Miller AUTO ARC SPOOL GUN Owner's manual

Miller
Brand
Miller
Model
AUTO ARC SPOOL GUN
Category
Welding System
Type
Owner's manual

This manual is also suitable for

May
1988
FORM:
121
364
OWN
ERS
MANUAL
Effective
With
Serial
No.
JJ358747
MODEL
AUTO
ARC
SPOOL
GUN
II
IT(~
Apr
L____
!JLI
RJ
I
%1
f
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
55
CENTS
IMPORTANT
____
Read
and
understand
the
entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equip
ment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equipment.
Do
not
allow
un
trained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
ONE
YEAR
LIMITED
WARRANTY
1*)
COVERAGE
-
Miller
Electric
Mfg.
Co.
warrants
to
the
buyer
REMEDY
FOR
DEFECTIVE
WELDER
-
Upon
receipt
of
any
~
~
who
purchases
this
Auto
Arc
Welder
(Welder)
for
personal,
defective
Welder,
Miller
Electric
will,
at
its
option,
repair
or
family
or
household
purposes
(Consumer)
that
this
Welder
replace
the
defective
Welder
at
its
expense,
refund
or
credit
will
be
free
from
defects
in
material
and
workmanship
for
a
the
purchase
price
(less
reasonable
depreciation
based
on
ac
period
of
one
year
from
the
date
of
purchase,
This
warranty
tual
use),
or
reimburse
the
Consumer
for
the
cost
of
repair
or
covers
only
the
original
purchaser
of
this
Welder.
Miller
Electric
replacement
at
an
approved
Miller
Electric
warranty
station,
~_
does
not
authorize
any
party,
including
its
authorized
provided
that
the
purchaser
of
that
Welder
has
followed
the
~
distributors,
to
offer
any
other
warranty
on
behalf
of
Miller
procedure
for
obtaining
warranty
performance
set
forth
below,
Electric,
Upon
expiration
of
the
warranty
period,
Miller
Electric
The Welder
so
repaired
or
used
as
a
replacement
will
be
ship-
,~
~
shall
have
no
further
liability
related
to
the
Welder,
except
on
ped
to
the
purchaser
of
the
defective
Welder,
with
transporta
warranty
claims
made
during
the
warranty
period.
tion
charges
prepaid
to
any
destination
in
the
continental
United
States
(transportation
charges
on
shipments
to
Alaska
~
THIS
WARRANTY
IS
OFFERED
IN
LIEU
OF
ANY
OTHER
or
Hawaii
will
be
paid
only
to
the
nearest
port
of
export).
~
EXPRESS
WARRANTY;
AND,
EXCEPT
TO
THE
EXTENT
%
PROHIBITED
BY
APPLICABLE
LAW,
THE
DURATION
OF
ALL
IMPLIED
WARRANTIES,
INCLUDING
BUT
NOT
THE
PURCHASERS
REMEDIES
FOR
A
DEFECTIVE
LIMITED
TO
THE
IMPLIED
WARRANTIES
OF
MERCHAN-
WELDER,
TO
THE
EXTENT
PERMITTED
BY
APPLICABLE
,~
TABILITY
AND
FITNESS
FOR
A
PARTICULAR
PURPOSE,
IS
LAW,
ARE
LIMITED
TO
THE
REMEDY
PROVIDED
BY
THIS
~
WARRANTY:
AND,
TO
THE
EXTENT
ENFORCEABLE
LIMITED
TO
THE
DURATION
OF
THIS
WARRANTY.
UNDER
APPLICABLE
LAW,
MILLER
ELECTRIC
SHALL
IN
Some
states
do
not
allow
limitations
on
how
long
an
implied
NO
EVENT
BE
LIABLE
FOR
CONSEQUENTIAL,
INCIDENTAL
~
warranty
lasts,
so
the
above
limitation
may
not
apply
to
you.
OR
SPECIAL
DAMAGES
ARISING
OUT
OF
THE
USE
OF,
OR
C~
This
warranty
gives
you
specific
legal
rights,
and
you
may
also
INABILITY
TO
USE,
THE
WELDER,
WHETHER
BASED
ON
have
other
rights
which
vary
from
state
to
state,
BREACH
OF
THIS
WARRANTY.
MILLER
ELECTRICS
NEGLIGENCE
OR
OTHER
TORT,
OR
ON
ANY
THEORY
OF
STRICT
LIABILITY.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
-
year.
such
as
spot
welder
tips,
relay
and
contactor
points,
Some
states
do
not
allow
the
exclusion
or
limitation
of
con
c~
parts
that
come
in
contact
with
the
welding
wire
including
sequential
or
incidental
damages,
so
the
above
limitations
may
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
not
apply
to
you.
defect
in
workmanship
or
material.
Miller
shall
be
required
to
honor
warranty
claims
on
war-
PROCEDURE
FOR
OBTAINING
WARRANTY
PERFORMANCE
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
As
soon
as
any
defect
in
a
Welder
becomes
known,
the
pur
within
the
following
periods
from
the
date
of
delivery
of
Equip-
chaser
of
the
Welder
must,
within
thirty
(30)
days,
notify
an
ment
to
the
original
user:
approved
Warranty
Station
or
Miller
Electric
in
writing
of
the
1
Arc
welders,
power
sources,
and
c~ien~
1
defect.
The
purchaser
must
then,
within
the
one
year
warranty
year
period,
return
the
Welder
to
Miller
Electric
at
the
following
ad-
2.
Original
main
power
rectifiers
3
years
dress:
(labor
-
1
year
only)
3.
All
welding
guns,
feeder/guns
and
Plasma
torches
...
90
d~YS
Miller
Electric
Mfg
Co
4.
Replacement
or
repair
parts,
exclusive
of
labor
. .
60
days
718
South
Bounds
Street
P.O.
Box
1079
WHAT
IS
NOT
COVERED
-
This
warranty
does
not
extend
Appleton,
Wisconsin
54912
to
any
Welder
subjected
to
misuse,
neglect,
accident,
or
in
~
warranty
repair
by
anyone
except
Miller
Electric,
Further,
this
All
transportation
charges
to
Warranty
Station
or
Miller
Electric
&~
warranty
Only
extends
to
those
purchasing
the
Welder
for
per-
must
be
prepaid.
sonal,
family
or
household
purposes.
Commercial
and
in
dustrial
users
are
given
a
different
warranty.
SECTION
1
-
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1-1.
INTRODUCTION
-
We
learn
by
experience.
Learning
safety
through
personal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
and
un
wise.
Let
the
experience
of
others
teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
Research,
development,
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained.
The
reason
for
the
safe
practices
may
not
always
be
given.
Some
are
based
on
common
sense,
others
may
require
technical
volumes
to
explain.
It
is
wiser
to
follow
the
rules.
Read
and
understand
these
safe
practices
before
at
tempting
to
install,
operate,
or
service
the
equipment.
Comply
with
these
procedures
as
applicable
to
the
par
ticular
equipment
used
and
their
instruction
manuals,
for
personal
safety
and
for
the
safety
of
others.
Failure
to
observe
these
safe
practices
may
cause
serious
injury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be
used
with
confidence.
These
safe
practices
are
divided
into
two
Sections:
1
-
General
Precautions,
common
to
arc
welding
and
cutting;
and
2
-
Arc
Welding
(and
Cutting)
(only).
Reference
standards:
Published
Standards
on
safety
are
also
available
for
additional
and
more
complete
pro
cedures
than
those
given
in
this
manual.
They
are
listed
in
the
Standards
Index
in
this
manual.
ANSI
Z49.1
is
the
most
complete.
The
National
Electrical
Code,
Occupational
Safety
and
Health
Administration,
local
industrial
codes,
and
local
inspection
requirements
also
provide
a
basis
for
equip
ment
installation,
use,
and
service.
1-2.
GENERAL
PRECAUTIONS
Different
arc
welding
processes,
electrode
alloys,
and
fluxes
can
produce
different
fumes,
gases,
and
radiation
levels.
In
addition
to
the
information
in
this
manual,
be
sure
to
consult
flux
and
elec
trode
manufacturers
for
specific
technical
data
and
precautionary
measures
concerning
their
material.
A.
Burn
Prevention
Wear
protective
clothing
-
gauntlet
gloves
designed
for
use
in
welding,
hat,
and
high
safety-toe
shoes.
Button
shirt
collar
and
pocket
flaps,
and
wear
cuffless
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet
with
safety
goggles
or
glasses
with
side
shields
underneath,
appropriate
filter
lenses
or
plates
(protected
by
clear
cover
glass).
This
is
a
MUST
for
welding
or
cutting,
(and
chipping)
to
protect
the
eyes
from
radiant
energy
and
flying
metal.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See
1-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal
such
as
electrode
stubs
and
workpieces
should
never
be
handled without
gloves.
Medical
first
aid
and
eye
treatment.
First
aid
facilities
and
a
qualified
first
aid
person
should
be
available
for
each
shift
unless
medical
facilities
are
close
by
for
im
mediate
treatment
of
flash
burns
of
the
eyes
and
skin
burns.
Ear
plugs
should
be
worn
when
working
on
overhead
or
in
a
confined
space.
A
hard
hat
should
be
worn
when
others
work
overhead.
Flammable
hair
preparations
should
not
be used
by
per
sons
intending
to
weld
or
cut.
B.
Toxic
Fume
Prevention
Severe
discomfort,
illness
or
death
can
result
from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
(or
cutting)
may
produce.
Prevent
them
with
adequate
ventilation
as
described
in
ANSI
Stan
dard
Z49.1
listed
1
in
Standards
index.
NEVER
ventilate
with
oxygen.
Lead
-,
cadmium
-,
zinc
-,
mercury
-,
and
beryllium
-
bearing
and
similar
materials,
when
welded
(or
Cut)
may
produce
harmful
concentrations
of toxic
fumes.
Ade
quate
local
exhaust
ventilation
must
be
used,
or
each
person
in
the
area
as
well
as
the
operator
must
wear
an
air-supplied
respirator.
For
beryllium,
both
must
be
us
ed.
Metals
coated
with
or
containing
materials
that
emit
toxic
fumes
should
not
be
heated
unless
coating
is
removed
from
the
work
surface,
the
area
is
well
ven
tilated,
or
the
operator
wears
an
air-supplied
respirator.
Work
in
a
confined
space
only
while
it
is
being
ven
tilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
Gas
leaks
in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in
the
space
if
downstream
valves
have
been
accidently
opened
or
left
open.
Check
to
be
sure
that
the
spae
is
safe
before
re-entering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed
by
the
heat
of
the
arc
(or
flame)
to
form
PHOSGENE,
a
F121364
Page
1
highly
toxic
gas,
and
other
lung
and
eye
irritating
pro
ducts.
The
ultraviolet
(radiant)
energy
of
the
arc
can
also
decompose
trichloroethylene
and
per
chloroethylene
vapors
to
form
phosgene.
DO
NOT
WELD
or
cut
where
solvent
vapors
can
be
drawn
into
the
welding
or
cutting
atmosphere
or
where
the
radiant
energy
can
penetrate
to
atmospheres
containing
even
minute
amounts
of
trichioroethylene
or
per
chloroethylene.
C.
Fire
and
Explosion
Prevention
Causes
of
fire
and
explosion
are:
combustibles
reached
by
the
arc,
flame,
flying
sparks,
hot
slag
or
heated
material;
misuse
of
compressed
gases
and
cylinders;
and
short
circuits.
BE
AWARE
THAT
flying
sparks
or
falling
slag
can
pass
through
cracks,
along
pipes,
through
windows
or
doors,
and
through
wall
or
floor
openings,
out
of
sight
of
the
goggled
operator.
Sparks
and
slag
can
fly
35
feet.
To
prevent
fires
and
explosion:
Keep
equipment
clean
and
operable,
free
of
oil,
grease,
and
(in
electrical
parts)
of
metallic
particles
that
can
cause
short
circuits.
If
combustibles
are
in
area,
do
NOT
weld
or
cut.
Move
the
work
if
practicable,
to
an
area
free
of
combustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
yen
tilators.
If
the
work
cannot
be
moved,
move
com
bustibles
at
least
35
feet
away
out
of
reach
of
sparks
and
heat;
or
protect
against
ignition
with
suitable
and
snug-fitting,
fire-resistant
covers
or
shields.
Walls
touching
combustibles
on
opposite
sides
should
not
be
welded
on
(or
cut).
Walls,
ceilings,
and
floor
near
work
should
be
protected
by
heat-resistant
covers
or
shields.
Fire
watcher
must
be
standing
by
with
suitable
fire
ex
tinguishing
equipment
during
and
for
some
time
after
welding
or
cutting
if:
a.
appreciable
combustibles
(including
building
construction)
are
within
35
feet
b.
appreciable
combustibles
are
further
than
35
feet
but
can
be
ignited
by
sparks
c.
openings
(concealed
or
visible)
in
floors
or
walls
within
35
feet
may
expose
com
bustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted
heat.
Hot
work
permit
should
be
obtained
before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have
been
taken.
After
work
is
done,
check
that
area
is
free
of
sparks,
glowing
embers,
and
flames.
An
empty
container
that
held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on
or
cut,
unless
container
has
first
been
cleaned
as
described
in
AWS
Standard
A6.O,
listed
7
in
Standards
index.
This
includes:
a
thorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing,
depending
on
the
com
bustibles
solubility)
followed
by
purging
and
inerting
with
nitrogen
or
carbon
dioxide,
and
using
protective
equipment
as
recommended
in
A6.O.
