Miller KF869436 Owner's manual

Miller
Brand
Miller
Model
KF869436
Category
Welding System
Type
Owner's manual

This manual is also suitable for

August
1995
Form:
OM-154501C
Effective
With
Serial
No.
KF869436
MW250
~LE
co~Y
m~
I
~ft
OWNERS
MANUAL
~
IMPORTANT:
Read
and
understand
the
entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equipment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
I
1~oIsfi
coven
5/92
ST-157
072-A
PRINTED
IN
USA
ARC
WELDING
SAFETY
PRECAUTIONS
ARC
WELDING
can
be
hazardous.
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
Turn
off
all
equipment
when
not
in
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
8.
Do
not
wrap
cables
around
your
body.
9.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
10.
Do
not
touch
electrode while
in
contact
with
the
work
(ground)
circuit.
11.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
12.
Wear
a
safety
harness
to
prevent
falling
if
working
above
floor
level.
13.
Keep
all
panels
and
covers
securely
in
place.
1.
Wear
approved
face
shield
or
safely
goggles.
Side
shields
recommended.
2.
Wear
proper
body
protection
to
protect
skin.
4A
WARNING
PROTECT
YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR
DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
6.
7.
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
burns.
The
electrode
and
work
circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touchin9
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
/,,
~9,-,~-
..
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Arc
rays
from
the
welding
process
produce
intense
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
earing.
~
1.
2.
3.
4.
5.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
(see
ANSI
Z49.1
listed
in
Safety
Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
Wear
approved
safety
glasses.
Side
shields
recommended.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
FUMES
AND
GASES
can
be
hazardous
5.
Work
in
a
confined
space
only
if it
is
well
ventilated,
or
while
to
your
health.
wearing
an
air-supplied
respirator.
Shielding
gases
used
for
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
a___..
6.
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes,
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturers
instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
and
cleaners.
containing
these
elements
can
give
off
toxic
fumes
if
welded.
WELDING
can
cause
fire
or
explosion.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Sparks
and
spatter
fly
oft
from
the
welding
arc.
The
flying
sparks
and
hot
metal,
weld
spatter,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
or
welding
wire
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
6.
7.
8.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
Do
not
weld
on
closed
containers
such
as
tanks
or
drums.
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
hazards.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
10.
Remove
stibk
electrode
from
holder
or
cut
off
welding
wire
at
If
this
is
not
possible,
tightly
cover
them
with
approved
covers,
contact
tip
when
not
in
use.
4.
Bealertthatweldingsparksandhotmaterialsfromweldingcan
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
easily
go
through
small
cracks
and
openings
to
adjacent
areas,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury.
and
grinding
cause
flying
metal.
As
welds
can
throw
off
slag.
ERRATA
SHEET
June
1,1995
FORM:
OM-154
501B
Use
above
FORM
number
when
ordering
extra
manuals.
18-
057478
18-8
022617
18-10
151
187
18-
152626
20-22
152632
20-23
174023
20-44
...
Fl
012654
20-44
...
F2
012 654
Description
169
654
.
..
BRACKET,
support
tank
(Eff
w/KF903919)
602 387
..
.
CYLINDER
CHAIN
089
899
...
LATCH
175
060
...
FRONT
PANEL,
(Eff
w/KF903919)
175
775
...
MOTOR
BRACKET,
(Eff
w/KF903919)
174815
...
BAFFLE,
(Eff
w/KF903919)
012
658
...
FUSE,
mintr
gi
slo-blo
2A
125V
073
426
...
FUSE,
mintr
gi
slo-blo
5A
125V
**First
digit
represents
page
no
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
CHANGES
TO
SECTION
7
-
PARTS
LIST
Change
Parts
List
as
follows:
Dia.
Part
**
Mkgs.
No.
Replaced
With
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cyhnders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
5.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
6.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
7.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
8.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.
1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
Safetyand
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
American
Weld
ing
Society
Standard
AWS
F4.1,from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
GSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178 Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
ANSI
Standard
Z87.1
,from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
EMF
INFORMATION
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
INFORMATION
1
SECTION
2SPECIFICATIONS
1
2-1.
Volt-Ampere
Curves
2
2-2.
Duty
Cycle
2
SECTION
3INSTALLATION
3
3-1.
Installing
Work
Clamp
3
3-2.
Installing
Gas
Supply
4
3-3.
Gun
Polarity
Connections
5
3-4.
Installing
Drive
Rolls
And
Welding
Gun
5
3-5.
