MK Products CopperHead 5001 Installation instructions

Welding Supplement
CAUTION
DISCONNECT UNIT FROM ALL POWER
SOURCES.
ELECTRIC SHOCK CAN KILL.
THIS GUIDE FOR USE ON: COPPERHEAD 5001, 5002, 5003
MK Products, Inc. 16882 Armstrong Ave., Irvine, CA 92606 Phone: [phone] Fax: [phone]
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CopperHead®Disassembly
Sheet P/N: 091-0589 Rev. A
Supercedes: N/A
1. Disconnect weldhead from power supply.
2. Remove coolant from weldhead by blowing air at 20 psi
max in one water line.
3. Lay the weldhead on a workbench with the handle serial
plate facing up.
4. Remove the screws and the top handle cover. (Figure A)
Figure A
5. Remove the two screws from the water-return/grounding
bar. Some coolant uid that is in the grounding bar and the
side-plate may leak out.
6. Remove the grounding bar. (Figure B)
Figure B

19 July 2007 2 OF 10 091-0589 Rev. A
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Sheet P/N: 091-0589 Rev. A
Figure G
11. Remove the upper right motor mount screw. (Figure G)
Figure D
7. Remove both side plate assemblies
by removing the mounting screws.
(Figures C and D)
Figure C
Figure E
8. Remove heat shrink and then screw from the brush plate.
(Figure E )
9. Remove gas line from barb connector. (Figure E)
Gas Line
Figure F
10. Unplug motor connector from circuit board. Remove cable
assembly. (Figure F)
Figure H
12. Separate cover from base assemblies with knife.
(Figure H)
Heat Shrink

19 July 2007 3 OF 10 091-0589 Rev. A
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Sheet P/N: 091-0589 Rev. A
Figure J
14. Remove motor mount assembly from the base. (Figure J)
Figure L
16. Remove the brush plate. (Figure L)
Figure I
13. Remove remaining motor mount screws. (Figure I)
Figure K
15. Remove sealant silicone with sharp tool. (Figure K)
Figure M
17. Rotate rotor to position shown. (Figure M)

19 July 2007 4 OF 10 091-0589 Rev. A
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Sheet P/N: 091-0589 Rev. A
Figure Q
21. Squeeze pin slightly to pass through orice in weldhead
base to remove contact pin from the base. (Figure Q)
20. Remove contact pin from connector with sharp tool.
(Figure P)
Figure P
Figure O
19. Loosen the screw that holds the clamp on the reed switch.
Mark the relative position of the switch for reference in
reassembly. (Figure O)
18. Remove the rotor. (Figure N)
Figure N
Figure R
22. Remove the reed switch by sliding it out of the clamp.
(Figure R)

19 July 2007 5 OF 10 091-0589 Rev. A
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Sheet P/N: 091-0589 Rev. A
Figure S
23. Inspect all gears for wear and obstructions. The bevel-slip
gear, the main gear and the miter gear (on the motor cou-
pler shaft) are most susceptible to wear and/or damage.
(Figure S)
Figure T
24. Inspect the gear-motor output shaft for alignment. Inspect
the coupler shaft for integrity and inspect each gear bush-
ing for gouging and burrs. (Figure T)
25. Clean the weldhead with a denatured alcohol dampened swab.
26. DO NOT IMMERSE any parts in any solvent.
27. Wipe the surfaces only as required to remove accumulated dirt and foreign par-
ticles.

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Sheet P/N: 091-0589 Rev. A
4. Reinstall the reed switch; sliding it into the clamp and tight-
ening the clamp screw. (Figure D)
Figure D
3. Insert contact pin into connector with sharp tool.
(Figure C)
Figure C
2. Squeeze pin slightly to pass through orice in weldhead
base. (Figure B)
Figure B
Figure A
1. Install gears into base and onto motor coupler
shaft. (Figure A)
CopperHead Reassembly
NOTE:
Reassembly of weldhead base and shims is explained in kit instructions 091-0587.
Follow directions for reassembly before continuing with this supplement.

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Sheet P/N: 091-0589 Rev. A
6. Reed Switch Adjustment:
Adjusting the reed switch position may be necessary to
properly align the rotor within the weldhead. When the
weldhead is in the “home” position, the rotor should be
centered on its race. In order to align the rotor, the motor
block needs to be connected to the base housing and both
the reed switch and the motor will need to be electrically
connected to the small circuit board within the handle of
the weldhead. Also, the weldhead electrical cable needs
to be connected to an MK Products power supply, so the
head can “jog” and “home.” The machine should be used
in “Test Mode” during this process, for safety reasons.
Start by securing the reed switch with the clamp. Tighten
the clamp enough so the switch does not move freely. With
the weldhead connected, “jog” the rotor a short distance,
then press “home” When the rotor stops at “home”, look
at each end of the rotor. If the rotor is positioned properly,
there will be the same amount of the white race material
extending from each end of the rotor. If there is more race
material at one end than the other, you can make small
adjustments to the position of the reed switch to correct
this. Press and release “jog” and then “home” to check if
the process should be repeated.
Some trial and error may be required to achieve the
desired results.
When the reed switch is in its desired location, secure the
clamp screw tightly, making sure the reed switch does not
move. Use a small amount of GE RTV 108 SiliconeAd-
hesive MK #823-0042 to secure the clamp in place and
prevent the clamp screw from backing out. Disconnect the
motor and reed switch from the weldhead circuit board,
and proceed with reassembly. (Figure F)
Figure F
Figure E
5. Position the top end of the reed switch over the small
round magnet pressed into the rotor. The top of the reed
switch should not overlap more than ½ of the magnet
diameter and should not be positioned entirely below the
magnet. (Figure E)

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Sheet P/N: 091-0589 Rev. A
Figure I
9. Seal the gap hole with GE RTV 108 SiliconeAdhesive MK
#823-0042. (Figure I)
Figure J
10. Fill square hole with GE RTV 108 SiliconeAdhesive MK
#823-0042. (Figure J)
7. Align the brush plate over the rotor and check that the
brass tube of the reed switch is not touching the brush
plate. (Figure G)
Figure G
8. Align the weldhead cover housing with the base. Check
the alignment of the pins in the cover with the holes in the
brush plate. With the base and cover closed together and
with no obstructions, replace the screws. (Figure H)
Figure H

19 July 2007 9 OF 10 091-0589 Rev. A
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Sheet P/N: 091-0589 Rev. A
12. Install gas line. (Figure L)
13. Install heat shrink prior to connecting
brush plate with screw. Cover brush
plate screw connector with approxi-
mately 2-inches of heat shrink tube
MK#739-0008. (Figure M).
Figure N
14. Install side plate (both sides). (Figure N)
Figure L Figure M
Figure K
11. Clean and let set for 24 hours. (Figure K)
1. Heat Shrink
2. Gas Line
11
22
15. Locate the water-return/grounding bar and inspect the four
o-rings. Replace o-rings if necessary. Otherwise coat the
o-rings with an o-ring lubricant and replace them between
the two aluminum side plates.
16. Install grounding bar with screws. (Figure O)
Figure O

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Sheet P/N: 091-0589 Rev. A
20. Assembly complete.
19. Perform a Weldhead Calibration to ensure proper operation. See weldhead calibra-
tion instructions (CobraTig Owner’s Manual 091-0541 andACL Owner’s Manual
091-0568). If the weldhead does not calibrate contact MK Customer Service at
[phone] or [email protected].
18. Install handle cover. (Figure Q)
Figure Q
Figure P
17. Re-connect motor assembly to the circuit board. (Figure P)