Bernard T-Gun Technical Manual

Bernard
Brand
Bernard
Model
T-Gun
Category
Welding System
Type
Technical Manual
;
Processes
MIG (GMAW) Welding
Description
TG408 – REV E March 2018
Semi-Automatic, Water-Cooled,
400 amp, MIG (GMAW) Welding
T-Gun
Semi-Automatic MIG Guns
TECHNICAL GUIDE
Bernard
A Division of Miller Electric Mfg. LLC
449 West Corning Road
Beecher, Illinois 60401 USA
(US & Canada)
1-519-737-3000 (International)
Fax: 708-946-6726
For more information, visit us at BernardWelds.com
TM
2
TABLE OF CONTENTS
WARRANTY………………………………………………………………………………………………………………3
SECTION
1 - SAFETY PRECAUTIONS FOR GMAW WELDING GUNS – READ BEFORE USING…………………………….4
1-1
SYMBOL USAGE……………………………………………………………………………………………………...4
1-2
ARC WELDING HAZARDS………………………………………………………………………………….................4
1-3
PROPOSITION 65 WARNINGS………………………………………………………………………………………..6
1-4
PRINCIPAL SAFETY STANDARDS…………………………………………………………………………................6
1-5
EMF INFORMATION…………………………………………………………………………………………………..6
SECTION
2 – INSTALLATION …………………………………………………………………………………………….7
2-1
INSTALLING QUICK CONNECT BLOCK TO FEEDER…………………………………………………………………..7
2-2
INSTALLING GUN TO QUICK CONNECT BLOCK……………………………………………………………………...7
2-3
INSTALLING POWER PIN TO GUN…………………………………………………………………………………...8
SECTION
3 – MAINTENANCE……………………………………………………………………………………………..9
3-1
TREGASKISS™ NOZZLE AND TOUGH LOCK™ CONSUMABLES……………………………………………………...9
3-2
SWITCH REPLACEMENT……………………………………………………………………………………………..9
3-3
NECK REPLACEMENT……………………………………………………………………………………................10
3-4
LINER REPLACEMENT……………………………………………………………………………………...............11
3-5
CABLE ASSEMBLY REPLACEMENT………………………………………………………………………...............12
SECTION
4 − TECHNICAL DATA…………………………………………………………………………………………15
4-1
NECK DIMENSIONS………………………………………………………………………………………...............15
4-2
GUN AMPERAGE RATINGS…………………………………………………………………………………………15
SECTION
5 – OPTIONS………………………………………………………………………………………………….15
5-1
DIRECT PLUG-INS………………………………………………………………………………………………….15
5-2
FEEDER ADAPTORS………………………………………………………………………………………………...16
5-3
CONTROL PLUGS ………………………………………………………………………………………..............16
5-4 CONNECTOR OPTIONS……………………………………………………………………………………………..16
SECTION
6 – TROUBLESHOOTING……………………………………………………………………………………..17
SECTION
7 − EXPLODED VIEW AND PARTS LIST………………………………………………………………..........18
SECTION
8 - ORDERING INFORMATION…..…………………………………………………………………..……….20
8-1
EXAMPLE OF STANDARD MODEL NO.……………………………………………………………………………...20
8-2
EXAMPLE OF CUSTOM BUILT GUN .……………………………………………………………………………...20
8-3
GUN STANDARDS CHART.…………………………………………………………………………………............20
3
Thank You for Choosing Bernard
Thank you for selecting a Bernard product. The MIG gun you have purchased has been carefully assembled and is
ready to weld and factory tested prior to shipment to ensure high performance. Before installing, compare the
equipment received against the invoice to verify that the shipment is complete and undamaged. It is the responsibility
of the purchaser to file all claims of damage or loss that may have occurred during transit with the carrier.
The owner’s manual contains general information, instructions and maintenance to help better maintain your MIG gun.
Please read, understand and follow all safety precautions.
While every precaution has been taken to assure the accuracy of this owner’s manual, Bernard assumes no
responsibility for errors or omissions. Bernard assumes no liability for damages resulting from the use of information
contained herein. The information presented in this owner’s manual is accurate to the best of our knowledge at the time of
printing. Please reference Bernardwelds.com for updated material.
For customer support and special applications, please call the Bernard Customer Service Department at 1-855-MIGWELD
(644-9353) (Canada & US) or 1-519-737-3000 (International) or fax 1-708-946-6726. Our trained Customer Service Team is
available Monday to Friday between 8:00 a.m. and 4:30 p.m. CST and will answer your product application or repair questions.
Bernard manufactures premium semi-automatic GMAW (MIG) and FCAW (flux-cored) welding guns, consumables,
accessories and manual arc products. For more information on other premium Bernard products, contact your local Bernard
distributor or visit us on the web at BernardWelds.com
Warranty
Seller’s Products specified below shall be free from defects in material and workmanship for the period specified below from
the delivery to an authorized Buyer provided the Products are operated, maintained, and repaired properly and pursuant to
Product documentation provided by the manufacturer. The Warranty against defects does not apply to: (1) consumable
components or ordinary wear items; or (2) use of the Products with equipment, components or parts not specified or
supplied by Seller or contemplated under the Product documentation.
Should there be a defect please refer to our Return Merchandise Policy.
PRODUCT
WARRANTY PERIOD
T-GUN™ Water-cooled MIG Guns and Components
180 days
Seller reserves the right to inspect any allegedly defective Product for the alleged deficiencies and that the deficiencies were
not caused by accident, misuse, neglect, improper installment, unauthorized alteration or repair or improper testing.
In the event of a defect covered by the above warranty, Seller will, at its option, repair, replace or refund the purchase price of
the defective Product. Product found not defective will be returned to Buyer at Buyer’s cost after notification by Seller’s
Customer Service Department.
EXCEPT AS SET FORTH ABOVE, SELLER MAKES NO WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING, BUT
NOT LIMITED TO, THE WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PURPOSE. SELLER SHALL NOT BE
LIABLE UNDER ANY CIRCUMSTANCES FOR DAMAGES OF ANY KIND. INCLUDING, BUT NOT LIMITED TO ANY, DIRECT,
INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OR LOSS OF PRODUCTION OR LOSS OF PROFITS
RESULTING FROM ANY CAUSE WHATSOEVER, INCLUDING, BUT NOT LIMITED TO, ANY DELAY, ACT, ERROR OR OMISSION
OF SELLER.
Genuine Bernard and Tregaskiss parts must be used for safety and performance reasons or the warranty above shall not be
valid. Warranty shall not apply if accident, abuse, or misuse damages a product, or if a product is modified in any way except
properly and by authorized Seller personnel.
4
SECTION 1 - SAFETY PRECAUTIONS FOR GMAW WELDING GUNS – READ BEFORE USING
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury.
The possible hazards are shown in the adjoining
symbols or explained in the text.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury. The
possible hazards are shown in the adjoining
symbols or explained in the text.
This group of symbols means Warning! Watch Out!
ELECTRIC SHOCK, MOVING PARTS, and HOT
PARTS hazards. Consult symbols and related
instructions below for necessary actions to avoid
the hazards.
The symbols shown below are used throughout this
manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and
follow the related instructions to avoid the hazard.
The safety information given below is only a
summary of the more complete safety information
found in the welding power source Owner’s
Manual. Read and follow all Safety Standards.
Only qualified persons should install, operate,
maintain, and repair this equipment. A qualified
person is defined as one who, by possession of a
recognized degree, certificate, or professional
standing, or who by extensive knowledge, training
and experience, has successfully demonstrated
ability to solve or resolve problems relating to the
subject matter, the work, or the project and has
received safety training to recognize and avoid the
hazards involved.
During operation, keep everybody, especially
children, away.
ELECTRIC SHOCK can kill.
• Always wear dry insulating gloves.
• Insulate yourself from work and
ground.
• Do not touch live electrode or electrical
parts.
• Replace worn, damaged, or cracked
guns or cables.
• Turn off welding power source before
changing contact tip or gun parts.
• Keep all covers and handle securely in
place.
FUMES AND GASES can be hazardous.
• Keep your head out of the fumes.
• Ventilate area, or use breathing device.
The recommended way to determine
adequate ventilation is to sample for the
composition and quantity of fumes and
gases to which personnel are exposed.
• Read and understand the Safety Data
Sheets (SDSs) and the manufacturer’s
instructions for adhesives, coatings,
cleaners, consumables, coolants,
degreasers, fluxes, and metals.
MOVING PARTS can injure.
• Keep away from moving parts.
• Keep away from pinch points such as
drive rolls.
WELDING can cause fire or explosion.
• Do not weld near flammable material.
• Do not weld on containers that have held
combustibles, or on closed containers
such as tanks, drums, or pipes unless
they are properly prepared according to
AWS F4.1 and AWS A6.0 (see Safety
Standards).
• Watch for fire; keep extinguisher nearby.
• Read and understand the Safety Data
Sheets (SDSs) and the manufacturer’s
instructions for adhesives, coatings,
cleaners, consumables, coolants,
degreasers, fluxes, and metals.
1-2 Arc Welding Hazards
1-1 Symbol Usage
Protect yourself and others from injury — read, follow, and save these important safety precautions and
operating instructions.
5
BUILDUP OF GAS can injure or kill.
• Shut off compressed gas supply
when not in use.
• Always ventilate confined spaces or
use approved air-supplied respirator.
WELDING WIRE can injure.
• Keep hands and body away from gun tip
when trigger is pressed.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process
produce intense visible and invisible
(ultraviolet and infrared) rays that can
burn eyes and skin. Sparks fly off from
the weld.
• Wear an approved welding helmet
fitted with a proper shade of filter
lenses to protect your face and eyes
from arc rays and sparks when
welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety
Standards).
• Wear approved safety glasses with
side shields under your helmet.
• Use protective screens or barriers to
protect others from flash, glare and
sparks; warn others not to watch the
arc.
• Wear body protection made from
durable, flame-resistant material
(leather, heavy cotton, wool). Body
protection includes oil-free clothing
such as leather gloves, heavy shirt,
cuffless trousers, high shoes, and a
cap.
READ INSTRUCTIONS.
• Read and follow all labels and the Owner’s
Manual carefully before installing, operating,
or servicing unit. Read the safety
information at the beginning of the manual
and in each section.
• Use only genuine replacement parts from
the manufacturer.
• Perform installation, maintenance, and
service according to the Owner’s Manuals,
industry standards, and national, state, and
local codes.
HOT PARTS can burn.
• Allow gun to cool before touching.
• Do not touch hot metal.
• Protect hot metal from contact by
others.
NOISE can damage hearing.
Noise from some processes or equipment
can damage hearing.
• Check for noise level limits exceeding
those specified by OSHA.
• Use approved ear plugs or ear muffs
if noise level is high.
• Warn others nearby about noise
hazard.
6
1-3 Proposition 65 Warnings
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive harm.
For more information, go to www.P65Warnings.ca.gov.
1-4 Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI
Standard Z49.1, is available as a free download from the
American Welding Society at http://www.aws.org or
purchased from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And
Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 25 West 43rd Street, New
York, NY 10036 (phone: 212-642-4900, website:
www.ansi.org).
Safe Practices for the Preparation of Containers and
Piping for Welding and Cutting, American Welding
Society Standard AWS F4.1, from Global Engineering
Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that
have Held Combustibles, American Welding Society
Standard AWS A6.0, from Global Engineering
Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from
National Fire Protection Association, Quincy, MA 02169
(phone: 1-800-344-3555, website: www.nfpa.org and
www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet P-1, from Compressed Gas Association, 14501
George Carter Way, Suite 103, Chantilly, VA 20151 (phone:
703-788-2700, website: www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA
Standard W117.2, from Canadian Standards Association,
Standards Sales, 5060 Spectrum Way, Suite 100,
Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And
Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 25 West 43rd Street, New
York, NY 10036 (phone: 212-642-4900, website:
www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and
Other Hot Work, NFPA Standard 51B, from National Fire
Protection Association, Quincy, MA 02169
(phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for
General Industry, Title 29, Code of Federal Regulations
(CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing
Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800)
(there are 10 OSHA Regional Offices—phone for Region 5,
Chicago, is 312-353-2220, website: www.osha.gov).
1-5 EMF Information
Electric current flowing through any conductor causes
localized electric and magnetic fields (EMF). The current
from arc welding (and allied processes including spot
welding, gouging, plasma arc cutting, and induction heating
operations) creates an EMF field around the welding circuit.
EMF fields may interfere with some medical implants, e.g.
pacemakers. Protective measures for persons wearing
medical implants have to be taken. For example, restrict
access for passers-by or conduct individual risk
assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF
fields from the welding circuit:
1. Keep cables close together by twisting or taping them,
or using a cable cover.
2. Do not place your body between welding cables.
Arrange cables to one side and away from the
operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power
source.
7. Do not weld while carrying the welding power source or
wire feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor
and the device manufacturer before performing or going near
arc welding, spot welding, gouging, plasma arc cutting, or
induction heating operations. If cleared by your doctor, then
following the above procedures is recommended.
7
SECTION 2 – INSTALLATION
2-1 INSTALLING QUICK CONNECT BLOCK TO FEEDER
2-2 INSTALLING GUN TO QUICK CONNECT BLOCK
Ensure correct liner and contact tip are utilized. Examine and replace power pin o-rings if necessary.
STEP #1
• Guide welding wire into power pin.
• Insert power pin to shoulder.
• Tighten thumb screw securely.
• Connect control plug lead to control
housing on gun.
• Insert control plug into feeder.
