Miller Electric OM-1589 manual Maintenance and Troubleshooting, Routine Maintenance, Months

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SECTION 11 − MAINTENANCE AND TROUBLESHOOTING

11-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replace

Unreadable

Labels

Clean

And

Tighten

Weld

Terminals

Repair Or

Replace

Cracked

Weld

Cable

Replace	14-Pin Cord	Gas	Gun
Cracked		Hose And
			Cable
Parts		Fittings

6 Months

Blow Out Or Vacuum

Inside. During HeavyOR

Service, Clean

Monthly

Clean

Drive

Rolls

11-2. Feeder Drive Assembly Maintenance

5

1

6

3

2 4

7

Retract wire onto spool.

1Pressure Roll Assembly

2Drive Motor Shaft

3Setscrew

4Drive Roll

.Number size of desired drive roll groove, located on side of drive roll closest to groove, must face inside toward shaft

when reinstalling drive roll.

Use wire brush to clean drive roll. Install drive roll with desired groove in, and turn drive roll so one setscrew faces flat side of shaft.

5 Bearing

Use wire brush to clean bearing.

6 Wire Conduit Fitting

Ref. 800 944 / 151 781 / Ref. 151 781

Line up drive roll groove with bearing groove and opening in conduit fitting. Tighten set- screws.

7 Wire Inlet Guide

Pull guide toward rear of feeder to remove. Install new guide.

Thread welding wire and adjust drive roll pressure, if necessary (see Sections 3-13and 3-14).

Tools Needed:

5/16 in

OM-1589 Page 35

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Contents Description OM-1589Processes From Miller to You Table of Contents 10-2 10-111-1 11-2Deccon 11/96 DirectivesStandards Page Marks a special safety message Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explo- sion ARC Rays can burn eyes and skinFlying Metal can injure eyes Buildup of GAS can injure or killPrincipal Safety Standards About Pacemakers EMF Information− Consignes DE Securite − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un incendie ou une explosionDES Pièces Chaudes peuvent pro- voquer des brûlures graves LE Bruit peut affecter l’ouïeLA Chute DE L’APPAREIL peut blesser Risque D’INCENDIE OU’EMPLOI Excessif peut DES Organes Mobiles peuvent provoquer des blessuresConsignes relatives aux stimulateurs cardiaques Principales normes de sécuritéInformation sur les champs électromagnétiques − Definitions Disconnect input plug or power before working on machineDrive rolls can injure fingers Keep your head out of the fumesManufacturer’s Rating Label for CE Products Symbols And DefinitionsSpecifications − InstallationType of Input Welding Power Wire Feed Welding Overall WeightTools Needed 16, 5/8, 11/16, 3/4 Typical Water-Cooled System ConnectionsPin Pin Information Rear Panel ConnectionsPin Plug Information Internal Connections for Air-Cooled Gun Internal Connections for Water-Cooled GunTions directly to gun hose To gun partsTools Needed 11/16, 1-1/8 Water-Cooled Model Shown Front Panel Connections for GunWater-Cooled Guns Air-Cooled GunSetting Torque Switch Adjusting Contact Tip PositionTorque Switch Removing Top Cover of GunWire Spool Top Cover Pressure Roll Assembly Gun Contact Tip Installing Wire SpoolHub Tension Adjustment Threading Welding Wire Through FeederWire Cally live when gun150 mm Open tension arm Tools Needed OM-1589Pulse Welding Terms − OperationOperational Terms Front Panel Controls Gun Controls Side and Rear Panel ControlsSequence Parameters in a Program − Setting Sequence ParametersSelecting Dual Schedule Pair − Setting Dual Schedule ParametersDual Schedule Switch Diagrams − Using the Optional Data CardData Card Terms AdapterWire feeder memory Installing Data CardCard Displays 3 seconds and the 8 programsDisplay Setting − System SetupSystem Setup Display Parameters Program 2 − Aluminum − Standard Pulse Welding ProgramsProgram 1 − Aluminum Program 4 − Aluminum Program 3 − AluminumGas 100% Argon / 20-Max CFH 24.5 435 325Program 6 − Aluminum Program 5 − Aluminum23.2 490 290 Gas 100% Argon / 20-45 CFHProgram 7 − Aluminum Program 8 Aluminum875 485 140 250 31.5 820 470 135 240 30.9 765 450 21.2 160 305 19.6 105 300 22.2Teach Points Explained − Teach PointsRedefining Pulse Parameters Redefining Teach PointsRedefining IPM Teach Point Serial Number Wire Feeder Date Program Number Wire Size/TypeFlowrate CFHL/min PositiveRoutine Maintenance − Maintenance and TroubleshootingFeeder Drive Assembly Maintenance Disconnect power before maintainingChanging Gun Contact Tip and Liner Gun Drive Assembly MaintenanceRemoving Water-Cooled Contact Tip Adapter Removing Air-Cooled Contact Tip AdapterBarrel Extension Remove as shownNo Volt Sensed Error Display Error DisplaysRelease Trigger Error Display E s s OM-1589 Using Self TestDisconnect power before troubleshooting TroubleshootingFilter, and clean fittings Trouble RemedyOM-1589 Circuit Diagram − Electrical Diagram184 771-A Circuit Diagram For Gun OM-1589 List Main AssemblyPLG1 PLG81 Motor & Wire Drive -1 Item Motor & Wire DrivePanel, Front w/Components -1 Item Panel, Front w/ComponentsPC40 PC60Barrel Assembly 137 Barrel ASSEMBLY, water cooled XRM-15W & 30W models Includes Item 34 33 13−5 48Fig133 Item Dia Part Mkgs Description Quantity Your distributor also gives ServiceSupport Step of the wayTo locate distributor nearest you call 1-800-4-A-Miller Miller Electric Mfg. Co