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TECHNICAL GUIDE
For T-Gun™ Semi-Automatic
Air-Cooled MIG Guns –
350, 450 and 550 amp
SAFETY & WARRANTY
INFORMATION
INSTALLATION
MAINTENANCE GUIDE
TECHNICAL DATA
OPTIONS
EXPLODED VIEW & PARTS
LIST
TROUBLESHOOTING
ORDERING INFORMATION
Please read instructions prior to use.
Save this manual for future reference.
TABLE OF CONTENTS
THANK YOU…
…for selecting a Bernard T-Gun™ MIG Gun. The T-Gun MIG Gun is made from durable materials and components engineered to perform in a rugged, welding environment. Your T-Gun MIG Gun has undergone numerous quality checks to ensure high performance.
The instructions and illustrations in this technical guide make it easy for you to maintain your T-Gun MIG Gun.
Please read, understand, and follow all safety procedures. Keep this Technical Guide booklet as a handy reference when ordering complete guns, parts and special options.
For technical support and special applications, please call Bernard Customer Service Department at 1-800-
946-2281 or fax 1-888-946-6726. Our trained Customer Support Team is available between 8:00 AM and 4:30 PM
CST, and will answer your application or repair questions.
Bernard employees are always striving to improve our products and services, and would appreciate receiving your suggestions or comments. Please contact us immediately if you experience any safety or operating problems.
2
WARRANTY
Product is warranted to be free from defects in material and workmanship for the period specified below after the sale by an authorized Buyer. Should there be a defect please refer to our Return Merchandise Policy.
PRODUCT
TGUN™ MIG Guns and Components
TGX™ Chassis and TGX™ Ready To Weld MIG Guns
WARRANTY PERIOD
180 days
90 days
Bernard reserves the right to repair, replace or refund the purchase price of non-conforming product. Product found not defective will be returned to the Buyer after notification by Customer Service.
Bernard makes no other warranty of any kind, expressed or implied, including, but not limited to the warranties of merchantability or fitness for any purpose. Bernard shall not be liable under any circumstances to Buyer, or to any person who shall purchase from Buyer, for damages of any kind, including, but not limited to any, direct, indirect incidental or consequential damages or loss of production or loss of profits resulting from any cause whatsoever, including, but not limited to, any delay, act, error or omission of Bernard.
Genuine Bernard ™ and Tregaskiss™ parts must be used for safety and performance reasons or the warranty becomes invalid. Warranty shall not apply if accident, abuse, or misuse damages a product, or if a product is modified in any way except by authorized Bernard personnel.
GENERAL SAFETY
Before installation or operation of T-Gun MIG Guns, please read the safety precautions listed below:
1. Always wear a properly fitted welding helmet with the proper grade of filter plate and suitable welding gloves.
2. All exposed skin should be covered with flame resistant, protective clothing. DO NOT WEAR CLOTHING
MADE FROM FLAMMABLE SYNTHETIC FIBERS.
3. Protective screens or barriers should be used to protect others from spatter, flash and glare while welding.
4. Prevent fires by ensuring that hot slag or sparks do not contact combustible solids, liquids or gases.
5. Ensure that operator’s head is not too close to the arc and that adequate ventilation is available.
6. Constant repetitive motion may lead to cumulative trauma disorders.
7. Do not touch live electrical parts. The following should be checked to prevent electrical shock.
- Equipment is adequate for the job, properly grounded and installed according to code.
- Faulty or damaged equipment is repaired or replaced.
- Proper operator maintenance is performed to prevent excess spatter accumulation in the nozzle, or the contact tip or other areas of the gun.
- Electrical insulating components are in place and not damaged. Repair or replace if necessary.
- Operator and surroundings are not wet.
- Cables are not wrapped around operato r’s body.
- Equipment is off when not in use.
8. CSA Standard W117.2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
9. ANSI Standard Z49.1 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the American
National Standards Institute, 1430 Broadway, New York, NY 10018.
CALIFORNIA PROPOSITION 65 WARNING
This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer.
This product contains chemicals, including lead, known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after use.
(California Health & Safety Code Section 25249.5 at seq.)
3
1.0 – INSTALLATION
1.1 INSTALLING QUICK CONNECT BLOCK TO FEEDER
STEP #1
Insert the correct feeder adaptor liner for desired wire diameter (3 provided) flush with the threaded end of the feeder adaptor.
Tighten set screw.
Thread feeder adaptor into Quick Connect
Block and tighten.
QUICK
CONNECT
BLOCK
SET SCREW
FEEDER ADAPTOR
STEP #2
Position assembly into feeder adaptor and trim liner within 1/16”
(1.6 mm) of the drive rolls and remove burrs if necessary.
Secure assembly into feeder.
Thread gas hose nipple into feeder gas fitting.
Connect power cable to 1/2 ” (13 mm) power bolt with appropriate lug.
Tighten all connections.
Feed welding wire through assembly by hand and tighten drive rolls.
DRIVE
ROLLS
1.2 INSTALLING GUN TO QUICK CONNECT BLOCK
Ensure correct liner and contact tip are utilized. Examine and replace power pin o-rings if necessary.
STEP #1
Guide welding wire into power pin.
Insert power pin to shoulder of feeder.
Tighten thumb screw (on Quick
Connect Block) securely.
Connect control plug lead to control housing on gun.
Insert control plug into feeder.
STEP #2
POWER PIN
WELDING
WIRE
THUMB
SCREW
With gun lying straightened, pull trigger and feed wire through gun. It may be necessary to remove contact tip when feeding small wire sizes).
