Tweco FUSION 250 Safety And Operating Instructions Manual

TWECO® FUSION™250

Safety and Operating Instructions

AIR-COOLED MIG GUN 250 AMP

Tweco.com

English

Canadien Français

Americas Español

Revision: B Issue Date: August 2, 2013 Manual No.: 89200015

IMPORTANT: Included inside - special

instructions for liner replacement.

WE APPRECIATE YOUR BUSINESS!

Congratulations on receiving your new Tweco product. We are proud to have you as our customer and will strive to provide you with the best service and support in the industry. This product is backed by our extensive warranty and world-wide service network.

We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done.

For more than 75 years Tweco has provided quality products you can trust, when your reputation is on the line.

YOU ARE IN GOOD COMPANY!

Tweco is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish ourselves from our competition through marketleading innovation and truly dependable products that will stand the test of time.

We strive to enhance your productivity, efﬁciency and welding performance enabling you to excel in your craft. We design products with the welder in mind delivering- advanced features, durability, ease of use and ergonomic comfort.

Above all, we are committed to a safer working environment within the welding industry. Your satisfaction with this product and its safe operation is our ultimate concern. Please take the time to read the entire manual, especially the Safety Precautions.

If you have any questions or concerns regarding your new Tweco product, please contact our friendly and knowledgeable Customer Service Team at:

1-800-462-2782 (USA) and 1-905-827-4515 (Canada), or visit us on the web at www.Tweco.com

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.

Tweco® Fusion 250 AMP MIG Gun Safety and Operating Instructions Instruction Guide Number 89200015

Published by: Victor Technologies, Inc. 2800 Airport Rd. Denton, TX. 76208 (940) 566-2000

www.tweco.com

U.S. Customer Care: (800) 426-1888 Canada Customer Care: 905-827-4515 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: December 17, 2012 Revision Date: August 2, 2013

Record the following information for Warranty purposes:

Where Purchased:

Purchase Date:

Equipment Serial #:

Table of Contents

SECTION 1: SAFETY PRECAUTIONS .........................................................................3

1.01 Safety Precautions .......................................................................... 3

SECTION 2: INTRODUCTION ......................................................................................5

2.01 How to Use this Manual ................................................................... 5

2.02 Receipt of Equipment ....................................................................... 5

2.03 Description ....................................................................................... 5

SECTION 3: MIG GUN SPECIFICATIONS.....................................................................6

3.01 MIG Gun Classiﬁcation ..................................................................... 6

3.02 Duty Cycles ..................................................................................... 6

3.03 Tweco® fusion 250A MIG Gun Selection guide ................................ 7

3.04 Tweco® Fusion 250A MIG Gun Part Number Identiﬁcation .............. 7

3.05 Velocity Contact Tip Nozzle Identiﬁcation .........................................8

3.06 Velocity 250 Amp Conductor Tube Identiﬁcation ............................. 8

SECTION 4: MIG GUN INSTALLATION ........................................................................9

4.01 Direct Plug MIG Gun Installation ...................................................... 9

4.02 Tweco® MIG-Kwik Connection and Adapter Kit Installation ........... 10

SECTION 5: REPLACEMENT INSTRUCTIONS ...........................................................11

5.01 Replacing Velocity Contact Tip ...................................................... 11

5.02 Replace Conductor Tube ............................................................... 11

5.03 Conduit Identiﬁcation and Replacement ......................................... 12

5.04 Replacing Handle, trigger .............................................................. 13

SECTION 6: CABLEHOZ® REPAIR ............................................................................14

6.01 Tools Required ............................................................................... 14

6.02 Repair of Cablehoz® ...................................................................... 14

SECTION 7: MAINTENANCE AND TROUBLESHOOTING............................................19

SECTION 8: 250 AMP REPLACEMENT PARTS .........................................................20

8.02 Tweco® Fusion 250 A MIG Gun Parts ............................................ 20

8.02 Tweco® Fusion MIG Gun Consumables ......................................... 22

SECTION 9: STATEMENT OF WARRANTY ................................................................24

9.01 Warranty Schedule .........................................................................24

Global Contact Information ...............................................Rear Cover

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SECTION 1:

SAFETY PRECAUTIONS

1.01 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

WARNING: This product contains chemicals, including lead, known to the State of California to cause birth defects and other reproductive harm. Wash hands

after handling.

