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OM-1592 Page 8

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

ELECTRIC SHOCK can kill.

•

Do not touch live electrical parts.

•

Turn Off cutter, and disconnect input power before
inspecting, maintaining, or servicing.

HOT PARTS can cause severe burns.

•

Allow cooling period before maintaining or servicing.

Maintenance to be performed only by qualified persons.

WARNING

swarn8.1* 2/93

5-1.

Routine Maintenance

Turn Off all power before maintaining.

Each Use

Check Tip
Electrode,

And Cup

Check

Trigger

Disabled

System

Every Week

Check 

Gas/Air

Pressure

At Cutter

Tape

Torn

Outer

Covering

 – –

Clean

And

Tighten

Torch

Connections

3-1

Torch Body

Gas/Air Hose

Torch Cable

– –

Replace
Cracked

Parts

3 Months

Cutter

Manual

See

Section

5-2

Cutter

Manual

Ref. ST-800 895

Figure 5-1. Maintenance Schedule

Summary of Contents for MC-80

Page 1: ...m Cable Machine HeldTorch Equipped With 50 ft 15 2 m Cable Fully Assembled And Supplied With Consumable Kit Read and follow these instructions and all safety blocks carefully Have only trained and qualified persons install operate or service this unit Call your distributor if you do not understand the directions Give this manual to the operator For help call your distributor or MILLER Electric Mfg...

Page 2: ...value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit...

Page 3: ...electrical parts 2 Wear dry hole free insulating gloves and body protection 3 Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground 4 Do not touch torch parts if in contact with the work or ground 5 Turn off power before checking cleaning or changing torch parts 6 Disconnect input power before installing or ser...

Page 4: ...ar muffs to prevent sparks from entering ears CYLINDERS can explode if damaged Gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of metalworking processes be sure to treat them carefully 1 Protect compressed gas cylinders from excessive heat mechanical shocks slag open flame sparks and arcs 2 Install and secure cylinders in an upr...

Page 5: ...netic fields in the workplace use the following procedures 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 the body 4 Keep welding power source and cables as far away as practical 5 Connect work clamp to workpiece as close to the weld as possible About Pacemakers The above procedures are among thos...

Page 6: ......

Page 7: ...ing WARNING READ SAFETY BLOCKS at start of Section 3 1 before proceeding WARNING 5 4 6 7 1 2 CAUTION MOVING PARTS can injure Keep away from moving parts Keep all panels and covers closed when operating 3 Turn Off switch when using high frequency Figure 1 1 Safety Information SECTION 2 SPECIFICATIONS Table 2 1 Cutting Torch Specification Description Cooling Method Air Overall Dimensions See Figure ...

Page 8: ...y Cycle CAUTION CUTTING LONGER THAN RATED DUTY CYCLE can damage cutter and torch and void warranty Do not cut at rated load longer than duty cycle of cutter see cutter s Owner s Manual miscwarn3 1 9 93 Duty Cycle is percentage of 10 minutes that cutter and torch can cut at rated load without overheating sb1 1 8 93 0 10 Minutes Definition Continuous Cutting 100 Duty Cycle At 80 Amperes Figure 2 2 D...

Page 9: ...10 91 Turn Off cutter and remove input power Remove top of cutter case 1 Trigger Switch Connector 2 Gas Hose Connector 3 Pilot Lead Terminal 4 Boot Insert hose and leads through boot 5 Gas Hose 6 Pilot Terminal Connect hose and leads as shown Reinstall top of case Ref ST 800 895 ST 800 896 3 8 5 8 in Tools Needed 4 5 1 2 6 4 3 2 1 Rear Panel Significant DC voltage can remain on capacitors in cutte...

Page 10: ...n Insert leads through boot and install in strain relief as shown Be sure insulation jacket is in strain relief 4 Torch Connection Receptacle 5 Gas Hose 6 Pilot Lead Insert receptacle hose and lead through boot 7 Pilot Terminal Connect pilot lead to terminal and gas hose to fitting as shown 8 Printed Circuit Board PC3 9 Three Way Connector Connect three way connector to matching receptacle on PC3 ...

Page 11: ...xplosion Do not cut near flammable material Provide protection from flying sparks Watch for fire keep extinguisher nearby Do not locate unit over combustible surfaces Do not cut on closed containers Allow work and equipment to cool before handling MOVING PARTS can cause injury Keep away from moving parts Keep all doors panels covers and guards closed and securely in place See Safety Precautions at...

Page 12: ...ng the cutting of chain fence will shorten tip electrode and torch life Put a continuous piece of sheet metal under the fence to prevent pilot arc from cycling on and off Avoid constant starting and restarting of the arc Check Torch Tip Electrode And Shield Cup Install standoff guide place After cutting arc starts slowly start moving torch across metal Adjust torch speed so sparks go thru metal an...

Page 13: ... Install Gouging Tip Check Gas Air Pressure Set Controls Begin Gouging EXAMPLE Of Gouging Operation ST 800 968 Use approx 1 8 in 3 mm standoff distance at about a 40 angle Establish arc length of 1 2 to 1 1 2 in 13 38 mm and slowly start moving torch across metal Adjust torch speed arc length and angle as needed Direct sparks away from torch Do not gouge too deeply in one pass make repeated passes...

Page 14: ...vicing Maintenance to be performed only by qualified persons WARNING swarn8 1 2 93 5 1 Routine Maintenance Turn Off all power before maintaining Each Use Check Tip Electrode And Cup Check Trigger Disabled System Every Week Check Gas Air Pressure At Cutter Tape Torn Outer Covering Clean And Tighten Torch Connections 3 1 Torch Body Gas Air Hose Torch Cable Replace Cracked Parts 3 Months Cutter Manua...

Page 15: ...the same time Do not overtighten electrode Ref ST 800 897 ST 800 973 Turn Off cutter and disconnect in put power 1 Shield Cup Remove shield cup Check shield cup for cracks and replace if need ed Also replace cup if it does not cover the tip 2 Tip 3 Opening Remove tip Check tip and replace if opening is deformed or 50 over size If inside of tip is not clean and bright clean with steel wool Be sure ...

Page 16: ... not clean Torch travel speed too fast reduce travel speed Figure 4 2 Metal being cut is too thick increase power source output control setting See power source Owner s Manual Check torch tip and electrode and replace if needed 5 2 Be sure work clamp is securely attached See power source Own er s Manual Arc goes out while cutting Make sure torch tip is within 1 8 in 3 mm standoff distance from met...

Page 17: ... ST 800 976 2 3 4 5 6 See Figure 3 1 For Additional Torch Consumables And Parts Includes Item 5 Figure 6 1 Torch MC 80 Hand Held Ref ST 800 897 Select correct consumables and parts for process being used as shown Torch is shipped with cutting parts installed Tools Needed Supplied 171 875 Hand Machine Held Cutting Gouging Electrode 171 870 Tip 171 871 Cup 171 874 Standoff Guide Hand Held Only 171 8...

Page 18: ...nsisting of 1 4 175 851 SCREW handle 4 5 175 839 O RING gas cup barrel 2 6 175 831 BARREL 1 7 175 832 RACK standard consisting of 1 8 175 838 SCREW rack 2 9 043 216 REMOTE PENDANT CONTROL on off 1 10 175 837 CONNECTOR three way 1 11 175 834 TORCH LEAD ASSEMBLY 50 ft 1 4 5 3 2 Includes Items 6 8 1 9 10 6 7 8 ST 801 197 043 216 is optional when replacing torch 11 Figure 6 3 Torch MC 80 Machine Held ...

Page 19: ...tting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories The...

Page 20: ... complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Informati...

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