Miller KB100704 Owner's manual

Miller
Brand
Miller
Model
KB100704
Category
Welding System
Type
Owner's manual

This manual is also suitable for

January
1992
FORM:
OM-151
016
L
Effective
With
Serial
No.
KB1
00704
MODEL:
Auto
Arcfi
140
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,
ormaintain
this
unit.
MILLER
ELECTRIC
Mfg.
Co.
A
MUter
Group
Ltd.,
Company
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
auto_arc
8191
ST-I
49 628
PRINTED
IN
USA
8
ONE
YEAR
LIMITED
WARRANTY
EFFECTIVE:
FEBRUARY
17,
1989
Thiswarranty
supersedes
all
previous
AUTO
ARC
warranties
and
is
exclusive
with
no
other
guarantees
orwarranties
expressed
or
implied.
COVERAGE
MILLER
Electric
Mfg.
Co.
warrants
to
the
for
the
purchase
price
(less
reasonable
depreciation
based
~
buyer
who
purchases
this
AUTO
ARC
Welder
(Welder)
for
upon
actual
use)
upon
return
of
the
goods
at
Consumers
risk
j
personal,
family
or
household
purposes
(Consumer)
that
this
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
I
Welderwillbefreefromdefectsinmaterialandworkmanshipfor
FOB.,
Factory
at
Appleton,
WI
or
F.O.B.
at
a
MILLER
autho
a
period
of
one
year
from
the
date
of
purchase.
This
warranty
rized
service
facility,
therefore,
no
compensation
for
transporta
A
covers
only
the
original
purchaser
of
this
Welder.
MILLER
Elec-
tion
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
()
tric
does
not
authorize
any
party,
including
its
authorized
dis-
apparentdefectorfailure,MlLLERshallinstructtheclaimanton
,~
tributors,
to
offer
any
other
warranty
on
behalf
of
MILLER
Elec-
the
warranty
claim
procedures
to
be
followed.
f\
tric.
Upon
expiration
of
the
warranty
period,
MILLER
Electric
V
shall
have
no
further
liability
related
to
the
Welder,
except
on
THIS
WARRANTY
IS
OFFERED
IN
LIEU
OF
ANY
OTHER
~
warranty
claims
made
during
the
warranty
period.
No
warranty
EXPRESS
WARRANTY;
AND,
EXCEPT
TO
THE
EXTENT
is
made
by
MILLER
with
respect
to
engines,
trade
accessories
PROHIBITED
BY
APPLICABLE
LAW,
THE
DURATION
OF
~
orother
items
manufactured
by
others.
Such
engines,
trade
ac-
ALL
IMPLIED
WARRANTIES,
INCLUDING
BUT
NOT
A
cessories
and
other
items
are
sold
subject
to
the
warranties
of
LIMITED
TO
THE
IMPLIED
WARRANTIES
OF
MERCHAN
~J
their
respective
manufacturers,
if
any.
All
engines
are
war-
TABIL1~Y
AND
FITNESS
FOR
A
PARTICULAR
PURPOSE,
IS
.f~
ranted
by
their
manufacturer
for
two
years
from
date
of
original
LIMITED
TO
THE
DURATION
OF
THIS
WARRANTY.
(~
purchase,
except
Deutz
engines
which
have
a
one
year,
2000
hour
warranty.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
I
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR.
REPRE
MILLER
shall
be
required
to
honor
warranty
claims
on
war-
SENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
j
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
~
within
the
following
periods
from
the
date
of
delivery
of
Equip-
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
~
ment
to
the
original
user:
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
I
Arc
w
Id
rs
w
r r
and
corn
onents
1
r
INCLUDING
ANY
IMPLIED
WARRANTY
OF MERCHANT-
2
On
ml
e
,
p0
e
sauces,
p
yea
ABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE,
(labori
aunpowe
ec
tie
yea
s
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FUR-
I
3.
All
welding
guns,
feeder/guns
and
torches
90
days
NISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
4.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
LLE
5.
Batteries
6
months
Some
states
do
not
allow
limitations
on
how
long
an
implied
provided
that
MILLER
is
notified
in
writing
within
thirty
(30)
days
warranty
lasts,
so
the
above
limitation
may
not
apply
to
you.
of
such
failure.
This
warranty
gives
you
specific
legal
rights,
and
you
may
also
have
other
rights
which
vary
from
state
to
state.
