AUTO ARC XLT 135 Owner's Manual
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AUTO ARC XLT 135 Owner's Manual

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Auto Arc XLT 135 / 165
For Warranty Claims And Technical Support, Contact:
Milweld Inc., National Distributor
P.O. Box 338, Hortonville, WI 54944-0338
Tel 920-779-0916 Fax 920-779-0924
OM-198 076
November 1999
Processes
Description
Arc Welding Power Source And
Wire Feeder
R
MIG (GMAW) Welding
Flux Cored (FCAW) Welding

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Summary of Contents for AUTO ARC XLT 135

  • Page 1 MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Auto Arc XLT 135 / 165 For Warranty Claims And Technical Support, Contact: Milweld Inc., National Distributor P.O. Box 338, Hortonville, WI 54944-0338 Tel 920-779-0916 Fax 920-779-0924...

  • Page 2: Table Of Contents

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

  • Page 3: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage OM-198 076 Page 1...
  • Page 4 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • Page 5: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. 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.

  • Page 6: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 7: Section 1 − Consignes De Securite − Lire Avant Utilisation

    SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 8 LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

  • Page 9: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 10: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 11: Section 2 − Specifications

    SECTION 2 − SPECIFICATIONS 2-1. Specifications A. 115 VAC Model Amperes Input at Maximum Open- Rated Welding Amperage Rated Load Output Weight Overall Circuit Voltage Output Range W/ Gun Dimensions 115 V, 60 Hz, Single- Phase Length: 18-7/8 in (479 mm) 90 A @ 19 Volts DC, 2.90 2.50...

  • Page 12: Duty Cycle And Overheating

    2-2. 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) A. 115 VAC Model opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool.

  • Page 13: Volt-Ampere Curves

    2-3. Volt-Ampere Curves The volt-ampere curves show the A. 115 VAC Model minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. 30.0 25.0 20.0 Range 4 15.0 Range 3 Range 2 10.0...

  • Page 14: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Installing Welding Gun Drive Assembly Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert gun end through opening until it bottoms against drive assembly. Tighten thumbscrew. Gun Trigger Leads Insert leads, one at a time, through gun opening on front panel.

  • Page 15: Process/Polarity Table

    3-3. Process/Polarity Table Cable Connections Process Process Polarity Polarity Cable To Gun Cable To Work GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) output ing gas put terminal terminal FCAW −...

  • Page 16: Installing Gas Supply

    3-5. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other station- Tools Needed: ary support so cylinder cannot fall and break off valve. 5/8, 1-1/8 in Cylinder Valve Remove cap, stand to side of valve, and open valve slightly.

  • Page 17: Selecting A Location And Connecting Input Power For 115 Vac Model

    3-6. Selecting A Location And Connecting Input Power For 115 VAC Model Rating Label Grounded Receptacle A 115 volt, 20 ampere individual 18 in branch circuit protected by time-de- (460 mm) lay fuses or circuit breaker is re- quired. Plug From Unit Select extension cord of 14 AWG for up to 50 ft (15 m) or 12 AWG for 50 up to 200 ft (61 m).

  • Page 18: Selecting A Location And Connecting Input Power For 230 Vac Model

    3-7. Selecting A Location And Connecting Input Power For 230 VAC Model Rating Label Supply correct input power. Plug Receptacle Connect plug to receptacle. Line Disconnect Device 18 in (457 mm) of space for airflow See Section 3-8. Y Special installation may be required where gasoline or volatile liquids are present −...

  • Page 19: Electrical Service Guide For 230 Vac Model

    3-8. Electrical Service Guide For 230 VAC Model Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) 66 (20) Min Grounding Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC) S-0092-J...

  • Page 20: Threading Welding Wire

    3-10. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. 4 in (102 mm) 6 in (150 mm) Open pressure assembly.

  • Page 21: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Controls Voltage Switch The higher the selected number, the thicker the material that can be welded (see weld setting label in welding power source or Sections 4-2 and 4-3, as applicable). Do not switch under load. Voltage Switch - Purge “0”...

  • Page 22: Weld Parameters For 115 Vac Model

    4-2. Weld Parameters For 115 VAC Model 196 052 OM-198 076 Page 20...

  • Page 23: Weld Parameters For 230 Vac Model

    4-3. Weld Parameters For 230 VAC Model 196 081-A OM-198 076 Page 21...

  • Page 24: Section 5 − Maintenance &Troubleshooting

    SECTION 5 − MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Repair or Clean unreadable replace tighten weld labels. cracked terminals. weld cable. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. 5-2.

  • Page 25: Changing Drive Roll Or Wire Inlet Guide

    5-4. Changing Drive Roll Or Wire Inlet Guide Inlet Wire Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. Drive Roll The drive roll consists of two differ- ent sized grooves.

  • Page 26: Cleaning Or Replacing Gun Liner

    5-6. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun from unit. 8 mm / 10mm Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide. Head Tube 8 mm Remove liner. Lay gun cable out straight To Reassemble Gun: before installing new liner.

  • Page 27: Replacing Switch And/Or Head Tube

    5-7. Replacing Switch And/Or Head Tube Y Turn Off welding power source /wire feeder and disconnect gun. Remove handle locking nut. Slide handle. Remove switch housing. Install new switch and connect leads (polarity is not important). Reas- semble in reverse order. If replacing head tube, continue to end of figure.

  • Page 28: Troubleshooting Table

    5-8. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 3-6). does not run. does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 4-1). Reset welding power source circuit breaker if open.

  • Page 29: Section 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM 194 324 Figure 6-1. Circuit Diagram For 115 VAC Model OM-198 076 Page 27...
  • Page 30 194 325 OM-198 076 Page 28 Figure...

  • Page 31: Section 7 − Mig Welding (Gmaw) Guidelines

    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/...

  • Page 32: Typical Mig Process Control Settings

    7-2. Typical MIG Process Control Settings NOTE These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or Convert Material .125 in Thickness to...

  • Page 33: Holding And Positioning Welding Gun

    7-3. Holding And Positioning Welding Gun NOTE Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. Hold Gun and Control Gun Trigger Workpiece...

  • Page 34: Conditions That Affect Weld Bead Shape

    7-4. Conditions That Affect Weld Bead Shape NOTE Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. ° Push ° Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long...

  • Page 35: Gun Movement During Welding

    7-5. Gun Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead − Steady Movement Along Seam Weave Bead −...

  • Page 36: Troubleshooting − Excessive Spatter

    7-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.

  • Page 37: Troubleshooting − Lack Of Penetration

    7-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.

  • Page 38: Troubleshooting − Waviness Of Bead

    7-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand.

  • Page 39: Common Mig Shielding Gases

    7-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.

  • Page 40: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 802 449 Figure 8-1. Main Assembly OM-198 076 Page 38...
  • Page 41 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ..... 195 999 . . . BASE, lower ..........
  • Page 42 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly (Continued) ..... 111 443 . . . BUSHING, strain relief .
  • Page 43 Item Part Description Quantity 042 053 Figure 8-2. Gun ..... 130 789 ..NOZZLE, slip type .500 orf flush .
  • Page 44 Notes...
  • Page 45 Notes...
  • Page 46 Notes...

  • Page 47: Warranty

    Warranty Effective January 1, 1999 (Equipment with a serial number preface of “KK” or newer) This limited warranty supersedes all previous manufacturers Limited Warranty shall not apply to: warranties and is exclusive with no other guarantees or Items furnished by manufacturer, but manufactured by warranties expressed or implied.
  • Page 48 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Resources Available Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment...

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Xlt 165

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