Instruction Manual 252 Air-Cooled Pistol Gun
Contents
1. H C 13469 E 13468 030 3 32 H C AL Requires Liner 13486 5 64 1 8 H C Requires Inlet 13486 Stub liners only required in feeder adapter when single piece casing is used TWECO Welding Alloys ORDERING INFORMATION Each D F gun is fully assembled and ready to in stall In order to make the installation complete the code number wire size amp type make model of wire feeder and inlet as needed must be speci fied when ordering If special welding tools or ac cessories other than those listed previously are required please consult with the factory FEEDER ADAPTER INLETS Steel Brass Nylon Wire Size Code No Code No Code No 030 035 045 052 1 16 5 64 3 32 7164 1 8 3 64 AL 1 16 AL 3 32 AL Esab Hobart Lincoln Linde Miller OTC Pana sonic ABB Fanuc Kuka Mavrix Motoman Ther mal Arc TWECO amp Welding Alloys are registered trademarks of their respective companies Names are mentioned for reference only D F Machine Specialties is in no way affiliated with these companies TROUBLESHOOTING POROSITY SUMMARY NOTE Most POROSITY is caused by gas problems followed by base metal contamination Causes of Porosity BASE METAL CONTAMINATION Impurities on base metal FILLER METAL CONTAMINATION Impurities on filler metal wire ATMOSPHERIC CONTAMINATION Drafts wind fans etc GAS MIXING APPARATUS 1 Too h2. 16 Soft Flat Head Screw SS Flat Head Screw Nylon Barrel Liner req d w single piece casing for 045 1 16 w Slip Iin Tip for 045 1 16 w Threaded Tip for 5 64 7 64 w Threaded Tip Socket Screw Handle Insulator Red Sleeve Jam Nut Adapter Collet Nut for Slip In Tip Collet Nut Adapter Threaded Tip Internal Insulator Insulator Nozzle Body w Insulator Nozzle Body less Insulator Gas Nozzle see Slip in Current Tip see p 6 Table 5 Nozzle Body w Insulator Nozzle Body less Insulator Insulator Gas Nozzle Gas Nozzle 540 ID Gas Nozzle 625 ID Nozzle Body w Insulator Nozzle Body less Insulator Gas Nozzle see p 6 Table 4 Threaded Current Tip see p 6 Table 5 Wrench Nozzle Thread Chaser Tap front Nozzle Thread Chaser Tap rear Heat Shrink Sleeve Cable Clamp Kit Switch amp Cable Assy see p 13 Table 8 Electrical Connector see p 13 Table 8 Power Cable Assembly 1 0 10 Ft Power Cable Assembly 1 0 12 Ft Power Cable Assembly 1 0 15 Ft Casing see p 13 Table 7 Gas Hose Assembly 10 Ft Gas Hose Assembly 12 Ft Gas Hose Assembly 15 Ft Liner see p 13 Table 6 Nut Cable Hose Sheath 8 Ft Cable Hose Sheath 10 Ft Cable Hose Sheath 12 Ft Wire Feeder Adapters see p 15 TABLE 6 LINERS Description Wire Size 2Ft 3Ft 4Ft 5Ft 6Ft 7Ft 8Ft 10Ft 12Ft 15 Ft Hard 030 Hard Cored 035
3. 2 Blade Hobart 27 Phone Jack Miller 50 Series AMP Compak 125 Cyclomatic Systematics Gilliand Amphenol 2 Pin Hobart Airco Westinghouse Amphenol 3 Pin Oxo All Auto Arc Amphenol 4 Pin Lincoln LN 7 LN 8 LN 9 Power Feed 10 LF 72 LF 74 Amphenol 5 Pin Miller 30 Series Compak75 Linde ESAB31 35 Machinery amp Welder Hubbell 2 Blade Hobart 27 Phone Jack Miller 50 Series AMP Compak 125 Cyclomatic Systematics Gilliand Amphenol 2 Pin Hobart Airco Westinghouse Amphenol 3 Pin Oxo All Auto Arc Amphenol 4 Pin Lincoln LN 7 LN 8 LN 9 Power Feed 10 LF 72 LF 74 Amphenol 5 Pin Miller 30 Series Compak75 Linde ESAB31 35 Machinery amp Welder Hubbell 2 Blade Hobart 27 Phone Jack UTILITY STATION 45184 AIR COOLED BARRELS ORDERING INFORMATION Utility Station Air Cooled Barrels 45184 D F TORCH CONNECTION 1 0 or 2 0 Power Cable CUSTOMER UTILITIES CONNECTION Shielding Gas 3 16 Hose Shank 1 0 or 2 0 Power Cable 1 125 DIMENSION SPECIFICATIONS Base Length Overall Length Base Width 2 25 Overall Width 25 Overall Height sn2r Overall Weight 251bs UTILITY STATION SIDE VIEW WITH COVER P_ 5 75 __________ B 125 3 75 __ _ FROM LEFT D F TORCH CONNECTION FROM RIGHT CUSTOMER UTILITIES CONNECTION 1 0 or 2 0 Power Cable Shielding Gas 3 16 Hose Shank Gas Hose 1 0 or 2 0 Power Cable c 2 75
4. 3 64 Aluminum MTW 1 16 Aluminum Tip provides 1 8 set back 5 64 Aluminum 3 32 Aluminum 1 8 Aluminum DISASSEMBLY 1 When repairs are made on the production line make certain the power source and wire feeder are disconnected from primary power 2 Remove forward gas nozzle If threads are damaged or clogged up with spatter use the nozzle thread chaser tap 14610 to recondi tion the nozzle body 3 Remove the current tip with the wrench provided 12111 by loosening the threaded tip or by loosening collet for a slip in tip 4 If the collet adapter 13205 or threaded adapter 12019 is to be replaced proceed as follows Unscrew the nozzle body If the insula tor threads off with the nozzle body it may be necessary to grip the edge of the insulator 13163 and turn it out Do not apply excessive pressure to the insulator The nozzle body insulator 16605 can be removed by sliding it to the rear NOTE Nozzle body 13197 insulator threads can be reconditioned and re chased with the rear nozzle thread chaser tap 14612 5 Remove the adapter by using two 5 8 wrenches one to hold the jam nut 16202 and the other to unscrew the adapter 6 The casing liner assembly can be removed and replaced by simply loosening the internal locking screw which is visible through the hole located behind the inner body holding screw 7 By removing the flat head inner body holding screw the inner body with utilities connected may
5. Accident Prevention Regulations UVV 26 0 and VGB 15 are fully observed and that all protective clothing eye and ear protectors specified are worn e The load data given are maximum limit figures Overloading will inevitably damage the torch e Before changing wear parts disconnect for the power supply e The operating instructions for the individual welding components e g power source wire feed and cooling unit must be followed e Never pull the cable assembly across sharp edges or set down close to weld spatter or on a hot workpiece e Those not involved in the welding process should be protected by curtains or partitions from radiation and the danger of being dazzled e When handling gas cylinders consult the instructions issued by the manufacturers and the suppliers of the pressurized gas e Workpieces which have been degreased using chlorinated solvents must be sprayed down with clean water before welding starts to avoid the risk of phosgene forming For the same reason no degreasing baths containing chlorine must be placed close to the welding point e All vapors given off by metals can cause harm and a special warning is attached to lead cadmium copper zinc and beryllium If necessary take ap propriate precautions by providing adequate ventilation or an extraction system to ensure that the legal maximum levels of toxic concentrations are not exceeded For more information refer to the following standards in their latest revisions
6. _ _ 2 ea 1 4 20 Screws lt a Lock Washers lt P Nuts Gp WIRE FEEDER ADAPTERS amp INLETS Direct Mount Remote Mount Adapter Adapter Manufac Models Wire Diameter turer Hardt Faas Stub Hard Cored or AL Liner or AL D20 20mm 030 3 32 H C AL 13098 13096 5 64 1 8 H C 13099 13097 All 030 3 32 H C AL 13067 13068 Models 5 64 1 8 H C 16087 LN 7 LN 8 030 3 32 H C AL 13110 13113 NA5 R 5 64 1 8 H C 13112 13116 LN 9 030 3 32 H C AL 5 64 1 8 H C NA3 NA5 030 3 32 H C AL 16879 i 16880 5 64 1 8 H C 16878 16881 ESAB ESAB Hobart Lincoln 030 3 32 H C AL 16879 16888 5 64 1 8 H C 16878 16888 Power Feed 030 3 32 H C AL 13479 13480 10 LF 72 5 64 1 8 H C 13469 13468 LF 74 Casing to Feeder Accepts Linde Outlet Guide D F Insert 035 045 Hard 13080 5 64 1 8 H C 13079 PA 10 030 3 32 H C AL Requires 5 64 1 8 H C 16568 Inlet 045 1 16 Hard 5 64 3 32 Cored Miller 030 3 32 H C AL 16557 50 Series 5 64 1 8 H C OTC Requires 030 1 8 18268 Insert 030 1 8 18275 Lincoln 030 3 32 H C AL Mavrix 3 64 1 16 AL CMRE 741 S 18282 18282 Panasonic PME 12X 030 1 16 13090 Reauires iniet YW50AKW1 030 1 16 13466 q 030 3 32 H C AL 13479 s 13480 5 64 1 8
7. and comply as applicable e ANSI Standard 249 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 2501 N W 7th St Miami FL 33125 e ANSI Standard 241 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 e ANSI Standard 249 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 e OSHA SAFETY AND HEALTH STANDARDS 29CRF 1910 obtainable from the U S Government Printing Office Washington D C 20402 e AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTABLES obtainable from the American Welding Society 2501 N W 7th St Miami FL 33125 e NFPA Standard 70 1978 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 e ANSI Standard 288 2 Practice for Respiratory Protection obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 e ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 e NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Printing Office Washington D C 20402 e American Welding Societ
8. and snug it up against the inner body Keeping that wrench on the jam nut and placing it on the table for force take a second 5 8 Open Ended Wrench place it on the adapter and push it down counter clockwise securing the adapter to the inner body Adjustable Crescent Wrench A medium size adjustable crescent wrench could be used as well CAUTION Never use excessive force with large wrenches for you could twist or break parts Standard Flat Head Screwdriver This is used to tighten or secure the torch s body screw Also the screwdriver can be used to straighten the contact tip if it is not aligned in the center of the gas cup or water cooled nozzle CAUTION This cannot be done unless the spatter disc has been removed from the torch Small Narrow Flat Head Screwdriver This is required to insert into the small body housing hole so you can access the casing conduit set screw Long Nose Pliers These are very handy when changing a slip in contact tip 1 16 Allen Wrench This is used for secure the button switch set screw in the aluminum pistol handle 3 32 Allen Wrench This is used to secure the socket cap screws in the handle bracket to the 3 t bolts required to secure the handle bracket 10338 to the body housing 12130 7 64 Allen Wrench This is used to secure the 4 socket cap screws in the sides of the aluminum pistol handle to the handle bracket and body housing 5 32 Allen Wrench This is used on the inne
9. checked again before shipping If a nozzle has been installed on a new complete torch they have also been hand checked while being assembled The only reason to ever take a gas cup out a nozzle is to clean it The nozzle and the gas cup must be blown out and all of the threads have to be wire brushed and blown out again before hand tightening the gas cup back into the nozzle If you can t thread it in by hand then something is wrong Never force a gas cup into a nozzle When using the D F Machine Specialties nozzle thread chaser taps be sure to always follow the steps below 1 Make sure that the nozzle is properly supported when tapping so it does not twist in the front of the torch body and cause damage e Improper support can cause the spigots to twist off the top of the rear nozzle collar or damage the torch internal body parts e Note where the water ports go down the sides of the water cooled nozzle following down in line with the spigots Too much direct pressure on these water ports could cause them to cave in and block of the flow of water e Best practice is to hold the water cooled nozzle in a vice with soft jaws perpendicular to the spigots e Over tightening of the vice can cause damage in general 2 Remove the tip from the front of the torch before tapping 3 Lightly lubricate the nozzle and nozzle thread chaser tap before tapping 4 Be sure to start the tap very carefully Do not cross thread the nozzle 5 Bevery careful t
10. 045 Hard Cored 045 1 16 Stainless 035 045 Stainless 045 1 16 Aluminum 3 64 Aluminum 1 16 Aluminum 3 32 Liners to be used with double asterisk casing TABLE 7 CASINGS 2Ft 3rt 4Ft 5Ft Grt 7Ft srt 10Ft 12Ft 15 Ft Casing Assembly Flexible Select Liner 030 14440 14441 14442 14443 12291 12286 12287 12290 Select Liner 035 1 16 14444 14445 14446 14447 16173 13751 13757 13752 Casing Assembly Reinforced Single Piece 035 045 Single Piece 045 1 16 Single Piece 5 64 3 32 Single Piece 7 64 1 8 Liners to be used with double asterisk casing TABLE 8 SWITCH amp CABLE ASSEMBLIES Feeder Manufacturer Model No Length Miller 50 Series AMP Compak 125 Cyclomatic Systematics Gilliand Amphenol 2 Pin Hobart Airco Westinghouse Amphenol 3 Pin Oxo All Auto Arc Amphenol 4 Pin Lincoln LN 7 LN 8 LN 9 Power Feed 10 LF 72 LF 74 Amphenol 5 Pin Miller 30 Series Compak75 Linde ESAB31 35 Machinery amp Welder Hubbell 2 Blade Hobart 27 Phone Jack Miller 50 Series AMP Compak 125 Cyclomatic Systematics Gilliand Amphenol 2 Pin Hobart Airco Westinghouse Amphenol 3 Pin Oxo All Auto Arc Amphenol 4 Pin Lincoln LN 7 LN 8 LN 9 Power Feed 10 LF 72 LF 74 Amphenol 5 Pin Miller 30 Series Compak75 Linde ESAB31 35 Machinery amp Welder Hubbell
11. Instruction Manual 252 PAC PAT Air Cooled Pistol Revised 06 2014 D F MACHINE SPECIALTIES INC MIG amp TIG Welding Products Consumables amp Accessories 1750 Howard Drive North Mankato MN 56003 Phone 507 625 6200 Fax 507 625 6203 Email sales dfmachinespecialties com www dfmachinespecialties com AIR COOLED MIG PISTOL GUN MODEL PAC Slip In Current Tip MODEL PAT Threaded Current Tip INSTRUCTION PARTS amp SPECIFICATIONS MANUAL D F MACHINE SPECIALTIES is a world leader in the design development and manufacture of MIG GMAW amp TIG GTAW weld ing products consumables and accessories D F offers several types of manual Air or Water Cooled MIG welding tools and with the increased use of automated and robotic welding systems a demand has been created for welding tools of the highest quality durability and interchangeability For over forty years D F welding products have been used extensively on MIG and TIG welding applications This experience coupled with patented design features unavailable on any other competitive equipment has made D F welding tools the most advanced MIG and TIG welding guns and barrels for semi automatic automatic or robotic welding applications This Catalog is a guide to helping you select the proper tool for a given semi automatic automatic or robotic welding application The fol lowing is only a partial listing of available semi a
12. PAT 76 Th d Tip 17777 PAT 77 Th d Tip 17778 PAT 78 Th d Tip TABLE 2 SPECIFICATIONS DIAMETER OF WEIGHT RECOMMENDED WIRE MISES CORNET nla sclih BODY HOUSING HEISE approx DIAMETER RANGE PAC 260 amp CO 42 875 030 062 Hard Cored 400 amp Argon 3 64 1 16 AL 260 amp CO 42 875 030 062 Hard Cored 400 amp Argon l 3 64 1 16 AL TABLE 3 RECOMMENDED SPARE PARTS Gas Nozzle To Be Selected Current Tip To Be Selected Collet Nut To Be Selected Body Liner To Be Selected Insulation Tube To Be Selected Insulator 13163 TABLE 4 GAS NOZZLES GUN MODEL REF _NOZZLETYPE O D 1 D _ CODENO NC HT Copper Tapered 63 64 5 8 Copper Straight 1 3 4 Copper Full Taper 63 64 5 8 Copper Straight 5 8 7116 Use With Nozzle Body 13198 1 1 16 3 4 TABLE 5 CURRENT TIPS CURRENT TIPS 1 4 DIAMETER SLIP IN Gun Barrel Model Wire Size Wire Type All NC NCC NCM Tip provides 1 8 set back All NC NCC NCM Aluminum Tip provides 1 8 set back Aluminum Aluminum Aluminum All NC NCC NCM Bent Tip Hard Tip provides 1 8 set back Hard Aluminum Aluminum CURRENT TIPS 7 16 DIAMETER THREADED _ Gun BarrelModel__ _ Wire Size Wire Type Code No All HT HTC HTM CTW CW T MTW Tip provides 1 8 set back All HT HTC HTM CTW CW T MTW Tip provides 3 8 set back All HT HTC HTM CTW CW T
13. be pulled from the rear of the body tube ASSEMBLY 1 If anew power cable is required proceed as follows Trim approximately 1 off of the cable covering Carefully wrap the copper strands with the copper sheet Slip the wrapped copper cable end with locking clip 16196 provided into the rear of the inner body cable adapter Prior to applying the cable place the heat shrink sleeve 12641 on the cable 2 Securely tighten the socket set screws on the power cable assembly Push the heat shrink sleeve forward so that after the heat is ap plied the cable adapter is covered completely 3 Carefully insert the inner body assembly into the body housing Make certain that the electrical cable is in its locating pocket provided in the body housing The flat head body holding screw may now be applied 4 Check to make sure that your gun assembly has the right size current tip and liners for wire to be used 5 When installing a new collet 11950 be careful not to over tighten it with the collet wrench Excessive pressure is not required due to the good gripping action of the collet 6 Current tips and nozzles should be cleaned as frequently as required A clogged gas nozzle will restrict the flow of shielding gases 7 Check regularly the condition of the service hose and control wire connections leading from the wire feeder and power source REQUIRED TOOLS LIST FOR DISASSEMBLY amp ASSEMBLY 1 10 11 12 13 D F 12111 Colle
14. d with a cover Make sure spare wire rolls are stored in a clean dry place Set the brake so that the coil immediately stops rotating as soon as welding is interrupted If the brake is applied too hard it will cause the feed rolls to slip resulting in uneven wire feed If it is too loose overrun of the wire will occur causing wire tangles inconsistent tension on the feed mechanism and irregular arc Characteristics Set the wire feed in relation to the arc voltage in such a way that the arc is stable and burns evenly In spray arc welding set the wire feed so that there are no short circuits and the filler metal is transferred in a spray across the arc Find the cause of the interference and correct it See ERRATIC WIRE FEED above When the internal diameter of the current tip becomes worn from the passage of wire through it the wire may no longer stay in continuous electrical contact with the tip This results in an unstable arc and an increase in spatter Paint mill scale silicon scale rust or flux deposits from previous weld runs may form an insulating layer causing an unstable arc Clean the surfaces to be welded Securely attach the ground cable as close to the point of welding as possible on the workpiece Clean the surfaces thoroughly to ensure good contact Check to insure the welding power connection on the power source is tight the and workpiece Connection on the wire feeder is tight the connection to the adaptor block is t
15. ennnnennnnennnnsrnnnsnrnrsrrersrrernnns 6 LIS ASSSITIIY ASSOCII eter se setae r EE E E EE eae donna E sacar T Required Tools List for Disassembly amp ASSEMDIY cccecccecceecceeeeeeeeeeeeeseeeseeeaees 8 9 How Do Cut Fit and Install a New Liner 0 ccc ccececececececeeeaseseceeeseaeaeaenenees 10 What is the Proper Use of the Nozzle Thread Chaser Tap cccccccecseeeeeeeeeeeees 11 Air Cooled Pistol Gun Parts a nnannannonnaenonnnnnnnnnnnnnnnnrrnrrnrrnnnnnrnrennrorernronrrnrrnrrnresrenns 12 Table 6 Liners Table 7 Casings Table 8 Switch amp Cable Assemblies 13 Utility Station Air Cooled Barrels cccccccccccecceeeceeeceeeeneceeeceeseeseeeseeeseesaeeseeeseeeas 14 Wire Feeder AGED TENS sisusse nN EEEE Raa EEA Ora EENE 15 TUCO SIO ONIN asst ane ate vests acts E em EE EE EEE 16 19 SAFETY MEASURES PLEASE READ Welding is not particularly hazardous when certain safety practices are followed Anyone using this equipment should be thoroughly trained in safe welding practices Failure to observe safe practices may cause serious injury Handling welding torches presents no dan ger if the appropriate safety regulations are strictly adhered to For example Starting up procedures must be reserved for those fully conversant with processes relating to arc welding equipment e Arc welding can prove damaging to eyes skin and hearing It is therefore imperative that the
16. he cause of the disturbance and correct the condition before proceeding Paint mill scale rust and other contamination on the base metal form an insulating layer causing an unstable arc that results in heavy spatter Clean the surfaces to be welded Inspect ground cable for loose connections fraying and cuts Correct any problem areas found and attach the ground cable directly to the workpiece after having cleaned the contact sur face first POOR GROUND CONTACT IS THE MOST COM MON CAUSE OF UNSTABLE MIG WELDING CONDITIONS The stick out should be 15 times the diameter of the wire elec trode being used With increasing stick out the current is re duced and the arc voltage rises giving a longer unstable arc and increased spaitter Check for correct polarity Follow the electrode manufacturer s recommendations TROUBLESHOOTING GENERAL GUIDE Problems Causes ERRATIC WIRE FEED Slipping feed rolls Clogged or worn gun liner Liners too long or too short Spatter on the wire Coil brake incorrectly adjusted UNSTABLE ARC Incorrect setting of voltage and or current Problems in wire feeding worn current tip Impurities on the base metal Poor contact between ground cable and work piece or loose power connection Stick out too long Possible Solutions Check that the feed roll size is correct for the wire size being used Increase the drive roll pressure until the wire feed is even Do not apply excessive pressure a
17. igh a gas flow causing turbulence and or sucking air at hose connections creating the venturi effect at end of gas nozzle 2 Too low a gas flow causing insufficient gas coverage 3 Damaged or kinked gas lines 4 Too high an oxygen content 5 Leaks in gas distribution system 6 Other impurities in gas moisture etc 7 Inconsistent gas flow cfh at the torch connection GAS TURBULENCE 1 Excessive spatter build up in gas nozzle and on current tip 2 Nozzle damage causing uneven gas coverage 3 Torch gas ports clogged or deformed 4 Super heated nozzle causing shielding gas to expand rap idly and create return effect at end of nozzle 5 Gas diffuser nozzle insulator missing 6 Too high a gas flow causing the venturi effect WELDING PARAMETERS ETC 1 Too long a wire stick out gas nozzle too far from weld puddle 2 Bad torch position too sharp a torch incline causing the venturi effect at the end of the nozzle leading to atmospheric contamination 3 Excessively wide weld pool for nozzle D 4 Arc voltage too high 5 Too high a travel speed Possible Solutions a Remove contamination clean surfaces b Use of specific wire gas mix for specific types of impurities a Replace wire b Install wire cleaning system c Prevent industrial dust dirt grit from contaminating wire dur ing storage or use d Prevent build up of aluminum oxide on exposed aluminum wire surface by using up quickly e Remove wire from w
18. ight Loose power connection and the connection of the gun to the adaptor block is tight Adjust the current tip to work distance to a minimum of 3 8 for short arc welding Amore precise distance is 15 times the wire diameter TROUBLESHOOTING GENERAL GUIDE Problems Causes AIR COOLED GUN RUNNING TOO HOT Poor ground Loose power connection Consumable items loose or worn Capacity of gun being exceeded Dirty connection Possible Solutions Inspect ground cable for loose connections fraying and cuts Correct any prob lem areas found Clean clamping area to insure good contact Securely attach the ground cable to the workpiece as close as possible to the point of welding Make sure there is a good connection to the welding power source Check to make sure the power connection on the power source is tight the con nection on the wire feeder is tight the connection to the adaptor block is tight and the connection of the gun to the adaptor block is tight Remove nozzle from gun and inspect current tip collet nut tip holder and spat ter disc gas diffuser for wear and tightness replace or tighten as necessary Note complete weld parameters including welding current Amps welding volt age wire feed speed type and size of wire type of gas and flow rate of gas and consult your local Authorized D F Machine Specialties Distributor or contact the factory Remove torch and inspect parts for dirt build up Periodic clean
19. ing is neces sary D F MACHINE SPECIALTIES INC MIG amp TIG Welding Products Consumables amp Accessories WARRANTY This Equipment is sold by D F MACHINE SPECIALTIES Incorporated under the warranty set forth in the following paragraph Such warranty is extended only to the buyer who purchases the equipment directly from D F or its authorized distributor as new merchandise The barrel and cable assemblies are warranted by D F to be free from manufacturing defects for 90 days after delivery by D F provided that the equipment is properly operated under conditions of normal use and that regular periodic maintenance and service is performed Expendable parts are not war ranted for any specific time Expendable parts referred to herein would be the nozzles current tips spatter discs insulators casing liners and wire inlets D F s sole obligation under this warranty is lim ited to making replacement at its manufacturing facility for barrel assemblies which are returned to it with transportation charges prepaid and upon D F s examination have been found to be so defective Genuine D F MACHINE SPECIALTIES Inc Parts Accessories and Consumables must be used for safety and performance reasons The use of anything other than genuine D F MACHINE SPECIAL TIES Inc Parts Accessories or Consumables will void this Warranty All units returned for warranty repair are subject to Warranty Inspection Warranty and repair work shall not appl
20. ire drive unit and store in a sealed plas tic bag when not in use for long periods a Protect weld from drafts curtains screens b Use tapered or bottleneck gas nozzles when drafts cannot be avoided 1a Reduce gas flow 1b Tighten all hose connection points 2 Increase gas flow 3 Repair or replace 4 Adjust mixer 5 Repair leaks 6 Overhaul system fit filters and or dryers 7 Regulate pressure into flow meter for consistent cfh delivery of gas 1 Clean nozzle and tip regularly spray with anti spatter fluid 2 Replace nozzle 3 Clean or replace 4 Check duty cycle rating of torch 5 Replace 6 Reduce gas flow 1 Use longer nozzle or adjust stick out 3 8 minimum or 15 times wire diameter 2 Correct torch angle 3 Width of the weld pool should be 1 3 times the nozzle D use suitable wider gas nozzle 4 Reduce voltage 5 Reduce speed TROUBLESHOOTING SPATTER Problems Causes SPATTER Too fast or too slow wire feed for the arc voltage Too long an arc Damaged current tip Inclination of welding gun too great Faulty power source Incorrect start Incorrect pulse parameters Uneven wire feed Impurities on the base metal Poor ground contact Too long stick out short arc welding Incorrect polarity Possible Solutions Set the wire feed rate and voltage in accordance with good weld ing practices as recommended by a qualified welding engineer Adjust the wire feed and voltage so
21. o start threads correctly Only tap 1 2 turn at a time always backing up and removing chips 1 2 cycle at a time before moving forward Do not try to tap further into the water cooled nozzle than needed or past the factory thread depth 6 Blow out the nozzle after tapping Wire brush and blow off the gas cup before threading it back into the nozzle 7 If nozzle is badly deformed or damaged please return to the factory for a repair estimate before disposing of product damaged parts can often be repaired ORDERING INFORMATION NOZZLE THREAD CHASER TAPS USED WITH USED FOR CODE NO DESCRIPTION NOZZLE ASSEMBLY GAS NOZZLE Nozzle Thread Chaser Tap 13197 for Standard A C amp W C 16184 Nozzle Assembly Front 11117 45101 11118 45102 11119 45103 45114 45107 NCC N HTC N NCC LRN HTC LRN Nozzle Thread Chaser Tap for BIG MIG amp BIG TIG Nozzle Assembly Front Nozzle Thread Chaser Tap for Nozzle Body Assembly Rear for Series A High Capacity 11138 45121 Nozzle Assembly Front 45127 11132 45129 45125 u Nozzle Thread Chaser Tap 11142 45120 Nozzle Thread Chaser Tap 13198 10379 for Nozzle Body Assembly Front 14617 Nozzle Thread Chaser Tap 41667 for Tandem Nozzle 41668 Assembly Front AIR COOLED PISTOL GUN MODEL PAC Slip in Tip MODEL PAT Threaded Tip Body Housing Handle Socket Head Cap Screw 4 req d Socket Set Screw Button Switch Inner Body Alignment Tube 035 1 16 Hard Alignment Tube 3 64 1
22. r body s set screws to secure the power cable to the torch s inner body REQUIRED TOOLS LIST FOR DISASSEMBLY amp ASSEMBLY HOW DO I CUT FIT AND INSTALL A NEW LINER 1 2 10 11 12 13 14 15 16 17 18 Be sure the MIG Gun cable is arranged in a straight line free from twists when installing or removing a wire liner Remove the old liner by first removing the MIG gun s contact tip Pull the old wire liner out of the conduit casing assembly from the feeder connector or feeder adapter plug end If you are using a feeder adapter that has an inlet the inlet must be removed first If you have any problems removing the liner you may un thread the feeder adapter first this will also back the liner out of the conduit casing If you know that the old liner is the correct length or is still the original liner that was cut at the factory you may hold the new liner up against the old liner and cut off the new liner to the same size as the old liner Make sure you have a good sharp cut off with no material sticking out To get the correct length of the new liner insert the liner into the feeder adapter and feed it through the conduit casing Once again be sure the MIG Gun cable is arranged in a straight line free from twists when installing a new wire liner Sometimes on longer conduits casings and liners it may take 2 people together one on each end to rotate and twist the conduit casing to get the line
23. r trough the torch If you have any troubles getting a liner through a torch make sure you have a good sharp cut off and if you have to you can gently sand the end of the liner on a belt sander You can remove the cast in the aluminum liner by pre bending and straightening the liner before loading After the new liner comes out the end of the torch you want to cut the new liner off flush with the end of the copper gas nozzle or Cu gas cup Now you have the overall length of the liner you still have to take out the length of the contact tip Carefully remove the liner one more time After removing the liner hold the gun end of the liner up against the tip Cut off the length off the tip plus the set back of the tip 1 8 or 3 8 tip setbacks Now that you have cut off the length of the tip plus the setback you may install the new liner and it will back up into the back of the tip chamfer We always recommend checking the condition of the insulation tube in the front of the torch and collet nut that holds the slip in tip We always recommend replacing the spatter disc gas diffuser contact tip and nozzle after installing a new liner Tighten the flat head set screw in the inner body or the Allen set screw in the docking spool onto the conduit casing to prevent back ward movement or an unwanted pumping action WHAT IS THE PROPER USE OF THE NOZZLE THREAD CHASER TAP All D F Nozzles are hand checked for fit before and after plating and
24. s this can damage the wire surface causing copper coating to loosen from steel wires or metal shavings to be formed from soft wires like aluminum These metal fragments or shavings can be drawn into the wire feed conduit and will rapidly clog the liner When welding with flux cored wires excessive drive roll pressure may open the wire seam and allow flux or metal powders to escape a Dust particles of copper drawing lubricants metal or flux and other forms of contamination can all clog the liner so that the wire feed is slowed or impeded A liner that has been in use for an extended period of time becomes worn and filled with dirt and must be replaced b When changing the welding wire remove the tip from the front end of the gun and blow out the body liner with clean dry compressed air from the back of the gun Repeat with the casing and liner assembly Note Wear safety goggles when using compressed air to clean the liners Make sure proper safety proce dures are followed in order to avoid possible serious eye injury Check the lengths of the liners and trim or replace if too long or too short The efficient feeding of the welding wire is dependent on the liners fitting correctly An unprotected coil of wire quickly collects dust and other airborne contamina tion If grinding is being performed in the vicinity particles can become attached to the wire severely interfering with the wire feed Replace with clean wire and keep it protecte
25. t Tip Wrench This is the only tool that should ever be used to tighten the collet nut or the tip Pressure should be 30 Ibs or as Snug as hand tightened Never use another wrench to apply more torque to this wrench D F Nozzle Thread Chaser Taps Front amp Rear This is used to re tap damaged threads that have been improperly cleaned or cross threaded Always blow out the nozzle and gas nozzle after changing gas cup or re tapping For more information on how to use the nozzle thread chaser tap use the following link www dfmachine com taps 3 8 Open Ended Wrench This is used on the inner body s gas hose fitting to secure the gas hose to the torch s inner body A crescent wrench could be used instead but due to the large size of crescent wrenches we prefer the smaller size of the open ended wrenches You never want to use excessive force by using too large of a wrench You will use the Long 7 16 Open Ended Wrench for the fitting on the gas hose itself while using the 3 8 wrench to steady the inner body at the fitting see 4 Long 7 16 Open Ended Wrench This is used to secure the gas hose to the torch s inner body see 3 5 8 Open Ended Wrench This wrench is used to secure the adapter and jam nut that hold the current tip to the inner body In your left hand hold the inner body and with your right hand thread up the adapter using the 5 8 Open Ended Wrench until it is tight Now place the same wrench on the jam nut
26. that the arc is in accordance with good welding practice for the joint to be welded The dis tance from the current tip to the workpiece should be 15 times the welding wire diameter If the arc is too long there will be spat ter usually in the direction of the weld If the current tip becomes worn the welding wire will not be in constant contact with the tip and the arc will become unstable A current tip contaminated with spatter will cause uneven wire feed resulting in further spatter The angle of the gas nozzle relative to the workpiece should be between 45 and 90 degrees If the angle is too small the wire runs parallel to the weld pool resulting in spatter in the direction of the welding Have the power source checked for faulty conditions such as broken wires and faulty contacts A great deal of spatter occurs if the stick out is too great and if the welding gun is held too far from the workpiece when striking the arc Try to start with as short a stick out as possible and with the welding gun as close to the starting point as possible If a large ball end is formed on the end of the welding wire remove it by cutting the wire with sharp wire cutters It is helpful if the wire is cut to a point Always remove the ball end before striking an aluminum arc Check the welding ground connection Check the user manual for your power supply or consult a quali fied welding engineer Uneven wire feed gives rise to heavy spatter Find t
27. ty driven welding professionals Customers still to this day choose D F over competitors because of our responsiveness and flex ibility Customers will continue to choose D F tomorrow for our superior hand made products and service To ensure this we need creative and competent personnel in all business divisions an intensive exchange of thoughts and ideas with all users par ticipation in working and study groups within the field of welding technology and intensive cooperation with institutes and univer sities Teamwork Striving for excellence is a commitment that is an integral com ponent of the D F Culture Our team of skilled and dedicated employees takes pride in the excellence products they produce Each of us willingly accepts personal responsibility for meeting our commitments and we hold each other to a high standard of accountability Responsibility We will continually strive to be environmentally responsible and to support the health and safety of our employees customers and neighbors We continue to support the communities in which we operate and the industries in which we participate Thank You for Choosing D F Machine Specialties TABLE OF CONTENTS Uy I E E A E E 4 Introduction Table 1 Ordering Information Table 2 Specifications Table 3 Recommended Spare Parts cccscccscccseceeeceecceeceeeceeeceeeauecseesuesaueseesaees 5 Table 4 Gas Nozzles Table 5 Current TipS 0nnononnenonn
28. utomatic automatic and robotic guns For further information on special MIG and TIG requirements please consult the factory Customer satisfaction and customer benefits are the center points of all strategic contents The spirit of the D F Machine Specialties personnel is to listen to and to integrate the customer throughout the process to develop and design marketable products to present prototypes to carry out pilot tests and to prepare for and be open to new technology and tasks We attract and carefully select talented individuals who share our values Together we will nurture and sustain a work environment with two way communication training men toring and rewarding career opportunities Innovation and quality Innovation and quality come from being receptive and willing to learn from others We encourage our people to be creative and take risks in the pursuit of excellence Innovative practices are deeply rooted in every one of our employees a philosophy that leads to continuous product development and industry firsts Progress By remaining confident focused and persistent in challenging times we will discover opportunity Commitment to quality and the pursuit on innovation ensure that D F Machine Specialties will remain an industry leader for years to come Commitment to excellence At D F Machine Specialties we commit to design build and de liver premium products and superior customer support to quali
29. y Standard AWSF4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances obtainable from the American Welding Society 2501 N W 7th St Miami FL 33125 INTRODUCTION These Air Cooled Pistol Guns are offered as two different models The Model PAC employs a slip in tip fastened by a collet action nut The Model PAT accommodates a threaded current tip Various front end nozzle body arrangements are offered to cover a broad range of applications Conversion to the use of a particular nozzle body arrangement is easily accomplished by selecting the desired nozzle body and current tip adapter arrangement The Air Cooled Gun assemblies operate on a current thru 400 amperes contingent on the front end nozzle body being used and the current tip The Model PAC with a slip in current tip operates on a current level thru 260 amperes Model PAT with a threaded current tip operates on a current thru 400 amperes The higher current levels would be obtainable with CO as the shielding gas Gun assemblies will accommodate a wire diameter range of 030 thru 1 16 diameter For further information or help with D F Machine Specialties products please visit our web site at www dfmachinespecialties com or consult the factory at 1 507 625 6200 TABLE 1 ORDERING INFORMATION 11286 PAC 91 Slip in Tip 11287 PAC 92 Slip in Tip 11288 PAC 93 Slip in Tip 17776
30. y to goods that have been altered or repaired have been subject to misuse or used while any parts are loose broken or damaged or used with other than original D F parts consumables or accessories which may affect performance and safety D F MACHINE SPECIALTIES INC 1750 Howard Drive North Mankato MN 56003 Phone 507 625 6200 Fax 507 625 6203 Rev 140612 1 www dfmachinespecialties com
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