WHAT
IS
NOT
COVERED
This
warranty
does
not
extend
to
any
Welder
subjected
to
misuse,
neglect,
accident,
or
in-
THE
PURCHASERS
REMEDIES
FOR
A
DEFECTIVE
warranty
repair
by
anyone
except
MILLER
Electric
or
its
autho-
WELDER,
TO
THE
EXTENT
PERMITTED
BY
APPLICABLE
rized
service
stations.
Further,
this
warranty
only
extends
to
the
LAW,
ARE
LIMITED
TO
THE
REMEDY
PROVIDED
BY
THIS
original
purchaser
of
this
Welder.
WARRANTY.
TO
THE
EXTENT
ENFORCEABLE
UNDER
APPLICABLE
LAW,
MILLER
ELECTRIC
SHALL
IN
NO
In
the
case
of
MILLERs
breach
of
warranty
or
any
other
duty
EVENT
BE
LIABLE
FOR
CONSEQUENTIAL,
INCIDENTAL
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
OR
SPECIAL
DAMAGES
ARISING
OUT
OF
THE
USE
OF,
OR
therefore
shall
be,
at
MILLERs
option
(1)
repair
or
(2)
replace-
INABILITY
TO
USE,
THE
WELDER,
WHETHER
BASED
ON
ment
or,
where
authorized
in
writing
by
MILLER
in
appropriate
BREACH
OF
THIS
WARRANTY,
MILLER
ELECTRICS
NEG
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
LIGENCE
OR
OTHER
TORT,
OR
ON
ANY
THEORY
OF
authorized
MILLER
service
station
or
(4)
payment
of
or
credit
STRICT
LIABILITY.
~
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_____________________________________________________
Serial
or
Style
No.
_________________________________________
Date
of
Purchase
_________________________________________
auto_arc
8/91
ERRATA
SHEET
January
19,
1993
FORM:
OM-151
016
Use
above
FORM
number
when
ordering
extra
manuals.
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
Figure
3-7.
Installing
Safety
Chain
CHANGES
TO
SECTION
8
PARTS
LIST
Change
Parts
List
as
follows:
Dia.
Part
Replaced
Mkgs.
No.
With
Description
Quantity
.25-19
.
.
PCi
...
137800..
+157
044
.
25-24
.
.
SR2
...
147535..
.
155056
TP1
155054
026701
.
25-25
147571
. .
.
147571
.
25-27
. .
PLG1
..
088297..
.152118
.
25-36
147578..
.
152872
.
25-37
087
341
. . .
Deleted
. .
26-
.
Added..
.
156339
. .
26-
.
Added..
.
147893
. .
26-
.
Added..
.090693
.
.
26-
Added..
.
109318
.
.
26-
Added..
.602250
. .
26-
Added
.
.
.
121
614
.
.
26-
Added
. .
.
602 384
.
.
26-
Added..
.602389
.
.
26-
Added..
.
156340
CIRCUIT
CARD,
motor
speed
control
(Eff
w/KD352528)
..
1
RECTIFIER,
si
diode
(consisting
of)
1
THERMOSTAT,
NC
1
INSULATION,
thermostat
1
HANDLE,
(qty
chg)
(Eff
w/KC229027)
1
CORD
SET,
250V
6-50P
l2ga
3/c
l2ft
(Eff
w/KC213453)
..
1
BASE,
(Eff
w/KC229027)
1
Eff
w/KC229027
RETAINER,
bottle
(Eff
w/KC229027)
1
AXLE,
running
gear
(Eff
w/KC229027)
1
WHEEL,
rubolene
spoke
8
in
x
2.000
wide
x
.760
bore
(Eff
w/KC229027)
2
CASTER,
swvl
cushionex
2.500
x
.812
x
.312-18
x
1.000
(Eff
w/KC229027)
2
WASHER,
flat
stl
SAE
.750
(Eff
w/KC229027)
4
RING,
retaining
ext
.750
shaft
x
.O85grv
depth
(Eff
w/KC229027)
2
SNAP,
chain
(Eff
w/KC229027)
1
HOOK,
S
blunt
1.500
in
(Eff
w/KC229027)
1
CHAIN,
weldless
2/0
x
11.000
(Eff
w/KC229027)
1
**First
digit
represents
page
no
digits
following
dash
represent
item
no.
+AlI
components
remain
the
same
with
listed
exceptions.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
.3
IMPORTANT:
Effective
with
Serial
No.
KC229027,
running
gear
is
standard
on
units
from
the
factoiy.
CHANGES
TO
SECTION
3
INSTALLATION
Add
Section
3-7.
Installing
Safety
Chain
1
cylinder
Bracket
2
S-Hook
crimp
between
small
hole
in
bracket
and
chain.
3
chain
4
Snap
crimp
onto
open
end
of
chain.
4
Tools
Needed:
Ref.
ST.149
255A
ARC
WELDING
SAFETY
PRECAUTIONS
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
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
Do
not
touch
live
electrical
parts.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
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.
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.
Do
not
wrap
cables
around
your
body.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
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.
a
WARNING
ARC
WELDING
can
be
hazardous.
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.
1.
2.
3.
6.
7.
8.
9.
10.
/)
~
ARC
RAYS
can
burn
eyes
and
skin;
1.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
(see
NOISE
can
damage
hearing.
ANSIZ49.1
IistedinSafetyStandards)toprotectyourfaceand
eyes
when
welding
or
watching.
Arc
rays
from
the
welding
process
produce
intense
2.
Wear
approved
safety
glasses.
Side
shields
recommended.
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
3.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
skin.
Noise
from
some
processes
can
damage
and
glare;
warn
others
not
to
watch
the
arc.
hearing.
4.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Use
approved
ear
plugs
or
ear
muffs
it
noise
level
is
high.
T
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
Weldingproducesfumesandgases.
Breathingthese
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
fumes
and
gases
can
be
hazardous
to
your
health.
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
1.
Keep
your
head
out
of
the
fumes.
Do
not
breath
the
fumes.
form
highly
toxic
and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
Il
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
(MSDS5)
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
off
from
the
welding
arc.
The
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
flying
sparks
and
hot
metal,
weld
spatter,
hot
can
cause
fire
on
the
hidden
side.
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
or
welding
wire
7.
Do
not
weld
on
closed
containers
such
as
tanks
or
drums.
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
8.
Connect
work
cable
to
the
work
as
close
to
the
welding
area as
practical
to
prevent
welding
current
from
traveling
long,
possibly
1.
Protect
yourself
and
others
from
flying
sparks
and
hot metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
9.
unknown
paths
and
causing
electric
shock
and
fire
hazards.
Do
not
use
welder
to
thaw
frozen
pipes.
3.
Removeallflammableswithin35ft(10.7m)oftheweldingarc.lt
this
is
not
possible,
tightly
cover
them
with
approved
covers,
10.
Remove
stick
electrode
from
holder
or
cutoff
welding
wire
at
contact
tip
when
not
in
use.
4.
Be
alert
that
welding
sparks
and
hot materials
from
welding
can
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
>~
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury,
Chipping
and
grinding
cause
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
1.
2.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
recommended.
Wear
proper
body
protection
to
protect
skin.
srI
11/91
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
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.
6.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
ENGINE
FUEL
can
cause
fire
or
1.
Stop
engine
before
checking
or
adding
fuel.
explosion.
2.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
open
flames.
3.
Allow
engine
to
cool
before
fueling.
If
possible,
check
and add
Engine
fuel
is
highly
flammable.
fuel
to
cold
engine
before
beginning
job.
4.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
5.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
starting
encilne.
MOVING
PARTS
can
cause
injury.
3.
Have
only
qualified
people
remove
guards
or
covers
for
maintenance
and
troubleshooting
as
necessary.
SPARKS
can
cause
BATTERY
GASES
TO
EXPLODE;
BATTERY
ACID
can
burn
eyes
and
skin,
1.
2.
Always
wear
a
face
shield
when
working
on
a
battery.
Stop
engine
before
disconnecting
or
connecting
battery
cables.
Batteries
contain
acid
and
generate
explosive
gases.
3.
4.
5.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
Observe
correct
polarity
(+
and
)
on
batteries.
PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superinten
dent
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,
Ameri
can
Welding
Society
Standard
AWS
F4.1,from
American
Welding
So
ciety.
550
N.W.
LeJeune
Ad,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-I,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
High
way,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Bou
levard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
For
Occupation
And
Educational
EyeAnd
Face
Protec
tion,
ANSI
Standard
Z87.1,
from
American
National
Standards
Insti
tute,
1430
Broadway,
New
York,
NY
10018.
Cuffing
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
a
WARNING
ENGINE
EXHAUST
GASES
can
kill.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
Engines
produce
harmful
exhaust
gases.
away
from
any
building
air
intakes.
ENGINES
can
be
hazardous.
Moving
parts,
such
as
fans,
rotors,
and
belts
can
cut
fingers
and
hands
and
catch loose
clothing.
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
2.
Stop
en
ne
before
installing
or
connecting
unit.
4.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
5.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
parts.
6.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
finished
and
before
starting
engine.
~4
~
~-.
~f
~
(-
STEAM
AND
COOLANT
can
skIn.
The
coolant
in
the
r
under
pressure.
PRESSURIZED
burn
face,
eyes,
adiator
can
be
very
h
HOT
and
ot
and
1.
2.
3.
Do
not
remove
radiator
cap
when
engine
is
hot.
Allow
engine
to
cool.
Wear
gloves
and
put
a
rag
over
cap
area
when
removing
cap.
Allow
pressure
to
escape
before
completely
removing
cap.
sri
11/91
OM-151
016
2/92
TABLE
OF
CONTENTS
SECTION
1
SAFETY
SIGNAL
WORDS
.
1
SECTION
2
SPECIFICATIONS
2-1.
Volt-Ampere
Curves
2
2-2.
Duty
Cycle
2
SECTION
3
INSTALLATION
3-1.
Installing
Work
Clamp
3
3-2.
Gun
Polarity
For
Wire
Type
3
3-3.
Selecting
A
Location
And
Connecting
Input
Power
3
3-4.
Threading
Welding
Wire
5
3-5.
Feeding
Welding
Wire
5
3-6.
Installing
Gas
Supply
6
SECTION
4
OPERATION
6
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
10
5-2.
Overload
Protection
10
5-3.
Cleaning
Or
Replacing
Drive
Roll
And
Replacing
Wire
Inlet
Guide
11
5-4.
Replacing
Pressure
Bearing
12
5-5.
Adjusting
Hub
Tension
12
5-6.
Installing
Wire
Spool
13
5-7.
Troubleshooting
13
SECTION
6
ELECTRICAL
DIAGRAMS
15
SECTION
7
WELDING
METHODS
&
TROUBLESHOOTING
7-1.
Flux
Cored
Arc
Welding
(FCAW)
And
Gas
Metal
Arc
Welding
(GMAW)
17
7-2.
Welding
Troubleshooting
19
SECTION
8
PARTS
LIST
Figure
8-1.
Main
Assembly
24
Figure
8-2.
Drive
Assembly,
Wire
27
SECTION
1
SAFETY
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
identify
different
levels
of
hazard
and
special
instructions.
a
WARNING
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
serious
personal
injury
or
loss
of
life.
a
CAUTION
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
~
IMPORTANT:
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equipment.
SECTION
2SPECIFICATIONS
Table
2-1.
Welding
Power
Source
Specifications
Description
Type
Of
Output
Rated
Weld
Output
Type
Of
Input
Input
Amperes
At
Rated
Output
KVA
Used
At
Rated
Output
KW
Used
At
Rated
Output
Max.
Open-Circuit
Voltage
Control
Circuit
Voltage
At
Gun
Welding
Processes
Constant
Voltage
(CV)
Direct
Current
(DC)
120
Amperes,
21
Volts
DC,
30%
Duty
Cycle
(see
Section
2-2)
Single-Phase
230
Volts
AC,
60
Hertz
20
Amperes
4.7
kVA
3.9
kW
32
Volts
DC
24
Volts
DC
Wire
Feed
Speed
Range
Wire Diameter
Range
Input
Power
Cord
With
Plug
Overall
Dimensions
Weight
Gas
Metal
Arc
Welding
(GMAW)
(Uses
Solid
Or
Aluminum
Wire
And
External
Shielding
Gas)
Flux
Cored
Arc
Welding
(FCAW)
(Uses
Wire
With
Flux
Inside
And
Requires
No
External
Shielding
Gas)
47
To
690
pm
(1.2
To
17.5
mpm)
.023
To
.035
in.
(0.58
To
0.89
mm)
5
ft.
(1.5
m)
Length:
27
in.
(686
mm),
Width:
12
in.
(305
mm),
Height:
22-1/2
in.
(571
mm)
Shipping
117
lbs.
(53
kg);
Net
117
lbs.
(50
kg)
OM-151
016
Page
1
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
Figure
2-2.
Welding
Power
Source
Duty
Cycle
Chart
SECTION
3INSTALLATION
Table
3-1.
Items
Included
With
Welding
Power
Source
Item
Quantity
Welding
Gun
Shipped
Set
To
Feed
.030
in.
(0.8
mm)
Wire
(See
Gun
Owners
Manual
Form
112
934)
1
lOft.
(3m)
Work
Cable
And
Clamp
1
4ft.