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.

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.

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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 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.

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SECTION 2:

INTRODUCTION

2.01 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.

2.02 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).

2.03 DESCRIPTION

Tweco MIG Guns are furnished with rear connections to ﬁt directly into most Miller®, Lincoln®, and Euro connection wire feeders. These guns are referred to as Direct Plug MIG Guns. Tweco MIG guns are also furnished with the time-proven MIG-Kwik connection. The MIG-Kwik connection, when utilized with a Tweco adapter kit, allows a Tweco MIG gun to be installed on almost any wire feed system. For a listing of available adapter kits, see the Tweco Adapter Kit Listing, Form No. TAKL-97, or call Tweco Customer Care.

MILLER is a registered trademark of Miller Electric Mfg. Co.; ESAB is a registered trademark of ESAB AB; LINCOLN is a registered trademark of LINCOLN Electric Co.; The aforementioned registered trademarks are no way afﬁliated with Tweco Products, Inc. or Victor Technologies, Inc. Tweco is a registered trademark of Victor Technologies, Inc.

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SECTION 3:

MIG GUN SPECIFICATIONS

3.01 MIG GUN CLASSIFICATION

Process MIG/MAG welding Method of Guidance Manually guided Voltage Class for Welding and Control Circuits L (up to 113 V peak) Type of Cooling Air or cooling gas Type of Shielding Gas All types

3.02 DUTY CYCLES

Duty Cycle

MIG Gun

250 AMP 10% 320 35% 290 80% 250

100% 195

The above duty cycles were established by testing under the following parameters:

Parameter MIG (metal inert gas) MAG (metal active gas) Type of Voltage D.C. Shielding Gas Argon Argon/CO2 Mixed Gas (80/20, 75/25) Gas Flow Rate 30-35 CFH (14,2- 16,5 l/m)

Gun Cable Length

10 ft. (3 m) 12 ft. (3,7 m) 15 ft. (4,6 m)

20 ft. (6 m) 25 ft. (7,6 m)

Electrode Polarity Positive

Wire Diameter

Wire (Continuous Electrode) Size

250 amp

.023" (0,6 mm) .030" (0,8 mm) .035" (0,9 mm) .040" (1,0 mm) .045" (1,2 mm) .052" (1,3 mm) 3/64” (1,2 mm) 1/16” (1,6 mm) 5/64” (2,0 mm) 3/32” (2,4 mm) 7/64” (2,8 mm) 1/8” (3,2 mm)

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3.03 TWECO® FUSION 250A MIG GUN SELECTION GUIDE

Rear

Connection

250 AMP MIG Gun*

Rear Connector

(Replacement)

Part Number

Stock Number

Part Number

Stock Number

Part Number

Stock Number

Part Number

Stock Number

Part Number

Stock Number

Part Number

Stock Number

10 ft cable 12 ft cable 15 ft cable 20 ft cable 25 ft cable

Tweco

FV210-3545

1023-1059

FV212-3545

1023-1060

FV215-3545

1023-1061

FV220-3545

1023-1062

FV225-3545

1023-1063

350-174H

2035-2110

Miller

FV210M-3545

1023-1067

FV212M-3545

1023-1068

FV215M-3545

1023-1069

FV220M-3545

1023-1070

FV225M-3545

1023-1071

350-174MH

2035-2111

Lincoln

----

FV212L-3545

1023-1084

FV215L-3545

1023-1085

---- ----

350-174LH 2035-2112

Euro-Kwik

FV210X-3545

1023-1089

FV212X-3545

1023-1090

FV215X-3545

1023-1091

----

FV225X-3545

1023-1092

174EX-1

2040-2276

252i

ThermalArc

---- ----

FV215TA3545

1023-1097

---- ----

350-174H

2035-2110

*Rear connector supplied as standard

3.04 TWECO FUSION 250A MIG GUN PART NUMBER IDENTIFICATION

NOTE

Tweco Fusion 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:

FV215TA3545

T=Tweco TA=Tweco (Bundle) L=Lincoln M=Miller X, XE=Euro-Kwik

Fusion Velocity

15 foot (5 M) cable

.035"-.045" Wire Capacity (0,9 mm - 1,2 mm)

So a part number "FV215TA3545" would identify the MIG gun as a: Tweco Fusion 250A MIG Gun bundle pack with a 8-pin rear connector, 15 foot long cable and having a 0.035" to 0.045" diameter wire capacity. So a part number"FV2253545" would identify the MIG gun as a: Tweco Fusion 250A MIG Gun with a 4-pin Tweco rear connector, 25 foot long cable and having a 0.035" to 0.045" diameter wire capacity.

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3.04 VELOCITY CONTACT TIP IDENTIFICATION

Velocity Contact Tips may be identiﬁed by the tip type and the part number marking for each tip.

Example Part Number:

VTSARZT30

Velocity Tip

Blank=CU, RZ=CHROM ZIRC, RS=SILVER ZIRC

T=Tapered, Blank=None

S=Small, M=Medium, L=Large

A=Aluminum, Blank=Other

Wire Size: 23=0.023” 116=1/16” 30=0.030” 564=5/64” 35=0.035” 332=3/32” 40=0.040” 764=7/64” 45=0.045” 18=1/8” 52=0.052” 364=3/64”

So a part number "VTSARZT30" would be: Velocity Tip Type, Small Size, Aluminum, RZ Alloy, Tapered for wire size 0.030" diameter. A part number "VTM40" would be: Velocity Tip Type, Medium Size, CU, wire size 0.040" diameter.

3.05 VELOCITY CONTACT TIP NOZZLE IDENTIFICATION

Nozzles for the Velocity contact tip Tweco Fusion MIG Guns may be identiﬁed by their type and part number marking on each nozzle.

Example Part Number:

Blank=Standard, H=Heavy Duty

VNSH50FS

Velocity Nozzle

Blank=Std Recess, F=Flush, P=Protrude, R= Recess ¼” (6.35mm) FAS=Spot Weld FC=Flux Core

S=Small Nozzle, M=Medium Nozzle, L=Large Nozzle

Oriﬁce Opening Size: 37=3/8” 62=5/8” 50=1/2” 75=3/4”

Blank=Threaded, S=Slip

So a part number "VNSH50FS" would be: Velocity Nozzle Type, Small Nozzle Size, Heavy Duty, oriﬁce opening size of 0.50 inch, Flush end, Slip ﬁt. A part number "VNS50" would be: Velocity Nozzle Type, Small Nozzle Size, Standard Duty, oriﬁce opening size of 0.50 inch, Standard Recess end, Threaded ﬁt.

3.06 VELOCITY 250 AMP CONDUCTOR TUBE IDENTIFICATION

Conductor tubes for the Velocity Contact Tip on the Tweco Fusion MIG Guns may be identiﬁed by their type and part number marking on each tube.

Example Part Number:

FVCTS45

Fusion

Velocity Conductor Tube

Bend Angle: 45˚, 60˚, or 180˚

S=Small Tip, M=Medium Tip, L=Large Tip

So a part number "FVCTS45" would be: Tweco Fusion Gun Type, Velocity 250 Amp Conductor Tube, Small Tip Size, 45 degree bend. A part number "FVCTM60" would be: Tweco Fusion Gun Type, Velocity 250 Amp Conductor Tube, Medium Tip Size, 60 degree bend.

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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 1 “Safety Precautions.”

WARNING

Electric shock can cause injury or death.

POWER

SOURCE

WIRE FEEDER

GROUND

WORK PIECE

GUN

Figure 1: Standard MIG Gun Installation

4.01 DIRECT PLUG MIG GUN INSTALLATION

Direct plug MIG guns install by directly inserting the rear connector plug into the feeder wire guide outlet (see ﬁgure 2) and tightening the plug retaining screw. All models of MIG guns, except the Euro-Kwik guns, require a control wire assembly to attach the MIG gun trigger leads to the feeder. The control wire assemblies plug into the rear connector case of the MIG gun, and into the control wire receptacle on the feeder. Euro-Kwik connections are installed by inserting the gun connection into the feeder receptacle, aligning the conduit plug ﬁrst, then the gas plug. Push until all ﬁttings are seated, then tighten the nut hand tight as shown in ﬁgure 3.

Figure 2

Figure 3

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4.02 TWECO® MIG-KWIK CONNECTION AND ADAPTER KIT INSTALLATION

Installation of a Tweco MIG gun with a Tweco connector plug, may require an adapter kit. Choose the correct adapter kit for your wire feeder from the Adapter Kit Listing Form No. TLAK-97 for more detail. To install, follow the instructions furnished with the adapter kit. Figure 4 shows the general adapter kit installation.

Receptacle (TLAK-1 or 6TLAK-1)

Receptacle (TAK-1 or 6TAK-1)

ADAPTER PLUG

WIRE FEEDER

GAS HOSE

POWER CABLE

CONTROL WIRE

MIG GUN

Figure 4

1. Screw adapter plug into the receptacle and tighten.

2. Insert the adapter plug and receptacle into the wire feeder wire guideout. Tighten the wire guide attachment screw.

3. If needed, attach a proper sized welding cable from the welding power source to the receptacle power connection.

4. Attach a gas hose to the receptacle and to the feeder gas solenoid.

NOTE

When using an adapter kit, the gas must be attached to the receptacle to provide gas to the MIG gun. If the feeder gas supply is attached to the feeder wire guideout block, it must be rerouted to the receptacle.

5. Insert the MIG gun rear connection plug into the receptacle and tighten the attachment screw.

6. Attach the control wire plug assembly to the wire feeder MIG gun control circuit. Then plug the ﬂat double female plug into the MIG gun.

The gun should now be installed and ready to feed wire as recommended by the feeder manufacturer.

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SECTION 5: REPLACEMENT INSTRUCTIONS

5.01 REPLACING VELOCITY CONTACT TIP

CAUTION

While nozzle and contact tip are removed, maintain an adequate distance of the wire from metal objects to avoid burnbacks to conduit or conductor tube.

1. Remove worn nozzle and tip. (Clean nozzle if reusing.)

2. Slide new contact tip over the conduit end and into the conductor tube end.

3. Replace the nozzle. Hand tighten

(Nozzle secures tip).

NOTE

For proper operation the nozzle MUST be tight.

4. Trim wire to desired stick out.

The MIG gun is now ready operation.

5.02 REPLACE CONDUCTOR TUBE

The conductor tube is attached to the Tweco® Fusion handle by two set screws on the side of the handle. To remove:

1. Remove the front end consumables from the conductor tube.

2. Loosen the conduit liner set screw with a 5/64" Allen wrench (supplied) and then loosen the socket head cap screw securing the conductor tube in place inside the handle with a 5/32" Allen wrench.

3. Remove conductor tube.

4. Slide the new tube over the liner and insert into the brass connection within the handle. Conﬁrm the tube is correctly aligned with the MIG Gun handle and wrench tighten the socket head cap screw.

5. Tighten the conduit set screw down against the liner. Do not overtighten to avoid damaging the liner.

6. Re-assemble the front end consumables.

The MIG gun is now ready for operation.

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Conduit liner set screw

Socket head cap screw

5.03 CONDUIT IDENTIFICATION AND REPLACEMENT

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:

44-116-15

44 Series

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

Liner length in feet

Conduit Removal

1. Lay the MIG 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. Remove the nozzle and tip.

NOTE

On Miller® Direct Plug MIG guns, remove the nipple on the end of the connector plug. On Euro-Kwik connections, remove the conduit retaining cap.

3. Loosen the conduit set screw in the front of the gun. This is usually located at the front of the handle. Then loosen the conduit set screw in the rear connector plug.

4. Grip the conduit stop and remove the conduit with a twisting motion. On Miller® Direct Plug MIG guns, twisting the rear of the gun approximately one revolution clockwise will raise the conduit stop out of the connector plug recess.

Conduit Installation - Velocity Contact Tip Style

WARNING

Failure to follow Conduit Installation Instructions will cause wire feed issues.

1. Uncoil the conduit and lay it in a straight line. Insert the conduit into the rear connector plug. Push the conduit into the gun with short strokes.

NOTE

If the conduit hangs up gently whip the cable while applying pressure to the conduit. New liners must be cut to the correct length.

2. When the conduit is completely in the gun, tighten the rear conduit set screw. On Miller® guns, reinstall the nipple. On Euro-Kwik guns, reinstall the conduit retaining cap.

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IMPORTANT!

3. The new conduit liner will need to be cut to length. This can be done by trimming the conduit to the appropriate length.

1/8” (3,2 mm)

Velocity

Conductor Tube

4. File the cut conduit end to remove burrs.

5. Replace the contact tip.

6. Replace the nozzle. Hand tighten (Nozzle secures tip).

NOTE

For proper operation the nozzle MUST be tight.

The MIG gun is now ready to be reinstalled on the feeder.

5.04 REPLACING HANDLE, TRIGGER

Remove the MIG gun from the feeder prior to beginning these steps.

Handle screws Back Cap

Gun Hanger

1. Lay MIG gun on side, screw side up and remove both handle screws at the front of the gun handle.

2. Remove the small screw from the other side of the gun hanger clip and remove the gun hanger clip being careful to keep all internal components in place.

3. Lay the gun back down on its side and untwist the handle back cap.

4. Remove the top handle half being careful to keep all components in place in the lower handle half.

5. (Follow this step ONLY if the trigger is to be replaced.) Lift out the molded trigger, the trigger mechanism, and disconnect the lead wires. Connect the wires to the new trigger mechanism then place the molded trigger and new trigger in the lower handle half.

6. Place the new top handle half on the old lower handle half and gently ﬂip the gun over. Replace the old lower handle half with the new lower handle half. Molded trigger should move within the handle.

7. Flip the gun back to the screw side up and press the handle halves together until they bottom. Be careful not to pinch the trigger lead wires.

8. Put the gun hanger in place and install the two handle screws. Rotate the gun handle to the other side and install the small gun hanger clip screw.

9. Slide the Back Cap into place and twist onto the handle end.

The MIG gun is now ready to be reinstalled on the feeder.

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SECTION 6:

CABLEHOZ® REPAIR

6.01 TOOLS REQUIRED

6.02 REPAIR OF CABLEHOZ®

A. Back-End Repair

1. Disassemble the rear case to expose the rear connector assembly and pull the assembly away from the rear case.

2. Cut the Cablehoz® to remove the damaged area.

3. Use replacement connector assembly, Part No. MS172-RK (Stock No. 2060-

2134) on 250 Amp Tweco® Fusion MIG Guns.

4. Measure back 2-1/2" (63,5 mm) from the end of the Cablehoz and cut away the outer jacket of the cable, being careful not to cut the copper strands and or lead wires.

5. Pull the copper strands and lead wires away from the inner core tube that is exposed and cut away leaving approximately ¼" (6,35 mm) past the end of the end of the Cablehoz.

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6. Cut the copper strands to a length of ¾" (19,05 mm) while leaving the wire leads intact.

7. Thread the pressure nut onto the replacement rear connector until it bottoms out and then slide the sleeve over the connector.

Note: Make sure the bevel is facing the

right direction.

Bevel

8. Insert the replacement connector nipple into the inner core tube of the Cablehoz. It is recommended to use a small amount of non-petroleum based lubricant* to help the connector to slide into the tube. The core tube should bottom out against the shoulder, approximately 15/16" (23,8 mm) onto the connector.

*A small amount of white glue works well.

9. Push the copper strands underneath the sleeve. It is recommended that a 1/8” glass ﬁlament tape be wrapped around the exposed copper to keep the copper strands together when tightening the pressure nut.

10. Begin to turn the pressure nut counterclockwise which will force the copper strands & sleeve against and then under the machined taper on the connector.

Use Torque Wrench and wrench to

perform this task.

11. Torque the pressure nut to 250 inch pounds, +/-50 inch pounds, (28,2 newton meters, +/- 5,6 newton meters).

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12. Apply clamp over outside cable and tighten. Trim excess clamp.

13. Connect lead wires accordingly.

14. Re-assemble the rear case.

Approx.

0.2” (5mm)

B. Front-End Repair

1. Disassemble the front handle halves to expose the front connector assembly and pull the assembly from the front handle case.

2. Cut the Cablehoz® to remove the damaged area.

3. Use replacement connector assembly, Part No. MS102-RK (Stock No. 2060-

2132) on 250 Amp Tweco® Fusion MIG Guns.

4. Measure back 2-1/2” (63,5 mm) from the end of the Cablehoz and cut away the outer jacket of the cable, being careful not to cut the copper strands and or lead wires.

5. Pull the copper strands and lead wires away from the inner core tube that is exposed and cut away leaving approximately ¼” (6,35 mm) past the end of the end of the Cablehoz.

6. Cut the copper strands to a length of ¾” (19,05 mm) while leaving the wire leads intact.

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7. Thread the pressure nut onto the replacement front connector until it bottoms out and then slide the sleeve over the connector.

Note: Make sure the bevel is facing the

right direction.

Bevel

*A small amount of white glue works well.

10. Begin to turn the pressure nut counterclockwise which will force the copper strands & sleeve against and then under the machined taper on the connector.

Use Torque Wrench and wrench to

perform this task.

11. Torque the pressure nut to 250 inch pounds, +/-50 inch pounds, (28,2 newton meters, +/- 5,6 newton meters).

12. Apply clamp over outside cable and tighten. Trim excess clamp.

13. Connect lead wires accordingly.

14. Re-assemble the front end.

Approx.

2” (5mm)

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SECTION 7:

MAINTENANCE AND 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

Wire feed inconsistent or not smooth

1. Loose contact tip. 1. Tighten nozzle.

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

3. Spatter buildup on end of contact tip.

3. Clean or replace contact tip.

4. Sharp bends or kinks in conduit.

4. Straighten or replace conduit.

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

6. Conduit pulled back from contact tip.

6. Reposition conduit and cable.

7. Machine improperly adjusted. 7. Reset machine per machine

and wire manufacturers’ recommendations.

MIG Gun is running hot

1. Loose contact tip. 1. Tighten nozzle.

2. Loose power connections. 2. Inspect complete gun for loose

connections and repair.

3. Loose or undersize ground cable or ground clamp.

3. Tighten or replace as required.

4. Operating gun above recommended amperage rating.

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

5. Operating gun above recommended duty cycle rating.

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

Porous weld

1. Poor or improper gas flow. 1. Check gas flow out of gun nozzle. Check for leaks or restrictions in gas hoses and connections.

2. Dirty or contaminated wire. 2. Change wire.

3. Base metal contaminated. 3. Replace base metal.

Conduit gets hung-up inside of the gun

1. Burr on the end of the cut

conduit.

2. Conduit liner has kinks.

1. Remove the burr with a file.

2. Replace conduit.

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SECTION 8:

250 AMP REPLACEMENT PARTS

8.02 TWECO® FUSION 250 A MIG GUN PARTS

13b

13a

10a

11a

12a

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Item No. Part No. Stock No. Description

VNS-50 1220-1201 Velocity Nozzle

VNS-50F 1220-1200 Flush Velocity Nozzle

VNS-62 1220-1203 Velocity Nozzle

VNS-62F 1220-1202 Flush Velocity Nozzle

VNS-37 1220-1206 Velocity Nozzle

VNS-37F 1220-1204 Flush Velocity Nozzle

VNS-75FAS 1220-1205 Spot Welding Velocity Nozzle

** **

VTS-23 1110-1308 0.023” Velocity Contact Tip VTS-30 1110-1309 0.030” Velocity Contact Tip VTS-35 1110-1310 0.035” Velocity Contact Tip VTS-40 1110-1311 0.040” Velocity Contact Tip VTS-45 1110-1312 0.045” Velocity Contact Tip

VTSA-364 1110-1313 3/64” Velocity Contact Tip (for Aluminmum)

VTS-52 1110-1314 0.052” Velocity Contact Tip

VTS-116 1110-1315 1/16” Velocity Contact Tip

VTSA-116 1110-1317 1/16” Velocity Contact Tip (for Aluminmum)

VTS-564 1110-1316 5/64” Velocity Contact Tip

** **

FVCT-S45 1620-1369 Velocity 45° Conductor Tube

FVCT-S60 1620-1368 Velocity 60° Conductor Tube 6 F84 2060-2126 Handle – Standard 7 ELC94 2060-2647 Trigger– Standard 8 ELC94-BL 2060-2671 Trigger Blade Assembly

MS210 1720-2115 Cablehoz® Assembly - 10 ft (3 m) MS212 1720-2116 Cablehoz Assembly - 12 ft (4 m) MS215 1720-2117 Cablehoz Assembly - 15 ft (5 m)

MS225 1720-2118 Cablehoz Assembly - 25 ft (8 m) MS212X 1720-2107 Cablehoz Assembly, Euro-Kwik - 12 ft (4 m) MS215X 1720-2108 Cablehoz Assembly, Euro-Kwik - 15 ft (5 m) MS225X 1720-2109 Cablehoz Assembly, Euro-Kwik - 25 ft (8 m)

