OM-1313
179 084P
September 2001
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
And Wire Feeder
R
Millermatic 185
And M-15 Gun
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TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Welding Power Source Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Welding Gun Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Setting Gun Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Changing Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12. Selecting A Location And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-13. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
5
5
5
6
6
7
7
8
8
9
9
10
10
11
The following terms are
used interchangeably
throughout this manual:
MIG = GMAW
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Weld Parameter Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
14
SECTION 4 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Circuit Breakers CB1 And CB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Changing Drive Roll And Inlet Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Cleaning Or Replacing Gun Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Replacing Switch And/Or Head Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Replacing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
16
17
18
19
19
SECTION 5 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 6 – MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Holding And Positioning Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Gun Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Troubleshooting – Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Troubleshooting – Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Troubleshooting – Excessive Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Troubleshooting – Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Troubleshooting – Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13. Troubleshooting – Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-14. Troubleshooting – Waviness Of Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-15. Troubleshooting – Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-16. Common MIG Shielding Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-17. Troubleshooting Guide For Semiautomatic Welding Equipment . . . . . . . . . . . . . . . . . . . . . . .
21
22
23
24
25
25
25
26
26
26
27
27
27
28
28
29
29
SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPTIONS AND ACCESSORIES
WARRANTY
OM1313
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
Y
Marks a special safety message.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
Y
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
D
D
D
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Y
Y
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D
D
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
ELECTRIC SHOCK can kill.
Do not connect more than one electrode or work cable to any
single weld output terminal.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
groundedequipment is a hazard.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D
D
D
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
FUMES AND GASES can be hazardous.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
D
D
Use AC output ONLY if required for the welding process.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If AC output is required, use remote output control if present on
unit.
D
D
If ventilation is poor, use an approved air-supplied respirator.
D
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D
D
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
D
D
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D
D
When making input connections, attach proper grounding conduc-
tor first – double-check connections.
Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-suppliedrespirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
D
D
D
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
OM-1313 Page 1
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ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
D
D
Shut off shielding gas supply when not in use.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Always ventilate confined spaces or use
approved air-supplied respirator.
D
Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
D
D
D
Wear approved safety glasses with side shields under your
helmet.
D
D
Do not touch hot parts bare handed.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Allow cooling period before working on gun or
torch.
Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
D
D
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
NOISE can damage hearing.
D
D
D
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can
damagehearing.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D
Wear approved ear protection if noise level is
high.
D
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D
D
Watch for fire, and keep a fire extinguisher nearby.
CYLINDERS can explode if damaged.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D
D
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D
D
Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D
D
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
D
D
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
FLYING METAL can injure eyes.
D
D
Turn face away from valve outlet when opening cylinder valve.
D
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
D
Wear approved safety glasses with side
shields even under your welding helmet.
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D
Do not install or place unit on, over, or near
combustiblesurfaces.
D
D
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
D
Do not install unit near flammables.
D
Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D
D
D
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Use equipment of adequate capacity to lift and
support unit.
D
Have only qualified persons familiar with
electronic equipment perform this installation.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
D
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
If notified by the FCC about interference, stop using the
equipmentat once.
OVERUSE can cause OVERHEATING
D
D
Allow cooling period; follow rated duty cycle.
D
D
Have the installation regularly checked and maintained.
Reduce current or reduce duty cycle before
starting to weld again.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
D
D
Put on grounded wrist strap BEFORE handling
boards or parts.
ARC WELDING can cause interference.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
MOVING PARTS can cause injury.
D
Be sure all equipment in the welding area is
electromagneticallycompatible.
D
D
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
D
D
D
D
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury.
Be sure this welding machine is installed and grounded
according to this manual.
D
D
Do not press gun trigger until instructed to do
so.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-1313 Page 3
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1-5. EMF Information
Considerations About 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.
Welding current, 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
committee’s 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 opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
To reduce magnetic fields in the workplace, use the following
procedures:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
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SECTION 2 – INSTALLATION
2-1. Specifications
Amperes Input at
Rated Load
Maximum
Rated Welding
Output
Amperage
Range
Overall
Dimensions
Output, 60 Hz,
Open-Circuit
Weight
Single-Phase
Voltage DC
200 V
230 V
KVA
KW
Length: 36 in
(915 mm)
150 A @ 23 Volts
DC, 60% Duty Cycle
165 lb
(75 kg)
Width: 18 in
(457 mm)
30 – 185
33
30 (1.6)* 26 (1.4)* 6 (0.27)* 5 (0.13)*
Height: 27 in
(686 mm)
Wire Type And Diameter
Solid Steel /
Calculated Wire Speed
Range At No Load
Max Wire Feed Speed
While Welding
Stainless
Steel
Flux Cored
Aluminum
.030 – .045 in
(0.8 – 1.2 mm) (0.8 – 0.9 mm)
.030 – .035 in
.023 – .035 in
(0.6 - 0.9 mm)
138 – 795 IPM (3.5 – 20.3 m/min)
650 IPM (16.5 m/min)
*While idling
Operating Temperature Range – –20C to +40C
Storage Temperature Range – -30C to + 50C
2-2. Volt-Ampere Curves
Volt-ampere curves show mini-
mum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall be-
tween curves shown.
va_curve1 4/95 – SB-180 824
OM-1313 Page 5
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2-3. Welding Power Source Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
voltage, or duty cycle before
welding.
Y
Exceeding duty cycle can
damage unit and void
warranty.
60% Duty Cycle At 150 Amperes
6 Minutes Welding
4 Minutes Resting
Overheating
A or V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 – SB-181 009
2-4. Welding Gun Duty Cycle And Overheating
CAUTION
WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty.
• Do not weld at rated load longer than shown below.
• Using gasless flux cored wire reduces gun duty cycle.
warn7.1 8/93
Definition
.023 To .045 in (0.6 To 1.1 mm)
Hard Or Flux Cored Wires
.023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires
60% Duty Cycle At 200 Amperes
0
100% Duty Cycle At 150 Amperes
Using CO
2
10
Minutes
Using CO
2
60% Duty Cycle At 150 Amperes
Using Mixed Gases
100% Duty Cycle At 120 Amperes
Using Mixed Gases
Duty Cycle is percentage of 10
minutes that gun can weld at
rated load without overheating.
6 Minutes Welding
4 Minutes Resting
Continuous Welding
SB1.1 8/93
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2-5. Installing Work Clamp
1
2
Work Cable
Boot
Slide boot onto work cable. Route
cable out front panel opening from
inside.
4
3
Negative (–) Output Terminal
Connect cable to terminal and
cover connection with boot.
5
4
5
Hardware
Work Clamp
Route cable through clamp handle
and secure as shown.
1
2
Close door.
Tools Needed:
3
1/2, 3/4 in
ST-801 566-A
2-6. Installing Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other station-
ary support so cylinder cannot fall
and break off valve.
1
2
1
2
Cap
Cylinder Valve
Tools Needed:
5/8, 1-1/8 in
Remove cap, stand to side of valve,
and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.
3
4
Cylinder
3
Regulator/Flowmeter
Install so face is vertical.
4
5
Regulator/Flowmeter Gas
Hose Connection
Argon Gas
6
Welding Power Source Gas
Hose Connection
Connect customer supplied gas
hose between regulator/flowmeter
gas hose connection, and fitting on
rear of welding power source.
OR
1
2
7
Flow Adjust
7
5
Typical flow rate is 20 cfh (cubic feet
per hour). Check wire manufactur-
er’s recommended flow rate.
8
CO Adapter (Customer Sup-
plied)
2
9
O-Ring (Customer Supplied)
3
Install adapter with O-ring between
8
9
regulator/flowmeter and
cylinder.
CO
2
CO Gas
2
6
ST-801 571 / ST-802 028
OM-1313 Page 7
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2-7. Installing Welding Gun
1
2
3
Drive Assembly
Gun Securing Knob
Gun End
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
nut.
1
2
4
Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
3
Close door.
4
Ref. ST-801 567
2-8. Setting Gun Polarity
1
Polarity Changeover Label
Always read and follow manufac-
ture’s recommended polarity.
1
Tools Needed:
3/4, 11/16 in
Ref. 190 821-A
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2-9. Installing Wire Spool And Adjusting Hub Tension
Use compression spring with
8 in (200 mm) spools.
Tools Needed:
When a slight force is needed
to turn spool, tension is set.
15/16 in
ST-072573-B
2-10. Changing Input Voltage
Y
Turn Off unit, and disconnect
input power.
Unit was shipped from factory set
for 230 volts.
1
2
3
Transformer T1
Rear Of Power Switch S1
Lead Marked 230 Volt And
Fan Motor Lead
2
Disconnect 230 volt lead and fan
motor lead from rear of S1. Leave
fan motor lead connected to 230
volt lead.
3
4
Lead Marked 200 Volt
Remove cable tie, and slide short
piece of sleeving off 200 volt lead,
and slide sleeving over end of 230
volt and fan motor leads. Fold
sleeving over and secure in place.
1
Connect 200 volt lead to S1 where
230 volt lead was removed.
Reinstall wrapper.
4
Tools Needed:
3/8, 7/16 in
ST-801 580-A
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2-11. Electrical Service Guide
Input Voltage
200
30
230
26
Input Amperes At Rated Output
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
1
2
3
35
45
10
30
40
10
Circuit Breaker , Time-Delay
Normal Operating
Min Input Conductor Size In AWG/Kcmil
97
(29)
128
(39)
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
10
10
Reference: 1999 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose – no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
Y
Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
2-12. Selecting A Location And Connecting Input Power
1
Rating Label
Supply correct input power.
2
3
Plug
Y
Do not move or operate unit
where it could tip.
Receptacle
Connect plug to receptacle.
18 in (457 mm) of
space for airflow
4
Input And Grounding
Conductors
Connect directly to line disconnect
device if hard wiring is required.
5
Line Disconnect Device
Y
Always connect grounding
conductor first.
See Section 2-11.
Y
Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
= GND/PE
5
L1
L2
1
2
1
4
3
L1
L2
230 VAC, 1
801 568 / Ref. 800 797-B
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2-13. Threading Welding Wire
Tools Needed:
4 in
(102 mm)
6 in
(150 mm)
Open pressure assembly.
Pull and hold wire; cut off end.
Push wire thru guides into gun;
continue to hold wire.
. Use pressure indicator
Tighten
scale to set a desired
drive roll pressure.
Pressure
Indicator
Scale
1
2
3
4
Close and tighten pressure
assembly, and let go of wire.
Remove gun nozzle and contact tip.
Turn On.
Tighten
1
2
3
4
WOOD
Press gun trigger until wire
comes out of gun. Reinstall
contact tip and nozzle.
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Cut off wire. Close
and latch door.
Ref. ST-801 570-A / ST-801 083 / S-0627-A
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Notes
OM-1313 Page 12
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SECTION 3 – OPERATION
3-1. Front Panel Controls
Controls For Standard Units
Wire Speed Control
1
Use control to select a wire feed
speed. Scale around control is not
actual wire feed speed, but is for
reference only.
2
Voltage Switch
The higher the selected number,
the thicker the material that can be
welded (see Section 3-2). Do not
switch while welding.
3
Power Switch
2
3
Ref. ST-180 930
OM-1313 Page 13
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3-2. Weld Parameter Chart
*Line voltage can affect weld output, settings on this chart are starting values only. You may need to adjust
voltage and wire feed speed to optimize your settings.
Input Line
Voltage*
Parameter
Chart Settings
Higher
e.g. 240
Volts AC
Weld Will Be
Hotter
Lower Settings
Use Parameter
Chart Inside
Door
230 Volts AC
Weld Will Be
Colder
Raise Settings
Lower
e.g. 218
Volts AC
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Ref. 197 949
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SECTION 4 – MAINTENANCE & TROUBLESHOOTING
4-1. Routine Maintenance
. Maintain more often
Y
Disconnectpower
before maintaining.
during severe conditions.
3 Months
6 Months
Clean And
Tighten
Weld
Repair Or
Replace
Cracked
Cables And
Cords
Replace
Damaged Or
Unreadable
Labels
Terminals
Remove drive roll
and apply light coat
of oil or grease to
drive motor shaft.
Blow Out Or
Vacuum Inside
4-2. Circuit Breakers CB1 And CB2
2
1
Y
Turn Off unit.
1
Circuit Breaker CB1
CB1 protects the transformer from
overload. If CB1 opens, wire
feeding stops.
