Miller KF975790 Owner's manual

Miller
Brand
Miller
Model
KF975790
Category
Welding System
Type
Owner's manual

This manual is also suitable for

October
1995
Form:
OM-173122A
Effective
With
Serial
No.
KF975790
OWNERS
MANUAL
MW
175
230
Volt
Wire
Welder
For
GMAW
And
FCAW
Welding
Rated
Welding
Output
Maximum
Open-
Circuit
Voltage
DC
Amperes
Input
at
Rated
Load
Output
230
V,
60
Hz,
Single-Phase
KVA
KW
Weight
Overall
Dimensions
150
A
@
22
Volts
DC,
40%
Duty
Cycle
32
26(1
.4)~
59
(0.33)*
~g
(0.16)
Net:
160
lb
(72.6
kg)
Ship:
180
lb
(81.6
kg)
Length:
34-1/2
in
(876
mm)
Width:
18-1/2
in
(470
mm)
Height:
22-1/4
in
(565
mm)
Wire Diameter
Range
WIre
Feed
Speed
Range
.023
.035
in
(0.580.89
mm)
0500
1pm
(0
19.1
m/min)
*
While
idling
mactools
6/95
-
ST-BOO
853-B
PRINTED
IN
LiSA
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
OM-173
122-
9/95
sat.ty.somI
4/95
1-1.
Symbol
Usage
4A
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
A
Marks
a
special
safety
message.
procedurel
The
possible
hazards
are
shown
in
the
adjoining
symbols.
~
Means
NOTE;
not
safety
related.
~
This
group
of
symbols
means
Warning!
Watch
Out!
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT
PARTS
hazards.
Consult
symbols
and
related
instructions
below
for
necessary
actions
to
avoid
the
hazards.
I
I
~
I
1-2.
Arc
Welding
Hazards
a
WARNING
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identity
possible
hazards.
When
you
see
the
symbol,
watch
out,
and
follow
the
related
instructions
to
avoid
the
hazard.
The
safety
Information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
In
the
Safety
Standards
listed
in
Section
1-4.
Read
and
follow
all
Safety
Standards.
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
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.
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
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
191
0.147
(see
Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
Always
verify
the
supply
ground
check
and
be
sure
that
input
now~r
~orr1
orotinr~
wirp
Ic
nron~æv
oonn~~t~r1
to
riroiinrl
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
7.
When
making
input
connections,
attach
proper
grounding
conductor
first
double-check
connections.
8.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
replace
cord
immediately
if
damaged
bare
wiring
can
kill.
9.
Turn
off
all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
NOISE
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing;
FLYING
SLAG
OR
SPARKS
can
injure
eyes.
Arc
rays
from
the
welding
process
produce
intense
visible
and
invisible
(ultraviolet
and
infrared)
rays
that
can
bum
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
grinding,
and
welds
cooling
throw
off
pieces
of
metal
or
slag.
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
~es.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
tr~
arc
to
remove
welding
fumes
and
gases.
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
manufacturers
Instruction
for
metals,
consumables,
coatings,
cleaners,
and
degreasers.
ARC
RAYS
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.1
listed
in
Safety
Standards).
3.
Wear
approved
safety
glasses
with
side
shields.
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
toot
protection
-
5.
Work
in
a
confined
space
only
if it
is
well
ventilated,
ci
while
wearing
an
air-supplied
respirator.
Always
have
a
~c~ned
watchperson
nearby.
Welding
fumes
and
gases
can
disp~a.~e
air
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
breathing
air
i
sate.
6.
Do
not
weld
itions
near
degreasing,
cleaning,
or
spraying
operations.
eat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless
the
coating
is
removed
trom
the
weld
area,
the
area
Is
well
ventilated,
and
If
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off
toxic
fumes
if
welded.
During
operation,
keep
everybody,
especially
children,
away.
11.
Do
not
drape
cables
over
your
body.
12.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable
do
not
use
work
clamp
or
work
cable.
13.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
14.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
15.
Wear
a
safety
harness
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workoi~p
or
wnrkt~hIa
~c
near
th~
wAIrl
~is
nr~otir~I
OM-173122Page1
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,
slag,
open
flames,
sparks,
and
arcs.
2.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
5.
Never
allow
a
.welding
electrode
to
touch
any
cylinder.
6.
Never
weld
on
a
pressurized
cylinder
explosion
will
result.
7.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
8.
Tum
face
away
from
valve
outlet
when
opening
cylinder
valve.
9.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
10.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blow
up.
Sparks
can
fly
off
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
bums.
Accidental
contact
of
electrode
to
metal
objects
can
cause
sparks,
explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is
safe
before
doing
any
welding.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
7.
Do
not
weld
on
closed
containers
such
as
tanks,
drums,
or
pipes,
unless
they
are
properly
prepared
according
to
AWS
F4.1
(see
Safety
Standards).
8.
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
hazards.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
1-3.
Additional
Installation,
Operation,
And
Maintenance
Hazards
FIRE
OR
EXPLOSION
can
result
from
placing
unit
on,
over,
or
near
combustible
surfaces.
1.
Do
not
locate
unit
on,
over,
or
near
surfaces.
2.
Do
not
install
unit
near
flammables.
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
1.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
2.
Use
equipment
of
adequate
capacity
to
lift
unit.
3.
If
using
lift
forks
to
move
unit,
be
sure
forks
are
long
enough
to
extend
beyond
opposite
side
of
unit.
HOT
PARTS
can
cause
severe
burns.
1.
Do
not
touch
hot
parts
bare
handed.
2.
Allow
cooling
period
before
working
on
gun
or
torch.
MOVING
PARTS
can
cause
injury.
1.
Keep
away
from
moving
parts
such
as
fans.
2.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
1.
Pacemaker
wearers
keep
away.
2.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
MOVING
PARTS
can
cause
injury.
1.
Keep
away
from
moving
parts.
2.
Keep
away
from
pinch
points
such
as
drive
rolls.
FLYING
PIECES
OF
METAL
or
DIRT
can
Injure
eyes.
1.
Wear
safety
glasses
with
side
shields
or
face
shield.
WELDING
WIRE
can
cause
puncture
wounds.
1.
Do
not
press
gun
trigger
until
instructed
to
do
so.
2.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
HIGH-FREQUENCY
RADIATION
can
interfere
with radio
navigation,
safety
services,
computers,
and
communications
equipment.
1.
Have
only
qualified
persons
familiar
with
electronic
equipment
perform
this
installation.
2.
The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from
the
installation.
3.
If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
4.
Have
the
installation
regularly
checked
and
maintained.
5.
Keep
high-frequency
source
doors
and
panels
tightly
shut,
keep
spark
gaps
at
correct
setting,
and
use
grounding
and
shielding
to
minimize
the
possibility
of
interference.
1.
2.
3.
OM-173
122
Page
2
OVERUSE
can
cause
OVERHEATED
EQUIPMENT.
1.
Allow
cooling
period.
2.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
3.
Follow
rated
duty
cycle.
1-4.
Principal
Safety
Standards
1-5.
EMF
Information
SIGNIFICANT
DC
VOLTAGE
exists
after
removal
of
Input
power
on
inverters.
1.
Turn
Off
lnverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
touching
any
parts.
STATIC
ELECTRICITY
can
damage
parts
on
circuit
boards.
1.
Put
on
grounded
wrist
strap
BEFORE
handling
move,
or
ship
PC
boards.
boards
or
parts.
2.
Use
proper
static-proof
bags
and
boxes
to
store,
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
1.
Shut
off
shielding
gas
supply
when
not
in
use.
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Ad,
Miami
FL
33126
Safety
and
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
Welding
Society
Standard
AWS
F4.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Ad,
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,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
i
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.
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
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.
Government
Printing
Office,
May
i989):
.
.
.
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
ce~Iular
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:
i.
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.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About
Pacemakers:
The
above
procedures
are
also
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
OM-173
i22
Page
3
2-4.
Gas
Hoses
And
Interconnecting
Cord
Connections
2-3.
Installing
Gas
Supply
1
Chain
gas
cylinder
to
running
gear,
wall,
or
other
stationary
support
so
cylinder
cannot
fall
and
break
off
valve.
2
3
OR
1
Cap
2
Cylinder
Valve
3
Cylinder
4
Regulator/Flowmeter
5
Gas
Hose
Connection
Fitting
has
5/8-18
right-hand
threads.
6.
Flow
Adjust
Typical
flow
rate
is
20
cfh
(cubic
feet
per
hour).
Check
wire
man
ufacturers
recommended
flow
rate.
Argon
Gas
Or
Mixed
Gases
1
2
Tools
Needed:
5/8,
1-1/8
in
3
Make
sure
flow
adjust
is
closed
when
opening
cylinder
to
avoid
damage
to
the
flowmeter.
7
CO2
Adapter
8
0-Ring
Install
adapter
with
0-ring
between
regulator/flowmeter
and
CO2
cylinder.
CO2
Gas
ssb3.1
5/94
ST-158
697-A/
Ref.
ST-149
I
2
1
Gas
In
Fitting
And
Gas
Hose
From
Regulator/Flowmeter
Connect
gas
hose
from
reguiator/
flowmeter
(see
Section
2-3).
2
Gas
Out
Fitting
And
Wire
Feeder
Gas
Hose
Connect
gas
hose
from
wire
feeder.
3
Interconnecting
Cord
And
Plug
4
Interconnecting
Receptacle
Connect
to
receptacle
as
follows:
align
keyway,
insert
plug,
and
tighten
threaded
collar.
Ref.
ST-SOO
365
/
Ref.
ST-SOt
366
3
OM-137
122
Page
5
2-5.
Connecting
To
Weld
Output
Receptacles
2-6.
Installing
Welding
Gun
For
GMAW
direct
current
electrode
negative
(DCEN),
reverse
cable
connections.
For
FCAW
direct
current
electrode
negative
(DCEN),
connect
wetd
cable
plug
to
negative
()
weld
out
put
receptacle
and
work
cable
plug
to
positive
(+)
weld
output
recep
tacle.
For
FCAW
direct
current
electrode
positive
(DCEP),
reverse
cable
connections.
1
Positive
(+)
Weld
Output
Receptacle
2
Negative
()
Weld
Output
Receptacle
3
Weld
Cable
4
Work
Cable
A
Be
sure
cables
are
secure
in
receptacles
before
welding,
and
do
not
change
recep
tacles
while
welding.
For
GMAW
direct
current
electrode
positive
(DCEP),
connect
weld
cable
plug
to
positive
(+)
weld
out
put
receptacle
and
work
cable
plug
to
negative
()
weld
output
recep
tacle.
4
ST-800
846-B
4
Gun
Trigger
Receptacle
5
Gun
Trigger
Plug
Insert
plug
into
receptacle,
and
tighten
threaded
collar.
Close
door.
1
Gun
End
2
Gun
Securing
Nut
3
Drive
Assembly
Loosen
securing
nut.
Insert
gun
end
through
opening
until
it
bot
toms
against
drive
assembly.
Tighten
nut.
ST-800
849-A
4
Tools
Needed:
~
1/2in
OM-173
122
Page
6
2-7.
Electrical
Service
Guide
Input
Voltage
230
Input
Amperes
At
Rated
Output
26
Max
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
40
Mm
input
Conductor
Size
In
AWG/Kcmil
12
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)
80(24)
Mm
Grounding
Conductor
Size
in
AWGIKcm1I
12
Reference:
1993
National
Electrical
Code
(NEC)
S.oog2-j
2-8.
Selecting
A
Location
OM-137
122
Page
7
2-9.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
Standard
Spool
Installation
1
lb
Spool
Installation
Install
1
lb
spool
When
a
slight
force
is
needed
to
turn
spool,
tension
is
set.
If
tension
is
to
tight,
circuit
breaker
CB1
can
open
(see
Section
4-3)
Tools
Needed:
~
9/l6in
ST-800318
/
s-o499
L
Remove
and
retain
OM-173
122
Page
8
2-10.
Threading
Welding
Wire
Tools
Needed:
1
Wire
Spool
2
InletWireGuide
3
Pressure
Adjustment
Knob
4
Drive
Roll
5
Outlet
Wire
Guide
6
Gun
Conduit
Cable
Lay
gun
cable
out
straight.
Remove
gun
nozzle
and
contact
tip.
Welding
wire
is
electrically
live
when
feedIng
welding
wire
with
gun
trigger.
Press
gun
trigger
until
v
comes
out
of
gun.
Reins
contact
tip
and
nozzle.
Feed
wire
to
check
drive
roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
Cut
off
wire.
Close
and
latch
door.
Ref.
ST-800
851-A
I
Ref.
ST-I
70
725
/
S-0627-A
Open
pressure
assembly.
Pull
and
hold
wire,
cut
off
end.
Push
wire
thru
guides
into
gun;
continue
to
hold
wire.
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
QoFc~
Turn
On.
OM-137
122
Page
9
Duty
Cycle
is
percentage
of
10
minutes
that
unit
can
weld
at
rated
load
without
overheating.
If
unit
overheats,
thermostat(s)
opens,
output
stops,
and
cooling
fan
runs.
Wait
fifteen
minutes
for
unit
to
cool.
Reduce
amperage
or
duty
cycle
before
welding.
A
Exceeding
duty
cycle
can
damage
unit
or
gun
and
void
warranty.
dutyl
4/95SB-173
353
S00
600
400
300
200
16
202530
%
DUTY
406060
CYCLE
70
800100
UNIT
40%
Duty
Cycle
At
150
Amperes
4
Minutes
Welding
6
Minutes
Resting
GUN
60%
Duty
Cycle
At
160
Amperes
Using
CO2
GUN
6
Minutes
Welding
4
Minutes
Resting
30%
Duty
Cycle
All
60
Amperes
Using
Mixed
Gases
3
Minutes
Welding
7
Minutes
Restir~
Overheating
I-,
Minutes
-,
OR
Reduce
Duty
Cycle
OM-137
122
Page
11
SECTION
4-
MAINTENANCE
&TROUBLESHOOTING
4-1.
Routine
Maintenance
4-2.
Fuses
Fl
And
F2
4-3.
Circuit
Breaker
CB1
0
C
0
0
1
Circuit
Breaker
CB1
CB1
protects
the
wire
feeder
motor
from
overload.
If
CB1
trips,
wire
feeding
stops.
Check
for
jammed
wire
or
misaligned
drive
roll.
Cor
rect
problem,
reset
breaker.
ST-800
850-A
OM-173
122
Page
12
10
Drive
Roll
Remove
drive
roll
as
shown.
Use
a
wire
brush
to
clean
drive
roll.
Push
drive
roil
onto
shaft
wilt
de
sired
groove
in.
Turn
drive
rc.
so
one
setscrew
faces
flat
side
of
shaft,
and
tighten
both
setscrews.
11
Knurled
Groove
For
Flux-Cored
Wire
12
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.
A
Turn
Off
power
before
re
placing
contact
tip.
1
Nozzle
2
Contact
Tip
Cut
off
welding
wire
at
ontact
tip.
Remove
nozzle.
Remove
contact
tip
and
install
new
contact
tip.
Reinstall
nozzle.
4-4.
Cleaning
Or
Repairing
Drive
Assembly
Tools
Needed:
A
Turn
Off
and
unplug
unit.
1
Wire
Spool
2
Gun
Contact
lip
Cut
welding
wire
off
at
contact
tip.
Retract wire
onto
spool
and
secure.
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.
8
Setscrew
9
Smooth
Groove
For
Hard
Wire
Thread
welding
wire
(see
Section
2-10).
4-5.
Replacing
Gun
Contact
Tip
Ref.
ST-800
851-A
/
ST-155
578
Tools
Needed:
ST-149
632-C
OM-137
122
Page
13
4-6.
Cleaning
Or
Replacing
Gun
Liner
Head
Tube
A
Turn
off
welding
power
source
and
disconnect
gun.
Tools
Needed:
~
s
3/Bin
Blow
out
gun
casing.
To
Reassemble
Gun:
Install
contact
tip.
Insert
new
liner.
Install
collet
onto
liner
and
tighten
into
gun/feeder
connector
using
wrench.
Cut
liner
off
near
collet
so
that
liner
end
is
as
close
to
drive
rolls
as
pos
sible
without
touching.
Install
nozzle.
3/B
in
Remove
nozzle,
contact
tip,
and
liner
collet.
Remove
liner.
Gun/feeder
Connector
Ref.
ST.155
509
OM-173
122
Page
14
4-7.
Welding
Trouble
i~d~
Trouble
Remedy
No
weld
output;
wire
does
not
feed;
fan
does
not
run.
Secure
power
cord
plug
in
receptacle
(see
Section
2.8).
Replace
line
disconnect
fuse
or
reset
circuit
breaker
if
open
(see
Section
2-8).
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch
(see
Sec
tion
2-6).
No
weld
output;
wire
does
not
feed;
fan
motor
contin-
ues
to
run.
Thermostat
TP1
open
(overheating).
Allow
fan
to
run;
the
thermostat
will
close
when
the
unit
has
cooled
(see
Section
3-2).
Check
circuit
breaker
CB1,
and
reset
if
necessary
(see
Section
4-3).
No
weld
output;
wire
feeds.
~
Connect
work
clamp
to
get
good
metal
to
metal
contact.
Check
for
proper
weld
cable
connections.
Replace
contact
tip
(see
Section
4-5).
Low
weld
output.
Connect
unit
to
proper
input
voltage
or
check
for
low
line
voltage
(see
Section
2-8).
4-8.
Wire
Drive/Gun
Trouble
!1~$~r~d
Trouble
Remedy
Electrode
wire
feeding
stops
during
welding.
Straighten
gun
cable
and/or
replace
damaged
parts.
Adjust
drive
roll
pressure
(see
Section
2-10).
Change
to
proper
groove
(see
Section
4-4).
Readjust
hub
tension
(see
Section
2-9).
Replace
contact
tip
if
blocked
(see
Section
4-5).
Clean
or
replace
wire
inlet
guide
or
liner
if
dirty
or
plugged
(see
Section
4-6).
Replace
drive
roll
or
pressure
bearing
if
worn
or
slipping
(see
Section
4-4).
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch
(see
Sec
tion
2-6).
Check
circuit
breaker
CB1,
and
reset
it
necessary
(see
Section
4-3).
Check
and
clear
any
restrictions
at
drive
assembly
and
liner
(see
Sections
4-4
and
4-6).
Have
nearest
Factory
Authorized
Service
Agent
check
drive
motor.
OM-137
122
Page
15
SECTION
5-ELECTRICAL
DIAGRAMS
Figure
5-1.
Circuit
Diagram
For
Welding
Power
Source
SB-170
520-A
OM-173
122
Page
16
SECTION
6-
WELDING
METHODS
&
TROUBLESHOOTING
mod4.1
9/92
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
(MSDSs)
and
manufacturers
instructions
for
material
used.
MAGNETIC
FIELDS
FROM
HIGH
CUR
RENTS
can
affect
pacemaker
operation.
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor before
going
near
arc
welding,
gouging,
or
spot
welding
opera
tions.
7-1.
Flux
Cored
Arc
Welding
(FCAW)
And
Gas
Metal
Arc
Welding
(GMAW)
4
Figure
7-1.
Holding
And
Positioning
Welding
Gun
AA
WARNING
j
~
~~
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.
W
ELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
WELDING
CURRENT
can
damage
elec
tronic
parts
in
vehicles.
S
S
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,
S
Disconnect
both
battery
cables
before
welding
on
a
vehicle.
S
Place
work
clamp
as
close
to
the
weld
as
possible.
See
Safety
Precautions
at
beginning
of
manual
for
ba
sic
welding
safety
information.
swa~
210/91
N
OTE
~
Welding
wire
is
not
energized
until
gun
trigger
is
pressed;
therefore,
should
extend
not
more
than
112Th
(13
mm)
beyond
edge
of
nozzle
a
placed
on
seam
before
lowering
helmet
and
pressmg
trigger.
welding
wire
nd
tip
of
wire
5
1
Hold
Gun
And
Control
Gun
Trigger
2
Workpiece
3
Work
Clamp
4
5
Electrode
Extension
(Stickout)
1/4
To
1/2
in
(6
To
13mm)
Cradle
Gun
And
Rest
Hand
On
Workpiece
End
View
Of
Work
Angle
Side
View
Of
Gun
Angle
End
View
Of
Work
Angle
Sid
e
View
Of
Gun
Angle
GROOVE
WELDS
FILLET
WELDS
S-0421-A
OM.173
122
Page
17
T
Short
Normal
ELECTRODE
EXTENSIONS
(STICKOUT)
Long
I&
~~&_s
Normal
FILLET
WELD
ELECTRODE
EXTENSIONS
(STICKOUT)
Short
Long
Figure
7-2.
Conditions
That
Affect
Weld
Bead
Shape
NOTE
~
Normally,
a
single
stringer
bead
is
satisfactoiy
for
most
narrow
groove
weld
joints;
ho
we
vei
for
wide
groove
weld
joints
or
bridging
across
gaps,
a
weave
bead
or
multiple
stringer
beads
works
better.
S-0054-A
w~
1
Stringer
Bead
Steady
Movement
Along
Seam
2
Weave
Bead
Side
To
Side
Movement
Along
Seam
3
Weave
Patterns
Use
weave
patterns
to
cover a
wide
area
in
one
pass
of
the
elec
trode.
Do
not
let
weave
width
ex
ceed
2-1/2
times
diameter
of
electrode.
Figure
7-3.
Gun
Movement
During
Welding
N
OTE
iI~
Weld
bead
shape
depends
on
gun
angle,
direction
of
travel,
electrode
extension
_____________________
(stickout),
travel
speed,
thickness
of
base
metal,
wire
feed
speed
(weld
current),
and
voltage.
100
S
Push
100
Perpendicular
GUN
ANGLES
AND
WELD
BEAD
PROFILES
S
Drag
Slow
Normal
GUN
TRAVEL
SPEED
Fast
S.0634
OM-173
122
Page
18
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Miller KF975790 Owner's manual

Miller
Brand
Miller
Model
KF975790
Category
Welding System
Type
Owner's manual
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