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AIR-COOLED MIG GUN 250 AMP, 350 AMP, 450 AMP
CURRENT
UP TO
450
AMPS
WIRE SIZE
3
UP TO
/
32"
(2.4 mm)
DUTY CYCL E
UP TO
80%
SPRAY MASTER™
WITH VELOCITY CONSUMABLES
MIG GUNS
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
WARNING
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
U.S. Customer Care: (800) 426-1888
International Customer Care: (940) 381-1212
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
Mesures de sécurité ......................................................................... 2
2.01 How to Use this Manual ................................................................... 4
2.02 Receipt of Equipment ....................................................................... 4
3.01 MIG Gun Classification ..................................................................... 4
3.03 MIG Gun Part Number Identification ................................................ 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
Conduit Removal .............................................................................. 5
Conduit Installation .......................................................................... 5
5.03 Installing/Replacing Stainless Steel Sleeve ...................................... 5
5.04 Replace Conductor Tube .................................................................. 6
6.01 Cablehoz® Repair ............................................................................ 6
SECTION 10: STATEMENT OF WARRANTY ................................................................9
SECTION 1: SAFETY PRECAUTIONS
MESURES DE SÉCURITÉ
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.
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.
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
2
AVERTISSEMENT
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
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.
89200016 3
SAFETY AND OPERATING INSTRUCTIONS
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 porte-
électrodes, 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.
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.
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
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 3: MIG GUN
SPECIFICATIONS
3.01 MIG GUN CLASSIFICATION
Process
Method of Guidance
Type of Cooling
Type of Shielding Gas
MIG/MAG welding
Manually guided
Air
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
SMV3153545
Spray Master with Velocity
.035"-.045" Wire Capacity
(0,9mm - 1,2mm)
GROUND
WORK PIECE
Figure 1: Standard MIG Gun Installation
4.01 DIRECT PLUG MIG GUN INSTALLATION
Direct plug MIG guns install by directly inserting the rear connector plug into the feeder wire guide outlet (see figure 2) and tightening the plug retaining screw. All models of MIG guns, except the Euro-Kwik guns, require a control wire assembly to attach the MIG gun trigger leads to the feeder. The control wire assemblies plug into the rear connector case of the MIG gun, and into the control wire receptacle on the feeder. Euro-Kwik connections are installed by inserting the gun connection into the feeder receptacle, aligning the conduit plug first, then the gas plug. Push until all fittings are seated, then tighten the nut hand tight as shown in figure 3.
Figure 2
Figure 3
4 89200016
SAFETY AND OPERATING INSTRUCTIONS
SECTION 5: SPRAY MASTER WITH VELOCITY MAINTENANCE
This section discusses servicing and or replacing various components of the Spray Master MIG Gun.
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.
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 Liner length in feet
CONDUIT REMOVAL
1. Lay the MIG gun out on a table or on the floor in a straight line. Make sure the gun is fully extended and all twists in the cable are removed.
2. Remove the nozzle and 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.
3. When the conduit is completely in the gun, tighten the rear conduit set screw.
On Miller ® guns, reinstall the nipple. On Euro-Kwik guns, reinstall the conduit retaining cap.
Conduit Trim Length
3/8” (9 mm to 10 mm)
Stainless Steel Sleeve end
4. File the cut conduit end to remove burrs because they could interfere with wire feeding or conflict with the tip seating into the Stainless Steel Sleeve.
5. Insert the contact tip and HAND tighten the nozzle.
The MIG gun is now ready to be reinstalled on the feeder.
5.03 INSTALLING/REPLACING STAINLESS STEEL SLEEVE
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.
Lock collar and wave spring are held in place by the stainless steel sleeve.
STAINLESS STEEL SLEEVE
Conduit set screw
NOTE
On Miller
®
Direct Plug MIG guns, remove the nipple on the end of the connector plug. On Euro-Kwik connections, remove the conduit retaining cap.
3. Remove the diffuser and contact tip.
4. Grip the conduit stop and remove the conduit with a twisting motion. On Miller clockwise will raise the conduit stop out of the connector plug recess.
®
Direct Plug MIG guns, twisting the rear of the gun approximately one revolution
CONDUIT INSTALLATION
1. Uncoil the conduit and lay it in a straight line. Insert the conduit into the rear connector plug. Push the conduit into the gun with short strokes. If the conduit hangs up, twist the conduit counterclockwise or gently whip the cable while applying pressure to the conduit.
2. The conduit liner will need to be cut to length. This can be done by cutting the conduit to match the one removed or inserting the new liner through the
MIG gun and trimming the conduit extending from the conductor tube to the appropriate length noted in the following chart.
89200016 5
CONDUCTOR TUBE END
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.
Lock Collar
Spring Washer Snap Ring
4. Start the Stainless Steel Sleeve set screw into the new sleeve and then slide the 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.
SAFETY AND OPERATING INSTRUCTIONS
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.
Spray Master Replacement Kit Parts List
Description Part No.
Wave Spring
Lock Collar
Stainless Steel Sleeve
O-Ring
VCTLSPR
VCTLSLK
VCTLSL
94-710-036
* Not Shown
Qty
4
1
1
1
Conductor Tube set screw
3. Remove and replace the conductor tube O-ring.
Slide the tube over the liner and insert into the brass connection within the handle.
Tighten the socket head cap screw wrench tight.
4. Tighten the conduit set screw down against the liner. Do not overtighten to avoid damages the liner.
5. Check the length of conduit extending from the conductor tube front end and adjust if necessary.
Conduit Trim Length
3/8” (9 mm to 10 mm)
Stainless Steel Sleeve end
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.
RED RED
NOT USED
WHITE WHITE
NOT USED
CABLEHOZ
CONTROL WIRE
{
BLUE
BROWN
BLACK
BLACK
BLACK
BLACK
TRIGGER
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
8.02 TIPS AND NOZZLES
Velocity Nozzle Identification
S=Small,
M=Medium,
L=Large
ET=Extended Taper
Blank=Threaded,
S=Slip
V N M 5 0 F S
Velocity
Nozzle
Orifice Opening Size:
37=3/8” 62=5/8”
50=1/2” 75=3/4”
Blank=Std Recess,
F=Flush,
P=Protrude,
R= Recess ¼” (6.35mm)
FAS=Spot Weld
FC=Flux Core
Velocity Contact Tip Identification
S=Small,
M=Medium,
L=Large
ET=Extended Taper
A=Alum,
Blank=Other
V T M A 3 0
Velocity
Tip
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”
NOTE
Two knurled bands on the nozzle outer surface indicate Medium
Duty.
Fixed Threaded 2 piece nozzle has three knurled bands on the nozzle outer surface (1 on the front half and 2 on the back half) to indicate Heavy Duty.
Stainless
Steel Sleeve
Lock Collar
Retaining Ring
Wave Spring
Set Screw
Spray Master Replacement Kit Parts List
Description
Conductor Tube Assy.
Set Screw* (Sleeve)
Set Screw (5/64" hex wrench drive)
Retaining Ring
Part No.
SMVCT60
V41CS
41CS
PMA64RS
Conductor Tube
Qty
1
1
1
1
O-ring
6 89200016
SAFETY AND OPERATING INSTRUCTIONS
MEDIUM DUTY CONTACT TIPS
Part No.
Description
VTM23
VTM30
VTM35
VTM40
.023" (0.6 mm)
.030" (0.8 mm)
.035" (0.9 mm)
.040" (1.0 mm)
VTM45 .045" (1.2 mm)
VTMA116 1/16" (1.6 mm)
VTM52
VTM116
.052" (1.3 mm)
1/16" (1.6 mm)
VTMA116 1/16" (1.6 mm)
VTM564 5/64" (2.0 mm)
Stock No.
1160-1750
1160-1751
1160-1752
1160-1753
1160-1754
1160-1755
1160-1756
1160-1757
1160-1758
1160-1759
HEAVY DUTY CONTACT TIPS
Part No.
Description
VTH30
VTH35
VTH40
VTH45
.030" (0.8 mm)
.035" (0.9 mm)
.040" (1.0 mm)
.045" (1.2 mm)
VTHA364 3/64" (1.2 mm)
VTH52 .052" (1.3 mm)
VTH116 1/16" (1.6 mm)
VTHA116 1/16" (1.6 mm)
VTH564 5/64" (2.0 mm)
VTH332
VTH764
VTH18
3/32" (2.4 mm)
7/64" (2.8 mm)
1/8" (3.2 mm)
Stock No.
1160-1760
1160-1761
1160-1762
1160-1763
1160-1764
1160-1765
1160-1766
1160-1767
1160-1768
1160-1769
1160-1770
1160-1771
EXTENDED TAPER CONTACT TIPS
Part No.
Description
VTET30 .030" (0.8 mm)
VTET35 .035" (0.9 mm)
VTET40 .040" (1.0 mm)
VTET45 .045" (1.2 mm)
VTETA364 3/64" (1.2 mm)
VTET52 .052" (1.3 mm)
VTET116 1/16" (1.6 mm)
Stock No.
1160-1772
1160-1773
1160-1774
1160-1775
1160-1776
1160-1777
1160-1778
MEDIUM DUTY NOZZLES
Part No.
Description
VNM50F
VNM62
VNM62F
VNM75
VNM75F
VNM50S
1/2" Threaded Nozzle Flush
5/8" Threaded Nozzle Recess
5/8" Threaded Nozzle Flush
3/4" Threaded Nozzle Recess
3/4" Threaded Nozzle Flush
1/2" Slip Nozzle
VNM62S
VNM75S
5/8" Slip Nozzle
3/4" Slip Nozzle
VNS Slip Nozzle Base
VNM50SC 1/2" Slip Nozzle Cone Only
VNM62SC 5/8" Slip Nozzle Cone Only
VNM75SC 3/4" Slip Nozzle Cone Only
VNFC Flux Core Nozzle
VNM62FAS 5/8" Spot Nozzle
VNM75FAS 3/4" Spot Nozzle
8.03 CONDUIT
250 AMP
Length
350 AND 450 AMP
12 Ft
15 Ft
20 Ft
25 Ft
Wire Size
.035" - .045" (1,0mm - 1,2)mm
Part No.
Stock No.
See 15 Ft
42-4045-15
See 20 Ft
42-4045-25
1420-1123
1420-1125
Stock No.
1240-1856
1240-1854
1240-1855
1240-1852
1240-1853
1240-1859
1240-1860
1240-1863
1240-1864
1240-1861
1240-1862
1240-1865
1240-1892
1240-1866
1240-1868
HEAVY DUTY NOZZLES
Part No.
Description
VNH62
VNH62F
VNH75
VNH75F
VNH62S
VNH75S
5/8" Threaded Nozzle Recess
5/8" Threaded Nozzle Flush
3/4" Threaded Nozzle Recess
3/4" Threaded Nozzle Flush
5/8" Slip Nozzle
3/4" Slip Nozzle
VNS
VNH62SC
Slip Nozzle Base
5/8" Slip Nozzle Cone Only
VNH75SC 3/4" Slip Nozzle Cone Only
VNH622PC 5/8" 2 Piece Nozzle Assembly Recess
VNH62C 5/8" 2 Piece Nozzle Cone Only Recess
VNH62F2PC 5/8" 2 Piece Nozzle Assembly Flush
VNH62FC 5/8" 2 Piece Nozzle Cone Only Flush
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
* Some parts may not be available at this time.
8.04 CONDUCTOR TUBES
250 AMP
SMVCT45
350 AMP
SMVCT60
Stock No.
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
450 AMP
SMVCT45
SMVCT60
SMVCT60LM
Length
10 Ft
12 Ft
15 Ft
20 Ft
25 Ft
Wire Size
.052" - 1/16" (1,3mm - 1,6mm)
Part No.
350 Amp
Stock No.
Part No.
450 Amp
Stock No.
