Tweco Eliminator Spool Gun User Manual

AIR-COOLED

SSG SERIES

300 AMP

ELIMINATOR

SPOOL GUN

®

English

Français

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SAFETY AND OPERATING

INSTRUCTIONS

Issue Date: December 8, 2009

Manual No: 89200011 Revision: A

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 market­leading, 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.

Eliminator Spool Gun
Safety and Operating Instructions
Instruction Guide Number 89200011
Published by:
Thermadyne® Industries, Inc.
2800 Airport Rd.
Denton, TX. 76207
[phone]

www.tweco.com

U.S. Customer Care: [phone]
International Customer Care: [phone]

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.

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: December 8, 2009

Record the following information for Warranty purposes:

Where Purchased:

Purchase Date:

Equipment Serial #:

i

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: SPOOL GUN SPECIFICATIONS .......................................................... 3-11

SECTION 4: STANDARD SETUP ........................................................................... 4-12

SECTION 5: ESG-1 (STOCK NO. 1028-1295) ....................................................... 5-14

SECTION 6: LOADING THE SPOOL OF WIRE ........................................................ 6-16

SECTION 7: PRE-WELDING PROCEDURE ............................................................7-17

SECTION 8: CHANGING OR REPLACING DRIVE ROLLS .......................................8-18

SECTION 9: CONDUCTOR TUBE & LINER REPLACEMENT ................................... 9-19

SECTION 10: WIRING SCHEMATIC .................................................................... 10-20

SECTION 11: TROUBLESHOOTING ..................................................................... 11-21

SECTION 12: CONTACT TIP IDENTIFICATION AND PARTS LIST ........................12-22

12.01 Contact Tip Replacement ..........................................................12-23

12.02 Nozzles ......................................................................................12-23

SECTION 13: JUMP LINER INSTALLATION ........................................................13-24

SECTION 14: LINER GUIDE ASSEMBLY REPLACEMENT .................................... 14-25

SECTION 15: REPLACEMENT PARTS ................................................................. 15-26

SECTION 16: STATEMENT OF WARRANTY ........................................................ 16-28

16.01 Warranty Schedule ....................................................................16-29

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safety and operating instructions

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 SSG series of Eliminator spool guns is designed to provide smooth positive wire feed when
welding aluminum or steel structures. The MIG gun incorporates the same cablehoz® found
on other Tweco Professional MIG guns providing excellent electrical and abrasion resistant
characteristics. The MIG gun can operate at 300 amps @ 60% duty cycle with mixed gases.
The patented Eliminator contact tips come standard on the MIG gun allowing for quick changing
over the conventional threaded contact tip.

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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.

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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.

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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.

Tweco® Products, Inc. declares under our sole responsibility that the product

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

DECLARATION OF CONFORMITY

Hand Held Air/Gas and Water Cooled MIG Welding Torches

IEC 60974-7:2005

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

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2.01 MESURES DE SÉCURITÉ

AVERTISSEMENT

DES BLESSURES GRAVES OU MORTELLES

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. L’opérateur, le superviseur et l’aide doivent
lire et comprendre les avertissements et les instructions de sécurité suivantes
avant d’installer ou d’utiliser tout équipement de soudage ou de découpage et être
conscients des dangers inhérents aux processus de soudage et de découpage.
Une formation et une supervision adaptées sont importantes pour assurer un lieu
de travail sûr. Gardez ces instructions pour une utilisation future. Chaque section
comporte des informations supplémentaires de sécurité et de fonctionnement.

AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb, ou engendre
des produits chimiques, reconnus par l’état de Californie comme pouvant
être à l’origine de cancer, de malformations fœtales ou d’autres problèmes
de reproduction. Il faut se laver les mains après toute manipulation.
(Code de Californie de la sécurité et santé, paragraphe 25249.5 et suivants)

UN CHOC ÉLECTRIQUE PEUT CAUSER DES BLESSURES OU LA MORT

L’installation et l’entretien de l’équipement doivent être conformes au Code national
de l’électricité NFPA 70 et aux codes locaux. N’effectuez pas l’entretien ou la
réparation d’équipement en marche. N’opérez pas l’équipement sans isolateurs ou
caches de protection. L’entretien ou la réparation de l’équipement doivent être
effectués uniquement par un technicien qualifié ou par du personnel formé.

Ne touchez pas aux pièces électriques chargées. Portez toujours des gants de soudage au sec
et en bon état. Les vêtements de protection aluminisés peuvent devenir une partie du chemin
électrique. Éloignez les bouteilles d’oxygène, les chaînes, les câbles métalliques, les appareils
de levage, les treuils et les élévateurs de toute partie du circuit électrique. Toutes les liaisons de
terre doivent être vérifiées périodiquement pour déterminer si elles sont solides et appropriées au
courant demandé. En cas de soudage ou de découpage en courant alternatif dans des conditions
d’humidité ou de chaleur où l’opérateur risque de transpirer, il est recommandé d’utiliser des
contrôles automatiques pour réduire la tension à vide et ainsi diminuer les risques de choc
électrique. Lorsque le procédé de soudage et de découpage exige des valeurs de tension en
circuit ouvert dans des machines à courant alternatif supérieur à 80 volts ou dans des machines
à courant continu supérieur à 100 volts, il faut prendre des mesures pour empêcher un contact
accidentel en prévoyant une isolation adéquate ou d autres moyens. Lorsqu’il faut interrompre
les activités de soudage pendant un certain temps, à l’heure du repas ou la nuit, par exemple, il
faut enlever toutes les électrodes du porte-électrode et mettre hors tension l’alimentation pour
éviter tout contact accidentel. Gardez les pistolets Mig, les porte-électrodes, les torches TIG, les
torches à plasma et les électrodes loin de l’humidité et de l’eau. Voir les références en matière

de sécurité et d’utilisation n° 1, 2 et 8.

peuvent résulter d’une installation,

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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. Les vapeurs de solvants chlorés
peuvent former un gaz toxique appelé « Phosgène » si elles sont exposées au

rayonnement ultraviolet d un arc électrique. Il faut enlever de la zone de travail
tous les solvants, décapants et sources potentielles de ces vapeurs. Servez-vous d’appareils
respiratoires à adduction d’air si la ventilation n’est pas suffisante pour enlever toutes les
émanations et gaz. L’oxygène alimente les incendies et en accélère la propagation il ne faut

jamais l’utiliser à des fins de ventilation. Voir les références en matière de sécurité et
d’utilisation n° 1, 2, 3 et 4.

