;

TG408 – REV E March 2018

Processes

MIG (GMAW) Welding

Description

Semi-Automatic, Water-Cooled,

400 amp, MIG (GMAW) Welding

T-Gun

TM

Semi-Automatic MIG Guns

TECHNICAL GUIDE

Bernard

A Division of Miller Electric Mfg. LLC

449 West Corning Road

Beecher, Illinois 60401 USA

Phone: 1-855-MIGWELD (644-9353) (US & Canada)

Fax:

1-519-737-3000 (International)

708-946-6726

For more information, visit us at BernardWelds.com

TABLE OF CONTENTS

WARRANTY………………………………………………………………………………………………………………3

SECTION 1 SAFETY PRECAUTIONS FOR GMAW WELDING GUNS – READ BEFORE USING…………………………….4

1-1 SYMBOL USAGE……………………………………………………………………………………………………...4

1-2 ARC WELDING HAZARDS………………………………………………………………………………….................4

1-3 PROPOSITION 65 WARNINGS………………………………………………………………………………………..6

1-4 PRINCIPAL SAFETY STANDARDS…………………………………………………………………………................6

1-5 EMF INFORMATION…………………………………………………………………………………………………..6

SECTION 2 – INSTALLATION …………………………………………………………………………………………….7

2-1 INSTALLING QUICK CONNECT BLOCK TO FEEDER…………………………………………………………………..7

2-2 INSTALLING GUN TO QUICK CONNECT BLOCK……………………………………………………………………...7

2-3 INSTALLING POWER PIN TO GUN…………………………………………………………………………………...8

SECTION 3 – MAINTENANCE……………………………………………………………………………………………..9

3-1 TREGASKISS™ NOZZLE AND TOUGH LOCK™ CONSUMABLES……………………………………………………...9

3-2 SWITCH REPLACEMENT……………………………………………………………………………………………..9

3-3 NECK REPLACEMENT……………………………………………………………………………………................10

3-4 LINER REPLACEMENT……………………………………………………………………………………...............11

3-5 CABLE ASSEMBLY REPLACEMENT………………………………………………………………………...............12

SECTION 4 − TECHNICAL DATA…………………………………………………………………………………………15

4-1 NECK DIMENSIONS………………………………………………………………………………………...............15

4-2 GUN AMPERAGE RATINGS…………………………………………………………………………………………15

SECTION 5 – OPTIONS………………………………………………………………………………………………….15

5-1 DIRECT PLUG-INS………………………………………………………………………………………………….15

5-2 FEEDER ADAPTORS………………………………………………………………………………………………...16

5-3 CONTROL PLUGS ………………………………………………………………………………………..............16

5-4 CONNECTOR OPTIONS……………………………………………………………………………………………..16

SECTION 6 – TROUBLESHOOTING……………………………………………………………………………………..17

SECTION 7 − EXPLODED VIEW AND PARTS LIST………………………………………………………………..........18

SECTION 8 ORDERING INFORMATION…..…………………………………………………………………..……….20

8-1 EXAMPLE OF STANDARD MODEL NO.……………………………………………………………………………...20

8-2 EXAMPLE OF CUSTOM BUILT GUN .……………………………………………………………………………...20

8-3 GUN STANDARDS CHART.…………………………………………………………………………………............20

2

Thank You for Choosing Bernard

Thank you for selecting a Bernard product. The MIG gun you have purchased has been carefully assembled and is ready to weld and factory tested prior to shipment to ensure high performance. Before installing, compare the equipment received against the invoice to verify that the shipment is complete and undamaged. It is the responsibility of the purchaser to file all claims of damage or loss that may have occurred during transit with the carrier.

The owner’s manual contains general information, instructions and maintenance to help better maintain your MIG gun.

Please read, understand and follow all safety precautions.

While every precaution has been taken to assure the accuracy of this owner’s manual, Bernard assumes no responsibility for errors or omissions. Bernard assumes no liability for damages resulting from the use of information contained herein. The information presented in this owner’s manual is accurate to the best of our knowledge at the time of printing. Please reference Bernardwelds.com for updated material.

For customer support and special applications, please call the Bernard Customer Service Department at 1-855-MIGWELD

(644-9353) (Canada & US) or 1-519-737-3000 (International) or fax 1-708-946-6726. Our trained Customer Service Team is available Monday to Friday between 8:00 a.m. and 4:30 p.m. CST and will answer your product application or repair questions.

