PARTS CATALOG MillerWelds.com
2015 Parts Catalog SERIAL NUMBER REFERENCE The letters of the serial numbers are very significant. Please supply the letters along with the numbers.
Yr/Month 1967/Jan. 1967/July 1968/Jan. 1968/July 1969/Jan. 1969/July 1970/Jan. 1970/July 1971/Jan. 1971/July 1972/Jan. 1972/July 1973/Jan. 1973/July 1974/Jan. 1974/July 1975/Jan. 1975/July 1976/Jan. 1976/July 1977/Jan. 1977/July 1978/Jan. 1978/July 1979/Jan. 1979/July 1980/Jan. 1980/July 1981/Jan. 1981/July 1982/Jan. 1982/July 1983/Jan. 1983/July 1984/Jan. 1984/July 1985/Jan. 1985/July 1986/Jan. 1986/July 1987/Jan. 1987/July 1988/Jan. 1988/July 1989/Jan. 1989/July 1990/Jan. 1990/July 1991/Jan. 1991/July 1992/Jan. 1992/July 1993/Jan. 1993/July 1994/Jan. 1994/July 1995/Jan. 1995/July 1996/Jan. 1996/July 1997/Jan. 1997/July 1998/Jan.
Serial # S-405265 S-420046 T-436102 T-452888 U-472600 U-493984 W-517910 70-539663 71-559155 71-581468 72-604096 72-626994 HD655498 HD689465 HE730188 HE778187 HF821067 HF860240 HG000500 HG044257 HH000500 HH050101 HJ106001 HJ169391 HK220001 HK286000 JA356001 JA410000 JB465001 JB522459 JC585001 JC626075 JD660001 JD688500 JE732465 JE783729 JF835606 JF905000 JG000500 JG071437 JH146311 JH229162 JJ319663 JJ413787 JK529151 JK636569 KA737051 KA824820 KB000500 KB089898 KC170500 KC262180 KD341750 KD449472 KE550001 KE668695 KF780420 KF923923 KG041900 KG173969 KH300251 KH438994 KJ000100
Style # S1 S6 T1 T6 U1 U6 W1 70-6 71-1 71-6 72-1 72-6 HD1 HD6 HE1 HE6 HF1 HF6 HG1 HG6 HH1 HH6 HJ1 HJ6 HK1 HK27 JA1 JA28 JB1 JB26 JC1 JC26 JD1 JD26 JE1 JE27 JF1 JF26 JG1 JG26 JH16 JH41 JJ15 JJ41 JK15 JK41 KA15 KA41 KB15 KB41 KC15 KC41 KD15 KD41 KE01 KE26 KF01 KF26 KG01 KG26 KH01 KH26 KJ01
Yr/Month 1998/July 1999/Jan. 1999/July 2000/Jan. 2000/July 2001/Jan. 2001/July 2002/Jan. 2002/July 2003/Jan. 2003/July 2004/Jan. 2004/July 2005/Jan. 2005/July 2006/Jan. 2006/July 2007/Jan. 2007/July 2008/Jan. 2008/July 2009/Jan. 2009/July 2010/Jan. 2010/July 2011/Jan. 2011/July 2012/Jan. 2012/July 2013/Jan. 2013/July 2014/Jan. 2014/July 2015/Jan 2015/July
Serial # KJ165696 KK000100 KK173909 LA000200 LA210095 LB000200 LB195125 LC000201 LC230270 LC361720 LC5280002 LE020006 LE260001 LF010001 LF260001 LG010001 LG260001 LH010001 LH260001 LJ010001 LJ260001 LK010001 LK260001 MA010001 MA260001 MB010001 MB260001 MC010001 MC0270001 MD010001 MD270001 ME010001 ME2700001 MF010001 MF270001
Style # KH26 KK01 KK26 LA01 LA27 LB01 LB26 LC01 LC26 LD01 LD26 LE02 LE26 LF01 LF26 LG01 LG26 LH01 LH26 LJ01 LJ26 LK01 LK26 MA01 MA26 MB01 MB26 MC01 MC27 MD01 MD27 ME01 ME27 MF01 MF27
Contents 4
Welding Protection Head and Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Heat Stress and Respiratory . . . . . . . . . . . . . . . . . . . . . . . . .7
10
MIG Guns Miller MIG Gun/Machine Reference . . . . . . . . . . . . . . . . . . .10 M-Series MIG Gun Parts/Consumables . . . . . . . . . . . . . . . . 11 Roughneck MIG Gun Parts/Consumables . . . . . . . . . . . . . .15 Bernard MIG Gun Parts/Consumables . . . . . . . . . . . . . . . . .17 Pipeworx MIG Gun Parts/Consumables . . . . . . . . . . . . . . . .22 Pipepro Dura-Flux XC Parts/Consumables . . . . . . . . . . . . . .24 Bernard MIG S-Gun Parts/Consumables . . . . . . . . . . . . . . .25 Bernard Dura-Flux Parts/Consumables . . . . . . . . . . . . . . . .26 Ironmate Flux Cored Gun Parts/Consumables . . . . . . . . . . .27 Hobart MIG Gun/Machine Reference . . . . . . . . . . . . . . . . .30 Hobart MIG Gun Parts/ Reference . . . . . . . . . . . . . . . . . . . .30 Millermatic Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . .34
35
Spool Guns Miller Spool Gun Parts/Consumables . . . . . . . . . . . . . . . . . .35
46
Drive Rolls Miller Drive Rolls, Guides and Kits . . . . . . . . . . . . . . . . . . .46 Hobart Drive Rolls, Guides and Kits . . . . . . . . . . . . . . . . . .50
51
Submerged Arc Torch Parts/Consumables . . . . . . . . . . . . . . . . . . . . . . . . . .51
55
Plasma Cutting Plasma Torches/Machine Reference . . . . . . . . . . . . . . . . . .55 XT Torch Parts/Consumables . . . . . . . . . . . . . . . . . . . . . . . .57 ICE Torch Parts/Consumables . . . . . . . . . . . . . . . . . . . . . . .60 HP Torch Parts/Consumables . . . . . . . . . . . . . . . . . . . . . . .72
51
Gas Equipment Hose Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Pressure Gauges & Filters . . . . . . . . . . . . . . . . . . . . . . . . . .73 Gas Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Smith Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
83
Engine Drives Portable Engine Drive Service Parts . . . . . . . . . . . . . . . . . .83 Portable Engine Drive Tune-Up Components . . . . . . . . . . . .84 Industrial Engine Drive Tune-Up Kit Components . . . . . . . . .88 Industrial Engine Drive Service Parts . . . . . . . . . . . . . . . . . .90
91
Spot Welders Tongs and Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
93
TIG Torches TIG Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Weldcraft TIG Torch Parts/Consumables . . . . . . . . . . . . . . .94
115
Welding Related Products Paint/Scrubs/Welpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
116
Service Parts Connectors/Plugs/Receptacles . . . . . . . . . . . . . . . . . . . . . 116 Cable Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Electrode Holders/Work Clamps . . . . . . . . . . . . . . . . . . . . .120 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 Power Terminal Parts/Receptacles and Plugs . . . . . . . . . .122 True Blue Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Letter Business A B C E F G H K L M N P Q R S T U W Y Z
Advanced Technologies Prod. Light Industrial Products 3-Phase Industrial Products Industrial Engine Driven Prod. ITW Cooling Systems Pipe Welding Products Portable Power Products Component Products TIG Industrial Products Fast Switch Products Small Integrated MIG Systems Plasma Products Performance Engine Drive Commercial Power Products WCC/Parts Business Tregakiss Advanced Manufacturing Sys. Wire Feed Systems Troy Equipment Other
Some serial numbers STARTING in 2003 have a letter at the end of the serial number. See chart below for business unit letter designations. Serial number example: LG360937P LG = 2006, 36 = Week 36, 0937 = Item 937 manufactured in week 36, P = manufactured by Plasma Products 2
Maxstar 150 models used the LD serial number prefix in 2003. Note: Style number replaces serial numbers on some models.
2
WELDING PROTECTION
Titanium Series Item #
1
Description
TITANIUM TITANIUM 1600™ 1600i™
13 14 15 16
Helmet shell, Titanium (QR) Inside lens cover (5 1/4 x 4 1/2 in) (5-pkg) Inside lens cover (4 1/4 x 2 in) (5-pkg) Inside lens cover (4 1/4 x 2 1/2 in) (5-pkg) Auto-darkening lens assembly Filter plate Gasket, Lens assembly (QR) Front lens cover (4 11/16 x 5 5/8 in) (5-pkg) Front lens holder, Titanium Ratchet headgear assembly (includes #9 & #10) Adjustment angle/stop hardware kit Fabric headband Replacement o-rings for kits #258 178 & #770 248 (5 per pkg) Comfort cushion Battery tray, kit (left/right) Battery, lithium CR2450 (not shown) Lens, Grinding Shield (Clear) Clips, Retaining Grinding Shield Button, Replacement External Grind Clips, Visor Hinge (i-Series Shell)
2
3 3b 5 6
™
TITANIUM 7300™
TITANIUM 9400™
TITANIUM 9400i™
243 530
245 820
ANALOG 243 530
DIGITAL 258 601
ANALOG 243 530
DIGITAL 258 601
ANALOG 245 820
DIGITAL 245 820
235 628
235 628
-
-
-
-
-
-
-
-
770 237
770 237
-
-
-
-
-
-
-
-
216 327
216 327
216 327
216 327
235 630 245 813
235 630 245 813
245 816 245 814
256 358 241 977
245 817 241 977
256 359 241 977
245 817 241 977
256 360 241 977
216 326
216 326
216 326
216 326
216 326
216 326
216 326
216 326
243 396
245 815
243 396
243 396
243 396
243 396
245 815
245 815
16 16
770 246
770 246
256 174
770 246
256 174
770 246
256 174
770 248 770 249
770 248 770 249
256 178 770 249
770 248 770 249
256 178 770 249
770 248 770 249
256 178 770 249
079 975
079 975
079 975
079 975
079 975
079 975
079 975
079 975
216 336 -
216 336 245 818 245 819 255 070
216 336 216 339 217 043 -
216 339 217 043 (2) 256 179 -
216 336 216 339 217 043 (2) -
216 339 217 043 (2) 256 179 -
216 336 216 339 217 043 (2) 245 818 245 819 255 070
216 339 217 043 (2) 245 818 245 819 255 070
17
Lens Tear-Off, Grind Shield (Clear) (not shown)
-
254 278
-
-
-
-
254 278
254 278
18
Kit, Weld Shield Hinge
-
269 929
-
-
-
-
269 929
269 929
11 12
Digital Elite Series
55
6
770 246
3b 3b
2 3 3a 3b 4 5 6 7 8 9 10 11 12
Description
Helmet shell, Black Helmet shell, Black (QR) Helmet shell, Red Flame Helmet shell, Camouflage Helmet shell, Stars and Stripes III Helmet shell, Inferno Helmet shell, Lucky's Speed Shop Helmet shell, UA Series 1 Helmet shell, Hockey Canada Helmet shell, Joker (Black) Helmet shell, Dig Camo Helmet shell, Fury Helmet shell, Vintage Roadster Helmet shell, Not Forgotten Helmet shell, Cat® - 1st Edition Helmet shell, Blue Flame Helmet shell, Hot Rod Garage Inside lens cover (4 1/4 x 2 1/2 in) (5-pkg) Auto-darkening lens assembly Gasket, auto-darkening lens assy Gasket, Lens assembly (QR) Gasket, front lens Front lens cover (4 11/16 x 5 5/8 in) (5-pkg) Front lens holder, Black, flat Frame, lens holding Ratchet headgear assembly (includes #9 & #10) Adjustment angle/stop hardware kit Fabric headband Replacement o-rings for kits #258 178 & #770 248 (5 per pkg) Comfort cushion Battery tray, kit (left/right) Battery, lithium CR2450 (not shown)
TITANIUM 1600i and 9400i™
8
10 10
9 9
10 9
9 ALL TITANIUM SERIES™ MODELS
079 975
079 975 216 339 217 043 (2)
5
Vintage Roadster™ #259 485
Not Forgotten™ #260 127
8
1
3
4
2
6
Stars and Stripes™ III #264 852
10 10
10
6
Elite Digital 216 331 241 976 216 332 227 190 265 709 223 454 237 872 229 366 245 136 247 058 248 261 256 172 260 086 260 128 268 619 269 274 269 947 216 327 256 469 234 758 241 977 216 337 216 326 241 978 234 759 256 174 256 178 770 249
4
5
1
3
Lucky’s Speed Shop™ #257 214
Black #257 213
©2014 Caterpillar. CAT, CATERPILLAR, BUILT FOR IT and their design marks are registered trademarks of Caterpillar. Miller Electric Mfg. CO., a licensee of Caterpillar Inc.
11
10
Blue Flame #269 273
10 9
CAT®- First Edition
Hot Rod Garage™ #269 946
12
12
9
Fury ™ #256 158
Inferno™ #257 217
8
Camouflage #256 173
11 11
88
8
2
Elite Analog 216 331 241 976 216 332 227 190 265 709 223 454 237 872 229 366 245 136 247 058 248 261 256 172 260 086 260 128 268 619 269 274 269 947 216 327 216 328 234 758 241 977 216 337 216 326 241 978 216 335 770 246 770 248 770 249 216 336 216 339 217 043 (2)
22
33 12
TITANIUM 881600™, 7300 and 9400™ 11 11
™
Item # 1
1
14 14
13 13
770 248 770 249
8 9 10
7300™ 1600™ 1600i™ #256 175 #255 519 #245 799
9400™ #256 176
9400i™ #256 177
88
#268 618
11 11 88
11 11
8
44
55
3a 3a
33
7a 7a
22
8
77 9
9
10 10
10
9 9
11
10 10
10
Digital Elite™ 2 5 6 8
4
881
3
9 9
11 11
2 5 6 8
10 10
4
10
9 9
2
4 6
88 1
3
5
4
3
10
10 10
Elite Analog (QR) Series
1
2
6
11 11
5
4
3
1
9
WELDING PROTECTION
Digital Performance Series ™
Item # 1
2 3 4 5 6
8 9 10 11 12
Description
Helmet shell, Black Helmet shell, American Eagle Helmet shell, Millermatic Helmet shell, Blue Flame Helmet shell, Camouflage Helmet shell, American Eagle II Helmet shell, Blue Rage Helmet shell, Illusion Helmet shell, '64 Custom Helmet shell, Velocity Helmet shell, Cat® - 1st Edition Inside lens cover (4 1/4 x 2 in) (5-pkg) Auto-darkening lens assembly Gasket, front lens Front lens cover (4 1/2 x 5 1/2 in) (5-pkg) Front lens holder, Black, flat Front lens holder, Gray Front lens holder, Red Front lens holder, Gloss Black Front lens holder, Blue Front lens holder, Camouflage Front lens holder, Light Blue Front lens holder, White Ratchet headgear assembly (includes #9 & #10) Adjustment angle/stop hardware kit Fabric headband Replacement o-rings for kits #258 178 & #770 248 (5 per pkg) Comfort cushion Battery tray, kit (left/right) Battery, lithium CR2450 (not shown)
Performance Series ANALOG DIGITAL 232 020 232 020 232 021 232 021 232 023 232 023 237 160 237 160 241 461 241 461 265 708 265 708 241 459 241 459 256 171 256 171 250 533 250 533 260 937 260 937 268 740 268 740 770 237 770 237 232 026 256 468 232 028 232 028 231 921 231 921 232 030 232 030 232 031 232 031 203 586 203 586 232 032 232 032 232 033 232 033 243 395 243 395 251 278 251 278 257 041 257 041 770 246 256 174 770 248 256 178 770 249 770 249 079 975 079 975 216 336 232 027 256 730 217 043 217 043 (2)
America’s Eagle™ II
Blue Rage™
’64 Custom™
Illusion™
#264 851
#256 164
#256 160
#256 165
11 11
88 8 Camouflage #256 163
9 9
Black
CAT® - First Edition
#256 159 10 10
#268 739
10
2 5
4
3
8 9
1
9
1
2 3 4 5 6
8 9 10 11 12
Helmet shell, Black Helmet shell, American Eagle Helmet shell, Red Flame Helmet shell, Camouflage Helmet shell, American Eagle II Helmet shell, Blue Heat Helmet shell, Metalworks Inside lens cover (4 1/4 x 1 3/4 in) (5-pkg) Auto-darkening lens assembly Gasket, front lens Front lens cover (4 1/2 x 3 3/4 in) (5-pkg) Front lens holder, Black, flat Front lens holder, Gray Front lens holder, Red Front lens holder, Blue Front lens holder, Camouflage Ratchet headgear assembly (includes #9 & #10) Adjustment angle/stop hardware kit Fabric headband Replacement o-rings for kits #258 178 & #770 248 (5 per pkg) Comfort cushion Battery tray, kit (left/right) Battery, lithium CR2450 (not shown) Battery cover (not shown)
DIGITAL 231 415 231 416 231 419 231 418 265 707 250 367 260 087 231 410 256 467 231 412 231 411 231 572 231 573 231 574 231 575 231 576 256 174 256 178 770 249 079 975 256 729 217 043 (2) -
9
10 10
10 10
10 Digital/Analog Performance™ Series 2 1 3 4 2 5 1 3 6 4 5 6
Pro-Hobby Series
ANALOG 231 415 231 416 231 419 231 418 265 707 250 367 260 087 231 410 231 409 231 412 231 411 231 572 231 573 231 574 231 575 231 576 770 246 770 248 770 249 079 975 216 336 AAA Alkaline 231 413
10
9
Digtal Pro-Hobby Series Description
11 11
88
8
6
11 11
88
™
Item #
©2014 Caterpillar. CAT, CATERPILLAR, BUILT FOR IT and their design marks are registered trademarks of Caterpillar. Miller Electric Mfg. CO., a licensee of Caterpillar Inc.
Stars and Stripes™
Metalworks™
#264 850
# 259 486
Camouflage #256 169
Red Flame #256 168
Black #256 166
Digital/Analog Pro-Hobby™ Series
5
WELDING PROTECTION
Classic Series Item #
Description
Classic Series
11
8 1 Helmet shell, Black 2 Inside lens cover (4 1/4 x 2 in) (5-pkg) Inside lens cover (4 1/4 x 1 3/4 in) (5-pkg) 3 Auto-darkening lens assembly 3b Gasket, Lens assembly (QR) 4 Gasket, front lens 5 Front lens cover (4 1/4 x 2 in) (5-pkg) Front lens cover (4 1/2 x 3 3/4 in) (5-pkg) Front lens cover (5 1/4 x 4 1/2 in) (5-pkg) 6 Front lens holder, Black, flat 7 Frame, lens holding 8 Ratchet headgear assembly (includes #9 & #10) 9 Adjustment angle/stop hardware kit 10 Fabric headband Replacement o-rings for kits #258 178 & #770 248 (5 per pkg) 11 Comfort cushion 12 Battery, lithium CR2450 (not shown) Battery cover (not shown) 13 Lens, Grinding Shield (Clear) 14 Clips, Retaining Grinding Shield 16 Clips, Visor Hinge (i-Series Shell) 17 Lens Tear-Off, Grind Shield (Clear) (not shown)
FS#10 231 415 231 410 231 571 231 412 231 411 231 572 770 246 770 248 770 249
VS 231 415 231 410 251 293 231 412 231 411 231 572 770 246 770 248 770 249
VSi™ 261 824 231 410 261 826 261 827 235 628 261 828 770 246 770 248 770 249
FS#10 Flip-Up 231 415 770 237 770 226 770 237 261 829 770 246 770 248 770 249
079 975
079 975
079 975
079 975
216 336 -
216 336 AAA Alkaline 231 413 -
216 336 217 043 266 781 245 818 245 819 255 070 254 278
216 336 261 830 -
FS#10 Flip-Up #26310038
FS#10
VSi
Variable Shade
#231 703 (4 Pk)
#260 938
#251 292
9 11
8
7
13
2
1
5
3
10 9 Classic Series FS#10 Flip-Up
7
13
3
2
5
1
Classic Variable Shade & FS#10 16 16
8
11 11
88 8 14 14
13 13
6
MP-10 Series
33
3b 3b
5
10
22
10
9
Description
1 Helmet shell, Black Helmet shell, Inferno 2 Inside lens cover (5 1/4 x 4 1/2 in) (5-pkg) 3 Filter plate 4 Gasket, front lens 5 Front lens cover (4 11/16 x 5 5/8 in) (5-pkg) 7 Frame, lens holding 7a Spacer, lens holding (MP-10) 8 Ratchet headgear assembly (includes #9 & #10) 9 Adjustment angle/stop hardware kit 10 Fabric headband Replacement o-rings for kits #258 178 & #770 248 (5 per pkg) 11 Comfort cushion
10
9
2
6
MP-10 Series 216 331 223 454 235 628 235 630 216 337 216 326 216 335 235 629 770 246 770 248 770 249 079 975 216 336
9
Classic VSi™
™
Item #
10 10
9
12
5
8
1
8
8
4
5
1
3
11
Inferno™
Black
#238 496 (Each)
#238 497 (Each) #235 626 (6 Pk)
10 9 10
12
12
9
11 11
88
44
55
3a 3a
33
22
7a 7a
8
77
88 8
9
9
10 10
10 9
11 9
10 10
10
MP-10™ 2
6
6
5
4
1
3
2 4
3
1
11 11
WELDING PROTECTION
Bulk Cover Lenses Part # 216326B 216327B
Front: Elite, Titanium, MP-10 Inside: Elite, Titanium, 9400i
Description
231921B
Front: Performance
Quantity 50 pkg. 50 pkg. 50 pkg.
770237B
Inside: Performance
50 pkg.
231411B
Front: Pro-Hobby, Classic
50 pkg.
Weld-Mask
™
Item #
Part #
Description
1 2
267 370 267 422 267 420
Weld-Mask Unit Guard, face Cover, lens
Quantity
3
270 053
Band, head
1 1 (5 per pkg) 1
4
267 421
Cover, head fr.
1
5
270 055
Battery, non-rechargeable CR2032
2 (1 per pkg)
TM
CoolBelt
™
Item # 1
2 3 4 5 6 7 8 9
Part # 245 230 245 235 079 975 770 249 245 236 245 232 245 231 245 233 247 921 245 234 245 237 245 238 246 964
2
Service Parts/Consumables Description CoolBelt unit Headgear (includes) Replacement O-rings Fabric headband Head shroud (hood) Belt Hose assembly Filter Spark Arrestor Filter cover Battery, blower Charger Hose cover
1 4
Quantity 3
1 1 1 1 1 1 1 1 1 1 1 1
(5 per pkg)
(6 per pkg)
9
8
5 6 7
7
WELDING PROTECTION
CoolBand II ™
Item # 1
Part # 261 970
2 3 4 5 6 7
261 243 261 261 770 261
971 930 972 973 249 974
8 9 10
243 243 261 261 261
927 932 975 976 977
1
Service Parts/Consumables
Description CoolBand II (entire system - helmet not included) Shroud, head Deflector, air Manifold Bracket, manifold Headband, fabric Headgear set (includes all knobs, headband, screws, and mainfold bracket) Battery, rechargeable lithium polymer Filter Tubing, stretch Charger, Battery Battery Door
8
Quantity 1
6
1 1 1 1 1 1 1 1 1 1 1
2
4
5
3
9
7 10
(10 per pkg)
LPR-100 Half Mask Respirator Description LPR-100 Half Mask Respirator, Small/Medium LPR-100 Half Mask Respirator, Medium/Large LPR-100 Half Mask Respirator with Nuisance Level OV Filter, Small/Medium LPR-100 Half Mask Respirator with Nuisance Level OV Filter, Medium/Large Consumables/Accessories P100 Filters P100 Nuisance Level OV Relief Filters Quantitative Face-Fit Test Kit
PAPR
Part # ML00894 ML00895 ML00994 ML00995 SA00818 SA00819 261 086
Service Parts/Consumables
1 13 14
17
26
16
24
18 15 19 27
21
20
Hard Hat
9400, 9400i
26
22 23
8
Head Seal 5
WELDING PROTECTION
15 19 27
26
PAPR Item #
1
2
3
4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29
Hard Hat
9400, 9400i PAPR w/ Titanium 9400 Helmet
Service Parts/Consumables Headw/ Seal PAPR Titanium 9400 (New Headgear)
PAPR w/ Titanium 9400i™
264 879
247 531
264 882
247 532 -
264 878
259 386
264 883
247 471
264 884
-
223 430 770 249
256 174 770 249
247 472 770 249
256 174 770 249
259 387 -
770 248
256 178
770 248
256 178
-
079 975 247 470
265 629
079 975 247 473
265 628
Lens holder, Front Outside Cover Lens (4-11/16 x 5-5/8) Frame/Gasket, ADF lens holding Auto-Darkening Lens Assembly (Titanium) (Infotrak) Battery tray kit (left/right)
243 396 216 326 241 977 256 360 256 359* 216 339
243 369 216 326 241 977
245 815 216 326 241 977
245 815 216 326 241 977
259 388 259 389 243 396 (9400) 245 815 (9400i) 216 326w 241 977
256 359* 216 339
256 360 216 339
256 360 216 339
256 359* 216 339
Battery, Lens (Lithium CR2450) Inside Cover Lens (4-1/4 x 2-1/2) (5 pack) Lens, Grinding Shield (Titanium 9400i) Tear-away, Grinding Shield Clip, Retaining Grinding shield (left/right) Kit, Weld Shield Hinge Shoulder Straps Belt Belt Pad Flowmeter Breathing Tube Assembly Breathing Tube Cover, Flame-resistant O-ring, Breathing Tube Blower Assembly Kit, Battery Contact
217 043 (2) 216 327 235 680 235 679 239 636 245 219 245 218 245 367 237 452 235 672 269 930
217 043 (2) 216 327 235 680 235 679 239 636 245 219 245 218 245 367 237 452 235 672 269 930
217 043 (2) 216 327 245 818 254 278 245 819 269 929 235 680 235 679 239 636 245 219 247 474 239 571 237 452 235 672 269 930
217 043 (2) 216 327 245 818 254 278 245 819 269 929 235 680 235 679 239 636 245 219 245 218 245 367 237 452 235 672 269 930
217 043 (2) 216 327 235 680 235 679 239 636 260 890 259 392 239 571 259 394 235 672 269 930
235 673-2 235 673-2 235 673-6 235 673-6 235 673-36 235 673-36 235 674 235 674 235 676 235 676 235 677 235 677 228 028 228 028 244 131 244 131 244 132 244 132 244 151 244 151 Titanium 9400 Helmet 8 9 7 256 179
235 673-2 235 673-6 235 673-36 235 674 235 676 235 677 228 028 244 131 244 132 244 151 -
235 673-2 235 673-6 235 673-36 235 674 235 676 235 677 228 028 244 131 244 132 244 151 -
235 673-2 235 673-6 235 673-36 235 674 235 676 235 677 228 028 244 131 244 132 244 151 259 460 259 637 259 390 256 179
PAPR w/ Titanium 5 9400™
Description
PAPR (Complete System w/ Helmet) PAPR (Complete System w/out AutoDarkening Lens) PAPR (Complete System w/out Helmet) Helmet Assy. (Shell, Headgear and Headseal) Helmet Assy. (Hard Hat, Headgear and Headseal) Headgear (Includes:) Fabric Headband Adjustment angle/stop hardware kit (w/O-rings) Replacement O-rings for kit 770248 (5 pack) Headgear (Hard Hat) Headseal
Filter, Particulate (HEPA) (2 pack) Filter, Particulate (HEPA) (6 pack) Filter, Particulate (HEPA) (36 pack) Filter, prefilter (foam) Spark Guard Filter Cover Tool Bag Battery, Blower Charger Belt Extension Hard Hat (for PAPR) PAPR w/ Slotted Hard Hat Adapter Lens, Clear (Hard Hat Headseal) 6 Button, Replacement External Grind
247 533 262 615* 247 534 262 616* 245 217 262 623*
8
7
6 PAPR w/ Titanium 9400i PAPR w/ (New Headgear) Hard Hat 259 385 (w/9400 Helmet) 261 659 (w/9400i 264 877 Helmet)
9
11 2 3
w/ New Headgear 2 3
PAPR w/ Titanium 9400i Helmet 10
2
6
7
8
9
11
3
w/ New Headgear 2 3
* Indicates part number features external grind control button.
11 2
9
12
MIG GUNS
Miller MIG Gun History Model Name Sidekick XL/ Cricket
Serial Number Effective
Original Gun Breakdown
Recommended Replacement Gun (S)
Amperage of Gun
Wire Size
Replacement Gun Breakdown
All Serial Numbers
GA-16C N/A
M-100 part number 248282 10 ft
100A at 100 % Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
Cricket ®
All Serial Numbers
GA-16C1 N/A
M-100 W/Friction terminals part number 220606 10 ft
100A at 100 % Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
Sidekick™ XL/ Cricket ®/ Millermatic® 90
All Serial Numbers
GA-17C N/A
M-100 part number 248282 10 ft
100A at 100 % Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
M-150 10 ft part number 249039
150A at 100% Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
150A at 100% Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
™
®
M-150 12 ft part number 249040 Millermatic®120/150
Millermatic®130 XP
Prior to KF849783
GA-17C N/A
M-150 10 ft part number 249039
Effective with KF849783
M-15 N/A
M-150 12 ft part number 249040
Prior to KK110539
10-A N/A
M-100 part number 248282 10 ft
100A at 100 % Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
Effective with KK110539
M-10
M-150 10 ft part number 249039
150A at 100% Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
All Serial Numbers
M-10 N/A
M-100 part number 248282 10 ft
100A at 100 % Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
pg 17
M-150 10 ft part number 249039
150A at 100% Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
.030-.035 (0.8-0.9 mm)
pg 18
MIGmatic™ M‑Series 100 – 250 Amp, Semi-Automatic, Air-Cooled MIG Welding Guns
M-150 12 ft part number 249040 Millermatic®135/ 140s/175/180/DVI™s/211
M-150 12 ft part number 249040 Millermatic®Challanger™
All Serial Numbers
M-15 N/A
M-100 part number 248282 10 ft
100A at 100 % Duty Cycle
pg 17
M-150 10 ft part number 249039
150A at 100% Duty Cycle
Prior to KK118238
10-A N/A
M-100 part number 248282 10 ft
100A at 100 % Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
Effective with KK118238
M-10 N/A
M-150 10 ft part number 249039
150A at 100% Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
pg 17
M-150 12 ft part number 249040
M-15 N/A
M-150 10 ft part number 249039
150A at 100% Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
pg 17
M-150 12 ft part number 249040
M-25
M-25 10 ft part number 169594
250A at 100% Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 19
pg 19
M-25 12 ft part number 169596
M-150 12 ft part number 249040 Millermatic® Challenger™ 172
Millermatic®185 Millermatic®200
All Serial Numbers
GA-20C
M-25 15 ft part number 169598 Millermatic®210/212/25 0X/251/252
All Serial Numbers
M-25
M-25 10 ft part number 169594
pg 19
M-25 12 ft part number 169596
Prior to KF851980
GA-21C N/A
M-25 10 ft part number 169594
Effective with KF851980
M-25 pg 19
M-25 12 ft part number 169596
250A at 100% Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 19
250A at 100% Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 19
M-25 15 ft part number 169598 Millermatic® 250
Millermatic®300
All Serial Numbers
All Serial Numbers
GA-20C; N/A
M-25 10 ft part number 169594
GA-21C; N/A
M-25 12 ft part number 169596
M-25 pg 19
M-25 15 ft part number 169598
M-40 N/A
Roughneck C-4010 10 ft part number 194754
250A at 100% Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 19
400A at 100% Duty Cycle
.035-.045 (0.9-1.2 mm)
pg 22
Roughneck C-4010 12 ft part number 194755
Millermatic 350 ®
Millermatic® Passport™/ Passport™ Plus
No Gun
Roughneck C-4012 12 ft part number 194755
400A at 100% Duty Cycle
.035-.045 (0.9-1.2 mm)
pg 22
Prior to LE443589
Roughneck C-4012
Roughneck C-4012 12 ft part number 194755
400A at 100% Duty Cycle
.035-.045 (0.9-1.2 mm)
pg 22
Effective with LE443589
Q3015AE8XM
Q3015AE8XM
.045
pg 24
All Serial Numbers
M-10 N/A
M-100 part number 248282 10 ft
150A at 100% Duty Cycle
.030-.035 (0.8-0.9 mm)
pg 18
pg 17
M-150 10 ft part number 249039
150A at 100% Duty Cycle
pg 18
M-150 12 ft part number 249040 M-150 15 ft part number 249041 Millermatic® Pulser
All Serial Numbers
M-15 N/A
M-150 10 ft part number 249039
pg 17
M-150 12 ft part number 249040 M-150 15 ft part number 249041
Optional Gun: M-25 Gun, Part Number 169 599, 15ft. 250A at 100% Duty Cycle, Wire Size (.035-.045in)
10
■
Consumable kits 234 607, 234 608 and 234 609 contain 10 contact tips, 1 nozzle and 1 contact tip adapter.
234 610 – M-25 Gun, .030” Wire ■ 234 611 –M-25 Gun, .035” Wire ■ 234 612 – M-25 Gun, .045” Wire ■
Roughneck C-4010 15 ft part number 194756 Millermatic® 300 without gun
234 607 – M-10/15, M-100/150 Gun, .023” Wire 234 608 – M-10/15, M-100/150 Gun, .030” Wire ■ 234 609 – M-10/15, M-100/150 Gun, .035” Wire ■
M-25 15 ft part number 169598 Millermatic®Vintage
M‑Series Consumable Kits (#234 607, #234 608, #234 609) To better serve you, Miller has introduced six improved, affordable MIG consumable kits that are compatible with the M-Series guns. Each kit contains consumables that are specific to your welding application, including gun type and wire size.
150A at 100% Duty Cycle
.035-.045 (0.9-1.2 mm)
pg 18
Consumable kits 234 610, 234 611 and 234 612 contain10 contact tips, 1 nozzle, 1 contact tip adapter and 1 nozzle adapter.
Accessories For a complete listing of gun consumables information, please refer to pages 11– 14.
MIG GUNS
M‑10/M‑15
Service Parts/Consumables
Item #
Part # 195 605 (N/A) 169 589 (N/A) 169 591 (N/A) 169 593 (N/A)
Description M‑10 Gun, 10 ft (3 m), 100A, .030‑.035 (0.8‑0.9 mm) M‑15 Gun, 10 ft (3 m), 150A, .030‑.035 (0.8‑0.9 mm) M‑15 Gun, 12 ft (3.7 m), 150A, .030‑.035 (0.8‑0.9 mm) M‑15 Gun, 15 ft (4.6 m), 150A, .030‑.035 (0.8‑0.9 mm)
1
3 4 5 6 7 8 9 10 11 11 12 13
169 715 226 190 087 299 000 067 000 068 000 069 169 716 170 470 169 718 169 738 169 719 169 737 169 741 (N/A) 227 800 209 495 209 486 079 974 194 010
13
194 011
14 15 16
079 975 227 798 079 878 079 531 169 736
Nozzle, slip type, .500 (12.7 mm) orf flush Nozzle, slip type, flux cored Tip, contact scr, .023 (0.6 mm) wire x 1.125 Tip, contact scr, .030 (0.8 mm) wire x 1.125 Tip, contact scr, .035 (0.9 mm) wire x 1.125 Tip, contact scr, .045 (1.2 mm) wire x 1.125 Adapter, contact tip Ring, retaining Tube, head Nut, locking handle Nut, jam (gun end) Handle Strain Relief, cable Cord Assembly Connector, feeder—M-10 (includes) Connector, feeder—M-15 (includes) O-Ring, .500 ID x .103CS rbr Kit, liner monocoil .023/.025 (0.6 mm) wire x 15 ft (includes) Kit, liner monocoil .030 – .035 (0.8 – 0.9 mm) wire x 15 ft (includes) O-Ring, .187 ID x .103CS rbr Switch, Red trigger Housing Plug and Pins Connector, circ cpc clamp str rlf Terminal Block
2
17
Quantity M‑10 / M‑15
1 1 1 1 1 1 1 1 1 1 1 1 — 1 1 — 2 1
1 (2 per pkg) 1 1 (10 per pkg) 1 (10 per pkg) 1 (10 per pkg) 1 (10 per pkg) 1 (2 per pkg) 1 1 2 1 2 2 1 — 1 2 1
1
1
1 1 1 1 —
1 1 — — 1
M‑Series MIG Guns *For a detailed listing, please reference page 10. Model M‑100 M‑150 M‑25
1
Stock # 248 282 220 6062 249 039 249 040 249 041 169 594 169 596 194 8053 169 598 169 599
Length 10 ft (3 m)
Rating and Duty Cycle (CO2 ) 1 100 A at 100% Duty Cycle
10 ft (3 m) 12 ft (3.7 m) 15 ft (4.6 m) 10 ft (3 m) 12 ft (3.7 m) 12 ft (3.7 m) 15 ft (4.6 m) 15 ft (4.6 m)
150 A at 100% Duty Cycle
Wire Size .030 – .035 in (0.8 – 0.9 mm) .030 – .035 in (0.8 – 0.9 mm)
250 A at 100% Duty Cycle
.030 – .035 in (0.8 – 0.9 mm)
250 A at 100% Duty Cycle
.035 – .045 in (0.9 – 1.2 mm)
60% with mixed gases 2#220 606 is an M‑100 gun with friction terminals for the Miller Cricket.® #194 805 is an M‑25 gun with friction lugs for the Hobart Beta‑MIG 2510.