9a MS102-RK 2060-2132 Cablehoz Front Mechanical Connector Replacement Kit 9b MS172-RK 2060-2134 Cablehoz Rear Mechanical Connector Replacement Kit

9c 172X-M 2020-2181 Cablehoz Rear Mechanical Connector Replacement Kit For Euro-Style

10a 350-174MH 2035-2111 Miller® Rear Connector 10b WM-354M 2030-2075 Miller Control Wire & Plug

11a 350-174H 2035-2110 Tweco® Rear Connector 11b MS354-TAJ 2060-2139 Tweco Control Wire

12a 350-174LH 2035-2112 Lincoln® Rear Connector 12b MS-354DS-LJ 2060-2137 Lincoln Control Wire & Plug

174EX-1 2040-2276 Euro-Kwik Connection Assy

13a 174X-2 2040-2177 Euro-Kwik Nut

13b X6RC 2060-2006 Euro-Kwik Connector Case 14 ** ** Conduit 15 152 2020-2152 Gun Hanger

NS = Not Shown

** Refer to Tweco Catalog No. for speciﬁc parts. * Patent Pending

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8.02 TWECO® FUSION MIG GUN CONSUMABLES

VNS-50F

5/8” (15,9 mm)

VNS-37

3/8” (9,5 mm)5/8” (15,9 mm)

VNS-75FAS

VNS-50

1/2” (12,7 mm) 1/2” (12,7 mm)

VNS-37F

3/8” (9,5 mm)

VNS-62F

VNS-62

3/4” (19,1 mm)

60° FVCTS60

45° FVCTS45

VTSARZT30

Velocity Tip

Blank=CU, RZ=CHROM ZIR, RS=SILVER ZIR

T=Tapered, Blank=None

S=Small, M=Medium, L=Large

A=Alum, Blank=Other

Wire Size: 23=0.023” 116=1/16” 30=0.030” 564=5/64” 35=0.035” 332=3/32” 40=0.040” 764=7/64” 45=0.045” 18=1/8”

52=0.052” 364=3/64”

Blank=Standard, H=Heavy Duty

VNSH50FS

Velocity Nozzle

Blank=Std Recess, F=Flush, P=Protrude, R= Recess ¼” (6.35mm) FAS=Spot Weld

S=Small Nozzle, M=Medium Nozzle, L=Large Nozzle

Oriﬁce Opening Size: 37=3/8” 62=5/8” 50=1/2” 75=3/4”

Blank=Threaded, S=Slip

VELOCITY CONTAC T TIP IDENTIFICATION

VELOCITY NOZZLE IDENTIFICATION

Velocity

Nozzle

Velocity

Contact Tip

VTS-23

VTS-45

VTSA-116

VTS-564

VTS-52

VTS-116

VTS-364

VTS-35

VTS-40

VTS-30

Replacement Conductor Tubes

250A MIG GUN

OPTIONAL

STANDARD

VNS-FC

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SECTION 9:

STATEMENT OF WARRANTY

9.01 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. Victor Technologies, Inc. reserves the right to request documented evidence of date of purchase.

Engine Driven Welders

Parts / Labor

Scout®, Rraider®, Explorer

™

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

1 year / 1 year

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.

See the Engine

Manufacturers’ Warranty for

Details

GMAW/FCAW (MIG) Welding Equipment

Parts / Labor

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

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

Parts / Labor

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

1 year / 1 year

Plasma Welding Equipment

Parts / Labor

Ultima® 150

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

1 year / 1 year

SMAW (Stick) Welding Equipment

Parts / Labor

Dragster™ 85

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

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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

3 years / NA

CutSkill

2 years / NA 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

1 year from date sold

by seller to authorized

distributor

MIG Torches and Arc Accessories Parts / Labor

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

Plasma Cutting Systems Parts / Labor

Automated Plasma 2 years / 1 year CutMaster

™

3 years / 3 years PakMaster® XL PLUS 3 years / 1 year Drag-Gun

1 year / 1 year Drag-Gun Plus 2 years / 1 year Torches 1 year / 1 year Consoles, Control Equipment, Heat Exchangers and Accessory Equipment 1 year / 1 year

+ 61 hidden pages

Tweco FUSION 250 Safety And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual