Miller 135, 175, M-10 User Manual

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OM-1324 204 408A

November 2001

Processes

MIG (GMAW) Welding Flux Cored (FCAW) Welding

Description

Arc Welding Power Source And Wire Feeder

Millermatic

135/175

And M-10 Gun

Visit our website at

www.MillerWelds.com

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System Standard.

help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Working as hard as you do – every power source from Miller is backed by the most hassle-free warranty in the business.

Miller offers a Technical Manual which provides more detailed service and parts information for your unit. T o obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMA W-P.

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.)

The following terms are used interchangeably throughout this manual: MIG=GMAW

OM-1324

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle And Overheating 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Volt-Ampere Curves 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Installing Welding Gun 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Installing Work Clamp 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Work Cable Routing Inside Unit 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Process/Polarity Table 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Changing Polarity 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Installing Gas Supply 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Selecting A Location And Connecting Input Power For 115 VAC Model 15. . . . . . . . . . . . . . . . .

3-8. Selecting A Location And Connecting Input Power For 230 VAC Model 16. . . . . . . . . . . . . . . .

3-9. Electrical Service Guide For 230 VAC Model 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Installing Wire Spool And Adjusting Hub Tension 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Threading Welding Wire 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Weld Parameter Chart For 115 VAC Model 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Weld Parameter Chart For 230 VAC Model 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – MAINTENANCE &TROUBLESHOOTING 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Overload Protection 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Drive Motor Protection And Tip Saver/Short Circuit Protection 24. . . . . . . . . . . . . . . . . . . . . . . .

5-4. Changing Drive Roll Or Wire Inlet Guide 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Replacing Gun Contact Tip 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Cleaning Or Replacing Gun Liner 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Replacing Switch And/Or Head Tube 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Troubleshooting Table 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – ELECTRICAL DIAGRAM 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – MIG WELDING (GMAW) GUIDELINES 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Typical MIG Process Connections 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Typical MIG Process Control Settings 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Holding And Positioning Welding Gun 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Conditions That Affect Weld Bead Shape 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Gun Movement During Welding 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Poor Weld Bead Characteristics 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Good Weld Bead Characteristics 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8. Troubleshooting – Excessive Spatter 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9. Troubleshooting – Porosity 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10. Troubleshooting – Excessive Penetration 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11. Troubleshooting – Lack Of Penetration 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-12. Troubleshooting – Incomplete Fusion 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-13. Troubleshooting – Burn-Through 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-14. Troubleshooting – W aviness Of Bead 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-15. Troubleshooting – Distortion 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-16. Common MIG Shielding Gases 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – PARTS LIST 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

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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.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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

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 grounded equipment is a hazard.

D Do not touch live electrical parts. D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on

unit.

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).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D 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 grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first – double-check connections.

D Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body.

power circuit and machine internal circuits are also

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.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section before touching any parts.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator. D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower th e oxygen level causing injury or death. Be sure the breathing air is safe.

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 Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

OM-1324 Page 1

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

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.

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).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

WELDING can cause fire or explosion.

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

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.

D Protect yourself and others from flying sparks and hot metal. D Do not weld where flying sparks can strike flammable material. D 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 Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

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).

D 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 Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

workpiece, and hot equipment can cause fires and

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed. D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away. D Wearers should consult their doctor before

going near arc welding, gouging, or spot welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

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 Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder – explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve. D 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.

OM-1324 Page 2

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

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.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained. D 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 Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts. D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D 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

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting 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

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according t o this manual.

D 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.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

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 Y ork, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-1324 Page 3

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Ma g netic Fields

Welding current, as it flows through welding cables, will cause electromagnetic 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.

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from operator as practical.

5. Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

OM-1324 Page 4

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT

UTILISATION

som _nd_fre 4/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

Y Identifie un message de sécurité particulier.

. Signifie NOTA ; n’est pas relatif à la sécurité.

1-2. Dangers relatifs au soudage à l’arc

Y Les symboles présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-4. Veuillez lire et respecter toutes ces normes de sécurité.

Y L’installation, l’utilisation, l’entretien et les réparations ne doi-

vent être confiés qu’à des personnes qualifiées.

Y Au cours de l’utilisation, tenir toute personne à l’écart et plus par-

ticulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les

tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger.

D Ne jamais toucher les pièces électriques sous tension. D Porter des gants et des vêtements de protection secs ne comportant

pas de trous.

D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres

moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.

D Ne pas se servir de source électrique àcourant électrique dans les zones

humides, dans les endroits confinés ou là où on risque de tomber.

D Se servir d’une source électrique àcourant électrique UNIQUEMENT si le

procédé de soudage le demande.

D Si l’utilisation d’une source électrique àcourant électrique s’avère néces-

saire, se servir de la fonction de télécommande si l’appareil en est équipé.

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal-

lation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

D Installer et mettre à la terre correctement cet appareil conformément à

son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

D Toujours v érifier la terre du cordon d’alimentation – Vérifier et s’assu-

rer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

D En effectuant les raccordements d’entrée fixer d’abord le conducteur

de mise à la terre approprié et contre-vérifier les connexions.

D Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas

endommagé ou dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution.

D Mettre l’appareil hors tension quand on ne l’utilise pas. D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

D Ne pas enrouler les câbles autour du corps. D Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct.

D Ne pas toucher l’électrode quand on est en contact avec la pièce, la

terre ou une électrode provenant d’une autre machine.

circuits internes de l’appareil sont également sous

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

D Porter un harnais de sécurité quand on travaille en hauteur. D Maintenir solidement en place tous les panneaux et capots. D Fixer le câble de retour de façon à obtenir un bon contact métal-métal

avec la pièce à souder ou la table de travail, le plus près possible de l a soudure.

D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact

avec tout objet métallique.

Il y a DU COURANT CONTINU IMPORT ANT dans les convertisseurs après la suppression de l’alimenta- tion électrique.

D Arrêter les convertisseurs, débrancher le courant électrique, et dé-

charger les condensateurs d’alimentation selon les instructions indiquées dans la partie entretien avant de toucher les pièces.

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.

D Eloigner votre tête des fumées. Ne pas respirer

D A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau

de l’arc pour l’évacuation des fumées et des gaz de soudage.

D Si la ventilation est insuffisante, utiliser un respirateur à alimenta-

tion d’air homologué.

D Lire les spécifications de sécurité des matériaux (MSDSs) et les

instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

D Travailler dans un espace fermé seulement s’il est bien ventilé ou en

portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.

D Ne pas souder dans des endroits situés à proximité d’opérations de

dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l ’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

D Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.

les fumées.

OM-1324 Page 5

LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses

des brûlures dans les yeux et sur la peau. Des étincelles sont projetées

pendant le soudage.

D Porter un casque de soudage muni d’un écran de filtre approprié pour

protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

D Porter des protections approuvés pour les oreilles si le niveau sondre est

trop élevé.

D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair

et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

D Porter des vêtements de protection constitué dans une matière dura-

ble, résistant au feu (cuir ou laine) et une protection des pieds.

(ultraviolets et infrarouges) susceptibles de provoquer

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.

D Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-

rateur d’adduction d’air homologué.

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

D Ne pas toucher des parties chaudes à mains nues D Prévoir une période de refroidissement avant

d’utiliser le pistolet ou la torche.

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être

les, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement o u u n incendie. A vant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

D Se protéger et d’autres personnes de la projection d’étincelles et de

métal chaud.

D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur

des substances inflammables.

D Déplacer toutes les substances inflammables à une distance de 10,7

m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

D Des étincelles et des matériaux chauds du soudage peuvent facile-

ment passer dans d’autres zones en traversant de petites fissures et des ouvertures.

D Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-

mité.

D Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

D Ne pas effectuer le soudage sur des conteneurs fermés tels que des

réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).

D Brancher le câble sur la pièce le plus près possible de la zone de sou-

dage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’élec- trocution et d’incendie.

D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

D En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

D Porter des vêtements de protection dépourvus d’huile tels que des

gants en cuir, une chemise en matériau lourd, des pantalons sans re- vers, des chaussures hautes et un couvre chef.

D Avant de souder, retirer toute substance combustible de vos poches

telles qu’un allumeur au butane ou des allumettes.

projetées de l’arc de soudure. La projection d’étincel-

DES PARTICULES VOLANTES peuvent blesser les yeux.

D Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent

lantes. Pendant la période de refroidissement des soudures, elles ris- quent de projeter du laitier.

D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

des étincelles et des particules métalliques vo-

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D Porteurs d e stimulateur cardiaque, restez à distance. D Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

D Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz

manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, du laitier, des flammes ouvertes, des étin- celles et des arcs.

D Placer les bouteilles debout en les fixant dans un support stationnai-

re ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.

D Tenir les bouteilles éloignées des circuits d e soudage ou autres cir-

cuits électriques.

D Ne jamais placer une torche de soudage sur une bouteille à gaz. D Une électrode de soudage ne doit jamais entrer en contact avec une

bouteille.

D Ne jamais souder une bouteille pressurisée – risque d’explosion. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la

bouteille.

D Maintenir le chapeau de protection sur la soupape, sauf en cas d’uti-

lisation ou de branchement de la bouteille.

D Lire et suivre les instructions concernant les bouteilles de gaz com-

primé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.

font normalement partie du procédé de soudage, les

OM-1324 Page 6

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance

Risque D’INCENDIE OU D’EXPLOSION.

D Ne pas placer l’appareil sur, au-dessus ou à proxi-

mité de surfaces infllammables.

D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique – s”assurer que l’alimen-

tation est correctement dimensionné et protégé avant de mettre l’appareil en service.

LA CHUTE DE L’APPAREIL peut blesser.

D Utiliser l’anneau de levage uniquement pour sou-

lever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.

D Utiliser un engin d’une capacité appropriée pour

D En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

soulever l’appareil.

L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement, respec-

ter le cycle opératoire nominal.

D Réduire le courant ou le cycle opératoire avant de

D Ne pas obstruer les passages d’air du poste.

recommancer le soudage.

DES ORGANES MOBILES peuvent provoquer des blessures.

D Rester à l’écart des organes mobiles comme le

ventilateur.

D Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de protection.

LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences.

D Le rayonnement haute frequence peut provoquer

des interférences avec les équipements de radio–navigation e t d e communication, les services

D Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installa- tion.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appa-

reil.

D Effectuer régulièrement le contrôle et l’entretien de l’installation. D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interfé- rences éventuelles.

de sécurité et les ordinateurs.

LE SOUDAGE À L’ARC risque de provoquer des interférences.

LES CHARGES ÉLECTROSTATI- QUES peuvent endommager les circuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de circuits imprimes.