3
11
MIG GUNS
M‑100/M‑150 Item #
1 2
3 4 5 6 7 8 9 10 11 12
Quantity M‑100 / M‑150
Part # 248 282 249 039 249 040 249 041
Description
246 372 226 190 087 299 000 067 000 068 000 069 170 470 169 716 246 373 243 865 246 082 246 376 079 878 242 833 079 974 194 010
Nozzle, slip type, .500 (12.7 mm) orf flush Nozzle, slip type, flux cored Tip, contact scr, .023 (0.6 mm) wire x 1.125 Tip, contact scr, .030 (0.8 mm) wire x 1.125 Tip, contact scr, .035 (0.9 mm) wire x 1.125 Tip, contact scr, .045 (1.2 mm) wire x 1.125 Ring, retaining Adapter, contact tip Tube, head Nut, jam Handle Switch, Blue trigger Housing Plug and Pins Connector, feeder O-Ring, .500 ID x .103CS rbr Kit, liner monocoil .023/.025 (0.6 mm) wire x 15 ft (includes) Kit, liner monocoil .030 – .035 (0.8 – 0.9 mm) wire x 15 ft (includes) Kit, liner monocoil .035 – .045 (0.9 –1.2 mm) wire x 15 ft (includes) O-Ring, .187 ID x .103CS rbr Housing, power pin
194 012 079 975 246 380
M‑100 can be used on:*
1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1
1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1
3
1
1
1
1
1 1
1 1
(10 per pkg) (10 per pkg) (10 per pkg) (10 per pkg)
5
6
7
7
(2 per pkg)
SideKick
■
SideKick™ XL/Cricket® XL/Millermatic® 90
■
SideKick™ XL/Cricket® XL/Millermatic® 90
■
Millermatic® 120/150
■
Millermatic® 130
■
Millermatic® 130
■
Millermatic® 130 XP
■
Millermatic® 130 XP
■
Millermatic® 135/140s/175/180s/DVI™s /211
■
Millermatic® 135/140s/175/180s/DVI™s /211
■
Millermatic® Challenger™
■
Millermatic® Challenger™
■
Millermatic® Challenger™ 172
■
Millermatic® Challenger™ 172
■
Millermatic Passport /Passport Plus
■
Millermatic 185
■
Millermatic® 141
■
Millermatic® Pulser
■
Millermatic® 190
™
4
(2 per pkg)
■
™
*For a detailed listing, please reference page 10.
12
2
8 9
M‑150 can be used on:*
™
®
1
M‑100 Gun, 10 ft (3 m), 100A, .030‑.035 (0.8‑0.9 mm) M‑150 Gun, 10 ft (3 m), 150A, .030‑.035 (0.8‑0.9 mm) M‑150 Gun, 12 ft (3.7 m), 150A, .030‑.035 (0.8‑0.9 mm) M‑150 Gun, 15 ft (4.6 m), 150A, .030‑.035 (0.8‑0.9 mm)
194 011
13 14
Service Parts/Consumables
®
13 12
11 10 14
MIG GUNS
M‑25 Item #
Service Parts/Consumables
Part # 169 594 169 596 169 598 169 599
Description
3 4 5 6 7 8 9 10 11 12 13 14 15
169 724 169 7251 200 258 169 7262 169 727 087 299 000 067 000 068 000 069 172 0341 169 728 169 729 170 468 169 730 169 731 169 738 169 732 169 737 227 799 227 800 209 495 079 974 194 010
15
194 011
15
194 012
15
194 0141
16 17 18 19 20
079 975 227 798 2520033 2280056 169 746
Nozzle, slip type, .500 (12.7 mm) orf .125 recess Nozzle, slip type, .625 (15.9 mm) orf .125 recess Nozzle, slip type, .500 (12.7 mm) orf flush Nozzle, slip type, .625 (15.9 mm) orf flush Nozzle, slip type, .625 (15.9 mm) orf .125 stickout Tip, contact scr, .023 (0.6 mm) wire x 1.125 Tip, contact scr, .030 (0.8 mm) wire x 1.125 Tip, contact scr, .035 (0.9 mm) wire x 1.125 Tip, contact scr, .045 (1.2 mm) wire x 1.125 Tip, contact scr 3/64 (1.19 mm) wire x 1.125 Adapter, contact tip Adapter, nozzle O-Ring Washer, shock Tube, head Nut, locking handle Nut, jam Handle, front Handle, rear Cord, trigger assembly Connector, feeder (includes) O-Ring, .500 ID x .103CS rbr Kit, liner monocoil .023/.025 (0.6 mm) wire x 15 ft (includes) Kit, liner monocoil .030 – .035 (0.8 – 0.9 mm) wire x 15 ft (includes) Kit, liner monocoil .035 – .045 (0.9 – 1.2 mm) wire x 15 ft (includes) Kit, liner monocoil 3/64 (1.19 mm) aluminum wire x 15 ft (includes) O-Ring, .187 ID x .103CS rbr Switch, trigger Cable strain relief 2 & 3 Screw Terminal
1
2
Quantity
M‑25 Gun, 10 ft (3 m), 250A, .030‑.035 (0.8‑0.9 mm) M‑25 Gun, 12 ft (3.7 m), 250A, .030‑.035 (0.8‑0.9 mm) M‑25 Gun, 15 ft (4.6 m), 250A, .030‑.035 (0.8‑0.9 mm) M‑25 Gun, 15 ft (4.6 m), 250A, .035‑.045 (0.9‑1.2 mm)
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1
(10 per pkg) (10 per pkg) (10 per pkg) (10 per pkg) (10 per pkg) (2 per pkg) (2 per pkg) (10 per pkg)
1 1 1 1 1 1 1 1
Included with #172 136 Kit, Aluminum Conversion .047 in (1.2 mm) Standard on all guns.
1 2
M‑25 can be used on:* ■
Millermatic® 200
■
Millermatic® 210/212/250x/251/252
■
Millermatic® 250
■
Millermatic® Vintage
■
Millermatic® Reach Wire Feeder
*For a detailed listing, please reference page 10.
13
MIG GUNS
Optional M‑Series Gun Nozzles and Tips Part # 176 243 178 386 176 797 176 793 176 794
187 117 187 118
14
Description M‑25 and M‑40 Tapered Nozzles Nozzle, Tapered 3/8 in (9.5 mm) Nozzle, Tapered 11/32 in (8.7 mm) M‑25 and M‑40 Tapered Contact Tips (1/4 in OD x 1.312 in) Contact Tip, Tapered .030 in (0.8 mm) Contact Tip, Tapered .035 in (0.9 mm) Contact Tip, Tapered .045 in (1.2 mm) M‑25 and M‑40 Heavy‑Duty Spray Contact Tips (5/16 in OD x 1.125 in) Contact Tip, Heavy Duty .035 in (0.9 mm) Contact Tip, Heavy Duty .045 in (1.2 mm)
Quantity 1 1 10 10 10
25 25
MIG GUNS Roughneck Consumables ®
Note: Standard gun components are in blue type.
VALUE MULTI-TURN FASTIP CONTACT TIPS .023–5/64" WIRE
VALUE MULTI-TURN DIFFUSERS
FLUSH (#199 622)
SCREW ON NOZZLES COPPER 5/8" ORIFICE 15/16" O.D. (#207 313)
1/8" RECESS (#199 621)
HEAVY DUTY 5/8" ORIFICE BRASS (#199 614) OR COPPER (#199 618)* *STD. ON 500/600A
EXTRA HEAVY DUTY FASTIP CONTACT TIPS .035–1/8" WIRE
HEAVY DUTY 3/4" ORIFICE BRASS (#199 612) OR COPPER (#199 617) STANDARD 1/2" ORIFICE BRASS (#199 610) OR COPPER (#199 615)
EXTRA HEAVY DUTY DIFFUSERS
FLUSH (#199 623)
1/8" RECESS (#198 857)
STANDARD 5/8" ORIFICE BRASS (#199 613) OR COPPER (#198 855)* *STD. ON 300/400A
STANDARD INSULATOR
STANDARD DIFFUSERS
STANDARD 3/4" ORIFICE BRASS (#199 611) OR COPPER (#199 616)
1/2" ORIFICE (#209 036)
(#198 856)
HEAVY DUTY FASTIP CONTACT TIPS .023–3/32" WIRE
FLUSH (#206 196)
.045" (#206 188) STD. ON 300/400A 1/16" (#206 190) STD. ON 500/600A
1/8" RECESS STD. ON ALL GUNS (#206 195)
SCREW ON COPPER TAPERED NOZZLES
GOOSENECKS
6.0" – STRAIGHT (#213 450)
4.5" – 48˚ BEND 360˚ SWIVEL STD. ON 300/400A (#199 625)
1/4" RECESS (#210 664) 6" – 48˚ BEND 360˚ SWIVEL STD. ON 500A (#199 626)
TAPERED FASTIP CONTACT TIPS .023–1/16" WIRE
3/8" ORIFICE (#209 035) 8" – 48˚ BEND 360˚ SWIVEL STD. ON 600A (#199 627)
SLIP ON COPPER TAPERED NOZZLES
1/2" ORIFICE (#209 033)
TAPERED FASTIP CONTACT TIPS .023–1/16" WIRE
SLIP ON TAPERED DIFFUSERS
1/8" RECESS (#D218)
TAPERED INSULATOR
(#209 047)
3/8" ORIFICE (#209 034)
Roughneck Contact Tips (10 p/pkg)
(25 p/pkg)
Heavy‑Duty FasTip™ — #206 184 — #206 185 #223 016 #206 186 #223 017 #206 187 #223 0181 #206 1881 #223 019 #206 189 #223 200 2 —
#206 1902 #206 191
— #206 192 — #206 193 Extra Heavy‑Duty FasTip™ — #199 605 — #199 606 — #198 851 — #198 852 — — —
#198 853 #198 854 #199 609
Description .023 in (0.6 mm) .030 in (0.8 mm) .035 in (0.9 mm) .040 in (1.0 mm) .045 in (1.2 mm) .052 in (1.3 mm) or 3/64 in (1.2 mm) alum wire 1/16 in (1.6 mm) .068 in (1.7 mm) 5/64 in (2.0 mm) 3/32 in (2.4 mm) .035 in (0.9 mm) .040 in (1.0 mm) .045 in (1.2 mm) .052 in (1.3 mm) or 3/64 in (1.2 mm) alum wire 1/16 in (1.6 mm) .068 in (1.7 mm) 7/64 – 1/8 in (2.8 mm)
(10 p/pkg) (25 p/pkg) Description Tapered FasTip™ — #209 024 — #209 025 — #209 026 — #209 027 — #209 028 — #209 029 — #209 030 Value Multi‑Turn — #087 300 — #071 825 — #054 202 — — — —
#054 201 #199 593 #047 566 #199 594
.023 in (0.6 mm) .030 in (0.8 mm) .035 in (0.9 mm) .045 in (1.2 mm) 3/64 in (1.2 mm) .052 in (1.3 mm) 1/16 in (1.6 mm) .023 in (0.6 mm) .030 in (0.8 mm) .035 in (0.9 mm) .045 in (1.2 mm) 3/64 in (1.2 mm) alum wire 1/16 in (1.6 mm) .068 in (1.8 mm) Optional For all gun lengths
1 2
15
MIG GUNS
Roughneck C‑Series ®
Item # 1* 2*
3*
Part # 198 855 199 6182 223 0181 206 1881 223 2002 206 1902 206 1953
Service Parts/ Consumables
Description Nozzle, scr type copper 5/8 in orifice Nozzle, scr type copper 5/8 in orifice heavy-duty Tip, contact, .045 in (1.2 mm) heavy-duty FasTip Tip, contact, .045 in (1.2 mm) heavy-duty FasTip Tip, contact, 1/16 in (1.6 mm) heavy-duty FasTip Tip, contact, 1/16 in (1.6 mm) heavy-duty FasTip Diffuser, gas 1/8 in tip recess – for standard and heavy-duty FasTip Liner, monocoil .023 – .030 wire x 15 ft round wound Liner, monocoil .035 – .045 wire x 15 ft round wound Liner, monocoil .052 – 1/16 wire x 15 ft round wound Liner, monocoil 1/16 – .078 wire x 15 ft flat wound Liner, monocoil 5/64 – 3/32 wire x 15 ft flat wound Liner, monocoil 7/64 – 1/8 wire x 15 ft flat wound Liner, monocoil 3/64 – 1/16 wire x 15 ft aluminum wires Gooseneck, jacketed 4.5 in/50˚ wrench swivel (C-30 / C-40) (includes) Gooseneck, jacketed 6 in/50˚ wrench swivel (C-50) (includes) Gooseneck, jacketed 8 in/50˚ wrench swivel (C-60) (includes) Gooseneck, jacketed 6 in/straight (optional for C-30 / C-40 /C-50 / C-60) (includes) Insulator, rubber Cover, nut Handle, small pair flared P style (C-30 / C-40 includes) Handle, large pair (C-50 / C-60 includes) Screw, M3 x 11 (for #199 630 C-30 / C-40 Handle only) Nut, M3 Hex (for #199 630 C-30 / C-40 Handle only) Screw, M4 x 18 Nut, M4 square Label, gun handle Miller Roughneck Switch, blue trigger Switch, locking trigger (optional) Switch, contact pin Conn, circ cpc clamp str rlf size 11.453 OD Housing plug + pins (service kit) Screw, machine binding head Adapter, Miller power pin (includes) O-ring, Miller power pin Cable Strain Relief 2 & 3 (300 Amp) Strain Relief Assy – Contact Bernard (400, 500, 600 Amp) Electrical Plug – Non D/S (Includes items 11 & 12) Strain Relief, Rear (works on all Amp guns) ™ ™
™ ™
Quantity 1 1 1 (10 per pkg) 1 (25 per pkg) 1 (10 per pkg) 1 (25 per pkg) 1
™
202 889 202 8901 202 8912 202 892 202 893 202 894 202 895 199 625
4
5
199 626 199 627 213 450 198 856 3 202 292 199 630 199 631 199 634 199 635 199 632 199 633 199 647 (N/A) 199 628 199 661 (N/A) 199 629 079 531 079 878 199 637 199 640 079 974 2520033 2520041 (N/A) GN2021 227 650
6 7 8 8
9 10 11 12 13 14 15 16 17 18
Aluminum Adapter Kit #202 895 Steel wrapped nylon liner allows 10 ft Roughneck welding guns to feed 3/64 – 1/16 in (1.2 – 1.6 mm) aluminum wire. Tweco No. 3, 4 & 5 Upgrade Kit #214 8934 Upgrades Tweco No. 3, No. 4, and No. 5 guns to use Roughneck consumables. Includes insulator and diffuser. Standard on 300 and 400 amp guns Standard on 500 and 600 amp guns 3 Standard on all guns 1 2
Nozzle (SCR type) and contact tip not included.
4
Note: For a complete listing of Roughneck consumables see page 15.
16
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 2 1 1 2 1 1 1 1 2 1 1 1
Stock No. 194 751 194 752 194 753 194 754 194 755 194 756 194 757 194 758 194 759
Roughneck MIG Gun Replacement Model No. Length Replaced by C-3010 10 ft. (3m) Q3010TE5EMC C-3012 12 ft. (3.7m) Q3012TE5EMC C-3015 15 ft. (4.6m) Q3015TE5EMC C-4010 10 ft. (3m) Q4010TE5EMC C-4012 12 ft. (3.7m) Q4012TE5EMC C-4015 15 ft. (4.6m) Q4015TE5EMC C-5010 10 ft. (3m) S5010GH5IMC C-5012 12 ft. (3.7m) S5012GH5IMC C-5015 15 ft. (4.6m) S5015GH5IMC Available through Bernard™
MIG GUNS Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
150 Amp MIG Gun
Service Parts/Consumables
Part # 235 570 NS‑1200B T‑030 DS‑1 4323R QT2‑45 QJL‑2330 2660001 1780062 2620054 4207 4209 18801941 (N/A) 49321 (N/A) 2520007 2520048 M1010027‑11 (N/A) 2520047M1 (N/A) 22001371 (N/A) 194011 214‑91 (N/A) 2280056 16200031 (N/A)
Description 150A Best of the Best, 10 ft. Centerfire Nozzle Assy Centerfire Contact Tip Centerfire Gas Diffuser Cap Neck Jump Liner Terminal, Quick Disconnect (2 Req'd) Handle Half, Upper Switch Assy, Handle Half, Lower Post Fastener (2 Req'd) Handle Screw (2 Req'd) Handle Kit - (Includes: (1) #8, (1) #9, (2) #10, (2) #11) Butt Connector (2 Req'd) Cap, Rigid Strain Relief Spring, Strain Relief Adaptor Block Strain Relief with Trigger Cable Miller® Power Pin Liner Miller Power Pin Tip Screw, Strain Relief (Not Req'd on Bernard Direct Plug) Screw Cover, Strain Relief (1 Req'd)
1 3 5 2 4 7
6
11
10
9
12 8
13
14 15 16
22 21
17
AMP
Bernard
™
18
19
20
17
MIG GUNS
Bernard
300 Amp Best of the Best MIG Gun Service Parts/Consumables
3
300 Amp Best of the Best MIG Gun, Miller Connection Part # Intergrated Miller Product Standard Configuration Cable Length Duty Cycle Q3015AE8XMC 22A and 24A Feeders, .045" (1.2 mm), Flush Tip 15' (4.57 m) 100% Millermatic 350/350P Q3015AE8HMC Suitecase 8RC, 8VS, X-TREME .052" (1.4 mm) 15' (4.57 m) 100% 8VS, 12RC, X-TREME 12VS MIG Packages Q3015AE8XMC can be converted to run .035” (0.9 mm) wire by simply changing the contact tip. Q3015AE8HMC can be converted to run .045” (1.2 mm) or 1/16” (1.6 mm) wire.
Quantity 5 4
7 9
11
13
10
6 12
8
9
15
14
16 22
17
25
20 21
23
24
18
19
18
2
1
Description Centerfire Nozzle Centerfire Contact Tip Centerfire Gas Diffuser Insulator Cap Neck Jump Liner Stay-Tite™ End Fitting Stay-Tite™ Cone Nut Conduit Clamp (2 Req'd) Jacket Clamp (2 Req'd) Handle Kit, Standard Trigger, Standard Post Fastener (1 Req'd) Post Fastener, Short (4 Req'd) Handle Screw (5 Req'd) Terminal, Quick Disconnect (2 Req'd) Handle Spring Straight Rear Strain Relief Adaptor Block Miller Power Pin Assembly Liner Power Pin Tip Power Pin Insulator Rear Terminal Housing Screw, Trigger Housing (2 Req'd) Cover, Rear Screw (2 Req'd) Trigger Control Plug Assembly
DS-
Part # Part # Part # Q3015AE8XMC Q3015AE8VMC Q3015AE8HMC N‑5800C NS‑5818C T‑045 T‑035 T‑052 D‑1 DS‑1 4423R 4323R QT3‑45 QJL‑3545 QJL‑116 4213B 4305 49911 (N/A) 49391 (N/A) 1880155 5662 4207 2030004 1 (N/A) 4209 2660001 25200741 (N/A) 4101 (N/A) 414‑4001 (N/A) 22001371 (N/A) L3A‑15 L3A‑15 L4A‑15 214‑1161 (N/A) 414‑400‑201 (N/A) 416‑151 (N/A) 411‑3M1 (N/A) 16200041 (N/A) 419‑4
1
RD
Item # 1 2 3 4 5 6 7 8 NS NS 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
™
MIG GUNS
Bernard Item # 1 2 3 4 5 6 7 8 NS NS 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
™
400 Amp Best of the Best MIG Gun
1
Service Parts/Consumables
Part # Q4015AE8EMC N‑5818C T‑045 D‑1 4423R QT3‑45 QJL‑3545 4313B 1540003 4992 4939 1880198 5662 4207 4209 2660001 2520042 1680088 412‑1 2520041 410 414‑400 2200137 414‑400‑20 L3A‑15 416‑5 411‑3M 1620004 419‑4 214‑332
2
Description Centerfire Nozzle Centerfire Contact Tip Centerfire Gas Diffuser Insulator Cap Neck Jump Liner Stay-Tite™ End Fitting Stay-Tite™ Cone Nut Conduit Clamp (2 Req'd) Jacket Clamp (2 Req'd) Handle Kit, Standard Trigger, Standard Post Fastener (1 Req'd) Handle Screw (5 Req'd) Terminal, Quick Disconnect (2 Req'd) Handle Spring End Fitting, Rear Switch Connector (2 Req'd) Spring, Strain Relief Straight Rear Strain Relief Adaptor Block Power Pin Power Pin Insulator Liner Terminal Housing Screw, Trigger Housing (2 Req'd) Screw, Cover Rear Housing (2 Req'd) Trigger Control Plug Assembly Power Pin Tip
Quantity
3
5 4 12
7 9
6
9
10
11 8
9 14
13
8
16
15
17
400 Amp Best of the Best MIG Gun, Miller Connection Intergrated Miller Part # Product Q4015AE8EMC 70 Series, R-115 Feeders, All Axcess feeders
18
Standard Configuration .045" (1.2 mm)
Cable Length 15' (4.57 m)
Gun can be converted to run .035” (0.9 mm) wire by simply changing the contact tip.
Duty Cycle 100%
19 20
23 24
27 21 22
25
26
19
MIG GUNS
Bernard Item # 1 2 3 4 5 6 7 NS NS 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
™
500 Amp Best of the Best MIG Gun Service Parts/Consumables
Part# Q5015GI8LMC N‑5814C T‑094 D‑1 4323R QT5‑60 1680050 1540004 4993 4944 1880220* 177488 177272 203296‑005 177271 616‑70 414‑400 2200137 L7A‑15 214‑332 414‑400‑20 416‑15 411‑3M 1620004 419‑4
Description Centerfire Nozzle Centerfire Contact Tip Centerfire Gas Diffuser Insulator Cap Neck Stay-Tite™ End Fitting Stay-Tite™ Cone Nut Conduit Clamp (2 Req'd) Jacket Clamp (2 Req'd) Handle Kit, Standard Trigger, Standard Nut, Square (4 Req'd) Screw (4 Req'd) Contact Pin (2 Req'd) Straight Rear Strain Relief Adaptor Block Miller Power Pin Assembly Liner Power Pin Tip Power Pin Insulator Rear Terminal Housing Screw, Trigger Housing (2 Req'd) Cover, Rear Screw (2 Req'd) Trigger Control Plug
1 3 2
5
7
10
8
4
11
6
9
12
*1880220 Handle Kit includes halves, screws and nuts
500 Amp Best of the Best MIG Gun, Miller Connection Part # Intergrated Miller Product Q5015GI8LMC Steel RunnerTM 650
19
13
Standard Configuration Cable Length Duty Cycle 3/32" (2.4 mm) 15' (4.57 m) 100%
20
Gun can be converted to run .035” (0.9 mm) wire by simply changing the contact tip.
14
21
15 22 16 17 18
20
MIG GUNS
Liners for Bernard Universal Conventional Liner Part Numbers Wire Size .023-.030 .030-.035 .035-.045 045-1/16 5/64 3/32 7/64 - 1/8
Liner Color Yellow Green White Red Blue Grey Black
™
300, 400 & 500 Amp Best of the Best MIG Guns Service Parts/Consumables 10' (3.05m) - - L3A-10 * (N/A) L4A-10 ** (N/A) - - - -
15'(4.57m) L1A-15 L2A-15 (N/A) L3A-15* L4A-15** L6A-15 L7A-15 L8A-15
10" (3.05 m) N/A N/A N/A N/A N/A N/A
15' (4.57 m) 43015X 1920343 43115X 1920344 44215X 1920345
*Standard Liner for .035 & .045 Guns **Stanard Liner for 1/16 Guns
Aluminum/Soft Wire Liners Wire Size .035 (.9 mm)
Gun Amperage 150A 600A Nylon 200A-600A Steel 200A-600A Nylon 200A-600A Steel 200A-600A Nylon 200A-600A Steel
3/64 (1.2 mm) 1/16 (1.6 mm)
Centerfire Consumable Series for ™
300, 400 & 500 Amp Best of the Best MIG Guns Service Parts/Consumables
NS-5800C (5/8" I.D.,(5/8" Flush, Copper) NS-5800C I.D., Flush, Copper) NS-5818C (5/8" I.D.,(5/8" 1/8" I.D., Rec.,1/8" Copper) NS-5818C Rec., Copper) NS-5800B (5/8" I.D., Flush, Brass) NS-5800B (5/8" I.D., Flush, Brass) NS-5818B (5/8" I.D.,(5/8" 1/8" I.D., Rec.,1/8" Brass) NS-5818B Rec., Brass)
™ ™ Small Centerfire Gas Diffusers and Nozzles Small Centerfire Gas Diffusers and Nozzles
'T' Series Tip 'T' Series Tip -see chart-see chart
NS-1218C (1/2" I.D.,(1/2" 1/8" I.D., Rec.,1/8" Copper) NS-1218C Rec., Copper) NS-1200B (1/2" I.D.,(1/2" Flush, Brass) NS-1200B I.D., Flush, Brass) NS-1218B (1/2" I.D.,(1/2" 1/8" I.D., Rec.,1/8" Brass) NS-1218B Rec., Brass)
7010024 7010024NS-FLX Self-Shielded Conversion Kit NS-FLX Self-Shielded Conversion Kit Insulator Insulator 4323R
4323R
DS-1
7010046 7010046 Tip HolderTip Holder
DS-1
(Includes(Includes tip holdertip and both and insulators) holder both insulators)
7010059 7010059 Insulator Insulator
'TT' Series'TT' TipSeries Tip -see chart-see chart
™ ™ Large Centerfire Gas Diffusers and Nozzles Large Centerfire Gas Diffusers and Nozzles
'T' Series Tip 'T' Series Tip -see chart-see chart
10012
10012
D-1
D-1
1.50 1.50 [38.1 mm] [38.1 mm]
'T' Series'T' Tip Series Tip T-023 T-030 T-035 T-039 T-045 T-052 T-062 T-072 T-078 T-094 T-109 T-125
.023" (.6 .023" mm) (.6 mm) T-023 .030" (.8 .030" mm) (.8 mm) T-030 .035" (.9 .035" mm) (.9 mm) T-035 .039" (1.0.039" mm)(1.0 mm) T-039 .045" (1.2.045" mm)(1.2 mm) T-045 .052" (1.4.052" mm)(1.4 mm) T-052 1/16" (1.6 mm)(1.6 mm) T-062 1/16" .072" (1.8.072" mm)(1.8 mm) T-072 5/64" (2.05/64" mm)(2.0 mm) T-078 3/32" (2.43/32" mm)(2.4 mm) T-094 7/64" (2.87/64" mm)(2.8 mm) T-109 1/8" (3.21/8" mm)(3.2 mm) T-125
NST-3800B (3/8" I.D.,(3/8" Flush, Brass) NST-3800B I.D., Flush, Brass) NST-3818B (3/8" I.D.,(3/8" 1/8" I.D., Rec.,1/8" Brass) NST-3818B Rec., Brass) NST-38XTB (3/8" I.D.,(3/8" 1/8" I.D., Extension, Brass) Brass) NST-38XTB 1/8" Extension,
N-3400CN-3400C (3/4" I.D.,(3/4" Flush, Copper) I.D., Flush, Copper) N-3418CN-3418C (3/4" I.D.,(3/4" 1/8" I.D., Rec.,1/8" Copper) Rec., Copper) N-3414CN-3414C (3/4" I.D.,(3/4" 1/4" I.D., Rec.,1/4" Copper) Rec., Copper) N-3418BN-3418B (3/4" I.D.,(3/4" 1/8" I.D., Rec.,1/8" Brass) Rec., Brass) N-3414BN-3414B (3/4" I.D.,(3/4" 1/4" I.D., Rec.,1/4" Brass) Rec., Brass) N-5800CN-5800C (5/8" I.D.,(5/8" Flush, Copper) I.D., Flush, Copper) N-5818CN-5818C (5/8" I.D.,(5/8" 1/8" I.D., Rec.,1/8" Copper) Rec., Copper) N-5814CN-5814C (5/8" I.D.,(5/8" 1/4" I.D., Rec.,1/4" Copper) Rec., Copper) N-5818BN-5818B (5/8" I.D.,(5/8" 1/8" I.D., Rec.,1/8" Brass) Rec., Brass) N-5814BN-5814B (5/8" I.D.,(5/8" 1/4" I.D., Rec.,1/4" Brass) Rec., Brass)
2.00 2.00 [50.8 mm] [50.8 mm]
'TT' Series Tip 'TT' Series Tip TT-023 TT-030 TT-035 TT-039 TT-045 TT-052 TT-062
.023" (.6 .023" mm) (.6 mm) TT-023 .030" (.8 .030" mm) (.8 mm) TT-030 .035" (.9 .035" mm) (.9 mm) TT-035 .039" (1.0.039" mm)(1.0 mm) TT-039 .045" (1.2.045" mm)(1.2 mm) TT-045 .052" (1.4.052" mm)(1.4 mm) TT-052 1/16" (1.61/16" mm)(1.6 mm) TT-062
NT-3800C (3/8" I.D.,(3/8" Flush, Copper) NT-3800C I.D., Flush, Copper) 'TT' Series'TT' TipSeries Tip -see chart-see chart
21
MIG GUNS U.S.
2 5 19
4
21 12
6
8 7 18
AMP
11
9
17
10
16
13
20
14
15
1
MIG Gun Part# 195400 ‑ 300 Amp 15ft Gun Service Parts/Consumables
DE MA IN
3
. U.S.A
.035
Pipeworx
3
Description Centerfire Nozzle Centerfire Contact Tip Centerfire Gas Diffuser Insulator Cap Q‑Nut Insulator, Front Neck Q‑Neck Cover Q‑Neck Insulator, Rear Jump Liner Nut Screw Handle Half, Upper Lower Handle Half & Switch Assy. Handle Kit (Includes items #10, #11, #12, #13) Terminal Butt Connector Spring Strain Relief Strain Relief Set with plug Screw Screw Cover Cover, Rear Screw (2 Req'd) Trigger Control Plug Liner Power Pin Tip
NST A.
Part# NST‑3800B TT‑035 DS‑1 4323R 1840057‑2 QT2‑60 1840057‑1 1840031 QJL‑3545 4207 4209 1780062 2620054 1880194 2660001 4932 2520048 2520007 2520047M 2280056 1620003 2200101 1010027 L3B‑15 2200135
Service Parts/Consumables
IN
Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
MIG Gun Part# 195399 ‑ 250 Amp 15ft Gun DE MA
Pipeworx
1
21
2 5
4
20
6 19
7
7
8
18
16
AMP
17
9
15
11 14
14
10 12
13
22
MIG GUNS
Pipeworx
E IN MAD U.S.
3
A.
.035
21
2
D-1
Description Centerfire Nozzle Centerfire Contact Tip Centerfire Gas Diffuser Insulator Cap Q-Nut Insulator, Front Neck Q-Neck Cover Q-Neck Insulator, Rear Jump Liner Handle Kit (Includes handle and items # 13, 14, 15, 16) Trigger Terminal Screw Nut Handle Spring Strain Relief Strain Relief Set Butt Connector Electrical Connection Screw Screw Cover Adaptor Block Power Pin Assy. Liner Power Pin Tip
1
D
Part# NS‑5818C T‑045 D‑1 4423R 1840057‑2 QT2‑60 1840057‑1 1840031 QJL‑3545 1880198 5662 2660001 4209 4207 2520042 2520041 2520066 4932 GN2021 2280056 1620003 1010027 2200101 L3B‑15 2200135
Service Parts/Consumables
R NA
Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
MIG Gun Part# 300240 ‑ 400 Amp 15ft Gun
5 4
20
6
19
7
7
8
18
16
AMP
17
9
15 12 14
10
14
11
13
23
MIG GUNS
PipePro Dura‑Flux XC ®
™
Service Parts/Consumables
1 2 3
Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Part # 7010070, 7010071, 7010072 7010062 T1116 7010068 QJL‑116 QJL‑564 1760010 1760011 2280047 2030030 4209 4207 5662 1880255 1880256 2660001 2520056 4932 1010027 GN2021 20006A 2520066 2280056 1620003 1880251 2200131 396 444715 444815
Description Insulator Tip Contact Tip, Quik Tip, 1/16" (1.6 mm) (Installed On Gun) Neck, R2" (50.8 mm) X 70 Jump Liner, .045-1/16" (Installed on Gun) Jump Liner, 5/64" (Included with Gun) Trigger Guard Heat Shield (Optional) Screw, #8-32 x 1-1/2 (2 req'd) Nut, #8-32 (2 req'd) Handle Screw (4 Req'd) Post Fastener (4 Req'd) Switch Assy, Trigger Handle Kit, Standard (Includes Handle Halves) Handle Kit, Dual Schedule (Includes Handle Halves) Terminal, Quick Disconnect (2 Req'd) Spring, Strain Relief Butt Connector, (2 Req'd) Adapter Block Electrical Plug - Non Dual Schedule Electrical Plug - Dual Schedule Rigid Strain Relief Screw, Strain Relief Screw Cover, Strain Relief Miller Power Pin Kit Power Pin, Miller Set Screw, Liner Liner, .045-1/16", 15' (4.57 m) (Installed on Gun) Liner, 5/16", 15' (4.57 m) (Installed on Gun)
8 6
7
9
5 4
11
10 11
12
13
14 15 16
18
Liner Replacement Instructions and Services Removing Existing Liner Turn off power. Remove neck from gun assembly. Lay cable straight. Loosen liner retention set screw on the power pin. Grasp liner which protrudes from power pin and remove from cable assembly. Install Replacement Liner Insert liner into power pin with cable laying straight. Position the liner so that it extends approximately 1" (25.4 mm) beyond the gun handle. Tighten liner retention set screw to secure liner to cable assembly. Make sure cable is straight before trimming liner. Trim and deburr the front of the liner with 1/4" (6.4 mm) extending beyond the gun handle and reinstall neck. Trim and deburr the back end of the liner with 1/8" (3.2 mm) extending beyond the power pin. Service Inspect for excessive wear and debris on the inside diameter. Do not dip liner in solvents for cleaning. Liner may be periodically blown out with shop air. Replace with new liner when excessive wear or debris produces poor electrode feed.
24
19
17
1-1/2" 1-1/4" 1" 3/4" 1/2" 1/4"
21 20
22
0 23
MIG GUNS
Bernard S‑Gun ™
Item # 1 2 3 4 5 6A 6B 6C 7 8 NS 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Part # S2515TE5EM N1C58Q T1045 T1052 D118Q 10012 QT3‑45L 1680074‑2 1840057 1840031 1680074‑1 1540007 407709‑013 1880219 203296‑005 2280044 177272 2030029 177488 177271 2520056 2520066 4932 1199M L4A‑15 1010036 2280056 1620003 GN2021
™
250 Amp MIG Gun
1
Service Parts/Consumables
Description Nozzle Assy Contact Tip, Quik Tip, .045" (1.2 mm) Contact Tip, Quik Tip, .052" (1.4 mm) Gas Diffuser Cap Neck, Rotatable/Locking, Medium End Fitting Lock (Included with Neck) Hand Nut (Included with Neck) Insulator (Included with Neck) Stay-Tite™ End Fitting Stay-Tite™ Cone Nut Jacket Clamp (2 Req'd) Handle Kit - Std. Trigger Handle Screw, Large (4 Req'd) Handle Screw, Small Handle Nut, (4 Req'd) Handle Nut, Small Trigger, Standard Trigger Pin (2 Req'd) Spring Strain Relief Strain Relief Butt Connector Miller Power Pin Assembly Liner Adapter Block Screw, Strain Relief Screw Cover, Strain Relief Electrical Plug - Non D/S
3
5
2
6b
4 7
6c
6a
12 14
9
10 8
11 13 9
15
16
17
18
22
21
23 24
19
20
25
MIG GUNS
Bernard Dura‑Flux ™
Item # 1 2 3 4 5
6
Part # FLX3515AM 7010024 7010059 7010026 1880229 T‑062 T‑072 T‑078 T‑094 7010031 7010032
7 1880232 1880222 1880230 1880223 1880231 1880236 1880233 1880235 1880234 1880237 7010034 2280047 2030030 1880224 1760002 2250017 198820 2280046 4209 2030004 1880225 5662 2660001 7010015 610 416‑15 7010035 4421 1880226
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
™
with Fixed Power Cable Liner Service Parts/Consumables
Description Insulator Tip Heavy-Duty Insulator Tip Tip Holder, Slip-On Tip Holder Kit (Includes: (1) #1, (1) #2, (1) #3) Centerfire Contact Tip, 1/16" (1.6 mm) (Included w/Gun) Centerfire Contact Tip, .072" (1.8 mm) (Included w/Gun) Centerfire Contact Tip, 5/64" (2.0 mm) (Included w/Gun) Centerfire Contact Tip, 3/32" (2.4 mm) (Included w/Gun) Neck Liner, 6" (15.2 cm) Neck, Liner, 12" (30.5 cm) Neck Replacement Kit (Includes: (1) #6, (1) #7) Sleeved, 6" (15.2 cm) x 30 Sleeved, 6" (15.2 cm) x 60 Sleeved, 8" (20.3 cm) x 90 Sleeved, 12" (30.5 cm) x 30 Sleeved, 12" (30.5 cm) x 60 Aluminum Armored, 6" (15.2 cm) x 30 Aluminum Armored, 6" (15.2 cm) x 60 Aluminum Armored, 8" (20.3 cm) x 90 Aluminum Armored, 12" (30.5 cm) x 30 Aluminum Armored, 12" (30.5 cm) x 60 Trigger Guard Screw, #8-32 x 1-1/2 (2 Req'd) Nut, #8-32 (2 Req'd) Trigger Guard Kit (Includes: (1) #8, (2) #9, (2) #10) Heat Shield (Optional) Snap Ring Clamp Screw, 1/4-20, Hex Socket Handle Screw (3 Req'd) Post Fastener (3 Req'd) Handle Kit (Includes: Handle Halves, (2) #9, (2) #10, (3) #16, (3) #17) Switch Assy, Trigger Terminal, Quick Disconnect (2 Req'd) Cord Assembly, 15' (4.57 m) Rigid Strain Relief Housing, Rigis Strain Relief Liner, Power Pin, Miller O-Ring Miller Power Pin Kit (Includes: Miller Power Pin, (1) #24, (1) #25)
For additional parts call Bernard at 1‑855‑MIGWELD (644‑9353).
Quantity
2
3
4
5
1 6
7
9 8 10
17 18
12 13
19
15
11
21 20
22 25 23
26
29
27
30
24
28
Dura-Flux 350 AMP
26
14
15 16
MIG GUNS
Ironmate™ FC‑1150 450-Amp, Self-Shielded Flux Cored Welding Gun
Ironmate™ FC‑1260 350-Amp, Self-Shielded Flux Cored Welding Gun
Ironmate Flux Cored Guns ™
Model FC‑1260 FC‑1260 90˚ FC‑1260LM FC‑1150
Part # 195 732 195 729 237 410 213 439 194 912 194 911 194 864 194 863
Length 10 ft (3 m) 15 ft (4.6 m) 10 ft (3 m) 15 ft (4.6 m) 10 ft (3 m) 15 ft (4.6 m) 10 ft (3 m) 15 ft (4.6 m)
Weight 8.5 lb (3 kg) 11 lb (5 kg) 8.5 lb (3 kg) 11 lb (5 kg) 8.5 lb (3 kg) 11 lb (5 kg) 9.5 lb (4.3 kg) 12 lb (5.4 kg)
Rating and Duty Cycle 350 A at 60% Duty Cycle 350 A at 60% Duty Cycle 350 A at 60% Duty Cycle 450 A at 60% Duty Cycle
.035 and .045 in (0.9 and 1.2 mm) are available via optional Conversion Kit #199 178.
1
Consumables Wire Size 1/16 – 3/32 in (1.6 – 2.4 mm) 1 1/16 – 3/32 in (1.6 – 2.4 mm) 1 1/16 – 3/32 in (1.6 – 2.4 mm) 1 3/32 – 1/8 in (2.4 – 3.2 mm)
Contact Tips (25 per package) .035 in (0.9 mm) .045 in (1.2 mm) 1/16 in (1.6 mm) .068 – .072 in (1.7 – 1.8 mm) 5/64 in (2.0 mm) 3/32 in (2.4 mm) 7/64 in (2.8 mm) .120 in (3.0 mm) 1/8 in (3.2 mm) Insulated Thread Protector (5 per package) Nozzles Insulated Flush Insulated 2 in (51 mm) Stickout Insulated 2-3/4 in (70 mm) Stickout Replacement Liners 1/16 – 3/32 in (1.6 – 2.4 mm) for Cable 1/16 – 3/32 in (1.6 – 2.4 mm) for Gooseneck (Short) 1/16 – 3/32 in (1.6 – 2.4 mm) for Gooseneck (Medium) 1/16 – 3/32 in (1.6 – 2.4 mm) for Gooseneck (Long) .045 in (1.2 mm) Conversion for Cable and Gooseneck 3/32 – 1/8 in (2.4 – 3.2 mm) for Cable 3/32 – 1/8 in (2.4 – 3.2 mm) for Gooseneck
FC‑1260 #209 248 2 #198 784 2 #198 785 #198 786 #198 788 #198 790 — — —
FC‑1150 — — — — — #201 256 #201 257 #201 258 #201 259
#198 800 3
—
#198 801 #198 802
#201 261 —
#198 803
#201 262 3
#195 731
—
#198 791
—
#198 792
—
#198 793
—
#199 178
—
—
#201 246
—
#201 260
Use .045 in Conversion Kit #199 178. Standard
2 3
27
MIG GUNS
Ironmate Item # 1 2 3
4 4 5 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 26 27 28 29 30 30 31 Optional
1
28
Part # 201 262 201 261 201 256 201 257 201 258 201 259 201 250 1 201 2511 201 247 201 2481 201 2491 201 2521 201 253 (N/A) 201 254 201 255 201 260 201 245 — 198 681 135 646 224 083 224 083 194 714 (N/A) 198 821 081 664 198 820 133 774 198 819 000 369 198 743 (N/A) 602 202 070 001 194 713 195 735 079 878 198 894 (N/A) 201 246 201 276 (N/A) 201 277 (N/A) 195 733
™
FC‑1150
Service Parts/Consumables Description Nozzle, insulated 2-3/4 in stickout Nozzle, insulated 2 in stickout Tip, contact 3/32 in Tip, contact 7/64 in Tip, contact .120 in Tip, contact 1/8 in Gooseneck, 82˚ bend (includes) Gooseneck, 82˚ bend, aluminum jacketed (includes) Gooseneck, 25˚ bend (includes) Gooseneck, 45˚ bend, (includes) Gooseneck, 45˚ bend, aluminum jacketed (includes) Gooseneck, straight 5˚ bend, (includes) Liner, locking screw 3/8 in – 16 Insert, steel Insert, ceramic Liner, gooseneck replacement (short, for 6 in goose) Shield Kit, heat (consists of) Shield, heat (not available separately) Nut, 008-32 .34 hex .23h stl pld elastic stop nut Screw, 008-32 x 1.50 rnd hd-phl stl pld Housing Kit with Hardware — less switch Housing assembly, trigger Handle Kit, assembly (consists of) Shield, spatter Ring, rtng ext .625 shaft grv x .042 thk e style Clamp Screw, cap stl sch .250-20 x .625 pld Handle Switch, limit 10 amp, 125/250 VAC Clamp, switch housing Washer, tooth .168 id x .340 od x .023 t stl pld Screw, 008-32 x .25 hexwhd-pln stl pld Switch Kit, assembly 15 ft (consists of) Switch Kit, assembly 10 ft (consists of) Housing Plug and Pins (service kit) Screw, set #8-32 x .312 — liner locking Kit, replacement standard liner 15 ft (includes) Label, FC-1150 gun, 10 ft Label, FC-1150 gun, 15 ft Kit, insulator sleeve with spring and screws
Quantity 1 1 1 (25 per pkg) 1 (25 per pkg) 1 (25 per pkg) 1 (25 per pkg) 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1
MIG GUNS
Ironmate Item # 1 2 3 4 5
6
7
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 31 32 33
Part # 198 803 198 802 198 801 198 800 1 209 248 2 198 784 2 198 785 198 786 198 788 198 790 198 794 1 199 332 198 795 199 333 198 798 199 334 198 796 199 335 198 797 199 336 198 799 198 752 3 198 758 3 198 806 3 198 791 198 792 198 793 194 712 — 198 681 135 646 194 714 (N/A) 198 821 081 664 198 820 133 774 198 819 194 713 195 735 198 743 (N/A) 602 202 070 001 224 083 079 531 079 878 000 369 198 894 (N/A) 195 731 199 178 166 575 198 759 (N/A) 198 767 (N/A) 195 733 202 295 202 294 202 692
™
FC‑1260 and FC‑1260LM Service Parts/Consumables
Description Nozzle, insulated 2-3/4 in stickout Nozzle, insulated 2 in stickout Nozzle, insulated Protector, thread Tip, contact .035 (0.9 mm) Tip, contact .045 (1.2 mm) Tip, contact 1/16 (1.6 mm) Tip, contact .068 – .072 (1.7 – 1.8 mm) Tip, contact 5/64 (2.0 mm) Tip, contact 3/32 (2.4 mm) Gooseneck, 6 in, 50˚ bend (includes) Gooseneck, 6 in, 50˚ bend, aluminum jacketed (includes) Gooseneck, 12 in, 50˚ bend (includes) Gooseneck, 12 in, 50˚ bend, aluminum jacketed (includes) Gooseneck, 6 in, 90˚ bend (includes) Gooseneck, 6 in, 90˚ bend, aluminum jacketed (includes) Gooseneck, 6 in, 30˚ bend (includes) Gooseneck, 6 in, 30˚ bend, aluminum jacketed (includes) Gooseneck, 12 in, 30˚ bend (includes) Gooseneck, 12 in, 30˚ bend, aluminum jacketed (includes) Gooseneck, 8 in straight with 5˚ bend (includes) Liner, locking screw 5/16 in – 18 Insert, steel Insert, ceramic Liner, gooseneck replacement (short, for 6 in goose) Liner, gooseneck replacement (med, for 8 in goose) Liner, gooseneck replacement (long, for 12 in goose) Shield Kit, heat (consists of) Shield, heat (not available separately) Nut, 008-32 .34 hex .23h stl pld elastic stop nut Screw, 008-32 x 1.50 rnd hd-phl stl pld Handle Kit, assembly (consists of) Shield, spatter Ring, rtng ext .625 shaft grv x .042 thk e style Clamp Screw, cap stl sch .250-20 x .625 pld Handle Switch Kit, assembly 15 ft (consists of) Switch Kit, assembly 10 ft (consists of) Clamp, switch housing Washer, tooth .168 id x .340 od x .023 t stl pld Screw, 008-32 x .25 hexwhd-pln stl pld Aluminum Housing Kit with Hardware — less switch Conn, circ cpc clamp str rlf size 11 .453 od Housing Plug and Pins (service kit) Switch, limit 10 amp, 125/250 VAC Screw, set #8-32 x .312 — liner locking Kit, replacement standard liner 15 ft (includes) Kit, .045 conversion monocoil liner 15 ft (includes) Wrench, hex .078 across flat Label, FC-1260 gun, 10 ft Label, FC-1260 gun, 15 ft Kit, insulator sleeve with spring Insulator, phenolic (FC-1260LM only) Adapter, Miller feeder (FC-1260LM only) Adapter, Miller to Lincoln trigger leads (FC-1260LM only)
Quantity 1 1 1 1 (5 per pkg) 1 (25 per pkg) 1 (25 per pkg) 1 (25 per pkg) 1 (25 per pkg) 1 (25 per pkg) 1 (25 per pkg) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Standard Use .045 in Conversion Kit 3 Items recessed in Gooseneck Note: Each Gooseneck includes locking screw liner, inserts, and appropriate gooseneck liner. 1 2
29
MIG GUNS
Hobart MIG Gun History Machine Handler®
Handler® 125 Handler® 125EZ
Spec # / Stock # 6969-1 All Other 6969 Series 7144-1 and 71441A-1 All Other All All
Original Gun GAL-90 GAL-100 GAL-100 Piecemaker® 14-A H-9A, pg 30; H-9, pg 30 H-9A, pg 30
Handler® 130XL Handler® 135/140 Handler® 150 Handler® 175/180 Handler® 187 Handler® 190 Handler® 210 Handler® 210MVP IronMan™ 210 IronMan™ 230 IronMan™ 250/270 Trek 180
All All All All All All All All All All All All
GA-16CA H-10, pg 37 Piecemaker® 14-A H-10, pg 37 H-10, pg 37 H100S4-10, pg 32 H-14, pg 37 H100S4-10, pg 32 M-10, pg 11 H200L4-15, pg 32 M-25, pg 13 H100L4-10, pg 33
Handler® 120
Recommended Replacement Gun Bernard TGX Series #S1815 and #214 (Tweco #4 Power Pin ) 1 Bernard TGX Series #S1815 and #214 (Tweco #4 Power Pin ) 1 Bernard TGX Series #XS1815 and #214-4 ( L-Tec Power pin) 1 Bernard TGX Series #XS1815 and #214-4 ( L-Tec Power pin) 1 H-9 #195 157R, pg 30 H-9 #195 157R, pg 30 M-100 #248 282, pg 12 (Purchase # 193681, Power Pin) H100S2-10 #245 924, pg 32 Bernard TGX Series #XS1815 and #214-4 ( L-Tec Power pin) 1 H100S2-10 #245 924, pg 32 H100S2-10 #245 924, pg 32 H100S4-10 #245 926, pg 32 H100S4-10 #245 926, pg 32 H100S4-10 #245 926, pg 32 M-100/M-150, pg 12 H200L4-15 #239 173, pg 33 M-25, pg 13 H100L4-10 #243 864, pg 33
1
H‑9A/9B 195 157R
—
H‑9A Gun 8 ft (2.4 m), 100 A, .030–.035 (0.8–0.9 mm)
—
195 157R
3 4 5 6
169 715 226 190 087 2991 000 067 000 068 169 716 170 470 210 969 (N/A) 210 970
169 715 226 190 087 2991 000 067 000 0681 169 716 — 226 079 210 970
7 8 9
211 450 (N/A) 226 080 — 226 010 — 225 410
H‑9B Gun 8 ft (2.4 m), 100 A, .030–.035 (0.8–0.9 mm) Nozzle, slip type .500 (12.7 mm) orf flush Nozzle, slip type flux cored Tip, contact scr .023 (0.6 mm) wire x 1.125 Tip, contact scr .030 (0.8 mm) wire x 1.125 Tip, contact scr .035 (0.9 mm) wire x 1.125 Adapter, contact tip Ring, retaining Tube, head Kit, liner, monocoil .023 – .035 (0.6 – 0.9 mm) wire x 8 ft Handle Assembly Nut, liner retainer Switch, trigger
2
Optional *H9B replaces H9A
1
30
5 7
Part # H‑9B
1
3
Service Parts/Consumables
Part # H‑9A*
Item #
2
Description
Quantity
9
6
6
1 (2 per pkg) 1 (1 per pkg) 1 (10 per pkg) 1 (10 per pkg) 1 (10 per pkg) 1 (2 per pkg) 1 1 1 1 2 1
8
H-9A Gun
MIG GUNS
H‑10
Service Parts/Consumables
Item #
Part # 195 957
1
169 715 226 190 087 2991 000 067 000 068 000 0691 169 716 170 470 169 718 169 738 194 524 197 123 194 0101
2
3 4 5 6 7 8 9
194 011 194 0121 079 975 227 798 604 464 169 737 209 494
10 11 12 13
Description H‑10 Gun 10 ft (3 m), 100 A, .030–.035 (0.8–0.9 mm) Nozzle, slip type .500 (12.7 mm) orf flush Nozzle, slip type flux cored Tip, contact scr .023 (0.6 mm) wire x 1.125 Tip, contact scr .030 (0.8 mm) wire x 1.125 Tip, contact scr .035 (0.9 mm) wire x 1.125 Tip, contact scr .045 (1.2 mm) wire x 1.125 Adapter, contact tip Ring, retaining Tube, head Nut, locking handle Nut, jam O-Ring, .312 ID x .062 70 Duro BUNA-N Kit, liner, monocoil .023 – .025 (0.6 mm) wire x 15 ft (includes) Kit, liner, monocoil .030 – .035 (0.8 – 0.9 mm) wire x 15 ft (includes) Kit, liner, monocoil .035 – .045 (0.9 – 1.2 mm) wire x 15 ft (includes) O-Ring, .187 ID x .103CS rbr Switch, trigger Terminals, friction Handle Power Pin
Quantity
1 (2 per pkg) 1 (1 per pkg) 1 (10 per pkg) 1 (10 per pkg) 1 (10 per pkg) 1 (10 per pkg) 1 (2 per pkg) 1 1 1 1 2 1 1 1 1 1 2 1 1
Optional
1
H‑14
Service Parts/Consumables
Item #
Part # 231 204
1
169 715 226 190 087 2991 000 067 000 0681 169 716 170 470 169 718 169 738 169 719 079 975 194 0101
2
3 4 5 6 7 8 9
194 011 194 0121 194 0141 10 11 12 13 1
079 975 227 798 227 800 079 878 209 494
Description H‑14 Gun 10 ft (3 m), 100 A, .030–.035 (0.8–0.9 mm) Nozzle, slip type .500 (12.7 mm) orf flush Nozzle, slip type flux cored Tip, contact scr .023 (0.6 mm) wire x 1.125 Tip, contact scr .030 (0.8 mm) wire x 1.125 Tip, contact scr .035 (0.9 mm) wire x 1.125 Adapter, contact tip Ring, retaining Tube, head Nut, locking handle Nut, jam O-ring, .187 ID x .103CS rbr Kit, liner, monocoil .023 – .025 (0.6 mm ) wire x 15 ft Kit, liner, monocoil .030 – .035 (0.8 – 0.9 mm) wire x 15 ft (includes) Kit, liner, monocoil .035 – .045 (0.8 – 0.9 mm) wire x 15 ft Kit, liner, monocoil .023 – .035 (0.6 – 0.9 mm) wire x 15 ft (includes) O-ring, .312 ID x .062 70 Dura BUNA-N Switch, trigger Cord, trigger assembly Housing Plug & Pins Power Pin
1
2
3 4
Quantity
1 (2 per pkg) 1 (1 per pkg) 1 (10 per pkg) 1 (10 per pkg) 1 (10 per pkg) 1 (2 per pkg) 1 1 1 1 1 1
5
6 7 13 12 11
1 1 1 1 1 1 1 1
9
8
10
Optional
31
MIG GUNS
H100S2‑10 Item # 1 2
3 4 5 6 7 8 9 10 11 12
13
1 2
3
4 5
Service Parts/Consumables
Part #
Description
245 924 169 715 226 190 087 2991 000 0671 000 0681 000 0691 170 470 169 716 246 373 234 865 242 832 225 410 246 380 245 927 197 123 194 0101 194 0111 194 0121 079 975
H100S2‑10 Gun .30‑.035 10 ft Nozzle, slip type .500 orf flush Nozzle, flux cored slip type Tip, contact scr .023 (0.6 mm) wire x 1.125 Tip, contact scr .030 (0.8 mm) wire x 1.125 Tip, contact scr .035 (0.9 mm) wire x 1.125 Tip, contact scr .045 (1.2 mm) wire x 1.125 Ring, retaining Adapter, contact tip Tube, head Nut, jam Handle Switch, trigger Housing, power pin Connnector, feeder O-Ring, .312 ID x .062 70 duro buna-n Liner, monocoil .023 – .025 wire x 15 ft (consisting of) Liner, monocoil .030 – .035 wire x 15 ft (consisting of) Liner, monocoil .035 –.045 wire x 15 ft (consisting of) O-Ring, .500 ID x .103CS rbr
Quantity
6
7
1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1
7
8
Friction Terminal #604 464
13 12
11 10
Optional
1
#245 927
9
H100S4‑10 Item # 1 2
3 4 5 6 7 8 9 10 11 12 13
Part #
Description
245 926 169 715 226 190 087 2991 000 067 000 0681 000 0691 170 470 169 716 246 373 243 865 242 832 225 410 079 878 246 380 245 927 197 123 194 0101
H100S4‑10 Nozzle, slip type .500 (12.7 mm) orf flush Nozzle, slip type flux cored Tip, contact scr .023 (0.6 mm) wire x 1.125 Tip, contact scr .030 (0.8 mm) wire x 1.125 Tip, contact scr .035 (0.9 mm) wire x 1.125 Tip, contact scr .045 (1.2 mm) wire x 1.125 Ring, retaining Adapter, contact tip Tube, head Nut, jam Handle Switch, trigger Housing plug and pins Housing, power pin Connector, feeder O-ring, .312 ID x .062 duro buna-n Kit, liner, monocoil .023 – .025 (0.6 mm ) wire x 15 ft Kit, liner, monocoil .030 – .035 (0.8 – 0.9 mm) wire x 15 ft Kit, liner, monocoil .035 – .045 (0.6 – 0.9 mm) wire x 15 ft O-ring, .187 ID x .103CS rbr
194 011 194 0121 079 975
14
Optional *H9B replaces H9A
1
Service Parts/Consumables
2
3
4
Quantity 1 (2 per pkg) 1 (1 per pkg) 1 (10 per pkg) 1 (10 per pkg) 1 (10 per pkg) 1 (10 per pkg) 1 1 (2 per pkg) 1 1 1 1 1 1 1 2 1
6
7
7
8 9
13 14
1 1 12
1 11
1
32
5
10
MIG GUNS
H100L4‑10 Item #
Part # 243 864
1
169 715 226 1901 087 2991 000 0671 000 0681 000 0691 170 470 169 716 242 831 243 865 242 832 225 410 079 878 242 833 079 974 194 0101 194 0111 194 0121 079 975
2
3 4 5 6 7 8 9 10 11 12
13
1
2
3
Service Parts/Consumables
Description H100L4‑10 Gun 10 ft (3 m), 100 A, .030–.035 (0.8–0.9 mm) Nozzle, slip type, .500 orf flush Nozzle, flux cored slip type Tip, contact scr .023 wire x 1.125 Tip, contact scr .030 wire x 1.125 Tip, contact scr .035 wire x 1.125 Tip, contact scr .045 wire x 1.125 Ring, retaining Adapter, contact tip Tube, head Nut, jam Handle Switch, trigger Housing plug & pins Connector, feeder O-ring, .500 ID x .103CS rbr Liner, monocoil .023/.025 wire x 15 ft (consisting of) Liner, monocoil .030/.035 wire x 15 ft (consisting of) Liner, monocoil .035/.045 wire x 15 ft (consisting of) O-ring, .187 ID x .103CS rbr
4
5
Quantity 1
6
7
1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1
7
8 9
12 13
11 10
Optional
1
H200L4‑15 Item #
Part # 239 173
1
200 258 169 7241 169 7251 169 7261 169 7271 087 2991 000 0671 000 0681 000 0691 169 728 169 729 170 468 169 730 242 585 242 635 225 410 242 597 242 598 242 604 079 974 194 010 194 011 194 012 079 975 227 800
2
3 4 5 6 7 8 9 10 11 12 13 14
15 16 Optional
1
1
2
Description H200L4‑10 Gun 15 ft (4.6 m), 200 A, .030–.035 (0.8–0.9 mm) Nozzle, slip type, .500 orf flush Nozzle, slip type, .500 orf .125 recess Nozzle, slip type, .625 orf .125 recess Nozzle, slip type, .625 orf flush Nozzle, slip type, .625 orf .125 stitch out Tip, contact scr .023 wire x 1.125 Tip, contact scr .030 wire x 1.125 Tip, contact scr .035 wire x 1.125 Tip, contact scr .045 wire x 1.125 Adapter, contact tip Adapter, nozzle w/retaining ring O-Ring Washer, shock Tube head assembly Handle, front H-20 welding gun Switch, trigger Handle, rear H-20 welding gun Collar, adapter feeder connector Connector, feeder H-20 welding gun O-ring, .500 ID x .103 cs rbr Liner, monocoil .023/.025 wire x 15 ft (consisting of) Liner, monocoil .030/.035 wire x 15 ft (consisting of) Liner, monocoil .035/.045 wire x 15 ft (consisting of) O-ring, .312 ID x .062 70 Dura Buna-N Cord, trigger assembly
3
Figure 5-1. H100L4-10 Gun 4
Service Parts/Consumables
5
6 7
Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (2 per pkg) 1 1 1 1 1
8 9
16
10
14 12
15
13
11
Figure 8-6. H200L4−15 Gun
33
MIG GUNS
Millermatic Service Parts Model Challenger™ Challenger™ 172 MM 90/130
Serial # Effective KG171523 KH511668 KB102926
On/Off Switch # 116 830 116 830 111 997 (115 V)
Contactor # 252 676 252 676 252 676
Gas Valve # 218 422 218 422 218 421
Wire Speed Pot/Rheostat # 000 101 See Manual 000 101
Wire Speed Knob # 097 922 097 922 097 922
Fan Motor # 495 429 495 429 111 931
Fan Blade # 005 656 005 656 005 656
Drive Motor # 173 446 186 212 173 446
CR‑1 Relay # — 006 393 006 393
Range Switch # — 250 658 —
116 830 (230 V) MM 120/150 MM 130 XP MM 135 MM 140/ 140 with Auto‑Set™ MM 175 MM 180 MM 185 MM 200 MM 210 MM 211 MM 212 MM 212 w/Auto‑Set™ MM 250 MM 250MP MM 250X w/o meters MM 250X w/ meters MM 251 MM 252 MM 300 w/o meters MM 300 w/meters MM 350/350P MM DVI™ MM DVI‑2™ MM Passport MM Passport Plus MM Pulser MM Reach Vintage
34
KB100704 KH418495 LB204281 LG320643
116 830 111 997 196 575 196 575
252 676 252 676 — —
218 422 218 421 218 421 218 421
072 623 186 207 See Manual 207 415
097 922 097 922 171 007 171 007
495 429 495 428 196 063 196 063
005 656 005 656 409953‑001 409953‑001
090 087 186 212 202 708 202 708
072 817 See Manual — —
— 250 658 202 663 202 663
LB204053 LG320643 KG171523 HK240615 LC218652 LJ330001N LH131786B LJ180754B
196 574 196 574 124 511 See Manual 124 511 196 575 124 511 124 511
— — See Manual See Manual 196 600 — 196 600 —
218 422 218 422 222 837 See Manual See Manual 232 516 246 753 246 753
See Manual 207 415 035 897 030 943 See Manual 207 415 228 104 238 100
207 078 207 078 171 007 171 007 See Manual 207 078 207 077 238 122
196 064 196 064 123 468 081 373 188 706 See Manual 188 706 188 706
409953‑001 409953‑001 005 656 081 372 148 809 See Manual 148 809 148 809
202 708 202 708 See Manual — 202 888 202 708 233 009 233 009
— — 072 817 See Manual — — — —
202 663 202 663 153 197 049 280 192 373 202 663 — —
KB054828 KB054828 KJ081597
250 006 250 006 250 006
— — —
222 837 222 837 222 837
035 897 — 035 897
171 007 — 171 007
148 808 148 808 188 706
148 809 148 809 148 809
See Manual See Manual 227 117
006 393 006 393 006 393
035 897 — 035 897
KK227730
250 006
—
222 837
See Manual
171 007
188 706
148 809
227 117
006 393
See Manual
LB170597 LG290851B KH457123
250 006 250 006 244 920
— — —
See Manual 246 753 222 837
See Manual — 035 897
See Manual 218 764 171 007
188 706 188 706 148 808
148 809 148 809 148 809
227 117 225 341 227 117
052 964 — —
See Manual — 035 897
KK310628
244 920
—
222 837
035 897
171 007
148 808
148 809
227 117
—
035 897
LC447907 LE204883 LH021271B LE444123 LH380053N
See Manual 219 552 219 552 — —
248 620 196 600 196 600 — —
See Manual 216 396 246 753 220 011 220 011
— 198 087 198 087 — —
— 207 077 207 077 174 992 174 992
213 043 188 706 188 706 234 728 234 728
— 148 809 148 809 — —
223 541 202 888 230 496 202 708 202 708
106 462 072 817 — — —
— 153 197 192 373 — —
LA259996 LK220947N KF806591
250 006 — 250 006
196 600 — See Manual
218 494 244 300 218 421
035 897 — 035 897
171 007 238 873 171 007
188 706 — See Manual
148 809 — See Manual
227 117 223 541 See Manual
— — 080 388
192 373 — 153 197
fax orders 1‑800‑637‑2315
SPOOL GUNS 1 9
8
7
4
6
3
2
5
10
Spoolmate 100 Series ™
Item # 1 2 3 4 5 6 7 8 8 8 9 10
Part # 186 404 234 348 206 363 194 633 209 080 186 408 186 409 186 419 186 406 199 730 186 405 111 400
Description Gun Tube Assembly (Includes) Head Tube Assembly Liner Kit Barrel Screw, M4 x 0.7 x 6 mm Gas Nipple Gas Diffuser Contact Tip .030 Contact Tip .035 Contact Tip .023 Nozzle Hose, SAE .187 ID x .410 OD x 8.000
Quantity 1 1 1 1 1 1 1 1 1 1 1 1
8
1
2
3
4
5
6
7
9
Spoolmate 200 Series ™
Item # 1 2 2 2 3 4 5 6 7 8 9
Part # 186 405 186 406 186 419 199 730 186 409 243 294 243 383 244 880 247 351 243 385 243 390
Description Nozzle, Scr Type .562 Orif x 1.437 Lg Contact Tip, .035 M5 x .8 mm Thread Contact Tip, .030 M5 x .8 mm Thread Contact Tip, .023 M5 x .8 mm Thread Gas Diffuser Barrel Locking Nut Head Tube Assembly Kit, Liner w/ Outlet Guide (4.75 in. long) Gun Tube Assembly Contact Adapter
Quantity 1 1 1 1 1 1 1 1 1 1 1
phone orders 1‑866‑931‑9730
35
DRIVE ROLLS Base selection of drive rolls upon the following recommended usages: 1. V-Grooved rolls for hard wire. 2. U-Grooved rolls for soft and soft shelled cored wires. 3. U-Cogged rolls for extremely soft shelled wires. 4. V-Knurled rolls for hard shelled cored wires. 5. Drive roll types may be mixed to suit particular requirement (example: V-Knurled roll in combination with U-Grooved).
Inlet Guide
2 Roll Kit
Drive Rolls Fraction .023 – .025 in .030 in .030 and .035 in .035 and .045 in .035 in .045 in .052 in 1/16 in .035 in 3/64 in .052 in 1/16 in 5/64 in 3/32 in 7/64 in 1/8 in .035 in .045 in .045 and 1/16 in .052 in 1/16 in .068 – .072 in 5/64 in 3/32 in 7/64 in 1/8 in .045 in .052 in 1/16 in 5/64 in 3/32 in 7/64 in 1/8 in
Wire Diameter Decimal .023 – .025 in .030 in .030 and .035 in .035 and .045 in .035 in .045 in .052 in .062 in .035 in .047 in .052 in .062 in .079 in .094 in .110 in .126 in .035 in .045 in .045 and 1/16 in .052 in .062 in .068 – .072 in .079 in .094 in .110 in .126 in .045 in .052 in .062 in .079 in .094 in .110 in .126 in
For a listing of special optional drive rolls:
see page 50
Millermatic 200/210/212/250/251/252/DVI s /Pulser/Vintage (2 Drive Roll) 22/32/52 Series, SuitCase 8/12RC & 8/12VS, Reach Feeders (2 Drive Roll) ™
®
™
Drive Rolls Metric 0.6 mm 0.8 mm 0.8 and 0.9 mm 0.9 and 1.22 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm 2.0 mm 2.4 mm 2.8 mm 3.2 mm 0.9 mm 1.2 mm 1.22 and 1.6 mm 1.3 mm 1.6 mm 1.8 mm 2.0 mm 2.4 mm 2.8 mm 3.2 mm 1.2 mm 1.3 mm 1.6 mm 2.0 mm 2.4 mm 2.8 mm 3.2 mm
Type V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved V-Knurled V-Knurled VK-Grooved V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled U-Cogged U-Cogged U-Cogged U-Cogged U-Cogged U-Cogged U-Cogged
Kit # 087 131 079 594 204 5791 190 3001 079 595 079 596 079 597 079 598 044 749 079 599 — 079 601 — — — — 079 606 079 607 238 6871 079 608 079 609 089 984 079 610 079 611 — — 083 318 — 079 614 — — — —
Individual Drive Roll Part # 087 130 053 695 203 5261 189 2851 053 700 053 697 053 698 053 699 072 000 053 701 053 702 053 706 053 704 053 703 053 705 053 707 132 958 132 957 238 6881 132 956 132 955 132 959 132 960 132 961 132 962 132 963 083 489 083 490 053 708 053 710 053 709 053 711 053 712
Inlet Wire Guide # 056 192 056 192 056 192 056 193 056 192 056 193 056 193 056 195 221 912 221 912 221 912 056 195 056 195 056 196 056 196 056 197 056 192 056 193 221 030 056 193 056 195 056 195 056 195 056 196 056 196 056 197 056 193 056 193 056 195 056 195 056 196 056 196 056 197
Dual-size reversible drive roll
1
22/24 Series & SuitCase Feeders Nylon Wire Guides (For Feeding Aluminum Wire) Wire Diameter .047 in (1.2 mm) 1/16 in (1.6 mm) 3/32 in (2.4 mm)
46
Inlet Guide # 151 203 151 205 194 264
Note: Each drive roll kit contains 2 Drive Rolls and an Inlet Guide. Note: U-Groove drive rolls are recommended when feeding aluminum wire.
DRIVE ROLLS
4 Roll Kit
Intermediate Guide Inlet Guide
Drive Rolls Fraction .023 – .025 in .030 in .035 in .035 and 3/64 in 3/64 in .052 in 1/16 in .035 in 3/64 in .035 and 3/64 in .052 in 1/16 in 5/64 in 3/32 in 7/64 in 1/8 in .035 in 3/64 in .052 in 1/16 in 5/64 in 3/32 in 7/64 in 1/8 in 3/64 in .052 in 1/16 in 5/64 in 3/32 in 7/64 in 1/8 in
Millermatic 300/350/350P with Meters (4 Drive Roll) 54 Series, 24A & R-115 Feeders (4 Drive Roll) ®
Wire Diameter Decimal .023 – .025 in .030 in .035 in .035/.045 in .045 in .052 in .062 in .035 in .047 in .035 and .045 in .052 in .062 in .079 in .094 in .110 in .126 in .035 in .045 in .052 in .062 in .079 in .094 in .110 in .126 in .045 in .052 in .062 in .079 in .094 in .110 in .126 in
Metric 0.6 mm 0.8 mm 0.9 mm 0.9/1.2 mm 1.2 mm 1.3 mm 1.6 mm 0.9 mm 1.2 mm 1.9 and 1.2 mm 1.3 mm 1.6 mm 2.0 mm 2.4 mm 2.8 mm 3.2 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm 2.0 mm 2.4 mm 2.8 mm 3.2 mm 1.2 mm 1.3 mm 1.6 mm 2.0 mm 2.4 mm 2.8 mm 3.2 mm
Type V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled U-Cogged U-Cogged U-Cogged U-Cogged U-Cogged U-Cogged U-Cogged
Kit # 087 132 046 780 046 781 227 0611 046 782 046 783 046 784 044 750 046 785 — — 046 787 — — — — 046 792 046 793 046 794 046 795 046 796 046 797 — — — — — — — — —
Drive Rolls Individual Drive Roll Part # 087 130 053 695 053 700 189 2851 053 697 053 698 053 699 072 000 053 701 232 826 053 702 053 706 053 704 053 703 053 705 053 707 132 958 132 957 132 956 132 955 132 960 132 961 132 962 132 963 083 489 083 490 053 708 053 710 053 709 053 711 053 712
Inlet # 056 192 056 192 056 192 056 193 056 193 056 193 056 195 221 912 221 912 221 912 221 912 058 836 056 195 056 196 056 196 056 197 056 192 056 193 056 193 056 195 056 195 056 196 056 196 056 197 056 193 056 193 056 195 056 195 056 196 056 196 056 197
Wire Guide Intermediate # 056 206 056 206 056 206 056 207 056 207 056 207 056 209 058 853 058 853 233 843 058 837 058 837 056 209 056 210 056 210 056 211 056 206 056 207 056 207 056 209 056 209 056 210 056 210 056 211 056 207 056 207 056 209 056 209 056 210 056 210 056 211
Dual-size reversible V-groove drive roll (one .035 and one .045 in groove)
1
Wire Diameter .035 – .047 in (0.9–1.2 mm) 1/16 in (1.6 mm) .023 – .052 in (0.6–1.3 mm)
Inlet Guide # 058 854 058 836 221 912
Intermediate Guide # 058 853 058 837 233 843
Note: Each drive roll kit contains 4 Drive Rolls, an Inlet Guide, and an Intermediate Guide. Note: U-Groove drive rolls are recommended when feeding aluminum wire.
47
DRIVE ROLLS
Antiwear Guide
Antiwear Guide Inlet Guide
2 Roll Kit
Base selection of drive rolls upon the following recommended usages: 1. V-Grooved rolls for hard wire. 2. U-Grooved rolls for soft and soft shelled cored wires. 3. U-Cogged rolls for extremely soft shelled wires. 4. V-Knurled rolls for hard shelled cored wires. 5. Drive roll types may be mixed to suit particular requirement (example: V-Knurled roll in combination with U-Grooved).
Inlet Guide
4 Roll Kit
Intermediate Guide
Drive Rolls
For a listing of special optional drive rolls:
62 series feeders, Pipe Pro 12 RC (2 roll kits), 64, 74 series feeder, Pipe Pro Single, Pipe Pro Single DX, Pipe Pro Dual DX, Pipe Worx 400 and all Axcess Feeders (4 roll kit)
Wire Diameter Fraction Decimal .023 – .025 in .023 – .025 in .030 in .030 in .035 in .035 in .035 and 3/64 in .035/.045 in .040 in .040 in 3/64 in .045 in .052 in .052 in 1/16 in .062 in .035 in .035 in .035 and 3/64 in .035/.045 in
Metric 0.6 mm 0.8 mm 0.9 mm 0.9/1.2 mm 1.0 mm 1.2 mm 1.3 mm 1.6 mm 0.9 mm 1.9/1.2 mm
Type V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved U-Grooved U-Grooved
2 Roll Kit # 151 030 — 151 032 190 3001 — 151 033 151 034 — 151 044 —
3/64 in .047 in .052 in 1/16 in 5/64 in 3/32 in 7/64 in 1/8 in .035 in 3/64 in .052 in 1/16 in .068 – .072 in 5/64 in 3/32 in 7/64 in 1/8 in 3/64 in .052 in 1/16 in 5/64 in 3/32 in 7/64 in 1/8 in
1.2 mm 1.2 mm 1.3 mm 1.6 mm 2.0 mm 2.4 mm 2.8 mm 3.2 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm 1.8 mm 2.0 mm 2.4 mm 2.8 mm 3.2 mm 1.2 mm 1.3 mm 1.6 mm 2.0 mm 2.4 mm 2.8 mm 3.2 mm
U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled U-Cogged U-Cogged U-Cogged U-Cogged U-Cogged U-Cogged U-Cogged
151 045 — — 151 047 — — — — 151 061 151 062 — 151 064 151 065 151 066 151 067 — — — — — — — — —
.045 in .047 in .052 in .062 in .079 in .094 in .110 in .126 in .035 in .045 in .052 in .062 in .068 – .072 in .079 in .094 in .110 in .126 in .045 in .052 in .062 in .079 in .094 in .110 in .126 in
see page 50
Intermediate Guide
Drive Rolls 4 Roll Kit # 151 024 151 025 151 026 209 5331 161 190 151 027 151 028 151 029 151 036 244 293 151 037 243 234 — 151 039 — 151 041 — — 151 052 151 053 151 054 151 055 151 056 151 057 151 058 151 059 151 060 151 070 — 151 072 — — — —
Individual Part # 087 130 053 695 053 700 189 2851 053 696 053 697 053 698 053 699 072 000 232 826
Inlet # 150 993 150 993 150 993 150 994 150 993 150 994 150 994 150 995 150 993 221 912
053 701 053 701 053 702 053 706 053 704 053 703 053 705 053 707 132 958 132 957 132 956 132 955 132 959 132 960 132 961 132 962 132 963 083 489 083 490 053 708 053 710 053 709 053 711 053 712
150 994 221 912 150 994 150 995 150 995 150 996 150 996 150 997 150 993 150 994 150 994 150 995 150 995 150 995 150 996 150 996 150 997 150 994 150 994 150 995 150 995 150 996 150 996 150 997
Wire Guide Intermediate # 149 518 149 518 149 518 149 519 149 518 149 519 149 519 149 520 149 518 242 417 (.035) 205 936 (3/64) 149 519 205 936 149 519 149 520 149 520 149 521 149 521 149 522 149 518 149 519 149 519 149 520 149 520 149 520 149 521 149 521 149 522 149 519 149 519 149 520 149 520 149 521 149 521 149 522
Antiwear # 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233
045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233 045 233
Dual-size reversible V-groove drive roll (one .035 and one .045 in groove)
1
60 & 70 Series Nylon Wire Guides (For Feeding Aluminum Wire) Wire Diameter .047 in (1.2 mm) 1/16 in (1.6 mm) 3/32 in (2.4 mm)
48
Inlet Guide # 151 203 151 205 151 207
Intermediate Guide # 151 204 151 206 151 208
Note: Each drive roll kit contains 2 or 4 Drive Rolls, an Inlet Guide, an Intermediate Guide, and #045 233 Antiwear Guide with #604 612 Setscrew 8-32 x .125. Note: U-Groove drive rolls are recommended when feeding aluminum wire.
DRIVE ROLLS
Miller Drive Rolls SideKick™ /SideKick™ XL
V-Groove .023/.024 (0.6 mm) 090 423
V-Groove .030 (0.8 mm) 090 423
V-Groove .035 (0.9 mm) 090 423
Cricket®/Cricket® XL
119 028
119 028
—
Millermatic® 35
—
059 590 (2)
059 590 (2)
Millermatic® 90/130/Challenger
119 028
119 028
—
Millermatic® 130 XP/150/185
090 423
090 423
090 423
Machine
V-Groove .045 (1.2 mm)
— — — — —
V-Knurl .030 (0.8 mm) 165 603
V-Knurl .035 (0.9 mm) 165 603
V-Knurl .045 (1.2 mm) 127 229
Inlet Wire Guide
119 028
119 028
119 028
058 549
— —
058 549
—
—
119 028
119 028
165 603
165 603
127 229
058 549
058 549 058 549
Millermatic® Challenger™172
090 423
090 423
090 423
165 603
165 603
127 229
058 549
Millermatic® Passport™ / Passport™ Plus
202 925
202 925
202 925
—
202 926
202 926
202 926
058 549
Millermatic® 200/210/212/250/250x/251
087 131 (kit)
079 594 (kit)
079 595 (kit)
079 596 (kit)
—
079 606
079 607
Page 52
204 579
204 579
Optional Drive Rolls
079 594 (kit)
079 595 (kit)
079 596 (kit)
079 606
079 607
Page 52
204 579
204 579
Optional Drive Rolls
087 131 (kit)
079 594 (kit)
079 595 (kit)
079 596 (kit)
079 606
079 607
Page 52
204 579
204 579
Optional Drive Rolls
Millermatic® 300 with meters/350P
087 132 (kit)
046 780 (kit)
046 781(kit)
046 762 (kit)
046 792 (kit)
046 793 (kit)
Page 53
Millermatic® 141/190/standard drive
261 157
261 157
261 157
—
Millermatic® 141/190/optional drive
220 179
220 179
220 179
Mulitmatic™ 200 standard drive rolls
220 179
220 179
220 179
Mulitmatic™ 200 optional drive rolls
261 157
261 157
261 157
Millermatic® 200/210/212/250/250x/251 Millermatic® 252/ 300 without meters
087 131 (kit)
Millermatic® 252/ 300 without meters Millermatic® DVI™ /Pulser/Vintage/Reach Millermatic® DVI™ /Pulser/Vintage/Reach
—
— — —
Page 52 Page 52
—
261 157
261 157
202 926
202 926
202 926
261 151
202 926
202 926
202 926
058 549
261 157
261 157
—
261 151
058 549
XR Controls Drive Rolls Machine XR/XR-S/XR-D
U-Groove .030 in. (.76 mm)
U-Groove .035 in. (.89 mm)
U-Groove U-Groove .040 in. (1.02 mm) .47 in. (1.19 mm)
U-Groove .062 in. (1.58 mm)
194 118
194 118
196 301
195 591
194 119
Sub Arc Drive Rolls Machine RAD-400, RAD-400T, RAD-780
Part #
Description
Wire sizes
132 955 132 960 132 961 132 962 132 963 193 700 193 701
V-K Groove Drive Roll V-K Groove Drive Roll V-K Groove Drive Roll V-K Groove Drive Roll V-K Groove Drive Roll V-K Groove Drive Roll V-K Groove Drive Roll
1/16 in. (.062 in.-1.6 mm) 5/64 in. (0.79 in.-2.0 mm) 3/32 in. (.094 in .-2.4 mm) 7/64 in. (.110 in.-2.8 mm) 1/8 in. (.125 in.-3.2 mm) 5/32 in. (.156 in.-4.0 mm) 3/16 in. (.188 in.-4.8 mm)
49
DRIVE ROLLS
Miller Spoolgun Drive Rolls V-Knurl .030 in. (0.8 mm) 186 414 183 413 186 414 183 413 136 135 183 357 053 131 053 131 136 135 183 357 194 114 227 434 227 434 227 434
Spoolguns Spoolmate™ 100/185/3035 Spoolmate™ 100/185/3035 Spoolmate™ 200/3545 Spoolmate™ 200/3545 Spoolmate® 15A/20A Spoolmate® 15A/20A Spoolmate® 1, 2, 3 XR™-15/XR™-30 XR™-A /XR™-W Pistol XR™-A /XR™-W Pistol XR™-Edge XR™Aluma-Pro™ XR™Aluma-Pro™ Lite XR™Aluma-Pro™ Plus
V-Knurl .035 in. (0.9 mm) 186 414 183 413 186 414 183 413 136 135 183 357 053 131 053 131 136 135 183 357 154 115 227 434 227 434 227 434
V-Knurl .045 in. (1.2 mm)
U-Knurl .062 in. (1.6 mm)
136 135 183 358 053 131 053 131 136 135 183 358 194 117 227 434 227 434 227 434
Inlet Wire Guide 186 410 186 410 186 410 186 410 132 521 132 521 058 949 on conduit on conduit on conduit on conduit 227 408 227 408 227 408
—
—
—
—
199 397 199 396 136 135 183 358 053 131 053 131 136 135 183 358 194 116 227 434 227 434 227 434
—
V-Knurl .030 – .035 & .045 (0.8 – 0.9 & 1.2 mm) 202 926
HT Wire (Hard Tubular) Rev. Knurl Rev. Knurl .030 & .035 .039 – .045 (0.8 & 0.9 (0.8 – 1.2 mm) mm) 193 330 193 331
Inlet Wire Guide —
202 926
193 330
—
—
Hobart Drive Rolls Soft Wire (Aluminum)
Hard Wire (Steel) V-Groove .024 (0.6 mm) Machine Handler® 120/130XL/ 202 925 or 135/140/150/170/175/ 407230-004 180/187/190/210 — IronMan™ 210/250 IronMan™ 275 IronMan™ 230 Handler® 125, 125EZ
Urethane .035 (0.9 mm) —
V-Groove .030 – .035 (0.8 – 0.9 mm) 202 925 246 565*
V-Groove .045 (1.2 mm) 407230-004
202 925
407230-004 —
#212 379 — 2-sided combination roll (.024 V-groove) (.030/.035 VK-groove)
Note: For all Beta-MIG drive rolls, contact Miller Service Parts Available for Handler 120 and IronMan 210
*
Part number available on ALL Handler models with serial number MDXXXXXX and after
9
Special Optional Drive Rolls For 22/32/52/54/60/70 Series Feeders Part # #203 526 #189 285 #190 300 #209 533 #198 078 #088 402 #0537160010890
50
193 331
Standard drive roll is part number 235286 v-grooved wire size is .030 - .035 other sizes available on page 46 under 52 series feeders.
Description Dual V-Groove (one .030 and one .035 in groove) Dual V-Groove (one .035 and one .045 in groove) Dual V-Groove (2 drive rolls each with one .035 and one .045 in groove plus inlet guide) Dual V-Groove 4 Roll Kit (4 drive rolls each with one .035 and one .045 in groove plus guides and setscrew) No-Groove, Universal Quick-Change (Steel) No-Groove, Non-Quick-Change (Hard Urethane — Green) No-Groove (Soft Urethane — Blue)
212 368 242 524 (wire size .023-.045)
SUBMERGED ARC
OBT-600
Consumables
Item #
Part #
Description
1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 9 10 10 10 10
043 923 192 700 2 192 7012 192 702 2 192 703 2 192 7042 192 705 2 192 706 2 192 692 192 694 192 693 192 695 192 697 192 696 200 566 193 1461 193 1451 043 9672 043 969 2 043 973 2 043 9752
600 Amp Torch for 3/32–3/16 in. (1.6–4.8 mm) wires Tip, contact 1/16 in. (1.6 mm) Tip, contact 5/64 in. (2.0 mm) Tip, contact 3/32 in. (2.4 mm) Tip, contact 7/64 in. (2.8 mm) Tip, contact 1/8 in. (3.2 mm) Tip, contact 5/32 in. (4.0 mm) Tip, contact 3/16 in. (4.8 mm) Torch body Hose, flux with insulator Cone assembly, body Ferrule, locking Nut, retaining Cone, flux Adapter, hose Liner, wire 1/16 − 1/8 x 8.125 Liner, wire 5/32 x 8.125 Extension, torch body OBT−1 inch Extension, torch body OBT−2 inch Extension, torch body OBT−4 inch Extension, torch body OBT–6 inch
Recommended spare part. Optional.
1 2
51
SUBMERGED ARC
OBT-1200
Consumables
Item #
Part #
Description
1 1 2 3 4 4 4 5 6 6 6 6 6 6 6 7 8 9 10 11 12 13 13 13
043 900 199 945 199 946 192 132 192 131 192 139 192 687 200 754 192 133 192 1411 199 0261 192 1421 200 7711 192 1431 192 1441 192 1361 192 135 192 758 192 137 192 138 043 9811 192 892 200 749 200 750 200 751
1200 Amp Subarc Torch 1/16-3/16 in. (1.6-4.8 mm) wire Guide, wire inlet 5/32−1/4 Guide, wire inlet 1/16−1/8 Inlet guide adapter, with breakaway feature Torch body assembly Liner, wire 1/16−1/8 in Liner, wire 5/32−3/16 in Liner, wire 7/32 in Extender, tip Tip, contact 1/16 in. (1.6 mm) Tip, contact 5/64 in. (2.0 mm) Tip, contact 3/32 in. (2.4 mm) Tip, contact 7/64 in. (2.8 mm) Tip, contact 1/8 in. (3.2 mm) Tip, contact 5/32 in. (4.0 mm) Tip, contact 3/16 in. (4.8 mm) Nut, tip Clamp, securing Nozzle assembly, flux Nozzle, flux replaceable Torch body extension 8.5 in. (includes) Torch body extension Liner, wire 1/16−1/8 x 36 in. Liner, wire 5/32−3/16 x 36 in. Liner, wire 7/32 x 36 in.
Optional.
1
52
SUBMERGED ARC
1200 Amp Single-Wire Torch
Consumables
Item #
Part #
Description
301 141 266 660 266 662 266 665 266 663 266 666 264 5801 264 5811 264 5861 266 667 266 668 264 590 2 264 5912 264 5871 264 593 2 264 5942 264 5891
Short, 11.3 in. (288 mm) 1200 Amp torch for 1/16–5/32in. (1.6–4.0mm) wire
1 2 3 4 5 6 7 8 9 10 11 11 11 11 11 12
Recommended spare part. Optional.
1
Torch body Power source connector Screw, HSHC, M6x30 Torch body insulator Wire feeder connector Nut Wire liner, 286 mm Flux nozzle, D.26 Clamp, D.40 Nut, M5 X 5 Tip, contact single wire 1/16 in. (1.6 mm) CuCrZr Tip, contact single wire 5/64 in. (2.0 mm) CuCrZr Tip, contact single wire 3/32 in. (2.4 mm) CuCrZr Tip, contact single wire 1/8 in. (3.2 mm) CuCrZr Tip, contact single wire 5/32 in. (4.0 mm) CuCrZr Flux conveyor
2 6
5
10
3 7 1 4
6
8
10
11
9
2
12
53
SUBMERGED ARC
1200 Amp Twin-Wire Torch 13
Item #
Part #
Description
1 2 3 4 5 6 7 8 9 10 11 11 11 11 12 13
301 143 266 660 266 662 266 665 266 663 266 669 264 5801 264 5841 264 5861 266 667 266 6681 264 5952 264 5962 264 5972 264 5881 264 5891 266 670
Short, 11.3 in. (288 mm) 1200 Amp torch for 3/64–3/32 in. (1.2–2.4 mm) wire Torch Body Power Source Connector Screw, HSHC, M6 X 30 Torch Body Insulator Wire Feeder Connector Nut Wire Liner, D. 5 X 3 146 mm Flux Nozzle, D.26 Clamp, D.40 Nut, M5 X 5 Tip, Contact Twin Wire 3/64 in. (1.2 mm) CuCrZr Tip, Contact Twin Wire 1/16 in. (1.6 mm) CuCrZr Tip, Contact Twin Wire 5/64 in. (2.0 mm) CuCrZr Tip, Contact Twin Wire 3/32 in. (2.4 mm )CuCrZr Flux Conveyor Alignment Plate
2
6 5 10
7 3
7
1
4
10 11
6 9
Recommended spare part. Optional.
1 2
12
8
13
Item #
Part #
Description
1 2 3 4 5 6 7 8 9 10 11 11 11 11 12 13
301 444 266 661 266 662 266 665 266 664 266 669 264 5801 264 5851 264 5861 266 667 266 668 264 5952 264 5962 264 5972 264 5881 264 5891 266 670
Long, 16.8 in. (427 mm) 1200 Amp torch for 3/64–3/32 in. (1.2–2.4 mm) wire Torch Body Power Source Connector Screw, HSHC, M6 X 30 Torch Body Insulator Wire Feeder Connector Nut Wire Liner, D. 5 X 3 287 mm Flux Nozzle, D.26 Clamp, D.40 Nut, M5 X 5 Tip, Contact Twin Wire 3/64 in. (1.2 mm) CuCrZr Tip, Contact Twin Wire 1/16 in. (1.6 mm) CuCrZr Tip, Contact Twin Wire 5/64 in. (2.0 mm) CuCrZr Tip, Contact Twin Wire 3/32 in. (2.4 mm )CuCrZr Flux Conveyor Alignment Plate
Recommended spare part. Optional.
1 2
2
6 5
10 3
7 3
7
10 1
4
10
10
11
6 9
12
8
54
PLASMA CUTTING
Spectrum Plasma Torch History ®
Model Spectrum® 125C Spectrum® 300 Spectrum® 375
Machine Stock # 907149, 907169 903479, 903787 903891, 903871 CE 907 532 907339, 907303 907529 903143, 903144, 903145, 903146, 903187, 903201 907058, 907058011
Original Torch ICE-12C, pg 60 ICE-25C, pg 60 ICE-27C, pg 60 XT-30C, pg 57 ICE-27T, pg 60 XT-30, pg 57 APT-5000
Recommended Replacement ICE-12C, 20 ft ( 6.1 m) Hand-Held #195172, pg 60 ICE-25CX, 20 ft (6.1 m) Hand-Held #195007, pg 60 XT-30C, 20 ft (6.1 m) Hand-Held #255685, pg 57 XT-30C, 20 ft (6.1 m) Hand-Held #255685, pg 57 XT-30, 12 ft (3.7 m) Hand-Held #249949, pg 57 XT-30, 12 ft (3.7 m) Hand-Held #249949, pg 57 ICE-50, 30 ft (9 m) Hand- held #169199 1, pg 64 ICE-50, 50 ft (15.2 m) Hand-Held #169244 1, pg 64 (N/A)
ICE-40C, pg 61
907404, 907404011 9074041012 907531, 907531001
ICE-40T, pg 61
Spectrum® 625 X-TREME
907579, 907579001 907579002, 907579003
XT-40 w/Connect
Spectrum® 650
903788, 903790
ICE-50C, pg 62
Spectrum® 700
903444, 903445 903446, 903447
ICE-50, pg 64
Spectrum® 701
903791, 903780, 903792
ICE-50C, pg 62
Spectrum® 750
903193, 903194, 903195
APT-7000
Spectrum® 875
907390011 907390012
ICE-60T, pg 65
Spectrum® 875
907583 907583001 907583002 907583003 907396 907396001
XT-60 pg 59
ICE-40C, 25 ft (7.6 m) Hand-Held #195110, pg 61 ICE-40C, 50 ft (15.2 m) Hand-Held #195111, pg 61 XT-40, 12 ft (3.7 m) Hand-Held #249951, pg 58 XT-40, 20 ft (6.1 m) Hand-Held #249952, pg 58 XT-40, 12 ft (3.7 m) Hand-Held #249951, pg 58 XT-40, 20 ft (6.1 m) Hand-Held #249952, pg 58 XT-40, 12 ft (3.7 m) Hand-Held W/ Disconnect #260633, pg 58 XT-40, 20 ft (6.1 m) Hand-HeldW/ Disconnecct #260635, pg 58 XT-40M Machine Long Body 25 ft (7.6 m) # 259365, pg 58 XT-40M Machine Torch Short Body 25 ft (7.6 m) # 257462, pg 58 ICE-50C, 25 ft (7.6 m) Hand-Held #176824, pg 62 ICE-50C, 50 ft (15.2 m) Hand-Held #176826, pg 62 ICE-50CM, 50 ft (15.2 m) Machine-Held #176828, pg 62 Note: ICE-55C Not Recommended ICE-50, 30 ft (9 m) Hand-Held #169199, pg 64 ICE-50, 50 ft (15.2 m) Hand-Held #169244, pg 64 (N/A) ICE-70 with 50 Amp Tip, 30 ft (9 m) Hand-Held #169203, pg 64 ICE-70 with 50 Amp Tip, 50 ft (15.2 m) Hand-Held #169245, pg 64 ICE-50C, 25 ft (7.6 m) Hand-Held #176824, pg 62 ICE-50C, 50 ft (15.2 m) Hand-Held #176826, pg 62 ICE-50CM, 50 ft (15.2 m) Machine-Held #176828, pg 62 Note: ICE-55C Not Recommended. ICE-70, 30 ft (9 m) Hand-Held #169203 2, pg 64 ICE-70, 50 ft (15.2 m) Hand-Held #169245 2, pg 64 ICE-100 with 70 Amp Tip, 30 ft (9 m) Hand-Held #1692072, pg 64 ICE-60T, 20 ft (7.6 m) Hand-Held #234132, pg 65 ICE-60T, 50 ft (15.2 m) Hand-Held #234134, pg 65 XT-60, 20 ft Hand-Held Torch #249953, pg 59 XT-60, 50 ft Hand-Held Torch # 249954, pg 59 XT-60M, 25 ft Machine Torch # 249955, pg 59 XT-60M, 50 ft Machine Torch #249956, pg 59 XT60 20 ft (7.6 m) Hand-Held #249953, pg 59 XT60 50 ft (15.2 m) Hand-Held #249954, pg 59 XT60M 25 ft (7.6 m) Machine Torch Long Body #249955, pg 59 XT60M 50 ft (15.2 m) Machine Torch Long Body #249956, pg 59 ICE-60TM, 25 ft (7.6 m) Machine-Held #234136, pg 65 ICE-60TM, 50 ft (15.2 m) Machine-Held #234138, pg 65 ICE-60TM, 25 ft (7.6 m) Machine-Held Torch with Pendant #300759, pg 65 Kit, ICE-60TM, Machine Torch 50 ft #300760 XT60M 25 ft (7.6 m) Machine Torch Short Body #257464, pg 59 XT60M 50 ft (15.2 m) Machine Torch Short Body #263952, pg 59
Spectrum® 375 X-TREME™ Spectrum® 500
Spectrum® 625 Spectrum® 625 X-TREME
Spectrum® 875 Auto-Line
Spectrum® 875 Auto-Line
907584 907584001 907584002 907584003 907584004 907584005
XT-40, pg 58
More Torch models continued on next page Requires Retrofit Kit #172 155 2Requires Retrofit Kit #172 156 (N/A) 3Requires Remote Pendant Control #180 605 4 Requires Remote Pendant Control #195 513 5Requires Retrofit Kit #172 157 1
55
SPOOL GUNS 3
12
Spoolmate 185 Spool Gun
11
9
10
8
7
6
5
4
2
1
Spoolmate 3035 Spool Gun
Spoolmate 185 & 3035 Series ™
Item # 1 2 3 4 5 6 7 8 9 10 11 11 11 12
Part # 197 570 196 848 196 827 196 849 206 363 196 847 194 633 209 080 186 408 186 409 186 419 186 406 199 730 186 405
Description Anti-Rotation Pin Contact Adapter Gun Tube Assembly (Includes) Head Tube Assembly Liner Kit Locking Nut Barrel Screw, M4 x 0.7 x 6 mm Gas Nipple Gas Diffuser Contact Tip .030 Contact Tip .035 Contact Tip .023 Nozzle
Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1
3
12
11
10
9
8
7
6
5
2 4
Spoolmate 250 Spool Gun
Spoolmate 3545 Spool Gun
Spoolmate 250 & 3545 Series ™
Item # 1 2 3 4 5 6 7 8 9 10 11 11 11 12
36
Part # 197 570 196 848 199 385 199 394 206 363 196 847 199 393 209 080 199 391 199 390 199 387 199 388 199 389 050 622
Description Anti-Rotation Pin Contact Adapter Gun Tube Assembly (consisting of) Head Tube Assy Liner Kit Locking Nut Barrel Screw, M5 x 0.7 x 6 mm Gas Nipple Gas Diffuser Contact Tip .030 Contact Tip .035 Contact Tip .047 Nozzle
Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1
SPOOL GUNS
XR-15/30: Effective with serial number JH-247300 though KC-171636.
XR -15/XR -30 and Spoolmatic 1,2,3 ™
Item # 1 2 3 4
5 6 7
8 9 10 11 12 13 14 15 16
™
Part # XR-15/30 112 704 112 885 (N/A) 602 172 — 112 708 112 707 — — 058 685 058 676 050 638 094 259 094 260 050 637 156 821 144 862 050 622 050 115 050 116 009 925 (N/A) 000 443 004 466 000 442 (N/A) 050 960 053 131 194 405 1 194 4101 191 065 191 066 197 440 191 061 191 062 191 063 156 486 (N/A)
Part # Spoolmatic 1,2,3 058 678 009 541 — 604 771 — — 058 681 058 682 058 685 058 676 050 638 094 259 094 260 050 637 156 821 144 862 050 622 050 115 050 116 009 925 (N/A) 000 443 004 466 000 442 (N/A) 050 960 053 131 — — — — — — — — —
®
Service Parts/Consumables
Description Adapter, contact tube Adapter, barrel Screw, set stl sch 10-32 x .187 cup point Screw, set stl sch 10-32 x .125 cup point Liner, teflon .030 – .035 (0.8 – 0.9 mm) wire x 4.125 Liner, teflon .047 – 1/16 (1.2 – 1.6 mm) wire x 4.125 Liner, teflon .030 – .035 (0.8 – 0.9 mm) wire x 5.187 Liner, teflon .047 – 1/16 (1.2 – 1.6 mm) wire x 5.187 Nut, jam nozzle extension Nut, brs cprsn .438-20 Tube, cont sl .030 (0.8 mm) wire x 4.000 Tube, cont sl .035 (0.9 mm) wire x 4.000 Tube, cont sl .047 (1.2 mm) wire x 4.000 Tube, cont sl 1/16 (1.6 mm) wire x 4.000 Extension, barrel 2.875 lg Extension, nozzle Nozzle, 5/8 orf (15.9 mm) x 1-5/8 lg Nozzle, 1/2 orf (12.7 mm) x 1-5/8 lg Nozzle, 13/16 (20.6 mm) orf x 1-5/8 lg Nozzle, spot outside corner .937 ID x 2.375 Nozzle, spot inside corner Nozzle, spot flat, 1-3/8 orf (35 mm) Nozzle, spot flat, 15/16 orf (24 mm) Wrench Drive Roll, V-knurl .030–1/16 (0.8–1.6 mm) Complete Conduit Assemblies with Liner and Fittings (replaces #112 715) Complete Conduit Assemblies with Liner and Fittings (replaces #112 716) Replacement Liner, gun feed cable .187 OD x .110 ID Replacement Liner, gun feed cable .187 OD x .110 ID Replacement Liner, bulk gun feed cable .187 OD x .110 ID Replacement Tubing, gun liner carrier Replacement Tubing, gun liner carrier Replacement Tubing, gun liner carrier Conversion Kit, converts XRs with 4" contact tubes to 1-7/16" tubes
Quantity 1 1 1 4 1 1 1 1 1 1 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 1 1 (2 per pkg) 1 (2 per pkg) 1 (2 per pkg) 1 1 1 1 1 1 15 ft 30 ft 32 ft 50 ft 500 ft 15 ft 30 ft 50 ft 1
Updates XRs from one-piece conduit (#112 715 or #112 716) to new style configuration that features replaceable feed cable liners and improved feedability.
1
37
SPOOL GUNS Spoolmatic serial numbers KD376404 - LC259177 XR prior to serial number LC373469
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Head Tube Liner O-Ring .614 ID O-Ring .176 ID Barrel Adapter (Air-cooled) Set Screw Jam Nut (Air-cooled) Head Tube (Air-cooled) Set Screw (Air-cooled) Contact Tip Adapter Collet Nut
(See chart below) #134 800 #164 485 #164 423 #602 172 #058 685 #164 422 #604 612 #164 421 #136 748
XR /XR-M, Spoolmatic 15/30A ™
Wire Diameter .030 in (0.8 mm) .035 in (0.9 mm) .047 in (1.2 mm) .062 in (1.6 mm)
11. 12. 13. 14.
Contact Tip Barrel Extension (Air-cooled) Nozzle Extension (Air-cooled) Nozzle (Standard) Wrench (Not shown)
Note: To use new FasTip tips, use Gas Diffuser #209 875, Head Tube Liner #212 523, and Insulator Contact Tip Adapter #185 097. Note: For optional nozzles see page 41.
Air-cooled parts breakdown and gun shown. Consult owner’s manual for water-cooled parts and consumables.
®
Standard Contact Tip I.D. .041 in (1.0 mm) #135 428 .052 in (1.3 mm) #135 430 .061 in (1.5 mm) #135 424 .081 in (2.1 mm) #135 425
(See chart below) #156 821 #144 862 #050 622 #136 821
Consumables
Gun Head Tube Liner #136 682 #136 682 #136 683 #136 683
Optional (Smaller) Contact Tip I.D. .036 in (1.0 mm) #135 427 .041 in (1.0 mm) #147 314 .052 in (1.0 mm) #135 429 .073 in (1.0 mm) #135 426
For guns between LC259177 and LE239243, call Miller parts for information. Spoolmatic effective with serial number LE239243 XR effective with serial number LE033395
1
2
3
4
5
6
7
8
9
#231 523 Air-Cooled Assembly Kit (Illustrated above) #231 524 Water-Cooled Assembly Kit (Not shown, consult owner’s manual)
1. 2. 3. 4. 5. 6.
Head Tube Liner O-Ring .614 ID Barrel Assembly (Air-cooled) Barrel Pistol Insulator Outer Insulating Jacket Nozzle Insulator
#212 156 #134 800 #221 087 #219 795 #219 794 #232 284
7. Diffuser 8. Contact Tip 9. Nozzle (Standard)
XR /XR-M, Spoolmatic 15/30A FasTip ™
Wire Diameter Steel / Aluminum .035 in (0.9 mm) / .030 in (0.8 mm) .040 in (1.0 mm) / .035 in (0.9 mm) .045 in (1.2 mm) / – .052 in (1.3 mm) / .047 in (1.2 mm) .062 in (1.6 mm) / –
38
®
FasTip Contact Tip I.D. .041 in (1.0 mm) #206 186 .047 in (1.2 mm) #206 187 .053 in (1.3 mm) #206 188 .061 in (1.5 mm) #206 189 .071 in (1.8 mm) #206 190
™
XR-Pistol Drive Rolls #183 357 #183 357 #183 357 #183 358 #183 358
XR-Pistol All-Wire Dual Groove Drive Rolls #136 135 #136 135 #136 135 #136 135 #136 135
#227 749 (See chart below) #199 613
Air-cooled parts breakdown and gun shown. Consult owner’s manual for water-cooled parts and consumables.
Cable Liners #191 065 15 ft (4.6 m) or 30 ft (9.1 m) #191 066 50 ft (15.2 m) #197 440 500 ft (152 m)
SPOOL GUNS 1
2
5
4
3
6
7
XR -A/Spoolmatic 30A Options ™
Item # 1 2 3 4 5 6 7
®
Part # 222 735 199 613 See Page 50 206 195 198 856 222 839 (N/A) 134 800 222 855 222 853 1910031
Description Kit, Flex Head 10 in for XRA Nozzle, Brass 5/8 in Orifice Tapered Contact Tip Diffuser, .281/.312 Od Fastip 1/8 Tip Recess Insulator, Nozzle Torch, Flex O-Ring, .614 ld x .070 CS 70 Duro Buna-N Kit, Liner (Includes) Liner, Nylon .030-.045 Wire x 11.625 Liner, Nylon .047-.062 Wire x 11.625 12 13
8 9
10
14
Kit Quantity 1 1 1 1 1 2 1 1 1
15
(Old Style)
11
17
19
18
21 17
20 19
16 (Includes item 18) 12
15
14
SX Flex Head Kit
(New Style) 18
Item # 8 9 10 11 12 13 14 15 16 17 18 19
20 21
Part # (Old Style) 136 821 — 144 862 130 632 — 136 748 136 431 — 153 667 140 665 134 800 131 171 (N/A) 138 255 132 682 — — —
Part # (New Style) — See page 47 144 862 130 632 See page 47 — — 209 875 153 667 212 679 (N/A) 134 800 131 171 (N/A) 222 853 222 854 212 401 134 799 212 680 (N/A)
Description Wrench (standard length), nut tip contact Nozzle Extension Nozzle Insulator, ring Contact Tip Nut, compression Adapter, contact tube Diffuser, FasTip slotted Clamp, Sst bundle dia 2.00 x .18 wide x 7.90 lg Tube, head flexible (includes) O-Ring, .614 ID x .070CS Tubing, npm convoluted 7.100 lg x .740 ID cuffs Liner, teflon .030 – .035 (0.8 – 0.9 mm) wire x 11.625 lg, black Liner, teflon .047 – .062 (1.2 – 1.6 mm) wire x 11.625 lg, yellow Liner, phos bronze .030 – 1/16 (0.8 – 1.6 mm) wire x 11.249 O-Ring, .176 ID x .070CS Flex torch (inside tubing) (Old Style)
SXA Curved Nozzle Kit
2 1
Item # 1 2 3 4
5 6 7 8
Part # (Old Style) 147 174 005 417 005 432 148 158 148 155 148 154 (N/A) 148 156 — — — 148 151 — —
Part # (New Style) 300 161 005 417 005 432 148 158 148 155 148 154 148 156 136 748 185 110 193 794 148 151 222 462 222 464
3
4
(New Style) 5
6
7
Description Kit, SXA Curved Nozzle 50 Degree, Machine Sales Item Nut, retaining ring Nozzle, curve with collar Insulator, nozzle Tip, cont sl .030 – .035 (0.8 – 0.9 mm) wire curved Tip, cont sl 3/64 (1.19 mm) wire curved Tip, cont sl 1/16 (1.6 mm) wire curved Nut, compression Adapter, quick-change contact tip Kit, nozzle adapter Wrench (short length), nut retaining tip contact Kit, 50 degree head tube (air-cooled), Machine Sales Item Kit, 50 degree head tube (water-cooled), Machine Sales Item
Kit Quantity 1 1 1 1 1 1 1 1 1 (Old Style) / 2 (New Style) 1 2 1 1 1 1 1 1 New style Spoolmatic effective with serial number LE239243. New style XR effective with serial number LE033395.
Kit Quantity 1 2 2 2 2 2 1 1 1 1 1 1
39
SPOOL GUNS XR from serial number KK082113 to LC373468
1. 2. 3. 4.
Head Tube Liner (See chart below) Liner O-Ring #164 485 Head Tube O-Ring #191 191 Head Tube (Air-cooled) (Not available — must update to new style with Assembly Kit #231 525 shown below.) 5. Lock Nut #185 111 6. Insulator #185 097
XR -Edge
7. 8. 9. 10. 11. 12.
Gas Diffuser Collet Nut Contact Tip Adapter Jam Nut Nozzle Adapter Nozzle (Standard) Wrench (Not shown)
#185 110 #136 748 (See chart below) #185 102 #185 105 #185 100 #136 821
Note: For optional nozzles see page 41.
™
Wire Diameter .030 in (0.8 mm) .035 in (0.9 mm) .040 in (1.0 mm) .047 in (1.2 mm)
Air-cooled parts breakdown and gun shown. Consult owner’s manual for water-cooled parts and consumables.
Consumables
Standard Contact Tip I.D. .041 in (1.0 mm) #135 428 .052 in (1.3 mm) #135 430 .052 in (1.3 mm) #135 430 .061 in (1.5 mm) #135 424
Optional (Smaller) Contact Tip I.D. .036 in (0.9 mm) #135 427 .041 in (1.0 mm) #147 314 — .052 in (1.3 mm) #135 429
Gun Head Tube Liners #193 793 #193 793 #193 793 #193 792
Aluminum Feed Cable Liners #191 065 30 ft (9 m) #191 066 50 ft (15.2 m) #197 440 500 ft (152 m)
XR from serial number LC373394 to LE033394
Head Tube Liner #212 523 Liner O-Ring #164 485 Head Tube O-Ring #191 191 Head Tube (Air-cooled) (Not available — must update to new style with Assembly Kit #231 525 shown below.) 5. Lock Nut #185 111 1. 2. 3. 4.
6. Insulator 7. Gas Diffuser 7. Heavy-Duty Gas Diffuser (Optional) 8. Contact Tip 9. Adapter Jam Nut 10. Nozzle (Standard)
#185 097 #209 875 #202 283 (See chart below) #185 102 #197 728
Note: For optional nozzles see page 41. XR effective with serial number LE033395
1. 2. 3. 4. 5.
XR -Edge FasTip ™
Wire Diameter Steel / Aluminum .035 in (0.9 mm) / .030 in (0.8 mm) .040 in (1.0 mm) / .035 in (0.9 mm) .045 in (1.2 mm) / – .052 in (1.3 mm) / .047 in (1.2 mm) .062 in (1.6 mm) / –
40
Head Tube Liner Head Tube O-Ring Lock Nut Head Tube (Air-cooled) Outer Insulating Jacket
#212 523 #191 191 #185 111 #221 514 #220 103
6. 7. 8. 9.
Nozzle Insulator Gas Diffuser FasTip™ Contact Tip Nozzle (Standard)
#232 284 #227 749 (See chart below) #199 613
Note: For optional consumables see page 41.
™
Air-cooled parts breakdown and gun shown. Consult owner’s manual for water-cooled parts and consumables.
Consumables
FasTip Contact Tip I.D. .041 in (1.0 mm) #206 186 .047 in (1.2 mm) #206 187 .053 in (1.3 mm) #206 188 .061 in (1.5 mm) #206 189 .071 in (1.8 mm) #206 190
XR-Edge Drive Rolls #194 114 #194 115 #196 302 #194 116 #194 117
Optional Isolated XR-Edge Drive Rolls #198 434 N/A) #198 435 #198 436 (N/A) #198 437 #198 438 (N/A)
Cable Liners #191 065 15 ft (4.6 m) or 30 ft (9.1 m) #191 066 50 ft (15.2 m) #197 440 500 ft (152 m)
SPOOL GUNS New Style XR -Edge and XR /Spoolmatic FasTip Consumables ™
™
®
Note: Standard gun components are in blue type.
™
For a complete parts listing:
see pages 38-40
XR /Spoolmatic 30A Nozzles (Serial Numbers KD376404-LC259177) ™
Contact Tips
®
(10 p/pkg)
(25 p/pkg)
Heavy-Duty FasTip™ #223 016 #206 186
#050 622(B) 5/8 in (16 mm) orifice (Standard) (2 per pkg)
#050 115 1/2 in (13 mm) orifice (2 per pkg)
#050 116 13/16 in (21 mm) orifice (2 per pkg)
#004 466 Spot flat 1-3/8 in (35 mm) orifice
#000 443 Spot inside corner
#223 017
#206 187
#223 018
#206 188
#223 019
#206 189
#223 200
#206 190
—
#206 191
XR -Edge Nozzles (Serial Numbers KK082113 - LE033394) ™
#185 100 1 5/8 in (16 mm) orifice (Standard with air-cooled gun)
#050 116 1 13/16 in (21 mm) orifice
#197 728 5/8 in (16 mm) orifice (Standard w/water-cooled gun)
#004 466 1 Spot flat 1-3/8 in (35 mm) orifice
#193 790 1/2 in (13 mm) orifice (Standard w/water-cooled gun)
#000 443 1 Spot inside corner
Tapered FasTip™ — #209 026 —
#209 027
— — —
#209 028 #209 029 #209 030
Description .030/.035 in (0.8/0.9 mm) aluminum wire .035/.040 in (0.9/1.0 mm) aluminum wire .040/.045 in (1.0/1.2 mm) aluminum wire .052 in (1.3 mm) or 3/64 in (1.2 mm) aluminum wire 1/16 in (1.6 mm) .068 in (1.7 mm) or 1/16 in (1.6 mm) aluminum wire .030/.035 in (0.8/0.9 mm) aluminum wire .035/.045 in (0.9/1.2 mm) aluminum wire 3/64 in (1.2 mm) .052 in (1.3 mm) 1/16 in (1.6 mm)
Can use with water-cooled guns, Nozzle Adapter Kit #193 794 required.
1
41
SPOOL GUNS XR-Aluma-Pro
3
4
6
5
7
8
9
#231 519 Air-Cooled Assembly Kit Short Barrel, 4 in (102 mm)
#231 518* Air-Cooled Assembly Kit Long Barrel, 6 in (152 mm)
2
1. 2. 3. 4. 5.
1
XR -Aluma-Pro ™
™
Wire Diameter Steel / Aluminum .035 in (0.9 mm) / .030 in (0.8 mm) .040 in (1.0 mm) / .035 in (0.9 mm) .045 in (1.2 mm) / – .052 in (1.3 mm) / .047 in (1.2 mm) .062 in (1.6 mm) / –
Head Tube Liner Head Tube O-Rings Lock Nut Insulator Ring Rear Head Tube Short Head Tube Long
(See chart below) #230 969 #227 168 #227 416 #227 158 #229 672
6. Insulating Jacket, short #227 159 Insulating Jacket, long #229 673 7. Gas Diffuser #229 670 (See chart below) 8. FasTip™ Contact Tip 9. Nozzle (Standard) #198 855 Note: For optional consumables see page 41.
Air-cooled parts breakdown and gun shown. Consult owner’s manual for water-cooled parts and consumables.
Consumables
FasTip Contact Tip I.D. .041 in (1.0 mm) #206 186 .047 in (1.2 mm) #206 187 .053 in (1.3 mm) #206 188 .061 in (1.5 mm) #206 189 .071 in (1.8 mm) #206 190
Drive Rolls #227 434 #227 434 #227 434 #227 434 #227 434
Idler Rolls #227 439 #227 439 #227 439 #227 439 #230 710
Inlet Guides #227 408 #227 408 #227 408 #227 408 #230 711
Air-Cooled Head Tube Liner Short Barrel, 4 in (102 mm) #227 161 #227 161 #230 239 #230 239 #230 239
Air/Water Cooled Head Tube Liner Long Barrel, 6 in (152 mm) #229 674 #229 674 #229 431 #229 431 #229 431
Cable Liners #229 887 15 ft (4.6 m) #229 891 25 ft (7.6 m) #232 321 35 ft (10.6 m) #233 999 Long* #233 998 Short*
*Optional phos bronze liners.
XR-Aluma-Pro Plus
3 2
4
5
6
7
8
#246 301 Air-Cooled Assembly Kit, Long Barrel
1 1. 2. 3. 4. 5.
Head Tube Liner Head Tube O-Ring Insulator Lock Nut Insulating Jacket, Long
#230 242 #191 191 #227 416 #227 168 #229 673
XR -Aluma-Pro Plus ™
Wire Diameter Steel / Aluminum .035 in (0.9 mm) / .030 in (0.8 mm) .040 in (1.0 mm) / .035 in (0.9 mm) .045 in (1.2 mm) / – .052 in (1.3 mm) / .047 in (1.2 mm) .062 in (1.6 mm) / –
6. Diffuser 7. Contact Tip 8. Nozzle (Standard)
™
Contact Tips (10 pack) Steel / Aluminum T-035 / – – / T-035AL T-045 / T-047AL – /– T-062 / T-062AL
Consumables
Drive Rolls #227 434 #227 434 #227 434 #227 434 #227 434
D-1AP (See chart below) N-5818C
Air-cooled parts breakdown and gun shown. Consult owner’s manual for water-cooled parts and consumables.
Idler Rolls #230 708 #230 708 #230 708 #230 708 #230 708
Figure (Air) Tube AlumaPro Gun Air-cooled parts8-3. breakdown andHead gun shown. ConsultAssembly owner's manual forOf water-cooled parts andPlus consumables. *Optional phos bronze liners.
42
Air/Water Cooled Head Tube Liner Long Barrel, 6 in (152 mm) #230 235 #230 235 #230 432 #230 432 #230 432
Cable Liners #229 887 15 ft (4.6 m) #229 891 25 ft (7.6 m) #232 321 35 ft (10.6 m) #233 999 Long* #233 998 Short*
SPOOL GUNS XR-Aluma-Pro Lite 1 6
2 3
5 4
XR -Aluma-Pro Lite ™
Item # 1
2 3 4 5 5 5 5 6 6 6 6
™
Part # 254 477 QT2-45 1840057 1840031 4323R DS-1 NS-1218C T-047AL T-035AL T-047AL T-035AL 258 541 258 542 258 726 258 727
Consumables
Description Head Tube Assy, Aluma-Pro Lite (Including) Tube, Body 45 Degree x 2.69 Lg Clip-on Q-Nut Cover Body Tube Insulating Sleeve Insulator, Nozzle (Small) Diffuser, C-Fire (Small Nozzle) Nozzle, C-Fire Small Copper 1/2 in. Recess 1/8 in. Centerfire Contact Tip, Aluminum 3/64 in. Centerfire Contact Tip, Aluminum .035 Centerfire Contact Tip, Aluminum 3/64 in. Centerfire Contact Tip, Aluminum .035 Kit, Jump Liner Assy .030-.035 (5 pk) Kit, Jump Liner Assy .047-.062 (5 pk) Kit, Jump Liner Assy .030-.035 14 in. Long (5 pk) Kit, Jump Liner Assy .047-.062 14 in. Long (5 pk)
Air-cooled parts breakdown and gun shown. Consult owner’s manual for water-cooled parts and consumables. Quantity 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1
Optional Head Tube Assemblies
(for XR-Aluma-Pro guns)
45 Degree/4 Inch (Air-Cooled) #255 037
45 Degree/4 Inch (Water-Cooled) #255 338
45 Degree/6 Inch (Air-Cooled) #255 040
45 Degree/6 Inch Heavy-Duty (Water-Cooled) #258 293
45 Degree/6 Inch (Water-Cooled) #231 517
45 Degree/10 Inch Tight ACS (Air-Cooled) #258 295
43
SPOOL GUNS
Optional Head Tube Assemblies
(for XR-Aluma-Pro guns) continued...
60 Degree/4 Inch (Air-Cooled) #231 519
60 Degree/4 Inch (Water-Cooled) #255 038
60 Degree/6 Inch (Air-Cooled) #231 518
60 Degree/6 Inch (Water-Cooled) #255 041
60 Degree/6 Inch Heavy-Duty (Water-Cooled) #258 294
180 Degree/4 Inch (Air-Cooled) #255 716
180 Degree/4 Inch (Water-Cooled) #255 717
180 Degree/6 Inch (Air-Cooled) #258 476
180 Degree/6 Inch (Water-Cooled) #258 477
180 Degree/8 Inch (Air-Cooled) #255 042
180 Degree/8 Inch (Water-Cooled) #255 043
45 Degree/6 Inch with Centerfire™ (Water-Cooled) #246 205
60 Degree/6 Inch with Centerfire™ (Air-Cooled) #246 301
180 Degree/4 Inch with Centerfire™ (Air-Cooled) #258 474
180 Degree/4 Inch with Centerfire™ (Water-Cooled) #258 475
44
SPOOL GUNS 5
XR-Pistol Pro 4
3
7
2 1
6
8
XR -Pistol Pro ™
Item #
Part # 255 716 198 855 206 189 229 670 232 284 M1366 227 168 191 191 M1273 230 969
1 2 3 4 5 6 7 8
Air-cooled parts breakdown and gun shown. Consult owner’s manual for water-cooled parts and consumables.
Consumables
Description Kit, Head Tube Assy (Air) AP/PP 180 Degree 4 in. Nozzle, Copper 5/8 in. Tip, Fastip .312 Od .052 And 3/64 Al Wires Diffuser, .281/.312 Od Collar Fastip 1/8 Rec Aluma Insulator, Nozzle Collared Jacket Outer Insulating A/C Pistol Pro Nut, Head Tube Rotation O-Ring, .312 Id x .070 Cs 70 Duro Buna-n Liner, Teflon .047-.062 Wire Pistol Pro Kit, Replacement O-Rings Head Tube Air
Quantity 1 1 1 1 1 1 1 2 1 1 5 4
XR-Pistol Pro Plus 3
2 1 7
6
XR -Pistol Pro Plus
8
™
Item # 1 2 3 4 5 6 7 8
Part # 258 474 N-5818C T-047AL D-1AP 232 284 M1190 (N/A) 227 168 230 969 191 191 M1442
Consumables
Air-cooled parts breakdown and gun shown. Consult owner’s manual for water-cooled parts and consumables.
Description Kit, Head Tube Assy (Air) AP/PP 180 Degree 4 in. Lg Cntrfr Nozzle, C-Fire Large Copper 5/8 in. Recess 1/8 in. Contact Tip, Centerfire .047 Aluminum Diffuser, Centerfire-D-1AP Insulator, Nozzle Collared Diffuser (For 180 Degree/ Straight Only) Insulator, Outer 180 Degree/ Straight (Air) Nut, Head Tube Rotation Kit, Replacement )-Rings Head Tube Air (Includes) O-Ring, .312 ld x .070 Cs 70 Duro Buna-n Liner, Teflon .047-.062 Wire Soft Pro/Plus
Quantity 1 1 1 1 1 1 1 1 2 1
45
PLASMA CUTTING
Spectrum Plasma Torch History Continued ®
Spectrum® 1000
903 448, 903 449
ICE-70, pg 64
907 162
ICE-80T, pg 68
Spectrum® 1250
903 450, 903 451, 903 452
ICE-100, pg 66
Spectrum® 1251
907 305
ICE-100T, pg 70
Spectrum® 1500
903 147, 903 148, 903 186, 903 149
APT-8000
Spectrum® 1500D
907 305
APT-8000
Spectrum® 2050
903 789
ICE-50C, pg 62
Spectrum® 2050
903 777
ICE-55C, pg 63
Spectrum® 2255 Spectrum® 3080
903 755 903 793, 903 795
ICE-80C, pg 67
Spectrum®LYNX
903 552
ICE-50C, pg 62
Spectrum® Thunder Spectrum® PLUS
903 741, 903 742 903 454, 903 460, 903 781 903 498, 903 499, 903 502 903 142, 903 177 903 139 903 140
ICE-12C, pg 60 MC-80
Spectrum® 1250MG Spectrum® 187 Spectrum® 187D Spectrum® 250D
ICE-102 APT-1000 APT-1000 APT-3000
ICE-70, 30 ft (9 m) Hand-Held #169203, pg 64 ICE-70, 50 ft (15.2 m) Hand-Held #169245, pg 64 ICE-100 with 70 Amp Tip, 30 ft (9 m) Hand-Held #169207, pg 64 ICE-100 with 70 Amp Tip, 50 ft (15.2 m) Hand-Held #169246, pg 64 ICE-80T, 25 ft (7.6 m) Hand-Held #195223, pg 68 ICE-80T, 50 ft (15.2 m) Hand-Held #195225, pg 68 ICE-80TM, 25 ft (7.6 m) Machine-Held #195221, pg 69, No Pendant 4 ICE-80TM, 50 ft (15.2 m) Machine-Held #223535, pg 69, No Pendant 4 ICE-100, 30 ft (9 m) Hand-Held #169207, pg 64 ICE-100, 50 ft (15.2 m) Hand-Held #169246, pg 64 ICE-100M, 50 ft (15.2 m) Machine-Held #169247, (N/A) ICE-100T, 25 ft (7.6 m) Hand-Held #225702, pg 70 ICE-100T, 50 ft (15.2 m) Hand-Held #225704, pg 70 ICE-100TM, 25 ft (7.6 m) Machine-Held #225706 4, pg 70 ICE-100TM w/Pendant, 25 ft (7.6 m) Machine-Held #2260574, pg 70 ICE-100TM, 50 ft (15.2 m) Machine-Held #225708 4, pg 70 ICE-100TM, 50 ft (15.2 m) Machine-Held #226058 4, pg 70 ICE-70, 30 ft (9 m) Hand-Held #169203 5, pg 64 ICE-70, 50 ft (15.2 m) Hand-Held #169245 5, pg 64 ICE-100 with 70 Amp Tip, 30 ft (9 m) Hand-Held #1692075, pg 64 ICE-70, 30 ft (9 m) Hand-Held #169203, pg 64 ICE-70, 50 ft (15.2 m) Hand-Held #169245, pg 64 ICE-100 with 70 Amp Tip, 30 ft (9 m) Hand-Held #169207, pg 64 ICE-50C, 25 ft (7.6 m) Hand-Held #176824, pg 62 ICE-50C, 50 ft (15.2 m) Hand-Held #176826, pg 62 ICE-55C, 25 ft (7.6 m) Hand-Held #193347, pg 63 ICE-55C, 50 ft (15.2 m) Hand-Held #193348, pg 63 ICE-55CM, 50 ft (15.2 m) Machine-Held #193349, pg 63, No Pendant ICE-80CX, 25 ft (7.6 m) Hand-Held #216300, pg 68 ICE-80CX, 25 ft (7.6 m) Hand-Held #216300, pg 68 ICE-80CX, 50 ft (15.2 m) Hand-Held #218044, pg 68 ICE-80CXM, 50 ft (15.2 m) Machine-Held #219944, pg 69 ICE-50C, 25 ft (7.6 m) Hand-Held #176824, pg 62 ICE-50C, 50 ft (15.2 m) Hand-Held #176826, pg 62 Note: ICE-55C Not Recommended ICE-12C, 20 ft ( 6.1 m) Hand-Held (kit) # 216407, pg 60 MC-80, 25 ft (7.6 m) Hand-Held #171847 (N/A) No Replacement Torch available No Replacement Torch available No Replacement Torch available No Replacement Torch available No Replacement Torch available No Replacement Torch available Leather Torch Cable Covers Description 20 ft Cable Cover
239 642 Part # 239 642
25 ft Cable Cover 50 ft Cable Cover
231 867 231 868
Requires Retrofit Kit #172 155 2Requires Retrofit Kit #172 156 (N/A) 3Requires Remote Pendant Control #180 605 Requires Remote Pendant Control #195 513 5Requires Retrofit Kit #172 157 (N/A).
1 4
56
PLASMA CUTTING
AirForce and Cybercut (Hobart) Plasma Torch History ™
Model AirForce™ 250 AirForce™ 250A AirForce™ 250CI AirForce™ 375 AirForce™ 400 AirForce™ 500i AirForce™ 625
Machine Stock # 500 436 500 437 500 534 500 453 500 474 500 548 500 493, 500 494
Original Torch ICE-12C, pg 60 ICE-12C, pg 60 HP-25, pg 72 ICE-25C, pg 67 ICE-27C, pg 60 HP-50, pg 72 ICE-40C, pg 61
AirForce™ 700i AirForce™ 750 Cybercut 1025 Cybercut 2050
500 546 500 455 903 665 903 667, 903 678, 903 666
HP-70, pg 72 ICE-50C, pg 62 ICE-25C, pg 60 ICE-55C, pg 63
XT30 & XT30C Item #
Part # 249 949
255 685 1 2 3 3 4 5 6
259 870 249 971 249 957 255 686 252 938 249 972 252 951 249 930 249 933 249 932 249 927 249 931 249 926 249 969 253 054 253 055 253 520
Recommended Replacement ICE-12C, 20 ft (6.1 m) Hand-Held #216 407, pg 60 ICE-12C, 20 ft (6.1 m) Hand-Held #216 407, pg 60 HP-25, 16 ft (5 m) Hand-Held #232 647, pg 72 ICE-25CX, 20 ft (6.1 m) Hand-Held #195 007, pg 60 XT-30C, 20 ft (6.1m) Hand-Held #255 685, pg 57 HP-50, 16 ft (5 m) Hand-Held #244 121, pg 72 ICE-40C, 25 ft (7.6 m) Hand-Held #195 110, pg 61 ICE-40C, 50 ft (15.2 m) Hand-Held #195 111, pg 61 HP-70, 16 ft (5 m) Hand-Held #244 122, pg 72 ICE-50C, 25 ft (7.6 m) Hand-Held #176 824, pg 62 ICE-25CX, 20 ft (6.1 m) Hand-Held #195 007, pg 60 ICE-55C, 25 ft (7.6 m) Hand-Held #193 347, pg 63 ICE-55C, 50 ft (15.2 m) Hand-Held #193 348, pg 63 ICE-55CM, 50 ft (15.2 m) Machine-Held #193 349, pg 63
Service Parts/Consumables
Description XT30 Torch, Replacement 12 ft XT30C Torch Replacement 20 ft
Quantity 1 1
Torch Handle Kit Torch Trigger Leads 12 ft (XT-30) Leads 20 ft ( XT-30C) Torch Body w/Cup Switch Torch Trigger Assembly w/Spring Grease, Silicone Consumables Drag Shield Shield Deflector Retaining Cup Tip Swirl Ring Electrode O-Ring Stand-Off Guide Circle Cutting Guide Consumables Kit XT30
1 1 1 1 1 1 1
XT30 & XT30C Torch
Consumables for XT30 & XT30C
57
PLASMA CUTTING
XT40
XT40 & XT40 with Disconnect
Service Parts/Consumables
Item #
Part # 249 951 249 952 260 633 260 635
Description XT40 Torch Replacement 12 ft XT40 Torch Replacement 20 ft XT40 Torch Replacement 12 ft W/ Disconnect XT40 Torch Replacement 20 ft W/ Disconnect
Quantity
1 2 3 3 3 3 4 5
259 870 249 971 249 959 249 960 260 637 260 638 252 938 249 972
Torch Handle Kit Torch Trigger XT40 Lead 12 ft XT40 Lead 20 ft XT40 Lead 12 ft W/ Disconnect XT40 Lead 20 ft W/ Disconnect Torch Body Kit Torch Trigger Assembly W/ Spring
1 1 1 1 1 1 1 1
259 305 257 462
XT40M Machine Torch Long Body XT40M Machine Torch Short Body
259 363 259 361 259 333 263 389 259 357 259 359 259 330 253 521
Mounting Screw Mounting Sleeve Kit, Torch Body W/Switch Positioning Sleeve Short Body Positioning Sleeve Long Body Stain Relief Torch Replacement Leaks 25 ft Consumables Kit XT40
1 2 3 4 5 6 7
3 1 1 1 1 1 1
XT40TM Torch Long & Short
Consumables for XT40
263 310 Shield Sense
58
PLASMA CUTTING
XT60 & XT60M Item #
1 2 3 3 4 5
1 2 3 3 4 5 6 7
Part #
Service Parts/Consumables
249 953
Description XT60, 20 ft Replacement Torch
Quantity
249 954
XT60, 50 ft Replacement Torch
263 950 249 971 249 961 249 962 256 039 249 972
1 1 1 1 1 1
249 955 249 956 257 464 263 952
Torch Handle Kit Torch Trigger XT60, Lead 20 ft XT60, Lead 50 ft Torch Body Kit Torch Trigger Assembly W/Spring XT60M Torches XT60M, 25 ft Long Body Machine Torch XT60M, 50 ft Long Body Machine Torch XT60M, 25 ft Short Body Machine Torch XT60M, 50 ft Short Body Machine Torch
259 357 263 389 249 963 249 964 259 361 256 040 259 334 243 754
Long Body Positioning Sleeve Short Body Positioning Sleeve XT60M Lead, W/QD 25 ft XT60M Lead, W/QD 50 ft Torch Sleeve Main Body W/Switch Cup Detect Switch Kit, XT60M QD W/Wing Head Fastener
1 1 1 1 1 1 1 1
XT60 Torch
Consumables for XT60 & XT60M
XT60M Torch
263 310 Shield Sense
59
PLASMA CUTTING
ICE-12C
Service Parts/Consumables
Item #
Part # 216 407 195 172
Description Torch (kit) (ICE-12C) Torch (ICE-12C)
Quantity 1 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14
196 928 196 926 196 925 196 927 196 935 196 932 196 930 183 427 196 9311 185 833 190 220 171 248 197 567 196 929 252 951 222 9382 253 054 253 055
Cup, shield (optional) Tip, 12 A Electrode, 12 A Swirl Ring, 12 A O-Ring, ICE-12C main body Main Body Label, ICE-12C Handle Assy, complete Leads, 20 ft Switch Assembly (includes) Spring Push Button Switch Cup, retaining Shield, drag Grease, silicon Consumable Kit (ICE-12C) Stand-off Guide Circle Cutting Guide
1 1 (5 per pkg) 1 (5 per pkg) 1 1 (3 per pkg) 1 2 1 1 1 1 1 1 1 1 1 1 1
If used with Spectrum Thunder, #216 277 fitting required. ICE-12C Consumable Kit includes (1) drag shield #196 929 (1) plastic case #127 493, (1) shield cup #197 567, (4) tips #196 926, (4) electrodes #196 925, (1) o-ring #196 935, and (1) silicone grease #252 951.
1 2
For a listing of original torch applications and replacements: see
pages 55–57
ICE-25C & 25CX/27C/27T Item #
1 2 3 4 5 6 7 8 9 10 11
Part # ICE-25C — — —
Part # ICE-25 CX/27C/27T 195 007 195 014 225 615
202 808 176 656 176 655 202 809 169 232 178 550 — 171 248 — — 183 428 — 177 893 177 894 — — 225 671 225 672 225 616 252 951 — 253 054
202 808 176 656 176 655 202 809 169 232 — 203 119 171 248 185 833 190 220 183 427 228 405 — — 205 881 (N/A) 203 120 225 671 225 672 225 616 252 951 222 939 3 253 054
253 055
253 055
Description Torch (ICE-25CX) Torch (ICE-27C) Torch (ICE-27T)
Quantity
Cup, shield Tip, 25/27 A Electrode, 25/27 A Swirl Ring, 25/27 A O-Ring (main body) Main Body Main Body (ICE-27C/27T only) Push Button Switch Switch Assembly (includes) Spring Handle Assy, complete Leads, 12 ft (ICE-27T) Leads, 15 ft Leads, 25 ft Leads, 20 ft (ICE-25 CX) Leads, 20 ft (ICE-27C) Tip, drag shield Retaining Cup, drag shield Drag Shield Grease, silicon Consumable Kit (ICE-27C/27T) Stand-off Guide Circle Cutting Guide
1 1 (5 per pkg) 1 (5 per pkg) 1 1 (3 per pkg) 1 1 1 1 1 1 1 1 1 1 1 1 (5 per pkg) 1 1 1 1 1 1
ICE-27C Consumable Kit includes (1) plastic case #127 493, (1) shield cups #202 808, (5) tips #176 656, (5) electrodes #176 655, (1) swirl ring #202 809, (1) o-ring #169 232, and (1) silicone grease #252 951.
3
60
fax orders 1-800-637-2315
PLASMA CUTTING
ICE-40C/T
Service Parts/Consumables
Part # ICE-40C 195 110 195 111 — —
Part # ICE-40T — — 237 502 237 504
1 2 3 4 5 6
192 059 185 833 190 220 171 248 183 427 209 298 209 299 252 951
192 059 185 833 190 220 171 248 183 427 238 558 238 559 (N/A) 252 951
7 8 9 10 11 12 13 14 15 16 17
204 323 192 050 204 325 192 047 192 049 169 232 177 888 192 052 192 048 192 203 204 332 222 9401 253 054 253 055
204 323 192 050 204 325 192 047 192 049 169 232 177 888 192 052 192 048 192 203 204 332 222 9401 253 054 253 055
Item #
Description Torch, 25 ft (ICE-40C) Torch, 50 ft (ICE-40C) Torch, 12 ft (ICE-40T) Torch, 20 ft (ICE-40T)
Quantity 1 1 1 1
Main Body Switch Assembly (includes) Spring Push Button Switch Handle Assembly, complete Leads, 25 ft/ Leads, 12ft Leads, 50 ft Grease, silicon Consumables Shield, drag Cup, retaining Tip, standard (40 A) Electrode, standard Swirl Ring O-Ring Deflector Tip, extended (40 A) Electrode, extended Shield, gouge Tip, gouge Consumable Kit (ICE-40C) Stand-off Guide Circle Cutting Guide
1 1 1 1 1 1 1 1 1 1 1 (5 per pkg) 1 (5 per pkg) 1 1 (3 per pkg) 1 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 1 1
ICE-40C/T Consumable Kit includes (1) plastic case #127 493, (3) tips #204 325, (3) electrodes #192 047, (1) extended tip #192 052, (1) extended electrode #192 048, (1) gouge shield #192 203, (1) gouge tip #204 332, (1) o-ring #169 232, (1) silicone grease #252 951, (1) swirl ring #192 049 and (1) retaining cup #192 050.
1
For a listing of original torch applications and replacements:
see pages 55– 57
61
PLASMA CUTTING
ICE-50C & 50CM Item #
Part # 176 824 176 826 176 828
1 2 3 4 5 6
188 794 185 833 190 220 171 248 183 427 179 829 179 830 (N/A) 252 951
7 8 9 10 11
180 611 (N/A) 180 605 180 342 (N/A) 180 610 (N/A) 188 795 (N/A)
12 13 14
192 053 192 050 177 890 192 0511 192 047 177 886 192 0491 169 232 192 058 177 888 177 876 192 0561 192 0521 189 407 192 048 192 203 177 878 192 2041 226 763 253 055
15 16 17 18 19 20
21 22 23 24
Service Parts/Consumables
Description Torch, 25 ft (ICE-50C) Torch, 50 ft (ICE-50C) Torch, 50 ft (ICE-50CM) ICE-50C Torch (Hand-Held) Main Body Switch Assembly (includes) Spring Push Button Switch Handle Assembly, complete Leads, 25 ft Leads, 50 ft Grease, silicon ICE-50CM Torch (Machine-Held) Torch Sleeve Remote Pendent Control Leads, 50 ft Position Sleeve Main Body Consumables Shield, drag Cup, retaining Tip, standard Tip, standard (ICE-55C) Electrode, standard Swirl Ring Swirl Ring (ICE-55C) O-Ring Shield, machine Deflector Tip, extended Tip, extended tapered 55 A (ICE-55C) Tip, extended tapered 40 A (ICE-55C) Tip, extended (flat) Electrode, extended Shield, gouge Tip, gouge Tip, gouge (ICE-55C) Sense tab Circle Cutting Guide
Quantity 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 1 1 (3 per pkg) 1 1 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 1 1 (5 per pkg) 1 1
Spectrum 2050 Enhancement — For improved cutting performance and increased consumable life, Spectrum 2050 users are encouraged to update their existing ICE-50C Cutting Tips and Swirl Ring with the ICE-55C components. (The ICE-55C Tips must be used in conjunction with the ICE-55C Swirl Ring.)
1
For a listing of original torch applications and replacements:
see pages 55– 57
24
Sense Tab
226 763 Sense Tab
62
PLASMA CUTTING
ICE-55C & 55CM Item #
Part # 193 347 193 348 193 349
1 2 3 4 5 6
192 059 202 932 185 833 190 220 171 248 183 427 192 062 192 063 252 951
7 8 9 10 11 12
198 644 198 643 192 060 180 610 (N/A) 192 061 (N/A) 180 605
13 14 15 16 17 18 19 20 21
192 053 192 050 192 051 192 047 192 049 169 232 192 058 177 888 192 056 192 052 192 048 192 203 192 204 226 763 222 9411 253 055
22 23 24 25
Service Parts/Consumables
Description Torch, 25 ft (ICE-55C) Torch, 50 ft (ICE-55C) Torch, 50 ft (ICE-55CM) ICE-55C Torch (Hand-Held) Main Body Plunger Repair Kit Switch Assembly (includes) Spring Push Button Switch Handle Assy, complete Leads, 25 ft Leads, 50 ft Grease, silicon ICE-55CM Torch (Machine-Held) Retaining Ring Torch Sleeve Main Body Position Sleeve Leads, 50 ft Remote Pendent Control Consumables Shield, drag Cup, retaining Tip, standard Electrode, standard Swirl Ring O-Ring Shield, machine Deflector Tip, extended tapered (55 A) Tip, extended tapered (40 A) Electrode, extended Shield, gouge Tip, gouge Sense tab Consumable Kit (ICE-55C) Circle Cutting Guide
Quantity 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (5 per pkg) 1 (5 per pkg) 1 1 (3 per pkg) 1 1 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 1 1
ICE-55C Consumable Kit includes (1) plastic case #127 493, (1) drag shield #192 053, (1) retaining cup #192 050, (4) tips #192 051, (4) electrodes #192 047, (2) extended tips #192 056, (2) extended electrodes #192 048, (1) gouge shield #192 203, (1) gouge tip #192 204, (3) o-rings #169 232, and (1) silicone grease #252 951.
1
For a listing of original torch applications and replacements:
see pages 55– 57
25
Sense763 Tab 226 Sense Tab
63
PLASMA CUTTING
ICE-50/70/100
Service Parts/Consumables
Item #
Part # 169 224 (N/A) 169 203 169 245 169 207 169 246
Description ICE-50, 50 ft Hand-Held Torch ICE-70, 30 ft Hand-Held Torch ICE-70, 50 ft Hand-Held Torch Torch, 30 ft (ICE-100) Torch, 50 ft (ICE-100)
1
171 258 171 257 171 246 171 248 171 255 (N/A) 171 263 171 252
Torch, main body Torch, main body Handle Pushbutton, switch Splice, 22 – 18 butt N-insul connector Lead Insulator, 5/8PVC 3.5 in long Teflon Tube 11/16 ID x.030W x 3.5 in long Lead Insulator, 7/16PVC 3 in long Teflon Tube 9/16 ID x.030W x 2.5 in long Boot Handle Screw, No. 6 x 3/4ph Leads, 30 ft Leads, 30 ft Leads, 50 ft Leads, 50 ft Consumables Standoff Guide Retaining Cup Standard Tip Swirl Ring Standard Electrode O-Ring Stop-Guide Sleeve Extended Tip Extended Electrode Gouge Tip Stand-off Guide Circle Cutting Guide
2 3 4
5
171 260 171 251
6 7 8
171 247 171 256 171 264 171 253 171 265 (N/A) 171 254
9 10 11 12 13 14 15 16 17 18
132 6571 169 2161 174 0341 169 2151 169 2121 169 2321 174 0351 169 2141 173 8951 169 2131 253 054 253 055
Quantity ICE-50 1 — — — —
ICE-70 & 100 — 1 1 1 1
1 — 1 1 2 1 —
— 1 1 1 2 — 1
1 —
— 1
1 5 1 — 1 —
1 5 — 1 — 1
1 (2 per pkg) 1 1 (5 per pkg) 1 1 (5 per pkg) 1 (3 per pkg) 1 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 1
1 1
For ICE-50 only — see page 66 for ICE-70 and ICE-100 torch consumables.
1
For a listing of original torch applications and replacements:
see pages 55– 57
(See above for ICE-70 & ICE-100 torch consumables)
64
PLASMA CUTTING
ICE-60T & 60TM Item #
Part # 234 132 234 134 234 136 234 138 300 759 300 760
1 2 3 4 5 6
215 477 185 833 190 220 215 592 215 594 234 170 234 171 252 951 215 478
7 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22
215 607 234 172 234 173 (N/A) 215 599 215 598 215 478 234 829 215 606 195 513 220 240 220 241 212 735 212 734 212 724 219 676 212 725 212 733 212 730 212 732 219 682 212 729 212 736 219 680 212 731 226 763
Service Parts/Consumables
Description Torch, 20 ft (ICE-60T) Torch, 50 ft (ICE-60T) Torch, 25 ft (ICE-60TM) Torch, 50 ft (ICE-60TM) Torch with Pendant, 25 ft (ICE-60TM) Torch with Pendant, 50 ft (ICE-60TM) ICE-60T Torch Torch, main body Switch assembly (includes) Spring Push button switch Handle assembly Leads, 20 ft Leads, 50 ft Grease, silicon Switch Cup, Sensor ICE-60TM Torch Sleeve, torch position Torch Lead, 25 ft (7.6 m) Torch Lead, 50 ft (15.2 m) Torch sleeve Torch, main body Switch Cup, Sensor Kit, ICE-60T/TM QD w/wing head fastener Clip, retaining Remote pendant control Cable, remote control trigger 25 ft (7.6 m) Cable, remote voltage sense 26.5 ft (8 m) Consumables O-ring Swirl ring Electrode Standard 60A tip Standard 40A tip Retaining cup Drag shield Shield Extended 60A tip Extended 40A tip Deflector Gouge tip Gouge shield Sense tab
For a listing of original torch applications and replacements:
Quantity 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1
ICE-60T Torch
1 1 1 1 1
3
4 5
1 (5 per pkg) 1 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 1 1 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 1
7
1 8
2
see pages 55– 57
6
ICE-60TM Torch ICE-60TM Torch
16
22
14
Consumables for ICE-60T/ICE-60TM and Kit 239 086
226 763 Sense Tab 65
PLASMA CUTTING
ICE-70M/100M Item # 1 2 3 4 5 6 7 8 9 10 11
Part # 169 247 (N/A) 171 245 171 241 (N/A) 185 999 (N/A) 186 000 (N/A) 186 001 (N/A) 171 243 (N/A) 171 242 (N/A) 010 860 (N/A) 170 993 (N/A) 170 825 (N/A) 010 907 171 244 (N/A) 169 224 169 230 169 223 179 2821 169 219 169 226 169 222 169 217 169 233 169 225 181 227 169 220 169 227 173 815 173 816 170 995 169 221 169 228 169 218 169 217 226 763 253 054 253 055
12 13 14 15 16 17 18 19 20
21 22 23 24 25 26
Service Parts/Consumables
Description ICE-100M, 50 ft Machine Torch Torch, main body Torch Assembly, rack and sleeve (consists of) Torch Position Sleeve Gear Rack Locking Ring Leads, 30 ft (ICE-70M) Leads, 50 ft (ICE-100M) Clamp, hose .750 – 1.750clp dia Collar, brass Washer, shldr 1.251 x 1.750 OD x .125thk Nut, 1.000 – 11 Black PVC, 5/8 ID x 3.5 long Consumables Shield, drag Machine Shield Retaining Cup Cup, bevel Tip (70 A) Tip (100 A) Swirl Ring Electrode O-Ring Deflector Tip (50 A) Tip (70 A) Tip (100 A) Tip (70 A) Electrode Gouge Shield (70 A) Tip (70 A) Tip (100 A) Electrode (70 A) Electrode (100 A) Sense tab Stand-off Guide Circle Cutting Guide
Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 (3 per pkg) 1 1 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 1 1
Use of the #179 282 Bevel Cup will eliminate the need to use item #19 (#169 225 Deflector).
1
For a listing of original torch applications and replacements:
see pages 55– 57
26
Sense763 Tab 226 Sense Tab
66
PLASMA CUTTING
ICE-80C & 80CM Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Part # ICE-80C 176 830 187 300 190 503 190 502 (N/A) 196 423 190 504 (N/A) 187 301 196 682 187 298 190 501 190 500 (N/A) 196 415 196 416 (N/A) 190 497 218 177 — 187 305 — — 177 899 177 898 177 896 177 895 177 897 177 902 187 292 177 900 187 289 187 288 187 291 187 290 187 293 177 901 226 763 253 054 253 055
Part # ICE-80CM — — — — — — — — 187 299 190 501 190 500 (N/A) — 196 417 (N/A) 190 497 — — — 190 498 (N/A) 190 499 (N/A) 177 899 177 898 177 896 177 895 177 897 177 902 (N/A) 187 292 177 900 187 289 187 288 187 291 187 290 187 293 177 901 226 763 253 054 253 055
Service Parts/Consumables
Description ICE-80C, 25 ft Hand-Held Torch Handle #6 x 5/8 Phillips Screw, pan head Boot Switch Assy (includes) Spring Switch, Cup Sensor Push Button Switch Main Body Heatshrink 1/2 in ID (2.5 in) Tubing, 5/8 in ID (4 in) Torch Lead, 25 ft (7.6 m) Torch Lead, 50 ft (15.2 m) Plug Assy, quick disconnect Both plastic halves and nut Sleeve, torch position O-ring, quick disconnect Plug, 3-socket female Contact, cap-on sensor Consumables Drag Shield Retaining Cup Standard Tip Standard Electrode Swirl Ring O-Ring, silicon .864 x .070 Machine Shield Deflector Extended Tip Extended Electrode 40 Amp Retaining Cup 40 Amp Tip Gouge Shield Gouge Tip Sense tab Stand-off Guide Circle Cutting Guide
Quantity 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 14
1 1 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 1 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 1 (5 per pkg) 1 1 1
7
8 9
10
12
13 10
For a listing of original torch applications and replacements:
see pages 55– 57
11
ICE-80CM Torch
31
Consumables for ICE-80C and ICE-80CM Torches
226 763 Sense Tab 67
PLASMA CUTTING
ICE-80CX/80T
Service Parts/Consumables
Item #
Part # ICE-80CX 216 300 218 044
Part # ICE-80T 195 223 195 225
Description Torch, 25 ft Torch, 50 ft
Quantity 1 1
1 2 3 4 5 6 7 8 9 10
215 594 215 478 215 477 215 479 212 735 185 833 190 220 215 592 215 606 216 309 218 045 (N/A) — 218 177 190 497 187 305
215 594 215 478 215 477 215 479 212 735 185 833 190 220 215 592 215 606 223 5431 (N/A) 223 5441 227 546 — — —
1 1 1 1 1 (5 per pkg) 1 1 1 1 1 1 1 1 1 2
212 730 212 733 212 725 212 726 212 724 212 734 212 735 212 736 212 729 212 728 212 731 212 727 222 9422 253 054 253 055
212 730 212 733 212 725 212 726 212 724 212 734 212 735 212 736 212 729 212 728 212 731 212 727 222 9422 253 054 253 055
Handle with screws Cup Sensor Switch Kit Main Body Torch Head Repair Kit O-Ring, main body Switch Assembly (includes) Trigger spring Switch trigger Clip, retaining Torch Lead, 25 ft (7.6 m) Torch Lead, 50 ft (15.2 m) Fastener Stud Plug Assy, quick disconnect Both Plastic Halves and Nut O-Ring, quick disconnect Consumables Drag Shield Retaining Cup 40 Amp Standard Tip 80 Amp Standard Tip Electrode Swirl Ring O-Ring Deflector 40 Amp Extended Tip 80 Amp Extended Tip 80 Amp Gouge Shield 80 Amp Gouge Tip Consumable Kit (ICE-80T) Stand-off Guide Circle Cutting Guide
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1 1 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 1 1
Item #10 for ICE-80T is a combination unit that includes both torch lead and overmolded quick disconnect plug assembly. 2 ICE-80T Consumable Kit includes (1) plastic case #127 493, (1) drag shield #212 730, (1) retaining cup #212 733, (3) tips #212 726, (6) electrodes #212 724, (2) extended tips #212 728, (1) gouge shield #212 731, (1) gouge tip #212 727, (3) o-rings #212 735, and (1) silicon grease #252 951. 1
For a listing of original torch applications and replacements:
68
see pages 55– 57
PLASMA CUTTING
ICE-80CXM/80TM Part # Item # ICE-80CXM — 219 944 — 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22
Part # ICE-80TM 195 221 — 223 535
215 599 215 598 215 607 216 309 218 045 (N/A) — 218 177 187 305 180 605 — — 215 478
215 599 215 598 215 607 223 5451 (N/A) 219 9641 227 546 — — 195 513 220 240 220 241 215 478
212 732 212 733 212 725 212 726 212 724 212 734 212 735 212 736 212 729 212 728 212 731 212 727 226 763 222 9422 253 054 253 055
212 732 212 733 212 725 212 726 212 724 212 734 212 735 212 736 212 729 212 728 212 731 212 727 226 763 222 9422 253 054 253 055
Service Parts/Consumables
Description ICE-80TM Machine Torch, 25 ft ICE-80CXM Machine Torch, 50 ft ICE-80TM Machine Torch, 50 ft
Quantity 1 1 1
Torch Sleeve with screws Torch, main body Sleeve, torch position Torch Lead, 25 ft (7.6 m) Torch lead, ICE-80TM, 50 ft Fastener Stud Both Plastic Halves and Nut O-Ring, quick disconnect Remote Pendant Control Cable, remote control trigger 25 ft (7.6 m) Cable, remote voltage sense 26.5 ft (8 m) Cup Sensor Switch Kit Consumables Machine Shield Retaining Cup 40 Amp Standard Tip 80 Amp Standard Tip Electrode Swirl Ring O-Ring Deflector 40 Amp Extended Tip 80 Amp Extended Tip 80 Amp Gouge Shield 80 Amp Gouge Tip Sense tab Consumable Kit (ICE-80T) Stand-off Guide Circle Cutting Guide
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 1 1 1
Item #4 for ICE-80TM is a combination unit that includes both torch lead and overmolded quick disconnect plug assembly. 2 ICE-80T Consumable Kit includes (1) plastic case #127 493, (1) drag shield #212 730, (1) retaining cup #212 733, (3) tips #212 726, (6) electrodes #212 724, (2) extended tips #212 728, (1) gouge shield #212 731, (1) gouge tip #212 727, (3) o-rings #212 735, and (1) silicon grease #252 951. 1
For a listing of original torch applications and replacements:
see pages 55– 57
22
Consumables for ICE-80CXM and ICE-80TM Torches 226 763 Sense Tab
69
PLASMA CUTTING
ICE-100T & 100TM Item #
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17
18 19 20 21 22
23 24 25
Part # ICE-100T 225 702 225 704
Part # ICE-100TM 225 706 225 708
215 594 215 478 223 774 223 775 212 735 185 833 190 220 215 592 215 606 223 6121 223 6131 227 546 — — — — —
— 215 478 223 773 223 775 — — — — — 223 6141 (N/A) 223 6151 227 546 215 599 215 607 195 513 220 240 220 241
212 730/219 6852 212 733/219 6842 212 725 219 676 212 726 219 679 212 724/219 6782 212 734/219 6772 212 735 212 736 212 729 219 682 212 728 219 683 212 731 219 680 — 212 727 219 681 227 0373 253 054 253 055
212 732/219 6872 212 733/219 6842 212 725 219 676 212 726 219 679 212 724/219 6782 212 734/219 6772 212 735 212 736 212 729 219 682 212 728 219 683 212 731 219 680 226 763 212 727 219 681 227 0373 — —
Service Parts/Consumables
Description Torch, 25 ft Torch, 50 ft
Quantity 1 1
Handle with screws Cup Sensor Switch Kit Main Body with switch Torch Head Repair Kit O-Ring, main body Switch Assembly (includes) Trigger Spring Switch Trigger Clip, retaining Torch Lead, 25 ft (7.6 m) Torch Lead, 50 ft (15.2 m) Fastener Stud Torch Sleeve, ICE-80TM Sleeve, torch position Remote Pendant Control Cable, remote control trigger 25 ft Cable, remote voltage sense 26.5 ft Consumables Drag/Machine Shield Retaining Cup 40 Amp Standard Tip 60 Amp Standard Tip 80 Amp Standard Tip 100 Amp Standard Tip Electrode Swirl Ring O-Ring Deflector 40 Amp Extended Tip 60 Amp Extended Tip 80 Amp Extended Tip 100 Amp Extended Tip Gouge Shield 60 Amp Gouge Tip Sense tab 80 Amp Gouge Tip 100 Amp Gouge Tip Consumable Kit (ICE-100T) Stand-off Guide Circle Cutting Guide
1 1 1 1 1 (5 per pkg) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 (5 per pkg) 1 1 (5 per pkg) 1 1 (5 per pkg) 1 (5 per pkg) 1 1 1
Item #10 includes both torch lead and overmolded quick disconnect plug assembly. First number is for 40/60/80 Amp components and second number is for 100 Amp components. 3 ICE-100T Consumable Kit includes (1) plastic case #127 493, (1) 100 A drag shield #219 685, (1) 100 A retaining cup #219 684, (3) 100 A tips #219 679, (6) 100 A electrodes #219 678, (2) 100 A extended tips #219 683, (1) gouge shield #212 731, (1) 100 A gouge tip #219 681, (3) o-rings #212 735, and (1) silicon grease #252 951. 1 2
For a listing of original torch applications and replacements:
see pages 55– 57
Consumables for ICE-100T and ICE-100TM Torches
70
25
226 763 Sense Tab
PLASMA CUTTING
ICE-102 & 102M Item #
Part #
6 7 8
180 333 (N/A) 183 448 (N/A) 171 246 171 248 171 255 (N/A) 171 263 171 252 171 260 171 251 171 247 171 256 183 450 (N/A)
9 10 11 12 13 14 15 16 17 18 19
183 449 (N/A) 171 241 (N/A) 185 999 (N/A) 186 000 (N/A) 186 001 (N/A) 183 452 (N/A) 010 860 (N/A) 170 993 (N/A) 170 825 (N/A) 010 907 171 244 (N/A)
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
169 224 169 230 180 412 180 408 180 404 169 217 180 406 (N/A) 169 233 170 995 183 447 (N/A) 180 411 (N/A) 180 410 (N/A) 180 405 (N/A) 169 218 180 407 (N/A) 226 763 253 054 253 055
1 2 3 4 5
Service Parts/Consumables
Description ICE-102 Torch (Hand-Held) Torch, 50 ft Torch, main body Handle Pushbutton, switch Splice, 22 - 18 butt N-insul connector Lead Insulator, 5/8PVC 3.5 in long Teflon Tube, 11/16 ID x .030W x 3.5 in long Lead Insulator, 7/16PVC 3 in long Teflon Tube, 9/16 ID x .030W x 2.5 in long Boot Handle Screw, No. 6 x 3/4ph Leads, 50 ft ICE-102M Torch (Machine-Held) Torch, 50 ft Torch, main body Torch Assembly, rack and sleeve (consists of) Torch Position Sleeve Gear Rack Locking Ring Leads, 50 ft Clamp, hose .750 — 1.750clp dia Collar, brass Washer, shldr 1.251 ID x 1.750 OD x .125thk1 Nut, 1.000 — 11 Black PVC, 5/8 ID x 3.5 long Consumables Drag Shield Machine Shield Retaining Cup Shielded Tip Swirl Ring Air Electrode Multiple Gas Electrode O-Ring Gouge Shield Retaining Cup Air Gouge Tip Multiple Gas Gouge Tip Swirl Ring Air Gouge Electrode Multiple Gas Gouge Electrode Sense tab Stand-off Guide Circle Cutting Guide
For a listing of original torch applications and replacements:
Quantity 1 1 1 1 2 1 1 1 1 1 5 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (10 per pkg) 1 1 (5 per pkg) 1 (5 per pkg) 1 (3 per pkg) 1 1 1 1 1 1 (5 per pkg) 1 1 1 1
see pages 55– 57
35
Consumables for ICE-102 and ICE-102M Torches 226 763 Sense Tab
71
PLASMA CUTTING
HP-25
Service Parts/Consumables 232 647
Item # Part # 232 647 1 230 429 2 232 081 3 230 432 4 230 430 5 770 4961 5 770 723 6 770 4971 233 321 233 046 245 993
Description HP-25 Hand-Held Plasma Torch Handle Assy, left and right w/screws Trigger Switch Leads, 16 ft Torch Head Consumable kit, tip/electrode Consumable kit, tip/electrode Consumable kit, cup/swirl ring/o-ring Stand-off Guide Wrench Kit, Detect Leads
Quantity 1 1 1 1 2 each/kit 5 each/kit 1 1 1 1
Parts not sold individually. No circle cutting guide for the HP-25, HP-50, and HP-70 torches. #244 117 Yellow Safety Switch.
1
For a listing of original torch applications and replacements:
see pages 55– 57
6
Consumable Kits for HP-25 Torch
5
Tip Retaining Cup
HP-50 Item # Part # 244 121 1 770 4961 1 770 723 2 770 6531 3 233 321 245 993
HP-25 Torch
Electrode Swirl Ring O-Ring
Service Parts/Consumables 244 121
2
Description HP-50 Hand-Held Plasma Torch Consumable kit, tip/electrode Consumable kit, tip/electrode Consumable kit, cup/swirl ring/O-ring Stand-off guide, HP-25/50/70 plasma torch Kit, Detect Leads
Quantity 2 each/kit 5 each/kit 1 1 1
1
Tip
HP-70 Item # Part # 244 122 1 770 6541 1 770 724 2 770 6551 3 233 321 245 993
see pages 55– 57
2
Description HP-70 Hand-Held Plasma Torch Consumable kit, tip/electrode Consumable kit, tip/electrode Consumable kit, cup/swirl ring/O-ring Stand-off guide, HP-25/50/70 plasma torch Kit, Detect Leads
Quantity 2 each/kit 5 each/kit 1 1 1
Parts not sold individually. No circle cutting guide for the HP-25, HP-50, and HP-70 torches. #244 117 Yellow Safety Switch.
1
72
O-Ring
Service Parts/Consumables 244 122
For a listing of original torch applications and replacements:
Swirl Ring
Consumable Kits for HP-50 Torch
Parts not sold individually. No circle cutting guide for the HP-25, HP-50, and HP-70 torches. #244 117 Yellow Safety Switch.
1
For a listing of original torch applications and replacements:
Electrode
Retaining Cup
see pages 55– 57
1
Tip Retaining Cup
Electrode
Swirl Ring O-Ring
Consumable Kits for HP-70 Torch
GAS EQUIPMENT
Hose Fittings
R3
Little Torch™ Hose Nuts Stock No. R2 R3
Type Oxygen Fuel Gas
Nut Thread & Number 9/16 in-18 RH 9/16 in-18 LH
Hose ID Size 1/8 in (3 mm) 1/8 in (3 mm)
Style Barbed
Hose ID Size 1/8 in (3 mm)
1882
Little Torch™ Hose Tailpiece Stock No. 1882
Type Oxygen/Fuel
NOTE: For Oxy and Fuel Connections.
Ferrule 7582
Little Torch™ & Quickbraze™ Hoze Ferrule Stock No. 7582
Inside Diameter 3/16 in/ 5 mm
Length 9/32 in/ 7 mm
Crimping Tool 7799
Hose Type Oxygen/Fuel
NOTE: 7799 - Crimping tool to crimp ferrule on Little Torch™ hose.
Hose Adaptors Stock No. 14389 (B to A) 14390 (B to A)
Type Oxygen Fuel Gas
Male Thread 3/8 in-24 RH 3/8 in-24 RH
Female Thread 9/16 in-18 RH 9/16 in-18 RH
Nut Thread & Number 9/16 in-18 RH 9/16 in-18 LH
Style Nickel Plated Nickel Plated
14389
NOTE: “B” Regulators fitting to “A” hose fitting.
Torch Hose Connections Stock No. 3060-1 3060-2
Type Oxygen Fuel Gas
3060-2 3060-1
Use With: All heavy duty torch handles and hand torches.
Pressure Gauges & Filter
#GA136-03 2-inch Diameter Pressure Gauge (50 CFH/25 LPM) #GA139-03 2-inch Diameter Pressure Gauge (4000 PSI/280 BAR) n Highly accurate read-out n UL listed n Shatter-proof polycarbonate crystal 15001-30 Gas Filter, Shielding (In-Line) This in-line shielding gas filter is now standard on every Miller wire feeder with a gas solenoid. It traps contaminants before they plug up solenoid valves which result in costly downtime cleaning.
GA136-03 1/4 NPT
GA139-03 1/4 NPT
15775-10 Sintered Filter (10 Pack) Sintered filter to prevent debris from entering torch. Installs inside Smith “B” torch inlet connections. NOTE: Not for use with Gas Axe torches.
15001-30
15775-10
73
GAS EQUIPMENT
Single Hoses for Acetylene
RL121
Important Note: The Grade “R” hose is for use with acetylene only as specified by the RMA-CGA Hose Standard. “T” Grade hose must be used with all other gases.
Single “R” Grade hoses for Acetylene Only - Red Hose Stock No. RL121
Length 12-1/2 ft (3.8 m)
Weight (lbs & kg) Connections 1-1/4 (.55 kg) 9/16 in-18 LH (“B”)
Diameter 3/16 in (5 mm)
Use with Torch Series I.D. Size NE180 3/16 in(5 mm) Handi-Heat
7294-1
Single Hose - Inert Gas - Black Hose Stock No. 7294-1
Use For Inert Gas
Length 6 ft (1.8 m)
Diameter 1/4 in (6 mm)
Connections 5/8 in-18 RH Male
Single Hose - Nitrogen
RL260
Heavy Duty Charging Hose for use with Nitrogen for HVAC Purging Applications.
Stock No. RL260
Connections To Regulator To A/C Unit Length 6 ft (1.8 m) 7/16 in-20 7/16 in-20 RH Internal RH w/core
Use with Regulators 30-450-580 depress to open Schraeder Valve
I.D. Size 1/4 in (6 mm)
Little Torch™ Replacement Hoses Stock No. 13254-1-81
Length 8 ft
Hose Type Oxygen
13254-3-81
8 ft
Any Fuel
13254-4-81
8 ft
Oxygen/Fuel
13254-5-8
8 ft
Australian Little Torch™ Twin Hose Assembly
13254-6-8
8 ft
British Little Torch™ Twin Hose Assembly
13254-7-8
8 ft
European Little Torch™ Twin Hose Assembly
1
13254-1-8, 13254-3-8, 13254-4-8
Note: “B” - 9/16" Hose Fittings. Replacement hoses include installation tool 7799 and Ferrule 7582.
QuickBraze™ Replacement Hoses
14777-4-10, 14778-4-10
Stock No. 14777-4-10
Length 10 ft
Hose Type “A” - 3/8 in
14778-4-10
10 ft
“B” - 9/16 in
Note: Replacement hoses include installation tool 7799 and Ferrule 7582.
Kevlar Brazing Hose ®
#14779-4-10 “A” & “B” Fitting Twin Hose 3/8 in and 9/16 in female connections. Kevlar® Hose Features & Benefits Extremely durable, heat resistant, light weight and flexible. Excellent for repetitious brazing operations. (Not recommended for use with cutting attachments.) NOTE: For AW1A Handle only.
74
14779-4-10
GAS EQUIPMENT
Twin Hoses for Acetylene & Oxygen Important Note: Grade “R” welding hose is for use with acetylene only as specified by the RMA-CGA Hose Standard. “T” Grade hose must be used with all other gases. WARNING: Do not exceed the maximum working pressures (regulator setting) listed for the hoses during welding and cutting operations. Oxygen ...........................................................................................150 PSIG Maximum Acetylene ........................................................................................15 PSIG Maximum Propane, Propylene & all other Fuel Gases .....................................40 PSIG Maximum
Two-In-One “R” Grade Hose for Acetylene Only Stock No. RL1131
Length 25 ft (7.6 m)
Weight Diameter (lbs & kg) 1/4 in 6-1/2 (mm) (2.9 kg)
Connections To Regulator To Torches R11 (Oxygen) R11 (Oxygen) R12 (Fuel) R12 (Fuel) 9/16 in-18(“B”) 9/16 in-18 (“B”)
RL921
12-1/2 ft (3.8 m) 20 ft (6.1 m) 12-1/2 ft (3.8 m)
3/16 in (5mm) 3/16 in (5mm) 3/16 in (5 mm)
2-3/4 (1.2 kg) 4 (1.8 kg)
R13D (Oxygen) R13D (Oxygen) DG, MW, CW, 3/16 in (5 mm) R14D (Fuel) R14D (Fuel) SC 9/16 in-18 (“B”) 9/16 in-18 (“B”)
2-1/2 (1.1 kg)
R13D (Oxygen) R13 (Oxygen) AW1 R14D (Fuel) R14 (Fuel) 9/16 in-18 (“B”) 3/8 in-24 (“A”)
RL935 RA921
Use with Torch Series I.D. Size DG, SC, SW, 1/4 in (6 mm) CW, MW
Two-In-One “T” Grade Hose use with fuel gases (LP or Acetylene Gas) Stock No. TRL1131
Length 20 ft (6.1 m)
Weight Diameter (lbs & kg) 1/4 in 6-1/2 (6 mm) (2.9 kg)
Connections To Regulator To Torches R11 (Oxygen) R11 (Oxygen) R12 (Fuel) R12 (Fuel) 9/16 in-18(“B”) 9/16 in-18 (“B”)
RL1131, RL921, RL935, RA921
TRL1131
Use with Torch Series I.D. Size DG, SC, SW, 1/4 in (6 mm) CW, MW, AW10
75
GAS EQUIPMENT
Repair Parts “O” Ring Replacements Stock No. AW15 MW15 LW15
Use with Welding/Heating Tips/Cutting Assemblies AW Series Welding Tips / AT Series Heating Tips / AC309 Cutting Assembly / NE180 Series Air-Acetylene Tips MW Series Welding Tips / MT Series Heating Tips / DG109A, MC509, MC505 & CC509P Cutting Assemblies SW Series Welding Tips / ST Series Heating Tips / DG209, DG205, DG200, SC209, SC205, SC200 Cutting Assemblies
NOTE: 25 per package.
SC100
Hand Cutting Torch Repair Kits Stock No. 15772 SC100
Use with Torches DG900 & SC900 Series DG100, 200 & 300 Series; SC100, 200,300 Series
Cutting Assembly Repair Kits Stock No. SC101 MC101
Use with Cutting Assemblies Heavy Duty DG200 & SC Series Medium Duty DG100 & MC Series
SC101
The Little Torch™ Valve Assembly & Packing Replacements Stock No. 7345 7346 7348
Oxygen Valve Assembly Fuel Valve Assembly PTFE Packing for Valve Assembly (for Oxy and Fuel Valves)
7345
7348
7346
G729-5A LW14B-1
LW17
AW11A
Torch Valve Replacements (2 valves per kit) Stock No. LW17 G729-5A AW11A LW14B-1
Use with Torch Handles & Hand Cutting Torches WH100, MW5, MW5A, CW5A & AW10A WH200, SW1A, SW1B Series, 780 Series Machine Torch AW1A DG900, DG200, SC200, SC900 Series Hand Torches, 770 Series Machine Torches, SW1 Series Torch Handles
Torch Head Replacement Nut Stock No. G690-8 G900-41A
15555
15720-1
Use with Cutting Assemblies MC509, CC509P, AC309, MC505 Use with All SC Series Hand and Machine Torches & Cutting Torch Assemblies SC900 Series, SC772A, SC782A, SC781A, SC780A, SC771, SC770, SC509, SC300 Series Torches, SC300 Series Torches, SC100 Series Torches, SC300 Cutting Assembly Use with All Heavy Duty Dual Guard Hand Torch & Cutting Assemblies DG900 Series, DG209 Cutting Assembly, DG205 Cutting Assembly, DG300 Series, DG200 Series, DG100 Series Use with DG109A Cutting Assembly - DG109A
Cutting Tip Seat Graftite® Packing Replacements
(1 Set Per Bag)
G691 G930
“MC” Cutting Tips “SC” Cutting Tips
Torch Head Replacement Nut (Tip Nut)
76
GAS EQUIPMENT
Smith Equipment
®
The Little Torch
™
Service Parts/Consumables
Jewelry Repair & Manufacture, Hobby & Crafts, Metal Sculpture, Glass Blowing, Plumbing, Electronics & Repair 23-1001D Works with any fuel gas and oxygen. Includes 11-1101C torch, #3-7 curved tips, 8’ (2.4m) hoses and instruction manual. Packaged in display box as shown (“B “ hose connections fuel 9/16”-18-LH, Oxygen 9/16”-18-RH). 239-047B with BRITISH hose connections (Fuel G-3/8”-19 LH, Oxygen G 3/8”-19 RH). Tips included #3-7. Replacement British hose 8 ft. #13254-6-8. 239-048A with EUROPEAN hose connections (Fuel G-3/8”-19 LH, Oxygen G ¼”-19 RH). Tips included #3-7. Replacement European hose 8 ft. #13254-7-8. 23-1013A with AUSTRALIAN hose connections (Fuel 5/8”-18-LH, Oxygen 5/8”-18 RH). Replacement Australian hose 8 ft. #13254-5-8.
23-1001D 23-1014
Hoses may be connected to any standard oxy-fuel regulators (no adaptors required).
Outfit for Disposable Tanks 23-1014 Includes 249-499B preset oxygen regulator, 249-500B preset propane regulator, cylinder holder, 11-1101C torch, #5 tip, 8ft (2.4m) hoses and instruction manual. Allows maximum portability and may be used in locations where larger pressurized cylinders are not allowed.
23-1003B
Kit shown in inset photo above may be used with disposable propylene or propane and oxygen cylinders (Cylinders not included). Disposable oxygen and fuel tanks may be purchased at most hardware locations. May not be used with LP Multi-Flame (Rosebud) tip.
23-1003B Includes 11-1101C torch, #3-7 tips, 30-15-520 acetylene regulator (for “B” 40 cubic foot tank), 30-20-540 oxygen regulator, reverse flow check valves, 8’ (2.4m) covered hoses and instruction manual.
OR
23-1003P Kit with regulator fitting for propane or larger industrial acetylene cylinders. Includes 11-1101C torch, #3-7 tips, 30-15-510 fuel regulator, 30-20-540 oxygen regulator, reverse flow check valves, 8’ (2.4m) covered hoses and instruction manual. 23-1003 Kit with regulator fitting for acetylene (for “MC” tank) 10 cu. ft. cylinder. Includes 11-1101C torch, #3-7 tips, 30-15-200 fuel regulator, 30-20-540 oxygen regulator, check valves, 8’ (2.4m) covered hoses and instruction manual.
77
GAS EQUIPMENT
Smith Equipment
®
The Little Torch
™
Service Parts/Consumables
Magnetic Torch Stand & Tip Organizer 14014 Solid metal stand comes with holes drilled and numbered for #2-7 tips. Just a twist of the wrist removes the torch from the magnet. Magnetic clip mounts easily on Little Torch body (torch and tips dold separately).
The Little Torch™ has unmatched flexibility - it can be used with several fuels including acetylene, hydrogen, propane, propylene, or natural gas. It produces a perfectly controlled, completely stable flame hot enough to melt commercially weldable metals, glass and even ceramics. It may also be used with special heating tips to melt up to 3 oz. of gold or silver. Excellent for soldering platinum.
Propane Caddy 23-1015P Propane Caddy Includes 13558 (5 lb.) refillable propane tank, OC20 (20 cu.ft.) oxygen tank, 11 1101C torch with 8 ft. (2.4m) covered hoses, #3-7 tips, 30-20-540 oxygen regulator, 30-15-510 propane regulator, H698 pair reverse flow check valves, 13787A powder coated metal carrier and complete operation and instruction manual.
Gas
Capacity
HeightDiameter
0C20 2329E 13558
Oxygen "MC" Acetylene Propane
20 cu.ft. 10 cu.ft 5 lb.
17 3/4" - 5 1/4" 14 1/2" - 4 1/8" 12 1/2" - 8"
It’s the complete works in a handy self-contained lightweight unit. These highly portable kits come complete with everything you need for your soldering or brazing operations. Kits include tanks, regulators, safety check valves, five tips, torch and hoses all in a handy carrying case. Oxygen and acetylene cylinders can be refilled at most welding supply stores (disposable LP tanks are not included). Kits weight less than 32 lbs.
Propane Caddy 23-1010P Propane Caddy Incudes 11-1101C torch, 8’ (2.4m) covered hoses, #3-7 tips, 249-500 B preset propane regulator, 30-20-540 oxygen regulator, 0C20 oxygen cylinder (20 cu.ft.) 13493 caddy carrier, H698 pair check valves, and complete instruction manual. The 14.1 oz. disposable LP tank provides up to 15 hours of running time with #5 tip. Disposable tanks not included.
78
Stock No.
OR
Acetylene Caddy 23-1004A Acetylene Caddy Includes 11-1101C torch, #3-7 tips, 30-15200 acetylene regulator, 30-20-540 oxygen regulator, H698 pair reverse flow check valves, 8’ (2.4m) covered hoses, 0C20 (20 cu.ft.) oxygen cylinder, 2329E (10 cu. ft..) acetylene cylinder, 13493 caddy carrier and instruction manual.
GAS EQUIPMENT
Smith Equipment
®
The Little Torch
™
Service Parts/Consumables
Curved 12-1401-07
Straight 129-124-04
Twin Flame 12-1402-04
Size #2 #3 #4 #5 #6 #7
Curved 12-1401-02 12-1401-03 12-1401-04 12-1401-5 12-1401-6 12-1401-7
Straight Use With N/A Acetylene, Hydrogen Only N/A Any Fuel Gas 129-124-04 N/A N/A N/A
Size #4 #5 #6
Twin Flame Use With 12-1402-04 Any Fuel Gas 12-1402-05 12-1405-06
Orifice 0.02 0.029 0.037
Drill Size 76 69 63
Sapphire Tips Due to the extraordinary small orifice diameter of tips sizes #2-3, tips are fitted with a laser drilled synthetic sapphire to assure accurate gas flow and consistent flame characteristics.
Flexible Tip Extension For customizing angle and distance from handle.
All tips are 100% flame tested.
Length 3 in. (76 mm)
Orifice Dia. 0.006 0.011 0.020 0.029 0.037 0.047
Drill Size 97 85 76 69 63 56
Gas Pressure (PSI) Oxygen Fuel 5 5 6 6 6 6
Stock No. 2327-3SP
Gas Pressure (PSI)
Gas Consumption (CFH)
Oxygen 2 4 5 6 6 8
Fuel 0.09 0.78 1.57 2.58 4.48 6.27
Oxygen 0.11 0.94 1.88 3.1 5.38 7.52
BTU/hr 4,300 6,900 9,550
Brazing Capacity Copper Pipe 1/4"-5/8" 5/16"-3/4" 3/8" -7/8"
Fuel 2 4 5 6 6 8
Gas Consumption (CFH) Fuel Oxygen 2.91 3.49 4.7 5.64 6.5 7.8
BTU/hr 130 1,150 2,300 3,800 6,585 9,200
Capacity N/A Up to 1/8" 1/4"-3/8" 5/16"-5/8" 3/8"-3/4" 1/2"-7/8"
Twin Flame
Note: All values determined using acetylene gas. 1''
2''
3''
4''
5''
6''
7''
Approximate flame sizes at neutral mixture (oxygen/acetylene) NOTE: 1 PSI minimum for Natural Gas use.
Heating Tips Stock No. 13-662 13717
Flame Average BTU/hr Fuel Acetylene 6,615 Hydrogen 10,800 Propane 3,497 Natural Gas 2,300
Gas Pressure (PSI) Oxygen 14
Fuel 10
14 7
10 5
Gas Consumption (CFH) Length 6" (153mm) 6" (153mm)
Fuel 5 9 5 3.5
Oxygen 4.5 36.0 1.4 2.3
Acetylene 13-662 Melts up to 3 oz. Gold or Silver
Propane or Nat. Gas 13-717 Melts up to 3 oz. Gold or Silver
Note: Heating tips not for use with disposable oxygen tanks.
79
GAS EQUIPMENT
Smith Equipment
®
Quickbraze Oxy-Fuel Outfits ®
Refridgeration Outfits/Airconditioning
23-5005A Adapts to A or B Style Regulator Connections
S6 Single Flame Tip
14711 Heating Tip
T7 Twin Flame Tip
C2 "C" Style Tip
23-5004A
Quickbraze Tip Data Chart ®
Stock No. S4 S6 T7 C2* 14711*
Gas Pressure (PSI) Oxygen Fuel 8 8 8 8 8 8 7 5 12 10
Gas Consumption (CFH) Fuel Oxygen 0.8 0.6 3.2 3.4 9.8 7.6 6.4 7.2 14.7 9.7
BTU Output/Hr 1,120 7,360 12,200 12,350 13,760
Brazing Capacity Copper Pipe 1/4"-3/8" 1/2"-3/4" 5/8"-1-3/8" 1/2"1-1/8" 1/2"-1-5/8"
No. Flames 1 1 2 5 4
Caddy Kit Tips supplied braze up to 1-5/8” (41mm) diameter pipe fits 10 cu.ft. “MC” acetylene and 20 cu. Ft. “R” oxygen tanks.
