ESAB MT-450W User manual

INSTRUCTION MANUAL F-15-450
March, 1998
Be sure this information reaches the operator.
You can get extra copies through your supplier.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe
practices for arc welding equipment we urge you to read our booklet "Precautions and Safe Practices for Arc Welding Cutting
and Gouging " Form 52-529. Do NOT permit untrained persons to install operate or maintain this equipment. Do NOT attempt
to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand
these instructions contact your supplier for further information. Be sure to read the Safety Precautions before installing or
operating this equipment.
MT-450W & MT-650W
COOL GRIP
Water-Cooled MIG Torches
Ready-to-Weld Torch Assemblies
Each of the following torches has a 45 degree gooseneck
and includes liner, contact tip and standard duty slide-on
#10 nozzle.
M -450W, .035, 12 ft. (3.6 m) ................................... 37018
M -450W, .035, 15 ft. (4.5 m) ................................... 37019
M -450W, .045-1/16, 12 ft. (3.6 m) ........................... 37020
M -450W, .045-1/16, 15 ft. (4.5 m) ........................... 37021
Basic Torches
Basic torches do not include liners, contact tips or
nozzles. Mix and match the accessories listed in appropri-
ate tables to customize a torch that is just right for your
job.
M -450W, 12 ft. (3.6 m) ............................................ 37024
M -450W, 15 ft. (4.5 m) ............................................ 37025
M -650W, 12 ft. (3.6 m) ............................................ 37026
M -650W, 15 ft. (4.5 m) ............................................ 37027

2
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual
and accompanying labels and/or inserts when installed, operated, maintained and repaired
in accordance with the instructions provided. This equipment must be checked periodically.
Malfunctioning equipment should not be used. Parts that are broken, missing, worn, dis-
torted or contaminated should be replaced immediately. hould such repair or replacement
become necessary, the manufacturer recommends that a telephone or written request for
service advice be made to the Authorized Distributor from whom purchased.
This equipment or any of its parts should not be altered without the prior written approval of
the manufacturer. The user of this equipment shall have the sole responsibility for any
malfunction which results from improper use, faulty maintenance, damage, improper repair
or alteration by anyone other than the manufacturer or a service facility designated by the
manufacturer.
TABLE OF CONTENTS
1.0 INSTALLATION ........................................................................................ 5
1.1 INSTALLING TORCHES EQUIPPED WITH EURO CONNECTORS ................................................ 5
2.0 MAINTENANCE ........................................................................................ 5
2.1 NOZZLE AND CONTACT TIP S STEMS ......................................................................................... 5
2.2 SWITCH REPLACEMENT ................................................................................................................ 5
2.3 GOOSENECK REPLACEMENT ....................................................................................................... 5
2.4 LINER REPLACEMENT .................................................................................................................... 6
2.5 POWER CABLE REPLACEMENT .................................................................................................... 7
3.0 EXPLODED VIEW AND PARTS LIST .................................................... 10
3.1 TORCH PARTS ............................................................................................................................... 10
3.2 EURO CONNECTOR PARTS .........................................................................................................11
3.3 NOZZLES ....................................................................................................................................... 12
3.4 CONTACT TIPS & TUBES .............................................................................................................. 12
3.5 LINERS ........................................................................................................................................... 12
3.6 MIG 4HD WATER KIT INSTALLATION ........................................................................................... 13
3.7 DIRECT TO CIRCULATOR INSTALLATION ................................................................................... 13
3.8 EURO ADAPTOR ASSEMBL ........................................................................................................13
4.0 TECHNICAL DATA ................................................................................. 15
4.1 TORCH AMPERAGE RATINGS ...................................................................................................... 15
4.2 SPECIFICATIONS .......................................................................................................................... 15
5.0 - TROUBLESHOOTING ............................................................................. 15

