Miller Electric OM-180 800 User Manual download pdf

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-Cooled Guns For GMAW And FCAW Welding

M-15 Rated At 150 Amperes Using CO

Shielding Gas. Feeds .023 To .035 in (0.6 To 0.9 mm) Hard Or

Flux Cored Wires.

M-25 Rated At 200 Amperes Using CO

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

M-25 Rated At 200 Amperes Using CO

Shielding 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 CO

Shielding Gas. Feeds .035 To 5/64 in (0.9 To 2.0 mm) Hard Or

Flux Cored Wires.

ST-801 727

M-40AL Rated 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.

Y Marks 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

trigger is pressed.

OVERUSE can damage gun and void

warranty.

1. Follow rated duty cycle.

2. Allow cooling period.

3. Reduce current or reduce duty cycle before

starting to 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.

1 2 3 4 5 6 ... 11 12

Summary of Contents

Page 1 - OWNER’S MANUAL

OWNER’S MANUAL 1996 MILLER Electric Mfg. Co.October 1996 FORM: OM-180 516AUse above FORM number when ordering extra manuals.M-15, M-25, M-40, And M-4

Page 2 - 4. Duty Cycle

OM-180 516 Page 10ST-801 726Figure 11-2. M-40 Euro1 23 45678910111314162717182221151923161110262829122520 21

Page 3 - . Thread wire according to

OM-180 516 Page 11DescriptionPartNo.ItemNo.Figure 11-2. M-40 EuroQuantity1 ♦+169 724 NOZZLE, slip type .500 orf .125 recess 1. . . . . . . . . . . .

Page 4 - Ref. ST-800 795-A

OM-180 516 Page 12Notes

Page 5

OM-180 516 Page 23. Installing GunRef. ST-801 7281 Gun Securing Collar2 Gun EndInsert gun end into receptacle andtighten collar.See wire feeder manual

Page 6 - 8. Switch Replacement

OM-180 516 Page 35. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning GunCasingRef. ST-801 729Y Disconnect gun first.1 Nozzle2 C

Page 7 - 10. Troubleshooting

OM-180 516 Page 46. Replacing Switch And/Or Head Tube (M-15 And M-25)Ref. ST-800 795-A3/4 inDo not disturb cable connection betweencable connector and

Page 8 - 11. Parts List

OM-180 516 Page 5ST-800 751-B7/8 in1/8 in5/16 in1 Secure headtube in vice.2 Remove switchhousing.3 Loosen cable connec-tor. Remove from viceand turn h

Page 9 - OM-180 516 Page 9

OM-180 516 Page 6ST-800 7501 Switch Housing2 ScrewRemove mounting screws fromswitch housing.3 Switch4 Switch LeadsCarefully pull up on leads to remove

Page 10 - Figure 11-2. M-40 Euro

OM-180 516 Page 710. TroubleshootingTrouble RemedyWire does not feed. Check contact tip. Check for kinks in gun cable.Check gun trigger plug connectio

Page 11 - OM-180 516 Page 11

OM-180 516 Page 811. Parts List1ST-801 725234567891011121415172618192221162021231712111025272813**Includes Item 1924Figure 11-1. M-15 & M-25 Euro

Page 12 - OM-180 516 Page 12

OM-180 516 Page 9QuantityDescriptionPartNo.ItemNo. M-25Figure 11-1. M-15 & M-25 EuroModelM-151 169 715 NOZZLE, slip type .500 orf flush 1. . . .