB1

Arc Establish Relay Closure

External Contact Signal; Connect 24VDC relay coil between TB1 – 8 (24V)
and TB1 – 4 (ARC). When arc is established, the relay coil will close.

ARC ESTABLISHED
K?

24V ARC ESTABLISHED

ARC
ARC ESTABLISHED RELAY
8
7
6
5
4
3
2
1

TB1

Cobramatic® Owner’s Manual - page 27

Cobramatic® Owner’s Manual - page 28
Torch Pot Output
Some power supplies can utilize a variable DC voltage signal from the gun
potentiometer adjustment as their external voltage control. Adjusting the
potentiometer at the gun will give 0 to 10VDC output between TB1 – 1 (GND)
and TB1 – 6 (POT).

POT

GND
8
7
6
5
4
3
2
1

TB1

A common “synergic” type of setup is to have the gun potentiometer signal

control the welding voltage of the welding power supply. As this external
signal adjusts the voltage up or down, its external 0-10VDC signal can come
back into TB-1, as shown below in External Motor Speed Control, and control
the wire feed speed.
DMD
0 TO 10VDC
GND
8
7
6
5
4
3
2
1

TB1
This is mainly dependant on the configuration and signal adaptation of the
welding power supply. Check with your welding equipment manufacturer to
see if your welding power source has this feature or can adapt to this type of
setup. Not all welding power sources can do this.

Cobramatic® Owner’s Manual - page 29

Manual Gas Purge
Jumper from TB1-7 to TB1-1 to externally operate the gas solenoid in the cabinet

Cobramatic® Owner’s Manual - page 30

Cobramatic® Owner’s Manual - page 31
Copyright © 2002 Lincoln Global Inc.

Cobramatic® Owner’s Manual - page 32

THIS PAGE INTENTIONALLY BLANK

Cobramatic® Owner’s Manual

LIMITED WARRANTY
Effective October 1, 2006
This warranty supersedes all previous MK Products warranties and is
exclusive, with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY - MK Products Inc., Irvine, California Classification of any item into the foregoing categories shall be at
warrants that all new and unused equipment furnished by MK the sole discretion of MK Products. Notification of any failure must
Products is free from defects in workmanship and material as of be made in writing within 30 days of such failure.
the time and place of delivery by MK Products. No warranty is
made by MK Products with respect to trade accessories or other A copy of the invoice showing the date of sale must accompany
items manufactured by others. Such trade accessories and other products returned for warranty repair or replacement.
items are sold subject to the warranties of their respective manu-
facturers, if any. All equipment returned to MK Products for service must be properly
packaged to guard against damage from shipping. MK Products
MK Products’ warranty does not apply to components having will not be responsible for any damages resulting from shipping.
normal useful life of less than one (1) year, such as relay points,
wire conduit, tungsten, and welding gun parts that come in contact Normal surface transportation charges (one way) for products
with the welding wire, including gas cups, gas cup insulators, and returned for warranty repair or replacement will be borne by MK
contact tips where failure does not result from defect in workman- Products, except for products sold to foreign markets.
ship or material.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
MK Products shall, exclusively remedy the limited warranty or IMPLIED WARRANTY, GUARANTY, OR REPRESENTATION AS TO
any duties with respect to the quality of goods, based upon the PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT
following options: WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICA-
(1) repair TION, OPERATION OF LAW, CUSTOM OF TRADE, OR COURSE OF
(2) replacement DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANT-
(3) where authorized in writing by MK Products, the reasonable ABILITY OR OF FITNESS FOR PARTICULAR PURPOSE, WITH
cost of repair or replacement at our Irvine, California plant. RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MK PROD-
UCTS, IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS.
As a matter of general policy only, MK Products may honor an
original user’s warranty claims on warranted equipment in the event EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRIT-
of failure resulting from a defect within the following periods from ING, MK’s PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE
the date of delivery of equipment to the original user: BY COMMERCIAL/INDUSTRIAL USERS AND FOR OPERATION BY
PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAIN-
1. Power Supplies and Wire Feed Cabinets ........... 3 years TENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS
2. Weldheads, Positioners, Prince XL and Prince XL Spool OR CONSUMER USE. MK PRODUCTS’ WARRANTIES DO NOT
Guns, Python, CobraMAX, Cobra SX, Cobra MX............. EXTEND TO, AND NO RE-SELLER IS AUTHORIZED TO EXTEND
.............................................................................1 year MK PRODUCTS’ WARRANTIES TO ANY CONSUMER.
3. Sidewinder® Spool Gun, Prince SG Spool Guns,
Modules .......................................................... 180 days U S E O F OT H E R T H A N G E N U I N E M K P R O D U C T S ’
4. Repairs/Exchanges/Parts ............................... 90 days CONSUMABLES, PARTS, AND ACCESSORIES MAY INVALIDATE
YOUR PRODUCT WARRANTY.

16882 Armstrong Ave.

Irvine, CA 92606
Tel (949)863-1234
Fax (949)474-1428
www.mkproducts.com
October 1, 2006
Copyright © 2007 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: www.lincolnelectric.com