AIR-COOLED
250 AMP
350 AMP
450 AMP
SPRAY MASTER®
MIG GUN
SAFETY AND
OPERATING
INSTRUCTIONS
English
Français
Español
Revision: AC Issue Date: 9-2016 Manual No.:
89200009
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 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, an ESAB Brand, is a global manufacture of welding products. We
manufacture and supply to major welding industry sectors worldwide, including:
Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural
and DIY/Hobbyist.
We distinguish ourselves from our competition through market-leading, dependable
products that have stood the test of time. We pride ourselves on technical innovation,
competitive prices, excellent delivery, superior customer service and technical
support, together with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced products to
achieve a safer working environment within the welding industry.
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before
installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s judgment,
the Manufacturer assumes no liability for its use.
Spray Master® MIG Guns
Safety and Operating Instructions
Instruction Guide Number 89200009
Published by:
ESAB Group Inc.
2800 Airport Rd.
Denton, TX. 76208
(940) 566-2000
www.tweco.com
U.S. Customer Care: (800) 426-1888
International Customer Care: (940) 381-1212
Copyright © 2009 ESAB. 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.
For Printing Material Specication refer to document 47X1920
Publication Date: July 20, 2009
Revision Date: 9-2016
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Equipment Serial #:
i
DECLARATION OF CONFORMITY
TWECO®, an ESAB Brand, declares under our sole responsibility that the product
Hand Held Air/Gas and Water Cooled MIG Welding Torches
To which this declaration relate(s) are in conformance with the following standards:
IEC 60974-7:2005
Following the provisions of the 73/23/EEC directive.
ii
Table of Contents
SECTION 1: INTRODUCTION ......................................................................................1
1.01 How to Use this Manual ................................................................... 1
1.02 Receipt of Equipment ....................................................................... 1
1.03 Description ....................................................................................... 1
SECTION 2: SAFETY PRECAUTIONS .........................................................................2
2.01 Security Measures ........................................................................... 2
2.02 Mesures de sécurité ......................................................................... 4
2.03 Precauciones de seguridad .............................................................. 6
SECTION 3: MIG GUN SPECIFICATIONS.....................................................................9
3.01 MIG Gun Classification ..................................................................... 9
3.02 Duty Cycles ..................................................................................... 9
SECTION 4: MIG GUN INSTALLATION ......................................................................11
4.01 Direct Plug MIG Gun Installation .................................................... 11
4.02 TWECO® MIG-Kwik Connection and Adapter Kit Installation .......... 12
SECTION 5: OPTIONAL FEATURES...........................................................................13
5.01 Dual Schedule ................................................................................ 13
5.02 Locking Trigger .............................................................................. 13
SECTION 6: REPLACE CONDUCTOR TUBE ...............................................................14
SECTION 7: WIRE CONDUIT REPLACEMENT ...........................................................15
7.01 Conduit Identification ..................................................................... 15
7.02 Conduit Removal ............................................................................ 15
7.03 Conduit Installation ........................................................................ 15
7.04 Repair of Cablehoz® ..................................................................... 16
SECTION 8: MAINTENANCE AND TROUBLESHOOTING............................................20
SECTION 9: CONSUMABLES ....................................................................................21
9.01 Nozzles ........................................................................................... 21
9.02 Contact Tips ................................................................................... 22
9.03 Conduit .......................................................................................... 22
9.04 Conductor tubes ............................................................................ 22
SECTION 10: REPLACEMENT PARTS ....................................................................... 24
SECTION 11: STATEMENT OF WARRANTY ..............................................................26
11.01 Warranty Schedule ......................................................................... 26
iii
This page intentionally blank.
iv
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 DANGER, 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!
An operation, procedure, or background information which requires additional emphasis
or is helpful in ecient operation of the system.
CAUTION
!
!
A procedure which, if not properly followed, may cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may cause injury to the operator or others in
the operating area.
