Page 2 - 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 nearestdistributor 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 - SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards
OM-237 326 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−01 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazard...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance
OM-237 326 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system isproperly siz...
Page 8 - California Proposition 65 Warnings; Principal Safety Standards
OM-237 326 Page 4 1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of California tocause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Section 25249.5 et seq.) Battery posts, termina...
Page 9 - SECTION 2 −; CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION; Symboles utilisés; Dangers relatifs au soudage à l’arc
OM-237 326 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−01 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 onl’évite pas peut donner la mort...
Page 12 - Proposition californienne 65 Avertissements
OM-237 326 Page 8 Les PIÈCES MOBILES peuventcauser des blessures. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincementtels que des rouleaux de commande. LES FILS DE SOUDAGE peuventprovoquer des blessures. D Ne pas appuyer sur la gâchette avant d’enavoir reçu l’inst...
Page 15 - SECTION 3 − DEFINITIONS; Serial Number And Rating Label Location; IP
OM-237 326 Page 11 SECTION 3 − DEFINITIONS 3-1. Serial Number And Rating Label Location The serial number and rating information for this product is located inside the cover. Use rating label to determine input power requirements and/orrated output. For future reference, write serial number in space...
Page 16 - SECTION 4 − INSTALLATION; Specifications
OM-237 326 Page 12 SECTION 4 − INSTALLATION 4-1. Specifications Type of Input Power Welding Power Source Type Wire Feed Speed Range Wire Diameter Range Input Welding CircuitRating IP Rating Max. Wire Spool Capacity Overall Dimensions Weight Open-Circuit/ Arc Voltage, 14 − 110 Volts DC Constant Volta...
Page 17 - Equipment Setup
OM-237 326 Page 13 4-4. WCC (Weld Cable Control) Applications . To take advantage of the WCC features, the Suitcase X−TREME WCC wire feeder must be used with a WCC Control, Dimension NT 456 w/WCC,or other power sources with WCC in the product description. The Suitcase X−TREME WCC wire feeder may als...
Page 18 - Installing And Aligning Wire Guide And Drive Rolls
OM-237 326 Page 14 4-7. Installing And Aligning Wire Guide And Drive Rolls Ref. 805 198-B Tools Needed: 3/16 in. Aligning Wire Guide And Drive Rolls Correct Incorrect 8 7 6 10 9 2 3 4 5 Installing Wire Guide And Drive Rolls 1 Installing Wire Guide And DriveRolls: 1 Drive Roll Securing Nut 2 Drive Ro...
Page 19 - Connecting Welding Gun And Voltage Sensing Clamp
OM-237 326 Page 15 4-8. Connecting Welding Gun And Voltage Sensing Clamp 246 100 / Ref. 804 002-C / 805 199-A / 805 198-B ! Turn Off wire feeder andwelding power source.Stop engine on weldinggenerator. 1 Gun Securing Knob 2 Gun Block 3 Gun Power Pin 4 Power Pin Groove 5 Gun Locking Tab Loosen knob, ...
Page 20 - Connecting Shielding Gas
OM-237 326 Page 16 4-9. Connecting Shielding Gas 805 128-A NOTICE − This feeder has a shield-ing gas filter that requires specialattention when cleaning. See Sec-tion 6-3 for proper cleaning instruc-tions. 1 Gas Hose With 5/8-18Right-hand Thread Fittings(Customer Supplied) 2 Shielding Gas Cylinder ....
Page 21 - Notes
OM-237 326 Page 17 4-11. Motor Board (PC1) DIP Switch Settings Ref. 247 678-A 1 Motor Control Board PC1 2 DIP Switch 3 LED5 If protective coating is present, re-move before setting DIP switch. It isnot necessary to reapply the protect-ive coating. Set switch positions 1 and 2 so the de-pressed secti...
Page 23 - -13. Installing And Threading Welding Wire
OM-237 326 Page 19 4-13. Installing And Threading Welding Wire Ref. 805 198-B Installing Wire And AdjustingHub Tension: 1 Retaining Nut 2 Hub Tension Adjustment Knob Remove retaining ring, and installspool so hub pin fits spool hole. Re-install retaining nut. Adjust tension knob so only a slightforc...
Page 26 - SECTION 5 − OPERATION; Controls With Meters
OM-237 326 Page 22 SECTION 5 − OPERATION 9 8 7 6 OFF ON 5-1. Controls With Meters Ref. 805 200-B Front Panel With Meters Internal Control Panel Internal Side View 5 2 1 4 3 1 Voltmeter When not welding and the wire feeder is notassociated with the WCC compatible weld-ing power source or WCC Control,...
Page 27 - Gun Consumables Information
OM-237 326 Page 23 5-2. Gun Consumables Information 235 264-A Notes
Page 28 - SECTION 6 − MAINTENANCE & TROUBLESHOOTING; Routine Maintenance
OM-237 326 Page 24 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance . Maintain more oftenduring severe conditions. ! Disconnect power before maintaining. 3 Months Replace Damaged Or Unreadable Labels Replace Damaged Gas Hose Repair Or Replace Cracked Cables And Cords 6 Months C...
Page 31 - Diagnostics
OM-237 326 Page 27 Trouble Remedy When associated to a WCC control orWCC compatible power source −Voltage displayed on feeder does notmatch voltage on power source. Preset voltages between the feeder and welding power source should be within 0.5 volt of each other. When associated to a WCC control, ...
Page 33 - SECTION 7 − ELECTRICAL DIAGRAM
OM-237 326 Page 29 SECTION 7 − ELECTRICAL DIAGRAM 237 325-B Figure 7-1. Circuit Diagram For Wire Feeder
Page 34 - SECTION 8 − PARTS LIST
OM-237 326 Page 30 SECTION 8 − PARTS LIST . Hardware is common andnot available unless listed. 6 3 1 (Fig 8-2) 17 20 15 2 4 5 9 8 7 32 33 34 18 19 10 21 22 23 24 25 26 27 28 29 31 30 11 16 12 15 14 13 Figure 8-1. Exploded View Of SuitCase X-TREME 12VS WCC
Page 41 - Pros weld and cut
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules atthe beginningof this manual.
Page 42 - Start Your Professional
Notes Over 80,000 trained since 1930! 400 Trade Square East, Troy, Ohio 45373 1-800-332-9448 www.welding.org Start Your Professional Welding Career Now!
Page 43 - (Equipment with a serial number preface of MB or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 2011−01 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Con...
Page 44 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2011 Miller Electric Mfg. Co. 2011−01 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters−USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX:...
