Miller Spoolmatic 15A User manual

Processes
Description
MIG (GMAW) Welding
Feeder Gun
TM-1213Q 2017−09
Eff. w/Serial No. KC248746
Spoolmatic 15A
And 30A
R
File: MIG (GMAW)
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com

TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1..........................................
1-1. Symbol Usage 1........................................................................
1-2. Servicing Hazards 1....................................................................
1-3. California Proposition 65 Warnings 2.......................................................
1-4. EMF Information 2......................................................................
SECTION 2 − DEFINITIONS 3...................................................................
2-1. Additional Safety Symbols And Definitions 3................................................
2-2. Miscellaneous Symbols And Definitions 3...................................................
SECTION 3 − SPECIFICATIONS 4................................................................
3-1. Unit Specifications 4....................................................................
3-2. Environmental Specifications 4...........................................................
SECTION 4 − INSTALLATION 4..................................................................
4-1. Removing Top Cover 4..................................................................
4-2. Installing Wire Spool And Threading Welding Wire 5..........................................
4-3. Rotating Canister 5.....................................................................
4-4. Connecting To 24 Volt Weld Control 6......................................................
4-5. Connecting To 115 Volt Weld Control 6.....................................................
4-6. Installing Gas Supply 7..................................................................
4-7. Adjusting Drive Roll And Spool Brake Pressure 8............................................
SECTION 5 − OPERATION 9....................................................................
5-1. Controls 9.............................................................................
5-2. Shielding Gas 9........................................................................
SECTION 6 − THEORY OF OPERATION 10........................................................
SECTION 7 − TROUBLESHOOTING 11............................................................
SECTION 8 − MAINTENANCE 14.................................................................
8-1. Routine Maintenance 14..................................................................
8-2. Changing Contact Tip And Liner (Effective With Serial No. KC248746 Thru LC478841) 15...........
8-3. Changing Gun Contact Tip (Effective With Serial No. LC478842 And Following) 15.................
8-4. Replacing Head Tube Liner (Effective With Serial No. LC478842 And Following) 16.................
8-5. Changing Or Cleaning Drive Roll (Prior To Serial No. KD376404) 17.............................
8-6. Replacing Or Cleaning Drive Roll Bearing (Prior To Serial No. KG193179) 18......................
8-7. Gun Drive Assembly Maintenance (Effective With Serial No. KG193179 Thru KJ260859) 19.........
8-8. Gun Drive Assembly Maintenance (Effective With Serial No. KJ260860 And Following) 20...........
8-9. Replacing Canister Inlet Guide 21..........................................................
8-10. Replacing Spool Canister 21..............................................................
8-11. Replacing Contact Tip Adapter (Effective With Serial No. KC248746 Thru LC408323) 22............
8-12. Replacing Diffuser (Effective With Serial No. LC478842 And Following) 22........................
SECTION 9 − ELECTRICAL DIAGRAMS 23........................................................
SECTION 10 − PARTS LIST PRIOR TO SERIAL NO. KD376404 26....................................
SECTION 11 − PARTS LIST FOR SERIAL NO. KD376404 THRU KG193178 30..........................
SECTION 12 − PARTS LIST FOR SERIAL NO. KG193179 THRU KJ260859 34..........................
SECTION 13 − PARTS LIST FOR SERIAL NO. KJ260860 THRU LB071103 38...........................
SECTION 14 − PARTS LIST FOR SERIAL NO. LB071104 THRU LC259177 42..........................
SECTION 15 − PARTS LIST FOR SERIAL NO. LC259178 THRU LC344600 46..........................
SECTION 16 − PARTS LIST FOR SERIAL NO. LC344601 THRU LC478841 50..........................
SECTION 17 − PARTS LIST FOR SERIAL NO. LC478842 THRU LE239242 54..........................
SECTION 18 − PARTS LIST FOR SERIAL NO. LE239243 THRU LJ210300V 58.........................
SECTION 19 − PARTS LIST INCLUDING CONSUMABLES 61........................................
SECTION 20 − PARTS LIST FOR SERIAL NO. LJ210301V AND FOLLOWING 66........................
SECTION 21 − PARTS LIST INCLUDING CONSUMABLES 69........................................

