Manuals / Brands / Power Tools / Welder / Miller Electric / Power Tools / Welder

Miller Electric XLT 135, XLT 165, XLT 165, XLT 135 SECTION 5 MAINTENANCE &TROUBLESHOOTING

1 48

Download 48 pages, 1.27 Mb

OM-198 076 Page 22

SECTION 5 − MAINTENANCE &TROUBLESHOOTING

5-1. Routine Maintenance

YDisconnect 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 heavy

service, clean

monthly.

5-2. Overload Protection

802 441

1 Circuit Breaker CB1

CB1 protects unit from overload. If

CB1 opens, unit shuts down.

Reset breaker.

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.

Contents

Main Auto Arc XLT 135 / 165 Page TABLE OF CONTENTS WARNING Page SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage . 1-2. 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. HOT PARTS can cause severe burns. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING STATIC (ESD) can damage PC boards. 1-5. EMF Information OM-198 076 Page 5 SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1-1. Signification des symboles . 1-2. Dangers relatifs au soudage larc UN CHOC LECTRIQUE peut tuer. LES RAYONS DE LARC peuvent pro- voquer des brlures dans les yeux et sur la peau. LE SOUDAGE peut provoquer un incendie ou une explosion. DES PARTICULES VOLANTES peuvent blesser les yeux. LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou mme la mort. DES PICES CHAUDES peuvent pro- voquer des brlures graves. 1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance 1-4. Principales normes de scurit 1-5. Information sur les champs lectromagntiques SECTION 2 SPECIFICATIONS 2-1. Specifications A. 115 VAC Model * CSA Rating 2-2. Duty Cycle And Overheating A or V A. 115 VAC Model Duty Cycle % Output Amperes 2-3. Volt-Ampere Curves A. 115 VAC Model SECTION 3 INSTALLATION 3-1. Installing Welding Gun 3-2. Installing Work Clamp 3-3. Process/Polarity Table 3-4. Changing Polarity 3-5. Installing Gas Supply 3-6. Selecting A Location And Connecting Input Power For 115 VAC Model 3-7. Selecting A Location And Connecting Input Power For 230 VAC Model 3-8. Electrical Service Guide For 230 VAC Model 3-9. Installing Wire Spool And Adjusting Hub Tension 3-10. Threading Welding Wire . INPUT POWER SECTION 4 OPERATION 4-1. Controls Page Page SECTION 5 MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance 3 Months 6 Months 5-2. Overload Protection 5-4. Changing Drive Roll Or Wire Inlet Guide 5-5. Replacing Gun Contact Tip 5-6. Cleaning Or Replacing Gun Liner 5-7. Replacing Switch And/Or Head Tube 5-8. Troubleshooting Table Page Page SECTION 7 MIG WELDING (GMAW) GUIDELINES 7-1. Typical MIG Process Connections 7-2. Typical MIG Process Control Settings 7-3. Holding And Positioning Welding Gun 7-4. Conditions That Affect Weld Bead Shape 7-5. Gun Movement During Welding 7-6. Poor Weld Bead Characteristics 7-7. Good Weld Bead Characteristics 7-8. Troubleshooting Excessive Spatter 7-9. Troubleshooting Porosity 7-10. Troubleshooting Excessive Penetration 7-11. Troubleshooting Lack Of Penetration 7-12. Troubleshooting Incomplete Fusion 7-13. Troubleshooting Burn-Through 7-14. Troubleshooting Waviness Of Bead 7-15. Troubleshooting Distortion 7-16. Common MIG Shielding Gases Page Page Page Page Page Warranty Effective January 1, 2000 (Equipment with a serial number preface of LA or newer) * Induction Heating Coils and Blankets Please complete and retain with your personal records. Resources Available Always provide Model Name and Serial/Style Number. Owners Record