10-1, Maintenance | Miller Electric Renegade 180 guide

SECTION 8 − MAINTENANCE		31
8-1.	Power Source Routine Maintenance	31
8-2.	Gun Routine Maintenance	32
8-3.	Welding Power Source Overload Protection	32
8-4.	Drive Motor Protection And Tip Saver/Short Circuit Protection	32
8-5.	Changing Drive Roll Or Wire Inlet Guide	33
8-6.	Replacing Gun Contact Tip	33
8-7.	Maintaining Gun	34
8-8.	Replacing Switch And/Or Head Tube	35
8-9.	Servicing Air Cleaner	36
8-10.	Adjusting Engine Speed	37
SECTION 9 − TROUBLESHOOTING		38
SECTION 10 − PARTS LIST		40
10-1.	Recommended Spare Parts	40
SECTION 11 − ELECTRICAL DIAGRAMS		41
SECTION 12 − MIG WELDING (GMAW) GUIDELINES		42
SECTION 13 − GENERATOR POWER GUIDELINES		51
COMPLETE PARTS LIST - www.MillerWelds.com
OPTIONS AND ACCESSORIES
WARRANTY

Page 4

Image 4

Miller Electric Renegade 180 manual 10-1, Maintenance

Contents

OM-228 042B ProcessesDescription File Engine Drive From Miller to You Table of Contents − Maintenance 10-1 Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burns Fumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Welding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injury Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiques LES 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 LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peut Principales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF − Specifications Symbol DefinitionsWeld, Power, And Engine Specifications − Definitions Gun Specifications Dimensions, Weights, And Operating AnglesOptional Lifting Eye Weight Rating Volt-Ampere Curves Power Source Duty Cycle Fuel Consumption Generator Power Curve Gun Duty Cycle And OverheatingVolts AC Amperes − Installation Installing Welding GeneratorMovement Airflow Clearance Grounding Generator When Supplying Building Systems Use ground device as stated in electrical codes Connecting The Battery Electric Start Models Only Engine Prestart Checks+ − Oil Installing Welding Gun Work Cable Routing Inside Unit Weld Process/Polarity Table Changing Weld Polarity Shown with optional cylinder rack Connecting Single−Phase, 230 Volt AC Utility Input PowerThis unit can provide weld out Electrical Service Guide Installing Wire Spool And Adjusting Hub TensionWhen a slight force is needed to turn spool, tension is set Adapter Weld Position Threading The Welding Gun Stamped Stamped .030/.035 Tighten Pressure Indicator ScaleTools Needed 150 mm 030/.035 Groove Wood − Operating the Welding Generator Controls See Section To Start Description Of Controls See SectionTo Stop Weld Parameter Chart Stainless Steel And 100% CO2 Weld Parameters 20 ga 18 ga 16 ga 14 ga Generator power decreases as weld current increases Generator Power Panel Receptacles− Operating Auxiliary Equipment − Maintenance Power Source Routine Maintenance Gun Routine Maintenance Welding Power Source Overload ProtectionDrive Motor Protection Tip Saver/Short Circuit Protection Turn Off power before replacing contact tip Changing Drive Roll Or Wire Inlet GuideReplacing Gun Contact Tip Turn off welding power source/wire feeder Maintaining Gun Replacing Switch And/Or Head Tube Tools Needed 19 mm Servicing Air Cleaner Precleaner Paper ElementDo not wash paper element or clean with compressed air Standard Model Shown Stop engine Adjusting Engine Speed Stop engine. Close fuel valve − Troubleshooting TroubleshootingGenerator Power Welding Engine Wire FeederDoes not run Recommended Spare Parts − Parts ListRecommended Spare Parts − Electrical Diagrams OM-217 454 Regulator Flowmeter Wire Feeder Power Source Shielding Gas − MIG Welding Gmaw GuidelinesTypical MIG Process Connections Gun Work Clamp Workpiece Typical MIG Process Control Settings These settings are guidelines only. MaterialWire Suggested Wire Speed Material thickness determines weld parameters Nozzle, and tip of wire is posi Holding And Positioning Welding GunTioned correctly on seam Groove Welds Conditions That Affect Weld Bead Shape Gun Angles And Weld Bead ProfilesElectrode Extensions Stickout Fillet Weld Electrode Extension Stickout Good 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 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 Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting Amperage Typical 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 Loads SOCKET/WRENCH Selection Table Standard Metric Your distributor also gives ServiceSupport 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

Miller Electric Renegade 180 manual 10-1, Maintenance

Models: Renegade 180

TABLE OF CONTENTS

SECTION 8 − MAINTENANCE

10-1.