Bernard Clean Air Gun CA-1.5 User manual

Issued Jan. 2008 • SPEC CA-1.5
Clean Air Gun™ Series
400, 600 Amp MIG Guns
Heavy-duty handles for durability.
45 degree bend for maximum feeding
characteristics.
Chrome parts to resist spatter adhesion.
Adjustable vacuum chamber maximizes suction
without affecting shielding gas and provides for
efficient smoke collection.
Ideally suited for almost any heavy-duty MIG
welding application.
Compatible with CenterfireTM series
consumables for better arc starts, less spatter,
more consistent welds and longer tip life.
All Guns are Not Created Equal.
A MIG gun should be durable, easy to
use and customized to your specific
application. Our MIG guns put you in
control: you choose the options you
need and we'll build a gun to last.
400 Amp Clean Air GunTM
Bernard Clean Air GunsTM help create an
efficient shop with reduced smoke and
fumes regardless of your operation.
USA
Made with
Pride and without
Compromise in the
Note: Bernard Clean Air Guns™ are only available with Bernard Quick Disconnect direct plug.
Bernard®
An Illinois Tool Works Company
449 West Corning Road, Box 667
Beecher, Illinois 60401 USA
Phone: [phone] (US Only) 708-946-2281 (Outside US)
Fax: [phone]
For more information, visit us at BernardWelds.com
A minimum of 70 CFM @ 35" H2O of air flow is required for efficient operation.
PART
NO.
CABLE
LENGTH
STD.
LINER
WIRE
SIZE
STD.
TIP
STD.
NOZZLE
STD.
GAS DIFFUSER
400
Amp
CA410A-B
CA415A-B
10' (3.05 m)
15' (4.57 m)
44115 .035" - .045"
(0.9 mm - 1.2 mm)
7490 4492 4435
CA410B-B
CA415B-B
10' (3.05 m)
15' (4.57 m)
44215 1/16"
(1.6 mm)
7491 4591 4435
600
Amp
CA610A-B
CA615A-B
10' (3.05 m)
15' (4.54 m)
44115 .035" - .045"
(0.9 mm - 1.2 mm)
7490 4492 4435
CA610B-B
CA615B-B
10' (3.05 m)
15' (4.57 m)
44215 1/6"
(1.6 mm)
1591 4591 4635
CA610C-B
CA615C-B
10' (3.05 m)
15' (4.57 m)
45415 3/32"
(2.4 mm)
1593 4591 4635

©2008 Bernard Printed in U.S.A.
Replacement Parts List
43
8
8B
8C
8A
9
1
7
6
5
2
10
11
11B
11A11A
11C
11A
12A
12B
12B2
12B1
12
13B
13A
15
14I
14H
14G
14F
14E
14D
14C
14B
14A
STRAIN RELIEF SET
AIR COOLED GUN COMPONENTS 400 Amp 600 Amp
1 Vacuum Chamber 1390006 1390008
2 Nozzle w/Insulator See Nozzle Chart (below)
3 Contact Tip See Tip Chart (below)
4 Gas Diffuser See Diffuser Chart (below)
5 Spacer 2460016 2460015
6 Vacuum Tube 2390002 2390001
(Smoke Shroud)
7 Body Tube 1040049 1040049
8 Handle Kit 1880037 1880037
8A Post Fastener 4207 4207
8B Screw 4209 4209
8C Trigger Screw 418 418
9 Trigger Assembly 422 422
AIR COOLED GUN CABLE COMPONENTS
10 Cable Saver, 3’ See Cable Saver Chart (below)
11 Vacuum Hose Kit 10’ 1880046 1880046
Vacuum Hose Kit 12’ 1880047 1880047
Vacuum Hose Kit 15’ 1880048 1880048
11A Clamp, Headless 1520011 1520011
11B Swivel Kit 1880036 1880036
11C Vacuum Hose, 10’ 1800013 1800013
Vacuum Hose, 12’ 1880014 1880014
Vacuum Hose, 15’ 1880015 1880015
12 Power Cable Assy, 10’ 1880054 1880040
Power Cable Assy, 12’ 1880055 1880041
Power Cable Assy, 15’ 1880056 1880042
12A Shrink Tube 9096 9096
12B Lead Set 1130016 1130016
12B1 Flag Terminal 457 457
12B2 Butt Connector 4932 4932
AIR COOLED GUN DISCONNECT COMPONENTS
13A Strain Relief 2520076 2520076
13B Clamp 1520011 1520011
14A Power Pin 2200008 2200008
14B O-Ring (2 Required) 4929 4929
14C Lead Wire (2 Required) 4924 4924
14D Gas Pin Assembly 2060033 2060033
14E Snap Ring, Large 4911 4911
14F Wave Ring 4916 4916
14G Snap Ring, Medium 4912 4912
14H Snap Ring, Small 2250016 2250016
14I Locking Sleeve 4925 4925
15 Liner See Liner Chart (below)
Elliptical Tips Heavy Duty Standard
(Item #3) Use w/4635 Head Use w/4435 Head
.023 (.6mm) 1597 7497
.030 (.8mm) 1588 7488
.035 (.9mm) 1589 7489
.039 (1.0mm) 1596 7496
.045 (1.2mm) 1590 7490
.052 (1.4mm) 1598 7498
1/16” (1.6mm) 1591 7491
5/64” (2.0mm) 1592 7492
3/32” (2.4mm) 1593 7493
7/64” (2.8mm) 1594 7494
1/8” (3.2mm) 1595 7495
Nozzles, Insulators, Assembled (Item #2)
1⁄2” Copper 4592
3⁄4” Brass 4491
1⁄2” Brass 4492
3⁄4” Copper 4591
Gas Diffusers (Item #4)
7400 Series Tips 4435
1500 Series Tips 4635
Liners (Item #16)
3/64”, 15’ Aluminum 43115X
.035 - .045, 15’ 44115
1/16”, 15’ 44215
5/64”, 15’ 44315
3/32”, 15’ 45415
7/64”, 15’ 45615
1/8”, 15’ 46715
Cable Cover (Item #10)
9’ Leather w/Velcro 1860005
13' Leather w/Velcro 1860008