Lincoln Compatible™
Owner’s Manual
Product:
Manual:
Serial:
Python
091-0618
09020001
Voltage Rating: 24 VDC
Revision:
Feb 2009
232-835
Gun models:
225 Ampere Air Cooled
Push-Pull Welding Gun
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Table of Contents
Safety Considerations ........................................................................i-iii
Installation ............................................................................... Section A
Technical Specifications.....................................................................................1
Support Equipment Required.............................................................................1
Gun Lead Connections ......................................................................................1
Operation.................................................................................Section B
General ..............................................................................................................1
Controls and Settings.........................................................................................2
Trigger Adjustment.............................................................................................2
Drive Roll and Idler Rolls....................................................................................2
Accessories .............................................................................Section C
Optional Kits.......................................................................................................3
Snake Skins.......................................................................................................4
Contact Tips.......................................................................................................4
Gas Cups...........................................................................................................4
Barrels................................................................................................................5
Maintenance............................................................................Section D
Periodic Maintenance.........................................................................................5
Recommended Spare Parts List........................................................................6
Troubleshooting.......................................................................Section E
Troubleshooting Guide.......................................................................................8
Testing The Gun.................................................................................................8
Appendices..............................................................................Section F
Diagrams / Parts List..........................................................................................9
Mechanical.......................................................................................................10
Electrical...........................................................................................................16
Safety Warnings
Warranty
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Declaration of Conformity for
European Community (CE) Products
Note
This information is provided for units with CE certification (see rating label on unit).
Manufacturer’s Name:
MK Products, Inc.
16882 Armstrong Ave.
Irvine, CA 92606
Declares that the product:
Python® Lincoln Compatible
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic Compatibility (EMC) Directive: 89/336/EEC
Standards
Arc Welding Equipment Part I: Welding Power Sources: IEC 60974-1
(September 1998 - Second Edition)
Arc Welding Equipment: Wirefeed Systems: IEC 974-5
(September 1997 - Draft Revision)
Degrees of Protection Provided by Enclosures (IP Code): IEC 529:1989
(November 1989 - First Edition)
Insulation Coordination For Equipment With Low-Voltage Systems:
Part I: Principles, Requirements and Tests: IEC 664-1: 1992
(October 1992 - First Edition)
Electromagnetic Compatibility, (EMC): EN 50199
(August 1995)
Torches And Guns For Arc Welding, EN 50078
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SAFety CONSiDeRAtiONS
eLeCtRiC ARC WeLDiNG eQUiPMeNt
CAUtiON : ReAD BeFORe AtteMPtiNG iNStALLAtiON, OPeRAtiON
OR MAiNteNANCe OF tHiS eQUiPMeNt
Hot metal such as electrode stubs and work
pieces should never be handled without
gloves.
hot slag, or heated material, misuse of
compressed gases and cylinders, and
short circuits.
1-1 iNtRODUCtiON
This equipment is intended for ultimate
applicationbycommercial/industrialusers
and for operation by persons trained and
experienced in the use and maintenance
of welding equipment. Operation should
notbeundertakenwithoutadequatetrain-
ingintheuseofsuchequipment. Training
is available from many public and private
schools or similar facilities.
Ear plugs should be worn when working on
overhead or in a confined space. Ahard hat
should be worn when others work overhead.
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.
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 defects or other reproductive harm.
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.
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.
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.
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.
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.
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.
Walls touching combustibles on oppo-
site sides should not be welded on (or
cut). Walls, ceilings, and floor near work
should be protected by heat-resistant
covers or shields.
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.
1-2 GeNeRAL PReCAUtiONS
Fire watcher must be standing by with
suitable fire extinguishing equipment
during and for some time after welding
or cutting if:
A. Burn Prevention
ELECTRICARC WELDING PRODUCES
HIGH INTENSITY HEAT AND ULTRA-
VIOLET RADIANT ENERGY WHICH
MAY CAUSE SERIOUS AND PERMA-
NENT EYE DAMAGEAND WHICH MAY
DAMAGEANY EXPOSED SKINAREAS.