DES ORGANES MOBILES peuvent provoquer des blessures.

D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D Ne pas appuyer sur la gachette avant d’en avoir

reçu l’instruction.

D Ne pas diriger le pistolet vers soi, d’autres person-

nes ou toute pièce mécanique en engageant le fil de soudage.

D L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement

D Veiller à ce que tout l’équipement de la zone de soudage soit com-

patible électromagnétiquement.

D Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).

D Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

D Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

D En cas d’interférences après avoir pris les mesures précédentes, il

incombe à l’utilisateur de prendre des mesures supplémentaires tel- les que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

commandé par ordinateur tel que les robots.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez à dis-

tance.

D Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’appro- cher des opérations de soudage à l’arc, de gou- geage ou de soudage par points.

OM-1324 Page 7

1-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme A WS

F4.1, de l ’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126

National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Règles de s écurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Pra ctices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les ef fets, pour l ’organisme, des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnéti- ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur. 3 Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est alors recommandé de respecter les consignes ci–dessus.

OM-1324 Page 8

2-1. Specifications

A. 115 VAC Model

Rated W elding

Output

90 A @ 18

Volts DC, 20%

Duty Cycle

63 A @ 21

Volts DC, 20%

Duty Cycle*

Wire Type

And Dia

* CSA Rating

B. 230 VAC Model

Rated W elding

Output

130 A @ 20 Volts

DC, 30% Duty Cycle

At 60 Hz Input

Wire Type

And Dia

Amperage Range

30 – 135

Solid Stainless Flux Cored Wire Feed Speed Range

.023 - .035 in

(0.6 - 0.9

mm)

Amperage

30 – 175

Stainless

.023 – .035 in

(0.6 – 0.9 mm)

SECTION 2 – SPECIFICATIONS

Amperes Input at

Rated Load Output 115 V, 60 Hz,

Single-Phase

15*

170 – 850 IPM (4.3 – 21.6 m/min) At No Load

75 – 750 IPM (1.9 – 19.1 m/min) Feeding Wire

Amperes Input at

Rated Load Output

230 V , 50/60 Hz,

Single-Phase

150 – 900 IPM (3.8 – 23.0 m/min) At No Load

75 – 850 IPM (1.9 – 21.6 m/min) Feeding Wire

KVA KW

2.88

2.20*

KVA KW

Wire Feed Speed Range

.023 - .030 in

Range

Solid/

(0.6 - 0.8

mm)

Maximum

Open-Circuit

Voltage DC

.030 - .045 in

(0.8 - 1.1 mm)

Maximum Open-

Circuit Voltage

30 19.5 4.60 3.75

Flux Cored

.030 – .045 in

(0.8 – 1.2 mm)

2.40

1.77*

Weight

W/ Gun

60 lb

(27 kg)

Weight

W/ Gun

73 lb

(33.0 kg)

Overall

Dimensions

Length: 17-1/2 in

(444 mm)

Width: 10-5/8 in

(273 mm)

Height: 15-3/4 in

(400 mm)

Overall

Dimensions

Length: 17-1/2 in

(444 mm)

Width: 10-5/8 in

(273 mm)

Height: 15-3/4 in

(400 mm)

OM-1324 Page 9

2-2. Duty Cycle And Overheating

A. 115 VAC

Model

B. 230 VAC

Model

140

120

100

Output Amperes

10 20 30 40 50 60 70 80 90 100

RatedOutput

Duty Cycle %

20% duty cycle at 90 amps

2 Minutes Welding 8 Minutes Resting 200 180

Duty Cycle is percentage of 10 mi n 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 duty cycle before welding.

Y Exceeding duty cycle can

damage unit or gun and void warranty.

Overheating

160 140 120 100

80 60

Output Amperes

40 20

10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Duty Cycle %

30% duty cycle at 130 amps, 60 Hz 20% duty cycle at 130 amps, 50 Hz

3 Minutes Welding 7 Minutes Resting

A or V

OM-1324 Page 10

Minutes

Reduce Duty Cycle

duty1 4/95 – 203 771 / 203 796

2-3. Volt-Ampere Curves

A. 115 VAC Model

VOLTAGE

0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100. 110. 120. 130.

The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown.

Voltage Control @ 0 Voltage Control @ 1 Voltage Control @ 2 Voltage Control @ 3 Voltage Control @ 4 Voltage Control @ 5 Voltage Control @ 6 Voltage Control @ 7 Voltage Control @ 8 Voltage Control @ 9 Voltage Control @ 10

AMPERAGE

B. 230 VAC Model

VOLTAGE

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

AMPERAGE

ssb1.1 10/91 – 203 772 / 203 797

OM-1324 Page 11

SECTION 3 – INSTALLATION

3-1. Installing Welding Gun

1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob. Insert gun end

through opening until it bottoms against drive assembly. Tighten knob.

4 Gun Trigger Plug Insert into receptacle, and tighten

threaded collar. Close door.

3-2. Installing Work Clamp

Tools Needed:

3/8, 7/16 in

3-3. Work Cable Routing Inside Unit

Ref. 802 982 / Ref. 801 987

1 Nut 2 Work Cable From Unit 3 Work Clamp 4 Screw 5 Work Clamp Tabs Bend tabs around work cable.

802 456

1 Work Cable 2 Output Terminal Block Insert work cable through opening

in front panel and route along back of front panel to output terminal block.

Close door.

OM-1324 Page 12

Ref. 802 982

3-4. Process/Polarity Table

Process Polarity

GMAW – Solid wire with shielding gas

FCAW – Self-shielding wire – no shielding gas

3-5. Changing Polarity

DCEP

Electrode POSITIVE

Electrode Positive

FOR SOLID WIRE

Wor kClamp

Wor kClamp Le a d

Le a d

Cable Connections

Cable To Gun Cable To W ork

DCEP – Reverse polarity Connect to positive (+) out-

put terminal

DCEN – Straight Polarity Connect to negative (–)

output terminal

CHANGING POLARITY

DCEN

Electrode Negative

Flux Core Wire

WorkClamp

WorkClamp Le a d

Le a d

Wir e Drive

Wir e Drive Le a d

Le a d

Wir e Drive Le a d

Le a d

Connect to negative (–) output terminal

Connect to positive (+) output terminal

1 Lead Connections For Direct

Current Electrode Positive (DCEP)

2 Lead Connections For Direct

Current Electrode Negative (DCEN)

Always read and follow wire manufacturer’s recommended po- larity , and see Section 3-4.

Close door.

Ref. 203 501

OM-1324 Page 13

3-6. Installing Gas Supply

Argon Gas

Tools Needed:

5/8, 1-1/8 in

Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve.

1 Cap 2 Cylinder Valve Remove c ap, stand to side of valve,

and open valve slightly. Gas flow blows dust and dirt from valve. Close valve.

3 Cylinder 4 Regulator/Flowmeter Install so face is vertical. 5 Regulator/Flowmeter Gas

Hose Connection

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.

7 Flow Adjust Typical flow rate is 20 cfh (cubic feet

per hour). Check wire manufacturer’s recommended flow rate.

8CO2 Adapter (Customer Sup-

plied) 9 O-Ring (Customer Supplied) Install adapter with O-ring between

regulator/flowmeter and CO

cylinder.

8 9

CO2 Gas

OM-1324 Page 14

802 028 / 802 441

3-7. Selecting A Location And Connecting Input Power For 115 VAC Model

1 Rating Label 2 Grounded Receptacle A 115 volt, 20 ampere individual

branch circuit protected by tim e- delay fuses or circuit breaker is required.

3 Plug From Unit Select extension cord of 14 AWG

for up to 50 ft (15 m) or 12 AWG for 50 up to 200 ft (61 m).

Y Special installation may be

required where gasoline or

volatile liquids are present –

see NEC Article 511 or CEC

Section 2 0 .

18 in

(460 mm)

18 in

(460 mm)

Ref. 802 980

OM-1324 Page 15

3-8. Selecting A Location And Connecting Input Power For 230 VAC Model

1 Rating Label Supply correct input power. 2 Plug 3 Receptacle Connect plug to receptacle.

18 in (457 mm) of space for airflow

Y Always connect

grounding conductor first.

= GND/PE

4 Line Disconnect Device See Section 3-9.

Y Special installation may be

required where gasoline or

volatile liquids are present –

see NEC Article 511 or CEC

Section 2 0 .

Y Do not move or operate unit

where it could tip.

230 VAC, 1

ssb2.2* 1/94 – 802 980 / Ref. 802 443 / Ref. 802 085

OM-1324 Page 16

3-9. Electrical Service Guide For 230 VAC Model

Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil

Reference: 1996 National Electrical Code (NEC) S-0092-J

230

20 20 14

66 (20)

3-10. Installing Wire Spool And Adjusting Hub Tension

Installing 4 in (102 mm) Wire Spool

When a slight force is needed to turn spool, tension is set.

Installing 8 in (203 mm) Wire Spool

Retaining ring used

with 8 in (203 mm)

spool only.

Tools Needed:

Adapter used with

8 in (203 mm)

spool only.

When a slight force is needed to turn spool, tension is set.

1/2 in

802 971 / 803 012 / 803 013

OM-1324 Page 17

3-11. Threading Welding Wire

Tools Needed:

1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight.

Open pressure assembly.

. Hold wire tightly to keep it

from unraveling.

4 in

(102 mm)

Tighten

6 in

(150 mm)

Pull and hold wire; cut off end.

. Use pressure indicator

scale to set a desired drive roll pressure.

1 2 3 4

Pressure Indicator

Scale

Push wire thru guides into gun;

continue to hold wire.

Close and tighten pressure

assembly, and let go of wire.

Press gun trigger until wire comes out of gun.

OM-1324 Page 18

Remove gun nozzle and contact tip.

Reinstall contact tip and nozzle.

INPUT

POWER

Turn power on.

Tighten

1 2 3

WOOD

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close door .

Ref. 802 444 / Ref. 205 837

4-1. Controls

SECTION 4 – OPERATION

WIRE SPEE D

MILLER ELECTRIC MF G. CO. APPLE TON, WI

1 Wire Speed Control Turn control clockwise to increase wire

feed speed. (see weld parameter chart in welding power source or Sections 4-2 and 4-3, as applicable).

MADE IN

VOL TAGE

TRIGGER OVER TEMP POWER

2 Voltage Control Turn control clockwise to increase voltage

(see weld parameter chart in welding power source or Sections 4-2 and 4-3, as applicable).

OFF

3 Power Switch 4 Over Temperature Light 5 Gun Trigger Receptacle

Ref. 203 498

OM-1324 Page 19

4-2. Weld Parameter Chart For 115 VAC Model

Selecting Wire, Gas and Control Settings

N o te : 1 . S ett ing s ar e ap p r o x im ate. A d j ust as r eq u ir ed .

2. ”––” M eans not recom m ended.

What Material You a re W e lding

Steel

Stainless Steel

Suggested Wire Types, Polarity

S o lid Wire (or Hard) ER70S –6 (DCEP)

Flux C ore E71T–11 (DCEN )

Stainless Steel (DCEP)

Sugge sted Shielding Gases

(

Flow R ate of 20–30 cfh

Gas Mixture

75% Ar / 25% CO (Ar / C O2produces less spa tte r – better overall appearance)

100% CO

N o S h ielding G as required. G ood for w indy or o utdoor applications. May require an oversized tip for improved feedibility .

Tri–Mix 90% He / 7.5% Ar / 2.5% CO

)

Wire Size

(

Diameters

.0 2 4 ” (0.6 m m ) .0 3 0 ” (0.8 m m ) .0 3 5 ” (0.9 m m )

.0 3 0 ” (0.8 m m ) .0 3 5 ” (0.9 m m ) .0 4 5 ” (1.2 m m )

.0 3 0 ” (0.8 m m )

)

OM-1324 Page 20

Select Voltage and W ire Speed Based on Thickness of M etal Being W elded

Num ber on left of slash is Voltage Knob Setting.

3/16”

(

4.8 mm

(

–– ––– ––

–

–– ––

––

)

3.2 m m)

7 / 80 8 / 70

7.5 / 65

1/8”

7 / 70 8 / 75 8 / 75

9 / 55 9 / 70

9 / 60

5 / 60 5 / 60 6 / 60

16 ga.

1.6 mm )

(

3 / 55

3.5 / 55 4 / 45

4 / 55

3.5 / 60 6 / 50

3 / 40 3 / 40

––

Num ber on right of slash is W ire Speed Knob Setting.

20 ga.

(

0.9mm)

2.5 / 40

2.5 / 40 2 / 25

3 / 40 2 / 40

3 / 40

–– –– ––

24 ga.

(

0.8 m m)

2 / 30 2 / 35

––

–– ––

––

–– –– ––

9 / 70

5 / 45

4.5 / 40

––

203 501

OM-1324 Page 21

4-3. Weld Parameter Chart For 230 VAC Model

Selecting Wire, Gas and Control Settings

Note: 1. Settings are approxim ate. Adj ust as required.

2. ”––” M eans not recom m ended.

W hat M aterial You are W elding

Steel

Stainless Steel

Sugge sted

W ire Types,

Polarity

S oli d Wire (or H a rd ) ER70S–6 (D CE P)

Flux Core E71T–11 (DCEN)

Stainless Steel (D CE P)

Sugge sted Shie lding Ga ses

(

Flow R ate of 20 –30cfh

Gas Mixture

75% Ar / 25% C O (A r / CO2produces less sp a tter – better overall appearance)

100% C O

N o Shield ing Gas required. G ood for w indy or outdoor applications. May require an oversized tip for im proved feedibility.

Tri–Mix 90% He / 7.5% A r / 2.5% C O

)

WireSize (

Diameters

.024” (0 . 6m m ) .030” (0 . 8m m ) .035” (0 . 9m m )

.030” (0 . 8m m ) .035” (0 . 9m m ) .045” (1 . 2m m )

.030” (0 . 8m m ) .035” (0 . 9m m )

)

OM-1324 Page 22

Se lect V oltage a nd W ire Spe ed Based on Thickne ss of M e ta l Be ing W e lded

Num ber on left of slash is V olt ag e Kn o b Sett in g .

1/4”

(

6.4 m m

8 / 90 8 / 80

8 / 75

––

9.5 / 70

6.5 / 70

8 / 80 8 / 70

5 / 70

)

3/16”

(

4.8 m m

8 / 90 5 / 75 5 / 75

8 / 85

4.5 / 70

5.5 / 70

6 / 80 6 / 75 5 / 60

Numberonrightofslash is W ire Speed Knob Setting.

1/8”

)

(

3.2 mm

)

4 / 75 4 / 70

3.5 / 75

4 / 70

3.5 / 60 4 / 70

5 / 50 4 / 70 4 / 50

16 ga.

(

1.6 m m

3 / 70

2.5 / 55 3 / 70

2 / 70

2.5 / 55 3 / 55

3 / 40 3 / 45

3.5 / 40

20 ga.

)

(

0.9 mm

)

2 / 45

1.5 / 60 2 / 60

1.5 / 60

1.5 / 45

1.5 / 40

–– –– ––

24 ga.

(

0.8 mm

1 / 50

1.5 / 45

––

–– ––

––

–– –– ––

)

–– ––

7 / 75 7 / 75

4 / 65 5 / 70

3.5 / 45

4.5 / 40

2.5 / 30

––

–– ––

203 501

OM-1324 Page 23

SECTION 5 – MAINTENANCE &TROUBLESHOOTING

5-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replace unreadable labels.

6 Months

Blow out or vacuum inside. During heavy service, clean monthly.

5-2. Overload Protection

Repair or replace cracked weld cable.

Clean and tighten weld terminals.

1 Circuit Breaker CB1 CB1 protects unit from overload. If

CB1 opens, unit shuts down. Reset breaker.

802 441

5-3. Drive Motor Protection And Tip Saver/Short Circuit Protection

A. Drive Motor Protection

Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release gun trigger and wait until protection circuit resets allowing drive motor to feed wire again.

B. Tip Saver/Short Circuit Protection

The tip saver/short circuit protection extends contact tip life and protects internal components from damage. If contact tip is shorted to workpiece, the unit shuts down the welding output, but the fan continues to run. To resume operation, release gun trigger to reset unit. If the contact tip has stuck to the workpiece, release gun trigger, turn off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged. Turn on unit to continue operation.

OM-1324 Page 24

5-4. Changing Drive Roll Or Wire Inlet Guide

.024 Groove.030/.035 Groove

1 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.

2 Drive Roll The drive roll consists of two differ-

ent sized grooves. The stamped markings on the end surface of the drive roll refers to the groove on t he opposite side of the drive roll. The groove closest to the motor shaft is the proper groove to thread (see Section 3- 11).

3 Retaining Pin T o secure drive roll, locate open slot

and push drive roll completely over retaining pin, then rotate drive roll 20° (1/4 turn) to closed slot.

Stamped .024

Stamped .030/.035

5-5. Replacing Gun Contact Tip

802 984

Y Turn Off power before

replacing contact tip.

1 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:

Ref. 802 399-A

OM-1324 Page 25

5-6. Cleaning Or Replacing Gun Liner

Y Disconnect gun from unit.

Head Tube

Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide.

8 mm

Tools Needed:

8 mm / 10 mm

10 mm

Lay gun cable out straight before installing new liner.

Blow out gun casing.

Remove liner.

To Reassemble Gun:

Install and tighten new liner. Cut liner off 3/4 in (20 mm) (3/8 in

[9.5 mm] for aluminum) from head tube.

Install adapter, contact tip, and nozzle.

OM-1324 Page 26

Ref. ST-802 399-A

5-7. Replacing Switch And/Or Head Tube

Remove handle locking nut.

Secure head tube in vice.

Y Turn Off welding power source

/wire feeder and disconnect gun.

Slide handle.

Remove switch housing. Install new switch and connect leads (polarity is not important). Reassemble in reverse order. If replacing head tube, continue t o end of figure.

Tools Needed:

Loosen jam nut. Remove from vice and turn head tube out by hand.

Hand-tighten head tube into cable connector.

Remove from vice. Reposition handle and install switch housing. Secure with handle locking nut.

Place head tube in vice and tighten until nuts are tight.

19 mm

Ref. ST-800 795-C

OM-1324 Page 27

5-8. Troubleshooting Table

Trouble Remedy

No weld output; wire does not feed; fan does not run.

Secure power cord plug in receptacle (see Section 3-7). Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 4-1). Reset welding power source circuit breaker if open.

No weld output; wire does not feed; fan motor continues to run.

No weld output; wire feeds.

Low weld output. Connect unit to proper input voltage or check for low line voltage.

Electrode wire feeding stops during welding.

Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when unit has cooled (see Section 2-2).

Secure gun trigger leads (see Section 3-1). Connect work clamp to get good metal to metal contact. Replace contact tip (see Section 5-5). Check for proper polarity connections (see Section 3-5). Check thumbscrew securing gun end to feed head adapter and tighten if necessary.

Place voltage switch in desired position (see Section 4-1). Straighten gun cable and/or replace damaged parts. Adjust drive roll pressure (see Section 3-11). Change to proper drive roll groove (see Section 5-4). Readjust hub tension (see Section 3-10). Replace contact tip if blocked (see Section 5-5). Oversized tip may be required for some wires. Clean or replace wire inlet guide or liner if dirty or plugged (see Section 5-4 or Section 5-6). Replace drive roll or pressure bearing if worn or slipping (see Section 5-4). Secure gun trigger leads or repair leads (see Section 3-1). Check and clear any restrictions at drive assembly and liner (see Section 3-11 or Section 5-6). Release gun trigger and allow gun and motor protection circuitry to reset. Have nearest Factory Authorized Service Agent check drive motor.

OM-1324 Page 28

SECTION 6 – ELECTRICAL DIAGRAM

Figure 6-1. Circuit Diagram For 115 VAC Model

203 765

OM-1324 Page 29

OM-1324 Page 30

203 794

Figure 6-2. Circuit Diagram For 230 VAC Model

SECTION 7 – MIG WELDING (GMAW) GUIDELINES

7-1. Typical MIG Process Connections

Regulator/

Flowmeter

Wire Feeder/

Power Source

Y Weld current can damage

electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. P l a c e w o r k c l a m p a s close t o the weld as possible.

Shielding Gas

Gas

Gun

Work Clamp

Workpiece

light mig 5/967 / Ref. 802 982

OM-1324 Page 31

7-2. Typical MIG Process Control Settings

NOTE

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.

Material thickness determines weld parameters.

.035 in

Wire Size Amperage Range

.023 in .030 in .035 in

1/8 or

.125 in

30 – 90 A 40 – 145 A 50 – 180 A

Convert Material

Thickness to

Amperage (A)

(.001 in = 1 ampere)

.125 in = 125 A

Select Wire Size

Wire Size (Approx.)

.023 in .030 in .035 in

Recommendation

3.5 in per ampere 2 in per ampere

1.6 in per ampere

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage.

Wire speed (amperage) controls weld penetration (wire speed = burn-off rate)

Voltage controls height and width of weld bead.

Wire Speed

3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

Select Wire Speed

(Amperage)

125 A based on 1/8 in

material thickness

ipm = inch per minute

Select Voltage

OM-1324 Page 32

Ref. 802 980

7-3. Holding And Positioning Welding Gun

NOTE

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.

0°-15°

90° 90°

End View Of Work Angle Side View Of Gun Angle

GROOVE WELDS

1 Hold Gun and Control Gun

Trigger

2 Workpiece

3 Work Clamp 4 Electrode Extension (Stickout)

1/4 to 1/2 in (6 To 13 mm)

5 Cradle Gun and Rest Hand on

Workpiece

45°

End View Of Work Angle Side View Of Gun Angle

FILLET WELDS

0°-15°

S-0421-A

OM-1324 Page 33

7-4. Conditions That Affect Weld Bead Shape

NOTE

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.

Push

Perpendicular Drag

GUN ANGLES AND WELD BEAD PROFILES

Short Normal Long

10°

ELECTRODE EXTENSIONS (STICKOUT)

Short Normal Long

FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)

Slow Normal Fast

GUN TRAVEL SPEED

S-0634

OM-1324 Page 34

7-5. Gun Movement During Welding

NOTE

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.

1 2

7-6. Poor Weld Bead Characteristics

1 Stringer Bead – Steady

Movement Along Seam

2 Weave Bead – Side To Side

Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide

area in one pass of the electrode.

S-0054-A

7-7. Good Weld Bead Characteristics

1 Large Spatter Deposits

2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration

S-0053-A

1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During

Welding Weld a new bead or layer for each

1/8 in (3.2 mm) thickness in metals being welded.

4 No Overlap 5 Good Penetration into Base

Metal

OM-1324 Page 35

S-0052-B

7-8. Troubleshooting – Excessive Spatter

Excessive Spatter – scattering of molten metal particles that cool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use shorter electrode extension (stickout). Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding. Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc. Dirty welding wire. Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

Wrong polarity. Configure polarity as shown in Section 3-5. Always read and follow wire manufacturer’s

recommended polarity, and see Section 3-4.

7-9. 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. Wrong gas. Use welding grade shielding gas; change to different gas. Dirty welding wire. Use clean, dry 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. Wrong polarity. Configure polarity as shown in Section 3-5. Always read and follow wire manufacturer’s

OM-1324 Page 36

recommended polarity, and see Section 3-4.

7-10. Troubleshooting – Excessive Penetration

Excessive Penetration – weld metal melting through base metal and hanging underneath weld.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Wrong polarity. Configure polarity as shown in Section 3-5. Always read and follow wire manufacturer’s

Good Penetration

Increase travel speed.

recommended polarity, and see Section 3-4.

S-0639

7-11. Troubleshooting – Lack Of Penetration

Lack Of Penetration – shallow fusion between weld metal and base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while

maintaining proper welding wire extension and arc characteristics. Improper weld technique. 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.

S-0638

Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed. Wrong polarity. Configure polarity as shown in Section 3-5. Always read and follow wire manufacturer’s

recommended polarity, and see Section 3-4.

7-12. Troubleshooting – Incomplete Fusion

Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead.

S-0637

Possible Causes Corrective Actions

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before

Insufficient heat input. Select higher voltage range and/or adjust wire feed speed. Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

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.

Use correct gun angle of 0 to 15 degrees. Wrong polarity. Configure polarity as shown in Section 3-5. Always read and follow wire manufacturer’s

recommended polarity, and see Section 3-4.

OM-1324 Page 37

7-13. Troubleshooting – Burn-Through

Burn-Through – weld metal melting completely through base metal resulting i n holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

S-0640

Wrong polarity. Configure polarity as shown in Section 3-5. Always read and follow wire manufacturer’s

recommended polarity, and see Section 3-4.

7-14. Troubleshooting – Waviness Of Bead

Waviness O f Bead – weld metal that is not parallel and does not cover joint formed by base metal.

S-0641

Possible Causes Corrective Actions

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.

7-15. 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.

OM-1324 Page 38

7-16. 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

Argon All Positions

Argon + 25% CO

Tri-Mix

1 Globular Transfer 2 Single Pass Welding Only 3 90% HE + 7-1/2% AR + 2-1/2% CO

Spray Arc Steel Short Circuiting Steel

Flat & Horizontal1 Fillet All Positions All Positions Flat & Horizontal1 Fillet All Positions

Short Circuiting

Stainless Steel

All Positions

Short Circuiting

Aluminum

OM-1324 Page 39

SECTION 8 – PARTS LIST

OM-1324 Page 40

36 37

. Hardware is common and

Figure 8-1. Main Assembly

not available unless listed.

907 020

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 8-1. Main Assembly

1 202 581 BASE, lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 202 582 BAFFLE, center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 202 583 WRAPPER, cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 202 584 DOOR, access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 202 411 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 202 412 HINGE, door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PC1 199 820 CIRCUIT CARD ASSY, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PC1 202 354 CIRCUIT CARD ASSY, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 134 201 STAND-OFF support PC board 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 SK1 193 191 RECTIFIER ASSY (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 SK1 193 316 RECTIFIER ASSY (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 204 215 BUS BAR (positive) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 193 194 BUS BAR (negative) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 C1 193 039 CAPACITOR, elctlt 53,000 uf (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 C1 193 040 CAPACITOR, elctlt 100,000 uf (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 203 491 CLAMP, capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CB1 210 109 CIRCUIT BREAKER, 25 amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 111 433 BUSHING, strain relief 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 147 545 CORD SET (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 152 118 CORD SET (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 195 585 HANDLE, carrying 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 605 227 NUT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 GS1 116 996 VALVE, 2 way (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 GS1 128 751 VALVE, 2 way (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 FM 196 063 MOTOR, fan (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 FM 196 064 MOTOR, fan (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 409 953-001 BLADE, fan cooling 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 T1 203 445 TRANSFORMER (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 T1 203 456 TRANSFORMER (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 Z1 203 868 STABILIZER, 90A (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 Z1 203 874 STABILIZER, 130A (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 196 467 TUBING, pvc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 196 619 WORK CABLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 S1 196 575 SWITCH, rocker SPST (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 S1 196 574 SWITCH, rocker DPDT (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 PL1 202 661 LED, yellow 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 R1 202 663 POTENTIOMETER, cp flat 1T .50W 50k 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 R2 202 662 POTENTIOMETER, cp flat 1T .25W 50k 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 205 882 KNOB, pointer 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

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-1324 Page 41

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 8-1. Main Assembly (Continued)

31 203 501 LABEL, weld guide (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 203 765 LABEL, weld guide (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 204 036 LABEL, precautionary static 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 204 711 LATCH, slide flush snap lock 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 202 725 HUB, spool 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 058 427 RING, retaining spool 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 202 726 ADAPTER, spool hub 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 203 072 WASHER, flat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 202 998 SPRING, cprsn 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 204 608 NUT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 602 211 WASHER, lock 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 203 071 SCREW 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 TE1 193 144 INSULATOR, output stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

OM-1324 Page 42

Figure 8-2. Wire Feed Drive Assembly

203 565

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 8-2. Wire Feed Drive Assembly

1 202 500 HOUSING, plastic drive motor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 203 424 PIN, spring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 058 549 GUIDE, wire inlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 196 895 KNOB, tension 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 090 415 SPRING, compression 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 198 080 CUP, spring tension 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 085 242 FASTENER, pinned 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 203 567 SCREW, motor 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 204 246 KNOB, tee 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 203 301 LEVER, pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 189 915 BEARING, ball 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 DM 202 708 MOTOR, gear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 196 009 FITTING, gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 203 418 SPRING, torsion 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 202 925 ROLL, feed .024, .030/.035 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 203 667 CABLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

OM-1324 Page 43

Figure 8-3. M-10 Gun

802 388-A

OM-1324 Page 44

Item

No.

Part

No.

QuantityDescription

Figure 8-3. M-10 Gun

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 170 470 RING, retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 169 718 TUBE, head 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 169 738 NUT, locking handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 194 524 NUT, jam 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 180 433 CORD, trigger assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 079 974 O-RING, .500 ID x .103CS rbr 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 ♦194 010 LINER, monocoil .023/.025 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 ♦194 011 LINER, monocoil .030/.035 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 ♦194 012 LINER, monocoil .035/.045 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 079 975 O-RING, .187 ID x .103CS rbr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 196 255 SWITCH, trigger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦OPTIONAL

Table 8-1. Optional Drive Rolls

For All Feed Head Assemblies

P ART NO. WIRE DIAMETER INCHES (mm)

202 925 .024 (.6) and .030/.035 (.8 and .9) 202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove)

Table 8-2. Options

PART NO. DESCRIPTION REMARKS

770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder , 100 lb (45 kg) 194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg) 195 605 M-10 Replacement Gun 10 ft length/.030-.035 wire size

NOTE: If individual parts are required, see Parts List chapter of this manual for part number to order.

OM-1324 Page 45

Notes

Warranty Questions?

Call 1-800-4-A-MILLER for your local Miller distributor.

Y our distributor also gives you ...

Service

Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.

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

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.

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.

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.

1. 5 Years Parts – 3 Years Labor

* Original main power rectifiers * Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources * Plasma Arc Cutting Power Sources * Semi-Automatic and Automatic Wire Feeders * Inverter Power Supplies * 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) * Process Controllers * Positioners and Controllers * Automatic Motion Devices * RFCS Foot Controls * Induction Heating Power Sources * Water Coolant Systems * HF Units * Grids * Maxstar 140 * Spot Welders * Load Banks * Miller Cyclomatic Equipment * Running Gear/Trailers * Plasma Cutting Torches (except APT & SAF

Models) * 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.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches * Induction Heating Coils and Blankets

guarantees or warranties expressed or implied.

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches * Remote Controls * Accessory Kits * Replacement Parts (No labor) * Spoolmate 185 & Spoolmate 250 * Canvas Covers

Miller’s True Blue Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear.

2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

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.

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.

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 bas e d u p o n a c tual 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.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. I N N O 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.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, 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.

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.

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.

miller_warr 7/00

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com 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 Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information

and Parts) Circuit Diagrams Welding Process Handbooks

Miller Electric Mfg. Co.

An Ill inoi s Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International Headquarters–USA

USA Phone: 920-735-4505 Auto-A t t ended USA & Canada FAX: 9 20-735-4134 International FAX: 920-735-4125

European Headquarters – United Kingdom

Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066

www.MillerWelds.com

Contact the Delivering Carrier for:

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

File a claim for loss or damage during shipment.

Miller 135, 175, M-10 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual