Miller M-15 Bedienungsanleitung

OWNER’S MANUAL

1996 MILLER Electric Mfg. Co.

October 1996 FORM: OM-180 516A

Use above FORM number when ordering extra manuals.

M-15, M-25, M-40, And M-40AL Guns (Euro-Connector)

1. Specifications

Air-CooledGuns For GMAW And FCAW Welding

M-15 Rated At 150 Amperes Using CO2Shielding Gas. Feeds .023 To .035 in (0.6 To 0.9 mm) Hard Or

Flux Cored Wires.

M-25Rated At 200 Amperes Using CO

Shielding Gas. Feeds .030 To .045 (0.8 To 1.1 mm) Hard Or Flu

M-25Rated At 200 Amperes Using CO2Shielding Gas. Feeds .030 To .045 (0.8 To 1.1 mm) Hard Or Flux

Cored Wires (Also Feeds .023 in (0.6 mm) Wire – See Parts List)

M-40 Rated At 400 Amperes Using CO2Shielding Gas. Feeds .035 To 5/64 in (0.9 To 2.0 mm) Hard Or

Flux Cored Wires.

ST-801 727 M-40ALRated At 275 Amperes Using Mixed Shielding Gas; Feeds .047 in (1.2 mm) Aluminium Wire

2. Safety Precautions For GMAW Guns

A. 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 and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions to avoid the hazards.

YMarks a special safety message.

.Means NOTE; not safety related.

B. GMAW Gun 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 wire

feeder and welding power source manuals. Read and follow all Safety Standards.

ELECTRIC SHOCK can kill.

1. Always wear dry insulating gloves.

2. Insulate yourself from work and ground.

3. Do not touch live electrode or electrical parts.

4. Repair or replace worn, damaged, or cracked gun

or cable insulation.

5. Turn off welding power source before changing

contact tip or gun parts.

6. Keep all covers and handle securely in place.

HOT SURFACES can burn skin.

1. Allow gun to cool before touching.

2. Do not touch hot metal.

3. Protect others from contact with hot metal.

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. Keep hands and body away from gun tip when

triggeris pressed.

OVERUSE can damage gun and void

warranty.

1. Followrated duty cycle.

2. Allow cooling period.

3. Reduce current or reduce duty cycle before

startingto weld again.

1. Read and follow these instructions and all safety

blocks carefully.

2. Have only trained and qualified persons install

operate,or service this unit.

3. Call your distributor if you do not understand the

directions.

4. For WELDING SAFETY and EMF information

read wire feeder and welding power source

manuals.

OM-180 516 Page 2

3. Installing Gun

Ref. ST-801 728

1 Gun Securing Collar

2 Gun End

Insert gun end into receptacle and

tightencollar.

See wire feeder manual for thread-

ing procedure.

Duty Cycle is percentage of 10 minutes that gun

can weld at rated load without overheating.

Definition

6 Minutes WeldingContinuous Welding 4 Minutes Resting

4. Duty Cycle

Model Duty

Cycle At

Amperes Shielding

Gas

M-15

M-25 100%

150

120

200

CO2

Mixed Gases

CO2

Model Duty

Cycle At

Amperes Shielding

Gas

M-15

M-25 60%

200

150

300

CO2

Mixed Gases

CO2

Minutes

M-40 400 CO2525 CO2

275 Mixed Gases 400 Mixed Gases

M-40AL

M-40

M-40AL

OM-180 516 Page 3

5. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun

Casing

Ref. ST-801 729

YDisconnectgun first.

1 Nozzle

2 Contact Tip

3 Adapter

.Check to make sure wire size

stamped on contact tip

matches actual wire size.

Head

Tube

Lay gun cable out

straightbefore installing

new liner.

Remove nozzle,

contact tip, adapter,

and wire outlet guide.

Remove

liner.

Blow out

gun casing.

3/8 in

3/4 in

(20 mm)

Liner

Stickout Install

Liner

.Thread wire according to

weldingpower source/wire

feeder manual.

Reassemble gun in

reverse order from

taking it apart.

123

3/8 in (7/16 in for M-25)

OM-180 516 Page 4

6. Replacing Switch And/Or Head Tube (M-15 And M-25)

Ref. ST-800 795-A

3/4 in

Do not disturb cable connection between

cable connector and connector nut.

Remove handle lock-

ing nut. Slide handle.

Secure head

tube in vice. Remove shock washers

from front and rear of

headtube.

Loosen jam nut.

Remove from vice

and turn head tube

out by hand.

Install both existing shock washers onto

new head tube, and hand-tighten head

tube into cable connector.

Place head tube in vice and tighten until

nuts are tight.

Remove from vice. Reposition handle and install

switch housing. Secure with handle locking nut.

YDisconnect gun first.

Removeswitch housing. Install new switch and

connect leads (polarity is not important). Reas-

semble in reverse order. If replacing head tube,

continueto end of figure.

