Miller Electric XLT 135, XLT 165 MIG Welding Gmaw Guidelines, Typical MIG Process Connections

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SECTION 7 − MIG WELDING (GMAW) GUIDELINES

7-1. Typical MIG Process Connections

Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.

Regulator/

Flowmeter

Wire Feeder/

Power Source

Shielding Gas

Gun

Gas

Work Clamp Workpiece

light mig 5/967 / Ref. 802 445

OM-198 076 Page 29

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Contents Processes OM-198 076ADescription AprilPage Table of Contents Page Marks a special safety message Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion 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 blessuresPrincipales normes de sécurité Information sur les champs électromagnétiquesConsignes relatives aux stimulateurs cardiaques − Specifications SpecificationsVAC Model Output Duty Cycle % Duty Cycle And OverheatingOutput Amperes OverheatingVolt-Ampere Curves Installing Welding Gun Installing Work Clamp − InstallationChanging Polarity Process/Polarity TableFlow Adjust Installing Gas SupplyCO2 Adapter Customer Sup- plied Regulator/flowmeter and CO2 cylinder CO2 GasGrounded Receptacle Rating LabelVolt, 20 ampere individual Up to 200 ft 61 mPlug Do not move or operate unit where it could tipReceptacle See SectionInstalling Wire Spool And Adjusting Hub Tension Electrical Service Guide For 230 VAC ModelStandard Wire Spool 8 Lb Wire Spool 4 Adjusting Hub TensionThreading Welding Wire Power Switch OM-198 076 Voltage Switch− Operation ControlsWeld Parameters For 115 VAC Model Weld Parameters For 230 VAC Model Routine Maintenance − Maintenance &TROUBLESHOOTINGOverload Protection Drive Motor 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 GuidelinesWire Size Amperage Range Typical MIG Process Control SettingsSelect Wire Size Recommendation Wire Speed Select VoltageHolding And Positioning Welding Gun Push Perpendicular Drag Conditions That Affect Weld Bead ShapeShort Normal Long ShortNormalLongPoor Weld Bead Characteristics Good Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Porosity Troubleshooting − Excessive SpatterTroubleshooting − Excessive Penetration Possible Causes Corrective ActionsTroubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Burn-Through Troubleshooting − Distortion Troubleshooting − Waviness Of BeadBase metal to move DirectionCommon 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