Miller | JJ23 | Owner Manual | Miller MTT-812HR User manual

Miller MTT-812HR User manual
March 1988
FORM: OM-1 558
Effective With Style No. JJ-23
Millerfi
MODEL
MU-812HR
MTF-825H R
MTr-912HF
MU-925 H F
MTI-912VHF
MU-925VH F
FilL! COpy
RETURN TO FOLDER
OWNERS
IMPORTANT
MANUAL
Read and understand the entire contents of both this
manual and the power source manual used with this unit, with special
emphasis on the safety material throughout both manuals, before in-
maintaining this equipment. This unit and these
instructions are for use only by persons trained and experienced in the
safe operation of welding equipment. Do not allow untrained persons to
stalling, operating,
install, operate,
not
fully
PRINTED IN U.S.A.
or
or
Miller Electric
Mfg.Co.
AMe~G~u~tr~1 CornQ~n~
p.o. Box 1079
Appleton, WI 54912 USA
Tel. 414-734-9821
maintain this unit. Contact your distributor if you do
understand these instructions.
ADDITONAL COPY PRICE 30 CENTS
t,
LIMITED WARRANTY
EFFECTIVE: FEBRUARY 16. 1988
supersedes all previous MILLER warranties and is exclusive with
This warranty
other guarantees
no
or
warranties
expressed
or
implied.
LIMITED WARRANTY
Subject to the terms and conditions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin
warrants to its Distributor/Dealer that all new end unused
In the case of Millers breach of warranty or any other duty
with respect to the quality of any goods, the exdusive remedies
therefore shall be, at Millers option (1) repair or (2) replacement
Equipment furnished by Miller is free from defect in workmanship and material as of the time and place of delivery by Miller.
No warranty is made by Miller with respect to engines, trade
accessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, if any
All
engines are warranted by their manufacturer for one year from
date of original purchase, except Tecumseh engines which
or, where authorized in
-
have
a
two year
warranty.
the reasonable cost of
writing by Miller in appropriate cases, (3)
repair or replacement at an authorized
Miller service station
(4) payment of
defect
Except
as
specified below, Millers warranty does
apply
not
or
or
credit for the purchase
price (less reasonable depreciation based upon actual-use) upon
risk and expense. MILLERs
return of the goods at Customers
option of repair or replacement will be F.O.B., Factory, at
Appleton, Wisconsin, or F.O.B., at a MILLER authorized sennce
facility, therefore, no compensation for transportation costs of
any kind will be allowed. Upon receipt of notice of apparent
failure, Miller shall instruct the claimant
or
on
the warranty
claim procedures to be followed.
components having normal useful life of less than one (1)
as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
nozzles and nozzle insulators where failure does
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA
to
year, such
wire
~
not
including
result from defect in
~
~j~
ranted
9
within the
or
lION
material.
Miller shall be required to honor warranty claims on warEquipment in the event of failure resulting from a defect
ment to
j~
workmanship
following periods
the original user:
from the date of
1. Arc waldera, power sources,
delivery
of
robots, and components
2. Loadbanks
j
3.
Equip-
1 year
.
Original
main power rectifiers
1 year only)
(labor
4. All welding guns, feeder/guns and torches
3 years
~
~4J
!~
(1
provided
or
days
1 year
repair parts, exclusive of labor
..
60
days
6 months
that Miller is notified in
writing
within
thirty (30) days
of the date of such failure.
As a matter of general policy only, Miller may honor claims
submitted by the original user within the foregoing periods.
.
.-
.-
EXPRESSLY PROVIDED BY MILLER IN
PRODUCTS ARE INTENDED FOR
MILLER
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
MAINTENANCE OF
EXPERIENCED
IN THE USE AND
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLERS WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
MILLERS WARRANTIES TO, ANY CONSUMER.
EXCEPT
90
5. All other Millermatic Feeders
6. Replacement
7. Batteries
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPUED WARRANTY OF MERCHANTABIUTY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
CLUDEO AND DISCLAIMED BY MILLER.
lyear
-
]
~
~
AS TO PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
AS
WRITING,
-
~...
.
.
-
SECTION 1
-
SAFETY RULES
UNSAFE PROCEDURES OR PRACpersonal injury or death.