Waterfilling
just
below
working
level
may
substitute
for
inerting.
A
container
with
unknown
contents
should
be
cleaned
(see
paragraph
above).
Do
NOT
depend
on
sense
of
smell
or
sight
to
determine
if it
is
safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be
vented
before
welding
or
cutting.
They
can
explode.
Explosive
atmospheres.
Never
weld
or
cut
where
the
air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and
those
detailed
in
CGA
Standard
P-i,
SAFE
HANDLING
OF
COMPRESSED
GASES
IN
CYLINDERS,
listed
ii
in
Standards
index.
1.
Pressure
Regulators
Regulator
relief
valve
is
designed
to
protect
only
the
regulator
from
overpressure;
it
is
not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
with
one
or
more
relief
devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other
than
that
for
which
the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
repair
(first
close
cylinder
valve).
The
following
symptoms
indicate
a
faulty
regulator:
Leaks
-
if
gas
leaks
externally.
Excessive
Creep
-
if
delivery
pressure
continues
to
rise
with
downstream
valve
closed.
Faulty
Gauge
-
if
gauge
pointer
does
not
move
off
stop
pin
when
pressurized,
nor
returns
to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
repair.
Send
faulty
regulators
for
repair
to
manufacturers
designated
repair
center,
where
special
techniques
and
tools
are
used
by
trained
personnel.
2.
Cylinders
Cylinders
must
be
handled
carefully
to
prevent
leaks
and
damage
to
their
walls,
valves,
or
safety
devices:
Avoid
electrical
circuit
contact
with
cylinders
in
cluding
third
rails,
electrical
wires,
or
welding
cir
cuits.
They
can
produce
short
circuit
arcs
that
may
lead
to
a
serious
accident.
(See
1
-3C.)
F121364
Page2
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
handled.
Identifying
gas
content.
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder.
It
is
illegal
and
hazardous.
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
Prohibited
use.
Never
use
a
cylinder
or
its
contents
for
other
than
its
intended
use,
NEVER
as
a
support
or
roller.
Locate
or
secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be
struck.
Transporting
cylinders.
With
a
crane,
use
a
secure
sup
port
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their
valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
allow
contents
to
exceed
130F.
Cool
with
water
spray
where
such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling
objects,
and
weather.
Replace
caps
securely
when
moving
cylinders.
Stuck
valve.
Do
NOT
use
a
hammer
or
wrench
to
open
a
cylinder
valve
that
can
not
be
opened
by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any
gases
in
a
cylinder.
Never
refill
any
cylinder.
Cylinder
fittings
should
never
be
modified
or
exchang
ed.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect
hose
from
damage
by
sharp
edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and
loose
con
nections.
Immerse
pressured
hose
in
water;
bubbles
in
dicate
leaks.
Repair
leaky
or
worn
hose
by
cutting
area
out
and
splic
ing
(1-2D3).
Do
NOT
use
tape.
4.
Proper
Connections
Clean
cylinder
valve
outlet
of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
lean
lintless
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder
marking
agree,
and
that
the
regulator
inlet
and
cylinder
outlet
match.
NEVER
CONNECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
con
nections,
clean
and
smooth
seats
where
necessary.
Tighten.
If
connection
leaks,
disassemble,
clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
sup
plier)
between
cylinder
and
regulator,
if
one
is
required.
Use
two
wrenches
to
tighten
adapter
marked
RIGHT
and
LEFT
HAND
threads.
Regulator
outlet
(or
hose)
connections
may
be
iden
tified
by
right
hand
threads
for
oxygen
and
left
hand
threads
(with
grooved
hex
on
nut
or
shank)
for
fuel
gas.
5.
Pressurizing
Steps:
Drain
regulator
of
residual
gas
through
suitable
vent
before
opening
cylinder
(or
manifold
valve)
by
turning
adjusting
screw
in
(clockwise).
Draining
prevents
ex
cessive
compression
heat
at
high
pressure
seat
by
allowing
seat
to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
3.
Hose
Stand
to
side of
regulator
while
opening
cylinder
valve.
Prohibited
use.
Never
use
hose
other
than
that
designed
for
the
specified
gas.
A
general
hose
identification
rule
is:
red
for
fuel
gas,
green
for
oxygen,
and
black
for
inert
gases.
Use
ferrules
or
clamps
designed
for
the
hose
(not
or
dinary
wire
or
other
substitute)
as
a
binding
to
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
f
it
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and
abuse.
Suspend
hose
off
ground
to
keep
it
from
being
run
over,
stepped
on,
or
otherwise
damaged.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve
in
following
position:
For
oxygen,
and
inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For
fuel
gas,
open
to
less
than
one
turn
to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
settings
on
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
there-after.
Brush
with
soap
solution
(capful
of
Ivory
F121364
Page
3
Liquid*
or
equivalent
per
gallon
of
water).
Bubbles
in
dicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from
service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used
for
welding
or
cutting
operation;
rope
may
burn.
1-3.
ARC
WELDING
-
Comply
with
precautions
in
1-1,
1
-2,
and
this
section.
Arc
Welding,
properly
done,
is
a
safe
process,
but
a
careless
operator
invites
trouble.
The
equipment
carries
high
currents
at
significant
voltages.
The
arc
is
very
bright
and
hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
infrared
energy
radiates,
weldments
are
hot,
and
compressed
gases
may
be
us
ed.
The
wise
operator
avoids
unnecessary
risks
and
pro
tects
himself
and
others
from
accidents.
Precautions
are
described
here
and
in
standards
referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is
intense
and
visibly
bright.
Its
radia
tion
can
damage
eyes,
penetrate
lightweight
clothing,
reflect
from
light-colored
surfaces,
and
burn
the
skin
and
eyes.
Skin
burns
resemble
acute
sunburn,
those
from
gas-shielded
arcs
are
more
severe
and
painful.
DONT
GET
BURNED;
COMPLY
WITH
PRECAU
TIONS.
1.
Protective
Clothing
Wear
long-sleeve
clothing
(particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and
shoes
(1-2A).
As
necessary,
use
additional
protective
clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and
fire-
resistant
leggings.
Avoid
outergarments
of
untreated
cotton.
Bare
skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest
and
neck
and
button
pockets
to
prevent
entry
of
sparks.
2.
Eye
and
Head
Protection
Protect
eyes
from
exposure
to
arc.
NEVER
look
at
an
electric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filter
plate
shade
no.
12
or
denser
must
be
used
when
welding.
Place
over
face
before
striking
arc.
Trademark
of
Proctor
&
Gamble.
Protect
fitter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield
should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted,
or
spattered.
