Miller Electric Renegade 180 Owner'S Manual Download Page 1

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Processes

OM-228 042B

2007

−

Renegade 180

Processes

Description

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Engine Driven Welding Power Source/

Wire Feeder/Generator

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www.MillerWelds.com

File: Engine Drive

Summary of Contents for Renegade 180

Page 1: ...228 042B 2007 09 Renegade 180 Processes Description MIG GMAW Welding Flux Cored FCAW Welding Engine Driven Welding Power Source Wire Feeder Generator Visit our website at www MillerWelds com File Eng...

Page 2: ...inue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get t...

Page 3: ...ifications 12 4 3 Gun Specifications 13 4 4 Dimensions Weights And Operating Angles 13 4 5 Volt Ampere Curves 13 4 6 Fuel Consumption 14 4 7 Power Source Duty Cycle 14 4 8 Gun Duty Cycle And Overheati...

Page 4: ...Or Wire Inlet Guide 33 8 6 Replacing Gun Contact Tip 33 8 7 Maintaining Gun 34 8 8 Replacing Switch And Or Head Tube 35 8 9 Servicing Air Cleaner 36 8 10 Adjusting Engine Speed 37 SECTION 9 TROUBLESHO...

Page 5: ...gh risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC m...

Page 6: ...ding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire...

Page 7: ...rts bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT ca...

Page 8: ...age and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury Wear a face shield...

Page 9: ...ec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Ass...

Page 10: ...i l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises...

Page 11: ...e provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux...

Page 12: ...ovoquer des tincelles avec les outils en travaillant sur la batterie Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicules de d marrage rapide Observer la polarit correcte et...

Page 13: ...st me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Le METAL CHAUD lors du coupage et gougeage plasma peu...

Page 14: ...INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pi ces de rechange recom mand es par le constructeur Effectuer la maintenance et le...

Page 15: ...n National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA...

Page 16: ...r source wire feeder can also use utility power to provide weld output no auxiliary power available in this mode 4 2 Weld Power And Engine Specifications Rated Welding Output Amperage Range Maximum Op...

Page 17: ...ine B 10 9 16 in 268 mm B Do not exceed tilt angles or engine could be damaged or unit could tip D t t it h C 13 25 64 in 340 mm Do not move or operate unit where it could tip D 22 3 4 in 577 mm it co...

Page 18: ...ycle 230 343 A Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty Overheating 0 15 A or V OR...

Page 19: ...ng duty cycle can damage unit and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes sduty1 5 95 Continuous Welding 100 dutycycle 4 8 Gun Duty Cycle And Overheating 6 Minutes Welding 4...

Page 20: ...o bare metal on the vehicle frame as shown Use 10 AWG or larger insulated copper wire to make metal to metal groundingconnection If unit does not have GFCI receptacles use GFCI protected extension cor...

Page 21: ...y ing power to a premises home shop farm wiring system 1 EquipmentGrounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device Use ground device as stated in electri...

Page 22: ...ing difficult Fuel Add fresh fuel before starting engine the first time see engine manual for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Check fuel level on...

Page 23: ...drive assembly Tighten knob 4 Gun Trigger Plug Insert into receptacle and tighten threaded collar 5 Mig Gun Spool Gun Select Switch Place switch in position for gun be ing used Close door 4 3 2 1 5 5...

Page 24: ...ielding gas DCEN Straight Polarity Connect to negative output terminal Connect to positive output terminal 5 8 Changing Weld Polarity Connection hardware must be tightened with proper tools Do not jus...

Page 25: ...een Or Green Yellow Grounding Conductor 4 Input Power Cord 5 Disconnect Device switch shown in the OFF position 6 Disconnect Device Grounding Terminal 7 Disconnect Device Line Terminals Connect green...

Page 26: ...UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipm...

Page 27: ...www MillerWelds com OM 228 042 Page 23 Notes FILLET GROOVE WELD JOINT TYPES BUTT BUTT BUTT BUTT T JOINT T JOINT T JOINT T JOINT FLAT VERTICAL HORIZONTAL OVERHEAD WELD POSITION Ref AWS ANSI D1 1 1G 1F...

Page 28: ...at www MillerWelds com OM 228 042 Page 24 5 12 Threading The Welding Gun Tools Needed 1 3 5 804 755 B Ref 229 573 A 2 Tighten 1 2 3 4 Pressure Indicator Scale 6 in 150 mm 6 4 024 Groove 030 035 Groov...

Page 29: ...wire tightly Be sure wire is positioned in proper feed roll groove Close and tighten pressure assembly Let go of wire Use pressure indicator scale to set desired drive roll pressure Begin with a sett...

Page 30: ...s List available at www MillerWelds com OM 228 042 Page 26 SECTION 6 OPERATING THE WELDING GENERATOR 6 1 Controls See Section 6 2 229 573 804 971 B 4 1 6 3 5 2 7 8 9 Electric Start Models Recoil Start...

Page 31: ...dle For Electric Start Turn Engine switch to Start When engine starts allow switch to return to Run position Open choke as engine warms NOTICE If the engine does not start let engine come to a complet...

Page 32: ...Complete Parts List available at www MillerWelds com OM 228 042 Page 28 6 3 Weld Parameter Chart Ref 230 748C...

Page 33: ...5 Ar 2 5 CO2 0 030 3 5 25 3 5 30 4 0 45 5 0 60 5 0 70 6 0 85 7 5 95 90 HE 7 5 Ar 2 5 CO2 0 035 2 5 20 3 5 25 4 0 40 4 5 50 6 0 65 7 5 80 Aluminum 4043 DCEP 100 Argon Shielding Gas 0 030 2 0 70 2 0 70...

Page 34: ...t weld power speed Maximum output from RC2 or RC3 is 2 4 kVA kW NOTICE Do not parallel the two 120 VAC duplex receptacles 4 Supplementary Protector CB1 CB1 protects the receptacles from over load If C...

Page 35: ...en if used in severe conditions Recycle engine fluids Check Change Clean Replace To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 5 3 Fuel Level Oil Level Oil Fuel Spills...

Page 36: ...ylinder rack 8 4 Drive Motor Protection And Tip Saver Short Circuit Protection A Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becomes inopera...

Page 37: ...ive roll refer to the groove on the opposite side of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 5 12 3 Retaining Pin To secure drive roll locate op...

Page 38: ...t gun from feeder Remove nozzle contact tip and adapter from head tube 5 Liner Unscrew and remove liner Lay gun cable out straight before installing new liner Blow out gun casing Reassemble gun in rev...

Page 39: ...Handle 4 Vise 5 Head Tube 6 Jam Nut Remove handle locking nut Remove switch housing Install new switch and connect leads po larity is not important Reassemble in reverse order Secure head tube in vise...

Page 40: ...with dirty element 1 Precleaner 2 Paper Element Do not wash paper element or clean with compressed air Remove cover Wash precleaner with soap and wa ter solution Allow precleaner to air dry completely...

Page 41: ...ls Needed 3750 30 rpm 62 Hz After tuning engine check engine speed See table for proper no load speed If necessary adjust speed as follows Start engine and run until warm 1 Adjustment Screw To increas...

Page 42: ...orized Service Agent check stator integrated rectifier SR2 stabilizer Z1 and main rectifier SR1 High weld output Check Wire Speed and Voltage control settings Check engine speed and adjust if necessar...

Page 43: ...feeds Connect work clamp to get good metal to metal contact Replace contact tip see Section 8 6 Check for proper polarity connections see Section 5 8 Check thumbscrew securing gun end to feed head ada...

Page 44: ...adjust if necessary see Section 8 10 Check throttle governor linkage for smooth non binding operation Tune up engine according to engine manual Battery discharges between uses Elec tric Start Models O...

Page 45: ...OM 217 454 Page 41 SECTION 11 ELECTRICAL DIAGRAMS 235 289 A Figure 11 1 Circuit Diagram For Welding Generator...

Page 46: ...ions Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Wire Feeder Power Source Workpiec...

Page 47: ...aterial thickness determines weld parameters 2 Select Wire Size 3 Select Wire Speed Amperage 125 A based on 1 8 in 3 mm material thickness ipm inch per minute Wire speed amperage controls weld pene tr...

Page 48: ...hen gun trigger is pressed Before lowering helmet and pressing trigger be sure wire is no more than 1 2 in 13 mm past end of nozzle and tip of wire is posi tioned correctly on seam 1 Hold Gun And Cont...

Page 49: ...0634 A 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 Gun Angles And Weld Bead Prof...

Page 50: ...t Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 12 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Sli...

Page 51: ...tion 5 7 12 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Inc...

Page 52: ...dge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed Wr...

Page 53: ...llel and does not cover joint formed by base metal S 0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond n...

Page 54: ...e most commonly used shielding gases are listed in the following table Application Gas Spray Arc Steel Short Circuiting Steel Short Circuiting Stainless Steel Short Circuiting Aluminum Argon All Posit...

Page 55: ...ectric shock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Grou...

Page 56: ...ve load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when...

Page 57: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100...

Page 58: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1...

Page 59: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Vol...

Page 60: ...k to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Insta...

Page 61: ...0 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GF...

Page 62: ...362 in 10 mm 10 mm 5 16 in 3125 in 1 2 in 9 16 in 8 mm 3150 in 14 mm 14 mm 3 8 in 375 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 16 in 4375 in 5 8 in 3 4 in 12 mm 4724 in 19 mm 19 mm 1 2 in 500 in...

Page 63: ...nduction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers...

Page 64: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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