Instruction/ maintenance manual of the product XLT 165, XLT 135 Miller Electric
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Processes OM-198 076A April 2000 A u t o A r c X L T 1 3 5 / 1 6 5 R ® Description MIG (GMA W) W elding Flux Cored (FCA W ) W elding Arc Welding Power Source And Wire Feeder For W arranty Claims And T echnical Support, Contact: Milweld Inc., National Distributor P .
The following terms are used interchangeably throughout this manual: MIG=GMA W T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . .
OM-198 076 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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. Y Marks a special safety message.
OM-198 076 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.
OM-198 076 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-198 076 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric And Magnetic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields.
OM-198 076 Page 5 SECTION 1 − CONSIGNES DE SECURITE − LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.
OM-198 076 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
OM-198 076 Page 7 1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION.
OM-198 076 Page 8 1-4. Principales normes de sécurité Safety in W elding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.
OM-198 076 Page 9 SECTION 2 − SPECIFICA TIONS 2-1. Specifications A. 1 15 V AC Model Rated W elding Output Amperage Range Maximum Open- Circuit V oltage DC Amperes Input at Rated Load Output 1 15 V .
OM-198 076 Page 10 2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes 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-198 076 Page 1 1 2-3. V olt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. ssb1.1 10/91 − 196 608 / 196 609 A.
OM-198 076 Page 12 SECTION 3 − INST ALLA TION 3-1. Installing W elding Gun Ref. 802 440 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew . Insert gun en d through opening until it bottoms against drive assembly . Tighten thumbscrew .
OM-198 076 Page 13 3-3. Process/Polarity T able Process Polarity Cable Connections P rocess P o l ar i ty Cable T o Gun Cable T o Work GMA W − Solid wire with shield- ing gas DCEP − Reverse polari.
OM-198 076 Page 14 3-5. Installing Gas Supply Obtain gas cylinder and chain to running gear , wall, or other station- ary support so cylinder cannot fall and break of f valve. 1 Cap 2 Cylinder V alve Remove cap, stand to side of valve, and open valve slightly .
OM-198 076 Page 15 3-6. Selecting A Location And Connecting Input Power For 1 15 V AC Model 1 Rating Label 2 Grounded Receptacle A 1 15 volt, 20 ampere individual branch circuit protected by time-de- lay fuses or circuit breaker is re- quired.
OM-198 076 Page 16 3-7. Selecting A Location And Connecting Input Power For 230 V AC Model 1 Rating Label Supply correct input power . 2 Plug 3 Receptacle Connect plug to receptacle.
OM-198 076 Page 17 3-8. Electrical Service Guide For 230 V AC Model Input V oltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 20 Min Input .
OM-198 076 Page 18 3-10. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. T ools Needed: 6 1 3 4 5 6 in (150 mm) Pull and hold wire; cut off end.
OM-198 076 Page 19 SECTION 4 − OPERATION 4-1. Controls 1 V oltage Switch The higher the selected number , the thicker the material that can be welded (see weld setting label in welding power source or Sections 4-2 and 4-3, as applicable). Do not switch under load.
OM-198 076 Page 20 4-2. W eld Parameters For 1 15 V AC Model 196 052.
OM-198 076 Page 21 4-3. W eld Parameters For 230 V AC Model 196 081-A.
OM-198 076 Page 22 SECTION 5 − MAINTENANCE &TROUBLESHOOTING 5-1. 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-198 076 Page 23 5-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide Securing Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touching. T ighten screw . 3 Drive Roll The drive roll consists of two dif fe r- ent sized grooves.
OM-198 076 Page 24 5-6. Cleaning Or Replacing Gun Liner Ref. 802 446 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 tight- en two full turns more.
OM-198 076 Page 25 5-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-C T ools Needed: 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-198 076 Page 26 5-8. 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 3-6). d oes no t run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 4-1).
OM-198 076 Page 27 SECTION 6 − ELECTRICAL DIAGRAM 194 324 (NEUTRAL) Figure 6-1. Circuit Diagram For 1 15 V AC Model.
OM-198 076 Page 28 194 325 Figure 6-2. Circuit Diagram For 230 V AC Model.
OM-198 076 Page 29 SECTION 7 − MIG WELDING (GMA W) GUIDELINES 7-1. T ypical MIG Process Connections Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla ce wo rk cla mp as close to the weld as possible.
OM-198 076 Page 30 7-2. 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 1/8 or .
OM-198 076 Page 31 7-3. 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-198 076 Page 32 7-4. 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-198 076 Page 33 7-5. 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-198 076 Page 34 7-8. T roubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed.
OM-198 076 Page 35 7-1 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-198 076 Page 36 7-14. 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-198 076 Page 37 7-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
OM-198 076 Page 38 SECTION 8 − P ARTS LIST . Hardware is common and not available unless listed. 802 449-A Figure 8-1. Main Assembly.
OM-198 076 Page 39 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 195 999 BASE, lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-198 076 Page 40 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly (Continued) Quantity 38 1 1 1 443 BUSHING, strain relief 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-198 076 Page 41 Quantity Description Part No. 042 053 Item No. Figure 8-2. Gun 1 130 789 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦ 130 792 TIP , contact scr .
Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This lim ited w arra nty s upers edes all pr evio us man ufac ture rs warranties and is exclusive with no other guarantees or warranties expressed or implied.
PRINTED IN USA 1/00 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.
An important point after buying a device Miller Electric XLT 165, XLT 135 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric XLT 165, XLT 135 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric XLT 165, XLT 135 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric XLT 165, XLT 135 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric XLT 165, XLT 135 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric XLT 165, XLT 135, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric XLT 165, XLT 135.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric XLT 165, XLT 135. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric XLT 165, XLT 135 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center