ESAB ST-16 User Manual

INSTRUCTIONS for
F11-744-R
September, 2004
ST-16 MIG WELDING TORCH
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting, and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
I. INTRODUCTION
The ST-16 Torch, P/N 997498, is a rugged all purpose, water cooled, manual Mig welding torch designed to operate at welding currents up to 600 amperes continu­ous duty using argon as the shielding gas. The ST -16 is intended for use with ESAB wire feeders which have provision for water cooling and will handle all types of welding wires in sizes from .030-in. through 7/64-in. di­ameter.
II. DESCRIPTION
To provide maximum resistance to the abuses of day to day service, the torch is of heavy-duty construction with metal parts well insulated from current carrying mem­bers. It’s 55-degree, curved stainless steel front body permits effective operation in tight, hard-to-reach cor­ners and other contained areas. The torch employs metal nozzles and either slip-in contact tubes or threaded con­tact tips (long or short). Each contact tube is threadless and is retained by a collet nut supplied with the torch. All service lines are internally connected to the torch body and exit from the rear of the torch handle for easy torch maneuverability. For weld start-stop control, the torch is provided with a positive action universal lever switch which can be positioned at any point on the torch handle preferred by the operator.
For feeding all wires, a self-lined conduit with either a spring or plastic jumper liner is normally used. An alter­nate replaceable liner conduit system is also available for feeding 0.35, .045 and 1/16-in. hard wires through a continuous metal conduit liner.
III. ACCESSORY EQUIPMENT
A. REQUIRED
The ST-16 requires a nozzle (see Table 1), and several wire feed accessories of the proper size for the wire be­ing used. (Refer to Table 2 if using the self-lined conduit system or Table 3 if using conduit with continuous or replaceable liner system). One other accessory whose selection depends upon wire size is the feed roll on the wire feeder itself. Selection of this accessory is covered in the appropriate wire feeder instruction booklet.
Table 1 - Nozzles
Description
No. 8 Nozzle .......................................
No. 10 Nozzle ......................................
No. 10L Nozzle ....................................
No. 12 Nozzle ......................................
No. 12M Med. Length Nozzle ...............
No. 12L Long Length Nozzle ................
No. 12 Spot Welding Nozzle ................
* Requires Sp atter Liner, P/N 633603
B. OPTIONAL
1.
Centering Bushing, P/N 994330 (For use with No.8
and No. 10 nozzles) - Eliminates any possibility of spatter bridging in the torch. This is accomplished by using this one-piece centering bushing and spat­ter liner in place of the two individual pieces nor­mally used. Note that it can only be used at maxi­mum current of 350 amps with argon or 550 amps with C02.
Part No.
P/N 598739* P/N 598721* P/N 598891 P/N 633985 P/N 997310 P/N 639756 P/N 993757
Be sure this information reaches the operator. You can get extra copies through your supplier.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained, and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted, or contami­nated should be replaced immediately . Should such repair or replacement become necessary, the manu­facturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair, or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
2
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precautionary information from the references listed in Addi-
tional Safety Information section. Before per­forming any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS -- Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equip­ment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves, trouser
cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing
5. Protect other personnel from arc rays and hot sparks with
a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far. By­standers should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and ex­plosions. Therefore:
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.
6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if move­ment is confined, or if there is danger of falling.
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or dam­aged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from work and from ground.
7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS — May be dangerous.
Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cut­ting current creates EMF around weld­ing cables and welding machines. There­fore:
1. Remove all combustible materials well away from the work area or cover the materials with a protective non-flam­mable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.“
3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or por­table fire extinguisher. Be sure you are trained in its use.
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimize exposure to EMF: A. Route the electrode and work cables together. Secure
them with tape when possible. B. Never coil the torch or work cable around your body. C. Do not place your body between the torch and work
cables. Route cables on the same side of your body. D. Connect the work cable to the workpiece as close as
possible to the area being welded. E. Keep welding power source and cables as far away from
your body as possible.
