Miller AFT-100 FLUX TANK Owner's manual

Miller
Brand
Miller
Model
AFT-100 FLUX TANK
Category
Welding System
Type
Owner's manual

This manual is also suitable for

June
1982
FORM:
OM-1542
Effective
With
Style
No.
JB-41
MODEL
GA-6OCF
Gun
AFT-100
Flux
Tank
FT-i
Cart
ITIPIIER
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
40
CENTS
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
OWNERS
MANUAL
î‚‘L~
î‚‘L-
~..
~
î‚‘Lî‚’~
~
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
(î‚‘
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Millerî‚’s
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millerî‚’s
option
(1)
repair
or
121
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
13)
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(41
payment
of
or
credit
for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
Iless
reasonable
depreciation
based
upon
actual
usel
upon
date
of
original
purchase.
return
of
the
goods
at
Customerî‚’s
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
~
Except
as
specified
below,
Millerî‚’s
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
k~
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
(
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
.
.
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
(labor
-
1
year
onlyl
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
î‚•1
4.
All
otherMillermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
6.
Batteries
6months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERî‚’
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
MILLERî‚’S
WARRANTIES
TO.
ANY
CONSUMER.
,~,
J~
,î‚‘,
:?t.
...~
j~
~t,
j~
~t,
~
ERRATA
SHEET
March
21,
1984
FORM:
OM-1542
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
-
Item
Part
Replaced
With
Description
Quantity
No.
No.
9
083611
094703
GUIDE,wire(Effw/JE-12)
1
10
083 588
094
705
094
698
INSERT,
nozzle-extension
(Effw/JE-12)
RING,
retaining
(added
to083697)(Effw/JE-12)
1
1
12
082313
094702
GUIDE,wire(Effw/JE-12)
1
14
082
312
094
704
094
698
INSERT,
nozzle-extension
(Effw/JE-12)
RING,
retaining
(added
to
083322)(Eff
w/JE-12)
1
1
39
049 319
Deleted
42
081
580
094
554
LINER,
monocoil
1/16-3/32
wire
x
lift
6
in
(Eff
w/JE-1
2)
1
42
081
581
094
555
LINER,
monocoil
1/16-3/32
wire
x
16
ft
8
in
(Eff
w/JE-1
2)
1
44
049
318
Deleted
48
082
750
094
701
ADAPTER,
hose-flux
(Effw/JE-12)
1
50
094699
091
062
602
178
TUBING,
5/16
lDxi/i6walIx4(Effw/JE-12)
STRAIN
RELIEF,
cable
SCREW,
set-socket
hd
1/4-20
x
1/2
(Part
of
082
544)
1
1
1
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
SECITON
1
-
INTRODUCTION
GUN
Rating
100%
Duty
Cycle
Wire
Diameter
Capacity
Cable
And
Hose
Length
Cooling
Method
I
î‚•
Weight
Net
Ship
600
Amperes
1/16
in.
(1.6
mm)
through
3/32
in.
(2.4
mm)
10
ft.
(3.05
m)
15
ft.
(4.57
m)
Air
12
lbs.
(5.44
kg)
13
lbs.
(5.89
kg)
17
lbs.
(7.71
kg)
18
lbs.
(8.16
kg)
TANK
Air
Requirements
Capacity
Dimensions
Weight*
Net
Ship
Pressure:
60
to
120
pounds
per
square
inch
(414
to
827
kilopascals)
100
lbs.
(45.4
kg)
Height
-
37-1
/2
in.
(953
mm)
Diameter
-
16
in.
(407
mm)
107
lbs.
(48.5
kg)
124
lbs.
(56.2
kg)
*lncludes
3-1
/4
lbs.
(1
.47
kg)
for
supplied
funnel.
CART
(OptionaP)
Weight
Dimensions
Net
I
Ship
Height
-
34-1/2
in.
(876
mm)
91
lbs.
98
lbs.
Width
-
24-1/4
in.
(616
mm)
Length
-65
in.
(1651
mm)
(41.3
kg)
(44.5
kg)
Figure
1-1.
Specifications
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
B.
Safety
WARNING
CAUTION
and
Information
presented
in
this
manual
and
on
various
labels,
tags,
and
plates
on
the
units
pertains
to
equip-
-
-
ment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
the
this
equip-
-
-
ment.
