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- Page 1 AIR-COOLED PMP SERIES PMPS SERIES 300 AMP PullMaster ™ MIG GUN English Français Español SAFETY AND OPERATING INSTRUCTIONS Issue Date: April 3, 2009 Revision: A Manual No: 89200008...
- Page 2 This Manual has been designed to instruct you on the correct ® installation and use of your Tweco product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore, please take the time to read the entire manual, especially the Safety Precautions.
- Page 3 ® 2800 Airport Rd. Denton, TX. 76207 (940) 566-2000 www.tweco.com U.S. Customer Care: (800) 426-1888 International Customer Care: (940) 381-1212 Copyright © 2009 Thermadyne Industries, Inc. All rights reserved. Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
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Page 4: Table Of Contents
Table of Contents SectIoN 1: INtRoDuctIoN .................. 1-1 1.01 How to Use this Manual ..............1-1 1.02 Receipt of Equipment ..............1-1 1.03 Description ..................1-1 SectIoN 2: Safety PRecautIoNS ..............2-2 2.01 Mesures de sécurité ..............2-5 2.02 Precauciones de seguridad ............2-8 SectIoN 3: MIG GuN SPecIfIcatIoNS............... 3-11 3.01 MIG Gun Part Number Identification ...........3-11 SectIoN 4: MIG GuN INStallatIoN .............. -
Page 5: Section 1: Introduction
Include a full description of the parts in error. If you want additional or replacement copies of this manual, please contact Tweco at the ®... -
Page 6: Section 2: Safety Precautions
safety and operating instructions SectIoN 2: Safety PRecautIoNS WARNING SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not properly installed, used, and maintained. Misuse of this equipment and other unsafe practices can be hazardous. The operator, supervisor, and helper must read and understand the following safety warnings and instructions before installing or using any welding or cutting equipment, and be aware of the dangers of the welding or cutting process. - Page 7 safety and operating instructions SMoKe, fuMeS, aND GaSeS caN be DaNGeRouS to youR health Ventilation must be adequate to remove smoke, fumes, and gases during operation to protect operators and others in the area. Vapors of chlorinated solvents can form the toxic gas “Phosgene” when exposed to ultraviolet radiation from an electric arc.
- Page 8 9. CSA W117.2. “Safety in Welding, Cutting and Allied Processes”. Canadian Standards Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3. DeclaRatIoN of coNfoRMIty Tweco Products, Inc. declares under our sole responsibility that the product ® Hand Held Air/Gas and Water Cooled MIG Welding Torches...
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Page 9: Mesures De Sécurité
safety and operating instructions 2.01 MeSuReS De SécuRIté AvERTISSEmENT DES BLESSURES GRAvES OU mORTELLES peuvent résulter d’une installation, d’un usage ou d’un entretien inadéquat de l’équipement de soudage et de découpage. Une mauvaise utilisation de cet équipement et d’autres pratiques risquées peuvent être dangereuses. - Page 10 safety and operating instructions la fuMée, leS éMaNatIoNS et leS Gaz PeuVeNt ÊtRe DaNGeReuX PouR VotRe SaNté La ventilation doit être suffisante pour enlever la fumée, les émanations et les gaz pendant le fonctionnement de la torche afin protéger les opérateurs et les autres personnes présentes dans la zone.
- Page 11 9. CSA W117.2. « Règles de sécurité en soudage, coupage et procédés connexes ». Association canadienne de normalisation, 178 boul. Rexdale, Rexdale, Ontario, Canada M9W 1R3. DeclaRatIoN of coNfoRMIty Tweco Products, Inc. declares under our sole responsibility that the product ® Hand Held Air/Gas and Water Cooled MIG Welding Torches...
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Page 12: Precauciones De Seguridad
safety and operating instructions 2.02 PRecaucIoNeS De SeGuRIDaD ADvERTENCIA Se pueden sufrir LESIONES GRAvES O LA mUERTE si el equipo de soldadura y corte no se instala, utiliza y mantiene debidamente. El uso inadecuado de este equipo y otras prácticas no seguras pueden ser peligrosos. El operador, supervisor y ayudante deben leer y comprender las siguientes advertencias e instrucciones de seguridad antes de instalar o usar cualquier equipo de soldadura o corte y deberán estar atentos a los peligros del proceso de soldadura y corte. - Page 13 safety and operating instructions el huMo, loS VaPoReS y loS GaSeS PueDeN SeR PelIGRoSoS PaRa la SaluD La ventilación debe ser adecuada para que salga el humo, los vapores y los gases durante la operación para proteger a los operadores y al resto del personal en el área.
