Tweco Velocity Operating Manual
Transcription
Tweco Velocity Operating Manual
AIR-COOLED MIG GUN 250 AMP, 350 AMP, 450 AMP CURRENT WIRE SIZE DUTY CYCL E UP TO UP TO UP TO 450 AMPS 3/32" (2.4 mm) 80% SPRAY MASTER™ WITH VELOCITY CONSUMABLES MIG GUNS Safety and Operating Instructions IMPORTANT: Included inside - special instructions for NEW consumables. Revision: AA Issue Date: May 15, 2014 Manual No.: 89200016 Tweco.com WE APPRECIATE YOUR BUSINESS! Congratulations on receiving your new Tweco Spray Master™ product. We are proud to have you as our customer and will strive to provide you with the best service and support in the industry. This product is backed by our extensive warranty and world-wide service network. We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done. For more than 75 years Tweco has provided quality products you can trust, when your reputation is on the line. YOU ARE IN GOOD COMPANY! Tweco is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish ourselves from our competition through market-leading innovation and truly dependable products that will stand the test of time. We strive to enhance your productivity, efficiency and welding performance enabling you to excel in your craft. We design products with the welder in mind delivering- advanced features, durability, ease of use and ergonomic comfort. Above all, we are committed to a safer working environment within the welding industry. Your satisfaction with this product and its safe operation is our ultimate concern. Please take the time to read the entire manual, especially the Safety Precautions. If you have any questions or concerns regarding your new Tweco product, please contact our friendly and knowledgeable Customer Service Team at: 1-800-462-2782 (USA) and 1-905-827-4515 (Canada), or visit us on the web at www.Tweco.com WARNING Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer’s judgment, the Manufacturer assumes no liability for its use. Spray Master™ with Velocity MIG Guns Safety and Operating Instructions Instruction Guide Number 89200016 Published by: Victor Technologies, Inc. 2800 Airport Rd. Denton, TX. 76208 (940) 566-2000 www.Tweco.com U.S. Customer Care: (800) 426-1888 International Customer Care: (940) 381-1212 Canada Customer Care: 905-827-4515 / fax 800-588-1714 Copyright © 2014 Victor Technologies, Inc. All rights reserved. Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited. The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause. Publication Date: May 15, 2014 Record the following information for Warranty purposes: Where Purchased: Purchase Date: Equipment Serial #: i Table of Contents 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 8.03Conduit............................................................................................. 7 8.04 Conductor tubes............................................................................... 7 SECTION 9: REPLACEMENT PARTS............................................................................8 SECTION 10: STATEMENT OF WARRANTY.................................................................9 10.01 Warranty Schedule............................................................................ 9 SECTION 1: SAFETY PRECAUTIONS 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 2 terre doivent être vérifiées périodiquement pour déterminer si elles sont solides et appropriées SAFETY AND OPERATING INSTRUCTIONS 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. 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 porteélectrodes, 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 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. 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. 3 89200016 SAFETY AND OPERATING INSTRUCTIONS SECTION 2: INTRODUCTION 2.01 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.” 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. WARNING Electric shock can cause injury or death. WIRE FEEDER CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in injury. GUN WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. POWER SOURCE 2.02 RECEIPT OF EQUIPMENT When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area, listed on the back cover of this manual. Include a full description of the parts in error. 2.03 DESCRIPTION Tweco Spray Master MIG Guns are furnished with rear connections to fit directly into most Miller®, Lincoln®, and Euro connection wire feeders. These guns are referred to as Direct Plug MIG Guns. Tweco Spray Master MIG guns are also furnished with the time-proven MIG-Kwik connection. The MIG-Kwik connection, when utilized with a Tweco adapter kit, allows a Tweco Spray Master MIG gun to be installed on almost any wire feed system. For a listing of available adapter kits, see the Tweco Adapter Kit Listing, Form No. TAKL-97, or call Tweco Customer Care. GROUND 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. Miller is registered trademark of Illinois Tool Works, Inc.. Lincoln is a registered trademark of Lincoln Electric Co. The aforementioned registered trademarks are no way affiliated with Tweco Products, Inc. or Victor Technologies, Inc. Tweco Spray Master is a registered trademark of Victor Technologies, Inc. SECTION 3: MIG GUN SPECIFICATIONS 3.01 MIG GUN CLASSIFICATION Process Method of Guidance Type of Cooling Type of Shielding Gas Figure 2 MIG/MAG welding Manually guided Air All types 3.02 DUTY CYCLE Spray Master with Velocity MIG Guns (250, 350, and 450 Amps) with mixed gas are rated at 80% duty cycle per IEC 60974-7. 3.03 MIG GUN PART NUMBER IDENTIFICATION Figure 3 NOTE Spray Master MIG guns, as a general rule, have a specific nomenclature incorporated within each part number to help determine the wire size of each MIG gun. Example Part Number: 350 AMP, 15 foot (5 M) cable S MV 315116 Spray Master with Velocity 89200016 WORK PIECE 1-/16" Wire Capacity (1,6mm) 4 SAFETY AND OPERATING INSTRUCTIONS SECTION 5: SPRAY MASTER WITH VELOCITY MAINTENANCE This section discusses servicing and or replacing various components of the Spray Master MIG Gun. WARNING Disconnect power from MIG Gun before servicing. 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 Score on nozzle end 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. Nozzle Example Part Number: 1/16" (1,6mm) Wire Capacity CUT Method I 44-116-15 44 Series Conduit Trim Length 3/8” (9 mm to 10 mm) Liner length in feet CONDUIT REMOVAL CUT 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 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 using one of two methods. 5 Stainless Steel Sleeve end Method II 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. 