Connecting
Input
Power
6
3-6.
Installing
Wire
Spool
And
Adjusting
Hub
Tension...
.
8
3-7.
Threading
And
Feeding
Welding
Wire
8
SECTION
4-OPERATION
10
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
12
5-1.
Routine
Maintenance
12
5-2.
Overload
Protection
13
5-3.
Wire
Drive
Assembly
Maintenance
14
5-4.
Gun
Maintenance
15
5-5.
Troubleshooting
16
SECTION
6
ELECTRICAL
DIAGRAMS
16
SECTION
7-
PARTS
LIST
17
Figure
7-1.
Main
Assembly
17
Figure
7-2.
MWG-200M
Gun
18
Figure
7-3.
Baffle
w/Cmpts
19
Magnetic
Fields
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
Background
Paper~
OTA-BP-E-53
(Washington,
DC:
U.S.
Govemment
Printing
Office,
May
1989):..
.
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
cellular
level
and
from
studies
with
animals
and
people
which
clearly
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
or
avoid
potential
risks.
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
1.
Keep
cables
close
together
by
twisting
or
taping
them.
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
3.
Do
not
coil
or
drape
cables
around
the
body.
4.
Keep
welding
power
source
and
cables
as
far
away
as
practical.
About
Pacemakers:
-
5.-
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
The
above
procedures
are
among
those
also
normally
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
mocjiO.1
4/93
6
SECTION
1
-
SAFETY
INFORMATION
R
Read
all
safety
messages
throughout
this
manual.
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
a
WARNING
a
CAUTION
modl.1
2/93
1
Safety
Alert
Symbol
2
SignalWord
1
2
2
~
\~
WARNING
means
possible
death
or
serious
injury
can
happen.
~
:1~II~e~U
3
CAUTION
means
possible
minor
/
~I
ELECTRIC
SHOCK
can
kilI.~
MOVING
PARTS
can
Injure.
injury
or
equipment
damage
can
Do
not
touch
live
electrical
parts.
~IIU~III~,
Keep
away
from
moving
parts.
happen.
Disconnect
input
power
before
Keep
all
panels
and
covers
closed
3
Statement
Of
Hazard
And
installing
or
servicing.
when
operating.
Result
4
Safety
Instructions
To
Avoid
5
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
READ
SAFETY
BLOCKS
at
start
of
I
Section
3-1
before
proceeding.
Read
safety
blocks
for
each
sym
bol
shown.
7
NOTE
7H
NOTE
~
Turn
Oft
switch
when
using
high
frequency.
Special
instructions
for
best
oper
ation
not
related
to
safety.
Figure
1-1.
Safety
Information
SECTION
2-
SPECIFICATIONS
Table
2-1.
Welding
Power
Source
Specifications
Description
Type
Of
Output
Direct
Current/Constant
Voltage
(DC/CV)
Rated
Weld
Output
200
Amperes,
28
Volts
DC,
60%
Duty
Cycle
(See
Section
2-2)
Type
Of
Input
Power
Single-Phase;
60
Hz;
At
200,
230, 460,
Or
575
Volts
AC
Input
Amperes
At
Rated
Output
46
A
At
200
V,
40
AAt
230
V
Maximum
Input
Amperes
While
Idling
1.2
A
At
200
V,
1
A
At
230
V
KVA/KW
Used
At
Rated
Output
9.5
kVA/8.3
kW
Maximum
KVAIKW
Used
While
Idling
0.24
kVAIO.17
kW
Max.
Open-Circuit
Voltage
42
Volts
DC
Control
Circuit
Voltage
At
Gun
24
Volts
DC
Welding
Processes
Gas
Metal
Arc
(GMAW)
And
Flux
Cored
Arc
Welding
(FCAW)
Calculated
Speed
Range
At
No
Load
128
To
1051
ipm
(3.2
To
266.9
mpm)
Wire
Diameter
Range
.030
To
.045
in
(0.8
To
1.1
mm)
Flux
Cored
Wire,
.023
To
.045
in
(0.6
To
1.1
mm)
Hard
Wire
Overall
Dimensions
Length:
37
in
(940
mm);
Width:
19
in
(483mm);
Height:
30-1/4
in
(768
mm)
Weight
Net:
225
lb
(102
kg);
Ship:
271
lb
(123
kg)
Welding
Gun
Rated
Output
(Air
Cooled)
200
Amperes
At
60%
Duty
Cycle
Using
CO2
Shielding
Gas
(See
Section
2-2)
Cable
Length
15
ft
(4.5
m)
OM-154
501
Page
1
3-1.
