Miller HJ195967 Owner's manual

Miller
Brand
Miller
Model
HJ195967
Category
Welding System
Type
Owner's manual

This manual is also suitable for

November
1978
FORM:
OM-1518
FIILE
CQp
EFURN
TO
FOLDER
OV~NEHS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Bo~
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
70
CENTS
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
EffectiveWith
Seria
No.
HJ195967
MODEL
AUTOMATIC
I
i~
LIMITED
WARRANTY
EFFECTIVE:
FEBRUARY
20,
1978
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYMiller
Electric
Mfg.
Co..
Apple-
1.
Arc
welders,
power
sources,
and
components.
-
1
year
ton,
Wisconsin
warrants
to
Customer
that
all
rrew
and
unused
2.
Original
main
power
rectifiers
3
years
Equipment
furnished
by
Miller
is
free
from
defect
in
(Labor
1
year
only)
warkmanship
and
material
as
of
the
time
and
place
of
3.
All
welding
guns
and
feeder/guns
90
days
delivery
by
Miller.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manu-
4.
All
other
Millermatic
Feeders
1
year
factured
by
others.
Such
engines,
trade
accessories
and
other
provided
that
the
user
so
notifies
Miller
in
writing
within
thirty
)
items
are
sold
subject
to
the
warranties
of
their
respective
(30)
days
of
the
date
of
such
failure.
manufacturers,
if
any.
The
manufacturers
warranty
on
5.
Replacement
or
repair
parts
exclusive
of
labor
60
days
engines
i~
for
~
period
Of
one
year.
MILLER
warranty
does
not
apply
to
components
having
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
HEREIN
AND
ANY
IMPLIED
WARRANTY.GUARANTY
welder
tips,
relay
and
contactor
points,
M!LLERMATIC
OR
REPRESENTATION
AS
TO
PERFORMANCE.
AND
parts
that
come
in
contact
with
the
welding
wire
including
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
nozzles
and
nozzle
insulators
where
failure
dQes
not
result
.
&UT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
14
from
defect
in
workmanship
or
material.
IMPLICATION.
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ANY
In
the
case
of
Millers
breach
of
warranty
or
any
other
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR OF
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefor
shall
be,
at
Millers
option,
(1)
repair
or
(2)
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
replacement
or,
where
authorized
in
writing
by
Miller
in
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
~
replacement
at
an
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
depreciation
based
upon
actual
use)
upon
return
of
the
goods
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
at
Customers
risk
and
expense.
All
transactions
are
F.O.B.
Appleton,
Wisconsin.
Upon
receipt
of
n&ice
of
apparent
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
warranty
claim
procedures
to
be
followed.
OF
WELDING
EQUIPMENT
AND
NOT,
FOR
CONSUMERS
As
a
matter
of
general
policy
only.
Miller
may
honor
an
OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
original
useri
warranty
claims
on
warranted
Equipment
in
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
EXTEND
MILLERS
WARRANTIES
TO,
ANY
the
original
user:
CONSUMER.
..,~
~%
j~:~
-~
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
Item
Dia.
Part
No.
Listed
Replaced
With
No.
Mkgs.
In
Parts
List
Part
No.
Description
Quantity
5
S2
011
059
011
043
SWITCH,
toggle
DPDT
6
amp
125
volts
(Eff
with
S/N
HJ21
5887)
1
117
M
059
138
080
802
MOTOR,
gear
1/8
hp
115
volts
dc
2000
rpm
1
141
079911
080868
INSULATOR,
motor
1
142
079 910
080
869
BRACKET,
mounting
-
motor
1
080
806
STOP,
cover
1
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
FIILE:
copy
4~
Ui~
~o
~
OM-1518
Page
A
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
designoccurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
Item
Dia.
Part
No.
Listed
Replaced
With
No.
Mkgs.
In
Parts
List
Part
No.
Description
011
043
SWITCH,
toggle
DPDT
6
amp
125
volts
(Eff
with
S/N
HJ21
5887)
080
802
MOTOR,
gear
1/8
hp
115
volts
dc
2000
rpm
080
868
INSULATOR,
motor
080
869
BRACKET,
mountir~g
.
motor
080
806
STOP,
cover
OM-1518
Page
A
5
S2
011
059
-
117
M
059138
141
079911
142
079910
Quantity
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
1
1
1
1
1
TABLE
OF
CONTENTS.
Section
No.
Page
No.
SECTION
1
INTRODUCTION
1-
1.
General
1
1
-
2.
Receiving-Handling
1
1
.
3.
Description
1
1-4.
Safety
1
SECTION
2INSTALLATION
2-
1.
Location
1
2-
2.
Control/Feeder
Interconnections
2
2
-
3.
Voltmeter
connections
2
2-
4.
Contactor
Connections
2
2-
6.
Secondary
Cormoctions
~Rever;e
Polarity)
2
2-
6..
Shielding
Gas
Connections
3
2-7.
Drive
Roll
And
Wire
Guide
Installation
3
2-
8.
Spindle
Assembly
Installation
4
2-
9.
Installation
Of
Spool-Type
Wire
4
2-10.
Installation
Of
Wire
Reel
(Optional)
4
2-11.
Installation
Of
Reel-Type
Wire
4
2-12.
Adjusting
Hub
Tension
4
2-13.
Welding
Wire
Threading
4
2-14.
Remote
Start
And
Stop
Connections
5
2-15.
Electrical
Input
Connections--~
5
SECTION
3
FUNCTION
OF
CONTROLS
3-
1.
Power
Switch
5
3-2.
Pilot
Light
5
3.
3
Retract-Advance
Switch
And
Inch
Push
Button
Switch
6
3-
4.
Purge
Push
Button
Switch
6
3-
5.
Start
Push
Button
Switch
6
3-
6.
Stop
Push
Button
Switch
6
3-7.
Run
In
Speed
Control
6
3-
8.
Wire
Feed
Speed
Control 6
3-
9.
Crater
&
Inch
Speed
Control
6
3-10.
Pre-Flow
Time
Control
6
3-11.
Spot-ContinuousSwitch
6
3-12.
Spot
Time
Control
6
3-13.
Crater
Time
Control
.6
3-14.
Burnback
Control
6
3-15.
Post-Flow
Time
Control
6
3-16.
Meters
7
3-17.
Overload
Protection
7
3-18.
Normally
Open
And
Normally
Closed
Contacts
7
SECTION
4SEQUENCE
OF
OPERATION
4-
1.
Gas.
Metal-Arc
Welding
(GMAW)
Continuous
7
4
-
2.
Gas
Metal-Arc
Welding
(GMAW)
Spot
7
4-
3.
Shutting
Down
7
SECTION.
5-.-MAINTENANCE
5-
1.
Inspection
And
Upkeep
8
5
-
2.
Cleaning
Of
Drive
Rolls
8
SECTION
6
TROUBLESHOOTING
44
SECTION
1
-
INTRODUCTION
Dimensions
(Inches)
Weight
(Pounds)
Height
Width
Depth
Weld
Control
15-1/2
13-7/8
6-1/8
29.5
Gas/Shunt
Control
4-1/8
5-1/8
10-1/2
5.5
Drive
Motor
10-1/4
11-1/2
9-1/4
18
Spindle
Assembly
21-7/8
10-11/16
19-112
6
Figure
1-1.
Specifications
I
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,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
Under
this
heading,
~nttelbrion,
operat~ng,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
tnay
create
a
hazard
to
per
sonnel.
L.
.
.
r~NTF:
-
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.
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
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
1-2.
RECEIVING-HANDLING
Prior
so
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
~r,d
~arefuiiy
inspect
for
an~
dem~ge
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
dam~ge
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
equipmentbe
supplied.
1
.
3.
DESCRIPTION
This
control/feeder
is
designed
to
automaticdlly
cycle
prepro
grammed
welding
events
and
provide
a
constant
wire
feed
speed
regardless
of
varying
motor
load
conditions.
This
unit
is
to
be
used
with
a
constant
potential
welding
power
source.
The
standard
weld
control
has
provisions
to
program
the
PRE-FLOW
TIME,
RUN
IN
SPEED,
WIRE
FEED
SPEED,
SPOT
TIME.
CRATER
&
INCH
SPEED,
CRATER
TIME,
BURNBACK
time,
and
POST-FLOW
TIME.
Normally
open
and
normally
closed
contacts
are
provided
on
each
time
control
to
interface
with
other
equipment
(i.e.,
starting
and
stoping
a
welding
fixture).
1-4.
SAFETY
Before
the
equipment
is
put
into
operation,
the
safety
sec
tion
at
the
front
of
the
welding
power
source
or
welding
~SECTION2-
2-1.
LOCATION
/
A
proper
installation
Site
should
be
sele~ted
for
the
control/
feeder
if
the
Unit
is
to
provide
dependable
service
and
remain
relatively
maintenance
free.
/
A
proper
installation
site
permits
freedom
of
air
movement
around
the
weld
control
and
also
least
subjects
the
control!
feeder
to
dust,
dirt,
moisture,
and
corrosive
vapors.
The
installation
site
should
also
permit
efficient
placement
of
all
components
to
provide
optimum
performance.
Provisions
have
been
made
for
mounting
the
gas/shunt
assembly
on
the
bottom
of
the
weld
control.
The
gas/shunt
assembly
may
also
be
mounted
in-line-with
the
welding
gun
thereby
avoiding
routing
the
weld
cables
and
gas
hpses
back
to
the
weld
control.
The
drive
motor
and
spindle
assembly
should be
placed
close
together
near
the
work
area.
The
pivot
bracket
can
be
removed
from
the drive
assembly
and
repositioned
for
ease
of
installation.
Remove
the
hex
head
screw
and
lock
washer
from
the
pivot
bracket
and
reposition
the
bracket;
replace
hardware
(see
Figure
2-4).
The
drive
motor
is
attached
to
a
ball
joint
and
mounting
bar
for
ease
of
installation.
Loosen
the
two
hex
head
bolts
on
the
ball
joint
and
adjust
the
position
of
the
drive
motor;
tighten
the
botts
to
lock
the
drive
motor
in
position.
The
installation
sight
should
also
permit
easy
access
to
all
components
for
operational
and
maintenance
functions.
Lead
lengths
must
be
considered
when
locating
all
components
of
the
control/
feeder.
-
NOTE
1
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
INSTALLATION
TC-080
430
Figure
2-1.
Overall
Dimensions
And
Mounting
Hole
Layout
(Continued
On
Next
Page)
OM-1
518
Page~
1
TB-080
486
Figure
2-1.
Overall
Dimensions
And
Mounting
Hole
Layout
(Contd.)
Mounting
holes
are
provided
in
all
components
of
the
control/feeder.
Figure
2-1
gives
overall
dimensions
and
mounting
hole
layout.
2-2.
CONTROL/FEEDER
INTERCONNECTIONS
A.
Drive
Motor
Connections
Insert
three-pole
plug
PLG6
from
the
weld
control
into
plug
PLG1
1
at
the
drive
motor.
Rotate
plug
PLG6
threaded
outer
ring
clockwise
into
plug
PLG11
threaded
body
as
far
as
possible.
This
action
will
secure
the
connection.
B.
Control
Cable
Connections
Insert
ten-pole
plug,
PLG7
from
the
weld
control
into
receptacle
RC7
on
the
gas/shunt
assembly.
Rotate
the
plug
threaded
outer
ring
clockwise
into
the
receptacle
threaded,
body
as
far
as
possible.
This
action
will
secure
the
plug
in
the
receptacle.
-
-
2-3.
VOLTMETER
CONNECTIONS
For
reverse
polarity,
connect
the
lead
with-
ring
terminal
from
the
weld
control
voltmeter
to
the
negative
output
terminal
on
the
welding
power
source.
For
straight
polarity,
connect
the
lead
with
the
ring
terminal
from
the
weld
control
voltmeter
to
the
positive
output
terminal
on
the
welding-power
source.
Reverse
the
leads
on
the
weld
control
voltmeter
and
ammeter.
2-4.
CONTACTOR
CONNECTIONS
Insert
two-pole
twistlock
plug
PLG8
into
the
contactor
control
receptacle
on
the
welding
power
source
and
rotate
the
plug
as
far
as
it
will
turn
in
a
clockwise
direction.
Once-
fully
rotated,
the
plug
will
be
locked
in
the
receptacle.
2-
5.
SECONDARY
CONNECTIONS
(Reverse
Polarity)
-
(Figure
2-2)
1.
Remove
the
gas/shunt
assembly
cover.
2.
Insert
the
proper
size
weld
cable
from
the
positive
output
terminal of
the
welding
power
source
through
the
grommet
on
the
IN
side
of
the
gasfshunt
assembly.
Connect
the
weld
cable
to
the
shunt.
-
3.
Insert
the
proper
size
weld
cable
from
the
weld
cable
terminal
on
the
drive
motor
(Figure
2-3)
through
the
grommet
on
the
other
end
of
the
gas/shunt
assembly.
This
cable
must
be
routed
through
the
reed
switch
bracket.
Connect
the
weld
cable
to
the
shunt.
4.
Connect
the
proper
size
weld
cable
from
the
negative
output
terminal
of
the
welding
power
source
to
the
work.
5.
Replace
the
gaslshunt
assembly
cover.
-
Figure
2-2.
Gas/Shunt
Assembly
TA-080
485
4.18~
-~
5116
Diameter
-
2Holes
~T.
9-7/8
-
10-1/2
-
TA-080
429
To
Welding
Power
Source
Positive
Output
To
Weld
Cable
Terminal
On
Drive
Motor
Control
cable
Receptacle
RC7
TA-080
424
Page
2
2-
6.
SHIELDING
GAS
CONNECTIONS
(Figures
2-2
&
2-3)
Connect
a
hose
of
suitable
length
and
construction
from
.the
shielding
gas
supply
to
the
connector
on
the
IN
side
of
the
gas/shunt
assembly.
The
gas
flow
must
be
accurately
controlled
by
a
regulator
and
flowmeter
at
the
source.
Connect
the
supplied
hose
from
the
gas/shunt
assembly
to
the
barbed
fitting
on
the
motor/drive
assembly.
2-7.
DRIVE
ROLL
AND
WIRE
GUIDE
INSTALLATION
(Figure
2-3
&
2-4)
Upon
initial
installation,
or
as a
result
of
changes
in
wire
size
and
type,
it
is
necessary
to
install
the
required
drive
rolls
and
wire
guides.
~~lection
of
d
rive
rofls
upon
the
f
ollowing
recommended
usages:
1.
V-Groove
rolls
for
hard
wire.
2.
U-Groove
rolls
for
soft
~,nd
soft
shelled
cored
wiros
3.
U-Cog
rolls
for
extremely
soft
shelled
wires
(usually
hard
surfacing
types).
4.
Split
V-Knurled
rolls
for
hard
shelled
cŁred
wires
(self-shielding
and
CO2
shielded
types).
5.
Drive
roll
types
may
be
mixed
to
suit
particular
requirements
(example:
V-knurled
roll
in
combination
with
U-groove).
Having
selected
the
appropriate
drive
rolls
and
wire
guides,
proceed
to
the
following
installation
instructions:
Figure-2-3.
One-Piece-Drive
Roll
Installation
A.
One
Piece
Drive
Roll
(Figure
2-3)
NOTE
1Drive
rolls
(8
&
13)
are
of
the
double
usage
type.
When
the
grooves
become
worn,
reverse
each
drive
roll,
locating
the
unused
groove
in
position
to
feed
the
wire.
1.
Loosen
the
pressure
adjustment
wing
nut
(item
2,
Figure
2-3)
and
pivot
it
free
of
the
cover.
2.
Pivot
gear
cover
(4)
away
until
it
is
in
an
open
postion.
3.
Loosen
and
remove
the
three
securing
screws
(7
&
12)
on
each
drive
roll
gear
(5
&
9).
4.
Slide
one
drive
roll
(13)
Onto
lower
gear
(9)
with
holes
-~
aligned.
Insert
securing
screws
(12)
and
tighten.
NOTE
1
To
ensure
proper
gripping
action
of
U-Cog
drive
rolls,
1
both
rolls
should
be
installed
showing
slots
on
the
side
or
both
should
show
the
side
without
slots.
Also,
it
is
necessary
to
line
up
the
blunted
teeth
on
the
upper
roll
directly
over
the
spaces.
between
the
teeth.
on
the
roll
as
illustrated
in
Figure
2-3.
5.
Slide
remaining
drive
roll
(8)
Onto
upper
gear
(5~
witl~
holes
aligned.
Insert
securing
screws
(7)
and
tighten.
B.
Split
Drive
Roll
(Figure
2-4)
Drive
rolls
(6
&
10)
are
of
the
double
usage
type.
When
the
knurled
groove
of
the
drive
rolls
becomes
worn,
the
split
halves
may
be
reversed
so
that
the
unused
edges
will
provide
a
new
knurled
groove.
2.
Pivot
gear
cover
(4)
away
until
it
is
in
an
open
position.
3.
Loosen
and
remove
the
three
securing
screws
(7
&
12)
on
each
drive
roll
gear
(5&
9).
4.
Separately
align
the
holes
on
each
pair
of
split
drive
rolls
(6
&
10)
and
insert
a
securing
screw
(7
&
12).
5.
Slide
a
pair
of
drive
rolls
(10)
with
securing
screw
(12)
onto
the
lower
gear
(9)
in
line
with
one
of
the
threaded
holes.
6.
Insert
remaining
screws
and
tighten.
7.
Repeat
steps
4
through
6
for
installation
of
upper
drive
rolls.
C.
Inlet
Wire
Guide
(Figure
2-3
&
2-4)
1.
Loosen
the
inlet
wire
guide
securing
screw
(item
3,
Figure
2-3).
I
NOTEJ~
1~ire
guides
should
be
installed
so
that
the
tip
of
the1
guide
is
as
close
to
the
drive
roll
as
possible
without
~~Jching.
