T-Gun Series Water-Cooled 450, 600 amp

TECHNICAL GUIDE
T-Gun™ Semi-Automatic
Water-Cooled MIG Guns –
450 amp and 600 amp
 SAFETY & WARRANTY
INFORMATION
 INSTALLATION
 MAINTENANCE GUIDE
 TECHNICAL DATA
 OPTIONS
 EXPLODED VIEW &
PARTS LIST
 TROUBLESHOOTING
 ORDERING INFORMATION
Please read instructions prior to use.
Save this manual for future reference.
TABLE OF CONTENTS
WARRANTY ................................................................................................................................................. 2
THANK YOU… .............................................................................................................................................. 3
GENERAL SAFETY ......................................................................................................................................... 3
1.0 – INSTALLATION ..................................................................................................................................... 4
1.1 INSTALLING QUICK CONNECT BLOCK TO FEEDER ............................................................................................... 4
1.2 INSTALLING GUN TO QUICK CONNECT BLOCK ................................................................................................... 4
1.3 INSTALLING T-GUN MIG GUNS EQUIPPED WITH “DIRECT PLUG-INS" .................................................................. 5
2.0 – MAINTENANCE .................................................................................................................................... 6
2.1 TREGASKISS™ NOZZLE AND TOUGH LOCK™ CONSUMABLES .............................................................................. 6
2.2 SWITCH REPLACEMENT – 450/600 AMP ............................................................................................................ 6
2.3 NECK REPLACEMENT ........................................................................................................................................ 7
2.4 LINER REPLACEMENT ....................................................................................................................................... 8
2.5 CABLE ASSEMBLY REPLACEMENT ...................................................................................................................... 8
3.0 – TECHNICAL DATA ...............................................................................................................................11
3.1 NECK DIMENSIONS......................................................................................................................................... 11
3.2 GUN AMPERAGE RATINGS .............................................................................................................................. 11
4.0 – OPTIONS ............................................................................................................................................11
4.1 DIRECT PLUG-INS ........................................................................................................................................... 11
4.2 FEEDER ADAPTORS......................................................................................................................................... 12
4.3 CONTROL PLUGS ............................................................................................................................................ 12
4.4 CONNECTOR OPTIONS.................................................................................................................................... 12
4.5 DUAL SCHEDULE GUN..................................................................................................................................... 12
5.0 – ACCESSORIES......................................................................................................................................13
6.0 – TROUBLESHOOTING ...........................................................................................................................13
7.0 – EXPLODED VIEW AND PARTS LIST .......................................................................................................14
8.0 – T-GUN MIG GUN ORDERING INFORMATION .......................................................................................16
8.1 GUN STANDARDS CHART................................................................................................................................ 16
WARRANTY
Product is warranted to be free from defects in material and workmanship for the period specified below after the sale by
an authorized Buyer. Should there be a defect please refer to our Return Merchandise Policy.
PRODUCT
T-GUN™ MIG Guns and Components
TGX™ Chassis and TGX Ready To Weld MIG Guns
WARRANTY PERIOD
180 days
90 days
Bernard reserves the right to repair, replace or refund the purchase price of non-conforming product. Product found not
defective will be returned to the Buyer after notification by Customer Service.
Bernard makes no other warranty of any kind, expressed or implied, including, but not limited to the warranties of
merchantability or fitness for any purpose. Bernard shall not be liable under any circumstances to Buyer, or to any person
who shall purchase from Buyer, for damages of any kind. Including, but not limited to any, direct, indirect incidental or
consequential damages or loss of production or loss of profits resulting from any cause whatsoever, including, but not
limited to, any delay, act, error or omission of Bernard.
2
Genuine Bernard and Tregaskiss parts must be used for safety and performance reasons or the warranty becomes
invalid. Warranty shall not apply if accident, abuse, or misuse damages a product, or if a product is modified in any way
except by authorized Bernard personnel.
THANK YOU…
…for selecting a Bernard T-Gun Water-Cooled MIG Gun. Manufacturing operations demand extremely dependable semiautomatic equipment. With this in mind, the T-Gun MIG Gun was designed and engineered to be a reliable tool to support
high production within a robotic cell. The T-Gun MIG Gun is made from durable materials and components engineered to
perform in a rugged, welding environment.
The instructions and illustrations in this technical guide make it easy for you to maintain your T-Gun MIG Gun. Please
read, understand, and follow all safety procedures. Keep this Technical Guide booklet as a handy reference when
ordering complete guns, parts and special options.
For technical support and special applications, please call the Customer Service Department toll free (in North
America) at 1-800-946-2281 or fax 1-888-946-6726. Our trained Customer Support Team is available between 8:00 a.m.
and 4:30 p.m. CST, and will answer your application or repair questions.
Bernard employees are always striving to improve our products and services, and would appreciate receiving your
suggestions or comments. Please contact us immediately if you experience any safety or operating problems.
GENERAL SAFETY
Before installation or operation of T-Gun MIG Guns, please read the safety precautions listed below.
1. Always wear a properly fitted welding helmet with the proper grade of filter plate and suitable welding gloves.
2. All exposed skin should be covered with flame resistant, protective clothing. DO NOT WEAR CLOTHING
MADE FROM FLAMMABLE SYNTHETIC FIBERS.
3. Protective screens or barriers should be used to protect others from spatter, flash and glare while welding.
4. Prevent fires by ensuring that hot slag or sparks do not contact combustible solids, liquids or gases.
5. Ensure that operator’s head is not too close to the arc and that adequate ventilation is available.
6. Constant repetitive motion may lead to cumulative trauma disorders.
7. Do not touch live electrical parts. The following should be checked to prevent electrical shock:

