2. Industrial & lab equipment
  3. Welding System
  4. Miller
  5. 5280-3

Miller 5280-3, 4770-2, 4770-3, 5280-2, HG053870 Owner's manual

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September
1976
FORM:
OM-1512A
Effective
With
Serial
No.
HG053870
FLE
Copy
RETURN
TO
uL~E~
MODEL
WIRE
SIZE
SINGLE
SWINGARC
4770-3
STOCK
NO.
5280-3
STOCK
NO.
.030
&
.035
hard
078
102
.045
hard
078
103
.052
hard
003 364
1/16hard
078 104
MODEL
WIRE
SIZE
1/16
hard
1/16
cored
5/64
cored
3/32
cored
7/64
cored
1/8
cored
4770-2
STOCK
NO.
078
106
078
107
078
108
078
109
078
110
078
111
5280-2
STOCK
NO.
078
117
078
118
078
119
078
120
078
121
078
122
MODEL/STOCK
NO.
SER%AL/STYLE
NO.
DATE
PURCHASED
ADDITIONAL
COPY
PRICE
55
CENTS
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
078
113
078
114
003
365
078
115
NWSA
CODE
NO.
4579
U
S
%.
s_.
LIMITED
WARRANTY
EFFECTIVE:
NOVEMBER
1,
1976
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
cl~ive
with
no
other
guarantees
or
warranties
expressed
or
implied.
d
LIMITED
WARRANTYMiller
Electric
Mfg.
Co.,
Apple-
3.
All
welding
guns
and
feeder/guns
90
days
ton,
Wisconsin
warrants
to
Customer
that
all
new
and
unused
4.
All
other
Millermatic
Feeders
I
year
~
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
provided
that
the
user
so
notifies
Miller
in
writing
within
thirty
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
(30)
days
of
the
date
of
such
failure.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
accessories
and
other items
are
sold
subject
to
the
warran-
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
ties
of
their
respective
manufacturers,
if
any.
At
the
present
time,
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REP-
the
manufacturers
warranty
on
the
Mag-Diesel
engine
on
DEL-
RESENTATION
AS
TO
PERFORMANCE,
AND
ANY
200
is
limited
to
six
months
and
on
all
other
engines
to
one
year.
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICA
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
TION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
therefor
shall
be,
at
Millers
option,
(1)
repair
or
(2)
replace-
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
ment
or,
where
authorized
in
writing
by
Miller
in
appropriate
WARRANTY
OF
MERCHANTABILITY
OR
OF
FITNESS
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
the
purchase
price
(less
reasonable
depreciation
based
upon
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
actual
use)
upon
return
of the
goods
at
Customers
risk
and
ex
pense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
Miller
shall
instruct
the
claimant
on
the
warranty
claim
proce-
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
dures
to
be
followed.
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUS
TRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
As
a
matter
of
general
policy
only,
Miller
may
honor
an
origi-
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
nal
users
warranty
claims
on
warranted
Equipment
in
the
event
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
of
failure
resulting
from
a
defect
within
the
following
periods
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
from
the
date
of
delivery
of
Equipment
to
the
original
user:
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RE-
1.
Arc
welders,
power
sources,
and
components
...
I
year
SELLER
IS
AUTHORIZED TO
EXTEND
MILLERS
WAR-
2.
Original
main
power
rectifiers
3
years
RANTIES
TO,
ANY
CONSUMER.
,J_
,,
J~
5, ,~r
,j~
5,
J~
5,
J~
5,
~
5,
Section
No.
SECTION
1
INTRODUCTION
TABLE
OF
CONTENTS
Page
No.
1
-1.
1
-
2.
1
-
3.
1
-
4.
2-1.
2
-
2.
2
-
3.
2
-
5.
2
-
6.
2
-
7.
2
-
8.
2
-
9.
2-10.
2-il.
2-12.
2-13.
2-14.
2-15.
2-16.
3-1.
3
-
2.
3
-
3.
3
-
4.
3~5
Pressure
Roll
Alignment
Installation
Of
Hub
And
Spindle
Assembly
Installation
Of
Wire
Reel
Installation
Of
Reel-Type
Wire
Installation
Of
Spool-Type
Wire
Adjustment
Of
Hub
Tension
Sheilding
Gas
Connections
Water
Connections
Weld
Cable
Connection
Contactor
Control
Connections
Gun
Switch
Receptacle
115
Volts
AC
Connections
2
2
2
2
3
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
5
General
Receiving-Handling
Description
Safety
SECTION
2
INSTALLATION
Location
Installation
Of
Electrode
Wire
Gun
Connector
Electrode
Wire
Inlet
&
Outlet
Guide
Installation
2
-
4.
Pressure
&
Feed
Roll
Installation
2-17.
Boom
Adjustments
SECTION
3
FUNCTION
OF
CONTROLS
Wire
Speed
Control
Circuit
Breaker
Purge
Switch
Inch-Advance
Switch
Burnback
Control
SECTION
4
SEQUENCE
OF
OPERATION
4
-
1.
Welding
Wire
Threading
4
-
2.
Gas
Metal-Arc
(GMAW)
Welding
4
-
3.
Shuttinci
Down
SECTION
5
TROUBLESHOOTING
SECTION
~
-
INTRODUCTION
Model
12
Foot
Boom
16
Foot
Boom
Motor
1/4
Horsepower.
D.C.
10,000
RPM
Control
Solid
State
Solid
State
Speed
Range
Boom
Turning
Radius
(Standard)
No.2
gear
70
to
500
1P.M.
LN0.
3
gear
100
to
750
l.P.M.
12
ft.
16
ft.
Swing
3600
0
n
Post
Mounting
Vertical
Lift
Horizontal
t
o
+700
Above
Maximum
Height
(With
4
Ft.
Post)
To
Top
Of
Boom
At
Tip
(+70
Position)
18
ft
~
23
ft
.
Counterbalance
(Patented)
Compression
spring
designed
to
hold
boom
at
any
angle
adjustable
pressure
(a
broken
spring
would
drop
weld
head
only
6
inches)
Adjustable
Burnback
Timer
3/8
to
3/4
sec.
3/8
to
3/4
sec.
Weight
(Pounds)
Net
170
Ship
230
Net
200
Ship
265
1-1.
GENERAL
Figure
1-1.
Specifications
This
manual
has
been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
design,
installation,
operation,
main
tenance,
and
troubleshooting
of
this
equipment.
All
informa
tion
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
1
-2.
RECEIVING-HANDLING
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equipment,
it
is
essential
that
Model
Description
and/or
Stock
Number
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
~this
heading.
installation,
opera~,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
per-
sonnel.
U
FT~1
1
I
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip
ment.
This
control/feeder
is
of
the
Constant
wire
feed
speed
type
and
is
designed
to
be
used
in
conjunction
with
a
constant
potential
welding
power
source.
The
control/feeder
is
a
heavy-duty
wire
feeding
unit
combin
ing
both
the
wire
feeder
and
the
control.
It
contains
all
the
controls
and
equipment
needed
to
supply
welding
wire
and
shielding
gas
to
the
welding
gun.
I
NOTE
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
2
-
INSTALLATION
2-1.
LOCATION
The
control/feeder
with
12
foot
boom
is
equipped
with
a
4
foot
long
by
2-1/2
inch
pipe
post
for
mounting
purposes.
The
control/feeder
with
16
foot
boom
is
equipped
with
a
4
foot
long
by
5
inch
pipe
post
for
mounting
purposes.
Ensure
that
the
item
to
which
the
unit
is
being
installed
is
of
sufficient
construction
to
permit
the
boom
to
be
pulled
completely
down
without
having
the
control/feeder
tip.
Also,
ensure
that
enough
space
is
available
to
permit
the
boom
to
swing
in
a
complete
circle.
NOTE
4.
Remove
pin
(1),
nut
(7),
washers
(6
&
12),
and
bolt(13)
from
the
boom.
Do
not
remove
safety
collar
(5)
until
instructed
to
do
so.
5.
Place
the
boom
base
plate
(14)
in
between
the
two
swivel
plates.
6.
Slide
washer
(12)
onto
bolt
(13)
and
insert
bolt
(13)
through
hole
(11).
Slide
washet
(6)
onto
bolt
(13)
and
install
nut
(7)
onto
bolt
(13).
Tighten
nut
(7)
then
back
off
nut
(7)
1/2
turn.
7.
Insert
pin
(1)
through
yoke
(4),
hole
(2),
and
install
cotter
pin
(3)
through
pin
(1).
If
an
optional
mounting
pedestal
was
purchased
with
the
control/feeder,
mounting
holes
are
provided
in
the
pedestal
for
attaching
the
control/feeder.
A.
Assembly
(Figure
2-1)
1.
Uncrate
and
remove
all
packing
material
from
the
con
trol/feeder.
2.
Mount
pipe
post
(10)
to
the
desired
fixture.
3.
Place
bearing
(9)
on
top
of
post
(10)
and
insert
swivel
(8)
into
post
(10).
8.
Connect
the
welding
gun
to
the
drive
assembly
as
in
structed
in
Section
2
of
this
manual.
9.
Grasp
bar
(14)
and
pull
boom
down
slightly.
The
boom
should
be
pulled
down
only
far
enough
to
re
move
the
pressure
which
is
applied
to
the
safety
collar
(5).
10.
Remove
the
safety
collar
(5).
11.
The
boom
should
now
balance
in
any
position
from
horizontal
to
70
degrees
above
horizontal.
If
the
boom
does
not
balance
properly,
proceed
to
Section
2-16.
1
-
4.
SAFETY
1
-
3.
DESCRIPTION
I
I
U
OM-1512A
Page
1
TB-003
418-A
Figure
2-1.
Control/Feeder
Assembly
2-2.
INSTALLATION
OF
ELECTRODE
WIRE
GUN
CONNECTOR
(Figure
2-2)
Proceed
as
follows
to
install
the
Electrode
Wire
Gun
Connec
tor
into
the
drive
assembly
on
the
control/feeder:
1.
Loosen
the
gun
connector
securing
screw.
See
Figure
2-2
for
the
location
of
the
securing
screw.
2.
Insert
the
Electrode
Wire
Gun
Connector
fully
into
the
outlet
hole
with
the
flat
side
of
the
connector
facing
the
gun
connector
securing
screw.
3.
Rotate
the
Electrode
Wire
Gun
Connector
90
degrees
in
a
clockwise
direction.
4.
Tighten
the
gun
connector
securing
screw.
2-3.
ELECTRODE
WIRE
INLET
&
OUTLET
GUIDE
INSTALLATION
(Figure
2-2)
1.
Loosen
the
outlet
guide
securing
screw
(11).
2.
Install
the
Electrode
Wire
Gun
Connector
into
the
drive
assembly
as
instructed
in
Section
2-2.
3.
Insert
the
outlet
guide
(12)
flat
end
first
into
the
back
side
of
the
outlet
guide
hole
in
the
drive
assembly.
4.
Push
the
outlet
guide
(12)
into
the
outlet
guide
hole
until
the
outlet
guide
seats
against
the
Electrode
Wire
Gun
Con
nector,
or,
if
the
outlet
guide
is
equipped
with
a
flange,
until
the
flange
seats
against
the
drive
assembly.
5.
Tighten
the
outlet
guide
securing
screw
(11).
6.
Loosen
the
inlet
guide
securing
screw
(2).
7.
Insert
the
inlet
guide
(1)
point
fIrst
into
the
inlet
guide
hole
until
the
flange
on
the
inlet
guide
(1)
seats
against
the
drive
assembly.
8.
Tighten
the
inlet
guide
securing
screw
(2).
2-4.
PRESSURE
&
FEED
ROLL
INSTALLATION
(Fig
ure
2-2)
1.
Loosen
the
pressure
adjustment
knob
and
pivot
the
pres
sure
adjustment
assembly
off
the
pressure
roll
mounting
lever.
Swing
she
pressure
roll
mounting
lever
up.
2.
Remove
nut
(6).
lock
washer
(5),
and
flat
washer
(4)
from
the
feed
roll
shaft.
I
Prior
to
installing
I
the
NOTEJ
feed
roll,
ensure
that
the
sup-
.
I
plied
key
is
in
the
groo
ye
in
the
feed
roll
shaft.
3.
Slide
the
keyed
feed
roll
(3)
onto
the
feed
roll
shaft.
4.
Insert
flat
washer
(4)
and
lock
washer
(5)
onto
the
feed
roll
shaft
and
install
nut
(61
onto
the
feed
roll
shaft.
5.
Remove
bolt
17),
lock
washer
(8),
and
flat
washer
(9)
from
the
pressure
roll
mounting
lever.
6.
Slide
pressure
roll
110)
onto
the
shaft
on
the
pressure
roll
mounting
lever.
7.
Slide
lock
washer
(8)
and
flat
washer
(9)
onto
bolt
(7),
and
install
bolt
(7)
into
the
shaft
on
the
pressure
roll
mounting
lever.
8.
Lower
the
pressure
roll
mounting
lever
until
the
teeth
in
the
upper
and
lower
drive
rolls
mesh
together.
NOTE
The
pressure
adjustment
knob
will
have
to
be
adjusted
for
proper
tension
prior
to
operation
of
the
control/
feeder.
The
amount
of
pressure
will
vary
from
one
given
set
of
welding
conditions
to
another,
and
should
be
just
tight
enough
to
prevent
pressure
and
feed
roll
slippage
on
the
wire.
I~
-~
I
I
1
6
7
8
9
10
S
Pressure
Adjustment
Knob
9.
Pivot
the
pressure
adjustment
assembly
until
is
is
on
top
of
the
pressure
roll
mounting
lever,
and
tighten
the
knob
so
the
desired
amount
of
pressure.
2-
5.
PRESSURE
ROLL-ALIGNMENT
(Figure
2-3)
NOTE
TB-003
410
Figure
2-2.
Drive
Roll
&
Wire
Guide
Installation
The
pressure
and
drive
rolls
shown
in
Figure
2-3
are
the
only
type
of
rolls
that
require
this
type
of
adjust
ment.
Page
2
~___
Counter-
Proper
Clockwise
clockwise
Alignment
Rotation
of
Rotation
of
Adjustment
Adjustment
Nut
Required
Nut
Required
Figure
2-3.
Pressure
Roll
Alignment
TB-078
036-5
The
pressure
roll
mounting
lever,
which
holds
the
pressure
roll,
can
be
moved
on
a
horizontal
plane
to
facilitate
align
ment
of
the
groove
in
the
pressure
roll
with
respect
to
the
groove
in
the
feed
roll.
The
pressure
roll
should
be
checked
for
proper
alignment
whenever
erratic
wire
feed
is
noted,
or
whenever
the
pressure
and
feed
rolls
are
changed.
To
check
for
proper
alignment
of
the
pressure
roll,
remove
the
outlet
guide
and
look
into
the
outlet
guide
hole
in
the
drive
as
sembly.
Upon
viewing
the
groove
between
the
pressure
and
feed
rolls,
it
should
be
noted
that
the
outer
edges
of
the
grooves
on
the
pressure
and
feed
rolls
should
be
precisely
aligned.
Figure
2-3
shows
examples
of
proper
and
improper
alignment.
If
the
pressure
and
feed
rolls
are
not
in
alignment,
proceed
as
follows
to
adjust
the
pressure
roll:
1.
Loosen
the
pressure
adjustment
collar
and
pivot
it
off
the
pressure
roll
mounting
lever.
2.
Using
a
9/16
wrench,
loosen
the
outer
securing
bolt.
3.
Using
a
5/8
wrench,
rotate
the
adjustment
nut
as
re
quired.
Rotating
the
adjustment
nut
clockwise
will
move
the
pressure
roll
outward
and
counterclockwise
rotation
will
move
the
pressure
roll
inward.
4.
When
proper
alignment
is
achieved,
tighten
the
outer
securing
bolt
to
lock
the
pressure
roll
in
position.
5.
Pivot
the
pressure
adjustment
assembly
until
it is
on
top
of
the
pressure
roll
mounting
lever
and
tighten
the
collar
to
the
desired
amount
of
pressure.
2-6.
INSTALLATION
OF
HUB
AND
SPINDLE
AS
SEMBLY
(Figure
2-4)
Figure
2-4.
Hub
and
Spindle
Assembly
1.
Insert
spindle
support
shaft
(12)
into
the
hole
in
spindle
support
(13).
2.
Slide
washer
(14)
onto
spindle
support
shaft
(12)
and
secure
with
cotter
pin
(15).
3.
Slide
the
following
items
onto
the
spindle
support
shaft
(12)
in
order
given:
A.
Flat
Washer
(11)
B.
Flat
Washer
(10)
C.
Hub
(9)
D.
Flat
Washer
(8)
E,
Fiber
Washer
(7)
F.
Keyed
Washer
(6)
G.
Spring
(5)
H.
Flat
Washer
(4)
4.
Rotate
hex
nut
(3)
onto
support
shaft
(12).
Hex
nut
(3)
should
be
rotated
only
until
a
slight
drag
is
felt
while
turning
spindle
(9).
5.
Depress
both
spring-loaded
stops
(1)
on
the
retaining
ring
(2)
simultaneously,
and
slide
the
retaining
ring
(2)
into
the
proper
position
on
the
hub
(9).
2-
7.
INSTALLATION
OF
WIRE
REEL
(Figure
2-5)
1.
Depress
the
two
spring-loaded
stops
(7)
on
the
retaining
ring
(8),
and
slide
the
retaining
ring
(8)
off
the
hub
(2).
2.
Slide
the
wire
reel
(3)
onto
the
hub
(2).
Rotate
the
wire
reel
(3)
until
the
hub
guide
pin
(1)
is
seated
in
the
reel
(3).
3.
Place
the
retaining
ring
(8)
into
the
proper
position
on
the
hub
(2).
TC-007
886
Figure
2-5.
Reel,
Hub
&
Spindle
Assembly
12
3
7
8
TB-058
432-A
OM-1
512
Page
3
SECTION
3-
FUNCTION
OF
CONTROLS
3-
1.
WIRE
SPEED
CONTROL
(Figure
3-1)
The
WIRE
SPEED
control
provides
a
means
of
determining
the
rate
at
which
welding
wire
will
be
fed
into
the
weld.
Rotating
the
WIRE
SPEED
control
in
a
clockwise
direction
will
increase
the
rate
of
wire
feed.
When
the
WIRE
SPEED
control
is
set
at
0,
wire
will
feed
at
the
minimum
1PM;
when
set
at
10,
the
wire
will
feed
at
the
maximum
1PM.
3-
2.
CIRCUIT
BREAKER
(Figure
3-1)
A
Circuit
Breaker,
located
on
the front
panel
of
the
control/
feeder,
provides
protection
to
the
control/feeder
circuitry.
In
the
event
the
motor
should
be
placed
in
an
overloaded
con
dition,
the
breaker
would
trip
and
suspend
all
output.
Should
this
breaker
trip,
it
would
have
to
be
manually
depressed
to
reset.
3-3.
PURGE
SWITCH
(Figure
3-1)
The
PURGE
switch,
located
on
the
front
panel
of the
con
trol/feeder,
is
a
momentary
contact
switch.
This
switch
will
energize
the
shielding
gas
solenoid
and
purge
the
shielding
gas
line
of
the
gun.
It
also
allows
the
shielding
gas
regulator
to
be
adjusted
without
energizing
the
welding
circuit.
3..
4.
INCH-ADVANCE
SWITCH
(Figure
3-1)
The
INCH-ADVANCE
switch,
located
on
the
front
panel
of
the
control/feeder,
is
a
spring-actuated
toggle
switch.
When
actuated
it
completes
the
circuit
to
the
motor
without
having
to
depress
the
gun
switch.
This
switch
will
permit
inching
or
threading
of
the
wire
at
whatever
setting
the
WIRE
SPEED
control
is
at,
without
energizing
the
welding
power
source
contactor
or
the
gas
valve.
3-
5.
BURNBACK
CONTROL
(Figure
3-1)
The
BURNBACK
circuitry
in
this
control/feeder
provides
a
means
of
keeping
the
welding
wire
from
sticking
to
the
work-
piece
or
the
contact
tube
in
the
gun
after
the
gun
switch
is
released.
The
BURNBACK
capability
in
this
control/feeder
will,
depending
upon
the
setting
of the
BURNBACK
control,
keep
weld
current
present
on
the
welding
wire
from
1/4
to
3/4
of
a
second
after
the
wire
has
stopped
feeding.
This
delay
action
will
permit
the
welding
wire
to
burn
back
to
a
point
where
it
will
neither
stick
to
the
workpiece
nor
the
contact
tube.
If
the
welding
wire
sticks
to
the
contact
tube
in
the
gun
after
the
gun
switch
is
released,
rotate
the
BURNBACK
con
trol
to
a
setting
closer
to
the
0
(1/4
second)
position.
If
the
welding
wire
sticks
to
the
workpiece
after
the
gun
switch
is
released,
rotate
the
BURNBACK
control
to
a
setting
closerto
the
10
(3/4
second)
position.
SECTION
4
-
SEQUENCE
OF
OPERATION
4
1.
WELDING
WIRE
THREADING
1.
Install
the
wire
(reel-type
or
spool-type)
as
instructed
in
Sections
2-8
and
2-9.
NOTE
Ensure
that
the
pressure
roll
is
checked
for
proper
I
alignment
before
proceeding
with
the
welding
wire
threading
operation.
See
Section
2-5,
and
Figure
2-3.
2.
Cut
off
any
portion
of
the
free
end
of
the
welding
wire
which
is
not
straight.
3.
Route
the
welding
wire
through
the
wire
guide
tube
on
the
side
of
the
boom
up
to
the
drive
assembly.
4.
Lift
up
the
pressure
roll
mounting
lever.
5.
Install
the
Electrode
Wire
Gun
Connector
as
instructed
in
Section
2-2.
6.
Feed
the
wire
through
the
inlet
guide
and
on
into
the
outlet
guide.
Feed
approximately
4
inches
of
wire
into
the outlet
guide.
7.
Secure
the
pressure
roll
mounting
lever.
8.
Tighten
the
pressure
adjustment
knob
for
the
approxi
mate
amount
of
pressure
desired
on
the
pressure
and
feed
rolls.
Precise
adjustment
of
the
pressure
adjust
ment
assembly
will
have
to
be
made when
welding
commences.
9.
Connect
the
115
volts
ac
plug
from
the
control/feeder
into
a
115
volts,
60
Hertz
source.
10.
Connect
the
Switch
Control
plug
from
the
gun
into
the
Gun
Switch
receptacle
on
the
boom.
11.
Lay
the
gun
cable
out
straight.
12.
Depress
the
ADVANCE
switch
until
the electrode
wire
extends
approximately
one
inch
out
of
the
gun
tip.
4-2.
GAS
METAL-ARC
(GMAW)
WELDING
~sU1ts]~j
I
Prior
to
welding,
it is
imperative
that
proper
protective
clothing
(welding
coat
and
gloves)
and
eye
protection
(glasses
and/or
welding
helmet)
be
put
on.
Failure
to
comply
may
result
in
serious
or
permanent
bodily
damage.
1.
Make
all
necessary
connections
as
instructed
in
Section
2
of
this
manual.
2.
Rotate
the
WIRE
SPEED
control
to
the
desired
setting.
3.
Rotate
the
BURNBACK
control
to
the
desired
setting.
4.
Turn
on
the
shielding
gas
supply
and
press
the
PURGE
switch
for
10
seconds.
CAUTION
I
The
welding
wire
and
all
metal
parts
i~actwit~it
are
energized
while
welding.
Do
not
touch
the
welding
wire
or
any
metal
part
making
contact
with
it.
5.
Depress
the
trigger
on
the
gun.
Gas
will
start
to
flow
and
wire
will
start
to
feed
if
drive
roll
pressure
is
properly
adjusted
to
prevent
slippage.
If
wire
slippage
is
noticed,
tighten
the
pressure
~djustment
collar
1/2
turn
clockwise.
Repeat
until
slippage
stops.
Do
not
tighten
pressure
ad
justment
collar
too
much.
4-3.
SHUTTING
DOWN
1.
Turn
off
the
shielding
gas
at
the
source.
2.
Remove
the
115
volts
ac
plug
from
the
source.
3.
Turn
off
all
associated
equipment.
Circuit
Breaker
Purge
Switch
Figure
3-1.
Control
Location
TA-003
408-A
OM-1512
Page
5
CAUTION
If
welding
is
performed
in
a
confined~failureto
turn
off
the
shielding
gas
supply
could
result
in
a
buildup
of
shielding
gas
fumes,
thereby
endangering
personnel
reentering
the
welding
area
SECTION
5
-
TROUBLESHOOTING
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
common
troubles
that
may
develop
in
this
control/feeder.
It
is
assumed
that
proper
installation
has
been
made,
according
to
Section
2 of
this
manual,
and
that
the
control/feeder
has
been
functioning
properly
until
this
trouble
developed.
Use
this
chart
in
conjunction
with
the
Circuit
diagram
while
performing
troubleshooting
procedures.
If
the
trouble
is
not
remedied
after
performing
these
procedures,
the
nearest
Factory
Authorized
Service
Station
should
be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should
be
strictly
followed.
TROUBLE
PROBABLE
CAUSE
REMEDY
Depressing
gun
switch
will
not
energize
control/feeder.
Electrode
wire
is
not
energized
and
shielding
gas
does
not
flow.
Circuit
breaker
(CB1)
tripped.
Reset
circuit
breaker.
Plug
from
Gun
Switch
(PLG4)
is
not
secure
in
Gun
Switch
receptacle
(R
C4)
on
control/feeder.
Insert
plug
(PLG4)
fully
into
Gun
Switch
receptacle
(RC4)
and
tighten.
Plug
from
Gun
Switch
not
secure
in
cable
receptacle
(RC3).
Ensure
that
plug
is
secure
in
cable
receptacle
(RC3).
115
vac
input
plug
(PLG1)
is
not
secure
in
receptacle,
Insert
plug
(P
LG
1)
fully
into
115
vac
receptacle.
Wire
feeds,
shielding
gas
flows,
but
electrode
wire
is
not
energized.
Contactor
Control
cable
leads
not
secure
on
contactor
plug
terminals.
Secure
leads
to
plug
terminals.
Defect
in
welding
power
source.
See
troubleshooting
section
in
welding
power
source
instruction
manual.
Wire
feeds
erratically.
Pressure
on
pressure
and
drive
rolls
is
insufficient.
Rotate
pressure
adjustment
knob
clockwise
in
1/4
turn
increments
until
wire
slippage
stops.
Pressure
roll
alignment
incorrect.
Ensure
that
proper
alignment
is
achieved.
See
Section
2-5
and
Figure
2-3.
Pressure
and
drive
rolls
are
too
large
for
wire
size
being
used.
Change
to
proper
size
pressure
and
drive
roll.
Worn
pressure
and
drive
rolls.
Replace
pressure
and
drive
rolls.
See
Section
2-4.
Dirt
in
pressure
and
drive
roll
grooves.
Clean
pressure
and
drive
rolls.
Motor
is
inoperative.
Worn
brushes.
Replace
motor
brushes.
Motor
plug
(PLG2)
not
secure
in
receptacle
(RC2).
Tighten
motor
plug
(PLG2).
Motor
plug
(PLG5)
not
secure
in
receptacle
(R
CS).
Tighten
plug
(PLG5)
in
receptacle
{RC5).
.
Page
6
Figure
5-1.
Circuit
Diagram
OM-1512
Page
7
September
1976
FORM:
OM-1512A
Effective
With
Serial
No.
HG053870
SINGLE
SWINGARC
MODEL
WIRE
SIZE
47
70-3
STOCK
NO.
5280-3
STOCK
NO.
.030
&
.035
hard
.045
hard
.052
hard
1/1
6hard
MODEL
WIRE
SIZE
1/16
hard
1/16
cored
5/64
cored
3/32
cored
7/64
cored
1/8
cored
078
102
078
103
003
364
078
104
47
70-2
STOCK
NO.
078
106
078
107
078
108
078
109
078
110
078
111
078
113
078
114
003
365
078
115
5280-2
STOCK
NO.
078
117
078
118
078
119
078
120
078
121
078
122
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
V.,.
U,,
Fig
4
Figure
A
Main
Assemby
TD.003
193
19
6
-~Fig
E
3~
Fig
B
30
29
28
OM-1512
Page
1
Quantity
Model
Item
Dia.
Factory
Single
Single
No.
Mkgs.
Part
No.
Description
12
Ft.
16
Ft.
Figure
A
Main
Assembly
1
075 074
CABLE,
interconnecting
-
motor/control
(consisting
of)
1
1
075
075
CABLE,
interconnecting
-
motor/control
(consisting
of)
1
2
RC5
073265
.
RECEPTACLE,6socketg7-3101A-20-17S
1
1
3
039
734
.
CLAMP,
cable
AN-3057-1
2
2
2
4
073
139
.
CORD,
portable
No.
16/6
conductor
(order
by
foot)
15 ft
19
ft.
5
PLG2
073
264
.
PLUG,
6pm
97-3106A-20-17P
1
1
077
650
.
TUBING,
vinyl
No.
7
x
3/4
12
12
6
079
202
HOSE,
gas
(consisting
of)
1
6
079
204
HOSE,
gas
(consisting
of)
1
7
010
604
.
ADAPTER,
brass
-
gas
1/4-18
NPT
5/8-18
female
1
1
8
079
196
.
COUPLING,
brass
-
female
3/16
ID
hose
x
1/4
NPT
1
1
9
604
550
.
HOSE,
whippet
3/16
x
1
(order
by
foot)
16
ft
19
ft.
10
073839
.FERRULE
2 2
11
010
606
.
NUT,
brass
-
swivel
5/8-18
right
hand
1
1
12
056
851
.
NIPPLE,
brass
-
hose
3/16
1
1
13
075
325
CONTROL
BOX
(See
Fig.
C
Page
5)
1
1
14
074
976
CABLE,
trigger
(consisting
of)
1
14
074
977
CABLE,
trigger
(consisting
of)
1
15
600
340
.
