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MAC TOOLS M-25 Gun Owner's manual

Other manuals for M-25 Gun: Owner's manual, Owner's Manual
Manual is about: Arc Welding Power Source And Wire Feeder

Summary of M-25 Gun

  • Page 1

    Mw 270 plus and m-25 gun ® for warranty claims and technical support, contact: milweld inc., national distributor p.O. Box 338, hortonville, wi 54944-0338 tel 920-779-0916 fax 920-779-0924 processes description mig (gmaw) welding flux cored (fcaw) welding arc welding power source and wire feeder om-...

  • Page 3: Table of Contents

    Table of contents section 1 − safety precautions - read before using 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 4: Table of Contents

    Table of contents section 6 − mig welding (gmaw) guidelines 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Typical mig process connections 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 5

    Om-219 806 page 1 section 1 − safety precautions - read before using som _3/05 y warning: protect yourself and others from injury — read and follow these precautions. 1-1. Symbol usage means warning! Watch out! There are possible hazards with this procedure! The possible hazards are shown in the adj...

  • Page 6

    Om-219 806 page 2 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. Arc rays can burn eyes and skin. D wear an approved welding helmet fitted with a proper shade of fil- ter lenses to pro...

  • Page 7

    Om-219 806 page 3 1-3. Additional symbols for installation, operation, and maintenance fire or explosion hazard. D do not install or place unit on, over, or near combustible surfaces. D do not install unit near flammables. D do not overload building wiring − be sure power supply system is properly s...

  • Page 8

    Om-219 806 page 4 1-5. Principal safety standards safety in welding, cutting, and allied processes, ansi standard z49.1, from global engineering documents (phone: 1-877-413-5184, website: www.Global.Ihs.Com). Recommended safe practices for the preparation for welding and cut- ting of containers and ...

  • Page 9

    Om-219 806 page 5 section 2 − consignes de sÉcuritÉ − lire avant utilisation fre_som _3/05 y avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés symbole graphique d’avertissement ! Attention ! Cette pro- cédure com...

  • Page 10

    Om-219 806 page 6 le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Les rayons d’arc peuvent entraî- ne...

  • Page 11

    Om-219 806 page 7 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance risque d’incendie ou d’explo- sion. D ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D ne pas installer l’appareil à proximité de produits inflammable...

  • Page 12

    Om-219 806 page 8 2-5. Principales normes de sécurité safety in welding, cutting, and allied processes, ansi standard z49.1, de global engineering documents (téléphone : 1-877-413-5184, site in- ternet : www.Global.Ihs.Com). Recommended safe practices for the preparation for welding and cut- ting of...

  • Page 13: Section 3 − Introduction

    Om-219 806 page 9 section 3 − introduction 3-1. Specifications max. Open amps input at rated output, 60 hz, single-phase rated output max. Open circuit voltage 200 v 230 v kva kw 200 a at 24 vdc, 60% duty cycle 35 40 1.1* 35 1.3* 8 0.31* 6.8 0.18* wire type and diameter no load wire feed speed dimen...

  • Page 14: Caution

    Om-219 806 page 10 3-3. Welding gun duty cycle and overheating caution welding longer than rated duty cycle can damage gun and void warranty. • do not weld at rated load longer than shown below. • using gasless flux cored wire reduces gun duty cycle. Warn7.1 8/93 duty cycle is percentage of 10 minut...

  • Page 15

    Om-219 806 page 11 3-5. Installing welding gun ref. 802 285-d 1 drive assembly 2 gun securing knob 3 gun end loosen knob. Insert gun end through opening until it bottoms against drive assembly. Tighten knob. 4 gun trigger plug insert plug into receptacle, and tighten threaded collar. Close door. 3 4...

  • Page 16

    Om-219 806 page 12 3-6. Connecting to weld output terminals 803 778-a y turn off power before connecting to weld output terminals. Y failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. 1 weld output terminal 2 supplied weld output terminal nut 3...

  • Page 17

    Om-219 806 page 13 3-8. Setting gun polarity for wire type tools needed: 3/4 in 1 1 polarity changeover label 2 positive (+/red) output terminal 3 negative (−/black) output terminal always read and follow wire manufacturer’s recommended polarity. Close door. Ref. 802 285-d ref. St-192 432 3 2 3-9. I...

  • Page 18

    Om-219 806 page 14 3-10. Installing gas supply ref. 220 747-a / 802 028-a / ref. 802 286-e tools needed: 1-1/8, 5/8 in 1 2 3 argon gas or mixed gas rear panel 6 . Do not use argon/mixed gas regulator/flowmeter with co 2 shielding gas. See parts list for optional co 2 gas regulator/flowmeter. Obtain ...

