Miller Electric XLT 165, XLT 135 Installation, Installing Welding Gun Installing Work Clamp

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SECTION 3 − INSTALLATION

3-1. Installing Welding Gun

3-2. Installing Work Clamp

Tools Needed:

3/8, 7/16 in

1Drive Assembly

2Gun Securing Thumbscrew

3Gun End

	4	Loosen thumbscrew. Insert gun
		end through opening until it bottoms
		against drive assembly. Tighten
		thumbscrew.
		4 Gun Trigger Leads
2	3	Insert leads, one at a time, through
		gun opening on front panel.
		Connect female friction terminals to
		matching male terminals in unit.
		Polarity is not important.

Close door.

		Ref. 802 440
3	1	Nut
3	2	Work Cable From Unit
	2	Work Cable From Unit
	3	Work Clamp
	4	Screw
	5	Work Clamp Tabs

Bend tabs around work cable.

802 456

OM-198 076 Page 12

Image 16

Contents OM-198 076A ProcessesDescription AprilPage Table of Contents Page Symbol Usage Marks a special safety messageArc Welding Hazards Electric Shock can killARC Rays can burn eyes and skin Welding can cause fire or explosionFlying Metal can injure eyes Buildup of GAS can injure or killPrincipal Safety Standards EMF Information About PacemakersSignification des symboles − Consignes DE Securite − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un incendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent pro- voquer des brûlures graves LE Bruit peut affecter l’ouïeRisque D’INCENDIE OU LA Chute DE L’APPAREIL peut blesser’EMPLOI Excessif peut DES Organes Mobiles peuvent provoquer des blessuresInformation sur les champs électromagnétiques Principales normes de sécuritéConsignes relatives aux stimulateurs cardiaques Specifications − SpecificationsVAC Model Duty Cycle And Overheating Output Duty Cycle %Output Amperes OverheatingVolt-Ampere Curves − Installation Installing Welding Gun Installing Work ClampProcess/Polarity Table Changing PolarityInstalling Gas Supply Flow AdjustCO2 Adapter Customer Sup- plied Regulator/flowmeter and CO2 cylinder CO2 GasRating Label Grounded ReceptacleVolt, 20 ampere individual Up to 200 ft 61 mDo not move or operate unit where it could tip PlugReceptacle See SectionElectrical Service Guide For 230 VAC Model Installing Wire Spool And Adjusting Hub TensionStandard Wire Spool 8 Lb Wire Spool 4 Adjusting Hub TensionThreading Welding Wire Voltage Switch Power Switch OM-198 076− Operation ControlsWeld Parameters For 115 VAC Model Weld Parameters For 230 VAC Model − Maintenance &TROUBLESHOOTING Routine MaintenanceOverload Protection Drive Motor ProtectionTurn Off power before replacing contact tip Changing Drive Roll Or Wire Inlet GuideReplacing Gun Contact Tip Disconnect gun from unit Cleaning Or Replacing Gun LinerTo Reassemble Gun Replacing Switch And/Or Head Tube Trouble Remedy Troubleshooting TableDoes not run − Electrical Diagram Circuit Diagram For 115 VAC ModelCircuit Diagram For 230 VAC Model − MIG Welding Gmaw Guidelines Typical MIG Process ConnectionsTypical MIG Process Control Settings Wire Size Amperage RangeSelect Wire Size Recommendation Wire Speed Select VoltageHolding And Positioning Welding Gun Conditions That Affect Weld Bead Shape Push Perpendicular DragShort Normal Long ShortNormalLongGood Weld Bead Characteristics Poor Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Excessive Spatter Troubleshooting − PorosityTroubleshooting − Excessive Penetration Possible Causes Corrective ActionsTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Burn-Through Troubleshooting − Waviness Of Bead Troubleshooting − DistortionBase metal to move DirectionApplication Common MIG Shielding GasesFlat & Horizontal1 Fillet − Parts List Main AssemblyDia Part Description Quantity Mkgs Gun 024 .6 and .030/.035 .8 042024 .6 and .045 Page Warranty Owner’s Record