Related Manuals for Miller Electric OM-1313
Summary of Contents for Miller Electric OM-1313
- Page 1 Millermatic 185 Visit our website at www.MillerWelds.com And M-15 Gun OM-1313 179 084P September 2001 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder...
- Page 2 ISO 9001 Quality System Standard. Warranty and service information for your particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.
-
Page 3: Table Of Contents
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage 1-2. Arc Welding Hazards 1-3. Additional Symbols For Installation, Operation, And Maintenance 1-4. Principal Safety Standards WARNING 1-5. EMF Information SECTION 2 – INSTALLATION This product, when used 2-1. -
Page 5: Section 1 - Safety Precautions - Read Before Using
The coatings and any metals containing these elements can give off toxic fumes if welded. som _nd_4/98 OM-1313 Page 1... - Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
-
Page 7: Additional Symbols For Installation, Operation, And Maintenance
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. OM-1313 Page 3... -
Page 8: Emf Information
To reduce magnetic fields in the workplace, use the following procedures: OM-1313 Page 4 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. -
Page 9: Section 2 - Installation
Max Wire Feed Speed While Welding 650 IPM (16.5 m/min) Volt-ampere curves show mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. va_curve1 4/95 – SB-180 824 OM-1313 Page 5 mini-... -
Page 10: Welding Power Source Duty Cycle And Overheating
100% Duty Cycle At 120 Amperes Duty Cycle is percentage of 10 minutes that gun can weld at rated load without overheating. OM-1313 Page 6 60% Duty Cycle At 150 Amperes 4 Minutes Resting Minutes .023 To .045 in (0.6 To 1.1 mm) .023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires... -
Page 11: Installing Work Clamp
Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour). Check wire manufactur- er’s recommended flow rate. Adapter (Customer Sup- plied) O-Ring (Customer Supplied) Install adapter with O-ring between regulator/flowmeter cylinder. ST-801 571 / ST-802 028 OM-1313 Page 7... -
Page 12: Installing Welding Gun
2-7. Installing Welding Gun 2-8. Setting Gun Polarity Tools Needed: 3/4, 11/16 in OM-1313 Page 8 Drive Assembly Gun Securing Knob Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly. Tighten nut. Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. -
Page 13: Installing Wire Spool And Adjusting Hub Tension
200 volt lead, and slide sleeving over end of 230 volt and fan motor leads. Fold sleeving over and secure in place. Connect 200 volt lead to S1 where 230 volt lead was removed. Reinstall wrapper. ST-801 580-A OM-1313 Page 9... -
Page 14: Electrical Service Guide
2-12. Selecting A Location And Connecting Input Power Y Do not move or operate unit where it could tip. 18 in (457 mm) of space for airflow Y Always connect grounding conductor first. OM-1313 Page 10 Circuit Breaker = GND/PE , Time-Delay Normal Operating (29) (39) Rating Label Supply correct input power. -
Page 15: Threading Welding Wire
Tighten knob enough to prevent slipping. 4 in (102 mm) Push wire thru guides into gun; continue to hold wire. Turn On. Cut off wire. Close and latch door. Ref. ST-801 570-A / ST-801 083 / S-0627-A OM-1313 Page 11... - Page 16 Notes OM-1313 Page 12...
-
Page 17: Section 3 - Operation
Voltage Switch The higher the selected number, the thicker the material that can be welded (see Section 3-2). Do not switch while welding. Power Switch Ref. ST-180 930 OM-1313 Page 13... -
Page 18: Weld Parameter Chart
Input Line Voltage* Higher e.g. 240 Volts AC 230 Volts AC Lower e.g. 218 Volts AC OM-1313 Page 14 Parameter Chart Settings Weld Will Be Hotter Lower Settings Use Parameter Chart Inside Door Weld Will Be... - Page 19 Ref. 197 949 OM-1313 Page 15...
-
Page 20: Section 4 - Maintenance & Troubleshooting
Labels Blow Out Or Vacuum Inside 4-2. Circuit Breakers CB1 And CB2 4-3. Changing Drive Roll And Inlet Wire Guide Tools Needed: OM-1313 Page 16 Y Disconnect power before maintaining. 3 Months 6 Months Remove drive roll and apply light coat of oil or grease to drive motor shaft. -
Page 21: Cleaning Or Replacing Gun Liner
To 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. Ref. ST-800 797-C OM-1313 Page 17... -
Page 22: Replacing Switch And/Or Head Tube
Hand-tighten head tube into connector cable. Tools Needed: 3/4 in OM-1313 Page 18 Y Disconnect gun first. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. -
Page 23: Replacing Gun Contact Tip
Have nearest Factory Authorized Service Agent check drive motor. Y Turn Off unit. Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. Remedy Remedy OM-1313 Page 19 Ref. 800 797-C... -
Page 24: Section 5 - Electrical Diagram
SECTION 5 – ELECTRICAL DIAGRAM SB-186 065 Figure 5-1. Circuit Diagram OM-1313 Page 20... -
Page 25: Section 6 - Mig Welding (Gmaw) Guidelines
Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Workpiece light mig 5/967 / Ref. 801 909 / Ref. 801 570-B OM-1313 Page 21... -
Page 26: Typical Mig Process Control Settings
High voltage: arc is unstable (spatter) Set voltage midway between high/low voltage. Wire speed (amperage) controls weld pe- netration (wire speed = burn-off rate) Voltage controls height and width of weld bead. OM-1313 Page 22 1/8 or .125 in Wire Size Amperage Range .023 in 30 –... -
Page 27: Holding And Positioning Welding Gun
0 -15 Side View of Gun Angle FILLET WELDS Hold Gun and Control Gun Trigger Workpiece Work Clamp Electrode Extension (Stickout) 1/4 to 1/2 in (6 To 13 mm) Cradle Gun and Rest Hand on Workpiece S-0421-A OM-1313 Page 23... -
Page 28: 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. Short Short FILLET WELD ELECTODE EXTENSIONS (STICKOUT) Slow OM-1313 Page 24 Push Perpendicular GUN ANGLES AND WELD BEAD PROFILES Normal ELECTRODE EXTENSIONS (STICKOUT) Normal... -
Page 29: Gun Movement During Welding
Bad Overlap Poor Penetration S-0053-A Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1/8 in (3.2 mm) thickness in metals being welded. No Overlap Good Penetration into Base Metal S-0052-B OM-1313 Page 25... -
Page 30: Troubleshooting - Excessive Spatter
6-10. Troubleshooting – Excessive Penetration Excessive Penetration Good Penetration Possible Causes Excessive heat input. OM-1313 Page 26 Excessive Spatter – scattering of molten metal particles that cool to solid form near weld bead. Corrective Actions Select lower wire feed speed. -
Page 31: Troubleshooting - Lack Of Penetration
Use correct gun angle of 0 to 15 degrees. Burn-Through – weld metal melting completely through base metal resulting in holes where no metal remains. Corrective Actions Select lower voltage range and reduce wire feed speed. Increase and/or maintain steady travel speed. S-0638 S-0637 S-0640 OM-1313 Page 27... -
Page 32: Troubleshooting - Waviness Of Bead
Possible Causes Excessive heat input. OM-1313 Page 28 Waviness Of Bead – weld metal that is not parallel and does not cover joint formed by base metal. Corrective Actions Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. -
Page 33: Common Mig Shielding Gases
Check gas hose between flowmeter and wire feeder, and gas hose in gun and cable assembly. Have Factory Authorized Service Agent repair wiring. Have Factory Authorized Service Agent replace gas solenoid valve. Check primary voltage and relink welding power source for correct voltage. Aluminum Remedy OM-1313 Page 29... - Page 34 Loose connections at the gun weld cable or work cable. Check and tighten all connections. Gun in poor shape or loose connection inside gun. OM-1313 Page 30 Remedy Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary.
- Page 35 Notes OM-1313 Page 31...
-
Page 36: Section 7 - Parts List
SECTION 7 – PARTS LIST Hardware is common and not available unless listed. 801 572-C Figure 7-1. Main Assembly OM-1313 Page 32... - Page 37 ............. OM-1313 Page 33 Quantity...
- Page 38 Hardware is common and not available unless listed. ST-801 631-D Figure 7-2. Center Baffle w/Components OM-1313 Page 34...
- Page 39 ............OM-1313 Page 35 Quantity...
- Page 40 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1313 Page 36 Description ......... . .
- Page 41 ......Hardware is common and not available unless listed. Includes Items 13, 16, 17 OM-1313 Page 37 Quantity ST-181 053-A...
- Page 43 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
-
Page 44: Options And Accessories
Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2001 Miller Electric Mfg. Co. 1/01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...