Installing
Work
Clamp
Figure
3-1.
Installing
Work
Clamp
SECTION
3-INSTALLATION
5
1
Work
Cable
2
Boot
Slide
boot
onto
work
cable.
Route
cable
out
front
panel
opening
from
inside.
3
Negative
()
Output
Terminal
Connect
cable
to
terminal
and
cov
er
connection
with
boot.
4
Hardware
5
Work
Clamp
Route
cable
through
clamp
handle
and
secure
to
top
of
clamp
with
hardware.
Close
door.
Tools
Needed:
-~
1/2,3/4
in
Ref.
ST-154
630-A
3
OM-154
501
Page
3
3-2.
Installing
Gas
Supply
£~
WARNING
CYLINDERS
can
explode
if
damaged.
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
Never
touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
I
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
j
Shut
off
shielding
gas
supply
when
not
in
use.
wam4.1
9191
1
Cylinder
Bracket
2
S-Hook
Crimp
between
smaff
hole
in
brack
et
and
chain.
3
Chain
4
Snap
2
Crimp
onto
open
end
of
chain.
Obtain
gas
cylinder
and
chain
to
running
gear.
5
Cap
6
Cylinder
Valve
Remove
cap,
stand
to
side
of
valve,
and
open
valve
slightly.
Gas
flow
blows
dust
and
dirt
from
valve.
Close
valve.
7
Cylinder
8
Regulator/Flowmeter
Install
so
face
is
vertical.
9
Gas
Hose
Connection
Fitting
has
5/8-18
right-hand
threads.
Obtain
and
install
gas
hose.
10
Flow
Adjust
Typical
flow
rate
is
20
cfh
(cubic
feet
per
hour).
Check
wire
man
ufacturers
recommended
flow
rate.
Make
sure
flow
adjust
is
closed
when
opening
cylinder
to
avoid
damage
to
the
flowmeter.
11
CO2
Adapter
12
0-Ring
Install
adapter
with
0-ring
between
regulator/flowmeter
and
CO2
cylinder.
Tools
Needed:
~
5/8,1-1/8in
Figure
3-2.
Typical
Regulator/Flowmeter
Installation
ssb3.2
5/94
ST.154
623/
Ref.
ST-149
827-B!
Ref.
ST-158
697-A
OM-154
501
Page
4
3-3.
Gun
Polarity
Connections
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Oft
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Shown
As
Shipped
Set
For
Electrode
Positive
(DCEP)
For
Solid
Steel
Or
Aluminum
Wires
(GMAW
Process).
Wire
Drive
Assembly
Lead
To
Positive
(+)
Output
Terminal
swami
.1
1
Polarity
Changeover
Label
2
Wire
Drive
Assembly
3
Positive
(+)
Output
Terminal
4
Negative
()
Output
Terminal
Always
read
and
follow
wire
man
ufacturers
recommended
polarity.
5
Circuit
Breaker
CB1
(see
Section
5-2).
6
Pilot
Light
(see
Section
5-2)
Close
door.
Work
Clamp
Lead
To
Negative
()
Output
Terminal
GUN
POLARITY
CHANGEOVER
CONNECTIONS
Reverse
Lead
Connections
For
Electrode
Negative
(DC
EN)
For
Flux
Cored
Wires
(FCAW
Process).
Drive
Assembly
Becomes
Negative
S.144
44g.C
Figure
3-3.
Gun
Polarity
Connections
Tools
Needed:
~
3/4,11/l6in
Ref.
ST-SOt
102
3-4.
Installing
Drive
Rolls
And
Welding
Gun
5
1
Pressure
Adjustment
2
Pressure
Assembly
3
Drive
Roll
4
Securing
Screw
Install
correct
drive
roll
for
wire
size
and
type
using
supplied
screws.
5
Wire
Drive
Assembly
6
Gun
Securing
Knob
7
Gun
End
Loosen
securing
knob.
Insert
gun
end
through
opening
until
it
bot
toms
against
drive
assembly.
Tighten
knob.
8
Gun
Trigger
Plug
Insert
into
receptacle,
and
tighten
threaded
collar.
Close
pressure
assembly.
Close
door.
ST- 154
621
I
Ref.
ST-SOt
101
Tools
Needed:
6
Figure
3-4.
Gun
Connections
OM-154
501
Page
5
3-5.
Connecting
Input
Power
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Have
only
qualified
persons
install
unit.
