ESAB PullMaster PMP3333545 User manual

Brand: ESAB

Model: PullMaster PMP3333545

Category: Welding System

Type: User manual

This manual is also suitable for

Issue Date: April 3, 2009

Manual No: 89200008 Revision: A

SAFETY AND OPERATING

INSTRUCTIONS

PullMaster

™

MIG GUN

English

Français

Español

AIR-COOLED

PMP SERIES

PMPS SERIES

300 AMP

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Tweco

product. We are proud to have

you as our customer and will strive to provide you with the best service

and reliability in the industry. This product is backed by our extensive

warranty and worldwide service network. To locate your nearest

distributor or service agency call 800-426-1888, or visit us on the web at

www.tweco.com.

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. They will help you to avoid potential hazards that may

exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Tweco

is a Global Brand of Welding Products for Thermadyne

Industries Inc. We manufacture and supply to major welding industry

sectors worldwide, including: Manufacturing, Construction, Mining,

Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through market-

leading, dependable products that have stood the test of time. We

pride ourselves on technical innovation, competitive prices, excellent

delivery, superior customer service and technical support, together

with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced

products to achieve a safer working environment within the welding

industry.

WARNINGS

Read and understand this entire Manual and your employer’s safety practices

before installing, operating, or servicing the equipment. While the information

contained in this Manual represents the Manufacturer’s judgment, the Manufacturer

assumes no liability for its use.

PullMaster MIG Gun

Safety and Operating Instructions

Instruction Guide Number 89200008

Published by:

Thermadyne

Industries, Inc.

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

Reproduction of this work, in whole or in part, without written permission of the publisher is

prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss

or damage caused by any error or omission in this Manual, whether such error results from

negligence, accident, or any other cause.

Publication Date: April 3, 2009

Record the following information for Warranty purposes:

Where Purchased:

Purchase Date:

Equipment Serial #:

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 .................................................................. 4-12

4.01 Standard Setup ...........................................................................4-12

4.02 Standard PullMaster with Other Feeders .....................................4-14

4.03 Calibration ...................................................................................4-15

SECTION 5: SMART GUN FEATURES ................................................................... 5-16

5.01 Settings and Controls ..................................................................5-16

SECTION 6: MANUAL GMAW WELDING ..............................................................6-17

6.01 Types of Weld Transfer Modes ....................................................6-17

6.02 Holding and Manipulating the Torch ...........................................6-18

SECTION 7: CONTACT TIP ...................................................................................7-20

7.01 Contact Tip Identiﬁcation and Parts List......................................7-20

7.02 Contact Tip Replacement ............................................................7-20

SECTION 8: WIRE CONDUIT .................................................................................8-21

8.01 Conduit Identiﬁcation and Parts List ...........................................8-21

8.02 Conduit Removal .........................................................................8-21

8.03 Conduit Installation .....................................................................8-22

8.04 Jump Liner Installation ...............................................................8-24

8.05 Liner Guide Assembly Replacement ............................................8-25

SECTION 9: CONDUCTOR TUBES ......................................................................... 9-26

SECTION 10: NOZZLES ........................................................................................ 9-26

SECTION 11: REPLACING PCB ASSEMBLY (SMART GUN) ................................11-27

SECTION 12: TROUBLESHOOTING .....................................................................12-29

SECTION 13: REPLACEMENT PARTS .................................................................13-30

SECTION 14: STATEMENT OF WARRANTY ........................................................14-32

14.01 Warranty Schedule ....................................................................14-33

safety and operating instructions

1-189200008

Introduction

SECTION 1:

INTRODUCTION

1.01 HOW TO USE THIS MANUAL

To ensure safe operation, read the entire manual, including the chapters on safety instructions

and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular

attention to the information provided under these headings. These special annotations are

easily recognized as follows:

NOTE

NOTE conveys installation, operation, or maintenance information which is

important but not hazard-related.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may

result in injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

1.02 RECEIPT OF EQUIPMENT

When you receive the equipment, check it against the invoice to make sure it is complete and

inspect the equipment for possible damage due to shipping. If there is any damage, notify the

carrier immediately to ﬁle a claim. Furnish complete information concerning damage claims

or shipping errors to the location in your area, listed on the back cover of this manual. Include

a full description of the parts in error.