Equipment is adequate for the job, properly grounded and installed according to code.

Faulty or damaged equipment is repaired or replaced.

Proper operator maintenance is performed to prevent excess spatter accumulation in the nozzle, on the contact tip or
other areas of the gun.

Electrical insulating components are in place and not damaged. Repair or replace if necessary.

Operator and his surroundings are not wet.

Cables are not wrapped around operator’s body.

Equipment is off when not in use.
8. CSA Standard W117.2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
9. ANSI Standard Z49.1 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018.
CALIFORNIA PROPOSITION 65 WARNING
This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer.
This product contains chemicals, including lead, known to the State of California to cause cancer, and birth defects or other
reproductive harm. Wash hands after use.
(California Health & Safety Code Section 25249.5 at seq.)
3
1.0 – INSTALLATION
1.1 INSTALLING QUICK CONNECT BLOCK TO FEEDER
SET SCREW
STEP #1
FEEDER ADAPTOR



Insert the correct feeder adaptor liner for desired
wire diameter (2 provided) flush with the threaded
end of the feeder adaptor.
Tighten set screw.
Thread feeder adaptor into Quick Connect Block
and tighten.
FEEDER ADAPTOR LINER
QUICK CONNECT
BLOCK
STEP #2






DRIVE ROLLS
Position assembly into feeder adaptor and trim liner within 1/16” (1.6
mm) of the drive rolls and remove burrs if necessary.
Secure assembly into feeder.
Thread gas hose nipple into feeder gas fitting.
Connect power cable to 1/2” (13 mm) power bolt with appropriate
lug.
Tighten all connections.
Feed welding wire through assembly by hand and tighten drive rolls.
1.2 INSTALLING GUN TO QUICK CONNECT BLOCK
Ensure correct liner and contact tip are utilized. Examine and replace power pin o-rings if necessary.
STEP #1
POWER PIN





Guide welding wire into power pin.
Insert power pin to shoulder.
Tighten thumb screw securely.
Connect control plug lead to control housing on
gun.
Insert control plug into feeder.
WELDING
WIRE
THUMB
SCREW
STEP #2
CONTROL PLUG
WATER LINES

Securely clamp blue hose on rear housing to water-out on water cooler and red hose on rear housing to water-in on
water cooler.
4
STEP #3
WARNING: Ensure water supply is on before operation.


Recheck proper gas flow, drive roll pressure, voltage and wire feed speed.
Water flow (minimum 0.5 gallon per minute).
1.3 INSTALLING T-GUN MIG GUNS EQUIPPED WITH “DIRECT PLUG-INS"
IMPORTANT: The thread-in two-piece power pin incorporates a taper to seat and lock the pin to the rear handle block. Make sure
power pin is tightened in the block with a wrench to insure pin is secure and will not come loose.
NOTE: The rear handle and screws do not have to be removed when installing the two-piece power pins.

Thread power pin into the rear handle block.

Tighten the power pin into the rear block using a 1 1/4” (32 mm) wrench on the rear block and a 5/8” (16 mm) or 3/4” (19 mm)
wrench on the power pin.

Install liner. See Section 2.4 LINER REPLACEMENT.
 Install gun to feeder. See Below.
 Most Power Pins
- Feed welding wire into power pin by hand and tighten drive rolls.
- Insert power pin to shoulder and secure.
- Insert control plug to control housing of gun.
-On Lincoln it is necessary to connect gas hose to barbed fitting on
- Insert control plug into feeder.
power pin.
5
2.0 – MAINTENANCE
2.1 TREGASKISS™ NOZZLE AND TOUGH LOCK™ CONSUMABLES
HEAVY DUTY NOZZLE
VARIOUS SIZES AVAILABLE.
HEAVY DUTY
TREGASKISS
TOUGH LOCK™
CONTACT TIP
HEAVY DUTY
CONVENTIONAL
CONTACT TIP
HEAVY DUTY
TREGASKISS
TOUGH LOCK
RETAINING HEAD
NECK INSULATOR
HEAVY DUTY
CONVENTIONAL
RETAINING HEAD
450 AMP
NECK INSULATOR
600 AMP
NOZZLE
NOZZLE
INSULATOR
THREAD ON
HEAVY DUTY
TREGASKISS
TOUGH LOCK
CONTACT TIP
HEAVY DUTY
TREGASKISS
TOUGH LOCK
DIFFUSER
IMPORTANT:




Neck insulator must be in place before welding to maintain insulation of neck armor.
Be sure all parts are tightened well before welding.
When using the heavy duty retaining head make sure it is tightened with a 7/16” wrench to prevent overheating of contact tip.
To prevent scoring on heavy duty retaining head DO NOT use pliers.
Removal and Replacement




Pull slip-on nozzles off with a clockwise twisting motion.
When installing nozzle, exposed insulator should nest inside neck insulator to assure concentricity.
Neck insulators are positioned on the end of the neck with the large insulated counter bore facing the nozzle.
Replace nozzle retainer with deep counter bore toward the neck. Tighten until retainer and neck insulator is secure.
2.2 SWITCH REPLACEMENT – 450/600 AMP
STEP #1
LEADS
SWITCH
SWITCH LEAD CONNECTORS
MOUNTING SCREWS



SWITCH HOUSING
Remove both mounting screws with a 5/16” (8 mm) nut driver.
Ease switch out of switch housing by gently pulling up on leads.
Remove switch from switch lead connectors with needle nose pliers.
6
STEP #2
SWITCH
Push switch lead connectors firmly onto switch terminals with needle
nose pliers.
 Depress switch plunger and nest back into housing.
 Fit switch housing into nest on handle (switch leads must lie
parallel).
 Align housing holes with threaded holes in body and insert
mounting screws.
 Start both screws first before tightening with 8 mm nut driver to
even alignment.
IMPORTANT: Use manufacturer’s screws (part # 411-3 or 411-3M) to
ensure proper length, hardness and tolerance.
LEADS (2)
SWITCH HOUSING
2.3 NECK REPLACEMENT
STEP #1
450/600 AMP



Remove liner from gun. See Section 2.4 LINER
REPLACEMENT.
Remove two switch housing screws with a 5/16”
(8 mm) nut driver.
Slide handle back.
STEP #2


NECK
WHITE CONDUIT LINE
Unthread power cable.
Cut off water line and conduit, cut off
clamps and pull hoses off barbed
fittings.
FRONT HANDLE
WATER LINE (BLUE)
& POWER CABLE (RED)
STEP #3
FRONT HANDLE
NECK
450/600 AMP
MOUNTING SCREWS




SWITCH HOUSING
Slide clamps on water line and conduit.
Thread power cable on and tighten.
Push water line and conduit on all the way to base of fittings and crimp.
Reposition the handle and place switch in housing, nest housing in handle and tighten screws.
7
2.4 LINER REPLACEMENT
NOTE: For guns equipped with “Direct Plug-Ins”, Bernard or Euro-connector, the procedure is the same.
On Miller® style guns, liner is held captive by a guide cap which must be removed and replaced when changing liner.
STEP #1
450/600 AMP
NOTE: Ensure power supply is off and gun is removed from feeder before proceeding.



Remove nozzle, tip and gas diffuser.
Using a 10 mm wrench, turn thread-in liner retainer counter-clockwise until liner is free from the power pin.
With gun straightened, grip conduit liner with pliers and remove.
STEP #2


Feed replacement liner through gun using short strokes to avoid kinking. Twist liner clockwise if necessary.
Using a 10 mm wrench, turn thread-in liner retainer in a clockwise direction and tighten in power pin.
STEP #3




NECK
Push liner back into gun and hold in place.
Trim conduit liner with a 3/4” (19 mm) stick-out.
Remove any burr that may obstruct wire feed,
especially on flat wire type conduit liner.
Replace nozzle, tip and gas diffuser onto neck.
CONDUIT LINER
3/4" (19 mm) Tregaskiss TOUGH LOCK
1/2” (13 mm) Conventional
2.5 CABLE ASSEMBLY REPLACEMENT
MOUNTING SCREWS
STEP #1
450/600 AMP


Remove nozzle, tip and retainer.
Take out rear housing screws and pull out liner.
8
STEP #2
REAR HOUSING
POWER CABLE (RED)
450/600 AMP
WHITE CONDUIT LINE






WATER LINE
(BLUE)
2-PIECE
POWER PIN
Pull the rear handle up the gun approximately 1 ft.
Unscrew power cable from rear power block.
Cut clamps off the water in (blue) line and gas line (white).
Pull gas and water line off of power block.
At this point, rear power block will be removed from gun.
Slide rear handle off gun.
STEP #3
450/600 AMP
NECK
WHITE CONDUIT LINE
WATER LINE (BLUE)
& POWER CABLE (RED)


FRONT HANDLE
OUTER JACKET
On front of gun, release front handle from neck.
Remove outer jacket by pulling outer jacket only from rear of gun; all that remains are the inner hoses attached to
the neck and switch lead wires.
STEP #4
NECK
WHITE CONDUIT LINE
USED POWER CABLE
(RED)
450/600 AMP
BLUE WATER LINE

Unthread power cable from front of gun and replace with new one.
9
REPLACEMENT POWER
CABLE (RED)
STEP #5
NECK
FRONT HANDLE
OUTER JACKET



From rear of gun, slide front handle over hoses.
Tape hoses together at rear of gun.
Slide outer jacket over hoses from rear of gun.
STEP #6
NECK
FRONT HANDLE
OUTER JACKET
450/600 AMP
MOUNTING SCREWS

SWITCH HOUSING
Slide outer jacket under front handle and bring front handle up to neck, replace switch and switch housing and
secure. See Section 2.2 SWITCH REPLACEMENT.
STEP #7
450/600 AMP
REAR HOUSING
POWER CABLE
(RED)
WATER LINE
(BLUE)
WHITE CONDUIT LINE



POWER PIN
At rear of gun, slide rear handle up over outer jacket.
Attach rear power block to power cable.
Attach the gas line and water line with new clamps and crimp to power block.
STEP #8
REAR HOUSING
450/600 AMP



Slide rear handle to rear power block and secure with mounting screws.
Put liner through gun and tighten.
Install liner. See Section 2.4 LINER REPLACEMENT.
10
POWER PIN
3.0 – TECHNICAL DATA
3.1 NECK DIMENSIONS
NECK
A
455-45
455-60
455-180
595-45
595-60
595-180
45°
60°
180°
45°
60°
180°
B
INCHES
6.00
5.73
7.45
7.05
5.916
8.94
mm
152
145
189
179
150
227
C
INCHES
3.81
5.27
0
4.856
5.602
0
mm
D
INCHES
mm
E
INCHES
mm
97
134
0
123
142
0
3.00
3.00
3.00
3.00
3.00
3.00
76
76
76
76
76
76
1.48
1.48
1.48
1.8
1.8
1.8
38
38
38
46
46
46
3.2 GUN AMPERAGE RATINGS
NOTE:
MODEL
60% DUTY CYCLE – MIXED GASES
OR 100% DUTY CYCLE – CO2
450
600
450 amp
600 amp
Ratings are based on tests that comply with IEC 60974-7 standards.
4.0 – OPTIONS
4.1 DIRECT PLUG-INS
PART #
214
DESCRIPTION
USE ON FEEDERS
TREGASKISS QUICK CONNECT BLOCK, HOBART® 2000 SERIES
FEEDERS, TWECO #4 RECEPTACLE BODY PART #TAK-1,
LINCOLN POWER MIG 300.
MILLERMATIC 200 & 250, S21E & S22 SERIES, 52 & 54 SERIES, 60
SERIES
MILLERMATIC 200 & 250, S21E & S22 SERIES, 52 & 54 SERIES, 60
SERIES
TREGASKISS™ POWER PIN
414-11-2
O-RING - FOR MILLER® POWER PINS
214-6-116
MILLER POWER PIN
214-116
214-332
214-9
414-116
414-332
414-9
214-12
414-12-2
214-2
414-21
214-13
GUIDE CAP ONLY - FOR 214-6-116 (NEW STYLE)
GUIDE CAP ONLY - FOR 214-6-332 (NEW STYLE)
GUIDE CAP ONLY –FOR 214-6 ALUMINUM (NEW STYLE)
GUIDE CAP ONLY - FOR 214-6-116 (OLD STYLE)
GUIDE CAP ONLY - FOR 214-6-332 (OLD STYLE)
GUIDE CAP ONLY - FOR 214-6 ALUMINUM (OLD STYLE)
TWECO® #5 STYLE POWER PIN
O-RING - FOR TWECO #5 STYLE POWER PIN
LINCOLN® POWER PIN
ESAB® (NON EURO)
PANASONIC®
11
ALL FEEDERS SET UP WITH TWECO #5
RECEPTACLE BODY PART #6TAK-1
LINCOLN LN7, 8 & 9, LN25 SUITCASE, LN22,NA2
A-10
4.2 FEEDER ADAPTORS
To be used with 417 Quick Connect Block
PART #
418-1
418-3
418-4
418-5
418-6
418-7
418-8
418-9
418-10
418-14
418-21
418-27
418-29
418-35
USE ON FEEDERS
AIRCO®
ESAB (NON EURO STYLE) AND HOBART BETA MIG
HOBART 27
LINCOLN LN4, LN5, LINDE SWM 31, 3A & 32A
LINCOLN LN7, 8 & 9, LN 25 SUITCASE, LN22
LINDE SWM-14
LINDE 35 SWM-23
MILLER 10A, 30A (MILLERMATIC 35S FEEDER)
MILLER 52E, 54E, S21, S22 SERIES AND MILLERMATIC 200 & 250, 60 SERIES
OTC DAIHEN®
GILLILAND®
PANASONIC
TWECO #5 PIN
KOBELCO®
4.3 CONTROL PLUGS
PART #
419-1
419-2
419-4
419-5
419-6
419-7
419-8
419-10
419-11
419-12
4.4 CONNECTOR OPTIONS
DESCRIPTION
AIRCO
HOBART
MILLER (52E, 54E)
WESTINGHOUSE
LINCOLN (LN7, 8, 9) NA2
MILLER (10E, 30E) & LINDE (SWM-35)
DIPSTICK 160,200, HOBART
HANDLER, LINCOLN SP-100
DUAL SCHEDULE MILLER
LINCOLN DUAL SCHEDULE
OXOMATIC
Euro Connector option - for European style feeders and
feeder adaptors for 450 & 600 amp.
PART #
DESCRIPTION
675
EURO CONNECTOR ASSEMBLY
675-2
EURO HOUSING
675-10
EURO CONNECTOR BODY
675-10-4
RETAINING RING
4.5 DUAL SCHEDULE GUN
416-13 D.S. CONTROL
HOUSING WITH PLUG
LEAD
NOTE: Dual schedule T-Gun MIG Guns are offered in two styles.
 D – TOGGLE STYLE A separate thumb switch is mounted on the housing to change schedules (lock-on
optional).


2D – TWO POSITION STYLE
Depress lever halfway for first schedule and fully for second schedule.
Both require special Dual Schedule unicable with 4 switch leads and special rear housing.
TWO POSITION SWITCH STYLE
PART #
411-11
DESCRIPTION
D.S. TWO-POSITION
SWITCH HOUSING ONLY
TOGGLE SWITCH STYLE
PART #
411-12
411-13
12
DESCRIPTION
D.S. SWITCH HOUSING - COMPLETE W/TOGGLE
SWITCH
D.S. LOCK-ON TRIGGER HOUSING
5.0 – ACCESSORIES
411-23 SWITCH HOUSING WITH
EXTENDED LEVER
420 GUN HANGER
421 HEAT SHIELD (450 & 600 AMP)
421-1 SHIELD MOUNTING SCREW (NOT SHOWN)
411-4 LOCK-ON TRIGGER HOUSING
6.0 – TROUBLESHOOTING
PROBLEM
Poor Wire Feed
Short Tip Life
Gun Overheating
Switch Malfunctioning
Weld Porosity
POSSIBLE CAUSE































conduit liner clogged or kinked
incorrect liner size or contact tip
liner cut too short and not seating properly in gas diffuser
drive rolls too tight resulting in scoring of welding wire
welding wire dirty, rusty or too much cast
drive rolls too tight resulting in scoring of welding wire
welding wire dirty, rusty or too much cast
uncoated wire being used, increasing usage
wrong tip size
loose consumables
over torch rated duty cycle
loose retaining screw on quick connect block
insufficient gauge power cable and/or ground cable
loose connector cones and/or cone nuts
gun being run beyond its amperage range
loose consumables
electrical malfunction in power source
bad connection of leads to switch terminals
spatter built up between lever and switch housing
contacts dirty in switch
switch housing screws loose
broken or worn switch lead
spatter built up in nozzle blocking gas
leaks in gas hose or improper connection
o-rings on power pin are cut or damaged
inner tube loose from connector cone
poor wire feed (see above)
improper shielding gas or welding wire
rusty or poor quality welding wire
parent metal rusty or contaminated or high in sulphur content
flow improperly set
13
7.0 – EXPLODED VIEW AND PARTS LIST
Numbers in this
column correspond to
the exploded view
images above.
450 AMP
PART #
600 AMP
1
401-5-62
401-5-75
401-6-62
401-6-75
401-8-62
601-5-62
601-5-75
601-6-62
601-6-75
601-5-75-3
401-1-62
401-1-75
2
403-20-30
403-20-35
403-20-1.0
403-20-45
403-20-364
403-20-1.4
403-20-52
403-20-116
403-20-1.8
403-20-564
403-20-332
403-20-30
403-20-35
403-20-1.0
403-20-45
403-20-364
403-20-1.4
403-20-52
403-20-116
403-20.18
403-20-564
403-20-332
403-1-35
403-1-1.0
403-1-45
403-1-52
403-1-116
403-1-564
403-1-332
403-1-364
403-1-1.8
3
454-1
404-20
404-3
454-1-2
404-38
402-6
N/A
DESCRIPTION
STANDARD NOZZLES
3/8" (10 mm) BORE - FLUSH TIP
1/2" (16 mm) BORE - 1/8" (3 mm) TIP RECESS
5/8” (16 mm) BORE - 1/4” (6 mm) TIP RECESS
3/4” (19 mm) BORE - 1/4” (6 mm) TIP RECESS
5/8” (16 mm) BORE - 1/8” (3 mm) TIP RECESS (STD)
3/4” (19 mm) BORE - 1/8” (3 mm) TIP RECESS
5/8” (16 mm) BORE - 1/8” (3 mm) TIP STICK-OUT
NOZZLE INSULATOR (CERAMIC) ALL 601 NOZZLES
ABOVE
HEAVY DUTY NOZZLES
5/8” (16 mm) BORE - 1/4” (6 mm) TIP RECESS
3/4” (19 mm) BORE - 1/4” (6 mm) TIP RECESS
4
PART #
450 AMP 600 AMP
452-1
452-3
5
455-45
455-60
455-180
595-45
595-60
595-180
652-8
O-RING (LARGE, quantity 4)
652-5
O-RINGS (3)
656-15
656-15
INTERNAL WATER LINE (C/W (2) 656-1 CLAMPS)
15’ SERVICE (CUT TO SIZE FOR OTHER LENGTHS)
657-15
657-15
CONDUIT (C/W (2) 657-1 CLAMPS)
15’ SERVICE (CUT TO SIZE FOR OTHER LENGTHS)
658
658-1
658
658-1
659-10
659-12
659-15
659-10
659-12
659-15
POWER CABLE ASSEMBLY
10’ SERVICE (ACTUAL LENGTH - 9.5’)
12’ SERVICE (ACTUAL LENGTH - 11.5’)
15’ SERVICE (ACTUAL LENGTH - 14.5’)
10
610
610
610
610
HANDLE - FRONT (c/w mounting screws)
HANDLE - REAR
11
411-1
411-2
411-3M
411-4
411-12
411-13
411-23
411-1
411-2
411-3M
411-4
411-12
411-13
411-23
SWITCH ONLY
SWITCH HOUSING (c/w mounting screws)
MOUNTING SCREW
LOCK-ON TRIGGER HOUSING
DUAL SCHEDULE SWITCH HOUSING
LOCK-ON TRIGGER HOUSING
EXTENDED LEVER
411-11
411-11
TWO POSITION SWITCH - HOUSING ONLY
7
8
9
CONVENTIONAL RETAINING HEAD - FOR HD TIPS
(STD)
TREGASKISS TOUGH LOCK RETAINING HEAD - FOR HD
TIPS
HEAVY DUTY CONVENTIONAL RETAINING HEAD
RETAINING RING
DIFFUSER - FOR HD TREGASKISS TOUGH LOCK (STD)
O-RING FOR TREGASKISS TOUGH LOCK RETAINING
HEAD
14
NECKS (C/W (1) 656-1 AND (1) 657-1 CLAMP
NECK - 45°
NECK - 60°
NECK - STRAIGHT
O-RING (SMALL, quantity 2)
495-7
6
HEAVY DUTY TREGASKISS™ TOUGH LOCK™
CONTACT TIPS - 5/16” (7.9 mm) O.D.
FOR .030" (0.8 mm) WIRE
FOR .035" (0.9 mm) WIRE
FOR 1.0 mm WIRE
FOR .045" (1.2 mm) WIRE
FOR 3/64 " (1.2 mm) WIRE
FOR 1.4 mm WIRE
FOR.052" (1.3 mm) WIRE
FOR 1/16" (1.6 mm) WIRE
FOR 1.8” (1.8 mm) WIRE
FOR 5/64" (2.0 mm) WIRE
FOR 3/32" (2.4 mm) WIRE
HEAVY DUTY CONVENTIONAL CONTACT TIPS - 5/16”
O.D.
FOR .035” (0.8 mm) WIRE
FOR 1.0 mm WIRE
FOR .045’ (1.2 mm) WIRE
FOR .O52” (1.3 mm WIRE
FOR 1/16” (1.6 mm) WIRE
FOR 5/64’ (2.0 mm) WIRE
FOR 3/32” (2.4 mm) WIRE
FOR 3/64” (1.2 mm) ALUMINUM WIRE
FOR 1/16” (1.8 mm) ALUMINUM WIRE
DESCRIPTION
NECK INSULATOR (CONVENTIONAL)
NECK INSULATOR (not shown TREGASKISS TOUGH LOCK)
RED WATER LINE - OUT (c/w (1) 656-1 clamp)
BLUE WATER LINE - IN (c/w (1) 656-1 clamp)
(Located at quick connect power block assembly).
PART #
450 AMP
600 AMP
12
662-10
662-15
662-15
662-10
662-15
662-15
662-210
662-212
662-215
662-210
662-212
662-215
13
412-1
412-1
SWITCH LEAD CONNECTOR
14
412-4
412-4
CONTROL PLUG LEAD
663-1-15
663-1-15
OUTER JACKET
15’ SERVICE
664-400
664-400
POWER PIN BLOCK
15
16
17
214
214-2
214-4
214-6-116
214-7
214-12
214-13
414-1
414-2
414-11-2
214
214-2
214-4
214-6-116
214-7
214-12
214-13
414-1
414-2
414-11-2
18
PART #
450 AMP
600 AMP
DESCRIPTION
CONTROL WIRE
10’ SERVICE
12’ SERVICE
15’ SERVICE
DUAL SCHEDULE CONTROL WIRE
10’ SERVICE
12’ SERVICE
15’ SERVICE
415-23-15
415-30-15
415-35-10
415-35-15
415-35-25
415-35-2
415-116-10
415-116-15
415-116-25
415-116-22
415-23-15
415-30-15
415-35-10
415-35-15
415-35-25
415-35-2
415-116-10
415-116-15
415-116-25
415-116-22
*415-25
*415-25
415-332-15
415-332-153
415-332-251
415-332-15
415-332-153
415-332-251
415-564-15
415-564-15
415-332-15
415-332-15
416-5
411-3M
416-5
411-3M
417
417
DESCRIPTION
CONDUIT LINERS
FOR .023" (0.6 mm) WIRE-15' (5 m)
FOR .030" (0.8 mm) WIRE-15' (5 m)
FOR .035" - .045" (0.9 mm-1.2 mm) WIRE - 10' (3 m)
FOR .035" - .045" (0.9 mm-1.2 mm) WIRE - 15' (5 m)
FOR .035" - .045" (0.9 mm-1.2 mm) WIRE - 25' (8 m)
FOR .035" (0.9 mm) ALUMINUM WIRE - 15' (5 m)
FOR .045" - 1/16" (1.2 mm-1.6 mm) WIRE - 10' (3 m)
FOR .045" - 1/16" (1.2 mm-1.6 mm) WIRE - 15' (5 m)
FOR .045" - 1/16" (1.2 mm-1.6 mm) WIRE - 25' (8 m)
FOR 3/64" - 1/16" (1.2 mm-1.6 mm) ALUM. WIRE-15' (5 m)
*BRONZE JUMP LINER, MUST USE 414-9 GUIDE CAP ON
MILLER® STYLE POWER PIN
FOR 5/64" - 3/32" (2 mm-2.4 mm) WIRE - 15' (5 m) FLAT WD
FOR 5/64"-3/32" (2 mm-2.4 mm) WIRE-15' (5 m) ROUND WD
FOR 5/64"-3/32" (2 mm-2.4 mm) WIRE-15' (5 m) ROUND WD
FOR all 5/64" (2 mm) WIRE & 1/16" (1.6 mm) FLUX CORE
WIRE
For .078-3/32 (2.24 mm) WIRE - 15’ (5 m) FLAT WD
®
TWECO #4
LINCOLN®
L-TEC MT SERIES®
MILLER®
LINCOLN® SHORT
TWECO® #5
PANASONIC®
O-RING
LINER SET SCREW
O-RING FOR MILLER® POWER PIN
19
20
TREGASKISS™ QUICK LOAD™ LINERS
LINER RETAINER (SOLD SEPARATELY)
415-26
415-26
415-35-10Q
415-35-10Q
FOR .035"-.045" (0.9 mm-1.2 mm) WIRE - 10' (3 m)
415-35-15Q
415-35-15Q
FOR .035"-.045" (0.9 mm-1.2 mm) WIRE - 15' (5 m)
415-35-25Q
415-35-25Q
FOR .035"-.045" (0.9 mm-1.2 mm) WIRE - 25' (8 m)
415-116-10Q
415-116-10Q
FOR .045”-1/16" (1.2 mm-1.6 mm) WIRE - 10' (3 m)
415-116-15Q
415-116-15Q
FOR .045"-1/16" (1.2 mm-1.6 mm) WIRE - 15' (5 m)
415-116-25Q
415-116-25Q
FOR .045"-1/16" (1.2 mm-1.6 mm) WIRE - 25' (8 m)
15
CONTROL HOUSING (C/W SCREWS)
MOUNTING SCREWS (METRIC)
FEEDER ADAPTOR REQUIREMENTS (Sold Separately))
QUICK CONNECT BLOCK ASSEMBLY TWECO #4
21
FEEDER ADAPTORS (To be used with Quick Connect Block)
22
CONTROL PLUGS (c/w Plugs Lead & Female Connectors)
OPTIONAL ACCESSORIES
GUN HANGER
23
422
24
421
421-1
25
657-1
657-1
OETIKER CLAMP – 11.3mm
26
656-1
656-1
OETIKER CLAMP – 9.5mm
27
661-XX
661-XX
HEAT SHIELD – 450 AMP ONLY
SHIELD MOUNTING SCREW
CABLE BUNDLE - XX = LENGTH
8.0 – T-GUN MIG GUN ORDERING INFORMATION
EXAMPLE OF STANDARD MODEL NO.
4510-116
Wire Size
Standard Lengths - 10, 12, 15 ft
Other lengths available upon request
Amperage (Manual)
45 - 450 amp
62 - 600 amp
EXAMPLE OF CUSTOM BUILT GUN
E 6210-116-60-9
Use these codes to order
special gun features.
E
C
M
LN
LT
PA
Option numbers should be added
only if desired option is not
included on standard gun model.
- Euro-Connector
- Century/Powcon
- Miller Power Pin
- Lincoln Power Pin
- L-TEC
- Panasonic
9 - Liner for Aluminum wire
Angle of Neck
Wire Size
Standard Gun Model No.
8.1 GUN STANDARDS CHART
GUN MODEL
NECK
NOZZLE
RETAINER
CONTACT TIPS
450 amp
600 amp
455-45
595-60
451-6-62
601-6-62
454-1
404-38
403-1
403-20
Distributed by:
09/12 REV D
16
TG008