Miller Electric Renegade 180 manual Wire Feeder, Engine, Does not run

Page 43

 

. Complete Parts List available at www. MillerWelds.com

 

 

Trouble

Remedy

 

 

Low output at generator power ac

Check engine speed, and adjust if necessary (see Section 8-10). Open circuit voltage is reduced as

receptacles.

engine speed drops.

 

 

Erratic output at generator power ac

Check fuel level.

receptacles.

 

Have Factory Authorized Service Agent check connections at terminal block 1T.

 

 

 

 

Check receptacle supplementary protector, wiring, and connections.

 

 

 

Check throttle linkage for smooth, non-binding operation.

 

 

 

Service air cleaner according to engine manual.

 

 

 

Check engine speed, and adjust if necessary (see Section 8-10).

 

 

C. Wire Feeder

 

 

 

Trouble

Remedy

 

 

No weld output; wire does not feed; fan

Secure power cord plug in receptacle (see Section 5-9).

does not run.

 

Replace building line fuse or reset circuit breaker if open.

 

 

 

 

Place Wall/Generator switch in Wall position.

 

 

 

Reset welding power source supplementary protector if open.

 

 

No weld output; wire does not feed; fan

Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when

motor continues to run.

unit has cooled.

 

 

 

Secure gun trigger leads (see Section 5-5).

 

 

 

Check position of Spool Gun/Mig Gun switch.

 

 

No weld output; wire feeds.

Connect work clamp to get good metal to metal contact.

 

 

 

Replace contact tip (see Section 8-6).

 

 

 

Check for proper polarity connections (see Section 5-8).

 

 

 

Check thumbscrew securing gun end to feed head adapter and tighten if necessary.

 

 

Low weld output.

Connect unit to proper input voltage or check for low line voltage.

 

 

 

Place voltage control in desired position (see Section 6-3).

 

 

Electrode wire feeding stops during

Straighten gun cable and/or replace damaged parts.

welding.

 

Adjust drive roll pressure (see Section 5-12).

 

 

 

 

Change to proper drive roll groove (see Section 8-5).

 

 

 

Readjust hub tension (see Section 5-11).

 

 

 

Replace contact tip if blocked (see Section 8-6). Oversized tip may be required for some wires.

 

 

 

Clean or replace wire inlet guide or liner if dirty or plugged (see Section 8-5or Section 8-7).

 

 

 

Replace drive roll or pressure bearing if worn or slipping (see Section 8-5).

 

 

 

Secure gun trigger leads or repair leads (see Section 5-5).

 

 

 

Check and clear any restrictions at drive assembly and liner (see Section 5-12or Section 8-7).

 

 

 

Release gun trigger and allow gun and motor protection circuitry to reset.

 

 

 

Have Factory Authorized Service Agent check drive motor.

 

 

D. Engine

 

 

 

Trouble

Remedy

 

 

Engine will not crank (Electric Start Mod-

Check and replace ignition fuse (see engine manual)

els Only)

 

Check battery voltage.

 

 

 

 

Check battery connections and tighten if necessary.

 

 

 

Have Factory Authorized Service Agent check engine ignition system.

 

 

 

OM-228 042 Page 39

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Contents File Engine Drive OM-228 042BProcesses DescriptionFrom Miller to You Table of Contents 10-1 − MaintenanceHOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationIndique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion ’EXPLOSION DE LA Batterie peu LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent pro voquer des blessures ’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresPrincipales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF − Definitions − SpecificationsSymbol Definitions Weld, Power, And Engine SpecificationsVolt-Ampere Curves Gun SpecificationsDimensions, Weights, And Operating Angles Optional Lifting Eye Weight RatingFuel Consumption Power Source Duty CycleAC Amperes Generator Power CurveGun Duty Cycle And Overheating VoltsAirflow Clearance − InstallationInstalling Welding Generator MovementUse ground device as stated in electrical codes Grounding Generator When Supplying Building SystemsOil Connecting The Battery Electric Start Models OnlyEngine Prestart Checks + −Work Cable Routing Inside Unit Installing Welding GunChanging Weld Polarity Weld Process/Polarity TableShown with optional cylinder rack Connecting Single−Phase, 230 Volt AC Utility Input PowerThis unit can provide weld out Adapter Electrical Service GuideInstalling Wire Spool And Adjusting Hub Tension When a slight force is needed to turn spool, tension is setWeld Position Threading The Welding Gun Stamped Stamped .030/.035 Tighten Pressure Indicator ScaleTools Needed 150 mm 030/.035 Groove Wood Controls See Section − Operating the Welding GeneratorTo Start Description Of Controls See SectionTo Stop Weld Parameter Chart 20 ga 18 ga 16 ga 14 ga Stainless Steel And 100% CO2 Weld ParametersGenerator power decreases as weld current increases Generator Power Panel Receptacles− Operating Auxiliary Equipment Power Source Routine Maintenance − MaintenanceTip Saver/Short Circuit Protection Gun Routine MaintenanceWelding Power Source Overload Protection Drive Motor ProtectionTurn Off power before replacing contact tip Changing Drive Roll Or Wire Inlet GuideReplacing Gun Contact Tip Maintaining Gun Turn off welding power source/wire feederTools Needed 19 mm Replacing Switch And/Or Head TubeStandard Model Shown Stop engine Servicing Air CleanerPrecleaner Paper Element Do not wash paper element or clean with compressed airStop engine. Close fuel valve Adjusting Engine SpeedWelding − TroubleshootingTroubleshooting Generator PowerEngine Wire FeederDoes not run Recommended Spare Parts − Parts ListRecommended Spare Parts OM-217 454 − Electrical DiagramsGun Work Clamp Workpiece Regulator Flowmeter Wire Feeder Power Source Shielding Gas− MIG Welding Gmaw Guidelines Typical MIG Process ConnectionsMaterial thickness determines weld parameters Typical MIG Process Control SettingsThese settings are guidelines only. Material Wire Suggested Wire SpeedGroove Welds Nozzle, and tip of wire is posiHolding And Positioning Welding Gun Tioned correctly on seamFillet Weld Electrode Extension Stickout Conditions That Affect Weld Bead ShapeGun Angles And Weld Bead Profiles Electrode Extensions StickoutGood Weld Bead Characteristics Poor Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Porosity Troubleshooting − Excessive SpatterPossible Causes Corrective Actions 12-11 Troubleshooting − Lack Of Penetration Troubleshooting − Excessive PenetrationTroubleshooting − Incomplete Fusion Troubleshooting − Waviness Of Bead 12-13 Troubleshooting − Burn-ThroughTroubleshooting − Distortion Application Common MIG Shielding GasesFlat & Horizontal1 Fillet Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Cord Lengths for 240 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Current Load Watts AmperesSOCKET/WRENCH Selection Table Standard Metric Your distributor also gives ServiceSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact