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Inert Gas Equipment

Bernard Vendor Code: BER

Custom Select Ordering System for Bernard Q-Guns

Bernard Q-Gun
The part number shown here, Q4010AE8EM, is an example of a typical conguration. It consists of a 400 AMP Q-Gun with a 15' cable, curved handle, locking trigger, rotatable short 45 neck, 7400 series 0.035" contact tip and a Miller style direct plug.

Q40
AMP and Cable Type Q15 Q20 Q30 Q40 Q50 Q60 S30 S40 S50 S60 150 AMP max. wire size: .045" (1.2 mm) 200 AMP max. wire size 1/16" (1.6 mm) 300 AMP max. wire size: 5/64" (2.0 mm) 400 AMP max. wire size: 5/64" (2.0 mm) 500 AMP max. wire size: 3/32" (2.4 mm) 600 AMP max. wire size: 1/8" (3.2 mm) 300 AMP steel Monocoil max. wire size: 5/64" (2.0mm) 400 AMP steel Monocoil max. wire size: 5/64" (2.0mm) 500 AMP steel Monocoil max. wire size: 3/32" (2.4 mm) 600 AMP steel Monocoil max. wire size: 1/8" (3.2 mm)

10
Cable Length feet m 08 10 12 15 20 25 8 10 12 15 20 25 2.44 3.05 3.66 4.57 6.16 7.63 Handle and Trigger 150 AMP Curved Handle Standard Cable 200, 300 AMP Curved Handle Standard Cable 400 AMP Curved Handle Standard Cable 150-400 AMP* OXO Style Small Curved Handle Standard or Steel Monocoil 400-600 AMP* OXO Style Large Curved Handle Standard or Steel Monocoil

Standard trigger A

Standard trigger A Locking trigger B Dual pull trigger C Standard trigger Locking trigger Dual pull trigger Dual schedule switch Dual schedule switch w/lock A B C D E

Standard trigger T Locking trigger U Standard trigger Locking trigger Dual pull trigger Dual schedule switch Dual schedule switch w/lock G H I K L

Combine steel Monocoil cable with OXO style handle and QuikTip for gun similar to former OXO APX gun.

*Only OXO style handle options can be used with Steel Monocoil power cable.

Select the right MIG gun to t your precise application requirements.


A Bernard Q-Gun congured with Custom Select really is the right tool for the job. Why settle for anything less?  Build a part number for a new Q-Gun by selecting: Amperage, Cable Length, Handle and Trigger, Neck, Contact Tip and Direct Plug. Bernard Q-Guns congured with Custom Select are tted at the factory with these Diffusers and Nozzles.  Bernard Q-Guns congured with electrode sizes of 1/16" or smaller will be tted at the factory with tube head diffusers where available.  A wide variety of alternative front end parts are available to t special applications.

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Bernard Vendor Code: BER

Inert Gas Equipment 2

Custom Select Ordering System for Bernard Q-Guns

E
Neck A B C J D E F K G H I N O P W Q R S X T U V Rotatable, short Rotatable, short Rotatable, short Rotatable, short Rotatable, medium Rotatable, medium Rotatable, medium Rotatable, medium Rotatable, long Rotatable, long Rotatable, long Fixed, short Fixed, short Fixed, short Fixed, short Fixed, medium Fixed, medium Fixed, medium Fixed, medium Fixed, long Fixed, long Fixed, long 30 45 60 80 30 45 60 80 30 45 60 30 45 60 80 30 45 60 80 30 45 60 QT2-30 QT2-45 QT2-60 QT2-80 QT3-30 QT3-45 QT3-60 QT3-80 QT5-30 QT5-45 QT5-60 QT2-30 QT2-45 QT2-60 QT2-80 QT3-30 QT3-45 QT3-60 QT3-80 QT5-30 QT5-45 QT5-60 1 5 7

8
Contact Tip 8 Centerre T Series tip

E
Wire Size Inches mm .023 0.6 .030 0.8 .035 0.9 .039 1.0 .045 1.2 .052 1.4 1/16 1.6 5/64 3/32 7/64 1/8 2.0 2.4 2.8 3.2

M
Direct Plug B C E H L M N O S T U W Bernard L-Tec Euro Hobart Lincoln Miller National OXO Tweco 4 (Lincoln lead) Tweco 4 (std. lead) Tweco 4 (two prong twist-lock lead) Tweco 5 (std. lead)

Elliptical, 7400 series, 1.25" long, std.

A B C D E H I K L M N

Quik Tip

Elliptical, 1500 series, 2.00" long, HD

Aluminum
Q R S Wire Size Inches mm .035 0.9 3/64 1.19 1/16 1.6

Illustrated below are the necks dened for Standard Q-Guns. Short 45 QT2-45, standard for 150, 200 AMP Medium 45 QT3-45, standard for 300, 400 AMP Long 60 QT5-60, standard for 500, 600 AMP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Typically Selected Necks by Amperage 150 - 200 AMP 300 - 400 AMP 500 - 600 AMP QT2-45 QT3-45 QT5-60

Short

Medium

Long

Bernard is the registered trademark of Illinois Tool Works, Inc. Other brands mentioned are for reference only and are the registered trade marks of their respective companies.

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197

Inert Gas Equipment

Bernard Vendor Code: BER

Q150 Replacement Parts List


Item Part No. See Centerre spec sheet See Centerre spec sheet

Description Nozzle assembly Contact tip Gas diffuser Cap Neck Jump liner Terminal, quick disconnect (2 reqd) Handle half, upper Switch assembly, handle half, lower Post fastener (2 reqd) Handle screw (2 reqd) Handle kit -(includes: (1) #8, (1) #9, (2) #10, (2) #11) 8' (2.44 m) 10' (3.05 m) 12' (3.66 m) 15' (4.57 m) 20' (6.10 m) 25' (7.62 m) Butt connector (2 reqd) Cap, rigid strain relief Spring, strain relief Strain relief with installed gas pin (Bernard direct plug) Strain relief (Euro direct plug) Strain relief with trigger cable adapter (OXO, Tweco 4 w/twist lock) Strain relief with trigger cable adapter (L-Tec, Hobart direct plug) Strain relief with trigger cable adapter (Lincoln direct plug) Strain relief with trigger cable adapter (National, Tweco direct plug) Strain relief with trigger cable adapter (All other direct plugs) Direct plug components Liner Spring, strain relief Adapter block (not reqd on Bernard or Euro direct plug) Screw, strain relief (not reqd on Bernard direct plug)

1 2 3 4 5

3 5 2

See Centerre spec sheet See Centerre spec sheet See neck spec sheet See jump liner spec sheet 2660001 1780062 2620054 4207 4209 1880194

6 7 8 9 10 11 12

10

11
1060107

Replacement Cable with Fittings 1060097 13 1060098 1060099 1060100 1060101

12

8 20

13 14

14 15 16

4932 2520007 2520048 Rigid Strain Relief

15 16 21
17

2520073 2520047 2520047E 2520047H 2520047L 2520047T 2520047M

22 17

17

18

18 19 20

See direct plug spec sheet See Liner spec sheet 2520049 1010027 W11127-002

19

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AMP

19

21 22

18

Bernard Vendor Code: BER

Inert Gas Equipment

Q200/Q300/Q400 Replacement Parts List


Item
1

Part No. Q200

Q300

Q400

Description
Nozzle assembly Contact tip Gas diffuser Cap Neck Jump liner

1 2 3 4 5 6 7 8 NS NS
12

See Centerre spec sheet See Centerre spec sheet See Centerre spec sheet See Centerre spec sheet See neck spec sheet See jump liner spec sheet 4213B 4305 4991 4823 1880155 4213B 4305 4991 4823 1880155 4313B 1540003 1520017 4939 1880198

21

Stay-Tite end tting Stay-Tite cone nut Conduit clamp (2 reqd) Jacket clamp (2 reqd) Handle kit, standard trigger* Handle kit, locking trigger* Handle kit, dual pull trigger* Handle kit, D/S, standard trigger* Handle kit, D/S, locking trigger* Trigger, standard Trigger, locking Trigger, dual pull, 3 wire (with insulated terminals) Post fastener (1 reqd - q200 & q300) (5 reqd - q400) Post fastener, short (4 reqd) Handle screw (5 reqd) Terminal, quick disconnect (2 reqd) Handle spring 8' (2.44 m) 10' (3.05 m) 12' (3.66 m) 15' (4.57 m) 20' (6.10 m) 25' (7.62 m) Strain Relief Strain relief with installed gas pin (Bernard direct plug) Strain relief (euro direct plug) Strain relief (all other direct plugs) Butt connector (2 reqd) Direct plug components Sheet liner

7 6 11 8 9

10

10

10

9 N/A 5662 10 5662L** 2690001 N/A 5662 5662L** 2690001 4207 2030004 4209 2660001 DSA-1 5662 5662L** 2690001 4207 N/A 4209 2660001

11

9 14

11 12
22

4207 2030004 4209 2660001

13

13 14

N/A N/A 2520042 Replacement Cable With Fittings 1060120 1060121 1060108 1060109 1060110 1060111 1060112 1060113 2520033 2520073 2520069 2520066 4932 1060114 1060115 1060116 1060117 1060118 1060119 2520041 2520073 2520069 2520066 4932

15

15

1060122 1060123 1060124

16

16 17 18

1060125 16 2520033 2520073 2520069


25 23

Rigid Strain Relief Kit (Includes top and bottom halves) 17

2520066 18 19 20 21 4932

See Direct Plug Spec Sheet See Liner Spec 1880012 1790002 1982 1010027 W11127-002 GN2021 1880012 1790002 1983Q 1010027 W11127-002 GN2021 20006A 1880012 1790002 1984Q 1010027 W11127-002 GN2021 20006A

24 26 19

20

AMP

Heat shield kit (includes heat shield, screws, posts, & spacers) Hang up hook kit (Includes hook, screw, & post) Rear Stay-Tite repair kit Adapter block (Not reqd on Bernard or Euro direct plug) Screw, strain relief (not reqd on Bernard direct plug) Electrical plug - Non D/S (Not reqd on Bernard or Euro direct plug) Electrical plug - D/S (Not reqd on Bernard or Euro direct plug)

22 23 24 25

26 20006A

*1880155 & 1880198 Handle Kits include halves, screws & posts. DSA-1 Handle Kits include halves, screws, posts, toggle switch and guard. **Patent Pending 1982, 1983Q & 1984Q Rear Cone Nut Repair Kits include jacket clamp, conduit clamp, cone nut, end tting, nipple, spacer & butt connectors.

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199

Inert Gas Equipment

Bernard Vendor Code: BER

Available Necks

1.0" 26.0 mm

1.4" 35.5 mm

Part No. QT2-30


(30 bend) 3.6" 92.3 mm

Part No. QT2-45


(45 bend) 3.4" 86.3 mm

2.5" 63.1 mm

Part No. QT2-60


(60 bend) 4.3" 110.1 mm

3.0" 76.6mm

1.6" 41.5 mm

Part No. QT2-80


(80 bend) 3.6" 91.8 mm

Part No. QT3-30


(30 bend) 5.1" 130.4 mm

2
2.1" 52.9 mm

Part No. QT3-45


(45 bend) 4.8" 122.1 mm

2.6" 65.4 mm

Part No. QT3-60


(60 bend) 4.4" 111.5 mm

4.3" 110.1 mm

Part No. QT3-80


(80 bend)

2.0" 51.2 mm

Part No. QT5-30


(30 bend) 7.3" 185.5 mm

5.0" 128.2 mm

2.9" 73.8mm

Part No. QT-180-3 Part No. QT5-45


(45 bend) 6.8" 172.6mm 3.6" 91.7mm

Part No. QT-180-5


5.2" 132.0mm

Part No. QT5-60


(60 bend)

3.0" 76.3 mm

6.2" 158.4mm

Part No. QT-180-7


7.0" 178.8mm

Note: Diffuser thread size: 1/4-18 NPT Bernard Special.


Part No. QT-180-12
12.4" 314.6 mm

Part No. QT-180-18


18.4" 467.0mm

Part No. QT-180-24


24.4" 619.4 mm

All body tubes (except the QT-F-6 and QT-F-8) include the components required to make the body tube fixed (wrench-tight) or rotatable (hand-tight).
Patent Pending

1.5" 37.3 mm

Part No. QT2-45-12 (45 bend)


11.9" 301.6 mm

Part No. 1840057

Part No. 1840031

1.5" 37.3 mm

Part No. QT2-45-18 (45 bend)


17.9" 454.0 mm

Part No. 4780

1.5" 37.3 mm

Part No. QT2-45-24 (45 bend)


23.9" 606.4 mm

Part No. QT-F-6 (rotatable/flexible neck)


6.6" 166.8mm

Part No. QT-F-8 (rotatable/flexible neck)


8.6" 217.6mm

200

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Bernard Vendor Code: BER

Inert Gas Equipment

Replacement Liners

Standard Liners
Wire Size .023" - .030" (.6 mm - .8 mm) .035" - .045" (.9 mm - 1.2 mm) .045" - 1/16" (1.2 mm - 1.6 mm) 5/64" (2.0 mm) 500A - 600A 500A - 600A Air-Cooled Only 400A Clean-Air 600A Water-Cooled 600A Air-Cooled Only Gun Amperage 150A - 600A 150A 200A - 600A 200A - 600A 200A - 400A Direct Plug All except Tweco 4, L-Tec Tweco 4, L-Tec All except Tweco 4, L-Tec Tweco 4, L-Tec All except Tweco 4, L-Tec Tweco 4, L-Tec All except Tweco 4, L-Tec Tweco 4, L-Tec All except Tweco 4, L-Tec Tweco 4, L-Tec All except Tweco 4, L-Tec Tweco 4, L-Tec All except Tweco 4, L-Tec All except Tweco 4, L-Tec All except Tweco 4, L-Tec Part No. 10' (3.05 m) N/A* 43110 N/A* 44110 N/A* 44210 N/A* N/A* 15' (4.57 m) 43015 43015T 43115 43115T 44115 44115T 44215 44215T 1920170 1920296 44315 44315T 45415 1920175 45615 46715 25' (7.62 m) 43025 43025T 43125 43125T 44125 44125T 44225 44225T 1920172 1920298 44325 44325T 45425 1920177 45625 46725

N/A* N/A* N/A*

3/32" (2.4 mm) 7/64" (2.8 mm) 1/8" (3.2 mm)

*10' (3.05 m) liner not available. Order 15' (4.57 m) liner and trim to size. Liners without outer jacket.

Aluminum / Soft Wire Liners


Wire Size Gun Amperage 150A - 600A Nylon .035" (.9 mm) 200A - 600A Steel Coil 200A - 600A Nylon 3/64" (1.2 mm) 200A - 600A Steel Coil 200A - 600A Nylon 1/16" (1.6 mm) 200A - 600A Steel Coil Direct Plug All except Tweco 4, L-Tec Tweco 4, L-Tec All except Tweco 4, L-Tec Tweco 4, L-Tec All except Tweco 4, L-Tec Tweco 4, L-Tec All except Tweco 4, L-Tec Tweco 4, L-Tec All except Tweco 4, L-Tec Tweco 4, L-Tec All except Tweco 4, L-Tec Tweco 4, L-Tec Part No. 10' (3.05 m) N/A* 15' (4.57 m) 43015X 43015XT 1920343 1920346 43115X 43115XT 1920344 1920347 44215X 44215XT 1920345 1920348 25' (7.62 m) N/A

N/A 1920350 N/A N/A 1920351 N/A

N/A*

N/A*

*10' (3.05 m) liner not available. Order 15' (4.57 m) liner and trim to size.

Replacement Instructions and Service


Install Replacement Liner
Insert liner into power pin with cable laying straight. Continue until liner lock is fully seated into power pin. A twisting motion may be necessary to seat O-ring (some direct plugs may require installation of additional components to secure liner). Making sure cable is straight, trim liner at the nozzle of the neck as follows:  DS-1 and D-1 Centerre gas diffusers (used with Centerre series tips) = between 5/8" and 3/4".  4235 and 4635 gas diffusers (used with 1500 series tips) = 3/8". 4335 and 4435 gas diffusers (used with 7400 or 4200 series tips) = 1-3/8" D118Q gas diffusers (used with Quik Tips) = 7/8". D114Q gas diffusers (used with Quik Tips) = 3/4". File the cut end of liner to eliminate burrs and reinstall insulator cap, gas diffuser, tip and nozzle. When Using Jump Liner: Trim and deburr liner with 1/4" (6.4 mm) extending beyond the gun handle and reinstall neck.

Remove Existing Liner


Turn off power. Remove nozzle, tip, gas diffuser and insulator cap (guns with jump liner remove neck). Lay cable straight. Grasp liner lock which protrudes from power pin (some direct plugs may require removal of additional components to access the liner lock) and remove from cable assembly.

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.

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201

Inert Gas Equipment

Bernard Vendor Code: BER

Tips / Diffusers / Nozzles

Elliptical
Item
5

Part No. 4423R 4323R 4435 4635 4635-116 4235 4235-116 4335 4335-116 7497 7488 7489 7496 7490 7498 7491 7492 7493 7494 7495 1597 1588 1589 1596 1590 1598 1591 1592 1593 1594 1595 4285 4281 4299 4282 4283 0036 1101QD 36-50 36-63 36-75 4491 4591 4591HD 4491 4591 4591HD 4391 4393 4392 4394 4295

Description Cap Cap Diffuser Diffuser Diffuser Diffuser

Size Inches

mm

2
2 3 4 5a

1 1a 2 2a 2b

1 2a 3a 5b

2c

5c

Contact tip, 7400 series

2b

3a

5d

1a

3 2c 3b

5e

5f

3a

Contact tip, 1500 series

Contact tip, 4200 series

3b

.023 .030 .035 .039 .045 .052 1/16 5/64 3/32 7/64 1/8 .023 .030 .035 .039 .045 .052 1/16 5/64 3/32 7/64 1/8 .030 .035 .039 .045 .052 3/4 1/2 5/8 3/4 3/4

0.6 0.8 0.9 1.0 1.2 1.4 1.6 2.0 2.4 2.8 3.2 0.6 0.8 0.9 1.0 1.2 1.4 1.6 2.0 2.4 2.8 3.2 0.8 0.9 1.0 1.2 1.4 19.1 12.7 15.9 19.1 19.1

4 5 5a

Nozzle body Nozzle; water cooled, copper Nozzle cone Nozzle, brass Nozzle, copper Nozzle, heavy duty Nozzle, brass Nozzle, copper Nozzle, heavy duty Nozzle, brass Nozzle, copper Nozzle, brass Nozzle, copper Nozzle; tapered, brass

