Miller Electric XLT 135, XLT 165, XLT 165, XLT 135 warranty Table of Contents

Page 3

WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

The following terms are used interchangeably throughout this manual:

MIG=GMAW

OM-198 076A

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

1

1-1.

Symbol Usage

1

1-2.

Arc Welding Hazards

1

1-3. Additional Symbols For Installation, Operation, And Maintenance

3

1-4.

Principal Safety Standards

3

1-5.

EMF Information

4

SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION

5

1-1.

Signification des symboles

5

1-2. Dangers relatifs au soudage à l’arc

5

1-3.

Dangers supplémentaires en relation avec l’installation, le fonctionnement

 

 

et la maintenance

7

1-4.

Principales normes de sécurité

8

1-5.

Information sur les champs électromagnétiques

8

SECTION 2 − SPECIFICATIONS

9

2-1.

Specifications

9

2-2.

Duty Cycle And Overheating

10

2-3.

Volt-Ampere Curves

11

SECTION 3 − INSTALLATION

12

3-1.

Installing Welding Gun

12

3-2.

Installing Work Clamp

12

3-3.

Process/Polarity Table

13

3-4.

Changing Polarity

13

3-5.

Installing Gas Supply

14

3-6.

Selecting A Location And Connecting Input Power For 115 VAC Model

15

3-7.

Selecting A Location And Connecting Input Power For 230 VAC Model

16

3-8.

Electrical Service Guide For 230 VAC Model

17

3-9.

Installing Wire Spool And Adjusting Hub Tension

17

3-10.

Threading Welding Wire

18

SECTION 4 − OPERATION

19

4-1.

Controls

19

4-2.

Weld Parameters For 115 VAC Model

20

4-3.

Weld Parameters For 230 VAC Model

21

SECTION 5 − MAINTENANCE &TROUBLESHOOTING

22

5-1.

Routine Maintenance

22

5-2.

Overload Protection

22

5-3.

Drive Motor Protection

22

5-4.

Changing Drive Roll Or Wire Inlet Guide

23

5-5.

Replacing Gun Contact Tip

23

5-6.

Cleaning Or Replacing Gun Liner

24

5-7.

Replacing Switch And/Or Head Tube

25

5-8.

Troubleshooting Table

26

SECTION 6 − ELECTRICAL DIAGRAM

27

SECTION 7 − MIG WELDING (GMAW) GUIDELINES

29

7-1. Typical MIG Process Connections

29

7-2. Typical MIG Process Control Settings

30

7-3.

Holding And Positioning Welding Gun

31

7-4.

Conditions That Affect Weld Bead Shape

32

7-5.

Gun Movement During Welding

33

7-6.

Poor Weld Bead Characteristics

33

7-7.

Good Weld Bead Characteristics

33

7-8.

Troubleshooting − Excessive Spatter

34

7-9.

Troubleshooting − Porosity

34

7-10.

Troubleshooting − Excessive Penetration

35

7-11.

Troubleshooting − Lack Of Penetration

35

7-12.

Troubleshooting − Incomplete Fusion

35

7-13.

Troubleshooting − Burn-Through

36

7-14.

Troubleshooting − Waviness Of Bead

36

7-15.

Troubleshooting − Distortion

36

7-16.

Common MIG Shielding Gases

37

SECTION 8 − PARTS LIST

38

WARRANTY

 

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Contents April OM-198 076AProcesses DescriptionPage Table of Contents Page Electric Shock can kill Symbol UsageMarks a special safety message Arc Welding HazardsBuildup of GAS can injure or kill ARC Rays can burn eyes and skinWelding can cause fire or explosion Flying Metal can injure eyesPrincipal Safety Standards About Pacemakers EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Securite − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un incendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent pro- voquer des brûlures gravesDES Organes Mobiles peuvent provoquer des blessures Risque D’INCENDIE OULA Chute DE L’APPAREIL peut blesser ’EMPLOI Excessif peutPrincipales normes de sécurité Information sur les champs électromagnétiquesConsignes relatives aux stimulateurs cardiaques − Specifications SpecificationsVAC Model Overheating Duty Cycle And OverheatingOutput Duty Cycle % Output AmperesVolt-Ampere Curves Installing Welding Gun Installing Work Clamp − InstallationChanging Polarity Process/Polarity TableRegulator/flowmeter and CO2 cylinder CO2 Gas Installing Gas SupplyFlow Adjust CO2 Adapter Customer Sup- pliedUp to 200 ft 61 m Rating LabelGrounded Receptacle Volt, 20 ampere individualSee Section Do not move or operate unit where it could tipPlug ReceptacleAdjusting Hub Tension Electrical Service Guide For 230 VAC ModelInstalling Wire Spool And Adjusting Hub Tension Standard Wire Spool 8 Lb Wire Spool 4Threading Welding Wire Controls Voltage SwitchPower Switch OM-198 076 − OperationWeld Parameters For 115 VAC Model Weld Parameters For 230 VAC Model Drive Motor Protection − Maintenance &TROUBLESHOOTINGRoutine Maintenance Overload ProtectionChanging Drive Roll Or Wire Inlet Guide Turn Off power before replacing contact tipReplacing Gun Contact Tip Cleaning Or Replacing Gun Liner Disconnect gun from unitTo Reassemble Gun Replacing Switch And/Or Head Tube Troubleshooting Table Trouble RemedyDoes not run Circuit Diagram For 115 VAC Model − Electrical DiagramCircuit Diagram For 230 VAC Model Typical MIG Process Connections − MIG Welding Gmaw GuidelinesSelect Voltage Typical MIG Process Control SettingsWire Size Amperage Range Select Wire Size Recommendation Wire SpeedHolding And Positioning Welding Gun ShortNormalLong Conditions That Affect Weld Bead ShapePush Perpendicular Drag Short Normal LongPoor Weld Bead Characteristics Good Weld Bead CharacteristicsGun Movement During Welding Possible Causes Corrective Actions Troubleshooting − Excessive SpatterTroubleshooting − Porosity Troubleshooting − Excessive PenetrationTroubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Burn-Through Direction Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Base metal to moveCommon MIG Shielding Gases ApplicationFlat & Horizontal1 Fillet Main Assembly − Parts ListDia Part Description Quantity Mkgs Gun 042 024 .6 and .030/.035 .8024 .6 and .045 Page Warranty Owner’s Record
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