Flash
goggles
with
side
shields
MUST
be
worn
under
the
helmet
to
give
some
protection
to
the
eyes
should
the
helmet
not
be
lowered
over
the
face
before
an
arc
is
struck.
Looking
at
an
arc
momentarily
with
unprotected
eyes
(particularly
a
high
intensity
gas-shielded
arc)
can
cause
a
retinal
burn
that
may
leave
a
permanent
dark
area
in
the
field
of
vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
separate
room
or
enclosed
bay
is
best.
In
open
areas,
surround
the
operation
with
low-reflective,
non-
combustible
screens
or
panels.
Allow
for
free
air
circula
tion,
particularly
at
floor
level.
Viewing
the
weld.
Provide
face
shields
for
all
persons
who
will
be
looking
directly
at
the
weld.
Others
working
in
area.
See
that
all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
B.
Toxic
Fume
Prevention
Comply
with
precautions
in
1-2B.
Generator
engine
exhaust
must
be
vented
to
the
outside
air.
Carbon
monoxide
can
kill.
C.
Fire
and
Explosion
Prevention
Comply
with
precautions
in
1-2C.
Equipments
rated
capacity.
Do
not
overload
arc
welding
equipment.
It
may
overheat
cables
and
cause
a
fire.
Loose
cable
connections
may
overheat
or
flash
and
cause
a
fire.
Never
strike
an
arc
on
a
cylinder
or
other
pressure
vessel.
It
creates
a
brittle
area
that
can
cause
a
violent
rupture
or
lead
to
such
a
rupture
later
under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1
-2D.
F121364
Page4
or
red-tag
switches)
to
prevent
accidental
turning
ON
of
power.
Disconnect
all
cables
from
welding
power
source,
and
pull
all
115
volts
line-cord
plugs.
Do
not
open
power
circuit
or
change
polarity
while
welding.
If,
in
an
emergency,
it
must
be
disconnected,
guard
against
shock
burns,
or
flash
from
switch
arcing.
Leaving
equipment
unattended.
Always
shut
OFF
and
disconnect
all
power
to
equipment.
Power
disconnect
switch
must
be
available
near
the
welding
power
source.
F.
Protection
For
Wearers
Of
Electronic
Life
Support
Devices
(Pacemakers)
Magnetic
fields
from
high
currents
can
affect
pacemaker
operation.
Persons
wearing
electronic
life
support
equipment
(pacemaker)
should
consult
with
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information,
refer
to
the
following
standards
or
their
latest
revisions
and
comply
as
applicable:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd,
P.O.
Box
351040,
Miami,
FL
33135.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
U.S.
Govern
ment
Printing
Office,
Washington,
D.C.
20402.
4.
ANSI
Standard
Z87.1,
SAFE
PRACTICES
FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
5.
ANSI
Standard
Z41
.1,
STANDARD
FOR
MENS
SAFETY-TOE
FOOTWEAR
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PRO
CESSES
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
AWS
Standard
A6.0,
WELDING
AND
CUT
TING
CONTAINERS
WHICH
HAVE
HELD
COM
BUSTIBLES
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd.
P.O.
Box
351040,
Miami
FL
33135.
8.
NFPA
Standard
51,
OXYGEN
-
FUEL
GAS
SYSTEMS
FOR
WELDING
AND
CUTTING
ob
tainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
9.
NFPA
Standard
70-1978,
NATIONAL
ELEC
TRICAL
CODE
obtainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
10.
NFPA
Standard
SiB,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
ii.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from
the
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
NY
10036.
12.
CSA
Standard
Wi
17.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY
obtainable
from
the
National
Welding
Supply
Association,
1900
Arch
Street,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.1
Recommended
Safe
Practices
for
the
Prepara
tion
for
Welding
and
Cutting
of
Containers
and
Piping
That
Have
Held
Hazardous
Substances,
obtainable
from
the
American
Welding
Society,
550
LeJeuneRd.
P.O.
Box351040,
MmrT~,
FL33135.
15.
ANSI
Standard
Z88.2
Practice
for
Respiratory
Protection
obtainable
from
the
American
Na
tional
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
F121364
Page
6
SECTION
2
-
INTRODUCTION
Electrode
Wire
Dia.
Capability
Electrode
Wire
Feed
Speed
Control
Circuit
Voltage
At
Gun
Dimensions
Weight
Height
I
Width
Length
9
in.
3
in.
16
in.
(229
mm)
1(76
mm)
1(406
mm)
Net
Ship
16
lbs
I
20
lbs.
(7
kg)
(9
kg)
0.030-0.035
in.
(0.8
-
0.9
mm)
80-630
ipm
(2-16
mpm)
24
Volts
DC
Figure
2
-
1.
Specifications
2
-
1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
CAUTION
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
minor
personal
injury
or
damage
to
this
equipment.
labels,
tags,
and
plates
on
the
unit
pertains
to
equip
ment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
safe
and
eftective
use
of
this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
installed,
operated,
and
maintained
only
by
qualified
persons
in
accordance
with
this
manual
and
all
ap
plicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source.
IMPORTANT
A
third
signal
word,
______________,
highlights
instruc
tions
which
need
special
emphasis
to
obtain
the
most
efficient
operation
of
this
equipment.
2
-
2.
RECEIVING-HANDLING
-
Before
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
will
be
furnished
by
the
manufacturer
on
re
quest
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Serial
Number
of
the
equipment
be
supplied.
WARNING
CAUTION
_____________statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed could
result
in
serious
personal
injury
or
loss
of
life.
SECTION
3
-
INSTALLATION
IMPORTANT:
The
gun/feeder
is
shipped
ready
to
feed
0.030
in.
(0.8
mm)
welding
wire.
If
0.030
in.
(0.8
mm)
we/ding
wire
is
used,
select
cor
rect
contact
tube
from
supplied
toolkit,
and
proceed
to
Section
3-1.
Gun/Feeder
Preparation.
If
0.035
in.
(0.
.9
mm)
we/ding
wire
is
used,
select
cor
rect
contact
tube
from
supplied
toolkit,
and
proceed
to
Section
3-1.
Gun/Feeder
Preparation.
3
-
1.
GUN/FEEDER
PREPARATION
(Figures
3-1
And
3-2)
I&lh~Ih~cf
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
disconnect
input
power
employing
lockout/tagging
pro
cedures
before
preparing
and
installing
gun/feeder.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
changing
gun/feeder
parts.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
L~
:hThTeI
and
___________
which
identify
different
levels
of
hazard.
2
-
3.
DESCRIPTION
-
This
gun/feeder
is
of
the
con
stant
wire
feed
speed
type
and
is
designed
for
use
with
a
constant
voltage
welding
power
source
for
DC
Gas
Metal
Arc
Welding
(GMAW).
F121364
Page
7
Changing
Parts
0.030
in.
(0.8
mm)
0.035
in.
(0.9
mm)
Drive
Roll
(A
side)
X
X
Drive
Roll
(B
side)
Contact
Tube
X
Contact
Tube
X
Contact
Tube
Contact
Tube
Liner
X
X
Liner
Table
3
-
1.
Gun/Feeder
Parts
The
chart
shows
parts
that
are
required
for
each
welding
wire
size.
Some
parts
are
common
to
more
than
one
wire
size.
Select
the
proper
size
parts
from
the
supplied
tool
kit
and
proceed.
A.
Drive
Roll
Replacement
The
drive
roll
used
in
this
gun
has
2
grooves
for
guiding
the
wire.
The
smaller
groove
is
designed
to
feed
0.030/0.035
in.
(0.8/0.9
mm)
wire.
d.
Position
the
drive
roll
vertically
until
the
drive
roll
groove
aligns
with
the
drive
roll
bearing
groove.
Retain
the
drive
roll
in
this
position
until
the
following
steps
are
completed.
e.
Pivot
the
tension
arm
upward
and
pivot
the
mounting
arm
outward.
f.
Tighten
the
two
setscrews
in
the
drive
roll
being
sure
that
one
of
the
two
setscrews
hits
the
flat
spot
on
the
drive
roll
shaft.
IMPORTANT:
When
replacing
drive
roll
the
smaller
groove
should
always
be
down
(towards
handle
of
gun).
1.
Disassembly
a.
Remove
the
spool
cover
by
loosening
the
securing
thumbscrew
(see
Figure
3-2).
b.
Pivot
the
tension
arm
upward
and
pivot
the
mounting
arm
outward.
c.
Loosen
the
two
setscrews
in
the
drive
roll
and
remove
the
drive
roll.
The
allen
wrench
used
for
removing
the
setscrews
may
also
be
used
as
a
lever
to
position
the
setscrews
in
a
more
accessible
location.
2.
Assembly
And
Alignment
g.
Check
drive
roll
alignment
by
sighting
through
inlet
guide
to
the
drive
roll.
If
necessary,
repeat
steps
2d
thru
2f.
If
align
ment
cannot
be
attained,
reposition
the
drive
motor
as
follows:
Loosen
the
pan
head
screw
on
the
motor
mounting
bracket,
and
pivot
the
motor
to
obtain
alignment.
Tighten
screw.
h.
Reinstall
spool
cover
and
secure
with
thumbscrew.
B.
Changing
The
Contact
Tube
And
Liner
IMPORTANT:
_____
A
contact
tube
securing
nut
tool
is
in
cluded
with
the
gun/feeder
for
replacing
the
contact
tube
without
removing
the
nozzle
or
nozzle
extension.
1.
Insert
tool
over
contact
tube
until
tool
key
engages
in
compression
nut
keyway.
a.
Install
drive
roll
with
desired
feeding
groove
down,
but
do
not
tighten
the
two
setscrews
at
this
time.
b.
Pivot
mounting
arm
inward
and
pivot
ten
sion
arm
downward.
c.
Sight
through
the
inlet
guide
to
the
drive
roll
(see
Figure
3-1).
2.
Rotate
tool
counterclockwise
until
the
contact
tube
can
be
pulled
out.
3.
If
the
liner
needs
to
be
changed,
tip
nozzle
down,
and
remove
liner.
Install
new
liner.
4.
Install
contact
tube.
Ensure
that
the
contact
tube
butts
tight
against
the
adapter
internal
flange.
5.
Tighten
contact
tube
securing
compression
nut.
F121364
Page
8
Guide
Mounting
C.
Shielding
Gas
Nozzle
Adjustment
(Figure
3-1)
WARNING
__________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Be
sure
that
the
nozzle
extension
jam
nut
butts
against
the
nozzle
extension
and
that
the
barrel
adapter
is
not
exposed.
The
barrel
adapter
is
electrically
hot
whenever
the
welding
power
source
contactor
is
energized.
The
nozzle
extension
can
be
adjusted
so
that
the
con
tact
tube
is
recessed
up
to
1/4
in.
(6.3
mm)
behind
the
nozzle
or
so
that
the
contact
tube
extends
up
to
1/16
in.
(1.6
mm)
beyond
the
nozzle.
To
adjust
nozzle
exten
sion
proceed
as
follows:
1.
Loosen
nozzle
extension
jam
nut.
2.
Rotate
nozzle
extension
for
desired
contact
tube
position.
Welding
Power
Source
Weld
Output
Terminal
To
3-Socket
Amphenol
Receptacle
On
Welding
Power
Source
Rot.
TB-ill
345
Nozzle
Extension
Contact
Tube
Adapter
Tension
Arm
Roll
Bearing
Tube
Securing
Compression
Nut
Brake
Tube
Tension
Adjustment
TB~OOO
819.5
Adjustable
3.
Tighten
nozzle
extension
jam
nut.
Hole
Nozzle
Extension
Jam
Nut
Thumbscrew
To
Shielding
Figure
3
-
2.
Gun/Feeder
F121364
Page9
3
-
2.
WELDING
WIRE
SPOOL
INSTALLATION
AND
WELDING
WIRE
THREADING
(Figures
3-1
And
3-2)
decreases
braking
pressure
on
the
wire
spol.
Adjust
this
thumbnut
just
tight
enough
so
that
the
wire
spool
has
no
backlash
in
operation.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
disconnect
input
power
employing
lockout/tagging
pro
cedures
before
installing
or
changing
welding
wire.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
changing
gun/feeder
parts,
if
applicable.
WARNING
EXCESSIVE
BRAKE
PRESSURE
can
damage
equipment.
Do
not
overtighten
spool
brake
adjustment
thumb
nut.
C.
Drive
Roll
Pressure
Adjustment
Rotating
the
drive
roll
pressure
adjustment
thumbnut
clockwise
increases
drive
roll
pressure
on
the
welding
wire.
Similarly,
rotating
the
drive
roll
pressure
adjust
ment
thumbnut
counterclockwise
decreases
drive
roll
pressure
on
the
welding
wire.
Adjust
drive
roll
pressure
until
slippage
on
the
welding
wire
ceases.
CAUTION
A.
Welding
Wire
Installation
And
Threading
Be
sure
that
the
liner
and
contact
tube
match
the
size
welding
wire
selected.
CAUTION
_________
EXCESSIVE
DRIVE
ROLL
PRESSURE
can
damage
equipment.
Do
not
overtighten
drive
roll
pressure
adjustment
thumbnut.
1.
Remove
the
spool
cover
by
loosening
the
secur
ing
thumbscrew
(see
Figure
3-2).
2.
Pivot
the
tension
arm
upward,
and
pivot
the
mounting
arm
outward.
3.
Install
the
welding
wire
spool
onto
the
spool
hub.
Move
the
spool
brake
slightly
with
the
lip
of
the
wire
spool
to
enable
installation.
