Millerfi
March
1
993
Form:
OM-1538B
Effective
With
Style
No.
JD-3
OWN
ERS
MANUAL
Al
Motor/Drive
Assemblies
Read
and
follow
these
instructions
and
all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributorif
you
do
not
understand
the
directions.
115
Volts
DC
Motor
And
Wire
Drive
Assembly
For
Automatic
Weld
Control
Or
Arc
Welding
Robot
For
GMAW,
FCAW
And
SAW
Welding
Two-
And
Four-Drive
Roll
Models
Available
U
Adjustable
Mounting
Bracket
(Not
Availabte
On
Robotic
Model)
Low
Speed
Motor
Available
Interconnecting
Cord
To
Weld
Control
Needed
U
Give
this
manual
to
the
operator.
For
help,
call
your
distributor
or:
MILLER
ELECTRIC
Mfg.
Co.,
P.O.
Box
1079.
Appleton,
WI
54912
414-734-9821
cover
0/92
-
ST-070
8a5-B
PRINTED
IN
USA
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
This
limited
warranty
supersedes
alt
previous
MILLER
warranties
end
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
Implied.
LIMITED
WARRANTy
Subject
to
the
terms
end
conditions
below.
MILLER
Electric
Mfg.
Co..
Appleton.
Wisconsin.
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
after
the
effective
date
of
this
limited
warranty
is
free
of
de
fects
in
material
and
workmanship
at
(Pie
time
It
Is
shIpped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTtES.
EXPRESS
OR
IMPLIED.
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below.
MILLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
tall
due
to
such
defects
In
material
or
worlimsnshlp.
MILLER
must
be
notified
In
writing
within
thirty
(30)
days
of
such
defect
or
failure,
at
which
lime
MILLER
will
provide
instructionS
on
the
warranty
claim
procedures
to
be
followed,
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
a
failure
withIn
the
warranty
lime
periods.
All
warranty
time
periods
start
on
the
dale
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
and
are
as
follows:
t.
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
end
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
Transformers
Running
Gear/Trailers
Field
Options
(NOTE
Field
options
are
covered
under
True
BIue
for
the
remaining
warranty
period
of
the
product
they
are
installed
in.
or
for
a
minimum
of
one
year
whichever
is
greater.)
5.
6
Months
Batteries
6.
90
Days
Parts
and
Labor
MIG
Guns/TIG
Torches
Plasma
Cutting
Torches
Remote
Controls
Accessory
Kits
Replacement
Parts
MILLERS
True
OluerM
Limited
Warranty
shall
not
apply
to:
1.
Items
furnished
by
MILLER.
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
Such
55
contact
tips,
cutting
nozzles.
coritactors
and
relays.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER.
or
equip
ment
that
has
bean
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
COMMER
CIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT.
In
the
event
ot
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be,
at
MILLERS
option:
(I)
repair:
or
(2)
replacement;
or,
where
authorized
In
writing
by
MILLER
in
appropriate
cases.
(3)
the
reasonable
Cost
of
repair
or
replace.
mental
an
authorized
MILLER
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(tess
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton.
Wisconsin.
or
F.O.B.
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
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS OF
PROFIT).
WHETHER
BASED
ON
CON
TRACT.
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY.
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE.
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH.
BUT
FOR
THIS
PROVISION.
MIGHT
ARISE
BY
IMPLICATION.
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING.
IN.
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
stales
in
the
U.S.A.
do
not
allow
limitalions
of
how
long
an
implied
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequenlial
damages,
so
the
above
limitation
or
esciusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
Irom
state
to
state.
In
Canada.
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
as
staled
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and
exclusions
set
Oul
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
province
10
province.
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
miller
5/92
ERRATA
SHEET
January
12,
1994
FORM:
OM-1538B
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
Figure
3-4.
Installing
Wire
Guide
And
Drive
Roil
(Four-Drive
Roll
ModeI.Shown)
Figure
3-4.
Installing
Wire
Guide
And
Drive
Roll
(Four-Drive
Roil
Model
Shown)
CHANGES
TO
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
Add
the
following
Caution
for
Four-Drive
Roll
Model
to
Section
5-2.
Aligning
Drive
Rolls
And
Wire
Guides
£~
CAUTION
IMPROPER
CLEARANCE
between
motor
gear
and
drive
gears
can
damage
equipment.
Maintain
0.003
in
(0.076
mm)
clearance
between
motor
gear
and
drive
gears.
Gears
may
wear
severely,
bind,
break,
or
cause
erratic
wire
feed
if
proper
clearance
Is
not
maintained.
When
changing
wire
size
or
type,
check
drive
roll
and
guide
size
(see
Table
6.1
and
Table
6-2).
1
Wire
Guide
Securing
Screw
2
Inlet
Wire
Guide
3
Intermediate
Wire
Guide
(Four-Drive
Roll
Models
Only)
Loosen
wire
guide
screws.
Slide
tip
as
close
to
drive
rolls
as
possible
without
touching.
lighten
screw.
4
Drive
Gear
5
Pressure
Gear
Driveandpressuregears(1
of
each
In
two
drive
roll
model)
Installed
be
fore
unit
Is
shipped
from
factoiy.
6
Pressure
Gear
Assembly
Open
pressure
gear
assembly.
7
Drive
Roll
8
Gear
Securing
Bolt
9
Drive
Roll
Securing
Screw
Install
correct
drive
roll
for
wire
size
and
type
using
supplied
hardware.
Close
pressure
gear
assembly.
ST-070
887.E
Tools
Needed:
7/16
in
9
CHANGES
TO
SECTION
6
PARTS
LIST
Change
Parts
List
as
follows:
Part
Replaced
**
No.
With
Description
Quantity
13-3...
.
079 669
166
071
..
LEVER,
mtg
pressure
gear
(Effw/KE555371)
1
13-
Added
166
072
..
SPACER,
gear
(part
of
wire
drive
assembly)
(Eff
w/KE555371)
1
16-16
..
.
046
621
166
337
..
HOUSING,
adapter
gun/feeder
(Eff
w/KE555371)
1
16-21
..
.
079 669
166
071
..
LEVER,
mtg
pressure
gear
(Eff
W/KE555371)
1
16-24
..
.
046
619
166
338
..
LEVER,
mtg
pressure
gear
(Eff
w/KE555371)
1
16-
Added
166
072
..
SPACER,
gear
(part
of
wire
drive
assembly)
(Eff
w/KE555371)
1
**First
digit
represents
page
no
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1538B
Page
2
ARC
WELDING
SAFETY
PRECAUTIONS
WARNIN.G
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.
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
small
cracks
and
openings
to
adjacent
areas.
5.
Properly
install
and
ground
this
equipment
accrding
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
When
making
input
connections,
attach
proper
grounding
conductor
first.
7.
Turn
off
all
equipment
when
not
in
use.
8.
Do
not
use
worn,
damaged,
undersized,
or
poorly
splIced
cables.
9.
Do
not
wrap
cables
around
your
body.
10.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground..
11.
Do
not
touch
electrode
if
in
contact
with
the
work
or
ground.
12.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
13.
Wear
a
safety
harness
if
working
above
floor
level.
14.
Keep
all
panels
and
covers
securely
in
place.
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.
1.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
recommended.
2.
Wear
proper
body
protection
to
protect
skin.
ARC
RAYS
can
burn
eyes
and
skin;
~
NOISE
can
damage
hearing.
Arc
rays
from
the
welding
process
produce
intense
-
-.
heat
and
strong
ultraviolet
rays
thai
can
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
.
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
(see
ANSI
Z49.
I
listed
in
Safety
Standards)
to
protect
your
facE,
and
eyes
when
welding
or
watching.
3.
Wear
approved
safety
glasses.
Side
shields
recommended.
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare:
warn
others
not
to
watch
the
arc.
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
FUMES
AND
GASES
can
be
hazardous
to
your
health,
1
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
manufacturers
instruction
for
metals,
consumables,
coatings,
and
cleaners,
5.
6.
7.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Shielding
gases
used
for
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
welding
can
displace
air
causing
lnfury
or
death.
Be
sure
the
breathing
air
is
safe.
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
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.
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
orwelding
wire
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
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.
5r1
9/92
CYLINDERS
can
explode
if
damaged.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
falling
or
tipping.
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,
associated
equipment,
and
CGA
publication
P-I
listed
in
Safety
Standards.
a
WARNING~
ENGINES
can
be
hazardous.
ENGINE
EXHAUST
GASES
can
kill.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
2.
If
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.
MOVING
PARTS
can
cause
Injury.
3.
Have
only
qualified
people
remove
guards
or
covers
for
maintenance
and
troubleshooting
as
necessary.
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.
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,
Batteries
contain
acid
and
generate
explosive
gases.
3.
4.
5.
cables.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
Observe
correct
polarity
(+
and
)
on
batteries.
fr.
~
(..~
~
-.
~
STEAM
AND
COOLANT
can
skin.
The
coolant
in
the
r
under
pressure.
PRESSURIZED
burn
face,
eyes,
adiator
can
be
very
h
HOT
and
ot
and
1.
2.
3.
Donotremoveradiatorcapwhenengineishot.Allowengine
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.
LeJeune
Rd.
Miami
FL
33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superinten
dent
of
Documents,
U.S.
Government
Printing
Office.
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers That
Have
Held
Hazardous
Substances,
Amen.
can
Welding
Society
Standard
AWS
F4.
1,
from
American
Welding
So
ciety.
550
N.W.
LeJeune
Ad,
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
Aexdale
Bou
levard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
ForOccupationAnd
Educational
EyeAnd
Face
Protec
tion,
ANSI
Standard
Z87.1,
from
American
National
Standards
Institute,
1430
Broadway.
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Ouincy,
MA
02269.
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.
2.
Stop
engine
before
installing
or
connecting
unit.
4.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
srI
9/92
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
INFORMATiON
1
SECTION
2
SPECIFICATIONS
1
SECTION
3
INSTALLATION
3-1.
Typical
Equipment
Location
3
3-2.
Installing
Pivot
Mounting
Bracket
3
3-3.
Removing
Vent
Screw
And
Mounting
Wire
Drive
Assembly
4
3-4.
Installing
Wire
Guide
And
Drive
Rolls
4
3-5.
Plug
Connections
5
3-6.
Gun,
Weld
Cable
And
Gas
Connections
6
3-7.
Threading
And
Feeding
Welding
Wire
7
SECTION
4
OPERATION
7
SECTION
5
MAINTENANCE
AND
TROUBLESHOOTING
5-1.
Routine
Maintenance
8
5-2.
Aligning
Drive
Rolls
And
Wire
Guides
9
5-3.
Brush
Inspection
And
Replacement
10
5-4.
Troubleshooting
11
SECTION
6PARTS
LIST
Figure
6-1.
Motor
&
Drive
Assembly
(Al
-2
Model
Illustrated)
12
Figure
6-2.
Motor
&
Drive
Assembly
15
OM.1538B-.3/93
SECTION
1
SAFETY
INFORMATION
modt.1
2/93
AA
CAUTION
U
Read
all
safety
messages
throughout
this
manual.
U
Obey
all
safety
messages
to
avoid
injury.
U
Learn
the
meaning
of
WARNING
and
CAUTION.
1
Safety
Alert
Symbol
1
2
2
2
Signal
Word
~
WARNING
means
possible
death
or
serious
injury
can
happen.
!~~L
:h1h~IeU
1
~
CAUTION
means
possible
minor
=9
ELECTRIC
SHOCK
can
kitl.f
~
MOVING
PARTS
can
Injure,
injury
or
equipment
damage
can
~\
Do
not
(Ouch
live
electrical
parts.
Keep
away
from
moving
parts.
happen.
Disconnect
input
power
before
S
Keep
all
panels
and
covers
dosed
3
Statement
Of
Hazard
And
installing
or
servicing,
when
operating.
Result
/
4
Safety
Instructions
To
Avoid
5
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
6_~__~L1_1.1IIj~
~
~
Read
safety
blocks
for
each
sym
7
NOTE
NOTE
~
Turn
Off
switch
when
using
high
frequency.
Special
instructions
for
best
oper
ation
not
related
to
safety.
FIgure
1-1.
Safety
Information
.
SECTION
2
SPECIFICATIONS
Table
2-1.
Wire
Drive
Assemblies
Specification
DescriptIon
Type
Of
Input
Power
115
Volts
DC
Mounting
Bracket
Adjustment
Up
To
200
In
Any
Direction
(Robotic
Model
Not
Adjustable)
Input
Power
Cord
(Two-Drive
Roil
Assemblies
Only)
2
ft
(0.6
m)
Overall
Dimensions
See
Figure
2-1
Options
See
Rear
Cover
Weight
Two-Drive
Roll
And
Robotic
Assemblies
18
lb
(7.9
kg)
Weight
Four-Drive
Roll
Assembly
Wire
Feed
Speed
Range
22
lb
(10
kg)
Standard
Digital
Or
Robotic
Low-Speed
Motor
Lo~~~Ior
7OTo
750
ipm
50
To
780
pm
20
To
190
ipm
15
To
200
ipm
(1.8
To
19.1
mpm)
(1.3
To
19.8
mpm)
(0.5
To
4.8
mpm)
(0.4
To
5.1
mprn)
Wire
Diameter
Range
.030
Thru
1/8
in
(0.8
Thru
3.2
mm)
.030
Thru
1/8
in
(0.8
Thru
3.2
mm)
5/64
Thru
5/32
in
(2
Thru
4
mm)
5/64
Thru
5/32
in
(2
Thru
4
mm)
OM-1538
Page
1
Nio-Drive
Roll
Models
Inches
Millimeters
A
8
C*
9-1/4
10-1/4
11-1/2
235
260
292
*Add
7/8
in
(22
mm)
for
D
models.
Four-Drive
Roll
Models
AID-4R
Inches
Millimeters
A
B
C*
10-1/4
13-1/4
12
260
337
305
*Add
7/8
in
(22
mm)
for
0
models.
/C
Mounting
Holes*
Inches
Millimeters
A
B
4-1/4
4-1/4
108
108
C
13/32Dia.
4
Holes
lODia.
4
Holes
Holes
shown
used
for
mounting
to
optional
cross
slide.
Additional
holes
provided
for
mounting
to
weld
oscillator.
ST-080
407-C
/
ST-076
085-B!
ST-lb
159-8
/
Rel.
5T-070
885-B
Figure
2-1.
Overall
Dimensions
And
Mounting
Hole
Layout
Inches
Millimeters
.;
7-3/4
197
B
1/2
13
C
1/2
13
0
5.1/2
140
E
10-1/2
267
F
12-3/4
324
-.
B
OM-1538
Page
2
SECTION
3INSTALLATION
4~
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
weld
control
and
welding
power
source.
and
disconnect
input
power
before
inspecting
or
installing.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
wetding
or
feeding
wire.
Have
only
qualified
persons
install
this
unit.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
3-1.
Typical
Equipment
Location
WELDING
WIRE
can
cause
puncture
wounds.
Do
not
try
to
feed
wire
until
instructed
to
do
so.
Do
not
point
gun
toward
any
part
of
the
body
when
threading
welding
wire.
HOT
SURFACES
can
burn
skin.
Allow
drive
assembly
and
gun
to
cool
before
touching.
Figure
3-1.
TypIcal
Equipment
LocatIon
3-2.
Installing
Pivot
Mounting
Bracket
Figure
3-2.
Installing
Pivot
Mounting
Bracket
Side
View
2
4
I
Welding
Power
Source
2
Side
Beam
3
Shunt
Control
4
Weld
Control
5
Wire
Drive
Assembly
1
Ref.
51-131
138
2
4
4
2
Robotic
model
not
equipped
with
pivot
bracket;
proceed
to
Section
3-3.
I
Motor
Mounting
Bracket
2
Mounting
Holes
3
Pivot
Bracket
Mount
motor
bracket
onto
pivot
bracket
using
hardware
from
pivot
bracket
as
shown.
To
adjust
position
of
pivot
bracket,
proceed
as
follows:
4
Securing
Screw
5
Clamp
Loosen
screws
on
clamp.
Adjust
pivot
bracket
position
as
neces
sary.
Tighten
securing
screws.
ST.158
543
Tools
Needed:
~
OM-1538
Pagie
3
3-3.
Removing
Vent
Screw
And
Mounting
Wire
Drive
Assembly
A~
CAUTION
LOSS
OF
GEAR
OIL
OR
DIRT
ENTERING
GEAR
CASE
DAMAGES
MOTOR.
Do
not
remove
either
vent
screw
if
both
are
at
the
bottom
or
positioned
so
that
gear
oil
runs
out.
Do
not
remove
either
vent
screw
if
dirt
can
easily
enter
gear
case.
3
1
Motor
Mounting
Bracket
2
Wire
Drive
Gears
3
Upper
Vent
Screw
Remove
and
discard
upper
vent
screw
before
operation.
4
Motor
Mount
motor
level
with
wire
drive
gear
end
so
that
gear
oil
does
not
enter
motor
seal.
Tools
Needed:
ST.156
578
Figure
3-3.
Removing
Vent
Screw
And
Mounting
Assembly
3-4.
Installing
Wire
Guide
And
Drive
Rolls
READ
Sectio
SAFETY
n
3
befor
BLOCKS
at
start
of
e
proceeding.
When
changing
wire
size
or
type,
check
drive
roll
and
guide
size
(see
Table
6-1
and
Table
6-2).
1
Wire
Guide
Securing
Screw
2
Inlet
Wire
GuideS
3
Intermediate
Wire
Guide
(Four-Drive
Roll
Models
Only)
Loosen
wire
guide
screws.
Slide
tip
as
close
to
drive
rolls
as
possible
without
touching.
Tighten
screw.
4
Drive
Gear
5
Pressure
Gear
Drive
and
pressure
gears
(1
of
each
in
two
drive
roll
model)
installed
be
fore
unit
is
shipped
from
factory.
6
Pressure
Gear
Assembly
Open
pressure
gear
assembly.
7
Drive
Roll
Tools
Needed:
1J~====1
7/16
in
L~D
9
5
4
8
Gear
Securing
Bolt
9
Drive
Roll
Securing
Screw
Install
correct
drive
roll
for
wire
size
and
type
using
supplied
hardware.
Close
pressure
gear
assembly.
ST-070
887.C
Do
not
tilt
assembly.
Position
assembly
level.
Figure
3-4.
Installing
Wire
Guide
And
Drive
Roll
(Four-Drive
Roll
Model
Shown)
OM-1538
Page
4
3-5.
Plug
Connections
Figure
3-5.
Plug
Connections
1
Plug
2
Keyway
3
Typical
Weld
Control
Connect
plug
to
matching
plug
from
weld
control.
To
connect
plugs,
align
keyways,
insert
plug,
and
tighten
connection.
ST.t58
933/
S.0149-A
3
Non-DIgital
Model
OM-1
538
Page
5
3-6.
Gun,
Weld
Cable
And
Gas
Connections
~
READ
SAFETY
BLOCKS
at
start
of
Section
3
before
proceeding.
Four-Drive
Roll
Model
I
Gun/Feeder
Securing
Knob
2
Gun/Feeder
Opening
Select
and
prepare
weld
cable
ac
cording
to
welding
power
source
manual.
6
Gun
Weld
Cable
Terminal
(Four-Drive
Roll
Models
Only)
For
guns
with
external
weld
cable.
connect
weld
cable
from
gun
toter
minal.
Gas
fitting
is
located
behind
gun/
feeder
opening.
For
guns
requiring
external
gas
connection,
remove
hose
from
fit
ting
and
connect
to
gun.
ST-156
544
Figure
3-6.
Gun,
Weld
Cable
And
Gas
Connections
3
Gun
End
Connect
To
Positive
(.4.)
Weld
Output
Terminal
On
Welding
Power
Source
For
Reverse
Polarity
Weld
Process
Or
Connect
To
Negative
()
Weld
Output
Terminal
On
Welding
Power
Source
For
Straight
Polarity
Weld
Process.
Loosen
knob.
Insert
gun
end
into
opening.
Position
as
close
as
pos
sible
to
drive
rolls
without
touching.
lighten
knob.
4
Weld
Cable
Terminal
5
Weld
Cable
7
Shielding
Gas
Fitting
8
Gas
Hose
2
3
6
Tools
Needed:
~
9/l6in
OM-1538
Page
6
3-7.
Threading
And
Feeding
Welding
Wire
Figure
3-7.
Thread
ing
An
d
Feeding
Welding
Wire
SECTION
4
OPERATION
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
~
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
welding
helmet
with
correct
shade
of
filter.
Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
area,
or
use
breathing
device.
Read
Material
Safety
Data
Sheets
(MSDS5)
and
manufacturers
instructions
for
material
used.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
.
h
RENTS
can
affect
pacemaker
operation.
MAGNETIC
FIELDS
FROM
HIGH
CUR
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor
before
going
near
any
welding
operations.
WELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
Do
not
weld
on
closed
containers.
.
.
See
Safety
Precautions
at
beginning
of
manual
for
be.
sic
welding
safety
information.
wfw~m3.I~t9L
Allow
work
and
equipment
to
cool
before
handling,
.
Wear
dry
insulating
gloves,
safety
glasses
with
side
shields,
and
a
welding
helmet
with
a
correct
shade
of
filter
(see
ANSI
Z49.1).
5b3.1
AA
WARNING
READ
SAFETY
BLOCKS
at
start
of
Section
3
before
proceeding.
7
2
3
4
5
6
6
1
Wire
Spool
Loosen
wire
from
wire
spool,
cut
off
bent
wire,
and
pull
Bin
(150mm)
of
wire
off
spool.
2
Wire
Inlet
Guide
3
Drive
Roll
4
Intermediate
Wire
Guide
(Four-Drive
Roll
Models
Only)
5
Gun
Thread
wire
through
inlet
guide,
along
drive
rolls,
through
interme
diate
guide
and
drive
rolls
(if
appli
cable),
and
into
gun.
Se
sure
wire
is
in
correct
groove.
6
Pressure
Adjustment
Knob
And
Arm
Close
pressure
roll
assembly.
7
Adjusting
Pressure
Check
drive
roll
pressure
by
feed
ing
wire
against
a
wood
board
or
concrete
surface;
wire
should
feed
steadily
without
slipping.
If
pressure
adjustment
is
neces
sary,
tighten
pressure
knob(s).
ST-150
798
Tools
Needed:
Figure
4-1.
Safety
Equipment
OM-1538
Page
7
Figure
4-2.
Sequence
Of
Operation
SECTION
5-
MAINTENANCE
AND
TROUBLESHOOTING
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
weld
control
and
welding
power
source.
and
disconnect
Input
power
before
inspecting,
maintaining,
or
servicing.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
Figure
5-1.
Maintenance
I
Equipment
______________
Equipment
}
~1)I~Sourc~~
Install
&
))
Thread
&
Feed~\\
Put
On
Set
))
Turn
On
Turn
On
Control
Weld
Control
Shielding
Gas
And
Welding
Personal
Safety
I
Connect
Welding
Wire
)
Begin
We~~
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
servicing
unit.
5-1.
Routine
Maintenance
Maintenance
to
be
performed
only
by
qualified
persons.
wtwam4.1
8/92
a
Turn
Off
all
power
before
main.
taming.
OM-1538
PageS
5-2.
Aligning
Drive
Rolls
And
Wire
Guides
Horizontal
Alignment
View
is
from
top
of
drive
rolls
look
ing
down
with
pressure
assembly
open.
1
Drive
Roil
Securing
Bolt
2
Drive
Roll
3
Wire
Guide
4
WeldIng
Wire
5
Drive
Gear
Turn
bolt
in
or
out
until
drive
roll
groove
lines
up
with
wire
guide.
Vertical
Alignment
6
HousIng
Bolts
7
Weld
Cable
Terminal
Loosen
bolts
and
terminal
nut(s).
8
Wire
Guide
9
Drive
Roll
10
Pressure
Roll
Slide
housing
up
or
down
until
groove
in
drive
roll
and
pressure
roll
line
up
with
wire
guide.
Tighten
hardware.
Close
pressure
roll
assembly.
Figure
5-2.
Aligning
Drive
Rolls
And
Wire
Guides
Horizontal
Alignment
Correct
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
2.
I
Incorrect
Vertical
Alignment
Two-Drive
Roil
Model
Four-Drive
Roll
Model
7
6
7
7
Tools
Needed:
7/16
in
~
9/l6in
S-0086
I
Ref.
57-080
487-C
/
Ret.
ST-070
885-B
/
S.0087
OM-1538
Page
9
5-3.
Brush
Inspection
And
Replacement
9
1/4
in(6.3
mm)~
Minimum
Length
I
Motor
2
Brush
Cap
Remove
cap.
3
Removing
Brush
4
Brush
Box
5
Spring
Assembly
Bracket
Remove
bracket
from
box.
6
Spring
Assembly
7
Brush
Pigtail
Pull
pigtail
to
remove
brush.
8
Brush
9
Checking
Brush
Replace
if
near
minimum
length.
10
Installing
Brush
To
reinstall
spring
assembly,
slide
into
box
as
shown
to
hook
bracket
into
box.
Install
brush
cap.
Check
brush
on
other
side
of
motor.
Figure
5-3.
Brush
Inspection
And
Replacement
7
Push
Back
And
Up
8
Pull
.3
Remove
Check
Side
View
Of
Box
Install
Tools
Needed:
Push
Up
And
Down
10
ST.156
693
OM-1538
Page
10
5-4.
Troubleshooting
I
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
weld
control
and
welding
power
source,
and
disconnect
input
power
before
inspecting.
maintaining,
or
servicing.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
servicing
unit.
Table
5-1.
Troubleshooting
Align
drive
rolls.
*See
gun
or
weld
control
Owners
Manual.
d
Trouble
Troubleshooting
to
be
performed
only
by
qualified
persons.
wtwam4.1
8192
Wire
feeds
i~rratically.
Remedy
Check
gun
contact
tube
and
liner
sizes,
and
replace
if
necessary.
Check
for
obstruction
in
gun
contact
tube
or
liner.
Adjust
drive
roll
pressure
by
turning
pressure
adlustment
knob(s)
114
turn
clockwise
until
wire
stops
slipping.
Check
gun
contact
tube
for
obstructions.
Check
size
of
drive
roll.
Replace
drive
roll
if
worn.
--~
--~
---~
--~
--~
--~
--~
Clean
drive
roll,
and
check weld
control
hub
tension.
Motor
runs
~Iowly.
Section
*
*
3-4
3-4
5-2
Reduce
load.
Check
for
correct
input
voltage.
--~
--
--~
--
Motor
runs
at
full
speed
regardless
of
J.
..~
IHave
Factory
Authorized
Service
Station
check
Tachometer
board
J
wire
speed
setting
on
weld
control.
and
encoder
disc.
I
___________
OM-1538
Page
11
SECTION
6-
PARTS
LISt
Figure
6-1.
Motor
&
Drive
Assembly
(A1-2
Model
Illustrated)
SC-080
366-J
12
3
4
67
5
Includes
I
Items
10-15
46
34
r
36
30
38
47
S.
42
.5.
43
.5.
.5.
29
12
11
45
30
j
41
OM-1538
Page
12
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