Miller 4880 CONTROL/FEEDER AUTO ARC Owners manual

October

1974

FORM:

OM-1500

Effective

4880

CONTROL/FEEDER

.030

flux

with

MODEL

hard

.045

hard

1/16

hard

1/16

cored

5/64

cored

serial

&

wire

.035

wire

No.

HE735320

STOCK

078

NO.

026

027

028

029

030

ADDITIONAL

50

PRICE

AUTO

COPY

CENTS

MODEL/STOCK

NO.

OWNERS

MILLER

APPLETON,

SERIAL/STYLE

NO.

MANUAL

ELECTRIC

WISCONSIN,

NWSA

CODE

NO.

PURCHASED

DATE

ARC

MFG.

USA

4579

CO.

54911

~.

~,s

-

C

Paragraph

SECTION

No.



INTRODUCTION

1

TABLE

OF

CONTENTS

Page

No.

SECTION

General

-1.

1

-

2.

1

Receiving-Handling

-

3.

1

Description

Safety

1:4.

INSTALLATION

2

Location

2-1. 2-

2.

Shielding

115

Gun

Weld

Electrode

Drive

Upper

Hanging

Wire

1.

Welding

FUNCTION

3

Wire

1. Circuit

Purge

Advance

Burnback

PilotLight

Volts

Switch

Cable

Roll

Spool

Speed

Switch

2-3.

2-4.

2-5. 2-6.

-

2

7.

-

8.

2

2-9. 2-10.

2-1 2-12.

-

3

-

3 3-3.

-

3 3-5. 3-6.

2.

4.

Connections

Gas

AC/Contactor

Receptacle

Connections Wire Wire

Installation

Drive

Roll

Bail

Positioning

Installation

Wire

Threading

Control

Breaker

Switch

Control

Outlet

&

Inlet

Alignment

CONTROLS

OF

Control

Connection

Guide

Outlet

Connections

Installation

1 1 1

1

2 2

2

3 3 3

4

5 5

5 5 5

SECTION

PARTS

-

4 4-2.

LIST



4

SEQUENCE

Metal-Arc

Gas

1.

Shutting



TROUBLESHOOTING

5

Down

OPERATION

OF

Welding

5

SECTION

-

1

INTRODUCTION

1

GENERAL

-1.

This

manual

izing

tenance,

tion

presented

assure

1

-2.

RECEIVING-HANDLING

Prior

from

that

may

or

damage

the

purchaser

and

freight

occasion

When

essential

Serial

-

1

3.

DESCRIPTION

This

control/feeder

is

and

potential

The

control/feeder

bining assembly.

to

supply

1

-4.

SAFETY

Caution

has

been

personnel

optimum

to

around

requesting

(or

designed

both

with

and

troubleshooting

herein

performance

installing

the

Unit

have occurred

that

may

with

bill

will

file

claim

to

information

that

Model

Number

Style)

to

welding

It

contains

the

power

wire

welding

shouldbeexercised

Electrode Dia.

Fraction

prepared

the

design,

should

this

equipment,

and

during

have

the

carrier.

be

furnished

arises.

Description

of

is

of

be

used

source.

is

a

heavy

feeder

all

the

and

wire

Wire

Capability

-

.030

5/64

especially

installation,

of

this

equipment.

be

carefully

occurred

the

shielding

careful

given

of

this

equipment.

clean

all

inspect

shipment.

A

by

concerning

in

copy

the

and/or

transit

of

carrier

this

Any

Stock

equipmentbeSupplied.

constant

in

and

controls

in

wire

conjunction

wire

duty

the

control

and

gas

taking

voltage

to

Electrode

Feed

50

to

Figure

for

in

use

operation,

All

consideration

packing

for

any

claims

must

be

the

bill

on

equipment,

Number

feed

speed

with

a

feeding

in

a

equipment

the

welding

measurements

Speed

700

familiar

informa

material

damage

for

filed

of

lading

request

constant

unit

compact

needed

Wire

Control

Voltage

ipm.

1-1.

Specifications

main

to

loss

by

if

it is

and

type

com

gun.

Circuit

Gun

At

24

Volts

when

tween

of

part

The

following

NOTE

and

~Ilation,

practices,

loss



Installation,

practices,

ment.

Installation,

practices.