I
Ball
Joint
Hex
Nuts
~
Ball
Joint
A
Pivot
Brat
Pivot
Bracket
-
HexNut
15
TC-080431
Weld
Cable
Terminal
Figure
2-4.
Split
Drive
Roll
Installation
1.
Loosen
the
pressure
adjustment
wing
nut
(item
2,
Figure
2-4)
and
pivot
it
free
of
the
cover.
Barbed
Gas
Fitting
On
Rear
Of
Assembly
OM-1518
Page
3
2.
Insert
the
inlet
wire
guide
into
drive
assembly
as
illustrated
in
Figure
2-3.
Secure
by
tightening
screw.
~nd
the
lowe
r
d
rive
ra
spring
wash
er
(s).
To
obtain
proper
alignment
of
the
lower
drive
roll
with
the
wire
guides
rotate
the
drive
roll
gear
securing
bolt
(11)
thereby
moving
the
drive
roll
in
or
out
to
the
desired
position.
The
top
drive
roll
will
locate
itself
on
the
wire
when
the
gear
cover
is
replaced
and
the
gears
~
mesh
together.
The
wire
drive
housing
is
made
with
mounting
holes
of
sufficient
clearance
to
provide
adjustment
of
the
wire
guides
up
or
down
in
relation
to
the
drive
rolls.
This
adjustment
has
been
factory
set,
but
if
the
adjustment
becomes
necessary.
loosen
mounting
bolts
(item
14,
Figure
2-3)
and
weld
terminal
nut
(15).
Slide
the
wire
drive
housing
upward
or
downward
until
the
wire
can
be
fed
straight
through
the
guides
while
seated
in
the
drive
roll
groove.
Tighten
mounting
bolts
and
weld
terminal
nut.
2-8.
SPINDLE
ASSEMBLY
INSTALLATION
(Figure
2-5)
1.
Insert
spindle
support
shaft
(item
15,
Figure
2.5)
into
the
desired
hole
in
spindle
support
(16).
The
hole
to-be
utilized
in
the
spindle
support
116)
will
~Jepend
on
the
size
of
the
wire
spool
being
used.
-
2.
Secure
spindle
support
shaft
(15)
with
cotter
pin
(17).
3.
Slide
the
following
items
onto
the
spindle
support
shaft
(15)
in
Order
given:
A.
Fiber
Wather
(14)
B.
Flat
Washer
(13)
C.
Hub
(12)
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
(15).
Hex
nut
(3)
should
be
rotated
only
until
a
slight
drag
is
felt
while
turning
hub
(12).
Figure
2-5.
Hub
And
Reel
Installation
2-9.
INSTALLATION
OF
SPOOL-TYPE
WIRE
(Figure
2-5)
1.
Slide
the
spool
of
wire
onto
the
hub
so
that
the
wire
feeds
off
the
bottom
or
top
(depending
on
installation)
with
the
minimum
bend
and
sharp
radius.
2.
Rotate
the
spool
until
the
hole
irs
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.
-
3.
Depress
the
two
spring-loaded
stops
(item
1,
Figure
2-5)
on
the
retaining
ring
(2)
and
slide
the
retaining
ring
into
proper
position
on
the
hub
(12).
Release
the
two
stops
(1).
-
2-10.
INSTALLATION
OF
WIRE
REEL
(Optional)
(Figure
2-5)
1.
Slide
the
wire
reel
(item
11.
Figure
24)
onto
the
hub
-
(12).
Rotate
the
wire
reel
(11)
Until
the
hub
guide
pin
is
seated
in
the
reel
(11).
2.
Depress
the
two
spring.loaded
stops
(1)
on
the
retaining
ring
(2)
and
slide
the
retaining
ring
(2)
into
proper
position
on
the
hub
(12).
Release
the
two
stops
(1).
4
2-11.
INSTALLATION
OF
REEL-TYPE
WIRE
(Figure
2-5)
-
-
1.:
Loosen
the
four
wing
nuts
(item
9,
Figure
2-5)
on
the
-
-
fingers
110)
or
the
wire
reel
~1
1).
2.
Pull
the
four
fingers
(10)
Out
until
they
can
be
rotated
toward
the
center
of
the
reel
(11).
3.
Install
the
wire
onto
the
reel
(11)
over
the
four
fingers
(10).
-
2-12.
ADJUSTING
HUB
TENSION
(Figure
2-5)
Check
hub
tension
by
slowly
pulling
wire
toward
the
feed
roll.
~rhe
wire
should
unwind
freely,
but
the
hub
tension
should
be
sufficient
to
keep
the
wire
taut
and
prevent
backlash
when
the
control/feeder
is
shut
off.
If
adjustment
is
required,
loosen
or
tighten
the
hex
nut
(item
3,
Figure
2-5)
on
the
end
of
the
spindle
support
shaft
(15)
accordingly.
2-13.
WELDING
WIRE
THREADING
1.
Connect
the
gun
to
the
drive
motor
assembly.
2.
Loosen
the
wing
nut
on
the
drive
roll
pressure
adjustment,
pivot
the
drive
roll
pressure
adjustment
free
of
the
cover,
and
pivot
the
pressure
gear
assembly
away
until
it
is
in
an
open
position.
3.
Cut
off
any
portion
of
the
free
end
of
the
welding
wire
which
is
not
straight.
Feed
the
welding
wire
through
the
inlet
wire
guide
in
thedrive
roll
assembly.
4.
Continue
to
feed
the
welding
wire
through
the
outlet
wire
guide.
5.
Pivot
the
pressure
gear
assembly
to
a
closed
position
--
making-sure
the
teeth
on
the
upper
gear
mesh
with
lower
drive
gear.
The
welding
wire
must
also
be
in
the
grooves
of
the
upper
and
tower
drive
rolls.
6.
Pivot
the
drive
roll
pressure
adjustment
into
the
slot
on
the
pressure
gear
assembly
making
sure
the
lower
flat
washer
is
above
the
pressure
gear
casing.
7.
Turn
the
wing
nut
on
the
drive
roll
pressure
adjust
ment
in
a
clockwise
direction
until
the
drive
rolls
are
tight
against
the
welding
wire.
Do
nor
overtighten.