3
WARNING: These Safety Precautions are for
your protection. They summarize precaution-
ary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels,etc.FailuretoobserveSafetyPrecautionscanresult
in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet(UV)andotherradiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip-
ment is essential to prevent accidents. Therefore:
1. Alwayswearsafetyglasseswithside shieldsinanywork
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wearflameproofgauntlettypegloves,heavylong-sleeve
shirt, cuffless trousers, high-topped shoes, and a weld-
ing helmet or cap for hair protection, to protect against
arcrays and hot sparks or hot metal. Aflameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystandersshouldalsoweargogglesoversafetyglasses.
FIRES AND EXPLOSIONS -- Heat from
flamesand arcs canstart fires.Hot slag
or sparks can also cause fires and ex-
plosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective non-
flammablecovering.Combustiblematerialsincludewood,
cloth,sawdust,liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might pro-
duce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Havefire extinguishingequipmenthandyforinstantuse,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
SAFETY PRECAUTIONS
11/95
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when neces-
sary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro-
cesses",availablefromtheNationalFireProtectionAsso-
ciation, Batterymarch Park, Quincy, MA 02269.
ELECTRICALSHOCK --Contactwith live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move-
ment is confined, or if there is danger of
falling.
1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or dam-
aged cables.
5. Keep everything dry, including clothing, work area,
cables, torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Donot standdirectlyonmetalortheearth whileworking
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Putondry,hole-freeglovesbeforeturningonthepower.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next
page) for specific grounding recommendations. Do not
mistake the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
Maybedangerous.Electriccurrentflow-
ing through any conductor causes lo-
calized Electric and Magnetic Fields
(EMF). Welding and cutting current cre-
ates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physi-
cian before welding. EMF may interfere with some pace-
makers.
2. ExposuretoEMFmayhaveotherhealtheffectswhichare
unknown.
3. Weldersshouldusethefollowingprocedurestominimize
exposure to EMF:
A. Routetheelectrodeandwork cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away
from your body as possible.

4
FUMES AND GASES -- Fumes and
gases,cancausediscomfortorharm,
particularly in confined spaces. Do
notbreathefumesandgases.Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by
naturalor mechanicalmeans.Donot weld,cut,or gouge
on materials such as galvanized steel, stainless steel,
copper,zinc,lead,beryllium,orcadmiumunlesspositive
mechanicalventilationisprovided.Donotbreathefumes
from these materials.
2. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
whileoperating,thisisanindicationthatventilationisnot
adequate. Stop work and take necessary steps to im-
prove ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylin-
der,valve,orreliefdevicecaninjureor
kill. Therefore:
1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer'soperatinginstructionsformountingregu-
lator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain
orstraptosuitablehandtrucks,undercarriages,benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautionsfor SafeHandlingofCompressedGasesin
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
EQUIPMENTMAINTENANCE--Faultyorim-
properly maintained equipment can cause
injury or death. Therefore:
1. Always have qualified personnel perform the installa-
tion, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.
2. Beforeperformingany maintenanceworkinsidea power
source, disconnect the power source from the incoming
electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for elec-
tric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Mi-
ami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWSC5.3-"RecommendedPracticesforAirCarbonArc
Gouging and Cutting"
5. AWSC5.5-"Recommended PracticesforGasTungsten
Arc Welding“
6. AWSC5.6 -"RecommendedPractices forGasMetal Arc
Welding"“
7. AWSSP-"SafePractices"-Reprint,WeldingHandbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
Thissymbolappearingthroughoutthismanual
means Attention! Be Alert! Your safety is
involved.
The following definitions apply to DANGER, WARNING,
CAUTION found throughout this manual:
Used to call attention to immediate haz-
ards which, if not avoided, will result in
immediate,seriouspersonalinjuryorloss
of life.
Used to call attention to potential haz-
ardswhichcouldresultinpersonalinjury
or loss of life.
Used to call attention to hazards which
could result in minor personal injury.

5
1.0 - INSTALLATION
1.1 INSTALLING TORCH TO WIRE FEEDER
•Euro Connector
•Feed welding wire through female adaptor by hand and tighten drive rolls.
•Guide welding wire into connector on torch, carefully insert connector into female adaptor and tighten
Euro hand nut.
2.0  MAINTENANCE
2.1 NOZZLE AND CONTACT TIP SYSTEMS
Removal - 650 AMP
•Before removal of nozzle, ensure water supply is turned off.
•Flip nozzle clasp from gooseneck and pull nozzle straight off.
•Remove contact tip using pliers.
•Remove tip adaptor using 5/8" (16 mm) wrench.
Removal - 450 AMP
•Pull slip on nozzles off with a clockwise twisting motion.
•Remove contact tip using pliers.
•Remove tip adaptor using 5/8" (16 mm) wrench.
NOTE: Ensure that all parts are tightened before welding and that the coolant circulator is turned on.
2.2 SWITCH REPLACEMENT
STEP #
•from handle.
•Using needlenose pliers Remove two switch housing
screws using 5/16" (8 mm) nut driver.
•Remove housing, remove switch leads from switch.
•Push leads onto new switch.
2.3 GOOSENECK REPLACEMENT
•Remove liner from torch (ref. pg. 6 Liner Replacement).
•Remove two switch housing screws, and remove housing.
HOUSING SCREWS
SWITCH
HOUSING
HOUSING
SCREWS
SWITCH
NOZZLE CONTACT TIP TIP ADAPTOR
STEP #

6
2.0 - MAINTENANCE
2.3 GOOSENECK REPLACEMENT CONTD.
STEP #2
•Slide handle back.
•Unthread power cable.
•Cut off water line and conduit clamps and pull hoses off barbed fittings
STEP #3
•Thread power cable on and tighten.
•Slide clamps on water line and conduit.
•Push water line and conduit all the way to base of fittings and crimp clamps.
•Slide handle back, place switch in housing, nest housing in handle and tighten screws.
2.4 LINER REPLACEMENT
STEP #
Ensure power source is off and torch is removed from feeder before proceeding.
•Remove nozzle, tip and tip adaptor and loosen liner set screw using 5/64 (2 mm) Allen wrench.
•With torch straightened, grip conduit liner with pliers and remove.
LINER SET SCREW
5/64" (2 mm) ALLEN
WRENCH
SWITCH
FRONT HANDLE
GOOSENECK
HOUSING
SCREWS
WATER LINES (RED & BLUE)
AND POWER LINE
FRONT HANDLE
WHITE CONDUIT LINE
GOOSENECK

7
2.0 - MAINTENANCE
2.4 LINER REPLACEMENT CONTD.
2.5 POWER CABLE REPLACEMENT
STEP #2
•Feed liner through torch using short strokes to
avoid kinking. Twist liner clockwise if necessary.
•Seat liner retainer with o-ring to shoulder inside
liner seat.
•Secure by tightening liner set screw.
Do not overtighten.
STEP #3
•Trim conduit liner to 5/8 (16 mm) stick out.
•Remove any burr that may obstruct wire feed,
especially on flat wire type conduit liner.
STEP #
•Remove liner (ref. Pg. 6).
•Remove nozzle, tip and tip adaptor
STEP #2
•Pull the rear handle up the torch approximately 1 (300 mm).
•Unscrew power cable from Euro body.
•Cut clamps off the water-in (blue line) and gas line (white).
•Pull gas and water line off of Euro body.
•At this point, Euro body will be removed from torch.
•Slide rear handle off of torch.
WHITE CONDUIT LINE EURO BOD
BLUE WATER LINE
POWER & WATER LINE
(RED WATER LINE)
REAR HOUSING
5/64" (2 mm) ALLEN
WRENCH
LINER SET SCREW
5/8" (16 mm)
CONDUIT LINER
GOOSENECK
5/64" (2 mm) ALLEN
WRENCH
LINER SET SCREW

8
2.0 - MAINTENANCE
2.5 POWER CABLE REPLACEMENT CONTD
STEP #3
•On front of torch, release front handle from neck (ref. Pg. 5 Gooseneck Replacement).
•Remove outer jacket by pulling from rear of torch.
STEP #4
•Unthread power cable from front of torch and replace with new one.
STEP #5
•From rear of torch, slide front handle over hoses.
•Tape hoses together at rear of torch.
•Slide outer jacket over hoses from rear of torch.
OUTER JACKET
TAPE
FRONT HANDLEGOOSENECK
BLUE WATER LINE
REPLACEMENT POWER CABLE (RED)
USED POWER
CABLE (RED)
WHITE CONDUIT LINE
GOOSENECK
WATER LINES (RED & BLUE)
& POWER LINE
OUTER JACKET
FRONT HANDLE
WHITE CONDUIT LINE
GOOSENECK

9
2.0 - MAINTENANCE
2.5 POWER CABLE REPLACEMENT CONTD.
•Slide outer jacket under front handle and bring front handle up to neck.
•Replace switch and switch housing and secure with mounting screws.
STEP #6
STEP #7
•At rear of torch, slide rear housing over outer jacket.
•Attach Euro body to power cable.
•Attach the gas and water lines to Euro body with new clamps.
STEP #8
EURO
BOD
WHITE CONDUIT LINE
BLUE WATER
LINE
POWER & WATER LINE
(RED WATER LINE)
REAR HOUSING
5/64" (2 mm) ALLEN
WRENCH
LINER SET SCREW
SWITCH
HOUSING
HOUSING
SCREWS
OUTER JACKET
FRONT HANDLE
GOOSENECK
•Slide rear handle over Euro body and secure with mounting screws.
•Install liner (see Section 2.4).
LINER

10
1 See Table 3.3 See Table 3.3 NOZZLE
2 See Table 3.4 See Table 3.4 CONTACT TIP OR TUBE
337244 37245 IP ADAP OR
3A 952635 RE AINING RING (5)
3B 952634 952634 O-RING (5)
4952633 SHOCKWASHER (2)
5952637 952638 GOOSENECK - 45 DEGREE
(includes 952670, 952671 clamps)
5A *952628 WA ER MANIFOLD ASSEMBLY
(incl. 952628, 952639, 952642, 952646)
5B *952629 WA ER MANIFOLD
5C *952630 NOZZLE CLASP
5D *952631 QUICK CONNEC WA ER FI ING
5E *952639 ARMOURED WA ER JUMPER
5F 952632 HEA RESIS AN O-RING (5)
6952652 952652 SWI CH
7952653 952653 SWI CH HOUSING WI H SCREWS
8952651 952651 FRON HANDLE
9*952656 *952656 SWI CH LEAD CONNEC ORS (4)
1 CONTROL WIRE
*952654 *952654 12' CON ROL WIRE
952655 952655 15' CON ROL WIRE
11 POWER CABLE (RED)
952649 952649 12' POWER CABLE
952650 952650 15' POWER CABLE
12 INTERNAL WATER LINE (BLUE) (incl. (2) 952642 clamps)
*952640 *952640 12' IN ERNAL WA ER LINE
952641 952641 15' IN ERNAL WA ER LINE
PA T # PA T #
ITEM 450 AMP 650 AMP DESC IPTION
3.0 - EXPLODED VIEW AND PARTS LIST
3.1 TORCH PARTS (WITH CABLE AND HOSES)
1
2
3
4
5
1
2
3
5
7
68
9
11
12
13 14 15
10
16
* On part number denotes non-stock item, allow 2-3 weeks for delivery.
(X) At end of description denotes package qty.

11
13 *952642 *952642 WA ER LINE CLAMP (6)
14 *952646 *652646 CONDUI CLAMP (12)
15 CONDUIT (WHITE) (incl. (2) 952646 clamps)
*952644 *652644 12' CONDUI
952645 952645 15' CONDUI
16 OUTER JACKET
*952657 *952657 12' OU ER JACKE
952658 952658 15' OU ER JACKE
17 CONDUIT LINER
37031 37031 FOR .030" HARD WIRE (12 & 15')
37032 37032 FOR .035" HARD WIRE (12 & 15')
37033 37033 FOR .045-.062" HARD WIRE (12 & 15')
37034 37034 FOR .078-.093" HARD WIRE(12 & 15')
37039 37039 FOR .035" SOF WIRE (12 & 15')
37040 37040 FOR 3/64-.062" SOF WIRE(12 & 15')
18 952647 952647 RED WA ER LINE - 2' (incl. (2) 952642)
19 952648 952648 BLUE WA ER LINE - 2' (incl. (2) 952642)
2 952643 952643 EURO WA ER FI ING
21 952659 952659 EURO ADAP OR COMPLE E
21A *952660 *952660 EURO HOUSING WI H S RAIN RELIEF
21B *952661 *952661 HOUSING BAND (2)
21C *952663 *952663 EURO CONNEC OR BODY WI H RE AINING RING
21D *952664 *952664 HAND NU (2)
21E *952665 *952665 CON ROL PIN (10)
23F 952666 952666 O-RING - GAS INLE (5)
23G *952662 *952662 MOUN ING SCREW (10)
PA T # PA T #
ITEM 450 AMP 650 AMP DESC IPTION
3.0 - EXPLODED VIEW AND PARTS LIST
3.2 E RO CONNECTOR PARTS
16
17
18 20
19
17
21D21C21B21A
21
* On part number denotes non-stock item, allow 2-3 weeks for delivery.
(X) At end of description denotes package qty.

12
3.0 - EXPLODED VIEW AND PARTS LIST
3.3 NOZZLES
Gas Nozzles
Nozzle
I.D.
#8 (450W) 1/2-in. (13 mm) 37045
#10 (450W) 5/8-in. (16 mm) 37046
#12 (450W) 3/4-in. (20 mm) 37047
#10 (650W) 5/8-in. (16 mm) 37028
#12 (650W) 3/4-in. (20 mm) 37030
Slide-on, Self-Insulated ype Gas Nozzle
3.4 CONTACT TIPS AND T BES
Contact Tips & Tubes
Contact Tip Contact I.D.
Short Long Tube*** Diameter
Wire Type & Size Part No. Part No. Part No. in. (mm)
Hard Cored & Soft Wires
.030 in. (0.8 mm) 632791 20123 - .037*
.035 in. (0.9 mm) 632793 632794 996104 .043*
.040 in. (1.0 mm) 37275** 37276** 37277** .048*
3/64/045 in. (1.2 mm) 632795 632796 996105 .054*
.045 in. (1.2 mm) 37278** 37279** 37280** .061
.052 in. (1.4 mm) 632795 632796 996816 .062
1/16 in. (1.6 mm) 37281** 37282** 37283** .072
1/16 in. (1.6 mm) 632797 632798 996106 .078*
*** Requires Collet Nut (P/N 632811)
** Available 2nd Quarter 1998
* Re ommended for Aluminum
3.5 LINER
Liners for MT-350W, 450W & 650W 12 & 15 ft.)
Wire Size
Hard Wires
.030 (0.8 mm) ................................................................ 37031
.035 (0.9 mm) ................................................................ 37032
.045-1/16 (1.2-1.6 mm) ................................................. 37033
.078/093H (2.0 - 2.4 mm) .............................................. 37034
Soft Wires
.035 (0.9 mm) ................................................................ 37039
3/64-1/16 (1.2-1.6 mm) ................................................. 37040
Long ip
Short ip
ube***
Collet Nut
632811
45 AMP
65 AMP

13
3.0 - EXPLODED VIEW AND PARTS LIST
3.6 Typical Set- p
When using Mig 4HD Water Kit  37303
WC-8C Coolant Circulator - Vertical design to fit in cylinder rack of
most power source trucks. High efficiency fan cooled radiator dissi-
pates 6480 BTU/hour ........................................................ 33739
3.7 Typical Set- p
When connecting torch directly to coolant circulator (2 of each part required
Options & Accessories
Water Kit for Mig 4HD - Kit consist of inlet/outlet fittings, mounting
hardware, 8 ft. (2.4 m) water hoses with B size water fittings and
mounting hardware ............................................................. 37303
Optional Water Fittings and Connectors - The following items
can be used to connect the MT-350W, 450W and 650W to any
water circulator having 5/8 B size connectors:
Quick Disconnect Fittings - Two required - one fitting for
each circulator water hose to torch water hose connection or
connect torch directly to the water circulator ........ 23610853
Water Hose Coupling - One required for each quick discon-
nect fitting to water hose connection .......................... 11N18
Water Hoses - Two required - one for water supply to the
torch and one for return to the water circulator. Use hose cou-
pling (11N18) for connecting water hoses together. See table
above.
Water Hose (3 ft.) 20634
Water Hose (6 ft.) 20633
Water Hose (12 ft.) 40V76
Water Hose (25 ft.) 406196
Water Coupler
11N18
Quick Disconnect
Fitting
23610853
Gun Water
Connection
included with
torch

14
3.0 - EXPLODED VIEW AND PARTS LIST
3.8 WIRE FEEDER CONNECTOR ASSEMBLY
(MIG-35, DIGIMIG) - 20572
SE SCREW - 19318
ADAP OR INSULA OR - 19316
ADAP OR BLOCK - 19315
( o orch Euro Connector)
SE SCREW - 19319
POWERLUG - 19314
ADAP OR PLUG - 19312
( o Wire Feeder)
(2) FEMALE CONN. W/LEAD - 19317
POWER CABLE - 19339
SWI CHCORD - 19340
Includes PLUG - 2062336
Supplied:
SUPPOR LINER - 19309
GAS HOSE
(Supplied w/19315)

15
4.0 - TECHNICAL DATA
4.1 TORCH AMPERAGE RATINGS
NOTE: Ratings are based on tests that comply with NEMA ARC Welding Section Standard 11-6-19 5 for Duty Cycle. The
time period of one complete cycle shall be 10 minutes (60% = 6 minutes). National Electrical Manufacturers
Association, 2101 L Street N.W. Washington D.C. 2003 .
5.0 - TROUBLESHOOTING
100% DUTY CYCLE 60% DUTY CYCLE
CO2MIXED CO2MIXED
450 AMP 450 375 550 475
650 AMP 650 550 750 650
Model MT-450W MT-650W
Length ........................................ 15.2 (386 mm) ................... 13.0 (330 mm)
Height ........................................... 4.2 (107 mm) ..................... 4.2 (107 mm)
Handle Dilameter ............................ 1.6 (41 mm) ....................... 1.6 (41 mm)
Weight ..................................... 28.8 oz. (816 gm) ................32.8 oz. (930 gm)
(less service lines)
Water Cooling Requirement: 0.5 Gal./Min. (2 L./Min.)
4.2 SPECIFICATIONS
PROBLEM POSSIBLE CAUSE
Poor Wire Feed •conduit liner clogged or kinked
•incorrect liner size or contact tip
•liner cut too short and not seating properly in tip adaptor
•drive rolls too tight resulting in scoring of welding wire
•welding wire dirty, rusty or too much cast
Short Tip Life •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
•torch being run beyond its amperage range
Torch Overheating •loose retaining screw on quick connect block
•insufficient gauge power cable and/or ground cable
•loose connector cones and/or cone nuts
•torch being run beyond its amperage range
•electrical malfunction in power source
•poor or no water flow
Weld Porosity •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
•gas flow improperly set
Torch Leaking • Power cable burnt
• Leak in gooseneck

16
F-15-450 3/98
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123/ Fax: [phone]/Web: http://www.esab.com
Hours: 7:30 AM to 5:00 PM EST
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
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