Read, understand, and follow ALL of these safety
PROTECT EYES AND SKIN FROM ARC
RAYS; PROTECT EARS FROM NOISE
WARNING
1 -3.
_________
TICES can cause serious
ru/es before
installing, operating,
or
Arc rays from the welding process produce intense heat
and strong ultraviolet rays that can burn eyes and skin.
Noise from some processes can damage hearing.
servicing this,
equipment.
Be
sure
that all end
users
equipment, the
of this
operator and helpers, read and understand these
safety rules.
1
-
a welding helmet fitted with a proper filter
lens (see ANSI Z49.1 for detailed information).
a.
Wear
b.
Use
-
1. PREVENT ELECTRIC SHOCK
a.
Do not touch live electrical parts,
b.
Do not work in wet
c.
Wear dry
or
damp
protective
screens
others from flash and
Touching live electrical parts can cause severe burns to
the body or fatal shock. Severity of e!ectrical shock is
determined by the path and amount of current through
the body. Therefore:
1
areas.
insulating gloves and body protection.
glare.
protective clothing and foot protection.
c.
Wear
d.
Always
work
barriers to protect
or
wear
safety glasses
or
safety goggles in
4. PREVENT FIRES AND BURNS
-
The hot
workpiece, hot equipment, other
arc sparks can cause fires and
spatter, and
d.
Disconnect all power before
ing this equipment.
equipment when
installing
or
Turn off all
f.
Properly install and ground the welding
Manual
source according to its Owners
applicable codes.
Do not use worn
that are too small
hot metal,
burns.
servic
a.
Wear correct eye, face, and body
the work area.
b.
Allow work and
protection
in
not in use.
e.
g.
a
area.
or
damaged cables
or
poorly spliced.
or
equipment
to
cool before harodl
ing.
power
and all
cables
c.
Do not weld
d.
Watch for fire, and keep
near
combustible material.
a
fire
extinguisher
near
by.
-
h.
i.
j.
Do not wrap cables around your body.
Do not touch electrode and any
or circuit at the same time.
grounded object
For additional information, refer to NFPA Stan
dard 51 B, Fire Prevention in Use of Cutting and
Welding Processes, available from the National
Fire Protec~tion Association, Batterymarch Park,
Quincy, MA 02269.
Use only well-maintained equipment.
replace damaged parts
e.
Repair
or
at once.
1 -5. PROTECT COMPRESSED GAS CYLINDERS
PROVIDE
1 -2.
AND GASES
PROTECTION
Breathing welding fumes and
FROM
FUMES
Since gas cylinders are normally part of the welding pro
cess, be sure to treat them carefully.
gases
be hazardous
can
to your health.
a.
Protect
compressed
gas
cylinders from excessive
heat, mechanical shocks, and
a.
Keep your head out of the fumes.
b.
Use
adequate ventilation in the
keep
fumes and gases from your
general work area.
work
area
breathing
arcs.
b.
Install and secure cylinders so that they cannot
fall or tip over by fastening them to a mounting
bracket, wall, or other stationary support.
C.
Keep cylinders away from
to
zone
and the
If ventilation is inadequate,
breathing device.
d.
Read the Material Safety Data Sheets (MSDSs)
instructions for any
and the manufacturers
materials used.
use
an
any
welding
or
other
electrical circuits.
approved
c.
d.
Never allow
a
welding
electrode to touch any
cylinder.
OM-15513
Page
1
1 -6.
PROVIDE
SITUATIONS
PROTECTION
FOR
SPECIAL
Do not weld or cut containers or materials which
have held or been in contact with hazardous
substances unless they are properly cleaned and
a.
inspected.
b.
Do not weld or cut painted or plated parts unless
special ventilation is provided to remove highly
toxic fumes
gases.
or
1 -8. ADDITIONAL SAFETY INFORMATION
For
more
and
operating electric welding and cutting equipment
on good working habits, ask your welding equip
and
information
on
safe practices for
setting up
ment supplier. The following publications, which are
available from the American Welding Society, 550
N.W. LeJuene Rd., Miami, FL 33126, are recommend
ed to you:
a.
Safety
in
Welding and Cutting
-
AWS Z49.1
(ANSI)
Since
c.
welding
pacemaker
affect pacemakers, keep all
of the work area. Have
doctor before coming near a
can
wearers out
them consult
a
b.