Installation
must
meet
National
Electrical
Code
and
all
other
codes.
Tools
Needed:
200
VOLTS
230
VOLTS
1o~~
S-153
980
Look
at
jumper
links
and
compare
link
position
with
applicable
label.
2
Screw
3
Access
Door
To
change
link
position,
remove
screw
and
pivot
door
up.
4
Input
Voltage
Jumper
Links
Location
Move
links
to
match
input
voltage.
For
example,
use
200
volts
posi
tion
when
200
volts
input
power
is
available.
Close
door
and
secure
with
screw.
Close
side
door.
~3
3/B
in
Ssb5.V
2/92
/
Ref.
ST-801
099
/
Ret.
ST.801
100
Figure
3-5.
Input
Voltage
Jumper
Links
Location
A.
Positioning
Jumper
Links
swarn3.1
2/93
Jumper
links
allow
operation
on
different
input
voltages
and
are
factory
set
for
the
highest
input
voltage.
Check
input
voltage
available
at
site.
1
Input
Voltage
Label
1
OM-154
501
Page
6
B.
Connecting
Input
Power
Table
3-1.
Electrical
Service
Requirements*
Have
only
qualified
persons
make
this
installation.
1
Line
Disconnect
Device
Of
Proper
Rating
2
230
Volts
AC
Wall
Receptacle
3
Input
Conductors
4
Grounding
Conductor
Select
size
and
length
using
Table
3-1.
Conductor
rating
must
comply
with
national,
state,
and
local
electrical
codes.
Install
and
connect
grounding
conductor
and
input
conductors
in
conduit
or
equivalent
between
wall
receptacle
and
deenergized
line
disconnect
device.
Connect
grounding
conductor
first,
then
line
input
conductors.
Be
sure
grounding
conductor
goes
to
an
earth
giound.
5
Overcurrent
Protection
Select
type
and
size
using
Table
3-1.
Install
into
deenergized
line
disconnect
device
(fused
dis
connect
switch
shown).
6
Input
Power
Plug
Turn
oft
unit
Power
switch,
and
connect
plug
to
wall
receptacle.
ssb2.2
12/94
Ref.
ST-154
619-B
/
Ret.
ST-149
405-B
Input
Votage
200
230
460
575
input
Amperes
At
Rated
Output
46
40
20
16
Max
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
in
Amperes
70 60 30
25
Mm
input
Conductor
Size
In
AWGIKcm1I
8 8
12
14
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)
89
(27)
117
(36)
188
(57)
190(58)
Mm
Grounding
Conductor
Size
in
AWGIKcm1I
8 10 12
14
Reference:
1993
National
Electrical
Code
(NEC).
S-0092J
5
3
Tools
Needed:
Figure
3-6.
Input
Power
Connections
OM-154
501
Page
7
3-6.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
Figure
3-7.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
3-7.
Threading
And
Feeding
Welding
Wire
4A
WARNING
CYLINDERS
can
explode
if
damaged.
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
Never
touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
welding
or
feeding
wire
using
gun
trigger.
WELDING
WIRE
can
cause
puncture
wounds.
Do
not
press
gun
trigger
until
instructed
to
do
so.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
HOT
SURFACES
can
burn
skin.
Allow
gun
to
cool
before
touching.
swom5.1
10/91
/swam2.1
9/91
Turn
Off
unit.
1
Wire
Spool
2
Gun
Contact
Tip
If
necessary,
cut
welding
wire
off
at
contact
tip,
and
retract
wire
onto
spool
and
secure.
3
Retaining
Ring
4
Compression
Spring
Remove
ring
and
pull
off
spool.
Compression
spring
Is
used
with
8
in
(200
mm)
spools.
5
Hub
6
Hub
Pin
Slide
spool
onto
hub
so
wire
feeds
off
bottom.
Turn
spool
until
hub
pin
fits
hole
in
back
of
spool.
Reinstall
retaining
ring.
7
Hub
Tension
Nut
Grasp
spool
in
one
hand
and
turn
while
using
a
wrench
to
adjust
hub
tension
nut.
When
a
slight
force
is
needed
to
turn
spool,
tension
is
set.
Thread
welding
wire
(see
S~ection
3-7).
Close
door.
Tools
Needed:
~
15/16
in
Rel.
ST-801
099
/
Ref.
ST-072
573-B
£9
OM-154
501
Page
8
1
Wire
Spool
2
Welding
Wire
3
Inlet
Wire
Guide
4
Pressure
Adjustment
Knob
5
Pressure
Assembly
6
Drive
Roll
7
Outlet
Wire
Guide
8
Gun
Conduit
Cable
Lay
gun
cable
out
straight.
