Page 2 - To locate your nearest; Thank you; From Miller to You
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearest distributor or service agency call...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1...
Page 5 - ELECTRIC SHOCK can kill.
OM-238 118 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007 − 04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible h...
Page 6 - ARC RAYS can burn eyes and skin.; BUILDUP OF GAS can injure or kill.
OM-238 118 Page 2 Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove...
Page 9 - SECTION 2; CONSIGNES DE SÉCURITÉ; UNE DÉCHARGE ÉLECTRIQUE peut
OM-238 118 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007 − 04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la m...
Page 12 - -4. Proposition californienne 65 Avertissements
OM-238 118 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer de...
Page 15 - SECTION 3; -1. Welding Power Source And MIG Gun Specifications
. A complete Parts List is available at www.MillerWelds.com OM-238 118 Page 11 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Wire Feed Output X Duty Cycle Do Not Switch While Welding V Volts Increase On Off Gas Metal Arc Welding (GMAW) Gun Wire Feed Spool Gun Gas Input Gas Output Voltage Inpu...
Page 16 - -2. Welding Power Source Duty Cycle And Overheating; A or V
. A complete Parts List is available at www.MillerWelds.com OM-238 118 Page 12 4-2. Welding Power Source Duty Cycle And Overheating 6 Minutes Welding 4 Minutes Resting Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.If unit overheats, thermostat(s) opens...
Page 17 - -4. Connecting To Weld Output Terminals
. A complete Parts List is available at www.MillerWelds.com OM-238 118 Page 13 4-4. Connecting To Weld Output Terminals 803 778-A ! Turn off power before connecting to weld output terminals. ! Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your ma- chine...
Page 18 - Changing Polarity; Electrode Positive
. A complete Parts List is available at www.MillerWelds.com OM-238 118 Page 14 4-6. Installing Welding Gun 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). Tight...
Page 22 - -10. Installing MIG Wire Spool and Adjusting Hub Tension
. A complete Parts List is available at www.MillerWelds.com OM-238 118 Page 18 4-10. Installing MIG Wire Spool and Adjusting Hub Tension When a slight force is needed to turn spool, tension is set. 15/16 in Use compression spring with 8 in (200 mm) spools. Tools Needed: 805 253-A Installing 1 Or 2 l...
Page 24 - -13. Selecting A Location And Connecting Input Power
. A complete Parts List is available at www.MillerWelds.com OM-238 118 Page 20 4-13. Selecting A Location And Connecting Input Power 805 244-A L1 L2 230 VAC, 1 18 in (457 mm) of space for airflow ! Do not move or operate unit where it could tip. 3 ! Installation must meet all National and Local Code...
Page 26 - SECTION 5
. A complete Parts List is available at www.MillerWelds.com OM-238 118 Page 22 SECTION 5 − OPERATION 5-1. Controls 3 Ref. 237 436-A 1 2 1 Voltage Control Turn control clockwise inside white scale (1-10) to increase voltage (see weld parameter chart in welding power source or Section 5-2).2 Wire Spee...
Page 27 - Notes
. A complete Parts List is available at www.MillerWelds.com OM-238 118 Page 23 Notes
Page 28 - - SIMPLE SETUP FOR WELDING MILD STEEL
. A complete Parts List is available at www.MillerWelds.com OM-238 118 Page 24 5-2. Weld Parameter Chart Stainless steel Aluminum with Spoolmatic 15/30A Spoolgun 9/65 7.5/857.5/75 9/80 8.5/90 MAX/6 6.5/50 6/757/60 Activate Auto-Set t by selecting the diameter of the welding wirewith the WIRE SPEED k...
Page 29 - Manual Setup
. A complete Parts List is available at www.MillerWelds.com OM-238 118 Page 25 238 552-F 8/70 7/60 5.5/50 4/35 5/45 3.7/31 4.5/40 8/60 7/55 5/45 4/28 4.8/40 4.5/32 6.5/70 7.5/80 4.5/45 4/35 6/60 3.7/35 5.5/55 6.5/75 6/70 4.8/60 2.5/40 2/38 2/31 4/50 3/45 6.5/60 5/55 4/50 2.5/35 2/30 2/28 3.5/45 3/40...
Page 30 - SECTION 6; A. Unit Overload Protection; -3. Changing Drive Roll and Wire Inlet Guide
. A complete Parts List is available at www.MillerWelds.com OM-238 118 Page 26 SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more oftenduring severe conditions. n = Check Z = Change ~ = Clean l = Replace * To be done by Factor...
Page 34 - Figure 7-1. Welding Power Source Circuit Diagram
OM-238 118 Page 30 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Welding Power Source Circuit Diagram
Page 37 - Typical MIG Process Control Settings
OM-238 118 Page 33 8-2. Typical MIG Process Control Settings . These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be surethey comply to specifications. 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 2...
Page 38 - Holding And Positioning Welding Gun
OM-238 118 Page 34 8-3. Holding And Positioning Welding Gun . Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm)past end of nozzle, and tip of wire is positioned correctly on seam. 1 Hold Gun and Control Gun...
Page 39 - Conditions That Affect Weld Bead Shape
OM-238 118 Page 35 8-4. Conditions That Affect Weld Bead Shape . Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed(weld current), and voltage. Slow FILLET WELD ELECTODE EXTENSIONS (STICKOUT) ELECTRODE EXT...
Page 43 - Waviness Of Bead; Distortion
OM-238 118 Page 39 8-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm...
Page 44 - -17. Troubleshooting Guide For Semiautomatic Welding Equipment
OM-238 118 Page 40 8-16. 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 Ga...
Page 47 - (Equipment with a serial number preface of LK or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2009 − 01 Your distributor also gives you ... Service You 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 ...
Page 48 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2009 Miller Electric Mfg. Co. 2009 − 01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters − USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 Internati...