Recommended Safe Practices for Gas-Shielded
AWS A6.1
Arc Welding
-
welding operation.
c.
1 -7.
PROVIDE
MAINTENANCE
PROPER
EQUIPMENT
-
Improperly maintained equipment can result in poor
work, but most importantly it can cause physical injury
or
through fires
death
a.
or
NFPA Standard 51 B, Fire Prevention in Use of
Cutting and Welding Processes, available from
the National Fire Protection Association, Bat
terymarch Park, Quincy, MA 02269.
e.
NFPA Standard 70, National Electrical Code,
available from the National Fire Protection
Association, Batterymarch Park, Quincy, MA
02269.
f.
ANSI Standard Z87.1, Safe Practice for Oc
cupation and Educational Eye and Face Protec
tion, available from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
g.
OSHA Standard 29 CFR, Part 1910, Subpart Q,
Welding, Cutting, and Brazing, available from
the Superintendent of Documents, U.S. Govern
ment Printing Office, Washington, DC 20402.
h.
CSA Standard Wi 17.2, Code
for Safety in
Welding and Cutting, available from the Cana
dian Standards Association, 178 Rexdale Blvd.,
Rexdale, Ontario, Canada M9W 1 R3.
Always have qualified personnel perform the in
stallation, troubleshooting, and maintenance
Before
performing
any maintenance work inside
supply, disconnect the
a
power
form the electrical power
c.
d.
electrical shock. Therefore:
work. Do not perform any electrical work unless
you are fully qualified.
b.
power
supply
source.
Maintain cables, grounding wire, connections,
power cord, and power supply in safe working
order. Do not operate any equipment in ques
tionable condition.
d.
Do not abuse any
accessories.
Keep equipment away from heat sources such as
furnaces, wet conditions such as water puddles,
oil
or
equipment
or
grease, corrosive atmospheres, and incle
ment weather.
e.
Keep all safety devices, guards, panels,
covers in position and in good repair.
f.
Use
OM-1 558
equipment for its intended
modify it in any manner.
Page
2
Recommended Safe Practices for the Prepara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances
AWS F4.1
and
purpose. Do not
i.
See also the Standards Booklet Index in the
power source Owners Manual.
welding
SECTION 2- INTRODUCTION
Ampere Rating
at
Tungsten
100% Duty Cycle
Size
Cable
Torch
Cooling
DCEN; ACHF
Capacity
Length
Body
Method
12.5 ft.
Length:
(3.8 m)
8.1 in. (206.0 mm)
Handle Diameter:
0.75 in. (19.0 mm)
80 Amperes
With
Argon*
HR
.020 thru
25 ft.
(7.6 m)
HF
3/32 in.
(0.5 thru
2.4 mm)
VHF
2 lbs.
3 lbs.
(1.1 kg)
4.5 lbs.
5.0 lbs.
(2.3 kg)
Weight:
3.0
-
1.
operated
at rated load con-
stated/n Figure 2-1.
carefully followed could result in serious personal injury
loss of life.
or
t~..~IlJi1
General
Information
presented in this manual
and
on
various
labels, tags, and plates on the unit pertains to equipmont design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective
use
of this
equip-
ment.
B.
Safety
installation,
damage
A third
to this
procedures
or
equipment.
signal word,
IMPORTANT
,
highlights instruc
tions which need special emphasis to obtain the most
efficient operation of this equipment.
Before installing
HANDLING
2-3. RECEIVING
this equipment, clean all packing material from around
the unit, and carefully inspect for any damage that may
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill of
lading will be furnished by the manufacturer on request
if occasion to file claim arises.
requesting information concerning this equipment, it is essential that Model Description and Style
Numbers of the equipment be supplied. The style
number is located on a label under the torch handle.
When
This torch is specifically for
4. DESCRIPTION
with the Gas Tungsten Arc Welding (GTAW) process. The alphanumeric model designation refers to the
following:
M
T
the end of Section 1
8
9
Safety Rules.
-
-
use
persons in accordance with this manual and all applicable codes such as, but not limited to, those listed at
-
installation, operation,
practices which if not
carefully followed could result in minor personal injury
2
operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated, and maintained only by qualified
The
statements include
and maintenance
-
2. GENERAL INFORMATION AND SAFETY
A.
(2.0 kg)
(85.0 9)
Specifications
or
RATED
TH E
EXCEEDING
AMPERAGE and duty cycle can result in damage
to the torch.
Do not exceed rated amperage and duty cycle
-
oz.
Body
ditions continuously,
2
5.0 lbs.
(2.3 kg)
(0.9 kg)
-
be
4.5 lbs.
(2.0 kg)
Length:
The duty cycle of a welding
1. DUTY CYCLE
2
torch is the percentage of a ten minute period that a
torch can be operated at a given load. This torch is rated
at 100% duty cycle using argon shielding gas. This
can
T
Miller
-
-
-
-
-
TIG/GTAW
Torch
Ampere Rating: 80 Amperes
Ampere Rating: 90 Amperes
Safety instructions specifically pertaining to this unit appear throughout this manual hiqhliqhted by the signal
words WARNING and CAUTION which dentify
12- 12.5 ft. (3.8 m) Cable
25 ft. (7.6m) Cable
25
H
High Flex Cable (1 piece assembly)
different levels of hazard.
R
WARNING
statements include
and maintenance
procedures
2.5 lbs.
8.0 in. (203.0 mm)
Handle Diamter:
Figure 2
that the torch
(1.1 kg)
0.75 in. (19.0 mm)
VHF
-
(57.0 g}
2 lbs.
(0.9 kg)
(3.8 m)
25 ft.
(7.6 m)
*Rated With Gas Lens Collet
oz.
Ship
Air
Argon*
HF
means
Weight:
2.0
Net
12.5 ft.
90 Amperes
With
Wei g t
or
installation, operation,
practices which if not
-
-
F
V
-
-
-
Rigid Head
Flexible Head
Gas Valve
OM-1658
Page3
SECTION 3
-
INSTALLATION
Gas
Collet
Body
Handle
Tungsten
EloctrodeZZ.~~~
>
Power Cable
Figure 3
-
1. Torch
Do not touch live electrical parts.
Shut down welding power source and disconnect
employing lockout/tagging pro
cedures before installing torch.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
3
-
power
1. TORCH BODY
CAUTION
(Figure 3-1)
BENDING
TORCH
HEAD
of
80
________
Ampere Models
damage torch.
rigid torch head of
can
Do not bend
80
Ampere
Models.
Warranty is void if rigid torch head is
bent in any
man
ner.
The torch body is shipped requiring consumables and
accessories indicated in Figure 3-1: cup, collet body,
collet, power cable adapter, and tungsten electrode.
Assemble torch
as
sion
A.
2.
Install collet body and collet into torch body
making sure heat shield is in place.
3.
Install
properly prepared tungsten electrode (see
Section 5-4) into collet body and position elec
trode tip. Tighten collet body.
Install cup onto collet body.
remove
high flex cable contains the power cable within the
hose.
The high flex cable has a 3/8-24 female rightgas
hand fitting (Figure 3-1).
cable,
high
to power
cable adapter.
connect
high
flex cable
fitting
If torch includes a gas valve, connect a suitable length
of gas hose (extra hose not supplied) from power cable
adapter
to
regulator/flowmeter (Figure 3-2).
If torch is without gas valve, connect a suitable length
of gas hose (extra hose not supplied) from power cable
adapter to gas valve outlet. Connect an extra hose (not
supplied) from
(Figure 3-3).
gas valve inlet to
Torch Gas Valve
regulator/flowmeter
Operation (If applicable)
The gas valve allows gas flow control at the torch. A
one-half turn counterclockwise opens the gas valve,
and a one-half turn clockwise closes the valve.
The gas valve allows control of gas postflow time, or
the length of time gas flows after the arc is extinguish
ed. Insufficient gas postflow results in an oxidized
(black) electrode surface. If an oxidized electrode were
used, the black surface would contaminate the weld
cause
poor
arc
IMPORTANT As
direction.
a
general rule,
postflow time per 100
before closing vav/e.
gas
OM-1 558 Page 4
flex
To install
and
cup and loosen
Gas Hose and Connection
The
B.
Install collet, slotted end last, into collet body.
To readust electrode,
collet body.
a general rule, electrode extension
equal electrode diameter; exact electrode exten
may vary according to application.
should
follows:
1.
4.
Components
II ~i psi . i.~ ~I ~ As
I~YI1~II~c~ ELECTRIC SHOCK can kill.
input
Ref. TA-120 671
Adapter
Requlred Consumables and Accessories.
ceobtain from Welding Equipment Supplier.
allow 10 seconds
amperes of weld current
Torch
Flowmeter
Valve
Work
Clamp
Gas
Cylinder
Ref. TA-120 909
Figure 3
-
2. GTAW Torch Connection Diagram For Models With Gas Valve
Torch
Work
Clamp
Gas
Cylinder
Ref. TA-120 909
Figure 3
3
-
-
3. GTAW Torch Connection Diagrams For Models Without Gas Valve
3. POWER CABLE CONNECTION
(Figures 3-2
and 3-3)
WARNING
ELECTRIC SHOCK
can
high flex cable assembly contains the power cable
within the gas hose. The high flex cable has a 3/8-24
female right-hand fitting (Figure 3-1).
The
kill.
__________
Do not touch live electrical parts.
Shut down welding power source and disconnect
input power employing lockout/tagging pro
cedures before installing torch.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
high flex cable, connect high flex cable fitting
power cable adapter (see Section 3-2A). Connect
power cable adapter to weld output terminal (Figures
To install
to
3-2 and 3-3).
OM.1558 Page 5
SECTION 4
ELECTRIC SHOCK
WARNING
can
-
SEQUENCE OF OPERATION
kill.
regulator/flowmeter valve closed,
cylinder valve.
3.
With
4.
Set power
5.
Wear
_________
Do not touch five electrical parts.
Keep all covers and handle in
place
open gas
while
operating.
ARC RAYS, SPARKS, AND HOT SURFACES can
burn eyes and skin; NOISE can damage hearing.
source
welding
for desired
amperage.
dry insulating clothing and gloves and
welding helmet with proper filter lens according
Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm your
health.
to ANSI Z49.1.
Ventilate to keep from breathing fumes and gases.
ventilation is inadequate,
use
approved
6.
Energize welding
breathing apparatus.
HOT METAL, SPATTER, AND SLAG can cause fire
and burns.
.
Watch for fire.
.
Have a fire ext/n quisher nearby, and know how to
7.
Set gas flow to desired level
power
source.
If
use.
Allow work and
equipment
to
(requires
open gas
valve).
Purge gas hose to clear hose of air,
contaminants. Allow gas to flow
other
moisture, or any
2 to 3 minutes on new torch; 5 to 6 seconds thereafter.
I I~ I ~i . V-i~I ~
cool before handl
ing.
Begin welding.
8.
MAGNETIC FIELDS FROM HIGH CURRENTS
affect pacemaker operation.
can
4 -2. SHUTTING DOWN
Wearers should consult with their doctor before
going near
operations.
See Section 1
mation.
4
-
arc
welding, gouging,
spot welding
or
Safety Rules for additional safety infor
~ As
1.
Install and connect torch
2.
Make sure backcap and all gas connections
securely tightened.
according
to Section 3.
are
2.
Turn off
3.
Turn off the
L~~U~E
Shut down
-
-
SURFACES
ELECTRIC
SHOCK
can cause severe
can
kill;
on
OF
supply when
not in use.
-
welding
power
source
before working
week
a
Inspect
condition of torch
body
com
ponents.
working
Replace
torch
CONCENTRATION
or kill.
harm health
Disconnect torch from we/ding power source
before inspecting, maintaining, or servicing.
Allow a cooling period before servicing.
Once
torch.
from
welding power source
before inspecting, maintaining, or servicing.
Allow a cooling period before servicing.
Disconnect
can
gas.
HOT
burns.
Do not touch five electrical parts.
Shut down welding power source before
shielding
source.
torch.
on
week.
ITIJ:h~II~e~
allow 10 seconds of
MAINTENANCE
AND
UPKEEP
1. INSPECTION
Usage and
shop conditions will determine frequency and type of
maintenance required. Perform inspections once a
5
power
HIGH
Shut off gas
-
genera/rule,
welding
SHIELDING GAS
SECTION 5
a
gas postf/ow time per 100 amperes of weld current
before closing valve.
1. GAS TUNGSTEN ARC WELDING (GTAW)
-
Stop welding.
1.
ed.
cup, heat
shield, backcap, and 0-rings if crack
Maintain
good weld
tight
quality.
fit of torch components to
ensure
5 -3.
1.
Inspect torch for broken areas, cracks and loose
parts; tighten, repair and replace as required.
2.
Remove
INSPECTING HOSES, CONNECTIONS AND
CABLES
I!iTh~a~Il~Ief ELECTRIC SHOCK
greaseand dirtfrom components,
and
moisture from electrical parts and cables.
input
5 -2. TORCH
BODY MAINTENANCE (Figure 3-1)
can
kill.
Do not touch live electrical parts.
Shut down welding power source and disconnect
power
cedures
employing lockout/tagging pro
inspecting, maintaining, or ser
before
vicing.
IaTLtlilI~e~
SURFACES
ELECTRIC
SHOCK
can cause severe
can
burns.
Do not touch live electrical parts.
OM-1 558
Page
6
kill;
HOT
consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
Lockout/tagging procedures
Table 5
Tungsten
Size Chart
Amperage Range
Electrode Diameter
~
Polarity
-
Gas Type
Electrode Positive/
Electrode
(Green Band)
-
DC-Argon
DC-Argon
Negative/
Tungsten
Pure
1.
-
Straight Polarity
Reverse Polarity
5-20
15-80
70-150
125-225
*
.020
.040
1/16
3/32
AC-Argon
Using High
Frequency
5-20
10-60
50-100
100-160
10-20
15-30
2% Thorium
Alloyed Tungsten
(Red Band)
.020
15-40
*
15-35
.040
1/16
3/32
25-85
50-160
135-235
*
20-80
10-20
15-30
50-150
130-250
.020
*
*
15-35
.040
*
*
1/16
*
*
20-80
50-150
3/32
*
~
Zirconium Alloyed
Tungsten
(Brown Band)
*NOT RECOMMENDED
are intended
The figures
Welding Society (AWS)
Once
A.
a
week
as a
guide and
are a
composite of recommendations from American
and electrode manufacturers.
grinding wheels, causing the tungsten to be chip
ped away rather than cut away, the grinding marks
should run lengthwise with the electrode.
inspect hoses and connections.
most
Gas Hose
Gas leaks may result in poor weld quality. Inspect hoses
for breaks. Keep connections clean and tight.
For additional
quest
Arc
B.
130-250
a
information,
see
handbook from factory
Welding (GTAW)
your distributor or re
on the Gas Tungsten
process.
Power Cable
Inspect cables for breaks in insulation, and ensure that
all connections are clean and tight. Repair or replace
cables if insulation breaks are present. Clean and
tighten connections at each inspection.
TUNGSTEN PREPARATION: IDEAL
--
Straight Ground
5
-
TUNGSTEN
4. PREPARING
ELECTRODES
Flat (the DIa. of this
Flat Governs
(Figure 5-1)
HOT FLYING METAL PARTICLES can
injure personnel, start fires, and damage equip
ment; TUNGSTEN CONTAMINATION can lower
weld quality.
Shape tungsten electrode only with properly
CAUTION
Amperage CapacIty)
_________
guarded grinder
in
a
safe location
wearing
TUNGSTEN PREPARATION: WRONG
Arc Wander
proper
face, hand, and body protection.
Do not
use same
wheel for any other
job
or
the
tungsten will become contaminated.
Tungsten electrode shaping should be done on a fine
grit, hard abrasive wheel. Since tungsten is harder than
Point
~
~
RadIal Ground
Figure 5
TA-120 630
-
1.
Tungsten PreparatIon
OM-1558Page7
Quantity
Model
Item
No.
Miller
Stock No.
Figure
Miller
Model No.
HR
Description
1
TUNGSTEN, electrode (consult your welding distributor)
CUP (see
3
4
5
6
6
7
8
9
9
10
11
11
12
13
120
116
116
116
116
116
117
118
t116
116
116
120
120
VHR
1
1
Complete Torch Assembly
A
2
6
HF
602
8OTHS
540
557
556
255
100VK
100R
254
1
HANDLE
1
1
1
1
.
1
.