Bernard manufactures premium semi-automatic GMAW (MIG) and FCAW (flux-cored) welding guns, consumables, accessories and manual arc products. For more information on other premium Bernard products, contact your local Bernard distributor or visit us on the web at BernardWelds.com

Warranty

Seller’s Products specified below shall be free from defects in material and workmanship for the period specified below from the delivery to an authorized Buyer provided the Products are operated, maintained, and repaired properly and pursuant to

Product documentation provided by the manufacturer. The Warranty against defects does not apply to: (1) consumable components or ordinary wear items; or (2) use of the Products with equipment, components or parts not specified or supplied by Seller or contemplated under the Product documentation.

Should there be a defect please refer to our Return Merchandise Policy.

PRODUCT

T-GUN™ Water-cooled MIG Guns and Components

WARRANTY PERIOD

180 days

Seller reserves the right to inspect any allegedly defective Product for the alleged deficiencies and that the deficiencies were not caused by accident, misuse, neglect, improper installment, unauthorized alteration or repair or improper testing.

In the event of a defect covered by the above warranty, Seller will, at its option, repair, replace or refund the purchase price of the defective Product. Product found not defective will be returned to Buyer at Buyer’s cost after notification by Seller’s

Customer Service Department.

EXCEPT AS SET FORTH ABOVE, SELLER MAKES NO WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING, BUT

NOT LIMITED TO, THE WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PURPOSE. SELLER SHALL NOT BE

LIABLE UNDER ANY CIRCUMSTANCES FOR DAMAGES OF ANY KIND. INCLUDING, BUT NOT LIMITED TO ANY, DIRECT,

INDIRECT, SPECIAL, 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 SELLER.

Genuine Bernard and Tregaskiss parts must be used for safety and performance reasons or the warranty above shall not be valid. Warranty shall not apply if accident, abuse, or misuse damages a product, or if a product is modified in any way except properly and by authorized Seller personnel.

3

SECTION 1 - SAFETY PRECAUTIONS FOR GMAW WELDING GUNS – READ BEFORE USING

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1 Symbol Usage

DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

The possible hazards are shown in the adjoining symbols or explained in the text.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

This group of symbols means Warning! Watch Out!

ELECTRIC SHOCK, MOVING PARTS, and HOT

PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

1-2 Arc Welding Hazards

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.

The safety information given below is only a summary of the more complete safety information found in the welding power source Owner’s

Manual. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this equipment. A qualified person is defined as one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to solve or resolve problems relating to the subject matter, the work, or the project and has received safety training to recognize and avoid the hazards involved.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

• Always wear dry insulating gloves.

• Insulate yourself from work and ground.

• Do not touch live electrode or electrical parts.

• Replace worn, damaged, or cracked

• guns or cables.

Turn off welding power source before changing contact tip or gun parts.

• Keep all covers and handle securely in place.

FUMES AND GASES can be hazardous.

• Keep your head out of the fumes.

• Ventilate area, or use breathing device.

The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.

• Read and understand the Safety Data

Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

MOVING PARTS can injure.

• Keep away from moving parts.

• Keep away from pinch points such as drive rolls.

WELDING can cause fire or explosion.

• Do not weld near flammable material.

• Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to

AWS F4.1 and AWS A6.0 (see Safety

•

Standards).

Watch for fire; keep extinguisher nearby.

• Read and understand the Safety Data

Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

4

BUILDUP OF GAS can injure or kill.

• Shut off compressed gas supply when not in use.

• Always ventilate confined spaces or use approved air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible

(ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

• Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety

Standards).

• Wear approved safety glasses with side shields under your helmet.

• Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the

• arc.

Wear body protection made from durable, flame-resistant material

(leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

HOT PARTS can burn.

• Allow gun to cool before touching.

• Do not touch hot metal.

• Protect hot metal from contact by others.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

• Check for noise level limits exceeding those specified by OSHA.

• Use approved ear plugs or ear muffs if noise level is high.

• Warn others nearby about noise hazard.

5

WELDING WIRE can injure.

• Keep hands and body away from gun tip when trigger is pressed.

READ INSTRUCTIONS.

• Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

• Use only genuine replacement parts from

• the manufacturer.

Perform installation, maintenance, and service according to the Owner’s Manuals, industry standards, and national, state, and local codes.

1-3 Proposition 65 Warnings

WARNING: This product can expose you to chemicals including lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm.

For more information, go to www.P65Warnings.ca.gov.

1-4 Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI

Standard Z49.1, is available as a free download from the

American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone:

1-877-413-5184, website: www.global.ihs.com).

Safe Practice For Occupational And Educational Eye And

Face Protection, ANSI Standard Z87.1, from American

National Standards Institute, 25 West 43rd Street, New

York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).

Safe Practices for the Preparation of Containers and

Piping for Welding and Cutting, American Welding

Society Standard AWS F4.1, from Global Engineering

Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society

Standard AWS A6.0, from Global Engineering

Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from

National Fire Protection Association, Quincy, MA 02169

(phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA

Pamphlet P-1, from Compressed Gas Association, 14501

George Carter Way, Suite 103, Chantilly, VA 20151 (phone:

703-788-2700, website: www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA

Standard W117.2, from Canadian Standards Association,

Standards Sales, 5060 Spectrum Way, Suite 100,

Mississauga, Ontario, Canada L4W 5NS

(phone: 800-463-6727, website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And

Face Protection, ANSI Standard Z87.1, from American

National Standards Institute, 25 West 43rd Street, New

York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and

Other Hot Work, NFPA Standard 51B, from National Fire

Protection Association, Quincy, MA 02169

(phone: 1-800-344-3555, website: www.nfpa.org).

OSHA, Occupational Safety and Health Standards for

General Industry, Title 29, Code of Federal Regulations

(CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and

Part 1926, Subpart J, from U.S. Government Printing

Office, Superintendent of Documents, P.O. Box 371954,

Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800)

(there are 10 OSHA Regional Offices—phone for Region 5,

Chicago, is 312-353-2220, website: www.osha.gov).

1-5 EMF Information

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit.

EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers-by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

1.

Keep cables close together by twisting or taping them, or using a cable cover.

2.

Do not place your body between welding cables.

Arrange cables to one side and away from the operator.

6

3.

Do not coil or drape cables around your body.

4.

Keep head and trunk as far away from the equipment in the welding circuit as possible.

5.

Connect work clamp to workpiece as close to the weld as possible.

6.

Do not work next to, sit or lean on the welding power source.

7.

Do not weld while carrying the welding power source or wire feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

SECTION 2 – INSTALLATION

2-1 INSTALLING QUICK CONNECT BLOCK TO FEEDER

STEP #1

• Insert the correct feeder adaptor liner for desired wire diameter (2 provided) flush with the threaded end of the feeder adaptor.

• Tighten set screw.

• Thread feeder adaptor into Quick Connect Block and tighten.

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.

2-2 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.

• Tighten thumb screw securely.

• Connect control plug lead to control

• housing on gun.

Insert control plug into feeder.

7

STEP #2

• Securely clamp blue hose on rear housing to water-out on water cooler and red hose on rear housing to water-in on water cooler.

WARNING : To prevent torch damage, it is highly advised that a Flow Sensor rated at 0.5 gpm be used at all times (Part #659-50).

STEP #3

• WARNING: Ensure water supply is on before operation.

• Recheck - Proper gas flow.

- Drive roll pressure.

- Voltage and wire feed speed.

- Water flow (minimum 1/2 gallon per minute) at 55-65 PSI.

2-3 INSTALLING POWER PIN TO GUN

IMPORTANT: The thread-in two-piece power pin incorporates a taper to seat and lock in the power pin to the rear handle block.

Make sure power pin is tightened in the block with a wrench to insure 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.

• Tighten the power pin into the rear block using a 1 1/4 ” wrench on the rear block and a 5/8” or a 3/4” wrench on the power pin.

• Install liner (See Section 2.4 LINER REPLACEMENT ).

• Install gun to feeder (See Below).

• Miller®, Tweco® #4 and #5, Lincoln® and

Hobart® Power Pin

- 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 it is necessary to connect gas

hose to barbed fitting on power pin.

• Bernard Style and Euro-Connector

- Feed welding wire through female adaptor by

hand and tighten drive rolls.

- Guide welding wire into connector on gun,

carefully insert connector into female adaptor

and tighten Euro hand nut or Bernard-style

locking collar.

• ESAB® Power Pin (Non-Euro Style)

- Insert power pin to shoulder and secure.

- Feed welding wire into power pin by hand and tighten.

8

SECTION 3 – MAINTENANCE

3-1 TREGASKISS™ NOZZLE AND TOUGH LOCK™ CONSUMABLES

HEAVY DUTY NOZZLE

VARIOUS LENGTHS AVAILABLE

HEAVY DUTY

TOUGH LOCK

CONTACT TIP

HEAVY DUTY

TOUGH LOCK

RETAINING HEAD

NECK

INSULATOR

IMPORTANT:

• Neck Insulator must be in place before welding to maintain insulation of neck armor.

• Be sure all parts are tightened well before welding.

• When using the heavy duty retaining head make sure it is tightened with a 5/8” wrench to prevent overheating of contact tip.

• To prevent scoring on heavy duty retaining head do not use pliers.

Removal and Replacement

• Pull slip-on nozzles off with a clockwise twisting motion.

• When installing nozzle, exposed insulator should nest inside neck insulator to assure concentricity.

• Neck insulators are positioned on the end of the neck with the large insulated counterbore facing the nozzle.

• Replace nozzle retainer with deep counterbore toward the neck. Tighten until retainer and neck insulator are secure.

3-2 SWITCH REPLACEMENT

STEP #1

• Twist handle locking caps.

• Pull handle locking caps away from handle.

• Remove Philips screw.

• Separate handle.

• Remove switch from nest in handle.

• Remove switch from switch lead connectors with needle nose pliers.

• Push switch lead connectors firmly onto switch terminals with needle nose pliers.

• Fit switch into nest on handle, switch leads must lie parallel.

• Reinstall handle halves & locking cap.

HANDLE FRONT

LOCKING CAP

LEADS

SWITCH

HANDLE REAR

LOCKING CAP

SWITCH LEAD

CONNECTORS

9

3-3 NECK REPLACEMENT

STEP #1

• Remove liner from gun.

• Twist handle locking caps.

• Pull handle locking caps away from handle.

• Remove Philips screw.

• Separate handle.

• Remove switch from nest in handle.

STEP #2

• Unthread power cable.

• Cut off water line and conduit clamp and pull hoses off barbed fittings.

HANDLE FRONT

LOCKING CAP

LEADS

SWITCH

WATER LINES (RED & BLUE)

& POWER LINE

NECK

HANDLE REAR

LOCKING CAP

SWITCH LEAD

CONNECTORS

WHITE CONDUIT LINE

STEP #3

• Slide on new clamps on water line and conduit.

• Thread power cable on connection and tighten.

• Push water line and conduit all the way to the base of the fittings and clamp.

• Reposition handle and switch.

• Reinstall handle locking caps & screw.

HANDLE FRONT

LOCKING CAP

HANDLE REAR

LOCKING CAP

NECK

LEADS

SWITCH

LEAD CONNECTORS

SWITCH

10

3-4 LINER REPLACEMENT

NOTE: For guns equipped with thread-in power pins, Bernard, or Euro-connectors, the procedure is the same.

On Miller-style guns, liner is held captive by a guide cap which must be removed and replaced when changing liner.

STEP #1

NOTE: Ensure power supply is off and gun is removed from feeder before proceeding.

• Remove nozzle, tip and retaining head.

• 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 counterclockwise until liner is free from the power pin.

• With gun straightened, grip conduit liner with pliers and remove.

STEP #2

• 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 collet in a clockwise direction and tighten in power pin.

NECK STEP #3

• Push liner back into gun and hold in place.

• Trim conduit liner with a 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 retaining head onto neck.

CONDUIT

LINER

3/4” (19 mm)

11

3-5 CABLE ASSEMBLY REPLACEMENT

STEP #1

MOUNTING SCREWS

• Remove nozzle, tip and retainer.

• Take out rear housing screws and pull out liner.

STEP #2

REAR

POWER & RED

WATER LINE BLUE WATER LINE

2-PIECE

POWER PIN WHITE CONDUIT LINE

• Pull the rear handle up the gun approximately 1 ft.

• Unscrew power cable from rear power block.

• Cut clamps off the water in (blue) line and gas line (white).

• Pull gas and water line off of power block.

• At this point, rear power block will be removed from gun.

• Slide rear handle off gun.

