Air-Cooled Automatic MIG Torches For Models 300A thru 500A Including Barrel/Rack and TAM Mount INSTALLATION, OPERATIONS AND REPLACEMENT PARTS MANUAL 1
TABLE OF CONTENTS INTRODUCTION/WARRANTY....................................................................................................................................... 2 GENERAL SAFETY ...................................................................................................................................................... 3 TORCH SPECIFICATIONS .............................................................................................................................................
LIMITED EXTENDED WARRANTY PROTECTION This limited extended warranty protection expands coverage to loyal customers who use all GENUINE American Weldquip consumables. Customers filing a claim under the extended warranty will need to prove, by providing past invoices, that they have been purchasing and using Genuine American Weldquip consumables.
GENERAL SAFETY PRECAUTIONS Before installing, operating or performing maintenance please read the safety precautions below. Failure to observe safety precautions can result in injury or death. WARNING – A welding arc emits ultraviolet (UV) and other radiation and can cause serious injury to unprotected skin and eyes. WARNING – Hot metal produced by welding can cause severe burns. Heat from arcs and hot weld spatter and sparks can start fires and cause explosions of flammable gases.
NOZZLE/TIP RELATIONSHIPS Shown below are typical relationship between the contact tip and nozzle in GMAW Semi-Automatic applications. Nozzles to tip relationships are usually dictated by the process and application but not necessarily the standard. Keep in mind that decreased tip life, increased spatter cleaning cycles may be required if the tip relationship is changed to achieve other objectives.
Using Feeder Adaptor Kit In some cases it may be desirable to use a feeder adaptor kit such as when using different manufactures wire feed units to commonize on a torch configuration. 1) Thread feeder adaptor plug into the adaptor block and tighten. 2) Insert the adaptor guide tube into the adaptor plug. 3) Fully insert the feeder adaptor assembly into the wire feeder. Tighten screw or other method on wire feeder to secure the adaptor assembly.
10) Trim the liner to ¾” stick out from the end of the gooseneck. 11) Replace the Diffuser, contact tip and nozzle. 12) Feed welding wire into the torch and tighten drive rolls. WARNING: WHEN FEEDING WELD WIRE THROUGH THE TORCH KEEP THE FRONT END OF THE TORCH POINTED AWAY FROM ANY PERSON OR OBJECT. DO NOT POINT AT FACE, HANDS ETC. FAILURE TO DO SO WILL RESULT IN BODILY INJURY AND POSSIBLY DEATH. Gooseneck Replacement 1) 2) 3) 4) 5) 6) 7) Secure Gooseneck in a vice. Remove the liner from the torch.
Inspect the cable for cuts, nicks or tears. If you can see bare copper return for maintenance. Inspect the front end consumables. Clean weld spatter and inspect the nozzle insulator. If nozzle insulation is damaged is should be replaced. Check that the gas diffuser is tight on the gooseneck. Check the gas holes on the diffuser and clean if necessary. Check and tighten the contact tip.
CONTACT TIP SELECTION CHART M6 CONTACT TIPS WIRE SIZE NOMINAL I.D. DESCRIPTION 75023511 .023" (.6mm) .034" CONTACT TIP (STANDARD) 75030511 .030" (.8mm) .038" CONTACT TIP (STANDARD) 75035511 .035" (.9mm) .044" CONTACT TIP (STANDARD) 75035512 .040" (1mm) .048" CONTACT TIP (STANDARD) 75045511 .045" (3/64") (1.2mm) .053" CONTACT TIP (STANDARD) 75045512 .045" (3/64") (1.2mm) .059" CONTACT TIP (STANDARD) WIRE SIZE NOMINAL I.D. DESCRIPTION 75030014 .030" (.8mm) .
PARTS BREAKDOWN – 300A/400A/500A 8a 6 1 2 5 3 7 7 9 4 8 22 10 19 BARREL/RACK MOUNT 20 17 TAM STYLE 18 15 11 12 8a 21 13 16 14 10
PARTS LISTING NO. DESCRIPTION 1 2 3 4 NOZZLE NOZZLE INSULATOR CONTACT TIP GAS DIFFUSER, STANDARD GAS DIFFUSER, SHORT GAS DIFFUSER, LONG GAS DIFFUSER, X-LONG INSULATING WASHER REPLACEABLE NOZZLE SEAT - OPTION GOOSENECK, 180 DEGREE GOOSENECK, 45 DEGREEGOOSENECK, 180 DEGREE –BARREL MNT. GOOSENECK, 45 DEGREE -BARREL MNT. GOOSENECK, 180 DEGREE –RACK MNT. GOOSENECK, 45 DEGREE -RACK MNT.
1375 Wolf Creek Trail – P.O.