Miller Electric Millermatic 155 And M-15 Gun Owner's Manual

Visit our website atwww.MillerWelds.comProcessesDescriptionMIG (GMAW) WeldingFlux Cored (FCAW) WeldingArc Welding Power SourceAnd Wire FeederOM-1313 1

OM-1313 Page 66 Minutes Welding 4 Minutes Resting2-3. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated lo

OM-1313 Page 72-4. Installing Work Clamp1 Work Cable2 BootSlide boot onto work cable. Routecable out front panel opening frominside.3 Negative (−) Out

OM-1313 Page 82-6. Installing Welding GunRef. ST-801 5671 Drive Assembly2 Gun Securing Knob3 Gun EndLoosen securing knob. Insert gunend through openin

OM-1313 Page 92-8. Installing Wire Spool And Adjusting Hub TensionST-072573-BWhen a slight force is needed to turn spool, tension is set.15/16 inUse c

OM-1313 Page 102-10. Electrical Service GuideInput Voltage200 230Input Amperes At Rated Output30 26Max Recommended Standard Fuse Or Circuit Breaker Ra

OM-1313 Page 112-12. Threading Welding WireRef. ST-801 570 / ST-801 083 / S-0627-A6 in(150 mm)4 in(102 mm)TightenWOODOpen pressure assembly. Pull and

OM-1313 Page 122-13. Weld ParameterWire Type,WireMaterial ThicknessWire Type,Shielding Gas,And Flow RateWireDiameter(inch)OperatorControls3/8 in(9.5mm

OM-1313 Page 132-14. Aluminum Weld Parameter For Use With Optional Spoolmate 185Wire Type,WireOperatorMaterial ThicknessWire Type,Shielding Gas,And Fl

OM-1313 Page 14SECTION 3 − OPERATION3-1. Front Panel ControlsRef. ST-180 930Controls For Standard Units1 Wire Speed ControlUse control to select a wir

OM-1313 Page 15SECTION 4 − MAINTENANCE & TROUBLESHOOTING4-1. Routine MaintenanceY Disconnect power before maintaining.. Maintain more oftenduring

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

OM-1313 Page 164-4. Cleaning Or Replacing Gun LinerRef. ST-800 797-A3/8 inTo Reassemble Gun:Insert new liner.Install and tighten wire outlet guide.Cut

OM-1313 Page 174-5. Replacing Switch And/Or Head TubeRef. ST-800 795-ADo not disturb cable connection betweencable connector and connector nut.1 Remov

OM-1313 Page 184-6. Replacing Gun Contact TipST-149 326-BY Turn Off unit.1 Nozzle2 Contact TipCut off welding wire at contact tip.Remove nozzle.Remove

OM-1314 Page 19SECTION 5 − ELECTRICAL DIAGRAMSB-186 065Figure 5-1. Circuit Diagram

OM-1313 Page 20SECTION 6 − MIG WELDING (GMAW) GUIDELINES6-1. Typical MIG Process ConnectionsY Weld current can damageelectronic parts in vehicles.Disc

OM-1313 Page 216-2. Typical MIG Process Control SettingsThese settings are guidelines only. Material and wire type, joint design, fitup,position, shie

OM-1313 Page 226-3. Holding And Positioning Welding GunWelding wire is energized when gun trigger is pressed. Before lowering helmet andpressing trigg

OM-1313 Page 236-4. Conditions That Affect Weld Bead ShapeWeld bead shape depends on gun angle, direction of travel, electrode extension(stickout), tr

OM-1313 Page 246-5. Gun Movement During WeldingNormally, a single stringer bead is satisfactory for most narrow groove weld joints;however, for wide g

OM-1313 Page 256-8. Troubleshooting − Excessive SpatterExcessive Spatter − scattering of molten metal particles thatcool to solid form near weld bead.

The following terms areused interchangeablythroughout this manual:MIG = GMAWTABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1. . .

OM-1313 Page 266-11. Troubleshooting − Lack Of PenetrationLack Of Penetration − shallowfusion between weld metal andbase metal.Lack of Penetration Goo

OM-1313 Page 276-14. Troubleshooting − Waviness Of BeadWaviness Of Bead − weld metal that is not parallel and does not coverjoint formed by base metal

OM-1313 Page 286-16. Common MIG Shielding GasesThis is a general chart for common gases and where they are used. Many different combinations (mixtures

OM-1313 Page 29Notes

OM-1313 Page 30SECTION 7 − PARTS LIST1234Fig 7-26758910 11121314151617 1819202122232425262729283031333435936Fig 7-3ST-801 57232. Hardware is common an

OM-1313 Page 31DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-1. Main AssemblyQuantity1 089 899 LATCH, slide flush 1. . . . . . . . . . . . . . . . . .

OM-1313 Page 32Figure 7-2. Center Baffle w/ComponentsST-801 631-C. Hardware is common andnot available unless listed. 1234567891011121314151617182021

OM-1313 Page 33DescriptionPartNo.ItemNo.Figure 7-2. Baffle, Center w/Components (Fig 7-1 Item 4)QuantityDia.Mkgs.1 058 427 RING, retaining spool 1. .

OM-1313 Page 34Description QuantityPartNo.169 589ItemNo.Figure 7-3. M-15 Gun (Fig 7-1 Item 36)1 169 715 NOZZLE 1. . . . . . . . . . . . . . . . . .

OM-1313 Page 35DescriptionPartNo.ItemNo.Figure 7-4. Drive Assembly, Wire (Fig 7-2 Item 29)Quantity1 180 926 MOTOR, gear 24VDC 1. . . . . . . . . . .

Notes

Notes

Notes

Effective January 1, 1998(Equipment with a serial number preface of “KJ” or newer)This limited warranty supersedes all previous Miller warranties and

PRINTED IN USA  1998 Miller Electric Mfg. Co. 9/98Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-1313 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_5/971-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-1313 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Spark

OM-1313 Page 31-3. Additional Symbols for Installation, Operation, and MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

OM-1313 Page 41-5. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flow

OM-1313 Page 5SECTION 2 − INSTALLATION2-1. SpecificationsRated WeldingOutputAmperageRangeMaximumOpen-CircuitVoltage DCAmperes Input atRated LoadOutput