WARNING
Gives information regarding possible electrical shock injury. Warnings will be enclosed in
a box such as this.
DANGER
Means immediate hazards which, if not avoided, will result in immediate, serious personal
injury or loss of life.
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 le 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
TWECO MIG Guns are furnished with rear connections to t 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 registered trademark of Illinois Tool Works, Inc.. Lincoln is a registered trademark of Lincoln Electric Co. The aforementioned registered trademarks are no way aliated with TWECO
products or ESAB. TWECO is a registered trademark of ESAB Group Inc.
189200009
SAFETY AND OPERATING INSTRUCTIONS
!
SECTION 2: SAFETY PRECAUTIONS
2.01 SECURITY MEASURES
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
!
ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH
Aluminized, protective clothing can become part of the electrical path. Keep oxygen cylinders, chains, wires, ropes,
cranes, and hoists away from any par t 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 o 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.
This product contains chemicals, including lead, or otherwise produces chemicals known
to the State of California to cause birth defects and other reproductive harm. Wash hands
after handling.
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 qualied
and/or trained personnel only.
Do not contact electrically live parts. Always wear dry welding gloves that are in good condition.
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 re and should never be used for ventilation.
See safety and operating references 1, 2, 3, and 4.
2
89200009
SAFETY AND OPERATING INSTRUCTIONS
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 lter lens provides the best protection against arc radiation. When in a conned
area, prevent the reected 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 cus 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 reective 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, ame, ying sparks, hot slag, and heated materials can cause re
and explosions. Remove combustibles from the work area and/or provide a re watch. Avoid oily
or greasy clothing as a spark may ignite them. Have a re 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 Oce, 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.
389200009
SAFETY AND OPERATING INSTRUCTIONS
!
2.02 MESURES DE SÉCURITÉ
AVERTISSEMENT
DES BLESSURES GRAVES OU MORTELLES peuvent résulter d’une installation, 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
!
UN CHOC ÉLECTRIQUE PEUT CAUSER DES BLESSURES OU LA MORT
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 vériées 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-élec trode 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.
LA FUMÉE, LES ÉMANATIONS ET LES GAZ PEUVENT ÊTRE DANGEREUX POUR VOTRE SANTÉ
d’appareils respiratoires à adduction d’air si la ventilation n’est pas susante 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 ns de
ventilation. Voir les références en matière de sécurité et d’utilisation n° 1, 2, 3 et 4.
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.
L’installation et l’entretien de l’équipement doivent être conformes au Code national de l’électricité NFPA
70 et aux codes locaux. N’eectuez 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 eectués uniquement par un technicien qualié ou par du personnel formé.
Ne touchez pas aux pièces électriques chargées. Portez toujours des gants de soudage au sec et
La ventilation doit être susante pour enlever la fumée, les émanations et les gaz pendant le
fonctionnement de la torche an 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
4
89200009
SAFETY AND OPERATING INSTRUCTIONS
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 ex trême 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 ltre de numéro
12 à 14 fournissent la meilleure protection contre le rayonnement de l’arc. Dans un endroit conné,
il faut éviter que les rayons reétés 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 eectuer de soudage ou de découpage et dans le cas des activités
intensives nécessitant de grandes électrodes. Les chaussures de sécurité montantes fournissent une protection susante
contre les brûlures aux pieds. Pour obtenir une plus grande protection, portez des guêtres en cuir. Il ne faut pas utiliser
de produits capillaires inammables avant d’eectuer 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 réectivité, 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 ammes, les vols d’étincelles, les scories chaudes et les
matériaux chaués 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 extinc teur 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’enammer 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
an d’évacuer tout l’air ou le gaz qui peut s’y trouver. Il est recommandé d’eectuer 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.
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 ecacement contre le bruit. Voir les références en matière de sécurité
et d’utilisation n° 1, 2 et 6.
589200009
SAFETY AND OPERATING INSTRUCTIONS
!
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 Oce, 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 Elec trical 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.
