Miller Electric Gold Seal Model 440 Owner`s manual


October 1997

Form: OM-174 470B
Effective With Serial No. KH531011
OWNER’S
MANUAL
Gold Seal Model 420
CV/DC Welding Power Source/Wire Feeder
For FCAW And GMAW Welding
90 Amperes, 18 Volts At 20% Duty Cycle
Uses 115 Volts AC, Single-Phase Input Power
Overheating, Short-Circuit, And Motor Overload Protection
Usable Range Of 30 To 130 Amperes
Includes Gun, Welding Wire, And Gas Valve
Read and follow these instructions and all
safety blocks carefully.
Give this manual to the operator.
Have only trained and qualified persons
install, operate, or service this unit.
For help, call your distributor
Call your distributor if you do not understand
the directions.
or: MILLER ELECTRIC Mfg. Co., P.O. Box
1079, Appleton, WI 54912
414-734-9821
cover 7/93 – ST-155 507-A
 1997 MILLER Electric Mfg. Co.
PRINTED IN USA
The following safety alert symbol and signal words are used throughout this manual to call attention to and identify
different levels of hazard and special instructions.
WARNING
WARNING statements identify procedures or practices which must be followed to avoid serious personal
injury or loss of life.
CAUTION
CAUTION statements identify procedures or practices which must be followed to avoid minor personal
injury or damage to this equipment.
ARC WELDING SAFETY PRECAUTIONS
WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
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
power circuit and machine internal circuits are also
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.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes and
skin. Noise from some processes can damage
hearing.
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
and cleaners.
4. Disconnect input power or stop engine before installing or
servicing this equipment.
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
6. Turn off all equipment when not in use.
7. Do not use worn, damaged, undersized, or poorly spliced cables.
8. Do not wrap cables around your body.
9. Ground the workpiece to a good electrical (earth) ground.
10. Do not touch electrode while in contact with the work (ground)
circuit.
11. Use only well-maintained equipment. Repair or replace
damaged parts at once.
12. Wear a safety harness to prevent falling if working above floor
level.
13. Keep all panels and covers securely in place.
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. 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.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding wire
to metal objects can cause sparks, overheating, or
fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
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.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. 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.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
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.
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 York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Ref. sr1 2/92
TABLE OF CONTENTS
SECTION 1 – SPECIFICATIONS
SECTION 4 – MAINTENANCE & TROUBLESHOOTING
1-1. Volt-Ampere Curve And Duty Cycle Chart . . . . . . .
1
SECTION 2 – INSTALLATION
2-1. Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . .
2-4. Gun Polarity For Wire Type . . . . . . . . . . . . . . . . . . .
2-5. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . .
2-6. Threading And Feeding Welding Wire . . . . . . . . . .
2
2
2
3
3
4
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . .
5
4-1.
4-2.
4-3.
4-4.
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Assembly Maintenance . . . . . . . . . . . . . . . . . .
Gun Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
7
8
8
SECTION 5 – ELECTRICAL DIAGRAM . . . . . . . . . . . . .
9
SECTION 6 – PARTS LIST
Figure 6-1. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 6-2. MWG-160M Gun . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 1 – SPECIFICATIONS
Table 1-1. Welding Power Source
Specifications
Description
Type Of Output
Direct Current/Constant Voltage (DC/CV)
Rated Weld Output
90 Amperes, 18 Volts DC, 20% Duty Cycle
Type Of Input Power
Single-Phase; 60 Hz; At 115 Volts AC
Input Amperes At Rated Output
20 A At 115 V
KVA/KW Used At Rated Output
3 kVA/2.2 kW
Max. Open-Circuit Voltage
30 Volts DC
Control Circuit Voltage At Gun
24 Volts DC
Welding Processes
Gas Metal Arc (GMAW) And Flux Cored Arc Welding (FCAW)
Calculated Speed Range At No Load
283 To 716 ipm (7.1 To 17.9 mpm)
Wire Diameter Range
.023 To .035 in (0.58 To 0.89 mm)
Overall Dimensions
Length: 16-1/2 in (419 mm); Width: 9-1/2 in (241 mm); Height: 17 in (432 mm)
Weight
Net: 73 lb (33 kg); Ship: 80 lb (36 kg)
Welding Gun
Rated Output (Air-Cooled)
160 Amperes At 60% Duty Cycle Using CO2 Shielding Gas
Cable Length
10 ft (3 m)
1-1. Volt-Ampere Curve And Duty Cycle Chart
CAUTION
USING GUN BEYOND DUTY CYCLE RATING can damage gun.
•
•
Do not use gun beyond rated amperage when using CO2 shielding gas.
Use gun at 30% duty cycle when using mixed shielding gas.
wfwarn8.1 10/91
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.
Duty cycle is how long the unit can
operate within a ten minute period
without causing overheating or
damage.
This unit is rated at 20% duty cycle
allowing welding 2 minutes out of
every 10 minutes.
This gun is rated at 60% duty cycle
when using CO2 shielding gas and
30% when using mixed shielding
gas.
ssb1.1 10/91 – SB-124 646-A / sb1.3 10/91 – SB-124 655-A
Figure 1-1. Volt-Ampere Curve And Duty Cycle Chart
OM-174 470 Page 1
SECTION 2 – INSTALLATION
2-1. Installing Work Clamp
1
2
3
4
1
Insulator
Bolt
Smaller Hole
Work Clamp Tabs
Bend tabs around work cable.
6
5
6
2
Work Cable From Unit
Nut
5
3
Tools Needed:
4
3/8, 7/16 in
Ref. ST-025 190-D
Figure 2-1. Installing Work Clamp
2-2. Installing Gas Supply
WARNING
CYLINDERS can explode if damaged.
•
•
•
BUILDUP OF SHIELDING GAS can harm
health or kill.
Keep cylinders away from welding and other
electrical circuits.
Never touch cylinder with welding electrode.
•
Shut off shielding gas supply when not in use.
Always secure cylinder to running gear, wall, or
other stationary support.
warn4.1 9/91
Chain gas cylinder to running gear,
wall, or other stationary support so
cylinder cannot fall and break off
valve.
1
1
2
3
4
5
2
4
Fitting has
threads.
3
6
OR
1
Argon Gas Or
Mixed Gases
2
5
6
Tools Needed:
1-1/8, 5/8 in
3
7
Cap
Cylinder Valve
Cylinder
Regulator/Flowmeter
Gas Hose Connection
5/8-18
right-hand
Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour). Check wire manufacturer’s recommended flow rate.
Make sure flow adjust is closed
when opening cylinder to avoid
damage to the flowmeter.
7
8
CO2 Adapter
O-Ring
Install adapter with O-ring between
regulator/flowmeter and
CO2
cylinder.
8
ssb3.1* 5/94 – ST-158 697-A / Ref. ST-149 827-B
Figure 2-2. Typical CO2 Regulator/Flowmeter Installation
OM-174 470 Page 2
2-3. Connecting Input Power
Connect unit to a properly grounded receptacle of a 20 ampere individual branch circuit protected by time-delay fuses
or circuit breakers. Select an extension cord of 12 AWG for up to 75 ft (23 m) or 10 AWG for up to 140 ft (46 m).
2-4. Gun Polarity For Wire Type
WARNING
ELECTRIC SHOCK can kill.
•
•
Do not touch live electrical parts.
Turn Off welding power source, and disconnect input power before inspecting or installing.
swarn1.1 2/93
1
STRAIGHT
POLARITY
REVERSE
POLARITY
For Solid
Steel Or
Aluminum
Wires
(GMAW)
Process)
For Flux
Cored Wires
(FCAW
Process)
DCEN
1
Polarity Changeover Label
2
Polarity Jumper Links
Always read and follow welding
wire manufacturer’s recommended
polarity.
Close door.
DCEP
GUN POLARITY CHANGEOVER
S-116 599
2
Tools Needed:
3/8 in
Ref. ST-155 506–A
Figure 2-3. Gun Polarity Connections
2-5. Installing Welding Gun
3
1
Gun Securing Nut
2
Drive Assembly
3
Gun End
Loosen securing nut. Insert end
through front panel opening until it
bottoms against drive assembly.
Tighten nut.
4
Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
Close door.
4
Tools Needed:
1
2
5/16 in
Ref. ST-155 506-A
Figure 2-4. Gun Connections
OM-174 470 Page 3
2-6. Threading And Feeding Welding Wire
WARNING
CYLINDERS can explode if damaged.
•
•
•
WELDING WIRE can cause puncture
wounds.
Keep cylinders away from welding and other
electrical circuits.
Never touch cylinder with welding electrode.
Always secure cylinder to running gear, wall, or
other stationary support.
•
•
ELECTRIC SHOCK can kill.
Do not press gun trigger until instructed to do so.
Do not point gun toward any part of the body, other
people, or any metal when threading welding wire.
HOT SURFACES can burn skin.
•
•
Do not touch live electrical parts.
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger.
TO USE 1 LB SPOOL:
Allow gun to cool before touching.
swarn5.1 10/91 / swarn2.1 9/91
TO USE Standard Wire Reel:
1
Wire Spool
2
Hub Tension Nut
Grasp spool in one hand and turn
while using a wrench to adjust nut.
When a slight force is needed to turn
spool, tension is set.
Loosen wire from spool, cut off bent
wire, and pull 6 in (150 mm) of wire
from spool.
3
Pressure Adjustment
Open pressure assembly.
Part No. 135 615
Part No. 183 312
4
Wire Inlet Guide
5
Drive Roll
6
Wire Outlet Guide
Thread wire through inlet guide,
along drive roll groove, and into outlet
guide. Close pressure assembly.
Lay gun cable out straight.
7
Nozzle
8
Contact Tip
Remove nozzle and contact tip.
9
Turn On unit, press gun trigger, and
feed 2 in (55 mm) of wire out of gun.
Turn Off unit and reinstall contact tip
and nozzle.
3
1
2
3
Gun Trigger
4
10 Adjusting Pressure
5
Turn On unit and check drive roll
pressure by feeding wire against a
wood board or concrete surface; wire
should feed steadily without slipping.
6
Tighten pressure
necessary.
adjustment
if
Close door.
9
8
Tools Needed:
9/16 in
7
10
WOOD
ST-800 316 / Ref. ST- 155 505-A / Ref. ST-155 504-A / S-0627-A
Figure 2-5. Feeding Welding Wire
OM-174 470 Page 4
SECTION 3 – OPERATION
READ SAFETY BLOCKS at beginning
of manual before proceeding.
WARNING
MOVING PARTS can cause injury.
•
•
ARCING can damage switch.
•
Keep away from pinch points such as drive rolls.
Keep all doors, panels, covers, and guards closed
and securely in place.
1
Do not change Voltage switch position while
welding.
Arcing inside switch can damage contacts, causing
switch to fail.
2
3
1
Insulating Gloves
2
Safety Glasses With Side
Shields
3
Welding Helmet
Wear dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct shade
of filter (see ANSI Z49.1).
sb3.1 10/91
Figure 3-1. Safety Equipment
1
Tools Needed:
Power Switch
Use switch to turn unit On and Off.
2
2
1
Wire Speed Control
Use control to select a wire feed
speed. As Voltage switch setting
increases, wire speed range also
increases. The numbers around
the control are not a wire feed
speed (see last page of Parts List).
3
Voltage Switch
Use switch to select an arc voltage.
The higher the selected number,
the thicker the material that can be
welded (see last page of Parts List).
4
Work Clamp
Connect work clamp to clean,
paint-free location on workpiece, as
close as possible to weld area.
Use wire brush or sandpaper to
clean metal at weld joint area.
3
4
Ref. ST-155 508-A / Ref. ST-182 488
Figure 3-2. Controls
OM-174 470 Page 5
SECTION 4 – MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
•
•
MOVING PARTS can cause injury.
•
•
Do not touch live electrical parts.
Turn Off welding power source, and disconnect
input power before inspecting, maintaining, or
servicing.
Keep away from moving parts.
Keep away from pinch points such as drive rolls.
HOT PARTS can cause severe burns.
•
Allow cooling period before maintaining or servicing.
Maintenance and troubleshooting to be performed only
by qualified persons.
swarn8.2* 2/93
Table 4-1. Maintenance Schedule
Time
Maintenance
Before each use.
Tighten all connections. Check gun and clean nozzle.
After each spool of wire.
Blow out gun liner. Clean and check wire drive parts; replace as necessary.
Every 3 months.
Tape or replace cracked cables; clean and tighten connections. Replace unreadable labels.
Every 6 months.
Blow out or vacuum inside of unit.
4-1. Overload Protection
READ SAFETY BLOCKS at start of
Section 4 before proceeding.
