Miller D-64M WIRE FEEDER, KF759252 Owner's manual

  • Hello! I am an AI chatbot trained to assist you with the Miller D-64M WIRE FEEDER Owner's manual. I’ve already reviewed the document and can help you find the information you need or explain it in simple terms. Just ask your questions, and providing more details will help me assist you more effectively!
Miller
March
1995
Form:
OM-1587B
Effective
With
Serial
No.
KF759252
OWNER๎‚’S
MANUAL
T'
~
U
๎‚•
๎‚•
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.
U
Give
this
manual
to
the
operator.
๎‚•
For
help,
call
your
distributor
๎‚•
or~
MILLER
Electric
Mfg.
Co.,
P0.
Box
1079,
Appleton,
WI
54912
414-734-9821
D-64M
Wire
Feeder
๎‚•
Microprocessor
Controlled
Constant
Speed
Dual
Wire
Feeder
๎‚•
Multi-Power
Source
Compatible
๎‚•
For
GMAW,
GMAW-P,
And
FCAW
Welding
๎‚•
For
.023
To
1/8
In
(0.6
To
3.2
mm)
Wires
๎‚•
Standard
Wire
Feed
Speed
Of
50
To
780
1PM
(1.3
To
19.8
MPM)
๎‚•
Programmable
Pulse
Weld
Parameters
๎‚•
See
Rear
Cover
For
Options
And
Accessories
cover
5/94
๎‚—
ST-800
179
'
1995
MILLER
BeCteC
Mfg.
Co.
PRINTED
IN
~SA
๎‚—I
I๎‚—
MILLER๎‚’S
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1995
(Equipment
with
a
serial
number
preface
of
๎‚“KD๎‚”
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
wsrranties
snd
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY๎‚—
Subject
to
the
tenns
end
conditions
below,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconain,
warranta
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
afterthe
effective
date
of
this
limited
warranty
is
free
ot
de
fects
in
materiel
end
workmanship
et
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANT1ES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war-
rented
parts
or
components
that
fail
due
to
such
defects
in
materiel
orwortoiianahip.
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
of
auch
defect
or
failure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
auch
a
failure
within
the
warranty
time
perioda.
All
warranty
time
perioda
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
or
one
year
aher
the
equipment
ia
sent
to
a
North
American
distributor
or
eighteen
months
aher
the
equipment
ia
sent
to
an
Intemational
distributor.
1.
BYeamParta๎‚—3YearaLabor
*
Original
main
power
rectifiers
2.
3
Years
๎‚—
Parta
and
Labor
Transformer/Rectifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
๎‚•
Semi-Automatic
and
Automatic
Wire
Feeders
๎‚•
Robota
3.
2
Yeara
๎‚—
Parts
and
Labor
๎‚•
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
๎‚•
Air
Compreasora
4.
1
Year
๎‚—
Parts
and
Labor
Motor
Driven
Guns
๎‚•
Process
Controllera
*
Water
Coolant
Systems
*
HF
Unita
*
Grids
*
Spot
Weldera
*
Load
Banks
๎‚•
SDX
Tranaformera
*
Running
Gear/Trailers
๎‚•
Plasma
Cutting
Torchea
(except
APE
ZIPCUT
&
PLAZCUT
Modela)
๎‚•
Tecumseh
Enginea
*
Deutz
Engines
(outside
North
America)
*
ReId
Options
(NOTE:
Field
options
are
covered
under
True
BIueTM
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
minimum
of
one
year
๎‚—
whichever
ia
greater.)
6
Months
๎‚—
Batteries
go
Days
๎‚—
Parts
and
Labor
*
MIG
Guns/TIG
Torches
๎‚•
APE
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
SI
*
Remote
Controla
๎‚•
Accessory
Kits
*
Replacement
Parts
MILLER๎‚’S
True
BIueTM
Umited
Warranty
ahall
not
apply
to:
1.
Itema
fumiahed
by
MILLER,
but
manufactured
by
ethers,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturer๎‚’a
warranty,
if
any.
2.
Consumable
componenta:
such
as
contact
ripe,
cutting
nozzlea,
contactors
and
relays
or
parts
that
fail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has
been
improperiy
inatalled,
improperiy
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reaaonable
and
neceasary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
apecificationa
for
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BYCOMMER
CIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENT.
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
excluaive
remedies
ahall
be,
at
MILLER๎‚’S
option:
(1)
repair-;
or(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
in
appropriate
caaea,
(3)
Ihe
reasonable
ccet
of
repairor
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
orcredit
forthe
pur
chaae
price
(leas
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customer๎‚’a
risk
and
expense.
MILLER๎‚’S
option
of
repair
or
replacement
will
be
FOB.,
Factoryat
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
coats
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENTSHALL
MILLER
BE
UABLE
FOR
DIRECT,
INDIRECT,
SPECIAL
INCIDENTALOR
CONSEOUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPUCA11ON,
OPERA11ON
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPUED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EOUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
atates
in
the
U.S.A.
do
nol
allow
limitationa of
how
long
an
implied
warranty
lasts,
or
Ihe exclusion
of
incidental,
indirect,
apecial
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
Thia
warranty
provides
ape
cific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state
to
state.
In
Canada,
legislation
in
some
provinces
providea
for
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitationa
and
exclusions
aet
out
above
may
not
apply.
This
Umited
Warranty
provides
apecific
legal
righta,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
๎‚—J
.
5.
6.
1~.
S
RECEIVING-HANDLING
Before
Unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
dUring
shipment.
File
any
claims
for
loss
or
damagB
with
the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturer๎‚’s
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Numberof
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
miller
1/95
ARC
WELDING
SAFETY
PRECAUTIONS
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
bums.
The
electrode
and
work
circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
poweraccording
to
OSHA
29
CFR
1910.147
(see
Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owner๎‚’s
Manual
and
national,
state,
and
local
codes.
6.
Always
verify
the
supply
ground
๎‚—
check
and
be
sure
that
input
power
cord
ground
wire
is
properly
connected
to
ground
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
7.
When
making
input
connections,
attach
proper
grounding
conductor
first
๎‚—
double-check
connections.
8.
Frequently
inspect
input
powercord
for
damage
or
bare
wiring
๎‚—
replace
cord
immediately
if
damaged
๎‚—
bare
wiring
can
kill.
9.
Tum
off
all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable
๎‚—
do
not
use
work
clamp
or
work
cable.
13.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
14.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
Wear
a
safety
harness
if
working
above
floor
level.
Keep
all
panels
and
covers
securely
in
place.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as
near
the
weld
as
practical.
a
WARNING
ARC
WELDING
can
be
hazardous.
PROTECT
YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR
DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
15.
16.
17.
ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
NOISE
can
damage
hearing;
FLYING
,_/~
SLAG
OR
SPARKS
can
injure
eyes.
Arc
rays
from
the
welding
process
produce
intense
visible
and
invisible
(ultraviolet
and
infrared)
rays
that
can
bum
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
grinding,
and
welds
cooling
throw
off
pieces
of
metal
or
slag.
NOISE
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
2.
3.
4.
5.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protectyourface
and
eyes
when
welding
orwatching
(see
ANSI
Z49.1
and
Z87.1
listed
in
Safety
Standards).
Wear
approved
safety
glasses
with
side
shields.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
FUMES
AND GASES
can
be
hazardous
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
=i~
b
these
fumes
and
gases
can
be
hazardous
to
your
health,
wearing
an
air-supplied
respirator.
Always
have
a
trained
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
form
highly
toxic
and
irritating
gases.
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturer๎‚’s
instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
cleaners,
and
degreasers.
containing
these
elements
can
give
off
toxic
fumes
if
welded.
CYLINDERS
can
explode
if
damaged.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
ec~in~J:~sur:r~
~
al~YmPc~e~iythe
welding
,
5.
6.
~,
Never
allow
a
welding
electrode
to
touch
any
cylinder.
Never
weld
on
a
pressurized
cylinder
๎‚—
explosion
will
result
Useontycorrectshieldinggascylinders,
regulators,
hoses,
and
flthngs
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
8.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
9.
Keepprotectivecapinplaceovervalveexceptwhencylinderis
2.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
in
use
or
connected
for
use.
support
or
cylinder
rack
to
prevent
falling
or
tipping.
10.
Read
and
follow
instructions
on
compressed
gas
cylinders,
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
circuits.
Standards.
srl.1.1
2/94
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blow
up.
Sparks
can
fly
off
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
to
metal
objects
can
cause
sparks,
explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is
safe
before
doing
any
welding.
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
7.
Do
not
weld
on
closed
containers
such
as
tanks,
drums,
or
pipes,
unless
they
are
properly
prepared
according
to
AWS
F4.1
(see
Safety
Standards).
8.
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garrrrents
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
a
WARNING
Engine
fuel
is
highly
flammable.
1.
Stop
engine
and
let
it
cool
off
before
checking
or
adding
fuel.
2.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
open
flan
es:
ENGINES
can
be
hazardous.
PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.
1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superinten
dent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
Ameri
can
Welding
Society
Standard
AWS
F4.
1,
from
American
Welding
So
ciety,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
National
Electncal
Code,
NFPA
Standard
70,
from
National
Fire
Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
High
way,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Bou
levard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
ForOccupationAndEducationalEyeAndFace
Protec
tion,
ANSI
Standard
Z87.1,
from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
~IJ~
P~~U
ENGINE
EXHAUST
GASES
can
kill.
Engines
produce
harmful
exhaust
gases.
1.
2.
Use
equipment
outside
in
open,
well-ventilated
areas.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
away
from
any
building
air
intakes.
ENGINE
FUEL
can
cause
fire
or
3.
Do
not
overfill
tan
k
๎‚—
all
ow
room
fo
r
fuel
t
o
expand.
explosion.
4.
Do
not
spill
fuel.
engine.
If
fuel
is
spilled,
clean
up
before
starting
๎‚‘๎‚‘
MOVING
PARTS
can
cause
injury.
~
Moving
parts,
such
as
fans,
rotors,
and
belts
can
cut
fingers
and
hands
and
catch
loose
clothing,
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
3.