2.03 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
!
LAS DESCARGAS ELÉCTRICAS PUEDEN CAUSAR HERIDAS O LA MUERTE
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 vericar periódicamente todas las conexiones a tierra para determinar si están
mecánicamente rmes 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 conables 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
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.
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 calicado o entrenado..
No toque componentes eléctricos mientras están eléctricamente vivos. Siempre use guantes de
6
89200009
SAFETY AND OPERATING INSTRUCTIONS
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.
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 ltro número 12 a 14 ofrecen la mejor
protección contra la radiación del arco. Cuando trabaje en un área connada, evite que los rayos
reejados 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 inamables para el cabello cuando se suelde o cor te.
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 reexión, 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 cor te 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.
789200009
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. Ocina 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), Batter y 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.
8
89200009
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
SAFETY AND OPERATING INSTRUCTIONS
Duty Cycle
10% 320 435 570
35% 290 390 520
60% 250 350 450
100% 195 240 351
MIG Gun Model (AMP)
250 350 450
The above duty cycles were established by testing under the following parameters:
Parameter MIG MAG
Electrode Aluminum 3% to 5% Magnesium Mild (low carbon) Steel
Type of Voltage D.C. D.C.
Shielding Gas Argon Argon/CO2 Mixed Gas (80/20, 75/25)
Gas Flow Rate 30 CFH (14.2 l/m) 30 CFH (14.2 l/m)
Weld Material AIMg3 to AIMg5 Mild (low carbon) Steel
Gun Cable Length 10 ft. (3 m) 15 ft. (5 m)
Electrode Polarity Positive Positive
Wire Diameter
Electrode Size
250 amp =
.045" (1.2mm)
350 amp =
.045" (1.2mm)
450 amp =
1/16" (1.6mm)
989200009
SAFETY AND OPERATING INSTRUCTIONS
3.03 MIG GUN PART NUMBER IDENTIFICATION
NOTE!
TWECO MIG guns, as a general rule, have a specic nomenclature incorporated within each
part number to help determine the wire size of each MIG gun.
Example Part Number:
350 AMP, 15 foot (5 M) cable
MS3153545
Spray Master
.035"-.045" Wire Capacity
(0,9mm - 1,2mm)
10
89200009
SAFETY AND OPERATING INSTRUCTIONS
!
SECTION 4:
MIG GUN INSTALLATION
NOTE!
Be certain that the end user (welder, operator, or helper) reads and understands these
instructions. Be certain that the welder also reads Section 2 “Safety Precautions.”
WARNING
Electric shock can cause injury or death.
WIRE FEEDER
GUN
POWER
SOURCE
GROUND
Figure 1: Standard MIG Gun Installation
WORK PIECE
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
gure 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 rst, then the gas
plug. Push until all ttings are seated, then tighten the nut hand tight as shown in gure 3.
Figure 2
1189200009
Figure 3
SAFETY AND OPERATING INSTRUCTIONS
4.02 TWECO® MIGKWIK 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. To install, follow the instructions furnished with the
adapter kit. Figure 4 shows the general adapter kit installation.
Receptacle
(TLAK-1 or 6TLAK-1)
WIRE FEEDER
Receptacle
(TAK-1 or 6TAK-1)
MIG GUN
GAS HOSE
CONTROL WIRE
ADAPTER PLUG
GAS HOSE
POWER CABLE
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 at
double female plug into the MIG gun.
The gun should now be installed and ready to feed wire as recommended by the feeder manufacturer.
12
89200009
SAFETY AND OPERATING INSTRUCTIONS
SECTION 5: OPTIONAL FEATURES
In addition to the standard Spray Master MIG gun, TWECO also makes a dual schedule gun and one with a locking
trigger, only oered in 350 and 450 AMP guns.
5.01 DUAL SCHEDULE
A rocker-style switch, located at the top of the handle, allows the user dual schedule functionality. To operate:
1. Press and hold trigger.
2. Press switch to change mode.
3. To end operation, hold trigger and press switch back to original position.
5.02 LOCKING TRIGGER
A steel pin is located on the side of the handle, in close proximity to the trigger.
To lock trigger:
1. Press and hold trigger.
2. Press steel pin down completely and release trigger to lock.
3. To unlock, press trigger completely and steel pin will release out to original position.
1389200009
SAFETY AND OPERATING INSTRUCTIONS
SECTION 6: REPLACE CONDUCTOR TUBE
The conductor tube is attached to the Spray Master handle by two set screws on the side of the handle. To remove:
1. 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. Refer to
the gure below.
2. Remove conductor tube.
3. With the front end consumables removed from the conductor tube. Slide the tube over the liner and
insert into the brass connection within the handle. Tighten the socket head cap screw wrench tight.
4. Tighten the conduit set screw down against the liner. Do not overtighten to avoid damages the liner.
Conduit liner set screw
Socket head cap screw
14
89200009
SAFETY AND OPERATING INSTRUCTIONS
SECTION 7: WIRE CONDUIT REPLACEMENT
7.01 CONDUIT IDENTIFICATION
The procedure for removal and installation of a wire conduit is similar for all TWECO MIG guns. Conduits may be identied
by the type of conduit stop and the part number marking on each conduit stop.
Example Part Number:
1/16" (1,6mm) Wire Capacity
44-116-15
44 Series
Liner length in feet
7.02 CONDUIT REMOVAL
1. Lay the MIG gun out on a table or on the oor in a straight line. Make sure the gun is fully extended and
all twists in the cable are removed.
2. Remove the nozzle and loosen the conduit set screw in the front of the gun. This is usually located in
the diuser, or at the front of the handle. Then loosen the conduit set screw in the rear connector plug.
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. Remove the diuser and contact tip.
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.
7.03 CONDUIT INSTALLATION
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. If the conduit hangs up, twist the conduit counterclockwise or gently whip the
cable while applying pressure to the conduit.
2. The conduit liner will need to be cut to length. This can be done by cutting the conduit to match the one
removed or inserting the new liner through the MIG gun and trimming the conduit extending from the
conductor tube to the appropriate length noted in the following chart.
3. 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.
Conduit Cut Lengths
250 amp = 1.125"
(28.6 mm)
4. File the cut conduit end to remove burrs because they could interfere with wire feeding or catch on the
diuser.
5. Replace the diuser and contact tip and tighten the nozzle.
The MIG gun is now ready to be reinstalled on the feeder.
350 amp = 1.25"
(28.6 mm)
1589200009
450 amp = 0.5"
(12.7 mm)
SAFETY AND OPERATING INSTRUCTIONS
7.04 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
Spray Master MIG Guns and MS174-RK (Stock No.
2060-2135) on 350 & 450 Amp Spray Master MIG
Guns.
4. Measure back 2-1/2” (63.5mm) 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’s exposed and cut away
leaving approximately ¼” (6.35mm) past the end
of the end of the Cablehoz.
6. Cut the copper strands to a length of ¾” (19.05mm)
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 that the end with the bevel on the inside diameter goes on rst allowing
the opposite end with a ¾” (19.05mm) to be facing the Cablehoz when assembled.
16
89200009
SAFETY AND OPERATING INSTRUCTIONS
8. Insert the replacement connector into the inner
core tube of the Cablehoz. It’s recommended to use
a small amount of lubricant to help the connector
to slide into the tube. The core tube should bottom
out against the shoulder, approximately 15/16”
(23.8mm) onto the connector.
9. Push the copper strands underneath the sleeve. It’s recommended that a 1/8” glass lament tape be
wrapped around the exposed copper to keep the copper strands together.
10. Begin to turn the pressure nut counter-clockwise
which will force the copper strands & sleeve
against the machined taper on the connector.