12

HANDLE FRONT

LOCKING CAP

WATER LINES (RED & BLUE)

& POWER LINE

NECK

HANDLE REAR LOCKING CAP

WHITE CONDUIT LINE OUTER JACKET

STEP #3

• On front of gun, release front handle from neck.

• Remove outer jacket by pulling outer jacket only from rear of gun; all that remains are the inner hoses attached to the neck and switch lead wires.

STEP #4

NECK

USED RED WATER

LINE & POWER LINE

REPLACEMENT RED WATER

LINE & POWER LINE

WHITE CONDUIT LINE

• Unthread power cable from front of gun and replace with new one.

STEP #5

• Slide outer jacket under front handle and bring front handle up to neck, replace switch and/or switch housing and secure (See Section 2.3 SWITCH REPLACEMENT ).

13

STEP #6

At rear of gun, slide rear handle up over outer jacket.

• Attach rear power block to power cable.

• Attach the gas line and water line with new clamps and crimp to power block.

STEP #7

• Slide rear handle to rear power block and secure with mounting screws.

• Put liner through gun and tighten.

14

SECTION 4 − TECHNICAL DATA

4-1 NECK DIMENSIONS

NECK

445-45

445-60

ANGLE

45°

60°

INCHES

5.63

4.99

B mm

142.95

126.75

4-2 GUN AMPERAGE RATINGS

100% DUTY CYCLE

MODEL CO

2

MIXED

400 425 350

NOTE: Ratings are based on tests that comply with IEC 60974-7 standards.

INCHES

4.02

5.14

C mm

102.16

130.56

INCHES

D

2.5

2.5 mm

63.5

63.5

CO

2

525

60% DUTY CYCLE

MIXED

425

SECTION 5 − OPTIONS

5-1 DIRECT PLUG-INS

PART # DESCRIPTION

214 TREGASKISS™ POWER PIN

414-11-2 O-RING - FOR MILLER® POWER PINS

214-6-116 MILLER POWER PIN

414-9 GUIDE CAP ONLY - FOR 214-6-9

414-116 GUIDE CAP ONLY - FOR 214-6-116

414-332 GUIDE CAP ONLY - FOR 214-6-332

214-12 TWECO® #5 STYLE POWER PIN

414-12-2 O-RING FOR TWECO #5 STYLE POWER PIN

214-2 LINCOLN® POWER PIN

214-13 PANASONIC®

214-6-9 MILLER POWER PIN (ALUMINUM OPTION)

USE ON FEEDERS

TREGASKISS QUICK CONNECT BLOCK, HOBART® 2000 SERIES

FEEDERS, TWECO #4 RECEPTACLE BODY PART #TAK-1,

LINCOLN POWER MIG 300.

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

15

5-2 FEEDER ADAPTORS

To be used with 417 Quick-Connect Block

PART #

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

USE ON FEEDERS

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®

#5 PIN

KOBELCO®

5-3 CONTROL PLUGS 5-4 CONNECTOR OPTIONS

Euro Connector option - for European style feeders adaptors for

400 amp T-Gun MIG Guns

PART #

419-2

419-4

419-5

419-6

419-7

419-8

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

Euro Connector option - for European style feeders and feeder and

Feeder adaptors for 400 amp T-Gun MIG Guns.

PART #

675

675-2

675-10

DESCRIPTION

EURO CONNECTOR ASSEMBLY

EURO HOUSING

EURO CONNECTOR BODY

16

SECTION 6 – TROUBLESHOOTING

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 SHORT AND NOT SEATING PROPERLY IN GAS DIFFUSER

• DRIVE ROLLS TOO TIGHT RESULTING IN SCORING OF WELDING WIRE

• WELDING WIRE DIRTY, RUSTY OR TOO MUCH CAST

• DRIVE ROLLS TOO TIGHT RESULTING IN SCORING OF WELDING WIRE

• WELDING WIRE DIRTY, RUSTY OR TOO MUCH CAST

• UNCOATED WIRE BEING USED, INCREASING USAGE

• WRONG TIP SIZE

• OVER TORCH RATED DUTY CYCLE

• LOOSE RETAINING SCREW ON QUICK CONNECT BLOCK

• INSUFFICIENT GAUGE POWER CABLE AND/OR GROUND CABLE

• LOOSE CONNECTOR CONES AND/OR CONE NUTS

• 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

17

SECTION 7 − EXPLODED VIEW AND PARTS LIST

Numbers in this column correspond to the exploded view images above.

2

ITEM

1

PART # DESCRIPTION

STANDARD NOZZLES (SELF-INSULATED)

401-40-38 SUPER TAPERED NOZZLE - 3/8" BORE (BRASS)

401-4-38

401-4-50

401-4-62

401-4-75

401-8-62

401-5-62

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

401-5-75 3/4" (19 mm) BORE - 1/4" (6 mm) TIP RECESS

401-6-50

401-6-62

401-6-75

401-7-62

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)

401-7-87 7/8" (22 mm) BORE - 1/4" (6 mm) TIP RECESS (BRASS)

HEAVY DUTY TREGASKISS™ TOUGH LOCK™ CONTACT TIPS -

5/16” (7.9 mm) O.D.

403-20-30 FOR .030" (0.8 mm) WIRE

403-20-35 FOR .035" (0.9 mm) WIRE

403-20-1.0 FOR 1 mm WIRE

403-20-45 FOR .045" (1.2 mm) WIRE

403-20-364 FOR 3/64" (1.2 mm) WIRE

403-20-1.4 FOR 1.4 mm WIRE

403-20-52 FOR .052" (1.3 mm) WIRE

403-20-116 FOR 1/16" (1.6 mm) WIRE

403-20-564 FOR 5/64" (2.0 mm) WIRE

403-20-332 FOR 3/32" (2.4 mm) WIRE

HEAVY DUTY TAPERED TREGASKISS TOUGH LOCK CONTACT TIP -

5/16" (7.9 mm) O.D.

403-21-30 FOR .030" (0.8 mm) WIRE

403-21-35 FOR .035" (0.9 mm) WIRE

403-21-1.0 FOR 1 mm WIRE

403-21-45 FOR .045" (1.2 mm) WIRE

10

10A

11

9

12

6

8

7

4

5

ITEM

3

PART # DESCRIPTION

404-20 TREGASKISS™ TOUGH LOCK™ RETAINING HEAD FOR HD TIPS

454-1-2 RETAINING RING

402-6

402-7

445-45

445-60

656-15

657-15

658

658-1

O-RING

NECK INSULATOR

NECKS (INCL. C/W (1) 357-2 AND (1) 413-5 CLAMP)

NECK - 45°

NECK - 60°

INTERNAL WATER LINE (INCL. C/W (1) 357-2 CLAMP FOR FRONT & (1)

656-1 CLAMP FOR REAR )

15’ SERVICE (CUT FOR OTHER LENGTHS)

CONDUIT (INCL. C/W (2) 657-1 CLAMPS)

15’ SERVICE (CUT FOR OTHER LENGTHS)

RED WATER INE - OUT (C/W (1) 656-1 CLAMP)

BLUE WATER LINE - IN (C/W(1) 656-1 CLAMP)

(LOCATED AT QUICK CONNECT POWER BLOCK ASSEMBLY)

659-10

659-12

659-15

320

POWER CABLE ASSEMBLY

10’ SERVICE (ACTUAL LENGTH - 9.5’)

12’ SERVICE (ACTUAL LENGTH - 11.5’)

15’ SERVICE (ACTUAL LENGTH - 14.5’)

HANDLE - FRONT

320-2

211-5

HANDLE LOCK NUT (FOR FRONT)

SWITCH ASSEMBLY

211-5-8 SWITCH WITH EXTENDED LEVER

662-10

662-15

662-15

CONTROL WIRE

10’ SERVICE

12’ SERVICE

15’ SERVICE

18

18

13

15

15A

15B

15C

15D

16

17

PART #

412-8

DESCRIPTION

SWITCH LEAD CONNECTOR

642-XX

320-5

320-4

663-1-XX

663-1

664-400

214

214-2

214-6-116

214-12

214-13

414-1

414-2

414-11-2

214-6-9

L1A-15

415-30-25

415-35-10

415-35-15

415-35-25

OUTER JACKET ASSEMBLY

JACKET BUSHING

REAR HANDLE CAP

OUTER JACKET

STRAIN RELIEF

POWER PIN BLOCK

TWECO®

LINCOLN®

MILLER®

TWECO 5

PANASONIC®

O-RING FOR TWECO

LINER SET SCREW

O-RING FOR MILLER POWER PIN

MILLER (FOR ALUMINUM)

