Miller Electric XLT 185 User Manual

XLT 185And H-10 GunOM-230 832A 2007−02®For Warranty Claims And Technical Support, Contact:Milweld Inc., National DistributorP.O. Box 338, Hortonville,

OM-230 832 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptib

OM-230 832 Page 72-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenanceRisque D’INCENDIE OU D’EXPLO-SION.D

OM-230 832 Page 82-5. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Docume

OM-230 832 Page 9SECTION 3 − DEFINITIONS3-1. Symbols And DefinitionsAAmperageVVoltageHzHertz NegativePositiveDirect Current(DC)Single Phase InputOutpu

OM-230 832 Page 104-2. Duty Cycle And OverheatingDuty Cycle is percentage of 10minutes that unit can weld at ratedload without overheating.If unit ove

OM-230 832 Page 11SECTION 5 − INSTALLATION5-1. Installing Welding Gun804 621-A1 Drive Assembly2 Gun Securing Thumbscrew3 Gun EndLoosen thumbscrew. Ins

OM-230 832 Page 125-2. Installing Work Clamp1 Nut2 Work Cable From Unit3 Work Clamp4 Screw5 Work Clamp TabsBend tabs around work cable.6 Insulating Sl

OM-230 832 Page 135-3. Process/Polarity TableProcessPolarityCable ConnectionsProcessPolarityCable To Gun Cable To WorkGMAW − Solid wire with shield-in

OM-230 832 Page 145-5. Installing Gas SupplyObtain gas cylinder and chain torunning gear, wall, or otherstationary support so cylindercannot fall and

OM-230 832 Page 155-6. Selecting A Location And Connecting Input PowerY Special installation may berequired where gasoline orvolatile liquids are pres

OM-230 832 Page 165-7. Electrical Service GuideInput Voltage 230Input Amperes At Rated Output 20.5Max Recommended Standard Fuse Or Circuit Breaker Rat

OM-230 832 Page 175-9. Installing Contact Tip And NozzleTools Needed:Ref. 802 399-AY Turn off welding power source.1 NozzleRemove nozzle.2 Contact Tip

OM-230 832 Page 185-10. Threading Welding Wire1 Wire Spool2 Welding Wire3 Inlet Wire Guide4 Pressure Adjustment Knob5 Drive Roll6 Gun Conduit CableLay

OM-230 832 Page 19SECTION 6 − OPERATION6-1. Controls1 Wire Speed ControlUse control to select a wire feed speed. AsVoltage switch setting increases, w

OM-230 832 Page 206-2. Weld Parameter Chart For 230 VAC ModelFlux CoredE71T−11“Set Polarityfor (DCEN)”Solid WireER70S−6“Set Polarityfor (DCEP)”Solid W

OM-230 832 Page 21227 010-A227010~~~~~~~~~~~~2/401/254/603/505/405/405/404/603/503/305/805/605/505/605/505/405/504/356/906/606/506/806/506 / 40*6/605/

OM-230 832 Page 22SECTION 7 − MAINTENANCE &TROUBLESHOOTING7-1. Routine MaintenanceY Disconnect power before maintaining.3 MonthsReplaceunreadablel

OM-230 832 Page 237-4. Changing Drive Roll Or Wire Inlet Guide1 Inlet Wire Guide SecuringScrew2 Inlet Wire GuideLoosen screw. Slide tip as close todri

OM-230 832 Page 247-6. Cleaning Or Replacing Gun LinerRef. 802 446-A8 mm / 10mmY Disconnect gun from unit.Tools Needed:To Reassemble Gun:Insert new li

OM-230 832 Page 257-7. Replacing Switch And/Or Head TubeRef. ST-800 795-CTools Needed:19 mmRemove handlelocking nut.Slide handle.Secure headtube in vi

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbo

OM-230 832 Page 267-8. Troubleshooting TableTrouble RemedyNo weld output; wire does not feed; fandoes not run.Secure power cord plug in receptacle (se

OM-230 832 Page 27Notes

OM-230 832 Page 28SECTION 8 − ELECTRICAL DIAGRAMFigure 8-1. Circuit Diagram

OM-230 832 Page 29228 180-A

OM-230 832 Page 30SECTION 9 − MIG WELDING (GMAW) GUIDELINES9-1. Typical MIG Process ConnectionsY Weld current can damageelectronic parts in vehicles.D

OM-230 832 Page 319-2. Typical MIG Process Control SettingsThese settings are guidelines only. Material and wire type, joint design, fitup,position, s

OM-230 832 Page 329-3. Holding And Positioning Welding GunWelding wire is energized when gun trigger is pressed. Before lowering helmet andpressing tr

OM-230 832 Page 339-4. Conditions That Affect Weld Bead ShapeWeld bead shape depends on gun angle, direction of travel, electrode extension(stickout),

OM-230 832 Page 349-5. Gun Movement During WeldingNormally, a single stringer bead is satisfactory for most narrow groove weld joints;however, for wid

OM-230 832 Page 359-8. Troubleshooting − Excessive SpatterExcessive Spatter − scattering of molten metal particles thatcool to solid form near weld be

TABLE OF CONTENTSSECTION 9 − MIG WELDING (GMAW) GUIDELINES 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-230 832 Page 369-11. Troubleshooting − Lack Of PenetrationLack Of Penetration − shallowfusion between weld metal andbase metal.Lack of Penetration

OM-230 832 Page 379-14. Troubleshooting − Waviness Of BeadWaviness Of Bead − weld metal that is not parallel and does not coverjoint formed by base me

OM-230 832 Page 389-17. Troubleshooting Guide For Semiautomatic Welding EquipmentProblem Probable Cause RemedyWire feed motor operates, butwire does n

OM-230 832 Page 39Notes

OM-230 832 Page 40SECTION 10 − PARTS LIST. Hardware is common andnot available unless listed.804 624-A123456789101112131415161718192021222324252627282

OM-230 832 Page 41DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-1. Main AssemblyQuantity1 199 566 DOOR, access 1. . . . . . . . . . . . . . . . . . .

OM-230 832 Page 42DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-1. Main Assembly (Continued)Quantity40 196 574 SWITCH, rocker DPST 1. . . . . . . . . .

OM-230 832 Page 431802 447234567981011Figure 10-2. H-10 GunQuantityDescriptionPartNo.195 957ItemNo.Figure 10-2. H-10 Gun1 169 715 NOZZLE, slip type .5

OM-230 832 Page 4410-3. Optional Drive RollsFor All Feed Head AssembliesPART NO.WIRE DIAMETERINCHES (mm)202 925 .023/.025 (.6) and .030/.035 (.8 and .

Notes

OM-230 832 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _3/05Y Warning: Protect yourself and others from injury — read and follow these

NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

Effective January 1, 2007(Equipment with a serial number preface of “LH” or newer)This limited warranty supersedes all previous manufacturerswarrantie

PRINTED IN USA 2007−01Model Name Serial/Style NumberPurchase Date (Date which equipment was delivered to original customer.)DistributorAddressCityStat

OM-230 832 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sp

OM-230 832 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over,

OM-230 832 Page 41-5. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Document

OM-230 832 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONfre_som _3/05Y Avertissement : se protéger et protéger les autres contre le