Professional Documents
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Millermatic 210
Millermatic 210
Millermatic 210
May 2001
Processes
MIG (GMAW) Welding
Description
Millermatic 210
R
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-2. Weld Parameter Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OM-1325 (Continued)
TABLE OF CONTENTS
SECTION 6 – MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-3. Holding And Positioning Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-4. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-5. Gun Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-6. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-7. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-8. Troubleshooting – Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-9. Troubleshooting – Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-10. Troubleshooting – Excessive Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-11. Troubleshooting – Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-12. Troubleshooting – Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-13. Troubleshooting – Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-14. Troubleshooting – Waviness Of Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6-15. Troubleshooting – Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6-16. Common MIG Shielding Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6-17. Troubleshooting Guide For Semiautomatic Welding Equipment . . . . . . . . . . . . . . . . . . . . . . . 37
WARRANTY
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.
OM-1325 Page 1
ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill.
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 a welding helmet fitted with a proper shade of filter 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 Use protective screens or barriers to protect others from flash and D Allow cooling period before working on gun or
glare; warn others not to watch the arc. torch.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks going near arc welding, gouging, or spot
can fly off from the welding arc. The flying sparks, hot welding operations.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding. NOISE can damage hearing.
D Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
D Do not weld where flying sparks can strike flammable material. damage hearing.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers. D Wear approved ear protection if noise level is
high.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can CYLINDERS can explode if damaged.
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes, Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
unless they are properly prepared according to AWS F4.1 (see gas cylinders are normally part of the welding
Safety Standards). process, be sure to treat them carefully.
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly D Protect compressed gas cylinders from excessive heat, mechani-
unknown paths and causing electric shock and fire hazards. cal shocks, slag, open flames, sparks, and arcs.
D Do not use welder to thaw frozen pipes. D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use. D Keep cylinders away from any welding or other electrical circuits.
D Wear oil-free protective garments such as leather gloves, heavy D Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap. D Never allow a welding electrode to touch any cylinder.
D Remove any combustibles, such as a butane lighter or matches, D Never weld on a pressurized cylinder – explosion will result.
from your person before doing any welding.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
FLYING METAL can injure eyes.
D Turn face away from valve outlet when opening cylinder valve.
D Welding, chipping, wire brushing, and grinding D Keep protective cap in place over valve except when cylinder is in
cause sparks and flying metal. As welds cool, use or connected for use.
they can throw off slag.
D Read and follow instructions on compressed gas cylinders,
D Wear approved safety glasses with side associated equipment, and CGA publication P-1 listed in Safety
shields even under your welding helmet. Standards.
OM-1325 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
OM-1325 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from opera-
committee’s judgment, has not demonstrated that exposure to power- tor as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as possi-
examined. Until the final conclusions of the research are reached, you ble.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.
OM-1325 Page 4
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT
UTILISATION
som _nd_fre 4/98
OM-1325 Page 5
LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris-
voquer des brûlures dans les yeux et quent de provoquer des blessures ou
sur la peau. même la mort.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas de
(ultraviolets et infrarouges) susceptibles de provoquer non utilisation.
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
pendant le soudage. rateur d’adduction d’air homologué.
D Porter un casque de soudage muni d’un écran de filtre approprié pour
protéger votre visage et vos yeux pendant le soudage ou pour regar-
der (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des protections approuvés pour les oreilles si le niveau sondre est DES PIÈCES CHAUDES peuvent pro-
trop élevé. voquer des brûlures graves.
D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas re- D Ne pas toucher des parties chaudes à mains nues
garder l’arc. D Prévoir une période de refroidissement avant
D Porter des vêtements de protection constitué dans une matière dura- d’utiliser le pistolet ou la torche.
ble, résistant au feu (cuir ou laine) et une protection des pieds.
OM-1325 Page 6
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
OM-1325 Page 7
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés connexes, norme
20402. CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Recommended Safe Practice for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, norme AWS Safe Practices For Occupation And Educational Eye And Face Protec-
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL tion, norme ANSI Z87.1, de l’American National Standards Institute,
33126 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, de la National Fire Protec- Cutting and Welding Processes, norme NFPA 51B, de la National Fire
tion Association, Batterymarch Park, Quincy, MA 02269. Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-1325 Page 8
SECTION 2 – INSTALLATION
Wire Type and Diameter Wire Feed Maximum Dimensions Net Weight
Speed Spool Size
Solid Steel Stainless Steel Flux Cored 35–700 IPM 12 in (305 H: 37 in (940 mm) 215 lb
(.89–17.8 mm) Diameter W: 19 in (483 mm) (98 kg)
.023 – .035 in .023 – .035 in .030 – .045 in m/min) 33 lb (15 kg) D: 30-1/4 in (768 mm)
(0.6 – 1.2 mm) (0.6 – 0.9 mm) (0.8 – 1.2 mm)
Operating Temperature Range – –20C to +40C Storage Temperature Range – -30C to + 50C
60% Duty Cycle At 160 Amperes 30% Duty Cycle At 210 Amperes
Overheating
0
A or V
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 – 204 075
OM-1325 Page 9
2-3. MIG Welding Gun Duty Cycle And Overheating
CAUTION
WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty.
• Do not weld at rated load longer than shown below.
• Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93
Definition .023 To .045 in (0.6 To 1.1 mm) .023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires
Hard Or Flux Cored Wires
0 60% Duty Cycle At 300 Amperes
100% Duty Cycle At 200 Amperes Using CO2
10 Using CO2
Minutes 60% Duty Cycle At 200 Amperes
100% Duty Cycle At 150 Amperes Using Mixed Gases
Using Mixed Gases
OM-1325 Page 10
2-5. Installing Work Clamp
1 Work Cable
2 Boot
Route cable through front panel
opening. Slide boot onto work
cable.
3 Negative (–) Output Terminal
Connect cable to terminal and
cover connection with boot.
Close door.
2 1
Tools Needed:
3/4 in
Ref. 802 713
4
2
OM-1325 Page 11
2-7. Connecting An Optional Spool Gun
1 Barbed Fitting
1
2 . If spool gun gas hose is
equipped with a pre-installed
barbed fitting, cut off fitting from
end of hose.
Connect spool gun gas hose to
barbed fitting.
2 Gun Trigger Plug
Insert plug into receptacle labeled
“SPOOL GUN”, and tighten
threaded collar.
3 Negative (–) Output Terminal
4 4 Positive (+) Output Terminal
3 Close door.
802 998
D
D
OM-1325 Page 12
2-9. Installing Gas Supply
Obtain gas cylinders and chain to
running gear, wall, or other
1 stationary support so cylinders
cannot fall and break off valve.
1 Cap
2 Cylinder Valve
2
Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
3 3 Cylinder
4 Regulator/Flowmeter
4 Install so face is vertical.
5 Regulator/Flowmeter Gas
Hose Connection
Argon Gas Or
6 Welding Power Source Gas
Mixed Gas 1
8 Hose Connection For Spool
Gun
OR 7 Welding Power Source Gas
5 Hose Connection For MIG
2 Gun
Connect gas hose between
regulator/flowmeter gas hose con-
nection, and fitting on rear of
3 welding power source.
8 Gas Flow Adjustment Control
9 10
Typical flow rate is 25 cfh (cubic
feet per hour). Check wire
CO2 Gas manufacturer’s recommended
flow rate.
9 CO2 Adapter (Customer
Supplied)
10 O-Ring (Customer Supplied)
Install adapter with O-ring between
regulator/flowmeter and CO2
cylinder.
Rear
Panel
Tools Needed:
1-1/8, 5/8 in
802 028-A / Ref. 802 991
OM-1325 Page 13
2-10. Installing MIG Wire Spool and Adjusting Hub Tension
Tools Needed:
15/16 in
072573-B
OM-1325 Page 14
2-11. Positioning Jumper Links
Check input voltage available at
site and listed on the machine rating
label.
1 Jumper Links Access Door
Open door.
3
2 Jumper Link Label
200 VOLTS
Check label – only one is on unit.
3 Input Voltage Jumper Links
Move jumper links to match input
230 VOLTS voltage.
Close and secure access door.
S-153 980
2
1
Tools Needed:
3/8 in
1 Rating Label
Supply correct input power.
2 Plug (NEMA Type 6-50P)
3 Receptacle
(NEMA Type 6-50R)
Connect plug to receptacle.
18 in (457 mm) of 4 Input And Grounding
Y Do not move or operate unit Conductors
space for airflow where it could tip.
Connect directly to line disconnect
device if hard wiring is required.
Y Always connect
grounding conductor first. 5 Line Disconnect Device
= GND/PE See Section 2-12.
Y Special installation may be
required where gasoline or
volatile liquids are present –
5 see NEC Article 511 or CEC
Section 20.
L1
L2
4 2
L2 L1
230 VAC, 1
802 991
OM-1325 Page 16
2-14. 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.
Tighten
. Use pressure indicator
scale to set a desired
drive roll pressure.
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-A / S-0627-A
OM-1325 Page 17
2-15. Using Gun/Cable Holder
1 1 Side Panel
2 Latch
2 3 Cable Holder
4 Press latch down to release and
open door.
3 4 Holster (2)
Wrap cable around cable holder,
and place gun nozzle into holster.
802 726
OM-1325 Page 18
SECTION 3 – OPERATION
3-1. Controls
V
WIRE SPEED VOLTAGE
50
40 60 2
1 3
2 1
30 70 4
20 80 5
10 6
90
DO NO T SWITCH
WHILE WELDING
100 7
ON OFF
5 4
OM-1325 Page 19
3-2. Weld Parameter Chart
. This chart provides starting parameters assuming that line voltage at the machine
location is close to the machine linked voltage setting (within several volts higher or
lower). If line voltage is significantly higher or lower than the linked voltage setting,
welding parameters will need to be adjusted accordingly (e.g. machine linked for 230
volts ac and line voltage measures 218 volts ac, parameter chart settings will be
slightly cold by weld bead appearance).
OM-1325 Page 20
204 890
OM-1325 Page 21
SECTION 4 – MAINTENANCE &TROUBLESHOOTING
3 Months
6 Months
1 3
Tools Needed:
OM-1325 Page 23
4-6. Aligning Drive Rolls and Wire Guide
Y Turn Off power.
View is from top of drive rolls look-
ing down with pressure assembly
open.
Correct Incorrect 1 Drive Roll Securing Nut
3 4 2 Drive Roll
2 3 Wire Guide
1 4 Welding Wire
5 Drive Gear
5 Insert screwdriver, and turn screw
in or out until drive roll groove lines
up with wire guide.
Close pressure roll assembly.
Tools Needed:
OM-1325 Page 24
4-7. Cleaning Or Replacing Gun Liner
Tools Needed:
Y Disconnect gun from unit first.
5/16 in, 10 mm
Head Tube
5/16 in
10 mm
Remove liner.
To Reassemble Gun:
Blow out gun casing.
Install and tighten new liner.
Cut liner off 3/4 in (20 mm) (3/8 in
[9.5 mm] for aluminum) from head
tube.
Install adapter, contact tip, and
nozzle.
OM-1325 Page 25
4-8. Replacing Switch And/Or Head Tube
1 Remove handle
locking nut.
3 Slide handle.
4 Secure head
tube in vice.
6 Install existing shock washer onto 7 Place head tube in vice and tighten
new head tube. Hand-tighten head until nuts are tight.
tube into connector cable.
Tools Needed:
3/4 in
OM-1325 Page 26
4-9. Troubleshooting
Check circuit breaker CB1, and reset if necessary (see Section 4-2).
Replace building line fuse or reset circuit breaker if open (see Section 2-13).
Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 2-6 and/or 4-8).
Thermostat TP1 or TP2 open (overheating). Allow fan to run; the thermostat will close when the unit has
cooled (see Section 4-3).
No weld output; wire feeds. Connect work clamp to get good metal to metal contact.
Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 2-13).
Low, high, or erratic wire speed. Readjust front panel settings (see Section 3-1).
Replace inlet guide, contact tip, and/or liner if necessary (see Sections 4-4, and 4-7).
Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts (see Section 4-7).
welding.
Adjust drive roll pressure (see Section 2-14).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 4-7).
Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 2-6 and/or 4-8).
Check and clear any restrictions at drive assembly and liner (see Section 4-7).
OM-1325 Page 27
SECTION 5 – ELECTRICAL DIAGRAM
204 891
Shielding
Gas
Supply
Wire Feeder/
Gas Power Source
Hose
Gun
Work Clamp
Workpiece
OM-1325 Page 29
6-2. 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.
802 992
OM-1325 Page 30
6-3. 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-1325 Page 31
6-4. 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-1325 Page 32
6-5. 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-1325 Page 33
6-8. 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-1325 Page 34
6-11. 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-1325 Page 35
6-14. 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-1325 Page 36
6-16. 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
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).
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-1325 Page 37
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-1325 Page 38
Notes
OM-1325 Page 39
SECTION 7 – PARTS LIST
. Hardware is common and
not available unless listed.
13
5
4
12
11
10
3
2 Fig. 7–3
7
9
8
6
1 Fig. 7–2
19
20
21
22
14
15
26
24
23
25
16 Fig. 7–4
18
17 Fig. 7–5
802 993
OM-1325 Page 40
Item Dia. Part
No. Mkgs. No. Description Quantity
OM-1325 Page 41
. Hardware is common and
13
not available unless listed.
14
15
16
12
11
17
10
18
9
19
8
21
20
7
22
6
5
23
4
3
2
1
27
26
25
24
28
802 989
OM-1325 Page 42
Item Dia. Part
No. Mkgs. No. Description Quantity
OM-1325 Page 43
. Hardware is common and
not available unless listed. 7
6 8
3
2
802 988
OM-1325 Page 44
. Hardware is common and 3
not available unless listed. 2
1
5
10
13
11
12
8
802 987
+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-1325 Page 45
16
15
14
13
11
12
10
11
12
9
8
7
6
17
5
4
3
2
1
OM-1325 Page 46
Item Part
No. No. Description Quantity
♦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-1325 Page 47
Item Dia. Part
No. Mkgs. No. Description Quantity
204857 Figure 7-6. Wire Drive And Gears (Figure 7-2 Item 24)
... 1 .......... 602009 . . SCREW,.250-20 x 1.25 soc hd gr 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .......... 172075 . . CARRIER,DRIVE ROLL W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .......... 166072 . . SPACER,GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .......... 010224 . . PIN,SPRING CS .187 X 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .......... 182788 . . HOUSING,ADAPTER GUN/FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .......... 085242 . . FASTENER,PINNED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 .......... 196896 . . CUP,SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .......... 196897 . . SPRING,CPRSN .695 OD X .095 WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .......... 196895 . . KNOB,TENSION ADJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 166071 . . LEVER,MTG PRESSURE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 204510 . . PIN,HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 151828 . . PIN,COTTER HAIR .054 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 173616 . . COVER,RIGHT ANGLE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 202888 . . MOTOR,GEAR 24VDC 122RPM 20:1 RATIO (CONSISTING OF) . . . . . . . . . 1
................ 193633 . . . . KEY,WOODRUFF .118 X .380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 193634 . . . . WASHER,WAVE .405 ID X .740 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
................ 193635 . . . . RING,RTNG EXT .394 SHAFT X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 079633 . . FITTING,HOSE BRS BARBED M 3/16TBG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 601966 . . SCREW,.375–16 X 1.25HEXHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . 604538 . . WASHER,FLAT STL SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 204585 . . KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 173619 . . CARRIER,DRIVE ROLL W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 174609 . . SCREW,M 4–.7 x 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 174610 . . SCREW,M 6–1.0 X 20 SOC HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . . . . . . . 192029 . . WASHER,FLAT .250 ID X .437 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 24 . . . . . . . . . . 173620 . . BUSHING,MOTOR MTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 25 . . . . . . . . . . 602243 . . WASHER,FLAT .438 ID X 1.00 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . 602213 . . WASHER,LOCK .380 ID X .683 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 203526 . . ROLL,DRIVE V GROOVE .030/.035 COMB WIRE . . . . . . . . . . . . . . . . . . . . . . 2
................ 056192 . . GUIDE,WIRE INLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ *045127 . . GUIDE,WIRE INLET ANTI–WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
See Table 7-1 9
Drive Roll & Wire Guide Kits. 13
6 11
5
4
16
3 26
2 25
1 24
23
22 15
16
21 20
18
19
Figure 7-6. Wire Drive And Gears 802 986
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).
.045 in. .045 in. 1.2 mm 079 596 053 697 V-Grooved 056 193
Ref. S-0026-B/7-91
OM-1325 Page 49
Notes
Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
Call LIMITED WARRANTY – Subject to the terms and conditions * APT, ZIPCUT & PLAZCUT Model Plasma Cutting
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches
1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold
* Remote Controls
for your local after the effective date of this limited warranty is free of defects
* Accessory Kits
in material and workmanship at the time it is shipped by Miller.
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Replacement Parts (No labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate 185 & Spoolmate 250
Within the warranty periods listed below, Miller will repair or * Canvas Covers
Your distributor also gives replace any warranted parts or components that fail due to
you ... Miller’s True Blue Limited Warranty shall not apply to:
such defects in material or workmanship. Miller must be
Service notified in writing within thirty (30) days of such defect or 1. Consumable components; such as contact tips,
failure, at which time Miller will provide instructions on the cutting nozzles, contactors, brushes, slip rings,
You always get the fast, warranty claim procedures to be followed.
reliable response you relays or parts that fail due to normal wear.
need. Most replacement Miller shall honor warranty claims on warranted equipment
2. Items furnished by Miller, but manufactured by others,
parts can be in your listed below in the event of such a failure within the warranty
such as engines or trade accessories. These items are
time periods. All warranty time periods start on the date that
hands in 24 hours. the equipment was delivered to the original retail purchaser, or
covered by the manufacturer’s warranty, if any.
Support one year after the equipment is sent to a North American 3. Equipment that has been modified by any party other
Need fast answers to the distributor or eighteen months after the equipment is sent to an than Miller, or equipment that has been improperly
International distributor. installed, improperly operated or misused based upon
tough welding questions?
Contact your distributor. 1. 5 Years Parts – 3 Years Labor industry standards, or equipment which has not had
The expertise of the reasonable and necessary maintenance, or equipment
* Original main power rectifiers which has been used for operation outside of the
distributor and Miller is specifications for the equipment.
* Inverters (input and output rectifiers only)
there to help you, every
step of the way. 2. 3 Years — Parts and Labor MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Transformer/Rectifier Power Sources PERSONS TRAINED AND EXPERIENCED IN THE USE
* Plasma Arc Cutting Power Sources AND MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Inverter Power Supplies exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
* Intellitig appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
3. 1 Year — Parts and Labor replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
* Motor Driven Guns (w/exception of Spoolmate transportation costs of any kind will be allowed.
185 & Spoolmate 250)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Process Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Positioners and Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* RFCS Foot Controls PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources ANY OTHER LEGAL THEORY.
* Water Coolant Systems ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
* HF Units AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Maxstar 140 OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
* Spot Welders OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Load Banks OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
* Miller Cyclomatic Equipment MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
* Running Gear/Trailers EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
* Plasma Cutting Torches (except APT & SAF DISCLAIMED BY MILLER.
Models) Some states in the U.S.A. do not allow limitations of how long
* Field Options an implied warranty lasts, or the exclusion of incidental,
(NOTE: Field options are covered under True indirect, special or consequential damages, so the above
Blue for the remaining warranty period of the limitation or exclusion may not apply to you. This warranty
product they are installed in, or for a minimum of provides specific legal rights, and other rights may be
one year — whichever is greater.) available, but may vary from state to state.
miller_warr 7/00
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier for: 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.