3
11/95
FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shield­ing gases can cause asphyxiation. Therefore:
1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocar­bon vapors to form phosgene, a highly toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.
5. WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health &
Safety Code
CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylin­der, valve, or relief device can injure or kill. Therefore:
1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition. Follow manufacturer's operating instructions for mounting regulator to a com­pressed gas cylinder.
2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas As­sociation, 1235 Jefferson Davis Highway, Arlington, VA
22202.
§25249.5 et seq.)
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore:
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work.
2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.
3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for elec­tric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.
The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for Weld­ing and Cutting of Containers That Have Held Hazardous Substances."
MEANING OF SYMBOLS - As used through­out this manual: Means Attention! Be Alert! Your safety is involved.
Means immediate hazards which, if not avoided, will result in immediate, seri­ous personal injury or loss of life.
Means potential hazards which could result in personal injury or loss of life.
Means hazards which could result in minor personal injury.
4
SP98-10
Collet Nut Wrench, P/N 996109 - Permits loosen-
2.
ing of the collet nut without removing nozzle. Par­ticularly recommended when using the 994330 cen­tering bushing. The wrench employes a stop-pin to assure proper position of contact tube when tighten­ing the collet nut.
3.
Zippered Hose Sheath, P/N 41V98 - Reduces abra-
sive wear of the cables and eliminates the need for taping the service lines together.
IV . INSTALLA TION
A. USING SELF-LINED CONDUITS (See Figure 1)
1.
When using all wire except 7/64-in. cored, insert the proper jumper liner through the rear of the torch handle and as far into the brass conduit connection fitting (see Fig. 3) as it will go.
NOTE:
2.
Insert the torch end of the conduit through the rear of the torch handle and into the conduit connection
7/64-in. cored wire does not require a jumper liner. For .035 and 3/64-in. soft wires, first insert the plastic jumper liner into the spring support liner and then place both in the torch.
fitting. As the conduit is inserted it will fully seat the jumper liner.
3.
Referring to Figure 3, loosen the two No. 10-32 screws on locking nut (598787), slide handle back, and then lock the conduit in place by locking the No. 10-32 setscrew on the conduit connection fitting. Re­assemble handle to locking nut and tighten setscrews.
4.
Screw the proper outlet guide into the drive (wire feeder) and of the conduit.
5.
Secure the outlet guide in the front clamp of the ac­cessory support assembly on the wire feeder (refer to the wire feeder instruction booklet).
6.
With the nozzle and contact tube or tip removed and wire in the wire feeder feed rolls, use the inching switch on the wire feeder to feed wire through the conduit and torch until it protrudes from the torch.
7.
Select the correct tube ot tip. If using a contact tube, slip the contact tube (small diameter end first)
over the wire and through the collet nut (632811, supplied with the torch). Tighten the collet nut firmly and hold the contact tube in place.
If using a contact tip, the collet nut is not needed. Remove and discard the collet nut. Slip the contact tip over the wire and screw it into the torch.
8.
If required, place a spatter liner (633603) in the proper size nozzle and install into front end of torch.
Wire Type
Hard
Cored
Table 2 - ST-16 Wire Feed Accessories Using Self-Lined Conduit System
Wire Size
.030 .035 .040 .045 .052 1/16 5/64 3/32
.030 .035 .040 .045 .052 1/16 5/64 3/32 7/64
Contact Tube (Slip-in)
-
996104
37277
37280*
996816*
37283* 37285*
996108*
-
996104
37277
37280*
996816*
37283* 37285*
996108
-
Contact Tip (Threaded)
Long Short
20123 632794 37276 37279* 632796 37282*
-
­20123
632794 37276 37279* 632796* 37282*
-
-
-
632791 632793 37275 37278* 632795 37281* 37284* 632800*
632791 632793 37275 37278* 632795* 37281* 37284* 632800 633611
Jumper Liner
993822 993822 993822 993823 993923 993823 993823 598927
993822 993822 993822 993823 993823 598927 598927 598927
-
Soft-Lined Conduit 10-ft.. x (I.D.)
633455 (.063) 633455 (.063) 633455 (.063) 633456 (.093) 633456 (.093) 633456 (.093) 633456 (.093) 598922 (.195)
633455 (.063) 633455 (.063) 633455 (.063) 633456 (.093) 633456 (.093) 598806 (.140) 598806 (.140) 598922 (.195) 598922 (.195)
Wire Outlet Guide Mig-31A, Mig-34
993859 993859 993859 04N19 04N19 04N19
-
­993859
993859 993859 04N19 04N19 04N19 2075247
-
-
Mig-35 Digimig
993860 993860 993860 39N15 39N15 39N15 39N15 62N17
993860 993860 993860 39N15 39N15 39N15 62N17 62N17 39N16
Outlet Guide Insert
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Soft
Spring support liner (598927) is also required. Use No. 12M Nozzle (P/N 997310). Includes replacement sleeve (995651).
.035 .040 3/64 1/16 3/32
996104
37277 996105 996106
632794 37276 632796 632798
-
632793 37275 632795 632797 632800
636877 636877 636877 636879 994552
*
5
633578 (.060) 633578 (.060) 633578 (.060) 634777 (.093) 46V68 (.128)
Includes replacement sleeve (995692). Includes replacement sleeve (995693). New I.D. for better arc permfrmance on hard and flux cored wire.
05N56 05N56 05N56 05N56
-
29N13 29N13 29N13 29N13 29N13
993902 993902 05N57 12N75 05N58
Mig-35
WIRE OUTLET GUIDE
SLEEVE
WIRE OUTLET GUIDE
HARD and CORED
INSERT
GUIDE
CONDUIT
SOFT
SPRING JUMPER LINER
PLASTIC JUMPER LINER
(For all soft wire)
(For all hard and cored wire)
COLLET NUT - 632811*
JUMPER LINER
SELF-LINED CONDUIT
Fig. 1 - Installation of Wire Feed Accessories Using Self Lined Conduit System
SPATTER LINER
CONTACT TUBE OR TIP
* Discard collet nut if using threaded contact tip.
6
Table 3 - ST-16 Wire Feed Accessories Using Conduit/Replaceable Liner System
Wire Type/ Size
Hard
Cored
Use No. 12M Nozzle (P/N 997310).
Contact Tube (Slip-in)
996104 996105 996816 996106
996105 996816 996816
Contact Tip (Threaded)
Long Short
632794 632796 948335 632798
-
-
-
632793 632795 948308 632797
632795 948308 632797
B. USING CONDUITS WITH REPLACEABLE LIN­ ERS
1.
Insert the torch end of the conduit through the rear of the torch handle and into the conduit connection fitting.
2.
Refering to Figure 3, loosen the two No. 10-32 screws on locking nut (598787), slide handle back, and then lock the conduit in place by tightening the No. 10-32 setscrew on the conduit connection fitting. Reas­semble handle to locking nut and tighten setscrews.
3.
Insert the liner into the conduit and through the torch. The shoulder spring about the liner should rest in­side and below the threads of the wire feeder end of the conduit.
4.
Slip the wire outlet guide (see Table 3) over the liner protruding from the conduit and screw into the con­duit connection. If necessary , adjust shoulder spring on liner so that the end of the liner is about flush with the end of the wire outlet guide.
5.
Complete the installation by following steps 5 through 8 as described on page 5 , (Section IV, Using Self­Lined Conduits).
V. ADJUSTMENT & OPERATION
Before adjustments are made, disengage the pessure roll to prevent wire from feeding and arcing to an accidental ground.
Soft-Lined Conduit 10-ft.. x (I.D.)
598922 (.195) 598922 (.195) 598922 (.195) 598922 (.195)
598922 (.195) 598922 (.195) 598922 (.195)
Specific operation of the torch depends on the p articular wire feeder with which it is used. Therefore, consult the instruction manual supplied with the wire feeder.
Replaceable
Spring
Liner
636843 598786 598786 598786
598786 598786 598786
Wire Outlet Guide
Mig-35 Digimig
29N13 29N13 29N13 29N13
29N13 29N13 29N13
VI. MAINTENANCE
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 replacements.
A. POWER CABLE
If the power cable assembly becomes damaged, it is recommended that (1) a new one be purchased, or (2) the damaged unit be turned over to an ESAB authorized repair station for repair. The connection fittings are crimped on at the factory by special crimping tools to ensure strong connections and prevent leakage. A sat­isfactory job cannot be done without these tools.
B. GAS AND W A TER HOSE ASSEMBLIES (Refer to Fig. 3)
If shielding gas (46V63) or water hose assemblies (46V25) require replacement, loosen the two No. 10-32 x 3/16-in. set screws on the handle locking nut and pull handle back.
To replace gas hose assembly, proceed as follows:
To set the shielding gas flow rate, press the torch lever to open the gas solenoid valve and adjust the flowmeter to the desired flow rate. For proper operation a minimun flow of .40 gpm of cooling water at 60-deg.F or less, must be maintained if the torch is to perform at rated capacity . A torch inlet water pressure of 25 psi minimum will provide adequate flow. Check these water flow re­quirements before starting. The wire feed conduit should be kept as straight as possible and without sharp bends to assure smoother wire feed.
1.
Clip off wire hose clamp (53N46) and remove hose.
2.
Clean off fitting, and then brush on some Loctite Prism 447 (P/N 71201202 - 20 gm tube) onto the fitting.
3.
Slide new wire hose clamp on the new hose and insert the hose over the grooved sealing area of the hose fitting on the torch.
3.
Using a pair of pliers, pull on the hose clamp tightly over the grooved sealing surface and apply 1/2 twist. Be sure to position the wire hose clamp so that the
7
twist does not interfere with another part or the in­side of the handle.
5.
Reposition the pliers about 1/8-in. from the hose and twist an additional 1-1/2 turns.
6.
Snip off excess wire about 1/8-in. from hose and bend the twisted ends as shown below.
T o replace the water hose assembly proceed as follows:
1.
Snip off the ear of the hose clamp by cutting into the sides with pincers.
2.
Clean off barbed fitting, and then brush on some Loctite Prism 447 (P/N 71201202-20gm tube) onto the fitting.
3.
Slide the hose clamp over the hose.
4.
Push hose into the short water connection tube of the torch body and tube assembly . Position the hose clamp over the grooved section of the short tube.
5.
Crimp the ear of the hose clamp with pincers.
6.
Rotate the hose clamp so the ear is positioned close to the power connection tube as shown in Section “A-A” of Figure 3.
C. NOZZLES
Adherence of spatter can be minimized and removal made easier by coating the inside of the nozzle with No. 65 Nozzle Compound (4-oz. container - 08N65; 1 quart container - 08N75). If insulator liner is damaged or cracked it should be replaced.
(2) SETSCREW
GASKET SEAL
HANDLE
WIRE GUIDE ASSEMBLY
INSULA TOR SLEEVE
END FITTING
NOZZLE BODY ASSEMBLY
CENTERING BUSHING
Fig. 2 - Exploded View of T orch
LOCKING NUT
D. CENTERING BUSHING (Refer to Figs. 2 &3)
To remove the centering bushing (17782) for inspection or replacement, first shut off power source and then re­move nozzle, contact tube, and collet nut. Insert the centering bushing removal tool (996300, supplied with the torch) through two adjacent bushing slots and then hook over two opposite bushing ribs. The centering bush­ing can then be removed by pulling the tool straight out.
If centering bushing is wedged against the nozzle body , do the following:
1.
Loosen the two No. 10-32 handle locking screws and pull back handle enough to clear the locking nut (598787).
2.
Holding nozzle body (598885), loosen locking nut at least one turn.
3.
Remove centering bushing as described above.
E. TORCH GAS SHIELDING (Refer to Figs. 2 &3)
Excellent gas coverage is assured by laminar gas flow techniques and efficient cooling. Any water leakage into the gas stream area, however slight, will disturb gas coverage and weld quality. If gas coverage falls below the desired level, tighten the torch locking nut a quarter turn, purge the torch with shielding gas for a moment and return to service. If this does not correct the condi­tion, the entire body and tube assembly should be re­moved to permit clearing the internal components of any collected spatter particles and then reassembling.
F. GASKET AND END FITTING (Refer to Figs. 2 &3)
To remove gasket (633884) or wire guide and fitting (996403) for replacement or inspection purposes, pro­ceed as follows:
1.
With power source turned off, disconnect all torch service lines.
2.
Remove nozzle, contact tube and collet nut.
3.
Loosen the two setscrews on locking nut (598787) and pull back torch handle (lever switch attached) enough to allow locking nut to rotate freely.
4.
Unscrew the locking nut from the nozzle body (598885)
5.
Pull the nozzle body away from wire guide assem­bly (997027). The centering bushing (17782) will fall free at this point.
6.
Check the gasket for cracks and deformed sealing surfaces. When replacing the old, or installing a new gasket, apply a thin film of silicone grease (17672) to the O.D. and sealing surfaces of the gasket.
7.
T o remove the wire guide end fitting (996403), clamp the curved wire guide assembly and then unscrew the end fitting using a 7/16-in. open-end wrench (note that the end fitting and wire guide are connected via a 1/8”-27 tapered pipe thread).
8
(Continued on page 10).
(Supplied with 997027)
Conduit Connection Fitting
SCREW - 10-32 X 3/16
6133-0907
RUBBER BAND - 595958
HANDLE
598738
HOSE CLAMP
950626
LOCKING NUT
598787
“A”
INSULATOR SLEEVE - 633880
5/8“ - 18 L.H.
WATER HOSE
ASSEM. - 46V25
“A”
LEVER SWITCH & CORD
ASSEM. - 996356
SCREW - 10-32 X 3/16
6133-0907
7/8 - 14 L.H.
(12 FT .)
(See Fig. 4)
POWER CABLE
ASSEM. - 598928
(12 FT .)
(Accessory - see Table 1)
5/8“ - 18
SHIELGING GAS HOSE
ASSEM. - 46V63
(12 FT .)
SWITCHCORD ASSEMBLY
(See Figure 4)
CONDUIT
GAS
WATER IN
Fig. 3 - ST-16 Torch, P/N 997498
SECTION “A” - “A’
GASKET - 633884
NOZZLE BODY
ASSEM. - 598885
WIRE GUIDE, BODY &
1/8” - 27
TAPERED
PIPE THRD.
TUBE ASSEM. - 997027
COLLET NUT - 63281 1
CENTERING BUSHING - 17782
END FITTING . - 996403
(Supplied with 997027)
NOZZLE
9
SPA TTER LINER
(Accessory - see Table 1)
(Accessory - see Table 2 & Section IV-7)
CONTACT TUBE
POWER AND WATER OUT
SWITCHCORD
SUPPLIED
CENTERING BUSHING 996300
REMOVA L TO OL
Hand tighten locking nut 598787; then another 3/16”
to 1/4” turn with a wrench (approx 125-in.lbs.)
(Continued from page 8).
Before installing a new end fitting, apply a thin film of Dow Corning Heat Sink Compound No. 340 (73585976) to both the male and female threads.
8.
Reassemble the torch in reverse order. When reas­sembling, tighten the lock nut hand tight, and then tighten another 3/16 to 1/4 of a turn (approx. 125 in.­lbs.) with a wrench. This should provide enough load­ing on gasket to prevent water and gas leakages.
G. LEVER SWITCH ASSEMBLY
If part replacement on the lever switch assembly is nec­essary , refer to Fig. 4 and seperate the two halves of the switch body by removing the two slotted No. 8-32 x 3/8­in. screws. Then proceed as directed below. You can pull back the rubber band off the torch handle and cut the plastic tape wrappings about the service lines for convenience but it is not necessary unless the switchcord replacement is also involved
To replace switch and cord assembly, switch (181W34), or other parts:
1.
Remove insulating strip (996340).
2.
Carefully clamp lower half of body (996212) in vise and drive out 1/8-in. dia. dowel pin (6190-0400); le­ver, lever return spring, and actuator spring will drop out.
3.
Lift out switch (181W34) from the locating lugs on body .
4.
If replacing the micro switch only, unsolder the con­nections. Do not snip off the leads. Replace switch by soldering the black lead (or longer lead) to the normally open terminal (NO) and the white lead to the common terminal (C).
5.
If cord removal is necessary or if cord and switch assembly is being replaced, use 5/64-in. hex socket wrench and loosen set screw (6133-0876). The brass strain relief (61N67) may be wedged in the body. If wedged, hit the strain relief through the slotted open­ing of the body with a screwdriver. This should free the strain relief and the switch and cord assembly can then be removed.
To reassemble lever switch assembly:
1.
Insert strain relief into body (if cord was removed).
2.
Locate holes through the switch onto the lugs of the body and slide into place. Move the strain relief back and forth as required. Be sure the leads are com­pletely down in the deep recess of the body.
3.
Tighten strain relief set screw (6133-0876) until top of the screw is flush with body surface.
4.
As illustrated in Fig. 4, place in position the actuator spring, lever, and lever return spring in that order.
5.
Hold the parts in position with your thumb and align the holes of lever body. Insert dowel pin and tap lightly with hammer until dowel pin is completely in
(2) SCREW No. 8 - 32 x 1/4-in.
SWITCH -181W34
(Included in 996359)
INSULATING STRIP - 996340
(2) SCREW No. 8 - 32 x 3/8-in.
“A”
2-PIECE BODY 996212
SET SCREW 61330876 No. 8 - 32 x 1/4-in.
“A”
ACTUA TOR SPRING - 58N18
SWITCH AND CORD ASSY . - 996359
INCLUDES:
SWITCH - 181W34 CORD - 7363-5182 - 12-ft. PLUG - 2062336 STRAIN RELIEF - 61N67
LEVER - 58N17
LEVER RETURN SPRING - 58N19
Fig. 4 - Lever Switch Assembly/12-ft. Cord, P/N 996356
10
place. Push lever down and listen for distinct click­ing noise of switch (energized position). Lever should return upward on its own spring power and another click will be heard (deenergized position). If the two clicking noises are heard, the lever switch assembly is correctly assembled.
6.
Reassemble or replace insulating strip (996340) which fits into a recess on the I.D. of the body and over the switch
To reassemble lever switch assembly to torch:
1.
Place the two halves of the torch switch body around the torch handle and tighten the two No. 8-32 screws.
2.
Locate lever switch assembly at any desired posi­tion and tighten down the two No. 8-32 x 1/4-in. pan head screws.
3.
If removed, place rubber band, that was hanging loosely over the service line back over the rear of the torch handle as illustrated in Fig. 3 to hold the
cord of the lever switch assembly in place. Opera­tor may wish to use 3 or 4 wraps of polyethylene tape (9025-0033) for added support.
4.
If plastic tape wrappings were cut, wrap 3 or 4 turns of plastic tape around all service lines spaced ap­proximately 4-ft. apart.
11
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATIONS GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS: Telephone (843) 664-5540/Fax: (800) 634-7548
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D. LITERATURE REQUESTS: Telephone: (843) 664-5501 / Fax: (843) 664-5548
E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4469 / Fax: (843) 664-5557
Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING:
Telephone: (843)664-4428 / Fax: (843) 664-4476 Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST
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Telephone: (843) 664-4248 / Fax: (843) 664-4454 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
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IF YOU DO NOT KNOW WHOM TO CALL
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F11-744-R 09/2004
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