Miller Electric S-44GL Owner's Manual

S-44GLProcessesDescriptionFlux Cored (FCAW) WeldingWire FeederOM-1534 045 215GAugust 1998Visit our website atwww.MillerWelds.com

OM-1534 Page 65. ANSI Standard Z41.1, STANDARD FOR MEN’SSAFETY-TOE FOOTWEAR obtainable from theAmerican National Standards Institute, 1430Broadway, Ne

OM-1534 Page 7SECTION 3 – SPECIFICATIONSTable 3-1. SpecificationsElectrode WireDiameter CapabilitySpeedRangeMax. WeldOutput @ 100%WeightNet Ship1/16 T

OM-1534 Page 84-3. WIRE GUIDE AND DRIVE ROLL INSTALLA-TION (Figure 4-1)Upon initial installation, or as a result of changes in wiresize and type, it i

OM-1534 Page 9B. Shielding Gas (If Applicable)An integral gas input fitting is provided on the wire driveassembly for guns utilizing this type of conn

OM-1534 Page 10Select and prepare weld cable according to informationin welding power source Owner’s Manual.For Electrode Positive/Reverse Polarity co

OM-1534 Page 11IMPORTANT: If the U-Cogged drive rolls do not alignproperly when the gear cover is closed, pivot the gearcover away from the drive gea

OM-1534 Page 125-2. JOG BUTTON (Figure 5-1)JOGThe JOG button is a momentary-contact switch. Whenpressed, it completes the circuit to the motor without

OM-1534 Page 13SECTION 6 – SEQUENCE OF OPERATION6-1. FLUX CORE ARC WELDING (FCAW) ANDGAS METAL ARC WELDING (GMAW)WARNING: ELECTRIC SHOCK can kill;MOV

OM-1534 Page 14SECTION 7 – MAINTENANCE & TROUBLESHOOTING7-1. ROUTINE MAINTENANCEIMPORTANT: Every six months inspect the labels onthis unit for le

OM-1534 Page 15A. Horizontal AdjustmentBehind the motor gear are spring washers. Turn motorgear securing bolt in or out until motor gear is horizon-ta

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-1534 Page 16Fuse F1 protects the unit from overload. If fuse F1should open, the wire feeder would completely shutdown. To replace F1, proceed as fo

OM-1534 Page 177-6. TROUBLESHOOTINGWARNING: ELECTRIC SHOCK can kill.• Do not touch live electrical parts.• Shut down welding power source, and dis-co

OM-1534 Page 18SECTION 8 – ELECTRICAL DIAGRAMSCircuit Diagram No. SA-150 528-BDiagram 8-1. Circuit Diagram

OM-1534 Page 19Notes

OM-1534 Page 20SECTION 9 – PARTS LIST1234567891011121314 15 16 17181920212023242526272829303233343536373839404142434445464722484950515253 35 55 565439

OM-1534 Page 21DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-1. Main AssemblyQuantity1 058 427 RING, retaining spool 1. . . . . . . . . . . . . . . .

OM-1534 Page 22Description QuantityPartNo.Dia.Mkgs.Optional Equipment046 820 REMOTE WIRE INCHING CONTROL, (consisting of) 1. . . . . . . . . . . . . .

OM-1534 Page 23DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-2. Switch, Magnetic Blowout (Fig 9-1 Item 30)Quantity1 139 392 PIN, hinge 2. . . . . . . .

OM-1534 Page 24DescriptionPartNo.ItemNo.Figure 9-3. Wire Drive & Gears (Fig 9-1 Item 51)Quantity1 096 359 DRIVE ASSEMBLY, (consisting of) 1. . . .

OM-1534 Page 25Table 9-1. Drive Roll & Wire Guide KitsBase selection of drive rolls upon the following recommended usages:1. V-Grooved rolls for

TABLE OF CONTENTSSection No. Page No.SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE1-1. Introduction 1. . . . . . . . . . . . . .

OM-1534 Page 26Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 7/00Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

7-5. Brush Inspection And Replacement 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Troubleshooting 17. . . . . . . . . . . . . . . .

OM-1534 Page 1SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE1-1. INTRODUCTIONWe learn by experience. Learning safety through per-s

OM-1534 Page 2atmosphere or where the radiant energy can penetrateto atmospheres containing even minute amounts oftrichloroethylene or perchloroethyle

OM-1534 Page 3Locate or secure cylinders so they cannot be knockedover.Passageways and work areas. Keep cylinders clear ofareas where they may be stru

OM-1534 Page 41-3. ARC WELDINGComply with precautions in 1-1, 1-2, and this section.Arc Welding, properly done, is a safe process, but acareless opera

OM-1534 Page 5quate to carry ground currents safely. Equipment madeelectrically HOT by stray current may shock, possiblyfatally. Do NOT GROUND to elec