T-Gun Series Small Handle Air

TECHNICAL GUIDE
For T-Gun™ Semi-Automatic
Air-Cooled MIG Guns
350 amp Compact Series
 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
WARRANTY .......................................................................................................................................... 2
GENERAL SAFETY .................................................................................................................................. 3
THANK YOU… ....................................................................................................................................... 3
1.0 – INSTALLATION .............................................................................................................................. 4
1.1 INSTALLING QUICK CONNECT BLOCK TO FEEDER ....................................................................................... 4
1.2 INSTALLING GUN TO QUICK CONNECT BLOCK............................................................................................ 4
1.3 INSTALLING POWER PIN TO GUN .............................................................................................................. 5
2.0 – MAINTENANCE ............................................................................................................................. 5
2.1
2.2
2.3
2.4
2.5
2.6
TREGASKISS™ NOZZLE AND TOUGH LOCK™ CONSUMABLES ...................................................................... 5
LINER REPLACEMENT ................................................................................................................................ 6
SWITCH REPLACEMENT ............................................................................................................................ 7
NECK REPLACEMENT ................................................................................................................................ 7
UNICABLE REPLACEMENT ......................................................................................................................... 8
UNICABLE REPAIR..................................................................................................................................... 9
3.0 – TECHNICAL DATA........................................................................................................................ 11
3.1 NECK DIMENSIONS ................................................................................................................................. 11
3.2 GUN AMPERAGE RATINGS ...................................................................................................................... 11
4.0 – OPTIONS .................................................................................................................................... 11
4.1
4.2
4.3
4.4
DIRECT PLUG-INS.................................................................................................................................... 11
SPECIALTY AND OPTIONAL ITEMS ........................................................................................................... 12
FEEDER ADAPTORS ................................................................................................................................. 12
CONTROL PLUGS .................................................................................................................................... 12
5.0 – TROUBLESHOOTING ................................................................................................................... 13
6.0 – DAILY WELDING GUN INSPECTION .............................................................................................. 13
7.0 – EXPLODED VIEW AND PARTS LIST ............................................................................................... 14
8.0 – ORDERING INFORMATION .......................................................................................................... 16
8.1 EXAMPLE OF STANDARD MODEL NO....................................................................................................... 16
8.2 GUN STANDARDS CHART ........................................................................................................................ 16
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
T-GUN™ 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.
2
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.
- Operator and his surroundings are not wet.
- Cables are not wrapped around operator’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.)
THANK YOU…
…for selecting a Bernard T-Gun™ Water-Cooled Robotic MIG Gun. Manufacturing operations demand extremely
dependable robotic equipment. With this in mind, the T-Gun was designed and engineered to be a reliable tool to
support high production within a robotic cell. The T-Gun MIG Gun is made from durable materials and
components engineered to perform in a rugged, welding environment.
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 customer support and special applications, please call the Bernard Customer Service Department at
1-800-946-2281 (USA and Canada) or +1-708-946-2281 (International). Our trained Customer Service Team is
available between 8:00 a.m. and 4:30 p.m. CST, and will answer your product 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.
3
1.0 – INSTALLATION
1.1 INSTALLING QUICK CONNECT BLOCK TO FEEDER
SET SCREW
STEP #1



FEEDER ADAPTOR
Insert the correct feeder adaptor liner for desired
wire diameter (2 provided) flush with the thread
end of the feeder adaptor.
Tighten set screw (20 in.-lbs.).
Thread feeder adaptor into Quick Connect Block
and tighten.
QUICK
CONNECT
BLOCK
FEEDER ADAPTOR LINER
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 (15 ft.-lb.).
Tighten all connections.
Feed welding wire through assembly by hand and tighten drive
rolls.
POWER
BOLT
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





POWER PIN
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.
WELDING WIRE
THUMB SCREW
STEP #2


With gun straightened, pull trigger and feed wire through gun (it may be necessary to remove contact tip
when feeding small wire sizes).
Re-check: - proper gas flow.
- drive roll pressure.
- voltage and wire feed speed.
4
1.3 INSTALLING POWER PIN TO GUN
JAM NUT
HANDLE LOCK NUT
HANDLE








POWER PIN
Remove handle screw, front / rear handle lock nuts and separate handle halves.
Thread jam nut onto power pin.
Thread power pin into the rear connector cone.
Tighten the power pin into the rear connector cone using a 3/4" (19 mm) wrench on the rear connector cone.
Tighten jam nut.
Power Pin Insulator.
Install liner (See Section 2.2 Liner Replacement).
Install gun to feeder (See below):
Most Pins (Note that Bernard, Euro and OXO™ are not direct connect 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® it is necessary to connect gas
hose to barbed fitting on power pin.
2.0 – MAINTENANCE
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 for heavy-duty tips (Part #450-18) or a pair of weld pliers are the optimal tools for
contact tip installation.
5
Retaining Head
 Thread retaining head onto neck 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.
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, liner is held captive by guide cap, which must be removed and replaced when
changing liner.
STEP #1
WARNING: Ensure power supply is
off and gun is removed from feeder
before proceeding.
 Remove nozzle, tip and gas
diffuser/retaining head.
 With gun straightened, unscrew
conduit liner will 10 mm wrench
and remove.
CONDUIT
LINER
STEP #2


Feed replacement liner through gun using
short strokes to avoid kinking.
Twist liner clockwise if necessary and with a
10 mm wrench, tighten liner (30 in.-lbs.).
STEP #3
NOTE: Compress liner back into torch before cutting.
 Trim conduit liner with 3/4" (20 mm) stick out.
 Remove any burr that may obstruct wire feed, especially on flat wire
type conduit liner.
 Replace nozzle, tip and gas diffuser/retaining head onto gooseneck.
6
3/4" (19 mm)
2.3 SWITCH REPLACEMENT
STEP #1









HANDLE LOCK NUT
2.4 NECK REPLACEMENT
STEP #1
NECK
HANDLE
UNICABLE
LOCK
NUT
JAM NUT
SWITCH







HANDLE LOCK NUT
Twist front and rear handle lock nut
in direction of arrows.
Pull handle locks away from handle.
Remove handle screw from handle
SCREW
and separate handle halves.
SWITCH LEAD
Remove switch from nest in handle.
CONNECTORS
SWITCH
Remove switch from switch lead
connectors with needle nose pliers.
Push switch lead connectors firmly onto
new switch terminals with needle nose pliers.
Fit switch into nest of handle; switch leads must lie parallel.
Reinstall handle making sure that handle is positioned correctly. Jam nut and cone should sit in handle
grooves. Neck will spin freely if handle is not positioned correctly.
Install handle screw and tighten handle lock nuts.
Place neck in vise.
Twist front handle lock nut counterclockwise and pull away from handle.
Twist rear handle lock nut counterclockwise and pull away from handle.
Remove handle screw and separate halves.
To remove switch, see Section 2.3 SWITCH REPLACEMENT.
Loosen jam nut using two 3/4" wrenches and unthread neck.
Remove from vise and unthread neck by hand.
7
STEP #2
HANDLE
LOCK
NUT
JAM NUT
UNICABLE
NECK
NOTE: OETIKER CLAMP EAR MUST BE
POSITIONED IN LINE WITH PINK AND BLUE
LEAD FACING SWITCH.




Install handle lock nut on new neck.
Thread jam nut onto new neck.
Thread neck into unicable (hand tighten) to desired orientation. Align flats on connector cone 90° to
gooseneck.
Place neck in vise and tighten unicable and jam nut (14 in.-lbs.).
STEP #3



HANDLE LOCK NUT
Reposition handle
and switch.
Tighten handle screw.
Reinstall handle lock
nuts.
HANDLE LOCK NUT
SWITCH LEAD CONNECTORS
SWITCH
2.5 UNICABLE REPLACEMENT
STEP #1




HANDLE
JAM NUT
LOCK NUT
NECK
Remove liner from gun
(See Section 2.2 LINER
REPLACEMENT)
Mount neck in vise.
Remove switch from leads
and remove handle (See
Section 2.3 SWITCH
REPLACEMENT).
Hold jam nut in place with
a 3/4" wrench and loosen
unicable with a 3/4” wrench
until threads are disengaged.
8
UNICABLE
STEP #2

HANDLE
JAM NUT
LOCK NUT
NECK
UNICABLE
Hold jam nut in place with a
3/4" wrench and tighten
replacement cable with a
3/4" wrench (14 ft.-lbs.).
STEP #3

Reinstall switch
(See Section
2.3 SWITCH
REPLACEMENT).
STEP #4


SWITCH
HANDLE
LOCK NUT
POWER PIN
UNICABLE
JAM NUT
Follow identical procedure on
rear of gun.
Wrench for power pin may be
3/4" or 5/8”.
2.6 UNICABLE REPAIR
STEP #1


Cut cable to length.
Cut outer casing 2.0”
(50 mm) from end.
OUTER
JACKET
SPARE LEAD
BARE COPPER
WIRE
CORE TUBE
SWITCH LEADS
9
STEP #2
CONE NUT
INNER TUBE
SHOULDER
Position the inner tube clamp on inner tube. Do not crimp yet. Slide outer jacket clamps into their proper
positions. Do not crimp yet.

Insert support tube into inner tube (lube if necessary) and push with connector cone until core tube shoulders
on connector cone (inner tube may shift – reposition if necessary). Double check that all components are in
correct positions and crimp both clamps with Oetiker pincers. Remove connector cone from end of Unicable.
 Strip off 3/16” (5 mm) of insulation from switch leads and crimp on switch lead connectors (Part #412-1) and
tug to ensure good connection. As there are two spare switch leads, be sure to use the same 2 wires
throughout, note color-coding.
NOTE: Spray the copper out in an even and consistent pattern as shown. Then move the cone nut up onto the
cone capturing the copper. Screw the cone nut into the cone.
STEP #3
UNICABLE
SPARE LEAD
HANDLE CAP
SWITCH LEAD
CONNECTORS
CLAMP
SWITCH LEADS



Trim and strip control leads.
Assemble control lead connectors.
Position and clamp outer hose clamp.
IMPORTANT:
Place the ear of the clamp near switch leads (pink & blue).
Pinch the outer jacket ear.
UNICABLE CLAMP KIT
REPAIR TOOL KIT
PART #
DESCRIPTION
313-9
UNICABLE CLAMP KIT (COMPLETE)
INDIVIDUAL PARTS
313-3
OUTER JACKET CLAMPS (1 REQUIRED)
PART #
DESCRIPTION
450
REPAIR TOOL KIT (COMPLETE)
INDIVIDUAL TOOLS
450-1
CABLE CUTTER
CLAMP PLIERS - FOR CRIMPING OUTER
450-2
JACKET AND INNER TUBE CLAMP
CONNECTOR CRIMPING TOOL - FOR SWITCH
450-3
LEAD TERMINALS
5/16” NUT DRIVER - FOR REMOVAL OF
450-4
SWITCH HOUSING
450-5
KNIFE - FOR TRIMMING OF OUTER JACKET
450-6
5/64” ALLEN KEY - FOR LINER REMOVAL
318
CONNECTOR CONE
319
CONE NUT
412-1
SWITCH LEAD CONNECTORS (2)
413-3
INNER SUPPORT TUBE CLAMP
10
3.0 – TECHNICAL DATA
3.1 NECK DIMENSIONS
B
NECK
205-60
ANGLE
60°
INCHES
4.5
C
mm
114
INCHES
3.8
D
mm
96.5
INCHES
2.0
E
mm
51
INCHES
1.9
mm
48
3.2 GUN AMPERAGE RATINGS
MODEL
350 amp
100% DUTY CYCLE
CO2
MIXED
350
250
60% DUTY CYCLE
CO2
MIXED
450
350
NOTE: Ratings are based on tests that comply with IEC 60974-7 standards.
4.0 – OPTIONS
4.1 DIRECT PLUG-INS
For a complete listing of all direct plug-ins, please call Customer Service at 1-708-946-2281.
PART #
214
DESCRIPTION
TREGASKISS™ POWER PIN
214-1
MILLER® POWER PIN - FOR .035” - 1/16” WIRE
214-2
LINCOLN® POWER PIN
214-12
TWECO® #5 STYLE & MILLER® POWER PINS
414-11-2
414-12-2
214-116
414-116
O-RING FOR MILLER POWER PINS
O-RING FOR TWECO #5 STYLE AND MILLER®
POWER PINS
GUIDE CAP ONLY FOR 414-11-116 (NEW STYLE)
GUIDE CAP ONLY FOR 414-11-116 (OLD STYLE)
11
USE ON FEEDERS
TREGASKISS QUICK CONNECT BLOCK HOBART
2000 SERIES FEEDERS, TWECO® #4 RECEPTACLE
BODY PART #TAK-1
MILLERMATIC 200 & 250, S22 SERIES, HOBART
IRONMAN 210
LINCOLN LN7, 8, 90 LN 25, NA2, A-10
TWECO #5 QUICK CONENCT BLOCK & HOBART
FEEDERS
RECEPTACLE BODY PART #6TAK-1
4.2 SPECIALTY AND OPTIONAL ITEMS
For a complete listing of all specialty and optional items, please call Customer Service at 1-708-946-2281.
ITEM
1
2
3
4
PART #
401-10-87
401-21
401-41-50
401-42-50
DESCRIPTION
SPOT NOZZLE (BRASS)
FLUX CORE NOZZLE (GASLESS)
EXTENDED REACH NOZZLE 3.5” (88.9 mm)
HIGH ACCESS NOZZLE (BOTTLENECK)
4.3 FEEDER ADAPTORS
4.4 CONTROL PLUGS
To be used with 417 (Tweco #4), 417-50 (Euro) & 417-60
(Tweco #5) Quick Connect Block.
Complete with plug lead and female
connectors.
PART #
418-1
418-3
418-4
418-5
418-6
418-7
418-8
418-9
418-10
418-14
418-21
418-26
418-27
418-28
418-29
418-35
USE ON FEEDERS
AIRCO®
ESAB® (NON EURO STYLE), HOBART BETA MIG
HOBART® 27
LINCOLN LN4, LN5, LINDE SWM-31, 3A, 32A
LINCOLN LN7, 8, 9, LN25 SUITCASE, LN22
LINDE® SWM-23
LINDE 35SWM-23
MILLER 10A, 30A (MILLERMATIC 35S FEEDER)
MILLER 52E, 54E, S21, S22 SERIES,
MILLERMATIC 200, 250, 60 SERIES
OTC®
GILLILAND®
LINCOLN NA2
PANASONIC®
TWECO® #4
TWECO #5
KOBELCO®
12
PART #
419-1
419-2
419-3
419-4
419-5
419-6
419-7
419-8
DESCRIPTION
AIRCO
HOBART
LINDE (SEM-14, 25)
MILLER (52E, 54E)
WESTINGHOUSE®
LINCOLN (LN7, 8, 9), NA2
MILLER (10E, 30E), LINDE (SWM-35)
DIPSTICK 160/200, HOBART
HANDLER, LINCOLN SP-100
For a complete listing of all control plugs, please
call Customer Service at 1-708-946-2281
5.0 – 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 RESULTINGH IN SCORING OR 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 WIRE SIZE

GUN BEING RUN BEYOND ITS AMPERAGE RANGE

TIPS LOOSE / RETAINING HEAD LOOSE

LOOSE RETAINING SCREW ON QUICK CONNECT BLOCK

INSUFFICIENT GUAGE POWER CABLE AND / OR GROUND CABLE

LOOSE CONNECTOR CONES AND / OR CONE NUTS

GUN BEING RUN BEYOND ITS AMPERAGE

ELECTRICAL MALFUNCTION IN POWER SOURCE

TIPS LOOSE / RETAINING HEAD LOOSE

BAD CONNECTION OF LEADS TO SWITCH TERMINALS

SPATTER BUILT UP BETWEEN LEVER AND SWITCH HOUSING

CONTACTS DIRTY IN SWITCH

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

GAS FLOW IMPROPERLY SET
6.0 – DAILY WELDING GUN INSPECTION
Performing the following checks on your T-Gun MIG Gun will help decrease weld problems, making your job
easier and safer. It will also minimize downtime for maintenance and increase consumable life.
BEGINNING OF SHIFT









Inspect the Unicable for deep cuts or nicks. If bare copper is visible, repair with electrical tape or replace.
Check the Power Cable from the power source to the wire feeder for loose connections. Tighten if
necessary. A loose connection can cause poor electrical contact which will result in overheated cables can
the loss of electrical output.
Check for tight connection of welding gun to feeder adaptor. Tighten if necessary.
Check for tight connection of welding feeder adaptor into wire feeder. Tighten if necessary.
Inspect Nozzle. Clean weld spatter and inspect insulation in nozzle. If nozzle insulation is damaged, replace
nozzle.
Inspect Neck Insulator on neck. If damaged, replace.
Tighten Nozzle Retaining Head / Gas Diffuser on neck.
Check gas holes in gas diffuser and clean if necessary.
Tighten Contact Tip.
WHEN CLEANING NOZZLE




Inspect insulation in nozzle. If damaged, replace.
Inspect and clean gas holes in diffuser.
Tighten nozzle retainer / gas diffuser to neck.
Tighten contact tip.
13
7.0 – EXPLODED VIEW AND PARTS LIST
PART #
1
DESCRIPTION
STANDARD NOZZLES
401-4-38
401-4-50
401-4-75
3/8" (10 mm) BORE - FLUSH
1/2" (13 mm) BORE - 1/2" (3 mm) TIP RECESS
5/8" (16 mm) BORE - 1/8" (3 mm) TIP RECESS
(STANDARD)
3/4" (19 mm) BORE - 1/8" (3 mm) TIP RECESS
401-5-62
401-5-75
401-6-50
HEAVY DUTY NOZZLES
5/8" (16 mm) BORE - 1/4" TIP RECESS
3/4" (19 mm) BORE - 1/4" TIP RECESS
1/2" (13 mm) BORE - 1/8" TIP RECESS
401-6-62
5/8" (16 mm) BORE - 1/8" TIP RECESS
401-6-75
3/4" (19 mm) BORE - 1/8" TIP RECESS
401-4-62
PART #
DESCRIPTION
404-26
454-1-2
TREGASKISS™ TOUGH LOCK RETAINING
HEAD
RETAINING RING ONLY
4
402-11
NECK INSULATOR
5
205-60
205-45
STANDARD NECK - 60°
OPTIONAL NECK - 45°
6
208-2
JAM NUT
3
7
CONNECTOR CONE (INC. IN 313-9 REPAIR
KIT)
8
CONE NUT (INC. IN 313-9 REPAIR KIT)
9
OETIKER CLAMP - 17 mm (INC. IN 313-9
REPAIR KIT)
HEAVY DUTY TREGASKISS™ TOUGH LOCK
CONTACT TIPS
2
403-20-30
FOR .030" (0.8 mm) WIRE
403-20-35
403-20-1.0
403-20-45
403-20-364
FOR .035" (0.9 mm) WIRE
FOR 1.0 mm WIRE
FOR .045" (1.2 mm) WIRE
FOR 3/64" (1.2 mm) WIRE
10
320
320 - 2
320 - 3
310-1-6 (10)
14
2-PIECE HANDLE (INC. CAPS AND SCREW)
FRONT LOCKING CAP
REAR LOCKING CAP
SCREW FOR 2-PIECE HANDLE
(6–32 X 5/8” BLACK)
425
PART #
11
214
414-1
414-2
214-1
214-2
214-4
214-13
214-12
12
415-24
415-26
415-30-15Q
415-35-10Q
415-35-15Q
415-35-25Q
415-116-10Q
415-116-15Q
415-116-25Q
415-564-15Q
415-332-15Q
415-332-25Q
DESCRIPTION
PART #
DESCRIPTION
SWITCH ASSEMBLY
EXTENDED LEVER USED WITH 211-5
SWTICH
POWER PIN #4
O-RING - TWECO
LINER SET SCREW
MILLER POWER PIN
(ALL MODELS EXCEPT 10 & 30
FEEDERS)
LINCOLN POWER PIN
L-TEC
PANASONIC
#5 PANASONIC PIN *214-400 ADAPTOR NEEDED
WITH THIS PIN
13
211-5
211-5-8
14
216-1
TREGASKISS QUICK LOAD™ LINERS (LINER
RETAINER NOT INCLUDED)
TREGASKISS QUICK LOAD LINER RETAINER
(3/32” ONLY)
TREGASKISS QUICK LOAD LINER RETAINER
FOR .030” (0.7 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 .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 1/16” - 5/64” (1.6 mm - 1.9 mm) WIRE, 15’ (5 m)
FOR .078” - 3/32” (1.9 mm - 2.3 mm) WIRE, 15’ (5 m)
FOR .078” - 3/32” (1.9 mm - 2.3 mm) WIRE, 25’ (8 m)
17
15
SWITCH LEAD CONNECTOR (INC. IN 313-9
REPAIR KIT)
16
SUPPORT TUBE (INC. IN 313-9 REPAIR
KIT)
321-10
UNICABLE ASSEMBLY
10’ (3.1 m)
321-12
12’ (3.7 m)
321-15
15’ (4.6 m)
18
320-6
LOCKING CAP
NOT
SHOWN
417
NOT
SHOWN
313-9
15
CONTROL PLUG TERMINAL BLOCK
QUICK CONNECT BLOCK ASSEMBLY
FEEDER ADAPTORS (TO BE USED WITH
417 QUICK CONNECT BLOCK)
EURO-CONNECTOR OPTION
UNICABLE REPAIR KIT
8.0 – ORDERING INFORMATION
8.1 EXAMPLE OF STANDARD MODEL NO.
3215-45
Wire Size
Standard Lengths - 10’ (3.05 m), 12’ (3.66 m), 15’ (4.58 m)
Amperage (Manual)
32 - 350 amp
M-3215-45-60-9-FL
Use these codes to order
special gun features.
B
M
LN
TW
E
PA
LT
Option numbers should be added
only if desired option is not included
on standard gun model
- Bernard Style
- Miller Power Pin
- Lincoln Power Pin
- Tweco #5 Power Pin
- Euro
- Panasonic
- L-Tec
FL - Flex Neck
9 - Liner for Aluminum wire
60 - Angle of neck 60°
Wire Size
8.2 GUN STANDARDS CHART
Standard models are shipped with the following components:
GUN MODEL
NECK
NOZZLE
350 amp
205-60
401-4-62
RETAINING
HEAD
404-26
NECK
INSULATOR
402-11
CONTACT
TIPS
403-20-xx
Distributed by:
09/12 REV F
16
TG063
Download PDF