OWNER’S
MANUAL
August 1996 Form: OM-1313
Effective With Serial No. KG171523
cover_om 4/95 − ST-801 565 PRINTED IN USA
1996 MILLER Electric Mfg. Co.
Millermatic 185 And M-15 Gun
CV/DC Wire Welder For GMAW And FCAW Welding
Rated Welding
Output
Amperage
Range
Maximum
Open-Circuit
Voltage DC
Amperes Input at
Rated Load
Output, 60 Hz,
Single-Phase
Weight
Overall
Dimensions
Voltage DC
200 V 230 V KVA KW
150 A @ 23 Volts
DC, 60% Duty Cycle
30 − 185 33 30 (1.6)* 26 (1.4)* 6 (0.27)* 5 (0.13)*
165 lb
(75 kg)
Length: 36 in
(915 mm)
Width: 18 in
(457 mm)
Height: 27 in
(686 mm)
Wire Type And Diameter
Calculated Wire Speed
Max Wire Feed Speed
Solid Steel /
Stainless Steel
Flux Cored Aluminum
Calculated Wire Speed
Range At No Load
Max Wire Feed Speed
While Welding
.023 − .035 in
(0.6 - 0.9 mm)
.030 − .045 in
(0.8 − 1.2 mm)
.030 − .035 in
(0.8 − 0.9 mm)
138 − 795 IPM (3.5 − 20.3 m/min) 650 IPM (16.5 m/min)
*While idling
OM-1313 Page 1
SECTION 1 − SAFETY PRECAUTIONS FOR ARC WELDING
safety_som1 4/95OM-1313 − 8/96
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.
This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to
avoid the hazards.
Y Marks a special safety message.
. Means NOTE; not safety related.
1-2. Arc Welding Hazards
WARNING
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The
safety information given below is only a summary of the more complete safety information found in the
Safety Standards listed in Section 1-4. Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children, away.
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.
1. 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 big enough to prevent any physical contact with the
work or ground.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
6. Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
7. When making input connections, attach proper grounding
conductor first − double-check connections.
8. Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
9. Turn off all equipment when not in use.
10. Do not use worn, damaged, undersized, or poorly spliced cables.
11. Do not drape cables over your body.
12. If earth grounding of the workpiece is required, ground it directly
with a separate cable − do not use work clamp or work cable.
13. Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
14. Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
15. Wear a safety harness if working above floor level.
16. Keep all panels and covers securely in place.
17. Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Noise from some
processes can damage hearing. Chipping, grinding,
and welds cooling throw off pieces of metal or slag.
NOISE
1. Use approved ear plugs or ear muffs if noise level is high.
ARC RAYS
2. Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
3. Wear approved safety glasses with side shields.
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
material (wool and leather) and foot protection.
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.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
cleaners, and degreasers.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-1313 Page 2
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, slag, open flames, sparks, and arcs.
2. Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never drape a welding torch over a gas cylinder.
5. Never allow a welding electrode to touch any cylinder.
6. Never weld on a pressurized cylinder − explosion will result.
7. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
8. Turn face away from valve outlet when opening cylinder valve.
9. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
10. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
WELDING can cause fire or
explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating,
or fire. Check and be sure the area is safe before
doing any welding.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
12. Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
1-3. Additional Installation, Operation, And Maintenance Hazards
FIRE OR EXPLOSION can result from
placing unit on, over, or near
combustible surfaces.
1. Do not locate unit on, over, or near combustible
surfaces.
2. Do not install unit near flammables.
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
1. Use lifting eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.
2. Use equipment of adequate capacity to lift unit.
3. If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
HOT PARTS can cause severe burns.
1. Do not touch hot parts bare handed.
2. Allow cooling period before working on gun or
torch.
MOVING PARTS can cause injury.
1. Keep away from moving parts such as fans.
2. Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH
CURRENTS can affect pacemaker
operation.
1. Pacemaker wearers keep away.
2. Wearers should consult their doctor before going
near arc welding, gouging, or spot welding
operations.
MOVING PARTS can cause injury.
1. Keep away from moving parts.
2. Keep away from pinch points such as drive rolls.
FLYING PIECES OF METAL or DIRT can
injure eyes.
1. Wear safety glasses with side shields or face
shield.
WELDING WIRE can cause puncture
wounds.
1. Do not press gun trigger until instructed to do so.
2. Do not point gun toward any part of the body, other
people, or any metal when threading welding wire.
HIGH-FREQUENCY RADIATION can
interfere with radio navigation, safety
services, computers, and
communications equipment.
1. Have only qualified persons familiar with electronic
equipment perform this installation.
2. The user is responsible for having a qualified
electrician promptly correct any interference
problem resulting from the installation.
3. If notified by the FCC about interference, stop using
the equipment at once.
4. Have the installation regularly checked and
maintained.
5. Keep high-frequency source doors and panels
tightly shut, keep spark gaps at correct setting, and
use grounding and shielding to minimize the
possibility of interference.
OM-1313 Page 3
OVERUSE can cause OVERHEATED
EQUIPMENT.
1. Allow cooling period.
2. Reduce current or reduce duty cycle before
starting to weld again.
3. Follow rated duty cycle.
STATIC ELECTRICITY can damage
parts on circuit boards.
1. Put on grounded wrist strap BEFORE handling
boards or parts.
2. Use proper static-proof bags and boxes to store,
move, or ship PC boards.
SIGNIFICANT DC VOLTAGE exists after
removal of input power on inverters.
1. Turn Off inverter, disconnect input power, and
discharge input capacitors according to
instructions in Maintenance Section before
touching any parts.
BUILDUP OF SHIELDING GAS can harm
health or kill.
1. Shut off shielding gas supply when not in use.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent 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,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields − Background
Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing
Office, May 1989): “. . . there is now a very large volume of scientific
findings based on experiments at the cellular level and from studies
with animals and people which clearly establish that low frequency
magnetic fields can interact with, and produce changes in, biological
systems. While most of this work is of very high quality, the results are
complex. Current scientific understanding does not yet allow us to
interpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as
practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are also recommended for pacemaker
wearers. Consult your doctor for complete information.
OM-1313 Page 4
SECTION 2 − INSTALLATION
2-1. Installing Work Clamp
1 Work Cable
2 Boot
Slide boot onto work cable. Route
cable out front panel opening from
inside.
3 Negative (−) Output Terminal
Connect cable to terminal and
cover connection with boot.
4 Hardware
5 Work Clamp
Route cable through clamp handle
and secure as shown.
Close door.
ST-801 566
1/2, 3/4 in
1
2
3
4
5
Tools Needed:
2-2. Installing Gas Supply
ST-801 571 / Ref. ST-109 492
1 Cylinder Rack
2 Chain
Obtain gas cylinder and chain cylin-
der to rack.
3 Gas Hose Fitting
4CO
2
Washer
5 Regulator
Install washer and regulator onto
cylinder.
6 Gas Hose Connection
Obtain gas hose with fittings and
install between regulator and
welding power source.
7 Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour).
56
7
4
1
2
3
5/8, 1-1/8 in
Tools Needed:
OM-1313 Page 5
2-3. Installing Welding Gun
Ref. ST-801 567
1 Drive Assembly
2 Gun Securing Knob
3 Gun End
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
nut.
4 Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
Close door.
2
1
3
4
2-4. Setting Gun Polarity
1 Polarity Changeover Label
(Located Near Drive
Assembly)
Always read and follow manufac-
ture’s recommended polarity.
1
3/4, 11/16 in
Wire Drive Assembly Lead
To Positive (+) Output Terminal
Work Clamp Lead To
Negative (−) Output Terminal
GUN POLARITY
CHANGEOVER CONNECTIONS
Reverse Lead Connections − For Electrode
Negative (DCEN) For Flux Cored Wires
(FCAW Process). Drive Assembly
Becomes Negative
S-144 449-D
Tools Needed:
OM-1313 Page 6
2-5. Installing Wire Spool And Adjusting Hub Tension
ST-072573-B
When a slight force is needed
to turn spool, tension is set.
15/16 in
Use compression spring with
8 in (200 mm) spools.
Tools Needed:
2-6. Changing Input Voltage
ST-801 580
Y Turn Off unit, and disconnect
input power.
Unit was shipped from factory set
for 230 volts.
1 Transformer T1
2 Top Half Of 230 Volt Lead
3 Bottom Half Of 230 Volt Lead
(Marked 230V)
Remove cable ties, and slide sleev-
ing down. Disconnect the 230 volt
connection.
4 200 Volt Stub (Marked 200V)
Remove cable tie, and slide sleev-
ing out of the way.
Connect top half of 230V lead to the
200V stub. Slide sleeving over con-
nection and secure.
Fold sleeving over end of bottom
half of 230V lead and secure.
Reinstall wrapper.
3/8, 7/16 in
1
2
4
3
Tools Needed:
OM-1313 Page 7
2-7. Electrical Service Guide
Input Voltage
200 230
Input Amperes At Rated Output
30 26
Max Recommended Standard Fuse Or Circuit Breaker Rating In
Amperes
45 40
Min Input Conductor Size In AWG/Kcmil
10 10
Max Recommended Input Conductor Length In Feet (Meters)
97 (29) 128 (39)
Min Grounding Conductor Size In AWG/Kcmil
10 10
Reference: 1996 National Electrical Code (NEC). S-0092-J
2-8. Selecting A Location And Connecting Input Power
1 Rating Label
Supply correct input power.
2 Plug
3 Receptacle
Connect plug to receptacle.
4 Input And Grounding
Conductors
Connect directly to line disconnect
device if hard wiring is required.
5 Line Disconnect Device
See Section 2-7.
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
ST-801 568
L1
L2
230 VAC, 1
18 in (457 mm) of
space for airflow
L1
L2
1
Y Always connect grounding
conductor first.
= GND/PE
Y Do not move or operate unit
where it could tip.
4
2
3
1
5
OM-1313 Page 8
2-9. Installing Drive Roll, Inlet Wire Guide, And Threading Welding Wire
1 Drive Roll
Choose correct drive roll for wire
type, and install as shown.
2 Inlet Wire Guide
Remove guide by pressing on
barbed area, or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole from
rear until it snaps in place.
2
1
Ref. ST-801 569 / Ref. ST-801 570 / ST-801 083
6 in
(150 mm)
4 in
(102 mm)
Tighten
WOOD
Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;
continue to hold wire.
Close and tighten pressure
assembly, and let go of wire.
Remove gun nozzle and contact tip. Turn On.
Press gun trigger until wire
comes out of gun. Reinstall
contact tip and nozzle.
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Cut off wire. Close
and latch door.
Tools Needed:
OM-1313 Page 9
2-10. Weld Parameter
Wire Type,
Wire
Material Thickness
Wire Type,
Shielding Gas,
And Flow Rate
Wire
Diameter
(inch)
Operator
Controls
3/8 in
(9.5
mm)
1/4 in
(6.4
mm)
3/16 in
(4.8
mm)
1/8 in
(3.2
mm)
12 ga 14 ga 16 ga 18 ga 20 ga 22 ga
.023
Voltage Tap − − 6 5 4 3 3 2 1 1 − −
.023
Wire Speed − − 100 90 70 65 60 40 25 20 − −
E70S-6
CO
2
.030
Voltage Tap − − 4 4 3 2 2 2 1 − − − −
CO
2
20 cfh+
.030
Wire Speed − − 70 60 50 45 40 30 25 − − − −
.035
Voltage Tap 6 4 4 3 3 2 2 1 − − − −
.035
Wire Speed 80 65 40 35 30 25 30 10 − − − −
.023
Voltage Tap − − 3 4 3 3 2 2 1 1 1
.023
Wire Speed − − 80 90 70 60 70 40 45 25 12
E70S-6
75% Argon
.030
Voltage Tap 6 4 4 3 3 2 2 1 1 − −
75% Argon
25% CO
2
20 cfh+
.030
Wire Speed 90 58 70 55 50 48 45 30 5 − −
20 cfh+
.035
Voltage Tap 6 4 4 3 3 2 2 1 1 − −
.035
Wire Speed 80 48 60 50 35 27 30 11 3 − −
.030
Voltage Tap 5 4 4 3 2 2 1 1 − − − −
E71T-GS
Flux Core
.030
Wire Speed 80 65 65 50 30 30 10 5 − − − −
E71T-GS
Flux Core
.035
Voltage Tap 5 4 3 2 2 2 1 1 − − − −
.035
Wire Speed 5 50 40 30 25 20 10 0 − − − −
.023
Voltage Tap 5 4 4 4 3 3 3 2 2 2
.023
Wire Speed 95 85 80 60 50 50 50 30 20 20
ER 308
Stainless Steel
.030
Voltage Tap 5 5 4 3 3 2 2 2 1 − −
Stainless Steel
Tri-Mix
20 cfh+
.030
Wire Speed 70 70 70 50 45 50 45 40 0 − −
20 cfh+
.035
Voltage Tap 6 5 5 4 3 2 2 2 − − − −
.035
Wire Speed 65 40 40 30 30 25 20 10 − − − −
*Do not change Voltage switch position while welding. Wire Speed value in Table is a starting value only, and Wire Speed control setting can be fine
tuned during welding. S-181 020-A
OM-1313 Page 10
SECTION 3 − OPERATION
3-1. Front Panel Controls
Ref. ST-180 930
Controls For Standard Units
1 Wire Speed Control
Use control to select a wire feed
speed. As Voltage switch setting in-
creases, wire speed range also in-
creases (see Section 2-10). Scale
around control is not actual wire
feed speed, but is for reference
only.
2 Voltage Switch
The higher the selected number,
the thicker the material that can be
welded (see Section 2-10). Do not
switch under load.