11. Torque the pressure nut to 250 inch pounds (+/-50 inch pounds).
12. Connect lead wires accordingly.
13. Reassemble the rear case.
1789200009
SAFETY AND OPERATING INSTRUCTIONS
B. Front-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.
MS102-RK (Stock No. 2060-2132) on 250 Amp
Spray Master MIG Guns and MS104-RK (Stock No.
2060-2133) on 350 & 450 Amp Spray Master MIG
Guns.
4. Measure back 2-1/2” (63.5mm) 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’s exposed and cut away
leaving approximately ¼” (6.35mm) past the end
of the end of the Cablehoz.
6. Cut the copper strands to a length of ¾” (19.05mm)
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 that the end with the bevel on the inside diameter goes on rst allowing
the opposite end with a ¾” (19.05mm) to be facing the Cablehoz when assembled.
18
89200009
SAFETY AND OPERATING INSTRUCTIONS
8. Insert the replacement connector into the inner
core tube of the Cablehoz. It’s recommended
to use a small amount of lubricant to help
the connector to slide into the tube. The core
tube should bottom out against the shoulder,
approximately 15/16” (23.8mm) onto the
connector.
9. Push the copper strands underneath the sleeve. It’s recommended that a 1/8” glass lament tape be
wrapped around the exposed copper to keep the copper strands together.
10. Begin to turn the pressure nut counter-clockwise
which will force the copper strands & sleeve
against the machined taper on the connector.
11. Torque the pressure nut to 250 inch pounds (+/-50 inch pounds).
12. Connect lead wires accordingly.
13. Re-assemble the front end back into the handle halves.
1989200009
SAFETY AND OPERATING INSTRUCTIONS
SECTION 8: 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 ow.
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 decient.
Problem Possible Cause Corrective Action
1. Loose contact tip or diuser. 1. Tighten contact tip and diuser plier
tight.
2. Excessively worn contact tip. 2. Replace contact tip.
Wire feed inconsistent or not
smooth
MIG Gun is running hot
Porous weld
3. Spatter buildup on end of 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 diuser. 6. Reposition conduit and tighten front set
7. Machine improperly adjusted. 7. Reset machine per machine and wire
1. Loose contact tip or diuser. 1. Tighten contact tip and diuser plier
2. Loose power connections. 2. Inspect complete gun for loose
3. Loose or undersize ground cable or
ground clamp.
4. Operating gun above recommended
amperage rating.
1. Poor or improper gas ow. 1. Check gas ow out of gun nozzle. Check
2. Dirty or contaminated wire. 2. Change wire.
3. Base metal contaminated. 3. Replace base metal.
3. Clean or replace contact tip.
screw.
manufacturers’ recommendations.
tight.
connections and repair.
3. Tighten or replace as required.
4. Readjust machine to correct setting for
size of gun being used.
for leaks or restrictions in gas hoses and
connections.
20
89200009
SAFETY AND OPERATING INSTRUCTIONS
SECTION 9: CONSUMABLES
9.01 NOZZLES
250 AMP
Nozzle Style
Standard, Slip-On
1/8" Tip Recess
Optional, Slip-On
Tip Flush
3/8" (9.5 mm) 1/2" (12.7 mm) 5/8" (15.9 mm)
HD22-37
1220-1305
HD22-37F
1220-1310
Furnished standard with 1/2" (12.7 mm) bore nozzle, HD22-50. Fits D iuser HD52-11 (1520-1130). Interchangeable front end
by changing diusers.