STEP #1
• Insert the correct feeder adaptor liner for desired
wire diameter (2 provided) flush with the threaded
end of the feeder adaptor.
• Tighten set screw.
• Thread feeder adaptor into Quick Connect Block and
tighten.
STEP #2
• Position assembly into feeder adaptor and trim
liner within
1/16” (1.6 mm) of the drive rolls and remove burrs if
necessary.
• Secure assembly into feeder.
• Thread gas hose nipple into feeder gas fitting.
•
Connect power cable to 1/2” (13 mm) power bolt with
appropriate lug.
• Tighten all connections.
• Feed welding wire through assembly by hand and tighten drive
rolls.
8
STEP #2
• Securely clamp blue hose on rear
housing to water-out on water cooler and
red hose on rear housing to water-in on
water cooler.
WARNING: To prevent torch damage, it is
highly advised that a Flow Sensor rated at 0.5
gpm be used at all times (Part #659-50).
STEP #3
• WARNING: Ensure water supply is on before operation.
• Recheck - Proper gas flow.
- Drive roll pressure.
- Voltage and wire feed speed.
- Water flow (minimum 1/2 gallon per minute) at 55-65 PSI.
2-3 INSTALLING POWER PIN TO GUN
IMPORTANT: The thread-in two-piece power pin incorporates a
taper to seat and lock in the power pin to the rear handle block.
Make sure power pin is tightened in the block with a wrench to
insure pin is secure and will not come loose.
NOTE: The rear handle and screws do not have to be removed
when installing the two-piece power pins.
• Thread power pin into the rear handle block.
• Tighten the power pin into the rear block using a 1 1/4 ”
wrench on the rear block and a 5/8” or a 3/4” wrench on the power pin.
• Install liner (See Section 2.4 LINER REPLACEMENT).
•
Install gun to feeder (See Below).
• Miller®, Tweco® #4 and #5, Lincoln® and
Hobart®
Power Pin
- Insert power pin to shoulder and secure.
- Insert control plug to control housing of gun.
- Insert control plug into feeder.
- Feed welding wire into power pin by hand
and tighten drive rolls.
- On Lincoln it is necessary to connect gas
hose to barbed fitting on power pin.
• Bernard Style and Euro-Connector
- Feed welding wire through female adaptor by
hand and tighten drive rolls.
- Guide welding wire into connector on gun,
carefully insert connector into female adaptor
and tighten Euro hand nut or Bernard-style
locking collar.
• ESAB® Power Pin (Non-Euro Style)
- Insert power pin to shoulder and secure.
- Feed welding wire into power pin by hand and tighten.
9
SECTION 3 – MAINTENANCE
3-1 TREGASKISS™ NOZZLE AND TOUGH LOCK™ CONSUMABLES
IMPORTANT:
• Neck Insulator must be in place before welding to maintain insulation of neck armor.
• Be sure all parts are tightened well before welding.
• When using the heavy duty retaining head make sure it is tightened with a 5/8” wrench to prevent overheating
of contact tip.
• To prevent scoring on heavy duty retaining head do not use pliers.
Removal and Replacement
• Pull slip-on nozzles off with a clockwise twisting motion.
• When installing nozzle, exposed insulator should nest inside neck insulator to assure concentricity.
• Neck insulators are positioned on the end of the neck with the large insulated counterbore facing the nozzle.
• Replace nozzle retainer with deep counterbore toward the neck. Tighten until retainer and neck insulator are
secure.
3-2 SWITCH REPLACEMENT
STEP #1
• Twist handle locking caps.
• Pull handle locking caps away from
handle.
• Remove Philips screw.
• Separate handle.
• Remove switch from nest in handle.
•
Remove switch from switch lead
connectors with needle nose pliers.
• Push switch lead connectors firmly onto
switch terminals with needle nose pliers.
•
Fit switch into nest on handle, switch
leads must lie parallel.
•
Reinstall handle halves & locking cap.
HANDLE FRONT
LOCKING CAP
LEADS
SWITCH LEAD
CONNECTORS
SWITCH
HANDLE REAR
LOCKING CAP
NECK
INSULATOR
HEAVY DUTY NOZZLE
VARIOUS LENGTHS AVAILABLE
HEAVY DUTY
TOUGH LOCK
CONTACT TIP
HEAVY DUTY
TOUGH LOCK
RETAINING HEAD
10
3-3 NECK REPLACEMENT
STEP #1
• Remove liner from gun.
• Twist handle locking caps.
•
Pull handle locking caps away from
handle.
• Remove Philips screw.
• Separate handle.
• Remove switch from nest in handle.
STEP #2
• Unthread power cable.
• Cut off water line and conduit clamp and
pull hoses off barbed fittings.
STEP #3
• Slide on new clamps on water line and conduit.
• Thread power cable on connection and tighten.
• Push water line and conduit all the way to the base of the fittings and clamp.
• Reposition handle and switch.
• Reinstall handle locking caps & screw.
HANDLE FRONT
LOCKING CAP
LEADS
SWITCH LEAD
CONNECTORS
SWITCH
HANDLE REAR
LOCKING CAP
NECK
WHITE CONDUIT LINE
WATER LINES (RED & BLUE)
& POWER LINE
NECK
HANDLE FRONT
LOCKING CAP
HANDLE REAR
LOCKING CAP
LEADS
SWITCH
LEAD CONNECTORS
SWITCH
11
3-4 LINER REPLACEMENT
NOTE: For guns equipped with thread-in power pins, Bernard, or Euro-connectors, the procedure is the same.
On Miller-style guns, liner is held captive by a guide cap which must be removed and replaced when changing liner.
STEP #1
NOTE: Ensure power supply is off and gun is removed from feeder before proceeding.
• Remove nozzle, tip and retaining head.
• If power pin uses a liner set screw, loosen the set screw using a 5/64” Allen wrench.
• If power pin is thread-in liner type, using a 10 mm wrench, turn thread-in liner retainer counterclockwise until
liner is free from the power pin.
• With gun straightened, grip conduit liner with pliers and remove.
STEP #2
• Feed replacement liner through gun using short strokes to avoid kinking. Twist liner clockwise if necessary.
Using a 10 mm wrench, turn thread-in liner collet in a clockwise direction and tighten in power pin.
STEP #3
• Push liner back into gun and hold in place.
• Trim conduit liner with a 3/4” (19 mm) stick out.
• Remove any burr that may obstruct wire feed, especially on flat wire
type conduit liner.
• Replace nozzle, tip and retaining head onto neck.
NECK
CONDUIT
LINER
3/4” (19 mm)
12
3-5 CABLE ASSEMBLY REPLACEMENT
STEP #1
• Remove nozzle, tip and retainer.
•
Take out rear housing screws and pull out liner.
STEP #2
• Pull the rear handle up the gun approximately 1 ft.
• Unscrew power cable from rear power block.
• Cut clamps off the water in (blue) line and gas line (white).
• Pull gas and water line off of power block.
• At this point, rear power block will be removed from gun.
•
Slide rear handle off gun.
MOUNTING SCREWS
REAR
WHITE CONDUIT LINE
BLUE WATER LINE
POWER & RED
WATER LINE
2-PIECE
POWER PIN
13
STEP #3
• On front of gun, release front handle from neck.
•
Remove outer jacket by pulling outer jacket only from rear of gun; all that remains are the inner hoses
attached to the neck and switch lead wires.
STEP #4
• Unthread power cable from front of gun and replace with new one.
STEP #5
• Slide outer jacket under front handle and bring front handle up to neck, replace switch and/or switch housing
and secure (See Section 2.3 SWITCH REPLACEMENT).
HANDLE FRONT
LOCKING CAP
WHITE CONDUIT LINE
OUTER JACKET
NECK
HANDLE REAR LOCKING CAP
WATER LINES (RED & BLUE)
& POWER LINE
NECK
USED RED WATER
LINE & POWER LINE
REPLACEMENT RED WATER
LINE & POWER LINE
WHITE CONDUIT LINE
14
STEP #6
At rear of gun, slide rear handle up over outer jacket.
• Attach rear power block to power cable.
• Attach the gas line and water line with new clamps and crimp to power block.
STEP #7
• Slide rear handle to rear power block and secure with mounting screws.
• Put liner through gun and tighten.
15
SECTION 4 − TECHNICAL DATA
4-1 NECK DIMENSIONS
B
C
D
NECK
ANGLE
INCHES
mm
INCHES
mm
INCHES
mm
445-45 45° 5.63 142.95 4.02 102.16 2.5 63.5
445-60
60°
4.99
126.75
5.14
130.56
2.5
63.5
4-2 GUN AMPERAGE RATINGS
MODEL
100% DUTY CYCLE 60% DUTY CYCLE
CO
2
MIXED
CO
2
MIXED
400
425
350
525
425
NOTE: Ratings are based on tests that comply with IEC 60974-7 standards.
SECTION 5 − OPTIONS
5-1 DIRECT PLUG-INS
PART # DESCRIPTION USE ON FEEDERS
214 TREGASKISS™ POWER PIN
TREGASKISS QUICK CONNECT BLOCK, HOBART® 2000 SERIES
FEEDERS, TWECO #4 RECEPTACLE BODY PART #TAK-1,
LINCOLN POWER MIG 300.