3 Pilot Light
4 Power Switch
1
2
3
4
OM-1313 Page 11
6 Minutes Welding 4 Minutes Resting
3-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
voltage, or duty cycle before
welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
Overheating
0
15
A or V
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − SB-181 009
60% Duty Cycle At 150 Amperes
OM-1313 Page 12
SECTION 4 − MAINTENANCE & TROUBLESHOOTING
4-1. Routine Maintenance
Y Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
3 Months
Replace
Damaged Or
Unreadable
Labels
Clean And
Tighten
Weld
Terminals
Repair Or
Replace
Cracked
Cables And
Cords
6 Months
Blow Out Or
Vacuum Inside
4-2. Circuit Breakers CB1 And CB2
Ref. ST-801 567
Y Turn Off unit.
1 Circuit Breaker CB1
CB1 protects the transformer from
overload. If CB1 opens, wire
feeding stops.
2 Circuit Breaker CB2
CB2 protects the trigger circuit from
overload. If CB1 opens, weld output
stops.
Press button to reset circuit
breaker. Close door.
1 2
OM-1313 Page 13
4-3. Cleaning Or Replacing Gun Liner
Ref. ST-800 797-A
3/8 in
To Reassemble Gun:
Insert new liner.
Install and tighten wire outlet guide.
Cut liner off 3/4 in (20 mm) (3/8 in
[9.5 mm] for aluminum) from head
tube.
Install adapter, contact tip, and
nozzle.
Lay gun cable out straight
before installing new liner.
Head tube
3/8 in
Wire Outlet Guide
Remove liner.
Remove nozzle, contact tip,
adapter, and wire outlet guide.
Blow out gun casing.
Y Disconnect gun first.
Tools Needed:
OM-1313 Page 14
4-4. Replacing Switch And/Or Head Tube
Ref. ST-800 795-A
Do not disturb cable connection between
cable connector and connector nut.
1 Remove handle
locking nut.
2 Remove switch housing. Note: If installing new
switch, push switch lead connectors onto terminal of
new switch (polarity is not important). Install switch
back into handle, and secure with handle locking nut.
If replacing head tube, continue to end of figure.
3 Slide handle.
4 Secure head
tube in vice.
5 Remove shock wash-
ers from front and
rear of head tube.
6 Loosen jam nut. Remove
from vice and turn head
tube out by hand.
7 Install both existing shock washers
to new head tube and hand-tighten
head tube into connector cable.
8 Place head tube in vice and tighten
to within 1/8 in (3.2 mm) spacing be-
tween connector cable and body.
9 Remove from vice. Reposition
handle and install switch housing.
Secure with handle locking nut.
Y Disconnect gun first.
3/4 in
Tools Needed:
OM-1313 Page 15
4-5. Replacing Gun Contact Tip
ST-149 326-B
Y Turn Off unit.
1 Nozzle
2 Contact Tip
Cut off welding wire at contact tip.
Remove nozzle.
Remove contact tip and install new
contact tip. Reinstall nozzle.
1
2
Tools Needed:
4-6. Unicable Repair
To repair or replace unicable, order Unicable Clamp Kit, part number 172 018.
4-7. Troubleshooting
Welding Trouble Remedy
No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-8).
Check and replace power switch if necessary.
Check circuit breakers CB1 and/or CB2, and reset if necessary (see Section 4-2).
Replace building line fuse or reset circuit breaker if open (see Section 2-8).
Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 2-3 and/or 4-4).
Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled
(see Section 3-2).
No weld output; wire feeds. Connect work clamp to get good metal to metal contact.
Replace contact tip (see Section 4-5).
Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 2-8).
Low, high, or erratic wire speed. Readjust front panel settings (see Section 3-1).
Change to correct size drive roll (see Section 2-9).
Readjust drive roll pressure (see Section 2-9).
Replace inlet guide, contact tip, and/or liner if necessary (see Sections 2-9, and 4-3).
Wire Drive/Gun Trouble Remedy
Electrode wire feeding stops during
welding.
Straighten gun cable and/or replace damaged parts (see Section 4-3).
Adjust drive roll pressure (see Section 2-9).
Readjust hub tension (see Section 2-5).
Replace contact tip if blocked (see Section 4-5).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 4-3).
Replace drive roll if worn or slipping (see Section 2-9).
Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 2-3 and/or 4-4).
OM-1314 Page 17
SECTION 5 − ELECTRICAL DIAGRAM
SB-178 359
Figure 5-1. Circuit Diagram
OM-1313 Page 18
SECTION 6 − WELDING METHODS & TROUBLESHOOTING
mod4.1* 9/9
2
A. Welding Methods
6-1. Holding And Positioning Welding Gun
Wire Extension (Stickout)
1/4 − 1/2 in (6 − 13 mm)
. Cradle gun and rest hand on workpiece. Place tip of wire on seam before lowering hel-
met and pressing trigger. Welding wire is not energized until gun trigger is pressed.
90° 90°
0°-15°
GROOVE WELDS
End View Of Work Angle Side View Of Gun Angle
S-0421-A
45°
45°
FILLET WELDS
End View Of Work Angle Side View Of Gun Angle
0°-15°
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