(
0o~
-
Push
wire
thru
guides
into
gun;
continue
to
hold
wire.
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
Remove
gun
nozzle
and
contact
tip.
POWER
Q0FF
I
I
Set
switch.
/
Press
gun
trigger
until
wire
comes
out
of
gun.
Reinstall
contact
tip
and
nozzle.
5T-801
103
/
51-154
251
/
5-0627-A
Figure
3-8.
Threading
And
Feeding
Welding
Wire
2
3 6
7
Hold
wire
tightly
to
keep
it
from
unraveling.
(
Open
pressure
assembly.
Pull
and
hold
wire;
cut
offend.
I
LI
Feed
wire
to
check
drive
roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
~1
Cut
off
wire.
Close
and
latch
door.
OM-154
501
Page
9
SECTION
4-
OPERATION
ƈ
WARNING
ELECTRIC
SHOCK
can
kill.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
Do
not
touch
live
electrical
parts.
Keep
all
panels
and
covers
securely
in
place
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
area,
or
use
breathing
device.
Read
Material
Safety
Data
Sheets
(MSDS5)
and
manufacturers
instructions
for
material
used.
WELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
Do
not
weld
on
closed
containers.
Allow
work
and
equipment
to
cool
before
handling
ARCING
can
damage
switch.
Do
not
change
Voltage
switch
position
while
welding.
Arcing
inside
switch
can
damage
contacts,
causing
switch
to
tail.
/
~
.~
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
welding
helmet
with
correct
shade
of
filter.
Wear
correct
eye,
ear,
and
body
protection.
,..~
~
0
MOVING
PARTS
can
cause
Injury.
Keep
away
from
pinch
points
such
as
drive
rolls.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
~
~
MAGNETIC
FIELDS
FROM
HIGH
CUR
RENTS
can
affect
pacemaker
operation.
Pacemaker
wearers
keep
away.
S
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
opera
tions.
WELDING
CURRENT
can
damage
elec
tronic
parts
in
vehicles.
Disconnect
both
battery
cables
before
welding
on
a
vehicle.
Place
work
clamp
as
close
to
the
weld
as
possible.
See
Safety
Precautions
at
beginning
of
manual
for
ba
sic
welding
safety
information.
Gwam6.2
8/92
Wear
the
following
while
welding:
2
3
/
1
Dry,
Insulating
Gloves
2
Safety
Glasses
With Side
Shields
3
Weldi~g
Helmet
With
Correct
Shade
Of
Filter
(See
ANSI
Z49.1)
sb3.1
1/94
Figure
4-1.
Safety
Equipment
1
Wire
Mode
Switch
For
better
control
of
wire
speed
use
Low
position
when
wire
speed
is
between
90
and 670
ipm.
Use
Full
position
when
wire
speed
is
be
tween
150
ipm
and
1030
1pm.
2
Voltage
Range
Selector
Place
switch
in
desired
position.
See
inside
rear
cover
for
settings.
Ret.
ST-801
102
/
S-ill
601
Figure
4-2.
Center
Baffle
Controls
OM-154
501
Page
10
Tools
Needed:
1
Wire
Speed
Control
Use
control
to
set
wire
feed
speed.
2
Voltage
Control
Use
control
and
Voltage
Range
Selector
(see
Figure
4-2)
to
set
arc
voftage.
Step
6
of
Low
range
and
Step
1
of
High
range
overlap.
3
Pilot
Light
4
Power
Switch
Use
switch
to
turn
unit
On
and
Off.
The
pilot
light
comes
on
when
unit
is
tumed
on.
5
Work
Clamp
Use
wire
brush
or
sandpaper
to
clean metal
at
weld
joint
area.
Connect
work
clamp
to
clean,
paint-free
location
on
workpiece,
as
close
as
possible
to
weld
area.
Ref.
ST.154
622-8
I
ST-171
639
/
Ref.
ST-154
251
Figure
4-3.
Controls
OM-154
501
Page
11
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling period
before
maintaining
or
servicing.
~
M
OVING
PARTS
can
cause
Injury.
Keep
away
from
moving
parts.
4f
Keep
away
from
pinch
points
such
as
drive
rolls.
5-1.
Routine
Maintenance
Maintenance
and
troubleshooting
to
be
performed
only
by
qualified
persons.
swarn8.2
2/93
Turn
Off
all
power
before
maIntaining.
-~
3
Months
WARNI
~
Replace
Unreadable
Labels
_______
Tighten
/
Clean
And
Weld
3-1
Terminals
Replace
\
Cracked
-
Parts
Gas
Hose
14-Pin
Cord
Gun
Cable
Figure
5-1.
Maintenance
Schedule
OM-154
501
Page
12
5-2.
Overload
Protection
a
WARNING
A.
Circuit
Breaker
CB1
B.
Fuses
Fl
And
F2
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
L
2
1
1
Circuit
Breaker
CB1
2
Pilot
Light
If
CB1
opens,
pilot
light
goes
out,
and
wire
feed
stops.
Check
gun
lin
er
for
blockage
or
kinks,
and
check
for
jammed
wire,
binding
drive
gear,
or
misaligned
drive
rolls.
Al
low
a
cooling
period
before
reset
ting
CB1.
Ref.
ST-801
102
Figure
5-2.
Circuit
Breaker
CB1
Tum
Off
unit
and
disconnect
input
power.
1
Fuse
Fl
(See
Parts
List
For
Rating)
Fl
protects
the
115
volts
ac
wind
ing
of
transformer
Ti.
If
Fl
opens,
all
weld
output
stops
and
pilot light
PL1
goes
out.
2
Fuse
F2
(See
Parts
List
For
Rating)
F2
protects
the
24
volts
ac
winding
of
transformer
Ti.
If
F2
opens,
all
weld
output
stops.
Ref.
ST-800
928-B
C.
Overheating
Figure
5-3.
Fuse
Location
Figure
5-4.
Overheating
OM-154
501
Page
13
5-3.
Wire
Drive
Assembly
Maintenance
a
WARNING
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
Figure
5-5.
Wire
Drive
Assembly
Maintenance
Turn
Off
unit
and
disconnect
input
power.
Ret.
ST-801
099
I
SA-145
763
/
ST-154
633
1
1
Wire
Spool
2
Gun
Contact
Tip
Cut
welding
wire
off
at
contact
tip.
Retract
wire
onto
spool
and
Se-
cure.
3
Drive
Roll
Alignment
Bolt
Turn
in
or
out
until
groove
lines
up
with
wire
guide.
4
Drive
Roll
5
Wire
Inlet
Guide
Remove
guide
by
pressing
on
barbed
area
or
cutting
off
one
end
near
housing
and
pulling
It
out
of
hole.
Push
new
guide
Into
hole
from
rear
until
it
snaps
in
place.
6
Pressure
Roll
Arm
7
Cotter
Pin
8
Pin
9
Screw
10
Bearing
Remove
bearing
as
shown.
Install
new
bearing
and
secure
with
screw.
Reinstall
arm
onto
pin
and
secure
with
cotter
pin.
Thread
welding
wire
(see
Section
3-7).
Close
door.
Tools
Needed:
OM-154
501
Page
14
5-4.
Gun
Maintenance
Figure
5-6.
Gun
Maintenance
Turn
Off
unit
and
disconnect
input
power.
I
Wire
Spool
Cut
welding
wire
oft
at
contact
tip.
Retract
wire
onto
spool
and
se
cure.
2
Gun
Securing
Knob
Loosen
knob
and
remove
gun
and
trigger
plug.
Reassemble
gun.
To
Reassemble
Gun:
Install
contact
tip.
Insert
new
liner.
Install
collet
onto
liner
and
tighten
into
gun/feeder
connector
using
wrench.
Cut
liner
oft
near
collet
so
that
liner
end
is
as
close
to
drive
rolls
as
pos
sible
without
touching.
Tools
Needed:
~==r
3/8
in
Ret.
ST-8O1
101
/
ST-aOl
149
a
WARNING
FLYING
METAL
CHIPS
AND
DIRT
can
cause
injury
and
damage
equipment.
Point
gun
away
from
people
and
in
a
safe
direction
when
blowing
out
with
compressed
air.
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
swamlO.1
10/91
1
2
7
Install
nozzle.
Reinstall
gun
(see
Section
3-4).
Thread
welding
wire
(see
Section
3-7).
Close
door.
Head
Tube
.~7/;;1~$~
Remove
nozzle,
contact
tip,
and
liner
collet.
\in
/
Remove
liner.
Gun/Feeder
Connector
Blow
out
gun
casing.
OM-154
501
Page
15
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Miller KF869436 Owner's manual

Miller
Brand
Miller
Model
KF869436
Category
Welding System
Type
Owner's manual
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