Miller Electric Renegade 180 manual Installation, Installing Welding Generator, Movement, Location

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. Complete Parts List available at www. MillerWelds.com

SECTION 5 − INSTALLATION

5-1. Installing Welding Generator

Movement

. Shown with standard running gear and optional cylinder rack.

Airflow Clearance

18 in	18 in
(460 mm)	(460 mm)

18 in

(460 mm)

18 in	18 in
(460 mm)	(460 mm)

Location

Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes.

2

GND/PE3

Do not install unit where air flow is restricted or engine may overheat.

Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards.

1Metal Vehicle Frame

2Equipment Grounding Terminal

3Grounding Cable

Bed liners, shipping skids, and some running gear insu- late the welding generator from the vehicle frame. Al- ways connect a ground wire from the generator equip- ment grounding terminal to bare metal on the vehicle frame as shown.

Use #10 AWG or larger insulated

1copper wire to make metal-to-metal grounding connection.

If unit does not have GFCI receptacles, use GFCI- protected extension cord.

Ref. install 11/02 − Ref. 800 652 / 804 476-C / S-0854

OM-228 042 Page 16

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Contents OM-228 042B ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Maintenance 10-1Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité − Specifications Symbol DefinitionsWeld, Power, And Engine Specifications − Definitions Gun Specifications Dimensions, Weights, And Operating Angles Optional Lifting Eye Weight Rating Volt-Ampere CurvesPower Source Duty Cycle Fuel ConsumptionGenerator Power Curve Gun Duty Cycle And OverheatingVolts AC Amperes− Installation Installing Welding GeneratorMovement Airflow ClearanceGrounding Generator When Supplying Building Systems Use ground device as stated in electrical codesConnecting The Battery Electric Start Models Only Engine Prestart Checks+ − OilInstalling Welding Gun Work Cable Routing Inside UnitWeld Process/Polarity Table Changing Weld PolarityThis unit can provide weld out Connecting Single−Phase, 230 Volt AC Utility Input PowerShown with optional cylinder rack Electrical Service Guide Installing Wire Spool And Adjusting Hub TensionWhen a slight force is needed to turn spool, tension is set AdapterWeld Position Tools Needed 150 mm 030/.035 Groove Stamped Stamped .030/.035 Tighten Pressure Indicator ScaleThreading The Welding Gun Wood − Operating the Welding Generator Controls See SectionTo Stop Description Of Controls See SectionTo Start Weld Parameter Chart Stainless Steel And 100% CO2 Weld Parameters 20 ga 18 ga 16 ga 14 ga− Operating Auxiliary Equipment Generator Power Panel ReceptaclesGenerator power decreases as weld current increases − Maintenance Power Source Routine MaintenanceGun Routine Maintenance Welding Power Source Overload ProtectionDrive Motor Protection Tip Saver/Short Circuit ProtectionReplacing Gun Contact Tip Changing Drive Roll Or Wire Inlet GuideTurn Off power before replacing contact tip Turn off welding power source/wire feeder Maintaining GunReplacing Switch And/Or Head Tube Tools Needed 19 mmServicing Air Cleaner Precleaner Paper ElementDo not wash paper element or clean with compressed air Standard Model Shown Stop engineAdjusting Engine Speed Stop engine. Close fuel valve− Troubleshooting TroubleshootingGenerator Power WeldingDoes not run Wire FeederEngine Recommended Spare Parts − Parts ListRecommended Spare Parts − Electrical Diagrams OM-217 454Regulator Flowmeter Wire Feeder Power Source Shielding Gas − MIG Welding Gmaw GuidelinesTypical MIG Process Connections Gun Work Clamp WorkpieceTypical MIG Process Control Settings These settings are guidelines only. MaterialWire Suggested Wire Speed Material thickness determines weld parametersNozzle, and tip of wire is posi Holding And Positioning Welding GunTioned correctly on seam Groove WeldsConditions That Affect Weld Bead Shape Gun Angles And Weld Bead ProfilesElectrode Extensions Stickout Fillet Weld Electrode Extension StickoutGun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Possible Causes Corrective Actions Troubleshooting − Excessive SpatterTroubleshooting − Porosity Troubleshooting − Incomplete Fusion Troubleshooting − Excessive Penetration12-11 Troubleshooting − Lack Of Penetration Troubleshooting − Distortion 12-13 Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Flat & Horizontal1 Fillet Common MIG Shielding GasesApplication Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Approximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Cord Lengths for 120 Volt LoadsCurrent Load Watts Amperes Cord Lengths for 240 Volt LoadsSOCKET/WRENCH Selection Table Standard Metric Support ServiceYour distributor also gives To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s