Tweco Spray Master Series Safety And Operating Instructions Manual
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Tweco Spray Master Series Safety And Operating Instructions Manual

Air-cooled 250 amp, 350 amp, 450 amp mig gun
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SPRAY MASTER
SAFETY AND
OPERATING
INSTRUCTIONS
English
Français
Español
Revision: AC
MIG GUN
Issue Date: 9-2016
AIR-COOLED
250 AMP
350 AMP
450 AMP
Manual No.: 89200009
®

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  • Page 1 AIR-COOLED 250 AMP 350 AMP 450 AMP SPRAY MASTER ® MIG GUN SAFETY AND OPERATING INSTRUCTIONS English Français Español Revision: AC Issue Date: 9-2016 Manual No.: 89200009...
  • Page 2 YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. TWECO, an ESAB Brand, is a global manufacture of welding products. We manufacture and supply to major welding industry sectors worldwide, including: Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
  • Page 3 ESAB Group 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 Copyright © 2009 ESAB. All rights reserved. Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
  • Page 4 DECLARATION OF CONFORMITY TWECO , an ESAB Brand, declares under our sole responsibility that the product ® Hand Held Air/Gas and Water Cooled MIG Welding Torches To which this declaration relate(s) are in conformance with the following standards: IEC 60974-7:2005...

  • Page 5: Table Of Contents

    Duty Cycles ..................9 SECTION 4: MIG GUN INSTALLATION ..............11 4.01 Direct Plug MIG Gun Installation ............ 11 ® 4.02 TWECO MIG-Kwik Connection and Adapter Kit Installation ..12 SECTION 5: OPTIONAL FEATURES................13 5.01 Dual Schedule ................13 5.02 Locking Trigger ................13 SECTION 6: REPLACE CONDUCTOR TUBE ...............14...
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  • Page 7: Section 1: Introduction

    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 or ESAB.

  • Page 8: Section 2: Safety Precautions

    SAFETY AND OPERATING INSTRUCTIONS SECTION 2: SAFETY PRECAUTIONS 2.01 SECURITY MEASURES 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 equip- ment, and be aware of the dangers of the welding or cutting process.
  • Page 9 SAFETY AND OPERATING INSTRUCTIONS 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.

  • Page 10: Mesures De Sécurité

    SAFETY AND OPERATING INSTRUCTIONS 2.02 MESURES DE SÉCURITÉ AVERTISSEMENT DES BLESSURES GRAVES OU MORTELLES peuvent résulter d’une installation, d’un usage ou d’un entretien inadéquat de l’ é quipement de soudage et de découpage. Une mauvaise utilisation de cet équipement et d’autres pratiques risquées peuvent être dangereuses. L’...
  • Page 11 SAFETY AND OPERATING INSTRUCTIONS 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’ e ssayez jamais de souder ou de couper sans casque soudage conforme aux normes du gouvernement fédéral et muni d’une lentille appropriée.

  • Page 12: Precauciones De Seguridad

    SAFETY AND OPERATING INSTRUCTIONS 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.
  • Page 13 SAFETY AND OPERATING INSTRUCTIONS emplazando un aislamiento u otros medios adecuados. Cuando se tenga que interrumpir la soldadura durante un importante período de tiempo, como durante el almuerzo o la noche, todos los electrodos deben ser retirados del portaelectrodos y se debe apagar la alimentación eléctrica de manera que no puedan producirse contactos accidentales. Evite que las pistolas MIG, los portaelectrodos, los sopletes Tig, los sopletes de Plasma y los electrodos se vean afectados por la humedad y el agua.
  • Page 14 SAFETY AND OPERATING INSTRUCTIONS EL RUIDO PUEDE DAÑAR LA AUDICIÓN El ruido del proceso con arco de aire/carbón puede dañar su audición. Use dispositivos de protección auditiva para contar con protección cuando los niveles superen las normas de la OSHA. Los operadores y personal próximo deben usar protectores auriculares para asegurar la protección contra el ruido.

  • Page 15: Section 3: Mig Gun Specifications

    SAFETY AND OPERATING INSTRUCTIONS SECTION 3: MIG GUN SPECIFICATIONS 3.01 MIG GUN CLASSIFICATION Process MIG/MAG welding Method of Guidance Manually guided Voltage Class for Welding and Control Circuits L (up to 113 V peak) Type of Cooling Air or cooling gas Type of Shielding Gas All types 3.02...
  • Page 16 3.03 MIG GUN PART NUMBER IDENTIFICATION NOTE! TWECO 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...

  • Page 17: Section 4: Mig Gun Installation

    SAFETY AND OPERATING INSTRUCTIONS 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. WIRE FEEDER POWER SOURCE...

  • Page 18: Tweco Mig-Kwik Connection And Adapter Kit Installation

    MIG-KWIK CONNECTION AND ADAPTER KIT INSTALLATION ® Installation of a TWECO MIG gun with a TWECO connector plug, may require an adapter kit. Choose the correct adapter kit for your wire feeder from the Adapter Kit Listing. To install, follow the instructions furnished with the adapter kit.

  • Page 19: Section 5: Optional Features

    SAFETY AND OPERATING INSTRUCTIONS SECTION 5: OPTIONAL FEATURES In addition to the standard Spray Master MIG gun, TWECO also makes a dual schedule gun and one with a locking trigger, only offered in 350 and 450 AMP guns. 5.01 DUAL SCHEDULE A rocker-style switch, located at the top of the handle, allows the user dual schedule functionality.

  • Page 20: Section 6: Replace Conductor Tube

    SAFETY AND OPERATING INSTRUCTIONS SECTION 6: REPLACE CONDUCTOR TUBE The conductor tube is attached to the Spray Master handle by two set screws on the side of the handle. To remove: 1. Loosen the conduit liner set screw with a 5/64" Allen wrench supplied and then loosen the socket head cap screw securing the conductor tube in place inside the handle with a 5/32"...

  • Page 21: Section 7: Wire Conduit Replacement

    7.01 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: 1/16"...

  • Page 22: Repair Of Cablehoz

    SAFETY AND OPERATING INSTRUCTIONS 7.04 REPAIR OF CABLEHOZ® Back-End Repair 1. Disassemble the rear case to expose the rear connector assembly and pull the assembly away from the rear case. 2. Cut the Cablehoz to remove the damaged area. 3. Use replacement connector assembly, Part No. MS172-RK (Stock No.
  • Page 23 SAFETY AND OPERATING INSTRUCTIONS 8. Insert the replacement connector into the inner core tube of the Cablehoz. It’ s recommended to use a small amount of lubricant to help the connector to slide into the tube. The core tube should bottom out against the shoulder, approximately 15/16”...
  • Page 24 SAFETY AND OPERATING INSTRUCTIONS B. Front-End Repair 1. Disassemble the rear case to expose the rear connector assembly and pull the assembly away from the rear case. 2. Cut the Cablehoz to remove the damaged area. 3. Use replacement connector assembly, Part No. MS102-RK (Stock No.
  • Page 25 SAFETY AND OPERATING INSTRUCTIONS 8. Insert the replacement connector into the inner core tube of the Cablehoz. It’s recommended to use a small amount of lubricant to help the connector to slide into the tube. The core tube should bottom out against the shoulder, approximately 15/16”...

  • Page 26: Section 8: Maintenance And Troubleshooting

    SAFETY AND OPERATING INSTRUCTIONS SECTION 8: MAINTENANCE AND 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.

  • Page 27: Section 9: Consumables

    Heavy Duty Furnished standard with 5/8" (15.9 mm) bore nozzle, HD24L-62. Fits diffuser HD54-16 (1540-1136). Interchangeable front end by changing diffusers or conductor tubes. May use consumables from TWECO standard #4 gun or TWECO Eliminator (by changing MS64-60 conductor tube).

  • Page 28: Contact Tips

    SAFETY AND OPERATING INSTRUCTIONS 9.02 CONTACT TIPS 250 AMP 350 AMP / 450 AMP Wire Size Tip I.D. in (mm) in (mm) Part No. Stock No. Part No. Stock No. .023" (0.6mm) .031" (0.79mm) 11-23 1110-1100 .030" (0.8mm) .038" (0.97mm) 11H-30 1110-1201 .035"...
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  • Page 30: Section 10: Replacement Parts

    SAFETY AND OPERATING INSTRUCTIONS SECTION 10: REPLACEMENT PARTS 89200009...
  • Page 31 TWECO Rear Connector 2035-2110 2035-2110 2035-2110 MS354-TAJ MS354-TAJ MS354-TAJ TWECO Control Wire 2060-2139 2060-2139 2060-2139 MS-354DS-TJ MS-354DS-TJ MS-354DS-TJ TWECO Dual Schedule Control Wire & Plug 2060-2138 2060-2138 2060-2138 350-174LH 350-174LH 350-174LH Lincoln® Rear Connector 2035-2112 2035-2112 2035-2112 MS-354DS-LJ MS-354DS-LJ MS-354DS-LJ Lincoln Control Wire &...

  • Page 32: Section 11: Statement Of Warranty

    SAFETY AND OPERATING INSTRUCTIONS SECTION 11: STATEMENT OF WARRANTY 11.01 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. ESAB reserves the right to request documented evidence of date of purchase.
  • Page 33 SAFETY AND OPERATING INSTRUCTIONS General Arc Equipment Parts / Labor Water Recirculators 1 year / 1 year Plasma Welding Torches 180 days / 180 days Gas Regulators (Supplied with Power Sources) 180 days / NA MIG and TIG Torches (Supplied with Power Sources) 90 days / NA Replacement Repair Parts 90 days / NA...
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  • Page 36 ESAB subsidiaries and representative offices North and South America Europe NORWAY ESAB SeAH Corporation Kyungnam AS ESAB AUSTRIA ARGENTINA Tel: +82 55 269 8170 Larvik ESAB Ges.m.b.H Fax: +82 55 289 8864 Tel: +47 33 12 10 00 CONARCO Vienna-Liesing Fax: +47 33 11 52 03 Buenos Aires UNITED ARAB EMIRATES...

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