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AGM 250C Instruction Manual

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AGM Pin Welder
Instruction Manual
Model 250C
AGM Industries, Inc.
16 Jonathan Drive, Brockton, MA 02301
TEL: 800 225-9990/ 508-587-3900 FAX: 800 342-5246
www.agmind.com
Read equipment manufacturer's manual before using this product. Failure to do so can result in
serious injury or death.

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  • Page 1 AGM Pin Welder Instruction Manual Model 250C AGM Industries, Inc. 16 Jonathan Drive, Brockton, MA 02301 TEL: 800 225-9990/ 508-587-3900 FAX: 800 342-5246 www.agmind.com Read equipment manufacturer’s manual before using this product. Failure to do so can result in serious injury or death.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Subject Page 1. Description of accessories 2. Installing & removing collets, stops, etc. 3. Disassembly of weld gun 4. Diagram & parts list 5. Weld gun Set-Up Sheets Welding Steel and Stainless Steel weld pins Welding Aluminum weld pins Welding pins over 7”...

  • Page 3: Description Of Accessories

    Its purpose is to back up the pin or stud to prevent it from being inserted too far into the gun. The Model 250C gun utilizes two types of stops; the 437G and the 250C-G. Both are easily installed.
  • Page 4 (CONTINUED) Model 250C Weld Gun (CONTINUED) ADJUSTABLE FOOT ASSEMBLY - This is necessary when welding Powerbase pins and large diameter studs and may also be used for welding very long CD pins. It is used in conjunction with a stop and spark shield to stabilize the pin or stud.

  • Page 5: Installing & Removing Collets, Stops, Etc

    Model 250C Weld Gun (CONTINUED) INSTALLATION AND REMOVAL PROCEDURES INSTALLING COLLET AND COLLET PROTECTOR A. Examine the inside of the collet adapter assembly for pitted areas or splatter. Clean by scraping with a sharp object, or replace if necessary. B. Insert the collet into the collet adapter assembly, making sure that it seats against the shoulder.
  • Page 6 Model 250C Weld Gun (CONTINUED) INSTALLING TYPE 437G STOP A. Place the stop inside the rear of the collet. B. Insert the collet, with stop, into the collet adapter assembly. C. Locate and tighten the collet holding set screws, as previously described.
  • Page 7 250C-G TYPE STOP STUD LENGTH CATALOG NUMBER STOP LENGTH 1/4” – 5/16” 250C-G-*-0250 7” 3/8” – 7/16” -0375 6.875” 1/2” – 9/16” -0500 6.750” 5/8” -0625 6.625” 3/4” -0750 6.500” 7/8” -0875 6.375” 1” -1000 6.250” 1-1/4” -1250 6.000” 1-1/2”...
  • Page 8 MODEL 250-C WELD GUN INSTALLATION OF COLLET ADAPTER ASSEMBLY This procedure can be accomplished with a collet and stop, or collet protector already installed. A. Before installing, be sure that the tapered surface of the collet adapter and shaft assembly are clean. Wipe with a clean cloth if necessary. B.
  • Page 9 MODEL 250-C WELD GUN INSTALLING OR CHANGING SPRING A. Unscrew the end cap from the gun housing. B. Unscrew stop nut from the end of gun shaft. C. Unscrew the spring retainer and remove the washer from the housing. D. Remove the spring from the shaft. E.

  • Page 10: Disassembly Of Weld Gun

    MODEL 250C WELD GUN DISASSEMBLY OF THE WELD GUN A. Remove handle cover screws (items 28, 29 & 45) B. Lift off the handle cover (item 38) C. Remove the nut, washer and cap screw (items 34, 35 & 36) from the welding lead (item 40) D.

  • Page 11: Diagram & Parts List

    2615-M ADAPTER ASSEMBLY INCLUDES ITEMS #25, 13, 14 &24...

  • Page 12: Welding Steel And Stainless Steel Weld Pins

    SET UP FOR WELDING STEEL/STAINLESS STEEL WELD PINS GUN SET UP WITH HEAVY (3”) SPRING & 1151-M STATIONARY LEGS 1. 12 & 10 gauge pins to galvanized steel A. Install collet and protector as described on page 3. Refer to the chart below for part numbers.

  • Page 13: Welding Aluminum Weld Pins

    SET UP FOR WELDING ALUMINUM WELD PINS GUN SET UP WITH HEAVY (3”) SPRING & 2367-M ADAPTER ASSEMBLY A. If previously installed, remove legs (2) and dust boot from gun. B. Install proper collet (5) and protector (4), being sure collet holding set screws are tightened securely.

  • Page 14: Welding Pins Over 7" Long

    SET UP FOR WELDING PINS OVER 7” LONG GUN SET UP WITH HEAVY (3”) SPRING & 2318-M FOOT PIECE ASSEMBLY A. Install proper collet (2), stop (1) and protector (3), being sure collet holding set screws are tightened securely. See pages 12 or 13 for part numbers. B.

  • Page 15: Welding Flanged Steel And Stainless Studs Up To 1/4-20 Diameter

    SET UP FOR WELDING FLANGED STEEL & STAINLESS STUDS THROUGH 1/4-20 DIAMETER GUN SET UP WITH HEAVY (3”) SPRING & 1151-M STATIONARY LEGS A. Install collet and protector as described on page 3. Be sure the collet holding set screws are tightened securely. Install (3) 1151-M stationary legs into the equally spaced threaded holes in the face plate.

  • Page 16: Welding Flanged And Non-Flanged Aluminum Studs. Non-Flanged

    SET UP FOR WELDING FLANGED & NON-FLANGED ALUMINUM STUDS AND HANGER STUDS (ALL WELDERS) & NON-FLANGED STEEL/STAINLESS STUDS THROUGH ¼-20 DIAMETER (ALL WELDERS EXCEPT 320SS, LS-400 & JS-1 WILL NOT WELD ¼-20 ALUMINUM STUDS) GUN SET UP WITH HEAVY (3”) SPRING & 1151-M STATIONARY LEGS A.
  • Page 17 SET UP FOR WELDING NON-FLANGED STEEL & STAINLESS STUDS THROUGH 1/4-20 DIAMETER (JS-1 320SS & LS-400 ONLY) GUN SET UP WITH HEAVY (3”) & MEDIUM (2”) SPRING & 1151-M LEGS A. Install collet and stop as described on pages 5 & 6. Be sure the collet holding set screws are tightened securely.

  • Page 18: Alternate Set-Up For Welding Studs Over 1-3/8" Long

    ALTERNATE GUN SET UP FOR STUDS OVER 1-3/8” LONG GUN SET UP WITH HEAVY (3”) SPRING & 2318-M FOOT PIECE ASSEMBLY A. Install proper stop (1), collet (2) and protector (3), being sure the collet holding set screws are tightened securely. See the chart below and previous page for part numbers.

  • Page 19: Welding Studs 5/16" Diameter And Larger

    SET UP FOR WELDING 5/16” DIAMETER AND LARGER STUDS GUN SET UP WITH HEAVY (3”) SPRING (SEE NOTE ON NEXT PAGE) AND 2318-M FOOT PIECE ASSEMBLY (SEE PAGE 21 FOR ALTERNATE SET UP USING 2958-M FOOT PIECE ASSEMBLY) A. Install proper stop (1) and collet (2), being sure that the collet holding set screws are tightened securely.
  • Page 20 SET UP FOR WELDING 5/16” DIAMETER AND LARGER STUDS (continued) Stud Size Collet 5/16-18 (M8) 437-S-307 5/16” Shoulder 437-S-312 3/8-16 (M10) 437-S-370 1/2-13 (M13) 437-S-495 Notes: 1. When welding flanged & non-flanged 5/16-18 and larger aluminum studs, the 2506-M-200 medium spring and 2526-M spring locator installed in the end cap is recommended, in addition to the 2506-M-300 heavy internal spring.
  • Page 21 ALTERNATE SET UP USING 2958-M FOOT PIECE ASSEMBLY If desired you may use the 2958-M Foot Piece Assembly instead of the 2318-M. The 2958-M uses the 3 standard 1151-M Stationary Legs, giving you added stability and the option to use a 1628-M Leg Support Ring if necessary.

  • Page 22: Welding Cupped Head/Mini-Cup Pins

    SET UP FOR WELDING CUPPED HEAD/MINI CUP PINS IN THE FIELD GUN SET UP WITH LIGHT (1-1/4”) SPRING (EXCEPT AS NOTED BELOW)* A. If previously installed, remove the three 1151-M, as they will interfere with the proper gun shaft movement. B.
  • Page 23 This is done by the application of a small length of plastic tubing, approximately 1/2” long, over the shank of each pin. AGM can also furnish this type of insulated pin upon special request. (continued)
  • Page 24 437-PM MAGNETIC COLLET INSTRUCTIONS FOR REPLACEMENT OF WORN OUT COLLET PARTS The 437-PM-RK Repair Kit should be used to rebuild the 437-PM Magnetic Collet. It includes the following: 437-PM-1 Collet Insert, 437-PM-2 Cap Screw, 437-PM-7 Insulator Disc, 437-PM-4 Screw Sleeve Insulator, as well as the proper size Allen Wrench.

  • Page 25: Welding Powerbase Pins

    SET UP FOR WELDING POWERBASE PINS GUN SET UP WITH LIGHT (1-1/4”) SPRING AND 2318-M FOOT PIECE ASSEMBLY The set up listed below is for pins 2-1/2” long and longer. For pins less then 2-1/2” long, see the note on the next page. A.
  • Page 26 SET UP FOR WELDING POWERBASE PINS (continued) Items 4,6,7,8, & 9 Part of 2318-M Foot Piece Assembly Steel/Stainless Collet Collet Powerbase Pins Protector 12 ga. (2.69mm) 437-106 437-P-106 10 ga. (3.42mm) 437-135 437-P-135 Note: Cables……………………………………1142-E and 1279-E (#6 Standard) Consult factory for information on use of Heavy Duty (#2) cables. CAUTION: DO NOT USE POWERBASE PINS ON METAL LESS THAN 1/16”...

  • Page 27: Welding To A Curved Surface

    SET UP FOR WELDING TO CURVED SURFACES GUN SET UP A. Set up the gun as described on pages 5 & 6, using the proper collet and collet protector (or stop if required). Be sure the collet holding set screws are tightened securely.

  • Page 28: Welding Through A Template

    SET UP FOR WELDING THROUGH A TEMPLATE GUN SET UP A. Set up the gun as described on pages 5 & 6, using the proper collet and collet protector (or stop, if required). Be sure the collet holding set screws are tightened securely.

  • Page 29: Spec. For A Typical Template

    TYPICAL TEMPLATE SPECIFICATIONS Material: Phenolic sheet, such as “Benelex”. Thickness: 1/8” min., 1/4” max The above drawing shows the spacing and diameter of the leg location holes. The two standard 1151-M legs are inserted into these holes. To ensure that the welded stud is perpendicular to the work surface, a third leg, shortened by an amount equal to the template thickness, may be used in the weld gun.

  • Page 30: Approximate Voltage Settings & Ground Polarity

    APPROXIMATE VOLTAGE SETTING & GROUND POLARITY BASE MATERIAL: MILD STAINLESS STEEL STUD/PIN MATERIAL: 1008/1010 MILD STEEL OR 302 STAINLESS STEEL GROUND POLARITY: POSITIVE MODEL WELDER 1175 STUD/PIN SIZE 575/580/600 1200 "HI" 1200 "LO" PA15 "CD" 12 GAUGE PINS 10 GAUGE CUPPED HEAD/ 14 GAUGE MINI CUP...

  • Page 31: Galvanized Steel Base / Mild Or Stainless Steel Pins Or Studs

    APPROXIMATE VOLTAGE SETTING & GROUND POLARITY BASE MATERIAL: GALVANIZED STEEL STUD/PIN MATERIAL: 1008/1010 MILD STEEL OR 302 STAINLESS STEEL GROUND POLARITY: NEGATIVE (EXCEPT AS NOTED BELOW**) MODEL WELDER 1175 STUD/PIN SIZE 575/580/600 1200 "HI" 1200 "LO" PA15 "CD" 12 GAUGE PINS 10 GAUGE CUPPED HEAD/...

  • Page 32: Aluminum Base / Aluminum Pins Or Studs

    APPROXIMATE VOLTAGE SETTING & GROUND POLARITY BASE MATERIAL: ALUMINUM STUD/PIN MATERIAL: STUDS - 1100 OR 5356 / PINS - 1100 ALUMINUM GROUND POLARITY: POSITIVE MODEL WELDER 1175 STUD/PIN SIZE 575/580/600 1200 "HI" 1200 "LO" PA15 "CD" 12 GAUGE PINS 10 GAUGE CUPPED HEAD/ 14 GAUGE MINI CUP...
  • Page 33 NOTES Welder Serial Number ________________ Gun Serial Number ________________ AGM Industries, Inc. 16 Jonathan Drive, Brockton, MA 02301 Telephone: 1 (800) 225-9990 FAX: 1 (800) 342-5246 www.agmind.com...

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