350 AMP
Bore Size
HD22-50
1220-1306
HD22-50F
1220-1311
HD22-62
1220-1307
HD22-62F
1220-1312
Nozzle Style
Standard, CT
1/8" Tip Recess
Optional, CT
Tip Flush
Optional, CT
Tip Protruded
Optional, CT
Heavy Duty
3/8" (9.5 mm) 1/2" (12.7 mm) 5/8" (15.9 mm) 3/4" (19.1 mm)
EL22CT-37
1260-1625
N/A
EL22CT-50
1260-1626
EL22CT-50F
1260-1636
EL22CT-50P
1260-1691
N/A
Bore Size
EL22CT-62
1260-1627
EL22CT-62F
1260-1637
EL22CT-62P
1260-1692
EL22CT-62H
1260-1629
EL22CT-75
1260-1628
N/A
N/A
N/A
Furnished standard with 5/8" (15.9 mm) bore nozzle, EL22CT-62. Fits diuser EL52CT-16 (1560-1107) Interchangeable front
end by changing diusers or conductor tubes.
450 AMP
Nozzle Style
Standard, Slip-On
1/8" Tip Recess
Optional, Slip-On
Tip Flush
Optional, Slip-On
1/8" Tip Recess
Heavy Duty
Optional, Slip-On
Tip Flush
Heavy Duty
3/8" (9.5 mm) 1/2" (12.7 mm) 5/8" (15.9 mm)
HD24L-50
1240-1200
HD24L-50F
1240-1204
HD24-50
1240-1240
Furnished standard with 5/8" (15.9 mm) bore nozzle, HD24L-62. Fits diuser HD54-16 (1540-1136). Interchangeable front
end by changing diusers or conductor tubes. May use consumables from TWECO standard #4 gun or TWECO Eliminator (by
changing MS64-60 conductor tube).
Bore Size
HD24L-62
1240-1201
HD24L-62F
1240-1205
HD24-62
1240-1241
HD24-62F
1240-1236
HD24L-75
1240-1202
HD24L-75F
1240-1206
HD24-75
1240-1242
HD24-75F
1240-1237
2189200009
SAFETY AND OPERATING INSTRUCTIONS
9.02 CONTACT TIPS
Wire Size
in (mm)
.023" (0.6mm) .031" (0.79mm) 11-23 1110-1100
.030" (0.8mm) .038" (0.97mm) 11H-30 1110-1201
.035" (0.9mm) .044" (1.12mm) 11H-35 1110-1202 16S-35 1160-1102
.040" (1.0mm) .048" (1.22mm) 11H-40 1110-1203 16S-40 1160-1103
.045" (1.2mm) .054" (1.37mm) 11H-45 1110-1204 16S-45 1160-1104
.052" (1.3mm) .064" (1.65mm)
1/16" (1.6mm) .073" (1.85mm) 16S-116 1160-1106
5/64" (2.0mm) .090" (2.29mm) 16S-564 1160-1109
3/64" (1.2mm) AL .059" (1.50mm) 11AH-364 1110-1213 16AS-364 1160-1113
1/16" (1.6mm) AL .082" (2.08mm) N/A 16AS-116 1160-1114
Tip I.D.
in (mm)
250 AMP 350 AMP / 450 AMP
Part No. Stock No. Part No. Stock No.
N/A
16S-52 1160-1105
N/A
9.03 CONDUIT
250 AMP
Wire Size
in (mm)
.023" (0.6mm) 42-23-15 1420-1103
.040" - .045" (1.0mm - 1.2)mm 42-4045-15 1420-1123
.035" - 3/64" (0.9mm - 1.2mm) 42N-3545-15 1420-1003 Aluminum
350 AND 450 AMP
Wire Size
in (mm)
.035" - .045" (0.9 mm- 1.2mm) 44-3545-15 1440-1103
5/64" (2.0mm) 44-564-15 1440-1123
.030" - 3/64" (0.8mm - 1.2mm) 44N-3545-15 1440-1003 Aluminum
Part No. Stock No. Type
Part No. Stock No. Type
Steel.030" - .035" (0.8mm - 0.9mm) 42-3035-15 1420-1113
Steel.052" - 1/16" (1.3mm - 1.6mm) 44-116-15 1440-1113
9.04 CONDUCTOR TUBES
250 AMP 350 AMP 450 AMP
MS63-60S / 1630-1196 MS63-60 / 1630-1189 MS64H-60 / 1640-1319
Rigid Style
Rigid Style*
Knucklehead™
(Flexible)
*For use with Eliminator® Style Consumables
MS63-45S / 1630-1195 MS63-45 / 1630-1188 MS64H-45 / 1640-1318
MS62SFLX3-60 / 1620-1341 MS63SFLX3-60 / 1630-1197 MS64SFLX3-60 / 1640-1307
MS62SFLX4-80 / 1620-1342 MS63SFLX4-80 / 1630-1198 MS64SFLX4-80 / 1640-1308
MS63-180 / 1630-1187 MS64H-180 / 1640-1314
MS64-60 / 1640-1340
MS64-45 / 1640-1341
MS64SFLX3-60LR / 1640-1309
MS64SFLX4-80LR / 1640-1310
22
89200009
SAFETY AND OPERATING INSTRUCTIONS
This page intentionally blank.
2389200009
SAFETY AND OPERATING INSTRUCTIONS
SECTION 10: REPLACEMENT PARTS
12a
12
11a
14
10
13
13b
13a
10a
11
7
8
7a
9b
9
9c
6
9a
5
4
3
4
24
2
3
2
1
1
89200009
SAFETY AND OPERATING INSTRUCTIONS
Item No. 250 AMP 350 AMP 450 AMP Description
1 -- -- -- Nozzles – Refer to Section 9
2 -- -- -- Contact Tips – Refer to Section 9
3
4
5 -- -- -- Conductor Tube – Refer to Sec tion 9
6
7
7b N/A
8
9
9a
9b
9c
10a
10b
NS N/A
11a
11b
NS
12a
12b
13
13a
13b
14 -- -- -- Conduit – Refer to Section 9
NS = Not Shown
HD52-11
1520-1130
63J-3
1630-1121
MS84
2060-2130
N/A
MS84-LC
2060-2127
ELC94
2060-2647
MS94-LC
2060-2693
ELC94-BL
2060-2671
N/A
MS212
1720-2116
MS215
1720-2117
MS225
1720-2118
MS212X
1720-2107
MS215X
1720-2108
MS225X
1720-2109
MS102-RK
2060-2132
MS172-RK
2060-2134
172X-M
2020-2181
350-174MH
2035-2111
WM-354M
2030-2075
350-174H
2035-2110
MS354-TAJ
2060-2139
MS-354DS-TJ
2060-2138
350-174LH
2035-2112
MS-354DS-LJ
2060-2137
174EX-1
2040-2276
174X-2
2040-2177
X6RC
2060-2006
EL52CT-16
1560-1107
63J-3
1630-1121
MS84
2060-2130
MS84-DSRS
2060-2128
MS84-LC
2060-2127
ELC94
2060-2647
MS94-LC
2060-2693
MS94-RSW
2060-2694
ELC94-BL
2060-2671
MS310
1730-2035
MS312
1730-2036
MS315
1730-2037
MS325
1730-2038
N/A
N/A
N/A N/A Cablehoz Assembly, Euro-Kwik - 25 ft (8 m)
MS104-RK
2060-2133
MS174-RK
2060-2135
174X-M
2040-2181
350-174MH
2035-2111
WM-354M
2030-2075
194DS
2040-2195
350-174H
2035-2110
MS354-TAJ
2060-2139
MS-354DS-TJ
2060-2138
350-174LH
2035-2112
MS-354DS-LJ
2060-2137
174EX-1
2040-2276
174X-2
2040-2177
X6RC
2060-2006
MS54-16W
1540-1127
66J-3
1660-1836
MS84
2060-2130
MS84-DSRS
2060-2128
MS84-LC
2060-2127 Handle – Locking Trigger
ELC94
2060-2647
MS94-LC
2060-2693
MS94-RSW
2060-2694
ELC94-BL
2060-2671
N/A Cablehoz® Assembly - 10 ft (3 m)
MS412
1740-2116
MS415
1740-2117
MS425
1740-2118
MS412X
1740-2122
MS415X
1740-2123
MS104-RK
2060-2133
MS174-RK
2060-2135
174X-M
2040-2181
350-174MH
2035-2111
WM-354M
2030-2075
194DS
2040-2195
350-174H
2035-2110
MS354-TAJ
2060-2139
MS-354DS-TJ
2060-2138
350-174LH
2035-2112
MS-354DS-LJ
2060-2137
174EX-1
2040-2276
174X-2
2040-2177
X6RC
2060-2006
Gas Diuser
Insulator
Handle – Standard Spray Master
Handle – Dual Schedule (Rocker Switch)
Trigger– Standard & Dual Schedule
Trigger – Locking
Dual Schedule Rocker Switch
Trigger Blade Assembly
Cablehoz Assembly - 12 ft (4 m)
Cablehoz Assembly - 15 ft (5 m)
Cablehoz Assembly - 25 ft (8 m)
Cablehoz Assembly, Euro-Kwik - 12 ft (4 m)
Cablehoz Assembly, Euro-Kwik - 15 ft (5 m)
Cablehoz Front Mechanical Connector Replacement Kit
Cablehoz Rear Mechanical Connector Replacement Kit
Cablehoz Rear Mechanical Connector Replacement Kit
For Euro-Style
Miller® Rear Connector
Miller Control Wire & Plug
Miller Dual Schedule Control Wire & Plug
TWECO Rear Connector
TWECO Control Wire
