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LIGHTNING

®

941-753-7557  •  FAX:941-753-6917  •  800 342-8477  •  [email protected]  •  www.AmericanTorchTip.com

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PART NUMBERING SYSTEM

Wire Size

30

 .030” 

35

 .035”

10

 

1.0 mm

45

 .045”

52

 .052”

116

 1/16”

332

 3/32”

364

 

3/64” al

564

 5/64”

Gooseneck (opt)

500

 180º

522

 22º

545

 45º 

560

 60º 

Cable Length

03

 

 3    feet 

3.5

 

 3.5 feet 

04

 

 4    feet

06

 

 6    feet

08

 

 8    feet

10

 

10   feet

12

 

12   feet

15

 

15   feet

LIGHTNING HANDLE

L

     Lightning

L   E    53   04

 - 

45

 - 

560  

Gun Model

53

    500 amp

Power Pin

T

  

Tweco

E

  

Euro

LN

   Lincoln

M

 Miller

100% Duty Cycle

60% Duty Cycle

Co2

Mixed Gas

Co2

Mixed Gas

500 amps

350 amps

650 amps

500 amps

Amperage Ratings (duty cycle)

Reliable Automatic Welding Equipment

The Lightning

®

 AUTO MIG gun is made to stand up to the high heat conditions typical in the 

production environment. Lightning

®

 precision consumables are designed to reduce change-out 

related downtime. All gun components and consumables are made in the USA.

High Strength Cable

The outer cover is strengthened using electron beam accelerators which cross-link the polymers 
and increase the tear, stretch and abrasion resistance of the cable. Hytrel inner tubing is kink and 
impact resistant for smooth and reliable wire feed. The copper strand count of our premium cable 
assures long life and maximum productivity.

Lightning

®

 Contact Tips

Tapered seat designed to dissipate heat and maximize electrical conductivity. 
Our dual start-point thread allows re-seating of the tip. When wire wear begins to effect 
performance, simply rotate the tip 180º to a new wear-point and double the life of the contact tip.

Heavy Duty Handle

Lifetime Warranty on gun body.
Fiber reinforced resin stands up to extreme heat and impact.
Slim compact design.

Summary of Contents for LE5304-45-560

Page 1: ...Fixed Automation MIG Gun Technical Guide MIG Technical Guide...

Page 2: ...on environment Lightning precision consumables are designed to reduce change out related downtime All gun components and consumables are made in the USA High Strength Cable The outer cover is strength...

Page 3: ...093 65 1193 Extra HD 3 32 110 65 11120 Extra HD 7 64 120 65 11125 Extra HD 1 8 136 65 1235 Extra HD 035 tprd 043 65 1245 Extra HD 045 tprd 055 65 1252 Extra HD 052 tprd 063 65 1335 Extra HD CuCr 035 0...

Page 4: ...63 6302 2 3 400A 65 6302 500A 63 6502 Clamps Front End Housing 64 6201 65 7902 500A Spring Guard Unicable Assembly Mounting Screw Cone Nut Connector Cone Body Set Screw 63 6501 See Chart on page 3 Se...

Page 5: ...Unicable See Chart on page 3 Control Plug Connector 64 7909 Clamp 64 7907 400A 65 7902 500A Spring Guard 63 6502 Handle 64 6106 Screws 64 6501 European Assembly Back End Assembly Spring Guard Euro 63...

Page 6: ...Tighten until retainer and shock washer are secure THREAD ON OPTIONAL FOR TWECO HD Thread on nozzle system does not require nozzle retainer and cannot be used with heavy duty head Shockwasher must be...

Page 7: ...Loosen connector cone fromneck using 1 25 mm wrench Remove from vise and thread out neck by hand Cable connection between cone and crimp ring should not be disturbed Unthread power pin and remove usi...

Page 8: ...e diameter 13 Gaps at liner into gas diffuser Reset liner and lock or replace with new liner B Premature contact tip failure Possible Cause Possible Solution 1 Improper voltage or wire feed speed Set...

Page 9: ...tallation Finger tighten then slightly tighten with correct tool G Erratic arc Possible Cause Possible Solution 1 Worn contact tip Replace 2 Buildup inside of liner Replace liner check condition of el...

Page 10: ...Bore Flush Copper 0 938 O D 63 2150 1 2 Bore 1 8 Recess Copper 0 938 O D 63 2162 5 8 Bore 1 8 Recess Copper 0 938 O D 63 2175 3 4 Bore 1 8 Recess Copper 0 938 O D Straight Bore 63 2362 5 8 Bore 1 8 R...

Page 11: ...re authorized repair or replacement consttutes the sole remedy for breach of warranty and expressly excludes claims for lost revenue down tme and other consequental damages The warranty is limited to...

Page 12: ...ing Gun Please read and follow all the safety procedures For technical support please call our Customer Service department at 1 800 371 8477 between 8 00 AM and 5 00 PM EST Monday through Friday We ar...

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