MK Products Python Advanced Gooseneck Welding System Owner's Manual

Product Description

Python

®

MK Manual Part Number

091-0505

MK Form Number

CM/OM

NWSA Form Number

550

Effective with Serial Number

03070085

Voltage Rating

24 VDC

Printing/Revision Date

November 2003 D

This manual applies to the following torch model numbers

226-XXX

225-XXX

Advanced

Gooseneck

16882 Armstrong Ave., Irvine, California 92606 TEL(949)863-1234 FAX(949)474-1428 www.mkproducts.com

SAFETY CONSIDERATIONS

ELECTRIC ARC WELDING EQUIPMENT

CAUTION : READ BEFORE ATTEMPTING INSTALLATION, OPERATION

OR MAINTENANCE OF THIS EQUIPMENT

1-1 INTRODUCTION

This equipment is intended for ultimate application by commercial/industrial users and for operation by persons trained and experienced in the use and maintenance of welding equipment.

Operation should not be undertaken without adequate training in the use of such equipment. Training is available from many public and private schools or similar facilities.

to the State of California to cause cancer and birth defects or other reproductive harm.

Adequate ventilation. Severe discomfort, illness 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.

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.

Safe practices in the installation, operation and maintenance of this equipment requires proper training in the art, a careful 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 Prevention

ELECTRIC ARC WELDING PRODUCES

HIGH INTENSITY HEAT AND

ULTRAVIOLET RADIANT ENERGY

WHICH MAY CAUSE SERIOUS AND

PERMANENT 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

(protected 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.

Lead-, cadmium-, zinc-, mercury-, beryllium-bearing and similar materials, when welded or cut, may produce harmful concentrations of toxic fumes.

Adequate local exhaust ventilation 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 dangerously. Do not bring gas cylinders into a confined space.

Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream 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 highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the arc can also decompose trichloroethylene and perchloroethylene vapors to form phosgene. DO NOT

WELD or cut where solvent vapors can be drawn into the welding or cutting 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: combustibles reached by the arc, flame, flying sparks, hot slag, or heated material, misuse of compressed gases and cylinders, and short circuits.

Walls touching combustibles on opposite sides should not be welded 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, ceilings, 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 combustibles, 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 inerting with nitrogen or carbon dioxide, and using protective equipment.

Water-filling just below working level may substitute for inerting.

A container with unknown contents should be cleaned (see paragraph above). Do NOT depend on sense of smell or sight to determine if it is safe 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.

BE AWARE THAT flying sparks or falling 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:

Hollow castings or containers must be vented before welding or cutting. They can explode.

B. Toxic Fume Prevention

WARNING: The use of this product may result in exposure to chemicals known

Keep equipment clean and operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause

Explosive atmospheres. NEVER weld or cut where the air may contain flammable dust, gas, or liquid vapors (such as gasoline).

D. Compressed Gas Equipment

The safe handling of compressed gas equipment is detailed in numerous industry publications. The following

Python Owner's Manual Page i

general rules cover many of the most common situations.

1. Pressure Regulators

Regulator relief valve is designed to protect only the regulator from overpressure; 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 manufacturer’s designated repair center, where special techniques and tools are used by trained personnel.

2. Cylinders

Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety devices:

Avoid electrical circuit contact with cylinders including third rails, electrical wires, or welding circuits. They can produced short circuit arcs that may lead to a serious 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 cylinders with name of gas marked on them; do not rely on color to identify gas content. 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 separate 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 cylinders 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 such exposure exists.

Protect cylinders, particularly valves from bumps, falls, falling objects, and weather. Replace caps securely when moving cylinders.

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 standard 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 momentarily, pointing outlet away from people and sources of ignition. Wipe with a clean, lintless cloth.

Match regulator to cylinder. Before connecting, 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 containing any other gas.

Tighten connections. When assembling threaded connections, clean and smooth seats where necessary. Tighten. If connection 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 regulator pressure increases slowly.

When gauge is pressurized (gauge reaches regulator maximum) 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 recommended 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.

A. Burn Protection

Comply with precautions in 1-2.

The welding 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

Python Owner's Manual Page ii

acute sunburn; those from gas-shielded arcs are more severe and painful.

DON’T GET BURNED; COMPLY WITH

PRECAUTIONS.

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, substantial 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 protection 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, noncombustible 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 persons 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 monoxide can kill.

C. Fire and Explosion Prevention

Comply with precautions in 1-2C.

Equipment’s rated capacity. Do not overload arc welding equipment. It may overheat 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 Equipment

Comply with precautions in 1-2D.

E. Shock Prevention

Exposed electrically hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a conductor. DO

NOT 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 adequate 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 resistance, enabling dangerous and possibly lethal currents to flow through the body.

1. Grounding the Equipment

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. Equipment 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 liquid such as oil or fuel.

Three-phase connection. Check phase requirement of equipment before installing. If only three-phase power is available, connect single-phase equipment to only two wires of the three-phase line. Do NOT connect the equipment ground lead to the third (live) wire, or the equipment will become electrically HOT - a dangerous condition that can shock, possibly fatally.

Before welding, check ground for continuity. Be sure conductors are touching bare metal of equipment frames at connections.

If a line cord with a ground lead is provided with the equipment for connection to a switch box, connect the ground lead to the grounded switch box. If a threeprong 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 other HOT parts.

6. Safety Devices

Safety devices such as interlocks and circuit breakers should not be disconnected 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 emergency, 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 available near the welding power source.

Python Owner's Manual Page iii

Thank You

For selecting a quality product. We want you to take pride in operating this product...as much pride as we have in bringing the product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Model Name & Number _____________________

Code & Serial Number _____________________

Date of Purchase _____________________

Whenever you request replacements parts for, or information on this equipment always supply the information you have recorded above.

Read this Owner’s Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.

Table of Contents

Safety Considerations ........................................................................i-iii

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

Technical Specifications.....................................................................................1

Support Equipment Required.............................................................................1

Coolant Recommendations................................................................................1

Torch Lead Connections ....................................................................................2

Operation.................................................................................Section B

General ..............................................................................................................2

Controls and Settings.........................................................................................2

Trigger Adjustment .............................................................................................3

Drive Roll and Idler Rolls ...................................................................................3

Accessories .............................................................................Section C

Optional Kits.......................................................................................................4

Conduits.............................................................................................................5

Snake Skins .......................................................................................................5

Contact Tips .......................................................................................................5

Gas Cups ...........................................................................................................6

Barrels................................................................................................................6

Maintenance............................................................................Section D

Periodic Maintenance ........................................................................................7

Recommended Spare Parts List ........................................................................8

Troubleshooting.......................................................................Section E

Troubleshooting Guide.....................................................................................10

Testing The Torch.............................................................................................10

Appendices..............................................................................Section F

Diagrams / Parts List........................................................................................ 11

Mechanical.......................................................................................................12

Electrical...........................................................................................................20

MK Repair Stations

Safety Warnings

Warranty

THIS PAGE INTENTIONALLY BLANK

Section A 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 - 100%

All ratings are using Argon gas

200 Amps/25 Volts Air cooled standard

225 Amps/25 Volts Water cooled standard

300 Amps/25 Volts Water cooled using optional W/C barrel

(P/N 003-2104)

400 Amps/25 Volts Water cooled using optional W/C barrel & cup

(P/N 003-2104 & 621-0065)

Shipping Weight (approximate)

Air Cooled

15ft. (4.5m)....................................... 13.09 lbs. (5.94 Kg)

25ft. (7.6m)....................................... 19.29 lbs. (8.29 Kg)

50ft. (15.2m)..................................... 29.9 lbs. (13.19 Kg)

Water Cooled

15ft. (4.5m)....................................... 13.59 lbs. (6.16 Kg)

25ft. (7.6m)....................................... 19.69 lbs. (8.93 Kg)

50ft. (15.2m)..................................... 34.79 lbs.(15.78 Kg)

Torch weight (less leads)

Air/Water cooled - 2.5 lbs. (1.13 kilogram)

Water cooled - 2.6 lbs (1.18 kilogram) with optional W/C barrel

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.

• Water source and hose capable of providing a minimum of

1 quart

(.95 liter) / min. at 45 p.s.i. when using water cooled torches.

Coolant Recommendations

Use a name-brand additive, which does not contain reactive sulphur or chlorine and does not react with copper, brass or aluminum or create a custom mix using this formula:

Use 3 Gallons (11.4 Liters) distilled water.

Use 1 Gallon (3.8 Liters) ethylene glycol.

Use 1 tsp (5 ml) liquid glycerin

The Coolant rate should be 1 quart (.95 liter) / minute at 35 p.s.i.

Python Owner's Manual - Page 1

Section B

Torch Lead Connections

Power Cable - Air Cooled

A #2 AWG power cable is used on the Python

®

air cooled torch. The torch end is threaded into the torch body. The power cable fitting connects to the power block in the Cobramatic

®

wire feed cabinet.

Power Cable - Water Cooled

Python

®

water cooled torch utilizes a power/water cable with a #4 AWG cable inside a 5/8” (16MM) 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 400 amps @ 100% duty cycle.

Conduit

The Python

®

torch comes standard with a poly-lined conduit, for feeding aluminum wire. The longer fitting with a shallow groove is used on the torch end. A set screw located on top of the torch handle secures the conduit in place.

Gas Hose

The gas hose is secured over the barbed gas fitting with a tie wrap. The cabinet end of the gas hose uses our standard gas fitting (1/8” - 27 nps).

Water Hose

If so equipped; one end of the water hose is secured over the barbed water fitting with a tie wrap and the other end is connected to the center fitting on the power block.

Electric Cable

A seven conductor control cable is used on the Python

®

torch. The torch end of the control cable is secured to the torch with a boot clamp and soldered into the pot assembly and micro switch connectors. Slack is left in the electric cable as it exits the back of the torch to prevent cable breakage. The cabinet end has a seven pin “W” clocked amphenol connector.

Operation

General

The Python

®

torch maintains a constant, steady, uniform wire feed 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 torch motor, causes the wire to literally float friction-free through the wire conduit. The

24VDC torch motor is controlled by a three and three-quarter (3 3/4) turn potentiometer in the torch handle.

Controls and Settings

Potentiometer

The laterally-positioned potentiometer is located in the lower end of the handle, providing up to 800 ipm with 3 3/4 turns.

Micro Switch

The micro switch assembly consists of the micro switch, and leads.


Trigger Sensitivity

The amount of trigger level travel can be shortened for a quicker 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 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 tortch 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

®

torch comes standard with a knurled drive roll and a grooved idler roll, which will handle both steel and aluminum wire with diameters from

.030-1/16 inch. 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

®

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 torch 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 torch.

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.

Section C

3. Tighten.

Figure 3

NOTE: Lock washer must be under idler roll or it will not turn freely.

Accessories

A gas flow control mechanism (i.e. solenoid or valve) is required so the

Python

®

can be used on Cobra wire feeders. The following kits are available depending on the wire feeder used. The factory set times (in seconds) for normal and latched trigger functions is 0.5 pre-purge and 1.0 post-purge.

Gas Purge/Trigger Latch Kit .......................................................... 005-0674

This kit is required when using the Python

®

on Cobramatic

®

, models 150-003

& 150-005 and the CobraMig

®

260, Model 186-002.

Pre/Post/BurnBack/Spot Timer kit ................................................ 005-0196

This kit is required when using the Python

®

on Cobramatic

®

II, model 150-

004.

Optional Kits

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..................................................... 005-0640

For .030" (0.8mm) dia. aluminum wire. Includes insulated drive roll

P/N 511-0102 and idler roll assy. P/N 003-1870.








Insulated Groove Drive Roll Kit.......................................................005-0643



Insulated Groove Drive Roll Kit.......................................................005-0644



Handle Kit..........................................................................................005-0699

Includes left and right handles, screws and drive roll door.

Trigger Kit..........................................................................................005-0694

Trigger adjustment kit includes a spring and sensitivity adjustment screw replacement for all Python

®

/CobraMAX™ torches.

Micro Switch Kit................................................................................005-0701

Replacement micro switch assembly for all Python

®


Potentiometer Kit..............................................................................005-0695

Replacement potentiometer assembly for all Python

®


Barrel Upgrade Kit............................................................................005-0696

Includes replacement barrel insulation.