TWECO Dual Schedule Control Wire & Plug
Lincoln® Rear Connector
Lincoln Control Wire & Plug
Euro-Kwik Connection Assy
Euro-Kwik Nut
Euro-Kwik Connector Case
2589200009
SAFETY AND OPERATING INSTRUCTIONS
SECTION 11: STATEMENT OF WARRANTY
11.01 WARRANTY SCHEDULE
The warranty is eective below for the time stated in the Warranty Schedule beginning on the date that the
authorized distributor delivers the products to the purchaser. ESAB reserves the right to request documented
evidence of date of purchase.
Engine Driven Welders
Scout®, Rraider®, Explorer
Original Main Power Stators and Inductors 3 years / 3 years
Original Main Power Rectiers, 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.
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
Original Main Power Transformer and Inductor 5 years / 3 years
Original Main Power Rectiers, 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, 400MST, 300MST, 400MSTP
Original Main Power Magnetics 5 years / 3 years
Original Main Power Rectiers, 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
Ultima® 150
Original Main Power Magnetics 5 years / 3 years
Original Main Power Rectiers, 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
Original Main Power Magnetics 1 year / 1 year
Original Main Power Rectiers, 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
160S, 300S, 400S Parts / Labor
Original Main Power Magnetics 5 years / 3 years
Original Main Power Rectiers, 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
™
®
Parts / Labor
1 year / 1 year
See the Engine Manufacturers’
Warranty for Details
Parts / Labor
Parts / Labor
Parts / Labor
1 year / 1 year
Parts / Labor
1 year / 1 year
1 year / 1 year
26
89200009
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
MIG Torches and Arc Accessories Parts / Labor
Arcair® N6000 90 days / NA
Spool and Pull Guns 90 days / NA
Robotic Deection 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
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
3 years / 3 years
1 year / 1 year
2789200009
SAFETY AND OPERATING INSTRUCTIONS
This page intentionally blank.
28
89200009
SAFETY AND OPERATING INSTRUCTIONS
This page intentionally blank.
2989200009
ESAB subsidiaries and representative oces
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 70 233 075
Fax: +32 15 257 944
BULGARIA
ESAB Kft Representative Oce
Soa
Tel/Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacic
AUSTRALIA
ESAB South Pacic
Archereld BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tok yo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacic Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
Distributors
For addresses and phone numbers
to our distributors in other countries, please visit our home page
www.esab.eu
©2009 ESAB Welding and Cutting Products
Loading...