February
1979
FORM:
OM-1092
F~LE
COPY
RETURN
TO
FOLDER
OWNERS
MANUAL
fullER
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON.
WI
54912
USA
ADDITIONAL
COPY
PRICE
25
CENTS
Effective
With
Style
No.
HK-6
MODEL
SPOO
L-PAK
NWSA
CODE
NO. 4579
PRINTED
IN
U.S.A.
I--.
~~
~.
i.
LIMITED
WARRANTY
EFFECTIVE:
JANUARY
1,1979
lhis
warranty
supersedes
all
previous
MILLER
warranties
and
is
cx
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYSubject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
submitted
by
the
original
user
within
the
foregoing
periods.
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
Miller
is
free
from
defect
in
workmanship
and
material
as
of
the
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
time
and
place
of
delivery
by
Miller.
No
warranty
is
made
by
Miller
therefor
shall
be,
at
Millers
option,
(I)
repair
or
(2)
replacement
or,
with
respect
to
engines,
trade
accessories
or
other
items
manu
factured
by
others.
Such
engines,
trade
accessories
and
other
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
items
are
sold
subject
to
the
warranties
of
their
respective
manu-
reasonable
cost
of
repair
or
replacement
at
an
authorized
Miller
5cr-
facturers,
if
any.
At
the
present
time,
the
manufacturers
warranty
on
vice
station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
the
Mag-Diesel
engine
on
DEL-200
is
limited
to
six
months
and
on
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
all
other
engines
to
one
year.
goods
at
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
Except
as
specified
below,
Millers
warranty
does
not
apply
to
warranty
claim
procedures
to
be
followed.
components
having
normal
useful
life
of
less
than
one
(I)
year,
such
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
as
spot
welder
tips,
relay
and
contactor
points,MILLERMATIC
parts
ANY
IMPLIED
WARRANTY
GUARANTY
OR
REPRESENTA
that
come
in
contact
with
the
welding
wire
including
nozzles
arid
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
/
nozzle
insulators
where
failure
does
not
result
from
defect
in
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
)
~l
workmanship
or
material.
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUS
TOM
OF
TRADE
OR
COURSE
OF
DEALING
INCLUDING
ANY
Miller
shall
be
required
to
honor
warranty
claims
on
warranted
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
FITNESS
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
following
periods
from
the
date
of
delivery
of
Equipment
to
the
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
~
original
user:
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
- .
.
.
1
year
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRIT-
)
2.
Original
main
power
rectifiers
3
years
ING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTIMATE
(labor
-
1
year
only)
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
3.
All
welding
guns
and
feeder/guns
90
days
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
(
4.
All
other
Millermatic
Feeders
I
year
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
- .
60
days
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
WAR-
J
6.
Batteries
6
months
RANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
of
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
the
date
of
such
failure.
ANY
CONSUMER.
I
~rk,
~
,t
~
ST.
~
ST
~
.~
~b
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
Item
Part
No.
Listed
Replaced
With
No.
In
Parts
List
Part
No.
Description
Quantity
28
058
968
058
968
RING,
retainer
E
(qty.
change)
4
34
004771
604612
SCREW,set-steelsockethd8-32x1/8
2
Page
4
I
602
084
Deleted
Page
4
602
200
Deleted
Page
4
602
237
Deleted
047
162
BRACKET,
tension
-
spring
(Eff
with
S/N
HK-33)
1
057
745
SPRING,
compression
1
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
COp
~
Lo~R
OM-1092
Page
A
SECTION
1
-
INTRODUCTION
Dimensions
(Inches)
Weight
(Pounds)
Height
-
19
Width
-9-1/2
23
Depth
-
17-3/4
Figure
1-1.
Specifications
1-1.
GENERAL
This
manual
has
been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
design,
installation,
operation,
main
tenance.
and
troubleshooting
of
this
equipment.
All
informa
tion
presented
herein
should
be
given
careful
consideration
to
assUre
optimum
performance
of
this
equipment.
1-2.
RECEIVING-HANDLING
Prior
to
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
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equipment,
it
is
essential
that
Model
Description
and/or
Stock
Number
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
This
unit
is
designed
to
enable
Spoolmatic
guns
to
utilize
12
inch
spools
of
wire.
The
unit
is
used
in
conjunction
with
the
Spoolmatic
guns
and
WC
series
weld
controls
or
with
the
MM200
welding
power
source.
1-4.
SAFETY
Before
the
equipment
is
put
into
operation,
the
safety
sec
tion
at
the
front
of
the
welding
power
source
or
welding
generator
manual
should
be
read
completely.
This
will
help
avoid
possible
injury
due
to
misuse
or
improper
welding
applications.
The
following
definitions
apply
to
CAUTION
and
IM
PORTANT
blocks
found
throughout
this
manual:
sonnel.
I
TAr)
I
U
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip
ment.
2-1.
BRAKE
OPERATION
(Figure
2-1)
The
BRAKE
lockout
should
be
set
to
ON
for
normal
operation.
This
will
prevent
wire
backlash
when
the
gun
trigger
is
released
and
wire
feed
ceases.
The
BRAKE
lockout
should
be
set
to
OFF
for
loading
and
threading
welding
wire.
2-2.
INSTALLING
SPOOL-PAK
TO
WELD
CONTROL
OR
WELDING
POWER
SOURCE
~I.V~IuIlIs]~
Ensure
that
all
electrical
power
to
the
welding
power
1
source
and
the
weld
control
unit
is
completely
i
disconnected
prior
to
installation
of
the
Spool-Pak.
1.
Insert
brake
control
receptacle
RC1
into
plug
PLG1
on
the
rear
of
the
Spool-Pak
control
box.
2.
The
remaining
end
of
the
brake
control
cable
is
attached
to
the
contactor
control
in
the
weld
control
or
welding
power
source.
a.
For
WC-l
models:
Attach
the
black
and
white
leads
to
terminals
No.
5
and
2
on
terminal
strip
iT
or
across
the
Contactor
Control
receptacle
RC2.
Attach
the
green
lead
to
ground.
I
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
per-
U
SECTION
2
-
INSTALLATION
I
U-
I
Figure
2-1
-
Component
Location
C-049
184
OM-1092
Page
1
b.
For
WC-ll,
WC-lIl
&
WC-IV
models:
Attach
the
black
and
white
leeds
to
terminals
No.42
and
43
on
termin
al
strip
iT.
Attach
the
green
lead
to
ground.
c.
For
MM200:
Attach
the
black
and
white
leads
to
terminals
No.
3
and
4
on
terminal
strip
iT.
Attach
the
green
lead
to
ground.
2-3.
INSTALLING
SPOOL-PAK
TO
SPOOLMATIC
GUN
1.
Remove
gun
spool
cover.
2.
Pivot
the
tension
arm
upward
and
pivot
the
mounting
arm
outward.
3.
Retract
the
welding
wire
onto
the
welding
wire
spool,
and
remove
the
wire
spool.
4.
Slip
the
ring
retainer
off
the
inlet
guide.
5.
Remove
the
inlet
guide
by
pushing
the
inlet
guide
towards
the
rear
of
the
gun.
Retain
inlet
guide
and
retainer
ring
for
future
reuse.
6,
Slide
adapter
block
into
gun
wire
spool
aligning
groove
in
block
with
the
rib
in
the
gun
case.
7.
Route
outlet
guide
and
interconnecting
conduit
through
the
hole
in
rear
of
gun
case
(on
early
Spoolmatic
models
the
hole
will
need
to
be
altered
so
the
conduit
can
be
routed
straight
out
the
rear
of
the
gun).
8.
Depress
securing
pin
lever
and
insert
outlet
guide
from
Spool-Pak
interconnecting
conduit
through
adapter
block
and
into
gun
drive
housing.
9.
Release
securing
pin
lever
and
ensure
outlet
guide
is
secured.
10.
Open
side
access
door
on
Spool-Pak.
11.
Depress
securing
pin
lever
on
adapter
block
and
insert
remaining
end
of
interconnecting
conduit.
12.
Release
securing
pin
lever
and
ensure
interconnecting
conduit
is
secured.
CAUTION
SECTION
3
-
I
-.
-~
Ensure
that
all
electrical
power
to
the
welding
power
source
and
the
weld
control
unit
is
completely
disconnected
before
attempting
any
inspection
or
work
on
the
Spool-Pak.
31.
INSPECTION
AND
UPKEEP
Usage
and
shop
conditions
will
determine
the
frequency
and
type
of
maintenance.
Inspect
equipment
as
follows:
1.
Repair
or
replace,
as
required,
all
cable
and
conduit.
Give
particular
attention
to
frayed
and
cracked
insulation,
connections,
and
areas
where
the
cable
or
conduit
enters
equipment.
2.
Remove
grease
and
grime
from
components;
moisture
from
electrical
parts
and
cable.
3.
Purge
the
interconnecting
conduit
with
compressed
air
when
changing
wire.
This
will
remove
any
metal
chips
and
dirt
that
may
have
accumulated.
2-4.
WELDING
WIRE
SPOOL
INSTALLATION
&
WELDING
WIRE
THREADING
(Figure
3-1)
flTANT
Place
the
Spool-Pak
BRAKE
in
the
OFF
position
and
keep
the
interconnecting
conduit
as
straight
as
pos
sible
during
the
following
procedures.
1.
Release
spring
tension
on
Spool-Pak
spool
cover
by
rotating
the
cover
locking
knob
clockwise.
2.
Remove
Spool-Pak
spool
cover.
3.
Depress
the
two
spring
loaded
stops
on
the
retaining
ring
on
the
Spool-Pak
wire
spool
spindle
and
remove
the
retaining
ring.
4.
Slide
spool
of
wire
onto
the
hub
so
that
the wire
feeds
off
the
bottom
of
the
spool.
The
spool
turns
in
a
counterclockwise
direction.
5.
Rotate
the
spool
until
the
hole
in
the
spool
aligns
with
the
pin
in
the
hub.
Slide
the
spool
onto
the
hub
until
it
seats
against
the
back
flange
of
the
hub.
6.
Replace
retaining
ring.
7.
Cut
off
any
portion
of
the
welding
wire
that
is
not
straight
or
is
deformed.
8.
Thread
the
welding
wire
into
the
interconnecting
conduit
inlet
guide
and
push
wire
forward
until
it
passes
through
the
gun
drive
rolls
and
enters
the
wire
guide
liner.
9.
Pivot
the
mounting
arm
in
the
gun
in
and
pivot
the
tension
arm
down.
10.
Replace
gun
spool
cover.
ii.
Place
the
Spool-Pak
BRAKE
in
the
ON
position
and
rotate
the
wire
spool
clockwise
to
take
up
the
wire
slack.
12.
To
replace
the
Spool-Pak
spool
cover,
align
notches
and
tip
cover
down
under
spring.
Tighten
spring
tension
by
rotating
the
cover
locking
knob
counter
clockwise.
MAINTENANCE
Nuts
Adjustment
Spring
Control
Brake
Adjustment
Bolt
Brake
Control
Plug
A-049
182
Figure
3-1.
Brake
Adjustment
Page
2
and
slide
bolt
up
or
down.
Sliding
the
bolt
down
will
increase
3-2.
BRAKE
ADJUSTMENT
(Figure
3-1)
the
brake
pressure,
thereby
causing
the
spool
to
stop
faster.
Some
small
slippage
of
the
brake
is
necessary
to
keep
the
Spring
tension
on
the
BRAKE
may
be
adjusted
to
ensure
wire
from
snapping
as
the
wire
feed
motor
Coasts.
When
the
proper
stopping
of
the wire
spool.
Loosen
nuts
(Figure
3-1
)
proper
spring
tension
is
obtained,
tighten
the
nuts.
SECTION
4
-
TROUBLESHOOTING
_________________
The
following
chart
is
designed
to
diagnose
and
to
provide
r
~1UlLs1~
remedies
for
some
of
the
troubles
that
may
develop
in
this
unit.
.
I
It
is
assumed
that
proper
installation
has
been
made.