2
Circuit Breaker CB2
CB2 protects the trigger circuit from
overload. If CB2 opens, weld output
stops.
Press button to reset circuit
breaker. Close door.
Ref. ST-801 567
4-3. Changing Drive Roll And Inlet Wire Guide
1
Drive Roll
Choose correct drive roll for wire
type, and install as shown.
2
Inlet Wire Guide
Remove guide by pressing on
barbed area, or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole from
rear until it snaps in place.
1
Tools Needed:
2
Ref. ST-801 569-A
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4-4. Cleaning Or Replacing Gun Liner
Tools Needed:
Y
Disconnect gun first.
3/8 in
Head Tube
Remove nozzle, contact tip, and
adapter.
3/8 in
Remove liner.
Lay gun cable out straight
before installing new liner.
To Reassemble Gun:
Insert new liner.
Install and tighten wire outlet guide.
Cut liner off 3/4 in (20 mm) (3/8 in
[9.5 mm] for aluminum) from head
tube.
Blow out gun casing.
Install adapter, contact tip, and
nozzle.
Ref. ST-800 797-C
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4-5. Replacing Switch And/Or Head Tube
Y
Disconnect gun first.
1
Remove handle
locking nut.
3
Slide handle.
2
Remove switch housing. Note: If installing new
switch, push switch lead connectors onto terminal of
new switch (polarity is not important). Install switch
back into handle, and secure with handle locking nut.
If replacing head tube, continue to end of figure.
4
Secure head
tube in vice.
5
Loosen jam nut. Remove
from vice and turn head
tube out by hand.
6
Install existing shock washer onto
new head tube. Hand-tighten head
tube into connector cable.
7
Place head tube in vice and tighten
until nuts are tight.
8
Remove from vice. Reposition
handle and install switch housing.
Secure with handle locking nut.
Tools Needed:
3/4 in
Ref. ST-800 795-C
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4-6. Replacing Gun Contact Tip
Y
1
Turn Off unit.
Nozzle
2
Contact Tip
Cut off welding wire at contact tip.
Remove nozzle.
Remove contact tip and install new
contact tip. Reinstall nozzle.
Tools Needed:
2
1
Ref. 800 797-C
4-7. Troubleshooting
Welding Trouble
Remedy
No weld output; wire does not feed.
Secure power cord plug in receptacle (see Section 2-12).
Check and replace power switch if necessary.
Check circuit breakers CB1 and/or CB2, and reset if necessary (see Section 4-2).
Replace building line fuse or reset circuit breaker if open (see Section 2-12).
Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 2-7 and/or 4-5).
ThermostatTP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled
(see Section 2-3).
No weld output; wire feeds.
Connect work clamp to get good metal to metal contact.
Replace contact tip (see Section 4-6).
Low weld output.
Connect unit to proper input voltage or check for low line voltage (see Section 2-12).
Readjust front panel settings (see Section 3-1).
Low, high, or erratic wire speed.
Change to correct size drive roll (see Section 4-3).
Readjust drive roll pressure (see Section 2-13).
Replace inlet guide, contact tip, and/or liner if necessary (see Sections 2-13, and 4-4).
Wire Drive/Gun Trouble
Remedy
Straightengun cable and/or replace damaged parts (see Section 4-4).
Adjust drive roll pressure (see Section 2-13).
Electrode wire feeding stops during
welding.
Readjust hub tension (see Section 2-9).
Replace contact tip if blocked (see Section 4-6).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 4-4).
Replace drive roll if worn or slipping (see Section 4-3).
Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 2-7 and/or 4-4).
Check and clear any restrictions at drive assembly and liner (see Section 4-4).
Have nearest Factory Authorized Service Agent check drive motor.
OM-1313 Page 19
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SECTION 5 – ELECTRICAL DIAGRAM
SB-186 065
Figure 5-1. Circuit Diagram
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SECTION 6 – MIG WELDING (GMAW) GUIDELINES
6-1. Typical MIG Process Connections
Y
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
Regulator/
Flowmeter
Wire Feeder/
Power Source
Gas
Gun
Shielding
Gas
Work Clamp
Workpiece
light mig 5/967 / Ref. 801 909 / Ref. 801 570-B
OM-1313 Page 21
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6-2. Typical MIG Process Control Settings
These settings are guidelines only. Material and wire type, joint design, fitup,
position, shielding gas, etc. affect settings. Test welds to be sure they comply to
specifications.
NOTE
Material thickness determines weld
parameters.
1/8 or
.125 in
Convert Material
Thickness to
Amperage (A)
(.001 in = 1 ampere)
.125 in = 125 A
Wire Size
Amperage Range
.035 in
.023 in
.030 in
.035 in
30 – 90 A
40 – 145 A
50 – 180 A
Select Wire Size
Select Wire Speed
(Amperage)
Wire
Size
Wire Speed
(Approx.)
Recommendation
.023 in
.030 in
.035 in
3.5 in per ampere
2 in per ampere
1.6 in per ampere
3.5 x 125 A = 437 ipm
2 x 125 A = 250 ipm
1.6 x 125 A = 200 ipm
125 A based on 1/8 in
material thickness
ipm = inch per minute
Low voltage: wire stubs into work
High voltage: arc is unstable (spatter)
Select Voltage
Set voltage midway between high/low voltage.
Wire speed (amperage) controls weld pe-
netration(wire speed = burn-off rate)
Voltage controls height and width of
weld bead.
Ref. ST-801 865
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6-3. Holding And Positioning Welding Gun
Welding wire is energized when gun trigger is pressed. Before lowering helmet and
pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle,
and tip of wire is positioned correctly on seam.
NOTE
1
Hold Gun and Control Gun
Trigger
1
2
3
4
Workpiece
Work Clamp
3
Electrode Extension (Stickout)
1/4 to 1/2 in (6 To 13 mm)
2
5
Cradle Gun and Rest Hand on
Workpiece
5
4
0°-15°
90°
90°
End View of Work Angle
Side View of Gun Angle
GROOVE WELDS
0°-15°
45°
45°
End View of Work Angle
Side View of Gun Angle
FILLET WELDS
S-0421-A
OM-1313 Page 23
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6-4. Conditions That Affect Weld Bead Shape
Weld bead shape depends on gun angle, direction of travel, electrode extension
(stickout), travel speed, thickness of base metal, wire feed speed (weld current),
and voltage.
NOTE
10°
Push
10°
Drag
Perpendicular
GUN ANGLES AND WELD BEAD PROFILES
Short
Normal
Long
ELECTRODE EXTENSIONS (STICKOUT)
Short
Normal
Long
FILLET WELD ELECTODE EXTENSIONS (STICKOUT)
Slow
Normal
Fast
GUN TRAVEL SPEED
S-0634
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6-5. Gun Movement During Welding
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads works better.
NOTE
1
2
3
Stringer Bead – Steady
Movement Along Seam
1
2
Weave Bead – Side To Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
3
S-0054-A
6-6. Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
1
Slight Crater During Welding
Bad Overlap
Poor Penetration
2
4
3
5
S-0053-A
6-7. Good Weld Bead Characteristics
1
2
3
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
1
Weld a new bead or layer for each
1/8 in (3.2 mm) thickness in metals
being welded.
4
5
No Overlap
Good Penetration into Base
Metal
2
4
3
5
S-0052-B
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6-8. Troubleshooting – Excessive Spatter
Excessive Spatter – scattering of molten metal particles that
cool to solid form near weld bead.
S-0636
Possible Causes
Wire feed speed too high.
Corrective Actions
Select lower wire feed speed.
Select lower voltage range.
Use shorter electrode extension (stickout).
Voltage too high.
Electrode extension (stickout) too long.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Use clean, dry welding wire.
Insufficient shielding gas at welding arc.
Dirty welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
6-9. Troubleshooting – Porosity
Porosity – small cavities or holes resulting from gas pockets
in weld metal.
S-0635
Possible Causes
Corrective Actions
Insufficient shielding gas at welding arc.
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Use welding grade shielding gas; change to different gas.
Use clean, dry welding wire.
Wrong gas.
Dirty welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
6-10. Troubleshooting – Excessive Penetration
Excessive Penetration – weld metal melting through base metal
and hanging underneath weld.
Excessive Penetration Good Penetration
S-0639
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase travel speed.
OM-1313 Page 26
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6-11. Troubleshooting – Lack Of Penetration
Lack Of Penetration – shallow
fusion between weld metal and
base metal.
Lack of Penetration Good Penetration
S-0638
Possible Causes
Corrective Actions
Improper joint preparation.
Improper weld technique.
Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
Insufficient heat input.
6-12. Troubleshooting – Incomplete Fusion
Incomplete Fusion – failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
S-0637
Possible Causes
Workpiece dirty.
Corrective Actions
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input.
Select higher voltage range and/or adjust wire feed speed.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Improper welding technique.
Use correct gun angle of 0 to 15 degrees.
6-13. Troubleshooting – Burn-Through
Burn-Through– weld metal melting completely through base metal
resulting in holes where no metal remains.
S-0640
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
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6-14. Troubleshooting – Waviness Of Bead
Waviness Of Bead – weld metal that is not parallel and does not cover
joint formed by base metal.
S-0641
Possible Causes
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Unsteady hand. Support hand on solid surface or use two hands.
Corrective Actions
6-15. Troubleshooting – Distortion
Distortion – contraction of weld metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
S-0642
Possible Causes
Corrective Actions
Excessive heat input.
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
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6-16. Common MIG Shielding Gases
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the
following table.
Application
Gas
Short Circuiting
Stainless Steel
Spray Arc Steel
Short Circuiting Steel
Aluminum
Argon
X
Argon + 25% CO
X
2
80% or greater Argon +
1
X
X
balance CO or Oxygen
2
100% CO
X
X
X
2
2
Tri-Mix
1
2
Limited short circuiting use
90% HE + 7-1/2% AR + 2-1/2% CO
2
6-17. Troubleshooting Guide For Semiautomatic Welding Equipment
Problem
Probable Cause
Remedy
Too little pressure on wire feed rolls.
Increase pressure setting on wire feed rolls.
Wire feed motor operates, but
wire does not feed.
Incorrect wire feed rolls.
Check size stamped on wire feed rolls, replace to match
wire size and type if necessary.
Wire spool brake pressure too high.
Restriction in the gun and/or assembly.
Decrease brake pressure on wire spool.
Check and replace cable, gun, and contact tip if
damaged. Check size of contact tip and cable liner,
replace if necessary.
Too much pressure on wire feed rolls.
Decrease pressure setting on wire feed rolls.
Wire curling up in front of the
wire feed rolls (bird nesting).
Incorrect cable liner or gun contact tip size.
Check size of contact tip and check cable liner length
and diameter, replace if necessary.
Gun end not inserted into drive housing properly.
Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.
Dirty or damaged (kinked) liner.
Gas cylinder empty.
Replace liner.
Replace empty gas cylinder.
Clean or replace gas nozzle.
Wire feeds, but no gas flows.
Gas nozzle plugged.
Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.
Restriction in gas line.
Check gas hose between flowmeter and wire feeder, and
gas hose in gun and cable assembly.
Loose or broken wires to gas solenoid.
Gas solenoid valve not operating.
Have Factory Authorized Service Agent repair wiring.
Have Factory Authorized Service Agent replace gas
solenoid valve.
Incorrect primary voltage connected to welding power Check primary voltage and relink welding power source
source. for correct voltage.
OM-1313 Page 29
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Problem
Probable Cause
Remedy
Wire slipping in drive rolls.
Adjust pressure setting on wire feed rolls. Replace worn
drive rolls if necessary.
Welding arc not stable.
Wrong size gun liner or contact tip.
Match liner and contact tip to wire size and type.
Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
welding power source.
Loose connections at the gun weld cable or work cable. Check and tighten all connections.
Gun in poor shape or loose connection inside gun.
Repair or replace gun as necessary.
OM-1313 Page 30
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Notes
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SECTION 7 – PARTS LIST
. Hardware is common and
not available unless listed.
801 572-C
Figure 7-1. Main Assembly
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 7-1. Main Assembly
Quantity
. . . 1 . . . . . . . . . . . . . 151 187 . . LATCH, slide flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 134 464 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . +151 565 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . Fig 7-2 . . CENTER BAFFLE, w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . SR1 . . . 191 487 . . RECTIFIER ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 180 920 . . . . BRACKET RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 191 375 . . . . RECTIFIER SI DIODE ASSEMBLY, POS . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 191 376 . . . . RECTIFIER SI DIODE ASSEMBLY, NEG . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 152 862 . . . . GROMMET, SCR .250 panel hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . 026 947 . . . . STAND-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . TP1 . . . 604 515 . . . . THERMOSTAT, NC open 211F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . FM . . . . 123 468 . . . . MOTOR, fan 230V 60/50 Hz 3000RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 005 656 . . . . BLADE, fan 6.000 4wg 30 deg .175 bore . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 180 918 . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 190 773 . . BEZEL, front rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . 180 923 . . BRACKET, bottle retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 200 285 . . LABEL, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 602 387 . . CHAIN, weldless 2/0 x 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 605 227 . . NUT, 750-14 knurled 1.68dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . PLG1 . . . 181 072 . . CORD SET, 250V 6-50P 12ga 3/c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 111 443 . . BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . GS1 . . . 125 785 . . VALVE, 24VAC 2 way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 180 916 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 203 417 . . AXLE, running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 186 758 . . WHEEL, rubolene 10in dia x 2.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . 602 250 . . WASHER, flat .812 ID x 1.469 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . 121 614 . . RING, rtng ext .750 shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . Z . . . . . *180 989 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . TP2 . . . 163 266 . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 008 999 . . CASTER, swvl 4.00 in plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . T1 . . . . 180 925 . . TRANSFORMER, power main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 180 924 . . PANEL, side lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . S2 . . . . 153 197 . . SWITCH, selector 6 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . RC2 . . . 048 282 . . RECEPTACLE W/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . S1 . . . . . 124 511 . . SWITCH, tgl DPST 40A 600VAC scr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 180 917 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 148 956 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 057 357 . . BUSHING, snap-in nyl .937 ID x 1.125mtg hole . . . . . . . . . . . . . . . . . . . . . 2
. . . 31 . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . R1 . . . . 035 897 . . POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . 200 033 . . LABEL, nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 147 571 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . 130 750 . . CLAMP, work 300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 600 318 . . CABLE, weld copper (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10ft
. . . . . . . . . . . . . . . . . . . 203 388 . . REGULATOR/FLOWMETER, 10–50 cfh . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 144 108 . . HOSE, gas 5ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*When ordering stabilizer 180 989, also order thermostat 163 266.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1313 Page 33
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. Hardware is common and
not available unless listed.
ST-801 631-D
Figure 7-2. Center Baffle w/Components
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-2. Baffle, Center w/Components (Fig 7-1 Item 4)
. . . 1 . . . . . . . . . . . . . 058 427 . . RING, retaining spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 085 980 . . NUT, 625-11 .94 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 605 941 . . WASHER, flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 186 437 . . SPRING, cprsn .84500 x .110W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 057 971 . . WASHER, flat .632 ID x 1.500 OD x .12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 057 745 . . SPRING, cprsn 2.430 OD x .90 wire x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 186 435 . . HUB, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 186 436 . . WASHER, brake plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 180 915 . . BAFFLE, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . C6 . . . . 191 385 . . CAPACITOR ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 191 374 . . . . CAPACITOR, elctlt 30000uf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 12 . . . . . . . . . . . . . 191 101 . . . . BUSS BAR, positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 191 102 . . . . BUSS BAR, negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 188 846 . . . . SCREW, .010-32 x .50 hex hd-slt S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 15 . . . . . . . . . . . . . 083 147 . . . . GROMMET, scr No. 8/10 panel hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 16 . . . . . . . . . . . . . 180 927 . . REEL SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 057 358 . . BUSHING, snap-in nyl 1.000 ID x 1.375mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . R2 . . . . 091 685 . . RESISTOR, WW fxd 50W 25 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . W . . . . 189 486 . . CONTACTOR, def prp 40A 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . PC1 . . . 171 986 . . CIRCUIT CARD ASSEMBLY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . 165 745 . . HOUSING & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 134 201 . . STAND-OFF SUPPORT, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 23 . . . . CB2 . . . 180 912 . . CIRCUIT BREAKER, man reset 5A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . CB1 . . . 183 492 . . CIRCUIT BREAKER, man reset 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 097 421 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 097 416 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . CR1 . . . 072 817 . . RELAY, encl 24VAC DPDT 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . Fig 7-4 . . DRIVE ASSEMBLY, wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 115 093 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC3 . . . 131 059 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 196 318 . . COVER, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 196 894 . . BRACKET, consumable/tool tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 202 449 . . PLATE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1313 Page 35
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Item
No.
Part
No.
Description
Quantity
169 589
Figure 7-3. M-15 Gun (Fig 7-1 Item 36)
. . . 1 . . . . . 169 715 . . NOZZLE, slip type .500 orf flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . ♦087 299 . . TIP, contact scr .023 wire x 1.125
. . . 2 . . . ♦000 067 . . TIP, contact scr .030 wire x 1.125
. . . 2 . . . ♦000 068 . . TIP, contact scr .035 wire x 1.125
. . . 2 . . . ♦000 069 . . TIP, contact scr .045 wire x 1.125
. . . 3 . . . . . 169 716 . . ADAPTER, contact tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . 170 470 . . RING, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . 169 718 . . TUBE, head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . 169 738 . . NUT, locking handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . 194 524 . . NUT, jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . 169 737 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . 169 741 . . STRAIN RELIEF, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . 180 433 . . CORD, trigger assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . 079 974 . . O-RING, .500 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . ♦194 010 . . LINER, monocoil .023/.025 wire x 15ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . ♦194 011 . . LINER, monocoil .030/.035 wire x 15ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . ♦194 012 . . LINER, monocoil .035/.045 wire x 15ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . 079 975 . . . . O-RING, .187 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . 196 255 . . SWITCH, trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8
2
1
3
5
9
10
15
11
12
16
17
13
14
9
11
12
800 792-B
Figure 7-3. M-15 Gun
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
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Item
No.
Part
No.
Description
Quantity
Figure 7-4. Drive Assembly, Wire (Fig 7-2 Item 29)
. . . 1 . . . . . . . . . . . . . 196 237 . . MOTOR, gear 24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 180 929 . . HOUSING, motor drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 198 789 . . DRIVE ASSEMBLY, wire (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 196 895 . . . . KNOB, tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 090 415 . . . . SPRING, cprsn .695 OD x .080 wire x 1.500 . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 198 080 . . . . CUP, spring 185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 085 242 . . . . FASTENER, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 090 416 . . . . PIN, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 124 817 . . . . HOUSING, wire drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . 090 443 . . . . BEARING, ball rdl sgl row .315 x .866 x .27 (consisting of) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 111 622 . . . . . . SPACER, bearing .196 ID x .310 OD x .500 collar . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 112 031 . . . . LEVER, pressure roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 151 828 . . . . PIN, cotter hair .054 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 124 778 . . KNOB, T 2.000 bar w/.312-18 st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 174 609 . . SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 15 . . . . . . . . . . . . . 090 423 . . ROLL, drive V groove .023-.035 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 058 549 . . GUIDE, wire inlet 1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 010 224 . . PIN, spring CS .187 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1
2
. Hardware is common and
not available unless listed.
4
5
6
3
7
8
9
10
11
12
Includes
Items
13, 16, 17
17
13
16
14
15
ST-181 053-A
Figure 7-4. Drive Assembly, Wire
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1313 Page 37
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Effective January 1, 2000
(Equipment with a serial number preface of “LA” 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.
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 185 & Spoolmate 250
Canvas Covers
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.
Your distributor also gives
you ...
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.
Service
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
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.
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.
1. 5 Years Parts – 3 Years Labor
*
*
Original main power rectifiers
Inverters (input and output rectifiers only)
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.
2. 3 Years — Parts and Labor
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
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.
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
3. 1 Year — Parts and Labor
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
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
Grids
Maxstar 140
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
Spot Welders
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
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.
*
Field Options
(NOTE: Field options are covered under True
Blue for 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
Induction Heating Coils and Blankets
miller_warr 7/00
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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
to locate 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
Contact the Delivering Carrier for:
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
2001 Miller Electric Mfg. Co. 1/01
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