Antorcha Mig Tweco 89200001 E

AIR-COOLED
TAM SERIES
400 AMP
500 AMP
RA SERIES AIR-COOLED
AUTOMATION
400 AMP
600 AMP
MIG GUNS
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SAFETY AND OPERATING

INSTRUCTIONS
Revision: A Issue Date: July 8, 2008 Manual No: 89200001
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 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® Robotics Automation Mig guns. 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® and Tweco® Robotics 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.
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.
Air-Cooled Automation MIG Guns

Safety and Operating Instructions
Instruction Guide Number 89200001
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: July 8, 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
1.03 Description........................................................................ 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 Installation......................................................... 4-7
4.02 Direct Plug........................................................................ 4-7
4.03 RA Series Conductor Tube Installation.............................. 4-7
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
Section 7: Maintenance and Troubleshooting.......................................... 7-12
section 8: replacement parts....................................................................... 8-13
8.01 Mig Gun Parts Listing...................................................... 8-13
8.02 Consumable Parts Listing............................................... 8-18
SECTION 9: Statement of Warranty............................................................... 9-24
ii
Air-Cooled automation MIG Guns
Section 1:
Introduction
1.01 How to Use this Manual
To ensure safe operation, read the entire manual, including the chapters on safety instructions 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 in the inside 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.
1.03 Description
Tweco® Robotics offers MIG guns with cable assemblies or a direct plug option - all furnished with
Tweco rear connections. The TAM series gives choices between direct plug or with cable assemblies
while the RA series is offered with cable assemblies. Automated welding MIG guns are either setup
on a machine or robot and monitored by an operator with specified instructions to perform a job. For
a listing of available parts, or consumables, or mounting accessories, see the “Replacement Parts”
Section or call Tweco® Customer Care.
89200001 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 89200001

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. See
safety and operating references 1, 2, and 3.
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. See safety and operating references 1, 2, and 6.
89200001 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 89200001

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 Air or cooling gas
Type of Shielding Gas All types
Duty Cycles
MIG Gun Model No. 150 160 180 200 250 300 350 400 450 500 600
10% Duty Cycle (amps) 230 200 230 260 320 375 435 500 570 600 700
35% Duty Cycle (amps) 205 185 205 230 290 340 390 450 520 550 660
60% Duty Cycle (amps) 180 160 180 200 250 300 350 400 450 500 600
100% Duty Cycle (amps) 140 125 140 150 195 205 240 275 351 350 400
The above duty cycles were established by testing under the following parameters:
Type of Gas Flow Gun Cable Electrode
Parameter Electrode Shielding Gas Weld Material
Voltage Rate Length Polarity
Aluminum 3% to 30 CFH / AIMg3 to
MIG D.C. Argon 10 ft./3 m Positive
5% Magnesium 14.2 l/m AIMg5
Mild (low carbon) Argon/CO2 Mixed 30 CFH / Mild (low
MAG D.C. 15 ft./5 m Positive
Steel Gas (80/20, 75/25) 14.2 l/m carbon) Steel
Electrode size
150 amp = .030"/0,8 mm 350 amp = .045"/1,2 mm
160 amp = .030"/0,8 mm 400 amp = 1/16"/1,6 mm
180 amp = .030"/0,8 mm 450 amp = 1/16"/1,6 mm
200 amp = .045"/1,2 mm 500 amp = 1/16"/1,6 mm
250 amp = .045"/1,2 mm 600 amp = 1/16"/1,6 mm
STANDARD CONSUMABLE PARTS
MIG Gun Series Nozzle Diffuser Contact Tip Conduit
TAM400 Direct Plug 24CT-62-S 54A 14H series R44-116-1
TAM500 Direct Plug 25CT-62 55SW 15H series R45-116-1
TAM400 w/ cable 24CT-62-S 54A 14H series R44-3545
TAM500 w/ cable 25CT-62 55SW 15H series R45-116
RA400 w/ cable 23/24 series 54P 14 series R44-3545
RA600 w/ cable 26 series 56SW 16 series R45-116
89200001 3-5 MIG Gun Specifications

