Miller Spoolmatic 15A User manual

Spoolmatic 15A
Processes
Description
R
MIG (GMAW) Welding
Feeder Gun
OM-1213 137531AQ
2017−04
File: MIG (GMAW)
And 30A
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com

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. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Mil_Thank 2009−09

TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING 1......
1-1. Symbol Usage 1.......................................................................
1-2. Arc Welding Hazards 1.................................................................
1-3. Proposition 65 Warnings 2...............................................................
1-4. Principal Safety Standards 2.............................................................
1-5. EMF Information 2.....................................................................
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION 3..............................................................................
2-1. Signification des symboles 3.............................................................
2-2. Dangers relatifs au soudage à l’arc 3......................................................
2-3. Proposition californienne 65 Avertissements 4..............................................
2-4. Principales normes de sécurité 4.........................................................
2-5. Informations relatives aux CEM 4.........................................................
SECTION 3 − DEFINITIONS 5..................................................................
3-1. Additional Safety Symbols And Definitions 5................................................
3-2. Miscellaneous Symbols And Definitions 5..................................................
SECTION 4 − SPECIFICATIONS 6..............................................................
4-1. Unit Specifications 6....................................................................
4-2. Environmental Specifications 6...........................................................
SECTION 5 − INSTALLATION 6................................................................
5-1. Removing Top Cover 6..................................................................
5-2. Installing Wire Spool And Threading Welding Wire 7.........................................
5-3. Rotating Canister 7.....................................................................
5-4. Connecting To 24 Volt Weld Control 8.....................................................
5-5. Connecting To 115 Volt Weld Control 8....................................................
5-6. Installing Gas Supply 9.................................................................
5-7. Adjusting Drive Roll And Spool Brake Pressure 10...........................................
SECTION 6 − OPERATION 11...................................................................
6-1. Controls 11............................................................................
6-2. Shielding Gas 11........................................................................
SECTION 7 − MAINTENANCE & TROUBLESHOOTING 12.........................................
7-1. Changing Gun Contact Tip 12.............................................................
7-2. Replacing Head Tube Liner 13............................................................
7-3. Gun Drive Assembly Maintenance 14......................................................
7-4. Replacing Canister Inlet Guide 15.........................................................
7-5. Replacing Spool Canister 15..............................................................
7-6. Replacing Diffuser 16....................................................................
7-7. Troubleshooting 16......................................................................
SECTION 8 − ELECTRICAL DIAGRAM 17........................................................
SECTION 9 − PARTS LIST 18...................................................................
SECTION 10 − PARTS LIST INCLUDING CONSUMABLES 21.......................................
WARRANTY

OM-1213 Page 1
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW
WELDING GUNS − READ BEFORE USING
SR7 (MIG) 2015-09
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plainedin the text.
NOTICE − Indicates statements not related to personal injury.
.Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the welding power source Owner’s Manual. Read
and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
DAlways wear dry insulating gloves.
DInsulate yourself from work and ground.
DDo not touch live electrode or electrical parts.
DReplace worn, damaged, or cracked guns or cables.
DTurn off welding power source before changing contact tip or gun
parts.
DKeep all covers and handle securely in place.
FUMES AND GASES can be hazardous.
DKeep your head out of the fumes.
DVentilate area, or use breathing device. The
recommended way to determine adequate
ventilationis to sample for the composition and quantity of fumes
and gases to which personnel are exposed.
DRead and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables,coolants, degreasers, fluxes, and metals.
WELDING can cause fire or explosion.
DDo not weld near flammable material.
DDo not weld on containers that have held com-
bustibles, or on closed containers such as
tanks, drums, or pipes unless they are properly prepared ac-
cordingto AWS F4.1 and AWS A6.0 (see Safety Standards).
DWatch for fire; keep extinguisher nearby.
DRead and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables,coolants, degreasers, fluxes, and metals.
BUILDUP OF GAS can injure or kill.
DShut off compressed gas supply when not in
use.
DAlways ventilate confined spaces or use ap-
proved air-supplied respirator.
MOVING PARTS can injure.
DKeep away from moving parts.
DKeep away from pinch points such as drive
rolls.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
thatcan burn eyes and skin. Sparks fly off from the
weld.
ARC RAYS can burn eyes and skin.
DWear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
DWear approved safety glasses with side shields under your
helmet.
DUse protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
DWear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothingsuch as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
HOT PARTS can burn.
DAllow gun to cool before touching.
DDo not touch hot metal.
DProtect hot metal from contact by others.

OM-1213 Page 2
NOISE can damage hearing.
Noise from some processes or equipment can
damagehearing.
DCheck for noise level limits exceeding those
specifiedby OSHA.
DUse approved ear plugs or ear muffs if noise level is high.
DWarn others nearby about noise hazard.
WELDING WIRE can injure.
DKeephands and body away from gun tip when
triggeris pressed.
READ INSTRUCTIONS.
DRead and follow all labels and the Owner’s
Manualcarefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
DUse only genuine replacement parts from the manufacturer.
DPerforminstallation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
1-3. Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductiveharm. Wash hands after use.
1-4. Principal Safety Standards
SafetyinWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone:[phone], website: www.global.ihs.com).
SafePractice For Occupational And Educational Eye And Face Protec-
tion,ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: [phone], web-
site: www.ansi.org).
SafePractices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: [phone], website: www.glo-
bal.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles,American Welding Society Standard AWS A6.0, from Global
EngineeringDocuments (phone: [phone],
website: www.global.ihs.com).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.organd www. sparky.org).
SafeHandling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:
www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2,from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone:[phone], website: www.csagroup.org).
SafePractice For Occupational And Educational Eye And Face Protec-
tion,ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: [phone], web-
site: www.ansi.org).
Standardfor Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
1-5. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and induc-
tionheating operations) creates an EMF field around the welding circuit.
EMF fields can interfere with some medical implants, e.g. pacemakers.
Protectivemeasures for persons wearing medical implants have to be
taken.For example, restrict access for passers−by or conduct individu-
al risk assessment for welders. All welders should use the following pro-
cedures in order to minimize exposure to EMF fields from the welding
circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
ImplantedMedical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding,gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.

OM-1213 Page 3
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES
PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION
SR7(MIG)_2015−09 fre
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évitepas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
.Indiquedes instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris-
ques de danger. Lorsque vous voyez un symbole, soyez vigi-
lant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées dans le manuel d’utilisation du poste de
soudage.Veuillez lire et respecter toutes ces normes de sé-
curité.
L’installation, l’utilisation, l’entretien et les réparations ne
doiventêtre confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrementles enfants.
UN CHOC ÉLECTRIQUE peut tuer.
DPorter toujours des gants secs et isolants.
DS’isoler de la pièce et de la terre.
DNe jamais toucher une électrode ou des pièces
électriquessous tension.
DRemplacer les pistolets ou câbles de soudage qui sont endom-
magés, usés ou craquelés.
DMettre la soudeuse hors tension avant de remplacer un bec
contact ou des pièces de pistolet.
DS’assurer que tous les couvercles et poignées sont fermement
assujettis.
LES VAPEURS ET LES FUMÉES
peuvent être nocives.
DÉloigner sa tête des endroits renfermant des
vapeurs.
DAérer la zone de travail ou porter un appareil respiratoire. Pour dé-
terminer la bonne ventilation, il est recommandé de procéder à un
prélèvementpour la composition et la quantité de fumées et de gaz
auxquelsest exposé le personnel.
DLire et comprendre les fiches de données de sécurité et les instruc-
tions du fabricant concernant les adhésifs, les revêtements, les net-
toyants, les consommables, les produits de refroidissement, les
dégraisseurs,les flux et les métaux.
LE SOUDAGE peut causer un in-
cendie ou une explosion.
DNe pas souder à proximité de matériaux inflam-
mables.
DNe pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparéscorrectement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
DPrendre garde aux incendies et toujours avoir un extincteur à
proximité.
DLire et comprendre les fiches de données de sécurité et les
instructionsdu fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
L’ACCUMULATION DE VAPEURS
peut causer des lésions ou la mort.
DQuandon n’utilise pas le gaz comprimé de pro-
tection,fermer le robinet de la bouteille.
DAssurer toujours la ventilation des zones fermées ou utiliser un
appareil respiratoire avec alimentation en air.
Les PIÈCES MOBILES peuvent
causer des blessures.
DNe pas s’approcher des organes mobiles.
DNe pas s’approcher des points de coincement
tels que des rouleaux de commande.
LE RAYONNEMENT DE L’ARC peut
brûler les yeux et la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultravioletset infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
DPorter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
DPorter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
DAvoir recours à des écrans protecteurs ou à des rideaux pour
protégerles autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
DPorter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

OM-1213 Page 4
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
DLaisser refroidir le pistolet avant de le toucher.
DNe pas toucher d’objets métalliques chauds.
DAbriter les objets métalliques contre tout
contact par les personnes à proximité.
Le BRUIT peut endommager l’ouie.
Le bruit des processus et des équipements peut
affecter l’ouïe.
DVérifiersi les niveaux de bruit excèdent les lim-
ites spécifiées par l’OSHA.
DUtiliserdes bouche-oreilles ou des serre-tête antibruit approuvés si
le niveau de bruit est élevé.
DAvertir les personnes à proximité au sujet du danger inhérent au
bruit.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
DÉloigner les mains et le corps de la buse du
pistoletaprès avoir appuyé sur la gâchette.
LIRE LES INSTRUCTIONS.
DLire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil.Lire les informations de sécurité au
débutdu manuel et dans chaque section.
DN’utiliserque les pièces de rechange recommandées par le cons-
tructeur.
DEffectuer l’installation, l’entretien et toute intervention selon les
manuelsd’utilisateurs, les normes nationales, provinciales et de
l’industrie,ainsi que les codes municipaux.
2-3. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fuméeset des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des
malformations congénitales et, dans certains cas, des
cancers.(Code de santé et de sécurité de Californie, chapitre
25249.5et suivants)
Ce produit contient des éléments chimiques, dont le plomb,
reconnus par l’État de Californie pour leur caractère
cancérogène ainsi que provoquant des malformations
congénitalesou autres problèmes de procréation. Se laver
les mains après toute manipulation.
2-4. Principales normes de sécurité
SafetyinWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone:[phone], website: www.global.ihs.com).
SafePractice For Occupational And Educational Eye And Face Protec-
tion,ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: [phone], web-
site: www.ansi.org).
SafePractices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: [phone], website: www.glo-
bal.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles,American Welding Society Standard AWS A6.0, from Global
EngineeringDocuments (phone: [phone],
website: www.global.ihs.com).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.organd www. sparky.org).
SafeHandling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:
www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2,from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone:[phone], website: www.csagroup.org).
SafePractice For Occupational And Educational Eye And Face Protec-
tion,ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: [phone], web-
site: www.ansi.org).
Standardfor Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
2-5. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Le courant
issu d’un soudage à l’arc (et de procédés connexes, y compris le
soudage par points, le gougeage, le découpage plasma et les
opérations de chauffage par induction) crée un champ
électromagnétique(CEM) autour du circuit de soudage. Les champs
électromagnétiquesproduits peuvent causer interférence à certains
implantsmédicaux, p. ex. les stimulateurs cardiaques. Des mesures de
protectionpour les porteurs d’implants médicaux doivent être prises:
Limiter par exemple tout accès aux passants ou procéder à une
évaluation des risques individuels pour les soudeurs. Tous les
soudeurs doivent appliquer les procédures suivantes pour minimiser
l’expositionaux CEM provenant du circuit de soudage:
1 Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2 Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3 Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4 Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5 Connecter la pince sur la pièce aussi près que possible de la
soudure.
6 Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7 Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par
induction.Si le médecin approuve, il est recommandé de suivre les pro-
cédures précédentes.

OM-1213 Page 5
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
.Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
3-2. Miscellaneous Symbols And Definitions
.Some symbols are found only on CE products.
AAmperes
X
Duty Cycle
U1Primary Voltage
VVolts
I
2Rated Welding
Current
U
2Conventional
Load Voltage
IP
Degree Of
Protection
Percent
I1Primary Current
Notes

OM-1213 Page 6
SECTION 4 − SPECIFICATIONS
4-1. Unit Specifications
Wire Diameter
Range
Approximate
Wire Feed
Range
Cooling
Method Maximum Spool Size Weld Circuit Rating Overall Dimensions Weight
.025Thru 1/16 in.
(0.6 Thru 1.6 mm)
Aluminum Wire
.025 Thru .045 in.
(0.6 Thru 1.1 mm)
Hard Or Cored Wire
70 To 875 ipm
(1.7 To 22.2
mpm) Air Cooled 4 in. (102 mm)
Diameter 100 Volts, 200 Amperes,
100% Duty Cycle
Using Argon Shielding Gas
Length: 15-3/8 in.
(390 mm)
Width: 2-1/2 in.
(64 mm)
Height: 10-3/4 in.
(273 mm)
2.9 lb
(1.3 kg) Gun
Only
15A Model:
9 lb (4.1 kg)
Gun With Cable
30A Model:
14 lb (6.4 kg)
Gun With Cable
4-2. Environmental Specifications
A. IP Rating
IP Rating
IP23
This equipment is designed for outdoor use. IP23 2017−02
B. Temperature Specifications
OperatingTemperature Range Storage Temperature Range
14 to 104 °F (−10 to 40°C) −4 to 131 °F (−20 to 55°C) Temp_2016-07
SECTION 5 − INSTALLATION
.Use weld control or welding power source Owner’s Manual during gun installation. If contact tip, liner, and drive roll groove are not correct for wire
size and type, see Section 7 to change parts as needed. See Parts List for other available contact tips.
5-1. Removing Top Cover
150 882-G
1 Top Cover Triangular Boss
Push up on triangular boss to open
door. Door hinges on handle.
To open door fully, push up on door
untilit clicks into position.
.If door is pushed too far it will
separate from handle. If this
happensthe door can be rein-
stalled.
Push door back into original posi-
tion to close.
1

OM-1213 Page 7
5-2. Installing Wire Spool And Threading Welding Wire
150 436-F
1 Top Cover
2 Canister
3 Canister Cover
4 Thumbscrew (Canister Cover)
Loosen thumbscrew and remove
cover.
5 Wire Spool
Loosenwire from spool, cut off bent
wire, and pull 6 in. (150 mm) of wire
off spool.
6 Pressure Roll Assembly
Lift arm and open pressure roll
assembly.
7 CanisterInlet Guide
8 Drive Roll Groove
.For wire sizes .035 in. (0.9 mm)
and smaller use small groove,
and.047 in. (1.2 mm) and 1/16
in (1.6 mm) use large groove.
9 Contact Tip
Thread wire through canister inlet
guide,along drive roll groove, and
out contact tip.
Install spool so wire feeds off
bottom.
10 SpoolBrake Thumbnut
If necessary, turn thumbnut coun-
terclockwise slightly to install spool.
11 Thumbscrew(Canister
Rotation)
Loosen thumbscrew to rotate can-
ister (see Section 5-3).
Close and secure pressure roll
assembly.
Reinstall top cover and canister
cover.
Tools Needed:
9
1210
3
4
5
6
7
8
11
5-3. Rotating Canister
150 433-A
1 Canister
Loosen canister rotation thumb-
screw (see Section5-2). Move can-
ister to desired position. Tighten
thumbscrew.
1
Rear View

OM-1213 Page 8
5-4. Connecting To 24 Volt Weld Control
150 917-G
1 Gas Hose
Connectfitting to regulator/flowme-
ter (see Section 5-6).
2 24 Volt Weld Control
3 Trigger Control Cord
Insert plug into receptacle, and
tightenthreaded collar.
4 Weld Cable
Connectto positive (+) weld output
terminal on welding power source
accordingto its Owner’s Manual.
Tools Needed:
1-1/8, 5/8 in.
1
2
3
4
5-5. Connecting To 115 Volt Weld Control
Ref. 149 549-A / 149 966-J
1 115 Volt Weld Control
2 Gas Hose
Connect to regulator/flowmeter.
3 Trigger Control Cord
Insert plug into receptacle, and
tightenthreaded collar.
4 Weld Cable
5 Positive (+) Weld Output
Terminal In Control
Connect weld cable to positive (+)
weldoutput terminal in weld control.
Reinstallweld control wrapper.
Left Side
Wrapper Off
5
61
2
3
4
3
Tools Needed:
1-1/8, 5/8 in.

OM-1213 Page 9
5-6. Installing Gas Supply
ssb3.1* 5/94 − 158 697-A
Obtain gas cylinder and chain to
runninggear, wall, or other station-
ary support so cylinder cannot fall
and break off valve.
1 Cap
2 Cylinder Valve
Removecap, stand to side of valve,
and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.
3 Cylinder
4 Regulator/Flowmeter
Install so face is vertical.
.Delivery pressure range must
not exceed 60 psi.
5 Gas Hose Connection
Fitting has 5/8-18 right-hand
threads.
6 Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour). Check wire manufactur-
er’s recommended flow rate.
Make sure flow adjust is closed
when opening cylinder to avoid
damageto the flowmeter.
7CO
2Adapter
8 O-Ring
Install adapter with O-ring between
regulator/flowmeter and CO2
cylinder.
Tools Needed:
1-1/8, 5/8 in.
CO2Gas
7 8
3
1
2
4
5
6
1
2
3
Argon Gas
OR

OM-1213 Page 10
5-7. Adjusting Drive Roll And Spool Brake Pressure
Ref. 151 112-F / 147 741-F
1 Top Cover
2 Canister Cover
3 Thumbscrew
Loosen thumbscrew and remove
cover.
4 Spool
Cut welding wire off at contact tip.
Retractwire onto spool and secure.
5 SpoolBrake Thumbnut
Grasp spool in one hand and turn
whileadjusting spool brake thumb-
nut. When a slight force is needed
to turn spool, tension is set. Do not
overtighten.
Reinstall canister cover. Thread
weldingwire (see Section 5-2).
6 Drive Roll Tension Thumbnut
Turn On unit and check drive roll
pressure by feeding wire against a
wood board or concrete surface;
wire should feed steadily without
slipping.
Adjust drive roll tension thumbnut if
necessary. Do not overtighten.
Turn Off unit. Reinstall top cover.
Tools Needed:
WOOD
Adjusting Pressure
12
5
3
4
6

OM-1213 Page 11
SECTION 6 − OPERATION
6-1. Controls
Ref. 147 741-F
1 Trigger
Press trigger to energize welding
power source contactor (if applica-
ble), start shielding gas flow, and
beginwire feed.
For shielding gas preflow and post-
flow, lightly press trigger before and
after welding.
2 Wire Speed Control
Use control to adjust wire feed
speed.The numbers in the opening
are not a wire feed speed and are
for reference only.
1
2
6-2. Shielding Gas
sb5.1* 6/92 − S-0621-C / Ref. 147 741-F
1 ShieldingGas Cylinder
2 Valve
3 Gun Trigger
Open valve on cylinder just before
welding.
Gun trigger turns weld output and
gas flow on and off. For shielding
gas preflow and postflow, lightly
press trigger before and after
welding.
Close valve on cylinder when fin-
ished welding.
1
2
3

OM-1213 Page 12
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
!Disconnectpower
before maintaining. .Maintain more often
during severe conditions.
n= Check Z= Change ~= Clean l= Replace
* To be done by Factory Authorized Service Agent
Daily
nCheck barrel clamp
screws for tightness. lRepair Or Replace Cracked Weld Cable
Every
Month
nl Gun Cables ~Drive Rolls ~Clean and Tighten
Weld Terminals
Every
3
Months
lDamaged Or Unread-
able Labels lDamaged Gas Hose nl Cords
Every
6
Months
~Blow out or Vacuum
Inside Unit
7-1. Changing Gun Contact Tip
Ref. 150 437-A
2
1
Remove nozzle
1 Nozzle
2 FasTip
Unscrew FasTip.
Install new FasTip.

OM-1213 Page 13
7-2. Replacing Head Tube Liner
Ref. 803 551-C
The standard head tube liner will
accommodatewire diameters from
.030-1/16 wire size.
1 Cover
2 Screw
3 Clamp
Loosenclamp screws and remove
clamp.
4 Head Tube
Remove head tube from gun.
5 Liner
Pull liner out of head tube.
Insert liner into head tube and
reinstallhead tube onto gun.
.A twisting motion may be need-
ed to feed liner thru head tube.
4
5
5/32 in.
1
2
3
4
Tool Needed:
Notes

OM-1213 Page 14
7-3. Gun Drive Assembly Maintenance
Ref. 149 967-H / Ref. 800 945-A
Retract wire onto spool.
1 Setscrew
2 Current Pick-Up Tab
This tab helps prevent burnback
caused by welding arcs inside the
contact tip. This tab may be re-
movedto provide an insulated drive
roll. (If tab is removed,a smaller di-
ameter contact tip is recom-
mended.See options in Parts List.)
Lightlygrease top of tab before rein-
stalling.
3 Drive Roll
Use wire brush to clean drive roll.
Installdrive roll with desired groove
down,and turn drive roll so one set-
screw faces flat side of shaft.
4 Bearing
Use wire brush to clean bearing.
Line up drive roll groove with bear-
ing groove and liner opening. Tight-
en setscrews.
Thread welding wire through gun
(see Section 5-2). Close and se-
cure pressure roll assembly. Adjust
drive roll pressure, if necessary
(see Section 5-7). Reinstall top cov-
er.
Tools Needed:
5/16 in.
3
12
4

OM-1213 Page 15
7-4. Replacing Canister Inlet Guide
Ref. 150 436-D / Ref. 149 967-H
1 Top Cover
2 Pressure Roll Assembly
Cut off welding wire where it enters
pressure roll assembly area.
3 Nozzle
Pull wire out nozzle.
4 Thumbscrew
5 Canister Cover
Loosen thumbscrew and remove
cover.
6 Wire Spool
7 Spool Brake Thumbnut
Loosenthumbnut, retract wire onto
spool, secure, and remove spool.
8 Canister Inlet Guide
Turn counterclockwise to remove.
Installnew guide.
Reinstall spool and thread welding
wire (see Section 5-2).
Close pressure roll assembly. Ad-
just spool brake pressure and drive
roll pressure if necessary (see Sec-
tion 5-7).
Reinstall covers.
Tools Needed:
1
24
5
6
7
8
3
7-5. Replacing Spool Canister
Ref. 149 967-H
1 Top Cover
2 Pressure Roll Assembly
Cut off welding wire where it enters
pressure roll assembly area.
3 Nozzle
Pull wire out nozzle.
4 Thumbscrew (Canister
Rotation)
Turn thumbscrew counterclock-
wise three full turns.
5 Spool Canister
Removeas shown. Push new can-
ister into wire drive housing until ful-
ly seated. Tighten thumbscrew.
Install spool and thread welding
wire (see Section 5-2).
Close pressure roll assembly. Ad-
just spool brake pressure and drive
roll pressure as necessary (see
Section5-7).
Reinstall covers.
Tools Needed:
1
3
5
2
4

OM-1213 Page 16
7-6. Replacing Diffuser
Ref. 803 348-G
Turn Off welding power source.
1 Nozzle
2 FasTip
To remove, see Section 7-1.
3 Diffuser
Remove diffuser and replace.
Tools Needed:
3/8 in.
1
2
3
7-7. Troubleshooting
Trouble Remedy
No weld output; gun/feeder does no
t
work. Secure weld control plug in 115 volts AC receptacle (see weld control Owner’s Manual).
Place Power switch on welding power source in the On position (see welding power source Owner’s
Manual).
Erratic weld output. Tighten and clean all connections.
Pressinggun/feeder trigger does not en-
ergize weld control; welding wire is not
energized;shielding gas does not flow.
Secureplug from gun/feeder trigger cord into 10-socket receptacle on weld control (see Sections 5-4 and
5-5).
Wire feeds, shielding gas flows, bu
t
weldingwire is not energized. Secure control cable leads in weld control (see weld control Owner’s Manual).
See Troubleshooting section in welding power source Owner’s Manual.
Wire feeds erratically. Check and correct drive roll pressure (see Section 5-7).
Clean drive roll or replace drive roll (see Section 7-3).
Decrease spool brake pressure (see Section 5-7).