Miller Gold SealTM Model 5000 Owner's Manual
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Miller Gold SealTM Model 5000 Owner's Manual

Miller Gold SealTM Model 5000 Owner's Manual

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MiOØrfi~
~i4 #~41uI14Ft~4S4IV1
-
~a
p
~
I
I
~.w
April
1993
Form:
OM-157
745
Effective With Serial No. KD398640
OWNERS
MANUAL
Gold SealTM Model
5000
Read and follow these instructions and all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install, operate,
or
service this unit.
Call your distributor if you do
not
understand
the directions.
CV/DC
Welding
Power
Source/Wire
Feeder
For
FCAW
Welding
Or GMAW
Welding
With
Optional
Gas
Valve
Rated
Output
Of 70
Amperes
At 16 Volts
DC,
20%
Duty Cycle
Uses 115 VAC
Single-Phase
Input
Power
Motor Overload Protection
Basic Model Includes
Gun,
Standard
Model Adds Gas
Valve,
Deluxe Model Adds Gas
Regulator/Flowmeter
U
Give
this manual to the
operator.
For
help,
call your distributor
or:
MILLER
ELECTRIC
Mfg.
Co.,
P.O. Box
1079,
Appleton,
WI 54912
414-734-9821
cover
8/92
ST.161
158
PRINTED
IN
USA

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Summary of Contents for Miller Gold SealTM Model 5000

  • Page 1 MiOØrfi~ Form: OM-157 April 1993 Effective With Serial No. KD398640 ~i4 #~41uI14Ft~4S4IV1 OWNERS MANUAL Gold SealTM Model 5000 CV/DC Power Source/Wire Feeder Welding FCAW Or GMAW With Valve Welding Welding Optional Rated Of 70 At 16 Volts Output Amperes Duty Cycle Uses 115 VAC Single-Phase Input...

  • Page 3: Section 3Operation

    MILLER eaclunive with supersedes previous warrentlas end other gusrentees warrenflea espreseed Implied. This limited werrenty WARRANTYSubject terms conditions below, MILLER Electric Acceeeory Kite LIMITED original retell purcheser thet Mlg. Co., Appleton, Wioconain, werrents to Perle Replecement effective dete of this limited...

  • Page 5: Arc Welding Safety Precautions

    ARC WELDING SAFETY PRECAUTIONS Read all safety throughout this manual. messages Obey safety to avoid injury. messages of WARNING and CAUTION. Learn the meaning Safety Alert Symbol SignalWord WARNING possible death means serious injury happen. WARNING CAUTION CAUTION possible minor means ______________ ELECTRIC SHOCK...
  • Page 7 if it is well FUMES GASES Work in confined space only ventilated, while hazardous gases used for your health. wearing air-supplied respirator. Shielding death. Be welding displace causing injury sure fumes and gases. these Welding produces Breathing air is safe. breathing fumes and gases be hazardous...
  • Page 9 TABLE OF CONTENTS SECTION SPECIFICATIONS Curve And 1-1. Volt-Ampere Duty Cycle Chart SECTION 2INSTALLATION 2-1. Installing Work Clamp 2-2. Polarity Wire Type 2-3. Installing Welding Connecting Power 2-4. Input 2-5. Threading Feeding Welding Wire 2-6. Supply Installing SECTION 3OPERATION SECTION MAINTENANCE &...

  • Page 13: Specifications

    SECTION SPECIFICATIONS Power Source Table 1-1. Welding Specifications Description Type Output Constant Voltage/Direct Current (CV/DC) Rated Weld Output 16 Volts Duty Cycle Amperes, At 115 Volts AC Type Input Power Single-Phase; At Rated Output 15 A Input Amperes kVN2 KVA/KW Used At Rated Output Max.

  • Page 15: Installation

    SECTION INSTALLATION 2-1. Installing Work Clamp Insulator Bolt Smaller Hole Work Clamp Tabs Bend tabs around work cable. Work Cable From Unit Tools Needed: ~ 3/8, 7/16 Ret. ST-025 190-C Figure 2-1. Installing Work Clamp For Wire 2-2. Polarity Type WARNING ELECTRIC SHOCK kill.
  • Page 17 2-3. Installing Welding Securing Drive Assembly Loosen securing nut. Insert end through front panel opening until it bottoms against drive assembly. Tighten nut. Trigger Leads Insert leads, time, through front Connect grommet panel. leads leads in unit. matching Close door. Tools Needed: 5/l6in Ref.
  • Page 19 Wire Spool Hub Tension Nut Grasp spool. Turn while using wrench to adjust When slight nut. force is needed to turn spool, sion is set. Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Tools Needed: Outlet Wire Guide Gun Conduit Cable gun cable straight.

