Antorcha Enfriada Por Agua 89200005 E

WATER-COOLED
WRS SERIES
400 AMP
600 AMP
WATER-COOLED
AUTOMATION
MIG GUNS
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SAFETY and Operating

Instructions
Revision: A Issue Date: November 3, 2008 Manual No: 89200005
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Tweco® Robotics 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 worldwide 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® Robotics 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® Robotics is a Global Brand of 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.
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.
Water-Cooled Automation MIG Guns

Safety and Operating Instructions
Instruction Guide Number: 89200005
Published by:
Thermadyne® Industries, Inc.
2800 Airport Rd.
Denton, TX. 76208
(940) 566-2000
www.tweco.com
U.S. Customer Care: (800) 426-1888

International Customer Care: (905) 827-9777
Copyright © 2008 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: November 3, 2008
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Equipment Serial #:

Table of Contents
Section 1: Introduction................................................................................... 1-1

1.01 How to Use this Manual.................................................................1-1
1.02 Receipt of Equipment.....................................................................1-1
Section 2: Safety Precautions ...................................................................... 2-2
Section 3: MIG Gun SPECIFICATIONS................................................................. 3-5
3.01 MIG Gun Classification...................................................................3-5
3.02 MIG Gun Part Number Identification..............................................3-6
Section 4: MIG gun Installation..................................................................... 4-7
4.01 Standard MIG Gun Installation.......................................................4-7
4.02 Direct Plug.....................................................................................4-7
4.03 Conductor Tube Installation...........................................................4-8
Section 5: cONTACT TIPS.................................................................................... 5-9
5.01 Identification..................................................................................5-9
5.02 Replacement..................................................................................5-9
Section 6: WIRE CONDUIT.................................................................................. 6-10
6.01 Identification................................................................................6-10
6.02 Removal.......................................................................................6-10
6.03 Installation...................................................................................6-11
6.04 Bronze Jump Liner.......................................................................6-11
6.05 Connecting Water Line to Tweco Watercooler..............................6-11
Section 7: Troubleshooting.......................................................................... 7-12
Section 8: REPLACEMENT PARTS...................................................................... 8-14
8.01 MIG Gun Parts Listing..................................................................8-14
8.02 Consumable Parts Listing............................................................8-18
Section 9: Statement of Warranty............................................................. 9-20
ii
SAFETY AND OPERATING INSTRUCTIONS
Section 1:
Introduction
1.01 How to Use this Manual
Information necessary to perform maintenance and service is contained in this manual. This
information is intended for use by technicians or personnel qualified to repair and service this
equipment. The information contained in this document, including performance specifications,
is subject to change without notice. To ensure safe operation, read the entire manual, including
the chapters on safety precautions and warnings.
Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these headings. These special annotations are
easily recognized as follows:
NOTE
NOTE conveys installation, operation, or maintenance information which is
important but not hazard-related.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may
result in injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
1.02 Receipt of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and
inspect the equipment for possible damage due to shipping. If there is any damage, notify the
carrier immediately to file a claim. Furnish complete information concerning damage claims
or shipping errors to the location in your area, listed on the back cover of this manual. Include
a full description of the parts in error.
If you want additional or replacement copies of this CD, please contact Tweco® Robotics at the
address and phone number in your area listed on the back cover of this manual. Include the
Manual number (from page i) and CD part number, CDROBOTICS.
89200005 1-1 Introduction

Section 2:
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.
Warning
This product contains chemicals, including lead, or otherwise produces chemicals
known to the State of California to cause cancer, birth defects and other
reproductive harm. Wash hands after handling. (California Health & Safety Code
§ 25249.5 et seq.)
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.
Safety Precautions 2-2 89200005

