Professional Documents
Culture Documents
Millermatic 251
Millermatic 251
2006−09
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Millermatic 251
R
Mil_Thank 4/05
TABLE OF CONTENTS
Arc rays from the welding process produce intense D Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
D Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards). HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet. D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
D Use protective screens or barriers to protect others from flash,
torch.
glare and sparks; warn others not to watch the arc.
D To handle hot parts, use proper tools and/or
D Wear protective clothing made from durable, flame-resistant mate-
wear heavy, insulated welding gloves and
rial (leather, heavy cotton, or wool) and foot protection.
clothing to prevent burns.
OM-1326 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
OVERUSE can cause OVERHEATING D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
D Allow cooling period; follow rated duty cycle. communications equipment.
D Reduce current or reduce duty cycle before D Have only qualified persons familiar with
starting to weld again. electronic equipment perform this installation.
D Do not block or filter airflow to unit. D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
STATIC (ESD) can damage PC boards. equipment at once.
D Have the installation regularly checked and maintained.
D Put on grounded wrist strap BEFORE handling D Keep high-frequency source doors and panels tightly shut, keep
boards or parts. spark gaps at correct setting, and use grounding and shielding to
D Use proper static-proof bags and boxes to minimize the possibility of interference.
store, move, or ship PC boards.
OM-1326 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som _3/05
Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
Y Indique un message de sécurité particulier Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
. Signifie NOTE ; n’est pas relatif à la sécurité. les dangers.
OM-1326 Page 6
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
OM-1326 Page 8
SECTION 3 − DEFINITIONS
3-1. Symbols And Definitions
SECTION 4 − INSTALLATION
4-1. Specifications
Max. Open- Amps Input at Rated Output (60% Duty Cycle), 50 or 60 Hz, Single-Phase
Rated Output Circuit
Voltage 200 (208) V 230 V 400 V 460 V 575 V KVA KW
250 A at 28 VDC, 200 A at 28 VDC, 38 48 42 24 21 17 9.8 7.5
40% Duty Cycle 60% Duty Cycle 2.3* 2* 1.2* 1* 0.8* 0.46* 0.13*
Wire Type and Diameter Wire Feed Speed Dimensions Net Weight
Solid Steel Stainless Steel Flux Cored 25−700 IPM H: 32 in (813 mm) 215 lb
((.65−17.8
65 17 8 m/min) W: 19 in (483 mm) (98 kg)
.023 − .045 in .023 − .045 in .030 − .045 in D: 39 in (991 mm)
(0.6 − 1.2 mm) (0.6 − 1.2 mm) (0.8 − 1.2 mm)
* While idling
Operating Temperature Range − −20C to +40C Storage Temperature Range − -30C to + 50C
OM-1326 Page 9
4-2. Welding Power Source Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
500 load without overheating.
450 If unit overheats, Thermistor (T)
400
opens, output stops, and cooling
350
fan runs. Wait fifteen minutes for
WELD AMPERES 300 unit to cool. Reduce amperage or
250 voltage, or duty cycle before
welding.
200
Y Exceeding duty cycle can
150 damage unit and void
warranty.
100
50
10 20 30 40 50 60 70 80 90 100
% DUTY CYCLE
60% Duty Cycle At 200 Amperes 40% Duty Cycle At 250 Amperes
Overheating
0
A or V
15
OR
Reduce Duty Cycle
Minutes
20
VOLTS
15
10
0
0 100 200 300 400
AMPERES ssb1.1 10/91 − 196 844 / S-0700
OM-1326 Page 10
4-4. Connecting To Weld Output Terminals
4
1
Do not place
anything between
weld cable terminal
and copper bar.
3
Tools Needed:
3/4 in (19 mm)
803 778-A
Correct Installation Incorrect Installation
Y Turn off power before connecting to 1 Weld Output Terminal minal. Slide weld cable terminal onto weld
weld output terminals. output terminal and secure with nut so that
2 Supplied Weld Output Terminal Nut
weld cable terminal is tight against copper
Y Failure to properly connect weld 3 Weld Cable Terminal bar. Do not place anything between weld
cables may cause excessive heat 4 Copper Bar cable terminal and copper bar. Make
and start a fire, or damage your ma- sure that the surfaces of the weld cable
chine. Remove supplied nut from weld output ter- terminal and copper bar are clean.
3
Tools Needed:
3/4 in Ref. 802 474-E
OM-1326 Page 11
4-6. Connecting Spoolmatic) 15A Or 30A Gun
1 Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
2 Weld Cable
3 Shielding Gas Hose
Route weld cable through opening
in front panel.
1 Route gas hose along side panel.
4 Positive Weld Output Terminal
Connect weld cable to weld output
terminal.
2 5 Regulator/Flowmeter
6 Y-Adapter Fitting
3 Route shielding gas hose up to
regulator/flowmeter. Connect gas
hose to Y-adapter fitting on regula-
tor/flowmeter.
2 6
Tools Needed:
3/4, 5/8 in
804 455-A
OM-1326 Page 12
4-7. Setting Gun Polarity For Wire Type
Changing Polarity
1 Polarity Changeover Label
Information
Always read and follow manufacture’s
recommended polarity.
D
D
Rear Panel
Tools Needed:
1-1/8, 5/8 in
802 028-A / Ref. 802 477-B
OM-1326 Page 13
4-9. Installing Wire Spool And Adjusting Hub Tension
Use compression spring When a slight force is needed
with 8 in (200 mm) spools. to turn spool, tension is set.
Remove these
components
from spindle.
Tools Needed:
15/16 in
072573-B / 802 922
1
2
OM-1326 Page 14
4-11. Electrical Service Guide
Input Voltage 200 230 400 460 575
Input Amperes At Rated Output 48 42 24 21 17
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
Circuit Breaker 1, Time-Delay 2 60 50 30 25 20
Normal Operating 3 70 60 35 30 25
Min Input Conductor Size In AWG4 8 8 12 12 14
96 127 156 206 209
Max Recommended Input Conductor Length In Feet (Meters)
(29) (39) (47) (63) (64)
Min Grounding Conductor Size In AWG4 8 10 12 12 14
OM-1326 Page 15
4-12. Selecting A Location And Connecting Input Power
18 in (457 mm) of 10
space for airflow
L1
5
L2 Y Do not move or operate
6
unit where it could tip.
4
2
1 3
L2 L1
230 VAC, 1
Y Installation must meet all National 2 Plug (NEMA Type 6-50P) 9 Disconnect Device Line Terminals
and Local Codes − have only qualified 3 Receptacle Connect green or green/yellow grounding
persons make this installation. [NEMA Type 6-50R (Customer conductor to disconnect device grounding
Y Disconnect and lockout/tagout input Supplied)] terminal first.
power before connecting input con-
4 Input Power Cord. Connect input conductors L1 and L2 to
ductors from unit.
disconnect device line terminals.
Y Always connect green or green/yel- Connect directly to line disconnect device if
low conductor to supply grounding hard wiring is required. 10 Over-Current Protection
terminal first, and never to a line ter- Select type and size of over-current
5 Black And White Input Conductor (L1
minal. protection using Section 4-11 (fused
And L2)
Y Special installation may be required disconnect switch shown).
where gasoline or volatile liquids are 6 Green Or Green/Yellow Grounding Connect plug to receptacle if hard wiring
present − see NEC Article 511 or CEC Conductor method is not used.
Section 20. 7 Disconnect Device (switch shown in Close and secure door on disconnect device.
1 Rating Label the OFF position) Remove lockout/tagout device, and place
Supply correct input power. 8 Disconnect Device Grounding Terminal switch in the On position.
OM-1326 Page 16
4-13. Threading Welding Wire
1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Pressure Adjustment Knob
5 Drive Roll
4 6 Outlet Wire Guide
7 Gun Conduit Cable
Lay gun cable out straight.
7
Tools Needed:
1 2 3 5 6
6 in
(150 mm)
Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;
continue to hold wire.
1 Pressure
2 Indicator
3 Scale
4
Close and tighten pressure Remove gun nozzle and contact tip. Turn On.
assembly, and let go of wire.
Tighten
1
2
3
WOOD 4
Press gun trigger until wire Feed wire to check drive roll pressure. Cut off wire. Close
comes out of gun. Reinstall Tighten knob enough to prevent slipping. and latch door.
contact tip and nozzle
Ref. 802 064-D / S-0627-A
OM-1326 Page 17
4-14. Using Gun/Cable Holder
1 Side Panel
2 Latch
3 Cable Holder
2 Press latch down to release and
4 open door.
1 3 4 Holster (2)
Wrap cable around cable holder,
and place gun nozzle into holster.
OM-1326 Page 18
Notes
OM-1326 Page 19
4-15. Weld Parameters
OM-1326 Page 20
201 202-A
OM-1326 Page 21
SECTION 5 − OPERATION
5-1. Controls
1 Voltage Control
Turn control clockwise to increase
voltage.
2 Wire Speed Control
4 Turn control clockwise to increase wire
feed speed.
JOG Mode
If the trigger on either gun is held for
1 more than 3 seconds without striking
an arc, the unit will automatically shut
off weld power (and shielding gas
output on MIG gun only), but will feed
wire continuously at the preset wire
feed speed (which may be faster or
slower than Run−in Speed) until trigger
is released.
Run−in Wire Feed Speed Settings
Run−in settings for the MIG and Spool
Guns are independently set and stored
in unit memory. The settings are in
2 percent of the welding wire feed speed
preset. Both settings are adjustable
from 25 to 150 percent.
MIG Gun Run−in is factory set at 100%
which is recommended for most wire
sizes and types.
Spool Gun Run−in is factory set at 50%
which is recommended for .030 & .035
wire. A Run−in setting of 25% is
recommended for .047 wire.
To check Run−in settings, start with
5 the power switch OFF. Press and hold
the MIG or Spool Gun Trigger while
turning the power switch ON. The unit
3 will power up with both the displays
reading 888 , then the voltage display
will read −−− and the wire feed display
will read the preset Run−in percentage
from memory for the gun selected. To
return to the weld mode without
making a change, simply release
trigger and pull the trigger again
momentarily (one second).
To change Run−in settings, start with
the power switch OFF. Press and hold
. This unit has three automatic timers included in its operation to the MIG or Spool Gun Trigger while
help save contact tips, gas, and wire: turning the power switch ON. The unit
will power up with both the displays
Tip Saver − Weld output shuts off if tip is shorted to work surface. reading 888 , then the voltage display
Safety shut-off − Weld output will shut off if no arc is detected within 3 will read −−− and the wire feed display
seconds after gun trigger is depressed. will read the preset Run−in percentage
from memory for the gun selected. To
Jog mode − When loading a new roll of wire or if the gun trigger is change the Run−in value, release the
accidentally pressed, gas will shut off after 1 minute and wire will shut off trigger and turn the wire feed control
after 2 minutes saving wire and gas. knob (or the wire feed adjustment knob
located on the bottom handle of the
spool gun) to the desired setting for the
selected gun. To return to weld mode
after the Run−in speed change, pull
the trigger momentarily (one second).
3 Power Switch
4 Voltmeter
5 Wire Feed Speed Meter
OM-1326 Page 22
5-2. Voltmeter And Wire Feed Speed Meter Operation
1 Voltmeter If welding resumes before unit displays Wire Feed Speed Display (001)
2 Wire Feed Speed Meter preset voltage, actual welding voltage will
HL.P 001 − Communication Lost between
appear on the voltmeter.
Power Up Status Control Board PC1 and Display Board PC2
The wire feed speed meter always displays
Both meters display 888 at unit power up. preset wire feed speed (IPM). HL.P 002 − Unit over temperature, unit is in-
After one second, preset values appear on Gun Selection operative until temperature is reduced in-
both meters. The MIG gun settings (not side unit (see Section 6-2)
The wire feed speed meter will display
spool gun) are always the default at initial HL.P 003 − No Open Circuit Voltage (OCV)
preset wire feed speed (IPM) for the
power up of the unit. If the power is reset to detected when either trigger is pulled
appropriate gun selection either MIG or
quickly, characters other than 888 may ap- spool gun. To preset desired wire feed
pear. To reset, turn power off for at least 3 HL.P 004 − Gun trigger was engaged for
speed, connect desired gun, press gun approximately 2 minutes with no arc
seconds, then turn power back on. trigger for one second, and release trigger. detected, or weld wire is stuck causing a
Welding Status The meter preset will be retained by the direct short. If HL.P 004 occurs during
meter board until a different gun is power up, see Section 6-6.
When either a MIG gun or spool gun trigger
connected and preset is performed or the
is pressed and a welding arc is established,
unit is turned off and back on. The MIG gun HL.P 005 − Wire feed malfunction. Check
the voltmeter displays actual weld voltage.
settings (not spool gun) are always the wire feed delivery system (see Section
When the gun trigger is released and
default at initial power up of the unit. 6-6).
welding arc extinguished, the voltmeter
displays the last actual voltage for 5 Error Messages See Section 6-6 for additional information
seconds and then returns to preset voltage. Volt Meter Display (HL.P) on all HL.P codes.
OM-1326 Page 23
SECTION 6 − MAINTENANCE &TROUBLESHOOTING
3 Months
6 Months
OM-1326 Page 24
6-3. Changing Drive Roll and Wire Inlet Guide
1 Securing Screw
4 2 Inlet Wire Guide
Loosen screw. Slide tip as close to
2 drive rolls as possible without
touching. Tighten screw.
3 Drive Roll
The drive roll consists of two
different sized grooves. The
stamped markings on the end
surface of the drive roll refers to the
groove on the opposite side of the
drive roll. The groove closest to the
motor shaft is the proper groove to
thread (see Section 4-13).
1
4 Drive Roll Securing Nut
Turn nut one click to secure drive
3 roll.
Tools Needed:
7/16 in
Ref. 802 990-A
Tools Needed:
OM-1326 Page 25
6-5. Removing Knob From Front Panel
Y Turn Off power.
1 Front Panel
2 Knob
3 Spring Clip
4 Control Shaft
5 Slot
1 Rotate knob to allow access to slot.
2
Insert Allen wrench (or stiff piece of
3 wire) into slot, and while depressing
4 spring clip, slide knob off control
shaft.
To reinstall, push knob fully onto
control shaft.
Slide Depress
Knob Spring
Clip
5
6-6. Troubleshooting
Trouble Remedy
No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 4-12).
Replace building line fuse or reset circuit breaker if open (see Section 4-12).
HL.P 001 appears on meters. Turn power switch off and back on, if HL.P 001 appears on meters again,
have Factory Authorized Service Agent check unit.
HL.P 002 appears on meters. Thermistor T is detecting an overheating condition. Wait for unit to cool
allowing the fan to run. After unit is cool, if HL.P 002 message remains, have Factory Authorized Service
Agent check for an open Thermistor T (see Section 6-2).
HL.P 004 appears on meters. Reset message by releasing the trigger or removing stuck wire causing
short circuit (see Section 5-2) . If message remains, have Factory Authorized Service Agent check for
shorted trigger leads.
Have Factory Authorized Service Agent check all board connections and main control board.
No Weld Output; wire feeds. Connect work clamp to get good metal to metal contact.
HL.P 003 appears on meters, have Factory Authorized Service Agent check main control board and main
rectifier.
Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 4-12).
Check input voltage jumper links and correct position if necessary (see Section 4-10).
Fan motor does not run. Have Factory Authorized Service Agent check fan-on-demand circuit.
Low, high, or erratic wire speed. Readjust front panel settings (see Section 5-1).
OM-1326 Page 26
Trouble Remedy
Change to correct size drive rolls (see Section 6-3).
Replace inlet guide, contact tip, and/or liner if necessary (see welding gun Owner’s Manual).
No wire feed. Turn Wire Speed control to higher setting (see Section 5-1).
Clear obstruction in gun contact tip or liner (see welding gun Owner’s Manual).
HL.P 002 appears on meters. Thermistor T is detecting an overheating condition. Wait for unit to cool
allowing the fan to run. After unit is cool, If HL.P 002 message remains, contact Factory Authorized
Service Agent (see Section 6-2).
HL.P 004 appears on meters. Reset message by releasing the trigger or removing stuck wire causing
short circuit (see Section 5-2) . If message remains, have Factory Authorized Service Agent check for
shorted trigger leads.
HL.P 005 appears on meters. Wire feed malfunction. Check wire feed delivery system.
OM-1326 Page 27
SECTION 7 − ELECTRICAL DIAGRAM
OM-1326 Page 28
226 707-A
OM-1326 Page 29
SECTION 8 − MIG WELDING (GMAW) GUIDELINES
Shielding
Gas
Supply
Wire Feeder/
Gas Power Source
Hose
Gun
Work Clamp
Workpiece
OM-1326 Page 30
8-2. 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.
(.001 in = 1 ampere)
.125 in = 125 A
Voltage controls
height and width
of weld bead.
OM-1326 Page 31
8-3. 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°
45° 0°-15°
45°
OM-1326 Page 32
8-4. 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.
10°
Push
10°
Perpendicular Drag
OM-1326 Page 33
8-5. 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.
S-0054-A
2 3 4
5
S-0053-A
5
S-0052-B
OM-1326 Page 34
8-8. Troubleshooting − Excessive Spatter
S-0636
Wire feed speed too high. Select lower wire feed speed.
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.
S-0635
Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas. Use welding grade shielding gas; change to different gas.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Excessive heat input. Select lower voltage range and reduce wire feed speed.
OM-1326 Page 35
8-11. Troubleshooting − Lack Of Penetration
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.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.
S-0637
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
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.
Momentarily hold arc on groove side walls when using weaving technique.
S-0640
Excessive heat input. Select lower voltage range and reduce wire feed speed.
OM-1326 Page 36
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
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Excessive heat input. Use restraint (clamp) to hold base metal in position.
OM-1326 Page 37
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
Argon X
Argon + 25% CO2 X
80% or greater Argon +
X X1
balance CO2 or Oxygen
100% CO2 X
Tri-Mix2 X
1 Limited short circuiting use
2 90% HE + 7-1/2% AR + 2-1/2% CO2
Wire spool brake pressure too high. Decrease brake pressure on wire spool.
Restriction in the gun and/or assembly. Check and replace cable, gun, and contact tip if
damaged. Check size of contact tip and cable liner,
replace if necessary.
Wire curling up in front of the Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.
wire feed rolls (bird nesting)
nesting).
Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner length
and diameter, replace if necessary.
Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.
Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder.
Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.
Restriction in gas line. Check gas hose between flowmeter and wire feeder, and
gas hose in gun and cable assembly.
Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.
Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gas
solenoid valve.
Incorrect primary voltage connected to welding power Check primary voltage and relink welding power source
source. for correct voltage.
OM-1326 Page 38
Problem Probable Cause Remedy
Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn
drive rolls if necessary.
Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.
Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
welding power source.
Loose connections at the gun weld cable or work cable. Check and tighten all connections.
Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.
OM-1326 Page 39
SECTION 9 − PARTS LIST
9
not available unless listed.
10
8
23
22
11
7
12
6
13
5
4
14
3 − Fig 9-5
15
2
16
1 − Fig 9-2
17 − Fig 9-3
21
20
19
18
803 008-B
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦OPTIONAL
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-1326 Page 41
. Hardware is common and
15
not available unless listed.
14
11
13
12
17
16
18
10
20
19
9
8
21
7
22
6
5
27
23
4
3
2
30
24
1
26
29
25 − Fig 9-4
28
803007-E
OM-1326 Page 42
Item Dia. Part
No. Mkgs. No. Description 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-1326 Page 43
Item Dia. Part
No. Mkgs. No. Description Quantity
4
5
6
1 5
8
9
10
15
12
13
14 7
803 307-B
11
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-1326 Page 44
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 9-4. Wire Drive And Gears (Fig 9-2 Item 26)
7 10
12
26 6 11
4 16
3 25
2 24
1 23
22
21 15
16
20 19
17
18 802 986-C
4
8
2
1
+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-1326 Page 46
9-6. Drive Roll And Wire Guide Kits
Note Base selection of drive rolls upon the following recommended usages:
1 V-Grooved rolls for hard wire.
2 U-Grooved rolls for soft and soft shelled cored wires.
3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4 V-Knurled rolls for hard shelled cored wires.
5 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination
with U-Grooved).
.030 in. .030 in. 0.8 mm 079 594 053 695 V-Grooved 056 192
.035 in. .035 in. 0.9 mm 079 595 053 700 V-Grooved 056 192
.045 in. .045 in. 1.2 mm 079 596 053 697 V-Grooved 056 193
Ref. S-0026-B/7-91
OM-1326 Page 47
Notes
Notes
Notes
Effective January 1, 2006
(Equipment with a serial number preface of “LG” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets, Cables, and
Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
* APT & SAF Model Plasma Cutting Torches
for your local material and workmanship at the time it is shipped by Miller. THIS * Remote Controls
Miller distributor. WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Accessory (Kits)
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Replacement Parts (No labor)
Within the warranty periods listed below, Miller will repair or * Spoolmate Spoolguns
Your distributor also gives replace any warranted parts or components that fail due to such * Canvas Covers
you ... defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which Miller’s True Blue® Limited Warranty shall not apply to:
Service time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings, relays
reliable response you Miller shall honor warranty claims on warranted equipment listed or parts that fail due to normal wear. (Exception:
need. Most replacement below in the event of such a failure within the warranty time brushes, slip rings, and relays are covered on Bobcat,
parts can be in your periods. All warranty time periods start on the date that the Trailblazer, and Legend models.)
hands in 24 hours. equipment was delivered to the original retail purchaser, or one 2. Items furnished by Miller, but manufactured by others, such
year after the equipment is sent to a North American distributor as engines or trade accessories. These items are covered
Support or eighteen months after the equipment is sent to an by the manufacturer’s warranty, if any.
Need fast answers to the International distributor.
tough welding questions? 3. Equipment that has been modified by any party other than
1. 5 Years Parts — 3 Years Labor Miller, or equipment that has been improperly installed,
Contact your distributor.
The expertise of the * Original main power rectifiers improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
distributor and Miller is 2. 3 Years — Parts and Labor
necessary maintenance, or equipment which has been
there to help you, every * Transformer/Rectifier Power Sources used for operation outside of the specifications for the
step of the way. * Plasma Arc Cutting Power Sources equipment.
* Process Controllers MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Semi-Automatic and Automatic Wire Feeders USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated)
In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Engine Driven Welding Generators replacement; or, where authorized in writing by Miller in
(NOTE: Engines are warranted separately by the appropriate cases, (3) the reasonable cost of repair or
engine manufacturer.) replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
3. 1 Year — Parts and Labor Unless Specified depreciation based upon actual use) upon return of the goods at
* Motor Driven Guns (w/exception of Spoolmate customer’s risk and expense. Miller’s option of repair or
Spoolguns) replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
* Positioners and Controllers Miller. Therefore no compensation or reimbursement for
* Automatic Motion Devices transportation costs of any kind will be allowed.
* RFCS Foot Controls TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Induction Heating Power Sources, Coolers, and PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
Electronic REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Controls/Recorders DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Water Coolant Systems (Non-Integrated)
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
* Flowgauge and Flowmeter Regulators (No Labor) OTHER LEGAL THEORY.
* HF Units ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Grids ANY IMPLIED WARRANTY, GUARANTY OR
* Spot Welders REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Load Banks OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Arc Stud Power Sources & Arc Stud Guns PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Racks OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Running Gear/Trailers MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Plasma Cutting Torches (except APT & SAF PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
Models) FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
* Field Options BY MILLER.
(NOTE: Field options are covered under True Blue® Some states in the U.S.A. do not allow limitations of how long an
for the remaining warranty period of the product they implied warranty lasts, or the exclusion of incidental, indirect,
are installed in, or for a minimum of one year — special or consequential damages, so the above limitation or
whichever is greater.) exclusion may not apply to you. This warranty provides specific
* Bernard-Branded Mig Guns (No Labor) legal rights, and other rights may be available, but may vary from
state to state.
* Weldcraft-Branded TIG Torches (No Labor)
In Canada, legislation in some provinces provides for certain
* Subarc Wire Drive Assemblies
additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
5. 90 Days — Parts provides specific legal rights, and other rights may be available,
* MIG Guns/TIG Torches and Subarc (SAW) Guns but may vary from province to province.
miller_warr 2006−01
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.