  • Page 21: Gas Supply

    2-6. Installing Supply WARNING £~ CYLINDERS BUILDUP OF SHIELDING GAS harm explode damaged. health kill. away from Keep cylinders welding other electrical circuits. Shut off when shielding supply not in use. Never touch cylinder with welding electrode. Always cylinder running wall, secure gear,...

  • Page 23: Operation

    SECTION OPERATION SAFETY BLOCKS READ beginning WARNING of manual before proceeding. MOVING PARTS ARCING injury. damage switch. can cause Keep away from pinch points such drive rolls. Do not change ThicknessNoltage switch position while welding. Keep doors, panels, covers, and guards closed inside switch...

  • Page 25: Maintenance And Troubleshooting

    SECTION MAINTENANCE& TROUBLESHOOTING WARNING ELECTRIC SHOCK kill. OVING PARTS injury. can cause touch live electrical Keep away from moving parts. parts. Turn Oft welding and disconnect power source, Keep away from pinch points such drive rolls. input power before inspecting, maintaining, servicing.

  • Page 27: Drive Assembly Maintenance

    4-2. Drive Assembly Maintenance I~4s. READ SAFETY BLOCKS at start of Section before proceeding. ______ Turn unit. unplug Wire Spool welding wire off at contact tube. Retract wire onto spool secure. Pressure Roll Arm Cotter Screw Bearing Remove bearing shown. Install bearing with secure...

  • Page 29: Gun Maintenance

    Gun Maintenance 4-3. SAFETY BLOCKS READ at start Section before proceeding. FLYING CHIPS METAL AND DIRT injury damage equipment. can cause Point gun away from people safe direction when blowing with air. compressed 10/91 swarrilOl Turn Off unit. unplug Wire Spool wire off tube.

  • Page 31: Troubleshooting

    4-4. Troubleshooting READ SAFETY BLOCKS at start Section before proceeding. Table 4-2. Welding Trouble Welding Trouble Remedy Section fee~ No weld wire does not Secure power cord output; plug receptacle. Motor fuse Fl open, fuse. replace reset circuit breaker if open. Replace building line fuse Secure gun...

  • Page 33: Circuit Diagram

    SECTION ELECTRICAL DIAGRAMS CR I 69N. ST-157 Figure Circuit Diagram Power Source 5-1. Welding OM-157 745 Page...
  • Page 35 3 7 9 - A S C - 1 5 7 C O R D P O W E R S o u r c e P o w e r S P L I c E W e l d i n g D i a g r a m W i r i n g 5-2.

  • Page 37: Parts List

    SECTION 6 PARTS LIST > c~:J Lf)~ OM-157 Page...
  • Page 39 Item Dia. Part Mkgs. Description Quantity 6-1. Main Figure Assembly 010909.. NUT, slflkg hex .375-16 010910.. WASHER, flatstl SAE .375 073355.. SPRING, cprsn .625 OD .093 wire .000 111998.. PIN, cotter hair .l2Odia 2.375 .500 shaft 111929.. HUB, spool 6..CR1 24VAC DPDT 120706..
  • Page 41 Dia. Part Item Quantity Mkgs. Description Wire Item 131 336 Figure 6-2. Drive Assembly, (Fig ..1..MOT.. MOTOR, gear 12VDC 80RPM 119 021 SCREW, .375-16 1.250 hexhd sti 604 657 WASHER, lock stl .375 602 213 split WASHER,fIatstlSAE.375 010 910 128 189 SCREW, .312-18 1.750 hexhd sti...
  • Page 43 Itern Part Quantity Description 119 697 Figure 6-3. GA-16C1 Gun (Fig 6-1 Item HANDLE ASSEMBLY 110793.. 110 795 TUBE, head (consisting of) 110780..NUT, MiOxi JACKET, head tube 110 779 ..110 781 STOP, nozzle ..ADAPTER, head tube/nozzle 128 878 ..
  • Page 45 t h i c k e r R e c o m m e n d e d R e c o m m e n d e d H I G H H I G H S - 1 5 7 0 .

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Gold seal 5000

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