Miller | LF090160 | Owner Manual | Miller DIAMONDBACK TIG TORCHES MODELS 26 AND 26V User manual

Miller DIAMONDBACK TIG TORCHES MODELS 26 AND 26V User manual
199 526E
Processes
TIG (GTAW) Welding
ENGLISH
OM-1601
1/2005
Description
DB2612R, DB2625R, DB26V12R And DB26V25R
Visit our website at
www.MillerWelds.com
DEUTSCH
ITALIANO
Diamondback Series
GTAW Torches
ESPAÑOL
FRANÇAIS
TIG Torch
TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR GTAW TORCHES − READ BEFORE USING . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. GTAW Torch Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMF INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Required Torch Parts And Torch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. International Style Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Connecting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING . . . .
5-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . .
5-2. Preparing Tungsten Electrode For Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
1
1
1
2
3
3
3
4
4
4
5
7
7
7
9
9
10
10
10
11
11
12
SR6_8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.
Y Marks a special safety message.
. Means NOTE; not safety related.
This group of symbols means Warning! Watch Out! Possible ELECTRIC SHOCK and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions to avoid the hazards.
1-2. GTAW Torch Hazards
GTAW WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information found in the welding
power source Owner’s Manual. Read and follow all safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK can kill.
1.
2.
3.
4.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Do not touch live electrode or electrical parts.
Repair or replace worn, damaged, or cracked
torch or cable insulation.
5. Turn off welding power source before changing
tungsten electrode or torch parts.
6. Keep all covers and handle securely in place.
WELDING can cause fire or explosion.
1. Do not weld near flammable material.
2. Do not weld on closed containers.
3. Watch for fire; keep extinguisher nearby.
HOT SURFACES can burn skin.
1. Allow torch to cool before touching.
2. Do not touch hot metal.
3. Protect hot metal from contact by others.
ARC RAYS can burn eyes and skin.
1. Wear welding helmet with correct shade of filter.
2. Wear correct eye and body protection.
3. Cover exposed skin.
FUMES AND GASES can be hazardous
to your health.
1. Keep your head out of the fumes.
2. Ventilate area, or use breathing device.
3. Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
NOISE can damage hearing; SOME
APPLICATIONS, SUCH AS PULSING,
are noisy.
1. Check for noise level limits exceeding those
specified by OSHA.
2. Use approved ear plugs or ear muffs if noise level
is high.
3. Warn others nearby about noise hazard.
BUILD UP OF GAS can injure or
kill
1. Shut off shielding gas supply when not in
use.
2. Always ventilate confined spaces or use
approved air-supplied respirator.
OM-1601 Page 1
ENGLISH
SECTION 1 −SAFETY PRECAUTIONS FOR GTAW
TORCHES − READ BEFORE USING
EMF INFORMATION
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-1601 Page 2
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.
ENGLISH
SECTION 2 − SPECIFICATIONS
2-1. Specifications
Model
DB2612R,
DB2625R,
DB26V12R (With Gas Valve)
DB26V25R (With Gas Valve)
Ampere Rating
200 Amps W/Argon Gas @ 100% Duty Cycle DCEN, ACHF
Cooling Method
Air
Cooling Requirements
1.1 quart/minute (1.0 liter/minute)
Tungsten Size
.020 Thru 5/32 in (0.5 Thru 4.0 mm)
Cable Options
12-1/2 ft (3.8 m) One-Piece High−Flex
Dimensions
25 ft (7.6 m) One-Piece High−Flex
DB2612R, DB2625R: Length: 8-7/8 in (225 mm); Handle Diameter: 1-1/4 in (32 mm);
Weight: 6.9 oz (196 g)
DB26V12R, DB26V25R: Length: 9-1/4 in (235 mm); Handle Diameter: 1-1/4 in (32 mm);
Weight: 8.6 oz (244 g)
2-2. Duty Cycle
100% Duty Cycle At 200 Amperes Using Argon Gas
0
Definition
10
Duty Cycle is percentage of 10
minutes that torch can weld at
rated load without overheating.
Minutes
Continuous Welding
sb1.5* 8/93
EXCEEDING RATED AMPERAGE can damage torch and void warranty.
•
Do not exceed rated amperage (see Section 2-1)
OM-1601 Page 3
SECTION 3 − INSTALLATION
3-1. Required Torch Parts And Torch Assembly
7
6
5
Assembling Torch Parts
4
3
2
1
12
9
13
10
8
Or
11
Ref. ST-802 566-B
1
2
Cup
Collet Body
3
4
5
Heat Shield
Backcap Insulator
Collet
6
7
O-Ring
Backcap
8
9
10
11
12
Torch Body
Handle
One-Piece Power Cable
Power Cable Adapter
International Style Flow-Through
Adapter
Note: Adapter needed only if torch is
equipped with one-piece cable.
Assembling Torch Body
Keep connections tight. Replace cup, heat
shield, and backcap as needed.
13 Tungsten Electrode (See Section 5)
Installing Tungsten
To adjust tungsten position, loosen backcap.
3-2. International Style Connector Assembly
1
1
3
2
1 in
(26 mm)
5
4
Weld Output Cable
2
Insulating Boot
3
Sleeve
Slide insulating boot onto cable;
strip cable and install sleeve.
4
Connector Body
5
Setscrew
Insert cable with sleeve fully into
connector body, tighten setscrew,
and slide insulating boot over connector.
3
Tools Needed:
ST-156 496
OM-1601 Page 4
ENGLISH
3-3. Connecting Torch
A. Connecting Torch With One-Piece Cable
Y Turn Off welding power
source power before installing torch.
Obtain the following hose:
If applicable, install high-frequency unit.
Torch Without Gas Valve
1
Gas Hose With 5/8-18 RightHand Fittings
Connections:
4
2
3
2
Regulator/Flowmeter
3
Gas Cylinder
4
Welding Power Source
5
Gas Valve
Operating Torch Gas Valve:
1
Valve controls gas preflow and postflow. Open valve on torch just before
welding.
Preflow is used to purge the immediate weld area of atomsphere.
6
Postflow is required to cool tungsten
and weld, and to prevent contamination of tungsten and weld. After welding, leave valve open about 1 second for every 10 amperes of weld
current. Close valve on torch when
postflow is finished.
5
7
8
9
6
One-Piece Torch Cable
7
Power Cable Adapter
Connect gas hose and power cable
to adapter before connecting adapter to weld output terminal.
8
Torch With Gas Valve
Work Clamp
Connect work clamp to clean, paintfree location on workpiece, close to
weld.
4
2
Use wire brush or sandpaper to
clean metal at weld joint area.
3
9
Foot Control
1
6
5
803 313
7
8
9
Tools Needed:
5/8, 7/8 in
OM-1601 Page 5
B. Connecting Torch With Two-Piece Cable
Y Turn Off welding power
source power before installing torch.
Obtain the following hose:
If applicable, install high-frequency unit.
1
Torch Without Gas Valve
2
4
Gas Hose With 5/8-18 RightHand Fittings
Connections:
3
1
2
Regulator/Flowmeter
3
Gas Cylinder
4
Welding Power Source
5
Torch Power Cable
6
Torch Gas-In Hose
7
Work Clamp
Connect work clamp to clean, paintfree location on workpiece, close to
weld.
5
Use wire brush or sandpaper to
clean metal at weld joint area.
8
7
Foot Control
6
803 314
Tools Needed:
8
5/8, 7/8 in
C. Connecting Torch With Flow-Through Type Connection
2
If applicable, install high-frequency unit.
3
1
4
Torch Without Gas Valve
Y Turn Off welding power
source power before installing torch.
Obtain the following hose:
Gas Hose With 5/8-18 RightHand Fittings
Connections:
1
5
6
2
Regulator/Flowmeter
3
Gas Cylinder
4
Welding Power Source
5
Gas Valve
6
One-Piece Torch Cable
7
Work Clamp
Connect work clamp to clean, paintfree location on workpiece, close to
weld.
Tools Needed:
Use wire brush or sandpaper to
clean metal at weld joint area.
7
5/8, 7/8 in
OM-1601 Page 6
Ref. ST-802 540-A
4-1. Routine Maintenance
Y Disconnect torch before maintaining.
40 Hours
Clean and
tighten weld
terminals.
Repair or
replace
cracked
weld cable.
Replace
unreadable
labels.
Replace cracked parts
Torch Body
Torch Cable
4-2. Troubleshooting
NOTE
Before using troubleshooting table, check selection and preparation of tungsten
electrode according to Section 5.
Trouble
Remedy
Arc will not start. High frequency present Check cable and work connections. Be sure weld circuit is complete (see Section 3-3).
and visible at the torch.
Check and be sure shielding gas is present.
Lack of high frequency; difficulty in es- Select proper size and type of tungsten. Properly prepare tungsten according to Section 5.
tablishing arc.
Check cables and torch for cracks or bad connections. Be sure that torch cables are not close to any
grounded metal. Repair or replace necessary parts.
Check torch consumables. Be sure collet and collet body are correctly installed and tightened (see Section 3-1).
Check welding power source High Frequency control, and if necessary, check and adjust spark gaps.