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.
ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE EYES AND BURN SKIN
Welding and cutting processes produce extreme localized heat and strong
ultraviolet rays. Never attempt to weld/cut without a federally compliant welding
helmet with the proper lens. A number 12 to 14 shade filter lens provides the
best protection against arc radiation. When in a confined area, prevent the
reflected arc rays from entering around the helmet. Approved shielding curtains
and appropriate goggles should be used to provide protection to others in the surrounding area.
Skin should be protected from arc rays, heat, and molten metal. Always wear protective gloves
and clothing. All pockets should be closed and cuffs sewn shut. Leather aprons, sleeves, leggings,
etc. should be worn for out-of-position welding and cutting, or for heavy operations using large
electrodes. Hightop work shoes provide adequate protection from foot burns. For added protection,
use leather spats. Flammable hair preparations should not be used when welding/cutting. Wear
ear plugs to protect ears from sparks. Where work permits, the operator should be enclosed in
an individual booth painted with a low reflective material such as zinc oxide.
WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS
Combustibles reached by the arc, flame, flying sparks, hot slag, and heated
materials can cause fire and explosions. Remove combustibles from the work
area and/or provide a fire watch. Avoid oily or greasy clothing as a spark may
ignite them. Have a fire extinguisher nearby, and know how to use it. If welding/
cutting is to be done on a metal wall, partition, ceiling, or roof, precautions must
be taken to prevent ignition of nearby combustibles on the other side. Do not
weld/cut containers that have held combustibles. All hollow spaces, cavities, and containers
should be vented prior to welding/cutting to permit the escape of air or gases. Purging with inert
gas is recommended. Never use oxygen in a welding torch. Use only inert gases or inert gas
mixes as required by the process. Use of combustible compressed gases can cause explosions
resulting in personal injury or death. Arcing against any compressed gas cylinder can cause
cylinder damage or explosion. See safety and operating references 1, 2, 5, 7, and 8.
NOISE CAN DAMAGE HEARING
Noise from the air carbon-arc process can damage your hearing. Wear protective
hearing devices to ensure protection when noise levels exceed OHSA standards.
Adequate hearing protection devices must be worn by operators and surrounding
personnel to ensure personal protection against noise.
89200005 2-3 Safety Precautions

SAFETY AND OPERATING REFERENCES
1. Code of Federal Regulations (OSHA) Section 29, Part 1910.95, 132, 133, 134, 139, 251,
252, 253, 254 and 1000. U.S. Government Printing Office, Washington, DC 20402.
2. ANSI Z49.1 “Safety in Welding and Cutting”.
3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection”.
4. ANSI Z88.2. “Standard Practice for Respiratory Protection”. American National
Standards Institute, 1430 Broadway, New York, NY 10018.
5. AWS F4.1. “Recommended Safe Practices for Welding and Cutting Containers”.
6. AWS C5.3. “Recommended Practices for Air Carbon-Arc Gouging and Cutting”.
The American Welding Society, 550 NW Lejeune Rd., P.O. Box 351040, Miami, FL
33135.
7. NFPA 51B. “Fire Prevention in Cutting and Welding Processes”.
8. NFPA-7. “National Electrical Code”. National Fire Protection Association, Battery Park,
Quincy, MA 02269.
9. CSA W117.2. “Safety in Welding, Cutting and Allied Processes”. Canadian Standards
Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3.
Safety Precautions 2-4 89200005

Section 3:
MIG Gun SPECIFICATIONS
3.01 MIG Gun Classification
Process MIG/MAG welding
Voltage Class for Welding and Control Circuits L (up to 113 V peak)
Type of Cooling Water
MIG Gun Model Duty Cycle (AMP)

(AMP) 10% 35% 60% 100%
350 440 420 400 380
400 470 440 420 400
600 700 660 630 600
The above duty cycles were established by testing under the following parameters:
Parameter MIG MAG
Electrode Aluminum 3% to 5% Magnesium Mild (low carbon) Steel
Type of Voltage D.C. D.C.
Shielding Gas Argon Argon/CO2 Mixed Gas (80/20, 75/25)
Gas Flow Rate 30 CFH / 14.2 l/m 30 CFH / 14.2 l/m
Weld Material AIMg3 to AIMg5 Mild (low carbon) Steel
Gun Cable
10 ft./3 m 15 ft./5 m
Length
Electrode size
350 amp = .045"/1,2 mm
400 amp = 1/16"/1,6 mm
600 amp = 1/16"/1,6 mm
89200005 3-5 MIG Gun Specifications

3.02 MIG Gun Part Number Identification
Note
Tweco Robotics MIG guns, as a general rule, have a specific nomenclature
®
incorporated within each part number to help determine the wire size of each
MIG gun.
Example Part Number:
400 amp gun, 4 foot cable
WRS4043545
Water-Cooled, .035-.045" Wire Capacity
Robotics Series
Water-Cooled Robotic Series 400 AMP Guns

Part No. Stock No.
WRS400-3545 3044-1320
WRS404-3545 3044-1322
WRS406-3545 3044-1323
WRS408-3545 3044-1324
WRS410-3545 3044-1325
WRS412-3545 3044-1326
WRS415-3545 3044-1327
Water-Cooled Robotic Series 600 AMP Guns
Part No. Stock No.
WRS600-116 3064-1725
WRS604-116 3064-1366
WRS606-116 3064-1367
WRS608-116 3064-1368
WRS610-116 3064-1369
WRS612-116 3064-1370
WRS615-116 3064-1371
MIG Gun Specifications 3-6 89200005

Section 4:
MIG gun Installation
Note
Be certain that the end user (welder, operator, or helper) reads and understands
these instructions. The welder must also read Section 2, “Safety Precautions”.
WARNING
ELECTRICAL SHOCK MAY KILL.
4.01 Standard MIG Gun Installation

WIRE FEEDER
GUN
POWER
SOURCE
WORK PIECE
GROUND
Figure 1: Standard MIG Gun Installation
4.02 Direct Plug

Direct Plug MIG guns install by directly inserting the Tweco rear connector plug into the feeder
wire guide outlet and tightening the plug retaining screw. Automated MIG guns differ from
other MIG guns in that they do not have the control wire for trigger control. Rear connectors
are available for Lincoln, Miller, and Panasonic, in addition to adapter kits.
89200005 4-7 MIG Gun Installation

4.03 Conductor Tube Installation
1. First, remove the nozzle, tip and diffuser from the used conductor tube.
2. Next, remove case cap. Loosen swivel nut with wrench, then pull the conductor tube
from the block and case.
3. Insert new conductor tube by aligning keyway on the tube with the guide pin inside
the block.
4. Tighten the swivel nut on the tube with a wrench, then replace case cap over the
nut.
5. Replace other front-end consumables.
NOTE
The conduit may need to be pulled out of the conductor tube area if the tube is
of a different size. Reference 6.02 for removal of conduit.
Conductor Tube Robot Torch Case Screw
Assembly
Contact Tip
Nozzle
Spatter Shield Robot Block

Assembly
Figure 2: Changing a Conductor Tube
MIG Gun Installation 4-8 89200005

Section 5:
cONTACT TIPS
5.01 Identification
Identify contact tips by markings on the side of the tip, for example 14H-45 (1,2 mm).
Figure 3: Contact Tip
5.02 Replacement
The procedure for removal and installation of a contact tip is similar for all Tweco® Robotic
MIG Guns.
NOTE
Replace contact tip if hole is enlarged or deformed.
1. Select the correct contact tip according to the wire used.
2. Remove the nozzle from the gun to reveal the contact tip.
3. Remove the contact tip using pliers. Replace contact tip and tighten securely.
89200005 5-9 Contact Tips

Section 6:
WIRE CONDUIT
6.01 Identification
Conduits may be identified by the markings on the conduit stop.
Example Part Number:
Wire Capacity
R44-3545-8
Robotic, 44 Series Liner length in feet
6.02 Removal
The procedure for removal and installation of a wire conduit is similar for all Tweco® Robotic
MIG Guns.
NOTE
Replace kinked liner or if the hole is dirty or worn. Make sure the end of the
liner is smooth.
1. Lay the MIG Gun out on a table or floor in a straight line. Fully extend the gun and remove
all twists in the cable.
2. Remove the nozzle and the gas diffuser, then loosen the conduit set screw in the handle
of the gun. Then, loosen the conduit set screw in the rear connector plug.
TWECO PLUG
CONDUIT ASSEMBLY
SET SCREW
Figure 4: Conduit
Wire Conduit 6-10 89200005