414-11-2 O-RING - FOR MILLER® POWER PINS
MILLERMATIC 200 & 250, S21E & S22 SERIES, 52 & 54
SERIES, 60 SERIES
214-6-116 MILLER POWER PIN
MILLERMATIC 200 & 250, S21E
& S22 SERIES, 52 & 54
SERIES, 60 SERIES
414-9
GUIDE CAP ONLY - FOR 214-6-9
414-116 GUIDE CAP ONLY - FOR 214-6-116
414-332
GUIDE CAP ONLY - FOR 214-6-332
214-12
TWECO® #5 STYLE POWER PIN
ALL FEEDERS SET UP WITH TWECO #5
414-12-2
O-RING FOR TWECO #5 STYLE POWER PIN
RECEPTACLE BODY PART #6TAK-1
214-2
LINCOLN® POWER PIN
LINCOLN LN7, 8 & 9, LN25 SUITCASE, LN22, NA2
214-13
PANASONIC®
214-6-9
MILLER POWER PIN (ALUMINUM OPTION)
16
5-2 FEEDER ADAPTORS
To be used with 417 Quick-Connect Block
PART #
USE ON FEEDERS
418-3
ESAB® (NON EURO STYLE) AND HOBART BETA MIG
418-4 HOBART® 27
418-5
LINCOLN® LN4, LN5, LINDE SWM 31, 3A & 32A
418-6
LINCOLN LN7, 8 & 9, LN 25 SUITCASE, LN22
418-7
LINDE® SWM-14
418-8
LINDE 35 SWM-23
418-9
MILLER® 10A, 30A (MILLERMATIC 35S FEEDER)
418-10 MILLER 52E, 54E, S21, S22 SERIES AND MILLERMATIC 200 & 250, 60 SERIES
418-14
OTC DAIHEN®
418-21
GILLILAND®
418-27
PANASONIC®
418-29
#5 PIN
418-35
KOBELCO®
5-3 CONTROL PLUGS
Euro Connector option - for European style feeders adaptors for
400 amp T-Gun MIG Guns
5-4 CONNECTOR OPTIONS
Euro Connector option - for European style feeders and feeder and
Feeder adaptors for 400 amp T-Gun MIG Guns.
PART # DESCRIPTION
PART # DESCRIPTION
419-2 HOBART
675 EURO CONNECTOR ASSEMBLY
419-4 MILLER (52E, 54E)
675-2 EURO HOUSING
419-5 WESTINGHOUSE
675-10 EURO CONNECTOR BODY
419-6 LINCOLN (LN7, 8, 9) NA2
419-7 MILLER (10E, 30E) & LINDE (SWM-35)
419-8
DIPSTICK 160, 200, HOBART HANDLER,
LINCOLN SP-100
17
SECTION 6 – TROUBLESHOOTING
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 GAS DIFFUSER
• 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
• OVER TORCH RATED DUTY CYCLE
GUN OVERHEATING
• LOOSE RETAINING SCREW ON QUICK CONNECT BLOCK
• INSUFFICIENT GAUGE POWER CABLE AND/OR GROUND CABLE
• LOOSE CONNECTOR CONES AND/OR CONE NUTS
• GUN BEING RUN BEYOND ITS AMPERAGE RANGE
• ELECTRICAL MALFUNCTION IN POWER SOURCE
SWITCH MALFUNCTIONING
• BAD CONNECTION OF LEADS TO SWITCH TERMINALS
• SPATTER BUILT UP BETWEEN LEVER AND SWITCH HOUSING
• CONTACTS DIRTY IN SWITCH
• SWITCH HOUSING SCREWS LOOSE
• BROKEN OR WORN SWITCH LEAD
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
• FLOW IMPROPERLY SET
18
SECTION 7 − EXPLODED VIEW AND PARTS LIST
ITEM
PART #
