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Miller KA000000, RUNNING GEA, RUNNING GEAR/CYLINDER RACK 042537 Owner's manual

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April 1991 FORFORM:
Use above FORM number when ordering extra manuals.
OWNER’S MANUAL
OM-680
Running Gear/Cylinder Rack Cart 042 537
IMPORTANT: Read and understand the entire contents of these instructions, with special emphasis
on the safety material throughout these instructions, before beginning this installation. This kit and
these instructions are for use only by persons trained and experienced in the safe methods of work-
ing on welding equipment. Do not allow untrained persons to install this kit. Contact your distributor
if you do not fully understand these instructions.
A. Specifications (Figure 1)
A
B
C
D
E
F
G
*H
Inches
21-3/4
27
7/8
10-3/4
10
54-1/2
33
40-3/4
Millimeters
553
686
22
273
254
1384
838
1035
Weight
Net Ship
105 lbs. 195 lbs.
(89 kg)(48 kg)
* Adjustable from 32-1/2 in. (826 mm)
to 40-3/4 in. (1035 mm)
A
B
C
D
F
G
H
E
SC-146 246
Figure 1. Dimensional Drawing
B. Description (Figure 2)
This multi-purpose running gear/cylinder rack cart has an inclined base for installing a welding power source so that
the front panel faces upward toward the operator. Holes and hardware are provided for installing XMT, Maxtron, and
Arc Pak model welding power sources.
A Coolmate model circular cooling system can be installed on the flat portion of the base behind the welding power
source. A Radiator model horizontal cooling system can be placed sideways in this same location. Position cooling
system to provide adequate clearance between cooling system and welding power source. A Watermate model
vertical cooling system can be installed in a gas cylinder location in the cylinder rack, and secured with a cylinder rack
chain.
Holes and hardware are provided for installing a 20, 50, 60, or XR Series wire feeder, or a Turntable Assembly on the
feeder tray. Extra holes are provided to install wire feeder or turntable in different positions on the feeder tray.
Holes and hardware are provided for installing an OPTIMA synergic pendent control.
OM-680 Page 2
SC-141 191
Wire Feeder/
Welding Power
Source Location
Gas Cylinder
And/Or Vertical
Style Coolant
System Location
Circular or Horizontal
Style Coolant System
Location
Holes For S-Hook
Ends Of Cylinder
Rack Chains
Slot For Snap End
Of Cylinder Rack Chain
Turntable
Location
Feeder
Tray
Cylinder Rack
Chain (2)
Snap-In Nylon
Bushing (4)
Handle
.250-20 x .750 In.
Bolt (26)
Cable Hanger (2)
.250-20 In. Nut (26)
Forward Strut (2)
Handle Spacer (2)
Inclined Base
Caster (2)
.500 In.
Lockwasher
(2)
.500-13 In.
Nut (2)
Rear
Strut (2)
Retaining
Ring (2)
Wheel (2)
Axle (2)
Figure 2. Running Gear/Cylinder Rack Cart
C. Assembly Instructions (Figure 2)
1. Attach forward struts and rear struts to inclined base with supplied .250-20 x .750 in. bolts and nuts.
2. Attach feeder tray to forward and rear struts with supplied .250-20 x .750 in. bolts and nuts.
3. Install handle with supplied hardware. Holes are provided in the forward struts for installing the handle at
different heights if desired. If handle is attached directly to forward struts, insert a supplied handle spacer on
inside of each handle mounting bracket before securing. Spacers are not required if installing handle in the
highest position directly to the feeder tray. If spacers are not used, secure them to the struts with supplied
hardware for possible future use.
4. Install wheels onto axles and secure with supplied retaining rings.
5. Install casters onto forward struts with supplied .500 in. lockwashers and .500-13 in. nuts.
6. Attach cable hangers in desired locations with supplied hardware. Two locations are provided on each side of
feeder tray for attaching cable hangers.
7. Insert supplied snap-in nylon bushings in feeder tray holes.
IMPORTANT: Wherever possible, run cables and hoses through the feeder tray holes to prevent them from being
pinched or damaged.
8. Refer to Figure 2 and attach supplied cylinder rack chains as follows:
a. Assemble cylinder rack chains by installing and securing chain snaps to one end of chains and S-hooks to
other end.
b. Lower S-hook end of chain down past slotted hole on feeder tray and insert S-hook in small hole located
directly below the slotted hole. Secure S-hook in hole by closing open end with pliers.
OM-680 Page 3
c. Attach snap on remaining end of chain to slot provided on outer edge of feeder tray.
d. Adjust chain length by lowering or raising chain inside slotted hole to desired length, and secure by sliding
chain link into slot.
e. Repeat for other cylinder rack chain.
D. Installation Of OPTIMA Synergic Pendent Control Onto Running Gear/Cylinder Rack (Figures 2 And 3)
1. Four sets of two holes are provided on the outside edges of the feeder tray for installing the synergic pendent
control. Select an installation site.
2. Install two supplied No. 10-24 x 1.250 in. screws and four supplied No. 10-24 flanged nuts in the mounting holes
as shown in Figure 3. Leave approximately 1/4 in. (6.4 mm) of clearance between each screw head and nut.
3. Hang synergic pendent control from the slots in its mounting bracket onto the screws installed in Step 2.
Top Of Feeder Tray
No. 10-24 Flanged Nuts
No. 10-24 x 1.250 in.
Screw
1/4 in. (6.4 mm)
S-0514
Figure 3. OPTIMA Installation
E. Installation Of XMT Models Onto Running Gear/Cylinder Rack (Figure 2)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power conductors from deenergized supply line BEFORE moving welding power
source.
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
• Lift unit at handles on top ends of case.
• Have two persons of adequate physical strength lift unit.
• Move unit with hand cart or similar device of adequate capacity.
• Use equipment of adequate capacity to lift the unit.
• If using a fork lift vehicle, place and secure unit on a proper skid before transporting.
This unit has built-in handles on top ends of case for lifting. Be sure unit is lifted and transported safely and
securely.
1. Remove and retain the four metal feet from the rubber mounting pads on the bottom of the XMT unit.
2. Carefully position the XMT unit on the inclined portion of the running gear/cylinder inclined base so that the front
control panel faces upwards, and the four mounting pads line up with the four matching holes in the base.
3. Secure the XMT from the bottom of the base by threading the metal feet removed in Step 1 back into the rubber
mounting pads.
OM-680 Page 4
F. Installation Of MAXTRON And ARC PAK Models Onto Running Gear/Cylinder Rack (Figure 2)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power conductors from deenergized supply line BEFORE moving welding power
source.
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
• Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other heavy accessories or devices.
• Use equipment of adequate capacity to lift the unit.
• If lifting or moving this unit with lift forks under the base, be sure that lift forks are long enough to extend
beyond opposite side of the base.
Using lift forks too short can damage internal parts if tips of the lift forks penetrate the unit base, or may cause
personal injury and/or equipment damage if unit falls off the lift forks.
1. Carefully position the welding power source on the inclined portion of the running gear/cylinder inclined base so
that the front control panel faces upwards, and the four base mounting holes line up with the four matching holes
in the running gear/cylinder rack base.
2. Secure MAXTRON units to the base using supplied .250-20 x .500 in. screws, lock washers, and nuts.
3. Secure ARC PAK units to the base using supplied .375-16 x 1.000 in. screws, lock washers, and nuts.
G. Installation Of 20, 50, And 60 Series Wire Feeders Onto Running Gear/Cylinder Rack (Figure 2)
1. Holes are provided in the feeder tray for installing the wire feeder in different locations. Carefully position the
wire feeder in the desired location.
2. Secure 50 Series wire feeders to the feeder tray with supplied No. 10-24 x 1.250 in. screws, lockwashers, and
nuts.
3. Secure 20 and 60 Series wire feeders to the feeder tray with supplied No. 10-24 x 2.000 in. screws,
lockwashers, and nuts.
H. Installation Of Turntable Assembly Onto Running Gear/Cylinder Rack (Figure 2)
1. Holes are provided in the feeder tray for installing the Turntable in different locations. Carefully position the
Turntable in the desired location.
2. Secure Turntable to the feeder tray using the supplied .250-20 x .500 in. screws, lock washers, and nuts.
3. Secure wire feeder onto the Turntable using hardware supplied with the Turntable (See Turntable Owner’s
Manual for installation instructions).
I. Installation Of XR Series Wire Feeders Onto Running Gear/Cylinder Rack (Figure 2)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down wire feeder and welding power source, and disconnect input power employing lockout/tagging
procedures before inspecting, installing, or adjusting.
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.
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
• Lift unit at handle on top of case.
• Have person of adequate physical strength lift unit.
1. Remove securing screws and right side panel, and release latches, and open left side access door.
2. Locate skids on bottom of XR feeder, and remove the center .250-20 in. screw, lockwasher, and nut which
secures each skid to bottom of feeder.
3. Holes are provided in the feeder tray for installing the XR feeder in different locations. Carefully position the XR
feeder in the desired location.
OM-680 Page 5
4. Secure XR feeder to the feeder tray with supplied .250-20 x 1.250 in. screws, lockwashers, and nuts.
IMPORTANT: Screws must be installed from inside of XR feeder using holes where screws were removed in Step 2.
Insert screw through the metal case, through the skid, and through the feeder tray. Secure each screw with supplied
lockwashers and nuts.
5. Close and secure left side access door, and reinstall and secure right side panel.
1
2
3
4
5
6
7
8
9
10
111213
141516
SC-141 191
Figure 4. Running Gear/Cylinder Rack Cart
Description Quantity
Part
No.
042 537
Item
No.
Figure 4. Running Gear/Cylinder Rack Cart
1 140 393 TRAY, feeder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 022 617 CHAIN, cyl racks 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 004 214 BUSHING, snap-in nyl 1.625 ID x 2.000mtg hole 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
4 140 390 HANDLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 115 807 BOLT, crg stl .250-20 x .750 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 140 398 HANGER, cable 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 089 800 NUT, stl flg lkd hex .250-20 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 140 399 STRUT, forward 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 140 392 SPACER, handle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 027 376 CASTER, rbr swvl 5dia 1/2-13 x 1 in stem 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-680 Page 6
Description Quantity
Part
No.
042 537
Item
No.
Figure 4. Running Gear/Cylinder Rack Cart (Contin-
ued)
11 602 216 WASHER, lock stl split .500 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 601 879 NUT, stl hex full fnsh .500-13 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 140 400 STRUT, rear 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 121 614 RING, retaining ext .750 shaft x .085 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 140 293 WHEEL, rubolene 10 in dia x 2.750 wide x .750 bore 2. . . . . . . . . . . . . . . . . . . . . . .
16 140 401 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware For Mounting Components
089 799 SCREW, cap stl hexwhd .250-20 x .500
(Maxtron Models and Turntable Assembly) 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108 942 SCREW, cap stl hexwhd .250-20 x 1.250 (XR Series Feeders) 2. . . . . . . . . . . . . . .
602 207 WASHER, lock stl split .250 (Maxtron Models, Turntable Assembly, and
XR Series Feeders) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 865 NUT, stl hex full fnsh .250-20 (Maxtron Models, Turntable Assembly, and
XR Series Feeders) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
086 863 SCREW, cap stl hexwhd slflkg .375-16 x 1.000 (Arc Pak Models) 4. . . . . . . . . . . . .
602 213 WASHER, lock stl split .375 (Arc Pak Models) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 872 NUT, stl hex full fnsh .375-16 (Arc Pak Models) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 115 SCREW, mach stl rdh 10-24 x 2.000 (20 & 60 Series Feeders) 4. . . . . . . . . . . . . . .
602 112 SCREW, mach stl rdh 10-24 x 1.250
(50 Series Feeders and Optima Accessory) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 238 WASHER, flat stl rvt burr .187 (20, 50, & 60 Series Feeders) 4. . . . . . . . . . . . . . . .
131 749 NUT, stl slflkg hex hvy whd 10-24
(20, 50, & 60 Series Feeders and Optima Accessory) 8. . . . . . . . . . . . . . . . . . . . . . .
BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS.
STAPLE THESE INSTRUCTIONS INSIDE THE COVER OF THE OWNER’S MANUAL AFTER COMPLETING
THIS INSTALLATION.
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