OWN
ERS
MANUAL
hullER
fi
~
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
30
CENTS
March
1983
FORM:
OM-1092B
Effective
With
Style
No.
JA-41
MODEL
SPOO
L-PAK
ALE
COPY
RETURN
TO
FOL~c
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1,
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
(I
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
(11
repair
or
(2)
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
141
payment
of
or
credit
for
the
purchase
~
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
date
of
original
purchase.
return
of
the
goods
at
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
S
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
conlactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
~t5
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
(
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
. .
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
Ilabor
-
1
year
only)
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
seeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4,
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
3
S
6.
Batteries
6
months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
k4
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
130)
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
~,
J~
,.,
SECTION
1
-
INTRODUCTION
Dimensions
(Inches)
Weight
(Pounds)
Height
-
19
Width
-
9-1/2
23
Depth
-
17-3/4
Figure
1-1.
Specifications
1-1.
GENERAL
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
~resented
herein
should
be
given
careful
consideration
to
assu!e
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
will
be
furnished
by
the
manufacturer
on
request
if
occasion
to
file
claim
arises.
Wheh
requesting
information
concerning
this
equipment,
it
is
essential
that
Model
Description
and/or
Stock
Number
and
SeriŁl
(or
Style)
Numbers
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
This
unit
is
designed
to
enable
Spoolmatic
1
guns
to
utilize
8
or,
12
inch
spools
of
wire.
The
unit
is
used
in
conjunction
with
the
Spoolmatic
1
guns
and
WC-1
series
weld
controls
or
with
the
MM200
welding
power
source.
1-4.
SAFETY
Before
the
equipment
is
put
into
operation,
the
safety
sec
tion
at
the
front
of
the
welding
power
source
or
welding
generator
manual
should
be
read
completely.
This
will
help
avoid
possible
injury
due
to
misuse
or
improper
welding
applications.
The
following
definitions
apply
to
CAUTION
and
IM
PORTANT
blocks
found
throughout
this
manual:
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
per
sonnel.
I
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.
Conduit
Adapter
Biock
SECTION
2
-
INSTALLATION
TC-044
062
OM-1092
Page
1
Spool
Cover
Cover
Locking
Brake
Lockout
Knob
Figure
2-1
-
Component
Location
Brake
Control
Connector
2-1.
BRAKE
OPERATION
(Figure
2-1)
9.
Release
securing
pin
lever
and
ensure
outlet
guide
is
secured.
The
BRAKE
lockout
should
be
set
to
ON
for
normal
operation.
This
will
prevent
wire
backlash
when
the
gun
trigger
is
released
and
wire
feed
ceases.
The
BRAKE
lockout
should
be
set
to
OFF
for
loading
and
threading
welding
wire.
2-2.
INSTALLING
SPOOL-PAK
TO
WELD
CONTROL
OR
WELDING
POWER
SOURCE
Ensure
that
all
electrical
power
to
the
welding
power
source
and
the
weld
control
unit
is
completely
disconnected
prior
to
installation
of
the
Spool-Pak.
1.
Insert
brake
control
receptacle
RC1
into
plug
PLG1
on
the
rear
of
the
Spool-Pak
control
box.
2.
The
remaining
end
of
the
brake
control
cable
is
attached
to
the
contactor
control
in
the
weld
control
or
welding
power
source.
a.
For
WC-l
models:
Attach
the
black
and
white
leads
to
terminals
No.
5
and
2
on
terminal
strip
iT
or
across
the
Contactor
Control
receptacle
RC2.
Attach
the
green
lead
to
ground.
b.
For
MM200:
Attach
the
black
and
white
leads
to
terminals
No.
3
and
4
on
terminal
strip
iT.
Attach
the
green
lead
to
ground.
2-3.
INSTALLING
SPOOL-PAK
TO
SPOOLMATIC
GUN
1.
Remove
gun
spool
cover.
2.
Pivot
the
tension
arm
upward
and
pivot
the
mounting
arm
outward.
3.
Retract
the
welding
wire
onto
the
welding
wire
spool,
and
remove
the
wire
spool.
4.
Slip
the
ring
retainer
off
the
inlet
guide.
5.
Remove
the
inlet
guide
by
pushing
the
inlet
guide
towards
the
rear
of
the
gun.
Retain
inlet
guide
and
retainer
ring
for
future
reuse.
6.
Slide
Conduit
adapter
block
into
gun
wire
spool
aligning
groove
in
block
with
the
rib
in
the
gun
case.
7.
Route
outlet
guide
and
interconnecting
conduit
through
the
hole
in
rear
of
gun
case
(on
early
Spoolmatic
models
the
hole
will
need
to
be
altered
so
the
conduit
can
be
routed
straight
out
the
rear
of
the
gun).
8.
Depress
securing
pin
lever
and
insert
outlet
guide
from
Spool-Pak
interconnecting
conduit
through
adapter
block
and
into
gun
drive
housing.
10.
Open
side
access
door
on
Spool-Pak.
11.
Depress
securing
pin
lever
on
adapter
block
and
insert
remaining
end
of
interconnecting
conduit.
12.
Release
securing
pin
lever
and
ensure
interconnecting
conduit
is
secured.
2-4.
WELDING
WIRE
SPOOL
INSTALLATION
&
WELDING
WIRE
THREADING
(Figure
3-1)
flRT~T
Place
the
Spool-Pak
BRAKE
in
the
OFF
position
and
keep
the
interconnecting
conduit
as
straight
as
pos
sible
during
the
following
procedures.
2.
Remove
Spool-Pak
spool
cover.
3.
Depress
the
two
spring
loaded
stops
on
the
retaining
ring
on
the
Spool-Pak
wire
spool
spindle
and
remove
the
retaining
ring.
4.
Slide
spool
of
wire
onto
the
hub
so
that
the
wire
feeds
off
the
bottom
of
the
spool.
The
spool
turns
in
a
counterclockwise
direction.
5.
Rotate
the
spool
until
the
hole
in
the
spool
aligns
with
the
pin
in
the
hub.
Slide
the
spool
onto
the
hub
until
it
seats
against
the
back
flange
of
the
hub.
6.
Replace
retaining
ring.
7.
Cut
off
any
portion
of
the
welding
wire
that
is
not
straight
or
is
deformed.
8.
Thread
the
welding
wire
into
the
interconnecting
conduit
inlet
guide
and
push
wire
forward
until
it
passes
through
the
gun
drive
rolls
and
enters
the
wire
guide
liner.
9.
Pivot
the
mounting
arm
in
the
gun
in
and
pivot
the
tension
arm
down.
10.
Replace
gun
spool
cover.
11.
Place
the
Spool-Pak
BRAKE
in
the
ON
position
and
rotate
the
wire
spool
clockwise
to
take
up
the
wire
slack.
12.
To
replace
the
Spool-Pak
spool
cover,
align
notches
and
tip
cover
down
under
spring.
Tighten
spring
tension
by
rotating
the
cover
locking
knob
counter
clockwise.
SECTION
3-.
MAINTENANCE
~.r.uIlr.1~j
Ensure
that
all
electrical
power
to
the
welding
power
source
and
the
weld
control
unit
is
completely
disconnected
before
attempting
any
inspection
or
work
on
the
Spool-Pak.
3-1.
INSPECTION
AND
UPKEEP
Usage
and
shop
conditions
will
determine
the
frequency
and
type
of
maintenance.
Inspect
equipment
as
follows:
1.
Repair
or
replace,
as
required,
all
cable
and
conduit.
Give
particular
attention
to
frayed
and
cracked
insulation,
connections,
and
areas
where
the
cable
or
conduit
enters
equipment.
2.
Remove
grease
and
grime
from
components;
moisture
from
electrical
parts
and
cable.
Brake
Adjustment
Spring
Brake
Adjustment
Bracket
I
I
Brake
Lockout
Knob
Control
Box
Brake
Control
Receptacle
Figure
3-1.
Brake
Adjustment
A.049
182-A
Page
2
3.
Purge
the
interconnecting
conduit
with
compressed
air
when
changing
wire.
This
will
remove
any
metal
chips
and
dirt
that
may
have
accumulated.
3-2.
BRAKE
ADJUSTMENT
(Figure
3-1)
Spring
tension
on
the
BRAKE
may
be
adjusted
to
ensure
proper
stopping
of
the
wire
spool.
Loosen
securing
screws
on
rear
panel
of
control
box
and
slide
brake
adjustment
bracket
up
or
down.
Sliding
the
bracket
down
will
increase
the
brake
pressure,
thereby
causing
the
spool
to
stop
faster.
Some
small
slippage
of the
brake
is
necessary
to
keep
the
wire
from
snapping
as
the
wire
feed
motor
coasts.
When
the
proper
spring
tension
is
obtained,
tighten
the
screws.
SECTION
4
-
TROUBLESHOOTING
~I~~Il.]~IJ
Aazardous
voltages
are
present
on
the
internal
cir
cuitry
of
this
Unit
as
long
as
power
is
supplied
to
the
welding
power
source
and
weld
control.
Disconnect
power
before
attempting
any
inspection
or
work
on
the
inside
of
the
unit.
Troubleshooting
of
internal
circuitry
should
be
performed
by
qualified
personnel
only.
The
following
chart
is
designed
to
diagnose
and
to
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
unit.
It
is
assumed
that
proper
installation
ha~
been
made.
according
to
Section
2
of
this
manual,
and
that
the
unit
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
manufacturers
recommendations
should
be
strictly
followed.
TROUBLE
PROBABLE
CAUSE
SUGGESTED
CHECK
AND/OR
REMEDY
Wire
backlash
at
end
of
weld.
~
~
~
,
BRAKE
lockout
in
wrong
position.
Ensure
BRAKE
is
set
to
ON
for
normal
operation.
Brake
control
receptacle
RC1
loose.
Ensure
that
RC1
is
secure
in
plug
PLG1.
Brake
spring
tension
not
properly
adjusted.
Adjust
brake
spring
tension
(see
Section
3-2).
Wire
feeds
erratically.
I
I
~
I
~
~
I
Dirt
in
interconnecting
conduit
and/or
wire
guides.
Blow
dirt
out
of
conduit
and/or
wire
guides
using
compressed
air.
Interconnecting
conduit
not
secure
in
adapter
blocks.
Ensure
that
conduit
is
secured
in
adapter
blocks.
Problem
in
gun
and/or
weld
control.
See
gun
and/or
weld
control
Owners
Manual.
Interconnecting
conduit
and/or
wire
guides
worn.
Replace
conduit
and/or
wire
guides.
WIDE
SLOT
PLGi
PCi
Figure
4-1
-
Circuit
Diagram
A-081
643
501
~BSi
i
503
>
502
TO
GRN
CONTACTOR
Ii
CONTROL
CIRCUIT
BLK.
OM-1092
Page
3
March
1983
FORM:
OM-1092B
PARTS
LIST
Effective
With
Style
No.
JA-41
0
0
-v
1
2
3
4
5
6
5
7
10
11
12
31
15
B
28
32
31
30
11
26
25
22
21
20
TD-049
185-A
Figure
A
Main
Assembly
Item
Dia.
Part
No.
Mkgs.
No.
Description
Figure
A
Main
Assembly
Quantity
1
081
427
COVER,
spool
1
2
058
427
RING,
retaining
-
spool
1
3
010
909
NUT,
self
-
locking
hex
3/8-16
2
4
010
910
WASHER,
flat
-
SAE
3/8
2
5
056
068
KEY,
1/8
x
1/8
x
1/2
2
6
081
729
SHAFT,
spool
1
7
081
726
COLLAR,
locking
-
hub
1
8
058428
057
745
HUB,spool
SPRING,
compression
(used
w/8
inch
spool)
1
1
g
081
664
RING,
retaining
-
internal
5/8
x
0.042
1
10
604423
GRIP,handle
1
11
057544
SPRING,compression0.2400Dx
1
4
12
081
733
BAR,cam-brake
1
13
081
642
SPRING,
extension
3/8
ID
x
1/2
OD
x
27-5/8
inches
long
14
PLG1
039
871
RECEPTACLE,
twistlock
-
flange
midget
3P3W
10
amp
15
RC1
081
765
CORD,
control
(consisting
of)
16
603
031
.
CONNECTOR
BODY,
twistlock
midget
3P3W
15
amp
17
604
825
.
CORD,
No.
183/c
(order
by
ft)
18
Figure
B
SPOOLPAK
BRAKE
ASSEMBLY
(Pg
3)
19
I
081
124
PANEL,
side-
upright
20
605
394
PIN,
cotter
1/8
x
3/4
21
BS1
081
660
SOLENOID,
ll5voltsac60hz
22
081
736
TUBING,
0.138
ID
x
3/16
OD
x
1/8
23
081
125
LOCKOUT,
brake
24
047
162
BRACKET,
tension
-
spring.
.
.
25
045
889
PIVOT,
brake
release
26
010104
BLANK,snap-in3/8dia
27
019
609
KNOB,
pointer
28
045888
BASE
29
081
121
ADAPTER,conduit
2
30
:
058968
RING,retainerE
4
31
081
129
LEVER,
release
-
cover
2
32
081
730
PIN,
adapter
-
conduit
2
33
081
518
CONDUIT,
1/16
aluminum
wire
x
10
ft
(consisting
of)
1
34
081
732
.
GUIDE,
outlet
-
wire
1
35
I
081
128
.BODY,connector
2
36
604 612
.
SCREW,
set
-
socket
hd
8-32
x
1/8
2
37
058
720
-
CONDUIT,
1/16
aluminum
wire
x
10
ft
w/fittings
1
38
081
731
.
GUIDE,
inlet
-
wire
1
39
605
669
LATCH,
spring
-
knurled
head
1
40
081
132
LEVER,
release
-
cover
1
41
000 366
RING,
retainer
E
1/4
x
1/4
groove
1
1
25
ft
2
2
2
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1092
Page
2
I
tern
No.
Part
No.
Figure
B
Spool
Pak
Brake
Assembly
Description
Quantity
1
081
123
BLOCK,
bearing
-
support
2
2
024
801
BEARING,baII
2
3
081
764
BAND,
brake
1
4
081
734
TUBING,
rnirdrene
1-1/8
ID
x
1/16
wall
x
1-1/8
1
5
081
727
DRUM,
brake
1
6
081
659
SPRING,extension
1/4
IDx
1/32wirex2
1
7
081
738
TUBING,
5/16
OD
x
17
ga
wall
x
9/32
2
8
081
133
LEVER,
brake
1
9
081
728
LINK,
connecting
-
solenoid
1
10
081
737
TUBING,
5/16
OD
x
17
ga
wall
x
1-5/8
1
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
1
2
3
4
2
1
7
Figure
B
Spool
Pak
Brake
Assembly
TB-049
248
Page
3
Factory
Part
No.
Common
Hardware
Description
000419
602
070
602
075
605
138
6O4804~
081
661
602
112
i
602
154
602 004
601
954
602
180
602
199
602
198
602
201
602
203,
602
207
602
241
602
221
601
859~
601
860~
601
865~
605
883
601
892~
SCREW,
machine
-
steel
flat
hd
4-40
x
1-1/4
SCREW,
machine
-
steel
truss
hd
6-32
x
3/8
SCREW,
machine
-
steel
round
hd
6-32
x
1
SCREW,
machine
-
steel
round
hd
6-32
x
1-1/4
SCREW,
sheet
-
metal
hexagonal
washer
No.
8
x
3/8
SCREW,
machine
-
steel
round
hd
8-32
x
2-3/4
SCREW,
machine
-
steel
round
hd
10-24
x
1-1/4
SCREW,
self
-
tapping
hexagonal
washer
hd
1/4-20
x
1/2
SCREW,
cap
-
steel
socket
hd
1/4-20
x
3/4
SCREW,
cap
-
steel
hex
hd
1/4-20
x
3/4
SCREW,
set
-
steel
socket
hd
5/16-18
x
1/4
WASHER,
lock
-
steel
external
tooth
No.
6
WASHER,
lock
-
steel
split
No. 6
WASHER,
lock
-
steel
external
tooth
No.
8
WASHER,
lock
-
steel
split
No.
10
WASHER,
lock
-
steel
split
1/4
WASHER,
flat
-
steel
SAE
1/4
WASHER,
lock
-
internal
tooth
3/8
NUT,
hex
-
machine
screw
6-32
NUT,
hex
machine
screw
8-32
NUT,
hex
full
1/4-20
NUT,
hex
-
jam
3/8-24
RIVET,
blind
1/8
dia
x
1/4
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1092
Page
4
/
/