*For use with Oxy-Acetylene only.
Kit Stock No. 23-5004A
23-5005A
Torch Assembly 11-1114 "B" -9/16" Hose Fittings 11-1116 "A" -3/8" Hose Fittings
Single Flame Tips Twin Flame Tip S6 T7
"C" Style Tip C2
Heating Tip 14711
Regulators Accessories 30-20-540 Cylinder Caddy Carrier, Striker, 30-15-200 Check Values & Operations Manual (tanks not included) None "A" to "B" Hose Adaptors & Operations Manual (hose may be attached to "A" or "B" Regulator Fittings
Note: All outfits include complete instruction and operation manual. Outfits with regulators, include reverse flow safety check valves.
Brazes solenoid and expansion valves so quickly that heat is unable to transfer to internal parts, protecting them from damage and eliminating the need for messy and costly heat sink materials.
80
Twin flame tips solder coil return bends quickly and evenly; concentrated heat will not heat and loosen surrounding joints.
Twin flame “C “ style tips quickly braze reversing valves without burning internal components.
Revolutionary patented “C” style tips provide 100% flame wrap for fast, efficient, even heating. Heat is confined to the joint area protecting surroundings from burning. “C” style tips also assure even heat on the blind side of the braze joint.
Accumulators can be brazed extremely fast by simply laying the patented “C” style tip near the joint.
GAS EQUIPMENT
Smith Equipment
®
Handi-Heet Acetylene-Air Kit ®
Soldering, Brazing, Sweating & Heating
Acetylene-Air Handi-Heet® Outfit Handi-Heet® soldering outfits provide fast heat with acetylene and atmospheric air. Concentrated soft flame delivers 4700 degrees F heat just where it is needed for maximum performance on all types of soldering, heating, thawing and other applications. No oxygen tank required. Tough NE180A torch handle is built to last – machined from solid brass. Unlike plastic torches, it is not sensitive to temperature changes. Full length fluted handle provided firm comfortable grip. Needle valve provides excellent flame adjustment. Easy to operate. Just hold torch and set flame with one hand. Handi-Heet soldering tips have Smith’s famous Slip-in design. Seats perfectly by hand… no wrench needed! “O” ring provides tight gas seal and allows operator to rotate tip to any position. All tips and torch body are nickel plated. Sturdy single stage regulator provides steady and sensitive gas regulation for maximum torch performance.
NE835A Outfit No. NE835A
Torch Handle NE180A
Tips NE180-1, NE180-2, NE180-3
Regulator 30-15-520 (CGA520)
Fits Tanks "B" 40 cu. ft.
Accessories RL121 12.5 ft. (3.8m) Hose N113A Lighter
Note: Torch does not require check valves or flashback arrestors.
OR
Air/Acetylene Torch & Tips NE180A Length-5-3/8”(130mm) Weight 8-1/4 oz.
NE180A Torch Handle 1 Year Warranty Use with acetylene gas. Machined from solid, brass. Hose connections 9/16”-18 LH thread, “B”. Fits R12 or R14D hose Connections.
• No oxygen tank needed • Clean, economical heat • No wrench needed-tips are hand tightened • One-handed flame adjustment • 360 degree Tip turning radius • Tough all brass body • Smooth turning needle valve • Rugged tips • Nickel plated for added heat resistance • Fuel pressure setting: 12-14 PSIG
Air/Acetylene Tips NE180-4 Length-8" (230mm) Weight 3-1/2 oz.
NE180-4 Extra Large Tip Use for fast paint burning, heavy soldering and heating. Replacement Orifice No. L704-6.
NE180-3 Length 7-5/8" (203mm) Weight 3-1/4 oz.
NE180-3 Large Tip Use for pipe thawing, light brazing and silver soldering. Replacement Orifice No. L703-6.
NE180-2 Length 6-7/8" (175mm) Weight 2-1/2 oz.
NE180-2 Medium Tip For all types of soft soldering, body leading, etc. Replacement Orifice No. L702-6.
NE180-1 Length 6-1/8" (156mm) Weight 1-7/8 oz.
NE180-1 Small Tip For fine instrument work, auto radiators, etc. Replacement Orifice No. L701-6
NE180-0 Length 4-3/4" (121mm) Weight 1-3/4 oz.
NE180-0 Fine Tip For jewelry, small tube and electronics soldering. Replacement Orifice No. L711-6
NE180-00 Length 4-3/4" (121mm) Weight 1-3/4 oz.
NE180-00 Super Fine Tip For delicate jewelry and electronic soldering. Replacement Orifice No. L710-6
NE180A Torch Handle 1 Year Warranty Burns acetylene with atmospheric air. Ideal for sweating copper joints up to 6” (152mm) in diameter, soldering, leading, thawing, heating and straightening.
Flame Opening
Flame Inner Cone Length
Tip No
Inch
mm
Inch
mm
Consumption BTU SCFH Output
NE180-4 NE180-3 NE180-2 NE180-1 NE180-0 NE180-00
3/8" 1/4" 3/16" 9/64" 3/32" 1/16"
10 6 5 3.6 2.4 1.7
1-3/4" 1-1/2" 1-1/4" 3/4" 1/4" 1/8"
45 38 32 19 6 3
22.8 9 5.2 2.8 1.5 0.5
32,900 13,000 7,500 4,000 2,200 720
81
GAS EQUIPMENT
Smith Equipment
®
Silver Smith Acetylene-Air Kit TM
Soldering, Brazing, Sweating & Heating
Silver SmithTM Designed for jewelers, silver smiths and hobbyists (excellent choice for light brazing and soldering). Air-fuel torches deliver the ultimate in quality and flame control. The all metal torch provides strength and long life, while precision jeweled orifice tips produce a soft, consistent flame. The Silver Smith™ torch system is designed to work with air and acetylene gas. Feature Benefits • Nickel plated brass handle for strength and long service • Heavy duty industrial regulators for added safety and service • Synthetic sapphire orifices provide consistent accurate flames control, and are easily replaced if obstructed.
239-193 Air/Acetylene Kit Outfit No. 239-193
Torch Handle NE180A
Tips NE180-00
Regulator 30-15-520 (CGA520)
Fits Tanks "B" 40 cu. ft.
Accessories RL121 12.5 ft. (3.8m) Hose N113A Lighter
Note: Torch does not require check valves or flashback arrestors.
OR
Air/Acetylene Torch & Tips NE180A Length-5-3/8”(130mm) Weight 8-1/4 oz.
NE180A Torch Handle 1 Year Warranty Burns acetylene with atmospheric air, soldering and heating.
NE180A Torch Handle 1 Year Warranty Use with acetylene gas. Machined from solid, brass. Hose connections 9/16”-18 LH thread, “B”. Fits R12 or R14D hose Connections.
• • • • • • • •
Air/Acetylene Tips
82
NE180-4 Length-8" (230mm) Weight 3-1/2 oz.
NE180-4 Extra Large Tip Replacement Orifice No. L704-6.
NE180-3 Length 7-5/8" (203mm) Weight 3-1/4 oz.
NE180-3 Large Tip Replacement Orifice No. L703-6.
NE180-2 Length 6-7/8" (175mm) Weight 2-1/2 oz.
NE180-2 Medium Tip Replacement Orifice No. L702-6.
NE180-1 Length 6-1/8" (156mm) Weight 1-7/8 oz.
NE180-1 Small Tip Replacement Orifice No. L701-6
NE180-0 Length 4-3/4" (121mm) Weight 1-3/4 oz.
NE180-0 Fine Tip Replacement Orifice No. L711-6
NE180-00 Length 4-3/4" (121mm) Weight 1-3/4 oz.
NE180-00 Super Fine Tip Replacement Orifice No. L710-6
No oxygen tank needed Clean , economical heat No wrench needed-tips are hand tightened One-handed flame adjustment 360 degree Tip turning radius Smooth turning needle valve Rugged tips Fuel pressure setting: 12-14 PSIG all tip sizes
Flame Opening
Flame Inner Cone Length
Tip No
Inch
mm
Inch
mm
Consumption BTU SCFH Output
NE180-4 NE180-3 NE180-2 NE180-1 NE180-0 NE180-00
3/8" 1/4" 3/16" 9/64" 3/32" 1/16"
10 6 5 3.6 2.4 1.7
1-3/4" 1-1/2" 1-1/4" 3/4" 1/4" 1/8"
45 38 32 19 6 3
22.8 9 5.2 2.8 1.5 0.5
32,900 13,000 7,500 4,000 2,200 720
ENGINE DRIVES
Portable Engine Drive Service Parts Model Blue Charger™ Blue Charger™ NT Blue Star® 145/145 DX Blue Star® 185/185 DX Blue Star® 3500 Blue Star® 6000 Bobcat™ 225 Bobcat™ 225D Bobcat™ 225D Plus Bobcat™ 225G Bobcat™ 225G Plus
Serial # Effective JJ377166 KH477915 LE366434 LE366294 KH519597 KH467216 LE294172 KB032454 KG076022 JK561993 KE582332
Bobcat™ 225 NT
KH329624
Bobcat™ 250 Bobcat™ 250 NT
LE237205 LB097734
Bobcat™ 250 D NT Bobcat™ 3 Phase Miller Legend® Miller Legend® NT Miller Legend® 301G Miller Legend® 302 Trailblazer® 250G Trailblazer® 251 Trailblazer® 251 NT Trailblazer® 275 DC/302 Trailblazer® 280 NT
LC357432 LE295787 JH242114 KH329624 KH329624 KH329624 JG018501 KG160691 KJ003470 LE246322 LA095390
Trailblazer® DC
LB159073
Trailblazer® 301 G
LB159073
Trailblazer® 300 D NT Trailblazer® 301 D Wildcat™ 200 Wildcat™ 225G
KJ022682 LC119875 LJ450001H JJ367046
Engine Model Onan Onan Kohler Honda/Kohler Honda/Kohler Honda/Kohler Kohler/Robin Deutz/Rugg. Deutz/Rugg. Onan Kohler Onan Kohler Onan Kohler/Robin Kohler Onan/Robin Kubota Kohler Onan Onan Kohler Kohler Onan Onan Onan Kohler/Robin Kohler Onan Onan Robin Kohler Onan Robin Kubota Kubota Subaru Onan
Ignition/ Start Switch # 172 070 176 606 Engine Mfg Engine Mfg Engine Mfg Engine Mfg 217 680 172 070 176 606 172 070 176 606 See manual See manual See manual 217 680 See manual See manual See manual See manual 172 070 176 606 176 606 217 680 See manual 176 606 176 606 217 680 176 606 176 606 176 606 176 606 176 606 176 606 176 606 176 606 176 606 217 680 172 070
Brushes/ Brush Assy # 126 984(3) 126 984(3) 493 509(1) 493 509(1) 493 509(1) 493 509(1) 205 725(1) 126 984(2) See manual 126 984(2) 126 984(2) 126 984(2) See manual See manual 205 725(1) See manual See manual 205 725(1) 205 725(1) 126 984(3) 126 984(3) 205 725(1) 205 725(1) 126 984(3) 126 984(3) 126 984(3) 205 725(1) 126 984(3) 126 984(3) 205 725(1) 205 725(1) 205 725(1) 205 725(1) 205 725(1) 126 984(3) 205 725(1) 493 509(1) 126 984(4)
Idle Solenoid # 106 977 186 308 218 794 218 794 — — Engine Mfg 149 618 See manual 151 485 199 530 165 810 See manual See manual Engine Mfg 199 530 See manual 248 995 Engine Mfg 106 977 See manual Engine Mfg Engine Mfg See manual 165 810 165 810 Engine Mfg Engine Mfg 165 810 165 810 165 810 199 530 165 810 165 810 See manual 248 995 — —
Note: Number in (parenthesis) following the order number denotes quantity needed of particular component.
230 Volt Plug # — 119 172 213 380 213 380 — — 119 172 119 172 119 172 119 172 119 172 119 172 119 172 119 172 119 172 119 172 119 172 119 172 119 172 See manual 119 172 119 172 119 172 025 234 025 234 119 172 119 172 119 172 119 172 119 172 119 172 119 172 119 172 119 172 119 172 119 172 119 172 119 172
Rheostat/ Pot # 081 712 081 712 241 165 241 165 494 618 See manual 233 060 205 839 205 839 205 839 205 839 205 839 See manual See manual 233 060 233 060 233 060 233 060 233 060 081 712 081 712 See manual See manual 072 462 072 623 072 623 See manual 072 623 072 623 See manual See manual See manual See manual See manual 072 462 See manual 238 905 205 839
Module (Idle) # 142 725 See manual 201 936 201 936 — — 201 936 142 725 See manual 189 742 189 742 189 742 See manual See manual 201 936 201 936 201 936 212 062 201 936 142 725 See manual — — See manual See manual 216 273 216 273 216 273 — — — — — — — 189 742 189 742
83
ENGINE DRIVES
Portable Engine Drive Tune-Up Components Engine Drive Blue Charger™ Blue Charger™ NT Blue Star® 145 Blue Star® 145 DX Blue Star® 185 Blue Star® 185 DX Blue Star® 3500 Blue Star® 6000 Bobcat™ 225/250 (Rear engine) Bobcat™ 225/250 (Front Engine)
Bobcat™ 250 EFI (Rear Engine) Bobcat™ 250 EFI (Front Engine) Bobcat™ 225
Bobcat™ 225D/225D Plus Bobcat™ 225G/225G Plus Bobcat™ 225G Plus Bobcat™ 225 NT Bobcat™ 250
Bobcat™ 250 NT
Bobcat™ 250 D NT Bobcat™ 250 Diesel Bobcat™ 250 Diesel (MD210321R) Bobcat™ 3 Phase (Rear Engine) Bobcat™ 3 Phase (Front Engine) Bobcat™ 3 Phase Miller Legend® Miller Legend® NT Miller Legend® 301 G/302
Engine Model Onan Performer P218 Onan Performer P218 Kohler CS10TG Kohler CS10STG Yamaha MZ300 Honda GX390 Kohler CS12STG Yamaha MZ360 Honda GX270 Kohler Command CS8.5TG Honda GX390 Kohler Command CS12STG Kohler Command CH23/CH680
Tune-Up Kit # 137 046 137 046 221 581 221 584 258 078 220 305 221 584 258 078 — — — — 230 015
Oil Filter # 065 251 065 251 — — — — — — — — — — 066 698
Air Filter # 064 617 064 617 221 579 221 582 258 077 220 303 221 582 258 077 190 109 203 952 220 303 203 952 230 016
Air Filter Pre-Cleaner # 065 653 065 653 221 580 221 583 — 220 304 221 583 — — 203 954 220 304 203 954 230 017
Spark Plug # 065 709(2) 065 709(2) 203 960 203 960 203 960 190 108 203 960 203 960 190 108 203 960 190 108 203 960 067 007(2)
Battery GP 58 GP 58 — GP U1 GP U1 — GP U1 GP U1 U1 — U1 — GP 58
Kohler Command CH730 Subaru EH65 Kohler Command CH730LP
230 015 199 062 252 838
066 698 198 754 066 698
230 016 198 755 067 272
230 017 With Air Filter 067 273
067 007(2) 198 777(2) 067 007(2)
GP 58 GP 58 GP 58
Kohler Command ECH730
246 115
066 698
230 016
230 017
067 007(2)
GP 58
Kohler Command ECH730
246 115
066 698
230 016
230 017
067 007(2)
GP 58
Kohler Command CH238 Kohler Command CH20 Robin EH 64/65 Deutz/Rugg. MD-151 Onan Performer P-216 Kohler Command CH18 Kohler Command CH18/CH20 Onan Performer P-216 Kohler Command CH23 9 Kohler Command CH20/CH730 Robin EH 64/65 Kohler Command CH20 Onan Performer P-220 Onan Performer OHV220/Robin Kubota D722FB-25 Kubota D722FB-25 Kubota D722
230 015 180 096 199 062 — 137 046 180 096 180 096 137 046 230 015 180 096 199 062 180 096 137 046 199 062 206 421 206 421 259 935
066 698 066 698 198 754 066 702 065 251 066 698 066 698 065 251 066 698 066 698 198 754 066 698 065 251 198 754 187 443 187 443 187 443
230 016 067 272 198 755 066 843 064 617 067 272 067 272 064 617 230 016 067 272 198 755 067 272 064 617 198 755 187 441 187 441 258 349
230 017 067 273 With Air Filter 066 842 065 653 067 273 067 273 065 653 230 017 067 273 With Air Filter 067 273 065 653 With Air Filter — — —
067 007(2) 067 007(2) 198 777(2) — 065 709(2) 067 007(2) 067 007(2) 065 709(2) 067 007(2) 067 007(2) 198 777(2) 067 007(2) 065 709(2) 198 777(2) — — —
GP 58 GP 58 GP 58 (See note4) (See note5) GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58
Kohler Command CH23/CH680
230 015
066 698
230 016
230 017
067007(2)
GP 58
Kohler Command CH730
230 015
066 698
230 016
230 017
067007(2)
GP 58
Kohler Command CH2310 230 015 066 698 230 016 Kohler Command CH20/CH730 180 096 066 698 067 272 Onan Performer P-218 137 046 065 251 064 617 Onan Performer P-218 137 046 065 251 064 617 Kohler Command CH23 230 015 066 698 230 016 Kohler Command CH20 180 096 066 698 067 272 More Portable Engine Drives on pages 82 and 83.
230 017 067 273 065 653 065 653 230 017 067 273
067 007(2) 067 007(2) 065 709(2) 065 709(2) 067 007(2) 067 007(2)
GP 58 GP 58 GP 586 GP 58 GP 58 GP 58
Prior to serial number KG045632 use #065 629. Effective with serial number KG045632 use #067 283. Prior to serial number KF926822 use #107 297. Effective with serial number KF926822 use #164 353. Note: Number in (parenthesis) following the order number denotes quantity needed of particular component.
Prior to JB482410 = U1. D=GP 24; DPlus=GP 58. 5 G=GP U1; GPlus=GP 58. 6 Prior to KF959177=24. 7 250=GP 24; 251=GP 58.
Effective with LG070820. Effective with LG071468. Effective with LG073969. 11 Effective with LG074229.
1
3
8
2
4
9
84
10
ENGINE DRIVES
Portable Engine Drive Tune-Up Components Engine Drive Blue Charger™ Blue Charger™ NT Blue Star® 145 Blue Star® 145 DX Blue Star® 185 Blue Star® 185 DX Blue Star® 3500 Blue Star® 6000 Bobcat™ 225/250 (Rear engine) Bobcat™ 225/250 (Front Engine)
Bobcat™ 250 EFI (Rear Engine) Bobcat™ 250 EFI (Front Engine) Bobcat™ 225
Bobcat™ 225D/225D Plus Bobcat™ 225G/225G Plus Bobcat™ 225G Plus Bobcat™ 225 NT Bobcat™ 250
Bobcat™ 250 NT
Bobcat™ 250 D NT Bobcat™ 250 Diesel Bobcat™ 250 Diesel (MD210321R) Bobcat™ 3 Phase (Rear Engine) Bobcat™ 3 Phase (Front Engine) Bobcat™ 3 Phase Miller Legend® Miller Legend® NT Miller Legend® 301 G/302
Voltage Regulator # 064 846 064 846 — — — — — — — — — — 190 249
Muffler Gasket # 065 313(2) 065 313(2) 203 959 203 959 203 959 — 203 959 203 959 — 203 959 — 203 959 189 477(2)
220 711* 220 711*
190 249 244 143 190 249
189 477(2) 249 313 261 651(2) 249 314 189 477(2) 249 313
190 248
220 711*
190 249
189 477(2) 245 396
—
220 711
—
189 477(2) 249 741
190 248 190 248 198 756 — (See note1) 190 248 190 248 067 283 190 248 190 248 198 756 190 248 067 283 198 756 — — —
220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711
190 249 190 249 198 778 — 064 846 190 249 190 249 064 846 190 249 190 249 198 778 190 249 064 846 198 778 187 821 187 821 —
189 477(2) 189 477(2) 217 441(2) — 065 313(2) 189 477(2) 189 477(2) 065 313(2) 189 477(2) 189 477(2) 217 441(2) 189 477(2) 065 313(2) 065 313(2) 189 766 189 766 192 517
190 248
220 711
190 249
189 477(2) (See note3)
—
220 711*
—
189 477(2) 249 313
190 249 190 249 064 846 064 846 190 249 190 249
189 477(2) 189 477(2) 065 313(2) 065 313(2) 189 477(2) 189 477(2)
Engine Model Onan Performer P218 Onan Performer P218 Kohler CS10TG Kohler CS10STG Yamaha MZ300 Honda GX390 Kohler CS12STG Yamaha MZ360 Honda GX270 Kohler Command CS8.5TG Honda GX390 Kohler Command CS12STG Kohler Command CH23/CH680
Fuel Filter # 066 113 066 113 — — 247 590 — — 247 590 — — — — 215 984
Fuel Pump # 065 629 065 629 — — — — — — — — — — 190 248
Fuel Cap # 220 711* 220 711* 203 955 220 711 220 711 198 522 220 711 220 711 198 522 203 955 198 522 203 955 220 711*
Kohler Command ECH730 Subaru EH65 Kohler Command CH730LP
215 984 237 857
190 248 198 756 —
246 110 246 112 Kohler Command CH730LP 246 110 246 112 Kohler Command CH23 215 984 Kohler Command CH20 215 984 Robin EH 64/65 215 984 Deutz/Rugg. MD-151 066 893 Onan Performer P-216 066 113 Kohler Command CH18 215 984 Kohler Command CH18/CH20 215 984 Onan Performer P-216 066 113 Kohler Command CH23 215 984 Kohler Command CH20/CH730 215 984 Robin EH 64/65 215 984 Kohler Command CH20 215 984 Onan Performer P-220 066 113 Onan Performer OHV220/Robin 237 857 Kubota D722FB-25 187 442 Kubota D722FB-25 187 442 Kubota D722 213 858 259 934 Kohler Command CH23/CH680 215 984 Kohler ECH730
Kohler Command ECH730
215 984
Kohler Command CH23 215 984 190 248 220 711 Kohler Command CH20/CH730 215 984 190 248 220 711 Onan Performer P-218 066 113 065 629 220 711 Onan Performer P-218 066 113 067 283 220 711 Kohler Command CH23 215 984 190 248 220 711 Kohler Command CH20 215 984 190 248 220 711 More Portable Engine Drives on pages 82 and 83.
Prior to serial number KG045632 use #065 629. Effective with serial number KG045632 use #067 283. Prior to serial number KF926822 use #107 297. Effective with serial number KF926822 use #164 353. 3 Prior to serial number MD210321R use #187 428. Effective with serial number MD210321R use #257 881. Note: Number in (parenthesis) following the order number denotes quantity needed of particular component. 1 2
Muffler # (See note2) 183 434 203 958 (N/A) 218 411 218 411 — 218 411 218 411 — 203 958 (N/A) — 203 958 (N/A) 228 681
228 681 228 681 228 680 — 107 297/164 353 (Plus) 173 065 183 435 183 434 228 681 228 681 228 680 183 435 183 434 204 841 187 428 187 428 257 880
228 681 228 681 (See note2) 183 434 207 458 207 458
*Gas tanks are EPA compliant starting 2012 week 10 (March 5, 2012). Contact Factory Service Department to ensure correct fuel cap is ordered.
85
ENGINE DRIVES
Portable Engine Drive Tune-Up Components Engine Drive Renegade™ 180 Trailblazer® 250G/251 Trailblazer® 251 NT Trailblazer® 275 DC/302
Trailblazer® 275 DC/302 Trailblazer® 275 DC/302 EFI Trailblazer® 275/325 Trailblazer® 275/325 EFI Trailblazer® 280 NT Trailblazer® DC/301 G Trailblazer® 301 G Trailblazer® 300 D NT/301 D Trailblazer® 302 Diesel Trailblazer® 302 Air Pak Trailblazer® 325 Diesel Wildcat 200
Engine Model Kohler 8.5, CS10, 12.0 Onan Performer P-220 Onan Performer P-220 Kohler Command CH2311 Kohler Command CH20/CH730 Robin EH 64/65 Kohler Command CH23/CH680 Kohler Command ECH730 Kohler Command CH730 w/e-gov Kohler Command CH730LP w/e-gov Kohler Command ECH730 w/e-gov Kohler Command CH20 Onan Performer P-220 Kohler Command CH20 Onan Performer P-220 Onan Performer OHV220/Robin Kubota D722FB-25 Kubota D722FB-25 Kohler CH750 Kubota D902 Subaru
Tune-Up Kit # 221 581 137 046 137 046 230 015 180 096 199 062 230 015 246 115 230 015 252 838 246 115 180 096 137 046 180 096 137 046 199 062 206 421 206 421 238 743 259 935 240 585
Oil Filter # — 065 251 065 251 066 698 066 698 198 754 066 698 066 698 066 698 066 698 066 698 066 698 065 251 066 698 065 251 198 754 187 443 187 443 066 698 187 443 —
Prior to serial number KG045632 use #065 629. Effective with serial number KG045632 use #067 283. Prior to serial number KF926822 use #107 297. Effective with serial number KF926822 use #164 353. Note: Number in (parenthesis) following the order number denotes quantity needed of particular component.
Air Filter # 221 579 064 617 064 617 230 016 067 272 198 755 230 016 230 016 230 016 067 272 230 016 067 272 064 617 067 272 064 617 198 755 187 441 187 441 238 744 258 349 240 597
Air Filter Pre-Cleaner # 221 580 065 653 065 653 230 017 067 273 With Air Filter 230 017 230 017 230 017 067 273 230 017 067 273 065 653 067 273 065 653 With Air Filter — — 238 745 — —
Spark Plug # 203 960 065 709(2) 065 709(2) 067 007(2) 067 007(2) 198 777(2) 067 007(2) 067 007(2) 067 007(2) 067 007(2) 067 007(2) 067 007(2) 065 709(2) 067 007(2) 065 709(2) 198 777(2) — — 238 746(2) — 240 598(2)
Effective with LG070820. Effective with LG071468. 10 Effective with LG073969. 11 Effective with LG074229.
1
3
8
2
4
9
86
Prior to JB482410 = U1. D=GP 24; DPlus=GP 58. 5 G=GP U1; GPlus=GP 58. 6 Prior to KF959177=24. 7 250=GP 24; 251=GP 58.
Battery GP U1 (See note8) GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP 58 GP51R GP 58 GP U1
ENGINE DRIVES
Portable Engine Drive Tune-Up Components Engine Drive Renegade™ 180 Trailblazer® 250G/251 Trailblazer® 251 NT Trailblazer® 275 DC/302
Trailblazer 275 DC/302 Trailblazer 275 DC/302 EFI Trailblazer 275/325 Trailblazer 275/325 EFI Trailblazer® 280 NT Trailblazer® DC/301 G Trailblazer® 301 G Trailblazer® 300 D NT/301 D Trailblazer® 302 Diesel Trailblazer® 302 Air Pak Trailblazer® 325 Diesel Wildcat 200
Engine Model Kohler 8.5, CS10, 12.0 Onan Performer P-220 Onan Performer P-220 Kohler Command CH23 Kohler Command CH20/CH730 Robin EH 64/65 Kohler Command CH23/CH680 Kohler Command ECH730 Kohler Command CH730 w/e-gov Kohler Command CH730LP w/e-gov Kohler Command ECH730 w/e-gov Kohler Command CH20 Onan Performer P-220 Kohler Command CH20 Onan Performer P-220 Onan Performer OHV220/Robin Kubota D722FB-25 Kubota D722FB-25 Kohler CH750 Kubota D902 Subaru
Fuel Filter # — 066 113 066 113 215 984 215 984 215 984 215 984 246 110, 246 112 215 984 — 246110, 246112 215 984 066 113 215 984 066 113 237 857 187 442 187 442 215 985 213 858, 259 934 241 408
Fuel Pump # — 065 629 067 283 190 248 190 248 198 756 190 248 190 248 190 248 190 248 190 248 190 248 067 283 190 248 067 283 198 756 — — 190 248 — 246 926
Prior to serial number KG045632 use #065 629. Effective with serial number KG045632 use #067 283. Prior to serial number KF926822 use #107 297. Effective with serial number KF926822 use #164 353. Note: Number in (parenthesis) following the order number denotes quantity needed of particular component.
1 2
Fuel Cap # 203 955 220 711 220 711 220 711 220 711 220 711 220 711* 220 711* 255 707 — 255 707 220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711 220 711
Voltage Regulator # — 064 846 064 846 190 249 190 249 198 778 190 249 190 249 244 143 244 143 244 143 190 249 064 846 190 249 064 846 198 778 187 821 187 821 244 143 — 241 434
Muffler Gasket # 203 959 065 313(2) 065 313(2) 189 477(2) 189 477(2) 217 441(2) 189 477(2) 189 477(2) 189 477(2) 189 477(2) 189 477(2) 189 477(2) 065 313(2) 189 477(2) 065 313(2) 065 313(2) 189 766 189 766 189 477 192 517 246 923
Muffler # (See note3) (See note2) 183 434 228 681 228 681 228 680 228 681 245 396 249 313 249 313 249 741 183 435 183 434 183 435 183 434 204 841 187 428 187 428 235 107 257 880 237 720
*Gas tanks are EPA compliant starting 2012 week 10 (March 5, 2012). Contact Factory Service Department to ensure correct fuel cap is ordered.
87
ENGINE DRIVES
Industrial Engine Drive Tune-Up Components Engine Drive Big 40® Big 40 ®G Big 40® Diesel Big 40® Diesel (CAT) Big 50 Diesel™ (Prior to JK718458) Big 50 Diesel™ (Eff. with JK718458) Big Blue® 251D (Prior to KF846844) Big Blue® 251D (Eff. with KF846844) Big Blue® 251D (Eff. with LA153592) Big Blue® 300/Pro
Big Blue® 302D Big Blue® 302P Big Blue® 350 PipePro® (Prior to MA 250132E) Big Blue® 350 PipePro® (Eff. s/n MA250132) Big Blue® 350 PipePro® Big Blue® 400D Big Blue® 400D Big Blue® 400 KX Big Blue® 400 Pro Big Blue® 400 Pro Big Blue® 400 Pro Big Blue® 402D /502D/602D Big Blue® 402P/502P/602P Big Blue® 450 duo CST™ Big Blue® 400/500 ECO Pro Big Blue® 500 Pro (Deutz) 4 Big Blue® 500X
Big Blue® 600D Big Blue® 700 Dual Pro4 Big Blue® 800 Duo Pro Big Blue® 800 Duo Pro Air Pak™ Big Blue® 800 Pro Air Pak (Deutz) 4 Big Blue® Air Pak™ 1 Big Blue® Turbo Miller Air Pak™ Miller Du-Op™ PRO 300 PipePro™ 304 Trailblazer®Pro 350
Engine Model Continental F-163 Continental TM-20 Continental TMD-20 CATERPILLAR 3024C/C2.2 Continental TMD-27 Continental TMD-27 Deutz F3L1011 Deutz F3L1011 Deutz F3L1011 Perkins 403C-15 CATERPILLAR C1.5 Deutz 2008 Mitsubishi-S4L2 Deutz F3L1011 Perkins 104.22 Mitsubishi-S4L2
Oil Filter # 061 760 114 559 064 983 202 166 064 983 064 983 066 212 067 265 067 265 197 899 202 166 228 778 242 882 067 265 197 899 242 882
Air Filter # 017 309 017 309 020 319 192 938 020 319 020 319 126 880 126 880 197 676 197 676 197 676 197 676 197 676 192 938 192 938 197 676
Air Filter (Safety Element) # — — — 192 939 — — — — 197 679 197 679 197 679 197 679 — 192 939 192 939 197 679
Fuel Filter (Primary) # — 047 420 192 744 192 744 062 342 192 744 192 744 192 744 192 744 213 858 213 858 213 858 252 781 192 744 192 744 213 858
Fuel Filter (Secondary) # — — — 202 167 065 346 — 066 217 066 217 066 217 197 997 217 687 202 167 213 858 066 217 197 997 242 881
Mitsubishi-S4L2
242 882
197 676
197 679
213 858
Caterpillar C1.5 Deutz F3L2011 Perkins 404.22 Deutz F3L912 Kubota V1505-EBG1 Mitsubishi S4L2 Cat C1.5 Kubota 1505 E3BG Deutz F4L1011 Deutz F3L912 Perkins 3.152 Mitsubishi S4L2 Mitsubishi-S4L2 Deutz 2.9L4 Deutz F3L912 Deutz F4L2011 Perkins 404.22T Deutz F4L912 Deutz F4L2011 Deutz TD2.94L4 Deutz TD2.9L4 Deutz 2.9L4 Deutz BF4M 2011 Deutz BF4M 2011 Deutz F4L912 Deutz F3L912/914 CATERPILLAR 3013C/C1.5 Kubota DH905/1005 Kubota DH905/1005
202 166 067 265 197 899 064 677 196 428 242 882 202 166 218 467 067 265 064 677 192 936 242 882 242 882 067 265 064 677 067 265 197 899 064 677 067 265 67265 67265 067 265 067 265 067 265 064 677 064 677 202 166 196 428 196 428
197 676 192 938 192 938 020 319 197 676 19676 197 676 197 676 192 938 192 938 192 938 197 676 197 676 192 938 192 938 192 938 192 938 020 319 192 938 192983 192939 192 938 192 938 192 938 020 319 (See note2) 197 676 187 441 187 441
197 679 192 939 192 939 — 197 679 N/A 197 679 197 679 192 939 192 939 192 939 197 679 197 679 192 939 192 939 192 939 192 939 — 192 939 192393 192939 192 939 192 939 192 939 — (See note3) 197 679 202 102 202 102
213 185 192 744 192 744 062 342 213 858 213 858 213 858 233 482 192 744 192 744 192 744 213 858 213 858 255 764 192 744 192 744 192 744 062 342 192 744 255764 255754 225 764 192 744 192 744 062 342 062 342 213 858 066 113 066 113
IR Compressor Filter Kit #246 991, Oil Filter #206 745, Separator Filter #206 747 and Air Filter #197 676. Prior to serial number LB043908 use #020 319. Effective with serial number LB043908 use #192 938. 3 Effective with serial number LB043908 use #192 939. 4 Single-Phase Plug #119 172, Three-Phase Plug #254 140. 1 2
88
Engine Filter Kit
244 711
Battery GP 24 GP 24 GP 24 GP 24 GP 24 GP 24 GP 55 GP 55 GP 55 GP 55 GP 55 GP 55 GP 55 GP 24 GP 24 GP 55
252 781
252 782
GP 55
202 167 066 217 197 997 064 686 207 715 252 781 217 687 218 469 066 217 064 686 192 937 252 781 252 781 255 765 064 686 066 217 197 997 064 686 066 217 255765 255765 255 765 066 217 066 217 064 686 064 686 202 167 192 744 192 744
246 987 246 988 246 985
GP 55 GP 24 GP 24 GP 24 GP 55 GP 35 GP 35 GP 35 GP 24 GP 24 GP 24 GP 35
246 985
246 987 246 986 252 782
244 711 246 987 N/A
244 711 262 459 246 989 246 988 246 985 246 988 262459 262459 262 459 246 988 246 988 246 989 246 987 246 990 246 990
GP 31 GP 24 GP 24 GP 24 GP 24 GP 24 GP 31 GP 31 GP 31 GP 24 GP 24 GP 24 GP 24 GP 24 GP 55 GP 55
ENGINE DRIVES
Industrial Engine Drive Tune-Up Components Engine Drive Big 40® Big 40®G Big 40® Diesel Big 40® Diesel (CAT) Big 50 Diesel™ (Prior to JK718458) Big 50 Diesel™ (Eff. with JK718458) Big Blue® 251D (Prior to KF846844) Big Blue® 251D (Eff. with KF846844) Big Blue® 251D (Eff. with LA153592) Big Blue® 300/Pro
Big Blue® 302D Big Blue® 302P Big Blue® 350 PipePro® (Prior to MA 250132E) Big Blue® 350 PipePro® (Eff. s/n MA250132) Big Blue® 350 PipePro® Big Blue® 400D Big Blue® 400D Big Blue® 400 KX Big Blue® 400 Pro Big Blue® 400 Pro Big Blue® 400 Pro Big Blue® 402D/502D/602D Big Blue® 402P/502P/602P Big Blue® 450 duo CST™ Big Blue® 500 ECO Pro Big Blue® 500 Pro (Deutz) Big Blue® 500X
Big Blue® 600D Big Blue® 700 Dual Pro Big Blue® 800 Duo Pro Big Blue® 800 Duo Pro Air Pak™ Big Blue® 800 Duo Air Pak (Deutz) Big Blue® Air Pak™ 1 Big Blue® Turbo Miller Air Pak™ Miller Du-Op™ PRO 300 PipePro™ 304 Trailblazer®Pro 350
Engine Model Continental F-163 Continental TM-20 Continental TMD-20 CATERPILLAR 3024/C2.2 Continental TMD-27 Continental TMD-27 Deutz F3L1011 Deutz F3L1011 Deutz F3L1011 Perkins 403C-15 CATERPILLAR C1.5 Duetz 2008 Mitsubishi-S4L2 Deutz F3L1011 Perkins 104.22 Mitsubishi-S4L2
Fuel Cap # 182 022 182 022 182 022 254 678 182 022 182 022 182 022 182 022 182 022 254 678 254 678 254 678 254 678 254 678 254 678 254 678
Blower/Fan Belt # — 118 156 118 156 197 944 118 156 118 156 066 213 066 213 066 213 217 686 217 686 228 780 242 883 067 266 197 944 242 883
Alternator Belt # — — — — — — — — — — — —
Mitsubishi-S4L2
254 678
242 883
—
Caterpillar C1.5 Deutz F3L2011 Perkins 404.22 Deutz F3L912 Kubota V1505-EBG1 Mitsubishi S4L2 Cat C1.5 Kubota 1505 E3BG Deutz F4L1011 Deutz F3L912 Perkins 3.152 Mitsubishi S4L2
254 678 254 678 254 678 182 022 254 678 254 678 254 678 254 678 254 678 254 678 254 678 254 678
217 686 216 959 197 944 064 690 218 468 N/A N/A N/A 067 266 066 271 193 163 N/A
— — — 136 250 — 242 883 217 686 218 468 — — — 242 883
Deutz 2.9L4 Deutz F3L912 Deutz F4L2011 Perkins 404.22T Deutz F4L912 Deutz F4L2011 Deutz TD2.94L4 Deutz TD2.9L4 Deutz 2.9L4 Deutz BF4M 2011 Deutz F4L 2011 Deutz F4L912 Deutz F3L912/914 CATERPILLAR 3013C/C1.5 Kubota DH905/1005 Kubota DH905/1005
254 678 254 678 254 678 254 678 024 035 254 678 190 198 190 198 254 678 254 678 254 678 024 035 182 022 254 678 182 022 182 022
260 572 066 271 067 266 197 944 066 271 197 944 N/A N/A 260 572 207 808 067 266 066 271 064 690 217 686 197 197 197 197
— — — — —
— — —
260 572 253 944 — — — — 066 213 — — —
IR Compressor Filter Kit #246 991, Oil Filter #206 745, Separator Filter #206 747 and Air Filter #197 676. Prior to serial number LB043908 use #020 319. Effective with serial number LB043908 use #192 938. 3 Effective with serial number LB043908 use #192 939. 1 2
89
ENGINE DRIVES
Industrial Engine Drive Service Parts Model Big 40® Big 40®G Big 40®WG Big 40® Diesel Big 40® Diesel (CAT) Big 50® Diesel Big Blue® 251D Big Blue® 300P Big Blue® 302D Big Blue® 302P Big Blue® 400
Serial # Effective 71-602793 JG011369 LA342228 JG011369 LB057623 JG011369 JK587486 LE099775 LA067251 LA067249 LC732100
Engine Model Continental Continental WIS•CON Continental CATERPILLAR Continental Deutz Perkins Deutz Perkins Deutz Perkins Deutz
Ignition/ Start Switch # See manual 172 070 176 606 See manual 176 606 See manual See manual 237 417 176 606 176 606 237 417 237 417 See manual
Brushes/ Brush Assy # 151 299(3) 151 299(3) 189 142(1)* 151 299(3) 189 142(1)* 151 299(3) 151 299(3) 126 984(2) 189 142(1)* 189 142(1)* 189 142(1)* 189 142(1)* 151 299(3)
Idle Solenoid # See manual 005 373 005 373 080 517 198 624 080 517 124 974 080 517 174 064 198 624 174 064 198 624 —
230 Volt Plug # 025 234 025 234 147 633 (N/A) 025 234 147 633 (N/A) 025 234 025 234 119 172 147 633 (N/A) 147 633 (N/A) 147 633 (N/A) 147 633 (N/A) 025 234
Big Blue® 400D
HK247676
Big Blue® 400 KX Big Blue® 400 Pro Big Blue® 400 Pro
LE253191 — —
Kubota Cat C1.5 Kubota 1505 E3BG Mitsubishi S4L2 Deutz
237 417 217 680 217 680
126 984(2) 244 290 244 290
Engine Mfg 235 023 264 327
Big Blue® 400 Pro
—
217 680
244 290
Big Blue® 402D/502D/602D
KK114464 —
176 606
Big Blue® 402P/502P/602P Big Blue® 450 duo CST™
KJ284383
Perkins
Big Blue® 500D
Note: Number in (parenthesis) following the order number denotes quantity needed of particular component.
Module (Idle) # — 189 742 195 706 See manual 195 706 See manual 189 742 214 761 195 706 195 706 195 706 195 706 —
— 182 954 182 954
Rheostat/ Pot # See manual 072 462 188 635 072 462 188 635 072 462 605 960 193 118 188 635 188 635 188 635 188 635 605 960 (CC) 072 462 (CC/CV) 193 118 193 118 193 118
242 538
182 954
193 118
N/A
189 142(1)*
See manual
195 706
176 606
189 142(1)*
See manual
217 680
244 290
242 538
LC585264
Mitsubishi S4L2 Deutz
147 633 (N/A) 188 635 (CC) See manual (CC/ CV) 147 633 (N/A) 188 635 (CC) 193 118 (CC/CV) 176 335 N/A
237 417
189 142(1)*
—
195 706
Big Blue® 500P
LE260460
Perkins
237 417
189 142(1)*
—
Big Blue® 500 Pro Big Blue® 600D Big Blue® Air Pak™ Big Blue® 800 Duo Pro Big Blue® 800 Duo Pro Air Pak™ Big Blue® 800 Duo Air Pak™ Big Blue® Turbo Miller Air Pak™ Miller Du-Op™ PRO 300 PipePro™ 304 Trailblazer® Pro 350 Trailblazer® Pro 350D
MD290001E KA748844 LC251836 — —
Deutz 2.9L4 Deutz Deutz Deutz TD2.94L4 Deutz TD2.9L4
217 680 See manual See manual 217 680 217 680
189 142* 151 299(3) 189 142(1)* 189 142 189 142
— — — N/A N/A
147 633 (N/A) 188 635 (CC) 193 118 (CC/CV) 147 633 (N/A) 188 635 (CC) 193 118 (CC/CV) 119 172 193 118 025 234 072 462 147 633 (N/A) 193 118 147 632 193 118 147 632 193 118
MD360063E LC351172 JJ338549 KK057228 LC732152 KK057228 LA199438 LC047815
Deutz 2.9L4 Deutz Deutz Deutz CATERPILLAR Kubota Kubota Kubota
217 680 See manual See manual 046 433 237 417 176 606 198 515 176 606
189 142* 189 142(1)* 151 299(3) 151 299(3) 126 984(2) See manual 126 984(3) 205 725(1)
— — 183 030 — 080 517 192 196 192 196 192 196
147 633 (N/A) 147 633 (N/A) 025 234 197 442 (N/A) 119 172 119 172 119 172 119 172
— 195 706 189 742 — 214 761 — 216 273 —
*Brush holder only — must order quantity of three brushes (#190 823) separately with part #189 142
90
193 118 193 118 072 623 035 897 193 118 See manual 035 897 See manual
214 761 N/A N/A
195 706 N/A
219 848 (N/A) — — 195 706 N/A N/A
SPOT WELDERS
MSW and LMSW Series Tongs and Tips Tongs
■
6 in (152 mm)
12 in (305 mm)
18 in (457 mm)
Tips
040 197
040 198
040 199
Standard 040 211
040 200
040 201
040 202
MO Offset 040 215
—
040 203
040 204
Standard 040 211
Flat 040 212
—
040 205
040 206
Standard 040 211
Flat 040 212
Standard 040 211
Flat 040 212
Standard
MO Offset
TT-6
TT-9
G-7
For your added convenience, spot welder tongs and tips can now be ordered through the Miller Service Parts business for use with the following models:
8 in (203 mm) 040 207
MSW-41, MSW-41T, MSW-42, MSW-42T, LMSW-52 and LMSW-52T
Flat 040 212
Gyro Bail #041 979 Supports the weight of the welder. Operates with boom and counterweight or from spring-loaded cable. Spot welds in any position.
Important Ordering Information FF
8 in (203 mm) 040 208
FF 040 213
FH
5 in (127 mm) 040 209
FH 040 214
To determine the correct tong reorder length, measure exposed tong length when installed in spot welder. Removed tongs measure 2 inches longer than the listed chart length. For correct reorder length, deduct 2 inches from the removed tong. ■ One set of tips is supplied with each set of tongs. ■ Maximum welding capabilities are obtained with minimum tong length. ■ Tips are made of RWMA Class 2 Alloy. ■
91
SPOT WELDERS
PSW and SSW Series Tongs Tongs
Description
6 in (152 mm)
12 in 18 in (305 mm) (457 mm)
Tips Included
4 - 1/4in (108mm)
6 - 1/4in (159mm)
Standard 90˚ No. 1 MT No. 2 MT
040 218 —
040 219 —
040 220 041 001
040 223 040 308
4 - 1/4in (108mm)
6 - 1/4in (159mm)
Standard 45˚ No. 1 MT No. 2 MT
— —
041 004 —
041 005 (N/A) 040 296
040 851 040 225
TT-6W No. 2 MT
—
—
041 838
040 308
TT-9W No. 2 MT
—
—
041 840
040 308
—
071 465 (N/A)
—
No. 1 Pointed 071 466 Top Flat Threaded 071 467 Bottom
7 - 1/1in (190mm)
9 in (229mm)
4 - 1/4 in (108 mm)
SW-12
PSW and SSW Series Tips Tips
92
Description No. 1 MT (Pointed) No. 1 MT (Offset) No. 2 MT (Pointed)
Part # 040 223 040 224 040 308
Quantity 2 tips 2 tips 2 tips
Where Used Standard 90˚ No. 1 Tongs Standard 90˚ No. 1 Tongs Standard 90˚ No. 2 Tongs, TT-6W Tongs, TT-9W Tongs
No. 1 MT (Offset)
040 851
2 tips
Standard 45˚ No. 1 Tongs
No. 1 MT (Offset)
040 226
2 tips
Standard 90˚ No. 1 Tongs
No. 1 MT (Offset)
040 298
2 tips
Standard 90˚ No. 1 Tongs
No. 2 MT (Offset)
040 225
2 tips
Standard 45˚ No. 2 Tongs
No. 1 MT (Pointed)
071 466
SW-12 Tongs
Threaded (Flat)
071 343
1 tip for top tong 1 tip for bottom tong 1 tip for bottom tong 2 tips
Threaded (Flat)
071 467
No. 1 MT (Flat Swivel Tip)
040 216
Adapter (Adapts No.1 Morse Taper Tip to No. 2 Receptacle)
040 227
For your added convenience, spot welder tongs and tips can now be ordered through the Miller Service Parts business for use with the following models: ■ ■
PSW-1020 ATT and PSW-2020 ATT SSW-1020 ATT, SSW-2020 ATT and SSW-2040 ATT
Important Ordering Information ■
Incorrect
Front Connection
■
■
SW-12 Tongs (Optional) ■
SW-12 Tongs
■ ■
Standard 90˚ No. 1 Tongs ■
2 adapters
Standard 90˚ No. 2 Tongs, TT-6W Tongs (Top), TT-9W Tongs (Top)
To determine the correct tong reorder length, measure from the center of the spot weld tip back to the front water hose connection.
Correct Requirement
Spot Welder Tip
Tongs and tips shown to the left can be used with all PSW and SSW model spot welders. Recommended maximum tong length is 18 in (457 mm). A limited group of special tongs are awvailable, contact Miller Service Parts. Tong throat-height dimension for standard 90° and 45° tongs is 4-1/4 in (108 mm). Throat length is measured from the center of the spot tips to the front water hose connection on the tong. One set of tips is supplied with each set of tongs. Tips are made of RWMA Class 2 alloy. Maximum welding capabilities are obtained with minimum tong length. MT = Morse Taper No. 1 Morse Taper diameter = 1/2 inch No. 2 Morse Taper diameter = 5/8 inch
TIG TORCHES
TIG Connectors
A-150/A-200 1-Piece Power Cable Connectors
194 722 / 194 723 50 mm Dinse-style gas thru for one-piece air-cooled torch.
195 378 / 195 379 50 mm Dinse-style for one-piece air-cooled torch.
A-150/A-200 2-Piece Power Cable Connector
105 Z57 Power cable adapter for one-piece A-150 torch.
45V62 Power cable adapter for one-piece A-200 torch.
129 527 50 mm Dinse-style for two-piece cable air-cooled torch.
W-225 Power Cable Connectors
195 380 50 mm Dinse-style gas thru with gas and water return lines for water-cooled torch. Machines
TIG Machines Syncrowave® 200/210 Syncrowave® 250 DX/350 DX (Dinse) Syncrowave® 250 DX/350 DX (Stud) Maxstar® 150 STL/STH Dynasty® 200/350, Maxstar® 200/350 Dynasty® 700, Maxstar® 700 Multiprocess Machines Multimatic™ 200 Dimension™ 302/452/NT 450/652 Pipeworx XMT® 304/350 XMT® 450 Engine-Driven Machines Most Big Blue®, Trailblazer®, Bobcat®, Blue Star®, and Wildcat® models Big Blue® 450 Duo CST General Reference
195 377 50 mm Dinse-style with water return line for water-cooled torch.
Connection Type
45V11 Power cable adapter for water-cooled torch.
A-150 Power Cable Connector 1-Piece 2-Piece
225 028 50 mm thread lock-style for water-cooled torch.
A-200 Power Cable Connector 1-Piece 2-Piece
W-225 Power Cable Connector
50 mm Dinse, Gas Thru 50 mm Dinse 1/2 in Stud 25 mm Dinse, Gas Thru 50 mm Dinse 50 mm Thread Lock
194 722 195 378 105 Z57 195 234 195 378 N/A
129 527* 129 527 N/A 127 836* 129 527 N/A
194 723 195 379 45V62 N/A 195 379 N/A
129 527* 129 527 N/A N/A 129 527 N/A
195 380 195 377 45V11 N/A 195 377 225 028
25 mm Dinse, Gas Thru 1/2 in Stud 1/2 in Stud 50 mm Dinse 1/2 in Stud
195 234 105 Z57 105 Z57 195 378 105 Z57
127 836* N/A N/A 129 527 N/A
N/A 45V62 45V62 195 379 45V62
N/A N/A N/A 129 527 N/A
N/A 45V11 45V11 195 377 45V11
1/2 in Stud
105 Z57
N/A
45V62
N/A
50 mm Dinse
195 378
129 527
195 379
129 527
195 377
25 mm Dinse, Gas Thru 50 mm Dinse 50 mm Dinse, Gas Thru 50 mm Thread Lock 1/2 in Stud
195 234 195 378 194 722 N/A 105 Z57
N/A 129 527 N/A N/A N/A
N/A 129 527 N/A N/A N/A
N/A 195 379 194 723 N/A 45V62
N/A 195 377 195 380 225 028 45V11
232 728
N/A
232 728
N/A
232 728
45V11
Other Adapter Stud to Dinse Adapter *Two-piece power cable connector is not gas thru.
93
SERVICE PARTS 4-Pin Amp Plastic Connectors
10-Pin Amphenol Metal Connectors PanelMounted Female
PanelMounted Male
CordMounted Female
CordMounted Male
#048 283 Kit (consists of) #081 905 Receptacle #079 535 Pins (Qty 5)
#048 284 Kit (consists of) #081 906 Connector #079 534 Sockets (Qty 5)
#046 958 Kit (consists of) #046 080 Connector #079 535 Pins (Qty 5)
#039 718
Note: Strain relief clamp #079 531 needs to be ordered separately with cord-mounted connections.
PanelMounted Female
CordMounted Male
CordMounted Female
#048 282 Kit (consists of) #081 560 Receptacle #079 534 Sockets (Qty 5)
#079 878 Kit (consists of) #079 532 Connector #079 535 Pins (Qty 5)
#080 328 Kit (consists of) #079 533 Connector #079 534 Sockets (Qty 5)
CordMounted Male
#076 624 #073 686 #073 688 (N/A) (N/A) Note: Pins are the solderable type and are pre-inserted into the receptacle Strain relief clamp #039 828 needs to be ordered separately w/cord-mounted connections
5-Pin Amphenol Metal Connectors PanelMounted Female #035 523
CordMounted Male #039 273
#091 380 (N/A)
PanelMounted Female
CordMounted Male #146 212
CordMounted Female #146 213
Note: Pins are the solderable type and are pre-inserted into the receptacle. Strain relief clamp #073 332 needs to be ordered separately w/cord-mounted connections.
4-Pin Amphenol Metal Connectors CordMounted Female
#039 716
CordMounted Female
Note: Pins are the solderable type and are pre-inserted into the receptacle. Strain relief clamp #073 332 needs to be ordered separately w/cord-mounted connections.
#139 268
Note: Strain relief clamp #079 531 needs to be ordered separately with cord-mounted connections.
PanelMounted Male
CordMounted Male
10-Pin Amp Plastic Connectors PanelMounted Female
CordMounted Male
CordMounted Female
#221 777 Kit (consists of) #189 238 Receptacle #134 733 (N/A) Sockets (Qty 10)
#217 292 Kit (consists of) #190 294 Connector #134 731 Pins (Qty 10) #134 732 Pins (Qty 10) #079 739 Clamp #143 922 Clamp
#222 857 Kit (consists of) #207 194 Connector #079 534 Sockets (Qty 10) #141 685 Sockets (Qty 10) #079 739 Clamp #143 922 Clamp
11-Pin Amphenol Metal Connectors PanelMounted Female
CordMounted Female
#073 515 (N/A)
#052 654
Note: Pins are the solderable type and are pre-inserted into the receptacle. Strain relief clamp #039 685 needs to be ordered separately w/cord-mounted connections.
6-Pin Amphenol Metal Connectors
CordMounted Male
#073 517 (N/A)
CordMounted Female
#073 516 (N/A)
Note: Pins are the solderable type and are pre-inserted into the receptacle. Strain relief clamp #039 734 needs to be ordered separately w/cord-mounted connections.
14-Pin Amphenol Plastic Connectors (Size 20) PanelMounted Female
CordMounted Male
CordMounted Female
Note: Pins are the solderable type and are pre-inserted into the receptacle. Strain relief clamp #039 828 needs to be ordered separately w/cord-mounted connections.
#143 976 Kit (consists of) #134 735 Receptacle #079 534 Sockets (Qty 15)
PanelMounted Female
#143 976 Kit (consists of) #134 735 Receptacle #079 534 Sockets (Qty 15)
#141 162 Kit (14-18 ga wire) #134 734 Connector #134 731 Pins (Qty 15) #079 739 Clamp #143 922 Clamp #144 310 Kit (20-24 ga wire) #134 734 Connector #134 732 Pins (Qty 15) #079 739 Clamp #143 922 Clamp
#152 369 Kit (consists of) #143 424 Connector #079 534 Sockets (Qty 15) #079 739 Clamp #143 922 Clamp #152 568 Kit (consists of) #143 424 Connector #141 685 Sockets (Qty 15) #079 739 Clamp #143 922 Clamp
PanelMounted Female #039 825
CordMounted Male #039 827
CordMounted Male
#235 429 #217 796 Note: For Maxstar 140 and 150’s.
CordMounted Female
CordMounted Female
N/A
N/A
9-Pin Amp Plastic Connectors
14-Pin Amphenol Plastic Connectors (Size 17)
PanelMounted Male
CordMounted Female
CordMounted Male
PanelMounted Female
CordMounted Male
CordMounted Female
#170 646 Receptacle (N/A) #079 535 Pins (Qty 5)
#048 380 Kit (consists of) #079 705 Connector #079 534 Sockets (Qty 10)
#048 306 Kit (consists of) #079 707 Connector #079 535 Pins (Qty 10)
#047 637 Kit (consists of) #048 286 Receptacle #079 534 Sockets (Qty 15)
#047 636 Kit (consists of) #048 287 Connector #079 535 Pins (Qty 15)
#071 892 Kit (consists of) #045 349 Connector #079 534 Sockets (Qty 15)
Note: Strain relief clamp #079 706 needs to be ordered separately with cord-mounted connections.
116
Note: Strain relief clamp #079 739 needs to be ordered separately with cord-mounted connections.
SERVICE PARTS 14-Pin Amphenol Metal Connectors PanelMounted Female #086 022 Receptacle
CordMounted Male #136 961 Kit (consists of) #094 481 Connector #116 964 Clamp
CordMounted Female #136 960 Kit (consists of) #137 301 Connector #116 964 Clamp
20A, 250V
20A, 250V
20A, 250V
Panel-Mounted Female
Cord-Mounted Male
Cord-Mounted Female
#039 602
#039 618
#039 635
Note: Pins are the solderable type and are pre-inserted into the receptacle.
17-Pin Amphenol Metal Connectors PanelMounted Female #097 869 (N/A)
CordMounted Male #097 866 (N/A)
15A
15A, 277V
15A, 277V
Panel-Mounted Male
Cord-Mounted Male
Cord-Mounted Female
#056 665 (N/A)
#039 687
#056 442
Note: Pins are the solderable type and are pre-inserted into the receptacle. Strain relief clamp #073 296 needs to be ordered separately w/cord-mounted connections.
28-Pin Amohenol Plastic Connector (Size-17) PanelMounted Female
15A, 277V
15A, 250V
Panel-Mounted Female
Cord-Mounted Male
#039 686
#035 494
Cord-Mounted Female #035 492 (N/A)
#218 715
15A, 125V
Connector Bodies, Plugs and Receptacles
Panel-Mounted Female Cord-Mounted Male #035 493 (N/A)
#032 898
Cord-Mounted Female #035 243 (N/A)
15A, 125V
PanelMounted Female #604 176
15A, 125V
15A, 125V
15A, 125V
20A, 125V
20A, 125V
Cord-Mounted Male
Cord-Mounted Female
Panel-Mounted Female
Cord-Mounted Male
Cord-Mounted Female
20A, 250V
50A, 125/250V
Cord-Mounted Female
Panel-Mounted Female
Cord-Mounted Male
#073 690
#124 150
#032 897
#605 797
#080 280 (N/A)
15A, 250V
PanelMounted Female #604 103
15A, 250V
Cord-Mounted Male #025 234
#603 029 (N/A)
20A, 250V
20A, 250V
20A, 250V
Panel-Mounted Male
Cord-Mounted Female
Cord-Mounted Male
#141 840
#039 635
#039 618
#039 607
50A, 125/250V
#119 172
50A, 125/250V
Flanged-Mounted Female Cord-Mounted Female #164 704 #117 512 (N/A)
#182 954
117
SERVICE PARTS
Cable Connectors
1
2
Cam-Lok Twistlock Receptacles/Connectors Item #
Part #
Description
Color
Cable Capacity
2
039 628 039 638 056 271
Receptacles Receptacle, Insul. (Female) Receptacle, Insul. (Female) Receptacle, Uninsul. (Male)
Black Black Black
No. 2/0 – 3/0 (25 – 70 mm) No. 3/0 – 4/0 (70 – 95 mm) —
3
039 6331
Red
No. 1/0 – 3/0 (50 – 70 mm)
4
039 629 039 630 039 639
Red Red Red
No. 2 – 1/0 (35 – 50 mm) No. 1/0 – 3/0 (50 – 70 mm) No. 3/0 – 4/0 (70 – 95 mm)
1
Connectors Connector, Insul. Set Scr. (In-Line Female) Connector, Insul. Set Scr. (Male) Connector, Insul. Set Scr. (Male) Connector, Insul. Set Scr. (Male)
3
4
5
For In-Line Connections, use with #039 629 or #039 630.
1
6
Miller Receptacles/Connectors Item #
Part #
Description
5
039 801 039 800 057 608
6
039 901 039 608 039 878
Receptacles Receptacle, Insulated (Female) Receptacle, Insulated (Female) Receptacle, Insulated (Female) Plugs Plug, Insulated (Male) Plug, Insulated (Male) Plug, Insulated (Male)
039 6112
Connectors Connector, Insulated (Female)
7
Color
Cable Capacity
Black Red Yellow
— — —
Black Red Yellow
No. 1 – 4 No. 1 – 4 No. 1 – 4
Black
No. 1 – 4
7
15 13 12 10
For In-Line Connections (Quick-Connect).
2
8
Tweco-Style Twistlock Receptacles/Connectors Item #
Part #
Part #
Description
8 9 10 11 12 13 14 15
209 219 208 431 — — — — 229 338 — 185 717
218 183 209 473 186 228 185 712 185 718 185 713 — 185 714 185 717
Receptacles Receptacle Assembly (Female) Receptacle, Brass (Female) O-Ring, 0.739 ID x 0.070 H Insulator, bulkhead front O-Ring, 0.989 ID x 0.070 H Insulator, bulkhead rear Washer, domed load .812 ID x 1.450 OD x .070 THK Tooth washer, 1 mm intern Nut, M20-1.5 1.00 Hex .19 H BRS locking
16 17
191 981 218 677
191 981 218 677
Connectors Connector, Insulated (Male), No. 4 – 1/0 - 2/0 (25 – 50 mm) Connector, Insulated (Female), No. 4 – 1/0 - 2/0 (25 – 50 mm)
18
218 678 242 251
218 678 —
Adapters Adapter, Threaded Stud to Tweco (stud hole dia. 5/8 in) Connector, TW LK Insulated Female (Tweco-Lenco Type) HD 3/0-4/0
#209 219
15 14
12 11 10 8
9
#218 183
16
17 18
Tweco Series 118
SERVICE PARTS
Cable Connectors
10 9 7
Dinse Twistlock Receptacles (50/70 Series) ™
Item # Part # Part # 208 967 202 813 1 208 968 (N/A) —
5
Description Receptacle Assembly (Female) Receptacle, Brass with O-ring (Female) (consists of items 2 and 3) 185 711 (N/A) 202 553 210 752 (N/A) 202 554 (N/A) Receptacle, Brass (Female) 185 710 — — 185 710 O-Ring, 0.296 ID x 0.139 H Silicone 186 228 186 228 — 186 228 O-Ring, 0.739 ID x 0.070 H 185 712 185 712 208 760 (N/A) 185 712 Insulator, bulkhead front 185 718 185 718 — 185 718 O-Ring, 0.989 ID x 0.070 H 185 713 185 713 208 430 (N/A) 185 713 Insulator, bulkhead rear — — 229 338 — Washer, domed load .812 ID x 1.450 OD x .070 THK 185 714 185 714 — 185 714 Tooth washer, 1 mm intern 185 717 185 717 185 717 185 717 Nut, M20-1.5 1.00 Hex .19 H BRS locking — — 229 333 — Screw, M10-1.5x 20 Hex HD-PLN 8.8 PLD SEMS
2 3 4 5 6 7 8 9 10 11
Part # 129 525 —
6
Part # 186 092 202 811
Dinse Twistlock Receptacles/Connectors Item # Part # Series Description
1
2
3
4
12 13 14 15
16
17
18 19
20 21
127 837 143 419 208 698 208 699
25 50 25 25
127 835 129 526 136 600 138 180 127 836 129 527 134 460 241 354 195 234 194 722
25 50 70 95 25 50 70 95 25 50
194 723
50
232 728 145 739
50/70
Connectors Connector, Insulated (Female) Connector, Insulated (Female) Connector, Insulated (Female) Connector, Insulated (Female) Connector, Insulated (Male) Connector, Insulated (Male) Connector, Insulated (Male) Connector, Insulated (Male) Connector, Insulated (Male) Flow-Thru Connector, Insulated (Male) Flow-Thru 125/150 A Connector, Insulated (Male) Flow-Thru 200 A
9 7
6 5 2
#202 813 4
11 9
TM
Receptacles Receptacle, Insulated (Female) Receptacle, Insulated (Male) Receptacle, Brass Power Pos. (Female) Receptacle, Brass Power/Gas Neg. (Female) with O-Ring #188 380 (.174 ID x .103 H)
10
#208 967
8
Cable Capacity/Thread Size
7 5
— — — —
2 10
#129 525
9 7
6
No. 3 – No. 4 No. 2 – 1/0 (35 – 50 mm) No. 1/0 – 3/0 (50 – 70 mm) No. 3/0 – 4/0 (70 – 95 mm) No. 3 – No. 4 No. 2 – 1/0 (35 – 50 mm) No. 1/0 – 3/0 (50 – 70 mm) No. 3/0 – 4/0 (70 – 95 mm) 3/8-24R 3/8-24R 7/8-14R
Adapters Adapter, Threaded Stud to Dinse (stud hole dia. 1/2 in) Sleeve, clamping
5 1
2
3
#186 092 4 12
14
15
Dinse 50/70 Series 16
17
Spectrum Connectors Item # Part # Description 263 801 Connector, TW LK Insulated Male (Tweco-Lenco Type) SK 10-25
18
Maxstar 700/Dynasty 700 Connectors Item # Part #
Description
19 20
Connectors 225 029 Connection Kit, Thread Lock Double Dry Adapters 225 028 Adapter, Torch-Thread Lock Water (7/8 LHT)
18
119
SERVICE PARTS
Electrode Holders Part #
Amperage Capacity
Professional Series PA532 200 PA316 250 PA732 300 PA14HD 400
#UT20
Electrode Capacity
Cable Capacity
Length
Weight
5/32" (4.0 mm) 3/16" (4.8 mm) 7/32" (5.6 mm) 1/4" (6.4 mm)
No. 2/0 (70 mm) No. 2/0 (70 mm) No. 2/0 (70 mm) No. 4/0 (105 mm)
8-1/2" (215 mm) 9-1/4" (235 mm) 10" (250 mm) 11" (280 mm)
15 oz (415 g) 16 oz (450 g) 19 oz (530 g) 23 oz (650 g)
Features include: n Ergonomic — High lever design for greater grip and hand clearance n Lightweight and easy-to-use n Fully insulated, high-strength springs for excellent gripping power n Heavy-duty, shock-proof nylon handle n Grooved jaw design insures firm electrode grip
#UT30#UT40
n High-impact, high-temperature fiberglass
tip insulators
n Professional series features high copper alloy
tongs, utility series features brass tongs n Holders supplied with allen wrench and cable connections ferrule assuring efficient connections
#PA532, #PA316, #PA732
#PA14HD
Work Clamps Part # EG200 EG300 EG500
Amperage Capacity 200 300 500
Electrode Capacity* 1-1/2" (40 mm) 2" (50 mm) 2" (50 mm)
PGC200 PGC300
200 300
1" (25 mm) 1-1/2" (40 mm)
MGC300 203 988 213 619 010 368 233 452 240 697
300 180 300 200 300 200
— 1-1/2" (40 mm) 2" (50 mm) 1-1/2" (40 mm) 2" (50 mm) 2" (50 mm)
Cable Capacity No. 6–4 (10–16 mm) No. 2–1 (25–35 mm) No. 1/0–4/0 (50–105 mm) No. 1–1/0 (35–50 mm) No. 1/0–3/0 (50–95 mm) No. 1–1/0 (35–50 mm) 2" (25 mm) 1/0 (50 mm) No. 4 No. 4–2 No. 6
Length 7" (175 mm) 8" (200 mm) 10" (245 mm)
Weight 7 oz (199 g) 14 oz (390 g) 17 oz (490 g)
6" (150 mm) 8" (200 mm)
16 oz (445 g) 25 oz (715 g)
— 7" (175 mm) 8" (200 mm) 6" 8" 6-1/4"
21 oz (600 g) 9 oz (255 g) 13 oz (368 g) 5 oz (142 g) 10 oz (290 g) 6 oz (168 g)
#EG500
#PGC300
#MGC300
*Jaw Distance
EG Series — Steel Work Clamps n Zinc plated n Large hex screw cable connection assures safe cable connection every time n Pure copper braided shunts on EG500 allows both jaws to carry welding current PGC Series — Copper Alloy n Contoured handle lever for easy jaw opening n Strong gripping power n Large contact area assures positive grounding n Fully insulated spring n Conductor body holds the cable securely n Large hex screw cable connection assures safe cable connection every time
MGC Series — Magnetic Work Clamps n Large contact area assures excellent electrical
contact
n Strong gripping power n Grounding concealed to prevent dislodgment n Insulated to prevent annealing n Easy installation or removal n Most popular magnetic work clamps
#240 697
#213 619
in the market
#010 368
#203 988
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SERVICE PARTS 7.6" Globe
Part #194 037 18.000"
3.5" Globe
Part #115 496 8.376"
Note: Actual color of Miller logo decal is white. Note: Actual color of Miller logo decal is white.
Miller/Hobart Replacement Labels Part # 124 462 109 844 115 496 119 503 121 389 194 037 109 838 109 839 109 840 109 841 109 842 109 843 184 791
Description Miller Miller Miller Miller Miller Miller Miller Miller Miller Miller Miller Miller Hobart
Format Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Vertical Vertical Vertical Vertical Vertical Vertical Horizontal
Height 1.625" 2.500" 3.500" 4.000" 5.250" 7.600" 1.562" 3.000" 4.500" 6.000" 7.750" 9.500" 2.5"
9.500"
Width 3.750" 6.000" 8.250" 9.562" 12.437" 18.000" 1.312" 2.500" 3.750" 5.125" 6.500" 8.000" 11.250"
Color White/Blue Bkgd White/Blue Bkgd White/Blue Bkgd White/Blue Bkgd White/Blue Bkgd White/Blue Bkgd White/Blue Bkgd White/Blue Bkgd White/Blue Bkgd White White/Blue Bkgd White Orange
Vertical
Part #109 843 8.000"
Note: Actual color of Miller logo decal is white.
Nothing completes the repair and repaint of a machine like the addition of the original equipment factory fresh decals. Above is a complete list of the wide variety of sizes available in both the horizontal and vertical formats.
Part #184 791 11.25"
121
SERVICE PARTS
Power Terminals Power Terminal Output Assemblies Part # 039 047 039 046 099 255 181 245 181 246 601 879
Description Group 1 With Hex Nut With Hex Nut With Hex Nut With Hex Nut With Hex Nut Hex Nut — Replacement
Color
Dimension A
Bolt Dimensions
Red Black White Red Black —
1-7/8" 1-7/8" 1-7/8" 1-7/8" 1-7/8" —
1/2" x 1-1/2" 1/2" x 1-1/2" 1/2" x 1-1/2" 1/2" x 1-3/4" 1/2" x 1-3/4" —
A
3"
#039 046
#180 732
Power Terminal Boots Part # 179 848 180 732 186 621 180 735 181 169 1
Description Rubber Boot (Positive) 1 Rubber Boot (Negative) 1 Rubber Boot (Generic) 1 Washer, Output Stud Spacer, Output Stud
Width 2" ID 2" ID 2" ID
Height 3-3/4" ID 3-3/4" ID 3-3/4" ID
#179 848
#180 735 & #181 169 are needed for Power Terminal Boots.
Part # 219 515 219 516 213 380 219 535 119 172 254 140
Description 50 amp, 230 volt pin-type wall receptacle 50 amp, 230 volt pin-type male plug 50 amp, 230 volt pin-type male plug (heavy-duty) 50 amp, 230 volt pin-type cord-mount receptacle 50 amp, 125/250 volt pin-type male plug Plug, str grd 3P4W 3PH 50A 240V 15-50P
Cord Range (Min. – Max.) — 0 – 1.00 0.625 – 1.320 0.425 – 1.31 0.62 – 1.31 —
#219 515
#219 516
#254 140
#219 535
122
#119 172
SERVICE PARTS
LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at EXPRESSLY IN OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor. 1. 3 Years — Parts and Labor * Auto-Darkening Helmet Lenses (Except Classic Series) (No Labor) 2. 2 Years — Parts and Labor * Auto-Darkening Helmet Lenses − Classic Series Only (No Labor) 3. 1 Year — Parts and Labor Unless Specified * CoolBelt and CoolBand Blower Unit (No Labor) * ICE/XT Plasma Cutting Torches (No Labor) * PAPR Blower Unit (No Labor) 4. 6 Months — Parts * Batteries * Bernard Guns (No Labor) 5. 90 Days — Parts * M-Guns * MIG Guns and Subarc (SAW) Guns * Replacement Parts (No labor) * Roughneck Guns
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.
Miller’s True Blue® Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.) 2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any. 3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.
WARRANTY QUESTIONS? Call 1-866-931-9730 for your local Miller distributor. Your distributor also gives you... Service - You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support - Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.
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