MIG Welding Gmaw Guidelines | Miller Electric XLT 135, XLT 165

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

Contents

Processes OM-198 076ADescription AprilPage Table of Contents Page Marks a special safety message Symbol UsageArc Welding Hazards Electric Shock can kill Welding can cause fire or explosion ARC Rays can burn eyes and skinFlying Metal can injure eyes Buildup of GAS can injure or kill Principal 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 dangereux DES 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’ouïe LA Chute DE L’APPAREIL peut blesser Risque D’INCENDIE OU’EMPLOI Excessif peut DES Organes Mobiles peuvent provoquer des blessures Principales normes de sécurité Information sur les champs électromagnétiquesConsignes relatives aux stimulateurs cardiaques − Specifications SpecificationsVAC Model Output Duty Cycle % Duty Cycle And OverheatingOutput Amperes Overheating Volt-Ampere Curves Installing Welding Gun Installing Work Clamp − Installation Changing Polarity Process/Polarity Table Flow Adjust Installing Gas SupplyCO2 Adapter Customer Sup- plied Regulator/flowmeter and CO2 cylinder CO2 Gas Grounded Receptacle Rating LabelVolt, 20 ampere individual Up to 200 ft 61 m Plug Do not move or operate unit where it could tipReceptacle See Section Installing Wire Spool And Adjusting Hub Tension Electrical Service Guide For 230 VAC ModelStandard Wire Spool 8 Lb Wire Spool 4 Adjusting Hub Tension Threading Welding Wire Power Switch OM-198 076 Voltage Switch− Operation Controls Weld Parameters For 115 VAC Model Weld Parameters For 230 VAC Model Routine Maintenance − Maintenance &TROUBLESHOOTINGOverload Protection Drive Motor Protection Changing 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 Diagram Circuit Diagram For 230 VAC Model Typical MIG Process Connections − MIG Welding Gmaw Guidelines Wire Size Amperage Range Typical MIG Process Control SettingsSelect Wire Size Recommendation Wire Speed Select Voltage Holding And Positioning Welding Gun Push Perpendicular Drag Conditions That Affect Weld Bead ShapeShort Normal Long ShortNormalLong Poor Weld Bead Characteristics Good Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Porosity Troubleshooting − Excessive SpatterTroubleshooting − Excessive Penetration Possible Causes Corrective Actions Troubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Burn-Through Troubleshooting − Distortion Troubleshooting − Waviness Of BeadBase metal to move Direction Common MIG Shielding Gases ApplicationFlat & Horizontal1 Fillet Main Assembly − Parts List Dia Part Description Quantity Mkgs Gun 042 024 .6 and .030/.035 .8024 .6 and .045 Page Warranty Owner’s Record

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

Models: XLT 135, XLT 165 XLT 165, XLT 135

SECTION 7 − MIG WELDING (GMAW) GUIDELINES

7-1. Typical MIG Process Connections