Miller Electric XLT 165, XLT 135 Maintenance &TROUBLESHOOTING, Routine Maintenance, Months

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SECTION 5 − MAINTENANCE &TROUBLESHOOTING

5-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replace unreadable labels.

Repair or replace cracked weld cable.

Clean and tighten weld terminals.

6 Months

Blow out or vacuum inside.

During heavyOr service, clean

monthly.

5-2. Overload Protection

1 Circuit Breaker CB1

CB1 protects unit from overload. If CB1 opens, unit shuts down.

Reset breaker.

802 441

5-3. Drive Motor Protection

Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release gun trigger and wait until protection circuit resets allowing drive motor to feed wire again.

OM-198 076 Page 22

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Contents Description OM-198 076AProcesses AprilPage Table of Contents Page Arc Welding Hazards Symbol UsageMarks a special safety message Electric Shock can killFlying Metal can injure eyes ARC Rays can burn eyes and skinWelding can cause fire or explosion Buildup of GAS can injure or killPrincipal Safety Standards EMF Information About PacemakersUN Choc Électrique peut tuer Signification des symboles− Consignes DE Securite − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent pro- voquer des brûlures graves LE Soudage peut provoquer un incendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïe’EMPLOI Excessif peut Risque D’INCENDIE OULA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessuresConsignes relatives aux stimulateurs cardiaques Principales normes de sécuritéInformation sur les champs électromagnétiques VAC Model − SpecificationsSpecifications Output Amperes Duty Cycle And OverheatingOutput Duty Cycle % OverheatingVolt-Ampere Curves − Installation Installing Welding Gun Installing Work ClampProcess/Polarity Table Changing PolarityCO2 Adapter Customer Sup- plied Installing Gas SupplyFlow Adjust Regulator/flowmeter and CO2 cylinder CO2 GasVolt, 20 ampere individual Rating LabelGrounded Receptacle Up to 200 ft 61 mReceptacle Do not move or operate unit where it could tipPlug See SectionStandard Wire Spool 8 Lb Wire Spool 4 Electrical Service Guide For 230 VAC ModelInstalling Wire Spool And Adjusting Hub Tension Adjusting Hub TensionThreading Welding Wire − Operation Voltage SwitchPower Switch OM-198 076 ControlsWeld Parameters For 115 VAC Model Weld Parameters For 230 VAC Model Overload Protection − Maintenance &TROUBLESHOOTINGRoutine Maintenance Drive Motor ProtectionReplacing Gun Contact Tip Changing Drive Roll Or Wire Inlet GuideTurn Off power before replacing contact tip To Reassemble Gun Cleaning Or Replacing Gun LinerDisconnect gun from unit Replacing Switch And/Or Head Tube Does not run Troubleshooting TableTrouble Remedy − Electrical Diagram Circuit Diagram For 115 VAC ModelCircuit Diagram For 230 VAC Model − MIG Welding Gmaw Guidelines Typical MIG Process ConnectionsSelect Wire Size Recommendation Wire Speed Typical MIG Process Control SettingsWire Size Amperage Range Select VoltageHolding And Positioning Welding Gun Short Normal Long Conditions That Affect Weld Bead ShapePush Perpendicular Drag ShortNormalLongGun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Troubleshooting − Excessive Penetration Troubleshooting − Excessive SpatterTroubleshooting − Porosity Possible Causes Corrective ActionsTroubleshooting − Burn-Through Troubleshooting − Lack Of PenetrationTroubleshooting − Incomplete Fusion Base metal to move Troubleshooting − Waviness Of BeadTroubleshooting − Distortion DirectionFlat & Horizontal1 Fillet Common MIG Shielding GasesApplication − Parts List Main AssemblyDia Part Description Quantity Mkgs Gun 024 .6 and .045 042024 .6 and .030/.035 .8 Page Warranty Owner’s Record