Miller Electric XLT 135, XLT 165, XLT 165, XLT 135 042, 024 .6 and .030/.035 .8, 024 .6 and .045

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	Item	Part	Description	Quantity
	No.	No.	Description	Quantity
		042 053	Figure 8-2. Gun

. . .	1	. 130 789 . . .	. NOZZLE, slip type .500 orf flush	. . . 1
. . .	2	♦130 792 . . .	. TIP, contact scr .023 wire x 1.125
. . .	2	♦130 794 . . .	. TIP, contact scr .030 wire x 1.125
. . .	2	♦130 796 . . .	. TIP, contact scr .035 wire x 1.125
. . .	2	♦130 798 . . .	. TIP, contact scr .045 wire x 1.125
. . .	3	. 169 716 . . .	. ADAPTER, contact tip	. . . 1
. . .	4	. 170 470 . . .	. RING, retaining	. . . 1
. . .	5	. 169 718 . . .	. TUBE, head	. . . 1
. . .	6	. 169 738 . . .	. NUT, locking handle	. . . 1
. . .	7	. 194 524 . . .	. NUT, jam	. . . 1
. . .	8	. 079 975 . . .	. O-RING, .187 ID x .103CS rbr	. . . 1
. . .	9	♦194 010 . . .	. LINER, monocoil .023/.025 wire x 15ft (consisting of)	. . . 1
. . .	9	♦194 011 . . .	. LINER, monocoil .030/.035 wire x 15ft (consisting of)	. . . 1
. . .	9	♦194 012 . . .	. LINER, monocoil .035/.045 wire x 15ft (consisting of)	. . . 1
. . .	9	♦194 014 . . .	. LINER, monocoil 4/64 AL wire x 10ft nyl(consisting of)	. . . 1
. . . 10		. 197 123 . . .	. O-RING, .312 ID x .062 70 Dura BUNA-N	. . . 2
. . . 11		. 196 255 . . .	SWITCH, trigger	. . . 1

♦OPTIONAL

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

	Table 8-1. Optional Drive Rolls

For All Feed Head Assemblies

PART NO.	WIRE DIAMETER
PART NO.	INCHES (mm)
	INCHES (mm)

407 230-1	.024 (.6) and .030/.035 (.8 and .9)

407 230-4	.024 (.6) and .045 (1.2)

NOTE: If individual parts are required, see Parts List chapter of this manual for part number to order or for further assistance contact:

Milweld Inc., National Distributor

P.O. Box 338, Hortonville, WI 54944-0338

Tel (920) 779-0916 Fax (920) 779-0924

OM-198 076 Page 41

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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