Python® Millermatic Compatible
Contents
1. nnn 003 2332 12 Curved 45 Air Cooled Barrel Assembly 003 2333 12 Straight Water Cooled Barrel Assembly 003 2318 12 Curved 45 Water Cooled Barrel Assembly 003 2319 18 Straight Air Cooled Barrel Assembly 003 2334 18 Curved 45 Air Cooled Barrel Assembly 003 2335 18 Straight Water Cooled Barrel Assembly 003 2320 18 Curved 45 Water Cooled Barrel Assembly 003 2321 Python Millermatic Compatible Owner s Manual Page 6 Section D 12 Flex Air Cooled Barrel Assembly 200 Amps 003 2495 12 18 Flex Air Cooled Barrel Assembly 200 Amps 003 2495 18 24 Flex Air Cooled Barrel Assembly 200 Amps 003 2495 24 36 Flex Air Cooled Barrel Assembly 200 Amps 003 2495 36 Optional 300 Amp Water Cooled Barrel Assemblies Straight Water Cooled Barrel Assembly 300 Amps 003 2380 Curved 45 Water Cooled Barrel Assembly 300 Amps 003 2381 Curved 60 Water cooled Barrel Assembly 300 Amps 003 2382 Barrel Removal and Installation To remove the barrel assembly loosen th2. 28 Power Manifold Water Cooled 29 EIC UC llann RNC M PEE 30 Python Millermatic Compatible Owner s Manual Page 11 Python Millermatic Compatible Head Assembly Python Millermatic Compatible Owner s Manual Page 12 APPLY COMPOUND GREASE TO CONTACT SURFACE FOR INSTALLATION APPLY COMPOUND NOALOX TO CONTACT SURFACE FOR INSTALLATION APPLY THREAD LOCKING COMPOUND TO CONTACT SURFACE FOR INSTALLATION JelO OMY 6 uougInsul ognL 870067 uogo sz ISS8 SOr rc8ludHJo9S 8seo6le u uouMd qouy J9A0O 89g0 76 ve LSS 8 x 0 Z8 lud H4 pel Ge0 6IE z Ob uou PepIOW Joo EGzo zep ez reuondo peedS iH OADg 1010W 0800 42 It 7 Ee pue EN Ea pepuelS OGAPZ JOIN 7700 2 IL 8L EL SWE ou sepnjou 1 9IDUBH WA O M Assy Apog eed zgzz e00 L L AIqulSSSV peop ojgneduioz onewa Uoyd Python Millermatic Compatible Owner s Manual Page 13 Python Millermatic Compatible Front Body Assembly P N 003 2271 Air Cooled P N 003 2108 Water Cooled Items 3 4 amp 9 available as package kit P N 005 0686 Front Body Assembly Not available separately 325 0206 10 24 x 3 8 PH Screw Items 3 4 amp 9 available as package kit Part number 005 0686 rrr EHE B Python Millermatic Compatible Owner s Manual Page 14 Python Millermatic Compatible Rear Body Assembly Air Coo
3. ae H P9 fill Millermatic Compatible PRODUCTS Owner s Manual Product Python Manual 091 0633 Serial 13020001 Voltage Rating 24 VDC Revision Feb 2013 Rev C Gun models 291 8XX 292 8XX 225 Ampere Air Cooled 450 Ampere Water Cooled Push Pull Welding Guns Table of Contents EE EEN i iii HS UE de BEE Section A Reie ee er ler Le EE 1 Support Equipment Ge e WE 1 aun bead Ee lee EE 1 ODEN ALO Mice ERE section B erac mm 2 Conmols and Setn Sristi TAE ies Hulu i DO ades 2 oger Ag s qierluuuuy Tn 3 DIVE te Ee el Le EE 3 Ae Section C OBIOHal Ki u u PN 4 S qS SKS WA IAA MBAWA RE MAANA NAI MME NANA a und WAMAMA NA 4 Gontact WS p 5 GaS GI x a eee 5 sig O M 6 MAMAA EEN oection D Period e Mamlehnahnee uuu E sakisha GR LIT 7 Recommended Spare Parts Uert 8 Troubleshooting Section E Troubleshooting REI e EE 10 TEUA Ui YU ADO EG OO Ud 10 eet 1 e LL e1 e1 PENFRO NR ens ees oection F Diagramme i Pa Se EE 11 Kleer ln e MERITO 12 miser e PE E 30 Safety Warnings Warranty Declaration of Conformity for European Community CE Products Note ll 3 This information is provided for units with CE certification see rating label on unit Manufacturer s Name M K P rod u cts y nc 16882 Armstrong Ave Irvine CA 92606 Declares that the proauct Python
4. 912 00 V p oo2o 191eM Ajquiessy pee Python Millermatic Compatible Owner s Manual Page 23 Python Millermatic Compatible Lead Assembly Spiral Wrap Installation 033 0929 Gun End Air Cooled Python Millermatic Compatible Owner s Manual Page 24 Python Millermatic Compatible Lead Assembly Spiral Wrap Installation 033 0929 Gun End Water Cooled Ring 431 1660 Power Cable _ mm Python Millermatic Compatible Owner s Manual Page 25 Python Millermatic Compatible Lead Assembly Spiral Wrap Installation 033 0929 Cabinet End Air and Water Cooled oa qp w Spiral Wrap p n 261 0094 d EM M Python Millermatic Compatible Owner s Manual Page 26 Python Millermatic Compatible Power Pin Adapter Assembly P N 003 2346 APPLY SILICONE LUBRICANT TO O RINGS BEFORE INSTALLING Power Pin Adapter Assembly 002 0761 Assy Brazed Power Pin Adapter 303 0010 O Ring 2 014 489 ID x 07 W Python Millermatic Compatible Owner s Manual Page 27 Python Millermatic Compatible Power Manifold Assembly Air Cooled P N 003 2337 Z TIGHTEN WITH KZ 6525 IN LBS TORQUE Wr APPLY HIGH STRENGTH THREAD SEALANT Air Cooled Power Manifold Assembly No Qty PartNo Description 321 1082 Set Screw Flat 1 4 20 x 3 8 SST 431 1905 Fitting 1 8 ID x 1 16 27 NPT 431 1936 Power Manifold AC Python Millermatic Compa
5. and insulated idler roll assy Insulated Groove Drive Roll Kit For 040 1 0mm dia aluminum wire and insulated idler roll assy Insulated Groove Drive Roll Kit For 3 64 1 2mm dia aluminum wire and insulated idler roll assy Insulated Groove Drive Roll Kit For 062 1 6mm dia aluminum wire and insulated idler roll assy Handle Kit YHA FOR 005 0715 Includes insulated groove drive roll 005 0716 Includes insulated groove drive roll asao us 005 0717 Includes insulated groove drive roll OO Ian 005 0718 Includes insulated groove drive roll EN EN UN 005 0719 Includes insulated groove drive roll NON 005 0699 Includes left and right handles screws and drive roll door TRIGGER IN Ee 005 0694 Trigger adjustment kit includes a spring and sensitivity adjustment screw replacement for all Python Millermatic Compatible guns Micro Switch Kit M 005 0701 Replacement micro switch assembly for all Python Millermatic Compatible guns Potentiometer Kit 005 0695 Replacement potentiometer assembly for all Python Millermatic Compatible guns Conduits Flat spiral steel conduit for steel
6. 2 Cylinders Cylinders must be handled carefully to prevent leaks and damage to their walls valves or safety devices Avoid electrical circuit contact with cylin ders including third rails electrical wires or welding circuits They can produced short circuit arcs that may lead to a seri ous accident See 1 3C ICC or DOT marking must be on each cylinder It is an assurance of safety when the cylinder is properly handled Identifying gas content Use only cylin ders with name of gas marked on them do not rely on color to identify gas con tent Notify supplier if unmarked NEVER DEFACE or alter name number or other markings on a cylinder It is illegal and hazardous Empties Keep valves closed replace caps securely mark MT keep them sepa rate from FULLS and return promptly Prohibited use Never use a cylinder or its contents for other than its intended use NEVER as a support or roller Locate or secure cylinders so they cannot be knocked over Passageways and work areas Keep cyl inders clear of areas where they may be stuck Transporting cylinders With a crane use a secure support such as a platform or cradle Do NOT lift cylinders off the ground by their valves or caps or by chains slings or magnets Do NOT expose cylinders to excessive heat sparks slag and flame etc that may cause rupture Do not allow contents to exceed 55 degrees C 130 degrees F Cool with water spray where suc
