Miller LK500173T Owner's manual

Brand: Miller

Model: LK500173T

Category: Welding System

Type: Owner's manual

This manual is also suitable for

XR A AND XR W GUNS

XR A And XR W

(With Quick Disconnect)

™

Processes

OM-236 297F

2010−01

MIG (GMAW) Welding

File: MIG (GMAW)

Visit our website at

www.MillerWelds.com

™

Description

Semi-Automatic, Air/Water-

Cooled, MIG (GMAW) Welding

Gun

Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor to receive the latest full

line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can get

the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller

products had to be more than the best they could be. They had to be the

best you could buy.

Today, the people that build and sell Miller products continue the

tradition. They’re just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

there’s a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001 Quality System

Standard.

Working as hard as you do

− every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Mil_Thank 2009−09

TABLE OF CONTENTS

SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING 1. . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − DEFINITIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. WEEE Label (For Products Sold Within The EU) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Symbols And Definitions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Gun Specifications 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Duty Cycle And Overheating 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Important Information Regarding CE Products (Sold Within The EU) 4. . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Connections With A Constant Current (CC), Constant Voltage (CV) Or Constant Current/Constant

Voltage (CC/CV) Welding Power Source Having A 14-Socket Receptacle 5. . . . . . . . . . . . . . . . . . . . . .

4-3. Air-Cooled Gun Connections 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Water-Cooled Gun Connections 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Millermatic 350/350P Water Cooled Gun Connections 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Threading Welding Wire Through Millermatic 350/350P 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Threading Welding Wire Through XR-Control Feeder 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Adjusting Tension At Feeder 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. 10-Pin Plug Information 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Removing Top Cover Of Pistol Grip Gun 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Threading Welding Wire Through Gun 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Gun Controls 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Shielding Gas 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Sequence Of Gas Metal Arc Welding (GMAW) − Continuous Or Spot 13. . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Coolant Supply For Water-Cooled Models Only 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE & TROUBLESHOOTING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Replacing The Liner 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Changing Gun Contact Tip 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Replacing Or Cleaning Gun Drive Roll In Pistol-Grip Guns 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Replacing Or Cleaning Gun Drive Roll Bearing In Pistol-Grip Guns 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Replacing Head Tube Liner In Pistol-Grip Guns 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Removing Diffuser In Air And Water-Cooled Pistol-Grip Guns 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Troubleshooting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAMS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − PARTS LIST 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − PARTS LIST INCLUDING CONSUMABLES 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-236 297 Page 1

SECTION 1 −SAFETY PRECAUTIONS FOR GMAW

WELDING GUNS − READ BEFORE USING

SR7 (MIG) 2009−08

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE − Indicates statements not related to personal injury.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the welding power source Owner’s Manual. Read

and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

D Always wear dry insulating gloves.

D Insulate yourself from work and ground.

D Do not touch live electrode or electrical parts.

D Repair or replace worn, damaged, or cracked gun or cable insula-

tion.

D Turn off welding power source before changing contact tip or gun

parts.

D Keep all covers and handle securely in place.

D Keep your head out of the fumes.

D Ventilate area, or use breathing device.

D Read Material Safety Data Sheets (MSDSs)

and manufacturer’s instructions for material

used.

FUMES AND GASES can be hazardous.

D Do not weld near flammable material.

D Do not weld on closed containers.

D Watch for fire; keep extinguisher nearby.

WELDING can cause fire or explosion.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use ap-

proved air-supplied respirator.

MOVING PARTS can injure.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

D Wear welding helmet with correct shade of fil-

ter.

D Wear correct eye and body protection.

D Cover exposed skin with spatter-resistant

clothing.

ARC RAYS can burn eyes and skin.

HOT PARTS can burn.

D Allow gun to cool before touching.

D Do not touch hot metal.

D Protect hot metal from contact by others.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Check for noise level limits exceeding those

specified by OSHA.

D Use approved ear plugs or ear muffs if noise level is high.

D Warn others nearby about noise hazard.