See 15 Ft
See 15 Ft
44-116-15
See 20 Ft
1440-1113
See 15 Ft
See 15 Ft
44-116-15
See 20 Ft
1440-1113
44-116-25 1440-1115
89200016 7
SAFETY AND OPERATING INSTRUCTIONS
SECTION 9: REPLACEMENT PARTS
12a
11a
12
14
10a
11
10
13b
13
13a
8
7
7a
9b
9
9c
9a
5
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
3
2
4
1
8 89200016
89200016
SAFETY AND OPERATING INSTRUCTIONS
6
7
7b
8
9
9a
9b
9c
10a
10b
NS
11a
11b
NS
12a
12b
13
13a
13b
14
Item
No.
1
2
3
4
5
250 AMP
--
MS84
2060-2130
N/A
MS84-LC
2060-2127
ELC94
2060-2647
MS94-LC
2060-2693
N/A
ELC94-BL
2060-2671
N/A
MS212
1720-2116
MS215
1720-2117
MS225
1720-2118
MS212X
1720-2107
MS215X
1720-2108
MS225X
1720-2109
MS102-RK
2060-2132
MS172-RK
2060-2134
172X-M
2020-2181
350-174MH
2035-2111
WM-354M
2030-2075
N/A
350-174H
2035-2110
MS354-TAJ
2060-2139
MS-354DS-TJ
2060-2138
350-174LH
2035-2112
MS-354DS-LJ
2060-2137
174EX-1
2040-2276
174X-2
2040-2177
X6RC
2060-2006
--
350 AMP
VCTLSL
VCTLSLK
VCTLSPR
PMA64R
--
MS84
2060-2130
MS84-DSRS
2060-2128
MS84-LC
2060-2127
ELC94
2060-2647
MS94-LC
2060-2693
MS94-RSW
2060-2694
ELC94-BL
2060-2671
MS310
1730-2035
MS312
1730-2036
MS315
1730-2037
MS325
1730-2038
N/A
N/A
N/A
MS104-RK
2060-2133
MS174-RK
2060-2135
174X-M
2040-2181
350-174MH
2035-2111
WM-354M
2030-2075
194DS
2040-2195
350-174H
2035-2110
MS354-TAJ
2060-2139
MS-354DS-TJ
2060-2138
350-174LH
2035-2112
MS-354DS-LJ
2060-2137
174EX-1
2040-2276
174X-2
2040-2177
X6RC
2060-2006
--
450 AMP
--
MS84
2060-2130
MS84-DSRS
2060-2128
MS84-LC
2060-2127
ELC94
2060-2647
MS94-LC
2060-2693
MS94-RSW
2060-2694
ELC94-BL
2060-2671
N/A
MS412
1740-2116
MS415
1740-2117
MS425
1740-2118
MS412X
1740-2122
MS415X
1740-2123
N/A
MS104-RK
2060-2133
MS174-RK
2060-2135
174X-M
2040-2181
350-174MH
2035-2111
WM-354M
2030-2075
194DS
2040-2195
350-174H
2035-2110
MS354-TAJ
2060-2139
MS-354DS-TJ
2060-2138
350-174LH
2035-2112
MS-354DS-LJ
2060-2137
174EX-1
2040-2276
174X-2
2040-2177
X6RC
2060-2006
--
NS = Not Shown
Description
Stainless Steel Sleeve
Lock Collar
Wave Spring
Retaining Ring
Conductor Tube – Refer to 8.04 Conductor Tube
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 - 10 ft (3 m)
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 Assembly, Euro-Kwik - 25 ft (8 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
Conduit – Refer to 8.03 Conduit
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
All MIG Gun products 30 days from date purchaser purchases from seller.
Parts / Labor
30 days / NA
9
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
Milan, Italy
Customer Care
Ph: +39 0236546801
Fax: +39 0236546840
ASIA/PACIFIC
Cikarang, Indonesia
Customer Care
Ph: 6221-8990-6095
Fax: 6221-8990-6096
Rawang, Malaysia
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
Shanghai, China
Sales Office
Ph: +86 21-64072626
Fax: +86 21-64483032
Singapore
Sales Office
Ph: +65 6832-8066
Fax: +65 6763-5812
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
I N N O V A T I O N T O S H A P E T H E W O R L D
™
Printed in Mexico
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