MK Products 240-8XX Owner'S Manual Download Page 1 | Manualshive

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Millermatic Compatible™

225 Ampere Push-Pull Welding Gun

Product:

Python

Manual:

091-0593

Serial:

08050001

Voltage Rating: 24 VDC
Revision:

May 2008 Rev B

Gun models:

240-8xx

Owner’s Manual

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Summary of Contents for 240-8XX

Page 1: ...Millermatic Compatible 225 Ampere Push Pull Welding Gun Product Python Manual 091 0593 Serial 08050001 Voltage Rating 24 VDC Revision May 2008 Rev B Gun models 240 8xx Owner s Manual ...

Page 2: ......

Page 3: ...Controls and Settings 2 Trigger Adjustment 2 Drive Roll and Idler Rolls 2 Accessories Section C Insulated Drive Roll Kits 3 Replacement Kits 4 Snake Skins 4 Contact Tips 4 Barrels 4 Maintenance Section D Periodic Maintenance 5 Recommended Spare Parts List 6 Troubleshooting Section E Troubleshooting Guide 6 Testing The Gun 6 Appendices Section F Diagrams Parts List 9 Mechanical 10 Electrical 17 War...

Page 4: ...EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 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 ...

Page 5: ...erminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spl...

Page 6: ...ode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding fLYING METAL can injure eyes Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool th...

Page 7: ... PARTS can cause injury Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place H f RADIATION can cause interference High frequency H F can interfere with radio navigation safety services computers and communicationsequipment Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for hav...

Page 8: ...ncy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 22...

Page 9: ...2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Don t weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watch person r...

Page 10: ...oolant In put Water Coolant Output Fuse Continuous Spot Welding SECTION 3 INTRODUCTION 3 1 Specifications Type of Input Power Welding Power Source Type Wire feed Speed Range Wire Diameter Range Welding Circuit Rating Overall Dimensions Weight 24 Volts AC Single Phase 5 Amperes 50 60 Hertz Constant Voltage CV DC For GMAW Or Constant Voltage CV Constant Current CC DC For GMAW P All Need 14 Pin And C...

Page 11: ...our 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 Please Examine Carton and...

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Page 13: ...into the gun body The cabinet end is secured in the central body with a set screw These connections utilize a conductive sealant and are tightened to a specific torque setting reference exploded parts drawing in the Appendix for details Conduit The Millermatic Compatible Python comes standard with a poly lined conduit for feeding aluminum wire The longer fitting with a shallow groove is used on th...

Page 14: ...ing the gap between the trigger lever and the micro switch lever By turning in the trigger sensitivity adjustment screw it closed the gap between the trigger lever and the micro switch lever This will enable the operator to increase the sensitivity of the trigger lever Sensitivity Adjustment With the wire feeder turned on with or without welding wire loaded turn the screw in until the micro switch...

Page 15: ... wire Idler Roll Installation and Removal Reference Figure 3 1 Using a slot type screwdriver loosen idler screw taking care not to lose lock washer under idler roll 2 Insert new idler roll and lock washer onto screw insuring that idler groove is toward top and lock washer is beneath 3 Tighten screw until tight NOTE Lock washer must be under idler roll or it will not turn freely Section C Options a...

Page 16: ...15 0621 50 Snake Skins A Snake Skin protective cover is standard on the Millermatic Compatible Python You may order spare replacement covers to protect the lead assy of the gun when the original becomes damaged or worn It can easily be replaced in the field by means of a hook and loop type fastener Snake Skin Cover 15 ft 4 5m 931 0110 Snake Skin Cover 25 ft 7 6m 931 0122 Snake Skin Cover 35 ft 10 ...

Page 17: ...Z Lock taper lock nut assembly no more than 1 turn Rotate barrel to the position of your choice and re tighten taper lock nut assembly firmly so that the barrel cannot rotate CAUTION Do not attempt to weld without the barrel being tightly secured in the gun body or damage to the barrel or body may result Barrel Liner The standard Teflon liner in the Millermatic Compatible Python barrel is designed...

Page 18: ...ce the table below for suggested Maintenance Tools used with the Millermatic Compatible Python welding gun Testing The Gun Reference the X clocked Amphenol diagram on the Millermatic Compatible Python electrical diagram for information about pin outs and locations Motor Check Remove the connector from the cabinet Using the Amphenol connector check the resistance across pins C and B motor leads The...

Page 19: ...slightly taut so it will not pull off the spool while feeding wire The high torque 24VDC gun motor is controlled by a solid state speed control located in the feeder and a pot located in the gun The gun motor potentiometer and micro switch are connected to the cabinet control box via a control cable and Amphenol connector If this cable becomes damaged a variety of symptoms can occur depending on w...

Page 20: ...t welding wire is not energized Loose or no cable connections Check all power connections Contactor control cable loose or in wrong position Check power supply owner s manual for location and type of contactor signal required Welding power source Check power source Wire feeds erratically Dirty or worn conduit Blow out or replace conduit Wrong size contact tip See contact tip table Idler roll stuck...

Page 21: ...ction F Appendices Millermatic Compatible Python Diagrams Parts List Exploded Parts View 10 Complete Parts List 11 Front Body Assembly Parts View 12 Barrel Assembly Parts View 13 Power Gas Connector Parts View 14 Electrical Connector Pinout 15 ...

Page 22: ...ription 15 25 35 50 36 Conduit 615 0602 15 615 0602 25 615 0602 35 615 0602 50 39 Power Cable 843 0619 843 0620 843 0622 843 0621 35 Gas Hose 552 0224 552 0225 552 0227 552 0226 40 Control Cable 843 0624 843 0625 843 0627 843 0626 43 Snake Skin 931 0110 931 0122 931 0132 931 0123 ...

Page 23: ...ap Motor 10 1 003 2241 Assy Power Pin Millermatic Compatible 32 1 005 0699 Handle Kit Includes line items 28 29 and 34 11 4 336 0247 Screw K40X12 Pan HD Phl ST 33 12 1 437 0285 Housing Pwr Pin Right Handle 34 1 437 0253 Door Molded 13 1 437 0286 Housing Pwr Pin Left Handle 35 1 SEE TABLE Assy Gas Hose 14 1 419 0101 Strain Relief Spring 36 1 SEE TABLE Assy Conduit 15 1 437 0287 Spring Retainer 37 0...

Page 24: ... No Qty Part No Description 1 Not available separately 2 3 1 325 0206 10 24 x 3 8 PH Screw 4 1 333 0082 10 Lock Washer 5 1 419 0092 0 29 x 0 047 x 0 32 Comp Spring 6 1 421 0525 1 8 x 7 8 SST Dowel Pin 7 1 431 1663 Idler Adjusting Screw 8 1 431 1598 Idler Arm 9 1 511 0001 Idler Wire Feed Assembly 10 1 511 0101 Drive roll Items 3 4 9 available as package kit Part number 005 0686 ...

Page 25: ...o Qty Part No Description 1 1 003 2213 Assy Taper Lock 2 4 303 0010 O Ring 0 489 I D x 070 Width 3 2 303 0094 O Ring 0 301 I D x 070 Width 4 1 931 0137 Liner Package 5 pieces 5 1 621 0250 Assy Cup CPR Finned 10 6 1 621 0393 Tip HD Spray 060 7 1 005 0696 Insulator Replacement Kit 8 1 431 1774 Cup Insulator 9 1 313 0091 Retaining Ring 5 8 Shaft ...

Page 26: ...or No Qty Part No Description 1 2 321 0070 Set Screw 10 32 2 1 321 1104 Set Screw 8 32 Mod Conduit 3 1 753 0089 Gas Hose Barbed Fitting 4 1 431 1742 Outlet Wire Guide 030 1 16 5 1 153 1210 Power Pin Assy 6 1 431 1743 Power Gas Connector Mod 7 1 321 0104 Set Screw 5 16 18 x 1 4 8 1 753 0088 Power Weld Fitting 9 2 303 0102 O Ring 0 487 ID x 103 Width ...

Page 27: ...r Polarizing Key Millermatic Compatible Python Electrical Schematic Connector Pinout WARNING ELECTRIC SHOCK HAZARD Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this units ...

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Page 29: ...Exchanges Parts 90 days Classification of any item into the foregoing categories shall be at the sole discretion of MK Products Notification of any failure must be made in writing within 30 days of such failure A copy of the invoice showing the date of sale must accompany products returned for warranty repair or replacement All equipment returned to MK Products for service must be properly package...

Page 30: ...16882 Armstrong Ave Irvine CA 92606 Tel 949 863 1234 Fax 949 474 1428 www mkproducts com ...

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