Millerfi
April
1994
Form:
OM-1544B
OWNERS
MANUAL
-
~
''I~7
~U~3
IT'
~
A2
Motor/Drive
Assemblies
Read
and
follow
these
instructions
and
all
Give
this
manual
to
the
operator.
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
~fl
For
help,
call
your
distributor
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
115
Volts
DC
Motor/Wire
Drive
Assembly
For
Automatic
Weld
Control
For
GMAW,
FCAW
And
SAW
Welding
High
And Low
Speed
Four-Drive
Roll
Models
3600
Swivel
Mounting
Bracket
Interconnecting
Cord
To
Weld
Control
Needed
See
Rear
Cover
For
Options
And
Accessories
cover
1/94
-
ST-087
042-B
'
1994
MILLER
Electflc
MIg.
Co.
PRINTED
IN
USA
ii:
MILLERS
TRUE
BLUET
LIMITED
WARRANTY
Effective
January
1.
1992
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
:j~u
LIMITED
WARRANTY
Subtect
to
the
terms
and
conditions
below.
MILLER
Electric
Mtg
Co
.
Appleton.
Wisconsin.
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
after
the
ehective
date
of
this
limited
warranty
is
free
of
de
fects
in
material
and
worhmanship
at
the
time
it
is
shipped
by
MILLER
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES.
EXPRESS
OR
IMPLIED.
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Wifhin
the
warranty
periods
listed
below.
MILLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
fail
due
to
such
defects
in
material
or
workmanship.
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
of
such
defect
or
failure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
a
failure
within
the
warranty
lime
periods
Alt
warranty
lime
periods
stan
on
the
date
that
the
equipment
was
detivered
to
the
original
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
the
distributor
5
Years
Parts
3
Years Labor
Original
main
power
rectifiers
2.
3
Years
Parts
and
Labor
Transformer/Rectifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
and
Aufomalic
Wire
Feeders
Robots
3.
2
Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE
Engines
are
warranted
separately
by
the
engine
manutactuier
for
a
period
ol
two
years.)
Air
Compressors
4
t
Year
Parts
and
Labor
*
Motor
Driven
Guns
,Process
Controllers
*
Water
Coolant
Systems
HF
Units
Grids
Spot
Welders
Load
Banks
SDX
Transformers
*
Running
Gear/Trailers
Field
Options
(NOTE.
Field
options
are
covered
under
True
Blue
for
the
remaining
warranty
period
of
the
product
they
are
installed
in.
or
for
a
minimum
Pt
one
year
whichever
is
greater.)
6
Months
Batteries
90
Days
Parts
and
Lsbor
MIG
Guns/TtG
Torches
Plasma
Cutting
Torches
Remote
Controls
Accessory
Kits
Replacement
Parts
MILLERS
True
BluerM
Limited
Warranty
shatt
not
apply
~p.
1
Items
turnished
by
MILLER.
but
msnutsctured
by
others,
such
as
engines
or
trade
accessories
These
items
are
covered
by
the
manutecturers
warranty,
it
any
2
Consumable
components:
such
55
contact
lips.
cuhing
nozzles.
contaclors
and
relays
or
parts
that
tail
due
to
normal
wear
3
Equipment
that
has
been
moditied
by
any
party
other
than
MILLER.
or
equip
ment
that
has
been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
speciticatrons
for
the
equipment
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIALINDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
In
the
evenr
of
s
warranty
claim
covered
by
this
warranty,
the
esctusive
remedies
shalt
be.
at
MILLERS
option
)t)
repair:
or
)2)
replacement:
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases.
(3)
the
reasonable
cost
of
repair
or
replace
ment
at
an
authoriced
MILLER
service
station:
or
(4)
payment
ot
or
credit
for
the
pur
chase
price
(tess
reasonable
depreciation
based
upon
actual
use)
upon
return
pt
the
goods
at
customers
risk
and
eapense.
MILLERS
option
of
repair
or
replacement
will
be
F
0
B
Factory
at
Appleton.
Wisconsin,
or
F
O.B.
at
a
MILLER
authorized
ser
vice
facility
ss
determined
by
MILLER.
Theretore
no
compensation
or
reimburse
ment
br
rrsnsportstipn
costs
of
any
kind
witl
be
allowed
TO
THE
EXTENT
PERMITrED
BY
LAW.
THE
REMEDIES PROVIDED
HEREtN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDtES.
tN
NO
EVENT
SHALL
MILLER BE
LIABLE
FOR
DIRECT.
INDIRECT.
SPECtAL,
INCI
DENTAL
OR
CONSEQUENTIAL
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
IMPLICATION.
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
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
slates
in
the
U
S.A
do
not
allow
limitations
p1
how
long
an
implied
warranly
lasts,
or
the
exclusion
of
incidental.
indirect.
special
or
consequential
damages,
so
the
above
limitation
or
esclusron
msy
not
apply
to
you.