Direct Plug
The TAM series direct plug MIG gun allows the wire feeder and workpiece to operate in close
proximity. The assembly (workpiece) being welded can be moved or rotated underneath the
conductor tube. The air-cooled welding applications are rated at 400 or 500 amperes at 60% duty
cycle. This option is without a cable assembly and is furnished with a 1 1/8" (28,58 mm) diameter
mounting surface.
MIG GUNS With Cable Assembly
The Automation MIG gun offerings with cable assemblies give the user the ability to set up the operation
for flexible movement of the MIG Gun rather than the workpiece, as with a direct plug setup.
The TAM MIG guns with cable assemblies range in lengths from 2 ft. (0,61 m) to 15 ft. (5 m). The
air-cooled welding applications are rated at 400 or 500 amperes at 60% duty cycle. These guns have
a 1 1/8" (28,58 mm) diameter mounting surface and are field repairable.
The RA MIG guns with a cable assemblies range in lengths from 4 ft (1,22 m) to 15 ft (5 m). The
air-cooled welding applications are rated at 400 or 600 amperes at 60% duty cycle. The RA has five
different bend configuration conductor tubes and is field repairable.
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, 2 foot cable 600 amp gun, 6 foot cable
TAM4023545 RA606116
Series .035-.045" Wire Capacity Series .052-1/16" Wire Capacity
MIG Gun Specifications 3-6 89200001

SECTION 4:
MIG Gun installation
Note
Be certain that the end user (welder, operator, or helper) reads and understands these
instructions. Be certain that the welder also reads the “Safety Precautions” in Section 2.
Warning
Electric shock can cause injury or death.
4.01 Standard 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.
4.03 RA Series Conductor Tube Installation

1. First remove the nozzle, tip, and diffuser from the used conductor tube.
2. Next, remove case cap. Loosen set screws from the case and block with Allen wrench.
3. Loosen swivel nut with wrench and pull conductor tube out from the block and case.
89200001 4-7 MIG Gun Installation

4. Insert new conductor tube by aligning keyway on the tube with the guide pin inside
the block.
5. Use Allen wrench to tighten set screws to secure the tube to the block.
6. Use the wrench to tighten the swivel nut on the tube and replace case cap over the nut.
7. Replace other front end consumables.
NOTE
The conduit may need to be pulled back out of the conductor tube area if the tube is
of a different size.
Set Set Pressure
Screws Screw Nut
Case
Conductor Tube
Diffuser
Contact Tip
Nozzle Swivel Nut Block

Connector
Sleeve
Case Cap
Figure 2: Changing a Conductor Tube
MIG Gun Installation 4-8 89200001

SECTION 5:
cONTACT TIPS
5.01 Identification
Contact tips may be identified 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 wire 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 if needed. Replace contact tip and tighten securely.
89200001 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
44-3545-8
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 liner if it is kinked, 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. Make sure the gun is fully extended
and all twists in the cable are removed.
2. Remove the nozzle and 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 89200001

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 taking
care not to kink (bend) 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 the 1/2"(12,6 mm).
4. File the cut 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.
89200001 6-11 Wire Conduit

Section 7:
Maintenance and Troubleshooting
Contact tips and nozzles should be cleaned frequently. Spatter buildup may cause bridging between
nozzle and tip. This could cause electrical shorting between the nozzle and work piece as well as
poor or improper gas flow. Regularly inspect the conductor tube, handle, cable, 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. Tighten contact tip and diffuser
1. Loose contact tip or 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.
4. Sharp bends or kinks in
Wire feed inconsistent 4. Straighten or replace conduit.
or not smooth conduit.
5. Dirty or plugged conduit. 5. Replace conduit.
6. Conduit pulled back from 6. Reposition conduit and tighten
diffuser. front set screw.
7. Reset machine per machine
7. Machine improperly adjusted. and wire manufacturers’
recommendations.
1. Tighten contact tip and diffuser
1. Loose contact tip or diffuser.
plier tight.
2. Inspect complete gun for loose
2. Loose power connections.
connections and repair.
MIG Gun is 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. Check gas flow out of gun
nozzle. Check for leaks or
1. Poor or improper gas flow. restrictions in gas hoses and
Porous weld connections. Check for o-ring
damage.
2. Dirty or contaminated wire. 2. Change wire.
3. Base metal contaminated. 3. Replace base metal.
Maintenance and Troubleshooting 7-12 89200001