(1.2
m)
Air
Hose
1
Contact
Tubes
(2
.030
in.,
3
.023
in.,
And
3
.035
in.)
8
Monocoil
Liner
For
.023
Thru
.030
in.
Wire
1
Figure
2-1.
Volt-Ampere
Curves
200
50
U,
uJ
0.
100
go
80
70
60
50
Duty
cycle
is
how
long
the
unit
or
gun
can
operate
within
a
ten
minute
period
without
causing
overheating
or
damage.
This
welding
power
source
is
rated
at
30%
duty
cycle
allowing
welding
3
minutes
out
of
every
10 minutes.
SB.124
624
.5
20
25
30
40
50
DUTY
CYCLE
Z
60
70
80
90
100
OM-151
016
Page
2
3-1.
Installing
Work
Clamp
3-2.
Gun
Polarity
For
Wire
Type
a
WARNING
Tools
Needed:
3/8in.
a
WARNING
Figure
3-1.
Work
Clamp
Installation
E
LECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
OFF
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
swarnl.1
9/91
1
Polarity
Changeover
Label
2
Polarity
Jumper
Links
Always
read
and
follow
wire
man
ufacturers
recommended
polarity.
Close
door.
2
Fi
gure
3-2.
Gun
P
olarity
Jump
er
Link
Position
3-3.
Selecting
A
Location
And
Connecting
Input
Power
Ret.
5T-149631.A
~
.~
E
S
LECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
1-lave
only
qualified
persons
install
unit.
Installation
must
meet
National
Electrical
Code
and
I
all
other
codes.
overheating
and
possible
damage
to
unit.
BLOCKED
AIRFLOW
causes
.
Do
not
block
or
filter
airflow
Warranty
is
void
if
any
type
of
filter
is
used.
OM-151
016
Page3
Figure
3-3.
Location
And
Input
Power
Connections
Table
3-2.
Electrical
Service
Requirements
230
(Amps)
20
Ia
(Amps)
lb
31
thru
41
(Amps)
30
Cop
(AWG
Or
Kcmil)
14
(feet)
(meters)
65
20
Fuse)
(AWG
Or
Kcmil)
14
These
calculations
of
Electric
Service
Requirements
are
based
on
the
1990
Edition
of
the
National
Elec
trical
Code
(NEC).
NEC
is
re-issued
every
3
years,
check
latest
edition
and
update
these
calculations,
if
required.
See
the
following
footnotes
for
specific
conductor
types,
temperatures,
exceptions,
and
etc.
I
(a)
150%
of
line
current,
1990
NEC
Article
630-12-a,
(bI
200%,
(C)
standard
fuse
size
nearest
150%
of
rating
label
line
current.
2
1990
NEC
Table
310-16-75-Cu.
with
+
note.
~
Maximum
input
conductor
length
is
based
on
not
more
than
a
3%
voltage
drop
from
the
service
entrance
panel
to
the
input
of
the
welding
unit,
Articles
210.19(a)
and
215-2(b)
of
NEC.
Ground
conductor
size
determined
by
Article
250-95
of
NEC
exception
No.
2,
ground
conductor
is
not
required
to
be
larger
than
line
conductor
and
Table
250-95-Copper.
S-0092-A
1
18
in.
(457
mm)
Open
Space
At
Front
And
Rear
2
Rating
Label
Supply
correct
input
power.
3
230
Volts
AC
Wall
Receptacle
4
Input
Conductors
Select
size
and
length
using
Table
3-2.
5
Line
Disconnect
Switch
Obtain
and
install
switch
and
wall
receptacle.
6
Grounding
Conductor
Select
size
and
length
using
Table
3-2.
Be
sure
grounding
con
ductor
goes
to
an
earth
ground.
Install
input
conductors
and
grounding
conductor
between
wall
receptacle
and
deenergized
line
disconnect
switch.
7
Line
Fuses
Select
fuses
or
circuit
breakers
using
Table
3-2.
Install
into
deenergized
line
disconnect
switch.
Connect
deenergized
supply
conductors
to
line
disconnect
switch.
8
Input
Power
Plug
Turn
OFF
unit
POWER
switch,
and
connect
plug
to
wall
receptacle.
Place
line
disconnect
switch
in
ON
position
before
using
welding
power
source.
ssb21
10/91
ST-149
630
OM-151
016
Page
4
3-4.
Threading
Welding
Wire
a
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.
3-5.
Feeding
Welding
Wire
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.
swarn2.4
9/91
I
Wire
Spool
Loosen
wire
from
spool,
cutoff
bent
wire,
and
pull
6
in.
(150mm)
of
wire
off
spool.
2
Wire
Inlet
Guide
3
Drive
Roll
4
Wire
Outlet
Guide
Thread
wire
through
wire
inlet
guide.
along
drive
roll,
and
into
wire
outlet
guide.
Be
sure
wire
is
in
correct
groove.
5
Pressure
Adjustment
Knob
And
Arm
Close
and
secure
pressure
roll
assembly.
Close
door.
Ret.
ST-150
193-A
/
Ref.
ST.149
632A
3
4
Tools
Needed:
Figure
3-4.
Threading
Welding
Wire
a
CAUTION
WELDING
WIRE
can
cause
puncture
HOT
SURF
ACES
can
burn
skin.
wounds.
Allow
gun
to
cool
before
touching.
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.
i~))l~(,,,fft,
swarn2.1
9/91
4
La
1
y
gun
cable
Out
straight.
Nozzle
5
3
Tools
Needed:
2
Contact
Tube
Remove
nozzle
and
contact
tube.
3
Gun
Trigger
Turn
ON
unit
and
feed
2
in.
(55
mm)
of
wire
out
of
gun.
Turn
OFF
unit
and
reinstall
contact
tube
and
nozzle.
4
Adjusting
Pressure
Turn
ON
unit
and
check
drive
roll
pressure
by
feeding
wire
against
a
wood
board
or
concrete
surface;
wire
should
feed
steadily
without
slipping.
5
Pressure
Knob
Tighten
pressure
knob
if
necessary.
1
Close
door.
Pet.
ST-151
288/S~O827-A
Figure
3-5.
Feeding
Welding
Wire
OM-151
016
Page
5
1
Fine
Tuning/Wire
Speed
Con
trol
1
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
3
Welding
Helmet
Wear
dry
insulating
gloves,
safety
glasses
with
side
shields,
and
a
welding
helmet
with
a
correct
shade
of
filter
(see
ANSI
Z49.1).
Figure
4-2.
Safety
Equipment
.
1
Work
Cable
I
2
~__
~
Tools
Needed
~
2
Work
Clamp
Use
wire
brush
or
sandpaper
to
clean
metal
at
weld
joint
area.
Connect
work
clamp
to
a
clean.
paint-free
location
on
workpiece.
as
close
to
weld
area
as
possible.
Ref.
ST-149
359
Figure
4-3.
Work
Clamp
.
1
Fine
Tuning/Wire
Speed
Control
Use
this
Control
to
select
a
wire
feed
speed.
As
THICKNESSVOLTAGE
switch
(Figure
4.5)
setting
increases,
wire
speed
range
also
increases.
The
numbers
around
the
control
are
not
a
wire
feed
speed
and
are
for
reference
only
(see
Table
4-1).
,~
i
60
~
,~
10
FiNE
TUNING
010
WIRE
SPEE
\~__________________
2
ThicknessNoltage
Switch
2
3
Power
Switch
3
>
ST-150
192
Figure
4-1.
Controls
Figure
4-4.
Wire
Speed
Control
OM-151
016
Page
7
a
CAUTION
ARCING
can
damage
switch.
Do
not
change
THICKNESSNOLTAGE
switch
position
while
welding.
Arcing
inside
switch
can
damage
contacts,
causing
switch
to
fail.
warn51
9/91
I
DO
NOT
SWITCH
2
UNDER
LOAD
,~J
~
3
THICKNESS
V
VOLTAGE
)___
1
1
ThicknessNoltage
Switch
Use
this
switch
to
select
an
arc
number,
the
thicker
the
material
that
can
be
welded
(see
Table
4-1).
voltage.
The
higher
the
selected
Figure
4-5.
Voltage
Switch
Figure
4-6.
Power
Switch
a
WARNING
3
Install
&
Put
On
Turn
On
\~\
Do
~~~Readjust
Contro~?\
Connect
J J
Personal
Safety
)
)Equipment
&
Gas
) j
Set
Controls
) )
Sample
Weld
) )
And
Prepare
J
Equipment
JJ
Equipment
JJ
(lfApplicable)7j
~/J
ForProduction
Figure
4-8.
Sequence
Of
Operation
BUILDUP
OF
SHIELDING
GAS
can
harm
health
S
Shut
off
shielding
gas
supply
when
not
in
use.
or
kill.
warnl
1
9/91
1
Shielding
Gas
Cylinder
2
Valve
3
Gun
Trigger
Open
valve
on
cylinder
just
before
welding.
Purge
air
from
gas
line
by
pressing
gun
trigger.
Close
valve
on
cylinder
when
fin
ished
welding.
S.0621
-c
Figure
4-7.
Shieldin
g
Gas
OM-151
016
Page
8
Table
4-1.
Suggested
Welding
Settings
Wire
Type,
Shielding
Gas,
And
Flow
Rate
Wire
Diameter
(inch)
Operator
Control
Settings
Material_Thickness
1/4
in.
(6.4
mm)
3/16
in.
(4.8
mm)
1/8
in.
(3.2
mm)
14
ga.
16
ga.
18
ga.
22
ga.
24
ga.
-
-
E70S6
CO
2
20
cfh+
.023
Voltage
4
3
2
2
1
1
1
Wire
Speed*
100%
80% 70%
60%
55%
45%
35%
.030
Voltage
4
4
3
2
2
1
1
Wire
Speed*
80%
75%
60%
60% 50%
40%
30%
.035
Voltage
4
4
3 2
1
1
1
Wire
Speed*
65%
60%
50%
40%
30%
20%
15%
E7OS-6
75%
Argon
25%
CO
2
20
cfh+
.023
Voltage
4
3 2
2
1
1
1
Wire
Speed*
100%
90%
80%
70%
60%
50%
.
40%
.030
Voltage
4
3
3
2
2
1
1
.
Wire
Speed*
90%
80%
70%
60%
50%
45%
30%
.035
Voltage
4
3
3
3
2
2
1
Wire
Speed*
75%
70%
60%
50%
40%
33%
25%
E7ITGS
Flux
Core
.030
Voltage
3
3
2
1 1
1
Wire
Speed*
40%
65%
45%
40%
30%
20%
.035
Voltage
3 3
2
1
1
1
Wire
Speed*
60%
50%
40%
30%
20%
10%
ER
308
Stainless
Steel
Tn-Mix
20
cfh+
.023
Voltage
4
4
3 3
3
2
1
Wire
Speed*
100%
100%
90%
859o
75%
70% 60%
.030
Voltage
4
4
3
3
2
2
Wire
Speed*
75~
75% 65%
60%
55%
50%
.035
Voltage
4
Wire
Speed*
60% 60%
50%
Aluminum
Argon
20
cfh+
.030
Voltage
4
3
3
2
1
1
Wire
Speed*
90%
85%
80%
90%
90%
85%
.035
Voltage
4
4
3
2
2
1
Wire
Speed*
85%
85%
85%
90%
90%
80%
*
Do
not
change
THICKNESSNOLTAGE
switch
position
while
welding.
FINE
TUNING/WIRE
SPEED
value
in
Table
4-1
is
a
starting
value
only,
and
WIRE
SPEED
control
setting
can
be
fine
tuned
during
welding.
+cfh
=
cubic
ft
per
hour
OM-iSi
016
Page
9
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
___
4~
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.
Maintenance
to
be
performed
only
by
qualified
persons.
swarn8.2
10/91
5-1.
Routine
Maintenance
Table
5-1.
Maintenance
Schedule
Time
Maintenajice
Before
each
use.
Check
gun
parts
for
looseness,
cracks,
and
breaks;
tighten,
repair,
and
replace
parts
as
required.
Carefully
clean
weld
spatter
or
dirt
from
around
nozzle
opening
using
a
hardwood
stick,
never
a
metal
tool.
Every
month.
Above
normal
equipment
use:
Check
all
labels
(see
6
month
entry),
repair
any
damaged
insula
tion
or
replace
gun
or
work
cable,
clean
internal
parts
(see
6
month
entry),
clean
and
tighten
connections
at
gun
cable
and
work
clamp.
Every
3
months.
Repair
cable
insulation
damage
or
replace
gun
or
work
cable.
Clean
and
tighten
gun
cable
and
work
clamp
connections.
Every
6
months.
Replace
any
labels
that
are
unreadable
or
damaged
(see
Section
8
for
part
number).
Remove
unit
outer
enclosure
to
blow
out
or
vacuum
dust
and
dirt
from
inside
using
a
clean,
dry
airstream
or
vacuum
suction.
5-2.
Overload
Protection
a
WARNING
A.
Overheating
ELECTRIC
SHOCK,
HOT
PARTS,
AND
MOVING
PARTS
HAZARDS.
Read
safety
infor
mation
at
beginning
of
Section
5
before
proceeding.