DESCRIPTION
ITEM
PART #
DESCRIPTION
1
STANDARD NOZZLES (SELF-INSULATED)
3
404-20
TREGASKISS™ TOUGH LOCK™ RETAINING HEAD FOR HD TIPS
401-40-38
SUPER TAPERED NOZZLE - 3/8" BORE (BRASS)
454-1-2
RETAINING RING
401-4-38
3/8" (10 mm) BORE - FLUSH TIP
402-6
O-RING
401-4-50
1/2" (13 mm) BORE - 1/8" (3 mm) TIP RECESS
401-4-62
5/8" (16 mm) BORE - 1/8" (3 mm) TIP RECESS
4
402-7
NECK INSULATOR
401-4-75
3/4" (19 mm) BORE - 1/8" (3 mm) TIP RECESS
SHORT ARC NOZZLE
5
NECKS (INCL. C/W (1) 357-2 AND (1) 413-5 CLAMP)
401-8-62
5/8” (16 mm) BORE - 1/8" (3 mm) TIP STICKOUT
445-45
NECK - 45°
HEAVY DUTY NOZZLES (SELF-INSULATED)
445-60
NECK - 60°
401-5-62
5/8" (16 mm) BORE - 1/4" (6 mm) TIP RECESS
401-5-75 3/4" (19 mm) BORE - 1/4" (6 mm) TIP RECESS
6
656-15
INTERNAL WATER LINE (INCL. C/W (1) 357-2 CLAMP FOR FRONT & (1)
656-1 CLAMP FOR REAR)
401-6-50
1/2" (13 mm) BORE - 1/8" (3 mm) TIP RECESS
15’ SERVICE (CUT FOR OTHER LENGTHS)
401-6-62
5/8" (16 mm) BORE - 1/8" (3 mm) TIP RECESS
401-6-75
3/4" (19 mm) BORE - 1/8" (3 mm) TIP RECESS
7
657-15
CONDUIT (INCL. C/W (2) 657-1 CLAMPS)
401-7-62
5/8" (16 mm) BORE - 1/4" (6 mm) TIP RECESS (BRASS)
15’ SERVICE (CUT FOR OTHER LENGTHS)
401-7-87
7/8" (22 mm) BORE - 1/4" (6 mm) TIP RECESS (BRASS)
8
658
RED WATER INE - OUT (C/W (1) 656-1 CLAMP)
2
HEAVY DUTY TREGASKISS™ TOUGH LOCK™ CONTACT TIPS -
5/16” (7.9 mm) O.D.
658-1
BLUE WATER LINE - IN (C/W(1) 656-1 CLAMP)
(LOCATED AT QUICK CONNECT POWER BLOCK ASSEMBLY)
403-20-30
FOR .030" (0.8 mm) WIRE
403-20-35
FOR .035" (0.9 mm) WIRE
9
POWER CABLE ASSEMBLY
403-20-1.0
FOR 1 mm WIRE
659-10
10’ SERVICE (ACTUAL LENGTH - 9.5’)
403-20-45
FOR .045" (1.2 mm) WIRE
659-12
12’ SERVICE (ACTUAL LENGTH - 11.5’)
403-20-364
FOR 3/64" (1.2 mm) WIRE
659-15
15’ SERVICE (ACTUAL LENGTH - 14.5’)
403-20-1.4
FOR 1.4 mm WIRE
403-20-52
FOR .052" (1.3 mm) WIRE
10
320
HANDLE - FRONT
403-20-116
FOR 1/16" (1.6 mm) WIRE
403-20-564
FOR 5/64" (2.0 mm) WIRE
10A
320-2
HANDLE LOCK NUT (FOR FRONT)
403-20-332
FOR 3/32" (2.4 mm) WIRE
11
211-5
SWITCH ASSEMBLY
HEAVY DUTY TAPERED TREGASKISS TOUGH LOCK CONTACT TIP -
5/16" (7.9 mm) O.D.
211-5-8
SWITCH WITH EXTENDED LEVER
403-21-30
FOR .030" (0.8 mm) WIRE
403-21-35
FOR .035" (0.9 mm) WIRE
12
CONTROL WIRE
403-21-1.0
FOR 1 mm WIRE
662-10
10’ SERVICE
403-21-45
FOR .045" (1.2 mm) WIRE
662-15
12’ SERVICE
662-15
15’ SERVICE
Numbers in this
column correspond to
the exploded view
images above.
19
PART #
DESCRIPTION
PART #
DESCRIPTION
13
412-8
SWITCH LEAD CONNECTOR
19
416-15
EURO HOUSING BLANK (C/W SCREWS)
416-5
CONTROL HOUSING (C/W SCREWS)
15
642-XX
OUTER JACKET ASSEMBLY
411-3M
MOUNTING SCREWS (METRIC)
15A
320-5
JACKET BUSHING
15B
320-4
REAR HANDLE CAP
20
FEEDER ADAPTOR REQUIREMENTS (SOLD SEPARATELY)
15C
663-1-XX
OUTER JACKET
417
QUICK CONNECT BLOCK ASSEMBLY TWECO #4
15D
663-1
STRAIN RELIEF
417-50
QUICK CONNECT BLOCK ASSEMBLY EURO
417-60
QUICK CONNECT BLOCK ASSEMBLY TWECO #5
16
664-400
POWER PIN BLOCK
21
FEEDER ADAPTORS (TO BE USED WITH QUICK CONNECT BLOCK)
17
214
TWECO®
214-2
LINCOLN®
22
CONTROL PLUGS (C/W PLUGS LEAD & FEMALE CONNECTORS)
214-6-116
MILLER®
214-12
TWECO
5
OPTIONAL ACCESSORIES
214-13
PANASONIC®
23
422
GUN HANGER
414-1
O-RING FOR TWECO
414-2
LINER SET SCREW
24
421
HEAT SHIELD
414-11-2
O-RING FOR MILLER POWER PIN
214-6-9
MILLER (FOR ALUMINUM)
25
610
HANDLE (REAR W/STRAIN RELIEF)
18
CONVENTIONAL LINERS
REPLACEMENT CABLE BUNDLES
L1A-15
FOR .023" (0.6 mm) WIRE - 15' (5 m)
661-10
10 FT. CABLE BUNDLE
415-30-25
FOR .030" (0.8 mm) WIRE - 25' (8 m)
661-12
12 FT. CABLE BUNDLE
415-35-10
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 10' (3 m)
661-15
15 FT. CABLE BUNDLE
415-35-15
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 15' (5 m)
415-35-25
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 25' (8 m)
26
413-5
OETIKER CLAMP - 11.3 mm
415-35-2
FOR .035" (0.9 mm) ALUMINUM WIRE - 15' (5 m)
415-116-10
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 10' (3 m)
27
357-2
OETIKER CLAMP - 8.7 mm
415-116-15
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 15' (5 m)
415-116-25
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 25' (8 m)
28
656-1
OETIKER CLAMP - 9.5 mm
415-116-2
FOR 3/64" - 1/16" (1.2 mm - 1.6 mm) ALUM. WIRE - 15' (5 m)
415-332-15
FOR 5/64" - 3/32" (2.0 mm - 2.4 mm) WIRE - 15' (5 m) FLAT WOUND
30
412-1
SWITCH LEAD CONNECTOR
415-332-153
FOR 5/64" - 3/32" (2.0 mm - 2.4 mm) WIRE - 15' (5 m) ROUND WOUND
415-332-251
FOR 5/64" - 3/32" (2.0 mm - 2.4 mm) WIRE - 15' (5 m) ROUND WOUND
415-332-25
FOR 5/64" - 3/32" (2.0 mm - 2.4 mm) WIRE - 25' (8 m) FLAT WOUND
415-564-15
FOR ALL 5/64" (2.0 mm) WIRE & 1/16" (1.6 mm) FLUX CORE WIRE
415-332-15
FOR .078” - 3/32” (2.24 mm) WIRE - 15’ (5 m) FLAT WOUND
415-1M
LINER O-RING
415-25
TREGASKISS JUMP LINER
415-45-01
FOR .035” - 3/64" WIRE - 6'
415-45-02
FOR .035” - 3/64" WIRE - 10'
415-45-03
FOR .035” - 3/64" WIRE - 15'
415-116-21
FOR 3/64" - 1/16” WIRE - 6'
415-116-22
FOR 3/64" - 1/16” WIRE - 10'
415-116-23
FOR 3/64" - 1/16” WIRE - 15'
SECTION 8 - ORDERING INFORMATION
8-1 EXAMPLE OF STANDARD MODEL NO.
8-2 EXAMPLE OF CUSTOM BUILT GUN
8-3 GUN STANDARDS CHART
GUN MODEL NECK NOZZLE RETAINING HEAD CONTACT TIPS
400 amp
445-60
401-6-62
404-20
403-20-XX
Bernard
A Division of Miller Electric Mfg. LLC
449 West Corning Road
Beecher, Illinois 60401 USA
Phone: 1-855-MIGWELD (644-9353)
(US & Canada)
1-519-737-3000 (International)
Fax: 708-946-6726
For more information, visit us at BernardWelds.com
©2018 Bernard
Option numbers should be
added only if desired option is
not included on standard gun
model.
9 - Liner for Aluminum wire
Angle of Neck
Wire Size
E 4210-116-60-9
Use these codes to order
special gun features.
E - Euro-Connector
M - Miller Power Pin
LN - Lincoln Power Pin
PA - Panasonic
TW - Tweco # 5
42
10-116
Wire Size
Standard Lengths
- 10, 12, 15 ft
Other lengths available upon request
Amperage (Manual)
42 - 400 amp
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Bernard T-Gun Technical Manual

Bernard
Brand
Bernard
Model
T-Gun
Category
Welding System
Type
Technical Manual
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