Instruction Manual 63 - TM1000 BIG TIG
Contents
1. 8 9 What is the Proper Use of the Nozzle Thread Chaser 10 Model TM1000 Ordering Information 11 Tungsten Extension Rod Installation Table 2 Recommended Spare Parts 12 19 Troubleshooting 14 17 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 Accident Prevention Regulations UVV 26 0 and VGB 15 fully observed and that all protective clothing eye and ear protectors specified are worn load data given are maximum limit figures Overloading will inevitably damage the torch e Before changing wear parts disconnect for the power supply operating instructions for the individual welding components e g power source wire feed and cooling unit must2. 2 Thoriated Tungsten Electrode 5 16 Diameter 2 Thoriated Tungsten Electrode 3 8 Diameter Zirconium Tungsten Electrode 5 16 Diameter Zirconium Tungsten Electrode 3 8 Diameter Knob Socket Set Screw O ring Top Load Shaft Assembly with knob Top Load Shaft Assembly less knob Adapter Inner Body Washer 2 required TABLE 1 GAS NOZZLES wee Copper Copper Copper 15914 12115 10743 13913 13914 11123 15913 10249 15876 14258 13990 12614 14041 14052 Collet Adapter 3 8 Wrench Insulating Collar includes o rings O ring Internal 2 required O ring External Water Cooled Nozzle Insulating Sleeve Nut Gas Nozzle see Table 1 below Socket Cap Screw Outer Top Shell Flat Head Screw 2 required Barrel Housing Boot REQUIRED TOOLS LIST FOR DISASSEMBLY amp ASSEMBLY 1 D F 12111 Collet Tip Wrench This is the only tool that should ever be used to tighten the collet nut or the tip Pressure should be 30 lbs as Snug as hand tightened Never use another wrench to apply more torque to this wrench D F 14611 Nozzle Thread Chaser Tap This is used to re tap damaged threads that have been improperly cleaned or cross thread ed 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 followin
3. guns For further information on special and 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 quality driven welding profes
4. 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 as 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 cor
5. the casing in the casing adapter REQUIRED TOOLS LIST FOR DISASSEMBLY amp ASSEMBLY a De CRAFTSMAN WHAT IS THE PROPER USE OF THE NOZZLE THREAD CHASER All D F Nozzles are hand checked for fit before and after plating and 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 vice with soft jaws perpendicular to the spigots e Over tightening of the vice can
6. 1668 Assembly Front 1000 MACHINE BARREL MOUNTING TUNGSTEN CURRENT CODE NO DESCRIPTION SIZE CAPACITY MODEL 3 Ft Assembly 1 8 3 8 4 Ft Assembly 1 8 3 8 6 Ft Assembly 1 8 3 8 8 Ft Assembly 1 8 3 8 10 Ft Assembly 1 8 3 8 2 750 Ref CodeNo Description 14086 Mounting Bracket 12534 Socket Cap Screw Gas Hose Assembly 3 8 Hose 16575 3 16575 4 Power Cable 2 0 15263 2 15263 3 15263 4 Power Cable 4 0 15270 2 15270 3 15270 4 Water In Out amp Power Cable Assy 19645 2 19645 3 19645 4 L H Nut Each End Consult factory for other cable lengths required INSTALLATION OF THE TUNGSTEN EXTENSION ROD The Tungsten Extension Rod page 6 7 Ref 1 permits top loading of 040 through 5 32 diameter tungsten electrodes It consists of a phenolic rod which provides a threaded stud at its lower end A tungsten sleeve ref 2 must be low tempera ture brazed to the end of the tungsten that will be used Apply this tungsten electrode with brazed sleeve to the threaded stud provided on the Tungsten Extension Rod ref 1 Slide the proper collet ref 3 on the tungsten for a distance of ap proximately 2 This assembly consisting of the Extension Rod Tungsten and Collet is now ready to be applied to the barrel Proceed by unscrewing the Top Load Shaft ref 8 and remove it from the barrel Next apply the Tungsten Extension Rod assembly by slidi
7. 50 Howard Drive North Mankato MN 56003 Phone 507 625 6200 Fax 507 625 6203 Rev 140612 2 www dfmachinespecialties com
8. 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 287 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 Society 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 IMPORTANT The D F torch is famous for the fact that if it is chilled properly the welder can grab the front of the torch with their bare hand and it will be cold to the touch seconds a
9. Instruction Manual 63TM TM1000 BIG TIG Revised 06 2015 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 WATER COOLED BIG MACHINE BARREL Model TM1000 INSTRUCTION PARTS amp SPECIFICATIONS MANUAL D F MACHINE SPECIALTIES is world leader in the design development and manufacture of MIG GMAW 8 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 interchangeability For over forty years D F welding products have been used extensively on and welding applications This experience coupled with patented design features unavailable on any other competitive equipment has made D F welding tools the most advanced and 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 automatic automatic and robotic
10. Out amp Power Cable Gas Hose CUSTOMER UTILITIES CONNECTION Water Out zZ a Water In 3 8 Hose Shank d 3 8 Hose Shank Voltage Shielding Gas Sensing 3 16 Hose Shank Lead 4 0 Power 4 0 Power Cable Cable H 1 125 DIMENSION SPECIFICATIONS Base Length Overall Length Base Width 225 Overall Width 25 Overall Height LA Overall Weight UTILITY STATION SIDE VIEW WITH COVER 5 75 c 3 15 4 3 125 FROM LEFT D F TORCH CONNECTION FROM RIGHT CUSTOMER UTILITIES CONNECTION Water In Out amp ng m Power Cable Water In Hose Gas Hose 2 ea 1 4 20 Screws 6 Lock Washers 5 Nuts CR Water Out 3 8 Hose Shank Water In 3 8 Hose Shank Shielding Gas 3 16 Hose Shank 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 high 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
11. 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 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 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 the current tip become
12. 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 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 and comply as applicable 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 MENG 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
13. 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 to 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 Nozzle Thread Chaser 11142 45120 Nozzle Thread Chaser Tap 13198 10379 for Nozzle Body Assembly Front 14617 Nozzle Thread Chaser Tap 41667 for Tandem Nozzle 4
14. ed 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 protected 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 i
15. erated liquid chiller for GMAW may be obtained from For single torch chillers Dynaflux 800 334 4420 www dynaflux com For multiple torch cooling systems Koolant Koolers 800 968 5665 www koolantkoolers com INTRODUCTION The high current water cooled barrel is of a design which offers the capability of operating at current levels of 1000 amperes Tungsten diameters accommodated by the barrel range from 1 8 thru 3 8 diameters A unique feature of this Water Cooled Machine Barrel is that the nozzle assembly water chamber and inner body water chamber are serially connected to each other with removable connectors making it a relatively simple matter to detach the nozzle assembly thus completely eliminating the need for gaskets or o rings in the water passage system 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 DISASSEMBLY To disassembly the Water Cooled Barrel proceed as follows 1 Remove the forward gas nozzle 2 Unscrew the collet adapter D F 15914 with wrench supplied Remove the insulating tube D F 15879 and gas diffuser D F 15858 3 Remove the body nut 4 With a screw driver remove the barrel body holding screws The upper shell may bow be removed from the barrel body 5 Push the barrel body upward until it bottoms out at service connections The nylon insulators at the front
16. es 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 cleaning 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 on
17. fter welding With the proper chiller this can be done even after a 4 hour arc time Make certain the cooling water supply is at least the minimum flow rate of 1 gallon per minute for each inner body at 40 psi 80 psi maximum with a 5 gallon reservoir and 15 000 BTU hr cooling capacity Gun ratings are affected by shielding gas used arc time cooling time and inlet water temperature Water outlet temperature should not exceed 27 C 80 F The torch s water out amp power cable is not cooled until the coolant has gone through the torch and out the water out amp power cable If water is not flowing through the D F torch for at least 1 minute prior to striking an arc when you apply the power and water hits the hot water out amp power cable you will generate steam Steam can damage the torches internals in seconds causing a leak It can also blow out the torches water out amp power cable A flow switch can be installed after the return line ensuring that coolant is present at the return line prior to striking an arc When High Deposition GMAW or extended periods of arc time are used it is recommended that a liquid chiller be considered with a larger reservoir and a minimum of 30 000 BTU hr cooling capacity Precise temperature control maintains the cooling at a constant 13 C 55 F temperature thus prolonging the life of the welding equipment and more specifically extending the service life of the gas nozzle and current tip A refrig
18. g link www dfmachine com taps D F 12114 Tip Adapter Nut Wrench This is the only tool that should ever be used to tighten the tip adapter nut Pressure should be 30 Ibs as Snug as hand tightened Never use another wrench to apply more torque to this wrench Long 7 16 Open Ended Wrench A Ashort wrench will work however we prefer the feel and comfort of the long 7 16 open ended wrench This is used to loosen or tighten interconnection hoses to the fitting on the inner body Also use this wrench to connect the torch s water cooled nozzle assembly to the interconnection hoses 11 16 amp 3 4 Open Ended Wrench A The 3 4 Open Ended Wrench is used on the inner body s water in and gas elbow fittings to secure them 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 also use the 3 4 Open Ended Wrench to secure the water in and gas adapters to the elbows and the water out adapter to the inner body B The 11 16 Open Ended Wrench is used to secure the gas hose and water in water out amp power cables or hoses to the torch s inner body C The 3 4 Open Ended Wrench is also used to secure the adapter and jam nut that hold the tip adapter nut which holds the current tip in the inner body In your left hand hold the inne
19. 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 wire 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
20. ly 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 apply 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 17
