WIA W64-1 User manual

Wirefeeder
WELDING.COM.AU
OPERATORS MANUAL | W64-1
From serial numbers W641A*

32
WELDING INDUSTRIES
AUSTRALIA
A Division of ITW Australia Pty Ltd
ABN: 63 004 235 063
1300 300 884
Email: [e-mail]
welding.com.au
WELDWELL
NEW ZEALAND
A Division of ITW New Zealand
NZBN: 9 429 039 833 129
GST NO: 080177186
0800 9353 9355
Email: [e-mail]
weldwell.co.nz

32
CONTENTS
Section General Information Page
Safe Practices 4
1 Introduction 7
2 Receiving 7
3 Specifications 8
4 Wirefeeder Controls 8
5 Installation 11
6 Basic Welding Information 12
7 General Maintenance 12
8 External Trouble Shooting 12
9 Trouble Shooting Chart 13
10 Wirefeeder Circuit Diagrams 14
11 Assembly & Parts Lists
11.1 Wirefeeder 15
11.2 Wirefeed Assembly 17
11.3.1 Gun & Cable Assembly
350 Amp Torch 18
11.3.2 Gun & Cable Assembly
400 Amp Torch 19
11.4 Work Lead &
Interconnecting Lead Kit
(270 & 356) 21
11.5 Work Lead &
Interconnecting Lead Kit
(396 & FABRICATOR) 22
12 Australia Warranty
Information 23
13 New Zealand Warranty
Information 25

54
Wirefeeder W64-1 | Operator Manual | Model No W64-1
SAFE PRACTICES WHEN USING
WELDING EQUIPMENT
These notes are provided in the interests
of improving operator safety. They should
be considered only as a basic guide to
Safe Working Habits. A full list of Standards
pertaining to industry is available from
the Standards Association of Australia,
also various State Electricity Authorities,
Departments of Labour and Industry or
Mines Department and other Local Health
or Safety Inspection Authorities may have
additional requirements. Australian Standard
AS1674.2 provides a comprehensive guide
to safe practices in welding.
Eye Protection
NEVER LOOK AT AN ARC WITHOUT
PROTECTION. Wear a helmet with safety
goggles or glasses with side shields
underneath, with appropriate filter lenses
protected by clear cover lens. This is a
MUST for welding, cutting, and chipping to
protect the eyes from radiant energy and
flying metal. Replace the cover lens when
broken, pitted, or spattered.
Recommended Shade Filter Lens
Amps TIG MMAW MIG
Pulsed
MIG
0-100 10 9 10 12-13
100-150 11 10 10 12-13
150-200 12 10-11 11-12 12-13
200-300 13 11 12-13 12-13
300-400 14 12 13 14
400-500 — 13 14 14
500 + — — 14 14
READ FIRST
The information contained in this
manual is set out to enable you
to properly maintain your new
equipment and ensure that you obtain
maximum operating efficiency.
Please ensure that this information
is kept in a safe place for ready
reference when required at any future
time.
When ordering spare parts, please
quote the model and serial number
of the power source and part number
of the item required. All relevant
numbers are shown in lists contained
in this manual. Failure to supply this
information may result in unnecessary
delays in supplying the correct parts.
SAFETY
Before this equipment is put into
operation, please read the Safe
Practices section of this manual.
This will help to avoid possible injury
due to misuse or improper welding
applications.
HANDLE ON WIREFEEDER
Please note that the handle fitted to
the Weldmatic W64-1 wirefeeder is
intended for carrying the equipment
by hand only.
DO NOT use this handle for
suspending or mounting the
wirefeeder in any other manner.

54
Burn Protection
The welding arc is intense and visibly bright.
Its radiation can damage eyes, penetrate
light-weight clothing, reflect from light-
coloured surfaces, and burn the skin and
eyes. Burns resulting from gas-shielded
arcs resemble acute sunburn, but can be
more severe and painful.
Wear protective clothing - leather or heat
resistant gloves, hat, and safety-toe boots.
Button shirt collar and pocket flaps, and
wear cuff less trousers to avoid entry of
sparks and slag.
Avoid oily or greasy clothing. A spark may
ignite them. Hot metal such as electrode
stubs and work pieces should never be
handled without gloves.
Ear plugs should be worn when welding in
overhead positions or in a confined space.
A hard hat should be worn when others are
working overhead.
Flammable hair preparations should not be
used by persons intending to weld or cut.
Toxic Fumes
Adequate ventilation with air is essential.
Severe discomfort, illness or death can
result from fumes, vapours, heat, or oxygen
depletion that welding or cutting may
produce. NEVER ventilate with oxygen.
Lead, cadmium, zinc, mercury, and
beryllium bearing and similar materials
when welded or cut may produce harmful
concentrations of toxic fumes. Adequate
local exhaust ventilation must be used,
or each person in the area as well as
the operator must wear an air-supplied
respirator. For beryllium, both must be used.
Metals coated with or containing materials
that emit fumes should not be heated
unless coating is removed from the work
surface, the area is well ventilated, or the
operator wears an air-supplied respirator.
Work in a confined space only while it is
being ventilated and, if necessary, while
wearing air-supplied respirator.
Vapours from chlorinated solvents can
be decomposed by the heat of the arc (or
flame) to form phosgene, a highly toxic
gas, and lung and eye irritating products.
The ultra-violet (radiant) energy of the arc
can also decompose trichlorethylene
and perchloroethylene vapours to form
phosgene. Do not weld or cut where solvent
vapours can be drawn into the welding or
cutting atmosphere or where the radiant
energy can penetrate to atmospheres
containing even minute amounts of
trichlorethylene or perchloroethylene.
Fire and Explosion Prevention
Be aware that flying sparks or falling slag can
pass through cracks, along pipes, through
windows or doors, and through wall or floor
openings, out of sight of the operator. Sparks
and slag can travel up to 10 metres from the arc.
Keep equipment clean and operable, free of
oil, grease, and (in electrical parts) of metallic
particles that can cause short circuits.
If combustibles are present in the work
area, do NOT weld or cut. Move the
work if practicable, to an area free of
combustibles. Avoid paint spray rooms, dip
tanks, storage areas, ventilators. If the work
can not be moved, move combustibles at
least 10 metres away out of reach of sparks
and heat; or protect against ignition with
suitable and snug-fitting fire-resistant
covers or shields.

76
Wirefeeder W64-1 | Operator Manual | Model No W64-1
Shock Prevention
Exposed conductors or other bare metal
in the welding circuit, or ungrounded
electrically alive equipment can fatally
shock a person whose body becomes
a conductor. Ensure that the equipment
is correctly connected and earthed. If
unsure have the equipment installed by a
qualified electrician. On mobile or portable
equipment, regularly inspect condition of
trailing power leads and connecting plugs.
Repair or replace damaged leads.
Fully insulated electrode holders should
be used. Do not use holders with
protruding screws. Fully insulated lock-type
connectors should be used to join welding
cable lengths.
Terminals and other exposed parts of
electrical units should have insulated knobs
or covers secured before operation.
Walls touching combustibles on opposite
sides should not be welded on or cut. Walls,
ceilings, and floor near work should be
protected by heat-resistant covers or shields.
A person acting as Fire Watcher must be
standing by with suitable fire extinguishing
equipment during and for some time after
welding or cutting if;
– Combustibles (including building
construction) are within 10 metres.
– Combustibles are further than 10
metres but can be ignited by sparks.
– Openings (concealed or visible) in floors
or walls within 10 metres may expose
combustibles to sparks.
– Combustibles adjacent to walls,
ceilings, roofs, or metal partitions can
be ignited by radiant or conducted heat.
After work is done, check that area is free of
sparks, glowing embers, and flames.
A tank or drum which has contained
combustibles can produce flammable
vapours when heated. Such a container
must never be welded on or cut, unless
it has first been cleaned as described in
AS.1674-2. This includes a thorough steam
or caustic cleaning (or a solvent or water
washing, depending on the combustible’s
solubility), followed by purging and inerting
with nitrogen or carbon dioxide, and using
protective equipment as recommended in
AS.1674-2. Water-filling just below working
level may substitute for inerting.
Hollow castings or containers must be vented
before welding or cutting. They can explode.
Never weld or cut where the air may contain
flammable dust, gas, or liquid vapours.
If the supply cable is damaged
it must be replaced by the
manufacturer, their service agent or
a similarly qualified person.

76
1 INTRODUCTION
Gas Metal Arc Welding (G.M.A.W.) is an
arc welding process where a consumable
wire is fed by motor driven feed rolls to a
welding gun, and where welding current is
supplied from the welding power source.
The welding arc is struck between the work
piece and the end of the wire, which melts
into the weld pool. The arc and the weld
pool are both shielded by gas flow from the
gun, or in the case of “self shielded” wires,
by gases generated by the wire core.
The process is very versatile in that by
selection of the correct wire composition,
diameter and shielding gas, it can be used
for applications ranging from sheet-metal
to heavy plate, and metals ranging from
carbon steel to aluminium alloys.
The Weldmatic W64-1 4RD has been
designed to be used with consumable
wires in the range from 0.6mm to 1.6mm
diameter. The smaller wire sizes are used
when welding at lower currents, such as
sheet-metal applications. Increasing the
wire diameter permits higher welding
currents to be selected.
A common application of G.M.A.W. is for
welding Mild Steel. In this application, a
Mild Steel solid consumable wire such as
AUSTMIG ES6 is used with a shielding gas
of Carbon Dioxide, or Argon mixed with
Carbon Dioxide. Alternatively, Flux-cored
consumable wires are available in both gas
shielded, and ‘gasless’ self shielding types.
Stainless steel and Aluminium can be
welded with G.M.A.W. using the correct
consumable wire and shielding gas.
The Weldmatic W64-1 4RD Wirefeeder
has been designed to feed a range of
hard, soft, and flux-cored wires for the
G.M.A.W. process. A compact motor with
integral gear box is coupled to a 4 roll drive
assembly forming the basic component of
the wirefeeder. The motor is controlled by
an electronic speed control which provides
speed regulation and compensation for
supply voltage variations.
2 RECEIVING
Check the equipment received against the
shipping invoice to make sure the shipment
is complete and undamaged. If any damage
has occurred in transit, please immediately
notify your supplier.
The W64-1 package contains:
– Weldmatic 4RD Enclosed Wirefeeder
W64-1 with Drive Rolls 0.9/1.2 V Groove
0.9/1.2mm Knurled.
– Interconnecting leads
– (This) Operating Manual W64-41.
If the W64-1, 4RD Wirefeeder is included in a
package with a Weldmatic MIG welder, it will
also contain the following:
– Welding gun and cable assembly
(see Section 10.4 for details)
– Work lead
– Gas hose
– Argon/mixed gas regulator/flow gauge.

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Wirefeeder W64-1 | Operator Manual | Model No W64-1
1 Power on Indicator
This indicator is illuminated when
wirefeeder is connected to a power source
and the power source is switched on.
2 Arc start
This control can be set to modify arc
starting conditions. For many applications
the control can be set at the mid point.
Rotating the knob towards ‘FAST’ will
provide faster wire acceleration at arc
start giving quicker starts, suitable for
applications such as rapid tack welding.
Rotating the knob towards ‘SOFT’ will
slow wire acceleration, providing a softer
start suitable for larger diameter and
aluminium wires.
3 Wire Speed Control
This control sets the speed of the wire
drive motor within the range of 0 - 172 RPM,
equivalent to 0 - 20 metres per minute of
welding electrode wire. Rotate the control
clockwise to increase the feed speed.
This control is used in conjunction with the
Wire Speed Range Select Switch. Switch to
low for slower (0-10 metres/min wirespeed
control and switch to high for higher (8-20
metres/min) wire speeds.
4 Wire Speed Range Indicator Light
This indicator is illuminated when speed
range is set to High speed range (8-20
metres/min).
5 Wire Speed Range Select Switch
Press to change from Low wire speed range
to High wire speed range.
6 Purge Button
Press to open the gas solenoid valve without
energising the welding power source.
4 CONTROLS
3 SPECIFICATIONS
Wirefeeder
Supply Voltage 32 volts AC, (from welding power source)
Rated Supply Current 5 Amps
Pre-gas Range 0 - 2 seconds
Post-gas Range 0 - 10 seconds
Start Speed Normal or Creep (switchable)
Spool Sizes 5 kg, 15 kg
Wirespeed Range 0 - 172 RPM: 0 - 20 Metres per min
(0 - 10 Metres per min Low Speed Range,
8 - 20 Metres per min High Speed Range)
Wire Size Range 0.6mm - 1.6mm diameter

98
7 Inch Button
Press to feed wire without energising the
welding power source. The wire will feed at
the current wirespeed setting.
8 Latch Select Button and Indicator
Press to select and deselect ‘Latch’
mode. When ‘Latch’ mode is selected, the
operator needs to close the gun switch
momentarily only to commence welding,
and again momentarily to end welding.
This can help to reduce operator fatigue
during long welding runs.
9 Creep Select Button and Indicator
‘Creep’ is selected when welding more
difficult materials such as aluminium or
stainless steel. In ‘Creep’ mode, the wire
is fed slowly until contact is detected and
then accelerated to the selected speed.
Because the wire comes into contact
with the work slowly the arc establishes
smoothly.
This is followed by rapid acceleration so
that the arc does not flare up and damage
the tip.
Even if an arc is not established, within one
second of the gun switch being operated
the wire feed accelerates to selected
welding speed.
1
2
Fig 1 Controls on front face of wirefeeder
3
4
5
6
7
89

1110
Wirefeeder W64-1 | Operator Manual | Model No W64-1
Wirefeeder Controls on Inside Panel
Pre Gas Control
Sets the time period of gas flow from gun
switch on until welding commences, and
can be set for 0 – 2 seconds.
Post Gas Control
This sets the time period of gas flow
after welding ceases, and can be set for
0 – 2 seconds.
Spot Time Control
When the setting is other than fully anti
clockwise, the welder will operate for a
short time after each trigger press. Turn
clockwise to increase the weld duration
up to a maximum of 5 seconds.
Burnback Control
This control sets the time period that
welding voltage continues after the gun
switch is released, and wirefeed ceases.
The extra time allows the wire to “burn
back” slightly toward the tip.
When set correctly ‘Burnback’
prevents the welding wire freezing
in the weld pool at the end of a weld.
PANTONE 2188 C
PRE GAS
POST GAS
SPOT TIME
BURNBACK
0 2 SEC
0 2 SEC
0 2 SEC
MIN MAX
WIN676A
Fig 2 Controls inside wirefeeder

1110
5 INSTALLATION
Remote Wirefeeder
The remote wirefeeder is connected to the
Weldmtic power source vi the composite
cble interconnecting led. Check ll
connections re firmly mde to ensure good
electricl contct, nd to prevent gs leks.
The Weldmatic W64-1 4RD wirefeeder is
supplied fitted with WF027 bottom rollers
which are suitable for both 0.9mm and
1.2mm diameter steel wire.
Fitting The Gun and Cable Assembly
The supplied welding gun/cable assembly
is equipped with a ‘Euro’ wirefeeder
connector which incorporates all required
connection points for welding current,
shielding gas and gun switch control.
To attach the gun/cable assembly to
the wirefeeder mechanism, engage the
mating parts of the male and female Euro
connectors, then rotate the locking ring
clockwise to firmly secure the connection.
Fitting the Consumable Wire
Place the spool of welding wire onto the
spool holder. The location pin should mate
with a hole provided on the wire spool body.
Secure the spool with plastic nut. Check
the adjustment of the spool brake, which
should be set to prevent over run of the wire
spool at the end of a weld, without unduly
loading the wirefeed motor. The braking can
be adjusted by using an allen key to adjust
Hex head bolt inside the hub.
Feeding the Consumable Wire
At the wirefeeder, release the compression
screw and rotate the top roller arms to
the open position. The end of the welding
wire can now be passed through the inlet
guide, over the first lower roller, through the
intermediate guide, over the second lower
roller and into the output wire guide tube.
Check that the drive roll grooves are correct
for the wire in use. The appropriate size is
stamped on the visible side of the installed
rollers. Check also that the correct size
contact tip is fitted at the gun end. Feed
roller and tip details are shown in Section 10
of this manual.
Return the top roller arms to the closed
position and adjust the compression screw
to provide sufficient clamping of the drive
rollers to achieve constant wirefeed. Do not
over tighten.
With the equipment energised, operate the
gun switch to feed wire through the gun cable.
Compression
screw
Top roller
arms
Fig 3 WF042 Four Roll Drive
Inlet guide
Drive
rollers
The quality of the consumable wire
greatly affects how reliably a gas
metal arc welder will operate. For
best results when welding mild
steel, we recommend quality WIA
AUSTMIG ES6. Dirty, rusty or kinked
wire will not feed smoothly through
the gun cable and will cause erratic
welding. Deposits from the wire will
clog the gun cable liner requiring it
to be replaced prematurely.

1312
Wirefeeder W64-1 | Operator Manual | Model No W64-1
Refer to the Weldmatic power source
Operators Manual for gas and weld setting
and gun position information.
6 BASIC WELDING INFORMATION
Dust
Care should be taken to prevent excessive
build-up of dust and dirt within the welding
power source. It is recommended that
at regular intervals, according to the
prevailing conditions, the equipment
covers be removed and any accumulated
dust be removed by the use of a dry, low
pressure compressed air, or a vacuum
cleaner. The machine should be blown
out with compressed air at least every 12
months as grinding dust can settle on PCB
componentry causing failure. Failure to
maintain machines may void warranty.
Wirefeed
In order to obtain the most satisfactory
welding results from the G.M.A.W. process,
the wirefeed must be smooth and constant.
Most causes of erratic wirefeed can be
cured by basic maintenance. Check that the:
1 Feed rolls are the correct size and type
for the wire in use. Check also that the
drive groove is aligned with the wire and
that the groove is not worn;
2 Gun cable liner is clear of dust and swarf
build-up. When replacement becomes
necessary, fit only the correct liner (see
page 19). The build-up of dust can be
minimised by regular purging of the liner
7 GENERAL MAINTENANCE
8 EXTERNAL TROUBLE SHOOTING
with dry compressed air. This may be
conveniently done each time the wire
spool is replaced;
3 Welding tip is free of obstructions such
as spatter build-up. Ream out the tip
bore with a suitable size oxy-tip cleaner.
Replace the welding tip as it becomes
worn;
4Feed roll pressure is not excessive. The
pressure should be just sufficient to
feed the wire evenly. Excessive pressure
will deform the electrode wire and make
feeding more difficult;
5Consumable wire spool holder rotates
smoothly and that the braking action is
not excessive. The spool should only
have sufficient braking to prevent over
run when the motor stops. This also may
be conveniently checked each time the
wire is replenished;
7Welding wire is straight and free of
buckles or ‘waviness’. To check, remove
2 or 3 metres of wire from the spool.
Clamp one end in a vice or similar,
then holding the other end pull the wire
out straight. Look down the length of
the wire, any buckles will be obvious.
Buckled wire is extremely difficult to
feed reliably and should be replaced;
8Welding wire is free of surface rust.
Replace if rust is evident.
Before removing the equipment
cover, ENSURE that the equipment
is disconnected from the mains
power supply. When the equipment
is energised LETHAL VOLTAGES are
present.
Refer to the Weldmatic power
source Operators Manual for
trouble shooting tips. If these
checks do not identify the fault
condition, the equipment should be
returned to a WIA Service agent.
Phone [phone] for details of
your nearest service agent.

1312
9 TROUBLE SHOOTING CHART
Problem Likely Reason Outcome
GMAW/MIG Models
The machine feeds
slowly and then speeds
up after 3-5 seconds.
Creep mode is selected, or
machine has a permanent
creep mode function.
Some models have a creep
mode function that cannot be
adjusted. Other models have
a push button selection for
creep mode on/off.
Nothing happens for
first x seconds after
trigger is pulled.
Pre gas is selected to
x seconds
Allow for Pre Gas time, or
adjust time.
The arc starts normally
but then stops
x seconds.
Spot time is selected to
x seconds.
Spot time selection should be
adjusted to 0 seconds.
The arc does not stop
after trigger is released.
Latch mode is selected Latch mode should be
switched off.
Motor continues to
run once arc is
extinguished.
Latch mode is selected Latch mode should be
switched off.
Weld is contaminated
with small bubbles
(presence of porosity).
Air in the gas hose. The torch
gas hose has not been purged
sufficiently.
The gas hose is not securely
connected at the machine or
at the regulator.
Air is being drawn into arc
through torch nozzle.
Purge the system and confirm
sufficient gas flow through the
regulator.
Ensure the gas connections
from regulator through to
the torch connection are
sufficiently tightened.
Remove nozzle, check O ring
on torch head, check condition
of insulator in nozzle.
Wire feed stutters and
arc is erratic. Also,
motor turns correctly
with roller tension
removed.
Torch consumables are
blocked/partially blocked.
Rusty MIG wire.
Liners and contact tips are
consumable and wear over
time.
Replace the torch liner and
reduce wire feed tension.
Presence of porosity
at weld start.
The torch gas hose has not
been purged sufficiently.
Purge the system and confirm
sufficient gas flow through the
regulator.

1514
Wirefeeder W64-1 | Operator Manual | Model No W64-1
10 WIREFEEDER CIRCUIT DIAGRAM
Fig 4 Wirefeeder Circuit Diagram

1514
11.1 ASSEMBLY AND PARTS LIST - W64-1 WIREFEEDER
Fig 5 W64-1 Wirefeeder Assembly
10
9
11
13
12
2
6
7
1
8
3
5
14
15
16
17
4

1716
Wirefeeder W64-1 | Operator Manual | Model No W64-1
Item # Part # Description Qty
1 M0049 Slam Action Latch 2
2 PAN196 Door 1
3 M0041 Hinge Set 2
4 M0042 Handle 1
5 PAN195 Top / Side Panel 1
6 M0047 Adjusting Knob, Large 2
7 WIN657 Front Panel Sticker 1
8 E0016 Adjusting knob, Small 5
9 WF001-6 Euro Surround, Plastic 1
10 PAN126 Front Panel 1
11 PAN125 PCB Cover 1
12 PWA099 Wirefeed Control Printed Circuit Assembly 1
Includes Potentiometer, Wirespeed Control (1K) 1
13 WF042 Four Roll Drive and Euro Adaptor Assembly
(see page 17)
1
14 M0043 Rubber Foot 4
15 E0041 Gas Valve 24 vdc 1
16 M0046 Spool Retaining Nut 1
17 M0044 Spool Holder Assembly (incl nut) 1
Not shown AM343 Current Sensor 1

1716
Fig 6 Wirefeed Assembly
11.2 ASSEMBLY AND PARTS LIST - WF042 WIREFEED ASSEMBLY
Item # Part # Description Qty
1 WF045 Roller Retaining Screw 2
2
WF027
Feed rolls
0.9 + 1.2 mm, Solid Wire (fitted) 2
WF026 0.6 + 0.8 mm, Solid Wire 2
WF028 1.2 + 1.6 mm, Solid Wire 2
WF029 1.0 + 1.2 mm, Aluminium 2
WF030 1.0 + 1.2 mm, Flux Cored Wire 2
WF031 1.2 + 1.6 mm, Flux Cored Wire 2
3 WF049 4 Roll Drive Box Assembly incl. Front & Rear Plastic Hous-
ing & Pressure Screw Complete
1
4 W26-0/13 Inlet Guide 1
5 W26-0/4 Woodruff Key 2
6 WF001-21 Outlet Guide Tube (oversize, cut to 41mm long) 1
7 WF038 Positioning Shaft, Brass 1
8 WF044 Euro Adaptor incl Gas Barb, Positioning Shaft & Guide Tube 1
9 WF001-6 Plastic Euro Cover 1
1
2
3
4
5
6
789

1918
Wirefeeder W64-1 | Operator Manual | Model No W64-1
11.3.1 350 AMP TORCH
Item # Part # Description
1 see ‘Nozzles’ (page 20) Nozzle
2 see ‘Tips’ (page 20) Contact Tip
3 BED-1 Gas Diffuser, Large
4 BE10012 Insulator
5 BEQT3-45 Body Tube 3”x 45°
6 GUN002 Handle Kit (includes both halves, screws & trigger
7 GUN003 Trigger Switch
8 GUN006 Rigid Casing
9 BE9165 Small “O” ring on gas nipple
10 BE4421 Large “O” ring on gas nipple
11 BEL3B-15
BE4154503N
Steel Liner 0.9-1.2mm, 300 amp
Nylon Liner 0.9-1.2mm
BEL3A-15 Steel Liner 0.9-1.2mm, 400 amp
GUN004 350A Gun & Cable Assembly
Fig 7 350 Amp Gun and Cable Assembly
1
2
3
4
5
6
7
8
10
911

1918
Fig 8 400 Amp Gun and Cable Assembly
Item # Part # Description
1 see ‘Nozzles’ (page 20) Nozzle
2 see ‘Tips’ (page 20) Contact Tip
3 BED-1 Gas Diffuser, Large
4 BE10012 Insulator
5 BEQT3-45 Body Tube 3”x 45°
6 GUN002 Handle Kit (includes both halves, screws & trigger
7 GUN003 Trigger Switch
8 GUN006 Rigid Casing
9 BE9165 Small “O” ring on gas nipple
10 BE4421 Large “O” ring on gas nipple
11 BEL3B-15
BE4154503N
Steel Liner 0.9-1.2mm, 300 amp
Nylon Liner 0.9-1.2mm
BEL3A-15 Steel Liner 0.9-1.2mm, 400 amp
GUN008 400A Gun & Cable Assembly
1
2
3
4
5
6
7
8
10
911
11.3.2 400 AMP TORCH

2120
Wirefeeder W64-1 | Operator Manual | Model No W64-1
To replace liner: Disconnect gun/cable
assembly at the Euro adaptor. Remove
nozzle (1) gas diffuser (3) and insulator (4).
Withdraw old liner from the wirefeeder
end. Insert new liner and refit gun/cable
assembly to the wirefeeder.
At the gun end, compress the liner within
the gun cable, then cut it approx 20mm
past the end of the body tube/neck (5).
Refit insulator and screw gas diffuser on
firmly with a wrench.
Insert tip (2) into gas diffuser then thread
nozzle onto gas diffuser/tip and tighten
firmly by hand.
Part # Description
BEN-3400C Nozzle, copper, 3/4” I.D,
flush
BEN-3414B Nozzle, brass, 1/4” I.D,
recess
BEN-3414C Nozzle, copper, 3/4” I.D,
1/4”, recess
BEN-3418B Nozzle, brass 3/4” I.D,
1/8”, recess
BEN-5800C Nozzle, copper, 5/8” I.D,
flush
BEN-5814B Nozzle, brass, 5/8” I.D,
1/4” recess
BEN-5814C Nozzle, copper, 5/8” I.D,
1/4” recess
BEN-5818B Nozzle, brass, 5/8” I.D,
1/8” recess
BEN-5818C Nozzle, copper, 5/8” I.D,
1/8” recess
Wire diameter Part #
0.8mm BET-030
0.9mm BEST-035
1.0mm BET-039
1.2mm BET-045
1.4mm BET-052
1.6mm BET-062
2.0mm BET-078
Nozzles
Tips
Cut Here
Compress Liner
Fig 9 Replacing the Gun Cable Liner
20mm