Be
sure
that
the
welding
wire
feeds
over
the
top
of
the
welding
wire
spool.
(When
the
welding
wire
spool
is
in
stalled
in
this
manner,
the
manufacturers
spool
label
will
usually
be
visible.)
3
-
3.
GUN/FEEDER
INSTALLATION
(Figure
3-2)
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
disconnect
input
power
employing
lockout/tagging
pro
cedures
before
making
gun/feeder
connections.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
A.
Shielding
Gas
Connection
4.
Cut
off
any
length
of
the
welding
wire
that
is
not
straight.
5.
Manually
route
the
welding
wire
into
the
inlet
guide,
through
the
drive
roll,
into
the
liner,
into
the
contact
tube,
and
out
past
the
contact
tube
tip
to
a
suitable
welding
wire
length.
6.
Pivot
the
mounting
arm
inward
and
pivot
the
tension
arm
downward
over
the
drive
roll
tension
adjustment
thumb
nut.
Be
sure
that
the
welding
wire
is
in
the
drive
roll
groove.
7.
Reinstall
and
secure
spool
cover.
B.
Spool
Brake
Adjustment
Rotating
the
spool
brake
adjustment
thumbnut
counterclockwise
(as
viewed
from
the
top)
increases
braking
pressure
on
the
wire
spool.
Similarly,
rotating
the
spool
brake
adjustment
thumbnut
clockwise
Connect
the
shielding
gas
hose
from
the
gun/feeder
to
the
regulator/flowmeter
at
the
shielding
gas
supply.
The
connector
has
5/8-18
right
hand
threads.
B.
Control
Connection
Insert
the
3-pin
Amphenol
plug
from
the
gun/feeder
in
to
the
3-socket
receptacle
on
the
welding
power
source,
and
rotate
threaded
collar
clockwise.
C.
Weld
Cable
Connections
Connect
the
weld
cable
from
the
gun/feeder
to
the
ap
propriate
weld
output
terminal
on
the
welding
power
source
for
the
wire
used.
Connect
correct
size
and
type
weld
cable
from
remain
ing
weld
output
terminal
on
the
welding
power
source
to
the
workpiece.
See
power
source
Owners
Manual
for
cable
size
information.
F121364
Page
10
SECTION
4
-
OPERATOR
CONTROLS
4
-
1.
WIRE
SPEED
CONTROL
(Figure
3-2)
-
The
WIRE
SPEED
control
provides
a
means
of
determining
the
rate
at
which
welding
wire
feeds
into
the
weld.
Rotating
the
WIRE
SPEED
control
clockwise
increases
the
rate
of
wire
feed.
The
scale
surrounding
the
WIRE
SPEED
control
is
calibrated
proportionately
and
does
not
indicate
an
ac
tual
ipm
value.
Use
meters
whenever
it
is
necessary
to
know
the
amperage
or
voltage
output.
I1~I~s]:IV..t~k~
The
WIRE
SPEED
control
may
be
ad
justed
while
we/ding.
4
-
2.
TRIGGER
(Figure
3-2)
-
When
the
trigger
is
depressed
fully
the
welding
power
source
contactor
energizes,
shielding
gas
flows,
and
welding
wire
feeds
into
the
weidment.
Shielding
gas
preflow
and
postflow
may
be
obtained
by
partially
depressing
the
trigger
at
the
beginning
and
end
of
the
welding
operation.
4
-
3.
WELDING
WIRE
SPOOL
SIGHT
HOLE
(Figure
3-2)
-
By
sighting
through
the
welding
wire
spool
sight
hole,
the
supply
of
welding
wire
on
the
welding
wire
spool
may
be
observed.
SECTION
5
-
SEQUENCE
OF
OPERATION
WARNING
_________
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
injury.
Do
not
touch
ilve
electrical
parts.
Do
not
touch
welding
wire
or
any
metal
part
in
contact
with
it
while
welding.
Keep
all
covers
in
place
while
operating.
Welding
wire
and
all
metal
parts
in
contact
with
it
carry
weld
output
when
the
welding
power
source
contactor
is
energized.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.
Use
enough
ventilation
to
keep
fumes
and
gases
from
the
breathing
zone.
WELDING
WIRE
can
cause
puncture
wounds.
Do
not
point
gun
toward
any
part
of
the
body
or
other
personnel.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
fire
and
burns.
Watch
for
fire.
Have
a
fire
extinguisher
nearby,
and
know
how
to
use
it.
Allow
work
and
equipment
to
cool
before
handl
ing.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
Wearers
should
consult
with
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
for
basic
welding
safety
infor
mation.
CAUTION:
HIGH
FREQUENCY
can
damage
gun/feeder.
Turn
off
high
frequency
when
using
the
Spoolma
tic
gun.
Disconnect
weld
cable
between
welding
power
source
and
gun/feeder
when
high
frequency
is
us
ed.
5
-
1.
GAS
METAL
ARC
WELDING
(GMAW)
1.
Prepare
and
install
gun/feeder
according
to
Sec
tion
3.
2.
Rotate
WIRE
SPEED
control
to
desired
setting.
3.
Turn
on
shielding
gas
supply.
4.
Energize
the
welding
power
source.
5.
Hold
the
tip
of
the
gun
approximately
1/2
inch
(13
mm)
from
the
workpiece.
6.
Depress
the
gun/feeder
trigger.
Gas
will
flow
and
wire
will
feed
if
drive
roll
pressure
is
properly
adjusted
to
prevent
slippage
(see
Section
3-2C
if
drive
roll
pressure
adjustment
is
necessary).
5
-2.
SHUTTING
DOWN
1.
Stop
welding.
2.
Shut
down
welding
power
source.
3.
Turn
off
all
associated
equipment.
4.
Turn
off
shielding
gas
at
the
source.
HIGH
CONCENTRATION
OF
SHIELDING
GASES
can
harm
health
or
kill.
Shut
off
gas
supply
when
not
in
use.
F121364
Page
11
SECTION
6
-
MAINTENANCE
&
TROUBLESHOOTING
ii~si~it~i~ig
Every
six
months
inspect
the
labels
on
this
unit
for
legibility.
All
precautionary
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
the
Parts
List
for
part
number
of
precautionary
labels.
6
-
1.
GUN/FEEDER
INSPECTION
AND
UPKEEP
-
Usage
and
shop
conditions
will
determine
frequency
and
type
of
maintenance
required.
WARNING
__________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
disconnect
input
power
employing
lockout/tagging
pro
cedures
before
inspecting,
maintaining,
or
ser
vicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
1.
Inspect
gun
every
three
months
for
broken
areas,
cracks,
and
loose
parts;
tighten,
repair,
and
replace
as
required.
2.
Carefully
remove
any
weld
spatter
or
foreign
matter
which
may
accumulate
around
the
noz
zle.
3.
Remove
any
weld
spatter
or
dirt
around
the
trig
ger.
4.
Repair
or
replace
as
required
all
hose
and
cabl
ing;
give
particular
attention
to
frayed
and crack
ed
insulation
and
areas
where
it
enters
equip
ment.
5.
Remove
grease
and
grime
from
components;
remove
moisture
from
electrical
parts
and
cables.
CAUTION:
FLYING
DIRT
AND
METAL
PAR
TICLES
can
injure
personnel
and
damage
equip
ment.
Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
6.
Blow
Qut
gun
liner
with
compressed
air
whenever
the
wire
or
liner
is
removed.
CAUTION
________
HIGH
ROTATIONAL
SPEED
CAN
cause
personal
injury
and
damage
to
drive
roll.
Do
not
allow
drive
roll
to
rotate
at
high
speed
if
compressed
air
is
used
for
cleaning
the
drive
roll
assembly.
7.
Occasionally
clean
the
wire
groove
on
the
drive
roll.
This
cleaning
operation
can
be
performed
with
a
wire
brush.
IhAl
~s
.
f.~1
~
I
~
Failure
to
properly
maintain
the
drive
roll
can
result
in
a
buildup
of
wire
particles
which
will
decrease
the
efficiency
of
the
wire
feeding
operation.
TB-000
819-B
Inlet
Guide
Roll
.Tension
Arm
Bearing
~Linar
Figure
6
-
1.
Gun/Feeder
Parts
Replacement
F121364
Page
12
6
-
2.
GUN/FEEDER
PARTS
REPLACEMENT
4.
Remove
drive
roll
bearing.
PROCEDURES
(Figure
6-1)
WARNING
__________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
disconnect
input
power
employing
lockout/tagging
pro
cedures
before
inspecting,
maintaining,
or
ser
vicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
MOVING
PARTS
can
cause
serious
injury.
Keep
c/ear
of
moving
parts.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
Obtain
necessary
replacement
parts
and
proceed
as
follows:
A.
Inlet
Guide
Replacement
1.
Remove
spool
cover.
2.
Pivot
the
tension
arm
upward
and
pivot
moun
ting
arm
outward.
3.
Manually
retract
welding
wire
and
remove
wire
spool.
4.
Slip
the
ring
retainer
off
the
inlet
guide.
5.
Remove
inlet
guide
by
pushing
it
towards
the
rear
of
the
gun/feeder.
6.
Insert
new
inlet
guide.
7.
Reinstall
ring
retainer.
8.
Reinstall
and
thread
welding
wire
(see
Section
3-2).
9.
Pivot
mounting
arm
inward,
and
tension
arm
downward.
10.
Reinstall
spool
cover.
B.
Drive
Roll
Bearing
Replacement
1.
Remove
spool
cover.
2.
Pivot
the
tension
arm
upward
and
pivot
moun
ting
arm
outward.
3.
Remove
screw
and
two
shoulder
washers
secur
ing
drive
roll
bearing
to
mounting
arm.
5.
Install
new
drive
roll
bearing,
and
secure
with
shoulder
washers
and
screw.
6.
Pivot
mounting
arm
inward,
and
tension
arm
downward.
7.
Reinstall
spool
cover.
C.
Drive
Roll
Replacement
Retract
welding
wire
onto
wire
spool,
and
follow
pro
cedure
in
Section
3-lA
for
replacing
and
aligning
drive
roll.
D.
Contact
Tube
And
Linder
Replacement
Retract
welding
wire
onto
wire
spool,
and
follow
pro
cedure
in
Section
3-1
B
for
replacing
the
contact
tube
and
liner.
6
-
3.
TROUBLESHOOTING
CHART
WARNING
_________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
disconnect
input
power
employing
lockout!
tagging
pro
cedures
before
inspecting
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
MOVING
PARTS
can
cause
serious
injury.
Keep
clear
of
moving
parts.
HOT
SURFACES
can
cause
serious
injury.
Allow
cooling
period
before
servicing.
Troubleshooting
to
be
performed
only
by
qualified
per
sons.
It
is
assumed
that
the
unit
was
properly
installed
accor
ding
to
Section
3,
the
operator
is
familiar
with
the
func
tion
of
controls,
the
welding
power
source
is
working
properly,
and
that
the
trouble
is
not
related
to
the
welding
process.
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
gun/feeder.
Use
this
chart
in
conjunction
with
the
circuit
diagram
while
performing
troubleshooting
procedures.
If
the
trouble
is
not
remedied
after
performing
these
pro
cedures,
the
nearest
Factory
Authorized
Service
Sta
tion
should
be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should
be
strictly
followed.
F121364
Page
13
TROUBLE
PROBABLE
CAUSE
REMEDY
Depressing
gun/feeder
trig-
ger
PB1
will
not
energize
feeder.
Welding
wire
is
not
energized.
Trigger
control
plug
not
secure
in
receptacle
on
welding
power
source.
Secure
plug
in
receptacle.
Welding
power
source
not
turned
on.
Turn
on
welding
power
source.
Welding
power
source
not
working.
Refer
to
welding
power
source
Owner~s
Manual.
Welding
wire
is
energized;
wire
does
not
feed.
Fuse
51
on
printed
Circuit
board
open.
Contact
nearest
Factory
Authorized
Service
Sta
tion.
Wire
feeds
erratically.
Incorrect
pressure
on
drive
roll.
Rotate
pressure
adjustment
thumbnut
clockwise
in
1/4
turn
increments
until
wire
slippage
stops
(see
Section
3-2C).
Worn
drive
roll.
Replace
drive
roll
(see
Section
6-2C).
Dirt
in
drive
roll.
Clean
drive
roll
(see
Section
6-1).
Excessive
spool
brake
pressure.
Decrease
spool
brake
pressure
(see
Section
3-2B).
IWORK
I
Figure
6
-
2.
Circuit
Diagram
Circuit
Diagram
No.
A-119
989
ITO
22
cW
F121364
Page
14
26
27
28
24
23
25
2/
Circuit
Diagram
No.
A-119
988
Figure
6
-
3.
Circuit
Diagram
For
Motor
Control
Board
PCi
T5
I
F121364
Page
15
21
22
23
24
23
25
.8MM
.9MM
.031
.035
.030
.035
18
19
17
Includes
Items
84
&
85
Includes
Items
86
thru
91
77
75
60
71
70
Ref.
TO-ill
346
Figure
A
-
Main
Assembly
Item
Dia.
Part
No.
Mkgs.
No.
Description
Quantity
Figure
A
Main
Assembly
2
120
826
NOZZLE,
5/8
orificexl-5/8
1
3
120
825
NOZZLE,
1/2orificexl-5/8
1
4
053
784
EXTENSION,
nozzle
1
5
053
785
EXTENSION,
barrel
1
6
120
828
TUBE,
contact
.030
wire
1
6
120
829
TUBE,
contact
.035
wire
1
7
058
676
NUT,
brass-compression
1
8
058
685
NUT,
jam-nozzle
extension
1
9
009
541
ADAPTER,
barrel
1
10
604
771
SCREW,
set-socket
hd
10-32
x
1/8
4
11
058
678
ADAPTER,
tube-contact
1
12
058 453
TUBE,
head
1
13
058282
0-RING,
.489
IDx.O70wide
5
14
044
047
VALVE,
gas
1
15
120827
GUIDETUBELINER
1
16
058410
GUIDE,wire
1
17
006 459
SCREW,
pivot-trigger
1
18
006
900
SCREW,
oval-hd
1/4-20
x3/4
3
19
059 260
CASE,
RH
1
20
058
419
POST,
spool-support
1
21
058 404
HOUSING,
wire
drive
components
1
22
605
970
BUSHING,
shoulder
.252
ID
x
.310
00
x
.064
thick
2
23
605971
BUSHING,.195IDx.236ODx.042
2
24
058
549
GUIDE,
wire-inlet
1
25
605798
BUSHING,flanged.168IDx3/8ODx3/32
2
26
058
409
BEARING,
drive
roll
1
27
045
841
PIN,
hinge
1
28
058 968
RING,
retainer
E
4
29
045
842
ARM,
pressure-drive
roll
1
30
605
973
WASHER,
teflon
1/4
ID
x9/16
00
x
.047
1
31
058
412
SPRING,
tension-adj
drive
roll
1
32
605
972
WASHER,
shoulder
.254
ID
x
1/2
00
x
5/16
1
33
000 366
RING,
retainer
E
1/4
shaft
1
34
000
449
CLAMP,
head
tube
(consisting
of)
1
35
000
416
.
SCREW,
flat-hd
10-24x7/8
1
36
058
403
.
CLAMP,
head
tube
1
37
057
544
.
SPRING,
compression
1
38
058
413
.
THUMB
NUT,
knurled
10-24
1
39
602
178
SCREW,
set-socket
hd
1/4-20
x
3/8
2
40
000
417
SCREW,
cap-sockethd
10-24x
1
4
41
053
131
ROLL,
drive
V-groove
knurled
.030-.035
wire
1
42
604
612
SCREW,
set-socket
hd
8-32
x
1/8
1
43
008
033
WASHER,
fIat-felt
15/16
ID
x
1/2
OD
x
3/32
1
44
049
116
STRIP,
mtg-motor
1
45
M
+
000
438
MOTOR
(consisting
of)
1
009944
.BRUSH,CYQM513-28
2
071
602
LABEL,
caution
HF
will
damage
ect
1
46
C1,R1
110
841
CAPACITOR/RESISTOR,
network
1
47
004
209
INSULATION,
bracket
1
48
iT
000
367
BLOCK,
terminal5
amp8
pole
1
49
000
368
LINK,
jumper-terminal
block
5
amp
3
50
000
444
BRACKET,
mtg-terminal
block
1
51
110
496
CIRCUITCARD,
control
(FigBPg4)
1
52
110
852
COVER,
circuit
card
1
53
PB1
000
369
SWITCH,
limit
lOamp
125/25OvoItsacSPDT
1
54
058
407
TRIGGER
1
55
058
462
BUSHING,
trigger-pivot
1
56
058
451
THUMB
NUT,
knurled
1/4-20
1
57
000
365
RING,
retainer
E
1/2
shaft
1
F121364
Page
17
Item
Dia.
Part
No.
Mkgs.
No.
Description
Quantity
Figure
A
Main
Assembly
(Contd)
58
008
836
COVER,
spool-feeder/gun
1
59
000 364
RING,
retainer
E
.188
shaft
1
60
058
420
THUMB
SCREW,
knurled
1/4-20
1
61
058 463
BRAKE,
spool
1
62
000
429
BOLT,
step
1/4-2
x
3/4
1
63
005
205
CASE,
LH
1
64
000
515
LABEL,
speed-control
indicator
1
65
058 465
BRACKET,
mtg
1
66
085
416
KNOB,
speed-control
1
67
005
464
SCREW,
set-socket
hd
1/4-20
x
3/8
oval
1
68
058
446
SPRING,
extension
1
69
000
424
SCREW,
set-socket
hd
8-32
x
1/4
oval
1
70
120
110
CABLE,
power
&
gas
(consisting
of)
1
023
562
.
CLAMP,
hose
5/16
x7/8
dia
1
71
120
356
.
CABLE,
control
(consisting
of)
1
72
053
212
.
.
CORD,
No.
184/c
(order
byft)
32ft
73
039 828
. .
CLAMP,
cable
AN-3057-6
1
74
PLG1
052
236
.
.
PLUG,
2
pin
MS31O6A-14S-1
P
1
75
120
109
.
CABLE,
power
(consisting
of)
1
76
600
318
.
.
CABLE,
weld-copper
No. 3
(order
by
ft)
3lft
77
039
608
.
.
PLUG,
jack-yellow
(consisting
of)
1
78
019833
...STRIP,copper.010x2-1/2x3/4
1
79
101
219
..
.
PLUG,
jack
1
80
602814
...INSULATOR
1
81
602
160
. . .
SCREW,
self-tapping
fillister
hd
8-32
x
1/4
1
82
602
178
..
.
SCREW,
set-socket
hd
1/4-20
x
3/8
2
83
010521
...WIRE,tie
1
84
604
737
.
.
TUBING,
heat
shrink
1/4
inch
(order
by
ft)
ift
85
019833
..STRIP,copper.010x2-1/2x3/4
1
86
110
634
.
HOSE,
gas
(consisting
of)
1
87
056
851
. .
FITTING,
hose-brass
nipplet3/16TBG
1
88
010 606
.
.
FITTING,
hose-brass
nut5/8-18
1
89
056
108
.
.
FITTING,
hose-brass
ferrule
.425IDx23/32
1
90
604
550
.
.
HOSE,
No.1
(order
byft
41ft
91
005
177
.
STRAIN
RELIEF
1
073
476
.
CLAMP,
strap
3/8
x
4-5/8
long
14
92
010323
CLAMP,hosel/4x5/8
1
93
000
426
SCREW,
oval-hd
10-24
x
2-1/2
1
94
058
262
CAP,
valve
1
95
114265
SPACER,
nylonl/4ODx.115
IDxl/8
4
010323
CLAMP,
hosel/4x5/8dia
1
050 960
WRENCH
1
tOptional
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.
F121364
Page
18
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Miller AUTO ARC SPOOL GUN Owner's manual

Miller
Brand
Miller
Model
AUTO ARC SPOOL GUN
Category
Welding System
Type
Owner's manual
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