CONVENTIONAL LINERS

FOR .023" (0.6 mm) WIRE - 15' (5 m)

FOR .030" (0.8 mm) WIRE - 25' (8 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)

415-35-2

415-116-10

415-116-15

415-116-25

415-116-2

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) ALUM. WIRE - 15' (5 m)

415-332-15 FOR 5/64" - 3/32" (2.0 mm - 2.4 mm) WIRE - 15' (5 m) FLAT WOUND

415-332-153 FOR 5/64" - 3/32" (2.0 mm - 2.4 mm) WIRE - 15' (5 m) ROUND WOUND

415-332-251 FOR 5/64" - 3/32" (2.0 mm - 2.4 mm) WIRE - 15' (5 m) ROUND WOUND

415-332-25

415-564-15

415-332-15

415-1M

415-25

FOR 5/64" - 3/32" (2.0 mm - 2.4 mm) WIRE - 25' (8 m) FLAT WOUND

FOR ALL 5/64" (2.0 mm) WIRE & 1/16" (1.6 mm) FLUX CORE WIRE

FOR .078” - 3/32” (2.24 mm) WIRE - 15’ (5 m) FLAT WOUND

LINER O-RING

TREGASKISS JUMP LINER

415-45-01

415-45-02

415-45-03

415-116-21

415-116-22

415-116-23

FOR .035” - 3/64" WIRE - 6'

FOR .035” - 3/64" WIRE - 10'

FOR .035” - 3/64" WIRE - 15'

FOR 3/64" - 1/16” WIRE - 6'

FOR 3/64" - 1/16” WIRE - 10'

FOR 3/64" - 1/16” WIRE - 15'

23

24

25

26

27

28

30

19

20

21

22

PART #

416-15

416-5

422

421

610

661-10

661-12

661-15

413-5

411-3M

417

417-50

417-60

357-2

656-1

412-1

DESCRIPTION

EURO HOUSING BLANK (C/W SCREWS)

CONTROL HOUSING (C/W SCREWS)

MOUNTING SCREWS (METRIC)

FEEDER ADAPTOR REQUIREMENTS (SOLD SEPARATELY)

QUICK CONNECT BLOCK ASSEMBLY TWECO #4

QUICK CONNECT BLOCK ASSEMBLY EURO

QUICK CONNECT BLOCK ASSEMBLY TWECO #5

FEEDER ADAPTORS (TO BE USED WITH QUICK CONNECT BLOCK)

CONTROL PLUGS (C/W PLUGS LEAD & FEMALE CONNECTORS)

OPTIONAL ACCESSORIES

GUN HANGER

HEAT SHIELD

HANDLE (REAR W/STRAIN RELIEF)

REPLACEMENT CABLE BUNDLES

10 FT. CABLE BUNDLE

12 FT. CABLE BUNDLE

15 FT. CABLE BUNDLE

OETIKER CLAMP - 11.3 mm

OETIKER CLAMP - 8.7 mm

OETIKER CLAMP - 9.5 mm

SWITCH LEAD CONNECTOR

19

SECTION 8 - ORDERING INFORMATION

8-1 EXAMPLE OF STANDARD MODEL NO.

42 10-116

Wire Size

Standard Lengths - 10, 12, 15 ft

Other lengths available upon request

Amperage (Manual)

42 - 400 amp

8-2 EXAMPLE OF CUSTOM BUILT GUN

M

LN

PA

TW

E

Use these codes to order special gun features.

- Euro-Connector

- Miller Power Pin

- Lincoln Power Pin

- Panasonic

- Tweco # 5

E 4210-116-60-9

Option numbers should be added only if desired option is not included on standard gun model.

9 - Liner for Aluminum wire

Angle of Neck

Wire Size

8-3 GUN STANDARDS CHART

GUN MODEL

400 amp

NECK

445-60

NOZZLE

401-6-62

RETAINING HEAD

404-20

CONTACT TIPS

403-20-XX

Bernard

A Division of Miller Electric Mfg. LLC

449 West Corning Road

Beecher, Illinois 60401 USA

©2018 Bernard

Phone: 1-855-MIGWELD (644-9353) (US & Canada)

Fax:

1-519-737-3000 (International)

708-946-6726

For more information, visit us at BernardWelds.com