21. ng it up through the Top Load Shaft from the bottom of the Shaft Grip the Tungsten Extension Rod above the Knob on the Top Load Shaft and replace this combination into the barrel After the Top Load Shaft has been threaded for several revolutions the tungsten may be adjusted upward or downward by the use of the Tungsten Extension Rod extend ing beyond the Shaft Knob The desired stickout of the tungsten electrode at the gas nozzle may now be set after which the shaft knob my be firmly tightened Since the tungsten erodes during welding the Top Load Shaft in combination with the Tungsten Extension Rod allows adjust ment during the weld cycle This may be accomplished by releasing the Top Load Shaft only enough to remove pressure from the Collet after which the Tungsten Extension Rod may be moved downward to compensate for electrode erosion This procedure may be repeated until the length of tungsten has been consumed A quantity of tungsten should be prepared with the sleeves applied so that a new electrode may be applied with minimum downtime TABLE 2 RECOMMENDED SPARE PARTS ITEM CODE NO MIN QTY Gas Nozzle To Be Selected Tungsten Sleeve To Be Selected Collet To Be Selected Gas Diffuser 15858 Insulation Tube 15879 UTILITY STATION 45188 DUAL POWER ORDERING INFORMATION Description Utility Station Utility Station Dual Power Cable 45188 D F TORCH CONNECTION Water In Out amp Power Cable Water In
22. r body and with your right hand thread up the adapter using the 3 4 Open Ended Wrench until it is tight Now place the same wrench on the jam nut and snug it up against the inner body Keeping that wrench on the jam nut and placing it on the table for force take another 3 4 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 We prefer the use of the larger wrenches on the power cable fitting to ensure that there are no water leaks and that it has been seated correctly 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 Long Nose Pliers These are used to grab the small white insulation tubes 10725 and get them into the correct position when work ing on the interconnection hose fittings inside the torch Also they are very handy when changing a slip in contact tip 3 16 Allen Wrench This is used to secure the socket cap screw that holds the casing adapter in the inner body It is also used to secure the socket cap screw that holds
23. s 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 tight 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 Caus
24. s 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 the 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
25. sionals 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 CONTENTS 4 Introduction Disassembly Assembly 5 Model TM1000 BIG Machine Barrel Parts 6 7 Table 1 Gas Nozzles E Required Tools List for Disassembly amp
26. small hole in the nylon collar be on the lower right hand side as the water cooled nozzle is connected to the hose fittings After fastening the hoses the barrel body should be moved forward until the flat head body screw may be fastened The water cooled nozzle may now be pushed back against the barrel body 5 Slide the upper barrel body shell into place and fasten with the screw The body nut may now be applied 6 Place the gas diffuser D F 15858 with parts facing forward on the inner body Replace insulation tube D F 15879 and apply collet adapter D F 15914 with wrench supplied 5 WATER COOLED BARREL PARTS BIG TIG MODEL TM1000 WATER COOLED BARREL PARTS CONTINUED BIG TIG MODEL TM1000 WS CODE DESCRIPTION Tungsten Extension Rod Assembly Tungsten Sleeve 1 8 Tungsten Sleeve 5 32 Tungsten Sleeve 3 16 Tungsten Sleeve 1 4 Tungsten Sleeve 5 16 Tungsten Sleeve 3 8 Collet 1 8 Collet 5 32 14336 16040 14555 14556 10972 10971 10725 15858 15879 CODE DESCRIPTION Nut 2 required Elbow Water Gas Water L H Adapter 2 required Gas R H Adapter Hose Assembly Short Hose Assembly Long Insulating Tube 2 required Gas Diffuser Insulation Tube Inner Body Collet 3 16 15914 188 Collet Adapter 3 16 Collet 1 4 15914 250 Collet Adapter 1 4 Collet 5 16 15914 313 Collet Adapter 5 16 Collet 3 8
27. water hose fittings are now exposed Push these into the barrel body concaves which will expose the interconnection water hose fittings Pull the water cooled nozzle assembly forward approx 1 4 while supporting the barrel body and inner body assembly This will extend the fixed interconnection hose to its full length With a 7 16 open end wrench unscrew the water hose nuts from the water cooled nozzle body The water cooled nozzle may now be removed from the inner body assembly Following this the barrel body may be removed from the inner body 6 Part replacement may now be performed ASSEMBLY 1 To assemble the water cooled barrel attach the short interconnection hose assemble to the upper block of the inner body Con nect the long interconnection hose to the fitting at the rear of the front inner body block It is recommended that at this point a leak test be made by attaching the interconnection hose fittings to the water cooled nozzle Apply a water hose to one of the service connections made within the inner body assembly 2 Place the long interconnection hose into the concave of the inner body with it extending outward form the inner body Place the inner body assembly into the barrel body until it bottoms out at service connections 3 Insert the two 2 nylon insulating collars over the interconnection hose fittings 4 The nylon collar should be in place on the rear of the water cooled nozzle assembly It is important that the
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