AUTO ARC BENCHMARK Manuel utilisateur

June

1989

FORM:

121

989A

OWN

ERS

MANUAL

IT?

VTLiQFL_____

1~J

V..~

MILLER ELECTRIC

MFG.

CO.

718

BOUNDS

SI,

P.O.

Box

1079

APPLETON,

54912

USA

ADDITIONAL

COPY

PRICE

$1.40

lMpOfl~TANT

_____________

Read

and

understand

the

entire

content3

this

manual,

with

special

emphasis

the

safety

material

throughout

the

manual,

before

installing,

operating,

maintaining

this

equip

ment.

Thts

unit

and

these

instructions

are

for

use

only

persons

trained

and

experienced

the

safe

operation

welding

equipment.

not

allow

trained

persons

install,

operate,

maintain

this

unit.

Contact

your

distributor

you

not

fully

understand

these

instructions.

Effective

With

Serial

No.

JJ368979

MODEL

BENCHMARKTM

Pro

MWG-160

Gun

NWSA

CODE

NO.

4579

PRINTED

U.S.A.

ONE

YEAR

LIMITED

WARRANTY

COVERAGE



Miller

Electric

Mfg.

Co.

warrants

the

buyer

who

purchases

this

Auto

Arc

Welder

(~Welder)

for

personal,

familyorhousehold

purposes

(Consumer)

thatthis

Welderwill

free

from

defects

material

andworkmanship

fora

period

one

year

from

the

date

purchase.

This

warranty

covers

only

the

original

purchaser

this

Welder.

Miller

Electric

does

not

authorize

any

party,

including

its

authorized

distributors,

offer

any

other

warranty

behalf

Miller

Electric.

Upon

expiration

the

warranty

period,

Miller

Electric

shall

have

further

liabil

ity

the

Welder,

excepton

warranty

claims

made

during

the

warranty

period.

THIS

WARRANTY

OFFERED

LIEU

ANY

OTHER

EXPRESS

WARRANTY;

AND,

EXCEPT

THE

EXTENT

PROHIBITED

APPLICABLE

LAW,

THE

DURATION

ALL

IMPLIED

WARRANTIES,

INCLUDING

BUT

NOT

LIMITED

THE

IMPLIED

WARRANTIES

MERCHAN

TABILITY

AND

FITNESS

FOR

PARTICULAR

PURPOSE,

LIMITED

THE

DURATION

THIS

WARRANTY.

Some

states

not

allow

limitations

how

long

implied

warranty

lasts,

the

above

limitation

may

not

apply

you.

This

warranty

gives

you

specific

legal

rights,

and

you

may

also

have

other

rights

which

vary

from

state

state.

Except

specified

below,

Millers

warranty

does

not

apply

components

having

normal

useful

life

less

than

one

(1)

year,

such

spot

welder

tips,

relay

and

contactor

points,

parts

that

come

contact

with

the

welding

wire

including

nozzles

and

nozzle

insulators

where

failure

does

not

result

from

defect

workmanship

material.

Miller

shall

required

honorwarranty

claims

warranted

Equipment

the

event

failure

resulting

from

defect

within

the

following

periods

from

the

date

delivery

Equipment

the

original

user:

Arc

welders,

power

sources,

and

components

...

year

Original

main

power

rectifiers

years

(labor



year

only)

All

welding

guns,

feeder/guns

and

torches

days

Replacement

repair

parts,

exclusive

labor

days

WHAT

NOT

COVERED



This

warranty

does

not

extend

any

Welder

subjected

misuse,

neglect,

accident,

in-

warranty

repair

anyone

except

Miller

Electric.

Further,

this

warranty

only

extends

those

purchasing

the

Welder

for

per

sonal,

family

household

purposes.

Commercial

and

indus

trial

users

are

given

different

warranty.

REMEDY

FOR

DEFECTIVE

WELDER



Upon

receipt

any

defective

Welder,

Miller

Electric

will,

its

option,

repair

place

the

defective

Welder

its

expense,

refund

credit

the

purchase

price

(less

reasonable

depreciation

based

actual

use),

reimburse

the

Consumer

for

the

cost

repair

placement

approved

Miller

Electric

warranty

station,

pro

vided

that

the

purchaser

that

Welder

has

followed

the

proce

dure

for

obtaining

warranty

performance

set

forth

below.

