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5/93a

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7/93

TABLE

OF

CONTENTS

SECTION

SECTION

SECTION

3-1.

3-2.
3-3.

SECTION

SECTION

5-1.
5-2.

SECTION

Figure

Figure

Table

-

1

SAFETY

2

SPECIFICATIONS

INSTALLATION

3-

Typical

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1

2

3

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7

8
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OM.1564A

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OM-1564

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S-0834

Page

1

SECTION

3

INSTALLATION

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2-13/16

8

1-1/8

C

1-5/8

0

E

F

G

in

3/4

3/16

1

4-1/4

ST-800

267

Millimeters

21197-A

/ST-i

71

29

41

19

25

108

2

ST-I

/

21

198-A

OM-1564

Page

3-1.

Figure

2

TypIcal

Mounting

Location

And

Overall

Dimensions

3-2.

Required

Required

Assembling

Torch

5

Torch

Torch

Parts

4

Parts

Parts

3

And

Torch

Assembly

2

Obtain

the

Section

2

3

4

5

I

Power

Collet

Collet

Cup
Tungsten

Section

6):

Body

Assembling

6

Torch

Body

7

8

Shield

Heat

Backcap
Shown)

9

0-Ring

Installing

To

adjust

Tungsten

tungsten

backcap.

connections

Keep

heat

cup.

if

O-nngs

cracked.

following

Cable

Adapter

Electrode

5)

Torch

(Short

position,

shield,

parts

(See

Body

Backcap

Replace

tIght.

backcap,

(see

loosen

and

Installing

8

2

4

Tungsten

Figure

3-2.

Required

Torch

Parts

And

Torch

Assembly

ST-800

280

CM-I

ST-BOO

/

564

I

39-A

Page

3

3-3.

Connecting

Torch

BUILDUP



Shut

OF

off

shielding

~

I

SHIELDING

gas

~

supply

when

GAS

not

can

READ

SAFElY

harm

health

in

use.

or

kill.

BLOCKS

Turn

and

installing

Obtain

1

2

Gas

3

4

5

6

7

Power/Coolant

To

material

only

300

at

beginning

Off

welding

disconnect

Gas

Hand

Coolant

Left-Hand

Connections:

torch.

the

following

Hose

Fittings

Hoses

input

With

Fittings

Regulator/Flowmeter

Gas

Cylinder

Valve

in

brass.

Series

Power

Gas

contact

copper,

stainless

In

Connections:

corrosion

Welding

Gas

Torch

decrease

be

power

With

Source

Hose

with

power

hoses:

5/8-18

coolant

silver

waml.1

source,

before

Right-

5/8-18

in

solder,

steel,

9/91

torch,

can

or

plastic.

Coolant

8

9

Coolant

10

11

Power

12

Torch

Cable

Torch

13

Cable

Connect

connecting

terminal

14

Work

Connect

paint-free

close

as

Use

clean

System

In

Coolant

Out

Cable

Coolant

Coolant

cables

adapter

on

welding

Clamp

work

location

weld

to

wire

brush

metalatweld

Fitting

Fitting

Adapter

In/Power

Out/Power

to

adapter

to

power

clamp

on

area

or

sandpaper

loint

before

weld

output

source.

to

a

clean,

workpiece,

as

possible.

area.

to

a

OM-1564

Do

not

ethylene

MILLER

as

4

Page

use

glycol

Tools

automotive

and

coolant

Needed:

antifreeze.

distilledordeionized

Part

No.

~

5/8,7/8in

Figure

128

Use

705.

3-3.

mix

only

water,

of

such

ConnectIng

Torch

TEMP.

To

Above

Distilled,
Deionized,

Or

Quality

Water

Typical

(0

High

GTAW

32

C)

:

Tap

0

F

32

to

35%

GIycoI

65%

System

F

(18

F

(0

Ethylene

And

Water

C)

C)

F

0

Below

(18

C)

See

Ethylene

Glycol

Manufacturers

Suggestion

ST~t2O

199.A

SECTION

4

MAINTENANCE

&

TROUBLESHOOTING

Turn

Off

all

power

before

I~

~

maintaining.