Overall

Dimensions

(Inches)

-

21

Height

-

Width

Depth

troubleshooting

any

the

of

10

-

23

of

the

part

control/feeder.

definitions

found

blocks

operating,

which

etc.,

life

if

not

carefully

r~i

operating,

which

etc.,

operating,

which

etc.,

Weight

(Pounds)

Net

44

the

unit.

human

apply

throughout

CAUTION

and

will

followed.

and

will

NOTE

and

essential

it

is

Ship

58

Always

body

to

CAUTION,

maintenance

result

maintenance

result

maintenance

avoid

and

current

any

this

in

to

IMPORTANT,

manual:

procedures,

personnel

procedures,

damagetoequip

procedures,

emphasize

contact

carrying

injury

be

or



I

2-1.

LOCATION

Refer

to

trol/feeder.

the

control/feeder.

located

near

installed

should

be

Figure

Lead

the

on

top

allowed

2-1.

2-1

of

for

dimensional

be

must

lengths

If

the

welding

the

work

for

the

area,

welding

making

control/feeder

power

necessary

Control/Feeder

SECTION

information

considered

power

source.

connections.

Dimensions

when

source

can

Suitable

N

TC-078

2-

the

con

on

installing

can

usually

space

027-3

INSTALLATION

2-2.

be

2-3.

SHIELDING

15

foot

A

Connections

trol/feeder.

disconnect

the

rear

of

the

end which

attaches

threading.

The

shielding

attached

control/feeder.

the

115

VOLTS

NECTIONS

The

115

cable

pole

on

volts

are

plug

the

rear

control/feeder

The

and

ready

connected

is

hose

Attach

connector

panel

gas

the

to

both

istobe

panel

between

hose

gas

(Figure

ac

to

CONNECTIONS

GAS

is

supplied

the

endofthe

it

on

of

control/feeder.

the

to

hose

the

This

shielding

which

gas

connector

to

shielding

AC/CONTACTOR

3-1)

input

power

attached

secured

of

operate

the

to

the

to

control/feeder.

CAUTION

will

as

115

with

the

shielding

the

to

comes

connector

cable

a

five-pole

into

the

be

electrically

soon

volts

ac

(Figure

control/feeder

source

gas

hose

gas

shielding

Connect

source.

gas

source

gas

from

the

on

has

right-hand

CONTROL

the

contactor

and

female

five-pole

she

115

as

source.

gas

the

hot

with

The

front

plug.

male

volts

and

connector

has

3-1)

for

making

the

quick

the

opposite

connector

left-hand

istobe

gun

panel

threading.

CON

control

This

receptacle

internally

ac

plug

con

on

of

five-

I

OM-1500

Page

1

The

115

volts

ac

the

contactor

the

three

by

115

volts

of

capable

The

contactor

These

two

on

facility

conjunction

type

is

necessary

volts

the

gun

2-4.

GUN

SWITCH

A

four-prong

of

the

control/feeder

the

unit.

is

threaded

2-5.

WELD

CABLE

A

is

bolt

as

a

junction

the

welding

1 i

I I

Ensure

terminals

the

boltonthis

above

result.

leads

cable

ac

supplying

leads

the

welding

that

operates

ac

through

switch

female

Ensure

completely

provided

point

power

ii

that

are

conditions

input

control

extending

must

115

control

are

to

con

with

because

the

is

closed.

RECEPTACLE

receptacle

that

CONNECTIONS

on

for

source

the

contacting

kept

terminal

is

cable

power

cable

(both

from

be

connected

volts60hertz

cable

has

be

connectedtothe

source.

power

jirc

jy

this

control/feeder

115

volts

on

the

control/feeder

contactor

for

connecting

the

securing

the

onto

can

cables

the

two

60

control

(Figure

is

provided

ring

Gun

be

distinguished

being

volts

115

an

to

electrical

leais

extending

thatis

must

Hertz

will

cable

on

the

gun

the

on

Switch

contactor

to

3-1)

Receptacle.

(Figure

the

front

of

the

drive

assembly

weld

joining

and

clean

not

at

met,

together

the

surfaces

all

is

secure.

erratic

gun.

times.

of

If

weld

the

Also

either

current

10

ac

outlet

be

power.

supply

whenever

the

switch

gun

3-1)

weld

ensure

one

feet

cable.

power.

used

of

front

switch

cables

cable

of

could

which

from

control

in

the

This

115

plug

to

that

the

from

long)

The

it.

J

panel

to

plug

serve

from

the

on

Securing

Gun

flat

the

Gun

Securing

securing

(1)

(point

Gun

2-6.

into

Wire

point

inlet

the

CONNECTION

Electrode

control/feeder:

Knob

turns.

Connector

of

side

outlet

guide

Connector

Knob

OUTLET

screw

first)

Connector

the

drive

Connector.

screw

first

assembly

(8).

(7).

into

Gun

screw

guide

(7).

screw

Wire

fully

the

hole.

90

as

(item

into

the

(2)

Gun

in

a

connector

degrees

far

GUIDE

8,

the

inlet

seats

(Fig

Con

counter

into

it

as

Figure

outlet

drive

until

guide

against

the

in

will

IN

a

it

OUTLET

follows

as

drive

the

Gun

direction

Electrode

the

guide

roll

the

Electrode

direction.

Gun

the

outlet

the

outlet

hole

in

the

Electrode

instructedinitem

as

the

outlet

the

outlet

the

inlet

the

assembly.

inlet

the

WIRE

to

assembly

Connector

four

hole

with

inside

Connector

direction.

WIRE

(Figure

guide

the

drive

guide

Electrode

guide

flange

guide

install

complete

Wire

of

Wire

INLET&

2-2)

assembly.

Wire

(1)

securing

(2)

on

securing

ELECTRODE

2-6.

is

ure

Proceed

nector

1.

Rotate

clockwise

Insert

2. outlet

3-1)

into

facing

Rotate

3.

clockwise

Rotate

4.

inaclockwise

turn

2-7.

ELECTRODE

STALLATION

1.

Loosen

2-2).

Insert

2.

guide

3.

Install

assembly

4.

Push

seats

against

5.

Tighten

6.

Loosen

Insert

7.

I

8.

until

hole the

drive

Tighten

Gun

Adjustment

Connector

Pressure

Knob

Pressure

Collar

Securing

Knob

Upper

Mounting

2

Drive

6

Bracket

Roll

TC-078

027-2

Page

2-2.

Drive

Figure

2

Roll&Wire

Guide

Installation

the

Pivot

2

2-10.

Bolt

8.

on

to

collar

9.

UPPER

The

upper

facilitate

to

with drive

erratic

changed.

roll,

hole

drive

the

grooves

aligned. alignment.

follows

1.

Loosen the

2.

Using

3.

Using

required.

move

tion

When

4.

securing

Pivot

5.

on

tighten

HANGING

The

positions pended hanging

control/feeder

suspend

hangling

Loosen

the

roll

ing

Remove

and

ROLL

the

pressure

mounting

bracket

the

flat

washers

INSTALLATION

pressure

adjustment

bracket.

up.

thumb

two

from

(4)

adjustment

assembly

Swing

screws

drive

the

knob

the

(6),

(Figure

and

off

of

drive

upper

-

lock

split

shafts.

roll

2-2)

collar

the

and

upper

roll

washer

mount

pivot

drive

(5),

2

-8.

DRIVE

1.

2.

NOTE

Prior

supplied

shaft.

3.

Slide

4.

Insert

of

(6)

Slide

5. shaft.

Insert

6.

(4)

into

7.

Lower

teethinthe

The for feeder.

given

be

the



the

into

onto

the

pressure

proper

just

wire.

to

the

installing

key

keyed

a

split-lock

thumb

two

the

lower

un-keyed

the

remaining

thumb

upper

the

upper upper

tension

The

of

set

welding

tight

the

drive

screw

drive

lower

roll

washer

screws

drive

split-lock

roll

drive

lower

and

isinthe

I

adjustment

priortooperation

amount

of

conditionstoanother

to

enough

Adjustment

Nut

drive

roll,

in

(9)

(5)

(6)

roll

and

the

onto

flat

and

install

and

(3)

onto

washer install

mounting

drive

the

washer

rolls

groove

shaft.

(6)

shaft.

roll

NOTE~]

will

have

will

drive

knob

pressure

prevent

lower

the

roll

ensure

lower

the

(5)

thumb

bracket

mesh

to

the

of

vary

that

drive

(4)

thumb

upper

flat

and

together.

be

adjusted

control/

from

should

and

slippage

onto

drive

screw

until

the

roll

shaft.

screw

washer

one

on

one

roll

(6)

the

U

Outer

Securing

top

the

DRIVE

upper

drive

respect

roll

wire

remove

in

the

on

Figure

to

upper

will

top

in

bail

the

pressure

of

desired

by

rotating

drive

roll,

alignment

to

should

feedisnoted

To

check

the

drive

rolls

the

If

adjust

the

9/16

a

the

move

proper

bolt

the

of the

BAIL

which

either

is

control/feeder

drive

the

amount

the

ROLL

roll

be

can

the

groove

checked

be

for

outlet

assembly.

it

should

and

upper

2-3

shows

drive

the

upper

pressure

roll

drive

wrench,

5/8

wrench,

Rotating

roll

drive

the

alignment

lock

to

pressure

the

upper

collartothe

POSITIONING

bail

supplied

will

a

shipped

be

to

Outlet

adjustment

roll

knob

mounting

moved

of

proper

guide

be

rolls

adjustment

mounting

the

outward

drive

the

adjustment

drive

permit

horizontal

in

suspended

Guide

assembly

and

cover

of

pressure.

until

ALIGNMENT

bracket,

on

a

the

groove

in

the

lower

for

proper

whenever

or

alignment

look

and

viewing

Upon

that

noted

lower

drive

examples

not

are

roll:

drive

bracket.

loosen

the

rotate

adjustment

and

roll

inward.

is

achieved,

drive

roll

assembly

roll

mounting

desired

with

this

the

or

the

position

vertically.

horizontally,

Hole

then

Lock

it

contacts

(Figure

horizontal

in

the

drive

alignment

the

of

into

the

outer

rolls

should

of

proper

in

alignment,

collar

and

outer

securing

the

adjustment

nut

counterclockwise

tighten

in

position.

amount

control/feeder

vertical

which

procedd

View

upward tighten

the

setting

the

which

plane

upper

roll.

drive

the

outlet

the

groove

edges

be

and

pivot

clockwise

upward

bracket

of

pressure.

position.

will

If

it

is

untilitis

the

collar.

2-3)

holds

in

drive

The

whenever

rolls

upper

between

precisely

improper

proceed

it

bolt.

the

until

and

has

be

to

permit

desired

follows:

as

collar

of

order

upper

drive

guide

of

off

nut

rota

outer

then

the

roll

are

the

will

it

two

sus

The

the

as

of

as

is

to

Drive

Roll

Grooves

Figure

2-3.

Upper

Drive

Roll

Counter-

clockwise

Rotation

Adjustment

Nut

Alignment

Required

of

Proper

Alignment

Clockwise

Rotation

Adjustment

Nut

Required

TC-07g

of

027-2

OM~1500

Page

3

2-11.

2-12.

1.

Remove

wire

2.

Tilt

mately

hanging

mounting

3.

Install

WIRE

1.

Remove

the

2.

Slide will direction,

3.

Rotate

with

Ensure

spindle.

4.

Rotate

direction

spool.

WELDING

1.

2.

the

spool

the

hanging

60

bail

bracket

the

two

SPOOL

the

retaining

the

spool

off

pay

the

protruding

that

the

until

WIRE

Install

in

item

Loosen

of

the

upper

two

9/16

spindle

mounting

bail

or

degrees

into

come

not

9/16

INSTALLATION

retaining

in

a

ring

of

wire

from

the

until

spool

the

spool

retaining

the

THREADING

the

wire

2-11.

the

pressure

drive

bolts

from

bracket.

in

clockwise

a

until

the

view

through

previously

bolts

removed

from

ring

counterclockwise

onto

the

bottom

of

the

hole

in

the

is

seated

onto

ring

retaining

spool

roll

ring

onto

adjustment

mounting

two

used.

the

spindle

the

in

flange

against

the

spindle

the

rear

direction

mounting

the

two

in

step

spindle

direction.

so

spool

the

spool

of

the

is

seated

spindle

collar

and

bracket.

sideofthe

approxi

holesinthe holes

1.

by

the

that

in

clockwise

a

hub

the

flange

in

clockwise

a

against

instructed

as

pivot

in

the

rotating

wire

aligns

spindle.

of

the

it

off

3.

Cut

wire

4.

Install

in

5.

Check

instructedinitem

6.

Feed

tinue

approximately

outlet

7.

Lower

teethinthe

8.

Pivot

it

Tighten

ximate

Precise

bly

9.

Connect

feeder

10.

Connect

the

11.

Lay

12.

Depress welding

current

Switch

approximately

item

is

off

which

on

will

Gun

the

any

is

the

Electrode

2-6.

the

upper

the

welding

feeding

guide.

the

upper

the

pressure

of

top

the

pressure

amount

adjustment

have

to

the

into

a

the

Switch

cable

gun

the

wire

the

on

after

portion

not

straight.

drive

2-9.

wire

the

wire

four

drive

and

adjustment

the

upper

of

pressure

of

be

made

Volts

115

Volts60Hertz

115

Switch

Receptacle

out

ADVANCE

through

welding

the

end

inch

one

free

of

the

Wire

Gun

for

roll

the

into

inches

of

roll

mounting

lower

drive

adjustment

desired

the

pressure

when

AC

Control

on

straight.

Switch.

the

gun

wire.

of

the

of

out

endofthe

Connector

proper

inlet

the

outlet

welding

bracket

rolls

assembly

roIl

mounting

collar

on

adjustment

welding

from

cable

source.

from

Plug

the

control/feeder.

This

without

Release

welding

the

gun

at

alignment

guide

guide.

wire

mesh

upward

for

the

drive

the

commences.

the

will

placing

the

ADVANCE

wire

tip.

welding

explained

and

con

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into

the

until

the

together.

until

bracket.

appro

rolls.

assem

control/

into

gun

the

run

weld

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as

weld

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Bolt

Wire

Speed

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Pressure

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Bail

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Collar

SECTION

3-FUNCTION

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Wire

CONTROLS

Spool

Spindle

/

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/5

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In

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AC/Contactor

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Page

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4

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TC-078

027-1

3-1.

3-2.

3-3.

3

-

4.

WIRE

SPEED

The

Wire

Speed

at

which

rate

Wire

the

0,

will

rate

wire

feed

Speed

of

will

ata

CIRCUIT

A

circuit

event

the

breaker

PURGE

of

the

breaker,

provides

the

breaker

SWITCH

the

gun.

without

feeder,

the

tion,

this

reset.

PURGE

The

trol/feeder.

energize

line

adjusted

ADVANCE

The

ADVANCE

control/feeder

actuated

to

threading

depress

it

complates

the

of

CONTROL

Control

welding

Control

wire

feed.

feed

atarate

rate

of

BREAKER

protection

motor

would

it

trip,

Switch,

is

a

momentary

shielding

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also

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is

a

gun

the

wire

(Figure

provides

wire

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in

clockwise

a

When

the

of

50

700

1PM.

(Figure

locatedonthe

to

should

would

(Figure

the

be

placed

and

trip

have

3-1)

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contact

solenoid

gas

the

allows

the

welding

(Figure

located

actuated

spring

the

circuit

switch.

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at

whatever

3-1)

means

a

fed

into

direction

Wire

Speed

when

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3-1)

rear

panel

control/feeder

in

an

suspend

be

to

manually

front

switch.

and

purge

shielding

circuit.

3-1)

front

the

on

toggle

the

to

motor

switch

will

setting

of

determining

the

weld.

will

Control

set

at

of

the

circuitry.

overloaded

all

output.

depressed

panel

This

the

shielding

regulator

gas

panel

switch.

without

permit

the

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the

10.

control/

of

the

switch

inching

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the

increase

is

set

wire

condi

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con

will

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to

of

the

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having

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without

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contactor

3-5.

3-6.

BURNBACK

The

means

piece

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depending

keep

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action whereitwill

tube.Ifthe

after

trol

welding

released,

to

PILOT

A feeder

light

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If

source

circuit

at

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to

be

or

is

or

burnback

of

keeping

the

or

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weld

of

second

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will

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gun

to

a

setting

wire

rotate

10

the

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pilot

lightisprovided

to

will

intoa115

115

the

and breaker

at,

the

contact

burnback

upon

current

permit

neither

welding

switch

sticks

second)

indicate

be

on

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the

valve.

gas

CONTROL

circuitry

the

welding

tube

the

present

after

the

stick

wire

is

closer

to

the

BURNBACK

(Figure

when

for

as

Volts60Hertz

AC

plug

pilot

light

the

on

rear

energizing

capability

setting

wire

welding

stickstothe

released,

to

the

position.

long

is

(Figure

in

this

wire

in

the

of

the

on

has

wire

the

to

rotate

the

0

(1/4

workpiece

3-1)

the

on

unit

the

as

connected

not

lighted,

is

panel

the

welding

3-1)

control/feeder

from

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after

this

control/feeder

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feeding.

to

burn

contact

the

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second)

after

to

panel

is

operational.

115

to

a

this

the

wire

the

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indicates

gun

in

the

welding

stopped

workpiece

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front

the

source.

open.

power

provides

the

to

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from

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back

to

the

nor

in

tube

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switch

gun

a

setting

of

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source

work-

switch

will.

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1/4

delay

a

point

contact

the

gun

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the

closer

control/

pilot

plug

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60

that

the

a

is

to

is

eye

on.

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roll

trouble

for

position.

-

4

SEQUENCE

2

setting.

protective

protection

Failure

to

bodily

will

start

to

pressure

is

5-TROUBLESHOOTING

is

still

reference

which

has

should

not

remedied,

during

problems

condition

OF

SHUTTING

4-2.

1.Turn

2.

3.

occur

may

achieved

been

be

adhered

strictly

it

troubleshooting.

OPERATION

properly

noticed,

clockwise.

pressure

The

welding

are

energized

wire

or

off

Remove

off

Turn

in

this

control/feeder.

and

has

recommended

is

adjusted

tighten

adjustment

any

DOWN

the

all

been

and

to

the

Repeat

wire

and

while

metal

part

shielding

Volts

115

associated

used

followed.

that

to

prevent

pressure

until

slippage

collar

too

CAUTION

all

metal

welding.

making

the

at

gas

AC

cable

equipment.

until

trouble

a

serviceman be

slippage.

adjustment

stops.

much.

parts

Do

touch

not

contact

source.

from

developed.

called.

in

the

If

contact

with

wire

collar

Do

the

source.

not

welding

it.

In

slippage

turn

1/2

tighten

it

with

all

cases

is

of

SECTION

4-

1.

GAS

1.

2.

3.

4.

5.

flow

Set

clothing

comply

damage.

Depress

METAL-ARC

Make

all

of

this

manual.

Rotate

the

Press

the

Prior

to

(glasses

and

necessary

BURNBACK

PURGE

welding,

(welding

and/or

may

the

wire

Wire

result

trigger

WELDING

connections

Speed

Switch

it is

coat

welding

on

will

start

Control

for

imperative

and

gloves)

helmet)

in

serious

the

gun

feed

to

as

instructedinSection

to

the

desired

in

the

desired

10

seconds.

that

proper

and

be

put

or

permanent

handle.

if

drive

SECTION

The

1.

The

equipment

If

It

data

assumption

after

performing

is

recommended

collected

of

malfunction,

here,

this

the

that

discusses

is

data

hianufacturers

the

following

the

circuit

of

some

that

a

proper

procedures

diagram

the

common

welding

recommendations

the

used

be

Depressing

energize

wire

gas

control/feeder.

is

not

does

not

TROUBLE

switch

gun

energized

flow.

and

will

not

Electrode

shielding

Circuit

Plug

Switch

115

tacle.

breaker

from

Receptacle

volt

ac

PROBABLE

tripped.

switch

gun

input

CAUSE

is

on

control/feeder.

cable

is

REMEDY

reset

circuit

into

breaker

Gun

vac

by

depressing.

Switch

Receptacle

receptacle.

OM-1500

Page

5

Manually

secure

in

recep-

not

Gun

Insert

and

Secure

plug

tighten.

cable

~

fully

leadsto115

Wire

feeds,

but

electrode

energized.

Wire

feeds

is

Motor

shielding

wire

erratically.

inoperative.

gas

flows,

is

not

Contactor

contactor

Defect

Pressure

Drive used.

Worn

Dirt

in

Worn

Motor

plug

in

welding

on

rolls

drive

brushes.

plug

Control

terminals.

drive

are

roll.

roll

not

secure

cable

power

rolls

too

groove.

leads

source.

is

insufficient.

for

large

in

receptacle.

wire

not

secure

size

being

on

Secure

leads

See

troubleshooting

instruction

source

Rotate

pressure

increments

turn

1/4

to

Change

drive

Replace

Clean

drive

motor

Replace

Tighten

motor

to

proper

roll.

plug

manual.

adjustment

size

roll

gear.

brushes.

plug.

terminals.

section

until

wire

drive

See

in

knob

slippage

roll

section

~

welding

clockwise

gear.

2-8.

power

in

stops.

p

Page

Figure

5-1.

Circuit

Diagram

Circuit

Diagram

No.

B-002

752

.1

6

October

1974

FORM:

OM-1500

Effective

4880

flux

with

serial

MODEL

CONTROL/FEEDER

.030

&

.035

hard

wire

.045

hard

wire

1/16

hard

wire

1/16

cored

wire

5/64

cored

wire

No.

HE7

35320

STOCK

078 026

078

NO.

027

028

029

030

MODEL/STOCK

AUTO

NO.

SERIAL/STYLE

PARTS

MILLER

APPLETON,

ELECTRIC

WISCONSIN,

NO.

LIST

ARC

MFG.

USA

DATE

CO.

54911

PURCHASED

4

NWSA

CODE

NO.

4579

Figure

027

TC-078



A

Main

Assembly

OM-iSGO

Page

1

Item

No.

Factory

Part

No.

Description

Quantity

Figure

1 2

3

4 5

6

7

8

9 10 11

12

13 14 15

16

17

18

BE

SURE

A

075

602

604 075446

075449

074

075 158

075159

074891

075

075 510

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605

075 150 010 078

075

TO

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314 224

657

932

152

246 620

336

910

368

056

Main

Assembly

MOTOR

&

WASHER, SCREW,

BASE

cap

BAIL,hanging

SHAFT,

HUB,

.HUB

.COLLAR

support

with

WASHER,

WASHER, WASHER,

SCREW, SCREW,

thumb self

WASHER,

MODULE,

INSULATOR,

STOCK,

MODEL,

DRIVE

-

steel

lock

-

steel

-

hub

collar

(consisting

flat-steel steel-lock

flat-steel

1/2.13

tapping

shoulder fiat-steel

control

motor

AND

ASSEMBLY

split

hex

hd

keyed

split

1/2

x

round

-

nylon

SAE

Fig.CPage

(See

drive

&

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(See

3/8

3/8-16x1-1/4

of)

ID

1-1/64

1

inch

1

inch

hd

10-32

3/8

6)

assembly

NUMBERS

Fig.

x

3/8

B

1-5/8

Page

OD

WHEN

4)

ORDERING

REPLACEMENT

1 5

5

1

1 1 1

1 1

1

6

3 3 1

1

PARTS.

OM-1500

Page

2

Page

1

TC-075

314



B

Motor

&

Figure

Drive

Assembly

3

Item

No.

Factory

Part

No.

Description

Quantity

Figure

26 27 28 29 30 31 32 33 34 35 36 37 38

39

40 41

42

43

44

45

46

47 48 49 50 51

52

53 54

55

56

57

58 59 60

61 62 63 64

65

66 67 68 69 70 71

72

73

74

75

76

77 78 79 80

B

075

075 073 702 078

073

073 073 073

077 073

*073

073

075

073

073 074

073 602 075 057

077

073 334

010 074

604 602 073

605

602 074

074

075 075 056

073 073 073 073 074 073

075

602

079

075 078 078 078

601

602 213

078

075 305

073

078 462

074

073

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314

316

671

597

762 763 593 214

595

591 596 069

296

264

696

911

514

243

318

910 905

538

211

707

209

221

811

865

532 058 068 309 268

774 240 859 694 099 008 256

553

685

687

672

965

686

703

776 701 224

Motor&Drive

MOTOR,

GEAR, PIN,

drive

miter

spring

BEARING

FIELD

ASSEMBLY

ARMATURE



SPRING,



brushholder

HOLDER,

brushholder

CAP,



BRUSH,

BEARING



SHIM

CLAMP,



PLUG,

KNOB,

COLLAR,

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contact

cable

amphenol6pin

3/8-16

adjusting

compression

flat-steel

FASTENER, BREATHER,

HELl

COIL,

WASHER,

LEVER, WASHER,

WASHER, SCREW, SCREW,

WASHER, BUSHING, TUBING, SCREW, SHAFT, KEY, SEAL, BEARING,

SHIM,

RING,

TUBING,

KNOB

WASHER,

SCREW,

CLAMP,

SCREW, SCREW, WASHER,

PIN,

SCREW,

WASHER,

SCREW,

flat-steel

mounting

flat-steel lock-steel

thumb

cap

lock-steel

steel

pan

drive

steel

oil-drive

1-3/8

retaining

steel

cap

guide

pan

round

spring

cap

round

9/16-18

1/8x1/8

ball

steel

3/16

steel-lock

HOUSING,

GASKET,

SCREW,

COVER,

GEAR,

PIN,

motor

truss

bearing

drive

spring

Assembly

(consisting

3/32x1/2

brush

amphenol

thread

-

brass

(included

-

5/16-18

-

hex

hd

OD

5/8

hd

1/4-20

shaft

xl

OD

-

external

OD

7/8

27/32

-

socket

steel

(included

hd

1/4-20

12-28x3

hd

-

lock

x

7/8

-

steel

hex

12-28

hd

drive

(includes

-

hd

phillips

1

x

3/16

(See

of)

97-3057-12-6

97-3106A-20-17P

-

tension

3/8

vent

pipe

when

SAE

3/8

drive

gear

SAE

5/16

split

x

1/2

3/8-16

internal

NF

x

1-5/16

22

x

1/2

x

1/2

ID

.010

x

9/16

OD

x

hd

when

x

5/8

No.

split

hd

3/8-16

3/8

split

x

3/4

items

10-24

Fig.APage

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1/8

ordering

x

2-1/4

tooth

lg

x

7/32

ga

thick

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x

31/64

ID

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1/2-20

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12

1

x

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and

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75)

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1 2

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1

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1 1

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1

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BE

TO

Spare

PROVIDE

Parts

STOCK,

MODEL,

AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-1500

Page

4

Page

TC-078

368



Figure

C

Module,

Control

5

Item

No.

Dia.

Mkgs.

Factory

Part

No.

Description

Quantity

Figure

91 92

93

94 95 96

97 98

99

C

R22

RC2

R21 Ti

RC3

TR1

S2,3

CB1

R20

078

076 073 248

073

100

101

PLG3

102

103

104 105 106

t*075

073

107

108

109

110 111

112

113

114

115

056

010 056 073 073

073 073

116

117

118

GS1

073

074

119

120

121 122

123

R18,19

RC4

074

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124 074

125

126

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630

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439 362

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600 340 600

341

307 756

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606 112 150

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523 522 089

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951

861

604

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326

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188

Module,

Control

POTENTIOMETER,

RECEPTACLE, RESISTOR,

electrolytic

TRANSFORMER,

RECEPTACLE, RECTIFIER, SWITCH,

CIRCUIT

control

toggle

BREAKER,

POTENTIOMETER,

CABLE,

.

-

.

CIRCUIT

NUT, KNOB,

HOSE,

-

.

-

interconnecting

PLUG,

amphenol

CLAMP,

CORD,

portable

CORD,

portable

CARD

special

control

gas

NIPPLE,

brass-swivel

NUT,

FERRULE,

braided

HOSE, COUPLING,

CONNECTOR,

cable

6-32

-

interconnecting

brass

CONNECTOR, COUPLING,

NIPPLE,

VALVE,

SHIM,

NIPPLE,

BUSHING,

ADAPTER,

RESISTOR,

brass

115

solenoid

brass

gas

WW

volts

RECEPTACLE, RECEPTACLE, CASE,module LIGHT,

NAMEPLATE

indicator

Fig.

carbon

A

(See

amphenol

25

control

amphenol5pin

200

volts

20

SPDT

amp

manual

carbon

15

97-3106A-18-295

No.

16

2

16

No.

ASSEMBLY

-

hose

3

x

5/S

3/16

5/8-18

3/16ID7/16

quick

valve

pipe

1/4

-

brass fixed

1/8

pipe

-

ac

1/8

MPT

connect

1/8

close

1/8

x

1/8

1/8-18

60

1/8

NPT

watt

male

quick

pipe

-

amphenol

red

1/2

by

inch

lens

stock,

screw

-

(order

2 Item

Page

1

turn2watt

6

conductor

2.5K

watt

115

volts

primary

97-3102A-18-29P-639

5

amp

125

volts

5

reset

2

1

turn

ft

(consisting

conductor

(See

Fig.

ft

15

(consisting

hand

right

OD

(order

ID

3/16

-

brass

-

brass

FPT

MPT

3/32

port

12-1/2

reducer

male

5/8-18

2

ohm

97-3102-18-4S-639

hole

4

250

watt

1/3

model&serial

13)

50K

ohm

97-3102-20-175-639

ohm

3%

amp

50K

watt

ohm

of)

(orderbyfoot) (orderbyfoot)

Cl

Page

7)

of)

by

foot)

hose

male

female

1/8

1/4

MPT

FPT

orifice

inches

lg

female

volts

numbers)

1 1 1 1

1 1

2 1

1

15

ft.

15

ft.

1

4 2

1

1 2

15

ft.

1 1

1

1 1 1 1 1

1 2 1 1 1

1

*Recommended

tCircuit

BE

card

SURE

assembly

TO

PROVIDE

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Parts

is

available

STOCK,

on

an

MODEL,

exchange

AND

basis.

SERIAL

Contact

NUMBERS

Factory

WHEN

Service

ORDERING

Department

for

details.

REPLACEMENTS

PARTS.

OM-1500

Page

6

Dia.

Mkgs.

Cl

Figure

Cl

C2

C3,6

C4

C5

C7

C8

C9 CAL

Q1 Q2 Q3 Q4 Q5 Q6 Q7

R1,8,i0

R3

R4 R5,12

R6,9

R7,i1

Ri

4 R15 Ri

6

REC1,16

REC2,11

REC3 REC4

REC5,6,12,13

REC7,9

REC8

REC1O

REC14 REC15

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T3

Factory

Part

075

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No.

307

201

197 549

460

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740

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560 246 551

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CAPACITOR, CAPACITOR, CAPACITOR, CAPACITOR,

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DIODE,

10

THYRISTOR, THYRISTOR, THYRISTOR,

TRANSISTOR,

THYRISTOR,

RESISTOR,

RESISTOR, RESISTOR, RESISTOR, RESISTOR,

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15

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electrolytic

mylar

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ceramic

6

amp

volts

10

amp

6

amp

7

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ac

unijunction

35

amp

0.25

carbon

0.25

carbon

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carbon

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carbon

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carbon

1

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carbon

0.25

carbon

0.25

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volts

25

volts

400

volts

75

volts

600

volts

400

integrated

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18

200

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pulse

15

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amp

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volts

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polarity

Description

6

Item

105)

dc

Quantity

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Page

+Resistors

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OM-1500

Page

8