7. 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 Section A CC Installation Technical Specifications Wire Capacity 030 045 0 6mm 1 2mm solid and hard wire 030 1 16 0 8mm 1 6mm aluminum and cored wire Wire Speed 800 IPM 20 3 mpm Max at rated feeder Input Voltage 120VAC 42VAC Duty Cycle 60 All ratings are using Argon Gas 225 Amps 25 Volts Air Cooled 450 Amps 25 Volts Water Cooled Support Equipment Required C V or C C Power Source of sufficient capacity for your needs e Regulated gas supply and hoses e Properly sized power leads from power source to wire feeder and ground e Water source and hose capable of providing a minimum of 1 quart 95 liter min at 45 p s i when using Water cooled guns Coolant Recommendations Use Cobra Coolant Aluminum Protection which does not contain reactive sulphur or chlorine and does not react with copper brass or aluminum The Cobra Coolant is available in quantities of 1 gallon P N 931 0060 5 gallon P N 931 0060 5GAL or a case of 4 gallons each P N 931 0060 4 The coolant flow rate should be a minimum of 10 GPH 1 qt min between 35
8. Dasligue a corrente antes de fazer maventes A ramovar luma da zoga respirat ria servi co M n operg com os paineis abertos ATENCAO Nip toque as partas IBTTlcas nuas nu guardias removidas ttri Af G N ERTESZELT BX NvwrrP gt A t EAUCH t PE Tar a E FEE PBMC ETMBA To FE PRESB EL E EFA REP RRL S TF EL OT t TF AY si PARE CZ TEX WR St MF adei Y E E E ME ER P desse SOL Ai e atiy AHR OS enwol e ace CES a Siess RHI R Obes ME HAI Til ISA EEE AHA nr ye Lg ui wd a Ma LL Aan dL ett Ae alll JAR i MA ja j da it Jani mirus a At ceid 0N AM cyn DARAN sag yd LEIA E COMPREENDA AS INSTRUC ES DO FABRICANTE PARA ESTE EOUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR ERREKO x b IF E F BA EFHRLT FS tL CRHODRESW AU SE T Oo EI FPE hh 3 ERAS 2 10 BH ARR EB P LEE BRP HAS RRR oi xjEol SEE AIA G IARI zial ai Z ien Jarl aba Kibasa Ai Llantas Lh a glia Shaali oigh SA sisal Slated madia cnoi i Python Millermatic Compatible Owner s Manual Page 32 LIMITED WARRANTY Effective August 1 2010 This warranty supersedes all previous MK Products warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY MR Products Inc Irvine California warrants that all new and unused equipment furnished By MK Products is free from de ects ir workmanship and material as of the time and place of d
9. Millermatic Compatible conforms to the following Directives and Standards Directives Low Voltage Directive 2006 95 EC Electromagnetic Compatibility EMC Directive 2004 108 EC Standards Electromagnetic Compatibility EMC EN 60974 10 2007 Torches And Guns For Arc Welding EN 60974 7 2005 SAFETY CONSIDERATIONS ELECTRIC ARC WELDING EGUIPMENT CAUTION READ BEFORE ATTEMPTING INSTALLATION OPERATION OR MAINTENANCE OF THIS EGUIPMENT 1 1 INTRODUCTION This eguipment is intended for ultimate application by commercial industrialusers and for operation by persons trained and experienced in the use and maintenance of welding eguipment Operation should not be undertaken without adequate train ing inthe use of such equipment Training is available from many public and private schools or similar facilities Safe practices in the installation opera tion and maintenance of this equipment requires proper training in the art a care ful study of the information provided with the equipment and the use of common sense Rules for safe use are generally provided by suppliers of welding power sources compressed gas suppliers and electrode suppliers Careful compliance with these rules will promote safe use of this equipment The following Safety Rules cover some of the more generally found situations READ THEM CAREFULLY In case of any doubt obtain qualified help before proceeding 1 2 GENERAL PRECAUTIONS A Burn Preven
10. RE SELLER IS AUTHORIZED TO EXTEND ME PRODUCTS WARRANTIES TO ANY CONSUMER USE OF OTHER THAN GENUINE IK PRODUCTS CONSUMABLES PATS AND ACCESSORIES MAY TMWALIDATE YOUR PRODUCT WARRANTY Tel 949 863 1234 Fax 949 474 1428 August 1 2010 MIL PRODUCTS 16882 Armstrong Ave Irvine CA 92606 Tel 949 863 1234 Fax 949 474 1428 www mkproducts com
11. amp cored wire T5 NP ESI 25 MA7 CI RET TERN So TE TO ZI BEE 50 TE EM eus den docte eie O ou Een u Y uu Optional nickel tube liner Snake Skins THE TH 615 0621 15 E 615 0621 25 FFF NIO deste RY 615 0621 35 hut LIU DE MU 615 0621 50 431 2031 Snake Skin protective covers are now standard on all guns You may order spare replacement covers to protect the lead assy of the gun when the factory one becomes damaged or worn It can easily be replaced in the field by means of Velcro Snake Skin Cover 13ft for 15ft leads 931 0110 Snake Skin Cover 23ft for 25ft leads 931 0122 Snake Skin Cover 33ft for 35ft leads 931 0132 Snake Skin Cover 48ft for 50ft leads 931 0123 Python Millermatic Compatible Owner s Manual Page 4 Contact Tips Heavy Duty Contact Tip 3 8 Diameter Wire Size TipID Arc TipLength PartNo _ 030 0 8mm 041 1 0mm Spray 1 57 39 9mm 621 0390 25 Short 1 82 46 2mm 621 0396 25 035 0 9mm 044 1 1mm Spray 1 57 39 9mm 621 0391 25 621 0391 250 621 0391 500 035 0 9mm 044 1 1mm 1 82 46 2mm 621 0397 25 045 1 1mm 053 1 35mm Short 1 82 46 2mm 621 0398 25 3 64 1 2mm 053 1 35mm Spray 1 57 39 9mm 621 0392 25 6
12. and 45psi Contact the re circulator manufacturer for specifications on pressure Gun Lead Connections Power Cable Air Cooled A 2 power cable is used on the Python Millermatic Compatible gun The gun and Power Pin ends of the cable are stripped to the copper strands and wrapped with a copper strip A setscrew holds the cable securely in the gun body and in the Power Manifold with torque requirements of 55 60 in lb Power Cable Water Cooled Python Millermatic Compatible water cooled gun utilizes a power water cable with a 6 AWG cable inside a 5 16 diameter hose When water is used with this cable and the 10 water cooled gas cup P N 621 0065 the system is rated at 450 amps 60 duty cycle The gun end is threaded into the gun body These connections utilize a conductive sealant and are tightened with torque requirements of 100 5 IN LB Conduit The Python Millermatic Compatible comes standard with a poly lined conduit for feeding aluminum wire The longer fitting with a shallow groove is used on the gun end A set screw located on top of the gun handle secures the conduit in place The cabinet end of the conduit is secured into the Power Pin connector with a set screw Gas Hose The BLACK gas hose is pushed over a barbed fitting on the end of the gun body and secured by twisting the hose retainer to the end of the hose shown next page The opposite end of the BLACK hose is pushed over a barbed fitting in the Power Pin The