6.03 Installation
1. Uncoil the conduit and lay it in a straight line. Remove any burrs or edges on the liner.
Insert the conduit into the rear connector plug. Push the conduit into the gun with short
strokes without kinking (bending) the liner. If the conduit hangs up, twist the conduit
counterclockwise or gently whip the cable while applying pressure to the conduit.
2. When the conduit is completely in the gun, tighten the rear conduit set screw.
3. Trim the conduit extending from the conductor tube to 1/2"(12,6 mm).
4. File the trimmed conduit end to remove burrs that could interfere with wire feeding or
catch on the diffuser.
5. Replace the diffuser and contact tip. Tighten securely, then replace the nozzle.
6. The MIG gun is now ready to be reinstalled on the feeder.
6.04 Bronze Jump Liner

Part No. AWC44-116 (Stock No. 1644-1085)
Using a jump liner improves arc starts and provides an improved current transfer between the
contact tip and aluminum wire. The jump liner can be used for wear issues found inside the
conductor tube area caused by the liner when using stainless steel wires.
6.05 Connecting Water Line to Tweco Watercooler

1. Attach the rear blue coolant inlet hose on the MIG gun to the pump connection labeled
“WATER OUT”.
2. Attach the rear red coolant outlet hose on the MIG gun to the sight glass connection
labeled “WATER IN”.
3. Use a minimum water supply of 3/4 gallons/minute (2.84 liters/minute) during
operation. If possible, install the water supply to run when the power source is turned
“on” to avoid damage to torch and/or cable assembly.
caution
Operating a water-cooled torch and cable assembly without water or with restricted
flow will result in damage to the cable assembly.
note
Do not exceed coolant temperature of 155ºF (60ºF).
4. Incorporating a flow switch on water-cooled assemblies is recommended to avoid
catastrophic failure and production loss. For best results, place the flow switch in
line with the water-cooled gun outlet hose. The circuit functions as an emergency
stop, normally-closed circuit. When water flows at .25 gallons/minute or more, the
circuit is closed.
89200005 6-11 Wire Conduit

Section 7:
Troubleshooting
Contact tips and nozzles should be cleaned frequently. Spatter buildup may cause bridging
between the nozzle and tip. This could cause electrical shorting between the nozzle and
workpiece as well as poor or improper gas flow.
Regularly inspect the conductor tube, handle, cablehose, and other parts of the MIG gun for
abrasion, cuts, or undue wear. Replace or repair any parts found deficient.
Problem Possible Cause Corrective Action
1. Loose contact tip or diffuser. 1. Tighten contact tip and diffuser
plier-tight.
2. Excessively worn contact tip. 2. Replace contact tip.
3. Spatter buildup on end of 3. Clean or replace contact tip.
contact tip.
Wire feed 4. Sharp bends or kinks in 4. Straighten or replace conduit.
inconsistent or not conduit.
smooth 5. Dirty or plugged conduit. 5. Replace conduit.
6. Conduit pulled back from 6. Reposition conduit and tighten
diffuser. front set screw.
7. Machine improperly adjusted. 7. Reset machine as per machine
and wire manufacturer’s
recommendations.
1. Loose contact tip or diffuser. 1. Tighten contact tip and diffuser
plier-tight.
2. Loose power connections. 2. Inspect complete gun for loose
connections and repair.
MIG gun running
hot. 3. Loose or undersized ground 3. Tighten or replace as required.
cable or ground clamp.
4. Operating gun above 4. Readjust machine to correct
recommended amperage setting for size of gun being
rating. used.
1. Poor or improper gas flow. 1. Check gas flow out of gun
nozzle. Check for leaks or
restrictions in gas hoses and
Porous weld connections.
2. Dirty or contaminated wire. 2. Change wire.
3. Base metal contaminated. 3. Replace base metal.
Troubleshooting 7-12 89200005

THIS PAGE LEFT BLANK INTENTIONALLY
89200005 7-13 Troubleshooting

Section 8:
REPLACEMENT PARTS
8.01 MIG Gun Parts Listing
WRS400 and 600 SERIES WITH CABLE ASSEMBLY
13
12
12
16
10
14
9
16
8
7
6
11
5
15
4
3
2
17
16
1
10
18
Replacement Parts 8-14 89200005

Item No. Part No. Stock No. Description
1 -- -- Nozzle Assembly
WC24-1 1244-1009 Spatter Shield 400 AMP
2
3 -- -- Contact Tip
4 -- -- Diffuser
WC34-R 2044-1034 Pressure Ring 400 AMP
5
NS* 224S 2064-2059 O-Ring 400 and 600 AMP
WCS34-H 1344-1844 400 AMP
6
WCS36-H 1344-1145 Sealed Conductor Tube Housing 500 AMP
7 -- -- Conductor Tube Assembly
NS 224S 2064-2059 O-Ring 400 and 600 AMP
8 WR6H 2066-2006 Conductor Tube Nut Cover
9 WR66-N 2066-2066 Conductor Tube Nut
10 WR6H 2066-2600 Case With Strain Relief Cap
11 WR106 2066-2106 Torch Block Assembly
12 WC146-6 2064-2146 Strain Relief (Front)
WC600-4 1764-2107 Cable Assembly With Fittings 4ft. (1,22m)
13
WC600-10 1764-2101 Cable Assembly With Fittings 10ft. (3m)
WC604-WH 1764-2137 Water Inlet Hose 4ft. (1,22m)
NS
WC610-WH 1764-2131 Water Inlet Hose 10ft. (3m)
WC604-PC 1764-2117 Power Cable Assembly 4ft. (1,22m)
NS
WC610-PC 1764-2111 Power Cable Assembly 10ft. (3m)
WC604-GH 1764-2127 Gas Hose Assembly 4ft. (1,22m)
NS
WC610-GH 1764-2121 Gas Hose Assembly 10ft. (3m)
NS 400LK-J 2044-2100 Outer Jacket - Sold Per Ft.
14 WC603-WH 1764-2130 Outer Water Hose 3ft. (900mm)
15 WC6-170H 2064-2171 Rear Connector Block Assembly
89200005 8-15 Replacement Parts

45B 2050-2045 O-Ring - Front & Rear Block - Power Cable
NS 46B 2062-2046 O-Ring - Front & Rear Block - Gas Hose
35-40-1 2000-2040 O-Ring - Front & Rear Block - Water Hose
16 WR6C 2064-2006 Rear Case Assembly
350-174H 2035-2110 Connector Plug Assembly 400amp - Tweco®
176SH 2066-2177 Connector Plug Assembly 600amp - Tweco
350-174PH 2035-2172 Panasonic® Connector Plug
(Uses R44 series Conduit)
R176MH 2060-2184 Miller® Connector Plug
(Includes Items #14 & #15)
R174MH 2035-2109 Miller Connector Plug (Includes Items #14 & #15)
17 R175M-N045 2050-2181 Miller Plug Nipple, .045" (1,0mm) Wire
(Use w/R176MH)
R174M-N045 2040-2192 Miller Plug Nipple, .045" (1,0mm) Wire
(Use w/R174MH)
R175M-N116 2050-2182 Miller Plug Nipple, .062" (1,6mm) WIre
(Use w/R176MH)
(Use w/R174MH)
18 -- -- Conduit
* Not Shown
WRS400 AND 600 DIRECT PLUG REPLACEMENT PARTS
1 6 8 9
2 3 4 5 7
Twe co WC 24-62
14
13
12
10 11
15 16

1 -- -- Nozzle Assembly
2
3 -- -- Contact Tip
4 -- -- Diffuser
5
NS* 224S 2064-2059 O-Ring 400 and 600 AMP
6
7 -- -- Conductor Tube Assembly
NS 224S 2064-2059 O-Ring 400 and 600 AMP
8 WR6H 2066-2006 Conductor Tube Nut Cover
9 WR66-N 2066-2066 Conductor Tube Nut
10 WR600-H 2066-2601 Case
11 WR600-106 2066-2107 Torch Block Assembly - 400 & 600 AMP
12 QTRW600-N 3044-1039 Water Hose Nipple
13 60957 60957 Water Hose – sold per ft.
14 WC35-5 1764-2140 Water Hose Fitting
176S-H 2060-2177 Tweco® Connector Plug
350-174H 2035-2110 Tweco Connector Plug (Uses R44 series Conduit)
QTR176LH 2086-2624 Lincoln® Connector Plug (2.71" – 68,83mm OAL.)
EL176LH 2060-2680 Lincoln Connector Plug (3.84" – 97,54mm OAL)
QTR174LH 2086-2623 Lincoln Connector Plug (Uses R44 series Conduit)
350-174PH 2035-2172 Panasonic® Connector Plug
(Uses R44 series Conduit )
R176MH 2060-2184 Miller® Connector Plug
15 R174MH 2035-2109 Miller Connector Plug
(Use w/R176MH)
(Use w/R174MH)
(Use w/R176MH)
(Use w/R174MH)
16 -- -- Conduit
* Not Shown

8.02 Consumable Parts Listing
CONTACT TIPS
Wire Size Tip I.D. 400 AMP 600 AMP
in(mm) in(mm) Part No. Stock No. Part No. Stock No.
.035(0,9) .044(1,12) 14H-35 1140-1202 16S-35 1160-1102
.040(1,0) .048(1,22) 14H-40 1140-1203 16S-40 1160-1103
.045(1,2) .054(1,37) 14H-45 1140-1204 16S-45 1160-1104
.052(1,3) .064(1,65) 14H-52 1140-1205 16S-52 1160-1105
1/16(1,6) .073(1,85) 14H-116 1140-1206 16S-116 1160-1106
5/64(2,0) .090(2,29) 14H-564 1140-1209 16S-564 1160-1109
3/32(2,4) .106(2,67) 16S-332 1160-1110
7/64(2,8) .120(3,05) N/A 16S-764 1160-1111
1/8(3,2) .144(3,66) 16S-18 1160-1112
3/64AL(1,2) .059(1,50) 14AH-364 1140-1213 16AS-364 1160-1113
1/16AL(1,6) .082(1,85) 14AH-116 1140-1214 16AS-116 1160-1114
NOZZLES
400 AMP
Bore Size
Part No. Stock No. Description
in(mm)
WC24-50 1244-1110 5/32" Tip Recess
1/2(12,7)
WC24-50-F 1244-1112 Tip Flush
WC24-62 1244-1120 5/32" Tip Recess
5/8(15,9)
WC24-62-F 1244-1122 Tip Flush
WC24-75 1244-1130 5/32" Tip Recess
3/4(19,1)
WC24-1 1244-1009 Spatter Shield Only
600 AMP
Bore Size
Part No. Stock No. Description
in(mm)
WC26-62-R 1264-1123 3/8" Tip Recess
5/8(15,9)
WC26-62-F 1264-1122 Tip Flush
3/4(19,1)
WC26-1 1264-1009 Spatter Shield Only

DIFFUSER
MIG Gun Part No. Stock No. Conduit
400 WC54A 1544-1141 44 series conduits .030" to 5/34"
WC56A-SW 1564-1145 45 series conduits 5/64" hard wire & 1/16" AL
600 WC56A 1564-1143 wire conduits
WC56A-H 1564-1144
45 series conduits 3/32" to 1/8"
Note
600 AMP MIG gun and Cable Assemblies are furnished with WC56A-SW
Diffuser.
CONDUIT
400 AMP 600 AMP

Wire Size
Part No. Stock No. Part No. Stock No.
R44-3545-1 1440-1223 R45-3545-1 1450-1027
.035" / .045" R44-3545-4 1440-1224 R45-3545-4 1450-1024
0,9mm / 1,2mm R44-3545-8 1440-1225 R45-3545-8 1450-1025
R44-3545-15 1440-1226 R45-3545-15 1450-1026
R44-116-1 1440-1228 R45-116-1 1450-1028
.052" / 1/16" R44-116-4 1440-1229 R45-116-4 1450-1029
1,53mm / 1,6mm R44-116-8 1440-1230 R45-116-8 1450-1030
R44-116-15 1440-1231 R45-116-15 1450-1031
R44WN-3545-4 1440-1040 R45WN-3545-4 1450-1041
.035" / .045" AL
0,9mm / 1,2mm R44WN-3545-8 1440-1041 R45WN-3545-8 1450-1042
R44WN-3545-15 1440-1042 R45WN-3545-15 1450-1043
1/16" AL R44WN-116-8 1440-1046 R45WN-116-8 1450-1044
1,6mm R44WN-116-15 1440-1047 R45WN-116-15 1450-1044
“WN” = Wire Nylon Wrapped
CONDUCTOR TUBE
400 AMP 600 AMP
Degree/Angle
Part No. Stock No. Part No. Stock No.
22° WRS64-22 1646-1604 WRS66-22 1663-1610
45° WRS64-45 1646-1605 WRS66-45 1663-1612
60° WRS64-60 1646-1606 WRS66-60 1663-1614
180° WRS64-180 1646-1607 WRS66-180 1663-1617
22°L WRS64-22L 1646-1625 N/A
45°L WRS64-45L 1646-1626 WRS66-45L 1663-1613
180°L WRS64-180L 1646-1635 WRS66-180L 1663-1618
“L”=Long Conductor Tube
Section 9:
Statement of Warranty
LIMITED WARRANTY: THERMADYNE® warrants that its products will be free of defects
in workmanship or material. Should any failure to conform to this warranty appear within
the time period applicable to the THERMADYNE products as stated below, THERMADYNE
shall, upon notification thereof and substantiation that the product has been stored, installed,
operated, and maintained in accordance with THERMADYNE’s specifications, instructions,
recommendations and recognized standard industry practice, and not subject to misuse,
repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement,
at THERMADYNE’s sole option, of any components or parts of the product determined by
THERMADYNE to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: THERMADYNE shall not under any circumstances be liable for
special or consequential damages, such as, but not limited to, damage or loss of purchased or
replacement goods, or claims of customers of distributor (hereinafter the “Purchaser”) for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of
THERMADYNE with respect to any contract, or anything done in connection therewith such as
the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any
goods covered by or furnished by THERMADYNE whether arising out of contract, negligence,
strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein,
exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR
ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE
OF ANY THERMADYNE PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED
PERSONS.
This warranty is effective for the time stated in the Warranty Schedule beginning on the date
that the authorized distributor delivers the products to the Purchaser.
Warranty repairs or replacement claims under this limited warranty must be submitted by an
authorized THERMADYNE repair facility within thirty (30) days of the repair. No transportation
costs of any kind will be paid under this warranty. Transportation charges to send products to
an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned
goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous
THERMADYNE warranties.
Statement of Warranty 9-20 89200005

Warranty SCHEDULE
The warranty is effective below for the time stated in the Warranty Schedule beginning on the date that the authorized distributor delivers
the products to the purchaser. THERMADYNE® reserves the right to request documented evidence of date of purchase.
Engine Driven Welders Parts / Labor

Scout®, raider®, Explorer™
Original Main Power Stators and Inductors 3 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year
Engines and Associated Components are NOT Warranted by Thermal Arc®, Although Most are Warranted by the Engine Manufacturer. SEE THE ENGINE See the Engine Manufacturers’ Warranty
MANUFACTURERS’ WARRANTY FOR DETAILS. for Details
GMaW/FCaW (MIG) Welding Equipment Parts / Labor
Fabricator® 131, 181, 190, 210, 251, 281; Fabstar® 4030; PowerMaster® 350, 350P, 500, 500P; Excel-arc® 6045; Wire Feeders: Ultrafeed®, Porta-feed®
Original Main Power Transformer and Inductor 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors 1 year / 1 year
GtaW (tIG) & Multi-process Inverter Welding Equipment Parts / Labor
160tS, 300tS, 400tS, 185aC/DC, 200aC/DC, 300aC/DC, 400GtSW, 400MSt, 300MSt, 400MStP
Original Main Power Magnetics 5 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors 1 year / 1 year
Plasma Welding Equipment Parts / Labor
Ultima® 150
Welding Console, Weld Controller, Weld Timer 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors, Coolant Recirculators 1 year / 1 year
SMaW (Stick) Welding Equipment Parts / Labor
Dragster™ 85
Original Main Power Magnetics 1 year / 1 year
Original Main Power Rectifiers, Control P.C. Boards 1 year / 1 year
160S, 300S, 400S
Original Main Power Rectifiers, Control P.C. Boards 3 years / 3 years
General arc Equipment Parts / Labor
Water Recirculators 1 year / 1 year
Plasma Welding Torches 180 days / 180 days
Gas Regulators (Supplied with Power Sources) 180 days / NA
MIG and TIG Torches (Supplied with Power Sources) 90 days / NA
Replacement Repair Parts 90 days / NA
MIG, TIG and Plasma Welding Torch Consumable Items NA / NA
Gas Welding and Cutting Equipment Parts / Labor
Victor® Professional 5 years / NA
Oxygen Conservers 2 years / NA
Aluminum Cylinders Lifetime / NA
Cutting Machine Motors 1 year / NA
HP&I Brass Regulators/Manifolds 2 years / NA
HP&I Stainless Regulators/Manifolds 1 year / NA
HP&I Corrosive Gas Regulators/Manifolds 90 days / NA
TurboTorch® 3 years / NA
CutSkill® 2 years / NA
Steel Cylinders 1 year / NA
Victor Medical 6 years / NA
Victor VSP 2 years / NA
Firepower® MIG Welders 5-2-1 years / NA
Transformers 5 years / NA
1 year from date sold by seller to authorized
Parts Used in Rental Applications
distributor
MIG torches and arc accessories Parts / Labor
Arcair® N6000 90 days / NA
Eliminator® Spool and Pull Guns 90 days / NA
Robotic Deflection Mounts 90 days / NA
QRM-100 Anti-Spatter Applicator 90 days / NA
TC and TCV Water Coolers 1 year / NA
TSC-96 Smoke Collector 1 year / NA
ESG-1, EPG-CR1, EPG-CR2 Control Boxes for Eliminator Spool & Pull Guns 1 year / NA
QRC-2000 Nozzle Cleaning Stations 1 year / 1 year
QRC-3000 UltraSonic Cleaning Stations 2 years / 2 years
All other products 30 days from date purchaser purchases from seller. 30 days / NA
Plasma Cutting Systems Parts / Labor
Automated Plasma 2 years / 1 year
CutMaster™ 3 years / 3 years
PakMaster® XL PLUS 3 years / 1 year
Drag-Gun® 1 year / 1 year
Drag-Gun Plus 2 years / 1 year
Torches 1 year / 1 year
Consoles, Control Equipment, Heat Exchangers and Accessory Equipment 1 year / 1 year
89200005 9-21 Statement of Warranty

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WATER-COOLED

SAFETY and Operating

YOU ARE IN GOOD COMPANY!

Water-Cooled Automation MIG Guns

U.S. Customer Care: (800) 426-1888

Copyright © 2008 Thermadyne Industries, Inc. All rights reserved.

Publication Date: November 3, 2008

Record the following information for Warranty purposes:

Section 1: Introduction................................................................................... 1-1

1.02 Receipt of Equipment

89200005 1-1 Introduction

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH

Safety Precautions 2-2 89200005

89200005 2-3 Safety Precautions

Safety Precautions 2-4 89200005

MIG Gun Model Duty Cycle (AMP)

89200005 3-5 MIG Gun Specifications

Water-Cooled Robotic Series 400 AMP Guns

MIG Gun Specifications 3-6 89200005

4.01 Standard MIG Gun Installation

4.02 Direct Plug

89200005 4-7 MIG Gun Installation

Spatter Shield Robot Block

Figure 2: Changing a Conductor Tube

MIG Gun Installation 4-8 89200005

Figure 3: Contact Tip

89200005 5-9 Contact Tips

Wire Conduit 6-10 89200005

6.04 Bronze Jump Liner

6.05 Connecting Water Line to Tweco Watercooler

89200005 6-11 Wire Conduit

Troubleshooting 7-12 89200005

THIS PAGE LEFT BLANK INTENTIONALLY

89200005 7-13 Troubleshooting

Replacement Parts 8-14 89200005

89200005 8-15 Replacement Parts

Replacement Parts 8-16 89200005

89200005 8-17 Replacement Parts

Replacement Parts 8-18 89200005

400 AMP 600 AMP

Statement of Warranty 9-20 89200005

Engine Driven Welders Parts / Labor

89200005 9-21 Statement of Warranty

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