4. Inspect the cut conduit end to remove burrs because they could interfere with wire feeding or conflict with the conduit seating inside the velocity tip. Remove burrs with a file or side cutter. 5. Insert the contact tip and HAND tighten the nozzle. The MIG gun is now ready to be reinstalled on the feeder. 5.03 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. Stainless Steel Sleeve end INSTALLING/REPLACING STAINLESS STEEL SLEEVE / LOCK COLLAR The Stainless Steel Sleeve is held in place by one screw (some models have two screws) and the sleeve holds the lock collar assembly in place. Lock collar and wave spring are held in place by the stainless steel sleeve. STAINLESS STEEL SLEEVE SCREW (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. 89200016 SAFETY AND OPERATING INSTRUCTIONS Lock Collar Spring Washer Spray Master Replacement Kit Parts List Snap Ring Description 4. Slide the Stainless Steel 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. 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. Part No. Qty Conductor Tube Assy. SMVCT60 1 Set Screw* (Sleeve) V41CS 1 Set Screw (5/64" hex wrench drive) 41CS 1 Retaining Ring PMA64RS 1 Wave Spring VCTLSPR 4 Lock Collar VCTLSLK 1 Stainless Steel Sleeve VCTLSL 1 94-710-036S 1 O-Ring * Not Shown 8.02 TIPS AND NOZZLES Velocity Nozzle Identification S=Light Duty M=Medium Duty H=Heavy Duty ET=Extended Taper Blank= Fixed Threaded S=Adjustable Slip V N M 5 0 F Blank=Std S Recess Velocity Nozzle Conductor Tube set screw 3. Mount the conductor tube O-ring on the end of the conductor tube. Orifice Opening Size: 37=3/8” 62=5/8” 50=1/2” 75=3/4” Nozzle Convention Slide the tube over the liner and insert into the brass connection within the handle. Tighten the socket head cap screw wrench tight using the 5/32" hex wrench. 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. There are two methods of trimming the conduit. See "Conduit Installation" on page 5. SECTION 6: CABLEHOZ® REPAIR 6.01 CABLEHOZ® REPAIR CONTROL WIRE { 3 Knurl Rings VNH 4 Knurl Rings VNET S=Light Duty M=Medium Duty H=Heavy Duty ET=Extended Taper RED CABLEHOZ WHITE BLUE BLACK BLACK BROWN BLACK BLACK NOT USED Heavy Duty A=Alum Blank=Other V T M A 3 0 TRIGGER Velocity Tip 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). 8.01 VNM Velocity Contact Tip Identification RED WHITE 2 Knurl Rings Medium Duty If you should find it necessary to repair Cablehoz connection(s), repair instructions can be found at www.Tweco.com our website. NOT USED F=Flush P=Protrude R= Recess ¼” (6.35mm) FAS=Spot Weld FC=Flux Core 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” Contact Tip Convention SECTION 8: CONSUMABLES 2 Rings VTM 3 Rings VTH REPLACEMENT KITS 4 Rings VTET Lock Collar Stainless Steel Sleeve Retaining Ring Medium Duty Conductor Tube Wave Spring Set Screw 89200016 O-ring 6 Heavy Duty SAFETY AND OPERATING INSTRUCTIONS MEDIUM DUTY CONTACT TIPS Part No. Description VTM23 .023" (0.6 mm) VTM30 .030" (0.8 mm) VTM35 .035" (0.9 mm) VTM40 .040" (1.0 mm) VTM45 .045" (1.2 mm) VTMA364 * 3/64" (1.2 mm) VTM52 .052" (1.3 mm) VTM116 1/16" (1.6 mm) VTMA116 * 1/16" (1.6 mm) VTM564 5/64" (2.0 mm) HEAVY DUTY CONTACT TIPS Stock No. 1160-1750 1160-1751 1160-1752 1160-1753 1160-1754 1160-1755 1160-1756 1160-1757 1160-1758 1160-1759 Part No. Description VTH30 .030" (0.8 mm) VTH35 .035" (0.9 mm) VTH40 .040" (1.0 mm) VTH45 .045" (1.2 mm) VTHA364 * 3/64" (1.2 mm) VTH52 .052" (1.3 mm) VTH116 1/16" (1.6 mm) VTHA116 * 1/16" (1.6 mm) VTH564 5/64" (2.0 mm) VTH332 3/32" (2.4 mm) VTH764 7/64" (2.8 mm) VTH18 1/8" (3.2 mm) EXTENDED TAPER CONTACT TIPS Stock No. 1160-1760 1160-1761 1160-1762 1160-1763 1160-1764 1160-1765 1160-1766 1160-1767 1160-1768 1160-1769 1160-1770 1160-1771 Part No. Description VTET30 .030" (0.8 mm) VTET35 .035" (0.9 mm) VTET40 .040" (1.0 mm) VTET45 .045" (1.2 mm) VTETA364 * 3/64" (1.2 mm) VTET52 .052" (1.3 mm) VTET116 1/16" (1.6 mm) Stock No. 1160-1772 1160-1773 1160-1774 1160-1775 1160-1776 1160-1777 1160-1778 * For Aluminum MEDIUM DUTY NOZZLES Part No. VNM50F VNM62 VNM62F VNM75 VNM75F VNM50S VNM62S VNM75S VNS VNM50SC VNM62SC VNM75SC VNLFC VNM62FAS VNM75FAS HEAVY DUTY NOZZLES Description 1/2" Threaded Nozzle Flush 5/8" Threaded Nozzle Recess 5/8" Threaded Nozzle Flush 3/4" Threaded Nozzle Recess 3/4" Threaded Nozzle Flush 1/2" Slip Nozzle 5/8" Slip Nozzle 3/4" Slip Nozzle Slip Nozzle Base 1/2" Slip Nozzle Cone Only 5/8" Slip Nozzle Cone Only 3/4" Slip Nozzle Cone Only Flux Core Nozzle 5/8" Spot Nozzle 3/4" Spot Nozzle Stock No. 1240-1856 1240-1854 1240-1855 1240-1852 1240-1853 1240-1859 1240-1860 1240-1863 1240-1864 1240-1861 1240-1862 1240-1865 1240-1892 1240-1866 1240-1868 Part No. VNH62 VNH62F VNH75 VNH75F VNH62S VNH75S VNS VNH62SC VNH75SC VNH622PC VNH62C VNH62F2PC VNH62FC VNH752PC VNH75C VNH75F2PC VNH75FC Description 5/8" Threaded Nozzle Recess 5/8" Threaded Nozzle Flush 3/4" Threaded Nozzle Recess 3/4" Threaded Nozzle Flush 5/8" Slip Nozzle 3/4" Slip Nozzle Slip Nozzle Base 5/8" Slip Nozzle Cone Only 3/4" Slip Nozzle Cone Only 5/8" 2 Piece Nozzle Assembly Recess 5/8" 2 Piece Nozzle Cone Only Recess 5/8" 2 Piece Nozzle Assembly Flush 5/8" 2 Piece Nozzle Cone Only Flush 3/4" 2 Piece Nozzle Assembly Recess 3/4" 2 Piece Nozzle Cone Only Recess 3/4" 2 Piece Nozzle Assembly Flush 3/4" 2 Piece Nozzle Cone Only Flush Stock No. 1240-1877 1240-1878 1240-1875 1240-1876 1240-1893 1240-1896 1240-1864 1240-1895 1240-1896 1240-1880 1240-1884 1240-1881 1240-1885 1240-1882 1240-1886 1240-1883 1240-1887 * Some parts may not be available at this time. 8.03CONDUIT 8.04 250 AMP SMVCT45 250 AMP Wire Size .035" - .045" (1,0mm - 1,2)mm Part No. Stock No. See 15 Ft 42-4045-15 1420-1123 See 20 Ft 42-4045-25 1420-1125 Length 12 Ft 15 Ft 20 Ft 25 Ft CONDUCTOR TUBES 350 AMP SMVCT60 450 AMP SMVCT45 SMVCT60 SMVCT60LM 350 AND 450 AMP Wire Size .052" - 1/16" (1,3mm - 1,6mm) Length 350 Amp Part No. 450 Amp Stock No. Part No. Stock No. 10 Ft See 15 Ft See 15 Ft 12 Ft See 15 Ft See 15 Ft 15 Ft 20 Ft 25 Ft 44-116-15 1440-1113 See 20 Ft 44-116-15 1440-1113 See 20 Ft 44-116-25 1440-1115 7 89200016 SAFETY AND OPERATING INSTRUCTIONS SECTION 9: REPLACEMENT PARTS 12a 12 11a 14 11 10a 10 13 13b 7 8 13a 7a 9b 9 9c 6 4 9a 3 2 5 1 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. 89200016 8 SAFETY AND OPERATING INSTRUCTIONS Item No. 250 AMP Wave Spring PMA64R 4 -SMV82 2060-2082 6 N/A SMV82LC 2060-2079 ELC94 2060-2647 MS94-LC 2060-2693 7b N/A 8 ELC94-BL 2060-2671 N/A 9 Lock Collar VCTLSPR 3 MS212 1720-2116 MS215 1720-2117 MS225 1720-2118 MS212X 1720-2107 MS215X 1720-2108 MS225X 1720-2109 MS102-RK 2060-2132 MS172-RK 2060-2134 172X-M 2020-2181 350174MHFS 2035-2118 WM-354M 2030-2075 Description Stainless Steel Sleeve VCTLSLK 2 7 450 AMP VCTLSL 1 5 350 AMP Retaining Ring -SMV83 2060-2083 SMV83DS 2060-2077 SMV83LC 