The

Welder

repaired

used

replacement

will

shipped

the

purchaser

the

defective

Welder,

with

transportation

charges

prepaid

any

destination

the

continental

United

States

(transportation

charges

shipments

Alaska

Hawaii

will

paid

only

the

nearest

port

export).

THE

PURCHASERS

REMEDIES

FOR

DEFECTIVE

WELDER,

THE

EXTENT

PERMITTED

APPLICABLE

LAW,

ARE

LIMITED

THE

REMEDY

PROVIDED

THIS

WARRANTY:

AND,

THE

EXTENT

ENFORCEABLE

UNDER

APPLICABLE

LAW,

MILLER

ELECTRIC

SHALL

EVENT

LIABLE

FOR

CONSEQUENTIAL,

INCIDEN

TAL

SPECIAL

DAMAGES

ARISING

OUT

THE

USE

OF,

INABILITY

USE,

THE

WELDER,

WHETHER

BASED

BREACH

THIS

WARRANTY,

MILLER

ELECTRICS

NEGLIGENCE

OTHER

TORT,

ANY

THEORY

STRICT

LIABILITY.

Some

states

not

allow

the

exclusion

limitation

conse

quential

incidental

damages,

the

above

limitations

may

not

apply

you.

PROCEDURE

FOR

OBTAINING

WARRANTY

PERFORM

ANCE

soon

any

defect

Welder

becomes

known,

the

pur

chaser

of the

Welder

must,

within

thirty

(30)

days,

notify

approved

Warranty

Station

Miller

Electric

writing

the

defect.

The

purchaser

must

then,

within

the

one

year

warranty

period,

return

the

Welder

Miller

Electric

the

following

dress:

Miller

Electric

Mfg.

Co.

1635

Spencer

St.

P.O.

Box

1079

Appleton,

Wisconsin

54912

All

transportation

charges

Warranty

Station

Miller

Electric

must

prepaid.

ERRATA

SHEET

After

this

manual

was

printed,

refinements

equipment

design

occurred.

This

sheet

lists

exceptions

data

appearing

later

this

manual.

IMPORTANT:

This

model

comes

equipped

with

V-Grooved

drive

rolls

installed.

AMENDMENT

SECTION

3

SPECIFICATIONS

Amend

Ampere

Model

portion

Chart

3-2.

Duty

Cycle

Ampere

Models

LI

2630

40 60

SOiO6OO1OO

DUTY

CYCLE

B.124

655-A

AMEN

DMENT

SECTION

4INSTALLATION

Amend

step

Section

4-5.

INSTALL

AND

THREAD

THE

WIRE

10.

Route

the

welding

wire

into

the

wire

inlet

guide,

along

the

drive

roil

groove,

and

into

the

wire

outlet

guide

the

gun

cable.

AMENDMENT

SECTION

MAINTENANCE

TROUBLESHOOTING

Amend

Figure

7-1.

Wire

Drive

Assembly

And

Replacement

(see

Page

this

Errata

Sheet)

(For

Ampere

Models,

Effective

With

Serial

No.

JK646341.

For

Ampere

Models,

Effective

With

Serial

No.

JJ368979.)

Amend

Section

7-7.

REPLACING

THE

WIRE

INLET

GUIDE

(Figure

7-1

this

Errata

Sheet)

(For

Ampere

Models,

Effective

With

Serial

No.

JK646341.

For

Ampere

Models,

Effective

With

Serial

No.

JJ368979.)

160

126

100

375

Pressure

Roll

Cover

Cotter

Drive

Roll

Setscrew

TC-121

488.A

FIgure

7-1.

WIre

Drive

Assembly

And

Replacement

WARNING:

HOT

SURFACES

can

cause

severe

burns.



Allow

equipment

cool

before

cleaning.

Turn

OFF

the

welder.

Open

the

left

side

access

door.

Loosen

the

drive

roll

pressure

adjustment

knob,

pivot

the

pressure

adjustment

arm

down~

away

from

the

cover.

Pivot

the

pressure

roll

assembly

until

the

open

position.

CAUTION:

LOOSE

WELDING

WIRE

can

cause

Injury.



Keep

firm

ho/don

wire

during

installation,

removal,

and

threading

operations.

Spooled

wire

has

tendency

unravel

rapidly

when

loosened from

the

spool.

Cut

the

welding

wire

the

point

where

enters

the

wire

inlet

guide.

Pull

the

wire

out

through

the

nozzle

end

the

welding

gun.

Remove

and

replace

the

inlet

guide.

IMPORTANT:

Wire

guides

should

installed

that

the

tip(s)

the

guide

the

drive

roll

possible

without

touching.

Thread

the

welding

wire

instructed

Section

4-5.

Pivot

the

pressure

adjustment

arm

until

seats

top

the

pressure

roll

assembly.

Turn

the

pressure

adjustment

knob

clockwise

until

the

drive

roll

assembly

secure.

Adjust

the

drive

roll

pressure

just

enough

prevent

the

wire

from

slipping

against

the

drive

roll

during

operation.

and

secure

the

access

door.

AMENDMENT

SECTION

8

ELECTRICAL

DIAGRAMS

Amend

Diagram

8.5.

Wiring

Diagram

For

Ampere

Models

(see

Page

this

Errata

Sheet)

121

9B9APage2

Gun

Cable

Pressure

Lever

Hinge

Pressure

Bearing

Screw

Pressure

Adjustment

Arm



Wire

inlet

Guide

Wiring

Diagram

No.

C-124

445-C

Diagram

8-5.

Wiring

Diagram

For

Ampere

Models

AMENDMENT

SECTION

12

PARTS

LIST

Amend

Parts

List

follows:

Model

Quantity

Dia.

Part

Replaced

Benchmark

Mkgs.

No.

With

Description

Benchmark

Pro

41-2

010910

WASHER,

flat-SAE

3/8

41-19

073

433

Deleted

Both

Models

(Eff

w/JK664661)

41-20

010

678

Deleted

Both

Models

(Effw/JK664661)

41-21

GS1

003538

116996

VALVE,

ll5VAC2way

custom

port

1/8orf

(Etfw/JK664661)

41-22

010

296

Deleted

Both

Models

(Eff

w/JK664661)

41-29

121

088

126416

HANDLE,

molded

plastic

(Eff

w/JK71

6640)

41-

Added

126415

CLAMP,

saddle

(Eff

w/JK71

6640)

1 1

41-

Added

605

227

NUT,

nyl

hex

jam

.750

(Effw/JK664661)

42-54

119123

130900

BAFFLE,air(Effw/JK716640)

42-56

083

147

Deleted

BOTH

MODELS,

(Eff

w/JK71

66400)

45-5

Added

604

536

SCREW,

cap

stl

hexhd

.312-18

(Eff

w/JK646341)

45-6

Added

602

211

WASHER,

lock

sfl

split

.312

(Etfw/JK646341)

45-7

Added

604

538

WASHER,

flat

SAE

.312

(Eff

w/JK646341)

45-8

118

871

129

893

INSULATOR,

housing-drive

(Effw/JK716640)

45-9

129

665

126838

DRIVE

ASSEMBLY,

wire

(Eff

w/JK646341)

45-11

118

928

124

817

HOUSING,

wire

drive

(Eff

w/JK646341)

45-

604 534

Deleted

(Eff

wIJK646341)

45-

604

538

Deleted

(Eff

w/JK646341)

45-

602

109

Deleted

(Effw/JK646341)

45-

120 678

058

549

GUIDE,

wire

inlet

1/16

(Effw/JK646341)

45-

Added

604

537

NUT,

stl

hex

full

fnsh

.312-18

(Eff

w/JK646341)

**First

digit

represents

page

digits

following

dash

represent

item

no.

SURE

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

121

989A

Paged

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

dam-

Use

the

following

spaces

record

the

Model

Designa

age

that

may

have

occurred

during

shipment.

File

any

tion

and

Serial

Style

Number

your

unit.

The

infor

claims

for

loss

damage

with

the

delivering

carrier.

mation

located

the

data

card

the

nameplate.

Assistance

for

filing

settling

claims

may

obtained

from

the

distributor

and/or

the

equipment

manufactur-

Model

______________________________________

ers

Transportation

Department.

Serial

Style

No.

________________________

When

requesting

information

about

this

equ!pment,

ways

provide

the

Model

Description

and

Serial

Style

Date

Purchase

____________________________

Number.

TABLE

CONTENTS

Section

No.

Page

No.

SECTION



SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

1-1.

Introduction

1-2.

General

Precautions

1-3.

Arc

Welding

1-4.

Standards

Booklet

Index

SECTION

SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

2-1

General

Information

And

Safety

2-2.

Safety

Alert

Symbol

And

Signal

Words

SECTION

3

SPECIFICATIONS

3-1.

Volt-Ampere

Curves

3-2.

Duty

Cycle

3-3.

Description

3-4.

Supplied

Equipment

3-5.

Personal

Safety

Equipment

3-6.

Optional

Equipment

3-7.

Consumable/Replacement

Parts

SECTION

INSTALLATION

4-1.

Locate

The

Welder

4-2.

Install

The

Work

Clamp

4-3.

Set

The

Welding

Polarity

4-4.

Install

The

Welding

Gun

4-5.

Install

And

Thread

The

Wire

4-6.

Adjust

The

Hub

Tension

4-7.

Shielding

Gas

Installation

4-8.

Connect

Power

4-9.

Feed

The

Wire

SECTION



OPERATOR

CONTROLS

5-1.

Power

Switch

5-2.

ThicknessNolts

Switch

5-3.

Fine

Tuning/Wire

Speed

Control

Section

No.

Page

No.

SECTION

6

OPERATION

6-1.

Gas

Metal

Arc

Welding

(GMAW)

6-2.

Flux

Cored

Arc

Welding

(FCAW)

6-3.

Shutting

Down

SECTION

MAINTENANCE

TROUBLESHOOTING

7-1.

Routine

Maintenance

7-2.

Drive

Roll

Cleaning

7-3.

Cable

Inspection

7-4.

Welding

Gun

Inspection

And

Maintenance

7-5.

Replacing

The

Drive

Roll

7-6.

Replacing

The

Pressure

Bearing

7-7.

Replacing

The

Wire

Inlet

Guide

7-8.

Short

Circuit

Shutdown

(90

Ampere

Models

Only)

7-9.

Circuit

Board

Replacement

(90

Ampere

Models

Only)

7-10.

Replacing

The

Contact

Tube 22

7-11.

Gun

Wire

And

Liner

Replacement

7-12.

Fuse

(70

Ampere

Models

Only)

7-13.

Thermal

Overload

Protection

7-14.

Troubleshooting

SECTION

8

ELECTRICAL

DIAGRAMS

Diagram

8-1.

Circuit

Diagram

For

Ampere

Models

Diagram

8-2.

Circuit

Diagram

For

Ampere

Models

Diagram

8-3.

Circuit

Diagram

For

Ampere

Model

Short

Circuit

And

Burnback

Control

Board

PCi

Diagram

8-4.

Wiring

Diagram

For

Ampere

Models

Diagram

8-5.

Wiring

Diagram

For

Ampere

Models

SECTION

9

PROJECT

INSTRUCTIONS

9-1.

Overview

9-2.

Dust

Pan

9-3.

Shop

Stool

9-4.

Adjustable

Support/Stand

9-5.

Trailer

Dolly

SECTION

10

WELDING

TECHNIQUES

TROUBLESHOOTING

10-1.

Gas

Metal

Arc

Welding

(GMAW)



Continuous

Seam

10-2.

Troubleshooting

The

Gas

Metal

Arc

Welding

(GMAW)

Process

....

34.

SECTION



AUTO

BODY

REPAIR

APPLICATION

11-1.

Pointers

For

Welding

Auto

Body

Sheet

Metal

11-2.

-Procedure

For

Welding

Mild

Steels

11-3.

Procedures

For

Welding

Door

Panels

11-4.

How

Prevent

Glass

Breakage

And

Spatter

Windows

11-5.

Procedures

For

Welding

Fenders

And

Quarter

Panels

11-6.

Welding

Frames

And

High

Strength

(HSS)

Steels

Section

No.

Page

No.

SECTION

12

PARTS

LIST

Figure

12-1.

Main

Assembly

Figure

12-2.

Circuit

Card,

Shutdown/Burnback

PCi

Figure

12-3.

Drive

Assembly,

Wire

(Benchmark

Pro

Illustrated)

Figure

12-4~

Exploded

View

MWG-160B

Gun

LIST

CHARTS

AND

TABLES

Table

3-i.

Specifications

Chart

3-1.

Volt-Ampere

Curves

Chart

3-2.

Duty

Cycle

Table

4-1.

Maximum

Allowable Extension

Cord

Lengths

Table

6-1.

Suggested

Welding

Settings

Table

7-1.

Maintenance

Schedule

Table

7-2.

Troubleshooting

Table

9-i.

Dust

Pan

Material

List

Table

9-2.

Shop

Stool

Material

List

Table

9-3.

Adjustable

Support/Stand

Material

List

Table

9-4.

Trailer

Dolly

Material

List

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