Conduits

Flat spiral steel conduit Standard conduit

for steel & cored wire. with additional protective cover.

615-0208 ................15 ft./4.5m 001-0774................ 15 ft./4.5m

615-0216 ................25 ft./7.6m 001-0775................ 25 ft./7.6m

615-0218 ................50 ft./15.2m 001-0777................ 50 ft./15.2m

Snake Skins

Snake Skin protective covers are now standard on all torches. You may order spare replacement covers to protect the lead assy of the torch 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 48ft (for 50ft leads) ....................................... 931-0123

Contact Tips

To remove contact tip when using full water cooled gas cup (P/N 621-0065), contact tip removal tool (P/N 931-0002) must be used.

Part No.

621-0390

Heavy Duty Contact Tip - 3/8" Diameter

Wire Size

.030” (0.8mm)

621-0396

621-0391

621-0397

621-0392

621-0398

621-0393*

621-0399

621-0394

.030” (0.8mm)

.035” (0.9mm)

.035” (0.9mm)

.045” (1.2mm)

.045” (1.2mm)

.045” or .052”

.045” or .052”

1/16” (1.6mm)

621-0400

621-0395

1/16” (1.6mm)

1/16” (1.6mm)

*standard - furnished with torch

Tip ID

.040” (1.0mm)

.040” (1.0mm)

.044” (1.1mm)

.044” (1.1mm)

.053” (1.35mm)

.053” (1.35mm)

.060” (1.5mm)

.060” (1.5mm)

.075” (1.9mm)

.075” (1.9mm)

.085” (2.16mm)

Arc

Spray

Short

Spray

Short

Spray

Short

Spray

Short

Spray

Short

Spray

Tip Length

1-5/8” (41.3mm)

1-7/8” (47.6mm)

1-5/8” (41.3mm)

1-7/8” (47.6mm)

1-5/8” (41.3mm)

1-7/8” (47.6mm)

1-5/8” (41.3mm)

1-7/8” (47.6mm)

1-5/8” (41.3mm)

1-7/8” (47.6mm)

1-5/8” (41.3mm)


Finned Copper Cups

Cup Size

No. 6

No. 8

Finned Copper Gas Cups

Cup I.D.

3/8” (9.5mm)

1/2” (12.7mm)

Part No.

621-0248

621-0249

No. 10

12

*Standard - furnished with torch

5/8” (15.8mm) 621-0250*

Heavy Duty Finned Copper Gas Cups

Cup Size Cup I.D.

Part No.

10 5/8" (15.8mm) 621-0251

3/4" (19.0mm) 621-0252

Air Cooled Cups for Python

®

Water Cooled Torch


Part No.

No. 6

No. 8*

3/8” (9.5mm)

1/2” (12.7mm)

621-0170

621-0159

No. 10 5/8” (15.8mm) 621-0160

*Standard - furnished with torch

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


®

Water Cooled Torch

Part No.

No. 10 5/8” (15.9mm) 621-0065

Part Number

931-0137

615-0338

621-0424

615-0250

Torch Barrel Liners

Description

Teflon liner package, 5 pieces

Steel wire only, .030 - .1/16" (0.8 - 0.9mm)

Python

®

tip extender (Air/Water cooled barrel only)

Spiral steel liner for tip extender

Barrel Assemblies

All barrels are rated at 100% duty cycle

Barrels

Air/Water Cooled

The Python

®

air cooled systems (225 Series) come standard with a 60˚ curved barrel. The barrel assembly locks to the Python

®

body using the patented EZ Lock™ system.

200 Amps, Air Cooled

(P/N 003-2147)


Water Cooled

The Python

®

water cooled systems (226 Series) come standard with a 60˚ curved water cooled barrel assembly.

Section D

300 Amps, Water Cooled

(P/N 003-2104)

400 Amps, Water Cooled

(P/N 003-2104)

(shown with optional #10 Gas Cup

P/N 621-0065)

Barrel Removal and Installation

Note: Turn off water circulator prior to loosening and removing barrels.

To remove the barrel assembly, loosen the patented EZ Lock™ taper lock nut until it is clear of the threads. Lift 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 torch 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 torch 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 importance 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

Tool

Contact Tip Removal Tool

Part Number

931-0002

Drive Roll Removal Tool 931-0100


Qty.

1

10

5

1

2

2

2

1

1

Recommended Spare Parts List

Part No.

Description

615-0007 Conduit - 15 ft

615-0008

615-0068

005-0694

005-0695

005-0699

005-0701

511-0101

005-0686

Conduit - 25 ft

Conduit - 50 ft

Trigger Assy Kit

Potentiometer Assy Kit

Handle Kit

Micro-Switch Assy Kit

Drive Roll

Idler Roll Kit

DRIVE ROLL REMOVAL TOOL

931-0100

KNURLED DRIVE ROLL

511-0101

IDLER ROLL

511-0001

MICRO SWITCH ASSY

005-0701


Section E Troubleshooting

Trouble

No wire feed at torch, feeder not operating, i.e. no slave motor or brake solenoid.

No wire feed at torch, feeder operating properly.

Wire feeds, but welding wire is not energized.

Wire feeds erratically.

Wire feeds one speed only.

Wire walks out of drive rolls.

Cause

Input power fuse in feeder/control box blown

Remedy

Replace fuse.

Micro-switch defective/not being activated

Broken electrical cable

Motor control fuse in feeder/control box blown

Bad potentiometer

Broken electrical cable.

Bad speed control/PCB.

Loose or no cable connections.

Contactor control cable loose or in wrong position

Welding power source

Dirty or worn conduit

Replace switch. Check switch for operation.

Check micro-switch wires for continuity.

Check motor leads for shorts; then replace fuse.

Check potentiometer with meter.

Check motor and potentiometer wires for continuity.

See specific cabinet/ control box owner's manual for speed control operation.

Check all power connections.

Check power supply owner's manual for location and type of contactor signal required, i.e. closing or 115VAC.

Check power source.

Blow out or replace conduit.

Wrong size contact tip

Idler roll stuck

Bad potentiometer

Broken electrical cable

Bad speed control

See contact tip table.

Check for lock washer under idler roll, or replace if damaged.

Check with meter.

Check potentiometer wires for continuity or short.

See specific cabinet/ control owner's manual for speed control operation.

Idler roll upside-down

Place groove in idler roll toward top.

Rear wire guide missing Replace wire guide.


Troubleshooting Guide

Regardless of which torch 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 torch 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 simply to keep the wire slightly taut, so it will not pull off the spool while feeding wire.

The high torque 24VDC torch motor is controlled by a solid state speed control located in the feeder, and a pot located in the torch. The torch 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 torch activates both the slave motor and torch motor circuits in the cabinet. Therefore, if the slave motor and brake solenoid operate, but the torch does not, look more toward the torch motor’s

24 V circuits, speed control, control cable, or the torch motor. If nothing operates, look more toward the slave motor’s input, micro switch leads, or micro switch.

Testing The Torch

Reference the "W" clocked torch wiring diagram on the Python

®

electrical diagram for information about pin-outs and locations.

Motor Check

Remove the torch connector from the cabinet.

Using the torch Amphenol connector, check the resistance across pins “A” 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 Potentiometer - “W” Clocked

Using the torch amphenol connector, check the resistance across pin “D”

(wiper) and pin “C”. The resistance should vary from 0 - 5K ohms as the potentiometer is turned.

Check the resistance across pin “D” (wiper) and pin “G”. The resistance should vary from 5K - 0 ohms as the potentiometer is turned.

Testing the Micro Switch

Using the torch amphenol connector, check for continuity across pins “E” and “F” when the trigger is pressed.


Section F

Appendices

Diagrams / Parts List

Python

®

Exploded View ......................................................12

Python

®

Bill of Material........................................................13

Python

®

Front Body Assembly ...........................................14

Air/Water Cooled Barrel Assembly......................................15

Optional Water Cooled Barrel Assembly ............................16

Removal of water cooled gas cups.....................................17

Ultra-Flex Air Cooled Lead Assembly .................................18

Water Cooled Lead Assembly ............................................19

Python

®

Electrical................................................................20


Python Exploded View

P/N 001-1320B

Python Owner's Manual - page 12


Python Front Body Assembly

P/N 003-2108

No. Qty

1

4

5

2

3

1

1

1

1

1

Part No.

Python Front Body Assembly

Description

003-2083 Output Shaft Assembly

003-2106 Body Assembly

325-0206 10-24 x 3/8 PH Screw

333-0082 # 10 Lock Washer

419-0092 0.29 x 0.047 x 0.32 Compression Spring

No.

Qty Part No.

6

9

10

7

8

Description

1 421-0525 1/8 x 7/8 SST Dowel Pin

1 431-1663 Idler Adjusting Screw

1 431-1598 Idler Arm

1 511-0001 Idler Wire Feed Assembly

1 511-0101 Driveroll


Air/Water Cooled Barrel Assembly

P/N 003-2147

Air/Water Cooled 60º Curved Barrel Assembly

No. Qty. Part Number Description

1

2

1

1

002-0671

003-2213

Assy Bend Barrel 60º AW

Assy Taper Lock

5

6

3

4

7

8

9

10 1

-

1

-

11 1

12 1

1

1

4

2

303-0010

303-0094

O-Ring 0.489 I.D. x .070 Width

O-Ring 0.301 I.D. x .070 Width

931-0137 Liner Package, 5 pieces

621-0250 Assy Cup CPR Finned #10

621-0393

-

-

005-0696

431-1774

313-0091

-

-

Tip HD Spray .060

Insulator Replacement Kit

Cup Insulator

Retaining Ring 5/8 Shaft


Optional Water Cooled Barrel Assembly

P/N 003-2104

Water Cooled Barrel Assembly

No. Qty. Part No.

Description

1

8

1

1

2

1

1

1

1

1

1

1

3

4

1

2

5

6

7

10

11

8

9

12

002-0630 60º Brazed Barrel Assembly

003-2572 Taper Lock Assembly

261-0381 WC Insulator Cup Assembly (Including 5 each 303-0012 O-Rings)

303-0010 0.489 I.D. x 0.629 O.D. O-Ring

303-0094 0.301 I.D. x 0.070 O.D. O-Ring

431-0977 Retaining Nut

449-0193 Gas Cup Nut

621-0101 WC Cup Adapter Assembly

621-0159 #8 WC Cup Assembly

621-0393 .060 HD Spray Tip

751-0011 Round Vinyl Cap

931-0137 Teflon Liner Package, 5 pieces


CUP INSULATOR AND O-RING MAINTENANCE

CAUTION: Power-off the coolant pump before disassembling water-cooled barrels.

1. Unscrew Retaining Nut (#6) and slide back on barrel.

2. Using a firm pull and twist action, the Water-Cooled Gas Cup (P/N 621-0065) or Air-Cooled

Gas Cup Assembly (# 7, 8 & 9) can be removed from the Cup Insulator.

3. Inspect the Cup Insulator (#3) 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 (P/N 303-

0012).

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 (#4) 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.

Correct Installation

Incorrect Installation


Ultra-Flex Air Cooled Lead Assy*

This power cable has a boot that is common to many assemblies but must be removed from this end when used on the Python.

*Leads shown for reference only

Length

15'/ 4.5m

25'/7.6m

50'/15.2m

225 Series Ultra-Flex Cable Assemblies

Conduit Power Cable Electrical Cable Gas Hose

615-0007 001-2527 005-0690 001-0537

615-0008

615-0068

001-2528

001-1042

005-0691

005-0692

001-0538

001-0665


Snake Skin

931-0110

931-0122

931-0123

This power cable has a boot that is common to many assemblies but must be removed from this end when used on the Python.

Water Cooled Lead Assy*

*Leads shown for reference only

Length Conduit

15'/4.5m

615-0007

25'/7.6

615-0008

50'/15.2m 615-0068

226 Series Water Cooled Cable Assemblies

#4 Power/

Water Cable

Electrical Cable Gas Hose Water Hose Snake Skin

001-2521 005-0690 001-0537 001-0529 931-0110

001-2524

843-0338

005-0691

005-0692

001-0538

001-0665

001-0530

001-0667

931-0122

931-0123


Python Electrical


MK WARRANTY REPAIR STATIONS for MK Products as of 07/02/03 for most up-to-date list, please visit www.mkproducts.com

A

LABAMA

AIRGAS - SOUTH, INC.

Birmingham, AL

205/251-6835

DIXIE WELDING SUPPLY

Atalla, AL

256/538-6157

INDUSTRIAL WELDING SERVICES

Quinton, AL

205/674-3258

KIBRO, INC.

Theodore, AL

251/653-4672

WELDING ENGINEERING SUPPLY CO.

Prichard, AL

334/457-8681

WELDING MACHINE HOSPITAL

Montgomery, AL

334/832-9353

A

LASKA

FAIRBANKS AERO SERVICES

Fairbanks, AK

907/479-6666

RNR, INC.

dba Rubey Engine & Electric

Anchorage, AK

907/336-5152

WELSCO

Little Rock, AR

501/372-2252

A

RIZONA

ALLSTATE ELECTRIC MOTOR CO.

Phoenix, AZ

602/233-0500

PRAXAIR DISTRIBUTION, INC.

Phoenix, AZ

602/269-2151

VERN LEWIS WELDING SUPPLY

Phoenix, AZ

602/252-0341

A

RKANSAS

APPLIED SERVICES, INC.

Benton, AR

501/860-6464

ARKANSAS WELDING IND’L SUPPLY

Hot Springs, AR

501/321-9922

EL DORADO WELDING & IND’L SUPPLY

El Dorado, AR

870/863-4088

WELSCO

Little Rock, AR

501/372-2252

C

ALIFORNIA

ADVANCED WELDER REPAIR

Commerce, CA

323/263-7383

AIRGAS - WEST, INC.

Gardena, CA

310/523-9355

ALL PHASE WELDER REPAIR & CONSULTING

Sacramento, CA

916/331-0595

ARC PRODUCTS

San Diego, CA

619/628-1022

ARCO WELDER REPAIR

Santa Fe Springs, CA

562/921-5240

ARK WELDER REPAIR

Fresno, CA

559/292-4714

CAL-WELD SUPPLY

Fresno, CA

209/445-0131

DELTA-TECH

Sun Valley, CA

818/767-4234

EMCO-EAST Welder Repair

Concord, CA

925/798-4411

FRESNO OXYGEN

Fresno, CA

559/233-6684

INDUSTRIAL ELECTRIC COMPANY

Modesto, CA

209/527-2800

INDUSTRIAL WELDER REPAIR

LaPuente, CA

626/961-7643

NESCO WELDING SUPPLY

Fontana, CA

909/427-9670


PRAXAIR DISTRIBUTION (ARC RENTS)

Signal Hill, CA

562/989-3212


Bakersfi eld, CA

661/321-9922

R. J. KATES

San Diego, CA

619/565-6960

RED-D-ARC, INC.

Carson, CA

310/233-3327

SIMS-ORANGE WELDING SUPPLY

Santa Ana, CA

714/549-9393

SOUTHWEST WELDER REPAIR

Fontana, CA

909/357-1661

SWEINHART ELECTRIC CO., INC.

Long Beach, CA

714/521-9100

C

OLORADO

AIRGAS - INTERMOUNTAIN, INC.

Colorado Springs, CO

719/473-1947

WELDERS & EQUIP. SVC. & TESTING

Littleton, CO

303/932-8755

WESTERN SLOPE WELDER REPAIR

Grand Junction, CO

970/243-9616

C

ONNECTICUT

ABCO WELDING & INDUSTRIAL SUPPLY

COMPANY

Waterford, CT

800/962-0285

TECH AIR

Milford, CT

203/783-1834

D

ELAWARE

KEEN COMPRESSED GAS CO.

New Castle, DE

302/594-4555

F

LORIDA

A & I SPECIALTIES

Lehigh Acres, FL

941/368-7435


AAA GENERATOR & PUMP, INC.

FT. Myers

941/332-1136

ACTION WELDING SUPPLY

Jacksonville, FL

904/786-2254

AMVEL CORPORATION

Miami, FL

305/592-5678

ELECTRICAL WELDERS SERVICE

Orlando, FL

407/999-5214

HAUN SYSTEMS REPAIR, INC.

Winter Park, FL

407/681-6064

HOLOX

Ocala, FL

352/351-4417

J.K. CIRCUIT TECHNOLOGY

Boynton Beach, FL

561/733-7859

ROPER ELECTRIC MOTOR SERVICE

Panama City, FL

850/769-6643

SMITTY’S WELDER SERVICE

West Palm Beach, FL

561/845-1224

TRI-GAS

Miami, FL

305/592-3180

TRI-STATE SALES & LEASING

Lake City, FL

904/397-3340

TRI-TECH

Sarasota, FL

941/758-3825

V.A. ELECTRICAL MOTORS CENTER

Hialeah, FL

305/825-3327

WELD DIRECT CORPORATION

Jacksonville, FL

904/387-5664

G

EORGIA

B&W INDUSTRIAL SERVICES

Augusta, GA

706/738-8722



Mc CULLOUGH ELEC. MOTOR SVC.

Atlanta, GA

404/688-5251

H

AWAII

DC ELECTRIC, INC.

Aiea, HI

808/483-8900

I

DAHO

NORCO

Boise, ID

208/336-1643

ROSSITER ELECTRIC

Idaho Falls, ID

208/529-3665

I

LLINOIS

CMS ELECTROMECHANICAL SVCS.

Galesburg, IL

309/342-4125 or 888/964-3526

FRED ARMS ELECTRIC MOTOR REPAIR

Stone Park, IL

708/343-6262

INDUSTRIAL WELDER REBUILDERS

Alsip, IL

708/371-5688

RELIABLE EQUIPMENT REPAIR

Hamel, IL

618/633-5000

ROCKFORD INDUSTRIAL WELDING SUPPLY

Rockford, IL

815/226-1900

I

NDIANA

AGA GAS, INC.

Hammond, IN

219/989-9030

AIRGAS-MID AMERICA, INC.

Evansville, IN

800/424-8905

B & H ELECTRIC

Seymour, IN

812/522-5607

COX EQUIPMENT COMPANY

Indianapolis, IN

317/241-8881

EVANSVILLE ARMATURE, INC.

Evansville, IN

812/428-9034

HARRISON ELECTRIC, INC.

Michigan City, IN

219/879-0444

MODERN SUPPLY CO., INC.

Evansville, IN

812/425-9353


Speedway, IN

317/481-4550

SUTTON-GARTEN COMPANY

Indianapolis, IN

317/264-3236

I

OWA

AIRGAS NORTH CENTRAL

Des Moines, IA

515/266-1111

CEDAR RAPIDS WELDING SUPPLY

Cedar Rapids, IA

319/365-1466

ELECTRICAL ENGRG. & EQUIPMENT

Des Moines, IA

515/266-8890

SUPERIOR WELDING SUPPLY CO.

Waterloo, IA

319/236-9660

WRIGHT WELDING SUPPLY

Ft. Dodge, IA

515/576-0640

K

ANSAS

AEROFORM CORPORATION

Coffeyville, KS

620/251-1430

KANOX

Hutchinson, KS

316/665-5551

K

ENTUCKY

GENERAL WELDING PRODUCTS

Louisville, KY

502/635-5218

RED-D-ARC

Lexington, KY

800/245-3660

WELDING EQUIPMENT

Louisville, KY

502/636-0545



L

OUISIANA

GT SERVICES OF MORGAN CITY

Morgan City, LA

985/385-4135

RED BALL OXYGEN CO.

Shreveport, LA

318/425-3211

WELDERS EQUIPMENT CO.

Broussard, LA

337/837-5701

WELDERS SUPPLY & EQUIPMENT RENTALS

Port Allen, LA

225/346-4712

M

ARYLAND

CCM MECH/ELEC REPAIR SERVICE

Owings, MD

301/855-7508

M

ASSACHUSETTS

AIMTEK

Auburn, MA

508/832-5035

M

ICHIGAN

ANN ARBOR WELDING SUPPLY CO.

Ypsilanti, MI

734/572-0444

APEX WELDING GASES & SUPPLY

Muskegon Heights, MI

616/722-3185

AUTOMATIC WELD

Midland, MI

517/496-9245

GREAT LAKES EQUIPMENT

Clare, MI

517/386-4630

HAMILTON ELECTRIC CO.

Saginaw, MI

517/799-6291

PLYMOUTH WAYNE, INC.

Wixom, MI

248/735-7700

SAGINAW WELDING SUPPLY CO.

Saginaw, MI

517/793-9696

SIMPKINS ELECTRICAL SERVICE, LLC

Michigan Center, MI

517/764-7766

SOUTHPARK WELDING

Marysville, MI

810/364-6521

WELDING METALS, INC.

Madison Heights, MI

248/585-0480

WESAR COMPANY

Three Rivers, MI

616/483-9125

WILSON WELDING & MEDICAL GASES

Warren, MI

586/751-7400

M

INNESOTA

AIRGAS - NORTH CENTRAL

Albert Lea, MN

507/373-2411

CAPITOL CITY WELDING SUPPLY

St. Paul, MN

651/224-4843

CENTRAL McGOWAN

St. Cloud, MN

320/252-5292

MINNEAPOLIS OXYGEN CO.

Minneapolis, MN

612/588-8855

OXYGEN SERVICE CO.

St. Paul, MN

612/644-7273

M

ISSISSIPPI

KOMP INDUSTRIAL & WELDING SUPPLY

Hattiesburg, MS

601/649-5889

NORDAN SMITH WELDING SUPPLY

Hattiesburg, MS

601/545-1800

3D SUPPLIES, INC.

Jackson, MS

601/353-3330

M

ISSOURI

CEE-KAY SUPPLY, INC.

St. Louis, MO

324/644-3500

P.G. WALKER

Springfi eld, MO

417/862-1745



ROD'S SERVICE, INC.

St. Louis, MO

314/721-6000

M

ONTANA

VALLEY WELDERS SUPPLY, INC.

Billings, MT

406/256-3330

N

EVADA

SIERRA WELDING SUPPLY CO.

Sparks, NV

775/359-0542

N

EW

H

AMPSHIRE

WELDING SYSTEMS SERVICE

Raymond, NH

603/895-4700

N

EW

J

ERSEY

INDUSTRIAL ELECTRIC SERVICE CO.

Hawthorne, NJ

973/423-1212

N

EW

Y

ORK

DELO WELDING SUPPLY

Syracuse, NY

315/478-2188

DYNAMIC WELDING REPAIR, INC

Bayshore, NY

631/643-1308

HAUN WELDING SUPPLY

Syracuse, NY

315/463-5241

JACKSON WELDING SUPPLY CO, INC.

Rochester, NY

585/235-2920

N

ORTH

C

AROLINA

ADAMS WELDER REPAIR

& ELECTRICAL SERVICE, INC.

Nashville, NC

252/459-1960

HOLOX LTD.

Colfax, NC

336/996-1974

M & L WELDER REPAIR

Asheville, NC

828/250-9353

MACHINE & WELDING SUPPLY CO.

Dunn, NC

910/892-4016

MACHINE AND WELDING SUPPLY CO.

Greenville, NC

252/752-3089


Raleigh, NC

919/772-9500


Winston-Salem, NC

336/723-9651

NATIONAL WELDERS SUPPLY CO.

High Point, NC

910/882-1110

NATIONAL WELDERS SUPPLY CO.

Charlotte, NC

704/392-7317

O

HIO

AGA GASES, INC.

Lima, OH

419/228-2828

ALBRIGHT WELDING SUPPLY

Wooster, OH

330/264-2021

ALL ABOUT SERVICE

Wickliffe, OH

440/516-0303

ARC EQUIPMENT COMPANY

Struthers, OH

333/750-9353

ARC SERVICES, INC.

Toledo, OH

419/478-6204

BELAIR PRODUCTS, INC.

Akron, OH

330/253-3116

BIG RIVER ELECTRIC

Gallipolis, OH

740/446-4360

CnD MACHINE, INC.

Canton, OH

330/478-8811

ELECTRIC WELDER REPAIR, INC.

Cuyahoga Heights, OH

216/271-5600

MAINTENANCE UNLIMITED AND TOOL

REPAIR, INC.

Cincinnati, OH

513/554-1313


O.E. MEYER COMPANY

Sandusky, OH

419/621-4201

OHIO AIR PRODUCTS

Canton, OH

330/821-2771

RICK’S WELDER REPAIR SERVICE

Eastlake, OH

440/269-1204

S.D. NOLD, INC.

Lisbon, OH

330/424-3134

VALLEY NATIONAL GASES

Cincinnati, OH

513/241-5840


Hilliard, OH

614/771-1311


Lima, OH

419/228-1008


Toledo, OH

419/241-9114

VOLLMER ELECTRIC CO.

Columbus, OH

614/476-8800

WEILER WELDING CO., INC.

Dayton, OH

937/222-8312

WELDINGHOUSE, INC.

Cleveland, OH

216/524-1955

O

KLAHOMA

AIRGAS MID-SOUTH

Tulsa, OK

918/582-0885

BILL’S WELDER REPAIR

Oklahoma City, OK

405/232-4799

MUNN SUPPLY

Enid, OK

580/234-4120

OKLAHOMA WELDERS SUPPLY

Madill, OK

580/795-5561


O

REGON

ARC SYSTEMS SERVICES

Central Point, OR

541/665-2676

E C COMPANY dba ELECTRICAL CONSTRUCTION CO.

Portland, OR

800/452-1511

INDUSTRIAL SOURCE

Eugene, OR

541/344-1438

WELDER SERVICE & REPAIR

Redmond, OR

541/548-8711

P

ENNSYLVANIA

ALLWELD EQUIPMENT REPAIR

Pittsburgh, PA

412/821-8460

BY DESIGN

Columbia, PA

717/681-9494

GEOVIC WELDING SUPPLY

Milton, PA

717/742-9377

J.A. CUNNINGHAM EQUIPMENT, INC.

Philadelphia, PA

215/426-6650

JOSEPH PINTO, JR. EQUIPMENT CO.

E. Lansdowne, PA

610/259-4100

POWER SOURCE REPAIR CO., INC.

Collingdale, PA

610/532-6460


Pittsburgh, PA

412/281-1835

S

OUTH

C

AROLINA

CAROLINA WELDER SERVICE

Lake City, SC

843/687-0413

T

ENNESSEE

ARC-ONE WELDER REPAIR, INC.

East Ridge, TN 37412

423-894-9353

INDUSTRIAL MACHINE REPAIRS

Rogersville, TN

423/272-8199


NATIONAL RENTAL & REPAIR

Knoxville, TN

423/584-6390

NEXAIR

Memphis, TN

901/523-6821

QUALITY WELDING EQUIPMENT SVC.

Nashville, TN

615/726-5282

TRAMCO

Bristol, TN

423/968-4499

T

EXAS

AIRGAS - SOUTHWEST, INC.

Austin, TX

512/835-0202

AIRGAS - SOUTHWEST, INC.

Houston, TX

713/462-8027

DENISON OXYGEN

Denison, TX

903/465-3369

FT. WORTH WELDERS SUPPLY, INC.

Fort Worth, TX

817/332-8696

GPC SERVICES, INC.

San Angelo, TX

915/655-4545

LEKTROTECH, INC.

Greenville, TX

903/454-7146

RITE-WELD SUPPLY, INC

Fort Worth, TX

817/626-8237

TEXAIR WELDING SUPPLY, LTD.

Longview, TX

903/238-9353

WELDING MACHINE & TORCH REPAIR

San Antonio, TX

210/680-8390

U

TAH

ARC SERVICES, LLC

West Valley City, UT

801/975-1121

C.W. SILVER INDUSTRIAL SERVICE

Salt Lake City, UT

801/531-8888


V

ERMONT

W.J. WELDING EQUIPMENT REPAIR

North Clarendon, VT

802-775-7422

V

IRGINIA

AIR PRODUCTS & CHEMICALS, INC.

Bristol, VA

540/669-3161

ARC WELDERS, INC.

Ashland, VA

804/798-1818

ARCET EQUIPMENT COMPANY

Hampton, VA

757/728-9353

N.W. MARTIN CO.

Springfi eld, VA

703/644-0120

NORFOLK WELDERS SUPPLY

Norfolk, VA

804/622-6571

W

ASHINGTON

AIRGAS - NORPAC, INC.

Tacoma, WA

253/473-2282

AIRGAS - NORPAC, INC.

Vancouver, WA

360/574-5311

A-L WELDING PRODUCTS

Tukwila, WA

425/228-2218

AMERICAN EQUIPMENT SERVICES

Kent, WA

253/395-9947

HARRIS ELECTRIC, INC.

Seattle, WA

206/782-6668

OXARC, INC.

Spokane, WA

509/535-7794

PACIFIC WELDING SUPPLIES

Tacoma, WA

253/572-5302

PRECISION WELDER & ENGINE REPAIR

Seattle, WA

206/382-6227



W

EST

V

IRGINIA

CARDINAL SALES & SERVICE, INC.

Clarksburg, WV

304/622-7590

WILLARD C. STARCHER, INC.

Spencer, WV

304/927-2520

W

ISCONSIN

INTERSTATE WELDING SALES CORP.

Appleton, WI

920/734-7173

MOSINEE MACHINE & ELECTRIC

Mosinee, WI

715/693-0858


Brookfi eld, WI

414/938-6365


Milwaukee, WI

414/281-9540

WELDER REPAIR & SERVICE, INC.

Fredonia, WI

262/692-3068

C

ANADA

A&A WELDER SERVICES LTD.

Saskatoon, Saskatchewan

306/934-1601

ARC & GENERATOR REPAIR

Garson, Ontario

705/525-2141

B. HARRIS WELDING SVCS. LTD.

Dartmouth, Nova Scotia

902/468-6255

BARRY HAMEL EQUIPMENT LTD.

Coquitlam, B.C.

604/945-9313

BEAUCE TECHNOLOGIES, INC.

St. Prosper, Quebec G0M 1Y0

418-594-8852

D-TECH WELD SERVICES, INC.

Regina, Saskatchewan

306/586-9353

ELECTRO-MÉCANIK, INC.

Sainte-Foy, Quebec

418/683-1724

GPR INDUSTRIES 1994 LTD.

Grande Prairie, Alberta

780/532-5900

HYPERDYNAMICS TECHNOLOGIES LTD.

Pickering, Ontario

905/683-9938

INDUSTRIAL ELECTRONIC SERVICES

Calgary, Alberta

403/279-3432

LADEL LTD.

Quebec

819/376-6577

LEBLANC ELECTRO-TECH, INC.

Boucherville, Quebec

450/449-5244

M.R.T. REPAIR CENTER, INC.

Montreal, Quebec

514/648-0800

OZARK ELECTRICAL MARINE LTD.

St. Johns, Newfoundland

709/726-4554

PEEL ENGINES

Mississauga, Ontario

905/670-1535

PROMOTECH ÉLECTRIQUE, INC.

Fleurimont, Quebec

819/822-2111

WELDERS SUPPLY

Winnipeg, Manitoba

204/772-9476

WELDERTECH

Calgary, Alberta

403/279-3432

WELDTEC

B.C.

604/545-3886

C

HINA

PHT Group Company

Beijing, China


Safety Warnings



3 YEAR

LIMITED WARRANTY

Effective February 1, 2003

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 warrants that all new and unused equipment furnished by MK

Products is free from defects in workmanship and material as of the time and place of delivery by MK Products. No warranty is made by MK Products with respect to trade accessories or other items manufactured by others. Such trade accessories and other items are sold subject to the warranties of their respective manufacturers, if any.

MK Products’ warranty does not apply to components having normal useful life of less than one (1) year, such as relay points, wire conduit, tungsten, and welding torch parts that come in contact with the welding wire, including gas cups, gas cup insulators, and contact tips where failure does not result from defect in workmanship or material.

MK Products’ shall, exclusively remedy the limited warranty or any duties with respect to the quality of goods, based upon the following options:

(1) repair

(2) replacement

(3) where authorized in writing by MK Products, the reasonable cost of repair or replacement at our Irvine, California plant; or

(4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Upon receipt of notice of apparent defect or failure, MK Products shall instruct the claimant on the warranty claim procedures to be followed.

As a matter of general policy only, MK Products may honor an original user’s warranty claims on warranted equipment in the event of failure resulting from a defect within the following periods from the date of delivery of equipment to the original user:

1. Torches, Weldheads & Water Recirculators.....1 year

2. All Other Equipment ....................................... 3 years

3. Repairs ......................................................... 90 days

Classifi cation of any item into the foregoing categories shall be at the sole discretion of MK Products. Notifi cation 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 packaged to guard against damage from shipping.

MK Products will not be responsible for any damages resulting from shipping.

Normal surface transportation charges (both ways) for products returned for warranty repair 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 REMEDY FOR BREACH OF

CONTRACT WHICH, BUT FOR THIS PROVISION, MIGHT

ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF

TRADE, OR COURSE OF DEALING, INCLUDING ANY IMPLIED

WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR

PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL

EQUIPMENT FURNISHED BY MK PRODUCTS, IS EXCLUDED

AND DISCLAIMED BY MK PRODUCTS.

EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN

WRITING, MK PRODUCTS ARE INTENDED FOR ULTIMATE

PURCHASE BY COMMERCIAL/INDUSTRIAL USERS AND FOR

OPERATION BY PERSONS TRAINED AND EXPERIENCED IN

THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND

NOT FOR CONSUMERS OR CONSUMER USE. MK PRODUCTS

WARRANTIES DO NOT EXTEND TO, AND NO RE-SELLER IS

AUTHORIZED TO EXTEND MK PRODUCTS’ WARRANTIES TO

ANY CONSUMER.

USE OF OTHER THAN

YOUR PRODUCT WARRANTY.

GENUINE

MK PRODUCTS’

CONSUMABLES, PARTS, AND ACCESSORIES MAY INVALIDATE

16882 Armstrong Ave.

Irvine, CA 92606

Tel (949)863-1234

Fax (949)474-1428 www.mkproducts.com

DATE: February 1, 2003

www.mkproducts.com

16882 Armstrong Ave.

Irvine, California 92606

TEL (949) 863-1234 FAX (949) 474-1428

MK Products Python Advanced Gooseneck Welding System Owner's Manual

Assistant Bot

Product Description

MK Manual Part Number

MK Form Number

NWSA Form Number

Effective with Serial Number

Voltage Rating

Printing/Revision Date

This manual applies to the following torch model numbers

Advanced

Gooseneck

SAFETY CONSIDERATIONS

ELECTRIC ARC WELDING EQUIPMENT

CAUTION : READ BEFORE ATTEMPTING INSTALLATION, OPERATION

OR MAINTENANCE OF THIS EQUIPMENT

Thank You

For selecting a quality product. We want you to take pride in operating this product...as much pride as we have in bringing the product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Model Name & Number _____________________

Code & Serial Number _____________________

Date of Purchase _____________________

Whenever you request replacements parts for, or information on this equipment always supply the information you have recorded above.

Table of Contents

Section A Installation

Technical Specifications

Support Equipment Required

Coolant Recommendations

Section B

Torch Lead Connections

Operation

General

Controls and Settings

Drive Roll and Idler Rolls

NO ADJUSTMENT IS REQUIRED FOR ALL SIZES

AND TYPES OF WIRES

Section C

Accessories

Optional Kits

Conduits

Snake Skins

Contact Tips

Part No.

Heavy Duty Contact Tip - 3/8" Diameter

Wire Size

Tip ID

Arc

Tip Length

Finned Copper Cups

Finned Copper Gas Cups

Heavy Duty Finned Copper Gas Cups

Air Cooled Cups for Python

Water Cooled Torch

Cup Size Cup I.D.

Part No.

Water Cooled Cups for Python

Cup Size Cup I.D.

Water Cooled Torch

Part No.

Part Number

Torch Barrel Liners

Description

Barrel Assemblies

Barrels

Section D

Maintenance

Periodic Maintenance

Maintenance Tools

Tool

Part Number

Qty.

Recommended Spare Parts List

Part No.

Description

Section E Troubleshooting

Trouble

Cause

Remedy