Instruction/ maintenance manual of the product AA40GBU Miller Electric
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AA40GBU Processes Description Wire Feeder Automatic W elding OM-227 674B 2006 − 08 File: Advanced Manufacturing Systems V isit our website at www.MillerWelds.
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-227 674 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-227 674 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
OM-227 674 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-227 674 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-227 674 Pa ge 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-227 674 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-227 674 Pa ge 7 2-3 . Dangers s uppl émentaire s en r el ation avec l’install ation, le f onc t i onnement et l a mainte nance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables.
OM-227 674 Page 8 2-5. Princi pales n orm es d e sécuri té Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .
OM-227 674 Page 9 SECTION 3 − INST ALLA TION 3-1. Specifications Model Wire Feed Wire Diameter Range T ype Of Input Power W eight M o d e l Wire Feed Speed Range Wi re Di ame t er R ange T ype Of I npu t P ower Net Ship AA40GBU 50 T o 1400 ipm (1.3 T o 35.
OM-227 674 Page 10 3-3. T ypical Equipment Location ST-131 138-A 1 W elding Power Source 2 Gas Cylinder 3 Side Beam 4 Weld Control 5 Spool Support 6 Wire Drive Assembly 7 Automatic Welding Gun 1 2 3 4 5 6 7 3-4.
OM-227 674 Page 1 1 3-5. Installing PD Continuous Wire Guides Ref. 804 192 / 804 188-A . PD Continuous Wire Guides: Should be used with .068/.072 in (1.8 mm) and smaller diameter wire for opti- mal performance. Should be used with PD drive rolls and cannot be used with non-PD (old-style) drive rolls.
OM-227 674 Page 12 3-6. Installing Non-PD (Old Style) Wire Guides Ref. 804 192-B / 804 188-A Installing wire guides with non- PD (old-style) drive rolls . Non-PD (old-style) wire guides and drive rolls should be used with 5/64 in (2.0 mm) and larger diameter wire.
OM-227 674 Page 13 3-7. Installing Welding Gun 804 189-A 1 Power Clamp Knob 2 Gun Locking T ab 3 Power Pin Groove 4 Gun Connection End Installing gun with Accu-Mate connection Loosen power clamp knob to allow power pin of gun to clear the gun locking tab.
OM-227 674 Page 14 3-8. Mounting Motor And Connecting Gas Hose And W eld Cable Ref. 804 591-A / Ref. 804 590-A / Ref. 804 183-A . Drive motor must be isolated from weld potential. 1 Insulator Plate When mounting motor , place factory-supplied insulator plate under motor mounting bracket to provide isolation.
OM-227 674 Page 15 3-9. Plug Connections 804 592-A 1 Weld Control 2 Motor Control Cord (Not Supplied) Cord is available in 20 ft (6.1 m), 30 ft (9.1 m) o r 50 ft (15.2 m) lengths. 3 Motor/Drive Assembly T o make connections, align key- way , insert plug, and tighten threaded collar .
OM-227 674 Page 16 3-10. Threading W elding Wire And Adjusting Pressure Drive Setting Ref. 804 391-A / Ref. 804 190-A / Ref. 156 798 T ools Needed: 1 Drive Roll Pressure Adjustment Lever 2 Notch In Lever (Indicates Pressure Settings) Pressure drive settings range from 1 to 8 with 8 being the maximum setting.
OM-227 674 Page 17 SECTION 4 − MAINTENANCE AND TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Aut.
OM-227 674 Page 18 4-3. T roubleshooting T rouble Remedy Electrode wire feeding stops or feeds er- ratically during welding Readjust hub tension and drive roll pressure. ratically during welding. Change to correct size drive roll. Clean or replace dirty or worn drive roll.
OM-227 674 Page 19 SECTION 6 − P ARTS LIST 804 593-A See T able 6-1 Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 11 12 13 14 15 16 17 18 19 20 22 21 23 24 25 8 9 10 Figure 6-1. Main Assembly Description Quantity Part No.
OM-227 674 Page 20 Description Quantity Part No. Dia. Mkgs. Item No. Figure 6-1. Drive Assembly , Wire (Continued) 15 221 537 CIRCUIT CARD ASSY , motor protection 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-227 674 Page 21 See T able 6-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 804 186-A 4 5 6 7 8 3 2 1 9 10 2 11 12 13 14 15 16 17 18 19 20 21 22 Figure 6-2. Drive Assembly , Wire Item No. Diagram marking Part No.
OM-227 674 Page 22 UC Groove 083 489 083 490 053 708 ve Rolls r ed) UC Groove 132 957 132 956 132 955 Standard Dri v (4 requir e U Groove 053 701 053 702 053 706 G uides V Groove 053 697 053 698 053 6.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wor k s Comp any 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarter.
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