TM-1213 Page 1Spoolmatic 15AAnd 30A
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
OM-1213-AQ, safety_stm 2015-09
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. Servicing 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.
Only qualified persons should test, maintain, and repair this
unit.
During servicing, keep everybody, especially children, away.
DDo not touch live electrical parts.
DTurn Off welding power source and wire feeder
and disconnect and lockout input power using
linedisconnect switch, circuit breakers, or by removing plug from re-
ceptacle,or stop engine before servicing unless the procedure spe-
cifically requires an energized unit.
ELECTRIC SHOCK can kill.
DInsulateyourself from ground by standing or working on dry insulat-
ing mats big enough to prevent contact with the ground.
DDo not leave live unit unattended.
DIf this procedure requires an energized unit, have only personnel
familiarwith and following standard safety practices do the job.
DWhentesting a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
DDisconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing power sources AFTER removal of input power.
DTurn Off inverter, disconnect input power, and discharge input
capacitorsaccording to instructions in Troubleshooting Section be-
fore touching any parts.
Arc flash is the rapid and violent release of energy tha
t
occurs when electric current leaves its intended path
and arcs to other conductors or to ground. Arc flash
can be caused by equipment failure (faulty insulation
,
corrosion,dust) improper installation, human error (improper too
l
placement),and other factors. Conductive vapors can sustain the
arc until over-current devices open the circuit. Individuals within
the arc flash boundary are at risk.
DDo not work on energized equipment unless an assessment of
arc flash risk from the electrical supply circuit has been conducted
by a qualified person and you have been trained in safe work prac-
tices by your employer.
DFollow requirements in NFPA 70E for safe work practices and
PersonalProtective Equipment (PPE).
ARC FLASH can kill.
STATIC (ESD) can damage PC boards.
DPut on grounded wrist strap BEFORE handling
boards or parts.
DUse proper static-proof bags and boxes to
store, move, or ship PC boards.
FIRE OR EXPLOSION hazard.
DDo not place unit on, over, or near combustible
surfaces.
DDo not service unit near flammables.
FLYING METAL or DIRT can injure eyes.
DWear safety glasses with side shields or face
shield during servicing.
DBe careful not to short metal tools, parts, or
wires together during testing and servicing.
HOT PARTS can burn.
DDo not touch hot parts bare handed.
DAllow cooling period before working on
equipment.
DTo handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
EXPLODING PARTS can injure.
DFailedparts can explode or cause other parts to
explodewhen power is applied to inverters.
DAlways wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
DTurn Off welding power source and wire feeder
or stop engine before making or changing me-
ter lead connections.
DUse at least one meter lead that has a self-
retainingspring clip such as an alligator clip.
DRead instructions for test equipment.

TM-1213 Page 2 Spoolmatic 15AAnd 30A
FALLING EQUIPMENT can injure.
DUse lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
DUse equipment of adequate capacity to lift and
supportunit.
DIf using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
DFollowthe guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment.
MOVING PARTS can injure.
DKeep away from moving parts such as fans.
DKeep away from pinch points such as drive
rolls.
DHave only qualified persons remove doors,
panels,covers, or guards for maintenance and
troubleshootingas necessary.
DKeep hands, hair, loose clothing, and tools
away from moving parts.
DReinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connectinginput power.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
DWearers of Pacemakers and other Implanted
MedicalDevices should keep away from serv-
icing areas until consulting their doctor and the
device manufacturer.
OVERUSE can cause OVERHEATING.
DAllow cooling period; follow rated duty cycle.
DReduce current or reduce duty cycle before
startingto weld again.
DDo not block or filter airflow to unit.
H.F. RADIATION can cause interference.
DHigh-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
DHave only qualified persons familiar with
electronicequipment install, test, and service
H.F. producing units.
DThe user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
DIf notified by the FCC about interference, stop using the
equipmentat once.
DHave the installation regularly checked and maintained.
DKeephigh-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimizethe possibility of interference.
READ INSTRUCTIONS.
DUse Testing Booklet (Part No. 150 853) when
servicing this unit.
DConsultthe Owner’s Manual for welding safety
precautions.
DUse only genuine replacement parts from the manufacturer.
DReadand follow all labels and the TechnicalManual carefully be-
fore installing, operating, or servicing unit. Read the safety in-
formationat the beginning of the manual and in each section.
DPerforminstallation, maintenance, and service according to the
TechnicalManual, industry standards, and national, state, and
local codes.
1-3. California 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. 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
inductionheating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace-
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment for welders. All welders should use the
following procedures 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:
Implanted Medical 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.

TM-1213 Page 3Spoolmatic 15AAnd 30A
SECTION 2 − DEFINITIONS
2-1. 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
2-2. 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

TM-1213 Page 4 Spoolmatic 15AAnd 30A
SECTION 3 − SPECIFICATIONS
3-1. 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
3-2. Environmental Specifications
A. IP Rating
IP Rating
IP23
This equipment is designed for outdoor use. IP23 2017−02
B. Temperature Specifications
OperatingTemperature Range* Storage/Transportation Temperature Range
14 to 104°F (−10 to 40°C) −4 to 131°F (−20 to 55°C) Temp1_2016-08
SECTION 4 − 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 8 to change parts as needed. See Parts List for other available contact tips.
4-1. 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

TM-1213 Page 5Spoolmatic 15AAnd 30A
4-2. 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 4-3).
Close and secure pressure roll
assembly.
Reinstall top cover and canister
cover.
Tools Needed:
9
1210
3
4
5
6
7
8
11
4-3. Rotating Canister
150 433-A
1 Canister
Loosen canister rotation thumb-
screw (see Section4-2). Move can-
ister to desired position. Tighten
thumbscrew.
1
Rear View

TM-1213 Page 6 Spoolmatic 15AAnd 30A
4-4. Connecting To 24 Volt Weld Control
150 917-G
1 Gas Hose
Connectfitting to regulator/flowme-
ter (see Section 4-6).
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
4-5. 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.

TM-1213 Page 7Spoolmatic 15AAnd 30A
4-6. 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
Typicalflow 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

TM-1213 Page 8 Spoolmatic 15AAnd 30A
4-7. 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 4-2).
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

TM-1213 Page 9Spoolmatic 15AAnd 30A
SECTION 5 − OPERATION
5-1. 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
5-2. 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

TM-1213 Page 10 Spoolmatic 15AAnd 30A
SECTION 6 − THEORY OF OPERATION
1 Gun Assembly
Connects to welding power source
or weld control, and provides weld
power to energized wire.
2 Trigger PB1
Provides contactor control of
welding power source, starts
shieldinggas flow, starts wire feed.
3 Wire Drive Motor B2
Feeds wire at speed set by R4.
4 Wire Speed Control R4
Selects wire speed.
2
3
4
Work
Gun
Assembly
Water
Wire
Gas
Weld Power
Cord 1
Cord 2
10 Pin
Plug PLG2
Trigger
PB1
Wire Drive
Motor B2
Wire Speed
Control R4
1
0 to 30 VDC
0 to 10 VDC
10 VDC
To Welding Power Source
DC Control Circuits
Weld Current Circuit