If you want additional or replacement copies of this manual, please contact Tweco

at the

address and phone number in your area listed on the back cover of this manual. Include the

Manual number (from page i)

1.03 DESCRIPTION

The Tweco

PullMaster guns are 300 AMP, pistol-grip pull guns that are designed to be used

in conjunction with the Thermal Arc PowerMaster SP welding utilize a power sourcea and wire

feed system. The PullMaster guns are available in 2 versions standard, and with smart controls.

The smart control will allow for welding current, material thickness, wire feed speed, and arc

length trim adjustments on the gun via a digital display board.

2-2

safety and operating instructions

89200008Safety Precautions

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. Training and proper supervision are important for a

safe work place. Keep these instructions for future use. Additional recommended

safety and operating information is referenced in each section.

WARNING

This product contains chemicals, including lead, or otherwise produces

chemicals known to the State of California to cause cancer, birth defects and

other reproductive harm. Wash hands after handling.

(California Health & Safety Code § 25249.5 et seq.)

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH

Install and maintain equipment in accordance with the National Electrical Code

(NFPA 70) and local codes. Do not service or repair equipment with power on.

Do not operate equipment with protective insulators or covers removed. Service

or repair to equipment must be done by qualified and/or trained

personnel only.

Do not contact electrically live parts. Always wear dry welding gloves that are in good condition.

Aluminized, protective clothing can become part of the electrical path. Keep oxygen cylinders,

chains, wires, ropes, cranes, and hoists away from any part of the electrical path. All ground

connections must be checked periodically to determine if they are mechanically strong, and

electrically adequate for the required current. When engaged in AC welding/cutting under wet

conditions or where perspiration is a factor, the use of automatic controls for reducing the no

load voltage is recommended to reduce shock hazards. Accidental contact must be prevented

when using open circuit voltage exceeding 80 volts AC, or 100 volts DC by adequate insulation

or other means. When welding is to be suspended for any length of time, such as during lunch

or overnight, all electrode holders and electrodes should be removed from the electrode holder

and the power supply should be turned off to prevent accidental contact. Keep MIG Guns,

electrode holders, Tig torches, Plasma torches, and electrodes away from moisture and water.

See safety and operating references 1, 2, and 8.

safety and operating instructions

2-389200008

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. All solvents, degreasers, and potential sources of these vapors must

be removed from the operating area. Use air-supplied respirators if ventilation

is not adequate to remove all fumes and gases. Oxygen supports, and vigorously accelerates ﬁre

and should never be used for ventilation.

See safety and operating references 1, 2, 3, and 4.

ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE EYES AND BURN SKIN

Welding and cutting processes produce extreme localized heat and strong

ultraviolet rays. Never attempt to weld/cut without a federally compliant welding

helmet with the proper lens. A number 12 to 14 shade ﬁlter lens provides the

best protection against arc radiation. When in a conﬁned area, prevent the

reﬂected arc rays from entering around the helmet. Approved shielding curtains

and appropriate goggles should be used to provide protection to others in the surrounding area.

Skin should be protected from arc rays, heat, and molten metal. Always wear protective gloves

and clothing. All pockets should be closed and cuffs sewn shut. Leather aprons, sleeves, leggings,

etc. should be worn for out-of-position welding and cutting, or for heavy operations using large

electrodes. Hightop work shoes provide adequate protection from foot burns. For added protection,

use leather spats. Flammable hair preparations should not be used when welding/cutting. Wear

ear plugs to protect ears from sparks. Where work permits, the operator should be enclosed in

an individual booth painted with a low reflective material such as zinc oxide.

See safety and operating references 1, 2, and 3.

WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS

Combustibles reached by the arc, ﬂame, ﬂying sparks, hot slag, and heated

materials can cause ﬁre and explosions. Remove combustibles from the work

area and/or provide a ﬁre watch. Avoid oily or greasy clothing as a spark may

ignite them. Have a ﬁre extinguisher nearby, and know how to use it. If welding/

cutting is to be done on a metal wall, partition, ceiling, or roof, precautions must

be taken to prevent ignition of nearby combustibles on the other side. Do not

weld/cut containers that have held combustibles. All hollow spaces, cavities, and containers

should be vented prior to welding/cutting to permit the escape of air or gases. Purging with inert

gas is recommended. Never use oxygen in a welding torch. Use only inert gases or inert gas

mixes as required by the process. Use of combustible compressed gases can cause explosions

resulting in personal injury or death. Arcing against any compressed gas cylinder can cause

cylinder damage or explosion. See safety and operating references 1, 2, 5, 7, and 8.

NOISE CAN DAMAGE HEARING

Noise from the air carbon-arc process can damage your hearing. Wear protective

hearing devices to ensure protection when noise levels exceed OHSA standards.

Adequate hearing protection devices must be worn by operators and surrounding

personnel to ensure personal protection against noise. See safety and operating

references 1, 2, and 6.

Safety Precautions

2-4

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89200008

SAFETY AND OPERATING REFERENCES

1. Code of Federal Regulations (OSHA) Section 29, Part 1910.95, 132, 133, 134, 139, 251,

252, 253, 254 and 1000. U.S. Government Printing Ofﬁce, Washington, DC 20402.

2. ANSI Z49.1 “Safety in Welding and Cutting”.

3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection”.

4. ANSI Z88.2. “Standard Practice for Respiratory Protection”. American National

Standards Institute, 1430 Broadway, New York, NY 10018.

5. AWS F4.1. “Recommended Safe Practices for Welding and Cutting Containers”.

6. AWS C5.3. “Recommended Practices for Air Carbon-Arc Gouging and Cutting”.

The American Welding Society, 550 NW Lejeune Rd., P.O. Box 351040, Miami, FL

33135.

7. NFPA 51B. “Fire Prevention in Cutting and Welding Processes”.

8. NFPA-7. “National Electrical Code”. National Fire Protection Association, Battery Park,

Quincy, MA 02269.

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

To which this declaration relate(s) are in conformance with the following standards:

IEC 60974-7:2005

Following the provisions of the 73/23/EEC directive.

Safety Precautions

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safety and operating instructions

3-1189200008

SECTION 3:

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:

PMPS3333545

PullMaster, Pull, Smart

300 AMP gun, 33' (10,1M) cable

.035" / .045" (0,9mm / 1,2mm)

Wire Diameter

Abbreviation / Deﬁnition

PM PullMaster

P Pull

S Smart Gun

Standard PullMaster Guns

Part No. Stock No. Rating Connection Description

PMP3333545 1027-1401

300A @

80%

Tweco

33 ft. (10,1M)

PMP3503545 1027-1402 50 ft. (15,2M)

Smart PullMaster Guns with Advanced Digital Controls

Part No. Stock No. Rating Connection Description

PMPS3333545 1027-1407

300A @

80%

Tweco

33 ft. (10,1M)

PMPS3503545 1027-1408 50 ft. (15,2M)

Standard Euro PullMaster Guns

Part No. Stock No. Rating Connection Description

PMPX3333545 1027-1404

300A @

80%

Euro-Kwik

33 ft. (10,1M)

PMPX3503545 1027-1405 50 ft. (15,2M)

Smart Euro PullMaster Guns

Part No. Stock No. Rating Connection Description

PMPSX3333545 1027-1410

300A @

80%

Euro-Kwik

33 ft. (10,1M)

PMPSX3503545 1027-1411 50 ft. (15,2M)

MIG Gun Speciﬁcations

4-12

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89200008

SECTION 4:

MIG GUN INSTALLATION

NOTE

Be certain that the end user (welder, operator, or helper) reads and understands

these instructions. Be certain that the welder also reads Section 2, "Safety

Precautions."

WARNING

Electric shock can cause injury or death.

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

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4-1389200008

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. When removing the inlet guide

or conduit, loosen this nut.

NOTE

DO NOT OVER-TIGHTEN. Ensure that the conduit/liner does not touch or rub

against drive rolls.

4. Adjust the drive roll pressure on the feeder to a minimum, then adjust the drive roll on gun

halfway. If needed, drive roll pressure may be increased on the feeder and pull gun.

NOTE

The tension adjusters on both drive rolls should be set to the minimum setting

when using 3/64" (1,2mm) aluminum. For 1/16" (1,6mm) aluminum, the user

may need to tighten the rolls one or two turns of the adjusting screw.

5. Tighten the wire spool drag to ﬁnger tip tight. The spool, when pushed 1/4 turn, should

freely spin one complete rotation.

6. Typically tighten down the idler until it touches the wire, then tighten one to two turns. A

nickel thick-sized gap should be between the tightening knob head and gun handle case.

Do not overtighten because it can cause the motor to stall and gun to stop working.

7. Adjust voltage and wire speed as recommended by the wire manufacturer. (Refer to

table in Section 6.01). Gun is now ready for operation.

NOTE

Do not weld with the gun if the cable is coiled in circles less than 3' in diameter

because this will cause wire feed problems.

NOTE

Wipe off drive rolls with a Scotch Pad between each spool of wire. Lay pad

against roller and push the inch switch button in the feeder cabinet to turn

the rollers.

MIG Gun Installation

4-14

safety and operating instructions

89200008

4.02 STANDARD PULLMASTER WITH OTHER FEEDERS

When using the standard PullMaster MIG gun on other feeders, the Control Box (Part No. EPG-CR2,

Stock No. 1028-1291) must be used in combination with the MIG gun. Follow the instructions

noted below and refer to any further instructions included with the EPG-CR2 Control Box.

NOTE

The PullMaster MIG Gun must have a jumper wire with a Tweco, Miller, or Lincoln

connection on one end and spade connections on the other. The PullMaster MIG

Gun must also have jumper wire PMP354T.

1. Connect the jumper wire to the receiver

on the feeder (refer to chart below to ﬁnd

which jumper wire is needed) and connect

the spade connectors on the other end of

the jumper wire to the spade connector

receiver on the EPG-CR2 box.

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).

Jumper wire # Connector Rear Plug # Connector Plug

EPG354T Tweco -- --

EPG354M Miller EPG174MH Miller

EPG354L Lincoln EPG174LH Lincoln

PMP354T Amphenol/Miller EPGHK1 Gas Hook Up Kit

MIG Gun Installation

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4-1589200008

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. Install gun as shown in Section 4.01.

2. Feed wire through gun and tube (drive rolls on gun and machine must be closed).

3. Go to menu on machine and press the up and down arrow keys at the same time.

4. Press the

“+” button to scroll to “Extra

Features 9: Push/Pull torch”.

5. Again, press the up and down arrow keys at the same time. You will select which torch

you are using by pressing the “+” button.

6. Press the ‘up’ arrow key; this should bring up a question asking if you want to calibrate.

Press the down arrow stating “Yes”.

7. The screen will ask if the drive rolls are ready. Press the down arrow stating “Yes”.

8. The screen will state to

“Press Wire

Feed Button” inside the feeder just

above the drive rolls.

9. Press this button one time. Do not hold the button down. The machine should feed a small

amount of wire and retract. The machine will now tell you “Calibration Running”.

10. The screen will now show “Calibration OK”. If not, the screen will show “M12

Wirefeed/Tachometer Calibration Error”. Retry.

11. If this does not work, refer to Troubleshooting in Section 12.

MIG Gun Installation

5-16

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89200008

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.

Digital Display

Control Up + : Allows operator to make upward

(increase) adjustments.

Control Down - : Allows operator to make downward

(decrease) adjustments.

Select: Allows operator to switch between welding current,

metal thickness, and wire speed adjustment mode

to arc length adjustment mode.

NOTE

When changing between Tiptronic programs on the gun controls: pressing the

select button will make the number on the left (set) start flashing and enable

the gun to switch between sets of programs by pressing the up or down button

while the screen is blinking. If you press just the up or down buttons, the gun

will scroll between programs in that set, but will not go through other sets.

Example: 3 - 4 (3 is the set, 4 is the program).

5.02 ADJUSTMENT OPTIONS

The SELECT button allows the operator to navigate between the following settings on the

power supply:

NOTE

The operator will need to adjust the settings manually on the welder to change from

welding current to metal thickness or to wire speed. The SELECT button allows the operator

to change from "length of arc mode" to the mode set manually on the welder.

Welding current (amperage), metal thickness, or wire speed mode.

Arc length adjustment mode

The ﬁrst setting to display will be the last setting used on the power supply.

Longer and Shorter arc settings are displayed as:

Longer arc length Shorter arc length

•

Smart Gun Features

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6-1789200008

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. Molten droplets form on the tip of the electrode bridge the gap between the

electrode and the weld pool as a result of the lower welding current. This causes a short circuit

and extinguishes the arc, but it is quickly reignited after the surface tension of the weld pool

pulls the molten metal bead off the electrode tip. Setting the weld process parameters (volts,

amps and wire feed rate) within a relatively narrow band is critical to maintaining a stable arc:

generally between 100 to 200 amps at 17 to 22 volts for most applications.

NOTE

The transition from the short circuit to spray arc depends on the amperage,

voltage, and the gas mixture.

B. Globular

GMAW with globular metal transfer is often considered the most undesirable of the four major

GMAW variations, because of its tendency to produce high heat, a poor weld surface, and spatter.

The method was originally developed as a cost efﬁcient way to weld steel using GMAW. This

variation uses carbon dioxide, a less expensive shielding gas than argon. As the weld is made,

a ball of molten metal from the electrode tends to build up on the end of the electrode, often in

irregular shapes with a larger diameter than the electrode itself. When the droplet ﬁnally detaches

either by gravity or short circuiting, it falls to the work piece, leaving an uneven surface and

often causing spatter. As a result of the large molten droplet, the process is generally limited

to ﬂat and horizontal welding positions. The high amount of heat generated also is a downside,

because it forces the welder to use a larger electrode wire, increases the size of the weld pool,

and causes greater residual stresses and distortion in the weld area.

C. Spray

Spray transfer GMAW is well-suited to weld aluminum and stainless steel while employing

higher percentages of an inert shielding gas such as argon. In this GMAW process, the weld

electrode metal is rapidly passed along the stable electric arc from the electrode to the work

piece, essentially eliminating spatter and resulting in a high-quality weld ﬁnish. As the current

and voltage increases beyond the range of short circuit transfer the weld electrode metal

transfer transitions from larger globules through small droplets to a vaporized stream. Since

this vaporized spray transfer variation of the GMAW weld process requires higher voltage and

current than short circuit transfer, and as a result of the higher heat input and larger weld pool

area (for a given weld electrode diameter), it is generally used only on work pieces of thicknesses

above about 6.4 mm (0.25 in). Also, because of the large weld pool, it is often limited to ﬂat

and horizontal welding positions and sometimes also used for vertical-down welds.

D. Pulsed-Spray

A more recently developed method, the pulse-spray metal transfer mode is based on the

principles of spray transfer but uses a pulsing current to melt the ﬁller wire and allow one small

molten droplet to detach with each pulse. The pulses allow the average current to be lower,

Manual GMAW Welding

6-18

safety and operating instructions

89200008

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. The smaller weld pool

gives the variation greater versatility, making it possible to weld in all positions. The process

also requires that the shielding gas be primarily argon with a low carbon dioxide concentration.

Additionally, it requires a special power source capable of providing pulse currents.

E. Typical Welding Parameters for GMAW welding

Welding Transfer Mode Spray Arc Globular Arc Short Circuit Arc

in (mm) A V A V A V

.030 (0,8) 140-180 23-25 110-150 18-22 50-130 14-18

.035 (0,9) 180-250 24-30 130-200 18-24 70-160 16-19

.045 or 3/64 (1,1) 220-320 25-32 170-250 19-26 120-200 17-20

1/16 (1,6) 260-320 26-34 200-300 22-28 150-200 16-21

Favorable welding characteristics are only possible if voltage and current are correctly adjusted.

requires an arc voltage approximately 3V higher than gas mixtures with a high argon content.

6.02 HOLDING AND MANIPULATING THE TORCH

NOTE

GMAW can be welded in all positions: horizontal, vertical-down, vertical-up,

overhead and in horizontal-vertical position.

When horizontal welding, hold the torch vertical to the workpiece (neutral torch position) or up to 30°,

“pushing" the torch. For best depth of penetration and shielding gas coverage, hold the torch in the

neutral position. Please note that if the torch is tilted too far, it is possible that air will be sucked into

the shielded gas and may result in porosity. For vertical or overhead welding, a slight pushing motion

is required. For vertical-down welding, mostly used for thin materials, hold the torch at the neutral

or slightly “dragging" position. Some experience is required since the welding pool could run ahead

of the arc and cause weld defects. Thicker material presents a danger of possible lacks of fusion

because the welding pool is very liquid from high voltage and quick travel speed.

Welding direction

pushing the weld

Welding direction

dragging the weld

Avoid extreme side-to-side movements to avoid the weld pool damming up in front of the arc. If the

welding pool ﬂows ahead of the welding arc, lacks of fusion might occur. Use a side-to-side motion at

a necessary width to reach both sides of the joint. If the joint is too wide, weld two parallel weld beads.

When performing vertical-up welding, the side-to-side motion follows the shape of an open triangle.

Manual GMAW Welding

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6-1989200008

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. A longer arc is useful for welding a ﬁllet weld to form a ﬂat or concave seam. Welding with a

shorter arc (at the same amperage) increases the penetration, and the welding bead is narrow and

high with reduced spattering. The welding material is transferred with smaller droplets.

Long Arc Short Arc

B. Length of the wire electrode

The distance between the torch and the workpiece should be 10-12 times the diameter of the wire.

Altering the distance of the torch will inﬂuence the electrode stick out.

A longer electrode stick out reduces the amperage and the penetration.

A shorter electrode stick out increases the amperage if the wire feed speed remains the same.

Long electrode stick out

Short electrode stick out

Manual GMAW Welding

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89200008

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

MIG

Guns. Contact tips may be identiﬁed by markings on the side of the tip.

Standard Contact Tips

Part Number Stock No.

Tip ID

in(mm)

Wire Size

in(mm)

16PS-30 1160-1543 0.038 (0,9) .030 (0,8)

16PS-35 1160-1535 0.044 (1,1) .035 (0,9)

16PS-40 1160-1536 0.048 (1,22) .040 (1,0)

16PS-45 1160-1537 0.054 (1,4) .045 (1,2)

16APS-364 1160-1538 0.063 (1,6) .047 (1,9)

16PS-52 1160-1541 0.058 (1,5) .052 (1,3)

16PS-116 1160-1539 0.073 (1,8)

.062 (1,6)

16APS-116 1160-1540 0.082 (2,1)

7.02 CONTACT TIP REPLACEMENT

NOTE

Replace contact tip if hole is enlarged or deformed.

1. Select the correct contact tip according to the wire used.

2. Remove the nozzle from the gun to reveal the contact tip.

3. Remove the contact tip. Replace contact tip and tighten plier tight.

Contact Tip

safety and operating instructions

8-2189200008

SECTION 8:

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.

Example Part Number: Abbreviation / Deﬁnition

PMP44-116-33

PullMaster

44 Series

1/16" (1,6mm) Wire Capacity

Liner length in feet

P PullMaster

TF Teﬂon

Construction

WN Wire / Nylon

J Jumper

Aluminum / Stainless Steel Series Wire Conduits

Part No. Stock No. Wire Size Length

PMP44-116-33

1441-1125

3/64" (1,2mm) - 1/16" (1,6mm) Aluminum

33' (10M)

PMP44-116-50 1441-1126 50' (15M)

PMP44-3545-33 1441-1127

.035 (0,9mm) - .045" (1,1mm) Aluminum

33' (10M)

PMP44-3545-50 1441-1128 50' (15M)

PMPS44-116-33 1411-1129

3/64" (1,2mm) - 1/16" (1,6mm) Steel Wire

33' (10M)

PMPS44-116-50 1441-1130 50' (15M)

PMPS44-3545-33 1441-1131

.035" (0,9mm) - .045" (1,1mm) Steel Wire

33' (10M)

PMPS44-3545-50 1441-1132 50' (15M)

PMP-44FLX-116 1644-1095 Teﬂon Jump Liner for Flex Tubes

N/APMP-44PTF-116 1644-1096 Teﬂon Jump Liner for Rigid Tubes

PMP-44-116 1644-1097 Bronze Jump Liner for Steel Wire And Rigid Tubes

8.02 CONDUIT REMOVAL

NOTE

Replace liner if it is kinked, or if the hole is dirty, or worn. Make sure the end of the

liner is smooth.

1. Lay the gun out on a table or on the ﬂoor in a straight line. Make sure the gun is fully

extended and all twists in the cable are removed.

2. Loosen the conduit set screw in the gas diffuser.Then loosen the conduit set screw in

the rear connector plug.

NOTE

On Euro-Kwik

connections, remove the conduit retaining cap.

3. Grip the conduit stop and remove the conduit with a clockwise twisting motion and pull

from assembly.

Wire Conduit

8-22

safety and operating instructions

89200008

CONDUCTOR TUBE

CONDUIT LINER

REMOVE

CONSUMABLES

CONDUIT LINER

CONDUIT

SET SCREW

O-RINGS

CONNECTOR PLUG

CONDUIT SET SCREW

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. Loosen the set screw in the front block and rear power plug, then remove the old liner

from the gun.

2. Lay the old liner out straight beside the new one. Cut new one to length.

3. Gently feed the new liner into the gun with short strokes without kinking. Ensure that

there are no burrs or sharp ends on the conduit.

NOTE

If the conduit is held too far away from the rear plug, the conduit may kink

when inserting. Kinks will cause poor feed.

3" - 4"

(7cm-10cm)

8" - 10"

(20cm-25cm)

a. Correct Liner Feed Method:

Use short strokes

b. Incorrect Liner Feed Method:

Handling liner too far from plug

Wire Conduit

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ESAB PullMaster PMP3333545 User manual

Brand: ESAB

Model: PullMaster PMP3333545

Category: Welding System

Type: User manual

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ESAB PullMaster PMP3333545 User manual

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