Liquid Cooled
Millermatic Compatible™
Owner’s Manual
Product:
Manual:
Serial:
Python
091-0597
07030001
Voltage Rating: 24 VDC
Revision:
March 2007
248-8xx
Gun Models:
400 Ampere 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
Coolant Recommendations................................................................................1
Operation.................................................................................Section B
General ..............................................................................................................2
Controls and Settings.........................................................................................2
Trigger Adjustment.............................................................................................2
Drive Roll and Idler Rolls....................................................................................2
Accessories.............................................................................Section C
Insulated Drive Roll Kits.....................................................................................3
Replacement Kits...............................................................................................4
Snake Skins.......................................................................................................4
Contact Tips.......................................................................................................4
Barrels................................................................................................................4
Maintenance............................................................................Section D
Periodic Maintenance.........................................................................................5
Recommended Spare Parts List........................................................................6
Troubleshooting.......................................................................Section E
Troubleshooting Guide.......................................................................................6
Testing The Gun.................................................................................................6
Appendices..............................................................................Section F
Diagrams / Parts List..........................................................................................9
Mechanical.......................................................................................................10
Electrical...........................................................................................................17
Warranty
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Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
Note
MK Products, Inc.
Manufacturer’s Name:
Manufacturer’s Address:
16882 Armstrong Ave.
Irvine, CA 92606
Declares that the product:
®
Python
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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SECTION 1 – SAfETY PRECAUTIONS - READ BEfORE USING
som _nd_7/02
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
�
Marks a special safety message.
� Means “Note”; not safety related.
1-2. Arc Welding Hazards
�
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
�
�
�
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
�
�
�
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
�
�
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
�
�
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
ELECTRIC SHOCK can kill.
Do not connect more than one electrode or work cable to any
single weld output terminal.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
SIGNIfICANT DC VOLTAGE exists after removal of
input power on inverters.
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
groundedequipment is a hazard.
�
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
�
�
�
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
fUMES AND GASES can be hazardous.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
�
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
�
�
Keep your head out of the fumes. Do not breathe the fumes.
�
�
Use AC output ONLY if required for the welding process.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If AC output is required, use remote output control if present on
unit.
�
�
If ventilation is poor, use an approved air-supplied respirator.
�
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
�
�
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
�
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
�
�
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
�
�
When making input connections, attach proper grounding conduc-
tor first – double-check connections.
Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-suppliedrespirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
�
�
�
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
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ARC RAYS can burn eyes and skin.
BUILDUP Of GAS can injure or kill.
�
�
Shut off shielding gas supply when not in use.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Always ventilate confined spaces or use
approved air-supplied respirator.
�
Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
�
�
�
Wear approved safety glasses with side shields under your
helmet.
�
�
Do not touch hot parts bare handed.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Allow cooling period before working on gun or
torch.
Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC fIELDS can affect pacemakers.
WELDING can cause fire or explosion.
�
�
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
NOISE can damage hearing.
�
�
�
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can
damagehearing.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
�
Wear approved ear protection if noise level is
high.
�
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
�
�
Watch for fire, and keep a fire extinguisher nearby.
CYLINDERS can explode if damaged.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
�
�
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
�
�
Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
�
�
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
�
�
�
�
�
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
�
�
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
fLYING METAL can injure eyes.
�
�
Turn face away from valve outlet when opening cylinder valve.
�
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
�
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
�
Wear approved safety glasses with side
shields even under your welding helmet.
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1-3. Additional Symbols for Installation, Operation, And Maintenance
fIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
�
Do not install or place unit on, over, or near
combustiblesurfaces.
�
�
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
�
Do not install unit near flammables.
�
Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
fALLING UNIT can cause injury.
H.f. RADIATION can cause interference.
�
�
�
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
�
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Use equipment of adequate capacity to lift and
support unit.
�
Have only qualified persons familiar with
electronic equipment perform this installation.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
�
�
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
If notified by the FCC about interference, stop using the
equipmentat once.
OVERUSE can cause OVERHEATING
�
�
Allow cooling period; follow rated duty cycle.
�
�
Have the installation regularly checked and maintained.
Reduce current or reduce duty cycle before
starting to weld again.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
�
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
�
�
Put on grounded wrist strap BEFORE handling
boards or parts.
ARC WELDING can cause interference.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
�
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
MOVING PARTS can cause injury.
�
Be sure all equipment in the welding area is
electromagneticallycompatible.
�
�
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
�
�
�
�
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury.
Be sure this welding machine is installed and grounded
according to this manual.
�
�
Do not press gun trigger until instructed to do
so.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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1-4. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
ternational.org).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-
ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212–642–4900,
website: www.ansi.org).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269–9101 (phone:
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202–4102 (phone: 703–412–0900, web-
site: www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices––phone for Region 5, Chicago, is
312–353–2220,website: www.osha.gov).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
1-5. EMf Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
To reduce magnetic fields in the workplace, use the following
procedures:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
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SECTION 2 – DEfINITIONS
2-1. Warning Label Definitions
A. Warning! Watch Out! There
are possible hazards as
shown by the symbols.
B. Drive rolls can injure fingers.
A
B
C
C. Welding wire and drive parts
are at welding voltage during
operation – keep hands and
metal objects clear.
1
Electric shock can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1
2
1.1
2.1
3.1
4.1
1.2
1.3
1.3 Disconnect input plug or
power before working on
machine.
2
Breathing welding fumes can
be hazardous to your health.
2.2
2.3
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3
4
5
3.2
3.3
3
Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
+ + +
3.3 Do not weld on drums or any
closed containers.
4
Arc rays can burn eyes and
injure skin.
6
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
+
S-178 936
5
Become trained and read the
instructions before working on
the machine or welding.
6
Do not remove or paint over
(cover) the label.
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2-3. Symbols And Definitions
Some symbols are found only on CE products.
Note
Amperes
Volts
AlternatingCurrent
Circuit Breaker
Duty Cycle
Wire Feed
A
IP
V
Hz
X
Degree Of
Protection
Hertz
Jog
Output
Trigger
Gun
Press To Set
Increase
Trigger Hold On
Trigger Hold Off
Purge
Spot Weld Time
Primary Voltage
Percent
Run-In
Burnback Time
Primary Current
Load Voltage
Read Instructions
U1
I2
U2
Water (Coolant) In-
put
Rated Current
Fuse
Line Connection
I1
Water (Coolant)
Output
Continuous
Spot Welding
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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!
Thank 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.
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Section A
Installation
Technical Specifications
Wire Capacity
Aluminum or Cored Wire .............................. .030" - 1/16" (0.8 mm - 1.6 mm)
Solid and Hard Wire ..................................... .030" - .045" (0.8 mm - 1.2 mm)
Wire Speed (At rated feeder input voltage) .................... 800 ipm (20.3 mpm)
Duty Cycle - 60% (All ratings are using Argon gas) ........................400 Amps
Shipping Weight (approximate) ......................................19.29 lbs. (8.29 Kg)
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
Millermatic Compatible™ Python® liquid cooled guns utilize a specially
designed cable with a #6 AWG cable inside a 1/2" (13 mm) diameter hose.
Liquid coolant is used with this cable and the #10 liquid cooled gas cup,
the system is rated at 400 amps @ 60% duty cycle. The welding power
connection is incorporated through the power pin type connector.
The power cable ends are threaded fittings which screw into the gun body
and the power pin connector. These connections utilize a conductive sealant
and are tightened with torque requirements of 100 + 5 IN-LB.
Conduit
The liquid cooled Millermatic Compatible™ Python® 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 barbed fittings on both gun body and the Power
Pin connector and is secured with a plastic tie wrap.
Coolant Connections
The blue coolant (supply) hose is pushed over a barbed fitting on the gun
body and secured with a plastic tie wrap. The red coolant (return) hose
connects through the power cable and the power pin connector.
Both hose fittings are standard coolant style, left-hand threads.
Control Cable
A multi-conductor control cable is used on the liquid cooled Millermatic
Compatible™ Python®. 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 10-Pin, "X" clocked connector.
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Coolant Recommendations
Use Cobra Coolant (Aluminum Protection), P/N 931-0060. Cobra Coolant
does not contain reactive sulphur or chlorine and does not react with copper,
brass or aluminum.
The coolant flow rate should be a minimum of 15 GPH (1 qt/min) between
35 and 45psi. Contact the re-circulator manufacturer for specifications on
pressure.
Section B
Operation
General
The Millermatic Compatible™ Python ® 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.
Controls and Settings
Potentiometer
The laterally-positioned potentiometer is located in the lower end of the
handle, providing up to 800 ipm (20.3 mpm) with 3 3/4 turns.
Micro Switch
The micro switch assembly consists of a normally open micro switch and
solder-attached leads.
Trigger Sensitivity
The amount of trigger lever 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 will enable the operator to increase the
sensitivity of the trigger lever.
Sensitivity Adjustment
With the wire feeder turned on (with or without
welding wire loaded), turn the screw in until the
micro-switch 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' satisfaction.
Drive Roll and Idler Rolls
The Millermatic Compatible™ Python ® comes standard with a knurled drive
roll and a grooved idler roll, which will handle .030" to 1/16" aluminum and
.030" to .045" solid and hard wire.
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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 Millermatic Compatible™ Python ® comes from the factory with
the pressure adjustment screw preset.
NO ADJUSTMENT REqUIRED fOR ANY WIRE SIZE OR ALLOY
Drive Roll Installation/Removal
Note: Neither of the handles needs to be removed to access the drive or
idler rolls.
1. Pull the cam lever away from the
Cam Lever
idler roll. This will relieve the pressure
against the drive roll (as shown in Figure
1).
2. Align the drive roll removal tool over the
flats of the drive roll (as shown in Figure
2). Hold the gun with one hand or on a
figure 1
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.
4. Install a new drive roll on the left-hand
threaded shaft. The drive roll will self-
tighten when it is feeding wire.
figure 2
Idler Roll Installation and Removal
(Reference Figure 3)
1. Using a slot type screwdriver, loosen idler screw, taking care not to lose
lock washer under idler roll.
2. Insert new idler roll and lock washer onto screw, insuring that idler groove
is toward top and lock washer is beneath.
3. Tighten screw until tight.
NOTE: Lock washer must be under idler roll or it will not turn freely.
figure 3
Liquid Cooled Millermatic Compatible™ Python® Owner's Manual - Page 3
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Section C
Options and Accessories
Insulated Drive Roll Kits
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" (0.8 mm) dia. aluminum wire. Includes insulated drive roll and idler
roll assy.
Insulated Groove Drive Roll Kit......................................................005-0716
For .035" (0.9 mm) dia. aluminum wire. Includes insulated drive roll
and idler roll assy.
Insulated Groove Drive Roll Kit......................................................005-0642
For .040" (1.0 mm) dia. aluminum wire. Includes insulated drive roll
and idler roll assy.
Insulated Groove Drive Roll Kit......................................................005-0718
For 3/64" (1.2 mm) dia. aluminum wire. Includes insulated drive roll
and idler roll assy.
Insulated Groove Drive Roll Kit......................................................005-0644
For .062" (1.6 mm) dia. aluminum wire. Includes insulated drive roll
and idler roll assy.
Replacement Kits
Handle Kit Gun.................................................................................005-0699
Left and right handles, screws and drive roll door, as a replacement for all
Millermatic Compatible™ Python® guns.
Trigger Kit.........................................................................................005-0694
Trigger adjustment kit includes a spring and sensitivity adjustment screw
replacement for all Millermatic Compatible™ Python® guns.
Micro Switch Kit...............................................................................005-0701
Replacement micro switch assembly for all Millermatic Compatible™ Python®
guns.
Potentiometer Kit.............................................................................005-0695
Replacement potentiometer assembly for all Millermatic Compatible™
Python® guns.
Barrel Insulator Kit ..........................................................................005-0696
Replacement barrel insulator and taper lock nut.
Conduits
Flat spiral steel conduit for steel & cored wire.
15 ft./4.5m.....................................................................................615-0621-15
25 ft./7.6m.....................................................................................615-0621-25
35 ft/10.7m....................................................................................615-0621-35
50 ft./15.2m...................................................................................615-0621-50
Snake Skins
A Snake Skin protective cover is standard on the Millermatic Compatible™
Python®. See below for replacement part numbers.
15 ft./4.5m.......................................................................................... 931-0110
25 ft./7.6m.......................................................................................... 931-0122
35 ft/10.7m......................................................................................... 931-0132
50 ft./15.2m........................................................................................931-0123
Liquid Cooled Millermatic Compatible™ Python® Owner's Manual - Page 4
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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
Gas Cups
Liquid Cooled Cup
Air Cooled Cup
Liquid Cooled Cup Adapter
Air Cooled Cups for Python® Liquid Cooled Gun
Cup Size
Cup I.D.
Part No.
621-0170
621-0159
621-0160
No. 6
3/8” (9.5mm)
1/2” (12.7mm)
5/8” (15.8mm)
No. 8
No. 10
To use air cooled gas cups, you must use a cup retaining nut (449-0193) and a liquid cooled cup adapter (621-0101).
Liquid Cooled Cups for Python® Liquid Cooled Gun
Cup Size
Cup I.D.
Part No.
No. 10*
5/8” (15.9mm)
621-0065
*Standard - furnished with gun
Barrels
The liquid cooled Millermatic Compatible™ Python® comes standard with a
60˚ curved barrel. The barrel assembly locks to the liquid cooled Millermatic
Compatible™ Python® body using the patented EZ Lock™ system.
Gun Barrel Liners
Part Number
931-0137
Description
Teflon liner package, 5 pieces
615-0338
Steel wire only, .030 - .1/16" (0.8 - 0.9mm)
Liquid Cooled Millermatic Compatible™ Python® Owner's Manual - Page 5
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Optional Barrels - Liquid Cooled
6" Straight..........................................................................................003-2315
6" Curved, 45° ...................................................................................003-2316
12" Straight .......................................................................................003-2318
12" Curved, 45° ................................................................................003-2319
18" Straight .......................................................................................003-2320
18" Curved, 45° .................................................................................003-2321
Barrel Removal and Installation
CAUTION: Power-off the coolant pump before removing or loosening
liquid-cooled cups and barrels.
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, push the barrel assembly into the gun body
until it clicks to a stop. To assure proper seating of the barrel, open the drive/
idler roll door in the top of the handle. The rear face of the barrel should
now be flush with the gun body. Take care not to damage the o-rings when
inserting into the body. Tighten taper lock nut assembly firmly so that barrel
cannot rotate while welding.
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 re-tighten taper lock nut assembly firmly so that the barrel cannot rotate.
CAUTION: Do not attempt to weld without the barrel being tightly
secured in the gun body, or damage to the barrel or body may result.
Section D
Maintenance
Disconnect Power
Before Maintaining.
Periodic Maintenance
Your liquid cooled Millermatic Compatible™ Python® 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 that are subject to normal wear are the conduit, contact tips,
nozzles, barrel 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.
It is recommended that you blow out your conduit each time you install a new
spool of wire.
If repairs do become necessary, qualified shop maintenance personnel can
easily replace any part.
Reference the table below for suggested Maintenance Tools used with the
liquid cooled Millermatic Compatible™ Python® welding gun.
Maintenance Tools
Tool
Part Number
931-0100
Drive Roll Removal Tool
Tip Removal Tool
931-0002
Liquid Cooled Millermatic Compatible™ Python® Owner's Manual - Page 6
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Recommended Spare Parts
Listed in the table below is the factory recommendation of the necessary
spare parts which should be kept on hand for maintaining proper operation of
the liquid cooled Millermatic Compatible™ Python® welding gun.
This list, in no way, indicates that these parts are more likely to fail or cause
equipment damage. This is not an indication of premature failure or defect in
manufacture of said parts.
Recommended Spare Parts List
qty. Part Number Description
1
1
615-0620-15 15' Conduit
615-0620-25 25' Conduit
615-0620-35 35' Conduit
615-0620-50 50' Conduit
1
1
2
005-0694
005-0695
005-0699
005-0701
511-0101
005-0686
931-0137
Trigger Assy Kit
2
Potentiometer Assy Kit
Handle Kit
1
2
Micro-Switch Assy Kit
Drive Roll
10
5
Idler Roll Kit
2
Liner Package - 5 pieces each
DRIVE ROLL REMOVAL TOOL
931-0100
KNURLED DRIVE ROLL
511-0101
IDLER ROLL KIT
005-0686
MICRO SWITCH ASSY KIT
005-0701
CONTACT TIp REMOVER TOOL
(SHOWN WITH TIp)
931-0002
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Section E
Troubleshooting Guide
Disconnect Power
Before Troubleshooting.
To aid in troubleshooting problems with your welding equipment, it is best
to understand the basic theory of operation for this Push-Pull System. 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 an electric 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 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
24VDC circuits, speed control, control cable, or the gun motor. If nothing
operates, look more toward the slave motor’s input, micro switch leads, or
micro switch.
Testing The Gun
Reference the "X" clocked diagram
on the liquid cooled Millermatic Compatible™ Python® electrical diagram
for information about pin-outs and locations.
Motor Check
Remove the connector from the cabinet.
Using the connector, check the resistance across pins “C” and “B” (motor
leads). The resistance across the motor should be between 5 - 10 ohms as
the potentiometer is turned.
If an open circuit or short exist, check the motor leads and motor
independently.
Testing the Gun Potentiometer
Using the connector, check the resistance across pin “f” (wiper) and pin
“E”. The resistance should vary from 0 - 5K ohms as the potentiometer is
turned.
Check the resistance across pin “f” (wiper) and pin “H”. The resistance
should vary from 5K - 0 ohms as the potentiometer is turned.
Testing the Micro Switch
Using the connector, check for continuity across pins “D” and “G” when the
trigger is pressed.
Liquid Cooled Millermatic Compatible™ Python® Owner's Manual - Page 8
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Troubleshooting Table
Symptoms
Cause
Remedy
Circuit breaker in feeder/
control box open.
Reset.
No wire feed at
gun, feeder not
operating, i.e. no
slave motor or
brake solenoid.
Micro-switch defective/not Replace switch. Check
being activated.
switch for operation.
Check micro-switch wires
for continuity.
Broken electrical cable.
Circuit breaker in feeder/ Check motor leads for
control box open.
short. Reset.
No wire feed
at gun, feeder
operating properly.
Check potentiometer with
meter.
Bad potentiometer.
Check motor and
potentiometer wires for
continuity.
Broken electrical cable.
Loose or no cable
connections.
Check all power
connections.
Wire feeds, but
welding wire is not
energized.
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 replace
if damaged.
Idler roll stuck.
Bad potentiometer.
Broken electrical cable.
Check with meter.
Check potentiometer
wires for continuity or
short.
Wire feeds one
speed only.
See specific feeder/
Bad speed control.
control owner's manual for
speed control operation.
Place groove in idler roll
toward top.
Idler roll upside-down.
Wire walks out of
drive rolls.
Rear wire guide missing. Replace wire guide.
Consult wire feeder and welding power supply owners manuals for further
problem solving solutions.
Liquid Cooled Millermatic Compatible™ Python® Owner's Manual - Page 9
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Section f
Appendices
Liquid Cooled Millermatic Compatible™ Python®
Diagrams / Parts List
Head Assembly Exploded Parts View....................................... 10
Head Assembly Parts List......................................................... 11
Front Body Assembly Parts View.............................................. 12
Rear Body Assembly Parts View .............................................. 13
Barrel Assembly Parts View...................................................... 14
Cup Insulator and O-Ring Maintenance ................................... 15
Lead Assembly Parts View ....................................................... 16
Electrical/Connector Pinout ...................................................... 17
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Liquid Cooled Millermatic Compatible™ Python®
Head Assembly
Liquid Cooled Millermatic Compatible™ Python® Owner's Manual - page 11
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Liquid Cooled Millermatic Compatible™ Python®
front Body Assembly
P/N 003-2108
Items 3, 4 & 9 available
as package kit:
P/N 005-0686
Liquid Cooled Millermatic Compatible™ Python®
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
Idler Wire Feed Assembly
Drive roll
10
* Items 3, 4 & 9 available as package kit: Part number 005-0686
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Liquid Cooled Millermatic Compatible™ Python®
Rear Body Assembly
P/N 003-2287
APPLY SILICONE LUBRICANT FOR
INSTALLATION
Liquid Cooled Millermatic Compatible™ Python®
Rear Body Assembly
No. qty.
Part No.
Description
Not available separately
O-Ring .145 ID x .07 W
Set Screw Mod Conduit
Scr PH Phil 4-40 x 5/16 SST
Tie Wrap SCR #4
1
2
3
4
5
-
-
6
1
1
1
303-0096
321-1104
336-0020
411-0243
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Liquid Cooled Millermatic Compatible™ Python®
Barrel Assembly
P/N 003-2317
lubricant to
fore installing.
Millermatic Compatible™ Python® Liquid Cooled 60º
Barrel Assembly
No. qty.
Part No.
Description
Not available separately
Assy Taper Lock Barrel
Insulator Barrel
1
2
-
-
1
1
1
8
2
1
1
1
003-2213
261-0141
261-0381
303-0010
303-0094
313-0091
431-0977
431-1774
615-0178
621-0065
621-0393
3
4
Insulator Cup with five O-Rings
O-Ring .489 ID x .07 W
O-Ring .301 ID x .07 W
Retaining Ring 0.625 Shaft
Retaining Nut
5*
6*
7
8
9
Cup Insulator Barrel
10 0.70 ft.
Liner Tef 0.084 ID x 0.174 OD
Cup #10 Assy
11
12
1
1
Tip HD Spray .060
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CUP INSULATOR AND O-RING MAINTENANCE
CAUTION: Power-off the coolant pump before disassembling liquid-cooled barrels.
1. Unscrew Retaining Nut and slide back on barrel.
2. Using a firm pull and twist action, the Liquid-Cooled Gas Cup can be removed from the Cup
Insulator.
3. Inspect the Cup Insulator and o-rings (included with Insulator) for wear and proper lubrication.
It is considered good practice to replace all o-rings at the same time.
4. To remove the Cup Insulator, it must be UNSCREWED and pulled from the barrel. Use a rag
or towel (due to o-ring lubrication) and wrap it around the Cup Insulator.
UNSCREW and pull when completly unthreaded from barrel. Be sure the Insulator is fully
unscrewed from the threads. Pulling the Insulator over barrel threads will damage the
threads on the Insulator.
Inspect o-rings on barrel for wear and lubrication. It is considered good practice to replace all
o-rings at the same time.
5. To install the Cup Insulator, it must be pushed all the way onto the barrel then screwed onto
the threads. If necessary, place small amount of o-ring lubricant on the inside diameter of the
Cup Insulator, this will help it slide onto the barrel.
Push the Insulator onto the barrel until it bottoms out, screw onto barrel threads.
The Insulator MUST be all the way onto the barrel to assure proper coolant passage and from
blocking the gas outlet orifices.
6. Push Liquid-Cooled Gas Cup onto Cup Insulator. Slide Retaining Nut forward and tighten.
Insulator
Barrel
Gas Outlet Orifices
Correct Installation
Incorrect Installation
Liquid Cooled Millermatic Compatible™ Python® Owner's Manual - page 16
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Liquid CooledMillermatic Compatible™ Python®
Lead Assembly, P/N 003-2309 Series
Liquid Cooled Millermatic Compatible™ Python® Lead Assembly
No qty Description
15' Part No. 25' Part No. 35' Part No. 50' Part No.
1
2
1
2
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
Assy Conn Power Pin
Wrap Spiral Cord
003-2322
261-0094
3
Screw K40X12 Pan Head STL
Tie Wrap
336-0247
4
411-0045
5
Spring Strain Relief
Power Pin Housing LH
Power Pin Housing RH WC
Strain Relief Spring Retainer
Assy Hose Liquid Red
Noalox
419-0101
6
437-0286
7
431-1803
8
437-0287
9
552-0209
10
11
12
13
14
15
16
17
823-0029
Assy Gas Hose
552-0241-15 552-0241-25 552-0241-35 552-0241-50
615-0620-15 615-0620-25 615-0620-35 615-0620-50
843-0680-15 843-0680-25 843-0680-35 843-0680-50
Assy Tube Conduit Miller
Assy Power Cable WC
Assy Controller Cable
Snake Skin
843-0624
931-0110
843-0625
931-0122
843-0627
931-0132
843-0626
931-0123
Assy Hose Liquid Blue
Cable Boot
552-0239-15 552-0239-25 552-0239-35 552-0239-50
301-0019
Liquid Cooled Millermatic Compatible™ Python® Owner's Manual - page 17
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Liquid Cooled Millermatic Compatible™ Python®
Power/Gas Connector
003-2322
Liquid Cooled Millermatic Compatible™ Python®
Power/Gas Connector
No. qty.
Part No.
003-2323
153-1210
303-0102
321-0070
321-1104
431-1724
431-1742
Description
S/A Conn Power Gas WC
Pin Power Assy
1
2
3
4
5
6
7
1
2
1
1
2
1
1
O-Ring, 0.487 ID x .103 Width
Set Screw 10-32
Set Screw Mod Conduit
Brass Fitting 1/8 Hose
Wire Outlet Guide
Liquid Cooled Millermatic Compatible™ Python® Owner's Manual - page 18
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Liquid Cooled Millermatic Compatible™ Python®
Electrical Schematic/Connector Pinout
Polarizing Key
"X" Clocked Connector
Viewed from back of connector
Do not touch live electrical parts.
•
•
WARNING
Disconnect input power or stop
engine before servicing.
Do not operate with covers removed.
•
•
ELECTRIC
SHOCK HAZARD
Have only qualified persons install,
use, or service this units.
Liquid Cooled Millermatic Compatible™ Python® Owner's Manual - page 19
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October 1, 2006
LIMITED WARRANTY
Effective October 1, 2006
This warranty supersedes all previous MK Products warranties and is
exclusive, with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY - MK Products Inc., Irvine, California warrants Classification of any item into the foregoing categories shall be at the
that all new and unused equipment furnished by MK Products is free from
sole discretion of MK Products. Notification of any failure must be made
defects in workmanship and material as of the time and place of delivery in writing within 30 days of such failure.
by MK Products. No warranty is made by MK Products with respect to
trade accessories or other items manufactured by others. Such trade A copy of the invoice showing the date of sale must accompany products
accessories and other items are sold subject to the warranties of their
respective manufacturers, if any.
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,includinggascups,gascupinsulators,andcontacttipswherefailure Normal surface transportation charges (one way) for products returned
does not result from defect in workmanship or material.
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, 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.
Warranty on the Liquid Cooled Millermatic Compatible™ Python® Welding Gun is recognized and admin-
istered by the original equipment manufacturer, known as MK Products, Inc.
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16882 Armstrong Ave.
Irvine, CA 92606
Tel (949)863-1234 Fax (949)474-1428
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