AMERICAN WELDQUIP 456CG User manual

INSTALLATION, OPERATIONS, AND REPLACEMENT PARTS MANUAL
Air‐Cooled Semi‐Automatic MIG Torches
For COOL‐GRIP Models
456CG, 500CG and 507CG

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Table of Contents
INTRODUCTION ................................................................................................................................................ 2
WARRANTY ....................................................................................................................................................... 2
ROHS COMPLIANT ........................................................................................................................................... 3
EU DIRECTIVE ................................................................................................................................................... 4
SAFETY PRECAUTIONS – READ BEFORE USING ...................................................................................... 5
FEATURES ........................................................................................................................................................ 10
TORCH SPECIFICATIONS .............................................................................................................................. 10
INSTALLATION ............................................................................................................................................... 10
EURO CONNECTION (USING FEEDER ADAPTOR KIT) ....................................................................... 11
DIRECT CONNECT ...................................................................................................................................... 11
DAILY MAINTENANCE .................................................................................................................................. 11
MAINTENANCE ............................................................................................................................................... 12
LINER REPLACEMENT ............................................................................................................................... 12
GOOSENECK REPLACEMENT .................................................................................................................. 12
TRIGGER SWITCH REPLACEMENT ......................................................................................................... 13
POWER CABLE REPLACEMENT .............................................................................................................. 14
NOZZLE/TIP RELATIONSHIPS ...................................................................................................................... 15
NOZZLE SELECTION CHART ........................................................................................................................ 16
400 SERIES NOZZLES ................................................................................................................................. 16
500 SERIES NOZZLES ................................................................................................................................. 16
CONTACT TIP SELECTION CHART ............................................................................................................. 17
M8 CONTACT TIPS ...................................................................................................................................... 17
LINER SELECTION CHART ........................................................................................................................... 17
PARTS BREAKDOWN – 456CG, 500CG, 507CG .......................................................................................... 18

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INTRODUCTION
Thank you for purchasing an American Weldquip product. The American Weldquip
product you have purchased has been carefully manufactured, assembled, and fully tested.
This manual contains information on the installation, operation, maintenance, and
replacement part breakdown. Please read, understand, and follow all safety instructions,
warnings, and procedures. Keep this manual handy for referencing installation, operation,
maintenance, and part ordering information. While every precaution has been taken as to the
accuracy in this manual, American Weldquip assumes no responsibility for errors or
omissions. American Weldquip assumes no liability for damages resulting from the use of the
information contained in this manual. American Weldquip shall have no liability to the buyer
for consequential damages or expenses by any defect whatsoever.
WARRANTY
AMERICAN WELDQUIP MIG guns and parts are warranted to be free of defects in
material and/or workmanship for the period listed below. For any product found to be
defective under normal use, AMERICAN WELDQUIP at our option, will repair, replace, or issue
acredit for the value of the defective product. All warranty claims must be submitted by the
original purchaser. Use of non-genuine AMERICAN WELDQUIP parts and/or consumables may
damage and/or severely limit the performance of the equipment which may limit or void any
warranties. AMERICAN WELDQUIP will not assume responsibility for incidental damages or
expenses related to any defect. This warranty does not cover damage caused by misuse or
abuse, accident, alteration of product, improper installation, misapplication, lack of reasonable
care and maintenance, unauthorized repairs or modifications, loss of use while at arepair
facility or other conditions that are beyond the control of American Weldquip.
AReturn Merchandise Authorization Number (RMA#) must be attained from the
factory for any product being returned for Warranty Repair or Replacement. All returned
products must be shipped freight prepaid by the sender. No-charge replacements, repaired
products, or credit will be issued once the returned product has been evaluated and warranty
condition has been verified. If an immediate replacement is required before proper warranty
evaluation, apurchase order number is required, and the goods will be invoiced. Acredit will
be issued once it is determined that awarranty condition exists.
STANDARD WARRANTY
All Semi-Automatic, Automatic, Robotic MIG Torches and Components…...= 120 Days
MIG Torch Trigger Switches (Contacts only) -Excludes Smoke Extraction =LIFETIME
Robotic Nozzle Cleaning Stations, Wire Cutter…………………………….....=6Months
Robotic Peripherals, ArcSafe, Gun Mounts………………………………........=90 Days
TIG POINT Tungsten Electrode Grinders………………………………….......=90 Days
LIMITED EXTENDED WARRANTY PROTECTION
This limited extended warranty protection expands coverage to loyal customers who
use all GENUINE American Weldquip consumables. Customers filing aclaim under the
extended warranty will need to prove, by providing past invoices, that they have been
purchasing and using Genuine American Weldquip consumables.
All Semi-Automatic, Automatic, Robotic MIG Torches and Components…....=1YEAR
MIG Torch Trigger Switches (Contacts only) -Excludes Smoke Extraction....=LIFETIME

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MIG Torch Handles…………………………………………………………........=LIFETIME
Robotic Nozzle Cleaning Stations, Wire Cutter……=1Year w/Exclusive Quip-Mist Use
Robotic Peripherals, ArcSafe, Gun Mounts…………………………………....=90 Days
TIG POINT Tungsten Electrode Grinders………………………………….......=90 Days
ROHS COMPLIANT
RoHS (Restriction of Hazardous Substances) is an environmental law which
addresses the European Union directive 2002/95/EC known as the RoHS Directive. The RoHS
directive restricts the use of hazardous substances listed below in electrical and electronic
equipment. While it is not arequirement to meet the directive in the United States, currently,
American Weldquip Inc. feels this is an important part of our “Go Green initiative. We have
taken all reasonable steps to try to ensure the supporting evidence regarding the absence of
the restricted substances to support RoHS compliance.
For reference, the maximum concentration values of the restricted substances by weight in
homogenous materials are:
Lead/Lead Components.......................................-0.1%
Mercury..................................................................-0.1%
Hexavalent Chromium..........................................-0.1%
Polybrominated Biphenyls (PBBs)......................-0.1%
Polybrominated Diphenyl Ethers (PBDEs)........-0.1%
Cadmium................................................................-0.01%
For RoHS Certification of Compliance Letter on aparticular product please visit our
website –www.weldquip.com or email us at [email protected] or call 330-239-0317.

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EU DIRECTIVE
This product has met the requirements set by the EU directive and the products listed below
are in conformity with the provisions of:
Council Directives -2014/35/EC Low Voltage Equipment Safety
Council Directives -2011/65/EU Restriction of the use of certain hazardous substances in
electrical and electronic equipment (RoHS)
Harmonization Standard Used -IEC 60974-7:2013 Arc welding equipment –Part 7: Torches
260 Amp Mig Torch -238CAXX
300 Amp Mig Torch -347CAXX
350 Amp Mig Torch -354CAXX
400 Amp Mig Torch -407CAXX
400 Amp Mig Torch -456CGXX
500 Amp Mig Torch -500CGXX
500 Amp Mig Torch -507CGXX
347 Amp Mig Torch -347PGXX
407 Amp Mig Torch -407PGXX
For EU Declaration of Conformity letter for this product please visit our website –
www.weldquip.com or email us at [email protected] or call 330-239-0317.

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SAFETY PRECAUTIONS –READ BEFORE USING
Before installing, operating, or performing maintenance please read the safety precautions
below. Failure to observe safety precautions can result in injury or death.
Read and follow the Owner’sManual carefully before installing, operating, or servicing
equipment. Read and understand all safety information.
CALIFORNIA PROPOSITION 65 WARNINGS
This product, when used for welding and cutting, can produce fumes or gases which
contain chemicals known to cause birth defects and cancer. (California Health &Safety Code
Section 25249.5 et seq.) WASH HANDS AFTER HANDLING
EMF –ELECTRICAL AND MAGNETIC FIELDS MAY BE DANGEROUS
Electrical current flowing through any conductor causes localized Electric and Magnetic
Fields (EMF). Welding current creates an EMF field around welding cables and welding
machines.
WARNING ‐EMF fields may interfere with some pacemakers and other medical
implants. Implanted medical device wearers should consult their doctor before
operating or going near any arc welding applications. In addition, exposure to EMF
fields in welding may have other unknown health effects.
 Welders should use the below procedures to minimize the exposure to EMF fields from
the welding circuit.
 Route the cables close together. Secure by twisting, taping, or using acable cover to keep
together.
 Never coil, wrap, or drape welding cables around your body.
 Do not place your body between welding cables. Arrange so that cables are on one side
and away from the operator.
 Connect the work clamp (ground) to the workpiece as close as possible to the area to be
welded.
 Do not sit, lean, and stand next to the welding power source.
 Do not breathe the fumes and gases as they can cause asphyxiation.
FUMES AND GASES CAN BE DANGEROUS
WARNING ‐WELDING AND CUTTING PRODUCE FUMES AND GASES THAT
ARE HAZARDOUS TO YOUR HEALTH
Fumes and gases generated from welding can cause severe injury to respiratory system and
even death. In poorly vented areas it is required to properly ventilate the area and/or use
local forced ventilation or other fume control equipment at the arc to remove welding and
cutting fumes and gases.
The recommended way to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed. The worker exposer level

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should be checked initially and periodically thereafter to maintain applicable OSHA PEL and
ACGIH TVL limits.
 In apoorly ventilated area, it is necessary to wear an approved air-supplied respirator.
 Always read and understand the Safety Data Sheets (SDSs) and the manufacturer’s
instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and
metals.
 Always have atrained watchperson nearby. Welding and cutting fumes and gases can
displace air and lower the oxygen level causing injury or death. Be sure the breathing air is
safe.
 Do not weld or cut in locations near degreasing, cleaning, or spraying operations. The heat
and rays of the arc can react with vapors to form highly toxic and irritating gases.
 Do not weld or cut on coated metals, such as galvanized, lead, or cadmium plated steel,
unless the coating is removed from the weld area, the area is well ventilated, and while
wearing an air-supplied respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ELECTRIC SHOCK CAN KILL
WARNING ‐ELECTRICAL SHOCK CAN KILL. DO NOT TOUCH LIVE
ELECTRICAL PARTS AND/OR USE IN DAMP LOCATIONS.
The electrode and work (ground) circuit are electrically “HOT”whenever the
welding equipment is on. Do not touch these electrically live parts with your
bare skin or wet/damp clothing. Wear dry, hole-free gloves. Incorrectly
installed or improperly grounded equipment is ahazard.
Insulate yourself from work and ground using dry insulating mats or covers big enough to
prevent any physical contact with the work or ground.
Additional safety precautions are required when any of the following electrically hazardous
conditions are present: in damp locations or while wearing wet clothing; on metal structures
such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or
lying; or when there is ahigh risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order presented: 1) asemi-
automatic DC constant voltage, 2) aDC manual (stick) welder or 3) an AC welder with
reduced open-circuit voltage. In most situations, use of aDC constant voltage wire welder is
recommended and do not work alone!
 Disconnect input power or stop engine before installing or servicing this equipment.
Lockout/tag out input power according to OSHA 29 CFR 1910.147 (see Safety Standards).
 Properly install ground and operate this equipment according to its Owner’sManual and
national, state/provincial, and local codes.
 Always verify the supply ground. Make sure that input power cord ground wire is properly
connected to ground terminal in disconnect box or that cord plug is connected to aproperly
grounded receptacle outlet.
 Keep cords dry, free of oil and grease and protected from hot metal and sparks.
 Frequently inspect input power cord for damage or bare wiring. Replace cord immediately
if damaged. Bare wiring can kill.
 Turn off all equipment when not in use.

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 Do not use worn, damaged, undersized, or poorly spliced cables. It is illegal to use electrical
tape to repair torch power cable or ground cable that has damaged outer insulation. The
cable must be replaced.
 Do not drape cables over your body.
 Do not touch electrode if you are in contact with the work, ground, or another electrode
from adifferent machine.
 Do not touch electrode holders connected to two welding machines at the same time since
double open circuit voltage will be present.
 Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain
unit according to manual.
 Wear asafety harness if working above floor level.
 Keep all panels and covers securely in place.
 Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the
weld as practical.
 Do not connect more than one electrode or work cable to any single weld output terminal.
Disconnect cable for process when not in use.
ARC RAYS HAZARDS
WARNING –AWELDING ARC EMITS ULTRAVIOLET (UV) AND OTHER
RADIATION AND CAN CAUSE SERIOUS INJURY TO UNPROTECTED SKIN
AND EYES.
Use ashield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or observing open
arc welding. Headshield and filter lens should conform to ANSI Z87. I
standards.
Use suitable clothing made from durable flame-resistant material to protect your skin
and that of your helpers from the arc rays.
Protect other nearby personnel with suitable, non-flammable screening and/or warn
them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
WELDING AND CUTTING CAN CAUSE FIRE OR EXPLOSION
WARNING –Welding and cutting produces sparks that fly off from
the arc and can cause fires and/or explosions.
 Welding or cutting on closed containers, such as tanks, drums or pipes can cause them to
blow up. Sparks can fly off from the welding or cutting arc. The flying sparks, hot work
piece and hot equipment can cause fires and burns.
 Accidental contact of electrode to metal objects can cause sparks, explosion, overheating or
fire. Check and be sure the area is safe before doing any welding or cutting.
 Do not weld or cut where flying sparks can strike flammable material.
 Remove all flammables and fire hazards from the welding area. If this is not possible, tightly
cover them with approved covers to prevent the welding sparks from starting afire.
 When not welding, make certain no part of the electrode circuit is touching the work or
ground. Accidental contact can cause overheating and create afire hazard.

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 Be alert that welding sparks and hot materials from welding and cutting can easily go
through small cracks and openings and cause afire in the adjacent areas.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and
have afire watcher and extinguisher nearby.
 Do not heat, cut, or weld tanks, drums or containers that have held combustibles until the
proper steps have been taken to ensure that such procedures will not cause flammable or
toxic vapors from substances inside. They can cause an explosion even though they have
been “cleaned”.For information, purchase “Recommended Safe Practices for the
Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous
Substances”,AWS F4.1 from the American Welding Society.
 Do not weld or cut where the atmosphere may contain flammable dust, gas, or liquid vapors
(such as gasoline).
 Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such
as leather gloves, heavy shirt, cuff-less trousers, high shoes, and acap over your hair. Wear
ear plugs when welding out of position or in confined places. Always wear safety glasses
with side shields when in awelding area.
 Connect work cable to the work as close to the welding or cutting area as practical to
prevent welding or cutting current from traveling long, possibly unknown paths and causing
electric shock, sparks, and fire hazards.
 Do not use welder to thaw frozen pipes.
 Remove any combustibles, such as abutane lighter or matches, from your person before
doing any welding or cutting.
 Inspect area to ensure it is free of sparks, glowing embers, and flames after work is
complete.
CYLINDERS CAN EXPLODE IF DAMAGED
WARNING –Compressed gas cylinders contain gas under high pressure
and/or flammable gas. If damaged, the cylinder can explode.
 Use only compressed gas cylinders containing the correct shielding gas for the process used
and properly operating regulators designed for the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and maintained in good condition.
 Always keep cylinders in an upright position securely chained to an undercarriage or fixed
support.
 Cylinders should be located away from areas where they may be struck or subjected to
physical damage and asafe distance from arc welding or cutting operations and any other
source of heat, sparks, or flame.
 Never allow the electrode, electrode holder or any other electrically “hot”parts to touch a
cylinder.
 Keep your head and face away from the cylinder valve outlet when opening the cylinder
valve.
 Valve protection caps should always be in place and hand tight except when the cylinder is
in use or connected for use.

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 Read and follow the instructions on compressed gas cylinders, associated equipment, and
CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,”
available from the Compressed Gas Association, 14501 George Carter Way Chantilly, VA
20151.
PRINCIPAL SAFETY STANDARDS
Safety in Welding, Cutting and Allied Processes, ANSI Standard Z49.1 – available for download
from the American Welding Society website at www.aws.org.
CSA Standard W117.2 – available from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS or website –www.csa-international.org.
Nation Electric Code, NFPA Standard 70 – available from National Fire Protection Association,
Quincy, MA 02269, or website –www.nfpa.org.
Safe Practices for Occupational and Educational Eye and Face Protection, ANSI Standard Z87.1
– available from the American National Standards Institute, 25 West 43rd Street, New York, NY
10036. Website –www.ansi.org.
OSHA, Occupational Safety and Health Standard for General Industry, Title 29, Code of Federal
Regulations, Part 1910, Subpart Q and Part 1926, Subpart J available from U.S. Government
Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburg, PA 15250. Website –
www.osha.gov.

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COOL‐GRIP SEMI‐AUTO TORCHES
FEATURES
American Weldquip torches have been designed with advanced features and benefits to
include:
Durability –Heavy-walled gooseneck design gives increased durability where it matters the
most.
Consumables –Common consumable platform keeps stock needs down.
Power Cable –Astrong, durable power cable promotes clean arc starts and cut resistance.
Custom Configurations –Custom configurations are readily available and can even ship
same day.
Extended Trigger –The aluminum, extended trigger provides comfortable reach while
preventing breaks as compared to plastic extended triggers.
“Cool Design”–The Cool-Grip design was made to provide relief from the high heat of
welding.
Strain‐relief –Our spring strain-relief prevents the power cable from being over bent
prolonging its lifetime while preventing feed issues.
Additional Options –Flex-necks, heat shield, thermal spring, and torch hangers are available
across all torch designs.
Adaptation –Adaptable to most wire feeders with quick change control cable.
Location –Manufactured in Sharon Center, Ohio allowing for quick turnaround.
TORCH SPECIFICATIONS
MODEL AMPERAGE
60% DUTY CYCLE 100% DUTY CYCLE
CO2 MIXED GAS
(AR/CO2) CO2 MIXED GAS (AR/CO2)
456CG 450 500A 450A 450A 350A
500CG 500 575A 500A 500A 390A
507CG 500 575A 500A 500A 390A
Duty Cycle is based on acomplete cycle time of 10 minutes. (60% Duty Cycle =6
minutes weld time, 4minutes off time).
INSTALLATION
Depending on how your torch was ordered your American Weldquip torch has been
supplied with either aEURO type feeder connection or aDIRECT wire feeder connection. The
American Weldquip torch can be installed to the wire feed unit in two ways.
 Euro Connection –Feeder Adaptor Kit may be required
 Direct Connection

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EURO CONNECTION (USING FEEDER ADAPTOR KIT)
In some cases, it may be desirable to use aEuro feeder adaptor kit when using different
manufactures wire feed units. This will commonize torches to aEuro style 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.
4) Connect the Euro torch to the feeder adaptor assembly.
5) 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.
DIRECT CONNECT
The direct connect torch system is designed for installation to the wire feeder without the
need for any adaptor system. The torch is supplied (depending on the torch configuration
ordered) with afeeder connection plug at the rear of the torch, gas connection, feeder control
cable.
1) Fully insert the torch Direct Connection into wire feeder. Tighten screw or other
method on wire feeder to secure torch.
2) Connect the gas hose if required:
a. Lincoln Universal –connect PtoC to power pin then hose from PtoC to feeder.
b. OTC/Daihen, Lincoln, and Panasonic –connect to feeder with attached hose.
3) Connect feeder control cable/plug to the feeder if required.
4) Feed welding wire into the torch and tighten drive rolls.
WARNING: WHEN FEEDING WELD WIRE THROUGHT 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.
DAILY MAINTENANCE
Afew minutes per day performing aquick check of your mig torch will help to
decrease weld problems, minimize downtime, and help increase consumable life.
 At Beginning of Shift
o Inspect the cable for cuts, nicks, or tears. If you can see bare copper return for
maintenance.
o Inspect the front-end consumables. Clean weld spatter and inspect the nozzle
insulator. If nozzle insulation is damaged, the nozzle should be replaced.
o Check that the gas diffuser is tight, and the insulating washer is on the gooseneck.

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 The insulating washer is pertinent to have in place as this helps prevent the
gooseneck from getting electrically charged.
o Check the gas holes on the diffuser and clean if necessary.
o Check and tighten the contact tip.
o Check all electrical connections including the power cable from the power supply,
torch/feeder connections, and control cables for loose connections. Tighten if
necessary. Loose connections can cause overheating of cables and/or loss of
electrical power.
MAINTENANCE
LINER REPLACEMENT
Warnings –To avoid accidental injury ensure power supply and wire feed unit is
turned off.
1) Trim the end of the weld wire at contact tip.
2) Retract or completely remove weld wire so torch can be removed from the wire
feeder.
3) Remove the nozzle, contact tip and diffuser.
4) Loosen the set screw, DO NOT REMOVE, at the torch feeder pin connection using a
5/64”Allen wrench. If retaining nut, remove and set aside.
5) Making sure the torch cable is straight, grasp the liner at the rear of the torch with a
pair of pliers and remove.
6) Carefully feed the new liner into the torch using short strokes to avoid kinking. You
may need to twist the liner for easier insertion.
7) Tighten the set screw or retaining nut to secure the liner in the torch.
8) Reinstall the torch to the wire feed unit.
9) IMPORTANT: at the front end of the torch push the liner back into the gun and hold to
trim.
10) Trim the liner to 13/32”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 THROUGHT 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) Secure Gooseneck in avice.
2) Remove the liner from the torch, see liner replacement.
3) Unscrew the spring from the front handle and slide back on cable.
4) Remove the four handle screws and separate the handle assembly.

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5) Using a5/8”wrench loosen the gooseneck/cable connection and remove from the
cable assembly.
6) Remove the Body Insulator from the old gooseneck and install on the new one.
7) Thread the new gooseneck on to the cable assembly and tighten with 5/8”wrench..
8) Install the bottom handle assembly (trigger side) onto the gooseneck/cable assembly.
The trigger wires will fit in the grooves on the sides of the body insulator. Make sure
the trigger wires stay seated in the body insulator and the insulator is fully inserted
into the bottom handle.
9) Install the top handle and secure with the (4) screws.
IMPORTANT: Ensure the trigger wires are not pinched between the handles.
10) Slide the handle spring up and twist onto the rear of the handle.
11) Reinstall the liner, see liner replacement.
12) Reinstall the insulating washer, diffuser, contact tip, and nozzle.
TRIGGER SWITCH REPLACEMENT
CG SERIES TORCHES
The Trigger Switch Assembly (75000004)
contains:
(1) Trigger Paddle
(2) Springs
(4) Screws
(1) Shoulder Screw
(2) Copper Outer Contact Plates
(1) Copper Contact Plate
1) Secure Gooseneck in avice.
2) Remove the four handle screws and
separate the handle assembly.
3) Remove the (4) screws securing the
copper contact assemblies and remove the
trigger leads and contacts.
4) Remove the trigger paddle shoulder screw
and spring securing the center copper
blade to the trigger paddle.
a. If using the extended trigger there are two screws that secure the trigger
paddle and must be removed.
5) Using ascrewdriver gently push, from the inside of the handle, the trigger paddle
where it attaches to the handle and remove the trigger paddle and return spring.
6) Insert the return spring (the smaller diameter spring) into the seat on the bottom
handle assembly.
7) Carefully insert the new trigger paddle and small diameter spring into the handle
assembly and tap the paddle in on the pivot point in the handle. The Trigger should
snap in place.
8) Place the copper cross contact on the shoulder screw, then install the remaining spring
over the screw, and thread into the trigger paddle until tight. DO NOT OVER TIGHTEN.

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9) Using the (4) four screws provided attach the (2) two outer contact plates and install
the (2) two trigger leads under the front contact plate screws.
10) Install the bottom handle assembly (trigger side) onto the gooseneck/cable assembly.
The trigger wires will fit in the grooves on the sides of the body insulator. Make sure
the trigger wires stay seating in the body insulator and the insulator is fully inserted
into the bottom handle.
11) Slide the handle spring or cable support up and insert in the rear of the handle.
12) Install the top handle and secure with the (4) four screws provided. IMPORTANT:
Ensure the trigger wires are not pinched between the handles.
POWER CABLE REPLACEMENT
1) Secure Gooseneck in avice.
2) Remove the liner from the torch., see liner replacement.
3) Unscrew the spring from the gooseneck and slide back on cable.
4) Remove the four handle screws and separate the handle assembly.
5) Using a5/8”wrench, loosen the gooseneck/cable connection and remove gooseneck
from the cable assembly.
6) Remove the spring from old cable and place on the new cable assembly.
7) Thread the gooseneck on to the new cable assembly and tighten.
8) Install the bottom handle assembly (trigger side) onto the gooseneck/cable assembly.
The trigger wires will fit through the slot on the bottom of the body insulator. Make
sure the insulator is fully inserted into the bottom handle.
9) Slide the handle spring or cable support up and insert in the rear of the handle.
10) Install the top handle and secure with the (4) screws.
IMPORTANT: Ensure the trigger wires are not pinched between the handles.
11) On the rear of the old cable assembly, unscrew the spring and slide back on the cable.
12) Unplug the trigger control cable if present and set aside.
13) Remove the screw securing the adaptor support to the feeder pin adaptor and
separate.
14) Unthread the power cable from the feeder adaptor block.
15) Slide the rear spring and adaptor support onto the new cable assembly.
16) Thread the feeder pin adaptor into the power cable and tighten.
17) Slide the rear adaptor support onto the feeder adaptor block and secure with screw.
18) Install the other handle half and screw on the rear spring.
19) Install the screw on the rear handle and feeder adaptor.
20) Plug trigger connector into socket on rear adaptor support if present.
21) Reinstall the liner, see liner replacement.
22) Replace the Diffuser, contact tip, and nozzle.
23) Feed welding wire into the torch and tighten drive rolls.

15
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.
Extended Tip –Short Circuit (Short Arc, Dip
Transfer) Welding Applications
The tip stick out is usually 1/8” or 1/4”
from the nozzle. Keep in mind that the further the
stick out the more susceptible to gas porosity
issues. Typically, this used in short circuit, lower amperage applications, and/or where you
may need to reach into acorner.
Flush Tip –Higher current Short Circuit (Short
Arc, Dip Transfer) Welding Applications
The tip is flush with the end of the nozzle.
Typically used in higher current and voltage short
circuit applications.
Recessed Tip –Spray Arc, Pulsed, Flux Core Welding Applications
The tip is usually recessed in the nozzle 1/8”
or 1/4”. Usually, the higher the heat and/or current
the further the recess. However, this is also
dependent on the wire used and the arc length
requirement.

16
NOZZLE SELECTION CHART
400 Series Nozzles
Part Number Description Bore Size Material O.A.L Insulator Req
75146202-I BOTTLE NOSE 5/8”(15.9mm) NI PLATED BRASS 3.125”(79.4mm) INSTALLED
75145001 BOTTLE NOSE 1/2”(12.7mm) NI PLATED BRASS 3.031”(77.0mm) 75001733
75146202 CONICAL 5/8”(15.9mm) NI PLATED BRASS 3.125”(79.4mm) 75001738
75146202C CONICAL 5/8”(15.9mm) NI PLATED COPPER 3.125”(79.4mm) 75001738
75146202CU CONICAL 5/8”(15.9mm) BARE COPPER 3.125”(79.4mm) 75001738
75145601-I TAPERED 9/16”(14.2mm) NI PLATED BRASS 3.125”(79.4mm) INSTALLED
75145002C TAPERED 1/2”(12.7mm) NI BARE COPPER 3.125”(79.4mm) 75001738
75145002CU TAPERED 1/2”(12.7mm) BARE COPPER 3.125”(79.4mm) 75001738
75145003 TAPERED (LONG) 1/2”(12.7mm) NI PLATED BRASS 3.915”(99.4mm) NONE REQ.
75146501S SPOT 5/8”(15.9mm) NI PLATED BRASS 3.437”(87.3mm) 75001738
75146204-I CONICAL 5/8”(15.9mm) NI PLATED BRASS 2.820”(71.6mm) INSTALLED
75146204CU CONICAL 5/8”(15.9mm) BARE COPPER 2.820”(71.6mm) 75001738
75145602-I SMALL CONICAL 9/16”(14.2mm) NI PLATED BRASS 2.820”(71.6mm) INSTALLED
75144301-I TAPERED 7/16”(11.1mm) NI PLATED BRASS 2.820”(71.6mm) INSTALLED
75145004 BOTTLE NOSE 1/2”(12.7mm) NI PLATED BRASS 3.125”(79.4mm) 75001733
75146205-I CONICAL 5/8”(15.9mm) NI PLATED BRASS 3.031”(77.0mm) INSTALLED
75146205CU TAPERED 5/8”(15.9mm) BARE COPPER 3.031”(77.0mm) 75001738
75146206-I SHORT CONICAL 5/8”(15.9mm) NI PLATED BRASS 1.875”(47.6mm) INSTALLED
75146207-I SHORT CONICAL 5/8”(15.9mm) NI PLATED BRASS 2.187”(55.6mm) INSTALLED
75147501 CYLINDRICAL 3/4”(19.0mm) NI PLATED BRASS 3.125”(79.4mm) 75001738
7514501CU CYLINDRICAL 3/4”(19.0mm) BARE COPPER 3.125”(79.4mm) 75001738
75145603-I SHORT TAPERED 9/16”(14.2mm) NI PLATED BRASS 2.375”(60.3mm)) INSTALLED
75145005 BOTTLE NOSE 1/2”(12.7mm) NI PLATED BRASS 2.820”(71.6mm) 75001733
75144302-I TAPERED 7/16”(11.1mm) NI PLATED BRASS 3.125”(79.4mm) INSTALLED
500 Series Nozzles
Part Number Description Bore Size Material O.A.L Insulator Req
75156201 CONICAL 9/16”(14.2mm) NI PLATED BRASS 2.670”(67.8mm) 75001740
75157001CU-I CYLINDRICAL 11/16”
(17.46mm) BARE COPPER 3.187”(81mm) INSTALLED
75157501-I CONICAL 3/4”(19mm) NI PLATED BRASS 3.187”(81mm) INSTALLED

17
CONTACT TIP SELECTION CHART
M8 Contact Tips
Part Number Wire Size Nominal I.D
Copper (CU)
75030014 0.030”(.8mm) 0.038”
75035014 0.035”(.9mm) 0.044”
75040014 0.040”(1.0mm) 0.048”
75045014 0.045”(1.2mm) 0.054”
75052014 0.052”(1.3mm) 0.061”
75062014 0.062”(1.6mm) 0.073”
75062015 0.062”(1.6mm) 0.076”
75078014 0.078”(2.0mm) 0.087”
75093014 0.093”(2.4mm) 0.106”
Heat Resistant Technology (HRT)
20030400 0.030”(.8mm) 0.039”
20035400 0.035”(.9mm) 0.041”
20040400 0.040”(1.0mm) 0.050”
20045400 0.045”(1.2mm) 0.054”
20052400TT 0.052” (1.3mm) 0.057”
20062400 0.062” (1.6mm) 0.069”
20030500 0.030”(.8mm) 0.039”
20035500 0.035”(.9mm) 0.041”
20040500 0.040”(1.0mm) 0.050”
20045500 0.045”(1.2mm) 0.054”
20052500 0.052”(1.3mm) 0.061”
20062500 0.062”(1.6mm) 0.069”
*TT is for tight tolerance.
LINER SELECTION CHART
Part Number Description
75005215T .023-.030 LINER, 5FT –TSTYLE
75010215T .023-.030 LINER, 10FT –TSTYLE
75015215T .023-.030 LINER, 15FT –TSTYLE
75001222T .035-.045 LINER, 1FT –TSTYLE
75005222T .035-.045 LINER, 5FT –TSTYLE
75010222T .035-.045 LINER, 10FT –TSTYLE
75015222T .035-.045 LINER, 15FT –TSTYLE
75025222T .035-.045 LINER, 25FT –TSTYLE
75001228T .045-1/16 LINER, 1FT –TSTYLE
75005228T .045-1/16 LINER, 5FT –TSTYLE
75010228T .045-1/16 LINER, 10FT –TSTYLE
75015228T .045-1/16 LINER, 15FT –TSTYLE
75025228T .045-1/16 LINER, 25FT –TSTYLE
75001229T 5/64-3/32 LINER, 1FT –TSTYLE
75005229T 5/64-3/32 LINER, 5FT –TSTYLE
75010229T 5/64-3/32 LINER, 10FT –TSTYLE
75015229T 5/64-3/32 LINER, 15FT –TSTYLE
75025229T 5/64-3/32 LINER, 25FT –TSTYLE

18
PARTS BREAKDOWN –456CG, 500CG, 507CG

19
NO. DESCRIPTION 456 500 507
1CONICAL NOZZLE SEE NOZZLE SELECTION CHART
TAPERED NOZZLE SEE NOZZLE SELECTION CHART
BOTTLENOSE NOZZLE SEE NOZZLE SELECTION CHART
2NOZZLE INSULATOR SEE NOZZLE SELECTION CHART
3CONTACT TIP SEE CONTACT TIP SELECTION CHART
4GAS DIFFUSER, STANDARD 75004033 75004033 75004033
GAS DIFFUSER, SHORT 75004033S 75004033S 75004033S
GAS DIFFUSER, LONG 75004033L 75004033L 75004033L
GAS DIFFUSER, X-LONG 75004033XL 75004033XL 75004033XL
5INSULATING WASHER 75001004 75001004 75001006
6GOOSENECK, 60-DEGREE 75004456 75005042 75005046
GOOSENECK, 45-DEGREE 75004455 75005041 75005045
6F FLEX NEC
K
(COMES WITH 6FA &7) 750CGFLEX 750CGFLEX N/A
6FA FLEX NEC
K
NOZZLE SEAT (REQUIRED) 75077FLX 75077FLX N/A
7BOD
Y
INSULATOR 75003002 75003002 75003000
8GUN HANGER (Optional) 75000009 75000009 75000009
9Gun hanger Bracket 75000030C 75000030C-.750 75000030C-.750
10 COOL GRIP HANDLE -STD 75000044 75000044 75000044
COOL GRIP HANDLE- EXT TRIGGER 75000046 75000046 75000046
COOL GRIP HANDLE TOP
–
STD. 75000040 75000040 75000040
COOL GRIP HANDLE TOP
–
DUAL SCHEDULE 75000045 75000045 75000045
COOL GRIP HANDLE BOTTOM –STD. 75000041 75000041 75000041
COOL GRIP HANDLE BOTTOM
–
EXT. TRIGGER 75000046 75000046 75000046
NS HANDLE SCREWS
–
COOL GRIP (4 REQUIRED) 75000008 75000008 75000008
NS SWITCH ASS
Y
–
DUAL SCHEDULE 75000017 75000017 75000017
NS SWITCH ASSY. –MULTI-SCHEDULE 75000018 75000018 75000018
NS DS/MS SWITCH CONNECTORS 75077018 75077018 75077018
11 FRONT SUPPORT SPRING 75002006 75002006 75002006
12 REAR SUPPORT SPRING 75002019 75002018 75002018
13 10’POWER CABLE 75010407CG 75010507CG 75010507CG
12’POWER CABLE 75012407CG 75012507CG 75012507CG
15’POWER CABLE 75015407CG 75015507CG 75015507CG
20’POWER CABLE 75020407CG 75020507CG 75020507CG
25’POWER CABLE 75025407CG 75025507CG 75025507CG
14 REAR ADAPTOR SUPPORT 75077006 75077006 75077006
15 DIR CON ADAPT BL
K
37077003 37077003 37077003
NS DIR CON ADAPT BL
K
–FRONIUS KIT
(INCLUDES 20,20A FRONIUS VERSION) 37677710 37677710 37677710
16 EURO BLOC
K
37030001 37030001 37030001
16A EURO LINER RETAINING NUT 37077005 37077005 37077005
17 ADAPTOR SCREW 75001151 75001151 75001151
18 LOC
K
NUT 75001029 75001029 75001029
19 HOLE PLUG 38000003 38000003 38000003
20 MILLER FEEDER PIN 37577705 37577705 37577705
OTC /DAIHEN FEEDER PIN 37577700 37577700 37577700
OTC DP SERIES FEEDER PIN 37577701 37577701 37577701
LINCOLN LN7 FEEDER PIN 37577832 37577832 37577832
PANASONIC FEEDER PIN 37577999 37577999 37577999
TWECO #4 FEEDER PIN 37577699 37577699 37577699
TWECO #5 FEEDER PIN 37577930 37577930 37577930
20A LINER RETAINING CAP, MILLER 37577705-N 37577705-N 37577705-N
LINER RETAINING CAP, OTC 38277001-N078 38277001-N078 38277001-N078
LINER RETAINING CAP, EURO 37077005 37077005 37077005
LINER RETAINING CAP, FRONIUS 37577706-N 37577706-N 37577706-N
LINER RETAINING CAP, OTC 38277001-N078 38277001-N078 38277001-N078
21 CONTROL CABLE, MILLER 37577201 37577201 37577201