Miller KC248746 Owner's manual

KC248746
Miller
Brand
Miller
Model
KC248746
Category
Welding System
Type
Owner's manual

This manual is also suitable for

MODEL:
XR
ATM
And
XR
WTM
Wire
Feeder
And
~Gun
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
MILLER
ELECTRIC
Mfg.
Co.
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
A
Mifler
Group
Ltd..
Company
equipment.
This
unitand
these
instructions
are
foruse
only
by
persons
trained
and
P.O.
Box
1079
experienced
in
the
safe
operation
of
welding
equipment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
Appleton,
WI
54912
USA
Tel.
414-734-9821
not
fully
understand
these
instructions.
/1
~MiHerfi
June
1992
FORM:
OM-1581B
Effective
With
Serial
No.
KC248746
4~.A
PRINTED
IN
LISA
La
MILLERS
TRUE
BLUE~
LIMiTED
WARRANTY
Effective
January
I,
1992
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
This
limited
warranty
supersedes
alt
previous
MILLER
warranties
snd
is
exclusive
with
no
other
gusrsntees
or
warrenties
espressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
snd
conditions
below.
MILLER
Electric
Mtg.
Co..
Appleton.
Wisconsin.
warrsnts
to
its
originsl
retsil
purchaser
that
new
MILLER
equipment
sold
after
the
effective
date
of
this
limited
warrsnly
is
free
ot
de
tects
in
msterisl
end
workmanship
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.
Within
the
wsrranty
periods
listed
below.
MILLER
wilt
repair
or
replace
sny
war
rsnted
parts
or
components
that
tell
due
to
such
detects
in
material
or
workmanship.
MILLER
must
be
notified
In
writing
within
thirty
(30)
days
ot
such
detect
or
failure,
at
which
time
MILLER
wilt
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
ot
such
a
failure
within
the
warranty
time
periods.
Alt
warranty
time
periode
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser.
and
are
aa
follows:
1.
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
Automatic
Wire
Feeders
Robots
3.
2
Years
Parts
and
Labor
*
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
4.
1
Year
Parts
and
Labor
Motor
Driven
Guns
Process
Controllers
Water
Coolant
Systems
HF
Units
Grids
Spot
Welders
Load
Banks
SDX
Transtormers
Running
Gear/Trailers
Field
Options
(NOTE:
Field
options
are
covered
under
True Blue
TM
tor
the
remaining
warranty
period
ot
the
product
they
are
installed
in.
or
for
a
minimum
ot
one
year
whichever
is
grester.l
5.
6
Months
Batteries
6.
90
Days
Parts
and
Labor
MIG
Guns/TIG
Torches
Plasma
Cutting
Torches
Remote
Controls
Accessory
Kits
Replacement
Parts
MILLERS
True
Blue
r
Umited
Warranty
shall
not
epply
to:
1.
Items
furnished
by
MILLER.
but
manufactured
by
others.
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty.
it
any.
2.
Consumable
components:
such
as
contact
tips,
cutting
nozzles,
contactora
and
relays.
3.
Equipment
that
hsa
been
moditled
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
specifications
for
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
CDMMER
CIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENt
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
eacluaive
remedlea
shall
be,
at
MILLERS
option:
(1)
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
authorized
MILLER
service
station:
or
(4)
payment
ot
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
relum
of
the
goods
at
customers
risk
and
espense.
MILLERS
option
of
repair
or
replacement
will
be
FOB..
Factory
at
Appleton.
Wisconsin.
or
FOB,
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW.
THE
REMEDIES PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
LIABLE
FOR
DIRECT
INDIRECT
SPECIAL.
INCIDENTAL
OR
CONSEOUENTIAL
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
EOUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
DY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
esclusion
may
not
apply
to
you.
This
warrsnty
provides
ape
citic
legal
rights,
and
other
rights
may
be
available,
but
may
very
from
state
to
state.
In
Canada.
legislation
in
some
provinces
provides
for
certain
additional
warrantIes
or
remedies
other
than
as
stated
herein.
snd
to
the
extent
that
they
may
not
be
waived,
the
limitations
and
esciusiona
set
out
above
may
not
apply.
This
Limited
Warranty
providea
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
ii
a
J
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
manufacturers
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
5/92
ERRATA
SHEET
September
18,
1992
FORM:
OM-1581B
Use
above
FORM
number
when
ordering
extra,
manuals.
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
CHANGES
TO
SECTION
3-
INSTALLATION
Replace
Section
3-7.
115
VAC/Contactor
Control
Plug
Information
I
Interconnecting
Cord
2
115
VAC/Contactor
Control
Plug
PLG5
If
welding
power
source
is
eauipped
with
matching
14-socket
receptacle,
insert
plug,
and
tighten
threaded
collar.
Proceed
to
Section
3-9
in
manual.
If
plug
PLG5
will
not
connect
to
welding
power
source
receptacle.
use
the
following
pin
information
and
following
Section
3-8
to
re
place
PLG5
with
a
suitable
plug.
Pin
Information
to
connect
the
following
equipment:
Remote
Contactor
A,B
Contact
closure
completes
the
contactor
control
circuit
Remote
Voltage
Control
(Optional)
C
Command
reference;
+10
volts
dc.
D
Remote
control
circuit
common.
E
Input
command
signal
from
potentiometer
wiper;
0
to
+10
volts
dc.
Remote
Contactor
G
Circuit
common
for
115
volts
ac
circuit.
l,J
Contact
closure
completes
the
115
volts
ac
contactor
control
circuit.
1<
Circuit
common.
Remaining
pins
are
not
used.
Ref.
S-0004.A
/
Ref.
ST.tSl
772
2
Figure
3-12.
115
VAC/Contactor
Control
Plug
Information
Replace
Section
3-8.
Replacing
115
VAC/Contactor
Control.Plug
With
Supplied
5-Pin
Or
Twistlock
Plug
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
OFF
wire
feeder
and
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Stop
engine
on
welding
generator.
Have
only
aualified
persons
make
wiring
connections.
wiwarni
i
gigi
1
115
VAC/Contactor
Control
Plug
PLG5
2
Contactor
Control
Cord
3
I15VACCord
Find
and
label
cords
by
following
leads
back
to
PLG5:
Contactor
control
cord
connects
to
pins
A
&
B
of
PLG5
115
VAC
cord
connects
to
pin
J
of
PLG5.
Cut
off
plug
PLG5.
4
5-Pin
Plug
5
Twistlock
Plug
For
connections
shown
in
Figure
3-3
or
Figure
3-4
in
manual,
install
5-pin
or
twistlock
plug
onto
contac
tor
control
cord.
For
Figure
3-2
connection
in
manu
al,
obtain
plug
to
match
contactor
control
receptacle
on
welding
pow
er
source,
and
install
plug
onto
contactor
control
cord.
Obtain
115
VAC
plug
and
connect
to
115
VAC
cord
as
follows:
green
lead
to
ground
white
lead
to
11
5VAC
common
black
lead
to
11
5VAC
hot.
6
Plug
PLG5O
7
Plug
PLG51
8
Plug
PLG52
Unit
shipped
with
PLG5O
con
nected
to
PLG5I
to
provide
115
VAC
for
contactor.
If
contact
closure
needed
for
con
tactor.
connect
PLG5O
to
PLG52.
ST-151
773-B
Figure
3-13.
Replacing
115
VAC/Contactor
Control
Plug
With
Supplied
5-Pin
Or
Twistlock
Plug
OM-1581B
Page
2
CHANGES
TO
SECTION
7
PARTS
LIST
Change
Parts
List
as
follows:
Quantity
-
.
22ft
.2
PULL
MOTOR
B2
GUN
ASSEMBLY
B
C
A
0
V
0
CORD
#1
CHANGES
TO
SECTION6
ELECTRICAL
DIAGRAMS
Replace
Figure
6-1.
Circuit
Diagram
For
Wire
Feeder
(see
Page
4
on
this
Errata
Sheet)
IReplace
Figure
6-2.
Wiring
Diagram
For
Wire
Feeder
(see
Page
5
on
this
Errata
Sheet)
IReplace
Figure
6-3.
Circuit
Diagram
For
Gun
~1
I
TRIGGER
.~
L
flPBI~~I
CORD
#2
SA.138
956-B
Figure
6-3.
Circuit
Diagram
For
Gun
Dia.
Part
Replaced
-~
Mkgs.
No.
With
Description
33-
007 826
...
007826
..
CABLE,
(qty
chg)
(order
by
ft)
-.
34-
601
219
601
219
..
LINK,
(qty
chg)
-.
34-
...
PLG51,52
..
Added
131
204
-.
HOUSING
PLUG
&
SOCKET,
(consisting
of)
-.
113
746
.
. .
.
TERMINAL,
female
lskt
24-18
wire
34-
PLG5O
...
Added
131
203
..
HOUSING
PLUG
&
PINS,
(consisting
of)
114
656
-
. . .
TERMINAL,
male
1
pin
24-18
wire
~First
digit
represents
page
no
digits
following
dash
represent
item
no.
l3E
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
\V
G
E
F
PLG2
OM-1581B
Page
3
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SC-156
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Figure
6-1.
Circuit
Diagram
For
Wire
Feeder
Effective
With
Serial
No.
KC288497
And
Following
60)21-K)
446(68LICEI)
88(R44-CW)
38)
SPL
ICE-3)
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REED
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E
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SC-156
400
Figure
6-2.
Wiring
Diagram
For
Wire
Feeder
Effective
With
Serial
No.
KC288497
And
Following
ARC
WELDING
SAFETY
PRECAUTIONS
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.
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.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
WELDING
can
cause
fire
or
explosion.
Sparks
and
spatter
fly
off
from
the
welding
arc.
The
flying
sparks
and
hot
metal,
weld
spatter.
hot
workpiece.
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
or
welding
wire
to
metal
oblects
can
cause
sparks.
overheating,
or
fire.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
Remove
allflammables
within
35
ft(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
i
through
small
cracks
and
openings
to
adjacent
areas.
5.
Properly
install
and
ground
this
equipment
according
to
itS
Owners
Manual
and
national,
state,
and
local
codes.
Turn
off
all
equipment
when
not
in
use.
Do
not
use
worn,
damaged.
undersized,
or
poorly
spliced
cables.
Do
not
wrap
cables
around
your
body.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
Do
not
touch
electrode
while
in
contact
with
the
work
(ground)
circuit.
11
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
12.
Wear
a
safety
harness
to
prevent
falling
if
working
above
floor
level.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side,
Do
not
weld
on
closed
containers
such
as
tanks
or
drums.
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.
Do
not
use
welder
to
thaw
frozen
pipes.
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.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
recommended,
2.
Wear
proper
body
protection
to
protect
skin.
6.
7
8.
9.
10.
13.
Keep
all
panels
and
covers
securely
in
place.
/~
...Li
ARC
RAYS
can
burn
eyes
and
skin;
1.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
(see
NOISE
can
damage
hearing.
ANSI
Z49.
I
listed
in
Safety
Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
Arc
rays
from
the
welding
process
produce
intense
2.
Wear
approved
safety
glasses.
Side
shields
recommended.
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
3,
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
skirt.
Noise
from
some
processes
can
damage
and
glare:
warn
others
not
to
watch
the
arc.
hearing.
4.
Wear
protective
clothing
made
from
durable.
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
FUMES
AND
GASES
can
be
hazardous
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated.
or
while
to
your
health.
wearing
an
air-supplied
respirator.
Shielding
gases
used
for
Q
Welding
produces
fumes
and
gases.
Breathing
these
welding
can
displace
air
causing
n~ury
or
death.
Be
sure
the
fumes
and
gases
can
be
hazardous
to
your
health.
breathing
air
is
sate.
6.
Do
not
weld
in
locations
near
degreasing.
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
1.
Keep
your
head
out
of
the
fumes.
Do
not
breath
the
fumes.
form
highly
toxic
and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor.
use
an
approved
air-supplied
respirator.
cadmium
plated
steel.
unless
the
coating
is
removed
from
the
4.
Read
the
Material
Safety
Data
Sheets
(MSDS5)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary.
while
manufacturers
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.
1.
2.
3.
4.
5
6.
7.
8.
9,
10
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury.
Chipping
and
grinding
cause
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
S.
9~
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
tailing
or
tipping.
~
MOVING
PARTS
can
cause
injury.
Moving
parts,
such
as
fans,
rotors,
and
belts
can
cut
fingers
and
hands
and
catch loose
clothing.
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
STEAM
AND
PRESSURIZED
HOT
COOLANT
can
burn
face,
eyes,
and
skin.
The
coolant
in
the
radiator
can
be
very
hot
and
under
pressure.
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
cylinder
is
in
use
or
connected
for
use.
8.
Read
and
follow
instructions
on
compressed
gas
cylinders.
associatedequipment.
and
CGA
publication
P-i
listed
in
Safety
Standards.
ENGINES
can
be
hazardous.
3.
Have
only
qualified
people
remove
guards
or
covers
for
maintenance
and
troubleshooting
as
necessary.
4.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
5.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
parts.
6.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
finished
and
before
starting
engine.
1.
Do
not
remove
radiator
cap
when
engine
is
hot.
Allow
engine
to
cool.
Wear
gloves
and
put
a
rag
over
cap
area
when
removing
cap.
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
N.W.
LeJeurie
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.
Amen.
can
Welding
Society
Standard
AWS
F4.
1,
from
American
Welding
So
ciety.
550
N.W.
LeJeune
Pd,
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,
GSA
Standard
Wi
17.2.
from
Canadian
Standards
Association,
Standards
Sales,
178
Pexdale
Bou
levard,
Rexdale,
Ontario,
Canada
M9W
1
P3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protec
tion,
ANSI
Standard
Z87.1.
from
American
National
Standards
Insti
tue.
1430
Broadway.
New
York.
NY
10018.
Cutting
And
Welding
Processes.
NFPA
Standard
518.
from
National
Fire
Protection
Association,
Batterymarch
Park.
Quincy,
MA
02269.
a
WARNING
~.
~
ENGINE
EXHAUST
GASES
can
kill.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
2.
II
used
in
a
closed
area,
vent
engine
exhaust
outside
and
Engines
produce
harmful
exhaust
gases.
away
from
any
building
air
intakes.
ENGINE
FUEL
can
cause
fire
or
1.
Stop
engine
before
checking
or
adding
fuel.
explosion.
2.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
open
flames.
3.
Allow
engine
to
cool
before
fueling.
If
possible,
check
and
add
Engine
fuel
is
highly
flammable.
fuel
to
cold
engine
before
beginning
job.
4.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
5.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
starting
engine.
2.
Stop
engine
before
installing
or
connecting
unit.
SPARKS
can
cause
BATTERY
GASES
1.
Always
wear
a
face
shield
when
working
on
a
battery.
TO
EXPLODE;
BATTERY
ACID
can
2.
Stop
engine
before
disconnecting
or
connecting
battery
burn
eyes
and
skin,
cables.
3.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
Batteries
contain
acid
and
generate
explosive
4.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
gases.
5.
Observe
correct
polarity
(+
and
)
on
batteries.
2.
3.
Sri
9/Si
TABLE
OF
CONTENTS
SECTION
1
SAFETY
SIGNAL
WORDS
.
1
SECTION
2
SPECIFICATIONS
2-1.
Duty
Cyc!e
1
SECTION
3INSTALLATION
3-1.
Equipment
Connection
Diagrams
2
3-2.
Removing
Top
Cover
Of
Gun
5
3-3.
Gun
To
Feeder
Connections
5
3-4.
Internal
Connections
To
Feeder
6
3-5.
Adjusting
Contact
Tube
Position
9
3-6.
Voltage
Sensing
Lead
Connections
9
3-7.
115
VAC/Contactor
Control
Plug
Information
10
3-8.
Replacing
115
VAC/Contactor
Control
Plug
With
Supplied
5-Pin
Or
Twistlock
Plug
10
3-9.
Installing
Wire
Spool
ti
3-10.
Threading
Welding
Wire
12
3-11.
Coolant
Guidelines
To
Prevent
Corrosion
13
SECTION
4
OPERATION
14
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
19
5-2.
Changing
Or
Cleaning
Gun
Drive
Roll
20
5-3.
Changing
Feeder
Drive
Roll
And
Wire
Inlet
Guide
21
5-4.
Replacing
Or
Cleaning
Gun
Drive
Roll
Bearing
22
5-5.
Replacing
Or
Cleaning
Feeder
Drive
Roll
Bearing
22
5-6.
Changing
Gun
Contact
Tube
And
Liner
23
5-7.
Replacing
Contact
Tube
Adapter
23
5-8.
Replacing
Hub
Assembly
24
5-9.
Adjusting
Hub
Tension
25
5-10.
Overload
Protection
25
5-11.
Water
Flow
Switch
(Optional
For
Water-Cooled
Models)
26
5-12.
Troubleshooting
26
SECTION
6
ELECTRICAL
DIAGRAMS
28
SECTION
7
PARTS
LIST
Figure
7-1.
Main
Assembly
32
Figure
7-2.
Motor
&
Wire
Drive
35
Figure
7-3.
Panel,
Front
w/Components
(XR-W
Model
Illustrated)
36
Figure
7-4.
Exploded
View
Of
Gun
38
OM.1
581
B
692
SECTION
1
-
SAFETY
SIGNAL
WORDS
modl.1
991
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
identify
different
levels
of
hazard
and
special
instructions.
4~
WARNING
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
serious
personal
injury
or
loss
of
life.
a
CAUTION
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
~l
M
PORTANT:
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equipment.
SECTION
2SPECIFICATIONS
Table
2-1.
~1ire
Feeder
Specification
Description
Type
Of
Input
Power
115
Volts
AC,
3
Amperes
At
50/GO
Or
100
Hz
Power
Control
Circuit
Voltage
Provided
At
Gun
30
Volts
DC
Wire
Feed
Speed
Range
70.875
ipm
(1.9-22.2
mpm)
Overall
Dimenstons
Length:
19
in.
(483
mm);
Width:
9-1/4
in,
(235
mm);
Height:
15-1/4
in.
(387
mm)
Maximum
Spool
Capacity
12
in.
(305
mm)
Cooling
Method
Air-Cooled
(A
Models)
Or
Water-Cooled
(W
Models)
Weight
(Feeder
With
Gun)
Models
With
15
ft.
(4.6
m)
Cable
Assembly
Net:
56
lbs.
(25
kg):
Ship:
58
lbs.
(26
kg)
Models
With
30
ft.
(9.1
m)
Cable
Assembly
Net:
63
lbs.
(29
kg);
Ship:
65
lbs.
(30
kg)
Table
2-2.
Gun
Specification
Description
Input
Voltage
30
Volts
DC
Duty
Cycle
(Air-Cooled
Models)
At
200
Amperes.
100%
Using
Argon
Or
Argon
Mixture
Shielding
Gas
At
250
Amperes,
60%
Using
Argon
Or
Argon
Mixture
Shielding
Gas
(See
Sec
tion
2.1)
Duty
Cycle
(Water-Cooled
Models)
At
400
Amperes,
100%
Using
Argon
Or
Argon
Mixture
Shielding
Gas
(See
Section
2-1)
Wire
Size
Range
.030
Thru
1/16
in.
(0.8
Thru
1.6
mm)
Aluminum
Wire
.030
Thru
.045
in.
(0.8
Thru
1.1
mm)
Hard
Or
Cored
Wire
2-1.
Duty
Cycle
a
CAUTION
USING
GUN
BEYOND
DUTY
CYCLE
RATING
can
damage
gun.
S
Do
not
exceed
indicated
duty
cycles.
OM.1581
Page
1
Duty
cycle
is
how
long
the
gun
can
operate
within
a
ten
minute
period
without
causing
overheating
or
damage.
Both
models
are
rated
using
argon
or
argon
mixture
shielding
gas.
The
air-cooled
model
is
rated
at
100%
duty
cycle
when
operated
at
200
amperes,
allowing
continuous
welding.
When
operated
at
250
amperes,
the
air-cooled
model
is
rated
at
60%
duty
cycle,
allowing
welding
6
minutes
out
of
every
10
minutes.
The
water-cooled
model
~s
rated
at
100%
duty
cycle
when
operated
at
400
amperes,
allowing
continuous
welding.
SECTION
3INSTALLATION
Table
3-1.
Items
Included
With
Feeder
And
Gun
Item
Quantity
Feeder
Drive
Roll
(Small
Groove
For
.030
Thru
1/16
in.
Wire,
Large
Groove
For
.045
Thru
1/16
in.
Wire)
Shipped
With
Large
Groove
In
Feed
Position
I
Gun
Drive
Roll*
(Small
Groove
For
.025
Thru
.035
in.
Wire,
Large
Groove
For
.047
Thru
1/16
in.
Wire)
Shipped
With
Large
Groove
In
Feed
Position
I
Contact
Tubes
(1
For
Each
Wire
Size
.023/.025,
.030.
.035,
.047,
And
1/16
in.)
Shipped
With
.047
Installed
5
lOft.
(3
m)
Gas
Hose
I
lOft.
(3
m)
Water
Hose
With
Adapter
Fitting
(Water-Cooled
Models
Only)
I
10
ft.
(3
m)
Water
Hose
(Water-Cooled
Models
Only)
I
Contact
Tube
Wrench
i
5-Pin
Plug
1
Twistlock
Plug
1
*A
.023/025
contact
tube
is
supplied
with
gun,
but
feeder
is
not
designed
to
feed
these
wire
sizes.
~
IMPORTANT:
Be
sure
that
contact
tube,
line,;
and
drive
rolls
are
correct
for
wire
size
and
type,
see
Section
5
to
change
parts
as
needed.
See
Section
7
for
list
of
other
available
contact
tubes.
3-1.
Equipment
Connection
Diagrams
a
WARNING
CYLINDERS
can
explode
if
damaged.
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
Never
touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
HOT
SURFACES
can
burn
skin.
Allow
gun
to
cool
before
touching.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
OFF
wire
feeder
and
welding
power
source.
and
disconnect
input
power
before
making
connections.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
welding
or
feeding
wire
using
gun
trigger.
Review
Figure
3-1
through
Figure
3-4
to
determine
how
equipment
will
be
connected.
Air-cooled
models
are
shown
in
Figure
3-1
through
Figure
3-4.
For
water-cooled
models,
supplied
water
hoses
must
be
connected
from
wire
feeder
to
coolant
supply.
Read
entire
Section
3
before
installing
equipment.
OM-1581
Page
2
Have
only
qualified
persons
install
this
unit.
wtwarn71
9/91
Figure
3-1.
Connections
With
A
Constant
Voltage
(CV)
Or
Constant
Voltage/Constant
Current
(CV/CC)
Welding
Power
Source
Having
A
14-Socket
Receptacle
Figure
3-2.
Connections
With
A
Constant
Voltage
(CV)
Welding
Power
Source
Having
Separate
115
VAC
And
Contactor
Control
Receptacles
1
CV
Or
CC/CV
Welding
Power
Source
2
115
VAC/Contactor
Control
14-Pin
Plug
PLG5
3
Positive
(+)
Weld
Cable
4
Negative
()
Weld
Cable
5
Workpiece
6
Voltage
Sensing
Lead
Connect
lead
to
workpiece
for
CC
welding
only.
7
Gun
8
Wire
Feeder
9
lOft.(3m)Gas
Hose
10
115
VAC/Contactor
Controt
Cord
11
Gas
Cylinder
ST-t5t
774
1
CV
Welding
Power
Source
2
Plug
Obtain
matching
plugs
for
connect
ing
to
power
source
receptacles.
3
Positive
1+)
Weld
Cable
4
Negative
()
Weld
Cable
5
Workpiece
6
Voltage
Sensing
Lead
Do
not
connect
to
workpiece.
7
Gun
8
Wire
Feeder
9
lOft.(3m)GasHose
10
115
VAC/Contactor
Control
Cord
11
Gas
Cylinder
10
9
8
STt51
775A
OM-1581
Page
3
FIgure
3-3.
Connections
With
A
Constant
Current
(CC)
Welding
Power
Source
Having
Contactor
Control
Receptacle
Figure
3-4.
Connections
With
A
Constant
Current
(CC)
Welding
Power
Source
And
A
115VAC/12VDC
Secondary
Contactor
1
CC
Welding
Power
Source
2
5-Pin
Or
Twistlock
Plug
(Supplied)
3
Positive
(+)
Weld
Cable
4
Negative
()
Weld
Cable
5
Workpiece
6
Voltage
Sensing
Lead
7
Gun
8
Wire
Feeder
9
lOft.(3m)GasHose
10
2-Conductor
Contactor
Con
trol
Cord
11
3-Conductor
115
VAC
Cord
12
Gas
Cylinder
13
115
VACPIug
Obtain
plug
for
wire
feeder.
ST-151
176
I
CC
Welding
Power
Source
2
Positive
(+)
Weld
Cable
3
Negative
()
Weld
Cable
4
Workpiece
5
Voltage
Sensing
Lead
6
Gun
7
Wire
Feeder
8
lOft.(3m)GasHose
9
3-Conductor
115
VAC
Cord
10
2-Conductor
Contactor
Con
trol
Cord
11
5-Pin
Plug
12
Secondary
Contactor
13
Gas
Cylinder
14
115
VACPIug
Obtain
plug
for
wire
feeder.
ST.~5~
177
3-2.
Removing
Top
Cover
Of
Gun
1
Top
Cover
Push
back
and
lift
off
as
shown.
To
reinstall
cover,
set
rear
of
cover
in
gun,
and
push
cover
back
and
down
until
it
clicks
into
position.
Ret.
ST.150
862-A
Figure
3-5.
Removing
Top
Cover
Of
Gun
3-3.
Gun
To
Feeder
Connections
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
OFF
wire
feeder
and
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Stop
engine
on
welding
generator.
wtwarnl
9J9~
A.
Air-Cooled
Gun
Connections
1
Gun
Control
Cable
Insert
plug
into
GUN
CONTROL
receptacle,
and
tighten
threaded
collar.
2
Gas
Hose
Connect
to
GAS
fitting
on
feeder.
3
Wetd
Cable
4
Weld
Cable
Terminal
In
Feeder
Connect
gun
weld
cable
to
weld
cable
terminal
in
feeder.
5
Wire
Conduit
6
Thumbscrew
7
Wire
Conduit
Block
Loosen
thumbscrew,
and
insert
conduit
through
WIRE
opening
un
til
it
bottoms
against
block.
Tighten
thumbscrew.
Close
and
latch
door.
Tools
Needed;
~Z~
5/6
in.,
3/4
~fl.
Ref.
ST.151
778-A
/
ST151
666
/
S1.145
432.A
3
Figure
3-6.
Air-Cooled
Gun
Connections
OM-1581
Page
5
B.
Water-Cooled
Gun
Connections
FIgure
3-7.
Water-Cooled
Gun
Connections
3-4.
Internal
Connections
To
Feeder
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
OFF
wire
feeder
and
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Stop
engine
on
welding
generator.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
welding
or
feeding
wire
using
gun
trigger.
CYLINDERS
can
explode
if
damaged.
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
Never
touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
HiGH
GAS
PRESSURE
can
cause
gun
gas
valve
to
leak.
Do
not
use
gas
pressure
above
50
psi
(345
kPa)
or
mechanical
gas
valve
in
gun
can
leak.
OVERHEATING
can
damage
gun
parts.
If
using
recirculating
coolant
system,
do
not
make
connections
from
coolant
system
to
water
valve;
instead
make
connections
directly
from
coolant
system
to
gun
hoses.
INCORRECT
COOLANT
FLOWRATE
can
damage
gun
parts.
Maintain
minimum
1
qt./min.
flowrate
at
all
times.
w~warn7
1.9191
2
I
I
Gas
Hose
Connect
to
GAS
fitting
on
feeder.
2
Water
Hose
Connect
to
WATER
TO
GUN
fitting
on
feeder
(left-hand
threads).
3
Wire
Conduit
4
Thumbscrew
5
Wire
Conduit
Block
Loosen
thumbscrew,
and
insert
conduit
through
WIRE
opening
un
til
it
bottoms
against
block.
Tighten
thumbscrew.
6
Gun
Control
Cable
Insert
plug
into
GUN
CONTROL
receptacle,
and
tighten
threaded
collar.
7
Strain
Relief
Remove
strain
relief
as
shown.
8
PoweriWater
Cable
Route
cable
through
strain
relief
and
connect
to
WELD/WATER
FROM
GUN
outlet
on
feeder.
Rein
stall
strain
relief.
Close
and
latch
door.
Ref
ST-151
778-A/
ST-152
456
7
8
6
Tools
Needed:
:~
518in..
l-1/8in.
OM-1581
Page
6
A.
Air-Cooled
Feeder
Connections
Rear
Panel
Figure
3-8.
Air-Cooled
Feeder
Connections
1
Gas
Hose
Grommet
2
lOft.(3m)GasHose
3
Rear
Of
Gas
Fitting
Route
one
end
of
gas
hose
through
grommet,
and
connect
hose
to
rear
of
GAS
fitting
in
feeder.
Connect
re
maining
end
of
hose
to
regulator/
flowmeter.
4
Weld
Cable
To
Welding
Power
Source
Select
and
prepare
weld
cable
ac
cording
to
welding
power
source
manual.
5
Weld
Cable
Grommet
6
Reed
Switch
7
Weld
Cable
Terminal
In
Feeder
Route
one
end
of
weld
cable
through
grommet.
through
reed
switch,
and
connect
to
weld
cable
terminal
in
feeder.
Connect
remaining
end
of
cable
to
positive
(+)
weld
output
ter
minal
on
welding
power
source.
8
Gun
Weld
Cable
Be
sure
that
terminal
of
welding
pow
er
source
weld
cable
is
in
direct
con
tact
with
terminal
from
gun
weld
cable.
Close
and
latch
door.
Ref.
ST.151
771
2
4
6
7
3
Tools
Needed:
5/8
in..
1-1/8
in.
OM-1581
Page
7
B.
Water-Cooled
Feeder
Connections
Rear
Panel
Obtain
coolant
supply.
1
Gas
Hose
Grommet
2
lOft.(3m)GasHose
3
Rear
Of
Gas
Fining
Route
one
end
of
gas
hose
through
grommet.
and
connect
hose
to
rear
of
GAS
fitting
in
feeder.
Connect
re
maining
end
of
hose
to
regulator/
flowmeter.
4
Coolant
Supply
Hose
Grom
met
5
10
ft.
(3
m)
Water
Supply
Hose
With
5/8
in.
Adapter
Fit
ting
6
Rear
Of
Water
Fitting
Remove
5/8
in.
adapter
fining
from
hose.
Route
one
end
of
a
water
hose
through
grommet,
and
con
nect
to
rear
of
WATER
TO
GUN
fit
ting
in
feeder.
Connect
remaining
end
to
supply
fitting
on
coolant
sup
ply.
7
Coolant
Return
Hose
Grom
met
8
lOft.
(3
m)
Water
Return
Hose
Connect
To
Regulator/
9
Connection
Block
Flowmeter
Route
one
end
of
remaining
water
hose
through
grommet.
and
con
nect
to
rear
of
connection
block
(not
shown).
Connect
remaining
end
of
hose
to
return
fining
on
cool
ant
supply.
10
Weld
Cable
Grommet
11
Weld
Cable
To
Welding
Pow
er
Source
Select
and
prepare
weld
cable
ac
cording
to
welding
power
source
manual.
12
Reed
Switch
6
13
Weld
Cable
Screw
In
Feeder
Route
one
end
of
weld
cable
through
grommet.
through
reed
switch,
and
connect
to
block
in
feeder
using
hardware
shown.
Connect
remaining
end
of
cable
to
positive
(+)
weld
output
terminal
on
welding
power
source.
Close
and
latch
door.
Tools
Needed:
~
5/Bin.,
1-1/Bin.
Ref.
ST.152
43l.A
Connect
To
Positive
(+)
Weld
Output
Terminal
On
Welding
Power
Source
2
11
9
3
Figure
3-9.
Water-Cooled
Feeder
Connections
OM-1581
Page
8
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Miller KC248746 Owner's manual

KC248746
Miller
Brand
Miller
Model
KC248746
Category
Welding System
Type
Owner's manual
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