Miller Titanium, Titanium 7300, Titanium 9400, Titanium 1600i, Titanium 9400i Series Manual

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OM-256 016A 2012−03

Auto-Darkening Helmets

Model: TitaniumtSeries w/Infotrackt

To help us serve you better, go to www.MillerWelds.Com/Register

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TABLE OF CONTENTS

SECTION 1 − WELDING HELMET SAFETY PRECAUTIONS −READ BEFORE USING 1......

1-1. Symbol Usage 1.............................................................

1-2. Arc Welding Hazards 1.......................................................

1-3. Proposition 65 Warnings 2....................................................

1-4. Lens Shade Selection Table 3.................................................

1-5. Principal Safety Standards 3..................................................

SECTION 2 − SPECIFICATIONS 4.....................................................

SECTION 3 − OPERATING INSTRUCTIONS − TITANIUM 7300/9400 HELMETS 5............

3-1. Helmet Configurations (Titanium 7300 And 9400 Series Helmets) 5..................

3-2. Helmet Controls (Titanium 7300 And 9400 Series Helmets) 6.......................

3-3. Auto On/Off Button And Grind Mode / Low Battery Light

(Titanium 7300 And 9400 Series Helmets) 7......................................

3-4. Mode Control Button (Titanium 7300 And 9400 Series Helmets) 8...................

3-5. Variable Shade Control (Titanium 7300 And 9400 Series Helmets) 9.................

3-6. Lens Delay Control (Titanium 7300 And 9400 Series Helmets) 10....................

3-7. Sensitivity Control (Titanium 7300 And 9400 Series Helmets) 11.....................

3-8. Typical Lens Adjustment Procedure 12..........................................

3-9. Info Control Button (Titanium 7300 And 9400 Series Helmets) 13....................

3-10. Arc Time Control (Titanium 7300 And 9400 Series Helmets) 14......................

3-11. Clock Control (Titanium 7300 And 9400 Series Helmets) 15........................

3-12. Timer Control (Titanium 7300 And 9400 Series Helmets) 16........................

3-13. Alarm Control (Titanium 7300 And 9400 Series Helmets) 17........................

SECTION 4 − OPERATING INSTRUCTIONS − TITANIUM 1600/1600i HELMETS 18..........

4-1. Controls − Titanium 1600 And 1600i Series Helmets 18............................

SECTION 5 − ADJUSTING HEADGEAR 19.............................................

5-1. Adjusting Headgear On Titanium 7300 And 9400 Series Helmets 19.................

5-2. Adjusting Headgear On Titanium 1600 And 1600i Series Helmets 20.................

SECTION 6 − REPLACING THE GRINDING SHIELD OR LENS COVERS 21................

6-1. Replacing Grinding Shield On 9400i And 1600i Helmets 21........................

6-2. Replacing Lens Covers On Quick Release Helmets 22............................

SECTION 7 − REPLACING THE BATTERY (AUTO-DARKENING LENS ASSEMBLIES) 23....

7-1. Replacing The Battery In Titanium 7300 And 9400 Series Helmets 23................

SECTION 8 − INSTALLING OPTIONAL MAGNIFYING LENS 24..........................

SECTION 9 − MAINTENANCE 24.....................................................

SECTION 10 − TROUBLESHOOTING 25...............................................

SECTION 11 − PARTS LISTS 26......................................................

SECTION 12 − LIMITED WARRANTY 35...............................................

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SECTION 1 − WELDING HELMET SAFETY PRECAUTIONS −

READ BEFORE USING

helmet 2012−02

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous

situation which, if not avoided, will

result in death or serious injury. The

possible hazards are shown in the

adjoining symbols or explained in

the text.

Indicates a hazardous situation

which, if not avoided, could result in

death or serious injury. The possible

hazards are shown in the adjoining

symbols or explained in the text.

NOTICE − Indicates statements not related to

personal injury.

 Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

1-2. Arc Welding Hazards

Only qualified persons should install, operate, maintain, and repair this unit.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

 Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when

welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Refer to Lens Shade Selection table in Section 1-4.

 Wear approved safety glasses with side shields under your helmet.  Use protective screens or barriers to protect others from flash, glare, and sparks; warn

others not to watch the arc.

 Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton,

and wool) and foot protection.

• Before welding, adjust the auto-darkening lens sensitivity setting to meet the application.

• Stop welding immediately if the auto-darkening lens does not darken when the arc is struck.

See the Owner’s Manual for more information.

WELDING HELMETS do not provide unlimited eye, ear, and face protection.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

 Use impact resistant safety spectacles or goggles and ear protection at all times when using

this welding helmet.

 Do not use this helmet while working with or around explosives or corrosive liquids.  Do not weld in the overhead position while using this helmet.  Inspect the auto-lens frequently. Immediately replace any scratched, cracked, or pitted cover

lenses or auto-lenses.

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NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

 Wear approved ear protection if noise level is high.

READ INSTRUCTIONS.

 Read and follow all labels and the Owner’s Manual carefully before installing,

operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

 Use only genuine replacement parts from the manufacturer.  Perform maintenance and service according to the Owner’s Manuals, industry standards,

and national, state, and local codes.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

 Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding

fumes and gases.

 If ventilation is poor, wear an approved air-supplied respirator.  Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s

instructions for metals, consumables, coatings, cleaners, and degreasers.

 Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator.

Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

 Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays

of the arc can react with vapors to form highly toxic and irritating gases.

 Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the

coating is removed from the weld area, the area is well ventilated, and while wearing an air- supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

1-3. Proposition 65 Warnings

Welding or cutting equipment 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 Section 25249.5 et seq.)

This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use.

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1-4. Lens Shade Selection Table

Process

Shielded Metal Arc

Welding (SMAW)

Gas Metal

Arc Welding

(GMAW)

Flux Cored

Arc Welding

(FCAW)

Gas Tungsten Arc

Welding (TIG)

Air Carbon

Arc Cutting (CAC-A)

Plasma Arc

Cutting (PAC)

Plasma Arc Welding

(PAW)

Electrode Size

in. (mm)

Less than 3/32 (2.4)

3/32−5/32 (2.4−4.0)

5/32−1/4 (4.0−6.4)

More than 1/4 (6.4)

Light

Heavy

Arc Current

Amperes

Less than 60

60−160 160−250 250−550

Less than 60

60−160 160−250 250−500

Less than 50

50−150 150−500

Less than 500

500−1000

Less than 20

20−40 40−60 60−80

80−300 300−400 400−800

Less than 20

20−100 100−400 400−800

Minimum Protective Shade No.

8 10 11

7 10 10 10

8 10

10 11

9 10

8 10 11

Suggested

Shade No. (Comfort)*

−−

10 12 14

−−

11 12 14

10 12 14

12 14

4 5 6 8

9 12 14

6−8

10 12 14

Reference: ANSI Z49.1:2005

* Start with a shade that is too dark to see the weld zone. Then, go to a lighter shade which gives a

sufficient view of the weld zone without going below the minimum.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free down- load from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).

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SECTION 2 − SPECIFICATIONS

Specification Titanium 7300

Viewing Field 3.81 x 1.85 in

Reaction Time 0.0000500 sec (1/20,000) −− Available Shades

All Shades Provide Continuous UV And IR Protection.

Sensitivity Control Adjustable For Varying

Delay Control Slows Lens Dark-To-Light State Between 0.1 And

Automatic Power Off

Low Battery Light Red Led Illuminates To Indicate 2−3 Days

Power Supply CR2450 Lithium Battery

Sensors Independent/Redundant

Operating Temperature

Storage Temperature

Total Weight 19 oz (538.6 g) Titanium 9400:

Standards ANSI Z87.1+(2010) and

Warranty Three Years From Date Of Purchase (Section 12) 30 Day Limited

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(97 x 47 mm)

Weld Mode

Darkened State: No. 8 − No. 13

Light State: No. 3

Cut Mode

Darkened State: No. 5 − No. 8

Light State: No. 3

Grind Mode

Light State: No. 3

X-Mode

Darkened State: No. 8 − No. 13

Light State: No. 3

Ambient Light And

Welding Arc

1.0 Seconds

Shuts Lens Off 45 Minutes After Last Arc Is Struck

Remaining Battery Life

(Miller Part No. 217 043)

(Three)

14F to 131F / −10C to +55C

 When Stored In Extremely Cold Temperatures,

Warm Helmet To Ambient Temperature Before Welding.