This
warranty
provides
spe
cilic
legal
rights,
and
other
rights
may
be
available,
but
may
vary
1rpm
stale
to
slate.
In
Canada.
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
as
slated
herein,
and
to
Ihe
eslenl
that
Ihey
may
not
be
waived,
the
limitations
and
exclusions
set
out
above
may
not
apply.
This Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
provrnce
to
province.
r..
S
B.
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
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
miller
9/93
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
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole.free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
When
making
input
connections,
attach
proper
grounding
conductor
first.
7.
Turn
off
all
equipment
when
not
in
use.
8.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
9.
Do
not
wrap
cables
around
your
body.
10.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
11.
Do
not
touch
electrode
if
in
contact
with
the
work
or
ground.
12.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
13.
Wear
a
safety
harness
if
working
above
floor
level.
14.
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.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
1.
ARC
RAYS
can
burn
eyes
and
skin;
~
NOISE
can
damage
hearing.
Arc
rays
from
the
welding
process
produce
intense
...
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
NOISE
ARC
RAYS
2.
Wearaweldinghelmetfittedwithapropershadeoffilter(see
ANSI
Z49.
1
listed
in
Safety
Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
3.
Wear
approved
safety
glasses.
Side
shields
recommended.
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
material
(wool
and
leather)
and
foot
protection.
k
~
~
~
-.-
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
5.
6.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Shielding
gases
used
for
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
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
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
oi
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
thEl
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturers
instruction
for
metals,
consumables,
coatings,
wearing
an
air.supplied
respirator.
The
coatings
and
any
metals
and
cleaners,
containing
these
elements
can
give
off
toxic
fumes
if
welded.
-
WELDING
can
cause
fire
or
explosion.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Sparks
and
spatter
fly
off
from
the
welding
arc.
The
flying
sparks
and
hot
metal,
weld
spatter,
hot
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
orwelding
wire
7.
Do
not
weld
on
closed
containers
such
as
tanks
or
drums.
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
8.
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
9.
unknown
paths
and
causing
electric
shock
and
fire
hazards.
Do
not
use
welder
to
thaw
frozen
pipes.
3.
Removeallflammableswithin35ft(10.7m)oftheweldingarc.lf
this
is
not
possible,
tightly
cover
them
with
approved
covers,
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
11.
Wear
oil-free
protective
garments
such
as
leathergloves,
heavy
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
-
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury,
I
Chipping
and
grinding
cause
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
1.
2.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
recommended.
Wear
proper
body
protection
to
protect
skin.
Sri
9/92
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from
excessive
heat.
mechanical
shocks,
and
arcs.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
5.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
6.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
7.
Keep
protective
cap
in
place
over
valve
except
when
cytinder
is
in
use
or
connected
for
use.
8.
Read
and
follow
instructions
on
compressed
gas
cylinders.
associated
equipment,
and
CGA
publication
P.1
listed
in
Safety
Standards.
ENGINES
can
be
hazardous.
ENGINE
EXHAUST
GASES
can
kill.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
Engines
pr
oduce
harmful
exhaust
gases.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
away
from
any
building
air
intakes.
ENGINE
FUEL
can
cause
fire
or
1.
Stopenginebeforecheckingoraddingfuel.
I
A
explosion.
Engine
fuel
is
highly
flammable.
2.
3.
4.
5.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
open
flames.
Allow
engine
to
cool
before
fueling.
If
possible,
check
and
add
fuel
to
cold
engine
before
beginning
job.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
starting
engine.
1.
Keep
all
securely
MOVING
PARTS
can
cause
injury.
Moving
parts,
such
as
fans,
rotors,
and
belts
can
I
cut
fingers
and
hands
and
catch
loose
clothing,
doors,
panels,
covers,
and
guards
closed
and
in
place.
3.
4.
5.
6.
Have
only
qualified
people
remove
guards
or
covers
for
maintenance
and
troubleshooting
as
necessary.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
parts.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
2.
Stop
eng
me
before
installing
or
connecting
unit,
finished
and
before
starting
engine.
SPARKS
can
cause
BATTERY
GASES
TO
EXPLODE;
BATTERY
ACID
can
burn
eyes
and
skin.
3.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
Observe
correct
polarity
(+
and
)
on
batteries.
STEAM
AND
PRESSURIZED
HOT
1.
Do
not
remove
radiator
cap
when
engine
is
hot.
Allow
engine
COOLANT
can
burn
face,
eyes,
and
to
cool.
skin.
2.
Wear
gloves
and
put
a
rag
over
cap
area
when
removing
cap.
The
coolant
in
the
radiator
can
be
very
hot
and
under
pressure.
3.
Allow
pressure
to
escape
before
completely
removing
cap.
PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.
1,
from
American
Welding
Society,
550
NW.
LeJeune
Rd,
Miami
FL
33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superinten
dent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
Ameri
can
Welding
Society
Standard
AWS
F4.1
from
American
Welding
So
ciety,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
High
way,
Suite
501.
