Miller KF914926 Owner's manual

Miller
Brand
Miller
Model
KF914926
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
October
1995
Form:
OM-1583J
Effective
With
Serial
No.
KF91
4926
OWNERS
Read
and
follow
these
instructions
safety
blocks
carefully.
Have
only
trained
and
qualified
inetall,
operate,
or
service
this
unit.
and
all
persons
~j,A
Give
this
manual
to
the
operator.
For
help,
call
your
distributor
Call
your
distributor
if
you
do
not
understand
I~I
U
or:
MILLER
Electric
Mtg.
Co.,
P.O.
Box
1079,
the
directions.
Appleton,
WI
54912
414-734-9821
MANUAL
c~..
~
~~~)
~
J
~
SWINGARCTM
SS-12
And
SS-16
24
Volts,
10
Amperes,
50/60
Hertz
Boom
Mounted
Wire
Feeder
For
Use
With
CV/DC
Welding
Power
Source
With
Contactor
For
GMAW
And
FCAW
Welding
Rated
At
100
Volts,
750
Amperes,
100%
Duty
Cycle
Wire
Feed
Speed
Range:
50
To
780
1pm
(1.3
To
19.8
mpm)
Wire
Diameter
Range:
.023
To
1/8
in
(0.6
To
3.2
mm)
Vertical
Lift
Of
Boom:
Horizontal
To
60
Above
Horizontal
For
Options
And
Accessories,
See
Rear
Cover
cover
5194
ST-142 705-B
'
1995
MILLER
Electric
Mtg.
Co.
PRINTED
IN
USA
(a
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,1995
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
werranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
1,
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
below,
MILLER
Electric
Mfg.
Co.,
Appleton.
Wisconsin.
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
after
the
effective
date
of
this
limited
warranty
is
tree
of
de
fects
in
material
and
workmanship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
tN
LIEU
OF
ALL
OTHER
WARRANTIES.
EXPRESS
OR
IMPLIED.
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FtT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
fait
due
to
such
defects
in
material
or
workmanship.
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
of
such
defect
or
Iailure,
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
avant
of
such
a
lailure
within
the
warranty
time
periods.
All
warranty
lime
periods
stan
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
after
the
equipment
is
sent
10
an
tnlamalional
distributor.
5
Years
Parts
3
Years
Labor
Original
main
power
rectifiers
tnvarters
(input
and
output
rectifiers
only)
2.
3 Years
Pans
and
Labor
Transformer/Rectifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
-
Semi-Automatic
and
Automatic
Wire
Feeders
-
Invanar
Power
Supplies
tnlallitigs
Robots
3.
2
Years
Pans
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
Air
Compressors
4.
1
Yaar
Pans
and
Labor
Motor
Driven
Guns
Process
Controllers
IHPS
Power
Sources
Wafer
Coolant
Systems
HF
Units
-
Grids
Spot
Welders
Load
Banks
SDX
Transformers
Running
Gear/Trailers
-
Plasma
Cutting
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
*
Tecomxeh
Enginas
Dautz
Engines
(outside
North
Amarica)
-
Field
Options
(NOTE:
Field
options
are
covered
under
True
Blua~~
br
the
remaining
warranty
period
of
the
product
Ihey
are
installad
in,
or
for
a
minimum
of
one
year
whichever
ix
greater.)
5.
6
Months
Batteries
6.
90
Days
Pans
and
Labor
MIG
Guns/FIG
Torches
APT,
ZIPCUT
&
PLAZCUT
Modal
Plasma
Cutting
Torches
Remote
Cont
rots
*
Accessory
Kits
Raplacamanf
Pans
MILLERS
True
BIuaTM
Limited
Warranty
shalt
not
apply
to:
1.
Items
furnished
by
MILLER,
but
manufactured
by
others,
such
as
engines
or
trade
accaasoriax.
Thaxa
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzlas,
contaclors
and
relays
or
pans
Ihal
tail
due
to
normal
wear.
3.
Equipmanl
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
thaI
has
been
improperly
installed,
improperly
oparstad
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
bean
used
br
operation
outside
of
tha
specifications
for
tha
aquipmant.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENL
In
tha
avant
of
a
warranty
claim
covered
by
this
warranty,
bra
exclusive
remedies
shall
be,
at
MILLERS
option:
(1)
rapair;
or
(2)
raplacament;
or.
where
authorized
in
writing
by
MILLER
in
appropriate
caxas,
(3)
the
reasonable
coal
of
repair
or
replace
ment
alan
authorizad
MILLER
sarvica
stafion;
or
(4)
payment
of
or
cradit
for
the
pur
chase
price
(lass
reasonable
dapracialion
baxad
upon
actual
usa)
upon
ralum
of
the
goods
xl
cuxtomars
risk
and
expanse.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
daterminad
by
MILLER.
Theralora
no
compensation
or
reimburse
ment
br
Iranaponaf
ion
costs
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW,
THE REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
LIABLE
FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
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
IMPUCATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
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
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
impliad
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consaquantixl
damages,
so
the
above
limitation
or
exclusion
may
not
apply
lo
you.
This
warranty
provides
spe
cific
legal
rights,
and
olhar
rights
may
ba
availabla,
but
may
vary
Irom
state
to
state.
In
Canada,
legislation
in
xoma
provinces
provides
for
certain
addilional
warranties
or
ramadiax
orhar
than
ax
xtalad
herein,
and
to
the
extant
that
they
may
not
be
waived,
the
limitations
and
exclusions
sat
out
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
availabfa,
but
may
from
provinca
to
province.
.}
WI,
i-u
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
with the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturer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
Seria)
or
Style
Number
of
your
unit,
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
miller
6/95
ERRATA
SHEET
January
17,
1996
FORM:
OM-1583J
Use
above
FORM
number
when
ordering
extra
manuals.
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
CHAN
GES
TO
SECTION
7-
PARTS
LIST
Change
Parts
List
as
follows:
**
Dia.
Part
Mkgs.
No.
Replaced
With
Description
Quantity
34-28
...
LED71
174
755
...
179
203
..
LED,
5100
2.OV
2OmA
green
(Eff
w/KG044454)
1
39-28
149
746
...
179
265
..
ADAPTER,
gun/feeder
LH
(Eff
w/KG044454)
1
39-33
149
527
...
179
263
..
COVER,
drive
roll
(Effw/KG044454)
1
39-37
149
964
...
Deleted
..
Eff
w/KG044454
**First
digit
represents
page
no
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
1.
;
~
ARC
WELDING
SAFETY
PRECAUTIONS
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
burns.
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
touchin9
the
weldin9
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
Do
not
touch
live
electrical
parts.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
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
power
according
to
OSHA
29
CFR
1910.147
(see
Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owner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
around
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
power
cord
for
damage
or
bare
wiring
replace
cord
Immediately
If
damaged
bare
wiring
can
kill.
9.
Turn
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.
15.
Wear
a
safety
harness
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
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.
Inwelding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
9iven
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.
2.
3.
17.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
wnrkt~hI~
as
near
the
weld
~
nr~gtlnnl
ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
t4~
.~
NOISE
can
damaae
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
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
grinding,
and
welds
cooling
throw
off
pieces
of
metal
or
slag.
2.
3.
4.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protectyourface
and
eyes
when
welding
orwatchlng
(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.
NOISE
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
1.
Use
appr
oved
ear
plugs
or
earmuffs
If
noise
level
is
high.
material
(wool
and
leather)
and
foot
protection.
FUMES
AND
GASES
can
be
hazardous
to
your
health.
fumes and
gases
can
be
hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
£~
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes and
gases.
5.
6.
7~
Work
In
a
confined
space
only
if
It
Is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Always
have
a
trained
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
breathing
air
is
safe.
Do
not
weld
in
locations
near
degreaslng,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
Irritating
gases.
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
(MSDS5)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturer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
aas
cylinders
contain
gas
under
high
pressure.
Irdamaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully,
5.
6.
7.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
Never
weld
on a
pressurized
cylinder
explosion
will
result.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
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.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
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.I
204
CONSIGNES
DE
SECURITE
POUR
LE
SOUDAGE
A
LARC
UN
CHOC
ELECTRIQuE
peut
tuer.
Un
simple
contact
avec
des
piŁces
Olectnques
peut
provoquer
une
electrocution
ou
des
blessures
graves.
LOlectrode
et
Ia
circuit
de
soudage
sont
sous
tension
des
que
lappareil
est
surON.
Le
circuit
dentrŁe
at
les
circuits
intemes
de
lappareil
sont
egalement
sous
tension
a
ce
moment-l.
En
soudage
semi-automatique
ou
automatique,
le
Id,
le
dØvidoir,
le
logement
des
galets
dentrafnement
at
las
piŁces
mOtalliques
en
contact
avec
Ia
Iii
de
soudage
sont
sous
tension.
Des
matØflels
mal
installŁs
ou
mal
mis
a
Ia
terre
prØsentent
un
danger.
1.
Ne
jamais
toucher
les
piŁces
Ølectriques
sous
tension.
2.
Porter
des
gants
at
des
vOtements
de
protection
secs
ne
comportant
pas
de
trous.
3.
Sisoler
de
Ia
piŁce
at
de
Ia
terre
au
moyen
de
tapis
ou
dautres
moyens
isolants
suffisamment
grands
pour
empŁcher
le
contact
physique
Øventuel
avec
Ia
piŁce
ou
Ia
terre.
4.
Coupar
lalimentation
ou
arrOter
le
moteur
avant
de
procØder
a
linstallation,
a
Ia
reparation
ou
a
Ientratien
de
lapparail.
DOverrouillerlalimentation
selon
Ia
norme
OSHA
29
CFA
1910.147
(voir
normes
de
sOcurite).
5.
Installer
et
maitre
a
Ia
terre
correctement
cel
appareil
conformØment
a
son
manuel
dutilisation
at
au
codes
nalionaux,
provinciaux
et
municipaux.
6.
Toujours
verifier
Ia
terre
du
cordon
dalimentation
Verifier
et
sassurer
qua
Ia
it)
de
terra
du
cordon
dalimentalion
esl
bien
raccordØ
ala
borne
de
terre
du
sectionneur
ou
qua
Ia
fiche
du
cordon
est
raccordØe
a
une
pnse
correctement
mise
~
Ia
terre.
7.
En
oft
ectuanl
las
raccordements
dentrØe
fixer
dabord
Ia
conducteur
de
mise
a
Ia
terre
appropne
at
contre-vØnfier
les
connexions.
8.
Verifier
frØquemment
le
cordon
dalirnentation
pour
voir
sil
nest
pas
endommagØ
ou
dØnudØ
remplacer
Ia
cordon
immØdiatement
sil
est
endommage
un
cable
dØnudØ
paul
provoquer
une
electrocution.
9.
Maitre
lappareil
hors
tension
quand
on ne
lutilise
pas.
10.
Ne
pas
Utiliser
des
cables
uses.
endommages,
de
grosseur
insuttisante
ou
mal
episses.
11.
Ne
pas
enrouler
las
cables
autour
du
corps.
12.
Si
Ia
piŁce
soudØe
dolt
Łtre
mise
ala
terre,
le
faire
directement
avec
tin
cable
distipct
ne
pas
utiliser
Ia
connecteur
de
piŁce
ou
le
cable
de
retour.
13.
Ne
pas
toucher
electrode
quand
on
asIan
contact
avec
Ia
piŁce,
Ia
terre
ou
une
electrode
provenant
dune
autre
machine.
14.
Nutiliser
quun
matØnel
en
bon
Øtat.
ROparer
ou
remplacer
sur-le-champ
les
piŁces
endommagees.
Entretenir
lappareil
contormØment
a
ce
manuel.
15.
Porter
un
hamais
de
sOcufltO
quand
on
travaille
en
hauteur.
16.
Maintenir
solidement
en
place
tous
las
panneaux
at
capots.
17.
Fixer
le
cable
de
retour
de
tacon
~
obtenir
un
bon
contact
mØtal-mŁtal
avec
Ia
piŁce
a
souderou
Ia
table
de
travail,
le
plus
prŁs
possible
de
Ia
soudure.
a
MISE
EN
GARDE
LE
SOUDAGE
A
LARC
peut
Œtre
dangereux.
SE
PROTEGER
El
PROTEGER
LES
AUTRES
COPITRE
LES
BLESSURES
GRAVES
VOIRE
MORTELLES.
TENIR
LES
ENFANTS
A
LECART.
L.ES
PERSONNES
QUI
PQRTENT
UN
STIMULATEUR
CARDIAQUE
NE
DOIVENT
PAS
NON
PLUS
SAPPROCHER
DU
POSTE
DE
SOUDAGE,
A
MOINS
DAVOIR
CONSULTE
UN
MEDECIN.
La
soudage,
comma
Ia
plupail
des
travaux,
prØsente
certains
dangers.
Par
contre.
Ia
soudage
peut
Otre
effectuØ
en
toute
sOcuntØ
quand
on
prend
les
mesures
qui
simposent.
Les
consignes
de
sŁcuritØ
donnØes
ci-aprŁs
ne
font
que
rØsumer
linformation
contenue
dans
las
normes
de
sØcuntO
OnumØres
a
Ia
page
suivante.
Lire
et
respecter
toutes
ces
normes
de
sØcufltØ.
DN
LLJTILISATiON,
LENTRETIEN
El
LES
R~PARATIONS
NE
DOl
VENT
ETRE
CONFIES
ouA
DES
PERSONNES
OUALIFIEES
LE
RAVONNEMENT
DE
LARC
peut
brOler
les
RAVONNEMENT
DE
LARC
yeux
et
Pa
peau.
Le
BRUIT
peut
endommager
~
IouIe;
les
PROJECTIONS
DE
LAITIER
OU
LES
ETINCELLES
peuvent
blesser
les
yeux.
2.
Porter
un
masque
a
serra-tOle
muni
dun
verre
filtrant
de
nuance
appropflØa
pour
protOger
le
visage
et
las
yeux
quand
on
souda
ou
Lam
de
soudage
produit
des
rayons
visibles
at
invisibles
observe
(a
travail
de
soudaga
(voir
les
normes
ANSI
Z49.
1
at
Z87.
1
intenses
(ultraviolets
at
intrarouges)
qui
peuvent
brOler
donnØes
sous
Ia
rubnque
Principalos
normes
de
sØcufllØ).
les
yeux
at
Ia
peau.
La
bruit
produit
par
certains
procŁdOs
pout
endommager
louie.
Des
projections
de
metal
ou
de
3.
Porter
des
lunettes
de
sØcuritØ
approuvØes
avec
Øcrans
IatØraux.
laitier
sont
produites
par
le
piquage
Ia
meulage
ou
Ia
refroidissement
des
soudures.
4.
Utiliser
des
paravents
ou
des
barnŁres
de
protection
pour
prolØger
les
parsonnes
a
proximitØ
contre
les
coups
darc
et
lblouissemenl;
BRUiT
avertar
les
autres
personnes
de
ne
pas
regarder
lam.
1.
Utiliser
des
bouche-oreillas
ou
des
serre-tOte
antibruit
approuvØs
si
5.
Porter
des
vØtaments
de
protection
en
tissu
ignifuge
durable
(lame
et
le
niveau
de
bruit
as)
ØlevØ.
cuir)
at
des
chaussures
de
sØcuntØ.
dangereuses
pour
Ia
sante.
portant
un
apparail
respiratoire
a
adduction
dair
pur.
Demander
a
un
observateur
ayant
recu
Ia
bonne
formation
do
toujours
se
tenir
a
~
~I
LES
VAPEURS
El
LES
FUMEES
peuvent
Œtre
5.
Ne
travailler
dans
un
aspace
confine
qua
siI
as)
bien
ventilØ,
ou
en
Le
soudage
produit
des
vapeurs
el
des
fumØes
quil
est
proximitØ.
Las
vapeurs
at
fumØos
de
soudage
peuvent
dØplacer
lair
dangereux
de
respirar.
at
abaisser
le
niveau
doxygŁne
at
causer
des
blessuras
graves
voire
mortelles.
Sassurer
qua
lair
est
propre
Ł
Ia
respiration.
1.
Garder
Ia
tŒte
a
lextØneur
des
vapeurs
et
des
fumØes
at
ne
pas
las
6.
Ne
pas
souder
a
proximitØ
dopŁrations
do
dOgraissage.
de
respirer.
nettoyage
ou
de
pulvØrisation.
La
chaleur
et
les
rayons
do
larc
peuvent
rØagir
avec
les
vapeurs
pour
former
des
gaz
hautement
2.
A
IintOnaur
ventiler
le
poste
de
travail
ou
utilisar
tin
dispositit
place
toxiques
at
irritants.
au
niveati
do
(arc
pour
Ovacuer
las
vapeurs
et
fumØes
de
soudage.
7.
Ne
pas
souder
sur
des
mOtaux
revØtus
comme
lacier
galvanisO,
au
3.
Si
Ia
ventilation
est
mauvaise
utiliser
un
appareil
respiratoire
a
plombou
cadmiØ
a
moms
qua
(a
piŁce
nail
ØtØ
entiŁrement
dØcapØe,
adduction
dair
pur
approuve.
qua
Ia
paste
do
travail
soil
bien
ventilØ.
Sil
y
a
lieu,
porter
un
appareil
4.
Consulter
los
fiches
signalØtiques
of
les
consignes
du
fabncant
respiratoire
a
adduction
dair
pur.
Los
revOlements
et
los
mØtaux
qui
relatives
au
mØtaux,
produits
dapport.
revOtoments.
nettoyants
at
contiennentde
telsØlØments
peuventdØgagerdes
vapeurs
toxiques
dOgraissants.
lors
du
soudage.
LES
BOUTEILLES
peuvent
exploser
si
elles
4.
Ne
jamais
poser
un
chalumeau
soudeur
sur
une
bouteille
do
gaz.
Les
bouteilles
contenant
des
gaz
de
protection
sont
a
6.
Ne
jamais
souder
stir
tine
bouteille
sous
pression
:
elle
expioseralt.
sont
endommagØes.
5.
Ne
jamais
laisser
tine
electrode
do
soudage
toucher
une
bouteille.
~.
haute
pression.
Une
bouteitle
endommageo
pout
7.
Nutiliser
quo
des
bouteilles
do
gaz
do
protection,
des
dØtendeurs,
exploser.
Etant
donnØ
qua
les
bouteilles
de
gaz
font
dos
tuyaux
souples
et
des
raccords
appropriØs
conus
pour
normalement
partie
du
materiel
do
soudage,
les
trailer
Iapplication
particuliŁra;
conserver
ces
materials
et
leurs
piŁces
en
avec
le
plus
grand
soin.
bon
Otat.
1.
ProtOger
las
bouteilles
do
gaz
compnme
contre
Ia
chaleur
intense,
8.
Eloignor
le
visage
de
Ia
Sortie
du
robinet
de
Ia
bouteille
quand
on
los
chocs,
le
laitier,
les
flammes
nues
las
Øtincelles
et
larc.
louvre.
2
Placer
las
bouteillos
a
Ia
verticale
en
los
fixant
a
tin
support
fixo
ou
a
9.
Replacer
le
chapeau
stir
Ia
bouteille
apres
utilisation.
tin
chariot
pour
Øviter
quelles
ne
tombont
ou
na
basculent.
10.
Lire
et
suivre
las
consignes
relatives
aux
bouteilles
do
gaz
compnmO,
3.
Tenir
los
bouteities
a
IØcart
du
paste
do
soudage
oti
dautres
circuits
au
matØrial
connexe
ainsi
quo
Ia
publication
P-i
de
Ia
CGA
donnØe
electnques.
sous
Ia
rtibnqtie
Principales
normes
de
sOcuritØ.
srl.1.1
2/94
LE
SOUDAGE
peut
causer
un
incendle
ou
une
explosion.
Ne
pas
souder
sur
des
recipients
fermØs
comme
des
reservoirs,
des
fOts
ou
des
tuyaux
its
peuvent
oxplosor.
Lam
do
soudage
pout
produire
des
Øtincelles.
Des
Øtincelles.
une
piŁce
chaude
et
un
materiel
chaud
peuvent
provoquer
des
incendios
et
des
blessures.
Le
contact
accidentel
de
lØlectrode
sur
des
objets
mOtalliques
pout
produire
des
Øtincelles
lexplosion,
Ia
surchaufto
ou
un
incendie.
Sassurer
quo
le
lieu
ne
prØsente
pas
de
danger
avant
deffectuer
le
soudage.
1.
Se
proteger
et
protØger
los
personnes
a
proximitO
desØtincellesetdu
metal
chaud.
2.
Ne
pas
souder
dans
un
endroit
o
les
Øtincelles
peuvent
atteindre
des
matØnaux
initammables.
3.
Enlevertoutes
les
matiŁres
inflammables
dans
un
rayon
de
moms
de
10
m
do
lam.
Si
cola
nest
pas
possible.
bien
les
recouvnren
uhlisant
des
bAches
approuvŁes.
4.
Prendre
garde
quo
los
Otincelles
et
los
projections
no
penetrent
dans
des
zones
adjacenles
en
sinfiltrant
dans
dos
petites
fissures
et
ouvertures.
5.
Prendre
garde
aux
incondies
ot
toujours
avoir
un
oxtincteur
a
proximitO.
6.
Se
rappeler
quo
si
lon
soude
sur
un
plafond.
un
plancher,
une
cloison
ou
autre,
le
teu
pout
prondre
do
lautre
cØtØ.
7.
Ne
pas
soudor
sur
des
recipients
termØs
camme
des
reservoirs,
des
lOts
ou
des
tuyaux
a
moms
quils
no
soient
prØparØs
do
taon
approprlee
conforrnØmont
ala
norme
F4.1
de
IAWS
(voir
Ia
rubflquo
Pnncipales
normes
do
sØcuritO).
8.
Raccorder
le
cable
do
rotour
a
Ia
piŁce.
le
plus
prØs
possible
de
Ia
zone
do
soudage,
pour
empecher
quo
Ia
courant
do
soudago
no
suive
une
trajectoire
tongue
ot
Øventuellement
inconnue
et
quil
no
provoque
des
risques
dØlectrocution
et
dincendie.
9.
No
pas
utiliser
le
chalumeau
soudeur
pour
degeler
des
tuyaux.
10.
Enlever
lØtectrode
enrobØe
du
porte.Ølectrode
ou
couper
Ia
SI
do
soudage
au
ras
du
bec
contact
quand
on
ne
lutilise
pas.
11.
Porter
des
vOtements
do
protection
non
huileux
comme
des
gants
en
cuir,
une
chemise
epaisse,
des
pantalons
sans
revers,
des
chaussures
montantes
et
un
casque.
12.
Ne
pas
porter
des
matiŁres
combustibles
sur
soi
comme
un
bnquet
a
aaz
ou
des
allumettes
quand
on
soude.
ji
~
LE
CARBURANT
peut
provoquer
un
Incendie
r
~
ou
une
explosion.
La
carburant
est
hautement
inflammable.
1.
ArrØter
to
moteur
et
le
laisser
ref roidir
avant
de
verifier
le
niveau
do
carburant
ou
de
refaire
le
plein.
LES
PIECES
EN
MOUVEMENT
peuvent
causer
des
blessures.
Los
piŁces
en
mouvement
comme
las
ventilateurs,
los
rotors
at
los
courroies
peuvent
couper
los
doigts
et
los
mains
et
happer
los
vØtemants
amples.
1.
Sassurer
quo
los
portes,
los
panneaux,
los
capots
et
les
protecteurs
sont
bien
fermØs
et
bien
a
lour
place.
2.
ArrŁtor
10
moleur
avant
do
mettro
en
place
ou
do
raccorder
un
LES
ETINCELLES
peuvent
faire
EXPLOSER
LE
GAZ
DES
BATrERIES;
LELECTROLYTE
peut
brUler
Ia
peau
et
Ies
yeux.
Los
batteries
contiennent
un
produit
acide
et
dogagent
dos
vapeurs
explosives.
~ofler
un
Øcran
facial
quand
on
travaillo
sur
une
battefle.
LES
MOTEURS
peuvent
presenter
un
danger.
2.
Ne
pas
turner
en
faisant
le
plein
ou
SI
lappareil
so
trouvo
a
proximite
dØtmncelles
ou
de
flammes
flues.
3.
Ne
pas
remplir
Ia
reservoir
Ł
ras
bord
:
prØvoir
de
lespace
pour
Ia
dilatation
du
combustible.
4.
No
pas
renverser
du
carburant.
Si
on
ranverso
du
carburant,
nettoyer
los
lieux
avant
do
faire
dØmarrer
to
moteur.
3.
Seules
des
personnes
qualiliØes
doivent
dØrnontar
los
protectours
ou
los
capots
pour
faire
lentrotien
ou
les
reparations
nØcessaires.
4.
Pour
empØcher
un
dØmarrage
accidental
dun
systŁme
pendant
lentretien
ou
los
reparations,
dØbrancher
te
cable
negatif
()
de
Ia
battene.
5.
Eloigner
los
mains,
les
cheveux,
los
vOternonts
amplos
et
los
outils
des
piŁces
en
mouvement.
6.
Replacer
los
capots
ou
los
prolocteurs
ot
reformer
los
portes
une
fois
lentretien
01
los
reparations
terminØs
et
avant
do
faire
dØrnarrar
le
--
rnotour.
ArrŁter
le
moteur
avant
de
brancher
ou
do
dØbrancher
los
cables
do
Ia
battene.
No
pas
faire
des
Øtincelles
avac
les
outils
quand
on
travaille
sur
une
battene.
Ne
pas
uliliser
Ia
source
do
courant
do
soudage
pour
charger
los
batteries
ou
pour
fairo
dØmarrer
un
vØhicule.
No
pas
intervertir
Ia
polantØ
des
batteries.
a
MISE
EN
GARDE
LES
GAZ
DECHAPPEMENT
DES
MOTEURS
1.
Utiliser
le
materiel
Ł
lextØfleur,
dans
des
lieux
ouverts
et
bien
peuvent
Œtre
mortels.
ventilOs.
Los
moteurs
produisent
des
gaz
dec
happ
ement
nocits.
2.
Si
on
utilise
un
moteur
dans
un
local
fermØ,
Øvacuer
los
gaz
dØchappement
a
lextØneur
et
loin
des
pflses
dair
du
btiment.
1.
Touioursi
2.
3.
4.
5.
*
4~
~
~.
~
~
~
W.LUJ
LA
VAPEUR
El
LE
LIQUIDE
DE
REFROIDISSEMENT
BRULANT
SOUS
PRESSION
peuvent
brUler
Ia
peau
et
lee
yeux.
II
vaut
mieux
verifier
le
niveau
du
liquide
do
ref
roidissement
quand
le
motour
est
froid
atm
dØvitor
los
brUlures.
1.
2.
3.
Si
Ion
doit
verifier
to
niveau
quand
10
moteur
est
chaud,
suivre
les
Øtapes
2
at
3.
Porter
des
lunettes
do
sØcuritØ
et
des
gants
et
placer
un
chiffon
sur
10
bouchon.
Toumer
lenternont
le
bouchon
at
laisser
Ia
prossion
sechapper
lenternent
avant
denlOver
complØtement
le
bouchon.
PRINCIPALES
NORMES
DE
SECURITE
Safety
in
Welding
and
Cutting,
norme
ANSI
Z49.
1,
do
lAmerican
Welding
Safe
Handling
of
Compressed
Gases
in
Cylinders.
CGA
Pamphlet
P-ide
Society,
550
N.W.
Lejeuno
Ad,
Miami
FL
33126
Ia
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway.
Suite
501,
Arlington,
VA
22202.
Safety
and
Health
Sandards,
OSHA
29
CFR
1910,
du
Supanntendent
of
Regles
do
securitd
en
soudage,
coupage
et
procØdØs
connexes,
norme
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
CSA
Wi17.2,
do
tAssociation
canadionne
do
normalisation.
yenta
do
normes,
178 Rexdale
Boulevard,
Aexdate
(Ontario)
Canada
M9W
1
R3.
Recommended
Safe
Practice
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
norma
AWS
F4.1.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
do
IAmencan
Welding
Society,
550
N.W.
Lojeuno
Ad,
Miami
FL
33126
norme
ANSI
Z87.1,
do IAmencan
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
NationalElectncal
Code,
NFPA
Standard
70,
do
Ia
National
Fire
Protection
Cutting
and
Welding
Processes,
norme
NFPA
51
B,
do
Ia
National
Fire
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
srl.1.1
2194
EMF
INFORMATION
TABLE
OF
CONTENTS
SECTION
1
SAFETY
INFORMATION
SECTION
2
SPECIFICATIONS
SECTION
3
INSTALLATION
3-1.
Equipment
Connection
Diagrams
3-2.
Installing
Swivel
Into
Pipe
Post
3-3.
Installing
Boom
And
Reel
Support
3-4.
Installing
Wire
Guide
Extension
3-5.
Wire
Guide
And
Drive
Roll
Installation
3-6.
Welding
Gun
Connections
3-7.
Wire
Feed
Motor
And
Gas
Valve
Control
Connections
3-8~
14-Pin
Plug
Connection
3-9.
Shielding
Gas
And
Weld
Cable
Connections
3-10.
Voltage
Sensing
Lead
(Optional)
3-11.
Removing
Safety
Collar
And
Adjusting
Boom
3-12.
Welding
Wire
Installation
3-13.
Motor
Start
Control
3-14.
Dip
Switches
Options
3-15.
Changing
Optional
Digital
Voltage
Control
For
Use
With
A
MILLER
Inverter-Type
Power
Source
3-16.
Adjusting
Control
Tilt
Bracket
3-17.
Threading
Welding
Wire
SECTION
4-OPERATION
17
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
5-2.
Replacing
The
Hub
Assembly
5-3.
Overload
Protection
5-4.
TroubleshootIng
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
Backg
round
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
cellular
level
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.
modlO.1
4/93
2
2
3
3
4
4
5
6
6
7
8
8
8
10
11
14
15
15
23
23
24
24
25
SECTION
6-
ELECTRICAL
DIAGRAMS
27
OM-1583J
-
10/95
SECTION
7
PARTS
LIST
30
Figure
7-1.
Main
Assembly
30
Figure
7-2.
Control
Box
32
Figure
7-3.
Support,
Hub
&
Reel
35
Figure
7-4.
Boom
Assembly
36
Figure
7-5.
Drive
Assembly,
Wire
38
Figure
7-6.
Control
Panel
40
Table
7-1.
Drive
Roll
And
Wire
Guide
Kits
42
SECTION
1
-
SAFETY
INFORMATION
Read
all
safety
messages
throughout
this
manual.
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
Figure
1-1.
Safety
Information
SECTION
2-
SPECIFICATIONS
Table
2-1.
Wire
Feeder
modl.1
2/93
1
2
V~~AI
h~II~LC
2
\
3
ELECTRIC
SHOCK
can
kIII.~
Do
not
touch
live
electrical
parts.
Disconnect
input
power
before
b
~
Installing
or
servicing.
-r
a
CAUTION
/
5
MOVING
PARTS
can
Injure.
~
Keep
away
from
moving
parts.
I
S
Keep
all
panels
and
covers
closed
I
when
operating.
1
Safety
Alert
Symbol
2
Signal
Word
WARNING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
injury
or
equipment
damage
can
happen.
3
Statement
Of
Hazard
And
Result
6
a
WARNING
READ
SAFETY
BLOCKS
at
start
of
Section
3-1
before
proceeding.
NOTE
~
Turn
Off
switch
when
using
high
frequency.
4
Safety
Instructions
To
Avoid
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
Read
safety
blocks
for
each
sym
bol
shown.
7
NOTE
Special
instructions
for
best
oper
ation
not
related
to
safety.
Specification
Type
Of
In
put
Power
From
Welding
Power
Source
Maximum
Weld
Circuit
Rating
Welding
Power
Source
Type
Wire
Feed
Speed
Range
Description
Wire
Diameter
Range
Welding
Process
Input
Power
Cord
Single-Phase
24
Volts
AC,
10
Amperes,
50/60
Hertz.
(If
115
Volts
AC
is
The
Only
Power
Available,
Use
Optional
Power
Supply
Adapter
Model
PSA-2.)
100
Volts,
750
Amperes,
100%
Duty
Cycle
Constant
Voltage
(CV)
DC,
With
Contactor
50
To
780
ipm
(1.3
To
19.8
mpm);
Standard
Motor
14
To
213
ipm
(0.6
To
5.4
mpm);
Low
Speed
Motor
90
To
1400
1pm
(2.3
To
35.6
mpm);
High
Speed
Motor
.023
To
1/8
in
(0.6
To
3.2
mm)
Gas
Metal
Arc
(GMAW)
Or
Flux
Cored
Arc
Welding
(FCAW)
lOft(3.1
m)
Maximum
Height
With
4
ft
(1.2
m)
Post
Weight
12
ft
(3.7
m)
Boom
17ft(5.2m)
Vertical
Lift
Of
Boom
16
ft
(4.9
m)
Boom
21
ft
(6.4
m)
Net:
160
lb
(73
kg)
Ship:
280
lb
(127
kg)
Horizontal
To
60
Above
Horizontal
Net:
210
lb
(95
kg)
Ship:
350
lb
(159
kg)
Horizontal
To
60
Above
Horizontal
OM-1583
Page
1
SECTION
3-INSTALLATION
3-1.
Equipment
Connection
Diagrams
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.
HOT
SURFACES
can
burn
skin.
Allow
gun
to
cool
before
touching.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
wire
feederand
welding
powersource,
and
disconnect
input
power
before
making
connections.
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.
Have
only
qualified
persons
install
this
unit.
wfwam9.1
2/93
2
3
13
4
1
Welding
Power
Source
2
Remote
14
Connection
3
Positive
(+)
Weld
Output
Cable
4
Negative
()
Weld
Output
Cable
5
Workpiece
6
Voltage
Sensing
Clamp
7
Weld
Control
8
Boom
9
Gun
10
Swivel
11
Pipe
Post
And
Base
12
12
Gas
Hose
13
Gas
Supply
ST-152
324
11
9
Figure
3-1.
Typical
System
Connections
OM-1
583
Page
2
3-2.
Installing
Swivel
Into
Pipe
Post
a
WARNING
I.
RELEASE
OF
SPRING
PRESSURE
WITHOUT
BOOM
ATTACHED
can
cause
serious
personal
injury.
Do
not
remove
safety
collar
until
instructed
to
do
so.
FALLING
BOOM
can
cause
serious
personal
injury
and
equipment
damage.
Securely
mount
pipe
post
to
base
that
can
support
weight
of
unit
with
boom
in
horizontal
position.
Use
proper
equipment
for
lifting
swivel
and
boom
into
place.
3-3.
Installing
Boom
And
Reel
Support
READ
SAFETY
BLOCKS
at
start
of
Section
3-2
before
proceeding.
5
4
3
Tools
Needed:
~
3/4in
1
Swingpak
Base
or
CBC
Cart
2
Pipe
Post
With
Base
3
Steel
Bolt
Secure
as
shown
using
as
a
mini
mum
1/2
in
diameter
SAE
grade
5
steel
bolts.
4
Swivel
Assembly
Insert
into
pipe
post.
Lubricate
swivel.
5
Safety
Collar
Do
not
remove
until
instructed
to.
ST-152
268
Figure
3-2.
Swivel
Installation
Tools
Needed:
~
_,~
3/4,3/8
in
1
1
Swivel
Plates
2
Yoke
Remove
hardware
from
swivel
7
plates
and
yoke.
3
Boom
Set
boom
into
swivel
as
shown.
4
Yoke
Pin
Install
pin
through
yoke.
Install
cot
ter
pin
and
spread
ends.
5
Bolt
Install
bolt,
tighten
hardware,
and
back
bolt
off
one
half
turn.
6
Locking
Knob
Install
locking
knob
but
do
not
tighten.
7
ReelSupport
Install
reel
support.
Ref.
ST-142
596-C
FIgure
3-3.
Boom
Installation
OM-1
583
Page
3
3-4.
Installing
Wire
Guide
Extension
Figure
3-4.
Wire
Guide
Extension
Installation
3-5.
Wire
Guide
And
Drive
Roll
Installation
READ
SAFETY
BLOCKS
at
start
of
Section
3-1
before
proceeding.
A.
Wire
Guide
Installation
1
1
Wire
Guide
Fitting
2
Bolt
4
3
Monocoil
Liner
4
Wire
Guide
Extension
Tighten
bolt
to
secure
liner
in
wire
guide
fitting.
Do
not
overtighten
bolt
and
crush
liner.
Tools
Needed:
c:::::=::i=n
3/8
in
ST-152
323
Figure
3-5.
Wire
Guide
Installation
OM-1
583
Page
4
B.
Drive
Roll
Installation
Figure
3-6.
Drive
Roll
Installation
3-6.
Welding
Gun
Connections
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.
wtwaml.1
2/93
4
~
.-
When
changing
wire
size
or
type,
check
drive
roll
size.
See
Table
7-1.
1
Spring
Shaft
Carrier
Close
spring
shaft
carrier.
2
Drive
Roll
Nut
3
Drive
Roll
Carrier
Turn
all
nuts
one
click
until
lobes
of
nut
line
up
with
lobes
of
drive
roll
carrier.
Open
spring
shaft
carrier.
4
Drive
Roll
Slide
drive
rolls
onto
drive
roll
carri
ers.
Close
spring
shaft
carrier.
Turn
nut
one
click.
5
Drive
Assembly
Cover
Close
cover.
ST-142
597-A
2
3
a
WARNING
4
3
1
Drive
Assembly
Cover
2
Gun
Securing
Knob
3
Gun
Connector
Loosen
securing
knob.
Insert
gun
connector
until
it
bottoms
against
drive
assembly.
Tighten
knob.
4
Gun
Trigger
Plug
5
Gun
Trigger
Receptacle
Insert
plug
into
free-hanging
recep
tacle
and
tighten
threaded
collar.
6
Trigger
Cord
7
Trigger
Plug
8
Weld
Control
Trigger
Receptacle
Insert
plug
into
receptacle
and
tighten
threaded
collar.
Ret.
ST-153
072
/
ST-152
321
/
Ret.
5T-142 708-B
Figure
3-7.
Gun
And
Trigger
Lead
Connections
OM-1
583
Page
5
3-7.
Wire
Feed
Motor
And
Gas
Valve
Control
Connections
3-8.
14-Pin
Plug
Connection
Figure
3-9.
14-Pin
Plug
Connection
Table
3-1.
Remote
14
Pin
Information
Pin*
Pin
Information
A
24
volts
ac.
B
Contact
closure
to
A
completes
24
volts
ac
contactor
control
circuit.
G
Circuit
common
for
24
volts
ac
circuit.
C
+10
volts
dc
input
to
remote
control.
D
Remote
control
circuit
common.
E
0
to
+10
volts
dc
output
command
signal
from
remote
control.
F
Current
feedback;
0
to
+10
volts
dc,
1
volt
per
100
amperes.
H
Voltage
feedback;
0
to
+10
volts
dc,
1
volt
per
10
arc
volts.
The
remaining
pins
are
not
used.
Figure
3-8.
Boom
Connections
eQ
~oo~
2
1
1
Plug
PLG1O
2
Keyway
3
Threaded
Collar
Connect
14-pin
plug
PLG1O
to
matching
receptacle
on
welding
power
source
as
follows:
align
key
ways,
insert
plug,
and
tighten
threaded
collar.
ST-162
179/Ref.
S.0512
3
1
OM-1583
Page
6
3-9.
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,
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
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
Shutoff
shielding
gas
supply
when
not
in
use.
wam4.1
2193
The
weld
cable
and
shielding
gas
hose
extend
10
ft
(3
m)
from
the
boom.
If
the
welding
power
source
or
gas
supply
are
further
from
the
boom,
extend
cable
or
hose
as
follows:
1
Weld
Cable
2
Insulated
Sleeving
Bolt
together
weld
cables
from
welding
power
source
and
boom.
Use
electrical
tape
and
insulated
sleeving
to
cover
connection.
3
Shielding
Gas
Hose
Connect
hose
to
gas
supply
or
ex
tension
hose.
The
hose
from
the
boom
has
5/8-18
right-hand
threads.
.
Tools
Needed:
5/Bin
Figure
3-10.
Shielding
Gas
And
Weld
Cable
Connections
sT-I
52
800-A
OM-1
583
Page
7
3-10.
Voltage
Sensing
Lead
(Optional)
A
35
ft
(10.6
m)
voltage
sensing
lead
is
provided
with
several
options.
Connect
voltage
sensing
lead
to
workpiece
(see
Figure
3i).
3-11.
Removing
Safety
Collar
And
Adjusting
Boom
a
WARNING
L
L
RELEASE
OF
SPRING
P________
WITHOUT
BOOM
ATTACHED
can
cause
serious
personal
injury.
S
Do
not
remove
safety
collar
until
instructed
to
do
so.
FALLING
personal
in
Adjustment
yoke.
BOOM
jury
and
rod
must
can
cause
serious
equipment
damage.
be
threaded
fully
through
4
3
1
Tool
s
Needed:
-~
1-1/8
in
.
1
Locking
Knob
Tighten
knob
to
prevent
boom
movement.
Loosen
knob
to
allow
boom
movement.
Change
knob
position
to
limit
upward
movement.
cD
~
kh
~
~h
Ti
~
3
2
Increasing
Spring
Decreasing
Spring
Pressure
ForA
Pressure
ForA
Heavy
Gun
Light
Gun
Pull
boom
down
slightly
and
re
move
safety
collar.
Boom
should
balance
in
any
position
from
hori
zontal
to
60
degrees
above
hori
zontal.
If
necessary,
adjust
boom
2
Threaded
Rod
JamNut
Loosen
jam
nut
and
turn
threaded
rod
until
boom
balances.
Tighten
jam
nut.
Be
sure
several
full
threads
are
through
yoke
to
pre
vent
boom
falling.
Retain
safety
collar
for
use
in
dis
assembling
or
moving
boom.
Ret.
ST-152
380-A
Figure
3-11.
Boom
Adjustments
3-12.
Welding
Wire
Installation
A.
Installation
Of
Spool-Type
Wire
1
Retaining
Ring
2
Wire
Spool
3
Hub
Remove
retaining
ring
and
slide
spool
onto
hub.
4
Hub
Pin
Turn
spool
until
hub
pin
fits
hole
in
spool.
Reinstall
retaining
ring.
E
ST-152
648-A
~?c
Figure
3-12.
Installation
Of
Spool-Type
Wire
OM-1583
Page
8
B.
Installation
Of
Optional
Wire
Reel
And
Reel
Type
Wire
C.
Adjusting
Hub
Tension
Figure
3-13.
Installation
Of
Optional
Wire
Reel
And
Reel
Type
Wire
Figure
3-14.
Adjusting
Hub
Tension
5
4
1
1
Retaining
Ring
2
Spanner
Nut
3
Lock
4
Wire
Retainer
5
Wire
Reel
6
Hub
7
Hub
Pin
8
Reel
Support
Remove
retaining
ring.
Pull
lock
and
turn.
Remove
spanner
nut,
wire
retainer,
and
wire
reel
from
hub.
Lay
wire
reel
assembly
on
flat
sur
face,
and
install
wire
as
shown.
Tighten
spanner
nut
until
lock
is
In
position
over
hole
in
wire
retainer.
Pull
lock
and
turn
to
insert
locking
pin
into
wire
retainer.
Slide
wire
reel
assembly
onto
hub,
and
turn
assembly
until
hub
pin
is
seated
in
hole
in
reel.
Reinstall
re
taining
ring.
ST.143
478-A
/
ST-152
463
Turn
Off
unit
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.
2
E
Tools
Needed:
~r
5/8
in
ST-152
649
OM-1583
Page
9
3-13.
Motor
Start
Control
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
TurnOffwirefeederandweldingpowersource,
and
disconnect
input
power
before
inspecting
or
installing.
STATIC
ELECTRICITY
can
damage
parts
on
circuit
boards.
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
wfwaml.r
2/93
non-conductive
ST-152
378
/
SB-146
862-D
Figure
3-15.
Motor
Start
Control
On
Motor
Control
Board
PCi
To
change
wire
feed
starting
speed
proceed
as
follows:
Turn
Off
unit
and
welding
power
source.
Remove
wrapper.
1
Front
Panel
Remove
screw
from
upper
left
cor
ner,
and
open
hinged
front
panel.
2
Motor
Board
PCi
3
Motor
Start
Control
Poten
tiometer
A70
Turn
potentiometer
clockwise
to
in
crease
time
it
takes
the
motor
to
ramp
up
to
speed.
Remove
protec
tive
white
rubber
cap
before
making
adjustment.
Adjust
poten
tiometer
R70
using
a
small
non-
conductive
screwdriver.
Close
and
secure
front
panel,
and
reinstall
wrapper.
Tools
Needed:
1/4
in
OM-1
583
Page
10
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Miller KF914926 Owner's manual

Miller
Brand
Miller
Model
KF914926
Category
Welding System
Type
Owner's manual
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