Recheck: - proper gas flow
- drive roll pressure
- voltage and wire feed speed
4
1.3 INSTALLING GUNS EQUIPPED WITH “DIRECT POWER PINS”
IMPORTANT: The thread-in two-piece power pin incorporates a taper to seat and lock the pin to the rear handle block.
Make sure the power pin is tightened in the block with a wrench to insure the pin is secure and will not come loose.
NOTE: The rear handle and screws do not have to be removed when installing the two-piece power pins.
Thread power pin into the rear handle block.
Tig hten the power pin into the rear block using a 1” (25 mm) wrench on the rear block and a 5/8” (16mm) or 3/4” (19 mm) wrench on the power pin.
Install liner (See Section 2.2 LINER REPLACEMENT).
Install gun to feeder (See below).
Most Pins
- Insert power pin to shoulder and secure.
- Insert control plug to control housing of gun.
- Insert control plug into feeder.
- Feed welding wire into power pin by hand and tighten drive rolls.
- On Lincoln
feeders it is necessary to connect the gas hose to the barbed fitting on the power pin.
2.0 – MAINTENANCE
NOTE:
Bernard, Euro and O
XO™ are not direct connect pins
2.1 TREGASKISS NOZZLE AND TOUGH LOCK™ CONSUMABLES
STANDARD DUTY NOZZLE
VARIOUS SIZES AVAILABLE
STANDARD DUTY
TREGASKISS
TOUGH LOCK
CONTACT TIP
STANDARD DUTY
TREGASKISS
TOUGH LOCK
RETAINING HEAD
NECK
INSULATOR
HEAVY DUTY NOZZLE
VARIOUS SIZES AVAILABLE
HEAVY DUTY
TREGASKISS
TOUGH LOCK
CONTACT TIP
HEAVY DUTY
TREGASKISS
TOUGH LOCK
RETAINING HEAD
NECK
INSULATOR
IMPORTANT:
Neck insulator MUST be in place before welding to properly insulate neck armor.
Check all parts to ensure that connections are tight before welding.
The retaining head MUST be tightened with a 5/8” (16 mm) wrench to prevent the contact tip from overheating.
DO NOT use pliers to remove or tighten the retaining head or scoring may result.
Removal and Replacement
Nozzle
Pull slip-on nozzles off with a twisting motion.
When installing the nozzle, ensure that it is fully seated.
Contact Tip
Thread the contact tip into the retaining head.
Torque to 30 in.-lbs. (3.5 Nm).
The Tregaskiss Tip Tool (Part # 450-18 – for heavy-duty tips) or a pair of weld pliers are the optimal tools for contact tip installation.
Retaining Head
Thread retaining head onto gooseneck with a 5/8” (16 mm) wrench.
Torque to 80 in.-lbs. (9 Nm) .
DO NOT use pliers to remove or tighten the heavy duty retaining head or scoring may result.
Neck Insulator
The neck insulator is pressed onto the neck by hand.
5
STEP #2
2.2 LINER REPLACEMENT
NOTE: For guns equipped with “Direct Plug-Ins”, Bernard or Euro-connector, the procedure is the same.
On Miller® style guns, the liner is held captive by a guide cap, which must be removed and replaced when changing the liner.
STEP #1
CONDUIT LINER
NOTE: Ensure power supply is off and gun is removed from feeder before proceeding.
Remove nozzle, tip and gas diffuser.
If power pin uses a liner set screw, loosen the set screw using a 5/64” Allen wrench.
If power pin is thread-in liner type, using a 10 mm wrench, turn thread-in liner retainer counter-clockwise until liner is free from the power pin.
With gun straightened, grip conduit liner with pliers and remove.
STEP #2 STEP #3
LINER
GAUGE
Feed replacement liner through gun using short strokes to avoid kinking. Twist liner clockwise if necessary.
Using a 10 mm wrench, turn thread-in liner retainer in a clockwise direction and tighten into the power pin.
3/4” (19 mm)
Push liner back into gun and hold in place.
Using liner gauge, trim conduit liner with 3/4 ” (19 mm) stick out.
Remove any burr that may obstruct wire feed, especially on flat wire type conduit liner.
Replace nozzle, tip and gas diffuser onto neck.
2.3 SWITCH REPLACEMENT
STEP #1
LEADS
SWITCH
SWITCH LEAD
CONNECTORS
SWITCH HOUSING
MOUNTING SCREWS
Loosen both mounting screws with a 5/16” (8 mm) nut driver or flathead screwdriver.
Ease switch out of switch housing.
Remove switch from switch lead connectors with needle nose pliers.
6
STEP #2
Push switch lead connectors firmly onto switch terminals with needle nose pliers.
Depress switch plunger and nest back into housing.
Fit switch housing into nest on handle (switch leads must lie parallel).
Align housing holes with threaded holes in body and insert mounting screws.
Start both screws first before tightening with 5/16” (8 mm) nut driver to even alignment.
IMPORTANT:
Use manufacturer ’s screws (part # 411-3 or 411-3M) to ensure proper length, hardness and tolerance.
SWITCH
SWITCH HOUSING
2.4 NECK REPLACEMENT
LEADS (2)
STEP #1
Place neck in vise.
Remove both switch housing mounting screws.
Slide handle back exposing the cable connection.
Loosen the cable / neck connection using a 7/8” wrench.
Remove from vise and unthread neck by hand.