WARNING
A. Overheating
Thermostat TP1 protects the unit from damage due to overheating. If main transformer gets too hot, TP1 opens and
weld output stops, but fans keep running to cool transformer. Wait several minutes before trying to weld.
B. Motor Fuse F1
CAUTION
STATIC ELECTRICITY can damage parts on circuit boards.
•
Put on grounded wrist strap BEFORE handling boards or parts.
fwarn5.1* 9/91
1
2
Turn Off and unplug unit. Unlatch
door, remove handle, and remove
door/wrapper.
1
Circuit Board PC1
Located behind fan.
2
Fuse F1 (See Parts List For
Rating)
If this fuse opens, the wire drive motor does not run.
Pull fuse from fuse holder on PC1.
To reinstall, push fuse into fuse
holder.
Reinstall wrapper and handle, and
latch door.
Tools Needed:
3/8 in
Ref. ST-155 640 / ST-149 327
Figure 4-1. Fuse F1 Location
OM-174 470 Page 6
C. Short Circuit Shutdown
If contact tip is shorted and sticks to workpiece, the unit shuts down, but fan runs. To resume operation, 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.
4-2. Drive Assembly Maintenance
READ SAFETY BLOCKS at start of
Section 4 before proceeding.
WARNING
Turn Off and unplug unit.
1
Wire Spool
2
Gun Contact Tip
Cut welding wire off at contact tip.
Retract wire onto spool and secure.
1
3
Pressure Roll Arm
4
Cotter Pin
5
Pin
6
Screw
7
Bearing
Remove bearing as shown. Install
new bearing and secure with screw.
Reinstall arm onto pin and secure
with cotter pin.
8
Setscrew
9
Smooth Groove For Hard Wire
10 Drive Roll
2
Remove drive roll as shown.
Use a wire brush to clean drive roll.
Push drive roll onto shaft with
desired groove in. Turn drive roll so
one setscrew faces flat side of shaft,
and tighten both setscrews.
11 Knurled Groove For Flux-Cored
Wire
3
5
12 Wire Inlet Guide
6
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.
7
Thread welding wire (see Section
2-6). Close door.
4
8
9
Tools Needed:
11
10
12
8
5/64 in
ST-155 504-A / ST-154 199
Figure 4-2. Drive Assembly Maintenance
OM-174 470 Page 7
4-3. Gun Maintenance
READ SAFETY BLOCKS at start of
Section 4 before proceeding.
WARNING
FLYING METAL CHIPS AND DIRT can cause injury and damage equipment.
•
Point gun away from people and in a safe direction when blowing out with compressed air.
swarn10.1 10/91
Turn Off and unplug unit.
1
Wire Spool
Cut welding wire off at contact tip.
Retract wire onto spool and secure.
2
Gun Securing Nut
Disconnect trigger leads. Loosen
nut and remove gun and trigger
leads.
3
1
2
3
Nozzle
4
Contact Tip
5
Head Tube
6
Liner Collet
Disassemble gun as shown.
4
7
5
6
Liner
Pull liner from this end. Blow gun
casing out with compressed air.
Insert new liner into gun casing until
even with end of head tube.
7
Install collet onto liner.
6
Install contact tip and nozzle.
7
Tools Needed:
3/8, 5/16 in
Insert gun into feeder and mark
where liner touches drive roll.
Remove gun and cut liner off.
Reinstall gun so that liner is as
close as possible to drive rolls
without touching.
Thread welding wire (see Section
2-6). Close door.
Ref. ST-155 506–A / ST-155 509-A
Figure 4-3. Gun Maintenance
4-4. Troubleshooting
READ SAFETY BLOCKS at start of
Section 4 before proceeding.
WARNING
Welding Trouble
No weld output; wire does not feed.
Remedy
Secure power cord plug in receptacle.
Motor fuse F1 open, replace F1.
Section
2-3
4-1B
Replace building line fuse or reset circuit breaker if open.
––
Secure gun trigger leads or repair leads, or replace trigger switch.
2-5
No weld output; wire does not feed; fan
motor continues to run.
Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled.
4-1A
No weld output; wire feeds.
Connect work clamp to get good metal to metal contact.
Low weld output.
Figure 3-2
Replace contact tip.
4-3
Connect unit to proper input voltage or check for low line voltage.
2-3
OM-174 470 Page 8
Wire Drive/Gun Trouble
Electrode wire feeding stops during
welding.
Remedy
Section
Straighten gun cable and/or replace damaged parts.
4-3
Adjust drive roll pressure.
2-6
Readjust hub tension.
2-6
Replace contact tip if blocked.
Clean or replace wire inlet guide or liner if dirty or plugged.
Replace drive roll or pressure bearing if worn or slipping.
Secure gun trigger leads or repair leads, or replace trigger switch.
Check and replace F1.
Check and clear any restrictions at drive assembly and liner.
Have nearest Factory Authorized Service Station/Service Distributor check drive motor.
4-3
4-2, 4-3
4-2
2-5
4-1B
4-2, 4-3
––
SECTION 5 – ELECTRICAL DIAGRAM
SB-162 261-A
Figure 5-1. Circuit Diagram For Welding Power Source
OM-174 470 Page 9
NOTES
OM-174 470 Page 10
2
1
3
OM-174 470 Page 11
17
4
16
5
6
7
10
9
Figure 6-1. Main Assembly
11
Fig 6-2
51
8
50
12
14
13
21
15
22
20
52
18
49
19
48
38
23
37
39
24
36
35
47
25
26
34
28
46
27
45
44
43
40
33
29
32
31
42
41
30
SECTION 6 – PARTS LIST
ST-155 532-A
Parts For Main Assembly
NOTE: All items indented by a dot(s) are included with the item listed directly above.
Item Part
No. No.
1
2
149 332
147 635
131 315
151 828
112 031
090 443
111 622
154 827
602 169
092 237
090 415
085 244
085 242
010 224
058 549
129 893
173 446
090 416
124 817
153 727
111 929
135 615
010 910
073 355
010 909
111 998
134 201
119 539
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Item Part
No. No.
Description
Hose Clamp
Hose
Drive Assembly
· Cotter Hair Pin
· Pressure Lever
· Bearing
· · Spacer
· Drive Roll
· Set Screw
· Knob
· Spring
· Cupped Washer
· Fastener
· Spring Pin
· Wire Guide
· Insulator
· Drive Motor
· Hinge Pin
· Drive Housing
Baffle
Hub
Bushing, .390 ID x .750 OD
Washer
Spring
Nut
Cotter Hair Pin
Stand-Off Support
Circuit Card
26
27
28
29
30
31
32
33
34
35
36
37
38
*073 426
118 936
079 747
006 393
111 931
005 656
153 729
154 596
+153 724
134 464
089 899
120 675
129 696
119 264
010 047
122 385
174 504
39
116 996
605 227
147 545
111 443
000 101
097 922
111 997
111 897
127 023
Description
· Fuse, slo-blo 5A
Housing, 10 pin
Terminal
Relay
Fan Motor
Fan Blade
Handle
Cap, Handle
Wrapper
Warning Label
Latch
Bracket
Contactor
Rectifier
Tubing
Terminal Assembly
· Link
Case w/Cmpts
· Gas Valve
· Nyl Nut, gas valve
· Cord Set
· Bushing, cord set
· Rheostat
· Knob
· Rocker Switch, SPST
· Rotary Switch
· · Knob
9
52
155 530
182 488
111 644
025 338
153 722
125 552
147 676
181 649
090 288
162 264
022 160
118 457
019 663
600 325
153 969
110 740
173 374
183 581
048 282
183 312
7
5
4
3
10
1
15
14
16
13
17
1
2
12
18
19
ST-110 832-D
· Case
· Nameplate
· Bushing, .875mtg
· Bushing, .625mtg
Side Panel
Thermostat, NC
Transformer
Resistor
Varistor
Capacitor
Clamp
Stabilizer
Foot
Cable
Clamp
GA-16 Gun,
(Fig 6-2)
Regulator/Flowmeter
Hose, gas
Connector
Adapter ring, wire spool
+When ordering a component originally displaying a precautionary label, the label should
also be ordered.
Be sure to provide Model and Serial Number
when ordering replacement parts.
8
1
Description
*Recommended Spare Parts.
1
2
3
4
5
6
7
8
6
11
40
41
42
43
44
45
46
47
48
49
50
51
Part
No.
Item Part
No. No.
8
2
Item
No.
8
9
9
9
10
11
12
13
14
15
16
17
18
19
110 793
110 795
110 780
110 779
110 781
128 878
118 571
110 785
♦110 786
♦110 787
110 789
♦112 420
♦110 790
110 794
080 565
110 792
110 797
167 440
110 784
079 974
110 796
079 878
048 834
Description
Handle Assembly, black
Head Tube
· Nut
· Jacket
· Stop
· Adapter
· Spring
Contact Tip, .023
Contact Tip, .030
Contact Tip, .035
Nozzle, 1/2 orf
Nozzle, 3/8 orf
Nozzle, flat spot
Trigger Switch Assembly
Terminal
Cable/Conduit
Sleeve
Liner, .023-.035
· Collet, .035
O-Ring, .500
Connector
Connector & Pins
Connector
♦OPTIONAL
Figure 6-2. GA-16 Gun (Fig 6-1 Item 52)
OM-174 470 Page 12
Suggested Welding Settings
Wire Type,
Shielding Gas,
And Flow Rate
Metal Thickness
Wire
Diameter
(inch)
Operator
Control
Settings*
1/8 in.
(3.2 mm)
12 ga.
14 ga.
16 ga.
0.030
Voltage
Wire Speed
4
30
3
30
3
20
1
25
0.035
Voltage
Wire Speed
4
30
3
25
2
25
ER70S-6,
Mild Steel,
CO2, 20 cfh+
0.023
Voltage
Wire Speed
4
50
4
50
0.030
Voltage
Wire Speed
4
40
ER70S-6,
Mild Steel,
75% Argon
25% CO2,
20 cfh+
0.023
Voltage
Wire Speed
0.030
E-71T-GS
Flux Core
ER 308,
Stainless Steel,
Tri-Mix,
20 cfh+
Aluminum,
Argon,
30 cfh+
20 ga.
22 ga. And
Thinner
1
20
1
20
–
–
1
25
1
25
1
20
–
–
3
50
2
45
2
40
1
30
1
30
4
40
3
40
3
40
2
40
1
40
1
35
4
60
4
55
3
50
2
45
2
40
1
35
1
35
Voltage
Wire Speed
4
50
4
50
3
50
3
50
2
45
1
45
1
40
0.023
Voltage
Wire Speed
4
40
4
35
4
35
3
30
3
30
2
20
–
–
0.030
Voltage
Wire Speed
4
30
4
30
4
30
3
25
3
20
2
15
–
–
0.035
Voltage
Wire Speed
4
15
4
15
4
15
3
15
2
15
–
–
–
–
0.030
Voltage
Wire Speed
–
–
4
85
3
80
2
75
1
70
–
–
–
–
0.035
Voltage
Wire Speed
–
–
4
55
4
60
2
60
2
55
–
–
–
–
18 ga.
*Do not change VOLTAGE switch position while welding. WIRE SPEED value in table is a starting value only, and WIRE SPEED control setting
can be fine tuned during welding.
+cfh = cubic feet per hour
OM-174 470 Page 13
Effective January 1, 1997
(Equipment with a serial number preface of “KH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
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.
2.
5 Years Parts – 3 Years Labor
*
Original main power rectifiers
*
Inverters (input and output rectifiers only)
3 Years — Parts and Labor
*
Transformer/Rectifier Power Sources
*
Plasma Arc Cutting Power Sources
*
Semi-Automatic and Automatic Wire Feeders
*
Inverter Power Supplies
Warranty Questions?
*
Intellitig
Call
1-800-4-AMILLER
for your local
Miller distributor.
*
Robots
*
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
3.
1 Year — Parts and Labor
*
Motor Driven Guns (w/exception of Spoolmate 185)
*
Process Controllers
*
Positioners and Controllers
*
Automatic Motion Devices
*
Orbital Weld Heads
*
IHPS Power Sources
*
Water Coolant Systems
*
HF Units
*
Grids
*
Spot Welders
*
Load Banks
*
SDX Transformers
*
Miller Cyclomatic Equipment
*
Running Gear/Trailers
*
Plasma Cutting Torches (except APT, ZIPCUT &
PLAZCUT Models)
*
Deutz Engines (outside North America)
*
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 and Labor
*
MIG Guns/TIG Torches
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate 185
Miller’s True Blue Limited Warranty shall not apply to:
1.
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.
2.
Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
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 based upon actual use) upon return of the
goods at customer’s risk and expense. Miller’s option of
repair or replacement will be F.O.B., Factory at Appleton,
Wisconsin, or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
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.