  • Page 19

    Om-219 806 page 15 3-11. Positioning jumper links ref. 802 285-d check input voltage available at site. 1 jumper links access door open door. 2 jumper link label check label − only one is on unit. 3 input voltage jumper links move jumper links to match input voltage. Close and secure access door. 3 ...

  • Page 20

    Om-219 806 page 16 3-12. Electrical service guide 60 hz single phase input voltage 200 230 input amperes at rated output 40 35 max recommended standard fuse rating in amperes circuit breaker 1 , time-delay 2 50 40 normal operating 3 60 50 min input conductor size in awg 4 8 10 max recommended input ...

  • Page 21

    Om-219 806 page 17 3-13. Selecting a location and connecting input power 803 766-b / 802 286-e 4 2 y do not move or operate unitwhere it could tip. 18 in (457 mm) of space for airflow 1 y installation must meet all na- tional and local codes − have only qualified persons make this installation. Y sp...

  • Page 22

    Om-219 806 page 18 3-14. Threading welding wire ref. 802 285-d 1 wire spool 2 welding wire 3 inlet wire guide 4 pressure adjustment knob 5 drive roll 6 outlet wire guide 7 gun conduit cable lay gun cable out straight. Tools needed: 6 in (150 mm) pull and hold wire; cut off end. 4 in (102 mm) tighten...

  • Page 23

    Om-219 806 page 19 3-15. Installing optional spool gun switch in welding power source 802 936-a tools needed: 1/4 in 9/16 in y turn off unit, and disconnect input power. 1 welding power source center baffle 2 switch location 3 switch mounting plate remove 2 screws securing switch mounting plate to c...

  • Page 24

    Om-219 806 page 20 3-16. Connecting spool gun to welding power source ref. 802 582-a tools needed: y turn off unit. Disconnect and remove mig (gmaw) welding gun, if applicable. 1 front panel opening 2 spool gun weld cable route weld cable through front panel open- ing. 3 positive (+) output terminal...

  • Page 25: Section 4 − Operation

    Om-219 806 page 21 section 4 − operation 4-1. Controls 1 wire speed control the scale around the control is per- cent, not wire feed speed. 2 voltage control the higher the selected number, the thicker the material that can be welded (see welding guide and section 4-2). 3 power switch 1 ref. 195 721...

  • Page 26

    Om-219 806 page 22 4-2. Weld parameters input line voltage parameter chart settings higher e.G. 240 volts ac 230 volts ac lower e.G. 218 volts ac weld will be hotter lower settings use parameter chart inside door weld will be colder raise settings steel steel − for outdoor, windy applications or whe...

  • Page 27

    Om-219 806 page 23 200 785-c 3/8” (9.5 mm) — — — 5/66 7/70 7/60 7/100 7/82 7/60 7/75 6/50 5/46 — — — — — — 1/4” (6.4 mm) 4/58 5/56 5/40 5/100 5/76 4/60 4/50 5/58 4/38 4/30 6/90 5/70 6/50 6/45 6/18 6/64 6/60 5/36 5/42 5/16 5/56 5/54 1/8” (3.2 mm) 4/75 3/45 4/44 3/75 3/60 3/48 2/30 2/20 2/0 2/0 4/60 4...

  • Page 28

    Om-219 806 page 24 section 5 − maintenance and troubleshooting 5-1. Routine maintenance y disconnect power before maintaining. 3 months replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 months blow out or vacuum inside. During heavy service, clean m...

  • Page 29

    Om-219 806 page 25 5-3. Replacing drive roll and wire inlet guide ref. 802 285-c 1 inlet wire guide securing screw 2 inlet wire guide loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 3 drive roll install correct drive roll for wire size and type. 4 drive r...

  • Page 30

    Om-219 806 page 26 5-5. Replacing gun contact tip ref. 800 797-c y turn off power before replacing contact tip. 1 nozzle 2 contact tip cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. Tools needed: 1 2.

  • Page 31

    Om-219 806 page 27 5-6. Removing nozzle, contact tip, and adapter, changing liner, and cleaning gun casing 804 466-a y turn off welding power source/wire feeder. 1 nozzle 2 contact tip 3 tip adapter 4 nozzle adapter . Wire size stamped on tip − check and match wire size. Head tube tools needed: 5/8,...

  • Page 32

    Om-219 806 page 28 5-7. Replacing switch and/or head tube ref. 800 795-d tools needed: 3/4 in remove handle locking nut. Slide handle. Secure head tube in vice. Loosen jam nut. Remove from vice and turn head tube out by hand. Install existing shock washer onto new head tube. Hand-tighten head tube i...

  • Page 33

    Om-219 806 page 29 5-8. Welding troubleshooting table welding trouble remedy no weld output; wire does not feed. Secure power cord plug in receptacle (see section 3-13). Check and replace power switch if necessary. Check supplementary protectors cb1 and/or cb2, and reset if necessary (see section 5-...

  • Page 34

    Om-219 806 page 30 section 6 − mig welding (gmaw) guidelines 6-1. Typical mig process connections y weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Wire feeder/ power source workpiece...

  • Page 35: Note

    Om-219 806 page 31 6-2. Typical mig process control settings these settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. Affect settings. Test welds to be sure they comply to specifications. Note 3.5 x 125 a = 437 ipm 2 x 125 a = 250 ipm 1.6 x 125 a...

  • Page 36: Note

    Om-219 806 page 32 6-3. Holding and positioning welding gun welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. Note 1 hold gun and control...

  • Page 37: Note

    Om-219 806 page 33 6-4. Conditions that affect weld bead shape weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. Note slow fillet weld electode extensions (stickout) electrode...

  • Page 38: Note

    Om-219 806 page 34 6-5. Gun movement during welding normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Note 1 stringer bead − steady movement along se...

  • Page 39

    Om-219 806 page 35 6-8. Troubleshooting − excessive spatter excessive spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 possible causes corrective actions wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range....

  • Page 40

    Om-219 806 page 36 6-11. Troubleshooting − lack of penetration lack of penetration − shallow fusion between weld metal and base metal. Lack of penetration good penetration s-0638 possible causes corrective actions improper joint preparation. Material too thick. Joint preparation and design must prov...

  • Page 41

    Om-219 806 page 37 6-14. Troubleshooting − waviness of bead waviness of bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 possible causes corrective actions welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm...

  • Page 42

    Om-219 806 page 38 6-16. Common mig shielding gases this is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application ga...

  • Page 43

    Om-219 806 page 39 problem remedy probable cause welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary. Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting ...

  • Page 44: Notes

    Om-219 806 page 40 notes.

  • Page 45

    Om-219 806 page 41 section 7 − electrical diagram 206 590-a figure 7-1. Circuit diagram for welding power source.

  • Page 46: Section 8 − Parts List

    Om-219 806 page 42 section 8 − parts list 802 281-f . Hardware is common and not available unless listed. 18 19 21 20 16 15 14 13 12 11 8 7 6 5 4 3 2 1 9 − fig 8 -2 10 − fig 8 -3 17 − fig 8 -4 22 − fig 8 -5 figure 8-1. Main assembly.

  • Page 47

    Om-219 806 page 43 description part no. Dia. Mkgs. Item no. Quantity figure 8-1. Main assembly 1 203 481 panel, side 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 151 187 latch, side flush 2 . . . . . ....

  • Page 48

    Om-219 806 page 44 802 284-d . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 12 13 14 11 10 15 16 20 23 25 27 28 29 33 34 35 37 26 17 18 19 25 24 30 31 32 36 21 22 figure 8-2. Center baffle w/components.

  • Page 49

    Om-219 806 page 45 description part no. Dia. Mkgs. Item no. Quantity figure 8-2. Center baffle w/components (fig 8-1 item 9) 1 058 427 ring, retaining spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 085 980 nut, 62...

  • Page 50

    Om-219 806 page 46 802 283 . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 figure 8-3. Rear panel w/components description part no. Dia. Mkgs. Item no. Quantity figure 8-3. Rear panel w/components (fig 8-1 item 10) 1 049 399 nut, 312−18 push-on 1 . . . . . . . . . . . . . ...

  • Page 51

    Om-219 806 page 47 802 282-f . Hardware is common and not available unless listed. 9 11 10 8 7 6 5 4 3 2 1 figure 8-4. Front panel w/components description part no. Dia. Mkgs. Item no. Quantity figure 8-4. Front panel w/components (fig 8-1 item 17) 1 143 974 handle 1 . . . . . . . . . . . . . . . . ...

  • Page 52

    Om-219 806 page 48 804 467-a 1 2 3 4 5 6 7 8 9 13 16 10 11 14 15 12 figure 8-5. M-25 gun description part no. Dia. Mkgs. Item no. Figure 8-5. M-25 gun (fig 8-1 item 22) quantity 1 200 258 nozzle, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 53

    Om-219 806 page 49 description part no. Dia. Mkgs. Item no. Figure 8-5. M-25 gun (continued) quantity 8 169 738 nut, locking handle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 169 732 nut, jam 1 . . . . . . . . ....

  • Page 54: Notes

    Notes.

  • Page 55

    Effective january 1, 2006 (equipment with a serial number preface of “lg” or newer) this limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied. Limited warranty − subject to the terms and conditions below, warra...

  • Page 56: Resources  Available

    Printed in usa 2006−01 model name serial/style number purchase date (date which equipment was delivered to original customer.) distributor address city state zip please complete and retain with your personal records. Always provide model name and serial/style number. Contact your distributor for: we...