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Summary of Contents for AMERICAN WELDQUIP 456CG
- Page 1 Air‐Cooled Semi‐Automatic MIG Torches For COOL‐GRIP Models 456CG, 500CG and 507CG INSTALLATION, OPERATIONS, AND REPLACEMENT PARTS MANUAL...
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Page 2: Table Of Contents
NOZZLE/TIP RELATIONSHIPS ........................15 NOZZLE SELECTION CHART ........................16 400 SERIES NOZZLES ..........................16 500 SERIES NOZZLES ..........................16 CONTACT TIP SELECTION CHART ......................17 M8 CONTACT TIPS ............................17 LINER SELECTION CHART ........................... 17 PARTS BREAKDOWN – 456CG, 500CG, 507CG ..................18... -
Page 3: Introduction
American Weldquip assumes no responsibility for errors or omissions. American Weldquip assumes no liability for damages resulting from the use of the information contained in this manual. American Weldquip shall have no liability to the buyer for consequential damages or expenses by any defect whatsoever. -
Page 4: Rohs Compliant
While it is not a requirement to meet the directive in the United States, currently, American Weldquip Inc. feels this is an important part of our “Go Green initiative. We have taken all reasonable steps to try to ensure the supporting evidence regarding the absence of the restricted substances to support RoHS compliance. -
Page 5: Eu Directive
EU DIRECTIVE This product has met the requirements set by the EU directive and the products listed below are in conformity with the provisions of: Council Directives - 2014/35/EC Low Voltage Equipment Safety Council Directives - 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment (RoHS) Harmonization Standard Used - IEC 60974-7:2013 Arc welding equipment –... -
Page 6: Safety Precautions - Read Before Using
SAFETY PRECAUTIONS – READ BEFORE USING Before installing, operating, or performing maintenance please read the safety precautions below. Failure to observe safety precautions can result in injury or death. Read and follow the Owner’s Manual carefully before installing, operating, or servicing equipment. - Page 7 should be checked initially and periodically thereafter to maintain applicable OSHA PEL and ACGIH TVL limits. In a poorly ventilated area, it is necessary to wear an approved air-supplied respirator. Always read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
- Page 8 Do not use worn, damaged, undersized, or poorly spliced cables. It is illegal to use electrical tape to repair torch power cable or ground cable that has damaged outer insulation. The cable must be replaced. Do not drape cables over your body. ...
- Page 9 Be alert that welding sparks and hot materials from welding and cutting can easily go through small cracks and openings and cause a fire in the adjacent areas. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.
- Page 10 Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association, 14501 George Carter Way Chantilly, VA 20151. PRINCIPAL SAFETY STANDARDS Safety in Welding, Cutting and Allied Processes, ANSI Standard Z49.1 –...
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Page 11: Features
Depending on how your torch was ordered your American Weldquip torch has been supplied with either a EURO type feeder connection or a DIRECT wire feeder connection. The American Weldquip torch can be installed to the wire feed unit in two ways. Euro Connection – Feeder Adaptor Kit may be required... -
Page 12: Euro Connection (Using Feeder Adaptor Kit)
EURO CONNECTION (USING FEEDER ADAPTOR KIT) In some cases, it may be desirable to use a Euro feeder adaptor kit when using different manufactures wire feed units. This will commonize torches to a Euro style configuration. 1) Thread feeder adaptor plug into the adaptor block and tighten. 2) Insert the adaptor guide tube into the adaptor plug. -
Page 13: Maintenance
The insulating washer is pertinent to have in place as this helps prevent the gooseneck from getting electrically charged. o Check the gas holes on the diffuser and clean if necessary. o Check and tighten the contact tip. o Check all electrical connections including the power cable from the power supply, torch/feeder connections, and control cables for loose connections. -
Page 14: Trigger Switch Replacement
5) Using a 5/8” wrench loosen the gooseneck/cable connection and remove from the cable assembly. 6) Remove the Body Insulator from the old gooseneck and install on the new one. 7) Thread the new gooseneck on to the cable assembly and tighten with 5/8” wrench.. 8) Install the bottom handle assembly (trigger side) onto the gooseneck/cable assembly. -
Page 15: Power Cable Replacement
9) Using the (4) four screws provided attach the (2) two outer contact plates and install the (2) two trigger leads under the front contact plate screws. 10) Install the bottom handle assembly (trigger side) onto the gooseneck/cable assembly. The trigger wires will fit in the grooves on the sides of the body insulator. Make sure the trigger wires stay seating in the body insulator and the insulator is fully inserted into the bottom handle. -
Page 16: Nozzle/Tip Relationships
NOZZLE/TIP RELATIONSHIPS Shown below are typical relationship between the contact tip and nozzle in GMAW Semi-Automatic applications. Nozzles to tip relationships are usually dictated by the process and application but not necessarily the standard. Keep in mind that decreased tip life, increased spatter cleaning cycles may be required if the tip relationship is changed to achieve other objectives. -
Page 17: Nozzle Selection Chart
NOZZLE SELECTION CHART 400 Series Nozzles Part Number Description Bore Size Material O.A.L Insulator Req 75146202-I BOTTLE NOSE 5/8” (15.9mm) NI PLATED BRASS 3.125” (79.4mm) INSTALLED 75145001 BOTTLE NOSE 1/2” (12.7mm) NI PLATED BRASS 3.031” (77.0mm) 75001733 75146202 CONICAL 5/8” (15.9mm) NI PLATED BRASS 3.125”... -
Page 18: Contact Tip Selection Chart
CONTACT TIP SELECTION CHART M8 Contact Tips Part Number Wire Size Nominal I.D Copper (CU) 75030014 0.030” (.8mm) 0.038” 75035014 0.035” (.9mm) 0.044” 75040014 0.040” (1.0mm) 0.048” 75045014 0.045” (1.2mm) 0.054” 75052014 0.052” (1.3mm) 0.061” 75062014 0.062” (1.6mm) 0.073” 75062015 0.062”... -
Page 19: Parts Breakdown - 456Cg, 500Cg, 507Cg
PARTS BREAKDOWN – 456CG, 500CG, 507CG... - Page 20 DESCRIPTION CONICAL NOZZLE SEE NOZZLE SELECTION CHART TAPERED NOZZLE SEE NOZZLE SELECTION CHART BOTTLENOSE NOZZLE SEE NOZZLE SELECTION CHART NOZZLE INSULATOR SEE NOZZLE SELECTION CHART CONTACT TIP SEE CONTACT TIP SELECTION CHART GAS DIFFUSER, STANDARD 75004033 75004033 75004033 GAS DIFFUSER, SHORT 75004033S 75004033S 75004033S...
- Page 21 CONTROL CABLE, LINCOLN 37777200 37777200 37777200 CONTROL CABLE, OTC 37777503 37777503 37777503 CONTROL CABLE, PANASONIC 37777504 37777504 37777504 CONTROL CABLE, TWECO 37677200 37677200 37677200 O-RING, MILLER FEEDER PIN 37577102 37577102 37577102 O-RING, TWECO #4 FEEDER PIN 37577102 37577102 37577102 O-RING, TWECO #5 FEEDER PIN 75000021 75000021 75000021...
- Page 22 AMERICAN WELDQUIP 1375 Wolf Creek Trail – P.O. Box 397 Sharon Center, Ohio 44274 Telephone 330‐239‐0317 Fax 800‐949‐9353 www.weldquip.com www.youtube.com/weldquip1 OM016 – 05/22...
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