- Page 14 Canadian Standards Association (Asociación canadiense de normas), 178 Rexdale Blvd., Rexdale, Ontario, Canadá M9W 1R3. DeclaRatIoN of coNfoRMIty Tweco Products, Inc. declares under our sole responsibility that the product ® Hand Held Air/Gas and Water Cooled MIG Welding Torches...
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Page 15: Section 3: Mig Gun Specifications
MIG GuN SPecIfIcatIoNS 3.01 MIG GuN PaRt NuMbeR IDeNtIfIcatIoN NOTE Tweco MIG guns, as a general rule, have a specific nomenclature incorporated ® within each part number to help determine the wire size of each MIG gun. example Part Number:... -
Page 16: Section 4: Mig Gun Installation
4.01 StaNDaRD SetuP Figure 1: Standard MIG Gun Setup 1. Plug the gun connector plug into the feeder. Tweco plug and Euro-Kwik. 2. Plug the 4-pin Amphenol plug, attached to the gun, into the 4-pin socket on the welder. MIG Gun Installation... - Page 17 safety and operating instructions 3. After inserting a wire inlet guide or conduit from the MIG Gun, tighten the brass nut and O-ring seal inside feeder. If this nut is not tightened, it may cause gas flow to escape resulting in decreased gas flow.
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Page 18: Standard Pullmaster With Other Feeders
2. Connect the PMP354T to the gun and the other end to the amphenol receiver in the EPG-CR2 box. 3. If using a Feeder other than Tweco, change the rear power plug on the gun to either the Miller or Lincoln plugs (whichever is needed for the feeder being used). -
Page 19: Calibration
safety and operating instructions 4.03 calIbRatIoN NOTE The Thermal Arc SP machine requires calibration EvERYTImE the machine is turned on while the PullMaster MIG gun is connected or when a different PullMaster gun is installed. NOTE This does not apply to standard MIG guns or PulseMaster guns. 1. -
Page 20: Section 5: Smart Gun Features
safety and operating instructions SectIoN 5: SMaRt GuN featuReS 5.01 SettINGS aND coNtRolS PullMaster Smart Guns include integrated digital controls in the gun handle. These controls allow the user to make adjustments to either welding current or arc length via the MIG gun handle. The digital display provides the user with a visual confirmation of the changes as they are made. -
Page 21: Section 6: Manual Gmaw Welding
safety and operating instructions SectIoN 6: MaNual GMaW WelDING 6.01 tyPeS of WelD tRaNSfeR MoDeS a. Short-circuiting A commonly used GMAW transfer mode is known as short-circuiting or short-arc. Typically, a carbon dioxide based shielding gas is used, the electrode wire is small, and the current is low. As a result of the lower current, the heat input for the short-arc variation is reduced, making it possible to weld thinner materials while decreasing the amount of distortion and residual stress in the weld area. -
Page 22: Holding And Manipulating The Torch
safety and operating instructions decreasing the overall heat input and thereby decreasing the size of the weld pool and heat- affected zone while making it possible to weld thin work pieces. The pulse provides a stable arc and no spatter, since no short-circuiting takes place. This also makes the process suitable for nearly all metals, and a larger electrode wire can be used as well. - Page 23 safety and operating instructions a. length of the arc Welding with a longer arc reduces the penetration and the welding bead is wide and flat with increased spattering. The welding material is transferred with slightly larger drops than welding with a shorter arc.
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Page 24: Section 7: Contact Tip
7.01 coNtact tIP IDeNtIfIcatIoN aND PaRtS lISt The procedure for removal and installation of a wire contact tip is similar for all Tweco ® Guns. Contact tips may be identified by markings on the side of the tip. -
Page 25: Section 8: Wire Conduit
WIRe coNDuIt 8.01 coNDuIt IDeNtIfIcatIoN aND PaRtS lISt The procedure for removal and installation of a wire conduit is similar for all Tweco MIG guns. ® Conduits may be identified by the type of conduit stop and the part number marking on each conduit stop. -
Page 26: Conduit Installation
safety and operating instructions REMOVE CONDUIT LINER CONSUMABLES CONDUIT SET SCREW CONDUCTOR TUBE CONDUIT SET SCREW O-RINGS CONDUIT LINER CONNECTOR PLUG Figure 2: Pull Gun - Change Conduit 8.03 coNDuIt INStallatIoN NOTE Fully extend the Pull Gun out in a straight line, removing all twists before proceeding. When installing a standard liner with the brass conduit cap, the following steps are recommended to install pieces into the gun: 1. - Page 27 safety and operating instructions NOTE If the liner gets caught inside the gun, twist in a clockwise direction while gently pushing. 4. Feed the end of the liner through the plug until the conduit tip reaches the front block guide hole and secure with the front block set screw.
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Page 28: Jump Liner Installation
safety and operating instructions 8.04 JuMP lINeR INStallatIoN When installing a jump liner, the following steps are recommended to install pieces into the tube: 1. Remove the conductor tube by loosening the conductor screw cap, then loosen gas diffuser set screw. 2. -
Page 29: Liner Guide Assembly Replacement
safety and operating instructions 8.05 lINeR GuIDe aSSeMbly RePlaceMeNt 1. Remove conductor tube and proceed with removing the conduit liner guide assembly with a 3/8" wrench and flat screwdriver. 2. Replace liner into guide. 3. Screw liner guide into gun and attach nut. Do not overtighten nut. -
Page 30: Section 9: Conductor Tubes
safety and operating instructions SectIoN 9: coNDuctoR tubeS coNDuctoR tubeS Part No. Stock No. Description PMP64EL-180 1642-1140 180° Rigid Conductor Tube (Standard) PMP64EL-30 1642-1141 30° Rigid Conductor Tube PMP64SFLX-360 1642-1142 Knucklehead Flexible Conductor Tube ™ SectIoN 10: NozzleS aIR-cooleD Nozzle ID Part No. -
Page 31: Section 11: Replacing Pcb Assembly (Smart Gun)
safety and operating instructions SectIoN 11: RePlacING Pcb aSSeMbly (SMaRt GuN) WARNING Turn off power supply and disconnect MIG gun BEFORE performing any maintenance. 1. Remove two screws on each side of the PCB cover panel using a Phillips screwdriver. 2. - Page 32 safety and operating instructions 4. Remove approximately a 1/4" (6,4mm) of the insulator jacket on each of the four control lead wires protruding from the cable of the MIG Gun. 5. Solder control lead wires from cable hose to proper control leads of PCB (as specified on the schematic below, "Smart Gun PCB Assembly Diagram").
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Page 33: Section 12: Troubleshooting
safety and operating instructions SectIoN 12: tRoubleShootING Contact tips and nozzles should be cleaned frequently. Spatter buildup may cause bridging between nozzle and tip. This could cause electrical shorting between the nozzle and work piece as well as poor or improper gas flow. Regularly inspect the conductor tube, handle, cable, and other parts of the MIG gun for abrasion, cuts, or undue wear. -
Page 34: Section 13: Replacement Parts
safety and operating instructions SectIoN 13: RePlaceMeNt PaRtS Replacement Parts 13-30 89200008... -
Page 35: Replacement Parts
Hose Clamp Package Of 5 EPG-HW 2031-2088 Hex Key PMP-PV 2060-2737 Poppet Valve Assembly PM85-PCB 2060-2738 Replacement PCB EPG354T 2031-2084 Tweco control wire EPG354M 2031-2086 Miller control wire EPG354L 2031-2085 Lincoln control wire PMP354T 2031-2145 EPG-CR2 Jumper wire EPG174MH 2040-2164... -
Page 36: Section 14: Statement Of Warranty
safety and operating instructions SectIoN 14: StateMeNt of WaRRaNty lIMIteD WaRRaNty: THERMADYNE warrants that its products will be free of defects ® in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the THERMADYNE products as stated below, THERMADYNE shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with THERMADYNE’s specifications, instructions, recommendations and recognized standard industry practice, and not subject... -
Page 37: 14.01 Warranty Schedule
safety and operating instructions 14.01 WaRRaNty ScheDule The warranty is effective below for the time stated in the Warranty Schedule beginning on the date that the authorized distributor delivers the products to the purchaser. THERMADYNE ® reserves the right to request documented evidence of date of purchase. Engine Driven Welders Parts / Labor Scout... - Page 38 safety and operating instructions General Arc Equipment Parts / Labor Water Recirculators 1 year / 1 year Plasma Welding Torches 180 days / 180 days Gas Regulators (Supplied with Power Sources) 180 days / NA MIG and TIG Torches (Supplied with Power Sources) 90 days / NA Replacement Repair Parts 90 days / NA...
- Page 39 safety and operating instructions 89200008 14-35...
- Page 40 U.S. Customer Care: ® ® ® ® ARCAIR / STOODY / THERMAL ARC / THERMAL DYNAMICS 800-426-1888 / 800-535-0557 ® ® TWECO / VICTOR ......800-858-4232 / 800-535-0557 ® FIREPOWER ........800-238-0282 / 800-535-0557 ® TURBOTORCH ........866-279-2628 / 800-535-0557 TDC AUTOMATION ........
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