8
OPERATION AND MAINTENANCE HINTS
If this equipment does not operate properly, stop
work immediately and investigate the cause of the
malfunction. Maintenance work must be performed
by an experienced person, and electrical work by a
trained electrician. Do not permit untrained persons
to inspect, clean, or repair this equipment. Use only
recommended replacement parts.
1. A poor shielding gas connection, or a leaky hose,
will not only waste gas but permit the entry of min-
ute amounts of air, sufcient to contaminate both
the electrode and the weld. Trouble signs: a bluish
coat on the electrode after it has cooled, in welding
aluminum, a dark gray deposit on or beside the weld
bead.
2. Keep the torch hose away from hot metal. The
plastic hose begins to lose strength at 125° F (52°
C).
3. Do not try to repair a damaged power cable or gas
or water hose. Replace it as directed below.
4. If the torch water passages become clogged, they
can sometimes be cleared by reversing the direction
of water ow (that is, sending water in through the
power cable, out through the water hose). However,
never weld with the ow reversed. A strainer in
the water inlet line (such as P/N 96W69) is good
insurance against clogging.
5. If an electrode becomes contaminated, shut off
power, then remove electrode from torch. Break off
the contaminated end (nicking with a grinding wheel
rst will help) and replace electrode.
6. Keep an eye on the sealing “O”ring on the torch
cap. If it shows signs of wear or distortion, cut it
off. Then install a new ring (98W18). Apply a little
silicone grease to the new ring before attempting
to slide it over the cap threads.
REPLACING GAS OR WATER HOSE
1. Unscrew the torch handle and slide it back over the
service lines to expose the hose clamp (see Fig.
5).
2. Clip off the hose clamp (98W43) and remove the
hose. The rubber torch bodies do not use a clamp,
the hose is retained with ferrule nuts.
3. Clean off the barbed tting, and then brush on some
3M type 1711 adhesive onto the tting.
4. Slide the new hose clamp over the new hose.
5. Place the end of the hose in hot water for a short
time, and then slide the new hose all the way over
the tting, so it completely covers the ridges.
6. Orient the hose clamp so the tabs will not interfere
with the handle, and position the clamp so it is over
the ridges on the tting.
7. Crimp both tabs using a crimping tool or pliers (see
Fig. 3).
REPLACEMENT OF GAS LENS SCREENS IN 45V63,
995795, AND 45V64 (See Figure 4)
Large diameter gas lens collet bodies contain replace-
able screens. If plugged by spatter, replace as follows:
1. With the collet body removed from the torch, remove
the outer snap ring, P/N 54N71. This can be done
by using a small screwdriver, or an electrode with
a diameter no greater than 3/32-in. Insert the tip in
the slot on the outer sleeve of the collet body, and
pry out the snap ring.
2. Using a pair of needle nose pliers, pry out the inner
snap ring, P/N 54N69.
3. Hold the collet body with the screens down, and
gently tap the body on the work bench. The body
contains three ne and one coarse screens, sepa-
rated by spacers. If the screens are not badly fouled,
they should drop out of the body. Excessive fouling
may necessitate prying out the screens.
4. Inspect the screens and replace those which show
plugging, or other damage.
5. Replace the screens and spacers making sure that
a spacer is installed between each screen, and that
the coarsest screen is inserted last. Replace the
snap rings.
Fig. 4 - Replaceable Parts in Collet Bodies 45V63,
995795, and 45V64Fig. 3 - Crimping a Hose Clamp
SCREEN (250 mesh)
54N66
SCREEN (100 mesh)
54N67
INNER SNAP RING
54N69
OUTER SNAP RING
54N71
OUTER SPACER
54N70
INNER SPACER
54N68