ESAB MT-450W & MT-650W Cool Grip Water-Cooled Mig Torches User manual

Brand: ESAB

Model: MT-450W & MT-650W Cool Grip Water-Cooled Mig Torches

Category: Welding System

Type: User manual

ESAB MT-450W & MT-650W Cool Grip Water-Cooled Mig Torches are professional-grade welding tools designed for industrial and heavy-duty applications. With their advanced cooling system, these torches offer superior performance and durability, allowing for extended welding sessions without overheating. The water-cooled design ensures a cooler and more comfortable welding experience, reducing operator fatigue and improving overall productivity.

INSTRUCTION MANUAL

F-15-450

March, 1998

Be sure this information reaches the operator.

You can get extra copies through your supplier.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe

practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting,

and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt

to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand

these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or

operating this equipment.

MT-450W & MT-650W

COOL GRIP

Water-Cooled MIG Torches

Ready-to-Weld Torch Assemblies

Each of the following torches has a 45 degree gooseneck

and includes liner, contact tip and standard duty slide-on

#10 nozzle.

MT-450W, .035, 12 ft. (3.6 m) ................................... 37018

MT-450W, .035, 15 ft. (4.5 m) ................................... 37019

MT-450W, .045-1/16, 12 ft. (3.6 m) ........................... 37020

MT-450W, .045-1/16, 15 ft. (4.5 m) ........................... 37021

Basic Torches

Basic torches do not include liners, contact tips or

nozzles. Mix and match the accessories listed in appropri-

ate tables to customize a torch that is just right for your

job.

MT-450W, 12 ft. (3.6 m) ............................................ 37024

MT-450W, 15 ft. (4.5 m) ............................................ 37025

MT-650W, 12 ft. (3.6 m) ............................................ 37026

MT-650W, 15 ft. (4.5 m) ............................................ 37027

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual

and accompanying labels and/or inserts when installed, operated, maintained and repaired

in accordance with the instructions provided. This equipment must be checked periodically.

Malfunctioning equipment should not be used. Parts that are broken, missing, worn, dis-

torted or contaminated should be replaced immediately. Should such repair or replacement

become necessary, the manufacturer recommends that a telephone or written request for

service advice be made to the Authorized Distributor from whom purchased.

This equipment or any of its parts should not be altered without the prior written approval of

the manufacturer. The user of this equipment shall have the sole responsibility for any

malfunction which results from improper use, faulty maintenance, damage, improper repair

or alteration by anyone other than the manufacturer or a service facility designated by the

manufacturer.

TABLE OF CONTENTS

1.0 INSTALLATION ........................................................................................ 5

1.1 INSTALLING TORCHES EQUIPPED WITH EURO CONNECTORS ................................................ 5

2.0 MAINTENANCE ........................................................................................ 5

2.1 NOZZLE AND CONTACT TIP SYSTEMS ......................................................................................... 5

2.2 SWITCH REPLACEMENT ................................................................................................................ 5

2.3 GOOSENECK REPLACEMENT ....................................................................................................... 5

2.4 LINER REPLACEMENT .................................................................................................................... 6

2.5 POWER CABLE REPLACEMENT .................................................................................................... 7

3.0 EXPLODED VIEW AND PARTS LIST .................................................... 10

3.1 TORCH PARTS ............................................................................................................................... 10

3.2 EURO CONNECTOR PARTS .........................................................................................................11

3.3 NOZZLES ....................................................................................................................................... 12

3.4 CONTACT TIPS & TUBES .............................................................................................................. 12

3.5 LINERS ........................................................................................................................................... 12

3.6 MIG 4HD WATER KIT INSTALLATION ........................................................................................... 13

3.7 DIRECT TO CIRCULATOR INSTALLATION ................................................................................... 13

3.8 EURO ADAPTOR ASSEMBLY ........................................................................................................13

4.0 TECHNICAL DATA ................................................................................. 15

4.1 TORCH AMPERAGE RATINGS ...................................................................................................... 15

4.2 SPECIFICATIONS .......................................................................................................................... 15

5.0 - TROUBLESHOOTING ............................................................................. 15

WARNING: These Safety Precautions are for

your protection. They summarize precaution-

ary information from the references listed in

Additional Safety Information section. Before

performing any installation or operating procedures, be

sure to read and follow the safety precautions listed below

as well as all other manuals, material safety data sheets,

labels, etc. Failure to observe Safety Precautions can result

in injury or death.

PROTECT YOURSELF AND OTHERS

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and

can injure skin and eyes. Hot metal can cause burns.

Training in the proper use of the processes and equip-

ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work

area, even if welding helmets, face shields, and goggles

are also required.

2. Use a face shield fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from

sparks and rays of the arc when operating or observing

operations. Warn bystanders not to watch the arc and

not to expose themselves to the rays of the electric-arc

or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a weld-

ing helmet or cap for hair protection, to protect against

arc rays and hot sparks or hot metal. A flameproof apron

may also be desirable as protection against radiated

heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cuffs, or pockets. Sleeves and collars should be

kept buttoned, and open pockets eliminated from the

front of clothing

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far.

Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from

flames and arcs can start fires. Hot slag

or sparks can also cause fires and ex-

plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non-

flammable covering. Combustible materials include wood,

cloth, sawdust, liquid and gas fuels, solvents, paints and

coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden

smoldering fire or fires on the floor below. Make certain

that such openings are protected from hot sparks and

metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there

are no substances on the workpiece which might pro-

duce flammable or toxic vapors. Do not do hot work on

closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or

portable fire extinguisher. Be sure you are trained in its

use.

SAFETY PRECAUTIONS

11/95

5. Do not use equipment beyond its ratings. For example,

overloaded welding cable can overheat and create a fire

hazard.

6. After completing operations, inspect the work area to

make certain there are no hot sparks or hot metal which

could cause a later fire. Use fire watchers when neces-

sary.

7. For additional information, refer to NFPA Standard 51B,

"Fire Prevention in Use of Cutting and Welding Pro-

cesses", available from the National Fire Protection Asso-

ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live

electrical parts and ground can cause

severe injury or death. DO NOT use AC

welding current in damp areas, if move-

ment is confined, or if there is danger of

falling.

1. Be sure the power source frame (chassis) is connected

to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or

missing connection can expose you or others to a fatal

shock.

4. Use well-maintained equipment. Replace worn or dam-

aged cables.

5. Keep everything dry, including clothing, work area,

cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from

work and from ground.

7. Do not stand directly on metal or the earth while working

in tight quarters or a damp area; stand on dry boards or

an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next

page) for specific grounding recommendations. Do not

mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —

May be dangerous. Electric current flow-

ing through any conductor causes lo-

calized Electric and Magnetic Fields

(EMF). Welding and cutting current cre-

ates EMF around welding cables and

welding machines. Therefore:

1. Welders having pacemakers should consult their physi-

cian before welding. EMF may interfere with some pace-

makers.

2. Exposure to EMF may have other health effects which are

unknown.

3. Welders should use the following procedures to minimize

exposure to EMF:

A. Route the electrode and work cables together. Secure

them with tape when possible.

B. Never coil the torch or work cable around your body.

C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close as

possible to the area being welded.

E. Keep welding power source and cables as far away

from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in confined spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area by

natural or mechanical means. Do not weld, cut, or gouge

on materials such as galvanized steel, stainless steel,

copper, zinc, lead, beryllium, or cadmium unless positive

mechanical ventilation is provided. Do not breathe fumes

from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly toxic

gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation

while operating, this is an indication that ventilation is not

adequate. Stop work and take necessary steps to im-

prove ventilation in the work area. Do not continue to

operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specific ventilation recommendations.

CYLINDER HANDLING -- Cylinders, if

mishandled, can rupture and violently

release gas. Sudden rupture of cylin-

der, valve, or relief device can injure or

kill. Therefore:

1. Use the proper gas for the process and use the proper

pressure reducing regulator designed to operate from

the compressed gas cylinder. Do not use adaptors.

Maintain hoses and fittings in good condition. Follow

manufacturer's operating instructions for mounting regu-

lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain

or strap to suitable hand trucks, undercarriages, benches,

walls, post, or racks. Never secure cylinders to work

tables or fixtures where they may become part of an

electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases in

Cylinders", which is available from Compressed Gas

Association, 1235 Jefferson Davis Highway, Arlington,

VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or im-

properly maintained equipment can cause

injury or death. Therefore:

1. Always have qualified personnel perform the installa-

tion, troubleshooting, and maintenance work. Do not

perform any electrical work unless you are qualified to

perform such work.

2. Before performing any maintenance work inside a power

source, disconnect the power source from the incoming

electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do not

operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do not

modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for elec-

tric arc welding and cutting equipment, ask

your supplier for a copy of "Precautions and

Safe Practices for Arc Welding, Cutting and

Gouging", Form 52-529.

The following publications, which are available from the

American Welding Society, 550 N.W. LeJuene Road, Mi-

ami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc

Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten

Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc

Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

This symbol appearing throughout this manual

means Attention! Be Alert! Your safety is

involved.

The following definitions apply to DANGER, WARNING,

CAUTION found throughout this manual:

Used to call attention to immediate haz-

ards which, if not avoided, will result in

immediate, serious personal injury or loss

of life.

Used to call attention to potential haz-

ards which could result in personal injury

or loss of life.

Used to call attention to hazards which

could result in minor personal injury.

1.0 - INSTALLATION

1.1 INSTALLING TORCH TO WIRE FEEDER

• Euro Connector

• Feed welding wire through female adaptor by hand and tighten drive rolls.

• Guide welding wire into connector on torch, carefully insert connector into female adaptor and tighten

Euro hand nut.

2.0  MAINTENANCE

2.1 NOZZLE AND CONTACT TIP SYSTEMS

Removal - 650 AMP

• Before removal of nozzle, ensure water supply is turned off.

• Flip nozzle clasp from gooseneck and pull nozzle straight off.

• Remove contact tip using pliers.

• Remove tip adaptor using 5/8" (16 mm) wrench.

Removal - 450 AMP

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

• Remove contact tip using pliers.

• Remove tip adaptor using 5/8" (16 mm) wrench.

NOTE: Ensure that all parts are tightened before welding and that the coolant circulator is turned on.

2.2 SWITCH REPLACEMENT

STEP #1

• from handle.

• Using needlenose pliers Remove two switch housing

screws using 5/16" (8 mm) nut driver.

• Remove housing, remove switch leads from switch.

• Push leads onto new switch.

2.3 GOOSENECK REPLACEMENT

• Remove liner from torch (ref. pg. 6 Liner Replacement).

• Remove two switch housing screws, and remove housing.

HOUSING SCREWS

SWITCH

HOUSING

SCREWS

SWITCH

NOZZLE

CONTACT TIP

TIP ADAPTOR

STEP #1

2.0 - MAINTENANCE

2.3 GOOSENECK REPLACEMENT CONTD.

STEP #2

• Slide handle back.

• Unthread power cable.

• Cut off water line and conduit clamps and pull hoses off barbed fittings

STEP #3

• Thread power cable on and tighten.

• Slide clamps on water line and conduit.

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

• Slide handle back, place switch in housing, nest housing in handle and tighten screws.

2.4 LINER REPLACEMENT

STEP #1

Ensure power source is off and torch is removed from feeder before proceeding.

• Remove nozzle, tip and tip adaptor and loosen liner set screw using 5/64 (2 mm) Allen wrench.

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

LINER SET SCREW

5/64" (2 mm) ALLEN

WRENCH

SWITCH

FRONT HANDLE

GOOSENECK

HOUSING

SCREWS

WATER LINES (RED & BLUE)

AND POWER LINE

FRONT HANDLE

WHITE CONDUIT LINE

GOOSENECK

2.0 - MAINTENANCE

2.4 LINER REPLACEMENT CONTD.

2.5 POWER CABLE REPLACEMENT

STEP #2

• Feed liner through torch using short strokes to

avoid kinking. Twist liner clockwise if necessary.

• Seat liner retainer with o-ring to shoulder inside

liner seat.

• Secure by tightening liner set screw.

Do not overtighten.

STEP #3

• Trim conduit liner to 5/8 (16 mm) stick out.

• Remove any burr that may obstruct wire feed,

especially on flat wire type conduit liner.

STEP #1

• Remove liner (ref. Pg. 6).

• Remove nozzle, tip and tip adaptor

STEP #2

• Pull the rear handle up the torch approximately 1 (300 mm).

• Unscrew power cable from Euro body.

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

• Pull gas and water line off of Euro body.

• At this point, Euro body will be removed from torch.

• Slide rear handle off of torch.

WHITE CONDUIT LINE

EURO BODY

BLUE WATER LINE

POWER & WATER LINE

(RED WATER LINE)

REAR HOUSING

5/64" (2 mm) ALLEN

WRENCH

LINER SET SCREW

5/8" (16 mm)

CONDUIT LINER

GOOSENECK

5/64" (2 mm) ALLEN

WRENCH

LINER SET SCREW

2.0 - MAINTENANCE

2.5 POWER CABLE REPLACEMENT CONTD

STEP #3

• On front of torch, release front handle from neck (ref. Pg. 5 Gooseneck Replacement).

• Remove outer jacket by pulling from rear of torch.

STEP #4

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

STEP #5

• From rear of torch, slide front handle over hoses.

• Tape hoses together at rear of torch.

• Slide outer jacket over hoses from rear of torch.

OUTER JACKET

TAPE

FRONT HANDLEGOOSENECK

BLUE WATER LINE

REPLACEMENT POWER CABLE (RED)

USED POWER

CABLE (RED)

WHITE CONDUIT LINE

GOOSENECK

WATER LINES (RED & BLUE)

& POWER LINE

OUTER JACKET

FRONT HANDLE

WHITE CONDUIT LINE

GOOSENECK

2.0 - MAINTENANCE

2.5 POWER CABLE REPLACEMENT CONTD.

• Slide outer jacket under front handle and bring front handle up to neck.

• Replace switch and switch housing and secure with mounting screws.

STEP #6

STEP #7

• At rear of torch, slide rear housing over outer jacket.

• Attach Euro body to power cable.

• Attach the gas and water lines to Euro body with new clamps.

STEP #8

EURO

BODY

WHITE CONDUIT LINE

BLUE WATER

LINE

POWER & WATER LINE

(RED WATER LINE)

REAR HOUSING

5/64" (2 mm) ALLEN

WRENCH

LINER SET SCREW

SWITCH

HOUSING

SCREWS

OUTER JACKET

FRONT HANDLE

GOOSENECK

• Slide rear handle over Euro body and secure with mounting screws.

• Install liner (see Section 2.4).

LINER

1 See Table 3.3 See Table 3.3 NOZZLE

2 See Table 3.4 See Table 3.4 CONTACT TIP OR TUBE

3 37244 37245 TIP ADAPTOR

3A 952635 RETAINING RING (5)

3B 952634 952634 O-RING (5)

4 952633 SHOCKWASHER (2)

5 952637 952638 GOOSENECK - 45 DEGREE

(includes 952670, 952671 clamps)

5A *952628 WATER MANIFOLD ASSEMBLY

(incl. 952628, 952639, 952642, 952646)

5B *952629 WATER MANIFOLD

5C *952630 NOZZLE CLASP

5D *952631 QUICK CONNECT WATER FITTING

5E *952639 ARMOURED WATER JUMPER

5F 952632 HEAT RESISTANT O-RING (5)

6 952652 952652 SWITCH

7 952653 952653 SWITCH HOUSING WITH SCREWS

8 952651 952651 FRONT HANDLE

9 *952656 *952656 SWITCH LEAD CONNECTORS (4)

10 CONTROL WIRE

*952654 *952654 12' CONTROL WIRE

952655 952655 15' CONTROL WIRE

11 POWER CABLE (RED)

952649 952649 12' POWER CABLE

952650 952650 15' POWER CABLE

12 INTERNAL WATER LINE (BLUE) (incl. (2) 952642 clamps)

*952640 *952640 12' INTERNAL WATER LINE

952641 952641 15' INTERNAL WATER LINE

PART # PART #

ITEM 450 AMP 650 AMP DESCRIPTION

3.0 - EXPLODED VIEW AND PARTS LIST

3.1 TORCH PARTS (WITH CABLE AND HOSES)

* On part number denotes non-stock item, allow 2-3 weeks for delivery.

(X) At end of description denotes package qty.

13 *952642 *952642 WATER LINE CLAMP (6)

14 *952646 *652646 CONDUIT CLAMP (12)

15 CONDUIT (WHITE) (incl. (2) 952646 clamps)

*952644 *652644 12' CONDUIT

952645 952645 15' CONDUIT

16 OUTER JACKET

*952657 *952657 12' OUTER JACKET

952658 952658 15' OUTER JACKET

17 CONDUIT LINER

37031 37031 FOR .030" HARD WIRE (12 & 15')

37032 37032 FOR .035" HARD WIRE (12 & 15')

37033 37033 FOR .045-.062" HARD WIRE (12 & 15')

37034 37034 FOR .078-.093" HARD WIRE(12 & 15')

37039 37039 FOR .035" SOFT WIRE (12 & 15')

37040 37040 FOR 3/64-.062" SOFT WIRE(12 & 15')

18 952647 952647 RED WATER LINE - 2' (incl. (2) 952642)

19 952648 952648 BLUE WATER LINE - 2' (incl. (2) 952642)

20 952643 952643 EURO WATER FITTING

21 952659 952659 EURO ADAPTOR COMPLETE

21A *952660 *952660 EURO HOUSING WITH STRAIN RELIEF

21B *952661 *952661 HOUSING BAND (2)

21C *952663 *952663 EURO CONNECTOR BODY WITH RETAINING RING

21D *952664 *952664 HAND NUT (2)

21E *952665 *952665 CONTROL PIN (10)

23F 952666 952666 O-RING - GAS INLET (5)

23G *952662 *952662 MOUNTING SCREW (10)

PART # PART #

ITEM 450 AMP 650 AMP DESCRIPTION

3.0 - EXPLODED VIEW AND PARTS LIST

3.2 EURO CONNECTOR PARTS

21D21C21B21A

* On part number denotes non-stock item, allow 2-3 weeks for delivery.

(X) At end of description denotes package qty.

3.0 - EXPLODED VIEW AND PARTS LIST

3.3 NOZZLES

Gas Nozzles

Nozzle

I.D.

#8 (450W) 1/2-in. (13 mm) 37045

#10 (450W) 5/8-in. (16 mm) 37046

#12 (450W) 3/4-in. (20 mm) 37047

#10 (650W) 5/8-in. (16 mm) 37028

#12 (650W) 3/4-in. (20 mm) 37030

Slide-on, Self-Insulated Type Gas Nozzle

3.4 CONTACT TIPS AND TUBES

Contact Tips & Tubes

Contact Tip Contact I.D.

Short Long Tube*** Diameter

Wire Type & Size Part No. Part No. Part No. in. (mm)

Hard, Cored & Soft Wires

.030 in. (0.8 mm) 632791 20123 - .037*

.035 in. (0.9 mm) 632793 632794 996104 .043*

.040 in. (1.0 mm) 37275** 37276** 37277** .048*

3/64/045 in. (1.2 mm) 632795 632796 996105 .054*

.045 in. (1.2 mm) 37278** 37279** 37280** .061

.052 in. (1.4 mm) 632795 632796 996816 .062

1/16 in. (1.6 mm) 37281** 37282** 37283** .072

1/16 in. (1.6 mm) 632797 632798 996106 .078*

*** Requires Collet Nut (P/N 632811)

** Available 2nd Quarter 1998

* Recommended for Aluminum

3.5 LINER

Liners for MT-350W, 450W & 650W (12 & 15 ft.)

Wire Size

Hard Wires

.030 (0.8 mm) ................................................................ 37031

.035 (0.9 mm) ................................................................ 37032

.045-1/16 (1.2-1.6 mm) ................................................. 37033

.078/093H (2.0 - 2.4 mm) .............................................. 37034

Soft Wires

.035 (0.9 mm) ................................................................ 37039

3/64-1/16 (1.2-1.6 mm) ................................................. 37040

Long Tip

Short Tip

Tube***

Collet Nut

632811

450 AMP

650 AMP

3.0 - EXPLODED VIEW AND PARTS LIST

3.6 Typical Set-Up

When using Mig 4HD Water Kit  37303

WC-8C Coolant Circulator - Vertical design to fit in cylinder rack of

most power source trucks. High efficiency fan cooled radiator dissi-

pates 6480 BTU/hour ........................................................33739

3.7 Typical Set-Up

When connecting torch directly to coolant circulator (2 of each part required)

Options & Accessories

Water Kit for Mig 4HD - Kit consist of inlet/outlet fittings, mounting

hardware, 8 ft. (2.4 m) water hoses with B size water fittings and

mounting hardware ............................................................. 37303

Optional Water Fittings and Connectors - The following items

can be used to connect the MT-350W, 450W and 650W to any

water circulator having 5/8 B size connectors:

Quick Disconnect Fittings - Two required - one fitting for

each circulator water hose to torch water hose connection or

connect torch directly to the water circulator ........ 23610853

Water Hose Coupling - One required for each quick discon-

nect fitting to water hose connection .......................... 11N18

Water Hoses - Two required - one for water supply to the

torch and one for return to the water circulator. Use hose cou-

pling (11N18) for connecting water hoses together. See table

above.

Water Hose (3 ft.) 20634

Water Hose (6 ft.) 20633

Water Hose (12 ft.) 40V76

Water Hose (25 ft.) 406196

Water Coupler

11N18

Quick Disconnect

Fitting

23610853

Gun Water

Connection

included with

torch

3.0 - EXPLODED VIEW AND PARTS LIST

3.8 WIRE FEEDER CONNECTOR ASSEMBLY

(MIG-35, DIGIMIG) - 20572

SETSCREW - 19318

ADAPTOR INSULATOR - 19316

ADAPTOR BLOCK - 19315

(To Torch Euro Connector)

SETSCREW - 19319

POWERLUG - 19314

ADAPTOR PLUG - 19312

(To Wire Feeder)

(2) FEMALE CONN. W/LEAD - 19317

POWER CABLE - 19339

SWITCHCORD - 19340

Includes PLUG - 2062336

Supplied:

SUPPORT LINER - 19309

GAS HOSE

(Supplied w/19315)

4.0 - TECHNICAL DATA

4.1 TORCH AMPERAGE RATINGS

NOTE: Ratings are based on tests that comply with NEMA ARC Welding Section Standard 11-6-1975 for Duty Cycle. The

time period of one complete cycle shall be 10 minutes (60% = 6 minutes). National Electrical Manufacturers

Association, 2101 L Street N.W. Washington D.C. 20037.

5.0 - TROUBLESHOOTING

100% DUTY CYCLE 60% DUTY CYCLE

MIXED CO

MIXED

450 AMP 450 375 550 475

650 AMP 650 550 750 650

Model MT-450W MT-650W

Length ........................................ 15.2 (386 mm) ................... 13.0 (330 mm)

Height ........................................... 4.2 (107 mm) ..................... 4.2 (107 mm)

Handle Dilameter ............................ 1.6 (41 mm) ....................... 1.6 (41 mm)

Weight ..................................... 28.8 oz. (816 gm) ................ 32.8 oz. (930 gm)

(less service lines)

Water Cooling Requirement: 0.5 Gal./Min. (2 L./Min.)

4.2 SPECIFICATIONS

PROBLEM POSSIBLE CAUSE

Poor Wire Feed • conduit liner clogged or kinked

• incorrect liner size or contact tip

• liner cut too short and not seating properly in tip adaptor

• drive rolls too tight resulting in scoring of welding wire

• welding wire dirty, rusty or too much cast

Short Tip Life • 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

• torch being run beyond its amperage range

Torch Overheating • loose retaining screw on quick connect block

• insufficient gauge power cable and/or ground cable

• loose connector cones and/or cone nuts

• torch being run beyond its amperage range

• electrical malfunction in power source

• poor or no water flow

Weld Porosity • 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

• gas flow improperly set

Torch Leaking • Power cable burnt

• Leak in gooseneck

F-15-450 3/98

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (803) 664-4452/Web: http://www.esab.com

Hours: 7:30 AM to 5:00 PM EST

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATIONS GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS: Telephone (803) 664-5540/Fax: (800) 634-7548

Order Entry Product Availability Pricing Hours: 8:30 AM to 5:00 PM EST

Order Changes Saleable Goods Returns Delivery

Shipping Information

B. ENGINEERING SERVICE: Telephone: (803) 664-4416 / Fax : (800) 446-5693

Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST

Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (803) 664-4452

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST

Performance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (803) 664-5501 / Fax: (803) 664-5548

Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (803) 664-4469 / Fax: (803) 664-5557

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:

Telephone: (803)664-4428 / Fax: (803) 664-4476

Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:

Telephone: (803) 664-4248 / Fax: (803) 664-4454 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone: (800) 934-9353 Hours: 7:30 AM to 5:00 PM EST

ESAB MT-450W & MT-650W Cool Grip Water-Cooled Mig Torches User manual

Brand: ESAB

Model: MT-450W & MT-650W Cool Grip Water-Cooled Mig Torches

Category: Welding System

Type: User manual

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report

ESAB MT-450W & MT-650W Cool Grip Water-Cooled Mig Torches User manual

ESAB MT-450W & MT-650W Cool Grip Water-Cooled Mig Torches User manual

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