Hazardous
voltages
are
present
on
the
internal
cir-
according
to
Section 2
of
this
manual,
and
that
the
unit
has
cuitry
of
this
unit
as
long
as
power
is
supplied
to
the
been
functioning
properly
until
this
trouble
developed.
welding
power
source
and
weld
control.
Disconnect
power
before
attempting
any
inspection
or
work
on
Use
this
chart
in
conjunction
with
the
circuit
diagram
while
the
inside
of
the
unit.
Troubleshooting
of
internal
performing
troubleshooting
procedures.
If
the
trouble
is
not
circuitry
should
be
performed
by
qualified
personnel
remedied
after
performing
these
procedures,
the
nearest
only.
Factory
Authorized
Service
Station
should
be
contacted.
In
I
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should
be
strictly
followed.
TROUBLE
PROBABLE
CAUSE
SUGGESTED
CHECK
AND/OR
REMEDY
Wire
backlash
at
end
of
weld.
BRAKE
lockout
in
wrong
position.
Ensure
BRAKE
is
set
to
ON
for
normal
operation.
.
Brake
control
receptacle
RC1
loose.
Ensure
that
RC1
is
secure
in
plug
PLG1.
Brake
spring
tension
not
properly
adjusted.
Adjust
brake
spring
tension
(see
Section
5-2).
Wire
feeds
erratically.
~
~
Dirt
in
interconnecting
conduit
and/or
wire
guides.
Blow
dirt
out
of
conduit
and/or
wire
guides
using
compressed
air.
Interconnecting
conduit
not
secure
in
adapter
blocks.
Ensure
that
conduit
is
secured
in
adapter
blocks.
Problem
in
gun
and/or
weld
control.
See
gun
and/or
weld
control
Owner~s
Manual.
Interconnecting
conduit
and/or
wire
guides
worn.
Replace
conduit
and/or
wire
guides.
501
503
>
I
502
WIDE
SLOT
~
GRN
>-~
PLGi
RCI
Figure
4-1.
Circuit
Diagram
TO
CONTACTOR
CONTROL
CIRCUIT
A-081
643
OM-1092
Page
3
February
1979
FORM:
OM-1092
PARTS
LIST
Effective
With
Style
No.
HK-6
MODEL
SPOOL-PA
K
In
0
a
0
I
.0
F
II
IC
C
(V
IC
(V
WI
LL
C,
e
N
I-
N
0
e
-
C)
1%
CO
U,
I-
OM-1092
Page
1
Item
Dia.
Factory
No.
Mkgs.
Part
No.
Description
Quantity
Figure
A
Main
Assembly
1
081
427
COVER,
spool
1
2
058
427
RING,
retaining
-
spool
1
3
010
909
NUT,
steel
-
self
-
locking
hex
3/8-16
2
4
010
910
WASHER,
flat
-
steel
SAE
3/8
2
5
056068
KEY,steel
1/8x
1/8x
1/2
2
6
081
729
SHAFT,
spool
1
7
081
726
COLLAR,
locking
-
hub
1
8
058
428
HUB,
spool
1
9
081
664
RING,
retaining
-
internal
5/8
x
0.042
1
10
604423
GRIP,handle
1
11
057
544
SPRING,
compression
0.240
OD
x
1
4
12
081
733
BAR,cam-brake
1
13
081
642
SPRING,
extension
3/8
ID
x
1/2
OD
x
27-5/8
inches
long
1
14
PLG1
039
871
RECEPTACLE,
twistlock
-
flange
midget
3P3W
10
amp
1
15
RC1
081
765
CORD,
control
(consisting
of)
1
16
603
031
CONNECTOR
BODY,
twistlock
midget
3P3W
15
amp
1
17
604
825
.
CORD,
portable
No.
18
3/c
(order
by
foot)
25
ft.
18
Figure
B
SPOOL
PAK
BRAKE
ASSEMBLY
(See
Page
3)
1
19
081
124
PANEL,
side
-
upright
1
20
605394
PIN,cotterl/8x3/4
1
21
BS1
081
660
SOLENOID,ll5voltsac60hz
1
22
081
736
TUBING,nylon0.138lDx3/l6ODx
1/8
2
23
081
125
LOCKOUT,
brake
1
24
010
104
BLANK,
snap
-
in
3/8
dia
2
25
019
609
KNOB,
pointer
2
26
081
120
BASE
1
27
081
121
ADAPTER,conduit
2
28
058968
RING,retainerE
2
29
081
129
LEVER,
release
-
cover
2
30
081
730
PIN,adapter-conduit
2
31
081
518
CONDUIT,
1/16
aluminum
wire
x
10
feet
(consisting
of)
1
32
081
732
.
GUIDE,
outlet
-
wire
1
33
081
128
.
BODY,
connector
2
34
604
771
.
SCREW,
set
-
steel
socket
hd
10-32
x
1/8
2
35
058
720
.
CONDUIT,
1/16
aluminum
wire
x
10
feet
w/fittings
1
36
081
731
GUIDE,
inlet
-
wire
1
37
605 669
LATCH,
spring
-
knurled
head
1
38
081
132
LEVER,
release
-
cover
1
39
000
366
RING,
retainer
E
1/4
x
1/4
groove
1
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1092
Page
2
I
tern
No.
Factory
Part
No.
Figure
B
Spool
Pak
Brake
Assembly
DescriPtion
Quantity
51
081
123
BLOCK,bearing-support
2
52
024
801
BEARING,baII
2
53
081
764
BAND,
brake
1
54
081
734
TUBING,
rnirdrene
1-1/8
ID
x
1/16
wall
x
1-1/8
1
55
081
727
DRUM,brake
1
56
081
659
SPRING,
extension
1/4
ID
x
1/32
wire
x
2
1
57
081
738
TUBING,
steel
5/16
OD
x
17
ga
wall
x
9/32
2
58
081
133
LEVER,
brake
1
59
081
728
LINK,
connecting
-
solenoid
1
60
081
737
TUBING,
steel
5/16
OD
x
17
ga
wall
x
1-5/8
1
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
51
54
60
Figure
B
Spool
Pak
Brake
Assembly
TB-049
248
Page
3
Factory:
Part
No~
000
419
602
070
602
075
605138
604
804
602084
081
66t
602
112
602
154
602 004
601
954
602
180
602
199
602198
602
200
602
201
602
237
602
203
602
207
602
241
601
859
601
869
601
865
601
892
Common
Hardware
Description
SCREW,machine
-
steel
flat
hd
4-40
x
1-1/4
SCREW,
machine
-
steel
truss
hd
6-32
x
3/8
SCREW,
machine
-
steel
round
hd
6-32
x
1
SCREW,
machine
-
steel
round
hd
6-32
x
1-1/4
SCREW,
sheet
-
metal
hexagonal
washer
No.
8
x
3/8
SCREW,
machine
-
steel
round
hd
8-32
x
5/8
SCREW,
machine
-
steel
round
hd
8-32
x
2-3/4
SCREW,
machine
-
steel
round
hd
10-24
x
1-1/4
SCREW,
self
-
tapping
hexagonal
washer
hd
1/4-20
x
1/2
SCREW,
cap
-
steel
socket
hd
1/4-20
x
3/4
SCREW,
cap
-
steel
hex
hd
1/4-20
x
3/4
SCREW,
set
-
steel
socket
hd
5/16-18
x
1/4
WASHER,
lock
-
steel
external
tooth
No.
6
WASHER,
lock
-
steel
split
No.
6
WASHER,
lock
-
steel
split
No.
8
WASHER,
lock
-
steel
external
tooth
No. 8
WASHER,
flat
-
steel
rivet
burr
No.
8
WASHER,
lock
-
steel
split
No.
10
WASH
ER,
lock
-
steel
split
1/4
WASHER,
flat
-
steel
SAE
1/4
NUT,
steel
-
hex
machine
screw
6-32
NUT,
steel
-
hex
machine
screw
8-32
NUT,
steel
-
hex
full
finish
1/4-20
RIVET,
blind
1/8diax
1/4
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1092
Page
4
a
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