Work in a confined space only while it is
being ventilated and, if necessary, while
wearing an air-supplied respirator.
1. Appreciable combustibles (including
building construction) are within 35 feet.
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.
2. Appreciable combustibles are further
than 35 feet, but can be ignited by sparks.
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.
3. Openings (concealed or visible) in
floors or walls within 35 feet may expose
combustibles to sparks.
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.
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.
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.
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 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.
After work is done, check that area is free
of sparks, glowing embers, and flames.
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.
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.
Avoid oily or greasy clothing. A spark
may ignite them.
This includes: a thorough steam or
caustic cleaning (or a solvent of water
washing, depending on the combustible’s
Flammable hair preparations should not
be used by persons intending to weld
or cut.
C. Fire and Explosion Prevention
Causes of fire and explosion are: combusti- solubility), followed by purging and inert-
bles reached by the arc, flame, flying sparks, ing with nitrogen or carbon dioxide, and
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using protective equipment.
Prohibited use. Never use a cylinder or its ing any other gas.
contents for other than its intended use,
Water-filling just below working level may
substitute for inerting.
Tighten connections. When assembling
NEVER as a support or roller.
threaded connections, clean and smooth
Locate or secure cylinders so they cannot seats where necessary. Tighten. If con-
A container with unknown contents
should be cleaned (see paragraph
be knocked over.
nection leaks, disassemble, clean, and
retighten, using properly fitting wrench.
above). Do NOT depend on sense of Passageways and work areas. Keep cyl-
smell or sight to determine if it is safe to inders clear of areas where they may be Adapters. Use a CGAadapter (available
weld or cut.
stuck.
from your supplier) between cylinder
and regulator, if one is required. Use
two wrenches to tighten adapter marked
RIGHT and LEFT HAND threads.
Hollow castings or containers must be Transporting cylinders. With a crane, use
vented before welding or cutting. They a secure support such as a platform or
can explode.
cradle. Do NOT lift cylinders off the ground
by their valves or caps, or by chains, slings, Regulator outlet (or hose) connections
Explosive atmospheres. NEVER weld
or cut where the air may contain flam-
or magnets.
may be identified by right hand threads
for oxygen and left hand threads (with
grooved hex on nut or shank) for fuel gas.
mable dust, gas, or liquid vapors (such Do NOTexpose cylinders to excessive heat,
as gasoline).
sparks, slag, and flame, etc. that may cause
rupture. Do not allow contents to exceed 5. Pressurizing Steps:
55 degrees C (130 degrees F.) Cool with Drain regulator of residual gas through
D. Compressed Gas Equipment
The safe handling of compressed gas
equipment is detailed in numerous indus-
try publications. The following general
rules cover many of the most common
situations.
water spray where such exposure exists.
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.
Protect cylinders, particularly valves from
bumps, falls, falling objects, and weather.
Replace caps securely when moving cyl-
inders.
1. Pressure Regulators
Stuck valve. Do NOT use a hammer or
wrench to open a cylinder valve that cannot
be opened by hand. Notify your supplier.
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.
Stand to side of regulator while opening
cylinder valve.
Mixing gases. NEVER try to mix any gases
in a cylinder.
Open cylinder valve slowly so that regu-
lator 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.
Never connect a regulator to a cylinder
containing gas other than that for which
the regulator was designed.
NEVER refill any cylinder.
Cylinder fittings should never be modified
or exchanged.
Remove faulty regulator from service
immediately for repair (first close cylinder
valve). The following symptoms indicate
a faulty regulator:
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.
Leaks - if gas leaks externally.
Use pressure charts (available from your
supplier) for safe and efficient recom-
mended pressure settings on regulators.
Excessive Creep - if delivery pressure
continues to rise with downstream valve
closed.
Use ferrules or clamps designed for the
hose (not ordinary wire or other substitute)
as a binding to connect hoses to fittings.
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.
Faulty Gauge - if gauge pointer does not
move off stop pin when pressurized, nor
returns to stop pin after pressure release.
No copper tubing splices. Use only stan-
dard brass fittings to splice hose.
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.
Avoid long runs to prevent kinks and abuse.
Suspend hose off ground to keep it from
being run over, stepped on, or otherwise
damaged.
E. User Responsibilities
Follow all Safety Rules.
Remove leaky or defective equipment
from service immediately for repair. Read
and follow user manual instructions.
Coil excess hose to prevent kinks and
tangles.
2. Cylinders
Cylinders must be handled carefully to
prevent leaks and damage to their walls,
valves, or safety devices:
Protect hose from damage by sharp edges,
and by sparks, slag, and open flame.
F. Leaving Equipment Unattended
Close gas supply at source and drain gas.
Examine hose regularly for leaks, wear, and
loose connections. Immerse pressured
hose in water; bubbles indicate leaks
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)
G. Rope Staging-Support
Rope staging-support should not be
used for welding or cutting operation;
rope may burn.
Repair leaky or worn hose by cutting area
out and splicing. Do NOT use tape.
4. Proper Connections
1-3 ARC WeLDiNG
ICC or DOT marking must be on each
cylinder. It is an assurance of safety
when the cylinder is properly handled.
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.
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.
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.
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-
Empties: Keep valves closed, replace
caps securely; mark MT; keep them sepa-
rate from FULLS, and return promptly.
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oxide can kill.
be used to join welding cable lengths.
A. Burn Protection
Comply with precautions in 1-2.
C. Fire and Explosion Prevention
3. Cables
Comply with precautions in 1-2C.
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.
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
acute sunburn; those from gas-shielded
arcs are more severe and painful. DON’T
GET BURNED; COMPLY WITH PRE-
CAUTIONS.
Equipment’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.
Keep cable dry, free of oil and grease,
and protected from hot metal and sparks.
1. Protective Clothing
4. Terminals and Other Exposed Parts
Terminals and other exposed parts of
electrical units should have insulating
covers secured before operation.
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.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
5. Electrode Wire
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
becomesaconductor. DONOTSTAND,SIT,
LIE, LEAN ON, OR TOUCH a wet surface
when welding without suitable protection.
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.
Bare skin protection. Wear dark, sub-
stantial clothing. Button collar to protect
chest and neck, and button pockets to
prevent entry of sparks.
6. Safety Devices
2. Eye and Head Protection
Safety devices such as interlocks and
circuit breakers should not be discon-
nected or shunted out.
To protect against shock:
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.
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 resis-
tance, enabling dangerous and possibly
lethal currents to flow through the body.
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.
Welding helmet or shield containing a
filter plate shade no. 12 or denser must
be used when welding. Place over face
before striking arc.
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.
Protect filter plate with a clear cover plate.
1. Grounding the Equipment
Cracked or broken helmet or shield
should NOT be worn; radiation can be
passed through to cause burns.
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 carryingANY gas or a flammable liquid
such as oil or fuel.
Leaving equipment unattended. Always
shut OFF, and disconnect all power to
equipment.
Cracked, broken, or loose filter plates
must be replaced IMMEDIATELY.
Replace clear cover plate when broken,
pitted, or spattered.
Power disconnect switch must be avail-
able near the welding power source.
Flash goggles with side shields MUST be
worn under the helmet to give some pro-
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.
Three-phase connection. Check phase
requirement of equipment before install-
ing. If only three-phase power is available,
connect single-phase equipment to only two
wires of the three-phase line. Do NOT con-
nect the equipment ground lead to the third
(live) wire, or the equipment will become
electrically HOT - a dangerous condition
that can shock, possibly fatally.
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.
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 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.
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-
2. Connectors
Fully insulated lock-type connectors should
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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 - 60% (All ratings are using Argon Gas)
225 Amps/25 Volts
Air cooled standard
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.
Gun Lead Connections
Power Cable
A #2 power cable is used on the Python® Lincoln 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.
Conduit
The Python® Lincoln 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 gas hose is pushed over a barbed fitting on the gun body and secured
with the hose retainer. On the Power Manifold the hose has a crimped fitting
screwed into the Power Manifold.
electric Cable
A multi-conductor control cable is used on the Python® Lincoln Compatible™.
The gun end of the cable is secured with a cable clamp and the wires are
connected 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 7-Pin, Amphenol connector.
Section B
Operation
General
The Python® Lincoln Compatible™gun 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 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-quarter (3
3/4) turn potentiometer in the gun handle.
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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 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® Lincoln Compatible™ gun 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® Lincoln 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 with one hand or on a
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table top, with the other hand give
the Removal Tool a quick snap-turn
in the CLOCKWiSe DiReCtiON.
3. Once the drive roll is loose,
continue to spin drive roll in the
clockwise direction to remove the
drive roll from the gun.
Figure 2
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.
Figure 3
NOTE: Lock washer must be under idler roll or it will not turn freely.
Section C
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..................................................... 005-0640
For .030" (0.8mm) dia. aluminum wire. Includes insulated groove drive roll
and insulated idler roll assy.
insulated Groove Drive Roll Kit..................................................... 005-0716
For .035" (0.9mm) dia. aluminum wire. Includes insulated groove drive roll
and insulated idler roll assy.
insulated Groove Drive Roll Kit..................................................... 005-0642
For .040" (1.0mm) dia. aluminum wire. Includes insulated groove drive roll
and insulated idler roll assy.
insulated Groove Drive Roll Kit..................................................... 005-0718
For 3/64" (1.2mm) dia. aluminum wire. Includes insulated groove drive roll
and insulated idler roll assy.
insulated Groove Drive Roll Kit...................................................... 005-0644
For .062" (1.6mm) dia. aluminum wire. Includes insulated groove drive roll
and insulated idler roll assy.
Handle Kit.........................................................................................005-0699
Includes left and right handles, screws and drive roll door.
Python® Lincoln Compatible™ Owner's Manual - Page 3
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Trigger Kit.........................................................................................005-0694
Trigger adjustment kit includes a spring and sensitivity adjustment screw
replacement for all Python-Plus guns.
Micro Switch Kit...............................................................................005-0701
Replacement micro switch assembly for all Python® Lincoln Compatible™
guns.
Potentiometer Kit.............................................................................005-0695
Replacement potentiometer assembly for all Python® Lincoln Compatible™
guns.
Snake Skins®
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 33ft (for 35ft leads) ....................................... 931-0132
Contact tips
Heavy Duty Contact Tip - 3/8" Diameter*
Wire Size
tip iD
Arc
tip Length
Part No.
.030” (0.8mm) .040” (1.0mm)
Spray
Short
Spray
1.57” (39.9mm) 621-0390-25
1.82” (46.2mm) 621-0396-25
1.57” (39.9mm) 621-0391-25
621-0391-250†
.035” (0.9mm) .045” (1.1mm)
621-0391-500††
.035" (0.9mm) .045" (1.1mm)
.045" (1.1mm) .054" (1.37mm)
3/64” (1.2mm) .054” (1.37mm)
Short
Short
Spray
1.82” (46.2mm) 621-0397-25
1.82” (46.2mm) 621-0398-25
1.57” (39.9mm)
621-0392-25
621-0392-250†
621-0392-500††
3/64” (1.2mm) .060” (1.5mm)
Spray
1.57” (39.9mm) 621-0393-25**
621-0393-250†
621-0393-500††
1/16” (1.6mm) .074” (1.9mm)
.085” (2.16mm)
Spray
Spray
1.57” (39.9mm) 621-0394-25
621-0395-25
† Alsosold in quantities of 250
† † Alsosold in quantities of 500
*Use of tip removal tool is recommended
**This size tip furnished with gun
Finned Copper Cups
Finned Copper Gas Cups
Cup Size
No. 6
Cup I.D.
Part No.
621-0248
621-0249
621-0250*
3/8” (9.5mm)
1/2” (12.7mm)
5/8” (15.8mm)
No. 8
No. 10
Heavy Duty Finned Copper Gas Cups
Cup Size
Cup I.D.
Part No.
10
5/8" (15.8mm)
3/4" (19.0mm)
621-0251
621-0252
12
*Standard - furnished with Air Cooled gun
Python® Lincoln Compatible™ Owner's Manual - Page 4
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Gun Barrel Liners
Part Number
931-0137
Description
Teflon liner package, 5 pieces
Steel wire only, .030 - .1/16" (0.8 - 0.9mm)
Python® tip extender (Air cooled barrel only)
Spiral steel liner for tip extender
615-0338
621-0424
615-0250
Barrel Assemblies
All barrels are rated at 100% duty cycle
225 Amps, Air Cooled
(P/N 003-2272)
Standard on AC
Barrels
Air Cooled
The Python® Lincoln Compatible™ gun comes standard with a 60˚ curved
barrel. The barrel assembly locks to the gun body using the patented EZ
Lock™ system.
Optional 6", 12” and 18” Straight and Curved Barrel Assemblies
6" Straight, Air Cooled Barrel Assembly ...........................................003-2330
6" Curved, 45° Air Cooled Barrel Assembly......................................003-2331
12" Straight, Air Cooled Barrel Assembly .........................................003-2332
12" Curved, 45° Air Cooled Barrel Assembly....................................003-2333
18" Straight, Air Cooled Barrel Assembly .........................................003-2334
18" Curved, 45° Air Cooled Barrel Assembly....................................003-2335
Barrel Removal and installation
To remove the barrel assembly, loosen the 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.
Section D
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
Python® Lincoln Compatible™ Owner's Manual - Page 5
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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
Part Number
931-0002
Contact Tip Removal Tool
Drive Roll Removal Tool
931-0100
Recommended Spare Parts List
Qty.
1
Part No.
615-0620-35
437-0253
005-0694
005-0695
005-0699
005-0701
511-0101
005-0686
Description
Conduit - 35 ft
Drive Roll Door
Trigger Assy. Kit
Potentiometer Kit
Handle Kit
1
2
2
1
2
Micro-Switch Kit
Drive Roll
10
5
Idler Roll Kit
Drive Roll Removal Tool
931-0100
Knurled Drive Roll
511-0101
Idler Roll Kit
005-0686
Micro Switch Assembly
005-0701
Python® Lincoln Compatible™ Owner's Manual - Page 6
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Section e
troubleshooting
trouble
Cause
Remedy
115/42 VAC Control fuse in
feeder/Control box blown.
Replace fuse.
No wire feed at gun,
feeder not operating, Micro-switch defective/not Replace switch. Check
i.e. no slave motor
or brake solenoid.
being activated.
switch for operation.
Broken electrical cable.
Check micro-switch
wires for continuity.
24 VAC Control fuse in
feeder/Control box blown.
Check motor leads for
shorts; then replace
fuse.
Check potentiometer
with meter.
Bad potentiometer.
No wire feed at gun,
feeder operating
properly.
Check motor and
potentiometer wires for
continuity.
Broken Electrical Cable.
See specific cabinet/
control box owners
manual for speed
control operation.
Bad Speed control/PCB
Loose or no cable
connections.
Check all power
connections.
Check power supply
owners manual for
location and type
of contactor signal
required.
Wire feeds, but
welding wire is not
energized.
Contactor control cable
loose or in wrong position.
Welding power source.
Dirty or worn conduit.
Wrong size contact tip.
Check power source.
Blow out or replace
conduit.
Wire feeds
erratically.
See Contact tip table.
Check for lock washer
under idler roll, or
Idler roll stuck.
replace if damaged.
Bad potentiometer.
Broken electrical cable.
Check with meter.
Check potentiometer
wires for continuity or
short.
Wire feeds one
speed only.
See specific cabinet/
control owners manual
for speed control
operation.
Bad speed control.
Place groove in idler
roll toward top.
Idler roll upside-down.
Wire walks out of
drive rolls.
Rear wire guide missing.
Replace wire guide.
Python® Lincoln Compatible™ Owner's Manual - Page 7
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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 simply to keep the wire
slightly taut, so it will not pull off the spool while feeding wire.
The high torque 24VDC gun motor is controlled by a solid state speed
control located in the feeder, and a pot located in the gun. The gun motor,
potentiometer, and micro switch are connected to the cabinet/control box via
a control cable and Amphenol connector. If this cable becomes damaged, a
variety of symptoms can occur, depending on 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 "W" clocked gun wiring diagram on
the Python® Lincoln Compatible™ Electrical Diagram for information
about pin-outs and locations.
Motor Check
Remove the gun connector from the cabinet.
Using the gun 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 gun 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 gun Amphenol connector, check for continuity across pins “E” and
“F” when the trigger is pressed.
E
F
D
G
A
C
B
"W" Clocked
Amphenol Connector
Viewed from front of connector
Python® Lincoln Compatible™ Owner's Manual - Page 8
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Section F
Appendices
Python® Lincoln Compatible™ Diagrams / Parts List
Exploded View................................................................................................10
Bill of Material.................................................................................................11
Front Body Assembly ....................................................................................12
Barrel Assembly .............................................................................................13
Rear Body Assembly......................................................................................14
Lead Assembly...............................................................................................15
Electrical.........................................................................................................16
Python® Lincoln Compatible™ Owner's Manual - Page 9
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®
Python Lincoln Compatible™ Head Assembly
Python® Lincoln Compatible™ Owner's Manual - Page 10
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Python® Lincoln Compatible™ Owner's Manual - Page 11
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®
Python Lincoln Compatible™ Front Body Assembly
P/N 003-2271
Items 3, 4 & 9 available
as package kit:
P/N 005-0686
Python® Lincoln Compatible™ Front Body Assembly
No. Qty.
Part No.
Description
1
2
-
-
Not available separately
-
-
3*
4*
5
1
1
1
1
1
1
1
1
325-0206
333-0082
419-0092
421-0525
431-1663
431-1598
511-0001
511-0101
10-24 x 3/8 PH Screw
# 10 Lock Washer
0.29 x 0.047 x 0.32 Comp. Spring
1/8 x 7/8 SST Dowel Pin
Idler Adjusting Screw
Idler Arm
6
7
8
9*
10
Idler Wire Feed Assembly
Drive roll
* Items 3, 4 & 9 available as package kit: Part number 005-0686
Python® Lincoln Compatible™ Owner's Manual - Page 12
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®
Python Lincoln Compatible™ Barrel Assembly
P/N 003-2272
*Apply silicone lubricant to
items 4 and 5 before installing.
Python® Lincoln Compatible™ Barrel Assembly
No. Qty.
Part Number
Description
Not available separately
Assy Taper Lock Barrel
Insulator Barrel
1
2
-
-
1
003-2213
261-0143
303-0010
303-0094
313-0091
431-1774
615-0178
621-0250
621-0393
3
1
4*
5*
6
2
O-Ring .489 ID x .07 W
O-Ring .301 ID x .07 W
Retaining Ring 5/8 Shaft
Cup Insulator Barrel
2
1
7
1
8
0.63 ft
Liner Tef 0.084 ID x 0.174 OD
Assy Cup Copper Finned #10
Tip HD Spray .060
9
1
1
10
Python® Lincoln Compatible™ Owner's Manual - Page 13
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®
Python Lincoln Compatible™ Rear Body Assembly
P/N 003-2289
APPLY SILICONE
LUBRICANT
FOR INSTALLATION
Python® Lincoln Compatible™ Rear Body Assembly
No. Qty.
Part No.
Description
Not available separately
O-Ring .145 ID x .07 W
Set Screw Flat 1/4-20 5/16 SST
Set Screw Mod Conduit
Scr PH Phil 4-40 x 5/16 SST
Tie Wrap Scr 4
1
2
3
4
5
6
-
-
2
1
1
1
1
303-0096
321-1082
321-1104
336-0020
411-0243
Python® Lincoln Compatible™ Owner's Manual - Page 14
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®
Python Lincoln Compatible™ Lead Assembly
tiGHteN WitH
65+5 iN-LBS tORQUe
tiGHteN WitH
55+60 iN-LBS tORQUe
tiGHteN WitH
25 Ft-LBS tORQUe
Python® Lincoln Compatible™ Lead Assembly
No.
1
Qty.
Part Number
003-2153
003-2337
003-2346
261-0094
338-0014
411-0045
431-1898
Description
1
Assy Boot Torch
2
1
Assy Power Manifold AC
Assy Power Pin Adapter
Wrap Spiral Cord
3
1
4
2
5
4
Screw SHC 4-40 x 1/2 SST
Tie Wrap .75 Dia N BLK
Retainer 5/16 Hose
6
4
7
1
8
1
437-0315-RED Handle RH Lead Universal
437-0316-RED Handle LH Lead Universal
9
1
10
11
12
13
14
1
931-0132
Snake Skin Cover, 35 ft
1
552-0245-35 Assy Gas Hose, 35 ft
615-0620-35 Conduit Tef Tube, 35 ft
843-0640-35 Assy Cable Power, 35 ft
1
1
1
005-0740
Assy Control Cable, 35 ft
Python® Lincoln Compatible™ Owner's Manual - Page 15
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®
Python Lincoln Compatible™
Power Pin Adapter Assembly
P/N 003-2346
APPLY SILICONE LUBRICANT TO
O-RINGS BEFORE INSTALLING
Python® Lincoln Compatible™ Power Pin Adapter Assembly
No. Qty.
Part No.
002-0761
303-0010
Description
1
2
1
4
Assy Brazed Power Pin Adapter
O-Ring 2-014 .489 ID x .07 W
Python® Lincoln Compatible™ Owner's Manual - Page 16
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®
Python Lincoln Compatible™
Power Manifold Assembly
P/N 003-2337
Python® Lincoln Compatible™ Power Manifold Assembly
No. Qty.
Part No.
321-1104
321-1082
431-1936
Description
Set Screw Conduit
1
2
3
1
1
1
Set Screw Flat 1/4 - 20 x 3/8 SST
Power Manifold AC
Python® Lincoln Compatible™ Owner's Manual - Page 17
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®
Python Lincoln Compatible™ electrical
E
F
D
G
A
C
B
"W" Clocked
Amphenol Connector
Viewed from front of connector
Python® Lincoln Compatible™ Owner's Manual - Page 18
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Python® Lincoln Compatible™ Owner's Manual - Page 19
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Python® Lincoln Compatible™ Owner's Manual - Page 20
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LIMITED WARRANTY
Effective August 1, 2008
This warranty supersedes all previous MK Products warranties and is
exclusive, with no other guarantees or warranties expressed or implied.
Classification of any item into the foregoing categories shall be at the
sole discretion of MK Products. Notification of any failure must be made
in writing within 30 days of such failure.
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 warran-
ties of their respective manufacturers, if any.
Acopyoftheinvoiceshowingthedateofsalemustaccompanyproducts
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.
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 gun 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.
Normal surface transportation charges (one way) for products returned
for warranty repair or replacement will be borne by MK Products, except
for products sold to foreign markets.
MK Products shall, exclusively remedy the limited warranty or any
duties with respect to the quality of goods, based upon the following
options:
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.
(1) repair
(2) replacement
(3) where authorized in writing by MK Products, the reasonable cost
of repair or replacement at our Irvine, California plant.
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:
EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING,
MK’s PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COM-
MERCIAL/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.
1. Power Supplies and Wire Feed Cabinets..................3 years
2. Weldheads, CobraCooler, Positioners, Prince XL and
Prince XL Spool Guns, Python, CobraMAX, Cobra SX,
Cobra MX ....................................................................1 year
3. Sidewinder Spool Gun, Prince SG Spool Guns, Modules ......
...............................................................................180 days
4. Repairs/Exchanges/Parts ......................................90 days
USE OF OTHER THAN GENUINE MK PRODUCTS’
CONSUMABLES, PARTS, AND ACCESSORIES MAY INVALIDATE YOUR
PRODUCT WARRANTY.
16882 Armstrong Ave.
Irvine, CA 92606
Tel (949)863-1234 Fax (949)474-1428
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16882 Armstrong Ave.
Irvine, CA 92606
Tel (949)863-1234 Fax (949)474-1428
Download from Www.Somanuals.com. All Manuals Search And Download.
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