May
1988
FORM:
121429
OWN
ERS
MODEL
AATT-1
512
VNR
MAN
UAL
Al
IT(S~i~FL___.
II
.._I
I
~
~
~
---i
MILLER
ELECTRIC
MFG.
CO.
718
5.
BOUNDS
ST,
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
30
CENTS
IMPORTANT
______________
Read
and
understand
the
entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equip
ment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equipment.
Do
not
allow
un
trained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
Effective
With
Style
No.
JJ-23
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A
ONE
YEAR
LIMITED
WARRANTY
COVERAGE
-
Miller
Electric
Mfg.
Co.
warrants
to
the
buyer
REMEDY
FOR
DEFECTIVE
WELDER
-
Upon
receipt
of
any
who
purchases
this
Auto
Arc
Welder
lWelder)
for
personal,
defective
Welder,
Miller
Electric
will,
at
its
option,
repair
or
c~/
family
or
household
purposes
(Consumer)
that
this
Welder
replace
the
defective
Welder
at
its
expense,
refund
or
credit
will
be
free
from
defects
in
material
and
workmanship
for
a
the
purchase
price
lless
reasonable
depreciation
based
on
ac
period
of
one
year
from
the
date
of
purchase.
This
warranty
tual
usel,
or
reimburse
the
Consumer
for
the
cost
of
repair
or
covers
only
the
original
purchaser
of
this
Welder.
Miller
Electric
replacement
at
an
approved
Miller
Electric
warranty
station,
does
not
authorize
any
party,
including
its
authorized
provided
that
the
purchaser
of
that
Welder
has
followed
the
distributors,
to
offer
any
other
warranty
on
behalf
of
Miller
procedure
for
obtaining
warranty
performance
set
forth
below.
~
Electric.
Upon
expiration
of
the
warranty
period,
Miller
Electric
The
Welder
so
repaired
or
used
as
a
replacement
will
be
ship-
shall
have
no
further
liability
related
to
the
Welder,
except
on
ped
to
the
purchaser
of
the
defective
Welder,
with
transporta
warranty
claims
made
during
the
warranty
period.
tion
charges
prepaid
to
any
destination
in
the
continental
United
States
(transportation
charges
on
shipments
to
Alaska
c~
THIS
WARRANTY
IS
OFFERED
IN
LIEU
OF
ANY
OTHER
or
Hawaii
will
be
paid
only
to
the
nearest
port
of
export),
EXPRESS
WARRANTY;
AND,
EXCEPT
TO
THE
EXTENT
C~
PROHIBITED
BY
APPLICABLE
LAW,
THE
DURATION
OF
ALL
IMPLIED
WARRANTIES.
INCLUDING
BUT
NOT
THE
PURCHASERS
REMEDIES
FOR
A
DEFECTIVE
LIMITED
TO
THE
IMPLIED
WARRANTIES
OF
MERCHAN-
WELDER,
TO
THE
EXTENT
PERMITTED
BY
APPLICABLE
TABILITY
AND
FITNESS
FOR
A
PARTICULAR
PURPOSE,
IS
LAW,
ARE
LIMITED
TO
THE
REMEDY
PROVIDED
BY
THIS
WARRANTY:
AND,
TO
THE
EXTENT
ENFORCEABLE
LIMITED
TO
THE
DURATION
OF
THIS
WARRANTY.
UNDER
APPLICABLE
LAW,
MILLER
ELECTRIC
SHALL
IN
Some
states
do
not
allow
limitations
on
how
long
an
implied
NO
EVENT
BE
LIABLE
FOR
CONSEQUENTIAL,
INCIDENTAL
~
warranty
lasts,
so
the
above
limitation
may
not
apply
to
you.
OR
SPECIAL
DAMAGES
ARISING
OUT
OF
THE
USE
OF,
OR
~~
This
warranty
gives
you
specific
legal
rights,
and
you
may
also
INABILITY
TO
USE,
THE
WELDER,
WHETHER
BASED
ON
have
other
rights
which
vary
from
state
to
state.
BREACH
OF
THIS
WARRANTY,
MILLER
ELECTRICS
NEGLIGENCE
OR
OTHER
TORT,
OR
ON
ANY
THEORY
OF
STRICT
LIABILITY.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
year.
such
as
spot
welder
tips,
relay
and
contactor
~
Some
states
do
not
allow
the
exclusion
or
limitation
of
con
c,~
parts
that
come
in
contact
with
the
welding
wire
including
sequential
or
incidental
damages,
so
the
above
limitations
may
~
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
not
apply
to
you.
defect
in
workmanship
or
material.
PROCEDURE
FOR
OBTAINING
WARRANTY
PERFORMANCE
Miller
shall
be
required
to
honor
warranty
claims
on
war
~
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
As
soon
as
any
defect
in
a
Welder
becomes
known,
the
pur
within
the
following
periods
from
the
date
of
delivery
of
Equip-
chaser
of
the
Welder
must,
within
thirty
(30)
days,
notify
an
ment
to
the
original
user:
approved
Warranty
Station
or
Miller Electric
in
writing
of
the
c3~
1.
Arc
welders,
power
sources,
and
components
.
1
defect.
The
purchaser
must
then,
within the
one
year
warranty
year
period,
return
the
Welder
to
Miller
Electric
at
the
following
ad-
2.
Original
main
power
rectifiers
3
years
dress:
(labor
-
1
year
only)
3.
All
welding
guns,
feeder/guns
and
plasma
torches...
90
~
Miller
Electric
Mfg.
Co.
4.
Replacement
or
repair
parts,
exclusive
of
labor
..
60
days
718
South
Bounds
Street
P.O.
Box
1079
WHAT
IS
NOT
COVERED
-
This
warranty
does
not
extend
Appleton,
Wisconsin
54912
~..
to
any
Welder
subjected
to
misuse,
neglect.
accident,
or
in-
warranty
repair
by
anyone
except
Miller
Electric.
Further,
this
All
transportation
charges
to
Warranty
Station
or
Miller
Electric
~
warranty
only
extends
to
those
purchasing
the
Welder
for
per-
must
be
prepaid.
sonal,
family
or
household
purposes.
Commercial
and
in
dustrial
users
are
given
a
different
warranty.
SECTION
1
-
SAFETY
RULES
a
WARNING:
UNSAFE
PROCEDURES
OR
1-3.
PROTECT
EYES
AND
SKIN
FROM
ARC
RAYS;
PRACTICES
can
cause
serious
personal
In-
PROTECT
EARS
FROM
NOISE
jury
or
death.
0
Read,
understand,
and
follow
ALL
of
these
Arc
rays
from
the
welding
process
produce
intense
heat
safety
rules
before
installing,
operating,
or
serv-
and
strong
ultraviolet
rays
that
can
burn
eyes
and
skin.
icing
this
equipment.
Noise
from
some
processes
can
damage
hearing.
Be
sure
that
all
end
users
of
this
equipment,
a.
Wear
a
welding
helmet
fitted
with
a
proper
filter
the
operator
and
helpers,
read
and
understand
tens
(see
ANSI
Z49.1
for
detailed
information).
these
safety
rules.
b.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare.
1-1.
PREVENT
ELECTRIC
SHOCK
c.
Wear
protective
clothing
and
foot
protection.
d.
Always
wear
safety
glasses
or
safety
goggles
in
Touching
live
electrical
parts
can
cause
severe
burns
to
a
work
area.
the
body
or
fatal
shock.
Severity
of
electrical
shock
is
de
termined
by
the
path
and
amount
of
current
through
the
1-4.
PREVENT
FIRES
AND
BURNS
body.
Therefore:
The
hot
workpiece,
hot
equipment,
other
hot
metal,
a.
Do
not
touch
live
electrical
parts.
spatter,
and
arc
sparks
can
cause
fires
and
burns.
a.
Wear
correct
eye,
face,
and
body
protection
in
b.
Do
not
work
in
wet
or
damp
areas.
the
work
area.
c.
Wear
dry
insulating
gloves
and
body
protection.
b.
Allow
work
and
equipment
to
cool
before
han
dling.
d.
Disconnect
all
power
before
installing
or
servic
ing
this
equipment.
c.
Do
not
weld
near
flammable
material.
d.
Watch
for
fire,
and
keep
a
fire
extinguisher
e.
Turn
off
all
equipment
when
not
in
use.
nearby.
f.
Properly
install
and
ground
the
welding
power
e.
For
additional
information,
refer
to
NFPA
Stan-
source
according
to
its
Owners
Manual
and
all
dard
51
B,
Fire
Prevention
in
Use
of
Cutting
and
applicable
codes.
Welding
Processes,
available
from
the
Na
tional
Fire
Protection
Association,
Bat
g.
Do
not
use
worn
or
damaged
cables
or
cables
terymarch
Park,
Quincy,
MA
02269.
that
are
too
small
or
poorly
spliced.
1-5.
PROTECT
COMPRESSED
GAS
CYLINDERS
h.
Do
not
wrap
cables
around
your
body.
Since
gas
cylinder
are
normally
part
of
the
welding
proc
I.
Do
not
touch
electrode
and
any
grounded
ob-
ess,
be
sure
to
treat
them
carefully.
ject
or
circuit
at
the
same
time.
a.
Protect
compressed
gas
cylinders
from
exces
j.
Use
only
well-maintained
equipment.
Repair
or
sive
heat,
mechanical
shocks,
and
arcs.
replace
damaged
parts
at
once.
b.
Install
and
secure
cylinder
so
that
they
cannot
fall
or
tip
over
by
fastening
them
to
a
mounting
1-2.
PROVIDE
PROTECTION
FROM
FUMES
AND
bracket,
wall,
or
other
stationary
support.
GASES
c.
Keep
cylinders
away
from
any
welding
or
other
Breathing
welding
fumes
and
gases
can
be
hazardous
electrical
circuits.
to
your
health.
d.
Never
allow
a
welding
electrode
to
touch
any
a.
Keep
your
head
out
of
the
fumes.
cylinder.
b.
Use
adequate
ventilation
in
the
work
area
to
1-6.
PROVIDE
PROTECTION
FOR
SPECIAL
SITU
ATIONS
keep
fumes
and
gases
from
your
breathing
zone
and
the
general
work
area.
a.
Donotweldorcutcontainersormaterialswhich
have
held
or
been
in
contact
with
hazardous
c.
If
ventilation
is
inadequate,
use
an
approved
substances
unless
they
are
properly
cleaned
breathing
device.
and
inspected.
d.
Readthe
Material
Safety
Data
Sheets
(MSDSs)
b.
Do
not
weld
or
Cut
painted
or
plated
parts
un
and
the
manufacturers
instructions
for
any
ma-
less
special
ventilation
is
provided
to
remove
terials
used.
highly
toxic
fumes
or
gases.
121429
Page
1
c.
Since
welding
can
affect
pacemakers,
keep
all
pacemaker
wearers
out
of
the
work
area.
Have
them
consult
a
doctor
before
coming
near
a
welding
operation.
1-7.
PROVIDE
PROPER
EQUIPMENT
MAINTE
NANCE
Improperly
maintained
equipment
can
result
in
poor
work,
but
most
importantly
it
can
cause
physical
injury
or
death
through
fires
or
electrical
shock.
Therefore:
a.
Always
have
qualified
personnel
perform
the
in
stallation,
troubleshooting,
and
maintenance
work.
Do
not
perform
any
electrical
work
unless
you
are
fully
qualified.
b.
Before
performing
any
maintenance
work
in
side
a
power
supply,
disconnect
the
power
sup
ply
from
the
electrical
power
source.
c.
Maintain
cables,
grounding
wire,
connections,
power
cord,
and
power
supply
in
a
safe
working
order.
Do
not
operate
any
equipment
in
ques
tionable
condition.
d.
Do
not
abuse
any
equipment
or
accessories.
Keep
equipment
away
from
heat
sources
such
as
furnaces,
wet
conditions
such
as
water
pud
dles,
oil
or
grease,
corrosive
atmospheres,
and
inclement
weather.
e.
Keep
all
safety
devices,
guards,
panels,
and
covers
in
position
and
in
good
repair.
f.
Use
equipment
for
its
intended
purpose.
Do
not
modify
it
in
any
manner.
1-8.