Thermostat
TP1
protects
the
unit
from
damage
due
to
overheating.
If
main
rectifier
SR2
gets
too
hot,
TP1
opens
and
weld
output
stops.
The
fan
keeps
running
to
cool
the
rectifier.
Wait
several
minutes
before
trying
to
weld.
B.
Short
Circuit
Shutdown
If
contact
tube
is
shorted
and
sticks
to
workpiece,
the
unit
shuts
down,
but
fan
runs.
To
resume
operation,
release
gun
trigger,
turn
OFF
unit,
and
remove
contact
tube
from
workpiece.
Check
contact
tube
and
replace
if
damaged.
Turn
ON
unit
to
continue
operation.
C.
Fuse
Fl
a
CAUTION
STATIC
ELECTRICITY
can
damage
parts
on
circuit
boards.
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
fwarn5.1
9/91
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
OM-151
016
Page
10
5-3.
Cleaning
Or
Replacing
Drive
Roll
And
Replacing
Wire
Inlet
Guide
a
WARNING
ELECTRIC
SHOCK
AND
MOVING
PARTS
HAZARDS.
Read
safety
information
at
begin
ning
of
Section
5
before
proceeding.
Figure
5-2.
Removing
Drive
Roll
And
Wire
Inlet
Guide
Turn
OFF
and
unplug
unit.
Unlatch
door,
and
remove
door/wrapper.
I
Motor
Control
Board
PCi
2
Fuse
Fl
(See
Parts
List
For
Size)
Pull
fuse
from
fuse
holder
on
PCi.
To
reinstall,
push
fuse
into
fuse
holder.
3
Control
Relay
CR1
Reinstall
wrapper,
and
latch
door.
Ref.
ST150
194
/
ST-149
921-A
Figure
5-1.
Fuse
Fl
Location
3
Turn
OFF
and
unplug
unit.
I
Wire
Spool
2
Gun
Contact
Tube
Cut
welding
wire
off
atcontact
tube.
Retract
wire
onto
spool
and
se
cure.
3
Pressure
Roll
Assembly
4
Securing
Screw
5
Washers
6
Drive
Roll
Remove
drive
roll
as
shown.
Use
a
wire
brush
to
clean
drive
roll.
Push
drive
roll
onto
shaft
and
secure
with
washers
and
screw.
7
Wire
Inlet
Guide
Remove
guide
by
pressing
or
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.
Thread
welding
wire
(see
Section
3-5).
Close
door.
Ref.
ST-ISO
193-A/ST-150
391-A
4
7
Tools
Needed:
5
OM-151
016
Page
ii
5-4.
Replacing
Pressure
Bearing
a
WARNING
ELECTRIC
SHOCK
AND
MOVING
PARTS
HAZARDS.
beginning
of
Section
5
before
proceeding.
Read
safety
information
at
Figure
5-3.
Replacing
Pressure
Roll/Bearing
Assembly
5-5.
Adjusting
Hub
Tension
~
WARNING
ELECTRIC
SHOCK,
HOT
PARTS,
AND
MOVING
PARTS
HAZARDS.
Read
safety
infor
mation
at
beginning
of
Section
5
before
proceeding.
~lMPORTANT:
If
hub
tension
is
too
tight,
motor
fuse
Fican
open
(see
Section
5-2).
If
hub
tension
is
too
loose,
wire
unravels
and
can
become
tangled
inside
unit.
Turn
OFF
and
unplug
unit.
1
Spool
Cut
welding
wire
off
at
contact
tube.
Retract
wire
onto
spool
and
se
cure.
2
Hub
3
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.
Tools
Needed:
Close
and
secure
pressure
roll
~
assembly.
Thread
welding
wire
(see
Section
3-5).
Close
door.
~
9/16
in.
pet.
sr.i~o
193-A
Turn
OFF
and
unplug
unit.
1
Wire
Spool
2
Gun
Contact
Tube
Cut
welding
wire
off
at
contact
tube.
Retract
wire
onto
spool
and
se
cure.
3
Pressure
Roll
Arm
4
Cotter
Pin
5
Pin
6
Screw
7
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
3-5).
Close
door.
Tools
Needed:
Ret.
ST-150
193-A
/
ST-153
390
3
5
Figure
5-4.
Hub
Tension
Adjustment
OM-151
016
Page
12
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Miller KB100704 Owner's manual

Miller
Brand
Miller
Model
KB100704
Category
Welding System
Type
Owner's manual
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