AIR-COOLED MIG GUN 250 AMP, 350 AMP, 450 AMP
SPRAY MASTER™
WITH VELOCITY CONSUMABLES
MIG GUNS
CURRENT
UP TO
450
AMPS
WIRE SIZE
UP TO
3
/
32
(2.4 mm)
DUTY CYCL E
UP TO
"
80
%
Safety and
Operating
Instructions
IMPORTANT: Included inside - special
instructions for NEW consumables.
Revision: AA Issue Date: May 15, 2014 Manual No.: 89200016
Tweco.com
WE APPRECIATE YOUR BUSINESS!
Congratulations on receiving your new Tweco Spray Master™ 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 market-leading 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
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™ with Velocity MIG Guns
Safety and Operating Instructions
Instruction Guide Number 89200016
Published by:
Victor Technologies, Inc.
2800 Airport Rd.
Denton, TX. 76208
(940) 566-2000
www.Tweco.com
WARNING
U.S. Customer Care: (800) 426-1888
International Customer Care: (940) 381-1212
Canada Customer Care: 905-827-4515 / fax 800-588-1714
Copyright © 2014 Victor Technologies, Inc. All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss
or damage caused by any error or omission in this Manual, whether such error results from
negligence, accident, or any other cause.
Publication Date: May 15, 2014
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Equipment Serial #:
i
Table of Contents
SECTION 1: SAFETY PRECAUTIONS ..........................................................................2
Mesures de sécurité ......................................................................... 2
SECTION 2: INTRODUCTION ......................................................................................4
2.01 How to Use this Manual ................................................................... 4
2.02 Receipt of Equipment ....................................................................... 4
2.03 Description ....................................................................................... 4
SECTION 3: MIG GUN SPECIFICATIONS.....................................................................4
3.01 MIG Gun Classification ..................................................................... 4
3.02 Duty Cycle ........................................................................................ 4
3.03 MIG Gun Part Number Identification ................................................ 4
SECTION 4: MIG GUN INSTALLATION ........................................................................4
4.01 Direct Plug MIG Gun Installation ...................................................... 4
SECTION 5: SPRAY MASTER WITH VELOCITY MAINTENANCE .................................5
5.01 Installing or Replacing Velocity Contact Tip ..................................... 5
5.02 Conduit Identification ....................................................................... 5
Conduit Removal .............................................................................. 5
Conduit Installation .......................................................................... 5
5.03 Installing/Replacing Stainless Steel Sleeve ...................................... 5
5.04 Replace Conductor Tube .................................................................. 6
SECTION 6: CABLEHOZ® REPAIR .............................................................................6
6.01 Cablehoz® Repair ............................................................................ 6
SECTION 7: TROUBLESHOOTING ...............................................................................6
SECTION 8: CONSUMABLES ......................................................................................6
8.01 Replacement Kits ............................................................................. 6
8.02 Tips and Nozzles .............................................................................. 6
8.03 Conduit ............................................................................................ 7
8.04 Conductor tubes .............................................................................. 7
SECTION 9: REPLACEMENT PARTS ...........................................................................8
SECTION 10: STATEMENT OF WARRANTY ................................................................9
10.01 Warranty Schedule ........................................................................... 9
SECTION 1: 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
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 : Ce produitcontient des produits chimiques, notamment du plomb, reconnu
par l'Étatde la Californie pour causerdes malformations congénitaleset d'autresdommages
touchant le système reproductif. Se laver les mainsaprès manipulation.
UN CHOC ÉLECTRIQUE PEUT CAUSER DES BLESSURES OU LA MORT
L’installation et l’entretien de l’équipement doivent être conformes au Code national
de l’électricité NFPA 70 et aux codes locaux. N’effectuez pas l’entretien ou la
réparation d’équipement en marche. N’opérez pas l’équipement sans isolateurs ou
caches de protection. L’entretien ou la réparation de l’équipement doivent être
effectués uniquement par un technicien qualifié ou par du personnel formé.
Ne touchez pas aux pièces électriques chargées. Portez toujours des gants de soudage au sec
et en bon état. Les vêtements de protection aluminisés peuvent devenir une partie du chemin
électrique. Éloignez les bouteilles d’oxygène, les chaînes, les câbles métalliques, les appareils
de levage, les treuils et les élévateurs de toute partie du circuit électrique. Toutes les liaisons de
terre doivent être vérifiées périodiquement pour déterminer si elles sont solides et appropriées
2
AVERTISSEMENT
SAFETY AND OPERATING INSTRUCTIONS
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.
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.
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.
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.
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.
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.
au courant demandé. En cas de soudage ou de découpage en courant alternatif dans des
conditions d’humidité ou de chaleur où l’opérateur risque de transpirer, il est recommandé
d’utiliser des contrôles automatiques pour réduire la tension à vide et ainsi diminuer les
risques de choc électrique. Lorsque le procédé de soudage et de découpage exige des valeurs
de tension en circuit ouvert dans des machines à courant alternatif supérieur à 80 volts ou
dans des machines à courant continu supérieur à 100 volts, il faut prendre des mesures pour
empêcher un contact accidentel en prévoyant une isolation adéquate ou d autres moyens.
Lorsqu’il faut interrompre les activités de soudage pendant un certain temps, à l’heure du repas
ou la nuit, par exemple, il faut enlever toutes les électrodes du porte-électrode et mettre hors
tension l’alimentation pour éviter tout contact accidentel. Gardez les pistolets MIG, les porteélectrodes, les torches TIG, les torches à plasma et les électrodes loin de l’humidité et de l’eau.
LA FUMÉE, LES ÉMANATIONS ET LES GAZ PEUVENT ÊTRE DANGEREUX POUR VOTRE SANTÉ
La ventilation doit être suffisante pour enlever la fumée, les émanations et les
gaz pendant le fonctionnement de la torche afin protéger les opérateurs et les
autres personnes présentes dans la zone. Les vapeurs de solvants chlorés
peuvent former un gaz toxique appelé « Phosgène » si elles sont exposées au
rayonnement ultraviolet d un arc électrique. Il faut enlever de la zone de travail
tous les solvants, décapants et sources potentielles de ces vapeurs. Servez-vous d’appareils
respiratoires à adduction d’air si la ventilation n’est pas suffisante pour enlever toutes les
émanations et gaz. L’oxygène alimente les incendies et en accélère la propagation il ne faut
jamais l’utiliser à des fins de ventilation.
L LES RAYONS DE L’ARC, LES SCORIES ET LES ÉTINCELLES CHAUDS PEUVENT BLESSER
LES YEUX ET BRÛLER LA PEAU
Les procédés de soudage et de découpage produisent une chaleur extrême
localisée et de puissants rayons ultraviolets. N’essayez jamais de souder ou de
couper sans casque soudage conforme aux normes du gouvernement fédéral et
muni d’une lentille appropriée. Des lentilles à filtre de numéro 12 à 14
fournissent la meilleure protection contre le rayonnement de l’arc. Dans un endroit confiné, il
faut éviter que les rayons reflétés de l’arc n’entrent autour du casque. Il faut utiliser des rideaux
de protection approuvés et des lunettes de protection appropriées pour protéger les autres
personnes se trouvant aux abords. Il faut aussi protéger la peau nue des rayons de l’arc, de la
chaleur et du métal fondu. Portez toujours des gants et des vêtements de protection. Toutes les
poches doivent être fermées et les manchettes, cousues. Il faut porter un tablier, des manches,
des guêtres, etc. en cuir pour effectuer de soudage ou de découpage et dans le cas des activités
intensives nécessitant de grandes électrodes. Les chaussures de sécurité montantes fournissent
une protection suffisante contre les brûlures aux pieds. Pour obtenir une plus grande protection,
portez des guêtres en cuir. Il ne faut pas utiliser de produits capillaires inflammables avant
d’effectuer des activités de soudage ou de découpage. Portez des bouchons d’oreilles pour vous
protéger les oreilles des étincelles. Lorsqu’il est possible de le faire dans la zone de travail,
l’opérateur doit s’isoler dans une cabine individuelle recouverte d’un revêtement à faible
réflectivité, comme l’oxyde de zinc.
LES ÉTINCELLES DE SOUDAGE PEUVENT CAUSER DES INCENDIES ET DES EXPLOSIONS
Les combustibles atteints par l’arc, les flammes, les vols d’étincelles, les
scories chaudes et les matériaux chauffés peuvent causer des incendies et des
explosions. Enlevez les combustibles de la zone de travail ou mettez en place du
personnel de surveillance. Évitez les vêtements huileux ou graisseux, car une
étincelle peut y mettre le feu. Ayez un extincteur à proximité et sachez comment
l’utiliser. Si l’activité de soudage ou de découpage doit être fait contre un mur, une cloison, un
plafond ou un toit, il faut prendre des précautions pour d’enflammer des combustibles qui se
trouveraient à proximité, de l’autre côté. Ne soudez pas et ne coupez pas de conteneurs ayant
contenu des combustibles. Il faut aérer tous les espaces creux, les cavités et les conteneurs
avant de les soumettre au soudage ou au découpage afin d’évacuer tout l’air ou le gaz qui peut
s’y trouver. Il est recommandé d’effectuer une purge avec du gaz inerte. N’utilisez jamais
d’oxygène dans une tête de soudage. N’utilisez que des gaz inertes ou des mélanges de gaz
inertes, conformément aux exigences du procédé. L’utilisation de gaz combustibles comprimés
peut causer des explosions entraînant des blessures ou la mort. Le fait d’utiliser l’arc sur une
bouteille de gaz comprimé peut endommager la bouteille ou causer une explosion.
LE BRUIT PEUT ENDOMMAGER L’OUÏE
Le bruit du procédé de l’arc avec électrode en carbone et jet d’air peut
endommager l’ouïe. Portez un dispositif de protection de l’ouïe pour vous
protéger lorsque le niveau de bruit dépasse les normes de l’OSHA. Les
opérateurs et le personnel aux abords doivent porter un dispositif de protection
de l’ouïe approprié pour les protéger efficacement contre le bruit.
RÉFÉRENCES EN MATIÈRE DE SÉCURITÉ ET D’UTILISATION
1. Code of Federal Regulations (OSHA), section 29, partie 1910.95, 132, 133, 134, 139, 251, 252,
253, 254 et 1000. U.S. Government Printing Office, Washington, DC 20402.
2. ANSI Z49.1 « Safety in Welding and Cutting ».
3. ANSI Z87.1 « Practice for Occupational and Educational Eye and Face Protection ».
4. ANSI Z88.2. « Standard Practice for Respiratory Protection ». American National Standards
Institute, 1430 Broadway, New York, NY 10018.
5. AWS F4.1. « Recommended Safe Practices for Welding and Cutting Containers ».
6. AWS C5.3. « Recommended Practices for Air Carbon-Arc Gouging and Cutting ». The American
Welding Society, 550 NW Lejeune Rd., P.O. Box 351040, Miami, FL 33135.
7. NFPA 51B. « Fire Prevention in Cutting and Welding Processes ».
8. NFPA-7. « National Electrical Code » (code national de l’électricité). National Fire Protection
Association, Battery Park, Quincy, MA 02269.
9. CSA W117.2. « Règles de sécurité en soudage, coupage et procédés connexes ». Association
canadienne de normalisation, 178 boul. Rexdale, Rexdale, Ontario, Canada M9W 1R3.
3 89200016
SAFETY AND OPERATING INSTRUCTIONS
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.
2.03 DESCRIPTION
Tweco Spray Master 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 Spray Master 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 Spray Master 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 affiliated with Tweco Products, Inc. or Victor Technologies, Inc. Tweco
Spray Master is a registered trademark of Victor Technologies, Inc.
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
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.
WORK PIECE
SECTION 3: MIG GUN
SPECIFICATIONS
3.01 MIG GUN CLASSIFICATION
Process MIG/MAG welding
Method of Guidance Manually guided
Type of Cooling Air
Type of Shielding Gas All types
3.02 DUTY CYCLE
Spray Master with Velocity MIG Guns (250, 350, and 450 Amps) with mixed gas are rated
at 80% duty cycle per IEC 60974-7.
3.03 MIG GUN PART NUMBER IDENTIFICATION
NOTE
Spray Master 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:
350 AMP, 15 foot (5 M) cable
SMV315116
Spray Master
with Velocity
1-/16" Wire Capacity
(1,6mm)
Figure 2
Figure 3
89200016
4
SECTION 5: SPRAY MASTER WITH VELOCITY MAINTENANCE
Stainless Steel
Sleeve end
Score on nozzle end
Conduit Trim Length
This section discusses servicing and or replacing various components of the Spray Master MIG Gun.
WARNING
Disconnect power from MIG Gun before servicing.
5.01 INSTALLING OR REPLACING VELOCITY CONTACT TIP
Avoid excessive consumables wear by periodically rotating tips.
Increase consumables life by occasionally rotating tips.
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. (REPLACING) Remove worn nozzle and tip. (Clean nozzle if reusing.)
2. (NEW INSTALL) 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.
SAFETY AND OPERATING INSTRUCTIONS
5.02 CONDUIT IDENTIFICATION
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:
1/16" (1,6mm) Wire Capacity
44-116-15
44 Series
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 loosen the conduit set screw in the front of the gun.
This is usually located in the diffuser, or at the front of the handle. Then loosen
the conduit set screw in the rear connector plug.
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 diffuser 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.
Liner length in feet
Conduit set screw
NOTE
Nozzle
CUT
Method I
3/8” (9 mm to 10 mm)
Stainless Steel
CUT
Method II
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.
4. Inspect the cut conduit end to remove burrs because they could interfere with
wire feeding or conflict with the conduit seating inside the velocity tip. Remove
burrs with a file or side cutter.
5. Insert the contact tip and HAND tighten the nozzle.
The MIG gun is now ready to be reinstalled on the feeder.
Sleeve end
5.03 INSTALLING/REPLACING STAINLESS STEEL SLEEVE / LOCK COLLAR
The Stainless Steel Sleeve is held in place by one screw (some models have two screws)
and the sleeve holds the lock collar assembly in place.
STAINLESS STEEL SLEEVE
Lock collar and wave spring are held
in place by the stainless steel sleeve.
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 using one of two methods.
SCREW (SLEEVE)
Tighten until screw head bottoms out.
1. Remove the front end consumables from the conductor tube.
2. Using a 5/64" Hex wrench remove the Sleeve Screw(s) and slide the Stainless
Steel Sleeve off the conductor tube end.
Notice that the Lock Collar assembly is now loose.
3. If the Lock Collar assembly is being replaced, remove the assembly now.
a) Clean conductor tube end and lock collar seat on the conductor tube.
b) Assemble the Lock Collar parts in this order and slide onto the
conductor tube end.
CONDUCTOR TUBE END
5 89200016
SAFETY AND OPERATING INSTRUCTIONS
TRIGGER
NOT USED
VTMA30
Lock Collar
4. Slide the Stainless Steel Sleeve onto the conductor tube end.
5. Align the set screw with the threaded hole in the conductor tube and tighten
until the screw bottoms out. Do not overtighten.
The conductor tube Stainless Steel Sleeve replacement is complete. Trim the
conduit and install the consumables.
Spring Washer Snap Ring
5.04 REPLACE CONDUCTOR TUBE
The conductor tube is attached to the MIG Gun handle by two set screws on the side of the
handle. To remove:
1. Remove the front end consumables from the conductor tube.
Loosen the conduit liner set screw with a 5/64" hex wrench supplied and then
loosen the socket head cap screw securing the conductor tube in place inside
the handle with a 5/32" hex wrench. Refer to the figure below.
2. Remove conductor tube.
Conductor Tube set screw
3. Mount the conductor tube O-ring on the end of the conductor tube.
Spray Master Replacement Kit Parts List
Description Part No. Qty
Conductor Tube Assy. SMVCT60
Set Screw* (Sleeve) V41CS
Set Screw (5/64" hex
wrench drive)
Retaining Ring PMA64RS
Wave Spring VCTLSPR
Lock Collar VCTLSLK
Stainless Steel Sleeve VCTLSL
O-Ring 94-710-036S
* Not Shown
41CS
8.02 TIPS AND NOZZLES
Velocity Nozzle Identification
S=Light Duty
M=Medium Duty
H=Heavy Duty
ET=Extended Taper
VNM50FS
Velocity
Nozzle
Orifice Opening Size:
37=3/8” 62=5/8”
50=1/2” 75=3/4”
1
1
1
1
4
1
1
1
Blank= Fixed Threaded
S=Adjustable Slip
Blank=Std Recess
F=Flush
P=Protrude
R= Recess ¼” (6.35mm)
FAS=Spot Weld
FC=Flux Core
Slide the tube over the liner and insert into the brass connection within the
handle. Tighten the socket head cap screw wrench tight using the 5/32" hex
wrench.
4. Tighten the conduit set screw down against the liner. Do not overtighten to
avoid damages the liner.
5. Check the length of conduit extending from the conductor tube front end and
adjust if necessary.
There are two methods of trimming the conduit. See "Conduit Installation" on
page 5.
SECTION 6: CABLEHOZ® REPAIR
6.01 CABLEHOZ® REPAIR
If you should find it necessary to repair Cablehoz connection(s), repair instructions can be
found at www.Tweco.com our website.
CONTROL WIRE
{
NOT USED
BLUE
BROWN
WHITE
BLACK
BLACK
RED
CABLEHOZ
RED
WHITE
BLACK
BLACK
SECTION 7: 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. Refer to www.Tweco.com for MIG Gun troubleshooting chart(s).
SECTION 8: CONSUMABLES
8.01 REPLACEMENT KITS
Nozzle Convention
2 Knurl Rings VNM
3 Knurl Rings VNH
4 Knurl Rings VNET
Medium Duty Heavy Duty
Velocity Contact Tip Identification
S=Light Duty
M=Medium Duty
H=Heavy Duty
ET=Extended Taper
Velocity
Tip
Contact Tip Convention
2 Rings VTM
3 Rings VTH
4 Rings VTET
A=Alum
Blank=Other
Wire Size: 364=3/64”
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”
Stainless
Steel Sleeve
Lock Collar
Set Screw
Retaining Ring
Wave Spring
89200016
Conductor Tube
O-ring
6
Medium Duty Heavy Duty
SAFETY AND OPERATING INSTRUCTIONS
MEDIUM DUTY CONTACT TIPS HEAVY DUTY CONTACT TIPS EXTENDED TAPER CONTACT TIPS
Part No. Description Stock No. Part No. Description Stock No. Part No. Description Stock No.
VTM23 .023" (0.6 mm) 1160-1772
VTM30 .030" (0.8 mm) 1160-1751 VTH35 .035" (0.9 mm) 1160-1761 VTET35 .035" (0.9 mm)
VTM35 .035" (0.9 mm) 1160-1752 VTH40 .040" (1.0 mm) 1160-1762 VTET40 .040" (1.0 mm)
VTM40 .040" (1.0 mm) 1160-1753 VTH45 .045" (1.2 mm) 1160-1763 VTET45 .045" (1.2 mm)
VTM45 .045" (1.2 mm) 1160-1754 VTHA364 * 3/64" (1.2 mm) 1160-1764 VTETA364 * 3/64" (1.2 mm)
VTMA364 * 3/64" (1.2 mm) 1160-1755 VTH52 .052" (1.3 mm) 1160-1765 VTET52 .052" (1.3 mm)
VTM52 .052" (1.3 mm) 1160-1756 VTH116 1/16" (1.6 mm) 1160-1766 VTET116 1/16" (1.6 mm)
VTM116 1/16" (1.6 mm) 1160-1757 VTHA116 * 1/16" (1.6 mm) 1160-1767
VTMA116 * 1/16" (1.6 mm) 1160-1758 VTH564 5/64" (2.0 mm) 1160-1768
VTM564 5/64" (2.0 mm) 1160-1759 VTH332 3/32" (2.4 mm) 1160-1769
* For Aluminum
MEDIUM DUTY NOZZLES HEAVY DUTY NOZZLES
Part No. Description Stock No. Part No. Description Stock No.
VNM50F 1/2" Threaded Nozzle Flush VNH62 5/8" Threaded Nozzle Recess
VNM62 5/8" Threaded Nozzle Recess VNH62F 5/8" Threaded Nozzle Flush
VNM62F 5/8" Threaded Nozzle Flush VNH75 3/4" Threaded Nozzle Recess
VNM75 3/4" Threaded Nozzle Recess VNH75F 3/4" Threaded Nozzle Flush
VNM75F 3/4" Threaded Nozzle Flush VNH62S 5/8" Slip Nozzle
VNM50S 1/2" Slip Nozzle VNH75S 3/4" Slip Nozzle
VNM62S 5/8" Slip Nozzle VNS Slip Nozzle Base
VNM75S 3/4" Slip Nozzle VNH62SC 5/8" Slip Nozzle Cone Only
VNS Slip Nozzle Base VNH75SC 3/4" Slip Nozzle Cone Only
VNM50SC 1/2" Slip Nozzle Cone Only VNH622PC 5/8" 2 Piece Nozzle Assembly Recess
VNM62SC 5/8" Slip Nozzle Cone Only VNH62C 5/8" 2 Piece Nozzle Cone Only Recess
VNM75SC 3/4" Slip Nozzle Cone Only VNH62F2PC 5/8" 2 Piece Nozzle Assembly Flush
VNLFC Flux Core Nozzle 1240-1892
VNM62FAS 5/8" Spot Nozzle
VNM75FAS 3/4" Spot Nozzle
1160-1750 VTH30 .030" (0.8 mm) 1160-1760 VTET30 .030" (0.8 mm)
VTH764 7/64" (2.8 mm) 1160-1770
VTH18 1/8" (3.2 mm) 1160-1771
1240-1856
1240-1854
1240-1855
1240-1852
1240-1853
1240-1859
1240-1860
1240-1863
1240-1864
1240-1861
1240-1862
1240-1865
VNH62FC 5/8" 2 Piece Nozzle Cone Only Flush
1240-1866
1240-1868
VNH752PC 3/4" 2 Piece Nozzle Assembly Recess
VNH75C 3/4" 2 Piece Nozzle Cone Only Recess
VNH75F2PC 3/4" 2 Piece Nozzle Assembly Flush
VNH75FC 3/4" 2 Piece Nozzle Cone Only Flush
1160-1773
1160-1774
1160-1775
1160-1776
1160-1777
1160-1778
1240-1877
1240-1878
1240-1875
1240-1876
1240-1893
1240-1896
1240-1864
1240-1895
1240-1896
1240-1880
1240-1884
1240-1881
1240-1885
1240-1882
1240-1886
1240-1883
1240-1887
* Some parts may not be available at this time.
8.03 CONDUIT
250 AMP
Length
12 Ft See 15 Ft
15 Ft 42-4045-15 1420-1123
20 Ft See 20 Ft
25 Ft 42-4045-25 1420-1125
350 AND 450 AMP
Length
Part No. Stock No. Part No. Stock No.
10 Ft See 15 Ft See 15 Ft
12 Ft See 15 Ft See 15 Ft
15 Ft
20 Ft See 20 Ft See 20 Ft
25 Ft
44-116-15 1440-1113 44-116-15 1440-1113
.035" - .045" (1,0mm - 1,2)mm
.052" - 1/16" (1,3mm - 1,6mm)
350 Amp 450 Amp
Wire Size
Part No. Stock No.
Wire Size
44-116-25 1440-1115
8.04 CONDUCTOR TUBES
250 AMP 350 AMP 450 AMP
SMVCT45 SMVCT45
SMVCT60 SMVCT60
SMVCT60LM
7 89200016
SAFETY AND OPERATING INSTRUCTIONS
SECTION 9: REPLACEMENT PARTS
12a
12
11a
13b
13a
14
10
13
9b
10a
11
7
8
7a
9
9c
9a
Refer to Section 8 for Nozzles and Contact Tips
Refer to 8.02 Tips and Nozzles for tip and nozzle part numbers and descriptions.
Refer to 8.03 Conduit for conduit part numbers and descriptions.
Refer to 8.04 Conductor Tube for conductor tube part numbers and descriptions.
6
4
3
2
5
1
89200016
8
SAFETY AND OPERATING INSTRUCTIONS
Item
No.
1
2
3
4
5 -- -- -- Conductor Tube – Refer to 8.04 Conductor Tube
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 8.03 Conduit
250 AMP 350 AMP 450 AMP Description
SMV82
2060-2082
N/A
SMV82LC
2060-2079
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
350174MHFS
2035-2118
WM-354M
2030-2075
350174HFS
2035-2119
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
VCTLSL
VCTLSLK
VCTLSPR
PMA64R
SMV83
2060-2083
SMV83DS
2060-2077
SMV83LC
2060-2080
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
350174MHFS
2035-2118
WM-354M
2030-2075
194DS
2040-2195
350174HFS
2035-2119
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
SMV84
2060-2084
SMV84DS
2060-2078
SMV84LC
2060-2081
ELC94
2060-2647
MS94-LC
2060-2693
MS94-RSW
2060-2694
ELC94-BL
2060-2671
N/A Cablehoz® Assembly - 10 ft (3 m)
MS512
1750-2116
MS515
1750-2117
MS525
1750-2118
MS512X
1750-2119
MS515X
1750-2120
MS104-RK
2060-2133
MS174-RK
2060-2135
174X-M
2040-2181
350174MHFS
2035-2118
WM-354M
2030-2075
194DS
2040-2195
350174HFS
2035-2119
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
Stainless Steel Sleeve
Lock Collar
Wave Spring
Retaining Ring
Handle – Standard Spray Master
Handle – Dual Schedule (Rocker Switch)
Handle – Locking Trigger
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
NS = Not Shown
SECTION 10: STATEMENT OF WARRANTY
10.01 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.
MIG Torches and Arc Accessories Parts / Labor
All MIG Gun products 30 days from date purchaser purchases from seller. 30 days / NA
9 89200016
THE AMERICAS
Denton, TX USA
U.S. Customer Care
Ph: 1-800-426-1888 (tollfree)
Fax: 1-800-535-0557 (tollfree)
International Customer Care
Ph: 1-940-381-1212
Fax: 1-940-483-8178
Miami, FL USA
Sales Office, Latin America
Ph: 1-954-727-8371
Fax: 1-954-727-8376
Oakville, Ontario, Canada
Canada Customer Care
Ph: 1-905-827-4515
Fax: 1-800-588-1714 (tollfree)
EUROPE
Chorley, United Kingdom
Customer Care
Ph: +44 1257-261755
Fax: +44 1257-224800
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Customer Care
Ph: +39 0236546801
Fax: +39 0236546840
ASIA/PACIFIC
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Customer Care
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Fax: 6221-8990-6096
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Customer Care
Ph: +603 6092-2988
Fax: +603 6092-1085
Melbourne, Australia
Australia Customer Care
Ph: 1300-654-674 (tollfree)
Ph: 61-3-9474-7400
Fax: 61-3-9474-7391
International
Ph: 61-3-9474-7508
Fax: 61-3-9474-7488
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Sales Office
Ph: +86 21-64072626
Fax: +86 21-64483032
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Sales Office
Ph: +65 6832-8066
Fax: +65 6763-5812
INNOVATION TO SHAPE THE WORLD
U.S. Customer Care: 800-426-1888 / fax 800-535-0557
Canada Customer Care: 905-827-4515 / fax 800-588-1714
International Customer Care: 940-381-1212 / fax 940-483-8178
© 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in Mexico
™
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