ESAB SPRAY MASTER™ User manual

Brand: ESAB

Model: SPRAY MASTER™

Category: Welding System

Type: User manual

This manual is also suitable for

Spray MASTER™ with Velocity Consumables Mig Guns

SPRAY MASTER™

WITH VELOCITY CONSUMABLES

MIG GUNS

Safety and

Operating

Instructions

AIR-COOLED MIG GUN 250 AMP, 350 AMP, 450 AMP

Tweco.com

Revision: AA Issue Date: May 15, 2014 Manual No.: 89200016

IMPORTANT: Included inside - special

instructions for NEW consumables.

CURRENT

450

AMPS

UP TO

WIRE SIZE

UP TO

/32

(2.4 mm)

DUTY CYCL E

UP TO

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

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 #:

SECTION 1: SAFETY PRECAUTIONS

Table of Contents

SECTION 1: SAFETY PRECAUTIONS ..........................................................................2

Mesures de sécurité ......................................................................... 2

SECTION 2: INTRODUCTION ......................................................................................4

2.01 How to Use this Manual ................................................................... 4

2.02 Receipt of Equipment ....................................................................... 4

2.03 Description ....................................................................................... 4

SECTION 3: MIG GUN SPECIFICATIONS.....................................................................4

3.01 MIG Gun Classiﬁcation ..................................................................... 4

3.02 Duty Cycle ........................................................................................ 4

3.03 MIG Gun Part Number Identiﬁcation ................................................ 4

SECTION 4: MIG GUN INSTALLATION ........................................................................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

5.02 Conduit Identiﬁcation ....................................................................... 5

Conduit Removal .............................................................................. 5

Conduit Installation .......................................................................... 5

5.03 Installing/Replacing Stainless Steel Sleeve ...................................... 5

5.04 Replace Conductor Tube .................................................................. 6

SECTION 6: CABLEHOZ® REPAIR .............................................................................6

6.01 Cablehoz® Repair ............................................................................ 6

SECTION 7: TROUBLESHOOTING ...............................................................................6

SECTION 8: CONSUMABLES ......................................................................................6

8.01 Replacement Kits ............................................................................. 6

8.02 Tips and Nozzles .............................................................................. 6

8.03 Conduit ............................................................................................ 7

8.04 Conductor tubes .............................................................................. 7

SECTION 9: REPLACEMENT PARTS ...........................................................................8

SECTION 10: STATEMENT OF WARRANTY ................................................................9

10.01 Warranty Schedule ........................................................................... 9

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.

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

MESURES DE SÉCURITÉ

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.

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

SAFETY AND OPERATING INSTRUCTIONS

389200016

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.

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

89200016

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.

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 MIG/MAG welding

Method of Guidance Manually guided

Type of Cooling Air

Type of Shielding Gas 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:

SMV3153545

Spray Master

with Velocity

350 AMP, 15 foot (5 M) cable

.035"-.045" Wire Capacity

(0,9mm - 1,2mm)

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.

POWER

SOURCE

WIRE FEEDER

GROUND

WORK PIECE

GUN

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

SAFETY AND OPERATING INSTRUCTIONS

589200016

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:

44-116-15

44 Series

1/16" (1,6mm) Wire Capacity

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.

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

Direct Plug MIG guns, twisting the rear of the gun approximately one revolution

clockwise will raise the conduit stop out of the connector plug recess.

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.

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.

SCREW (SLEEVE)

Lock collar and wave spring are held

in place by the stainless steel sleeve.

STAINLESS STEEL SLEEVE

CONDUCTOR TUBE END

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

89200016

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.

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

WHITE

BLACK

RED

WHITE

BLACK

TRIGGER

NOT USED

BLUE

BROWN

CONTROL WIRE

CABLEHOZ

{

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

Conductor Tube

O-ring

Set Screw

Retaining Ring

Wave Spring

Stainless

Steel Sleeve

Lock Collar

Spray Master Replacement Kit Parts List

Description Part No. Qty

Conductor Tube Assy. SMVCT60

Set Screw* (Sleeve) V41CS

Set Screw (5/64" hex

wrench drive)

41CS

Retaining Ring PMA64RS

Spray Master Replacement Kit Parts List

Description Part No. Qty

Wave Spring VCTLSPR

Lock Collar VCTLSLK

Stainless Steel Sleeve VCTLSL

O-Ring 94-710-036

* Not Shown

8.02 TIPS AND NOZZLES

Velocity Nozzle Identiﬁcation

VNM50FS

Velocity

Nozzle

Blank=Std Recess,

F=Flush,

P=Protrude,

R= Recess ¼” (6.35mm)

FAS=Spot Weld

FC=Flux Core

S=Small,

M=Medium,

L=Large

ET=Extended Taper

Oriﬁce Opening Size:

37=3/8” 62=5/8”

50=1/2” 75=3/4”

Blank=Threaded,

S=Slip

Velocity Contact Tip Identiﬁcation

VTMA30

Velocity

Tip

S=Small,

M=Medium,

L=Large

ET=Extended Taper

A=Alum,

Blank=Other

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.