L LES RAYONS DE L’ARC, LES SCORIES ET LES ÉTINCELLES CHAUDS PEUVENT BLESSER
LES YEUX ET BRÛLER LA PEAU

Les procédés de soudage et de découpage produisent une chaleur extrême
localisée et de puissants rayons ultraviolets. N’essayez jamais de souder ou de
couper sans casque soudage conforme aux normes du gouvernement fédéral et
muni d’une lentille appropriée. Des lentilles à filtre de numéro 12 à 14 fournissent

la meilleure protection contre le rayonnement de l’arc. Dans un endroit confiné,
il faut éviter que les rayons reflétés de l’arc n’entrent autour du casque. Il faut utiliser des rideaux
de protection approuvés et des lunettes de protection appropriées pour protéger les autres personnes
se trouvant aux abords. Il faut aussi protéger la peau nue des rayons de l’arc, de la chaleur et du
métal fondu. Portez toujours des gants et des vêtements de protection. Toutes les poches doivent
être fermées et les manchettes, cousues. Il faut porter un tablier, des manches, des guêtres, etc.
en cuir pour effectuer de soudage ou de découpage et dans le cas des activités intensives nécessitant
de grandes électrodes. Les chaussures de sécurité montantes fournissent une protection suffisante
contre les brûlures aux pieds. Pour obtenir une plus grande protection, portez des guêtres en cuir.
Il ne faut pas utiliser de produits capillaires inflammables avant d’effectuer des activités de soudage
ou de découpage. Portez des bouchons d’oreilles pour vous protéger les oreilles des étincelles.
Lorsqu’il est possible de le faire dans la zone de travail, l’opérateur doit s’isoler dans une cabine
individuelle recouverte d’un revêtement à faible réflectivité, comme l’oxyde de zinc. Voir les

références en matière de sécurité et d’utilisation n° 1, 2 et 3.
LES ÉTINCELLES DE SOUDAGE PEUVENT CAUSER DES INCENDIES ET DES EXPLOSIONS

Les combustibles atteints par l’arc, les flammes, les vols d’étincelles, les scories
chaudes et les matériaux chauffés peuvent causer des incendies et des explosions.
Enlevez les combustibles de la zone de travail ou mettez en place du personnel
de surveillance. Évitez les vêtements huileux ou graisseux, car une étincelle peut
y mettre le feu. Ayez un extincteur à proximité et sachez comment l’utiliser. Si

l’activité de soudage ou de découpage doit être fait contre un mur, une cloison,
un plafond ou un toit, il faut prendre des précautions pour d’enflammer des combustibles qui se
trouveraient à proximité, de l’autre côté. Ne soudez pas et ne coupez pas de conteneurs ayant
contenu des combustibles. Il faut aérer tous les espaces creux, les cavités et les conteneurs avant
de les soumettre au soudage ou au découpage afin d’évacuer tout l’air ou le gaz qui peut s’y
trouver. Il est recommandé d’effectuer une purge avec du gaz inerte. N’utilisez jamais d’oxygène
dans une tête de soudage. N’utilisez que des gaz inertes ou des mélanges de gaz inertes,
conformément aux exigences du procédé. L’utilisation de gaz combustibles comprimés peut
causer des explosions entraînant des blessures ou la mort. Le fait d’utiliser l’arc sur une bouteille
de gaz comprimé peut endommager la bouteille ou causer une explosion. Voir les références

en matière de sécurité et d’utilisation n° 1, 2, 5, 7 et 8.

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LE BRUIT PEUT ENDOMMAGER L’OUÏE

Le bruit du procédé de l’arc avec électrode en carbone et jet d’air peut endommager
l’ouïe. Portez un dispositif de protection de l’ouïe pour vous protéger lorsque le
niveau de bruit dépasse les normes de l’OSHA. Les opérateurs et le personnel aux
abords doivent porter un dispositif de protection de l’ouïe approprié pour les protéger
efficacement contre le bruit. Voir les références en matière de sécurité et

d’utilisation n° 1, 2 et 6.

RÉFÉRENCES EN MATIÈRE DE SÉCURITÉ ET D’UTILISATION

1. Code of Federal Regulations (OSHA), section 29, partie 1910.95, 132, 133, 134,
139, 251, 252, 253, 254 et 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 » (code national de l’électricité). National Fire
Protection Association, Battery Park, Quincy, MA 02269.

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.

Tweco® Products, Inc. declares under our sole responsibility that the product

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

DECLARATION OF CONFORMITY

Hand Held Air/Gas and Water Cooled MIG Welding Torches

IEC 60974-7:2005

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

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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. El
entrenamiento y supervisión adecuados son importantes para un lugar de trabajo
seguro. Guarde estas instrucciones para uso futuro. En cada sección se incluyen
otras recomendaciones sobre seguridad y operación.

ADVERTENCIA

Este producto contiene sustancias químicas, dentro de las que se incluye el
plomo, o de otro modo produce sustancias químicas que el Estado de California
sabe que provocan cáncer, defectos congénitos y/u otros daños reproductores.

Lávese las manos después de haber estado en contacto con estas
sustancias.

(Código sobre Salud y Seguridad de California, Sec. 25249.5 y siguientes)

LAS DESCARGAS ELÉCTRICAS PUEDEN CAUSAR HERIDAS O LA MUERTE

Instale y mantenga el equipo de acuerdo al Código Nacional Eléctrico (NFPA 70)
y las normas locales. No realice mantenimiento o reparaciones con el equipo
prendido. No opere equipos sin los aisladores de protección o sin tapas. Los
servicios o reparación de los equipos solamente deben ser ejecutados por personal
calificado o entrenado..

No toque componentes eléctricos mientras están eléctricamente vivos. Siempre use guantes
de soldar secos y en buen estado. La ropa de protección aluminizada puede ser conductora
de la electricidad. Mantenga los tubos de oxígeno, cadenas, cuerdas de alambre, guinchos,
grúas y elevadores fuera del alcance de cualquier parte del circuito eléctrico. Se deben verificar
periódicamente todas las conexiones a tierra para determinar si están mecánicamente firmes y
eléctricamente adecuadas para la tensión requerida. Al trabajar con corriente alterna para soldar
o cortar en condiciones de humedad o en ambientes calurosos donde se transpira copiosamente,
se recomienda utilizar mandos automáticos confiables para reducir el voltaje y así reducir los
riesgos de descarga eléctrica. Se debe evitar cualquier tipo de contacto accidental al utilizar un
voltaje de circuito abierto que supere los 80 VCA o 100 VCC emplazando un aislamiento u otros
medios adecuados. Cuando se tenga que interrumpir la soldadura durante un importante período
de tiempo, como durante el almuerzo o la noche, todos los electrodos deben ser retirados del
portaelectrodos y se debe apagar la alimentación eléctrica de manera que no puedan producirse
contactos accidentales. Evite que las pistolas Mig, los portaelectrodos, los sopletes Tig, los
sopletes de Plasma y los electrodos se vean afectados por la humedad y el agua. Consulte las

referencias de seguridad y uso 1, 2 y 8.

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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. Los vapores de solventes clorados pueden formar el gas tóxico
“Fosgeno” cuando quedan expuestos a los rayos ultravioletas producidos por

un arco eléctrico. Todos los solventes, desengrasantes y fuentes potenciales de
esos vapores deben ser retirados del área de trabajo. Utilice respiradores con tanque de aire si
la ventilación no resulta adecuada para eliminar todos los humos y gases. El oxígeno sostiene y
acelera vigorosamente el fuego, por lo que nunca debe ser utilizado para ventilación. Consulte

las referencias de seguridad y uso 1, 2, 3 y 4.

LOS RAYOS DEL ARCO, LA ESCORIA CALIENTE Y LAS CHISPAS PUEDEN LASTIMAR LOS OJOS
Y QUEMAR LA PIEL

Los procesos de soldadura y corte producen calor extremadamente localizado
y fuertes rayos ultravioletas. Nunca intente soldar o cortar sin una máscara de
soldadura con lentes adecuados y que cumpla con las exigencias federales. Los
lentes con filtro número 12 a 14 ofrecen la mejor protección contra la radiación

del arco. Cuando trabaje en un área confinada, evite que los rayos reflejados del
arco entren alrededor de la máscara. Se deben usar cortinas de protección y gafas apropiadas
para proteger al personal presente en áreas cercanas. La piel también debe ser protegida de los
rayos del arco, del calor y del metal derretido. Siempre se deberán utilizar guantes y vestimenta
de protección. Todos los bolsillos deben estar cerrados y los dobladillos cosidos. Se deben usar
delantales de cuero, mangas, pantalones, etc., para la soldadura y el corte fuera de posición o
para operaciones pesadas con electrodos grandes. Las botas de trabajo de caña alta ofrecen
protección adecuada contra las quemaduras de los pies. Use protectores de cuero para brazos
y piernas para contar con protección adicional. No se deben usar productos inflamables para el
cabello cuando se suelde o corte. Usar orejeras para proteger las orejas de las chispas. Cuando
el área de trabajo lo permita, el operador debe trabajar dentro de una cabina individual pintada
con una terminación de baja reflexión, como por ejemplo: óxido de zinc. Consulte las referencias

de seguridad y uso 1, 2 y 3.

LAS CHISPAS DE SOLDADURA PUEDEN CAUSAR INCENDIO Y EXPLOSIONES

Los combustibles alcanzados por el arco, por llamas, chispas, escorias o materiales
calientes pueden ser las causas de incendios y explosiones. Retire los combustibles
del área de trabajo u organice una guardia contra incendios. Evite que las ropas
estén sucias con aceite o grasa, ya que una chispa puede encenderlas. Tenga un
extintor de incendios cerca y sepa como usarlo. Si se está soldando o cortando

en una pared, un divisorio, un cielorraso o un techo metálico, se deben tomar
precauciones para evitar la ignición de combustibles que puedan estar del otro lado. No suelde
ni corte recipientes que hayan contenido combustibles. Todos los espacios vacíos, cavidades y
recipientes deben ventilarse antes de soldar o cortar para permitir la salida de aire o gases. Se
recomienda purgarlos con gas inerte. Nunca use oxígeno en un soplete de soldar. Use solamente
gases inertes o mezclas de gases inertes conforme a lo exigido por el proceso. El uso de gases
comprimidos combustibles puede provocar explosiones y causar daños personales o la muerte.
La radiación del arco contra cualquier tubo de gas comprimido puede causarle daños al tubo o
su explosión. Consulte las referencias de seguridad y uso 1, 2, 5, 7 y 8.

2-989200011 Safety Precautions

safety and operating instructions

EL RUIDO PUEDE DAÑAR LA AUDICIÓN

El ruido del proceso con arco de aire/carbón puede dañar su audición. Use dispositivos
de protección auditiva para contar con protección cuando los niveles superen las
normas de la OSHA. Los operadores y personal próximo deben usar protectores
auriculares para asegurar la protección contra el ruido. Consulte las referencias

de seguridad y uso 1, 2 y 6.

REFERENCIAS DE SEGURIDAD Y USO

1. Código de Normas Federales (OSHA), Sección 29, Partes 1910.95, 132, 133, 134,
139, 251, 252, 253, 254 y 1000. Oficina de la Imprenta Gubernamental de los EE.UU.,
Washington, DC 20402.

2. ANSI Z49.1 “Safety in Welding and Cutting” (Seguridad en la soldadura y el corte).

3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection” (Práctica
para la protección ocupacional y educativa de ojos y rostro).

4. ANSI Z88.2. “Standard Practice for Respiratory Protection” (Práctica estándar para
protección respiratoria). American National Standards Institute (Instituto norteamericano
de normas nacionales), 1430 Broadway, New York, NY 10018.

5. AWS F4.1. “Recommended Safe Practices for Welding and Cutting Containers” (Prácticas
seguras recomendadas para soldadura y corte de recipientes).

6. AWS C5.3. “Recommended Safe Practices for Air Carbon-Arc Gouging and Cutting”
(Prácticas seguras recomendadas para ranurado y corte con arco de aire/carbón). The
American Welding Society (Sociedad norteamericana de soldadura), 550 NW Lejeune
Rd., P.O. Box 351040, Miami, FL 33135.

7. NFPA 51B. “Fire Prevention in Cutting and Welding Processes” (Prevención de incencios
en procesos de corte y soldadura).

8. NFPA-7. “National Electrical Code” (Código eléctrico nacional). National Fire Protection
Association (Asociación nacional para la protección contra incendios), Battery Park,
Quincy, MA 02269.

9. CSA W117.2. “Safety in Welding, Cutting and Allied Processes” (Seguridad en procesos
de soldadura, corte y asociados). Canadian Standards Association (Asociación canadiense
de normas), 178 Rexdale Blvd., Rexdale, Ontario, Canadá M9W 1R3.

Safety Precautions

Tweco® Products, Inc. declares under our sole responsibility that the product

DECLARATION OF CONFORMITY

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.