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Bou
levard.
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
For
OccupationAndEducationalEyeAndFace
Protec
tion,
ANSI
Standard
Z87.1,
from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
a
WARNING
1.
2.
Batteries
contain
acid
and
generate
explosive
gases.
Always
wear
a
face
shield
when
working
on
a
battery.
Stop
engine
before
disconnecting
or
connecting
battery
cables.
4.
5.
~rl
9/92
EMF
INFORMATION
NOTE
~
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
_____________________
Magnetic
Fields
The
following
is
a
quotation
from
the
General
Conclusions
Section
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
procedures:
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
1.
Keep
cables
close
together
by
twisting
or
taping
them.
Background
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):.
. .
there
is
now
a
very
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
large
volume
of
scientific
findings
based
on
experiments
at
the
3.
Do
not
coil
or
drape
cables
around
the
body.
cellularlevel
and
from
studies
with
animals
and
people
which
clearly
4.
Keep
welding
power
source
and
cables
as
far
away
as
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
nractjcal
produce
changes
in,
biological
systems.
While
most
of this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
possible.
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
About
Pacemakers:
allow
us
to
draw
definite
conclusions
about
questions
of
possible
The
above
procedures
are
among
those
also
normally
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
or
avoid
potential
risks.
complete
information.
modlo.1
419~
TABLE
OF
CONTENTS
.
SECTION
1
SAFETY
INFORMATION
1
SECTION
2
SPECIFICATIONS
1
SECTION
3-
INSTALLATION
3-1.
Typical
Equipment
Location
2
3-2.
Installing
Swivel
Mounting
Bracket
3
3-3.
Installing
Wire
Guide
And
Drive
Rolls
3
3-4.
Plug
Connections
4
3-5.
Gun,
Weld
Cable,
And
Gas
Connections
4
3-6.
Threading
And
Feeding
Welding
Wire
5
3-7.
Changing
Wire
Feed
Speed
Range
5
SECTION
4-OPERATION
6
SECTION
5
MAINTENANCE
AND
TROUBLESHOOTING
5-1.
Routine
Maintenance
7
5-2.
Aligning
Drive
Rolls
And
Wire
Guides
7
5-3.
Brush
Inspection
And
Replacement
8
5-4.
Troubleshooting
9
SECTION
6
PARTS
LIST
Figure
6-1.
Motor/Drive
Assembly
(A2-4L,
A2-4H)
10
Table
6-1.
Drive
Roll
&
Wire
Guide
Kits
For
A2-41-l
&
A2-4L
13
OM-1544B
-4/94
SECTION
1
-
SAFETY
INFORMATION
modl.1
2)93
U
Read
all
safety
messages
throughout
this
manual.
Obey
all
safety
messages
to
avoid
injury.
U
Learn
the
meaning
of
WARNING
and
CAUTION.
a
WARNING
a
CAUTION
1
Safety
Alert
Symbol
1
2
2
2
Signal
Word
WARNING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
ELECTRIC
SHOCK
can
kIII.~
~
MOVING
PARTS
can
Injure,
injury
or
equipment
damage
can
~
S
Do
not
touch
live
electrical
parts.
Keep
away
from
moving
parts.
happen.
I
S
Disconnect
input
power
before
Keep
all
panels
and
covers
closed
3
Statement
Of
Hazard
And
L~
Installing
or
servicing,
when
operating.
Result
/
4
Safety
Instructions
To
Avoid
5
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
~
~
~
of
Road
safety
blocks
for
each
sym~
7
NOTE
NOTE
~
Turn
Off
switch
when
using
high
frequency.
Special
instructions
for
best
oper
ation
not
related
to
safety.
Figure
1-1.
Safety
Information
SECTION
2-SPECIFICATIONS
Table
2-1.
Wire
Drive
Assemblies
Specification
Description
Type
Of
Input
Power
115
Volts
DC
Mounting
Bracket
Adjustment
3600
Rotation
Of
Drive
Assembly
Input
Power
Cord
2
ft
(0.6
m)
Overall
Dimensions
See
Figure
2.1
Weight
Wire
Feed
Speed
Range
~
36
lb
(16.3
kg)
Low
Speed
Motor
High
Speed
Motor
Low
Range:
12
To
128
ipm
(0.3
To
3.3
mpm)
High
Range:
27
To
288
ipm
(0.7
To
7.3
mpm)
Low
Range:
46
To
500
1pm
(1.2
To
12.7
mpm)
High
Range:
105
To
1125
ipm
(2.7
To
28.6
mprn)
Wire
Diameter
Range
5/64
To
1/4
in
(2
To
6.4
mm)
.030
To
3/32
in
(0.9
To
2.4
mm)
OM-1
544
Page
1
Four-Drive
Roll
Models
Inches
Millimeters
A
B
C
10
14-1/2
12-1/4
254
368
311
Inches
Millimeters
A
B
4-1/4
4-1/4
108
108
C
13/32Dia.
4
Holes
lODia.
4
Holes
Figure
2-1.
Overall
Dimensions
And
Mounting
Hole
Layout
SECTION
3-INSTALLATION
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
weld
control
and
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
welding
or
feeding
wire.
Have
only
qualified
persons
install
this
unit.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls
3-1.
Typical
Equipment
Location
Mounting
Holes*
C
/
*Holes
shown
used
for
mounting
to
optional
cross
slide.
Additional
holes
provided
for
mounting
to
weld
oscillator.
ST-087
042-B
/
Ref.
5T.070
885-B
WELDING
WIRE
can
cause
puncture
wounds.
Do
not
try
to
feed
wire
until
instructed
to
do
so.
Do
not
point
gun
toward
any
part
of
the
body
when
threading
welding
wire.
H
01
SURFA
Allow
drive
CES
ca
assembly
n
bu
and
rn
skin.
gun
to
cool
before
touching.
1
Welding
Power
Source
2
Gas
Cylinder
3
Side
Beam
4
Gas/Current
Sensing
Control
5
Weld
Control
6
Spool
Support
7
Wire
Drive
Assembly
8
Automatic
Welding
Gun
ST-131
138-A
Figure
3-1.
Typical
Equipment
Location
OM-1
544
Page
2
3-2.
Installing
Swivel
Mounting
Bracket
3-3.
Installing
Wire
Guide
And
Drive
Rolls
~
____
READ
SAFETY
BLOCKS
at
start
of
I
7
Section
3
before
proceeding.
When
changing
wire
size
or
type,
check
drive
roll
and
guide
size
(see
Table
6-1).
1
Wire
Guide
Securing
Screw
2
Inlet
Wire
Guide
3
Intermediate
Wire
Guide
Se
curing
Screws
Loosen
wire
guide
screws.
Slide
tip
as
close
to
drive
rolls
as
possible
without
touching.
Tighten
screw.
4
Drive
Gear
5
Pressure
Gear
Drive
and
pressure
gears
installed
5~
before
unit
is
shipped
from
factory.
\
..~.
6
Pressure
Gear
Assembly
7\
~
Open
pressure
gear
assembly.
>c
~
~-
-
7
Drive
Roll
8
Gear
Securing
Bolt
9
Drive
Roll
Securing
Screw
I
\
~,
..S~j
Install
correct
drive
roll
for
wire
size
and
type
using
supplied
hardware.
8 9
~
Close
pressure
gear
assembly.
~
\
Tools
Needed:
~
\~
~
j
7/16
in
-
ST-087
040-C
Figure
3-3.
Installing
Wire
Guide
And
Drive
Roll
3
1
Mounting
Bracket
2
Mounting
Holes
3
Swivel
Mount
bracket
onto
side
beam.
cross
slide,
or
weld
oscillator.
Allow
enough
room
for
swivel
crank
oper
ation.
Tools
Needed:
~
9/l6in
4
Swivel
Crank
Use
crank
to
change
position
of
drive
assembly.
5
Swivel
Brake
Setscrew
Tighten
setscrew
to
secure
drive
assembly
position.
Loosen
set
screw
to
change
drive
assembly
position.
Figure
3-2.
Installing
Pivot
Mounting
Bracket
ST-087
042-B
OM-1
544
Page
3
3-4.
Plug
Connections
3-5.
Gun,
Weld
Cable,
And
Gas
Connections
1
Plug
2
Keyway
3
Typical
Weld
Control
Connect
plug
to
matching
plug
from
weld
control.
To
connect
plugs,
align
keyways,
insert
plug,
and
tighten
connection.
Ref.
ST.156
933/Ref.
ST-087
042-6/
S-0749-A
Figure
3-4.
Plug
Connections
_____
READ
SAFETY
BLOCKS
at
start
of
Section
3
before
proceeding.
1
Gun/Feeder
Securing
Block
Connect
To
Positive
(+)
Weld
Output
Terminal
On
Welding
2
Gun/Feeder
Opening
Power
Source
For
Reverse
3
Gun
End
Polarity
Weld
Process
Or
Connect
To
Negative
()
Weld
Loosen
bolts.
Insert
gun
end
into
Output
Terminal
On
Welding
opening.
Position
as
close
as
pos
Power
Source
For
Straight
sible
to
drive
rolls
without
touching.
Polarity
Weld
Process.
Tighten
bolts.
4
Weld
Cable
Terminal
5
Weld
Cable
Select
and
prepare
weld
cable
ac
cording
to
welding
power
source
Owners
Manual.
For
guns
with
external
weld
cable,
connect
weld
cable
from
gun
to
terminal.
6
Shielding
Gas
Fitting
7
Gas
Hose
Gas
fitting
is
located
behind
gunl
feeder
opening.
For
guns
requiring
external
gas
connection,
remove
hose
from
fit
ting
and
connect
to
gun.