SAFETY AND OPERATING INSTRUCTIONS

789200016

VNFC Flux Core Nozzle 1240-1892

MEDIUM DUTY NOZZLES HEAVY DUTY NOZZLES

Part No. Description Stock No. Part No. Description Stock No.

VNM50F 1/2" Threaded Nozzle Flush VNH62 5/8" Threaded Nozzle Recess

VNM62 5/8" Threaded Nozzle Recess VNH62F 5/8" Threaded Nozzle Flush

VNM62F 5/8" Threaded Nozzle Flush VNH75 3/4" Threaded Nozzle Recess

VNM75 3/4" Threaded Nozzle Recess VNH75F 3/4" Threaded Nozzle Flush

VNM75F 3/4" Threaded Nozzle Flush VNH62S 5/8" Slip Nozzle

VNM50S 1/2" Slip Nozzle VNH75S 3/4" Slip Nozzle

VNM62S 5/8" Slip Nozzle VNS Slip Nozzle Base

VNM75S 3/4" Slip Nozzle VNH62SC 5/8" Slip Nozzle Cone Only

VNS Slip Nozzle Base VNH75SC 3/4" Slip Nozzle Cone Only

VNM50SC 1/2" Slip Nozzle Cone Only VNH622PC 5/8" 2 Piece Nozzle Assembly Recess

VNM62SC 5/8" Slip Nozzle Cone Only VNH62C 5/8" 2 Piece Nozzle Cone Only Recess

VNM75SC 3/4" Slip Nozzle Cone Only VNH62F2PC 5/8" 2 Piece Nozzle Assembly Flush

VNM62FAS 5/8" Spot Nozzle

VNH62FC 5/8" 2 Piece Nozzle Cone Only Flush

VNM75FAS 3/4" Spot Nozzle

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

MEDIUM DUTY CONTACT TIPS HEAVY DUTY CONTACT TIPS EXTENDED TAPER CONTACT TIPS

Part No. Description Stock No. Part No. Description Stock No. Part No. Description Stock No.

VTM23 .023" (0.6 mm) 1160-1772

1160-1773

1160-1774

1160-1775

1160-1776

1160-1777

1160-1778

1160-1750 VTH30 .030" (0.8 mm) 1160-1760 VTET30 .030" (0.8 mm)

VTM30 .030" (0.8 mm) 1160-1751 VTH35 .035" (0.9 mm) 1160-1761 VTET35 .035" (0.9 mm)

VTM35 .035" (0.9 mm) 1160-1752 VTH40 .040" (1.0 mm) 1160-1762 VTET40 .040" (1.0 mm)

VTM40 .040" (1.0 mm) 1160-1753 VTH45 .045" (1.2 mm) 1160-1763 VTET45 .045" (1.2 mm)

VTM45 .045" (1.2 mm) 1160-1754 VTHA364 3/64" (1.2 mm) 1160-1764 VTETA364 3/64" (1.2 mm)

VTMA116 1/16" (1.6 mm) 1160-1755 VTH52 .052" (1.3 mm) 1160-1765 VTET52 .052" (1.3 mm)

VTM52 .052" (1.3 mm) 1160-1756 VTH116 1/16" (1.6 mm) 1160-1766 VTET116 1/16" (1.6 mm)

VTM116 1/16" (1.6 mm) 1160-1757 VTHA116 1/16" (1.6 mm) 1160-1767

VTMA116 1/16" (1.6 mm) 1160-1758 VTH564 5/64" (2.0 mm) 1160-1768

VTM564 5/64" (2.0 mm) 1160-1759 VTH332 3/32" (2.4 mm) 1160-1769

VTH764 7/64" (2.8 mm) 1160-1770

VTH18 1/8" (3.2 mm) 1160-1771

1240-1895

1240-1896

1240-1880

1240-1884

1240-1886

1240-1883

1240-1887

1240-1881

1240-1885

1240-1882

1240-1877

1240-1878

1240-1875

1240-1876

1240-1893

1240-1896

1240-1864

1240-1863

1240-1864

1240-1861

1240-1862

1240-1865

1240-1866

1240-1868

1240-1856

1240-1854

1240-1855

1240-1852

1240-1853

1240-1859

1240-1860

* Some parts may not be available at this time.

8.03 CONDUIT

250 AMP

Length

Wire Size

.035" - .045" (1,0mm - 1,2)mm

Part No. Stock No.

12 Ft See 15 Ft

15 Ft 42-4045-15 1420-1123

20 Ft See 20 Ft

25 Ft 42-4045-25 1420-1125

350 AND 450 AMP

Length

Wire Size

.052" - 1/16" (1,3mm - 1,6mm)

350 Amp 450 Amp

Part No. Stock No. Part No. Stock No.