READ

40

Hours

Clean

And

Tighten

~sL~c

3-3

4-1.

Figure

Table

Maintenance

4-1.

Troubleshooting

Weld

Terminals

Schedule

SAFETY

~

~

BLOCKS

33

-~

not

Do

coolant

center.

at

beginning

Months

6

~

throw

take

away

to

area

Flush

System

And

Replace

Coolant

antIfreeze

recycling

N

OTE

of

Lack

high

arc.

Wandering

Tungsten

after

bright

No

decreased

or

frequency;



arc

poor

electrode

conclusion

coolant

~

Trouble

difficulty

control

oxidizing

of

weld.

flow

Before
electrode

in

establishing

of

direction

and

not

rate.

using

of

arc.

remaining

troubleshooting

Section









-~

H

-~

to

Check

not

are

Check

and

adlust

Reduce

Shield

Increase

Replace

Add

coolant,

ant

supply

according







~



1
J

table,

cables

close

welding

spark

flow

gas

weld

zone

postflow

torch

and

Owners

5.

and

to

power

parts

torch

any

gaps.

rate

from

time

check

check

:

for

cracks

grounded

source

according

drafts.

according

if

water

for

clogged

Manual.

selection

Remedy

bad

or

metal.

Frequency

High

to

welding

Check

to

welding

leaked

has

hosesorcoolant

and

connections.

Repair

power

and

tighten

into

preparation

Be

or

replace

necessary

and

control,

source

all

fittings.

gas

source

power

torch.

strainer

of

that

sure

if

necessary,

Owners

Owners

according

tungsten

torch

cables

parts.

check

Manual.

Manual.

cool

to

OM-1564

Page

5

SECTION

5

TUNGSTEN

ELECTRODE

rnod2.1

3/93

N

5-1.

Electrode

Pure

2%

Tungsten

Zirconium

Tungsten

OTE

Selecting

-

Diameter

Tungsten

Band)

(Green

.010

.020

.040

1/16

3/32

1/8

5/32

3/16

1/4

ThorIum

(Red

.010

.020

.040

1/16

3/32

1/8

5/32

3/16

1/4

Alloyed

(Brown

.010

.020

.040

1/16

3/32

1/8

5/32

3/16

1/4

Alloyed

Band)

~

Tungsten

Band)

For

additionalin

Arc

Welding

Wear

clean

Electrode



DC

Negative/Straight

Argon

Uptol5

70-150

125-225

225-360

360-450

450-720

720-950

Up

25-85

50-160

135-235

250-400

400-500

500-750

750-1000

5-20

15-80

to

15-40



*

*

a

a

a

a

a

*



Electrode

Polarity

25

formation,

(GTAW)

gloves

Table

see

process:

to

prevent

5-1.

Tungsten

Amperage



DC

Positive/Reverse

Argon

25-40

80-125

25-40

40-55

80-125

Range



*

a

10-20

15-30

40-55

55-80

a

*

a

10-20

15-30

55-80

*

a

a

a

a

a

a

distributor

your

contamination

Size

-

Gas

Electrode

Polarity

Type

AC

High

-

handbook

fora

of

tungsten

Polarity



Argon

Frequency

UptOl5

5-20

10-60

50-100

100-160

150-210

200-275

250-350

325-450

Up

15-35

20-80

50-150

130-250

225-360

300-450

400-500

600-800

Upto2O

15-35

20-80

50-150

130-250

225-360

300-450

400-550

600-800



20

to

on

electrode.

Using

the

AC

Wave

Gas



Argon

Using

Tungsten



Balanced

High

UptolO

10-20

20-30

30-80

60-130

100-180

160-240

190-300

250-400

to

15

Up

5-20

20-60

60-120

100-180

160-250

200-320

290-390

340-525

Uptol5

5-20

20-60

60-120

100-180

160-250

200-320

290-390

340-525

Freq.

Typical

Not

The

manufacturers.

OM-1564

argon

Recommended.

figures

Page

shielding

listed

6

are

gas

intended

flow

as

rates

a

are

guide

15

and

to

35

are

cth

(cubic

a

composite

feet

per

of

recommendations

hour).

from

American

Welding

Society

(AWS)

and

electrode

S0009

5-2.

Preparing

Tungsten

_____________________

Figure

a

FLYING



Shape



Keep

5-1.

Preparing

CAUTION

SPARKS

tungsten

flammables

1-1/2

Electrode

Times

Diameter

-

I?~IIIE

2

For

AC

Or

DC

cause

guards

AND

electrode

away.

Tungsten

METAL

HOT

on

only

grinderwith

can

proper

2

-

Electrode

injury

in

safe

a

Positive

and

start

location

fIres.

wearing

1

Tungsten

2

BaIled

Ball

end

of

by

applying

slightly

higher

mended

eter

(see

trode

positive

(DCEP)

Welding

properface.

I

Tungsten

2

Tapered

Grind

end

hard

abrasive

Do

not

ing.

or

tungsten

nated

causing

End

tungsten

either

fora

given

Table

hand,

End

of

use

can

Electrode

before

ac

an

what

than

electrode

5-1),

amperage.

and

body

Electrode

tungsten

wheel

wheel

become

lower

weld

welding

amperage

is

recom

diam

dc

a

or

S-0181

Ref.

protection.

wam2.19~91

fine

on

weld

before

for

other

contami

quality.

elec

grit,

jobs

Figure

Ideal

Wrong

5-2.

Preparing

2-1/2

Electrode

4

Tungsten

Tungsten

Times

Diameter

Preparation

4

Preparation

Tungsten

1



Stable



Wandering

For

2

Arc

1

2

3

DC

Arc

Electrode

Negative

l

2

Diameter

amp*age

3

4

1

2

3

4

(DCEN)

StableArc

FIat

of

capacity.

Grinding

Straight

Arc

Point

Gnndlng

RadIal

Wheel

Ground

Wander

Wheel

Ground

Welding

this

______R1



flat,

SO~5~

Ret

determines

Ret

5.0182

s-o~

OM-1564

Page

7

SECTION

6

PARTS

LIST

13

Item

No.

1

....

2

....

...

...

....

....

....

....

....

116240

116239

2

2
3

4

5

6

6

7....120720..

..8....120721

9

....

..9....116268..

10....

11

....

12....

13...

14....

14...

14...

15
16

17

18
19

116248

116242
116241

20

21

OPTIONAL

BE

SURE

OM-1564

TO

Page

Stock

No. No.

118507

116245



120230

120720

120721

116246
116247

116267

118512

116266

116269

116243

116244

116249

116244

PROVIDE

8

21

ModeL

M4G-HS

M3G-HS...

M412PC...

M425PC

.212AH

225AH

2AN

3HF

M3PCA

AS35



AM35.



AL35

A2R35



..ACM....

A2R35



MODEL

20Fig

___________________

AND

19

Fig

6-2

Figure

Figure

BODY,

HEAT

HEAT
HEAT

POWER

RINGNUT

...RHNUT

WATER
WATER

RINGNUT

..RHNUT

GAS
GAS

HOSE,

..GASNUT

HOSE

POWER
BACK

BACK

BACK

..O-RING

COLLET,

ADJUSTING

0-RING

COLLET

CUP,

TUNGSTEN,

SERIAL

6-2

6-1.

6-1.

gun

SHIELD
SHIELD
SHIELD

COOLED

COOLED

HOSE,
HOSE,

FITTING
CABLE

CAP,

CAP,
CAP,

(see

NUMBER

Complete

black

(see

BODY,

17

Torch

Description

Complete

(consisting

CABLE

short

medium

long

FITTING,

POWER

POWER

12-1/2ft

25ft

(consisting

2

series

ADAPTER

(consisting

(consisting

Fig

6-2)

CAP,

(consisting

(consisting

(consisting

(see

6-2)

Fig

electrode

WHEN

16

Fig

Assembly

Torch

of)

CABLE,

CABLE,

1/8

6-2)

Fig

(consult

ORDERING

6-2

Assembly

90

(consisting

of)

of)

ID

(order

of)

of)

of)

of)

your

14

-

12-1/2ft

25ft

(consisting

ft

as

by

welding

REPLACEMENT

..-

of)

(consisting

of)

of)

required)

supply

distributor)

PARTS.

ST.121

196-A

Quantity

1

1

1

1

2

1

2

2

1

1
1
1

1

1
1

1
1
1

1

1

1

1

1
1

1

....

4C.XXX

Count

Short

S-0830

Using

Duty

Body

When

Continuous

25%

Cotlet/Couiet

By

Reduce

Rating

Shod

SELECTOR

Length

PARTS

Standard

240

Length

116

Body

No.

Shield

MHS

3C8-XXX

Coilet

Standard

Stock

Heat

Use

239

.

116

No.

Shield

M3G-HS.

Lens

3GL-XXX

Stock

Heat

Gas

Use

USAGE

RECOMMENDED

INDICATE

AREAS

SHADED

Parts

Consumable

6-2.

CONSUMABLE

tofch.)

torch.a

complt.

cooisd

to

watur

nsquksd

and

Cup

cabl.

Gas

adapt.r.

and

coinposits

Body

cabi.

flsx

Collet

pow.r

high

a

with

Colist,

ruqlr.

Torchss

(Hots:

also

Figure

Table

6-1.

Cross

Reference

To

Competitive

Model

OM-1564

STOCK

NO.

116367
116368
116369

116

370

116371

116

372

116379

116

380

116381

116

382

116

383

116384

116361
116362
116363

116364

116365
116366
116

347

116348

116

349

116350

116351
116352
116

353
116354
116343

116344

116345
116346

116330

116331

332

116

333

116

116334

116335

116336
119926

119927
119928
119929

119

930
119

931

119

917

119918

119

919
119

920

119921

922

119

119923

119

924

Page







MODEL

NO.

3CG16

3AG4
3AG5
3AG6
3AG7
3AG8

3AG11

3GLL332
3GLL418
3GLL532

3AG8LD

3AG1OLD

3AG12LD

4C20

4C40

4C116

4C332

4C418
4C532

4C820
4C840

4CB116

4CB332
4CB418

4CB532

2C4
2C5
2C6

2C7

2C8

2C10

2C3L

2C4L

2C5L

2C6L

2A4
2A5
2A6

2A7

2A8

2A10

4GL20

4GL40

4GL116

4GL332

4GL418
4GL532

2AG4

2AG5

2AG6

2AG7

COMPETITIVE

NO.

N/A

54N18
54N17
54N16
54N15
54N14

54N19

45V64

995795

45V63

57N74

53N88
53N87

N/A

10N22S

10N23S

10N24S

10N25S

N/A

N/A

17CB20
17CB20,

17C820
17CB20

N/A
13N14
13N15



13N16
13N17

13N18

13N19

796F70

796F71

796F72

796F73

13N08
13N09

13N10

13N11

13N12

13N13

N/A

N/A

N/A

N/A

N/A

N/A

53N58

53N59
53N60

53N61

S~O631

MODEL

NO.

3C20
3C40

3C116 10N23

3C332
3C418

3C532

7C20
7C40

7C116
7C332
7C418
7C532

3CB20

3C840

3CB116

3C8332
3CB418

3CB532

3C3

3C4
3C5
3C6
3C7
3C8

3C10

3C12

3C4L

3C5L
3C6L
3C7L

3A4

3A5
3A6

3A7

3A8

3A10

3A12

3GL20

3GL40

3GL116
3GL332

3GL418

3GL532

3C04
3CG5
3CG6
3CG7
3CG8

3CG11

3CG12
3CG14

10



COMPETITIVE

NO.

10N21

10N21

10N24
10N25
54N20

N/A

N/A



N/A

N/A

N/A

N/A

10N29
10N30

10N31

10N32

10N28

406488

N/A

1Q5Z~i3

105Z42

105Z44
105Z45

08N78

.

08N79

08N80

12N03

105Z60

12N02

105Z61

10N50

10N49

10N48

I

0N47

10N46

10N45

10N44

45V29

45V24
45V25
45V26

45V27

45V28
54N35
54N34

54N33
54N32

54N31
54N35

N/A

N/A

STOCK

NO.

119925

119932

119933

119

934

119935

119

936

119937

119

902

119903

119

904

119

911

119912
119913

116373

116374
116375
116376
116377

116378
116355

116

356

.

116357
116358

116359
116

360

116337

.

116338

116339
116340
116341

116342

116326

116

327

116328

116329
116310
116311
116312

116313
116314

116315

119

905

119

906

119907
119908

909

119
119

910

119893

894

119

119895

119

896

OPTIONS

POWER

(Required

high-flex

water-cooled

Adaptor

M3PCA

INTERNATIONAL

CONNECTOR

80

Amp

direct

For

torchesorwater-cooled

into

power

connectors.

style

FUSE

BLOCK

(For

torches.

Protects

damage

torch

its

use

260

to

Up

260to550

is

run

rated

AND

CABLE

on

cable

Torch

sourceswith

Five

torch
if

waterisnot

capacity.

ADAPTERS

torches

assembly

torches.)

KIT

connection

ASSEMBLY

with
fuse

Amps

Amps

from

considerably

links

overheating

ACCESSORII

with

one-piece,

and

all

Stock

No.

(#116248)

TIG

TORCH

492)

(#135

of

one-piece

TIG

torches

International

water-cooled

Included.)

(#116

163)

(#116

164)

and

circulating

higher

or

than

CABLE

(For

torches.)

CEB
CEB26OFA

(Fused

CEB

(260

Designed

torch

extended

Available

tion.

a

by

sure.

Note:

source

Use

and

performance.

if

EXTENSION

use

(non-fused)

to

up

550FA

550

to

to

and

hose

from

with

All

components

Hose

to

and

CEB

diameter

welding

non-conductive

strong,

large

heavy

with

260

Amps)

allow

cable

the

without

or

cables

box

BOX

water-cooled

(#120
(#116

Amps)

(#116

water-cooled

a

assembly

power

fuse

are

from

not

are

extension

cable

for

797)

161)

162)

be

to

source.

protec

protected

enclo

power

supplied.

hoses

optimum

HOSE

TIG

THK-1

Provides

hardware

torches

coolant

GAS

HRF-2425

The

is

designed

inert
includes

connector.

preset

inletis3000

SCFH

AF-1

The

which

connector

the

to

a

system.

REGULATORS

HRF-2425

gas

at

gas

50

AF-1

50

includes

argon/CO2

justable

SCFH

for

with

HOOK-UP

KITS

(#128

necessary

to

connect

power

water-cooled

source

hoses

and

(#127

regulator/flowmeter

for

MIG,

welding

the

580

The

outlet

25

PSIG;

PSIG

and

TIG,

applications.

CGA
pressure

the

maximum

and

has

delivery.

(#127662)

is

a

flowgauge

580

for

use

gases.

gas

argon

the

The

delivery

gas.

with

CGA

argon

AF-1

(THK)

065)

and

water

661)

other

it

inlet

is

5-40

regulator

inlet

and

50

is

ad

of

8-25

9