Ref.
ST-156
544
I
Ref.
$T-080
847-A
/
Ret.
ST-087
042-B
Tools
Needed:
~
9/16in
Figure
3-5.
Gun,
Weld
Cable,
And
Gas
Connections
OM-1
544
Page
4
3-6.
Threading
And
Feeding
Welding
Wire
READ
SAFETY
BLOCKS
at
start
of
Section
3
before
proceeding.
3-7.
Changing
Wire
Feed
Speed
Range
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
weld
control
and
welding
power
source,
and
disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
Do
not
replace
plastic
gear
with
steel
gear.
The
plastic
gear
provides
electrical
isolation.
Using
two
steel
pears
would
allow
weld
current
to
be
present
on
the
drive
motor.
MOVING
PARTS
can
cause
Injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
The
wire
drive
assembly
is
shipped
to
provide
the
lower
wire
feed
speed
range.
To
change
speed
range:
remove
gear
cover,
loosen
setscrews,
and
remove
and
swap
gears,
align
gears
allowing
a
small
amount
of
backlash,
tighten
setscrews,
and
reinstall
gear
cover.
£~
CAUTION
IMPROPER
CLEARANCE
between
gears
can
damage
equipment.
Maintain
0.003
In
(0.076
mm)
clearance
between
gears.
Gears
may
wear
severely,
bind,
break,
or
cause
erratic
wire
feed
if
proper
clearance
is
not
maintained.
1
2
3
4
5,
1
Wire
Spool
Loosen
wire
from
wire
spool,
cut
off
bent
wire,
and
pull
6
in
(150mm)
of
wire
off
spool.
2
Wire
Inlet
Guide
3
Drive
Roll
4
Intermediate
Wire
Guide
5
Gun
Thread
wire
through
inlet
guide,
along
drive
rolls,
through
interme
diate
guide
and
drive
rolls
(if
appli
cable),
and
into
gun.
Be
sure
wire
is
in
correct
groove.
6
Pressure
Adjustment
Knob
And
Arm
Close
pressure
roll
assembly.
Check
drive
roll
pressure
by
feed
ing
wire
against
a
wood
board
oi
concrete
surface;
wire
should
feed
steadily
without
slipping.
If
pressure
adjustment
is
neces
sary,
tighten
pressure
knob(s).
ST-156
798
Tools
Needed:
Figure
3-6.
Threading
And
Feeding
Welding
Wire
0
0
wfwam4.V
2/93
OM-1544
Page
5
SECTION
4-
OPERATION
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
area,
or
use
breathing
device.
Read
Material
Safety
Data
Sheets
(MSDS5)
and
manufacturers
instructions
for
material
used.
WELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
Do
not
weld
on
closed
containers.
Allow
work
and
equipment
to
cool
before
handling.
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
welding
helmet
with
correct
shade
of
filter.
Wear
correct
eye,
ear,
and
body
protection.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
MAGNETIC
FIELDS
FROM
HIGH
CUR
RENTS
can
affect
pacemaker
operation.
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor
before
going
near
any
welding
operations.
See
Safety
Precautions
at
beginning
of
manual
for
ba
sic
welding
safety
information.
~arn31
8/92
__
4A
WARNING
__
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
weld
control
and
welding
power
source,
and
disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
servicing
gun
or
unit.
=4
3
Wear
the
following
while
welding:
1
Dry,
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
I
2
3
Welding
Helmet
With
Correct
Shade
Of
Filter
(See
ANSI
Z49.1)
sb3.1
1/94
Figure
4-1.
Safety
Equipment
Install
&
_))
Thread
&
F~\
\
Put
On
et
))
Turn
On
~
Control
Connect
Welding
Wire
______________
______________
Equipment
______________
If
Applicable
)j
Power
Source
J
~
J
Equipment
J)
Personal
SafetY))
Weld
Control
Shielding
Gas
And
I
Welding
~
)
Begin
Welding
Figure
4-2.
Sequence
Of
Operation
SECTION
5-
MAINTENANCE
AND
TROUBLESHOOTING
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
p
Maintenance
to
be
performed
only
by
qualified
persons.
wfwarn4.r
2/93
OM-1
544
Page
6
5-1.
Routine
Maintenance
5-2.
Aligning
Drive
Rolls
And
Wire
Guides
a
CAUTION
Vertical
Alignment
Tools
1.
Turn
Off
all
power
before
maintaining.
-
6
Months
Figure
5-1.
Maintenance
READ
Sectio
SAFETY
n
5
befor
BLOCKS
at
start
of
e
proceeding.
IMPROPER
CLEARANCE
between
motor
gear
and
drive
gears
on
can
damage
equipment.
Maintain
0.003
in
(0.076
mm)
clearance
between
motor
gear
and
drive
gears.
Gears
may
wear
severely,
bind,
break,
or
cause
erratic
wire
feed
if
proper
clearance
is
not
maintained.
