Miller Electric
XLT 165, XLT 135, XLT 135, XLT 165
warranty
Troubleshooting
Specs
Poor Weld Bead Characteristics
Install
Parts list
Electrical Diagram
Symbol Usage
Threading Welding Wire
Warranty
Flow Adjust
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Contents
OM-198 076A
Processes
Description
April
Page
Table of Contents
Page
Symbol Usage
Marks a special safety message
Arc Welding Hazards
Electric Shock can kill
ARC Rays can burn eyes and skin
Welding can cause fire or explosion
Flying Metal can injure eyes
Buildup of GAS can injure or kill
Principal Safety Standards
EMF Information
About Pacemakers
Signification des symboles
− Consignes DE Securite − Lire Avant Utilisation
UN Choc Électrique peut tuer
LES Fumées ET LES GAZ peuvent être dangereux
LE Soudage peut provoquer un incendie ou une explosion
DES Particules Volantes peuvent blesser les yeux
DES Pièces Chaudes peuvent pro- voquer des brûlures graves
LE Bruit peut affecter l’ouïe
Risque D’INCENDIE OU
LA Chute DE L’APPAREIL peut blesser
’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
Duty Cycle And Overheating
Output Duty Cycle %
Output Amperes
Overheating
Volt-Ampere Curves
− Installation
Installing Welding Gun Installing Work Clamp
Process/Polarity Table
Changing Polarity
Installing Gas Supply
Flow Adjust
CO2 Adapter Customer Sup- plied
Regulator/flowmeter and CO2 cylinder CO2 Gas
Rating Label
Grounded Receptacle
Volt, 20 ampere individual
Up to 200 ft 61 m
Do not move or operate unit where it could tip
Plug
Receptacle
See Section
Electrical Service Guide For 230 VAC Model
Installing Wire Spool And Adjusting Hub Tension
Standard Wire Spool 8 Lb Wire Spool 4
Adjusting Hub Tension
Threading Welding Wire
Voltage Switch
Power Switch OM-198 076
− Operation
Controls
Weld Parameters For 115 VAC Model
Weld Parameters For 230 VAC Model
− Maintenance &TROUBLESHOOTING
Routine Maintenance
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
− Electrical Diagram
Circuit Diagram For 115 VAC Model
Circuit Diagram For 230 VAC Model
− MIG Welding Gmaw Guidelines
Typical MIG Process Connections
Typical MIG Process Control Settings
Wire Size Amperage Range
Select Wire Size Recommendation Wire Speed
Select Voltage
Holding And Positioning Welding Gun
Conditions That Affect Weld Bead Shape
Push Perpendicular Drag
Short Normal Long
ShortNormalLong
Good Weld Bead Characteristics
Poor Weld Bead Characteristics
Gun Movement During Welding
Troubleshooting − Excessive Spatter
Troubleshooting − Porosity
Troubleshooting − Excessive Penetration
Possible Causes Corrective Actions
Troubleshooting − Incomplete Fusion
Troubleshooting − Lack Of Penetration
Troubleshooting − Burn-Through
Troubleshooting − Waviness Of Bead
Troubleshooting − Distortion
Base metal to move
Direction
Application
Common MIG Shielding Gases
Flat & Horizontal1 Fillet
− Parts List
Main Assembly
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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