TM-1213 Page 11Spoolmatic 15AAnd 30A
SECTION 7 − TROUBLESHOOTING
7-1. Troubleshooting Table
.See Section 7-2 for test points and values and
Parts Sections for parts location.
.Use MILLER Testing Booklet (Part No. 150 853)
when servicing this unit.
.See the Miller Extranet for service memos that
may aid in the repair of this product.
Trouble Remedy
Motor does not run; pressing gun trig-
ger does not energize weld control/
welding power source.
Check connection of 10 pin plug PLG2 to weld control or welding power source. Repair if necessary
(see Sections 4-4 and 4-5).
Check continuity of gun trigger switch and leads. Repair or replace if necessary (see Section 7-2).
Check control cords for continuity. Repair or replace if necessary (see Section 7-2).
Readjust drive roll pressure (see Section 4-7).
See Troubleshooting Section in weld control and/or welding power source Technical Manual.
Wire feeds; welding wire is not ener-
gized. Check switch positions on welding power source.
Check connection of 10 pin plug PLG2 to weld control. Repair if necessary
(see Sections 4-4 and 4-5).
Check control cords for continuity. Repair or replace if necessary (see Section 7-2).
See Troubleshooting Section in weld control and/or welding power source Technical Manual.
Wire does feed but is energized. Check motor B2. Replace if necessary (see Section 7-2).
Check control cords for continuity. Repair or replace if necessary (see Section 7-2).
See Troubleshooting Section in weld control and/or welding power source Technical Manual.
Wire feeds erratically and/or no contro
l
of wire speed by Wire Speed Control
R4.
Change to correct size contact tip or liner (see Section 8-2).
Clear obstruction in contact tip or liner (see Section 8-2).
Readjust drive roll pressure (see Section 4-7).
Change to correct size drive roll (see Section 8-5 or 8-7).
Clean or replace dirty or worn drive roll (see Section 8-5 or 8-7).
Readjust spool brake pressure (see Section 4-7).
Check resistance and connections of Wire Speed control R4; R4 is 0 to 10,000 ohms ±10%. Replace
R4 if necessary (see Section 7-2).
Check resistance and connections of Wire Speed control R4; R4 is 0 to 10,000 ohms ±10%. Replace
R4 if necessary (see Section 7-2).
Check motor B2. Replace if necessary (see Section 7-2).
Check control cords for continuity. Repair or replace if necessary (see Section 7-2).
See Troubleshooting Section in weld control and/or welding power source Technical Manual.
Erratic weld output. Replace worn or damaged contact tip (see Section 8-2).
Repair loose or incorrect welding connections.
Check control cords for continuity. Repair or replace if necessary (see Section 7-2).
See Troubleshooting Section in weld control and/or welding power source Technical Manual.

TM-1213 Page 12 Spoolmatic 15AAnd 30A
Trouble Remedy
Wire feeds but burns back into contac
t
tip. Readjust voltage setting on welding power source.
Repair ground cable connection.
Readjust burnback time on weld control (see weld control Owner’s Manual).
Replace worn or damaged contact tip (see Section 8-2).
Clean or replace current pickup tab [(located between bottom of drive roll and the gun housing) see
Section 8-5 or 8-7].
Readjust wire speed ramp up setting (see weld control Owner’s Manual).
No gas flow. Turn on gas cylinder.
Check and repair or replace valve cap.
Repair gas hose.
Continuous gas flow. Reduce regulator pressure to below 50 PSI.
Check and repair or replace valve cap.
Check and repair or replace misaligned or missing spring.
Check orifice in gun housing. Replace if necessary.

TM-1213 Page 13Spoolmatic 15AAnd 30A
7-2. Troubleshooting Circuit Diagram For Spoolmatic 15A And 30A Guns
For Gun Using WC-115
V1 2 volts DC input, motor running,
R4 totally CCW
30 volts DC input, motor running,
R4 totally CW
V2 28 volts DC (±4V)
0 volts DC with trigger pressed
V3 0 volts DC, R4 totally CCW,
WC115 in Constant Speed Mode
6.8 volts DC, R4 totally CW,
WC115 in Constant Speed Mode
For Gun Using WC-24 Or Welding
Power Source With Remote 10
Option
V1 2 volts DC input, motor running,
R4 totally CCW
30 volts DC input, motor running,
R4 totally CW
V2 15 volts DC
0 volts DC with trigger pressed
V3 0 volts DC, R4 totally CCW
7.5 volts DC, R4 totally CW
For Gun Using XR Feeder
V1 2 volts DC input, motor running,
R4 totally CCW
30 volts DC input, motor running,
R4 totally CW
V2 32 volts DC (±4V)
0 volts DC with trigger pressed
V3 0 volts DC, R4 totally CCW
9 volts DC, R4 totally CW
Test Equipment Needed:
V1 0.5 to 2.5 volts DC while slowly
rotating motor by hand
(use drive roll)
R1 10 to 100 ohms
R2 0 ohms
R3 0 ohms with trigger pressed
R4 10k ohms
R5 0 ohms totally CCW
10k ohms totally CW
195712-B
Voltage Readings: a) 10-pin plug PLG2 CONNECTED b) power applied c) Tolerance ±10% unless specified.
Voltage Readings And
Resistance Values:
a) 10-pin plug PLG2 CONNECTED
b) Tolerance ±10% unless specified
R1 R2 R3 R4
V1 V2 R5
V3

TM-1213 Page 14 Spoolmatic 15AAnd 30A
SECTION 8 − MAINTENANCE
8-1. Routine Maintenance
!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

TM-1213 Page 15Spoolmatic 15AAnd 30A
8-2. Changing Contact Tip And Liner
(Effective With Serial No. KC248746 Thru LC478841)
150 437
Remove top cover and open
pressure roll assembly.
1 Contact Tip Wrench
Insert wrench into nozzle over
contact tip.
2 Compression Nut
Loosen nut. Pull out contact tip.
3 Contact Tip
4 Nozzle
Pullwire out nozzle and liner should
slide out. If necessary, tilt nozzle
down to remove liner.
Close pressure roll assembly.
Reinstalltop cover.
Installnew liner and contact tip over
wire. Cut off wire at end of contact
tip.
Tighten nut just until contact tip is
secure. Overtightening nut will
damageadapter.
Tools Needed:
1
2
3
4
8-3. Changing Gun Contact Tip (Effective With Serial No. LC478842 And Following)
Ref. 150 437-A
Remove nozzle
1 Nozzle
2 FasTip
Unscrew FasTip.
Install new FasTip.
2
1

TM-1213 Page 16 Spoolmatic 15AAnd 30A
8-4. Replacing Head Tube Liner (Effective With Serial No. LC478842 And Following)
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:

TM-1213 Page 17Spoolmatic 15AAnd 30A
8-5. Changing Or Cleaning Drive Roll (Prior To Serial No. KD376404)
Ref. 149 967-B
Turn Off weld control and welding
power source.
1 Top Cover
2 Drive Roll Assembly
Cut off wire where it enters drive roll
assembly area.
3 Setscrew
4 Current Pick-Up Tab
This tab helps prevent burnback
caused by welding arcs inside the
contact tip. This tab may be
removed to provide an insulated
driveroll. (If tab is removed, a small-
er diameter contact tip is
recommended. See options in
Parts List.) Lightly grease top of tab
beforereinstalling.
5 Motor Shaft
6 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.
7 Bearing
8 Liner
Line up drive roll groove with
bearing groove and liner opening.
Tighten setscrews.
Thread welding wire (see Section
4-2). Close and secure pressure
roll assembly. Adjust drive roll pres-
sure, if necessary (see Section
4-7). Reinstall top cover.
Tools Needed:
5/16 in.
1
6
34
2
78
5

TM-1213 Page 18 Spoolmatic 15AAnd 30A
8-6. Replacing Or Cleaning Drive Roll Bearing (Prior To Serial No. KG193179)
Ref. 149 967-B
Turn Off weld control and welding
power source.
1 Top Cover
2 Pressure Roll Assembly
3 Screw
4 Shoulder Washer
5 Drive Roll Bearing
Remove as shown.
Use a wire brush to clean bearing.
Reinstallwith washers, and tighten
screw.
Close pressure roll assembly.
Reinstalltop cover.
1
2
3
4
5
Tools Needed:
4
Notes