Miller LE186466 Owner's manual

Brand: Miller

Model: LE186466

Category: Welding System

Type: Owner's manual

This manual is also suitable for

PUSH-PULL ADAPTER 195324 FOR MM 251

Owner’s Manual

2006−06 FORM: OM-220 093B

Use above FORM number when ordering extra manuals.

Push-Pull Adapter 195 324 For Millermatic

251

Models Eff w/LE152159

The push-pull adapter enables the Millermatic 251 to be used for aluminum MIG

welding by providing connections for the XR-A Edge gun, XR-A Pistol gun, or

XR-A Python gun.

The push−pull system for aluminum requires installation of U-groove drive rolls in

the Millermatic 251, as well as the correct contact tube, and drive rolls in the

welding gun. These parts are available in the drive roll and accessory kit (order

separately).

NOTE

1. Safety Symbol Definitions

Warning! Watch Out! There are possible hazards as

shown in the adjoining symbols.

Have only trained and qualified persons install, operate,

or service this unit. Call your distributor if you do not un-

derstand the directions. For WELDING SAFETY and

EMF information, read welding power source Owner’s

Manual.

Beware of electric shock from wiring. Turn Off welding

power source and disconnect power before installing this

kit. Reinstall all panels and covers.

Hot parts can cause burns. Welding makes parts very hot

− let them cool before touching.

Wear safety glasses with side shields. Cylinders contain gas under high pressure and can ex-

plode if damaged. Never let a welding electrode touch

any cylinder. Always secure cylinder to running gear, wall,

or other stationary support.

Drive rolls can injure − keep away from pinch points and

moving parts on wire feeder.

Welding wire can cause puncture wounds. Do not point

gun toward any part of the body or at other people when

threading welding wire, or anytime when running out wire

and not welding.

2. Specifications

Specification

Input Power 24 Volts AC (Provided By Millermatic 251 )

Control Circuit Voltage Provided to Gun 24 Volts DC

Welding Power Source Type Millermatic 251 Eff w/LE152159

Gun Requirement XR-A Edge Gun, XR-A Pistol Gun, or XR-A Python gun.

Wire Size And Type .035, .040, and .047 in. Aluminum

Connections Gun Power And Trigger Controls, Negative Weld Cable

Welding Process DC Gas Metal Arc Welding (GMAW)

Overall Dimensions Of Control Box

(Length x Width x Depth)

9 x 3 x 11 in (227 x 76 x 279 mm)

Weight 7 lb (3.2 kg)

3. Tools Needed

OM-220 093 Page 2

4. Preparing Millermatic 251 And Gun For Push-Pull Adapter Kit Installation

Make the changes listed in Sections A and B below prior to installing the push-pull

adapter.

NOTE

A. Changing Millermatic 251 Drive Roll

1 Drive Roll

Install U-groove drive rolls in the

Millermatic 251 to match wire

diameter. Drive rolls are included in

drive roll and accessory kit.

2 Drive Roll Securing Nut

Turn nut one click to secure drive

roll.

Ref. 802 990 / Ref. 802 064-D / Ref. 800 412-A

Top View

B. Changing XR-A Gun Drive Rolls

1 Barrel Assembly

2 Nut

3 Capscrew

XR-A Edge Gun: Loosen nut and

remove gun barrel assembly.

XR-A Pistol: Remove two

capscrews beneath cover to

remove barrel.

Install correct drive rolls in gun to

match wire diameter (see gun

Owner’s Manual). Drive rolls and

other required parts are included in

drive roll and accessory kit.

801 556-B / 151 599

XR-A Edge Gun

XR-A Pistol

OM-220 093 Page 3

5. Mounting Push-Pull Adapter

803 462

Y Turn Off and disconnect input

power.

1 Millermatic 251

2 Push-Pull Adapter

3 Screw

Remove two wrapper mounting screws

on lower right side of Millermatic 251 as

shown. Align adapter slots with mounting

holes and reinstall screws.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-220 093 Page 4

6. Connecting Push-Pull Adapter

803 432

.An XR-A Edge gun is shown in these

instructions.

Make connections as shown:

1 Millermatic 251

Install U-groove drive rolls in Millermatic 251

to match wire diameter. See Section 4 for

U-groove drive roll installation information.

Drive rolls are included in drive roll and

accessory kit.

2 XR-A Edge Gun

.See gun Owner’s Manual for information

on installing gun components.

Install correct liner and drive rolls in gun to

match wire diameter (see Section 4). Drive

rolls, liner, and other required parts are

included in drive roll and accessory kit.

See Section 8 for gun installation

instructions.

3 Gun Cable w/10-Pin Male Connector

4 Adapter Cable w/10-Pin Female

Connector

5 Adapter Cable w/10-Pin Male

Connector

6 Adapter Cable w/4-Pin Male

Connector

7 Adapter Negative (−) Weld Cable

Connect cable as shown in Section 7.

8 Work Cable w/Clamp

9 Adapter Negative (−) Weld Terminal

10 Gas Cylinder

Y Do not use gas pressure above 50

psi (345 kPa).

Connect gun and weld

cable as shown in

Sections 7 and 8.

OM-220 093 Page 5

7. Installing Adapter Work Cable

Ref. 802 474-E

1 Adapter Work Cable

2 Boot

Route cable through front panel

opening. Slide boot onto work

cable.

3 Negative (−) Output Terminal

Connect cable to terminal and

cover connection with boot.

From Adapter

8. Installing Welding Gun

1 Drive Roll Assembly

2 Pressure Arm Assembly

Open drive roll and pressure arm

assemblies.

3 Gun Liner

4 Wire Outlet Guide

.For welding guns prior to Serial No.

LE273538, wire outlet guide 202 216,

included with drive roll kits, must be

installed in gun.

Trim excess liner from end of gun so no

more than 3/32 in (2.4 mm) of liner extends

past wire outlet guide.

5 Gun Securing Knob

Loosen securing knob. Insert gun end

through opening until it bottoms

against drive assembly (make sure gun

end does not touch drive rolls). Tighten

knob.

6 Gun Trigger Plug

Connect plug to adapter cable w/10-pin

female connector (see Section 6).

Close the drive roll assembly. Leave

pressure arm assembly open.

Go to Step 9.

803 463

3/32 in

(2.4 mm) .Be sure to

trim liner

to proper

extension.

OM-220 093 Page 6

9. Installing 12 Inch Wire Spool And Adjusting Hub Tension

Use compression spring

with 8 in (200 mm) spools.

072 573-B / 802 922

Loosen spool tension nut so threaded shaft

is recessed 1/8 in (3 mm) inside of nut.

1/8 in (3 mm)

1 12 in (305 mm) Spool

2 Tension Nut

3 Shaft

Loosen spool tension nut so

threaded shaft is recessed 1/8 in

(3 mm) inside of nut.

2 3

OM-220 093 Page 7

10. Threading Welding Wire Through Millermatic 251

1 Wire Spool

2 Welding Wire

3 Inlet Wire Guide

4 Pressure Adjustment Knob

5 Drive Roll

6 Outlet Wire Guide

7 Gun Conduit Cable

Lay gun cable out straight.

621

6 in

(150 mm)

.Hold wire tightly to keep it

from unraveling.

Open pressure assembly. Pull and hold wire; cut off end.

Push wire thru guides into gun;

continue to hold wire.

Close and tighten pressure

assembly, and let go of wire.

803 463 / S-0627-A

Tighten

.Set pressure indicator to

1 for aluminum wire.

Pressure

Indicator

Scale

Set Adapter Run-In speed to 40%.

Thread wire through gun

(see Section 11).

OM-220 093 Page 8

11. Threading Welding Wire Through XR-A Gun

Ref. 802 193-A / 801 556

Tools Needed:

Y Welding wire is electrically live

when gun trigger is used to jog

wire.

.Refer to Section 10 for instructions on

feeding wire through Millermatic 251.

1 Pressure Roll Assembly

Lay gun cable out straight.

Open top cover, and open pressure roll as-

sembly. If not already done, remove gun

barrel assembly.

Press gun trigger until about 4 in (102 mm)

of wire is sticking out front of gun. Insert

wire into barrel liner and tighten barrel as-

sembly. Install correct size contact tube

and install collet nut.

Close top cover on gun. Press trigger

switch until about 6 in (152 mm) of wire is

sticking out end of contact tip. See final

pressure adjustment at bottom of page.

Feed wire to check drive roll

pressure. If necessary, slightly

tighten thumb nut inside gun.

.Do not exceed midrange setting.

Cut off wire. Close and latch wire

feeder door.

Y Turn Millermatic 251 Off.

Nonconductive

Surface

For XR-A Edge Gun:

.Procedure is the same for

pistol-grip gun.

For XR-A Pistol Gun:

For Both Guns:

1 Pressure Roll Assembly

2 Drive Roll

3 Thumbscrew

Lay gun cable out straight. Open top

cover, and lift pressure arm and open

pressure roll assembly. If not already

done, remove gun barrel assembly.

Manually thread wire along drive roll

groove. Close pressure roll assembly.

Press gun trigger until about 4 in (102 mm)

of wire is sticking out front of gun. Insert

wire into barrel liner and tighten barrel as-

sembly. Install correct size contact tube

and install collet nut. Reinstall gun cover.

4 Pressure Adjustment Knob

See final pressure adjustment at bottom of

page.

Turn On

Millermatic

251.

Turn On

Millermatic

251.

Remove barrel assembly before

threading wire through gun.

Remove barrel assembly

before threading wire

through gun.

OM-220 093 Page 9

12. Setting Push-Pull Adapter And XR-A Gun Controls

1 Adapter Run-In Speed Control

Use control to set run-in wire feed speed

before arc initiation.

After arc initiation, weld wire feed speed is

controlled by the wire speed setting on the

welding gun.

The scale around the run-in speed control

is a percent of weld wire feed speed.

If using .047 wire, set control to 10% for best

results. If using .040 wire, set control to 25%

for best results. If using .035 wire, set con-

trol to 40% for best results.

.The gun wire feed speed control adjusts

wire speed from minimum to maximum

setting as displayed on Millermatic 251.

2 Trigger

Press trigger to energize Millermatic 251,

weld output, start shielding gas flow, and

begin wire feed.

3 Wire Speed Control

Use control to adjust wire feed speed. The

numbers around the control are for

reference only.

803 432 / 151 666

OM-220 093 Page 10

13. Push-Pull Adapter Electrical Diagram

210 633-A

OM-220 093 Page 11

14. Parts

803 433

. Hardware is common and

not available unless listed.

Figure 15-1. Push-Pull Adapter

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 15-1. Push-Pull Adapter

Quantity

1 211333 Case, Control Box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 211334 Baffle, Control Box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 211335 Cover, Control Box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 PLG5 211252 Cable, Interconnecting 2 Ft 7 In 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PLG6 211253 Cable, Interconnecting 1 Ft 10 In 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 PLG7 211257 Cable, Trigger 1 Ft 10 In 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 REED 211301 Switch, Reed 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 PC1 216400 Circuit Card Assy, Motor Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 WORK 097416 Terminal, Pwr Output Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 180732 Boot, Negative Output Stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 PLG3 131054 Conn, Rect Mini 045 2skt 2row Plug Cable Lkg (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . .

12 PLG1 115091 Conn, Rect Mini 045 10skt 2row Plug Cable Lkg (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . .

13 PLG2 115092 Conn, Rect Mini 045 8skt 2row Plug Cable Lkg (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . .

14 139041 Bushing, Strain Relief .481/.617 Id X1.115 Mtg Hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 057358 Bushing, Snap−in Nyl 1.000 Id X 1.375 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 134201 Stand−off Support, Pc Card .312/.375w/Post&lock .43 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 207076 Knob, Pointer .868 Dia. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 R1 208399 Pot, Cp Std Slot 1t 2. W 10k Linear W/Frict Tabs 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115093 Conn, Rect Mini 045 6skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 131515 Label, Warning Electric Shock And Arc Welding Can 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 212154 Label, Dial Indicator Run−in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 180735 Washer, Output Stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 600318 Cable, Weld Cop Strd No 3 Epdm Jkt 4 ft.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 181169 Spacer, Output Stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .