Miller KG202179 Owner's manual

Brand: Miller

Model: KG202179

Category: Welding System

Type: Owner's manual

This manual is also suitable for

OWNER’S

MANUAL

September 1996 Form: OM-1313A

Effective With Serial No. KG202179

cover_om 4/95 − ST-801 565 PRINTED IN USA

 1996 MILLER Electric Mfg. Co.

Millermatic 185 And M-15 Gun

CV/DC Wire Welder For GMAW And FCAW Welding

Rated Welding

Output

Amperage

Range

Maximum

Open-Circuit

Voltage DC

Amperes Input at

Rated Load

Output, 60 Hz,

Single-Phase

Weight

Overall

Dimensions

Voltage DC

200 V 230 V KVA KW

150 A @ 23 Volts

DC, 60% Duty Cycle

30 − 185 33 30 (1.6)* 26 (1.4)* 6 (0.27)* 5 (0.13)*

165 lb

(75 kg)

Length: 36 in

(915 mm)

Width: 18 in

(457 mm)

Height: 27 in

(686 mm)

Wire Type And Diameter

Calculated Wire Speed

Max Wire Feed Speed

Solid Steel /

Stainless Steel

Flux Cored Aluminum

Calculated Wire Speed

Range At No Load

Max Wire Feed Speed

While Welding

.023 − .035 in

(0.6 - 0.9 mm)

.030 − .045 in

(0.8 − 1.2 mm)

.030 − .035 in

(0.8 − 0.9 mm)

138 − 795 IPM (3.5 − 20.3 m/min) 650 IPM (16.5 m/min)

*While idling

OM-1313 Page 1

SECTION 1 − SAFETY PRECAUTIONS FOR ARC WELDING

safety_som1 4/95OM-1313A − 9/96

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this

procedure! The possible hazards are shown in the adjoining symbols.

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.

Y Marks a special safety message.

. Means NOTE; not safety related.

1-2. Arc Welding Hazards

WARNING

The symbols shown below are used throughout this manual to call attention to and identify 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.

During operation, keep everybody, especially children, away.

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 1910.147 (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

power cord ground wire is properly connected to ground 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.

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 workpiece

or worktable as near the weld as practical.

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 burn eyes and skin. Noise from some

processes can damage hearing. Chipping, grinding,

and welds cooling throw off pieces of metal or slag.

NOISE

1. Use approved ear plugs or ear muffs if noise level is high.

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 foot protection.

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 fumes.

2. If inside, ventilate the area and/or use exhaust at the 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.

5. Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained

watchperson nearby. Welding fumes and gases can displace air

and lower the oxygen level causing injury or death. Be sure the

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

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 from 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.

OM-1313 Page 2

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. Turn 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-1 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 burns. 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.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. 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 combustible

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.

OM-1313 Page 3

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.

STATIC ELECTRICITY can damage

parts on circuit boards.

1. Put on grounded wrist strap BEFORE handling

boards or parts.

2. Use proper static-proof bags and boxes to store,

move, or ship PC boards.

SIGNIFICANT DC VOLTAGE exists after

removal of input power on inverters.

1. Turn Off inverter, disconnect input power, and

discharge input capacitors according to

instructions in Maintenance Section before

touching any parts.

BUILDUP OF SHIELDING GAS can harm

health or kill.

1. Shut off shielding gas supply when not in use.

1-4. 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

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 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-1, from Compressed Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

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 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. EMF Information

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 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.

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-1313 Page 4

SECTION 2 − INSTALLATION

2-1. Installing Work Clamp

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

cover connection with boot.

4 Hardware

5 Work Clamp

Route cable through clamp handle

and secure as shown.

Close door.

ST-801 566

1/2, 3/4 in

Tools Needed:

2-2. Installing Gas Supply

ST-801 571 / Ref. ST-109 492

1 Cylinder Rack

2 Chain

Obtain gas cylinder and chain cylin-

der to rack.

3 Gas Hose Fitting

4CO

Washer

5 Regulator

Install washer and regulator onto

cylinder.

6 Gas Hose Connection

Obtain gas hose with fittings and

install between regulator and

welding power source.

7 Flow Adjust

Typical flow rate is 20 cfh (cubic feet

per hour).

5/8, 1-1/8 in

Tools Needed:

OM-1313 Page 5

2-3. Installing Welding Gun

Ref. ST-801 567

1 Drive Assembly

2 Gun Securing Knob

3 Gun End

Loosen securing knob. Insert gun

end through opening until it bottoms

against drive assembly. Tighten

nut.

4 Gun Trigger Plug

Insert plug into receptacle, and

tighten threaded collar.

Close door.

2-4. Setting Gun Polarity

1 Polarity Changeover Label

(Located Near Drive

Assembly)

Always read and follow manufac-

ture’s recommended polarity.

3/4, 11/16 in

Wire Drive Assembly Lead

To Positive (+) Output Terminal

Work Clamp Lead To

Negative (−) Output Terminal

GUN POLARITY

CHANGEOVER CONNECTIONS

Reverse Lead Connections − For Electrode

Negative (DCEN) For Flux Cored Wires

(FCAW Process). Drive Assembly

Becomes Negative

S-144 449-D

Tools Needed:

OM-1313 Page 6

2-5. Installing Wire Spool And Adjusting Hub Tension

ST-072573-B

When a slight force is needed

to turn spool, tension is set.

15/16 in

Use compression spring with

8 in (200 mm) spools.

Tools Needed:

2-6. Changing Input Voltage

ST-801 580-A

Y Turn Off unit, and disconnect

input power.

Unit was shipped from factory set

for 230 volts.

1 Transformer T1

2 Rear Of Power Switch S1

3 Lead Marked 230 Volt And

Fan Motor Lead

Disconnect 230 volt lead and fan

motor lead from rear of S1. Leave

fan motor lead connected to 230

volt lead.

4 Lead Marked 200 Volt

Remove cable tie, and slide short

piece of sleeving off 200 volt lead,

and slide sleeving over end of 230

volt and fan motor leads. Fold

sleeving over and secure in place.

Connect 200 volt lead to S1 where

230 volt lead was removed.

Reinstall wrapper.

3/8, 7/16 in

Tools Needed:

OM-1313 Page 7

2-7. Electrical Service Guide

Input Voltage

200 230

Input Amperes At Rated Output

30 26

Max Recommended Standard Fuse Or Circuit Breaker Rating In

Amperes

45 40

Min Input Conductor Size In AWG/Kcmil

10 10

Max Recommended Input Conductor Length In Feet (Meters)

97 (29) 128 (39)

Min Grounding Conductor Size In AWG/Kcmil

10 10

Reference: 1996 National Electrical Code (NEC). S-0092-J

2-8. Selecting A Location And Connecting Input Power

1 Rating Label

Supply correct input power.

2 Plug

3 Receptacle

Connect plug to receptacle.

4 Input And Grounding

Conductors

Connect directly to line disconnect

device if hard wiring is required.

5 Line Disconnect Device

See Section 2-7.

Y Special installation may be

required where gasoline or

volatile liquids are present −

see NEC Article 511 or CEC

Section 20.

ST-801 568

230 VAC, 1

18 in (457 mm) of

space for airflow

Y Always connect grounding

conductor first.

= GND/PE

Y Do not move or operate unit

where it could tip.

OM-1313 Page 8

2-9. Installing Drive Roll, Inlet Wire Guide, And Threading Welding Wire

1 Drive Roll

Choose correct drive roll for wire

type, and install as shown.

2 Inlet Wire 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.

Ref. ST-801 570 / ST-801 083 / S-0627-A

6 in

(150 mm)

4 in

(102 mm)

Tighten

WOOD

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.

Remove gun nozzle and contact tip. Turn On.

Press gun trigger until wire

comes out of gun. Reinstall

contact tip and nozzle.

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close

and latch door.

Tools Needed:

OM-1313 Page 9

2-10. Weld Parameter

Wire Type,

Wire

Material Thickness

Wire Type,

Shielding Gas,

And Flow Rate

Wire

Diameter

(inch)

Operator

Controls

3/8 in

(9.5

mm)

1/4 in

(6.4

mm)

3/16 in

(4.8

mm)

1/8 in

(3.2

mm)

12 ga 14 ga 16 ga 18 ga 20 ga 22 ga

.023

Voltage Tap − − 6 5 4 3 3 2 1 1 − −

.023

Wire Speed − − 100 90 70 65 60 40 25 20 − −

E70S-6

.030

Voltage Tap − − 4 4 3 2 2 2 1 − − − −

20 cfh+

.030

Wire Speed − − 70 60 50 45 40 30 25 − − − −

.035

Voltage Tap 6 4 4 3 3 2 2 1 − − − −

.035

Wire Speed 80 65 40 35 30 25 30 10 − − − −

.023

Voltage Tap − − 3 4 3 3 2 2 1 1 1

.023

Wire Speed − − 80 90 70 60 70 40 45 25 12

E70S-6

75% Argon

.030

Voltage Tap 6 4 4 3 3 2 2 1 1 − −

75% Argon

25% CO

20 cfh+

.030

Wire Speed 90 58 70 55 50 48 45 30 5 − −

20 cfh+

.035

Voltage Tap 6 4 4 3 3 2 2 1 1 − −

.035

Wire Speed 80 48 60 50 35 27 30 11 3 − −

.030

Voltage Tap 5 4 4 3 2 2 1 1 − − − −

E71T-GS

Flux Core

.030

Wire Speed 80 65 65 50 30 30 10 5 − − − −

E71T-GS

Flux Core

.035

Voltage Tap 5 4 3 2 2 2 1 1 − − − −

.035

Wire Speed 5 50 40 30 25 20 10 0 − − − −

.023

Voltage Tap 5 4 4 4 3 3 3 2 2 2

.023

Wire Speed 95 85 80 60 50 50 50 30 20 20

ER 308

Stainless Steel

.030

Voltage Tap 5 5 4 3 3 2 2 2 1 − −

Stainless Steel

Tri-Mix

20 cfh+

.030

Wire Speed 70 70 70 50 45 50 45 40 0 − −

20 cfh+

.035

Voltage Tap 6 5 5 4 3 2 2 2 − − − −

.035

Wire Speed 65 40 40 30 30 25 20 10 − − − −

*Do not change Voltage switch position while welding Wire Speed value in Table is a starting value only, and Wire Speed control setting can be fine

tuned during welding. S-181 020-A

OM-1313 Page 10

SECTION 3 − OPERATION

3-1. Front Panel Controls

Ref. ST-180 930

Controls For Standard Units

1 Wire Speed Control

Use control to select a wire feed

speed. As Voltage switch setting in-

creases, wire speed range also in-

creases (see Section 2-10). Scale

around control is not actual wire

feed speed, but is for reference

only.

2 Voltage Switch

The higher the selected number,

the thicker the material that can be

welded (see Section 2-10). Do not

switch under load.

3 Pilot Light

4 Power Switch

OM-1313 Page 11

6 Minutes Welding 4 Minutes Resting

3-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-

utes 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

voltage, or duty cycle before

welding.

Y Exceeding duty cycle can

damage unit and void

warranty.

Overheating

A or V

Reduce Duty Cycle

Minutes

duty1 4/95 − SB-181 009

60% Duty Cycle At 150 Amperes

OM-1313 Page 12

SECTION 4 − MAINTENANCE & TROUBLESHOOTING

4-1. Routine Maintenance

Y Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

3 Months

Replace

Damaged Or

Unreadable

Labels

Clean And

Tighten

Weld

Terminals

Repair Or

Replace

Cracked

Cables And

Cords

6 Months

Blow Out Or

Vacuum Inside

4-2. Circuit Breakers CB1 And CB2

Ref. ST-801 567

Y Turn Off unit.

1 Circuit Breaker CB1

CB1 protects the transformer from

overload. If CB1 opens, wire

feeding stops.

2 Circuit Breaker CB2

CB2 protects the trigger circuit from

overload. If CB1 opens, weld output

stops.

Press button to reset circuit

breaker. Close door.

1 2

OM-1313 Page 13

4-3. Cleaning Or Replacing Gun Liner

Ref. ST-800 797-A

3/8 in

To Reassemble Gun:

Insert new liner.

Install and tighten wire outlet guide.

Cut liner off 3/4 in (20 mm) (3/8 in

[9.5 mm] for aluminum) from head

tube.

Install adapter, contact tip, and

nozzle.

Lay gun cable out straight

before installing new liner.

Head tube

3/8 in

Wire Outlet Guide

Remove liner.

Remove nozzle, contact tip,

adapter, and wire outlet guide.

Blow out gun casing.

Y Disconnect gun first.

Tools Needed:

OM-1313 Page 14

4-4. Replacing Switch And/Or Head Tube

Ref. ST-800 795-A

Do not disturb cable connection between

cable connector and connector nut.

1 Remove handle

locking nut.

2 Remove switch housing. Note: If installing new

switch, push switch lead connectors onto terminal of

new switch (polarity is not important). Install switch

back into handle, and secure with handle locking nut.

If replacing head tube, continue to end of figure.

3 Slide handle.

4 Secure head

tube in vice.

5 Remove shock wash-

ers from front and

rear of head tube.

6 Loosen jam nut. Remove

from vice and turn head

tube out by hand.

7 Install both existing shock washers

to new head tube and hand-tighten

head tube into connector cable.

8 Place head tube in vice and tighten

to within 1/8 in (3.2 mm) spacing be-

tween connector cable and body.

9 Remove from vice. Reposition

handle and install switch housing.

Secure with handle locking nut.

Y Disconnect gun first.

3/4 in

Tools Needed:

OM-1313 Page 15

4-5. Replacing Gun Contact Tip

ST-149 326-B

Y Turn Off unit.

1 Nozzle

2 Contact Tip

Cut off welding wire at contact tip.

Remove nozzle.

Remove contact tip and install new

contact tip. Reinstall nozzle.

Tools Needed:

4-6. Unicable Repair

To repair or replace unicable, order Unicable Clamp Kit, part number 172 018.

4-7. Troubleshooting

Welding Trouble Remedy

No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-8).

Check and replace power switch if necessary.

Check circuit breakers CB1 and/or CB2, and reset if necessary (see Section 4-2).

Replace building line fuse or reset circuit breaker if open (see Section 2-8).

Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 2-3 and/or 4-4).

Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled

(see Section 3-2).

No weld output; wire feeds. Connect work clamp to get good metal to metal contact.

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).

Low, high, or erratic wire speed. Readjust front panel settings (see Section 3-1).

Change to correct size drive roll (see Section 2-9).

Readjust drive roll pressure (see Section 2-9).

Replace inlet guide, contact tip, and/or liner if necessary (see Sections 2-9, and 4-3).

Wire Drive/Gun Trouble Remedy

Electrode wire feeding stops during

welding.

Straighten gun cable and/or replace damaged parts (see Section 4-3).

Adjust drive roll pressure (see Section 2-9).

Readjust hub tension (see Section 2-5).

Replace contact tip if blocked (see Section 4-5).

Clean or replace wire inlet guide or liner if dirty or plugged (see Section 4-3).

Replace drive roll if worn or slipping (see Section 2-9).

Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 2-3 and/or 4-4).

OM-1313 Page 16

Welding Trouble Remedy

Check and clear any restrictions at drive assembly and liner (see Section 4-3).

Have nearest Factory Authorized Service Agent check drive motor.

OM-1314 Page 17

SECTION 5 − ELECTRICAL DIAGRAM

SB-178 359-A

Figure 5-1. Circuit Diagram

OM-1313 Page 18

SECTION 6 − WELDING METHODS & TROUBLESHOOTING

mod4.1* 9/9

A. Welding Methods

6-1. Holding And Positioning Welding Gun

Wire Extension (Stickout)

1/4 − 1/2 in (6 − 13 mm)

. Cradle gun and rest hand on workpiece. Place tip of wire on seam before lowering hel-

met and pressing trigger. Welding wire is not energized until gun trigger is pressed.

90° 90°

0°-15°

GROOVE WELDS

End View Of Work Angle Side View Of Gun Angle

S-0421-A

45°

FILLET WELDS

End View Of Work Angle Side View Of Gun Angle

0°-15°

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Miller KG202179 Owner's manual

Brand: Miller

Model: KG202179

Category: Welding System

Type: Owner's manual

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Miller KG202179 Owner's manual

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