4.
5.
6.
Have
only
qualified
people
remove
guards
or
covers
for
To
prevent
accidental
starting
during
servicing,
disconnect
maintenance
and
troubleshooting
as
necessary.
negative
(๎‚—)
battery
cable
from
battery.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
parts.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
2.
Stop
eng
ne
before
installing
or
connecting
unit.
finished
and
before
starting
engine.
SPARKS
can
cause
BATTE
TO
EXPLODE;
BATTERY
RY
GASES
ACID
can
1.
2.
Always
wear
Stop
engine
a
face
s
before
hield
when
working
on
a
battery.
disconnecting
or
connecting
battery
burn
eyes
and
skin,
cables.
3.
Batteries
contain
acid
and
generate
explosive
4.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
gases.
5.
Observe
correct
polarity
(+
and
๎‚—)
on
batteries.
.~
๎‚•~
STEAM
AND
PRESSURIZED
HOT
COOLANT
can
burn
face,
eyes,
and
skin.
It
is
best
to
check
coolant
level
when
engine
is
cold
to
avoid
scalding.
1.
2.
3.
If
the
engine
is
warm
and
checking
is
needed,
follow
steps
2
and
3.
Wear
safety
glasses
and
gloves
and
put
a
rag
over
cap.
Tum
cap
slightly
and
let
pressure
escape
slowly
before
completely
removing
cap.
S
srl.1.1
2/94
EMF
INFORMATION
TABLE
OF
CONTENTS
SECTION
1
๎‚—
SAFETY
INFORMATION
1
SECTION
2๎‚—
SPECIFICATIONS
1
SECTION
3๎‚—
INSTALLATION
3-1.
Site
Selection
3-2.
Connection
Diagram
3-3.
Wire
Guide
And
Drive
Roll
Installation
3-4.
Welding
Gun
Connections
3-5.
Motor
Start
Control
3-6.
Control
Connections
3-7.
Shielding
Gas
And
Weld
Cable
Connections
3-8.
Welding
Wire
Installation
3-9.
Threading
Welding
Wire
With
Drive
Assembly
Horizontal
3-10.
Threading
Welding
Wire
And
Rotating
The
Drive
Assembly
SECTION
4-
GLOSSARY
SECTION
5-OPERATION
5-1.
Front
Panel
Controls
5-2.
Side
Panel
Controls
5-3.
Rear
Panel
Controls
5-4.
Setting
Switches
On
450
Ampere
Inverter
Model
Welding
Power
Source
SECTION
6-
STEPPING
THROUGH
THE
MICROPROCESSOR
CONTROLS
6-1.
Front
Panel
Microprocessor
Controls
6-2.
Side
Panel
Microprocessor
Push
Buttons
SECTION
7-
STANDARD
PULSE
WELDING
PROGRAMS
SECTION
8๎‚—
GETTING
STARTED
36
8-1.
Welding
With
Only
Front
Panel
Controls
37
8-2.
Setting
Sequence
Pulse
Welding
Parameters
On
Side
Panel
Display
38
SECTION
9-
TEACHING
A
PULSE
WELDING
PROGRAM
42
9-1.
Pulse
Waveform
Explained
42
9-2.
Teach
Points
Explained
43
9-3.
Teaching
A
Pulse
Welding
Program
44
9-4.
Changing
To
Adaptive
Pulse
Welding
47
0M-15878
-
3)95
NOTE
~
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
the U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
๎‚—
Background
Paper~
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):๎‚”..
.
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
cellularlevel
and
from
studies
with
animals
and
people
which
clearly
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
or
avoid
potential
risks.๎‚”
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
1.
Keep
cables
close
together
by
twisting
or
taping
them.
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
3.
Do
not
coil
or
drape
cables
around
the
body.
4.
Keep
welding
power
source
and
cables
as
far
away
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About
Pacemakers:
The
above
procedures
are
among
those
also
normally
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
modi
0.1
4/93
2
2
3
4
5
5
6
7
9
11
13
15
17
18
20
21
22
23
23
25
28
SECTION
10-
TEACHING
A
MIG
WELDING
PROGRAM
10-1.
Changing
to
MIG
Welding
10-2.
Setting
Sequence
MIG
Welding
Parameters
On
Side
Panel
Display
SECTION
11
๎‚—
SETTING
DUAL
SCHEDULE
PARAMETERS
52
SECTION
12-
USING
THE
OPTIONAL
DATA
CARD
12-1.
Installing
DataCard
12-2.
Using
The
Data
Card
SECTION
15-
ELECTRICAL
DIAGRAMS
76
48
48
49
SECTION
13๎‚—SETUP
13-1.
13-2.
13-3.
13-4.
13-5.
13-6.
13-7.
13-8.
13-9.
13-10.
13-11.
13-12.
13-13.
13-14.
13-15.
13-16.
13-17.
13-18.
13-19.
13-20.
Setup
Flow
Chart
Using
Setup
Displays
Selecting
Process
Capability
Selecting
Welding
Power
Source
Range
Selecting
Security
Lock
Selecting
Or
Changing
Access
Code
Selecting
Voltage
Correction
Selecting
Voltage
Sensing
Method
Selecting
Regular
Or
Hot
Arc
Start
Selecting
Type
Of
Dual
Schedule
Switch
Selecting
Trigger
Program
Select
Selecting
Remote
Increase/Decrease
Capability
Resetting
Arc
Time
Using
Self
Test
Selecting
Units
For
Wire
Feed
Speed
And
Motor
Type..
Selecting
Bench
Or
Boom
Model
Type
Resetting
Memory
Selecting
Voltage
Error
Shutdown
Selecting
Program
Name
Feature
Software
Version
Number
SECTION
14๎‚—
MAINTENANCE
&
TROUBLESHOOTING
14-1.
Routine
Maintenance
14-2.
Replacing
The
Hub
Assembly
14-3.
Overload
Protection
14-4.
Error
Screens
14-5.
Troubleshooting
54
54
54
58
58
59
59
60
61
62
63
63
64
64
65
66
66
67
68
68
69
69
70
70
71
71
72
72
73
74
SECTION
16๎‚—
PARTS
LIST
Figure
16-1.
Main
Assembly
Figure
16-2.
Control
Box
Figure
16-3.
Panel,
Front
w/Components
Figure
16-4.
Drive
Assembly,
Wire
Figure
16-5.
Panel,
Side
w/Components
Table
16-1.
Drive
Roll
And
Wire
Guide
Kits
80
80
82
85
86
88
89
.
3-1.
Site
Selection
SECTION
3-
INSTALLATION
WARNING:
FALLING
WIRE
FEEDER
can
cause
serious
personal
injury
and
equipment
damage.
๎‚•
Do
not
put
wire
feeder
where
it
will
tip
or
fall.
๎‚•
Put
all
four
rubber
feet
solidly
on
a
flat
surface.
CYLINDERS
can
explode
if
damaged.
๎‚•
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
๎‚•
Never
touch
cylinder
with
welding
electrode.
๎‚•
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
ELECTRIC
SHOCK
can
kill.
๎‚•
Do
not
touch
live
electrical
parts.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
welding
or
feeding
wire
using
gun
trigger.
wfwam7.1
9/91
WARNING
I.
--o-,c~-J
.
Do
not
put
feeder
where
welding
wire
hits
cylinder.
1
Wire
Feeder
2
Rubber
Feet
3
Base
Slot
If
installing
wire
feeder
over
a
lifting
eye
on
a
welding
power
source,
se
lect
the
slot
that
allows
all
four
rub
ber
feet
on
base
of
feeder
to
sit
se
curely
on
top
of
welding
power
source.
4
Wire
Spool/Reel
5
Gas
Cylinder
(Customer
Supplied)
6
Welding
Power
Source
Position
wire
feeder
on
welding
power
source
or
cart
so
that
weld
ing
wire,
or
wire
spool/reel,
does
not
touch
gas
cylinder.
5
4
2
6
Figure
3-1.
Installing
Wire
Feeder
5T-156925-A/ST-162
131
/ST-162
130
OM-1
587
Page
2
3-2.
Connection
Diagram
1
Welding
Power
Source
2
17-Pin
Plug
And
Intercon
necting
Cord
3
14-Pin
Plug
And
Intercon
necting
Cord
4
Positive
(+)
Weld
Cable
5
Negative
(๎‚—)
Weld
Cable
6
Workpiece
7
Voltage
Sensing
Lead
8
Gun
ST-162
1~
N
OTE
~
If
using
wire
feeder
with
an
engine-driven
power
source,
place
engine
control
____________________
switch
in
Run
(high
speed)
position.
Some
wire
feeders
may
work
with
switch
in
Run/Idle
position.
9
Wire
Feeder
10
Gas
Hose
With
๎‚“Y๎‚”
Adapter
11
Gas
Cylinder
2.
11.
3-
4
5-
10
8
Figure
3-2.
Connection
Diagram
OM-1
587
Page
3
3-3.
Wire
Guide
And
Drive
Roll
Installation
a
WARNING
ELECTRIC
SHOCK
can
kill.
๎‚•
Do
not
touch
live
electrical
parts.
๎‚•
Turn
Off
wire
feeder
and
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
A.
Wire
Guide
Installation
B.
Drive
Roll
Installation
.
wfwaml.1
2/93
When
changing
wire
size
or
type,
check
guide
size
(see
Table
16-1).
1
Drive
Rolls
Remove
drive
rolls
before
install
ing
wire
guides
(see
Figure
3-4).
2
Wire
Guide
Securing
Screws
Loosen
wire
guide
screws.
3
Antiwear
Guide
Install
antiwear
guide
onto
inlet
wire
guide,
and
secure
with
set
screw.
Use
existing
antiwear
guide
when
changing
inlet
wire
guide
size.
4
InletWire
Guide
Install
inlet
guide
so
wire
guide
screw
is
centered
in
groove
in
guide.
5
Intermediate
Wire
Guide
Insert
intermediate
guide
until
flange
on
guide
rests
against
cast
ing,
and
secure
with
guide
screw.
Install
drive
rolls
(see
Figure
3-4).
Repeat
procedure
for
opposite
side
of
wire
feeder.
ST-153
125-B
/
ST-137
377-0
Tools
Needed:
5/64
in
Figure
3-3.
Wire
Guide
Installation
When
changing
wire
size
or
type,
check
drive
roll
size
(see
Table
16-1).
1
Spring
Shaft
Carrier
2
Drive
Roll
Nut
3
Drive
Roll
Carrier
Turn
nut
one
click
until
lobes
of
nut
line
up
with
lobes
of
drive
roll
carrier.
4
Drive
Roll
Slide
drive
roll
onto
drive
roll
carrier.
Turn
nut
one
click.
Repeat
procedure
for
all
drive
rolls.
5
Drive
Assembly
Cover
Close
cover.
Repeat
procedure
for
opposite
side
of
wire
feeder.
ST-137
377-D
4
Figure
3-4.
Drive
Roll
Installation
OM-1
587
Page
4
3-4.
Welding
Gun
Connections
4A
WARNING
ELECTRIC
SHOCK
can
kill.
๎‚•
Do
not
touch
live
electrical
parts.
๎‚•
Turn
Oft
wire
feeder
and
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
wfwaml.1
2/93
3-5.
Motor
Start
Control
a
WARNING
Ci~1===zn
1/4
in
~:~==~
Non-conductive
1
Gun
Securing
Knob
2
Gun
Block
3
Gun
End
Loosen
gun
securing
knob.
Insert
end
into
block.
Position
as
close
as
possible
to
drive
rolls
without
touching.
Tighten
knob.
4
Gun
Trigger
Plug
5
Gun
Trigger
Receptacle
Insert
plug
into
receptacle,
and
tighten
threaded
collar.
6
Drive
Assembly
Cover
Close
cover.
Repeat
procedure
on
opposite
side
of
wire
feeder.
ST-162
1.83/
Ref.
ST-167
703
Figure
3-5.
Gun
And
Trigger
Lead
Connections
๎‚•
Do
not
touch
live
electrical
parts.
ELECTRIC
SHOCK
can
kill.
๎‚•
TumOftwirefeederandweldingpowersource,and
disconnect
input
power
before
inspecting
or
installing.
on
circuit
boards.
STATIC
ELECTRICITY
can
damage
parts
๎‚•
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
wfwaml
.1
๎‚•
2/93
To
change
wire
feed
starting
speed
proceed
as
follows:
Turn
Oft
wire
feeder
and
welding
power
source.
Remove
wrapper.
1
Motor
Board
PCi
2
Motor
Start
Control
Poten
tiometer
R70
Turn
potentiorneterclockwiseto
in
crease
time
it
takes
the
motor
to
ramp
up
to
speed.
Remove
protec
tive
white
rubber
cap
before
mak
ing
adjustment.
Adjust
potentiome
ter
R70
using
a
small
nonconduc
tive
screwdriver.
Figure
3-6.
Motor
Start
Control
On
Motor
Control
Board
PCi
Reinstall
wrapper.
ST-162
132/Ref.
SB-14$8~-D
OM-i
587
Page
5
3-6.
Control
Connections
*The
remaining
pins
are
not
used.
OM-1
587
Page
6
17-Socket
Receptacle
(See
Table
3-1)
2
Keyway
To
connect
interconnecting
cord
to
receptacle,
align
keyway,
insert
plug,
and
tighten
threaded
collar.
3
Weld
Current
Sensor
Recep
tacle
(For
Use
With
Field
Op
tion
Only)
4
35
ft
(10.6
m)
Voltage
Sens
ing
Lead
Connect
to
woiipiece
to
read
arc
voltage
at
the
arc
when
welding
power
source
has
a
17-pin
connec
tion
(see
Figure
3-2).
5
Threaded
Collar
6
14-Pin
Plug
(See
Table
3-2)
To
connect
plug
to
matching
recep
tacle
on
welding
power
source,
align
keyway,
insert
plug,
and
tight
en
threaded
collar.
6
Figure
3-7.
Control
Connections
With
Pin
Information
S-162
132/Ref.
S-0512
I
S-0003-A
/
S-0628
Table
3-1.
Remote
17
Socket
Information
.
.
.
REMOTE
17
Socket*
Socket
Information
B
,
~
C
G
CC/CV
select;
+13
to
+24
volts
dc
is
CV,
0
volts
dc
is
CC.
Arc
controllinductance
control;
0
to
+10
volts
dc.
E
Actual
weld
current
output
signal;
+1
voltdc
is
100
amps.
M
Actual
weld
voltage
output
signal;
+1
voltdc
is
10
volts
dc.
F
H
Current
feedback
from
welding
power
source;
0
to
+10
volts
dc,
1
volt
per
100
amperes.
Voltage
feedback
from
welding
power
source;
0
to
+10
volts
dc,
1
volt
per
10
arc
volts.
*The
remaining
sockets
are
not
used.
Table
3-2.
Remote
14
Pin
Information
REMOTE
14
Pin*
Pin
Information
A
24
volts
ac.
(CONTACTOR)
B
G
Contact
closure
to
A
completes
24
volts
ac
contactor
control
circuit.
Circuit
common
for
24
volts
ac
circuits.
C
+10
volts
dc
input
to
remote
control.
Ai~I
AMPERAGE
MIV
VOLTAGE
D
E
Remote
control
circuit
common.
0
to
+10
volts
dc
output
command
signal
from
feeder
voltage
control.
3-7.
Shielding
Gas
And
Weld
Cable
Connections
a
WARNING
CYLINDERS
can
explode
if
damaged.
๎‚•
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
๎‚•
Never
touch
cylinder
with
welding
electrode.
๎‚•
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
A.
Shielding
Gas
Connections
To
Regulator/Flowmeter
E
๎‚•
LECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
๎‚•
Turn
Oft
wire
feederand
welding
powersource,
and
disconnect
input
power
before
inspecting
or
installing.
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
๎‚•
Shut
oft
shielding
gas
supply
when
not
in
use.
warn4.19/91
/wfwaml.1
2/93
Obtain
gas
cylinder
and
chain
to
running
gear,
wall,
or
other
station
ary
support
so
cylinder
cannot
fall
and
break
off
valve.
1
Cap
1-1/8,5/8
in
2
Cylinder
Valve
Remove
cap,
stand
to
side
of
valve,
and
open
valve
slightly.
Gas
flow
blows
dust
and
dirt
from
valve.
Close
valve.
3
Cylinder
4
Regulator/Flowmeter
Install
so
face
is
vertical.
5
Gas
Hose
Connection
Fifting
has
5/8-18
right-hand
threads.
Obtain
gas
hose
and
in
stall
between
cylinder
and
๎‚“Y๎‚’
adapter
(see
Figure
3-9).
6
Flow
Adjust
Check
wire
manufacturer๎‚’s
recom
mended
flow
rate.
Make
sure
flow
adjust
is
closed
when
opening
cylinder
to
avoid
damage
to
the
flowmeter.
7
CO2
Adapter
8
0-Ring
2
Install
adapterwith
0-ring
between
regulator/flowrneter
and
CO2
cylinder.
ssbar
5/94
-
ST-158
697-A
Figure
3-8.
Typical
RegulatorlFlowmeter
Installation
2
r
3
OR
Argon
Gas
4
3
CO2
Gas
Tools
Needed:
OM-1
587
Page
7
B.
Shielding
Gas
And
Weld
Cable
Connections
At
Feeder
1
๎‚“Y๎‚”
Adapter
Hose
(Supplied)
2
Shielding
Gas
Fitting
When
using
one
source
of
shield
ing
gas,
route
and
connect
๎‚“Y๎‚”
adapter
and
gas
hose
as
shown.
If
two
sources
of
shielding
gas
are
being
used,
obtain
two
gas
hoses
with
5/8-18
right-hand
threaded
fit
tings.
Route
a
hose
from
each
shielding
gas
source
under
spool
support
arm,
and
connect
to
appro
pnate
shielding
gas
fitting.
3
Weld
Cable
Terminal
4
Jumper
Weld
Cable
Install
one
end
of
jumper
weld
cable
to
each
weld
cable
terminal.
5
Weld
Cable
(Customer
Supplied)
Select
and
prepare
weld
cables
ac
cording
to
welding
power
source
Owner๎‚’s
Manual.
When
possible,
route
weld
cable
under
spool
support
arm,
and
con
nect
to
either
weld
cable
terminal.
If
there
is
not
enough
room
under
spool
support
arm,
route
cables
and/or
hoses
along
side
of
spool
support
arm.
9/16,5/8in
Figure
3-9.
Shielding
Gas
And
Weld
Cable
Connections
Ref.
ST-152
567-A
.
I
4
5
Connect
To
Regulator/
Flowmeter
Connect
To
Positive
(+)
Weld
Output
Terminal
On
Welding
Power
Source
For
Direct
Current
Electrode
Positive
(DCEP),
Or
Con
nect
To
Negative
(๎‚—)
Weld
Output
Terminal
On
Weld
ing
Power
Source
For
Di
rect
Current
Electrode
Neg
ative
(DCEN)
Tools
Needed:
OM-1
587
Page
8
3-8.
Welding
Wire
Installation
A.
Positioning
Spool
Support
Arm
Figure
3-10.
Positioning
The
Spool
Support
Arm
Wire
feeder
is
shipped
from
factory
with
spool
support
arm
installed
to
handle
a
wire
spool/reel
up
to
12
inches
in
diameter.
If
a
larger
spool/reel
is
to
be
used,
reposition
spool
support
arm
as
instructed.
1
Base
2
SpoolSupportArm
3
Self-Tapping
Securing
Screws
Install
spool
support
arm
in
the
po
sition
that
allows
the
spool/reel
to
turn
without
touching
the
wire
feed
er
or
gas
cylinder,
while
allowing
the
welding
wire
to
run
the
straight
est
line
from
the
wire
spooVreel,
through
the
drive
rolls.
Tools
Needed:
~
3/8
in
ST-152
565
B.
Installation
Of
Spool-Type
Wire
8
3
2
1
Hex
Nut
Remove
hex
nut.
2
Hub
Support
Shaft
3
Holes
For
Positioning
Hub
Support
Shaft
Install
shaft
into
hole
that
allows
welding
wire
to
run
the
straightest
line
from
wire
spool,
through
the
drive
rolls.
Reinstall
hex
nut.
4
Spacer
5
Hub
Pin
6
Hub
7
Spool
8
Retaining
Ring
Remove
retaining
ring,
and
slide
wire
spool
onto
hub
(wire
may
feed
from
top
or
bottom
of
spool,
see
Figure
3-14
and
Figure
3-1
6).Tum
spool
until
hub
pin
fits
hole
in
spool.
Reinstall
retaining
ring.
9
Hub
Bracket
Repeat
procedure
using
hub
bracket
to
install
spool-type
wire
Tools
Needed:
onto
right
side
of
wire
feeder.
r
15/l6in
ST-152
564-A
1
Figure
3-11.
Installation
Of
Spool-Type
Wire
OM-1
587
Page
9
C.
Installation
Of
Optional
Wire
Reel
And
Reel
Type
Wire
D.
Adjusting
Hub
Tension
Figure
3-13.
Adjusting
Hub
Tension
.
11
12
9
1
Hub
Support
Shaft
2
Hex
Nut
7
Remove
hex
nut.
3
Holes
For
Positioning
Hub
Support
Shaft
6
Install
shaft
into
hole
that
allows
welding
wire
to
run
the
straightest
line
from
wire
spool,
through
the
drive
rolls
withouttouching
the
wire
feeder
or
gas
cylinder.
Reinstall
hex
nut.
5
43
4
Spacer
5
Hub
Pin
6
Hub
7
Wire
Reel
8
Wire
13
9
Wire
Retainer
10
Spanner
Nut
11
Lock
12
Retaining
Ring
Remove
retaining
ring.
Pull
lock
and
turn.
Remove
spanner
nut,
wire
retainer,
and
wire
reel
from
hub.
~i~I
Lay
wire
reel
assembly
on
flat
sur
face,
and
install
wire
as
shown
(wire
may
be
installed
to
feed
from
top
or
bottom
of
reel).
Tools
Needed:
Tighten
spanner
nut
until
lock
is
in
position
over
hole
in
wire
retainer.
Pull
lock
and
turn
to
insert
locking
pin
into
wire
retainer.
15/16
in
Wire
Installation
Slide
wire
reel
assembly
onto
hub,
and
turn
assembly
until
hub
pin
is
seated
in
hole
in
reel.
Reinstall
re
taining
ring.
13
Hub
Bracket
Figure
3-12.
Installation
Of
Optional
Wire
Reel
And
Reel
Type
Wire
Repeat
procedure
using
hub
bracket
to
install
reel-type
wire
onto
right
side
of
wire
feeder.
ST-i
52
563-B
/
ST-i
52
463/
Ref.
ST-157
999-A
Toots
Needed:
~iiiiii~i~ir
15/16
in
Turn
Off
wire
feeder
and
welding
power
source.
1
Hex
Nut
2
Spool
Grasp
spool
in
one
hand
and
turn
while
using
a
wrench
to
adjust
hex
nut.
When
a
slight
force
is
needed
to
turn
spool,
tension
is
set.
Repeat
procedure
to
adjust
hub
tension
on
right
side
of
wire
feeder.
ST-i
52
562-A
OM-1587
Page
10
3-9.
Threading
Welding
Wire
With
Drive
Assembly
Horizontal
a
WARNING
CYLINDERS
can
explode
if
damaged.
๎‚•
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
๎‚•
Never
touch
cylinder
with
welding
electrode.
๎‚•
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
ELECTRIC
SHOCK
can
kill.
๎‚•
Do
not
touch
live
electrical
parts.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
welding
or
feeding
wire
using
gun
trigger.
WELDING
WIRE
can
cause
puncture
wounds.
๎‚•
Do
not
press
gun
trigger
until
instructed
to
do
so.
๎‚•
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
HOT
SURFACES
can
burn
skin.
๎‚•
Allow
gun
to
cool
before
touching.
if
wfwam2.1
/wfwam7.1๎‚’
9/91
OM-1
587
Page
11
1
Wire
SpooVReel
2
Wire
Guide
3
Pressure
Adjustment
Knob
4
Drive
Rolls
5
Spring
Shaft
Carrier
Close
spnng
shaft
carrier.
6
Drive
Roll
Pressure
Indicator
Scale
7
JO9
Button
8
Gun
Conduit
Cable
Lay
gun
conduit
cable
out
straight.
9
Drive
Assembly
Cover
Repeat
procedure
for
opposite
side
of
wire
feeder.
If
desired,
either
side
drive
assembly
may
be
rotated
(see
Figure
3-15).
OFF
Wire
Feeder
(see
Figure
5-10)
I~1
See
Figure
5-13
for
switch
positions
of
450
ampere
inverter
model
welding
power
source
or
see
welding
power
source
Owner๎‚’s
Manual
for
other
models.
Welding
Power
Source
Push
wire
thru
guides
up
to
drive
rolls;
continue
to
hold
welding
wire.
Press
Select
button
(see
Figure
5-6)
to
choose
active
side
of
wire
feeder.
Press
Jog
button
(see
Figure
5-8)
until
drive
rolls
grab
wire.
Adjust
tension
until
wire
does
not
slip.
Indicator
is
for
reference
only.
Press
Jog
button
until
wire
comes
out
gun.
-*
Feed
wire
to
check
drive
roll
pressure.
Adjust
knob
enough
to
prevent
slipping.
Pat.
ST-i
53
091
/
Ref.
ST-i
50
922
/
Ref.
ST-i
61
713
/
S-0627-A
Figure
3-14.
Threading
Welding
Wire With
Drive
Assembly
Horizontal
Tools
Needed:
Set
switches.
Hold
wire
tightly
to
keep
it
from
unraveling.
~6in~
(150
mm)
Pull
and
hold
wire;
cut
off
end.
-~
JOG
o๎‚’~o
0
-,o
Cutoff
wire.
Close
cover.
OM-1
587
Page
12
3-10.
Threading
Welding
Wire
And
Rotating
The
Drive
Assembly
a
WARNING
CYLINDERS
can
explode
if
damaged.
๎‚•
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
๎‚•
Never
touch
cylinder
with
welding
electrode.
๎‚•
Always
secure
cylinder
to
running
gear,
wall,
other
stationary
support.
ELECTRIC
SHOCK
can
kill.
๎‚•
Do
not
touch
live
electrical
parts.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
welding
or
feeding
wire
using
gun
trigger.
WELDING
WIRE
can
cause
puncture
wounds.
๎‚•
Do
not
press
gun
trigger
until
instructed
to
do
so.
๎‚•
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
HOT
SURFACES
can
burn
skin.
๎‚•
Allow
gun
to
cool
before
touching.
wfwam2.1
Iwfwam7.1*
9191
A.
Rotating
Drive
Assembly
Figure
3-15.
Rotating
The
Drive
Assembly
4
Feeder
is
shipped
with
drive
as
sembly
in
a
horizontal
position.
To
rotate
drive
assembly,
proceed
as
follows:
Remove
screws
(6)
from
front
edge
of
wrapper,
and
loosen
screws
on
back
edge
of
wrapper.
1
Front
Panel
Remove
screw
from
upper
left
car
nerof
nameplate,
and
open
hinged
front
panel.
2
Drive
Assembly
Rotation
Ad
justment
Openings
3
Drive
Assembly
4
Wire
SpoollReel
Insert
3/16
in
allen
wrench
into
opening,
and
loosen
socket
head
cap
screw.
Turn
drive
assembly
to
a
position
that
allows
welding
wire
to
run
the
straightest
line
from
spooVreel,
through
the
drive
rolls
(wire
may
feed
from
top
or
bottom
of
spool/reel,
see
Section
3-8.).
Tighten
bolt.
Close
and
secure
front
panel,
and
go
to
Figure
3-16.
Tools
Needed:
Ref.
ST-i
53
093/
STBOO
289
3
3/16
in
OM-1
587
Page
13
B.
Threading
Welding
Wire
With
Drive
Assembly
Rotated
1
Wire
Spool/Reel
2
Wire
Guide
3
Pressure
Adjustment
Knob
4
Spring
Shaft
Carrier
Close
spring
shaft
carrier.
5
Drive
Roll
Pressure
Indicator
Scale
6
Jog
Button
7
Gun
Conduit
Cable
8
Drive
Rolls
9
Drive
Assembly
10
Drive
Assembly
Cover
If
position
of
drive
assembly
needs
further
adjusting,
go
back
to
Figure
3-15.
Press
Jog
button
until
wire
comes
out
gun.
-*
Feed
wire
to
check
drive
roll
pressure.
Adjust
knob
enough
to
prevent
slipping.
Ref.
ST-153
093/
Ref.
ST-i
50
9~
I
Ref.
ST-iOi
713
/
S-0627-A
Figure
3-16.
Threading
Welding
Wire
With
Drive
Assembly
Rotated
.
Hold
wire
tightly
to
keep
it
from
unravel
ing.
Tools
Needed:
ci
6
in
(150
mm)
See
Figure
5-13
for
ON
switch
positions
of
450
ampere
inverter
model
~
welding
power
source
or
....+
see
welding
power
source
Owner๎‚’s
Manual
OFF
for
other
models.
Wire
Feeder
(see
Figure
5-10)
Welding
Power
Source
Set
switches.
Pull
and
hold
wire;
cut
off
end.
JOG
SELECT
O~,O
~oo~
Press
Select
button
(see
Figure
5-6)
to
choose
active
side
of
wire
feeder.
Press
Jog
button
(see
Figure
5-8)
until
drive
rolls
grab
wire.
Push
wire
thru
guides
up
to
dnve
rolls;
continue
to
hold
welding
wire.
Adjust
tension
until
wire
does
not
slip.
Indicator
is
for
reference
only.
Cut
off
wire.
Close
cover.
OM-1
587
Page
14
/