Miller AA40G Owner's Manual
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Miller AA40G Owner's Manual

Miller AA40G Owner's Manual

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AA40G
File: Advanced Manufacturing Systems
OM-200580T
2018−05
Processes
Automatic Welding
Description
Wire Feeder

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Summary of Contents for Miller AA40G

  • Page 1 OM-200580T 2018−05 Processes Automatic Welding Description Wire Feeder AA40G File: Advanced Manufacturing Systems For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com/ams...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2018−01 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.
  • Page 6 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 8: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2018−01_fre 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.
  • Page 10 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 12: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.

  • Page 13: Section 3 − Definitions

    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 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.

  • Page 14: Section 4 − Specifications

    Speed Range Range Power Ship 50 To 1400 ipm .023 To 1/8 in. 16-1/2 lb 17-1/2 lb AA40G 40 VDC, 10 A 2 ft (0.6 m) (1.3 To 35.6 mpm) (0.6 To 1.3/1.4 mm) (7.5 kg) (7.9 kg) 4-2. Environmental Specifications A.

  • Page 15: Overall Dimensions And Mounting Hole Layout

    4-3. Overall Dimensions And Mounting Hole Layout Inches Millimeters Inches Millimeters 9-7/16 3-1/4 11-1/2 3-1/2 7-1/64 3/8 Dia. 9.5 Dia. 4 Holes 4 Holes Inches Millimeters 3-1/2 3-1/4 5-1/2 1-1/2 25/64 Dia. 9.9 Dia. 2 Holes 2 Holes 3/8 Dia. 9.5 Dia.

  • Page 16: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Typical Equipment Location Welding Power Source Weld Control Wire Drive Assembly Gas Cylinder Spool Support Automatic Welding Gun Side Beam ST-131 138-A 5-2. Installing Wire Guides And Drive Rolls When changing wire size or type, check drive roll and guide size (see Table 8-1).

  • Page 17: Motor Mounting And Gun, Weld Cable, And Gas Connections

    5-3. Motor Mounting And Gun, Weld Cable, And Gas Connections Drive motor must be isolated from weld potential. Insulator Plate When mounting motor, place factory-supplied insulator plate under motor mounting bracket to provide isolation. Customer Supplied Gas Hose Shielding Gas Valve Fitting Requires hose fitting with 5/8-18 right-hand threads.

  • Page 18: Installing Welding Gun

    5-4. Installing Welding Gun Gun Locking Tab Power Clamp Knob Gun Connection End Power Pin Groove Installing gun with Accu-Mate connection Loosen power clamp knob to allow power pin of gun to clear the gun locking tab. Push power pin into power clamp as far as possible to align the groove in the power pin of the gun with the gun locking tab.

  • Page 19: Plug Connections

    5-5. Plug Connections Weld Control Motor Control Cord (Not Supplied) Cord is available in 30 ft (9.1 m) length. Motor/Drive Assembly To make connections, align key- way, insert plug, and tighten threaded collar. 803 251-B / 801 443-C OM-200580 Page 15...

  • Page 20: Threading And Feeding Welding Wire

    5-6. Threading And Feeding Welding Wire Tools Needed: Hold wire tightly to keep it from unraveling. Welding Power Source PURGE POWER 6 in (150 mm) Turn on power at welding power source. Pull and hold wire; cut off end. Pressure Indicator Pressure Scale...

  • Page 21: Section 6 − Maintenance And Troubleshooting

    SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Maintain more often Disconnect power before maintaining. during severe conditions. Reference n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent 3 Months l Unreadable Labels ~ Weld Terminals...

  • Page 22: Troubleshooting

    6-3. Troubleshooting Trouble Remedy Electrode wire feeding stops or feeds er- Readjust hub tension and drive roll pressure. ratically during welding. Change to correct size drive roll. Clean or replace dirty or worn drive roll. Incorrect size or worn wire guides. Replace contact tip or liner.
  • Page 23 Notes OM-200580 Page 19...

  • Page 24: Section 8 − Parts List

    SECTION 8 − PARTS LIST See Table 8-1 Drive Roll & Wire Guide Kits Hardware is common and not available unless listed. 33 32 802895-K Figure 8-1. Drive Assembly, Wire Item Dia. Part Description Quantity Mkgs. Figure 8-1. Drive Assembly, Wire .
  • Page 25 Item Dia. Part Description Quantity Mkgs. Figure 8-1. Drive Assembly, Wire ....137248 Spring, Indicator ..........
  • Page 26 Table 8-1. Drive Roll And Wire Guide Kits OM-200580 Page 22...
  • Page 27 Effective January 1, 2018 (Equipment with a serial number preface of MJ 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 —...
  • Page 28 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 2018 Miller Electric Mfg. LLC 2018−01...

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