Tweco Spool gun Maintenance and service guide

Issue Date: April 20, 2012 Manual No: 89210007Revision: A
Safety and Operating
Instructions
SPOOL GUN
English

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Tweco®product. We are proud to have you
as our customer and will strive to provide you with the best service and
reliability in the industry. This product is backed by our extensive warranty
and world-wide service network.To locate your nearest distributor or service
agency call 800-426-1888, or visit us on the web at www.tweco.com.
This Manual has been designed to instruct you on the correct installation
and use of your Tweco®product.Your satisfaction with this product and its
safe operation is our ultimate concern. Therefore, please take the time to
read the entire manual, especially the Safety Precautions.They will help you
to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators
Worldwide.
Tweco®is a Global Brand of Arc Welding Products for Thermadyne
Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through market-leading,
dependable products that have stood the test of time. We pride ourselves
on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales
and marketing expertise.
Above all, we are committed to develop technologically advanced products
to achieve a safer working environment within the welding industry.

i
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before
installing, operating, or servicing the equipment. While the information contained in
this Manual represents the Manufacturer’s judgment, the Manufacturer assumes no
liability for its use.
Tweco Spool Gun: SG160TAX-12-3035
Set-up and Safe Operating Procedures
Instruction Guide Number 89210007
Published by:
Thermadyne®Industries, Inc.
2800 Airport Rd.
Denton, TX. 76208
[phone]
www.thermadyne.com
U.S. Customer Care: [phone]
International Customer Care: [phone]
Copyright © 2011, 2012 Thermadyne Industries, Inc. All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any
error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Publication Date: April 2012
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Equipment Serial #:

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Table of Contents
SECTION 1: SAFETY PRECAUTIONS ....................................................................... 1-1
SECTION 2: MODEL SPECIFICATIONS .................................................................... 2-5
SECTION 3: INSTALLATION AND OPERATION ........................................................ 3-7
3.01 Connecting the spool gun................................................. 3-7
3.02 Adjusting wire feed pressure and speed........................... 3-8
3.03 Installing the wire spool ................................................... 3-8
SECTION 4: CARE AND MAINTENANCE ................................................................ 4-11
4.01 Changing the contact tip................................................. 4-11
4.02 Changing the wire conduit.............................................. 4-12
4.03 Changing the drive rolls ................................................. 4-13
SECTION 5: TROUBLESHOOTING CHECK LIST ...................................................... 5-15
SECTION 6: REPLACEMENT PARTS LIST.............................................................. 6-16
STATEMENT OF WARRANTY................................................................................. 6-19
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION............................Rear Cover

SET-UP AND SAFE OPERATING PROCEDURES
1-1
89210007 Safety Precautions
SECTION 1:
SAFETY PRECAUTIONS
WARNING
SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not properly
installed, used, and maintained. Misuse of this equipment and other unsafe practices
can be hazardous. The operator, supervisor, and helper must read and understand the
following safety warnings and instructions before installing or using any welding or cutting
equipment, and be aware of the dangers of the welding or cutting process. Training
and proper supervision are important for a safe work place. Keep these instructions for
future use. Additional recommended safety and operating information is referenced in
each section.
ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH
Install and maintain equipment in accordance with the National Electrical Code (NFPA
70) and local codes. Do not service or repair equipment with power ON. Do not operate
equipment with protective insulators or covers removed. Service or repair to equipment
must be done by qualified and/or trained personnel only.
Do not contact electrically live parts. Always wear dry welding gloves that are in good
condition.Aluminized, protective clothing can become part of the electrical path. Keep oxygen cylinders,
chains, wires, ropes, cranes, and hoists away from any part of the electrical path.All ground connections
must be checked periodically to determine if they are mechanically strong, and electrically adequate for
the required current. When engaged in AC welding/cutting under wet conditions or where perspiration
is a factor, the use of automatic controls for reducing the no load voltage is recommended to reduce
shock hazards. Accidental contact must be prevented when using open circuit voltage exceeding 80
volts AC, or 100 volts DC by adequate insulation or other means. When welding is to be suspended for
any length of time, such as during lunch or overnight, all electrode holders and electrodes should be
removed from the electrode holder and the power supply should be turned OFF to prevent accidental
contact. Keep MIG-Guns, electrode holders, Tig torches, Plasma torches, and electrodes away from
moisture and water. See safety and operating references 1, 2, and 8.
SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH
Ventilation must be adequate to remove smoke, fumes, and gases during operation to
protect operators and others in the area. Vapors of chlorinated solvents can form the
toxic gas “Phosgene” when exposed to ultraviolet radiation from an electric arc. All
solvents, degreasers, and potential sources of these vapors must be removed from the
operating area. Use air-supplied respirators if ventilation is not adequate to remove all
fumes and gases. Oxygen supports, and vigorously accelerates fire and should never be used for
ventilation. See safety and operating references 1, 2, 3, and 4.