Instruction Manual 397NCC/HTC - 45 Degree
Contents
1. Shielding Gas 4 0 Power Cable 1 125 c 2 75 2 ea 1 4 20 Screws d Lock Washers ax CH Nuts CR WIRE FEEDER ADAPTERS amp INLETS Direct Mount Remote Mount Adapter Adapter Manufac E Models Wire Diameter turer Hardt feaa 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 ii 13113 NA5 R 5 64 1 8 H C 13112 i 13116 LN 9 030 3 32 H C AL D 5 64 1 8 H C KR NA3 NAS 030 3 32 H C AL 16879 S 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 HIC 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 BEER 18282 18282 Panasonic PME 12X 030 1 16 13090 Reouiresinlst YW5OAKWA 030 1 16 13466 q 030 3 32 H C AL 134792. Cut Fit and Install a New merde 10 What is the Proper Use of the Nozzle Thread Chaser Tap 11 Models NCC HTC W C Curved 45 Gun Standard Parts 12 Models NCC HTC W C Curved 45 Gun Series A High Capacity Hate 13 Ordering Information amp Utilities Conventional Utilities 14 15 Ordering Information amp Utilities EURO Utilities esses 16 17 Robot Safety Mount amp Mounting Arms errar 18 Robotic Gun Layout 3 Standard amp Series A High Capacity 19 Robotic Gun Layout 4 Standard amp Series A High Capacity 20 Robotic Gun Layout 5 Gtondard seen nnne nnn 21 Gun Dimensions Smoke Extractor Kit eei 22 Sis STO E 23 Wire Feeder AGA CN E 24 Troubleshooting D 20 28 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 Arc welding can prove damaging to eyes skin and
3. 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 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 wi
4. 3 To remove the water cooled nozzle or making a replacement of the inner body first remove the gas nozzle when used next with wrench remove the current tip tip adapter nut or collet nut whichever may be in use This will allow the insulation tube spatter disc 10405 or spatter disc 18253 and support tube to be removed Also remove the elbow nut that retains the water cooled nozzle 4 Remove the round head screw which secures the inner body to the elbow casting Reference inner body pages 12 amp 13 note that inter connection hose is a fixed length hose To expose the interconnection hose nuts by which these are fastened to the water cooled nozzle it is necessary that interconnection hose 19 be released at the rear spool of the inner body thus allowing it to move forward The inner body may now be moved forward Should the insulation tubes and elbow insulator extend forward beyond elbow push these back far enough to expose the water hose fittings By removing the water hose fittings the water cooled nozzle may be removed from the elbow 5 If replacement of the inner body is required the tip adapter must be removed to allow the inner body to be pulled out of the elbow by using a slight twisting motion ASSEMBLY 1 Make certain that the interconnection hose Code No 42242 is securely fastened at the rear of the casting Before connecting hose note the position of the stainless steel spring liner within hose assembly It is most desirable
5. Cooled Nozzle Configuration Hi Capacity Series A Water Cooled Nozzle Configuration Ref Code No Description O EE Extractor Shell Extractor Shell Clamp 1 Clamp 1 1 2 Insulator 3 Insulator Deflector Ring Gas Noz 10359 10362 10374 4 Deflector Ring Deflector Ring Gas Noz 10340 5 Vacuum Hose 2 Dia Vacuum Hose 2 Dia 6 Clamp 2 Clamp 2 7 Transition Hose Adapter Transition Hose Adapter 8 Transition Hose 3 4 Silicon Transition Hose 3 4 Silicon 9 Clamp 3 4 EE NOTE For Vacuum Hose 40049 Add Footage Digit NOTE For Vacuum Hose 40049 Add Footage Digit for Length Required for Length Required Example Require 15 Ft Code No 40049 15 Example Require 15 Ft Code No 40049 15 UTILITY STATION ORDERING INFORMATION DIMENSION SPECIFICATIONS Description C BaseWian 225 Overall Width 25 Utility Station Utility Station Dual Power Cable 45188 Overall Height 3 125 Mounting Hole Center Distance Overall Weight 35lbs UTILITY STATION SIDE VIEW WITH COVER P_ 5 75 __________ D F TORCH CONNECTION Water In Hose Water Out amp Power Cable Hose 6 125 FROM LEFT D F TORCH CONNECTION CUSTOMER UTILITIES CONNECTION FROM RIGHT CUSTOMER UTILITIES CONNECTION Water Water Water Out amp Out In Power Cable Water Out Voltage Water In Hose Sensing er Water In PER Shielding Gas Gas Hose
