Miller Electric
XLT 135, XLT 165, XLT 165, XLT 135
warranty
Weld Parameters For 230 VAC Model
Troubleshooting
Specs
Poor Weld Bead Characteristics
Install
Parts list
Electrical Diagram
Symbol Usage
Threading Welding Wire
Warranty
Flow Adjust
Page 25
4-3.
Weld Parameters For 230 VAC Model
196
081-A
OM-198
076 Page 21
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Page 26
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Page 24
Page 26
Contents
Processes
OM-198 076A
Description
April
Page
Table of Contents
Page
Marks a special safety message
Symbol Usage
Arc Welding Hazards
Electric Shock can kill
Welding can cause fire or explosion
ARC Rays can burn eyes and skin
Flying Metal can injure eyes
Buildup of GAS can injure or kill
Principal Safety Standards
About Pacemakers
EMF Information
− Consignes DE Securite − Lire Avant Utilisation
Signification des symboles
UN Choc Électrique peut tuer
LES Fumées ET LES GAZ peuvent être dangereux
DES Particules Volantes peuvent blesser les yeux
LE Soudage peut provoquer un incendie ou une explosion
DES Pièces Chaudes peuvent pro- voquer des brûlures graves
LE Bruit peut affecter l’ouïe
LA Chute DE L’APPAREIL peut blesser
Risque D’INCENDIE OU
’EMPLOI Excessif peut
DES Organes Mobiles peuvent provoquer des blessures
Information sur les champs électromagnétiques
Principales normes de sécurité
Consignes relatives aux stimulateurs cardiaques
Specifications
− Specifications
VAC Model
Output Duty Cycle %
Duty Cycle And Overheating
Output Amperes
Overheating
Volt-Ampere Curves
Installing Welding Gun Installing Work Clamp
− Installation
Changing Polarity
Process/Polarity Table
Flow Adjust
Installing Gas Supply
CO2 Adapter Customer Sup- plied
Regulator/flowmeter and CO2 cylinder CO2 Gas
Grounded Receptacle
Rating Label
Volt, 20 ampere individual
Up to 200 ft 61 m
Plug
Do not move or operate unit where it could tip
Receptacle
See Section
Installing Wire Spool And Adjusting Hub Tension
Electrical Service Guide For 230 VAC Model
Standard Wire Spool 8 Lb Wire Spool 4
Adjusting Hub Tension
Threading Welding Wire
Power Switch OM-198 076
Voltage Switch
− Operation
Controls
Weld Parameters For 115 VAC Model
Weld Parameters For 230 VAC Model
Routine Maintenance
− Maintenance &TROUBLESHOOTING
Overload Protection
Drive Motor Protection
Turn Off power before replacing contact tip
Changing Drive Roll Or Wire Inlet Guide
Replacing Gun Contact Tip
Disconnect gun from unit
Cleaning Or Replacing Gun Liner
To Reassemble Gun
Replacing Switch And/Or Head Tube
Trouble Remedy
Troubleshooting Table
Does not run
Circuit Diagram For 115 VAC Model
− Electrical Diagram
Circuit Diagram For 230 VAC Model
Typical MIG Process Connections
− MIG Welding Gmaw Guidelines
Wire Size Amperage Range
Typical MIG Process Control Settings
Select Wire Size Recommendation Wire Speed
Select Voltage
Holding And Positioning Welding Gun
Push Perpendicular Drag
Conditions That Affect Weld Bead Shape
Short Normal Long
ShortNormalLong
Good Weld Bead Characteristics
Poor Weld Bead Characteristics
Gun Movement During Welding
Troubleshooting − Porosity
Troubleshooting − Excessive Spatter
Troubleshooting − Excessive Penetration
Possible Causes Corrective Actions
Troubleshooting − Incomplete Fusion
Troubleshooting − Lack Of Penetration
Troubleshooting − Burn-Through
Troubleshooting − Distortion
Troubleshooting − Waviness Of Bead
Base metal to move
Direction
Application
Common MIG Shielding Gases
Flat & Horizontal1 Fillet
Main Assembly
− Parts List
Dia Part Description Quantity Mkgs
Gun
024 .6 and .030/.035 .8
042
024 .6 and .045
Page
Warranty
Owner’s Record
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