The
installation,
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
persons
in
accordance
with
this
manual
and
all
ap
plicable
codes
such
as,
but
not
limited
to,
those
listed
at
WARNING
CAUTION
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
in
the
welding
power
source
Ownerî‚’s
Manual.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
____________
___________
which
identify
different
levels
of
hazard.
____________statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed could
result
in
serious
personal
injury
or
loss
of
life.
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
minor
personal
injury
or
damage
to
this
equipment.
OM-1
542
Page
1
IMPORTANT
A
third
signal
word,
,
highlights
instruc
tions
which
need
special
emphasis
to
obtain
the
most
efficient
operation
of
this
equipment.
1-2.
RECEIVING-HANDLING
-
Prior
to
installing
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
re
quest
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Style
Number
of
the
equipment
be
supplied.
The
alpha-numeric
designations
of
the
components
are
explained
as
follows:
Gun
G
=
Gun
A
=
Air-Cooled
60
=
Ampere
Rating:
600
Amperes
C
=
Curved
Head
Tube
F
=
Flux
(For
Flux
Use)
The
gun
is
equipped
with
a
trigger
lock
for
operator
comfort
during
long
welds.
The
gun
trigger
is
dual
pur
pose
-
it
controls
flux
flow
and
energizes
the
wire
feeder.
Tank
Y
1-3.
DESCRIPTION
-
The
pressurized
flux
delivery
system
is
designed
for
use
with
the
semiautomatic
Submerged
Arc
Welding
(SAW)
process
and
includes
two
pieces
of
equipment:
A
GA-6OCF
gun
and
an
AFT-100
flux
tank.
An
optional
FT-i
cart
is
available
to
make
the
system
portable.
A
wire
feeder
and
constant
potential
welding
power
source
are
required
to
com
plete
the
package.
AFT-iOO
=
Air-Operated
Flux
Tank
With
100
lbs.
(45.4
kg)
Flux
Capacity
Cart
(Optional)
FT-i
=
Flux
Tank
Model
1
Cart
SECTION
2
-
INSTALLATION
2-1.
CART
ASSEMBLY
AND
COMPONENT
IN
STALLATION
(Figure
2-1)
-
Assemble
cart,
if
ap
plicable,
as
shown
in
Figure
2-1.
Be
sure
all
bolts,
nuts,
etc.,
are
tightened
securely.
Install
flux
tank
onto
cart,
if
applicable,
as
shown
in
Figure
2-1.
Tighten
all
mounting
hardware
securely.
If
applicable,
install
wire
feeder
onto
cart
as
shown
in
Figure
2-1.
Tighten
bolts
securely.
the
unit
can
be
lifted
with
a
hoist
or
overhead
crane
us
ing
the
provided
lifting
bail
on
cart
(see
Figure
2-1).
CAUTION
________
IMPROPER
LIFTING
OF
EQUIPMENT
can
result
in
personal
injury
and
equipment
damage.
î‚•
Use
equipment
of
adequate
capacity
to
lift
the
unit.
Lifting
eyes
are
provided
on
the
sides
of
the
tank
for
handling
purposes
when
the
tank
is
not
installed
on
a
TC-084
388-A
Once
the
cart
is
assembled
and
components
installed,
cart.
Figure
2-1.
Assembly
And
Installation
Page
2
2-2.
FLUX
TANK
CONNECTIONS
AND
INFORMA
TION
(Figure
2-2)
Air
Air
Dryer
With
Line
Ref:
TC-084
:388-A
Connect
gun
flux
hose
to
tank
fitting,
and
secure
with
supplied
hose
clamp
(see
Figures
2-2
and
2-3).
Connect
air
supply
to
air
hose
fitting
(see
Figure
2-2).
This
fitting
will
accept
standard
air
hose
connectors.
For
normal
welding
conditions,
open
air
valve
and
ad
just
the
regulator
for
30
pounds
per
square
inch
(207
kilopascals)
of
air
pressure.
If
necessary,
readjust
air
pressure
for
different
welding
conditions.
If
the
flux
is
pushed
up
and
over
a
boom,
or
the
hoses
are
extended,
the
pressure
will
also
have
to
be
increased.
WARNING
EXPOSED
ARC
RAYS
can
burn
eyes
and
skin.