NOTE: The body is now an integral part of the neck and the handle mounting holes are metric (M5). Use the screws supplied with the new neck to avoid stripping of threads. Old style 407 bodies used
Imperial (U.S.) threads.
NECK
STEP #2
Thread the neck into the cable connection (hand tighten).
Place neck in vise and tighten with a wrench to within 1/8” (3.2 mm) spacing between the cable connection and neck body.
MOUNTING
SCREWS
CONE
NUT
CONNECTOR
CONE
HANDLE
NECK
SWITCH HOUSING
SWITCH
1/8 ” (3.2 mm)
CONNECTOR
CONE
STEP #3
Install the switch and reposition handle and switch housing.
Reinstall switch housing mounting screws.
MOUNTING SCREWS
7
2.5 UNICABLE REPLACEMENT
STEP #1
CONE NUT
SWITCH HOUSING
Remove liner from gun (See Section 2.2 LINER
REPLACEMENT).
Mount neck in vise.
Remove both switch housing mounting screws.
Slide handle back exposing the cable connection.
Loosen the cable / neck connection using a 7/8”
NECK wrench.
Remove from vise and unthread neck by hand.
Remove switch from leads and slide handle back
(See Section 2.3 SWITCH REPLACEMENT).
CONE
NUT
CONNECTOR
CONE
SCREWS
SWITCH
HANDLE
STEP #2
Remove power pin from power pin block using a 5/8” wrench on the pin and a 1” wrench on the block.
Remove both terminal housing screws.
Slide handle back exposing the cable connection.
Remove power pin block from unicable using a 7/8” wrench and a 1” wrench.
HANDLE CONE NUT
POWER
PIN BLOCK
POWER PIN
STEP #3
MOUNTING SCREWS
SWITCH HOUSING
NECK
CONE
NUT
SWITCH
CONNECTOR
CONE
HANDLE
Take new unicable and starting from the front install the neck.
Slide the handle up over the connection ensuring that the switch leads slide out the hole on the handle.
Install the switch to the switch leads and secure the handle and switch housing in place using the two screws.
STEP #4
Reinstall power pin block to rear of unicable and thread power pin into block.
Slide handle up over connection ensuring that switch leads can slide out of the hole.
Plug switch leads into terminal housing and secure handle and housing using two screws.
Reinstall liner. Make sure that there is 3/4 ” of the liner sticking out past the end of the neck when the gun is fully extended; if there is not, a new liner will be required.
Reinstall consumables and reconnect to wire feeder.
8
2.6 UNICABLE REPAIR
Remove consumables (Nozzle, Retaining Head, Contact Tip).
Remove the liner from the gun.
Mount neck in the vise.
Remove switch housing and switch from leads.
MOUNTING
SCREWS
SWITCH
HOUSING
NECK
CONE NUT
SWITCH
Crimp the support tube clamp. Crimp between the black and white switch leads.
Position copper wires between roll marked numbers on cone and first step before threads. Crimp the large O etiker clamps 1/4” and 1” behind the outer jacket at the front of the gun.
INNER TUBE
CONNECTOR
CONE
CONNECTOR
CONE
Move the handle back.
HANDLE
Bend unicable behind connector cone. Cut unicable at bend.
Slide two large “Oetiker” clamps 1.5 ft. down the unicable
(required for crimping later).
O UTER JACKET
SWITCH
LEADS
BARE COPPER
3/4”
(19 mm)
3.5”
(89 mm)
8”
(200 mm)
From your cut (end of cable), measure 8” back and cut away the outer jacket of the cable. **Be careful not to cut the copper wiring and leads**
Slide outer jacket forward to expose the copper wiring and leads.
Pull out the lead wires.
From the 8” cut, measure 3 1/2” towards the front of the gun and cut off the excess cable.
Fan back copper and remove 3/4” of the inner gas tube.
Take the old liner you just removed and cut it to approximately
2 ft. long.
Thread cone onto vise mounted neck.
Insert the 2 ft. of old liner into the neck from the front end of the neck, then slide on the support tube.
Slide small Oetiker clamp over top of inner gas tube (Hytrel).
Using the 2’ old liner as a guide, slide the inner gas tube over the support tube and up to the cone shoulder.
CONE NUT
Remove the inner gas tube (Hytrel) from the cone.
Fan out the copper and bring the copper around the inner gas tube
(Hytrel) evenly.
CONE NUT
Slide the inner gas tube on the Cone up to the cone shoulder.
Fan the copper evenly around the inner gas tube up to the shoulder of the Cone Connector. Thread on the Cone Nut onto Connector
Cone. Torque the Cone Nut to 30 ft.-lbs (there should be about a
1/8” gap between the cone and cone nut).
Using 3/4 ” Teflon electrical tape, wrap up the copper and spare switch leads neatly. Loop the 2 switch leads that will be used. This is to ensure that there is enough slack in the wire for gun articulation.
Make sure that the control wire sheath is over switch leads where the cone and cone nut are to prevent any wear.
Pull up the handle and feed switch leads through handle.
Strip leads about 1/8” back and crimp switch terminals to open leads.
Connect the leads to the switch and lay the switch back into the housing.
Screw the switch housing back onto the handle.
If assistance is required, please contact your authorized Bernard Distributor or the Customer Service Department at Bernard at 1-800-946-2281.
9
UNICABLE CLAMP KIT
PART #
350 amp
450 amp
550 amp
DESCRIPTION
313-8 413-7 513-7 UNICABLE CLAMP KIT (COMPLETE)
INDIVIDUAL PARTS
308 408 408 CONNECTOR CONE
509 409 509 CONE NUT
313-3 513-1 523-1 OUTER JACKET CLAMPS (2)
413-5 413-5 413-5 SUPPORT TUBE CLAMP
413-4 413-4 413-4 SUPPORT TUBE
412-1 412-1 412-1 SWITCH LEAD CONNECTORS (2)
412-3 412-3 412-3 CONTROL WIRE SHEATH
3.0 – TECHNICAL DATA
3.1 NECK DIMENSIONS
REPAIR TOOL KIT
PART # DESCRIPTION
450 REPAIR TOOL KIT (COMPLETE)
INDIVIDUAL TOOLS
450-1
450-2
450-3
450-4
CABLE CUTTER
CLAMP PLIERS - FOR CRIMPING OF OUTER
JACKET AND INNER TUBE CLAMPS
CONNECTOR CRIMPING TOOL - FOR SWITCH
LEAD TERMINALS
5/16" NUT DRIVER - FOR REMOVAL OF
SWITCH HOUSING
450-5 KNIFE - FOR TRIMMING OF OUTER JACKET
450-21 5 mm ALLEN KEY
450-13-2
SUPPORT TUBE INSTALLATION PIN – 350/450 amp
450-13-3 SUPPORT TUBE INSTALLATION PIN – 550 amp
E
NECK
305-60
405-45
405-60
405-180
505-45
505-60
A
60°
45°
60°
180°
45°
60°
INCHES
B
4.10
5.19
4.98
7.35
7.23
6.04 mm
105
132
127
187
184
153
C
INCHES
4.00
3.55
4.78
---
3.87
5.30 mm
103
90
121
---
98
135
INCHES
D
2.00
3.00
3.00
---
4.00
4.00 mm
51
76
76
---
102
102
3.2 GUN AMPERAGE RATINGS
GUN MODEL
350 amp
450 amp
60% DUTY CYCLE – MIXED GASES
OR 100% DUTY CYCLE – CO
2
350 amp
450 amp
550 amp 550 amp
NOTE: Ratings are based on tests that comply with IEC 60974-7 standards.
10
INCHES
E
1.90
1.90
1.90
1.90
1.90
1.90 mm
48
48
48
48
48
48
4.0 – OPTIONS
4.1 SPECIALTY AND OPTIONAL ITEMS
ITEM
1
2
3
4
5
6
7
8
9
PART #
401-10-87 SPOT NOZZLE (BRASS)
DESCRIPTION
401-21 FLUX CORE NOZZLE (GASLESS)
401-41-50 EXTENDED REACH NOZZLE - 3.5" (88.9 MM)
401-42-50 HIGH ACCESS NOZZLE (BOTTLE-NECKED)
401-26-62 WATER-COOLED NOZZLE - FIXED HOSE SYSTEM 5/8" (15.9 MM) FOR 5/16" (7.9 mm) TIP RECESS
401-26-75 WATER-COOLED NOZZLE - FIXED HOSE SYSTEM 3/4" (19 MM) FOR 5/16" (7.9 mm) TIP RECESS
402-26 NECK INSULATOR USED WITH 401-26-62 & 401-26-75
430-3
656-1
WATER HOSE ONLY - 15' (4.6 M)
HOSE CLAMP
4.2 FEEDER ADAPTORS
To be used with 417 (Tweco #4), 417-50 (Euro) & 417-60 (Tweco #5) Quick Connect Block
PART # USE ON FEEDERS
418-1
418-3
418-4
AIRCO®
ESAB® (NON EURO STYLE) AND HOBART® BETA MIG
HOBART 27
418-5
418-6
418-7
418-8
418-9
418-10
418-14
418-21
418-27
418-29
418-35
LINCOLN® LN4, LN5, LINDE SWM 31, 3A & 32A
LINCOLN LN7, 8 & 9, LN 25 SUITCASE, LN22
LINDE® SWM-14
LINDE 35 SWM-23
MILLER 10A, 30A (MILLERMATIC 35S FEEDER)
MILLER 52E, 54E, S21, S22 SERIES AND MILLERMATIC 200 & 250, 60 SERIES
OTC DAIHEN®
GILLILAND®
PANASONIC®
TWECO® #5 PIN
KOBELCO®
4.3 DIRECT PLUG-INS
PART # DESCRIPTION
214 TREGASKISS ™ POWER PIN
414-11-2 O-RING - FOR MILLER POWER PINS
214-6-116 MILLER POWER PIN - FOR .035" - 1/16" WIRE
214-6-332 MILLER POWER PIN - FOR 5/64" - 3/32" WIRE
214-116 GUIDE CAP ONLY - FOR 214-6-116 (NEW STYLE)
214-332 GUIDE CAP ONLY - FOR 214-6-332 (NEW STYLE)
214-9 GUIDE CAP ONLY - FOR ALUMINUM LINER (NEW STYLE)
414-116 GUIDE CAP ONLY - FOR 214-6-116 (OLD STYLE)
414-332 GUIDE CAP ONLY - FOR 214-6-332 (OLD STYLE)
414-9 GUIDE CAP ONLY - FOR ALUMINUM LINER (OLD STYLE)
214-12 TWECO #5 STYLE POWER PIN
414-12-2 O-RING - FOR TWECO #5 STYLE POWER PIN
214-2
414-21
214-13
LINCOLN POWER PIN
ESAB (NON EURO)
PANASONIC
11
USE ON FEEDERS
TREGASKISS QUICK CONNECT BLOCK, HOBART 2000 SERIES
FEEDERS, TWECO #4 RECEPTACLE BODY PART #TAK-1
MILLERMATIC 200 & 250, S21E & S22 SERIES, 52 & 54 SERIES, 60
SERIES
MILLERMATIC 200 & 250, S21E & S22 SERIES, 52 & 54 SERIES, 60
SERIES
MILLERMATIC 200 & 250, S21E & S22 SERIES, 52 & 54 SERIES, 60
SERIES
ALL FEEDERS SET UP WITH TWECO #5
RECEPTACLE BODY PART #6TAK-1
LINCOLN LN7, 8 & 9, LN25 SUITCASE, LN22,NA2
A-10
NOTE:
Dual Schedule TOUGH GUNS are offered in two styles.
D - TOGGLE STYLE - A separate thumb switch is mounted on the housing to change schedules (lock-on optional).
2D - TWO POSITION STYLE - Depress lever halfway for first schedule and fully for second schedule.
Both require special Dual Schedule unicable with 4 switch leads and special rear housing.
4.4 CONNECTOR OPTIONS
Euro Connector option - for European style feeders and feeder adaptors for 350, 450,
550 & 650 amp T-Gun MIG Guns.
PART #
425
425-10
425-2
666-10
416-5
425-6
425-8
425-5
Old Style Euro
HANDLE
DESCRIPTION
EURO CONNECTOR ASSEMBLY
EURO CONNECTOR BODY
HAND NUT
TERMINAL HOUSING
SPACER RING
CONTROL PIN
MOUNTING SCREW
New Style Euro (Oct. 2004)
PART
#
DESCRIPTION
425 EURO CONNECTOR ASSEMBLY
425-10 EURO CONNECTOR BODY
425-11 HAND NUT
425-7 EURO HANDLE
Bernard Style Connector Option - for Quick Connect feeder adaptors for 350, 450, 550 & 650 amp T-Gun
MIG Guns.
Bernard Style
PART #
426
426-1
426-2
426-3
426-4
426-5
426-6
BERNARD STYLE CONNECTOR ASSY.
CONNECTOR BODY
LOCKING COLLAR
LOCK SPRING
CONNECTOR HOUSING
CONTROL PINS
O-RINGS
DESCRIPTION
4.5 CONTROL PLUGS
PART #
419-2
419-4
419-5
419-6
419-7
419-8
419-10
419-11
419-12
DESCRIPTION
HOBART
MILLER (52E, 54E)
WESTINGHOUSE
LINCOLN (LN7, 8, 9) NA2
MILLER (10E, 30E) & LINDE (SWM-35)
DIPSTICK 160,200, HOBART HANDLER, LINCOLN SP-100
DUAL SCHEDULE MILLER
LINCOLN DUAL SCHEDULE
OXOMATIC
4.6 DUAL SCHEDULE MIG GUN
TWO POSITION SWITCH STYLE
PART # DESCRIPTION
411-11
DUAL SCHEDULE TWO-POSITION
SWITCH HOUSING ONLY
416-13 D.S. CONTROL
HOUSING WITH PLUG
LEAD
TOGGLE SWITCH STYLE
PART #
411-12
411-13
DESCRIPTION
DUAL SCHEDULE SWITCH HOUSING - COMPLETE
W/TOGGLE SWITCH
DUAL SCHEDULE LOCK-ON TRIGGER HOUSING
12
5.0 – ACCESSORIES
411-20 SWITCH
HOUSING
WITH EXTENDED
LEVER
411-4 SWITCH
HOUSING WITH
LOCK ON TRIGGER
422
421
422 GUN HANGER
421 HEAT SHIELD
421-1 SHIELD MOUNTING
SCREW (NOT SHOWN)
6.0 – TROUBLESHOOTING
SPRING GUARD
406-1 400 AMP 60 DEG
406-2 400 AMP 45 DEG
506-1 500AMP 60 DEG
PROBLEM
POOR WIRE FEED
SHORT TIP LIFE
GUN OVERHEATING
SWITCH MALFUNCTIONING
WELD POROSITY
POSSIBLE CAUSE
CONDUIT LINER CLOGGED OR KINKED
INCORRECT LINER SIZE OR CONTACT TIP
LINER CUT TOO SHOR AND NOT SEATING PROPERLY IN GAS DIFFUSER
DRIVE ROLLS TOO TIGHT, RESULTING IN SCORING OF WELDING WIRE
WELDING WIRE DIRTY, RUSTY, AND/OR TOO MUCH CAST
DRIVE ROLLS TOO TIGHT, RESULTING IN SCORING OF WELDING WIRE
WELDING WIRE DIRTY, RUSTY, AND/OR TOO MUCH CAST
UNCOATED WIRE BEING USED, INCREASING USAGE
WRONG TIP SIZE
OVER TORCH-RATED DUTY CYCLE
LOOSE CONTACT TIP AND/OR RETAINING HEAD
LOOSE RETAINING SCREW ON QUICK CONNECT BLOCK
INSUFFICIENT GAUGE POWER CABLE AND/OR GROUND CABLE
LOOSE CONNECTOR CONE AND/OR CONE NUT
GUN BEING RUN BEYOND ITS AMPERAGE RANGE
ELECTRICAL MALFUNCTION IN POWER SOURCE
BAD CONNECTION OF LEADS TO SWITCH TERMINALS
SPATTER BUILT UP BETWEEN LEVER AND SWITCH HOUSING
CONTACTS DIRTY IN SWITCH
SWITCH HOUSING SCREWS LOOSE
BROKEN OR WORN SWITCH LEAD
SPATTER BUILT UP IN NOZZLE, BLOCKING GAS
LEAKS IN GAS HOSE OR IMPROPER CONNECTION
O-RINGS ON POWER PIN ARE CUT OR DAMAGED
INNER TUBE LOOSE FROM CONNECTOR CONE
POOR WIRE FEED (SEE ABOVE)
IMPROPER SHIELDING GAS OR WELDING WIRE
RUSTY OR POOR QUALITY WELDING WIRE
PARENT METAL RUSTY OR CONTAMINATED OR HIGH IN SULPHUR CONTENT
FLOW IMPROPERLY SET
13
7.0 – EXPLODED VIEW AND PARTS LIST
3
4
1
Numbers in this column correspond to the exploded view images above.
PART #
350 amp 450 amp 550 amp
401-40-38
401-4-38
401-4-50
401-4-62
401-4-75
401-8-62
401-5-62
401-5-75
401-6-50
401-6-62
401-6-75
401-7-62
401-7-87
401-40-38
401-4-38
401-4-50
401-4-62
401-4-75
401-8-62
401-5-62
401-5-75
401-6-50
401-6-62
401-6-75
401-7-62
401-7-87
401-40-38
401-4-38
401-4-50
401-4-62
401-4-75
401-8-62
401-5-62
401-5-75
401-6-50
401-6-62
401-6-75
401-7-62
401-7-87
2
403-14-23
403-14-30
403-14-35
403-14-1.0
403-14-45
403-14-23
403-14-30
403-14-35
403-14-1.0
403-14-45
403-14-23
403-14-30
403-14-35
403-14-1.0
403-14-45
403-20-30
403-20-35
403-20-1.0
403-20-45
403-20-364
403-20-1.4
403-20-52
403-20-116
403-20-564
403-20-332
403-21-30
403-21-35
403-21-45
404-15
404-18
403-20-30
403-20-35
403-20-1.0
403-20-45
403-20-364
403-20-1.4
403-20-52
403-20-116
403-20-564
403-20-332
403-21-30
403-21-35
403-21-45
404-15
404-18
403-20-30
403-20-35
403-20-1.0
403-20-45
403-20-364
403-20-1.4
403-20-52
403-20-116
403-20-564
403-20-332
403-21-30
403-21-35
403-21-45
404-15
404-18
404-26 404-26 404-26
DESCRIPTION
STANDARD NOZZLES (SELF-INSULATED)
SUPER TAPERED NOZZLE - 3/8" BORE (BRASS)
3/8" (10 mm) BORE - FLUSH TIP
1/2" (13 mm) BORE - 1/8" (3 mm) TIP RECESS
5/8" (16 mm) BORE - 1/8" (3 mm) TIP RECESS
3/4" (19 mm) BORE - 1/8" (3 mm) TIP RECESS
SHORT ARC NOZZLE
5/8” (16 mm) BORE - 1/8" (3 mm) TIP STICKOUT
HEAVY DUTY NOZZLES (SELF-INSULATED)
5/8" (16 mm) BORE - 1/4" (6 mm) TIP RECESS
3/4" (19 mm) BORE - 1/4" (6 mm) TIP RECESS
1/2" (13 mm) BORE - 1/8" (3 mm) TIP RECESS
5/8" (16 mm) BORE - 1/8" (3 mm) TIP RECESS
3/4" (19 mm) BORE - 1/8" (3 mm) TIP RECESS
5/8" (16 mm) BORE - 1/4" (6 mm) TIP RECESS (BRASS)
7/8" (22 mm) BORE - 1/4" (6 mm) TIP RECESS (BRASS)
STANDARD DUTY
TREGASKISS™ TOUGH LOCK™
CONTACT TIP - 1/4
” (6.4 mm) O.D.
FOR .023” (0.6 mm) WIRE
FOR .030” (0.8 mm ) WIRE
FOR .035” (0.9 mm) WIRE
FOR 1 mm WIRE
FOR .045” (1.2 mm) WIRE
HEAVY DUTY TREGASKISS TOUGH LOCK CONTACT TIPS
- 5/16” (7.9 mm) O.D.
FOR .030" (0.8 mm) WIRE
FOR .035" (0.9 mm) WIRE
FOR 1 mm WIRE
FOR .045" (1.2 mm) WIRE
FOR 3/64 " (1.2 mm) WIRE
FOR 1.4 mm WIRE
FOR.052" (1.3 mm) WIRE
FOR 1/16" (1.6 mm) WIRE
FOR 5/64" (2.0 mm) WIRE
FOR 3/32" (2.4 mm) WIRE
HEAVY-DUTY TREGASKISS TOUGH LOCK TAPERED TIPS
5/16” (7.9 mm) O.D.
FOR .030" (0.8 mm) WIRE
FOR .035" (0.9 mm) WIRE
FOR .045" (1.2 mm) WIRE
GAS DIFFUSER
TREGASKISS TOUGH LOCK ™ - HEAVY DUTY
RETAINING HEAD - TREGASKISS TOUGH LOCK
TREAGSKISS TOUGH LOCK RETAINING HEAD - FOR
STANDARD DUTY TIPS
TREGASKISS TOUGH LOCK RETAINING HEAD - FOR
HEAVY DUTY TIPS
10
11
12
13
14
5
6
7
8
9
15
16
17
18
19
20
21
313-10
313-12
313-15
313-20
313-25
410
411-1
411-2
411-4
411-11
411-12
411-13
411-23
411-24
411-3M
313-8
412-1
412-3
413-5
313-3
413-4
308
509
350 amp
402-3
454-1-2
402-16
402-11
305-45
305-60
305-180
406-2
406-1
405-45F
405-60F
405-80F
505-45F
NA
NA
412-1
412-3
413-5
513-1
413-4
408
409
413-10
413-12
413-15
413-20
413-25
410
411-1
411-2
411-4
411-11
411-12
411-13
411-23
411-24
411-3M
413-7
PART #
450 amp 550 amp
402-3 402-3
454-1-2
402-16
402-11
405-45
405-60
405-180
406-2
406-1
405-45F
405-60F
405-80F
505-45F
NA
NA
454-1-2
402-16
402-11
505-45
505-60
505-180
506-1
506-1
405-45F
405-60F
405-80F
505-45F
505-60F
505-80F
412-1
412-3
413-5
523-1
413-4
408
509
513-10
513-12
513-15
513-20
513-25
410
411-1
411-2
411-4
411-11
411-12
411-13
411-23
411-24
411-3M
513-7
DESCRIPTION
NOZZLE RETAINER
RETAINING RING ONLY
O-RING ONLY
NECK INSULATOR
NECKS (INTERCHANGEABLE BETWEEN ALL 3 AMPERAGES)
45 DEGREE
60 DEGREE
STRAIGHT
SPRING THERMO GUARD - 45° (NOT SHOWN)
SPRING THERMO GUARD - 60° and 22° (NOT SHOWN)
45 DEGREE – GASLESS
60 DEGREE
– GASLESS
80 DEGREE
– GASLESS
45 DEGREE – GASLESS
60 DEGREE – GASLESS
80 DEGREE – GASLESS
UNICABLE ASSEMBLY (INCLUDES HANDLE / SPRING ASSEMBLY)
10' (3 m) SERVICE
12' (4 m) SERVICE
15' (5 m) SERVICE
20' (6 m) SERVICE
25' (8 m) SERVICE
HANDLE / SPRING GUARD ASSEMBLY - FRONT AND REAR
SWITCH ONLY
SWITCH HOUSING WITH SCREWS
SWITCH HOUSING - LOCK-ON TRIGGER
SWITCH HOUSING DUAL SCHEDULE - 2 POSITION
SWITCH HOUSING DUAL SCHEDULE - TOGGLE STYLE
SWITCH HOUSING D/S 2 POSITION - LOCK-ON
SWITCH HOUSING - EXTENDED TRIGGER
SWITCH HOUSING - EXTENDED LOCK-ON TRIGGER
MOUNTING SCREWS (Metric M5)
UNICABLE REPAIR KIT (INCLUDES PARTS 15 - 21)
SWITCH LEAD CONNECTOR
SHEATH
SUPPORT TUBE CLAMP
OUTER JACKET CLAMP
SUPPORT TUBE
CONNECTOR CONE
CONE NUT
14
415-564-15
415-1
416-13
416-5
417
417- 50
417- 60
417-1
417-2
417-3
417-4
415-26
415-35-10Q
415-35-15Q
415-35-25Q
415-116-10Q
415-116-15Q
415-116-25Q
415-23-15
415-30-15
415-35-10
415-35-15
415-35-25
415-35-2
415-116-10
415-116-15
415-116-25
415-116-2
415-332-15
415-332-25
350 amp
414-400
214
214-6-116
214-6-332
214-9
214-2
214-4
214-12
214-13
22
23
24
25
24a
26
27
415-332-15
415-332-25
415-564-15
415-1
416-13
416-5
417
417- 50
417- 60
417-1
417-2
417-3
417-4
415-26
415-35-10Q
415-35-15Q
415-35-25Q
415-116-10Q
415-116-15Q
415-116-25Q
415-23-15
415-30-15
415-35-10
415-35-15
415-35-25
415-35-2
415-116-10
415-116-15
415-116-25
415-116-2
PART #
450 amp
414-400
214
214-6-116
214-6-332
214-9
214-2
214-4
214-12
214-13
550 amp
414-400
214
214-6-116
214-6-332
214-9
214-2
214-4
214-12
214-13
415-332-15
415-332-25
415-564-15
415-1
416-13
416-5
417
417 - 50
417 - 60
417-1
417-2
417-3
417-4
415-26
415-35-10Q
415-35-15Q
415-35-25Q
415-116-10Q
415-116-15Q
415-116-25Q
415-23-15
415-30-15
415-35-10
415-35-15
415-35-25
415-35-2
415-116-10
415-116-15
415-116-25
415-116-2
DESCRIPTION
POWER PIN BLOCK
POWER PINS
TWECO® #4
MILLER® 1/16 ”
MILLER 3/32 ”
MILLER GUIDE CAP FOR ALUMINUM
LINCOLN®
L-TEC® - MT SERIES
TWECO #5
PANASONIC®
TREGASKISS QUICK LOAD ™ LINER (LINER
RETAINER NOT INCLUDED)
LINER RETAINER
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 10' (3 m)
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 15' (5 m)
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 25' (8 m)
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 10' (3 m)
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 15' (5 m)
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 25' (8 m)
THREAD-IN STYLE LINER
FOR .023" (0.6 mm) WIRE - 15' (5 m)
FOR .030" (0.8 mm) WIRE - 15' (5 m)
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 10' (3 m)
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 15' (5 m)
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 25' (8 m)
FOR .035" (0.9 mm) ALUMINUM WIRE - 15' (5 m)
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 10' (3 m)
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 15' (5 m)
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 25' (8 m)
FOR 3/64" - 1/16" (1.2 mm - 1.6 mm) ALUMINUM WIRE
- 15' (5 m)
FOR 5/64" - 3/32" (2 mm - 2.4 mm) WIRE - 15' (5 m)
FLAT WOUND
FOR 5/64" - 3/32" (2 mm - 2.4 mm) WIRE - 25' (8 m)
FLAT WOUND
FOR all 5/64" (2 mm) WIRE & 1/16" (1.6 mm) FLUX-
CORED WIRE
LINER O-RING (NOT SHOWN)
CONTROL HOUSING WITH DUAL SCHEDULE
OPTION
CONTROL HOUSING WITH SCREWS
FEEDER ADAPTOR REQUIREMENTS (SOLD
SEPARATELY)
QUICK CONNECT BLOCK ASSEMBLY (TWECO #4)
QUICK CONNECT BLOCK ASSEMBLY (EURO)
QUICK CONNECT BLOCK ASSEMBLY (TWECO #5)
RETAINING SCREW
GAS HOSE ADAPTOR
POWER BOLT
GAS HOSE & NIPPLE
29
28
418-27
418-29
418-35
419-2
419-4
419-6
419-7
419-8
419-10
419-11
NA
NA
NA
PART #
350 amp 450 amp
418-3
418-4
418-5
418-6
418-7
418-8
418-9
418-10
418-3
418-4
418-5
418-6
418-7
418-8
418-9
418-10
418-14 418-14
418-21
NA
NA
418-21
418-27
418-29
418-35
419-2
419-4
419-6
419-7
419-8
419-10
419-11
406-1
406-2
422
421
421-1
550 amp
418-3
418-4
418-5
418-6
418-7
418-8
418-9
418-10
418-14
418-21
418-27
418-29
418-35
419-2
419-4
419-6
419-7
419-8
419-10
419-11
506-1
NA
NA
NA
NA
HEAT SHIELD (SOLD WITH TORCH HANGER)
HEAT SHIELD MOUNTING SCREWS
ESAB and L-Tec are trademarks of ESAB AB.
Kobelco is a trademark of Kobe Steel, Ltd.
Lincoln is a trademark of the Lincoln Electric Company.
Linde is a trademark of Linde AG.
OTC is a trademark of the SPX Corporation.
Panasonic is a trademark of Matsushita Electric Industrial Co., Ltd.
Tweco is a trademark of Victor Technologies.
DESCRIPTION
FEEDER ADAPTOR PINS
ESAB® (NON EURO STYLE) AND HOBART BETA MIG
HOBART® 27
LINCOLN LN4, LN5, LINDE SWM 31, 3A & 32A
LINCOLN LN7, 8 & 9, LN 25 SUITCASE, LN22
LINDE® SWM-14
LINDE 35 SWM-23
MILLER 10A, 30A (MILLERMATIC 35S FEEDER)
MILLER 52E, 54E, S21, S22 SERIES AND MILLERMATIC
200 & 250, 60 Series
OTC DAIHEN®
GILLILAND®
PANASONIC®
TWECO #5 PIN
KOBELCO®
CONTROL PLUGS (SOLD SEPARATELY)
HOBART
MILLER (52E, 54E)
LINCOLN (LN7, 8, 9) NA2
MILLER (10E, 30E) & LINDE (SWM-35)
DIPSTICK 160, 200, HOBART HANDLER, LINCOLN SP-100
MILLER DUAL SCHEDULE
LINCOLN DUAL SCHEDULE
ACCESSORIES (NOT SHOWN)
SPRING GUARD FOR 60 DEGREE NECK
SPRING GUARD FOR 45 DEGREE NECK
GUN HANGER
15
8.0 – ORDERING INFORMATION
8.1 EXAMPLE OF STANDARD MODEL NO.
4010-116
Wire Size
Standard Lengths - 10, 12, 15 ft
Other lengths available upon request
Amperage (Manual)
30 - 350 amp
40 - 450 amp
50 - 550 amp
8.2 EXAMPLE OF CUSTOM BUILT GUN
Use these codes to order special gun features.
POWER PINS
E - Euro-Connector
B - Bernard E-Z Connector
M - Miller
LN - Lincoln
LT - L-TEC
PA - Panasonic
TW - Tweco #5
ES - ESAB
F
OTHER
- Gasless Flux core
D - Dual-schedule
2D - 2-position dual-schedule
L - Lock-on trigger
8.3 GUN STANDARDS CHART
GUN MODEL
350 amp
450 amp
550 amp
NECK
305-60
405-60
505-60
NOZZLE
401-6-62
401-6-62
401-5-75
E 4015-116-60-FL-9
Option numbers should be added only if desired option is not included on standard gun model.
9 - Liner for Aluminum wire
FL - 405-FL Flex Neck
Angle of neck
Wire Size
Standard Gun Model No.
RETAINING HEAD NECK INSULATOR
404-26
404-26
404-26
402-11
402-11
402-11
CONTACT TIPS
403-20-xx
403-20-xx
403-20-xx
M001 REV G 09/12
16
M00
1
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