section 8:
replacement parts
8.01 Mig Gun Parts Listing
tam400 and 500 series direct plug
5
1 3 4
2 6
Item
Part No. Stock No. Description
No.
1 ----- ----- Nozzle Assembly
2 ----- ----- Contact Tip
3 ----- ----- Diffuser
4 ----- ----- Nozzle Insulator
5 ---- ----- TAM Direct Plug Body
A 64TAM-174 2080-2401 TAM 400 Amp Body – Overall Length – 9.100" (231,14 mm)
65TAM-175 2080-2501 TAM 500 Amp Body – Overall Length - 9.440" (239,78 mm)
B 64STAM-174 2080-2403 TAM 400 Amp Body – Overall Length – 5.900" (149,86 mm)
65STAM-175 2080-2503 TAM 500 Amp Body - Overall Length - 6.240" (158,5 mm)
C 65MTAM-175 2080-2504 TAM 500 Amp Body – Overall Length - 2.920" (74,19 mm)
NS 224S 2064-2059 O-Ring
6 ----- ----- Conduit
89200001 8-13 Replacement Parts

11
10
12
13
14
5
18
20
15
4
16 17 19
3
2
1 21
tam series
Replacement Parts 8-14 89200001

Item
No.
3 ----- ----- Diffuser
4 ----- ----- Nozzle Insulator
64TAM-N 2080-2400 TAM Body & Nipple – 400 Amp
5 64STAM-N 2080-2402 TAM Body & Nipple – 400 Amp
65TAM-N 2080-2500 TAM Body & Nipple – 500 Amp
64N 2040-2064 400 Ampere Gas Nipple
6
65N 2050-2065 500 Ampere Gas Nipple
7 185 2050-2185 Connector Case With Screws
8 104 2040-2104 Connector Block With Separator
9 136 2060-2690 Band Clamp
234-6 2040-2234 Front Cable Support For 400 Ampere TAM
10
235-6 2050-2235 Front Cable Support For 500 Ampere TAM
QTR400CS 1740-2520 400 Ampere Cablehoz (Per Foot)
11
QTR600CS 1760-2125 500 Ampere Cablehoz (Per Foot)
234-12 2040-2235 Rear Cable Support & Cap For 400 Ampere TAM
12
235-12 2050-2236 Rear Cable Support & Cap For 500 Ampere TAM
M170-4H 2020-2166 Direct Plug Adapter For 400 Ampere TAM
13
TAM170-6H 2064-2090 Direct Plug Adapter For 500 Ampere TAM
14 WTAM6-RC 2081-2006 Upper & Lower Case
176S-H 2060-2177 Tweco® Connector Plug
15
350-174H 2035-2110 Tweco Connector Plug (Uses R44 series Conduit)
QTR176LH 2086-2624 Lincoln® Connector Plug, 2.71" (68,83 mm) OAL
16 EL176LH 2060-2680 Lincoln Connector Plug, 3.84" (97,54 mm) OAL
QTR174LH 2086-2623 Lincoln Connector Plug (Uses R44 series Conduit)
17 350-174PH 2035-2172 Panasonic® Connector Plug (Uses R44 series Conduit )
R176MH 2060-2184 Miller® Connector Plug (Includes Items #14 & #15)
18
R174MH 2035-2109 Miller Connector Plug (Includes Items #14 & #15)
R175M-N045 2050-2181 Miller Plug Nipple, .045" (1,0 mm) Wire (Use w/R176MH)
19
20
21 ----- ----- Conduit

16
15
14
10
13
6
5
9
4 9
2 12
Replacement Parts 8-16 89200001

ra series
Item
No.
3 ----- ----- Diffuser
4 WR6C 2066-2006 Conductor Tube Nut Cover
5 ----- ----- Conductor Tube Assembly
6 WR66-N 2066-2066 Conductor Tube Nut
7 RA104 2084-2104 Torch Block – 400 Amp
RA106 2086-2106 Torch Block – 600 Amp
8 RA6H 2086-2600 Handle Case w/ Strain Relief Cap
9 136 2060-2690 Cablehoz Clamp – 400 Amp
134-16 2040-2135 Cablehoz Clamp – 600 Amp
10 146T 2080-2646 Strain Relief – Front
11 QTR400C 1740-2520 Cablehoz – 400 Amp
QTR600C 1760-2125 Cablehoz – 600 Amp
12 350R-230-10 2035-2235 Strain Relief – Rear
13 T6RC 2060-2016 Rear Case
14 350-170K 2035-2171 Rear Power Connection – 400 Amp
170KL-K 2061-2170 Rear Power Connection – 600 Amp
15 350-174H 2035-2110 Tweco® Connector Plug Assembly – 400 Amp
176SH 2066-2177 Tweco Connector Plug Assembly – 600 Amp
NS 350-174PH 2035-2172 Panasonic® Connector Plug (Uses R44 series Conduit )
NS R176MH 2060-2184 Miller® Connector Plug (Includes Items #14 & #15)
NS R174MH 2035-2109 Miller Connector Plug (Includes Items #14 & #15)
NS R175M-N045 2050-2181 Miller Plug Nipple, .045" (1,0 mm) Wire (Use w/R176MH)
16 ----- ----- Conduit

8.02 Consumable Parts Listing
contact tip
TAM400 / RA400 TAM500
Wire Size Tip I.D. Std: 1/8"(3,2 mm) tip
Replacement Parts
TAM RA (Opt TAM) Opt Tapered
recess
in(mm) in(mm) Part No. Stock No. Part No. Stock No. Part No. Stock No. Part No. Stock No.
.023(0,6) .031(0,79) 14-23 1140-1100 14T-23 1140-1300
N/A N/A
.030(0,8) .038(0,97) 14-30 1140-1101 14T-30 1140-1301
.035(0,9) .044(1,12) 14-35 1140-1102 14H-35 1140-1202 14T-35 1140-1302 15H-35 1150-1202
.040(1,0) .048(1,22) 14-40 1140-1103 14H-40 1140-1203 14T-40 1140-1303 N/A
.045(1,2) .054(1,37) 14-45 1140-1104 14H-45 1140-1204 14T-45 1140-1304 15H-45 1150-1204
.052(1,3) .064(1,65) 14-52 1140-1105 14H-52 1140-1205 14T-52 1140-1305 15H-52 1150-1205
1/16(1,6) .073(1,85) 14-116 1140-1106 14H-116 1140-1206 14T-116 1140-1306 15H-116 1150-1206
8-18
5/64(2,0) .090(2,29) 14-564 1140-1107 14H-564 1140-1209 15H-564 1150-1209
3/32(2,4) .106(2,67) 15H-332 1150-1210
7/64(2,8) .120(3,05) N/A N/A 15H-764 1150-1211
N/A
1/8(3,2) .144(3,66) 15H-18 1150-1212
3/64 AL(1,2) .059(1,50) 14A-364 1140-1113 14AH-364 1140-1213 15AH-364 1150-1213
1/16 AL(1,6) .082(1,85) 14A-116 1140-1114 14AH-116 1140-1214 15AH-116 1150-1214
89200001
TAM400 / RA400 TAM500
Wire Size Tip I.D.
Opt: 3/8"(9,5 mm) recess Std (Opt TAM) Std EL Tip Opt Tapered EL Tip
89200001
in(mm) in(mm) Part No. Stock No. Part No. Stock No. Part No. Stock No. Part No. Stock No.
.023(0,6) .031(0,79) N/A
N/A
.030(0,8) .038(0,97) EL16-30 1160-1610 EL16T-30 1160-1601
.035(0,9) .044(1,12) 15HFC-35 1150-1252 16S-35 1160-1102 EL16-35 1160-1611 EL16T-35 1160-1602
.040(1,0) .048(1,22) N/A 16S-40 1160-1103 EL16-40 1160-1612 EL16A-40 1160-1603
.045(1,2) .054(1,37) 15HFC-45 1150-1254 16S-45 1160-1104 EL16-45 1160-1613 EL16T-45 1160-1604
.052(1,3) .064(1,65) 15HFC-52 1150-1255 16S-52 1160-1105 EL16-52 1160-1615 EL16T-52 1160-1605
1/16(1,6) .073(1,85) 15HFC-116 1150-1256 16S-116 1160-1106 EL16-116 1160-1616 EL16T-116 1160-1606
5/64(2,0) .090(2,29) 15HFC-564 1150-1259 16S-564 1160-1109 EL16-564 1160-1618
3/32(2,4) .106(2,67) 15HFC-332 1150-1260 16S-332 1160-1110 EL16-332 1160-1619
N/A
7/64(2,8) .120(3,05) 15HFC-764 1150-1261 16S-764 1160-1111 EL16-764 1160-1620
8-19
1/8(3,2) .144(3,66) 15HFC-18 1150-1262 16S-18 1160-1112 EL16-18 1160-1621
3/64 AL(1,2) .059(1,50) 15AHFC-364 1150-1263 16AS-364 1160-1113 EL16A-64 1160-1614 EL16AT-364 1160-1607
1/16 AL(1,6) .082(1,85) 15AHFC-116 1150-1264 16AS-116 1160-1114 EL16A-116 1160-1617 EL16AT-116 1160-1608
note
TAM500 Series MIG Guns require a 55S style diffuser with 16S tips (See Diffusers table). Use 55S-SWL or 55S-HL for 5/32" (3,96 mm) tip recess.
Use 55S-SW and 55S-H for 3/8" (9,5 mm) tip recess.
Replacement Parts
NOZZLE
Bore Size
MIG Gun
Nozzle Description 3/8"(9,5 mm) 1/2"(12,7 mm) 5/8"(15,9 mm) 3/4"(19,1 mm)
Series
Part No. Stock No. Part No. Stock No. Part No. Stock No. Part No. Stock No.
Replacement Parts
Std - Coarse Thread,
24CT-37-S 1240-1404 24CT-50-S 1240-1414 24CT-62-S 1240-1424 24CT-75-S 1240-1434
1/8" Tip Recess *
TAM400 Opt - Coarse Thread,

24CT-50-F 1240-1412 24CT-62-F 1240-1422 N/A
Tip Flush *
N/A
Opt - Coarse Thread,
N/A 24CT-62-R 1240-1423 24CT-75-R 1240-1433
1/2" Tip Recess *
Std - Coarse Thread,
25CT-50 1250-1410 25CT-62 1250-1420 25CT-75 1250-1430

1/8" Tip Recess **
TAM500 N/A
Opt - Self-Insulated,
N/A 25I-62 1250-1120 25I-75 1250-1130
Tip Flush
8-20
Std - Self-Insulated,
23-37 1230-1100 23-50 1230-1110 23-62 1230-1120 23-75 1230-1130
1/8" Tip Recess
Opt - Self-Insulated,
23-37-F 1230-1102 23-50-F 1230-1112 23-62-F 1230-1122 23-75-F 1230-1132
Tip Flush
RA400 Opt - Heavy Duty,
Self-Insulated, 23H-50 1230-1210 23H-62 1230-1220 23H-75 1230-1230
1/8" Tip Recess
N/A
Opt - Heavy Duty,
Self-Insulated, Tip 23H-50-F 1230-1212 23H-62-F 1230-1222 23H-75-F 1230-1232
Flush
Std - Self-Insulated,
N/A 26I-62 1260-1120 26I-75 1260-1130
1/8" Tip Recess
RA600
Opt - Coarse Thread,
N/A 26CT-62 1260-1420 26CT-75 1260-1430
1/8" Tip Recess ***
89200001
* Uses Part# 34CT (Stock# 1340-1400) Insulator
** Uses Part# 35CT (Stock# 1350-1400) Insulator
*** Uses Part# 36CT (Stock# 1360-1400) Insulator
note
MIG Gun series RA600 & RAEL600 uses nozzle part# 26I-87 (Stock# 1260-1140) for
bore size 7/8"(22,22 mm).
DIFFUSeRs
MIG Gun Diffuser
Conduit
Series Part No. Stock No.
54P 1540-1103
TAM400 /
54A 1540-1100 Standard
RA400
54A-16 1540-1104
55SW 1550-1101 45-3545, 45-116, 45N-3545
TAM500 55 1550-1100 45-564, 45N-116
55H 1550-1102 45H-332, 45H-764, 45H-18
55S-SW 1550-1110 45-3545, 45-116, 45N-3545
RA600 55S-H 1550-1111 45-564, 45N-116, 45H-332, 45H-764, 45H-18
/ OPT
TAM500* 55S-SWL 1550-1120 45-3545, 45-116, 45N-3545
55S-HL 1550-1121 45-564, 45N-116, 45H-332, 45H-764, 45H-18
* Use with 16S Tips and 3/8" Tip Recess

CONDUIT
Conduit Wire
TAM400 / RA400 TAM500 / RA600
Size
8 ft (2,4m) 15 ft (5 m) 8 ft (2,4m) 15 ft (5 m)
in (mm)
Replacement Parts
Part No. Stock No. Part No. Stock No. Part No. Stock No. Part No. Stock No.
.030-.045
R44-3545-8 1440-1225 R44-3545-15 1440-1226 R45-3545-8 1450-1025 R45-3545-15 1450-1026
(0,8-1,2)
.052-1.16
R44-116-8 1440-1230 R44-116-15 1440-1231 R45-116-8 1450-1030 R45-116-15 1450-1031
(1,3-1,6)
5/64 (2,0) R44-564-15 1440-1123 45-564-8 1450-1328 45-564-15 1450-1123
3/32 (2,4) 45H-332-15 1450-1133
7/64 (2,8) N/A 45H-764-15 1450-1143

N/A
1/8 (3,2) 45-18-15 1450-1153
N/A
.030-3/64 AL
8-22
44N-3545-15 1440-1003 45N-3545-15 1450-1003
(0,8-1,2)
1/16 AL (1,6) 44N-116-8 1440-1014 44N-116-15 1440-1012 45N-116-15 1450-1013
89200001
CONDUCTOR TUBES
MIG Gun Series Part No. Stock No. Description
64TAM-174 2080-2401 Std body 12”, no cablehoz
TAM400 64S-TAM-174 2080-2403 Opt body 8 3/4”, no cablehoz
64TAM-N 2080-2400 Std body with cablehoz
65TAM-175 2080-2501 Std body 12”, no cablehoz
65S-TAM-175 2080-2503 Opt body 8 3/4”, no cablehoz
TAM500
65MTAM-175 2080-2504 Opt body 6”, no cablehoz
65TAM-N 2080-2500 Std body with cablehoz
RA64-22 1684-1800 22˚ Conductor Tube
RA400
RAEL64-22 1684-1826 22˚ Conductor Tube
RA600 RA66-60 1686-1802 60˚ 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 9-24 89200001

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
89200001 9-25 Statement of Warranty

Antorcha Mig Tweco 89200001 E

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AIR-COOLED

SAFETY AND OPERATING

YOU ARE IN GOOD COMPANY!

Air-Cooled Automation MIG Guns

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

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

Publication Date: July 8, 2008

Record the following information for Warranty purposes:

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

1.02 Receipt of Equipment

89200001 1-1 Introduction

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH

Safety Precautions 2-2 89200001

WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS

NOISE CAN DAMAGE HEARING

89200001 2-3 Safety Precautions

Safety Precautions 2-4 89200001

89200001 3-5 MIG Gun Specifications

3.02 MIG Gun Part Number Identification

MIG Gun Specifications 3-6 89200001

4.01 Standard Installation

4.02 Direct Plug

4.03 RA Series Conductor Tube Installation

89200001 4-7 MIG Gun Installation

Nozzle Swivel Nut Block

Figure 2: Changing a Conductor Tube

MIG Gun Installation 4-8 89200001

Figure 3: Contact Tip

89200001 5-9 Contact Tips

Wire Conduit 6-10 89200001

89200001 6-11 Wire Conduit

Maintenance and Troubleshooting 7-12 89200001

89200001 8-13 Replacement Parts

Replacement Parts 8-14 89200001

89200001 8-15 Replacement Parts

Replacement Parts 8-16 89200001

89200001 8-17 Replacement Parts

TAM400 Opt - Coarse Thread,

25CT-50 1250-1410 25CT-62 1250-1420 25CT-75 1250-1430

89200001 8-21 Replacement Parts

7/64 (2,8) N/A 45H-764-15 1450-1143

89200001 8-23 Replacement Parts

Statement of Warranty 9-24 89200001

Engine Driven Welders Parts / Labor

89200001 9-25 Statement of Warranty

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