î‚•
Do
not
allow
flux
flow
to
stop
while
welding.
î‚•
Do
not
use
wet
or
damp
flux.
î‚•
Do
not
restrict
flux
feed
hose.
î‚•
Ensure
continuous
air
supply
to
flux
system.
î‚•
Keep
foreign
material
out
of
flux
system.
î‚•
Use
reclaimed
flux
only
which
has
been
sifted
through
.062
inch
(1.57
mm)
mesh.
Do
not
allow
flux
flow
to
stop
while
welding
to
avoid
be
ing
exposed
to
a
bare
arc.
The
arc
must
be
covered
at
all
times
to
prevent
arc
flashing.
WARNING
FLYING
FLUX
PARTICLES
can
punc
ture
eyes
and
skin.
î‚•
Wear
proper
eye,
hand,
and
body
protection.
î‚•
Close
air
line
valve
and
bleed
pressure
from
tank
before
disconnecting
air
supply
or
opening
top
or
bottom
cover(s).
î‚•
After
connecting
air
supply,
open
air
line
valve
to
energize
tank.
IMPORTANT:
Consult
the
flux
manufacturer
for
the
proper
ratio
of
new
to
recycled
flux.
To
bleed
air
pressure
from
tank,
pult
out
and
hold
safety
valve
bleeder
handle
(see
Figure
2-2).
To
add
flux,
proceed
as
follows:
1.
Close
air
valve,
bleed
pressure
from
tank,
and
disconnect
air
supply.
2.
Remove
cover
from
tank
slowly.
(A
screen
is
provided
inside
the
tank
and
must
remain
in
place.)
3.
Place
supplied
funnel
into
tank
opening,
and
pour
in
flux.
Prescreen
reclaimed
flux
through
.062
inch
(1
.57
mm)
mesh
before
adding
to
tank.
4.
Remove
funnel
and
reinstall
cover
tightly
onto
tank.
5.
Reconnect
air
supply
and
open
air
valve.
To
change
to
a
different
flux,
proceed
as
follows:
1.
Close
air
valve,
bleed
pressure
from
tank,
and
disconnect
air
supply.
2.
Remove
bottom
tank
cover
(see
Figure
2-2),
and
drain
existing
flux
into
an
appropriate
container.
3.
Reinstall
bottomtank
cover
tightely.
4.
Add
desired
flux
to
tank
according
to
the
preceeding
instructions.
Air
Hose
Tank
Cover;
Remove
To
Add
Flux
Flux
Hose
Fitting
Air
Pressure
Safety
Valve
With
Bleeder
Handle
Flux
Drain
Cover
Figure
2-2.
Flux
Tank
Component
Identifications
OM-1
642
Page
3
IMPORTANT
2-3.
GUN/WIRE
FEEDER
CONNECTIONS
(Figure
2-1)
______________
If
an
optional
gun/feeder
adapter
kit
is
to
be
used,
make
gun/feeder
connections
according
to
the
instructions
furnished
with
the
kit.
A.
Gun/Feeder
Connector
Installation
Loosen
the
gun/feeder
connector
securing
knob
on
wire
feeder
drive
housing
(see
wire
feeder
Ownerî‚’s
Manual
for
location).
Insert
the
gun/feeder
connector
into
opening
in
housing
(see
Figure
2-1).
Whenever
the
electrode
wire
size
is
changed,
blow
out
both
the
monocoil
liner
and
monocoil
casing
with
compressed
air.
1.
Remove
the
nozzle
and
extension
if
applicable.
2.
Cut
off
any
portion
of
the
electrode
wire
which
extends
beyond
the
end
of
the
contact
tube.
3.
Remove
the
contact
tube.
4.
Retract
remaining
electrode
wire
onto
wire
spool.
IMPORTANT
I
M
P0
RTA
NF
Install
connector
so
that
outlet
wire
guide
is
as
close
to
drive
rolls
as
possible
without
touching.
5.
Install
the
appropriate
contact
tube.
6.
Reinstall
the
nozzle
and
extension
if
applicable.
Tighten
the
gun/feeder
connector
securing
knob.
B.
Gun
Trigger
Connections
Locate
TRIGGER
receptacle
on
wire
feeder
control.
Connect
gun
trigger
plug
to
this
receptacle
and
secure.
2-4.
GUN
TRIGGER
OPERATION
-
The
gun
trigger
has
two
standard
features:
a
locking
device,
and
control
of
both
flux
flow
and
wire
feeder.
The
locking
device
allows
the
trigger
to
be
held
fully
depressed
providing
operator
comfort
on
long
or
sus
tained
welds.
The
control
of
flux
flow
and
wire
feeder
is
obtained
by
depressing
the
trigger.
Up
to
approximately
2/3
depres
sion
will
allow
partial
flux
flow
only
without
energizing
the
wire
feeder.
Full
depression
gives
full
flux
flow
and
energizes
wire
feeder.
WARNING
___________
FLYING
FLUX
PARTICLES
can
punc
ture
eyes
and
skin;
WELDING
WIRE
can
cause
puncture
wounds.
î‚•
Do
not
point
gun
toward
any
part
of
the
body
or
other
personnel.
î‚•
Do
not
depress
gun
trigger
until
ready
to
begin
welding.
7.
Make
necessary
changes
to
wire
feeder
to
ac
comodate
new
wire
size.
8.
Thread
new
size
electrode
wire
(see
wire
feeder
Ownerî‚’s
Manual).
9.
Reconnect
air
supply
to
flux
tank.
2-5.
CHANGING
WIRE
SIZE
(Figure
2-3)
-
To
change
the
size
of
the
electrode
wire,
the
only
gun
part
necessary
to
change
is
the
contact
tube.
It
may
be
necessary
to
change
the
wire
feeder
inlet
wire
guide
-see
wire
feeder
Ownerî‚’s
Manual
for
information.
WARNING
_________
ELECTRIC
SHOCK
can
kill;
FLYING
FLUX
PARTICLES
can
puncture
eyes
and
skin;
WELDING
WIRE
can
cause
puncture
wounds.
î‚•
Do
not
touch
live
electrical
parts.
î‚•
Shut
down
we/ding
power
source
and
wire
feeder
and
be
sure
they
cannot
be
accidentally
energized
before
working
on
gun
components.
î‚•
Close
air
valve,
bleed
pressure
from
tank,
and
disconnect
air
supply.
î‚•
Do
not
point
gun
toward
any
part
of
the
body
or
other
personnel.
10.
Resume
operation.
Head
Tube
Monocoll
LIner
Tube
Flux
Figure
2-3;
Gun
Components
TC-084
443
Page
4
2-6.
CHANGING
CONTACT
TUBE
(Figure
2-3)
1.
Remove
the
nozzle
and
extension
if
applicable.
ELECTRIC
SHOCK
can
kill;
FLYING
FLUX
PARTICLES
can
puncture
eyes
and
skin;
WELDING
WIRE
can
cause
puncture
wounds.
î‚•
Do
not
touch
live
electrical
parts.
î‚•
Shut
down
welding
power
source
and
wire
feeder
and
be
sure
they
cannot
be
accidentally
energized
before
working
on
gun
components.
î‚•
Close
air
valve,
bleed
pressure
from
tank,
and
disconnect
afr
supply.
î‚•
Do
not
point
gun
toward
any
part
of
the
body
or
other
personnel.
WARNING
2.
Cut
off
any
portion
of
the
electrode
wire
which
extends
beyond
the
end
of
the
contact
tube.
3.
Remove
the
contact
tube.
4.
Install
new
contact
tube.
5.
Reinstall
the
nozzle
and
extension
if
applicable.
6.
Resume
operation.
SECTION
3
-
SEQUENCE
OF
OPERATION
3-1.
SUBMERGED
ARC
WELDING
(SAW)
WARNING
EXPOSED
ARC
RAYS
can
burn
eyes
and
skin.
î‚•
Do
not
allow
flux
flow
to
stop
while
welding.
î‚•
Do
not
use
wet
or
damp
flux.
î‚•
Do
not
restrict
flux
feed
hose.
î‚•
Ensure
continuous
air
supply
to
flux
system.
î‚•
Keep
foreign
material
out
of
flux
system.
î‚•
Use
reclaimed
flux
only
which
has
been
sifted
through
.062
inch
(1.57
mm)
mesh.
Do
not
allow
flux
flow
to
stop
while
welding
to
avoid
be
ing
exposed
to
a
bare
arc.
The
arc
must
be
covered
at
all
times
to
prevent
arc
flashing.
_________
ELECTRIC
SHOCK
can
kill;
FLYING
FLUX
PARTICLES
can
puncture
eyes
and
skin.
î‚•
Do
not
touch
live
electrical
parts.
-
î‚•
Do
not
energize
welding
power
source
or
wire
feeder
until
instructed
to
do
so.
î‚•
Do
not
touch
welding
wire
or
any
metal
part
in
contact
with
it
while
welding.
î‚•
Wear
proper
eye,
hand,
and
body
protection
when
welding.
Welding
wire
and
all
metal
parts
in
contact
with
it
carry
weld
current
when
the
gun
trigger
is
depressed
and
the
welding
power
source
contactor
is
energized.
See
Sec
tion
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
in
welding
power
source
Ownerî‚’s
Manual
for
basic
welding
safety
information.
WARNING
1.
Assemble,
install,
end
connect
components
as
applicable
as
instructed
in
Section
2.
2.
Fill
tank
with
flux
as
instructed
in
Section
2-2.
WARNING
FLYING
FLUX
PARTICLES
can
puinc
ture
eyes
and
skin.
î‚•
Wear
proper
eye,
hand;
and
body
protection.
î‚•
Close
air
fine
valve
and
bleed
pressure
from
tank
before
disconnecting
air
supply
or
opening
top
or
bottom
cover(s).
î‚•
After
connecting
air
supply,
open
air
line
valve
to
energize
tank.
3.
Connect
air
supply
to
tank,
open
air
valve,
and
adjust
pressure
as
instructed
in
Section
2-2.
4.
Make
connections
to
welding
power
source
as
instructed
in
power
source
and
wire
feeder
Ownerî‚’s
Manuals.
5.
Begin
welding.
3-2.
SHUT~lNG
DOWN
1
.
Turn
off
all
equipment.
2.
Close
air
valve,
bleed
pressure
from
tank,
and
disconnect
air
supply
as
instructed
in
Seci~on
2-2.
SECTION
4
-
MAINTENANCE
Periodically
inspect
the
labels
on
this
unit
for
legibility.
All
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
the
Parts
List
for
part
number
of
labels.
Usage
and
shop
conditions
will
determine
frequency
and
type
of
maintenance
required.
1.
Inspect
gun
for
broken
areas,
cracks
and
loose
parts;
tighten,
repair
and
replace
as
required.
2.
Carefully
remove
any
weld
spatter
or
foreign
matter
which
may
accumulate
around
the
nozzle
orifice
and
inside
nozzle:
3.
Repair
or
replace
as
required
all
hose
and
cables;
give
particular
attention
to
frayed
and
cracked
in
sulation
and
areas
where
it
enters
equipment.
4.
Remove
grease
and
grime
from
moisture
from
electrical
parts
and
IMPORTANT:
-
4-1.
GUN
INSPECTION
AND
UPKEEP
WARNING
_________
ELECTRIC
SHOCK
can
kIll;
FLYING
FLUX
PARTICLES
can
puncture
eyes
and
skin;
WELDING
WIRE
can
cause
puncture
wounds.
î‚•
Do
not
touch
live
electrical
parts.
î‚•
Shut
down
welding
power
source
and
wire
feeder
and
be
sure
they
cannot
be
accidentally
energized
before
inspecting
or
servicing
gun.
î‚•
Close
air
valve,
bleed
pressure
from
tank,
and
disconnect
air
supply.
components;
cables.
OM-1
542
Page
5
IMPORTANT:
5.
Blow
out
the
casing
with
compressed
air
when
changing
wire.
This
removes
any
loose
metal
chips
and
dirt
that
may
have
accumulated..
4-2.
FLUX
SYSTEM
________
Flux
is
very
abrasive
and
has
a
wear
ing
and
clogging
effect
on
all
parts
and
pieces
exposed
to
it.
Good
maintenance
is
essential
for
proper
opera
tion.
Periodically,
depending
on
usage
and
conditions,
check
flux
hose
and
tank
for
secure
connections.
Be
sure
hose
is
securely
installed
onto
tank
and
gun
fittings
and
that
clamps
are
tight.
Be
sure
all
component
mounting
bolts
are
tight.
Using
a
soft
brush
or
cloth,
clean
dirt
and
flux
particles
off
all
components.
Check
hose
and
air
lines
for
damage
or
leaks.
Repair
or
replace
defective
com
ponents
as
necessary.
Periodically
examine
flux
screen
inside
tank
and
clean
out
large
particles
if
necessary.
4-3.
CHANGING
MONOCOIL
LINER
(Figure
2-3)
WARNING
__________
ELECTRIC
SHOCK
can
kill;
FLYING
FLUX
PARTICLES
can
puncture
eyes
and
skin;
WELDING
WIRE
can
cause
puncture
wounds.
î‚•
Do
not
touch
live
electrical
parts.
î‚•
Shut
down
welding
power
source
and
wire
feeder
and
be
sure
they
cannot
be
accidentally
energized
before
working
on
gun
components.
î‚•
Close
air
valve,
bleed
pressure
from
tank,
and
disconnect
air
supply.
î‚•
Do
not
point
gun
toward
any
part
of
the
body
or
other
personnel.
IMPORTANT:
Whenever
the
monocoil
liner
is
changed,
blow
out
both
the
monocoll
liner,
and
monocoil
casing
with
compressed
air.
1.
Cut
off
any
portion
of
the
electrode
wire
which
extends
beyond
the
end
of
the
nozzle.
2.
Retract
remaining
electrode
wire
onto
wire
spool.
3.
Disconnect
gun
from
wire
feeder
and
lay
gun
out
flat
(no
coils
in
cable/conduit).
&
Remove
outlet
wire
guide
from
gun/feeder
con
nector.
5.
Loosen
setscrew
in
gun
handle
and
large
setscrew
in
gun/feeder
connector
(see
Figure
2-3).
6.
Pull
out
monocoil
liner
from
gun/feeder
connec
tor
end
of
casing.
7.
Insert
new
liner
fully
into
casing
and
tighten
both
setscrews
to
hold
liner
in
place.
~~LW.E
OVERTIGHTENING
MONOCOIL
LINER
SETSCREWS
will
damage
liner.
î‚•
Do
not
overtighten
setscrews.
8.
Reinstall
outlet
wire
guide
into
gun/feeder
con
nector.
9.
Cut
off
new
liner
so
that
it
sticks
out
approx
imately
1/8
in.
(3.2
mm)
from
wire
guide.
10.
Reconnect
gun
to
wire
feeder.
11.
Thread
electrode
wire
through
gun
(see
wire
feeder
Ownerî‚’s
Manual).
12.
Reconnect
air
supply
to
flux
tank.
13.
Resume
operation.
Page
6
June
1982
FORM:
OM-1542
PARTS
LIST
Effective
With
Style
No.
JB-41
/
/
e
t
(5
C~)
4
C
(5
Iî‚—
î‚‘C
U..
C
I
C)
6.
a)
U.
C
4î‚’
r
/
/
OM-1
642
Page
1
Item
Part
No. No.
Description
Quantity
Figure
A
Gun,
Flux
Tank
&
Cart
1
601
956
2
602 336
3
602
250
4
605
755
5
082 643
6
601
965
7
602213
8
601
872
9
Figure
B
10
601
948
11
602211
12
082646
13
082637
14
604631
15
082636
16
602207
17
601
865
18
601
957
19
027376
20
602216
21
601
879
22
082
644
23
604
423
24
Figure
C
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
4
2
2
4
4
7
7
2
2
4
4
2
2
2
2
SCREW,
cap
-
hex
hd
1/4-20
x
1-1/4
PIN,
cotter1/8x1~1/2
WASHER,flatSAE-3/4
WHEEL,
rubber
10
OD
x2-3/4
x3/4
bore
BRACKET,
lifting
-
cart
SCREW,
cap
-
hex
hd
3/8-16
xl
WASHER,
lock-split
3/8
NUT,
hex
-
full
3/8-16
FLUXTANK,AFT-100(Pg4)
SCREW,cap-hexhd5/16-18x1
WASHER,
lock-split
5/16
BASE
.:
AXLE
SCREW,
cap
-
hex
hd
1/4-20
x
1
BRACE,
handle
WASHER,
lock
-
split
1/4
NUT,
hex
full
1/4-20
SCREW,
cap
-
hex
hd
1/4-20
x
1-1/2
CASTER,
swivel
5
inch
WASHER,
lock
-
split
1/2
NUT,
hex-fulll/2-13
HANDLE
GRIP,
handle
GA-6OCF
Gun
(Pg
6)
OM-1542Page2
1
TC-084
387-C
31
Figure
B
-
AFT-100
Flux
Tank
Page
3
Item
No.
