Miller Electric Welder DB1812R User Manual

OM-1603  
199 528C  
1/2005  
Processes  
TIG (GTAW) Welding  
Description  
TIG Torch  
Diamondback Series  
GTAW Torches  
DB1812R And DB1825R  
Visit our website at  
 
SECTION 1 −SAFETY PRECAUTIONS FOR GTAW  
TORCHES − READ BEFORE USING  
SR6_1/00  
1-1. Symbol Usage  
Y
Marks a special safety message.  
Means Warning! Watch Out! There are possible hazards with this  
procedure! The possible hazards are shown in the adjoining symbols.  
.
M
e
a
n
s
N
O
T
E
;
n
o
t
s
a
f
e
t
y
r
e
l
a
t
e
d
.
This group of symbols means Warning! Watch Out! Possible ELECTRIC SHOCK and HOT PARTS hazards.  
Consult symbols and related instructions below for necessary actions to avoid the hazards.  
1-2. GTAW Torch Hazards  
GTAW WELDING can be hazardous.  
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN  
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.  
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The  
safety information given below is only a summary of the more complete safety information found in the welding  
power source Owner’s Manual. Read and follow all safety precautions.  
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY  
QUALIFIED PEOPLE.  
ELECTRIC SHOCK can kill.  
WELDING can cause fire or explosion.  
1. Always wear dry insulating gloves.  
2. Insulate yourself from work and ground.  
3. Do not touch live electrode or electrical parts.  
1. Do not weld near flammable material.  
2. Do not weld on closed containers.  
3. Watch for fire; keep extinguisher nearby.  
4. Repair or replace worn, damaged, or cracked  
torch or cable insulation.  
5. Turn off welding power source before changing  
tungsten electrode or torch parts.  
HOT SURFACES can burn skin.  
1. Allow torch to cool before touching.  
2. Do not touch hot metal.  
6. Keep all covers and handle securely in place.  
3. Protect hot metal from contact by others.  
ARC RAYS can burn eyes and skin.  
1. Wear welding helmet with correct shade of filter.  
2. Wear correct eye and body protection.  
3. Cover exposed skin.  
NOISE can damage hearing; SOME  
APPLICATIONS, SUCH AS PULSING,  
are noisy.  
FUMES AND GASES can be hazardous  
to your health.  
1. Check for noise level limits exceeding those  
specified by OSHA.  
2. Use approved ear plugs or ear muffs if noise level  
is high.  
3. Warn others nearby about noise hazard.  
1. Keep your head out of the fumes.  
2. Ventilate area, or use breathing device.  
3. Read Material Safety Data Sheets (MSDSs) and  
manufacturer’s instructions for material used.  
BUILD UP OF GAS can injure or  
kill  
1. Shut off shielding gas supply when not in  
use.  
2. Always ventilate confined spaces or use  
approved air-supplied respirator.  
OM-1603 Page 1  
 
 
EMF INFORMATION  
ConsiderationsAbout Welding And The Effects Of Low Frequency  
Electric And Magnetic Fields  
1. Keep cables close together by twisting or taping them.  
2. Arrange cables to one side and away from the operator.  
3. Do not coil or drape cables around your body.  
Weldingcurrent, as it flows through welding cables, will cause electro-  
magnetic fields. There has been and still is some concern about such  
fields. However, after examining more than 500 studies spanning 17  
years of research, a special blue ribbon committee of the National  
Research Council concluded that: “The body of evidence, in the  
committees judgment, has not demonstrated that exposure to power-  
frequency electric and magnetic fields is a human-health hazard.”  
However, studies are still going forth and evidence continues to be  
examined.Until the final conclusions of the research are reached, you  
may wish to minimize your exposure to electromagnetic fields when  
welding or cutting.  
4. Keep welding power source and cables as far away from oper-  
ator as practical.  
5. Connect work clamp to workpiece as close to the weld as  
possible.  
About Pacemakers:  
To reduce magnetic fields in the workplace, use the following  
procedures:  
Pacemaker wearers consult your doctor first. If cleared by your doc-  
tor, then following the above procedures is recommended.  
OM-1603 Page 2  
 
 
SECTION 2 − SPECIFICATIONS  
2-1. Specifications  
Model  
DB1812R  
DB1825R  
Ampere Rating  
Cooling Method  
Cooling Requirements  
Tungsten Size  
350 Amps W/Argon Gas @ 100% Duty Cycle DCEN, ACHF  
Water  
1.1 quart/minute (1.0 liter/minute)  
.020 Thru 5/32 in (0.5 Thru 4.0 mm)  
Cable Options  
12-1/2 ft (3.8 m) One-Piece High−Flex  
25 ft (7.6 m) One-Piece High−Flex  
Dimensions  
Length: 9 in (229 mm); Handle Diameter: 1−1/8 in (29 mm); Weight: 5.8 oz (165 g)  
2-2. Duty Cycle  
100% Duty Cycle At 350 Amperes Using Argon Gas  
0
Definition  
Duty Cycle is percentage of 10  
10  
minutes that torch can weld at  
rated load without overheating.  
Minutes  
ContinuousWelding  
sb1.5* 8/93  
EXCEEDING RATED AMPERAGE can damage torch and void warranty.  
OM-1603 Page 3  
 
 
SECTION 3 − INSTALLATION  
3-1. Required Torch Parts And Torch Assembly  
1
2
3
4
5
6
7
8
9
Cup  
Collet Body  
Heat Shield  
Backcap Insulator  
Collet  
7
Assembling Torch Parts  
4
6
5
O-Ring  
3
2
Backcap  
Torch Body  
Handle  
1
16  
10 Power Cable  
11 Water Hose  
8
12 Gas Hose  
12  
9
13 Power Cable Adapter  
14 International Style Adapter  
15 Water Hose For International  
Style Adapter  
11  
13  
Assembling Torch Body  
Keep connections tight. Replace  
cup, heat shield, and backcap as  
needed.  
14  
10  
16 Tungsten Electrode (See Sec-  
Installing Tungsten  
To adjust tungsten position, loosen  
backcap.  
15  
Ref. 802 676  
3-2. International Style Connector Assembly  
1
2
3
Weld Output Cable  
Insulating Boot  
Sleeve  
1
3
2
Slide insulating boot onto cable;  
strip cable and install sleeve.  
1 in  
(26 mm)  
4
5
Connector Body  
Setscrew  
Insert cable with sleeve fully into  
connector body, tighten setscrew,  
and slide insulating boot over con-  
nector.  
5
4
3
Tools Needed:  
ST-156 496  
OM-1603 Page 4  
 
 
3-3. Connecting Torch  
A. Connecting Torch When Using A Freestanding Coolant System  
If applicable, install high-frequency unit.  
2
1
3
4
11  
7
10  
12  
6
8
9
5
Tools Needed:  
802 560  
5/8, 7/8, 1-1/8 in  
Y
Turn Off welding power source and  
cooling system power before in-  
stalling torch.  
5
6
7
Torch  
9
Torch Gas Hose  
Power Cable Adapter  
Coolant Hose (Customer Supplied)  
10 Coolant-Into Torch Hose (Blue)  
11 Cooling System  
1
2
3
4
Welding Power Source  
Regulator/Flowmeter  
Gas Cylinder  
Obtain correct length with 5/8-18 left-hand  
fittings.  
12 Work Clamp  
8
Coolant-Out Of Torch/Power Cable  
(Red)  
Connect work clamp to a clean, paint-free  
location on workpiece, close to weld.  
Gas Hose (Customer Supplied)  
Connect coolant-out of torch/power cable  
to power cable adapter, and connect adapt-  
er to weld output terminal.  
Obtain correct length with 5/8-18 right-hand  
fittings.  
Use wire brush or sandpaper to clean metal  
at weld joint area.  
OM-1603 Page 5  
 
 
B. Connecting Torch To A Dynastyt 300 DX Or MaxstarR 300 DX TIGRunnert Unit  
Y
Turn Off welding power source  
power before installing torch.  
2
Tools Needed:  
1
11  
1
Gas Hose With 5/8-18 Right-  
Hand Fittings (Customer Sup-  
plied)  
3
Connections:  
5/8, 7/8, 1-1/8 in  
2
3
4
5
6
7
8
Regulator/Flowmeter  
9
Gas Cylinder  
7
Coolant System  
Torch  
8
Coolant-Into Torch Hose (Blue)  
Torch Gas Hose  
6
Coolant-Out Of Torch/Power  
Cable (Red)  
9
International Style Adapter  
Connect coolant-out of torch/power  
cable to power cable adapter, and con-  
nect adapter to weld output terminal.  
5
4
10 Work Clamp  
Connect work clamp to a clean, paint-  
free location on workpiece, close to  
weld.  
Use wire brush or sandpaper to clean  
metal at weld joint area.  
10  
11 Welding Power Source  
12 Foot Control  
803 311  
12  
C. Connecting Torch To A Syncrowave  
R
250 DX Or 350 LX TIGRunnert Unit  
Y
Turn Off welding power source  
power before installing torch.  
Tools Needed:  
3
1
1
Gas Hose With 5/8-18 Right-Hand  
Fittings (Customer Supplied)  
2
Connections:  
2
3
4
5
6
Regulator/Flowmeter  
5/8, 7/8, 1-1/8 in  
4
Power Source  
Gas Cylinder  
Coolant System  
Coolant Hose (Supplied With TI-  
GRunner)  
7
8
9
Power Cable Adapter  
Torch  
Coolant-Into Torch Hose (Blue)  
5
10 Coolant-Out Of Torch/Power  
Cable (Red)  
Connect torch coolant-out of torch/pow-  
er cable to power cable adapter, and  
connect adapter to weld output terminal.  
8
11 Torch Gas Hose  
12 Work Clamp  
9
6
Connect work clamp to a clean, paint-  
free location on workpiece, close to  
weld.  
7
12  
10  
11  
Use wire brush or sandpaper to clean  
metal at weld joint area.  
13 Foot Control  
13  
803 311  
OM-1603 Page 6  
 
SECTION 4 − MAINTENANCE & TROUBLESHOOTING  
4-1. Routine Maintenance  
Y
Disconnect torch before maintaining.  
40 Hours  
Repair or  
replace  
cracked  
Clean and  
tighten weld  
terminals.  
Replace  
unreadable  
labels.  
weld cable.  
Replace cracked parts  
Torch Body  
Torch Cable  
4-2. Troubleshooting  
Before using troubleshooting table, check selection and preparation of tungsten  
NOTE  
Trouble  
Remedy  
and visible at the torch.  
Check and be sure shielding gas is present.  
tablishingarc.  
Check cables and torch for cracks or bad connections. Be sure that torch cables are not close to any  
grounded metal. Repair or replace necessary parts.  
Check torch consumables. Be sure collet and collet body are correctly installed and tightened (see Sec-  
tion 3-1).  
Check welding power source High Frequency control, and if necessary, check and adjust spark gaps.  
Torch gas valve not working properly (if Have Factory Authorized Service Station/Service Distributor check valve.  
applicable).  
No shielding gas flow from torch.  
Be sure valves on gas supply are open.  
Check cable for kinks or blockage.  
Check and tighten all gas supply fittings.  
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.  
mainingbright after conclusion of weld.  
Increase postflow time.  
Increase gas flow rate. Check manufacture’s recommendations.  
Check and tighten all gas fittings.  
Check gas valve and flow meter/regulator.  
sumption.  
Check polarity setting on welding power source (see welding power source Owner’s manual).  
Check for proper gas flow rate. Check manufacture’s recommendations.  
If torch is water cooled, check torch and cables for water leaks. Repair or replace if necessary (see Sec-  
tion 4-1).  
OM-1603 Page 7  
 
 
Trouble  
Remedy  
Wandering arc  
Shield weld zone from drafts.  
Reduce gas flow rate.  
When using AC, check welding power source High Frequency control setting, and increase setting if nec-  
essary.  
Yellow powder or smoke on cup.  
Use proper type shielding gas.  
Check for proper gas flow rate. Check manufacture’s recommendations.  
Increase postflow time.  
Check torch cup size. Match cup size to joint being welded.  
When using DC, check polarity, and/or polarity of welding cables.  
Erratic arc  
When using AC, check welding power source High Frequency control setting, and be sure it is operating  
continuously.  
Use proper arc length. Arc length may be too long or too short.  
Make sure base material is clean and free of contaminates.  
When using AC, slow travel speed can cause erratic arc. Adjust travel speed.  
Check for proper gas flow rate. Check manufacture’s recommendations.  
Check and tighten gas fittings.  
Porosity in weld.  
Make sure base material and filler material is clean and free of contaminates.  
Check for impurities and moisture in gas lines. Purge if necessary.  
If torch is water cooled, check torch and cables for water leaks. Repair or replace if necessary (see Sec-  
tion 4-1).  
OM-1603 Page 8  
 
SECTION 5 − SELECTING AND PREPARING TUNGSTEN  
ELECTRODE FOR DC OR AC WELDING  
ac/dc_gtaw 2/2004  
Y
Whenever possible and practical, use DC weld output instead of AC weld output.  
5-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten)  
Amperage Range - Gas Type- Polarity  
Electrode Diameter  
DC − Argon − Electrode  
Negative/Straight Po-  
larity  
DC − Argon − Elec-  
trode Positive/Rev-  
erse Polarity  
AC − Argon  
AC − Argon −  
Balanced Wave  
2% Ceria (Orange Band), 1.5% Lan-  
thanum (Gray Band), Or 2% Thorium  
(Red Band) Alloy Tungstens  
.010”  
.020”  
.040”  
1/16”  
3/32”  
1/8”  
Up to 25  
15-40  
*
Up to 20  
15-35  
Up to 15  
5-20  
*
25-85  
*
20-80  
20-60  
50-160  
10-20  
15-30  
25-40  
40-55  
55-80  
80-125  
50-150  
130-250  
225-360  
300-450  
400-500  
600-800  
60-120  
100-180  
160-250  
200-320  
290-390  
340-525  
135-235  
250-400  
400-500  
500-750  
750-1000  
5/32”  
3/16”  
1/4”  
Pure Tungsten  
(Green Band)  
.010”  
.020”  
.040”  
1/16”  
3/32”  
1/8”  
Up to 15  
5-20  
*
Up to 15  
5-20  
Up to 10  
10-20  
*
15-80  
*
10-60  
20-30  
70-150  
125-225  
225-360  
360-450  
450-720  
720-950  
10-20  
15-30  
25-40  
40-55  
55-80  
80-125  
50-100  
100-160  
150-210  
200-275  
250-350  
325-450  
30-80  
60-130  
100-180  
160-240  
190-300  
250-400  
5/32”  
3/16”  
1/4”  
Zirconium Alloyed Tungsten (Brown  
Band)  
.010”  
.020”  
.040”  
1/16”  
3/32”  
1/8”  
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Up to 20  
15-35  
Up to 15  
5-20  
20-80  
20-60  
50-150  
130-250  
225-360  
300-450  
400-550  
600-800  
60-120  
100-180  
160-250  
200-320  
290-390  
340-525  
5/32”  
3/16”  
1/4”  
Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).  
*Not Recommended.  
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.  
OM-1603 Page 9  
 
 
5-2. Preparing Tungsten Electrode For Welding  
Y
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use  
local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety infor-  
mation. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from  
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environ-  
mentally safe way. Wear proper face, hand, and body protection. Keep flammables away.  
A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines  
2-1/2 Times  
Electrode Diameter  
1
Grinding Wheel  
Radial Grinding  
Grind end of tungsten on fine grit, hard  
abrasive wheel before welding. Do not use  
wheel for other jobs or tungsten can become  
contaminatedcausing lower weld quality.  
Causes Wandering Arc  
3
2
1
2
3
Tungsten Electrode  
Flat  
Diameter of this flat determines amperage  
capacity.  
4
Wrong Tungsten Preparation  
4
Straight Ground  
Ideal Tungsten Preparation − Stable Arc  
Grind lengthwise, not radial.  
1
2
Tungsten Electrode  
Balled End  
B. Preparing Tungsten For Conventional AC Welding  
Ball end of tungsten by applying AC amper-  
age recommended for a given electrode  
diameter(see Section 5-1). Let ball on end of  
the tungsten take its own shape.  
1 − 1-1/2 Times  
Electrode Diameter  
1
2
SECTION 6 − GUIDELINES FOR TIG WELDING (GTAW)  
6-1. Positioning The Torch  
Y
Weld current can damage electronic parts in vehicles. Discon-  
nect both battery cables before welding on a vehicle. Place work  
clamp as close to the weld as possible.  
.
F
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a
d
d
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3
Gas Tungsten Arc Welding (GTAW) process.  
2
1
Workpiece  
Make sure workpiece is clean before welding.  
Work Clamp  
Place as close to the weld as possible.  
4
2
3
4
5
6
Torch  
1
90°  
Filler Rod (If Applicable)  
Gas Cup  
Tungsten Electrode  
10−15°  
4
Guidelines:  
5
6
The inside diameter of the gas cup should be at least three times the  
tungsten diameter to provide adequate shielding gas coverage. (For  
example, if tungsten is 1/16 in diameter, gas cup should be a minimum of  
3/16 in diameter.  
10−25°  
5
6
Tungsten extension is the distance the tungsten extends out gas cup of  
torch.  
The tungsten extension should be no greater than the inside diameter of  
the gas cup.  
1/16 in  
3/16 in  
Arc length is the distance from the tungsten to the workpiece.  
Bottom View Of Gas Cup  
Ref. ST-161 892  
OM-1603 Page 10  
 
 
6-2. Torch Movement During Welding  
Tungsten Without Filler Rod  
75°  
Welding direction  
Form pool  
Tilt torch  
Move torch to front  
of pool. Repeat process.  
Tungsten With Filler Rod  
75°  
15°  
Welding direction  
Form pool  
Tilt torch  
Add filler metal  
Remove rod  
Move torch to front  
of pool. Repeat process.  
ST-162 002-B  
6-3. Positioning Torch Tungsten For Various Weld Joints  
“T” Joint  
Butt Weld And Stringer Bead  
20°  
90°  
70°  
75°  
20°  
15°  
10°  
Corner Joint  
Lap Joint  
20-40°  
90°  
75°  
75°  
15°  
15°  
30°  
ST-162 003 / S-0792  
OM-1603 Page 11  
 
 
SECTION 7 − PARTS LIST  
1
3
4
6
5
7
2
10  
8
11  
14  
15  
9
12  
18  
13  
17  
19  
20  
16  
21  
Ref. 802 676-A  
Figure 7-1. Complete Torch Assembly  
OM-1603 Page 12  
 
 
Quantity  
Model  
Item  
No.  
Stock  
No.  
Model  
No.  
Description  
DB1812R DB1825R  
Figure 7-1. Complete Torch Assembly  
. . 1 . . . . . . 57Y02 . . . . . . . . . . . . . . . BACK CAP, long (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 2 . . . . . 57Y04 . . . . . . . . . . . . . . . BACK CAP, button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . . . . . . . . 199 591 . . . . . . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 3 . . . . . . . . 18-7 . . . . . . . . . . . . . . . INSULATOR, back cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 4 . . . . . . . DB18 . . . . . . . . . . . . . . . TORCH BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 5 . . . . . . . 18CG . . . . . . . . . . . . . . . INSULATOR, cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 6 . . . . . 54N01 . . . . . . . . . . . . . . . GAS LENS INSULATOR, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 7 . . . . . 54N63 . . . . . . . . . . . . . . . GAS LENS INSULATOR, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 8 . . . . . . 10N24 . . . . . . . . . . . . . . . COLLET, 3/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 8 . . . . . 10N21 . . . . . . . . . . . . . . . COLLET, .020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 8 . . . . . 10N22 . . . . . . . . . . . . . . . COLLET, .040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 8 . . . . . 10N23 . . . . . . . . . . . . . . . COLLET, 1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 8 . . . . . 10N25 . . . . . . . . . . . . . . . COLLET, 1/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 8 . . . . . 54N20 . . . . . . . . . . . . . . . COLLET, 5/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 9 . . . . . . 10N32 . . . . . . . . . . . . . . . COLLET BODY, 3/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 9 . . . . . 10N29 . . . . . . . . . . . . . . . COLLET BODY, .020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 9 . . . . . 10N28 . . . . . . . . . . . . . . . COLLET BODY, 1/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 9 . . . . . 10N30 . . . . . . . . . . . . . . . COLLET BODY, .040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 9 . . . . . 10N31 . . . . . . . . . . . . . . . COLLET BODY, 1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. . 9 . . . 406 488 . . . . . . . . . . . . . . . COLLET BODY, 5/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 10 . . . . 45V25 . . . . . . . . . . . . . . . GAS LENS, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 10 . . . . 45V26 . . . . . . . . . . . . . . . GAS LENS, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 10 . . . . 45V27 . . . . . . . . . . . . . . . GAS LENS, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 10 . . . . 45V24 . . . . . . . . . . . . . . . GAS LENS, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 10 . . . . 45V28 . . . . . . . . . . . . . . . GAS LENS, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 10 . . . . 45V29 . . . . . . . . . . . . . . . GAS LENS, medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 11 . 45V0204 . . . . . . . . . . . . . . . GAS LENS, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 11 . . . 45V116 . . . . . . . . . . . . . . . GAS LENS, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 11 . . . . 45V64 . . . . . . . . . . . . . . . GAS LENS, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 11 . . . 995795 . . . . . . . . . . . . . . . GAS LENS, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 11 . . . . 45V63 . . . . . . . . . . . . . . . GAS LENS, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 12 . . . . . 10N47 . . . . . . . . . . . . . . . NOZZEL, #7 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 12 . . . . 10N44 . . . . . . . . . . . . . . . NOZZEL, #12 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 12 . . . . 10N45 . . . . . . . . . . . . . . . NOZZEL, #10 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 12 . . . . 10N46 . . . . . . . . . . . . . . . NOZZEL, #8 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 12 . . . . 10N48 . . . . . . . . . . . . . . . NOZZEL, #6 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 12 . . . . 10N49 . . . . . . . . . . . . . . . NOZZEL, #5 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 12 . . . . 10N50 . . . . . . . . . . . . . . . NOZZEL, #4 alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 13 . . . . 54N14 . . . . . . . . . . . . . . . NOZZEL, medium alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 13 . . . . 54N15 . . . . . . . . . . . . . . . NOZZEL, medium alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 13 . . . . 54N16 . . . . . . . . . . . . . . . NOZZEL, medium alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 13 . . . . 54N17 . . . . . . . . . . . . . . . NOZZEL, medium alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 13 . . . . 54N18 . . . . . . . . . . . . . . . NOZZEL, medium alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 14 . . . . 57N74 . . . . . . . . . . . . . . . NOZZEL, large alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 14 . . . . 57N75 . . . . . . . . . . . . . . . NOZZEL, large alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 14 . . . . 53N87 . . . . . . . . . . . . . . . NOZZEL, large alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 14 . . . . 53N88 . . . . . . . . . . . . . . . NOZZEL, large alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 15 . . . . H200M . . . . . . . . . . . . . . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1  
. 16 . . . . 41V29R . . . . . . . . . . . . . . . CABLE, power 25 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. 16 . . . . 40V64R . . . . . . . . . . . . . . . CABLE, power 12 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. 17 . . . . 41V32R . . . . . . . . . . . . . . . HOSE, water 25 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. 17 . . . . 40V74R . . . . . . . . . . . . . . . HOSE, water 12 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. 18 . . . . 41V30R . . . . . . . . . . . . . . . HOSE, gas 25 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. 18 . . . . 40V75R . . . . . . . . . . . . . . . HOSE, gas 12 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. 19 . . . . 45V11 . . . . . . . . . . . . . . . ADAPTER, power cable (included in DTP kit) . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. 20 . . 190 219 . . . . . . . . . . . . . . . ADAPTER, international style (water hose included) . . . . . . . . . . . . 1 . . . . 1  
OM-1603 Page 13  
 
Quantity  
Model  
Item  
No.  
Stock  
No.  
Model  
No.  
Description  
DB1812R DB1825R  
Figure 7-1. Complete Torch Assembly (continued)  
. 21 . . 198 314 . . . . . . . . . . . . . . . HOSE, water side adapter international style (included w/190 219) 1 . . . . 1  
. . . . . . . . . AK3C . . . . . . . . . . . . . . . ACCESSORY KIT (included in DTP kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . CC322HD . . . . . . . . . . . . . . . CABLE COVER, 22 ft (not shown)  
. . . . . CC310HD . . . . . . . . . . . . . . . CABLE COVER, 10 ft (not shown)  
. . . . . . . . 194738 . . . . . . . . . . . . . . . REGULATOR (included in DTP kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . 198 319 . . . . . . . . . . . . . . . CLAMP, ground 15ft (included in DTP kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . 198 317 . . . . . . . . . . . . . . . HOSE, gas 12 ft (included in DTP kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . 198 316 . . . . . . . . . . . . . . . HOSE, gas 3 ft (included in DTP kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . 198 315 . . . . . . . . . . . . . . . HOSE, water 6 ft (included in DTP kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
OPTIONAL  
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.  
OM-1603 Page 14  
 
Notes  
 
Notes  
 
Effective January 1, 2005  
(Equipment with a serial number preface of “LF” or newer)  
This limited warranty supersedes all previous Miller warranties and is exclusive with no other  
guarantees or warranties expressed or implied.  
Warranty Questions?  
LIMITED WARRANTY − Subject to the terms and conditions  
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to  
its original retail purchaser that new Miller equipment sold after  
the effective date of this limited warranty is free of defects in  
material and workmanship at the time it is shipped by Miller.  
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER  
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE  
WARRANTIES OF MERCHANTABILITY AND FITNESS.  
*
*
*
*
*
*
*
Induction Heating Coils and Blankets  
APT & SAF Model Plasma Cutting Torches  
Remote Controls  
Call  
1-800-4-A-MILLER  
for your local  
Miller distributor.  
Accessory Kits  
Replacement Parts (No labor)  
Spoolmate Spoolguns  
Within the warranty periods listed below, Miller will repair or  
replace any warranted parts or components that fail due to such  
defects in material or workmanship. Miller must be notified in  
writing within thirty (30) days of such defect or failure, at which  
time Miller will provide instructions on the warranty claim  
procedures to be followed.  
Canvas Covers  
Your distributor also gives  
you ...  
Miller’s True BlueLimited Warranty shall not apply to:  
Service  
1. Consumable components; such as contact tips,  
cutting nozzles, contactors, brushes, slip rings,  
relays or parts that fail due to normal wear. (Exception:  
brushes, slip rings, and relays are covered on Bobcat,  
Trailblazer, and Legend models.)  
You always get the fast,  
reliable response you  
need. Most replacement  
parts can be in your  
hands in 24 hours.  
Miller shall honor warranty claims on warranted equipment  
listed below in the event of such a failure within the warranty  
time periods. All warranty time periods start on the date that the  
equipment was delivered to the original retail purchaser, or one  
year after the equipment is sent to a North American distributor  
or eighteen months after the equipment is sent to an  
International distributor.  
2. Items furnished by Miller, but manufactured by others,  
such as engines or trade accessories. These items are  
covered by the manufacturer’s warranty, if any.  
Support  
Need fast answers to the  
tough welding questions?  
Contact your distributor.  
The expertise of the  
distributor and Miller is  
there to help you, every  
step of the way.  
3. Equipment that has been modified by any party other than  
Miller, or equipment that has been improperly installed,  
improperly operated or misused based upon industry  
standards, or equipment which has not had reasonable  
and necessary maintenance, or equipment which has  
been used for operation outside of the specifications for the  
equipment.  
1. 5 Years Parts — 3 Years Labor  
*
*
Original main power rectifiers  
Inverters (input and output rectifiers only)  
2. 3 Years — Parts and Labor  
*
*
*
*
Transformer/Rectifier Power Sources  
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND  
USE BY COMMERCIAL/INDUSTRIAL USERS AND  
PERSONS TRAINED AND EXPERIENCED IN THE USE AND  
MAINTENANCE OF WELDING EQUIPMENT.  
Plasma Arc Cutting Power Sources  
Semi-Automatic and Automatic Wire Feeders  
Inverter Power Sources (Unless Otherwise Stated)  
*
*
Water Coolant Systems (Integrated)  
Intellitig  
In the event of a warranty claim covered by this warranty, the  
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)  
replacement; or, where authorized in writing by Miller in  
appropriate cases, (3) the reasonable cost of repair or  
replacement at an authorized Miller service station; or (4)  
payment of or credit for the purchase price (less reasonable  
depreciation based upon actual use) upon return of the goods at  
customer’s risk and expense. Miller’s option of repair or  
replacement will be F.O.B., Factory at Appleton, Wisconsin, or  
F.O.B. at a Miller authorized service facility as determined by  
Miller. Therefore no compensation or reimbursement for  
transportation costs of any kind will be allowed.  
*
*
Maxstar 150  
Engine Driven Welding Generators  
(NOTE: Engines are warranted separately by  
the engine manufacturer.)  
3. 1 Year — Parts and Labor Unless Specified  
*
*
DS-2 Wire Feeder  
Motor Driven Guns (w/exception of Spoolmate  
Spoolguns)  
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers  
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES  
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE  
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR  
Positioners and Controllers  
Automatic Motion Devices  
RFCS Foot Controls  
DIRECT,  
INDIRECT,  
SPECIAL,  
INCIDENTAL  
OR  
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF  
PROFIT), WHETHER BASED ON CONTRACT, TORT OR  
ANY OTHER LEGAL THEORY.  
Induction Heating Power Sources and Coolers  
Water Coolant Systems (Non-Integrated)  
Flowgauge and Flowmeter Regulators (No Labor)  
HF Units  
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND  
ANY  
IMPLIED  
WARRANTY,  
GUARANTY  
OR  
REPRESENTATION AS TO PERFORMANCE, AND ANY  
REMEDY FOR BREACH OF CONTRACT TORT OR ANY  
OTHER LEGAL THEORY WHICH, BUT FOR THIS  
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION  
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,  
Grids  
Maxstar 85, 140  
Spot Welders  
INCLUDING  
ANY  
IMPLIED  
WARRANTY  
OF  
Load Banks  
MERCHANTABILITY OR FITNESS FOR PARTICULAR  
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT  
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED  
BY MILLER.  
Arc Stud Power Sources & Arc Stud Guns  
Racks  
Running Gear/Trailers  
Some states in the U.S.A. do not allow limitations of how long an  
implied warranty lasts, or the exclusion of incidental, indirect,  
special or consequential damages, so the above limitation or  
exclusion may not apply to you. This warranty provides specific  
legal rights, and other rights may be available, but may vary  
from state to state.  
Plasma Cutting Torches (except APT & SAF  
Models)  
*
Field Options  
(NOTE: Field options are covered under True  
Bluefor the remaining warranty period of the  
product they are installed in, or for a minimum of  
one year — whichever is greater.)  
In Canada, legislation in some provinces provides for certain  
additional warranties or remedies other than as stated herein,  
and to the extent that they may not be waived, the limitations  
and exclusions set out above may not apply. This Limited  
Warranty provides specific legal rights, and other rights may be  
available, but may vary from province to province.  
4. 6 Months — Batteries  
5. 90 Days — Parts  
*
MIG Guns/TIG Torches  
miller_warr 1/05  
 
Owner’s Record  
Please complete and retain with your personal records.  
Model Name  
Purchase Date  
Distributor  
Address  
Serial/Style Number  
(Date which equipment was delivered to original customer.)  
City  
State  
Zip  
For Service  
Contact a DISTRIBUTOR or SERVICE AGENCY near you.  
Always provide Model Name and Serial/Style Number.  
Contact your Distributor for:  
Welding Supplies and Consumables  
Options and Accessories  
Personal Safety Equipment  
Service and Repair  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
Replacement Parts  
Training (Schools, Videos, Books)  
International Headquarters−USA  
USA Phone: 920-735-4505 Auto-Attended  
USA & Canada FAX: 920-735-4134  
International FAX: 920-735-4125  
Technical Manuals (Servicing Information  
and Parts)  
Circuit Diagrams  
European Headquarters −  
United Kingdom  
Phone: 44 (0) 1204-593493  
FAX: 44 (0) 1204-598066  
Welding Process Handbooks  
To locate a Distributor or Service Agency visit  
www.MillerWelds.com  
Contact the Delivering Carrier to:  
File a claim for loss or damage during  
shipment.  
For assistance in filing or settling claims, contact  
your distributor and/or equipment manufacturer’s  
Transportation Department.  
PRINTED IN USA  
2005 Miller Electric Mfg. Co. 1/05  
 

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