Horizontal
Alignment
Correct
Alignment
Incorrect
Alignment
Horizontal
Alignment
.
View
is
from
top
of
drive
rolls
look
ing
down
with
pressure
assembly
open.
1
Drive
Roll
Securing
Bolt
2
Drive
Roll
3
Wire
Guide
4
Welding
Wire
5
Drive
Gear
Turn
bolt
in
or
out
until
drive
roll
groove
lines
up
with
wire
guide.
Vertical
Alignment
6
Housing
Bolts
Loosen
bolts.
7
Wire
Guide
8
Drive
Roll
9
Pressure
Roll
Slide
housing
up
or
down
until
groove
in
drive
roll
and
pressure
roll
line
up
with
wire
guide.
7/16
in
9/16
in
S-0629-A
I
Ref.
ST-087
042.B
/
S~OO87
Figure
5-2.
AlIgning
Drive
Rolls
And
Wire
Guides
Tighten
hardware.
Close
pressure
roll
assembly.
OM-1
544
Page
7
5-3.
Brush
Inspection
And
Replacement
1
Motor
Tools
Needed:
2
Brush
Cap
Location
Remove
cap.
3
Removing
Brush
4
Brush
Box
5
Spring
Assembly
Bracket
Remove
bracket
from
box.
6
Spring
Assembly
7
Brush
Pigtail
Pull
pigtail
to
remove
brush.
8
Brush
9
Checking
Brush
Replace
if
near
minimum
length.
10
Installing
Brush
To
reinstall
spring
assembly,
slide
into
box
as
shown
to
hook
bracket
into
box.
Install
brush
cap.
Check
brush
on
other
side
of
motor.
~5t%
Push
Back
And
Up
1/4
in
(6.3
mm>
0
Minimum
Length
Side
View
Of
Box
6~
Install
Push
Up
And
Down
10
Ret.
ST-i
56
693
I
ST-087
042-B
Figure
5-3.
Brush
Inspection
And
Replacement
6
Pull
3
Remove
Check
1~
9
OM-1
544
Page
8
5-4.
Troubleshooting
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Oft
weld
control
and
welding
power
source,
and
disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
servicing
gun
or
unit.
Troubleshooting
to
be
performed
only
by
qualified
persons.
wfwarn4.r
2/93
Table
5-1.
Troubleshooting
S
Trouble
Wire
feeds
erratically.
Remedy
Adjust
drive
roll
pressure
by
turning
pressure
adjustment
knob(s)
1/4
turn
clockwise
until
wire
stops
slipping.
Check
gun
contact
tip
for
obstructions.
Check
size
of
drive
roll.
Replace
drive
roll
if
worn.
Clean
drive
roll,
and
check
wire
spool
hub
tension.
Align
drive
rolls.
Motor
runs
slowly.
Section
-~
3-3
-~
3-3
-~
5-2
-
--
Reduce
load.
Check
for
correct
input
voltage.
OM-1544
Page
9
SECTION
6-
PARTS
LIST
Figure
6-1.
Motor/Drive
Assembly
(A2-4L,
A2-4H)
SC-085
263-F
1
2
3
7~
9
17
18
192021
22
21
71
23
24
28
29
3
4
30
31
65
44
56
42
51
49
57
58
59
60
63
OM-1
544
Page
10
Item
Part
No. No.
Description
Figure
6-1.
Motor/Drive
Assembly
(A2-4L,
A2-4H)
Quantity
4
1
10
6
1
1
4
1
5
1
...
071952
2...
071956
3
...
602213
4...
601965
5...
071954
6...
071959
7
...
010910
8...
601850
9
...
602009
10...
085595
11...
071955
12..
+083513
070
634
13...
083518
14...
044278
15...
000527
16...
070421
17...
094583
18...
605789
19...
087133
20...
602200
21
...
070427
22...
070455
23...
070238
24...
094582
010651
25...
601976
26...
602247
27...
602216
28...
601879
29...
602243
30...
070501
31
...
083625
32...
076871
33...
144172
34...
085242
35...
166071
36...
085244
37...
010231
38...
085243
39...
079634
40...
151828
41
...
166338
42...
166072
43...
084445
44...
070538
45...
093736
46...
602211
47...
601948
48...
601
926
49...
053842
50...
070283
51
...
602211
52...
604538
53...
072010
54...
079626
55...
605518
56...
602173
57...
083516
1
1
1
1
1
1
1
1
1
2
1
2
6
1
4
1
1
1
2
1
1
8
1
1
2
1
2
SCREW,
mach
stl
flh
.312-18
x
1.000
PLATE,
rear
WASHER,
lock
stl
split
.375
SCREW,
cap
sti
hexhd
.375-16
x
1.000
GEAR,
worm
stl
16P
56
tooth
HOUSING,
swivel
mtg
WASHER,
flat
stl
SAE
.375
NUT,
sti
slflkg
hex
thin
.375-24
SCREW,
cap
stl
sch
.250-20
x
1.250
SHOE,
brake
AXLE,
swivel
gear
BRACKET,
mtg
wire
drive
LABEL,
warning
electric
shock
can
kill
etc
INSULATOR,
housing
BUSHING,
reducer
inlet
guide
BLANK,
snap-in
nyl
.875mtg
hole
STRIP,
insulating
cover/housing
GEAR,
spur
stl
26
tooth
SCREW,
set
stl
sch
10-24
x
.250
STRIP,
holddown
gasket
WASHER,
lock
stl
split
No.
8
SCREW,
cap
sti
sch
8-32
x
.500
COVER,
gear
BUSHING,
insulating
cover
hear
GEAR,
spur
insulating
(consisting
of)
PIN,
spring
CS
.156
x
1.000
SCREW,
cap
stl
hexhd
.500-13
x
1.500
WASHER,
flat
sti
SAE
.500
WASHER,
lock
stl
split
.500
NUT,
stl
hex
full
fnsh
.500-13
WASHER,
flat
stl
std
.375
BUS
BAR,
connector
DRIVE
ASSEMBLY,
(consisting
of)
PIN,
spring
CS
.187x1.500
FITTING,
brs
barbed
M
3/l6tbg
x
.250-20
FASTENER,
pinned
LEVER,
mtg
pressure
gear
WASHER,
cupped
stl
.328
ID
x
.812
OD
x
.125
lip
SPRING,
cprsn
.77000
x
.105
wire
x
1.225
KNOB,
adjustment
tension
PIN,
hinge
PIN,
cotter
hair
.054
x
.750
LEVER,
mtg
pressure
gear
SPACER,
gear
HOUSING,
wire
drive
(consisting
of)
BEARING,
fig
brz
.500
ID
x
.750
OD
x
1.000
CLAMP,T
WASHER,
lock
stl
split
.312
SCREW,
cap
stl
hexhd
.312-18
x
1.000
SCREW,
cap
stl
hexhd
.250-20
x
.625
GEAR,
spur
insulating
w/bearing
SCREW,
cap
stl
sch
.312-18
x
1.250
WASHER,
lock
stl
split
.312
WASHER,
flatstl
SAE
.312
WASHER,
shldr
nyl
.437
00
x
.316
ID
x
.187
lip
SCREW,
mach
stl
filh
10-32
x
.875
SCREW,
cap
stl
hexhd
.250-20
x
1.250
SCREW,
set
stl
sch
10-32
x
.250
GEAR,
spur
stl
25
tooth
22224444
12
2
2
2
OM-1
544
Page
11
Item
Part
No. No.
58...
59...
60...
..61...
62...
63...
64...
65...
66...
67...
68...
..69...
70...
71
72...
73...
74...
74...
75...
76...
77...
78...
605
304
083515
028
342
080413
079
625
053841
092
865
000418
605
151
602
207
083517
605518
094
585
601
964
048
306
079
535
079
706
007 826
080
803
080 802
080
283
080
282
*080
281
005
464
071
953
010650
044
205
4
1
6
1
ift
*Recommended
Spare
Parts.
When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Description
Figure
6-1.
Motor/Drive
Assembly
(A2-4L,
A2-4H)
(Continued)
Quantity
KEY,
stl
.125
x
.125
x
.937
4
SHAFT,
drive
1
BEARING,
ball
rdl
sgl
row
.625
x
1.375
x
.437
2
RETAINER,
bearing
2
WASHER,
spring
stl
.500
shakeproof
4
GEAR,
spur
insulated
wikey
(consisting
of)
2
KEY,stl.1215/.1230x.750
1
SCREW,
cap
stl
hexhd
slflkg
.250-20
x
.500
2
SCREW,
mach
stl
flh
8-32
x
.375
4
WASHER,
lock
stl
split
.250
2
GEAR,
spur
w/bearing
1
SCREW,
cap
stl
hexhd
.250-20
x
1.250
1
SHAFT,
drive
1
SCREW,
cap
stl
hexhd
.375-16
x
.750
RECEPTACLE
w/PINS,
(consisting
of)
TERMINAL,
male
1
pin
18-14
wire
CLAMP,
cable
strain
relief
CABLE,
port
No.
18
3/c
(order
by
ft)
MOTOR,
gear
1/8hp
115VDC
2000RPM
(A2-4L)
(consisting
of)
MOTOR,
gear
1/8hp
115VDC
2000RPM
(A2-4H)
(consisting
of)
COVER,
brush
SPRING,
brush
....BRUSH
2
SCREW,
set
sti
sch
.250-20
x
.375
1
SCREW,
lead
1
PIN,springCS.125x1.000
1
CRANK,
handle
1
1
1
2
2
OM-1544
Page
12
Table
6-1.
Drive
Roll
&
Wire
Guide
Kits
For
A2-4H
&
A2-4L
NOTE
~
Base
selection
of
drive
rolls
upon
the
following
recommended
usages:
_____________________
1.
V-Grooved
rolls
for
hard
wire.
2.
U-Grooved
rolls
for
soft
and
soft
shelled
cored
wires.
3.
U-Cogged
rolls
for
extremely
soft
shelled
wires
(usually
hard
surfacing
types).
4.
V-Knurled
rolls
for
hard
shelled
cored
wires.
5.
Drive
roll
types
may
be
mixed
to
suit
particular
requirements
(example:
V-Knurled
roll
in
combination
with
U-Grooved).
Model
Wire
Diameter
Kit
No.
Drive
Roll
Wire
Guide
Fraction
Decimal
Metric
Part
No.
Type
Inlet
IntermedIate
A2-4H
.030
in
.030
in
0.8
mm
046
780
053
695
V-Grooved
056
192
056
206
A2-4H
.035
in
.035
in
0.9
mm
046
781
053 700
V-Grooved
056
192
056 206
A2-4H
.045
in
.045
in
1.2
mm
046
782
053 697
V-Grooved
056
193
056
207
A2-4H
.052
in
.052
in
1.3
mm
046 783
053
698
V-Grooved
056
193
056 207
A2-4H
1/16
in
.062
in
1.6
mm
046784 053699
V-Grooved
056195 056209
A2-4H
.035
in
.035
in
0.9
mm
044 750
072
000
U-Grooved
056
192
056 206
A2-4H
.045
in
.045
in
1.2
mm
046 785
053
701
U-Grooved
056
193
056 207
A2-4H
.052
in
.052
in
1.3
mm
046
786
053
702
U-Grooved
056
193
056 207
A2-4H
1/16
in
.062
in
1.6mm
046 787 053 706
U-Grooved
056
195
056 209
A2-4H
&
4L
5/64
in
.079
in
2.0mm
046 788
053
704
U-Grooved
056
195
056
209
A2-4H
&
4L
3/32
in
.094
in
2.4mm
046 789 053 703
U-Grooved
056
196
056
210
A2-4L
7/64
in
.110
in
2.8
mm
046
790
053 705
U-Grooved
056
196
056
210
A2-4L
1/8
in
.125
in
3.2mm
046
791
053
707
U-Grooved 056
197
056
211
A2-41-I
.035
in
.035
in
0.9mm
046
792
132
958
V-Knurled
056
192
056 206
A2-4H
.045
in
.045
in
1.2
mm
046 793
132957
V-Knurled
056
193
056 207
A2-4H
.052
in
.052
in
1.3mm
046
794
132956
V-Knurled
056
193
056
207
A2-4H
1/l6in
.062in
1.6mm
046795
132955
V-Knurled
056
195
056209
A2-4H
.072
in
.072
in
1.8
mm
089 985
132959
V-Knurled
056
195
056
209
A2-4H
&
4L
5/64
in
.079
in
2.0mm
046 796
132
960
V-Knurled
056
195
056
209
A2-4H
&
4L
3/32
in
.094
in
2.4mm
046 797
132
961
V-Knurled
056
196
056 210
A2-4L
7/64
in
.110
in
2.8mm
046
798
132
962
V-Knurled
056
196
056 210
A2-4L
1/8
in
.125
in
3.2mm
046
799
132
963
V-Knurled
056
197
056
211
A2-4H
&
4L
5/32
in
.156
in
4.0
mm
083
621
070
417
V-Knurled
044277
A2-4L
3/l6in
.188in
4.8mm
083622
070416
V-Knurled
044277
A2-4L
7/32in
.219in
5.6mm
083623
070415
V-Knurled
044277
A2-4L
1/4
in
.25
in
6.4mm
083
624
070
418
V-Knurled
044277
A2-4H
.045
in
.045
in
1.2
mm
083319
083
489
U-Cogged
056
193
056 207
A2-4H
.052
in
.052
in
1.3mm
083 320
083 490
U-Cogged
056
193
056 207
A2-4H
1/16
in
.062
in
1.6
mm
046800 053708
U-Cogged
056195
056209
A2-4H
& 4L
5/64
in
.079
in
2.0mm
046
801
053 710
U-Cogged
056
195
056
209
A2-4H
3/32
in
.094
in
2.4
mm
046
802
053 709
U-Cogged
056
196
056
210
A2-4L
3/32
in
.094
in
2.4mm
079 616
053 709
U-Cogged
056
196
A2-4L
7/64
in
.110
in
2.8
mm
046 803
053
711
U-Cogged
056
196
056
210
A2-4L
1/8
in
.125
in
3.2
mm
046 804
053
712
U-Cogged
056
197
]
056
211
S-0866
OM-1544
Page
13
I
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Miller A2-2H Owner's manual
- Category
- Welding System
- Type
- Owner's manual
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Miller Spoolmatic 30W Owner's manual
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