Figure
B
AFT-100
Flux
Tank
Description
Quantity
1
083
757
2
082
544
602
178
3
082
540
4
082 622
5
083
485
6
082
546
7
605
106
8
082613
9
071
270
10
082621
11
082589
12
010678
13
082579
14
082536
15
082587
16
082537
17
082586
18
602934
19
602920
20
601
117
21
082
593
084
640
22
082
578
23
082
588
24
082
541
25
082
538
26
082
577
27
082
594
28
073
524
29
602 902
30
082614
31
084
939
FUNNEL
1
CAP,
tank
-
flux
(consisting
of)
1
SCREW,
set
socket
hd
1/4-20
x
3/8
1
SEAL,
cap-tank
1
STRAINER,
tank
-
flux
1
TANK
1
FITTING,
Y-45
deg
tank
bottom
1
FITTING,
pipe-cap2NPT
1
FITTING,
w/screen
1
FITTING,
pipe-teestLl/4
NPT
1
TUBING,
copper
1/4
OD
x
0.030
wall
(order
by
ftî‚•)
4
ft
FITTING,
brass
-
compression
connector
M
1/4
TBG
x
1/4
NPT
..
.
..........
.
1
FITTING,
pipe
-
brass
elbow
st
1/4
NPT
L
1
VALVE,
relief
-
pressure
75
PSi
G
1/4
NPTF
1
VENT,
air
-
filter
1
FITTING,
brass
-
compression
union
1/2
TBG
1
TUBE,
filter
-
final
1
FITTING,
brass
-
compression
elbow
F
1/2
TBG
x
1/4
1
FITTING,
pipe
-
coupling
1/4
NPT
3
FITTING,
pipe
-
nipple
L
1/4
NPT
x
2
3
CLIP,
jiffy
-
tubing
1/2
inch
3
REGULATOR,
pressure
-
air
1
KIT,
repair
-
regulator
1
GAUGE,
pressure
-
air
0.60
+
0-4
PSi
G
1
FITTING,
brass
-
compression
elbow
F
1/4
TBG
x
1/4
1
BRACKET,
mtg
-
components
1
CAN
NISTER,
filter
1
0-RING,
2-1/8
ID
x
2-5/16
OD
x
3/32
1
FILTER,
air-5ozl/4
NPT
1
FITTING,
pipe
-
brass
quick
disconnect
M
1/4
NPT,
1
FITTING,
pipe
-
valve
2
way
1/4
FPT
x
1/4
NP
1
VALVE,
check
1
PSIG
1/4
MNPT
both
ends
1
LABEL,
warning
-
flux
particles,
etc
1
AttachIng
Hardware
602 085
SCREW,
machine
-
round
hd
8-32
x
3/4
601
925
SCREW,
cap
-
hex
hd
1/4-20
x
1/2
602
200
WASHER,
lock
-
split
No.
8
602
207
WASHER,
lock
-
split
1/4
601
860
NUT,
hex8-32
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Part
No.
2
2
2
2
2
OM-1
542
Page
4
Figure
C
-
GA-6OCF
Gun
2.
56
11
55
21
37,
33
I
TC-084
444-B
Page
5
Item
Part
No. No.