6. 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 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 spatter 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 pressu
7. Gun Barrel Model Wire Size Wire Type All NC NCC NCM All NC NCC NCM Tip provides 1 8 set back Tip provides 1 8 set back All NC NCC NCM Aluminum Tip provides 1 8 set back Aluminum Aluminum All NC NCC NCM Aluminum Tip provides 3 8 set back All NC NCC NCM Bent Tip Hard Tip provides 1 8 set back Hard Aluminum Aluminum All NC NCC NCM 3 64 Tip provides 1 8 set back 1 16 5 64 3 32 CURRENT TIPS 7 16 DIAMETER THREADED Gun Barel Model 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 Aluminum MTW Aluminum Tip provides 1 8 set back Aluminum Aluminum Aluminum Bali UI REQUIRED TOOLS LIST FOR DISASSEMBLY amp ASSEMBLY 1 10 11 12 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 or as Snug as hand tightened Never use another wrench to apply more torque to this wrench D F Nozzle Thread Chaser Tap This is used to re tap damaged threads that have been improperly cleaned or cross threaded Al ways 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 Long 5 16 Ope
8. Washer Insulator Elbow Socket Set Screw Casting Body Liner see chart above O ring 3 req d Inner Body Interconnection Hose Flat Head Screw Interconnection Hose Jam Nut Adapter 7 16 Th d Tip for A3 W C Noz Adapter 7 16 Th d Tip for A4 W C Noz Adapter 1 4 Slip In Tip for A3 W C Noz Adapter 1 4 Slip In Tip for A4 W C Noz Adapter 5 16 Slip In Tip for A3 W C Noz Adapter 5 16 Slip In Tip for A4 W C Noz Insulation Tube 2 req d Insulating Collar O ring Internal O ring External Water Cooled Nozzle 3 Water Cooled Nozzle 4 Insulation Tube for 3 Nozzle Insulation Tube for 4 Nozzle Nut Spatter Disc Collet Nut 1 4 Slip In Tip Collet Nut 5 16 Slip In Tip Threaded Current Tip see p 7 Table 3 Slip In Current Tip see p 7 Table 3 Gas Nozzle see p 5 Table 2 Wrench Nozzle Thread Chaser Tap Round Head Screw Support Tube for 3 Nozzle Support Tube for 4 Nozzle CONVENTIONAL ASSEMBLY DEDICATED OR ROBOTIC 45 DEGREE WATER COOLED CURVED GUN MODELS NCC HTC Water Cooled Nozzles Short 3 Inter 4 Long 5 o KITO RN High Capacity Series A Water Cooled Nozzles Short A3 Inter A4 ORDERING INFORMATION To obtain a complete Water Cooled Nozzle Assembly reference the table below and the parts list Note Specify wire diameter Gas Nozzle page 5 Table 2 and Current Tip page 7 Table 3 REF CODE NO DESCRIPTION W
9. before hand tightening the gas cup back into the nozzle If you can t thread itin 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 Improper support can cause the spigots to twist off the top of the rear nozzle collar or damage the torch internal body parts 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 Best practice is to hold the water cooled nozzle in a vice with soft jaws perpendicular to the spigots 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 Be very 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
10. hearing It is therefore imperative that the Accident Prevention Regulations UVV 26 0 and VGB 15 are fully observed and that all protective clothing eye and ear protectors specified are worn The load data given are maximum limit figures Overloading will inevitably damage the torch Before changing wear parts disconnect for the power supply The operating instructions for the individual welding components e g power source wire feed and cooling unit must be followed Never pull the cable assembly across sharp edges or set down close to weld spatter or on a hot workpiece Those not involved in the welding process should be protected by curtains or partitions from radiation and the danger of being dazzled When handling gas cylinders consult the instructions issued by the manufacturers and the suppliers of the pressurized gas 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
11. 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 NW 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 WATER COOLED CURVED 45 GUN STANDARD PARTS MODEL NCC Slip In Tip MODEL HTC Threaded Tip 030 035 035 045 045 052 1 16 5 64 3 32 7 64 3 64 Soft 1 16 Soft 3 32 Soft Interconnection Hose Jam Nut Adapter 7 16 Th d Tip for 3 W C Noz Adapter 7 16 Th d Tip for 4 W C Noz Adapter 7 16 Th d Tip for 5 W C Noz Adapter 1 4 Slip In Tip for 3 W C Noz Adapter 1 4 Slip In Tip for 4 W C Noz Adapter 1 4 Slip In Tip for 5 W C Noz Adapter 5 16 Slip In Tip for 3 W C Noz Adapte
12. partial listing of available semi automatic 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 su
13. s 13480 5 64 1 8 H C 13469 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 7 64 1 8 3 64 AL 1 16 AL 3 32 AL Esab Hobart Lincoln Linde Miller OTC Pana sonic ABB Fanuc Kuka Mavrix9 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
14. secure the adapter and jam nut to the inner body see 6 C 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 screws 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 10723 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 32 Allen Wrench This is used to secure the socket set screw that holds the casing conduit in the inner body 7 64 Allen Wrench This is used to secure the 2 socket screws that hold the elbow on the body housing REQUIRED TOOLS LIST FOR DISASSEMBLY amp ASSEMBLY IR CRAFTSMAN 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 f
15. C Curved Gun Assembly Short 3 Nozzle W C Curved Gun Assembly Inter 4 Nozzle W C Curved Gun Assembly Long 5 Nozzle W C Curved Gun Assembly Short A3 High Capacity Nozzle W C Curved Gun Assembly Inter A4 High Capacity Nozzle COMPLETE ASSEMBLY Add footage to code number for length desired Example Require Model NCC with 5 Nozzle amp 8 Ft Utilities Code No 42162 8 COMPLETE STANDARD ASSEMBLIES CONSISTS OF GUN ASSEMBLY AND WIC NOZZLE UTILITY COMBINATION MODEL NCC MODEL HTC Short 3 Inter 4 Long 5 Short A3 High Cap Inter A4 High Cap STANDARD ASSEMBLY UTILITIES ec 2 LG ec 1 NIE l In M ausu TE e From p 14 A cu Ki LES T 6 d CET 9 x 1 10 1 i E leen Descrpion Ile Denim Casing 030 035 Requires Liner 5 64 3 32 Casing 035 1 16 Requires Liner 7 64 1 8 Casing 035 045 Single Piece Optional Utility Station see p 23 Casing 045 1 16 Single Piece Feeder Adapter see p 24 Casing 5 64 3 32 Single Piece Inlet see p 24 Casing 7 64 1 8 Single Piece Liner 030 035 Hard Cored Casing 1 8 AL Single Piece Liner 035 045 Hard Cored Water In Hose Assembly Liner 045 1 16 Hard Cored Clamp Liner 3 64 Soft Water Out Hose amp Power Cable Assembly Liner 1 16 Soft Gas Hose Assembly Standard Liner 3 32 Soft Cable Hose Sheath Utility Combination Co
16. Instruction Manual 397 NCC HTC 45 Degree D e Revised 10 2013 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 CURVED 45 DOCKING SPOOL MACHINE BARREL COMBINATIONS Model NCC Slip In Tip Model HTC Threaded Tip Standard and EURO Assemblies 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
17. Length Required Example Require 10 Ft Casing 035 3 32 46370 10 Example Require 6 Ft Liner 045 47022 6 ROBOT SAFETY MOUNT amp MOUNTING ARMS Rer coseno Description Insulating Disc Ref Table A Rumble Safety Mount Medium Duty Standard Rumble Safety Mount Medium Duty Quick Disconnect Rumble Safety Mount Heavy Duty Standard Rumble Safety Mount Heavy Duty Quick Disconnect Rear Shaft Bracket Only Arm Assembly Complete 6 Arm Assembly Complete 8 Arm Assembly Complete 10 Bushing Arm Only 6 Arm Only 8 Arm Only 10 40519 S 41246 QD 40520 S 41247 QD 40865 40869 40870 40871 40539 40565 40566 Straight Mounting Arms Available in various lengths up to 10 overall Consult factory for details 10 Degree Mounting Arms Available in various lengths up to 10 overall Consult factory for details 45 Degree Mounting Arms Available in various lengths up to 10 overall Consult factory for details Extension Arms 1 062 RS 750 LD 1 625 4 440841 6 440842 8 440843 10 4440844 Universal Mounting Arms Rumble Safety Mount Table A Insulating Discs Robot Model CTBiotech H 80 Series H 280 Series WV 15 TH 8 GA 100 Gantry 100 200 Arc Mate PW 10 T3 726 T3 746 T3 776 T3 786 T3 556 T3 586 T3 735 T3 646 GMF Hitachi Milacron Motoman Westinghouse Komatsu RWL 0005 Unimation 760 Flanged P
