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Страница 1: ...ty material throughout the manual before installing operating or maintaining this equip ment Thts unit and these instructions are for use only by persons trained and experienced in the safe operation...

Страница 2: ...ranty does not extend to any Welder subjected to misuse neglect accident or in warranty repair by anyone except Miller Electric Further this warranty only extends to those purchasing the Welder for pe...

Страница 3: ...step 10 of Section 4 5 INSTALL AND THREAD THE WIRE 10 Route the welding wire into the wire inlet guide along the drive roil groove and into the wire outlet guide in the gun cable AMENDMENT TO SECTION...

Страница 4: ...rs the wire inlet guide Pull the wire out through the nozzle end of the welding gun 5 Remove and replace the inlet guide IMPORTANT Wire guides should be installed so that the tip s of the guide is as...

Страница 5: ...Wiring Diagram No C 124 445 C Diagram 8 5 Wiring Diagram For 90 Ampere Models...

Страница 6: ...ffw JK716640 I I 42 56 083 147 Deleted BOTH MODELS Eff w JK71 66400 45 5 Added 604 536 SCREW cap stl hexhd 312 18 Eff w JK646341 1 45 6 Added 602 211 WASHER lock sfl split 312 Etfw JK646341 1 45 7 Add...

Страница 7: ...TABLE OF CONTENTS Section No Page No SECTION 1 SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1 1 Introduction 1 1 2 General Precautions 1 1 3 Arc Welding 3 1 4 Standards Booklet Index 5 SECT...

Страница 8: ...it Diagram For 70 Ampere Models 24 Diagram 8 2 Circuit Diagram For 90 Ampere Models 25 Diagram 8 3 Circuit Diagram For 90 Ampere Model Short Circuit And Burnback Control Board PCi 25 Diagram 8 4 Wirin...

Страница 9: ...ST OF CHARTS AND TABLES Table 3 i Specifications 7 Chart 3 1 Volt Ampere Curves 8 Chart 3 2 Duty Cycle 8 Table 4 1 Maximum Allowable Extension Cord Lengths 14 Table 6 1 Suggested Welding Settings 16 T...

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Страница 11: ...lates protected by clear cover glass This is a MUST for welding or cutting and chipping to protect the eyes from radiant energy and flying metal Replace cover glass when broken pitted or spattered See...

Страница 12: ...busti bles solubility followed by purging and inerting with ni trogen or carbon dioxide and using protective equip ment as recommended in A6 O Waterfilling just below working level may substitute for...

Страница 13: ...a clean lintless cloth Match regulator to cylinder Before connecting check that the regulator label and cylinder marking area and thatthe regulator inlet and cylinderoutlet match NEVER CONNECT a regu...

Страница 14: ...open areas sur round the operation with low reflective non combusti ble screens or panels Allow for free air circulation par ticularly at floor level Viewing the weld Provide face shields for all pers...

Страница 15: ...tng ob ject in contact with the electrode circuit unless the welding power source is off b Equipment without output on off control no contactor Welding power sources used with shielded metal arc weldi...

Страница 16: ...n National Standards Institute 1430 Broadway New York NY 10018 SECTION 2 SAFETY PRECAUTIONS AND SIGNAL WORDS 2 1 GENERAL INFORMATION AND SAFETY A General Information presented in this manual and on va...

Страница 17: ...mperes At 16 Volts DC 29 115V 15 2 2 2 24 DC Volts 28 to 163 1pm 0 7 to 4 1 mpm 023 0 58 mm 035 to 0 89 mm Net I Ship 53 lbs t 62 lbs 24 kg 28 kg 68 lbs 72 lbs 31 kg kg 550 to 716 ipm 13 8 to 17 9 mpm...

Страница 18: ...ated duty cycles Chart 3 2 Duty Cycle 70 Ampere Models 7 5 27 25 32 CC 50 00 9 121 475 90 Ampere Models 20 2530 40 50607080 100 x ou rv cvci B124 655 B WeldIng Gun The duty cycle of a welding gun is t...

Страница 19: ...res 18 volts I dc at 20 duty cycle 3 4 SUPPLIED EQUIPMENT Figure 3 2 Figure 3 3 Personal Safety Equipment The following equipment has been included with the welder 3 6 OPTIONAL EQUIPMENT 1 One welding...

Страница 20: ...bes 3 Nozzles 4 Drive rolls 5 Liner Spare parts are available from welding equipment dis tributors SECTION 4 INSTALLATION 4 1 LOCATE THE WELDER Figure 3 1 a CAUTION RESTRICTED AIRFLOW causes overheati...

Страница 21: ...ition the jumper links and tighten the securing hardware 5 Close and secure the access door 4 4 INSTALL THE WELDING GUN A Connect The Gun Cable Figure 4 2 1 Turn OFF the welder 2 Open the left side ac...

Страница 22: ...9 Unreel and straighten approximately 6 in 152 mm of wire from the spool 10 Route the welding wire into the wire inlet guide along the knurled drive roll groove and into the wire outlet guide in the g...

Страница 23: ...ealing agents 3 Install gas regulator flowmeter onto gas cylinder valve keep the face of the regulator flowmeter gauge in vertical position and tighten stem nut se curely to gas cylinder valve 4 A shi...

Страница 24: ...placing the gun nozzle twist it in a clockwise direction to avoid damage to the internal spring 1 Be sure the welding gun and wire are installed according to Sections 4 4 and 4 5 2 Lay the gun cable a...

Страница 25: ...ENVIRONMENT can damage Internal parts Do not touch live electrical parts Keep away from moving parts Keep all covers and panels in place while operating Warranty is void if the wire feeder is operated...

Страница 26: ...s hose of air IMPORTANT Gas pressure of 6 pounds or flow rate of 15 cfh are typical Welding out of position at high wire feed speeds or welding in a drafty environment will require more shielding gas...

Страница 27: ...030 Range 4 3 3 1 1 1 Feed Speedt 30 30 20 25 20 20 _____ 035 Range 4 3 2 1 1 1 Feed Speedt 30 25 25 25 25 20 _____ ER 308 Stainless Steel Tn Mix 20cfh 023 Range 4 4 4 3 3 2 Feed Speedt 40 35 35 30 3...

Страница 28: ...nary labels must be maintained in a clearly readable state and replaced when necessary See Parts List for part number of precautionary labels 4A WARNING ELECTRIC SHOCK can kill Do not touch live elect...

Страница 29: ...ive roll setscrews making sure that one is centered on the flat of the motor shaft 3 Loosen the drive roll pressure adjustment knob pivot the pressure adjustment arm down away from 9 Reinstall the wir...

Страница 30: ...open position a CAUTION LOOSE WELDING WIRE can cause Injury Keep firm hold on wire during installation removal and threading operations Spooled wire has a tendency to unravel rapidly when loosened fro...

Страница 31: ...uit boards Transport a I static sensitive components in proper static shielding carriers or packages IMPORTANT All directions such as left or right are with respect to the operator facing the unit fro...

Страница 32: ...out through the adapter end of the gun assembly a CAUTION FLYING DIRT AND METAL CHIPS can Injure personnel and damage equip ment Point gun liner only in a safe direction away from personnel and equipm...

Страница 33: ...r performing these proce dures the nearest Factory Authorized Service Station should be contacted In all cases of equipment malfunc tion the manufacturers recommendations should be strictly followed T...

Страница 34: ...Only Replace PCi according to Section 7 9 Broken or damaged casing or liner Replacedamagedparts see Section 7 11 Drive roll or pressure bearing worn or slipping Replace drive roll or pressure bearing...

Страница 35: ...ircuIt Diagram For 90 Ampere Models C 24VAC H K CONTROL RELAY NEC VFB A E MOTOR F 24VAC POS VFB 0 B TRIGGER C PC I Circuit Diagram No B 124 474 Diagram 8 3 Circuit Diagram For 90 Ampere Model Short Ci...

Страница 36: ...1 CD CD D 03 Ca 03 0 Wiring Diagram No C 119 811 B SI TcwUl TRIG R LEADS P2 CNO POWER CORD Diagram 8 4 Wiring Diagram For 70 Ampere Modeis...

Страница 37: ...Diagram 8 5 WirIng Diagram For 90 Ampere Models Wiring Diagram No C 124 445 B...

Страница 38: ...s Do not point gun toward any part of the body any conductive surface or other personnel Butt Overhead Position Welds HOT METAL SPAUER AND SLAG can cause tire and burns Watch for fire Keep a fire exti...

Страница 39: ...tal Handle 1 6 in 152 4 mm 5 8 in 15 9 mm Pipe 1 Cut materials according to the material list Table 9 1 and Figure 9 2 Smooth sharp edges 2 Drill hole for hanging 1 2 in 12 7 mm from one end of handle...

Страница 40: ...Nut 4 Matching Nuts 1 Cut materials according to the material list Table 9 2 and Figure 9 3 Smooth sharp edges 2 Drill hole through c nter of each of the top frame pieces 3 Weld the four top frame pi...

Страница 41: ...1 in 25 4 mm Hex Head Bolt Nut 1 Hex Head Nut To Match Bolt 1 Cut materials according to the material list Table 9 3 and Figure 9 4 Smooth sharp edges 2 Weld end pieces to support 3 Weld end of slide...

Страница 42: ...cotter pins Allow room forwheel rotation and mark the location of the inside washer on each end of the axle Take apart the wheel assembly 4 Weld one washer to the axle at each of the marked locations...

Страница 43: ...rom the seam when the arc starts as this will create a long wire extension and result in a poor weld The welding wire is not energized until the trigger is pressed Therefore the welding wire can be ex...

Страница 44: ...ration The drag technique is generally employed when welding in the vertical position but when bridging a gap the arc can be oscillated from one side of the work to the other Figure 10 5 WeldIng in Th...

Страница 45: ...gulator flowmeter 2 Wrong gas Use welding grade shielding gas 3 Dirty welding wire Use clean and dry welding wire Eliminate pick up of oil or lubricant on welding wire from feeder or conduit 4 Workpie...

Страница 46: ...le Causes Corrective Actions 1 improper joint preparation Material too thick Joint preparation and design must be adequate to provide access to the bottom of the groove while maintaining proper weldin...

Страница 47: ...d distortion Select lower voltage range and reduce wire speed Increase travel speed G Waviness of Bead Figure 10 10 Waviness of Bead Possible Causes Corrective Actions 1 Welding wire extends too far O...

Страница 48: ...r after weld ing is completed 2 Remove damaged metal using hand cutters shears or a power hand grinder equipped with a cut ting wheel 3 Fit a new piece of sheet steel over the section which was remove...

Страница 49: ...ld panel must be removed by cutting along the weld if welded by continu ous seam or by drilling out the spot welds if it IS spot welded in place Car and body manufacturers have the panels welded in di...

Страница 50: ...0 2 a 5 E U C 0 E C CS c 1 U SECTION 12 PARTS LIST c1 C N LC I c 1 121 989 Page 40...

Страница 51: ...6000 uf 35VDC CLAMP capacitor 2 1 2 dia HOSE brd No 1 x 3 16 order by ft CLAMP hose 3 8 450 dia FITTING brs barbed M 3 16 TBG x 1 4 NPT FITTING brs elbow St 1 4 NPT LH VALVE 115VAC 2 way 1 4 IPS port...

Страница 52: ...EMBLY changeover consisting of NUT brs hex 10 32 1 8 1 8 51 038 887 STUD brs 10 32 x 1 3 8 4 4 52 116620 TERMlNALBOARD 1 1 53 54 038 618 119 123 LINK jumper BAFFLE air 2 1 2 1 55 56 603 107 083147 HOS...

Страница 53: ...gure 12 2 119 539 CIrcuit Card Shutdown Burnback FIg 12 1 Item 11 pci CAPACITOR elctlt 68 uf 35VDC CAPACITOR cer 01 Ut 1000VDC C8 C9 Cl 0 CR1 D5 D6 8 D7 Fl OC1 Q2 Q3 R13 R14 R15 Ri 6 21 R17 R18 R19 R2...

Страница 54: ...TC 121 448 A 9 4 29 12 through 21 12 16 4 5 7 Figure 12 3 DrIve Assembly Wire Benchmark Pro illustrated...

Страница 55: ...604 741 PIN cotter hair 042 x 15 16 1 1 13 112 031 LEVER pressure roll 1 1 14 111 523 BEARING ball 1 1 15 114415 604534 604538 602109 SCREW stl phillips flat hd 10 24x 625 1 1 1 1 1 16 1 17 18 19 20...

Страница 56: ...1 Figure 12 4 Exploded View Of MWG 1 608 Gun 6 5 9 3 2 10 1 12 14 15 2 16 17 Ref TB 121 4 47 Ret IC lw 832 121 989 Page 46...

Страница 57: ...935 TUBE contact 035 wire 3 8 110 789 NOZZLE slip type 1 2 orifice 1 9 080 565 TERMINAL friction female 3 16 x 020 2 10 110 794 TRIGGER SWITCH ASSEMBLY 1 11 047 994 TERMINAL friction female 1 4 x 032...

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