CORD,
portable
No.
16/2
conductor
(order
by
foot)
15
ft
20
ft.
16
073
331
.
CLAMP,
cable
97-3057-10-6
2
2
17
PLG4
073
329
.
PLUG,
4
pin
97-3106A-18-4P
1
1
18
RC3
073
441
.
RECEPTACLE,
4
socket
MS-3101A-18-4S
1
1
077 650
.
TUBING,
vinyl
No.
7
x
3/4
4
4
19
078
992
CORD,
power
No.
2
gear
or
19
074
983
CORD,
power
No.
3
gear
(consisting
of)
1
19
078
993
CORD,
power
No.
2
gear
or
19
074
986
CORD,
power
No.
3
gear
(consisting
of)
1
20
077
455
.
TERMINAL,
ring
tongue
1/2
stud
3/0
wire
(No.
2
gear)
or
20
600
734
.
TERMINAL,
ring
tongue
1/2
stud
2/0
wire
(No.
3
gear)
1
1
21
600
323
.
CABLE,
weld
-
copper
stranded
3/0
(No.
2
gear)
or
21
600
322
.
CABLE,
weld
-
copper
stranded
2/0
(No.
3
gear)
27
ft
30
ft.
22
600
742
.
TERMINAL,
ring
tongue
3/8
stud
3/0
wire
(No.
2
gear)
or
22
600
732
.
TERMINAL,
ring
rongue
3/8
stud
2/0
wire
(No.
3
gear)
1
1
23
Figure
E
BOOM
(See
Page
9)
1
1
24
t079
214
BASE,
support
-
boom
(18
inch
base)
1
24
t079
216
BASE,
support
-
boom
(24
inch
base)
1
25
601
865
NUT,
steel
-
hex
full
1/4-20
4
4
26
602
207
WASHER,
lock
-
steel
split
1/4
4
4
601
926
SCREW,
cap
-
steel
hex
hd
1/4-20
x
5/8
(attaching
control
box)
4
4
27
601
967
SCREW,
cap
-
steel
hex
hd
3/8-16
x
1-1/2
3
3
28
602
224
WASHER,
lock
-
steel
split
3/8
3
3
29
010
910
WASHER,
flat
-
steel
SAE
3/8
3
3
30
075
150
WASHER,
nylon
-
shoulder
.622
x
1
x
3/8
3
3
31
074772
INSULATOR
1
1
32
078
143
MOTOR
&
DRIVE
ASSEMBLY,
No.
2
gear
or
32
078
144
MOTOR
&
DRIVE
ASSEMBLY,
No.
3
gear
(See
Fig.
B
Page
3)
1 1
073329
PLUG,4pin97-3106A-18-4P
1 1
073
331
CLAMP,
cable
1
1
tOptional
Equipment
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1512
Page
2
71
72
73
74
75
76
77
78
79
80
81
82
83
075
31
5
073
308
074
780
073
307
074
771
074
781
073
597
073
581
073
583
073
598
077
214
073
595
*073
591
Item
Factory
No.
Part
No.
Description
Figure
B
Motor
&
Drive
Assembly
(See
Fig.
A
Page
2
Item
32)
Quantity
Model
No.
21
No.
3
MOTOR,
drive
(consisting
of)
1
1
BEARING,
ball
1
1
SHAFT,
idler
gear
1
1
RING,
retaining
-
external
2
2
GEAR,
spur
-
steel
40
pitch
43
tooth
1
1
STUD,
steel
12-28
x
1-314
3
3
BEARING,
ball
1
1
.FIELDASSEMBLY
1
1
.ARMATURE
1
1
SPRING,
brushholder
2 2
HOLDER,
brush
2
2
CAP,
brushholder
2 2
BRUSH,
contact
2
2
71
114
11590
117
116
Figure
B
Motor
&
Drive
Assembly
TD-039
159
Page
3
*
Recommended
Spare
Parts
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Factory
No.
Part
No.
Figure
B
Description
Motor
&
Drive
Assembly
(See
Fig.
A
Page
2
Item
32)
(Contd)
Quantity
Model
No.
21
No.
3
84
073596
.BEARING,baIl
1
1
85
073
593
.
WASHER,
spring
1
1
86
073
296
.
CLAMP,
cable~
amphenol
97-3057-12-6
1
1
87
073
264
073
703
.
PLUG,
amphenol
97-3106A-20-17P
GASKET,
motor
1
1
1
1
88
074
768
GEAR,
drive
1
1
89
073268
BEARING,ball
3
3
90
010 910
WASHER,
flat
-
steel
SAE
3/8
7
7
91
602
221
WASHER,
lock
-
steel
internal
tooth
3/8
2
2
92
074 902
LEVER,
mounting
-
pressure
gear
1
1
94
604
538
WASHER,
flat-
steel
SAE
5/16
1
1
95
602
211
WASHER,
lock
-
steel
split
5/16
1
1
96
601
948
SCREW,
cap-
steel
hex
hd
5/16-18
x
1 1
1
97
074811
BUSHING,
9/16-18x
1-13/32
with
3/8
hole
1
1
98
605
209
SCREW,
cap
-
steel
hex
hd
3/8-16x
2-1/4
1
1
99
073356
KNOB
1 1
100
073
303
SPRING,
compression
1
1
101
074
783
ARM,
adjustment
-
pressure
(consisting
of)
1 1
102
076647
.FASTENER,pin
1
1
103
076
682
.
BLOCK,
pressure
stud
1
1
104
010324
.PIN,spring3/16x
1/2
1
1
105
074
778
SHAFT,
drive
1
1
106
056 068
KEY,
steel
1/8
x
1/8
x
1/2
1
1
107
073
309
SEAL,
oil
-
drive
shaft
1
1
108
073
240
RING,
retaining
-
external
4
4
109
074
858
TUBING,
steel
7/8
OD
x
19/32
ID
x
.303
1
1
110
602
247
WASHER,
flat
-
steel
SAE
1/2
1
1
111
602
216
WASHER,
lock
-
steel
split
1/2
..
.
1
1
112
601
881
NUT,
steel-hex
jam
1/2-20
1 1
113
602
177
SCREW,
set
-
steel
socket
hd
1/4-20
x
1/4
2 2
114
601
967
SCREW,cap-steel
hex
hd
3/8-16x
1-1/2
5 5
115
602
224
WASHER,
lock
-
steel
split
anti link
positive
3/8
5
5
116
078
880
SCREW,
cap
-
steel
socket
hd
5/16-18
x
1-1/2
1
1
117
079
375
HOUSING,
adapter-
gun/feeder
1
1
118
078
881
SCREW,
cap-brass
hex
hd
3/8-16
x
2-1/2
1
1
119
078
882
WASHER,
lock
-
brass
split
3/8
1
1
120
078
751
WASHER,
flat
-
bronze
3/8
1
1
121
078
687
WASHER,
lock
-
steel
split
No.
12
3
3
122
078
858
NUT,
steel
-
hex
full
12-28
3
3
123
075
229
HOUSING,
drive
(consisting
of)
1
1
124
073334
.HELICOIL
1
1
125
075
150
WASHER,
nylon
-
shoulder
.622
x
1
x
3/8
3
3
126
074
772
INSULATOR
1 1
127
078 879
SCREW,
machine
-
steel
truss
phillips
hd
10-24
x
1/2
12
12
128
074
775
COVER,
bearing
2
2
,~
129
073
306
RING,
retaining
-
internal
3
130
073302
BEARING,ball
1
131
073
300
RING,
retaining
-
internal
1
132
074
827
GEAR,
helical
-
bronze
12
pitch
30
tooth
double
thread
No.
2
1
132
074
828
GEAR,
helical
-
bronze
12
pitch
30
tooth
triple
head
No.
3
1
133
134
076
871
074
822
PIN,
spring
3/16
x
1-1/2
GEAR,
miter
No.
2
1
1
1
134
074
823
GEAR,
miter
No.
3
1
135
078
672
PIN,
spring
3/16
x
7/8
1
1
136
073
304
GASKET,
cover
-
housing
drive
1
1
137
074
777
COVER,
housing
-
drive
1
1
3
OM-1512
Page
4
Item
Dia.
Factory
006
750
CB1
073676
R22
*073
361
S2,3
073362
R23
073562
075
308
073
756
TR1
030112
075
369
R25
030617
075
364
073
483
078
035
010
116
007
709
007
708
R18,19
074154
605
742
Ti
073630
075
117
2
4
2
2
4
1
No.
Mkgs.
Part
No.
Description
Quantity
Figu
re
C
075
325
Control
Box
(See
Fig.
A
Page
2
Item
13)
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
PANEL,
front
(attaching
hardware
C
&
P)
CIRCUIT
BREAKER,
manual
reset
7
amp
POTENTIOMETER,
carbon
1
turn
2
watt
55K
ohm
SWITCH,
toggle
SPDT
10
amp
250
volts
ac
POTENTIOMETER,
carbon
1
turn
2
watt
10K
ohm
CIRCUIT
CARD
ASSEMBLY
(attaching
hardware
A,
D
&
J)
(See
Fig.
Ci
Page
7)
SPACER,
hex
1/2
x
5/8
x
6-32
thread
(attaching
hardware
A
&
J)
THYRECTOR,
protector
-
surge
(attaching
hardware
K
&
N)
BASE
RESISTOR,
WW
adj
25
watt
2000
ohm
(attaching
hardware
A,
J
&
M)
COVER
(attaching
hardware
E,
G,
K
&
N)
RETAINER,
screw
FASTENER,
screw
GROMMET,
rubber
3/8
ID
x
1/2
mounting
hole
1/16
groove
BRACKET,
mounting
-
resistor
(attaching
hardware
E,
K
&
N)
SHIELD,
resistor
(attaching
hardware
G)
RESISTOR,
WW
fixed
100
watt
1.6
ohm
BRACKET,
mounting
-
resistor
(attaching
hardware
A,
J
&
M)
TRANSFORMER,
filament
26
volts
CT
115
volts
pri
(attaching
hardware
E,
K
&
N)
BRACKET,
mounting
-
components
Figure
C
Control
Box
TD-003
195-B
Page
5
/