18. TIES From p 16 MM Rc RENEIRL BEA Lnd E culpe ced Tessino 030 035 Requires Liner O ring 4 required Casing 035 3 32 Requires Liner Nut Connector Casing 035 045 Single Piece Stub Liner at Connector Casing 045 1 16 Single Piece Required with Single Piece Casings Casing 5 64 3 32 Single Piece Stub Liner 030 035 Casing 7 64 1 8 Single Piece Stub Liner 035 045 Water In Hose Assembly Stub Liner 045 1 16 Clamp Stub Liner 5 64 3 32 Water Out amp Power Cable Stub Liner 7 64 1 8 Gas Hose Assembly Spool Rear Cable Hose Sheath Sleeve Contact Pin Utilities Combination Connector Body Consists of 1 2 4 5 6 amp 8 Liner 030 035 Hard Cored 030 035 46460 Req Liner Liner 035 045 Hard Cored 035 1 16 D F Casing Req Liner Liner 045 1 16 Hard Cored 035 045 Single Piece Casing Liner 3 64 Soft 045 1 16 Single Piece Casing Liner 1 16 Soft 5 64 3 32 Single Piece Casing Liner 3 32 Soft 7 64 1 8 Single Piece Casing Q D Water In Hose Assembly Casing Adapter 030 1 16 Q D Water Out Hose Assembly Casing Adapter 5 64 1 8 Plug Water in from Cooler Body Housing Socket Water Out Socket Set Screw EURO Connector Complete Machine Screw Nylon Consists of 9 14 16 18 amp 20 23 Socket Set Screw ORDERING INFORMATION WIRE CASINGS WATER IN HOSE WATER OUT amp POWER CABLE GAS HOSE UTILITIES COMBINATION amp LINERS ONLY Add Footage Digit to Item Code Number for
19. Wrench for the fitting on the water out amp power cable hose see 7 A B This is used on the docking spool s gas fitting to secure the gas hose to the docking spool A crescent wrench could be used in stead but due to the large size of crescent wrenches we prefer the smaller size of the open ended wrenches see 7 B C This wrench is also 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 1 2 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 7 Long 1 2 Open Ended Wrench place it on the adapter and push it down counter clockwise securing the adapter to the inner body see 7 C Long 1 2 amp 9 16 Open Ended Wrench A This is used to secure the water out amp power cable to the docking spool 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 see 6 A B This is used to secure the gas hose to the docking spool 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 see 6 B C This wrench is also used to
20. age 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 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
21. 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 1750 Howard Drive North Mankato MN 56003 Phone 507 625 6200 Fax 507 625 6203 Rev 130423A www dfmachinespecialties com
22. ected 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
23. el HTC Water Cooled Curved Gun has a current capacity of up to 500 amps Rating would be contingent on the combination of the current tip and shielding gas to be used The Model HTC employs threaded current tips and accommo dates 030 1 8 Hard Cored wires and 3 64 3 32 AL wire 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 RECOMMENDED SPARE PARTS ITEM CODE NO MIN QTY Gas Nozzle To Be Selected Current Tip To Be Selected Collet Nut To Be Selected Spatter Disc To Be Selected Body Liner To Be Selected Insulation Tube To Be Selected TABLE 2 GAS NOZZLES O 2 Gun Model Ref Nozzle Type op ID Code No NC HT Copper Tapered Std Capacity Copper Straight Copper Straight Copper Tapered NC HT Copper Short Taper 1 11 16 Hi Capacity Copper Short Taper 1 13 16 Series A Copper Short Taper 1 15 16 Copper Full Taper 11 16 Copper Full Taper 13 16 Copper Full Taper 15 16 DISASSEMBLY 1 Prior to removing the curved gun from the Docking Spool body make sure that the power source and wire feeder are turned off 2 Remove the 4 machine screws which fasten the transfer spool to the inner body The nut and transfer spool may now be removed By removing flat head screw and releasing the elbow fastening socket screws the body tube may be pulled from elbow casting
24. following standards in their latest revisions 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 ANSI Standard Z41 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 OSHA SAFETY AND HEALTH STANDARDS 29CRF 1910 obtainable from the U S Government Printing Office Washington D C 20402 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 ANSI Standard Z88 2 Practice for Respiratory Protection obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 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 Washingt
25. 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 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 c
26. leaning 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
27. n Ended Wrench A Ashort wrench will work however we prefer the feel and comfort of the long 5 16 open ended wrench This is used to loosen or tighten interconnection hoses 42196 42242 to the fittings on the inner body B Also use this wrench to connect the torch s water cooled nozzle assembly to the interconnection hoses 3 8 Open Ended Wrench This is used on the docking spool s water in hose fitting to secure the water in hose to the docking spool 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 water in hose itself while using the 3 8 wrench to steady the docking spool at the fitting see 5 Long 7 16 Open Ended Wrench This is used to secure the water in hose to the docking spool see 4 9 16 amp 1 2 Open Ended Wrench A This is used on the inner body s water out amp power cable fitting to secure the water out and power cable to the docking spool 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 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 You will use the 7 Long 9 16 Open Ended
28. ner 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 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
29. nsists of Items 1 2 3 4 5 6 amp 11 030 035 035 1 16 035 045 045 1 16 NOTE for Casings Water In Water Out amp Power Cable Gas Hose Sheath Utility Combination and Liner only Add footage to code number for length desired Example Require 6 Ft Water In Hose Assembly Code No 46300 6 CONVENTIONAL ASSEMBLY DEDICATED OR ROBOTIC 45 DEGREE WATER COOLED CURVED GUN MODELS NCC HTC Water Cooled Nozzles Short 3 Inter 4 Long 5 o KITO RN High Capacity Series A Water Cooled Nozzles Short A3 Inter A4 ORDERING INFORMATION To obtain a complete Water Cooled Nozzle Assembly reference the table below and the parts list Note Specify wire diameter Gas Nozzle page 5 Table 2 and Current Tip page 7 Table 3 REF CODENO DESCRIPTION W C Curved Gun Assembly Short 3 Nozzle W C Curved Gun Assembly Inter 4 Nozzle W C Curved Gun Assembly Long 5 Nozzle W C Curved Gun Assembly Short A3 High Capacity Nozzle W C Curved Gun Assembly Inter A4 High Capacity Nozzle COMPLETE ASSEMBLY Add footage to code number for length desired Example Require Model NCC with 5 Nozzle amp 8 Ft Utilities Code No 42181 8 COMPLETE STANDARD ASSEMBLIES CONSISTS OF GUN ASSEMBLY AND WIC NOZZLE UTILITY COMBINATION MODEL NCC MODEL HTC Short 3 Inter 4 Long 5 Short A3 High Cap Inter A4 High Cap EURO ASSEMBLY UTILI
30. on D C 20402 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 Make certain the cooling water supply is at least the minimum flow rate of 3 quarts per minute at 40 psi 80 psi maximum Gun ratings are affected by shielding gas used arc time cooling time and inlet water temperature Water outlet temperature should not exceed 120 degrees F For normal GMAW a water circulator of the radiator cooler type with a 3 gallon capacity will provide ample cooling When High Deposition GMAW or extended periods of arc time are used it is recommended that a liquid chiller be consid ered Precise temperature control