585
516
572
550
551
720
Figure B)
COLLET BODY (see Figure B)
COLLET (see Figure B)
HEAT SHIELD
TORCHBODY
TORCHBODY
TORCH BODY, with valve (consisting of)
VALVE KNOB (consisting of)
.0-RING
1
HANDLE, model w/valve
1PCA
112PCW
125PCW
723
1
POWER CABLE ADAPTER
HI-FLEXPOWER CABLE, 12-1 /2ft (consisting of)
HI-FLEX POWER CABLE, 25ft (consisting of)
.RINGNUT
POWER CABLE NUT
1
.
1
1
1
1
1
2
2
2
2
6.
4
3
7
2
.9
>
~.
I
10
11
TA-120 671
Figure
A
-
Complete
Torch
Assembly
tOptional Equipment
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1558Page8
Orif ce
1/4
Cup
5/16
10-235 150-250 8CG3 2 234120 2GL3 2 1 9 0
1/16 (1.6) 50-150 70-150 8CG1 233120 2GL1 1 98 9
.040 (1.0) 10-80 15-80 8CG40 232120 2GL40 1 98
.020 (0.5) 5-20 5-20 8CG20 231120 2GL20 1 98 7
3/8
7/16
3/32 (2.4)
16
Len. Body Sepia,
Col et
shield 887
C0I .t Sari.
Ga.
8GHS Stock
Ga. 2GL
heat 119
No.
Len,
U..
8CG
in
Body Sari.
Standr Colet BCB
SELCTOR
PARTS
CONSUMABLE
Diametr
Tungsten
No.
80THS Stock
Standr Colet Series
Us.
8C
Model Stock Model Stock
REF NCE
L5to~1M0de1 Li~
Lens Cup
Col et Col et
For
1/4
Cup
5/16
3/8
10 -235 150-250 8C3 2 1 9416 8CB3 2 1 98 6
1/16 (1.6) 50-150 70-150 8C1 6 1 9417 8CB1 6 1 98 5
Cable .040 (1.0) 10-80 15-80 8C40 1 9418 8CB40 1 98 4
Power
(0.5) 5-20 5-20 8C20 1 9419 8CB20 1 98 3
and .02
Cup
Gee
Gas
1/4
3/8
Body.
Coliet
Col et.
Note:
3/32 (2.4)
in
(m ) ACHF DCSP
Diametr
Range
Tungsten Amperag ColIet(Sandr)
(Standr)
Body
Col et
Alumina
NO.
24GLC32
53N62 53N63 53N64 45V41 45V42 45V43 45V4 53N58 53N59 53N60 53N61
NO.
C
O
M
P
E
T
I
V
1985(2AG6) 1986(2AG7) MILER 12031 1203 1987 1989 190 1983 1984 1985 1986
STOCK
MIL ER MODEL 8CG20 8CG40 8CG1 6 8CG3 2 2GL20 2GL40 2GL1 6 2GL3 2 2AG4 2AG5 2AG6 2AG7
CROS
NO.
Chart
232 234 898
120
120
119
Refrnce
Long ~
1
Cros
Indicate Usage
Parts
Shade Recom nd
Consumable
Areas
-
B
TO
~
No. No.
ModelNo. StockN. ModelNo. Stock
893 894
119
Lens) (Gas
(Gas Body
to
required
Adapter
(2AG4) )2AG5)
CMODEL OMPETIV
and
Orif ce
complet
Lens)
AmperagRn
TO
No. No. No. No. No.
shield 602
heat 120
torch.
(m ) ACHF DCSP
16
Stock/Mdel 1940(8C)
Cup Long
(8C5) (8C6)
(8C4L) (8C6L)
409 408 421 420
119 119 119 119
~
Cup Long
Ceramic 5/8 ~ Ceramic 1/8
1
REF NC
CROS
)
CMODEL OMPETIV
COMPETIV
NO.
Figure
53N15 53N16 53N14 24C3 2 53N17 53N18 53N19 24CB3 2 53N23 53N24 53N25 53N27 53N28 53N26
NO.
MIL ER MODEL 8C20 8C40 8C1 6 8C3 2 8CB20 8CB40 8CB1 6 8CB3 2 8C1 8C4 8C5 8C6 8C4L 8C6L
NO.
MIL ER STOCK 1 9419 1 9418 1 9417 1 9416 1 98 3 1 98 4 1 98 5 1 98 6 1 941 1 9410 1 9409 1 9408 1 9421 1 9420
0
01 01
-~
CD
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