−4F to 158F / −20C to +70C

 When Stored In Extremely Cold Temperatures,

Warm Helmet To Ambient Temperature Before Welding.

CSA

Titanium 9400

Titanium 9400i

3.81 x 2.62 in (97 x 60mm)

Independent/Redundant

(Four)

18 oz (510.3 g)

Titanium 9400i:

26 oz (737 g)

ANSI Z87.1+(2010) and DIN/CSA/TUV

Titanium 1600

Titanium 1600i

3.86 x 3.54 in. (98 x 90 mm)

Standard: No. 10

Upgradeable To Auto-

Darkening Lens

−−

Titanium 1600: 17 oz (481.9 g)

Titanium 1600i

22 oz (630 g)

ANSI Z87.1+(2010)

And DIN/CSA/TUV

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SECTION 3 − OPERATING INSTRUCTIONS − TITANIUM 7300 And 9400 SERIES HELMETS

3-1. Helmet Configurations (Titanium 7300 And 9400 Series Helmets)

1 Titanium 7300 Helmet The 7300 helmet features a large

fixed-position, auto-darkening lens and is designed for standard welding applications.

2 Titanium 9400 Helmet The 9400 helmet features a larger

fixed position, auto-darkening lens than the 7300 series and is also de- signed for standard welding applica- tions.

3 Titanium 9400i Helmet The 9400i helmet features a flip-up

auto-darkening lens and a separate, clear grinding shield. Flip the lens up when grinding and performing other non-welding work. Flip the lens down when welding or cutting.

2 3

OTOS / Ref. 804 111

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3-2. Helmet Controls (Titanium 7300 And 9400 Series Helmets)

The lens on Titanium 7300 and 9400 Series Helmets turns on (darkens) automati- cally when welding begins and turns off when welding stops.

1 Auto On/Off Button

(See Section 3-3)

2 Grind Mode / Low

Battery Light (Section 3-3)

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1 34

3 Mode Control Button

(Section 3-4)

4 Lens/Info Adjustment

Buttons (See Sections 3-5 Thru 3-7)

 Use adjustment buttons

to change shade, delay, and sensitivity settings when lens is in Mode function. Use adjustment buttons to change arc time, clock, timer,

and alarm settings when lens is in Info function.

5 Info Control Button

(See Section 3-9)

6 External Grinding Mode

Button (Section 3-4)

 The External Grinding

Mode button is not available on the 9400i helmet.

 The lens assembly

saves the shade, sensitivity, and delay settings.

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3-3. Auto On/Off Button And Grind Mode / Low Battery Light

(Titanium 7300 And 9400 Series Helmets)

 The auto-darkening lens

on Titanium 7300 and 9400 Series Helmets turns on (darkens) automatically when welding begins and turns off when welding stops.

1 Auto On/Off Button

Press Auto On/Off button to check if the lens is working

properly and to begin Mode and Info adjustments.

When the On/Off button is pressed, the lens should darken and return to the clear state. Do not use the helmet if the lens does not function as described. (See Section 10, Troubleshooting.)

2 Grind / Low Battery Light

The Grind / Low Battery light blinks when the lens is in the Grind mode. Light stays on when 2−3 days of battery life remain.

If battery power is low, replace with CR2450 lithium batteries (2 required − Miller Part No. 217 043). See Section 7.

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3-4. Mode Control Button (Titanium 7300 And 9400 Series Helmets)

2 1

1 Mode Control Button 2 External Grind Mode

Button

Press Mode button to select the mode appropriate for the work activity:

Weld Mode − used for most welding applications. In this mode the lens turns on when it optically senses a welding arc. Adjust shade, sensitivity, and delay set- tings as needed.

Cut Mode − used for cutting applications. In this mode the lens turns on when it optically senses a cutting arc. Adjust shade, sensitivity, and delay settings as needed.

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! If nearby objects

may inadvertently contact the extern- al Grind Mode but- ton while you are welding, unplug the Grind Mode button to prevent accidental activa- tion of the Grind mode.

Grind Mode − used for met-

al grinding applications. In this mode the shade is fixed shade No. 3. No lens adjustments are possible.

Use external Grind Mode button to select grinding

mode without raising hel- met.

To use Grind mode, push and hold the external Grind button for two seconds. Push Grind Mode button again to turn off Grind mode.

X Mode − used for outdoor or low current welding ap- plications. In this mode the lens turns on when it senses weld current. Adjust shade, sensitivity, and delay set- tings as needed.

 Nearby welding may af-

fect helmet operation when lens is in X-Mode. Stay at least 12 ft (3.7 m) away from other welding activity.

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3-5. Variable Shade Control (Titanium 7300 And 9400 Series Helmets)

1 Variable Shade

Adjustment Buttons 2 Mode Control Button Use the LTR and DKR ad- justment buttons to adjust

the lens shade in the dark- ened state. Use the table in Section 1-4 to select proper shade control setting based on your welding process. The shade ranges for each mode are as follows:

Weld − No. 8 − No. 13 Cut − No. 5 − No. 8

Grind − No. 3 only X Mode − No. 8 − No. 13

Start at the highest setting and adjust lighter to suit the application and your person- al preference.

Variable Shade Adjustment Procedure

 Press Auto On/Off but-

ton to turn lens On. Helmet lens will darken twice and then clear.

 Press Mode Control

Button to select desired function: Weld, Cut, or X-Mode.

 Use LTR and DKR ad-

justment buttons to se- lect desired shade.

 Begin welding or contin-

ue with other lens adjustments.

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3-6. Lens Delay Control (Titanium 7300 And 9400 Series Helmets)

1 Lens Delay Adjustment

Buttons 2 Mode Control Button Use the Lens Delay Short

and Long buttons to adjust the time for the lens to switch to the clear state after weld- ing or cutting.

The delay is particularly use- ful in eliminating bright after-rays present in higher amperage applications where the molten puddle remains bright momentarily after welding. Use the Lens Delay Control buttons to adjust delay from 0 to 10 (0.1 to

1.0 second).

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The delay ranges for each mode are as follows:

Weld, Cut, X Modes − 0 − 10 Grind Mode − No delay ad-

justment

 There is no lens delay

adjustment in the Grind mode.

Lens Delay Adjustment Procedure

 Press Auto On/Off but-

ton to turn helmet On. Helmet lens will darken twice and then clear.

 Press Mode button to se-

lect desired function: Weld, Cut, or X-Mode.

 Use Short and Long ad-

justment buttons to select desired delay.

 Begin welding or contin-

ue with other lens adjustments.

Page 13

3-7. Sensitivity Control (Titanium 7300 And 9400 Series Helmets)

1 Sensitivity Adjustment

Buttons

2 Mode Control Button Use control to make the lens

more responsive to different light levels in various weld- ing processes. Use a Mid-

Range or 30−50% sensitiv- ity setting for most ap- plications.

It may be necessary to adjust helmet sensitivity to accom- modate different lighting con- ditions or if lens is flashing On and Off.

The sensitivity ranges for each mode are as follows:

Weld, Cut, X Modes − 0 − 10 Grind Mode − No sensitivity

adjustment

! Do not weld in the

Grind mode; the lens will not darken.

Sensitivity Adjustment Procedure

 Adjust helmet sensitivity

in lighting conditions hel- met will be used in.

 Press Auto On/Off but-

ton to turn helmet On. Helmet lens will darken twice and then clear.

 Press Mode button to

select desired function: Weld, Cut, or X-Mode.

 Use Sensitivity Less and

More buttons to adjust sensitivity control to low- est setting.

 Face the helmet in the di-

rection of use, exposing it to the surrounding light conditions.

 Press sensitivity More

button until the lens darkens, then press Less button until lens clears. An alternative method is to press and hold the Less button until the lens clears.

Helmet is ready for use. Slight readjustment may be necessary for certain applications or if lens is flashing on and off.

 Reduce Sensitivity set-

ting if lens stays dark longer than Delay set- ting.

Recommended Sensitivity Settings

Stick Electrode Mid-Range Short Circuiting (MIG) Low/Mid-Range Pulsed & Spray (MIG) Mid-Range Gas Tungsten Arc (TIG) Mid/High-Range Plasma Arc Cutting/Welding Low/Mid-Range

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3-8. Typical Lens Adjustment Procedure

 Lens assembly displays prior

settings when turned On. Retained settings are not shown in example.

 In the Grind mode the lens is a

fixed shade No. 3. No lens adjustments are possible.

Adjusting Lens Assembly:

 Turn lens On. Display screen

appears.

 Select mode (Weld, Cut, Grind,

X-Mode).

 Select shade by pressing LTR

and DKR buttons.

 Select Delay by pressing

Short and Long buttons.

 Select Sensitivity by pressing

Less and More Buttons.

 Begin work.

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3-9. Info Control Button (Titanium 7300 And 9400 Series Helmets)

1 Info Control Button Press button to select from

the following functions: Arc Time − records the

amount of time the lens assembly is in the dark state (exposed to arc). See Section 3-10 to reset Arc Time.

Clock − displays actual

time of day. See Section 3-11 to set clock.

Timer − emits an audible signal and the Grind mode light flashes to alert the operator after a specific period of time has elapsed. See Section 3-12 to set timer.

Alarm − emits an audible signal and the Grind mode light flashes to alert the op- erator at a specific time. See Section 3-13 to set alarm.

 Lens automatically

exits the Info function after 15 seconds of inactivity.

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3-10. Arc Time Control (Titanium 7300 And 9400 Series Helmets)

The arc time function records the amount of time the lens assembly is dark (exposed to an arc).

1 Info Control Button 2 Arc Time Clear Button 3 Arc Time Exit Button

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Arc Time Procedure

 Press Auto On/Off but-

ton to turn helmet On. Helmet lens will darken twice and then clear.

 Press Info button re-

peatedly until Arc Time is displayed on screen.

 Use the Clear button to

reset the arc time to zero.

 Press the Exit button

when finished.

Page 17

3-11. Clock Control (Titanium 7300 And 9400 Series Helmets)

The clock displays the actual time of day.

1 Info Control Button

2 12/24 Hour Cycle Button

3 Clock Set Button

4 Hour +/− Buttons

5 Minute +/− Buttons

6 Save Button

7 Exit Button

4 5 6 7

Clock Procedure

 Press Hour +/− buttons

 Press Auto On/Off but-

ton to turn helmet On. Helmet lens will darken twice and then clear.

 Press Minute +/− but-

 Press Info button re-

peatedly until Clock is displayed on screen.

 Press 12/24 button to

select either 12 or 24 hour clock format.

 Press Save button.

 Press the Exit button

 Press the Set button to

enter set mode.

to change hour setting.

tons to change minute setting.

when finished.

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3-12. Timer Control (Titanium 7300 And 9400 Series Helmets)

243 5

The Timer emits an audible signal and the Grind mode light flashes to alert the oper- ator after a specific period of time has elapsed.

1 Info Control Button 2 Hour +/− Buttons 3 Minute +/− Buttons 4 Save Button 5 Clear Button 6 Exit Button

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5 6

Arc Time Procedure

 Press Auto On/Off but-

ton to turn helmet On. Helmet lens will darken twice and then clear.

 Press Info Control but-

ton repeatedly until Timer is displayed on screen.

 Press Hour +/− buttons

to change hour setting.

 Press Minute +/− but-

tons to change minute setting.

 Press Save button.

 Press the Clear button

to start over, or press the Exit button when finished.

 Press External Grind

Mode button or any lens button to turn off alarm.

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3-13. Alarm Control (Titanium 7300 And 9400 Series Helmets)

243

The Alarm emits an audible signal and the Grind mode light flashes to alert the oper- ator at a specific time.

1 Info Control Button 2 Hour +/− Buttons 3 Minute +/− Buttons 4 Save Button 5 Clear Button 6 Exit Button

5 6

Timer Procedure

 Press Auto On/Off but-

ton to turn helmet On. Helmet lens will darken twice and then clear.

 Press Info button re-

peatedly until Alarm is displayed on screen.

 Press Hour +/− buttons

to change hour setting.

 Press Minute +/− but-

tons to change minute setting.

 Press Save button.

 Press the Clear button

to start over, or press the Exit button if finished.

 Press external Grind

Mode button or any lens button to turn off alarm.

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SECTION 4 − OPERATING INSTRUCTIONS −

TITANIUM 1600 And 1600i SERIES HELMETS

4-1. Controls − Titanium 1600 And 1600i Series Helmets

The 1600 series passive welding helmet provides continuous UV and IR protection and uses a fixed shade No. 10 lens.

The helmet can also be fitted with other standard lenses (No. 9 −13) or an auto-darkening lens.

Use the table in Section 1-4 to select proper lens based on your welding process.

 See Section 6 for lens cov-

er replacement informa- tion.

Notes

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Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at the beginning of this manual.

Page 21

SECTION 5 − ADJUSTING HEADGEAR

5-1. Adjusting Headgear On Titanium 7300 And 9400 Series Helmets

 There are four headgear

adjustments: headgear top, tightness, angle adjustment, and distance adjustment.

1 Headgear Top

Adjusts headgear for proper depth on the head to ensure correct balance and stability.

2 Headgear Tightness To adjust, turn the adjusting

knob located on the back of the headgear left or right to desired tightness.

3 Angle Adjustment (Not

Shown)

Seven slots on the right side of the headband provide ad- justment for the forward tilt of the helmet. To adjust, lift and reposition the control arm to the desired position.

4 Distance Adjustment Adjusts the distance be-

tween the face and the lens. To adjust, press black tabs on the top and bottom of the pivot point and use other hand to slide headgear for- ward or backward. Release tabs. (Both sides must be equally positioned for proper vision.)

 Numbers on the adjust-

ment slides indicate set position so both sides can be adjusted equally.

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5-2. Adjusting Headgear On Titanium 1600 And 1600i Series Helmets

 There are four headgear adjust-

ments: headgear top, tightness, angle adjustment, and distance adjustment.

1 Headgear Top Adjusts headgear for proper depth

on the head to ensure correct bal-

ance and stability. 2 Headgear Tightness To adjust, push in the adjusting knob

located on the back of the headgear and turn left or right to desired tight- ness.

 If adjustment is limited, it may be

necessary to remove the com- fort cushion.

3 Distance Adjustment Adjusts the distance between the

face and the lens. To adjust, loosen both outside tension knobs and press inward to free from adjustment slots. Move forward or back to de- sired position and retighten. (Both sides must be equally positioned for proper vision.)

4 Angle Adjustment

Four pins on the right side of the headband top provide adjustment for the forward tilt of the helmet. To adjust, loosen the right outside ten- sion adjustment knob then lift on the control arm tab and move it to the de- sired position. Retighten tension ad- justment knob.

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 When using the back distance

adjustment positions, only the back three angle adjustment pins can be used.

804 118

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SECTION 6 − REPLACING THE GRINDING SHIELD OR

LENS COVERS

6-1. Replacing Grinding Shield On 9400i And 1600i Helmets

! Never use the auto-dark-

ening lens without the in- side and outside lens covers properly installed. Welding spatter will dam- age the auto-darkening lens and void the warranty.

1 Grinding Shield 2 Retaining Clip 3 Tab Rotate both retaining clips to the

Open position.

Gently push shield toward bot- tom tab and remove shield from helmet.

Remove retaining clips from shield. Install clips in same loc- ation on new shield. (Retaining clips are not interchangeable.)

Install new shield in helmet and rotate clips to the Lock position.

Tear-Away Protective Sheets

Tear-away sheets are available to prolong the life of the griding shield (see Parts List).

To install tear-away sheets, pull backing from both sides of the tear-away, remove white ad- hesive backing strips, and place on clear shield.

Ref. 804 109

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Page 24

6-2. Replacing Lens Covers On Quick Release Helmets

! Never use the auto-dark-

ening lens without the inside and outside lens

covers properly installed. Welding spatter will damage the auto-darkening lens and void the warranty.

Outside Lens Cover

1 Lens Holder 2 Release Points 3 Outside Lens Cover Remove lens holder by press-

ing release points and pulling the holder away from the hel- met.

Remove lens cover from hold- er. Replace lens cover in lens holder. Reinstall lens holder in helmet.

Inside Lens Cover

4 Gasket 5 Lens 6 Inside Lens Cover Remove the inside lens cover

by prying cover from groove in gasket.

Replace the lens cover by gent- ly bowing it in the center and in- serting it, one end at a time, into the gasket.

45 6

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 Be sure the cover lens is

seated properly (flat) to prevent fogging.

804 814 / 804 816 / OTOS

Page 25

SECTION 7 − REPLACING THE BATTERY

(AUTO-DARKENING LENS ASSEMBLIES)

7-1. Replacing The Battery In Titanium 7300 And 9400 Series Helmets

To replace the batteries, re- move the auto-darkening lens assembly (see Section 6).

1 Battery Tray After removing the lens assem-

bly, slide the battery holding

trays out and remove the old batteries.

Replace with CR2450 lithium type batteries (2 required) or equivalent (Miller Part No.

217043).

Be sure Positive (+)

side of battery

faces up.

 Be sure Positive (+) side of

the battery faces up (to- ward inside of helmet).

Reinstall the battery trays. To test battery, press the Auto On/ Off button. The display screen should turn on. Reinstall the lens assembly.

 Left and right battery trays

are not interchangeable. The auto−darkening hel- met will not work if battery trays are installed on the wrong sides.

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SECTION 8 − INSTALLING OPTIONAL MAGNIFYING LENS

1 Optional Magnifying Lens Starting at the bottom, slide magni-

fying lens into the helmet retaining brackets. Align the magnifying lens with the auto-darkening lens assembly.

 Remove lens holding frame

(with auto-darkening lens) from helmet shell.

 Remove auto-darkening

lens from lens holder.

 Position lens holder so the

magnifying lens holding tabs are facing toward you. From the bottom up, slide magnifying lens into posi- tion. (Slide magnifying lens up or down slightly as de- sired.)

 Reinstall the auto-darkening

lens in the lens holder.

 Reverse procedure to re-

move magnifying lens.

 To prevent lens fogging, install

flat side of magnifying lens to- ward auto-darkening lens.

804 818

SECTION 9 − MAINTENANCE

NOTICE − Never use solvents or abrasive cleaning detergents. NOTICE − Do not immerse the lens assembly in water.

The helmet requires little maintenance. However, for best performance clean after each use. Using a soft cloth dampened with a mild soap and water solution, wipe the cover lenses clean. Allow to air dry. Occasionally, the filter lens and sensors should be cleaned by gently wiping with a soft, dry cloth.

OM-256 016 Page 24

Page 27

SECTION 10 − TROUBLESHOOTING

Trouble Remedy

Auto lens not On – autolens will not darken mo- mentarily when the Reset button is pressed.

Not switching – auto-lens stays light and will not darken when welding.

Not Switching – auto-lens stays dark after the weld arc is extinguished, or the auto-lens stays dark when no arc is present.

Sections of the auto-lens are not going dark, distinct lines separate the light and dark areas.

Switching or Flickering – the auto-lens darkens then lightens while the welding arc is present.

Check batteries and verify they are in good condition and installed properly.

Check battery surfaces and contacts and clean if necessary. Check battery for proper contact and gently adjust contact points

if necessary. This is particularly important if the helmet has been dropped. Verify left and right battery trays are installed on the correct sides.

Stop welding immediately: Press the Auto On/Off button if lens is Auto-On type.

If power is On, review the sensitivity recommendations and adjust sensitivity.

Clean lens cover and sensors of any obstructions. Make sure the sensors are facing the arc; angles of 45 or more may not allow the arc light to reach the sensors.

Fine-tune the sensitivity setting in small increments. In extreme light conditions, it may be necessary to reduce the surrounding light levels.

Stop welding immediately: The auto-lens may be cracked which can be caused by the impact of dropping the helmet.

Weld spatter on the auto lens may also cause cracking. (The lens may need to be replaced; most cracked lenses are not covered by warranty).

Review the sensitivity setting recommendations and increase the sensitivity if possible. Be sure the arc sensors are not being blocked from direct access to the arc light.

Check the lens cover for dirt and spatter that may be blocking the arc sensors. Increasing Lens Delay 0.1 − 0.3 second may also reduce switching.

Inconsistent or lighter auto-lens shading in the dark-state, noticeable on the outside edges and cor- ners.

Referred to as an angle of view effect, auto-darkening lenses have an optimum viewing angle.

The optimum viewing angle is perpendicular or 90 to the surface of the auto-lens. When that angle of view varies in the dark-state, welders may notice slightly lighter areas at the outside edges and the corners of the lens. This is normal and does not represent any health or safety hazard.

This effect may also be more noticeable in applications where magnifying lenses are used.

OM-256 016 Page 25

Page 28

SECTION 11 − PARTS LISTS

Figure 11-1. Titanium 7300 Auto-Darkening Welding Helmet

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Page 29

Item

No. Quantity

Part

No.

Description

Figure 11-1. Titanium 7300 Auto-Darkening Welding Helmet

1 243 530 Shell, Helmet Titanium (Qr) (Includes Item 6) 1............ ........ .........

2 770 237 Lens Cover, Inside 4−1/4 in x 2 in 1............ ........ ...................

3 256 358 Lens Assembly, Auto−Darkening Titanium w/Cable 1............ ........ ....

4 241 977 Gasket, Lens Assembly 1............ ........ ...........................

5 216 326 Lens Cover, Front 4−11/16 in x 5−5/8 in 1............ ........ .............

6 243 396 Lens Holder, Titanium (Qr) 1............ ........ .........................

7 256 174 Headgear, Gray (Includes Items 8 And 9) 1............ ........ ............

8 *256 178 Kit, Adjustment Angle/Stop Hardware 1........... .......... .............

9 770 249 Headband, Fabric 1............ .......... .............................

079 975 Replacement O-Rings (5 Per Pkg.) 1.............. ........ .................

10 216 339 Tray, Battery (Left/Right) 1........... ........ ..........................

217 043 Battery, Lithium (CR2450) 2.............. ........ .........................

11 770 250 Bag, Helmet (Miller Logo) 1........... ........ .........................

♦222 003 Adapters, Hard Hat (Not Shown) 1............ ........ ...................

12 256 179 Button, Grind Mode 1........... ........ ..............................

13 ♦212 235 Lens, 0.75 Magnification 1......... ........ ..........................

13 ♦212 236 Lens, 1.00 Magnification 1......... ........ ..........................

13 ♦212 237 Lens, 1.25 Magnification 1......... ........ ..........................

13 ♦212 238 Lens, 1.50 Magnification 1......... ........ ..........................

13 ♦212 239 Lens, 1.75 Magnification 1......... ........ ..........................

13 ♦212 240 Lens, 2.00 Magnification 1......... ........ ..........................

13 ♦212 241 Lens, 2.25 Magnification 1......... ........ ..........................

13 ♦212 242 Lens, 2.50 Magnification 1......... ........ ..........................

* Adjustment Hardware Kit With O-rings.

♦Optional

OM-256 016 Page 27

Page 30

Miller

Figure 11-2. Titanium 9400 Auto-Darkening Welding Helmet

OM-256 016 Page 28

Page 31

Item

No. Quantity

Part

No.

Description

Figure 11-2. Titanium 9400 Auto-Darkening Welding Helmet

1 243 530 Shell, Helmet Titanium (Includes Item 6) 1............ ........ .............

2 216 327 Lens Cover, Inside 4-1/4 x 2-1/2 in (5 Per Pkg.) 1............ ........ .......

3 256 359 Lens Assembly, Auto-Darkening With Cable 1............ ........ ..........

4 241 977 Gasket, Lens Assembly 1............ ........ ...........................

5 216 326 Lens Cover, Outside (4-11/16 x 5-5/8) (5 Per Pkg.) 1............ ........ ....

6 243 396 Lens Holder, Front (Titanium) 1............ ........ ......................

7 256 174 Headgear Gray (Includes Items 8 And 9) 1............ ........ .............

8 *256 178 Kit, Adjustment Angle/Stop Hardware 1........... .......... .............

9 770 249 Headband, Fabric 1............ .......... ..............................

079 975 Replacement O-rings For Kit 256 178 (5 Per Pkg.) 1.............. ........ ....

10 216 339 Tray, Battery (Left/Right) 1........... ........ ..........................

217 043 Battery, Lithium (CR2450) 2.............. ........ .........................

11 770 250 Helmet Bag − Miller 1........... ........ ..............................