1
082
741
2
052
098
3
009
709
3
052
055
3
008
926
4
082 298
5
t082
297
6
t083
697
7
000
425
8
083610
9
083611
10
083588
11
t083
322
12
082313
13
082311
14
082312
15
000425
16
082782
17
059290
18
082870
19
082745
20
084
463
21
602
196
22
082
858
23
082
856
24
084 465
25
084
464
26
023
562
27
049 872
28
079
878
29
079
535
30
048
834
31
604525
32
081
909
33
082
796
33
082
797
34
004
732
35
004
733
36
082
757
37
004731
38
078
892
49
049319
40
049312
41
079852
42
081
580
42
081
581
43
082
749
44
049318
45
602
173
46
605
422
46
605
422
47
073
476
48
082
750
49
082
861
50
082
754
51
082
747
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
2
2
1
1
1
2
2
1
1
4
1
2
ft
2
1
1
2
2
1
1
1
1
3
1
1
1
1
1
2
15
ft
20
ft
12
1
1
1
1
Description
Quantity
Figure
C
GA-6OCF
Gun
ADAPTER,
nozzle
SCREW,
set
-
hollow
lock
3/8-16
x
3/16
(included
with
head
tube)
TUBE,
contact
1/16
wire
TUBE,
contact
5/64
wire
TUBE,
contact
3/32
wire
NOZZLE,
screw
type
3/4
orifice
x
1-3/8
NOZZLE,
screw
type
5/8
orifice
x
1-3/8
EXTENSION,
nozzle
(consisting
of)
SCREW,
machine-filister
4-40
x
3/48
EXTENSION,
nozzle
GUIDE,
wire
1-1/4
long
INSERT,
nozzle-extension
EXTENSION,
nozzle
(consisting
of)
GUIDE,
wire
INSERT,
nozzle-extension
EXTENSION,
nozzle
SCREW,
machine-filister
hd
4-40
x
3/8
RIVET,
round
hd
5/32
dia
x
7/8
NUT,
speed-push
on
0.320
IDx7/16OD
SPRING,
compression
0.22
OD
x
3/4
inches
TRIGGER,
gun
SCREW,
pan-hd4-40x9/16
WASHER,
lock
-
internal
tooth
No.
4
LOCK,
trigger
HANDLE,
gun
-
bottom
SWITCH
TUBING,
No.
7
x
2
inches
long
CLAMP,
hose
5/16-7/8
dia
CORD,
power
(consisting
of)
HOUSING
PLUG
&
PINS
(consisting
of)
TERMINAL,
male
CLAMP,
cable
CORD,
No.18
2/c
(order
byft)
SPLICE,
20-16
wire
-
insulated
CABLE/CONDUIT,
lOft.
(consisting
of)
CABLE/CONDUIT,
15
ft.
(consisting
of)
CLAMP,
cable
conduit
CLAMP,
cable
conduit
ADAPTER,
gun/feeder
ADAPTER,
head
tube/power
cable
SCREW,
set
-
socket
hd
3/8-16
x
3/8
STRAIN
RELIEF,
bottom
-
cable
RING,
locking
-
handle
GUIDE,
wire
-
outlet
.045-5/64
wire
MONOCOIL,
0.230
OD
x
.030-1/8
wire
x
11
ft
MONOCOIL,
0.230
OD
x
.030-1/8
wire
x
16
ft
SLEEVE,
centering
-
monocoil
STAIN
RELIEF,
top
-
cable
SCREW,
set
-
socket
hd
10-32
x
1/4
HOSE,
No.1
x3/81D(orderbyft)
HOSE,
No.1
x3/8
ID
(order
byft)
CLAMP,
strap
3/8
x
4-5/8
ADAPTER,
hose
-
flux
INSULATOR,
terminal
-
switch
TUBING,
5/l6IDxO.O62walIx6
GUARD,
switch
OM-1542
Page
6
Item
Part
No. No.
Description
Quantity
Figure
C
GA-6OCF
Gun
52
082 746
CLIP,
wire
-
trigger
1
53
082
748
HANDLE,
gun
-
top
1
54
052
884
SCREW,
set
-
socket
hd
10-32
x
1/4
2
55
082
781
SCREW,set-sockethds/16-18x3/8
1
56
082
743
TUBE,
head
(includes
item
2)
1
t085
277
ADAPTER,
gun/feeder
(LN-7,
8
&9)
(consisting
of)
1
085
697
.
ADAPTER,
gun/feeder
1
048
713
.
CLAMP,
power
1
t084
172
ADAPTER,
gun/feeder
(Hobart
27)
(consisting
Qf)
1
084
358
.
ADAPTER,
gun/feeder
1
084
355
.
ADAPTER,
cord-power
1
602
177
.
SCREW,
set-socket
hd
1/4-20
x
1/4
1
tOptional
Parts.
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Page7
I
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Miller AFT-100 FLUX TANK Owner's manual

Miller
Brand
Miller
Model
AFT-100 FLUX TANK
Category
Welding System
Type
Owner's manual
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