AMERICAN WELDQUIP 550A User manual

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Water‐Cooled Automatic MIG Torches
For Models
550A &600A
STANDARD/BARREL/RACK AND TAM MOUNTS
(450A discontinued; parts still available; see appendix A‐1)
INSTALLATION, OPERATIONS AND REPLACEMENT PARTS

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TABLE OF CONTENTS
INTRODUCTION ................................................................................................................................................ 2
WARRANTY ....................................................................................................................................................... 2
ROHS COMPLIANT ........................................................................................................................................... 3
SAFETY PRECAUTIONS – READ BEFORE USING ...................................................................................... 4
FEATURES .......................................................................................................................................................... 9
TORCH SPECIFICATIONS ................................................................................................................................ 9
INSTALLATION ................................................................................................................................................. 9
EURO CONNECTION (USING FEEDER ADAPTOR KIT) ....................................................................... 10
DIRECT CONNECT ...................................................................................................................................... 10
TORCH MOUNT INSTALLATION ............................................................................................................. 10
DAILY MAINTENANCE .................................................................................................................................. 11
MAINTENANCE ............................................................................................................................................... 11
LINER REPLACEMENT ............................................................................................................................... 11
HYBRID GOOSENECK REPLACEMENT .................................................................................................. 12
WATER-COOLED GOOSENECK REPLACEMENT .................................................................................. 12
HYBRID AIR-COOLED POWER CABLE REPLACEMENT ..................................................................... 13
WATER COOLED ASSEMBLY REPLACEMENT ..................................................................................... 13
NOZZLE/TIP RELATIONSHIPS ...................................................................................................................... 15
NOZZLE SELECTION CHART ........................................................................................................................ 16
400 SERIES NOZZLES ................................................................................................................................. 16
CONTACT TIP SELECTION CHART ............................................................................................................. 16
M8 CONTACT TIPS ...................................................................................................................................... 16
LINER SELECTION CHART ........................................................................................................................... 17
PARTS BREAKDOWN ..................................................................................................................................... 18
550A ............................................................................................................................................................... 18
600A ............................................................................................................................................................... 20
APPENDIX A-1 450A TORCHES .................................................................................................................... 22

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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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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 Qand Part 1926, Subpart Javailable from U.S. Government
Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburg, PA 15250. Website
–www.osha.gov.

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Automatic Welding Torches
FEATURES
American Weldquip torches have been designed with advanced features and benefits
to include:
Durability –Heavy-walled gooseneck design helps with heat sink dissipation.
Robust Design –Provides unparalleled resistance to bending in “crash situations.”
Nozzle –Heavy duty, thread on nozzle prevents the nozzle from coming loose.
Consumables –Common consumables across American Weldquip torches alleviate inventory
requirements.
Strain‐relief –Our spring strain-relief prevents the power cable from being over bent
prolonging its lifetime while preventing feed issues.
Adaptation –Adaptable to most wire feeders.
Water‐Cooled –The full water-cooled design allows for complete power cable and neck
cooling in high heat applications.
Hybrid Water‐Cooled –Ahybrid design utilizes an air-cooled power cable with awater-
cooled neck providing alow maintenance application.
Customs –Special designs and custom configurations and lengths are readily available.
Location –Manufactured in Sharon Center, Ohio for quality you can trust.
TORCH SPECIFICATIONS
MODEL AMPERAGE 100% CYCLE DUTY 60% CYCLE DUTY
CO2 Mixed Gas
(AR/CO2) CO2 Mixed Gas (AR/CO2)
550A 550A 550A 450A 625A 550A
600A 600A 600A 500A 650A 600A
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 it is 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, and 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 feeder pin then hose from PtoC to feeder.
b. OTC/Daihen, Lincoln, and Panasonic –connect to feeder with attached hose.
3) Connect the power cable if required (Lincoln, NA5, and OTC/Daihen feeder pins).
4) Feed welding wire into the torch and tighten drive
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.
TORCH MOUNT INSTALLATION
Mounting of Automatic torches are done per customer. Mounting fixtures not supplied by
American Weldquip.

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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.
 For 600A, check outer cover for cuts, nicks, holes, or tears. If you can see
internal components through the outer cover, return for maintenance.
o Inspect the front-end consumables. Clean weld spatter and inspect the nozzle
insulator. If nozzle insulation is damaged it should be replaced.
o Check that the gas diffuser is tight, and the insulating washer is on the
gooseneck.
 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.

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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 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.
HYBRID GOOSENECK REPLACEMENT
1) Purge water from lines and disconnect the water lines from the circulator.
2) Secure gooseneck in avice.
3) Remove the liner from the torch, see liner replacement.
4) Remove the adaptor support screw and slide back on the power cable.
5) Cut off the (2) 8.7mm clamps from the water line at neck. You may have to slit water
line with knife to remove from barbed fitting.
6) Using a5/8”wrench loosen the gooseneck/power cable connection and remove from
the power cable assembly.
7) Thread the new gooseneck onto the power cable assembly and tighten with 5/8”
wrench.
8) Trim hose behind slit and slide on (2) new 8.7mm clamp on each hose.
9) Push water line onto barbed fitting and secure with clamps.
10) Slide the adaptor support up and onto the mounting piece. Install the adaptor support
screw.
11) Reinstall the liner, see liner replacement.
12) Reinstall the diffuser, contact tip and nozzle.
WATER‐COOLED GOOSENECK REPLACEMENT
1) Purge water from lines and disconnect the water lines from the circulator.
2) Secure Gooseneck in avice.
3) Remove the liner from the torch, see liner replacement.
4) Remove the adaptor support screw and slide the adaptor support back on the power
cable.
5) Hold the nut at the power cable with an 10mm wrench and unthread the gooseneck
using a11mm wrench.
6) Cut off the (2) 8.7mm clamps from the water line and (1) 7/16”clamp from the gas
conduit and pull off neck assembly. You may have to slit water line with knife to
remove from barbed fitting.
7) Slide (2) new 8.7mm clamps on the water line and (1) 7/16”clamp on the gas conduit
of the cable assembly.
8) Thread the power cable onto the gooseneck and tighten (11mm on gooseneck and
10mm on power cable).

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9) Push the water line onto copper barb and conduit onto brass barb on the gooseneck
assembly and crimp the (2) 8.7mm and (1) 7/16”clamps.
10) Slide the cable support up and secure with screw on neck.
11) Reinstall the liner, see liner replacement.
12) Reinstall the diffuser, contact tip and nozzle.
HYBRID AIR‐COOLED POWER CABLE REPLACEMENT
1) Purge water from water lines of the torch then disconnect the water lines from the
cooler and cap the ends.
2) Secure Gooseneck in avice.
3) Remove the liner from the torch, see liner replacement.
4) Unscrew the spring from the adaptor support and slide back onto power cable.
5) Remove the adaptor support screw and slide the adaptor support back on the cable.
6) Using a5/8”wrench, loosen the gooseneck/power cable connection and remove
gooseneck from the power cable assembly.
7) Remove the adaptor support and spring from old power cable and place on the new
power cable assembly.
8) Thread the gooseneck on to the new power cable assembly and tighten.
9) Slide the power cable support up and secure with screw on neck.
10) On the rear of the old power cable assembly, unscrew and slide the spring back on the
power cable.
11) Remove the screw securing the adaptor to the feeder pin adaptor block and slide the
adaptor support back on to the power cable.
12) Unthread the power cable from the feeder adaptor block.
13) Slide the rear spring and adaptor support onto the new power cable assembly.
14) Thread the feeder adaptor onto the new power cable and tighten.
15) Slide the cable support up and secure with screw on the feeder adaptor.
16) Install the screw on the rear adaptor and feeder adaptor assembly.
a. Install the other handle half if required.
17) Screw the rear spring onto the adaptor assembly.
18) Reinstall the liner, see liner replacement.
19) Reinstall the diffuser, contact tip and nozzle.
WATER COOLED ASSEMBLY REPLACEMENT
**WARNING: This replacement is alabor‐intensive process. Torch assembly can be sent
into the manufacture to be evaluated for replacement parts.**
1. Purge water from water lines of the torch then disconnect the water lines from the cooler
and cap the ends.
2. Secure Gooseneck in avice.
3. Remove the liner from the torch, see liner replacement.
4. On the front adaptor unscrew the spring from the front adaptor. Ascrewdriver may be
used to push/twist the spring to unthread it from the front adaptor. The front adaptor will
come apart in 2pieces. Slide the spring down the cable assembly. Remove the front
adaptor support screw and slide down the cable assembly.

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5. On the rear adaptor support unscrew the spring from the rear adaptor. Ascrewdriver may
be used to push/twist the spring to unthread it from the rear adaptor. The rear adaptor
will come apart in 2pieces. Slide the spring down the cable assembly. Remove the rear
adaptor support screw and slide down the cable assembly.
6. At the rear adaptor block, hold the nut on the power cable with a12mm wrench and
unthread the rear adaptor block nut using a12mm wrench.
7. Cut off the clamp from the gas conduit and remove the gas conduit from the rear adaptor
block.
8. Set the rear adaptor and rear adaptor block components aside and save.
9. Slide the outer cover and front &rear springs from around the cable assembly. Set the
springs aside for reuse.
Power Cable Replacement (if necessary)
a. At the gooseneck, hold the nut on the power cable with a10mm wrench and
unthread the gooseneck nut using an 11mm wrench.
b. Replace the power cable with anew power cable and attach to the gooseneck with a
10mm wrench on the power cable and an 11mm wrench on the gooseneck nut and
tighten.
Gas Conduit Replacement (if necessary)
a. At the gooseneck, cut off the clamp and remove from the brass fitting.
b. Replace gas conduit with anew gas conduit and attach to the brass fitting with a
7/16”clamp.
Blue Water Line Replacement (if necessary)
a. At the gooseneck, cut off both clamps and remove from the copper fitting. The blue
water line may have to be cut off the fitting with aknife.
b. At the rear of the blue water line, cut off the clamps and remove from the brass
fitting (connects to the chiller). Keep this fitting to reuse on the new water line. The
blue water line may have to be cut off the fitting with aknife.
c. Replace the blue water line with anew blue water line and attach to the copper
fitting with (2) 8.7mm clamps and the rear quick disconnect brass fitting with (1)
8.7mm clamps.
Outer Cover Replacement (if necessary)
a. Remove the plastic boots (1 on each end) from the old outer cover with a
screwdriver as they can be reused.
b. Place aplastic boot on each end of the new outer cover. Secure each with super glue
to the inside of the new outer cover.
10. Slide the outer cover over the power cable, gas conduit and water line.
11. Slide the front adaptor assembly back over the rear of the gooseneck and secure with the
front adaptor screw. Set the outer cover boot inside the front adaptor assembly and slide
the 2nd part of the front adaptor into the first. Slide the spring up the outer cover and
thread onto the 2-piece front adaptor assembly securing in place.
12. Slide the second spring onto the rear of the outer cover, small end toward the front.
13. Slide the rear adaptor over the power cable, gas conduit and water line.
14. Attach the power cable to the rear adaptor block by holding the nut on the power cable
with an 12mm wrench and thread the rear adaptor block nut using a12mm wrench.
15. Attach the gas conduit to the rear adaptor block on the brass fitting with a7/16”clamp.

15
16. Slide the rear adaptor onto the rear adaptor block and attach with the rear adaptor screw.
Set the outer cover boot inside the rear adaptor assembly and slide the 2nd part of the
rear adaptor into the first. The red and blue water lines should come out the notch in the
side. Be sure not to pinch the red and blue water lines. Slide the spring down the outer
cover and thread onto the 2-piece rear adaptor assembly securing in place.
17. Reinstall the liner, see liner replacement.
18. Reinstall the diffuser, contact tip and nozzle.
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, is 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.

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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
CONTACT TIP SELECTION CHART
M8 Contact Tips
Part Number Wire Size Nominal I.D Description
Copper (CU)
75030014 0.030”(.8mm) 0.038”Contact Tip (Standard)
75035014 0.035”(.9mm) 0.044”Contact Tip (Standard)
75040014 0.040”(1.0mm) 0.048”Contact Tip (Standard)
75045014 0.045”(1.2mm) 0.054”Contact Tip (Standard)

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75052014 0.052”(1.3mm) 0.061”Contact Tip (Standard)
75062014 0.062”(1.6mm) 0.073”Contact Tip (Standard)
75062015 0.062”(1.6mm) 0.076”Contact Tip (Standard)
75078014 0.078”(2.0mm) 0.087”Contact Tip (Standard)
75093014 0.093”(2.4mm) 0.106”Contact Tip (Standard)
Heat Resistant Technology (HRT)
20030400 0.030”(.8mm) 0.039”HRT Contact Tip
20035400 0.035”(.9mm) 0.041”HRT Contact Tip
20040400 0.040”(1.0mm) 0.050”HRT Contact Tip
20045400 0.045”(1.2mm) 0.054”HRT Contact Tip
20030500 0.030”(.8mm) 0.039”HRT Contact Tip
20035500 0.035”(.9mm) 0.041”HRT Contact Tip
20040500 0.040”(1.0mm) 0.050”HRT Contact Tip
20045500 0.045”(1.2mm) 0.054”HRT Contact Tip
20052500 0.052”(1.3mm) 0.061”HRT Contact Tip
20062500 0.062”(1.6mm) 0.069”HRT Contact Tip
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

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PARTS BREAKDOWN
550A