10 Ft See 15 Ft See 15 Ft

12 Ft See 15 Ft See 15 Ft

15 Ft

44-116-15 1440-1113 44-116-15 1440-1113

20 Ft See 20 Ft See 20 Ft

25 Ft

44-116-25 1440-1115

8.04 CONDUCTOR TUBES

250 AMP 350 AMP 450 AMP

SMVCT45 SMVCT45

SMVCT60 SMVCT60

SMVCT60LM

SAFETY AND OPERATING INSTRUCTIONS

89200016

SECTION 9: REPLACEMENT PARTS

13b

13a

10a

11a

12a

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.

SAFETY AND OPERATING INSTRUCTIONS

989200016

Item

No.

250 AMP 350 AMP 450 AMP Description

VCTLSL

Stainless Steel Sleeve

VCTLSLK

Lock Collar

VCTLSPR

Wave Spring

PMA64R

Retaining Ring

5 -- -- -- Conductor Tube – Refer to 8.04 Conductor Tube

MS84

2060-2130

MS84

2060-2130

MS84

2060-2130

Handle – Standard Spray Master

N/A

MS84-DSRS

2060-2128

MS84-DSRS

2060-2128

Handle – Dual Schedule (Rocker Switch)

MS84-LC

2060-2127

MS84-LC

2060-2127

MS84-LC

2060-2127

Handle – Locking Trigger

ELC94

2060-2647

ELC94

2060-2647

ELC94

2060-2647

Trigger– Standard & Dual Schedule

MS94-LC

2060-2693

MS94-LC

2060-2693

MS94-LC

2060-2693

Trigger – Locking

7b N/A

MS94-RSW

2060-2694

MS94-RSW

2060-2694

Dual Schedule Rocker Switch

ELC94-BL

2060-2671

ELC94-BL

2060-2671

ELC94-BL

2060-2671

Trigger Blade Assembly

N/A

MS310

1730-2035

N/A Cablehoz® Assembly - 10 ft (3 m)

MS212

1720-2116

MS312

1730-2036

MS412

1740-2116

Cablehoz Assembly - 12 ft (4 m)

MS215

1720-2117

MS315

1730-2037

MS415

1740-2117

Cablehoz Assembly - 15 ft (5 m)

MS225

1720-2118

MS325

1730-2038

MS425

1740-2118

Cablehoz Assembly - 25 ft (8 m)

MS212X

1720-2107

N/A

MS412X

1740-2122

Cablehoz Assembly, Euro-Kwik - 12 ft (4 m)

MS215X

1720-2108

N/A

MS415X

1740-2123

Cablehoz Assembly, Euro-Kwik - 15 ft (5 m)

MS225X

1720-2109

N/A N/A Cablehoz Assembly, Euro-Kwik - 25 ft (8 m)

MS102-RK

2060-2132

MS104-RK

2060-2133

MS104-RK

2060-2133

Cablehoz Front Mechanical Connector

Replacement Kit

MS172-RK

2060-2134

MS174-RK

2060-2135

MS174-RK

2060-2135

Cablehoz Rear Mechanical Connector Replacement

Kit

172X-M

2020-2181

174X-M

2040-2181

174X-M

2040-2181

Cablehoz Rear Mechanical Connector Replacement

Kit For Euro-Style

10a

350-174MH

2035-2111

350-174MH

2035-2111

350-174MH

2035-2111

Miller® Rear Connector

10b

WM-354M

2030-2075

WM-354M

2030-2075

WM-354M

2030-2075

Miller Control Wire & Plug

NS N/A

194DS

2040-2195

194DS

2040-2195

Miller Dual Schedule Control Wire & Plug

11a

350-174H

2035-2110

350-174H

2035-2110

350-174H

2035-2110

Tweco Rear Connector

11b

MS354-TAJ

2060-2139

MS354-TAJ

2060-2139

MS354-TAJ

2060-2139

Tweco Control Wire

MS-354DS-TJ

2060-2138

MS-354DS-TJ

2060-2138

MS-354DS-TJ

2060-2138

Tweco Dual Schedule Control Wire & Plug

12a

350-174LH

2035-2112

350-174LH

2035-2112

350-174LH

2035-2112

Lincoln® Rear Connector

12b

MS-354DS-LJ

2060-2137

MS-354DS-LJ

2060-2137

MS-354DS-LJ

2060-2137

Lincoln Control Wire & Plug

174EX-1

2040-2276

174EX-1

2040-2276

174EX-1

2040-2276

Euro-Kwik Connection Assy

13a

174X-2

2040-2177

174X-2

2040-2177

174X-2

2040-2177

Euro-Kwik Nut

13b

X6RC

2060-2006

X6RC

2060-2006

X6RC

2060-2006

Euro-Kwik Connector Case

14 -- -- -- Conduit – Refer to 8.03 Conduit

NS = Not Shown

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 Parts / Labor

All MIG Gun products 30 days from date purchaser purchases from seller. 30 days / NA