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MIG (GMAW) and Pulsed MIG (GMAW-P) Welding TIG (GTAW) Welding Flux Cored (FCAW) Welding Stick (SMAW) Welding Multiprocess Welding Description Arc Welding Power Source Wire Feeder PipeWorx 400 VRD Welding System (380-400 Volt Model) File: MIG (GMAW) Visit our website at www.MillerWelds.com...
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We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
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DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2013−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
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D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2013−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
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D Ne pas raccorder plus d’une électrode ou plus d’un câble de D Avoir recours à des écrans protecteurs ou à des rideaux pour masse à une même borne de sortie de soudage. Débrancher le protéger les autres contre les rayonnements les éblouissements câble pour le procédé...
LES BOUTEILLES peuvent exploser DES PIECES DE METAL ou DES si elles sont endommagées. SALETES peuvent provoquer des blessures dans les yeux. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Le soudage, l’écaillement, le passage de la endommagée, elle peut exploser.
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LES CHARGES ÉLECTROSTATI- RAYONNEMENT HAUTE QUES peuvent endommager les cir- FRÉQUENCE (H.F.) risque cuits imprimés. provoquer des interférences. D Établir la connexion avec la barrette de terre D Le rayonnement haute fréquence (H.F.) peut avant de manipuler des cartes ou des pièces. provoquer des interférences avec les équi- pements de radio−navigation et de com- D Utiliser des pochettes et des boîtes antista-...
2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres formations congénitales et, dans certains cas, des cancers.
SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground.
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Disconnect input plug or power before working on machine. Safe5 2012−05 When power is applied failed parts can explode or cause other parts to explode. Safe26 2012−05 Flying pieces of parts can cause injury. Always wear a face shield when servicing unit. Safe27 2012−05 Always wear long sleeves and button your collar when servicing unit.
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Consult rating label for input power requirements. Safe34 2012−05 Drive rolls can injure fingers. Safe32 2012−05 Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away. Safe33 2012−05 Become trained and read the instructions before working on the machine or welding.
3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Direct Current Alternating Amperage Voltage (DC) Current (AC) Gas Input Circuit Breaker To Power Source Shielded Metal Arc Positive Gas Output Welding (SMAW) Gas Tungsten Arc Welding (GTAW) / Protective Earth Work Connection Wire Feed...
SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.
4-3. MIG Duty Cycle and Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.
4-5. Environmental Specifications A. Wire Feeder IP Rating IP Rating IP21 This equipment is designed for indoor use and is not intended to be used or stored outside. 4-6. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
SECTION 5 − INSTALLATION 5-1. Selecting a Location Movement Do not move or operate Tipping unit where it could tip. Special installation may be required where gasoline or Location volatile liquids are present − see NEC Article 511 or CEC Section 20.
5-2. Remote 14 Accessory Receptacle Information If a remote control is connected to the Remote 14 receptacle, the unit will automatically adjust output control to a primary/secondary configuration. In this configuration, the Amperage Adjust knob on the unit becomes the primary and sets the maximum amperage output of the unit. The remote control becomes the secondary and provides an amperage range of 0 to 100% based on the Amperage Adjust knob setting.
5-3. Turning On Remote 14 Receptacle Control For Stick Turn Off welding power source, disconnect input power, and check voltage on input capacitors accord- ing to Section 7-6 before proceeding. Stick Stick When this control is active and a current/contactor control Remote Remote...
5-4. Changing Wire Feed Speed From Inches Per Minute (IPM) To Meters Per Minute (MPM) Turn Off welding power source, disconnect input power, and check voltage on input capacitors according to Section 7-6 before proceeding. PipeWorx Feeder Operator Interface Board Dip Switch Remove feeder wrapper.
5-5. Remote 14 Wire Feeder Control Receptacle Information Remote 14 Feeder Control Socket* Socket Information 8, 12 24 volts AC. Protected by supplementary protector CB2. 24 VOLTS AC 24 volts AC return. Connected to chassis common. Completes 24 volts AC power supply circuit to feeder.
5-6. Supplementary Protector CB2 Supplementary Protector CB2 CB2 protects the 24 volts ac power supply to the wire feeder (see Section 5-5). Press button to reset supplementary protector. 254 085-A OM-253 906 Page 23...
5-7. 115 Volts AC Single Receptacle RC2 And Supplementary Protector 115 V 10 A AC Receptacle RC2 (Cooler Power Supply Only When Power Source Is On) RC2 is designated receptacle intended only for supplying AC power PipeWorx cooler. Power is available at receptacle RC2 only when the power source is on.
5-8. Lifting Eye On Power Source Turn Off welding power source, disconnect input power. Lifting Eye The wire feeder allows access to the lifting eye on the power source. The entire welding system as shown with cable hangers, cooler with coolant, dual feeder, and running gear can be lifted with the lifting eye.
5-9. Electrical Service Guide Elec Serv 2014−01 NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera- tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
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5-10. Connecting 3-Phase Input Power (Continued) national, state, and local electrical codes. If Connect input conductors L1 (U), L2 (V) and Installation must meet all National applicable, use lugs of proper amperage L3 (W) to welding power source line and Local Codes − have only qualified capacity and correct hole size.
5-12. Assembling And Installing Cable Hanger Bracket Tube Cap (4) Cable Holder Tube (2) Install caps in tubes. Assemble cable holder tubes to bracket using supplied hardware. Place cable holder assembly on top of power source or cart and set wire feeder on cable hanger.
5-13. Proper Ring Terminal Connection To Volt Sense Lead If volt sense lead is cut or broken at end Jacket Center Conductor 10 ga with ring terminal, be sure that new ring ter- Insulated Tape Or Heat-Shrink minal is connected as shown. Tubing Ring Terminal 1/2 in.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use. ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart) Ref. S-0007-K 2013−09 OM-253 906 Page 33...
5-16. Connecting Weld Output Cables Do not place anything between weld cable terminal and copper bar. Tools Needed: 19 mm (3/4 in.) Incorrect Installation 803 778-B Weld Output Terminal weld output terminal and secure with nut so Turn off power before connecting to that weld cable terminal is tight against weld output terminals.
5-17. Typical Connection Diagram For MIG (GMAW) Equipment With Feeder On Power Source 254 079-A Gas Hose of gas hose to gas solenoid connector on Do not put feeder where welding rear of feeder or Y-hose for dual wire feeder. wire hits cylinder.
5-18. Typical Connection Diagram For MIG (GMAW) Equipment With Feeder On Cart 254 086-A Gas Cylinder connect remaining end of gas hose to gas Do not put feeder where welding solenoid connector on rear of feeder or wire hits cylinder. Locate end of composite cable where gas Y-hose for dual wire feeder.
5-22. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs A. Ideal Setup 805 289-B Welding Power Source signal to the welding system. Use of this This arrangement is an ideal setup for lead is critical stable welding supporting separate voltage feedback to Composite Cable performance.
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B. Bad Setup 805 290-B Welding Power Source Workpiece across the workpiece will not be measured correctly for the voltage feedback signal. Composite Cable This arrangement is a bad setup due to Voltage feedback to the welding power sensing leads being directly in the current Work Cable sources will not be correct at either sense flow path of the welding arc.
5-23. Arranging Welding Cables To Reduce Welding Circuit Inductance Welding Power Source Composite Cable Work Cable Volt Sense Lead Ideal Wire Feeder Workpiece The method used to arrange cables has significant affect welding performance. As an example, Pro-Pulse and RMD welding processes can produce high welding circuit inductance depending on cable length and arrangement.
5-24. Typical Connection Diagram For Stick (SMAW) Equipment Welding Power Source Work (−) Weld Cable Stick (+) Weld Cable Workpiece Electrode Holder Volt Sense Lead Attach volt sense lead to work clamp and attach work clamp as close to arc as possible. 115V 10A AC Receptacle (Cooler Power Supply Only) READ OWNER'S MANUAL...
5-25. Typical Connection Diagram For Two Piece Air-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside Power Source) Welding Power Source Gas Hose TIG (−) Weld Cable Work (+) Weld Cable Workpiece TIG Torch Volt Sense Lead Remote Foot Control (Optional) Attach volt sense lead to work clamp and attach work clamp as close to arc as possible.
5-26. Typical Connection Diagram For One Piece Air-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside Power Source) Welding Power Source Gas Hose 237 415 (Short Black Hose Supplied With Power Source) TIG Block (Customer Supplied) TIG (−) Weld Cable Work (+) Weld Cable Workpiece TIG Torch Volt Sense Lead...
SECTION 6 − OPERATION 6-1. Operational Terms The following is a list of terms and their definitions as they apply to this interface unit: General Terms: 98/2 Ox Gas mixture of 98% Argon and 2% O Amps Indicates average amperage while welding and holds the value for 10 seconds at end of weld. Arc Control The adjustment of arc cone width and arc characteristics in the RMD and Pulse processes.
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6-1 . Operational Terms (Continued) Pulse An advanced pulse spray transfer process suited for the fill and cap passes on pipe. The Pulse process utilizes (Pro-Pulset) constant current ramps with constant voltage control of peaks and backgrounds. Adaptive response is controlled by peak and minimum current levels.
6-2. Welding Power Source Controls A. Front Panel Controls 252 613-B Stick Electrode Type Select Button 14 Wire Diameter Select Button Only illuminated controls can be Ammeter Display changed or adjusted. 15 Gas Type Select Button Memory Card Busy Indicator Amperage Adjust Knob 16 Gas Selection Table Memory Card Save Button...
6-3. Memory Card Slot Memory Card Slot This is the memory card slot. The memory card slot uses an SD memory card. A memory card can be inserted into the slot and used for storing and retrieving operator settings, providing custom MIG type weld process data, and loading firmware updates to the unit.
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B. Using Optional Memory Card Memory Card Insertion Lift and hold memory card access cover open. Insert memory card into slot (push card all the way into slot and then release). Close memory card access cover. Memory Card Removal Lift and hold memory card access cover open. Push in and release memory card to eject card.
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D. Stick And TIG Welding Process Controls Stick Process Select Button Press and release this button to activate the stick welding process controls. The STICK text below the button illuminates as well as the active stick electrode type text and the swoosh above the amperage adjust knob. The operator must select the desired stick electrode type and adjust the amperage knob to the appropriate setting within a range from 40 to 400 amps.
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Ramp down time − 0.0 to 10.0 seconds Final amperage − 10 to 350 amps Final time − 0.0 to 10.0 seconds (2T only) Postflow time − 0 to 60 seconds 2T Trigger Operation When in the 2T trigger mode the following weld sequence will occur: Press and hold the TIG torch trigger to start the sequence.
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Gas Selection Table The gas selection table provides the available shielding gas selections. For any MIG process except FCAW, gas selections are structured into columns based first on WIRE TYPE type and then on MIG process selections. The gas type text illuminates to indicate the active gas selection. Shielding gas selections are as follows: C8-C15 (92% Argon/8% CO to 85% Argon/15% CO...
6-5. Stick Process Selection Setup Example Ref. 252 613-B Stick Process Active Amperage Setting 350A Only illuminated controls can be changed or adjusted. EXX10 Electrode Type Selected Memory Location 1 Active OM-253 906 Page 56...
6-6. TIG Process Selection Setup Example Ref. 252 613-B TIG Process Active Amperage Setting 350A Only illuminated controls can be changed or adjusted. HF Start Method Selected Memory Location 2 Active OM-253 906 Page 57...
6-7. MIG Process Selection Setup Example 1 252 613-B Carbon Steel Wire Type Selected Trigger Select On Only illuminated controls can be changed or adjusted. 0.9 Wire Diameter Selected Side Select Left MIG Process Active C8-C15 Gas Type Selected Memory Location 3 Active OM-253 906 Page 58...
6-8. MIG Process Selection Setup Example 2 252 613-B Stainless Steel Wire Type Selected Trigger Select On Only illuminated controls can be 0.9 Wire Diameter Selected Side Select Left changed or adjusted. Pro-Pulse MIG Process Active 98/2 Ox Gas Type Selected Memory Location 4 Active OM-253 906 Page 59...
6-9. Wire Feeder Controls A. Front Panel Controls 252 620-C Right Side Controls Select Button* 10 Trigger Hold Select Button Only illuminated controls can be Wire Feed Speed Display 11 Purge Button changed or adjusted. Wire Feed Speed Adjust Knob 12 Memory Select Button And Location Left Side Controls Select Button Indicator...
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Left Side Controls Select Button Press and release this button to activate the wire feeder left side controls. The LEFT text below the button will illuminate and the swooshes above the volts/arc length adjustment knob and wire feed speed adjustment knob will illuminate. See Section 6-2 for the procedure to select the appropriate MIG process type parameters.
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Wire Feed Speed Adjust Knob Use this knob to adjust the desired wire feed speed setting [1.3 to 19.8 mpm (50 to 780 ipm)]. Rotating the knob clockwise increases wire feed speed and counter-clockwise decreases wire feed speed. Wire feed speed adjustment is active when the swoosh above the knob is illuminated. The setting can be different for left and right sides and MIG process type, and the unit will hold these settings for both sides.
6-10. Preflow And Postflow Adjustment Postflow will not function without an arc initiation. Preflow and Postflow times can be configured for each of the TIG, Wire Feeder Left and Wire Feeder Right outputs. These times are global settings (i.e. all memory slots share the same three preflow and postflow settings; it is not possible to set different postflow times between memory slots). The unit is shipped in the standard configuration (“Std”...
Unit will display PSt on the Voltage display. Adjust postflow time to desired value by rotate the Wire Feed Speed knob. Available selections include Std and numeric values from 0 to 60 seconds. Press any button to return to the normal display. 6-11.
6-12. Wire Feeder Right Side Active Setup Example (Dual Feeder Only) 252 620-C Right Side Controls Active Trigger Hold On Only illuminated controls can be changed or adjusted. Pulse Process Selected Memory Location 2 Active OM-253 906 Page 65...
6-13. Wire Feeder Non-MIG Setup Example 252 620-C Non-MIG Process Selected Memory Location 3 Active Only illuminated controls can be changed or adjusted. OM-253 906 Page 66...
6-14. Wire Feeder Timed Purge Example 252 620-C Pressed Simultaneously Purge Time Remaining Display Only illuminated controls can be Purge Time Setting Adjustment Knob changed or adjusted. Purge And Trigger Hold Buttons OM-253 906 Page 67...
6-15. Wire Feeder Auto Jog Example 15.3 252 620-C Simultaneously Jog Wire Feed Speed Adjustment Knob Only illuminated controls can be Jog Feet Adjustment Knob Jog Wire Feed Speed Display changed or adjusted. Jog And Trigger Hold Buttons Pressed Jog Feet Remaining Display OM-253 906 Page 68...
Flux Core Wire Size Rolling Pipe/In Position Voltage Shielding Gas Process Wire Feed Speed 1.3-19.8 w/6.4 Nominal* 24.5-32 w/25.0 Nominal Not Dependent Flux Core/GMAW Dependent Note: Arc Length − Length of arc from end of wire to weld puddle. Wire feed speed and voltage are synergic for the RMD and ProPulse processes.
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. n = Check ~ = Clean l = Replace Every Months l Unreadable Labels ~ Weld Terminals nl Weld Cable l Cracked Parts n 14-Pin Cord n Gas Hose and Fittings n Gun Cable l Cracked Electrode l Cracked Torch Body...
7-3. Restoring Factory Defaults Full System A full factory reset can be accomplished by pressing memory location buttons 1 and 4 on the power source simultaneously for more than four seconds. The display will show rSt and then go to dashes when the reset is complete. Memory Location See Section 6-2 C2 the reset procedure.
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Calibrate STICK voltage as follows: Connect voltmeter from STICK stud (front left) to Work stud (front center). Press memory 3 button on the power source front panel. Open circuit voltage should now be present from STICK output stud to the Work stud.
7-6. Removing Right Side Panel and Measuring Input Capacitor Voltage Turn Off welding power source, disconnect input power. Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit.
7-7. Welding Power Source And Feeder Diagnostic Help Codes Display Example Display Code Fault Description Primary Power Circuit Over Current Indicates a malfunction in the primary power circuit. If this code appears on the display, contact the nearest Factory Authorized Service Agent.
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Motor Low Bus Indicates input primary line voltage is too low. Increase primary line voltage to at least 90% of specified nominal voltage. If this code continues to appear on the display, contact the nearest Factory Authorized Service Agent. Button Stuck Feeder Indicates button is stuck on the feeder upon feeder power up.
7-8. Troubleshooting Welding Power Source/Wire Feeder Issues If the welding power source and wire feeder are NOT responding after everything is connected, follow the items listed below before contacting the nearest factory-authorized service agent: Welding power source is plugged in and there is no power after turning on unit. If unit is directly connected to a line disconnect box or plugged into a receptacle from a line disconnect box, be sure that the line disconnect switch or main breaker is in the ON position.
7-9. Welding Power Source Troubleshooting Disconnect power before troubleshooting. Trouble Remedy No weld output; unit completely in- Place line disconnect switch in On position (see Section 5-10). operative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-10). Check for proper input power connections (see Section 5-10).
7-10. Wire Feeder Troubleshooting Disconnect power before troubleshooting. Trouble Remedy Wire feeds, shielding gas flows, but Check cable connections. Check cables for continuity, and repair or replace cables if necessary. electrode wire is not energized. Wire feeder is on, display does not light Check and reset circuit breaker at welding power source.
SECTION 9 − HIGH FREQUENCY 9-1. Welding Processes Requiring High Frequency High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. Work high_freq 5/10 − S-0693 9-2. Installation Showing Possible Sources Of HF Interference Weld Zone 11, 12 50 ft...
9-3. Recommended Installation To Reduce HF Interference Weld Zone 50 ft (15 m) 50 ft (15 m) Ground all metal ob- jects and all wiring in welding zone using #12 AWG wire. Ground workpiece if required by Nonmetal codes. Building Best Practices Followed Metal Building Ref.
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Hardware is common and not available unless listed. See Table 10-1 For Drive Roll & Wire Guide Kits 803 790-A Figure 10-4. Drive Assembly, Wire Item Dia. Part Mkgs. Description Quantity Figure 10-4. Drive Assembly, Wire (Figure 10-2 Item 31 And Figure 10-3 Items 30 And 31) .
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Item Dia. Part Mkgs. Description Quantity Figure 10-4. Drive Assembly, Wire (Continued) ..... 203 642 Pressure Arm, R & Vert L 4 Roll (Includes) .
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Table 10-1. Drive Roll And Wire Guide Kits Wire Size V-GROOVE VK-GROOVE Intermediate Inlet Guide Guide Fraction Metric 4 Roll Kit Drive Roll 4 Roll Kit Drive Roll .035 in. 0.9 mm 150 993 149 518 151 026 053 700 151 052 132 958 .040 in.
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Hardware is common and not available unless listed. 9 10 805 302-b Figure 10-5. Running Gear OM-253 906 Page 101...
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Item Dia. Part Mkgs. Description Quantity Figure 10-5. Running Gear ... . . 236827 Handle, Power Source ..........
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Hardware is common and not available unless listed. 805 301-A / Ref. 239 780-B Figure 10-6. Composite Cables Quantity Model Item Dia. Part 5 ft 25 ft 50 ft Mkgs. Description 300 367 300 454 300 456 Figure 10-6. Composite Cables .
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Hardware is common and not available unless listed. 805 148-B Figure 10-7. Cable Hanger Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-7. Cable Hanger Assembly ... . . 285304 Bracket, Cable Holder w/Edge Trim .
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Hardware is common and not available unless listed. 805 318-A Figure 10-8. Feeder Cart OM-253 906 Page 105...
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Effective January 1, 2014 (Equipment with a serial number preface of ME or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
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Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. ORIGINAL INSTRUCTIONS − PRINTED IN USA 2014 Miller Electric Mfg. Co. 2014−01...