ADDITIONAL
SAFETY
INFORMATION
For
more
information
on
safe
practices
for
setting
up
and
operating
electric
welding
and
cutting
equipment
and
on
good
working
habits,
ask
your
welding
equip
ment
supplier.
For
your
protection,
read
and
comply
with
the
latest
editions
of
the
following
standards:
a.
ANSI
Standard
Z49.
1
available
from
the
Ameri
can
Welding
Society,
550
N.W.
LeJeune
Rd.
Miami,
FL
33126.
b.
AWS
Standard
A6.1,
Recommended
Safe
Practices
for
Gas
Shielded
Arc
Welding,
avail
able
from
the
American
Welding
Society,
550
N.W.
LeJeune
Ad,
Miami,
FL
33126.
c.
AWS
Standard
F4.1,
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
and
Piping
That
Have
Held
Hazardous
Substances,
available
from
the
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
d.
NFPA
Standard
51
B,
Fire
Prevention
in
Use
of
Cutting
and
Welding
Processes,
available
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
e.
NFPA
Standard
70,
National
Electrical
Code,
available
from
the
National
Fire
Protection
As
sociation,
Batterymarch
Park,
Quincy,
MA
02269.
ANSI
Standard
Z87.1,
Safe
Practice
for
Occu
pation
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.
Gov
ernment
Printing
Office,
Washington,
DC
20402.
h.
CSA
Standard
W117.2,
Code
for
Safety
in
Welding
and
Cutting,
available
from
the
Cana
dian
Standards
Association,
178
Rexdale
Blvd.,
Rexdale,
Ontario,
Canada
M9W
1R3.
See
also
the
Standards
Booklet
Index
in
the
welding
power
source
Owners
Manual.
SECTION
2INTRODUCTION
Ampere
Rating
For
Hand
Held
Manual
Applications
Tungsten
Size
Capacity
Cable
Length
Torch
Body
Cooling
Method
Weight
Net
Ship
150
Amperes
With
Argon
.040
thn.i
1/16
in.
(1.1
thru
1.6mm)
12.5
ft.
(3.8
m)
Length:
8.0
in.
(203.0
mm)
Handle
Diameter:
0.9
in.
(22.9
mm)
Weight:
4.5oz.
(127.6
g)
Air
3.0
lbs.
(1.4kg)
3.5
lbs.
(1.6
kg)
~
FIgure
2-1.
SpecifIcatIons
121429
Page
2
2-1.
DUTY
CYCLE
The
duty
cycle
of
a
welding
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
means
that
the
torch
can
be
oper
ated
at
rated
load
conditions
continuously.
a
CAUTION:
EXCEEDING
THE
RATED
AM
PERAGE
can
result
In
damage
to
the
torch.
Do
not
exceed
rated
amperage
stated
in
Figure
2-1.
2-2.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troub
leshooting
which
should
be
read,
understood,
and
fol
lowed
for
the
safe
and
effective
use
of
this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
troub
leshooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by
qualified
per
sons
in
accordance
with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
WARNING
and
CAUTION
which
identify
differ
ent
levels
of
hazard.
WARNING
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss
of
life.
CAUTION
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
minor
personal
injury
or
damage
to
this
equipment.
A
third
signal
word,
IMPORTANT
highlights
instruc
tions
which
need
special
emphasis
to
obtain
the
most
ef
ficient
operation
of
this
equipment.
2-3.
RECEIVING
HANDLING
Before
installing
this
equipment,
clean
all
packing
mate
rial
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
manu
facturer
on
request
it
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Style
Numbers
of
the
equipment
be
supplied.
The
style
num
ber
is
located
on
a
label
under
the
torch
handle.
2-4.
DESCRIPTION
This
torch
is
specifically
for
use
with
the
Gas
Tungsten
Arc
Welding
(GTAW)
process.
SECTION
3-INSTALLATION
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shutdown
welding
powersource
and
discon
nect
input
power
employing
lockout/tagging
procedures
before
installing
torch.
Lockout/tagging
procedures
consist
of
padlo
cking
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
3-1.
TORCH
BODY
(Figure
3-1)
Assemble
torch
body
as
follows:
1.