OM-180 516 Page 5

ST-800 751-B

7/8 in

1/8 in

5/16 in

1 Secure head

tube in vice.

2 Remove switch

housing.

3 Loosen cable connec-

tor. Remove from vice

and turn head tube

out by hand.

Do not disturb cable connec-

tion between cable connector

and connector nut.

4 Slide handle.

1/8 in

5 Loosen set screws

on body and remove

head tube.

6 Install new head tube. Tighten set

screws to keep head tube in de-

sired position.

7 Hand-tighten head tube into cable connector. Place

head tube in vice and tighten to within 1/8 in (3 mm)

spacing between cable connector and body.

8 Reposition handle and

install switch housing

(see Section 8).

Install shock washer from

existing head tube.

YDisconnect gun first.

7. Replacing Head Tube (M-40)

OM-180 516 Page 6

ST-800 750

1 Switch Housing

2 Screw

Remove mounting screws from

switch housing.

3 Switch

4 Switch Leads

Carefullypull up on leads to remove

switch from housing.

5 Switch Lead Connectors

Remove switch lead connectors

from switch terminals and discard

old switch.

Push switch lead connectors onto

terminalsof new switch.

6 Switch Plunger

Insert switch back into switch hous-

ing until it snaps into place.

Install switch housing back onto

handle.

5/16 in

See Parts List for correct replacement parts.

Switch leads must

lay parallel.

8. Switch Replacement

9. Routine Maintenance

YDisconnectgun before maintaining.

Each Spool Of Wire

Blow Out

Gun

Casing

Clean

Nozzle

And Check

Contact Tip

3 Months

Control

Cord Gas

Hose Gun Cable

Replace

Cracked

Parts

OM-180 516 Page 7

10. Troubleshooting

Trouble Remedy

Wire does not feed. Check contact tip. Check for kinks in gun cable.

Check gun trigger plug connection at welding power source/wire feeder.

Check, and if necessary, replace gun trigger switch.

Wire is not energized. Check contact tip.

Check gun trigger plug connection at welding power source/wire feeder.

Check, and if necessary, replace gun trigger switch.

Wire feeds unevenly. Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing.

Weld porosity. Remove weld spatter buildup in nozzle.

Make sure inner support tube is tight in cable connector.

Check shielding gas flow/supply.

Wire feeding stops or does not feed

properlyduring welding. Straighten gun cable and/or replace damaged parts.

Adjust drive roll pressure (see wire feeder manual).

Change to proper drive roll groove (see wire feeder manual).

Readjust hub tension (see wire feeder manual).

Clean or replace wire inlet guide or liner if dirty or plugged.

Replace drive roll or pressure bearing if worn or slipping (see wire feeder manual).

OM-180 516 Page 8

11. Parts List

ST-801 725

234567 8

17 26

21 23

11 10

13*

*Includes Item 19

Figure 11-1. M-15 & M-25 Euro

OM-180 516 Page 9

Quantity

Description

Part

No.

Item

No. M-25

Figure 11-1. M-15 & M-25 Euro

Model

M-15

1 169 715 NOZZLE, slip type .500 orf flush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 +169 724 NOZZLE, slip type .500 orf .125 recess 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 +169 725 NOZZLE, slip type .625 orf .125 recess 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 +169 726 NOZZLE, slip type .625 orf flush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 +169 727 NOZZLE, slip type .625 orf .125 stickout 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2♦000 067 TIP, contact scr .030 wire x 1.125 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2♦000 068 TIP, contact scr .035 wire x 1.125 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 +000 069 TIP, contact scr .045 wire x 1.125 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 169 716 ADAPTER, contact tip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 169 728 ADAPTER, contact tip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 169 729 ADAPTER, nozzle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 170 470 RING, retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 170 467 RING, retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 170 471 O-RING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 170 468 O-RING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 169 717 WASHER, shock 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 169 730 WASHER, shock 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 169 718 TUBE, head 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 169 731 TUBE, head 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 169 738 NUT, locking handle 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 169 719 NUT, jam (gun end) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 169 732 NUT, jam 1 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 169 720 CONNECTOR, cable (gun end) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 169 733 CONNECTOR, cable 1 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 169 721 NUT, connector 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 169 734 NUT, connector 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 172 017 M15 UNICABLE CLAMP KIT, (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 172 018 M25 UNICABLE CLAMP KIT, (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 169 735 CLIP, compression 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 169 742 TUBE, support 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 169 743 CLAMP, inner 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 169 740 CLAMP, jacket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 170 469 CLAMP, jacket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 169 746 CONNECTOR, switch lead 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 169 739 SWITCH, trigger 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 172 691 HANDLE, (gun end) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 169 741 STRAIN RELIEF, cable 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 602 177 SET SCREW 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 180 517 HANDLE, Euro 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 180 514 COLLAR, threaded 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .