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Contents

 

INTRODUCTION ................................................................................................................................................ 2

 

WARRANTY ....................................................................................................................................................... 2

 

ROHS COMPLIANT ........................................................................................................................................... 3

 

EU DIRECTIVE ................................................................................................................................................... 4

 

SAFETY PRECAUTIONS – READ BEFORE USING ...................................................................................... 5

 

FEATURES ........................................................................................................................................................ 10

 

TORCH SPECIFICATIONS .............................................................................................................................. 10

 

INSTALLATION ............................................................................................................................................... 10

 

EURO CONNECTION (USING FEEDER ADAPTOR KIT) ....................................................................... 11

 

DIRECT CONNECT ...................................................................................................................................... 11

 

DAILY MAINTENANCE .................................................................................................................................. 11

 

MAINTENANCE ............................................................................................................................................... 12

 

LINER REPLACEMENT ............................................................................................................................... 12

 

GOOSENECK REPLACEMENT .................................................................................................................. 12

 

TRIGGER SWITCH REPLACEMENT ......................................................................................................... 13

 

POWER CABLE REPLACEMENT .............................................................................................................. 14

 

NOZZLE/TIP RELATIONSHIPS ...................................................................................................................... 15

 

NOZZLE SELECTION CHART ........................................................................................................................ 16

 

300 SERIES NOZZLES ................................................................................................................................. 16

 

400 SERIES NOZZLES ................................................................................................................................. 16

 

CONTACT TIP SELECTION CHART ............................................................................................................. 17

 

M6 CONTACT TIPS ...................................................................................................................................... 17

 

M8 CONTACT TIPS ...................................................................................................................................... 17

 

LINER SELECTION CHART ........................................................................................................................... 18

 

PARTS BREAKDOWN – 238, 347, 407 ........................................................................................................... 19

 

 
 
 
 
 
 
 
 
 
 

Summary of Contents for 238CA

Page 1: ...INSTALLATION OPERATIONS AND REPLACEMENT PARTS MANUAL A Ai ir r C Co oo ol le ed d S Se em mi i A Au ut to om ma at ti ic c M MI IG G T To or rc ch he es s For Models 238CA 347CA PG 354CA PG 407CA PG ...

Page 2: ...ER ADAPTOR KIT 11 DIRECT CONNECT 11 DAILY MAINTENANCE 11 MAINTENANCE 12 LINER REPLACEMENT 12 GOOSENECK REPLACEMENT 12 TRIGGER SWITCH REPLACEMENT 13 POWER CABLE REPLACEMENT 14 NOZZLE TIP RELATIONSHIPS 15 NOZZLE SELECTION CHART 16 300 SERIES NOZZLES 16 400 SERIES NOZZLES 16 CONTACT TIP SELECTION CHART 17 M6 CONTACT TIPS 17 M8 CONTACT TIPS 17 LINER SELECTION CHART 18 PARTS BREAKDOWN 238 347 407 19 ...

Page 3: ...ranty does not cover damage caused by misuse or abuse accident alteration of product improper installation misapplication lack of reasonable care and maintenance unauthorized repairs or modifications loss of use while at a repair facility or other conditions that are beyond the control of American Weldquip A Return Merchandise Authorization Number RMA must be attained from the factory for any prod...

Page 4: ...et the directive in the United States currently American Weldquip Inc feels this is an important part of our Go Green initiative We have taken all reasonable steps to try to ensure the supporting evidence regarding the absence of the restricted substances to support RoHS compliance For reference the maximum concentration values of the restricted substances by weight in homogenous materials are Lea...

Page 5: ...l and electronic equipment RoHS Harmonization Standard Used IEC 60974 7 2013 Arc welding equipment Part 7 Torches 260 Amp Mig Torch 238CAXX 300 Amp Mig Torch 347CAXX 350 Amp Mig Torch 354CAXX 400 Amp Mig Torch 407CAXX 400 Amp Mig Torch 456CGXX 500 Amp Mig Torch 500CGXX 500 Amp Mig Torch 507CGXX 347 Amp Mig Torch 347PGXX 407 Amp Mig Torch 407PGXX For EU Declaration of Conformity letter for this pro...

Page 6: ...sure to EMF fields in welding may have other unknown health effects Welders should use the below procedures to minimize the exposure to EMF fields from the welding circuit Route the cables close together Secure by twisting taping or using a cable cover to keep together Never coil wrap or drape welding cables around your body Do not place your body between welding cables Arrange so that cables are ...

Page 7: ...roperly grounded equipment is a hazard Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Additional safety precautions are required when any of the following electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds...

Page 8: ...the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 I standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot...

Page 9: ...tting area as practical to prevent welding or cutting current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes Remove any combustibles such as a butane lighter or matches from your person before doing any welding or cutting Inspect area to ensure it is free of sparks glowing embers and flames after work is complete...

Page 10: ...s Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS or website www csa international org Nation Electric Code NFPA Standard 70 available from National Fire Protection Association Quincy MA 02269 or website www nfpa org Safe Practices for Occupational and Educational Eye and Face Protection ANSI Standard Z87 1 available from the American National Standards Institute 25 West 43rd Street New Y...

Page 11: ...being over bent prolonging its lifetime while preventing feed issues Additional Options Flex necks heat shield thermal spring and torch hangers are available across all torch designs Adaptation Adaptable to most wire feeders with quick change control cable Location Manufactured in Sharon Center Ohio allowing for quick turnaround TORCH SPECIFICATIONS MODEL RATED AMPERAGE 60 Duty Cycle 100 Duty Cycl...

Page 12: ...ion plug at the rear of the torch gas connection feeder control cable 1 Fully insert the torch Direct Connection into wire feeder Tighten screw or other method on wire feeder to secure torch 2 Connect the gas hose if required a Lincoln Universal connect PtoC to power pin then hose from PtoC to feeder b OTC Daihen Lincoln and Panasonic connect to feeder with attached hose 3 Connect feeder control c...

Page 13: ... nut remove and set aside 5 Making sure the torch cable is straight grasp the liner at the rear of the torch with a pair of pliers and remove 6 Carefully feed the new liner into the torch using short strokes to avoid kinking You may need to twist the liner for easier insertion 7 Tighten the set screw or retaining nut to secure the liner in the torch 8 Reinstall the torch to the wire feed unit 9 IM...

Page 14: ...ffuser contact tip and nozzle TRIGGER SWITCH REPLACEMENT CA SERIES TORCHES The Trigger Switch Assembly 75000004 contains 1 Trigger Paddle 2 Springs 4 Screws 1 Shoulder Screw 2 Copper Outer Contact Plates 1 Copper Contact Plate 1 Secure Gooseneck in a vice 2 Remove the four handle screws and separate the handle assembly 3 Remove the 4 screws securing the copper contact assemblies and remove the tri...

Page 15: ...all the six 6 handle screws and tighten POWER CABLE REPLACEMENT 1 Secure Gooseneck in a vice 2 Remove the liner from the torch see liner replacement 3 Unscrew the spring from the gooseneck and slide back on cable 4 Remove the four handle screws and separate the handle assembly 5 Using a 5 8 wrench loosen the gooseneck cable connection and remove gooseneck from the cable assembly 6 Remove the sprin...

Page 16: ...s may be required if the tip relationship is changed to achieve other objectives Extended Tip Short Circuit Short Arc Dip Transfer Welding Applications The tip stick out is usually 1 8 or 1 4 from the nozzle Keep in mind that the further the stick out the more susceptible to gas porosity issues Typically this used in short circuit lower amperage applications and or where you may need to reach into...

Page 17: ...LLED 75145001 BOTTLE NOSE 1 2 12 7mm NI PLATED BRASS 3 031 77 0mm 75001733 75146202 CONICAL 5 8 15 9mm NI PLATED BRASS 3 125 79 4mm 75001738 75146202C CONICAL 5 8 15 9mm NI PLATED COPPER 3 125 79 4mm 75001738 75146202CU CONICAL 5 8 15 9mm BARE COPPER 3 125 79 4mm 75001738 75145601 I TAPERED 9 16 14 2mm NI PLATED BRASS 3 125 79 4mm INSTALLED 75145002C TAPERED 1 2 12 7mm NI BARE COPPER 3 125 79 4mm ...

Page 18: ... NI PLATED BRASS 2 820 71 6mm 75001733 75144302 I TAPERED 7 16 11 1mm NI PLATED BRASS 3 125 79 4mm INSTALLED CONTACT TIP SELECTION CHART M6 CONTACT TIPS Part Number Wire Size Nominal I D Copper CU 75023511 0 023 6mm 0 034 75030511 0 030 8mm 0 038 75035511 0 035 9mm 0 044 75040511 0 040 1 0mm 0 048 75045511 0 045 1 2mm 0 054 M8 CONTACT TIPS Part Number Wire Size Nominal I D Copper CU 75030014 0 030...

Page 19: ...215T 023 030 LINER 15FT T STYLE 75001222T 035 045 LINER 1FT T STYLE 75005222T 035 045 LINER 5FT T STYLE 75010222T 035 045 LINER 10FT T STYLE 75015222T 035 045 LINER 15FT T STYLE 75025222T 035 045 LINER 25FT T STYLE 75001228T 045 1 16 LINER 1FT T STYLE 75005228T 045 1 16 LINER 5FT T STYLE 75010228T 045 1 16 LINER 10FT T STYLE 75015228T 045 1 16 LINER 15FT T STYLE 75025228T 045 1 16 LINER 25FT T STY...

Page 20: ...19 PARTS BREAKDOWN 238 347 407 ...

Page 21: ...000003 75000003 75000003 75000003 75000003 HANDLE ASSEMBLY PISTOL GRIP N A 75000003P 75000003P 75000003P N A HANDLE ASSEMBLY EXT TRIGGER 75000003 ET 75000003 ET 75000003 ET 75000003 ET 75000003 ET HANDLE TOP STD 75000006 75000006 75000006 75000006 75000006 HANDLE TOP DUAL SCHEDULE N A 75000006 SW 75000006 SW 75000006 SW 75000006 SW HANDLE BOTTOM STD 75000007 75000007 75000007 75000007 75000007 HAN...

Page 22: ...LE LINCOLN 37777505 37777505 37777505 37777505 37777505 CONTROL CABLE OTC 37777503 37777503 37777503 37777503 37777503 CONTROL CABLE PANASONIC 37777504 37777504 37777504 37777504 37777504 CONTROL CABLE TWECO 37777500 37777500 37777500 37777500 37777500 22 CABLE CONNECTOR 38000001 38000001 38000001 38000001 38000001 23 TRIGGER SWITCH ASSY STD 75000004 75000004 75000004 75000004 75000004 NS TRIGGER ...

Page 23: ...22 AMERICAN WELDQUIP 1375 Wolf Creek Trail P O Box 397 Sharon Center Ohio 44274 Telephone 330 239 0317 Fax 800 949 9353 www weldquip com www youtube com weldquip1 OM001 05 22 ...

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