2060-2080 ELC94 2060-2647 MS94-LC 2060-2693 MS94-RSW 2060-2694 ELC94-BL 2060-2671 MS310 1730-2035 MS312 1730-2036 MS315 1730-2037 MS325 1730-2038 -SMV84 2060-2084 SMV84DS 2060-2078 SMV84LC 2060-2081 ELC94 2060-2647 MS94-LC 2060-2693 MS94-RSW 2060-2694 ELC94-BL 2060-2671 N/A Conductor Tube – Refer to 8.04 Conductor Tube Handle – Standard Spray Master Handle – Dual Schedule (Rocker Switch) Handle – Locking Trigger Trigger– Standard & Dual Schedule Trigger – Locking Dual Schedule Rocker Switch Trigger Blade Assembly Cablehoz® Assembly - 10 ft (3 m) Cablehoz Assembly - 12 ft (4 m) N/A MS512 1750-2116 MS515 1750-2117 MS525 1750-2118 MS512X 1750-2119 N/A MS515X 1750-2120 Cablehoz Assembly, Euro-Kwik - 15 ft (5 m) Cablehoz Assembly, Euro-Kwik - 25 ft (8 m) Cablehoz Assembly - 15 ft (5 m) Cablehoz Assembly - 25 ft (8 m) Cablehoz Assembly, Euro-Kwik - 12 ft (4 m) N/A N/A MS104-RK 2060-2133 MS174-RK 2060-2135 174X-M 2040-2181 350174MHFS 2035-2118 WM-354M 2030-2075 194DS 2040-2195 350174HFS 2035-2119 MS354-TAJ 2060-2139 Cablehoz Front Mechanical Connector Replacement Kit Cablehoz Rear Mechanical Connector Replacement Kit Cablehoz Rear Mechanical Connector Replacement Kit For Euro-Style NS N/A 11a 11b 350174HFS 2035-2119 MS354-TAJ 2060-2139 MS104-RK 2060-2133 MS174-RK 2060-2135 174X-M 2040-2181 350174MHFS 2035-2118 WM-354M 2030-2075 194DS 2040-2195 350174HFS 2035-2119 MS354-TAJ 2060-2139 NS 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 MS-354DS-LJ 2060-2137 174EX-1 2040-2276 174X-2 2040-2177 X6RC 2060-2006 -- 350-174LH 2035-2112 MS-354DS-LJ 2060-2137 174EX-1 2040-2276 174X-2 2040-2177 X6RC 2060-2006 -- 350-174LH 2035-2112 MS-354DS-LJ 2060-2137 174EX-1 2040-2276 174X-2 2040-2177 X6RC 2060-2006 -- Lincoln® Rear Connector 9a 9b 9c 10a 10b 12b 13 13a 13b 14 Miller® Rear Connector Miller Control Wire & Plug Miller Dual Schedule Control Wire & Plug Tweco Rear Connector Tweco Control Wire Lincoln Control Wire & Plug Euro-Kwik Connection Assy Euro-Kwik Nut Euro-Kwik Connector Case 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 All MIG Gun products 30 days from date purchaser purchases from seller. 9 Parts / Labor 30 days / NA 89200016 THE AMERICAS Denton, TX USA U.S. Customer Care Ph: 1-800-426-1888 (tollfree) Fax:1-800-535-0557 (tollfree) International Customer Care Ph:1-940-381-1212 Fax:1-940-483-8178 Miami, FL USA Sales Office, Latin America Ph:1-954-727-8371 Fax:1-954-727-8376 Oakville, Ontario, Canada Canada Customer Care Ph:1-905-827-4515 Fax:1-800-588-1714 (tollfree) EUROPE Chorley, United Kingdom Customer Care Ph: +44 1257-261755 Fax:+44 1257-224800 Milan, Italy Customer Care Ph: +39 0236546801 Fax:+39 0236546840 ASIA/PACIFIC Cikarang, Indonesia Customer Care Ph:6221-8990-6095 Fax: 6221-8990-6096 Rawang, Malaysia Customer Care Ph: +603 6092-2988 Fax:+603 6092-1085 Melbourne, Australia Australia Customer Care Ph: 1300-654-674 (tollfree) Ph:61-3-9474-7400 Fax:61-3-9474-7391 International Ph:61-3-9474-7508 Fax:61-3-9474-7488 Shanghai, China Sales Office Ph: +86 21-64072626 Fax: +86 21-64483032 Singapore Sales Office Ph: +65 6832-8066 Fax:+65 6763-5812 INNOVATION TO SHAPE THE WORLD™ U.S. Customer Care: 800-426-1888 / fax 800-535-0557 Canada Customer Care: 905-827-4515 / fax 800-588-1714 International Customer Care: 940-381-1212 / fax 940-483-8178 © 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in Mexico