Gebruiksaanwijzing /service van het product XLT 185 van de fabrikant Miller Electric
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X L T 1 8 5 And H-10 Gun OM-230 832A 2007−02 ® For W arranty Claims And T echnical Support, Contact: Milweld Inc., National Distributor P .O. Box 338, Hortonville, WI 54944-0338 T el 920-779-0916 F.
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T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 9 − MIG WELDING (GMA W) GUIDELINES 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. T ypical MIG Process Connections 30 . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-230 832 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
OM-230 832 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly of f from the weld.
OM-230 832 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.
OM-230 832 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .
OM-230 832 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
OM-230 832 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
OM-230 832 Page 7 2-3 . Dange rs supplémenta ires en relation avec l ’install ation, le f onctionnement et l a m aintenanc e Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables.
OM-230 832 Page 8 2-5. Prin cipales nor mes de sécur it é Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .
OM-230 832 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperage V V oltage Hz Hertz Negative Positive Direct Current (DC) Single Phase Input Output V oltage Input Of f On Do Not Switch While W elding Gas Metal Arc W elding (GMA W) Wire Feed Flux Cored Arc W elding (FCA W) SECTION 4 − SPECIFICA TIONS 4-1.
OM-230 832 Page 10 4-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool.
OM-230 832 Page 1 1 SECTION 5 − INST ALLA TION 5-1. Installing Welding Gun 804 621-A 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew . Insert end through opening until it bottoms against drive assembly . Tighten thumbscrew . W elding gun must be inserted completely to prevent leakage of shielding gas.
OM-230 832 Page 12 5-2. Installing Work Clamp 1 Nut 2 W ork Cable From Unit 3 W ork Clamp 4 Screw 5 W ork Clamp T abs Bend tabs around work cable. 6 Insulating Sleeves Slide one insulating sleeve over work cable before connecting to clamp. Slide insulating sleeves over handles.
OM-230 832 Page 13 5-3. Process/Polarity T able Process Polarity Cable Connections Process Polarity Cable T o Gun Cable T o Work GMAW − Solid wire with shield- ing gas DCEP − Reverse polarity Conn.
OM-230 832 Page 14 5-5. Installing Gas Supply Obtain gas cylinder and chain to running gear , wall, or other stationary support so cylinder cannot fall and break off valve. 1 Cap 2 Cylinder V alve Remove c ap, stand to side of valve, and open valve slightly .
OM-230 832 Page 15 5-6. Selecting A Location And Connecting Input Power Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 51 1 or CEC Section 20. Y Installation must meet all Na- tional and Local Codes − have only qualified persons make this installation.
OM-230 832 Page 16 5-7. Electrical Service Guide Input V oltage 230 Input Amperes At Rated Output 20.5 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker 1 , Time-Delay.
OM-230 832 Page 17 5-9. Installing Contact Tip And Nozzle T ools Needed: Ref. 802 399-A Y T u rn off welding power source. 1 Nozzle Remove nozzle. 2 Contact T ip 3 T ip Adapter Thread welding wire through gun (see Section 5-10 ). Slide contact tip over wire and tighten tip into tip adapter .
OM-230 832 Page 18 5-10. Threading Welding Wire 1 Wire Spool 2 W elding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. T ools Needed: Pull and hold wire; cut off end. Remove gun nozzle and contact tip.
OM-230 832 Page 19 SECTION 6 − O P E R A T I O N 6-1. Controls 1 Wire Speed Control Us e control to select a wire feed speed. As V oltage switch setting increases, wire speed range also increases (see weld setting label in welding power source or Section 6-2 , as applicable).
OM-230 832 Page 20 6-2. W eld Parameter Chart For 230 V AC Model Flux Cored E71T−11 “Set Polarity for (DCEN)” Solid Wire ER70S−6 “Set Polarity for (DCEP)” Solid Wire ER70S−6 “Set Polar.
OM-230 832 Page 21 227 010-A 227010 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 2/40 1/25 4/60 3/50 5/40 5/40 5/40 4/60 3/50 3/30 5/80 5/60 5/50 5/60 5/50 5/40 5/50 4/35 6/90 6/60 6/50 6/80 6/50 6 / 40* 6/60 5/35 6 / 70*.
OM-230 832 Page 22 SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside.
OM-230 832 Page 23 7-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire G u i d e S e c u r i n g Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touching.
OM-230 832 Page 24 7-6. Cleaning Or Replacing Gun Liner Ref. 802 446-A 8 mm / 10mm Y Disconnect gun from unit. T ools Needed: T o Reassemble Gun: Insert new liner . Install wire outlet guide so that 1/8 in (3 mm) of liner sticks out. Hand tighten outlet guide, and then tighten two full turns more.
OM-230 832 Page 25 7-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-C T ools Ne e d e d : 19 mm Remove handle locking nut. Slide handle. Secure head tube in vice. Loosen jam nut. Remove from vice an d turn head tube out by hand. Hand-tighten head tube into cable connector .
OM-230 832 Page 26 7-8. T roubleshooting T able T rouble Remedy No weld output; wire does not feed; fan does not run. Secure power cord plug in receptacle (see Section 5-6). does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 6-1).
OM-230 832 Page 27 Notes.
OM-230 832 Page 28 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram.
OM-230 832 Page 29 228 180-A.
OM-230 832 Page 30 SECTION 9 − MIG WELDING (GMA W) GUIDELINES 9-1. T ypical MIG Process Connections Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. P l a c e w o r k c l a m p a s close to the weld as possible.
OM-230 832 Page 31 9-2. T ypical MIG Process Control Settings These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. NOTE 3.
OM-230 832 Page 32 9-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger , be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam.
OM-230 832 Page 33 9-4. Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage.
OM-230 832 Page 34 9-5. Gun Movement During Welding Normally , a single stringer bead is satisfactory for most narrow groove weld joints; however , for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better .
OM-230 832 Page 35 9-8. T roubleshooting − Excessive Spatter Excessive Spa tter − scattering of molten metal partic les that cool t o solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed.
OM-230 832 Page 36 9-1 1. T roubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick.
OM-230 832 Page 37 9-14. T roubleshooting − W aviness Of Bead W aviness O f Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding wire extends too far out of nozzle.
OM-230 832 Page 38 9-17. T roubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates, bu t wire does not feed. T oo little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.
OM-230 832 Page 39 Notes.
OM-230 832 Page 40 SECTION 10 − P ARTS LIST . Hardware is common and not available unless listed. 804 624-A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 34 32 31 49 43 48 47 46 45 44 51 50 36 35 42 41 40 38 39 37 30 33 52 53 54 Figure 10-1.
OM-230 832 Page 41 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly Quanti ty 1 199 566 DOOR, access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-230 832 Page 42 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly (Continued) Quanti ty 40 196 574 SWITCH, rocker DPST 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-230 832 Page 43 1 802 447 2 34 5 6 7 9 8 10 11 Figure 10-2. H-10 Gun Quanti ty Description Part No. 195 957 Item No. Figure 10-2. H-10 Gun 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-230 832 Page 44 10-3. Optional Drive Rolls For All Feed Head Assemblies P ART NO. WIRE DIAMETER INCHES (mm) 202 925 .023/.025 (.6) and .030/.035 (.8 and .9) 202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove) 10-4. Options P ART NO. DESCRIPTION REMARKS 770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder , 100 lb (45 kg) max.
Notes.
Notes W o r k l i k e a P r o! Pros wel d and cut safel y . Read the safety rules at the beginning of this m anual..
Effective January 1, 2007 (Equipment with a serial number preface of “LH” or newer) This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties express ed or implied.
PRINTED IN USA 2007−01 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Please complete and retain with your personal records. Always provide Model Name and Serial/Style Number.
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