5b

5c 5d 5e 5f

9/16 5/8 1/2 3/8

14.3 15.9 12.7 9.5

202

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Bernard Vendor Code: BER

Inert Gas Equipment

Tips / Diffusers / Nozzles

Centerre Series
Centerfire Nozzles Part Number
Use a Centerre nozzles part number to identify its specications. The part number below represents a large Centerre nozzle manufactured with 5/8" I.D., 1/8" tip recess and copper. Nozzle Style Orice I.D. Tip Recess Material Item 1 1a 2 2a Part No. 4323R 10012 DS-1 D-1 T-023 T-030 T-035 T-039 T-045 3
4 3

Description Cap Cap Diffuser Diffuser

58
(i.e. 58 = 5/8")

18
(i.e. 18 = 1/8")

Size Inches

mm

 Available nozzle styles: N = nozzle large, NT = nozzle large tapered, NS = nozzle small, NST = nozzle small tapered Tip recess XT = 1/8" extension beyond end of nozzle  Available nozzle materials: B = brass and C = copper

.023 .030 .035 .039 .045 Contact tip, T series


1.50 [38.1 mm]

0.6 0.8 0.9 1.0 1.2 1.4 1.6 2.0 2.4 2.8 3.2 0.6 0.8 0.9 1.0 1.2 1.4 1.6

T-052 T-062 T-078 T-094 T-109 T-125

.052 1/16 5/64 3/32 7/64 1/8 .023 .030 .035

4a 1 2

TT-023 TT-030 TT-035 3a TT-039 TT-045 TT-052 TT-062 NS-5800C NS-5818C 4 NS-5814C NS-5800B NS-5818B NS-5814B NS-1218C 4a NS-1200B NS-1218B NST-3800B 4b NST-3818B NST-38XTB N-3400C Contact tip, TT series
2.00 [50.8 mm]

.039 .045 .052 1/16

3a

4b

Nozzle, 5/8" I.D., ush, copper Nozzle, 5/8" I.D., 1/8" recess, copper Nozzle, 5/8" I.D., 1/4" recess, copper Nozzle, 5/8" I.D., ush, brass Nozzle, 5/8" I.D., 1/8" recess, brass Nozzle, 5/8" I.D., 1/4" recess, brass Nozzle, 1/2" I.D., 1/8" recess, copper Nozzle, 1/2" I.D., ush, brass Nozzle, 1/2" I.D., 1/8" recess, brass Nozzle, 3/8" I.D., ush, brass Nozzle, 3/8" I.D., 1/8" recess, brass Nozzle, 3/8" I.D., 1/8" extension, brass Nozzle, 3/4" I.D., ush, copper Nozzle, 3/4" I.D., 1/8" recess, copper Nozzle, 3/4" I.D., 1/4" recess, copper Nozzle, 3/4" I.D., ush, brass Nozzle, 3/4" I.D., 1/8" recess, brass Nozzle, 3/4" I.D., 1/4" recess, brass Nozzle, 5/8" I.D., ush, copper Nozzle, 5/8" I.D., 1/8" recess, copper Nozzle, 5/8" I.D., 1/4" recess, copper Nozzle, 5/8" I.D., ush, brass Nozzle, 5/8" I.D., 1/8" recess, brass Nozzle, 5/8" I.D., 1/4" recess, brass Nozzle, 3/8" I.D., ush, copper

'TT' Series Tip

4c 3

4 1a 2a

3a 4d

N-3418C 4c N-3414C N-3400B N-3418B N-3414B N-5800C N-5818C 4d N-5814C N-5800B N-5818B N-5814B 4e NT-3800C

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203

Inert Gas Equipment

Bernard Vendor Code: BER

Available Direct Plug Kits & Replacement Parts


Bernard Quick Disconnect Kit
B E F G A H
A

Miller Direct Plug Kit

Tweco 4/5 Direct Plug Kits


C A B
C

2
C D
strain relief set (included in kit)

Part No. 1199 Item A B C D E F G H I Part No. 2200008 4929 4924 2060033 4911 4916 4912 2250016 4925 Description Power pin assembly O-Ring (2 required) Lead wire (2 required) Gas pin assembly Snap ring, large Wave ring Snap ring, medium Snap ring, small Locking sleeve Item A B

Part No. 1199M Part No. Description 2200101 Power pin assembly 4478 O-Ring (2 required) 4477 Power pin tip (.023" - .045") C 4474 Power pin tip (3/32" - 1/8") 4477-564 Power pin tip (.052" - 5/64")* Power Pin Tips for Aluminum Wire 2200105 Power pin tip (.030" - .035")* C 2200106 Power pin tip (.040" - 3/64")* 2200107 Power pin tip (.052" - 1/16")* *Optional

Part No. 1199T4- Tweco 4 Direct Plug Kit Part No. 1199T5- Tweco 5 Direct Plug Kit Item A B C D *Optional Part No. 2200103 2200104 4713 4929 4714 SCT1N SCL1N SCX1N Description Power pin assembly (Tweco 4) Power pin assembly (Tweco 5) O-Ring (2 required - Tweco 4) O-Ring (2 required - Tweco 5) Set screw Trigger cable adapter Trigger cable adapter, Lincoln* Trigger cable adapter, ESAB*

Euro Direct Plug Kit

Hobart Direct Plug Kit

Lincoln Direct Plug Kit


C A

A
D

Part No. 1199E Item A B Part No. 5060 4816 Description Euro block assembly Adaptor nut Item A B C

Part No. 1199H Part No. 2200098 4713 SCT1N Description Power pin assembly O-ring (2 required) Trigger cable adapter Item A B C D

Part No. 1199L Part No. 2200099 1840059 GLM1 SCL1N Description Power pin Insulator Gas line assembly Trigger cable adapter

L-Tec Direct Plug Kit

National Direct Plug Kit


C

OXO Direct Plug Kit


D

A B

B A
C

A B

Part No. 1199LT Item A B C D Part No. 2200100 4713 4714 SCX1N Description Power pin assembly O-Ring (2 required) Set screw Trigger cable adapter Item A B C D

Part No. 1199N Part No. 2200102 1840059 GLM1 SCT1N Description Power pin Insulator Gas line assembly Trigger cable adapter Item A B C D E

Part No. 1199X Part No. 2200108 4929 4714 6234 SCX1N Description Power pin assembly O-Ring (2 required) Set screw Adaptor nut Trigger cable adapter

204

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Bernard Vendor Code: BER

Manual Products
Cable Connectors
 eavy-duty ball-point set screw cable connection. H Fully insulated covers for maximum safety.  Interchangeable with most popular models.  Connector locking screw designed for longer life  and superior electrical connection. Part No. 01BC 2-1BC 02BC 04BC Cable Sizes 4,2,1 (35-50 mm2) 4,2,1 (35-50 mm2) 1/0, 2/0, 3/0 (50-70 mm2) 3/0, 4/0 (70-95 mm2) Details 1BC-F: female 1BC-M: male Mates w/ 2BC-F or 4BC-F 2BC-F: female 2BC-M: male 4BC-F: female 4BC-M: male

Welding Accessories

Positive Lock Terminal Lugs


 ug screw designed for enhanced eld repairability. L Composite copper alloys for superior conductivity.  Increased cable depth for better connections.  Fully insulated covers are heat, oil and abrasion  resistant.

Part No. B-1AF B-2AF

Accepts Cable Connector(s) 1BC-M 2BC-M, 4BC-M, 2-1BC

S  imple as driving a nail to attach.  No soldering, no bolting, no set screws, no crimping tools required.  Twice as heavy as most crimp-type connectors.  Same conductivity as the cable they connect.

Hammer-On Cable Lugs & Splicers

Lugs
Part No. 0L11 0L22 0L33 0L44 Cable Sizes 3/0 and 4/0 1/0 and 2/0 2 and 1 6 thru 2 Size of Stud Hole 21/32" 17/32" 33/64" 13/32" ID Cable Socket 5/8" 33/64" 13/32" 19/64"

Splicers
Part No. 0S11 0S22 0S33 Cable Sizes 3/0 and 4/0 1/0 and 2/0 2 and 1 Amperage Rating 150 225 250 ID Cable Socket 5/8" 33/64" 13/32" Size of Stud Hole 17/32" 17/32" 17/32" ID Cable Socket .461" .559" .660"

Solder Type Lugs

C  opper alloy for excellent electrical conductivity.  Flared end for easy cable access.  Stud hole size 17/32.

Part No. B-62 B-120 B-3040

Cable Sizes 6-2 1-2/0 3/0 and 4/0

Electrode can be used to within one inch of the high heat, high impact head. Capable of utilizing more of the electrode than the typical tong-type holder. Greatly improves productivity it is designed for quick, easy installation of electrodes.  Built to last with a proven high impact, high heat replaceable head. Over 2,000 pounds of gripping pressure. Time-tested design. Part No. 040B
1 2 3 4 5

Shortstub

Specications

Capacity Electrode Size Weight Length Cable Connection Cable Socket

Accessories for Part No. 040B 400 AMPs/60% duty cycle 1/16"-1/4" (1.6 - 6.4mm) 17 oz. (481 g) 8-3/4" (22 cm) Model B large ball point screw connection 19/32" (1.5 cm)

Replacement Parts
Item 1 2 3 4 5 6 7 8 9 10 11 12 12 Part No. 0K40 00S5 0MH4 0B37 0B33 00EL 0BB4 0SR4 00V4 00J4 0JP4 00H4 OPP4 Description Head Assembly Coil Spring Handle (molded) Connector Body Ball Point Set Screw Head Insulators (pair) Boot Snap Ring V Jaw Spring Jaw Jaw Pin Head Pressure Pin

9
10

11

12

13

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Bernard Vendor Code: BER

Carts

1. B  oom must not be loaded beyond 200 lbs (90.9 kg); this should be a balanced, hanging load. 2.  When boom is mounted on cart, outrigger screws must be rmly tightened against oor, and adequate ballast must be provided. 3.  When boom is mounted on cart, all weight must be removed from the boom before the cart can be moved. 4.  Add proper ballast before extending boom. See diagram with ballast requirements to the far right. 5.  Check boom daily for safe operation. Carefully test the installation by swinging the boom through its full rotation before placing unit into service.

Bernard Boom and Cart Warning

6. A  ny boom in a high use application (continually swung side to side, loaded near maximum weight at full extension) should have the mast periodically inspected and regreased. Greasing all other pivot points on the boom will give smoother operation and increased boom life.

Ballast Requirements
1. 3  60 with 1000 lbs. ballast when boom is fully retracted. 2.  2000 lbs. ballast required for full boom extension in shaded areas. NOTE: Power sources, water in tank and other weighted objects can be considered ballast.

Welding Accessories

M  aximum capacity available from 2000 lbs. to 3000 lbs. Durable rubber tires and cast iron wheels. Swivel front steering.  Bernard Carts make the work station accessible by organizing and storing power sources, feeders, gas cylinders and water coolers. Rack holds 2 cylinders.

Carts

5,6,7,8 9 14,15 13 12 10 13 12 1

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 1 14 15 16 17 18 19 20 21 22 23 24 3 2 4 25 26 27

Cart 2910 0709 1056 1055 1087 1041 1456 1452 1103 0708 2036 0924 2902 0951 2420 1040 1045 0947 1034 0921 1046 0916 0719 0723 0932 0922 0923 0941 1045 0947 1034 0921 1046 0721 0719 0723 0932 1034 0710 0714 2710 0709 1056 1055 1087 1041 1456 1452 1103 0708 2036 0710 2704

6
Description Handle assembly Washer Mounting pad nut Mounting pad Chain Nut (for chain) Washer (for chain) Bolt (for chain) Cylinder support Cap plug Rear wheel Leveling screw Gusset assembly Clevis pin Cotter pin Handle pin Nut (front wheel) Washer Bolt (front wheel) Nylon washer Swivel bushing Drain plug Spring Cotter pin Washer Front wheel Front wheel bracket Qty. 1 4 4 4 1 2 2 1 1 2 2 2 4 8 8 1 1 1 1 1 1 1 1 4 4 2 1

2910 Cart
Wheels: Capacity: Cart size: Weight:

11 front 10" (25.6 cm) rear 12" (30.7 cm) 3000 lbs (1360 kg) 57" x 30" x 8-3/4", (144.8 x 76.8 cm x 22.2 cm) 333 lbs (151 kg)

Part No. 2910

2710 Cart

Wheels: 8" (20.5 cm) diameter Capacity: 2000 lbs. (907 kg) Cart size:  57" x 30" x 8-3/4" (146 x 76.8 cm x 22.4 cm) Weight: 233 lbs (105.9 kg) Part No. 2710

5,6,7,8 9

11

10

12

Front Wheel and Mounting Pad Breakdown 16


17,18,19,20,21

23 24 26 27 25

Mounting pad welds easily to cart, providing 22 a secure anchor of power sources. NOTE:  Fill cart with water prior to welding pads to cart.

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Bernard Vendor Code: BER

Booms

Booms

2300 Boom
Item 1 2 3 4 5 6 7 8 Part No. 2329 2327 2328 2334 2335 2346 2332 2342 2323 9 10 11 12 13 13a 14 15 16 17 18 19 20 21 2479 1040 1034 1046 2319 2352 2349 2326 2331 2344 2337 2301 2320 2424 2696K * Optional Description Thrust bearing Gear Pinion Roll pin Rod stop pin Handle bar Handle bolt Handle Handle assembly (includes 6,7,8) Grease tting Cotter pin Washer Nylon washer Mast Mast assembly (includes 10,11,12,13) Upright Lifting rod Hairpin clip Pin Main boom Boom extension Pivot pin Hair pin clip Boom locking device* Qty. 1 1 1 1 1 1 1 1

Welding Accessories

Easy telescoping boom sections create greater horizontal reach. Single handle crank for superior elevation. Boom locking device for added safety, optional on 2300. Holds up to 200 pounds hanging load at maximum reach. 360 rotation with proper ballast.