maintains the cooling at constant temperature thus prolonging the life of the welding equipment and more specifically extending the service life of the gas nozzle and current tip A refrigerated liquid chiller for GMAW may be obtained from Remcor Products Company A Division of IMI Cornelius Inc 500 Regency Drive Glendale Heights IL 60139 6850 Call Toll Free 800 551 4423 Fax Toll Free 866 394 5140 International Telephone 630 539 6911 International Fax 630 539 6960 INTRODUCTION This manual covers Remote Mounted Water Cooled Curved Guns which offer a concept with interchangeability of models for mechanized
31. or robotic MIG welding The curved guns accommodate a wire diameter range of 030 1 8 Hard and Cored wires and 3 64 3 32 AL wire The equipment consists of four 4 basic components a Utility Station an intermediate Utilities Combination assembly a Docking Spool body and a Water Cooled Curved Gun The Docking Spool body is the principal component in this welding equipment arrangement It accepts the utilities at the top end of the spool and provides a means of accepting the curved gun assembly at the lower end in addition several other features important to a welding system are provided Incorporated within the water chamber of the Docking Spool body are check valves which provide a means of retaining the residual wa ter in the lines when the curved gun is removed from the Docking Spool body Also a Posit ring is provided to allow positive location at the mounting bracket to achieve dimensional stability The curved gun assemblies are designated by two 2 models illustrated in the parts breakdown list The Model NCC Water Cooled Curved Gun has a current capacity of 400 amps in argon shielding It accommodates a slip in current tip fastened by a collet action nut This arrangement increases the versatility of the equipment by allowing tip extension beyond the gas nozzle where critical access problems to the weld area are encountered The wire diameter range is 030 1 8 with Hard Cored wires and 3 64 3 32 with AL wire The Mod
32. ost Mount Code No 40509 ROBOTIC GUN LAYOUT 45 Degree WIC Docking Spool Curved Gun Models NCC HTC NCC A HTC A Standard Short 3 and Series A3 Nozzles CS lt gt We fo d 1 125 e AS A Water Cooled Nozzle Short 3 RUMBLE SAFETY MOUNT ut fe Water Cooled Nozzle Series A High Capacity Short A3 ROBOTIC GUN LAYOUT 45 Degree WIC Docking Spool Curved Gun Models NCC HTC NCC A HTC A Standard Intermediate 4 and Series A4 Nozzles gt a RUMBLE 4 RUMBLE SAFETY We AE iu Ska Chum TITT 3 E 3 Hill put MEME ES 12 500 Water Cooled Nozzle Series A High Capacity Intermediate A4 Water Cooled Nozzle Intermediate 4 ROBOTIC GUN LAYOUT 45 Degree WIC Docking Spool Curved Gun Models NCC HTC Standard Long 5 Nozzle Po a SE d RUMBLE H SAFETY 13 437 Water Cooled Nozzle Long 5 GUN DIMENSIONS Docking Spool Body Docking Spool Body Mounting Area 1 750 Diameter 1 250 Width mn MICNOZZLE DIMENSIONS DESCRIPTION A B Short 3 12 837 5 733 5 227 Intermediate 4 13 312 6 450 6 562 q Long 5 13 787 7 132 6 611 E w Series A3 12 837 5 733 5 227 Series A4 13 312 6 450 6 562 SMOKE EXTRACTOR ORDERING INFORMATION ORDERING INFORMATION Standard Water
33. perior customer support to quality 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 Introduction Table 1 Recommended Spare Paris Table 2 Gas Nozzles 5 Disassembly Assembly A 6 Table 3 Current TipS T H Required Tools List for Disassembly amp Assemblv err 8 9 How Do
34. r 5 16 Slip In Tip for 4 W C Noz REF CODENO DESCRIPTION Adapter 5 16 Slip In Tip for 5 WIC Noz Socket Set Screw Insulation Tube 2 req d Docking Spool Body Insulating Collar Posit Ring O ring Internal Spring O ring External ball Water Cooled Nozzle 3 Seat Water Cooled Nozzle 4 Screw 4 req d Water Cooled Nozzle 5 OO OO Jo 01 P GAMM O ring 6 req d Transfer Spool Nut Body Tube Elbow Casting Washer Insulator Elbow Socket Set Screw Casting Body Liner see chart above O ring 3 req d Inner Body Interconnection Hose Flat Head Screw Insulation Tube for 3 Nozzle Insulation Tube for 4 Nozzle Insulation Tube for 5 Nozzle Nut Spatter Disc Collet Nut 1 4 Slip In Tip Collet Nut 5 16 Slip In Tip Threaded Current Tip see p 7 Table 3 Slip In Current Tip see p 7 Table 3 Gas Nozzle see p 5 Table 2 Wrench Nozzle Thread Chaser Tap Round Head Screw WATER COOLED CURVED 45 GUN SERIES A HIGH CAPACITY PARTS MODEL NCC Slip In Tip MODEL HTC Threaded Tip 030 035 035 045 045 052 1 16 5 64 3 32 7 64 3 64 Soft 1 16 Soft 3 32 Soft REF CODE NO DESCRIPTION REF CODE NO DESCRIPTION c OO Jo Om P GAMM Socket Set Screw Docking Spool Body Posit Ring Spring ball Seat Screw 4 req d O ring 6 req d Transfer Spool Nut Body Tube Elbow Casting
35. re 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 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 prot
36. re 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 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 volt
37. rom 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 liner 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 li
38. ting washer to fasten the inner body to the elbow Upon completion the nut may be applied to the elbow to retain the water cooled nozzle 5 Apply the insulation tube to the water cooled nozzle 6 The above should be followed by applying the spatter disc When spatter disc is replaced make certain that the counter bored end is facing the weld body Replacement of spatter disc support tube arrangement is accomplished by sliding the spatter disc into the water cooled nozzle followed by pushing the support tube up into the water cooled nozzle apply the current tip and replace the gas nozzle 7 The body tube may now be applied by placing it over the rear spool of the inner body and pushing if forward until the hole aligns in the rear spool to allow applying the flat head screw Following this the socket screws may be tightened in the elbow 8 Place nut on the body tube The transfer spool may be applied Make certain at this point that the o rings are in position in the counter bores provided in the rear spool of the inner body Slide the transfer spool down over the center tube and apply the four 4 machine screws Distribute the fastening pressure evenly 9 To complete the gun assembly at this point examine the transfer o rings Make replacement if necessary Lubricate o rings with silicone spray TABLE 3 CURRENT TIPS CURRENT TIPS 5 16 DIAMETER SLIP IN CURRENT TIPS 1 4 DIAMETER SLIP IN Gun Barrel Model Wire Size Wire Type
39. to connect the end of the hose to the casting water fitting using the end that indicates stainless spring liner closest to it In other words the nose end that indicates the open space within the hose should be the end that is fastened to the water cooled nozzle The interconnection hose assembly may be bent into a U shape normally before applying it to the rear of the casting When in proper position the interconnection hose will be over the top of the center tube extending from the casting and will be in location in the upper right hand concave viewing the inner body from the rear 2 Hold both interconnection hoses in their relative position and slide inner body into body elbow Slide the black insulator into position in the body elbow 3 Insert the two 2 nylon insulating tubes over the hoses extending from the front of the elbow assembly 4 The nylon collar should be in place on the rear of the water cooled nozzle assembly It is important that the small hole in the nylon collar be on the lower right hand side viewing the nozzle from the rear when the interconnection hoses are fastened After connecting the interconnection hoses push the water cooled nozzle up against the face of the body elbow At the same time make certain that the interconnection hose nut at rear aligns with the fitting at the rear spool so that it may be applied and fastened The black elbow insulator should be in position to allow applying the round head body screw with insula
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