Further
adjustment
can
be
made
after
the
welding
power
source
and
control/feeder
are
put
into
oper
ation.
8.
Energize
the
welding
power
source.
9.
Place
the
control/feeder
POWER
switch
in
the
ON
position.
10.
Set
the
CRATER
&
INCH
SPEED
control
to
desired
position.
Place.
the
RETRACT-ADVANCE
switch
in
the
ADVANCE
position.
11.
Depress
the
INCH
switch.
This
will
run
the
welding
wire
through
the
gun
without
placing
weld
current
on
the
welding
wire.
Release
the
INCH
switch
alter
the
4.
Rotate
the
four
fingers
(10)
back
to
their
proper
position.
Tighten
the
four
wing
nuts
(9).
5.
Proceed
to
install
welding
wire
according
to
the
applicable
Section:
2-9
for
spool-type
wire;
and
2-10,
2-11
for
reel-type
wire.
-
-
5
6 7
8
9*
10*
11*
13
16
17
*Optjona$
Page
4
end
of
the
welding
wire
is
approximately
one
inch
out
of
the
end
of
the
gun
tip.
2-14.
REMOTE
START
AND
STOP
CONNECTIONS
For
remote
control
of
starting
and
stopping,
connections
must
be
made
to
terminal
strips
11
and
2T
in
the
weld
control.
Loosen
screw
from
door
on
upper
panel
of
the
weld
control
and
open
door.
Terminal
strips
1
T
and
2T
are
located
on
the
right
side
of
the
control.
A.
Momentary
Contact
Push
Button
Switch
1.
Remove
jumper
between
iT
J
and
iT
11.
2.
Route
cable
from
switch
through
the
cable
clamp
on
the
right
side
of
the
weld
control.
3.
Attach
two
leads
from
the
normally
open
(start)
switch
to
lTHandlTK.
4.
Attach
two
leads
from
the
normally
closed
(stop)
switch
to
1TJ
and
1TH.
B.
Maintained
Contact.(ReIa
itch
1.
Rnove,umperbetwce
TJ
d
17,1-I.
2.
Route
cable
from
relay
t
rou9h
the
cable
clamp
on
the
right
side
of
the
weld
control.
3.
Connect
the
normally
open
maintained
cntact
of
the
-
-
relaytolTJandlTK.
.
.
.
4.
Closing
relay
Contact
will
start
unit
and
opening
relay
contact
will
stop
unit.
C.
Skip
Welding
1.
Removejumperlink
between
ITH
and
iTG.
2.
Route
cable
from
double-pole,
single
throw
maintained
contact
switch
through
the
cable
clamp
on
the
right
side
of
the
weld
control.
3.
Attach
leads
from
one
set
of
contacts
of
iT
H
and
iT
G.
4.
Attach
leads
from
the
other
set
of
contacts
to
iT
H
and
2T
A.
5.
Set
SPOT-CONTINUOUS
switch
to
SPOT
position.
6.
Closing
switch
will
start
weld
cycle
and
unit
will
weld
for
the
time
set
on
the
SPOT
TIME
control.
Wcld
current
ie
not
present
for
pre-flow
or
post-flow.
The
unit
will
automatically
recycle
through
the
weld
cycle
until
the
switch
is
opened.
After
all
connections
are
secured,
close
door
on
upper
panel-
of
wclo.
control
end
tighten
screw.
2-15.
ELECTRICAL
INPUT
CONNECTIONS
Insert
three-pole
twistlock
plug
PLG9
into
a
115
volts
ac
power
supply
and
rotate
the
plug
as
far
as
it
will
turn
in
a
clockwise
direction.
Once
fully
rotated,
the
plug
will
be
locked
in
the
receptacle.
SECTION
.3
-
FUNCTION
OF
CONTROLS
PreFloW
Tlme~
Spot-Continuous
Switch
Figure
3-1.WeId
Control
3-
1.
POWER
SWITCH
(Figure
3-1)
Placing
the
POWER
switch
in
the
OFF
position
does
not
remove
power
from
all
of
the
control/feeders
internal
circuitry.
Completely
terminate
all
electrical
power
to
the
control/feeder
by
removing
the
115
volts
ac
plug
from
its
power
supply,
and
ensure
that
machinery
lockout
procedures
have
been
employed
on
the
welding
power
sources
input
line
(see
Instruction
Manual
on
welding
power
source)
before
attempting
any
inspection
or
work
inside
the
unit.
Placing
the
POWER
switch
on
the
control/feeder
in
the
ON
position
will
apply
115
volts
ac
to
the
unit
and
thereby
place
it
in
an
operational
condition,
permitting
the
preprogrammed
welding
cycle
to
start
when
the
START
button
is
depressed,
or
gas
to
flow
when
the
PURGE
button
is
depressed,
or
welding
wire
to
feed
if
the
INCH
switch
is.depressed.
Placing
the
POWER
switch
in
the
OFF
position
will
shut
the
control/feeder
down.
3-2.
PILOT
LIGHT
(Figure
3-1)
The
pilot
light
PL1,
when
illuminated,
indicates
that
the
control/feeder
POWER
switch
is
ON
and
the
unit
is
ener
gized.
~fO~
ac
maybe
present
on
throl/feeder
internal
circuitry
even
though
the
pilot
light
is
not
illuminated
and
the
POWER
switch
is
in
the
OFF
position.
Completely
terminate
all
electrical
power
to
the
control/feeder
by
removing
the
115
volts
ac
plug
from
its
power
supply.
Votnietev
Ammeter,,
Fuse
Pilot
Light
Circuit
Breaker
Start
Switch
Stop
Switch
Run
In
Speed
~
Wire
Feed
Speed
Crater
&
Inch
Speed
Inch
Push
Button
Push
Button
/
Spot
Time
Crater
Time
BurnbaCk
~PostFloW
Time
TC-080
430
OM-1518
Page
5
3-9.
CRATER
&
INCH
SPEED
CONTROL
(Figure
3-1)
3-3.
RETRACT-ADVANCE
SWITCH
AND
INCH
PUSH
BUTTON
SWITCH
(Figure
3-1)
With
the
RETRACT-ADVANCE
switch
in
the
RETRACT
position,
the
welding
wire
will
retract
into
the
gun
at
the
speed
set
by
the
CRATER
&
INCH
SPEED
control
only
while
the
INCH
push
button
switch
is
depressed.
With
the
RETRACT-ADVANCE
switch
in
the
ADVANCE
position,
the
welding
wire
will
advance
from
the
gun
at
the
speed
set
by
the
CRATER
&
INCH
SPEED
control
only
while
the
INCH
push
button
switch
is
depressed.
The
INCH
push
button
switch
is
a
normally
open,
momen
tary
contact
switch.
Depressing
the
switch
will
energize
the
drive
motor
without
energizing
the
welding
power
source
contactor
or
gas
control
circuitry.
3-4.
PURGE
PUSH
BUTTON
SWITCH
(Figure
3-1)
-~
The
PURGE
push
button
switch
is
a
normally
open,
momentary
contact
switch.
Depressing
the
push
button
will
energize
the
gas
solenoid
and
thereby
purge
the
shielding
gas
line
to
the
gun...~..
-
---..,.~.--~-
3-5,
START
P!JSH~UTTQN
SWITCH
(F~gur~
3-1
&
3-2)-
Depressing
the
START
push
button
switch
will
start
the
preprogrammed
weld
cycle.
See
Figure
3-2
for-weld
cycle
events.
The
weld
cycle
will
continue
until
the
STOP
push
button
switch
is
depressed
or
the
SPOT
TIME
times
Out.
Ei
II
.-
-
CR5&01--1
1__~
-
&
_____________
__
CRS5*0}.._____.~l
-
L
~
-
CR5001
E1
CR51O,_____~
Run
In
Speed
o
,
Weld
Time
Spot
Time
a,
0-
infinity
r
0-2.5
Sec.
a,
E
~
.
Surnback
Time
~
~
0
Crater
Time
o-.25
sec.
~
crater&inz~fl~~~sFime
Arc
STOP
Time
START
Initiation
TB-080
432
The
0
condition
indicates
the
time
during
the
weld
cycle
that
the
control
relay
is
deenergized.
The
E
condition
indicates
the
time
during
the
weld
cycle
that
the
control
relay
is
energized.
See
Section
3-18
for
information
on
connecting
relays
to
interface
with
associated
equipment.
Figure
3-2.
Weld
Control
Cycle
3-
6.
STOP
PUSH
BUTTON
SWITCH
(Figure
3-1
&
3-2)
Depressing
the
STOP
push
button
switch
will
initiate
the
preprogrammed
crater
fill,
burnback,
and
post-flow
time.
See
Figure
3-2
for
weld
cycle
events.
3-7.
RUN
IN
SPEED
CONTROL
(Figure
3-1)
The
RUN
IN
SPEED
control
provides
a
means
of
selecting
the
rate
at
which
welding
wire
will
feed
prior
to
arc
initiation.
After
arc
initiation,
the
wire
feed
speed
is
governed
by
the
WIRE
FEED
SPEED
control.
The
RUN
IN
SPEED
control
is
marked
0-100
for
reference.
When
the
control
is
set at
0,
wire
will
feed
at
the
slowest
rate;
when
set at
100,
wire
will
feed
at
the
fastest
rate.
-
3-
8.
WIRE
FEED
SPEED
CONTROL
(Figure
3-1)
The
WIRE
FEED
SPEED
control
provides
a
means
of
selecting
the
rate
at
which
welding
wire
will
feed
into
the
weld
during
the
welding
cycle.
The
WIRE
FEED
SPEED
control
is
marked
0-100
for
reference.
When
the
control
is
set
at
0,
wire
will
feed
at
the
slowest
rate;
when
set
at
100,
wire
will
feed
at
the
fastest
rate;
The
CRATER
&
INCH
SPEED
control
provides
a
means
of
selecting
the
rate
at
which
wire
will
feed
into
the
weld
during
the
crater
fill
time
and
the
rate
at
which
wire
will
advance
or
retract
when
the
INCH
switch
is
depressed.
The
CRATER
&
INCH
SPEED
control
is
marked
0-100
for
reference.
When
the
control
is
set
at
0,
wire
will
feed
at
the
slowest
rate;
when
set
at
tOO,
wire
will
feed
at
the
fastest
rate.
-
3-10.
PRE-FLOW-TIME
CONTROL
(Figure
3-1)
An
adjustable
0
to
5
PRE-FLOW
TIME
control
is
provided
for
selecting
the
period
of
time
the
shielding
gas
flows
before
-
arc
initiation.
The
PRE-FLOW
TIME
control
starts
to
time
when
the
START
switch
is
depressed.
Rotating
the
control
in
a
clockwise
direction
increases
the
pre-f
low
time.
The
scale
surrounding
the
PRE-F
LOW
TIME
-
control
s
calibrated
in
seconds
to
aid
in
the
selection
of
a
pre-flow
time
period
suited
to
the
individual
welding
oper
ation.
--
-
3-11.
SPOT-CONTINUOUS
SWITCH
(Figure
3-1)
-
The
SPOT-CONTINUOUS
switch
provides
the
means
to
select
either
normal
weld
cycle
or
a
timed
weld
cycle.
Placing
the
SPOT-CONTINUOUS
switch
in
the
SPOT
position
will
provide
a
timed
weld
as
determined
by
the
SPOT
TIME
control.
Placing
the
SPOT-CONTINUOUS
switch
in
the
CONTINUOUS
position
will
cause
the
control/feeder
to-,
operate
normally.
-
3-12.
SPOTTIME
CONTROL
(Figure
3-1)
-.
An
adjustable
0
to
2.5
second
SPOT
TIME
control
is
provided
for
selecting
the
time
welding
wire
will
feed
into
the
weld
at
the
speed
selected
by
the
WIRE FEED
SPEED
control.
The
SPOT
TIME
control
starts
to
time
out
at
arc
initiation.
-
Rotating
the
control
in
a
clockwise
direction
increases
the
spot
time.
The
scale
surrounding
the
SPOT
TIME
control
is
calibrated
in
seconds
to
aid
in
the
selection
of
a
spot
time
suited
to
the
individual
welding
operation.
3-13.
CRATER
TIME
CONTROL
(Figure
3-1)
An
adjustable
0
to
2.5
second
CRATER
TIME
control
is
-
provided
for
selecting
the
time
welding
wire
will
feed
into
the
weld
at
the
rate
set
by
the
CRATER
&
INCH
SPEED
control.
The
CRATER
TIME
control
Starts
to
time
out
when
the
STOP
switch
is
depressed
or
when
the
SPOT
TIME
times
out.
Rotating
the
control
in
a
clockwise
direction
increases
the
crater
fill
time.
The
scale
surrounding
the
CRATER
TIME
control
is
calibrated
in
seconds
to
aid
in
the
selection
of
a
crater
fill
time
period
suited
to
the
individual
welding
operation.
-
3-14.
BURNBACK
CONTROL
(Figure
3-1)
An--adjustable---0-to-
.25
second
BURNBACK
control
is
provided
for
selecting
the
time
the
welding
wire
will
remain
electrically
energized
after
the
drive
motor
stops.
The
BURNBACK
control
starts
to
time
out
after
the
CRATER
TIME
control
has
timed
out.
Rotating
the
control
in
a
clockwise
direction
increases
the
burnback
time.
The
scale
surrounding
the
BURNBACK
control
is
calibrated
in
seconds.
By
adjusting
this
control
properly,
the
welding
wire
will
neither
freeze
in
the-
weld
puddle
nor
in
the
contact
tube
of
the
gun.
If
the
welding
wire
freezes
to
the
work,
increase
the
burnback
time.
II
the
welding
wire
burns
back
into
the
contact
tube,
decrease
the
burnback
time.
3-15.
POST-FLOW
TIME
CONTROL
(Figure
3-1)
-
An
adjustable
0-5
second
POST-FLOW
TIME
control
is.
provided
for
selecting
the
time
shielding
gas
will
flow
after
the
BURNBACK
control
has
timed
out.
Rotating
the
control
in
a
clockwise
direction
increases
the
post-flow
time.
The
scale
surrounding
the
POST-F
LOW
TI
ME
control
is
calibrated
in
seconds
to
aid
in
the
selection
of
a
post-flow
time
period
suited
to
the
individual
welding
operation.
-
---h
ii
-
4-~
II
Page
6
3-16.
METERS
(Figure
3-1)
The
meters
are
provided
to
monitor
the
welding
operation.
They
are
not
intended
for
exact
current
or
voltage
measure
ments.
The
voltmeter
will
indicate
the
voltage
at
the
output
terminals,
but
not
necessarily
the
actual
voltage
at
the
welding
arc
(due
to
cable
resistance,
poor
connections,
etc.).
The
ammeter
will
indicate
the
current
output
of
the
unit.
3-17.
OVERLOAD
PROTECTION
(Figure
3-1)
The
control/feeder
is
protected
from
damage
due
to
an
internal
short
or
excessive
overload
by
fuse
Fl.
Fuse
Fl
is
located
on
the
front
panel
of
the
weld
control.
If
fuse
Fl
should
open,
the
control/feeder
would
completely
shut
down.
The
drive
motor
is
protected
from
damage
due
to
overload
by
circuit
breaker
CB1.
Circuit
breaker
CB1
is
located
on
the
front
panel
of
the
weld
control.
If
circuit
breaker
CB1
should
open,
the
control/feeder
would
completely
shut
down.
The
reset
button
would
have
to
be
manually
depressed
in
order
to
reset
the
circuit
breaker.
3-18.
NORMALLY
OPEN
AND
NORMALLY
CLOSED
CONTACTS
A
set
of
normally
open
and
normally
closed
contacts
are
1.
Make
all
connections
as
instructed
in
Section
2.
2.
Position-welding
gun
and/or
fixture.
3.
Set
wire
feed
speed
controls
and
weld
cycle
timers
to
desired
positions
to
program
the
weld
cycle.
Ensure
that
the
SPOT-CONTINUOUS
switch
is
in
the
CONTINUOUS
position.
4.
Turn
on
shielding
gas
at
the
source.
5.
Energize
the
welding
power
source.
:
6.
Place
the
control/feeder
POWER
switch
in
the
ON
position.
7.
Purge
the
gas
line
by
depressing
the
PURGE
button
for
one
minute.
,,-
,
8.
Depress
the
control/feeder
START
button.
I
The
welding
wire
and
all
metal
parts
in
contact
with
it
are
energized
while
welding.
Do
not
touch
the
welding
wire
or
any
metal
part
making
contact
with
it.
9.
To
terminate
the
weld
cycle,
depress
the
STOP
button.
4-
2.
GAS
METAL-ARC
WELDING
(GMAW)
SPOT
1.
Recheck
to
assure
proper
connections have
been
made
in
accordance
with
Section
2.
2.
Position
weld
gun
and/or
fixture.
3.
Set
wire
feed
speed
controls
and
weld
cycle
timers
to
desired
positions
to
program
the
weld
cycle.
provided
to
work
in
conjunction
with
each
weld
cycle
timing
Circuit.
These
contacts
may
be
used
to
determine
fixture
movement
in
conjunction
with
the
weld
cycle.
Connections
can-
be
made
to
the
3/16
male
friction
connectors
on
receptacle
RC4
and
RC1Q
located
behind
the
timing
circuit
card
assembly
in
the
weld
control.
To
gain
access
to
these
receptacles
the
timing
Circuit
Card
assembly
may
be
removed
as
follows:
1.
Loosen
screw
from door
on
upper
panel
of
the
weld
control
and
open
door.
2.
Remove
three
screws
securing
timer
panel.
3.
Gently
pull
timer
panel
part
way
out.
4.
Remove
plugs
PLGI
and
PLG2
from
the
printed
circuit
card
assembly.
5.
Remove
timer
panel.
-
Route
leads
from
the
receptacles
through
the
cable
clamp
provided
on
the
side-of
the
weld
control.
After
connections-
are
made
to
the
receptacles,
reverse
thern
steps
above
tc~
install
the
timer
panel.
4.
Ensure
that
the-SPOT-CONTINUOUS
switch
is
in
the
SPOT
position.
Set
the
SPOT
TIME
control,
to
the
desired
setting.
5.
Turn
on
shielding
gas
at
the
source.
6.
Energize
the
welding
power
source.
7.
Place
the
control/feeder
POWER
switch
in
the
ON
position.
8.
Purge
the
gas
line
by
depressing
the
PURGE
button
for
one
minute.
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.
-
9.
Depress
the
control/feeder
START
button.
The
welding
wire
and
all
metal
parts
in
contact
with
it
-
-
-
are
energized
while
welding.
Do
not
touch
the
welding
wire
or
any
metal
part
making
contact
with
it.
10.
The
weld
cycle
will
automatically
terminate
when
the
SPOT
TIME
control
times
out.
4-3.
SHUTTING
DOWN
1.
Turn
the
shielding
gas
off
at
the
source.
If
welding
is
performed
in
a
confined
area,
failure
to
turn
off
gas
supply
could
result
in
a
build
up
of
gas
fumes,
endangering
personnel
reentering
the
welding
area.
2.
Place
the
control!feeder
POWER
switch
in
the
OFF
position.
3.
Turn
off
all
associated
equipment.
-
4-1.GAS
METAL-ARC
WELDING
(GMAW)
CONTINUOUS
SECTION
4
-
SEQUENCE
OF
OPERATION
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
and
even
permanent
bodily
damage.
OM-1518
Page.7
5-
1.
INSPECTION
AND
UPKEEP
Usage
and
shop
conditions
will
determine
the
frequency
and
type
of
maintenance.
Inspect
equipment
as
follows:
1.
Make
sure
welding
power
source
is
shut
down.
2.
Inspect
gun
for
broken
areas,
cracks
and
loose
parts:
tighten,
repair,
and
replace
as
required.
3.
Carefully
remove
any
weld
spatter
or
foreign
matter
which
may
accumulate
around
the
nozzle
orifice.
Use
a
hardwood
stick,
never
a
metal
tool.
4.
Repair
or
replace,
as
required,
all
hose
and
cable;
give
particular
attention
to
frayed
and
cracked
insulation
and
areas
where
it
enters
equipment.
5.
Remove
grease
and
grime
from
components;
moisture
from
electrical
parts
and
cable.
6.
Blow
out
the
gun
wire
guide
liner
with
compressed
air
when
changing
wire.
This
will
remove
any
metal
chips
and
dirt
that
may
have
accumulated.
5-2.
CLEANING
OF
DRIVE
ROLLS
Occasionally
it
will
become
necessary
to
clear,
the
wire
groove
on
the
drive
rolls.
This
cleaning
operation
can
be
performed
with
a
wire
brush.
To
clean
the
wire
grooves
it
will
be
necessary
to
first
remove
the
drive
roll(s).
See
Section
2-7
for
removal
and
installation
instructions.
SECTION
6
TROUBLESHOOTING
Hazardous
voltages
are
present
on
the
iiiternal
cir
cuitry
of
this
unit
as
long
as
power
is
connected.
Disconnect
power
before
attempting
any
inspection
or
work
on
the
inside
of
the
unit.
Troubleshooting
of
internal
circuitry
should
be
performed
by
qualified
t..,~~sonnel
only.
-
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
unit.
ft
is
assumed
that
proper
installation
has
been
made,
according
to
Section
2
of
this
manual,
and
that
the
unit
has
been
functioning
propedv
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
matfunction,
the
manufacturers
recommendations
should
be
strictly
followed.
If
it
becomes
necessary
to
replace
any
fuse
in
this
Unit,
ensure
that
a
fuse
of
the
proper
size
is
used.
SECTION
5
-
MAINTENANCE
NOTE
Failure.
to
properly
maintain
the-drive
rolls
can
result
in
a
build-up
of
wire
particles
which
will
decrease
the
efficiency
of
the
wire
feeding
operation.
-
TROUBLE
PRpBABLE
CAUSE
REMEDY
Depressing
START
button
will
not
start
weld
cycle.
Electrode
wire
is
not
energized
and
shielding
gas
does
not
flow.
ON-OFF
POWER
switch
in
wrong
position
or
defective.
.
Place
switch
to
ON
position.
Replace
defective
POWER
switch.
-.
.
Circuit
breaker
CB1
tripped.
~
Manually
reset
Circuit
breaker
by
depressing
the
button
on
the
frbnt
panel
of
the
control/feeder
labeled
RESET.
115
v6lts
ac
input
plug
is
not
secure
in
receptacle,
Insert
plug
fully
into
115
vac
receptacle
and
rotate
plug
1/2
turn
clockwise.
115
volts
input
fuse
Fl
open.
Replace
fuse.
Wire
feeds,
shielding
gas
flows,
but
electrode
wire
is
not
energized.
~
115
v~c
Contactor
Control
plug
is
not
secure
in
contactor
receptacle
on
welding
power
source.
Insert
plug
fully
into
receptacle
and
rotate
plug
1/2
turn
clockwise.
ContŁctor
Control
cable
leads
not
secure--.on---contactor~__pJug
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
drive
rolls
is
insufficient,
Rotate
pressure
adjustment
wing
nut
clockwise
in
1/4
turn
increments
until
wire
slippage
stops.
Drive
roll
is
too
large
for
wire
size
being
used.
Change
to
proper
size
drive
roll.
See
Section
2-7.
Worn
drive
roll.
Replace
drive
roll.
See
Section
2-7.
Dirt
in
drive
roll.
Clean
drive
roll
as
instructed
in
Section
5-2.
Page
8
U)
I.
C54
0
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OM-1513Page9
November
1978
FORM:
OM-151
-PARTS
LIST
Effective
With
Serial
No.
HJI
95967
MODEL
AUTOMATIC
I
I
N
a.
(0
0
(0
9
0
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C,
a.
IL
OM1518
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1
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Miller HJ195967 Owner's manual

Miller
Brand
Miller
Model
HJ195967
Category
Welding System
Type
Owner's manual
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