Miller ElectricメーカーM-15の使用説明書/サービス説明書
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Millermatic Challenger And M-15 Gun R Visit our website at www.MillerWelds.com Arc Welding Power Source And Wire Feeder Processes Description MIG (GMA W) W elding Flux Cored (FCA W) W elding OM-1314 1.
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T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-1314 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message.
OM-1314 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.
OM-1314 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit.
OM-1314 Page 4 1-5. EMF Information Considerations About W elding And The Ef fects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields.
OM-1314 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives.
OM-1314 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage.
OM-1314 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables.
OM-1314 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.
OM-1314 Page 9 SECTION 2 – INST ALLA TION 2-1. Specifications Rated W elding Output Amperage Range Maximum Open-Circuit V oltage DC Amperes Input at Rated Load Out- put 230 V , 60 Hz, Single-Phase KV A KW W eight Overall Dimensions 130 A @ 20.5 V olts DC, 30% Duty Cycle 40 – 170 33 20.
OM-1314 Page 10 2-3. Duty Cycle And Overheating 3 Minutes W elding 7 Minutes Resting Duty Cycle is percentage of 10 m in - utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs.
OM-1314 Page 1 1 2-4. Installing Work Clamp 1 Insulator 2 Bolt 3 Smaller Hole 4 W ork Clamp T ab s Bend tabs around work cable. 5 W ork Cable From Unit 6 Nut Ref.
OM-1314 Page 12 2-6. Installing W elding Gun And Setting Gun Polarity For Wire T ype 1 Gun Opening 2 Gun Trigger Receptacle 3 Gun Securing Nut 4 Drive Assembly 5 Gun End Loosen securing nut. Insert gun en d through opening until it bottoms against drive assembly .
OM-1314 Page 13 2-7. Electrical Service Guide Input V oltage 230 Input Amperes At Rated Output 20.5 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 25 Min Input Conductor Size In A .
OM-1314 Page 14 2-9. Installing Wire Spool And Adjusting Hub T ension S-0499 15/16 in Standard Wire Spool 1 Lb Wire Spool When a slight force is needed to turn spool, tension is set.
OM-1314 Page 15 2-10. Installing Drive Roll And Threading Welding Wire Ref. ST-149 266-B / Ref. ST -149 326-B / Ref. 150 093-A / Ref. 180 968 / S-0627-A Install drive roll onto shaft with de- sired groove in, and one set screw facing flat side of shaft.
OM-1314 Page 16 2-1 1. Weld Parameters Wire T ype, Wire Material Thickness Wire T ype, Shielding Gas, And Flow Rate Wire Diameter (inch) Operator Controls 1/4 in. (6.4 mm) 3/16 in. (4.8 mm) 1/8 in. (3.2 mm) 14 ga. 16 ga. 18 ga. 20 ga. 22 ga. V oltage T a p – – 5 4 3 3 2 2 1 .
OM-1314 Page 17 SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions.
OM-1314 Page 18 4-4. Replacing Gun Contact Tip ST-149 326-B Y T urn Off power before replacing contact tip. 1 Nozzle 2 Contact Tip Cut of f welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. 1 2 T ools Needed: 4-5.
OM-1314 Page 19 4-6. Cleaning Or Replacing Gun Liner Ref. ST-800 797-A 3/8 i n T o Reassemble Gun: Insert new liner . Install and tighten wire outlet guide. Cut liner off 3/4 in (20 mm) (3/8 in [9.5 mm] for aluminum) from head tube. Install adapter , contact tip, and nozzle.
OM-1314 Page 20 4-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-A Do not disturb cable connection between cable connector and connector nut. 1 Remove handle locking nut. 2 Remove switch housing. Note : If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important).
OM-1314 Page 21 4-8. Cleaning Or Repairing Drive Assembly Ref. ST-150 093-A / ST -149 266-B Y T urn Off power before cleaning or repairing drive assembly . 1 Wire Spool 2 Nozzle Cut welding wire of f at nozzle. Retract wire onto spool and secure. 3 Pressure Roll Arm 4 Cotter Pin 5 Pin 6 Screw 7 Bearing Remove bearing.
OM-1314 Page 22 4-9. T roubleshooting W elding T rouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-8). Check and replace power switch if necessary . Check fuse F1, and replace if necessary (see Section 4-2).
OM-1314 Page 23 SECTION 5 – ELECTRICAL DIAGRAM SB-180 784-B Figure 5-1. Circuit Diagram.
OM-1314 Page 24 SECTION 6 – MIG WELDING (GMA W) GUIDELINES 6-1. T ypical MIG Process Connections Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla c e w o r k c l a m p a s close to the weld as possible.
OM-1314 Page 25 6-2. T ypical MIG Process Control Settings These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. NOTE 1/8 or .
OM-1314 Page 26 6-3. Holding And Positioning Welding Gun Welding wire is energized when 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 positioned correctly on seam.
OM-1314 Page 27 6-4. Conditions That Affect Weld Bead Shape 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.
OM-1314 Page 28 6-5. Gun Movement During Welding Normally , a single stringer bead is satisfactory for most narrow groove weld joints; however , for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better .
OM-1314 Page 29 6-8. T roubleshooting – Excessive Spatter Excessive Spatter – scattering of molten metal particles that cool t o solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed.
OM-1314 Page 30 6-1 1. T roubleshooting – Lack Of Penetration Lack Of Penetration – shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick.
OM-1314 Page 31 6-14. T roubleshooting – W aviness Of Bead W aviness O f Bead – weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
OM-1314 Page 32 6-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
OM-1314 Page 33 Notes.
OM-1314 Page 34 SECTION 7 – P ARTS LIST 1 Fig 7-3 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 23 24 25 26 22 19 20 18 21 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Fig 7-2 44 45 46 50 49 ST-801 633 47 48 . Hardware is common and not available unless listed.
OM-1314 Page 35 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly Quantity 1 131 315 DRIVE ASSEMBL Y , wire (Fig 7-3) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 010 909 NUT , 375-16 1 .
OM-1314 Page 36 1 ST-801 140 23 4 5 6 7 6 8 9 10 11 13 16 24 17 28 18 19 14 18 19 17 16 11 10 9 8 23 25 27 12* *Includes Item 17 15 26 22 20 21 Figure 7-2.
OM-1314 Page 37 Quantity Description Part No. 169 589 Item No. Figure 7-2. M-15 Gun (Fig 7-1 Item 43) 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1314 Page 38 Description Quantity Part No. Dia. Mkgs. Item No. Figure 7-3. Drive Assembly , Wire (Fig 7-1 Item 1) 1 MOT 173 446 MOTOR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor .
PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool W orks Company 1635 W est S pencer Street Applet on, W I 5 4914 USA International He adquarters .
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