Miller Electric M-15 User Manual

Millermatic ChallengerAnd M-15 GunRVisit our website atwww.MillerWelds.comArc Welding Power Source And WireFeederProcessesDescriptionMIG (GMAW) Weldin

OM-1314 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles

OM-1314 Page 71-3. Dangers supplémentaires en relation avec l’installation, le fonctionnementet la maintenanceRisque D’INCENDIE OUD’EXPLOSION.D Ne pas

OM-1314 Page 81-4. Principales normes de sécuritéSafety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-ding Society, 550 N.W. Lejeune Rd,

OM-1314 Page 9SECTION 2 – INSTALLATION2-1. SpecificationsRated WeldingOutputAmperageRangeMaximumOpen-CircuitVoltage DCAmperes Input atRated Load Out-p

OM-1314 Page 102-3. Duty Cycle And Overheating3 Minutes Welding 7 Minutes RestingDuty Cycle is percentage of 10 min-utes that unit can weld at rated l

OM-1314 Page 112-4. Installing Work Clamp1 Insulator2 Bolt3 Smaller Hole4 Work Clamp TabsBend tabs around work cable.5 Work Cable From Unit6 NutRef. S

OM-1314 Page 122-6. Installing Welding Gun And Setting Gun Polarity For Wire Type1 Gun Opening2 Gun Trigger Receptacle3 Gun Securing Nut4 Drive Assemb

OM-1314 Page 132-7. Electrical Service GuideInput Voltage230Input Amperes At Rated Output20.5Max Recommended Standard Fuse Or Circuit Breaker Rating I

OM-1314 Page 142-9. Installing Wire Spool And Adjusting Hub TensionS-049915/16 inStandard Wire Spool1 Lb Wire SpoolWhen a slight force is neededto tur

OM-1314 Page 152-10. Installing Drive Roll And Threading Welding WireRef. ST-149 266-B / Ref. ST-149 326-B / Ref. 150 093-A / Ref. 180 968 / S-0627-AI

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-1314 Page 162-11. Weld ParametersWire Type, WireMaterial ThicknessWire Type,Shielding Gas,And Flow RateWireDiameter(inch)OperatorControls1/4 in.(6.

OM-1314 Page 17SECTION 4 – MAINTENANCE & TROUBLESHOOTING4-1. MaintenanceY Disconnect powerbefore maintaining.. Maintain more oftenduring severe co

OM-1314 Page 184-4. Replacing Gun Contact TipST-149 326-BY Turn Off power beforereplacing contact tip.1 Nozzle2 Contact TipCut off welding wire at con

OM-1314 Page 194-6. Cleaning Or Replacing Gun LinerRef. ST-800 797-A3/8 inTo Reassemble Gun:Insert new liner.Install and tighten wire outlet guide.Cut

OM-1314 Page 204-7. Replacing Switch And/Or Head TubeRef. ST-800 795-ADo not disturb cable connection betweencable connector and connector nut.1 Remov

OM-1314 Page 214-8. Cleaning Or Repairing Drive AssemblyRef. ST-150 093-A / ST-149 266-BY Turn Off power beforecleaning or repairing driveassembly.1 W

OM-1314 Page 224-9. TroubleshootingWelding Trouble RemedyNo weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-8).Ch

OM-1314 Page 23SECTION 5 – ELECTRICAL DIAGRAMSB-180 784-BFigure 5-1. Circuit Diagram

OM-1314 Page 24SECTION 6 – MIG WELDING (GMAW) GUIDELINES6-1. Typical MIG Process ConnectionsY Weld current can damageelectronic parts in vehicles.Disc

OM-1314 Page 256-2. Typical MIG Process Control SettingsThese settings are guidelines only. Material and wire type, joint design, fitup,position, shie

TABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1. . .

OM-1314 Page 266-3. Holding And Positioning Welding GunWelding wire is energized when gun trigger is pressed. Before lowering helmet andpressing trigg

OM-1314 Page 276-4. Conditions That Affect Weld Bead ShapeWeld bead shape depends on gun angle, direction of travel, electrode extension(stickout), tr

OM-1314 Page 286-5. Gun Movement During WeldingNormally, a single stringer bead is satisfactory for most narrow groove weld joints;however, for wide g

OM-1314 Page 296-8. Troubleshooting – Excessive SpatterExcessive Spatter – scattering of molten metal particles thatcool to solid form near weld bead.

OM-1314 Page 306-11. Troubleshooting – Lack Of PenetrationLack Of Penetration – shallowfusion between weld metal andbase metal.Lack of Penetration Goo

OM-1314 Page 316-14. Troubleshooting – Waviness Of BeadWaviness Of Bead – weld metal that is not parallel and does not coverjoint formed by base metal

OM-1314 Page 326-16. Common MIG Shielding GasesThis is a general chart for common gases and where they are used. Many different combinations (mixtures

OM-1314 Page 33Notes

OM-1314 Page 34SECTION 7 – PARTS LIST1Fig 7-323456 789101112 131415161723242526221920182127 28293031323334353637383940414243Fig 7-24445465049ST-801 63

OM-1314 Page 35DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-1. Main AssemblyQuantity1 131 315 DRIVE ASSEMBLY, wire (Fig 7-3) 1. . . . . . . . . . . . .

OM-1314 Page 361ST-801 140234567689101113162417281819141819171611109823252712**Includes Item 171526222021Figure 7-2. M-15 Gun. Hardware is common andn

OM-1314 Page 37QuantityDescriptionPartNo.169 589ItemNo.Figure 7-2. M-15 Gun (Fig 7-1 Item 43)1 169 715 NOZZLE, slip type .500 orf flush 1. . . . . .

OM-1314 Page 38Description QuantityPartNo.Dia.Mkgs.ItemNo.Figure 7-3. Drive Assembly, Wire (Fig 7-1 Item 1)1 MOT 173 446 MOTOR 1. . . . . . . . .

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 7/00Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-1314 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_5/971-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-1314 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Spark

OM-1314 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

OM-1314 Page 41-5. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flow

OM-1314 Page 5SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANTUTILISATIONsom _nd_fre 5/971-1. Signification des symbolesSignifie Mise en garde ! Soyez v