2-10

89200011

safety and operating instructions

SSG 225 3545

Eliminator Spool Gun

300 Amp-25' (8M) Cable

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

Wire Diameter

SECTION 3:

SPOOL GUN SPECIFICATIONS

Example Part Number:

Process: MIG/MAG welding
Voltage Class: L (up to 113V peak)
Type of Cooling: Air-Cooled
Duty Cycle: 300 Amps @ 60% Duty Cycle
Gas Flow Rate: 30 CFH / 14.2 l/m
Gun Length: 25 ft. (8M) & 50 ft. (15M)

Wire Size: .030" (0,8mm) to 1/16" (1,6mm)

Eliminator Spool Gun

Part No. Stock No. Connection Description

SSG225-3545 1027-1370
SSG250-3545 1027-1371 50 ft. (15M)

25mm Dinse

25 ft. (8M)

The Dinse style connector can be removed and a lug (included) can be installed
for attachment to machines with studs.

NOTE

3-1189200011

Spool Gun Specifications

safety and operating instructions

SECTION 4:

STANDARD SETUP

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.

The Eliminator Spool Gun requires 24VDC power for the motor inside the handle to feed the
wire from the spool. For power supplies having the capability to supply the 24VDC, no added
modules will be required to operate this MIG gun. A 10-pin amphenol plug is attached to the
cord coming out of the rear of the MIG gun that can be either attached directly to the mating
connection on the machine or through jump cords, refer to available options noted below:

Control Wire Jumper Cords

Manufacturer Machine Part Number Stock Number

Miller Millermatic 210 WSPMIU4PJC2 2031-2246

Miller Millermatic 212 WSPMILLOPJC 2031-2246
Lincoln Power MIG 255C WSPLIN7PJC 2031-2247
Hobart Ironman 210, 250 WSPMILL4PJC 2031-2245

Esab Migmaster 203 WSPESAB7PJC 2031-2248
Esab Migmaster 253 WSPESAB7PJC 2031-2248
Esab Migmaster 250 WSPESAB7PJC 2031-2248

Generic See pin configuration WSPESAB7PJC 2031-2249

For those that cannot supply the 24VDC from a power source, Part No. ESG-1 Solid State
Control Box (Stock No. 1028-1295) will be required to interface with the power source. Refer
to Section 5 on the operation of the ESG-1 control box.

NOTE

When connecting the Spool gun to a Thermal Arc Arcmaster & Power Master
series power sources, use the Thermal Arc SGI-100 Spool Gun interface box.
Follow the set-up procedures outlined in the SGI-100 Instruction Manual, Form
No. 0-5061.

Standard Setup

4-12

89200011

safety and operating instructions

Gas Supply

Control Cable

Gas Line

ESG-1 Control

Tweco

Spool Gun

(Gas and

Control Lines)

Tweco Spool Gun

Work Table

Power Cord

Weld Cables

Power Source

FRONT VIEW

REAR VIEW

STANDARD SYSTEM OUTLINE

Figure 4-1: ESG-1 Connection

Mount the control box on the power source and attach the MIG gun to the power source

1.
by using the 25mm dinse connector supplied with the gun or if the power supply has a
stud, remove the connector from the MIG gun and attach the lug option (supplied) to the
gun to make this connection.

a) One (1) straight power lug is furnished with the MIG gun if the connection of the MIG gun

can only be made with a lug. Remove the dinse connector from the MIG gun by using a
5/32” allen wrench to remove the socket head cap screw found on the brass connector.

b) Using the flat head cap screw furnished with the lug, place the lug on the brass block

and secure the lug in place. This connection must be wrench tight.

Using the jumper cord, Part No. SSG300-106JC (Stock No. 2031-2150), connect the 10-pin

2.
amphenol plug attached to the gun to the mating connection on the jumper cord. The opposite
end of the jump cord has a 6-pin connection that connects to the ESG-1 box.

3. Locate the two (2) cords coming from the back of the control box, one will not have a connector
attached. Strip the ends of the 2 wire cable and install the proper terminals required to connect
into the trigger circuit on the power source.

On some machines it may require the leads to be attached directly to the contactor
relay inside the power source.

4. Attach the gas hose from the rear of the MIG gun to the gas hose connection on the front
side of the control box.

5. Attach the gas hose from the flow meter/regulator to the rear of the control box.

6. Plug the 120V cord coming out of the rear of the control box to a suitable 120V outlet.

For more information on the control box read the instructions furnished with the
ESG-1 control box.

NOTE

NOTE

4-1389200011

Standard Setup

safety and operating instructions

Spool Gun
Connection
(CONTROL)

Spool Gun
Connection
(GAS)

Pre-Flow

Control

(0 - 2.5 sec)

Post-flow

Control

(0 - 2.5 sec)

Run-In

Speed

Control

SECTION 5:

ESG-1 (STOCK NO. 1028-1295)

The ESG-1 is a solid state control for the Tweco Spool gun assembly. It's responsible for the
on/off flow of shielding gas to the gun including pre-flow and post-flow, the on/off flow of the
welding current from the power source, the run-in speed of the filler metal during arc initiation,
and the constant wire feed speed of the filler metal while welding.

Front Panel Controls & Connections

1. Located on the front panel are three (3) potentiometers that allows control of the following
functions;

t-1 - This knob is used to select the amount of pre-flow time desired. The range of pre-

flow time control is 0 - 2.5 seconds.

t-2 - This knob is used to select the amount of post-flow time desired. The range of post-

flow time control is 0 - 2.5 seconds.

O/O - This knob controls the run-in speed of the filler metal towards the workpiece.

2. Spool gun connection (GAS) - the spool gun gas fitting plugs into this connection. Shielding
gas is delivered to the spool gun through this connection.

3. Spool gun connection (CONTROL) - The spool gun control cable plugs into this receptacle.
The ESG-1 and the spool gun communicate with one another through the following pins:

a) Pin A - Motor Voltage (+)
b) Pin B - Motor Voltage (-)
c) Pin C - Gun Switch Output
d) Pin D - Wire Feed Speed Maximum
e) Pin E - Wire Feed Speed Reference
f) Pin F - Wire Feed Speed Minimum

ESG-1

Figure 5-1: Front Panel Controls and Connection

5-14

89200011

safety and operating instructions

Gas Valve Inlet

Primary Circuit

Breaker

Secondary Circuit

Breaker

Power Cord

Control Cable

Rear Panel Controls & Connections

1. Power Cord - The power cord plugs into a 120VAC outlet to get input power to the ESG-1.
Outlets found on the power source are acceptable.

2. Control Cable - The control cable connects to the power source. After depressing the gun
switch on the spool gun, an internal relay on the ESG-1 provides closure between the two
wires of the control cable. This closure is then used to energize the power source.

NOTE

The control cable will have to be adapted to properly mate with the power
source I/O device.

3. Gas Valve Inlet - This is where the shielding gas hose from the gas supply is connected to
the ESG-1. The gas valve inlet controls the on/off flow of shielding gas through the spool
gun assembly.

4. Primary Circuit Breaker - The circuit breaker provides protection against faults or overloads
on the primary side of the circuit.

5. Secondary Circuit Breaker - This circuit breaker provides protection against faults or
overloads on the secondary side of the circuit.

Figure 5-2: Rear Panel Connections

5-1589200011

ESG-1

safety and operating instructions

SECTION 6:

LOADING THE SPOOL OF WIRE

1. Load a spool of wire by loosening the
outer knob on the spool cover and
removing the cover.

2. Hold the spool of wire above the
opening while exposing 3” (76,2mm)
of wire away from the spool.

3. Straighten the wire to remove the normal cast and begin lowering the spool downward
over the shaft while inserting the straightened wire into the wire guide.

4. When the wire is positioned between
the drive rolls, adjust the drive roll
pressure to engage the wire enough to
begin feeding the wire forward through
the conductor tube. The spool should
be lowered in place while the wire is
feeding into the conductor tube.

5. Replace the cover and tighten the outer knob.

6. Make final adjustments to the drive roll pressure and adjust the spool brake with
the inner knob of the spool cover.

7. Adjust voltage and wire speed to that recommended by the wire manufacturer.

8. The gun is now ready for operation.

Loading the Spool of Wire

6-16

89200011

safety and operating instructions

SECTION 7:

PRE-WELDING PROCEDURE

1. Make sure all connections have been made.

2. Turn the power source “on”.

3. Adjust the flow of the shielding gas to the desired level.

NOTE

The gun trigger on the spool gun assembly will have to be depressed to allow
gas flow.

4. If using the ESG-1 control box, adjust the run-in speed of the filler metal to the desired
value by means of the run-in speed control located on the front panel of the ESG-1.

5. Adjust the wire speed of the filler metal to the desired value by means of the wire feed
speed control located in the handle of the spool gun assembly.

6. Adjust the voltage of the power source to the desired value by means of the voltage control
located on the power source.

7-1789200011 Pre-Welding Procedure

safety and operating instructions

SECTION 8:

CHANGING OR REPLACING DRIVE ROLLS

1. Guns are shipped standard with 3/64” (1,2mm) drive rolls installed. Optional drive rolls
are available for .030” (0,8mm) through 1/16” (1,6mm) wire, see below table.

Optional Drive Rolls

Wire Size Part No. Stock No.

.030” (0,8mm) EPG103-2-0,8 2031-2091
.035” (0,9mm) EPG103-2-0,9 2031-2077
.040” (1,0mm) EPG103-2-1,0 2031-2023
3/64” (1,2mm) EPG103-2-1,2 2031-2003
1/16” (1,6mm) EPG103-2-1,6 2031-2022

2. To change or replace drive roll, loosen the setscrew on the drive roll with the allen wrench
furnished.

3. Remove the drive roll from the motor shaft and reinstall the new drive roll in its place.

NOTE

Make sure that the drive roll is seated against the brass washer before tightening
the set screw.

4. Drive rolls have two u-grooves in each roll and maybe inverted to double the life of one
drive roll.

Changing or Replacing Drive Rolls

8-18

89200011

safety and operating instructions

SECTION 9:

CONDUCTOR TUBE & LINER REPLACEMENT

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

1. To remove and replace the conductor tube from the MIG gun, unscrew the insulated
conductor tube-retaining nut from the front end of the gun.

2. To remove the liner within the conductor tube, remove the nozzle from the conductor tube.

3. Unscrew the gas diffuser and remove.

4. Pull the liner out of the conductor tube and cut the replacement liner to the same length
as the one removed.

5. Remove any obstructions to the liner that may be present after cutting to length and insert
into the conductor tube.

NOTE

Make sure the liner fits into the front wire guide in the gun body.

6. Reinstall the nozzle.

9-1989200011

Conductor Tube & Liner Replacement

safety and operating instructions

3

2

1

BEND
SOLDERED
TABS OVER
AS SHOW

N

ORIENT WIRES
ON THE SIDES
AS SHOW

N

ORANGE

ESG89-F
POTENTIOMETER
SUB-ASSY

ESG90-F

MICRO SWITCH

SUB-ASSY

RED LEAD

TRIM 9” LG

.

EPG-24-MTR-F

SPURGEAR MOTOR

SUB-ASSY

BLA

CK
LEAD
TRIM
9” LG.

NO

NC

YELLOW

BLUE

GREEN

WHITE

PINK

GREY

CABLEHOZ CONTROL

LEAD WIRE

S

SECTION 10:

WIRING SCHEMATIC

Wiring Schematic

10-20

89200011

safety and operating instructions

SECTION 11:

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. Replace or repair any
parts found deficient.

Problem Possible Cause Corrective Action

1. Tighten contact tip and diffuser
plier tight.

3. Clean or replace contact tip.

4. Straighten or replace conduit.

6. Reposition conduit and tighten
front set screw.

7. Reset machine per machine
and wire manufacturers’
recommendations.

8. Move outlet guide right up to
drive rolls without touching and
tighten the guide nut.

1. Tighten contact tip and diffuser
plier tight.

2. Inspect complete gun for loose
connections and repair.

3. Tighten or replace as required.

4. Readjust machine to correct
setting for size of gun being used.

1. Check gas flow out of gun nozzle.
Check for leaks or restrictions
in gas hoses and connections.
Check for O-ring damage on rear
connector plug.

2. Check outlet guide nut on feeder;
tighten if not already done.

4. Replace base metal or
brush clean.

Wire feed inconsistent, not

smooth, or is bird nesting.

MIG gun is running hot

Porosity

1. Loose contact tip or diffuser.

2. Excessively worn contact tip. 2. Replace contact tip.

3. Spatter buildup on end of
contact tip.

4. Sharp bends or kinks in
conduit.

5. Dirty or plugged conduit. 5. Replace conduit.

6. Conduit pulled back from
diffuser.

7. Machine improperly adjusted.

8. Gap between drive rolls and
outlet guide inside feeder.

1. Loose contact tip or diffuser.

2. Loose power connections.

3. Loose or undersized ground
cable or ground clamp.

4. Operating gun above
recommended amperage
rating.

1. Poor or improper gas flow,
possibly due to the outlet

2. Guide nut on feeder not being
tightened down on guide

3. Dirty or contaminated wire. 3. Change wire.

4. Base metal contaminated.

11-2189200011

Troubleshooting

safety and operating instructions

SECTION 12:

CONTACT TIP IDENTIFICATION AND PARTS LIST

ELIMINATOR® STYLE CONTACT TIPS - Standard Alloy Copper Tubing

Standard Tapered

Wire Size in/mm Tip I.D. in/mm Part No. Stock No. Part No. Stock No.

EL11 SERIES

.035” (0,9mm) .044” (1,12mm) EL11-35 1140-1177

.045” (1,2mm) .054” (1,37mm) EL11-45 1140-1179

EL16 & EL16T SERIES

.023” (0,6mm) .031” (0,79mm) EL16T-23 1160-1600

.030” (0,8mm) .038” (0,97mm) EL16-30 1160-1610 EL16T-30 1160-1601

.035” (0,9mm) .044” (1,12mm) EL16-35 1160-1611 EL16T-35 1160-1602

.040” (1,0mm) .048” (1,22mm) EL16-40 1160-1612 EL16T-40 1160-1603

.045” (1,2mm) .054” (1,37mm) EL16-45 1160-1613 EL16T-45 1160-1604

.052” (1,3mm) .064” (1,65mm) EL16-52 1160-1615 EL16T-52 1160-1605

1/16” (1,6mm) .073” (1,85mm) EL16-116 1160-1616 EL16T-116 1160-1606

5/64” (2,0mm) .090” (2,29mm) EL16-564 1160-1618

3/32” (2,4mm) .106” (2,67mm) EL16-332 1160-1619

7/64” (2,8mm) .120” (3,05mm) EL16-764 1160-1620

3/64” AL (1,2mm) .059” (1,50mm) EL16A-364 1160-1614 EL16AT-364 1160-1607

1/16” AL (1,6mm) .082” (2,08mm) EL16A-116 1160-1617

LONG LIFE ELIMINATOR® STYLE CONTACT TIPS - Chrome Copper Material

Standard Tapered

Wire Size in/mm Tip I.D. in/mm Part No. Stock No. Part No. Stock No.

EL16RZ & EL16RZT SERIES

.035” (0,9mm) .044” (1,12mm) EL16RZ-35 1160-1730 EL16RZT-35 1160-1705

.040” (1,0mm) .048” (1,22mm) EL16RZ-40 1160-1731 EL16RZT-40 1160-1706

.045” (1,2mm) .051” (1,30mm) EL16RZ-45 1160-1732 EL16RZT-45 1160-1707

.045” (1,2mm) .054” (1,37mm) EL16RZ-45C 1160-1735 EL16RZT-45C 1160-1710

.052” (1,3mm) .064” (1,65mm) EL16RZ-52 1160-1733 EL16RZT-52 1160-1708

1/16” (1,6mm) .073” (1,85mm) EL16RZ-116 1160-1734 EL16RZT-116 1160-1709

1/16” (1,6mm) .068” (1,73mm) EL16RZ-116-68 1160-1736 EL16RZT-116-68 1160-1711

Contact Tip Identification and Parts List

12-22

89200011

safety and operating instructions

12.01 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.

12.02 NOZZLES

AIR COOLED ELIMINATOR NOZZLES

Nozzle Style

Slip-On (A)

Thread-On (B)

Note: Self Insulated Nozzles

(A) - Use with Part No. EL54 Series Gas Diffusers

(B) - Use with Part No. EL54CT Series Gas Diffusers

Bore Diameter

(in/mm)

3/8’ (9,5mm) EL24I-37 1260-1606 Tapered 1/8” - 5/32” (3,2mm - 3,97mm) Tip Recess

1/2” (12,7mm) EL24I-50 1260-1607 Tapered 1/8” - 5/32” (3,2mm - 3,97mm) Tip Recess

5/8” (15,9mm) EL24I-62 1260-1608 Tapered 1/8”-5/32” (3,2mm - 3,97mm) Tip Recess

5/8” (15,9mm) EL24I-62F 1260-1618 Tapered Flush To 1/16” (1,6mm) Tip Recess
5/8” (15,9mm) EL24I-62R 1260-1677 Tapered 3/8” (9,5mm) Tip Recess

5/8” (15,9mm) EL24I-62H 1260-1631

5/8” (15,9mm) EL24I-62HF 1260-1641

3/4” (19,5mm) EL24I-75 1260-1609 Tapered 1/8” - 5/32” (3,2mm - 3,97mm) Tip Recess

3/4” (19,5mm) EL24I-75H 1260-1632

3/8’ (9,5mm) EL24CT-37 1260-1650 Standard 1/8” - 5/32” (3,2mm - 3,97mm) Tip Recess

1/2” (12,7mm) EL24CT-50 1260-1651 Standard 1/8” - 5/32” (3,2mm - 3,97mm) Tip Recess

1/2” (12,7mm) EL24CT-50F 1260-1666 Standard Flush To 1/16” (1,6mm) Tip Recess
1/2” (12,7mm) EL24CT-50P 1260-1701 Standard 5/32” (3,97mm) Tip Protruding
5/8” (15,9mm) EL24CT-62 1260-1652 Standard 1/8” - 5/32” (3,2mm - 3,97mm) Tip Recess
5/8” (15,9mm) EL24CT-62F 1260-1667 Standard Flush To 1/16” (1,6mm) Tip Recess
5/8” (15,9mm) EL24CT-62P 1260-1702 Standard 5/32” (3,97mm) Tip Protruding
5/8” (15,9mm) EL24CT-62R 1260-1682 Standard 3/8” (9,5mm) Tip Recess

5/8” (15,9mm) EL24CT-62H 1260-1657

3/4” (19,5mm) EL24CT-75 1260-1653 Standard 1/8” - 5/32” (3,2mm - 3,97mm) Tip Recess

3/4” (19,5mm) EL24CT-75H 1260-1658

Part No. Stock No. Nozzle Design Nozzle/Contact Tip Relationship

EL24I SERIES

Tapered

Heavy-Duty

Tapered

Heavy-Duty

Tapered

Heavy-Duty

EL24CT SERIES

Standard

Heavy-Duty

Standard

Heavy-Duty

1/8” - 5/32” (3,2mm - 3,97mm) Tip Recess

Flush To 1/16” (1,6mm) Tip Recess

1/8” - 5/32” (3,2mm - 3,97mm) Tip Recess

1/8” - 5/32” (3,2mm - 3,97mm) Tip Recess

1/8” - 5/32” (3,2mm - 3,97mm) Tip Recess

12-2389200011 Contact Tip Identification and Parts List

safety and operating instructions

SECTION 13:

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. Remove jump liner from conductor tube.

3. Make sure that both new and old jump
liners are the same length. Feed the end of
the new jump liner into the conductor tube
until it stops. Secure with diffuser set screw.
If unsure if the liner is seated properly in
the diffuser, remove the set screw and liner
should be visible inside the set screw hole.

NOTE

Do not overtighten the set screw
on the jump liner or the bronze
material will collapse under
extreme pressure. The jump liner
should extend 3/16" (4,7mm) past
the rear flat on the conductor tube.

4. Install conductor tube on the front of the
handle and twist locking nut clockwise to
secure. Insure that the liner in the tube is
seated in the front guide on gun before
tightening.

Jump Liner Installation

13-24

89200011

safety and operating instructions

SECTION 14:

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.

4. Install new assembly into block using
pliers or a 3/8" open end wrench and
screwdriver.

5. If using the white Teflon liner in the front
steel liner guide, the liner should be 1 3/4"
(44,5mm) long and protrude out the rear
of the guide (threaded end) 1/8"- 3/16"
(3,2mm - 4,8mm).

6. The plated steel or copper liner guide
that anchors the conduit between the
gun drive roll and conductor tube should
protrude no more than 1/8" (3,2mm) from
the gun body after assembly.

NOTE

Make sure the white liner is
not forced back against the
gun drive roll.

14-2589200011

Liner Guide Assembly Replacement

safety and operating instructions

1

2

3

7

5

8

10

11

12

13

14

16

17

18

19

21

20

23

9

25

26

27

29

31

32

33

34

35

36

15

6

4

24

22

37

30

SECTION 15:

REPLACEMENT PARTS

15-26

89200011Replacement Parts

safety and operating instructions

# Description Part No. Stock No.

1 Nozzle Refer to Section 12
2 Contact Tip Refer to Section 12
3 Diffuser EL54CT-SW 1560-1116
4 Head Block Assembly SPG103 2031-2100
5 Pressure Arm Assembly SPG103-1 2060-1727
6 Idler Bearing Assembly SPG103-8 2060-1728
7 Adapter Nut & Wire Guide EPG66-N 2031-2096

Drive Roll (0,8mm/0.030" Wire) EPG103-2-0,8 2031-2091
Drive Roll (0,9mm/0.035" Wire) EPG103-2-0,9 2031-2077

8

Drive Roll (1,0mm/0.040" Wire) EPG103-2-1,0 2031-2023
Drive Roll (1,2mm/5/64" Wire) Standard EPG103-2-1,2 2031-2003
Drive Roll (1,6mm/1/16" Wire) EPG103-2-1,6 2031-2022

9 Gas Nipple & Wire Tie EPG-FGN 2031-2082
10 Handle Cover Assembly EPG86-2 2031-2013
11 Trigger Switch ESG90 2025-2399
12 Motor Assembly (24VAC) SSGM24 2031-2101
13 Trigger Lever SPG-96TL 2060-2733
14 Handle Sub-Assembly SSG86 2060-2739
15 Poppet Valve Assembly PMP-PV 2060-2737

Conductor Tube 30 Degree PMP64EL-30 1642-1141

16

Conductor Tube 180 Degree PMP64EL-180 1642-1140
Flexible Conductor Tube PMP64SFLX-360 1642-1142
Jump Liner PMP44PTF-116 1644-1096

17

Jump Liner Teflon PMP44FLX-116 1644-1095

Jump Liner Copper PMP44-116 1644-1097
18 Spool Gun Assembly W/O Cable & Support SSG300G 2031-2117
19 Pivot Assembly ESG186 2025-2397
20 Spool Canister Assembly ESG186S 2025-1392
21 Spool Cover Assembly ESG186C 2025-2393
22 Friction Tube Replacement ESG186S-3 2025-2385
23 Conduit Assembly ESG44TF-116 2025-2394
24 Wire Tie BG-53N04 8040-1998
25 Gas Hose Assembly F/SSG Spool Gun SSG3003GH 2060-2741

Extruded Spool Gun Cablehoz, 25 Ft. Long SSG30025 2060-2742
26

Extruded Spool Gun Cablehoz, 50 Ft. Long SSG30050 2060-2743
27 10 Pin Control Cable Assembly F/SSG Spool Gun SSG300CW 2060-2744
28 Hex Wrench Set ESG-HW 2025-2395
29 25MM Dinse Connector SSG-DINS25 2035-2186
30 Rear Gas Nipple EPG-RGN 2031-2083
31 Straight Lug ESG-172SL 2031-2110
32 Rear Case Sub-Assembly SSGT6RC 2031-2111
33 Front Strain Relief Assembly SPG146R 2031-2112
34 Cable Connector Assembly SPG102 2031-2113
35 Hose Barb Connector ESG6RCUGN 2031-2114
36 10-24 X 1/2" BH Plastic Screw SSG172PS 2031-2115
37 Rear Power Connector ESG172 2031-2116

15-2789200011 Replacement Parts

safety and operating instructions

SECTION 16:

STATEMENT OF WARRANTY

LIMITED WARRANTY:

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 to misuse,
repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement,
at THERMADYNE®’s sole option, of any components or parts of the product determined by
THERMADYNE® to be defective.

THERMADYNE® warrants that its products will be free of defects in

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITY:

liable for special or consequential damages, such as, but not limited to, damage or loss
of purchased or replacement goods, or claims of customers of distributor (hereinafter the
“Purchaser") for service interruption. The remedies of the Purchaser set forth herein are
exclusive and the liability of THERMADYNE® with respect to any contract, or anything done in
connection therewith such as the performance or breach thereof, or from the manufacture,
sale, delivery, resale, or use of any goods covered by or furnished by THERMADYNE® whether
arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not,
except as expressly provided herein, exceed the price of the goods upon which such liability
is based.

THERMADYNE® shall not under any circumstances be

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES
ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY
THERMADYNE PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED
PERSONS.

This warranty is effective for the time stated in the Warranty Schedule beginning on the date
that the authorized distributor delivers the products to the Purchaser.

Warranty repairs or replacement claims under this limited warranty must be submitted
by an authorized THERMADYNE® repair facility within thirty (30) days of the repair. No
transportation costs of any kind will be paid under this warranty. Transportation charges
to send products to an authorized warranty repair facility shall be the responsibility of the
Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty
supersedes all previous THERMADYNE® warranties.

16-28

89200011Statment of Warranty

safety and operating instructions

16.01 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

Scout®, Rraider®, Explorer

™

Parts / Labor

Original Main Power Stators and Inductors 3 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays,

Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors
Engines and Associated Components are NOT Warranted by Thermal Arc®, Although

Most are Warranted by the Engine Manufacturer. SEE THE ENGINE MANUFACTURERS’
WARRANTY FOR DETAILS.

1 year / 1 year

See the Engine
Manufacturers’

Warranty for Details

GMAW/FCAW (MIG) Welding Equipment

Fabricator® 131, 181, 190, 210, 251, 281; Fabstar® 4030; PowerMaster®

320SP, 350, 350P, 400SP, 500SP, 500, 500P; Excel-Arc® 6045; Wire Feeders:

Ultrafeed®, Porta-feed

®

Parts / Labor

Original Main Power Transformer and Inductor 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays,

Switches, Contactors, Solenoids, Fans, Electric Motors

1 year / 1 year

GTAW (TIG) & Multi-process Inverter Welding Equipment

160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW,

Parts / Labor

400MST, 300MST, 400MSTP

Original Main Power Magnetics 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays,

Switches, Contactors, Solenoids, Fans, Electric Motors

Plasma Welding Equipment

Ultima® 150

1 year / 1 year

Parts / Labor

Original Main Power Magnetics 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years
Welding Console, Weld Controller, Weld Timer 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays,

Switches, Contactors, Solenoids, Fans, Electric Motors, Coolant Recirculators

SMAW (Stick) Welding Equipment

Dragster™ 85

1 year / 1 year

Parts / Labor

Original Main Power Magnetics 1 year / 1 year
Original Main Power Rectifiers, Control P.C. Boards 1 year / 1 year
All Other Original Circuits and Components Including, but not Limited to, Relays,

Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors

1 year / 1 year

160S, 300S, 400S Parts / Labor

Original Main Power Magnetics 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays,

Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors

1 year / 1 year

16-2989200011

Statment of Warranty

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
MIG, TIG and Plasma Welding Torch Consumable Items NA / NA

Gas Welding and Cutting Equipment Parts / Labor

Victor® Professional 5 years / NA
Oxygen Conservers 2 years / NA
Aluminum Cylinders Lifetime / NA
Cutting Machine Motors 1 year / NA
HP&I Brass Regulators/Manifolds 2 years / NA
HP&I Stainless Regulators/Manifolds 1 year / NA
HP&I Corrosive Gas Regulators/Manifolds 90 days / NA
TurboTorch
CutSkill
Steel Cylinders 1 year / NA
Victor Medical 6 years / NA
Victor VSP 2 years / NA
Firepower® MIG Welders 5-2-1 years / NA
Transformers 5 years / NA

Parts Used in Rental Applications

Arcair® N6000 90 days / NA
Spool and Pull Guns 90 days / NA
Robotic Deflection Mounts 90 days / NA
QRM-100 Anti-Spatter Applicator 90 days / NA
TC and TCV Water Coolers 1 year / NA
TSC-96 Smoke Collector 1 year / NA
ESG-1, EPG-CR2 Control Boxes for Spool & Pull Guns 1 year / NA
QRC-2000 Nozzle Cleaning Stations 1 year / 1 year
QRC-3000 UltraSonic Cleaning Stations 2 years / 2 years
All other products 30 days from date purchaser purchases from seller. 30 days / NA

Automated Plasma 2 years / 1 year
CutMaster
PakMaster® XL PLUS 3 years / 1 year
Drag-Gun
Drag-Gun Plus 2 years / 1 year
Torches 1 year / 1 year
Consoles, Control Equipment, Heat Exchangers and Accessory Equipment 1 year / 1 year

®

®

3 years / NA
2 years / NA

1 year from date sold

by seller to authorized

distributor

MIG Torches and Arc Accessories Parts / Labor

Plasma Cutting Systems Parts / Labor

™

®

3 years / 3 years

1 year / 1 year

Statment of Warranty

16-30

89200011

safety and operating instructions

16-3189200011

© Thermadyne Industries, Inc., 2009 www.thermadyne.com

Printed in U.S.A.

W O R L D H E A D Q UA R T E R S:

16052 Swingley Ridge Road, Suite 300 • St. Louis, Missouri 63017 U.S.A.

A Global Cutting & Welding Market Leader

™

Oakville, Ontario, Canada
Canada Customer Care

Ph: (1) 905-827-4515
Fax: [phone]

International Customer Care

Ph: (1) 905-827-9777
Fax: [phone]

Melbourne, Australia
Australia Customer Care

Ph: 1300-654-674
Fax: 613+ 9474-7391

International

Ph: 613+ 9474-7508
Fax: 613+ 9474-7488

Rawang, Malaysia
Customer Care

Ph: 603+ 6092-2988
Fax: 603+ 6092-1085

Shanghai, China
Sales Office

Ph: 86 21+ 6280-1273
Fax: 86 21+ 3226-0955

Singapore
Sales Office

Ph: 65+ 6832-8066
Fax: 65+ 6763-5812

Denton, TX USA
U.S. Customer Care

Ph: (1) 800-426-1888
Fax: [phone]

Miami, FL USA
Sales Office, Latin America

Ph: (1) 954-727-8371
Fax: [phone]

THE AMERICAS

Chorley, United Kingdom
Customer Care

Ph: (44) 1257-261755
Fax: [phone]

Milan, Italy
Customer Care

Ph: (39) 0236546801
Fax: [phone]

EUROPE

Cikarang, Indonesia
Customer Care

Ph: 62 21+ 8983-0011 / 0012
Fax: 62 21+ 893-6067

Osaka, Japan
Sales Office

Ph: 816-4809-8411
Fax: [phone]

ASIA/PACIFIC

U.S. Customer Care:

ARCAIR® / STOODY® / THERMAL ARC® / THERMAL DYNAMICS® /

TWECO® / VICTOR

®

............................. 800-426-1888 / FAX [phone]

FIREPOWER

®

....................................... 800-858-4232 / FAX [phone]

TURBOTORCH

®

..................................... 800-238-0282 / FAX [phone]

TDC AUTOMATION................................ 866-279-2628 / FAX [phone]

VICTOR MEDICAL ................................. 800-382-8187 / FAX [phone]

VICTOR SPECIALTY PRODUCTS........... 800-569-0547 / FAX [phone]

Canada Customer Care: 905-827-4515 / FAX [phone]

International Customer Care: 940-381-1212 / FAX [phone]

CIGWELD Customer Care: 1300-654-674 / FAX 613+ 9474-7391

www.thermadyne.com

Form No.: 89200011