2300 Boom

Fits carts: 2710 and 2910. Horizontal Reach: 5' to 8' (1.5 to 2.5 m) Elevation: 3' to 14' (.9 to 4 m) Capacity: 200 lbs (90.9 kg) Rotation: 360 Shipping Weight: 110 lbs (50 kg) Part No. 2300 16,17 20,21 5,15 1 2
10 11

19 18

1 1 1 1 1

3 9 4 6 7 8
Cutaway Gear Box

14

12 13

1 1 2 2 1 1 1 2 1

2475 Boom
Item 1 2 3 4 5 6 7 8 9 10 11 12 Part No. 2436 2431 2435 2432 2427 2334 3504 2423 1040 0922 1046 2290 2296 2460 2437 2408 2422 2466 2471 2424 2469 2419 2331 2367 2369 2372 2420 Description Thrust bearing Gear Bearing Pinion gear Pinion arm Roll pin Retaining ring Rod stop pin Cotter pin Washer Nylon washer Mast Mast assembly (includes 9,10,11,12) Upright assembly Handle roll pin Handle assembly Lifting rod Boom locking device Pin Hairpin clip Pivot pin Clevis pin Hairpin clip Main boom section Center boom section Front boom section Clevis pin Qty 1 1 2 1 1 1 1 1 1 1 1 1

13a Mast Assembly

2475 Boom

Fits cart: 2910. Horizontal Reach: 6' to 14' (1.8 to 4.3m) Elevation: 3' to 17' ( .9 to 5m) Capacity: 200 lbs (90.9 kg) Rotation: 360 Shipping Weight: 192 lbs (87 kg) Part No. 2475
18,19 22,26 19,20 21, 22 23 8, 16 15 17 13
9 10 11 12

12a 13 14 15 16 17 18 19 20 21 22 23 24 25 26

25 24

1 2 14 7 3

12a Mast Assembly Cutaway Gear Box

6 4

1 1 1 1 1 2 6 1 1 3 1 1 1 2

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Bernard, Aquasol Vendor Code: BER, ASW

Booms / Water Soluble Products

BOOM Mounting System


Floor Mount

Boom mounts are the right choice when space is limited on the shop oor or when a xed installation is desired. Both models provide excellent stability and t all Bernard booms.

Floor mount bolts to the platform of a truck or shop oor. Capacity: 200 lbs. (90.9 kg) Size (H x L x W): 14" x 14" x 14" (35.56 cm x 35.56 cm x 35.56 cm) Mounting Holes: 13/16" (2.06 cm) Weight: 37 lbs (16.7 kg) Part No. 2380

Wall Mount

Wall Mount bolts to a vertical steel column or masonry wall. Capacity: 200 lbs (90.9 kg) Size (H x L x W): 16" x 16" x 7" (40.64 cm x 40.64 cm x 17.78 cm) Mounting Holes: 13/16 (2.06 cm) Weight: 42 lbs. (19 kg) Part No. 2390

Welding Accessories 6

EZ Tape

EZ Tape is traditional aluminum welding tape that can be used to seal root gaps while purging, however, we recommend EZ Zone Tape be used for this purpose to achieve the purest weld. EZ Tape has many other conventional uses in the eld such as sealing pipe ends for transporting, sealing ducts for heating, air conditioning and refrigeration, and acting as a vapor barrier.

Part No. EZ Tape EZ-T2.0 EZ Zone Tape EZ-ZT2.5 EZ-ZT4.0

Size 2" x 75' 2.5" x 75' 4" x 75'

EZ Wipes Canister

EZ Wipes allow a welder to quickly and effectively clean pipes prior to welding, reducing the risk of weld contamination and increasing the number of pure nished welds. EZ Wipes feature a specialized two-sided cleaning fabric, an abrasive side to loosen dried on surface contaminants and a smooth side to reveal a cleaner, polished surface.

Part No. EZW-30 EZW-70

Description 30 per canister 70 per canister

EZ Purge Paper

Aquasol water-soluble paper and tape is a cost saving alternative to conventional purging systems. This paper is used to dam argon or helium gases during tungsten inert gas (TIG) welding of steel or aluminum pipes. Aquasol water-soluble paper dissolves instantaneously. Use water soluble tape for fast adhesion of paper to pipe. ASW-35 (.0035" thick) is for use on pipes 4"ID or less. ASW-60 (.0060" thick) is for use on pipes 4"ID or greater.

Part No. Size 35S-11 8.5" x 11" 500/CA 35S-14 8.5" x 14" 500/CA 60S-22 15" x 22" 250/CA 35S-22 17" x 22' 500/CA 35R-9 9" x 165' 35R-15 15" x 165' 60R-15 15.5" x 165' 60R-31 31" x 165' Water Soluble Tape WT-1 1" x 300' WT-2 2" x 300'

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