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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

    Processes om-198 781a february 2000 mw260x and m-25 gun description mig (gmaw) welding flux cored (fcaw) welding arc welding power source and wire feeder for warranty claims and technical support, contact: milweld inc., national distributor p.O. Box 338, hortonville, wi 54944-0338 tel 920-779-0916 f...

  • Page 3: Table of Contents

    Table of contents section 1 − safety precautions - read before using 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc welding hazards ...

  • Page 5

    Om-198 781 page 1 section 1 − safety precautions - read before using som _nd_4/98 1-1. Symbol usage means warning! Watch out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y marks a special safety message. . Means “note”; not safety related....

  • Page 6

    Om-198 781 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 a welding helmet fitted with a proper shade of filter to protect your face and ...

  • Page 7

    Om-198 781 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-198 781 page 4 1-5. Emf information considerations about welding and the effects of low frequency electric and magnetic fields 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 exami...

  • Page 9: Utilisation

    Om-198 781 page 5 section 1 − consignes de securite − lire avant utilisation som _nd_fre 4/98 1-1. Signification des symboles signifie mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y identifie un m...

  • Page 10

    Om-198 781 page 6 le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Les rayons de l’arc peuvent pro- voqu...

  • Page 11

    Om-198 781 page 7 1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance risque d’incendie ou d’explosion. D ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. D ne pas installer l’appareil à proximité de produits inflammables...

  • Page 12

    Om-198 781 page 8 1-4. Principales normes de sécurité safety in welding and cutting, norme ansi z49.1, de l’american wel- ding society, 550 n.W. Lejeune rd, miami fl 33126 safety and health sandards, osha 29 cfr 1910, du superintendent of documents, u.S. Government printing office, washington, d.C. ...

  • Page 13: Section 2 − Introduction

    Om-198 781 page 9 section 2 − introduction 2-1. Specifications max. Open circuit amps input at rated output, 60 hz, single-phase rated output max. Open circuit voltage 200 v 230 v 460 v 575 v kva kw 200 a at 24 vdc, 60% duty cycle 35 40 1.1* 35 1.3* 18 0.65* 14 0.50* 8 0.31* 6.8 0.18* wire type and ...

  • Page 14: Caution

    Om-198 781 page 10 2-3. 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-198 781 page 11 2-5. Installing welding gun ref. St-802 285-b 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. ...

  • Page 16

    Om-198 781 page 12 2-7. 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. 3 2 ref. St-802 285-b ref. St-192 432.

  • Page 17

    Om-198 781 page 13 2-8. Installing gas supply ref. St-801 789 / ref. St-149 827-b / ref. St-158 697-a 1 tools needed: 2 co 2 gas 4 5 1 argon gas or 3 chain gas cylinder to running gear, wall, or other stationary sup- port so cylinder cannot fall and break off valve. 1 regulator/flow gauge install so...

  • Page 18

    Om-198 781 page 14 2-10. Positioning jumper links ref. St-802 285-b 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....

  • Page 19

    Om-198 781 page 15 2-12. Selecting a location and connecting input power st-802 563 1 rating label supply correct input power. 2 plug 3 receptacle connect plug to receptacle. 4 input and grounding conductors connect directly to line disconnect device if hard wiring is required. 5 line disconnect dev...

  • Page 20

    Om-198 781 page 16 2-13. Threading welding wire ref. St-802 285-b 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) tigh...

  • Page 21: Section 3 − Operation

    Om-198 781 page 17 section 3 − operation 3-1. 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 3-2). 3 power switch 1 ref. 195 721...

  • Page 22

    Om-198 781 page 18 3-2. Weld parameters wire type wire machine material thickness gas size settings* 3/8 5/16 1/4 3/16 12ga 14ga 16ga 18ga 20ga 22ga flow rate .023” voltage − − 6 5 4 3 3 2 2 1 0.6mm wirespeed − − 100 85 75 60 50 36 30 15 e70s−6 .030” voltage 5 5 4 4 3 3 2 2 2 1 co2 0.8mm wirespeed 6...

  • Page 23

    Om-198 781 page 19 section 4 − maintenance and troubleshooting 4-1. 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 24

    Om-198 781 page 20 4-3. Replacing drive roll and wire inlet guide ref. St-802 285-a 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 driv...

  • Page 25

    Om-198 781 page 21 4-5. Cleaning or replacing gun liner ref. St-800 797-c 5/16 in, 10 mm to reassemble gun: install and tighten new liner. Cut liner off 3/4 in (20 mm) (3/8 in [9.5 mm] for aluminum) from head tube. Install adapter, contact tip, and nozzle. Y disconnect gun from unit first. Tools nee...

  • Page 26

    Om-198 781 page 22 4-6. Replacing switch and/or head tube ref. St-800 795-c 1 remove handle locking nut. 2 remove switch housing. Note: if installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with hand...

  • Page 27

    Om-198 781 page 23 4-7. Welding troubleshooting table welding trouble remedy no weld output; wire does not feed. Secure power cord plug in receptacle (see section 2-12). Check and replace power switch if necessary. Check circuit breakers cb1 and/or cb2, and reset if necessary (see section 4-2). Repl...

  • Page 28

    Om-198 781 page 24 section 5 − electrical diagram 197 515 figure 5-1. Circuit diagram for welding power source.

  • Page 29: Notes

    Om-198 781 page 25 notes.

  • Page 30: Section 6 − Parts List

    Om-198 781 page 26 section 6 − parts list st-802 564 . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9−(fig 6-2) 10−(fig 6-3) 11 12 13 14 15 16 17−(fig 6-4) 18 19 20−(fig 6-5) figure 6-1. Main assembly.

  • Page 31

    Om-198 781 page 27 description part no. Dia. Mkgs. Item no. Quantity figure 6-1. Main assembly 1 146 165 panel, side 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 089 899 latch, side flush 2 . . . . ....

  • Page 32

    Om-198 781 page 28 st-802 284-c . Hardware is common and not available unless listed. Figure 6-2. Center baffle w/components.

  • Page 33

    Om-198 781 page 29 description part no. Dia. Mkgs. Item no. Quantity figure 6-2. Center baffle w/components (fig 6-1 item 9) 1 058 427 ring, retaining spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 085 980 n...

  • Page 34

    Om-198 781 page 30 st-802 283 . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 figure 6-3. Rear panel w/components description part no. Dia. Mkgs. Item no. Quantity figure 6-3. Rear panel w/components (fig 6-1 item 10) 1 049 399 nut, 312−18 push-on 1 . . . . . . . . . . . ....

  • Page 35

    Om-198 781 page 31 st-802 565 . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 11 12 figure 6-4. Front panel w/components description part no. Dia. Mkgs. Item no. Quantity figure 6-4. Front panel w/components (fig 6-1 item 17) 1 143 974 handle 1 . . . . . . . . . . . . . . ...

  • Page 36

    Om-198 781 page 32 ref. 800 792-b 1 23 4 56 7 8 9 10 14 17 11 12 11 12 13 9 15 16 figure 6-5. M-25 gun.

  • Page 37

    Om-198 781 page 33 quantity description part no. Item no. Figure 6-5. M-25 gun (fig 6-1 item 20 ) 1 ♦ 169 724 nozzle, slip type .500 orf .125 recess . . . . . . . . 1 ♦ 169 725 nozzle, slip type .625 orf .125 recess . . . . . . . . 1 169 726 nozzle, slip type .625 orf flush 1 . . . . . . . . . . . ....

  • Page 39

    Effective january 1, 2000 (equipment with a serial number preface of “la” 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 40: Resources  Available

    Printed in usa 1/00 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: weldi...