WELDING WIRE can injure.

D Keep hands and body away from gun tip when

trigger is pressed.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or

servicing unit. Read the safety information at

the beginning of the manual and in each

section.

D Use only genuine replacement parts from the manufacturer.

D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local

codes.

OM-236 297 Page 2

1-3. EMF Information

Electric current flowing through any conductor causes localized electric

and magnetic fields (EMF). Welding current creates an EMF field

around the welding circuit and welding equipment. EMF fields may inter-

fere with some medical implants, e.g. pacemakers. Protective meas-

ures for persons wearing medical implants have to be taken. For ex-

ample, access restrictions for passers−by or individual risk assessment

for welders. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Do not place your body between welding cables. Arrange cables

to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the

welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire

feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

OM-236 297 Page 3

SECTION 2 − DEFINITIONS

2-1. Symbols And Definitions

Primary Voltage

Volts

Primary Current

Amperes

Degree Of

Protection

Conventional Load

Voltage

Rated Welding

Current

Duty Cycle

Percent

SECTION 3 − INTRODUCTION

3-1. Gun Specifications

Specification Description

Input Voltage 30 Volts DC

Duty Cycle (Air-Cooled Models) At 200 Amperes, 100% Using Argon Or Argon Mixture Shielding Gas

At 250 Amperes, 60% Using Argon Or Argon Mixture Shielding Gas

Duty Cycle (Water-Cooled Models) At 400 Amperes, 100% Using Argon Or Argon Mixture Shielding Gas

Wire Size Range .030 Thru 1/16 in. (0.8 Thru 1.6 mm) Aluminum Wire

.030 Thru .045 in. (0.8 Thru 1.1 mm) Hard Or Cored Wire

Net Weight (Torch Only) XR-A (2.2 lbs)

XR-W (2.4 lbs)

3-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

NOTICE − Exceeding duty cycle

can damage unit and void warranty.

sduty1 5/95

6 Minutes Welding 4 Minutes Resting

Continuous Welding

Air-Cooled Models

Water-Cooled Models

100% Duty Cycle At 400 Amperes Using Argon

Continuous Welding

100% Duty Cycle At 200 Amperes Using Argon 60% Duty Cycle At 250 Amperes Using Argon

OM-236 297 Page 4

SECTION 4 − INSTALLATION

. Be sure that contact tip, liner, and drive rolls are correct for wire size and type. See Parts List to change parts as needed.

4-1. Connections With A Constant Current (CC), Constant Voltage (CV) Or Constant

Current/Constant Voltage (CC/CV) Welding Power Source Having A 14-Socket

Receptacle

Ref. 151 666-G / 804 542-B / 804 653-A

1 CC, CV Or CC/CV Welding

Power Source

2 24 VAC/Contactor Control

14-Pin Plug

3 Workpiece

4 Voltage Sensing Lead

(Optional)

Connect lead to workpiece for CC

welding only.

5 Gun

6 Wire Feeder

7 24 VAC/Contactor Control

Cord

! Do not use gas pressure

above 50 psi (345 kPa).

8 Gas Cylinder

Millermatic 350P

XR Control

OM-236 297 Page 5

4-2. Air-Cooled Gun Connections

Ref. 801 577-A / 801 564-E / Ref. 151 666-G

1 Gun Control Cable

Insert plug into Gun Control

receptacle, and tighten threaded

collar.

2 Gun Connector

3 Gun Securing Knob

4 Gun Connector Block

Loosen gun securing knob, and

insert gun connector through Wire

opening until it bottoms against

block. Tighten knob. Close and

latch door.

Tools Needed:

9/16, 3/4 in.

Left Side

OM-236 297 Page 6

4-3. Water-Cooled Gun Connections

Ref. 801 577-A / 805 107-A

. Turn on coolant supply before

welding or gun will be dam-

aged.

1 Gun Control Cable

Insert plug into Gun Control

receptacle, and tighten threaded

collar.

2 Gun Connector

3 Gun Securing Knob

4 Gun Connector Block

Loosen gun securing knob, and

insert gun connector through Wire

opening until it bottoms against

block. Tighten knob. Close and

latch door.

5 Gun (Coolant) “In” Hose

Connect to Water “In” fitting on

feeder (left-hand threads).

6 Gun (Coolant) “Out” Hose

Connect to Water “Out” fitting on

feeder (left-hand threads)

7 Water (Coolant) Output

8 Water (Coolant) Input

9 XR Control (Coolant) Output

10 XR Control (Coolant) Input

Close and latch door.

Tools Needed:

9/16 in.

Left Side

OM-236 297 Page 7

4-4. Millermatic 350/350P Water Cooled Gun Connections

Ref. 804 945-A / 151 666-G

. Turn on coolant supply before welding

or gun will be damaged.

1 Coolant Supply

2 Millermatic 350P

3 Gun Control Cable

Insert plug into gun control receptacle and

tighten threaded collar.

4 Water In Hose

Connect to coolant supply with supplied

coupler and water hose (left-hand threads).

5 Gun Connector

Loosen gun securing knob, and insert gun

connector through Wire opening until it

bottoms against block. Tighten knob. Close

and latch door.

6 Water Out Hose

Connect to coolant supply with supplied

coupler and water hose (left-hand threads).

7 Coolant “In”

8 Coolant “Out”

Tools Needed:

9/16 in.

OM-236 297 Page 8

4-5. Threading Welding Wire Through Millermatic 350/350P

1 Wire Spool

2 Welding Wire

3 Inlet Wire Guide

4 Drive Roll

5 Intermediate Wire Guide

6 Outlet Wire Guide

7 Pressure Adjustment Knob

8 Gun Conduit Cable

Lay gun cable out straight.

Tools Needed:

6 in.

(150 mm)

. Hold wire tightly to keep it

from unraveling.

Open pressure assembly.

Pull and hold wire; cut off end.

Push wire thru guides into gun;

continue to hold wire.

Close and tighten pressure

assembly, and let go of wire.

. Set pressure indicator

scale to 1/2 lb.

Ref. 803 544-A / 218 243-A / 218 244-A / S-0627-A

Pressure

Indicator

Scale

218243-A

IMPORTANT!

For Aluminum Push-Pull welding.

Thread hub tension nut loosely

IMPORTANT!

For Aluminum

Push-Pull welding.

218244-A

35621 4

See Section 4-10 for threading weld-

ing wire through XR guns.

3/4 in.

Tighten to

1/2 lb.

OM-236 297 Page 9

4-6. Threading Welding Wire Through XR-Control Feeder

Ref. 802 193-A / 801 577

Tools Needed:

1 Cable Assembly

Lay cable assembly out straight.

2 Jog Switch

Push Jog switch up to feed wire through

cable assembly.

3 Torque Switch

. Select proper push feeder torque set-

ting for wire size being used. Use low

torque for .030 in. (0.8mm) wire. Use

high torque for all other wire sizes.

. Hold wire tightly to keep

it from unraveling.

4-7. Adjusting Tension At Feeder

Ref. 802 193-A

Tools Needed:

Pull and hold wire; cut off end.

6 in.

(150 mm)

Open tension arm.

Thread wire thru inlet guide, along drive roll groove, and

into wire conduit. Close tension arm. Adjust tension as

follows: grasp spool with one hand, press Jog switch, and

turn thumb nut clockwise until motor stalls when Jog

switch is pressed. Back thumb nut off slightly.

Proceed to Section 4-10.

OM-236 297 Page 10

4-8. 10-Pin Plug Information

Pin* Pin Information

A Electrode sense lead

B Motor Common

G Trigger

C Motor 0 to +24 volts DC with respect to pin B

D Trigger

E Wire speed Ref. +9 volts DC

H Wire speed com

F Wire speed 0 to +9 volts DC with respect to pin H

J Gun sensing resistor with respect to pin H

I Not used

4-9. Removing Top Cover Of Pistol Grip Gun

1 Top Cover Triangular Boss

Push up on triangular boss to open

door. Door hinges on handle.

To open door fully, push up on door

until it clicks into position.

. If door is pushed too far it will

separate from handle. If this

happens the door can be rein-

stalled.

Push door back into original posi-

tion to close.

802 528-C

OM-236 297 Page 11

4-10. Threading Welding Wire Through Gun

Ref. 802 193-A / 801 556-B / 151 599-F

Tools Needed:

. Refer to Section 4-6 for instructions on feeding wire

through feeder.

Feed wire to check drive roll pressure.

If necessary, slightly tighten thumb nut

inside gun.

Cut off wire. Close and latch wire

feeder door.

WOOD

! Welding wire is electrically live when gun trigger

is used to jog wire.

. Turn OFF coolant supply before removing head tube

on water-cooled gun.

1 Pressure Roll Assembly

Lift arm and open pressure roll assembly.

2 Cable Assembly

Lay cable assembly out straight.

Push Jog switch up to feed wire through cable assembly.

3 Drive Roll

For wire sizes .035 in. (0.9 mm) and smaller use small

groove, and .047 in. (1.2 mm) and 1/16 in. (1.6 mm) use

large groove.

4 Contact Tip

Manually thread wire along drive roll groove and out con-

tact tip 2 in. (51 mm). Close pressure roll assembly.

5 Tension Thumbnut

6 Pressure Adjustment Knob

7 Final Pressure Adjustment

See procedure at bottom of page. Reinstall gun cover.

OM-236 297 Page 12

SECTION 5 − OPERATION

5-1. Gun Controls

1 Trigger

Press trigger to energize welding

power source contactor

(if applicable), start shielding gas

flow, and begin wire feed.

2 Wire Speed Control

Use control to fine adjust wire feed

speed set on wire feeder Weld

Speed control. The numbers

around the control are for reference

only.

Ref. 151 666-F

5-2. Shielding Gas

sb5.1 6/92 − S-0621-C / Ref. 151 666-F

1 Shielding Gas Cylinder

2 Valve

3 Gun Trigger

Open valve on cylinder just before

welding.

Gun trigger turns weld output and

gas flow on and off (see Section

5-1).

Close valve on cylinder when

finished welding.

5-3. Sequence Of Gas Metal Arc Welding (GMAW) − Continuous Or Spot

Begin Welding

ssb6.1* 9/92

Install &

Connect

Equipment

Put On

Personal Safety

Equipment

Set Controls

Turn On Gas

And Water (If

Applicable)

Turn On Feeder

And Welding

Power Source

OM-236 297 Page 13

5-4. Coolant Supply For Water-Cooled Models Only

Ref. 150 755-A

1 Coolant Supply

2 Coolant “In”

3 Coolant “Out”

See table below for coolant

guidelines.

Turn On coolant supply before

welding.

Turn Off coolant supply when

finished welding.

MILLER Low

Conductivity Coolant

No. 043 810**

MILLER Aluminum Protecting

Coolant No. 043 809**;

Distilled Or Deionized Water OK

Above 32° F (0° C)

GTAW Or Where

HF* Is Used

GMAW Or Where Coolant

Contacts Aluminum Parts Or

Where HF* Not Used

Application

*HF: High Frequency Current

**MILLER coolants protect to -37° F (-38°C) and resist algae growth.

Coolant

SECTION 6 − MAINTENANCE & TROUBLESHOOTING

. Maintain more often

during severe conditions.

! Disconnect power

before maintaining.

3 Months

Replace

Damaged Or

Unreadable

Labels

Replace

Damage

Gas Hose

Clean

And

Tighten

Weld

Terminals

Repair Or Replace

Cracked Cables

And Cords

6 Months

Blow Out Or

Vacuum Inside

Clean

Drive

Rolls

OM-236 297 Page 14

Ref. 151 599-F / Ref. 801 556-C / 801 564−E / Ref. 151 666-G / Ref. 200 371

6-1. Replacing The Liner

! Turn Off wire feeder and

welding power source.

1 Drive Roll

2 Collet Nut

Lay gun cable out straight. Remove

drive roll on gun and collet nut on lin-

er tube assembly.

3 Gun Connector

Remove inlet guide from gun con-

nector, and remove old liner.

4 New Liner

Insert split end of new liner into gun

connector and continue feeding lin-

er through cable assembly until lin-

er is through liner tube assembly

and all of split portion is visible.

. If gun is a 15 ft (4.5 m) model,

push the split end of liner

through until the opposite end

is sticking out of the gun con-

nector 1 to 2 inches (2.5 to 5

cm). After trimming, the section

with the split on it can be saved

to use as another replacement

liner.

Cut off split portion of liner. Replace

collet nut with new nut from this kit.

Reinstall inlet guide at gun connec-

tor and tighten onto liner.

The liner end will not stick out of the

collet nut supplied with this kit.

At the gun connection end, cut liner

as close as possible to control

(push motor) drive rolls.

See Section 4-10 for instructions on

rethreading wire.

. It may be easier to replace the

collet nut with the liner conduit

removed from the gun housing

block.

Split End

Pistol Grip Gun

OM-236 297 Page 15

6-2. Changing Gun Contact Tip

Ref. 150 437-A

Remove nozzle

1 Nozzle

2 FasTip

Unscrew FasTip.

Install new FasTip.

6-3. Replacing Or Cleaning Gun Drive Roll In Pistol-Grip Guns

! Turn Off wire feeder and

welding power source.

1 Top Cover

2 Pressure Roll Assembly

Cut off wire where it enters

pressure roll assembly area.

3 Setscrew

4 Current Pick-Up Tab

This tab helps prevent burnback

caused by welding arcs inside the

contact tip. This tab may be re-

moved to provide an insulated drive

roll. (If tab is removed, a smaller di-

ameter contact tip is recom-

mended. See options in Parts List.)

Lightly grease top of tab before rein-

stalling.

5 Drive Roll

Use wire brush to clean drive roll.

Install drive roll with desired groove

down, and turn drive roll so one

setscrew faces flat side of shaft.

6 Bearing

7 Liner

Line up drive roll groove with bear-

ing groove and liner opening.

Tighten setscrews.

Thread welding wire through gun,

and adjust drive roll pressure, if

necessary (see Section 4-10).

Close and secure pressure roll

assembly. Reinstall top cover.

Ref. 151 599-F

Tools Needed:

5/64 in.

OM-236 297 Page 16

! Turn Off wire feeder and

welding power source.

1 Top Cover

2 Pressure Roll Assembly

3 Screw

4 Pressure Roll

Remove as shown.

Use a wire brush to clean bearing.

Reinstall with washers, and tighten

screw.

Close pressure roll assembly.

Reinstall top cover.

Ref. 151 599−F

Tools Needed:

6-4. Replacing Or Cleaning Gun Drive Roll Bearing In Pistol-Grip Guns

6-5. Replacing Head Tube Liner In Pistol-Grip Guns

Ref. 803 917-A

. Turn Off coolant supply before

removing head tube on

water-cooled gun.

The standard head tube liner will

accommodate wire diameters from

.030-1/16 wire size.

When changing wire size, change

gun drive roll (see Section 6-3).

1 Cover

2 Screw

3 Clamp

Loosen clamp screws and remove

clamp.

4 Head Tube

Remove head tube from gun.

5 Liner

Pull liner out of head tube.

Insert new liner into head tube and

reinstall head tube onto gun.

. A twisting motion may be need-

ed to feed liner thru head tube.

5/32 in.

Tool Needed:

Page is loading ...

Miller LK500173T Owner's manual

Brand: Miller

Model: LK500173T

Category: Welding System

Type: Owner's manual

This manual is also suitable for

XR A AND XR W GUNS

Download PDF

report

Miller LK500173T Owner's manual

This manual is also suitable for

Miller LK500173T Owner's manual

Related papers

Other documents