13. arc is intense and visibly bright Its radiation can damage eyes penetrate lightweight clothing reflect from light colored surfaces and burn the skin and eyes Skin burns resemble acute sunburn those from gas shielded arcs are more severe and painful DON T GET BURNED COMPLY WITH PRE CAUTIONS 1 Protective Clothing Wear long sleeve clothing in addition to gloves hat and shoes As necessary use additional protective clothing such as leather jacket or sleeves flameproof apron and fire resistant leggings Avoid outer garments of untreated cotton Bare skin protection Wear dark sub stantial clothing Button collar to protect chest and neck and button pockets to prevent entry of sparks 2 Eye and Head Protection Protect eyes from exposure to arc Eyes may be damaged by radiant energy when exposed to the electric arc even when not looking in the direction of the arc Never look at an electric arc without protection Welding helmet or shield containing a filter plate shade no 12 or denser must be used when welding Place over face before striking arc Protect filter plate with a clear cover plate Cracked or broken helmet or shield should NOT be worn radiation can be passed through to cause burns Cracked broken or loose filter plates must be replaced IMMEDIATELY Replace clear cover plate when broken pitted or spattered Flash goggles with side shields MUST be worn under the helmet to give some pro
14. contents should be cleaned see paragraph above Do NOT depend on sense of smell or sight to determine ifitis safe to weld or cut Hollow castings or containers must be vented before welding or cutting They can explode Explosive atmospheres NEVER weld or cut where the air may contain flam mable dust gas or liguid vapors such as gasoline D Compressed Gas Eguipment The safe handling of compressed gas eguipment is detailed in numerous indus try publications The following general rules cover many of the most common situations 1 Pressure Regulators Regulator relief valve is designed to protect only the regulator from overpres sure it is not intended to protect any downstream equipment Provide such protection with one or more relief devices Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed Remove faulty regulator from service immediately for repair first close cylinder valve The following symptoms indicate a faulty regulator Leaks if gas leaks externally Excessive Creep if delivery pressure continues to rise with downstream valve closed Faulty Gauge if gauge pointer does not move off stop pin when pressurized nor returns to stop pin after pressure release Repair Do NOT attempt repair Send faulty regulators for repair to manufac turer s designated repair center where special techniques and tools are used by trained personnel
15. da Isole se da pepa 2 terra ATENCAO A a b Lal NR Xi Wi F Z wh TU h ii ISO UN TE ke KKK t ok re A fTu Stil LU CES a DEFN SAU eCrwW SHES HE Se Fe PE YA Z i oA Sg Suz HAR zx ojas AB wl qon yd nj qat ve d ng slay oy CHE Ma i AFYA pal PAi dag ele y nme amp Keep llammable materiais away Manko el material combustible fuera dal rea da Irahajn e Garder l cart da tout mat riel inflammable amp Entfernen Sie hrennbarres Matarial amp Mantenha inffamaveis ham guarda dos Hi PT VEO Kat h HEYETE U ETA o OQS2U 20 R Liam ened Hl H2 i mais ym Oz vd iu GAU gl au e Wear eye ear and body protection Prot jase los ojos Ips nidos y el cuerpo e Prot gez vos yapx vos argilips st voka corps amp Tragen Sle Augen Dhren und K r perschutzi Use protegie para a vista ouvido e come eB FAUSHCARREL TF Cy ARE BANANA ez 734 Eo 26578 HEHA di y Spy ele Ad 3 gag An gan a maai 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 DUE 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 PRGC
16. momentarily pointing outlet away from people and sources of ignition Wipe with a clean lintless cloth Match regulator to cylinder Before con necting check that the regulator label and cylinder marking agree and that the regulator inlet and cylinder outlet match NEVER Connect a regulator designed for a particular gas or gases to a cylinder contain ing any other gas Tighten connections When assembling threaded connections clean and smooth seats where necessary Tighten If con nection leaks disassemble clean and retighten using properly fitting wrench Adapters Use a CGA adapter available from your supplier between cylinder and regulator if one is required Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads Regulator outlet or hose connections may be identified by right hand threads for oxygen and left hand threads with grooved hex on nut or shank for fuel gas 5 Pressurizing Steps Drain regulator of residual gas through suitable vent before opening cylinder or manifold valve by turning adjusting screw in clockwise Draining prevents excessive compression heat at high pressure seat by allowing seat to open on pressurization Leave adjusting screw engaged slightly on single stage regulators Stand to side of regulator while opening cylinder valve Open cylinder valve slowly so that regu lator pressure increases slowly When gauge is pressurized gauge reaches regulator ma
17. simply to keep the wire slightly taut so it will not pull off the spool while feeding wire The high torgue 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 which wire s break To test check each wire for continuity and shorts Remember the micro switch in the gun activates both the slave motor and gun motor circuits in the cabinet Therefore if the slave motor and brake solenoid operate but the gun does not look more toward the gun motor s 24V circuits speed control control cable or the gun motor If nothing operates look more toward the slave motor s input micro switch leads or micro switch Testing The Gun Reference the X clocked Amphenol diagram on the Python Millermatic Compatible 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 resistance across the motor should be between 5 10 ohms as the potentiometer is turned If an open circuit or short exist check the motor leads and motor independently Testing the Gun Potentiometer Using the amphenol connector check the resistance a
18. tection to the eyes should the helmet not be lowered over the face before an arc is struck Looking at an arc momentarily with unprotected eyes particularly a high intensity gas shielded arc can cause a retinal burn that may leave a permanent dark area in the field of vision 3 Protection of Nearby Personnel Enclose the welding area For production welding a separate room or enclosed bay is best In open areas surround the operation with low reflective noncom bustible screens or panels Allow for free air circulation particularly at floor level Viewing the weld Provide face shields for all persons who will be looking directly at the weld Others working in area See that all per sons are wearing flash goggles Before starting to weld make sure that screen flaps or bay doors are closed B Toxic Fume Prevention Comply with precautions in 1 2B Generator engine exhaust must be vented to the outside air Carbon mon oxide can kill C Fire and Explosion Prevention Comply with precautions in 1 2C Eguipment s rated capacity Do not over load arc welding equipment It may over heat cables and cause a fire Loose cable connections may overheat or flash and cause afire Never strike an arc on a cylinder or other pressure vessel It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling D Compressed Gas Eguipment Comply with precautions in 1 2D E Sho
19. the gap between the trigger lever and the micro switch lever This well 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 is activated Once activated the gun and wire feeder motors will begin feeding wire Retract the screw accordingly until the system is deactivated and adjusted to the operators liking Drive Roll and Idler Rolls General The Python Millermatic Compatible gun comes standard with a knurled drive roll and a grooved idler roll which will handle aluminum wire with diameters of 030 to 1 16 inch and steel from 030 to 045 inches Optional insulated V groove drive rolls are also available for aluminum wire if desired see Optional Kits Drive roll tension is accomplished with a unique spring loaded pressure screw The Python Millermatic Compatible comes from the factory with the pressure adjustment screw preset NO ADJUSTMENT IS REQUIRED FOR ALL SIZES AND TYPES OF WIRES Drive Roll Installation Removal NOTE Neither of the handles needs to be removed to access the Drive or Idler Rolls Cam Lever 1 Pull the Cam Lever away from the idler roll This will relieve the pressure against the drive roll as shown in Figure 1 Figure 1 2 Align the Drive Roll Removal Tool P N 931 0100 over the flats of the drive roll as shown in Figure 2 Hold the gun
20. to the potentiometer the micro switch the motor and the gun body mechanically Slack is left in the electric cable as it exits the back of the gun to prevent cable and or wire breakage The cabinet end of the control cable uses a 10 Pin X clocked Amphenol connector Operation General u The Python Millermatic Compatible gun aaa maintains a constant steady uniform wire feed Location speed regardless of curved or looped wire conduit The constant push exerted by the slave motor in the cabinet combined with the pull of the gun motor causes the wire to literally float friction free through the wire conduit The 24VDC gun motor is controlled by a three and three guarter 3 3 4 turn potentiometer in the gun handle Controls and Settings Potentiometer The laterally positioned potentiometer is located in the lower end of the handle providing upto 800 ipm with 3 3 4 turns Micro Switch Screw adjusted cul of trigger The micro switch assembly consists of the micro pre setting the micro switch switch and leads lever for shorter trigger motion l sensitivity Python Millermatic Compatible Owner s Manual Page 2 Trigger Sensitivity The amount of trigger level travel can be shortened for a guicker or more responsive action A more sensitive trigger lever is produced by reducing the gap between the trigger lever and the micro switch lever By turning in the Trigger Sensitivity Adjustment Screw it closed
21. 21 0392 2501 621 0392 500t1 3 64 1 2mm 060 1 5mm Spray 1 57 39 9mm 621 0393 25 621 0393 500t1 1 16 1 6mm 074 1 9mm 1 57 39 9mm 085 2 16mm Spray 621 0395 25 Use of tip removal tool is recommended t Also sold in quantities of 250 This size tip furnished with gun tt Also sold in quantities of 500 Spring Loaded Contact Tip 3 8 Diameter 030 0 8 mm 041 1 0 mm 1 57 39 9 mm 621 0331 035 0 9 mm 044 1 1 mm Spray 1 57 39 9 mm 621 0332 3 64 1 2mm 060 1 5 mm 1 57 39 9 mm 621 0334 1 16 1 6 mm 074 1 9mm Spray 1 57 39 9 mm 621 0335 3 8 Diameter Flex Barrel Tip Recommended for Flex Barre ___TiplD Arc Tip Length Qty 030 0 8 mm 621 0480 25 035 0 9 mm 1 0 25 4 mm 621 0481 25 045 1 1mm 1 0 25 4 mm 621 0482 25 3 64 1 2 mm Spray 621 0483 25 Used with Flex Barrel cups 621 0465 and 621 0466 on Air Cooled models only E erm E Finned Copper Cups Finned Copper Gas Cups No 6 3 8 9 5mm 621 0248 No 8 1 2 12 7mm 621 0249 No 10 621 0250 Heavy Duty Finned Copper Gas Cups CupSize CuplD PartNo 5 8 15 8mm 621 0251 3 4 19 0mm 621 0252 Standard furnished with Air Cooled gun Python Millermatic Compatible Owner s Manual Page 5 Air Cooled Cup Water Cooled Cup Adapter Water Cooled Cup Air Cooled Cups for Python Millermatic Compatib
22. EDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSAFZ DES HER STELLERS DIE UNFALLVERH TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Pythor Millermatic Compatible Owner s Manual Page 31 e Keep your head out of fumes e Turn power oft belore servieing Da not operate with panel apen ar Usb vertilation or sxhaust te Quart off ramove fumes from breathing zone Los humos fuera de ta tona de mes g Desconeciar al cablu da ai Ho cpurar con panel abierto a Spanien pirasi n menlaci n de poder de la m quina quardas quitatas AVISO DE isl ede farci ni los antes de Iniciar tuatqeter ssrvicia P R EC AUC IO N asplraciiin para gases Gardez la tite Ficar deslumbas e D branchez le courant avant Fenka e H on rez pas avec les panneaux French Udfisaz un ventilateur au un aspira tien Duveris nd avec les disposili s du teur pour Star les fum es des zones protection snieyis A E NTI O N de travail Vermaidan Sie das Einaimea von Strom vor Wartungsarkeiler Anlage nie thie Schabgehiuse Scinws brauch alrsctaiten Netetirom volle H oder InnemschutreerkInidung In Sorgen Sta F r gute Bea urd nen Maschine anhaiten Betrieb seiten Entiittung des Arbeitaniatres e Mantenha sen rosto da tumaga amp Nao opere com as tampas removidas e Mantenha se afastado das partes 9e Use venlila o s exhasst c para
23. J9Aod Assy 2 6GIZ 600 uoJOL 100g Assy b RL Lm D OO2 uly AJguiossy DB9 Python Millermatic Compatible Owner s Manual Page 21 Python Millermatic Compatible Lead Assembly AUSNT3 HOH HERS JON INE LA E mas ONY 2 Wap N33 4138 32 4815 Leiw 3H1 OL KOTON INOT untayka Me NE t WR SHOAH Oe ug GODI FOD LORI OL 3381 HOH Uu ATI 314v NI NOT wear SEA l Wi HI THAAL FHL CH XOTEPON DAC CR MOJADO ddr ME J WI MO MORI TE EE CH LU V Lj E1 zr SABU AC ONG OMY NON RON EET 3564 OI 04 gv S abo De M gel n x E S iN INOIO L ST NI Water Cooled Wa JM s ne OL amp KUM NILH INOAOL SITNI S 001 HLM N3IHOL ao JnO801 591 13 SZ ef HUM N31HDL Python Millermatic Compatible Owner s Manual Page 22 pepeeu se pojjejsui e1 pue p Aoul 1 aq ued pue ejgesn eJ SI 7907 79g esoH KEE EE EELER 6 05 09e0 500 9e 0900 500 2 0900 500 g1 0860 500 aeo jonuoo ssy L e1 x OO DEE EEN 09 0200 519 90 0700 519 57 0290 519 51 090 519 saner unpu r s os eczo zesse eezo zes sceezozes sr eezozes nia ew eson fesv L Lu Sozss Si aad em eson fesv L ZL J Y18 G8 0 S00 waji sepnjoul Hy ejpueH ee Y Ed GrO0 hy MIAN 2A X Gz deme v 8y v 100 8 1SS2 LXOr p OHS AeJoS v 4 1 p600 192 u P400 ids deM L gy 7600 192 ul G G P100 eads deM L vv GYEZ 00 O M Doug amod Assy 9662 600
24. ck Prevention Exposed electrically hot conductors or other bare metal in the welding circuit or in ungrounded electrically HOT eguipment can fatally shock a person whose body becomes a conductor DONOT STAND SIT LIE LEAN ON OR TOUCH a wet surface when welding without suitable protection To protect against shock Keep body and clothing dry Never work in damp area without adeguate insulation against electrical shock Stay on a dry duckboard or rubber mat when dampness or sweat cannot be avoided Sweat sea water or moisture between body and an electrically HOT part or grounded metal reduces the body surface electrical resis tance enabling dangerous and possibly lethal currents to flow through the body 1 Grounding the Eguipment When installing connect the frames of each unit such as welding power source control work table and water circulator to the building ground Conductors must be adequate to carry ground currents safely Eguipment made electrically HOT by stray currents may shock possibly fatally Do NOT GROUND to electrical conduit or to a pipe carrying ANY gas or a flammable liguid such as oil or fuel Three phase connection Check phase reguirement of eguipment before install ing If only three phase power is available connect single phase eguipment to only two wires of the three phase line Do NOT con nect the eguipment ground lead to the third live wire or the eguipment will become electrica
25. cross pin F wiper and pin E The resistance should vary from 0 5K ohms as the potentiometer is turned Check the resistance across pin F wiper and pin H The resistance should vary from 5K 0 ohms as the potentiometer is turned Testing the Micro Switch Using the amphenol connector check for continuity across pins D and G when the trigger is pressed Python Millermatic Compatible Owner s Manual Page 10 Appendices Diagrams Parts List EIA dd On a Ond 12 BOT Mal6rialuu uuu ico dd OS tO cad eds 13 Front BOOdY ASSOITIDIV u uuu EEA 14 Rear Body Assembly Air Cooled 15 Rear Body Assembly Water Cooled 16 Barrel Assembly Air Cooled 17 Barrel Assembly Water Cooled 18 Cup Insulator and O Ring Maintenance 19 Lead Assembly Air Cooled 20 Bikor GE a SAA EET 21 Lead Assembly Water Cooled 22 sm LLW a a EN 23 Spital Wrap Installation uo E orte ioc t oa o ao este test 24 Power Pin Adapter Assembly 27 Power Manifold Air Cooled
26. e Water Cooled Gas Cup or Air Cooled Gas Cup Assembly can be removed from the Cup Insulator 3 Inspect the Cup Insulator and o rings included with Insulator for wear and proper lubrication It is considered good practice to replace all o rings at the same time 4 To remove the Cup Insulator it must be unscrewed and pulled from the barrel Use a rag or towel due to o ring lubrication and wrap it around the Cup Insulator Unscrew and pull when completed unthreaded from barrel Be sure the Insulator is fully unscrewed from the threads Pulling the Insulator over barrel threads will damage the threads on the Insulator Inspect o rings on barrel for wear and lubrication It is considered good practice to replace all o rings at the same time 5 To install the Cup Insulator it must be pushed all the way onto the barrel then screwed onto the threads If necessary place small amount of o ring lubricant on the inside diameter of the Cup Insulator this will help it slide onto the barrel Push the Insulator onto the barrel until it bottoms out screw onto barrel threads The Insulator MUST be all the way onto the barrel to avoid assure proper coolant passage and from blocking the gas outlet orifices 6 Push Water Cooled Gas Cup or Chrome Nut Cup Adapter and Gas Cup Assembly onto Cup Insulator Slide Retaining Nut forward and tighten Insulator Barrel fg Fr rir LEE MS DITE i ah 4 rat bd T Correct Installation Incorrec
27. e patented EZ Lock Taper lock nut until it is clear of the threads Pull barrel out of the gun body To replace a barrel assembly open the drive and idler roll door and seat the barrel assembly until the inlet guide is almost touching the drive and idler roll and the rear face of the barrel is flush with the aluminum body block Take care not to damage the O rings when inserting into the body Tighten taper lock nut assembly firmly so that barrel cannot rotate Barrel Rotation To rotate a barrel assembly loosen the patented EZ Lock Taper lock nut assembly no more than 1 turn Rotate barrel to the position of your choice and retighten taper lock nut assembly firmly so that the barrel cannot rotate WARNING Do not attempt to weld without the barrel being tightly secured in the gun body or damage to the barrel or body may result Maintenance Periodic Maintenance Your Cobramatic System is designed to provide years of reliable service Maintenance of the gun will normally consist of a general cleaning of the wire guide system including barrels 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 The number of units in operation and the impo
28. elded on or cut Walls ceilings and floor near work should be protected by heat resistant covers or shields Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if 1 Appreciable combustibles including building construction are within 35 feet 2 Appreciable combustibles are further than 35 feet but can be ignited by sparks 3 Openings concealed or visible in floors or walls within 35 feet may expose combustibles to sparks 4 Combustibles adjacent to walls ceil ings roofs or metal partitions can be ignited by radiant or conducted heat Hot work permit should be obtained before operation to ensure supervisor s approval that adequate precautions have been taken After work is done check that area is free of sparks glowing embers and flames An empty container that held combus tibles or that can produce flammable or toxic vapors when heated must never be welded on or cut unless container has first been cleaned in accordance with industry standards This includes a thorough steam or caustic cleaning or a solvent of water washing depending on the combustible s solubility followed by purging and inert ing with nitrogen or carbon dioxide and using protective equipment Python Millermatic Compatible Owner s Manual Page i Water filling just below working level may substitute for inerting A container with unknown
29. elivery by MK Products No warranty is made by MK Products with respect o ade accessories or other items maeufaccured by others Such trade accessories and other izers are sold subject to the warran ties Of their respeczive manufacturers if any MK Products warranty does not apply to components having normal useful life of less han ane 11 year such as relay points wire comduil tungster and welding gun parts that come in contact with the welding wire including gas cups gas cup insulators and contact tips where failure does not result trom defect in workmanship or material MK Products shall exclusively remedy the limited warranty or ary duties with respect zo the quality of goods based upon the following options 1 repair 2 replacemenr 3 where authorized in writing by M lt Preduczs de reasonable cos of repair or replacement at our Irvine California plant As a matter c general policy only MK Products may honor an original user s warranty claims on warranted equipment in the event of failure resultira from a defect within the following periods from the date or delivery o equipment co the original user 1 Power Supplies and Wire Feed Cabinets 3 years 2 Weldheads Coolers Positioners and Push Pull Guns 1 year 3 Spool Guns and Spool Gur Modules 180 days 4 Repairs Exchanges FT 16882 Armstrong Ave Irvine CA 92606 MIL PRODUCTS www mkproducts com Class
30. ghly toxic gas and other lung and eye irritating prod ucts The ultraviolet radiant energy of the arc can also decompose trichloroethylene and perchloroethylene vapors to form phos gene DO NOT WELD or cut where solvent vapors can be drawn into the welding or cut ting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene C Fire and Explosion Prevention Causes of fire and explosion are com bustibles reached by the arc flame flying sparks hot slag or heated material misuse of compressed gases and cylinders and short circuits BE AWARE THAT flying sparks or fall ing slag can pass through cracks along pipes through windows or doors and through wall or floor openings out of sight of the goggled operator Sparks can fly many feet To prevent fires and explosion Keep equipment clean and operable free of oil grease and in electrical parts of metallic particles that can cause short circuits If combustibles are in area do NOT weld or cut Move the work if practicable to an area free of combustibles Avoid paint spray rooms dip tanks storage areas ventilators If the work cannot be moved move combustibles at least 35 feet away out of reach of sparks and heat or protect against ignition with suitable and snug fitting fire resistant covers or shields Walls touching combustibles on oppo site sides should not be w
31. h exposure exists Protect cylinders particularly valves from bumps falls falling objects and weather Replace caps securely when moving cyl inders Stuck valve Do NOT use a hammer or wrench to open a cylinder valve that cannot be opened by hand Notify your supplier Mixing gases NEVER try to mix any gases in a cylinder NEVER refill any cylinder Cylinder fittings should never be modified or exchanged 3 Hose Prohibited use Never use hose other than that designed for the specified gas A general hose identification rule is red for fuel gas green for oxygen and black for inert gases Use ferrules or clamps designed for the hose not ordinary wire or other substitute as a binding to connect hoses to fittings No copper tubing splices Use only stan dard brass fittings to splice hose Avoid long runs to prevent kinks and abuse Suspend hose off ground to keep it from being run over stepped on or otherwise damaged Coil excess hose to prevent kinks and tangles Protect hose from damage by sharp edges and by sparks slag and open flame Examine hose regularly for leaks wear and loose connections Immerse pressured hose in water bubbles indicate leaks Repair leaky or worn hose by cutting area out and splicing Do NOT use tape 4 Proper Connections Clean cylinder valve outlet of impurities that may clog orifices and damage seats before connecting regulator Except for hydrogen crack valve
32. hose retainer is re usable and can be removed and re installed as needed Python Millermatic Compatible Owner s Manual Page 1 Section B Coolant Connections If so eguipped the ends of the coolant hose push over a barbed fitting on the end of the gun body and are secured by twisting the hose retainer to the end of the hose The hose retainer is re usable and can be removed and re installed as needed The BLUE coolant supply hose pushes over a barbed fitting on the end of the gun body and is secured by twisting the hose retainer to the end of the hose The hose retainer is re usable and can be removed and re installed as needed The opposite end of the BLUE hose pushes into a threaded coolant fitting The RED coolant return hose pushes over the barbed fitting in the Power Manifold The opposite end of the RED hose pushes into a threaded return hose of the coolant recirculator Both threaded fittings on the end of the BLUE and RED hoses are standard left hand thread MK Products compatible guns have interchangeable fittings so you can match as needed for your cooler Both types of fittings reguire a hose retainer 431 1898 431 1910 431 1893 753 3379 5 16 Hose Retainer Quick Connect Fitting Nipple Left Hand Threaded Fitting Must be ordered together Control Cable A multi conductor control cable is used on the Python Millermatic Compatible The gun end of the cable is secured with a cable clamp and the wires are connected
33. ifcadon of any item into the foregoing categories shall be at the sole discretion of MK Products otif cation of any failure must be made HY writing within 30 days of Such failure A copy of the invoice showing the date of sale rust accompany products recurned For warranty repair or replacement All equipment returned to IK Products for service must be property packaged to guard agains damage rom shipping MK Products will no be resporsible for any damages resulting from shipping Non al surface cransportauon charges tane way or products returned for wairar y r pair or replacement will be borne by MK Products except for products sold to foreign markets ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REFTEDY FOR BREACH OF CONTRACT WHICH BUT FOR THIS PROVISION MIGHT ARISE 3Y IMPLICATION GPESATION OF AW CUSTOM OF TRADE OR COURSE OF DEALING INCLU DIG AMY IMPLIED WARRANTY OF MEXCHARTABILITY OR OF FITNESS Ox PARTICU AR PURPOSE WITH ESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MKPRODUCTS IS EXCLUDED ANO DISCLATMED BY MK PRODUCTS EXCEPT AS EXPRESSLY PROVIDED SY MK PRODUCTS IN WRITING MKE PRODUCTS ARE INTENDED FOR ULTIMATZ PURCHASE BY COM PERCIAL INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF W EL3ING EQUIPMENT AND NOT FO CONSUMERS OR CONSUMER USE MK PRODUCTS WARRANTIES DO NOT EXTEND TO AND NO
34. le Water Cooled Gun No 6 3 8 9 5mm 621 0170 E 12 7mm 621 0759 SE 1 8mm 621 0760 To use air cooled gas cups you must use a cup retaining nut 449 0193 and a water cooled cup adapter 621 0101 Water Cooled Cups for Python Millermatic Compatible Water Cooled Gun 5 8 15 0mm 621 0065 Standard furnished with gun Flex Barrel Gas Cups 1 2 12 7mm 621 0465 5 8 15 8mm 621 0466 Works with Air Cooled models only Tip Extender Tip Extenders and Gun Barrel Liners PartNumber Description k Steel wire only 030 1 16 0 8 0 9mm Barrel Assemblies All barrels are rated at 6096 duty cycle A CP 225 Amps 50 Amps 225 Amp Air Cooled 60 M Water Cooled 60 ji P N 003 2272 P N 003 2317 Air Water Cooled 45 Standard on AC Standard on WC P N 003 2152 Optional on AC 300 Amps 7 200Amp Water Cooled Air Cooled Only P N 003 2380 P N 003 2495 12 Optional on WC Optional on AC Barrels Air Cooled The Python Millermatic Compatible air cooled gun comes standard with a 60 curved barrel The barrel assembly locks to the gun body using the patented EZ Lock system Water Cooled The Python Millermatic Compatible water cooled gun comes standard with a 60 curved water cooled barrel assembly Optional 6 12 and 18 Straight and Curved Barrel Assemblies 12 Straight Air Cooled Barrel Assembly
35. led P N 003 2289 APPLY SILICONE LUBRICANT FOR INSTALLATION Air Cooled Rear Body Assembly No Qty PartNo Description af Notavailable separately 6 1 41 0243 TieWrapSor4 Python Millermatic Compatible Owner s Manual Page 15 Python Millermatic Compatible Rear Assembly Water Cooled P N 003 2287 eS 2 br APPLY SILICONE LUBRICANT FOR INSTALLATION Water Cooled Rear Body Assembly No Qty PartNo Description af Notavailable separately Cz s 308 0006 O Ring 1451Dx 07W Python Millermatic Compatible Owner s Manual Page 16 Python Millermatic Compatible Barrel Assembly Air Cooled P N 003 2272 0 05 a G C RONG GROOVE REF _Oty Part Number REN CNN 1 005 0696 1 261 0143 1 3130091 1 6210250 1 5210393 Python Millermatic Compatible Owner s Manual Page 17 r F 431 1774 r Python Millermatic Compatible Barrel Assembly Water Cooled P N 003 2317 Apply silicone lubricant to items 5 and 6 before installing Description Cox 303 0094 O Ring 301 ID x 07 W Python Millermatic Compatible Owner s Manual Page 18 CUP INSULATOR AND O RING MAINTENANCE CAUTION Power off the coolant pump before disassembling water cooled barrels 1 Unscrew Retaining Nut and slide back on barrel 2 Using a firm pull and twist action th
36. lly HOT a dangerous condition that can shock possibly fatally Before welding check ground for continuity Be sure conductors are touching bare metal of eguipment frames at connections If a line cord with a ground lead is provided with the eguipment for connection to a switch box connect the ground lead to the grounded switch box If a three prong plug is added for connection to a grounded mating receptacle the ground lead must be connected to the ground prong only If the line cord comes with a three prong plug connect to a grounded mating receptacle Never remove the ground prong from a plug or use a plug with a broken ground prong 2 Connectors Fully insulated lock type connectors should be used to join welding cable lengths 3 Cables Frequently inspect cables for wear cracks and damage IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable Cables with damaged areas may be taped to give resistance equivalent to original cable Keep cable dry free of oil and grease and protected from hot metal and sparks 4 Terminals and Other Exposed Parts Terminals and other exposed parts of electrical units should have insulating covers secured before operation 5 Electrode Wire Electrode wire becomes electrically HOT when the power switch of gas metal arc welding equipment is ON and welding gun trigger is pressed Keep hands and body clear of wire and o
37. ns connections Check power supply owners manual for location and type of contactor signal required Welding power source Check power source Dirty or worn conduit PON OU GE conduit Wire feeds Wrong size contact tip See Contact tip table erratically Check for lock washer Idler roll stuck under idler roll or replace if damaged Bad potentiometer Check with meter Check potentiometer Broken electrical cable wires for continuity or Wire feeds one short speed only See specific cabinet control owners manual for speed control operation i Idler roll upside down noe O THAI Wire walks out of p roll toward top drive rolls Rear wire guide missing Replace wire guide Bad Speed control PCB Wire feeds but welding wire is not Contactor control cable energized loose or in wrong position Bad speed control Python Millermatic Compatible Owner s Manual Page 9 Troubleshooting Guide Regardless of which gun or feeder used all MK Products push pull guns operate on the same principle The 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 motor gets all it wants it slows the slave motor preventing a bird s nest Because of the low torque produced by the slave motor a brake system is used to prevent wire overrun rather than tension The drag adjustment in the feeder is used
38. rtance of minimal down time will determine to what extent spare parts should be stocked on hand See the Recommended Spare Parts List for the most commonly replaced parts If repairs do become necessary qualified shop maintenance personnel can easily replace any part Maintenance Tools Contact Tip Removal Tool 31 0044 Drive Roll Removal Tool 931 0100 Python Millermatic Compatible Owner s Manual Page 7 Recommended Spare Parts List PartNo Description DRIVE ROLL REMOVAL TOOL 931 0100 IDLER ROLL 005 0686 KNURLED DRIVE ROLL 511 0101 MICRO SWITCH ASSEMBLY 005 0701 Python Millermatic Compatible Owner s Manual Page 8 Section E Troubleshooting Trouble Cause Remedy 115 42 VAC Control fuse in i feeder Control box blown REDODD No wire feed at gun UE feeder not operating Micro switch defective not Replace switch Check i e no slave motor being activated switch for operation or brake solenoid Broken electrical cable Check micro switch wires for continuity 24 VAC Control fuse in Check motor leads for feeder Control box blown shorts then replace fuse Bad potentiometer Check potentiometer with meter Check motor and Broken Electrical Cable potentiometer wires for continuity No wire feed at gun feeder operating properly See specific cabinet control box owners manual for speed control operation Loose or no cable Check all power connectio
39. s or other reproductive harm Adequate ventilation Severe discomfort ill ness or death can result from fumes vapors heat or oxygen enrichment or depletion that welding or cutting may produce Prevent them with adequate ventilation NEVER ventilate with oxygen Lead cadmium zinc mercury beryllium bearing and similar materials when welded or cut may produce harmful concentrations of toxic fumes Adequate local exhaust ven tilation must be used or each person in the area as well as the operator must wear an air supplied respirator For beryllium both must be used Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed form the work surface the area is well ventilated or the operator wears an air supplied respirator Work in a confined space only while it is being ventilated and if necessary while wearing an air supplied respirator Gas leaks in a confined space should be avoided Leaked gas in large quantities can change oxygen concentration danger ously Do not bring gas cylinders into a confined space Leaving confined space shut OFF gas supply at source to prevent possible accu mulation of gases in the space if down stream valves have been accidentally opened or left open Check to be sure that the space is safe before reentering it Vapors from chlorinated solvents can be decomposed by the heat of the arc or flame to form PHOSGENE a hi
40. t Installation Python Millermatic Compatible Owner s Manual Page 19 Python Millermatic Compatible Lead Assembly Air Cooled ALWYD 303 MIMOHS EON WEL Le k ril a E YMI ON Wall N33AISS OI OVINOS JHI OL XOTvON INO ONDOGWOD M e Wi y m WAU ONOX3E SIHIN SCOPSO O ANI CL M3NIT NOWELL AIBA MaL INT MO Wiel NEZ d mm a K J W3U JO NOLYTTYISNI SCH ZI W31l JO SQN3 HIC Semi hr OHONUA CHEN A dd Ver Yw T lt lt n Gert 3800032084 335 E 3n o1 Sg TNI S 66 HIM N31HOL AAA OL SgT HI S SS HIM NBLHOL y nO SJ Fld SZ HLM N3IHZH Python Millermatic Compatible Owner s Manual Page 20 L G00 LOZ N d deim 1eddoo sopnjoui ajqed 4 MOd pepeeu se pojjejsul ei pue peanouiei aq ued pue ojgesn eJI si Jeule eH esoH 0S 1 20 r8 SE S1L0 r6 Se S1Z0 r8 si sizo eve guoHdo eiqeO emoa xa enin 0s 0r90 era se 0r90 era Sz Ora0 era si ore0 eval reqoro lqed amod ssy 1 7 09 0860 900 0860 000 52 0860 00 91 0880 900 egeo JelouoO 4ssy 1 9r DRECHEN 0S 0290 S19 6 0290 S19 ENEE oanu er impuoo er JN 1d G860 G00 w sepnjoul hy ejpueH 8681 1 f 91 9 ueure ou esoH 2 6 GO LI Wa N ead X GZ dem al p 8x v L00 8 LSS Z L X 0t OHS MEDS 1 P600 192 97 0 E P100 eads dem L sv 600 192 91 99 P100 ends dem L eeg 600 Io 181depy uid jewod Assy c 00 ON plolueW
41. ther HOT parts 6 Safety Devices Safety devices such as interlocks and circuit breakers should not be discon nected or shunted out Before installation inspection or service of equipment shut OFF all power and remove line fuses or lock or red tag switches to prevent accidental turning ON of power Disconnect all cables from welding power source and pull all 115 volts line cord plugs Do not open power circuit or change polarity while welding If in an emer gency it must be disconnected guard against shock burns or flash from switch arcing Leaving equipment unattended Always shut OFF and disconnect all power to equipment Power disconnect switch must be avail able near the welding power source Python Millermatic Compatible Owner s Manual Page iii For selecting a guality product We want you to take UL pride in operating this nroduct as much pride as we have in bringing the product fo you Please Examine Carton and Eguipment For Damage Immediately When this eguipment is shipped title passes to the purchaser upon receipt by the carrier Conseguently 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 amp Number Code amp Serial Number Date of Purchase
42. tible Owner s Manual Page 28 Python Millermatic Compatible Power Manifold Assembly Water Cooled P N 003 2345 APPLY HIGH STRENGTH THREAD SEALANT a 2 TIGHTEN WITH 6545 IN LBS TORQUE Water Cooled Power Manifold Assembly No Qty PartNo Descrption 431 1905 Fitting 1 8 ID x 1 16 27 NPT 431 1951 Power Manifold WC 751 0017 Plug Sealing 4MM x 4MM SST Python Millermatic Compatible Owner s Manual Page 29 Python Millermatic Compatible Electrical 26 oi un P Sg C Om boo Oo Oz o o Co em oe e O nu ot _ e T Polarizing Key X Clocked Connector Viewed from back of connector ke eo Se 00000000 ES lt O m T u UOO sl CO Python Millermatic Compatible Owner s Manual Page 30 Do not touch electrically We parts or electrode with skin pr wel clothing Insulala yoursel from work and 0 No toque las partes o Ips eleciredos bajo carga con la pial c ropa moja AVISO DE PRECAUCION ATTENTION WARNUNG iz Alsiazn cal trabajo y da ja tiarra 4 Ha lalss82 ni la peau ni deg vHe ments mouill s entrar en contact aver dez paces sous tension e Enler vous du iravai et de a terra 4 Herikon Sle kelne stromi hren an Teils oder Eiekiroden mit Ihrem Korgar oder feuchter Kieldung e lgnligE Sip sich ynn den Elektroden um dem Erdboden Hic toque partes E HIT U EE d alet todos enm a pele ou roupa malha
43. tion ELECTRIC ARC WELDING PRODUCES HIGH INTENSITY HEAT AND ULTRA VIOLET RADIANT ENERGY WHICH MAY CAUSE SERIOUS AND PERMA NENT EYE DAMAGE AND WHICH MAY DAMAGE ANY EXPOSED SKIN AREAS Wear helmet with safety goggles or glasses with side shields underneath appropriate filter lenses or plates pro tected by clear cover glass This is a must for welding or cutting and chipping to protect the eyes from radiant energy and flying metal Replace cover glass when broken pitted or spattered Medical first aid and eye treatment First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for immediate treatment of flash burns of the eyes and skin burns Wear protective clothing leather or asbestos gauntlet gloves hat and high safety toe shoes Button shirt collar and pocket flaps and wear cuffless trousers to avoid entry of sparks and slag Avoid oily or greasy clothing A spark may ignite them Flammable hair preparations should not be used by persons intending to weld or cut Hot metal such as electrode stubs and work pieces should never be handled without gloves Ear plugs should be worn when working on overhead or in a confined space A hard hat should be worn when others work overhead B Toxic Fume Prevention WARNING The use of this product may result in exposure to chemicals known to the State of California to cause cancer and birth defect
44. with one hand or on a table top with the other hand give the Removal Tool a quick snap turn in the CLOCKWISE DIRECTION Figure 2 3 Once the drive roll is loose continue to spin drive roll in the clockwise direction to remove the drive roll from the gun 4 Install a new drive roll on the left hand threaded shaft The drive roll will self tighten when it is feeding 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 Python Millermatic Compatible Owner s Manual Page 3 Section C idler Roll 38 Groove Towards Top Fm Lock Washer Pl Spring Figure 3 Idler Arm Screw NOTE Lock washer must be under idler roll or it will not turn freely Accessories Options Insulated Drive Roll Kits are used to prevent preheating of the wire which may soften it and clog the liner This picking up of current at the drive rolls rather than at the contact tip is usually not a problem unless using too large of a contact tip or excessively oxidized aluminum wire Insulated Groove Drive Roll Kit For 030 0 8mm dia aluminum wire and insulated idler roll assy Insulated Groove Drive Roll Kit For 035 0 9mm dia aluminum wire
45. ximum leave cylinder valve in following position for oxygen and inert gases open fully to seal stem against possible leak for fuel gas open to less than one turn to permit quick emergency shut off Use pressure charts available from your supplier for safe and efficient recom mended pressure settings on regulators Check for leaks on first pressurization and regularly thereafter Brush with soap solution Bubbles indicate leaks Clean off soapy water after test dried soap is combustible E User Responsibilities Follow all Safety Rules Remove leaky or defective equipment from service immediately for repair Read and follow user manual instructions F Leaving Equipment Unattended Close gas supply at source and drain gas G Rope Staging Support Rope staging support should not be used for welding or cutting operation rope may burn 1 3 ARC WELDING Comply with precautions in 1 1 1 2 and this section Arc Welding properly done is a safe process but a careless operator invites trouble The equipment carries high currents at significant voltages The arc is very bright and hot Sparks fly fumes rise ultraviolet and infrared energy radiates weldments are hot and compressed gases may be used The wise operator avoids unnecessary risks and protects himself and others from accidents Python Millermatic Compatible Owner s Manual Page ii A Burn Protection Comply with precautions in 1 2 The welding
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