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Millerfi
OWNERS
MANUAL
Read and follow these instructions and all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install, operate,
or
service this unit.
Call
your distributor if you do
not
understand
the directions.
''~~
__~' ~'~1~3
April
1993
Effective With
Style
No. JD-25
Form:
OM-1553
Tandem
Systems
U
U
U
For
help,
call your distributor
or:
MILLER
ELECTRIC
Mfg.
Co.,
P.O. Box
1079,
Appleton,
WI 54912
414-734-9821
cover
8/92
-
ST
I
10
784-A
PRINTED
IN
USA
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Table of Contents
Related Manuals for Miller Electric Tandem Systems
Summary of Contents for Miller Electric Tandem Systems
- Page 1 Millerfi Form: OM-1553 April 1993 Effective With Style No. JD-25 OWNERS MANUAL ''~~ __~' ~'~1~3 Tandem Systems Read and follow these instructions and all safety blocks carefully. Have only trained qualified persons call your distributor help, install, operate, service this unit. Call MILLER ELECTRIC...
- Page 2 This limited supersedes previous warranties and is other guarantees warranties expressed implied. warranty LIMITED WARRANTY Subject conditions below. MILLER Electric Remote Controls terms Co.. Mtg. Appleton. WIsconsin, warrants to original retail purchaser that Accessory Kits limited is free of de...
- Page 3 TABLE OF CONTENTS Section No. Page SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE SECTION 1 Introduction General Precautions Welding Standards Booklet Index SECTION 2 INTRODUCTION General Information Safety Receiving-Handling Description SECTION 3 INSTALLATION 3-1. Location Drive Roll And Wire Guide Installation Gun Connections Welding Drive Motor Connections...
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Page 5: Introduction
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SECTION SOURCE INTRODUCTION 1-1. learn experience. cutting, chipping) protect the eyes welding (and Learning safety through personal experience, like from radiant flying metal. Replace energy and cover child touching harmful, wasteful, when broken, pitted, spattered. - Page 6 be welded cut, unless container has first irritating never highly and eye toxic gas, and other lung cleaned described in AWS Standard been A6.O, ducts. The ultraviolet (radiant) arc can energy listed 3 in Standards index. also trichioroethylene decompose DO NOT chloroethylene form phosgene.
- Page 7 Coil hose prevent kinks each cylinder. It is tangles. marking excess must properly when the cylinder safety assurance Protect hose from damage by sharp edges, handled. and open flame. sparks, slag, with cylinders only Identifying content. Examine hose regularly leaks, and loose rely color...
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Page 8: Arc Welding
Liquid of water). Bubbles in Protect filter plate with clear equivalent gallon plate. cover dicate leak. Clean off after test; dried water soap soapy Cracked is combustible. broken helmet shield should radiation through burns. worn; to cause pass User Responsibilities loose filter Cracked, broken, plates... - Page 9 Electrode Holders Shock Prevention insulated electrode holders should be used. Do Fully other bare metal in the Exposed hot conductors holders with protruding electrically-HOT screws. welding circuit, ungrounded, shock person whose body equipment fatally Connectors DO NOT STAND, SIT, LIE. becomes conductor.
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Page 10: Standards Booklet Index
Z49.2, FIRE red-tag switches) ANSI Standard prevent accidental PREVENTION turning THE USE OF CUTTING AND WELDING PRO Disconnect cables from welding power. power CESSES obtainable from the American National pull all 115 volts line-cord plugs. source, Standards Institute, 1430 Broadway, York, NY 10018. -
Page 11: General Information And Safety
INTRODUCTION SECTION 2 Weight Speed Range Electrode Wire Model Per Minute Diameter Capacity Dimensions Ship 190 in. (0.5 4.8 m) Height: 20-7/8 in. (530 5/64 thru 5/32 in. 44 lb. Width: 11-1/2 in.~ (292 mm) thru 4 13-3/4 in. (349 mm) Length: Al D (0.4... -
Page 12: Location
INSTALLATION SECTION (22.2 mm) for D Modele. Add 7/8 in. TC-I 10764 Hole Layout Figure 1. Overall Dimensions And Mounting LOCATION The service life efficiency of this system associated components reduced when they levels of dust, dirt, moisture, jected high corrosive heat. -
Page 13: Welding Gun Connections
TRAILING GUN POSITION ADJUSTMENT the three securing Loosen remove screws on 3-3) (Figure Trailing be ad angle height each gear. justed provide required and bead weld penetration width. Align holes each pair split drive rolls, insert securing and slide drive roll Onto screw trailing... - Page 14 L~1 a.1~I The monocoil liner is used for HOPPER CONNECTIONS Connect fA~I ~ 6. FLUX 5/64 (2 mm) wire tube the flux inlet only. the flux flux dispensing hopper leading gun. The flux flow regulated by Leading (Flux) the valve hopper (Figure 3-4)
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Page 15: Weld Cable Connections
Remove gun from drive The flux gun be used with grav,~ IMPORTANT: assembly. When used pressurized flux delivery ty feed system. or a Remove flux system, install bushing (see tube with pressurized contact adapter. flux flux inlet adapter tube Figure 3-4) hose, c/amp flux hose in... -
Page 16: Shutting Down
wire damp flux. t~I~1:If1~L~ Spooled tendency when loosened (rain the firm flux feed hose. unravel spool. Maintain pinch threading of flux wire during operation. Keep foreign matter Out system. grip welding wire and all metal with it contact parts of the free of the wire Cut off portion... -
Page 17: Cleaning Of Drive Rolls
MAINTENANCE SECTION INSPECTION UPKEEP Usage Remove and clean the drive roll(s) (see Section 3-2 conditions will determine the frequency removal and installation shop type instructions). equipment follows: of maintenance. Inspect I WaI 1 . f..~kI ~ Failure properly maintain the drive L~~U~E ELECTRIC SHOCK... -
Page 18: General
Route pigtail through slot brush box. Ensure that the pigtail will into with come contact metal surface. Insert brush into brush box. Ensure that the low end of the bevel the top of the brush is towards the spring. Using long-nose pliers, insert spring... - Page 19 TROUBLE PROBABLE CAUSE REMEDY Wire feeds erratically. Obstruction in gun Clear obstruction. contact tube. Drive plug Secure plug connection. motor secure cord plug. Incorrect pressure drive Rotate pressure adjustment knob(s) clockwise in rolls. increments until wire slippage turn stops. pressure is required, check gun contact...
- Page 21 CO -I...
- Page 22 Rel: TC.080366F TO-! !O 018 Motor/Drive Assembly Figure OM-1553 Page...
- Page 23 Quantity Model Item Dia. Part Description Mkgs. Motor/Drive Assembly Figure 109 189 BRACKET, mtg-components 109 186 BRACKET, mtg-motor 109 179 CLAMP, holddown-motor 109188 INSULATOR,motor 109 187 STRIP, mtg-motor 110 407 GUIDE, wire inlet 111 119 DRIVEASSEMBLY(consistingof) 079 671 HOUSING, adapter-gun/feeder 089 562 FASTENER, pinned...
- Page 24 Quantity Model Dia. Part Item Mkgs. Description Al D Motor/Drive (Contd) Figure Assembly (consisting 080 803 MOTOR, gear 1/8 115 volts 2000 080 283 COVER, brush SPRING, 080 282 brush BRUSH 081 630 motorl7 inch .CORD, 079 739 CLAMP, cable HOUSING PLUG&...
- Page 25 Part Item Description Quantily (Flux) Figure Leading monocoil .183 OD .041 lOx 15 109 181 LINER, 081 925 GUIDE, wire-outlet 081 920 ADAPTER, gun/feeder 109 176 INSULATOR, tube-head 109 182 TUBE, head-extension 081 923 ADAPTER, tube-head (consisting 071 590 RING, external 3/4 shaft .042 retaining...
- Page 26 Part tern Description Quantity Figure Trailing 109 181 LINER, monocoil .183 ODx.041 lOx 15 081 925 GUIDE, wire outlet 081 919 ADAPTER, tube contact INSULATOR,tube head TUBE HEAD-EXTENSION 109 182 TUBE HEAD 081 924 RING, 071 950 retaining .750 shaft .O42thk ADAPTER, gun feeder...