Torch gas valve not working properly (if Have Factory Authorized Service Station/Service Distributor check valve.
applicable).
No shielding gas flow from torch.
Be sure valves on gas supply are open.
Check cable for kinks or blockage.
Check and tighten all gas supply fittings.
Check cables and torch for cracked insulation or bad connections. Repair or replace (see Section 4-1).
Make sure collect is installed correctly (see Section 3-1).
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
Increase postflow time.
Increase gas flow rate. Check manufacture’s recommendations.
Check and tighten all gas fittings.
Check gas valve and flow meter/regulator.
Select proper size and type of tungsten. Properly prepare tungsten (see Section 5).
Excessive tungsten electrode con- Select proper size and type of tungsten. Properly prepare tungsten according to Section 5.
sumption.
Check polarity setting on welding power source (see welding power source Owner’s manual).
Check for proper gas flow rate. Check manufacture’s recommendations.
If torch is water cooled, check torch and cables for water leaks. Repair or replace if necessary (see Section 4-1).
OM-1601 Page 7
ENGLISH
SECTION 4 − MAINTENANCE & TROUBLESHOOTING
Trouble
Wandering arc
Remedy
Shield weld zone from drafts.
Reduce gas flow rate.
Select proper size and type of tungsten. Properly prepare tungsten according to Section 5.
When using AC, check welding power source High Frequency control setting, and increase setting if necessary.
Yellow powder or smoke on cup.
Use proper type shielding gas.
Check for proper gas flow rate. Check manufacture’s recommendations.
Increase postflow time.
Check torch cup size. Match cup size to joint being welded.
Erratic arc
Make sure base material is clean and free of contaminates.
When using DC, check polarity, and/or polarity of welding cables.
Select proper size and type of tungsten. Properly prepare tungsten according to Section 5.
Use proper arc length. Arc length may be too long or too short.
When using AC, check welding power source High Frequency control setting, and be sure it is operating
continuously.
When using AC, slow travel speed can cause erratic arc. Adjust travel speed.
Porosity in weld.
Check for proper type gas and correct flow rate. Check manufacture’s recommendations.
Check and tighten gas fittings.
Make sure base material and filler material is clean and free of contaminates.
Check for impurities and moisture in gas lines. Purge if necessary.
If torch is water cooled, check torch and cables for water leaks. Repair or replace if necessary (see Section 4-1).
OM-1601 Page 8
ac/dc_gtaw 2/2004
Y Whenever possible and practical, use DC weld output instead of AC weld output.
5-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten )
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
DC − Argon − Electrode
Negative/Straight Polarity
DC − Argon − Electrode Positive/Reverse Polarity
AC − Argon
AC − Argon −
.010”
Up to 25
*
Up to 20
Up to 15
.020”
15-40
*
15-35
5-20
Balanced Wave
2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium
(Red Band) Alloy Tungstens
.040”
25-85
*
20-80
20-60
1/16”
50-160
10-20
50-150
60-120
3/32”
135-235
15-30
130-250
100-180
1/8”
250-400
25-40
225-360
160-250
5/32”
400-500
40-55
300-450
200-320
3/16”
500-750
55-80
400-500
290-390
1/4”
750-1000
80-125
600-800
340-525
.010”
Up to 15
*
Up to 15
Up to 10
.020”
5-20
*
5-20
10-20
.040”
15-80
*
10-60
20-30
1/16”
70-150
10-20
50-100
30-80
3/32”
125-225
15-30
100-160
60-130
1/8”
225-360
25-40
150-210
100-180
5/32”
360-450
40-55
200-275
160-240
3/16”
450-720
55-80
250-350
190-300
1/4”
720-950
80-125
325-450
250-400
.010”
*
*
Up to 20
Up to 15
.020”
*
*
15-35
5-20
.040”
*
*
20-80
20-60
1/16”
*
*
50-150
60-120
3/32”
*
*
130-250
100-180
1/8”
*
*
225-360
160-250
5/32”
*
*
300-450
200-320
3/16”
*
*
400-550
290-390
1/4”
*
*
600-800
340-525
Pure Tungsten
(Green Band)
Zirconium Alloyed Tungsten (Brown
Band)
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
OM-1601 Page 9
ENGLISH
SECTION 5 − SELECTING AND PREPARING TUNGSTEN
ELECTRODE FOR DC OR AC WELDING
5-2. Preparing Tungsten Electrode For Welding
Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use
local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines
2-1/2 Times
Electrode Diameter
Radial Grinding
Causes Wandering Arc
1
3
2
1
2
3
Tungsten Electrode
Flat
Diameter of this flat determines amperage
capacity.
4
Wrong Tungsten Preparation
Grinding Wheel
Grind end of tungsten on fine grit, hard
abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.
Ideal Tungsten Preparation − Stable Arc
4
Straight Ground
Grind lengthwise, not radial.
B. Preparing Tungsten For Conventional AC Welding
1 − 1-1/2 Times
Electrode Diameter
1
2
1
2
Tungsten Electrode
Balled End
Ball end of tungsten by applying AC amperage recommended for a given electrode
diameter (see Section 5-1). Let ball on end of
the tungsten take its own shape.
SECTION 6 − GUIDELINES FOR TIG WELDING (GTAW)
6-1. Positioning The Torch
Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work
clamp as close to the weld as possible.
. For additional information, see your distributor for a handbook on the
3
Gas Tungsten Arc Welding (GTAW) process.
2
1
Workpiece
Make sure workpiece is clean before welding.
4
2
Work Clamp
Place as close to the weld as possible.
1
4
3
4
5
6
90°
10−15°
Select and prepare tungsten according to Sections 5-1 and 5-2.
5
6
10−25°
5 6
Guidelines:
The inside diameter of the gas cup should be at least three times the
tungsten diameter to provide adequate shielding gas coverage. (For
example, if tungsten is 1/16 in diameter, gas cup should be a minimum of
3/16 in diameter.
Tungsten extension is the distance the tungsten extends out gas cup of
torch.
1/16 in
The tungsten extension should be no greater than the inside diameter of
the gas cup.
3/16 in
Arc length is the distance from the tungsten to the workpiece.
Bottom View Of Gas Cup
OM-1601 Page 10
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Ref. ST-161 892
ENGLISH
6-2. Torch Movement During Welding
Tungsten Without Filler Rod
75°
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75°
Welding direction
Form pool
15°
Tilt torch
Remove rod
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
6-3. Positioning Torch Tungsten For Various Weld Joints
“T” Joint
Butt Weld And Stringer Bead
20°
90°
70°
75°
20°
10°
15°
Corner Joint
Lap Joint
20-40°
90°
75°
75°
15°
15°
30°
ST-162 003 / S-0792
OM-1601 Page 11
SECTION 7 − PARTS LIST
1
3
8
7
6
4
5
11
2
9
12
15
20
16
10
13
21
14
18
17
19
803 267
Figure 7-1. Complete Torch Assembly
OM-1601 Page 12
Model
Item
No.
Stock
No.
Model
No.
Description
DB
2612R
DB
2625R
DB
DB
26V12R 26V25R
Figure 7-1. Complete Torch Assembly
. . 1 . . . . . . 57Y02 . . . . . . . . . BACK CAP, long (consisting of) . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . 2 . . . . . ♦57Y04 . . . . . . . . . BACK CAP, button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . . . . . . . . 199 591 . . . . . . . . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . 3 . . . . . . . . 18-7 . . . . . . . . . INSULATOR, back cap . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . 4 . . . . . . . DB26 . . . . . . . . . TORCH BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 4 . . . . . . DB26V . . . . . . . . . TORCH BODY, w/valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . 5 . . . . . . . . VS1 . . . . . . . . . VALVE STEM (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . . . . . . . . 199 591 . . . . . . . . . . . . . . . . . . O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . 6 . . . . . . . 18CG . . . . . . . . . INSULATOR, cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . 7 . . . . . ♦54N01 . . . . . . . . . GAS LENS INSULATOR, medium . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . 8 . . . . . ♦54N63 . . . . . . . . . GAS LENS INSULATOR, large . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . 9 . . . . . . 10N24 . . . . . . . . . COLLET, 3/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . 9 . . . . . ♦10N21 . . . . . . . . . COLLET, .020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . 9 . . . . . ♦10N22 . . . . . . . . . COLLET, .040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . 9 . . . . . ♦10N23 . . . . . . . . . COLLET, 1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . 9 . . . . . ♦10N25 . . . . . . . . . COLLET, 1/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . 9 . . . . . ♦54N20 . . . . . . . . . COLLET, 5/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 10 . . . . . 10N32 . . . . . . . . . COLLET BODY, 3/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 10 . . . . ♦10N29 . . . . . . . . . COLLET BODY, .020 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 10 . . . . ♦10N28 . . . . . . . . . COLLET BODY, 1/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 10 . . . . ♦10N30 . . . . . . . . . COLLET BODY, .040 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 10 . . . . ♦10N31 . . . . . . . . . COLLET BODY, 1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 10 . . ♦406 488 . . . . . . . . . COLLET BODY, 5/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 11 . . . . ♦45V24 . . . . . . . . . GAS LENS, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 11 . . . . ♦45V25 . . . . . . . . . GAS LENS, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 11 . . . . ♦45V26 . . . . . . . . . GAS LENS, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 11 . . . . ♦45V27 . . . . . . . . . GAS LENS, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 11 . . . . ♦45V28 . . . . . . . . . GAS LENS, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 11 . . . . ♦45V29 . . . . . . . . . GAS LENS, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 12 . ♦45V0204 . . . . . . . . . GAS LENS, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 12 . . . ♦45V116 . . . . . . . . . GAS LENS, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 12 . . . . ♦45V64 . . . . . . . . . GAS LENS, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 12 . . . ♦995795 . . . . . . . . . GAS LENS, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 12 . . . . ♦45V63 . . . . . . . . . GAS LENS, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 13 . . . . . 10N47 . . . . . . . . . NOZZEL, #7 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 13 . . . . ♦10N44 . . . . . . . . . NOZZEL, #12 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 13 . . . . ♦10N45 . . . . . . . . . NOZZEL, #10 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 13 . . . . ♦10N46 . . . . . . . . . NOZZEL, #8 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 13 . . . . ♦10N48 . . . . . . . . . NOZZEL, #6 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 13 . . . . ♦10N49 . . . . . . . . . NOZZEL, #5 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 13 . . . . ♦10N50 . . . . . . . . . NOZZEL, #4 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 14 . . . . ♦54N14 . . . . . . . NOZZEL, alumina medium . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 14 . . . . ♦54N15 . . . . . . . NOZZEL, alumina medium . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 14 . . . . ♦54N16 . . . . . . . NOZZEL, alumina medium . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 14 . . . . ♦54N17 . . . . . . . NOZZEL, alumina medium . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 14 . . . . ♦54N18 . . . . . . . NOZZEL, alumina medium . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 14 . . . . ♦54N19 . . . . . . . NOZZEL, alumina medium . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 15 . . . . ♦57N74 . . . . . . . NOZZEL, alumina large . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 15 . . . . ♦57N75 . . . . . . . NOZZEL, alumina large . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 15 . . . . ♦53N87 . . . . . . . NOZZEL, alumina large . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 15 . . . . ♦53N88 . . . . . . . NOZZEL, alumina large . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 16 . . . . H200M . . . . . . . . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 17 . . . . 46V30R . . . . . . . . . CABLE, power 25 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . .
. 17 . . . . 46V28R . . . . . . . . . CABLE, power 12 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . 1
1
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OM-1601 Page 13
ENGLISH
Quantity
Quantity
Model
Item
No.
Stock
No.
Model
No.
Description
DB
2612R
DB
2625R
DB
DB
26V12R 26V25R
Figure 7-1. Complete Torch Assembly (continued)
. 18 . . . . ♦45V62 . . . . . . . . . ADAPTER, power cable (included in DTP kit) . . . . . . . . . . . . . . 1 . . . . . . . . . . . .
. 19 . . ♦194 724 . . . . . . . . . ADAPTER, international style (includes gas hose) . . 1 . . . . . 1 . . . . . 1 . . . . .
. 20 . . ♦198 313 . . . . . . . . . HOSE, gas side adapter international style
. . . . . . . . . . . . . . . . . . . . . . . . . . (included w/194 724) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. 21 . . ♦194 723 . . . . . . . . . ADAPTER, international style flow through . . . . . . . . . 1 . . . . . 1
. . . . . . . . . ♦AK3C . . . . . . . . . ACCESSORY KIT (included in DTP kit) . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . .
. . . . . ♦CC422HD . . . . . . . . . CABLE COVER, 22 ft (not shown) . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . .
. . . . . ♦CC410HD . . . . . . . . . CABLE COVER, 10 ft (not shown) . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . 1
. . . . . . . . ♦194738 . . . . . . . . . REGULATOR (included in DTP kit) . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . .
. . . . . . . ♦198 319 . . . . . . . . . CLAMP, ground 15ft (included in DTP kit) . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . .
. . . . . . . ♦198 317 . . . . . . . . . HOSE, gas 12 ft (included in DTP kit) . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . .
. . . . . . . ♦198 316 . . . . . . . . . HOSE, gas 3 ft (included in DTP kit) . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . .
♦OPTIONAL
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1601 Page 14
1
1
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1
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
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.
*
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 the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
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’s True Blue Limited Warranty shall not apply to:
1.
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 date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
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.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
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_warr 1/05
ENGLISH
Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
www.MillerWelds.com
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2005 Miller Electric Mfg. Co.
1/05
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