Install
collet
body
into
torch
body
making
sure
heat
shield
is
in
place.
2.
Install
cup
onto
collet
body.
3.
install
collet,
slotted
end
first,
through
back
of
torch
body
into
collet
body.
4.
Install
backcap
and
0-ring
(supplied
on
backcap)
onto
torch
body.
5.
Install
properly
prepared
tungsten
electrode
(see
Section
5-4)
through
front
of
collet
body
to
position
electrode
tip
outside
cup
rim..Securely
tighten
back-
cap.
To
readjust
electrode,
loosen
backcap.
IMPORTANT:
As
a
general
rule,
electrode
extension
should
equal
electrode
diameter;
exact
electrode
exten
sion
may
vary
according
to
application.
3-2.
GAS
HOSE
CONNECTIONS
AND
GAS
VALVE
(If
applicable)
IMPORTANT:
To
install
gas
hose,
connect
gas
hose
fit
ting
to
regulator/flowmeter.
An
extra
hose
may
be
re
quired
to
make
connection.
A.
Cable
Assembly
The
cable
assembly
has
separate
power
cable
and
gas
hose.
The
gas
hose
has
a
5/8-18
male
right-hand
fitting
(Figure
3-1).
To
install
gas
hose,
connect
gas
hose
fitting
to
regulator!
flowmeter
(Figure
3-2).
121429
Page
3
0Ring
\~....._Backcap
Gas
Valve
¶-4-
0-Ring
TA-121
670
Figure
3-1.
Torch
Components
Work
Clamp
Figure
3-2.
Connection
Diagram
B.
Torch
Gas
Valve
Operation
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
extinguished.
In
sufficient
gas
postf
low
results
in
an
oxidized
(black)
electrode
surface.
If
an
oxidized
electrode
were
used,
the
black
surface
would
contaminate
the
weld
and
cause
poor
arc
direction.
IMPORTANT:
As
a
general
rule,
allow
10
seconds
of
gas
postflow
time
per
100
amperes
of
weld
current
be
fore
closing
valve.
3-3.
POWER
CABLE
CONNECTION
(Figure
3-1
and
Figure
3-2)
a
WARNING:
ELECTRIC
SHOCK
can
kIll.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
discon
nect
input
power
employing
lockout/tagging
procedures
before
installing
torch.
Lockout/tagging
procedures
consist
of
padlo
cking
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
aid
red-tagging
circuit
breaker
or
other
disconn~
Ct
ing
device.
The
cable
assembly
has
separate
power
cable
and
gas
hose.
To
install
power
cable,
connect
power
cable
jack
plug
to
weld
output
receptacle
on
power
source
(Figure
3-2).
Torch
Heat
Shi
Cup
Electrode
Jack
Plug
Gas
Hose
Fitting
.Torch
Regulator/Flowmeter
TA-120
824
121429
Page
4
SECTION
4-
SEQUENCE
OF
OPERATION
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Keep
all
covers
and
handle
in
place
while
op
erating.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.
Ventilate
to
keep
from
breathing
fumes
and
gases.
If
ventilation
is
inadequate,
use
approved
breathing
apparatus.
HOT
METAL,
SPATrER,
AND
SLAG
can
cause
fire
and
burns.
Watch
for
fire.
Have
a
fire
extinguisher
nearby,
and
know
how
to
use
it.
Allow
work
and
equipment
to
cool before
han
dling.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
Wearers
should
consult
with
their
doctor
be
fore
going
near
arc
welding,
gouging,
or
spot
welding
operations.
See
Section
1
Safety
Rules
for
additional
safety
information.
4-1.
GAS
TUNGSTEN
ARC
WELDING
(GTAW)
1.
Install
and
connect
torch
according
to
Section
3.
2.
Make
sure
backcap
and
all
gas
connections
are
se
curely
tightened.
3.
With
regulator/flowmeter
valve
closed,
open
gas
cylinder
valve.
Set
power
source
for
desired
welding
amperage.
Wear
dry
insulating
clothing
and
gloves
and
welding
helmet
with
proper
filter
lens
according
to
ANSI
Z49.1.
6.
Energize
welding
power
source.
7.
Set
gas
flow
to
desired
level
(requires
open
gas
valve).
IMPORTANT:
Purge
gas
hose
to
clear
hose
of
air,
moisture,
or
any
other
contaminants.
Allow
gas
to
flow
2
to
3
minutes
on
new
torch;
5
to
6
seconds
thereafter.
8.
Begin
welding.
4-2.
SHUTTING
DOWN
1.
Stop
welding.
IMPORTANT:
As
a
general
rule,
allow
10
seconds
of
gas
postflow
time
per
100
amperes
of
weld
current
be
fore
closing
valve.
2.
Turn
off
welding
power
source.
3.
Turn
off
the
shielding
gas
and
coolant
supplies
at
their
sources.
SECTION
5-
MAINTENANCE
5-1.
INSPECTION
AND
UPKEEP
Usage
and
shop
conditions
will
determine
frequency
and
type
of
maintenance
required.
Perform
inspections
once
a
week.
a
WARNING:
ELECTRIC
SHOCK
can
kill;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
before
working
on
torch.
Disconnect
torch
from
welding
power
source
before
inspection,
maintaining,
or
servicing.
1.
Inspect
torch
for
broken
areas,
cracks,
and
loose
parts;
tighten,
repair
and
replace
as
required.
2.
Remove
grease
and
dirt
from
components,
and
moisture
from
electrical
parts
and
cables.
5-2.
TORCH
BODY
MAINTENANCE
(Figure
3-1)
4~
WARNING:
ELECTRIC
SHOCK
can
kill;
HOT
SURFACES
can
cause
severe
burns.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
before
working
on
torch.
Disconnect
torch
from
welding
power
source
before
inspecting,
maintaining,
or
servicing.
Allow
a
cooling
period
before
servicing.
Once
a
week
inspect
condition
of
torch
body
compo
nents.
4.
5.
a
WARNING:
HIGH
CONCENTRATION
OF
SHIELDING
GAS
can
harm
health
or
kill.
Shut
off
gas
supply
when
not
in
use.
121429
Page
5
Replace
cup,
heat
shield,
backcap,
and
0-rings
if
chipped
away
rather
than
cut
away,
the
grinding
marks
cracked.
Maintaintightfitoftorchcomponentstoensure
should
run
lengthwise
with
the
electrode.
good
weld
quality.
4A
CAUTION:
HOT
FLYING
METAL
PARTICLES
5-3.
INSPECTING
HOSES,
CONNECTIONS
AND
can
Injury
personnel,
start
fires,
and
damage
CABLES
equipment;
TUNGSTEN
CONTAMINATION
can
lower
weld
quality.
~
WARNING:
ELECTRIC
SHOCK
can
kill.
Shape
tungsten
electrode
only
with
properly
Do
not
touch
live
electrical
parts.
guarded
grinder
in
a
safe
location
wearing
Shut
down
welding
power
source
and
discon-
proper
face,
hand,
and
body
protection.
nect
input
power
employing
lockouttagging
Do
not
use
same
wheel
for
any
other
job
or
procedures
before
inspecting,
maintaining,
or
the
tungsten
will
become
contaminated.
seivicing.
Lockout/tagging
procedures
Consist
of
padlo-
For
additional
information,
see.
your
distributor
or
re
cking
line
disconnect
switch
in
open
position,
re-
quest
a
handbook
from
factory
on
the
Gas
Tungsten
Arc
moving
fuses
from
fuse
box
or
shutting
off
and
Welding
(GTAW)
process.
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
TUNGSTEN
PREPARATION:
IDEAL
Stable
Arc
Once
a
week
inspect
hoses
and
connections.
Straight
Ground
A.
Gas
Hose
Gas
leaks
may
result
in
poorweld
quality.
Inspect
hoses
Flat
(the
Dia.
of
this
for
breaks.
Keep
connections
clean
and
tight.
Amperage
Capacity~
Flat
Governs
B.
Power
Cable
Inspect
cables
for
breaks
in
insulation,
and
ensure
that
TUNGSTEN
PREPARATION:
WRONG
all
connections
are
clean
and
tight.
Repair
or
replace
ca
bles
if
insulation
breaks
are
present.
Clean
and
tighten
connections
at
each
inspection.
Arc
Wander_____~*_~~~II1l
5-4.
PREPARING
TUNGSTEN
ELECTRODES
Point
(FIgure
5-1)
TA.1
20
630
Tungsten
electrode
shaping
should
be
done
on
a
fine
Radial
Gro
grit,
hard
abrasive
wheel.
Since
tungsten
is
harder
than
most
grinding
wheels,
causing
the
tungsten
to
be
Figure
5-1.
Tungsten
PreparatIon
Table
5-1.
Tungsten
Size
Chart
Electrode
Diamter
Amperage
Range
-
Polarity
-
Gas
Type
Pure
Tungsten
(Green
Band)
DC-Araon
Electrode
I~egatlve/
Straight
Polarity
DC-Araon
Electrode
~osltlve/
Reverse
Polarity
ACAraon
using
AIgh
Frequency
.020
.040
1/16
3/32
1/8
5-20
15-80
70-150
125-225
225-360
*
10-20
15-30
25-40
5~
10-60
50-100
100-160
150-210
2%
Thorium
Alloyed
Tungsten
(Red_Band)
.020
.040
1/16
3/32
1/8
15-40
25-85
50-160
135-235
250-400
10-20
15-30
25-40
15-35
20-80
50-150
.
130-250
225-360
Zirconium
Alloyed
Tungsten
(Brown_Band)
.020
.040
1/16
3/32
1/8
15-35
20-80
50-150
130-250
225-360
NOT
RECOMMENDED
The
figures
are
intended
as a
guide
and
are
a
composite
of
recommendations
from
American
Welding
Society
(AWS)
and
electrode
manufacturers.
121429
Page
6
May
1988
FORM:
121429
PARTS
LIST
Effective
With
Style
No.
JJ-23
9
Figure
A
-
Complete
Torch
Assembly
T~6
TA-120
670
2
19
23
Item
19
17
12
13
I
121429
Page
1
Item
Stock
Model
No. No.
No.
Figure
A
1
121476
1
121
477
2
120784
1
3
120787
1
3
120
788
1
4
116250
1
5
116256
1
6
116255
1
7
116254
2
8
120785
1
8
120
786
1
9
116259
1
10
116260
1
11
118514
1
12
121340
1
13
121
339
1
14
118512
l9ft
15
116266
1
16
116269
1
17
121337
1
18
600317
l3ft
19
116263
1
20
120729
1
21
120761
1
22
120720
1
23
039
608
1
24
602814
1
25
602160
1
26
101
219
1
27
602178
2
28
019833
1
29
010521
1
Optional
Equipment
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
121429
Page
2
Complete
Torch
Assembly
Description
Quantity
TUNGSTEN,
electrode
1/16
TUNGSTEN,
electrode
.040
CUP
COLLET
BODY,
1/16
tungsten
COLLET
BODY,
.040
tungsten
TORCH
BODY
(consisting
of)
300
HS
HEAT
SHIELD
100VK
VALVE,
knob
(consisting
of)
100R
0-RING
COLLET,
1/16
tungsten
COLLET,
.040
tungsten
300S
BACKCAP,
short
(consisting
of)
300R
P0-RING
HANDLE
POWER
CABLE
&
HOSE
ASSY,
19
ft
(consisting
of)
GAS
HOSE,
19
ft
(consisting
of)
HOSE,
black
1/8
ID
(order
by
ft)
2AN
~~GAS
NUT
3HF
.
.
HOSE
FITTING
CABLE,
power
12-1/2
ft
(consisting
of)
CABLE,
weld
-
copper
No.
4
(order
by
ft)
15PFN
.
.
POWER
CABLE
FITTING
(consisting
of)
~CRlMP,cabIe
FITTING,
gas
(consisting
of)
RING
NUT
PLUG,
jack-red
(consisting
of)
INSULATOR,
jack
plug
SCREW,
self-tapping
filister
hd
8-32
x
1/4
PLUG,
jack
SCREW,
set-socket
hd
1/4-20
x
3/8
.
STRIP,
copper
0.010
x
2-1/2
x
3/4
WIRETIE
V
/
